Covering all categories of testing including GIS, disconnect switches, and transformers, Changgao Group has selected the DEMIKS fully automated temperature rise testing system 分批。

產品介紹：

德米克斯·鮑爾 DDL-WS Series Fully Automatic Temperature Rise Test System(Heat Run Test system)

I. Overall Equipment Composition

The entire system is divided into two core units:

Blue touch-screen industrial control console (first image) ,

The fully automated human-machine interaction control center is equipped with an industrial touch screen and has built-in three-phase control programs, multiple temperature acquisition channels, and a current closed-loop regulation module. It can display the A/B/C three-phase output current, hundreds of temperature measurement points, temperature rise curves, and test duration in real time, and automatically record, store, and export test reports.

Stainless steel three-phase current generator (second picture)

The main body features high-current output and incorporates multiple high-power voltage-regulating and current-boosting transformers, as well as a water-cooled/air-cooled heat dissipation system. It has red, yellow, and green three-phase high-current terminal outputs, capable of continuously outputting thousands of amperes of power frequency current to supply rated load current to transformers, switch-gear, and bus-bars.

二。 Core Uses

A type test and mandatory factory inspection item for high and low voltage electrical equipment . This system is used to simulate the long-term full-load operation and heat generation conditions of equipment to verify whether heat dissipation and temperature rise limits comply with GB/IEC standards. Applicable test samples:

Test the temperature rise of high and low voltage windings, core, oil tank, and terminals of power transformers (oil-fired/dry-fired) to determine the risk of insulation aging and whether the load capacity meets the standards.

High and low voltage switch - gear, ring main units, bus-bar trunking, copper bus-bar connectors are tested for overheating of circuit breaker contacts, disconnecting switches, and busbar lap joints to prevent overheating and erosion during long-term operation;

Multiple samples of current transformers, contactors, cable connectors, and reactive power compensation components are simultaneously tested for temperature rise on a mass production line.

Third-party testing agencies, power research institutes, and switch manufacturers conduct factory quality inspections , supporting 24-hour unattended long-term steady-state temperature rise tests.

of the fully automatic temperature rise test system is to determine the test results.

Electrical equipment that is powered on for a long time will generate heat due to copper and iron losses. Exceeding the temperature limit will accelerate insulation aging, shorten lifespan, and even cause fire or explosion. Temperature rise test measures the stable temperature rise of each part and compares it with the national standard limit to determine whether the product is qualified.

第三。 Complete Working Principle of the Fully Automated Temperature Rise Test System

1. High-current boosting loading principle

The control panel issues commands to control the internal induction voltage regulator and current-boosting transformer of the current-boosting main unit .

• Input 380V three-phase mains power, output is continuously regulated via voltage adjustment;
• The current-boosting transformer reduces voltage and increases current, outputting low-voltage, ultra-large power frequency sinusoidal current (0~10000A, three-phase independent adjustable, model 10000S represents a maximum single-phase current of approximately 10000A).
• Current closed-loop PID constant current control ensures that the current fluctuation is less than 1% during long-term testing, guaranteeing stability under simulated full-load conditions.

2. Principle of Multi-channel Temperature Acquisition and Monitoring

The matrix-style points on the touchscreen interface represent PT-100 platinum resistance temperature measurement channels (up to dozens to hundreds of channels):

The temperature probe is attached to key temperature measurement points such as the sample winding, contacts, casing, and ambient air.

The system automatically collects the real-time temperature of all points every second and records the ambient baseline temperature simultaneously.

The software automatically calculates the temperature rise as follows: Stable temperature at the measuring point – Ambient temperature .

Real-time temperature rise-time curve plotting.

溫度上升 測試程序

Parameter presets : The touchscreen allows you to set the three-phase target current, test duration, temperature alarm threshold, and shutdown conditions.

Automatic current ramp-up : The equipment slowly ramps up the voltage and current from zero, smoothly loading to the rated test current to avoid impact;

Steady-state thermal insulation monitoring : Continuous constant flow operation, synchronously collecting temperature data at all points throughout the process, and automatically storing the data;

the hot DC resistance test (for transformers) reaches a stable temperature rise, the system automatically cuts off the high current and briefly connects to the DC resistance measurement module to quickly measure the hot resistance of the winding. The average temperature rise of the winding is accurately calculated through the resistance change (national standard algorithm).

Cooling data acquisition : After power failure, continuously record the cooling curve to improve the experimental data;

Automatic Reporting : Once the test is completed, a PDF report can be exported with one click, including the current curve, temperature curve, temperature rise values at each point, and the pass/fail conclusion.

Multiple security protection mechanisms

The system has built-in hardware and software dual protection: over-current, over-temperature, short circuit, phase loss, fan failure, and automatic current reduction/shutdown in case of over-temperature; any temperature measurement point exceeding the set threshold will immediately trigger an audible and visual alarm and cut off the output to prevent the sample from burning out.

IV. Core Technical Features of Temperature Rise Test Equipment ( Example: DEMIKS DDL-WS-10000S)

1. The three independent closed-loop constant current A/B/C phase currents can be set to different values to perfectly simulate unbalanced load conditions.
2. The ultra-large temperature measurement channel capacity supports simultaneous acquisition of hundreds of PT100 channels. One device can simultaneously perform synchronous testing of multiple switch cabinets and multiple winding transformers, improving production line efficiency.
3. The stainless steel booster unit, equipped with a forced cooling air duct, can run continuously for 24 hours at full load, meeting the national standard requirements for long-term steady-state temperature rise .
4. The entire process is unattended, with automatic current boosting, constant temperature monitoring, resistance temperature measurement, shutdown, and data saving, requiring no on-site personnel supervision.
5. The foreign trade-compatible software supports switching between Chinese and English, meets IEC international standards, is CE certified, and is compatible with overseas transformer and switch-gear production lines.
6. The modular split-structure control console is separated from the power supply unit, allowing for flexible layout. The main unit is equipped with casters, making it easy to move within the workshop.

V. Industry Standards for Temperature Rise Testing

• GB 1094.11 Temperature Rise of Power Transformers
• GB 7251 Low-voltage switch-gear and control-gear assemblies
• IEC 60865 and IEC 60076 International Standards for Temperature Rise Testing

Partner Clients:

DEMIKS 10,000 Amp Temperature Rise Equipment Installed in Changgao Group’s Three Core Testing Halls

• Recently, DEMIKS’ fully automated three-phase temperature rise test equipment was successfully delivered in batches to Changgao Group, a leading listed electrical equipment manufacturer. The equipment covers Changgao’s high-voltage GIS test hall, transformer mass production workshop, and medium-voltage switchgear quality inspection production line. It is used for rated load temperature rise assessment of disconnect switches, tank circuit breakers, dry-type transformers, and complete sets of power distribution equipment, and has received high praise from Changgao Group’s technology center and quality inspection department.

1. High Voltage Switch - gear Division (Changgao High Voltage, 12kV~1100kV Disconnect Switches/Grounding Switches)

Tested products : GW series outdoor high-voltage disconnect switches, JW series grounding switches, indoor high-voltage disconnect contacts, and high-current busbar connection components.

測試目標 :

• Verify the temperature rise of the switch moving/stationary contacts, conductive arms, and terminals under rated continuous current;
• Detect the heat generated by the contact resistance of the high current circuit to prevent contact erosion during long-term operation;
• Completed the State Grid type test certification and random inspection of each batch before leaving the factory, corresponding to GB 1985 “High Voltage Disconnect Switch Standard”.

2. Ultra-high voltage GIS Business Unit (Changgao Electric, 110kV~550kV GIS/HGIS, circuit breakers)

測試產品 : 550kV/220kV high-voltage GIS, tank-type circuit breakers, environmentally friendly C4 gas-insulated switchgear, busbars. Test Contents : Steady-state temperature rise test of internal conductive contacts, busbar conductors, and flange connections of GIS; Long-term heat generation verification of environmentally friendly gas-insulated switchgear under rated load, conforming to IEC 62271 high-voltage switch standard; Temperature rise test is mandatory for new product R&D and finalization.

3. Changgao Senyuan (dry-type/oil-immersed transformers, medium and low voltage switchgear)

(1) Power transformers (dry-type SCB, oil-immersed S11/S20 series)

Core application scenarios of temperature rise system:

Average winding temperature rise test: After energizing to thermal stability, the hot DC resistance is automatically measured, the winding temperature rise is calculated, and the insulation life is determined.

Temperature rise monitoring of iron core, oil tank, and wiring terminals to verify whether the heat dissipation structure meets the standards;

All transformers undergo full inspection before leaving the production line, and each transformer must complete a short-time temperature rise load test.

(2) Medium and low voltage complete sets of electrical equipment

Tested products: 10kV ring main unit, integrated primary and secondary intelligent switchgear, busbar trunking, JP integrated 配電箱, cable branch box. Key testing points: circuit breaker contacts, busbar joints, and cable terminal temperature rise. These are mandatory testing items for low-voltage complete sets of equipment for 3C certification and factory release.

The group’s three core production bases have all purchased DDL-WS series fully automatic three-phase temperature rise test systems (6000A/8000A/10000S multiple specifications) in bulk, with two configurations: a type-type test hall (large capacity 10000A model) and a production line factory quality inspection system (6000~8000A model), covering temperature rise testing of all categories of high-voltage switches, GIS switchgear, transformers, and medium and low voltage complete sets.

Test Product List

SF6 Gas Insulated Switch - gear (GIS/HGIS) 40.5kV/126kV/252kV/363kV/550kV/800kV Temperature measurement points for whole-bay GIS and tank-type circuit breakers: circuit breaker contacts, disconnector conductor rods, busbar conductors, flange connection surfaces, and cable terminal blocks.

Temperature rise assessment of conductor connections in long-distance busbars, tees/elbows, and GIL high-voltage gas-insulated transmission pipelines.

Environmentally friendly C4 mixed gas switchgear without SF6: Full-load temperature rise verification of environmentally friendly switchgear, conforming to IEC 62271 standard.

GIS has built-in current transformer, grounding switch, and surge arrester conductive circuit.

Equipment Selection & Usage Scenarios Comparison Table for Each Base

子公司	Temperature rise equipment model	最大輸出電流	Core test object	測試類型
Changgao High Voltage Switch	DDL-WS-8000/10000S	10000A	12~1100kV disconnect switches and grounding switches	Type testing + factory sampling inspection
Changgao Electric (GIS)	DDL-WS-10000S	10000A	550kV/800kV GIS and GIL tank-type circuit breakers	Ultra-high voltage type qualification test
Changgao Senyuan (Hengyang)	DDL-WS-6000/8000S	8000A	Dry-type/oil-type transformers, 10kV switchgear, busbar trunking	Production line batch factory testing
Changgao New Energy	Single-phase 1000A temperature rise device	1000A	New energy high-voltage distribution box, wire harness connector	Component R&D Verification

This in-depth cooperation with Changgao Group fully demonstrates DEMIKS’ leading position in the high-voltage electrical testing equipment sector. For many years, we have focused on the R&D and production of complete sets of high-voltage power testing equipment, creating a comprehensive testing equipment system covering all voltage levels and all categories of electrical products. With our independent core control technology, stringent quality control standards, and one-stop customized service capabilities, we have earned the long-term trust of many leading listed high-voltage electrical companies in China. We are a highly representative benchmark brand in the field of domestic high-end power testing equipment, with products simultaneously covering the domestic market and global overseas export business, meeting the multiple testing standard requirements of State Grid, China Southern Power Grid, and international projects.

As an indispensable core testing equipment in the power manufacturing industry chain, the fully automated temperature rise test system has extremely broad industry application value: all current-carrying equipment such as transformers, high-voltage switches, GIS switch-gear, complete switch-gear, and busbar trunking rely on temperature rise equipment to simulate full-load operating conditions, assess the risk of heating and insulation aging in conductive circuits, and are a mandatory testing link for product type certification and factory release. The DEMIKS temperature rise equipment, relying on its advantages of stable current rise at the 10,000 ampere level, multi-channel high-precision temperature measurement, and fully automated unattended testing, is perfectly adapted to the entire process of testing from R&D finalization to mass production. Its mass deployment across all Changgao Group bases is strong evidence of the equipment’s comprehensive performance, intelligence level, and long-term operational stability. We will continue to deepen our technological innovation in temperature rise testing, empowering the quality upgrade of power transmission and distribution and new energy electrical manufacturing enterprises nationwide with more reliable, efficient, and intelligent testing equipment.