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Insulation systems for HV rotating machines

Insulating systems for HV Motors HV Motors

Vacuum Pressure Impregnation today:

An increasing number of manufacturers and repair shops of high

voltage motors are applying the VPI technology in their coil shop.
The VPI process is a well established technology and has proven
to give a high level of performance and reliability if the insulating
materials are selected carefully to fit the type of machine and if
they are applied properly.

Two main application technologies:

Global VPI VPI cycle
Hermetic sealing
Low costs 1. Predrying
Not applicable for large machines
RR Difficilt repair 2. Dry vacuum
Improved testing 3. Wet vacuum
High costs Single bar VPI 4. Pressure phase
Improved testing
Applicable for large machines 5. Curing
High costs

2 | Company Presentation
Materials used for HV motor coils HV Motors

Many different materials are

used for the construction of a
high voltage coil or bar:
» Winding wire (A)
» Conductor insulation (B)
» Stack consolidation (C)
» Main wall insulation:
Mica tape (D) + VPI resin (H)
» Conductive paint or tape (F)
» Stress grading paint or tape (F)
» Finishing or sealing tapes (E)
» Bracing materials (G)
» Slot wedging materials (I)

3 | Company Presentation
Conductors and conductor insulation
for Coils HV Motors

The preferred conductor insulations Samicafilm® is a family of Samica/Polyesterfilm

for coils used in HV Motors are: conductor tapes with improved binder resin and a

Glass fibers (Silix®) special bond coat to enable fast consolidation of the

Daglas® conductor stack. The bond coat is thermo-plastic when

Austraflex ® pressing and thermo-setting during the cure cycle.

Samicafilm ® Advantages:

a universal conductor tape

can be used with resin-rich or VPI systems

coils can be reshaped and repaired

shorter pressing time

reduces cost of producing coil

Stack consolidation:
Hot press 5 min/150°C
+ cold press 5 min.

4 | Company Presentation
 HV Motors

Samicafilm ® tapes

A complete range of mica tapes for all needs.

315.14 315.15-11 F2-90 F2-90+ 315.23-11

Thickness mm 0.09 0.09 0.09 0.09 0.09

Total weight g/m2 131 135 124 126 126
Samica g/m2 75 75 65 65 50
Polyester film g/m2 42 42 17 17 17
mm 0.03 0.03 0.0127 0.0127 0.0127
g/m2 - - 32 32 32
mm - - 0.023 0.023 0.023
Resin g/m2 14 18 10 12 27
Adhesive No Yes No Yes 2 X yes

5 | Company Presentation
Samicafilm ® taped wires HV Motors

Examples of insulation design with Samicafilm® wires:

Wire Samicafilm® Insulation Max. thickness Rated voltage

design increase due to
insulation
Unpressed Pressed <6 6 – 13.8 > 13.8 kV
kV kV
Bare 315.14 2 butt- 0.36 mm 0.30 mm
copper 315.15-11 lapped 
layers

F2-90 3 butt- 0.54 mm 0.43 mm

F2-90+ lapped  
layers

Enamel F2-90 1 half- 0.50 mm 0.43 mm

-led F2-90+ lapped   
copper layer
grade 2

6 | Company Presentation
VPI Insulating systems for HV motors HV Motors

Von Roll offers three VPI insulating systems for

high voltage motors:
Epoxy Catalyzed Polyesterimide
anhyddride Epoxy system
system Samicabond®
Class F F H
Mica Accel. Non Non
Tape Accel. Accelerated

In both cases Von Roll offers complete insulation

systems with all needed materials:

Wires

Mica tapes

Auxiliary tapes
All systems have been tested for compatibility as
well thermal / mechanical / electrical ageing.
Resins

All systems can be processed with state of the art
Conductive / Semi-conductive tapes
machines.
Composites

7 | Company Presentation
7
Worldwide use of VPI resins HV Motors

Polyester Epoxy Epoxy Catalyzed Polyester- Silicone

Hybrid Anhydride Epoxy imide
Thermal class F F F F H 220
Shelf life Average Average Average/ Average/ High Average/
High High High
Storage temperature of resin RT 5-10°C < RT < RT RT RT
Cure cycle Average/ Average/ Average Average/ Short Long
Long Long Long
Mechanical properties Average Average/ Average/ Average/ Average/ Poor
Good Good Good Good
Flexibility Average Average/ Average/ Average/ Average Good
Good Good Good
Electrical properties Average Good Good Average/ Good Good
Good
Estimated sales volume 500 150 1000 150 150 100
worldwide (tons/year)
Price (€/kg) 4-6 7-9 6-8 8-10 6-8 30-40

8 | Company Presentation
8
Approx. prices of VPI resins HV Motors

Price 100
(€/kg)
50
Silicone

10 Epoxy Polyesterimide

5 Polyester

1
100 120 140 160 180 200 220 240 260
Temperature index / class

9 | Company Presentation
VPI insulation systems for class F motors:
Epoxy / anhydride resin Damisol ® 3407 HV Motors

3407
Liquid Viscosity at 23°C 300-500 Special features of Damisol® 3407
resin: (mPas) are:
Viscosity at 50°C 60-100
High tank stability at room
(mPas) temperature
Storage temp. RT
High flash point
Shelf life at 23°C ≥ 1 year
Low viscosity
Flash point 170°C

Fast curing with accelerated
Gel time at 160°C ≥5h mica tapes
Cure time at 170°C 8-10 h
Excellent electrical properties
Cured Thermal class F
High mechanical strength
resin:
Application: HV machines ≤ 30 kV

10 | Company Presentation
VPI insulation systems for class F motors:
Mica tapes to be used with Damisol ® 3407 HV Motors

Samicapor® Samicapor® P Samicapor®

366.55-10 315.33 374.15
Thickness mm 0.15 0.13 0.18

Total weight g/m2 200 214 241

Samica g/m2 160 160 160

Glass fabric g/m2 23 - 23

Resin content g/m2 17 12 38

Polyester fleece g/m2 - - 20

Polyester film g/m2 - 42 -

µm 30
Accelerator mg/m2 480 480 400

11 | Company Presentation
VPI insulation systems for class F motors:
Catalyzed Epoxy resin Permafil ® 74050 HV Motors

74050
Liquid Viscosity at 23°C 500
Special features of
resin: (mPas)
Permafil® 74050 are:
Storage temp. RT
High tank stability at room
Shelf life at 23°C ≥ 1 year temperature

Flash point 53°C
Low VOC emissions

New technology
Gel time at 171°C ≥ 16 min

Very stable formulation
Cure time at 170°C 6h

Excellent electrical properties
Cured Thermal class F
resin:
High mechanical strength

Application: HV machines ≤ 30 kV

12 | Company Presentation
VPI insulation systems for class F motors:
Mica tape to be used with Permafil ® 74050 HV Motors

Mica Mat® 2432XS Mica Mat® 2404XS

Thickness mm 0.16 0.16

Total weight g/m2 211 232

Samica g/m2 160 180

Glass fabric g/m2 32 32

Resin content g/m2 19 20

13 | Company Presentation
VPI insulation systems for class H motors HV Motors

Von Roll’s class H Samicabond ® insulation

system for motors is composed of:

Damisol® polyesterimide VPI resins

Samicapor ® mica tapes

CoronaShield® conductive and semi-
conductive materials

Range of auxiliary materials
The main advantage of the resins are:

High tank stability at room temperature due
to a peroxide-free accelerator

Not susceptible to moisture

Low viscosity

Fast curing with non-accelerated mica tapes

Excellent electrical properties

14 | Company Presentation
VPI insulation systems for class H motors:
Resins for the Samicabond® system HV Motors

Damisol® Damisol® Damisol® Damisol®

3032 3340 3308 3309
Liquid resin: Viscosity (mPas) 200/300 300/500 150 170
Diluent Styrene Vinyl Toluene Styrene Vinyl Toluene
Storage temp. RT RT RT RT
Shelf life at storage temp. 6 months 6 months 18 months 12 months

Flash point > 32°C > 32°C > 32°C > 32°C
Gel time 120°C 1.5 - 2 min. 2 - 4 min. 2 - 3 min. 2 - 4 min.
Cure time 8h/140°C 8h/150°C 8h/130°C 8h/150°C
Cured resin: Thermal class H H H H
Application: Dry type transformers




LV machines ≤ 1 kV

o o
HV machines ≤ 6.6 kV




HV machines ≤ 15.75 kV o o


Traction motors

15 | Company Presentation
VPI insulation systems for class H motors:
Non accelrated tapes HV Motors

Samicapor® Samicapor® P
366.58 366.58-18 366.58-20 366.53-01 374.04 315.45 323.12
Thickness mm 0.15 0.15 0.17 0.12 0.18 0.14 0.18

Total weight g/m2 192 213 224 153 241 214 251

Samica g/m2 160 180 180 120 160 160 160

(Calcined
mica paper)
Glass fabric g/m2 23 23 32 23 23 - -

Resin g/m2 9 10 12 10 38 12 20
content
Polyester g/m2 - - - - 20 - 20
fleece
Polyester g/m2 - - - - - 42 50
film µm 30 36

16 | Company Presentation
Resin-rich insulation systems for
high voltage motors HV Motors

17 | Company Presentation
Resin-rich insulation: Samicatherm ® HV Motors

Samicatherm® Samica- Mica Mat® Filosam® Samicafle

therm® P L x®
366.28 366.32 315.20 77984 77956 326.57-50 366.18/19
Thickness mm 0.19 0.28 0.16 0.2 0.147 0.13 0.14/0.18
Total weight g/m2 303 458 290 193 206 177 150/215
Samica g/m2 120 240 150 153 109 75 75/120
calcined uncalc. calcined calcined calcined calcined calcined
Glass fabric g/m2 32 32 - 31.2 Long.lglass Long. glass 23
strands strands
Resin content g/m2 113 148 70 50 50 52/72
% 43 35 28 33% 27% 28 35/33
Resin type Epoxy Epoxy Epoxy Epoxy Polyester Epoxy Silicone
Polyester g/m2 - - 32 9/9 35/17 -
film(s) µm 23 6/6 50/13
Polyester Mat g/m2 27
Thermal class F F F F F H

18 | Company Presentation
Corona Protection HV Motors

Laminated stator core

Slot exit

Copper conductors
~
Voltage ≥ Partial
Main wall insulation Discharge Inception
Voltage (PDIV)

19 | Company Presentation
Corona Protection HV Motors

Laminated stator core

External corona Slot exit

protection

Copper conductors

Main wall insulation

~
End corona protection

20 | Company Presentation
Conductive materials
for external corona protection HV Motors

Conductive tapes CoronaShield®

215.51 215.51-03 215.55 215.63

VPI* and VPI* and VPI and resin- Slot liner
resin-rich resin-rich rich

Thickness mm 0.10 0.10 0.085 0.17

Total weight g/m2 80 75 80 113

Polyester fleece g/m2 60 60 60 70

Resin content g/m2 20 15 20 43

Elongation % ≥ 10 ≥ 10 ≥8 ≥5

Surface resistivity Ω cm/cm 200-400 400-1000 200-400 200-400

21 | Company Presentation
Conductive tape based
technology: CoronaShield® NB HV Motors

Von Roll and DuPont have joined their R&D’s to

CoronaShield create new materials for our industry.
® NB 2500 NB 70
CoronaShield ® NB is an example of this
VPI and resin-rich
development. Advantages are:

High resistivity
Thickness mm 0.070

Better ageing compared to conventional tapes
Total weight g/m2 54
Surface Resistivity at TEA 17 kV/175°C
Resin content g/m2 -
8000

Tensile 7000
N/cm ≥35

R in Ohm cm/cm
6000
strength 5000
CoronaShield
4000
Shrinkage % 0 3000
c Conventional

2000
Surface
Ω cm/cm 1500 - 3000 1000
resistivity 0
0 200 400 600 800 1000
Thermal class 220 t in h

DuPont™ and NOMEX® are trademarks or registered trademarks of DuPont and its affiliates.

22 | Company Presentation
Materials for slot exit :
Semi-conductive materials HV Motors

Semiconductive tapes
CoronaShield® Voltaqe distribution along end
windings:
217.21 217.22 217.31
B-stage tape B-stage Fully cured
tape
Thickness mm 0.22 0.22 0.25
Total weight g/m2 360 360 360
Polyester
g/m2 70 70 70
fleece
Resin
g/m2 290 290 290
content Without stress grading tape
Shrinkage % ≥6 ≥6 ≤5 CoronaShield 217.01 / 217.21
after 2h at CoronaShield 217.13 / 217.31
160°C CoronaShield 217.02 / 217.22
Curing 2h/
2 h / 165°C -
conditions 165°C

23 | Company Presentation
Corona protection: Slot packing materials HV Motors

Flexible or rigid conductive materials are used to provide a good fit of the coil in the slot.

Conductive Vetronite®
432.10/11 or
Conductive ripple
springs 92.200

24 | Company Presentation
Support materials HV Motors

A number of support materials are used for

the construction of high voltage motors:

Stack consolidation tapes and resins

Finishing tapes

Bracing cords

Stator and rotor slot wedges

Coating and finishing varnishes

25 | Company Presentation
Support materials: Stack consolidation
Glasoflex
Polyester fleece tape 101.74-07 is applied for stack
® 261.10-
03
Thermopreg® 251.78 or
Polyester fleece tape
101.74-07 (if conductors are
insulated with Samicafilm)
26 | Company Presentation
HV Motors

Thermopreg® 251.78 is an epoxy resin impregnated
woven glass prepreg with a high resin content. It is
used for the consolidation of the conductor stacks.
The resin fills the interstices in the coil before curing.
consolidation of conductors insulated with
Samicafilm®. Consolidation is done without release
film and the fleece tape is not removed after the
process. It helps to give a good bonding to the main
insulation.

Glasoflex ® 261.10-03 is an epoxy resin impregnated
glass fleece used as vertical and horizontal
separator.

Damival® 15182 is a two-component epoxy resin
which can be used for stack consolidation.
Application of anti-corona products and
endwinding tapes HV Motors

Epoflex® Epoflex® is used as a protection tape

endwinding tape for the endwindings.
Conductive There are three types of Epoflex®
tape depending on the application. They
consist of:

an epoxy resin impregnated
polyester fleece,

polyester/glass fabric

poly-ester/glass fabric covered with a
polyester film.
CoronaShield
The tapes shrink during curing ensuring
tape the consolidation of the main wall,
providing a smooth surface and helping
to improve the contact between the
layers of the anti-corona tape(s).
Mica tape

27 | Company Presentation
Epoflex® endwinding protection tapes HV Motors

Epoflex®

215.01 219.61-10 324.03

For resin rich For resin rich For VPI
and soft cell
Thickness mm 0.19 0.18 0.09

Total weight g/m2 220 180 76

Polyester fleece g/m2 40 - -

Polyester / glass fabric g/m2 - 61 25

Polyester film g/m2 - - 28

Resin content g/m2 180 119 23

Elongation % ≥ 10 ≥ 20 ≥ 20

Shrinkage at 2h / 70°C Shrinkage % - - ≥1

at 2h / 120‘°C % - ≥1 ≥ 20

28 | Company Presentation
Support materials: Slot wedges HV Motors

Stator and rotor slot wedges are

supplied in full size sheets or
machined according to the
customer‘s drawings. Materials
used for high voltage motors are:

Delmat® 68.660 (Glass mat
/ epoxy)

Delmat® 68.420 (Glass
mat / epoxy)

Vetronite® 64.120 (Glass
fabric / epoxy)

Vetroferrite ® 432.20/21
(Magnetic slot wedges, glass
fabric / ferrite / epoxy)

29 | Company Presentation
Support materials: Coating and finishing
varnishes HV Motors

Coating and finishing varnishes

are used to protect coils,
housings and laminations
against dirt and moisture. They
are air or oven drying.
Varnishes mostly used are:

Coating varnish Damicoat®
2404 HFP for class F motors

Coating varnish Damicoat®
2407 for class H motors

30 | Company Presentation
Production equipment HV Motors

Von Roll offers the complete range

of production equipment for high
voltage coil manufacturing:

Loop winding machines

Coil spreading machines

Taping machines

VPI plants

Drying ovens
The flat coil technology provides
another possibility for a significant
cost reduction in high voltage coil
manufacturing.

31 | Company Presentation
Flat Coil Production center HV Motors

Loop Winder

Taping
Machine
Forming
Machine

Wire Dispenser

32 | Company Presentation
Testing HV Motors

Von Roll tests in its own laboratories all materials

as well as complete insulation systems according
to a variety of international standards such as the
IEC, the UL® and specific customer standards.

Our customers profit from our experience

to modify, develop and improve their electrical
insulation systems. Von Roll provides the
following evaluation tests:

UL 1446/IEEE117 up to 1 kV

IEEE275/IEEE429 up to 6.9 kV

IEE1043 voltage endurance up to 50 kV

NEMA MG1 immersion test

IEC60034 testing

Electrical life graphs of systems

Mechanical life graphs (thermal index IEC
216) of systems

Multistress ageing

Failure analysis

Manufacturing parameters for resin rich and
VPI technology

33 | Company Presentation
Von Roll: The Full Technology Provider HV Motors

Von Roll is the unique partner for:

Insulation system components (flexible
materials, conductors and composites)

Insulation systems

Manufacturing technology and equipments (M Tec)

Consulting & application engineering

Testing

Training

We Enable Energy

34 | Company Presentation