RESIBLOC

Small Power Transformers

112.5 kVA Through 25,000 kVA
2300V Through 34.5 kV Primary Voltage
120V Through 15 KV Secondary Voltage

RESIBLOC transformers provide the ultimate mechanical strength in

severe operating conditions.

RESIBLOC transformers feature windings

which are hermetically cast in epoxy
without the use of a mold. The epoxy
insulation system is reinforced by a licensed
glass fiber roving technique that binds the
coil together into a virtual winding block.
The result: Unsurpassed mechanical
strength with design optimization through
25,000 kVA.
RESIBLOC transformers provide the ultimate
withstand to thermal and mechanical
stresses from severe climates, cycling loads,
and short circuit forces. The epoxy
insulation system is highly resistant to
moisture, freezing, and chemicals, and is
used in the most demanding applications.
RESIBLOC transformers are non-explosive
with high resistance to flame and do not
require vaults, containment dikes, or
expensive fire suppression systems.
Product Scope:
112.5 kVA-25,000 kVA
Primary Voltages: 2300V through 34.5 kV
Primary BIL: Up to 150 kV
Secondary Voltages: 120V through 15 kV
Secondary BIL: Up to 75 kV
Temperature Rise 80C
RESIBLOC Construction:
RESIBLOC HV / Open Wound LV
RESIBLOC HV / Resi-Cast LV
RESIBLOC Benefits/Advantages:
Resistant to Moisture
Resistant to Chemical Contamination
No danger of fire or explosion
No liquids to leak
Partial Discharge Free (Less than 20 PC @
120% rated voltage)
Minimal Maintenance
ISO 9001 Certified
Indoor and outdoor enclosures

Roving glass fiber reinforcement for maximum mechanical strength.

Quality Products...Built With Pride

As a single-source supplier, ABB is the largest and most complete
manufacturer of power transmission and distribution equipment in
the world. We make certain that our world renowned quality is
exemplified by every product that bears our name. An experienced
and dedicated work force ensures the quality of our work and your
satisfaction with our products. We strive for operational excellence,
lowest manufacturing costs, and short cycle times.
ABBs mission is to be the leader in delivering quality products and
services for power generation, transmission and distribution, industrial
processes, mass transit, and environmental control that meet the needs
and requirements of our customers and contribute to their success.
To ensure customer satisfaction ABB will provide value-added,
integrated solutions that are driven by superior technology
and performance.
ABBs employees are committed to leadership standards in applying
the Companys unique combination of experience and global
resources to meet societal goals for sustainable growth and
clean energy.

The RESIBLOC Process

RESIBLOC transformers are classified

self-extinguishing per IEC 92-101.

Complete windings are continuously rotated in

specially designed ovens during the curing
process.

lightning, impulse and transient

voltage withstand.

Mechanical Strength
RESIBLOC cast resin transformers
provide ultimate withstand to thermal
and mechanical stress associated
with overload and short circuit
conditions because of the licensed
glass fiber roving technique which
binds the coil together for maximum
mechanical strength.
Short Circuit Integrity
The RESIBLOC design components,
70% glass fiber content, epoxy
insulation system, and the licensed
combination of glass fiber radial
and cross bracing introduced during
the winding process are all
combined in the RESIBLOC cast
resin coil to achieve a virtual
winding block. The result is a
hermetically sealed coil with
exceptional mechanical strength,
high short circuit withstand
capability and extreme thermal
shock stability at both high and
low temperature levels.
Environmentally Friendly
An environmentally safe epoxy
insulation system which is highly
resistant to moisture, chemical
contamination, fire and explosion,

RESIBLOC transformers withstand most

demanding applications.

RESIBLOC in NEMA 1 enclosure.

is utilized in RESIBLOC cast resin

transformers.
Minimal Maintenance
Epoxy protects RESIBLOC cast
resin transformers from the
environment. This epoxy shield
provides a smooth surface which
limits dust accumulation and
impedes the entrance of moisture
and other destructive elements.
Electrical Integrity
RESIBLOC cast resin transformers are
manufactured using a sectionalized
HV winding construction which
provides linear voltage distribution.
This design provides superior

Optimum Basic Impulse Levels

As a result of the linear voltage
distribution obtained from using a
sectionalized layer winding concept,
RESIBLOC cast resin transformers
provide superior lightning impulse
and transient voltage withstand. This
coil construction also provides
excellent partial discharge integrity
through uniform electrical field
distribution.
The windings are encapsulated with
epoxy resin which makes them
impervious to moisture. Therefore,
RESIBLOC cast resin transformers are
effectively protected against
mechanical and chemical effects,
humidity sensitivity, and are practically
maintenance free.
Long Life
RESIBLOC cast resin transformers are
manufactured under the strict control
of an ISO 9001 certified quality
assurance program. The units are
tested to meet or exceed the
customer requirements as well as
ANSI, NEMA, and IEEE standards.
1

Core and Coil Construction

Core Construction
The core is manufactured from high
permeability cold-rolled, grain
oriented silicon steel. The steel is
precision cut to assure that it will
be smooth and burr-free.
RESIBLOC transformers utilize a
step-lap mitered core construction
to ensure optimum performance
and minimal sound levels. The
mitered core joints allow efficient
flux transfer along natural grain
lines between the core legs
and yoke.
The step-lap construction further
enhances the efficiency of the
joint by reducing joint fringing,
which reduces core losses and
exciting current. The core is
designed and built to provide the
lowest possible losses from the
effects of magnetic hysteresis and
eddy currents. All possible steps
are taken to prevent local
circulating currents and to avoid
built-in bending stresses.
The finished core is coated with a
corrosion resistant sealant, which
provides lamination cohesion and
environmental protection.
For rigidity and support, the upper
and lower yokes are solidly clamped
with steel support members.

Step-lap mitered core joints are utilized for

efficiency and noise reduction.

Smooth outer
surfaces of the
RESIBLOC
cast resin
transformer
restricts dirt
and dust
accumulation.
Strip wound secondary and sectionalized
primary winding cutaway view.

This eliminates axial forces that are

developed in other types of windings
under short circuit conditions.
Impregnated insulation bonds the
sheet conductors together to form a
solid winding block for internal
mechanical strength. Low voltage
windings are blocked radially against
the core for additional short circuit
integrity. The windings are supported
axially using a combination of solid
and resilient mounts for sound
suppression and thermal expansion
compensation.

Coil Construction
Low Voltage Windings

High Voltage Windings

Low voltage windings, insulation

class 1.2 kV (600V) and below, are
wound using sheet conductors
which allow free current distribution
within the axial width of the coil.

High voltage windings, insulation

class 2.5 kV (2400V) and above, are
wound using the exclusive RESIBLOC
cast resin coil construction which
employs an epoxy insulation system

that is reinforced with a licensed glass

fiber roving technique.
The specific epoxy used in RESIBLOC
cast resin transformers, a bisphenol A
based epoxy, is halogen free to ensure
no harmful decomposition products
are formed in the event of a fire.
The RESIBLOC transformer will not
ignite during an electrical arc of nominal
duration. If ignited with a direct
flame, RESIBLOC will self-extinguish
when the flame is removed.
The roving winding technique
achieves a high fill factor of glass fibers
(70% of the coils total insulation weight)
with uniform distribution. High short
circuit strength is accomplished during
the winding process with a combination
of radial and cross wound helical
lathe patterns.

Indoor/Outdoor Application

RESIBLOC transformers are utilized

in some of the harshest indoor and
outdoor environments imaginable.
While core and coil technologies
have been enhanced to combat
caustic and humid environments,
RESIBLOC transformers still
require the protection of a
properly designed enclosure.
An enclosure which flexes or
bends under high wind loading
can compromise electrical
clearances from the transformer to
the enclosure, which can lead to
transformer failures as well as
electrical safety hazards. An
enclosure that allows excess water
entry into the enclosure also poses
undue risk. ABB designs have
been tested for extreme weather
requirements and the mechanical
stresses associated with seismic
criteria. ABBs enclosure designs
have been used along coastal
areas and frigid northern slopes
where high winds and driving rain
are common.

NEMA1
Indoor Enclosure

NEMA 3R
Outdoor Enclosure

ABB enclosures are custom

fabricated using heavy gauge sheet
steel as standard. Aluminum and
stainless are also available.
Electrostatically deposited dry
powder paint, baked onto a
phosphated surface, provides
added protection against harsh
outdoor or indoor environments.
A variety of options ranging from
NEMA 2 drip-proof roofs to filters,
screens, hinged panels, and
special hardware can be added.
Modifications can be made to
extend the enclosure, add bottom
plates, add end sheets, and special
cut-outs for specific applications.

Special colors such as ANSI 24

are available.

ABBs dry powder state-of-the

art paint system keeps
enclosures looking new for years.
3

Forced Air Cooling Increases kVA Capacity

Provisions for future fan

cooling (FFA)
RESIBLOC transformers, when
specified, can be supplied with
provisions for future forced air cooling.
This option includes bus work
rated for increased current capacity
and provisions for future installation
of fans and fan control equipment.
Forced air cooling (AA/FA)
RESIBLOC transformers, when
specified, can be supplied with
forced air cooling. Forced air cooling
equipment includes fans, control
wiring, thermal sensors, and a
three phase electronic temperature
monitor. The temperature sensors
are located in the low voltage
windings and are factory connected
to the three phase winding
temperature monitor which controls
the forced air cooling automatically.

Typical forced air cooling increases the rated capacity of RESIBLOC transformers 33 1/3% on units
up to 3750 kVA and 25% for units 3751 kVA and larger.

Electronic Temperature
Monitor (ETM)
The ETM combines temperature
indication and fan control functions
for the transformer and accepts
input from three thermal sensors.

The three phase electronic temperature

monitor tracks the transformer temperature
with automatic displays and functions.

Features:
Digital temperature display
Hottest winding temperature is
automatically displayed
Temperature of any single
winding can be displayed
Maximum temperature can be
recalled even if the supply
power has been interrupted
Fan, alarm, and trip functions
are controlled by the hottest
winding temperature
DPDT contacts are provided
for fan, alarm, and trip functions
Contacts are dry
Alarm relay is fail-safe
Fans can be manually operated
Includes internal sonic alarm,
which can be temporarily silenced
without canceling the alarm circuit

Isolation box to separate gauge

from energized components
Alarm reset can be automatic
or manual with auto condition
start-up
State-of-the-art solid state
construction
UL component recognized
Non-magnetic Type E
thermocouple standard
Easy retrofit with existing panels
Open thermocouple circuits are
detected and indicated, but do
not affect instrument operation
Accepts 115 or 230 VAC supply
power
Form C relays.

Optional Features
Fan exerciser (programmable)
will energize fans once per week
Remote communication available
through RS-232 port.

Standard Enclosure Design Dimension & Weights

15 kV 95 kV BIL Copper 80
kVA

Height

Width

Depth

Weight

Inches (mm)

Inches (mm)

Inches (mm)

Lbs. (kg)

300

90 (2286)

90 (2286)

60 (1524)

500
750

96 (2438)
102 (2591)

60 (1524)
60 (1524)

1000

90 (2286)
90 (2286)
90 (2286)

6000 (2724)
7500 (3405)
9000 (4086)

102 (2591)

60 (1524)
60 (1524)

10,500 (4767)

1500

102 (2591)
114 (2896)

2000
2500
3000

102 (2591)
102 (2591)
102 (2591)

102 (3048)
126 (3200)
138 (3505)

66 (1676)
66 (1676)
66 (1676)

15,500 (7037)
20,000 (9080)
23,500 (10,669)

14,500 (6583)

Values listed are typical and should not be used for construction purposes.

Solid high voltage termination

Winding temperature indicator provided

with isolation barrier for added safety

Coordinated low voltage bus termination with flexible connectors

Quality Assurance

The following tests are made on all

transformers unless noted as an
exception. The numbers shown do
not necessarily indicate the sequence
in which the tests will be made. All
tests will be made in accordance with
the latest revision of ANSI C57.12.91
Test Code for Transformers.
1. Resistance measurements of all
windings on the rated tap and
on the tap extremes on one unit
of a given rating on a multiple
unit order
2. Ratio Tests on the rated voltage
connection and all tap
connections
3. Polarity and Phase-relation Tests
4. No-load loss at rated voltage
5. Excitation current at rated voltage
6. Impedance and load loss at rated
current on the rated voltage
connection of each unit and on
the tap extremes on one unit of a
given rating on a multiple unit
order
7. Applied Potential Tests
8. Double Induced Potential Test
9. Induced Partial Discharge Test.
Optional tests which are
routinely performed:
Temperature Tests will be made

RESIBLOC coils have successfully passed severe thermal shock tests with no cracking.

made on one unit only of an order

covering one or more units of a
given rating.
When a transformer is supplied
with auxiliary cooling equipment to
provide more than one kVA rating,
Temperature Tests will be made

Temperature Test or tests will be

Audible Sound Level Test

Induced Partial Discharge
Temperature Test
Insulation Power-factor Test
Switch and Soak Test
Short Circuit Test
Seismic Qualification.

on all nameplate kVA ratings.

ABBs quality assurance begins

Optional Tests:
1. Impulse Tests-full and

with contract negotiations and

continues through design, control of
purchased materials, manufacturing
and test, and is not complete until

when a record of a Temperature

Test that has been made in
accordance with ANSI standards
is not available on a duplicate or
essentially duplicate unit.

3.
4.
5.
6.
7.
8.
9.

chopped-wave Tests per ANSI

and NEMA standards
2. Quality Control Impulse Test
(100% full wave)

the transformer is installed and

operating successfully in the
customers application for many years.

Specifications

Self-Cooled
Power Rating
kVA

Primary
Voltage
kV

Primary BIL
kV

Secondary
Voltage
kV

Secondary BIL
kV

Temperature
Rise
C

112.5-25,000

Up through 35

Up to 150

Up through 15

Up to 75

80

Standard RESIBLOC Features

1. High-voltage windings cast in epoxy reinforced by
2.
3.
4.
5.
6.
7.

Options & Accessories

fiber glass rovings

Copper high voltage aluminum low voltage windings

____ NEMA 3R enclosure

____ Copper low voltage windings

Step-lap mitered core

155C insulation system-80C average temperature rise
Four (4) full-capacity taps on HV winding rated 2 1/2%
2-FCAN2-FCBN on units with voltage above 601 V
NEMA 1 heavy-gauge ventilated enclosure with
removable panels front and rear
ANSI 61 gray paint electrostatically applied using dry
powder

____ Provisions for future forced air cooling (FFA)

____ Three-phase electronic temperature monitor
____ Forced cooling package with three-phase
electronic temperature monitor
____ Increased basic impulse levels
____ Loss optimized designs
____ Air-filled terminal chambers
____ Special paint colors

8.

Vibration isolation pads between core and coil and

enclosure
9. Base equipped with jacking pads and designed for
rolling or skidding enclosure in any direction
10. Provisions for lifting core and coil assembly

____ Retrofit designs

11. Diagrammatic aluminum nameplate

12. Partial discharge-free (less than 20 pc @ 120% rated
voltage)

Temperature Rise

Standards and Certifications

RESIBLOC transformers are constructed with 155C class

ANSI C57.12.01

insulation and have a maximum temperature rise of 80C.

ANSI C57.12.91
ANSI N45.2-1977
NRC 10CFR50 Appendix B
ISO 9001
NEMA ST20
MIL-I-45208A

Altitude Derating Factor

Standard Transformer Ratings

Primary Voltage Class 2300V through 34.5 kV 80C rise 30C average ambient

kVA 3-Phase

112 1/2

FanCooled
Ventilated
Dry

150
225

300
500

400
667

750

1000

1000

SelfCooled

Secondary Voltage

Fan-Cooled
208Y/120 480Y/277
Weather
480
240
Resistant
Delta
Delta
Ventilated

X
X
X

X
X
400
X
X

kVA Correction

2400 Delta
4160Y /
2400
4160 Delta

Altitude
(FT)

RESIBLOC
(AA)

3300

4000
5000

.994
.985

6000

.975

Forced Air
(FA)

1.00

BIL
Correction

1.00
.989

1.00
.98
.95

.974

667

7000

.966

X
X

8000

1333

1000
1333

X
X

.959
.944

9000

.957
.948

.929
.914

1000
1500

1333
2000

1333
2000

X
X

X
X

X
X

.939
.930

.898
.883

.80
.77

2000
2500
3750

2666
3333
4687

2666
3333
4687

.868
.853
.838

.75
.72
.70

6250
9375
12,500

6250
9375

X
X
X
X
X

.921
.912
.903

5000
7500

X
X

10,000
11,000
12,000
13,000
14,000
15,000

.894

.823

.67

12,500

10,000

.92
.89
.86
.83

NOTE: 3.28 FT = 1 Meter

X denotes standard or available.

Audible Sound Levels

Self-Cooled
Equivalent
Two-Winding
(kVA)

BILs Associated Voltages

Ventilated Forced Air
Cooled

Ventilated
(Class AA
Rating)

kVA

40
45
50

0-1167
1168-1667
1668-2000

68
69

501-700
701-1000
1001-1500
1501-2000
2001-3000
3001-4000
4001-5000

55
60
62
64
65
66
68
70
71

2001-3333
3334-5000
5001-6667
6668-8333

71
73
74
75

5001-6000
6001-7500

72
75

0-9
10-50
51-150
151-300
301-500

Class FA
and AFA
Rating
67

BIL's in common use (kV crest)

Nominal
System
Voltage (kV) 10 20 30 45 60 95 110 125 150 200
1.2
2.5
5.0
8.7

1
S

1
1
S

1
1
S

15.0
25.0
34.5

1
1
S

1
1
2

1
2

1
S

NOTES:
S = Standard value.
1 = Optional higher levels where exposure to overvoltage occurs
and improved protective margins are required.
2 = Lower levels where protective characteristics of applied surge
arresters have been evaluated and found to provide appropriate
surge protection.

Impedance Chart
kVA

ANSI Std.

112.5-500
None Specified
501 & Larger *
5.75%
* For Units with 60 kV Primaries and below.

1
S

ABB
5.75%
5.75%

Specification Guide
The transformer shall be RESIBLOC epoxy cast resin,
dry type construction, three (3) phase, (50,60) Hz. The
epoxy cast resin design being offered must have a minimum
5 years documented field experience. Mean time to failure
analysis per ANSI C57.117-1986 must be provided as
evidence for field experience.

Each coil shall be provided with four (4) approximately 2.5% full capacity tap connections on the surface
of the coil in the high voltage winding, two (2) above
and two (2) below normal, for deenergized tap changing
made accessible by removable panels on the transformer
enclosure.

The transformers shall be manufactured by a company

which is certified to ISO 9001:1994, EN ISO 9001:1994; BS
EN ISO 9001:1994; ANSI/ASQC Q9001: 1994 for design
and manufacture of Power, Distribution and Specialty Dry
Type Transformers. A Certificate of Compliance to this
requirement shall be provided with the proposal.

The transformer core shall be constructed with step-lap

mitered joints and shall use only grain oriented, high permeability cold rolled steel with a magnetic flux density
well below saturation levels. The finished core shall be
coated to protect against corrosion.

The unit shall be self cooled, AA rated; forced air cooled,

AA/FA rated, with an average temperature rise not to
exceed 80C when operating at full nameplate rating above
30C average, 40C maximum ambient.
The transformers shall be rated ______kVA with a primary
voltage of ____kV (delta, wye) connected with a BIL rating
of ____kV and a secondary voltage of ____kV (delta,
wye) connected with a BIL rating of ____kV.

The transformer shall be mounted in a heavy gauge ventilated steel enclosure for (indoor, outdoor) use. The
enclosure shall be finished with ANSI 61 paint color. The
paint shall be applied using an electrostatically deposited
dry powder paint system. The transformer bus and enclosure shall be custom manufactured to ensure interchangeability with existing HV and LV equipment.
The transformer base shall be designed and fabricated to
permit jacking, rolling, or skidding in any direction.

The high voltage and low voltage winding conductor

shall be copper.

The transformer shall have vibration isolation pads

installed between core and coil assembly and enclosure
base structures to prevent the transmission of structure
borne vibration.

The low voltage windings, nominal system voltage 1.2 kV

(480V) shall be wound using epoxy resin impregnated
insulation with foil or sheet conductors. The low voltage
coil shall be hermetically sealed with epoxy. The coil
shall be blocked radially to the core to ensure short
circuit integrity.

Routine testing shall be performed per ANSI C57.12.01

and ANSI C57.12.91. Testing shall be accomplished using
calibrated test equipment which have recorded accuracy
traceable to National Institute of Standards Technologies
(NIST). Certification of Calibration shall be provided with
test reports, if requested.

The high voltage windings, insulation class 2.5 kV

(2400V) and above, shall be epoxy cast coil hermetically
sealed in epoxy with reinforced multi-directional glass
fiber. The glass fiber to epoxy ratio must be a minimum
of 70:30 based on insulation weight and must be uniformly distributed throughout the coil. The reinforced
glass fiber is essential to ensure mechanical strength in
both radial and axial directions for short circuit withstand
capability and to avoid the possibility of cracking caused
by mechanical stresses due to temperature variations or
sudden load peaks.

In addition to routine testing, a 100% QC Impulse Test

shall be performed on each transformer furnished.

The transformer is to have a nominal impedance of _____%Z.

The coil must be hermetically cast in epoxy utilizing a

proven manufacturing system that demonstrates its
ability to minimize hot spots and partial discharge. An
induced partial discharge test shall be performed on each
winding. The induced partial discharge test shall be performed by measuring partial discharge levels beginning
at 80% rated voltage and continuing in 10% step increments through 200% rated voltage. Partial discharge
inception and extinction levels are defined as levels
above 10 Pico-Coulombs and shall be recorded.
Acceptance criteria is Partial discharge extinction at or
above 120% rated voltage.

In addition to the standard design test requirements, the

transformer coil design shall have been verified to show
the elimination of cracks in the epoxy insulation system
due to thermal shock. As a minimum, verification must
be provided that the transformer coil design has undergone the following severe thermal shock test.
One complete set of transformer coils, rated not less than
1000 kVA, and typical of the design series shall be dipped
alternately 6 times into tanks of boiling and freezing
water. Each submersion shall not be less than 2 hours
and the transfer time between tanks shall not exceed 2
minutes. The total submersion time shall not be less than
12 hours and the cycles must be consecutive. Upon
completion of the submersion cycle, the coils are to be
visually examined for cracks and then subjected to a
complete set of design tests including dielectric and partial
discharge. Cracking or increased partial discharge levels
after the test are evidence of failure.
All NEMA standard accessories shall be provided.

The Musselman Group, Roanoke, VA

Descriptive Bulletin 47-850 Revised 01/02

ABB Inc.
Dry Type

State Rt. 42, P.O. Box 38

Bland, VA 24315
(276) 688-3325 Fax: (276) 688-4588

Liquid Filled

2135 Philpott Road

South Boston, VA 24592
(434) 575-7971 Fax: (434) 575-2208

www.abb.com/transformers