Cable Tester Manufacturer for Accurate Cable Fault Location and Electrical Testing

 

Precision diagnostic equipment engineered for power cable fault distance measurement, path tracing, and high-voltage insulation testing. Microprocessor-controlled time-domain reflectometry (TDR) and multi-stage surge generators ensure accurate fault pin-pointing for underground XLPE distribution and transmission cables.

Product Series
Portable TDR Cable Fault Locators
Testing Range: Up to 32 kilometers (Adjustable VOP)
Sampling Frequency: Up to 100 MHz with high-resolution LCD touch screen
Primary Use: Fast pre-location of low-resistance, short-circuit, and open-circuit faults in power and control cables.

High-Voltage Surge Generators (Thumpers) and Pin-Pointing Systems
Output Voltage: 0 to 32 kV DC (Multi-tap selectable)
Surge Energy: 1000 J / 2000 J / 4000 J (Configurable)
Primary Use: High-resistance and intermittent fault breakdown generation combined with acoustic-magnetic pin-pointing.

 

 
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Standards and Calibration
 

Design and Testing Compliance:

Built in accordance with IEEE 400 (Guide for Field Testing and Evaluation of Shielded Power Cable Systems), IEEE 400.3, and IEC 60502 standards.

Calibration Traceability:

Each cable testing unit is supplied with a factory routine test report and calibration certificate traceable to ISO/IEC 17025 accredited metrology standards.

Safety Interlocks:

Automated internal discharge circuits, zero-start high-voltage safety locks, emergency stop buttons, and continuous external ground connection monitoring to protect field operators.

 

 

Technical Specifications

 

 

Specification Parameter

Portable TDR Locator

HV Surge Generator (32kV)

Integrated System Controller

Max Testing Distance

32 km

N/A (Surge Output Unit)

Up to 60 km

Distance Measurement Accuracy

plus-minus 0.2 percent reading

N/A

plus-minus 0.1 percent reading

Pulse Amplitude and Width

0 to 100V adjustable; 40 ns to 10 microseconds

0 to 32 kV DC Surge Voltage

Combined TDR, SIM, and Arc Reflection

Surge Energy Capacity

N/A

1000 J / 2000 J (Model dependent)

Up to 4000 J

Sampling Methods

TDR, Low-Voltage Impulse

Current Impulse (CI) / Voltage Impulse (VI)

Arc Reflection Method (ARM), Secondary Impulse

Data Storage and Transfer

1000 test waveforms; USB, Ethernet

N/A

5000 test records; USB, RS485, Wi-Fi

Operating Temperature

-10 degrees C to +50 degrees C

-20 degrees C to +50 degrees C

-10 degrees C to +45 degrees C

Power Supply Options

Built-in Li-ion battery / AC 220V

AC 220V / 380V (50/60 Hz)

Dedicated Generator / AC Main Supply

 

Applications

 

Underground Power Distribution Grids:

Locating high-resistance insulation breakdowns, cable cuts, and water-treeing defects in municipal 10kV to 35kV XLPE cables.

Renewable Energy Installations:

Fault diagnosis and sheath testing for solar farm DC collector cables and wind turbine interconnects.

Cable Fault Tester

Industrial Plant and Substation Cabling:

Routine acceptance and maintenance testing for heavy-duty power supply cables across manufacturing facilities.

Telecommunications and Control Networks:

Verifying transmission integrity and locating open/short faults in multi-core control lines.

 

Configuration and Manufacturing Quality

 

High-Voltage Transformer and Capacitor Construction:

Epoxy-encapsulated high-voltage transformers and oil-immersed low-inductance surge capacitors designed to deliver clean, repeatable discharge pulses without core degradation.

Enclosure and Field Ruggedness:

IP65-rated ruggedized transport cases and heavy-duty shock-absorbing chassis designed to withstand harsh outdoor substation environments and mobile vehicle vibration.

Factory Burn-In and Stress Testing:

Every high-voltage surge generator and TDR system undergoes 72-hour continuous thermal cycling, full-voltage output endurance testing, and signal calibration prior to dispatch.

 

Our Certificate

 

 

ISO9001, ISO14001, ISO45001 

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FAQ

 

 

Q: How does Time Domain Reflectrometry (TDR) locate a cable fault?

A: TDR operates by transmitting a low-voltage electrical pulse down the cable. When the pulse encounters a change in impedance (such as an open circuit, short circuit, or splice), a portion of the pulse energy is reflected back to the instrument. By measuring the time delay between transmission and reception, and knowing the velocity of propagation (VOP) of the cable, the instrument calculates the exact distance to the fault.

Q: What is the advantage of the Arc Reflection Method (ARM) for high-resistance faults?

A: High-resistance faults and water trees often act like open circuits under low-voltage TDR testing, making them invisible to standard pulses. The Arc Reflection Method uses a high-voltage surge to temporarily flash over the fault into a short circuit for a few microseconds, allowing the TDR unit to capture a clear, precise distance reflection at the exact moment of the arc.

Q: Can these cable testers be integrated into custom mobile test vehicles?

A: Yes. We supply modular rack-mounted surge generators, burn-down units, TDR controllers, and motorized high-voltage cable drums specifically engineered for integration into customer-owned test vans or trailers.

Q: What is required to test cables with different types of insulation (XLPE, PVC, PILC)?

A: The core requirement is setting the correct Velocity of Propagation (VOP) value in the TDR software, which varies depending on whether the cable uses XLPE, EPR, or paper insulation (PILC). Our software includes a pre-loaded database of common cable types and VOP reference values.

Q: What safety features protect the operator from high-voltage hazards?

A: All high-voltage outputs feature automatic internal discharge resistors that immediately drain residual energy upon test completion or power shutdown. Additionally, systems include safety ground monitoring interlocks that prevent high-voltage generation if the grounding rod is improperly connected.

Q: What is the standard lead time for cable testers and mobile systems?

A: Standard portable TDR locators and 32kV surge generators ship within 5 to 7 business days. Custom truck-mounted test systems or specialized multi-stage high-voltage configurations require 3 to 4 weeks for assembly, wiring, and factory calibration.

 

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Request a Technical Quote

Need a portable cable fault locating kit or a customized mobile test system for your utility fleet? Provide your specifications below, and our applications engineering team will return technical drawings and pricing within 24 hours.

Required Testing Scope: [ Portable TDR Locator / 32kV Surge Generator / Complete Mobile System ]
Target Cable Voltage Rating: [ Low Voltage / 10kV to 35kV / High Voltage Transmission ]
Primary Application: [ Underground Distribution / Industrial Plant / Renewable Energy / Substation ]
Power Supply Requirement: [ Battery Powered / AC 220V / Vehicle Generator ]

Contact Email: wang@transformer-test.com
Technical Support Line: +8616630291792
Factory Location: Mancheng District, Baoding City, China

Refine On (Hebei) Electric Power Technology Co., Ltd. is one of the most reliable cable tester manufacturers and suppliers in China, also supports customized service. Please feel free to wholesale advanced cable tester at competitive price from our factory. Contact us for quotation.

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