Amendment 1 - Safety of transformers, reactors, power supply units and similar products for supply voltages up to 1 100 V - Part 2-16: Particular requirements and tests for switch mode power supply units and transformers for switch mode power supply units

Amendement 1 - Sécurité des transformateurs, bobines d'inductance, blocs d'alimentation et produits analogues pour des tensions d'alimentation jusqu'à 1 100 V - Partie 2-16: Règles particulières et essais pour les blocs d'alimentation à découpage et les transformateurs pour blocs d'alimentation à découpage

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Publication Date
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IEC 61558-2-16:2009/AMD1:2013 - Amendment 1 - Safety of transformers, reactors, power supply units and similar products for supply voltages up to 1 100 V - Part 2-16: Particular requirements and tests for switch mode power supply units and transformers for switch mode power supply units
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IEC 61558-2-16
Edition 1.0 2013-08
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
colour
inside
GROUP SAFETY PUBLICATION
PUBLICATION GROUPÉE DE SÉCURITÉ
AMENDMENT 1
AMENDEMENT 1
Safety of transformers, reactors, power supply units and similar products for
supply voltages up to 1 100 V –
Part 2-16: Particular requirements and tests for switch mode power supply units
and transformers for switch mode power supply units
Sécurité des transformateurs, bobines d’inductance, blocs d'alimentation et
produits analogues pour des tensions d’alimentation jusqu'à 1 100 V –
Partie 2-16: Règles particulières et essais pour les blocs d'alimentation à
découpage et les transformateurs pour blocs d'alimentation à découpage
IEC 61558-2-16:2009/A1:2013
---------------------- Page: 1 ----------------------
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---------------------- Page: 2 ----------------------
IEC 61558-2-16
Edition 1.0 2013-08
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
colour
inside
GROUP SAFETY PUBLICATION
PUBLICATION GROUPÉE DE SÉCURITÉ
AMENDMENT 1
AMENDEMENT 1
Safety of transformers, reactors, power supply units and similar products for
supply voltages up to 1 100 V –
Part 2-16: Particular requirements and tests for switch mode power supply units
and transformers for switch mode power supply units
Sécurité des transformateurs, bobines d’inductance, blocs d'alimentation et
produits analogues pour des tensions d’alimentation jusqu'à 1 100 V –
Partie 2-16: Règles particulières et essais pour les blocs d'alimentation à
découpage et les transformateurs pour blocs d'alimentation à découpage
INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
COMMISSION
ELECTROTECHNIQUE
PRICE CODE
INTERNATIONALE
CODE PRIX M
ICS 29.180 ISBN 978-2-8322-0996-7

Warning! Make sure that you obtained this publication from an authorized distributor.

Attention! Veuillez vous assurer que vous avez obtenu cette publication via un distributeur agréé.

® Registered trademark of the International Electrotechnical Commission
Marque déposée de la Commission Electrotechnique Internationale
---------------------- Page: 3 ----------------------
– 2 – 61558-2-16 Amend. 1 © IEC:2013
FOREWORD

This amendment has been prepared by IEC technical committee 96: Transformers, reactors,

power supply units, and combinations thereof.
The text of this amendment is based on the following documents:
FDIS Report on voting
96/401/FDIS 96/405/RVD

Full information on the voting for the approval of this amendment can be found in the report

on voting indicated in the above table.

The committee has decided that the contents of this amendment and the base publication will

remain unchanged until the stability date indicated on the IEC web site under

"http://webstore.iec.ch" in the data related to the specific publication. At this date, the

publication will be
• reconfirmed,
• withdrawn,
• replaced by a revised edition, or
• amended.

IMPORTANT – The 'colour inside' logo on the cover page of this publication indicates

that it contains colours which are considered to be useful for the correct

understanding of its contents. Users should therefore print this document using a

colour printer.
_____________
INTRODUCTION to the Amendement
This amendment has been prepared to allow the use of FIW wires in SMPS.

The manufacturer should be careful, that during production and transport no damage of the

FIW wire will be possible.
_____________
2 Normative references
Add, to the existing list of references, the following new references:

IEC 60317-0-7:2012, Specifications for particular types of winding wires – Part 0-7: General

requirements – Fully insulated (FIW) zero-defect enamelled round copper wire with nominal

conductor diameter of 0,040 mm to 1,600 mm
---------------------- Page: 4 ----------------------
61558-2-16 Amend. 1 © IEC:2013 – 3 –

IEC 60317-43, Specifications for particular types of winding wires – Part 43: Aromatic

polyimide tape wrapped round copper wire, class 240

IEC 60317-56, Specifications for particular types of winding wires – Part 56: Solderable fully

insulated (FIW) zero-defect polyurethane enamelled round copper wire with nominal

conductor diameter 0,040 mm to 1,600 mm, class 180
IEC 60851-3:2009, Winding wires – Test methods – Part 3: Mechanical properties
IEC 60851-5:2008, Winding wires – Test methods – Part 5: Electrical properties
3 Terms and definitions

Add, at the end of the existing text, the following new instruction and new terms and

definitions as follows:
Addition:
3.101
FIW
fully insulated winding wire

wire according to IEC 60317-0-7, IEC 60317-56 and IEC 60851-5:2008 which is a zero-defect

wire construction
3.102
zero-defect wire

winding wire that exhibits no electrical discontinuities when tested under specific conditions

3.103
grade of FIW
range of overall diameter of a wire (FIW3 – FIW9)
18 Insulation resistance, dielectric strength and leakage current
18.3
Add, after the existing Table 8a, the following new instruction:
Replacement of the text in footnote a of Table 8a:

For construction according to 26.2.4.1, test B the voltage is multiplied by the factor 1,25. For

the construction according to 26.2.4.2 the voltage is multiplied by the factor 1,35.

Add, after the existing subclause 18.101, the following new subclause and new figure:

18.102 A partial discharge test according to IEC 60664-1, (test description see below) shall

be performed, if FIW wires are used and if the recurring peak working voltage U across the

insulation is greater than 750 V. The relevant recurring peak voltage is the maximum

measured voltage between the input and the output circuit of the SMPS, if the secondary side

is earthed. The measuring shall be done at 1,0 of the maximum rated input voltage.

A partial discharge test shall be done at the transformer for the SMPS with the measured

recurring peak voltage U , greater than 750 V peak.
U is the maximum peak working voltage;
is 5 s;
---------------------- Page: 5 ----------------------
– 4 – 61558-2-16 Amend. 1 © IEC:2013
t is 15 s.
Partial discharge shall be less than or equal to 10 pC at time t .
The test shall be done according to the following Figure 104.
For other applications higher values may be required (e.g. IEC 61800-5-1).
1,25 U
t t
1 1
IEC 1763/13
Figure 104 – Test voltages
19 Construction
Add, at the end of the existing text of this clause, the following new text:
19.12.3 Replacement:

Insulated winding wires, in an insulation system providing basic, supplementary or

reinforced insulation, shall meet the following requirements.

Wire that has multi-layer extruded or spirally wrapped insulation (where only the finished wire

can be tested) and passes the tests of Annex K.

The minimum number of constructional layers applied to the conductor shall be as follows:

– BASIC INSULATION: two wrapped layers or one extruded layer;
– SUPPLEMENTARY INSULATION: two layers, wrapped or extruded;
– REINFORCED INSULATION: three layers wrapped or extruded.

For spirally wrapped insulation where the CREEPAGE DISTANCES between layers, as wrapped,

are less than those given in Clause 26. for pollution degree 1, the path between layers shall

be sealed as for a cemented joint in 26.2.3, Test A and the test voltages of the TYPE TESTS in

Clause K.2 are increased to 1,35 times their normal values.

NOTE 1 One layer of material wound with more than 50 % overlap is considered to constitute two layers.

---------------------- Page: 6 ----------------------
61558-2-16 Amend. 1 © IEC:2013 – 5 –

The finished component shall pass ROUTINE TEST for electric strength using the appropriate

value of test voltages in 18.3.

Compliance is checked by inspection and measurement and, if applicable, as specified in

Annex K.

a) Where the insulation on the winding wire is used to provide basic- or supplementary

insulation in a wound part:

– the insulated wire (for example polyimide or insulation of equivalent quality) shall

comply with Annex K;

– the insulation of one insulated winding wire shall consist of at least two layers for

supplementary insulation;

– the insulation of one insulated winding wire shall consist of at least one layer for

basic insulation;

– an insulation for mechanical separation which fulfil the electric strength test for basic

insulation shall be provided between the insulated wires and the enamelled wires.

NOTE 2 If for basic or supplementary insulation a triple insulated wire is used in combination with

enamelled wire, an additional interleaved insulation (mechanical separation) is not required.

b) Where the insulation on the winding wire is used to provide reinforced insulation in a

wound part:

– the insulated wire (for example polyimide or insulation of equivalent quality) shall

comply with Annex K;

– the insulation of one insulated winding wire shall consist of at least three layers;

– the insulation is subjected to the relevant dielectric strength test of 18.3.
Where the insulated winding wire is wound:
– upon metal or ferrite cores or
– upon enamelled wire or;
– under enamelled wire;

an insulation for mechanical separation which fulfil the electric strength test for basic

insulation shall be provided between the insulated wires and the core or between the

insulated wires and the enamelled wires. The both windings shall not touch each other and

both wires shall not touch the core.

NOTE 3 This requirement takes into consideration the mechanical production stress applied to the insulated

winding wires.

The manufacturer of the transformer shall demonstrate that the winding wire has been

subjected to 100 % routine dielectric strength test as in Clause K.3.

No requirements for creepage distances and clearances are applicable for the insulated

winding wires.

For windings providing reinforced insulation, no value is required in box 2) c) of Table 13,

Table C.1 and Table D.1 of Part 1 and no values are required of 26.106.

Compliance is checked by inspection of the part and the declaration of the wire manufacturer

19.12.101 The transformer which use fully insulated winding wires (FIW), shall only be used

up and including insulation class F.

19.12.102 Fully insulated winding wires (FIW) shall comply with IEC 60851-5:2008,

IEC 60317-0-7 and IEC 60317-56. If the wire has other nominal diameter than in Table 111

defined, so the minimum high voltage strength value can be calculated according to formula

below Table 111:
---------------------- Page: 7 ----------------------
– 6 – 61558-2-16 Amend. 1 © IEC:2013

• FIW wires used for basic or supplementary isolation for transformers according to 19.1.2:

– the test voltage required in Table 8a for basic/supplementary insulation according to

the working voltage of the transformer, shall comply with the minimum voltage strength

of basic insulation for the FIW-wire according to Table 111;
– between an basic insulated FIW wire and an enamelled wire an insulation for

mechanical separation shall be used. The both windings shall not touch each other.

The insulation for mechanical separation shall fulfil the high voltage test of basic

insulation. Creepage distances and clearances to the FIW wire are not required.
• FIW wires used for double or reinforced insulation according to 19.1.3:

– the test voltage required in Table 8a for basic-/supplementary insulation according to

the working voltage of the transformer, shall comply with the minimum voltage strength

of basic insulation for the FIW-wires according to Table 111. For the primary and the

secondary winding a basic insulated FIW wire shall be used;

– between the two basic insulated FIW wires an insulation for mechanical separation

shall be used. The both windings shall not touch each other. The insulation for

mechanical separation shall fulfil the high voltage test of basic insulation. Creepage

distances and clearances between the FIW wires are not required.
• Alternative construction with FIW-wires reinforced insulated:

– the test voltage required in Table 8a for reinforced insulation according to the working

voltage of the transformer, shall comply with the minimum voltage strength for the FIW

wire according to Table 111;

– between a reinforced insulated FIW wire and an enamelled wire an insulation for

mechanical separation shall be used. The both windings shall not touch each other.

The insulation for mechanical separation shall fulfil the high voltage test of basic

insulation. Creepage distances and clearances to the FIW wire are not required.

• Alternative construction with FIW wires, basic or supplementary insulated for transformers

with double or reinforced insulation according to 19.1.3:

– the test voltage required in Table 8a for basic-/supplementary insulation according to

the working voltage of the transformer, shall comply with the minimum voltage strength

of basic insulation for the FIW-wire according to Table 111. For the primary or the

secondary winding a basic insulated FIW wire shall be used. For the other winding

enamelled wire can be used;
– between the basic insulated FIW wire and the enamelled wire an supplementary
insulation according to the working voltage is required. Creepage distances and
clearances between the FIW wire and the enamelled wire are required for
supplementary insulation.
• Where the FIW wire is wound:

– upon metal or ferrite cores, an insulation for mechanical separation which fulfil the

electric strength test for basic insulation shall be provided between the FIW wires and

the core.The FIW wire and enamelled wire (if used) shall not touch the metal or ferrite

core.
26 Creepage distances, clearances and distances through insulation
Add, at the end of the existing clause, the following new subclause:
26.107 For transformers with FIW wires the following test is required:
To test the FIW-winding at the final transformer, three specimens shall be used.

The specimens shall be subjected 10 times to the following sequence of temperature cycles:

68 h at
the highest winding temperature ± 2 °C measured in normal use plus 10 K with a
minimum of 85 °C;
---------------------- Page: 8 ----------------------
61558-2-16 Amend. 1 © IEC:2013 – 7 –
1 h at
25 °C ± 2 °C;
2 h at
0 °C ± 2 °C;
1 h at
25 °C ± 2 °C.

During each thermal cycling test, a voltage of twice the value of the working voltage at 50 Hz

or 60 Hz shall be applied to the specimens between the windings where the reduced values

apply.

Two of the three specimens are then subjected to the humidity treatment of 17.2 (48 h

treatment) and the relevant dielectric strength test of 18.3.

One of the three specimens shall be subjected to the relevant dielectric strength test of 18.3

immediately at the end of the last period at highest temperature during the thermal cycling

test.

The partial discharge test shall be done at the end of the cycling test at normal room

temperature as performed in 18.101.
---------------------- Page: 9 ----------------------
– 8 – 61558-2-16 Amend. 1 © IEC:2013
Table 111 – Values of FIW wires with maximum overall diameter
and minimum test voltages according to the enamel increase
---------------------- Page: 10 ----------------------
61558-2-16 Amend. 1 © IEC:2013 – 9 –

The values of allowed voltage strength for other FIW dimensions than defined in Table 111

are calculated according following formula:
d − d
a cu 3
V= ×U×10
where
d is the maximum overall diameter in (mm);
d is the nominal copper diameter in (mm);

U is the voltage value according to Table 7 of IEC 60317-0-7 (see column 2) in (V/µm);

V is the allowed voltage strength for FIW wire in (V).

Higher voltage values, based on the "enamel increase" of Table 7 of IEC 60317-0-7:2012, are

under consideration.
Annexes

Add, before the existing word "Addition", the following new text and new annex as follows:

Replacement of Annex K:
---------------------- Page: 11 ----------------------
– 10 – 61558-2-16 Amend. 1 © IEC:2013
Annex K
(normative)
Insulated winding wires
K.1 General

This annex specifies the winding wires of the insulation that may be used to provide basic

insulation, supplementary insulation, double insulation or reinforced insulation in

wound components. For details of the construction, see 19.12.3.

This annex applies to solid circular winding wires and stranded winding wires having

diameters between 0,05 mm and 5,0 mm and solid square and solid rectangular (flatwise

bending) winding wires with equivalent cross-sectional areas (0,002 to 19,6 mm ).

If the wire is insulated with two or more spirally wrapped layers of tape, the overlap of layers

shall be adequate to ensure continued overlap during manufacture of the wound component.

The layers of spirally wrapped wire insulation shall be sufficiently secured to maintain the

amount of overlap.
K.2 Type tests
K.2.1 General

The winding wire shall pass the following type tests, carried out at a temperature between

15 °C and 35 °C and a relative humidity between 25 % and 75 %, unless otherwise specified.

K.2.2 Electric strength
K.2.2.1 Solid circular winding wires and stranded winding wires

The test sample is prepared according to 4.4.1 of IEC 60851-5:2008 (twisted pair). The

sample is then subjected to the electric strength test of 18.3 in this standard with a test

voltage standard, with a minimum of:
– 6 kV r.ms. for reinforced insulation, or
– 3 kV r.m.s. for basic insulation or supplementary insulation.
K.2.2.2 Square or rectangular wires

The test sample is prepared according to 4.7.1 of IEC 60851-5:2008 (single conductor

surrounded by metal shots). The sample is then subjected to the electric strength test of 18.3

of this standard, with a minimum test voltage of:
– 5,5 kV r.m.s. for reinforced insulation, or
– 2,75 kV r.m.s. for basic insulation or supplementary insulation.
K.2.3 Flexibility and adherence

5.1 (in Test 8) of IEC 60851-3:2009 shall be used, using the mandrel diameters of Table K.1.

The test voltage is applied between the wire and the mandrel.

The test sample is then examined in accordance with 5.1.1.4 of IEC 60851-3:2009, followed

by the electric strength test of 18.3 in this standard, with minimum test voltage of:

– 5,5 kV r.m.s. for reinforced insulation, or
---------------------- Page: 12 ----------------------
61558-2-16 Amend. 1 © IEC:2013 – 11 –
– 2,75 kV r.m.s. for basic insulation or supplementary insulation.
The test voltage is applied between the wire and the mandrel.
Table K.1 – Mandrel diameter
Nominal conductor Mandrel diameter
diameter or thickness
mm mm
up to but excluding
0,35
4,0 ± 0,2
0,50 6,0 ± 0,2
0,75 8,0 ± 0,2
2,50
10,0 ± 0,2
5,00 Four times the conductor diameter or thickness
In accordance with IEC 60317-43.

The tension to be applied to the wire during winding on the mandrel is calculated from the

wire diameter to be equivalent to 118 MPa ± 10 % (118 N/mm ± 10 %).

Edgewise bending on the smaller dimension side (width) is not required for rectangular wire.

For mandrel winding test of the square and rectangular wire, two adjacent turns do not need

to contact each other.
K.2.4 Heat shock

The test sample shall prepared in accordance with 3.1.1 (in Test 9) of IEC 60851-6:1996,

followed by the electric strength test of 18.3 in this standard, with a minimum test voltage of:

– 5,5 kV r.m.s. or for reinforced insulation, or
– 2,75 kV r.m.s for basic insulation or supplementary insulation.

The test voltage is applied between the wire and the mandrel. The oven temperature is the

relevant temperature of the thermal class of insulation in Table K.2. The mandrel diameter

and tension applied to the wire during winding on the mandrel are as in Table K.1. The test

voltage is applied between the wire and the mandrel.

The electric strength test is conducted at room temperature after removal from the oven.

Table K.2 – Oven temperature
Class 105 Class 120 Class 130 Class 155 Class 180
Thermal class
(A) (E) (B) (F) (H)
Oven temperature °C 200 215 225 250 275

Edgewise bending on the smaller dimension side (width) is not required for rectangular wire.

NOTE 3.1.2 in Test 9 of IEC 60851-6:1996 is not used for solid square and solid rectangular winding wires.

K.2.5 Retention of electric strength after bending

Five samples are prepared as in K.2.3 and tested as follows. Each sample is removed from

the mandrel, placed in a container and positioned so that it can be surrounded by at least

5 mm of metal shot. The ends of the conductor in the sample shall be sufficiently long to avoid

flash over. The shot shall be not more than 2 mm in diameter and shall consist of balls of

stainless steel, nickel or nickel plated iron. The shot is gently poured into the container until

---------------------- Page: 13 ----------------------
– 12 – 61558-2-16 Amend. 1 © IEC:2013

the sample under test is covered by at least 5 mm of shot. The shot shall be cleaned

periodically with a suitable solvent.

NOTE The above test procedure is reproduced from 4.6.1 c) of IEC 60851-5:1988 but is not included in the fourth

edition (2008) of that standard.

The samples shall be subjected to the electric strength test of 18.3 in this standard, with a

minimum test voltage of:
– 5,5 kV r.m.s. for reinforced insulation, or
– 2,75 kV r.m.s. for basic insulation or supplementary insulation.

The mandrel diameter and tension applied to the wire during winding on the mandrel are as in

K.2.
K.3 Testing during manufacturing
K.3.1 General

The wire shall be subjected by the wire manufacturer to electric strength tests during

manufacture as specified in K.3.2 and K.3.3.
K.3.2 Routine test

The test voltage for routine test shall be in accordance with the electric strength test of 18.3

in this standard, with a minimum of:
– 4,2 kV r.m.s. for reinforced insulation, or
– 2,1 kV r.m.s. for basic insulation or supplementary insulation.
K.3.3 Sampling test
K.3.3.1 Solid circular winding wires and stranded winding wires

Twisted pair samples shall be tested in accordance with 4.4.1 of IEC 60851-5:2008. The test

voltage shall be in accordance with the electric strength test of 18.3 in this standard, with a

minimum of:
– 6 kV r.m.s. for reinforced insulation, or
– 3 kV r.m.s. for basic insulation or supplementary insulation.
K.3.3.2 Square or rectangular wire

The test sample is prepared according to 4.7.1 of IEC 60851-5:2008. The sample is then

subjected to the electric strength test of 18.3. The test voltage shall be in accordance with the

electric strength test of 18.3 in this standard, with a minimum of:
– 5,5 kV r.m.s. for reinforced insulation, or
– 3 kV r.m.s. for basic insulation or supplementary insulation.
BB.4.2

Add, in the existing third paragraph of this subclause, references to "18.102" and "26.107".

Add, at the end of the existing text, the following new bibliography:
---------------------- Page: 14 ----------------------
61558-2-16 Amend. 1 © IEC:2013 – 13 –
Bibliography
The bibliography of Part 1 is applicable, except as follows:
Addition:

IEC 61800-5-1, Adjustable speed electrical power drive systems – Part 5-1: Safety

requirements – Electrical, thermal and energy
______________
---------------------- Page: 15 ----------------------
– 14 – 61558-2-16 Amend. 1 © CEI:2013
AVANT-PROPOS

Le présent amendement a été établi par le comité d'études 96 de la CEI: Transformateurs,

bobines d'inductance, blocs d'alimentation et combinaisons de ces éléments.
Le texte de cet amendement est issu des documents suivants:
FDIS Rapport de vote
96/401/FDIS 96/405/RVD

Le rapport de vote indiqué dans le tableau ci-dessus donne toute information sur le vote ayant

abouti à l'approbation de cet amendement.

Le comité a décidé que le contenu de cet amendement et de la publication de base ne sera

pas modifié avant la date de stabilité indiquée sur le site web de la CEI sous

"http://webstore.iec.ch" dans les données relatives à la publication recherchée. A cette date,

la publication sera
• reconduite,
• supprimée,
• remplacée par une édition révisée, ou
• amendée.

IMPORTANT – Le logo "colour inside" qui se trouve sur la page de couverture de cette

publication indique qu'elle contient des couleurs qui sont considérées comme utiles à

une bonne compréhension de son contenu. Les utilisateurs devraient, par conséquent,

imprimer cette publication en utilisant une imprimante couleur.
_____________
INTRODUCTION à l'Amendement

Le présent amendement a été établi afin de permettre l’utilisation de fils FIW dans les SMPS.

Il convient que le constructeur veille à ce qu’aucun endommagement du fil FIW ne soit

possible durant la production et le transport.
_____________
2 Références normatives
Ajouter à la liste existante de références, les nouvelles références suivantes:

CEI 60317-0-7:2012, Spécifications pour types particuliers de fils de bobinage – Partie 0-7:

Exigences générales – Fil de section circulaire en cuivre émaillé sans défaut d'isolation

électrique avec diamètre nominal de conducteur compris entre 0,040 mm et 1,600 mm

CEI 60317-43, Spécifications pour types particuliers de fils de bobinage – Partie 43: Fil de

section circulaire en cuivre recouvert d'un ruban de polyimide aromatique, classe 240

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