Cable connecting systems & Accessories
High quality and innovative
products in Medium Voltage
We connect your energy
www.cellpack.com
D988 | 0719
COMPANY PROFILE
Electrical Products
Being an SME company within the Behr Bircher Cellpack 1935
(BBC) Group in Villmergen/Switzerland, BBC Cellpack Founding
of Cellpack
Electrical Products has successfully established itself in AG by the
the global markets, in the fi elds of development, Dreifuss
production and customer oriented sales of cable 1964
Expansion of
connecting systems and accessories for the low and cable fi ttings
medium voltage up to 42 kV.
1967
Construction
of factory
for electrical
pipes and
cable fi ttings
1983
*the
Netherlands
Power utilities, electrical wholesalers, specialist electrical
trade or the industry – they all share one thing in
common: regarding a high operational safety for the 1990
*Singapore
power supply services in the distribution network as
their fi rst priority. The system solutions and products 1991
*Spain
developed by BBC Cellpack for complex, high-tech
applications have significantly contributed to this.
1992
*Italy
1993
*France
2003
With our customer-oriented understanding of into Behr
technologies and the distinctive culture of innovation, Bircher
Cellpack
we have committed ourselves to concentrate, not only 2006
on the demands of our customers for technically *Poland
innovative and thoroughly tested products, but also to
ensure the safe and reliable functioning of our system
2008
solutions. Opening of
the manu-
facturing site
in Malaysia
2010
New manuf-
acturing site
in Radeberg
2011
Quality & Service Take over of
connector
BBC Cellpack has gained worldwide recognition for in Czech
highest material and product quality with standards 2015 Republic
*Australia
laboratories and testing facilities in Germany. This high
benchmark also applies to the availability and delivery
service of our products. The quality standard “Swiss 2019
Quality – Made in Germany“ is our commitment. *India
*Founding of distribution company
2
INTRODUCTION
INTRODUCTION
Cable accessories are indispensable components of a cable network which exert a direct infl uence on its quality. The same
level of operational safety must be guaranteed for the accessories as for the cable itself. Due to high operational costs
incurred by medium voltage networks, it is necessary to avoid outages. The safe, quick and easy assembly of cable
accessories is there-fore essential for network reliability. Exceptional innovative solutions are thus required to ensure that
excessive demands are not placed on the capabilities of assembly staff .
We at BBC Cellpack produce innovative, high-performance cable accessories for medium voltage networks based on the
stress control system (FSE) developed by us. We off er a full range of products for a wide variety of applications using heat
shrink, silicone, slip-on, plug-in and cast resin technologies which comply with the standard requirements for energy
suppliers and the set industrial norms. The system components of all of our cable accessories are compatible so as to ensure
safe and reliable functioning.
As a result of intensive testing carried out in our laboratories, as well as numerous type tests carried out in international test
facilities, we are able to guarantee an operationally reliable conductor connection, an adequate insulation level and
excellent resistance against all environmental infl uences for all our cable accessories. All our medium voltage products are
tested according to DIN VDE 0278, CENELEC HD 629.1, HD 629.2, IEC 60502-4 and comply with IEEE and BS requirements.
3
HYBRID
Hybrid cable joints and terminations combines components made from silicone rubber with high voltage resistant
heat shrink products. This renders our cable accessories compatible with all existing medium voltage cable cross-
sections and ensures maximum operational reliability. The full product range comprises plug-in straight-through and
transition joints, indoor and outdoor terminations for single and three-core cables, which comply with the standard
requirements for energy suppliers and the set industrial norms. We also off er products based on customer specifi
cations.
Heat shrink Joints
The main insulation material used in hybrid plug-in straight through and transition joints consist of a combination
of heat-shrink tubing supplied in telescoped form. The insulation materials are manufactured from high-perfor
mance polymeric materials with appropriate additives. Stress control is achieved by slipping the silicone rubber
stress control elements (FSE) onto the prepared cable end using the patented slip-on auxiliary device. The resulting
joint system can be positioned and heat-shrunk onto the cable cores to be connected. Assembly is safe, quick and
easy, due to the compatibility of all system components.
Product Range
• Straight-through joints for single and three core
cables
• Transition joints for single and three core cables
Voltage Range
• U0/U(Um) 6/10 (12)kV - 19/33 (36) kV
Cross Section Range
• 10 Sqmm - 1000 Sqmm
Heat shrink Terminations
The main insulation material used in terminations is heat-shrink tubing, which is manufactured from high
performance tracking resistant polymeric materials. Stress control within cable terminations is achieved in the same
way as for the hybrid joint system by slipping the silicone rubber stress control elements (FSE) onto the cable end,
using the patented slip-on auxiliary device. A sealing tape another well established product- is wrapped around the
cable shielding and the cable lug to provide a reliable seal. A heat-shrink spreader cap with integrated heat-sealing
adhesive provides a reliable seal for the connector distributor and the cable sheath in the distribution region of three
core cables. To establish the necessary creepage distances, highly-elastic shields manufactured from tracking resistant
silicone rubber are installed on the tubing after shrinking.
Product Range
• Indoor and outdoor terminations for single and
three core cables
Voltage Range
• U 0/U (U m ) 6/10 (12) kV - 20.8/36 (42) kV
Cross Section Range
• 25 Sqmm - 1000 Sqmm
4
HYBRID
Anti-Tracking Properties
The medium voltage insulation properties of
polymeric materials can be severely aff ected in
polluted at-mospheric conditions where moisture,
together with salts, dust particles, acid gases and
ultra-violet radiation reduce the surface resistivity of
the insulation, thereby giving way for leakage
currents to fl ow across the surface of the insulation.
These leakage currents may cause a rise in
temperature of the insulation material, causing
surface moisture evaporation and the formation of
dry solid bands of deposited material on the polymer
surface. Electrical discharges or arcing can occur
across these bands resulting in the degradation of
the insulation and the formation of conductive paths
on the surface. A complete failure of the system will
occur when these paths reach to the extent that the
remaining insulation can no longer withstand the
applied system voltage.
To resist this phenomenon of tracking, Cellpack
off ers its own heat shrink tubes which are made
from thermally stabilized, cross linked, anti-tracking
and weather resistant polymeric material. The tubes
are tested according to DIN standards and
characterized by excellent resistance against ozone
and UV radiation. Its unique design has undergone
years of rigorous testing under challenging climatic
conditions. Standard hybrid terminations are
designed for challenging climatic conditions and
comply with CENELEC and IEC 60815 requirements.
Hydrophobic Properties
The exceptional hydrophobic properties, resistance
to leakage current and high elasticity of silicone
rubber guarantee sustained operational safety.
5
CONTRAX
The contrax slip-on products off er a compact and simplifi ed design that ensures high reliability and fault tolerant
installations. Here all primary components of the joints / terminations are integrated into a single piece slip on silicon
insulating body, greatly simplifying assembly. The insulating bodies are manufactured from high voltage resistant
silicone rubber using controlled injection process. Its compact design reduces the associated assembly, storage and
transportation costs to the energy supplier.
Silicon slip-on Joints
The single-piece insulating body of contrax straight-through joints consists of an inner conductive electrode which
acts as a Faraday cage around the connector with the main insulating layer above it, and an outer semi-conducting
layer. Each joint body comes equipped with an integrated slip-on auxiliary device for easy assembly and the
prevention of damage during installation.
Stress control at the cable end is achieved by sliding our silicone rubber stress control element (FSE) onto the prepared
cable using the patented slip on auxiliary device. Cable screen continuity is achieved using a copper braid sleeve which
is easily connected to the copper wire/ tape screen using highly elastic pressure springs. Outer protection sheath is
one single piece EPDM off ered with heat or cold shrink variations.
Product Range:
• Straight-through joints for single and three core
cables
Voltage Range:
• U0/U(Um) 6/10 (12)kV - 12.7/22 (24) kV
Cross Section Range:
• 35 Sqmm - 630 Sqmm
Silicon slip-on Terminations
The silicon slip-on terminations consist of a single-piece insulating body manufactured from a creepage tracking
resistant silicone rubber using a quality-controlled injection moulding process. The stress control element and
necessary shields are also integrated into the insulating body. The compact optimized design minimizes assembly,
storage and transportation costs to energy suppliers.
Assembly is carried out in a single-step process, in which the single-piece body is safely, quickly and easily slid onto
the prepared cable end using the patented slip-on auxiliary device.
Product Range:
• Indoor and outdoor terminations for single and
three core cables
Voltage Range:
• U0/U (Um) 6/10 (12) kV - 19/33 (36) kV
Cross Section Range:
• 35 Sqmm - 630 Sqmm
6
CONTRAX
A silicone spreader cap using special cold-shrink technology, patented by BBC Cellpack, and silicone tubes with an
-
integrated slip-on auxiliary device are used in the distribution region of three core cable, ensuring simple and accurate
assembly. A special sealing tape provides a reliable seal at the cable shielding and around the cable lug.
Anti-Tracking & Hydrophobic
Properties
The silicone rubber used is characterized by excellent
resistance against ozone and UV radiation, as well
as exceptional hydrophobic properties. Its unique
design has undergone years of rigorous testing under
challenging climatic conditions. The silicon slip-on
terminations are designed for challenging climatic
Designed by Freepik
conditions and thus comply with CENELEC and IEC
60815 requirements.
Hydrophobic properties of the silicone used
7
COMPAX
This innovative integrated system developed by BBC Cellpack maximizes the reduction of assembly, storage and
transportation costs to energy suppliers. On the basis of application (i.e.) cable joints or bushing connections,
the Plug-in products are divided into
• Compax plug-in straight through joint – Suitable for all polymeric cables and
• Cellplux plug-in connectors – Suitable for bushing types A,B and C.
The Compax plug-in joints and connectors are the result of more than fi ve years of intensive development work at
BBC Cellpack. It represents the perfect joint/connection system for the medium voltage fi eld.
Plug-in straight-through Joints
The Compax plug-in straight-through joint has been especially developed for connecting plastic insulated medium
voltage single core cables. All system components the conductor connection, main insulation, stress control element
and outdoor protection system- are combined to form a single element thereby ensuring that assembly is extremely
safe, quick and easy.
This innovative integration concept for this type of joint permits the majority of installation steps (formerly
performed at the construction site) to be accomplished in advance, under controlled conditions, at the BBC Cellpack
factory where every element can be tested electrically. Only a few installation steps are performed on site by the
installer himself.
Product Range
• Straight-through joints for single core cables
Voltage Range
• U0/U (Um) 6/10 (12) kV - 12.7/22 (24) kV
Cross Section Range
• 50 Sqmm - 630 Sqmm
7 6 1 2 3 4 5
Diagram of type CKM straight-through joint
1 Screw connector
2 Joint insulation
3 Insulating support
4 Stress control element
5 Screen continuity
6 Outer sheath
7 Seal
8
COMPAX
Plug-in Connectors
The Cellplux plug-in connectors have been especially developed to connect plastic insulated medium voltage cables to
electrical systems with bushing types A, B and C. The components of the plug-in connectors are harmoniously
matched to one another so that assembly is very simple, secure and done quickly.
Insulation materials in plug-in connectors possess exceptional electrical and mechanical properties and are
manufactured from high voltage resistant EPDM using a controlled injection moulding process. Stress control is
achieved by means of the silicone stress control element (FSE). Further, the connectors are equipped with a tried and
tested screw-in cable lug system, compatible with all cross-sections, which has been designed to guarantee reliable
connection for both copper and aluminium conductors. The optimized design of the contact bolts permits the use of
a single conventional tool for assembly across the entire range of cross sections.
CTS CWS Product Range:
• CWS 250A & 400A: Elbow separable connector
• CGS 250A: Straight separable connector
• CTS 630A & 1250A: T shaped separable connector
• CTKS 630A: T shaped separable coupling connector
• CTKSA: Coupling surge arrestor
Voltage Range:
• U0/U (Um) 6/10 (12) kV – 19/33 (36) kV
Cross Section Range:
• 50 Sqmm – 630 Sqmm
CGS CTKS
Diagram of CTS 630A Separable Connector
1 Silicone stress control element
2 Screw-in cable lug with shear bolt screw and integrated bracket
3 Contact bolts with shear bolt screw
4 Inner electrode
5 Main insulation
6 Shielding
7 Screw-in insulating supports with capacitive test point
8 Protective cap
9
Stress control
Removal of the cable insulation and the outer semi-conducting layer when connecting or terminating medium
voltage cables results in damage to the cable structure. In addition to this, the electric fi eld becomes strongly
inhomogeneous at particular points. During this process the electric fi eld strength value greatly increases, resulting in
a risk of partial discharge, breakdown or spikes.
Stress control infl uences the strong inhomogeneous fi eld distribution at the cable end so as to reduce the high fi eld
strengths to a non-critical value.
Refractive stress control is the most suitable method for medium voltage cable accessories. It off ers the following
signifi cant advantages over other methods:
• Leaner stress control element design, enabling the development of compact solutions which are very easy to
assemble.
• Reduced sensitivity to incorrect positioning or incorrect cable preparation, allowing compensation for errors
made during assembly.
Refractive stress control infl uences the electric fi eld by
means of a combination of two insulation materials
having diff erent dielectric strengths. The insulation
material with the higher dielectric constant is placed
in the area at which the higher electrical fi eld strength
occurs. The use of the term "refractive“ derives from
the fact that the process defl ects electric fi eld lines
which cross the surface of these materials at an angle
(see Figure 1).
Fig. 1: Interruption of electric fi eld lines at the point of
transition between materials with diff erent dielectric
constants.
When using the above principle in medium voltage cable accessories, a thin stress control and insulation layer is
placed in the region above the strippable edge of the outer semi-conducting layer (for cables with plastic insulation),
or above the Hochstädter foil or lead sheath (for cables with paper insulation), or above the core insulation when the
cable insulation has been removed. This layer has a considerably higher dielectric constant (εr) than the insulating
material of the cable itself. This results in a targeted reduction of the original fi eld strength (see Fig. 2).
Fig. 2: Comparison of lines of equipotentiality in a plastic-insulated cable with the insulation Screen removed, with
and without refractive stress control).
10
Stress control
In addition to stress control itself, the positioning of the contact surfaces of cable insulation and accessory during
assembly is very signifi cant. Trapped air can result in partial discharge even at low voltages, particularly in the area of
stress control, resulting in the breakdown of the cable accessory.
In order to avoid these problems, we have developed a stress control element (FSE) made from a special silicone
rubber, manufactured using injection-moulding. This product owes its uniqueness to its optimised design and to the
specifi c properties of the HTV silicone rubber used. The dimensions of the cylinder body have been carefully selected
to ensure that a single stress control element size is compatible with a wide range of medium voltage cable cross-
sections. The dimensions of the inner cylindrical area allow the positioning of the FSE on the smallest possible cross-
sectional area, where it expands to the correct size, thus exerting a permanent contact pressure on the base.
The permanent high elasticity of the silicone ensures that a constant pressure is applied to the contact surface under
all operating conditions. The high gas permeability of the special material constitutes a signifi cant advantage. As a
result of constant pressure on the contact surface, pockets of air arising during assembly will completely diff use
through the stress control material within a few minutes (Fig. 3). This protects the cable accessory against partial
discharge under all operating conditions.
Fig. 3: Disappearance of an air bubble in the gap between the sleeve insulating body and the FSE.
11
INTERNATIONAL SALES ORGANISATIONS
Europe International Asia Pacific
Cellpack AG
Distributors Behr Bircher Cellpack BBC Far East
Electrical Products Pte Ltd
Cellpack AG
Anglikerstrasse 99 128 Joo Seng Road # 06 – 01
Electrical Products
5612 Villmergen
Anglikerstrasse 99
Schweiz
5612 Villmergen
Cellpack Benelux B.V. Schweiz Behr Bircher Cellpack
Keersluisweg 13 BBC Malaysia Sdn. Bhd.
No 17, Jalan Laman Setia 7/3
Nederland
Middle East
Cellpack Polska Sp. z o.o. Johor
ul. Matuszewska 14, Behr Bircher Cellpack Malaysia
03-876 Warszawa
Polska B12-210
Behr Bircher Cellpack
Behr Bircher Cellpack BBC Italia S.r.l. BBC Australia Pty Ltd
R.A.K / United Arab Emirates PO Box 73
22100 Como Oakdale, NSW, 2570
Italia Australia
Behr Bircher Cellpack
Ibérica, S.A.
C/.Mas Pujol, nr. 47 – Nave 4
Pol. Ind. Sector V
08520 – Les Franqueses del Vallès
Behr Bircher Cellpack
BBC France s.à.r.l.
France
India
Bircher Cable Connection Works :
& Grid Systems Pvt. Ltd. Bircher Cable Connection
801, 8th Floor, NDM-1, Blocks-B, & Grid Systems Pvt. Ltd.
Netaji Subhash Place, Pitampura, Plot No. 149, EHTP
New Delhi-110034 (India) Phase-5, Sector-56, HSIIDC Kundli,
Phone +91 11 46 08 91 50 Sonipat-131028, Haryana (India)
[email protected] www.cellpack.com
Further information
on our products:
electricalproducts.cellpack.com
www.cellpack.com
