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Insulating Systems for the Motor Repair Industry 5Mica Mat ® Tapes and WrappersMica 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 followedby 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 optionsavailable for almost all applications. For the repair market, these are the styles most popularin the shop. For other applications, please contact your Von Roll representative.Product nameThermalclassNominal finishedthickness Binder Application suggestionsMica Mat ®77956Mica Mat ®77877Mica Mat ®77986Mica Mat ®2473XS155 °C 0.006 Polyester155 °C 0.007 Epoxy155 °C 0.007 Epoxy155 °C 0.007 Polyester– Industry standard for dip and bake coil applications– The tape of choice for VPI processing with polyester resinscontaining DAP monomers– Our premier VPI tape with new technology to provide aflexible tape– Excellent voltage-endurance properties– Compatible with most epoxy and polyester VPI resinsused in the motor repair industry– An industry standard for many years– Compatible with most epoxy and polyester VPI resinsused in the motor repair industry– A fully cured four-ply tape offering additional thickness whileremaining very flexible– Recommended for VPI systems using resins with a DAPmonomerMica Mat ®77984155 °C 0.0085Solventlessepoxy– This three ply B-staged tape is used to manufactureformed coils where VPI processing is not available– Useful in the shop for insulating connectionsMica Mat ®77676 (2480XS)155 °C 0.0065 Epoxy– Very flexible 2 ply mica main wall tape ideal forVPI applications. Mica weight 180 gr/m 2Mica Mat ®77675 (2537XS)155 °C 0.0065 Epoxy– Very flexible 2 ply mica main wall tape ideal forVPI applications. Mica weight 160 gr/m 2Von Roll’s commitment to mica starts with mining and stops with the production of mica taped wires.

6 Insulating Systems for the Motor Repair IndustryCorona ProtectionAnytime voltages are high enough to generate partial discharge or corona, semi-conductivematerials are needed to manage the discharge without damaging the insulation. Von Rolloffers several styles of tapes and paints that can be used to safely control destructivevoltages. These products are generally used for designs of 6 kV and above, but are sometimesuseful in improving the life of 4 kV machines in inverter-driven applications.Product nameCoronashield ® 215 4 mils BlackNominalthickness Color Special properties– Coated polyester tapes in the 200 –1000 ohm/sq range used inslot sections motor or generator to prevent corona dischargeCoronashield ® 217 9 mils Gray– Variable resistance (grading) tapes used to safely discharge voltageson the extensions or overhangs of coils– Several styles availableCoronashield ® 8001 Paint Gray– Gray paint loaded with semi-conductive particles usefulin repairing damaged grading on extensions or overhangs ofhigh-voltage coils. Dries in 15 – 30 minutes; tack-freeCoronashield ® conductive and semi-conductive tapes.

Insulating Systems for the Motor Repair Industry 7Slot and Phase InsulationIn random mush-wound motors, as well as some form-wound designs, a high-quality slotliner is the principal guarantee of a long electrical life of the machine. Von Roll offers avery wide range of flexible laminates and coated cloths for any application. All of the flexiblelaminates are available in 2, 3, 4 or more plies, and most coated materials are availablewith glass or Daglas ® substrates.Product nameAcuflex ® DMD 155 °CAcuflex ® NMN 180 °CThermal H ® 180 °CThermalclass Description Application suggestionsNonwoven polyester matbonded to both sides of anelectrical grade polyester filmAramid fiber paper bonded toboth sides of an electrical gradepolyester filmPolyester-coated glass clothwith or without an acrylicpressure-sensitive adhesive onone side– Preferred choice in hand-winding applications– Industry standard for class F designs– Available in either 70% or 100% saturated– 70% allows for improved resin absorption– Aramid paper-based flexible laminates available in awide range of constructions– Used where high-reliability performance is required– Also available with polyimide film for high-temperatureapplications– Used as slot liners or phase cloth where extreme flexibilityis required– Excellent electrical, mechanical and conformability propertiesFusa-Flex ® 155 °CFusa-Fab ® 155 °C180 °CFlexible B-stage epoxy resin onDaglas ® clothFlexible B-stage polyester resinon Daglas ® cloth– Used as core insulation on field coils as bolt insulators andrepairing tubes– When properly applied it results in a watertight sealed coilwith outstanding electrical strength for use where VPI is notavailable

8 Insulating Systems for the Motor Repair IndustrySupport MaterialsMade 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 forsupporting structures against rotational forces as well as surge inrush currents on startup.These products are normally fully cured before resin treatment, so compatibility is assuredwith most dip or VPI resins.Product namePoly Glas ® 76870 220 °CThermalclass Size range Application suggestions1/4–1“(20 – 80 ends)– A 220 (C) banding tape used in supporting traction andindustrial DC armatures– Also used for tying AC stators where maximum supportis neededPoly Glas ® 76831 155 °C 1/4 – 1“ diameter– Used in conjunction with blocking and tie cords, creatinga rigid support for motor and generator windings and endturns during startup and load changes.Poly Glas ® 76881 155 °C 1/4 – 1“ diameter– Lower temperature cure tape can be used when bakingovens are not available or when thermal sensitive materialsare used

10 Insulating Systems for the Motor Repair IndustryVarnishes and ResinsPermafil ® varnishes and resins have been used for manufacturing and repairing motorsand generators for over 100 years and have broad acceptance among repair companiesexpecting the highest in quality and performance. Available in different chemistries, thereis a product for almost any application that requires high quality and performance.Product namePermafil ®9637Thermalclass Chemistry Flash point °F Special properties220 °C Solventpolyester88– General purpose polyester varnish for motors andtransformers in dip tanksPermafil ®74043155 °C Solventepoxy88– General purpose epoxy varnish for motors and hermeticmotors in dip tanksPermafil ®1217180 °C Solventpolyester88– Fast RT curing polyester varnish for general purposeapplications– Available in clear, red or yellowPermafil ®712/716220 °C Solventlesspolyester200/132– These two polyester resins use a DAP monomer allowing forexcellent room temperature stability– Permafil 716 contains a blend of monomers allowing it to beused in a dip or VPI applicationPermafil ®707/724220 °C Solventlesspolyester132– 707 sets the standard for performance in high-vibration andhigh-temperature applications– Used in many VPI tanks– An excellent choice for repair shops that support the steeland mining industries– 724 is a general purpose resin used in industrial andcommercial applicationsPermafil ®74041180 °C Solventlessepoxy200– High-performance resin for general purpose industrialand mining motors in VPI applicationsPermafil ®74050220 °C Solventlessepoxy132– High-performance resin used in high-voltage insulationsystems– When used with the proper mica tapes this insulationsystem can be used for motors and generators up to 18 kV

Insulating Systems for the Motor Repair Industry 11Product nameThermalclass Chemistry Flash Point °F Special propertiesSynthite ®AC-41155 °C Solventpolyurethane81– High-temperature, fast-cure, air-dry polyurethane varnishwith excellent circuit board-coating properties– Available in aerosolSynthite ®AC-43155 °C Solventpolyester81– High-temperature, fast-cure, air-dry polyester varnish– Perfect for dip, spray or brushing– Air-dries in 1 hour or can be baked to speed-cureSynthite ®AC-46Solventpolyurethane81– Air-dry polyurethane that has excellent moistureand fungus resistance– Available in aerosol sprayHi-Therm ®BC-346A220 °C Solventpolyester88– High-temperature varnish used in a wide range of dipand bake applicationsHi-Therm ®BC-352200 °C Solventepoxy88– Excellent dipping varnish used for motors exposed tomoisture and harsh environments or hermetic applicationsDolphon ®CC-1105220 °C Solventlesspolyester> 200– High-flash, high-bond solventless polyester resin whichprovides excellent storage at room temperatureXL ® -2103 220 °C Solventlesspolyester> 200– Low-odor, high-flash very low VOC solventless polyesterresin. Formulated for high build in dip and bake applicationsSynthite ®ER-41/EB-41Solventpolyurethane81– Red or black high-temperature, fast-cure, air-dry varnish,used as an insulator coating– Both are available in aerosol spray cansAqua-Therm ®BC-379Water borneepoxy> 200– High bond strength– Excellent coverage– Low VOC/No HAPS– Excellent tank stability

12 Insulating Systems for the Motor Repair IndustryKits and CompoundsOften, repairing electric motors and generators for special applications requires manyspecialty compounds, potting materials and top coats. Here are just a few of the materialsavailable from Von Roll.Product name Chemistry Flash point °F Gel time Main characteristicsPermafil ® 704 Polyester 1323 – 4 hat 25 °C– Two-component pour-through resin for generalpurpose motorsPermafil ®74036Epoxy 20015 minat 40 °C– Two-component pour-through resin for generalpurpose motorsPermafil ®74010A/74010 Epoxy 200 2 – 4 hat 25 °C– High-performance two-component clear coating for sprayor flooding applicationsPermafil ®74115Epoxy 200 Single part– Thixotropic wet winding compound for DC polewoundcoilsPermafil ® 277 Krytox ® 1) 55 Single part– Masking compound for use on surfaces where adhesionof a cured resin is not desiredDolphon ®CB-1069Dolphon ®CB-1078Dolphon ®CB-1109Dolphon ®CB-1128Dolphon ®CC-1120Dolphon ®CR-1034-HEpoxy 200 R/T cureEpoxy 200 R/T curePolybutadiene 200 R/T curePolybutadiene 200 R/T curePolybutadiene 200 R/T cureEpoxy 200 R/T cure– General purpose, high thermal conductivity blackepoxy casting compound for use in all types of electricalassemblies– Black epoxy compound for use in all electrical assemblies– Also used to cast end windings of wind generators andinduction heaters– Two-part low-viscosity polybutadiene compound– Can be used for potting, casting and coatingelectrical apparatus– Two-part flexible black polybutadiene compoundformulated for motor and generation encapsulation– Excellent for high abrasion and moisture environments– Low viscosity– Clear compound for potting coils and transformers– Easily repaired– Two-part semi-rigid epoxy compound specificallyformulated for encapsulation by “buttering” on electricmotors1)Registered trademark of DuPont de Nemours.

Insulating Systems for the Motor Repair Industry 13Testing and Laboratory SystemsVon Roll has specialized low-voltage application system testing labs that are focused onclient 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 prototypeparts.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 systemstesting to ASTM, IEEE, IEC and UL standards.

14 Insulating Systems for the Motor Repair IndustryResin and Varnish Analysis ProgramAt Von Roll, our focus is always on customer satisfaction and long-term relationships forgedin the industry, based in part on the technical support we offer before, during and after thedecision to purchase has been made. An example of this is our unique, pro-active resinanalysis program, designed to promote regular testing and adjustment, if required, of resinsand varnishes at our many installations at both manufacturing and repair facilities. Theperiodic testing of resin properties ensures manufacturing consistency yielding predictableresults. An added benefit is the peace of mind that comes from the knowledge that yourresin or varnish is safe and stable. The provided shipping kits and friendly remind ers helpkeep your testing on a regular schedule, and all required adjusters are shipped directly fromthe 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 andhelical coil bond strength is available for a nominal charge. All of this is to keep your facilityproducing good machines every day. Join the many Von Roll customers who have securedtheir investment through timely analysis, feedback and recommendations from Von Rollon keeping their tanks stable.Laboratory Services» Insulation materials and systems testingto ASTM standards» NEMA-RE-2 resin compliance testing» High-voltage testing» IEEE 1043 voltage-endurance testing» IEEE 1776 systems performance testing» Partial discharge evaluation and testing» US Army Corps of Engineersqualified testing» Accelerated testing capabilities» Thermal conductivity testingTesting in the Von Roll laboratory.

Insulating Systems for the Motor Repair Industry 15TrainingFor a number of years we have been offering a unique program of high-voltage insulationtraining within our Von Roll Corporate University. The objectives of this program are:» Better understanding of high-voltage insulation technology for rotating machines andup-to-date knowledge on insulating materials and systems» Practical experience in the application of electrical insulating materialsOur training courses are attended by customers and partners from around the globe.» Development and applications support» Systems consulting and development» Evaluation of systems/systemsdevelopment» Systems engineering consulting» Plant design evaluation and consultingservices» On-site applications and engineeringsupport» Resin and varnish analysis program» Development of testing protocols» VPI processing of sample bars,coils and units» Materials and resin prototypedevelopment