I know, yet one more soft start 🙂
But here it is, I'm sharing what I have, which may be of interest to some users.
It's only the soft start function, for one toroid only, and it's activated by a push button with a led to show status.
Nothing more beyond that. No dc blocker, no snubbers on the mains, except the one on the triac, no ground lifter or anything else of that nature.
But also no electromechanical relay, no power dissipating stuff like power resistors, no MOVs, nothing bulky.
Just an 8 pins PIC to handle it all, by phase control, like a plain old dimmer.
The unit is in standby when power is first applied, waiting for the push button to be hit. When the button is hit, the start up sequence starts, the led blinks during the whole process, while the push button is ignored.
Once the full sequence is done, the led and toroid are fully turned on and the push button is polled again, with a small delay, waiting for the next push to shut the unit down and go back to stand by. The led is turned off as well as the toroid at that point and so the status is back to the same as when power was first applied.
The pcb is 55x70mm. The PIC can be reprogrammed on board via the ICSP header and a pickit or whatever is used to do pic programming.
I will post more stuff in a while. The gerbers, pic asm source code..
I have already verified the software using a breadboarded version of the circuit on a 200VA toroid, and it worked just fine. I didn't have a bigger toroid handy, so I don't know how it will behave on that, but the software is easily adjustable in case of need for a hard to handle load.
I have pcbs coming to me, so I'll be testing the whole thing built for real in a few days.
Maybe this might be of help to some users, so I'm sharing it.
The start up sequence is smooth, starting with pulsing the triac gate (~250us) at ~9us from zero-crossing, for several cycles, then the delay decreases by ~500us at each step in the sequence, all the way down to zero delay when the sequence is all done and the triac is then fully turned on permanently (well, at least until we tell it to shut down, or power is lost).
The zero-crossing is sensed via optocoupler, as well as the triac triggered via optotriac.
I used a 5V power module instead of a transformer based PSU for the pic power, so fewer parts and smaller footprint overall, plus it turns out a bit cheaper as well, not to mention simpler to assemble.
I priced all the parts from mouser and compiled a excel based BOM, which should make it easier for anyone to make. It's fairly cheap to make, with less than 15euros worth in parts, plus the pcb.