BS EN 60851-3:2009+A1:2013 BS BSI Standards Publication Winding wires – Test methods — Part 3: Mechanical properties BS EN 60851-3:2009+A1:2013 BRITISH STANDARD National foreword This British Standard is the UK implementation of EN 60851-3:2009+A1:2013 It is identical to IEC 60851-3:2009, incorporating amendment 1:2013 It supersedes BS EN 60851-3:2009 which is withdrawn The start and finish of text introduced or altered by amendment is indicated in the text by tags Tags indicating changes to IEC text carry the number of the IEC amendment For example, text altered by IEC amendment is indicated by The UK participation in its preparation was entrusted to Technical Committee GEL/55, Winding wires A list of organizations represented on this committee can be obtained on request to its secretary This publication does not purport to include all the necessary provisions of a contract Users are responsible for its correct application © The British Standards Institution 2013 Published by BSI Standards Limited 2013 ISBN 978 580 75807 ICS 29.060.10 Compliance with a British Standard cannot confer immunity from legal obligations This British Standard was published under the authority of the Standards Policy and Strategy Committee on 30 June 2009 Amendments/corrigenda issued since publication Date Text affected 31 October 2013 Implementation of IEC amendment 1:2013 with CENELEC endorsement A1:2013 BS EN BS 60851-3:2009+A1:2013 EN 60851-3:2009 EUROPEAN STANDARD EN EN 60851-3+A1:2013 60851-3 NORME EUROPÉENNE EUROPÄISCHE NORM April 20092013 September ICS 29.060.10 Supersedes EN 60851-3:1996 + A1:1997 + A2:2003 English version Winding wires Test methods Part 3: Mechanical properties (IEC 60851-3:2009) Fils de bobinage Méthodes d'essai Partie 3: Propriétés mécaniques (CEI 60851-3:2009) Wickeldrähte Prüfverfahren Teil 3: Mechanische Eigenschaften (IEC 60851-3:2009) This European Standard was approved by CENELEC on 2009-04-01 CENELEC members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European Standard the status of a national standard without any alteration Up-to-date lists and bibliographical references concerning such national standards may be obtained on application to the Central Secretariat or to any CENELEC member This European Standard exists in three official versions (English, French, German) A version in any other language made by translation under the responsibility of a CENELEC member into its own language and notified to the Central Secretariat has the same status as the official versions CENELEC members are the national electrotechnical committees of Austria, Belgium, Bulgaria, Cyprus, the Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, the Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland and the United Kingdom CENELEC European Committee for Electrotechnical Standardization Comité Européen de Normalisation Electrotechnique Europäisches Komitee für Elektrotechnische Normung Central Secretariat: avenue Marnix 17, B - 1000 Brussels © 2009 CENELEC - All rights of exploitation in any form and by any means reserved worldwide for CENELEC members Ref No EN 60851-3:2009 E BS EN 60851-3:2009 BS 60851-3:2009 BS EN EN 60851-3:2009 BS EN 60851-3:2009+A1:2013 EN 60851-3:2009 BS EN 60851-3:2009 EN 60851-3:2009 BS EN 60851-3:2009 EN 60851-3:2009+A1:2013 EN 60851-3:2009 EN 60851-3:2009 EN 60851-3:2009 –2– – ––2 22– –– –2– –2– Foreword Foreword Foreword Foreword The text of document 55/1043/CDV, future edition of IEC 60851-3, prepared by IEC TC 55, Winding Foreword The text of document 55/1043/CDV, future edition IEC 60851-3, prepared by Winding wires, wasofsubmitted the IEC-CENELEC approved by CENELEC as 55, EN 60851-3 The text documentto55/1043/CDV, futureparallel edition vote of of and IECwas 60851-3, prepared by IEC IEC TC TC 55, Winding The text of document 55/1043/CDV, future edition of IEC 60851-3, prepared by IEC TC 55, Winding wires, was submitted to the IEC-CENELEC parallel vote and was approved by CENELEC as EN 60851-3 on 2009-04-01 wires, was submitted to the IEC-CENELEC parallel vote and was approved by CENELEC as EN 60851-3 The text documentto55/1043/CDV, futureparallel edition vote of and IECwas 60851-3, prepared by IEC TC Winding wires, wasofsubmitted the IEC-CENELEC approved by CENELEC as 55, EN 60851-3 on 2009-04-01 on 2009-04-01 wires, was submitted to the IEC-CENELEC parallel vote and was approved by CENELEC as EN 60851-3 on 2009-04-01 This European Standard supersedes EN 60851-3:1996 + A1:1997 + A2:2003 on 2009-04-01 This This European European Standard Standard supersedes supersedes EN EN 60851-3:1996 60851-3:1996 + + A1:1997 A1:1997 + + A2:2003 A2:2003 This European Standard supersedes EN 60851-3:1996 + A1:1997 + A2:2003 With respect to EN 60851-3:1996, significant technical changes appear in Subclause 5.3, Jerk test This European Standard supersedes EN 60851-3:1996 + A1:1997 + A2:2003 With With respect respect to to EN EN 60851-3:1996, 60851-3:1996, significant significant technical technical changes changes appear appear in in Subclause Subclause 5.3, 5.3, Jerk Jerk test test Withfollowing respect todates EN 60851-3:1996, significant technical changes appear in Subclause 5.3, Jerk test The were fixed: With respect to EN 60851-3:1996, significant technical changes appear in Subclause 5.3, Jerk test The The following following dates dates were were fixed: fixed: The following dates were fixed: The following were fixed: – latest date dates by which the EN has to be implemented – date which the implemented at national level by publication – latest latest date by by which the EN EN has hasofto toanbe beidentical implemented – latest date by which the EN hasoftoanbeidentical implemented at national level by publication national standard or by endorsement (dop) 2010-01-01 at national level by publication oftoanbeidentical – latest date by which the EN has implemented at national level byorpublication of an identical national standard by endorsement (dop) national standard by endorsement (dop) 2010-01-01 2010-01-01 at national level byor of an identical national standard orpublication by endorsement (dop) 2010-01-01 national standard or the by endorsement (dop) 2010-01-01 – latest date by which national standards conflicting – latest date which the national ENby have to be (dow) 2012-04-01 – with latestthe date by which thewithdrawn national standards standards conflicting conflicting – with latestthe date by which thewithdrawn national standards conflicting EN have to be (dow) with the ENby have to be withdrawn (dow) 2012-04-01 2012-04-01 – with latest date which the national standards conflicting the EN have to be withdrawn (dow) 2012-04-01 withZA thehas EN been have added to be withdrawn (dow) 2012-04-01 Annex by CENELEC Annex Annex ZA ZA has has been been added added by by CENELEC CENELEC Annex ZA has been added by CENELEC Annex ZA has been added by CENELEC EN 60851-3:2009/A1:2013 -2 Endorsement notice Endorsement notice EN 60851-3:2009/A1:2013 -2Endorsement notice notice The text of the International StandardEndorsement IEC 60851-3:2009 was approved by CENELEC as a European Endorsement notice The text of the International Standard IEC 60851-3:2009 EN 60851-3:2009/A1:2013 Standard without any modification The text of the International Standard IEC 60851-3:2009 was was approved approved by by CENELEC CENELEC as as a a European European The text of the International Standard IEC 60851-3:2009 was approved by CENELEC as a European Standard without any modification Standard without any modification The text of the International Standard IEC 60851-3:2009 was approved by CENELEC as a European Standard without any modification ENthe 60851-3:2009/A1:2013 - notes In official version, for Bibliography, the following have to be added for the standards indicated: Foreword Standard without any modification In the official version, for Bibliography, the following notes In the official version, for Bibliography, the following notes have have to to be be added added for for the the standards standards indicated: indicated: In the official version, for Bibliography, the following notes have be added for the standards indicated: IEC 60851-5 NOTE Harmonized asForeword EN 60851-5:2008 (notto modified) In the official version, for Bibliography, the following notes have be added for the standards indicated: IEC 60851-5 NOTE Harmonized as EN 60851-5:2008 (notto modified) IEC 60851-5 NOTE Harmonized as EN 60851-5:2008 (not modified) 60851-5 60851-5:2008 (not modified) IEC 61033 + A1 NOTE Harmonized as EN 61033:2006 (not modified) The textIEC of61033 document futureasForeword IEC 60851-3:2009/A1, prepared by 60851-5 60851-5:2008 (not modified) + A1 55/1392/FDIS, NOTE Harmonized EN 61033:2006 (not modified) IEC 61033 + A1 NOTE Harmonized as EN 61033:2006 (not modified) wires" IEC was61033 submitted toNOTE the Harmonized IEC-CENELEC parallel (not vote and approved + A1 as EN 61033:2006 modified) + A1 55/1392/FDIS, NOTE Harmonized EN 61033:2006 (not modified) The60851-3:2009/A1:2013 textIEC of61033 document futureasForeword IEC 60851-3:2009/A1, prepared by EN IEC/TC 55 "Winding by CENELEC as IEC/TC 55 "Winding wires" was submitted to the IEC-CENELEC parallel vote and approved by CENELEC as Foreword to amendment A1 The text of document 55/1392/FDIS, future IEC 60851-3:2009/A1, prepared by IEC/TC 55 "Winding EN 60851-3:2009/A1:2013 The following dates are fixed: wires" was submitted to the IEC-CENELEC parallel vote and approved by CENELEC as The60851-3:2009/A1:2013 text of document future IEC 60851-3:2009/A1, prepared by IEC/TC 55 "Winding EN The following are55/1392/FDIS, fixed: – latest datedates by which the document has to be implemented at (dop) 2014-06-04 wires" was submitted to the IEC-CENELEC parallel vote and approved by CENELEC as national level by publication of an identical national EN The following dates are fixed: – 60851-3:2009/A1:2013 latest dateor by the document has to be implemented at (dop) 2014-06-04 standard bywhich endorsement national level by publication of an identical national The following or dates are fixed: – latest the has to beconflicting implemented (dop) 2014-06-04 bywhich endorsement – standard latest date date by by which the document national standards with at (dow) 2016-09-04 national level by publication of an identical national the document have to be withdrawn – the has to beconflicting implemented (dop) 2014-06-04 standard bywhich endorsement – latest latest date dateorby by which the document national standards with at (dow) 2016-09-04 national level by publication of an identical national the document have to be withdrawn bywhich endorsement – standard latest dateorby the national standards conflicting with (dow) 2016-09-04 the document have to be withdrawn Attention is drawn to the possibility that some of the elements of this document may be the subject of – latest date by which the national standards conflicting with (dow) 2016-09-04 patent rights CENELEC [and/or CEN] shall not be held responsible for identifying any or all such the document have topossibility be withdrawn Attention is drawn to the that some of the elements of this document may be the subject of patent rights patent rights CENELEC [and/or CEN] shall not be held responsible for identifying any or all such Attention is drawn to the possibility that some of the elements of this document may be the subject of patent rights patent rights CENELEC [and/or CEN] shall not be held responsible for identifying any or all such Attention is drawn to the possibility that some of the elements patent rights Endorsement noticeof this document may be the subject of patent rights CENELEC [and/or CEN] shall not be held responsible for identifying any or all such patent rights Endorsement notice notice The text of the International StandardEndorsement IEC 60851-3:2009/A1:2013 European Standard without any modification The text of the International StandardEndorsement IEC 60851-3:2009/A1:2013 notice European Standard without any modification The text of the International Standard IEC 60851-3:2009/A1:2013 European Standard without any modification The text of the International Standard IEC 60851-3:2009/A1:2013 European Standard without any modification was approved by CENELEC as a was approved by CENELEC as a was approved by CENELEC as a was approved by CENELEC as a –3– BS EN 60851-3:2009+A1:2013 BS EN 60851-3:2009 EN 60851-3:2009+A1:2013 –3– EN 60851-3:2009 Annex ZA (normative) Normative references to international publications with their corresponding European publications The following referenced documents are indispensable for the application of this document For dated references, only the edition cited applies For undated references, the latest edition of the referenced document (including any amendments) applies NOTE When an international publication has been modified by common modifications, indicated by (mod), the relevant EN/HD applies Publication Year 1) Title EN/HD Year Winding wires - Test methods Part 1: General EN 60851-1 1996 IEC 60851-1 - IEC 60851-2 1996 Winding wires - Test methods Part 2: Determination of dimensions EN 60851-2 1996 ISO 178 A1 2001 2004 Plastics - Determination of flexural properties EN ISO 178 A1 2003 2005 1) 2) Undated reference Valid edition at date of issue 2) BS EN 60851-3:2009+A1:2013 60851-3 © IEC:2009+A1:2013 –4– –2– BS EN 60851-3:2009 60851-3 IEC:2009 CONTENTS INTRODUCTION Scope .7 Normative references .7 Test 6: Elongation 3.1 Elongation at fracture 3.2 Tensile strength Test 7: Springiness 4.1 Round wire with a nominal conductor diameter from 0,080 mm up to and including 1,600 mm 4.1.1 Principle 4.1.2 Equipment 4.1.3 Procedure 4.2 Round wire with a nominal conductor diameter over 1,600 mm and rectangular wire 10 4.2.1 Principle 10 4.2.2 Equipment 10 4.2.3 Specimen 11 4.2.4 Procedure 11 Test 8: Flexibility and adherence 12 5.1 5.2 5.3 5.4 5.5 Test Mandrel winding test 12 5.1.1 Round wire 12 5.1.2 Rectangular wire 13 5.1.3 Covered bunched wire 14 Stretching test (applicable to enamelled round wire with a nominal conductor diameter over 1,600 mm) 14 Jerk test (applicable to enamelled round wire with a nominal conductor diameter up to and including 1,000 mm) 15 Peel test (applicable to enamelled round wire with a nominal conductor diameter over 1,000 mm) 15 Adherence test 17 5.5.1 Enamelled rectangular wire 17 5.5.2 Impregnated fibre covered round and rectangular wire 17 5.5.3 Fibre covered enamelled round and rectangular wire 17 5.5.4 Tape wrapped round and rectangular wire (for adhesive tape only) 18 11: Resistance to abrasion (applicable to enamelled round wire) 18 6.1 Principle 18 6.2 Equipment 18 6.3 Procedure 19 Test 18: Heat bonding (applicable to enamelled round wire with a nominal conductor diameter over 0,050 mm up to and including 000 mm) 20 7.1 7.2 Vertical bond retention of a helical coil 20 7.1.1 Nominal conductor diameter up to and including 0,050 mm 20 7.1.2 Nominal conductor diameter over 0,050 mm up to and including 2,000 mm 20 Bond strength of a twisted coil 23 7.2.1 Principle 23 7.2.2 Equipment 23 BS EN 60851-3:2009 BS EN 60851-3:2009 60851-3 IEC:2009 60851-3 IEC:2009 –5– BS EN 60851-3:2009+A1:2013 60851-3 © IEC:2009+A1:2013 –3– –3– 7.2.3 Specimen 23 7.2.3 23 7.2.4 Specimen Procedure 25 7.2.4 7.2.5 Procedure Result 25 25 7.2.5 Result 25 Annex A (informative) Bond strength of heat bonding wires 27 Annex A (informative) (informative) Friction Bond strength of heat bonding wires 27 Annex B test methods 33 Annex B (informative) Friction test methods 33 Bibliography 44 43 Bibliography 43 Figure Figure Figure Figure Figure 1 2 – – – – – Test equipment to determine springiness Test equipment determine springiness Construction andtodetails of the mandrel (see Table 1) Construction andtodetails of the mandrel (see Table 1) Test equipment determine springiness 11 Figure Figure Figure Figure 4 – – – – Test Test Test Test Figure Figure Figure Figure 8 – – – – Scraper 17 Cross-section of the wire after removal of the coating 17 Cross-section theunidirectional wire after removal the coating 17 Test equipmentoffor scrapeoftest 19 Figure Figure Figure Figure 6 – – – – equipment equipment equipment equipment to springiness 11 fordetermine mandrel winding test 14 for mandrel winding test 14 for jerk test 15 Test Test equipment equipment for for jerk peel test test 15 16 Test equipment for peel test 16 Scraper 17 Figure Figure Figure Figure scrape test 10– –Test Testequipment equipmentfor forunidirectional bond retention of a helical coil 19 22 10 – Test equipment for bond retention of a helical coil 22 11 – Coil winder 24 Figure Figure Figure Figure 13 – – Twisting device a load applied to the twisted coil specimen 26 25 14 Arrangement of with supports 14 of supports 26 A.1––Arrangement Example of voltage-time graphs of twisted coil specimens with a nominal Figure Figure Figure Figure 11 12 12 13 – – – – Coil Ovalwinder shape coil 24 25 Oval shape coil 25 Twisting device with a load applied to the twisted coil specimen 25 conductor of of 0,300 mm with isothermic graphs coil 29 Figure A.1 diameter – Example voltage-time graphs of twisted specimens with a nominal conductor diameter of 0,300 mm with isothermic graphs 29 Figure A.2 – Example of voltage-time graphs of twisted coil specimens with a nominal conductor of of 0,315 mm with isothermic graphs coil 30 Figure A.2 diameter – Example voltage-time graphs of twisted specimens with a nominal conductor diameter of 0,315 mm with isothermic graphs 30 Figure A.3 – Example of voltage-time graphs of twisted coil specimens with a nominal conductor of of 0,355 mm with isothermic graphs coil 31 Figure A.3 diameter – Example voltage-time graphs of twisted specimens with a nominal conductor diameter of 0,355 mm with isothermic graphs 31 Figure A.4 – Example of voltage-time graphs of twisted coil specimens with a nominal conductor of of 0,500 mm with isothermic graphs coil 32 Figure A.4 diameter – Example voltage-time graphs of twisted specimens with a nominal conductor diameter of 0,500 mm with isothermic graphs 32 Figure B.1 – Static coefficient of friction test apparatus 38 Figure B.2 B.1 – – Dynamic Static coefficient of friction testtest apparatus 38 Figure coefficient of friction apparatus 39 Figure B.3 B.2 –– Diagram Dynamic of coefficient of friction frictioncoefficient test apparatus apparatus Dynamic coefficient test 40 Figure a typical of dynamic of friction tester 39 Figure Figure Figure Figure Figure B.3 B.4 B.4 B.5 B.5 Table Table Table Table Table – – – – – Figure Figure Figure Table Table Table Table B.5 B.6 B.6 B.7 B.6 1 2 3 4 – – – – – Material Dynamic of friction apparatus 40 – –coefficient sapphire (synthetic) Detail drawing of friction head test assembly with mechanical dynamometer 41 – Detail drawing friction head assembly with mechanical dynamometer 41 – sapphires mounted on load block 42 – Synthetic Load block withofsapphires 42 – Load applied block with sapphires perpendicular to wire path 42 – Twisted specimen 42 – Twisted 43 Twisted specimen specimen 42 Mandrels for springiness Mandrels for springiness Magnification to detect cracks 12 Magnification to detect cracks 12 Load for peel test 16 Load for peeloftest Preparation helical coils 16 21 Preparation of helical coils 21 Bond retention at elevated temperature 22 Table – Bond retention at elevated temperature 22 Table B.1 – Twisted pair method 37 Table block weights for dynamic coefficient of friction testing 37 36 Table B.1 B.1 –– Load Twisted pair method Table B.2 – Twisted pair method 37 BS EN 60851-3:2009+A1:2013 60851-3 © IEC:2009+A1:2013 –6– –6– BS EN 60851-3:2009 60851-3 IEC:2009 INTRODUCTION This part of IEC 60851 forms an element of a series of standards, which deals with insulated wires used for windings in electrical equipment The series has three groups describing a) winding wires − Test methods (IEC 60851); b) specifications for particular types of winding wires (IEC 60317); c) packaging of winding wires (IEC 60264) –7– BS EN 60851-3:2009 60851-3 IEC:2009 BS EN 60851-3:2009+A1:2013 60851-3 © IEC:2009+A1:2013 –7– WINDING WIRES ± TEST METHODS ± Part 3: Mechanical properties Scope This part of IEC 60851 specifies the following methods of test for winding wires: – Test 6: Elongation; – Test 7: Springiness; – Test 8: Flexibility and adherence; – Test 11: Resistance to abrasion; – Test 18: Heat bonding For definitions, general notes on methods of test and the complete series of methods of test for winding wires, see IEC 60851-1 Normative references The following referenced documents are indispensable for the application of this document For dated references, only the edition cited applies For undated references, the latest edition of the referenced document (including any amendments) applies IEC 60851-1, Winding wires ± Test methods ± Part 1: General IEC 60851-2:1996, Winding wires ± Test methods ± Part 2: Determination of dimensions ISO 178:2001, Plastics ± Determination of flexural properties Amendment 1:2004 3.1 Test 6: Elongation Elongation at fracture Elongation is the increase in length expressed as a percentage of the original length A straight piece of wire shall be elongated to the point of fracture of the conductor at a rate of (5 ± 1) mm/s with an elongation tester or with tensile testing equipment with a free measuring length of between 200 mm and 250 mm The linear increase at fracture shall be calculated as a percentage of the free measuring length Three specimens shall be tested The three single values shall be reported The mean value represents elongation at fracture 3.2 Tensile strength Tensile strength is the ratio of the force at fracture to initial cross-section BS EN 60851-3:2009+A1:2013 60851-3 © IEC:2009+A1:2013 –8– BS EN 60851-3:2009 60851-3 IEC:2009 –8– A straight piece of wire shall be elongated to the point of fracture of the conductor at a rate of (5 ± 1) mm/s with tensile testing equipment with a free measuring length of between 200 mm and 250 mm and which records the force at fracture Three specimens shall be tested The initial cross-section and the three single values of the force at fracture shall be reported The mean value of the ratio of the force at fracture and the initial cross-section represents the tensile strength Test 7: Springiness Springiness is the recoil measured in degrees after the wire is wound in the form of a helical coil or bent through an angle 4.1 Round wire with a nominal conductor diameter from 0,080 mm up to and including 1,600 mm 4.1.1 Principle A straight piece of wire is wound five times around a mandrel with a diameter and under a tension applied to the wire as specified in the relevant standard The reading of the angle by which the end of the five turns recoils is the measure of springiness 4.1.2 Equipment Figure shows an example of the test equipment with details of the mandrel given in Figure and Table Figure indicates a helical groove, which may be used to facilitate winding The provision of this groove, however, is not mandatory The dial is marked with 72 equally spaced divisions so that with five turns of the wire the reading corresponds to the number of degrees that each turn springs back 4a 44 4b 40 36 32 28 24 48 52 20 56 16 60 12 64 68 72 IEC 019/09 Key mandrel dial locking device locking device base-plate mandrel-fixing screw Figure ± Test equipment to determine springiness BS EN 60851-3:2009+A1:2013 60851-3 © IEC:2009+A1:2013 – 32 – BS EN 60851-3:2009 60851-3 IEC:2009 – 32 – 30 300 °C 15 A 250 °C 13 A 200 °C Voltage output (V) 20 150 °C 11 A 100 °C 10 A 9A 50 °C 8A 7A 10 6A 0 10 20 30 40 Heating period (s) 50 60 70 IEC 039/09 Figure A.4 ± Example of voltage-time graphs of twisted coil specimens with a nominal conductor diameter of 0,500 mm with isothermic graphs BS EN 60851-3:2009 BS EN 60851-3:2009 60851-3 IEC:2009 60851-3 IEC:2009 – 33 – BS EN 60851-3:2009+A1:2013 60851-3 © IEC:2009+A1:2013 – 33 – – 33 – Annex B Annex B (informative) (informative) Friction test methods Friction test methods B.1 B.1 General General annex provides recommendations thepurchaser purchaserand andsupplier supplierofof winding winding wires wires with ThisThis annex provides recommendations to to the This annex provides tofor the purchaser and of winding wires with respect to friction test methods winding wires Thesupplier use of additional methods can test recommendations methods to to be be used used for winding wires respect to friction test methods to beand used for winding be agreed upon between purchaser supplier wires B.2 B.2 Test A: Static coefficient of friction test method Test A: Static coefficient of friction test method B.2.1 Method of test (applicable to enamelled round wires with a nominal conductor B.2.1 Method of test to enamelled round wires with a nominal conductor diameter from 0,050 mm (applicable up to and including 1,600 mm) diameter from 0,050 mm up to and including 1,600 mm) The static coefficient of friction (Ìs ) is determined by measuring the inclining angle ( α ) of a is determined measuring thefrom inclining angle ( α ) of a The static coefficient of friction (Ìs )begins plane at the moment when a block to slip onbythe track made the wire specimen planewire at the when block beginsfrom to slip the track made the wire specimen The testmoment specimen shalla be removed theon delivery spools byfrom de-reeling over the end The wireThe testtop specimen removed from the delivery de-reeling over the end flange layers ofshall the be spool shall be removed beforespools testingbywhen the wire surface is flange The top the One spoolpart shall before istesting when the is contaminated bylayers dirt orofdust of be theremoved wire specimen straightened andwire thensurface fixed on contaminated by dirt or dust One part of the wire specimen is straightened and then fixed on the inclining plane by means of the two posts and the two clamps constituting the sliding the inclining plane the two is posts and the clamps constituting sliding track The other partby of means the wireofspecimen mounted in a two similar way on the slidingthe block track The other part of the wire specimen is mounted in a similar way on the sliding block The sliding block with the wire specimen is then placed on the track of the plane to be inclined theplane trackare of the planeattoright be inclined The sliding block is then in such a way thatwith the the wirewire on specimen the block and the placed wire ononthe crossed angles in such a way that the wire on the block and the wire on the plane are crossed at right angles at the point of contact at the point of contact The plane is The is track.plane At that track At that then slowly inclined (approximately then slowly moment, theinclined angle of(approximately inclination ( α ) moment, the angle of inclination ( α ) 1°/s) until the block starts to slide down the 1°/s) until thethe block starts to slide down the is read from scale is read from the scale The static coefficient of friction is calculated as follows: The static coefficient of friction is calculated as follows: Ìs = tan α Ìs = tan α B.2.2 Test B.2.2 Test The general The general apparatus apparatus arrangement of the test apparatus is shown in Figure B.1 arrangement of the test apparatus is shown in Figure B.1 The apparatus consists of a plane (1), which can be inclined to an The apparatus consists a plane (1),(9) which cana be inclined to an plane around the axis (8).ofThe support carries scale (7) marked plane around the axis (8) The support (9) carries a scale (7) marked ( α ) or the coefficient of friction (tan α ) ( α ) or the coefficient of friction (tan α ) angle ( α ) by turning the ) by turning the angle with the( αinclination angle with the inclination angle The plane has means for fixing the wire specimen (3), for example the two posts (5) and the The plane has for fixing the specimen (3),110 for mm example twoform posts (5) andtrack the two clamps (6).means The parallel parts of wire the wire shall be apart.the They a sliding parallel of the shall be 110 mm apart They form a sliding track two clamps running from(6) theThe scale end toparts the axis onwire the plane running from the scale end to the axis on the plane On the block (2) clamps and posts are provided to fix the second wire specimen (4) The On the block (2) the clamps and posts provided to fixThe thesize second wire specimen (4) The parallel parts of specimen shall are be 60 mm apart of the block must allow the parallel and partsposts of the 60 mm The size of the block must The allow the clamps to specimen stay clear shall of thebeplane (1) apart to avoid additional friction forces block clamps and posts to stay clear of the plane (1) to avoid additional friction forces The block shall have shall have BS EN 60851-3:2009+A1:2013 60851-3 © IEC:2009+A1:2013 – 34 – – 34 – BS EN 60851-3:2009 60851-3 IEC:2009 – a mass of about 50 g for a wire with a nominal conductor diameter up to and including 0,150 mm; – a mass of about 500 g for a wire with a nominal conductor diameter over 0,150 mm The mass is not critical as it is anyway changed by the mass of the second wire specimen The angle of inclination shall be changed slowly by means of a motor-operated block and tackle B.3 B.3.1 Test B: First dynamic coefficient of friction test method Principle The coefficient of friction, Ìd , is determined by measuring the frictional force, C, applied on the wire when moving under the pressure of a known mass, E: 60851-3 Amend © IEC:2013 –3– C μd = 9,81 × E B.1 General B.3.2 Method of test Replace this subclause by the following: The general arrangement of the test apparatus is shown in Figure B.2 This annex provides recommendations to the purchaser and supplier of winding wires with respect to friction testruns methods be used for and winding wires.(D) The usea ofmetal additional The enamelled wire via a toguide wheel a brake over plate methods (B) Via can be agreed upon between and this supplier another guide wheel, the wirepurchaser is lead below plate (B) and runs back, parallel with the first passage, over this plate again (see Figure B.2) By means of a capstan (A), the wire is drawn with a speed of 0,25 m/s A mass (E) is placed on the running wire over the plate (B), which is coupled to a force indication meter (C) B.4 Test C: Second meter dynamic friction test recorder method (measuring range The force indication can coefficient be coupledof to a linear mV - 250 mV) This linear recorder shows the spread of the smoothness and the level of the Replace the entireover clause by the following: wire smoothness a long distance B.4 Test C: C: Second Second dynamic dynamic coefficient coefficient of of friction friction test test method method (applicable to Test enamelled round wires with a nominal conductor diameter from 0,050 mm to andofincluding 1,600 mm) B.4.1 upMethod test (applicable to enamelled round wires with a nominal conductor diameter from 0,050 mm up to and including 1,600 mm) B.4.1 Test equipment The wire specimen is pulled under a test load The force is developed between the wire surface and of thetypical load contact surface and transferred an appropriate device The The design test equipment is illustrated in to Figure B.3 Figuremeasuring B.4 contains detailed reading divided and by the loadB.5 in isNewtons for determination of theThe dynamic drawingsinof Newtons synthetic issapphires Figure a photograph of the load block tester ) coefficient friction (Ìdguiding is supplied of with a wire system and a take-up which pulls the wire over the test bed at 15 m/min as shown in Figure B.6 The test block is aligned parallel with the test bed and the test perpendicular to removed the wire specimen The weights wire testare specimen shall be from the delivery spools by de-reeling over the end flange or from the pail or drum The top wire specimen layer of the spool shall be removed As the testing wire is ifpulled under the testhas block (synthetic sapphires), friction between the wire before the wire specimen been contaminated by dirtthe or dust surface and the sapphire surface develops a longitudinal force, which is transferred to the measuring a shaft by surface two sets(6) of using linear the ball levelling bearings leg in contact the Referring tosystem FigurebyB.4, levelsupported the smooth screws with (2) and measuring system The force indicated by the measuring system is divided by the load on the float level (8) test surface to obtain the dynamic coefficient of friction Adjust the electronic force transducer (5) (Figure B.4) sensitivity to the appropriate range, The measuring system to in full-scale Figure B.3 showsforthe coefficient of friction with a and set chart recorder setting thedynamic wire size being tested using tester a calibrating load cell in place to measure the force An LVDT may also be used to measure the weight (9) (Figure B.3) The calibrating weight should be removed after the transducerforce and instead of a load The electrical output from the force measurement device is fed into a chart recorder are cell adjusted computer or into a microprocessor that collects data measurements, usually 000 points Statistics are performed on this data set so that proper interpretation of the results can be made. NOTE Values for the dynamic coefficient of friction are characteristic of the type of lubrication and the magnet wire specimen surface The dynamic coefficient of friction values are generally not dependent on wire size The measuring system in Figure B.3 shows the dynamic coefficient of friction tester with a load cell in place to measure the force An LVDT may also be used to measure the force BS EN 60851-3:2009+A1:2013 instead of a load cell The electrical output from the force measurement device is fed into a – 35 – 60851-3usually © IEC:2009+A1:2013 computer or into a microprocessor that collects data measurements, 000 points Statistics are performed on this data set so that proper interpretation of the results can be made NOTE Values for the dynamic coefficient of friction are characteristic of the type of lubrication and the magnet wire specimen surface The dynamic coefficient of friction values are generally not dependent on wire size NOTE Wire lubricated with a mineral oil typically will have a mean dynamic coefficient of friction in the range of 0,9 to 0,16 Wire lubricated with a paraffin wax will typically have a mean dynamic coefficient of friction ranging from 0,03 to 0,06 and will be more consistent in value as evidenced by a lower standard deviation The mean value, maximum value and standard deviation value can be used to evaluate the application of the lubricant to the wire and smoothness of the wire surface The test procedure is designed to provide a measure of the lubrication and the film surface smoothness as a combined value It is assumed that the wire will be de-reeled from its packaging with minimal contact with surfaces other than those associated with the tester and packaging If there is suspicion that the presence of dust or dirt may have an effect on the coefficient of friction, one or two outer layers of wire should be removed from the package and the sample –4– 60851-3 Amend © IEC:2013 retested Test surfaces in contact with the wire shall be clean and dry at the start of each separate test The solvent used to clean the test load surface should remove the various types of lubricants used and should dry without leaving a film residue B.4.2 Test specimen The surface of the wire should be examined for damage, tangles, or excessive dust or dirt If any of these conditions are present, the top wire specimen layer of the spool should be surfaced off before testing The wire test specimen should be removed from the shipping package by de-reeling over the end flange or pulling the wire from a pail or drum B.4.3 Specimen preparation The wire specimen is pulled over a test bed surface under a test load (L) A frictional force (F d ) is developed between the wire surfaces and transferred to an appropriate measuring device The reading (F d ) in grams-force is divided by the test load (L) in grams-force to obtain the dynamic coefficient of friction µd μd = Fd L A motor should pull the wire specimen at 15 ± 1,5 m/min across a smooth surface using a motor driven take-up Various load weights should be available that will provide 100 – 000 grams-force The test block should be comprised of two mounted synthetic sapphires that have a surface roughness of not more than 2,4 microns The sapphires are described in Figure B.4 and are mounted in accordance with Figure B.5 There should be a means to guide the wire and a means to maintain a slight tension if needed An electrical force measuring device or transducer measures the force due to friction A force transducer with a range of – 500 grams-force, a data storage device, and a microprocessor or computer to statistically analyse the data sets should be installed A mechanical dampening system consisting of a paddle and a container filled with oil may be used The electrical signals from the load cell or LVDT can also be dampened electronically A cleaning solvent appropriate for dissolving the lubricant being tested should be used for cleaning the sapphires and metal surfaces between tests. B.4.4 Procedure A mechanical dampening system consisting of a paddle and a container filled with oil may be BS ENThe 60851-3:2009+A1:2013 used electrical signals from the load cell or LVDT can also be dampened electronically – 36 – 60851-3 © IEC:2009+A1:2013 A cleaning solvent appropriate for dissolving the lubricant being tested should be used for cleaning the sapphires and metal surfaces between tests B.4.4 Procedure The coefficient of friction tester should be level so that the only force being measured by the pressure transducer is that which is perpendicular to the load being applied and that gravity is not a factor Calibrate the pressure transducer by setting the zero without any load, and setting the span by hanging a 100 or 200 gram weight Remove the weight and the display should again read zero Enter the parameters of the test into the microprocessor or personal computer De-reel the wire from its packaging by pulling the wire over the flange, through the tensioning 60851-3through Amend.the ©guides, IEC:2013 – –spindle device, and onto the take-up Adjust the guide pulleys so that the wire is parallel with the test bed Clean the test bed, any guide pulleys, and the sapphire surfaces with a suitable solvent Place the appropriate weight from Table B.1 onto the load block: Table B.1 – Load block weights for dynamic coefficient of friction testing BS EN 60851-3:2009 Conductor diameter mm – 36 – Weight g 0,050 – 0,071 100 0,450 – 1,600 000 60851-3 IEC:2009 Various load weights (7) (Figure B.4) should be available which will provide 0,98 N – 9,81 N 0,125 force The load surface 0,071 shall –be synthetic sapphire and have a 200 surface roughness of not more 0,125are – 0,450 than 0,5 μ m The sapphires described and shall be mounted600 as shown in Figure B.5 There shall be a means to guide the wire (Figure B.3 (4) and Figure B.4 (9)) and a means to maintain a slight tension (Figure B.3, (1) (5)) if needed Adjust the test bed to make the test load parallel with the test surface Turn the wire take up B.4.3 Measuring on and start collectingdevice data after the setup is stable and aligned and continue until the desired number of data points has been stored The measuring device consists of Analyse the data minimum reading, maximum reading, mean and standard – electronic force for measuring devices or transducers (2) (Figure B.3)value, incorporated with a deviation chart recorder for measuring the force due to friction The electronic force measuring device will provide a record indicating the peak variation along the surface of the wire A beN, calculated as follows: Theforce dynamic coefficient µd0should transducer withofa friction range of N – 4,9 and a chart recorder with a V – V range and a 0,5 s full-scale response time are satisfactory; Figure B.4 illustrates the use of a mechanical Fd dynamometer (5) in place of an electronic μd =dynamometer force transducer and chart recorder Two ranges, N – 0,49 N and N – L 1,96 N, are satisfactory; – where – a dampening system (4) (Figure B.4) consisting of a paddle and a container filled to a of 5reading mm with having a viscosity of approximately 10 200 mPa × s at 25 ° C; = force in oil, grams force F depth – L d an solvent = appropriate test load in cleaning grams force for the lubricant being tested B.5 Test D: Force of friction by the twisted pair method B.5.2 Method of test B.5.1 Enamelled round wires with a nominal conductor diameter from 0,1 mm up to Replace, and in the first paragraph of this subclause, the words “Figure B.6” by “Figure B.7” and including 1,500 mm the words “Table B.1” by “Table B.2” From an enamelled wire specimen a twist is made similar to the one used for test 13 (breakdown voltage) in 4.3 of IEC 60851-5 The end of the first twist strand is attached to a fixed jaw and a force is applied to the opposite end of the second strand that has been kept free to slide by traction and without rotating, using for example a dynamometer The force to Table B.1the – Twisted pairismethod separate two strands the sliding force Re-designate the existing B.5.2 Method of test Table B.1 as Table B.2 From an enamelled wire specimen a twist is made similar to one used for test 13 BSthe EN 60851-3:2009+A1:2013 (breakdown voltage) in 4.3 of IEC 60851-5 The end of the first twist strand is attached to a – 37 – 60851-3 © IEC:2009+A1:2013 fixed jaw and a force is applied to the opposite end of the second strand that has been kept free to slide by traction and without rotating, using for example a dynamometer The force to separate the two strands is the sliding force B.5.2 Method of test A specimen approximately of 400 mm in length shall be twisted back on itself for a distance of 125 shown in The force(weight) (weight)applied appliedtoto the the wire of 125 mm mm on onan anapparatus apparatusasas shown in Figure B.7 B.6. The force pair while being twisted and the number of twists are given in Table Table B.1.B.2 At the twisted end, the loop is cut in two separate places to obtain a maximum separation between these cut ends Any bending of the wires, at the cut end or at the other untwisted end, to ensure adequate separation between the wires, shall avoid sharp bends or damage to the insulation One end of one wire shall be attached firmly to a jaw, while at the opposite end of the other wireEN a 60851-3:2009 force (weight) is applied to let that wire slide without any rotation Three specimens BS shall be tested 60851-3 IEC:2009 – 37 – ± Twisted pairpair method Table Table B.1 B.2 ± Twisted method Nominal conductor diameter mm Over Up to and including Force applied to wire pairs Number of twists per 125 mm N 0,10 0,25 0,85 17 0,25 0,315 1,40 15 0,315 0,40 2,40 13 0,40 0,50 3,40 12 0,50 0,71 6,00 11 0,71 0,80 8,50 10 0,80 0,90 10,00 0,90 1,00 12,50 1,00 1,12 15,00 1,12 1,25 20,00 1,25 1,50 27,00 BS EN 60851-3:2009+A1:2013 60851-3 © IEC:2009+A1:2013 – 38 – BS EN 60851-3:2009 60851-3 IEC:2009 – 38 – 30° 25° 350 mm 20° 60 mm 15° 10° 5° 10 Angle α 0° IEC 040/09 Figure B.1a ± Side view 110 mm 350 mm IEC 041/09 Figure B.1b ± Top view Key plane block wire specimen wire posts clamps scale axis support 10 winding wire specimen Figure B.1 ± Static coefficient of friction test apparatus BS EN 60851-3:2009+A1:2013 60851-3 © IEC:2009+A1:2013 – 39 – BS EN 60851-3:2009 60851-3 IEC:2009 – 39 – C E D B A IEC 042/09 Figure B.2a ± Side view IEC 043/09 Figure B.2b ± Top view Components A capstan B plate C force indication meter D brake E mass Figure B.2 ± Dynamic coefficient of friction test apparatus BS EN 60851-3:2009+A1:2013 60851-3 © IEC:2009+A1:2013 – 40 – –6– 60851-3 Amend © IEC:2013 LO AD C E LL ASSEM B LY W R I E TAKE U -P M ANDR E L SAPPH R I E TES T H EAD AND SU PPO R T B LO C K ASSEM B LY W R I E TEN S O I N ER IEC 1765/13 Key Wire tensioner Load cell assembly Sapphire test head and support block assembly Wire take-up mandrel Figure B.3 – Diagram of a typical dynamic coefficient of friction tester 60851-3 Amend © IEC:2013 –7– BS EN 60851-3:2009+A1:2013 Figure B.4 – Detail drawing of friction head –assembly with mechanical 41 – 60851-3 ©dynamometer IEC:2009+A1:2013 Replace Figure B.4 by the following: 10 ± 0,5 = R END VIEW ± 0,05 = R ± 0,05 0,01 SURFACE ROUGHNESS 0,5 Microns SQUARENESS ± 0,1 0,01 NOTE PARALLEL TAPER SIDE VIEW IEC 1766/13 Dimensions used in the figure are in millimetres Figure B.4 – Material – sapphire (synthetic) –8– BS EN 60851-3:2009+A1:2013 60851-3B.5 © IEC:2009+A1:2013 Figure – Load block with sapphires 60851-3 Amend © IEC:2013 – 42 – Replace Figure B.5 by the following: Sapphires IEC 1767/13 Figure B.5 – Synthetic sapphires mounted on load block Add the following figure as new Figure B.6: IEC 1768/13 Figure B.6 – Load applied perpendicular to wire path Figure B.6 – Twisted specimen Re-designate the existing Figure B.6 as Figure B.7 _ these surfaces to be flat/parallel sapphire blocks (cemented in place) sapphire synthetic BS EN 60851-3:2009+A1:2013 60851-3 © IEC:2009+A1:2013 – 43 – Figure B.5 ± Load block with sapphires A B A B IEC 049/09 ± Twisted specimen Figure B.6 B.7 ± Twisted specimen BS EN 60851-3:2009+A1:2013 60851-3 © IEC:2009+A1:2013 BS EN 60851-3:2009 60851-3 IEC:2009 – 44 – – 43 – Bibliography IEC 60851-5:2008, Winding wires ± Test methods ± Part 5: Electrical properties IEC 61033:1991, Test methods for the determination of bond strength of impregnating agents to an enamelled wire substrate Amendment 1:2006 _ This page deliberately left blank NO COPYING WITHOUT BSI PERMISSION EXCEPT AS PERMITTED BY COPYRIGHT LAW British Standards Institution (BSI) BSI is the national body responsible for preparing British Standards and other standards-related publications, information and services BSI is incorporated by Royal Charter British Standards and other standardization products are published by BSI Standards Limited About us 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