Fully Insulated (FIW) Non-defective Enameled Round Copper Wire

IEC 60317-0-7 is an international standard for fully insulated (FIW) non-defective enameled round copper wire. This standard specifies in detail the manufacturing requirements, performance tests and application areas of these wires to ensure their reliability and safety in electrical and electronic equipment.

Standard Overview

IEC 60317-0-7 standard provides comprehensive technical requirements for fully insulated (FIW) non-defective enameled round copper wire. These requirements cover the mechanical properties, electrical properties and environmental adaptability of the wire to ensure excellent performance under various conditions of use.

Main specifications

1. Insulation Performance

Fully insulated (FIW) enameled wire emphasizes the integrity of the insulation layer and requires no insulation defects (such as pinholes, bubbles, etc.). This ensures that the wire has excellent insulation performance under high voltage conditions to prevent current leakage and short circuits.

—Pinhole test: The insulation layer must undergo a rigorous pinhole test to ensure that there are no tiny defects. For example, the standard stipulates that the number of pinholes in enameled wire per 100 meters of length should be zero.

—Dielectric strength: The insulation layer should be able to withstand high voltage without being broken down, and the dielectric strength is usually required to reach 5000 V/mm or more.

2. Mechanical Properties

In terms of mechanical properties, IEC 60317-0-7 requires the wire to have high strength and ductility to ensure reliability during processing and use.

—Tensile strength: The wire must have sufficient tensile strength, usually above 200 N/mm², to withstand tensile and bending stresses.

—Ductility: The enameled wire needs to have good ductility, and the elongation is usually required to reach more than 20% to ensure that it will not break during winding and installation.

3. Thermal Performance

Fully insulated enameled wire must be able to work stably in high temperature environments without performance degradation.

—Thermal grade: The standard specifies different thermal grades (such as 130, 155, 180, etc.), which indicate that the wire can work for a long time at the corresponding temperature without significant aging.

—Thermal shock test: The wire must pass the thermal shock test, such as keeping it at 200°C for 72 hours, and the insulation layer must not crack or peel off.

4. Electrical Properties

In addition to insulation performance, IEC 60317-0-7 also specifies the conductivity and resistance requirements of enameled wire to ensure that it has low loss and high efficiency when transmitting current.

—Conductivity: The conductivity of the wire must meet the conductivity of international standard copper, usually requiring 58 MS/m or more.

—Resistance: The resistivity of the wire should be within the specified range to ensure that no excessive heat is generated under high load.

5. Environmental Adaptability

IEC 60317-0-7 also specifies the adaptability test of enameled wire under different environmental conditions, including moisture resistance, chemical resistance and weather resistance.

—Moisture resistance: The wire must pass the high humidity environment test to ensure that there is no performance degradation under humid conditions.

—Chemical resistance: The enameled wire must be able to withstand certain chemical corrosion, such as acids, alkalis and solvents, to ensure performance in complex industrial environments.

—Weather resistance: The standard also requires that the wire remain stable under UV and other climatic conditions without significant aging.

Specific Requirements for FIW

1. Dimensions

Dimensions of enameled wires for grade FIW 3,5,7,9

Nominal conductor diameter	Conductor tolerance	Minimum overall diameter mm				Maximum overall diameter mm
mm	amm	Grade of FIW 3	Grade of FIW 5	Grade of FIW 7	Grade of FIW 9	Grade of FIW 3	Grade of FIW 5	Grade of FIW 7	Grade of FIW 9
040.0 0,045 0,050 0.056 0,063		0,055 0,062 0,067 0.075 0,084	0.070 0.079 0.084 660.0 0.103	0600 0,101 0,106 0,117 0.129		0.058 0,066 0.072 0,081 0600	0.079 0.089 960.0 0,104 0,115	660.0 0,111 0.116 0.128 0,141
0,071 0,080 0600 0,100 0,112	0,003 0.003 0.003 0.003 0.003	0.092 0,102 0,114 0,126 0,140	0,111 0.123 0,135 0,149 0,165	0,137 0,151 0,163 0,181 0.199	0,163 0,179 0,191 0.213 0,233	0,098 0,108 0.120 0,132 0,147	0.123 0.136 0,148 0,164 0,181	0.149 0,164 0.176 0.196 0,215	0,175 0.192 0,204 0,228 0,249
0.125 0,140 0,160 0.180 0,200	0.003 0.003 0.003 0.003 0.003	0.155 0,172 0.195 0,218 0,240	0,182 0,202 0.228 0,254 0.278	0,218 0,242 0,272 0,302 0,328	0,254 0,282 0,316 0,350 0,378	0,163 0,181 0.205 0,229 0,252	0,199 0,221 0,249 0,277 0,302	0,235 0,261 0.293 0.325 0,352	0,271 0,301 0.337 0,373 0,402
0,224 0,250 0,280 0,315 0,355	0.003 0,004 0,004 $00.0 0,004	0,267 0,298 0,330 0,368 0,412	0,308 0,343 0,377 0,416 0,460	0,362 0,403 0,439 0.478 0,522	0,416 0,463 0,501 0,540 0,584	0,280 0,312 0,345 0,384 0,428	0,334 0,372 0,407 0,446 0,490	0,388 0,432 0,469 0.508 0,552	0,442 0,492 0,531 0,570 0,614
0,400 0,450 0,500 0,560 0,630	0.005 0,005 0.005 9000 900 0	0,460 0,514 0,567 0,631 0,705	0,510 0,565 0.629 0,695 0,770	0,572 0,627 0,711 0,777 0.852		0,478 0,533 0.587 0,653 0,728	0,540 0,595 0.669 0,753 0,810	0.602 0,657 0,751 0,817 0,892
0.710 0090 0060 1,000 1.120 1.250 1,400 1,600	0.007 0,008 6000 010.0 0,011 0.013 0,014 0,016	0.790 0.885 0660 1.095 1,218 1,350 1,503 1,707	0.856 0,963 1.070 1.176 1,310 1,443 1,597 1,802	0.938		0,814 0,911 1,018 1,124 1,248 1,381 1,535 1,740	0,896 1,013 1.120 1,226 1,370 1,503 1,657 1,862	0.978

Dimensions of enameled wires for grade FIW 4,6,8

Nominal conductor diameter	Conductor tolerance	Minimum overall diameter mm			Maximum overall diameter mm
mm	1mm	Grade of FIW 4	Grade of FIW 6	Grade of FIW 8	Grade of FIW 4	Grade of FIW 6	Grade of FIW 8
0.040 0,045 0.050 0,056 0,063 0,071 0,080 060.0	0.003 0,003 0.003	690.0 0,067 0.073 0,082 0600 0,098 0,109 0.121	0800 0600 S600 0,105 0.116 0,124 0,137 0.149	0,100 0,112 0,117 0.129 0,142 0,150 0,165 0,177	690’0 0.078 C8o.0 0,092 0,102 0,110 0,122 0,134	0,089 0,100 0,105 0,116 0.128 0,136 0,150 0.162	0,109 0,122 0,127 0,140 0,154 0,162 0,178 0.190
1,000 1.120 1,250 1,400 1,600	0,010 0,011 0,013 0,014 0,016	1.125 1,249 1,382 1,536 1,741	1,227		1,175 1,309 1,442 1,596 1,801	1,277

 

2. Electrical Resistance

Nominal conductor diameter mm	Resistance 0/m
	Minimum	Maximum
0,040 0,045 0,050 0,056 0.063	12,280 9,705 7,922 6,316 5,045	14,920 11,790 9,489 7,565 5,922
NOTE 1 The limit values shown in Table 3 are derived from calculations madeaccording to IEC 60317-0-1:2013, Annex B.NOTE 2 For the nominal resistance,see IEC 60317-0-1:2013,Annex C.

 

3. Elongation at Break

Nominal conductor diameter mm	Minimum elongation at break %
0,040 0,045 0900 0.056 0.063 0.071 0900 0600	9 9 10 10 12 13 14 15
1,000 1.120 1,250 1,400 1,600	30 30 31 32 32

 

4. Springiness

 

Springiness for grades FIW 3,5.7,9

Nominal conductor diameter mm	Mandrel diameter mm	Tension N	Maximum springback
			Grade of FIW 3	Grade of FIW 5	Grade of FIW 7	Grade of FIW 9
080.0 0600 0,100	5.0	0.25	100 94 90	N/A N/A N/A	N/A N/A N/A	N/A N/A N/A
0,112 0.125 0.140	7.0	0.50	88 84 79	N/A N/A N/A	N/A N/A N/A	N/A N/A N/A
0,160 0.180 0,200	10.0	1.00	7 75 72	N/A N/A N/A	N/A N/A N/A	N/A N/A N/A
0,224 0,250 0,280	12.5	002	68 65 61	N/A N/A N/A	N/A N/A N/A	N/A N/A N/A
0,315 0,355 0,400	19.0	4.00	62 59 55	N/A N/A V/N	N/A N/A N/A	N/A N/A
0,450 0,500 099.0	25.0	8.00	53 51 48	N/A 73 68	N/A 06 88
0,630 012.0 008.0	37.5	12.00	53 50 46	75 71 65	N/A N/A
0060 1,000 1.120 1,250 1,400 009.7	50.0	15.00	51 47 43 39 36 32	96 90 84 78 72 65

 Springiness for grades FIW 4,6,8

Nominal conductor diameter mm	Mandrel diameter mm	Tension N	Maximum springback
			Grade of FIW 4	Grade of FIW 6	Grade of FIW 8
090’0 0600	5.0	0.25	N/A N/A	N/A N/A	N/A N/A
1,000 1.120 1,250 1,400 1,600	0.09	15.00	65 60 54 50 45	N/A

 

5. Mandrel winding test

Mandrel diameters for mandrel winding test for grade FIW 3,5,7 and 9

Nominal conductor diameter mm		Grade of FIW 3		0%elongation before winding
				Grade of FIW 5	Grade of	Grade of FIW 9
Over	Up to and Including	Elongation before winding %	Mandrel diameter mm	Mandrel diameter mm	Mandrel diameter mm	Mandrel diameter mm
090.0 C90.0 0800 0600 0,140 0,200 0,355 0,450 0,710 006 0 1,000	0,050 0.063 0,080 060 0 0,140 0,200 0,355 0,450 0,710 0,900 0000 1,600	20 15* 10 5 0 0 0 0 0 0 0 0	0,150 0.150 0,150 0,150 0,150 8 8 8 8 8 8	0020 0020 0,200 000.0 0,300 1-■ 1- 1x■ 3x 3x 3x■ 3x■	0,200 0,200 0,200 000.0 0,300 2- 2- 2x■ 4x■	– 0,200 000.0 000.0 3x 3x
Or to the breaking point of the copper conductor,whichever is less. · df is thenominal diameter of the wire.

Mandrel diameters for mandrel winding test for grade FIW 4, 6 and 8, nominal conductor diameters up to and including 0,090 mm and over 0,900 mm

Nominal conductor diameter		Grade of FIW 4		0%elongation before winding
mm				Grade of FIW 6	Grade of FIW 8
Over	Up to and including	Elongation before winding %	Mandrel diameter mm	Mandrel diameter mm	Mandrel diameter mm
0,050 C900 0.080	0.050 0.063 080.0 060 0	10 10 S 0	0,200 0,200 0.200 0,300	0,200 0.200 0,200 0000	0,200 0.200 0.200 0,300
0060 1,000	1,000 1,600	0 0	2x■ 8-2	4x –	–
Or to the breaking point of the copper conductor,whichever is less. d is the nominal diameter of the wire.

 

6. Heat shock

Heat shock for grades FIW 3, 5, 7 and 9

Nominal conductor diameter mm	Mandrel diameter mm
	Overall diameter range
	Grade of FIW 3	Grade of FIW 5	Grade of	Grade of FIW 9
0,160 0,180 0,200 0,224 0,250	0,250 0,280 0.315 0,355 0,400	0,450 0.450 0,450 0690 0,630	0,560 0,560 0990 0080 0,800	0,560 0.560 0.560 0001 0001
0.280 0,315 0,355 0,400 0,450 009.0	0090 0,710 0,800 0060 000.1 1.120	0090 1,000 1,000 1,000 1.120 1.120	0080 1,250 1,250 1,250 0002 0000	1,000 1.600 0091
0,560 0,630 0,710 0,800 0060	1,250 1,400 0091 1,800 0002	1,400 2,000 000.0 3,550 5,000	0002 2,800 2,800
1,000 1.120 1,250 1,400 1,600	2,240 3,550 4,000 4,500 5,000	0000 0009 5,000 5,600 6,300

Heat shock for grades FIW 4, 6 and 8

Nominal conductor diameter mm	Mandrel diameter mm
	Overall diameter range
	Grade of FIW 4	Grade of FIW 6	Grade of FIW 8
0001 1,120 1,250 1,400 1,600	4,000 0009 0000 4,500 5,000	0009 0009

 

7. Breakdown voltage

Nominal conductor diameter mm		Minimum specific breakdown voltage Vium
Over	Up to and Including	Room temperature	Elevated temperature
–	0.100	81
006.0	0091	47	33
NOTE The specific breakdown voltage is the result of the quotient of the measuredbreakdown voltage and enamel increase.

 

Application Areas

Fully insulated (FIW) defect-free enameled round copper wire that meets the IEC 60317-0-7 standard is widely used in various types of electrical and electronic equipment, such as:

1. Transformers: used for high-efficiency, low-loss power transformer windings.
2. Motors: used in various motors to improve insulation performance and durability.
3. Reactors: used for reactor windings in industrial and power systems to ensure high reliability.
4. Electronic equipment: used in high-demand electronic components and circuits, such as sensors, relays, etc.

IEC 60317-0-7:2020 standard provides detailed technical specifications for the manufacture and performance of fully insulated (FIW) defect-free enameled round copper wire. By complying with these strict standards, manufacturers can produce high-quality, high-reliability enameled wires to meet the needs of various types of electrical and electronic equipment. This not only improves the market competitiveness of the product, but also ensures the safety and satisfaction of the end user. In the electrical and electronic fields, fully insulated enameled wires that comply with IEC 60317-0-7 are undoubtedly a guarantee of performance and reliability.