I. Introduction to AS/NZS 1802 Type 210 1.1/1.1 kV Mining Cables

Standard and Designation

Type 210 cables are manufactured in compliance with AS/NZS 1802:2003, the Australian/New Zealand Standard for electric cables for use in underground coal mining applications. These cables are specifically designed for trailing and reeling applications at a rated voltage of 1.1/1.1 kV.

Core Construction

The cable design incorporates three flexible, stranded tinned annealed copper power conductors. Each power conductor is individually screened with polyester or semiconductive tape to control the electrical field and prevent electrical tracking. A central extensible pilot conductor is included for control or monitoring signals, enhancing operational safety and functionality.

Insulation & Sheath

Each power core is insulated with ethylene-propylene rubber (EPR), chosen for its excellent electrical properties and thermal stability. The cable is protected by a heavy-duty polychloroprene (PCP) elastomer outer sheath, providing superior resistance to:

• Mechanical abrasion

• Oil and chemical exposure

• Moisture ingress

• Flame propagation

This construction ensures reliable operation in the challenging environment of underground mining operations.

II. Application Scenarios

Hand-Held Machinery

Type 210 cables are primarily designed as power feeders for hand-held drilling equipment and boring machines in underground mining operations. Their flexibility and ruggedness make them ideal for these applications where frequent handling and movement are expected.

Auxiliary Equipment Feeders

Smaller cross-section sizes of Type 210 cables serve a variety of auxiliary mining equipment, including:

• Ventilation fans

• Water pumps

• Crushers

• Hydraulic supports

In these applications, the cable's combination of flexibility and abrasion resistance provides reliable power delivery under demanding conditions.

Trailing vs. Reeling Use

While Type 210 cables are suitable for both trailing (drag) applications and limited reeling operations, it's important to note they are not intended for high-speed continuous reeling applications such as:

• Shuttle cars

• Heavy-duty drum systems

• High-cycle retrieval applications

For such demanding dynamic applications, more specialized cable types should be selected.

Environmental Conditions

Type 210 cables are engineered to withstand the harsh conditions typically found in underground mining galleries:

• High humidity and direct water contact

• Exposure to hydraulic fluids and lubricating oils

• Risk of fire in confined spaces

• Abrasive surfaces and sharp rock edges

• Chemical exposure from mining operations

III. Electrical and Mechanical Parameters

Voltage Rating

The nominal voltage rating for Type 210 cables is 1.1/1.1 kV. In manufacturing, similar AS/NZS mining cables typically undergo factory AC testing at 4.2 kV to ensure dielectric integrity and safety margins.

Conductors

The power conductors consist of flexible stranded tinned annealed copper manufactured according to AS/NZS 1125. This construction provides:

• High electrical conductivity

• Enhanced mechanical flexibility

• Superior corrosion resistance

• Reduced oxidation at connection points

Insulation

The ethylene-propylene rubber (EPR) insulation complies with AS/NZS 3808 requirements and offers:

• Excellent dielectric properties

• High temperature stability (90°C continuous rating)

• Good mechanical flexibility

• Resistance to moisture and many chemicals

Core Screens

Each power core is wrapped with a semiconductive elastomer or polyester barrier tape that:

• Controls the electrical field around the conductor

• Prevents electrical tracking between cores

• Distributes electrical stress evenly

• Enables easier fault detection

Composite Earth Screen

An overall earth screen made of tinned copper braid interwoven with polyester yarn provides:

• Effective grounding continuity

• Mechanical reinforcement

• Enhanced flexibility

• Protection against electrical faults

Pilot Core

The central extensible pilot conductor features EPR covering and supports:

• Remote monitoring of cable integrity

• Safety interlock systems

• Emergency shutdown capabilities

• Communication between equipment and control systems

Outer Sheath

The heavy-duty PCP elastomeric sheath delivers:

• Superior oil resistance

• Flame retardance

• Excellent abrasion resistance

• Good flexibility in low temperatures

For special applications, neoprene (CPE/CSP) variants are available upon request, offering modified chemical resistance profiles.

IV. FAQ: Common Mining-Site Issues and Solutions

1. How do I prevent moisture ingress?

• Use proper sealing at cable terminations with heat-shrink sleeves or cable-specific sealing kits

• Maintain cable gland integrity with regular inspections and proper torque

• Conduct regular pressure and leakage tests to detect early water ingress

• Store unused cable on reels and protect cable ends with watertight caps

• Immediately repair or replace cables showing signs of sheath damage

2. What if the sheath is mechanically damaged?

• Perform daily visual inspections before power-up

• Minor abrasions can be repaired with approved PCP repair tapes if the damage hasn't penetrated to the conductors

• Any cables with through-cuts or exposed cores must be removed from service and replaced

• Document all repairs and create scheduled follow-up inspections

• Implement protective measures in high-abrasion areas (cable trays, rollers)

3. How can I locate and diagnose cable faults?

• Utilize time-domain reflectometry (TDR) for precise fault location

• Take advantage of the pilot-core continuity measurements for quick diagnostics

• The pilot conductor often aids in pinpointing faults without full excavation

• Regular insulation resistance testing can detect degradation before catastrophic failure

• Consider implementing online monitoring systems for critical applications

4. Can Type 210 be used on shuttle cars or high-speed reels?

No—Type 210 is optimized for hand-held equipment and light-duty trailing/reeling applications. For heavy-duty shuttle-car applications, more flexible and dynamic-rated cables like AS/NZS 1802 Type 275 are required. Using Type 210 in high-cycle, high-speed reeling applications will result in premature failure and potential safety hazards.

5. How do I handle chemical exposure (oil, solvents)?

• Verify sheath compatibility (PCP is oil-resistant but may be affected by certain solvents)

• Immediately clean and inspect cables after chemical spills

• Avoid prolonged contact with aggressive chemicals

• Consider specialized sheath materials for unique chemical environments

• Implement regular cleaning protocols in areas with high chemical exposure

V. Technical Specifications

Dimensions and Weight

Applicable Standards

• AS/NZS 1802:2003 - Electric cables for use in underground coal mines

• AS/NZS 1125 - Conductors in insulated electric cables and flexible cords

• AS/NZS 3808 - Insulation and sheathing materials for electric cables

• AS/NZS 5000.1 - Electric cables—Polymeric insulated

VI. Maintenance and Best Practices

Routine Inspection

• Conduct daily visual inspections before use

• Check for sheath integrity, particularly at stress points

• Inspect cable glands and terminations for signs of movement or damage

• Verify pilot circuit continuity before operations

• Test insulation resistance monthly or after significant environmental events

Handling Guidelines

• Maintain proper bend radius (typically 6-8 times cable diameter)

• Avoid sharp edges and abrasive surfaces when routing cables

• Use approved suspension systems for trailing applications

• Implement proper cable management to prevent crushing or twisting

• Train operators on correct handling procedures

Storage Recommendations

• Store on appropriate-sized reels to prevent excessive bending

• Protect cable ends with watertight caps

• Keep in dry, temperature-controlled environment when possible

• Avoid direct sunlight during long-term storage

• Maintain complete spooling to prevent deformation

VII. Conclusion

AS/NZS 1802 Type 210 1.1/1.1 kV mining cables represent a specialized solution for power distribution in the challenging environment of underground mining. Their robust construction, featuring EPR insulation and heavy-duty PCP sheathing, provides the durability and performance required for hand-held equipment and auxiliary mining applications.

While offering excellent resistance to environmental factors like moisture, oil, and abrasion, these cables have specific application limitations and are not suitable for high-speed reeling operations. Proper selection, installation, and maintenance are essential to maximize service life and ensure safe operation in underground mining environments.

AS/NZS 1802 Type 210 1.1/1.1 kV Mining Cables: Technical Guide and Applications