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4hv.org :: Forums :: General Science and Electronics
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Troubleshooting a variac

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Fulmen
Sat Jan 28 2012, 03:15PM Print
Fulmen Registered Member #3883 Joined: Fri May 13 2011, 06:30PM
Location: Norway
Posts: 87
I have an old Philips variac, 220V in, 0-260V @8A out that's busted. It worked fine the first time I tried it, but now it just blows the fuses when plugged in. I've measured it from head to toe without finding anything wrong, the "primary" measures 1.6H @120Hz, DC resistance 2Ω. No shorts detected, windings look fine, but even without the brushes connected it blows the uses instantaneously. Any pointers to where the fault can be?
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radiotech
Sat Jan 28 2012, 03:28PM
radiotech Registered Member #2463 Joined: Wed Nov 11 2009, 03:49AM
Location:
Posts: 1546
If your inductance is correct he impedance at 50 Hz is essentially 480 ohms. The 2 ohms
DC means there will be a large unsymeterical inrush. You might trouble shoot it
by using a bank of lightbulbs in series and an ammeter. You just keep adding lightbulbs
until the unloaded current drops to where the bulbs dim out.

Then use that current and the voltage across the variac to calculate the full voltage
inductance.
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Fulmen
Sat Jan 28 2012, 06:03PM
Fulmen Registered Member #3883 Joined: Fri May 13 2011, 06:30PM
Location: Norway
Posts: 87
That can't be right. I just swapped probe wires and redid my measurements. Here's the correct numbers:
DC resistance: 1.5ohm
Inductance @ 120Hz: 2.3H
AC resistance @ 120Hz: 5.9k

I also connected it to a 24V transformer and measured 8.4mA @ 26V.
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Steve Conner
Sat Jan 28 2012, 06:47PM
Steve Conner Registered Member #30 Joined: Fri Feb 03 2006, 10:52AM
Location: Glasgow, Scotland
Posts: 6706
Big variacs often blow fuses even when they're working fine, from inrush current. Circuit breakers are more vulnerable than old fuses were.
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Fulmen
Sat Jan 28 2012, 07:05PM
Fulmen Registered Member #3883 Joined: Fri May 13 2011, 06:30PM
Location: Norway
Posts: 87
You have an excellent point, Steve. I have modern fast breakers, maybe all I need is a inrush limiter.

Update: You were spot on, with a 5ohm resistor in series it works just fine. For low-power experiments I could just run it with the resistor, but I might as well make a more permanent solution. A varistor should fit the bill, need to start searching for a suitable one.
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radiotech
Sat Jan 28 2012, 08:55PM
radiotech Registered Member #2463 Joined: Wed Nov 11 2009, 03:49AM
Location:
Posts: 1546
Assuming your test voltage at 26 volts is at 50 Hz, I get the following :

6.28 * 2.3 * 50 = 722 ohms Xl , Z = ~ 722 ohms.

26 / 722 = 0.036 amps

Using 120 Hz gives about 15 Ma.

Is the 120 Hz the test bridge frequency?


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Fulmen
Sat Jan 28 2012, 09:07PM
Fulmen Registered Member #3883 Joined: Fri May 13 2011, 06:30PM
Location: Norway
Posts: 87
radiotech wrote ...

Is the 120 Hz the test bridge frequency?

Correct, I used a 120/100Hz LCR meter.

Everything works now, I've assembled the variac and with the 5ohm resistor it works as it should. Didn't want to test my CW-multiplier directly with mains, a good excuse for fixing the variac (which wasn't broken in the first place).
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