bonitron M3628PUT User manual
Model M3628PUT
Portable Ultracapacitor Tester
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
M3628PUT
4
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: M3628PUT ........................................................................................................................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
2.3. General Specifications.............................................................................................................10
Table 2-1: General Specifications Table ............................................................................................10
2.4. General Precautions and Safety Warnings ..............................................................................11
3. INSTALLATION INSTRUCTIONS................................................................................................13
3.1. Environment............................................................................................................................13
3.2. Wiring and Customer Connections .........................................................................................13
3.2.1. Power Wiring ..............................................................................................................................13
Figure 3-1: M3628PUT Faceplate......................................................................................................13
3.2.2. Source Considerations.................................................................................................................14
3.2.3. Load Considerations....................................................................................................................14
4. OPERATION..............................................................................................................................15
4.1. Functional Description............................................................................................................15
4.2. Features .............................................................................................................................15
4.2.1. AC Power Input Connector .........................................................................................................15
4.2.2. DC Output Connectors ................................................................................................................15
4.2.3. Display ........................................................................................................................................15
4.2.4. Interface Buttons .........................................................................................................................15
4.2.5. LEDs............................................................................................................................................15
4.2.6. Abort Button................................................................................................................................15
4.2.7. Voltage Present Indicator ............................................................................................................16
4.2.8. Fuse .............................................................................................................................................16
4.2.9. Power Switch / Circuit Breaker...................................................................................................16
4.3. Screens & Menu Navigation ...................................................................................................16
4.3.1. Main Menu..................................................................................................................................16
Figure 4-1: M3628PUT Charging Profile...........................................................................................17
Figure 4-2: M3628PUT Interface Screen Tree...................................................................................18
4.4. Faults .............................................................................................................................20
4.4.1. Overtemp.....................................................................................................................................20
4.4.2. Communication Loss...................................................................................................................20
4.4.3. Reverse Bias................................................................................................................................20
4.4.4. Fuse Loss.....................................................................................................................................20
4.4.5. Relay Failure ...............................................................................................................................20
4.4.6. Short IGBT..................................................................................................................................20
5. MAINTENANCE AND TROUBLESHOOTING...............................................................................21
5.1. Maintenance Items ..................................................................................................................21
5.2. Troubleshooting.......................................................................................................................21
Table 5-1: Troubleshooting ................................................................................................................21
5.3. Technical Help ........................................................................................................................22
6. ENGINEERING DATA................................................................................................................23
Table of Contents
5
6.1. Ratings Chart...........................................................................................................................23
Table 6-1: Ratings Chart.....................................................................................................................23
6.2. Dimensional Drawing..............................................................................................................23
Figure 6-1:M3628PUT Dimensions ...................................................................................................23
6.3. Block Diagram ........................................................................................................................23
Figure 6-2: Block Diagram.................................................................................................................23
7. APPENDIX.................................................................................................................................25
7.1. Application Notes....................................................................................................................25
7.1.1. Typical Capacitor Bank Forming / Testing Procedure ................................................................25
M3628PUT
6
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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 Ultracapacitors.
Please keep this manual for future reference.
1.2. PURPOSE AND SCOPE
This manual is a user’s guide for the Model M3628PUT. It will provide the user with
the necessary information to successfully connect and operate the M3628PUT.
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
Rev 00 is the original printing of the M3628PUT manual.
The Example of the Part Number Breakdown was changed in Rev 00a.
Input Voltage options were added in Rev 01.
The manual template was updated in Rev01a.
Figure 1-1: M3628PUT
M3628PUT
8
1.4. SYMBOL CONVENTIONS USED IN THIS MANUAL AND ON
EQUIPMENT
Earth Ground or Protective Earth
AC Voltage
DC Voltage
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!
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 / FEATURES
The M3628PUT is designed for testing of ultracapacitors. As ultracapacitors age and
wear, their capacitance decreases, and their ESR increases. This can result in
decreased system performance, and ultimately, process failure. Measurement of an
ultracapacitor's capacitance and ESR can help avoid expensive preemptive
replacement.
The M3628PUT is a portable digitally-controlled capacitor tester. The digital interface
allows the user to charge an attached ultracapacitor to a specified voltage, and then
discharge the capacitor. After discharge is complete, the display will show the
capacitance and ESR of the ultracapacitor.
2.1. RELATED PRODUCTS
M3528 ULTRACAPACITOR/BATTERY CHARGER
The M3528 Charger can charge strings of batteries or ultracapacitors 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.
M3628 ULTRACAPACITOR DISCHARGE CONTROLLER
Large capacitor banks store huge amounts of energy, and can be a hazard when
systems are shut down for system maintenance. The M3628 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 900
VDC, and the system is capable of supplying 1 ADC continuously. The unit can be
used for reforming disused capacitors.
M3628PCT PORTABLE CAPACITOR TESTER
The M3628 Portable Capacitor Tester can be used to charge, discharge and
measure capacitor banks as large as 300 kJ. The output voltage can be set by
digital control to between 0 and 800 VDC, and the system is capable of supplying 1
ADC up to 450 VDC. When discharging, the unit times the discharge and gives a
capacitance value for capacitor banks between 2200 uF and 1F. The unit can also
be used for automatic reforming of disused capacitors.
M3628PUT
10
2.2. PART NUMBER BREAKDOWN
Figure 2-1: Example of Part Number Breakdown
BASE MODEL NUMBER
The Base Model Number for all Portable Ultracapacitor Testers is M3628PUT.
OUTPUT VOLTAGE RATING
The Maximum Output Voltage Rating indicates the DC output voltage the unit can
supply. At present there is only a U model.
MAX OUTPUT CURRENT RATING
The Maximum Output Current rating indicates the maximum DC current the unit can
supply at its maximum voltage.
INPUT VOLTAGE RATING
This indicates the input voltage for the unit.
2.3. GENERAL SPECIFICATIONS
Table 2-1: General Specifications Table
PARAMETER
SPECIFICATION
Input Voltage
110-120VAC, 220-240VAC, 1ø
Output Voltage
0-130VDC
Output Current
1-7ADC
Minimum Load Capacitance
1 Farad
Maximum Load Energy
500 kJ
Minimum Cycle Voltage
5V
Controls
Six display soft keys
Abort button
Display
Four line, eighty character LCD (4x20)
Unit Size (H x W x D)
18.00" x 22.00" x 10.50"
Weight
50 lbs.
Storage Temp
-20°C to +65°C
Humidity
Below 90% non-condensing
Atmosphere
Free of corrosive gas and dust
M3628PUT
U
07
BASE MODEL NUMBER
OUTPUT VOLTAGE
MAXIMUM OUTPUT CURRENT
INPUT VOLTAGE
110
User’s Manual
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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 M3628PUT TO A CAPACITOR BANK,
ENSURE THAT THE BANK IS FULLY DISCHARGED BY CHECKING
WITH A VOLTMETER.
CONNECTING THE M3628PUT’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.
M3628PUT
12
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User’s Manual
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3. INSTALLATION INSTRUCTIONS
3.1. ENVIRONMENT
While closed, the M3628PUT 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 AC from the included standard
C13 power cable. The DC Output connectors supply DC voltage at the
user-selected level via a pair of high-current 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.
WARNING!
Attaching the unit to an AC input voltage other than that specified for your
unit may cause improper operation or damage!
Figure 3-1: M3628PUT Faceplate
ABORT
ON
OFF
110 VAC IN
NEGATIVE POSITIVE
VOLTAGE PRESENT
0-130 VDC OUT
M3628PUT
PORTABLE ULTRACAPACITOR TESTER
Dwg: 120270 Rev: 20120726
M3628PUT
14
3.2.2. SOURCE CONSIDERATIONS
It is important to only connect this unit to a source that meets the specified
voltage and current requirements.
The source must be capable of supplying 14A @110VAC or 7A @ 220VAC
under normal operating conditions.
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.
3.2.3. LOAD CONSIDERATIONS
To ensure the most accurate possible measurements, the capacitor under
test should be charged to its full rated voltage. Note that the M3628PUT will
discharge the attached load capacitor to 2VDC. This unit is thus not
recommended for use on ultracapacitors rated at less than 5VDC.
Before charging or discharging an attached capacitor, ensure that the
capacitor is capable of safely sourcing the current which will be drawn by
the .6 ohm discharge resistor at the desired charge voltage. I=V/R.
WARNING!
Drawing current from a capacitor in excess of its maximum rated current
can cause the capacitor to overheat and explode! Confirm the maximum
current rating of the capacitor before charging or discharging.
User’s Manual
15
4. OPERATION
4.1. FUNCTIONAL DESCRIPTION
The M3628PUT is a digitally controlled DC supply capable of sourcing between 1
and 7 amps at between 0 and 130VDC. The unit is powered by standard 50-60 Hz
AC. The output voltage is controlled by the digital interface panel on the front of the
unit. The unit is capable of safely charging and discharging connected capacitors. It
is also capable of executing a pre-programmed charging profile, with defined step
voltages and hold times. When a capacitor is discharged, the unit will calculate and
display the capacitance and ESR of the capacitor. An Abort button is present in case
of user error when selecting charge voltage. The unit automatically enters discharge
mode when powered off.
4.2. FEATURES
4.2.1. AC POWER INPUT CONNECTOR
The M3628PUT 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.
4.2.2. DC OUTPUT CONNECTORS
Two high-current jacks provide the user with DC output voltage between 0
and 130VDC, and provide a discharge path for the current from the
capacitor being tested. Cables are included, and can be constructed as
desired.
4.2.3. 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.
4.2.4. INTERFACE BUTTONS
The function of each button depends on the active screen. For menu
screens, enter selects a menu option, while cancel moves back to the
previous screen. Up and down move the menu curser. 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 digit. Enter stores the
present value, while cancel undoes any changes. On some screens,
certain buttons may perform no function.
4.2.5. LEDS
Three LEDs indicate the present status of the PUT. Red indicates a fault
condition. Yellow indicates that the unit is presently charging or discharging.
Green indicates that the unit has power.
4.2.6. ABORT BUTTON
There is a red Abort button on the face of the unit. This button will cause
the system to immediately switch to discharge mode, regardless of the
M3628PUT
16
present system activity. In the event the unit is accidentally set to charge to
a higher voltage than is safe for one load, this button should be pressed
immediately.
4.2.7. VOLTAGE PRESENT INDICATOR
WARNING!
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 protocols
when working with high voltages!
A red light indicates that there is an unsafe 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.
4.2.8. FUSE
This fuse is in the charging output of the PUT. If the fuse fails, power down
the unit, and replace it with the same fuse. (see Section 5) Do not replace
the fuse while the system is live!
4.2.9. 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.
NOTE: When switched OFF, the unit is in Discharge mode.
4.3. 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 ‘>’
character. This selection indicator is moved using the up and down buttons. If a line
on the menu represents another screen, that screen may be accessed with the enter
key. The cancel button will typically return the display to the parent screen.
4.3.1. MAIN MENU
The Charging Profile, Single Charge, Discharge, and Previous Results
screens may be accessed from the Main Menu.
4.3.1.1. CHARGING PROFILE
From this selection, the user may input the variables necessary to
execute an automatic Charging Profile. A charging profile charges the
capacitor in steps, each step 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. See Figure 4-2.
User’s Manual
17
Figure 4-1: M3628PUT Charging Profile
4.3.1.1.1. SET PROFILE FINAL VOLTAGE
From this screen the user may set the final charge voltage. The
right and left buttons control which digit is being edited, and the
up and down buttons increment or decrement that digit. Enter will
save changes. Cancel will abort changes.
4.3.1.1.2. SET PROFILE 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 being edited, and the up and down buttons
increment or decrement that digit. Enter will save changes.
Cancel will abort changes.
4.3.1.1.3. SET PROFILE CURRENT
From this screen the user may set the maximum charge current.
The right and left buttons control which digit is being edited, and
the up and down buttons increment or decrement that digit. Enter
will save changes. Cancel will abort changes.
4.3.1.1.4. SET PROFILE STEP HOLD TIME
From this screen the user may set the number of seconds each
step voltage will be held. The right and left buttons control which
digit is being edited, and the up and down buttons increment or
decrement that digit. Enter will save changes. Cancel will abort
changes.
4.3.1.1.5. SET PROFILE 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 being edited, and the up and down buttons increment or
decrement that digit. Enter will save changes. Cancel will abort
changes.
Dwg: 090115 Rev: 20090421
M3628PUT
18
Figure 4-2: M3628PUT Interface Screen Tree
MENU
MAIN
RESULTS/
CONFIRM
DISCHARGE DISCHARGING
PREVIOUS RESULTS
STATUS
VOLTAGE
CHARGE
SINGLE CHARGE
DISCHARGE
CURRENT
CHARGE CHARGE
CONFIRM CHARGE
EXECUTING
CHARGE PROFILE
VOLTAGE
FINAL
PROFILE
VOLTAGE
STEP
PROFILE
CURRENT
PROFILE
TIME
STEP
PROFILE
TIME
FINAL
PROFILE
PROFILE
CONFIRM PROFILE
EXECUTING
Dwg: 090114 Rev: 20120803
User’s Manual
19
4.3.1.1.6. CHARGE PROFILE CONFIRM
At this screen the user is asked to confirm the Profile settings.
Enter will start charging. Cancel will abort charging.
4.3.1.1.7. EXECUTING PROFILE
This screen displays the present output voltage and current and
seconds left for each step. It transitions to the "Discharging"
screen (4.3.1.2.6.) when the output voltage reaches the set point
and is held for the specified number of seconds. Charging may
be aborted by pressing cancel. This will not initiate discharging; if
charging is aborted via the cancel button, the load will remain at
voltage until discharging is manually initiated or the unit is turned
off.
4.3.1.2. SINGLE CHARGE MENU
The user may set the charge voltage and current, and initiate charging
from here.
4.3.1.2.1. SET CHARGE VOLTAGE
From this screen the user may set the charge voltage. The right
and left buttons control which digit is being edited, and the up and
down buttons increment or decrement that digit. Enter will save
changes. Cancel will abort changes.
4.3.1.2.2. SET CHARGE CURRENT
From this screen the user may set the maximum charge current.
The right and left buttons control which digit is being edited, and
the up and down buttons increment or decrement that digit. Enter
will save changes. Cancel will abort changes.
4.3.1.2.3. CHARGE CONFIRM
At this screen, the user is asked to confirm the charge voltage
and current. Enter will start charging. Cancel will abort charging.
4.3.1.2.4. CHARGING
This screen displays the present output voltage and current. It
transitions to the Results screen (4.3.1.2.7) when the output
voltage reaches the set point. Charging may be aborted by
pressing any of the four directional buttons. This does not initiate
discharging. Caps will remain at voltage until discharging is
manually initiated or the unit is turned off.
4.3.1.3. 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 2VDC. The time the capacitor takes to
discharge is measured, and from this value the load capacitance is
calculated.
4.3.1.4. DISCHARGING
This screen displays the present output voltage and discharge current.
It transitions to the “Results” screen when the output voltage reaches
2VDC.
M3628PUT
20
4.3.1.5. RESULTS
This screen presents the user with the present output voltage and the
results of the previous capacitor discharge and measurement, including
capacitance and ESR. The system transitions to this screen after a
period of inactivity.
4.4. FAULTS
If a fault condition occurs, the red LED will illuminate, and the display will indicate the
nature of the fault. Once a fault state has cleared, the red LED will turn off; and the
description of the fault will remain. Press the cancel button to return to the main
menu.
4.4.1. OVERTEMP
This fault indicates that the unit has exceeded its safe operating
temperature range. Leave the unit connected to power and load, and allow
the unit to cool. The fault should clear within 60 minutes.
4.4.2. COMMUNICATION LOSS
This fault indicates that a serial connection has been lost within the
M3628PUT. This is not user-serviceable. Contact Bonitron for service
options (Section 5.3).
4.4.3. REVERSE BIAS
This fault indicates that the voltage on the output terminals of the
M3628PUT is of the incorrect polarity; the negative terminal is higher than
the positive terminal. Check the polarity of the leads attached to the
ultracapacitor under test.
4.4.4. FUSE LOSS
This fault indicates that the fuse in the charging link of the M3628PUT has
failed. Power down the unit and replace the fuse with one of comparable
specifications (Section 5.1).
4.4.5. RELAY FAILURE
This fault indicates that the relay driving the output of the M3628PUT is
open. If the fault will not clear, your unit is damaged. Contact Bonitron for
service options (Section 5.3).
4.4.6. SHORT IGBT
This fault indicates that the discharge control transistor has shorted. If this
fault will not clear, your unit is damaged. Contact Bonitron for service
options (Section 5.3).
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