Transformer Inrush Current

It is a form of over-current that occurs during energization of

a transformer and is a large transient current which is caused
by part cycle saturation of the magnetic core of the
transformer. For power transformers, the magnitude of the
inrush current is initially 5 to 10 times the rated load current
but slowly decreases by the effect of oscillation damping due
to winding and magnetizing resistances of the transformer as
well as the impedance of the system it is connected to until it
finally reaches the normal exciting current value. This process
typically takes several milliseconds.
Inrush current is the maximum, instantaneous input current drawn by an electrical device, when the device is turned on.
Normal Transformer Operation
 Saturation
Characteristic

Core Flux Magnetizing

Curren t
a)

Inrush Current

The flux/current (saturation) characteristic determines the magnitude of the magnetizing and Inrush current for :
a) symmetrical.
b) b) unsymmetrical core fluxes.
c) Note: (a) and (b) have different scale factors).
 Why Do You Need to Limit Inrush Current ?

Inrush current can damage components when any equipment is turned on. if steps
are not taken to minimize this inrush current, it can damage power devices and
reduce equipment life

In many items of electrical equipment, switched mode power supplies, motors,

transformers or amplifiers etc., high inrush currents occur, when the devices are
turned on. These can damage individual components or entire assemblies or
blow fuses in error. Such high currents are caused by extremely low impedance
of smoothing capacitors or coils which produce nearly short circuits at the
moment of switching on. However, if NTC thermistors are used as inrush current
limiters, this problem can be solved without elaborate circuitry at low cost.
How Do You Limit Inrush Current ?

Here are two ways to limit inrush current:

Using NTC Thermistor-based inrush current limiters

Using various forms of active circuits - including triacs, power resistors, and thyristors
 About NTC Thermistors
Thermistors are electronic components that are used for temperature sensing, or to detect changes in the
temperature of an object.

A Negative Temperature Coefficient or an NTC Thermistor is capable of lowering its resistance when there is an
increase in the temperature of a measuring object.

Thermistors can detect very small changes in temperature through the manifestation of a big change in resistance
(i.e., a nonlinear characteristics).

Thermistors are also tough, reliable and easy to use.

Polycrystalline NTC thermistor bodies are formed by subsequent sintering of these blanks at temperatures
between 1000 and 1400C .

NTC Thermistor exhibits nonlinear behavior. For example, if the temperature of a measuring object increases
because of some internal heating the resistance of a working (engaged for this purpose) NTC Thermistor
decreases nonlinearly to indicate this increase in temperature.
NTC Thermistor Characteristics Curve

Notice that it has a negative temperature coefficient (NTC), that is its resistance decreases
with increasing temperatures.
ADVANTAGES:
Minimise line-current distortion and radio noise
Protect switches, rectifier diodes and smoothing
capacitors against premature failures
Prevent fuse from blowing in error

APPLICATIONS:
Switched Mode Power Supplies
Motors
Transformers
Amplifiers
Monitors Colour Televisions
Series and parallel connection

An NTC thermistor is always connected in series with the

load to be protected. If the inrush current cannot be
handled by one thermistor alone, two or more thermistor
elements can be connected in series.

Paralleling several NTC thermistors is inadmissible, since the

load will not be evenly distributed. The thermistor carrying
the largest portion of current will heat up until it finally
receives the entire current (which may result in destruction
of the device), while the other paralleled thermistors remain
cold.
The NTC thermistor thus provides protection from
undesirably high inrush currents, while its resistance
remains negligibly low during continuous operation.
 Note:
Inductive reactance of the transformer
Peak Inrush Current occurs in one cycle = 564 A, as
measured on the oscilloscope
Input Voltage = 120 VAC
Frequency = 60 Hz

Assume, Efficiency of transformer: 70%, Ambient

Temperature: 75C, Minimum input voltage: 90 V

Normally thermistors are rated up to .tnuocca ot ni nekat eb tsum rotcaf gnitar-ed a neht dna ,tnerruc gnitarepo rieht rof C65
Decision criteria: choose an NTC Thermistor that can provide at least the steady state current as calculated above:
Using the de-rating curve at 90% gnidnopserroc esu , C75of max rated steady state current,
0.90 =X 36 A = 32.40 A
You can use any of the NTC Thermistors that are rated up to 36.0 A to meet your Steady State Current and Energy Requirements. See the charts for
part numbers.
 Each transformer rating: 1000 VA, transformer step-down: 30 V
Total transformer rating: 2000 VA
Filter capacitors used: 30V, 2300 F

NTC Selection Criteria #1: Energy

Energy required for the NTC: Inductive reactance of the transformer

Note:
Peak Inrush Current occurs in one cycle = 564 A, as measured on the oscilloscope
Input Voltage = 120 VAC
Frequency = 60 Hz
NTC Selection Criteria #2: Steady State Current
Assume, Efficiency of transformer: 70%, Ambient Temperature: 75C, Minimum input voltage: 90 V

Normally thermistors are rated up to 65C for their operating current, and then a de-rating factor must be take
in to account.
Decision criteria: choose an NTC Thermistor that can provide at least the steady state current as calculated
above:
Using the de-rating curve at 75C , use corresponding 90% of max rated steady state current,
= 0.90 X 36 A = 32.40 A
You can use any of the NTC Thermistors that are rated up to 36.0 A to meet your Steady State Current and
Energy Requirements. See the charts for part numbers.
 Transformer Protection Guide Typical Inrush Current Limiters for Select Transformers
Single phase Continuous
Transformer Input Voltage Current Inrush Current Impedence X Inductance Xl F Energy Min R Recommended
KVA Vac A A () (H) (HZ) (J) () Part
.50 120 4.16 104 1.63 4328 60 23.4 4.9 SL12 10006
1.0 240 4.16 104 3.26 8642 60 46.7 9.78 SL22 10008
2.0 240 8.33 208 1.63 4328 60 93.62 4.89 SL32 10015
3.0 240 12.5 312 1.09 2881 60 140.6 3.26 AS32 5R020
5.0 480 10.42 260 2.6 6913 60 234 7.83 MS32 10015
2x MS32 2R025
or
10.0 480 20.83 521 1.3 3457 60 469 3.92 1x MS35 5R025

Inrush Current Limiters for Transformer Applications Try It Now In Stock

SSI Joules Voltage
Part UL R Max Max Max Digikey Mouser Farnell
SL12 10006 Y 10.0 6 40 240 570-1078-ND 995-SL12-10006 72J6734
SL22 10008 Y 10.0 8 90 240 570-1034-ND 995-SL22-10008 72J6819
SL32 10015 Y 10.0 15 150 240 570-1058-ND 995-SL32-10015 72J6844
AS32 5R020 Y 5.0 20 300 240 570-1106-ND 995-AS32-5R020
MS32 10015 Y 10.0 15 250 480 570-1014-ND 995-MS32-10015 9006052
MS32 2R025 Y 2.0 25 300 480 570-1019-ND 995-MS32-2R025 72J6622
MS35 5R025 N 5.0 25 600 680 570-1029-ND 72J6634
 The 7 step process below will walk you through the calculation we did for a transformer

Step 1: Define the Characteristics of Your Transformer

The 40VA transformer has the following given values. If you are doing these
calculations for your own application, these values will vary.
Given Values:
KVA or VA of transformer= 40VA
Input voltage= 110VAC

Step 2: Write Inrush Current Assumptions

We will use the following assumptions throughout our calculations. Depending on the shape of
your transformer, you will use either 10 or 30 in the first assumption (see note).
Assumptions:
Inrush Current = 30 x Steady State Current (SSI)
Maximum Tolerable Inrush Current = 1/5 of Inrush Current
Frequency= 50Hz
Note:
Use 10 x SSI if the geometry of the core is rectangular.
Use 30 x SSI if the geometry is toroidal (i.e. donut shape).
These are typical values that we have seen based on scope traces.
The max tolerable inrush current reduces inrush current by 80.
Step 3: Calculate Steady State Current of Transformer
Now that we have the given values and assumptions for our application, we are
ready to start the calculations. First, we will calculate the steady state current of
the transformer during normal operation by using the given values found in Step
1.

Step 4: Calculate Inrush Current

Second, we are going to calculate the inrush current
caused when the transformer is powered on. You can find
an explanation of this calculation in Step 2.
 Step 5: Calculate Inductive Impedance
Third, we are going to calculate the inductive impedance.
This is the amount of resistance the coil and core present
to the electrical current.

Step 6: Calculate the Energy

Next, we will calculate the amount of energy the
thermistor needs to prevent it from self-destructing.
 Step 7: Calculate Minimum Cold
Resistance of Thermistor
Finally, we are going to calculate the minimum cold
resistance of the thermistor.

Select the Correct NTC Thermistor

Now that steps 1-7 are completed, you can use the
voltage, SSI, and energy parameters to look up your data
sheet on the chart below. The data sheet will direct you
towards the correct part number for your thermistor.
For this example, we recommend using the SL03
12101 thermistor because it meets all the necessary
requirements for this application.
 Residual flux
Transient Flux
Voltage
Residual Flux
F
L
Core Flux U
X
F
L Time
U Time
X
1 2 Normal Peak

Prospective Flux

Optimal energization of a single-phase

transformer is shown. Optimal energization points
Core flux showing worst energization case exist at times (1) and alternate optimal time (2).
for this residual condition