Insulation Systems for HV Motors
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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 highvoltage motors are applying the VPI technology in their coil shop.The VPI process is a well established technology and has provento give a high level of performance and reliability if the insulatingmaterials are selected carefully to fit the type of machine and if
2 | Company Presentation
materials are selected carefully to fit the type of machine and ifthey are applied properly.
Two main application technologies:
RRImproved testing
High costs
Global VPIHermetic sealing
Low costsNot applicable for large machines
Difficilt repair
Single bar VPIImproved testing
Applicable for large machinesHigh costs
VPI cycle
1. Predrying
2. Dry vacuum
3. Wet vacuum
4. Pressure phase
5. Curing
Materials used for HV motor coils
» Winding wire (A)» Conductor insulation (B)» Stack consolidation (C)
Many different materials areused for the construction of ahigh voltage coil or bar:
HV Motors
3 | Company Presentation
» 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)
Conductors and conductor insulationfor Coils
The preferred conductor insulationsfor coils used in HV Motors are:
Glass fibers (Silix®) Daglas®
Austraflex ®
Samicafilm ®
Samicafilm® is a family of Samica/Polyesterfilmconductor tapes with improved binder resin and aspecial bond coat to enable fast consolidation of theconductor stack. The bond coat is thermo-plastic whenpressing and thermo-setting during the cure cycle.
Advantages:
a universal conductor tape
can be used with resin-rich or VPI systems
HV Motors
4 | Company Presentation
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 .
315.14 315.15-11 F2-90 F2-90+ 315.23-11
Samicafilm ® tapesHV Motors
A complete range of mica tapes for all needs.
5 | Company Presentation
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
Wire Samicafilm ® Insulationdesign
Max. thicknessincrease due to
insulation
Rated voltage
Unpressed Pressed < 6 kV
6 – 13.8 kV
> 13.8 kV
Samicafilm ® taped wires
Examples of insulation design with Samicafilm® wires:
HV Motors
6 | Company Presentation
Bare copper
315.14315.15-11
2 butt-lapped layers
0.36 mm 0.30 mm
F2-90F2-90+
3 butt-lapped layers
0.54 mm 0.43 mm
Enamel-led
coppergrade 2
F2-90F2-90+
1 half-lapped layer
0.50 mm 0.43 mm
VPI Insulating systems for HV motors
Von Roll offers three VPI insulating systems forhigh voltage motors:
Epoxy anhyddride
system
CatalyzedEpoxy
Polyesterimidesystem
Samicabond ®
Class F F H
Mica Accel. Non Non
HV Motors
7 | Company Presentation7
Mica Tape
Accel. Non Accel.
Non Accelerated
In both cases Von Roll offers complete insulationsystems with all needed materials:
Wires
Mica tapes
Auxiliary tapes
Resins
Conductive / Semi-conductive tapes
Composites
All systems have been tested for compatibility aswell thermal / mechanical / electrical ageing.
All systems can be processed with state of the artmachines.
Polyester Epoxy Hybrid
Epoxy Anhydride
Catalyzed Epoxy
Polyester-imide
Silicone
Thermal class F F F F H 220
Shelf life Average Average Average/High
Average/High
High Average/High
Storage temperature of resin RT 5-10°C < RT < RT RT RT
Cure cycle Average/ Average/ Average Average/ Short Long
Worldwide use of VPI resins HV Motors
8 | Company Presentation8
Cure cycle Average/Long
Average/Long
Average Average/Long
Short Long
Mechanical properties Average Average/Good
Average/Good
Average/Good
Average/Good
Poor
Flexibility Average Average/Good
Average/Good
Average/Good
Average Good
Electrical properties Average Good Good Average/Good
Good Good
Estimated sales volume worldwide (tons/year)
500 150 1000 150 150 100
Price (€/kg) 4-6 7-9 6-8 8-10 6-8 30-40
Approx. prices of VPI resins
100
Silicone
Price (€/kg)
50
HV Motors
9 | Company Presentation
1
10
100 120 140 160 180 200 220 240 260
Epoxy
Polyester
Polyesterimide
Temperature index / class
5
3407
Liquid resin:
Viscosity at 23°C (mPas)
300-500
Viscosity at 50°C (mPas)
60-100
Storage temp. RT
Special features of Damisol® 3407 are:
High tank stability at room temperature
High flash point
VPI insulation systems for class F motors:Epoxy / anhydride resin Damisol ® 3407 HV Motors
10 | Company Presentation
Storage temp. RT
Shelf life at 23°C ≥ 1 year
Flash point 170°C
Gel time at 160°C ≥ 5 h
Cure time at 170°C 8-10 h
Cured resin:
Thermal class F
Application: HV machines ≤ 30 kV
High flash point
Low viscosity
Fast curing with accelerated mica tapes
Excellent electrical properties
High mechanical strength
Samicapor® 366.55-10
Samicapor® P 315.33
Samicapor®374.15
Thickness mm 0.15 0.13 0.18
Total weight g/m2 200 214 241
Samica g/m2 160 160 160
VPI insulation systems for class F motors:Mica tapes to be used with Damisol ® 3407 HV Motors
11 | Company Presentation
Samica g/m 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
µm- 42
30-
Accelerator mg/m2 480 480 400
74050
Liquid resin:
Viscosity at 23°C (mPas)
500
Storage temp. RT
Shelf life at 23°C ≥ 1 year
Special features ofPermafil® 74050 are:
High tank stability at room temperature
VPI insulation systems for class F motors:Catalyzed Epoxy resin Permafil ® 74050 HV Motors
12 | Company Presentation
Shelf life at 23°C ≥ 1 year
Flash point 53°C
Gel time at 171°C ≥ 16 min
Cure time at 170°C 6h
Cured resin:
Thermal class F
Application: HV machines ≤ 30 kV
temperature
Low VOC emissions
New technology
Very stable formulation
Excellent electrical properties
High mechanical strength
Mica Mat® 2432XS Mica Mat® 2404XS
Thickness mm 0.16 0.16
VPI insulation systems for class F motors:Mica tape to be used with Permafil ® 74050 HV Motors
13 | Company Presentation
Total weight g/m2 211 232
Samica g/m2 160 180
Glass fabric g/m2 32 32
Resin content g/m2 19 20
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
VPI insulation systems for class H motors HV Motors
14 | Company Presentation
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
Damisol®3032
Damisol®3340
Damisol®3308
Damisol®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
VPI insulation systems for class H motors:Resins for the Samicabond® system HV Motors
15 | Company Presentation
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
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
VPI insulation systems for class H motors:Non accelrated tapes HV Motors
16 | Company Presentation
Samica g/m2 160 180 180 120(Calcined
mica paper)
160 160 160
Glass fabric g/m2 23 23 32 23 23 - -
Resin content
g/m2 9 10 12 10 38 12 20
Polyester fleece
g/m2 - - - - 20 - 20
Polyester film
g/m2
µm- - - - - 42
305036
Resin-rich insulation systems forhigh voltage motors HV Motors
17 | Company Presentation
Resin-rich insulation: Samicatherm ®
Samicatherm® Samica-therm® P
Mica Mat® Filosam®L
Samicaflex®
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 120calcined
240uncalc.
150calcined
153calcined
109calcined
75calcined
75/120calcined
HV Motors
18 | Company Presentation
calcined uncalc. calcined calcined calcined calcined calcined
Glass fabric g/m2 32 32 - 31.2 Long.lglassstrands
Long. glassstrands
23
Resin content g/m2
%11343
14835
7028
5033% 27%
5028
52/7235/33
Resin type Epoxy Epoxy Epoxy Epoxy Polyester Epoxy Silicone
Polyester film(s)
g/m2
µm- - 32
239/96/6
35/1750/13
-
Polyester Mat g/m2 27
Thermal class F F F F F H
Corona Protection
Laminated stator core
HV Motors
19 | Company Presentation
~
Slot exit
Copper conductors
Main wall insulationVoltage ≥ Partial
Discharge Inception Voltage (PDIV)
Corona Protection
Laminated stator core
Slot exitExternal corona
HV Motors
20 | Company Presentation
Copper conductors
Main wall insulation
End corona protection
~
External corona protection
Conductive tapes CoronaShield ®
215.51
VPI* and resin -rich
215.51-03
VPI* and resin -rich
215.55
VPI and resin-rich
215.63
Slot liner
Conductive materialsfor external corona protection HV Motors
21 | Company Presentation
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
CoronaShield® NB 2500 NB 70
VPI and resin-rich
Thickness mm 0.070
Total weight g/m2 54
Conductive tape based technology: CoronaShield® NB
Von Roll and DuPont have joined their R&D’s tocreate new materials for our industry.
CoronaShield ® NB is an example of thisdevelopment. Advantages are:
High resistivity
Better ageing compared to conventional tapes
HV Motors
22 | Company Presentation
Total weight g/m 54
Resin content g/m2 -
Tensile strength
N/cm ≥35
Shrinkage % 0
Surface resistivity
Ω cm/cm 1500 - 3000
Thermal class 220
DuPont™ and NOMEX® are trademarks or registered trademarks of DuPont and its affiliates.
Surface Resistivity at TEA 17 kV/175°C
0
1000
2000
3000
4000
5000
6000
7000
8000
0 200 400 600 800 1000
t in h
R in
Ohm
cm
/cm
CoronaShield
Conventionalc
Semiconductive tapesCoronaShield ®
217.21B-stage tape
217.22 B-stage
tape
217.31Fully cured
Thickness mm 0.22 0.22 0.25
Materials for slot exit :Semi-conductive materials
Voltaqe distribution along endwindings:
HV Motors
23 | Company Presentation
Thickness mm 0.22 0.22 0.25
Total weight g/m2 360 360 360
Polyester fleece
g/m2 70 70 70
Resin content
g/m2 290 290 290
Shrinkage after 2h at 160°C
% ≥ 6 ≥ 6 ≤ 5
Curing conditions
2 h / 165°C2 h /
165°C-
Without stress grading tape
CoronaShield 217.01 / 217.21
CoronaShield 217.13 / 217.31
CoronaShield 217.02 / 217.22
Corona protection: Slot packing materials
Conductive Vetronite®
Flexible or rigid conductive materials are used to provide a good fit of the coil in the slot.
HV Motors
24 | Company Presentation
Conductive Vetronite®432.10/11 or
Conductive ripple springs 92.200
Support materials
A number of support materials are used forthe construction of high voltage motors:
Stack consolidation tapes and resins
Finishing tapes
Bracing cords
HV Motors
25 | Company Presentation
Bracing cords
Stator and rotor slot wedges
Coating and finishing varnishes
Support materials: Stack consolidation
Thermopreg® 251.78 is an epoxy resin impregnatedwoven glass prepreg with a high resin content. It isused for the consolidation of the conductor stacks.The resin fills the interstices in the coil before curing.
Polyester fleece tape 101.74-07 is applied for stackconsolidation of conductors insulated withSamicafilm®. Consolidation is done without release
Glasoflex® 261.10-
HV Motors
26 | Company Presentation
Samicafilm®. Consolidation is done without releasefilm and the fleece tape is not removed after theprocess. It helps to give a good bonding to the maininsulation.
Glasoflex ® 261.10-03 is an epoxy resin impregnatedglass fleece used as vertical and horizontalseparator.
Damival® 15182 is a two-component epoxy resinwhich can be used for stack consolidation.
Thermopreg® 251.78 or
Polyester fleece tape 101.74-07 (if conductors are insulated with Samicafilm)
® 261.10-03
Application of anti-corona products andendwinding tapes
Conductive tape
Epoflex® endwinding tape
Epoflex® is used as a protection tapefor the endwindings.
There are three types of Epoflex®depending on the application. Theyconsist of:
an epoxy resin impregnated
HV Motors
27 | Company Presentation
CoronaShieldtape
Mica tape
polyester fleece,
polyester/glass fabric
poly-ester/glass fabric covered with a polyester film.
The tapes shrink during curing ensuringthe consolidation of the main wall,providing a smooth surface and helpingto improve the contact between thelayers of the anti-corona tape(s).
Epoflex® endwinding protection tapes
Epoflex®
215.01For resin rich and soft cell
219.61-10For resin rich
324.03For VPI
Thickness mm 0.19 0.18 0.09
Total weight g/m2 220 180 76
HV Motors
28 | Company Presentation
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 at 2h / 120‘°C
% %
--
-≥ 1
≥ 1≥ 20
Stator and rotor slot wedges aresupplied in full size sheets ormachined according to thecustomer‘s drawings. Materialsused for high voltage motors are:
Delmat® 68.660 (Glass mat
Support materials: Slot wedges HV Motors
29 | Company Presentation
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)
Coating and finishing varnishesare used to protect coils,housings and laminationsagainst dirt and moisture. Theyare air or oven drying.
Support materials: Coating and finishing varnishes HV Motors
30 | Company Presentation
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
Von Roll offers the complete rangeof production equipment for highvoltage coil manufacturing:
Loop winding machines
Coil spreading machines
Production equipment HV Motors
31 | Company Presentation
Coil spreading machines
Taping machines
VPI plants
Drying ovens
The flat coil technology providesanother possibility for a significantcost reduction in high voltage coilmanufacturing.
Loop Winder
Flat Coil Production center HV Motors
32 | Company Presentation
Wire Dispenser
Taping Machine
Forming Machine
Testing
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:
HV Motors
33 | Company Presentation
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
Von Roll: The Full Technology Provider
Von Roll is the unique partner for:
Insulation system components (flexible materials, conductors and composites)
Insulation systems
Manufacturing technology and equipments (M Tec)
HV Motors
34 | Company Presentation
Manufacturing technology and equipments (M Tec)
Consulting & application engineering
Testing
Training
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