Inrush current

Last updated
An example of inrush current transients during capacitor bank energization Inrush current.gif
An example of inrush current transients during capacitor bank energization

Inrush current, input surge current, or switch-on surge is the maximal instantaneous input current drawn by an electrical device when first turned on. Alternating-current electric motors and transformers may draw several times their normal full-load current when first energized, for a few cycles of the input waveform. Power converters also often have inrush currents much higher than their steady-state currents, due to the charging current of the input capacitance. The selection of over-current-protection devices such as fuses and circuit breakers is made more complicated when high inrush currents must be tolerated. The over-current protection must react quickly to overload or short-circuit faults but must not interrupt the circuit when the (usually harmless) inrush current flows.

Contents

Capacitors

A discharged or partially charged capacitor appears as a short circuit to the source when the source voltage is higher than the potential of the capacitor. A fully discharged capacitor will take approximately 5 RC time periods to fully charge; during the charging period, instantaneous current can exceed steady-state current by a substantial multiple. Instantaneous current declines to steady-state current as the capacitor reaches full charge. In the case of open circuit, the capacitor will be charged to the peak AC voltage (one cannot actually charge a capacitor with AC line power, so this refers to a varying but unidirectional voltage; e.g., the voltage output from a rectifier).

In the case of charging a capacitor from a linear DC voltage, like that from a battery, the capacitor will still appear as a short circuit; it will draw current from the source limited only by the internal resistance of the source and ESR of the capacitor. In this case, charging current will be continuous and decline exponentially to the load current. For open circuit, the capacitor will be charged to the DC voltage.

Safeguarding against the filter capacitor’s charging period’s initial current inrush flow is crucial for the performance of the device. Temporarily introducing a high resistance between the input power and rectifier can increase the resistance of the powerup, leading to reducing the inrush current. Using an inrush current limiter for this purpose helps, as it can provide the initial resistance needed.

Transformers

When a transformer is first energized, a transient current up to 10 to 15 times larger than the rated transformer current can flow for several cycles. Toroidal transformers, using less copper for the same power handling, can have up to 60 times inrush to running current. Worst-case inrush happens when the primary winding is connected at an instant around the zero crossing of the primary voltage (which for a pure inductance would be the current maximum in the AC cycle) and if the polarity of the voltage half-cycle has the same polarity as the remanence in the iron core has (the magnetic remanence was left high from a preceding half cycle). Unless the windings and core are sized to normally never exceed 50% of saturation (and in an efficient transformer they never are, such a construction would be overly heavy and inefficient), then during such a start-up the core will be saturated. This can also be expressed as the remnant magnetism in normal operation is nearly as high as the saturation magnetism at the "knee" of the hysteresis loop. Once the core saturates, however, the winding inductance appears greatly reduced, and only the resistance of the primary-side windings and the impedance of the power line are limiting the current. As saturation occurs for part half-cycles only, harmonic-rich waveforms can be generated and can cause problems to other equipment. For large transformers with low winding resistance and high inductance, these inrush currents can last for several seconds until the transient has died away (decay time proportional to XL/R) and the regular AC equilibrium is established. To avoid magnetic inrush, only for transformers with an air gap in the core, the inductive load needs to be synchronously connected near a supply voltage peak, in contrast with the zero-voltage switching, which is desirable to minimize sharp-edged current transients with resistive loads such as high-power heaters. But for toroidal transformers only a premagnetising procedure before switching on allows to start those transformers without any inrush-current peak.

An example of an inrush current transient during a 100 VA toroid transformer energization. Inrush peak around 50 times of nominal current Rktr-Inrush-100Va.png
An example of an inrush current transient during a 100 VA toroid transformer energization. Inrush peak around 50 times of nominal current

Inrush current can be divided in three categories:

Energization inrush current result of re-energization of transformer. The residual flux in this case can be zero or depending on energization timing.
Recovery inrush current flow when transformer voltage is restored after having been reduced by system disturbance.
Sympathetic inrush current flow when multiple transformer connected in same line and one of them energized.

Motors

When an electric motor, AC or DC, is first energized, the rotor is not moving, and a current equivalent to the stalled current will flow, reducing as the motor picks up speed and develops a back EMF to oppose the supply. AC induction motors behave as transformers with a shorted secondary until the rotor begins to move, while brushed motors present essentially the winding resistance. The duration of the starting transient is less if the mechanical load on the motor is relieved until it has picked up speed.

For high-power motors, the winding configuration may be changed (wye at start and then delta) during start-up to reduce the current drawn.

Heaters and filament lamps

The inrush current of an incandescent lamp causes a bench power supply to limit its output current. Lamp inrush current.png
The inrush current of an incandescent lamp causes a bench power supply to limit its output current.

Metals have a positive temperature coefficient of resistance; they have lower resistance when cold. Any electrical load that contains a substantial component of metallic resistive heating elements, such as an electric kiln or a bank of tungsten-filament incandescent bulbs, will draw a high current until the metallic element reaches operating temperature. For example, wall switches intended to control incandescent lamps will have a "T" rating, indicating that they can safely control circuits with the large inrush currents of incandescent lamps. The inrush may be as much as 14 times the steady-state current and may persist for a few milliseconds for smaller lamps up to several seconds for lamps of 500 watts or more. [1] (Non-graphitized) carbon-filament lamps, rarely used now, have a negative temperature coefficient and draw more current as they warm up; an "inrush" current is not found with these types.

Protection

A resistor in series with the line can be used to limit the current charging input capacitors. However, this approach is not very efficient, especially in high-power devices, since the resistor will have a voltage drop and dissipate some power.

Inrush current can also be reduced by inrush current limiters. Negative-temperature-coefficient (NTC) thermistors are commonly used in switching power supplies, motor drives and audio equipment to prevent damage caused by inrush current. A thermistor is a thermally-sensitive resistor with a resistance that changes significantly and predictably as a result of temperature changes. The resistance of an NTC thermistor decreases as its temperature increases. [2]

As the inrush current limiter self-heats, the current begins to flow through it and warm it. Its resistance begins to drop, and a relatively small current flow charges the input capacitors. After the capacitors in the power supply become charged, the self-heated inrush current limiter offers little resistance in the circuit, with a low voltage drop with respect to the total voltage drop of the circuit. A disadvantage is that immediately after the device is switched off, the NTC resistor is still hot and has a low resistance. It cannot limit the inrush current unless it cools for more than 1 minute to get a higher resistance. Another disadvantage is that the NTC thermistor is not short-circuit-proof.

Another way to avoid the transformer inrush current is a "transformer switching relay". This does not need time for cool down. It can also deal with power-line half-wave voltage dips and is short-circuit-proof. This technique is important for IEC 61000-4-11 tests.

Another option, particularly for high-voltage circuits, is to use a pre-charge circuit. The circuit would support a current-limited precharge mode during the charging of capacitors and then switch to an unlimited mode for normal operation when the voltage on the load is 90% of full charge.

Switch-off spike

When a transformer, electric motor, electromagnet, or other inductive load is switched off, the inductor increases the voltage across the switch or breaker and cause extended arcing. When a transformer is switched off on its primary side, inductive kick produces a voltage spike on the secondary that can damage insulation and connected loads. [3]

See also

Related Research Articles

<span class="mw-page-title-main">Relay</span> Electrically-operated switch

A relay is an electrically operated switch. It consists of a set of input terminals for a single or multiple control signals, and a set of operating contact terminals. The switch may have any number of contacts in multiple contact forms, such as make contacts, break contacts, or combinations thereof.

<span class="mw-page-title-main">Thermistor</span> Type of resistor whose resistance varies with temperature

A thermistor is a semiconductor type of resistor whose resistance is strongly dependent on temperature, more so than in standard resistors. The word thermistor is a portmanteau of thermal and resistor.

<span class="mw-page-title-main">Rectifier</span> Electrical device that converts AC to DC

A rectifier is an electrical device that converts alternating current (AC), which periodically reverses direction, to direct current (DC), which flows in only one direction. The reverse operation is performed by an inverter.

<span class="mw-page-title-main">Electrical resistance and conductance</span> Opposition to the passage of an electric current

The electrical resistance of an object is a measure of its opposition to the flow of electric current. Its reciprocal quantity is electrical conductance, measuring the ease with which an electric current passes. Electrical resistance shares some conceptual parallels with mechanical friction. The SI unit of electrical resistance is the ohm, while electrical conductance is measured in siemens (S).

<span class="mw-page-title-main">Power supply</span> Electronic device that converts or regulates electric energy and supplies it to a load

A power supply is an electrical device that supplies electric power to an electrical load. The main purpose of a power supply is to convert electric current from a source to the correct voltage, current, and frequency to power the load. As a result, power supplies are sometimes referred to as electric power converters. Some power supplies are separate standalone pieces of equipment, while others are built into the load appliances that they power. Examples of the latter include power supplies found in desktop computers and consumer electronics devices. Other functions that power supplies may perform include limiting the current drawn by the load to safe levels, shutting off the current in the event of an electrical fault, power conditioning to prevent electronic noise or voltage surges on the input from reaching the load, power-factor correction, and storing energy so it can continue to power the load in the event of a temporary interruption in the source power.

<span class="mw-page-title-main">Switched-mode power supply</span> Power supply with switching regulator

A switched-mode power supply (SMPS), also called switching-mode power supply, switch-mode power supply, switched power supply, or simply switcher, is an electronic power supply that incorporates a switching regulator to convert electrical power efficiently.

A transducer is a device that converts energy from one form to another. Usually a transducer converts a signal in one form of energy to a signal in another. Transducers are often employed at the boundaries of automation, measurement, and control systems, where electrical signals are converted to and from other physical quantities. The process of converting one form of energy to another is known as transduction.

A DC-to-DC converter is an electronic circuit or electromechanical device that converts a source of direct current (DC) from one voltage level to another. It is a type of electric power converter. Power levels range from very low to very high.

<span class="mw-page-title-main">Voltage regulator</span> System designed to maintain a constant voltage

A voltage regulator is a system designed to automatically maintain a constant voltage. It may use a simple feed-forward design or may include negative feedback. It may use an electromechanical mechanism, or electronic components. Depending on the design, it may be used to regulate one or more AC or DC voltages.

<span class="mw-page-title-main">Electronic component</span> Discrete device in an electronic system

An electronic component is any basic discrete electronic device or physical entity part of an electronic system used to affect electrons or their associated fields. Electronic components are mostly industrial products, available in a singular form and are not to be confused with electrical elements, which are conceptual abstractions representing idealized electronic components and elements. A datasheet for an electronic component is a technical document that provides detailed information about the component's specifications, characteristics, and performance.

<span class="mw-page-title-main">Tap changer</span> Mechanism to change turn ratios in transformers

A tap changer is a mechanism in transformers which allows for variable turn ratios to be selected in distinct steps. This is done by connecting to a number of access points known as taps along either the primary or secondary winding.

<span class="mw-page-title-main">Electronic symbol</span> Pictogram used to represent various electrical and electronic devices or functions

An electronic symbol is a pictogram used to represent various electrical and electronic devices or functions, such as wires, batteries, resistors, and transistors, in a schematic diagram of an electrical or electronic circuit. These symbols are largely standardized internationally today, but may vary from country to country, or engineering discipline, based on traditional conventions.

<span class="mw-page-title-main">Blocking oscillator</span>

A blocking oscillator is a simple configuration of discrete electronic components which can produce a free-running signal, requiring only a resistor, a transformer, and one amplifying element such as a transistor or vacuum tube. The name is derived from the fact that the amplifying element is cut-off or "blocked" for most of the duty cycle, producing periodic pulses on the principle of a relaxation oscillator. The non-sinusoidal output is not suitable for use as a radio-frequency local oscillator, but it can serve as a timing generator, to power lights, LEDs, EL wire, or small neon indicators. If the output is used as an audio signal, the simple tones are also sufficient for applications such as alarms or a Morse code practice device. Some cameras use a blocking oscillator to strobe the flash prior to a shot to reduce the red-eye effect.

In electronics, a bleeder resistor, bleeder load, leakage resistor, capacitor discharge resistor or safety discharge resistor is a resistor connected in parallel with the output of a high-voltage power supply circuit for the purpose of discharging the electric charge stored in the power supply's filter capacitors when the equipment is turned off, for safety reasons. It eliminates the possibility of a leftover charge causing electric shock if people handle or service the equipment in the off state, believing it is safe. A bleeder resistor is usually a standard resistor rather than a specialized component.

<span class="mw-page-title-main">Push–pull converter</span>

A push–pull converter is a type of DC-to-DC converter, a switching converter that uses a transformer to change the voltage of a DC power supply. The distinguishing feature of a push-pull converter is that the transformer primary is supplied with current from the input line by pairs of transistors in a symmetrical push-pull circuit. The transistors are alternately switched on and off, periodically reversing the current in the transformer. Therefore, current is drawn from the line during both halves of the switching cycle. This contrasts with buck-boost converters, in which the input current is supplied by a single transistor which is switched on and off, so current is drawn from the line during only a part of the switching cycle. During the remainder of the cycle, the output power is supplied by energy stored in inductors or capacitors in the power supply. Push–pull converters have steadier input current, create less noise on the input line, and are more efficient in higher power applications.

<span class="mw-page-title-main">Test probe</span>

A test probe is a physical device used to connect electronic test equipment to a device under test (DUT). Test probes range from very simple, robust devices to complex probes that are sophisticated, expensive, and fragile. Specific types include test prods, oscilloscope probes and current probes. A test probe is often supplied as a test lead, which includes the probe, cable and terminating connector.

<span class="mw-page-title-main">Pre-charge</span>

Pre-charge of the powerline voltages in a high voltage DC application is a preliminary mode which limits the inrush current during the power up procedure.

An inrush current limiter is a component used to limit inrush current to avoid gradual damage to components and avoid blowing fuses or tripping circuit breakers. Negative temperature coefficient (NTC) thermistors and fixed resistors are often used to limit inrush current. NTC thermistors can be used as inrush-current limiting devices in power supply circuits when added in series with the circuit being protected. They present a higher resistance initially, which prevents large currents from flowing at turn-on. As current continues to flow, NTC thermistors heat up, allowing higher current flow during normal operation. NTC thermistors are usually much larger than measurement-type thermistors and are purposely designed for power applications.

<span class="mw-page-title-main">Applications of capacitors</span> Uses of capacitors in daily life

Capacitors have many uses in electronic and electrical systems. They are so ubiquitous that it is rare that an electrical product does not include at least one for some purpose. Capacitors allow only AC signals to pass when they are charged blocking DC signals. The main components of filters are capacitors. Capacitors have the ability to connect one circuit segment to another. Capacitors are used by Dynamic Random Access Memory (DRAM) devices to represent binary information as bits.

This glossary of electrical and electronics engineering is a list of definitions of terms and concepts related specifically to electrical engineering and electronics engineering. For terms related to engineering in general, see Glossary of engineering.

References

  1. Ralph Fehr, Industrial Power Distribution, John Wiley & Sons, 2015 ISBN   1119065089, pages 8–73.
  2. NTC thermistors Archived 2008-07-10 at the Wayback Machine at Temperatures.com.
  3. "Electrical Engineer". 1896.