Application & Operating Conditions
SANS 1520-2 Type 611 and Type 611-ECC are 6.35/11 kV medium-voltage flexible screened reeling, trailing, and section feeder cables manufactured to SANS 1520-2 for powering open-cast walking draglines, electric rope shovels, hydraulic excavators, blast-hole drills, and hazardous-area underground or surface mobile substations.
11 kV Draglines, Shovels & Reeling
Reinforced with a minimum 16-string open nylon braid vulcanized between double CR sheaths to handle 1.1 kN to 10.8 kN dynamic reeling and pit-bench trailing loads.
Triple-Extruded Strippable Core Screen
Co-extruded conductor screen, 6.35/11 kV EPR insulation, and free-stripping semi-conducting outer core screen prevent partial discharge under bending and speed field termination.
Dual Earth-Fault Topologies (611 / 611-ECC)
Choose Type 611 (3 EPM pilots; 1.6–4.1 kA screen fault rating) for NER-limited 11 kV systems, or Type 611-ECC (2 EPM pilots + 16–120 mm² bare ECC; up to 17.0 kA) for high-fault feeders.
Minimum Bending Radius (9 × Overall Diameter): For 6.35/11 kV Type 611 and Type 611-ECC cables (OD 50.7 mm to 85.6 mm), maintain a minimum drum barrel and sheave bending radius of 9 × OD (456 mm at 25 mm² up to 770 mm at 240 mm²) to preserve partial-discharge-free triple-extruded screen bonding.
Cable Construction (SANS 1520-2 Type 611 & Type 611-ECC)
Engineered to SANS 1520-2, SANS 1411-1, and SANS 1411-3 for void-free 11 kV electrical field control combined with heavy elastomeric mechanical protection.
| Layer / Component | Material & SANS 1520-2 Engineering Specification |
|---|---|
| 1. Power Conductors | Class 5 flexible stranded tinned annealed copper to SANS 1411-1 (25 mm² to 240 mm²). |
| 2. Triple-Extruded 11 kV Insulation | Thermosetting EPR dielectric compound (SANS 1411-3) triple-extruded with semi-conducting conductor screen and a strippable semi-conducting core screen. |
| 3. Composite Phase Screens | Individual nylon and 0.31 mm tinned copper wire composite braid (29 mm² to 52 mm² screen cross-section) incorporating Red, Yellow, and Blue phase tracers. |
| 4. Interstitial EPM Pilot Cores | EPM-insulated flexible tinned copper pilot cores (10–25 mm²): three pilots in Type 611; two pilots in Type 611-ECC. |
| 5. Bare ECC Variant Conductor | Type 611-ECC only: one interstitial pilot replaced by an uninsulated stranded tinned copper ECC conductor (16 mm² to 120 mm²; 0.15–0.7 Ω/km min. ECC resistance). |
| 6. Inner Sheath & Nylon Braid | CR polychloroprene rubber inner sheath + open nylon reinforcement braid (minimum 16 strings). |
| 7. Outer Sheath | Heavy-duty black CR polychloroprene rubber outer sheath — UV resistant, sunlight resistant, oil resistant, and abrasion/flame resistant. |
SANS 1520-2 Type 611 & Type 611-ECC (25–240 mm²): 3 triple-extruded 6.35/11 kV EPR power cores with strippable semi-conducting screens and composite copper/nylon braids, laid with 3 EPM pilots (Type 611) or 2 EPM pilots + 1 bare tinned copper ECC (Type 611-ECC).
Technical Characteristics
Complete electrical, thermal, and mechanical operating ratings for SANS 1520-2 Type 611 and Type 611-ECC 6.35/11 kV mining cables.
| Parameter | SANS 1520-2 Rated Value |
|---|---|
| Applicable Standards | SANS 1520-2; SANS 1411-1; SANS 1411-3 |
| Rated Voltage (Uo/U) | 6.35 / 11 kV AC |
| Operating Temperature Range | -25 °C to +90 °C |
| Minimum Bending Radius | 9 × Overall Cable Diameter (456 mm at 25 mm² to 770 mm at 240 mm²) |
| Ambient Current Rating Basis | 105 A (25 mm²) to 400 A (240 mm²) at 30 °C Ambient |
| Maximum Pulling Tension | 1.1 kN (25 mm²) up to 10.8 kN (240 mm²) |
| 1-Second Conductor S/C Rating | 3.1 kA (25 mm²) up to 29.3 kA (240 mm²) |
| 1-Second Screen / ECC S/C Rating | Screen S/C: 1.6–4.1 kA | ECC S/C (Type 611-ECC): 3.6–17.0 kA |
SANS 1520-2 Type 611 & Type 611-ECC Complete Specification Tables (25–240 mm²)
Nominal dimensional, ECC conductor, standardized mass (kg/km), impedance, current rating, and 1-second short-circuit withstand tables across all nine 6.35/11 kV sizes.
1. SANS 1520-2 Type 611 (Standard 3-Pilot) — Dimensions, Screen Area, Tension & Nominal Weight (9 Sizes)
| Configuration (mm²) | Power Wire Dia. (mm) | Power Cond. Dia. (mm) | Screen Wire Dia. (mm) | Screen Area (mm²) | Pilot Size (mm²) | Pilot Wire / Cond. Dia. (mm) | Max. Tension (kN) | Overall Dia. (mm) | Nominal Weight (kg/km) |
|---|---|---|---|---|---|---|---|---|---|
| Type 611 3×25 + 3×10 | 0.41 | 6.8 | 0.31 | 29 | 10 | 0.41 / 4.2 | 1.1 | 50.7 | 4,100 |
| Type 611 3×35 + 3×10 | 0.41 | 8.5 | 0.31 | 31 | 10 | 0.41 / 4.2 | 1.6 | 52.2 | 4,500 |
| Type 611 3×50 + 3×10 | 0.41 | 10.3 | 0.31 | 34 | 10 | 0.41 / 4.2 | 2.3 | 59.4 | 5,300 |
| Type 611 3×70 + 3×16 | 0.51 | 11.9 | 0.31 | 37 | 16 | 0.41 / 5.3 | 3.2 | 60.4 | 6,500 |
| Type 611 3×95 + 3×16 | 0.51 | 13.5 | 0.31 | 41 | 16 | 0.41 / 5.3 | 4.3 | 65.2 | 8,000 |
| Type 611 3×120 + 3×16 | 0.51 | 15.5 | 0.31 | 43 | 16 | 0.41 / 5.3 | 5.4 | 71.3 | 9,800 |
| Type 611 3×150 + 3×25 | 0.51 | 17.3 | 0.31 | 46 | 25 | 0.41 / 6.8 | 6.8 | 75.0 | 10,700 |
| Type 611 3×185 + 3×25 | 0.51 | 20.2 | 0.31 | 49 | 25 | 0.41 / 6.8 | 8.3 | 85.1 | 13,400 |
| Type 611 3×240 + 3×25 | 0.51 | 22.9 | 0.31 | 52 | 25 | 0.41 / 6.8 | 10.8 | 85.6 | 14,700 |
2. SANS 1520-2 Type 611-ECC (2 Pilots + 1 Bare ECC) — ECC Sizing & Nominal Weight (9 Sizes)
| Configuration (mm²) | Conductor Size (mm²) | Interstitial Pilots (mm²) | Bare ECC Size (mm²) | ECC Max. Wire Dia. (mm) | Overall Dia. (mm) | Max. Tension (kN) | Nominal Weight (kg/km) |
|---|---|---|---|---|---|---|---|
| Type 611-ECC 3×25 + 2×10 + 16ECC | 25 | 2 × 10 | 16 | 0.41 | 50.7 | 1.1 | 4,200 |
| Type 611-ECC 3×35 + 2×10 + 25ECC | 35 | 2 × 10 | 25 | 0.41 | 52.2 | 1.6 | 4,600 |
| Type 611-ECC 3×50 + 2×10 + 25ECC | 50 | 2 × 10 | 25 | 0.41 | 59.4 | 2.3 | 5,400 |
| Type 611-ECC 3×70 + 2×16 + 35ECC | 70 | 2 × 16 | 35 | 0.41 | 60.4 | 3.2 | 6,700 |
| Type 611-ECC 3×95 + 2×16 + 50ECC | 95 | 2 × 16 | 50 | 0.41 | 65.2 | 4.3 | 8,200 |
| Type 611-ECC 3×120 + 2×16 + 70ECC | 120 | 2 × 16 | 70 | 0.51 | 71.3 | 5.4 | 10,200 |
| Type 611-ECC 3×150 + 2×25 + 95ECC | 150 | 2 × 25 | 95 | 0.51 | 75.0 | 6.8 | 10,900 |
| Type 611-ECC 3×185 + 2×25 + 95ECC | 185 | 2 × 25 | 95 | 0.51 | 85.1 | 8.3 | 13,900 |
| Type 611-ECC 3×240 + 2×25 + 120ECC | 240 | 2 × 25 | 120 | 0.51 | 85.6 | 10.8 | 15,000 |
3. SANS 1520-2 Type 611 & 611-ECC — Electrical Resistance, Impedance, Current & 1s Short-Circuit Ratings
| Conductor Size (mm²) | DC Res. 20 °C (Ω/km) | DC Res. 90 °C (Ω/km) | Reactance (Ω/km) | Impedance 90 °C (Ω/km) | Min. Screen Res. (Ω/km) | Min. ECC Res. (Ω/km) | Current @ 30 °C (A) | Cond. S/C 1s (kA) | Screen S/C 1s (kA) | ECC S/C 1s (kA) |
|---|---|---|---|---|---|---|---|---|---|---|
| 25 mm² | 0.795 | 1.05 | 0.134 | 1.06 | 1.6 | 0.7 | 105 | 3.1 | 1.6 | 3.6 |
| 35 mm² | 0.565 | 0.749 | 0.124 | 0.759 | 1.2 | 0.5 | 130 | 4.3 | 2.1 | 5.0 |
| 50 mm² | 0.393 | 0.521 | 0.117 | 0.534 | 0.8 | 0.5 | 160 | 6.1 | 3.1 | 5.0 |
| 70 mm² | 0.277 | 0.368 | 0.113 | 0.385 | 0.7 | 0.4 | 195 | 8.5 | 3.5 | 7.5 |
| 95 mm² | 0.210 | 0.279 | 0.108 | 0.299 | 0.6 | 0.3 | 230 | 11.6 | 4.1 | 9.0 |
| 120 mm² | 0.164 | 0.218 | 0.103 | 0.241 | 0.6 | 0.23 | 260 | 14.6 | 4.1 | 11.5 |
| 150 mm² | 0.132 | 0.176 | 0.098 | 0.201 | 0.6 | 0.18 | 300 | 18.3 | 4.1 | 14.0 |
| 185 mm² | 0.108 | 0.145 | 0.096 | 0.174 | 0.6 | 0.18 | 340 | 22.57 | 4.1 | 14.0 |
| 240 mm² | 0.0817 | 0.110 | 0.092 | 0.143 | 0.6 | 0.15 | 400 | 29.3 | 4.1 | 17.0 |
kg/km (4,100–15,000 kg/km, equivalent to 410–1,500 kg/100m) for exact dragline reel and freight calculations.SANS 1520-1 & SANS 1520-2 South African Mining Cable Selection Matrix
Compare Type 611 & Type 611-ECC (6.35/11 kV) across the full SANS 1520 low-voltage and medium-voltage mining trailing and reeling cable family.
| 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) | 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) (This Product) | 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 FAQs for 11 kV open-cast dragline, shovel, and section feeder engineers specifying SANS 1520-2 Type 611 / 611-ECC.
Why does SANS 1520-2 Type 611 specify a strippable semi-conducting core screen?
At 6.35/11 kV, radial electrical field gradients require a smooth, void-free interface between the EPR dielectric and the metallic braid screen to prevent corona and partial discharge. Triple-extruding a controlled-adhesion strippable semi-conducting screen guarantees zero air pockets during reeling while allowing jointers to peel the screen cleanly without scoring the 11 kV EPR insulation.
When should I specify Type 611-ECC instead of standard Type 611 on an 11 kV mine network?
Specify Type 611 when your 11 kV pit substation uses neutral-earthing resistors (NERs) limiting earth-fault current below 1.6–4.1 kA and requires three insulated pilot cores. Specify Type 611-ECC when feeding mobile substations, draglines, or shovels with prospective earth-fault currents up to 3.6–17.0 kA (1s) where a dedicated bare tinned copper earth conductor is required.
How does SANS 1520-2 Type 611 compare with Australian AS/NZS 2802 Type 411 (6.35/11 kV)?
Both serve 6.35/11 kV draglines, shovels, and reeling drums, but follow different regional coupler and earth-pilot standards: SANS 1520-2 Type 611 uses composite tinned-copper/nylon braided phase screens plus three interstitial EPM pilots (or 2 pilots + 1 bare ECC) and an open 16-string nylon sheath reinforcement braid tailored to Southern African mine protection relays.
What routine high-voltage factory tests are performed on TEBAOFLEX Type 611 cables?
Every drum undergoes conductor DC resistance measurement, partial discharge testing, high-voltage AC withstand testing per SANS 1520-2, semi-conducting screen strip-force verification, and dimensional/sheath inspection prior to export dispatch.
Request a Quote for SANS 1520-2 Type 611 or Type 611-ECC (6.35/11 kV)
Send your required variant (Type 611 or Type 611-ECC), cross-section (25–240 mm²), and drum cut lengths for direct factory pricing and test certification.
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