Application & Operating Conditions
SANS 1520-2 Type 63 is an unarmoured 1.9/3.3 kV medium-voltage flexible trailing and reeling cable manufactured to South African National Standard SANS 1520-2 to deliver primary 3.3 kV power (130 A to 520 A) to high-output underground continuous miners, longwall shearers, tunnel boring machines, and mobile open-cast mining equipment in hazardous areas.
3.3 kV Continuous Miners & Shearers
Covers nine standard cross-sections from 25 mm² up to 240 mm² (520 A continuous at 30 °C; 29 kA 1s symmetrical short-circuit) for modern high-tonnage 3.3 kV coal and hard-rock cutting faces.
Reeling & Non-Reeling Dynamic Service
Composite nylon/tinned-copper phase screens (31–64 mm² screen cross-section) flex repeatedly at 6 × OD without metallic work-hardening, while the 16-string open nylon braid handles up to 10.8 kN axial tension.
Three Interstitial Pilot Cores
Integrates three unscreened pilot/control cores (10 mm², 16 mm², or 25 mm²) nestled in the outer phase valleys for earth-continuity monitoring, pilot-relay interlocking, and telemetry.
Cross-Standard Identification Notice (SANS 1520-2 vs BS 6708): Do not confuse South African SANS 1520-2 Type 63 (unarmoured 1.9/3.3 kV medium-voltage flexible reeling/trailing cable, 25–240 mm²) with British Standard BS 6708 Type 63 (640/1100 V pliable steel-wire armoured roadway cable). Always verify both standard prefix and rated voltage before ordering couplers.
Cable Construction (SANS 1520-2 Type 63)
Manufactured to SANS 1520-2, SANS 1411-1, and SANS 1411-3, Type 63 balances medium-voltage 3.3 kV dielectric integrity with tight 6 × OD bending flexibility.
| Layer / Component | Material & SANS 1520-2 Engineering Specification |
|---|---|
| 1. Power & Pilot Conductors | Class 5 flexible stranded tinned annealed copper to SANS 1411-1 (power cores 25–240 mm²; three interstitial pilot cores 10–25 mm²). |
| 2. Medium-Voltage Insulation | 3.3 kV grade thermosetting Ethylene Propylene Rubber (EPR) compound to SANS 1411-3 rated for continuous +90 °C conductor temperature. |
| 3. Composite Phase Screens | Individual composite braid of 0.31 mm tinned copper wires and nylon yarn (31 mm² to 64 mm² screen cross-section) applied over each of the three MV power cores. |
| 4. Six-Core Lay-Up & Centre | Three composite-screened MV power cores (Red, Yellow, Blue) and three unscreened insulated pilot cores laid up symmetrically around a central rubber filler cradle. |
| 5. Inner Sheath | Extruded heavy-duty Polychloroprene (CR) rubber inner bedding maintaining core geometry under reel compression. |
| 6. Anti-Torsion Reinforcement | Open nylon reinforcement braid (minimum 16 strings) bonded between the inner and outer sheaths for axial tensile stability (1.1–10.8 kN). |
| 7. Outer Sheath | Heavy-duty black Polychloroprene (CR) outer sheath resistant to abrasion, mine water, hydraulic oil, ozone, and flame propagation (optional TPU outer sheath available for severe rock-drag applications). |
SANS 1520-2 Type 63 (25–240 mm²): 3 medium-voltage EPR power cores with composite tinned-copper/nylon braided screens + 3 interstitial pilot cores laid around a central rubber filler, with CR inner sheath, 16-string open nylon braid, and black CR outer sheath.
Technical Characteristics
Verified electrical, fault-current, thermal, and mechanical specifications for SANS 1520-2 Type 63 1.9/3.3 kV trailing cables.
| Parameter | SANS 1520-2 Rated Value |
|---|---|
| Applicable Standards | SANS 1520-2; SANS 1411-1; SANS 1411-3 |
| Rated Voltage (Uo/U) | 1.9 / 3.3 kV AC |
| Operating Temperature Range | -25 °C to +90 °C |
| Minimum Bending Radius | 6 × Overall Cable Diameter (264 mm to 468 mm across 25–240 mm²) |
| Ambient Current Rating Basis | 130 A (25 mm²) to 520 A (240 mm²) Laid Out Straight at 30 °C Ambient |
| Installation Use | Reeling and Non-Reeling Operation for Portable & Mobile 3.3 kV Mining Equipment |
| Maximum Pulling Tension | 1.1 kN (25 mm²) up to 10.8 kN (240 mm²) |
| 1-Second Fault Ratings | Symmetrical S/C: 3.1–29 kA | Earth Fault: 1.6–4.1 kA (1s) |
SANS 1520-2 Type 63 Complete Dimensional & Electrical Tables (9 Sizes)
Complete nominal dimensional, screen cross-section, tensile load, standardized mass (kg/km), impedance, current rating, and 1-second short-circuit tables for all nine 1.9/3.3 kV sizes.
1. SANS 1520-2 Type 63 — Dimensions, Screen Cross-Section, Tension & Nominal Weight (25–240 mm²)
| Configuration (mm²) | Power Wire Dia. (mm) | Power Cond. Dia. (mm) | Screen Wire Dia. (mm) | Screen Area (mm²) | Pilot Size (mm²) | Pilot Wire Dia. (mm) | Pilot Cond. Dia. (mm) | Max. Tension (kN) | Overall Dia. (mm) | Nominal Weight (kg/km) |
|---|---|---|---|---|---|---|---|---|---|---|
| Type 63 3×25 + 3×10 | 0.41 | 6.8 | 0.31 | 31 | 10 | 0.41 | 4.2 | 1.1 | 44.0 | 3,600 |
| Type 63 3×35 + 3×10 | 0.41 | 8.5 | 0.31 | 33 | 10 | 0.41 | 4.2 | 1.6 | 48.0 | 4,200 |
| Type 63 3×50 + 3×10 | 0.41 | 10.3 | 0.31 | 38 | 10 | 0.41 | 4.2 | 2.3 | 50.5 | 4,200 |
| Type 63 3×70 + 3×16 | 0.51 | 11.9 | 0.31 | 42 | 16 | 0.41 | 5.3 | 3.2 | 56.0 | 6,400 |
| Type 63 3×95 + 3×16 | 0.51 | 13.5 | 0.31 | 47 | 16 | 0.41 | 5.3 | 4.3 | 61.0 | 7,700 |
| Type 63 3×120 + 3×16 | 0.51 | 15.5 | 0.31 | 50 | 16 | 0.41 | 5.3 | 5.4 | 63.0 | 8,500 |
| Type 63 3×150 + 3×25 | 0.51 | 17.3 | 0.31 | 55 | 25 | 0.41 | 6.8 | 6.8 | 66.0 | 10,500 |
| Type 63 3×185 + 3×25 | 0.51 | 20.2 | 0.31 | 60 | 25 | 0.41 | 6.8 | 8.3 | 72.0 | 11,400 |
| Type 63 3×240 + 3×25 | 0.51 | 22.9 | 0.31 | 64 | 25 | 0.41 | 6.8 | 10.8 | 78.0 | 14,000 |
2. SANS 1520-2 Type 63 — 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 63 3×25 + 3×10 | 0.859 | 1.10 | 0.122 | 1.11 | 130 | 3.1 | 1.6 |
| Type 63 3×35 + 3×10 | 0.610 | 0.778 | 0.113 | 0.786 | 160 | 4.3 | 2.1 |
| Type 63 3×50 + 3×10 | 0.424 | 0.542 | 0.107 | 0.552 | 200 | 6.1 | 3.1 |
| Type 63 3×70 + 3×16 | 0.299 | 0.382 | 0.103 | 0.396 | 245 | 8.5 | 3.5 |
| Type 63 3×95 + 3×16 | 0.227 | 0.290 | 0.090 | 0.304 | 295 | 11.6 | 4.1 |
| Type 63 3×120 + 3×16 | 0.177 | 0.227 | 0.088 | 0.243 | 345 | 14.6 | 4.1 |
| Type 63 3×150 + 3×25 | 0.143 | 0.183 | 0.085 | 0.202 | 390 | 18.3 | 4.1 |
| Type 63 3×185 + 3×25 | 0.117 | 0.150 | 0.084 | 0.172 | 440 | 23 | 4.1 |
| Type 63 3×240 + 3×25 | 0.0882 | 0.115 | 0.083 | 0.142 | 520 | 29 | 4.1 |
kg/km (3,600–14,000 kg/km, equivalent to 360–1,400 kg/100m) and verified for 10 mm² pilot conductor diameter (4.2 mm) so reel torque and shipping calculations remain exact.SANS 1520-1 & SANS 1520-2 South African Mining Cable Selection Matrix
Compare Type 63 (1.9/3.3 kV medium-voltage trailing & reeling cable) across the complete SANS 1520 underground and open-cast voltage hierarchy from 640/1100 V up to 19/33 kV.
| 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) | 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) (This Product) | 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)
Frequently asked engineering questions for 3.3 kV SANS 1520-2 Type 63 trailing and reeling cables.
How is SANS 1520-2 Type 63 decoded in the South African mining cable numbering system?
Under SANS 1520, the first digit “6” denotes a 6-core lay-up (3 individually screened power cores + 3 interstitial pilot/earth-continuity cores), and the following digits “3” indicate the 3.3 kV system voltage class (1.9/3.3 kV). Similarly, Type 66 is rated 3.8/6.6 kV, Type 611 is 6.35/11 kV, Type 622 is 12.7/22 kV, and Type 633 is 19/33 kV.
What is the difference between SANS 1520-2 Type 63 and UK BS 6708 Type 63?
Although both share the number “Type 63”, they belong to completely different national standards and voltage classes: South African SANS 1520-2 Type 63 is an unarmoured 1.9/3.3 kV flexible trailing/reeling cable for mobile machines, whereas British BS 6708 Type 63 is a 640/1100 V pliable galvanized-steel-wire armoured cable for semi-flexible roadway distribution.
Can SANS 1520-2 Type 63 be manufactured with a TPU outer sheath instead of CR?
Yes. Standard SANS 1520-2 Type 63 features a heavy-duty black Polychloroprene (CR) outer sheath for balanced flexibility, oil resistance, and flame retardance. For severe hard-rock shuttle-car or jumbo-drill reeling conditions, TEBAOFLEX can custom-extrude a high-visibility or black Thermoplastic Polyurethane (TPU) outer sheath.
How should current ratings be de-rated when Type 63 is coiled on a reeling drum?
The 130 A to 520 A values in Table 2 apply to single cables laid out straight in free air at 30 °C ambient. When operated dynamically on cylindrical or mono-spiral drums, apply SANS 1520-2 layer de-rating factors (typically 0.85 for 1 layer, 0.65 for 2 layers, and 0.45 for 3 layers) and ambient temperature correction above 30 °C.
Request a Quote for SANS 1520-2 Type 63 (1.9/3.3 kV) Cable
Send your required conductor cross-section (25 mm² to 240 mm²), coupler gland entry range, and drum cut lengths for direct factory pricing and routine HV test documentation.
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