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Air Core Versus Iron Core Reactors

The document compares iron-core and air-core reactors that are often used in harmonic filters at medium voltage levels. Iron-core reactors have an iron core that confines the magnetic field, requiring fewer turns than an air-core reactor to achieve the same inductance. However, iron-core reactors are susceptible to saturation. Air-core reactors do not saturate but have higher stray magnetic fields that require shielding. Both reactor types can perform well if their limitations are properly addressed in the filter design.

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269 views

Air Core Versus Iron Core Reactors

The document compares iron-core and air-core reactors that are often used in harmonic filters at medium voltage levels. Iron-core reactors have an iron core that confines the magnetic field, requiring fewer turns than an air-core reactor to achieve the same inductance. However, iron-core reactors are susceptible to saturation. Air-core reactors do not saturate but have higher stray magnetic fields that require shielding. Both reactor types can perform well if their limitations are properly addressed in the filter design.

Uploaded by

BISLA ANO
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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CONTROLLIX CORPORATION CONTROLLIX.

COM
Air Core vs. Iron Core Reactors

Introduction
At the medium voltage level, 2.4kV through 34.5kV, harmonic filters are often
designed, specified, and manufactured with either Iron-core or Air-core reactors.
The preference for one reactor over the other may be from experience,
familiarity, misconception, or some good technical reason. This document should
help in presenting the major differences and benefits that exist between these
two types of reactors.

Background
Figure one shows the physical characteristics of typical Iron-Core and Air-Core
reactors utilized in harmonic filters. Iron core reactors usually consists of a
copper winding wound around an iron core that has an air gap. The number of
winding turns, area of the air gap, and length of the gap, determine the reactors
inductance. Due to the high permeability of iron, the magnetic field is confined to
the core, and the inductance of the reactor is accomplished with a low number of
turns. The iron-core may be put at either line or ground potential. At line potential,
the core would be supported on post insulators and the voltage gradient between
the core and the winding would be minimal. When the iron-core is at ground
potential, the winding-to-core insulation must be rated for the line potential.

The air-core reactor consists of either an aluminum or copper winding wound


around and supported by an aluminum structure. The aluminum structure is
typically floated at line potential with post insulators to minimize insulation
requirements and cost. The air-core reactors inductance is primarily determined
by the number of turns, height, and diameter of the reactor. It is usually large and
consists of many turns as compared to and iron-core reactor with equal

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CONTROLLIX CORPORATION CONTROLLIX.COM

inductance. Since there is no iron, the stray magnetic field is quite high and it
should be accounted for in the early stages of a harmonic filter design.

The type of reactor used typically determines the harmonic filter layout. Figure 2
shows how the type of reactor changes the physical characteristic and design of
the filter. Air core reactors are typically associated with rack mounted capacitor
banks and are mainly placed in substations. Iron-core reactors are usually placed
inside enclosures which may be rated for indoor or outdoor locations.

Filter Performance

Issues
The question often arises over which reactor is superior for harmonic filter
applications. Table 1 should help to answer this question. The table shows that
there are both benefits and draw backs to both types of reactors. The major
issues in regards to harmonic filters is primarily limited to stray magnetic fields,
saturation, harmonic current rating and space requirements.

Stray Magnetic Fields


Air-core reactors have high stray magnetic fields. These fields may interfere with
other power system equipment, produce eddy currents (which may cause
heating) in nearby steel structures, and present a health hazard to people with
pace makers and other medical devices. These problems may be reduced or
eliminated by providing enough clearance around the reactor. Where real-estate
is an issue, 3/8″ aluminum plates may be placed around the reactors (floor,
ceiling, and even sides) to reduce external fields. Eddy currents can also be

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CONTROLLIX CORPORATION CONTROLLIX.COM

reduced by providing isolation (effectively breaking the current paths). In any


case, the solution to stray magnetic fields may increase the cost of the
installation. The reactor manufacturer should be consulted, and informed of
nearby conducting bodies, since they may have an effect on the reactors
inductance.

Saturation
Saturation is problem inherent in Iron-core reactors. The amount of flux, or flux
density, that an iron-core reactor can carry is limited, and is dependent upon its
cross-sectional area. The higher the cross-sectional area, the higher the amount
of flux it can carry. The flux density is directly related to the peak current that the
reactor will carry, which can be as high as the fundamental peak current plus the
sum of the individual peak harmonic currents. This is seldom the case, but would
lead to a very conservative reactor design. Less conservative designs assume a
coincidence factor, which defines the peak current as a percentage of the sum of
the harmonic peak current plus the fundamental peak current. The point to be
made here, is the concern of saturation in iron-core reactors can be eliminated by
proper design of the reactor. In specifying Iron-core reactors, the following points
should be noted:
• The Iron-core reactor should be designed so that it will not saturate when the
harmonic flux and fundamental flux is totally additive (coincidence factor of 1.0).
• Saturation should be defined as the point in which there is a 10% loss of
inductance.
• The harmonic current spectrum should account for voltage regulation,
manufacturing tolerances in both the reactors and the capacitors, and harmonic
load growth.

If the above points are specified, saturation should not be of concern for Iron-
core reactors.

Harmonic Current Rating (RMS)


The harmonic current rating is the vector sum of the harmonic currents, and is a
concern in both Iron-core and Air-core reactors. The current rating determines
the winding conductor cross sectional area and should be specified when
ordering the reactor. The current should account for present and future harmonic
load growth, plus increased fundamental and harmonic currents due to voltage
regulation and manufacturing tolerances in the capacitors and the reactors.
When specifying the reactor, the current spectrum should be specified since
higher order harmonics have increased heating effects.

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CONTROLLIX CORPORATION CONTROLLIX.COM
Space Requirements
Space requirements are usually a concern associated with Air core reactors due
to the stray magnetic field. These fields can be reduced by shielding, but
shielding can add cost to the bottom line. If shielding is necessary, it should be
specified when ordering the reactor since it can have an effect on the reactor
inductance. The following practices are usually followed when Air-core reactors
are utilized:
• No metallic objects forming closed loops (re-bar, ground grid, ceiling joist, etc.)
shall be within one diameter of the reactor. Typically, this would create a 12 foot
x 12 foot area (assuming the reactors are stacked) with the reactor at the center.
If the reactors are not stacked, more floor area would be necessary.
• Aluminum and sectionalized gasketed steel enclosures can have clearances
down to 1/2 diameter between enclosure walls and the reactor.
• If re-bar directly below the reactor is of concern (or other metal forming loops),
pedestals may be used to raise the reactors away from the floor, ceiling or
ground. If the reactors can not be raised due to height limitations, a 12 foot x 12
foot x 3/8″ thick aluminum plate can be placed directly under the reactor for
shielding.
• If health effects are of concern, the reactor manufacture should be consulted to
determine the distance requirements to meet safe magnetic field levels. As a
general rule, the magnetic field 1/2 diameter from the reactor will be
approximately 30 Gauss. A thin wall enclosure will supply no shielding effect. To
get lower fields, more space can be provided, or a 3/8″ Aluminum curtain (shield)
around the reactor could be used. If personnel can come in contact with the
aluminum curtain, a double wall enclosure may be be required due to excessive
temperature of the Aluminum and the danger of burns.

Conclusion
Both Iron-core and Air-core reactors have benefits and disadvantages, but when
properly designed, specified and applied, their performance is equivalent.

1Information provided compliments of Transformer Engineering Corporation,


Cleveland, Ohio.

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