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


» 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


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.


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


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

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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


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


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


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


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:


500

Storage temp. RT


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



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


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


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


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


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


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


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


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


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


~

Slot exit

Copper conductors

Main wall insulationVoltage ≥ Partial

Discharge Inception Voltage (PDIV)

Corona Protection

Laminated stator core

Slot exitExternal corona

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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


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


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


Materials for slot exit :Semi-conductive materials

Voltaqe distribution along endwindings:

HV Motors




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



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


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


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


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


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



HV Motors



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


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


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


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


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


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


Manufacturing technology and equipments (M Tec)

Consulting & application engineering

Testing

Training

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