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Small AC-DC bridge popping 1

AG-PPI

Electrical
Oct 22, 2024
8
My companys test department needs a DC power supply to give 110Vdc to power a DC relay for testing purposes, and they don't want to buy a purpose built one.
Up until now our test department has been chaining a couple of 30V dual output DC power supplies in series to get the voltage needed but it's not ideal.

110vdc.PNG

Above is a circuit they put together on some veroboard mounted in a little PCB enclosure.
They have been using a variac to drop 230Vac mains down to about 125Vac for the input of this circuit to give ~110Vdc out.
I put this into Multisim just for visual purposes.
R2 is simulating the coil impedance, and R1 was apparently selected to act as a discharge resistor through the coil when power is disconnected.
The problem our test department is having is the track highlighted in green is vaporising upon power-up.

I am suspecting that R1 should actually be in parallel across the output terminals, but I am puzzled as to why the highlighted track is vaporising.
Any ideas? I feel like I am missing something really obvious here, but I am going to blame Monday morning for this one.

For reference, the coil on the relay is rated 110Vdc, 9.7R, 11mA.
 
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1. One of the 1N4007s is reverse polarity.
2. C1 charging current.
Check diode polarities.
2.Add a charging resistor to C1 circuit.
Put a jumper in place of the undersized trace that is vapourizing.

With 125 VAC in, your C1 may charge to 176 Volts.
Of the theoretical 176 Volts output,
Expect to see about 0.170 Volts across the coil and 175.8 Volts across the 10k resistor.
Google freewheeling diode.
Should you really be doing this?
 
Is that really an earth ground in the schematic that matches an earth ground in the actual circuit? A variac might not isolate the mains from this circuit.
 
1. One of the 1N4007s is reverse polarity.
2. C1 charging current.
Check diode polarities.
2.Add a charging resistor to C1 circuit.
Put a jumper in place of the undersized trace that is vapourizing.

With 125 VAC in, your C1 may charge to 176 Volts.
Of the theoretical 176 Volts output,
Expect to see about 0.170 Volts across the coil and 175.8 Volts across the 10k resistor.
Google freewheeling diode.
Should you really be doing this?
I have checked the diodes they put into the veroboard. Everything seems fine there.
The capacitor in use is a 400Vdc electrolytic, so not concerned about voltage there.
The resistor in use is a 3W resistor with a max working voltage of 500V, so not a concern there either.
The 110Vdc relay already has an internal freewheeling diode. Yes, it has been connected the correct way around.
 
Is that really an earth ground in the schematic that matches an earth ground in the actual circuit? A variac might not isolate the mains from this circuit.
It is. I probably should have taken that out for the purposes of taking a screenshot.
I ran the simulation on Multisim just to see if any errors popped up, and it requires a ground point for that.
No errors popped up though, so I was a little more confused after that.
 
Closing this thread.

I told them to shift R1 to go across C1 like a normal discharge resistor should.
Now seems to be working fine.
 

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