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I have seen, but cannot find again, a really simple implementation of a mains soft start circuit.The thing I'm thinking of involves a power resister inline of the mains. When the device is started, current is restricted until a relay is energised, which shorts out the resistor allowing full power
The thing is, I can't remember (and so can't decide on) a good way to energise the relay after a second or so.
Does anyone know of a link to a reference implementation for such a circuit?
Cheers
Wayne BoothWayne Booth
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4 Answers$begingroup$
I have seen, but cannot find again, a really simple implementation of a mains soft start circuit. The thing I'm thinking of involves a power resister inline of the mains. When the device is started, current is restricted until a relay is energised, which shorts out the resistor allowing full power
Something like this: -
Or maybe like this: -
Or just use one of these: -
It's a thermistor that when cold has a resistance of tens of ohms and rapidly warms down to a low on resistance but it's slow enough to take the edge of the inrush current.
Andy akaAndy aka
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[ Sparky256Sparky256
This diagram is close but has too many parts: K1 and K2 are terminal block - or large wire nuts. K1 goes to what should be a 20 to 30 amp 250 volt slow-blow fuse. Assuming Re1 has a 120VDC coil, R1=R2=R3 = 2.2K ohm 3 watts each. C1 can be omitted as can C2. B1 can be a bridge rectifier with a 1 amp 600 volt rating, or make one from 4 1N4007 diodes. C3 can be 47uF 150VDC, enough so Re1 does not chatter. Increase C3 value if longer delay time is needed. Re1 should be a relay with a 120VDC coil (common) and contacts rated for 20 to 30 amps 250VAC. The high current rating will ensure a long life. R4, R5, R6, R7 should be 2 ohm 300 watt ceramic resistors mounted to a panel or on a fiberglass threaded rod. They take some of the punishment if the motor stalls, giving time for the fuse to blow. I would suggest 600 watt resistors but they get expensive (in case the motor is jammed and cannot rotate). These are all bulky brute-force parts designed to last even if the motor stalls. I suggest adding a thermal cut-off next to R4-R7 unless it is built into the motor. ] ![]() Electric Switches For Power Tools
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Soft Start Switch For Table Saw$endgroup$$begingroup$
Back when high-powered tube-based amplifiers were commonly used by amateur radio operators, it was common to control the main contactor (the one that bypasses the current-limiting resistor) using a thermal time-delay control relay.
Dave Tweed
![]() Soft Start Switch For Power Tools ReviewsDave Tweed
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There are several ways to do the delayed energize of the resistor bypass relay coil. One method is that there is a separate isolated power supply off the mains that is designed with its PWR_GOOD indicator status to come valid at the end of the 1 to 2 second delay period. This indicator signal can turn on a transistor that energizes the bypass relay coil using the voltage rail of this separate power supply to give power to the relay.
Another method is to design a direct off mains power circuit that is not isolated but can provide power to a 1 second delay circuit and then drive the relay coil.
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Replacement Power Tool Switch
Some products that need a soft start run on a off mains switch mode power supply. These products often have rectifier diodes right off the line and then the resistor to the main SMPS switcher curcuit operates as a DC rail. On these cases it is possible to use a FET to bypass the soft start resistor.
Michael KarasMichael Karas
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