Type 409 Flexible Copper Screened Mining Cable With Central Pilot
The Type 409 Flexible Copper Screened Mining Cable with Central Pilot is a heavy-duty flexible cable engineered for reliable and safe underground mining operations. It features finely stranded tinned copper conductors (class 5) for excellent flexibility and corrosion resistance, EPR (ethylene propylene rubber) insulation for superior dielectric strength and 90°C continuous thermal rating, an overall tinned copper braid screen providing effective EMI protection and grounding, a central pilot core for earth continuity monitoring, safety interlocks, and fault detection, and an extra-heavy-duty flame-retardant rubber outer sheath resistant to oil, abrasion, tearing, crushing, impact, and chemicals. Compliant with AS/NZS 2802 and mining safety standards, it supports high tensile loads, frequent reeling/drag, tight bending radii, and reliable performance in wet, dusty, and hazardous mine conditions. The Type 409 is ideal for power supply to continuous miners, shuttle cars, longwall equipment, drills, and other mobile machinery in coal and metalliferous mines, ensuring enhanced safety through pilot core monitoring and maximum durability.
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Voltage Rating
Type 409.1 - 1.1kV
Type 409.3 - 3.3kV
Type 409.6 - 6.6kV - Temperature Rating -25°C to +90°C
Construction
Technical Specifications
Quality Control
Application
Construction
Type 409 Flexible Copper Screened Mining Cable With Central Pilot Constrution
Conductor
Tinned anneaIed copper wires
Insulation
EPR (EthyIene PropyIene Rubber) type R–EP–90
Separator/Screen
1.1kV: Paper separator
For other nominal voltages semi-conductive tape+ thermosetting compound over conductors
For other nominal voltages semi-conductive tape+ thermosetting compound over conductors
Insulation Screen
1.1kV: Synthetic tape
From 3.3kV: Semi–conductive thermosetting compound
From 3.3kV: Semi–conductive thermosetting compound
Cable Assembly
Three screened power and three pilot cores laid up with right hand direction on cradle separator with central pilot core
Cradle Separator
Semi–conductive thermosetting compound
Sheath
PCP (PoIychIoroprene) thermosetting compound HD–85–PCP – extra heavy duty, oiI resistance and fIame retardant
Sheath Colour
Black
Manufacturer Standard
AS/NZS 1125:2001, AS/NZS 2802:2000
Application
Type 409 Flexible Copper Screened Mining Cable With Central Pilot is used as a flexible feeder cable to machinery, especially suitable for trailing applications. Larger sizes are ideal for powering draglines, shovels, and drills, while smaller sizes serve portable drills, handheld tools, and equipment.
Technical Specifications
Type 409 Flexible Copper Screened Mining Cable With Central Pilot
Type 409 Flexible Copper Screened Mining Cable With Central Pilot
| No. Of Cores |
NOMINAL CONDUCTOR AREA mm² |
THICKNESS OF INSULATION mm |
CORE SCREEN SIZE mm |
AREA OF SCREEN mm² |
NOMINAL THICKNESS OF SHEATH mm |
NOMINAL DIAMETER mm |
NOMINAL WEIGHT kg/km |
| 3+1 | 6 | 1.5 | 7/0.25 | 7.2 | 3.8 | 30 | 129 |
| 3+1 | 10 | 1.5 | 7/0.25 | 8.6 | 3.8 | 32.6 | 157 |
| 3+1 | 16 | 1.6 | 7/0.25 | 9.6 | 4 | 35.8 | 157 |
| 3+1 | 25 | 1.6 | 7/0.25 | 11.3 | 4.3 | 39.7 | 255 |
| 3+1 | 35 | 1.6 | 7/0.25 | 12.4 | 4.6 | 43.8 | 312 |
| 3+1 | 50 | 1.7 | 7/0.25 | 14.4 | 5 | 48.4 | 386 |
| 3+1 | 70 | 1.8 | 7/0.25 | 16.5 | 5.4 | 54 | 502 |
| 3+1 | 95 | 2 | 7/0.30 | 21.8 | 6 | 59.4 | 622 |
| 3+1 | 120 | 2.1 | 7/0.30 | 24.7 | 6.4 | 65.2 | 760 |
| 3+1 | 150 | 2.3 | 7/0.40 | 36.9 | 6.9 | 72.2 | 960 |
| 3+1 | 185 | 2.5 | 7/0.40 | 40.5 | 7.4 | 78.8 | 1139 |
| 3+1 | 240 | 2.8 | 7/0.50 | 57.7 | 8.2 | 88.7 | 1465 |
| 3+1 | 300 | 3 | 7/0.50 | 63.2 | 8.8 | 96.5 | 1790 |
| 3+1 | 16 | 3 | 7/0.25 | 13.1 | 5.3 | 46.3 | 301 |
| 3+1 | 25 | 3 | 7/0.25 | 14.8 | 5.6 | 50 | 371 |
| 3+1 | 35 | 3 | 7/0.25 | 15.8 | 5.9 | 53.5 | 430 |
| 3+1 | 50 | 3 | 7/0.25 | 17.2 | 6.3 | 57.5 | 511 |
| 3+1 | 70 | 3 | 7/0.25 | 18.6 | 6.6 | 62.4 | 624 |
| 3+1 | 95 | 3 | 7/0.30 | 20.3 | 7.1 | 66.1 | 724 |
| 3+1 | 120 | 3 | 7/0.40 | 27.2 | 7.4 | 72.1 | 880 |
| 3+1 | 150 | 3 | 7/0.40 | 39.6 | 7.8 | 77.9 | 1079 |
| 3+1 | 185 | 3 | 7/0.40 | 42.2 | 8.2 | 83.5 | 1251 |
| 3+1 | 240 | 3 | 7/0.40 | 46.6 | 8.8 | 90.3 | 1502 |
| 3+1 | 16 | 5 | 7/0.25 | 17.2 | 6.4 | 57.3 | 440 |
| 3+1 | 25 | 5 | 7/0.25 | 18.6 | 6.7 | 61.2 | 516 |
| 3+1 | 35 | 5 | 7/0.25 | 18.6 | 7 | 64.6 | 584 |
| 3+1 | 50 | 5 | 7/0.25 | 21.3 | 7.3 | 68.5 | 659 |
| 3+1 | 70 | 5 | 7/0.25 | 23.4 | 7.7 | 73.7 | 804 |
| 3+1 | 95 | 5 | 7/0.25 | 29.3 | 8.1 | 77.8 | 934 |
| 3+1 | 120 | 5 | 7/0.30 | 31.7 | 8.5 | 83.1 | 1090 |
| 3+1 | 150 | 5 | 7/0.40 | 34.1 | 8.9 | 89.1 | 1310 |
| 3+1 | 185 | 5 | 7/0.40 | 47.5 | 9.3 | 94.5 | 1479 |
Quality Control
Type 409 Flexible Copper Screened Mining Cable With Central Pilot
Raw Material Test
Raw Material Test for Type 409 Flexible Copper Screened Mining Cable with Central Pilot ensures mining-grade durability and pilot safety. The detailed process includes: Supplier Certification Review: Verify class 5 tinned copper conductors meet AS/NZS 1125 or IEC 60228 for purity (>99.9% Cu), stranding, and tin coating; EPR insulation, pilot core, and rubber sheath compounds certified to AS/NZS 2802 for flame retardancy and mechanical properties. Conductor Analysis: Test tinned copper (phase/pilot) for tensile strength (>200 MPa), elongation (>20%), conductivity (≥97% IACS), and tin uniformity to ensure corrosion resistance in wet mining conditions. Insulation Testing: EPR insulation evaluated for tensile (>6.5 MPa), elongation (>300%), dielectric strength (>20 kV/mm), thermal aging (100°C/168h), hot set test (≤175% elongation after 200°C/15 min), and water absorption resistance.
Process inspection
Process Inspection during the manufacturing of Type 409 Flexible Copper Screened Mining Cable with Central Pilot maintains mining safety and consistency. Steps include: Conductor & Pilot Stranding: Monitor class 5 stranding of phase and central pilot conductors for uniform lay length, compactness, and no loose strands. Insulation Extrusion: Apply EPR insulation at controlled thickness; inline diameter scanners, eccentricity monitors, and spark testers detect voids or defects. Screening Application: Braid tinned copper with precise coverage (>80%) and tension control; real-time monitoring of braid angle and optical coverage for effective EMI protection. Outer Sheath Extrusion: Extrude extra-heavy-duty rubber sheath; continuous checks on thickness, surface finish, adhesion, and enhanced mechanical properties.
Finished Product
Finished Product Test confirms the Type 409 Flexible Copper Screened Mining Cable with Central Pilot meets mining standards before shipment. The procedure includes: Visual & Dimensional Inspection: Examine full length for defects, uniformity, markings, and measure outer diameter/weight per meter. Electrical Tests: Conductor DC resistance, insulation resistance (>1000 MΩ·km), high-voltage withstand (e.g., 11kV for 3.6/6kV class/5 min), partial discharge, screen continuity, and pilot core functionality per AS/NZS 2802/IEC. Mechanical Evaluation: Bending radius (6–8× OD), tensile strength, crush resistance, abrasion/tear tests, and dynamic flexing to simulate mining reeling.
Application
The Type 409 Flexible Copper Screened Mining Cable with Central Pilot is perfect for underground coal and metalliferous mining trailing/reeling operations, continuous miners, shuttle cars, longwall systems, drills, loaders, and mobile equipment requiring screened, flame-retardant cable with central pilot core for earth continuity monitoring and enhanced safety.
Technical Advantages
● 30+ years of manufacturing experience
● ISO and UL certified production
● Customized cable and transformer solutions
Product Packaging
Wires and Cables packaging (1)
Wires and Cables packaging (2)
Wires and Cables packaging (3)
Wires and Cables packaging (4)
Wires and Cables packaging (5)
Wires and Cables packaging (6)
Wires and Cables packaging (7)
Wires and Cables packaging (8)
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