HF-T-604 Transformer Winding Temperature Monitoring

This transformer winding temperature monitoring solution boasts universal compatibility with the entire series of oil-immersed and dry-type transformers, functioning as a high-accuracy intelligent system dedicated to temperature monitoring and regulation.
Sensors pre-embedded in key positions including windings, iron cores, oil circuits and radiators collect real-time temperature data, enabling accurate detection of internal hot spots inside windings that conventional equipment fails to identify.
Leveraging edge computing and cloud-based data analysis, the system conducts comprehensive joint analysis incorporating multiple parameters such as load, ambient temperature and humidity. It can proactively detect potential hazards including insulation aging, poor heat dissipation and local overheating, so as to ensure the safe operation of transformers throughout their entire service life.
This system is widely deployed in power scenarios such as substations, new energy booster stations and industrial power distribution rooms.

Main Product Features

1. Fully Insulated Intrinsically Safe Design The core sensing unit adopts a completely passive and electroless structure with no exposed metal parts. It can be directly embedded inside high-voltage windings, withstand strong electromagnetic environments and cause no damage to the original insulation performance of transformers.
2. Accurate Temperature Measurement with Multi-technology Integration Three sensing technologies including Pt100 platinum resistance, fluorescent optical fiber and infrared thermal imaging can be freely combined. It pinpoints millimeter-level hotspots inside windings and realizes full coverage scanning on equipment surfaces, with maximum temperature measurement accuracy up to ±0.3℃.
3. Stable Operation under Strong Electromagnetic Interference The hardware is equipped with multi-layer anti-interference design and passes all national-level EMC tests. No data fluctuation or communication disconnection occurs in complex high-electromagnetic-field substation environments, achieving 99.99% data transmission stability.
4. Long Service Life & Maintenance-free Structure The core fluorescent fiber probe is encapsulated with special rare earth materials, boasting a service life of over 20 years under normal working conditions. It is fully calibrated before delivery and requires no factory recalibration during long-term operation, greatly cutting later operation and maintenance costs.
5. Flexible Compatibility with All Types of Transformers Custom monitoring solutions are available for dry-type transformers from 10kV up to large 500kV oil-immersed main transformers. Wall-mounted, DIN rail-mounted and embedded installation modes are supported to fit control cabinets of various sizes.
6. Black Box Full Data Traceability Built-in power-off data protection storage module permanently records full historical temperature data for nearly 3 years. Key operation data will not be lost in case of sudden power failure, providing complete basis for fault tracing.

Core Functions

1. Whole-area Temperature Collection with Multiple Measuring Points Supporting up to 64 monitoring channels, it collects multi-dimensional temperature data including three-phase winding hot spot temperature, top oil temperature, bottom oil temperature, iron core temperature, radiator inlet and outlet temperature as well as ambient temperature to achieve blind-spot-free monitoring.
2. Automatic Intelligent Control of Cooling System It automatically starts and stops cooling fans and adjusts the rotating speed of heat dissipation oil pumps according to real-time winding temperature. For dry-type transformers, pumps start automatically at 110℃ and stop at 90℃, ensuring heat dissipation while greatly reducing energy consumption of the cooling system.
3. Multi-level Early Warning & Tripping Protection Custom multi-level temperature thresholds are available. Audible and visual alarms plus remote signal push will be triggered upon overtemperature. A reliable tripping signal will be output once the temperature hits the dangerous threshold to cut off power supply and prevent winding burnout.
4. Automatic Fault Diagnosis & Prompt When a sensor has open or short circuit faults, the system automatically identifies the faulty phase and indicates fault types via indicator light colors and screen codes. Single-channel faults will not affect the normal monitoring of other measuring points.
5. Intelligent Analysis with Multi-parameter Correlation It builds a correlation model between temperature data, real-time load and ambient temperature, automatically generates temperature rise trend curves, and distinguishes normal temperature rise caused by overload from abnormal overheating resulting from insulation deterioration, lifting early warning accuracy by 40%.
6. Remote Centralized Monitoring & Cloud Service Equipped with RS485, 4G and WiFi communication interfaces and standard Modbus protocol, it seamlessly connects to substation integrated automation systems or cloud operation platforms. Operation staff can check real-time temperature status of all transformers via mobile APP remotely.
7. Automatic Generation of Temperature Health Files It generates daily, monthly and annual temperature statistical reports recording peak temperature, average temperature rise, overtemperature duration and other key indicators, and automatically produces transformer temperature health assessment reports to provide quantitative support for condition-based maintenance.

Product Technical Parameters

Parameter Category	Specific Index
Applicable Transformer Type	Full series of 10kV~500kV oil-immersed and dry-type power transformers
Temperature Measuring Range	-40℃ ~ +260℃
Temperature Measurement Accuracy	±0.5℃ for Pt100; ±0.3℃ for fluorescent optical fiber
Resolution	0.1℃
Supported Channels	Expandable from 3 to 64 channels
Optional Sensor Types	Pt100 Platinum Resistance, Fluorescent Optical Fiber, Infrared Temperature Measurement
Operating Power Supply	AC 170V~250V, 48~60Hz
Total Power Consumption	≤5VA
Relay Contact Capacity	Fan contact: 10A/250VAC; Alarm & Tripping contact: 5A/250VAC
Communication Interface	RS485 (Standard); Optional 4G / WiFi / 4~20mA analog output
Ambient Operating Temperature	-20℃ ~ +55℃
Relative Humidity Resistance	≤95% (no condensation at 25℃)
MTBF (Mean Time Between Failures)	≥50000 hours
Storage Capacity	Store full temperature historical data for more than 3 years

Product Application

1. Safety Protection for Dry-type Transformers Real-time winding temperature monitoring for dry-type transformers in power distribution rooms, commercial buildings and data centers, avoiding insulation aging caused by poor heat dissipation and eliminating fire risks from winding burnout.
2. Condition Monitoring of Large Oil-immersed Main Transformers Monitor internal winding hot spot temperature of main transformers in hub substations of 110kV and above, making up for the defect that traditional oil temperature gauges cannot reflect the maximum winding temperature and detecting local overheating risks in advance.
3. Equipment Protection for New Energy Booster Stations Adapt to harsh field working conditions of wind power and photovoltaic booster stations, realize remote transformer temperature monitoring under unattended mode, and prevent delayed troubleshooting of overtemperature faults in remote areas.
4. Continuous Operation Guarantee for Core Industrial Equipment 24-hour temperature monitoring for transformers used in core production lines of petrochemical, metallurgy, rail transit and other industries, avoiding unplanned shutdown of entire production lines caused by sudden transformer overheating and massive economic losses.
5. Life Extension Management for Aging Transformers Accurate temperature tracking for aged transformers with long service time, optimizing load distribution on the premise of safety, avoiding unnecessary derated operation and extending equipment service life by 3 to 5 years.
6. Support for Digital Power Distribution Renovation Provide basic temperature data for digital upgrading of power distribution systems in smart parks and intelligent factories, access the overall energy management system to realize transformer energy efficiency analysis and digital operation and maintenance management.

Installation Instructions

1. Pre-project Scheme Customization Determine sensor layout points according to transformer type, capacity and operation requirements. For oil-immersed transformers, arrange sensors at winding hotspots, top/bottom oil temperature and iron core positions; embed Pt100 platinum resistors inside three-phase winding packages for dry-type transformers.
2. Sensor Embedding & Deployment Embed fluorescent fiber probes or Pt100 resistors at preset hotspots during transformer manufacturing or overhaul. High-temperature resistant special leads are led out from dedicated sealed interfaces on the transformer side wall without damaging equipment tightness.
3. Main Control Unit Installation Mount the temperature monitoring host on the wall or embed it into the control cabinet near the transformer, with the operation panel facing the direction convenient for inspectors to view. The mounting hole spacing matches standard cabinet opening dimensions.
4. Wiring & Calibration Connect all sensor leads to corresponding acquisition channels of the host. Power on and calibrate temperature display of each measuring point one by one, and set threshold parameters including fan startup/shutdown temperature, overtemperature alarm temperature and tripping temperature.
5. Communication & Platform Connection Connect communication cables and debug communication with local monitoring back-end or cloud platform to ensure real-time remote transmission of temperature data and test remote alarm push function.
6. Acceptance & Training Explain the definition of temperature thresholds and disposal procedures for abnormal alarms to maintenance personnel, deliver complete installation manuals and parameter configuration documents, and complete project acceptance and handover.

Why Choose Us

1. Customization Capability for All Scenarios As an original manufacturer focusing on power temperature measurement, we achieve full independent R&D covering sensing probes to monitoring hosts. Custom exclusive solutions are provided for transformers of different voltage levels and special working conditions instead of simple application of standardized general products.
2. Compliance with Strict Industry Standards Products are designed and manufactured in accordance with JB/T7631-2016 Electronic Temperature Controllers for Transformers, and pass national EMC tests for long-term stable operation under strong electromagnetic interference. Our products have been applied and verified in thousands of power projects nationwide.
3. Extremely Reliable Temperature Measurement Performance Core fluorescent fiber probes are encapsulated with special rare earth materials, completely immune to high voltage, strong electromagnetic interference and oil corrosion. Unlike traditional platinum resistors that suffer from aging and data drift in high-temperature oily environments, no calibration is needed within 20 years of service.
4. Minimal Operation & Maintenance to Reduce Costs Built-in automatic fault diagnosis visually indicates sensor faults without manual line-by-line inspection. The overall operation and maintenance workload is reduced by 70% compared with conventional temperature control products throughout the lifecycle.
5. Open Compatibility for Seamless Docking Support all mainstream power communication protocols to directly access existing substation integrated automation and environmental monitoring platforms without extra system transformation and data isolation.
6. Rapid Localized Service Response Service outlets cover Hebei Province and the whole country. On-site technical support is available within 4 hours for local projects in Baoding. We provide full-cycle services including installation guidance, commissioning training and regular inspection to eliminate after-sales worries.

FAQ

Q1: Will embedding sensors inside transformer windings affect equipment insulation performance?

A1: Absolutely not. Our fiber sensors adopt fully insulated quartz material with no metal components, whose insulation level far exceeds that of the transformer itself. Embedding will not change the original winding insulation structure and fully complies with safety specifications for power equipment.

Q2: Is this system applicable to all types of transformers?

A2: Yes. We offer matched monitoring solutions ranging from small 10kV dry-type transformers to large 500kV oil-immersed main transformers. Sensor types and measuring point quantities can be flexibly configured according to actual equipment structure and monitoring demands.

Q3: Do sensors require regular calibration or replacement?

A3: Fluorescent fiber probes are fully and accurately calibrated before delivery. Their temperature measurement performance depends only on physical properties of rare earth materials with no drift during long-term operation. No calibration or replacement is required within 20 years under normal working conditions with extremely low maintenance costs.

Q4: Can the system directly control the transformer cooling fans?

A4: Yes. The host is equipped with high-capacity relay output contacts to automatically start and stop fans per preset temperature thresholds, and supports manual forced startup as well as timed automatic fan operation for regular heat dissipation tests.

Q5: Will the whole system break down if one single sensor fails?

A5: It will not. The system features single-channel fault isolation. When a sensor has open or short circuit faults, the system pinpoints the fault position automatically, while monitoring, fan control and alarm protection of other normal measuring points function normally.

Q6: Can this system connect to our existing power distribution room monitoring platform?

A6: Fully compatible. RS485 interface and standard Modbus protocol are standard configuration. Optional 4G, WiFi modules and 4~20mA analog output are available to seamlessly dock most mainstream power monitoring systems without secondary development.