Type 455 Flexible Screened Mining Cable With Two Earth And One Pilot Core
The Type 455 Flexible Screened Mining Cable With Two Earth And One Pilot Core is an extra-heavy-duty flexible cable designed for the most severe underground mining operations requiring enhanced electrical safety. It features finely stranded tinned copper conductors (class 5) for exceptional flexibility and corrosion resistance, EPR insulation for high dielectric strength and 90°C continuous rating, tinned copper braid screen for effective EMI protection and grounding, two dedicated earth cores for redundant grounding and increased safety, one pilot core for earth continuity monitoring and machine interlock protection, 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 very high tensile loads, frequent reeling/drag, tight bending radii, and reliable performance in wet, dusty, and hazardous conditions. The Type 455 is ideal for high-power trailing applications in coal and metalliferous mines, powering longwall shearers, continuous miners, face conveyors, shuttle cars, and critical mobile equipment with dual earth redundancy and pilot monitoring for maximum safety.
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Voltage Rating
Type 455.3 - 3.3kV
Type 455.6 - 6.6kV
Type 455.11 - 11kV - Temperature Rating -25°C to +90°C
Construction
Technical Specifications
Quality Control
Application
Construction
Type 455 Flexible Screened Mining Cable with two earth and one pilot core Constrution
Conductor
Tinned anneaIed copper wires
Insulation
EPR (Ethylene Propylene Rubber) type XR-EP-90
Conductor Screen
Semi-conductive tape + thermosetting compound
Insulation Screen
Semi-conductive thermosetting compound
Cable Assembly
Three screened power, two earth and one pilot core laid up with right hand direction on the rubber centre filler
Screen
Tinned copper/polyamide braid
Inner Sheath
Semi-conductive thermosetting compound
Armour
Polyamide yarns
Outer Sheath
HD-CSP (Heavy-duty Chlorosulphonated Polyethylene) - extra heavy duty, oil resistant and flame retardant
Sheath Colour
Black
Manufacturer Standard
AS/NZS 2802: 2000, AS/NZS 1125:2001, AS/NZS 2802:2003
Application
Type 455 Flexible Screened Mining Cable is particularly suited for stacker-reclaimer applications and is ideal for reeling and trailing operations. It is used where two earth and one pilot cores are required, and is also suitable for various industrial applications.
Technical Specifications
Type 455 Flexible Screened Mining Cable With Two Earth And One Pilot Core
Type 455 Flexible Screened Mining Cable With Two Earth And One Pilot Core
| 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+2+1 | 16 | 2.2 | 128/0.25 | 6.3 | 4.5 | 42.8 | 266 |
| 3+2+1 | 25 | 2.2 | 118/0.3 | 8.3 | 4.8 | 46.9 | 338 |
| 3+2+1 | 35 | 2.2 | 127/0.3 | 9 | 5.1 | 50.4 | 392 |
| 3+2+1 | 50 | 2.4 | 141/0.3 | 10 | 5.6 | 55.7 | 487 |
| 3+2+1 | 70 | 2.4 | 117/0.4 | 14.7 | 6 | 61.3 | 637 |
| 3+2+1 | 95 | 2.4 | 123/0.4 | 15.5 | 6.3 | 64.5 | 734 |
| 3+2+1 | 120 | 2.4 | 135/0.4 | 17 | 6.4 | 69.2 | 867 |
| 3+2+1 | 150 | 2.4 | 144/0.4 | 18.1 | 6.6 | 73.5 | 1022 |
| 3+2+1 | 185 | 2.4 | 144/0.4 | 26.7 | 6.7 | 78.3 | 1175 |
| 3+2+1 | 240 | 2.4 | 156/0.5 | 28.3 | 6.9 | 84.7 | 1741 |
| 3+2+1 | 16 | 3 | 118/0.3 | 8.3 | 5 | 47.7 | 317 |
| 3+2+1 | 25 | 3 | 129/0.3 | 9.1 | 5.2 | 51.3 | 382 |
| 3+2+1 | 35 | 3 | 139/0.3 | 9.8 | 5.5 | 54.8 | 443 |
| 3+2+1 | 50 | 3 | 149/0.3 | 10.5 | 5.9 | 58.9 | 534 |
| 3+2+1 | 70 | 3 | 123/0.4 | 15.5 | 6.3 | 64.3 | 682 |
| 3+2+1 | 95 | 3 | 130/0.4 | 16.3 | 6.4 | 67.1 | 771 |
| 3+2+1 | 120 | 3 | 141/0.4 | 17.7 | 6.5 | 71.9 | 912 |
| 3+2+1 | 150 | 3 | 144/0.4 | 18.1 | 6.6 | 76.2 | 1073 |
| 3+2+1 | 185 | 3 | 144/0.4 | 18.1 | 6.8 | 81 | 1222 |
| 3+2+1 | 240 | 3 | 144/0.5 | 27.7 | 7 | 87.5 | 1592 |
| 3+2+1 | 25 | 5 | 120/0.4 | 15.1 | 6.3 | 62.8 | 542 |
| 3+2+1 | 35 | 5 | 127/0.4 | 16 | 6.4 | 65.8 | 601 |
| 3+2+1 | 50 | 5 | 135/0.4 | 17 | 6.5 | 69.4 | 692 |
| 3+2+1 | 70 | 5 | 144/0.4 | 18.1 | 6.6 | 73.9 | 826 |
| 3+2+1 | 95 | 5 | 144/0.4 | 18.1 | 6.7 | 76.7 | 926 |
| 3+2+1 | 120 | 5 | 144/0.5 | 18.1 | 6.9 | 81.8 | 1082 |
| 3+2+1 | 150 | 5 | 139/0.5 | 27.3 | 7 | 86.2 | 1263 |
Quality Control
Type 455 Flexible Screened Mining Cable With Two Earth And One Pilot Core
Raw Material Test
Raw Material Test for Type 455 Flexible Screened Mining Cable With Two Earth And One Pilot Core ensures extreme mining-grade durability and safety redundancy. 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/earth cores, and rubber sheath compounds certified to AS/NZS 2802 for flame retardancy and mechanical properties. Conductor Analysis: Test tinned copper (phase/earth/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).
Process inspection
Process Inspection during manufacturing of Type 455 Flexible Screened Mining Cable With Two Earth And One Pilot Core maintains mining safety and extra-heavy-duty consistency. Steps include: Conductor & Core Stranding: Monitor class 5 stranding of phase, two earth, and one 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 455 Flexible Screened Mining Cable With Two Earth And One Pilot Core 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/dual earth 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. Sheath & Insulation Performance: Oil immersion, flame retardancy (AS/NZS 1660.5.1 or IEC 60332), thermal aging, and moisture resistance verified.
Application
The Type 455 Flexible Screened Mining Cable With Two Earth And One Pilot Core excels in severe underground coal and metalliferous mining for high-voltage trailing/reeling power to longwall shearers, continuous miners, face conveyors, shuttle cars, and heavy equipment requiring screened, flame-retardant cable with dual earth cores and pilot core for enhanced grounding safety and monitoring.
Technical Advantages
● 30+ years of manufacturing experience
● ISO and UL certified production
● Customized cable and transformer solutions
Product Packaging
Wires and Cables packaging (1)
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What are the measures for cable fire prevention?(1) Use flame-retardant cables; (2) Use fireproof cable tray; (3) Use fireproof paint; (4) Fire partition walls and fire baffles are installed at cable tunnels, mezzanine exits, etc.; (5) Overhead cables should avoid oil pipelines and explosion-proof doors, otherwise local pipes or heat insulation and fire prevention measures should be taken.
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What inspections should be carried out for the acceptance of cable lines?(1) The cable specifications should meet the regulations, the arrangement should be neat, no damage, and the signs should be complete, correct and clear; (2) The fixed bending radius of the cable, the related distance and the wiring of the metal sheath of the single-core power cable should meet the requirements; (3) The cable terminal and the middle head should not leak oil, and the installation should be firm. The oil pressure of the oil-filled cable and the meter setting should meet the requirements; (4) Good grounding; (5) The color of the cable terminal is correct, and the metal parts such as the bracket are completely painted; (6) There should be no debris in the cable trench, tunnel, and bridge, and the cover should be complete.
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