High Voltage Surge Generator | XHHV512-12L
The XHHV512-12L high voltage surge generator is a portable all-in-one device designed for impulse discharge testing during cable fault location and DC withstand voltage testing of electrical equipment rated at 12 kV and below. It fully complies with DL/T846-2016 "General Technical Conditions for High Voltage Test Equipment" and DL/T474-2017 "Implementation Guidelines for Field Insulation Tests", making it an ideal product for power cable fault detection.
The unit integrates a DC high-voltage source, an energy storage capacitor and a discharge sphere gap into a single housing, completely replacing the traditional test transformer, control box and pulse energy storage capacitor that together weigh hundreds of kilograms. Built with high-precision dedicated high-voltage electronic components and high-frequency high-voltage technology, the XHHV512-12L features a simple overall structure and ultra-light weight, and remains fully operational even when the high-voltage output is short-circuited to ground.
Applications & Target Audience: Engineered for underground power cable maintenance teams, cable fault location contractors, municipal power distribution utilities, mining and industrial plants with buried cable networks, railway and infrastructure electrical maintenance departments, and third-party electrical testing and commissioning companies that need fast, safe and portable 12 kV cable fault location and DC withstand voltage testing.
Key Specifications
| Parameter |
Specification |
| Impulse Voltage |
0 ~ 12 kV |
| Burst-through Voltage |
0 ~ 12 kV |
| Short-circuit Current |
0 ~ 320 mA |
| High Voltage Accuracy |
Class 1.5 |
| Built-in Capacitor |
12 μF |
| Discharge Energy |
0 ~ 864 J |
| Output Voltage Polarity |
Negative polarity |
| Impact Power |
400 W |
| Over-temperature Protection |
65 °C |
| Overcurrent Protection |
8 mA (over 4 s), high-voltage side |
| Dimensions |
540 × 310 × 460 mm |
| Weight |
≤ 25 kg |
| Operating Power Supply |
AC 220V ±10% / 50Hz ±1Hz |
| Ambient Temperature |
-25 °C to +65 °C |
Advanced Features
Automatic overcurrent, overvoltage and overheating protection for worry-free field operation
Dual testing functions in one unit: DC withstand voltage test and impulse discharge test
Uniform and controllable high-voltage pulse output
Superior short-circuit protection, allowing the high-voltage output to operate directly even when short-circuited to ground
1.5-level pointer displays for current and voltage, providing clear and intuitive real-time feedback on the discharge process
High-voltage side voltage measurement, real-time and accurate
Zero-position start protection with potentiometer zero output function for enhanced safety and reliability
Unique high-voltage measurement design: the voltmeter indicates the capacitor voltage in real time even in the stopped state
Discharge time can be set arbitrarily within an appropriate interval
Ultra-light integrated design: one unit replaces the traditional transformer, control box and pulse capacitor weighing hundreds of kilograms
This instrument provides power engineers and cable maintenance crews with a reliable, comprehensive solution for cable fault detection, helping to locate and clear faults quickly while keeping operators safe.
One Device Replaces Three
Traditional cable fault testing requires a test transformer, a control box and a pulse energy storage capacitor as separate units. A typical 5kVA transformer alone weighs more than 60 kg, the control box more than 30 kg, and the pulse energy storage capacitor more than 20 kg. The XHHV512-12L integrates all three functions into one portable housing weighing no more than 25 kg, dramatically reducing site logistics and setup time.
| Comparison |
Traditional Testing Setup |
XHHV512-12L |
| Units Required |
Transformer + control box + pulse capacitor (3 units) |
1 integrated unit |
| Total Weight |
Hundreds of kilograms |
≤ 25 kg |
| Wiring Complexity |
Complex inter-unit wiring |
Simple one-box connection |
| Short-circuit Safety |
Risk of component damage |
Protected, keeps operating |
| Site Portability |
Requires a truck or multiple carriers |
Carried by hand |
Panel Function Description
Safety ground: Instrument casing ground, preventing the casing from becoming electrified.
High-voltage ground: Also known as the high-voltage tail, it must be reliably grounded to prevent high-voltage leakage and discharge; poor contact may cause failure to raise voltage, breakdown damage to internal components, or safety accidents.
Sampling place: The negative terminal of the pulse energy storage capacitor carries high voltage and must be reliably grounded; it is used for waveform sampling in the high-voltage flashover state of cable fault testing.
Discharge button: Press to make contact with the ball gap for manual discharge; the duration of each press must not exceed 1 second.
Start button / zero-position indicator: When the zero-position light is on, the start button is valid; press it to start the device and generate high-voltage output.
Stop button / high-voltage indicator light: Press to cut off high-voltage output when the test is completed or an abnormality occurs; the indicator light shows whether high-voltage output is active.
Overcurrent protection switch: Pressed means the overcurrent protection is armed; when it pops up, overcurrent protection has operated. High-voltage output is available only while this switch is pressed.
Voltage adjustment knob: Turn counterclockwise to zero first, press the start button, then adjust clockwise to increase the output voltage from small to large.
Power switch: "Position I" turns on the AC 220V power supply; "Position 0" turns off the system power.
Fuse socket: Where the fuse of the AC 220V power supply system is installed.
Power socket: The instrument working power supply, AC 220V connection port.
Time setting: Sets the discharge time interval; the ball engagement time is fixed at 0.05 seconds and the disconnection time should be set between 4 and 9 seconds depending on site conditions.
Ammeter: Indicates the current on the high-voltage side.
Voltmeter: Indicates the high-voltage output voltage in kV.
High-voltage output (EMP): Connect the high-voltage output line here during impulse discharge testing.
High-voltage output (DC): Connect the high-voltage output line here during DC withstand voltage testing.
Quick Operation Guide
Connect the high-voltage output line plug to the DC terminal of the instrument and the other end to the test object; ensure the ground wire and the high-voltage output line have good contact.
Connect the AC 220V power supply and turn the power switch to "Position I"; the switch indicator light will illuminate.
Confirm the zero-position indicator light is on, the voltage adjustment knob is rotated counterclockwise to the end, and the overcurrent protection switch is pressed; then press the start button.
Slowly increase the voltage to the required level and perform the DC withstand voltage test, observing the voltmeter and ammeter for leakage or breakdown indications.
After the test, return the voltage adjustment knob to zero, press the stop button, and use the discharge rod to fully discharge the object under test.
Turn off the power switch and put away all test leads.
Field Applications
In DC withstand voltage mode, the XHHV512-12L outputs 0 ~ 12 kV DC voltage for withstand testing of electrical equipment. In impulse discharge mode, it generates high-energy pulse signals for high-voltage flashover fault testing and acoustic-magnetic synchronous fault point location of power cables rated at 12 kV and below.
Packing list: high voltage pulse generator (1 unit), power cord (1 piece), transparent grounding wire (1 set), high-voltage output line (1 piece), fuse (5 pieces) and discharge rod (1 piece) are supplied with the instrument.
Cable fault test site: the instrument is used on site for high-voltage flashover fault testing and acoustic-magnetic synchronization fault point location of underground power cables.
Inductive sampling wiring diagram: connect the high-voltage output line to the EMP terminal for impulse discharge testing of the cable under test.
Safety & Precautions:
The ground must be reliably grounded (grounding resistance less than 5Ω) before the voltage is increased.
It is strictly forbidden to set the pull-in time greater than 0.2 seconds or the capacitor storage (disconnect) time less than 3 seconds, otherwise the boost source or discharge device may burn out.
The instrument is a highly precise electronic device; it must not be disassembled by non-professionals and must be handled with care during transportation.
Ensure the instrument is powered off and fully discharged before switching between DC withstand voltage and impulse discharge functions.
If any abnormality occurs at any time during the test, press the "Stop" button or turn off the power switch immediately.
When removing high-voltage lines, always perform a complete discharge first to guarantee safety.
FAQ
Q1: What is the XHHV512-12L high voltage surge generator used for?
It is used for impulse discharge testing during fault location of power cables rated at 12 kV and below, and for DC withstand voltage testing of other electrical equipment, fully complying with DL/T846-2016 and DL/T474-2017.
Q2: How is it different from a traditional cable fault testing setup?
It integrates the DC high-voltage source, energy storage capacitor and discharge sphere gap into one unit, replacing the traditional test transformer, control box and pulse capacitor that together weigh hundreds of kilograms. The complete XHHV512-12L weighs no more than 25 kg.
Q3: What safety protections does it provide?
It features automatic overcurrent, overvoltage and overheating protection, zero-position start protection, an emergency stop function, and superior short-circuit protection that allows normal operation even when the high-voltage output is short-circuited to ground.
Q4: What are the discharge energy and output capabilities?
It delivers 0 ~ 864 J discharge energy with impulse voltage from 0 to 12 kV, short-circuit current up to 320 mA, class 1.5 high-voltage accuracy and a built-in 12 μF capacitor.
Q5: Who is this surge generator designed for?
It is designed for underground power cable maintenance teams, cable fault location contractors, municipal power distribution utilities, mining and industrial plants with buried cable networks, and third-party electrical testing and commissioning companies.
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