Application & Operating Conditions
SANS 1520-2 Type 622 and Type 622-ECC are heavy-duty 12.7/22 kV flexible screened reeling and section feeder cables manufactured to SANS 1520-2 to transmit high-power 22 kV supply over long open-cast pit benches with minimal voltage drop to walking draglines, electric shovels, drills, and mobile skid substations.
Long-Haul 22 kV Open-Cast Feeders
Stepping pit distribution from 11 kV to 22 kV halves line current for the same MVA load, allowing 25–150 mm² Type 622 cables (up to 11.4 MVA at 300 A) to feed distant benches.
22 kV Triple-Extruded Dielectric Integrity
Heavy-wall EPR compound co-extruded with inner conductor semi-con and outer strippable semi-con screens maintains partial-discharge-free stress control during reeling.
UV, Oil & Rock-Bench CR Protection
Double black polychloroprene (CR) sheaths bonded across a minimum 16-string open nylon reinforcement braid resist intense African solar UV, ozone, diesel/hydraulic oil, and haul-road drag.
Coupler & Bend Radius Planning (22 kV): SANS 1520-2 Type 622 and Type 622-ECC span 60.6 mm to 85.6 mm nominal overall diameter across 25–150 mm². Size reeling drums and over-sheave guides to a strict minimum bending radius of 9 × OD (545 mm to 770 mm).
Cable Construction (SANS 1520-2 Type 622 & Type 622-ECC)
Manufactured in compliance with SANS 1520-2, SANS 1411-1, and SANS 1411-3 with identical outer diameters between standard 3-pilot Type 622 and bare-earth Type 622-ECC.
| 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 150 mm²; 0.41 mm strands up to 50 mm², 0.51 mm strands from 70 to 150 mm²). |
| 2. Triple-Extruded 22 kV Insulation | 12.7/22 kV thermosetting EPR compound (SANS 1411-3) triple-extruded with semi-conducting conductor screen and strippable semi-conducting core screen. |
| 3. Composite Phase Screens | Individual composite braid of 0.31 mm tinned copper wires and nylon yarn (min. screen resistance 0.6–1.6 Ω/km) with Red, Yellow, and Blue phase tracers. |
| 4. Interstitial EPM Pilot Cores | EPM-insulated flexible tinned copper pilot cores (10, 16, or 25 mm²): three pilots in Type 622; two pilots in Type 622-ECC. |
| 5. Bare ECC Variant Conductor | Type 622-ECC only: one interstitial pilot replaced by an uninsulated Class 5 tinned copper ECC conductor (16 mm² to 95 mm²; min. ECC resistance 0.18–0.7 Ω/km). |
| 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 flame retardant. |
SANS 1520-2 Type 622 & Type 622-ECC (25–150 mm²): 3 heavy-wall triple-extruded 12.7/22 kV EPR power cores with strippable semi-conducting screens and composite copper/nylon braids, plus 3 EPM pilots (Type 622) or 2 EPM pilots + 1 bare tinned copper ECC (Type 622-ECC).
Technical Characteristics
Electrical, thermal, mechanical, and 1-second short-circuit ratings for SANS 1520-2 Type 622 and Type 622-ECC 12.7/22 kV mining cables.
| Parameter | SANS 1520-2 Rated Value |
|---|---|
| Applicable Standards | SANS 1520-2; SANS 1411-1; SANS 1411-3 |
| Rated Voltage (Uo/U) | 12.7 / 22 kV AC |
| Operating Temperature Range | -25 °C to +90 °C |
| Minimum Bending Radius | 9 × Overall Cable Diameter (545 mm at 25 mm² to 770 mm at 150 mm²) |
| Ambient Current Rating Basis | 105 A (25 mm²) to 300 A (150 mm²) at 30 °C Ambient |
| Maximum Pulling Tension | 1.1 kN (25 mm²) up to 6.8 kN (150 mm²) |
| 1-Second Conductor S/C Rating | 3.1 kA (25 mm²) up to 18.3 kA (150 mm²) |
| 1-Second Screen / ECC S/C Rating | Screen S/C: 1.6–4.1 kA | ECC S/C (Type 622-ECC): 3.6–14.0 kA |
SANS 1520-2 Type 622 & Type 622-ECC Complete Specification Tables (25–150 mm²)
Verified nominal dimensions, ECC conductor cross-sections, standardized weights (kg/km), reactances, current ratings, and 1-second short-circuit withstand data for all seven 12.7/22 kV sizes.
1. SANS 1520-2 Type 622 (Standard 3-Pilot) — Dimensions, Pilot Sizing, Tension & Nominal Weight (7 Sizes)
| Configuration (mm²) | Power Wire Dia. (mm) | Power Cond. Dia. (mm) | Screen Wire Dia. (mm) | Pilot Size (mm²) | Pilot Wire Dia. (mm) | Pilot Cond. Dia. (mm) | Max. Tension (kN) | Overall Dia. (mm) | Nominal Weight (kg/km) |
|---|---|---|---|---|---|---|---|---|---|
| Type 622 3×25 + 3×10 | 0.41 | 6.8 | 0.31 | 10 | 0.41 | 4.2 | 1.1 | 60.6 | 5,500 |
| Type 622 3×35 + 3×10 | 0.41 | 8.5 | 0.31 | 10 | 0.41 | 4.2 | 1.6 | 64.9 | 6,400 |
| Type 622 3×50 + 3×10 | 0.41 | 10.3 | 0.31 | 10 | 0.41 | 4.2 | 2.3 | 68.5 | 7,200 |
| Type 622 3×70 + 3×16 | 0.51 | 11.9 | 0.31 | 16 | 0.41 | 5.3 | 3.2 | 72.4 | 8,300 |
| Type 622 3×95 + 3×16 | 0.51 | 13.5 | 0.31 | 16 | 0.41 | 5.3 | 4.3 | 77.1 | 9,600 |
| Type 622 3×120 + 3×16 | 0.51 | 15.5 | 0.31 | 16 | 0.41 | 5.3 | 5.4 | 81.4 | 11,000 |
| Type 622 3×150 + 3×25 | 0.51 | 17.3 | 0.31 | 25 | 0.41 | 6.8 | 6.8 | 85.6 | 12,600 |
2. SANS 1520-2 Type 622-ECC (2 Pilots + 1 Bare ECC) — ECC Sizing & Nominal Weight (7 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 622-ECC 3×25 + 2×10 + 16ECC | 25 | 2 × 10 | 16 | 0.41 | 60.6 | 1.1 | 5,500 |
| Type 622-ECC 3×35 + 2×10 + 25ECC | 35 | 2 × 10 | 25 | 0.41 | 64.9 | 1.6 | 6,400 |
| Type 622-ECC 3×50 + 2×10 + 25ECC | 50 | 2 × 10 | 25 | 0.41 | 68.5 | 2.3 | 7,300 |
| Type 622-ECC 3×70 + 2×16 + 35ECC | 70 | 2 × 16 | 35 | 0.41 | 72.4 | 3.2 | 8,400 |
| Type 622-ECC 3×95 + 2×16 + 50ECC | 95 | 2 × 16 | 50 | 0.41 | 77.1 | 4.3 | 9,800 |
| Type 622-ECC 3×120 + 2×16 + 70ECC | 120 | 2 × 16 | 70 | 0.51 | 81.4 | 5.4 | 11,300 |
| Type 622-ECC 3×150 + 2×25 + 95ECC | 150 | 2 × 25 | 95 | 0.51 | 85.6 | 6.8 | 13,000 |
3. SANS 1520-2 Type 622 & 622-ECC — Electrical Resistance, Reactance, Current & 1s Short-Circuit Ratings
| Conductor Size (mm²) | DC Res. 20 °C (Ω/km) | DC Res. 90 °C (Ω/km) | Reactance (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 | 0.145 | 1.6 | 0.7 | 105 | 3.1 | 1.6 | 3.6 |
| 35 mm² | 0.565 | 0.749 | 0.135 | 1.2 | 0.5 | 130 | 4.3 | 2.1 | 5.0 |
| 50 mm² | 0.393 | 0.521 | 0.127 | 0.8 | 0.5 | 160 | 6.1 | 3.1 | 5.0 |
| 70 mm² | 0.277 | 0.368 | 0.122 | 0.7 | 0.4 | 195 | 8.5 | 3.5 | 7.5 |
| 95 mm² | 0.210 | 0.279 | 0.117 | 0.6 | 0.3 | 230 | 11.6 | 4.1 | 9.0 |
| 120 mm² | 0.164 | 0.218 | 0.111 | 0.6 | 0.23 | 260 | 14.6 | 4.1 | 11.5 |
| 150 mm² | 0.132 | 0.176 | 0.106 | 0.6 | 0.18 | 300 | 18.3 | 4.1 | 14.0 |
kg/km (5,500–13,000 kg/km, equivalent to 550–1,300 kg/100m) and verified for 16 mm² pilot conductor diameter (5.3 mm).SANS 1520-1 & SANS 1520-2 South African Mining Cable Selection Matrix
Compare Type 622 & Type 622-ECC (12.7/22 kV) against 6.6 kV (Type 66), 11 kV (Type 611), and 33 kV (Type 633) SANS 1520-2 open-cast reeling and feeder 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) | 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) | 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) (This Product) | 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 questions for 22 kV open-cast mine electrical distribution and dragline reeling.
How is SANS 1520-2 Type 622 decoded?
In SANS 1520-2, “6” identifies the 6-core lay-up (3 individually screened MV power cores + 3 interstitial pilot/ECC cores) and “22” denotes the 22 kV system voltage rating (Uo/U = 12.7/22 kV).
Why does the maximum standard cross-section of Type 622 stop at 150 mm² compared to 240 mm² on 11 kV Type 611?
Because 22 kV operates at twice the voltage of 11 kV, a 150 mm² Type 622 cable (300 A at 30 °C) delivers approximately 11.4 MVA—exceeding the 7.6 MVA power capacity of a 240 mm² 11 kV cable while keeping overall cable diameter within manageable coupler and reel limits (85.6 mm OD).
What is the difference between Type 622 and Type 622-ECC?
Type 622 incorporates three EPM-insulated interstitial pilot cores and relies on the three composite phase screens for earth-fault return (1.6–4.1 kA for 1s). Type 622-ECC substitutes a bare Class 5 tinned copper conductor (16–95 mm²) in place of one pilot core, boosting 1-second earth-fault withstand to 3.6–14.0 kA while maintaining two insulated pilot cores.
Can TEBAOFLEX supply Type 622 / 622-ECC pre-tested for 22 kV coupler termination kits?
Yes. Our strippable semi-conducting core screen is engineered for clean cold-shrink and slip-on 22 kV mining coupler terminations, and full dimensional drawings plus routine HV and partial-discharge certificates are supplied with every reel.
Request a Quote for SANS 1520-2 Type 622 or Type 622-ECC (12.7/22 kV)
Specify Type 622 or Type 622-ECC, conductor size (25 mm² to 150 mm²), and individual reel lengths for direct factory quotation.
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