bonitron M3628ACF User manual

Web: www.bonitron.com ●Tel: [phone] ●Email: [email protected]m
Model M3628ACF
Automatic Capacitor Former
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

M3628ACF
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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: M3628ACF ..............................................................................................................7
1.4. Symbol Conventions Used in this Manual and on Equipment.....................................................8
2. PRODUCT DESCRIPTION /FEATURES........................................................................................9
2.1. Related Products........................................................................................................................... 9
2.2. Part Number Breakdown ............................................................................................................10
Figure 2-1: Example of Part Number Breakdown ....................................................................10
Table 2-1: Max Output Voltage................................................................................................ 10
Table 2-2: Input Voltage...........................................................................................................10
2.3. General Specifications................................................................................................................11
Table 2-3: General Specifications Table...................................................................................11
2.4. General Precautions and Safety Warnings .................................................................................12
3. INSTALLATION INSTRUCTIONS................................................................................................13
3.1. Environment ...............................................................................................................................13
3.2. Wiring and Customer Connections.............................................................................................13
3.2.1. Power Wiring.......................................................................................................................13
Figure 3-1: M3628ACF ............................................................................................................13
3.2.2. Source Considerations..........................................................................................................13
4. OPERATION..............................................................................................................................15
4.1. Functional Description ...............................................................................................................15
4.2. Features....................................................................................................................................... 16
4.2.1. Hardware..............................................................................................................................16
4.2.2. Screens & Menu Navigation................................................................................................17
Figure 4-2: M3628ACF Charging Profile.................................................................................17
Figure 4-3: M3628ACF Interface Screen Tree.........................................................................18
5. TROUBLESHOOTING ................................................................................................................21
Table 5-1: Troubleshooting....................................................................................................... 21
6. ENGINEERING DATA................................................................................................................23
6.1. Ratings Chart..............................................................................................................................23
Table 6-1: Ratings Chart...........................................................................................................23
Table 6-2: Dimensions..............................................................................................................23
6.2. Block Diagram............................................................................................................................23
7. APPENDIX.................................................................................................................................25
7.1. Application Notes....................................................................................................................... 25
7.1.1. Typical Capacitor Bank Forming / Testing Procedure.........................................................25

M3628ACF
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User’s Manual
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1. INTRODUCTION
1.1. WHO SHOULD USE
This manual is intended for use by trained personnel responsible for maintaining or
testing capacitor banks.
Please keep this manual for future reference.
1.2. PURPOSE AND SCOPE
This manual is a user’s guide for the model M3628ACF. It will provide the user with
the necessary information to successfully connect and operate the M3628ACF.
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.
Updates to the Menu Tree were added in Rev 00b.
Figure 1-1: M3628ACF

M3628ACF
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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
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2. PRODUCT DESCRIPTION / FEATURES
As capacitors age and wear, their internal chemistries change, leading to a decrease in
capacitance. It is important to be able to measure this capacitance, and thus estimate the
remaining useful life of your capacitor bank. This can help reduce expensive pre-emptive
replacement. Capacitors stored for long periods of time also display chemistry changes,
which may cause them to fail if full voltage is suddenly applied.
The Bonitron M3628ACF is a portable, digitally controlled DC power supply with a variable
output voltage and current limiting. The digital display indicates the current status and
charging profile as well as the calculated capacitance. This product may be used for many
purposes, including charging, discharging and forming of capacitors.
2.1. RELATED PRODUCTS
M3528 ULTRA CAPACITOR/BATTERY CHARGER
The M3528 charger can charge strings of batteries or ultra capacitors to voltages
required for industrial and commercial applications. AC or DC input is available, along
with separate float and equalization charge levels. 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 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.
M3628PCFPORTABLE CAPACITOR FORMER
The M3628 portable capacitor former can be used to charge or discharge capacitor
banks as large as 50 kJ. The output voltage is manually variable between 0 and 800
VDC, and the system is capable of supplying 1 ADC continuously. The unit can also
be used for reforming disused capacitors.
M3628PUT PORTABLE ULTRACAPACITOR TESTER
The M3628PUT portable ultracapacitor tester can be used to charge, discharge, and
measure ultracapacitors as large as 500 kJ. The output voltage can be set to between
0 and 130 VDC, and the unit is capable of supplying up to 7 ADC. After discharging,
the unit reports the capacitance and ESR of the ultracapacitor.

M3628ACF
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2.2. PART NUMBER BREAKDOWN
Figure 2-1: Example of Part Number Breakdown
BASE MODEL NUMBER
The base model number for all Automatic Capacitor Formers is M3628ACF.
MAX OUTPUT VOLTAGE RATING
The max output Voltage rating indicates the maximum DC output voltage the unit can
supply. The max output voltage is indicated by a code letter.
Table 2-1: Max Output Voltage
RATING CODE
VOLTAGES
(DC VOLTAGE OUTPUT)
Y
1000VDC out
MAX OUTPUT CURRENT RATING
The max output current rating indicates the maximum DC current the unit can supply
at its maximum voltage.
INPUT VOLTAGE
A three digit code represents the input voltage that should be used.
Table 2-2: Input Voltage
RATING CODE
INPUT VOLTAGE
120
110-120 VAC
240
220-240 VAC
M3628ACF
Y
01
BASE MODEL NUMBER
MAX OUTPUT VOLTAGE
MAX OUTPUT CURRENT
INPUT VOLTAGE
120

User’s Manual
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2.3. GENERAL SPECIFICATIONS
Table 2-3: General Specifications Table
PARAMETER
SPECIFICATION
Input Voltage
110-120 VAC 1Ø
220-240 VAC 1Ø
Output Voltage
0-1000VDC
Output Current
0-1ADC
Maximum Load Capacitance
300,000uF
Maximum Discharging Time
20 minutes
Controls
Six display soft keys
Display
Four line, eighty character LCD (4x20)
Unit Size (H x W x D)
22.0" x 13.9" x 9.0"
Weight
49 lbs.
Storage Temp
-20°C to + 65°C
Humidity
Below 90% non-condensing
Atmosphere
Free of corrosive gas and conductive dust

M3628ACF
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2.4. 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 M3628ACF TO A CAPACITOR BANK,
ENSURE THAT THE BANK IS FULLY DISCHARGED BY CHECKING
WITH A VOLTMETER.
•CONNECTING THE M3628ACF’S VOLTAGE OUTPUT TO A LOAD
WITH THE POLARITY REVERSED CAN CAUSE DAMAGE TO YOUR
EQUIPMENT AND POTENTIALLY CREATE A FIRE OR EXPLOSION
HAZARD,THREATENING LIVES.ENSURE THAT THE POSITIVE AND
NEGATIVE TERMINALS ON BOTH THE SOURCE AND LOAD ARE
POSITIVELY IDENTIFIED AND CORRECTLY CONNECTED BEFORE
OPERATION.
•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.

User’s Manual
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3. INSTALLATION INSTRUCTIONS
3.1. ENVIRONMENT
While closed, the M3628ACF 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 included standard C13
power cable. The DC Output connectors supply DC voltage at the user-
selected level via a pair of banana connectors. Output leads can be
constructed as needed.
The unit should be powered ON before connecting to a load, as the unit is in
discharge mode when powered off.
Figure 3-1: M3628ACF
3.2.2. SOURCE CONSIDERATIONS
Input voltage should not exceed 120VAC / 240VAC or damage to the unit
may result. The source must be capable of supplying at least seven (7)
amps to guarantee correct system operation at all output voltages.

M3628ACF
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User’s Manual
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4. OPERATION
4.1. FUNCTIONAL DESCRIPTION
The M3628ACF is a digitally controlled DC supply capable of sourcing between 100
mA and 1A, at voltages between 0 and 1000 volts. Actual available charge current
depends on load voltage. The unit is powered by standard 50-60 Hz 110-120 VAC or
220-240 VAC. The user may select to charge the capacitor to a specified voltage with
a specified current limit. The user may then discharge the capacitor, after which the
ACF will display a measurement of its capacitance. Alternately, the user may initiate a
forming profile with defined current limits, step voltages, and hold times before the unit
automatically discharges the load. (Figure 4.2) The Cancel button will act as an
immediate discharge button in case of accidental overvoltage. The unit automatically
enters discharge mode when powered off.
NOTE!
If the non-capacitive system load, including leakage current and bleeder
resistors, is higher than the current shown in the above chart, the M3628ACF
may not be able to charge to the full specified voltage. It may be necessary to
disconnect bleeder resistors to obtain a full charge.

M3628ACF
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4.2. FEATURES
4.2.1. HARDWARE
4.2.1.1. AC POWER INPUT CONNECTOR
The M3628ACF 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.
4.2.1.2. DC OUTPUT CONNECTORS
Two banana jacks provide the user with DC output voltage between 0 and
1000VDC. These connectors accept standard 4mm banana plugs.
4.2.1.3. DISPLAY
The digital display presents the user with information about the present
status of the system, including the output voltage and current. The display
also presents the user with options to control system operation, including
charging and discharging attached capacitors.
4.2.1.4. DIRECTIONAL BUTTONS
Each of the four buttons corresponds to a direction, up, down, left or right.
Up and down move the cursor among menu items. On screens where
numbers are input by the user, the left and right buttons move the cursor,
while the up and down buttons change the selected digits. On some
screens, certain buttons may have no function at all.
4.2.1.5. ENTER AND CANCEL BUTTON
The green enter button selects menu options. On a menu screen, the
cancel button will return you to the previous menu. While a standard
charge or profile charge is active, the cancel button will act as an
immediate discharge button.
4.2.1.6. VOLTAGE PRESENT INDICATOR
DANGER!
Do not use this light as an indication that the output is safe to work on!
Always check the output with a working voltmeter before servicing
equipment, as the lamp may be malfunctioning!
ELECTROCUTION HAZARD! This unit produces dangerous levels of
voltage that can cause injury or death. Always follow safety protocolswhen
working with high voltages!
A red light indicates that there is voltage on the DC output of the unit. Do
not touch the output connectors or the attached equipment while this light
is on, as electric shock will result.
4.2.1.7. POWER SWITCH /CIRCUIT BREAKER
The 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 back on.

User’s Manual
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4.2.2. SCREENS &MENU NAVIGATION
Many screens are menus allowing access to other screens, or lists presenting
a number of options. The presently selected item on the menu is indicated by
a ‘>’ cursor. This selection indicator is moved using the up and down buttons.
If a line on the menu represents another screen, that screen is accessed with
the Enter button. The Cancel button will return the display to the parent
screen. See Figure 4-3.
4.2.2.1. MAIN MENU
The Charge menu, Discharge Confirmation screen, and previous
measurement Results may be accessed from the Main Menu.
4.2.2.1.1. CHARGING PROFILE
From the Charge Menu, the user may input the variables
necessary to execute an automatic forming profile. A forming
profile charges the capacitor in steps, eachstep a specified voltage
apart. When each step voltage is reached, the load is held at that
voltage for a specified number of seconds before charging to the
next step voltage. When the final voltage is reached, the load is
held at that voltage for a specified number of seconds before
discharging. Voltage setpoints may vary by up to ±10V. See Figure
4-2.
Figure 4-1: M3628ACF Charging Profile

M3628ACF
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Figure 4-2: M3628ACF Interface Screen Tree
STEP VOLTAGE
CURRENT
HOLD TIME
SET STEP
CONFIRM NO
RESULTS
MENU
MAIN
RESULTS
DISCHARGE
CHARGE PROFILE
CHARGE CAP
CONFIRM
DISCHARGE NO
YES DISCHARGING
SET VOLTAGE
MENU
BASIC CHARGE
START CHARGING
SET CURRENT
CONFIRM
CHARGE YES
NO
SET
VOLTAGE
MENU
PROFILE CHARGE
SET FINAL HOLD TIME
SET STEP VOLTAGE
SET FINAL VOLTAGE
SET CHARGE CURRENT
SET STEP HOLD TIME
START CHARGING CHARGE YES
HOLD TIME
SET FINAL
SET
FINAL VOLTAGE
CHARGING
SET
CURRENT
SET
SET

User’s Manual
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4.2.2.1.1.1. SET FINAL VOLTAGE
From this screen the user may set the final voltage they wish
to charge the load to. The right and left buttons control which
digit is presently being edited, and the up and down buttons
increment or decrement that digit. Pressing Enter will exit this
screen and save the voltage.
4.2.2.1.1.2. SET STEP VOLTAGE
From this screen the user may set the voltage step by which
the load will approach the final voltage. The right and left
buttons control which digit is presently being edited, and the
up and down buttons increment or decrement that digit.
Pressing Enter will exit this screen and save the voltage.
4.2.2.1.1.3. SET CURRENT
From this screen the user may set the maximum current with
which they wish to charge the load. The right and left buttons
control which digit is presently being edited, and the up and
down buttons increment or decrement that digit. Pressing
Enter will exit this screen and save the current.
4.2.2.1.1.4. SET STEP HOLD TIME
From this screen the user may set the number of minutes
each step voltage will be held. The right and left buttons
control which digit is presently being edited, and the up and
down buttons increment or decrement that digit. Pressing
Enter will exit this screen and save the hold time.
The maximum step time is 999 minutes or about 16 hours and
39 min.
4.2.2.1.1.5. SET FINAL HOLD TIME
From this screen the user may set the number of seconds the
final voltage will be held. The right and left buttons control
which digit is presently being edited, and the up and down
buttons increment or decrement that digit. Pressing Enter will
exit this screen and save the hold time.
The maximum final hold time is 999 minutes or about 16
hours and 39 min.
4.2.2.1.1.6. CHARGE CONFIRM
At this screen the user is asked to confirm the charge voltage
and current, and begin charging the output.
4.2.2.1.1.6.1. CHARGING
This screen displays the present output voltage and
current. It transitions to the "Discharging" screen
(4.2.2.1.3.1.) when the output voltage reaches the
set point and is held for the specified number of
seconds. Charging may be aborted by pressing the
Cancel button.

M3628ACF
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4.2.2.1.2. CHARGE MENU
The user may set the charge voltage and current, and initiate
charging from here.
4.2.2.1.2.1. SET VOLTAGE
From this screen the user may set the voltage they wish to
charge the load to. The right and left buttons control which
digit is presently being edited, and the up and down buttons
increment or decrement that digit. Pressing Enter will exit this
screen and save the voltage.
4.2.2.1.2.2. SET CURRENT
From this screen the user may set the maximum current with
which they wish to charge the load. The right and left buttons
control which digit is presently being edited, and the up and
down buttons increment or decrement that digit. Pressing
Enter will exit this screen and save the current.
4.2.2.1.2.3. CHARGE CONFIRM
At this screen, the user is asked to confirm the charge voltage
and current, and begin charging the load.
4.2.2.1.2.3.1. CHARGING
This screen displays the present output voltage and
current. It transitions to the Voltage screen (4.2.2.2)
when the output voltage reaches the set point.
Charging may be aborted by pressing the Cancel
button.
4.2.2.1.3. DISCHARGE CONFIRM
At this screen the user is asked to confirm their intent to discharge
the capacitor bank. If the user confirms, the capacitor starts
discharging, until the load voltage reaches 10VDC. The time the
capacitor takes to discharge to half of its starting voltage is
measured, and from this value the load capacitance is calculated.
4.2.2.1.3.1. DISCHARGING
This screen displays the present output voltage and
discharge current. It transitions to the “Results” screen when
the output voltage reaches 20VDC.
4.2.2.1.4. RESULTS
This screen presents the user with the results of the previous
capacitor discharge and measurement.
4.2.2.2. VOLTAGE
If the system is idle and no button is pressed for fifteen seconds, the
system will transition to this screen, displaying the present load voltage
and leakage current. Pressing left or right will transition back to the main
menu.