IEEE STANDAR'OS:

Proposed
ARCHIVES
DO NOT REMOVE Test Procedure

for Evaluation of
SYSTEMS OF INSULATING MATERIALS
FOR A-C ELECTRIC MACHINERY EMPLOYING
FORM-WOUND PREINSULATED STATOR COILS
[Machines rated at 50 to 2000 horsepower
(35 to 1500 kilowatts mechanical output)
and below 6600 volts]

(Published jor Trial Use)

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 ACKNOWLEDGMENT

The Institute wishes to acknowledge its indebtedness to those who have so freely given of
their time and knowledge, and have conducted experimental work on which many of the IEEE
publications are based.

This publication was prepared by a Working Group of the Insulation Subcommittee of the
Rotating Machinery Committee of the IEEE Power Group, whose membership was:

*G. L. Moses, Chairman

*J. C. Botts, Secretary

D. A. Addison W. B. Penn
J. S. Askey W. G. Rhudy
E. A. Boulter C. D. Richardson
J. M. Brown C. L. Sidway
A. W. W. Cameron R. W. Stevens
J. F. Dexter E. W. Summers
P. W. Hernick H. P. Walker
L. M. Johnson P. G. Whitmore
*J. L. Kuehlthau *E. S. Yates
*P. Monsarrat

* Task Force Members participating in the tests.

)
Copyright 1966 by The Institute of Electrical and Electronics Engineers, Inc.

This publication m a y be reproduced, without change, in part or in its entirety,

provided that notice of its copyright by the IEEE is included.

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 CONTENTS

Part I —Introduction 5

Part II —Model Motors for Alternating-Current Form-Wound Stator Coil Insulation Systems 6
Section 1—Insulation Test Models 6
Section 2—Test Exposures 7
Section 3—Voltage Checks 9

Part III—Procedure for Analysis and Reporting of Thermal Life Test Data 9

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 EVALUATION OF SYSTEMS OF INSULATING MATERIALS
FOR A-C ELECTRIC MACHINERY EMPLOYING
FORM-WOUND PREINSULATED STATOR COILS
PART I
INTRODUCTION
Purpose.—The chief purpose of this Test Pro-
cedure is to classify insulation systems in accord-
ance with their temperature limits by test, rather
than by chemical composition. T h e intention is
to classify according to the recognized A, B, F
and H categories, whose usual continuous hot-
spot temperatures are 105°C, 130°C, 155°C and
180°C respectively.
Other insulation systems may then be com-
pared to service-proven systems under similar
test conditions. Data from such tests may be
used to establish the temperature classification
of new insulation systems before they are service
proven. T h e concepts implemented herein are
based on I E E E No. 1 (formerly A I E E No. 1,
December, 1 9 6 2 ) .
A wide variety of synthetic electrical insulat-
ing materials are available for application in elec-
tric machinery and apparatus. Included in these
materials are the silicones, fluorocarbons, wire
enamels, new films, rubbers and varnishes. As
there is a growing tendency to either rely solely
on these materials as electrical insulation, or to
employ them with the old familiar materials in
novel combinations, there is a corresponding in-
crease in the problems associated with the selec-
tion and evaluation of insulations. Frequently
an insulation "system" or combination of insula-
tion materials must be evaluated rather than one
insulating "material."
Many of the specifications regulating the use
of insulation materials were written before the
advent of the newer synthetics and were based
upon experience gained with the old materials
over a long period of time. Difficulties arise,
therefore, when an effort is made to classify
these new materials or combinations for insula-
tion purposes under the U S A Standards as Class
A, Class B, Class F or Class H insulations.
This Test Procedure has been prepared to out-
line useful procedures for the evaluation of
systems of insulation for form-wound rotating
electric machines. It is expected that the several
insulating materials, or components, making up
any insulation system to be tested will first be
screened in accordance with specific test pro-
cedures for each type of material.
This Procedure is intended to evaluate insula-
tion systems for use in usual service conditions
with air cooling. It does not cover such special
requirements as machines enclosed in gas atmos-
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pheres, subjected to strong chemicals, to metal
dusts or to submersion in liquids, etc.
Methods of Evaluation.—This Test Procedure
describes model motors suitable for use in insula-
tion evaluation tests, and recommends a series
of exposures t o heat, mechanical stress, and
moisture to which the models may be subjected
to represent cumulative effects of long service,
under accelerated conditions. Procedures are
given for applying periodic voltage checks, to
establish the end point of insulation life by elec-
tric failure.
It is recommended that for each particular
system to be evaluated a suitable type of a speci-
men be selected; and that an adequate number
of these be subjected to repeated cycles of heat,
vibration, moisture and electric stress as outlined
in this procedure.
An adequate number of samples to obtain a
good statistical average should be carried
through the test procedure until failure occurs,
for each chosen temperature of heat exposure.
It is recommended that the tests be carried
through on the indicated number of specimens
for at least three different test temperatures, for
each insulation system to be evaluated. T o pro-
mote uniformity in the results there are given
seven alternative ranges of temperature, requir-
ing from 1 day to 49 days per cycle, that are
appropriate for making these tests.
T h e number of cycles and the total number
of hours of heat aging, to the end of life for the
average of each group of samples, and for each
of the test temperatures, are then reported as the
final results of the tests. T h e ratios of these hours
of life for the new insulation system to those for
the old established insulation system provide a
rough measure of the ratio of the service life
expectancy of the new system to that of the old
system but not absolute evaluation of service
life. T h e combined effects of the heat, vibration,
moisture and electric stresses imposed on the
insulation during these tests are intentionally
made more severe than those normally found in
service at the same temperature. Therefore, the
life of any given insulation system in these tests
will be shorter than that to be expected in actual
service at a comparable temperature.
This Procedure will permit approximate com-
parisons only, and cannot be relied upon to com-
pletely determine the merits of any particular
insulation. Such information can only be ob-
tained from extended service experience. In the
course of time, however, it is expected that
enough data may be obtained from tests of this
kind to establish a normal number of hours of
heat aging before failure that will be representa-
tive of each of the standard temperature classes
of insulation A, B, F and H for each type of
specimen.* It may also be feasible to specify
the number of hours before failure that will be
appropriate as indications of satisfactory per-
formance under special service conditions, such
as short-time or intermittent and high-tempera-
ture exposures. Following the general pro-
cedures above outlined, the temperature classi-
fication in which any new insulating material or
system properly belongs may be determined.
Summary.—This Test Procedure has been
prepared in the hope that it will serve as a useful
guide for the evaluation of insulation systems for
form-wound coils for alternating-current stators
and to establish a sound basis for their tempera-
ture classification. Once this is accomplished in
orderly and organized fashion, the problems of
insulation selection for use in electric apparatus
should be simplified.
The purpose is to define procedures, and not
to establish any normal values for insulation life,
nor to provide any standards of performance
whatever.
PART II
MODEL MOTORS FOR ALTERNATING-
CURRENT FORM-WOUND STATOR COIL
INSULATION SYSTEMS
SECTION 1
INSULATION T E S T MODELS
1-1 Scope.—This section makes general sug-
gestions concerning appropriate samples of in-
sulating materials or insulating systems, which
may be usefully subjected to the exposures out-
lined in Section 2, to simulate their behavior in
service. It is considered that no one type of coil
or model motor will adequately represent all the
machines covered by this Test Procedure. It is
considered that a suitable type of model motor
can be designed to adequately represent each
basic type of machine employing form-wound
preinsulated coils in the medium size (50 to
2000 horsepower) and medium voltage class
(440 to 6600 volts). It is recognized that no
single model can represent all the types of ma-
chines covered by this range.
1-2 Models.—When size and convenience
require that models rather than complete ma-
chines be used for evaluation of insulation sys-
* With such a background of information, it should be
possible to classify insulation systems on a performance
basis. Ultimately, therefore, the definition of insulating
materials may be based on their performance in such
tests as these, instead of solely on chemical composition.
6
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terns, the models should be made to embody all
the essential elements, and should be as nearly
as possible representative of a complete winding
system and its structural supports. The generic
name form-wound motorette shall be applied to
models coming within the scope of this Pro-
cedure.
Since no standard model can be established
for all the types and sizes of machines employ-
ing the insulation systems to be evaluated by
this Test Procedure, it shall be the responsibility
of each test laboratory to use suitable models.
Full and complete design information on the
model shall be published at the time of present-
ing test data. It shall be the responsibility* of
the organization using a model to make such
models or the specialized components available,
so that the results of all functional evaluation
tests may be subject to recheck by independent
laboratories.
The slot and support structure shall simulate
the magnetic core and mechanical supports inso-
far as it is necessary to reproduce operating ex-
posure conditions during the testing. It is recog-
nized that dierent models must be employed to
cover the range of machines included in this
Test Procedure. It is suggested that the ma-
chines be grouped as follows and that dimen-
sions be standardized approximately within these
limits.
(a) Small or Lowvoltasje Alternating-Current
Machines (below 200 horsepower or below
750 volts)
(1) Slot Width—6 to 10 millimeters
(0.25 to 0.375 inch)
(2) Slot Depth—25 to 40 millimeters
(1.0 to 1.5 inch)
(3) Core Length—100 to 150 millimeters
(4 to 6 inches)
(b) Medium Size Alternating-Current Ma-
chines (above 200 horsepower)
(1) Slot Width—6 to 12 millimeters
(0.25 to 0.5 inch)
(2) Slot Depth—25 to 65 millimeters
(1.0 to 2.5 inches)
(3) Core Length—200 to 300 millimeters
(8 to 12 inches)
The coils shall contain all the elements em-
ployed in the coils they simulate and should be
considered only as smaller replicas. Insulation
thicknesses and creepages shall be appropriate
for the voltage class and industry or equipment
standards or practices. If the windings are not
to be tested with impulse testing equipment be-
tween turns, the coils may be wound with two
* Note—Models may be sold by the organization using
them or arrangements made for their manufacture and
sale by an outside concern.
parallel conductors so that turn-to-turn tests
may be made with conventional lowvoltage al-
ternating-current or direct-current test equip-
ment.
Each designer of a specific model shall select
the over-all design and components carefully
with the objective of truly evaluating the insula-
tion system as a whole. Each component used
should be subjected to separate screening tests,
to establish uniformity and normality before
they are assembled.
SECTION 2
TEST EXPOSURES
2-1 Scope.-It is the purpose of this section
of the Test Procedure to specify appropriate ex-
posures to heat, mechanical stress, moisture and
voltage, concurrently, or in repeated cycles,
which will represent the cumulative deteriorat-
ing effects of service, on insulation materials
and systems, on an accelerated basis.
Extensive experience with other tests of this
general nature has indicated that most of the
deteriorating effects of service can be reasonably
approximated by such a sequence of exposures
to high temperature, mechanical stress, moisture
and voltage, as outlined in this section.
The best results are obtained when the sample
.is first aged (and thus made brittle); then ex-
posed to mechanical stress (thus producing
cracks in the most brittle parts); and finally ex-
posed to moisture followed by application of
the test voltage.
It is recognized that ovens provide the most
convenient means of obtaining high tempera-
tures. This method of aging subjects all the
parts of the insulation system to the full temper-
ature, while in actual service a large proportion
of the insulation may operate at considerably
lower temperatures than the hottest-spot tem-
perature. Also, the products of decomposition
are likely to remain near the insulation during
oven aging, whereas- they are usually carried
away by the ventilating air in actual operation.
The life in oven aging at a given hot-spot tem-
perature should be expected to be shorter than
in actual service, but is presumed to be com-
parable.
It is recognized also that failures resulting
from abnormally high mechanical stresses or
voltages are generally of a different character
from those failures which are produced in long
service. For this reason, the mechanical and
electrical exposures recommended are only mod-
erately above those normally met in service.
The temperature and moisture exposures are in-
tentionally made more severe than usually met
in service, in order to shorten the required time
for testing.
7
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2-2 Temperature Exposure.-Table I lists
the suggested temperatures and corresponding
periods of exposure in each cycle for insulating
systems for different temperature classes. For
example, the recognized A, B, F, and H classes
of insulation would normally be tested at the
times and temperatures shown in columns 1, 2,
3, and 4 of the table, respectively. Either the
time or the temperature may be adjusted to
make the best use of facilities, but comparisons
must take such variations into consideration.
The selected temperature of heat exposure for
the tests should be held constant within a ±3
percent limit.
It is permissible to change the exposure pe-
riods a small percentage either way, as may be
desirable to fit into a five-day work week.
It is recommended that models be subjected
to the temperature corresponding to either the
28 or the 49-day exposure period, and to at least
one other of the above temperatures; and that
at least ten samples be carried through succes-
sive cycles of exposure at each of the test tem-
peratures until failure occurs.
Normally, it is intended that these tempera-
ture exposures be obtained by placing the
models in enclosed ovens, with just sufficient
ventilation or forced convection to maintain
temperatures uniform over the models. The cold
models should be placed directly in preheated
ovens, so as to subject them to a uniform degree
of thermal shock in each cycle. Likewise, the
hot specimens should be removed from the ovens
directly into room air, so as to subject them to
uniform thermal shock on cooling as well as on
heating.
It is recognized that some materials age more
rapidly when the products of decomposition re-
main in contact with the insulation surface,
whereas other materials age more rapidly when
the decomposition products are continually re-
moved. It is, therefore, desirable that the condi-
tions of ventilation and temperature be precisely
maintained for tests on other specimens with
which the test materials are to be compared. If
the insulation in actual service is so arranged
that the products of decomposition remain in
contact with it, the test specimens should then
be designed in the same way; so that the oven
ventilation will not remove these decomposition
products.
It is also recognized that, depending on the
test facilities available, the type of specimen
employed, and other factors, it may be desirable
to modify the methods of exposing and ventilat-
ing the specimens during these tests. It is all
important that, when any two different materials
or insulation systems are to be compared, the
test specimens of each shall be subjected to pre-
cisely the same exposures and other conditions
of test.
 TABLE I*
TEMPERATURE AND EXPOSURE PERIODS

Insulation Temperature Classes

Exposure
Temperature**
Degrees 1 2 3 4
Celsius Class A Class B Class F Class H

250 lday
240 2 days
230 4 days
220 lday 7 days
210 2 days 14 days
200 lday 4 days 28 days
190 2 days 7 days 49 days
180 lday 4 days 14 days
170 2 days 7 days 28 days
160 4 days 14 days 49 days
150 7 days 28 days
140 14 days 49 days
130 28 days
120 49 days

* The schedule is selected to fit into a five-day work week with most of the humidity
exposure occurring on weekends and is based upon an approximate "ten-degree" rule for
insulation deterioration, which states that the life of the insulation is reduced one-half for
each ten degrees Celsius rise in temperature. However, the aging times at the lowest
temperatures for each of the above four classifications have purposely been shortened in
order to have more tests at the lower temperature.
** The temperature measurements should be taken in the immediate neighborhood of
each model, as the temperature is rarely uniform over the entire oven space. Random
rearrangement of the specimens from time to time will minimize this effect.

The periods of exposure time for each of the
temperatures and each of the insulation classes
have been selected so as to give a mean life of
about 10 cycles before failure for each condition,
under normal circumstances. For the longer pe-
riods, the number of days of exposure has been
made a whole number of weeks, to fit conve-
niently with the schedule of a normal five-day
work week.
2-3 Mechanical Stress Exposure.—Following
each cycle of high-temperature exposure of the
specimen as outlined in Section 2, each specimen
will be subjected to a period of one hour of
mechanical stress.
It is recommended that the mechanical stress
applied be of the same general nature as would
be experienced in service, and of a severity com-
parable with the highest forces expected in nor-
mal service. The procedure for applying this
stress may vary with each type of specimen and
kind of service. It is important that whenever
any new insulating materials are subjected to
stress exposure, the stresses should also be ap-
plied in precisely the same way to familiar in-
sulations, so that the test results will be truly
comparable.
As a preferred method of applying mechanical
stress to models, after each cycle of high-temper-
ature exposure, each model should be mounted
on a shake table and operated for a period of
one hour with a 60-hertz oscillating motion, with
a peak-to-peak amplitude of approximately 0.2
millimeter, corresponding to a peak acceleration
of about ll/2 times the acceleration of gravity.
The models should be so mounted that the
motion occurs at right angles to the plane of the
coils, so that the coil ends will be free to vibrate
as they would under radial end winding forces
in an actual motor. This vibration test should
be made at room temperature and humidity and
without any applied voltage. (Adequate time
should be allowed after removal from oven to
reach room temperature).
2-4 Moisture Exposure.—After each cycle of
mechanical stress exposure, as described in Sec-
tion 2 of this Test Procedure, each specimen
should be exposed for 48 hours to an atmos-
phere of 100 percent relative humidity with
visible condensation on the winding at 5 to 10
degrees Celsius above normal room temperature.
No voltage should be applied to the specimens
during this period.
Exposure to condensation for a two-day period
is recognized to be a more severe test than is
met in normal service. The time period of two
days is recommended because experience has

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shown that at least this long a time is required
for moisture to penetrate throughout the wind-
ing, i.e., for the insulation resistance to reach a
fairly stable value. In service, insulation is ex-
posed to alkalies and other chemicals as well as
to moisture, and salt spray (fog) tests may be
used to determine its endurance under these con-
ditions. Experience has indicated, however, that
the 100 percent relative humidity test is quite
adequate, and is much simpler, for the purposes
of this test procedure.
This severe moisture condition without chemi-
cals is considered to be the most satisfactory way
of making an over-all test of the insulation en-
durance when exposed to industrial atmospheres
which produce conducting surface contaminants.
NOTE: An atmosphere of 100 percent relative humid-
ity and condensation is readily obtained by covering the
floor of the test chamber with a shallow layer of water,
and using an immersion heater to heat the water to a
temperature from 5 to 10 degrees Celsius above room
temperature. The exterior walls of the moisture cham-
ber should be thermally insulated. The roof of the
chamber should not be insulated and should be sloped
so as to drain the condensed water to the back of the
sides of the cabinet and prevent drip on the samples.
The interior of the cabinet should be constructed of
corrosion-resistant materials, and junctions of dissimilar
metals should be avoided. Doors or removable covers
should be constructed with overhanging lips so that
moisture collecting around them will drain into the
interior of the chamber. Visible and continuous moisture
may also be achieved by other means e.g. fog chamber,
condensation chamber, etc.
SECTION 3 paths employed.
VOLTAGE CHECKS
3-1 Recommended Check Voltages.—Each
model will be carried through repeated cycles of
the high temperature, mechanical stress and
moisture exposure in sequence until failure
occurs as determined by the voltage test. In
order to check the condition of the samples and
determine when the end of their useful life has
been reached, a 60—hertz voltage will be applied
after each successive exposure to heat, mechani-
cal stress and moisture as follows:
T h e voltage will be applied in succession to
ground, between phases, and between conduc-
tors for a period of ten minutes following each
exposure to moisture, while the specimens are
still in the humidity chamber and are wet from
exposure, at approximately room temperature.
Experience has shown that this prolonged time
of voltage application in the wet condition is
necessary to detect failures. Many of the failures
in this condition occur as the result of creepage
along wet surfaces, with gradual building up of
the leakage current which could not occur in
the usual one-minute test.
Failure in any of these voltage check tests will
be indicated by an unusual current flow, unusual
local heating, or the presence of smoke. Minor
spitting and surface sparking should be recorded,
but do not constitute a failure. It is desirable in
these tests to use an alternating-current "non-
surge" high-potential tester, which automatically
trips on overcurrent. Test equipment should be
of sufficient capacity ( 1 kilovoltampere or more)
to assure identification of failure.
Any such failure in any component of the in-
sulation system constitutes failure of the entire
sample, and fixes the end point of the life.
It is recognized that by applying the voltages
as above recommended, which are fixed by the
intended voltages in actual service, markedly
different periods of life may be obtained for the
same insulating materials, depending on the in-
sulation barriers and lengths of the creepage
As this indicates, the test procedures recom-
mended are adapted to prove the reliability of
the insulation proposed for a given temperature,
for high humidity, and for a given voltage. This
reliability may be improved by greater thickness
or other changes in the insulation system with
usual insulating materials, as well as by employ-
ing insulating materials of higher temperature
endurance.
PART III

PROCEDURE FOR A N A L Y S I S AND REPORTING OF

Tests between conductors*
To ground and THERMAL LIFE TEST DATA
Rated-line-to-line between coils
rms voltage in alternating Impulse** Alternating
service-volts voltage (rms) (peak) (rms) T h e test data compiled under this Test Pro-
cedure shall be analyzed in accordance with the
500 and below 1,000 250 115 method specified in I E E E No. 101 (formerly
551-1,000 2,000 250 115 A I E E No. I F ) .
1,001-1,500 3,000 250 115
1,501-2,000 4,000 250 115
2,001-2,500 5,000 250 115
2,501-3,500 7,000 250 115
3,501-4,500 9,000 250 115
4,501-5,500 11,000 250 115
5,501-6,600 13,200 250 115

* Optional tests depending on available equipment.

** Surge comparison tester volts/turn.
9

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