Product Description2450J Workhorse
The XHHV535-4T is a high-energy trolley-mounted DC high-voltage surge generator delivering 2450J discharge energy—the highest in the XHHV535 series—at up to 35kV for underground power cable fault testing and DC withstand voltage analysis. Built around a single 4μF/35kV energy storage capacitor, it provides maximum flashover energy for challenging high-resistance cable faults in a simplified, cost-effective single-capacitor design.
Integrating a DC high-voltage source, energy storage capacitor, discharge ball gap, automatic discharge device, and built-in fault sampling waveform module into a mobile trolley chassis (119kg), the XHHV535-4T features tri-mode operation: DC withstand voltage testing, single impulse discharge, and periodic cycle discharge with 7-second auto-impulse timing. A dual-Q line communication socket enables synchronized waveform acquisition with cable fault locators during high-voltage flashover testing. The trolley's humanized design allows easy movement within workshop and laboratory environments.
Why Choose XHHV535-4T?
Maximum Energy, Minimal Complexity—The XHHV535-4T delivers the highest single-pulse discharge energy (2450J) in the XHHV535 family through a proven single-capacitor architecture. For organizations that prioritize peak flashover energy over multi-voltage switching flexibility, the 4T offers exceptional value with fewer components, lower maintenance complexity, and a more accessible price point compared to the 3-speed XHHV535-4TS. Ideal for high-resistance cable fault applications where maximum discharge power is critical for breaking through fault barriers.
2450JMax Surge Energy
35kVOutput Voltage
4μFCapacitor
2kVASurge Power
7sAuto-Impulse Cycle
Key Features
- 2450J maximum discharge energy—highest in the XHHV535 series for challenging high-resistance faults
- Tri-mode operation: DC withstand voltage, single impulse, and periodic cycle discharge
- 7-second auto-impulse timing with manual override capability
- Built-in fault sampling waveform module for high-precision cable fault test waveform acquisition
- Communication socket (Signal port): dual-Q line interface with cable fault locators for synchronized flashover sampling
- Zero-start protection: high voltage blocked unless voltage knob at zero position
- Auto-discharge: residual capacitor voltage automatically discharged upon stop or shutdown
- Dual 2.5-level pointer meters for real-time voltage and current monitoring
- Humanized trolley design (119kg) with smooth-rolling casters for easy workshop mobility
- Robust single-capacitor architecture: simplified maintenance, lower total cost of ownership
Front Panel Layout
| Control | Function |
|---|
| Ammeter | Indicates low-voltage side current in real time |
| Voltmeter | Shows high-voltage output level |
| Zero Indicator | Voltage knob at zero position; must be lit before Start is effective |
| HV Indicator | Illuminated = high voltage active; Off = no high voltage output |
| Power Indicator | Illuminated when AC220V power is normal after power switch on |
| Power Switch | AC220V 50Hz input; 8A fuse; main system power control |
| Mode Selector | Withstand Voltage (DC), Single impulse, Cycle discharge |
| Start Button | Initiates high voltage at zero state; HV light on; non-zero = invalid |
| Stop Button | Cuts high-voltage output; auto-discharges residual voltage on device and cable |
| Voltage Control Knob | Zero state = zero light on; after HV start, rotate to boost voltage |
| Signal Socket | Dual-Q line to cable fault locator for flashover waveform sampling |
Technical Parameters
| Output Voltage | 0–35kV (continuous adjustment) |
|---|
| Built-in Capacitor | 4μF/35kV |
|---|
| Discharge Energy | 2450J |
|---|
| Surge Power | 2kVA |
|---|
| Auto-Impulse Time | ~7s automatic (manual override available) |
|---|
| Voltage Accuracy | 2.5 level |
|---|
| High-Voltage Divider | Built-in; real-time high-voltage side metering |
|---|
| Operating Modes | DC withstand / Single impulse / Cycle discharge |
|---|
| Safety Protections | Zero-start interlock, auto-discharge, over-current, over-voltage |
|---|
| Waveform Sampling | Built-in fault sampling module + communication socket |
|---|
| Weight | ~119kg (trolley-mounted) |
|---|
| Power Supply | AC220V±10%, 50Hz±2Hz (other frequencies customizable) |
|---|
| Ambient Temperature | -20 – +50°C |
|---|
Target Applications
The XHHV535-4T serves cable testing workshops, power utility maintenance depots, industrial electrical testing teams, and budget-conscious testing service providers who need maximum single-pulse discharge energy for high-resistance fault resolution. The single-capacitor architecture delivers lower maintenance overhead and superior cost-performance compared to multi-speed alternatives, making it the practical choice for organizations that test predominantly at 35kV and below without the need for voltage-level capacitor switching. For applications requiring multi-voltage capacitor selection, see the XHHV535-4TS (3-speed). For field-portable needs, see the XHHV535-2L (25kg) or XHHV535-4Z (35kg).
▎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 heavy-duty trolley with locking casters for safe transport. 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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