Production Tests of Insulation Systems Using Advanced iTIG II Technology

Modular and flexible test systems

Whether you manufacture motors, generators, alternators, reactors, various types of transformers or any type of coil, large or small, we probably have a solution for your winding tests. The iTIG II winding analyzer is used to test everything from solenoid coils and small sensors to utility type generators and form coils.

Electrom Instruments’ Production Line Test Automation Systems (PLTA) are based on advanced iTIG II technology and may be the flexible and cost effective solution you are looking for.

Full Range of Tests

The test systems are modular, there are options for what tests are included from surge only to multi test systems. Max output peak voltages range from 1kV to 40kV.

Features and Benefits

Tests Available

  • 4-wire winding resistance measurements
  • Inductance and impedance measurements
  • Various Insulation Resistance (megohm) tests
  • DC Hipot, Step Voltage tests and Ramp tests
  • AC Hipot tests
  • High Frequency Surge tests that find more faults than low frequency tests
  • Surge tests of assembled motors
  • Surge comparisons to master coils and master stators
  • Partial Discharge (PD) measurements under short-rise pulses (models D4P, D6P D12P and D15P)
  • Partial Discharge Inception Voltage (PDIV)
  • Historical trending of all tests including PD and incipient PD detection
  • NEW: Programmable pulse trains for advanced PD analysis and Non-Shorting Insulation Fault detection (NSIF option)

System Packages

For some applications, the system is an iTIG II Winding Analyzer with or without additional software. When it comes with additional production line test automaton software, the model changes from iTIG II to PLTA. For more complex applications it is a rack cabinet containing the various test components including a modular lead switching matrix.

System Features

  • All tests included in the PLTA package can be done on various types of coils, stators, assembled motors, generators, alternators, single phase or 3-phase equipment, etc.
  • The production lines can be single product or multi product.
  • The PLTA test system can be manual, semi-automatic or fully automatic. Tests can be started by the operator or by a PLC/PC.
  • Test information can be entered manually, a bar code scanner can be used, or it can be sent by a computer to the PLTA test system via a serial port interface.
  • For more complex test systems, information about the units to be tested can be retrieved by the PLTA test system. In conjunction with another input such as a bar code scanner the PLTA will determine test parameters and pass/fail limits for each unit to be tested.
  • Modular lead switching matrix: The matrix is sized to handle the maximum number of motor (DUT) connections for your application.
  • Complete sets of test data can be exported to a server allowing advanced data analysis. Data transfer is done using a Flash Drive, an Ethernet connection, or wireless network connection.


  • Handles single coils, single phase motors, and 3 phase motors with 3 leads.
  • Uses a standard iTIG II with additional software
  • Max peak output voltage ranges from 1kV to 12kV

PLTA-6 to PLTA-12

  • Handles single coils and single phase motors as well as motors with 3, 6, 9 or 12 leads.
  • Rack cabinet containing the various test components including a modular lead switching matrix for the required number of leads.
  • Max peak voltage outputs range from 4kV to 40kV

Summary of Available Features:

  • Peak output voltages from 1kV to 40kV
  • Modular lead switching matrix to meet your needs
  • Single or multi product production lines
  • Manual, semi-automatic or fully automatic systems
  • File driven testing for stand-alone operation
  • Interface option for PLC/PC control of the system
  • Bar code reader / interface
  • Fully configurable test sequences
  • Configurable test limits and test parameters
  • Stored reference coil/motor capability
  • Self-test capability
  • Input/outputs for safety mats, curtains, warning lights and fault indicator light
  • Safety accessories
  • Network interface to remote servers for test control data download and/or test results upload
  • Windows 7 Embedded OS

Please contact us to discuss your application.

Click here for a more detailed summary available features