Application & Operating Conditions
SANS 1520-1 Type 61B is a 0.64/1.1 kV heavy-duty flexible copper-screened trailing cable designed for high-current electrically driven coalface shearers, continuous miners, roadheaders, feeder-breakers, and movable switchgear in hazardous underground mining areas operating in non-reeling trailing service.
Continuous Miners & Longwall Shearers
Delivers 160 A to 390 A continuous current capacity (35 mm² to 150 mm²) with symmetrical 1-second short-circuit ratings up to 18.3 kA and earth-fault withstand up to 4.1 kA.
Triple-Extruded Semi-Conductive Shielding
Unlike basic low-voltage trailing cables, Type 61B applies medium-voltage-grade triple extrusion (conductor screen + RD 3 EPR + strippable core screen) beneath an 80%-fill all-copper wire braid.
Flame-Retardant Type RS 6 Elastomer
Inner and outer sheaths use thermosetting polychloroprene compound Type RS 6 bonded across an open 16-string nylon braid for water, oil, ozone, UV, and flame resistance.
High Earth-Fault Capacity (2.1 kA to 4.1 kA for 1s): Because Type 61B replaces composite textile/copper phase braids with an 80% minimum fill all-tinned-copper braided screen (27 mm² to 52 mm² metallic screen area) laid around a semi-conductive rubber centre, it provides superior fault-current conductivity for high-MVA 1.1 kV underground gate-end transformers.
Cable Construction (SANS 1520-1 Type 61B)
Built to SANS 1520-1, SANS 1411-1, and SANS 1411-3, Type 61B combines Class 5 tinned copper conductors, triple-extruded RD 3 dielectric layers, high-fill copper wire braids, and Type RS 6 polychloroprene sheathing.
| Layer / Component | Material & SANS 1520-1 Engineering Specification |
|---|---|
| 1. Conductors & Conductor Screen | Class 5 flexible stranded tinned annealed copper (SANS 1411-1; 35–150 mm² power, 6–16 mm² pilots) with extruded semi-conducting rubber conductor screen on power cores. |
| 2. Triple-Extruded Core Insulation | EPR thermosetting compound Type RD 3 (SANS 1411-3) co-extruded with a strippable semi-conducting elastomeric outer core screen for clean cold termination. |
| 3. Metallic Phase Screens | Tinned copper wire braided screen (0.31 mm wires, 80% coverage fill, 27–52 mm² cross-sectional area) over each of the three power cores. |
| 4. Six-Core Right-Hand Lay-Up | Three copper-braid-screened power cores and three unscreened pilot cores (one in each interstice) laid in right-hand lay (12 × PCD lay ratio) around a semi-conductive rubber filler. |
| 5. Inner Sheath | Extruded Polychloroprene thermosetting compound Type RS 6 (SANS 1411-3). |
| 6. Reinforcement Braid | Open nylon reinforcement braid (minimum 16 nylon strings) vulcanized between inner and outer sheaths. |
| 7. Outer Sheath | Heavy-duty black Polychloroprene thermosetting compound Type RS 6 — flame retardant, water resistant, oil resistant, and ozone/UV resistant. |
SANS 1520-1 Type 61B (35–150 mm²): 3 power cores with triple-extruded RD 3 EPR + semi-conductive screens + 80%-fill tinned copper wire braids, 3 interstitial pilot cores around a semi-conductive filler, and double RS 6 CR sheaths.
Technical Characteristics
Physical, electrical, and fault-current ratings for SANS 1520-1 Type 61B 0.64/1.1 kV flexible copper-screened mining cables.
| Parameter | SANS 1520-1 Rated Value |
|---|---|
| Applicable Standards | SANS 1520-1; SANS 1411-1; SANS 1411-3 (Compound Types RD 3 & RS 6) |
| Rated Voltage (Uo/U) | 0.64 / 1.1 kV (640 / 1100 V AC) |
| Operating Temperature Range | -25 °C to +90 °C |
| Ambient Current Rating Basis | 160 A to 390 A Laid Out Straight at 30 °C Ambient |
| Installation Application | Non-Reeling Trailing Operation for Movable Underground Mining Apparatus |
| Minimum Bending Radius | 300 mm (35 mm²) to 500 mm (150 mm²) |
| Maximum Pulling Tension | 1.6 kN (35 mm²) up to 6.8 kN (150 mm²) |
| 1-Second Fault Ratings | Symmetrical S/C: 4.3–18.3 kA | Earth Fault: 2.1–4.1 kA (1s) |
SANS 1520-1 Type 61B Physical & Electrical Specification Tables (6 Sizes)
Complete physical dimensions, screen fill cross-sections, bend radii, pulling tensions, standardized weights (kg/km), impedances, and 1-second short-circuit ratings.
1. SANS 1520-1 Type 61B — Physical Properties, Bend Radius, Tension & Mass (35–150 mm²)
| Configuration (mm²) | Power Wire / Cond. Dia. (mm) | Screen Wire Dia. (mm) | Screen Fill (%) | Screen Area (mm²) | Pilot Size (mm²) | Pilot Wire / Cond. Dia. (mm) | Lay Ratio (×PCD) | Cable OD (mm) | Min. Bend (mm) | Max. Tension (kN) | Nominal Weight (kg/km) |
|---|---|---|---|---|---|---|---|---|---|---|---|
| Type 61B 3×35 + 3×6 | 0.41 / 8.5 | 0.31 | 80 | 27 | 6 | 0.31 / 3.2 | 12 | 41.0 | 300 | 1.6 | 3,100 |
| Type 61B 3×50 + 3×6 | 0.41 / 10.3 | 0.31 | 80 | 32 | 6 | 0.31 / 3.2 | 12 | 42.5 | 340 | 2.3 | 3,600 |
| Type 61B 3×70 + 3×16 | 0.51 / 11.9 | 0.31 | 80 | 37 | 16 | 0.41 / 5.2 | 12 | 48.0 | 390 | 3.2 | 4,800 |
| Type 61B 3×95 + 3×16 | 0.51 / 13.5 | 0.31 | 80 | 43 | 16 | 0.41 / 5.2 | 12 | 52.3 | 430 | 4.3 | 5,700 |
| Type 61B 3×120 + 3×16 | 0.51 / 15.5 | 0.31 | 80 | 47 | 16 | 0.41 / 5.2 | 12 | 58.0 | 460 | 5.4 | 7,100 |
| Type 61B 3×150 + 3×16 | 0.51 / 17.3 | 0.31 | 80 | 52 | 16 | 0.41 / 5.2 | 12 | 63.5 | 500 | 6.8 | 8,500 |
2. SANS 1520-1 Type 61B — DC Resistance, Reactance, Impedance, Current & 1s Fault Ratings
| Configuration (mm²) | DC Res. @ 20 °C (Ω/km) | DC Res. @ 90 °C (Ω/km) | Reactance (Ω/km) | Impedance @ 90 °C (Ω/km) | Current Laid Straight @ 30 °C (A) | Sym. S/C 1s (kA) | Earth Fault 1s (kA) |
|---|---|---|---|---|---|---|---|
| Type 61B 3×35 + 3×6 | 0.576 | 0.734 | 0.090 | 0.740 | 160 | 4.3 | 2.1 |
| Type 61B 3×50 + 3×6 | 0.401 | 0.511 | 0.090 | 0.519 | 200 | 6.1 | 3.1 |
| Type 61B 3×70 + 3×16 | 0.283 | 0.360 | 0.088 | 0.371 | 245 | 8.5 | 3.5 |
| Type 61B 3×95 + 3×16 | 0.214 | 0.273 | 0.086 | 0.287 | 295 | 11.6 | 4.1 |
| Type 61B 3×120 + 3×16 | 0.167 | 0.213 | 0.086 | 0.230 | 345 | 14.6 | 4.1 |
| Type 61B 3×150 + 3×16 | 0.135 | 0.171 | 0.085 | 0.191 | 390 | 18.3 | 4.1 |
kg/km (3,100–8,500 kg/km), directly corresponding to 3.1–8.5 kg/m in the downloadable PDF datasheet.SANS 1520-1 & SANS 1520-2 South African Mining Cable Selection Matrix
Compare Type 61B (0.64/1.1 kV high-fill copper-braid screened non-reeling cable) against Type 41, Type 61A (TPU reeling), and SANS 1520-2 medium-voltage cables.
| SANS 1520 Model | Voltage, Core & Pilot Architecture & Primary Mining Duty |
|---|---|
| SANS 1520-1 Type 41 (640/1100V) | SANS 1520-1 Type 41 (640/1100V): 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) (This Product) | 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)
Engineering FAQs covering Type 61B vs Type 61A selection, strippable core screens, and earth-fault protection.
What is the main structural difference between SANS 1520-1 Type 61A and Type 61B?
Type 61A uses composite nylon/tinned-copper phase braids and a tough TPU outer sheath engineered for dynamic reeling and extreme rock-floor abrasion. Type 61B uses triple-extruded Type RD 3 EPR insulation with semi-conducting conductor and strippable core screens, an 80%-coverage all-tinned-copper braided phase screen, a semi-conductive rubber centre, and Type RS 6 flame-retardant polychloroprene sheaths specifically optimized for non-reeling movable coalface and underground machinery.
Why does a 0.64/1.1 kV cable like Type 61B include semi-conducting conductor and core screens?
High-power 1000 V / 1100 V variable-frequency drives (VFDs) and heavy thyristor starters on continuous miners and shearers generate steep voltage transients (dV/dt) and localized electrical stress. Triple extrusion with smooth semi-conducting screens eliminates air voids at the conductor and screen interfaces while allowing clean, nick-free stripping during coupler termination.
Is SANS 1520-1 Type 61B intended for dynamic motorized cable reels?
No. Per SANS 1520-1 service conditions, Type 61B is designed for non-reeling movable trailing duty (such as shearer cable handlers, monorail loops, and floor-laid machine feeders) because its dense 80% all-copper wire braid prioritizes maximum 2.1–4.1 kA earth-fault capacity over high-speed drum reeling. For dynamic reeling at 640/1100 V, select Type 61A or Type 41.
What drum lengths and routine test reports are provided?
TEBAOFLEX supplies SANS 1520-1 Type 61B in standard 250 m, 500 m, or custom project cut lengths with routine conductor resistance, AC dielectric withstand, partial-free insulation check, and RS 6 flame-retardant compound verification.
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