Electronic – use a resistor before a bridge rectifier to lower inrush current

bridge-rectifierinrush-currentpower supply

I have been looking for ways to limit inrush current in a power supply circuit I am designing. In LTspice, with no current limiting, I see a spike of around 24A before my caps are charged.

Looking around, I see NTC inrush current limiters as a common solution as well as some ideas with inductors and resistors inline with the capacitor, each with its own advantages and disadvantages.

My idea though was to put a resistor before the bridge rectifier in my circuit, so the resistor would always provide some resistance before the capacitors got charged. Playing around again in LTspice, this drops my inrush current to about 4A (and changes with the resistor value obviously).

Is this ever done? Are there any major good or bad reasons to do this? I suspect no one does this due to decreased power efficiency, but is that the only reason?

Best Answer

There are good and complicated solutions, relay, FET, and simpler, thermistor, but it still may be possible to use the simplest, fixed resistor, without too much dissipation for your application.

If you get an inrush, does it matter? Well, only if it breaks something. So what could break? Supply fuse, transformer, or diode rectifiers.

Fuses have 'T' rated versions that take a long time to blow, for just this application. The transformer is a heavy lump of copper, that's not going to fail.

Read the specification of your diodes carefully. You may be surprised at how much the 'single cycle surge current' is. In a 1N40xx (cheapo workhorse mains diode), the continuous current is 1A, the surge is 30A. For 1N54xx series, the figures are 3A and 200A. This is specifically to allow them to survive inrush. You may find you already have enough stray resistance in your circuit to limit the current to the safe surge value. If not, you maybe won't need much more, and it still may give you acceptable efficiency. If it doesn't, then try smarter solutions.