864J 12kV High Voltage Surge Generator Portable Underground Cable Fault Locator Pulse Tester | XHHV512-12L

Used mainly for shock discharge during low-voltage cable fault testing, the XHHV512-12L high voltage surge generator is a tie-rod portable integrated device. It is easy to operate and convenient to carry due to its humanized design operation mode, high-precision dedicated high-voltage electronic components and high-frequency high-voltage technology. It is primarily designed for impulse discharge in fault testing of cables with voltage levels of 12 kV and below, and can also be used for DC withstand voltage testing of other electrical equipment.

The high-voltage pulse generator fully complies with DL/T846-2016 "General Technical Conditions for High Voltage Test Equipment" and DL/T474-2017 "Implementation Guidelines for Field Insulation Tests", the authoritative Chinese power industry standards for high-voltage test equipment and field insulation testing. It integrates a DC high-voltage source, energy storage capacitor and discharge sphere gap into one compact unit, completely replacing the traditional test transformer, control box and pulse energy storage capacitor weighing hundreds of kilograms - a typical 5kVA transformer weighs more than 60 kilograms, the control box weighs more than 30 kilograms, and the pulse energy storage capacitor weighs more than 20 kilograms. This integration not only saves enormous weight but also eliminates the complex wiring and calibration work required between separate units, reducing setup time from hours to minutes and minimizing the risk of connection errors.

This power supply utilizes high-precision, high-stability dedicated high-voltage electronic components and high-frequency high-voltage technology, resulting in a simple overall structure and ultra-light weight. The pulse generator features a user-friendly design and is safe and reliable. It truly achieves the effect of being undamaged by impacts and can operate normally even with a high-voltage short circuit to ground. It is currently the lightest and most user-friendly portable DC impulse high-voltage device on the market, making it an ideal product for power cable fault detection.

As an independently developed product from our factory with CE and ISO certification, the XHHV512-12L delivers reliable performance for cable fault location and insulation testing worldwide. OEM and ODM customization services are available to meet specific market requirements, and every unit is transported in a wooden box with foam inside for safe delivery.

• Automatic protection against overcurrent, overvoltage and overheating ensures safe operation in all field conditions.

• Dual functions: DC withstand voltage testing and impulse discharge testing in one portable instrument.

• High-voltage pulse output is uniform and controllable, delivering consistent test results every time.

• Superior short-circuit protection function enables high-voltage output to operate directly even when short-circuited to ground.

• 1.5-level pointer displays for current and voltage provide a clear and intuitive view, making it easy to see whether the fault point has been fully discharged, with real-time feedback on the discharge process.

• High-voltage side voltage measurement is real-time and accurate, giving operators precise readings.

• Zero-position start protection enhances safety and reliability by preventing accidental high-voltage startup.

• Unique high-voltage measurement design: even when stopped, the voltmeter can indicate the capacitor voltage value in real time, allowing operators to always have a clear understanding of the remaining high voltage.

• The discharge time can be set arbitrarily within an appropriate interval, adapting to different fault conditions and site requirements.

• Ultra-lightweight design: the complete instrument weighs no more than 25 kg, replacing traditional equipment weighing hundreds of kilograms.

• Tie-rod portable integrated design with humanized operation mode, easy to move and operate in the field.

• High-frequency high-voltage technology with high-precision, high-stability dedicated high-voltage electronic components ensures long-term reliable performance.

DC withstand voltage function: Powered by AC 220V, the instrument outputs 0-12 kV DC voltage for DC withstand voltage testing of cables and other electrical equipment. The operator connects the high-voltage output line to the DC terminal and the test object, then starts the high voltage and slowly raises the voltage to the required level while observing the voltmeter and ammeter fluctuations to detect leakage or breakdown.

Impulse discharge function: The instrument generates DC high-voltage pulse signals to produce electrical test signals with the required parameters, serving as an impulse high-voltage power supply for fault detection of power cables with voltage levels of 12 kV and below. It is composed of a charging circuit and a discharging circuit: the charging circuit samples the voltage of the high-voltage cable and sends it to the voltage regulation control circuit, while the impact magnet organically integrates the DC high-voltage power supply, energy storage capacitor and high-voltage discharge sphere into one unit. It is typically used in high-voltage flashover fault testing and acoustic-magnetic synchronization fault point location, where the 864J discharge energy repeatedly strikes the fault point to generate audible and measurable signals for precise fault location.

• Shipbuilding and ship repair enterprises: locate and test cable faults in ship power systems and shore power facilities during construction and repair works, using the portable design in confined spaces where traditional bulky equipment cannot be deployed.

• Wastewater treatment plants and environmental protection facilities: maintain and test the extensive buried cable networks of pumps, aeration systems and control equipment, locating faults quickly to keep treatment processes running continuously.

• Cold chain logistics parks and cold storage facilities: verify and test power cables serving refrigeration units and temperature control systems, minimizing downtime that could compromise stored goods.

• Charging pile operators and new energy vehicle service enterprises: test the power supply cables of charging stations and service facilities, ensuring safe and reliable operation of the growing charging infrastructure network.

• Elevator and building automation maintenance companies: locate cable faults in building power distribution systems during maintenance contracts, providing fast and safe service for commercial and residential buildings.

• Municipal drainage pumping stations and flood control facilities: maintain and test power cables of drainage pumps and flood control equipment, ensuring reliable operation during rainy seasons and emergency flood response.

Step 1: Connect the high-voltage output line plug to the DC terminal of the instrument and the other end to the test object. Ensure that the ground wire and the high-voltage output line have good contact.

Step 2: Make a special check to ensure that the ground wire and high voltage output wire are in good contact. Once everything is ready, connect the AC 220V power supply.

Step 3: After connecting the power cord, press position I to turn on the AC 220V power switch; the switch indicator light will then illuminate.

Step 4: Observe that the zero-position indicator light is on and the voltage adjustment knob is rotated counterclockwise to the end, and ensure that the overcurrent protection switch is pressed. Then press the start button. The high voltage indicator light will light up and the voltage will start to rise slowly. Observe the voltmeter value at any time.

Step 5: After the high voltage is started, other personnel should not move or approach the connected wires.

Step 6: Slowly increase the voltage to the required level, then perform a DC withstand voltage test on the test sample. Observe the fluctuations of the voltmeter and ammeter to indicate whether there is leakage or breakdown.

Step 7: After the test is completed, turn the voltage adjustment knob counterclockwise to the end to ensure that the knob is in the zero position. At this time, the zero position light will light up. Press the stop button, noting that there is still high voltage in the internal capacitor - you can see the voltage value on the voltmeter. Use the special discharge rod to properly and fully discharge the object under test.

Step 8: Turn off the power switch and put away all test leads.

Step 1: Connect the high-voltage output line plug to the EMP terminal of the instrument and the other end to the test object. Ensure that the ground wire and the high-voltage output line have good contact.

Step 2: Make a special check to ensure that the ground wire and high voltage output wire are in good contact. Once everything is ready, connect the AC 220V power supply.

Step 3: After connecting the power cord, turn on the AC 220V power supply switch by pressing position I. At this time, the switch light will turn on.

Step 4: Adjust the time setting. The left half of the time setting is the ball attraction time and the right half is the disconnection time. For example, setting means the two balls collide and discharge once every 6 seconds, with each contact duration of 0.05 seconds.

Step 5: The ball engagement time is 0.05 seconds and must not be changed; the disconnection time should be set between 4 and 9 seconds depending on the site conditions.

Step 6: After setting the time, check again whether the ground wire and high voltage output wire are in good contact. When everything is ready, observe that the zero position light is on and the voltage adjustment knob is turned counterclockwise to the end. Make sure the overcurrent protection switch is pressed, then press the start button.

Step 7: The high voltage indicator light will be on. At this time you can hear the interval between the ball collisions inside the equipment. If it is the time we need, start to slowly increase the voltage and observe the voltmeter value at any time.

Step 8: After the discharge is completed, to ensure that there is no high voltage in the internal capacitor, insert the ground wire into the copper head hole at the end of the discharge rod and touch it to the end of the cable under test. Then another person presses the discharge button to perform a complete short circuit discharge.

Step 9: Turn off the power switch and put away all test leads.

Shipyards and repair docks: when testing cable systems on vessels, ensure the instrument is placed on a stable, dry surface and the grounding point is connected to the ship hull grounding system. The portable design allows the instrument to be carried to the work site, avoiding long cable runs through the vessel.

Wastewater treatment plants: cable trenches and buried conduits are often exposed to moisture and corrosive gases. Before testing, inspect the cable insulation condition visually and keep the instrument away from water sources. The DC withstand voltage function is particularly useful for evaluating insulation degradation caused by long-term moisture exposure.

Cold storage and refrigeration facilities: the low ambient temperature environment is within the instrument operating range of -25°C to +65°C. Allow the instrument to stabilize at the site temperature before testing, and ensure the LCD indicators remain clearly readable in low-temperature conditions.

Charging stations and new energy facilities: DC fast charging stations involve high-power cables that must be verified de-energized before maintenance. Coordinate with the station operator to isolate the charging equipment and follow the complete discharge procedure before connecting or removing test leads.

1. When adjusting the time settings, it is strictly forbidden to set the pull-in time greater than 0.2 seconds, and strictly forbidden to set the capacitor storage time (disconnect time) less than 3 seconds. Otherwise, there is a risk of burning out the boost source or discharge device.

2. Read the instruction manual carefully and master the operating procedures, wiring method and precautions before using this device.

3. The instrument is a highly precise electronic device. It must not be disassembled by non-professionals. Handle it with care during handling and transportation; rough handling or impact is strictly prohibited.

4. The ground must be reliably grounded before the voltage is increased, and the grounding resistance must be less than 5Ω.

5. Ensure that the instrument is powered off and discharged before switching between DC withstand voltage and impulse discharge functions.

6. If any abnormality occurs at any time during the test, press the Stop button or turn off the power switch to ensure safety.

7. When removing high-voltage lines, to ensure safety, it is essential to perform a complete discharge by short-circuiting the copper head hole at the end of the discharge rod to the high-voltage output and pressing the discharge button on the control panel.

8. If you need to continue increasing the voltage after the overcurrent protection switch has tripped, turn off the instrument power, rotate the voltage adjustment knob counterclockwise to the zero position, press the overcurrent protection switch, and operate the instrument to increase the voltage again.

9. If the instrument malfunctions, contact the dealer or our company immediately. Damage to the instrument caused by human error will void the warranty.

The XHHV512-12L is a highly precise electronic device that must be handled with care. During handling and transportation, avoid rough handling and impacts. Store the instrument in the original wooden box with foam inside, in a dry, clean and ventilated environment with stable temperature.

Keep the panel, high-voltage output terminals and discharge rod contacts clean and free of dust and moisture. Check the high-voltage output line and grounding wire insulation regularly for cracks or wear, and replace damaged accessories with original parts. The backup fuses included in the package should be kept accessible for quick replacement when needed.

If the instrument is not used for a long period, power it on and perform a functional check periodically to keep the electronic components in good condition. The instrument must not be disassembled by non-professionals - any internal maintenance must be performed by qualified service personnel or the manufacturer.

Calibration is recommended annually or after major repairs to maintain the Class 1.5 high voltage accuracy. Contact our service team for calibration services and technical support.

The instrument is covered by a one-year warranty from the date of purchase for product quality issues, and lifetime maintenance and technical services are provided. If you find any abnormalities or malfunctions in the instrument, please contact us so we can arrange the most convenient and effective solution for you.

As a factory-direct supplier based in Xi'an, China, we support OEM and ODM customization, provide professional technical consultation, complete documentation and responsive after-sales service for customers worldwide. For bulk orders or customized branding, please contact our export team directly anytime.

When placing an order for the XHHV512-12L, please specify the model number, quantity, target voltage rating and any customization requirements such as OEM branding, packaging language or accessory configuration. Standard delivery includes the complete package contents listed above, with a wooden box with foam inside for safe international transport.

We recommend confirming your typical cable voltage levels and fault types with our engineers before ordering, so we can advise on the optimal discharge energy settings, time setting ranges and any supplementary accessories such as acoustic-magnetic synchronization receivers for complete fault location solutions. Lead time for standard orders is generally short, and our export team will provide full shipping documentation and tracking information.

For training support, we provide operator manuals, quick reference guides and remote technical assistance to help your team master the instrument quickly. Spare parts including fuses, high-voltage output lines, grounding wires and discharge rods are available for long-term maintenance.

For bulk orders, OEM branding, customized packaging or training support, please contact our export team directly anytime. We provide professional technical consultation, complete documentation and responsive after-sales service to support your cable fault location and insulation testing operations worldwide. Welcome to contact us anytime for more information, quotations from our factory team, or a tailored solution for your specific testing requirements. Our engineers are ready to help you select the right accessories, train your field teams, and ensure your instrument delivers reliable performance for years of service. We value long-term partnerships and are committed to supporting your cable testing operations with dependable products and professional service. Your satisfaction is our priority, and we welcome your feedback to continuously improve our products and services. Contact us to discuss your requirements and let us support your success.