Fully Automatic AC/DC High Voltage Test System for Wires and Cables
The Fully Automatic AC/DC High Voltage Test System is designed for testing the insulation integrity of electrical wires, cables, and optical fiber cables. It evaluates insulation between conductors or between conductors and the outer sheath under controlled high-voltage conditions. The system gradually increases voltage and monitors current to ensure the sample withstands the applied voltage without breakdown. The high-voltage section incorporates an oil-immersed transformer and dry-type voltage regulator for stable and precise output.
Application
This high-voltage test system is applicable for:
Finished wires and cables for insulation withstand testing between cores and between core and sheath
Optical fiber cables for insulation and dielectric integrity evaluation
Electrical component R&D to verify cable performance under high-voltage conditions
Automotive, aerospace, and industrial cables requiring strict insulation quality assurance
Production quality control to ensure all batches meet insulation standards before shipment
Standards
The system supports multiple international standards for insulation and high-voltage testing:
(1) IEC 60811 — Electrical insulating materials for wires and cables
(2) IEC 60270 — High-voltage test techniques for partial discharge measurement
(3) ISO 2878 — Insulation resistance and dielectric strength of wires and cables
(4) ASTM D149 — Dielectric breakdown voltage and dielectric strength of insulating materials
(5) GB/T 328.1-2016 — Electrical wires and cables AC high-voltage testing
(6) VDE 0276 — Testing of cables and conductors for insulation withstand
(7) SAE J1128 / ISO 6722 — Automotive wire insulation voltage withstand
Parameters
| Item | Specification |
|---|---|
| Input voltage | AC 220V ±10%, 50Hz |
| Power | 5 kVA |
| Output voltage | 0.00 ~ 50.000 kV |
| Breakdown current | 1.0 ~ 100.0 mA, adjustable |
| Voltage rise rate | 100 ~ 5000 V/s, adjustable |
| Accuracy | Class 1.0 |
| Test duration | 0.00 ~ 999.9 H/M/S, adjustable |
| Control | Digital touch screen |
| Control console dimensions | 800 × 800 × 1300 mm |
| High-voltage transformer dimensions | 500 × 500 × 1000 mm |
| Weight | 150 kg |
Features
Full digital control: Set test voltage, duration, breakdown current, and voltage rise rate via touch screen.
Precise voltage ramping: Servo motor-controlled voltage increase ensures accurate test conditions.
Safety lock: High voltage cannot be applied unless the safety lock is disengaged.
Safety door interlock: High voltage will not activate if the door is open, ensuring operator safety.
Stable high-voltage output: Oil-immersed transformer ensures consistent voltage without fluctuations.
Flexible testing: Supports AC, DC, and combined AC/DC insulation withstand tests.
Compact and robust design: Space-saving footprint while ensuring industrial durability.
Accessories
(1) High-voltage output leads and clamps
(2) Grounding cable
(3) Control software and touch screen interface
(4) Safety interlock keys and warning indicators
(5) Optional printer for test report generation
(6) Oil filling kit for transformer maintenance
Test Procedures
Connect the test sample (wire or cable) between high-voltage output and ground clamp.
Set the desired test voltage, duration, and voltage rise rate via the touch screen.
Engage safety lock and close the protective door.
Start the test sequence. The system will gradually ramp up voltage and monitor current.
If the breakdown current is reached or insulation fails, the system automatically stops.
Record test results via touch screen or optional printer.
Disconnect the sample and reset the system for the next test.
Maintenance Information
Regularly inspect high-voltage leads and clamps for wear or damage.
Verify transformer oil level and dielectric strength periodically.
Ensure the safety interlock and door mechanism function correctly.
Clean the control console and touch screen interface to avoid dust interference.
Check calibration of voltage and current measurement systems annually.
FAQ
What is this product?
A fully automatic high-voltage test system for evaluating insulation performance of wires, cables, and optical fiber cables.
What is it used for?
Measures insulation withstand voltage and breakdown current to ensure electrical safety and compliance.
Why is it important?
Prevents insulation failure, ensures cable safety in automotive, industrial, and aerospace applications, and verifies product quality before shipment.
Which industries use this product?
Automotive wiring, cable manufacturing, aerospace, industrial power cables, and electrical equipment R&D.
What types are available?
Systems with AC, DC, or combined AC/DC output; voltage ranges from 50 kV to higher custom specifications; optional data acquisition and reporting modules.
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