Microtest 3-in-1 Transformer Testing System

The Microtest 3-in-1 Transformer Testing System integrates low-voltage parameter measurement, hipot safety testing, and impulse winding testing in a single 20-channel platform, delivering complete transformer qualification without moving the device under test between separate instruments. This three-function consolidation eliminates fixture changes, reduces cycle time, and ensures that every transformer undergoes the full test regimen including turn-to-turn insulation verification that hipot testing alone cannot detect.

Specifications

Feature	Specification
Test Channels	20
LV Tests	Turns ratio, inductance, leakage L, DCR, phase polarity
AC Withstand	Up to 5000 V
DC Withstand	Up to 6000 V
Impulse Voltage	200 V to 5000 V
Impulse Detection	Shorted turns, layer shorts, insulation weakness
Scanner	Electronic matrix for multi-winding routing
Test Sequences	Programmable LV + hipot + impulse flow
Interface	Handler, barcode, USB

Three-Function Consolidation

Low-voltage tests measure turns ratio, inductance, leakage inductance, DCR, and phase polarity. Hipot testing verifies dielectric withstand at up to AC 5000 V between windings and between windings and core. Impulse winding testing applies 200 V to 5000 V impulses to detect shorted turns and insulation weak points within individual windings, a fault mode that causes field failures but passes conventional hipot testing. The 20-channel scanner matrix routes all three test types to the correct winding pairs automatically.

Why Impulse Testing Matters

Shorted turns within a winding represent a defect that hipot testing cannot detect. A hipot test verifies insulation between windings, but a shorted turn within a single winding does not create a path between windings. The impulse test catches this critical failure mode by applying a voltage impulse and comparing the resulting waveform against a reference, even a single shorted turn produces a detectable frequency and amplitude shift.

Applications

Transformer manufacturers meeting OEM quality specifications that mandate impulse testing alongside traditional LV and hipot tests deploy the 3-in-1 to consolidate three test stations into one. Power transformer, switching transformer, and automotive magnetics production lines benefit from reduced floor space, lower capital expenditure, and faster cycle times.

Watch the Microtest 3-in-1 Transformer Testing System on YouTube

GSAS Micro Systems delivers the Microtest 3-in-1 system to transformer and magnetics manufacturers across India with INR invoicing and turnkey production integration support. Teams in Bengaluru, Hyderabad, Chennai, Pune, Mumbai, and Delhi NCR provide fixture design, test sequence programming, and commissioning services.