Trolley High Voltage Surge Generator 2048J 3-Speed Capacitor for 35kV Cable Fault Testing
The XHHV535-4TS is a lab-grade trolley high-voltage surge generator engineered for high-precision cable fault testing and DC withstand voltage analysis at voltage levels up to 35kV. Featuring a unique 3-speed capacitor system (4μF/32kV, 16μF/16kV, 64μF/8kV), it delivers up to 2048J discharge energy with adjustable output levels for precise test waveform acquisition. Built on a heavy-duty trolley chassis at 120kg, the unit provides the stability and durability required in permanent testing facilities.
This device integrates a high-voltage DC source, energy storage capacitor, discharge ball gap, automatic discharge device, and voltage level switching mechanism into a single cart-type platform. Tri-mode operation—DC withstand voltage, single impulse discharge, and periodic cycle discharge—enables comprehensive cable fault characterization. A dedicated communication socket interfaces with cable fault testers for high-voltage flashover waveform sampling. Rated IP54, with zero-start protection and automatic residual voltage discharge after shutdown.
| Control | Function |
|---|---|
| Ammeter | Indicates output current in real time |
| Voltmeter | High-voltage output indication (8/16/32kV ranges combined with voltage level switch) |
| HV Indicator Light | Illuminated = high voltage active; Off = no high voltage output |
| Power Light | Illuminated when main power switch is on |
| Zero Indicator | Voltage knob at zero position; must be lit before high voltage can start |
| Overcurrent Protection Switch | Pressed = overcurrent protection active; Pops up = protection triggered |
| Power Switch | Clockwise on, counterclockwise off; system power control |
| Mode Selector | Three positions: DC (withstand), Single (impulse), Cycle (periodic discharge) |
| Start Button | Initiates high voltage when zero light is on; non-zero = blocked |
| Voltage Control Knob | Continuous adjustment of output voltage; boost enabled only after high voltage start |
| Stop Button | Cuts high-voltage output immediately; triggers automatic residual discharge |
| Voltage Level Switch | Lift-turn-press: 8kV, 16kV, 32kV levels; set before power on |
| Terminal | Function |
|---|---|
| Power Socket (AC220V) | Instrument working power supply input; 220V 50Hz |
| Fuse Holder | AC220V power supply system fuse |
| Signal Socket | Dual-Q line interface to cable fault tester for flashover waveform sampling |
| Safety GND | Instrument chassis ground; must be reliably connected to earth |
| HV GND | High-voltage tail grounding; reliable connection essential to prevent leakage |
| Sampling GND | Pulse energy storage capacitor negative terminal for flashover sampling |
| HV OUT | Dedicated DC high-voltage output terminal |
| Surge Voltage Levels | Level 1: 0–8kV / Level 2: 0–16kV / Level 3: 0–32kV (manual switch, continuous adjustment) |
|---|---|
| Max Surge Energy per Level | Up to 2048J |
| Built-in Capacitor | 4μF/32kV, 16μF/16kV, 64μF/8kV (3-speed) |
| Operating Modes | Single trigger, Cycle, DC withstand |
| Impact Power | 2kVA |
| Impact Time | ~5s automatic, arbitrary manual control |
| Continuous Output Current | 60mA |
| DC Withstand Output | 0–32kV adjustment, 0–20A current indication range |
| Burn Current | 60mA/32kV, 120mA/16kV, 240mA/8kV |
| Voltage Indication | High-voltage side metering, real-time, 1.5-level accuracy |
| Safety Protections | Over-voltage, over-current, overheating; auto-discharge; zero-start interlock |
| Protection Rating | IP54 |
| Power Supply | AC220V±10%, 50Hz±2Hz (other voltage & 60Hz optional) |
| Included Cables | HV output cable 5m, Ground cable 5m, Power cord 2.5m (customizable lengths) |
The XHHV535-4TS trolley platform is designed for permanent testing laboratories, cable manufacturer QC departments, third-party testing and certification agencies, and utility training centers—environments where equipment stays in a fixed location and where maximum energy output, multi-level testing capability, and instrument-grade waveform acquisition are valued over portability. The 3-speed capacitor system enables voltage-matched testing across low, medium, and high voltage cable ratings. The trolley form factor with IP54 protection makes it suitable for semi-permanent workshop installations and sheltered outdoor test bays. For field-portable applications, refer to the XHHV535-2L (25kg) or XHHV535-4Z (35kg) models.
▎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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