Conference Record of the 1998 IEEE International Symposium on Electrical Insulation,Arlington, Virginia, USA, June 7-10, 1998

A NEW TYPE OF INSULATION STRUCTURE FOR CLASS H MOTOR

Zhang Dong Lin and Shi Xiao Feng
Harbin Institute of Large Electrical Machinery of Ministry
of Machinery Industry, Insulation Research Department
89 Daqing Road, Harbin-150040, China
Lei Qing Quan
Harbin University of Science and Technology
Department of Electrical Materials Engineering
121 Daqing Road, Harbin-150040, China

Abstract
In present paper, we have proposed a designing scheme
for a new type of insulation structure of class H shielded
motor according to study on the insulation system of class
H asynchronous motors and DC machines, and have described
the choice of main insulation materials ,such as Kapton
polyimide film, flat copper wires wrapped by common Kapton
film-46 composite, and specially by a newly developed
corona-resistant (CR) Kapton polyimide film-46, polyimide
film glass cloth-reinforced mica paper tape and
impregnating varnish etc, as well as their properties and
technical indexes. By estimating the data of the thermally
accelerated aging for this new type of insulating structure
of class H machine, we have obtained a temperature index(T1)
of 187"C, and a thermal lifetime of 27 year in terms of
extrapolating to 150OC. Thus we believe that this new
insulation structure not only provides the designing basis
for class H asynchronous machine, shielded machine and DC
motor, but also improves their temperature rise and makes
insulation thickness thin and low lost. Therefore it will
bring us greater economic results, as most part of
insulation materials comes from domestic supply. AS a
result, it is very beneficial for class H machine to develop
widely.
Introduction
Class H motors have good thermal endurance, but the
process of manufacturing is complex. Before the 80s their
output was small. Most of them were used in special
circumstances, such as nuclear power plants, military
affairs, space flight and traction motors and so on, The
earliest insulation structure was organic silicon system,
later, polyimide system or both of them were applied. Up
to now , some countries still use them. A series of
non-silicon class H insulating products occurred in the
80s. Their adhesive ability is greater than silicon
products. And the synthesizing process is simple and the
cost.is low. So they gradually took the place of silicon
products Therefore class H motors below tens of kWs
developed rapidly in recent years. Large electric
machinery companies in China and overseas have all set
about,to design new types of insulation structures for
class H motors and produce large and medium type of class
H machines. We expect that class H machine will achieve
great development and they will be widely used in early 21
century.
In order to meet the needs of the users for class H
asynchronous motors and DC machines, various sorts of class
H insulating materials were collected. A new insulation
structure of class H asynchronous motors and DC machines
is proposed. The results show that the properties of the
new structure are better than the silicon systems.
Choice of the insulating materials
Winding wire
We have collected more than ten types of winding wires
and listed a few among them( such as flat (round) copper wire
(QZYB-2, QZY-2), flat copper wire wrapped by organic
silicon double glass silk(SBEGB1, flat copper wire wrapped
by polyimide-46 composite film (MYFB,MYFEB) and corona-
resistant Kapton polyimide-46 flat copper wire (150 FCR 019
4896, 150 FCR 019 63%) provided by Dupont company of USA)
and some representative properties in Table 1. It is better
to choose the flat copper wire wrapped by Kapton
polyimide-46 composite film in order to ensure the
reliability of the inter-turn insulation.
Mica tape
The tested mica tapes are as follows: mica 453-1 ( mica
tape made of diphenyl ether derivatives glass cloth and
mica paper), mica 454-1 (new mica tape made of diphenyl
ether glass cloth polyimide film and mica paper) and5450
(mica tape made of organic silicon glass cloth and mica
splitting) The routine test results are shown in Table 2.
The mechanical and electrical properties of D tape (mica
tape made of glass cloth polyimide film and mica paper) and
453-1 tape are shown in Table 3. Both Table 2 and Table 3
indicate that all of the behaviors of mica tapes 453-1 and
454-1 are than those of organic silicon glass cloth
splitting mica tape. The electrical and mechanical
properties of mica 454-1 were improved by the reinforcement
of polyimide film. In the mean time, the processing
difficulty of polyimide films was overcome.
Impregnating varnish
The choice of impregnating varnish is one of the key
items in the design of insulation structures. A good choice
can increase the heat endurance, heat conductivity,
electrical strength, mechanical strength and the ability
to endure erosion by environment and so on. We have
collected seven kinds of class H solvent-free impregnating
resins and four kinds of impregnating resin with solvent.
From the whole analysis of the measured data in Table
4 it can be seen that the 9116 polyester-polyimide
impregnating varnish and the 145 heat-proof polyester
impregnating varnish are useful. Since their
solidification temperatures are all within 15O-16O0C, the
time is short and the cost is also low.
Bar test
Polyimide and polyimide-46 composite films have been
used to make test bars. The testing results showed that the

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Table 1 Some representative properties of several winding wires
insulation thickness was thin, its mechanical and
electrical properties were good, but the processing
was complex, the integrity was bad, there were gaps in
insulation, and the bar sizes were hard to control.
The measured data show that the electrical properties
of the bar wrapped by mica 453-1 and 454-1 tapes are
better than the bar wrapped by 5450 organic silicon
glass cloth splitting mica. Especially, the breakdown
voltages of bars wrapped by mica 454-1 were twice as
high as bar wrapped by 5450 splitting mica tape, and
the insulation was thinner.
The bars rolled up by 0.07 mm polyimide film
mica-paper foil and 50% lapped and wrapped by 0.07mm
polyimide film mica tape were molded with a hot press.
Table 2. Routine test results of three-mica tapes
It is evident that the insulation structure with bar
rolled up is better, because this structure can make
the insulation thin, and improve the electrical
strength. But it needs special rolling equipment.
Insulation structure of class H machine
Insulation structure of medium asynchronous motor
structure of asynchronous motor
Our principle f o r designing of insulation structure
302
of asynchronous motor is than the electrical safety
factor K(the ratio of power frequency breakdown
voltage U to phase-voltage U p should be bigger than
ten, and breakdown voltage level of new insulation in
low-voltage machine is twenty times as high as rated
voltage. Its main insulating structures are shown in
Tabel.5.
Insulating structure of DC machine
Armature in DC machine uses rectangular slot, and
the main pole uses the ways of vacuum pressure
impregnation, its main insulation structures are shown
in table.6.
Evaluation of the new type
insulation structure
We prepared the simulation windings of the
insulation structure for 1kV level by using the
splitting mica tape with Dupont CR film for a main
insulation and evaluated them via the accelerated
thermal aging by referring a IEEE-275 document. They
underwent a thermal endurance at 250 for 24hours,
O C
vibration and wetting, and withstood voltage
throughout a testing cycle. The initial level of
breakdown voltage of simulation windings was higher
than 23kV, the residual level of breakdown voltage
after running 30 testing cycles was on an average
greater than 10kV. We have thereby obtained a
temperature index (TI) of 187 ‘Cfor this new type of
insulating structure, and a thermal lifetime of 27
years in terms of extrapolating to 150°C.
Application
Application of insulating structure of class H to
asynchronous motor
The new insulation structures above have been used
in 380 V, 120 kW-250 kW asynchronous motor. By
Table 3. Electrical and mechanical properties of mica 453-1

surface I
resistivity normal temperature m 2.29~10
dielectric normal temperature 0.873
loss tglj x lo2 18OOC 33.53
dielectric strength bN/m 37. 6

Table 4. Some characteristics of both the 9116 and 145 impregnating varnish

items unit 1053 9116

appearance pale yellow brown
transparent transparent transparent transparent 1iquid
without liquid liquid without impurities
impurities ~

viscosity S 32 67 70 156
solid content % 51 47.57 48.3 8-12
bonding strength N 258 618 100
volume resistivity MQ .m 6 I I I
(normal 21x10 5.17~10 1.38~10 9.2xlO
temperature) 3 3 J
18OOC 21x10 2.26~10 1.65~10
surface resistivity 8 8
MR 1.83~10 5.876~10
dielectric
2 0.758 1.425 0.700
lossx10 (normal
temperature)
18OOC 32.57 47.12 I
dielectric
strength(normal
temperature)
MV/m 89 117.2 139.4 I 66.4
I
180OC 70. 3

referring the stator winding insulation testing Conclusion

specifications in related standards, such as for the
level of 1 kV, we can estimate that the peak value of
impulse voltage test of the turn to turn insulation
was 3 kV, the testing time was 5 s. All of the stator
winding must pass every testing requirement.
Insulation resistance exceeds 500 MQ.
Application of insulation structure of
class H to DC machine
The new insulation structures above have been used
in DC machines. The commutator has undergone an over
speed dynamic pressure test at 1.25 times rated speed
after running 10 minutes at a temperature of 125°C.
After testing the change in outside diameter of
commutatortestedwassmallerthan0.03mm, andnosign
of dropping resin and no short-circuit between copper
plates or high bars were observed. These tests meets
the requirements of designing, technology and final
testing.
By estimating the data of the thermally accelerated
aging for this new type of insulating structure of
class H machine, we determined its temperature index
to be 187°C and its thermal lifetime to be 27 years
in terms of extrapolating to 150°C. Thus it not only
provides designing basis for class H asynchronous
f
mac ine, shielded motor, DC machine, but also lifts
the emperature rise limits and makes the insulation
thickness thin, and low cost, so it has broad prospects,
and will bring greater economic results, as most part
of insulating materials comes from domestic supply.
This insulation will be beneficial for a wide use of
class H machine.
If the machine works in special or harsh
environments, such as in oil, water and radiation and
so on, it is necessary to do special design of
insulation structure.

303
Table 5. Main insulation structures of class H asynchronous motor

5 winding diamond coils and strip coils

insulation treatment
6 VPI resin with solvent and VPI resin without solvent

iaDie o. .Main
m . . , . .insulating
n - , . structures
. . .
or,. UL macnine
”.s .

I material and mode

~~~

item
number items
flat varnished copper wires wrapped by glass fiber and flat
armature coil copper wires wrapped by polyimide-46 composite film
1 slot Nomex paper
insulation
commutator
insulation wD550-3 commutator mica plate
main pole insulation
2 windinn class H enameled round comer
..
pole body NHN combined material
insulation
VPI resin with solvent and VPI resin without solvent
3 insulation treatment

References
[l] Xu Xiao Ying, Electrical Insulation Handbook, Chinese).
Mechanical Industry Publishing House 1990, [3] M. Katz ans R. J. Theis, “ New High Temperature
3-141. ( in Chinese). Polyimide Insulation for Partial Discharge
[2] Liu Wei Xi, “Development of 145 Heat-Resistant Resistance in Harsh Environments”, IEEE
Polyester Resin”, Insulation Materials Electrical Insulation Magazine, vol. 13, No. 4,
Communications, No. 3, pp. 1-6, 1992, ( in pp. 24-30, 1997.

304