NKE-DTTS-SP-AUTO/5000 Super Fully Automatic Distribution Transformer Test System
Product Overview
The NKE-DTTS-SP-AUTO/5000 super fully automatic distribution transformer test system adopts an integrated containerized design, consolidating core components such as the inverter power supply, intermediate transformer, measurement unit, and switches into a single containerized unit, greatly simplifying transportation and installation. This system features fully automated testing capabilities, supporting complete transformer test procedures with a single wiring connection, covering DC resistance, turns ratio, insulation resistance, no-load loss, load loss, induced withstand voltage, and applied withstand voltage tests. Optional functions include temperature-rise testing and partial-discharge testing. Relying on computer programs to automatically execute test procedures, process data, and generate comprehensive factory test reports, it completely replaces traditional manual operation modes, significantly improving testing efficiency and data accuracy. The product strictly complies with IEC 60076 / IEEE C57.12.90-2021 international standards, equipped with 0.05-class precision current transformers and YOKOGAWA WT500 series or higher power analyzers, suitable for dry-type and oil-immersed three-phase transformers up to 38.5 kV and 5000 kVA. Special-parameter samples can be provided upon request, fully meeting the factory inspection needs of global transformer manufacturers.
Core Technical Configuration
1. Integrated Hardware Architecture: The system integrates the inverter power supply, intermediate transformer, high-precision measurement unit, and control switches into a single containerized unit, achieving equipment integration without additional assembly or debugging, allowing for rapid deployment upon arrival at the site.
2. High-Precision Measurement Components: Equipped with 0.05-class precision current transformers to ensure accurate acquisition of voltage and current data, providing a reliable data foundation for loss tests, turns-ratio tests, and other applications; utilizing YOKOGAWA WT500 series or higher power analyzers, which offer excellent power measurement accuracy and stability, guaranteeing precise testing of key parameters such as no-load loss and load loss.
3. Fully Automated Control System: Built-in intelligent computer programs automatically handle all stages of the testing process, including switching test items, adjusting parameters, collecting data, and calculating results, eliminating the need for manual intervention, minimizing human error, and generating standardized factory test reports, thereby enhancing the standardization of the testing workflow.
Adapted Parameter Range
1. Applicable Transformer Types: Three-phase dry-type transformers, three-phase oil-immersed transformers
2. High-Voltage Side Voltage: Up to 38.5 kV (covering the range from 38.5 kV to 4.16 kV)
3. Low-Voltage Side Voltage: 0.12–2.5 kV
4. Transformer Impedance: 2–10%
5. Transformer Capacity: Up to 5000 kVA
6. Compliance Standards: IEC 60076 / IEEE C57.12.90-2021
Core Test Items
1. DC Resistance: Precisely measures the DC resistance of transformer windings, assessing winding solder quality and verifying compliance with design specifications, while identifying potential faults such as short circuits or open circuits.
2. Turns Ratio and Connection Group Testing: Evaluates turns-ratio errors and connection group classifications, ensuring voltage conversion accuracy meets design standards and maintaining compatibility during grid-connected operations.
3. Insulation Resistance: Measures insulation resistance between transformer windings, core, and housing, assessing insulation performance and detecting issues like aging or damage to insulation, thus ensuring electrical safety.
4. No-Load Loss: Measures transformer losses under no-load conditions, evaluating core material properties and manufacturing process rationality, providing data support for energy-saving optimization.
5. Load Loss: Simulates rated-load conditions to measure transformer losses, assessing winding resistive losses and additional losses, and evaluating winding manufacturing quality and heat-dissipation design adequacy.
6. Induced Withstand Voltage Test: Applies induced voltage to assess the insulation's ability to withstand voltage, identifying localized defects in the insulation layer and ensuring safety under overvoltage conditions.
7. Applied Withstand Voltage Test: Applies specified voltages between windings and ground, as well as between windings, to evaluate overall insulation strength and verify electrical safety performance.
8. Optional Test Items: Temperature-rise testing simulates load conditions to monitor temperature changes across various transformer parts, assessing cooling-system performance; partial-discharge testing detects internal partial discharges, enabling early identification of potential insulation faults.
Core Advantages
1. Complete Testing with a Single Wiring Connection: Eliminates the need for repeated wiring changes, covering all routine test items with one connection, drastically reducing operational steps and compressing the traditional multi-hour testing process into just a few minutes, boosting detection efficiency by over 90%.
2. Fully Automated Process Management: Computer programs autonomously execute the entire testing, calculation, and report-generation workflow, completely avoiding human adjustments and manual data transcription that can lead to misjudgments and errors, ensuring the accuracy and consistency of test data.
3. Containerized Integrated Design: All equipment is consolidated within a container unit, offering excellent mobility and portability, facilitating cross-border transportation and on-site deployment, particularly suited for overseas factories and temporary testing sites, with installation and commissioning times shortened to just a few hours.
4. High-Precision Measurement Assurance: The combination of 0.05-class precision current transformers and YOKOGAWA WT500 series power analyzers ensures test data accuracy meets international standards, providing a reliable basis for transformer factory quality.
5. International Standard Compliance: Designed and manufactured in strict accordance with IEC 60076 / IEEE C57.12.90-2021 standards, with test reports conforming to global market access requirements, helping transformer manufacturers expand into overseas markets.
6. Flexible Customization Support: Special-parameter samples can be provided upon request, adapting to non-standard transformer testing needs and satisfying the personalized testing scenarios of different manufacturers.
Core Product Value
1. Efficiency Enhancement: Optimizes the traditionally cumbersome multi-step testing process into a "one-click" automated operation, significantly shortening factory inspection cycles and boosting transformer production and delivery efficiency, helping manufacturers meet large-scale production demands.
2. Quality Assurance: High-precision measurement equipment and automated processes eliminate human error, ensuring each transformer's test data is accurate and reliable, increasing the pass rate of factory inspections and reducing post-sale quality risks.
3. Cost Reduction: Reduces labor-intensive operations, lowering manpower costs; integrated design cuts equipment handling and assembly expenses; efficient testing workflows improve site utilization, indirectly reducing production and operational costs.
4. Global Adaptability: Designed to meet international standards and featuring containerized portability, it supports rapid deployment at overseas factories, helping manufacturers smoothly expand into global markets and comply with diverse national regulatory requirements.
Target Customer Groups
Global three-phase transformer manufacturing plants, smart transformer producers, transformer export traders, power-equipment testing institutions, manufacturing enterprises undertaking overseas transformer contract manufacturing, and power-equipment manufacturers advancing smart-manufacturing upgrades.
Application Scenarios
1. Factory Inspection at Transformer Manufacturing Plants: As a core inspection device at the end of the production line, it completes full-compliance testing for every 5000 kVA and below transformer leaving the factory, issuing standardized factory test reports.
2. Smart Factory Intelligent Manufacturing Upgrade: Integrated into automated production workflows, achieving unmanned and intelligent inspection processes, elevating the overall automation level of the factory and aligning with Industry 4.0 trends.
3. Specialized Testing for Custom Transformers: Provides tailored testing services for custom transformers with special parameters, meeting quality verification needs for non-standard products.
4. Deployment at Overseas Factories: Leveraging its containerized portability, it can be swiftly transported to overseas production bases, completing equipment installation and commissioning to ensure overseas factories maintain testing capabilities consistent with domestic standards.
5. Third-Party Power-Equipment Testing: Offers high-precision, standardized transformer testing solutions to third-party testing agencies, fulfilling clients' compliance-testing requirements.
Solutions to Industry Pain Points
1. Addressing the Pain Point of Traditional Testing Complexity: Conventional transformer testing requires repeatedly disconnecting and reconnecting wires for different test items, involving numerous steps and consuming significant time. This system completes all test items with a single wiring connection, thoroughly simplifying the operation process and saving substantial time and costs.
2. Eliminating Risks of Human Error: Manual adjustments of voltage, gear shifts, and data transcription are prone to misjudgments and mistakes that affect test data accuracy. This system employs fully automated process management, completely replacing manual operations and ensuring precise, reliable data.
3. Enhancing Data Processing Efficiency: Manually organizing and calculating test data is inefficient and error-prone. This system automates data processing and report generation, producing standardized reports with accurate data that can be directly used for factory registration and customer delivery.
4. Solving Equipment Transportation Challenges: Traditional testing equipment is scattered across multiple independent instruments, making transport and relocation difficult. The containerized integrated design enables unified movement of all equipment, facilitating convenient transportation, quick installation, and commissioning, and accommodating diverse site usage needs.
Frequently Asked Questions (FAQ)
Q1: What types of transformers can this system test?
A: This system is compatible with three-phase dry-type and three-phase oil-immersed transformers up to 5000 kVA, supporting high-voltage sides up to 38.5 kV and low-voltage sides ranging from 0.12 to 2.5 kV.
Q2: How does the system ensure test accuracy?
A: Equipped with 0.05-class precision current transformers and YOKOGAWA WT500 series or higher power analyzers, the system's measurement accuracy meets IEC 60076 / IEEE C57.12.90-2021 international standards, ensuring precise and reliable test data.
Q3: Does the system support testing of transformers with special parameters?
A: Yes, for custom transformers with special parameters, we can provide adapted test samples upon request to meet the testing needs of non-standard products.
Q4: How long does it take to install and deploy the system?
A: With its containerized integrated design, after transportation to the site, only basic wiring and power connections are required before the system can be put into operation. In typical scenarios, installation and commissioning take no more than 48 hours.
Q5: Do the test reports comply with international market requirements?
A: The system is designed in strict accordance with IEC 60076 / IEEE C57.12.90-2021 standards, and the automatically generated factory test reports meet the market-access compliance requirements of most countries worldwide, making them directly applicable for product export registration.
