Insulation system

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The electrical insulation system for wires used in generators, electric motors, transformers, and
other wire-wound electrical components is divided into different classes by temperature and
temperature rise. The electrical insulation system is sometimes referred to as insulation class or
thermal classification. The different classes are defined by NEMA,[1] Underwriters Laboratories
(UL),[2] and IEC standards.
IEC
Old IEC
Maximum
Relative
NEMA/UL
60085
60085 NEMA
hot spot
thermal
Letter
[4]
Thermal Thermal Class
temperature endurance
class
class[3]
class[3]
allowed index (C)[3]
70
< 90C
90

90C

>90 - 105

105

105C

>105 - 120

120

120C

>120 - 130

130

130

130C

>130 - 155

155

155

155C

>155 - 180

180

180

180C

>180 - 200

105

Typical materials

Unimpregnated paper,
silk, cotton, vulcanized
natural rubber,
thermoplastics that soften
above 90 C [5]
Organic materials such as
cotton, silk, paper, some
synthetic fibers [6]
Polyurethane, epoxy
resins, polyethylene
terpthalate, and other
materials that have shown
usable lifetime at this
temperature
Inorganic materials such
as mica, glass fibers,
asbestos, with hightemperature binders, or
others with usable lifetime
at this temperature
Class 130 materials with
binders stable at the
higher temperature, or
other materials with
usable lifetime at this
temperature
Silicone elastomers, and
Class 130 inorganic
materials with hightemperature binders, or

200
220

250

200C

220

220C

240C

250C

other materials with

usable lifetime at this
temperature
As for Class B,and
>200 - 220
including teflon
>220 - 250 As for IEC class 200
Polyimide enamel (PyreML) or Polyimide films
(Kapton and Alconex
GOLD)
As for IEC class 200.
Further IEC classes
>250
designated numerically at
25 C increments.

The maximum hot-spot operating temperature is reached by adding the rated ambient
temperature of the machine (often 40C), a temperature rise, and a 10 C hot-spot allowance.
Electrical machines are usually designed with an average temperature below the rated hot-spot
temperature to allow for acceptable life. Insulation does not suddenly fail if the hot-spot
temperature is reached, but useful operating life declines rapidly; a rule of thumb is a halving of
life for every 10 C.
Older editions of standards listed materials to be used for the various temperature classes.
Modern editions of standards are proscriptive, only indicating that the insulation system must
provide acceptable life at the specified temperature rise.
In large machines, different systems may be used according to the predicted temperature rise of
the machine; for example, in large hydroelectric generators, stator windings may be Class B but
the more difficult to cool rotor winding may be Class F.