000198 resiblockatalog en

8/13/2019 000198 Resiblockatalog En

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Power IT RESIBLOC Dry Type Distribution Transformers250 kVA through 40,000 kVA


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3/223AB B

Mission

ABB is a global leader in power and automati-on technologies that enable utility and industrycustomers to improve performance whilelowering environmental impact.

Introduction to ABB

ABB is the worlds leading supplier of DistributionT ransformers. We offer:

A ll technologies ( D ry/Li quid)All standards ( I EC, AN SI , etc)Appli cations up to 72.5 kV

Facts and figures (approx)

Production facili ties around the world: 30Countri es wi th Sales and Servi ces centers: 140N umber of units produced yearly: 400,000

Work ing wi th us, you have access to a world-wi de network of factories and faci li ties servingyou locally with a full range of products andsolutions. O ur warrenty provi des one ABB qua-li ty and service. Work ing together gives you ac-cess to production facili ties using Industrial I T

and the most up to date technologies, provi-ding the highest quality for standard and specialtyproducts as well as solutions.

Introduction to Industrial IT

I ndustrialI T

is ABB's name for a powerful com-mi tment to solutions for Real-T ime Automationand Information. I ndustrial I T guides every stepABB takes going forward in technology, businessprocesses, and more. All ABB D istribution T rans-former products are Industrial I T certified, whi chguarantees structured, easy accessible and on-line documentation. I t can be viewed on i ts ownbut also as a part of a larger system.

Quality statement

O ur production faci li ties are ISO 9001/14001certifi ed. O ur aim i s to deliver your distributiontransformers fast, on time and conform to yourspecifications.


4/224 AB B

The Opportunity

D ry type transformers are being specified morefrequently by users seeking to minimi ze conta-mi nation ri sk s to the environment and flamma-bi li ty risk s to persons and property. T hese trans-formers are required to meet more stringent pa-rameters wi th respect to electrical system de-mands as well as extreme operating climates.Appli cations today include high density officebuildings, nuclear power plants, offshore drillingplatforms, and high volume industrial processplants. N ew technology has enabled the trans-former engineer to apply new materials withnew processes to provide resilience to theseenvironments while ensuring unprecedentedreliability.

I f your transformer appl ication requi res any of the following characteristics, A BB has the so-lution to meet your needs.

N o risk of any contamination to theapplication environmentN on-explosive wi th high resistanceto flameSevere load cycles ( cold start tomaximum load)H igh short ci rcui t withstandExposure to harsh climates ( freezing,heat, chemicals, moisture)M inimal maintenance

The solution: RESIBLOC - the cast resintransformer

For more than 30 years, we have been supply-ing cast resin transformers all over the world.RESIBLO C transformers answer the need fora safe, reliable transformer designed to fulfillthe most exacting specification requirementswhile providing a non-flammable, environ-mentally safe product. The glass fibre reinforcedRESIB LO C transformer offers an extremely ro-bust and proven design for medium voltagetransformer requirements and conforms to I EC60726/I EC 60076-11 standards.

RESIBLOC - the clean technology

Glass fibre reinforcementelimi nates the ri sk of crack sand provi des highest mecha-ni cal strength

Thermal shock proof even at highest and lowesttemperatures

Smooth surfacerestricts dust accumulation

G lass fi bre and epoxy resinencapsulation preventsingress of moi sture andprotects against agressiveenvironments

High impulse withstandthrough layer winding,giving a linear voltagedistribution


5/225AB B

Main technical data

Power rating (A N) 250 kV A to 40,000 kV A

Rated voltage up to 45 k V

Compact self-supportingwinding in a one-pieceblock optimum to with-stand short-ci rcuit-forces

Aluminium or Copper foilin LV -winding

High short circuit with-stand through glass fibreprepreg resin impregnatedLV-foil winding

Self-extinguishing in theevent of secondary fire orarcing and no gases releasedwith high danger potential

Cylindrical cooling-ductsgive the advantage ofoptimal cooling through thecoil itself

Classification acc. to IEC 60076-11 Climatic classification C2 Environmental classification E2 Fire classification F1


6/226 AB B

T he material epoxy resin, reinforced with glassfibre rovings, is a material of immense strength.

M odern winding processes, combined with electro-nically controlled wi nding machinery, ensurean even distribution of glass fibre rovings andepoxy resin, and the highest precision in themanufacture of transformer windings. M ulti-spa-ced ribs, built-in during the winding process,integrate the HV and LV windings into a singlecompact wi nding block.

Glass fi bre rovin gs

Layer i n sul ati on w ith glass fibr e cross ban dage

Glass fibre reinforcement -guarantee against cracks


7/227AB B

Low voltage windings

In RESIBLO C

transformers, either aluminiumor copper foils are used for the low voltagewinding with thermal class F fibre prepreg win-dings insulation. A considerable reduction i naxial short circuit forces is obtained from the useof a foil winding.

T o rai se the space factor on transformers wi thsmall ratings, the LV-winding is produced usinga wire layer winding.

Low voltage windings for use in operating vol-tages higher than 1.1 kV are produced in thesame manner as high voltage windings.

I f necessary to provide satisfactory cooling, theLV-windings are equipped with one or moreaxial cooling ducts.

High voltage windings

T he cylindrical high voltage windings are wounddirectly onto the low voltage wi ndings. T he su-perior lightning impulse voltage withstand of RE-SIBLO C transformers i s a result of the li nearimpulse voltage distribution obtained by using alayer-wi nding concept.

Circular, or for larger cross-sections, rectangu-lar copper conductor material ( insulation classH ) is used. T he outer encapsulation and the in-termediate layer winding insulation, consists of glass fi bre reinforced epox y resin material ( in-sulation class F) , appli ed using the RO V I N G -winding process.

T he completed wi nding block is finally curedunder rotation in specially designed curingovens.

LV alumini um foi l win dingwi th gla ss fibr e prepreg in sul ati on

HV layer win din g


8/228 AB B

Wi th approx. 80 % glass fi bre content and thefavourable combination of glass fibre radial andcross bracings introduced during the windingprocess, an exceptionally robust winding blockis achieved, with high mechanical strength inboth axial and radial directions. Furthermore,this results in windings with high short circuitwi thstand levels and extreme thermal shock sta-bility at both high and low temperature levels.T he risk of crack s due to di fferent thermalcoefficients of expansion between conductingand solid resin insulation materials is effective-ly prevented for the transformers whole lifetime.Also, cracks never arise under extreme work ingconditions, i.e. very low ambient temperaturesand followi ng sudden peak overloads.

H igh rating transformers, e.g. 40 M VA, can bemade as self cooled uni ts ( AN) as multi ple coo-ling channels can be located direct within thehigh voltage windings.

G lass fi bre rovi ng winding technology makesit possible to build the largest windings in asingle piece, due to the exceptionally high me-chanical strength achieved from this type of solid insulation.

T hrough the encapsulation wi th glass fi bre re-inforced epoxy resin insulation materials, the

windings are effectively protected against me-chanical and chemical effects, insensitive to hu-mi di ty and practically maintenance free. A s nomoulds are necessary to manufacture RESIBLO C

transformers, minimum restrictions exist to pro-duce windings to suit specific customer requi-rements. T he smooth outer surfaces of the win-ding restrict dirt and dust from accumulation.

Block windings

I n the block winding principle, both high andlow voltage windings are bound together bymulti -spaced ribs, formi ng a soli d block . A nymovement during a short circuit, due to eitheraxial or radial short circuit forces is thereforeprevented. T he need for coil -supports to ab-sorb these forces, is wi th this concept no longernecessary, and the function of the supports usedi s only as spacers to p rovide the electricallyrequi red distance between the core yok es andthe windings. T he block winding principle en-sures, for the voltage wi thstand i mportant, spa-cing between H V - and LV -wi ndings, guarante-eing no changes during a short circuit or anytransformer movement.

RESIBLOC windings

RESIBLOC wi n di ngs

RESIBLOC - short circuit proof block winding


9/229AB B

Fire safety

RESIBLO C

transformers can be characteri sedas hard to ignite and self-extinguishing. Lessthan 5 % of the materials used can burn i f thetransformer is drawn into a normal fi re. T estshave proven that RESIB LO C transformers ful-fil the requirements of fire behaviour class F1acc. to Cenelec H D 46451 ( later IEC 60076-11) :

N o toxic gases, and no gases appear otherthan those present in any normal fire.

T his very favourable fire behaviour i s a di-rect result from use of approx . 80 % glassfibre content in the insulation material. T hegood self-extinguishing effect is achievedwithout using any environmentally unde-si red halogens.

Core design

T he design of the core is an important factor of any transformers efficiency. T he geometric corearrangement and the materials chosen determi-ne the losses and noi se levels. G rain ori entedtransformer sheet steel i s used i n the core con-struction. I t is cut by the most modern, fully au-tomated core cutting machinery and assembledinto li mb and yok e sets. T his results in high di -mensional accuracy, excellent space factor, andlow loss values. T he core jo ints between thelimb and yok e sections are interleaved and mi t-red (45) creating the optimum conformi ty of the magnetic flux pattern to the preferred ma-gnetic flow. By using the modern step-lap tech-nology (SLT) a multip le stepped joint is crea-ted between the li mbs and yok e sections. W ithuse of SLT the no-load currents can also be re-duced and consequently the size of a possiblyneeded reactive power compensation unit. Fora lasting protection against corrosion, each corei s given a protective epox y resin fi ni sh. T heblock wi ndi ngs are fi rmly braced to the coreusing made to measure synthetic resin insulatingstri ps.

Core clamp design

T he yok e sets of RESIB LO C tranformers areheld firmly together by exactly located steelcore clamps. Core bolts are located where ne-cessary.

RESIBLO C transformers are provided with flatrollers for longitudinal and traverse movement.T o raise the transformer, four li fting holes are si-tuated in the upper core clamps, designed for usewith a chain or cable.

Finish

Core clamps and transformer mainframe is sand-blasted, primed and given a final R AL 2000 topcoat colour.

Core design - optimal in materials and geometry

Fir e test equi pemen t


10/2210 AB B

Tests

Every RESI BLO C transformer undergoes a de-tailed individual test and inspection, includingall routine tests accordi ng to I EC 60726/I EC60076-11 and VD E 0532, prior to di spatch. T hisincludes:

Routine TestsM easurement of voltage ratio and checkof phase displacementSeparate-source AC wi thstand voltage test( applied voltage)I nduced AC overvol tage wi thstand testM easurement of no load loss and currentM easurement of wi ndi ng resistanceM easurement of impedance voltage,short-circuit impedance and load lossPartial discharge measurement ( specialtest)Function- and insulation test of controlwiring, auxiliary operation, tests on on-load tap changers, where appropriate

Optional tests

Type TestsLightning impulse (LI ) testT emperature-ri se test

Special TestsD etermination of sound levelsD etermination of capaci tances of win-dings to earth and between windingsM easurement of zero-sequence i mpedan-ce( s) on three-phase transformersM easurement of the harmoni cs of the no-load currentM easurement of insulation resistance toearth of the windings and between thewindings

Tested one by one


11/2211AB B

Thermal shock test

T he thermal shock test under extremely severeconditions is documented evidence that theRESIB LO C cast resin coi ls even under extre-me and rapid fluctuating thermal loads remaincompletely crack-free. T hese tests consist of animmersion cycle from hot- to cold-water tanks,involving 6 complete immersion cycles. T his re-sults in ex treme mechani cal and thermal stres-ses due to the temperature gradient and the ma-terials own separate expansion coefficients.

T he visual and electrical tests, including partialdi scharge tests, carried out and wi tnessed byK EM A-T est-Institute after completion of the im-mersion cycles has proven that the RESI BLO C

has retained completely its electrical functiondespite the thermal loads endured during thetest program.

T hese tests are described in detai l i n a separa-te document.

200

190

180

170

160

150

140

130

120

110

100

90

80

70

60

50

40

30

20

10

0

-10

-20

-30

-40

-50

-60

-70

T / C

0 5 10 15 20 25 30 35 40 45 50 55 60 65

Kammer/chamber

el. 6

el. 1

el. 2

el. 3

el. 4

el. 5

Deep temperature test at - 60 C

A severe test on a RESIBLO C

transformer hasbeen performed at the D epartment H igh-VoltageD ielectric Testing of U niversitt K arlsruhe: T heRESIB LO C has passed a deep temperaturestorage test at - 60 C , whereas class C2 ac-cordi ng to V D E 0532 part 6 requi res only -- 25 C . I n addition, 3 thermal shock tests havebeen made: 2 tests with double rated current at- 60 C and the 3rd test wi th 2,55 times ratedcurrent at - 60 C . V D E requi res only 1 test at- 25 C . B efore and after thi s test sequence, afull IEC routine test and partial discharge test wasperformed successfully.

T hese tests prove that the RESIBLO C trans-formers are exceeding the requirements of V D E0532 resp. Cenelec H D 46451 (I EC 60076-11)class C2. T herefore the RESIB LO C is very wellsuited for operation in arctic conditions andfor application with strongly varying loads.


12/2212 AB B

Enclosures

Standard RESI BLO C

transformers are suppliedwi thout enclosures, i .e. , protection class I P 00.Addi tional protection i s offered by use of en-closures of di fferent protection classes.

IP 21 enclosures

Enclosures class I P 21 protect against entranceof solid objects larger than 12 mm diameter andvertical drippi ng water. T o ensure the free mo-vement of cooling air, this type of enclosure isfitted with perforated sheet floor and air ventgrills at both front and rear sides.

IP 23 enclosures

I n additi on to I P 21, the IP 23 enclosures offerprotection against water dripping at an angleof up to 60 from the vertical. A solid roof isused together with a perforated sheet floor andair louvres at the top of both front and rearsides.

Special enclosures

D epending on individual customer requirements,specially designed enclosures can be offered,for example:

Protection class I P X 4D which preventsentrance of objects larger than 1 mm dia-meter and spraying water from all direc-tions.

Protection class I P 54 provi des a safetybarrier against accidental live contact.I t protects against spraying water from alldirections.Enclosures I P 54 are available up to ra-tings of 1000 kV A wi th AN cooling. Forhigher ratings, we can offer air-watercooli ng ( A FWF) - see photo page 15.

Both IP X 4D and IP 54 offer protection againstspraying water from all directions.

O ther protection degrees can be quoted on de-mand.

Enclosu re IP 23

Enclosu re IP 54

A suitable enclosure for each site

Enclosu re IP X4D


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General design

All enclosures are manufactured using galvani -sed sheet steel. O n request, enclosures can besupplied with an additional paint finish. Everyenclosure is fitted with removable front and rearpanels, for easy reconnection of H V-tappi ngs,and assembling of connecting cables. Cutouts areprovided in the enclosure floor to bring cablesthrough.

T o ensure a satisfactory supply of cooling air, thebase of the enclosure for transformers up to 800k VA must be 150 mm above the ground, up to1600 kV A 200 mm, and fo r transformers over1600 kV A 240 mm. T he mini mum cooling airrequirements are 4 m 3/k W/ mi nute of dissi -pated heat loss.

For outdoor installation specially designedenclosures are necessary.

Specia l outd oor en closu re

IP 23 en closur e wi th ra in cover an d OLTC

IP 23 enclosur e for outd oor in stallation wi th rain cover in the Nort h of Sweden


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15/2215AB B

Rectifier transformers

Standard transformers cannot be loaded to theirfull rating in circuit with a rectifier, due to theharmoni cs generated in the network wi th e.g. 6,12, 18 or 24 pulse recti fi ers. T he harmoni cscause additional losses in the windings, andthereby higher temperatures. I t is therefore es-sential, that transformers intended for use withrectifi ers are designed specifi cally for that pur-pose. T he additional eddy losses have to be mi -nimised and the cooling must be improved totake care of the remaini ng losses. T he extentof the harmonics in the system should be clear-ly speci fi ed in the enqui ry and order. O n re-quest, rectifier transformers can be suppliedwith dual LV-windings.

10 MVA RESIBLOC tr an sform erwith on load tap changer

IP 54 RESIB LOC tran sform er w ith AFWF cooler

Specia l out door encl osu res

Specia l out door en closu res


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Further options

- D ial type thermometer with maximumpointer, and 2 changeover contacts

- PT 100 sensors with digital indicator

Forced air cooling

O ptionally, RESI BLO C transformers can beequipped with cross-flow cooling fans. Fansused have low noise levels and can increasethe transform ers rated output by up to 40 % ,ideal for example for longer periods of inter-mi ttent overloads. T he fans are automaticallycontrolled using thermal sensors, to avoid ex-cessive unnecessary fan use.

2 stage temperatu re contr ol

Forced air coolin g

+

~

-

~

F1H1K5

Customer's wiring

Trip unit MS F 220 V (VU) *Signal lampCircuit-breaker trip coil

DC type

AC type

N K 5 NH1

AC/D C/ 24-240V 50/60 Hz

F1

T1T2T

K1

A

l a r m

S i g n a

l 1 A l a r m

O p e r a

t i o n

1 A l a r m

22 14 11 12

T0 T

K0

F

a n

/ A l 1

0 8 0 5

K2

T

r i p

O p e r a

t i o n

2 T r i p

S i g n a

l 2 T r i p

2 4 21

R

Circuit 2 (Trip)

Circuit 1 (Alarm)

M SF 220 V : AC 220-240 VM SF 220 VU: A C/DC 24...240 V

C ontacts of F1 shown without supply voltage

( +) ( -)

PEA 1 A 2

Overload without risk Overload capability

T he long time-constants of cast resin transformerwindings allow short-period high overloads du-ring operation. Benefits can be made of thiswhen selecting the transformers size rating. T hemaximum permitted winding temperature hotspot of 155 C will not be exceeded by specificloads, when the RESIB LO C transformer, priorto overload, is only partially loaded and/or ope-rated at a lower ambient temperature than thedesign value.

Options for overload protection

H igh ambi ent temperature, inadequate cooli ngand overloads can lead to thermal overstressingof the transformer. RESIBLO C transformers canbe protected by installing a temperature moni-toring system without limiting the transformersmaxi mum power output at all load cycles. T hetemperature monitoring system consists of twoseparate circuits, each with three PT C sensors toregister different temperatures and values.

Overload protection schema tic


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T olerances, acc. to I EC:

1 a) To tal losses+ 10 % total losses

b) N o-load or load losses+ 15 % of no-load or load losses oncondition that the tolerance for totallosses are not exceeded.

2. Voltage ratioRated voltage ratio ( principal tappi ng)

the lower of the following values:a) 0.5 % of the obligatory rated valueb) a percentage of the obligatory volta-

ge ratio which equals 1/10 of themeasured rated impedance voltagepercentage

V oltage ratio for other tappings 1 % unless otherwi se speci fied

3. I mpedance voltage at rated current( principal tapping)

10 %

4. I mpedance voltage for other tappings 15 % of agreed value for this tapping

5. N o-load current+ 30 % of the obligatory no-loadcurrent

6. Sound-pressure levelwithout tolerance

Transformer for 60 Hz

T ransformers designed for 50 Hz operation canalso operate on a 60 H z supply wi th the follo-wing amendments to the technical data:

Power: approx. 97 %N o-load losses: 80 - 85 %Load losses: approx. 105 %I mpedance: 115 - 120 %

Notes

Requirements other than shown can be quo-ted to suit individual requirements.

Technical data

RESIBLO C

transformers can be supplied withrated voltages up to 45 k V. T he high voltagewindings can be supplied reconnectable to ope-rate from several voltage suppli es. T he H V/LVno-load ratio must be stated in both enquiryand order, as voltages can be supplied to suit in-divi dual needs. R ESI BLO C transformers withdual high voltage windings can also be sup-plied.

T appings:T he standard tapping i s 2 x 2.5% at an impe-dance voltage of 4% and 6% . O ther tappingsare available on request.

I mpedance voltage:For transformers with impedance voltages otherthan the standard impedance values given i nthe following table please speci fy the reque-sted impedance values in your enquiry.

Connection groups:O n ratings up to 200 kV A the vector group i sY zn 5. O n ratings of 250 kV A and above D yn 5is used. O ther vector groups are available on de-mand.

T emperature rise:RESIB LO C transformers are designed to ensu-re that the permitted class F temperature rise of 100 K, according to IEC 60726/I EC 60076-11 andVD E 0532 is not exceeded.

N oi se levels:Noi se levels are expressed in the table as sound-power levels. A ll these levels apply for I P 00transformers, measured at 1 m di stance.

Technical data


18/2218 AB B

Service conditions

IEC Standards ambient coolingair temperature limits

Below are the maximum temperature limits thestandard dry type transformers are designed to,as defined in the standards IEC 60726/I EC 60076-11 and VD E 0532, part 6. T he cooli ng air of thetransformer must therefore never exceed:

M ax imum ambi ent temperature 40 C

Average of the hottest month 30 C

Average in any one year 20 C

Special designed units are available for use inother cooling air conditions. Standard RESIBLO C

transformers can also be used in ambient tem-peratures up to 55 C, when a calculation for areduced loading has been carried out. A s a gui-deline the load ability must be reduced by 7 %for every 10 C increased ambient temperatu-re.

Minimum temperature limits

T he colder temperatures are of special interestfor the dry type transformers, not only duringtransport and storage, but also i n service. T heRESIBLO C transformer can be placed in ope-ration at low temperatures down to - 60C with-out restrictions following low-load or switch-off periods. T he extreme mechanical strengthof the glassfibre reinforced cast resin rovingwi ndings eliminates any danger of crack ing inthe windings.

Altitude

Accordi ng to IEC 60726/I EC 60076-11 and VD E0523, part 6, a normal height above sea levelof 1000 m ( 3300 feet) must not be exceeded.For operation at higher altitudes, a special tech-ni cal design i s necessary to allow for the coo-ling air and the dimensioning of the electrical airinsulati on distances.

Humidity and pollution

T he RESIB LO C transformer is designed accor-ding to IEC 60726/I EC 60076-11 class E2 for useunder extreme service conditions, with high hu-midity levels, frequent condensation and/or pol-lution.


19/2219AB B

Outline drawing - standard ABB RESIBLOC transformer IP 00

Outline drawing - standard ABB RESIBLOC transformer IP 23

1 HV terminal2 LV te rmina l3 LV star point4 G round e a rth. Termina l5 Ra ting plate6 Termina l st rip7 Lifting eyes

1 HV terminal2 LV te rmina l3 LV star point4 G round e a rth. Termina l5 Ra ting plate6 Termina l st rip7 Lifting eyes


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21/2221 AB B

Distribution transformers offered by ABB

Liquid filled distribution transformers:- up to 72,5 kV- single phase and three phase- ground mounted, pole mounted or

pad mounted

D ry transformers:- O pen Wound- Vacuum C ast Coi l- RESI BLO C

T ransformers for special appli cations li k e:

- Railway application- M arine: propulsion and distribution- Carrier V essel N uclear- Rectifi er T ransformers- Variable Speed D rive- Excitation T ransformers- H VD C Converter- T ransformers for wi ndmi lls- Autotransformers- G rounding/Earthing Transformers- N eutral Earthing Reactors- Current Limiting Reactors- Arc Furnace- Boostertransformers

Services offered byABB Distribution Transformers

- Environmental Services - PCBElimination Services

- I nstallation and Commissioning- T raini ng- T esting and mai ntenance- Retrofits, Revamping and up-grading- Spare parts procurement- T echnical information available from

abb.com/distributiontransformers


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ABB Distribution Transformers

Affolternstrasse, 54P. O . B ox 8131C H 8050 Zurich - Switzerland

www.abb.com/distributiontransformers

1 L D E 0 0 0 0 1 7

O ur transformers are being continually developed andimproved. We must therefore reserve the right to makealterations.

000198 resiblockatalog en

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