[Kevin Haskins]

Hey... we have a new SoftStart circuit.   I know... Hypex already makes one.   Why make another?  

The simple answer is that we needed something smaller that would fit in a new chassis design we have in the works.    The second reason is that we didn't need all the functionality of the Hypex unit.   The third and real reason is that our chassis vendor messed up on our dimensions and the Hypex unit wouldn't fit.    
 
The end result is the Exodus Softstart.   It has a grand total of seven components so it is about as simple as simple gets.   The relay is a 16A@250V unit powered by the AC mains, no need for another low-voltage supply.   In addition, the time constant for the relay is controlled by a single capacitor.   There is no active circuit with a timer.  

The end result is that we are running a 3A fast blow fuse with a 1KVA transformer and 120,000uF of capacitance.    The board is small, easy to mount and the only thing in the circuit once the relay fires is the relay.   The board traces are double sided and oversized to prevent any DC resistance other than that of the 16A relay.

Priced right at $35 populated.    You only need to connect four wires to make it function (Live IN, Neutral IN, Live OUT & Neutral OUT).

Exodus Softstart

[guest1632]

Hey... we have a new SoftStart circuit.   I know... Hypex already makes one.   Why make another?  

The simple answer is that we needed something smaller that would fit in a new chassis design we have in the works.    The second reason is that we didn't need all the functionality of the Hypex unit.   The third and real reason is that our chassis vendor messed up on our dimensions and the Hypex unit wouldn't fit.    :roll:
 
The end result is the Exodus Softstart.   It has a grand total of seven componemts. ...

Now, we're talkin.  That seems a whole lot more reasonable. Is the board populated, or is that part of the putting it all together?

Ray

[Dr. Krull]

Priced right at $35 populated. You only need to connect four wires to make it function...

Now, we're talkin.  That seems a whole lot more reasonable. Is the board populated, or is that part of the putting it all together?

Ray

My guess is that it's already populated.  Sounds like you only need to connect four wires to make it function.

-Krull

[Kevin Haskins]

It is populated and all you have to do is connect the four wires for it to work.

[guest1632]

It is populated and all you have to do is connect the four wires for it to work.

Cool!

Say, that link about your supplies, it's not there, at least it wasn't as of Saturday. Also, as a suggestion, you might see if Hypex can also offer you a supply using the BHC Tnetwork caps. They are not available here in the States. They are a faster cap than the Pansonics, more on the order of the 4 pole Jensens. Not cheap, but will help to make those modules really sing.

Ray

[Kevin Haskins]

It is populated and all you have to do is connect the four wires for it to work.

Cool!

Say, that link about your supplies, it's not there, at least it wasn't as of Saturday. Also, as a suggestion, you might see if Hypex can also offer you a supply using the BHC Tnetwork caps. They are not available here in the States. They are a faster cap than the Pansonics, more on the order of the 4 pole Jensens. Not cheap, but will help to make those modules really sing.

Ray

We ran into some problems while Q/Cing the 5-ch supplies.   It looks like the build house who populated the PCB incorrectly used 47K resistors in five positions rather than 4.7K.    

Currently I'm going through the stock of boards to try and determine if all of them where done incorrectly.   It only effects the DC protection scheme but I've pulled the 5-ch supply off the site until I get it ironed out.

I'm a sceptic until proven otherwise on the T-Network caps.  

[guest1632]

We ran into some problems while Q/Cing the 5-ch supplies.   It looks like the build house who populated the PCB incorrectly used 47K resistors in five positions rather than 4.7K.    

Currently I'm going through the stock of boards to try and determine if all of them where done incorrectly.   It only effects the DC protection scheme but I've pulled the 5-ch supply off the site until I get it ironed out.

I'm a sceptic until proven otherwise on the T-Network caps.   ;-)

I understand, but if you could get it done at least on the standard supply, or on the HG supply, frankly, there would be no need for me to build one.

Ray

[Kevin Haskins]

Hypex builds those supplies, not me so  you would need to talk to them.

Also... figure the cost of a couple of those capacitors.   Now figure that a minimum order is going to be 1000 units in order to do a production run.    Start calculating the cost for building 100 boards with them.    Calculate how much money we would have tied up in inventory and how many we would sell at the price necessary to cover our butts.    My guess is it would take your years to sell them even if they have an audible benefit.    Also consider that what is in vouge in the tweako market changes every six months so we would have a six month window of opportunity to sell them before the next best thing comes along.    

[guest1632]

Hypex builds those supplies, not me so  you would need to talk to them.

Also... figure the cost of a couple of those capacitors.   Now figure that a minimum order is going to be 1000 units in order to do a production run.    Start calculating the cost for building 100 boards with them.    Calculate how much money we would have tied up in inventory and how many we would sell at the price necessary to cover our butts.    My guess is it would take your years to sell them even if they have an audible benefit ...

Hi Kevin,

Point well taken. However, you might want to look in to getting these caps. They are slip foil. Hey, if you can get them, I definitely will buy 4 of them. You would be the importer here in the States. Oh, well, just a thought.

Ray

[Kevin Haskins]

I just don't have the money to take on another project at this date.    I'm a small company and you have to focus on one goal at a time.  

[guest1632]

I just don't have the money to take on another project at this date.    I'm a small company and you have to focus on one goal at a time.  ;-)

Now, if only, Kevin, you could produce money out of thin air, like our government does. lol. Yeah, I do  understand.

Ray

[Kevin Haskins]

They don't produce it... they borrow it.   Our kids will end up paying for our excessive spending habits.

[guest1632]

They don't produce it... they borrow it.   Our kids will end up paying for our excessive spending habits.

And backed not by gold, but thin air, ... have faith in Uncle Sam. If the government just needs more mula, they just print them bills.

Oh well, just enjoy what we have for now til the house of cards come atumblin down.

Anyway, good price on the softstart module. Hope the power supply stuff gets worked out.

Ray

[Kevin Haskins]

Update:   

The revision II of the Exodus Softstart is now in stock.    I made some changes to the PCB to increase the distance from AC traces to the mounting screws and standoff.   I'm kind of anal and paranoid about AC line rated parts for obvious reasons.   The big problem with Revision I of the PCB is that I only had 6-7mm of spacing to the standoffs and for 240V situations that was pushing it.   It could conceivably induce a current on the chassis via AC leakage across the junction which could cause ground noise in a system.   I also took the chance to simplify the design even more and increase the rating of the resistors for a larger safety margin.   

The design is pretty simple.   One resistor to set the voltage, one bridge rectifier to convert it to DC powering one coil on a relay.   The timing is determined by one capacitor and the initial voltage drop is controlled by a single 51R dropping resistor bypassed by the 240V 16A rated relay after the timer trips.  This is as simple as it gets.   Five components..... mounted on as small of a PCB as I could fit them.

[Kevin Haskins]

Here is an updated picture with the latest PCB.   



http://www.diycable.com/main/product_info.php?cPath=140&products_id=607

[JoshK]

I ordered some of these kits, I should have something to add for feedback shortly (hopefully).  Kevin is certainly easy to deal with and the price was right.