Application & Operating Conditions
600–2,000 V Two-Conductor Blast-Hole Drilling Mast Cable is engineered for high-cycle vertical mast power tracks, hanging catenary loops, travelling rotary head festoons, and DC/AC top-drive assemblies on open-pit rotary blast-hole drills and heavy mining rigs. Integrating high-current power leads, equipment grounding, and custom rotary/pulldown control circuits inside one torsion-balanced reinforced rubber sheath eliminates multi-cable entanglement inside mast drag chains while resisting rock chips, drill grease, UV, sub-zero pit winds, and continuous vibration.
Rotary Blast-Hole Drill Masts
Delivers up to 524 A continuous DC/AC power alongside custom limit-switch, encoder, and solenoid control circuits to travelling rotary drill heads.
Festoons, Loops & Drag Chains
High strand-count ASTM B33 tinned copper (266 to 1,221 wires per core) and polypropylene braid reinforcement extend flex life in suspended mast loops and power tracks.
Harsh Open-Pit Chemical & Impact Duty
Mold-cured thermosetting rubber outer jacket withstands hydraulic oil, thread grease, ozone, sunlight, alkaline/acidic drill cuttings, and cold-pit flexing.
Custom Control Group Engineering: Because every rotary drill OEM (such as Pit Viper, Bucyrus/Cat, or Sandvik mast tracks) specifies different auxiliary pair/conductor counts, the internal Control Group is built to your exact wire count and gauge (e.g., 4 × 14 AWG, 8 × 16 AWG, or shielded encoder pairs).
Cable Construction (600–2000 V Two-Conductor + Ground + Control Group)
Round torsion-balanced hybrid construction combining ultra-flexible tinned copper power conductors, equipment grounding, and custom control cores under a braid-reinforced mold-cured elastomer jacket.
| Layer / Component | Material & ICEA S-75-381 / CSA C22.2 No. 96 Engineering Specification |
|---|---|
| 1. Power Conductors (2×) | Two extra-flexible rope-lay stranded annealed tinned copper conductors (1/0 AWG to 500 kcmil; 266 to 1,221 minimum wires per conductor) per ASTM B33. |
| 2. 90°C EPR Power Insulation | Ethylene Propylene Rubber (EPR) rated +90°C continuous: 0.080 in (2.03 mm) wall for 1/0–4/0 AWG and 0.095 in (2.41 mm) wall for 250–500 kcmil. |
| 3. Control Conductor Group | User-specified multi-conductor control sub-assembly (EPR or XL-polyolefin insulated flexible tinned copper control cores cabled in the upper interstice). |
| 4. Equipment Grounding Wire | Flexible rope-stranded annealed tinned copper grounding conductor cabled in the opposite interstice for balanced round geometry. |
| 5. Tape & PP Reinforcing Braid | Non-conducting separator tape over the cabled core assembly followed by a high-flex-life polypropylene reinforcing braid. |
| 6. Mold-Cured Rubber Outer Jacket | Reinforced mold-cured thermosetting rubber (extra-heavy-duty CPE / Polychloroprene) resisting abrasion, impact, oil, heat, flame, ozone, acids, and alkalis. |
Drilling Mast Cable cutaway: 2 large 90°C EPR power cores, 1 flexible tinned copper ground conductor, 1 cabled multi-core control group, polypropylene braid, and mold-cured black rubber sheath.
Technical Characteristics
Electrical, thermal, material compliance, and reel correction specifications for 600–2,000 V Drilling Mast Cable.
| Parameter | ICEA S-75-381 / CSA C22.2 No. 96 Rated Value |
|---|---|
| Rated Voltage Range | 600 V to 2,000 V DC / AC continuous drill mast, festoon, and power-track service |
| Core Architecture | Round hybrid: 2 insulated power cores + 1 flexible ground wire + user-specified control group |
| Maximum Conductor Temperature | +90°C continuous operation | +40°C reference ambient air temperature |
| Dimensional & Weight Tolerance | ±5% manufacturing tolerance (dependent on final custom control-group core count) |
| Environmental Resistance | Abrasion, impact, drill oil, grease, flame, sunlight, ozone, alkalis, and acids |
| Material & Conductor Standards | ICEA S-75-381 / NEMA WC 58; CAN/CSA-C22.2 No. 96; ASTM B33 annealed tinned copper |
600–2000 V Blast-Hole Drilling Mast Cable Specifications (1/0 AWG to 500 kcmil)
Nominal baseline dimensions, minimum wire strand counts, EPR insulation wall, dual-unit weights, and +90°C continuous ampacity ratings.
Table 1: 600–2000 V Two-Conductor Drilling Mast Cable (2 Power + Ground + User-Specified Control Group)
| Power Conductors | Area (mm²) | Min. Wires / Core | EPR Wall (in / mm) | Control Group | Ground Wire | Nominal OD (in / mm) | Weight (lb/kft / kg/km) | Ampacity 40°C (A) |
|---|---|---|---|---|---|---|---|---|
| 2 × 1/0 AWG | 53.49 | 266 | 0.080 / 2.03 | User Specified | Included | 1.52 / 38.6 | 1,780 / 2,649 | 217 |
| 2 × 2/0 AWG | 67.43 | 323 | 0.080 / 2.03 | User Specified | Included | 1.65 / 41.9 | 2,425 / 3,609 | 250 |
| 2 × 3/0 AWG | 85.01 | 418 | 0.080 / 2.03 | User Specified | Included | 1.77 / 45.0 | 2,872 / 4,274 | 286 |
| 2 × 4/0 AWG | 107.2 | 532 | 0.080 / 2.03 | User Specified | Included | 1.92 / 48.8 | 3,478 / 5,176 | 328 |
| 2 × 250 kcmil | 126.7 | 627 | 0.095 / 2.41 | User Specified | Included | 2.10 / 53.3 | 4,155 / 6,183 | 363 |
| 2 × 350 kcmil | 177.3 | 888 | 0.095 / 2.41 | User Specified | Included | 2.36 / 59.9 | 5,483 / 8,160 | 436 |
| 2 × 500 kcmil | 253.4 | 1,221 | 0.095 / 2.41 | User Specified | Included | 2.70 / 68.6 | 7,249 / 10,788 | 524 |
Blast-Hole Drill Mast vs. Portable Mining Power & Control Cables
Compare hybrid Drilling Mast Cable against 3-phase trailing cables (Type G-GC / SHD-PCG), VFD cables, and TPU control cables.
| Mining Cable Model | Voltage Class, Ground / Shield Architecture & Primary Mining Duty |
|---|---|
| Mining VFD 2kV (3+3+GC) | Symmetrical 3 power + 3 green grounds + yellow GC (2 AWG–500 kcmil) with 100% Al/polyester foil + overall tinned copper braid EMC shield for AC variable-frequency mine drives. |
| Blast-Hole Drilling Mast (600–2000V) | High-flex round hybrid cable combining 2 EPR power cores (1/0–500 kcmil) + tinned ground + user-configurable multi-core control group for rotary drill masts, festoons, and loops. |
| Longwall Signal Cable (50V TPU) | Extra-flexible 50 V underground control & signal cable (2–9 cores, 18 to 10 AWG) with cross-linked FR polyolefin insulation, extra-tough TPU jacket, and optional copper braid. |
| Underground Lighting Cable (110V TPU) | Heavy-duty 110 V mine luminaire & drift lighting cable (2–9 cores, 18 to 10 AWG) with non-chlorinated cross-linked FR polyolefin insulation and cut-resistant TPU outer sheath. |
| Type SHD-PCG (2kV & 5kV) | Shielded 3-phase power + 2 integrated control/pilot cores + ground trailing cable for continuous miners and longwall face equipment. |
Frequently Asked Questions (FAQ)
Answers to open-pit drill maintenance questions on control-group customization, hanging mast tension, and three-phase AC drills.
What control-group configurations can TEBAOFLEX integrate into this Drilling Mast Cable?
We build custom control groups ranging from 2 to 19+ insulated flexible tinned copper control cores (typically 16 AWG, 14 AWG, or 12 AWG, unshielded or individually pair-shielded) to match your rotary blast-hole drill schematic.
Why does a two-conductor 500 kcmil Drilling Mast Cable carry 524 A while a three-phase 500 kcmil trailing cable carries 536 A?
Ampacity ratings follow ICEA S-75-381 thermal dissipation models at +90°C conductor / +40°C ambient air, accounting for the additional internal thermal blanket of the bundled control group and heavy mast reinforcing braid.
What cable should we use for the ground trailing feeder from the pit substation to the blast-hole drill?
Use Type G-GC 2kV for low-voltage pit drills or Type SHD-GC (5kV / 8kV / 15kV) for medium-voltage electric blast-hole drills; this Drilling Mast Cable is specifically optimized for the vertical travelling mast loop/power-track section on the rig itself.
Request a Custom 600–2000V Blast-Hole Drilling Mast Cable Quote
Share your power conductor size (1/0 AWG to 500 kcmil), required control-group wire count/gauge, and mast cut length for an engineering drawing and quote.
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