Mark Pictor wrote:
> I knew there would be inrush current to the capacitors, but I
> didn't realize that the transformer, in and of itself, would have
> an inrush current.  Guess that shows how much I know!
> 
Yup.  It varies with the transformer design, and if you end up 
using a 240 V primary winding on 120 V, the "inrush" will be 
very small.  What is going on is that the transformer integrates 
volts times time, and the iron in the core is designed to just 
handle the rated conditions, where the magnetic field builds in 
one half cycle, and is cancelled out in the next half-cycle.

But, when you close the switch, the power line phase at that 
moment could be anything.  If it happens to be right at the 
voltage zero crossing, then it gets a complete half cycle of the 
same polarity starting from zero magnetic field, and that 
saturates the core.  The transformer will make a huge buzz for a 
half second, and the current will be enormous.
> I was planning to use one or more motor run capacitors to limit
> inrush current - use a relay in parallel with the cap, and close
> the relay a few seconds after applying power.
> 
This will kill your relay.  Shorting a capacitor bank charged to 
168 V peak will cause a minor explosion, and the L-C circuit 
will never settle.  You need to use a low-value resistor, not 
capacitor, for this purpose.
> Now that Jon brought it up, I think I will visit the local junkyard
> instead.
Depends entirely on the junkyard, of course, but almost any 
instance where old machinery is torn out of a plant, they get 
these transformers.

Jon

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