Dielectric Breakdown Test Equipment for Wire and Cable Materials

HJC-100kV Computer-Controlled Voltage Breakdown Tester

Technical Documents

Main Functions and Applications:

Voltage Breakdown Tester utilizes computer control and operates via human-machine interaction to perform AC voltage breakdown and withstand voltage tests on insulating medium materials. Suitable for solid insulating materials.Insulating varnishes, resins and adhesives, impregnated fiber products, laminates, mica and its products, plastics, film laminates, ceramics, and glass, etc., are tested for breakdown voltage, breakdown strength, and voltage endurance under industrial frequency voltages. The instrument rapidly and accurately collects, processes, stores, displays, and prints various data throughout the experimental process.

Pursuant to the specificationPlease provide the Chinese content to be translated.

GB1408.1-2016 "Insulating Materials - Dielectric Strength Test Methods - Part 1: Tests under power frequency, Part 2:"

GB/T1695-2005"Determination of Dielectric Strength and Voltage Resistance for Vulcanized Rubber under Industrial Frequency"

GB/T 3333-1999 "Cable Paper Industrial Frequency Dielectric Breakdown Voltage Test Method"

GB/T 1 2656-1990 "Method for Determining the Impulse Breakdown Voltage of Capacitor Paper"

ASTM D149- 09 Standard Test Methods for Dielectric Breakdown Voltage and Dielectric Strength of Solid Electrical Insulating Materials at Commercial Power Frequencies

DL/T 3 76-201General Technical Conditions for Silicon Rubber Insulating Material Used in Composite Insulators

IEC 60243-1-2013 Insulating Materials - Electrical Strength - Test Methods - Part 1: Industrial Frequency Tests

IEC 60684-2 Specification for Insulating Flexible Tubing Test Methods

TestPrinciple

1、Penetrate Tensile TestInspectionApply a certain voltage to the specimen and maintain it for a specific duration to consider the specimenInsulation capable of withstanding various voltages. Insulation resistance andAbsorption ratio test, leakage current, and DC withstand voltage test Dielectric Loss Angle Measurement TestInspection for insulation level can uncover many defects, but due to the test voltage being lower than that of the tested product, Operating voltageInsulation defects are not yet detectable in time. To further expose equipment defects, inspect the electrical... Insulated water for gas equipmentPeace ensures the operability; it is necessary to conduct breakdown and withstand voltage tests. 

2、ItIsAn effective and direct method for assessing the insulation strength of electrical equipment, crucial for determining if electrical appliances can be put into use. Operation with decisiveSignificance. Voltage, waveform, frequency, and internal insulation conditions during withstand tests of the tested item. The pressure distribution is uniformly distributed.International operating conditions, therefore, AC/DC breakdown and withstand voltage tests can effectively detect electrical equipment failures. ExistingMore dangerous concentrated defects. The higher the test voltage, the more effective in detecting insulation defects.

Complete Set-Up

Step-up components: Composed of regulators and high-voltage transformers0-20KV step-up section.

Drive Components: The voltage applied to the high-voltage transformer is uniformly adjusted by a stepper motor regulating the voltage regulator.

Test Components: Data collected by voltage and current sensors, transmitted, processed, and then sent to the host computer

Computer Software: Transmits measured control signals collected by detection equipment to the computer via intelligent circuits. The computer controls the operation of the equipment based on the collected information and processes the test results.

Test Electrode: In accordance with National StandardsWith equipment provided (1408.1-2006)StandardTwo electrodes, specific specifications are:Two Φ25mm x 25mm, one Φ75mm x 25mm(Additional test electrodes available upon customer's request)。

AC/DC Switching Test

（1) This instrument's high-voltage output is AC voltage. DC is obtained by串联 a high-voltage silicon stack in the original circuit, making the test circuit a pulsating DC voltage. The process is as follows: the silicon stack is already in the high-voltage transformer's high-voltage insulating tower, usually short-circuited by a shorting rod. When a DC test is needed, remove the shorting rod to connect the high-voltage silicon stack to the test circuit, at which point the circuit voltage becomes a pulsating DC voltage.

（2) The switching of AC and DC voltages in the test primarily depends on whether the short-circuit rod is removed from the high-voltage insulating tower. When the short-circuit rod is removed, the voltage on the high-voltage equalizing sphere is DC voltage; when the short-circuit rod is inserted, the voltage on the high-voltage equalizing sphere is AC voltage. Refer to the illustration on the left for the removal and insertion of the short-circuit rod.

（3) During DC testing, the computer must also be set to DC mode; otherwise, the results obtained will be incorrect. In simple terms, AC voltage and DC voltage haveTen times.

Key Technical Requirements

　  Input Voltage:     AC 220 V   

High-voltage output voltage: AC 0-100kV (Alternating Current) / DC 0-100kV (Direct Current)

Test Voltage: 0-100 kV Continuous Variable

High-voltage Grading:   0-100kV (Full range, non-step)

Rise Rate:   0.5kV/s～5kV/s

Voltage Measurement Accuracy:（10%--99%FS）： ≤ 2％

Output Power: 6kVA（Optional)

Boosting Methods: Continuous Boosting, Pressure Resistance, Step-wise Boosting

Test Method: Breakdown TestInspection, Voltage Resistance Test, Step Test

Testing Method: Communication Test   DC Test  (Dual-purpose)

Pressure Resistance Time:(Adjustable)

Leakage Current: 1～100 mACan be freely set by computer software.

Power Supply: Communication220V±10%Single-phase AC voltage and50Hz±1%The frequency

Test Environment:Temperature:15 ～ 30°C, Relative Humidity:0～85%Stable operation.

    Two methods of shutdown judgment: ①Voltage Shutdown  ②Current shutdown

Test environment methods available:①Insulation specimen air test  ②Insulation samples tested in oil immersion

Overcurrent protection device: Breakdown at the sample whenPower off within 0.1 seconds.

Software Features

  1During the testing process, dynamic plotting of test curves is possible. The curves can be overlaid and compared in multiple colors, with the option to zoom in on specific areas. Any segment of the curve can be analyzed in an enlarged regional view.

2Editable and adaptable to trial data.

3Data such as test conditions and results can be automatically stored.

4The format of the test report is flexible and adaptable to meet the varying needs of different users.

5The validity of curve data from a set of test can be manually selected.

6、Test result data is importableEXECL,WORDDocument Editing

7Software equipment personnel management feature, where test personnel can set their own test projects and parameters. Once they set their test content, others cannot access the program.

8Overcurrent protection devices have sufficient sensitivity to ensure that the sample is not punctured when subjected to the test.0.1SDisconnect internal power supply.

9Durability of the instrument's operation: The equipment can be continuously operated without the need to shut down regularly for equipment protection.

SoftwareOperation Interface:（①Parameters Setting Interface②Test Interface③Test Curve Interface )

High-voltage Breakdown Equipment Safety Instructions:

1Equipment must be installed with a separate protective grounding wire. Connecting the protective grounding wire mainly reduces the strong electromagnetic interference generated around the sample during breakdown. It can also prevent the control computer from going out of control.

2Direct Current Test Discharge Alarm Function:During the completion of the DC test on the equipment,When the test door is opened, the equipment will automatically alarm.,The alarm will automatically cancel once the discharge device on the equipment is used to discharge..(Note: Failure to discharge after DC testing poses a danger to personal safety.,Do not directly handle the electrodes.,Reminds users to discharge to prevent personal injury)。

3The test discharge unit is integrated with the main unit, improving the functionality of the previous setup that required a separate discharge rod.

4The circuit of this testing equipment is equipped with multiple protection measures, including: overcurrent protection, voltage drop protection, leakage protection, short circuit protection, and DC test discharge alarm.

5Six-level high-voltage safety power-off control:

Main power switch

High Voltage Breaker Switch (Key Switch)

Pressure Regulator Reset Switch

④ Test Box Door Safety Switch

⑤ Current-limiting circuit breaker on the high-voltage transformer input side

Leakage Protection Switch

AboutHigh-voltage Breakdown EquipmentIntroductionDescription:

The difference between dielectric strength and breakdown voltage:

Dielectric Strength:It is a measure of the electrical strength of a material when used as an insulator. It is defined as the electrical strength at which the specimen is punctured.Unit thickness voltage withstand, unit: kV/mm or MV/m; the higher the dielectric strength, the better its quality as an insulator. Dielectric strength is also known as electrical strength.

Breakdown Voltage:The voltage value that a material can withstand as an insulator, which is also the high voltage value at the point of breakdown or puncture, with the unit being:kV

How to select the appropriate voltage breakdown tester range:

In the standard requirements for materials or in test reports, the pressure rating of materials is typically expressed in terms of dielectric strength, i.e.kV/mm, the relationship between breakdown voltage and dielectric strength can be expressed by the following formula:

                                 Breakdown Voltage ValuekV）

    Dielectric StrengthkV/mm）=------------------------------------------

                                 Sample Thicknessmm）

The conclusion can be drawn from the above formula.The selection of a test instrument with multiple measurement ranges depends on the thickness of the sample, namely:

              Breakdown voltage value(kV) = Dielectric Strength (kV/mm) * Sample Thickness (mm)

The breakdown voltage value calculated from the formula is the effective voltage value during the thickness test of the specimen. Therefore, it is more reasonable to appropriately broaden the range of the voltage after determining the breakdown voltage value. It is recommended to increase the range after calculating the breakdown voltage value.10kV-20kV。

3. Differences between voltage breakdown testers with the same voltage range but different power ratings:

In testing procedures and standards, the commonly used test data is the breakdown voltage value. When there are no requirements for the output current of the instrument, it is not necessary to consider the equipment's capacity value; instead, focus on the equipment's range only, which will not affect the test data.

In some test standards or requirements, it is mandatory to specify the required high output current for the instrument. Consequently, when selecting the instrument's range, one must also pay attention to the transformer's capacity value (i.e., power kVA).

C: The relationship between output current, voltage, and power is expressed by the following formula:

                               Transformer CapacitykVA）

      Output CurrentMA）=----------------------------------------------

                               Voltage Range:kV）

D: The GB/T 1408.1-2006 standard provides the following overview of capacity requirements (screenshot):

4. How to Choose the Appropriate Test Electrode:

Specifications for test electrodes are varied. For different materials and sizes, choose different electrode dimensions. Specifically, the dimensions are based on the testing standards required by the material. If there are no special requirements in the standards, the commonly used test electrodes for sheet materials are typically equal diameter and unequal diameter electrodes.

What's the difference between voltage breakdown tests in air and oil?

Test medium air: Refers to placing the test sample and electrode in the air for voltage resistance and breakdown tests.

B; Test medium oil: Refers to placing the test sample and electrodes completely immersed in oil for voltage resistance and breakdown tests. Typically, 25# transformer oil is used as the test medium.

C: Testing in air or oil has no effect on the test data. Generally, experiments are conducted in air unless there are specific requirements for the sample. There are two cases where testing in oil is necessary: one is when the standard specifies it, and the other is when the sample cannot be punctured due to arcing or releasing sparks in air, and must be tested in oil instead.

6. The differences between the voltage breakdown test methods of uniform voltage rise, stepped voltage rise, and withstand voltage test:

The following voltage boosting curve chart can be used to represent.

Dimensions of the equipment: Length1500mm wide1300mm x 1 high700mm

Equipment Weight:255kg

Input Power Voltage:220V

MeasurePlease tryElectrode

All electrodes are compliant.GB/T -1408-2-16 ASTM149 Standard Designed and Manufactured

Plate and Sheet Materials: Unequal Diameter Electrodes, Equal Diameter ElectrodesStraps, film, and narrow strips:Thinfilm Electrode Software

Other Electrodes: SoftTubular electrodes, parallel plate electrodes, cone pin electrodes, parallel cylindrical electrodes, spherical electrodes.

Simultaneously customize themItTest electrodes.

Voltage Breakdown Test Equipment (Configuration List)

Equipment Calibration Training Instructions

To ensure the smooth operation of the purchased equipment and the user's proficiency in its use, our company is committed to providing free installation, debugging, and technical training to our customers.

Installation and Commissioning:

Upon arrival of the equipment, the customer shall inspect the outer packaging of the goods. In case of any damage and the extent of it, the customer should immediately notify our company by phone or in writing. The customer may only open the box in the presence of an installation engineer sent by our company. Otherwise, any damage or missing parts of the items shall be the responsibility of the customer.{Some matters can be negotiated.}

Before installation and debugging, the user party should provide the necessary preparation and give prior notice. (The specific installation and debugging date can be negotiated between both parties.)

3.Our company is responsible for dispatching engineers to arrange for the installation and debugging of this equipment, ensuring that it is set up quickly upon arrival at the factory.Speed up usage