MOTOR RUN CAPACITORS SELECTION GUIDELINES

Engineers who need to design-in motor run capacitors for their applications have many choices available to them today. While this means that a close match for the required application is probably readily available, it also complicates the selection process. Designers have a choice of a large variety of shapes and electrical performance ratings, not to mention agency approvals. With so many variables, choosing the best capacitor can become a daunting task. Selection of the best capacitor requires a step-by-step process, as outlined below. First and foremost is the selection of the capacitance valuethe most important parameter to be determined. The wrong capacitance value could change AC power phase and will prevent optimum motor operation. A rule of thumb has been developed over the years to help simplify this process. To select the correct capacitance value, start with 30 to 50F/kW and adjust the value as required, while measuring motor performance. Once the capacitance value has been selected the voltage rating of the capacitor must be determined. This is not just a simple process of choosing a capacitor that has a voltage rating at or above the supply voltage to the motor. Factors that affect the selection of the proper voltage rating of the capacitor include: Voltage de-rating factor (because of special operating conditions) Safety agency requirements. UL 810, ENEC 60252 Class A, B or C, etc. Reliability requirements Maximum operating temperature Space available Strict attention should be given to determining the voltage rating of the capacitor, with special weight being given to the type of operation: intermittent or continuous. In general, the voltage across the capacitor will be higher than the supply voltage. For these reasons, it is recommended that the rated voltage of the capacitor be at least 30% higher than the supply voltage to the motor. For higher reliability or if other adverse conditions exist, an even higher rating may be recommended. Now that the main electrical requirements have been determined, the physical requirements need to be specified, starting with the type of capacitor container (or package). Many choices exist here too.

Boxes

Round tubes

Metal cans

The first parameter to be determined is the type of container plastic box plastic tube metal can (oval or round) specialized casing Then, the type of leads or terminals needs to be selected. Does the design require? 2 lead wires (un-insulated) 4 lead wires. (un-insulated) 2 or 4 faston lead connections. 2, 3 or 4 insulated lead wires with a specified length of lead wires 2, 3 or 4 insulated lead wires with quick connect terminations and of a specified length of lead wires. Combination of any of the above lead wire configurations. After selection termination, explore mounting considerationshow the container is to be secured in place and where the mounting tab or bracket is to be located: No mounting tab. Along one edge of box. Along center of top or bottom of box. Screw thread on bottom of round tube Mount tab at a 90 degree angle or in line with container or at some other angle Metal mounting bracket Dont forget the mounting tab material Plastic tab molded to container Metal tab incorporated into container Screw type mounted into container (round tubes only) Once the case size, mounting requirements and lead style has been chosen, the physical size of the capacitor must determined. Here the dielectric material becomes a major factor. Today, the most commonly used dielectric materials in motor run applications are Polyester and Polypropylene. Each material has characteristics that give it advantages over the other in different situations. Both materials are typically supplied in metallized form when used in motor run applications. There are several different types of metallization material, but here we will limit discussion to two types. Different types of metallization have been utilized in motor run capacitors for many years in order to meet the reliability requirements of the various safety agencies (UL, CSA, VDE, ENEC, etc). This is particularly true for polypropylene film, which is the dielectric of choice for motor run capacitors.

Polypropylenes low loss factors and other dielectric properties make it ideal for use in applications where AC voltages and currents are present. (SEE TABLE 1) Characteristic Melting Temp (C) Dielectric constant Dissipation Factor (%) @1 kHz Insulation Resistance (100VDC) Dielectric absorption Maximum Operating Temperature Temperature Coefficient Density G/cm3 Table 1 Polypropylene capacitors are supplied not only with standard metallization, but are now available with safety film construction. Safety film construction has significant differences compared to standard metallized film. Both types of metallization have the self healing property. However, safety film types are constructed in such a way that the self healing process is more controlled. This reduces characteristic changes that occur in the capacitor when self healing happens. Safety film differs from standard metallization in that the foils surface has thousands of micro fuses built into the material. These fuses are formed by a mosaic or T pattern on the film, where standard metallization is a solid appearance. When a fault develops in the foil area, only the fuses around the fault react. The area affected is limited and the fault is more controlled, significantly reducing internal damage to the capacitor. Safety films design patterns are illustrated below. Polyester 260 3.2 1.0 5000MxuF .2% 125C +400 ppm/C 1.4 Polypropylene 165 2.2 .1 30000MxuF .02% 105C -200 ppm/C .95

Safety film capacitors are only slightly larger than standard film capacitors and have electrical specifications similar to standard film capacitors. But with improved failure mechanism control and reliability, the safety film design offers significant long-term advantages. Conclusion When selecting motor run capacitors all of the required parameters need to be identified in an organized process. Remember that, not only are the physical and basic electrical requirements important, but the type of dielectric material and the metallization technique should be examined. The wrong choice here can have adverse effects on the overall performance of the capacitors. Designers should take into consideration both the short term and long term affects that could occur when the performance specifications are compromised due to physical size constraints. It is recommended the product designer contact the capacitor supplier early in the design phase so the capacitor supplier can help identify the best capacitor for the application that meets the physical and electrical requirements.