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Your cabling installer should shield installed cabling against other workers. This is far cheaper than future cabling changes.
Before protecting cable routes that cannot be opened between termination & installation, terminate the cables so they can be tested.
Cable testing reduces testing time. These checks:
A cable issue is often visible before it turns into a problem. A visual assessment of the entire facility’s wires might detect issues before downtime. We check for copper corrosion, insulation cracks, cable wetness, and other cable damage signs.
Cable defects cost money and cause interruption; thus, cable test methods are in high demand to ensure cables and couplings are in a good condition and find cable faults quickly.
Cable testing to predict and fix errors is essential for electricity distributors. Cable testing can be difficult; however, many test methods and equipment can handle this issue.
Equally as important as test equipment is experience to assist choose and use it to get the best results.
Tests conducted during cable testing are listed below:
Cable low resistance, measured in the range of 1 mΩ to 250 Ω, is determined by the continuity test, often known as low resistance measurement.
Depending on the amount of resistance to be measured, the continuity test can be performed with two or four wires: two wires for resistances greater than 1Ω and four wires for resistances less than 1Ω.
When conducting a continuity test in the two-wire mode, voltage & current at the resistance’s terminals are measured while a programmable current is injected. The specific amount can be found using Ohm’s law.
Dividing the switching matrix into two internal buses to route the test current carrying the voltage of the element under measurement’s terminals is known as the “four wires mode” or “Kelvin method” continuity test.
Odd addresses are assigned to current injection, and even addresses are assigned to the measurement’s sensitivity. When combined by 2 wire continuity tests, this arrangement can be implemented all the way across the switching matrix.
A DC source is always used for the insulation test, commonly referred to as the high resistance test.
A short-circuit & high voltage test in DC are coupled with the insulation test.
There are multiple uses for the insulation test.
The insulation test can measure the strength of the dielectric and detect short circuits.
It can also determine insulation resistances between 50 kΩ and 2000MΩ at high voltage, or from 20V to 2000V.
The resistance of the cable is measured by the Megger after it has applied a high voltage to the insulation of the cable. It is also called Megger test. The higher the resistance, the better the insulation in the system. As a result of comparing the results to the norms, poor resistance may be an indication of problems.
Each location where LV cables are terminated into fuse bases or every place where an LV cable is run from one point to another must have its proper phasing audited.
Use of an instrument made specifically for the test is required. For this test, 240 volts of mains frequency voltage is unacceptable.
For this test, it is necessary to connect the neutral conductor to the earth stake.
It is required that the duration of burning after the flame has been removed not exceed sixty seconds, and the distance between the lower edge of top clamp and the unaffected area must be at least 50 millimeters.
Under fire conditions, tests are performed on electric & optical fiber cables according to IEC 60332.
The earth resistance test for any overhead or subterranean network requires that, before connecting to the current network, the earth resistance at every point along the length of an LV feeder have a maximum resistance of 10Ω.
An earth resistance of less than 1Ω must exist before connecting to an existing network, whether it is underground (or) overhead line.
Note: The capacitance value of the tested equipment penalizes the high voltage (HV) test under alternating current. The generator’s 5 mA maximum power must be kept in reference.
For new cable circuits, a minimum testing duration of 60 minutes at 0.1 Hz is advised for installation or acceptance tests. If there is no failure and the observed feature stays steady for at least 15 minutes, a test duration of 15 to 30 minutes may be taken into consideration.
are some of the most common cable faults.
These cable faults also have an impact on the equipment’s electrical performance. However, detecting them early can save you from major problems subsequently.
Much of what goes into the design and manufacture of quality electronic components revolve around testing – individual parts and the assembly itself, once completed. For the electrical connections that make up cables, harnesses, or any other wired assemblies, cable testing is performed to check for conformity to plans, quality, and functionality. An experienced turnkey electronic manufacturer can oversee your project from start to finish while performing all necessary tests along the way.
These undergo their own testing processes and requirements because, without proper electrical components, the assembly becomes useless. While all assemblies do not require the same level of certified quality, some level of dependability is required in all finished products.
In order to identify and fix cabling issues as early in the manufacturing process as possible, cable testers are used to automatically test for conformity, quality, and functionality. A range of tests can be used to make determinations for each. Below, we discuss some of the more common cable testing processes and the intended outcome of each.
Cable conformity means that the cabling matches the design plans. If cables are conforming, the connector pins, twisted pairs, and shielding are all in the correct places. Cable quality means all the connectors, insulations, and the cables work how they are supposed to work. Quality tests seek to root out damages, scratches, dust, and air where it should not be. Cable functionality is tested after conformity and quality to determine that the components will work in realistic conditions and still do what they are designed and manufactured to do.
Additionally, cable testing reduces the overall time required for testing and consequently makes the manufacturing process more efficient. An electronic manufacturer can detect problems early and fix them before the full product is manufactured. The last thing you want is to find out that the wiring in a completed project would never have passed cable testing.
A range of cable testing processes can help determine if an electrical component meets the needs, specs, and certification required by the manufacturer or end-product. Point to point testing, high potential testing, measured charge testing, RF cable testing and complex cables pegboards all assist with identifying quality and reducing manufacturing time.
Point to Point Testing – In point to point testing, a charge is sent from one designated connector to another designated connector. The charge is sent and then measured. In this way, the point to point test confirms the functionality of the electrical connections.
Measured Charge Testing – In the measured charge test, similar to in point to point, a charge is sent through two specific connectors. In this case, voltage is also specified and measured at the endpoint to be sure the voltage remained the same from start to finish. This test also is ensuring functionality.
High Potential Testing – In a high potential test, cables are encapsulated in foam or another form of insulation and given a high charge, 5000 VAC, and 6000 VDC, for example. If the cable can withstand these voltages, it passes this quality test.
RF Cable Testing – In an RF cable test, the length of the voltage waves is measured. This is a performance test, return loss and voltage standing wave ratio are monitored. Fault locations and impendence changes and their causes are also noted.
Complex Cables Pegboards – Complex cables pegboards are used to keep everything organized during testing and assist in determining how well the wiring conforms to the design plans. Organized cables also assist in performing other cable testing processes and ensure accuracy throughout.
Cable testing is used in both production and maintenance of electrical components. Everything from consumer products to heavy machinery projects may involve cable testing. Aerospace satellites, airplanes, trains and subways, Army equipment, cell phones and microwaves all involve cable testing to ensure quality, conformity, and functionality before, during, and after manufacturing.
A major factor that can reduce cable testing problems is sourcing quality products and materials. This is an area of specialty for Levison Enterprises. We work with a reputable and robust network of suppliers and we know the provenance of the parts and supplies offered by our supply partners. Eliminating counterfeit parts has many advantages, but from the viewpoint of cable testing, real parts are important to improving the overall quality and functionality of electronic assemblies.
In addition to offering a range of cable testing options, we work closely with our manufacturing partners and our suppliers to obtain high-quality and ethically sourced parts. Combined, this produces fewer cable testing issues and a quicker manufacturing process for our partners.
Further, our cable testing and sourcing are underscored by our commitment to quality. This commitment is best summed up in the list of quality certifications that Levison Enterprises maintains with pride. Everything from procedures to individual staff training is carefully monitored, continuously improved, and regularly upgraded to ensure constant regulation and quality compliance.
Our certifications include AS9100C, NIST, and ISO 9001. We are ITAR registered and maintain IPC and J Standard certifications. While we believe in the quality set by all these standards, what we really aim for is excellent products for our partners.
Contact Levison Enterprises to discuss how our commitment to quality can improve your projects.
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