E-stop relay welds contacts for load dump resistor
Posted by
kzf817
on 2011-01-30 07:25:29 UTC
Good afternoon guys. I am just completing a Bridgeport series 1 CNC Stepper to Servo retrofit. I am using the servo E-stop circuit that Mariss recommends on his site. It is the "Electromechanical E-stop" schematic shown at the top of this page: http://geckodrive.com/support.aspx?q=10003
Whenever I clear the E-stop button and press "Reset" the lights in the workshop blink, clearly from high instantaneous load as the filter capacitor charges. After my initial power up tests, I blew the load dump resistor after about the 5th or 6th E-stop cycle over a period of a couple of hours. When I inspected the contacts that carry the load between the 50 watt, 7 ohm wirewound resistor, and ground, I saw that the contacts were welded together, clearly from high load. This, of course, made the resistor carry current continuously, instead of only as a bleed resistor immediately after an E-stop event. My transformer toroid is 1000va, and my filter capacitor is 56,000uf, and DC out is a nominal 60 volts. I know that this CAP is a little bigger than is strictly necessary, but it is what I had available. My E-stop relay contacts are rated for 15 amps, so it should be able to carry this load. I clearly must be arcing the contacts HUGE every time the relay cycles. Can anyone tell if I am overlooking anything obvious in how I have things sized and configured? Thanks!
Whenever I clear the E-stop button and press "Reset" the lights in the workshop blink, clearly from high instantaneous load as the filter capacitor charges. After my initial power up tests, I blew the load dump resistor after about the 5th or 6th E-stop cycle over a period of a couple of hours. When I inspected the contacts that carry the load between the 50 watt, 7 ohm wirewound resistor, and ground, I saw that the contacts were welded together, clearly from high load. This, of course, made the resistor carry current continuously, instead of only as a bleed resistor immediately after an E-stop event. My transformer toroid is 1000va, and my filter capacitor is 56,000uf, and DC out is a nominal 60 volts. I know that this CAP is a little bigger than is strictly necessary, but it is what I had available. My E-stop relay contacts are rated for 15 amps, so it should be able to carry this load. I clearly must be arcing the contacts HUGE every time the relay cycles. Can anyone tell if I am overlooking anything obvious in how I have things sized and configured? Thanks!
Discussion Thread
kzf817
2011-01-30 07:25:29 UTC
E-stop relay welds contacts for load dump resistor
David Speck
2011-01-30 07:45:47 UTC
Re: [CAD_CAM_EDM_DRO] E-stop relay welds contacts for load dump resistor
kzf817
2011-01-30 09:26:29 UTC
Re: E-stop relay welds contacts for load dump resistor
Jon Elson
2011-01-30 09:28:22 UTC
Re: [CAD_CAM_EDM_DRO] E-stop relay welds contacts for load dump resistor
kzf817
2011-01-30 09:47:16 UTC
Re: E-stop relay welds contacts for load dump resistor
David Speck
2011-01-30 11:17:30 UTC
Re: [CAD_CAM_EDM_DRO] Re: E-stop relay welds contacts for load dump resistor
kzf817
2011-01-30 11:48:21 UTC
Re: E-stop relay welds contacts for load dump resistor
David Speck
2011-01-30 12:21:04 UTC
Re: [CAD_CAM_EDM_DRO] Re: E-stop relay welds contacts for load dump resistor
kzf817
2011-01-30 12:53:27 UTC
Re: E-stop relay welds contacts for load dump resistor
David Speck
2011-01-30 13:08:45 UTC
Re: [CAD_CAM_EDM_DRO] Re: E-stop relay welds contacts for load dump resistor
kzf817
2011-01-30 14:09:18 UTC
Re: E-stop relay welds contacts for load dump resistor
David Speck
2011-01-30 16:51:40 UTC
Re: [CAD_CAM_EDM_DRO] Re: E-stop relay welds contacts for load dump resistor
David G. LeVine
2011-01-30 17:06:44 UTC
Re: [CAD_CAM_EDM_DRO] Re: E-stop relay welds contacts for load dump resistor
kzf817
2011-01-30 17:44:51 UTC
Re: E-stop relay welds contacts for load dump resistor
Earle Rich
2011-01-31 05:00:48 UTC
Re: E-stop relay welds contacts for load dump resistor
Dave Sage
2011-01-31 18:02:18 UTC
Re: E-stop relay welds contacts for load dump resistor
kzf817
2011-01-31 18:43:11 UTC
Re: E-stop relay welds contacts for load dump resistor
kzf817
2011-01-31 19:55:19 UTC
Re: E-stop relay welds contacts for load dump resistor
David Speck
2011-01-31 21:53:55 UTC
Re: [CAD_CAM_EDM_DRO] Re: E-stop relay welds contacts for load dump resistor
Les Newell
2011-02-01 02:15:41 UTC
Re: [CAD_CAM_EDM_DRO] Re: E-stop relay welds contacts for load dump resistor
Les Newell
2011-02-01 02:27:29 UTC
Re: [CAD_CAM_EDM_DRO] Re: E-stop relay welds contacts for load dump resistor
Randy Abernathy
2011-02-08 20:54:09 UTC
RE: [CAD_CAM_EDM_DRO] Re: E-stop relay welds contacts for load dump resistor