HF-T-604 Transformer Winding Temperature Monitoring

The Transformer Winding Temperature Monitoring system is an intelligent temperature monitoring solution designed for oil-immersed and dry-type power transformers. As a transformer winding temperature monitor, it provides real-time measurement of winding, core, oil and radiator temperatures to help operators identify abnormal temperature rise and potential overheating conditions.

Sensors embedded at key positions, including transformer windings, iron cores, oil circuits and radiators, collect real-time temperature data. This enables accurate transformer hot spot monitoring and helps detect localized overheating that conventional oil temperature gauges may not identify.

The transformer winding temperature monitoring system combines temperature measurement with load, ambient temperature and humidity data for comprehensive operating-condition analysis. It can identify potential risks such as insulation aging, poor heat dissipation and abnormal temperature rise, supporting reliable transformer operation and condition-based maintenance.

The system can be configured for applications including substations, new energy booster stations, industrial power distribution rooms and other transformer installations requiring continuous winding temperature monitoring.

Main Product Features

Fully Insulated Intrinsically Safe Design

The core sensing unit adopts a completely passive and electroless structure with no exposed metal parts. The transformer winding temperature sensors can be directly embedded inside high-voltage windings, withstand strong electromagnetic environments and avoid compromising the original transformer insulation performance.

Accurate Temperature Measurement with Multi-technology Integration

Three sensing technologies, including Pt100 platinum resistance, fluorescent optical fiber and infrared thermal imaging, can be configured according to the transformer application. The system provides accurate winding temperature measurement, localized hot spot detection and equipment surface temperature monitoring. Temperature values can be displayed through the monitoring host, providing the functions of a transformer winding temperature indicator as well as a continuous temperature monitoring platform.

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.

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.

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.

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

Whole-area Temperature Collection with Multiple Measuring Points

Supporting up to 64 monitoring channels, the system continuously collects temperature data from three-phase winding hot spots, top and bottom oil, iron core, radiator inlet and outlet, and ambient conditions. This multi-point architecture provides comprehensive winding temperature monitoring and supports Transformer Winding Temperature Monitoring across critical transformer components.

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.

Multi-level Early Warning & Tripping Protection

Custom multi-level temperature thresholds can be configured according to transformer operating requirements. Audible and visual alarms, remote signals and other notifications are triggered when the monitored winding temperature exceeds the preset limits. A tripping signal can also be output when the temperature reaches the defined dangerous threshold, providing an additional protection layer for transformer windings.

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.

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%.

Remote Centralized Monitoring & Cloud Service

Equipped with RS485, 4G and WiFi communication interfaces and standard Modbus protocol, the system can connect to substation automation systems or cloud-based monitoring platforms. As a centralized transformer temperature monitor, it allows operators to view real-time winding, oil and other temperature data remotely through a connected monitoring platform.

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
Transformer Winding Temperature 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

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.

Condition Monitoring of Large Oil-immersed Main Transformers

Monitor internal winding hot spot temperature in large oil-immersed main transformers, particularly in 110kV and above substations. The system provides continuous transformer hot spot monitoring and helps identify localized overheating that conventional oil temperature gauges may not adequately reflect. This additional temperature information supports transformer condition monitoring and maintenance decisions.

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.

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.

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.

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

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.

Sensor Embedding & Deployment

Embed fluorescent fiber probes or Pt100 temperature sensors at predetermined monitoring points during transformer manufacturing or overhaul. For winding temperature measurement, transformer winding temperature sensors can be positioned at designated winding hot spots according to the transformer design and monitoring requirements. High-temperature-resistant leads are routed through dedicated sealed interfaces without compromising transformer enclosure integrity

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.

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.

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.

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 transformer winding temperature monitoring system applicable to all types of transformers?

A2: Yes. The system can be configured for different transformer structures and operating conditions, including dry-type transformers from 10kV to large 500kV oil-immersed main transformers. The number and type of transformer winding temperature sensors can be selected according to the transformer design, temperature monitoring requirements and installation conditions.

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.