Webster Wilkinson Ltd.

High Voltage Engineering

Transformer and Reactor Cable

Boxes (EN50336:2002)

David Fishman M.I.I.E. I. Eng

Sales and Technical Director

Webster Wilkinson Ltd.

High Voltage Engineering

My aim today is to give you an

overview of the relevant
standards relating to cable box
and cable box bushing design

Webster Wilkinson Ltd.

High Voltage Engineering

Why use cable box bushings?

Bushings designed for the specific application

No porcelain sheds therefore will fit into a smaller enclosure
Designed to be mounted vertically or horizontally
Standard termination kits designed to suit these bushings
End terminations designed to suit standard cable terminations

EN50336:2002
Bushings for transformers and reactor cable
boxes not exceeding 36kV

Normative references
EN60137 Insulated bushings
HD 329 S1 Tests on hollow insulators
HD 428.2.1 3 phase oil immersed
transformers
We also have 2 historical documents that form the basis for EN50336
BS2562:1979 Cable boxes for transformers and reactors
BS6435:1984 Unfilled enclosures for the dry terminations of cable boxes

EN50336:2002
Standard definitions

Air insulated cable box a metallic box designed to protect the ends of
the cables and bushings, providing a weatherproof enclosure; air being
the sole insulation for the terminal connections.
Shroud insulated cable box an air filled cable box (as above) but the
cable cores are terminated with local insulation enhancements (e.g.
phase barriers, bushing protection or taping.
Fully insulated cable box a cable box where those parts of the
termination and bushing within the enclosure including live metal parts
and cable cores are insulated by liquid or compound suitable for the
appropriate system voltage. The box shall be suitable sealed to contain
the liquid or compound and allow for their expansion due to temperature
changes.

Cable box / Bushings

Cable Box Bushings

Bushings covered by this specification are suitable for operation with
one end fully immersed in an insulating liquid and the other end either
Immersed in an insulating liquid; or with shrouded insulation in air; or
in air but not exposed to atmospheric conditions.

Ceramic Bushings
Ceramic bushings shall meet the requirements of both type and
routine tests laid down in EN60137.
Bushings should be capable of sealing a liquid filled chamber.
24kV and 36kV bushings shall allow the insulating liquid into the
space between the conductor and ceramic.
Preferred glaze colour is a uniform shade of brown, other glaze
colours are acceptable subject to agreement between purchaser
and manufacturer.
All ceramic insulators shall be subjected to tests in accordance with
HD329.
Bushing mounting holes, clamping arrangement and end terminals
will be in accordance with EN50336.

Ceramic Bushings
Selection Criteria
Insulation type
Voltage level (inclusive of testing voltage)
Current rating
Transformer side connection
Cable side connection
Number of cable connections
Glaze colour
Mounted vertically / horizontally

High Voltage (above 170

kVp) cable box bushings
Resin bonded paper design bushings.
Voltages up to 72kV.
Current ratings up to 2500A.
Low partial discharge as standard.
Standard mounting flange information.
Multiple cable connections available.
Designed and tested in accordance with
EN60137.

Cable Box Fabrications

A cable box is the interface between the transformer and the cabling
contractor and any problems at the cable jointing stage have high visibility to
our customers. It is essential therefore that every effort is made to ensure the
correct cable box is supplied to suit the cables being used

Cable Box General Rules

Definitions
A metallic box designed for the purpose of receiving and protecting the end of
cable or cables.
Open backed cable box as above but with a detachable bushing plate.
Boxes are defined by the number of poles and glands.
Bushing mounting plate a plate in which the bushings between the cable box
and the transformer are mounted, it may be an integral part of the box or a
separate plate to be used with an open backed cable box shell.
Cable gland a device to seal and secure the sheath and to secure the armour of
an electric cable.
Cable wiping gland a cable gland having a wiping gland body
Mechanical (compression) cable gland a non ferrous bush which secures and
seals the cable to the box by mechanical means.
Armour clamp a fitting for gripping the armour of a cable at its termination.

Cable box designs

Cable Box General Rules

Testing requirements
General unless otherwise specified when inviting tenders the purchaser shall
accept type tests on a box or bushing similar to the one purchased.
Cable boxes above 12kV rated voltage will be subjected to a rated lightning
impulse test, the tests shall be carried out with all fittings (excluding cables).
Rated lightning impulse type tests on standalone bushings shall be in accordance
with EN60137.
Rated short duration power frequency withstand voltage type test on standalone
bushings will be in accordance with EN60137.
Filled cable boxes will be subjected to a hydraulic type test at a pressure of 15PSI
(1 BAR) for 15 minutes at room temperature there shall be no permanent
distortion when the pressure is released.
The only routine tests required are on filled cable boxes (pressure tests) and
insulated wiping glands require power frequency testing.

Cable Box General Rules

Design requirements
The cable boxes when installed must be capable of withstanding the high voltage
tests specified for the equipment.
Electrical clearances are as stated in BS2562:1979 table 1 and BS6435 table 1
Where necessary, steps shall be taken to minimize the effects of eddy currents.
Cable boxes shall be self contained with the bushing mounting plate being an
integral part of the cable box (unless specified differently from the customer)
Cable boxes shall be designed to minimize the danger of fragmentation (cast iron
shall not be used in the construction).
A minimum expansion space of 8% of the volume of the cable box shall be
provided for filled cable boxes.
Flange dimensions of the cable box facing are given in BS2562:1979 figure 23-25
Air filled boxes will have a ventilation provision to minimise condensation.

Cable box designs

Cable Box General Rules

Design Information
Clearances BS2562:1979
Rated voltage

1.1kV
3.6kV
3.6kV
12kV
24kV
36kV

Insulating medium
Compound or air
Compound
Air
Compound
Compound or oil
Compound or oil

Clearance
Phase / Phase

Clearances
Phase / Earth

20mm
20mm
90mm
45mm
100mm
125mm

20mm
20mm
65mm
32mm
75mm
100mm

Cable Box General Rules

Design Information
Clearances BS6435:1984
Rated voltage

12kV
12kV
24kV
24kV
36kV
36kV

Insulating medium
Air fully insulated
Air partially insulated
Air fully insulated
Air partially insulated
Air fully insulated
Air partially insulated

Clearance
Phase / Phase

Clearances
Phase / Earth

45mm
127mm
100mm
242mm
125mm
356mm

32mm
76mm
75mm
140mm
100mm
222mm

Cable Box General Rules

Cabling height filled boxes
The minimum vertical distance from the centreline of the bushing to the
gland plate is critical for ease of cabling and subsequent connection

Multi core
3 Pole
4 Pole

Rated voltage

Current rating

Single core

1.1kV

250/400
800/1600

200mm
200mm

320mm
460mm

345mm
485mm

3.6kV

250/400
800/1600

200mm
200mm

320mm
460mm

12kV

250/400
800/1600

280mm
310mm

420mm
560mm

24kV
36kV

All

520mm

670mm

All

610mm

900mm

Cable Box General Rules

Cabling height Air boxes
The minimum vertical distance from the centreline of the bushing to the
gland plate is critical for ease of cabling and subsequent connection

Multi core
3 Pole
4 Pole

Rated voltage

Current rating

Single core

1.1kV

250/400
800/1600

200mm
280mm

320mm
460mm

345mm
485mm

3.6kV

250/400
800/1600

320mm
320mm

320mm
460mm

12kV
17.5kV
24kV
36kV

All

425mm

720mm

All

475mm

770mm

All

525mm

820mm

All

625mm

1070mm

Cable Box General Rules

Materials for construction
Air filled box body 3mm THK mild steel plate.
Compound filled box body 4mm THK mild steel plate.
Gland plates (multi core cables) 4mm THK mild steel plate.
Gland plates (single core cables) 3mm THK non mag stainless steel.
Gland plates (non-ferrous) 5mm THK Aluminum plate.
Front cover 5mm THK mild steel plate.
Bushing mounting plate (400A MAX) 6mm THK mild steel plate.
Bushing mounting plate (over 400A) 5mm THK non mag stainless steel.
Mounting flange (open back boxes) 6mm THK mild steel plate.
Gaskets 5mm THK NBC

Fully insulated air filled

cable boxes

Cable Box fitting options

within the cable boxes
Current transformers and Voltage transformers
Disconnecting facility
Surge arrestors
Anti- condensation heaters

Cast Resin Bushing

Assemblies (Monoblocks)
Cast Resin bushings (monoblocks) give us an LV
connection option (up to 1.1kV in air)
Simple 1 piece assembly for typical 3 pole and
neutral connection.
No requirements for stainless steel bushing
mounting plate (Eddy current considerations).
Suitable for vertical or horizontal connection.
Multiple cable connections are standard for this
style of bushing.
Various cable connections are available
depending on connection method.
A wide range of conductor sizes are available for
current ratings up to 4 000A.

Cast Resin Bushing

General Rules
The dimension, style and arrangement of the four pole cast resin bushing
assembly (monoblock) shall be in accordance with EN50336:2002 figure 4.
Resin insulated bushings shall meet the requirements for both type and
routine tests as laid out in EN60137.
Cast resin bushings shall withstand short circuits no less onerous than those
of the associated transformer.
Resin insulated bushings shall not be adversely affected by continuous
immersion in insulating liquids not exceeding 105 C neither shall be affected
by insulating compounds having a temperature not exceeding 160 C.
Each resin bushing shall have both ends of each conductor clean and free
from resin for the whole of their length from 3mm clear of the moulding.
Each resin insulated bushing shall be marked in a legible and reasonably
permanent manner with the trade mark of the manufacture, a unique
identification code to ensure material traceability.

Cast Resin Bushing

Testing Requirements
Temperature cycle type tests A resin insulated bushing of each design shall
be subjected to a temperature cycle test. Each cycle shall comprise of 3
stages 1) 10 C
2) 105 C
3) ambient temperature. The duration of each
stage shall be between 20 30 minutes. The cycle shall be repeated 10 times
consecutively. The bushing shall not exhibit signs of cracking and shall
withstand further testing as listed below.
Liquid leakage sample test each resin bushing sample shall be subjected
to a liquid test for 6 hours maintained at 75 C with an applied pressure of 1
Bar. At the conclusion of this test, no leakage or liquid ingress into normally
free spaces shall have occurred.
Air leakage routine test each resin insulated bushing shall be subjected to
a 15 minute air leakage test at a pressure of 1.5 Bar.
Over voltage routine test each resin insulated bushing shall withstand a dry
power frequency withstand voltage of 28kV for 1 minute between conductors.
Routine partial discharge test if the resin bushing is to be used at a voltage
greater than 1.1kV then each bushing shall be subject to PD testing.

Cast Resin Bushing

Special applications
Standard flanged monoblock available in 5 current
rating:- 1 000A, 1 700A, 2 500A, 3 150A, and 4 000A
Single phase cast resin bushings available from 250A
upwards.
A wide range of special tooling available for both low
volume applications and high volume requirements.

Cable entry wiping glands

The cable entry wiping glands are manufactured from

brass type DCB1.
The armour clamp shall be made of steel and after
manufacture a metallic non corrosion finish added.
Available in 3 standard sizes to suit cable sheath
diameters up to 90mm.

Cable connection to suit

cable box bushings

Webster Wilkinson Limited

Webster Wilkinson Limited
Unit A, Halesfield 10,
Telford, Shropshire,
TF7 4QP.
United Kingdom
Tel: +44 (0) 1952 585 701
Fax: +44 (0) 1952 581 901
Email: sales@webster-wilkinson.com
Website: www.webster-wilkinson.com