Application & Operating Conditions
AS/NZS 2802 Type 450 is a Class 1 composite screened medium- and high-voltage reeling and trailing cable (3.3 kV to 22 kV standard, 33 kV on request; 25–300 mm²) engineered for open-cut draglines, electric rope shovels, bucket-wheel excavators, stacker-reclaimers, bulk materials handling plants, and port wharf cranes.
Compact Class 1 Reeling Geometry
Reduced Class 1 XR-EP-90 EPR insulation radials cut overall diameter and suspended mass compared to Class 2 cables, allowing smaller reeling drum barrels and higher multi-layer spool capacity.
Dual Earths + Equal-Size Interstitial Pilot
Two elastomer-covered earth cores and one equal-cross-section elastomer-covered pilot (8–80 mm² each) occupy the three outer interstices for 120-degree torsional symmetry under drum tension.
Polyaramid-Reinforced XHD-85-PCP Sheath
Extra heavy-duty XHD-85-PCP polychloroprene jacket reinforced with an integral polyaramid yarn braid resists torsional corkscrewing, sheath creep, oil, solar UV, and pit-water immersion.
Coupler Pinout Requires a Reduced-Size Pilot? If your HV coupler pilot receptacle accepts 9–13.2 mm² pilot pins rather than an equal-sized 18–80 mm² pilot, specify AS/NZS 2802 Type 451.
Cable Construction (AS/NZS 2802 Type 450)
Type 450 combines composite-screened Class 1 XR-EP-90 power cores with three equal-diameter elastomer-covered interstitial cores (2 earths + 1 pilot) and an anti-torsion polyaramid-reinforced XHD-85-PCP outer sheath.
| Layer / Component | Material & AS/NZS 2802 Specification |
|---|---|
| 1. Phase Conductors | Flexible stranded tinned annealed copper, three power cores (25 mm² to 300 mm²) |
| 2. Conductor Screen | Semiconductive barrier tape and extruded semiconductive elastomeric conductor screen |
| 3. Class 1 EPR Insulation | Cross-linked XR-EP-90 EPR Class 1 compound (2.2–2.4 mm @ 3.3 kV; 3.0 mm @ 6.6 kV; 5.0 mm @ 11 kV; 7.6 mm @ 22 kV) |
| 4. Composite Insulation Screen | Composite screen of tinned annealed copper wire and polyester yarn applied over semiconductive layer with Red, White, and Blue tracers (7.9–34 mm²/phase) |
| 5. Two Interstitial Earths + One Pilot | Two semiconductive elastomer-covered earths + one equal-size insulating elastomer-covered pilot in the outer interstices (8–80 mm² each) |
| 6. Central Cradle & Outer Sheath | Central elastomeric cradle filler; extra heavy-duty black XHD-85-PCP sheath (4.8–7.7 mm) incorporating polyaramid braid reinforcement |
Type 450 Cross-Section Geometry: Three composite-screened Class 1 XR-EP-90 phase cores in trefoil around a central elastomeric filler, balanced by 2 interstitial earths and 1 equal-size interstitial pilot under a polyaramid-reinforced XHD-85-PCP sheath.
Technical Characteristics
Built to AS/NZS 2802 Class 1 tolerances, Type 450 pairs metallic fault-return screening with supplemental interstitial earth conductors for high earth-fault settings on open-cut and port HV networks.
| Parameter | AS/NZS 2802 Rated Value |
|---|---|
| Manufacturing Standard | AS/NZS 2802 Class 1 (Reeling and trailing cables for mining and general use) |
| Rated Voltages & Sub-Types | 450.3 (3.3 kV) | 450.6 (6.6 kV) | 450.11 (11 kV) | 450.22 (22 kV) | 450.33 (33 kV on request) |
| Combined Earth Return Path | 3 composite copper phase screens (7.9–34 mm²/phase) + 2 dedicated interstitial earths (8–80 mm² each) |
| Interstitial Pilot Sizing | Equal cross-section to interstitial earths (8 mm² on 25/35 mm² scaling up to 80 mm² on 300 mm²) |
| Operating Temperature Range | −25 °C min. installation to +90 °C max. continuous conductor (250 °C short-circuit) |
| Duty & Flame Classification | Slow monospiral/cylindrical reeling & heavy trailing | C1 flame retardant | Oil & water immersion resistant |
Specification, Screen & Earth/Pilot Data (38 Standard Sizes, 3.3 kV – 22 kV)
Complete AS/NZS 2802 Type 450 electrical and dimensional tables combining conductor diameter, Class 1 XR-EP-90 insulation thickness, AC impedance, per-phase screen area, earth/pilot cross-section, overall diameter, and mass.
Type 450.3 — Rated Voltage: 3.3/3.3 kV (25 mm² to 300 mm² | 10 Sizes)
| Area (mm²) | Cond. Dia. (mm) | Insul. (mm) | AC Res. (Ω/km) | React. (Ω/km) | Volt Drop (mV/A·m) | Cap. (μF/km) | Screen (mm²/ph) | Earth & Pilot Each (mm²) | Sheath (mm) | Cable Dia. (mm) | Mass (kg/100m) |
|---|---|---|---|---|---|---|---|---|---|---|---|
| 3 × 25 | 7.2 | 2.2 | 0.951 | 0.118 | 1.66 | 0.395 | 7.9 | 8 | 4.8 | 46.7 | 355 |
| 3 × 35 | 8.4 | 2.2 | 0.698 | 0.113 | 1.22 | 0.437 | 8.5 | 8 | 5.1 | 49.7 | 415 |
| 3 × 50 | 9.7 | 2.4 | 0.523 | 0.109 | 0.925 | 0.450 | 9.3 | 12 | 5.6 | 54.5 | 515 |
| 3 × 70 | 12.0 | 2.4 | 0.346 | 0.103 | 0.625 | 0.525 | 14 | 18 | 6.0 | 60.5 | 660 |
| 3 × 95 | 13.3 | 2.4 | 0.271 | 0.0986 | 0.500 | 0.563 | 15 | 25 | 6.3 | 63.9 | 765 |
| 3 × 120 | 15.3 | 2.4 | 0.210 | 0.0947 | 0.399 | 0.628 | 16 | 31 | 6.4 | 68.4 | 900 |
| 3 × 150 | 17.2 | 2.4 | 0.166 | 0.0918 | 0.329 | 0.687 | 17 | 39.5 | 6.6 | 72.8 | 1070 |
| 3 × 185 | 18.8 | 2.4 | 0.137 | 0.0896 | 0.284 | 0.741 | 18 | 50 | 6.7 | 76.5 | 1225 |
| 3 × 240 | 21.7 | 2.4 | 0.107 | 0.0867 | 0.239 | 0.833 | 25 | 60 | 6.9 | 83.3 | 1485 |
| 3 × 300 | 24.3 | 2.4 | 0.0851 | 0.0844 | 0.208 | 0.917 | 27 | 80 | 7.0 | 89.0 | 1800 |
Type 450.6 — Rated Voltage: 6.6/6.6 kV (25 mm² to 300 mm² | 10 Sizes)
| Area (mm²) | Cond. Dia. (mm) | Insul. (mm) | AC Res. (Ω/km) | React. (Ω/km) | Volt Drop (mV/A·m) | Cap. (μF/km) | Screen (mm²/ph) | Earth & Pilot Each (mm²) | Sheath (mm) | Cable Dia. (mm) | Mass (kg/100m) |
|---|---|---|---|---|---|---|---|---|---|---|---|
| 3 × 25 | 7.2 | 3.0 | 0.951 | 0.124 | 1.66 | 0.309 | 8.8 | 8 | 5.2 | 51.1 | 410 |
| 3 × 35 | 8.4 | 3.0 | 0.698 | 0.118 | 1.23 | 0.340 | 9.3 | 8 | 5.5 | 54.2 | 470 |
| 3 × 50 | 9.7 | 3.0 | 0.523 | 0.113 | 0.927 | 0.375 | 10 | 12 | 5.9 | 57.8 | 560 |
| 3 × 70 | 12.0 | 3.0 | 0.346 | 0.106 | 0.627 | 0.435 | 15 | 18 | 6.3 | 63.9 | 710 |
| 3 × 95 | 13.3 | 3.0 | 0.271 | 0.102 | 0.502 | 0.465 | 16 | 25 | 6.4 | 66.8 | 810 |
| 3 × 120 | 15.3 | 3.0 | 0.210 | 0.0979 | 0.401 | 0.518 | 17 | 31 | 6.5 | 71.4 | 950 |
| 3 × 150 | 17.2 | 3.0 | 0.166 | 0.0948 | 0.331 | 0.566 | 18 | 39.5 | 6.6 | 75.5 | 1120 |
| 3 × 185 | 18.8 | 3.0 | 0.137 | 0.0923 | 0.286 | 0.608 | 20 | 50 | 6.8 | 79.3 | 1280 |
| 3 × 240 | 21.7 | 3.0 | 0.106 | 0.0893 | 0.240 | 0.682 | 27 | 60 | 7.0 | 86.2 | 1545 |
| 3 × 300 | 24.3 | 3.0 | 0.0850 | 0.0871 | 0.211 | 0.754 | 29 | 80 | 7.1 | 92.3 | 1875 |
Type 450.11 — Rated Voltage: 11/11 kV (25 mm² to 300 mm² | 10 Sizes)
| Area (mm²) | Cond. Dia. (mm) | Insul. (mm) | AC Res. (Ω/km) | React. (Ω/km) | Volt Drop (mV/A·m) | Cap. (μF/km) | Screen (mm²/ph) | Earth & Pilot Each (mm²) | Sheath (mm) | Cable Dia. (mm) | Mass (kg/100m) |
|---|---|---|---|---|---|---|---|---|---|---|---|
| 3 × 25 | 7.2 | 5.0 | 0.951 | 0.136 | 1.66 | 0.217 | 14 | 8 | 6.3 | 62.3 | 565 |
| 3 × 35 | 8.4 | 5.0 | 0.698 | 0.129 | 1.23 | 0.236 | 15 | 8 | 6.4 | 65.0 | 625 |
| 3 × 50 | 9.7 | 5.0 | 0.523 | 0.123 | 0.931 | 0.258 | 16 | 12 | 6.5 | 68.1 | 715 |
| 3 × 70 | 12.0 | 5.0 | 0.346 | 0.115 | 0.632 | 0.296 | 17 | 18 | 6.6 | 73.1 | 855 |
| 3 × 95 | 13.3 | 5.0 | 0.271 | 0.111 | 0.507 | 0.317 | 18 | 25 | 6.7 | 76.1 | 965 |
| 3 × 120 | 15.3 | 5.0 | 0.210 | 0.107 | 0.408 | 0.350 | 20 | 31 | 6.9 | 80.7 | 1115 |
| 3 × 150 | 17.2 | 5.0 | 0.166 | 0.103 | 0.338 | 0.381 | 26 | 39.5 | 7.0 | 85.2 | 1315 |
| 3 × 185 | 18.8 | 5.0 | 0.137 | 0.100 | 0.294 | 0.407 | 27 | 50 | 7.1 | 89.0 | 1485 |
| 3 × 240 | 21.7 | 5.0 | 0.106 | 0.0964 | 0.248 | 0.453 | 30 | 60 | 7.3 | 95.5 | 1745 |
| 3 × 300 | 24.3 | 5.0 | 0.0846 | 0.0937 | 0.219 | 0.499 | 32 | 80 | 7.4 | 101 | 2080 |
Type 450.22 — Rated Voltage: 22/22 kV (35 mm² to 240 mm² | 8 Sizes)
| Area (mm²) | Cond. Dia. (mm) | Insul. (mm) | AC Res. (Ω/km) | React. (Ω/km) | Volt Drop (mV/A·m) | Cap. (μF/km) | Screen (mm²/ph) | Earth & Pilot Each (mm²) | Sheath (mm) | Cable Dia. (mm) | Mass (kg/100m) |
|---|---|---|---|---|---|---|---|---|---|---|---|
| 3 × 35 | 8.4 | 7.6 | 0.698 | 0.142 | 1.23 | 0.178 | 19 | 8 | 6.8 | 77.2 | 835 |
| 3 × 50 | 9.7 | 7.6 | 0.523 | 0.135 | 0.936 | 0.194 | 20 | 12 | 6.9 | 80.2 | 930 |
| 3 × 70 | 12.0 | 7.6 | 0.346 | 0.127 | 0.638 | 0.219 | 27 | 18 | 7.0 | 85.6 | 1105 |
| 3 × 95 | 13.3 | 7.6 | 0.271 | 0.122 | 0.515 | 0.234 | 27 | 25 | 7.2 | 88.9 | 1230 |
| 3 × 120 | 15.3 | 7.6 | 0.210 | 0.117 | 0.416 | 0.256 | 29 | 31 | 7.3 | 93.4 | 1395 |
| 3 × 150 | 17.2 | 7.6 | 0.165 | 0.113 | 0.346 | 0.276 | 31 | 39.5 | 7.4 | 97.5 | 1580 |
| 3 × 185 | 18.8 | 7.6 | 0.136 | 0.110 | 0.303 | 0.294 | 32 | 50 | 7.5 | 101 | 1760 |
| 3 × 240 | 21.7 | 7.6 | 0.106 | 0.105 | 0.258 | 0.325 | 34 | 60 | 7.7 | 108 | 2035 |
Selection: Type 450 vs. Type 451 vs. Type 409
Type 450, Type 451, and Type 409 all employ composite copper/polyester phase screens; selection depends on pilot conductor size, reeling drum diameter, and ground-drag severity.
| Cable Model | Radial Class, Earth/Pilot Geometry & Application |
|---|---|
| Type 450 (This Product) | Class 1 reduced radial + 2 interstitial earths + 1 equal-size interstitial pilot (8–80 mm², 25–300 mm², 3.3–22/33 kV). Maximum geometric symmetry and low pilot-loop impedance for large draglines, shovels, and stacker-reclaimers. |
| Type 451 (Reduced Pilot) | Type 451 matches Type 450 electricals and OD from 25–150 mm², but steps the interstitial pilot down to 9 mm² or 13.2 mm² to fit standard HV coupler pilot pins without reducer ferrules. |
| Type 409 (Class 2 Trailing) | Type 409 uses heavy Class 2 EPR & sheath radials with 1 central pilot (no separate interstitial earths) for non-reeled open-cut ground trailing over sharp blast rock. |
Frequently Asked Questions (FAQ)
Engineering guidance on Class 1 vs. Class 2 diameter savings, 33 kV custom builds, and wharf crane reeling suitability.
How much smaller and lighter is Class 1 Type 450 compared with Class 2 Type 409 at 11 kV or 22 kV?
At 11 kV (3 × 95 mm²), Class 1 Type 450.11 uses a 5.0 mm XR-EP-90 insulation wall for a 76.1 mm OD and 965 kg/100m mass, whereas Class 2 Type 409.11 uses a 7.6 mm wall for a 90.0 mm OD and 1275 kg/100m mass — a 15% diameter reduction and 24% weight saving on reeling drums.
Can TEBAOFLEX manufacture AS/NZS 2802 Type 450 for 33/33 kV mine and port systems?
Yes. In addition to the catalogued 3.3 kV, 6.6 kV, 11 kV, and 22 kV ranges, Type 450.33 (33/33 kV) is manufactured to order with triple-extruded XR-EP-90 insulation and full routine partial-discharge and HV AC dielectric test reports.
Is Type 450 suitable for port container cranes and bulk ship-loader reeling drums?
Type 450 is widely specified for slow-to-moderate monospiral and level-wind reeling on bulk stacker-reclaimers, ship loaders, and wharf cranes where AS/NZS 2802 composite earth screening is required. For high-speed dynamic container spreader/gantry reeling, ask our engineers to verify travel speed and acceleration against your drum diameter.
Request a Quote for AS/NZS 2802 Type 450 Class 1 Reeling Cables
Share your system voltage (3.3 kV to 33 kV), phase cross-section (25–300 mm²), drum dimensions, and delivery port for technical drawings and mill-direct pricing.
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