bonitron M3628UCT User manual

Web: www.bonitron.com ● Tel: [phone] ● Email: [email protected]
Model M3628UCT
Ultracapacitor Cell 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

M3628UCT
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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: M3628UCT..............................................................................................................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: Max Output Voltage................................................................................................10
Table 2-2: Input Voltage...........................................................................................................10
2.3. General Specifications................................................................................................................11
Table 2-3: General Specifications Table...................................................................................11
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: M3628UCT............................................................................................................13
3.2.1. Kelvin Connections..............................................................................................................13
3.2.2. Source Considerations..........................................................................................................14
3.2.3. Load Considerations.............................................................................................................14
4. OPERATION..............................................................................................................................15
4.1. Functional Description ...............................................................................................................15
4.2. Architecture and Circuit Schematic............................................................................................15
Figure 4-1: M3628UCT Schematic...........................................................................................15
4.3. Hardware Features......................................................................................................................15
4.3.1. AC Power Input Connector..................................................................................................15
4.3.2. DC Output and Measurement Connectors ...........................................................................16
4.3.3. Display.................................................................................................................................16
4.3.4. Indicator LEDs.....................................................................................................................16
4.3.5. Directional Buttons .............................................................................................................. 16
4.3.6. Enter and Cancel Button ...................................................................................................... 16
4.3.7. Voltage Present Indicator.....................................................................................................16
4.3.8. Power Switch / Circuit Breaker............................................................................................16
4.3.9. Safety Bleeder Resistor........................................................................................................17
4.4. Modes, Screens & Menu Navigation..........................................................................................17
Figure 4-1: M3628UCT Interface Screen Tree.........................................................................17
4.4.1. Status/Idle.............................................................................................................................18
4.4.2. Main Menu...........................................................................................................................18
Figure 4-3: M3628UCT Example Test Cycle...........................................................................18
Figure 4-4: M3628UCT Example Measurement Stage ............................................................19
Figure 4-5: M3628UCT Example V-I Curve and Operating Area ...........................................20
4.5. Faults22
4.5.1. Over-Current........................................................................................................................22
4.5.2. Over-Voltage........................................................................................................................22
4.5.3. DC Bus Out of Range ..........................................................................................................22
4.5.4. Over-Temperature................................................................................................................22

M3628UCT
6
4.5.5. Timeout................................................................................................................................23
5. TROUBLESHOOTING ................................................................................................................24
Table 5-1: Troubleshooting....................................................................................................... 25
6. ENGINEERING DATA................................................................................................................27
6.1. Ratings Chart.............................................................................................................................. 27
Table 6-1: Ratings Chart...........................................................................................................27
Table 6-2: Dimensions..............................................................................................................27
7. APPLICATION NOTES...............................................................................................................29
7.1. Typical Capacitor Testing Procedure .........................................................................................29

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 M3628UCT. It will provide the user with
the necessary information to successfully connect and operate the M3628UCT.
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 manual is Rev 00a.
Updated section 4.5 in Rev 00b.
Figure 1-1: M3628UCT

M3628UCT
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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
9
2. PRODUCT DESCRIPTION
As ultra-capacitors age and wear, their internal chemistries change, leading to a decrease
in capacitance and efficiency. It is important to be able to measure capacitance and
equivalent series resistance (ESR), and thus estimate the remaining useful life of your
capacitor bank or constituent cells/modules. This can help reduce expensive pre-emptive
replacement. Capacitors stored for long periods of time also display chemistry changes,
which gradually reduces capacitance and increases ESR.
The Bonitron M3628UCT 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. This product may
be used for many purposes, including a general purpose voltage/current source, charging
and discharging capacitors, and measuring capacitance and ESR.
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.
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.

M3628UCT
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 Cell Testers is M3628UCT.
MAX OUTPUT VOLTAGE RATING
The Max Output Voltage rating indicates the maximum DC output voltage the unit can
supply, which is indicated by a code letter.
Table 2-1: Max Output Voltage
RATING CODE
VOLTAGES
(DC VOLTAGE OUTPUT)
D
20VDC 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
M3628UCT
D
30
BASE MODEL NUMBER
MAX OUTPUT VOLTAGE
MAX OUTPUT CURRENT
INPUT VOLTAGE
120

User’s Manual
11
2.3. GENERAL SPECIFICATIONS
Table 2-3: General Specifications Table
PARAMETER
SPECIFICATION
Input Voltage
110-120 VAC 1Ø
Test Voltage Range
2.0-20.0VDC
Test Current Range
1-30ADC
Minimum Test Capacitance
1F
Maximum Test Capacitance
6,500F
Minum Measurable ESR
0.1mΩ
Maximum Measurable ESR
500mΩ
Maximum Test Time
90 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
30lbs
Storage Temp
-20°C to + 65°C
Humidity
Below 90% non-condensing
Atmosphere
Free of corrosive gas and conductive dust

M3628UCT
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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 M3628UCT TO A CAPACITOR,
ENSURE THAT THE CELL OR MODULE IS FULLY DISCHARGED BY
CHECKING WITH A VOLTMETER.
•CONNECTING THE M3628UCT’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
13
3. INSTALLATION INSTRUCTIONS
3.1. ENVIRONMENT
While closed, the M3628UCT 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 are PowerPoles that supply user
selected DC voltage and currents. Two standard cable assemblies using
alligator clips and ring lugs are included.
Figure 3-1: M3628UCT
3.2.1. MEASUREMENT CONNECTIONS
In addition to the DC output connections, two clip leads are provided for the
system to make differential voltage measurements through Kelvin
connections. On the standard cable assembly, this is done connecting the
clip leads as close to the capacitor as possible, thus avoiding the voltage
drop from the high current flowing through the cables and power
connections.

M3628UCT
14
3.2.2. SOURCE CONSIDERATIONS
Input voltage should notexceed the rating—120VAC or 240VAC depending
on model—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 10 amps for 120VAC supply or 5 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.
3.2.3. LOAD CONSIDERATIONS
In orderto obtain themost accurate measurements, thecapacitor under test
would ideally be charged to its full rated voltage. However, the
recommendation is to test capacitors at 95% of their rated voltage to allow
a margin for device error and capacitor tolerances.

User’s Manual
15
4. OPERATION
4.1. FUNCTIONAL DESCRIPTION
The M3628UCT is a digitally controlled DC supply capable of sourcing and sinking 1
to 30 amps between 2 and 20VDC. The unit is powered by standard 50-60 Hz
120VAC/240VAC. The output voltage and current is set by the digital interface panel
on the front of the unit. The unit is capable of safely charging and discharging
connected capacitors with a constant current as well as running a complete
charge/hold/discharge test cycle appropriate for ultra-capacitors. When a capacitor is
discharged, the unit will calculate and display the capacitance and ESR of the
capacitor.
4.2. ARCHITECTURE AND CIRCUIT SCHEMATIC
Electrically, the M3628UCT is a current and voltage regulated, bi-directional DC-DC
converter with response times on the order of milliseconds. Additionally, in order to
manage the flow ofpower into the system during discharge operations, the M3628UCT
includes an integrated resistor bank and regulating chopper capable of dissipating
600W continuously.
Figure 4-1: M3628UCT Schematic
CB1
Q1 C1
R1
Q2
Q3 L1
C2
D1
F1
A
V
V
DC
SUPPLY
4.3. HARDWARE FEATURES
4.3.1. AC POWER INPUT CONNECTOR
The M3628UCT 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.

M3628UCT
16
4.3.2. DC OUTPUT AND MEASUREMENT CONNECTORS
Four PowerPole connectors provide the user with DC output voltage between
0 and 20VDC, a charge/discharge path for the current to and from the
capacitor being tested, and precision Kelvin measurements for ESR. The
standard cables shipped with the system include either two high-current
alligator clips or ring terminals, and two measurement clip leads.
4.3.3. DISPLAY
The digital display presents the user with information about the presentstatus
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.
4.3.4. INDICATOR LEDS
There are three LEDs below the Display to indicate the operational status of
the unit.
•Green: Unit is powered on.
•Yellow: Unit is active.
•Red: A fault has occurred. Check display for description.
4.3.5. 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.
4.3.6. ENTER AND CANCEL BUTTON
The green enter button selects menu options. On most screens, the
cancel button will return you to the previous screen. While the system is
active, the cancel button will halt the operation and return to an idle state.
4.3.7. 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 potentially dangerous
voltages from low impedance sources that can cause injury or death.
Always follow safety protocols when working with energized equipment
and charged capacitors!
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 could result.
4.3.8. 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
17
4.3.9. SAFETY BLEEDER RESISTOR
In the event power is lost to the unit, but a charged capacitor is connected, a
230Ωresistor will automatically be connected to the output terminals, slowly
discharging the capacitor and the “Voltage Present” LED will continue to
function. If the voltage is sufficiently high, the capacitor will also back-feed
the system, allowing it to remain powered in the absence of external power.
4.4. MODES,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.
Figure 4-2: M3628UCT Interface Screen Tree
Status
Confirm
Adjust Charge
Voltage
Adjust Charge
Current
Adjust Hold Time
Test Status
Adjust Final Voltage
Adjust Charge
Current
Confirm Charge Status
Adjust Discharge
Current
Confirm Discharge Status
Complete Yes
No
Yes
Complete
No
Set Date and Time
Set Menu Timeout
Adjust Date and
Time
Adjust Menu
Timeout
Test Results
Faults
Erase History
Test Cycle
Charge
Discharge
View History
Settings
MAIN MENU
Set Charge Voltage
Set Charge Current
Set Hold Time
Start Test
TESTMENU
Set Final Voltage
Set Charge Current
Start Charging
CHARGEMENU
Set Discharge
Current
Start Discharging
DISCHARGE MENU
Show Test Records
Show Faults
Erase History
HISTORY MENU

M3628UCT
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4.4.1. STATUS/IDLE
This is the default screen while the system is idle, displaying the present
terminal voltage and indicating that the system is ready for operation. If the
system is idle in another screen and no button is pressed for a period of time,
the system will transition to this screen. Pressing Enter will transition to the
main menu.
4.4.2. MAIN MENU
The Test Cycle menu, Charge Menu, Discharge Menu, and History may be
accessed from the Main Menu.
4.4.2.1. TEST MENU
From this menu, the user may input the variables necessary to execute a
complete capacitor test cycle. A test cycle is broken into three distinct
stages: charging the capacitor with a constant current, holding the set
voltage for a specified amount of time, then discharging the capacitor at
the same constant current, during which measurements are taken. See
Figures 4-3 and 4-4 for detailed examples. In the event that the voltage
drops too rapidly during discharge to make accurate capacitance
measurements, the test will return to the hold stage, then attempt the
measurement again at a reduced current. The ESR measurement uses
a pulse technique and will similarly automatically adjust the current to an
appropriate value.
Figure 4-3: M3628UCT Example Test Cycle
-40
-30
-20
-10
0
10
20
30
40
0 5 10 15 20 25 30 35 40 45
Voltage (V) / Current (A)
Time (minutes)
Current (A)
Voltage (V)
Hold

User’s Manual
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Figure 4-4: M3628UCT Example Measurement Stage
4.4.2.1.1. SET CHARGE 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.
4.4.2.1.2. SET CHARGE 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.
4.4.2.1.3. SET HOLD TIME
From this screen the user may set the number of minutes the
charge 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 hold time is 30
minutes.
0
5
10
15
20
25
30
35
050 100 150 200 250 300 350 400
Time (s)
Example Measurement Stage
Current (A)
Voltage (V)
ESR
Hold
ESR
Test

M3628UCT
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4.4.2.1.4. START TEST
At this screen the user is asked to confirm the charge voltage and
current, and begin charging the output.
4.4.2.1.4.1. TEST STATUS
This screen displays thepresent output voltage (at the panel
connector), current, stage of the test, and a timer or
stopwatch. The stopwatch resets for the charging,
capacitance measurement, and discharging stage
transitions, subsequently displaying the time the system has
been in the present stage. Alternately, a timer appears in
the holding and ESR stages, showing the time remaining in
the stage. The test may be halted at any time by pressing
the Cancel button.
4.4.2.2. CHARGE MENU
The user may set the charge voltage and current, and initiate charging
from this menu. Operating the system in charge mode causes it to
behave as a current limited voltage source. An example V-I curve is
shown in Figure 4-5 below.
Figure 4-5: M3628UCT Example V-I Curve and Operating Area
4.4.2.2.1. SET FINAL VOLTAGE
From this screen the user may set the voltage they wish to charge
the load to. The right andleft buttons control which digit is presently
being edited, and the upand down buttons increment or decrement
that digit. Pressing Enter will exit this screen and save the voltage.
-40
-30
-20
-10
0
10
20
30
40
0 5 10 15 20 25
Current (A)
Voltage (V)
Adjustable Current Limit
Adjustable Voltage Limit
Fixed Current Limit