News Archives - Cimbian UK

Ensuring Cable Safety with Insulation Withstand Testing: Why Precision Matters

When it comes to cable assemblies, safety and reliability are non-negotiable. One of the most critical tests performed to ensure these qualities is the Insulation Withstand Test, also known as Dielectric Breakdown Testing, high-voltage withstand testing, or Isolation Testing. This high-voltage test verifies that the insulation within a cable assembly can withstand a specified voltage without allowing excessive current to flow, confirming that the product is safe for use in the field… or is it?

What is an Insulation Withstand Voltage Test?

Typically conducted during end-of-line testing, this process involves applying a known high voltage and monitoring the resulting current. If the current remains below a preset threshold, the assembly passes the test; however, not all test systems are created equal—and that’s where the CableEye^® HVX Series stands out.

Going Beyond the Basics with CableEye®

While many HiPot testers can perform a basic insulation withstand test, the CableEye HVX Series offers advanced features that ensure a more accurate, repeatable, and reliable result. For instance, when high voltage is applied to a cable, the inherent capacitance can cause the power supply to trip prematurely. To counter this, CableEye allows users to precisely program both the voltage ramp-up and ramp-down rates in 1V increments. This fine control enables the system to accommodate the charging characteristics of the cable under test, ensuring the full test voltage is applied without triggering a fault.

Intelligent Current Monitoring

Another key advantage of the CableEye system is its programmable current range, from 0.05mA to 1.5mA. This ensures that the assembly is protected throughout the test, including during ramp-up and ramp-down phases. The system continuously monitors current levels, preventing damage while maintaining test integrity.

Additionally, CableEye allows for a programmable trip current—a brief allowance for over-current conditions caused by voltage ringing when the maximum test voltage is reached. This feature ensures that minor, short-lived current spikes don’t result in a failed test or reduced voltage application.

Confidence in Every Test

Once the maximum voltage is applied and stabilised, the system enters a programmable dwell time, during which the high voltage is maintained before ramping down. This ensures the insulation is tested under sustained stress, providing a more thorough validation.

All of these programmable parameters—ramp rates, current limits, trip thresholds, and dwell times—combine to deliver a test that is not only precise but also repeatable and trustworthy. With CableEye, manufacturers can ship their cable assemblies with full confidence that the test specifications were met—not compromised.

screenshot of hipot test settings from cableeye hvx

motorsport harnesses - hvx printed test report with insulation withstand testing

More than just HiPot

The CableEye^® HVX series of testers are based upon the well-established low voltage M3Z and M4 CableEye^® testers from CAMI Research. What this means is that all products are tested for the low-voltage parameters including Continuity, Resistance, Diodes. Only after the assembly under test passes these tests will the CableEye^® HVX system enter HiPot test mode.

A single test station for a one-stop test solution.

A well-considered investment

By investing in precision tools for insulation withstand testing, companies signal a clear commitment to excellence. It’s not merely about passing a test; it’s about protecting your brand, your clients, and ultimately, the end-users who depend on your products every day. In this context, precision isn’t just important—it’s indispensable.

Not All Cable Testers Are the Same

In a world where product safety and compliance are paramount, having the right tools makes all the difference. The CableEye^® HVX Series doesn’t just perform insulation withstand testing—it elevates it, ensuring your assemblies meet the highest standards of quality, safety, and reliability.

New CableEye M2Z

News

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Announcing the new CableEye M2Z

The all-new CableEye M2Z entry-level tester from CAMI Research provides essential continuity measurement in cables and small wire harnesses.

It is ideal for cables carrying digital signals or any electronic signalling where small amounts of resistance in the cable or connections will not affect the function of the equipment to which the cables are connected. The CableEye M2Z cable tester includes a 128-point fixture, a probe port, and electronics permitting it to test cables with up to 64 conductors.

Measurement for a typical cable completes in less than a second, with results displayed by LEDs on the tester as well as on the PC monitor.

We use industry-standard 64-pin dual-row latch headers as an interface to our plug-in connector boards and external test fixtures. Presently we have over 60 Connector Boards (CB) and most of them are directly compatible with the new CableEye M2Z

A standard Windows (7 and up) PC with one free USB port is all that is needed to use the powerful software supplied with the CableEye M2Z… exactly the same software used by the top-of-the-range CableEye testers.

The price includes a board set (CB15c), probe, operating software, power module, USB cable, Getting Started Guide, Software Introduction Booklet, User’s Manual (PDF), and Product Support Subscription.

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How to make easy CableEye backups

Wire & Cable Equipment, CAMI Research, News, Testing

Easy CableEye backups

Working with any programmable equipment really needs a way of keeping data secure. This page will show you how to make easy CableEye backups for your CableEye M2/M3/HVX tester from CAMI Research.

CableEye includes a built-in Backup and Restore function that has a number of uses:

to make secure regular backups to avoid data loss
to make a secure backup prior to upgrading any software
to copy the correct folder structure between computers
to send essential data to us for support

In the following video we are creating a data file for backups, but the process is the same for support requests or transferring data to another machine.

Of course, as CableEye is a PC based system, it is just as easy for you to send your backups to a network drive that is also included in your Company’s IT backup process, thereby creating another layer of security for your investment.

How frequently you make backups depends on how often you make changes in your software; however, as the process is so simple you should look to do this at least once per week. Perhaps at the close of business on Friday; however, our recommendation is daily.

Making life easy for our customers is a cornerstone of what we do at Cimbian UK.

For more information on CableEye or on how we can provide you with support just drop us a line by returning the form below:

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Generate test reports quickly and easily with CableEye

Wire & Cable Equipment, CAMI Research, Harness Testing, News, Testing

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In these days of traceability the ability to generate test reports is essential, but how easy can it be?

With a manual test using a buzzer, bulb or semaphore, generating test reports is also manual, generally involving a clipboard and a pen. Manual tests are normally restricted to ‘GO NOGO’ testing only unless a fault is suspected. What this means is that a positive connection from end-to-end marks a pass; however, it does not test for stray connections on other pins/cores in the cable. So an open circuit is a NOGO, and a short circuit is a GO. The potential, here, for allowing ‘False Accepts’ is huge.

Wiring mistakes, tin whiskers, faulty materials can all lead to shorts within the cable and are unlikely to be found. Overall, Manual testing is far from desirable, particularly if having to test AND generate test reports at the same time.

So, we come to ‘system’ testing of cables. Again, there are some products that will test GO NOGO on individual cores, albeit simultaneously. Aside from speed this kind of tester is no better than manual testing and is best avoided. The report may be generated by a simple ticket printer or the ubiquitous clipboard and pen.

Let’s now get a computer involved.

A computer will switch test points much faster and much more reliably than manual testing and can, therefore, test for connections that should NOT be present. Really good computer-based cable testers will also learn the connections (and resistances) from a known-good cable so there is no real programming involved.

Obviously, once we involve a computer we can generate test reports… or can we?

With an embedded computer this can often be a time-consuming task, particularly if it uses an operating system where printer drivers are not readily available.

Enter CableEye, from CAMI Research!

CableEye is Windows PC based where the ever-increasing power and speed of PCs can, and does, positively affect the overall performance of a test station. CableEye will generate test reports and print to just about any printer that has a Windows driver and will print to label printers for labels or A4 printers for generating test reports.

This video will demonstrate the ease and speed of loading a cable, testing a cable, getting the result and generating test reports:

Now THAT is cable testing…

For more information or the loan of a demo system, get in contact with us.

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Unique Braided Shield Cutting Machine

Wire & Cable Equipment, Boewe Elektrik, News, Shield cutting

Today we shipped another shield cutting machine, this time to Korea.

Because of automotive cables being under stress and in a generally harsh environment, it is critical that cables are produced and terminated correctly. As well as this, it’s also essential to avoid damage to the insulation of the inner cores.

Companies like Prettl, Korea, decided to invest in the BSF1004 shield cutting machine for their cable assembly operation in Kyunggi-Do, Korea.

The BSF1004, from Boewe Elektrik, offers a unique solution to a problem faced by most cable assembly companies, and that is, removing shielding, tapes, and liners etc. quickly, and without damaging the insulation of the inner cores.

With a wide range of different milling heads (cutters) for different diameter cables, the BSF1004 shield-cutting machine is versatile and provides totally repeatable results, even in the hands of low-skilled operators.

How do I use this machine?

The process is simple.

Remove the outer jacket
unbraid (using A BSB1005/B shield-brushing machine)
fold all the unwanted parts back over the jacket
place the inner conductors into the milling head
start the machine and push the bundle onto the cutter
Job done, and with no damage to the inner insulation!

Take a look at the video of the BSF1004 in action and judge for yourself: Click this link for video

We’d be happy to run a sample using your own cable, and video the process for you. Just drop us a line.

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Use your Cirris adaptor boards on your new CableEye

CAMI Research, Military, News, Testing

We are often asked to replace old (or not so old in some cases) Cirris cable testers with our CableEye system, often due to improved flexibility through the Windows PC control that it has.

One stumbling block is the number of interface adaptors that have been produced by the customer over the years; clearly not something they would like to do again.

What is needed is a Cirris converter…

CAMI Research has developed the CB34 Cirris converter board-set; a direct interface replacement that means it is normally a plug-and-go operation to reuse the old interface adaptors but with the benefit of using an up-to-date, PC-controlled system that self-learns cables, provides easy reports, data logs to a network and remote use of the data via internet… a true 21^st century Windows application.

The CB34 (Item #764 – Set of two boards) will accept one 64-point Cirris Adapter board or two 32-point Cirris adapter boards, and show results as a 64-pin header numbered 1-64 on each bank.

The CableEye software does not compute the board or cable signature or automatically identify which Cirris board is connected but it is a simple and quick task to use the PinMap software (Item #708), to obtain a proper graphic and pin numbering.

Most Cirris-made boards are numbered so that the test point number corresponds with the connector’s pin number, so the pin numbering shown on the 64-pin header will be correct even if the graphic is not.

You may use the CB34 Cirris converter with CableEye HVX systems. It has been certified to operate at test voltages of up to 1500vDC and 1000vAC, assuming that a suitably-rated Cirris board is also used.

It is now a simple and low-cost option for you to get a new, modern and very fast cable tester without the worry of losing your investment in all those adaptors. Drop us a line and we’ll do the rest.

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Ensuring Cable Safety with Insulation Withstand Testing: Why Precision Matters

Ensuring Cable Safety with Insulation Withstand Testing: Why Precision Matters