O.W.

Andersen

USER’S MANUAL, FLD10

REACTOR WITH SERIES CONNECTED LAYERS

PROGRAM DESCRIPTION

FLD10 is a subprogram of the general purpose magnetic field program FLD11. It consists basically of
an input and an output routine for this program, but everything can now be installed in only one
directory (folder). Input can be either in metric or English units, but output is only metric.

The reactors can be without or with an iron core, where the core leg is made of up to 20 axially
separated disks.

The program assumes that the winding is made of small, transposed conductors, wound in up to 30
concentric layers. A layer can consist of several segments with varying conductor dimensions. The
program calculates reactance and maximum and average eddy current losses due to axial and radial flux
densities. The losses are referred to the whole reactor, as well as individual layers and segments. Post
processors can be used to calculate forces and a graph of flux densities.

If FLD8 is to be used in the calculations and not FLD11, see page 7. This option was made to
accommodate sheet windings, but losses have a tendency of being too high with gapped iron cores and
this type of winding.

PROGRAM INSTALLATION

FLD10 is transmitted as a zip-file. It is extracted and installed in any directory (folder). The program
can also be installed on a memory stick and run from there.

RUNNING THE DEMO INPUT

Here all the Command Prompt commands and file names will be in capital letters. However, they are
case insensitive, and small letters can also be used.

To run the program with an input file DEMO.INP, enter:

RUN DEMO.INP
 –2–

After a few seconds, a flux plot with 25 flux lines appears on the screen. It has been drawn on a Visual
Basic Form. If the picture appears to be cropped or too small, adjust the file SIZESCR.FIL. At the same
time a bitmap picture file PLOTFILE.BMP has been produced. Close the form and enter command:

PLOT

The flux plot now reappears in a standard Windows program. The tic-marks to the left and at the
bottom show the positions of horizontal and vertical finite element grid lines. The conductors are red.

If it is now desired to print the flux plot, crop the picture file first to remove empty space and save it.
Microsoft Office Picture Manager or Microsoft Paint can be used for that. Rather than printing it
directly, it is recommended to transfer the picture file to Microsoft Word. Here it can easily be resized
and comments added before printing.

Output from FLD10 is stored in file OUTPUT. To display it on the screen, enter:

FILE OUTPUT

Batch command FILE starts the standard Windows program NOTEPAD. It will be used here for
viewing, editing and printing text files. The first time it is invoked, it should be set to Courier New size
9, word wrap, and to no top and bottom extra text when printing. The window should always be
maximized.

To display the finite element grid on the screen, enter:

GRID

After the form is closed, the grid also reappears with the command:

PLOT
 -3-

INPUT

The demo input file can be viewed with the command:

FILE DEMO.INP

What the numbers mean can be found on the input sheet, page 5. For an explanation of what else can be
done with the input file, copy it first to a new file with the command:

COPY DEMO.INP NEW.INP

Introduce headings with the command:

HEADINGS NEW.INP

To see how the file now has been modified, enter:

FILE NEW.INP

The abbreviated headings on the input file also explain the numbers. With a little experience, that
explanation suffices to enter new numbers and to make up new input files.

Old input as similar as possible is first copied to a new input file. Then headings are introduced and the
file changed. Numbers always start in columns 1, 11, 21 and so on. They can be entered with or without
decimal point.

Before the new file can be run, the headings must be removed. Do this first with:

CLEANUP NEW.INP

A file without headings can have headings introduced and be viewed at the same time with:

HEADFILE NEW.INP

Headings can also be removed and the file run at the same time with:

CLEANRUN NEW.INP

New input must be entered very carefully, following explanations on the input sheets and instructions
elsewhere in this manual. Small mistakes like a comma instead of a decimal point or a number starting
in the wrong column are not tolerated. Some mistakes are caught by the program and are explained on
the output. Another way to catch mistakes is by giving a command such as:

CHECK NEW.INP

The input must here be without headings. A picture similar to a flux plot, but without flux lines, will be
displayed on the screen. Mistakes with the geometry can be caught this way.
 -4-

SYMBOLS

The symbols that are used in the input and output routines are listed and explained in file SYMBOLS.

POST PROCESSING

After the main program has been run, the run identification and all the essential calculated and input
information are in file FOR.FIL, and can be retrieved for further processing. This includes all the vector
potentials, current densities and node and contour line coordinates.

Two post processors are supplied with the program. Forces between horizontal and vertical grid lines
are calculated with the command:

FORCES

A graph of flux densities is drawn with command:

GRAPH
USER PROGRAMMING

The input and output routines for FLD10 are completely decoupled from the main program, and can be
changed by the program user. A suitable Fortran 77 compiler must then be available, such as the free
Watcom compiler. The routines are supplied in source code in the files:

INP10.FOR Input routine.

OUT10.FOR Output routine.
REACTORS WITH SERIES CONNECTED LAYERS PROGRAM FLD10 INPUT SHEET

Numerical data are entered with the first digit in columns 1,11,21 etc., as indicated. Decimal point is optional.

IDENTIFICATION (line 1): No commas and max. 80 characters, including blanks

Col. Data Line

INPUT/OUTPUT UNITS (mm=1, inches=2) *1 1
RATED CURRENT 11
FREQUENCY 21
COPPER/ALUMINUM (1 or 2) 31
NUMBER OF WOUND LIMBS (or coils, 3 for three phase) 41 2
FRACTION OF HEIGHT CALCULATED (0.5 or 1, 0.5 is recommended) 51
SCALE, FLUX PLOT (used only for printer or plotter, not on screen) 61
NUMBER OF FLUX LINES 71
Z - LOWER BOUNDARY(often zero, can be negative) *2 1
Z - UPPER BOUNDARY (upper yoke or beyond) 11
RADIUS, OUTER BOUNDARY 21
GAP YOKE - UPPER CORE DISK (zeros from here if air core) 31 3
GAP YOKE - LOWER CORE DISK (zero if half height calculated) 41
YOKE EXTENSION (beyond core disks, usually zero) 51
NUMBER OF CORE DISKS SPECIFIED (max. 20) 1
R-MIN (zero if no center hole) 11
R-MAX 21 4
NUMBER OF CABLES SPECIFIED (max. 4, usually 1) 31
NUMBER OF LAYERS SPECIFIED (max. 30) 41
For each core disk, from the bottom:
Z-MIN 1
Z-MAX 11
For each cable (usually only one):
CABLE NUMBER 1
NUMBER OF STRANDS PER TURN 11
STRAND DIMENSION, RADIALLY *3 21
STRAND DIMENSION, AXIALLY *4 31
For each layer, starting from the inside:
LAYER NUMBER 1
LAST SEGMENT NUMBER (max. 100) 11
INNER RADIUS 21
RADIAL WIDTH 31
For each segment, starting from the inside and from the bottom:
SEGMENT NUMBER 1
CABLE NUMBER 11
Z-MIN 21
Z-MAX 31
NUMBER OF TURNS, TOTAL 41
ACTIVE 51

*1: When the reactor has a sheet winding, UNITS is entered as 8 for input in mm and 9 for input in inches. FLD10 is then
run with “RUN8 INPUT.FIL”.
*2: Instead of having lower and upper boundaries at the yoke positions, it is recommended to have them at twice the yoke
distances from the windings, as a weighted average of conditions around the periphery.
*3: Strands are assumed to have rounded corners, with an area 0.5 mm 2 subtracted if width times depth exceeds 15 mm 2,
otherwise 0.25 mm2 subtracted. If width = depth and  4 mm, round wire is assumed.
*4: For a normal sheet winding with half the window height calculated, half the depth of the sheet.
 -6-

THE COMMAND PROMPT ENVIRONMENT

The Command Prompt window should be maximized and the size adjusted to fill the screen after right
clicking the top title bar. Cursor size small and letter size 12x16 pixels are recommended. If Command
Prompt goes into full screen mode by an application, it can be brought back with Alt-Enter.

Since many PC users are not familiar with Command Prompt, here are some hints and frequently used
commands. The commands are examples and may be modified in obvious manners. Large and small
letters are interchangeable.

Commands given once on startup, perhaps in a STARTUP.BAT file:

SET COPYCMD=/Y Deactivates warning on overwriting existing files.
PATH=C:\SYSTEM;C:\QBASIC Specifies search paths for executable files.
SUBST P: C:\DRIVEP Substitutes drive P for directory (or folder) C:\DRIVEP making P a virtual
drive (or unit).

Other commands:
C: Moves to unit C or another unit.
CD\ Changes to base directory.
MD GRAPHICS Makes directory GRAPHICS.
CD\GRAPHICS Changes directory to GRAPHICS, just below the base directory.
COPY OLD.INP NEW.INP Copies old file OLD.INP to a new file NEW.INP.
COPY /? Explains options available for command COPY.
REN OLD.INP NEW.INP Renames OLD.INP as NEW.INP.
DEL OLD.INP Deletes OLD.INP.
DIR *.INP Lists all files in the directory with extension INP.
DIR *.I?? Lists all files in the directory with three letter extension starting with I.
START NOTEPAD OUTPUT Invokes Windows program NOTEPAD with file OUTPUT.
START PLOTFILE.BMP Starts a standard Windows program to process the bitmap file.
 -7-

CALCULATIONS WITH FLD8

Reactors with sheet (foil) windings can also be analyzed. See instructions on the input sheet. With
gapped iron cores, sheet windings can easily get excessively high losses.

An input file for a sheet winding reactor can be analyzed with:

RUN8 SHEETWDG.INP

Output is studied with:

FILE OUTPUT

It is normal output from FLD8, with some extra reactor information at the end.

Current density distribution in individual turns can be studied with the post processor:

GRAPHC
PROGRAM FLD10 REACTORS WITH SERIES CONNECTED LAYERS

TWO LAYER REACTOR

RATED CURRENT 1078.00 Z-LOWER BOUNDARY 0.0

FREQUENCY 60.00 Z-UPPER BOUNDARY 570.0
COPPER CONDUCTORS RADIUS, OUTER BOUNDARY 750.0
NUMBER OF WOUND LIMBS 3.0 GAP YOKE - UPPER CORE DISK 3.00
FRACTION OF HEIGHT CALCULATED 0.5 GAP YOKE - LOWER CORE DISK 0.00
SCALE, FLUX PLOT 1.000 YOKE EXTENSION 0.0
NO. OF FLUX LINES 25.0 R-MIN, CORE DISKS 0.0
R-MAX, CORE DISKS 263.0

CORE DISK NO. Z-MIN Z-MAX

1 0.0 32.5
2 57.5 122.5
3 147.5 212.5
4 237.5 302.5
5 318.5 383.5
6 391.5 456.5

CABLE NO. NO. OF STRANDS/TURN STRAND DIM. RADIALLY AXIALLY

1 45.0 2.00 5.30

LAYER NO. LAST SEGM. NO. INNER RADIUS RADIAL WIDTH

1 1 293.0 49.0
2 2 362.0 49.0

SEGMENT NO. LAYER NO. CABLE NO. Z-MIN Z-MAX TURNS, TOTAL ACTIVE
1 1 1 0.0 350.0 25.0 25.0
2 2 1 0.0 350.0 25.0 25.0

RADIAL POSITIONS, VERTICAL GRID LINES

1-10 0.0 25.0 50.0 75.0 99.9 124.9 149.9 174.9 199.9 224.9
11-20 249.9 256.4 263.0 269.6 276.1 284.6 293.0 302.8 312.6 322.4
21-30 332.2 342.0 352.0 362.0 371.8 381.6 391.4 401.2 411.0 433.5
31-37 456.0 493.5 531.0 568.5 629.0 689.5 750.0

AXIAL POSITIONS, HORIZONTAL GRID LINES

1-10 0.0 6.0 12.0 18.0 24.0 30.0 37.5 45.0 52.5 60.0
11-20 72.0 84.0 96.0 108.0 120.0 127.5 135.0 142.5 150.0 162.0
21-30 174.0 186.0 198.0 210.0 217.5 225.0 232.5 240.0 252.2 264.4
31-40 276.5 288.7 300.9 305.7 310.5 315.3 320.1 332.6 345.1 357.7
41-50 370.2 382.7 387.5 392.3 405.1 417.9 430.6 443.4 456.2 459.8
51-54 487.3 514.9 542.4 570.0

FOR SEGMENT NO. 1 BETWEEN

R-MIN R-MAX Z-MIN Z-MAX
293.0 342.0 0.0 350.0
BELONGING TO LAYER NO. 1
DC LOSS, KW 2.613
EDDY CURRENT LOSS
KW DUE TO AXIAL FLUX 0.843
KW DUE TO RADIAL FLUX 0.060
KW TOTAL 0.902
PER UNIT, AVERAGE 0.3453
DC + EDDY CURRENT LOSS, KW 3.516
PER UNIT, MAXIMUM 0.9228
OCCURS BETWEEN
R-MIN R-MAX Z-MIN Z-MAX
293.0 302.8 108.0 120.0
FOR SEGMENT NO. 2 BETWEEN
R-MIN R-MAX Z-MIN Z-MAX
362.0 411.0 0.0 350.0
BELONGING TO LAYER NO. 2
DC LOSS, KW 3.181
EDDY CURRENT LOSS
KW DUE TO AXIAL FLUX 0.119
KW DUE TO RADIAL FLUX 0.096
KW TOTAL 0.215
PER UNIT, AVERAGE 0.0676
DC + EDDY CURRENT LOSS, KW 3.396
PER UNIT, MAXIMUM 0.3046
OCCURS BETWEEN
R-MIN R-MAX Z-MIN Z-MAX
362.0 371.8 332.6 350.0

LOSSES IN LAYERS REFER TO THE FULL HEIGHT

FOR LAYER NO. 1

DC LOSS, KW 5.226
EDDY CURRENT LOSS
KW DUE TO AXIAL FLUX 1.686
KW DUE TO RADIAL FLUX 0.119
KW TOTAL 1.805
PER UNIT, AVERAGE 0.3453
DC + EDDY CURRENT LOSS, KW 7.031
PER UNIT, MAXIMUM 0.9228
OCCURS BETWEEN
R-MIN R-MAX Z-MIN Z-MAX
293.0 302.8 108.0 120.0

FOR LAYER NO. 2

DC LOSS, KW 6.362
EDDY CURRENT LOSS
KW DUE TO AXIAL FLUX 0.238
KW DUE TO RADIAL FLUX 0.192
KW TOTAL 0.430
PER UNIT, AVERAGE 0.0676
DC + EDDY CURRENT LOSS, KW 6.792
PER UNIT, MAXIMUM 0.3046
OCCURS BETWEEN
R-MIN R-MAX Z-MIN Z-MAX
362.0 371.8 332.6 350.0

FOR THE WHOLE REACTOR

DC LOSS, KW 34.766
EDDY CURRENT LOSS
KW DUE TO AXIAL FLUX 5.772
KW DUE TO RADIAL FLUX 0.934
KW TOTAL 6.705
PER UNIT, AVERAGE 0.1929
DC + EDDY CURRENT LOSS, KW 41.471
PER UNIT, MAXIMUM 0.9228
OCCURS BETWEEN
R-MIN R-MAX Z-MIN Z-MAX
293.0 302.8 108.0 120.0

REACTIVE KV, RATED CURRENT 6.456

REACTANCE, OHMS PER PHASE 5.9887