Transformer Tester Manufacturer for Accurate Transformer Testing and Diagnostics
Engineered for transformer manufacturers and electrical field service teams, our transformer testers integrate turns ratio, winding resistance, insulation power factor, and sweep frequency response analysis into compact, high-precision instrument architectures. Built to withstand strong electromagnetic environments, each unit delivers NIST/ILAC-traceable measurements compliant with IEC 60076 and IEEE C57 standards.
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Typical Applications
Transformer OEM Factory Acceptance Testing (FAT)
Automates multi-winding tap changer tests without manual wire changing. Reduces total test cycle time on a 110 kV transformer from 45 minutes to under 12 minutes.
Substation Commissioning & Preventative Maintenance
Monitors winding deformation, contact erosion in On-Load Tap Changers (OLTC), and insulation thermal degradation in severe field environments (-20°C to 55°C).
Industrial Plant Diagnostics
Detects turn-to-turn short circuits and core displacement in arc-furnace, drive, and solar/wind step-up transformers following overvoltage transients or short-circuit events.
Technical Specifications
TTR & DC Resistance Module
|
Parameter |
Specification |
|
Turns Ratio Accuracy |
±0.05% from 0.8 to 2,000; ±0.1% from 2,001 to 10,000 |
|
Test Voltage Output |
12 V AC, 40 V AC, 80 V AC, 100 V AC, auto-selectable |
|
Resistance Test Current |
10 mA / 1 A / 5 A / 10 A / 20 A / 50 A DC, selectable |
|
Resistance Resolution |
0.01 μΩ |
|
Resistance Accuracy |
±(0.2% of reading + 2 digits) |
|
Discharge Safety |
Built-in discharge circuit with audio-visual status indicators and automatic energy dissipation |
Insulation & Dielectric Diagnostics
|
Parameter |
Specification |
|
Power Factor / Tan Delta Resolution |
0.001% |
|
Power Factor / Tan Delta Accuracy |
±(1% of reading + 0.004%) |
|
Interference Suppression |
Frequency conversion technology: 45 Hz / 55 Hz and 47.5 Hz / 52.5 Hz |
|
Interference Resistance |
Designed to suppress power-frequency interference in substations up to 500 kV |
|
Data Interfaces |
USB host/device, RS-232, Ethernet |
|
Data Export Formats |
CSV, PDF, IEC 61850 database schemas |
Standards Compliance & Calibration
|
Parameter |
Specification |
|
Manufacturing & Test Standards |
IEC 60076-1/10, IEEE C57.12.90, ASTM D924, GOST 3484 |
|
Factory Testing |
72-hour thermal burn-in at 50°C ambient temperature |
|
Calibration Protocol |
100-point calibration before packing |
|
Calibration Certificate |
ISO/IEC 17025-accredited laboratory test certificate, ILAC-MRA compliant, stated validity of 12 months |
|
Recalibration Support |
Software-based calibration routines for local ISO/IEC 17025-accredited laboratories, without hardware modification |
[Raw Material Screening] -> [SMT Assembly & Optical Inspection] -> [72h Thermal Burn-In (50°C)]
|
[ISO/IEC 17025 Calibration] <- [High-Voltage Interference Stress Test] <----+
Component Selection: Instrumentation-grade operational amplifiers and high-precision current shunts with temperature coefficients below 5 ppm/°C.
EMC Shielding: Heavy-duty aluminium alloy housing with internal Faraday cage segmentation to protect low-voltage sensing electronics against induced high voltages.
Safety Isolation: Optical isolation between high-voltage generating modules and the user interface panel up to 10 kV DC.
Configuration & Support Options
mill CNC machine
Base Transformer Tester Unit (Rugged IP67 transport case)
Heavy-duty test lead set (10 m standard, 15 m / 20 m optional with gold-plated Kelvin clips)
Ground cable, power cord, RS-232/USB connection cables
Calibration Certificate, Factory Inspection Report, English User Manual
PC Diagnostic & Data Management Software (License-free, unlimited installation)
Spare Parts & Extended Technical Support
Lead Sets & Adapters: Custom terminal adapters for bushings, GIS systems, and non-standard connection posts.
Global Support: Direct engineering support for software integration, firmware updates, and remote diagnostic assistance.
Warranty: 24-month standard warranty; optional 36-month extended coverage with expedited replacement unit dispatch.
Our Certificate
ISO9001, ISO14001, ISO45001
FAQ
Q: How does the unit suppress strong power frequency interference in live 500 kV substations?
A: Our instruments utilize variable-frequency power sources combined with digital narrow-band filtering. By injecting test signals at non-power frequencies (e.g., 45 Hz and 55 Hz), the system isolates and filters out 50 Hz or 60 Hz induced currents, providing stable readings without external filter add-ons.
Q: Can the instrument test transformers with non-standard vector groups or single-phase units?
A: Yes. The built-in vector group recognition algorithm supports all standard IEC/IEEE configurations (Dyn11, YNd11, YNyn0, etc.) as well as single-phase, Scott, Z-type, and non-standard phase angle shift transformers without manual calculation.
Q: What safety mechanisms protect the instrument when testing high-inductance windings?
A: A multi-stage inductive energy dissipation circuit automatically locks the output terminals and discharges stored magnetic energy upon test completion or accidental power disconnection. An audible buzzer and visual LED display indicate real-time discharge status until voltage drops below safe threshold levels (12 V).
Q: Are lead resistance and temperature variations automatically compensated during DC resistance tests?
A: Yes. The four-wire Kelvin sensing configuration eliminates test lead resistance errors. The internal software features an automatic temperature conversion function (Tk values for Copper and Aluminum per IEC standards), calculating equivalent resistance values at standard reference temperatures (75°C or 85°C).
Q: What software capabilities are included for report generation and asset management?
A: The PC software connects via USB or Ethernet to import raw test files, display trend curves over time, compare historical baseline data, and generate customized PDF test reports compliant with utility company formats.
Q: How often is recalibration required, and can local calibration facilities perform it?
A: Recalibration is recommended every 12 months. The instrument software includes an open calibration mode with password protection, enabling any certified ISO/IEC 17025 calibration laboratory to perform adjustments without returning the unit to the factory.
Request a Quote / Contact Engineering
Looking for a custom lead length, specific test voltage range, or OEM packaging? Submit your requirements below to receive technical data sheets, test reports, and a formal quote within 24 hours.
Contact Email: wang@transformer-test.com
Technical Support Line: +8616630291792
Factory Location: Mancheng District, Baoding City, China
[ Request Technical Quotation ] | [ Download Datasheet (PDF) ] | [ Speak to an Application Engineer ]
Refine On (Hebei) Electric Power Technology Co., Ltd. is one of the most reliable transformer tester manufacturers and suppliers in China, also supports customized service. Please feel free to wholesale advanced transformer tester at competitive price from our factory. Contact us for quotation.
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