Screw Terminal Aluminum Electrolytic Capacitors ALS60/61 Series, +85°C Overview Applications KEMET's ALS60/61 Series of screw terminal capacitors is designed for high voltage, high ripple current applications. They are ideally suited for industrial and commercial applications demanding high reliability and long-life expectancy such as frequency converters, uninterruptible power supply (UPS) systems and switch mode power supplies (SMPS). Typical applications for KEMET's ALS60/61 Series of capacitors include smoothing, energy storage, demanding power supplies, AC motor control, traction and welding. Benefits • • • • Long life, up to 20,000 hours at +85°C (VR, IR applied) High ripple current Excellent surge voltage capability Optimized designs available upon request Click image above for interactive 3D content Open PDF in Adobe Reader for full functionality Part Number System ALS6 0 A 561 KE 550 Series Stud Option Termination Capacitance Code (µF) Size Code Voltage (VDC) Screw Terminal Aluminum Electrolytic 0 = Plain Can 1 = Threaded mounting stud See Termination Table First 2 digits equals first 2 significant figures, 3rd digit is the number of additional zeros. See Dimension Table 550 = 550 One world. One KEMET © KEMET Electronics Corporation • P.O. Box 5928 • Greenville, SC 29606 (864) 963-6300 • www.kemet.com A4042_ALS60_61 • 8/24/2015 1 Screw Terminal Aluminum Electrolytic Capacitors – ALS60/61 Series, +85°C Performance Characteristics Item Performance Characteristics Capacitance Range Rated Voltage 560 – 3,300 µF 550 VDC Operating Temperature -40 to +85°C Storage Temperature Range -55 to +85°C Capacitance Tolerance Operational Lifetime ±20% at 100 Hz/+20°C D (mm) Rated Voltage and Ripple Current at +85°C (hours) Rated Voltage at +85°C (hours) 51 18,000 36,000 66 19,000 38,000 77, 90 20,000 40,000 End of Life Requirement Shelf Life Leakage Current Vibration Test Specifications Standards ∆ C/C < ±15%, ESR < 3 x initial ESR limit, IL < initial specified limit 2,000 hours at +85°C or 30,000 hours at +40°C 0 VDC I = 0.003 CV or 6,000 (µA, whichever is smaller) C = rated capacitance (µF), V = rated voltage (VDC). Voltage applied for 5 minutes at +20°C. Case Length < 220 mm Procedure Requirements 0.75 mm displacement amplitude or 10 g maximum acceleration. Vibration applied for three 2-hour sessions at 10 – 55 Hz (capacitor clamped by body). No leakage of electrolyte or other visible damage. Deviations in capacitance from initial measurements must not exceed: Δ C/C < 5% IEC 60384–4 long life grade 40/85/56 Surge Voltage Condition ≤ 30 s surge followed by a no load period of 330 s, 1,000 cycles at 85°C Voltage (VDC) 550 605 © KEMET Electronics Corporation • P.O. Box 5928 • Greenville, SC 29606 (864) 963-6300 • www.kemet.com A4042_ALS60_61 • 8/24/2015 2 Screw Terminal Aluminum Electrolytic Capacitors – ALS60/61 Series, +85°C Test Method & Performance Endurance Life Test Conditions Performance Temperature +85°C Test Duration 2,000 hours Ripple Current Voltage Performance Rated ripple current in specified table The sum of DC voltage and the peak AC voltage must not exceed the rated voltage of the capacitor The following specifications will be satisfied when the capacitor is tested at +20°C: > 160 V Capacitance Change Equivalent Series Resistance Leakage Current Within 10% of the initial value Does not exceed 1.5 x initial limit Does not exceed leakage current limit Dimensions – Millimeters Dimensions in mm Size Code KE KF KJ KM ME MF MJ MM MP NF NJ NM NP QH D L LT S V ±1 ±2 ±1 ±0.5 Nominal Mounting Stud (M x H) ±1 51 82 86.5 22.2 13.7 M12 x 16 51 105 110.5 22.2 13.7 M12 x 16 51 115 119 22.2 13.7 M12 x 16 51 131 136 22.2 13.7 M12 x 16 66 82 86 28.5 15.8 M12 x 16 66 105 110.5 28.5 15.8 M12 x 16 66 115 119 28.5 15.8 M12 x 16 66 131 135 28.5 15.8 M12 x 16 66 146 150 28.5 15.8 M12 x 16 77 105 110.5 31.8 19 M12 x 16 77 115 119 31.8 19 M12 x 16 77 131 135 31.8 19 M12 x 16 77 146 150.5 31.8 19 M12 x 16 90 98 103.5 31.8 25 M12 x 16 Note: Dimensions include sleeving. LT listed is for A-type termination code. Information for other termination codes is available upon request. Approximate Weight Grams 220 300 340 385 428 505 540 610 675 690 765 860 960 900 © KEMET Electronics Corporation • P.O. Box 5928 • Greenville, SC 29606 (864) 963-6300 • www.kemet.com A4042_ALS60_61 • 8/24/2015 3 Screw Terminal Aluminum Electrolytic Capacitors – ALS60/61 Series, +85°C Termination Tables Termination Code Diameter (mm) A C • • • • • • • 51 66 77 90 Termination Code Termination Style Thread T DT Thread Depth (TD) Z ± 0.5 ± 0.5 Minimum Nominal 10 Standard Termination Option A M5 Oval 5.5 13 10 C M6 Round 5.5 13 10 Dimensions in mm SIDE VIEW LT L S D Optional Mounting Stud (M x H) T (From Deck) OVAL TERMINAL END VIEW ROUND TERMINAL END VIEW Safety Vent Safety Vent V + TD Z DT Polarity Mark V + TD DT Polarity Mark Case Polarity Due to the presence of electrolyte in the capacitor, the aluminum can and stud mounting will essentially be at the same polarity as the negative terminal. We recommend that the stud and can be insulated (see accessories for insulating nuts). Terminations Aluminum inserts with M5 threads as standard, maximum torque 2NM. Optional M6 threaded inserts have a maximum torque 4NM. Maximum torque for stud mounting M8:4NM and M12:8NM. © KEMET Electronics Corporation • P.O. Box 5928 • Greenville, SC 29606 (864) 963-6300 • www.kemet.com A4042_ALS60_61 • 8/24/2015 4 Screw Terminal Aluminum Electrolytic Capacitors – ALS60/61 Series, +85°C Shelf Life The capacitance, ESR and impedance of a capacitor will not change significantly after extended storage periods, however the leakage current will very slowly increase. KEMET products are particularly stable and allow a shelf life in excess of three years at 40°C. See sectional specification under each product series for specific data. Re-age (Reforming) Procedure Apply the rated voltage to the capacitor at room temperature for a period of one hour, or until the leakage current has fallen to a steady value below the specified limit. During re-aging a maximum charging current of twice the specified leakage current or 5 mA (whichever is greater) is suggested. Reliability The reliability of a component can be defined as the probability that it will perform satisfactorily under a given set of conditions for a given length of time. In practice, it is impossible to predict with absolute certainty how any individual component will perform; thus, we must utilize probability theory. It is also necessary to clearly define the level of stress involved (e.g. operating voltage, ripple current, temperature and time). Finally, the meaning of satisfactory performance must be defined by specifying a set of conditions which determine the end of life of the component. Reliability as a function of time, R(t), is normally expressed as: R(t)=e-λt where R(t) is the probability that the component will perform satisfactorily for time t, and λ is the failure rate. Failure Rate The failure rate is the number of components failing per unit time. The failure rate of most electronic components follows the characteristic pattern: • Early failures are removed during the manufacturing process. • The operational life is characterized by a constant failure rate. • The wear out period is characterized by a rapidly increasing failure rate. The failures in time (FIT) are given with a 60% confidence level for the various type codes. By convention, FIT is expressed as 1 x 10-9 failures per hour. Failure rate is also expressed as a percentage of failures per 1,000 hours. e.g., 100FIT = 1 x 10-7 failures per hour = 0.01%/1,000 hours End of Life Definition Catastrophic Fail: short circuit, open circuit or safety vent operation Parametric Failure: • Change in capacitance > ±15% • Leakage current > specified limit • ESR > 3 x initial ESR limit © KEMET Electronics Corporation • P.O. Box 5928 • Greenville, SC 29606 (864) 963-6300 • www.kemet.com A4042_ALS60_61 • 8/24/2015 5 Screw Terminal Aluminum Electrolytic Capacitors – ALS60/61 Series, +85°C Failure Rate cont'd MTBF The mean time between failures (MTBF) is simply the inverse of the failure rate. MTBF= 1/λ Failure Rate early failures wear out operational life Time The failure rate is derived from our periodic test results. The failure rate (λR) is, therefore, only given at test temperature for life tests. An estimation is also given at 40°C. The expected failure rate for this capacitor range is based on our periodic test results for capacitors with structural similarity. Failure rate is frequently quoted in FIT (Failures In Time) where 1 FIT = 1 x 10-9 failures per hour. Failure rates include both catastrophic and parametric failures. Environmental Compliance As an environmentally conscious company, KEMET is working continuously with improvements concerning the environmental effects of both our capacitors and their production. In Europe (RoHS Directive) and in some other geographical areas like China, legislation has been put in place to prevent the use of some hazardous materials, such as lead (Pb), in electronic equipment. All products in this catalog are produced to help our customers’ obligations to guarantee their products and fulfill these legislative requirements. The only material of concern in our products has been lead (Pb), which has been removed from all designs to fulfill the requirement of containing less than 0.1% of lead in any homogeneous material. KEMET will closely follow any changes in legislation world wide and makes any necessary changes in its products, whenever needed. Some customer segments such as medical, military and automotive electronics may still require the use of lead in electrode coatings. To clarify the situation and distinguish products from each other, a special symbol is used on the packaging labels for RoHS compatible capacitors. Because of customer requirements, there may appear additional markings such as LF = Lead Free or LFW = Lead Free Wires on the label. © KEMET Electronics Corporation • P.O. Box 5928 • Greenville, SC 29606 (864) 963-6300 • www.kemet.com A4042_ALS60_61 • 8/24/2015 6 Screw Terminal Aluminum Electrolytic Capacitors – ALS60/61 Series, +85°C Table 1 – Ratings & Part Number Reference VDC Rated Capacitance Size Code 100 Hz 20°C (µF) Case Size Ripple Current ESR Maximum Impedance Maximum Part Number D x L (mm) 100 Hz 85°C (A) 10 kHz 85°C (A) 100 Hz 20°C (mΩ) 10 kHz 20°C (mΩ) 550 550 550 550 550 550 550 550 550 550 550 550 550 550 550 560 680 820 1000 1000 1200 1200 1500 1800 1800 2200 2200 2200 2700 3300 KE KF KF KJ ME KM MF MJ MM NF MP NJ QH NM NP 51 x 82 51 x 105 51 x 105 51 x 115 66 x 82 51 x 131 66 x 105 66 x 115 66 x 131 77 x 105 66 x 146 77 x 115 90 x 98 77 x 131 77 x 146 4.6 4.9 5.7 6.4 6.5 7.1 7.8 9.0 10.2 10.3 11.3 11.7 12.2 13.2 14.6 7.4 8.1 9.0 10.1 10.6 11.0 12.4 14.1 15.6 16.0 17.1 17.5 18.8 19.1 20.9 536 441 367 302 303 252 254 204 171 167 140 137 137 113 93 475 391 325 268 269 224 225 181 151 147 124 121 120 100 83 ALS6(1)(2)561KE550 ALS6(1)(2)681KF550 ALS6(1)(2)821KF550 ALS6(1)(2)102KJ550 ALS6(1)(2)102ME550 ALS6(1)(2)122KM550 ALS6(1)(2)122MF550 ALS6(1)(2)152MJ550 ALS6(1)(2)182MM550 ALS6(1)(2)182NF550 ALS6(1)(2)222MP550 ALS6(1)(2)222NJ550 ALS6(1)(2)222QH550 ALS6(1)(2)272NM550 ALS6(1)(2)332NP550 VDC Rated Capacitance Size Code Case Size ESR IMP Part Number Ripple Current (1) Mounting Code: 0 = plain can, 1 = threaded mounting stud (2) Termination Code: See Termination Tables for available options © KEMET Electronics Corporation • P.O. Box 5928 • Greenville, SC 29606 (864) 963-6300 • www.kemet.com A4042_ALS60_61 • 8/24/2015 7 Screw Terminal Aluminum Electrolytic Capacitors – ALS60/61 Series, +85°C Mechanical Data Polarity and Reversed Voltage Aluminium Electrolytic capacitors manufactured for use in DC applications contain an anode foil and a cathode foil. As such, they are polarized devices and must be connected with the +ve to the anode foil and the -ve to the cathode foil. If this were to be reversed then the electrolytic process that took place in forming the oxide layer on the anode would be recreated in trying to form an oxide layer on the cathode. In forming the cathode foil in this way, heat would be generated and gas given off within the capacitor, usually leading to catastrophic failure. The cathode foil already possesses a thin stabilized oxide layer. This thin oxide layer is equivalent to a forming voltage of approximately 2 V. As a result, the capacitor can withstand a voltage reversal of up to 2 V for short periods. Above this voltage, the formation process will commence. Aluminium Electrolytic capacitors can also be manufactured for use in intermittent AC applications by using two anode foils in place of one anode and one cathode. Mounting Position The capacitor can be mounted in any position as long as the safety vent can operate. It is possible for some electrolyte to be expelled. As this is a conducting liquid, suitable precautions should be initiated by the system designer to avoid secondary short circuits. The capacitors are designed to be mounted in free air and are not suitable for submersion in liquid. Insulating Resistance ≥ 100 MΩ at 100 VDC across insulating sleeve. Voltage Proof ≥ 2,500 VDC across insulating sleeve. Safety Vent A safety vent for overpressure is featured on the terminal deck in the form of a rubber plug designed to relieve build-up of internal pressure due to overstress or catastrophic failure. © KEMET Electronics Corporation • P.O. Box 5928 • Greenville, SC 29606 (864) 963-6300 • www.kemet.com A4042_ALS60_61 • 8/24/2015 8 Screw Terminal Aluminum Electrolytic Capacitors – ALS60/61 Series, +85°C Marking KEMET Logo Rated Capacitance, Capacitance Tolerance Climatic Category Date of Manufacture, Batch Number Rated Voltage (VDC) Part Number Code Made in The European Union Construction Screw Terminal Insulating End Disc Detailed Cross Section Safety Vent Deck Insulating Sleeve Laser Welded Terminal Tab Aluminum Can Laser Welded Terminal Tabs Margin Aluminum Can Insulating Sleeve Deck Paper Spacer Impregnated with Electrolyte (First Layer) Polarity Mark (+) Screw Terminal (+) Cathode Aluminum Foil, Etched (Second Layer) Paper Spacer Impregnated with Electrolyte (Third Layer) Anode Aluminum Foil, Etched, Covered with Aluminum Oxide (Fourth Layer) © KEMET Electronics Corporation • P.O. Box 5928 • Greenville, SC 29606 (864) 963-6300 • www.kemet.com Safety Vent Plug Screw Terminal (-) A4042_ALS60_61 • 8/24/2015 9 Screw Terminal Aluminum Electrolytic Capacitors – ALS60/61 Series, +85°C Construction cont'd The manufacturing process begins with the anode foil being electrochemically etched to increase the surface area and then “formed” to produce the aluminum oxide layer. Both the anode and cathode foils are then interleaved with absorbent paper and wound into a cylinder. During the winding process, aluminum tabs are attached to each foil to provide the electrical contact. Extended cathode Anode foil The deck, complete with terminals, is attached to the tabs and then folded down to rest on top of the winding. The complete winding is impregnated with electrolyte before being housed in a suitable container, usually an aluminum can, and sealed. Throughout the process, all materials inside the housing must be maintained at the highest purity and be compatible with the electrolyte. Each capacitor is aged and tested before being sleeved and packed. The purpose of aging is to repair any damage in the oxide layer and thus reduce the leakage current to a very low level. Aging is normally carried out at the rated temperature of the capacitor and is accomplished by applying voltage to the device while carefully controlling the supply current. The process may take several hours to complete. Damage to the oxide layer can occur due to variety of reasons: • Slitting of the anode foil after forming • Attaching the tabs to the anode foil • Minor mechanical damage caused during winding A sample from each batch is taken by the quality department after completion of the production process. The following tests are applied and may be varied at the request of the customer. In this case the batch, or special procedure, will determine the course of action. Electrical: • Leakage current • Capacitance • ESR • Impedance • Tan Delta Mechanical/Visual: • Overall dimensions • Torque test of mounting stud • Print detail • Box labels • Packaging, including packed quantity © KEMET Electronics Corporation • P.O. Box 5928 • Greenville, SC 29606 (864) 963-6300 • www.kemet.com Foil tabs Tissues Cathode foil Etching Forming Winding Decking Impregnation Assembly Aging Testing Sleeving Packing A4042_ALS60_61 • 8/24/2015 10 Screw Terminal Aluminum Electrolytic Capacitors – ALS60/61 Series, +85°C KEMET Corporation World Headquarters Europe Asia Southern Europe Sasso Marconi, Italy Tel: 39-051-939111 Northeast Asia Hong Kong Tel: 852-2305-1168 Mailing Address: P.O. Box 5928 Greenville, SC 29606 Skopje, Macedonia Tel: 389-2-55-14-623 Shenzhen, China Tel: 86-755-2518-1306 www.kemet.com Tel: 864-963-6300 Fax: 864-963-6521 Central Europe Landsberg, Germany Tel: 49-8191-3350800 Corporate Offices Fort Lauderdale, FL Tel: 954-766-2800 Kamen, Germany Tel: 49-2307-438110 North America Northern Europe Wyboston, United Kingdom Tel: 44-1480-273082 Taipei, Taiwan Tel: 886-2-27528585 Espoo, Finland Tel: 358-9-5406-5000 Southeast Asia Singapore Tel: 65-6701-8033 2835 KEMET Way Simpsonville, SC 29681 Northeast Wilmington, MA Tel: 978-658-1663 Southeast Lake Mary, FL Tel: 407-855-8886 Central Novi, MI Tel: 248-994-1030 Beijing, China Tel: 86-10-5877-1075 Shanghai, China Tel: 86-21-6447-0707 Seoul, South Korea Tel: 82-2-6294-0550 Penang, Malaysia Tel: 60-4-6430200 Bangalore, India Tel: 91-806-53-76817 Irving, TX Tel: 972-915-6041 West Milpitas, CA Tel: 408-433-9950 Mexico Guadalajara, Jalisco Tel: 52-33-3123-2141 Note: KEMET reserves the right to modify minor details of internal and external construction at any time in the interest of product improvement. KEMET does not assume any responsibility for infringement that might result from the use of KEMET Capacitors in potential circuit designs. KEMET is a registered trademark of KEMET Electronics Corporation. © KEMET Electronics Corporation • P.O. Box 5928 • Greenville, SC 29606 (864) 963-6300 • www.kemet.com A4042_ALS60_61 • 8/24/2015 11 Screw Terminal Aluminum Electrolytic Capacitors – ALS60/61 Series, +85°C Disclaimer All product specifications, statements, information and data (collectively, the “Information”) in this datasheet are subject to change. The customer is responsible for checking and verifying the extent to which the Information contained in this publication is applicable to an order at the time the order is placed. All Information given herein is believed to be accurate and reliable, but it is presented without guarantee, warranty, or responsibility of any kind, expressed or implied. Statements of suitability for certain applications are based on KEMET Electronics Corporation’s (“KEMET”) knowledge of typical operating conditions for such applications, but are not intended to constitute – and KEMET specifically disclaims – any warranty concerning suitability for a specific customer application or use. The Information is intended for use only by customers who have the requisite experience and capability to determine the correct products for their application. Any technical advice inferred from this Information or otherwise provided by KEMET with reference to the use of KEMET’s products is given gratis, and KEMET assumes no obligation or liability for the advice given or results obtained. Although KEMET designs and manufactures its products to the most stringent quality and safety standards, given the current state of the art, isolated component failures may still occur. Accordingly, customer applications which require a high degree of reliability or safety should employ suitable designs or other safeguards (such as installation of protective circuitry or redundancies) in order to ensure that the failure of an electrical component does not result in a risk of personal injury or property damage. Although all product–related warnings, cautions and notes must be observed, the customer should not assume that all safety measures are indicted or that other measures may not be required. © KEMET Electronics Corporation • P.O. Box 5928 • Greenville, SC 29606 (864) 963-6300 • www.kemet.com A4042_ALS60_61 • 8/24/2015 12