Hi Folks lets start this thread with my problems on the power supply end
First here is the list of parts going into the PS
1. 220V primary and 78V 20 AMPS secondary toroidal transformer (gives 110V after conversion to DC)
2. 50 AMPS Bridge mounted on Alu heatsink
3. 5x 5000uF 150V electrolytic caps connected in parallel to give 25000uF
4. 5x 1uF 400V film capacitors connected at the electrolytic capacitor terminals
5. 2x 1k 20W wire wound resistors - wired in series to get 2K 20 W (used as bleeder resistors)
6. Regenerative dump circuit (Henrik Design)
7. 3x Fuses 8 amps cartridge.
When I connect the powersupply transformer to the mains, the phase fuse in the main's blows, I see the fuse has only 4 to 6 strands of thin copper wire in it. I replace it and then go in for thicker wire on the fuses. then i connect again and again the fuses in the main switch blow. again there are only four copper strands connecting them, I thicken them to like 10 to 15 strands, then I connect the PS again, now the fuse (8 amps cartridge) just before the HP UHU blows, and immediately the Bridge rectifier burns out.
This time the phase fuse in the electric pole outside is gone, the 32 amps MCB did not kick in!!!!
This is what I am assuming : the toroid has a high inrush current at the start: how much can that be? is that causing the fuses to burn out?
am I using wrong components anywhere?
what is the right way to check the PS step by step?
are there any extra components I need to add to the PS for safety concerns?
find the photos attached! this problem is giving me nightmares - kindly help me solve it.