Grace,
> One of our hardware design engineers comes up with a question for
> rated voltage for a capacitor.
> 
> Under the second page (Page 19) of the datasheet found at
> http://www.avxcorp.com/docs/Catalogs/safecc.pdf, the rated voltage for
> 61V is different when using as a X1 and when using as an Y1.  The
> question is: for a same capacitor, why is the rated voltage different
> due to its usage (X1 400VAC vs Y1 250VAC)?

The short answer is "safety".  Here is an excerpt from page 8-16 of my
book, Robust Electronic Design Reference Book, Volume 1:

"Capacitors that connect straight to primary power, such as ones used in
AC-line filters, may be subjected to high-voltage spikes and surges, and
thus require a surge-voltage rating.  These capacitors are considered
safety-critical parts by safety agencies, and usually must be certified
to EN 60384-14, EN 132400, UL 1414, and CSA C22.2 No. 1.  An X-capacitor
goes line-to-neutral or line-to-line, and can not cause an electric
shock if it fails.  A Y capacitor goes line-to-ground or
neutral-to-ground, and can cause an electric shock if it fails.  These
capacitors have several subcategories, with surge-test voltages of:
· 4,000V peak for X1 capacitors.
· 2,500V peak for X2 capacitors.
· 8,000V peak for Y1 capacitors.
· 5,000V peak for Y2 capacitors."

John Barnes KS4GL, PE, NCE, NCT, ESDC Eng, ESDC Tech, PSE, SM IEEE
dBi Corporation
http://www.dbicorporation.com/

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