Application & Operating Conditions
AS/NZS 2802 Type 409 is a heavy-duty Class 2 composite screened trailing and reeling cable (1.1 kV to 22 kV, 6–300 mm²) built for severe open-cut mining duty on electric rope shovels, walking draglines, rotary blasthole drills, pit dewatering pumps, and mobile crusher skids.
Electric Shovels, Draglines & Drills
Heavy Class 2 R-EP-90 EPR insulation radials (up to 10.5 mm at 22 kV) and thick HD-85-PCP sheathing resist haul-road rock impact, bench dragging, and solar UV weathering across open-pit benches.
Composite Earth Fault Screening
Individual tinned-copper wire and polyester yarn braids around all three phase cores deliver 8.2–77 mm² collective earth-fault conductivity without requiring separate outer interstitial earth cores.
Central Pilot & Immersion Resilience
A single central extensible pilot lies along the neutral bending axis for earth-continuity tripping, while polyaramid yarn braid reinforcement and C1 PCP sheathing handle flooded pit sumps.
Need 3 Interstitial Pilots or Lighter Class 1 Reeling Radials? Compare Type 440 (Class 2, 3 Pilots) for multi-pilot circuits, or Type 450 (Class 1 Reeling) for reduced diameter on crane and excavator cable reels.
Cable Construction (AS/NZS 2802 Type 409)
Type 409 features symmetrical three-core trefoil geometry around a single central extensible pilot, utilizing heavy Class 2 EPR insulation walls and polyaramid-reinforced HD-85-PCP sheathing.
| Layer / Component | Material & AS/NZS 2802 Specification |
|---|---|
| 1. Phase Conductors | Flexible finely stranded tinned annealed copper, three phase cores (6 mm² to 300 mm²) |
| 2. Conductor Barrier / Screen | Polyester barrier tape for 1.1/1.1 kV; extruded semiconductive conductor screen for 3.3 kV and above |
| 3. Class 2 Insulation | Class 2 R-EP-90 EPR thermosetting compound (1.5–3.0 mm @ 1.1 kV; 3.0 mm @ 3.3 kV; 5.0 mm @ 6.6 kV; 7.6 mm @ 11 kV; 10.5 mm @ 22 kV) |
| 4. Insulation Screen / Tape | Proofed textile tape for 1.1/1.1 kV; extruded semiconductive insulation screen for 3.3 kV and above |
| 5. Composite Earth Screen | Composite braid of tinned annealed copper wire and polyester yarn over each phase core (Red, White, and Blue core identification; 8.2–77 mm² total earth area) |
| 6. Central Pilot Core | Single central extensible pilot core positioned along the cable neutral axis |
| 7. Reinforced Outer Sheath | Heavy-duty black HD-85-PCP sheath (3.8–11.3 mm wall) with polyaramid yarn braid reinforcement where applicable |
Type 409 Cross-Section Geometry: Three composite-screened Class 2 EPR phase cores laid around a single central extensible pilot inside a moulded elastomeric cradle and heavy-duty HD-85-PCP outer sheath.
Technical Characteristics
Manufactured to AS/NZS 2802 for surface and general mining reeling/trailing applications, Type 409 spans five voltage ratings from 1.1/1.1 kV up to 22/22 kV.
| Parameter | AS/NZS 2802 Rated Value |
|---|---|
| Manufacturing Standard | AS/NZS 2802 (Electric cables — Reeling and trailing — For mining and general use, other than underground coal mining) |
| Voltage Grades & Sub-Types | 409.1 (1.1 kV) | 409.3 (3.3 kV) | 409.6 (6.6 kV) | 409.11 (11 kV) | 409.22 (22 kV) |
| Insulation Thickness Class | Class 2 Heavy Radial EPR (designed for rough open-cut ground trailing, rock impact & high dielectric safety factor) |
| Max. Continuous Conductor Temp. | +90 °C |
| Minimum Installation Temperature | −25 °C |
| Installation Conditions | In free air for mobile equipment, open-cut mine trailing, and drum reeling service |
| Oil, Water & Flame Performance | Very good water/oil immersion performance, high abrasion resistance, and C1 flame retardancy |
Specification & Electrical Data (48 Standard Sizes, 1.1 kV – 22 kV)
Complete conductor diameter, Class 2 EPR insulation wall, AC resistance, 50 Hz reactance, voltage drop, capacitance, earth screen area, overall diameter, and mass tables across all five Type 409 voltage classes.
Type 409.1 — Rated Voltage: 1.1/1.1 kV (6 mm² to 300 mm² | 13 Sizes)
| Area (mm²) | Cond. Dia. (mm) | Insul. (mm) | Max AC Res. (Ω/km) | React. (Ω/km) | Volt Drop (mV/A·m) | Cap. (μF/km) | Earth Screen (mm²) | Sheath (mm) | Cable Dia. (mm) | Mass (kg/100m) |
|---|---|---|---|---|---|---|---|---|---|---|
| 3 × 6 | 3.5 | 1.5 | 4.32 | 0.145 | 7.49 | 0.259 | 8.2 | 3.8 | 32.2 | 160 |
| 3 × 10 | 4.6 | 1.5 | 2.58 | 0.133 | 4.47 | 0.314 | 8.2 | 3.8 | 34.3 | 185 |
| 3 × 16 | 6.2 | 1.6 | 1.58 | 0.120 | 2.74 | 0.379 | 10 | 4.0 | 38.1 | 235 |
| 3 × 25 | 7.2 | 1.6 | 0.951 | 0.113 | 1.66 | 0.432 | 12 | 4.3 | 40.9 | 290 |
| 3 × 35 | 8.4 | 1.6 | 0.698 | 0.108 | 1.22 | 0.493 | 14 | 4.6 | 44.0 | 345 |
| 3 × 50 | 9.7 | 1.7 | 0.523 | 0.107 | 0.925 | 0.526 | 14 | 5.0 | 49.1 | 430 |
| 3 × 70 | 12.0 | 1.8 | 0.346 | 0.0997 | 0.624 | 0.599 | 16 | 5.4 | 54.8 | 550 |
| 3 × 95 | 13.3 | 2.0 | 0.271 | 0.0971 | 0.499 | 0.591 | 22 | 6.0 | 60.0 | 675 |
| 3 × 120 | 15.3 | 2.1 | 0.210 | 0.0932 | 0.398 | 0.640 | 25 | 6.4 | 65.2 | 815 |
| 3 × 150 | 17.2 | 2.3 | 0.166 | 0.0928 | 0.329 | 0.652 | 37 | 6.9 | 72.3 | 1025 |
| 3 × 185 | 18.8 | 2.5 | 0.137 | 0.0915 | 0.285 | 0.657 | 40 | 7.4 | 77.8 | 1200 |
| 3 × 240 | 21.7 | 2.8 | 0.106 | 0.0905 | 0.241 | 0.672 | 58 | 8.2 | 88.3 | 1555 |
| 3 × 300 | 24.3 | 3.0 | 0.0849 | 0.0883 | 0.212 | 0.719 | 63 | 8.8 | 95.7 | 1860 |
Type 409.3 — Rated Voltage: 3.3/3.3 kV (16 mm² to 300 mm² | 11 Sizes)
| Area (mm²) | Cond. Dia. (mm) | Insul. (mm) | Max AC Res. (Ω/km) | React. (Ω/km) | Volt Drop (mV/A·m) | Cap. (μF/km) | Earth Screen (mm²) | Sheath (mm) | Cable Dia. (mm) | Mass (kg/100m) |
|---|---|---|---|---|---|---|---|---|---|---|
| 3 × 16 | 6.2 | 3.0 | 1.58 | 0.131 | 2.75 | 0.255 | 14 | 5.3 | 47.4 | 335 |
| 3 × 25 | 7.2 | 3.0 | 0.951 | 0.125 | 1.66 | 0.280 | 15 | 5.6 | 50.5 | 400 |
| 3 × 35 | 8.4 | 3.0 | 0.698 | 0.119 | 1.23 | 0.311 | 16 | 5.9 | 53.6 | 460 |
| 3 × 50 | 9.7 | 3.0 | 0.523 | 0.115 | 0.928 | 0.347 | 17 | 6.3 | 57.8 | 545 |
| 3 × 70 | 12.0 | 3.0 | 0.346 | 0.107 | 0.627 | 0.408 | 19 | 6.6 | 62.8 | 665 |
| 3 × 95 | 13.3 | 3.0 | 0.271 | 0.102 | 0.502 | 0.439 | 21 | 7.1 | 66.5 | 765 |
| 3 × 120 | 15.3 | 3.0 | 0.210 | 0.0985 | 0.402 | 0.492 | 28 | 7.4 | 72.0 | 935 |
| 3 × 150 | 17.2 | 3.0 | 0.166 | 0.0954 | 0.332 | 0.541 | 32 | 7.8 | 76.7 | 1095 |
| 3 × 185 | 18.8 | 3.0 | 0.137 | 0.0942 | 0.288 | 0.584 | 42 | 8.2 | 82.5 | 1290 |
| 3 × 240 | 21.7 | 3.0 | 0.106 | 0.0906 | 0.242 | 0.659 | 48 | 8.8 | 89.8 | 1560 |
| 3 × 300 | 24.3 | 3.0 | 0.0849 | 0.0890 | 0.213 | 0.727 | 63 | 9.4 | 97.8 | 1900 |
Type 409.6 — Rated Voltage: 6.6/6.6 kV (16 mm² to 300 mm² | 11 Sizes)
| Area (mm²) | Cond. Dia. (mm) | Insul. (mm) | Max AC Res. (Ω/km) | React. (Ω/km) | Volt Drop (mV/A·m) | Cap. (μF/km) | Earth Screen (mm²) | Sheath (mm) | Cable Dia. (mm) | Mass (kg/100m) |
|---|---|---|---|---|---|---|---|---|---|---|
| 3 × 16 | 6.2 | 5.0 | 1.58 | 0.143 | 2.75 | 0.181 | 17 | 6.4 | 58.2 | 475 |
| 3 × 25 | 7.2 | 5.0 | 0.951 | 0.137 | 1.66 | 0.193 | 19 | 6.7 | 61.7 | 560 |
| 3 × 35 | 8.4 | 5.0 | 0.698 | 0.130 | 1.23 | 0.212 | 21 | 7.0 | 64.7 | 625 |
| 3 × 50 | 9.7 | 5.0 | 0.523 | 0.124 | 0.931 | 0.234 | 22 | 7.3 | 68.3 | 715 |
| 3 × 70 | 12.0 | 5.0 | 0.346 | 0.116 | 0.632 | 0.271 | 23 | 7.7 | 73.9 | 860 |
| 3 × 95 | 13.3 | 5.0 | 0.271 | 0.113 | 0.509 | 0.292 | 30 | 8.1 | 78.2 | 1005 |
| 3 × 120 | 15.3 | 5.0 | 0.210 | 0.108 | 0.409 | 0.325 | 32 | 8.5 | 83.4 | 1160 |
| 3 × 150 | 17.2 | 5.0 | 0.166 | 0.105 | 0.340 | 0.354 | 46 | 8.9 | 89.4 | 1380 |
| 3 × 185 | 18.8 | 5.0 | 0.136 | 0.102 | 0.294 | 0.381 | 49 | 9.3 | 93.7 | 1545 |
| 3 × 240 | 21.7 | 5.0 | 0.106 | 0.0981 | 0.250 | 0.426 | 53 | 9.9 | 101 | 1830 |
| 3 × 300 | 24.3 | 5.0 | 0.0845 | 0.0959 | 0.221 | 0.467 | 71 | 10.4 | 109 | 2195 |
Type 409.11 — Rated Voltage: 11/11 kV (25 mm² to 240 mm² | 9 Sizes)
| Area (mm²) | Cond. Dia. (mm) | Insul. (mm) | Max AC Res. (Ω/km) | React. (Ω/km) | Volt Drop (mV/A·m) | Cap. (μF/km) | Earth Screen (mm²) | Sheath (mm) | Cable Dia. (mm) | Mass (kg/100m) |
|---|---|---|---|---|---|---|---|---|---|---|
| 3 × 25 | 7.2 | 7.6 | 0.951 | 0.150 | 1.67 | 0.150 | 24 | 8.1 | 76.1 | 810 |
| 3 × 35 | 8.4 | 7.6 | 0.698 | 0.143 | 1.23 | 0.163 | 30 | 8.4 | 79.8 | 920 |
| 3 × 50 | 9.7 | 7.6 | 0.523 | 0.136 | 0.936 | 0.178 | 32 | 8.7 | 83.2 | 1020 |
| 3 × 70 | 12.0 | 7.6 | 0.346 | 0.127 | 0.638 | 0.204 | 35 | 9.1 | 88.8 | 1185 |
| 3 × 95 | 13.3 | 7.6 | 0.271 | 0.124 | 0.516 | 0.219 | 48 | 9.6 | 93.9 | 1365 |
| 3 × 120 | 15.3 | 7.6 | 0.210 | 0.119 | 0.418 | 0.241 | 53 | 9.9 | 98.8 | 1540 |
| 3 × 150 | 17.2 | 7.6 | 0.165 | 0.114 | 0.347 | 0.261 | 56 | 10.3 | 104 | 1730 |
| 3 × 185 | 18.8 | 7.6 | 0.136 | 0.111 | 0.304 | 0.279 | 56 | 10.7 | 108 | 1900 |
| 3 × 240 | 21.7 | 7.6 | 0.106 | 0.107 | 0.261 | 0.309 | 77 | 11.3 | 116 | 2280 |
Type 409.22 — Rated Voltage: 22/22 kV (35 mm² to 95 mm² | 4 Sizes)
| Area (mm²) | Cond. Dia. (mm) | Insul. (mm) | Max AC Res. (Ω/km) | React. (Ω/km) | Volt Drop (mV/A·m) | Cap. (μF/km) | Earth Screen (mm²) | Sheath (mm) | Cable Dia. (mm) | Mass (kg/100m) |
|---|---|---|---|---|---|---|---|---|---|---|
| 3 × 35 | 8.4 | 10.5 | 0.698 | 0.160 | 1.24 | 0.147 | 53 | 10.0 | 102 | 1420 |
| 3 × 50 | 9.7 | 10.5 | 0.523 | 0.153 | 0.944 | 0.159 | 56 | 10.3 | 106 | 1540 |
| 3 × 70 | 12.0 | 10.5 | 0.346 | 0.143 | 0.648 | 0.178 | 60 | 10.7 | 111 | 1735 |
| 3 × 95 | 13.3 | 10.5 | 0.271 | 0.138 | 0.527 | 0.189 | 62 | 11.1 | 115 | 1870 |
Selection: Type 409 (AS/NZS 2802 Class 2) vs. Type 450 (Class 1) vs. Type 209 (AS/NZS 1802)
Choosing between AS/NZS 2802 Class 2, Class 1, and AS/NZS 1802 cables depends on whether the machine operates in an open-cut pit, on a constrained crane/reclaimer drum, or in an underground coal mine.
| Cable Model | Standard, Insulation Radial & Primary Duty |
|---|---|
| Type 409 (This Product) | AS/NZS 2802 Class 2 (heavy insulation & sheath radials, 1.1–22 kV, 1 central pilot). Engineered for rough open-cut ground trailing behind draglines, electric shovels, drills, and pit pumps. |
| Type 450 / Type 451 | AS/NZS 2802 Class 1 (Type 450 / Type 451, 3.3–33 kV) uses reduced Class 1 EPR radials + 2 interstitial earths + 1 interstitial pilot for smaller OD and lower weight on stacker-reclaimers, wharf cranes, and reeling drums. |
| Type 209 (AS/NZS 1802) | For underground gassy coal mines governed by AS/NZS 1802 (1.1–11 kV), specify AS/NZS 1802 Type 209. |
Frequently Asked Questions (FAQ)
Technical answers covering Class 2 insulation thickness, 22 kV dragline/shovel supply, and outer sheath options.
What does “Class 2” mean in AS/NZS 2802 Type 409?
AS/NZS 2802 defines two radial thickness grades: Class 2 specifies heavier EPR insulation and outer PCP sheath wall thicknesses (for example, 5.0 mm insulation at 6.6 kV and 7.6 mm at 11 kV, vs. 3.0 mm and 5.0 mm in Class 1) to withstand severe crushing, rock impact, and ground dragging in open-cut pits.
Is Type 409 available up to 22/22 kV for high-voltage open-cut pit distribution?
Yes. Type 409.22 (22/22 kV) is manufactured in 35, 50, 70, and 95 mm² cross-sections with 10.5 mm Class 2 R-EP-90 EPR insulation, semiconductive screens, 53–62 mm² composite copper earth screens, and 10.0–11.1 mm polyaramid-reinforced HD-85-PCP sheathing.
Can TEBAOFLEX supply Type 409 with high-visibility yellow/orange sheaths or reflective stripes?
Yes. While black UV-stabilized HD-85-PCP is standard, we extrude high-visibility yellow, orange, or striped outer sheaths for haul-road visibility in surface mining fleets.
Request a Quote for AS/NZS 2802 Type 409 Trailing & Reeling Cables
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