Application & Operating Conditions
AS/NZS 1802 Type 209 is a heavy-duty composite screened three-core rubber mining cable with an extensible central pilot core, designed for 1.1/1.1 kV to 11/11 kV power distribution. It is specified for feeder connections between transformers and gate-end boxes, and for feeder supply to underground pumps, fans, crushers and mobile mining equipment.
Transformer to Gate-End Box Feeders
Engineered for low- and medium-voltage feeder links connecting underground mining substations, section switchgear and gate-end control boxes with integrated earth-continuity pilot monitoring.
Pumps, Fans, Crushers & Mobile Plant
Provides high-reliability power supply to heavy underground dewatering pumps, main and auxiliary ventilation fans, mineral crushers and mobile surface or underground mining machines.
Wet, Oily & C1 Flame-Retardant Duty
Suitable for installation in free air, underground cable ducts and mobile equipment routes requiring water immersion stability, oil resistance, mechanical flexibility and C1 flame retardancy.
Engineering Selection Note: Voltage-Class Screen Construction
Confirm system voltage before specifying: Type 209.1 (1.1/1.1 kV) utilizes a polyester conductor separator tape and proofed textile insulation tape, whereas Type 209.3 (3.3/3.3 kV), Type 209.6 (6.6/6.6 kV) and Type 209.11 (11/11 kV) incorporate semi-conductive conductor and insulation screens for medium-voltage electrical stress control.
Cable Construction (AS/NZS 1802 Type 209)
Type 209 cables assemble three tinned copper phase cores around a single extensible central pilot core, with each phase individually enclosed by a composite earth screen of tinned annealed copper wire and polyester yarn over R-EP-90 EPR insulation and protected by an HD-85-PCP outer sheath.
| Layer / Component | Material & Construction Specification |
|---|---|
| Phase Conductors | Flexible stranded tinned annealed copper, three phase cores |
| Conductor Separator / Screen | Polyester tape for 1.1/1.1 kV (Type 209.1); semi-conductive screen for 3.3 kV and above (Type 209.3, 209.6, 209.11) |
| Insulation | Ethylene Propylene Rubber (EPR) thermosetting compound, type R-EP-90 |
| Insulation Tape / Screen | Proofed textile tape for 1.1/1.1 kV; semi-conductive insulation screen for 3.3 kV and above |
| Composite Earth Screen | Composite earth screen braided from tinned annealed copper wire and polyester yarn applied over each phase core |
| Core Identification | Red, white and blue braid tracers woven into the composite earth screen |
| Central Pilot Core | Single extensible central pilot conductor positioned at the cable axis |
| Outer Sheath | Heavy-duty HD-85-PCP polychloroprene elastomer sheath (black, oil & abrasion resistant) |
Type 209 Cross-Section Geometry: Three screened phase cores laid in trefoil around a single extensible central pilot core inside an HD-85-PCP elastomer sheath.
Technical Characteristics
Manufactured to AS/NZS 1802 requirements, Type 209 general-use mining cables support continuous conductor temperatures up to +90 °C, minimum installation temperatures down to −25 °C and C1 flame performance across four voltage classes from 1.1/1.1 kV to 11/11 kV.
| Parameter | Standard Requirement / Rated Value |
|---|---|
| Reference Standard | AS/NZS 1802 (Electric cables — Reeling and trailing — For underground coal mining applications) |
| Voltage Grades & Sub-Types | Type 209.1 (1.1/1.1 kV) | Type 209.3 (3.3/3.3 kV) | Type 209.6 (6.6/6.6 kV) | Type 209.11 (11/11 kV) |
| Nominal Cross-Section Range | 10–300 mm² (1.1/1.1 kV) | 16–300 mm² (3.3/3.3 kV & 6.6/6.6 kV) | 25–240 mm² (11/11 kV) |
| Max. Continuous Conductor Temperature | +90 °C |
| Minimum Installation Temperature | −25 °C |
| Installation Conditions | In free air, in underground ducting and for mobile mining equipment connections |
| Oil & Water Immersion Performance | Excellent immersion resistance, oil resistance and mechanical flexibility |
| Flame Performance | C1 flame retardant classification |
Specification & Dimensional Data
Nominal dimensional and electrical data for all 43 AS/NZS 1802 Type 209 cable sizes are summarized across the four voltage grades below, followed by complete part-level specification tables for each sub-type.
| Sub-Type | Rated Voltage | Screen & Tape Construction | Conductor Range | EPR Insulation | Earth Screen | Cable OD Range | Mass (kg/100m) |
|---|---|---|---|---|---|---|---|
| Type 209.1 | 1.1/1.1 kV | Polyester tape + proofed textile tape + composite braid | 10–300 mm² (12) | 1.5–3.0 mm | 8.2–49 mm² | 33.3–94.3 mm | 175–1790 |
| Type 209.3 | 3.3/3.3 kV | Semi-conductive conductor & insulation screens + composite braid | 16–300 mm² (11) | 3.0 mm | 14–63 mm² | 47.3–97.7 mm | 335–1900 |
| Type 209.6 | 6.6/6.6 kV | Semi-conductive conductor & insulation screens + composite braid | 16–300 mm² (11) | 5.0 mm | 17–71 mm² | 58.2–109 mm | 475–2195 |
| Type 209.11 | 11/11 kV | Semi-conductive conductor & insulation screens + composite braid | 25–240 mm² (9) | 7.6 mm | 24–77 mm² | 75.9–116 mm | 805–2280 |
Type 209.1 — Rated Voltage: 1.1/1.1 kV (10 mm² to 300 mm² | 12 Sizes)
Type 209.1 (1.1/1.1 kV): Polyester conductor separator tape, 1.5–3.0 mm R-EP-90 EPR insulation, proofed textile tape, composite earth screen (8.2–49 mm²) and 3.8–8.8 mm HD-85-PCP sheath.
| Part No. | Area (mm²) | Cond. Dia. (mm) | Insul. (mm) | AC Res. (Ω/km) | React. (Ω/km) | Volt Drop (mV/A·m) | Cap. (µF/km) | Screen (mm²) | Sheath (mm) | Cable Dia. (mm) | Mass (kg/100m) |
|---|---|---|---|---|---|---|---|---|---|---|---|
| TBF-10-209-1 | 10 | 4.6 | 1.5 | 2.58 | 0.130 | 4.47 | 0.314 | 8.2 | 3.8 | 33.3 | 175 |
| TBF-16-209-1 | 16 | 6.2 | 1.6 | 1.58 | 0.118 | 2.74 | 0.379 | 10 | 4.0 | 37.3 | 225 |
| TBF-25-209-1 | 25 | 7.2 | 1.6 | 0.951 | 0.112 | 1.66 | 0.432 | 12 | 4.3 | 40.3 | 285 |
| TBF-35-209-1 | 35 | 8.4 | 1.6 | 0.698 | 0.107 | 1.22 | 0.493 | 14 | 4.6 | 43.6 | 335 |
| TBF-50-209-1 | 50 | 9.7 | 1.7 | 0.523 | 0.104 | 0.924 | 0.526 | 14 | 5.0 | 47.7 | 410 |
| TBF-70-209-1 | 70 | 12.0 | 1.8 | 0.346 | 0.0981 | 0.623 | 0.599 | 16 | 5.4 | 54.0 | 540 |
| TBF-95-209-1 | 95 | 13.3 | 2.0 | 0.271 | 0.0955 | 0.498 | 0.591 | 18 | 6.0 | 58.9 | 645 |
| TBF-120-209-1 | 120 | 15.3 | 2.1 | 0.210 | 0.0925 | 0.397 | 0.640 | 21 | 6.4 | 64.6 | 790 |
| TBF-150-209-1 | 150 | 17.2 | 2.3 | 0.166 | 0.0907 | 0.328 | 0.652 | 23 | 6.9 | 70.4 | 955 |
| TBF-185-209-1 | 185 | 18.8 | 2.5 | 0.137 | 0.0902 | 0.284 | 0.657 | 30 | 7.4 | 76.5 | 1155 |
| TBF-240-209-1 | 240 | 21.7 | 2.8 | 0.107 | 0.0883 | 0.240 | 0.672 | 34 | 8.2 | 85.5 | 1445 |
| TBF-300-209-1 | 300 | 24.3 | 3.0 | 0.0850 | 0.0873 | 0.211 | 0.719 | 49 | 8.8 | 94.3 | 1790 |
Type 209.3 — Rated Voltage: 3.3/3.3 kV (16 mm² to 300 mm² | 11 Sizes)
Type 209.3 (3.3/3.3 kV): Semi-conductive conductor and insulation screens, 3.0 mm R-EP-90 EPR insulation, composite earth screen (14–63 mm²) and 5.3–9.4 mm HD-85-PCP sheath.
| Part No. | Area (mm²) | Cond. Dia. (mm) | Insul. (mm) | AC Res. (Ω/km) | React. (Ω/km) | Volt Drop (mV/A·m) | Cap. (µF/km) | Screen (mm²) | Sheath (mm) | Cable Dia. (mm) | Mass (kg/100m) |
|---|---|---|---|---|---|---|---|---|---|---|---|
| TBF-16-209-3 | 16 | 6.2 | 3.0 | 1.58 | 0.131 | 2.75 | 0.255 | 14 | 5.3 | 47.3 | 335 |
| TBF-25-209-3 | 25 | 7.2 | 3.0 | 0.951 | 0.125 | 1.66 | 0.280 | 15 | 5.6 | 50.4 | 400 |
| TBF-35-209-3 | 35 | 8.4 | 3.0 | 0.698 | 0.119 | 1.23 | 0.311 | 16 | 5.9 | 53.5 | 460 |
| TBF-50-209-3 | 50 | 9.7 | 3.0 | 0.523 | 0.114 | 0.927 | 0.347 | 17 | 6.3 | 57.2 | 540 |
| TBF-70-209-3 | 70 | 12.0 | 3.0 | 0.346 | 0.106 | 0.627 | 0.408 | 19 | 6.6 | 62.6 | 665 |
| TBF-95-209-3 | 95 | 13.3 | 3.0 | 0.271 | 0.102 | 0.502 | 0.439 | 21 | 7.1 | 66.4 | 765 |
| TBF-120-209-3 | 120 | 15.3 | 3.0 | 0.210 | 0.0985 | 0.402 | 0.492 | 27 | 7.4 | 72.0 | 930 |
| TBF-150-209-3 | 150 | 17.2 | 3.0 | 0.166 | 0.0954 | 0.332 | 0.541 | 32 | 7.8 | 76.7 | 1095 |
| TBF-185-209-3 | 185 | 18.8 | 3.0 | 0.137 | 0.0942 | 0.288 | 0.584 | 42 | 8.2 | 82.3 | 1285 |
| TBF-240-209-3 | 240 | 21.7 | 3.0 | 0.106 | 0.0906 | 0.242 | 0.659 | 48 | 8.8 | 89.6 | 1555 |
| TBF-300-209-3 | 300 | 24.3 | 3.0 | 0.0849 | 0.0890 | 0.213 | 0.727 | 63 | 9.4 | 97.7 | 1900 |
Type 209.6 — Rated Voltage: 6.6/6.6 kV (16 mm² to 300 mm² | 11 Sizes) — Click to Expand
Type 209.6 (6.6/6.6 kV): Semi-conductive conductor and insulation screens, 5.0 mm R-EP-90 EPR insulation, composite earth screen (17–71 mm²) and 6.4–10.4 mm HD-85-PCP sheath.
| Part No. | Area (mm²) | Cond. Dia. (mm) | Insul. (mm) | AC Res. (Ω/km) | React. (Ω/km) | Volt Drop (mV/A·m) | Cap. (µF/km) | Screen (mm²) | Sheath (mm) | Cable Dia. (mm) | Mass (kg/100m) |
|---|---|---|---|---|---|---|---|---|---|---|---|
| TBF-16-209-6 | 16 | 6.2 | 5.0 | 1.58 | 0.143 | 2.75 | 0.181 | 17 | 6.4 | 58.2 | 475 |
| TBF-25-209-6 | 25 | 7.2 | 5.0 | 0.951 | 0.137 | 1.66 | 0.193 | 19 | 6.7 | 61.7 | 560 |
| TBF-35-209-6 | 35 | 8.4 | 5.0 | 0.698 | 0.130 | 1.23 | 0.212 | 21 | 7.0 | 64.8 | 630 |
| TBF-50-209-6 | 50 | 9.7 | 5.0 | 0.523 | 0.124 | 0.931 | 0.234 | 22 | 7.3 | 68.2 | 715 |
| TBF-70-209-6 | 70 | 12.0 | 5.0 | 0.346 | 0.116 | 0.632 | 0.271 | 23 | 7.7 | 73.8 | 860 |
| TBF-95-209-6 | 95 | 13.3 | 5.0 | 0.271 | 0.113 | 0.509 | 0.292 | 30 | 8.1 | 78.0 | 995 |
| TBF-120-209-6 | 120 | 15.3 | 5.0 | 0.210 | 0.108 | 0.409 | 0.325 | 32 | 8.5 | 83.2 | 1155 |
| TBF-150-209-6 | 150 | 17.2 | 5.0 | 0.166 | 0.105 | 0.340 | 0.354 | 46 | 8.9 | 89.2 | 1370 |
| TBF-185-209-6 | 185 | 18.8 | 5.0 | 0.136 | 0.102 | 0.294 | 0.381 | 48 | 9.3 | 93.3 | 1540 |
| TBF-240-209-6 | 240 | 21.7 | 5.0 | 0.106 | 0.0981 | 0.250 | 0.426 | 53 | 9.9 | 101 | 1825 |
| TBF-300-209-6 | 300 | 24.3 | 5.0 | 0.0845 | 0.0959 | 0.221 | 0.467 | 71 | 10.4 | 109 | 2195 |
Type 209.11 — Rated Voltage: 11/11 kV (25 mm² to 240 mm² | 9 Sizes) — Click to Expand
Type 209.11 (11/11 kV): Semi-conductive conductor and insulation screens, 7.6 mm R-EP-90 EPR insulation, composite earth screen (24–77 mm²) and 8.1–11.3 mm HD-85-PCP sheath.
| Part No. | Area (mm²) | Cond. Dia. (mm) | Insul. (mm) | AC Res. (Ω/km) | React. (Ω/km) | Volt Drop (mV/A·m) | Cap. (µF/km) | Screen (mm²) | Sheath (mm) | Cable Dia. (mm) | Mass (kg/100m) |
|---|---|---|---|---|---|---|---|---|---|---|---|
| TBF-25-209-11 | 25 | 7.2 | 7.6 | 0.951 | 0.150 | 1.67 | 0.150 | 24 | 8.1 | 75.9 | 805 |
| TBF-35-209-11 | 35 | 8.4 | 7.6 | 0.698 | 0.143 | 1.23 | 0.163 | 30 | 8.4 | 79.6 | 915 |
| TBF-50-209-11 | 50 | 9.7 | 7.6 | 0.523 | 0.136 | 0.936 | 0.178 | 32 | 8.7 | 83.0 | 1010 |
| TBF-70-209-11 | 70 | 12.0 | 7.6 | 0.346 | 0.127 | 0.638 | 0.204 | 35 | 9.1 | 88.7 | 1185 |
| TBF-95-209-11 | 95 | 13.3 | 7.6 | 0.271 | 0.124 | 0.516 | 0.219 | 48 | 9.6 | 93.8 | 1360 |
| TBF-120-209-11 | 120 | 15.3 | 7.6 | 0.210 | 0.119 | 0.418 | 0.241 | 53 | 9.9 | 98.7 | 1540 |
| TBF-150-209-11 | 150 | 17.2 | 7.6 | 0.165 | 0.114 | 0.347 | 0.261 | 56 | 10.3 | 103 | 1725 |
| TBF-185-209-11 | 185 | 18.8 | 7.6 | 0.136 | 0.111 | 0.304 | 0.279 | 56 | 10.7 | 108 | 1900 |
| TBF-240-209-11 | 240 | 21.7 | 7.6 | 0.106 | 0.107 | 0.261 | 0.309 | 77 | 11.3 | 116 | 2280 |
Frequently Asked Questions (FAQ)
What is the difference between Type 209.1 and Type 209.3 / 209.6 / 209.11?
Type 209.1 is rated at 1.1/1.1 kV and uses a polyester conductor separator tape and proofed textile insulation tape beneath the composite earth screen. Type 209.3 (3.3/3.3 kV), Type 209.6 (6.6/6.6 kV) and Type 209.11 (11/11 kV) incorporate semi-conductive conductor screens and semi-conductive insulation screens to manage medium-voltage electrical stress.
What is the role of the extensible central pilot core in AS/NZS 1802 Type 209 cables?
The single extensible central pilot core is positioned at the geometric center of the three phase cores to support earth-continuity monitoring, pilot-circuit interlocking and remote trip protection between the substation transformer or switchgear and the underground gate-end box.
What parameters are required to request a technical quotation or custom drum length?
Specify the required Type 209 voltage grade (1.1/1.1 kV, 3.3/3.3 kV, 6.6/6.6 kV or 11/11 kV), phase conductor cross-section (10 mm² to 300 mm²), total route length, individual drum lengths and project testing or factory inspection requirements.
Need a Custom Type 209 Mining Cable Quotation or Technical Review?
Share your system voltage, conductor size, route length and gate-end termination details with TEBAOFLEX engineering sales for factory-direct pricing, production lead times and test documentation.
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