X-Treme Inrush Current Limiter

A controlled start for Big Electrolytics & Co.

This all-analog, microcontroller free (!) project got designed in response to cries for help from a diehard model plane enthusiast on the Elektor staff, who likes to fly large high powered models. One problem he ran into was self-destructing power connectors when connecting the battery pack to the plane (i.e. the motor controller). Every time the damage was due to heavy sparking, due in turn to of high inrush currents. Those were expensive sparks as it turned out, because the connectors are 6-mm diameter, gold plated types. Clearly an inrush current limiter is called for to ensure a controlled, spark-free initial current flow rather than a thump and a small explosion. Such a regulator did not drop from the skies however, and took some time to develop at Elektor Labs.

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Materials

www.bonavolta.ch/hobby/files/MotorolaAN1542.pdf

www.infineon.com/dgdl/IPB017N06N3_Rev2.2.pdf?folderId=db3a30431441fb5d01148ca9f1be0e77&fileId=db3a30431ddc9372011e264a7ab746ea

120733-PCB.pdf

Gerber file

CAM/CAD data for the PCB referred to in this article is available as a Gerber file. Elektor GREEN and GOLD members can exclusively download these files for free as part of their membership. Gerber files allow a PCB to be produced on an appropriate device available locally, or through an online PCB manufacturing service.

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PCB

Download Gerber file: 120733-1.zip

Components

The BOM (Bill of Materials) is the technically exhaustive listing of parts and other hardware items used to produce the working and tested prototype of any Elektor Labs project. The BOM file contains deeper information than the Component List published for the same project in Elektor Magazine. If required the BOM gets updated directly by our lab engineers. As a reader, you can download the list here.
Want to learn more about our BOM list? Read the BOM list article for extra information.

Download the BOM list

Component list

COMPONENT LIST
Resistors
(All 0.25 W, 1%, SMD 1206)
R1 = 2.74kOhm *
R2 = 1.5kOhm
R3,R6,R8 = 3.3kOhm
R4,R5 = 470kOhm
R7 = 1.8MOhm
R9 = 10kOhm
R10 = 0Ohm
Capacitors
C1,C2 = 10µF 10% 25V, X5R, 1206
C3 = 470nF 10% 100V, X7R, 1206
Semiconductors
D1 = 1SMB5925B zener diode, SMB (Newark/Farnell # 1894811)
D2 = PMEG6010CEH, Schottky diode, NXP, SOD-123F (Newark/Farnell # 1510694)
D3 = SM6T12CA, TVS diode, STmicroElectronics, SMB (Newark/Farnell # 9885870)
D4 = HSME-A401-P4PM1, LED, green, Avago, PLCC-4 (Newark/Farnell # 1058419)
IC1 = LT1716CS5#PBF, comparator, Linear Technology, SOT-23-5 (Newark/Farnell # 1417738)
T1,T2,T3,T4,T5,T6 = IPB017N06N3, N-MOSFET, Infineon, TO-263-7 (Newark/Farnell # 1775519)
T7,T8 = 2N7002, N-MOSFET, Diodes Inc., SOT-23 (Newark/Farnell # 1713823)
Miscellaneous
K1-K4 = high current connectors, male & female pairs, gold plated *
Heatsink, ½ brick form, Aavid Thermalloy type 241204B92200G, dim. 60.96mm x 57.91mm x 11.4mm (Newark/Farnell # 1703176)
PCB 120733-1
* user configurable component, see text