Application & Operating Conditions
AS/NZS 2802 Type 440 is a Class 2 composite screened trailing and reeling mining cable (1.1 kV to 22 kV, 6–300 mm²) incorporating three heavy-section interstitial pilot cores for long-distance open-cut power runs, pit-rim substation interconnects, draglines, shovels, and multi-channel interlocked reeling equipment.
Long Pit-Bench Feeder Runs
Generously sized interstitial pilots (up to 3 × 35.7 mm² on 300 mm²) minimize pilot-loop resistance drop across multi-kilometer open-cut bench runs and mobile skid substations.
Three-Channel Control & Earth-Continuity
Three independent elastomer-covered and proofed-tape pilots support earth-continuity tripping alongside two spare control, emergency-stop, or pilot-interlock circuits.
Polyaramid-Reinforced Class 2 Armouring
Full Class 2 R-EP-90 EPR insulation radials paired with polyaramid braid reinforcement inside a heavy-duty HD-85-PCP sheath withstand high reeling tension and abrasive pit rock.
Only Need a Single Central Pilot? Where standard single-pilot earth-continuity protection suffices, compare AS/NZS 2802 Type 409 (Class 2, 1 central pilot) or underground coal AS/NZS 1802 Type 240.
Cable Construction (AS/NZS 2802 Type 440)
Type 440 arranges three composite-screened Class 2 EPR power cores in trefoil with three elastomer-covered and proofed-tape pilot cores occupying the outer interstices beneath a polyaramid-reinforced HD-85-PCP jacket.
| Layer / Component | Material & AS/NZS 2802 Specification |
|---|---|
| 1. Phase Conductors | Flexible stranded tinned annealed copper, three power 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 EPR Insulation | White R-EP-90 EPR Class 2 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. Composite Earth Screen | Composite braid of tinned annealed copper wire and polyester yarn with Red, White, and Blue braid tracers (8.2–71 mm² per phase) |
| 5. Three Interstitial Pilots | Three elastomer-covered and proofed-tape tinned copper pilots disposed in the outer cable interstices (1–35.7 mm² each) |
| 6. Polyaramid-Reinforced Sheath | Heavy-duty black HD-85-PCP sheath (3.8–11.1 mm) incorporating polyaramid braid reinforcement |
Type 440 Cross-Section Geometry: Three composite-screened Class 2 EPR phase cores with Red/White/Blue tracer braids, balanced by three symmetrical interstitial pilot cores inside a heavy HD-85-PCP sheath.
Technical Characteristics
Compliant with AS/NZS 2802 from 1.1 kV through 22 kV, Type 440 delivers high earth-screen fault capacity, multi-pilot versatility, and immersion-grade elastomer durability.
| Parameter | AS/NZS 2802 Rated Value |
|---|---|
| Manufacturing Standard | AS/NZS 2802 (Reeling and trailing cables for mining and general use) |
| Voltage Grades & Sub-Types | 440.1 (1.1 kV) | 440.3 (3.3 kV) | 440.6 (6.6 kV) | 440.11 (11 kV) | 440.22 (22 kV) |
| Phase Screen Area (Per Phase) | 8.2 mm²/phase up to 71 mm²/phase (up to 213 mm² combined 3-phase copper screen area!) |
| Interstitial Pilot Sizing | 3 × 1.0 mm² (on 6 mm²) scaling up to 3 × 35.7 mm² (on 300 mm²) |
| Operating Temperature Range | −25 °C min. installation to +90 °C max. continuous conductor temperature |
| Immersion & Flame Performance | Excellent oil/water immersion stability, polyaramid anti-torsion reinforcement, C1 flame retardant |
Specification, Screen & Pilot Data (47 Standard Sizes, 1.1 kV – 22 kV)
Unified electrical and dimensional tables combining conductor diameter, Class 2 EPR wall, AC impedance, per-phase copper screen area, individual pilot cross-section, overall diameter, and mass.
Type 440.1 — Rated Voltage: 1.1/1.1 kV (6 mm² to 300 mm² | 13 Sizes)
| Area (mm²) | Cond. Dia. (mm) | Insul. (mm) | AC Res. (Ω/km) | React. (Ω/km) | Volt Drop (mV/A·m) | Cap. (μF/km) | Screen (mm²/ph) | Pilot Each (mm²) | Sheath (mm) | Cable Dia. (mm) | Mass (kg/100m) |
|---|---|---|---|---|---|---|---|---|---|---|---|
| 3 × 6 | 3.5 | 1.5 | 4.32 | 0.141 | 7.49 | 0.259 | 8.2 | 1 | 3.8 | 31.0 | 150 |
| 3 × 10 | 4.6 | 1.5 | 2.58 | 0.130 | 4.47 | 0.314 | 8.2 | 1.5 | 3.8 | 33.3 | 175 |
| 3 × 16 | 6.2 | 1.6 | 1.58 | 0.118 | 2.74 | 0.379 | 10 | 3 | 4.0 | 37.3 | 230 |
| 3 × 25 | 7.2 | 1.6 | 0.951 | 0.112 | 1.66 | 0.432 | 12 | 4.5 | 4.3 | 40.3 | 295 |
| 3 × 35 | 8.4 | 1.6 | 0.698 | 0.107 | 1.22 | 0.493 | 14 | 6 | 4.6 | 43.6 | 350 |
| 3 × 50 | 9.7 | 1.7 | 0.523 | 0.104 | 0.924 | 0.526 | 14 | 8 | 5.0 | 47.7 | 425 |
| 3 × 70 | 12.0 | 1.8 | 0.346 | 0.0981 | 0.623 | 0.599 | 16 | 12.5 | 5.4 | 54.0 | 565 |
| 3 × 95 | 13.3 | 2.0 | 0.271 | 0.0964 | 0.498 | 0.591 | 22 | 12.5 | 6.0 | 59.5 | 695 |
| 3 × 120 | 15.3 | 2.1 | 0.210 | 0.0932 | 0.398 | 0.640 | 25 | 13.75 | 6.4 | 65.2 | 845 |
| 3 × 150 | 17.2 | 2.3 | 0.166 | 0.0928 | 0.329 | 0.652 | 37 | 17 | 6.9 | 72.3 | 1065 |
| 3 × 185 | 18.8 | 2.5 | 0.137 | 0.0915 | 0.285 | 0.657 | 40 | 22 | 7.4 | 77.8 | 1245 |
| 3 × 240 | 21.7 | 2.8 | 0.106 | 0.0905 | 0.241 | 0.672 | 58 | 27 | 8.2 | 88.1 | 1610 |
| 3 × 300 | 24.3 | 3.0 | 0.0849 | 0.0883 | 0.212 | 0.719 | 63 | 35.7 | 8.8 | 95.5 | 1930 |
Type 440.3 — Rated Voltage: 3.3/3.3 kV (16 mm² to 300 mm² | 11 Sizes)
| Area (mm²) | Cond. Dia. (mm) | Insul. (mm) | AC Res. (Ω/km) | React. (Ω/km) | Volt Drop (mV/A·m) | Cap. (μF/km) | Screen (mm²/ph) | Pilot Each (mm²) | Sheath (mm) | Cable Dia. (mm) | Mass (kg/100m) |
|---|---|---|---|---|---|---|---|---|---|---|---|
| 3 × 16 | 6.2 | 3.0 | 1.58 | 0.131 | 2.75 | 0.255 | 14 | 3 | 5.3 | 47.3 | 340 |
| 3 × 25 | 7.2 | 3.0 | 0.951 | 0.125 | 1.66 | 0.280 | 15 | 4.5 | 5.6 | 50.4 | 410 |
| 3 × 35 | 8.4 | 3.0 | 0.698 | 0.119 | 1.23 | 0.311 | 16 | 6 | 5.9 | 53.5 | 475 |
| 3 × 50 | 9.7 | 3.0 | 0.523 | 0.114 | 0.927 | 0.347 | 17 | 8 | 6.3 | 57.2 | 555 |
| 3 × 70 | 12.0 | 3.0 | 0.346 | 0.106 | 0.627 | 0.408 | 19 | 12.5 | 6.6 | 62.6 | 690 |
| 3 × 95 | 13.3 | 3.0 | 0.271 | 0.102 | 0.502 | 0.439 | 21 | 12.5 | 7.1 | 66.4 | 785 |
| 3 × 120 | 15.3 | 3.0 | 0.210 | 0.0985 | 0.402 | 0.492 | 28 | 13.75 | 7.4 | 72.0 | 960 |
| 3 × 150 | 17.2 | 3.0 | 0.166 | 0.0954 | 0.332 | 0.541 | 32 | 17 | 7.8 | 76.7 | 1130 |
| 3 × 185 | 18.8 | 3.0 | 0.137 | 0.0942 | 0.288 | 0.584 | 42 | 22 | 8.2 | 82.3 | 1330 |
| 3 × 240 | 21.7 | 3.0 | 0.106 | 0.0906 | 0.242 | 0.659 | 48 | 27 | 8.8 | 89.6 | 1615 |
| 3 × 300 | 24.3 | 3.0 | 0.0849 | 0.0890 | 0.213 | 0.727 | 63 | 35.7 | 9.4 | 97.7 | 1980 |
Type 440.6 — Rated Voltage: 6.6/6.6 kV (16 mm² to 300 mm² | 11 Sizes)
| Area (mm²) | Cond. Dia. (mm) | Insul. (mm) | AC Res. (Ω/km) | React. (Ω/km) | Volt Drop (mV/A·m) | Cap. (μF/km) | Screen (mm²/ph) | Pilot Each (mm²) | Sheath (mm) | Cable Dia. (mm) | Mass (kg/100m) |
|---|---|---|---|---|---|---|---|---|---|---|---|
| 3 × 16 | 6.2 | 5.0 | 1.58 | 0.143 | 2.75 | 0.181 | 17 | 3 | 6.4 | 58.2 | 480 |
| 3 × 25 | 7.2 | 5.0 | 0.951 | 0.137 | 1.66 | 0.193 | 19 | 4.5 | 6.7 | 61.7 | 570 |
| 3 × 35 | 8.4 | 5.0 | 0.698 | 0.130 | 1.23 | 0.212 | 21 | 6 | 7.0 | 64.8 | 645 |
| 3 × 50 | 9.7 | 5.0 | 0.523 | 0.124 | 0.931 | 0.234 | 22 | 8 | 7.3 | 68.2 | 730 |
| 3 × 70 | 12.0 | 5.0 | 0.346 | 0.116 | 0.632 | 0.271 | 23 | 12.5 | 7.7 | 73.8 | 880 |
| 3 × 95 | 13.3 | 5.0 | 0.271 | 0.113 | 0.509 | 0.292 | 30 | 12.5 | 8.1 | 78.0 | 1020 |
| 3 × 120 | 15.3 | 5.0 | 0.210 | 0.108 | 0.409 | 0.325 | 32 | 13.75 | 8.5 | 83.2 | 1180 |
| 3 × 150 | 17.2 | 5.0 | 0.166 | 0.105 | 0.340 | 0.354 | 46 | 17 | 8.9 | 89.2 | 1410 |
| 3 × 185 | 18.8 | 5.0 | 0.136 | 0.102 | 0.294 | 0.381 | 49 | 22 | 9.3 | 93.6 | 1590 |
| 3 × 240 | 21.7 | 5.0 | 0.106 | 0.0981 | 0.250 | 0.426 | 53 | 27 | 9.9 | 101 | 1885 |
| 3 × 300 | 24.3 | 5.0 | 0.0845 | 0.0959 | 0.221 | 0.467 | 71 | 35.7 | 10.4 | 109 | 2275 |
Type 440.11 — Rated Voltage: 11/11 kV (25 mm² to 185 mm² | 8 Sizes)
| Area (mm²) | Cond. Dia. (mm) | Insul. (mm) | AC Res. (Ω/km) | React. (Ω/km) | Volt Drop (mV/A·m) | Cap. (μF/km) | Screen (mm²/ph) | Pilot Each (mm²) | Sheath (mm) | Cable Dia. (mm) | Mass (kg/100m) |
|---|---|---|---|---|---|---|---|---|---|---|---|
| 3 × 25 | 7.2 | 7.6 | 0.951 | 0.150 | 1.67 | 0.150 | 24 | 4.5 | 8.1 | 75.9 | 815 |
| 3 × 35 | 8.4 | 7.6 | 0.698 | 0.143 | 1.23 | 0.163 | 30 | 6 | 8.4 | 79.6 | 930 |
| 3 × 50 | 9.7 | 7.6 | 0.523 | 0.136 | 0.936 | 0.178 | 32 | 8 | 8.7 | 83.0 | 1025 |
| 3 × 70 | 12.0 | 7.6 | 0.346 | 0.127 | 0.638 | 0.204 | 35 | 12.5 | 9.1 | 88.7 | 1210 |
| 3 × 95 | 13.3 | 7.6 | 0.271 | 0.124 | 0.516 | 0.219 | 48 | 12.5 | 9.6 | 93.8 | 1385 |
| 3 × 120 | 15.3 | 7.6 | 0.210 | 0.119 | 0.418 | 0.241 | 53 | 13.75 | 9.9 | 98.7 | 1565 |
| 3 × 150 | 17.2 | 7.6 | 0.165 | 0.114 | 0.347 | 0.261 | 56 | 17 | 10.3 | 103 | 1765 |
| 3 × 185 | 18.8 | 7.6 | 0.136 | 0.111 | 0.304 | 0.279 | 56 | 22 | 10.7 | 108 | 1945 |
Type 440.22 — Rated Voltage: 22/22 kV (35 mm² to 95 mm² | 4 Sizes)
| Area (mm²) | Cond. Dia. (mm) | Insul. (mm) | AC Res. (Ω/km) | React. (Ω/km) | Volt Drop (mV/A·m) | Cap. (μF/km) | Screen (mm²/ph) | Pilot Each (mm²) | Sheath (mm) | Cable Dia. (mm) | Mass (kg/100m) |
|---|---|---|---|---|---|---|---|---|---|---|---|
| 3 × 35 | 8.4 | 10.5 | 0.698 | 0.160 | 1.24 | 0.147 | 53 | 6 | 10.0 | 102 | 1430 |
| 3 × 50 | 9.7 | 10.5 | 0.523 | 0.153 | 0.944 | 0.159 | 56 | 8 | 10.3 | 106 | 1550 |
| 3 × 70 | 12.0 | 10.5 | 0.346 | 0.143 | 0.648 | 0.178 | 60 | 12.5 | 10.7 | 111 | 1755 |
| 3 × 95 | 13.3 | 10.5 | 0.271 | 0.138 | 0.527 | 0.189 | 62 | 12.5 | 11.1 | 115 | 1890 |
Selection: Type 440 vs. Type 409 vs. Type 240
All three models utilize composite tinned-copper/polyester phase screens; selection is governed by pilot core count, voltage ceiling, and surface vs. underground coal mine standards.
| Cable Model | Pilot Architecture, Voltage Ceiling & Best-Fit Application |
|---|---|
| Type 440 (This Product) | AS/NZS 2802 Class 2, 3 interstitial pilots (1–35.7 mm² each), rated 1.1 kV to 22 kV. Ideal for long open-cut feeder runs, dragline/shovel substations, and multi-pilot reeling systems. |
| Type 409 (AS/NZS 2802) | Type 409 shares the same Class 2 1.1–22 kV ratings but replaces the three interstitial pilots with a single central extensible pilot for standard trailing machines. |
| Type 240 (AS/NZS 1802) | For underground coal mine 3-pilot feeders up to 11 kV, specify AS/NZS 1802 Type 240. |
Frequently Asked Questions (FAQ)
Technical answers covering Type 440 interstitial pilot sizing, per-phase screen ratings, and reeling capability.
Why are the three pilots in Type 440 scaled up to 35.7 mm² on larger cable sizes?
Open-cut pit bench runs from perimeter substations to shovel/dragline skids frequently span several kilometers. Scaling the three interstitial pilots proportionally with phase size (from 1 mm² on 6 mm² up to 35.7 mm² each on 300 mm²) maintains mechanical lay symmetry and low loop resistance over long runs.
How is the Screen Area column reported in the Type 440 specification tables?
Per the AS/NZS 2802 Type 440 datasheet, Screen Area is stated in mm² per phase (8.2 mm²/phase up to 71 mm²/phase), providing substantial per-core earth-fault current capacity across all three power phases.
Does Type 440 include anti-torsion reinforcement for reeling drums?
Yes. Type 440 incorporates an integral polyaramid yarn reinforcement braid within the heavy-duty HD-85-PCP outer sheath to resist tensile stretch and torsional twist in reeling and long trailing service.
Request a Quote for AS/NZS 2802 Type 440 3-Pilot Mining Cables
Specify your voltage rating (1.1 kV to 22 kV), conductor cross-section (6–300 mm²), sheath colour, and drum length for factory pricing.
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