bonitron M3628PUD User manual

Web: www.bonitron.com ● Tel: [phone] ● Email: [email protected]
Model M3628PUD
Ultracapacitor Discharge Module
Customer Reference Manual

Bonitron, Inc.
2
Bonitron, Inc.
Nashville, TN
An industry leader in providing solutions for AC drives.
ABOUT BONITRON
Bonitron designs and manufactures quality industrial electronics that improve the reliability of
processes and variable frequency drives worldwide. With products in numerous industries, and
an educated and experienced team of engineers, Bonitron has seen thousands of products
engineered since 1962 and welcomes custom applications.
With engineering, production, and testing all in the same facility, Bonitron is able to ensure its
products are of the utmost quality and ready to be applied to your application.
The Bonitron engineering team has the background and expertise necessary to design, develop,
and manufacture the quality industrial electronic systems demanded in today’s market. A strong
academic background supported by continuing education is complemented by many years of
hands-on field experience. A clear advantage Bonitron has over many competitors is combined
on-site engineering labs and manufacturing facilities, which allows the engineering team to have
immediate access to testing and manufacturing. This not only saves time during prototype
development, but also is essential to providing only the highest quality products.
The sales and marketing teams work closely with engineering to provide up-to-date information
and provide remarkable customer support to make sure you receive the best solution for your
application. Thanks to this combination of quality products and superior customer support,
Bonitron has products installed in critical applications worldwide.

Bonitron, Inc.
3
AC DRIVE OPTIONS
In 1975, Bonitron began working with AC inverter drive specialists at synthetic fiber plants to
develop speed control systems that could be interfaced with their plant process computers. Ever
since, Bonitron has developed AC drive options that solve application issues associated with
modern AC variable frequency drives and aid in reducing drive faults. Below is a sampling of
Bonitron’s current product offering.
WORLD CLASS PRODUCTS
Undervoltage Solutions
Overvoltage Solutions
Uninterruptible Power for Drives
(DC Bus Ride-Thru)
Voltage Regulators
Chargers and Dischargers
Energy Storage
Braking Transistors
Braking Resistors
Transistor/Resistor Combo
Line Regeneration
Dynamic Braking for Servo Drives
Common Bus Solutions
Portable Maintenance Solutions
Single Phase Power Supplies
3-Phase Power Supplies
Common Bus Diodes
Capacitor Formers
Capacitor Testers
Power Quality Solutions
Green Solutions
12 and 18 Pulse Kits
Line Regeneration

M3628PUD
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Table of Contents
5
1. INTRODUCTION .............................................................................................................................................7
1.1. Who Should Use..................................................................................................................................7
1.2. Purpose and Scope...............................................................................................................................7
1.3. Manual Version and Change Record...................................................................................................7
Figure 1-1: M3628PUD.....................................................................................................................7
1.4. Symbol Conventions Used in this Manual and on Equipment ............................................................8
2. PRODUCT DESCRIPTION ...............................................................................................................................9
2.1. Related Products..................................................................................................................................9
2.2. Part Number Breakdown ...................................................................................................................10
Figure 2-1: Example of Part Number Breakdown ...........................................................................10
Table 2-1: Capacitor Voltage...........................................................................................................10
Table 2-2: Capacitance Rating.........................................................................................................10
2.3. General Specifications.......................................................................................................................12
Table 2-3: General Specifications Table..........................................................................................12
General Precautions and Safety Warnings...................................................................................................13
3. INSTALLATION INSTRUCTIONS...................................................................................................................14
3.1. Environment ......................................................................................................................................14
3.2. Wiring and Customer Connections....................................................................................................14
3.2.1. Power Wiring..............................................................................................................................14
Figure 3-1: M3628PUD...................................................................................................................14
3.2.1. Discharge Connections ...............................................................................................................14
3.2.2. Source Considerations ................................................................................................................15
4. OPERATION .................................................................................................................................................16
4.1. Functional Description.......................................................................................................................16
The M3628PUD module is powered by plugging in the 120V or the 240V line cord. The module uses a
switch to close a DC contactor across an internal resistor. When the switch is placed in the
“DISCHARGE ON” position, the voltage on the Ultra-capacitor module will decrease to a safe level
within 60 seconds. Once the digital display indicateS that the capacitor is drained, the discharge
switch can be placed in the “DISCHARGE OFF” position until the exhaust air from the discharger
is close to ambient room temperature................................................................................................16
4.2. Circuit Schematic...............................................................................................................................16
Figure 4-1: M3628UMT Schematic.................................................................................................16
4.3. Hardware Features.............................................................................................................................17
4.3.1. AC Power Input Connector.........................................................................................................17
4.3.2. Power Switch / Circuit Breaker ..................................................................................................17
4.3.3. Discharge switch.........................................................................................................................17
4.3.4. DC Capacitor Connectors ...........................................................................................................17
4.3.5. Display........................................................................................................................................17
4.3.6. Discharge Resistor......................................................................................................................17
4.3.7. Cooling fan .................................................................................................................................17
5. STARTUP AND TROUBLESHOOTING............................................................................................................18
5.1.1. Pre-power checks........................................................................................................................18
5.1.2. Discharge Procedure...................................................................................................................18
5.2. Troubleshooting.................................................................................................................................19
Table 5-1: Discharge System Troubleshooting................................................................................19
6. ENGINEERING DATA ...................................................................................................................................20
6.1. Ratings Chart.....................................................................................................................................20
Table 6-1: Ratings Chart..................................................................................................................20
Table 6-2: Dimensions.....................................................................................................................20

M3628PUD
6

User’s Manual
7
1. INTRODUCTION
1.1. WHO SHOULD USE
This manual is intended for use by trained personnel responsible for maintaining or
testing ultra-capacitor cells and modules.
Please keep this manual for future reference.
1.2. PURPOSE AND SCOPE
This manual is a user’s guide for the model M3628PUD. It will provide the user with
the necessary information to successfully connect and operate the M3628PUD.
In the event of any conflict between this document and any publication and/or
documentation related to any associated hardware (capacitor bank, etc.), the latter
shall have precedence.
1.3. MANUAL VERSION AND CHANGE RECORD
The initial release for this module is Rev 00a.
Added info about the 96V 83 farad module in Rev 00b.
Figure 1-1: M3628PUD

M3628PUD
8
1.4. SYMBOL CONVENTIONS USED IN THIS MANUAL AND ON
EQUIPMENT
Earth Ground or Protective Earth
AC Voltage
DC Voltage
DANGER!
DANGER: Electrical hazard - Identifies a statement that indicates
a shock or electrocution hazard that must be avoided.
DANGER!
DANGER: Identifies information about practices or circumstances
that can lead to personal injury or death, property damage, or
economic loss.
CAUTION!
CAUTION: Identifies information about practices or circumstances
that can lead to property damage, or economic loss. Attentions
help you identify a potential hazard, avoid a hazard, and
recognize the consequences.
CAUTION!
CAUTION: Heat or burn hazard - Identifies a statement regarding
heat production or a burn hazard that should be avoided.

User’s Manual
9
2. PRODUCT DESCRIPTION
The M3628PUD portable discharger is designed to deplete energy stored in Ultra cap
modules for industrial power use. The unit can be powered from the supplied 115vac line
cord or the supplied 230vac line cord. This portable discharger contains DC contactor
and resistor element to discharge the capacitor, with 6’ leads to the capacitor terminal and
6’ power cord. The discharger module also contains a digital display for capacitor voltage
and a temperature sensor for safety. The unit is equipped with a fan for cooling theresistor
element and is capable of a full discharge cycle every 2 minutes with the fan running.
2.1. RELATED PRODUCTS
M5628 ULTRA CAPACITOR/BATTERY CHARGER
The M5628 charger can charge strings of batteries or ultra-capacitors to voltages
required for industrial and commercial applications. The charger is current limited, and
designed for use in integrated storage and backup systems, but can also be used in
bench or mobile systems.
KIT 3628T ULTRA CAPACITOR STRING DISCHARGER
Large capacitor banks store huge amounts of energy, and can be a hazard when
systems are shut down for system maintenance. The KIT 3628T system discharges
capacitor banks to safe working levels quickly, allowing work on the system to begin
in seconds, rather than hours.
M3628UMT ULTRA CAPACITOR MODULE TESTER
The M3628UMT is a portable, digitally controlled DC power supply and capacitor test
system with a variable output voltage and current limit. It can perform accurate,
informative measurements of an ultra-capacitor’s capacitance and ESR.
M3628ACF AUTOMATIC CAPACITOR FORMER
The M3628ACF automatic capacitor former can be used to reform capacitor banks as
large as 150 kJ. The output voltage is programable between 0 and 1000 VDC, and is
capable of supplying 1 ADC continuously.

M3628PUD
10
2.2. PART NUMBER BREAKDOWN
Figure 2-1: Example of Part Number Breakdown
BASE MODEL NUMBER
The base model number for all Ultra-Capacitor Discharge Module is M3628PUD.
CAPACITOR VOLTAGE RATING
The Capacitor Voltage rating indicates the DC voltage rating for each capacitor
module, the most common ratings are 16V, 48V, 96V and 160V. A three-digit code
represents the capacitor voltage.
Table 2-1: Capacitor Voltage
RATING CODE
DC DISCHARGE VOLTAGE
016
16V (18V MAX)
048
48V (56V MAX)
096
96V(108V MAX)
160
160V (180V Max)
CAPACITANCE RATING
A three digit code represents the module capacitance.
Table 2-2: Capacitance Rating
RATING CODE
FARAD
006
5.8F –6F
058
58F –62F
083
83F
166
165F –166F
500
500F
M3628PUD
160
BASE MODEL NUMBER
CAPACITOR VOLTAGE
CAPACITANCE
006

User’s Manual
11

M3628PUD
12
2.3. GENERAL SPECIFICATIONS
Table 2-3: General Specifications Table
PARAMETER
SPECIFICATION
Input Voltage
85-264 VAC 1Ø 52 watts Max
Cooling
Forced Air
Display
3.5 Digit LED Display
Operating Temp Range
0°C to + 40°C
Storage Temp
-20°C to + 65°C
Humidity
Below 90% non-condensing
Atmosphere
Free of corrosive gas and conductive dust

User’s Manual
13
GENERAL PRECAUTIONS AND SAFETY WARNINGS
ELECTROCUTION
HAZARD!
•THIS UNIT PRODUCES VOLTAGES CAPABLE OF CAUSING
INJURY OR DEATH!
•FOR USE BY QUALIFIED AND TRAINED PERSONNEL ONLY!
•IMPROPER OPERATION OF THE PRODUCT OR
IGNORING THESE WARNINGS MAY RESULT IN
SERIOUS BODILY INJURY OR DEATH!
•BEFORE CONNECTING THE M3628PUD TO A CAPACITOR,
ENSURE THAT THE CAP MODULE IS DRY THEN MEASURE THE
VOLTAGE USING VOLTMETER.
•CONNECTING THE M3628PUD’S VOLTAGE CABLE TO A CAP
WITH THE POLARITY REVERSED CAN CAUSE DAMAGE TO
YOUR CAP AND POTENTIALLY THE EQUIPMENT.ENSURE THAT
THE POSITIVE AND NEGATIVE TERMINALS ON BOTH SIDES ARE
POSITIVELY IDENTIFIED AND CORRECTLY CONNECTED
BEFORE OPERATION.
•BEFORE POWERING UP THE MODULE,MAKE SURE THE
DISCHARGE SWITCH IS IN (OFF) POSITION.
•NEVER OPERATE THIS PRODUCT WITH THE ENCLOSURE
COVER REMOVED.
DANGER!
•NEVER ATTEMPT TO SERVICE THIS PRODUCT.
•CERTAIN PARTS INSIDE THIS PRODUCT MAY GET HOT DURING
OPERATION.
•BEFORE CONNECTING THIS DEVICE TO ANY OTHER PRODUCT,
BE SURE TO REVIEW ALL DOCUMENTATION OF THAT PRODUCT
FOR PERTINENT SAFETY PRECAUTIONS.
ANY QUESTIONS AS TO APPLICATION, INSTALLATION, OR SERVICE
SAFETY SHOULD BE DIRECTED TO THE EQUIPMENT SUPPLIER.

M3628PUD
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3. INSTALLATION INSTRUCTIONS
3.1. ENVIRONMENT
While closed, the M3628PUD is water, dust, and crush resistant. When open and in
operation, the unit should be used only in dry, clean areas. Ensure that the interior of
the unit casing is kept dry.
3.2. WIRING AND CUSTOMER CONNECTIONS
3.2.1. POWER WIRING
The Power Input connector accepts 50-60Hz from the standard C13 power
cable. The unit will include the standard 120 VAC cable and the 240VAC
cable .
Figure 3-1: M3628PUD
3.2.1. DISCHARGE CONNECTIONS
The DC connections are POWERPOLE type connections. The M3638PUD-
096-083, M3628PUD-048-166 and M3628PUD-016-500 units uses
POWERPOLE PP75 connector. The M3628PUD-016-058 and
M3628PUD-160-006 units use POWERPOLE 45 connectors. The included
discharge cable will be six feet long with alligator clips at the end.

User’s Manual
15
3.2.2. SOURCE CONSIDERATIONS
Input voltage should not exceed the rating—264VAC or damage to the unit
may result. To guarantee correct system operation at all output voltages,
the source must be capable of supplying at least 0.95 amps for 120VAC
supply or 0.56 amps for a 240VAC supply. Failure to meet the minimum
current requirement may result in improper operation. Connecting the unit
to an input voltage other than that specified on the unit faceplate may also
result in improper operation or damage to the unit.

M3628PUD
16
4. OPERATION
4.1. FUNCTIONAL DESCRIPTION
The M3628PUD module is powered by plugging in the 120V or the 240V line cord.
The module uses a switch to close a DC contactor across an internal resistor. When
the switch is placed in the “DISCHARGE ON” position, the voltage on the Ultra-
capacitor module will decrease to a safe level within 60 seconds. Once the digital
display indicates that the capacitor is drained, the discharge switch can be placed in
the “DISCHARGE OFF” position until the exhaust air from the discharger is close to
ambient room temperature.
4.2. CIRCUIT SCHEMATIC
Electrically, the M3628PUD is a bleeding resistorand a DC contactor that are manually
controlled by the Discharge switch . Additionally, the AC line input feeds an internal
DC power supply. A temperature switch is installed near the resistor to stop the
discharge process in case the unit overheats. If the unit overheats, the temp switch
will open causing the contactor to open and stop discharging. once the unit cools
down, the temp switch closes and the unit will go back to normal operation.
Figure 4-1: M3628UMT Schematic

User’s Manual
17
4.3. HARDWARE FEATURES
4.3.1. AC POWER INPUT CONNECTOR
The M3628PUD is equipped with a standard IEC C14 connector for input
power. This connector mates with a standard C13 cable, commonly used with
desktop computers, to provide power to the unit
4.3.2. POWER SWITCH /CIRCUIT BREAKER
The AC Power Switch also acts as a circuit breaker to protect from overload
conditions. If the breaker is tripped, you can reset it by simply turning the
switch off, then back on
4.3.3. DISCHARGE SWITCH
When the discharge switch is ON, the contactor will close putting the internal
resistor across the Ultra-cap module and the unit will drain the energy stored
in the cap within sixty seconds. The M3628PUD-096-083 will drain the energy
stored in the cap within three hundred seconds.
4.3.4. DC CAPACITOR CONNECTORS
The M3638PUD-096-083, M3628PUD-048-166 and M3628PUD-016-500
units are equipped with Four PowerPole PP75 connectors, M3628PUD-016-
058 and M3628PUD-160-006 units are equipped with two PowerPole PP45
connectors. The standard cables shipped with the system includes six foot
long wires and two high-current alligator clips to allow the user to discharge
the Ultra-Capacitor module.
4.3.5. DISPLAY
The digital display shows the present DC voltage on the Ultra-capacitor
module.
4.3.6. DISCHARGE RESISTOR
The discharge resistor is designed to drain the energy stored in the Ultra-cap
module within sixty seconds.
4.3.7. COOLING FAN
The internal fan run for continued cooling of the resistor element. Cooling
back to room temperature may take up to 3 minutes after one full discharge
cycle.

M3628PUD
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5. STARTUP AND TROUBLESHOOTING
5.1.1. PRE-POWER CHECKS
•Ensure DC is securely fastened to the plug.
•Ensure DC bus polarity is correct.
•Plug power cord into the 120/240VAC outlet.
•Turn ON discharge switch and ensure the contactor closes in DISCHARGE
position only.
•Turn switch to OFF position.
5.1.2. DISCHARGE PROCEDURE
CAUTION
Ensure the voltage rating of the system before connecting to cap
module! Unit is designed for 1 minute drain of properly sized Ultra-
Capacitor module.
WARNING
Ensure M3628PUD switch is in the OFF position BEFORE
connecting discharge cables to system.
Connect cables one at a time, keeping one hand on the plug and
the rest of your body away from any other potential or grounded
surface. For additional safety, stand on insulated surface when
connecting plugs.
1. Disconnect any source that charges the ultra-capacitors.
2. Ensure that DISCHARGE switch is in the off position.
3. Connect the alligator clips to the ultra-capacitor.
4. Turn DISCHARGE switch to ON position.
▪Storage voltage should begin to decrease.
▪Load resistor will begin to heat up.
▪In approximately 1 minute the cap storage voltage should be around
5% to 10% of the cap voltage.
▪The M3628PUD will continue to drain cap bank as long as the unit is
in DISCHARGE mode.
5. If excessive heat is noticed, the discharge cycle can be aborted by turning
the DISCHARGE switch to OFF position at any time during the discharge
cycle.
▪Internal temp sensor will automatically stop discharging in case of over
temperature

User’s Manual
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5.2. TROUBLESHOOTING
Repairs or modifications to this equipment are to be performed by Bonitron approved
personnel only. Any repair or modification to this equipment by personnel not approved
by Bonitron will void any warranty remaining on this unit.
Table 5-1: Discharge System Troubleshooting
SYMPTOM
ACTION
Unit will not discharge
Capacitor
•Ensure switch is in the DISCHARGE position
•Ensure the Ultra-capacitor is properly connected
•Measure actual DC voltage across the cap
•Ensure the display voltage is accurate
Unit will not allow
Capacitor to charge
•Ensure Discharge switch is in OFF position
•Ensure proper connection to the M3628PUD module
No Display voltage
•Ensure power cord is plugged in to a 120/240VAC outlet
•Ensure power switch in ON and it is not tripped.
•Ensure all connectors are in place.
OVER-TEMP
•Measure temperature of the front panel
•Measure temperature of resistor element.
•If above 50°C, allow time to cool
Fan not running
•Ensure power cord is plugged in to a 120/240VAC outlet
•Ensure power switch in ON and it is not tripped.
DANGER!
Always monitor the output voltage while operating the unit. Ensure that the
attached loads do not exceed their rated voltage, as catastrophic damage,
injury, or death may occur.

M3628PUD
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6. ENGINEERING DATA
6.1. RATINGS CHART
Table 6-1: Ratings Chart
BONITRON PART
NUMBER
DC VOLTAGE
RATING
MAX DISCHARGE
CURRENT
RESISTANCE
MAX DISCHARGE
TIME
CONTINUOUS
WATTAGE
M3628PUD-016-058
16 VDC
32A
0.5 Ohm
60 Seconds
100 W
M3628PUD-016-500
16 VDC
307A
0.09 Ohm
60 Seconds
500W
M3628PUD-048-166
48VDC
288A
0.16 Ohm
60 Seconds
1200 W
M3628PUD-096-166
96VDC
80A
1.2 Ohm
300 Minutes
1200 W
M3628PUD-160-006
160 VDC
36A
5.0 Ohm
60 Seconds
400 W
Table 6-2: Dimensions
BONITRON PART
NUMBER
OVERALL
(INCHES)
WEIGHT
(LBS.)
HEIGHT
WIDTH
DEPTH
M3628PUD-016-058
13.4
11.6
6.0
9
M3628PUD-016-500
16.4
13.0
6.8
19
M3628PUD-048-166
22.0
13.8
9.0
32
M3628PUD-096-083
22.0
13.8
9.0
32
M3628PUD-160-006
16.4
13.0
6.8
16