Application Note - Interpoint

Crane Aerospace & Electronics Power Solutions

Inrush Current

Crane Aerospace & Electronics Power Solutions

Inrush Current
Application Note
Although the concepts stated are universal, this application note was written specifically for Interpoint products.
The inrush current phenomenon for a PWM switching power
supply comes in two parts. The first involves the charging of
the input capacitors and/or filter elements. The second is the
power converter input current time profile which is supposed to
be controlled by the soft start circuitry which in turn controls the
PWM and charging rate of the output filter and load elements.
Each of these is discussed in the following.
1) The input power line filter may consist of a capacitor across
the power line or, more generally, a 2 or 4 pole LC differential
filter which will generally be under damped. Refer to Figure 1
for a functional example of a forward converter complete with
the input line filter. If the power is applied as a step with a rise
time of 1 s or less, the initial inrush current can be 50 amps or
more on an unlimited 28 V power bus. This could occur if power
were applied with a switch on an aircraft power bus. Where the
input filter is only a capacitor, the initial surge current will be a
single surge lasting the duration of the input step. Where an
under-damped line filter is involved, the initial inrush current will
be an exponentially damped sinusoid lasting for as long as a
few hundred s. Using a current limited supply or ramping up
the input line voltage will reduce the inrush surge amplitude.

Using a ramp with a 100 s rise time or longer will reduce the
surge currents to reasonable limits. Refer to Figures 2, 3, and 4
for examples of inrush current. Figure 5 illustrates the input filter
model used in the examples. For an input capacitor only, the 100
s ramp reduces the surge to about 1% of that where the rise
time is 1 s. Where a current limited supply is used, beware that
starting a single or several PWM supplies can cause problems
with hang-ups and possible damage to the supplies due to their
negative input impedance characteristic. Refer to the following
paragraphs for further explanation on this issue.
Figures 6 and 7 show the circuit for a simple power ramp circuit
and its starting voltage profile in response to a step application
of the 28 volt power line. The circuit utilizes a HEX 5 N channel
FET in the return line configured as an integrator controlled by
a current source. The integrator time constant is determined by
the voltage across RT, about 6 volts, and the sum of CT and the
FET Drain Gate capacitance, on the order of 1000 PF total. As
configured, the turn on voltage ramp rise time is about 200 s.
Once timed out, the FET becomes a closed switch, and is full
on with its Rds in series with the 28 volt return line. Alternately,
a P channel FET could be used in the high line with the circuit

MHD/MTR SERIES DUAL OUTPUT TYPE

VBIAS

+VIN

INPUT FILTER
+VOUT

SYNC
INH

VOUT

600 kHz
CONTROLLER

LIMITER

CMOS
DRIVER

RTN
REF AMP
CASE

MAG. COUPLER

Figure 1: Forward Converter with Input Line filter

Crane Aerospace & Electronics
Crane Electronics Group (Interpoint Brand)
PO Box 97005 Redmond WA 98073-9705
425.882.3100 electronics@craneae.com
www.craneae.com

Page 1 of 6
Rev C - 20061206

REF

COM

Crane Aerospace & Electronics Power Solutions

Inrush Current
Application Note

Power Line (Volts)

50
40
30
20
10
0

100

200

Time (s)

300

400

500

400

500

28 Volt Input 1 s Rise Time

Inrush Current (Amps)

50
30
10
10
30
50

100

200

Time (s)

300

Converter
Inrush
Current
Figure
2: 1 s
Rise
Time

re-configured to change active component polarities, or an N

channel FET source follower could be used in the high line. The
latter has the disadvantage of requiring a charge pump or other
means to provide the FET with gate enhancement above the +28
volt line.
2) The input starting current profile of the power converter will
follow that due to the filter elements by a few hundred s to a
few milliseconds, and can last from a few to tens of milliseconds.
Refer to the figures for examples. A properly designed forward

or flyback converter will have a smooth inrush profile where the

current will not exceed the normal values for a step or ramp
start similar to that discussed earlier. For a ramp or slow start,
the input current when the PWM begins to control will be on
the order of 2.5 times the normal value at 28 V, and will decline
smoothly as the line voltage comes up. This is because of the
negative input impedance characteristic where the input line
current is inversely proportional to the input line voltage. This
means that for a constant load, the product of input voltage and
current is constant as a function of line voltage except for small

Power Line (Volts)

50
40
30
20
10
0

100

200

Time (s)

300

400

500

400

500

28 Volt Input 100 s Rise Time

Inrush Current (Amps)

5
3
1
1
3
5

100

200

Time (s)

300

Converter
Inrush
Current
Figure
3: 100
s R
ise Time

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Page 2 of 6
Rev C - 20061206

Crane Aerospace & Electronics Power Solutions

Inrush Current
Application Note

Power Line (Volts)

50
40
30
20
10
0

100

200

Time (s)

300

400

500

400

500

28 Volt Input 250 s Rise Time

Inrush Current (Amps)

5
3
1
1
3
5

100

200

Time (s)

300

Converter Inrush Current

Figure 4: 250 s Rise Time

0.02
Source
0.1
Power
Source

3 H
6 F

0.02
0.001

Power
Converter

I inrush

Figure 5: Input Filter Model

differences in conduction losses over the input range. Then,

where a current limited power source is to be used, the limit
current must be set based on maximum load and the low line
starting voltage, usually 11 to 15 volts for 28 volt devices. Where
the input line is applied as a step, depending on the individual
part and type of soft start, the input current may rise monotonically rather than beginning at a high value and then decreasing
as the line voltage rises. Where this is important, it is best to
assume the latter case unless the user has proven it to be otherwise.
3) Some examples of output voltage and input current starting
profiles follow. All were taken from lab data using a step start
from a HP Model 602A, 200 watt switching power supply.

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Figure 8 shows the starting profiles for an MCH2805S flyback

converter with current mode control. This part starts at just under
12 volts and has a 0.5 watt load. The efficiency should be about
70% at this load such that the input power will be 0.71 watts.
When starting occurs at about 12 volts, the input current will be
about 0.71 watts/12 volts = 0.06 amps, in agreement with the
measured value. At 28 volts, the current decreases to 0.025
amps due to the incrementally negative input impedance. The
starting profiles with the load paralleled with 1000 fd is also
shown and is well behaved with the current mode control, but
requires some additional time to start. Also, due to the large
capacitance, there is some overshoot of output voltage. Note that
the surge for charging the input capacitor has occurred at time
zero on the graph and is not shown.

Page 3 of 6
Rev C - 20061206

Crane Aerospace & Electronics Power Solutions

Inrush Current
Application Note

Figure 9 shows the starting profiles for an MTR2805D with a

1 ohm load on the positive output only, and also a 2 ohm load
paralleled with a 2000 fd capacitor. The MTR is a voltage mode
forward converter, and the large capacitor significantly modifies
the control loop characteristics. The input current peak is defined
by the peak output power at current limit. Large capacitive loads
should be used with flyback rather than forward power converters
whenever possible, since the former doesnt have the disadvantage of a low frequency 2nd order output filter inside its control
loop.
Figure 10 shows the starting profiles for an MTR2815S with
about a 20 watt load and two different values of paralleled
capacitors. The first with a 47 fd paralleled capacitor has a
smooth and orderly starting profile. The second with a larger
207 fd capacitor shows an oscillatory behavior where starting
is controlled by the current limit loop which causes the ON/OFF
behavior on the way up. This by itself should not cause any type
of damage during startup.
Figure 11 shows the starting profile of an MHV2815DF with
nearly full load, and with an added 1000 fd capacitor across
the load. This is a continuous flyback device with current mode
control, and a good soft start. The input current is monotonic and
well behaved with and without the added capacitive load.

28 V
1N4148
62 k

RTN
1N753

Power Line (Volts)

1 Meg

2N2907

62 k

28 V
Power
Line

CT
5k
470 pF

100 pF
1N757

IRF150

Figure 6: Controlled Ramp Voltage

Starting Circuit 200 s Ramp

1) Determine the maximum continuous output power in watts.

Add a safety factor, like 30%. Then multiply by 1.3 to add the
safety factor.

2) Divide this figure by the decimal efficiency to get the maximum
input power. Look for the efficiency curves on the data sheet. If
you cant find it, use a figure like 70%, and divide by 0.7. If you
are not sure, talk to one of the Interpoint Application Engineers.

3) Now you have the maximum input power. Divide this by the
low line voltage at which the PWM starts working to get the
maximum input current you will need. You can determine this
voltage on the bench by turning the power source voltage up
slowly and monitoring the power converter
50
output. You may want to apply an additional
40
safety factor like maybe 10%. Do this by multiplying the low line starting voltage by 0.9. Now
30
divide this voltage into the maximum input
20
power you found in step 2), and you have the
10
maximum current you will require. If several
power converters are involved, go through
0
100
200
300
400
500
the previous procedure on each, and then
Time (s)
add the line currents. The answer you get is
28 Volt Input
30
the minimum current capacity you need from
your power source at current limit. If you get
24
an answer like 7.5 amps, then the actual line
18
current at 28 volts will be more like 3.5 amps
due to the negative input impedance charac12
teristics of the power converters. If you have a
6
supply with an adjustable current limit, be sure
0
to set the limit at 7.5 amps or more, not the 3.5
100
200
300
400
500
Switch closed
Time (s)
amp normal line voltage operating current. The
Voltage across FET
lower current limit may cause hang-ups and
Figure 7: Voltage Across NCH FET in Ramp Start Circuit
damage to the supplies.

If you are using Interpoint power converters, make sure the

power source is large enough for starting as well as for continuous operation. For starting, the following procedure should work
safely.

Voltage Across IRF150 (Volts)

PWM
Converter

RT

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Page 4 of 6
Rev C - 20061206

Crane Aerospace & Electronics Power Solutions

Inrush Current
Application Note

50 load only

VOUT (Volts)

Output Voltage (Volts)

50 load paralleled with 1000 F

1 load only

2 load paralleled with 2000 F

(similar results with 1 load
paralleled with 2000 F)

0
0

10

15

20

25

30

0.08

Input Line Current (Amps)

Input Line Current (Amps)

0.10

50 load only

Time (ms)

Time (ms)

50 load paralleled with 1000 F

0.06

0.04

2 load paralleled with 2000 F

(similar results with 1 load
paralleled with 2000 F)

0.02

0.00

1 load only
0

10

15

20

25

30

Time (ms)

Time (ms)

Full Filter Board with 2 ohm damper

Step start at 28 V, load on +5 only

MTR2805D SN 0044

Figure 9: Starting Profile MTR2805D

MCH2805S SN 0081

Figure 8: Starting Profile MCH2805S

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Page 5 of 6
Rev C - 20061206

Crane Aerospace & Electronics Power Solutions

Inrush Current
Application Note

20

20

11 load paralleled
with 47 F

13.9 V

15

VOUT (Volts)

VOUT (Volts)

15

11 load paralleled with 207 F

10

15 load

10

15 load paralleled
with 1000 F

0
0

10

12

1.0

0.8

Oscillatory

Input Line Current (Amps)

Input Line Current (Amps)

Time (ms)

Time (ms)

3
11 load paralleled with 207 F
2

0.6 A

0.6

15 load

0.4

15 load paralleled
with 1000 F

0.2

1
11 load paralleled
with 47 F
0

0.0
0

10

12

Time (ms)

Time (ms)
28 V

Profile on +15 V output only, 28 V

start
Inrush current is measured across a 0.1 resistor in series with input return.

start

MTR2815S SN 0068

Figure 10: Starting Profile MTR2815S

MHV2815DF SN 0012

Figure 11: Starting Profile MHV2815DF

Inrush Current Rev C - 20061206

All information is believed to be accurate, but no responsibility is assumed for errors or omissions. Interpoint reserves the right to
make changes in products or specifications without notice. Copyright 1999 - 2006 Interpoint Corporation. All rights reserved.

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