bonitron M3628UMT User manual

Web: www.bonitron.com ● Tel: [phone] ● Email: [email protected]
Model M3628UMT
Ultracapacitor Module 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

M3628UMT
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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: M3628UMT .............................................................................................................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: M3628UMT ...........................................................................................................13
3.2.1. ESR Measurement 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: M3628UMT 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
4.4. Modes, Screens & Menu Navigation..........................................................................................17
Figure 4-2: M3628UMT Interface Screen Tree........................................................................17
4.4.1. Idle Mode and Status Screen................................................................................................18
4.4.2. Main Menu...........................................................................................................................18
Figure 4-3: M3628UMT Example Test Cycle..........................................................................18
Figure 4-4: M3628UMT Example Measurement Stage............................................................ 19
Figure 4-5: M3628UMT Example V-I Curve and Operating Area ..........................................20
4.5. Faults and Test Report Errors.....................................................................................................22
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
4.5.5. Timeout................................................................................................................................23

M3628UMT
6
4.5.6. High Impedance...................................................................................................................23
4.5.7. Low Voltage.........................................................................................................................23
4.5.8. High Cap..............................................................................................................................23
4.5.9. Pulse Error, Probes N/C, Vcx2 Sat, and Vcx20 Sat.............................................................23
4.5.10.Probes Swap.........................................................................................................................23
5. TROUBLESHOOTING ................................................................................................................25
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 Ultra-Capacitor Module 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 modules.
Please keep this manual for future reference.
1.2. PURPOSE AND SCOPE
This manual is a user’s guide for the model M3628UMT. It will provide the user with
the necessary information to successfully connect and operate the M3628UMT.
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.
Corrected part number and updated functions in Rev 00b.
Figure 1-1: M3628UMT

M3628UMT
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
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 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. 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.
M3628PUD PORTABLE 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 M3628PUD discharges capacitor
banks to safe working levels quickly, allowing work on the system to begin in seconds,
rather than hours.
M3628UCT ULTRACAPACITOR CELL TESTER
The M3628UCT Ultracapacitor Cell Tester 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.
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.

M3628UMT
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 Module Testers is M3628UMT.
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
170VDC 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
M3628UMT
U
07
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
90-130 VAC 1Ø
Test Voltage Range
10-170VDC
Test Current Range
1-7ADC
Minimum Test Capacitance
1F
Maximum Test Capacitance
2,000F
Minimum Measurable ESR
0.1mΩ
Maximum Measurable ESR
500mΩ
Maximum Test Time
240 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
33lbs
Storage Temp
-20°C to + 65°C
Operating Temp
0°C to + 40°C
Humidity
Below 90% non-condensing
Atmosphere
Free of corrosive gas and conductive dust

M3628UMT
12
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 M3628UMT TO A CAPACITOR,
ENSURE THAT THE MODULE IS FULLY DISCHARGED BY CHECKING
WITH A VOLTMETER.
•CONNECTING THE M3628UMT’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 M3628UMT 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 120VAC, 50-60Hz from the included
standard C13 power cable. The DC Output connectors are PowerPoles that
supply user selected DC voltage and currents. Three standard cable
assemblies using alligator clips and ring lugs are included.
Figure 3-1: M3628UMT
3.2.1. ESR MEASUREMENT CONNECTIONS
In addition to the DC output connections, two clip leads are provided for the
system to make ESR 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. Failing to
connect these will result in a failed ESR test.

M3628UMT
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
The UMT will return measurements for capacitors that have a capacitance
of at least 1F and an ESR under 0.5Ω. Lower capacitances or higher
resistances may return unreliable results or trigger a high impedance fault,
in which case the test will be immediately terminated.
One should also keep in mind how long testing a particular capacitor will
likely take, as the testing process has built-in time limits on the charging and
discharging stages of the test cycle. Essentially, a capacitor should be able
to be charged to its test voltage in less than 1 hour, which can be estimated
using the formula below, assuming the current is constant for the
overwhelming majority of the cycle. Resistance introduced into the test
circuit should be minimized as this increases the time spent in the constant-
voltage portion at the end of the charging profile.
∆𝑡 = 𝐶∆𝑉/𝐼
Additionally, in order to obtain the most accurate measurements, the
capacitor 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. Tests
which do not achieve a voltage greater than 10V will proceed through the
entire cycle, but not yield any capacitance or ESR measurements.

User’s Manual
15
4. OPERATION
4.1. FUNCTIONAL DESCRIPTION
The M3628UMT is a digitally controlled DC supply capable of sourcing and sinking 1
to 7 amps between 10 and 170VDC. 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 M3628UMT 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 of power into the system during discharge operations, the
M3628UMT includes an integrated resistor bank and regulating chopper capable of
dissipating 1200W.
Figure 4-1: M3628UMT Schematic
CB1
Q1 C1
R1
Q2
Q3 L1
C2
D1
F1
A
V
V
ISOLATED
PFC DC
SUPPLY
4.3. HARDWARE FEATURES
4.3.1. AC POWER INPUT CONNECTOR
The M3628UMT 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.

M3628UMT
16
4.3.2. DC OUTPUT AND MEASUREMENT CONNECTORS
Four PowerPole connectors provide the user with DC output voltage between
10 and 170VDC, 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
4.4. 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: M3628UMT 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

M3628UMT
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4.4.1. IDLE MODE AND STATUS SCREEN
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 MODE AND 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. A time limit of 1 hour is
imposed on the Charge stage, while a limit of 2 hours is imposed on the
Discharge/Measurements stage. In the event that the voltage drops too
rapidly during discharge to make accurate capacitance measurements,
(>20% upon discharge initiation), 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: M3628UMT Example Test Cycle
-20
0
20
40
60
80
100
120
140
160
180
0 5 10 15 20 25 30 35 40 45
Voltage (V) / Current (A)
Time (minutes)
Example Test Cycle
Current (A)
Voltage (V)
Hold

User’s Manual
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Figure 4-4: M3628UMT 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
20
40
60
80
100
120
140
160
050 100 150 200 250 300 350 400
Time (s)
Example Measurement Stage
Current (A)
Voltage (V)
ESR
Hold ESR Test

M3628UMT
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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 MODE AND 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: M3628UMT 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.
-10
-8
-6
-4
-2
0
2
4
6
8
10
020 40 60 80 100 120 140 160 180 200
VI Curve with Limits and Example Settings
Adjustable Current
Adjustable Voltage Limit
Fixed Current Limit