Customizable Shielded HV Cable Thumper XHHV535-4TS Three Voltage Ranges 8 16 32kV for Fault Locating Contractors
Designed for: Cable Fault Locating Contractors, Utility Maintenance Departments, OEM/ODM Equipment Distributors
Core Value: Fully customizable shielded cable thumper with three selectable voltage ranges delivering 2048 joules of surge energy. Integrated DC power source, energy storage capacitor, and discharge sphere in a single trolley-mounted unit — configurable to match your voltage, capacitor, and branding specifications.
The XHHV535-4TS is built for organizations that require flexibility in their cable fault locating equipment. Whether you are a contractor managing diverse voltage classes across your service territory, a utility standardizing its fleet with custom-configured surge generators, or a distributor seeking OEM-branded equipment for your market — the 4TS adapts to your requirements.
Shielded Design — Built for the Demanding Industrial Environment
The XHHV535-4TS features a fully shielded high-voltage compartment that isolates the DC power source, energy storage capacitor, and discharge sphere assembly within an enclosed metal housing. This design serves three critical purposes for field and industrial operations:
Three Voltage Ranges — Performance That Adapts to Your Cable Network
| Voltage Range | Capacitor Configuration | Typical Application |
|---|---|---|
| 0–8 kV | 64μF | LV/MV distribution cables (6kV–10kV), urban feeder faults, building service entrances |
| 0–16 kV | 16μF | Industrial plant feeders (11kV–20kV), renewable energy collector cables, medium-distance circuits |
| 0–32 kV | 4μF | Sub-transmission cables (33kV–35kV), long-distance industrial incomers, wind farm collector arrays |
2048 Joules at Your Disposal: At 32kV with the 4μF capacitor, the XHHV535-4TS delivers 2048J of surge energy — sufficient acoustic output for reliable pinpointing even on high-resistance faults and long cable runs where weaker surge generators fail to produce detectable discharge signatures.
Technical Specifications
| Parameter | Specification |
|---|---|
| Selectable Output Voltages | 0–8 kV / 0–16 kV / 0–32 kV (three ranges) |
| Internal Capacitor Bank | 64μF/8kV · 16μF/16kV · 4μF/32kV (auto-switched with voltage range) |
| Maximum Surge Energy | 2048 J (at 32kV / 4μF) |
| Surge Power Rating | 2 kVA |
| Surge Timing | Auto-surge ~4 second interval · Manual discharge mode available |
| HV Measurement Accuracy | 1.5-grade voltage divider, real-time kV and mA display |
| Discharge Modes | Automatic timed discharge + Manual push-button discharge |
| Safety Systems | Zero-position start interlock, potentiometer return-to-zero, auto capacitor discharge on stop, overcurrent/overvoltage protection |
| Additional Functions | DC withstand voltage testing, integrated waveform sampling module for TDR fault pre-location |
| Dimensions | 534L * 444W * 805H mm (trolley-mounted) |
Customization Capabilities — Your Brand, Your Specifications
The XHHV535-4TS is engineered as a customizable platform. XZH TEST supports OEM and ODM orders with the following configurability:
| Customization Area | Available Options |
|---|---|
| Voltage Ranges | Default 8/16/32kV — can be reconfigured to match your regional cable voltage standards (e.g., 6/12/24kV, 10/20/35kV) |
| Capacitor Values | Custom capacitance-to-voltage matching for specific surge energy targets |
| Branding | Custom front-panel logo, equipment labeling, model numbering per client requirements |
| Packaging | Custom-branded wooden crate, multilingual user manual, logo-printed accessories case |
| Accessories | Custom cable lengths, connector types, discharge rod configurations |
| Color | Default black — custom RAL-matched enclosure colors available for volume orders |
Interested in an OEM or customized configuration? Contact our sales team with your specifications for a tailored quotation.
Integrated System Architecture
Unlike modular surge generator setups that require separate DC supply, capacitor bank, and discharge sphere modules interconnected by high-voltage cables on-site, the XHHV535-4TS integrates all three subsystems into one shielded enclosure:
How the XHHV535-4TS Integrates into Your Fault Location Workflow
▎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 protective transport solution. 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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