Sparktester Electrical Insulation Testing
Continuous in-line spark testing for flawless cable insulation
Detects insulation defects instantly to ensure reliable, high-quality production of wires and cables
Why Sparktester?
The Zumbach Sparktester is a critical inline quality control system for cable and wire manufacturing, designed to continuously detect insulation defects during extrusion. By applying high voltage as the cable passes through an electrode, it instantly identifies faults such as pinholes, cracks, and insulation gaps. This real-time detection ensures product safety, minimizes scrap, and guarantees compliance with industry standards for insulated cables and wires.
Built for high-speed production environments, the Sparktester uses electrically conductive electrodes, ensuring 100% ionization of the test area to monitor the integrity of the insulating jacket while the grounded conductor completes the circuit. Any defect triggers an immediate spark discharge, enabling fast response and preventing defective product from continuing downline, making it an essential solution for reliable, high-quality cable production.
- Instant detection of insulation defects: Identifies pinholes, cracks, porosity, and exposed conductor areas in real time, including faults invisible to the naked eye, ensuring maximum cable safety and integrity.
- High-voltage spark testing for continuous production: Applies voltage matched to insulation thickness while cables run at full speed, detecting faults without restricting the process.
- Reliable fault identification through discharge detection: Insulation failures trigger a visible and measurable spark/discharge, providing clear, immediate indication of defects for rapid corrective action.
- Essential quality assurance for cable manufacturing: The Sparktester ensures compliance with industry standards, reduces scrap, and protects downstream operations by verifying insulation performance before products reach the market.
Properties
- Testing with AC (50/60 Hz), DC, or high-frequency voltage options
- Models available up to 40 kV AC (Sparktester AST) / 28 kV DC (Sparktester DST)
- Detects pinholes, bare patches, and insulation faults
- Electrodes for product diameters up to 250 mm
- Integrated web server for monitoring and control
- Supports industrial communication protocols (e.g. PROFIBUS, PROFINET IO, EtherNet/IP)
- Compliant with IEC 62230, UL 1581, UL 2556 / BS EN 50356
- Dedicated solutions for low-medium speeds and thick cables, high-speed lines, foamed cables and thin wires
- Robust, compact, and durable industrial design
Benefits
- Reliable detection of even the smallest defects for maximum product safety
- Continuous, non-destructive inline testing with no interruption to production
- Reduced scrap and faster process correction through real-time fault detection
- High operational reliability in harsh industrial environments
- Improved cable quality and compliance with global industry standards
- Flexible adaptation to different cable types and production speeds
- Enhanced quality assurance before market release
Object diameter (mm)
Test voltage (kV)
Line speed (m/min
Scan rate (kHz)
Technical data
For accessories and detailed product information, refer to the respective brochures
AST H 15A
- Object diameter
- ø 30 mm bead chain electrodes, 40/125 mm lengths
- Test voltage
- 0.5 … 15 kV AC
- Scan rate
- 3 kHz
- Line speed
- Till 7’500 m/min IEC / 2’084 m/min UL
- Brochure
- AST H 15A (PDF, 1.55 MB)
AST L
- Object diameter
- Bead chain electrodes: ø 50/90/250 mm, 200/300/400/1000 mm lengths
- Test voltage
- 2 … 40 kV AC
- Scan rate
- 50-120 Hz
- Line speed
- Up to 1’200 m/min IEC / 333 m/min UL
- Brochure
- AST L (PDF, 1.55 MB)
DST 10
- Object diameter
- Bead chain electrodes: 30 mm, 102 mm lengths, flat electrode: 30×30 mm
- Test voltage
- 0.5 … 10 kV DC
- Scan rate
- NA
- Line speed
- Up to 6,120 m/min IEC / 3,019 m/min UL
- Brochure
- DST 10 (PDF, 495.68 KB)
DST 28A
- Object diameter
- ø 30 mm with bead chain electrodes, ø 40 mm or 20…75 mm with ring electrodes, 60×30 mm or 150×30 mm with flat electrodes
- Test voltage
- 1 … 28 kV DC
- Scan rate
- NA
- Line speed
- Up to 7,500 m/min IEC / 3,700 m/min UL
- Brochure
- DST 28A (PDF, 1.55 MB)
CALIBRATOR SP 40A
- Test voltage
- 0 … 40 kV
- Frequency range
- 0 … 4 kHz
- Max. short circuit current
- 15 mArms
- Brochure
- SP 40A (PDF, 957.59 KB)
VISU-Touch
- Number of sensors (ODAC®, CAPAC® etc.)
- 1
- Number of controllers
- Up to 5
- Display, int.
- 7 Inch
- Brochure
- VISU-Touch (PDF, 740.58 KB)
Proven performance worldwide
The Zumbach Sparktester is used by leading manufacturers across the global wire and cable industry, providing reliable, non-destructive insulation testing for plastic, rubber, and silicone cable production. As a mandatory testing method defined by international standards such as IEC 62230, UL 1581, and BS EN 50356, spark testing is essential for ensuring cable safety and compliance.
With an insulation fault detection rate close to 100% under normal operating conditions, the Sparktester delivers highly accurate defect detection for pinholes, cracks, and insulation failures. Its continuous inline operation supports quality assurance in high-speed cable manufacturing, helping producers reduce risk, ensure compliance, and deliver consistently high-quality cable products to the market.
Areas of application
Wire & Cable Manufacturing:
Ideal for testing power, data, telecommunications, automotive, and high-voltage cables, ensuring insulation integrity across a wide range of cable types.
Energy & Electrical Infrastructure:
Supports cable production for power transmission, distribution networks, and renewable energy systems such as wind and solar.
Construction, Automotive & Transportation:
Ensures safe, compliant cables for residential and commercial buildings, automotive wiring, e‑mobility, and transport systems.
Industrial & High-Demand Environments:
Designed for reliable performance in telecommunications networks, data centers, building management and heavy industries including oil & gas, petrochemical, and marine.
Frequently asked questions
What voltage should be used for spark testing cables?
The required test voltage depends on the insulation (or jacket) thickness, material type (e.g. PVC, PE), and applicable standards such as IEC 62230 or UL 1581. Selecting the correct voltage ensures reliable defect detection without damaging the cable.
Should I use AC, DC, or high-frequency spark testing?
The choice depends on industry standards, line speed, and product type. For thicker insulation and lower speeds, AC (50/60 Hz) is recommended. For high-speed extrusion lines, High Frequency (HF) is recommended. For thin wires and sensitive applications, DC is recommended. Each method balances detection sensitivity and production efficiency.
Is spark testing safe for operators?
Yes. While spark testers operate at high voltage, the current is limited to safe levels (<10 mA). Systems include safety features such as protective enclosures, grounding, and electrode open sensors that automatically shut off high voltage when accessed.
Does spark testing generate ozone?
Yes. The ionization of air and electrical arcs can produce ozone during operation. Sparktesters are designed with integrated ventilation or exhaust connections to safely remove ozone from the testing area.
How can I verify the Sparktester is working correctly?
Functionality is typically verified using a calibration or test device, such as the SP40A calibrator, which checks voltage accuracy and ensures reliable fault detection performance before production starts.
How do I maintain and clean the electrodes?
Regular maintenance is essential for accurate results. Dust, contamination, or moisture on chains or brushes can lead to false readings or reduced sensitivity. Routine inspection and cleaning of electrodes ensures consistent, reliable performance.
