Standards:

Applications:

Product Information:

The Insulated Winding Wire Breakdown Voltage Tester manufactured by our company is a multifunctional automatic AC voltage testing instrument designed in accordance with the requirements of the national standards GB/T 4074.5-2008 and IEC 60851-5:2008.

It can also be referred to as an electrical insulation strength tester or dielectric strength tester. Its working principle is to apply a voltage higher than the normal operating voltage to the insulation material of the specimen and maintain it for a specified period of time. If only a very small leakage current is generated under the applied voltage, the insulation performance is considered satisfactory.

The equipment adopts advanced microelectronic chip processing technology, touchscreen control, and PC-based operation, making the operation simple and user-friendly. The testing system consists of three modules: a programmable power supply module, a signal acquisition and conditioning module, and a computer control system. After all test parameters are set, the testing process is carried out automatically without manual intervention.

Application Range

This equipment is mainly suitable for testing the breakdown voltage resistance performance of enameled round wires, film-insulated round wires, and various specifications of flat wires with a nominal diameter of

0.02 mm and above under room temperature or high-temperature conditions (when used together with the RD-300 Thermal Voltage Tester).

The withstand voltage test is used for high-temperature failure testing of enameled round wires (when used together with a high-temperature oven). The test voltage range is 0–15.000 V, and the withstand time can be freely set from 1 second to over 10 hours.

It can also be used for withstand voltage testing of electrical products and instruments.

Product Features

A 7-inch high-definition color touchscreen displays voltage, current, time, status information, and prompt messages clearly and intuitively.

Five specimens can be clamped at one time, and the system can automatically complete the entire process of specimen switching, voltage increasing, voltage decreasing, test result display, and data storage.

Equipped with testing fixtures such as round rods, twisting devices, and weights for clamping five specimens simultaneously.

The equipment features test parameter memory function. Under the same test conditions, parameters do not need to be reset for each test, and the last test settings will still be retained even after power failure.

The test interface is simple and intuitive, making it easy to understand.

The control panel is concise, with clearly marked functions and easy operation.

The system can store up to 100 sets of test data simultaneously. Every 10 test records are displayed on one page, making comparative analysis of test data more convenient.

The testing interface adopts real-time display mode, allowing easier observation of the testing process.

The instrument is equipped with multiple protection measures to ensure operator safety.

9.1  Door Interlock Protection

If the door is not closed, the equipment will not respond even when powered on and the test is started.

9.2  Voltage Zero-Return Protection

If a sudden power failure occurs during the test, the system will automatically return to the zero position after restart, ensuring that the initial voltage starts from zero.

9.3  Overvoltage Protection

The cutoff voltage can be preset through the software. If abnormal voltage increase occurs during testing, the system will automatically stop the test and return to zero once the preset voltage is reached.

9.4  High-Voltage Mechanical Limit Protection

If the software system loses control and the voltage continues to rise, the system will issue an upper-limit warning once the high-voltage mechanical limit is reached.

9.5  Operation Indicator Light

The equipment is equipped with an operation indicator light, allowing users to determine whether the system is running by observing the indicator status.

Main Technical Specifications

1. Test Voltage

a. The test voltage is an AC voltage with a nominal frequency of 50 Hz and an approximately sinusoidal waveform, with a peak factor of √2 × (1 ± 5%).

b. Maximum test voltage: ≤ 15.000 V.

The indication error of the test voltage is ±3%.

2. When a current of (5 ± 0.5) mA passes through the high-voltage circuit, the instrument can automatically issue a high-voltage breakdown signal and display the breakdown voltage value. The voltage drop of the test voltage shall not exceed 2%.

3. The voltage rising speed of the test voltage shall conform to Table 1. and the error of the voltage rising speed shall be within 10%.

Table 1

Test Voltage Range	Voltage Rising Speed
0–500 V (1000 V)	(20 ± 2.0) V/s
>500 V (1000 V) – 2500 V	(100 ± 10) V/s
>2500 V – 15000 V	(500 ± 50) V/s

4. The capacity of the test transformer is > 900 VA.

5. The voltage withstand time setting range is 0–9999 s (unit: second).

6. Other Specifications

Operating environment:

(1) Temperature: 0–40°C

(2) Relative humidity: ≤ 85%

External power supply: 220 V ± 5%, 50 Hz

To ensure the required voltage rising speed, it is recommended to use an AC stabilized power supply with a power rating of ≥ 3 kVA.

FAQ

1. What is an Insulated Winding Wire Breakdown Voltage Testing Device?

An Insulated Winding Wire Breakdown Voltage Testing Device is a specialized instrument used to measure the dielectric strength of enamelled or insulated winding wires. It determines the voltage level at which the insulation layer fails and electrical breakdown occurs, ensuring the safety and reliability of electrical conductors used in motors, transformers, and other electrical equipment.

2. What is the working principle of the device?

The device applies a gradually increasing or preset high voltage across the insulated winding wire sample. When the insulation can no longer withstand the applied electric field, a breakdown occurs, resulting in a sudden current surge. The system automatically records the breakdown voltage value, which reflects the insulation strength of the material.

3. What parameters does the device test?

The main test parameters include:

Breakdown voltage value

Insulation withstand strength

Dielectric strength stability

Leakage current during testing

Insulation failure point detection

These parameters help evaluate the electrical safety performance of winding wires.

4. Which standards does it comply with?

The device typically complies with international and national testing standards such as:

IEC 60851 (Methods of test for winding wires)

GB/T 4074 (Test methods for winding wires)

NEMA MW 1000 (Magnet wire standards)

These standards ensure consistency, accuracy, and global applicability of test results.

5. Which industries commonly use this equipment?

It is widely used in:

Motor manufacturing industry

Transformer production industry

Magnet wire and cable manufacturing

Electrical insulation material R&D

Quality inspection laboratories (QC/QA)

Third-party testing institutions

It is an essential tool for ensuring electrical insulation safety and product reliability.