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Transformer Comprehensive Test System

type:ZC-200-5000kVA-33kV
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  • Product Introduction
System Overview
1.1 Test object required
1. Transformer specification: 33kV/ 0.4kV;
2. Transformer Maximum capacity: 50kVA ~ 5000kVA;
1.2 Analysis of no-load loss and load loss
1.2.1.For no-load test and load test, the maximum capacity of the transformer is 5000kVA, and the rated current at the high-voltage side is 87.4773A; Low voltage side rated current 7216.878A;
1.2.2.During no-load test, apply voltage at the low-voltage side of the transformer, and the system needs to provide 0.4kV voltage output; The percentage of no-load current is considered as 0.5%, the maximum no-load current is 36.0843A, and the total power required is 25kVA;
1.2.3.During the load test, the voltage is applied at the high voltage side of the transformer, the percentage of short-circuit impedance voltage is considered as 6.5%, the maximum applied voltage is 2.145kv, the maximum current is 87.4773A, and the total power required is 325kVA;
1.3 Conclusion
1.3.1.The system is equipped with an induction voltage regulator of 0.4kV/650V/100kVA, an intermediate transformer of 0.4kV/2.2kV/100kVA, and a reactive power compensation power cabinet of 500kVA/3kV to meet the power requirements for the no-load and short-circuit tests of the above products.
1.3.2.The no-load test voltage of a 33kV/0.4kV transformer is directly measured by the transformer power analyzer.
1.3.3.For the short-circuit test of a 33kV/0.4kV transformer, the voltage is measured through a 3kV/100V voltage transformer.

1.3.4.During the no-load and load characteristics tests of a 33kV transformer, the current is measured by a current transformer. The current transformer's gears include: 100A, 50A, 25A, 10A, 5A, 2.5A, 1A/1A, totaling seven gears, with an accuracy level of 0.05S.


Test items:

1.No load characteristic test of transformer

2.Transformer load characteristic test

3.Transformer ratio group error test

4.Withstand voltage test of transformer

5.Frequency doubling withstand voltage test of transformer

6.Power transformer insulation test

7.DC resistance test of power transformer




  • Product Parameters


List of test items and equipment
Equipment NameType No.Qty.Remark
Main Control Bench
Integrated Bench of automatic test systemZC-200

1 pcs


High voltage test auxiliary control cabinetZC-200-HA-33

1 pcs


Automatic test software system

1 set


Industrial computers and printers

1 set


Transformer characteristic test
Transformer power analyzerZC-2011 pcsEmbedded in the Bench
Three phase induction voltage regulator100kVA/400V/650V1 pcsControlled by the Bench
Intermediate step-up transformer 100kVA/0.4kV/2.2kV1 pcs
Reactive compensation power cabinet 500kVA/3kV1 pcs
Withstand voltage test
AC test transformerZC-501/25kVA/100kV1 set

Controlled by the Bench

Double frequency withstand voltage test
Medium frequency generator setZC-432/50kVA1 set

Controlled by the Bench

Transformation ratio test
Transformer Winding Resistance and Ratio Comprehensive Tester ZC-2081 pcs
Insulation resistance test
Insulation resistance testerZC-430D 5kV1 pcs



Equipment Technical Index 
ZC-112 standard current transformer
Primary rated current 100A, 50A, 25A, 10A, 5A, 2.5A, 1A
Secondary current1A
Operating frequency50 ~ 200Hz
Shift modesecondary side switching
Accuracy level0.05S
Rated capacity1VA
Power factor0.8
Insulation level3KV
ZC-122 Standard VT
Primary voltage3kV 
Second voltage100V 
Working frequency50~200Hz
Nominal load5VA
Accuracy0.05
Power factor
Insulation level5kV
Structuredry air cooling
Bureau volumeless than 10pC
ZC432/50kVA  Medium frequency generator set
Rated capacity50KVA
Rated input voltagethree-phase four wire 400V / 50Hz
Rated output voltagethree-phase 0~800V / 150Hz
Rated speed1480r / min
Power factor0.8
Waveform distortion rate of output voltage≤ 2%
ZC501A-25kVA/100kV AC test transformer
Input voltage400V, 50Hz
Output voltage0 ~ 100kV
Capacity25kVA
The accuracy level of voltage measurement± (2%) × Reading (+ 1KV)
ZC-201 Transformer Power Analyzer
Frequency measurement range40~65Hz, measurement accuracy level 0.2
Current measurement range100mA~5A, measurement accuracy level 0.2
Voltage measurement range10V~650V, measurement accuracy level 0.2
ZC-208 Transformer Winding Resistance and Ratio Comprehensive Tester
Environmental conditions
Temperature-5℃~40
Relative humidity<95% (25℃)
Altitude<2500m
External interferenceno strong vibration, no strong electromagnetic field
Power supply160VAC~280VAC, 45Hz~55Hz
Transformer ratio measurement range and accuracy
Test range of transformation ratio0.5 ~ 10000
Group test range1~12
Angle difference test range0~360°
Measurement accuracy of transformation ratio+0.1% (1~200); +0.2% (201~2000); +0.35% (2001~4000); +0.5% (4001~10000)
Angle difference measurement accuracy30
DC resistance test range and accuracy
Range

0-180mΩ  (10A)             180mΩ-360mΩ (5A)       360mΩ-1.8Ω  (1A)  

1.8Ω-4.5Ω (400mA)        4.5Ω-9Ω  (200mA)          9Ω-45Ω  (40mA)

45Ω-20kΩ  (<5mA)        0 mΩ-20kΩ(Automatic)

Accuracy+0.2% ±2μΩ 
Resolution0.1μΩ
Insulation strength
The insulation resistance of the voltage and current input terminals to the case is ≥100MΩ
The power frequency is 2KV (effective value) between the input end of the working power supply and the shell, and the experiment lasts for 1 minute
ZC430-5kV Insulation Resistance Tester
AC Power220V±10%,50/60 HZ ,20 VA
Battery16.8V Lithium ion rechargeable battery 
Battery Life5000V@100MΩ, 6 hour 
Test voltage accuracythe nominal value  100% to 110%
Voltage measurement accuracy5%+3V
Current test range10mA
Current measure precision5%+0.2nA
Short-circuit current5mA
Capacitance test range20uF
Capacitance testing accuracy15%+0.03uF
Capacitor discharge ratefrom 5000V to 10V,0.5S/µF

Insulation resistance testing range and accuracy

T:23±5ºC ,RH :45 – 75%
Size/Weight26cm x 20cm x 16cm/3kg


  • Product Features

1.Safe and reliable

① The high-voltage test has a grounding verification function, and the test transformer cannot be closed without grounding with the tested object;

② During the ratio test, it has the function of checking the high and low voltage wiring, and automatically alarms and prompts when the high and low voltage sides are connected in reverse;

③ The closing of the voltage regulator has a zero position check function, and it cannot be closed when the voltage regulator is not in the zero position;

④ Equipped with a software, electrical, and mechanical three-level safety interlock design mechanism to prevent misoperation;

⑤ Equipped with software and hardware two-stage overvoltage and overcurrent protection mechanisms;

2.Efficient system working     

① After setting the nameplate parameters of the test object on the computer, automatically generate the test parameters for each test item, and connect the test equipment to automatically complete the test;

② The transformation ratio test and direct resistance test can be connected once, and the equipment automatically completes the transformation ratio test and direct resistance test of all windings;

③ All experimental projects can be completed through a computer, which automatically collects test results and generates reports;

3.High measurement accuracy   

① The CT and PT used in the system have an accuracy of 0.05 level and can be independently calibrated;

② The transformer ratio test, direct resistance test, power analyzer, etc. are all equipped with equipment not less than 0.2 level;

③ The instrument samples at high speed in real time and calculates the results. Computer software is used to collect test results, so the test process and results are not affected by computer configuration and communication bandwidth;

4.Simple operation and convenient maintenance

① The operation software has functions such as testing process guidance, wiring diagrams, online help, etc., which can enable testers to quickly get started;

② The system has three operating modes: manual, semi-automatic, and fully automatic, and the fully automatic mode provides a simple and efficient working mode; Manual and semi-automatic systems facilitate system debugging and maintenance;

③ The system adopts a distributed modular design for easy maintenance and replacement;


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