Application & Operating Conditions
Type SHD-CGC 2 kV and 5 kV round portable mining cables are engineered specifically for high-cycle underground longwall shearers, articulated automatic cable-handling chains, and monospiral reels. In conventional interstitial SHD-GC cables, rapid reverse S-bending stretches and fatigues the outer ground-check wire; Type SHD-CGC solves this failure mode by cushioning the yellow ground-check conductor along the zero-strain geometric center axis while balancing ground return across symmetric interstitial tinned copper grounds.
Longwall Shearer Handler Chains
Survives tens of thousands of reverse S-bend cycles along armored face conveyors without stretching or work-hardening the central 16 AWG ground-check pilot.
995 V, 2.4 kV & 4.16 kV Face Drives
Covers both low-voltage 2,000 V continuous miners/shearers (80–95 mil EPR) and high-horsepower 4,160 V / 5,000 V longwall faces (110–120 mil EPR with semi-con strand shield).
Anti-Torsion Integral Core Fill
Pure elastomeric integral filling locks the three shielded phases, interstitial grounds, and central pilot cradle against corkscrewing under hydraulic tension.
Engineering Note on Cable Profile: Despite occasional distributor catalog typos referring to CGC cables as flat, true ICEA S-75-381 Type SHD-CGC is a round symmetrically cabled construction (53.1 mm to 74.9 mm nominal OD) so the ground-check wire remains on the neutral bending axis in every direction.
Cable Construction (ICEA S-75-381 Type SHD-CGC 2kV & 5kV)
Built outward from the cushioned neutral-axis yellow Ground-Check core, surrounded by three individually shielded 90°C EPR power phases, symmetric interstitial bare tinned grounds, and a torsion-locked mold-cured CPE jacket.
| Layer / Component | Material & ICEA S-75-381 / NEMA WC 58 Engineering Specification |
|---|---|
| 1. Center Ground-Check (1×) | High-flexibility 16 AWG stranded tinned copper pilot conductor insulated with yellow polypropylene and cushioned along the central neutral axis of the cable. |
| 2. Power Conductors (3×) | Flexible rope-lay stranded annealed tinned copper conductors (2/0 AWG, 3/0 AWG, 4/0 AWG, and 350 kcmil; 323 to 888 strands) per ASTM B172 and ASTM B33. |
| 3. Strand Shield & 90°C EPR | Semiconducting strand stress-control layer (standard on 5 kV) beneath 90°C Ethylene Propylene Rubber (EPR): 80–95 mil wall at 2 kV; 110–120 mil wall at 5 kV. |
| 4. Individual Phase Shielding | Tinned copper and color-coded nylon tracer braid shield (Black, White, Red phase identification) applied over each insulated power conductor. |
| 5. Symmetric Grounding Cores | Flexible stranded bare tinned copper grounding conductors (5 AWG to 1 AWG, 133 to 259 strands) laid symmetrically in the outer interstices in contact with the phase shields. |
| 6. Integral Fill & CPE Jacket | Non-conducting separator tape and pure integral torsion-resistant fill beneath a reinforced mold-cured extra-heavy-duty black CPE jacket (205–265 mil wall). |
Type SHD-CGC round longwall cutaway: 16 AWG yellow PP Ground-Check core at the exact geometric center, 3 braided EPR power phases, symmetric bare grounds, and anti-torsion CPE jacket.
Technical Characteristics
Electrical, thermal, dimensional tolerance, and compliance specifications for 2,000 V and 5,000 V Type SHD-CGC.
| Parameter | ICEA S-75-381 / NEMA WC 58 Rated Value |
|---|---|
| Rated Voltage Classes | Up to 2,000 V AC (2 kV Series) | Up to 5,000 V AC (5 kV Longwall Series) |
| Core Configuration | Round 3 shielded power cores + outer interstitial grounds + 1 center 16 AWG yellow GC core |
| Maximum Conductor Temperature | +90°C continuous operation | +130°C emergency overload | +250°C short circuit |
| Minimum Bending Radius | 6 × overall cable diameter (static); 8 × OD inside dynamic longwall cable-handler troughs |
| Outside Diameter Tolerance | +8% / -5% of nominal overall diameter |
| Standards & Approvals Ref. | ICEA S-75-381 / NEMA WC 58; ASTM B172 & ASTM B33; MSHA & Pennsylvania DEP flame-resistant reference |
2000 V & 5000 V Longwall Shearer Specifications (2/0 AWG to 350 kcmil)
Complete dual-unit nominal dimensions, stranding, insulation/jacket walls, weights, and +90°C continuous ampacities for 2 kV and 5 kV Type SHD-CGC.
Table 1: Type SHD-CGC 3/C 2000 V (2 kV) — Round Center Ground-Check Longwall Cable
| Power + Ground Size | Area (mm²) | Power / Ground Strands | Center GC | Insul. / Jkt (mil) | Nominal OD (in / mm) | Weight (lb/kft / kg/km) | Ampacity 40°C (A) |
|---|---|---|---|---|---|---|---|
| 3 × 2/0 AWG + 5 AWG Gnd | 67.43 | 323 / 133 | 16 AWG | 80 / 205 | 2.09 / 53.1 | 3,400 / 5,059 | 243 |
| 3 × 3/0 AWG + 4 AWG Gnd | 85.01 | 418 / 259 | 16 AWG | 80 / 205 | 2.21 / 56.1 | 3,934 / 5,855 | 279 |
| 3 × 4/0 AWG + 3 AWG Gnd | 107.2 | 532 / 259 | 16 AWG | 80 / 220 | 2.36 / 59.9 | 4,860 / 7,231 | 321 |
| 3 × 350 kcmil + 1 AWG Gnd | 177.3 | 888 / 259 | 16 AWG | 95 / 250 | 2.81 / 71.4 | 7,400 / 11,012 | 435 |
Table 2: Type SHD-CGC 3/C 5000 V (5 kV) — Medium-Voltage Center Ground-Check Longwall Cable
| Power + Ground Size | Area (mm²) | Power / Ground Strands | Center GC | Insul. / Jkt (mil) | Nominal OD (in / mm) | Weight (lb/kft / kg/km) | Ampacity 40°C (A) |
|---|---|---|---|---|---|---|---|
| 3 × 2/0 AWG + 5 AWG Gnd | 67.43 | 323 / 133 | 16 AWG | 110 / 220 | 2.20 / 55.9 | 3,716 / 5,529 | 243 |
| 3 × 3/0 AWG + 4 AWG Gnd | 85.01 | 418 / 259 | 16 AWG | 110 / 235 | 2.36 / 59.9 | 4,130 / 6,146 | 279 |
| 3 × 4/0 AWG + 3 AWG Gnd | 107.2 | 532 / 259 | 16 AWG | 110 / 235 | 2.50 / 63.5 | 5,190 / 7,723 | 321 |
| 3 × 350 kcmil + 1 AWG Gnd | 177.3 | 888 / 259 | 16 AWG | 120 / 265 | 2.95 / 74.9 | 7,571 / 11,265 | 435 |
Type SHD-CGC vs. Interstitial Type SHD-GC & SHD-PCG
Choose between center-axis CGC for high-cycle longwall handler chains and interstitial GC/PCG designs for general mining duty.
| Mining Cable Model | Voltage Class, Ground / Shield Architecture & Primary Mining Duty |
|---|---|
| Type SHD-GC (2kV / 5kV / 8kV) | Round 3 shielded power cores + 2 interstitial bare tinned grounds + 1 interstitial yellow PP ground-check core for general trailing miners, drills, and pit shovels. |
| Type SHD-GC (15kV & 25kV) | High-voltage 210 mil (15kV) and 260 mil (25kV) EPR shielded trailing cable for ultra-class walking draglines, electric rope shovels, and mobile pit substations. |
| Type SHD Flat (2kV) | Flat parallel 3 shielded power cores + 1 grounding core (no GC monitor core) engineered for high-layer-count level-wind shuttle-car and continuous-miner reels. |
| Type SHD-CGC (2kV & 5kV) | Round longwall shearer cable with 16 AWG yellow Ground-Check positioned along the neutral geometric center axis + 3 symmetrical grounds to prevent dynamic S-bend pilot breakage. |
| Type SHD-PCG (2kV & 5kV) | Composite round cable integrating 3 shielded power cores + 2 insulated control/pilot cores + grounding for permissible remote-interlock underground mining equipment. |
Frequently Asked Questions (FAQ)
Answers to longwall electrical maintenance questions on pilot-wire breakage and SHD-CGC splicing.
Why do longwall shearers experience fewer ground-check trips with Type SHD-CGC than standard Type SHD-GC?
When a standard Type SHD-GC cable bends back and forth inside an articulated longwall cable-handler chain, the interstitial GC wire alternates between outer tension and inner compression arcs, causing strand fatigue. Positioning the GC wire at the geometric center places it on the neutral bending axis where tensile strain approaches zero.
How many grounding conductors are inside Type SHD-CGC?
Moving the ground-check wire to the center frees up all three outer interstices between the three power cores, allowing three symmetrical bare tinned copper grounding conductors for balanced mechanical roundness and uniform shield grounding.
Can Type SHD-CGC 5kV be terminated in standard 5kV explosion-proof / permissible longwall couplers?
Yes. The 2.20 in to 2.95 in outside diameters match standard 5 kV mine coupler packing glands, and the central 16 AWG pilot wire routes directly to the coupler ground-check pilot pin.
Request a Type SHD-CGC 2kV or 5kV Longwall Cable Quote
Specify 2 kV or 5 kV rating, shearer conductor size (2/0 AWG to 350 kcmil), and exact face cut length for engineering confirmation and factory pricing.
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