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/ Technical Services / Spare & Wear Parts / Extrusion Line Parts / Spark Tester

Spark Tester High-Voltage Insulation Fault Detection for Wire & Cable Extrusion

High-voltage electrode system for continuous online insulation testing
Detects pinholes, voids, cracks, and thin spots in insulation and jacket
Adjustable test voltage to match insulation type and wall thickness
Compatible with single-conductor, multi-conductor, and coaxial cable lines
Fast fault response with counter, alarm, and line stop signal output
Compact electrode housing for easy integration into existing extrusion lines
Suitable for PVC, XLPE, PE, rubber, and specialty compound insulations
Available in multiple electrode lengths and configurations

PVC and PE insulated wire extrusion lines
XLPE cross-linked cable production
Automotive wire and harness cable manufacturing
Building wire and low-voltage power cable extrusion
Coaxial and data cable jacketing lines
Rubber-insulated flexible cable production
Medium and high-voltage cable extrusion
Fiber optic cable outer jacket lines

We assist in identifying the correct spark tester model based on your line speed, insulation material, wall thickness, and required test voltage range. Support includes cross-referencing OEM part numbers, electrode sizing, and compatibility verification with your existing extrusion equipment.

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We supply spark testers for wire and cable extrusion lines, including complete units, replacement electrodes, and associated control components. These instruments are a critical part of any wire extrusion quality control process, ensuring that insulation and jacket layers are free of defects before the cable leaves the production line. We source units compatible with equipment from leading manufacturers such as Troester, Maillefer, Rosendahl, Nextrom, and many others.

A spark tester — also known as a holiday tester, pinhole detector, or high-voltage spark tester — applies a controlled high-voltage electrical field around the cable as it passes through the electrode. Any defect in the insulation, such as a pinhole, void, crack, thin wall, or contamination, causes an electrical discharge that is immediately detected and logged. This process is essential for compliance with international standards including IEC 60227, IEC 60245, IEC 60502, UL 44, UL 83, VDE 0281, and VDE 0282.

We offer spark testers in a wide range of configurations, covering test voltages typically from 1 kV up to 50 kV DC or AC, depending on the insulation type and wall thickness. Compatible insulation materials include PVC, polyethylene (PE), cross-linked polyethylene (XLPE), EPR, silicone rubber, TPE, TPU, and specialty compounds used in automotive, aerospace, marine, and industrial cable applications. Electrode designs are available in bead chain, spring contact, and water trough configurations to suit different cable diameters and line setups.

All units and spare components are available with worldwide shipping and full technical support. Whether you need a complete spark tester unit, a replacement high-voltage electrode, a control unit, or individual components such as cables, connectors, or fault counters, we can help you identify and source the right part for your line — minimizing downtime and keeping your cable extrusion quality control process running without interruption.