Fuse for toroid transformer... sanity check

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18 Jul 2024 12:58 - 18 Jul 2024 14:55 #305573 by mooser
I'm building a new power supply setup for use with a some feedback hybrid stepper motor. The driver for these motors can accept 24-80V AC so I'm just using a toroid transformer without the rectifier/cap

The transformer is a Hammond 1182S30:  625VA
Pri: 2x 117v
Sec: 2x 30v @10.42A

It will be wired with the primary in parallel for 120V 60Hz and the secondary in series for 60V at 10A

The toroid needs a slo-blow fuse because of the inrush but I'm finding all kinds of different information on calculating the fuse size. My first instinct is 625VA / 120V = 5A but when I'm looking around the net I'm seeing values down closer to 750mA or 1A being used. I know this is a larger than "normal" transformer but I just wanted to double check in case I'm missing something.

Also, I'm tapping off before the toroid to another 120 to 3.3/5/12vdc small transformer for the control system PLC, is that going to be an issue?

Any input would be greatly appreciated
Thanks
M
 
Last edit: 18 Jul 2024 14:55 by mooser.

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18 Jul 2024 14:11 #305575 by scotth

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18 Jul 2024 17:09 #305580 by mooser
Thanks for that link, a lot to absorb...
M

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19 Jul 2024 04:56 #305607 by rodw
I would not be too worried about the slow blow fuse. I have done three Toroid setups now for steppers. The first one, I used 2 x 32V toroids in series (cos thats what I could get) to give 64 Volts @ 20 amps. I was a bit worried about inrush and when I queried that,  the manufacturer gve me a couple of Thermistors to limit the inrush.

But the recommendation from the Stepper drive manufacturer was to add fuses on the power to the motor (hence all the terminals)
 

 
Next time round, I got 2 x 60 volt x 12.5 V toroids made and did not worry about the thermistors.
 
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19 Jul 2024 13:34 - 19 Jul 2024 13:36 #305648 by mooser
Thanks for that info. I went through all the references on the ametherm webiste/videos and calculators and ended up realizing that those guys and the guys at Hammond need to go out for lunch together... The numbers needed for some of the calculations don't seem to be on any of the transformer data sheets.
I did finially find a reference for a different brand of toroid that oddly enough has the exact same specs as this one and they actually listed
For 115V use: primary: 6.3A, 5x20mm, IEC127, high I²t value
in series with 2 NTC-resistors type NTC2.5
secondary: none

So.... both a slow blow fuse close to what I figured AND a NTC, belt and suspenders I guess.  On order now

For Stepper power fuses, Never thought about protecting that side.... The stepper is a 12Nm nema 32 rated at 6A, so are you saying you would add a 6A (or 6.5~7.0) to each of the four leads? between the controller and the stepper?
It's a hybrid stepper/encoder system if that matters

Thanks for the help
M  
Last edit: 19 Jul 2024 13:36 by mooser.

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21 Jul 2024 20:37 - 21 Aug 2024 13:37 #305817 by mooser
Last edit: 21 Aug 2024 13:37 by mooser.

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21 Aug 2024 13:37 #308287 by mooser
Closing this off.
Completed and installed the new power supply. Ended up using a combination of what rodw suggested and some other info I eventually found online.

One main Fuse from the 120v line on the hot side (it also splits off into a 120v > 3.3v/5v/12v power supply for the other various circuits before hitting the toroid)
A thermister and a slo-blow fuse on each of the input coils which are in series to each other.
One fuse on each pair of the output to the stepper coils
Seems like overkill somehow but that's what's there.
M
The following user(s) said Thank You: rodw

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