High Voltage Surge Generator | XHHV515-8L
The XHHV515-8L 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 15 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 ball gap into a single housing, completely replacing the traditional test transformer, operation box and pulse energy storage capacitor that together weigh hundreds of kilograms. A typical 5kVA transformer set weighs more than 60 kg, the control box more than 30 kg, and the pulse energy storage capacitor more than 20 kg. Built with high-precision, high-stability dedicated high-voltage electronic components and high-frequency high-voltage technology, the XHHV515-8L keeps the whole machine simple in structure and ultra-light in weight.
Applications & Target Audience: Engineered for power emergency repair and rapid response teams performing 24-hour cable fault rescue, transmission and distribution engineering general contractors, electrical commissioning teams of wind farm and PV plant substations, electrical equipment manufacturers performing factory withstand voltage tests on switchgear and transformers, university and research institute electrical laboratories, and power industry training centers.
Key Specifications
| Parameter |
Specification |
| Impulse Voltage |
0 ~ 15 kV |
| Short-circuit Current |
0 ~ 320 mA |
| High Voltage Accuracy |
Class 1.5 |
| Built-in Capacitor |
8 μF |
| Discharge Energy |
0 ~ 900 J |
| Output Voltage Polarity |
Negative polarity |
| Overcurrent Protection |
8 mA (over 4 seconds), high-voltage side |
| Impact Power |
400 W |
| Over-temperature Protection |
65 °C |
| Dimensions (L × W × H) |
540 × 300 × 450 mm |
| Weight |
≤ 25 kg |
| Working Power Supply |
AC 220V ±10% / 50Hz ±2Hz |
| 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
Super short-circuit protection function, allowing the high-voltage output to operate directly even when short-circuited to ground
Dual 1.5-level pointer meters for current and voltage display, intuitive and clear, showing whether the fault point is fully discharged and reflecting the discharge process in real time
High-voltage side voltage measurement, real-time and accurate
Zero-start protection with potentiometer zero output function for enhanced safety and reliability
Unique high-voltage measurement design: in the stopped state, the voltmeter can indicate the capacitor voltage in real time
Discharge time can be set arbitrarily within an appropriate interval
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, Two Test Modes
The XHHV515-8L integrates two complementary test modes in one portable unit, covering the two most common high-voltage field testing tasks for power cables and electrical equipment.
| Comparison |
DC Withstand Voltage Mode |
Impulse Discharge Mode |
| Output Terminal |
High-voltage output (DC) |
High-voltage output (EMP) |
| Output Range |
0 ~ 15 kV DC |
0 ~ 15 kV pulse, up to 900 J |
| Typical Use |
Withstand voltage testing of electrical equipment |
Shock discharge during cable fault testing |
| Test Object |
Other electrical equipment, cable insulation |
Power cables rated at 10 kV and below |
| Result Indication |
Voltmeter and ammeter show leakage or breakdown |
Acoustic and magnetic synchronization fault point determination |
DC Withstand Voltage Operation
The DC withstand voltage function is used to test the insulation strength of electrical equipment. The following procedure ensures a safe and correct test.
Connect the high-voltage output line plug to the DC terminal of the instrument and the other end to the tested product, ensuring good contact between all lines and the high-voltage output line
Check that the ground wires and high-voltage output wires are in good contact; when everything is ready, connect to the AC 220V power supply
Turn on the AC 220V power supply switch at the "I" gear; the switch light comes on
Confirm the zero-position light is on and the voltage adjustment knob is rotated counterclockwise to the end, and ensure the overcurrent protection switch is pressed; press the start button and the voltage starts to increase slowly
After starting the high voltage, other personnel should not move or approach the connected wires to prevent high-voltage
Slowly ramp up to the desired voltage 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 special discharge rod to correctly and fully discharge the measured object
Turn off the power switch and put away all test leads
Cable Fault Test Site
The impulse discharge function is used for fault testing and acoustic and magnetic synchronization fault point determination of power cables with voltage levels of 10 kV and below.
Connect the high-voltage output line plug to the EMP terminal of the instrument and the other end to the tested cable, ensuring good contact
Check the ground wires and high-voltage output wires are in good contact, then connect to the AC 220V power supply
Adjust the time setting: the left half sets the ball pull-in time and the right half sets the disconnection time, for example 6S means the two balls collide and discharge once, with one contact duration of 0.05s
Start the instrument and apply high-energy pulse signals to the cable under test; use acoustic and magnetic synchronization to determine the fault point
Instrument Composition
The standard delivery includes the high-voltage pulse generator host, the high-voltage output line, the ground wire (safety ground and discharge rod grounding wire), the power cord, 5 spare fuses (8A) and the discharge rod. The host applies high-voltage and high-energy pulse signals to the cable under test, the high-voltage output line connects the host and the tested cable core, and the discharge rod performs DC current-limiting discharge or DC short-circuit discharge at the end of the cable under test.
Panel Function Description
Safety ground: the instrument shell ground must be reliably connected to the ground to prevent the shell from becoming electrified or causing to personnel
Discharge button: press to make contact with the ball gap for manual discharge; each key press must not exceed 1 second
High-voltage start button: the start is valid when the start button light is on; press to start the device and generate high-voltage output
High-voltage stop button: press to cut off the high-voltage output when the test is completed or an abnormality occurs; the high-voltage light goes out and the internal discharge ball stops working
Overcurrent protection switch: pressed means the overcurrent protection function is started; popped up means overcurrent protection has been triggered
Voltage adjustment knob: turn counterclockwise to the end first, press the start button, then adjust clockwise to increase the output high voltage from small to large
Power switch: "I gear" turns on the AC 220V power supply, "0 gear" turns off the system power
Fuse holder and power socket: where the fuse of the AC 220V power supply system is installed and where the working power cord is connected
Time setting: sets the discharge time interval of the ball gap
Ammeter and voltmeter: indicate the current and output voltage on the high-voltage side in kV
High-voltage output (EMP): connect the high-voltage output line for impulse discharge testing
High-voltage output (DC): connect the high-voltage output line for DC withstand voltage testing
Safety & Precautions
Read the manual carefully before use and observe all relevant precautions; it is strictly forbidden to hit the instrument violently
The safety ground, sampling ground and high-voltage ground must be reliably grounded before boosting; ground resistance must be less than 5Ω
The 4mm2 ground wire is connected to the instrument ground, and the 2.5mm2 ground wire is connected to the discharge rod; do not connect them in reverse
Before boosting, the overcurrent protection switch must be pressed, otherwise there will be no high-voltage output; when overcurrent protection is triggered, shut down and restart it
When the high-voltage indicator light is on, there is high-voltage output; pay attention to safety
After the test is completed, the high-voltage terminal must be fully discharged before touching any connection
When an abnormality occurs at any time during the test, press the "Stop" button or turn off the power switch to ensure safety
FAQ
Q1: What is the XHHV515-8L high voltage surge generator used for?
It is used for shock discharge during cable fault testing of power cables rated at 10 kV and below, and for DC withstand voltage testing of other electrical equipment, fully complying with DL/T846-2016 and DL/T474-2017.
Q2: What is the difference between the DC and EMP output terminals?
The DC terminal is used for DC withstand voltage testing, where the instrument outputs 0 ~ 15kV DC voltage. The EMP terminal is used for impulse discharge testing, where the instrument generates high-energy pulse signals of up to 900J for cable fault testing and acoustic and magnetic synchronization fault point determination.
Q3: How does it compare with traditional cable fault testing equipment?
It integrates the DC high-voltage source, energy storage capacitor and discharge ball gap into one unit, replacing the traditional test transformer, operation box and pulse energy storage capacitor that together weigh hundreds of kilograms. The complete XHHV515-8L weighs no more than 25 kg.
Q4: What safety protections does it provide?
It features automatic overcurrent, overvoltage and overheating protection, zero-start protection with potentiometer zero output, super short-circuit protection that allows normal operation even when the high-voltage output is short-circuited to ground, and a unique high-voltage measurement design that shows capacitor voltage in the stopped state.
Q5: Who is this surge generator designed for?
It is designed for power emergency repair and rapid response teams, transmission and distribution engineering contractors, electrical commissioning teams of wind farm and PV plant substations, electrical equipment manufacturers, university and research institute laboratories, and power industry training centers.
Working Principle
The XHHV515-8L is powered by AC 220V and outputs 0 ~ 15kV DC voltage through a high-frequency high-voltage conversion circuit. The pulse generator is a system used to generate DC high-voltage pulse signals and electrical test signals with the required parameters, and is often used as an impulse high-voltage power supply for fault detection of power cables with voltage levels of 10 kV and below.
The system is composed of a charging circuit and a discharging circuit. The voltage of the high-voltage cable is sampled and sent to the voltage-stabilizing control circuit. The impact magnet organically combines the DC high-voltage power supply, the energy storage capacitor and the high-voltage discharge ball gap, and is used for fault testing and acoustic and magnetic synchronization fault point determination.
XHHV515-8L vs Traditional Test Transformer Set
Traditional DC high-voltage generation requires a test transformer, an operation box and a pulse energy storage capacitor as separate units, with heavy inter-unit cabling and complex site setup. The XHHV515-8L replaces all of them with one integrated unit.
| Comparison |
Traditional Test Set |
XHHV515-8L |
| Units Required |
Transformer + operation 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 |
| Voltage Indication |
Separate measurement setup |
Dual 1.5-level pointer meters, real-time |
| Site Portability |
Requires a truck or multiple carriers |
Carried by hand |
Typical Application Scenarios
Power Emergency Repair
When an underground power cable fails, every minute of downtime costs revenue and affects customers. Emergency repair teams need equipment that can be carried to the site quickly and set up in minutes. The 25 kg XHHV515-8L fits in the trunk of a service vehicle, and its one-box design reduces site setup time dramatically compared with traditional transformer sets.
Wind Farm & PV Plant Substations
Renewable energy plants perform periodic withstand voltage testing of cables and equipment during commissioning and maintenance. The XHHV515-8L provides the DC withstand voltage function needed for these tests, and its impulse discharge function handles collector circuit cable faults, helping plants restore generation capacity quickly.
Electrical Equipment Factories
Switchgear, transformer and cable accessory manufacturers perform factory acceptance tests that require a portable high-voltage source. The XHHV515-8L offers 0 ~ 15kV adjustable DC output with accurate 1.5-class measurement, suitable for routine withstand voltage testing on the production floor and in the test bay.
Laboratories & Training Centers
University electrical laboratories and power industry training centers use the XHHV515-8L for teaching high-voltage testing methods and cable fault location techniques. Its humanized design keeps the familiar transformer and operation box operation mode, so trainees can master it quickly while benefiting from modern protection functions.
Why Choose the XHHV515-8L
15kV impulse voltage with up to 900J discharge energy for 10kV and below cable fault testing
Dual functions in one portable 25kg unit: DC withstand voltage and impulse discharge
Super short-circuit protection allows high-voltage output to work normally even when short-circuited to ground
Dual 1.5-level pointer meters show whether the fault point is fully discharged and reflect the discharge process in real time
Zero-start protection and potentiometer zero output function for enhanced safety
Humanized design retaining the familiar transformer and operation box operation mode, safe and reliable
Common Faults & Solutions
No high-voltage output: check that the overcurrent protection switch is pressed and the zero-position light is on; turn the voltage adjustment knob counterclockwise until the start light is on
Overcurrent protection triggered: shut down the instrument, restart the overcurrent protection switch, and check the test object for short-circuit conditions
Cannot raise voltage: verify that the safety ground, sampling ground and high-voltage ground are reliably grounded with ground resistance less than 5Ω
Unstable voltage indication: check the contact of the high-voltage output line and the test leads, and confirm the power supply is within the AC 220V ±10% range
Voltmeter shows voltage in stopped state: this is normal; the unique high-voltage measurement design indicates the capacitor voltage in real time, and the capacitor must be fully discharged with the discharge rod before touching connections
After-sales Service & Packing List
Every XHHV515-8L is backed by professional after-sales service, including commissioning guidance, operator training materials and technical support for cable fault location applications. The standard packing list includes the high-voltage pulse generator host, the high-voltage output line, the ground wire, the power cord, 5 spare fuses (8A) and the discharge rod. Please contact us for the warranty terms and service details applicable to your order.
For more information about the XHHV515-8L high voltage surge generator, including detailed specifications, demonstration videos and pricing, please contact our sales team. We are glad to recommend the most suitable cable fault location solution for your cable network.
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