XHHV535-4Z Portable High Voltage Surge Generator
Compliance and Certification
The XHHV535-4Z high voltage surge generator is designed and manufactured in full compliance with DL/T846-2016 (General Technical Conditions for High Voltage Test Equipment) and DL/T474-2017 (Guidelines for the Implementation of Field Insulation Tests). Certified to CE and ISO standards, this instrument meets the rigorous requirements of industrial power cable testing applications.
Application Scope
Engineered for impulse discharge testing and DC withstand voltage testing on power cables rated 35kV and below, the XHHV535-4Z integrates a DC high voltage source, energy storage capacitor, and discharge ball gap into a single portable unit. This integration replaces traditional test configurations requiring separate test transformers, control boxes, and pulse energy storage capacitors — significantly reducing on-site equipment footprint and setup complexity.
Core Advantages
- Class 1.5 Measurement Accuracy: High-voltage side voltage metering with dual pointer display (current and voltage) provides real-time, high-precision readings during both DC withstand and impulse discharge operations.
- 2048J Maximum Discharge Energy: 4μF built-in capacitor delivers consistent impulse energy up to 2048J at 32kV, ensuring reliable breakdown of high-resistance cable faults.
- Dual-Mode Operation: Supports DC withstand voltage testing for cable insulation evaluation and impulse discharge mode for fault pre-location and pinpointing — two essential functions in a single instrument.
- Ultra-Lightweight Portable Design: At ≤35kg with compact dimensions of 430*345*550mm, the XHHV535-4Z is the lightest portable DC impulse high voltage equipment in its class, enabling single-operator transport and rapid field deployment.
- Zero-Start Safety Interlock: Voltage adjustment must return to zero before high voltage can be initiated, eliminating risk of accidental high-voltage output on startup.
- Comprehensive Protection Suite: Integrated overcurrent protection (12A threshold, >8s delay at low-voltage side), overtemperature protection (65°C), and overvoltage protection ensure safe operation under adverse field conditions.
- Short-Circuit Resilient: Designed to operate normally even when high voltage output is short-circuited to ground, providing robust fault tolerance during field testing.
- Manual Discharge Capability: Dedicated discharge button allows controlled dissipation of residual capacitor energy after testing, with real-time voltmeter indication of capacitor voltage.
Technical Specifications
| Parameter | Specification |
|---|
| Impulse Voltage Range | 0~32kV adjustable (default 0~28kV) |
| Burn-Through Voltage | 0~28kV |
| Short-Circuit Current | 0~320mA |
| High Voltage Accuracy | Class 1.5 |
| Built-in Capacitor | 4μF |
| Discharge Energy | 0~2048J (at 32kV) |
| Output Voltage Polarity | Negative |
| Impact Power | 400W |
| Discharge Interval | Adjustable, time-relay controlled |
| Overcurrent Protection | 12A (>8s threshold), low-voltage side |
| Overtemperature Protection | 65°C |
| Working Power Supply | AC 220V±10%, 50Hz±1Hz (60Hz customizable) |
| Dimensions (L*W*H) | 430*345*550mm |
| Weight | ≤35kg |
| Ambient Temperature Range | -25°C to +65°C |
Operating Modes
DC Withstand Voltage Mode: Applies regulated 0-32kV DC voltage for cable insulation withstand testing. The voltage adjustment knob provides smooth ramping with real-time voltmeter and ammeter indication. Suitable for routine insulation assessment and commissioning tests on medium-voltage power cables.
Impulse Discharge Mode: Generates periodic high-energy impulses for cable fault pre-location and pinpointing when used in conjunction with a TDR cable fault locator and acoustic-magnetic pinpointer. Discharge interval is adjustable via the front-panel time relay, allowing optimization for different cable lengths and fault characteristics.
Typical System Configuration
| Equipment | Model | Function |
|---|
| High Voltage Surge Generator | XHHV535-4Z | Impulse discharge and DC withstand |
| Cable Fault Pre-Locator | XHGG502A / XHGG501D | TDR and ARC multi-pulse fault ranging |
| Digital Cable Fault Pinpointer | XHDD503E / XHDD503C | Acoustic-magnetic precision pinpointing |
| Insulation Resistance Tester | XHMR-10kV | Preliminary insulation diagnostics |
Safety and Reliability
All high-voltage terminals incorporate dedicated grounding points. The zero-start interlock requires the voltage adjustment knob to be returned to zero before the high-voltage output can be initiated. The stop button provides immediate high-voltage cutoff with automatic internal capacitor discharge. A dedicated manual discharge button enables controlled residual energy dissipation, with real-time voltmeter monitoring of capacitor voltage throughout the discharge process.
For technical consultation, product specifications, or a commercial quotation, please contact our engineering team.
▎Frequently Asked Questions
Q: How does a high voltage surge generator work in cable fault detection?
The surge generator discharges a high-energy pulse into the faulty cable, creating a controlled high-voltage arc at the fault point. This arc produces both an acoustic signal (loud thumping sound detectable by ground microphones) and an electromagnetic pulse (detectable by an inductive receiver). By combining acoustic and electromagnetic signal arrival times, operators can pinpoint the exact fault location with precision—a technique known as acoustic-magnetic synchronization.
Q: Which voltage range should I select for different cable types?
Voltage selection follows the cable's rated operating voltage as a general guideline. For low-voltage cables (up to 1kV), use the 8kV or 12kV range. For medium-voltage distribution cables (6-15kV), the 16kV range is appropriate. For high-voltage transmission cables (35kV and above), use the 32kV range. Always consult the cable manufacturer's maximum test voltage specifications and ensure all safety clearances are maintained during high-voltage operation.
Q: What safety precautions must be observed during surge generator operation?
High voltage surge generator testing requires strict safety protocols. Always verify the cable is fully de-energized and isolated from all power sources before connection. Establish a minimum 5-meter safety perimeter around the test zone with warning signs. All personnel must wear appropriate PPE including arc-rated clothing, HV insulating gloves, and dielectric overshoes. The integrated safety features—automatic discharge upon power-off, emergency stop, and zero-voltage interlock—provide additional layers of protection but should never replace proper safety procedures.
Q: What is the advantage of multiple energy levels (Joules) on this unit?
Different energy levels serve different diagnostic purposes. Low energy settings (e.g., 864J–1024J) are ideal for initial fault confirmation and locating high-resistance faults where excessive energy could worsen cable damage. Medium energy (1225J–2048J) provides optimal acoustic signal strength for most routine fault pinpointing. High energy (2450J+) is reserved for very long cables, deep burial scenarios, or high-impedance faults that require stronger arc generation to produce a detectable acoustic signature. The three-level selection allows operators to match energy output to field conditions.
Q: What warranty and support is included with this surge generator?
12-month standard warranty against manufacturing defects with lifetime technical support. CE and ISO 9001:2015 certified. Each unit includes the surge generator, HV output cable, ground cable, discharge rod, user manual, and a rugged transport case. On-site installation, commissioning, and operator safety training are available upon request. Spare parts including discharge gaps, capacitors, and HV diodes are stocked for rapid replacement.
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