Winding Wire Breakdown Voltage Tester – IEC 60851-5 Figure 3 U-Bend Specimen Insulation Test Equipment

Winding Wire Breakdown Voltage Tester – IEC 60851-5 Figure 3 Insulation Tester

The Winding Wire Breakdown Voltage Tester is a precision insulation test instrument manufactured by KingPo, designed to evaluate the dielectric strength of enameled wires after U-shaped bending. Fully compliant with IEC 60851-5 Figure 3, this tester forms the wire into a U-bend specimen and applies high voltage using steel balls (diameter <2mm) to detect breakdown, ensuring insulation integrity under mechanical stress and electrical load.

In wire manufacturing and medical electrical equipment (patient cables, diagnostic leads), enameled wire insulation must resist breakdown after bending to prevent short circuits or safety hazards. The KINGPO Winding Wire Breakdown Voltage Tester addresses this by providing accurate U-bend forming and uniform voltage application with <2mm balls, allowing manufacturers, testing labs and certification bodies to verify wire performance and compliance with global standards (CE, UL, CB Scheme, CCC).

This tester features a robust metal frame, precise specimen fixture and reliable voltage control, delivering repeatable, certification-grade results for enameled wire breakdown voltage validation.

Core Role & Purpose

The Winding Wire Breakdown Voltage Tester verifies:

• Dielectric strength of enameled wires after U-bend forming
• Compliance with IEC 60851-5 Figure 3 specimen requirements
• No insulation breakdown under applied voltage with <2mm balls
• Resistance to mechanical bending stress in real-world use

It simulates combined mechanical and electrical stress, ensuring wire safety and reliability.

Test procedure

• A straight piece of wire of sufficient length, with the insulation removed at one end, shall be bent around a mandrel as shown in Figure 3.
• The diameter of the mandrel shall be 50 mm ± 2 mm.
• The specimen shall be placed in the container and shall be surrounded by shot at least 5 mm between the specimen and the inner walls of the container.
• The ends of the specimen shall be sufficiently long to avoid flashover.
• The shot shall be poured gently into a container until the specimen is covered by shot at a depth of 90 mm.
• The metal shot shall be not more than 2 mm in diameter;
• The test voltage shall be applied according to IEC60851-5-cl.4.1 , between the conductor and the shot.
• Five specimens shall be tested. The five single values shall be reported
• 

Professional Construction & Technical Precision

Key features include:

• Specimen Preparation: U-shaped bend fixture per IEC 60851-5 Figure 3
• Voltage Application: Steel balls diameter <2mm for uniform contact
• Compliance: IEC 60851-5 Figure 3 standard
• Construction: Durable metal frame for lab reliability
• Operation: Precise forming and voltage loading for consistent results

These ensure accurate, repeatable breakdown voltage testing.

Primary Use Cases & Business Value

The Winding Wire Breakdown Voltage Tester supports key stages:

• Wire R&D Validation — Test enameled wire insulation after U-bend in new designs
• Certification Reporting — Labs generate compliant data for IEC 60851-5 submissions
• Production QC — Manufacturers verify batch wire dielectric strength
• Failure Analysis — Investigate insulation breakdown defects in returned products

It helps deliver reliable wires, reduce field failures and accelerate certification.

Compliance & Regulatory Assurance

Fully compliant with IEC 60851-5 Figure 3 U-bend specimen breakdown voltage requirements. Aligned with CE, UL, CB Scheme, CCC for medical and electrical equipment. Regular calibration recommended.