INCAP LIMITED

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RECOMMENDATION FOR SAFE USAGE ALUMINIUM ELECTROLYTIC CAPACITORS

INCAP Limited ( ICL ) has set up a unit for manufacture of Aluminum Electrolytic Capacitors ( AECs ) of different sizes.

Following precaution may be taken to ensure safety of end product while Screw Terminal/Large dia capacitors.

Item		Instructions
Operating temp. Ripple Current	1.	Check the operating and installation environment and use the capacitor within the range of the rated performance specified in the catalogue or delivery specifications
	2.	Maintain operating temperature and ripple current with in the specified ranges. Base your choice of capacitors on the maximum load conditions. A capacitor will overheat under Excessive current, potentially resulting in open/ short circuit, or other major failure.
	3.	A capacitor also generates its won heat. Please bear in mind that the capacitor heats up the interior of the equipment, and the user has to take appropriate precautions. Operate the unit under normal conditions and check the temperature of the area surrounding the capacitor.
	4.	The allowable ripple current declines with the rise in ambient temperature (the temperature of the capacitor surroundings). Consider the allowable ripple current at the maximum predictable ambient temperature.
	5.	Electric Characteristics change as frequency changes. Check frequency changes in order to choose the right capacitor. Special attention needs to be given to low frequencies, when equivalent series resistance rises, generating greater heat.
Applied Voltage / Polarity	1.	In general, capacitors have polarity. Applying reverse voltage or AC voltage to a capacitor may active the safely vent or cause a short circuit, fire or other major failure. Use a separate AC capacitor in an AC voltage.
	2.	Use a bipolar capacitor for circuits whose polarity reverses. However, as in any other case, do not use a bipolar capacitor in an AC circuit.
	3.	Do not apply voltage in excess of the rated voltage. When an AC voltage is superimposed on DC voltage, peak value sum of DC + AC Voltage) should not exceed rated voltage. Excessive voltage may spoil the capacitor accordingly
	4.	Specifications on surge voltage have restricted conditions and therefore do not guarantee long hours of operation. Voltage should never exceed the rated voltage of the capacitor, even for brief periods. Choose your capacitor accordingly.
	5.	Do not use standard capacitor for a circuit that is quickly charged and discharged repeatedly. Use a dedicated capacitor for application such as welding unit or our photo flash charging / discharging.

Before Installation	1.	Dropping or otherwise impacting a large dia capacitor may result in a decline in its electric performance, causing Do not use any capacitor if it is physically damaged.
Installation	1.	Do not install wiring or a circuit pattern near the safety vent. When the safety vent is activated, electrolyte may spurt out, resulting in short circuit followed by fire or other secondary hazard due to tracking or migration.
	2.	Do not lay out heat-generating components near the capacitor. Radiated heat and other partially high temperatures may shorten the life of the capacitor.
	3.	Do not hinder the activation of the safety vent. Allow a minimum clearance of 5 mm above the safety vent for all large dia capacitors. This shall permit easy escape of gas under pressure while safety vent in operation.

Guide lines for Installation, Maintenance and disposal of screw Terminal Capacitors
Item		Instructions
Installation	1.	For better reliability and life the Screw Terminal Capacitor mounting should be Screw-terminal type done with screw terminal coming up. In case the capacitor is to be installed on its capacitors side, the anode terminal side must face up-ward. If the anode terminal is located below the cathode terminal, internal corrosion may result during long-term use and hence not recommended.
	2.	The pressure valve (cap face) should not face downward. Electrolytic solution and compounds (element fixing agents) may leak through valve when it fails in adverse operating condition.
	3.	Recommended tightening torque and permissible terminal current (maximum current a terminal can withstand) for each terminal screw are listed below.
		Terminal	Recommended Torque (permissible level) (N.m) IDEAL MIN MAX	Permissible terminal current (A)	Remarks
		M5	2.2 (1.5 - 3.0 )	60	For cap 0 36 to 0 90
		M6	3.1 (3.0 - 3.5 )	100	Shall be provided on 0 90 on request
	4.	The terminal screws (M5 standard under head: 10mm, M6 standard under head : 12mm) are assembled on capacitors and designed for wire/thickness not exceeding 2mm. Add to the screw length for wires more than 2mm thick. Heat generated due to small screw clamping area could cause a failure.
	5.	If a screw is loose or angled, that portion generates heat, with a danger of fire or other serious failure. Check that the screw is inserted perpendicular and securely tightened with torque wrench.
	6.	We recommend a bar hole diameter of 6mm for M5 terminals. And 7mm for M6 terminals. Large hole diameter may result in poor contact between the terminal surface and the bar, causing local heat buildup, with a danger of major failure.
	7.	Do not apply physical stress (tightening with clamp or fixture, etc.) to the curled portion of capacitor (seal contacting the case and cap). Any such practice may result in seepage of electrolyte or cracking of sleeve.
Operating Environment	1.	Water, saltwater, oil or other electrically conductive liquid on a capacitor, or using a capacitor when it is damp with dew may cause a failure. Oil on the rubber seal or safety vent may cause a decline in alright ness. Do not use any capacitor in contact with liquid. Do not use capacitors that have been wet with water or other liquids.
	2.	Do not use or leave a capacitor in areas where there is hazardous compound such as hydrogen sulfide, nitrous acid, sulfurous acid, chloring and bromine, or ammonia which may corrode the capacitor.
	3.	Do not use or leave a capacitor in an area exposed to ultraviolet light, or radiation.
	4.	Powders (dust, etc.) that settle between terminals can absorb moisture and cause corrosion and short circulating of the terminal. To clean the surface, disconnect power, allow the capacitor to discharge, and wipe the terminals with paper or a towel lightly dampened with water or ethanol. Do not use soap solution or other cleaning agent.
	5.	Do not use a capacitor in an area subject to excessive vibration or impact. Specially designed capacitor is needed for such application.
Storage	1.	Store all capacitors indoors at a temperature at 20-35^oC and relative humidity not more than 75%. Don not expose the capacitor direct to sunlight. The maximum shelf life of Screw Terminal Capacitors is three years. All large diameter capacitors which have been on the shelf for more than two years shall have high leakage current. Treat them with appropriate rated DC voltage before use by charging through a 1 kW resistor in series for a minimum period of 1/2 hour at Room Temperature. It is better not to use capacitor stored more than five years.
	2.	Store capacitors in their original packaging whenever possible.
	3.	Even after discharged, capacitors may hold an electrical charge due to re-striking. Do not touch the terminals with bare hands. Touching the terminals could cause an electric shock. Discharge all capacitors with a resistor of approx. 1 kW or using incandescent lamp across the terminals.
Test Run	1.	Do not touch the terminals of medium or H.V capacitor with bare hands, which may cause an electric shock.
	2.	Do not short-circuit a capacitor between its terminals with an electricity conductive material as it will spoil the capacitor quality.
Maintenance and Servicing	1.	Conduct periodic checkups on all large diameter capacitors for industrial equipment following checkpoints given below:
		(1) Appearance : Condition of the safety vent (open, notably swollen), liquid leaks of any other abnormality
		(2) Electrical Performance : Capacitance, tangent of loss angle, leakage current, and other parameter specified in the delivery specifications.
		The standard temperature for measuring electrical performance is 20^oC. Leave the capacitor at 25^oC and wait for the inside of the capacitor to reach the specified temperature before taking measurements. Before each periodic checkup, turn off the equipment and completely discharge the capacitor.
	2.	Replace all capacitors whose service life has reached its end. When replacing one capacitor, always replace all of them. Mixing old and new capacitors may cause an imbalance in the ripple current of voltage sharing, risking failures such as activation of the safety vent or short circuit.
In an emergency	1.	If gas is detected while a product is in use, turn off the main power supply or unplug it.
	2.	When the safety vent of a capacitor is activated, a hot gas exceeding 100^oC will escape. Avoid proximity to the vent and to areas exposed to the gas.
	3.	Should the gas jet get in your eyes, wash them immediately with clean water. If you inhale the gas, gargle immediately. The gas is composed of a gaseous form of hydrogen or organic solvents.
	4.	Should the electrolyte come in contact with your skin, wash with soap and water.
For scrapping or disposal of used capacitors Burial	1.	Used capacitors/capacitors stored more than 5 years are classified as scrapped of used capacitors material. For burial they are handled as controllable industrial waste because of Burial the nature of the contents (electrolyte). Entrust that no waste products enter the market.

Incineration	2.	Most of the material is aluminium and cannot be completely burnt. In incineration, take the following into consideration: - To prevent capacitor explosion, before incineration, in an incineration chamber either pierce the exterior or crush the capacitor. Be sure to wear protective clothing during this operation, since electrolyte or gas will jet out if the inner pressure of there capacitor is high. - Because of the sleeve material (polyvinly chloride), low temperature incineration may emit hazardous gases. Burn the material at high temperature only.