1. Introduction
The Huazheng HZZH-5 Transformer Parameter Comprehensive Tester is an advanced instrument designed for comprehensive testing of large power transformers. It integrates multiple testing functions into a single device, including DC resistance testing, low-voltage short-circuit impedance testing, on-load switch testing, demagnetization testing, and transformer ratio testing. This manual provides detailed instructions for the safe and effective operation, maintenance, and troubleshooting of the HZZH-5 tester.
2. Product Features
2.1. General Design Features
- Integrated Testing: One-time wiring allows for the completion of all test items, significantly reducing on-site workload.
- User Interface: Equipped with a 7-inch color touch LCD screen for intuitive control and display.
- Data Output: Built-in micro printer for immediate on-site printing of test results.
- Data Storage: USB storage function for external saving of test results.
- Communication: Features one isolated RS232 communication interface with standard protocol and a Bluetooth communication module for wireless connectivity.
- Internal Communication: High-reliability RS485 bus for robust internal communication.
- Interference Suppression: Isolated circuit design, hardware and software filtering, and effective grounding/shielding measures ensure high anti-interference capability.
2.2. DC Resistance Test Features
- Simultaneous Three-Phase Testing: Supports simultaneous three-phase testing and automatic magnetization.
- Simplified Wiring: High and low voltage current and potential test leads can be connected once, eliminating the need for switching during the test.
- Star-Connected Windings: For star-connected windings with a neutral point, A0, B0, and C0 phase resistances can be tested simultaneously, saving time.
- Delta-Connected Transformers: Utilizes an automatic excitation method for low-voltage side testing of internally delta-connected three-phase five-limb transformers, ensuring fast testing speed.
- Comprehensive Reporting: Displays and prints all test data for high, medium, and low voltage windings, automatically calculates three-phase unbalance, and prints resistance values converted to rated temperature.
- Safety: Comprehensive back EMF protection.
2.3. Short-Circuit Impedance Test Features
- Automated Current Application: Uses a single-phase 220V power supply to automatically apply current to AB, BC, and CA windings, synchronously collecting data and converting it to the rated impedance percentage.
- Three-Phase Measurement: For three-phase transformers (Y/, Y/Y, /Y connections), a single wiring setup allows for three-phase measurement, automatically calculating impedance value and error.
- Rated Capacity Input: When using the single-phase method for three-phase transformers, input 1/3 of the rated capacity.
- Data Display & Storage: Displays and prints all test data and can permanently store test data.
2.4. On-load Switch Test Features
- Independent Current Sources: Three independent constant current sources.
- Powerful Functions: Measures transition waveform, transition time, transition resistance, and three-phase synchronization.
- Intelligent Analysis: Intelligent testing and result analysis.
- Waveform Display & Storage: Displays and prints test waveforms and can permanently store them.
- Safety: Equipped with an automatic discharge circuit and overvoltage protection circuit.
2.5. Transformer Demagnetization Test Features
- Efficient Demagnetization: Fast demagnetization with noticeable effects.
- Operation Modes: Offers fully automatic and manual demagnetization functions, with progress bar and percentage display.
- Safety: Comprehensive back EMF protection.
- Application: Suitable for eliminating residual magnetism in large power transformers of 35kV and above before operation.
- Automated Processes: Automatic current stabilization judgment, data acquisition, and processing functions.
- Ease of Use: One-button operation and strong anti-interference ability.
- Convenient Wiring: Can directly use the current leads of the DC resistance test.
2.6. Transformer Ratio Test Features
- User-Friendly Interface: Chinese/English menu prompts for simple and convenient operation.
- Automatic Group Measurement: For three-phase testing, only inputting the high-voltage side connection method is required to automatically measure the group.
- Flexible Measurement: Capable of both single-phase measurement and automatic testing of three-phase windings. The connection group can be arbitrarily selected, completing the measurement of parameters such as ratio, error, and connection group of AB, BC, and CA phases in one go.
- Safety: Protection function for high and low voltage reverse connection, and protection functions for transformer short-circuit and inter-turn short-circuit.
- Speed: Fast testing speed, completing single-phase testing in 15 seconds.
3. Technical Specifications
| Parameter | Value |
|---|---|
| Product Name | HZZH-5 Transformer Parameter Comprehensive Tester |
| Brand Name | HuaZheng |
| DIY Supplies | Electrical |
| Electronic | Yes |
| High-concerned chemical | None |
| Origin | Mainland China |
| Place of Origin | Hebei, China |
| Power | Electric |
| Voltage | 220V |
| Type | Testing machine |
| Protection Class | IP55 |
| Ambient Temperature | -10~45°C |
| Using Relative Humidity | 85% |
| Customized Support | OEM |
| Warranty | 1 Year |
3.1. DC Resistance Test Specifications
| Parameter | Value | |
|---|---|---|
| Three-Phase Test Current Ranges | 10A, 5A, 1A | |
| Three-Phase Test Range | 10A | 500.0μΩ~2Ω |
| 5A | 10mΩ~4Ω | |
| 1A | 1Ω~20Ω | |
| Phase-Separated Test Current Ranges | 20A, 10A, 5A, 1A | |
| Phase-Separated Test Range | 20A | 100.0μΩ~1Ω |
| 10A | 500.0μΩ~2Ω | |
| 5A | 10mΩ~4Ω | |
| 1A | 1Ω~20Ω | |
| Resolution | 0.1μΩ | |
| Measurement Accuracy | Class 0.2 | |
3.2. Short-Circuit Impedance Test Specifications
| Parameter | Value |
|---|---|
| Voltage Measurement Range | 5~400V |
| Current Measurement Range | 0.1~10A |
| Measurement Accuracy | Class 0.2 |
3.3. On-load Switch Test Specifications
| Parameter | Value |
|---|---|
| Output Current | 1A: 0.5A |
| Resistance Resolution | 0.01Ω |
| Transition Resistance Range | 0.2Ω~20Ω, 1Ω~50Ω |
| Transition Time Range | 0~240ms |
| Measurement Accuracy (Transition Resistance) | ± (5% + 0.2Ω) |
| Synchronization Time | 0.1ms |
3.4. Transformer Demagnetization Test Specifications
| Parameter | Value |
|---|---|
| Output DC Current | 1A - 10A |
| Output DC Voltage | 20V, 30V, 40V, 50V |
3.5. Transformer Ratio Test Specifications
| Parameter | Value |
|---|---|
| Range of Ratio | 1-5000 |
| Measurement Accuracy | 0.1% (0.8—1000) |
| 0.2% (1000—2000) | |
| 0.5% (2000—5000) | |
| Transformer Connection Group | YY0, YY6, YD1, YD5, YD7, YD11, DD0, DD2, DD4, DD6, DD8, DD10, DY1, DY5, DY7, DY11 |
| Testing Voltage | 10V/160V |
4. Setup and Connections
Before operating the HZZH-5 tester, ensure it is placed on a stable, level surface in an environment within the specified ambient temperature and humidity ranges (-10~45°C, 85% relative humidity). Proper grounding is essential for safety and accurate measurements.
4.1. Power Connection
- Connect the tester to a stable 220V AC power supply.
- Ensure the power cable is securely connected to both the instrument and the power outlet.
4.2. Test Lead Connections
The HZZH-5 is designed for one-time wiring for multiple tests. Carefully connect the high and low voltage current and potential test leads to the transformer terminals according to the specific test requirements. Refer to the labels on the instrument's connection points (e.g., Ua, Ub, Uc, U0, Va, Vb, Vc, V0, Power Supply).
- Ensure all connections are firm and correct to prevent measurement errors or damage to the equipment.
- The instrument features comprehensive back EMF protection and short-circuit protection, but correct wiring is paramount.
5. Operating Instructions
The HZZH-5 features a 7-inch color touch LCD screen for operation. Navigate through the menus using the touch interface.
5.1. General Operation Steps
- Power On: After ensuring all connections are secure, turn on the instrument using the main power switch.
- Menu Navigation: The main menu will appear on the LCD screen. Select the desired test function (DC Resistance, Short-Circuit Impedance, On-load Switch, Demagnetization, or Transformer Ratio) by tapping its icon.
- Parameter Input: Follow the on-screen prompts to input necessary parameters for the selected test (e.g., rated capacity for impedance tests, connection method for ratio tests).
- Start Test: Initiate the test by pressing the "Start" or equivalent button on the screen.
- Monitor Progress: Observe the test progress and real-time data on the display.
- Review Results: Once the test is complete, review the results displayed on the screen.
- Print/Save Results: Use the built-in micro printer for immediate hard copies or the USB storage function to save data externally.
5.2. Specific Test Procedures
5.2.1. DC Resistance Test
- Connect the test leads as described in Section 4.2.
- Select "DC Resistance Test" from the main menu.
- Choose between "Three-Phase Simultaneous Test" or "Phase-Separated Test" based on your requirements.
- The instrument will automatically apply current and measure resistance. For star-connected windings with a neutral point, A0, B0, and C0 phase resistances will be tested simultaneously.
- Review and save/print the results, including three-phase unbalance and temperature-converted resistance values.
5.2.2. Short-Circuit Impedance Test
- Ensure the transformer is de-energized and properly connected.
- Select "Short-Circuit Impedance Test" from the main menu.
- If using the single-phase method for a three-phase transformer, input 1/3 of the rated capacity.
- The tester will automatically apply current and collect data to calculate impedance percentage.
- For Y/, Y/Y, /Y connections, the instrument will automatically measure and calculate impedance values and errors.
- Review and save/print the test data.
5.2.3. On-load Switch Test
- Connect the test leads to the on-load tap changer terminals.
- Select "On-load Switch Test" from the main menu.
- The instrument will apply current and measure transition waveform, time, and resistance.
- The results will include intelligent analysis of the switch's performance.
- Review and save/print the test waveforms and data.
5.2.4. Transformer Demagnetization Test
- Connect the current leads, potentially reusing those from the DC resistance test.
- Select "Transformer Demagnetization Test" from the main menu.
- Choose between "Fully Automatic" or "Manual" demagnetization.
- Monitor the progress bar and percentage on the screen.
- The instrument will automatically stabilize current, acquire data, and process the demagnetization.
- This function is particularly useful for large power transformers (35kV and above) before operation.
5.2.5. Transformer Ratio Test
- Connect the high and low voltage leads to the transformer.
- Select "Transformer Ratio Test" from the main menu.
- Input the high-voltage side connection method; the instrument will automatically determine the connection group.
- Choose between single-phase or automatic three-phase winding measurement.
- The tester will measure the ratio, error, and connection group for AB, BC, and CA phases.
- Review and save/print the results.
6. Maintenance
Regular maintenance ensures the longevity and accuracy of your HZZH-5 tester.
- Cleaning: Keep the instrument clean and free from dust and moisture. Use a soft, dry cloth for cleaning the exterior. Do not use abrasive cleaners or solvents.
- Storage: When not in use, store the tester in its protective case in a dry, cool environment, away from direct sunlight and extreme temperatures.
- Cable Inspection: Periodically inspect all test leads and power cables for any signs of wear, damage, or fraying. Replace damaged cables immediately.
- Software Updates: Check with Huazheng support for any available software updates to ensure optimal performance and new features.
- Calibration: For continued accuracy, periodic calibration by qualified personnel is recommended.
7. Troubleshooting
This section addresses common issues you might encounter with the HZZH-5 tester. If the problem persists, contact technical support.
| Problem | Possible Cause | Solution |
|---|---|---|
| Instrument does not power on. | No power supply; loose power cable; blown fuse. | Check power connection and outlet. Ensure power cable is secure. Check and replace fuse if necessary (refer to service manual for fuse location). |
| Inaccurate test results. | Incorrect wiring; poor contact of test leads; external interference; instrument out of calibration. | Verify all test lead connections are correct and secure. Ensure proper grounding. Minimize external electromagnetic interference. Consider professional calibration. |
| Test fails or stops unexpectedly. | Protection circuit triggered (e.g., overvoltage, short-circuit, reverse connection); internal error. | Check for any reverse connections or short-circuits in the transformer or wiring. Power cycle the instrument. If persistent, contact support. |
| Touch screen unresponsive. | Temporary software glitch; screen damage. | Restart the instrument. If the problem persists, contact technical support. |
| Cannot save data to USB. | USB drive not properly inserted; USB drive full or corrupted; incompatible USB format. | Ensure USB drive is fully inserted. Try a different USB drive. Format the USB drive to a compatible file system (e.g., FAT32) on a computer. |
8. User Tips
- Pre-Test Checks: Always perform a visual inspection of the transformer and all connections before starting any test.
- Environmental Conditions: Ensure the testing environment is stable and free from excessive vibrations, dust, or extreme temperatures to maintain measurement accuracy.
- Data Backup: Regularly back up your test results to an external USB drive to prevent data loss.
- Safety First: Always follow standard electrical safety procedures when working with transformers and high-voltage equipment.
9. Warranty and Support
Huazheng provides comprehensive support for its products.
9.1. Warranty Information
From the date of purchase, the instrument is covered by a one-year warranty for product quality problems, offering free repair or replacement. Lifetime supply of maintenance and technical services is also provided.
9.2. Technical Support
If the instrument exhibits anomalies or malfunctions, please contact Huazheng technical support to arrange the most convenient treatment options. You can reach us via:
- WhatsApp: +8619192168996
- Email: 2407896675@qq.com
