Type 409 is a Class 2, composite screened, three-core trailing cable designed for open cut and surface mining applications. It incorporates a central pilot core surrounded by three EPR-insulated power cores, three interstitial earth conductors, and a collective composite copper-wire screen, all enclosed in a heavy-duty PCP or CSP/CPE outer sheath.
Rated 1.1/1.1 kV through 22/22 kV (U0/U), it is the open-cut surface equivalent of the underground Type 209, sharing the same constructional numbering convention per AS/NZS 2802:2000.
Sheath abrasion from haul road surfaces: HD-85-PCP or HD-90-CSP/CPE sheath provides high abrasion resistance for cables dragged or laid across cut surfaces.
Screen damage from mechanical impact: Collective composite screen (Cu wire interwoven with textile yarn) provides earth fault detection with robust mechanical protection.
Insulation degradation at higher voltages: R-EP-90 insulation with increasing radial thickness from 1.5 mm (1.1 kV) to 10.5 mm (22 kV) provides appropriate dielectric withstand.
USE WHEN: Three-phase trailing supply to open cut draglines, shovels, drills and surface conveyors at 1.1–22 kV requiring collective earth fault detection via composite screen.
DO NOT USE WHEN: Underground coal mines (use Type 209). Where per-core individual earth fault detection is required (use Type 441). At voltages above 22 kV.
AS/NZS 2802:2000
AS/NZS 1125
AS/NZS 3808
Class 2
409.1 — 1.1/1.1 KV
409.3 — 3.3/3.3 KV
409.6 — 6.6/6.6 KV
409.11 — 11/11 KV
409.22 — 22/22 KV
Flame retardant and self-extinguishing per AS/NZS 2802. HD-85-PCP sheath resists ignition and limits flame propagation. Suitable for surface plant areas subject to fire risk protocols.
Rope-lay tinned annealed copper conductors per AS/NZS 1125. Minimum bending radius 8× overall diameter for trailing duty; 10× in fixed installations. Suitable for continuous trailing and reeling service.
Rope-lay tinned annealed copper conductors per AS/NZS 1125. Minimum bending radius 8× overall diameter for trailing duty; 10× in fixed installations. Suitable for continuous trailing and reeling service.
| Oils & Hydraulic Fluids | Good (PCP/CSP sheath) |
| Acids & Alkalis | Good |
| UV / Ozone | Excellent |
| Abrasion | Very High |
| Water Immersion | Suitable |
| Property | Specification |
|---|---|
| Min. bend radius (trailing) | 8 × OD |
| Min. bend radius (fixed) | 10 × OD |
| Conductor stranding | Rope-lay, Class 5 flexible (AS/NZS 1125) |
| Sheath hardness | HD-85-PCP or HD-90-CSP/CPE |
| Sheath colour | Black |
| Approx. OD range | 23.7 mm (1.5 mm2/1.1 kV) to 111.7 mm (70 mm2/22 kV) |
ZNE[size]-409.[voltage]
e.g. ZNE95-409.6 = 95 mm2 Type 409 at 6.6/6.6 kV
| Normal Operation | Emergency | Short Circuit |
|---|---|---|
| 90°C Conductor | 130°C | 250°C (5 s max) |
Standard: AS/NZS 2802:2000 — Class 2 (Table 12
Configuration: 3C + 3E (interstitial) + 1P (central) + collective screen
Conductor: Tinned annealed copper, rope-lay (Class 5 flex) per AS/NZS 1125
Insulation: R-EP-90 elastomer per AS/NZS 3808
Conductor screen: Semiconductive tape (≥3.3 kV only)
Conductor screen: Composite — Cu wire interwoven with textile yarn over core assembly
Pilot core: Central, tinned Cu, R-EP-90 insulated, in cradle separator
Earth conductors: 3 × tinned Cu, interstitial, elastomer covered
Separator tape: Polyester (1.1 kV); semiconductive (≥3.3 kV)
Outer sheath: HD-85-PCP or HD-90-CSP/CPE per AS/NZS 3808
| Parameter | Value |
|---|---|
| Voltage rating | 1.1/1.1 kV to 22/22 kV (U0/U) |
| Max conductor temp | 90 °C continuous |
| Insulation material | R-EP-90 (Class 2) |
| ti range | 1.5 mm (1.1 kV) to 10.5 mm (22 kV) |
| Screen type | Composite Cu wire — collective |
| Screen conductance | ≥ 331⁄3 % of one power conductor per AS/NZS 2802 |
| Symmetry | Electrically symmetrical design |
| Test voltage (1.1 kV) | 4.2 kV a.c. / 5 min |
| Test voltage (3.3 kV) | 10 kV a.c. / 5 min |
| Test voltage (6.6 kV) | 17 kV a.c. / 5 min |
| Type | Voltage | Size Range (mm2) |
|---|---|---|
| 409.1 | 1.1/1.1 kV | 1.5 – 300 |
| 409.3 | 3.3/3.3 kV | 16 – 150 |
| 409.6 | 6.6/6.6 kV | 16 – 300 |
| 409.11 | 11/11 kV | 25 – 150 |
| 409.22 | 22/22 kV | 35 – 70 |
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