CATALOGUE

FLUORESCENT STARTERS & CAPACITORS

FOR LIGHTING

MOTOR START & RUN CAPACITORS

POWER FACTOR CORRECTION

THYCOM & C.V.T. POWER CAPACITORS

GENERAL

FOR ANY SPECIAL CAPACITORS (VALUES AND SIZES NOT LISTED)

PLEASE COMPLETE THE ENCLOSED APPLICATION DATA QUESTIONNAIRE FORM AND FAX BACK AT YOUR

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SABS ISO 9001

FLUORESCENT STARTERS

&

CAPACITORS FOR

LIGHTING

Metallized polypropylene film capacitors for lighting applications for use with gas discharge

Lamps

General information • Metal halide lamps Discharge lamps are the most convenient light source, and have a very high efficiency level. At the same level of absorbed power, a discharge lamp provides a light emission much higher than that of a traditional incandescent lamp, while life and output in time are also much longer.

Typology Different base models are available, each of them has optimal characteristics for various uses. Please consider the following range: • Fluorescent lamps The discharge occurs in inert gas (neon-krypton-xenon, etc.). Ultraviolet radiation is emitted, converted into visible light. It is possible to obtain different light tones including the solar one. Due to the high quality of the light and the low level of glare, these lamps are particularly suitable for domestic and industrial use.

• Metal vapour lamps (mercury-vapour, sodium, high and low pressure). The modest quality of the emitted light (nearly monochromatic) is counterbalanced by a very high lighting performance. Typical applications: Street lighting and flood lighting.

These are used for the lighting of large surfaces, to simulate daylight. Lamps of this kind, but of low power are used in lighting shops and shop windows. Working principle • An electric arc is provoked between two electrodes suspended in the above mentioned gases or metal vapours. The arc is supplied by alternate current, therefore in case of a standard 50Hz main it starts and extinguishes 100 times 0 per second. • The electric arc is unstable: increasing the current, when its resistance diminishes. Therefore it is necessary to stabilize the arc by connecting in series an impedance, usually called 'ballast' or reactor. • The 'ballast' is generally a more or less complex inductance, which can include also the starting circuit (first ignition). The presence of the 'ballast' produces inevitably a great reduction of the power factor (cos) of the group, up to values even lower than 0,5. To obtain the value of power factor requested today (cos(p > 0,9), it is necessary to provide a proper power factor correction by means of suitable capacitors.

Capacitors - Application notes

Parallel connectionThe capacitor is directly connected to the mains, in parallel to the ballast-lamp group. Its voltage is the same as the network voltage.

L = Lamp, S = Starter. B = Ballast, C = Capacitor, R = Discharge ResistorThe capacitor has only the function of power factor correction, it does not intervene in the functioning of the group.

Series connection The power factor correction of the group and the elimination of the stroboscopic effect are simultaneously obtained, since the ignition and the extinguishing of the arc in the two sides of the circuit (inductive and capacitive) are in opposite phase. The capacitor is directly hit by the current of the lamp. The presence of the inductance B causes a voltage increase to the capacitors' terminals much higher than the mains voltage. (i.e. V main 250 Vac V capacitor 450 Vac).

Typical working conditions Capacitors are generally located inside the fittings, where the temperature is always high. The duty is quite heavy, since the lamp may remain continuously switched on. At the moment of the switching, some remarkable transient overvoltages, can also take place. The discharge resistor R is indispensable; if it is not incorporated in the capacitor or in its assembling fitting, it must be included in the power supply.

FSU Glowstarters for tubular fluorescent lamps

General characteristics

The Afcap starter is a device, other than an on/off switch, which is suitable for opening and closing the pre-heating circuit of a fluorescent lamp for the purpose of starting the lamp. The Afcap starter will operate reliable and consistently ignite your fluorescent lamp. They are fitted with a special radio interference suppressor and are manufactured to the highest standards.

Technical data

Specifications FSU glowstarter

Lamp types T8 - T 12 600mm - 2400mm 4 - 80W

Ballast types Standard or low loss types

Supply voltage 200 - 250 Vac

Supply frequency 50 - 60 Hz

Temperature range 10°C / + 80°C

Starting time 1.8 - 2.5 seconds

Reference standards S.A.B.S. 1479 - 1989 / IEC 155 - 1983

Safety Government Gazette Notice No. 1489 14-7-1989

Approvals S.A.B.S. 1479-1989

Principle of Operations

When the supply is connected to the circuit the full mains voltage across the starter will establish a glow discharge and the increase in temperature due to the discharge will dose the bimetalic contact in the starter. The circuit for the lamp electrodes is now closed and they are now preheated before the ignition of the lamp can take place. The bimetalic contact in the starter cools down due to the elimination of the glow discharge by the closure of the contact and when the contact reopens the ballast will create a voltage sufficient to ignite the lamp. Once the lamp is on, the reduced voltage across the starter is not large enough to produce a glow discharge and the starter will not re-close again.

Performances required of the capacitor- Long working life (maximum 3% of pieces out of service after 30 000 hours) - Wide range of working temperature, (at least -25 ... +85°C). - No damages in case of failure - High stability of the capacitance value during the working life, in particular for series connected capacitors.

Additional informationThe life of a capacitor depends mainly on its working conditions. Temperature and voltage are particularly important in this respect.

Temperature It may be considered that each 10°C rise of the working temperature causes a 50% reduction of the capacitor life. Usually the following formula is adopted:

where: L(tx) is the capacitor life at temperature tx L(tn) is the capacitor life at the maximum rated temperature

Voltage A small rise of the working voltage causes a significant reduction of the capacitor life, according to the following formula:

Where: L(Ux) is the capacitor life at the voltage Ux L(Un) is the capacitor life at the rated voltage

Capacitors - General characteristics - Dielectric: bi-axially oriented polypropylene - Plates: self-healing metal layer deposited by evaporation under vacuum - Rated voltages: from 230 to 440V (see each series) - Rated frequency: 50 to 60 Hz - Range of working temperature: from -25°C to +100°C (see each series) - Climatic category: HPF/HMF (standard DIN 40040); 28/85/21 (standard CEI 34-26) - Storage temperature: from -40°C to +100°C - Reference standards: IEC 566 (ed.08-89); CEI 34-26 (ed-02-91); VDE 0560-6 SABS 1250-1979 IEC 1048-1991 - Approvals: see each series - Materials used: not polluting, compatible with the environment.

Regulations - International approvals The most qualified Approval Institutes has issued specific standards on this matter. The approvals are granted after the positive conclusion of all the foreseen, carried out in the laboratories of the various Institutes or in the other ones, duly authorised. For each standard there is a mark; the most recognised ones are:

In many countries it is forbidden to use capacitors which do not have the corresponding approval mark.

Electrical characteristics General values relevant to capacitors with discharge resistor and leads

Capacitance required for parallel connection at 230/250Vac (Values by way of example only: information provided by the manufacturers of lamps and ballast to obtain cos p >0,9).

Remark: For the correction of series power factor the capacitance is critical and is suggested by the manufacturer of ballasts. In this application the capacitance tolerance must be close (±4%).

Metal –Halide Lamps Lamp power (W) Capacitance

35 6 70 12 100 12 150 20 250 30

400 30-40 1000 70-90 2000 125

Mercury Vapour Lamps Lamp power (w) Capacitance (uF)

50 7

80 8 125 10 250 18 400 25

700 40 1000 60

Sodium low- Pressure Lamps Lamp power (W) Capacitance (uF)

18 6 35 20 55 20

90 30 135 40

180 40

Sodium high- Pressure Lamps

Lamp power (W) Capacitance (uF) 35 6 50 8 70 12 100 12

150 20 250 30-32

400 50 600 60

1000 100

Fluorescent Lamps Lamp power (W) Capacitance (uF)

4-6-8-10-13 2 15 4 16 4,5

18-20-30-36-40 4,5 22-32 5

2x36 9 58-65 7

80 10

115-125-140 18

Remark: Higher capacitance values can be obtained by connecting more capacitors in parallel.

Plastic Case

Applications: Metallized polypropylene film capacitors for power factor correction of lighting circuits

General characteristics: - Dielectric: bi-axially oriented polypropylene film - Plates: self-healing metal layer deposited by evaporation under vacuum - Case: plastic, self-extinguishing and UV stabilised

Terminals: - unipolar leads 0,8 mm on white PVC (105°C) 200 mm long (standard) - faston 2,8 mm (optional) - push-in wire adaptor (optional)

Discharge resistors: included

Technical data

Reference standards IEC566 CEI 34-26 BS14017 SABS 1250-1979 IEC 1048/9

Operating voltage (voltage temperature) 250Vac -25 ... +85°C

Rated frequency from 50 to 60 Hz

Dissipation factor tgδ<30 x 104(Vn- 50Hz)

Voltage test, between terminals 375 Vac

Voltage test, between terminals and case 2000Vac

Capacitance tolerance ±10%

Assembly - plastic stud M8 x 10 mm (standard) - with clip-on fixing (standard) - without clip-on fixing (optional)

Product range for lighting applications

Rated Capacitance

Dimensions

(mm)

SABS 1250/ 1979

IEC 1048/9

VDE 0560

(µF) D±0,5 L±2

2,0 25 55 # * 3,5 30 68 # * * 4,0 30 68 # * *4,5 30 68 # * *5,0 30 68 # * *6,0 30 68 # * * 7,0 30 68 # * *8,0 30 68 # * *9,0 30 68 # * *

10,0 30 68 # * *12,0 30 68 # * *14,0 37 68 # * 15,0 37 68 # *16,0 37 68 # *18,0 37 68 # * 20,0 37 68 # *25,0 40 93 # * 30,0 40 93 # *35,0 45 93 # * 40,0 45 93 # *45,0 52 93 # *

Other capacitor values available upon request # = Approval * = Approval pending

Note: For Clip-on applications, materials and Paint Finish must not exceed 1.0 mm in thickness.

STADIUM HIGH MAST LIGHTING CAPACITORS

General characteristics

These single-phase capacitors are designed and suitable for use in high mast stadium lighting applications, especially where the lights are switched on in stages. The capacitors are manufactured with heavy-edge metallised polypropylene film which not only provides self-healing properties but also increases the bonding between electrodes and endspray, thereby improving the current carrying capacity and ensuring better capability to withstand electromechanical stresses which occur due to switching surges. The self-healing metallised electrodes can withstand voltage transients exceeding the rated voltage. The capacitors are of the dry-type construction and are standard supplied in aluminium cases and fitted with discharge resistors.

Technical data Overloads Temperature range (case): -25°C to +70°C Voltage: 1.1Un Capacitance tolerance: ±5% Current: 1.3 InTest voltage terminal to 1.5 x rated voltage Max dv/dt: 25V/µsecTest voltage terminal to case: 1.5KV 50Hz 60sec Permissible relative humidity: Annual average < 95%, on 30 days/year continuously 100%, on other days occasionally 100% Dewing not admissible

Part no. C Un In Termination L Lt ∅ µF

01-12-0004 30 440V 4.15A 1mm2 PVC 350mm 157mm 60mm01-12-0015 60 440V 8.3A 1mm2 PVC 350mm 157mm 60mm

Standard packaging

Can size DXL Number of PCS Approximate weight

25x55 200 8

30x68 125 5

37x68 125 8

40x93 100 12

45x93 75 12

52x93 75 12

All dimensions are in mm Weight in kg (for indication only)

Standard box (cardboard)Biodegradeable packing materials

Stock 3 A = 250 x B= 150 x C = 250 Stock 4 A = 300 x B = 230 x C = 300 (standard)

MOTOR START

&

RUN CAPACITORS

Metallized polypropylene film capacitors for motor running applications

DescriptionMetallized polypropylene dry capacitors produced by African Capacitors offers high electrical characteristics as well as quality and reliability. The dielectric is a thin layer of low-losses polypropylene film on which the electrode is deposited by vacuum evaporation. This technology gives the capacitors self-healing capability when a short-circuit occurs in any point of the dielectric. The healing process, lasting a few microseconds, involves an amount of charges of some nano Coulombs and fully restores the efficiency of the capacitor. The high electrical characteristics of the polypropylene film and the manufacturing technology permit the manufacturer to produce capacitors with light weight, very small sizes and a high stability of the capacitance versus time. Capacitors are PCB free.

ConstructionThe capacitive element, made of wound layers of metallized polypropylene (dielectric), is housed in a cylindrical can with or without central fixing screw. The terminations can be either Quick-Connect type or cable.

The element is locked inside the can by a suitable sealing material.

Cans are made of suitable plastic.

The sealing lids and the supporting terminals are made of plastic material.

The plastic materials are self-extinguishing, Class V1 according to UL-94 Standards.

Capacitors with protection degree IP66 and cable outlets are sealed with epoxy resin.

ApplicationsThese capacitors are designed for general A.C. applications and particularly for: - starting and running of mono-phase induction motors. - single-phase supply of three-phase asynchronous motors. - series and parallel power factor correction of fluorescent and discharge lamps.

Nominal characteristicsRated voltage Vn: it is the r.m.s. value of the sinusoidal A.C. voltage applicable to the capacitor over the working temperature range and for which the capacitor has been designed. Rated current In: it is the r.m.s. value of the current flowing through the capacitor when the rated voltage Vn and the rated frequency fn is applied. Overloads: the capacitor can work with the following overloads over the permitted temperature range: - maximum voltage: 1,1 Vn - maximum current: 1,3 In the presence of overloads produced will result in a reduction of the life of the capacitors. Rated frequency fn: capacitors are designed for a frequency range between 50 and 60 Hz. Higher frequencies are permitted with a proper voltage derating. Temperature range: temperatures are measured on the surface of the capacitor: - minimum temperature: -25°C - maximum temperature: +70°C or +85°C (hottest-spot)

Storage temperature: -40°C - +85°C

Losses (tgδ): <0,1% at 50 Hz.

Capacitance tolerance: nominal tolerance ±5%. Different tolerances can be provided on request.

Pulse rise time dv/dt: the maximum permitted value is 20V/ µ sec. Short-time over voltages resistance: the self-healing characteristics, gives the motorrun capacitors a considerable strength to the transient over-voltages. They can stand short over-voltage up to peak values of 3 Vn. Tracking currents resistance (DIN 53480): on the plastic materials supporting terminals: KB175. Tests: the A.C. test voltages at 50 Hz for 2 sec, are, according to SABS 1353-1982 and VDE 560-8 Standards, the following: - terminal to terminal (DB) at 2,15 x Vn (AB) at l,4x Vn - terminals to case (DB) (AB) at 3 Kv During the tests self-healing discharges are admitted. DC current: capacitors can be used in D.C. current; the relevant values for our standard series are shown in the table 1.

D.C. Rated Voltage 600V

Non repet. peak 800V

dv/dt 20 V/µS

Self-discharge time: RC>3000 sec.

Protection degree: IP 00.

Capacitors with cables have IP 66 degree.

Definitions The service on motors is defined, according to SABS 1353 - 1982 and VDE 0560-8 par. 15, as follows; Continuous service «DB» The capacitor remain energised for a period of time much longer than the one necessary to reach the thermal equilibrium. Intermittent service «AB» Periods of operation are alternating with no voltage applied periods. The relative operation time «ED» is defined in percentage as the ratio between working time and the total cycle duration «SD». Ex: AB 25% ED - SD 24h. This capacitor is for an intermittent service with a cycle duration of 24h of which 6h with the voltage applied and 18h without voltage.

Climatic category and reference reliability (DIN 40040) According to DIN 40040 standard, climatic categories and reference reliability are defined by five letters with the relevant meanings listed in the tab. 2.

Table 2

1st Code letter

2nd Code letter

3rd Code letter

4th Code letter

5th Code letter

Lower Temperature

Limit

Upper Temperature

Limit (1)

Limits of the relative Humidity

%

Failure quotient Failure per 109

components hours

Duration of stress in hours

(4)

°C °C Average Max pcs hours

G -40 S 70 (2) (3) M 1000 S 30000 H -25 R 75 F <75 <95 N 3000 T 10000 J -10 P 85 P 10000 U 3000K 0 M 100 Q 30000 V 1000

(1) measured on the surface of the capacitor (2) yearly average value. (3) maximum value for no longer than 30 days a year During the remaining days it is occasionally

permitted a value of no more than 85%. (4) life duration at the rated voltage and maximum temperature with a failure rate started by the 4th letter (Ex.: MS - Expected life 30 000 hours and failure rate <3%).

Mechanical characteristics Vibrations: Capacitors conforms to DIN 40046 and IEC 68 - 2 - 6 standards under the following test conditions: - frequency range: 10-55 Hz - stress: 10 g - duration: 6 h - variation: logarithmic or linear Fixing: Capacitors may be provided of a M8 or M12 fixing stud. - 3,5 Nm torque for the plastic bolt. - 6 Nm torque for the aluminium bolt. Marking: Data shown on the capacitors are the following: - mark, series, capacitance and relevant tolerance, frequency, rated voltage and relevant reference reliability, climate

category (according to DIN 40040), temperature range, symbol of the discharge resistor if it is foreseen, international approvals marks, code of the manufacturing date. Reference SABS 1353-1982.

QualityThe uniformity and consistency of the quality of African Capacitors products is assured by the checks made on 100% of the finished products, by the quality control made on all the working stages and by life tests made on samples from the production.

Mounting considerationsCapacitors can be mounted in any direction. Apart from their resistance to vibrations, it would be better to mount them away from those parts subject to intensive vibrations; this is to avoid any undue stress. Take care not to mount the capacitor in areas close to devices radiating a strong heat. The temperature on the surface of the capacitor cannot exceed, even under the worst conditions, the maximum permitted temperature. It is advisable to make an experimental measurement of the temperature reached by the capacitor under the working conditions in the final application and after the thermal equilibrium has been achieved.

Remarks on the expected life duration The precise knowledge of the expected duration of the life of a capacitor, under certain working conditions, permits its correct use on the designated application.

The life of a capacitor depends on the working voltage and the temperature according to well defined laws.

Voltage: (with constant temperature)

Ln = expected life at the rated voltage Vn Lo = expected life at the working voltage Vo n = experimental value (about 7-10)

Temperature: (with constant voltage) The temperature influences the life of the capacitor as it favours the chemical reactions that are responsible for the dielectric aging. It may be considered that each 10°C rise of the working temperature causes a 50% reduction of the capacitor life. Usually the following formula is adopted:

where: L(tx) is the capacitor life at temperature tx. L(tn) is the capacitor life at the maximum rated temperature.

1 Technical information 1.1 Capacitance stability The present technology offers such a high stability of the capacitance versus time that the decrease of the capacitance in the expected life of the capacitor under normal conditions is about 1% with a maximum of less than 3% as requested by the norms. As the average capacitance from the production is normally higher than the nominal capacitance, it can still be expected to be within tolerance at the end of the expected life. Figure 2 represents the typical trend of the capacitance versus time.

Figure 2 AC/C%

1.2 Capacitance The capacitance of capacitors with polypropylene dielectric has negligeable variations either versus the temperature or the applied voltage. Figure 3 and Figure 4 show respectively the typical trends for the above mentioned series.

1.3 Loss angle The losses of the capacitor are defined as the tangent of the angle δ between Xc and Zc of the capacitor and therefore from the ratio Rc/Xc (ratio W/var).

Rc represents the losses in the dielectric, in the electrodes and in the inner connections of the capacitor.

Figure 5 and Figure 6 show the typical trends versus the temperature and the frequency.

1.4 Insulation resistance The value of the insulation resistance is not usually given. It is the given time constant of the capacitor τ = RxC, that represents a constant, in seconds (or MΩ x µF), independent from the capacitance. The real insulation resistance can be obtained from the abovementioned formula. Figure 7 shows the typical polypropylene trend of the constant τ versus the temperature.

2 Applications 2.1 Mono-phase induction motors A capacitor applied to a mono-phase induction motor improves its performance by generating or reinforcing the rotating field. Motors of this kind are made with two stator windings; one of them is the auxiliary and is fed by a suitable capacitor (Figure 8). The capacitor increases either the starting torque and the full load power as the current flowing through the auxiliary winding, de-phased by the capacitor, creates a rotating field. It has to be considered, in the case of the applicable capacitor, the voltage across it is usually higher than the mains supply. The choice of the capacitance is usually empirically made on the motor. This is because of suttle differences between different motor manufacturers. As the torque and the power of the motor also depends on the reactive power of the capacitor, the power can be calculated with the following formula.

2.1.1 Starting capacitor A high starting torque is required by the motor, in this case a high capacitance capacitor is used. A centrifugal switch generally disconnects this when approximately half the speed is reached. This is to avoid overloads of the auxiliary winding. The capacitor remains energised for very short periods therefore it will have sizes smaller than a running capacitor with the same capacitance. It is possible in this way to get starting torque’s about equal to double of the nominal requirements. The capacitance has to be such as to provide a reactive power about double of the nominal power of the motor with a Vc voltage. 2.1.2 Running capacitor After the initial start of the motor this capacitor is also needed to obtain the full load power of the motor where it then remains in continuous operation with the motor, thus forming an integral part of this circuit. The voltage Vc is about 1,5-2 times the mains supply and decrease with the increase of the load. With capacitive reactive power of about 75% of the nominal power of the motor, the comparison of power is slightly lower than that of a three-phase motor of equal size.

2.1.3 Starting and running capacitor Where both characteristics mentioned above are required by the motor design. It will therefore be equipped with a starting capacitor of a high capacitance which is disconnected once the speed has increased and with a running capacitor to remain in the circuit. 2.2 Three-phase asynchronous motors It is possible to connect a three-phase motor to a single-phase power line, using a capacitor of an appropriate capacitance. The capacitor will be connected as shown in Figure 9. With a capacitance of about 70µF/KW at 220 V it is possible to get a starting torque of about 1/4 of the nominal one, while the rated power will be about 3/4 of the nominal one. It is often necessary to increase the starting torque by also adding a starting capacitor that is disconnected once the motor is running. It is possible to reverse the rotation of the motor by connecting the capacitor to the other mains of the three-phase supply. The voltage on the capacitor, in steady conditions, is about 15% higher than the mains supply-

Technical data

Series MKP

Reference Standards SABS 1353 - 1982 VDE 0560-8; IEC

Application class (DIN 40040) See table Operating temperature range (case) -25 to +70°C

Storage temperature -40 to +85°C

Rated D.C. Voltage 630V

Peak non repetitive D.C. voltage 800V

Voltage rise/fall time (dv/dt) max 20V/u.sec.

Test voltage terminal to terminal 1,5 Un

Test voltage terminal to case 3KV 50 Hz. 1 minute according to VDE 0560-8 Case Self extinguishing plastic case and sealing cover according to IEC 707 and UL 94 standard Grade V1

Terminals Single 2,8 mm or 6,35 mm tags, double 6,35 mm tags, 0,8 mm thick. Cabtyre cable with top or side entry

Creepage distance > 7 mm

Clearance in air >5 mm

Permissible relative humidity Annual average < 75% at 24°C on 30 days/year. continuously < 95% on other days. Dewing not admissible.

Self discharge time RC > 3000 s

Degree of protection IPOO IP30 with plastic cap

Dissipation factor 20 x 104, over 30µF <50 x 10-4 at 20°C and 50 Hz

Vibration strength DIN 40040, Table 6 Class U

Fixing torque max M8 Stud driving torque 6Nm for aluminium 3,5 Nm for plastic

Plastic CaseApplications General purpose A.C. capacitors for motor run applications. General characteristics - Capacitive elements are wound on high speed automated machines, in cylindrical shape, non inductive, self-

healing, surge proof with low loss metallised polypropylene plastic film. - Filled with self-extinguishing resin (NO P.C.B).

Product range for motor run applications Plastic case

High duty cycle standard Low duty cycle optional

HPF/MS 30 000 hours 400V-

HPF/NT 10 000 hours 440V- 380V-

HPF/PU 3 000 hours 500V- 400V-

HPF/QV 1000 hours 440V-

Rated Capacitance (µ F)

Dimensions (mm) SABS 1353-1982

IEC VDE O56O-8

D±0,5 L±2

1,5 25 55 0 A A

2 25 55 0 A A 2,5 25 55 0 A A 3 35 55 0 A A

3,5 35 55 0 A A 4 35 55 0 A A 5 35 55 0 A A 6 35 55 0 A A 7 35 73 0 A A 8 35 73 0 A A 9 40 73 0 A A

10 40 73 0 A A 12 40 73 0 A A 14 40 73 0 A A 15 40 73 0 A A 16 45 73 0 A A 18 45 93 0 A A 20 45 93 0 A A 22 45 93 0 A A 25 45 93 0 A A 30 45 93 0 A A 32 45 93 0 A A 35 45 128 0 A A 40 50 128 0 A A 45 50 128 0 A A 50 50 128 0 A A

Typical dimension shown; Other dimension upon request 0 Approval A Approval pending

Starting arrangements for single-phase motorsGeneral information:-

It is not always realised that a true, pure single-phase induction motor would be impossible to start. The inherent characteristics of the motor and its single-phase windings mean that the rotor does not know which way to rotate when the winding is energised. Hence, the single-phase motor requires a second phase to start it. This second phase is commonly produced by an auxiliary or starting winding which produces a second phase artificially by means of a phase-splitting device. In this article, AFCAP presents some of the techniques for getting the rotor to rotate. Split-phase motors The phase-splitting device can be simply resistive by making the auxiliary winding out of much thinner wire than the main winding and therefore of a higher resistance (see figure 1). This, in effect keeps it more in phase with the a.c. supply than is the main winding. The resultant small phase shift (around 30°) gives a sufficient starting torque for light loads such as fans, where the initial inertia is low.

This arrangement takes a very heavy starting current, typically seven to eight times normal running value. It also requires the auxiliary winding to be switched out immediately after starting, to prevent overheating. It can however, be used for many intermittent duties, such as small drills, lathes and food-mixers, where full speed can be reached quickly. Motors using this technique are called split-phase motors. Capacitor motors A much higher starting torque can be produced by installing a capacitor in the auxiliary winding instead of resistance. A capacitor in series with this winding will

cause the current to be up to 90° in advance of that in the main winding. This enables motors to be produced which can operate from start against a heavy inertia, for example driving a refrigerator compressor. These motors also draw less starting current (around 4 to 4,5 times full load

value) than resistive split-phase arrangements. Starting capacitors (electrolytics) To produce a strong starting torque, large capacitance values may be necessary. This could mean large and expensive capacitors. Furthermore, although a large capacitor may be the correct value for starting the motor, it will be poorly matched to the motor once full speed is reached. Both these difficulties are resolved by using a special type of electrolytic capacitor in conjunction with an automatic cut-out device (see figure 2). Electrolytic capacitors provide a large capacitance in a small space at low cost. Although electrolytic capacitors are essentially d.c. devices, a special type is used for motor-starting. These special capacitors

will withstand a.c. for a few seconds providing they are not called upon to do this more than 20 times within an hour. These electrolytic motor-starting capacitors are entirely unsuitable for use with a.c. except strictly on an intermittent basis: they must be switched out of circuit after a maximum of three seconds. They are only used on single-phase a.c. motors which are provided with a centrifugal switch, or other device which cuts the capacitor out of circuit immediately after starting. Selection To obtain the correct starting torque, the correct capacitance value must be selected. This is basically a question of motor design: there is no straightforward regular relationship between capacitance and the motor size in kW. When replacing these capacitors, the capacitance value and voltage should be taken from the manufacturer's plate on the motor or from the old capacitor. Voltages and capacitance For most practical purposes, the electrolytic starting capacitors used in South Africa fall into three voltage divisions: Low voltage 110/125 V a.c. supply voltage 150 V r.m.s. max capacitor voltage (see Table 1). This range is moderately common in South Africa. Although these capacitors can be used on motors operating directly from a 110/125 V a.c. supply, they are also sometimes used across half of the main winding only, in dual voltage motors (see Figures 5 and 5a). In such instances the supply may be 220/250 V a.c., but the capacitors will only see 100/125 V a.c. The capacitance range extends from about 21/25 µF to say 1 000/1 200 pF. Medium voltage 220/250 V a.c. supply voltage. 275 V r.m.s. max capacitor voltage (see Table 2). This range is the most common in South Africa. The capacitance range is normally from about 20/30 µF to around 200/250 µ F. High voltage 280 V a.c. supply voltage. 350 V r.rn.s. max capacitor voltage (see Table 3). Although capacitors in this range are manufactured overseas; they are uncommon in South Africa. This range normally begins at say 21/25 µF but terminates at around 145/174 µF maximum.

Storage and reforming These capacitors contain a small amount of moisture. For reasons of safety they are not hermetically sealed, but, on the contrary, normally incorporate a safety vent via which the capacitor contents may be expelled on overstress. They therefore have a limited shelf life depending on the storage temperature. Well made capacitors can typically have a shelf-life in excess of five years when the storage temperature does not exceed 40°C. Starting capacitors which have not been used for, say, over a year should normally be tested before placing them in service. If any deterioration is suspected, the capacitors should be 'reformed'.

This can be done by applying the mains voltage to the capacitor for a second or so at a time, repeating at intervals up to a maximum of ten times. In the case of capacitors already installed on motors, the motor should be released from load and then switched on several times. The main voltage in all cases, should not exceed the rated voltage of the capacitors. The deterioration of these capacitors when not in use, does not follow any clear linear law. In general, under typical South African conditions they appear to have a very fair shelf-life, although it can be anticipated that at least a few out of any batch will break down if not 'reformed' after a few years. Running capacitors (non-electrolytic). In certain applications a lower starting torque is acceptable. In these cases a small capacitor can be considered as a phase-shifting device. This smaller capacitor need not be an electrolytic type and can be of paper or metallised-film construction which can be left permanently in circuit (see Figure 3), dispensing with the centrifugal switch or other 'cut-out' arrangement. This arrangement not only provides some capacity to assist motor-starting, but improves the motor power factor and the running characteristics. However, because the capacitor must withstand a.c. continuously, it tends to be large physically, despite the limited capacitance. These capacitors are always described as 'running capacitors'. Selection Once again, this is a matter for the designer: the user must adhere to the capacitor parameters shown on the motor nameplate or on the capacitor being replaced. The choice of a running capacitor is even more limited than with a starting capacitor: Capacitance This must be correct within ±5% and is sometimes stipulated down to a fraction of a µF (e.g. 6,8 µ F). Voltage This is almost always above that of the mains voltage (e.g. a motor operating from a 250 V a.c. mains supply will normally take a running capacitor rated at 380/440 V a.c. continuous). A 440 V a.c. capacitor should always be used unless there are positive indications that a lower voltage is permissible. Motors using both starting and fanning capacitors. Motors may be fitted with starting capacitors only or running capacitors only, depending on type of duty which faces the motor. Alternatively, the motor may be fitted with both a starting and also a running capacitor.

This gives the advantages of both worlds: i.e. the motor now has a maximum starting torque plus the advantage of an improved power factor and running characteristics whilst running on full load (see Figure 4). Table 4 shows the various types and values of capacitors over a complete range of small single-phase 200/250 V a.c. motors manufactured by a large international company. It will be noted that motors with similar parameters do not always use similar capacitors. The capacitor values shown are those selected by the designer for this particular range of motors: these may or may not apply to other ranges or to similar motors made by another manufacturer.

Some typical values:-Motor Starting Capacitors (electrolytic) This information is given as a general indication only, without commitment. The specific capacitance and voltage should be taken from the motor name plate or from the capacitor being replaced.

Table 1. Low voltage 110/125 V a.c. supply voltage 150 V r.m.s. max capacitor voltage.

Motor size Typical capacitor value

kW µ F0,093 100/1300,124 120/1500,186 160/2000,249 240/2300,373 320/4000,560 400/5000,746 500/580

Table 2. Medium voltage 200/250 V a.c. supply voltage 275 V max capacitor voltage

Motor size Typical capacitor value

kW µ F0,093 20/300,124 30/400,185 40/700,249 60/800,373 80/1100,560 108/1400,746 138/182

Table 3. High voltage 280 V a.c. supply voltage 350 V r.m.s. max capacitor voltage

Motor size Typical capacitor value

kW µF 0,093 26/370,124 37/510,186 51/680,249 68/900,373 90/1150,560 105/1300,746 130/165

Electrolytic motor start capacitors

Description The Afcap motor starting capacitors are non-polarised aluminium electrolytic capacitors for a.c. applications. To start a.c. single phase motors. These capacitors are for intermittent working only with a maximum duty cycle of typically 20 starts, each of 3 seconds duration, per one hour. These capacitors must be switched out of circuit by a centrifugal switch, or other devices, immediately after starting the motor.

Construction

The capacitive element, made of wound layers of aluminium foil and craft paper is housed in a cylindrical can. The terminations can be either quick-connect type or cable. - The element is locked inside the can by a suitable sealing material - Cans are made of a suitable plastic - The sealing LIDS incorporating a pressure vent supporting the terminals are made of plastic

material The plastic materials are self-extinguishing and according to UL-94 Standards. V1

Mechanical characteristics Vibrations: Reference Standards Din 40046 and IEC 68-2 - Frequency range: 10 - 55 Hz - Stress: 10 g - Duration: 6 h - Variation: Logarithmic or linear Fixing: - Normally by enclosure or fixing clamp Marking: Data shown on the capacitors are the following: - Logo, series, capacitance and relevant tolerance, frequency, rated voltage and temperature range, symbol of the

discharge resistor if fitted, appropriate approval marks and the code of manufacturing date. Quality: The uniformity and consistency of the quality of African Capacitors products is assured by the checks made on 100% of the finished products, by the quality control checks made on all the working stages and by life tests made on samples from the production.

Technical characteristics and measurements Using the circuit shown in Fig. 1, apply rated voltage to the capacitor and measure current and dissipated power. Current will be measured after 2 - 3 seconds, dissipated power within 3 seconds after application of rated voltage. Capacitance and power factor must be calculated with the following formula:

Note: To have accurate measurements one requires special types of instruments Other characteristics Please, inquire for information about different duty cycles or particular applications.

Type Standard Applications Max working voltage (1/10 max. of the start period)

Vg 1.2 Vn

Climatic category up to 260 Vac - 10/ +60/ F=JUF (DIN 40040) 280 ÷330 Vac - 10/ +55/ F=JVF (DIN40040)

Capacitance tolerance % see table; ± 10% on request

Power factor: Typical value Max. value

% %

8% 12%

Vn °C NT N T t

124÷ 330 V a.c. 60°C 40°C

(*)60 80 6 8

(10) (10) 590 350

1.7% 2.8%

Cycle characteristics: Max. start-up time =

Note Different cycles are possible with the limits of the indicated NT and T max.; for ex. (*): NT= 60 could also represent N= 10 / T=6 or N=20 / T=3 etc.

°C The max temperature in conformity with the specified climatic category.

Stability test: 8h. at 1.2 Vn According to vide 560-8

NT N T t

60 20 3s

177s 1.7%

Rapid test 6h. at Vn

°C NT N T t

25°C 120 60 2

58 3.3%

Expected life: No. of starts up

°C NT

~ 40 °C 30

> 100.000

Storage test h l00h at 85 °C

S

Working voltage depending on the starter rating NT

• Standard use at rated V. with NT=60 (N=20 starts/hour and T=3" of start-up time). At the rated V., N and T can change on the line VN=1OO% in conformity with the max values of start-up time indicated in the data sheet-TABLE 2. • For heavier cycles NT>60, the allowed working V. is lower than the rated V. of the % indicated on the lines in conformity with the required NT (es.: a 260VN capacitor with a NT= 120 can work at a W.V=260x0.7 = 182 Vac). • The indicated values K represent the multiplicative coefficient that, according to the wished NT and the real working voltage, give us the possibility to find out the rated voltage of the capacitor (es.: an appliance at W.V=220 VN With NT=90 needs using of capacitor at working V=220xl.25 = 275 Vac).

Product range for motorstart applications

Rated Capacitance (µ F) Dimension (mm)

D±l L±2

20-30 40 80

30-40 40 80

40- 50 40 80

50-65 40 80

65-80 40 80

80 -100 40 80

100 -125 40 80

125 -160 40 80

125 -160 40 114

160 - 200 40 80

160 - 200 40 114

200 - 250 40 114

250 - 300 40 114

Plastic caseTypical dimensions shown other dimensions upon request

CAPTYRE SIDE ENTRY SINGLE MALE TAG

POWER FACTOR CORRECTION

Power Factor CapacitorsGeneral Characteristics The single-phase capacitors are designed and suitable for use in fixed or automatic industrial power factor correction units. The capacitors can be used in single phase or 3 phase installations, and they can easily be assembled so as to obtain the three-phase delta connection. The capacitors are manufactured with heavy - edged metallised Polypropylene film which not only provides self-healing properties but also increases the bonding between electrodes and ensure, thereby improving the current carrying capacity and ensuring better capability to withstand electro-mechanical stresses which occur due to switching surges. The plastic can type capacitors are of the dry type construction and no liquid fillers are present inside the dielectric. They should be fitted inside a metal enclosure and properly protected to ensure they stay within their specification. The metal can type capacitor is fitted with a pressure sensitive safety device. Should the internal pressure of the capacitor rise, the safety device will operate and isolate the elements from the power source.

Electrical characteristics Overloads Rated voltage : 400, 415, 460VAC Voltage : 1.1 Un Rated frequency : 50Hz Current : 1.3 In Tolerance : ± 5 % Standard Max dv/dt : 25 V / µsec Dielectric losses : < 0.4W / KVAR Temperature : -25C°/+45C° Discharge resistor : Optional Reference specification: IEC 831/1-2 Note An unrestricted clearance of ± 15mm is required above the capacitor to facilitate the free movement of the quick disconnect device.

Part no. C µF

Un Vac

In A

Kvar Rating

Termination L Lt D Canister type

01-12-0006 33.3 415 4.34 1.8 2.5 mm2 PVC 128 128 50 fig l

01-12-0020 66.6 415 8.68 3.6 2.5 mm, PVC 130 130 65 fig l

01-12-0025 50.0 460 7.23 3.3 2.5 mm, PVC 130 130 65 fig l 01-12-0016 66.6 400 8.37 3.3 6 x 30 HEX 150 193 60 fig.2 (metal)

Fig 1 Fig 2 African Capacitors is not responsible to any extent for possible damage to persons or things, of any kind derived from the improper installation or application of power factor capacitors.

Pulse Grade Capacitors General Characteristics Pulse grade or discharge capacitors are used in a variety of applications of which all are dependent on cycles of rates of change and discharge. Typical applications would be in electric fencing energisers or in lasers. Features These capacitors for discharge duty usually need to specially designed and constructed, therefore full details of the application must be made available. Note A completed capacitor questionnaire would greatly assist with the design of the capacitor. Please complete the questionnaire in the back of the catalogue. Technical data

Part no. C µF

U Vdc

Tg§ max.

ESR mΩ

du/dt V/u

Irms A

Ipk A

L mm

D mm

01-04-0017 30 900 0.0015 7 20 8 600 93 45

THYCOM

&

C.V.T. POWER CAPACITORS

C.V.T. Capacitors General characteristics The technological development of thyristors started an ever increasing use of industrial power electronics. Many applications are based on forced commutation by means of capacitors. They are wound in such a way to provide a minimum Series induction (ESL) and a low Series Resistance (ESL), to reduce power dissipation. These values are obtained by using dielectrics which offer very low losses and give high stability of the capacitance versus temperature and time. Features The capacitive elements are wound on high speed automated machines, in cylindrical shapes, non-inductive, self-healing, surge proof with low loss metallised polypropylene dielectric. Terminations are connected to electrodes through sprayed ends, ensuring high contact reliability and low ESR. The tight construction of the case guarantees complete protection against external pollutants. The self-healing metallised electrodes can withstand voltages transients exceeding the rated voltage without causing short circuits.

Technical data Temperature range (case): -25°C to +70°C Capacitance tolerance: ±5% Test voltage terminal to terminal: 1.5 x rated voltage Test voltage terminal to case: 1.5 KV 50 Hz 60S Permissible relative humidity: Annual average < 95% on 30 days/year, continuously 100%, on other days occasionally 100% Dewing not admissible Life expectancy: > 30 000 hours at Un

Note A unrestricted clearance of ± 15mm is required above the capacitor to facilitate the free movement of the quick disconnect device.

MECHANICAL SPECIFICATION

Termination Part no. C µ F Screw Nut

P L Lt ∅

01-05-0071 15 6 x 30HEX M6X5HEX 24 117 159.75 60

01-05-0084 20 6 x 30HEX M6X5HEX 24 117 159.75 60

01-05-0093 25 6 x 30HEX M6X5HEX 24 117 159.75 60

01-05-0101 30 6 x 30HEX M6X5HEX 24 150 192.75 60

01-05-0111 35 6 x 30HEX M6X5HEX 24 150 192.75 60

01-05-0177 40 6 x 30HEX M6X5HEX 24 150 192.75 60

01-05-0128 50 6 x 30HEX M6X5HEX 24 150 192.75 60

01-05-0341 12 6 x 30HEX M6X5HEX 24 196 238.75 60

01-05-0351 18 6 x 30HEX M6X5HEX 24 196 238.75 60

01-05-0380 40 6 x 30HEX M6X5HEX 24 150 192.75 60

ELECTRICAL SPECIFICATION

Part no. C µ F

Urms Tgδ MAX

ESR mΩ

du/dt V/µs

Irms A

Lpkr A

01-05-0071 15 440V 0.0018 17 30 16 450

01-05-0084 20 440V 0.0019 14 30 16 600

01-05-0093 25 440V 0.002 11 30 16 750

01-05-0101 30 440V 0.0029 14 25 16 750

01-05-0111 35 440V 0.003 13 25 16 875

01-05-0177 40 440V 0.0031 12 25 16 1000

01-05-0128 50 440V 0.0033 10 20 16 1000

01-05-0341 12 660V 0.0019 23 15 12 180

01-05-0351 18 660V 0.0022 17 15 12 270 01-05-0380 40 660V 0.003 11 15 16 600

Other dimensions and values available on request.

Thyristor Commutation Capacitors General characteristics Non-inductively wound metallised polyester and polypropylene film capacitors are highly suited to SCR commutation applications, by virtue of their low dielectric loss characteristics. All designs have heavy duty internal and external connections rated to carry the high current needed to reverse bias thyristors in chopper circuits.

Features High current capability Heavy duty internal connectionsSpace saving Robust zinc plated brass screw terminalsMetal cased. Vibration and shock proof

Technical data Temperature range (case):

-25°C to +70°C

Capacitance tolerance: ±5% Test voltage terminal to terminal: 1.5 x rated voltageTest voltage terminal to case: 1.5 KV 50 Hz 60S Permissible relative humidity: Annual average < 95% on 30 days/years, continuously

100%, on other days occasionally 100% Dewing not admissible Life expectancy: > 30 000 hours at Un

Note An unrestricted clearance of ±15mm is required above the capacitor to facilitate the free movement of the quick disconnect device.(fig. 2 construction)

ELECTRICAL SPECIFICATION FOR POLYPROPYLENE FILM CAPACITORS

Part no. C µ F

Urms Tgδ MAX

ESR mΩ

du/dt V/µs

Irms A Ipk A Canister type

01-08-0051 25 440V 0.0015 8 20 16 500 fig.2

01-08-0096 16 660V 0.0016 14 20 16 320 fig 2

01-08-0106 20 660V 0.0017 12 20 16 400 fig.2

ELECTRICAL SPECIFICATION FOR POLYESTER FILM CAPACITORS

Part no. C µ F

Urms Tgδ MAX

ESR mΩ

du/dt V/µs

lrms Ipk Canister type

01-08-0020 50 300V DC 0.0070 22 10 14 190 fig.l

01-08-0040 45 400V DC 0.0070 22 10 22 225 Fig.2

All values taken at 1 Khz at 20oC

MECHANICAL SPECIFICATION FOR POLYPROPYLENE FILM CAPACITORS

Termination Part no. C µF

Urms

Screw Nut

P L Lt ∅ Canister type

01-08-0051 25 440V M6x30HEX M6x5 24 115 157.75 60 fig.2

01-08-0096 16 660V M6x30HEX M6x3.3 24 191 233.75 60 fig.2

01-08-0106 20 660V M6x30HEX M6x5 24 191 233.75 60 fig.2

MECHANICAL SPECIFICATION FOR POLYESTER FILM CAPACITORS

Termination Part no. C µF

Urms

Screw Nut

P L Lt ∅ Canister type

01-08-0020 50 300V DC M6x20HEX M6x5 NA NA NA NA fig.l

01-08-0040 45 400V DC M6x30HEX M6x5 24 155 197.75 60 fig.2

Other dimensions and values available on request.

2.0 Personal safety 2.1 Electrical or mechanical misapplication of capacitors for power electronics may be hazardous. Personal injury or property damage may result from explosion of a capacitor. 2.2 Do not dispose of capacitors in fire, explosion may result.

Warning Do not misapply capacitors for power electronics

African Capacitors is not responsible to any extent for possible damage to persons or things, of any kind, from the improper installation and application of capacitors for power electronics. 1.0 Misapplication forms The more common types of misapplications that result in failures are: 1.1 Ripple current or voltage above specification. 1.2 Application voltage beyond surge voltage specified. 1.3 Temperature exposure beyond specified limits. 1.4 Unusual service conditions: - Unusual mechanical shocks and vibration - corrosive and abrasive particles in cooling air, conducting dust in cooling air oil or water vapour or corrosive

substance - explosive gas or dust radioactivity - unusual storage or transport - unusual humidity (tropical or subtropical region) - excessive and rapid change of ambient temperature or humidity - superimposed radio frequency voltages In case of doubt between service conditions and corresponding capacitor performances, please consult the AFCAP technical department.