Datasheet: Sparktester – Wire and cable insulation tester.
Basic applications
This equipment was developed for use in dielectric strength tests, at high voltage, carried out during the
manufacturing process of electrical wires and cables. Its principle is based on the application of alternating high
voltage between the copper cable or wire and its insulating layer. This situation causes a capacitive current that
will have its value determined by the dielectric strength of the insulator (cover). If there is any failure in the
insulating coating of the cable (cover), the capacitive current will have its value alternating, and such abnormality
is detected by the instrument, informed through light and sound signaling of the occurrence.
An event counter was attached to the equipment in order to register the number of arrests of the capacitive
current increase in a given manufacturing batch, which could be used as a verification or control item for testing
the batch in question.
The test standards for wires and cables suggest that high voltage remains in the test region of the
insulating material (cover), for 9 (nine) complete cycles, with a known frequency and average speed of
displacement of the wire/cable. To facilitate the calculation of the length of the electrode where the cable/wire will
pass, being exposed to the application of high voltage, we suggest an empirical formula:
Vm= (L x F) / 150
Where: VM= Average speed of displacement of the cable in "m/min".
L= Electrode length in “mm“
F= High voltage frequency applied in “Hertz“.
Sparking test for cables or cords.
Models
Frequency
voltage kV
dimensions
ST 2000
60Hz
15/20 kV
65/30/20cm
Supply of Project for the
manufacture of electrical
cable testing equipment
The construction of the
equipment can be made in
a module with the high
voltage and electrode
together, or two modules
with the high voltage and
separate electrodes,
according to the buyer's
option.
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Fault counter and stop programming.
Sparking test for cables or cords.
Table 01 - Tests according to IEC 60227-5
Cables
Conductor
Nominal Thickness
test voltage
nominal section
of insulation (mm)
sparking (kV)
2
HERE
CC
(mm )
300V
750V
300V 750V 300V 750V
0.5 0.75 1.0
0.5
0.6
4.0
5.0
6.0
7.0
1.5
2.5
0.8
7.5
10.5
4.0
1.0
10.0
16.6
6.0 10.0
1.0
10.0
16.0
Table 02 - according to IEC 60227-3
Conductor sparking section
insulation thickness
2
(mm)
(mm )
0.5
0.75
1.0
0.6
1.5
0.7
2.5
4.0
6.0
0.8
10.0
16.0
1.0
Table 04 - cables according to IEC 60227/08
Working Voltage – 300/500V
Working Voltage – 450/750V
cords
Nominal
insulation
thickness (mm)
0.8
0.8
0.8
-
test voltage
sparking
(kV)
7.5
7.5
7.5
-
10.5
10.5
10.5
-
Test voltage at; (kV)
HERE
CC
5.0
7.0
6.0
8.5
7.5
10.5
10.0
16.5
2000Vac
2500 Vac
Equipment Description:
Below, the function of the components that make up the control and protection of the equipment will be
explained.For a better view, see attachment 1.
1- Glass fuse (F1, F2): Its function is to protect the equipment as a whole, against surges and overloads from the
network or due to failure that may occur by chance.
2- Alloy key: Responsible for energizing the command module. When activated there will be light indication
through the pilot lamp.
3- Microswitch (m): Responsible for guaranteeing the operator's safety, only when the electrode cap is in its
working position, the high voltage will be generated by the command module.
4- High voltage carriers (TAT):Responsible for providing the high voltage necessary for energizing the electrode
and test cable.
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5- Auxiliary Transformer (TBT):Responsible for supplying low voltage power to the protection and measurement
board.
6- Current sensor (CT): Transducer responsible for converting the increment of current of the electrode supply
circuit, for comparison with the actuation value of the signaling and protection of maximum current allowed.
7 – Sensitivity: Potentiometer located on the front of the command module, whose function is to adjust the trigger
sensitivity of the signaling and fault counter. Its setting varies the capacitive leakage current detection that the
equipment will detect.
8- Pre-Determiner Plate:Its function is to detect the increase in the capacitive leakage current in the electrode and
increase the failure indicator, as well as inform the measurement board to activate the light and sound signaling.
9- Failure Counter : It accumulates in increasing order the number of times that the capacitive leakage current in
the electrode exceeded the established value. In the case of starting a new test process, it can be reset through a
button located on its body.
10- Measuring Plate : It processes the capacitive leakage current information coming from the electrode, sending
them for comparison in the pre-determination board. It also has the function of informing through the kilovoltmeter
located on the front of the command module the voltage applied to the electrode. This board has an auxiliary
control relay that activates, in the event of an increase in capacitive current, the light signaling and a warning
sound signal, featuring a reversible contact to act directly in the manufacturing process. located on the back of the
command module.
11- Reset button: Interrupts the external signaling (Lamp) and the sound signal warning of increased capacitive
current, whenever activated.
12- Tension Adjustment (Tension Adjustment:Multi turn potentiometer, responsible for adjusting the input voltage
level on the amplifier board, which will consequently vary the voltage level applied to the cable under test (voltage
output on the electrode).
DESCRIPTION OF CONTROLS AND INTERCONNECTIONS
COMMAND MODULE: REAR AND FRONT PANEL
Caixa Frontal e Tazeira do SPARK
8
9
1 2345
10
12
1
11
7
2
0000
4
3
6
5
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1- 15 / 20kV full scale analog voltmeter.
2- Potentiometer for adjusting the electrode output voltage.
3- Button on/off the equipment.
4- Pilot light indicating energized equipment.
5- Reset button, deactivates light and sound signals.
6- Event Counter.
7-
Sensitivity adjustment potentiometer.
8-
External remote warning signaling (OPTIONAL).
9-
Input protection fuses (F1, F2).
10- Command module power cable (220VAC).
11- Interconnection terminal board, where:
- Terminals 1 and 2 – NC.
- Terminals 1 and 3 – NO
- Terminals 4 and 5 – Microswitch
12- AT output
Electrode
3
6
2
5
4
12
1
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1- Protective metallic box.
2- Electrode.
3- Metal box grounding terminal.
4- Terminal strip for interconnection to the command module, through a harness.4 and 5
5- Door microswitch.
6- High Voltage Cable
Installation Instructions
1-Choose the installation location of the equipment properly.
2- Isolate the place where the equipment will be used, signaling it with “DANGER – HIGH VOLTAGE”
signs.
3- The power supply point of the equipment must provide a voltage of 220 V with its own grounding in the
connection plug.
4- Connect the interconnection harness between the command module and the electrode, respecting the
identification of each cable.
5- Ground the metallic box of the electrode (fig 3 – pos 3) at the same grounding point of the command
module.
6- If necessary, connect the auxiliary contact (fig 2- pos 11) to the production line stop command system.
Operating instructions
1- Check if the “VARIAC” of the output voltage is positioned with its “Knob” all the way to the left
(counterclockwise).
2- Check that all interconnections have been carried out correctly.
3- Close the electrode door.
4- Connect the equipment connection plug to a grounded 220V ac / 60Hz point.
5- Activate the “ON” switch of the equipment.
6- press the “RESET” button and also reset the event counter.
7- Gradually increase the voltage value on the electrode using the “ADJUSTMENT POTENTIOMETER”, up
to the desired value.
8- Adjust the value of the sound warning trigger sensitivity by turning the potentiometer clockwise until the
trigger occurs. At this time, turn it clockwise approximately ¼ of a turn.
9- Activate the production line, respecting the average speed value used to calculate the electrode length.
10- In the work process, any current leakage that occurs between the insulation of the cable under test and its
conductor will activate the sound signal, the light signal and the event counter will be incremented. If the
auxiliary contact of the command module terminal strip is connected to the machine activation, it will be
deactivated, allowing the operator to identify the leakage point.
Sales Informations and Project, Please contact: sergio.murilo@voltheon.com.br WhatsApp 5511972180944
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VOLTHEON High Voltage | voltheon.com.br | contato@voltheon.com.br | @voltheon | Phone + 55 11 25761677 | Mobile: +55 11 996978307