Transformer Comprehensive Test System | VS-ZHSY

Products Details

The VS-ZHSY is built as a complete transformer test platform for production and laboratory environments where multiple transformer test items must be completed with consistent wiring logic, controlled operation, and traceable data. Instead of using separate instruments independently, the system integrates the main test units into a coordinated control bench, helping users improve test workflow and reduce repeated manual switching.

The system is suitable for power transformers with capacity up to 10000 kVA. The referenced scheme covers transformer voltage levels including 33 kV, 22 kV, 11 kV, 6.6 kV, 3.3 kV, 1.0 kV, 0.63 kV, 0.41 kV, and 0.38 kV. It can be configured for both oil-immersed and dry-type transformer testing according to the user’s transformer range and test requirements.

The control architecture combines PLC logic with an industrial computer human-machine interface. Operators can control the test bench through software or through panel buttons. The software mode and button mode are interlocked, so the system works under one selected operation mode at a time. This helps avoid conflicting commands during voltage regulation, generator operation, range switching, or withstand voltage testing.

For transformer characteristic tests, the VS-ZHSY manages voltage regulation, CT range switching, and measurement data acquisition. During no-load and load testing, the system can record test voltage or current and calculate key transformer test results under rated conditions, including no-load loss, no-load current, no-load current percentage, load loss, and impedance voltage.

For withstand voltage testing, the system integrates the control of the power frequency test transformer and related protection functions. The technical scheme includes a 20 kVA / 100 kV power frequency test transformer and a withstand voltage control cabinet with an internal 20 kVA regulator, enabling 0-100 kV power frequency withstand voltage output according to configuration.

For induced withstand voltage testing, the system can control the medium-frequency generator set, including start, stop, excitation adjustment, output control, and test timing. Operators can set protection current, test voltage, and withstand time through the control interface before starting the induced voltage test.

Specification

Technical Parameters
Item	Specification
Product Model	VS-ZHSY
Product Type	Transformer comprehensive test system / transformer test bench
Control Mode	PLC control with industrial computer interface
Operation Modes	Computer software mode and panel button mode
Operation Interlock	Software mode and button mode are mutually interlocked
Main Function Interlock	Characteristic test, power frequency withstand test, and induced withstand test are mutually interlocked
Applicable Transformer Capacity	Up to 10000 kVA
Applicable HV Rated Voltage	33 kV, 22 kV, 11 kV, 6.6 kV
Applicable LV Rated Voltage	3.3 kV, 1.0 kV, 0.63 kV, 0.41 kV, 0.38 kV
Supported Test Item	Transformer ratio and vector group test
Supported Test Item	Transformer DC winding resistance measurement
Supported Test Item	Insulation resistance measurement
Supported Test Item	Partial discharge test
Supported Test Item	No-load test
Supported Test Item	Load test
Supported Test Item	Power frequency withstand voltage test
Supported Test Item	Induced withstand voltage test / double-frequency induced voltage test
Power Supply Input	Three-phase four-wire system from power distribution room
Power Management	Main power cabinet controls system power distribution
Measurement Cabinet	Built-in voltage and current transformers with range switching
Characteristic Tester	Transformer no-load and load loss measurement unit with computer data exchange
Withstand Voltage Control Cabinet	Built-in 20 kVA regulator and protection/control functions
Power Frequency Test Transformer	20 kVA / 100 kV
Power Frequency Withstand Output	0-100 kV according to regulator output
Medium-Frequency Generator Set	VSZF-100 kVA configuration referenced in scheme
Induced Test Note	Generator configuration should be matched to transformer capacity and test requirement
Induction Voltage Regulator	400 kVA
Intermediate Transformer	400 kVA
Compensation Capacitor	1000 kvar integrated in intermediate transformer control cabinet
Auxiliary Instrument	Insulation resistance tester
Auxiliary Instrument	Insulating oil dielectric strength tester
Referenced Standards	GB 1094 series, GB/T 1094.10, GB/T 16927.1, GB 50150, JB/T 501, GB/T 6451, GB/T 10228, GB/T 25438, GB/T 25446, GB/T 507, IEC 60076 series

Product Guide

Before using the VS-ZHSY Transformer Comprehensive Test System, the operator should confirm the transformer capacity, voltage level, winding connection group, and required test items, then select the matching system configuration and connect the transformer according to the selected test procedure. After the main power cabinet is energized, the user can choose either computer software mode or panel button mode, with the two modes automatically interlocked for safe operation. For ratio, vector group, DC resistance, insulation resistance, no-load, load, power frequency withstand voltage, and induced withstand voltage tests, the operator sets the required range, voltage, current, protection value, and test duration through the control interface or panel controls. During characteristic testing, the system records measured data and calculates rated-condition results such as no-load loss, no-load current percentage, load loss, and impedance voltage. After each test item is completed, the function should be reset before starting the next test, and the final data can be saved, uploaded, or used to generate the transformer test report.

Features

• Supports comprehensive transformer factory and routine testing.
• Measures transformer ratio and vector group.
• Measures transformer winding DC resistance.
• Measures insulation resistance according to configured instrument.
• Supports partial discharge test workflow integration.
• Measures no-load loss, no-load current, and no-load current percentage.
• Measures load loss and impedance voltage.
• Provides power frequency withstand voltage test control.
• Provides induced withstand voltage test control.
• Automatically interlocks software mode and button mode.
• Automatically interlocks test functions so only one main test function operates at a time.
• Displays test operation through an industrial computer interface.
• Calculates characteristic test results under rated conditions.
• Includes power management, measurement cabinet, withstand voltage control cabinet, generator control, and auxiliary test instruments according to configuration.
• Supports data upload and report generation for transformer ratio and DC resistance test instruments.

Application Scenarios

The VS-ZHSY is suitable for transformer manufacturers that need a centralized test system for finished product inspection. It allows production teams to complete multiple factory test items in one test area, reducing the need to move the transformer between separate instruments and test stations.

For transformer repair and maintenance companies, the system can support post-repair verification of winding resistance, transformer ratio, insulation condition, no-load behavior, load characteristics, and withstand voltage performance. This helps confirm whether the transformer is ready for return to service.

For research institutes and inspection organizations, the VS-ZHSY provides a structured platform for routine tests, type-test preparation, and comparative transformer performance evaluation. The combination of computer control, measurement cabinet range switching, and integrated instruments supports repeatable test procedures.

For power equipment laboratories, the system can be configured around the transformer voltage level and capacity range. Users can select the appropriate generator, regulator, intermediate transformer, compensation capacitor, withstand voltage transformer, and auxiliary test instruments according to actual test scope.

Applications

• Power transformer factory test
• Distribution transformer routine test
• Transformer type-test preparation
• Transformer no-load loss measurement
• Transformer load loss measurement
• Transformer impedance voltage measurement
• Transformer ratio and vector group test
• Transformer DC winding resistance test
• Transformer insulation resistance test
• Transformer partial discharge test workflow
• Power frequency withstand voltage test
• Induced withstand voltage test
• Transformer repair verification
• Transformer laboratory inspection
• Transformer production quality control

Customer Case

A transformer manufacturer needed to improve the efficiency of final inspection for distribution transformers with different voltage levels. Before using an integrated system, operators had to coordinate several independent instruments, regulators, and control devices, which increased wiring time and made data management less consistent.

The factory configured the VS-ZHSY Transformer Comprehensive Test System for transformers up to 10000 kVA. The system integrated the main control bench, power management cabinet, voltage/current measurement cabinet, transformer characteristic tester, ratio tester, DC resistance tester, withstand voltage control cabinet, power frequency test transformer, and induced voltage test equipment.

During daily production testing, operators used the software interface for no-load and load tests, then performed transformer ratio, DC resistance, and withstand voltage tests through the same coordinated test area. Function interlocks helped prevent simultaneous activation of incompatible test modes. Test results from supported instruments were uploaded to the industrial computer for report preparation.

After installation, the manufacturer reduced repeated setup work, improved test sequence control, and created a clearer workflow for factory acceptance testing of transformer products.

FAQ

• What is the VS-ZHSY Transformer Comprehensive Test System used for?
  It is used for comprehensive transformer testing, including factory tests, routine tests, type-test preparation, and special test workflows for power transformers.
• What transformer capacity does the system support?
  The referenced configuration supports power transformers up to 10000 kVA. The final capacity should be confirmed according to the selected generator, regulator, and test equipment configuration.
• What test items can the system perform?
  It supports transformer ratio and vector group testing, DC resistance measurement, insulation resistance testing, partial discharge testing, no-load testing, load testing, power frequency withstand voltage testing, and induced withstand voltage testing.
• Can the system calculate transformer loss results?
  Yes. During no-load and load testing, the system can lock measured data and calculate results such as no-load loss, no-load current, no-load current percentage, load loss, and impedance voltage under rated conditions.
• Does the system support computer control?
  Yes. The system uses PLC control with an industrial computer interface. Operators can control test functions through software according to configuration.
• Can it also be operated manually?
  Yes. The system provides computer software mode and panel button mode. These two modes are mutually interlocked so that only one operation mode is active at a time.
• What is the power frequency withstand voltage configuration?
  The referenced scheme includes a 20 kVA / 100 kV power frequency test transformer and a withstand voltage control cabinet with an internal 20 kVA regulator for 0-100 kV output.
• Is the system customizable?
  Yes. Transformer test systems are usually configured according to transformer capacity, voltage level, required test items, site power supply, laboratory layout, and reporting requirements.

Weshine Advantages

Weshine provides transformer test instruments and integrated electrical test systems for manufacturers, laboratories, utilities, and maintenance companies. For transformer comprehensive testing, Weshine can support users from requirement analysis to system configuration, helping match the test bench to transformer capacity, voltage class, test standards, and workflow requirements.

Weshine can provide coordinated solutions including measurement units, voltage regulation units, withstand voltage equipment, transformer characteristic testing, DC resistance testing, ratio testing, insulation testing, oil dielectric strength testing, control software, and report workflow support. This helps customers build a practical transformer test area with clear operation logic and scalable configuration options.