DC shunt field rewind wire size considerations
The purpose of this ar- Table 1: Sample solid round magnet wire data.
By Mike Howell
EASA Technical Support Specialist
When rewinding the shunt fields of
a DC machine, it is important to avoid
making changes that could negatively
impact performance. The recommended
practice is to maintain the manufac-
turer’s winding configuration during
the repair. That is, the field circuit
connection, turns per coil, mean or
average length of turn (MLT) and wire
size should not be changed. However,
service centers do sometimes encounter
issues around wire size availability.
Our goal is to use a re-
placement wire with the
same diameter and there-
fore same cross sectional
area as the original. When
working with round mag-
net wire, it is very likely
that the original size was
manufactured according
to some sizing standard.
However, due to existence
of multiple standards, you
should never use a wire
gauge to determine the
original size. Always mea-
sure with a micrometer
and then determine the
size from the measured
diameter.
January 2014 • EASA CURRENTS
ticle is to provide some
guidance for making BARE WIRE CROSS-SECTIONAL
wire size substitutions DIAMETER WIRE GAUGE* AREA
when the original size Inches mm AWG SWG Metric Cir Mils Square mm
is unavailable.
.0427 1.085 17.5 1820 .924
For guidance in
changing conductor .0417 1.060 1.06 1740 .882
material, see the De- .0403 1.024 18 1620 .823
cember 2011 Currents
article “Aluminum- .0400 1.016 19 1600 .811
to-copper magnet .0394 1.000 1.0 1550 .785
wire winding conver-
sions: Considerations .0380 .965 18.5 1440 .732
for deciding whether .0374 .950 .95 1400 .709
wire area should be
reduced.” .0360 .914 20 1300 .657
.0359 .912 19 1290 .653
Wire size
Our goal is to use
Service centers that usually work
a replacement wire with the same
with AWG sizes may not have access
diameter and therefore same cross
to metric sizes or even some AWG
sectional area as the original. When
half sizes and vice versa. In order to
working with round magnet wire, it
facilitate a timely and cost-effective
is very likely that the original size was
repair for the customer, it is sometimes
manufactured according to some sizing
necessary to make a substitution and it
standard. However, due to existence
is desirable to do this using simple and
of multiple standards, you should
practical calculations. The approach
never use a wire gauge to determine
here will be to essentially wind two
the original size. Always measure with
coils in series per pole using two differ-
a micrometer and then determine the
ent wire sizes such that the finished coil
size from the measured diameter. The
has the same number of total turns and
two most common round magnet wire
same total resistance as the original.
sizing conventions are American Wire
Gage (AWG) and metric. Calculations
The AWG size can be calculated The objective when making this
once the diameter is known. However, change is to maintain the shunt field
the calculation is complex, so it is rec- ampere-turns per pole (see “Importance
ommended to simply cross reference of Wire Size” at the end of the article for
the measured diameter with its cor- more information). We will be consid-
responding size on a reference table ering the cross sectional areas of three
such as EASA’s Solid Round Magnet wire sizes: (a) the area of a size larger
Wire Data chart (see Table 1). than the original, (b) the area of a size
Metric sizes are much easier; the smaller than the original and (c) the area
size is simply the diameter in milli- of the original size. The ratio of area (c)
meters. However, if you measure the to area (b) should not exceed 1.15. The
diameter in inches, you can cross refer- total number of turns must not change.
ence the metric size using EASA’s Solid
Round Magnet Wire Data chart tables as
well. For example, if the diameter is
measured to be 0.0394 inches, you can We want to calculate a number of
see in Table 1 that the original wire is turns Ta of wire area (a) and a number
metric size 1.0 mm.
Continued On Page 2
Copyright ©2014 Electrical Apparatus Services Association, Inc. 1
DC shunt field rewind wire size considerations
Continued From Page 1
of turns Tb of wire area (b) such that
the average cross sectional area over
all the turns is very close to the origi-
nal wire area (c). If change to the coil
length is insignificant, then the coil
resistance will be sufficiently close to
that of the original. The calculations
are as follows:
Although the new coil will have
approximately the same I2R heat loss
as the original, the portion of the coil
with the larger wire area will have a
lower current density than the original
while the portion of the coil with the
smaller wire area will have a higher
current density. Therefore, it is prudent
to check the current density in the por-
tion of the coil with the smaller wire
area. Standard units of current density
are amperes per unit of area (e.g., A/
in2, A/mm2) but it is customary when
working with areas in circular mils to
use area per unit of current or circular
mils per amp (CMA).
When calculating current density,
assume an even current division be-
tween parallel paths. That is, assume
that series connected coils carry rated
field current, series-parallel coils carry
half of rated field current, etc. If the
rated field current (If), the conductor
area (Af) and the number of circuits (cf)
are known, then the current density (J)
in standard units (e.g., A/in2, A/mm2)
is calculated as follows:
If calculating current density in cir-
cular mils per amp, then the calculation
is modified as follows:
It is recommended that EASA’s
Technical Support Department be
consulted if the current density in
2 January 2014 • EASA CURRENTS
the smaller conductor is
less than 500 CMA (or Area of highest
greater than 3.9 A/mm2). temperature
If the current den-
sity in the smaller wire
size is acceptable, the
shunt field is then re-
wound by first winding
Ta turns of wire with
area (a) and then splic-
ing to it the wire with
area (b) and winding
an additional Tb turns.
The larger wire por-
tion should be wound
first to minimize any Figure 1: Shunt field potted to pole iron.
increase in field coil
temperature rise. Additionally, it may
be beneficial to pot the field coil to the 2. Check the current density.
pole piece (see Figure 1) to improve
heat transfer. See the January 2000 Cur-
rents article “Follow These Procedures
To Reduce Problems When Rewinding OR
Field Coils” for guidance with this
process.
Example 1
Since the current density is accept-
A set of four shunt field coils to be
able (greater than 500 CMA or less
rewound each has 700 turns. The wire
than 3.9 A/mm2), proceed with
diameter is measured to be 0.0394
the turn calculations.
inches and cross referenced with Table
1 to identify the wire size to be 1.0 mm. 3. Calculate the new turns.
The service center performing the re-
pair cannot obtain that size. The rated
field current (If) is 2.7 amps and the
fields are connected in series (cf = 1).
1. Choose new
wire sizes. 4. Check the total turns
calculated.
From Table 1, they choose the
closest size above (#18 AWG) and
below (#18.5 AWG) the 1.0 mm Example 2 – special case
that they have. Based on these If the original wire area (c) is very
three sizes, they have close (e.g., within 5%) to the area of one
a = 1620 CM (0.823 mm2) available size (a), it may be practical to
b = 1440 CM (0.732 mm2) rewind the coil with the one size. An
c = 1550 CM (0.785 mm2) example of this would be if the original
c/b = 1550/1440 = 1.08 < 1.15 wire size was #18.5 AWG (1440 CM,
Note: It does not matter which 0.732 mm2) and the service center had
units of area you use for your 0.95 mm (1400 CM, 0.709 mm2) avail-
calculations providing you use the able. This change would eliminate the
same units throughout. need for a splice in the coil and would
Continued On Page 3
Copyright ©2014 Electrical Apparatus Services Association, Inc.
DC shunt field rewind wire size considerations
Continued From Page 2
constitute a change in cross sectional
area of less than 5% as shown below.
In this case, the current density
will be sufficiently close to the origi-
nal and while it is always good to
verify (can identify errors in connec-
tion data, etc.) it is not necessary to
evaluate it for this specific change.
Example 3 – special case
If the original wire area (c) is very
close (e.g. 5%) to the average of new
wire areas (a) and (b), it may be practi-
cal to wind both coils at the same time
(2 in-hand) and connect the finish of
coil (a) to the start of coil (b). Since
the two coils to be connected in series
would be wound simultaneously,
only half as many turns by the wind-
ing machine would be required. In
this case, the ratio of area (c) to area
(b) still should not exceed 1.15. An
example of this would be if the origi-
nal wire size was #18.5 AWG and the
service center had #18 AWG and #19
AWG available. They would have:
a = 1620 CM (0.823 mm2)
b = 1290 CM (0.653 mm2)
c = 1440 CM (0.732 mm2)
c/b = 1440/1290 = 1.12 < 1.15
This change still requires a splice
in the coil, but it would constitute a
change in average cross sectional area
of less than 5% as shown below.
In this case, it would be important
to check the current density in the
smaller conductor as previously dem-
onstrated. The benefit of this method
is two-fold: First, heat dissipation
in the smaller wire is improved by
intermingling the two sizes; second,
winding time is halved.
January 2014 • EASA CURRENTS
Appendix 1: Splicing guidance
Remove the magnet wire insula-
tion before beginning. Some magnet
wire insulation can leave a residue
that inhibits brazing. Braze using a
silver solder (never use soft solder)
and alloys containing 3% silver or just
phos-copper are typically suitable for
this type of braze joint.
Practical tips
1. Secure the wire to be brazed.
2. Tin (deposit) a bit of the brazing
alloy onto the end of wire 1.
3. Slip a 2-3 inch (50-75 mm)
length of snug acrylic sleeving
over wire 2, at least 3 inches (75
mm) from the end.
4. Touch the second wire to the tip
of the first, play the torch over
the joint, and the brazing alloy
on wire 1 should flow to wire 2
when the temperature of both is
correct.
5. Cool the joint quickly with a
damp cotton rag.
6. Inspect visually and by feel to
make sure the joint is smooth
with no burs that could pen-
etrate the insulation.
7. Slide the sleeving up over the
cooled joint.
Appendix 2:
Importance of wire size
The torque produced by a DC mo-
tor is proportional to the product of
the armature current (Ia) and the field
magnetic flux density (B).
T ∝ Ia ⋅ B
So, for instance, if the field mag-
netic flux density was reduced, more
current would be required to flow
through the armature to produce the
same torque. Now, let’s look at how
the shunt field wire size can affect the
field magnetic flux density.
The field magnetic flux density is
proportional (although not directly)
to the field coil ampere-turns (AT).
AT ∝ B
Copyright ©2014 Electrical Apparatus Services Association, Inc.
As the name implies, the field coil
ampere-turns are calculated by multi-
plying the current in field coil by the
number of turns. So, to produce the
same torque without changing the
armature current, the field magnetic
flux density and thus the field coil
ampere-turns must remain constant.
To maintain the same field current
at rated field voltage and a given
temperature, Ohm’s Law applies and
the resistance must be held constant.
V = IR
The resistance of a coil (R) is di-
rectly proportional to the length of the
coil and inversely proportional to the
cross sectional area of the conductor.
L
R∝
A
If the number of turns and general
coil geometry are maintained, there
will not be a significant difference in
length (L). This leaves the conductor
area (A) as the remaining variable.
Increases in the conductor area will
cause a decreased resistance and
therefore an increase in field current
at a given voltage. Increasing the field
ampere-turns will reduce armature
speed requiring a corresponding
increase in armature voltage to re-
turn to rated speed. However, most
modern drives are current-set, so
using a slightly larger wire would
reduce the voltage required to obtain
the current and the net field strength
would be the same. Decreasing the
conductor area will do the opposite
and for a given field current will result
in increased heating of the field coil
as well. n
n n n n n n n
Editor’s Note: A PDF of this article
is available in the “Engineering/
Technical Article Archive” section of
“Members Only” at www.easa.com.
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