You're asking for a very specific and demanding piece of equipment: a reusable, NEMA 3R, 35kV junction box that allows disconnection without retermination. This is challenging for a few key reasons: High Voltage Safety

35kV is serious voltage. Safety is paramount. Any junction box must be designed and tested to withstand that voltage and prevent flashover, even in wet conditions. This necessitates robust insulation and creepage/clearance distances.

Cable Termination Integrity

35kV cable terminations are carefully engineered to provide stress control, insulation, and a weatherproof seal. Interrupting this connection and then re-establishing it reliably without affecting the integrity of the termination is difficult.Given those challenges, here's a breakdown of considerations and possible (though likely custom or semi-custom) solutions:

Why This Is Difficult/Things to Consider



Standard NEMA 3R Enclosures Aren't Enough

A standard metal NEMA 3R enclosure won't cut it for 35kV. The insulation inside isn't sufficient to prevent flashover.

Custom Design is Likely Needed

You'll probably need to work with a manufacturer specializing in high-voltage equipment to create something that meets your exact requirements.

Cost

Expect this to be a significant investment.

Termination Type

The type of 35kV cable terminations you're using will heavily influence the design. Are they cold-shrink, heat-shrink, or bolted?

Current Rating

How much current will the junction box need to carry? This affects the size of the conductors and connections inside.

Testing and Certification

Any custom junction box should be rigorously tested and certified by a reputable testing laboratory (e.g., UL, CSA) to ensure it meets relevant safety standards.

Maintenance and Inspection

Regular inspection and maintenance will be crucial to ensure the junction box remains safe and reliable.

Qualified Personnel

Only properly trained and qualified personnel should install, maintain, and operate high-voltage equipment like this.

Possible (But Likely Custom) Solutions


Modified Standard Enclosure with Specialized Bushings/Connectors



Enclosure

Start with a robust, weather-resistant (NEMA 3R or better) enclosure made of a suitable material (stainless steel or coated steel are common). Size it appropriately for the terminations and clearances.

High-Voltage Bushings

Instead of direct cable entry, use high-voltage bushings specifically designed for 35kV. These provide a secure, insulated entry point. The cable terminations would connect to these bushings inside the enclosure.

Disconnectable Connectors

The key element is using disconnectable connectors between the cable termination and the bushing. These connectors would have to be rated for 35kV and the current you're using. Examples:

Elbow Connectors

These are commonly used in pad-mounted transformers. They are fully shielded and submersible. While designed to plug directly into a transformer bushing, you could adapt their mating surface to a bushing inside your enclosure.

Separable Connectors

Some manufacturers offer separable connector systems specifically for high-voltage applications. These are designed for frequent disconnection and reconnection.

Bolted Connections with Insulating Boots

A very carefully designed bolted connection with thick, molded insulating boots might be feasible, but it would be the least desirable option due to the risk of contamination and the need for extremely careful installation.2.

Fully Custom Molded Enclosure

This is the most expensive option but could offer the best performance and reliability. A custom enclosure could be molded from a high-strength, high-dielectric-strength polymer. The bushings and connector interfaces could be molded directly into the enclosure.

Where to Look for Equipment/Help



High-Voltage Equipment Manufacturers

Start by contacting manufacturers that specialize in high-voltage switchgear, transformers, and cable accessories. They may have existing products that can be adapted or be willing to design a custom solution. Examples include (but are not limited to): Eaton (Cooper Power Systems) ABB Siemens Hubbell Power Systems G&W Electric

Electrical Engineering Consultants

Hire an electrical engineering consultant with experience in high-voltage power systems. They can help you define your requirements, evaluate different solutions, and oversee the design and testing process.

Cable Termination Manufacturers

Contact the manufacturers of the 35kV cable terminations you're using. They may have compatible connectors or be able to recommend suitable solutions.

Important Safety Considerations



Arc Flash

Be aware of the arc flash hazard associated with 35kV equipment. Proper personal protective equipment (PPE) and safety procedures are essential.

Lockout/Tagout

Strict lockout/tagout procedures must be followed when working on high-voltage equipment.

Qualified Personnel

Only qualified personnel with the necessary training and experience should work on this type of equipment.

In Summary:

What you're asking for is complex and requires a specialized solution. It likely involves a custom-engineered enclosure with high-voltage bushings and disconnectable connectors. Working with experienced professionals and prioritizing safety are absolutely critical. Be prepared for a significant investment. Good luck! Flag for review