Application & Operating Conditions
SANS 1520-1 Type 41 is a 640/1100 V four-core screened flexible trailing cable manufactured to South African National Standard SANS 1520-1 for connecting portable mining machinery, face drills, mobile pumps, and auxiliary reeling or non-reeling electrical apparatus operating in hazardous underground and open-cast mining zones.
Portable Face Drills & Bolters
Compact 20 mm to 39 mm overall diameters and 6 × OD minimum bending radius allow tight handling on roof bolters, face drills, and portable underground maintenance tools.
Reeling & Non-Reeling Drum Duty
Open 16-string nylon reinforcement braid vulcanized between the CR inner and outer sheaths resists torsional twist and axial tension (0.15 kN to 1.1 kN) on mono-spiral and multi-layer cable drums.
Hazardous-Area Earth Fault Protection
Each power core carries an individual composite tinned-copper and nylon braided screen (8–25 mm² equivalent screen fill) paired with an insulated pilot core for earth-continuity interlock.
Drum De-Rating Guidance (SANS 1520-1): Type 41 specifies distinct continuous current ratings for cables laid out straight (45–130 A at 30 °C ambient) versus wound in 1, 2, or 3 layers on a reeling drum. Always size conductors to the maximum number of active drum layers at low-payout duty.
Cable Construction (SANS 1520-1 Type 41)
Manufactured in strict compliance with SANS 1520-1, SANS 1411-1, and SANS 1411-3, Type 41 arranges three individually screened phase cores and one unscreened pilot core symmetrically around a central elastomeric cradle.
| Layer / Component | Material & SANS 1520-1 Engineering Specification |
|---|---|
| 1. Power & Pilot Conductors | Class 5 flexible stranded tinned annealed copper wires in accordance with SANS 1411-1 (power cores 2.5–25 mm²; pilot core 2.5–16 mm²). |
| 2. Core Insulation | Thermosetting Ethylene Propylene Rubber (EPR) dielectric compound to SANS 1411-3 rated for continuous +90 °C conductor operation. |
| 3. Power Core Screens | Individual composite braid of tinned copper wires (0.21 mm or 0.31 mm wire diameter) and nylon yarn applied over each of the three power cores. |
| 4. Core Lay-Up & Centre | Three screened power cores (Red, Yellow, Blue) and one unscreened insulated pilot core (Black) laid up symmetrically around a profiled rubber filler centre. |
| 5. Inner Sheath | Extruded heavy-duty Polychloroprene (CR) thermosetting elastomer bedding locking the four-core geometry. |
| 6. Anti-Torsion Reinforcement | Open nylon reinforcement braid (minimum 16 strings) embedded between the inner and outer sheaths to limit elongation and jacket creep. |
| 7. Outer Sheath | Heavy-duty black Polychloroprene (CR) outer sheath resistant to mine water, mineral oils, abrasion, ozone, and flame propagation. |
SANS 1520-1 Type 41 (2.5–25 mm²): 3 composite nylon/tinned-copper screened EPR power cores + 1 unscreened EPR pilot core laid around a central rubber filler, enclosed in CR inner sheath, 16-string open nylon braid, and black CR outer sheath.
Technical Characteristics
Verified electrical, thermal, and mechanical operating parameters for SANS 1520-1 Type 41 flexible trailing cables.
| Parameter | SANS 1520-1 Rated Value |
|---|---|
| Applicable Standards | SANS 1520-1; SANS 1411-1 (Conductors); SANS 1411-3 (EPR / CR Compounds) |
| Rated Voltage (Uo/U) | 640 / 1100 V AC |
| Operating Temperature Range | -25 °C to +90 °C (Maximum Conductor Temperature +90 °C) |
| Ambient Current Rating Basis | 30 °C Ambient Temperature (Laid Out Straight & 1 / 2 / 3 Drum Layers) |
| Minimum Bending Radius | 6 × Overall Cable Diameter (120 mm to 234 mm across 2.5–25 mm² range) |
| Maximum Tensile Load | 0.15 kN (2.5 mm²) up to 1.1 kN (25 mm²) |
| Short-Circuit Rating Basis | 1 Second Symmetrical (0.49–3.1 kA) & Earth Fault (0.5–1.6 kA) for 2.5–16 mm² |
| Outer Sheath Colour & Finish | Black Heavy-Duty Polychloroprene (CR) |
SANS 1520-1 Type 41 Dimensional & Electrical Specification Tables
Complete nominal dimensional, tensile, mass, impedance, drum-layer ampacity, and 1-second fault current data per SANS 1520-1.
1. SANS 1520-1 Type 41 — Construction Dimensions, Tensile Rating & Nominal Weight (6 Sizes)
| Configuration (mm²) | Power Wire Dia. (mm) | Power Cond. Dia. (mm) | Screen Wire Dia. (mm) | Screen Fill (mm²) | Pilot Size (mm²) | Pilot Wire Dia. (mm) | Pilot Cond. Dia. (mm) | Max. Tension (kN) | Overall Dia. (mm) | Nominal Weight (kg/km) |
|---|---|---|---|---|---|---|---|---|---|---|
| Type 41 3×2.5 + 1×2.5 | 0.26 | 2.1 | 0.21 | 8 | 2.5 | 0.26 | 2.1 | 0.15 | 20 | 712 |
| Type 41 3×4 + 1×4 | 0.31 | 2.7 | 0.21 | 9.5 | 4 | 0.31 | 2.7 | 0.24 | 25 | 902 |
| Type 41 3×6 + 1×6 | 0.31 | 3.3 | 0.21 | 10.4 | 6 | 0.31 | 3.3 | 0.36 | 26 | 1,103 |
| Type 41 3×10 + 1×10 | 0.41 | 4.2 | 0.31 | 19 | 10 | 0.41 | 4.2 | 0.60 | 29 | 1,563 |
| Type 41 3×16 + 1×16 | 0.41 | 5.3 | 0.31 | 22 | 16 | 0.41 | 5.3 | 0.95 | 33 | 2,105 |
| Type 41 3×25 + 1×16 | 0.41 | 6.8 | 0.31 | 25 | 16 | 0.41 | 5.3 | 1.1 | 39 | 2,705 |
2. SANS 1520-1 Type 41 — Resistance, Impedance, Drum-Layer Ampacity & 1s Fault Ratings
| Configuration (mm²) | DC Res. @ 20 °C (Ω/km) | DC Res. @ 90 °C (Ω/km) | Reactance (Ω/km) | Impedance @ 30 °C (Ω/km) | Straight (A) | 1 Drum Layer (A) | 2 Drum Layers (A) | 3 Drum Layers (A) | Sym. S/C 1s (kA) | Earth Fault 1s (kA) |
|---|---|---|---|---|---|---|---|---|---|---|
| Type 41 3×2.5 + 1×2.5 | 5.50 | 7.01 | 0.123 | 7.01 | 45 | 38 | 29 | 20 | 0.49 | 0.5 |
| Type 41 3×4 + 1×4 | 3.66 | 4.67 | 0.115 | 4.67 | 57 | 48 | 37 | 25 | 0.73 | 0.7 |
| Type 41 3×6 + 1×6 | 2.11 | 2.69 | 0.108 | 2.69 | 77 | 65 | 50 | 34 | 1.2 | 0.6 |
| Type 41 3×10 + 1×10 | 1.34 | 1.71 | 0.103 | 1.71 | 100 | 85 | 65 | 45 | 2.0 | 1.0 |
| Type 41 3×16 + 1×16 | 0.859 | 1.10 | 0.100 | 1.10 | 130 | 110 | 84 | 58 | 3.1 | 1.6 |
| Type 41 3×25 + 1×16 | — | — | — | — | — | — | — | — | — | — |
3×25+1×16 mm² size are available from TEBAOFLEX engineering upon project request.SANS 1520-1 & SANS 1520-2 South African Mining Cable Selection Matrix
Compare Type 41 (640/1100 V 4-core auxiliary trailing cable) against 6-core heavy-duty low-voltage (Type 61A, Type 61B) and medium-voltage (Type 63 to Type 633) SANS 1520 trailing and reeling cables.
| SANS 1520 Model | Voltage, Core & Pilot Architecture & Primary Mining Duty |
|---|---|
| SANS 1520-1 Type 41 (640/1100V) (This Product) | 640/1100 V 4-core (3 composite-screened power cores + 1 unscreened pilot, 2.5–25 mm²) CR-sheathed reeling & trailing cable for drills, pumps, and portable underground tools. |
| SANS 1520-1 Type 61A (640/1100V TPU) | SANS 1520-1 Type 61A (640/1100V TPU): 640/1100 V heavy-duty 6-core (3 composite-screened power cores + 3 interstitial pilots) reeling & trailing cable with abrasion-resistant TPU outer sheath (black or reflective transparent). |
| SANS 1520-1 Type 61B (0.64/1.1kV) | SANS 1520-1 Type 61B (0.64/1.1kV): 0.64/1.1 kV 6-core (35–150 mm²) non-reeling coalface cable with triple-extruded RD 3 EPR, 80% tinned copper braid screens, 3 interstitial pilots, and RS 6 CR sheaths. |
| SANS 1520-2 Type 63 (1.9/3.3kV) | SANS 1520-2 Type 63 (1.9/3.3kV): 1.9/3.3 kV medium-voltage 6-core (25–240 mm², up to 520 A) composite-screened reeling & trailing cable for 3.3 kV continuous miners, shearers, and jumbo drills. |
| SANS 1520-2 Type 66 & 66-ECC (3.8/6.6kV) | SANS 1520-2 Type 66 & 66-ECC (3.8/6.6kV): 3.8/6.6 kV screened reeling & section feeder cable (25–240 mm²) with 3 interstitial pilots (Type 66) or 2 pilots + 1 bare ECC earth conductor up to 17.0 kA 1s (Type 66-ECC). |
| SANS 1520-2 Type 611 & 611-ECC (6.35/11kV) | SANS 1520-2 Type 611 & 611-ECC (6.35/11kV): 6.35/11 kV medium-voltage dragline, shovel, and reeling cable (25–240 mm²) with triple-extruded EPR insulation, strippable semi-con screen, and CR outer sheath. |
| SANS 1520-2 Type 622 & 622-ECC (12.7/22kV) | SANS 1520-2 Type 622 & 622-ECC (12.7/22kV): 12.7/22 kV heavy-duty open-cast dragline, excavator, and mobile pit substation feeder cable (25–150 mm²) in 3-pilot or high-fault ECC topology. |
| SANS 1520-2 Type 633 & 633-ECC (19/33kV) | SANS 1520-2 Type 633 & 633-ECC (19/33kV): 19/33 kV highest-voltage SANS 1520-2 screened reeling & pit feeder cable (25–120 mm²) delivering up to ~14.8 MVA three-phase bench capacity. |
Frequently Asked Questions (FAQ)
Technical answers for mine electrical engineers specifying SANS 1520-1 Type 41 trailing cables.
How does SANS 1520-1 Type 41 differ from Type 61A and Type 61B?
In the SANS 1520 designation code, the first digit indicates the total core lay-up: Type 41 is a 4-core construction (3 composite-screened power cores + 1 unscreened pilot core) sized from 2.5 mm² to 25 mm² for auxiliary portable tools, drills, and pumps. Type 61A and Type 61B are 6-core constructions (3 screened power cores + 3 interstitial pilot cores) engineered for higher-power 35 mm² to 150 mm² coalface machines, shuttle cars, and LHDs.
Can SANS 1520-1 Type 41 be operated on multi-layer spring or motorized cable reels?
Yes. Type 41 incorporates a vulcanized CR inner sheath and a minimum 16-string open nylon anti-torsion braid beneath the black CR outer sheath specifically for reeling and non-reeling service. When wound onto a drum, apply the multi-layer ampacity ratings (e.g., 16 mm² drops from 130 A laid straight to 110 A for 1 layer, 84 A for 2 layers, and 58 A for 3 layers at 30 °C ambient).
Why does SANS 1520-1 specify Class 5 tinned copper conductors and composite copper/nylon screens?
Tinning protects fine 0.26–0.41 mm copper strands against sulfur cross-migration during high-pressure EPR vulcanization and prevents corrosion in damp, acidic underground mine water. Combining tinned copper wires with high-tenacity nylon yarn in each phase screen maintains radial fault interception without wire breakage under repeated 6 × OD flexing.
What customization options and factory test certificates are supplied with TEBAOFLEX Type 41 cables?
TEBAOFLEX manufactures SANS 1520-1 Type 41 cables in custom drum cut lengths with full routine conductor DC resistance, high-voltage AC dielectric test, and insulation resistance inspection reports. Optional TPU outer sheaths or embossed mine identification markings are available upon inquiry.
Request a Quote for SANS 1520-1 Type 41 Trailing Cable
Send your required conductor size (2.5 mm² to 25 mm²), reeling drum parameters, and total meterage for direct factory pricing and technical datasheet verification.
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