Industry 4.0



ASAInsuTrack707+™ is a fully automated Tracking Wheel compliant with IEC 62217 and CSA 156.1 standards. ASAInsuTrack707+™ uses a revolutionary and efficient design for testing diverse types of distribution (15 to 35 kV) insulators including dead-ends, station posts, and line posts. This version also supports cutout switches rated between 15kV and 28kV. ASAInsuTrack707+™ is a versatile and modern testing platform for product validation, accelerated life cycle testing and insulator performance verification. ASAInsuTrack707+™ is designed, developed and manufactured in Canada.

Standards and Industry Benchmarks

Dead-EndStation PostLine PostCutout
IEEEC37.41 & C37.42

A culmination of decades-long research, development and product design, ASAInsuTrack707+™ is helping utilities, manufacturers and product designers apply modern materials, methodologies and Industry 4.0 principles in their grid modernization efforts. While traditional insulator technologies have a strong foothold in the industry, changing operating conditions, system stress, and effects of climate change and pollution, advances in manufacturing and materials technologies are revolutionizing the insulator industry.  ASAInsuTrack707+™ is proudly made in Canada with our traditional values of rugged, modern and reliable performance. Let us help you move forward!

What is a tracking wheel? 

A tracking wheel, alternatively known as a tracking wheel test or tracking test, is a technique used to evaluate the resistance of insulating materials, particularly composite insulators, to tracking and erosion. This was first introduced in Canada in the 70s and then further developed by other institutes. 

The name “tracking wheel” comes from the equipment used in the test setup, which includes a rotating wheel that carries the insulating samples through different stations where they are exposed to potential testing conditions. Overall, tracking wheel tests are essential for assessing the performance and reliability of insulating materials used in electrical equipment and systems, helping to ensure their safety and longevity during service. 

What is tracking wheel testing?

The Tracking Wheel Test is an accelerated life cycle test for insulators’ resistance to insulation surface tracking and erosion. The electric utility industry requires tracking wheel tests to confirm the performance and reliability of insulators, cutouts and other equipment to ensure their safety and longevity in service. During a tracking wheel test, insulating samples are subjected to various environmental conditions, such as high voltage and contaminant solutions, to simulate real-world conditions. The test typically involves exposing the insulating material to a combination of electrical stress and environmental factors, which can accelerate the aging process and reveal any weaknesses in the material’s resistance to tracking (surface breakdown due to electrical stress) and erosion (surface deterioration due to environmental factors). 

The Tracking Wheel Test is utilized to accelerate the aging process of composite insulators to test their resistance to tracking and erosion. There are 4 stations in testing, and the insulator should stay at each station for approximately 40 seconds. In the first station, the insulator is dipped in a contaminant solution. Following this, the insulator moves to the next station to drip off any excess contaminant solution. The insulator is supplied with high voltage at the next station where damage is inflicted to the product. The insulator then moves to the final station where it cools before starting the next cycle. The expected time to transition between stations is around 8 seconds. Standards for this testing require a total test duration of a minimum of 30,000 cycles. This includes repeated cycles of wet cycles and dry cycles to simulate outdoor operating conditions encountered in the field.

Revolutionary design

ASAInsuTrack707+™ is specifically designed to meet the goal – “anyone can operate.” A user-friendly and modern HMI supports initiating, configuring and monitoring the test cycles. A built-in data logger records all test parameters including voltage applied, cycles completed cycles remaining and the leakage current during operation.

ASAInsuTrack707+™ is designed to automatically detect tripping faults, smoke due to the burning of material, and any hardware/firmware issues. The operator is alerted automatically via email of all events of interest.  The fully operated operation includes an automated lift platform to support a 24-hour dry cycle followed by a wet cycle. Sensors maintain the level of water in the tanks and an agitator prevents contaminants from accumulating on the bottom of the tanks. The design allows different lengths and types of insulators.

Ushering Industry 4.0 – Set it and Forget It

ASAInsuTrack707+™ exemplifies Industry 4.0 features:

  • Fully automated design –  “Anyone Can Operate.” 
  • Modern, fully integrated HMI with built-in data logging and real-time monitoring 
  • Predictive maintenance and self-diagnosis capabilities
  • Zero manual intervention, increased productivity, safety and efficiency.

For more information regarding insulator failure versus insulator technology failure, click here.

ASAInsuTrack707+™ Technical Specifications

ManufacturerASAsoft™ (Canada) Inc.
ModelHALT – TW1
Input Voltage240 VAC 3Ph
Testing range0 – 35,000V
Rated Frequency 50/60Hz (check power supply)
Dimension [testing platform]   L x W x H 129 x 42 x 112 in
Dimension [control panel]L x W x H40 x 41.5 x 71 in
Current rating50A (NEMA 14-50)
Interrupting Rating10kA
Test objects supported15kV – 35kV: Dead-ends, Station Post and Line Post
15kV – 28kV: Cutout switches
Tank Capacity400L per tank
High Voltage contact time40s per insulator
Total duration for 1 cycle200s
Pre-set Cycle (Cycle duration with full dip tank)30,000
Total test TimeDays per spec
Testing optionsUser configurable 50%, 100%, 150% of pre-set cycle and user set cycles 

To learn more, refer to our whitepaper titled “Design and Construction of an Advanced Tracking Wheel for Insulator Materials Testing“.