This is only a preview of the March 2024 issue of Practical Electronics. You can view 0 of the 72 pages in the full issue. Articles in this series:
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Active Mains
Soft Starter
Part T wo by John Clarke
Our Active Mains Soft Starter, introduced last month, is ideal for eliminating
the switch-on kick from power tools rated up to 750W. You can also use it
to avoid high inrush currents for stationary equipment that can trip circuit
breakers or wear out switches. This article covers the assembly, testing,
adjustment and calibration of this new Soft Starter.
T
he Active Mains Soft Starter
uses a combination of an NTC
thermistor and a MOSFET to provide an adjustable soft-starting period.
Using a MOSFET means the thermistor
experiences little heating, so repeated
starts (within reason) do not degrade the
effectiveness of the Soft Starter.
Both the MOSFET and the thermistor are bypassed by a relay after
soft starting so that there is very little
power loss or heating within the Soft
Starter, even with a high load current
draw. It is housed in a conveniently
compact 17.1 × 12.1 × 5.5cm plastic
enclosure with an IEC mains input
socket, GPO/mains output and three
(optional) neon indicators to show
what it is doing.
Because it monitors the load current,
it is automatically activated whenever the load appliance is switched
on, even if the Soft Starter is already
powered. That means you can use the
trigger or switch on power tools to activate them. Or, you can simply switch
it on at the wall, which is handy if
you have multiple devices connected
to the output (eg, via a power board).
Having described what it does and
how it works, let’s move on to building it.
Construction
Most of the parts mount on a double-
sided, plated-through PCB coded
10110221 that measures 159 × 109mm
and is avaiable form thr PE PCB
Warning: Mains Voltage
The entire circuit of the Active Soft Starter floats at mains potential and could
be lethal should you make contact with it. Don’t assume that because we use
isolation between different parts of the circuit that some parts are safe to
touch – they are not! The isolation between parts of the circuit is to allow for
the differing voltage potentials in parts of the circuit rather than for safety.
36
Service. Once assembled, it is housed
in a polycarbonate or ABS enclosure
measuring 171 × 121 × 55mm. The
only off-board parts are the IEC mains
input socket, mains output socket and
three neon indicators.
Fig.7 shows the parts layout on the
PCB. Begin by installing the surface-
mounting dual op amp (IC2). You will
need a soldering iron with a fine tip
(or a regular tip and some flux paste),
a magnifier (if you do not have excellent vision) and good lighting.
Solder the IC to its PCB pads by
first placing it with the pin 1 locating
dot to the top left and aligning the IC
leads to the corresponding pads. Then
solder a corner pin and check that it
is still aligned correctly. If it needs
to be realigned, re-melt the soldered
connection and gently nudge the IC
into alignment.
When you’re sure it’s placed correctly, solder all the IC pins. Any solder that runs between and bridges
two pins can be removed with solder
wicking braid (adding extra flux paste
is recommended). Note that pins 6 and
Practical Electronics | March | 2024
Fig.7: assembly is
straightforward,
with most parts
LIVE
mounting on the
PCB, as shown
here. Q1 has no
mounting hole
and is adhered to the PCB
using double-sided adhesive
thermal tape. Because of
supply constraints, we have
designed the board to accept
two different types of current
transformer, with either
two or three pins. Note that
the three
TVSs are
bidirectional,
so their
orientations
are not
critical.
7 are joined on the PCB, so a bridge
between them won’t matter.
Fit the resistors next. Table 1 shows
their colour-code values, but we recommend using a digital multimeter (DMM)
to check each resistor before soldering it
in place. Three resistor types are used;
one is a 1kW 5W wirewound, six are 1W
types, and the remainder are smaller
1/2W resistors. Mount the 5W resistor
with a gap of about 1mm from the PCB
to allow air to circulate.
Diodes D1-D3 and zener diodes
ZD1-ZD3 are next on the list. Ensure
they are oriented correctly and the
types are not mixed up before soldering their leads.
TVS1-TVS3 can also be installed
now. These are bi-directional (AC)
devices, so they can be installed either
way around on the PCB. Make sure
the correct type number for each TVS
is inserted in the specified location.
Mount the remaining ICs, taking
care to get the correct IC in each place
and with the proper orientation. We
used a socket for IC1, although you
could solder it directly to the PCB,
assuming it has already been programmed. IC3 and IC4 both have six
pins, so don’t get them mixed up. On
the PCB, pin 5 of IC4 has only a tiny
pad to provide an increased creepage
distance between pins 4 and 6.
You can fit the capacitors next,
of which there are four types: the
mains X2-rated capacitors, electrolytic capacitors, MKT polyester and
Practical Electronics | March | 2024
a multi-layer ceramic. Note that the
electrolytic capacitors need to be oriented correctly since they are polarised, while the others can be installed
either way around.
Remember that the 100nF capacitors
could be labelled as 104 (10pF × 104),
while the 4.7nF capacitor could be
labelled 472 (47pF × 102) and the 1μF
ceramic capacitor could be labelled as
105 (10pF × 105).
Next, install potentiometer VR1
and thermistor NTC1. Bridge rectifier
BR1 is next; its positive lead is spaced
wider than the remaining leads, so it
will only fit in one way.
MOSFET Q1 can also be fitted now.
Bend its leads by 90° about 5mm from
the package and secure the metal tab
to the PCB using some double-sided
thermal transfer tape before soldering the leads. Because the tracks are
thin near the pads for the MOSFET
leads, build up their exposed copper
tracks on the underside of the PCB
with solder.
Install CON1 to CON4 next, as
well as the current transformer (T1).
Depending on which type of transformer you have, it might have two or
three leads. The PCB will accommodate either type.
The next step is to install relay
RLY1 with its coil terminals toward
CON4. The relay is secured using
15mm-long M3 screws and nuts, with
each screw inserted from the underside of the PCB.
Winding transformer T2
The windings on the toroidal ferrite
core for T2 are made with 0.25mmdiameter enamelled copper wire, as
shown in Fig.8. The primary has 10
turns, while the secondary has 48
turns. Cut a 125mm length for the primary and 1m for the secondary, and
wind on each side-by-side; the winding directions are unimportant. The
windings must be separated by at least
3mm at each end.
Mount the finished transformer on
the PCB with two cable ties that both
secure the toroid and keep the primary
and secondary windings separated, so
make sure they go between the windings. The third cable tie holds down
the toroid in the middle of the secondary winding – see Fig.7 above.
Pass the primary and secondary wires
through the PCB pads and strip off the
Fig.8: wind T2 as shown here,
keeping the windings neat and close
together and ensuring at least 3mm of
separation between the primary and
secondary at either end.
37
Table 1: Resistor Colour Codes
Fig.9: these are the required cut-outs in
the side of the case and the lid. You can
download this diagram as a PDF from
the March 2024 page of the PE website
and print it to use as a template. Be
careful making the IEC cut-out and
neon holes brcause if they are too large,
the parts will fall out. Try to avoid
the GPO* cut-out coming too close to
the separate hole as, if the plastic in
between is thin, it could break.
*UK users will need a UK socket cut-out.
insulation at all four ends to allow the
wires to be soldered. The insulation can
be burnt off with a hot soldering iron,
by holding a blob of hot solder over the
wire ends for a few seconds. Otherwise,
you can scrape the insulation off with a
sharp hobby or craft knife.
Final assembly
The Soft Starter PCB is secured to the
base of the enclosure using 6mm-long
M3 machine screws that screw into
the integral brass inserts. But before
attaching the PCB, the IEC connector
cut-out will need to be made in the side
of the enclosure. You will also need to
drill holes in the lid for the GPO/mains
socket and neon indicators.
Fig.9 is a template for the required
cut-outs. You can photocopy it from
the magazine at 1:1 scale or download
a PDF from the March 2024 page of
38
the PE website and print it out (make
sure to print it at ‘actual size’) – see:
https://bit.ly/pe-downloads
The large cut-outs for the mains
GPO/mains socket and IEC connector can be made by drilling a series of
small holes around the inside perimeter, knocking out the centre piece and
filing the outline to a smooth finish.
If you use Jaycar neon indicators,
the holes must be sized so that they
stay clipped in place when inserted
into the cut-out. So take care with the
hole size; the inside of the hole will
need a slight chamfer to reduce the
panel thickness so that the clips can
spring outward to secure each neon.
The Altronics neon indicators are
secured with a nut threaded onto the
plastic housing instead of clips.
Once the drilling and filing are complete, install the IEC connector. The
PCB can then be placed inside the case,
but don’t secure it just yet.
First, the IEC connector must be
secured using countersunk nylon M3
× 10mm screws, although you can use
metal nuts. You may need to cut away
some of the internal ribs in the case to
allow the nuts to fit as we had to for
the prototype (you can just see this in
the photo overleaf).
The nylon screws are essential
as they avoid the possibility of the
screws becoming live (at mains voltage) should a mains wire inside the
enclosure come adrift and contact a
screw holding the IEC connector.
Before attaching the mains/GPO
socket and neon indicators, you can
print out the front panel label shown
in Fig.10. You can also download it as
a PDF from from the March 2024 page
of the PE website.
Practical Electronics | March | 2024
Fig.10: there are
two different
versions of the
front panel
artwork that you
can download,
either with
the neon holes
marked (as
shown here) or
without, if you’d
prefer not to fit
them.
The download includes two versions of the front panel. One does not
have the three neon indicator holes,
and is included if you prefer not to
use them. The wiring is also simplified when not using neon indicators.
All wiring must be run as shown
in Fig.11, using mains-rated cable. Be
sure to use 10A cable for the thicker
wires shown in Fig.11; brown wire
must be used for the live wiring while
the blue wire is used for neutral.
Green/yellow-striped wire is used for
the earth wiring only, and the earth
lead from the IEC socket must go
straight to the GPO/mains outlet.
The thinner wires shown (without
a red asterisk) can use lighter-duty
7.5A mains wire, or simply 10A wiring throughout if you prefer.
Be sure to insulate all the connections with heatshrink tubing for safety
and cable tie the wires as shown, to
prevent any wire breakages coming
adrift. Use 10mm-diameter heatshrink
around the bodies of the neon indicators, 5mm for the wires to the IEC connector (red or brown for live, blue or
black for neutral, and green for Earth)
and 3mm for the wires to the relay
(similar colour coding).
Note how the relay contact connections are made using 4.8mm spade
crimp lugs while the relay coil wires are
soldered. Try to avoid melting the surrounding relay plastic housing while
doing that, and be sure to insulate the
joints afterwards with heatshrink tubing. The wires to the IEC socket are also
soldered and then insulated.
Practical Electronics | March | 2024
Secure the live and neutral leads
to the GPO/mains outlet using cable
ties that pass through the holes in its
moulding. Also, use neutral-cure silicone (eg, roof and gutter silicone) to
cover the live bus piece that connects
the live pin to the fuse at the rear of the
IEC connector as it is live, and there
is no good reason for it to be exposed.
Take great care when making the
connections to the mains socket (GPO).
In particular, be sure to run the leads
to their correct terminals (the GPO/
mains socket has the L, N and E clearly
labelled) and do the screws up tightly
so that the leads are held securely.
Similarly, ensure that the wires to the
screw terminals are firmly secured.
Testing
Always attach the lid using at least
two screws at diagonal locations before
switching on the power.
Before applying power, check your
wiring carefully and ensure all mains
connections are covered in heatshrink
tubing, and the wiring is cable tied.
Then install the 10A fuse inside the fuse
holder and verify that IC1 is plugged into
its socket and correctly oriented.
The relay
wires are cabletied to other mains wires
after installation in the case.
39
Fig.11: be very careful to run all the wiring as shown here, including using the colours
shown, adding all the required insulation and the cable ties as indicated. All wires can
be run using 10A mains-rated cable, or you can use 7.5A-rated cable for the thinner wires
shown (without the red asterisks) if desired.
LIVE
LIVE
Should you forget to install IC1
before powering up, the 4.7nF capacitor at the pin 4 connection could be
left with a remnant voltage when you
switch off the power. This can destroy
IC1 when it is plugged in. So if you
power it up without IC1 plugged in,
wait for a few minutes with power off
and check that the voltage between
pins 4 and 8 is less than 1V before
plugging in the IC.
Typically, VR1 would be set to midtravel for a nominal one-second softstart period. If set full anti-clockwise,
VR1 gives a 9.5s soft-start period while
near full-clockwise gives a half-second
soft start period.
40
Calibration
Rotating VR1 fully clockwise has the
Soft Starter enter another mode. This
is used to measure the voltage from the
precision rectifier when no appliance
is connected. This is the offset voltage
that needs to be taken into consideration when detecting whether there is
current flow or not when an appliance
is detected.
Typically, the output of IC2a (the
full-wave rectified current waveform)
will not sit at the negative supply at
pin 4 with no load, but will be slightly
positive. This offset can be measured
and taken into account by IC1. This
setting only needs to be done if the soft
start circuit does not correctly detect
when the appliance is off.
To set this offset, with the power off
and unplugged from the wall, rotate
VR1 fully clockwise. No appliance
should be plugged into the Soft Starter’s mains/GPO outlet. Attach the lid,
power it up and wait a few seconds
before switching it off. This will let it
store the DC voltage produced by IC2
when no current is measured.
Unplug it, remove the lid and rotate
VR1 back from fully clockwise to the
desired soft-start period. As mentioned earlier, somewhere mid-way
will give a suitable soft-start duration of one or two seconds for most
Practical Electronics | March | 2024
www.poscope.com/epe
The completed unit just before the lid is attached. The numerous cable ties
mean that even if a wire breaks off, it can’t make contact and damage other
parts of the circuit or create a shock hazard.
situations. However, other periods are
available depending on your appliance’s requirements.
Choosing the soft-start period
The available periods are 9.5, 5.5, 2.0,
1.0, 0.625 or 0.5 seconds, adjusted
using VR1. You can use the slower
rates for soft-starting capacitive loads
if you are not concerned about how
long it will take to power up the load.
The 9.5s startup period is probably too
long for most cases, but a 5.5s period
is a good option.
The finished
Active Mains
Soft Starter
is easy to
use, just plug
your desired
appliance
into the GPO
on the front
panel and then
connect the
Soft Starter to
mains power
via the IEC
plug on its
side. (UK
constructors
will use a UK
mains outlet.)
Practical Electronics | March | 2024
For power tools, the best period
depends on the time the tool takes to
get up to full speed and the acceptable
amount of movement the tool makes
during starting. A shorter duration will
produce more tool movement than a
longer duration, but will let you get to
work faster. If the period is longer than
necessary, you will need to wait longer
for the tool to be ready to use.
Reproduced by arrangement with
SILICON CHIP magazine 2024.
www.siliconchip.com.au
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