MARKETS // PRODUCTS

INSULATING
SYSTEMS
FOR HIGH-VOLTAGE
ROTATING MACHINES
2 Insulating Systems for High-Voltage Rotating Machines

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 machi-
nes 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 electrical machines such as turbo and hydro generators.

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 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 is committed to creating added value for its customers with the insulating materials
and processes used in state-of-the-art electrical high-voltage motors as well as small
generators with similar design. We offer the solutions you need for higher performance and
reliability together with low manufacturing costs. No matter what the precise requirements of
your machines, we have materials that will suit them using
either resin-rich (RR) or vacuum pressure impregnation (VPI) technologies.

Von Roll has developed a VPI insulation system, under the name Samicabond®,
with a number of distinct advantages:
» Resins with high tank stability at room temperature
» Imperviousness to moisture
» Low viscosity
» Fast curing with non-accelerated mica tapes
» Excellent electrical properties
» Class H
» Very high price/quality ratio

This document introduces the main products associated with this system.
 Insulating Systems for High-Voltage Rotating Machines 3

Our Products for High-Voltage Motors

Large Generators

HV Rotating
Enameled Round Wires Machines

Enameled Flat Wires

Covered Flat and Traction Motors

Round Wires

Mica

Wind Turbine
Auxiliary Tapes Generators

Conductive/Semi-
Conductive Tapes

Resins LV Rotating Industrial

Flexible Laminates

LV Rotating Auto-
Composites motive

Machined Parts

Testing LV Rotating 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 High-Voltage Rotating Machines

Mica Tapes for Insulation of Conductors

Samicafilm® products are based on Von Roll Samica® mica paper impregnated with modified
epoxy resin, reinforced with one or two polyester film backings and with or without adhesive
coating.

Weight g/m2

Thickness Breakdown
Samicafilm® type mm Total Mica PET Film 1 PET Film 2 Resin voltage kV Adhesive
315.11-01 0.06 72 30 32 10 ≥5 No
315.12-01 0.07 93 50 32 11 ≥5 No
315.70-01 0.075 101 50 42 9 ≥8 No
315.14 0.09 131 75 42 14 ≥8 No
315.15-01 0.09 131 75 42 14 ≥8 No
315.11-11 0.06 76 30 32 14 ≥5 Yes
315.12-11 0.07 97 50 32 15 ≥5 Yes
315.15-11 0.09 135 75 42 18 ≥8 Yes
315.72-01 0.085 124 65 32 17 10 ≥8 No
315.23-01 0.09 112 50 32 17 13 ≥8 No
315.25-03 0.1 141 75 42 8 16 ≥8 No
315.72-21 0.09 133 65 32 17 19 ≥8 1 side
315.23-11 0.09 126 50 32 17 27 ≥8 2 sides
315.25-11 0.11 151 75 32 17 27 ≥8 2 sides

Samicafilm® tapes show excellent corona resistance, although they are thin.

Conductors
Von Roll offers a complete range of high-quality conductors for high-voltage coils:
» Covered wires with impregnated glass yarn (Silix®)
» Covered wires with mixed glass/polyester yarn (Daglas®), with or without coating
» Samicafilm® tape-covered wires
» Flat rolled Litz wires with bare or enameled single conductors, covered with
Samicafilm® tape
 Insulating Systems for High-Voltage Rotating Machines 5

Samicafilm® tape covering on bare or enameled wires is the preferred conductor

insulation for stator and rotor coils due to its substantial advantages:
» Better corona resistance
» Reduced insulation thickness
» Softer copper, enabling easier workability
» Greater manufacturing flexibility

Samicafilm® tapes are applied butt-lapped or overlapped to the conductor. We supply both
tape and taped conductors to our customers.

Silix® coverings are impregnated with varnishes based on epoxy, polyester-imide,

polyamide-imide, silicone or polyimide resins, depending on the thermal class required.
For Silix® and Daglas® special grades with B-stage overcoat varnishes are also available for
conductor stack consolidation. Flat litz conductors instead of solid flat wires allow smaller
overhangs, bigger copper cross sections and higher efficiency by minimizing the eddy
losses (proximity and skin effects).

Rated voltage
Product name < 6 kV 6–13.8 kV > 13.8 kV Dimensions Description
Silix® on bare wire • On request Glass-lapped wire with or without
B-stage overcoat
Silix® on enameled wire • • • On request Glass-lapped wire with or without
B-stage overcoat
Daglas® on bare wire • On request Daglas®-lapped wire with or without
B-stage overcoat
Daglas® on enameled wire • • • On request Daglas®-lapped wire with or without
B-stage overcoat

Stack Consolidation
Employing Samicafilm® with hot-melt adhesive or glass-lapped wires at B-stage enables
rapid consolidation of conductor stacks without the need for additional consolidation
products.

When using Samicafilm® without hot-melt adhesive or non-B-stage wires, traditional

hot-press consolidation is preferred. This system can be achieved by overlapping the stack
with Thermopreg® 251.78.

Von Roll standard materials for stack consolidation:

Thickness
Product name Form mm Description
Thermopreg® 251.78 Tape 0.10 Impregnated glass cloth
Polyester fleece 101.74-07 Tape 0.56 Nonimpregnated polyester fleece
Glasoflex® 261.10-03 Tape 0.50 Impregnated glass fleece with high resin content
Damival® 15182/9030 Resin Solventless two-component epoxy resin
6 Insulating Systems for High-Voltage Rotating Machines

Main Wall Insulation for the VPI System

Von Roll is highly committed to mica. Our added value is visible throughout the complete
manufacturing chain. It starts by mining, preparation of the mica scrap, preparation of the
mica paper pulp, production of mica paper and finally production of mica tapes that can be
used to the highest standards to make main wall insulations.

Von Roll has the right solution to improve the quality and cost-effectiveness of the high-
voltage insulation you need for your applications.

With Samicapor®, Von Roll has designed a range of outstanding VPI mica tapes that fulfill
the requirements of main wall and end-winding insulation, namely:
» High dielectric strength
» Corona discharge resistance
» Fast and easy impregnation
» Resin retention without draining
» Smooth application without creasing
» Both manual and fast-running machine application
» Full compatibility with predefined resin systems

Von Roll’s commitment to mica starts with mining and ends with finished tapes.
 Insulating Systems for High-Voltage Rotating Machines 7

Rated voltage Weight g/m2 Resin compatibility and thermal class

Non-accelerated Accelerated Polyesterimide

Thickness epoxy- epoxy Samicabond®
Product name < 6 kV > 6 kV mm Total Mica Composition anhydride VPI systems system
Samicapor® • • 0.15 200 160 Mica/ 155 (F)
366.55-10 Glass

Samicapor® • • 0.14 198 160 Mica/ 155 (F)

366.55-12 Glass

Samicapor® • • 0.15 195 160 Mica/ 155 (F) 155 (F)/

366.58 Glass 180 (H)

Samicapor® • • 0.15 213 180 Mica/ 155 (F) 155 (F)/

366.58-18 Glass 180 (H)

Samicapor® • • 0.17 224 180 Mica/ 155 (F) 155 (F)/

366.58-20 Glass 180 (H)

Samicapor® • 0.18 241 160 Glass/ 155 (F) 155 (F)

374.04 Mica/
PET fleece

Samicapor® • 0.18 241 160 Glass/ 155 (F)

374.15 Mica/
PET fleece

Samicapor® P • 0.13 214 160 Mica/ 155 (F)

315.33 PET film

Samicapor® P • 0.14 214 160 Mica/ 155 (F) 155 (F) 155 (F)
315.45 PET film

With high-speed taping machines Samicapor® und Samicatherm® tapes are precisely wrapped around the conductors.
8 Insulating Systems for High-Voltage Rotating Machines

Main Wall Tapes for the RR System

Assuring optimum quality of main wall insulation requires careful selection of micaceous
tape and detailed attention to the way the tape is applied and processed.
The solutions we have devised to get you the best possible results include a complete
range of resin-rich (RR) main wall insulation tapes and systems under the name Samica-
therm® for both conventional and hydrostatic pressing and Filosam® and Samicaflex® for the
overhang areas.

The advantages of these tapes are that they:

» Have high dielectric strength
» Resist corona discharge
» Can be applied smoothly without creasing
» Can be applied by fast-running machines or manually
» Have short cutting times

Main wall tapes for conventional hot pressing:

Rated voltage Weight g/m2

Thickness
Product name < 6 kV 6–13.8 kV > 13.8 kV mm Total Mica Description
Samicatherm® • • 0.19 265 120 Mica/Glass with/without
366.28/366.28-02 interleaving foil
Samicatherm® • • 0.19 265 120 Mica/Glass with/without
366.28-04/366.28-03 interleaving foil, slightly drier
Samicatherm® • • 0.19 265 120 Mica/Glass with interleaving foil,
366.28-05 slightly drier
Samicatherm® • • 0.20 277 120 Mica/Glass without interleaving foil, with
366.28-06 slightly higher resin content
Samicatherm® • • • 0.25 350 180 Mica/Glass without
366.33-62 interleaving foil
Samicatherm® • • • 0.26 458 240 Mica/Glass with
366.32 interleaving foil
Samicatherm® P • 0.16 252 150 Mica/PET film with/without
315.20/315.20-02 interleaving foil
Samicatherm® P • 0.17 270 150 Mica/PET film without
315.20-10 interleaving foil
Samicatherm® PI • 0.09 117 60 Mica/Polyimide film, class H
315.51

Overhang tapes for conventional hot pressing:

Weight g/m2
Thickness
Product name mm Total Mica Description
Filosam® 326.57-20 0.15 206 109 PET film/Mica/Glass threads, highly flexible
Filosam® 326.57-50 0.13 177 75 PET film/Mica/Glass threads, highly flexible
Samicaflex® 366.18 0.12 150 75 Mica/Glass, class H, flexible for higher voltages
Samicaflex® 366.19 0.18 109 120 Mica/Glass, class H, flexible for higher voltages
 Insulating Systems for High-Voltage Rotating Machines 9

Corona Protection
Electrical stress control measures are an essential component of any high-voltage machine.
Von Roll has developed a number of superior products under the trade name CoronaS-
hield®, namely:
» Conductive tapes impregnated and in paper form
» Semi-conductive tapes
» Conductive varnishes

All these tapes can be applied as:

» External corona protection – within the slot
» End corona protection – outside the slot

Thickness
Product name mm Resistivity Ohm/m2 Description
CoronaShield® 0.10 200–400 Conductive tape, impregnated PET fleece,
215.51 not compatible with epoxy anhydride, cured
CoronaShield® 0.085 200–400 Conductive tape, impregnated PET fleece, cured
215.55
CoronaShield® 0.17 200–400 Conductive tape, impregnated PET fleece, cured
215.63
CoronaShield® 0.22 Variable Semi-conductive tape, impregnated PET fabric,
217.01/217.21 with specific characteristics, not cured (B-stage)
CoronaShield® 0.22 Variable Semi-conductive tape, impregnated PET fabric,
217.02/217.22 with specific characteristics, not cured (B-stage)
CoronaShield® 0.22 Variable Semi-conductive tape, impregnated PET fabric,
217.03 with specific characteristics, not cured (B-stage)
CoronaShield® 0.25 Variable Semi-conductive tape, impregnated PET fabric,
217.31 with specific characteristics, cured

CoronaShield® conductive and semi-conductive tapes.

10 Insulating Systems for High-Voltage Rotating Machines

Finishing Tapes
To protect your equipment, the use of finishing tape is highly recommended. This material
will protect the main wall insulation in the overhang area against:
» Moisture
» Mechanical load
» Damage
» Resin flow
» Atmospheric pollutants

With Epoflex Von Roll found the right solution to meet these requirements:

Thickness
Product name mm Description
Epoflex 215.01 0.19 Polyester fleece with epoxy resin, not cured
Epoflex 219.61-10 0.18 Polyester glass fabric with with epoxy resin, not cured
Epoflex 324.03 0.09 Polyester glass fabric with a polyester film and reduced binder quantity, cured
 Insulating Systems for High-Voltage Rotating Machines 11

Winding and Bracing of Machines

The simplicity of the winding process for machines with “dry” coils is a recognized benefit of
VPI technology. Substantial advantages arise during the end-winding bracing and support
procedure. Von Roll has developed a range of ropes, cords and sleeves
for “surge ring” intercoil lacing and tying applications.

The main advantages of these products are:

» Class C (glass) and F (polyester) applications
» Compressibility and resilience
» Glass or polyester yarn on the outside
» Wide range of dimensions
» Nonimpregnated for use with VPI; no further processing
» Impregnated polyester shrink cord for RR uses

Thickness
Product name Form mm Description
Isocord® 151.10 Cord 1.8–50 Braided silane E glass yarn outside with glass filler
Isocord® 151.12 Cord 1.5–60 Braided polyester yarn outside with glass filler

Glass and glass polyester cords.

12 Insulating Systems for High-Voltage Rotating Machines

Composite Materials
Von Roll offers a variety of state-of-the-art composite materials that can be delivered as
U and L profiles, strips and sheets, machined parts or special components for use in
different areas of high-voltage rotating motors. The following are just a selection. Please
ask our specialists about additional products.

Machined parts tailored to customer specifications.

Different materials used for rotor and stator components:

Rated voltage
Commutator
Stator slot

stator slot
insulation

Rotor slot
Magnetic

wedges
wedges

Product name Type < 6 kV 6–13.8 kV >13.8 kV

Vetronit® Machined component
G-11 or full-size sheet • • • • •

Delmat® Epoxy Machined component

68660 or full-size sheet • • • • •

Delmat® Polyester Machined component

68420 or full-size sheet • • • •

Samicanite® Machined component

41120 or full-size sheet • • • •

Mica rings Part on design

• • • •

Vetroferrite® Machined component

• • • •

Vetroferrite® H Machined component

• • • •
 Insulating Systems for High-Voltage Rotating Machines 13

VPI Impregnation Resins

Our wide range of high-performance resins is designed to meet the expected
electrical and mechanical characteristics of high-voltage rotating machines. The factors that
influence the final choice of resin are complex. Important considerations relate
to features of the design of the machines and the choice of insulating system, taping and
VPI processes. Important criteria include:

» Resin thermal class » Total processing time

» Tank stability » Compatibility with mica tapes
» Storage conditions (cooled or and remaining materials
ambient temperature) » Rated voltage
» Moisture sensitivity » Dielectric properties
» VOCs (volatile organic compounds) » Thermal conductivity
» Impregnating temperature » Continuous and maximum peak
» Necessity of rotating curing operating temperature

» Curing time

Von Roll offers a variety of high-performance resins:

Rated voltage

Product Thermal 6.6– 15– Impregnation Curing

name Type class < 6.6 kV 15 kV 22 kV temperature process Description
Damisol® Polyesterimide 180 (H) • 23 °C 8 h at
3340 Samicabond®- 150 °C
System

Damisol® Polyesterimide 180 (H) • 23 °C 8 h at

3032 Samicabond®- 140 °C
System Highly reactive, yet highly
stable room-temperature imp-
Damisol® Polyesterimide 180 (H) • • 23 °C 8 h at regnating resin. Good results
3308 Samicabond®- 140 °C on static curing.
System

Damisol® Polyesterimide 180 (H) • • 23 °C 8 h at

3309 Samicabond®- 150 °C
System

Damisol® Epoxy/ 180 (H) • • 23 °C 8 h at Low-viscosity 2K

3313 Polyesterimide 150 °C accelerated epoxy resin with
outstanding
mechanical properties.

Permafil® Epoxy 1K 180 (H) • • 23–60 °C 8 h at 1K epoxy resin without diluent.

74038 160 °C Very low organic emission
(VOC < 2%).

Damisol® Epoxy/ 155 (F) • • • 40–70 °C 10 h at Accelerated tape

3407 Anhydride 2K 170 °C needed.
Damisol® Epoxy/ 155 (F) • • • 23 °C 8 h at Highly reactive
3415 Polyester 150 °C room-temperature
impregnating epoxy-modified
resin.
Storage below 5 °C.
14 Insulating Systems for High-Voltage Rotating Machines

Finishing Coating
The Damicoat® range of finishing and overcoat varnishes includes air-drying and
oven-curing solutions. They are all single components for easy processing by spray,
brush and even dipping and dip-rolling processes.

Rated voltage
Product
name Color < 6 kV 6–15 kV < 15–22 kV Drying time Description
Damicoat® N/RB/G • • 15 to 20 h Highly chemically resistant overcoat varnish.
2404
Damicoat® RB • • 1 to 2 h High-temperature-resistant overcoat
2407 varnish, used for up to class H
high-voltage and traction machines.
 Insulating Systems for High-Voltage Rotating Machines 15

Testing
Materials and systems have to be tested in order to ensure the requested specifications
concerning mechanical, electrical and thermal characteristics.

At Von Roll HV laboratories we are able to test our customers’ materials and systems
according to IEC, UL and other specifications.
» Thermal, electrical and mechanical aging tests
» Tan δ-measurements at different temperatures
» Partial discharge measurements with different voltage ranges

Testing in the Von Roll laboratory.

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.
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 Roll’s commitment to mica starts with applications such as flexible laminates.
mining and ends with finished tapes.

System components Ballistic Protection

Producer of integrated and ready-to-install High-quality systems for armored defense
system components for high-voltage electric based on thermoset / thermoplastic products
motors, railway drives and generators. in single-use or tailored combinations.

Cables Testing
Mica tapes for fire-resistant cables. Von Roll Von Roll provides electrical, thermal and
provides a wide range of products that are mechanical testing of individual materials as
ideally suited to all commonly used standards. well as complete insulating systems.
Resins and varnishes
Impregnation resins for high- and low-voltage, Training
potting resins, casting resins, as well Von Roll Corporate University provides a
as encapsulating and conformal coatings. training program in high- and low-voltage

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

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

Europe Americas Asia/Pacific

Von Roll Schweiz AG Von Roll USA, Inc. Von Roll Asia Pte Ltd.
Passwangstrasse 20 200 Von Roll Drive 6 Serangoon North Avenue 5 #03-01
4426 Breitenbach Schenectady, NY 12306 Singapore 554910
Switzerland USA Singapore
P +41 61 785 5111 P +1 518-344-7100 P +65 6556 4788
F +41 61 785 5188 F +1 518-344-7288 F +65 6556 4959
cs.europe.mica@vonroll.com sales.us@vonroll.com cs.asia@vonroll.com

Von Roll Deutschland GmbH Von Roll do Brasil Ltda Von Roll Shanghai Co., Ltd.
Theodor-Sachs-Str. 1 Rua Vaticano, No. 179 Unit C, No.1235, Minqiang Road
86199 Augsburg 06713-040, Jd. Fontana Cotia, Songjiang District
Germany Sao Paulo Shanghai, 201612
P +49 821 9020 Brazil China
F +49 821 902 239 P +55 11 4208 5995 P +86 21 6768 7020
cs.europe.comp@vonroll.com F +55 11 4193 6789 F +86 21 5768 7891
cs.south.america@vonroll.com cs.asia.china@vonroll.com
About Von Roll
We Enable Energy – As one of Switzerland’s longest-established industrial companies, Von Roll focuses on products
and systems for electrical power generation, transmission, storage and industrial applications. Von Roll’s 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.