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Fully Automatic Transformer Testing System 2500kVA 35kV Transformer Comprehensive Test Bench for Power Transformer Inspection
✔ Fully automatic one-key test
✔ Integrated multi-function testing
✔ High precision test data
- Overview
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Product Overview
This GDBZ‑IV fully automatic transformer comprehensive testing system is developed for routine, type and special tests of 30‑2500kVA, 10‑35kV oil‑immersed and dry‑type distribution transformers. Adopting Siemens PLC as core controller together with industrial PC human‑machine interface, it integrates multiple test functions including insulation resistance, turns ratio, DC resistance, no‑load & load loss, power‑frequency withstand voltage, induced withstand voltage, temperature rise, noise, lightning impulse and insulating oil analysis into one complete testing platform. It complies with GB1094 series and related industry standards, realizing automatic test execution, data acquisition, calculation, storage and report output.
Key Advantages
1. Integrated Multi-item Automatic Testing
Supports 11 main transformer test items. Complete full sequence tests with one-time wiring, eliminating repeated manual reconnection and boosting inspection efficiency.
2. High-precision Measuring Configuration
Adopts Yokogawa WT500 power analyzer and 0.05-grade high-precision sensors, delivering stable, repeatable test results for loss, resistance and turns ratio.
3. Dual-layer Control & Anti-interference Design
PC+PLC dual control with RS-485 isolation communication. Resists high voltage interference, with adjustable voltage/current rise and fall speed.
4. Multi-level Comprehensive Safety Protection
4-stage protection system with emergency stop, audible & visual alarm, zero-boost interlock, overvoltage & overcurrent protection to protect personnel and equipment.
5. Convenient Data Management & Custom Report
Auto save test data, support data query, Excel export and printing. Customizable report templates and user-friendly HMI.
6. Modular Expandable Structure
Container integrated cabinet with reserved interfaces. Optional lightning impulse and insulating oil test modules for function expansion.
Applications
This testing system is widely used in: ‑ Transformer manufacturing factory factory acceptance test (FAT) ‑ Routine & type test for 10‑35kV oil‑immersed / dry‑type distribution transformers ‑ Transformer repair and re‑winding workshop verification test ‑ Power research institute and quality inspection laboratory ‑ Non‑ferrous metallurgy & power equipment manufacturing enterprises
Main Equipment Configuration
| No | Name | Qty (set) | Application of equipment |
| 1 | GDBZ‑IV Integrated Test Console | 1 | Human‑machine operation, centralized status monitoring |
| 2 | Siemens S7‑200 PLC Control Cabinet | 1 | System logic control, signal distribution & protection |
| 3 | Yokogawa WT500 Power Analyzer | 1 | High‑precision power & loss parameter measurement |
| 4 | Full‑set Special Test Instruments | 1 | Ratio, DC resistance, temperature & insulation resistance measurement |
| 5 | 100kVA Three‑phase Variable‑frequency Power Supply | 1 | Adjustable‑frequency excitation source for no‑load, load & induced withstand test |
| 6 | 200kVA Intermediate Transformer | 1 | Voltage conversion for high‑voltage test conditions |
| 7 | 30kVA/100kV High‑voltage Test Transformer | 1 | Power frequency withstand voltage test |
| 8 | 100kVAR High‑voltage Capacitor Compensation Device | 1 | Reactive‑power compensation for load & temperature‑rise test |
| 9 | Lightning Impulse & Insulating Oil Test Units | 1 | Lightning impulse test and full insulating‑oil performance analysis |
FAQ
Q1: What capacity & voltage level of transformers can this system test?
A: It is applicable for three‑phase transformers of 30‑2500 kVA, high‑voltage grade up to 35kV, covering oil‑immersed and dry‑type distribution transformers.
Q2: Can test reports be customized and exported?
A: Yes. All test data is stored in database. Reports support custom template editing, export to Excel format or direct printer output.
Q3: How does the system guarantee safety during high‑voltage tests?
A: It adopts four‑level protection mechanism, equipped with emergency‑stop, audible‑visual alarm, zero‑boost interlock and multi‑layer over‑voltage / over‑current protection. PLC and computer are electrically isolated to avoid high‑voltage interference damage.
Q4: Is it possible to add extra test functions later?
A: Yes, the system adopts modular design. Lightning impulse, oil analysis and other peripheral instruments can be expanded according to actual requirements.
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