Insulating Systems for

the Motor Repair Industry

2 Insulating Systems for the Motor Repair Industry

We Enable Energy
As one of the oldest industrial companies in Switzerland, founded in 1803, we focus on
products and systems for power generation, transmission and distribution, rotating
machines and mechanical engineering. Von Roll is the global market leader for insulation
products and the only company to offer the complete range of insulation products,
composites, consulting, tests and services for the electro-technical industry.

For more than 100 years we have been making outstanding contributions to this market,
developing a number of highly innovative products that have enabled both steady increases
in power output and more compact and efficient machines.

Customers enjoy the following benefits:

One single source for all insulating materials
Thorough expertise from power generation and transmission to its efficient utilization
Proven compatibility for system components
Testing at Von Roll of both materials and systems
Consulting for applications and technologies
Training in insulation materials and systems

Von Roll, the premier supplier of electrical insulating materials to the electrical rotating
equipment industry, has developed, tested, manufactured and delivered materials that are
specially designed for use in electric motors and generator manufacturing and repair.

This product and application overview represents just a few of our most popular products,
but it should serve as a useful guide for most basic applications.

Our insulating systems for motors and generators include the following materials:
Magnet Wire
Slot and Phase Insulation
Mica Tape
Corona Tape
Mica Splittings and Tubes
Support Materials
Resins and Varnishes
Kits and Compounds
 Insulating Systems for the Motor Repair Industry 3

Our Products for Motor Repair Large

Generators

HV Rotating
Machines
Enameled Round Wires

Enameled Flat Wires

Traction
Covered Flat and Motors
Round Wires

Mica

Wind Turbine
Auxiliary Tapes Generators

Conductive/
Semi-Conductive Tapes

LV Rotating
Liquids Industrial

Flexible Laminates

LV Rotating
Composites Automotive

Machined Parts

LV Rotating
Testing Consumer

Consulting and Training

Transformers
and Switchgear

Repair
Von Roll offers full system solutions for every market shown
in this application tree. Please contact us or visit our website
www.vonroll.com for further information.
4 Insulating Systems for the Motor Repair Industry

Magnet Wire
Von Roll Austral specializes in the rapid delivery of copper rectangular magnet wires,
both enameled and covered. Also offered are unique insulations to provide improved
performance and to optimize motor and generator designs.

Rectangular wire is available in sizes ranging from as thin as 0.020 to as wide as 0.700;
2- to 3-day delivery is available for most constructions.

Thermal
Product name class Composition Special properties

Excellent thermal and chemical properties

Polyester enameled rectangular
HPAM 200C Suitable for windings that are subjected to constantly
MW-36C
high temperatures and mechanical stress

100% in-line testing

Polyester enameled rectangular
HDT-3000 200C HDT-3000 enameled wire exceeds the NEMA-MW-36C volt
MW-36C
requirement

Glass over enameled or bare

Austraflex 220C A unique Daglas insulation for AC and DC field coils
rectangular conductor MW-46C

The ultimate in conductors for high-voltage machines

Mica covered over rectangular
Austravolt 200C Excellent voltage endurance characteristics without
enameled or bare conductor
additional turn tap

Polyimide enameled retangular

Polyimide HML 220C Polyimide heavy and quadruple enameled rectangular wire
NEMA-MW-20C

Induction and radiant heat-fused polyimide film

Polyimide taped rectangular
Polyimide 240C Suitable for windings that are subjected to
NEMA-MW-62C
high-temperature applications

Others
Standard enamel-, film-, paper- and glass-covered wires are, of course, also available
with very rapid delivery and unexcelled quality and customer service.
 Insulating Systems for the Motor Repair Industry 5

Mica Mat Tapes and Wrappers

Mica is an excellent insulator that is commonly used in formed coil and field coil applications.
The commitment of Von Roll to mica is unique, starting with mining of the raw mica followed
by production of paper and mica tapes. With literally hundreds of styles and sizes available,
Von Roll is the world leader in the design and production of mica tapes with many options
available for almost all applications. For the repair market, these are the styles most popular
in the shop. For other applications, please contact your Von Roll representative.

Thermal Nominal finished

Product name class thickness Binder Application suggestions

Industry standard for dip and bake coil applications

Mica Mat
155C 0.006 Polyester The tape of choice for VPI processing with polyester resins
77956
containing DAP monomers

Our premier VPI tape with new technology to provide a

flexible tape
Mica Mat
155C 0.007 Epoxy Excellent voltage-endurance properties
77877
Compatible with most epoxy and polyester VPI resins
used in the motor repair industry

An industry standard for many years

Mica Mat
155C 0.007 Epoxy Compatible with most epoxy and polyester VPI resins
77986
used in the motor repair industry

A fully cured four-ply tape offering additional thickness while

Mica Mat remaining very flexible
155C 0.007 Polyester
2473XS Recommended for VPI systems using resins with a DAP
monomer

This three ply B-staged tape is used to manufacture

Mica Mat Solventless
155C 0.0085 formed coils where VPI processing is not available
77984 epoxy
Useful in the shop for insulating connections

Mica Mat Very flexible 2 ply mica main wall tape ideal for
155C 0.0065 Epoxy
77676 (2480XS) VPI applications. Mica weight 180 gr/m2

Mica Mat Very flexible 2 ply mica main wall tape ideal for
155C 0.0065 Epoxy
77675 (2537XS) VPI applications. Mica weight 160 gr/m2

Von Rolls commitment to mica starts with mining and stops with the production of mica taped wires.
6 Insulating Systems for the Motor Repair Industry

Corona Protection
Anytime voltages are high enough to generate partial discharge or corona, semi-conductive
materials are needed to manage the discharge without damaging the insulation. Von Roll
offers several styles of tapes and paints that can be used to safely control destructive
voltages. These products are generally used for designs of 6 kV and above, but are some
times useful in improving the life of 4 kV machines in inverter-driven applications.

Nominal
Product name thickness Color Special properties
Coated polyester tapes in the 2001000 ohm/sq range used in
Coronashield 215 4 mils Black
slot sections motor or generator to prevent corona discharge

Variable resistance (grading) tapes used to safely discharge voltages

Coronashield 217 9 mils Gray on the extensions or overhangs of coils
Several styles available

Gray paint loaded with semi-conductive particles useful

Coronashield 8001 Paint Gray in repairing damaged grading on extensions or overhangs of
high-voltage coils. Dries in 1530 minutes; tack-free

Coronashield conductive and semi-conductive tapes.

 Insulating Systems for the Motor Repair Industry 7

Slot and Phase Insulation

In random mush-wound motors, as well as some form-wound designs, a high-quality slot
liner is the principal guarantee of a long electrical life of the machine. Von Roll offers a
very wide range of flexible laminates and coated cloths for any application. All of the flexible
laminates are available in 2, 3, 4 or more plies, and most coated materials are available
with glass or Daglas substrates.

Thermal
Product name class Description Application suggestions
Preferred choice in hand-winding applications
Nonwoven polyester mat
Industry standard for class F designs
Acuflex DMD 155C bonded to both sides of an
Available in either 70% or 100% saturated
electrical grade polyester film
70% allows for improved resin absorption
Aramid paper-based flexible laminates available in a
Aramid fiber paper bonded to wide range of constructions
Acuflex NMN 180C both sides of an electrical grade Used where high-reliability performance is required
polyester film Also available with polyimide film for high-temperature
applications
Polyester-coated glass cloth
Used as slot liners or phase cloth where extreme flexibility
with or without an acrylic
Thermal H 180C is required
pressure-sensitive adhesive on
Excellent electrical, mechanical and conformability properties
one side
Flexible B-stage epoxy resin on Used as core insulation on field coils as bolt insulators and
Fusa-Flex 155C
Daglas cloth repairing tubes

W
 hen properly applied it results in a watertight sealed coil
155C Flexible B-stage polyester resin
Fusa-Fab with outstanding electrical strength for use where VPI is not
180C on Daglas cloth
available
8 Insulating Systems for the Motor Repair Industry

Support Materials
Made of 100% electrical grade glass yarns with B-staged resins, Von Roll Poly Glas
banding tapes and ropes are manufactured to provide excellent mechanical strength for
supporting structures against rotational forces as well as surge inrush currents on startup.
These products are normally fully cured before resin treatment, so compatibility is assured
with most dip or VPI resins.

Thermal
Product name class Size range Application suggestions
A 220 (C) banding tape used in supporting traction and
1/41 industrial DC armatures
Poly Glas 76870 220C
(2080 ends) Also used for tying AC stators where maximum support
is needed

Used in conjunction with blocking and tie cords, creating

Poly Glas 76831 155C 1/41 diameter a rigid support for motor and generator windings and end
turns during startup and load changes.

Lower temperature cure tape can be used when baking

Poly Glas 76881 155C 1/41 diameter ovens are not available or when thermal sensitive materials
are used
 Insulating Systems for the Motor Repair Industry 9

Mica Splittings and Tubes

Sheet materials, plates and tubes made from traditional mica splittings or mica paper
laminates provide excellent mechanical strength and unsurpassed electrical performance
for the most extreme applications of heat and voltage stress. Special splitting tapes are
also available where coil designs require their unique properties.

Molding Plates
Made with high-grade mica splittings and a variety of resins, these flexible sheets can
be shaped or molded to specific configurations, then heat-cured for mechanical stability.
They are useful in DC armature insulation as well as many other uses in the shop.

Segment Plates
These rigid plates, made from either mica splittings or laminated mica papers, are useful in
commutator manufacturing and for mechanical machined parts where glass-based
composites are not adequate. Available with modified alkyd, epoxy or inorganic binders.

Tubes
Made from either mica splittings or paper, fully cured tubes can be quickly constructed to
virtually any ID or OD. They are very resistant to high temperatures and mechanical forces
and are useful as bolt insulators, shaft insulators and as resistor grid components.
10 Insulating Systems for the Motor Repair Industry

Varnishes and Resins

Permafil varnishes and resins have been used for manufacturing and repairing motors
and generators for over 100 years and have broad acceptance among repair companies
expecting the highest in quality and performance. Available in different chemistries, there
is a product for almost any application that requires high quality and performance.

Thermal
Product name class Chemistry Flash point F Special properties
Permafil
Solvent General purpose polyester varnish for motors and
220C 88
9637 polyester transformers in dip tanks

Permafil Solvent General purpose epoxy varnish for motors and hermetic
155C 88
74043 epoxy motors in dip tanks

Fast RT curing polyester varnish for general purpose

Permafil Solvent
180C 88 applications
1217 polyester
Available in clear, red or yellow

These two polyester resins use a DAP monomer allowing for

Permafil Solventless excellent room temperature stability
220C 200/132
712/716 polyester Permafil 716 contains a blend of monomers allowing it to be
used in a dip or VPI application
707 sets the standard for performance in high-vibration and
high-temperature applications
Used in many VPI tanks
Permafil Solventless
220C 132 An excellent choice for repair shops that support the steel
707/724 polyester
and mining industries
724 is a general purpose resin used in industrial and
commercial applications

Permafil Solventless High-performance resin for general purpose industrial

180C 200
74041 epoxy and mining motors in VPI applications
High-performance resin used in high-voltage insulation
Permafil Solventless systems
220C 132
74050 epoxy When used with the proper mica tapes this insulation
system can be used for motors and generators up to 18 kV
 Insulating Systems for the Motor Repair Industry 11

Thermal
Product name class Chemistry Flash Point F Special properties

High-temperature, fast-cure, air-dry polyurethane varnish

Synthite Solvent
155C 81 with excellent circuit board-coating properties
AC-41 polyurethane
Available in aerosol

High-temperature, fast-cure, air-dry polyester varnish

Synthite Solvent
155C 81 Perfect for dip, spray or brushing
AC-43 polyester
Air-dries in 1 hour or can be baked to speed-cure

Air-dry polyurethane that has excellent moisture

Synthite Solvent
81 and fungus resistance
AC-46 polyurethane
Available in aerosol spray

Hi-Therm Solvent High-temperature varnish used in a wide range of dip

220C 88
BC-346A polyester and bake applications

Hi-Therm Solvent Excellent dipping varnish used for motors exposed to

200C 88
BC-352 epoxy moisture and harsh environments or hermetic applications

Dolphon Solventless High-flash, high-bond solventless polyester resin which

220C >200
CC-1105 polyester provides excellent storage at room temperature

Solventless Low-odor, high-flash very low VOC solventless polyester

XL-2103 220C >200
polyester resin. Formulated for high build in dip and bake applications

Red or black high-temperature, fast-cure, air-dry varnish,

Synthite Solvent
81 used as an insulator coating
ER-41/EB-41 polyurethane
Both are available in aerosol spray cans

High bond strength

Aqua-Therm Water borne Excellent coverage
>200
BC-379 epoxy Low VOC/No HAPS
Excellent tank stability
12 Insulating Systems for the Motor Repair Industry

Kits and Compounds

Often, repairing electric motors and generators for special applications requires many
specialty compounds, potting materials and top coats. Here are just a few of the materials
available from Von Roll.

Product name Chemistry Flash point F Gel time Main characteristics

34 h Two-component pour-through resin for general
Permafil 704 Polyester 132
at 25 C purpose motors

Permafil 15 min Two-component pour-through resin for general

Epoxy 200
74036 at 40 C purpose motors

Permafil 24 h High-performance two-component clear coating for spray

Epoxy 200
74010A/74010 at 25 C or flooding applications

Permafil Thixotropic wet winding compound for DC pole-

Epoxy 200 Single part
74115 wound coils

Masking compound for use on surfaces where adhesion

Permafil 277 Krytox 1) 55 Single part
of a cured resin is not desired

General purpose, high thermal conductivity black

Dolphon
Epoxy 200 R/T cure epoxy casting compound for use in all types of electrical
CB-1069
assemblies

Black epoxy compound for use in all electrical assemblies

Dolphon
Epoxy 200 R/T cure Also used to cast end windings of wind generators and
CB-1078
induction heaters

Two-part low-viscosity polybutadiene compound

Dolphon
Polybutadiene 200 R/T cure Can be used for potting, casting and coating
CB-1109
electrical apparatus

Two-part flexible black polybutadiene compound

Dolphon
Polybutadiene 200 R/T cure formulated for motor and generation encapsulation
CB-1128
Excellent for high abrasion and moisture environments

Low viscosity
Dolphon
Polybutadiene 200 R/T cure Clear compound for potting coils and transformers
CC-1120
Easily repaired

Two-part semi-rigid epoxy compound specifically

Dolphon
Epoxy 200 R/T cure formulated for encapsulation by buttering on electric
CR-1034-H
motors

1)
Registered trademark of DuPont de Nemours.
 Insulating Systems for the Motor Repair Industry 13

Testing and Laboratory Systems

Von Roll has specialized low-voltage application system testing labs that are focused on
client needs and requirements. We can process customer parts in the lab by dipping,
trickle, roll-through, vacuum-aided dipping or VPI processing methods to produce prototype
parts.

We customize systems for customers and offer the following tests:

Full system testing
Long term thermal aging
Motorette testing
Formette testing
Chemical compatibility testing
Short-term component aging (sealed-tube test)
Component thermal aging
Twisted pair testing (TP)
Helical coil bond strength testing (HC)

The wire test pieces are being tested with regard to the adhesive power of the wire coating.

Our Lab in Schenectady, NY is capable of performing insulation materials and systems

testing to ASTM, IEEE, IEC and UL standards.
14 Insulating Systems for the Motor Repair Industry

Resin and Varnish Analysis Program

At Von Roll, our focus is always on customer satisfaction and long-term relationships forged
in the industry, based in part on the technical support we offer before, during and after the
decision to purchase has been made. An example of this is our unique, pro-active resin
analysis program, designed to promote regular testing and adjustment, if required, of resins
and varnishes at our many installations at both manufacturing and repair facilities. The
periodic testing of resin properties ensures manufacturing consistency yielding predictable
results. An added benefit is the peace of mind that comes from the knowledge that your
resin or varnish is safe and stable. The provided shipping kits and friendly reminders help
keep your testing on a regular schedule, and all required adjusters are shipped directly from
the factory, assuring prompt delivery and fresh material.

Basic stability tests viscosity, gel time, moisture content, liquid and cured appearance
are performed free of charge. Additional testing such as film build, dielectric strength and
helical coil bond strength is available for a nominal charge. All of this is to keep your facility
producing good machines every day. Join the many Von Roll customers who have secured
their investment through timely analysis, feedback and recommendations from Von Roll
on keeping their tanks stable.

Laboratory Services
Insulation materials and systems testing Partial discharge evaluation and testing
to ASTM standards US Army Corps of Engineers
NEMA-RE-2 resin compliance testing qualified testing
High-voltage testing Accelerated testing capabilities
IEEE 1043 voltage-endurance testing Thermal conductivity testing
IEEE 1776 systems performance testing

Testing in the Von Roll laboratory.

 Insulating Systems for the Motor Repair Industry 15

Training
For a number of years we have been offering a unique program of high-voltage insulation
training within our Von Roll Corporate University. The objectives of this program are:
Better understanding of high-voltage insulation technology for rotating machines and
up-to-date knowledge on insulating materials and systems
Practical experience in the application of electrical insulating materials

Our training courses are attended by customers and partners from around the globe.

Development and applications support On-site applications and engineering

Systems consulting and development support

Evaluation of systems/systems Resin and varnish analysis program

development Development of testing protocols
Systems engineering consulting VPI processing of sample bars,
Plant design evaluation and consulting coils and units
services Materials and resin prototype
development
 We Enable Energy
Von Roll is the sole full-range supplier of materials and systems for the insulation of electrical machines
as well as high-performance products for various high-tech industries.

Mica Flexibles
All materials related to high-voltage insulation. Insulating flexible materials for low-voltage
Von Rolls commitment to mica starts with applications such as flexible laminates and
mining and ends with finished tapes. adhesive tapes.

Wires Ballistic Protection

Insulated round, flat and Litz wires for high- High-quality systems for armored defense
voltage, low-voltage and electronic applica- based on thermoset / thermoplastic products
tions. in single-use or tailored combinations.

Cables
Mica tapes for fire-resistant cables. Von Roll Water and wastewater treatment
provides a wide range of products that are Von Roll BHU provides solutions for process
ideally suited to all commonly used standards. engineering tasks in the field of water and
wastewater management.
Liquids
Impregnation resins for high- and low-voltage, Testing
potting resins, casting resins, as well Von Roll provides electrical, thermal and
as encapsulating and conformal coatings. mechanical testing of individual materials as
well as complete insulating systems.

All information in this document subject to the product liability clause as published on the website www.vonroll.com under General Terms and Conditions.
Composites
Engineered materials made from a resin and a Training
support structure with distinct physical, thermal Von Roll Corporate University provides a
and electrical properties. They can be molded, training program in high- and low-voltage
machined or semi-finished. insulation for its customers.

Please contact us or visit our website www.vonroll.com for further information:

Customer Service :

Europe Asia/Pacific North- and South America

Von Roll Schweiz AG Von Roll Asia Pte Ltd. Von Roll USA, Inc. Von Roll do Brasil Ltda.
Passwangstrasse 20 6 Serangoon North Avenue 5 #03-01 200 Von Roll Drive Av. Aruana, 201
4226 Breitenbach Singapore 554910 Schenectady, NY 12306 06410-010 Sao Paolo
Switzerland Singapore USA Brazil
P +41 61 785 51 11 P +65 6556 4788 P +1 518-344-7100 P +55 11 4208 5995
F +41 61 785 51 88 F +65 6556 4959 F +1 518-344-7288 F +55 11 4193 6789

About us
We Enable Energy As one of Switzerlands longest-established industrial companies, Von Roll focuses on
products and systems for electrical power generation, power transmission and industrial applications. Von Rolls
business portfolio is divided into the following businesses: Von Roll Insulation offers electrical insulation products,
systems and services for generators, high- and low-voltage motors, transformers and other applications.
Von Roll Composites produces composite materials and parts for a variety of industrial equipment. Other activities
of Von Roll include solutions for process engineering tasks in the field of water and wastewater management.