TecTalk

Electrical Testing of Uncured Resin Rich or Untreated VPI Coils

Hal Miller and Kevin Alewine

Spring 2007

ne of the most common questions posed to mica tape suppliers is how to electrically test coils during the manufacturing, winding and final test stages during motor manufacturing or repair. For completed machines, NEMA MG-1, IEEE 43 and IEEE 95 address the issue clearly, but for green, untreated or uncured coils intended for vacuum pressure impregnation (VPI) or resin rich hot pressing, there are really no official standards. Each motor OEM, coil manufacturer or repair center has its own procedures, but there are always issues when more failures than expected arise during the testing process. In this edition of TecTalk, we will address some general guidelines that have been used in the USA for many years and make some

Photo courtesy of Grayson Armature Works

suggestions from a tape manufacturers perspective. Most technicians and engineers recognize that a VPI insulation system is very dependent on the resin impregnation process to realize the full properties, thermal, electrical and mechanical, that are expected of the system. To expect an untreated coil to

be held to the same standards as a finished system is unrealistic and can lead to false conclusions as well as premature motor failure even if the coil successfully passes the hipot testing. Incipient damage or pregnant failure can result in an unexpectedly short service life of the motor. It is difficult to trace the failure back to the testing proceTo expect an untreated dure as the damcoil to be held to the age is normally same standards as a worsened during finished system is the failure due to additional carbon unrealistic. tracking or, in the case of catastrophic failure, destruction of insulation materials as well as the copper conductor. From a chemical standpoint, reduced voltage testing is recommended because these styles of porous mica tapes or uncured resin rich mica tapes normally contain uncured binder, which may be slightly conductive before processing. Secondly, the mica paper and the other tape components will absorb moisture from the environment. This further weakens the apparent dielectric strength. If the relative humidity is 60% or higher, the unit should be heat dried and cooled to ambient temperature (as long as it is above the dew point) before testing. The condition of the coils can be confirmed by testing with a megohmmeter. Electrical testing at elevated temperatures may also increase the conductivity of the uncured mica binders. The first rule of thumb, is to not exceed 1000VAC per lap layer of tape. As an example, a typical 4160volt coil is made with 4 layers of mica tape. Using this rule, the hipot testing should not exceed 4000VAC or, using the 1.7 conversion factor suggested in IEEE 43, 6800VDC. A more common alternative is to use the line voltage of the machine as the maximum. For example, a 4160VAC machine would be tested at 4160VAC or 7070VDC. Some procedures allow for a +/- of 10% with no evi-

dent problems. Either of these guidelines is probably acceptable to most coil manufacturers and fall within our suggested test ranges. The frequency of testing during the winding process is also debated. Most coil manufacturers will hipot and/or surge test the coils before shipment as it is in their interest to catch errors or defective products before they are shipped for many reasons. They are, therefore, skeptical regarding quality claims related to electrical failure. The winding department wants to assure that the coils are not damaged during the winding process. The resin treatment department wants to know if the stator is good before processing, as that is the point of no return.

Good workers and good work practices make good products.

All of these concerns can lead to excessive testing of the coils with the resulting potential for damage if the voltage ranges are not carefully controlled. Our suggestion is to test the coils at the coil shop as usual and to test each group once during the winding process. A final test after all connections are made, including a de-rated surge test, also makes sense. This would limit the electrical testing to three times in the untreated state. At the suggested testing levels, this should not endanger the windings but will still give confidence in the quality of the coils and the winding process. Remember, testing does not improve product quality. Good workers and good work practices make good products.

Suggested Hipot Test Voltages Untreated VPI or Uncured Resin Rich Coils Machine Voltage AC 2300 4160 6600 7200 11000 13800 Green Hipot AC 2300 4160 6600 7200 11000 13800 DC 3910 7072 11220 12240 18700 23460 Finished Machine AC 5600 9320 14200 15400 23000 28600 DC 9520 15844 24140 26180 39100 48620

World Leader
Von Roll is the world leader in fully evaluated insulation systems for electric motors and generators. With broad testing capabilities for both life testing and agency approval, Von Roll offers invaluable assistance in customizing and analyzing systems for both OEM and aftermarket applications to the highest voltage levels.
EBU4/2007

TecTalk is a publication of Technical Marketing Von Roll USA, Inc. Kevin Alewine, Editor One West Campbell Road Schenectady, NY 12306 800-654-7652 www.vonroll.com

All information in this document is subject to the product liability clause as published in the website www.vonroll.com

www.vonroll.com