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Soft-Start Circuit For Power Amps =20
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Elliott Sound Products
Project =
39
Soft-Start Circuit For Power Amps Rod =
Elliott=20
(ESP), Updated 18 April 2006
=20
=20
Please Note: PCBs are available for the latest =
revision of=20
this project. Click the PCB image for details.
WARNING: This circuit =
requires=20
experience with mains wiring. Do not attempt construction unless=20
experienced and capable. Death or serious injury may result from =
incorrect=20
wiring.
Updates ... PCBs are available for a somewhat modified =
version of the=20
soft-start project. Rather than the MOSFET switch, the PCB version uses =
a cheap=20
opamp, and provides power and soft start switching. Full details are =
available=20
when you purchase the PCB, but the schematic and a brief description is =
shown below.=20
The delay time for all circuits shown has been revised. The optimum =
is around=20
100ms - sufficient for around 5 full cycles at 50Hz, or 6 cycles at =
60Hz. It is=20
also quite alright to run the transformer to around 200-500% of full =
load=20
current at start-up, and the formulae have been revised for up to 200%. =
Without=20
the soft-start, inrush current can be so high as to be limited only by =
wiring=20
resistance - well in excess of 50A is not at all uncommon for average =
sized 230V=20
transformers.
Thermistors - Important ! Using thermistors rather than =
resistors is a=20
common question, and while there are many caveats they will generally =
work well.=20
Unfortunately, it can be very difficult for the novice (and =
not-so-novice) to=20
determine the proper value and size, and manufacturers don't help much. =
The=20
specification format from one maker rarely matches that of another, and =
making=20
direct comparisons is rarely easy. Some quote a maximum current, others =
a rating=20
in Joules, and some include almost nothing except the nominal resistance =
at 25=B0C=20
and the dimensions - hardly helpful.=20
Many people like the idea of using NTC (negative temperature =
coefficient)=20
thermistors for inrush limiting, with a common claim being that no =
additional=20
circuitry is needed. In a word, DON'T. This is possibly =
controversial,=20
because they are used by a number of major manufacturers so must be =
alright - or=20
so it might seem. If used in a switched system as described here, they =
are safe=20
enough, but I have personally seen (yes, with my very own eyes) NTC =
thermistors=20
explode mightily if there is a fault. Resistors can also fail, but the =
failure=20
is (usually) contained - there are exceptions of course. In general, NTC =
thermistors are designed for very high peak current, but as noted =
earlier, you=20
will see many different ways to describe the same thing, with almost no=20
commonality between makers.=20
If the relay fails to operate because you didn't listen to me and =
used the=20
amp's supply, the thermistor will (in theory) become a low resistance =
due to the=20
current flow and the fuse will blow. However, if current is too high due =
to a=20
major fault, the thermistor may explode before the fuse has a chance. =
I'm unsure=20
why some people insist that the thermistor is somehow "better" than =
resistors -=20
it isn't, and in some cases may even be a less robust solution. As noted =
below,=20
a resistor (or thermistor) value of about 50 ohms (230V) or 25 ohms =
(120V) is a=20
pretty good overall compromise, and works perfectly with transformers up =
to=20
about 500VA. The resistance should be reduced for higher power =
transformers.=20
If a thermistor is used, it needs to be sized appropriately. While =
some small=20
thermistors may appear quite satisfactory, they will often be incapable =
of=20
handling the maximum peak current. I suggest that you read the article =
on inrush=20
protection circuits for more information. A suitably rated =
thermistor can be=20
used in any version of this project (including the PCB based unit shown =
in=20
Figure 6).=20
Under no circumstances will I ever suggest a thermistor without a =
bypass=20
relay for power amplifiers, because their standby or low power current =
is=20
generally insufficient to get the thermistor hot enough to reduce the =
resistance=20
to a sensible value. You may therefore get power supply voltage =
modulation, with=20
the thermistor constantly thermally cycling.=20
If there is enough continuous current (Class-A amplifier for =
example),=20
the surface temperature of any fully functioning thermistor is typically =
well=20
over 100=B0C, so I consider bypassing mandatory to prevent excess =
unwanted heat. A=20
bypass circuit also means that the thermistor is ready to protect =
against inrush=20
current immediately after power is turned off. Without the bypass, you =
may have=20
to wait 90 seconds or more before it has cooled.
Introduction=20
When your monster (or not so monster) power amplifier is switched on, =
the=20
initial current drawn from the mains is many times that even at full =
power.=20
There are two main reasons for this, as follows ...=20
Transformers will draw a very heavy current at switch on, until =
the=20
magnetic flux has stabilised. The effect is worst when power is =
applied as=20
the AC voltage passes through zero, and is minimised if power is =
applied at=20
the peak of the AC waveform. This is exactly the opposite to what you =
might=20
expect
At power on, the filter capacitors are completely discharged, and =
act as a=20
short circuit for a brief (but possibly destructive) period
These phenomena are well known to manufacturers of very high power =
amps used=20
in PA and industrial applications, but 'soft start' circuits are not =
commonly=20
used in consumer equipment. Anyone who has a large power amp - =
especially one=20
that uses a toroidal transformer - will have noticed a momentary dimming =
of the=20
lights when the amp is powered up. The current drawn is so high that =
other=20
equipment is affected.
This high inrush current (as it is known) is stressful on many =
components in=20
your amp, especially ...
Fuses - these must be slow-blow, or nuisance fuse blowing will be=20
common
Transformer - the massive current stresses the windings =
mechanically and=20
electrically. It is not uncommon to hear a diminishing mechanical =
buzz as the=20
chassis and transformer react to the magnetic stress
Bridge rectifier - this must handle an initial current way beyond =
the=20
normal, because it is forced to charge empty filter capacitors - =
these look=20
like a short circuit until a respectable voltage has been reached
Capacitors - the inrush current is many times the ripple current =
rating of=20
the caps, and stresses the internal electrical connections
It should come as no surprise to learn that a significant number of =
amplifier=20
failures (especially PSU related faults) occur at power on (unless the =
operator=20
does something foolish). This is exactly the same problem that causes =
your=20
lights at home to 'blow' as you turn on the light switch. You rarely see =
a light=20
bulb fail while you are quietly sitting there reading, it almost always =
happens=20
at the moment that power is applied. It is exactly the same with power=20
amplifiers.
The circuit presented here is designed to limit inrush current to a =
safe=20
value, which I have selected as 200% of the full load capacity of the =
power=20
transformer. Please be aware that there are important safety issues with =
this=20
design (as with all such circuits) - neglect these at your peril. Up to =
500% of=20
full power is quite alright, and the decision as to which value to use =
is up to=20
you. The transformer manufacturer may have some specific =
recommendations.
NOTE: Do not attempt this project if you =
are=20
unwilling to experiment - the relay operation must be 100% =
reliable, your=20
mains wiring must be to an excellent standard, and some metalwork =
may be=20
needed. There is nothing trivial about this circuit (or any other =
circuit=20
designed for the same purpose), despite its apparent=20
simplicity.
Description=20
Although the soft start circuit can be added to any sized =
transformer, the=20
winding resistance of 300VA and smaller transformers is generally =
sufficient to=20
prevent a massive surge current. Use of a soft start circuit is =
definitely=20
recommended for 500VA and larger transformers.
As an example, a 500VA transformer is fairly typical of many high =
power=20
domestic systems. Assuming an ideal load (which the rectifier is not, =
but that=20
is another story), the current drawn from the mains at full power is ... =
I =3D VA / V (1) Where VA is the VA =
rating of the=20
transformer, and V is the mains voltage used
Since I live in a 230V supply country I will use this for my =
calculations,=20
but they are easy for anyone to do. Using equation 1, we will get the =
following=20
full power current rating from the mains (neglecting the transformer =
winding=20
resistance) ...
I =3D 500 / 230 =3D 2A (close enough)
At a limit of 200% of full power current, this is 4A AC. The =
resistance is=20
easily calculated using Ohm's law ...
R =3D V / I (2)
so from this will get ...
R =3D 230 / 4 =3D 60 Ohms (close enough)
Not really a standard value, but 3 x 180 Ohm 5W resistors in parallel =
will do=20
just fine, giving a combined resistance of exactly 60 Ohms. A single 56 =
Ohm=20
resistor could be used, but the power rating of over 900W =
(instantaneous) is a=20
little daunting. We don't need anything like that for normal use, but be =
aware=20
that this will be the dissipation under certain fault conditions.
To determine the power rating for the ballast resistor, which is 200% =
of the=20
transformer power rating at full power ...=20
P =3D V=B2 / R (3)
For this resistance, this would seem to indicate that a 930W resistor =
is=20
needed (based on the calculated 60 Ohms), a large and expensive =
component=20
indeed.
In reality, we need no such thing, since the resistor will be in =
circuit for=20
a brief period - typically around 100ms, and the amp will (hopefully) =
not be=20
expected to supply significant output power until stabilised. The =
absolute=20
maximum current will only flow for 1 half-cycle, and diminishes rapidly =
after=20
that.=20
The only thing we need to be careful about is to ensure that the =
ballast=20
resistor is capable of handling the inrush current. During testing, I =
managed to=20
split a ceramic resistor in half because it could not take the current - =
this=20
effect is sometimes referred to as "Chenobyling", after the nuclear =
disaster in=20
the USSR some years ago, and is best avoided.
It is common for large professional power amps to use a 50W resistor, =
usually=20
the chassis mounted aluminium bodied types, but these are expensive and =
not easy=20
for most constructors to get. For the above example, 3 x 5W ceramic =
resistors in=20
parallel (each resistor being between 150 and 180 Ohms) will give us =
what we=20
want, and is comparatively cheap.
For US (and readers in other 120V countries), the resistance works =
out to be=20
12 Ohms, so 3 x 33 Ohm 5W resistors should work fine (this gives 11 Ohms =
- close=20
enough for this type of circuit).
It has been claimed that the resistance should normally be between 10 =
and 50=20
ohms, and that higher values should not be used. I shall leave this to =
the=20
reader to decide, since there are (IMO) good arguments for both ideas. =
As=20
always, this is a compromise situation, and different situations call =
for=20
different approaches.
A 10 ohm resistor is the absolute minimum I would use, and the =
resistor needs=20
to be selected with care. The surge current is likely to demolish lesser =
resistors, especially with a 230V supply. While it is true that as =
resistance is=20
reduced, the resistance wire is thicker and more tolerant of overload, =
worst=20
case instantaneous current with 10 ohms is 23A at 230V. This is an =
instantaneous=20
dissipation of 5,290W (ignoring other resistances in the circuit), and =
it will=20
require an extremely robust resistor to withstand this even for short =
periods.=20
For 120V operation, the peak current will 'only' be 12A, reducing the =
peak=20
dissipation to 1,440W.
In reality, the worst case peak current will never be reached, since =
there is=20
the transformer winding resistance and mains impedance to be taken into =
account.=20
On this basis, a reasonable compromise limiting resistor (and the values =
that I=20
use) will be in the order of 50 Ohms for 230V (3 x 150 ohm/ 5W), or 11 =
Ohms (3=20
x 33 ohm/ 5W) for 120V operation. Resistors are wired in parallel. You =
may=20
decide to use these values rather than calculate the value from the =
equations=20
above, and it will be found that this will work very well in nearly all =
cases,=20
and will still allow the fuse to blow in case of a fault. These values =
are=20
suitable for transformers up to 500VA.
This is in contrast to the use of higher values, where the fuse will =
(in all=20
probability) not blow until the relay closes. Although the time period =
is short,=20
the resistors will get very hot, very quickly. Thermistors may be =
helpful,=20
because as they get hot their resistance falls, and if suitably rated =
they will=20
simply fall to a low enough resistance to cause the fuse to blow.
Another good reason to use a lower value is that some amplifiers have =
a=20
turn-on behaviour that may cause a relatively heavy current to be drawn =
for a=20
brief period. These amplifiers may not reach a stable operating point =
with a=20
high value resistance in series, and may therefore cause a heavy speaker =
current=20
to flow until full voltage is applied. This is a potentially disastrous=20
situation, and must be avoided at all costs. If your amplifier exhibits =
this=20
behaviour, then the lower value limiting resistors must be =
used.
If flaky mains are a 'feature' where you live, then I would suggest =
that you=20
may need to set up a system where the amplifier is switched off if the =
mains=20
fails for more than a few cycles at a time. The AC supply to a toroidal=20
transformer only has to 'go missing' for a few cycles to cause a =
substantial=20
inrush current, so care is needed.=20
If a thermistor is used, I suggest a robust version, rated for a=20
comparatively high maximum current. 20mm diameter devices are generally =
rated=20
for much higher currents than you are likely to need, so will suffer =
minimal=20
thermal cycling. A nice round value is 10 ohms at 25=B0C - this does =
mean higher=20
peak currents than I suggest above, but you can always use two in series =
-=20
especially for 230V operation.
Bypass Circuit=20
Many of the large professional amps use a TRIAC (bi-lateral silicon=20
controlled rectifier), but I intend to use a relay for a number of very =
good=20
reasons ...
Relays are virtually indestructible
They are easy to obtain almost anywhere
Useful isolation is provided so control circuitry is not at mains=20
potential
No RF noise or harmonics of the mains frequency are generated. =
These are=20
low level, but can be very troublesome to eliminate from TRIAC =
circuits
No heatsink is needed, eliminating a potential safety hazard =
should there=20
be an insulation breakdown between triac and heatsink
They will also cause their share of problems, but these are addressed =
in this=20
project. The worst is providing a suitable coil voltage, allowing =
commonly=20
available devices to be used in power amps of all sizes and supply =
voltages.
Figure 1 - Soft-Start Resistors and Relay=20
Contacts
Figure 1 shows how the resistors are connected in series with the =
supply to=20
the transformer, with the relay contacts short circuiting the resistors =
when the=20
relay is activated. This circuitry is all at the mains voltage, and must =
be=20
treated with great respect.
A represents the Active (Live or Hot) lead from the mains switch, and =
SA is=20
the 'soft' Active, and connects to the main power transformer. Do not =
disconnect=20
or bypass any existing wiring, simply place the resistor pack in series =
with the=20
existing transformer.
Do not attempt any wiring unless the mains lead is disconnected, and =
all=20
connections must be made so that accidental contact to finger or chassis =
is not=20
possible under any circumstance. The resistors may be mounted using an =
aluminium=20
bracket that shrouds the connections preventing contact. All leads =
should be=20
kept a safe distance from the chassis and shroud - where this seems =
impossible,=20
use insulation to prevent any possibility of contact. Construction notes =
are=20
shown later in this project. The safety aspect of this project cannot be =
stressed highly enough !
The relay contacts must be rated for the full mains voltage, and at =
least the=20
full power current of the amplifier. The use of a relay with 10A contact =
rating=20
is strongly recommended.
HINT: You can also add a second relay to mute the input =
until=20
full power is applied. I shall leave it to you to make the necessary=20
adjustments. You will have to add the current for the two relays =
together, or=20
use separate supply feeds if utilising the existing internal power =
supply=20
voltage.
Control Circuits=20
If a 12V supply were to be available in all power amps, this would be =
very=20
simple, but unfortunately this is rarely the case. Most amps will have =
DC=20
supplies ranging from +/-25V to about +/-70V, and any attempt to obtain =
relays=20
for these voltages will be met with failure in the majority of cases.=20
An auxiliary supply can be added, but this means the addition of a =
second=20
transformer, which will be quite impossible due to space limitations in =
some=20
cases. It is still a viable option (and is the safest way to go), and a =
control=20
circuit using this approach is shown in Figure 2. This is the simplest =
to=20
implement, but the added cost of the second transformer may be hard to =
justify.=20
It is pretty much mandatory for Class-A amps though (See Class-A=20
Amplifiers).=20
This uses simple bridge rectifier, and a small but adequate =
capacitor. The=20
control circuit uses readily available and low cost components, and can =
easily=20
be built on Veroboard or similar. All diodes can be 1N4004 or =
equivalent. Use a=20
transformer with a 9V AC secondary, which will supply close enough to 12 =
Volts=20
for this circuit. No regulation is needed, and the controller is a =
simple timer,=20
activating the relay after about 100ms. I have chosen a MOSFET for the =
switch,=20
since it has a defined turn-on voltage, and requires virtually no gate =
current.=20
With the component values shown, the relay will activate in about 100=20
milli-seconds. This can be increased (or decreased) by increasing =
(decreasing)=20
the value of R1 (27k). The transformer need only be a small one, since =
current=20
is less than 100mA.
Q1 is used to ensure that power is applied to the relay quickly. When =
a=20
voltage of 0.65V is sensed across the relay, Q1 turns on, and instantly=20
completes the charging of C2. Without the "snap action", the circuit =
will be=20
sluggish, and is not suited to some of the other variations below. Feel =
free to=20
use a 2N7000 or similar low power MOSFET if you can get them easily. =
These use=20
the TO92 package so are the same size as the small signal =
transistor.
NOTE: C1 should be rated at a minimum of =
50V to=20
ensure that the ripple current rating is sufficient to prevent capacitor =
heating. Be warned that if the cap gets warm (or hot), then its =
reliability and=20
longevity will be compromised.
It is possible to make the relay release much faster, but at the =
expense of=20
circuit complexity. A simple logic system could ensure that the circuit =
was=20
reset with a single AC cycle dropout, but this would be too fast for =
normal use,=20
and quite unnecessary. C1 (marked with a *) will have to be selected =
based on=20
the relay. If the value is too small, the relay will chatter or at least =
buzz,=20
and will probably overheat as well, due to eddy currents in the solid =
core used=20
in DC relays. The capacitor should be selected based on the value that =
makes the=20
relay quiet, but still releases quickly enough to prevent high inrush =
current if=20
there is a momentary interruption to the mains supply. The value shown =
(470uF)=20
will generally be suitable for most applications.
You might want to consider using a mains switch with an additional =
set of=20
contacts, so that the second set will short circuit the 12V supply when =
power is=20
turned off. Make sure that the switch has appropriate ratings, and be =
sure to=20
mark and insulate all connections. This is not really necessary though, =
and for=20
a DIY project I'd have to say that it's not recommended because of the =
risk.
Where it is not possible to use the transformer for any reason, then the =
circuit=20
in Figure 3 can be used. This uses a resistor to drop the supply voltage =
for the=20
relay, and has a simple zener diode regulator to supply the control =
circuit. The=20
method of determining the resistor values and power for Rx and Ry is =
shown=20
below.
Figure 3 - Control Circuit Using Existing=20
Supply
WARNING: In the event of an amplifier fault at=20
power-on, the fuse may not blow immediately with this circuit installed, =
since=20
there may be no power to operate the relay. The current is limited to =
200% of=20
that at normal full power, so the fuse may be safe for long enough for =
it to=20
destroy the resistor(s)! The ballast resistors will overheat very =
quickly, and=20
if you are lucky they will fail. If you don't like this idea - =
USE THE=20
AUXILIARY TRANSFORMER.=20
I very strongly suggest the auxiliary transformer =
- it is=20
MUCH safer!
The first calculation is based on the supply voltage, and determines =
the=20
current available to the zener. This should be about 20mA (it is not too =
critical). Since the zener is 12V, use the following formula to obtain =
the value=20
for Rx ...
R =3D (Vcc - 12) / I (4) Where Vcc is the =
voltage=20
of the main positive supply rail, I is current
Example. The Vcc (the +ve supply rail) is 50V, so ...
R =3D (50 - 12) / 0.02 =3D 1900 Ohms (1.8k is quite=20
acceptable)
A 2W resistor (or two 3k6 1W resistors in parallel) is indicated to =
allow a=20
safety margin. Where possible, I always recommend that a resistor be at =
least=20
double the expected power dissipation, to ensure long life and cooler =
operation.=20
It may be necessary to select different resistor values to obtain =
standard=20
values - not all calculations will work out as neatly as this. Remember =
that the=20
20mA is only approximate, and anything from 15 to 25mA is quite =
acceptable.=20
The relay coil limiting resistor (Ry) is worked out in a similar =
manner, but=20
first you have to know the resistance of the relay coil. This may be =
obtained=20
from specifications, or measured with a multimeter. I have details of a =
suitable=20
relay that has a 12V DC coil, and has a claimed resistance of 285 Ohms. =
Coil=20
current is therefore ...
I =3D Vc / Rc (6) Where Vc is coil =
voltage=20
and Rc is coil resistance I =3D 12 / 285 =3D 0.042A =
(42mA)
Using the same supply as before, formula 4 is used to determine the=20
'build-out' resistance ...
R =3D (50 - 12) / 0.042 =3D 904 Ohms. 1k Ohms will be =
fine here=20
(less than 10% variation)
Power is determined using equation 5 as before ...
If the coil current is calculated with the resistor in place, it is =
found=20
that it is 39mA - this is a variation of about 7%, and is well within =
the=20
tolerance of a relay. A 5W resistor is indicated, as this has a more =
than=20
generous safety margin. These resistors will be very much cheaper than a =
transformer, and require less space. Wasted power is not great, and is =
probably=20
less than that lost in a transformer due to internal losses (small =
transformers=20
are not very efficient).=20
With relays, it is often beneficial to use a power saver circuit, =
where an=20
initial high current pulse is used to pull the relay in, and a lower =
holding=20
current is then used to keep it energised. This is very common in relay=20
circuits, and can provide a saving of about 50%. The basic scheme is =
shown in=20
Figure 4 with some typical values for the relay as mentioned in the =
text. I have=20
based my assumptions on the relay I have - I tested this part =
thoroughly, since=20
it is very difficult to make calculations based on an electro-mechanical =
device=20
such as a relay - there are too many variables. If you want to use this =
method,=20
then I suggest that some experimentation is in order. Typically, the =
relay=20
holding current will be between 20% and 50% of the pull-in current - =
generally=20
at the lower end of the scale.=20
Figure 4 - Power Saving Relay =
Circuit
The values shown are those estimated for the 12V 285 Ohm relay - =
yours will=20
be different! Do not mess about with this method if you are unsure =
of what=20
you are doing. Failure of the relay to operate will cause the ballast =
resistors=20
to overheat, with possibly catastrophic results (See below). This method =
can=20
also be used with Class-A amps, as it is possible to make sure that the =
relay=20
activates even on the lower voltage present while the ballast resistors =
are in=20
circuit. (Although I strongly suggest the separate power supply circuit =
for=20
Class-A, see Class-A=20
Amplifiers, below.)=20
Notice that the power savings are across the board. The relay feed =
resistor=20
now will dissipate 0.8W instead of 1.4W, and the auxiliary limiting =
resistor can=20
be a 0.5W type - instantaneous dissipation is only 0.7W, and that is for =
a very=20
short time. The feed resistor is now 2k2 instead of 1k, but an extra =
capacitor=20
and resistor are the price you pay. The capacitor can be used in the =
circuit of=20
Figure 3 too, and will force a large current at turn on. This will not =
save any=20
power, but will most certainly ensure that the relay pulls in reliably.=20
A Few Test Results The relay I used for testing is a 24V =
type -=20
this in itself is of little consequence, since it can easily be =
re-calculated or=20
re-measured for a 12V unit. A coil resistance of 750 Ohms means that at =
nominal=20
supply voltage the relay draws 32mA. I measured the pull-in current at =
23.5mA=20
(typically about 65% of the nominal rating), and drop-out current was =
7.5mA, or=20
about 25% of rated current.
Using the 12V relay mentioned above, this would translate to =
(approximately -=20
these are educated guesses)=20
Nominal current - 42mA
Pull-in Current - 28mA
Drop-out Current - 10mA
Most (all?) relays will hold in perfectly well at 1/2 rated current, =
and I=20
would suggest that this is as low as you should go for reliability. If =
you don't=20
feel like including it, the resistor in series with the electro can be =
omitted.=20
Sure this will pulse a 12V relay with 50V, but it won't care. Personally =
I=20
suggest that a series limiter be used, calculated to provide an =
instantaneous=20
current of 150% of the relay's nominal rating - this will protect the =
cap from=20
excessive current. For a 12V unit (as above), this would mean a maximum =
current=20
of 60mA and a holding current of 20mA.
Because of the vast number of variables, I shall leave this to your=20
experimentation - Please do not ask me to calculate the values for you, =
because=20
I won't. It is entirely the reader's responsibility to determine the =
suitability=20
of this (or any other) project to their individual needs. If in any =
doubt, use=20
the auxiliary transformer method.
Construction Notes=20
As described above, electrical safety is paramount with a circuit =
such as=20
this. Figure 5 shows a suggested method of mounting the input ballast =
resistors=20
that ensures that the minimum of 5mm creepage and clearance is =
maintained when=20
the resistors are mounted, and still provides good thermal contact with =
the case=20
and protection from fingers or other objects coming into contact with =
the=20
mains.
Figure 5 - Suggested Resistor =
Mounting
This arrangement may be a little over the top, but feel free to use =
it if you=20
want to. The aluminium bracket clamps the resistors firmly in position, =
and the=20
plate above and below (which needs to be 5mm shorter than the resistor =
bodies)=20
maintain clearance distances. It is imperative that the resistors cannot =
move in=20
the bracket, and a good smear of heatsink compound will ensure thermal=20
conductivity.
The alternative is to obtain one of the bolt-down aluminium bodied =
resistors.=20
This is obviously much simpler than making up a bracket. In case you are =
wondering why all this trouble for resistors that will be in circuit for =
100=20
milliseconds, the reason is safety. The cover will keep fingers away, =
and stops=20
the resistors moving about. It also provides a measure of safety if the =
relay=20
does not operate, since dissipation will be very high. Since the =
resistors will=20
get extremely hot, simply wrapping them in heatshrink tubing will do no =
good at=20
all because it will melt. The idea is to prevent excessive external =
temperatures=20
until the resistors (hopefully) fail and go open circuit. The method =
used with=20
the P39 PCB is simpler again - 3 x 5W resistors are mounted on an =
auxiliary=20
circuit board. I have yet to see or hear of a resistor failure.
The relay wiring is not critical, but make sure that there is a =
minimum of=20
5mm between the mains contacts and any other part of the circuitry. =
Mains rated=20
cable must be used for all power wiring, and any exposed connection must =
be=20
shrouded using heatshrink tubing or similar. Keep as much separation as =
possible=20
between any mains wiring and low voltage or signal wiring.
The connections to the ballast resistors are especially important. =
Since=20
these may get very hot if the relay fails to operate, care must be taken =
that=20
the lead will not become disconnected if the solder melts, and that =
there is=20
sufficient solder to hold everything together and no more. A solder =
droop could=20
cause a short to chassis, placing you or other users at great risk of=20
electrocution. An alternative is to use a screw-down connector, which =
must be=20
capable of withstanding high temperature without the body melting.
Do not use heatshrink tubing as insulation for the incoming power =
leads to=20
the ballast resistors. Fibreglass or silicone rubber tube is available =
from=20
electrical suppliers, and is intended for high temperature =
operation.
Class-A Amplifiers
NOTE: I strongly suggest that the =
auxiliary=20
transformer method is used with a Class-A amp, as this will =
eliminate any=20
possibility of relay malfunction due to supply voltages not being =
high=20
enough with the ballast resistors in =
circuit.
Because of the fact that a Class-A amp runs at full power all the =
time, if=20
using the existing supply you must not go below the 200% suggested =
inrush=20
current limit. In some cases, it will be found that even then there is =
not=20
enough voltage to operate the relay with the input ballast resistors in=20
circuit.
If this is found to be the case, you cannot use this method, or will =
have to=20
settle for an inrush of perhaps 3-5 times the normal full power rating. =
This is=20
still considerably less than that otherwise experienced, and will help =
prolong=20
the life of the supply components, but is less satisfactory. The =
calculations=20
are made in the same way as above, but some testing is needed to ensure =
that the=20
relay operates reliably every time. See note, above.
Special Warning=20
In case you missed this the first time: In the event of an amplifier =
fault at=20
power-on, the fuse may not blow (or at least, may not blow quickly =
enough to=20
prevent damage) with this circuit installed, since there may be no power =
to=20
operate the relay. If you don't like this idea - USE THE =
AUXILIARY=20
TRANSFORMER. The fuse might only blow after the relay closes, =
but at=20
least it will blow. 100ms is not too long to wait. =20
This circuit by its very nature is designed to limit the maximum =
current at=20
power on. If there is no power to operate the relay, the ballast =
resistors will=20
absorb the full mains voltage, so for my example above will dissipate =
over 900W!=20
The resistors will fail, but how long will they last? The answer to this =
is a=20
complete unknown (but "not long" is a good guess). Thermistors may or =
may not=20
survive.
The reliability of the relay circuit is paramount. If it fails, the =
ballast=20
resistor dissipation will be very high indeed, and will lead to it =
overheating=20
and possibly causing damage. The worst thing that can happen is that the =
solder=20
joints to the resistors will melt, allowing the mains lead to become=20
disconnected and short to the chassis. Alternatively, the solder may =
droop, and=20
cause a short circuit. If you are lucky, the ballast resistors will fail =
before=20
a full scale meltdown occurs.
Make sure that the mains connections to the resistors are made as =
described=20
above (Constructio=
n=20
Notes) to avoid any of the very dangerous possibilities. You may =
need to=20
consult the local regulations in your country for wiring safety to =
ensure that=20
all legalities are accounted for. If you build a circuit that fails and =
kills=20
someone, guess who is liable? You!
It is possible to use a thermal switch mounted to the resistor =
cover=20
to disconnect power if the temperature exceeds a set limit. These =
devices=20
are available as spare parts for various household appliances, or =
you may=20
be able to get them from your normal supplier. Although this may =
appear to=20
be a desirable option, it is probable that the resistors will fail =
before=20
the thermal switch can operate.=20
WARNING: The small metal bullet shaped=20
non-resetting thermal fuses have a live case (it is connected to =
one of=20
the input leads). Use this type with great caution !! Also, be =
aware that=20
you cannot solder these devices. If you do, the heat from =
soldering will=20
melt the wax inside the thermal fuse and it will be open circuit.=20
Connections should use crimped or screw =
terminals.
PCB Version=20
The circuit diagram for the PCB version of this project is shown =
below. It=20
uses a small transformer, and mains switching is only required for the =
small=20
transformer, and the circuit takes care of the rest. The relays have a =
standard=20
footprint, and should be available (almost) everywhere.
Figure 6 - PCB Version of Soft Start/ Mains=20
Switch
A 9V transformer is needed, having a rating of around 5VA. The DC =
output is=20
close to 12V, and will activate the relays reliably. The circuit has a=20
reasonably fast drop-out and stable and very predictable timing (approx =
100ms).=20
The PCB has space for 3 x 5W resistors (or a suitable thermistor), and =
the=20
circuit has been used on 500VA transformers with great success. The =
other=20
comments above still apply (of course), but this circuit simplified the=20
construction process considerably.=20
Feel free to use a thermistor instead of the resistors, but =
only if=20
the thermistor is rated for high enough peak current. If you use a 25 =
ohm=20
thermistor with 230V mains, assume worst case instantaneous peak current =
of 13A.=20
With 120V mains, a 10 ohm thermistor will allow a maximum peak of just =
under=20
17A. The thermistor (or resistor) used must be able to handle the peak =
current=20
without failure.
Full details, bill of materials, etc. for the PCB version of P39 are=20
available on the secure server, along with detailed construction guide =
and mains=20
wiring guidelines.
=20
Projects=20
Index Main Index
Copyright Notice. =
This=20
article, including but not limited to all text and diagrams, is =
the=20
intellectual property of Rod Elliott, and is Copyright (c) 1999.=20
Reproduction or re-publication by any means whatsoever, whether=20
electronic, mechanical or electro- mechanical, is strictly =
prohibited=20
under International Copyright laws. The author (Rod Elliott) =
grants the=20
reader the right to use this information for personal use only, =
and=20
further allows that one (1) copy may be made for reference while=20
constructing the project. Commercial use is prohibited without =
express=20
written authorisation from Rod Elliott.
Page Created and Copyright (c) 06 Dec 1999./ =
Updates: 03 Apr=20
- Modified suggested startup current./ 30 Jan 2000 - added warning about =
non-resetting thermal fuse./ 18 Apr 06 - corrected errors and =
inconsistencies./=20
12 Nov 2010 - added extra info about thermistors.