BRITISH STANDARD BS 787-4:1972

Specification for

Mining type flameproof

gate-end boxes —
Part 4: Gate-end boxes for drilling
machines (for use on 3-phase
a.c. circuits up to 650 V)

Confirmed
January 2011
BS 787-4:1972

Co-operating organizations

The Mining and Quarrying Requisites Industry Standards Committee, under

whose supervision this British Standard was prepared, consists of
representatives from the following Government department and scientific and
industrial organizations:

Association of Mining Electrical and Mechanical Engineers*

British Electrical and Allied Manufacturers’ Association*
British Steel Industry
Council of Underground Machinery Manufacturers
Department of Trade and Industry*
Engineering Equipment Users’ Association
Federation of Manufacturers of Construction Equipment and Cranes
Institute of Quarrying
Institution of Mechanical Engineers
Institution of Mining Engineers
National Coal Board*

The Government department and industrial organizations marked with an

asterisk in the above list were directly represented on the committee entrusted
with the preparation of this British Standard.

This British Standard, having

been approved by the Mining
and Quarrying Requisites
Industry Standards Committee,
was published under the
authority of the Executive
Board on Amendments issued since publication
25 January 1972
Amd. No. Date Comments
© BSI 01-2000

The following BSI references

relate to the work on this
standard:
Committee reference MQE/16
Draft for comment 70/34177

ISBN 0 580 06867 6

 BS 787-4:1972

Contents

Page
Co-operating organizations Inside front cover
Foreword ii
1 Scope 1
2 Definitions 1
3 Service conditions 2
4 Ratings 2
5 Marking 3
6 Design and construction 3
7 Tests 7
8 Information to be supplied to the manufacturer with the enquiry 8
Appendix A Metric values 9
Figure 1 — Arrangement of busbar chamber end flange,
terminals and interconnections 10
Figure 2 — Busbar interconnecting trunk 11
Figure 3 — Skid coupling arrangement 12
Figure 4 — Busbar end cover 13

© BSI 01-2000 i
BS 787-4:1972

Foreword

This standard makes reference to the following British Standards:

BS 88, Cartridge fuses of voltage ratings up to 660 volts.
BS 159, Busbars and busbar connections.
BS 171, Power transformers.
BS 229, Flameproof enclosure of electrical apparatus.
BS 542, Cable glands and sealing boxes for association with apparatus for use at
mines.
BS 587, Motor starters and controllers.
BS 775, Contactors.
BS 861, Air-break switches and isolators.
BS 1259, Intrinsically safe electrical apparatus and circuits for use in explosive
atmospheres.
BS 1395, 30-ampere flameproof plugs-and-sockets and cable-couplers.
BS 2613, Electrical performance of rotating electrical machines.
BS 3101, Intrinsically safe remote-control circuits associated with restrained
plugs and sockets for use in coal mines.
BS 3454, 3.3 kV 300 A interchangeable bolted flameproof cable couplers and
adaptors (including 660 V 300 A adaptors) primarily for use in mines.
BS 3871, Miniature and moulded case circuit-breakers.
This British Standard has been prepared, under the authority of the Mining and
Quarrying Requisites Industry Standards Committee, to standardize the main
features of gate-end boxes used primarily in coal mining in the United Kingdom.
It is recognized that the term “gate-end box” is quite general and may be applied
to boxes containing different essential components, such as contactors,
circuit-breakers, lighting transformers, etc., depending upon the purpose for
which they are to be used.
BS 787 was issued in 1938, and has been revised and re-issued as BS 787-1,
BS 787-2 and BS 787-3, to cover gate-end boxes in which the essential apparatus
is, respectively, an air-break electrically operated contactor, an air-break
circuit-breaker and a lighting transformer. This additional specification,
designated BS 787-4, extends the scope of the original BS 787 by covering
gate-end boxes in which the essential apparatus is for controlling electrically
operated drilling machines.
NOTE Although metric equivalents have been given (see Appendix A), the figures in imperial units
are to be regarded as the standard. The metric conversions are approximate. More accurate
conversions should be based on the relevant tables in BS 350, “Conversion factors and tables”.
A British Standard does not purport to include all the necessary provisions of a
contract. Users of British Standards are responsible for their correct application.

Compliance with a British Standard does not of itself confer immunity

from legal obligations.

Summary of pages
This document comprises a front cover, an inside front cover, pages i and ii,
pages 1 to 13 and a back cover.
This standard has been updated (see copyright date) and may have had
amendments incorporated. This will be indicated in the amendment table on the
inside front cover.

ii © BSI 01-2000
 BS 787-4:1972

1 Scope 2.6
cable coupling unit (flit plug)
This British Standard specifies requirements for
flameproof gate-end boxes designed primarily for a unit consisting of a cable sealing box and cable
use in the mining industry, on 3-phase a.c. circuits gland, together with means for connecting the cable
up to 650 V, for controlling one or two conductors to insulated contact tubes within the
electrically-operated drilling machines. sealing box, which is designed to receive the cable;
NOTE The titles of the British Standards referred to in this
to provide room to spread and connect the cores; to
standard are listed on page ii. protect the cores; to allow for the attachment of the
cable gland; to provide for sealing the insulating
2 Definitions materials of the cable, and to facilitate ready
connection to or disconnection from a similar unit or
For the purposes of this British Standard, the
other apparatus
following definitions apply:
2.7
2.1
cable coupler adaptor
gate-end box
a device used to connect a cable coupling unit to
a flameproof enclosure containing electrical
apparatus. It may be either separate from or
apparatus, such as control gear, switchgear and/or
integral with the flameproof enclosure of the
protective gear, designed primarily for use
apparatus to which the cable coupling unit is to be
underground
connected
NOTE For the purposes of this standard the apparatus is
essentially a transformer, frequency changer or frequency for the purposes of this standard, the term “adaptor”
transformer, with contactor(s) and associated equipment to also includes the unit to connect other types of cable
provide control and protection of drilling machines. termination to apparatus
2.2 2.8
isolating switch cable sealing and dividing box
a switch which isolates a circuit and is capable of a box designed to receive and protect the end of the
breaking not less than its rated current at rated cable, with provision for sealing the conductors and
voltage the insulating material of the cable with a suitable
2.3 compound, and having a cable gland for attaching
contactor the cable to the box, together with any terminals
a device suitable for repeatedly opening and closing provided for connection to the conductors of the
the circuits of electrical apparatus; it functions cable within the box. The box may form part of, or be
electro-magnetically, the speed of make and of detachable from, the apparatus with which it is
break being independent of the operator associated
2.4 2.9
transformer detachable cable sealing box
a piece of apparatus, without moving parts, which a cable sealing box so designed that it can be
transforms alternating voltage in one winding into detached from associated apparatus without cutting
alternating voltage in one or more other windings, the cable and without disturbing the sealing
usually at different values 2.10
2.5 flameproof enclosure
frequency changer a flameproof enclosure for electrical apparatus is
a rotating machine for converting a.c at one one that will withstand, without injury, any
frequency and voltage to a.c. at another frequency explosion of the prescribed flammable gas that may
and voltage occur within it, under practical conditions of
operation within the rating of the apparatus (and
NOTE Where a static device is used without a rotating
machine, the term “frequency transformer” should be used to recognized overloads, if any, associated therewith)
distinguish it from a frequency changer. and will prevent the transmission of flame such as
will ignite the prescribed flammable gas which may
be present in the surrounding atmosphere (see 6)

© BSI 01-2000 1
BS 787-4:1972

2.11 3 Service conditions

rating
Gate-end boxes in accordance with the
the value assigned by the maker to some limits of requirements of this standard are suitable, within
performance under certain specified conditions the limits of their ratings, for installations where
known as the “rated conditions” the service conditions are not more severe than the
2.12 following.
restrained plug and socket 3.1 Ambient temperature. A peak value not
a plug and socket, the two portions of which, when exceeding 40 °C with an average value not
engaged, are designed to be held together by an exceeding 35 °C over 24 h periods.
operating bolt, a screwed union ring, or some other 3.2 Altitude. An altitude not
equivalent device. Such device enables the plug to exceeding 3 300 ft (1 000 m) above sea-level.
be readily inserted or withdrawn NOTE When a gate-end box intended for service at high
altitudes is tested near sea-level the limits of temperature rise, as
2.13 indicated in 6.16, should be reduced by 1 % for
bolted plug and socket each 1 000 ft (300 m) above sea-level at which the gate-end box is
intended to work in service. The correction does not apply for
a plug and socket, the two portions of which, when altitudes below 3 300 ft (1 000 m).
fully engaged, are designed to be held together by
one or more bolts or screws, or studs and nuts, in 4 Ratings
such a way that they cannot be disengaged without
the use of tools 4.1 Voltages. The maximum voltage shall be 650 V.
Standard gate-end boxes shall be suitable for a
2.14 voltage variation at least 10 % below and at
intrinsically safe circuit least 6 % above the declared voltage of the supply
a circuit in which any electrical sparking that may for which they are designed, subject again to the
occur in normal working, under the conditions maximum of 650 V.
specified by the certifying authority, and with the 4.2 Supply frequencies. The standard frequency
prescribed components, is incapable of causing an shall be 50 Hz. Gate-end boxes designed for other
ignition of the prescribed flammable gas or vapour frequencies within the range of 42 Hz to 60 Hz,
2.15 provided they satisfy all other requirements
remote control specified herein, shall be deemed to comply with the
control by means of a manually operated switch or requirements of this standard.
push-button located at a point separate from the 4.3 Output voltages. The preferred no-load output
gate-end box voltage shall be 125 V 3-phase. Other voltages may
be used, subject to agreement between the
2.16
purchaser and the manufacturer.
overcurrent release
4.4 Output frequency. The standard output
a device that causes the contactor to open the circuit frequency shall be the same as the supply
automatically when the current exceeds the
frequency, except when a frequency changer or
predetermined value at which the release has been
frequency transformer is employed, when the
adjusted to operate
output frequency shall be 150 Hz.
NOTE The preferred term “overcurrent” is used throughout
this standard, but in certain other British Standards to which 4.5 Output kV A. The standard output kV A shall
reference is made the term “overload” may be used when be not less than 1.25 kV A for single circuit units
referring to these devices. or 2.5 kV A for double circuit units.
2.17 4.6 Current rating of busbars. The standard
inverse time lag overcurrent release current rating of busbars, where fitted, shall
a device that retards the opening of the contactor by be 300 A. Busbars of other ratings agreed between
a time inversely dependent upon the magnitude of the manufacturer and the purchaser shall also be
the overcurrent deemed to comply with the requirements of this
standard.
2.18
instantaneous short circuit release
a device which operates without intentional time
delay, at a predetermined current, to cause the
supply to be cut off from a circuit

2 © BSI 01-2000
 BS 787-4:1972

5 Marking Unless otherwise agreed between the manufacturer

and the purchaser, no external component shall be
5.1 Nameplates. All gate-end boxes shall be
made of aluminium, magnesium or titanium, or of
permanently marked with the following particulars:
any alloys except those in which the total content of
1) The registered trade name or trademark of the these three constituents does not exceed 15 % by
manufacturer or his agent. weight and in which the content of magnesium and
2) Manufacturer’s type or reference. titanium together does not exceed 10 % by weight.
3) Manufacturer’s serial number. Neither shall any such component be painted or
coated with preparations containing, in metallic
4) Maximum rated output in kV A. form, any of the metals referred to above.
5) Supply voltage or voltage range, and NOTE 1 These limitations have been imposed to avoid the
frequency. hazards of incendive sparking due to friction between rusted
steel or iron and the metals described.
6) Output voltage or voltage range, and
NOTE 2 When applying for flameproof certification, it will be
frequency. necessary for compliance with the requirements of BS 229 for the
7) The number of the flameproof certificate and manufacturer to specify the types of fittings for which he has
made provision in accordance with the requirements of 6.2 to 6.6
the number or numbers indicating the group of inclusive.
gases and vapours covered by the certificate.
The following subclauses relate to the basic unit:
8) A reproduction of the registered flameproof
mark (if the manufacturer holds a licence to apply 6.1 Enclosing case
this mark). 6.5 Outgoing cable
9) Where applicable, the intrinsic safety 6.7 Means of isolation
certificate details as required by the Department 6.8 Means of reversing
of Trade and Industry.
6.9 Contactors
10) Additional marking as may be required by
any other certifying authority. 6.11.1 Overcurrent and short circuit
protection
5.2 Terminals. Terminal markings, if required, for
incoming and outgoing connections shall be agreed 6.12 Provision for control
between the manufacturer and the purchaser. 6.13 External control devices
5.3 Busbar interconnecting trunks. All busbar 6.14 Provision for earthing
interconnecting trunks (see 6.3) shall be
The following subclauses relate to optional items:
permanently marked with the following particulars:
1) Manufacturer’s name or trade mark. 6.2 Incoming and throughgoing cable
2) Manufacturer’s type or reference. 6.3 Coupling of units
5.4 Busbar end covers. All busbar end covers 6.4 Busbar end covers
(see 6.4) shall be marked with the following 6.6 Busbars
particulars: 6.10 Voltage and frequency changers
1) Manufacturer’s registered name or trademark.
6.11.2 Undervoltage protection
2) Manufacturer’s type or reference.
6.11.3 Earth fault protection and electrical
5.5 Diagrams. Diagrams of connections, which lockout for outgoing circuits
shall be durable and legible, shall be securely
6.11.4 Electrical interlocking and earth
attached in an accessible position within the main
continuity protection
chamber.
6.11.5 Pilot-to-earth fault protection
6 Design and construction The following subclauses relate to both the basic
A gate-end box in accordance with the requirements unit and optional items:
of this standard shall comply with the requirements 6.15 Fuses
of BS 229 (see Note) and shall have been certified by
the Department of Trade and Industry as 6.16 Temperature limits
flameproof for Group I gases (methane/firedamp). 6.17 Clearances
The gate-end box may also be certified for any group
of gas by an appropriate certifying authority as may
be required.

© BSI 01-2000 3
BS 787-4:1972

6.1 Enclosing case. The enclosing case shall 6.4 Busbar end covers. When required, a suitable
comprise a main chamber and an isolator/busbar cover shall be fitted to either end of the busbar
chamber, each with suitable access covers, and shall chamber, as appropriate, to complete the enclosure
incorporate or be adapted for mounting on skids to when a cable fitting is provided at one end only.
facilitate transport. Where the preferred design of busbar flange
The design shall include such provision as will specified in 6.1 is adopted the end cover shall
permit, without structural alteration, the conform to the dimensions and tolerances shown
attachment of adaptors, cable fittings, in Figure 4, and the preferred minimum width of
interconnecting trunks, etc., as specified in 6.2 flange shall be 1 in.
to 6.5, in any combination that may be required for 6.5 Outgoing cable. Provision shall be made for
normal installation and operation of the gate-end the attachment of each outgoing cable by means of:
box. To facilitate this a preferred design of 1) a socket for the reception of a suitable plug
busbar-coupling flange is shown in Figure 1, but which, when combined, forms a restrained plug
other designs shall be considered to comply with the and socket coupling; or
requirements of this standard provided they satisfy
2) a socket for the reception of a suitable plug
all other requirements specified herein.
which, when combined, forms a bolted plug and
6.2 Incoming and throughgoing cable. For the socket coupling,
attachment of incoming or through-going cables the
in each instance constructed in accordance with
busbar chamber shall be fitted at either end, or both
the requirements of the appropriate
ends, as required, with:
British Standard (e.g. BS 1395) where
1) an adaptor suitable for the reception of a cable applicable, or as otherwise agreed between the
coupling unit (flit plug), e.g. as specified in manufacturer and the purchaser.
BS 3454;
6.6 Busbars. When required, provision shall be
2) a detachable cable sealing and dividing box, made for the fitting of three throughgoing busbars
e.g. as specified in BS 542, or complying with the requirements of BS 159.
3) any other fitting which is approved by the 6.7 Means of isolation
certifying authority.
6.7.1 Main isolating switch. A triple pole isolating
6.3 Coupling of units. When two or more gate-end switch, having a continuous current rating of not
boxes are required to be coupled together, this shall less than 15 A and being capable of making and
be achieved either by:
breaking its rated current at 650 V, shall be
1) the bolting together of appropriate flanges, or provided in the busbar chamber. It shall not be
2) the fitting of interconnecting busbar trunking. possible to open the main chamber unless the
Where the preferred design of busbar flange isolator is in the OFF position, or to close the
indicated in 6.1 is adopted the interconnecting isolating switch while the main chamber is open.
busbar trunk shall conform to the dimensions The ON and OFF positions of isolating switch shall be
and tolerances shown in Figure 2, and the clearly indicated and provision shall be made for
preferred minimum width of flange shall be 1 in. locking in the OFF position.
The coupling arrangements shall be sufficiently 6.7.2 Outgoing circuit isolating switch. Where
robust to prevent, in normal use, undue strain being required, a suitably rated triple pole on/off
placed on the flanges of the gate-end box or those of switch(es) or circuit breaker(s) with external
the interconnecting busbar trunking. operating handle(s) capable of being locked in the
OFF position, may be provided to isolate separately
Where skids are provided it is usual for the skids to
be either continuous or, where individual skids are each outgoing circuit.
fitted, for coupling plates to be bolted between the 6.8 Means of reversing. Means shall be provided,
skids. Where the preferred design of busbar without opening the gate-end box, for separately
trunking [see 2)] is adopted, the design of coupling reversing the phase rotation of each outgoing
plate shall conform to that shown in Figure 3. circuit.
NOTE In some designs the bottom of the enclosing case may be
utilized as an individual skid.

4 © BSI 01-2000
 BS 787-4:1972

6.9 Contactors. Each outgoing circuit shall be 6.11 Protection

controlled by an electro-magnetically operated 6.11.1 Overcurrent and short circuit protection
triple pole contactor and in addition, for 150 Hz
units, a main contactor suitable for operation at the 6.11.1.1 Primary circuit protection. Suitably rated
line voltage shall be provided. Each contactor shall HBC fuses complying with the requirements of
be situated in the main chamber and shall have a BS 88, category AC 16 as minima, shall be provided
continuous rating of not less than 10 A and shall in the main chamber, in each phase of the circuits
comply with the requirements of BS 775, Utilization between the main isolating switch and the
category AC4 (8 h duty), Mechanical duty Class II. transformer primary windings.
Where a contactor is controlled by an auxiliary 6.11.1.2 Outgoing circuit protection. Each outgoing
relay, the minimum voltage at which the contactor circuit shall be provided, in at least two phases,
shall pick up and drop off shall be less than the with:
corresponding values for the relay. In all cases the 1) overcurrent protection conforming to the
operating voltage of contactor coils shall be agreed requirements of BS 587, and
between the purchaser and the manufacturer.
2) unless otherwise agreed between the
6.9.1 Provision may be made for a “test” feature purchaser and the manufacturer, an
which shall allow operation of control circuit instantaneous short circuit release which is not
components in the main chamber without the self-resetting.
outgoing circuits being energized.
6.11.2 Undervoltage protection. Means shall be
6.10 Voltage and frequency changers provided to ensure that the contactor(s) open(s)
6.10.1 Transformer. The transformer, conforming when the supply voltage (see 4.1) falls to the value
to the requirements of the relevant clauses of specified in 6.12.
BS 171, shall be of the 3-phase, “AN” type, 6.11.3 Earth fault protection and electrical
continuously rated at not less than 1.25 kV A for lockout for outgoing circuits. Provision shall be
single units and not less than 2.5 kV A for double made in the gate-end box for the fitting, when
units, the primary winding being suitable for required, of earth fault protection. Additionally,
compliance with the requirements of 4.1 and 4.2. means may be provided for locking out the circuit
A separate 3-phase winding shall be provided on the electrically while an earth fault exists, but any such
secondary side of the transformer, for each drill arrangement shall be of a type certified as
circuit, as the preferred method. Alternatively, a intrinsically safe.
single full capacity winding for both drill circuits The earth fault protection shall operate to remove
will be considered to meet the requirements of this power from any outgoing defective circuit when the
standard. The neutral point of the secondary earth fault current attains 5 A, or such lower figure
winding shall be arranged for connection to earth as may be agreed between the purchaser and the
through a removable link to facilitate testing, one supplier. The earth fault trip shall not be
side of the link having a direct connection to an self-resetting unless earth fault electrical lock-out
earthing terminal (see also 6.11.3). which is not self-resetting is provided.
6.10.2 Voltage and frequency changer. The Resetting of either the earth fault trip or the
voltage and frequency changer shall have a electrical lockout shall be arranged for external
continuous rating of not less than 1.25 kV A for operation by hand, means being provided to prevent
single units and not less than 2.5 kV A for double operation by unauthorized persons.
units. The changer shall be suitable for operating on In all cases:
a 3-phase supply in accordance with the
1) visible indication of the earth fault trip shall be
requirements of 4.1 and 4.2.
provided, and
A separate 3-phase 150 Hz output winding shall be
provided to supply drilling machine(s). The neutral 2) it shall be possible for an authorized person,
point shall be brought out from the winding, for without opening the enclosure, to test that the
earthing purposes. Where a frequency changer is protection functions correctly.
used, it shall conform appropriately with the
requirements of BS 2613.

© BSI 01-2000 5
BS 787-4:1972

6.11.4 Electrical interlocking and earth 6.13 External control devices. External handles,
continuity protection. Where restrained plug(s) levers or push-buttons shall be so designed and
and socket(s) are utilized, each outgoing circuit proportioned as to minimize risk of damage or
shall incorporate control circuit(s) for the purpose of distortion due, for example, to mishandling, falls of
interlocking the plug(s) to ensure that the circuit of roof, or collison with other gear.
the contactor coil shall be broken before the main 6.14 Provision for earthing. An external earthing
pins of the plug leave their corresponding socket terminal, with brass nuts, not less in size than " in
contacts. Whitworth, shall be provided to enable the
The electrical connections shall be such that the containing case to be earthed, irrespective of any
insertion of a plug into its socket shall not alone means provided for attaching the metallic covering
cause the main contactor to close. of the cable feeding the apparatus, and be so
This type of circuit shall give earth continuity designed that the connection between an earthing
protection which, in the event of an open circuit or conductor and the casing can be made mechanically
undue increase in resistance to earth, connection secure and electrically efficient.
between the gate-end box and the drilling machine 6.15 Fuses. Where auxiliary circuits are connected
shall cause the contactor to open if in the closed to the primary supply, they shall be protected by
position, or not to close if in the open position. fuses. These fuses shall comply with the
6.11.5 Pilot-to-earth fault protection. If requirements of BS 88, category AC 16 as minima.
required, provision shall be made in the gate-end 6.16 Temperature limits. The temperature limits
box to cause, in the event of accidental contact of individual components shall comply with the
between the pilot core and earth, the contactor(s) to requirements of the appropriate British Standards
open if in the closed position or not to close if in the when tested in accordance with such standards.
open position. Any such circuit involved shall be of a NOTE In this connection the following particular
type certified as intrinsically safe. Means may be British Standards are quoted for reference:
provided at the box to enable an authorized person, BS 88, Cartridge fuses of voltage ratings up to 660 volts.
without opening the enclosure, to test the BS 159, Busbars and busbar connections.
BS 171, Power transformers.
pilot-to-earth protection for correct functioning. BS 587, Motor starters and controllers.
Where pilot-to-earth fault protection is provided it is BS 775, Contactors.
recommended that the circuit should be capable of BS 861, Air-break switches and isolators.
working with a remote rectifier complying with the BS 2613, Electrical performance of rotating electrical
machines.
requirements of BS 3101. BS 3871, Miniature and moulded case circuit-breakers.
6.12 Provision for control. Each outgoing circuit Where the temperature reached by a component in
shall be arranged for remote control from the switch a fully assembled unit could, due to the heating
in the drilling machine, via the pilot and earth effect of other component(s), exceed the temperature
conductors in the drill cable. The control circuit(s) limit prescribed by the relevant British Standard,
shall be of a type certified as intrinsically safe by the the design shall be such that this excess
Department of Trade and Industry and/or any other temperature does not cause deterioration of
certifying authority as may be agreed. performance of the component(s) to a value below
The actual values of incoming supply voltage at that specified in the relevant British Standard.
which the contactor will “pick-up” and “drop-off” NOTE Reference should be made to 3 for service conditions.
shall be less than the actual values of “pick-up” and 6.17 Clearances. The minimum clearance in air
“drop-off” voltages for the remote control circuit. between live parts at different potentials, and
The minimum pick-up voltage of the control circuit between live parts and earth, shall be such that no
which causes its associated contactor to close shall flash-over occurs when the gate-end box is tested in
be not less than 80 % and not greater than 85 % of accordance with the requirements of 7.2 and 7.3.
the declared supply voltages. With the drill switch
NOTE There is at present insufficient evidence available to
closed, the control circuit shall cause its associated determine the minimum safe creepage distance for any class of
contactor to open when the supply voltage falls to a insulating material. The creepage distance between live parts at
value not greater than 70 % nor less than 60 %1) of different potentials, and between live parts and earth, may vary
according to the expected surface resistivity of the insulating
the declared value. These conditions shall be material under service conditions.
satisfied with any external cable, pilot and earth
lead return resistance in the range 0 7 to 3 7.

1)
The value of 60 % may be increased to 65 % in the future, subject to investigations.

6 © BSI 01-2000
 BS 787-4:1972

7 Tests 3) The contactor(s) complies with the

requirements of 6.9.
7.1 General. Tests shall be made to prove
compliance with all the requirements of this 4) Any combination of fuses and contactor, used
standard. It is not intended, nor is it recommended to control outgoing circuits, shall be capable of
that all tests shall be made on every gate-end box making and interrupting the prospective fault
supplied. Two kinds of tests are recognized, as current.
follows: 5) If a circuit breaker is used to provide an
1) Type tests, which shall be made on a instantaneous short circuit release, the circuit
representative sample of each particular type of breaker shall be capable of interrupting
box. prospective fault currents.
2) Routine (individual) tests, which shall be made 7.2.3 Flameproofness. The gate-end box shall
on each gate-end box manufactured to this comply with the test requirements of BS 229 for
standard. Group 1 (methane/firedamp) gas, and the
requirements of any certifying authority as may be
All tests shall be carried out with the box in clean
required.
and new condition.
Any circuits required to be intrinsically safe shall
7.2 Type tests. Unless otherwise specified when
comply with the test requirements of BS 1259
inviting tenders, type tests on boxes identical in appropriate to Class 1 and shall be certified as
essential respects with those purchased shall be intrinsically safe by any certifying authority as may
regarded as evidence of compliance of the boxes with
be required.
the general requirements of this standard.
7.2.4 Mechanical tests. A mechanical endurance
Type tests shall be made by a recognized authority
test shall be made by operating the contactor, by
who, except for tests for flameproofness and
means of its own operating mechanism and
intrinsic safety, may be the manufacturer, unless associated control circuits, without passing current
the purchaser specifies otherwise. through the main contacts, on-and-off 1.2 million
Records of all type tests, with appropriate detailed times, after which all mechanical working parts
drawings of the box, as tested, shall be held (except contacts) shall be in order and shall be
available by the manufacturer. without permanent distortion and/or undue wear.
7.2.1 Temperature rise tests. Tests shall be made During the test no adjustment or replacement of
at the declared output kV A on a fully assembled parts other than contacts (main and auxiliary) shall
unit with all covers closed and all apparatus be permissible, and the number of such adjustments
energized at the declared voltage and frequency, to or replacements shall not exceed 10.
ensure compliance with the requirements of 6.16.
The frequency of operation shall be not less
Tests on all current carrying parts in circuit shall be than 150 times per hour.
made to prove compliance with the requirements
A similar mechanical endurance test shall be made
of 6.16. During these tests, all covers shall be closed
by operating 5 000 times all working parts of the
and all shunt connected apparatus shall be fed from isolator, or isolating switch, and its associated
an a.c. supply at the declared voltage and auxiliary contacts. During the test no adjustment or
frequency, since the heating of one part may
replacement of parts shall be permissible. The
materially affect another. Where a transformer
mechanical endurance test for the isolating switch
having primary tappings is used, the tests shall be
and secondary circuit switches or circuit breakers
conducted at the declared output kV A with the
shall satisfy the relevant clauses of BS 861 or
supply connected to the tapping giving the BS 3871.
maximum watts loss, with a secondary current of
sinusoidal wave form. 7.3 Routine (individual) tests
7.2.2 Performance tests. Tests shall be made on a 7.3.1 High voltage test. The gate-end box shall be
completely assembled gate-end box, with covers capable of withstanding a high voltage test when in
closed, to ensure that: clean new condition with the cover (or covers) closed
1) The isolating switch shall be capable of after being exposed to ordinary atmosphere with the
breaking the supply current with the output cover (or covers) open for at least 24 h prior to the
circuits on a. no-load, and b. full load. test.
2) Where out-going circuit isolating switch(es) or In carrying out the following test it shall be ensured
circuit breaker(s) are fitted these shall be capable that the test voltage is applied in such manner as to
of breaking the full rated output of the circuit. avoid overstressing the transformer insulation by
induced overvoltage.

© BSI 01-2000 7
BS 787-4:1972

Each test shall be made with an approximately 8 Information to be supplied to the

sinusoidal a.c. voltage, of frequency between 42 Hz manufacturer with the enquiry2)
and 60 Hz; the test voltage shall be 1 000 V plus
twice the working voltage of the circuit being tested The purchaser should supply with the enquiry the
and shall be applied for at least one minute. following information.
Alternatively, a value of 1 250 V plus twice the 8.1 Information relating to the supply system
working voltage of the circuit being tested may be 1) Voltage.
applied for at least three seconds, as follows:
2) Frequency.
1) Test a. between phases and b. between phases
and earth on incoming and outgoing circuits, also 8.2 Information relating to the drilling
between the incoming and outgoing circuits, with machine gate-end boxes
the transformer connected or disconnected as 1) Number of drilling machines, horsepower and
appropriate. frequency.
2) With the contactor open, across any auxiliary 2) Current rating of busbars, when required
contacts connected directly or indirectly to a main (see 4.6).
pole or poles and which in operation may be 3) Any other requirements (e.g. type of
required to withstand the supply voltage. protection).
3) Between the main poles and any other
8.3 Cables and cable entries
independent circuits.
1) Provision for main supply cables. Whether
Instruments and other ancillary apparatus may be
provision is required at one end of both ends of
disconnected during this test and tested separately
the gate-end box for main cable attachments; the
in accordance with the requirements of the
type required should be stated.
appropriate British Standard.
NOTE A value of insulation resistance is not specified, as it is
2) Provision for outgoing cables. Details should be
not practicable to prescribe limits for the range of apparatus given as to the type of outgoing cable attachment
covered by this standard. Further, it is considered that the high required.
voltage test determines whether the insulation is satisfactory or
not. In either case, full details should be given in
7.3.2 Control circuits. The contactor control accordance with the requirements of the
circuits shall be tested to prove compliance with the appropriate British Standard.
operating values stated in 6.12.
7.3.3 Overcurrent releases. Overcurrent releases
shall be proved by test to function correctly at
currents within 10 % of the marked operating value,
at each end of the range.
Additional tests shall be made to ensure that the
time delay characteristics are in accordance with
the declared characteristics. It is the responsibility
of the manufacturer to show that his method of test
is such as to prove compliance.
7.3.4 Operation test. Tests shall be made at the
manufacturer’s works to ensure that the gate-end
box complies with the operational requirements of
this standard and, where applicable, is in
accordance with the appropriate clauses of other
relevant British Standards.

2)
It is recognized that the whole of this information may not be available at the time of enquiry, in which case further details
should be supplied with the order.

8 © BSI 01-2000
 BS 787-4:1972

Appendix A Metric values

The following metric values are calculated
equivalents of the respective inch dimensions given
in Figure 1, Figure 2, Figure 3 and Figure 4.
in mm in mm

0.006 0.15 35/8 92.1

0.010 0.25 33/4 95.2
1/ 3.2 37/8 98.5
8
3
/16 4.8 4 101.6
1
/4 6.4 41/2 114.3
3/ 9.5 5 127.0
8
7
/16 11.1 53/4 146.0
1
/2 12.7 5.995 152.3
9/ 14.3 6 152.4
16
5
/8 15.9 6.005 152.5
1 25.4 61/2 165.1
11/8 28.6 71/2 190.5
11/4 31.8 9 228.6
13/4 44.5 12 305
2 50.8 141/2 368
21/4 57.2
21/2 63.5 181/4 463
25/8 66.7 211/4 540
3 76.2 26 662
31/4 82.5

© BSI 01-2000 9
10

BS 787-4:1972
Figure 1 — Arrangement of busbar chamber end flange, terminals and interconnections (see 6.3)
© BSI 01-2000
© BSI 01-2000

BS 787-4:1972
Figure 2 — Busbar interconnecting trunk
11
12

BS 787-4:1972
© BSI 01-2000

Figure 3 — Skid coupling arrangement

 BS 787-4:1972
Figure 4 — Busbar end cover
© BSI 01-2000 13
BS 787-4:1972

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