ZJC-50KV Dielectric Breakdown Tester by AVIC Era

Overview

The ZJC-50KV Dielectric Breakdown Tester by AVIC Era is a precision high-voltage test system engineered for determining the dielectric strength and voltage withstand characteristics of solid insulating materials under standardized AC or DC excitation. It operates on the principle of controlled voltage ramping until electrical breakdown occurs across a defined electrode gap—enabling quantitative measurement of the material’s intrinsic insulation performance. Designed in strict compliance with GB 1408.1–2006 (equivalent to IEC 60243-1), GB 1408.2–2016 (aligned with IEC 60243-2), and ASTM D149, this instrument delivers repeatable, traceable results essential for R&D validation, quality control, and regulatory conformance in electrical insulation applications.

Key Features

• Integrated touch-screen control panel with intuitive HMI—enabling full parameter configuration, real-time voltage/current monitoring, and standalone operation without external PC.
• Dual-mode output: Simultaneously supports AC (50 Hz) and DC high-voltage generation up to 50 kV, both with programmable ramp rates from 0.02 to 10 kV/s.
• Automated electrode alignment mechanism ensures precise coaxial positioning of standard electrodes (Φ25 mm × Φ25 mm and Φ25 mm × Φ75 mm), minimizing field distortion and enhancing measurement reproducibility.
• Embedded automatic discharge circuitry for DC tests—activated upon test completion or door opening—complying with safety requirements in GB/T 32302 and IEC 61010-1.
• Multi-layer safety architecture: Interlocked test chamber door, overvoltage/overcurrent cut-off (<0.1 s response), emergency stop button, tri-color status indicator (green/yellow/red), and integrated grounding terminal meeting Class I protection requirements.
• Modular hardware design—including isolated high-voltage transformer, digital measurement module (ZNDY-2022), and stepless voltage regulation (ZNDY2023)—facilitates field-level maintenance and calibration traceability.
• USB and Bluetooth interfaces support data export to U-disk and wireless remote supervision—eliminating physical cable constraints in shielded lab environments.

Sample Compatibility & Compliance

The ZJC-50KV accommodates rigid and semi-rigid dielectric specimens including polymer films, laminated composites, ceramic substrates, impregnated papers (e.g., capacitor paper per GB 12913–2008), molded resins, and glass-ceramic insulators. Electrode immersion in insulating oil (provided in integrated oil tank) ensures uniform field distribution per GB/T 1695–2005 and ASTM D149 protocols. All operational modes satisfy national metrological verification requirements per JJG 795–2016 and are suitable for GLP-compliant laboratories conducting ASTM, ISO, and GB-standardized electrical safety testing. The system supports audit-ready documentation through timestamped test logs, operator ID tagging, and configurable electronic signatures—facilitating alignment with FDA 21 CFR Part 11 and ISO/IEC 17025 documentation frameworks.

Software & Data Management

When connected to the included industrial PC (Tsinghua Tongfang chassis, HP A4 inkjet printer), the system runs proprietary AVIC Era TestSuite v3.2 software. This application provides dynamic real-time plotting of voltage vs. time and current vs. time waveforms, with multi-curve overlay, region zoom, and differential analysis tools. Test records—including breakdown voltage, time-to-failure, leakage current profile, and ramp rate—are stored in encrypted binary format with SHA-256 integrity checksums. Export options include CSV, Excel (.xlsx), and Word (.docx) report templates compliant with internal QA templates or third-party certification bodies. The software implements role-based access control (RBAC), audit trail logging (per ISO 13485 Annex C), and automatic backup to network drives—ensuring data integrity and long-term archival readiness.

Applications

This tester serves critical functions across multiple sectors: qualification of wire insulation coatings and heat-shrink tubing per UL 1581; evaluation of encapsulation resins used in power electronics modules; verification of dielectric integrity in printed circuit board (PCB) substrate materials (e.g., FR-4, polyimide); routine QC screening of transformer pressboard and bushing porcelain; and comparative aging studies of polymer nanocomposites under accelerated voltage stress. Its dual AC/DC capability supports both traditional power-frequency assessments and emerging HVDC insulation characterization needs aligned with IEEE Std 4–2013 and CIGRE Technical Brochures on HVDC converter station insulation coordination.

FAQ

Does the ZJC-50KV comply with international standards such as IEC 60243 or ASTM D149?
Yes—it is designed and verified against GB 1408.1/2 (technically equivalent to IEC 60243-1/-2) and fully implements ASTM D149 test procedures, including electrode geometry, oil immersion, and voltage ramp specifications.
Can test data be exported without connecting to a computer?
Yes—via USB flash drive directly from the touch-screen interface. However, waveform visualization, curve analysis, and advanced reporting require PC connectivity.
What safety certifications does the system carry?
It meets GB/T 32302–2015 (Safety Requirements for High-Voltage Test Equipment) and incorporates design elements aligned with IEC 61010-1:2010 (Measurement, Control and Laboratory Equipment). Full CE marking requires end-user site-specific risk assessment and local authority sign-off.
Is remote firmware update supported?
Firmware updates are delivered via secure download portal; installation requires local administrator credentials and offline verification checksum matching.
How is calibration traceability maintained?
Each unit ships with a factory calibration certificate referencing CNAS-accredited standards (GB/T 19022). Users may perform periodic verification using NIST-traceable high-voltage dividers (e.g., Tettex 8110 series) per ISO/IEC 17025 Clause 6.5.