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Using transformer with 3 28.5V secondary windings to supply 57VAC/80VDC
- langdons
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24 Feb 2025 16:35 #322505
by langdons
Using transformer with 3 28.5V secondary windings to supply 57VAC/80VDC was created by langdons
I have a transformer (toroidal) that has 3 isolated 28.5VAC secondary windings.
2 of the windings are in parallel with each other with the third winding in series to supply 57VAC to 2 DM860H stepper drivers.
This means one winding is handling double the current of the others.
Right now there is no problem, as the winding can power 2 drives without any issue.
In the future, I plan to add a third stepper driver.
Can I get away with overloading that one misfortunate winding, Or should i place more load on the 2 parallel windings using a voltage-doubling rectifier.
2 of the windings are in parallel with each other with the third winding in series to supply 57VAC to 2 DM860H stepper drivers.
This means one winding is handling double the current of the others.
Right now there is no problem, as the winding can power 2 drives without any issue.
In the future, I plan to add a third stepper driver.
Can I get away with overloading that one misfortunate winding, Or should i place more load on the 2 parallel windings using a voltage-doubling rectifier.
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- tommylight
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24 Feb 2025 17:18 #322508
by tommylight
Replied by tommylight on topic Using transformer with 3 28.5V secondary windings to supply 57VAC/80VDC
I am sure i answered this on the other topic.
But since internet has become a cesspool of bad information, you have every right to doubt me.
Just in case:
-normal metal core transformers can withstand a lot of overload, granted they do not exceed the isolation melting temperature
-stepper drives do not pull 5A from the transformer for a 5A motor, and yes the motor gets 5A easily but the drive might pull a single amp from the transformer. This is an EXAMPLE!!!
-the above depends hugely on the motor and drive voltage
-etc
But since internet has become a cesspool of bad information, you have every right to doubt me.
Just in case:
-normal metal core transformers can withstand a lot of overload, granted they do not exceed the isolation melting temperature
-stepper drives do not pull 5A from the transformer for a 5A motor, and yes the motor gets 5A easily but the drive might pull a single amp from the transformer. This is an EXAMPLE!!!
-the above depends hugely on the motor and drive voltage
-etc
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- Hastrh2o
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24 Feb 2025 18:20 #322512
by Hastrh2o
Replied by Hastrh2o on topic Using transformer with 3 28.5V secondary windings to supply 57VAC/80VDC
You just have to respect the max current of the transformer ! Tommy say metal core transformers can withstand a lot of overload, he's right, but I would think a toroidal one is not this type, and you could have magnetic saturation.
If you don't know your load current, just put a fuse to protect the output and you will see.
If you don't know your load current, just put a fuse to protect the output and you will see.
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24 Feb 2025 19:29 #322522
by tommylight
Replied by tommylight on topic Using transformer with 3 28.5V secondary windings to supply 57VAC/80VDC
Saturation takes a lot of overload, and you find out after 30 seconds to 1 minute that is it overloaded to much as it starts smoking, a lot.
And yes, toroidal transformers are metal core, wound in a doughnut shape, while normal transformers have E and I sections alternatively pushed inside. Microwave transformers usually have all the E on one side and all the I on the other side welded together, but that is not the best way for efficiency, they are on for several minutes at a time so not important.
And yes, toroidal transformers are metal core, wound in a doughnut shape, while normal transformers have E and I sections alternatively pushed inside. Microwave transformers usually have all the E on one side and all the I on the other side welded together, but that is not the best way for efficiency, they are on for several minutes at a time so not important.
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24 Feb 2025 23:32 #322540
by langdons
Replied by langdons on topic Using transformer with 3 28.5V secondary windings to supply 57VAC/80VDC
But mostly equal current load across all windings seems like a good idea, right?
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24 Feb 2025 23:35 #322541
by langdons
Replied by langdons on topic Using transformer with 3 28.5V secondary windings to supply 57VAC/80VDC
Plus I have to make a flyback diode board because the motor drivers I have, while very good, have either no flyback diodes at all or only half (4) flyback diodes.
Making a power supply on the same PCB is not that much extra work.
Making a power supply on the same PCB is not that much extra work.
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25 Feb 2025 08:18 - 25 Feb 2025 10:34 #322564
by Hastrh2o
Replied by Hastrh2o on topic Using transformer with 3 28.5V secondary windings to supply 57VAC/80VDC
I was wrong with saturation. I'm used to small ferrite toroidal transformers wich are sensible to saturation, but your is surely iron core. Like Tommy said, the limit is the temperature.
And even with ferrite, it's only one magnetic circuit, so saturation would only appear when the total windings current exceed the maximum of the transformer.
We don't care of unbalanced current between windings.
Tommy advice is to overload it and check the temperature, I agree it works, put the right fuse after test on the output and then. Are you even sure you will overload it ? Maybe not !
I would although consider to change it because I think it's a small one (you don't say how many amps you have), and I have many unused transformers. Maybe you don't. Have a look around you, it's easy to find some...
Doing a power supply.. For me no, if you put the three in series you will have 90VAC, better to use directly 120VAC or 240VAC in this case.
But once again, I assume your transformer is a small one (300VA ?), it's not the same if it's a 2kVA one, but in this case you wouldn't need to worry for the third driver.
And even with ferrite, it's only one magnetic circuit, so saturation would only appear when the total windings current exceed the maximum of the transformer.
We don't care of unbalanced current between windings.
Tommy advice is to overload it and check the temperature, I agree it works, put the right fuse after test on the output and then. Are you even sure you will overload it ? Maybe not !
I would although consider to change it because I think it's a small one (you don't say how many amps you have), and I have many unused transformers. Maybe you don't. Have a look around you, it's easy to find some...
Doing a power supply.. For me no, if you put the three in series you will have 90VAC, better to use directly 120VAC or 240VAC in this case.
But once again, I assume your transformer is a small one (300VA ?), it's not the same if it's a 2kVA one, but in this case you wouldn't need to worry for the third driver.
Last edit: 25 Feb 2025 10:34 by Hastrh2o.
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25 Feb 2025 13:38 #322583
by langdons
Replied by langdons on topic Using transformer with 3 28.5V secondary windings to supply 57VAC/80VDC
I mean like rectify from the 2 parallel 28.5 windings and then double the voltage the way that power supplies with a 110V/220V switch do.
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25 Feb 2025 13:40 #322584
by langdons
Replied by langdons on topic Using transformer with 3 28.5V secondary windings to supply 57VAC/80VDC
From what I can see, there is absolutely no writing or info about the transformer at all.
I have no clue what the transformer can supply.
No idea.
I have no clue what the transformer can supply.
No idea.
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25 Feb 2025 13:42 #322585
by langdons
Replied by langdons on topic Using transformer with 3 28.5V secondary windings to supply 57VAC/80VDC
There is no sticker on the side of the toroid.
Is it common to place the sticker on the top (where is is covered by the mounting plate)?
Is it common to place the sticker on the top (where is is covered by the mounting plate)?
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