Winding Temperature Controller

Relying solely on oil temperature monitoring to estimate winding conditions introduces unavoidable lag, allowing thermal risks to build up unnoticed. To solve this, our Winding Temperature Controller innovatively combines a dual-data acquisition approach: an armored PT100 sensor installed directly against the winding or within oil channels for high-accuracy (±0.5°C) real-time readings, and a current transformer (CT) that continuously tracks load current. This pairing eliminates the lag of traditional methods, delivering real-time, precise, and load-synchronized monitoring of winding thermal states-enabling early risk awareness and reliable protection for transformer safety and efficiency.

Built to withstand harsh environments inside energy storage containers-dust, moisture, and strong EMI-our 1007 series control unit is housed in a durable, C4M-rated corrosion-resistant aluminum alloy casing with IP55 protection. At its core are four independent micro-switches, allowing multi-level temperature thresholds to be set for staged control of cooling, alarms, and trip commands. This means a single device can automate the entire temperature management cycle from warning to protection,securing transformer operation while significantly simplifying system configuration and maintenance-even under demanding conditions.

Accurate monitoring must pair with effective action. Our system integrates full execution components-fans, oil pumps, etc.-and links them intelligently with the control unit. Once winding temperature reaches a preset threshold, the system automatically activates a staged cooling response: starting with fans, engaging oil pumps if temperature continues to rise, and even triggering emergency cooling in extreme scenarios. This closed-loop "sense–decide–act" system ensures temperature is brought under control quickly and reliably, reducing manual intervention while delivering proactive protection that extends equipment life and maintains stable transformer operation under all load conditions.

Transforming local temperature data into centrally managed digital assets is key to smart operations. We offer a complete expansion solution-from Remote Indicators (RI) and Power Supply Units (PSU) to standard SCADA interfaces (RS-485, Modbus RTU). This allows real-time temperature data from each transformer to be seamlessly integrated into the energy storage plant's central control system. Operators gain remote monitoring and historical traceability from the control room, while building a data foundation for predictive maintenance and analytics-shifting from reactive response to proactive prediction, and comprehensively improve plant management efficiency and operational reliability.

Together, these modules form a cohesive, adaptive safety environment for transformers-ensuring that your Winding Temperature Controller delivers continuous, stable, and efficient energy throughput for the entire storage system.

Traditional oil-temperature monitoring alone suffers from inherent lag in warning capability. Our solution employs an innovative dual-parameter thermal simulation algorithm that combines oil temperature and real-time load current, achieving high accuracy within ±1.5% FSD across a 0–160°C measurement range. The true value lies in its ability to detect localized winding overheating 30–60 minutes earlier than conventional methods. This provides crucial lead time for intervention, helping prevent serious failures such as insulation degradation or winding short circuits-thereby minimizing unplanned downtime and safeguarding both asset integrity and operational continuity.

The control unit operates reliably from -40°C to 60°C, withstands short-circuit currents up to 63kA, and features a core MTBF exceeding 100,000 hours. With an armored sensor and fully sealed housing, it resists high temperatures, corrosion, and oil immersion, making it well-suited for extreme outdoor energy storage installations in deserts, high-altitude sites, and other challenging environments.

Our smart algorithm enables the cooling system to act like an experienced "dispatcher" that understands your plant's operating patterns. By dynamically correlating load and temperature, the system proactively adjusts cooling strategies-reducing power during low-demand charging periods and ramping up cooling ahead of high-demand discharge cycles. This ensures adequate cooling when it matters most, while avoiding wasteful continuous operation or overloading of cooling equipment. Field tests show this approach can lower overall cooling energy consumption by 20–30%, enhancing reliability while significantly cutting long-term operational costs.

Built for long-term reliability and minimal upkeep, the Winding Temperature Controller is engineered to stringent standards: core components undergo accelerated aging tests (120°C for 1,000 hours) to ensure enduring performance. The fully sealed construction and broad compatibility with insulating oils protect against environmental degradation and eliminate the need for periodic recalibration or replacement. As a result, routine maintenance is simplified to an annual visual inspection. This design can reduce overall maintenance costs by more than 60% compared to conventional solutions, perfectly aligning with the industry's move toward unattended, continuously operating storage facilities.

Designed for easy adoption, the controller supports standard 152mm × 76mm panel cutouts and M27 universal flange mounting, making it directly compatible with mainstream oil-immersed energy storage transformers (including 400V–600V bidirectional buck-boost units and those paired with PV/wind systems). With open communication protocols such as Modbus RTU, it integrates seamlessly into plant Energy Management Systems (EMS) for coordinated, site-wide control.

By providing precise early warnings and staged protection, it prevents failures caused by winding overheating-such as insulation degradation and short-circuit fires-reducing unplanned transformer downtime by over 60%. It plays a critical role in mitigating "thermal runaway" risks, safeguarding the overall security of your energy storage plant.

Maintaining winding temperature within safe thresholds effectively slows insulation aging, extending transformer service life by 5–8 years (increasing average lifespan from 10 years to over 15 years). This reduces replacement frequency and enhances the long-term return on investment for your storage facility.

The maintenance-free design and remote monitoring capability minimize onsite staffing needs. Historical temperature data and fault logs ensure traceability, enabling faster troubleshooting-reducing diagnostic time from the traditional 2–3 days down to 2–4 hours.