AS/NZS 1802 Type 209 Mining Cables: Engineering Guide

I. Introduction to AS/NZS 1802 Type 209 Mining Cables

Definition and Standard

Type 209 cables are specialized flexible, copper-screened, elastomer-sheathed power cables designed specifically for underground mining applications operating at 1.1/1.1 kV. These cables conform to multiple Australian and New Zealand standards including AS/NZS 1802:2003, AS/NZS 1125, AS/NZS 3808, and AS/NZS 5000.1.

Key Features

The distinguishing characteristics of Type 209 cables include:

• Three screened power cores for reliable power transmission

• A central extensible pilot conductor for control and monitoring

• Composite screening system with tinned copper braiding

• Heavy-duty elastomeric sheathing for durability in harsh environments

II. Application Scenarios

Underground Coal Mines

These cables serve as main feeders to critical mining equipment including:

• Longwall equipment

• Belt conveyors

• Gate-end power boxes

Trailing Cables for Machinery

Type 209 cables function primarily as flexible feeders to various mining machinery:

• Larger cables supply power to pumps, crushers, winches, and hydraulic supports

• Smaller diameter variants are used for drills and hand-held tools and equipment

Fixed vs. Reeling Use

According to the documentation, Type 209 series cables are "mainly used as a flexible feeder to machinery, more suitable as a trailing cable rather than for reeling." This makes them ideal for applications where the cable must follow equipment movement without continuous spooling on and off drums

III. Electrical and Mechanical Parameters

Voltage Ratings

• Standard operational rating: 1.1/1.1 kV

• For higher voltage applications, cables with ratings of 3.3/3.3 kV and above receive additional conductor screening

Conductor

The cables feature flexible stranded tinned annealed copper conductors, available in various cross-sectional areas from 6mm² to 300mm², with specific strand configurations for each size. For example:

• 6mm²: 84/0.30 (84 strands of 0.30mm diameter)

• 300mm²: 854/0.67 (854 strands of 0.67mm diameter)

Insulation

The conductors are insulated with Ethylene Propylene Rubber (EPR), with thickness varying based on the voltage rating:

• Type 209.1: 1.5-3.0mm insulation thickness

• Type 209.3: 3.0mm standard insulation thickness

• Type 209.6: 5.0mm insulation thickness

• Type 209.11: 7.6mm insulation thickness

Screening

The screening system consists of multiple components:

• Conductor Screen: Semiconductive compound (for cables rated 3.3/3.3kV and above)

• Insulation Screen: Semiconductive elastomer

• Composite Screen (earth conductor): Tinned annealed copper braiding interwoven with polyester yarn

• Core Screen area ranges from approximately 7.2mm² to 71.5mm² depending on cable size

Pilot Core

A central extensible pilot conductor features:

• EPR-covered flexible stranded tinned copper conductor

• Standard 24/0.20 or 40/0.20 strand configuration

• 0.8mm covering thickness

Sheath

The cables are protected by a heavy-duty Polychloroprene (PCP) sheath:

• Thickness ranges from 3.8mm to 10.7mm depending on cable size

• Alternative heavy-duty CPE/CSP sheath available upon request

• Provides resistance against oils, flames, and mechanical damage

Dimensions and Weight

The documentation provides detailed specifications for each cable variant:

• Overall diameter: From 30.0mm (6mm² 209.1) to 109.3mm (300mm² 209.11)

• Weight: From 129kg/100m (6mm² 209.1) to 2120kg/100m (300mm² 209.11)

IV. FAQ: Common Mining-Site Issues and Solutions

Moisture Ingress Prevention

• Ensure proper gland installation with appropriate compression

• Regularly inspect sheath integrity, especially at connection points

• Use end-of-drum seals when storing unused sections

Handling Mechanical Damage

• Implement regular inspection protocols for cable sheaths

• For minor damage, apply approved elastomeric repair tapes

• Replace heavily damaged sections to maintain safety integrity

Fault Location Techniques

• Utilize time-domain reflectometry (TDR) for pinpointing fault locations

• Monitor pilot core continuity for early warning of potential issues

• Implement regular insulation resistance testing

Appropriate Applications

• Not recommended for shuttle car applications due to specified exclusions

• Select appropriate cable size based on current requirements and duty cycle

• Consider voltage drop over extended runs when sizing conductors

Service Life Considerations

• Under normal conditions, expect 3-5 years of service life

• Monitor insulation resistance values to determine replacement timing

• Replace after multiple repairs to maintain system integrity

Chemical Exposure Management

• The PCP sheath provides good oil resistance

• Clean spills promptly and inspect for degradation

• Request CPE/CSP sheath variants for environments with specific chemical challenges

Temperature Derating

• Follow AS/NZS standards for derating in environments exceeding 40°C

• Monitor operating temperature to prevent premature insulation aging

• Consider additional ventilation in high-temperature zones

Installation Best Practices

• Maintain minimum bend radius (typically 6-8 times overall diameter)

• Secure cables to prevent dragging across abrasive surfaces

• Allow sufficient slack for equipment movement without tension

• Use appropriate cable management systems to minimize mechanical stress