Tables: Aluminum Electrolytic Capacitor Overview

Aluminum Electrolytic Capacitor Application Guide
This guide is a full handbook on aluminum electrolytic capacitors, of course with emphasis on Cornell Dubilier’s types. It covers
construction in depth and discloses the latest information on performance and application for the major aluminum electrolytic
types made worldwide. We encourage you to tell us what more you’d like to know, so we can improve this guide.
CONTENTS PAGE
Capacitor Construction 2
Other Types of Capacitors Comparison 4
Characterization and Circuit Model 5 TABLES PAGE
Temperature Range 6 Capacitor Parameter Formulas 6
Capacitance 7 Base Lives and Max Core Temperatures 14
Dissipation Factor (DF) 7 Thermal Resistance Screw Terminal Capacitors 17
Equivalent Series Resistance (ESR) 8 Thermal Resistance for Snap-in Capacitors 19
Impedance (Z) 8 Pressure Relief Device Clearance 21
Low-Temperature Impedance 8 Screw Tightening Torque for Screw Terminals 21
DC Leakage Current (DCL) 8 Maximum Currents for Screw Terminals 21
Voltage Withstanding 9 Tightening Torque for Nylon Mounting Nuts 22
Ripple Current 10
Inductance 10
Self-Resonant Frequency 10
Dielectric Absorption 11
Insulation and Grounding 11
Elevation & External Pressure 11
Vibration Withstanding Capability 11
Safety Considerations 11
Capacitor Bank Configurations 12
Non-Polar and Motor Start Capacitors 13
Reliability and Lifetime 13
Cooling and Thermal Resistance 16
Process Considerations 19
Mounting 20
Disposal of Capacitors 22
ALUMINUM ELECTROLYTIC CAPACITOR OVERVIEW electrolyte. The positive plate is the anode foil; the dielectric is the
insulating aluminum oxide on the anode foil; the true negative
Except for a few surface-mount technology (SMT) aluminum plate is the conductive, liquid electrolyte, and the cathode foil
electrolytic capacitor types with solid electrolyte systems, an connects to the electrolyte. However, just as the anodic-oxide
aluminum electrolytic capacitor consists of a wound capacitor dielectric insulates the anode foil from the electrolyte, so too the
element, impregnated with liquid electrolyte, connected to cathode is insulated from the electrolyte by the low voltage air
terminals and sealed in a can. The element is comprised of an oxide on the cathode foil and the double-layer ionic barrier. This
anode foil, paper separators saturated with electrolyte and a makes the cathode a capacitor in series with the anode. In high
cathode foil. The foils are high-purity aluminum and are etched voltage capacitors the cathode capacitance is hundreds of times
with billions of microscopic tunnels to increase the surface area the anode capacitance and does not measurably affect the
in contact with the electrolyte. overall capacitance, but in capacitors of less than about 50 V the
anode capacitance begins to approach the value of the cathode
While it may appear that the capacitance is between the two capacitance and requires use of higher capacitance cathode to
foils, actually the capacitance is between the anode foil and the avoid needing to increase the anode length to achieve the rated
CDM Cornell Dubilier • 140 Technology Place • Liberty, SC 29657 • Phone: (864)843-2277 • Fax: (864)843-3800
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capacitance. Aluminum electrolytic capacitor construction for miniature-can styles,
delivers colossal capacitance because etching the foils can
increase surface area more than 100 times and the aluminum- 1200 µF at 450 V and 39,000 µF at 50 V for snap-in can
oxide dielectric is less than a micrometer thick. Thus the styles and
resulting capacitor has very large plate area and the plates are
intensely close together. 9000 µF at 450 V and 390,000 µF at 50 V for large-can,
screw-terminal styles.
These capacitors routinely offer capacitance values from 0.1 µF
to 3 F and voltage ratings from 5 V to 550 V. Up to 700 V are If two, same-value, aluminum electrolytic capacitors are
commercially available. They are polar devices, having distinct connected in series with the positive terminals or the negative
positive and negative terminals, and are offered in an enormous terminals connected together, the resulting single capacitor
variety of styles which include molded and can-style SMT is a non-polar capacitor with half the capacitance. The two
devices, axial- and radial-leaded can styles, snap-in terminals capacitors rectify the applied voltage and act as if they had
styles and large-can, screw-terminal styles. Representative been bypassed by diodes. When voltage is applied, the correct-
capacitance-voltage combinations include: polarity capacitor gets the full voltage. In non-polar aluminum
electrolytic capacitors and motor-start aluminum electrolyte
330 µF at 100 V and 6,800 µF at 10 V for SMT devices, capacitors a second anode foil substitutes for the cathode foil to
achieve a non-polar capacitor in a single case.
100 µF at 450 V, 6,800 µF at 50 V and 10,000 µF at 10 V
CAPACITOR CONSTRUCTION
Rivet
Terminal
Lead Wire
Phenolic/
Rubber Disc Aluminum
Tabs
Aluminum Rubber
Tabs
Tape Sleeve over
Sleeve over Aluminum Can
Aluminum Can
Capacitor
Capacitor Element
Element
Snap-in Type
Miniature, Radial-Leaded Type
Snap-in Type
Terminals Terminals
Rubber Gasket Rubber Gasket
Tabs Tabs
Phenolic / Nylon Phenolic / Nylon
Cover w/ Cover w/
Centering Peg Centering Peg
Tape Tape
Sleeve Sleeve
Over Over
Aluminum Aluminum
Can Can
Rills
Aluminum Aluminum
Centering Peg Centering Peg
Aluminum Aluminum
Extended Extended
Stiffening Stiffening
Cathode Cathode
Ribs Ribs
Thermal Pak Construction Rilled Construction
CDMThermal
Cornell Dubilier • 140 Technology Place • Liberty, SC 29657 • Phone:
Pak Construction (864)843-2277
Rilled • Fax: (864)843-3800
Construction
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These figures show typical constructions of the non-surface- WINDING
mount aluminum electrolytic capacitors. All Cornell Dubilier The capacitor element is wound on a winding machine with
capacitors use compression-fit construction so there is no spindles for one-to-four separator papers, the anode foil,
thermoplastic potting compound to interfere with safety- another set of one-to-four separator papers and the cathode
vent operation. Thermal Pak™ and Rilled are Cornell Dubilier’s foil. These are wound into a cylinder and wrapped with a strip
exceptional constructions for screw terminal capacitors. of pressure-sensitive tape to prevent unwinding. The separators
Compared to conventional, potted construction, Thermal Pak prevent the foils from touching and shorting, and the separators
operates cooler, provides longer life, withstands higher shock later hold the reservoir of electrolyte.
and vibration, delivers more reliable safety vent operation and
is lighter weight. Rilled offers superior shock and vibration Before or during winding aluminum tabs are attached to the
withstanding, typically withstanding more than 15 g acceleration foils for later connection to the capacitor terminals. The best
forces. method is by cold-welding of the tabs to the foils with tab
locations microprocessor controlled during winding so that
ETCHING the capacitor element’s inductance can be less than 2 nH. The
The anode and cathode foils are made of high purity, thin older method of attachment is by staking, a process of punching
aluminum foil, 0.02 to 0.1 mm thick. To increase the plate area and the tab through the foil and folding down the punched metal.
the capacitance, the surface area in contact with the electrolyte Cold welding reduces short-circuit failures and performs better
is increased by etching the foils to dissolve aluminum and create in high-ripple current and discharge applications in which the
a dense network of billions of microscopic tunnels penetrating individual stakes may fail from high current like buttons popping
through the foil. For maximum increase in surface area in off one at a time from a fat-man’s vest.
higher voltage capacitors the anode foil is 99.99% high purity,
high cubicity aluminum that allows the billions of microscopic
etch tunnels to be parallel and mostly perpendicular to the foil
surface.
Etching involves pulling the aluminum foil on rollers through a

chloride solution while applying an AC, DC or AC-and-DC voltage
between the etch solution and the aluminum foil. Surface
area can increase as much as 200 times for foil in low-voltage
capacitors and up to 60 times for high-voltage capacitors.
FORMING
The anode foil carries the capacitor’s dielectric. The dielectric
is a thin layer of aluminum oxide, Al2O3, which is chemically
grown on the anode foil during a process called “formation.”
Formation is accomplished by pulling the anode foil on rollers
through an electrolyte bath and continuously applying a DC
voltage between the bath and the foil. The voltage is 135% to
200% of the final capacitor’s rated voltage. The thickness of
the aluminum oxide is about 1.4 to 1.5 nm for each volt of the
formation voltage, e.g., the anode foil in a 450 V capacitor may
get a formation voltage in excess of 600 V and have an oxide CONNECTING TERMINALS
thickness of about 900 nm. That’s about a hundredth of the In SMT capacitors and miniature capacitors with rubber-bungs,
thickness of a human hair. extensions of the tabs are the capacitor terminals. But in large-
can capacitors like snap-ins and screw-terminal styles, the
Formation reduces the effective foil surface area because the tabs are riveted or welded on the underside of the capacitor
microscopic tunnels are partially occluded by the oxide. The tops to terminal inserts. Welding produces the lowest contact
tunnel etch pattern is adjusted by choice of foil and etching resistance and highest current handling. Both resistive welding
process so that low-voltage anodes have dense tunnel patterns and ultrasonic welding are used. The up to 12 tab pairs that
compatible with thin oxide and high-voltage anodes have coarse may be used in large screw-terminal capacitors often require
tunnel patterns compatible with thick oxide. The cathode foil is more mechanical support during assembly so the tabs in such
not formed and it retains its high surface area and dense etch capacitors may be both riveted to post extensions on the
pattern. terminals and then welded. In an axial-leaded capacitor the
cathode tab is welded to the can before sealing.
SLITTING
Foil is etched and formed in jumbo rolls of 40 to 50 cm wide and
then slit into various widths according to the lengths of the final IMPREGNATION
capacitors. The capacitor element is impregnated with electrolyte to
saturate the paper separators and penetrate the etch tunnels.
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The method of impregnation may involve immersion of the
elements and application of vacuum-pressure cycles with
or without heat or, in the case of small units, just simple COMPARISON TO OTHER TYPES OF
absorption. The electrolyte is a complex blend of ingredients CAPACITORS
with different formulations according to voltage and operating
temperature range. The principal ingredients are a solvent and CERAMIC CAPACITORS
a conductive salt – a solute – to produce electrical conduction. Ceramic capacitors have become the preeminent, general-
The common solvent is ethylene glycol (EG) and is typically used purpose capacitor, especially in SMT chip devices where their
for capacitors rated –20 ºC or –40 ºC. Dimethylformamide (DMF) low cost makes them especially attractive. With the emergence
and gammabutyrolactone (GBL) are often used for capacitors of thinner-dielectric, multilayer units with rated voltages of less
rated –55 ºC. Common solutes are ammonium borate and other than 10 V capacitance values in the hundreds of microfarads
ammonium salts. have become available. This intrudes on the traditional, high-
capacitance province of aluminum electrolytic capacitors.
Water in the electrolyte plays a big role. It increases conductivity
thereby reducing the capacitor’s resistance, but it reduces the Ceramic capacitors are available in three classes according to
boiling point so it interferes with high temperature performance, dielectric constant and temperature performance. Class 1 (NPO,
and it reduces shelf life. A few percent of water is necessary COG) is suitable for low capacitance, tight tolerance applications
because the electrolyte maintains the integrity of the aluminum in the range of 1 pF to a few mF. Class 2 (X7R, X5R, Y5V) has 20
oxide dielectric. When leakage current flows, water is broken to 70 times as much capacitance per case size, but capacitance
into hydrogen and oxygen by hydrolysis, and the oxygen is typically varies about ± 10% over its –55 to 125 ºC temperature
bonded to the anode foil to heal leakage sites by growing more range. The maximum change is +15 % to –25%. Class 3 (Z5U)
oxide. The hydrogen escapes by passing through the capacitor’s with about 5 times the capacitance of Class 3 has wild swings
rubber seal. of capacitance with voltage and temperature. The temperature
range is –25 ºC to 85 ºC, and capacitance varies about +20%
–65% over the range. All classes of ceramic capacitors are
available in a variety of physical forms, ranging from round disc
or rectangular single layer to multilayer types as well as tubular
and feed-through types. Ceramic chip capacitors are brittle and
sensitive to thermal shock, so precautions need to be taken to
avoid cracking during mounting, especially for high-capacitance
large sizes.
The typical temperature range for aluminum electrolytic

capacitors is –40 ºC to 85 ºC or 105 ºC. Capacitance varies about
+5% –40% over the range with the capacitance loss all at cold
temperatures. Capacitors rated –55 ºC generally only have
–10% to –20% capacitance loss at –40 ºC. Cold temperature
performance for rated voltages of 300 V and higher is often
SEALING worse, and temperature performance varies by manufacturer.
The capacitor element is sealed into a can. While most cans Thus Class 1 and 2 ceramic capacitors perform better than
are aluminum, phenolic cans are often used for motor-start aluminum electrolytic capacitors at cold temperatures, and
capacitors. In order to release the hydrogen the seal is not Class 3 ceramic capacitors perform worse at all temperatures.
hermetic and it is usually a pressure closure made by rolling the
can edge into a rubber gasket, a rubber end-plug or into rubber Aluminum electrolytic capacitors readily deliver much more
laminated to a phenolic board. In small capacitors molded capacitance. Aluminum electrolytic capacitors give more
phenolic resin or polyphenylene sulfide may replace the rubber. capacitance and energy storage per unit volume than ceramic
Too tight a seal causes pressure build up, and too loose a seal capacitors for all types except for low-voltage, Class 3 ceramic
shortens the life by permitting drying out, loss of electrolyte. SMT chip capacitors. While tolerances of ±5% and ±10% are
routine for ceramic capacitors, ±20% and –10% +50% are
AGING the norms for aluminum electrolytic. This makes aluminum
Here the capacitor assembly comes full circle. The last electrolytics the choice for high-capacitance applications like
manufacturing step is “aging” during which a DC voltage greater rectification filters and power hold up where more capacitance
than the rated voltage but less than the formation voltage is is a bonus.
applied to the capacitor. Usually the voltage is applied at the
capacitor’s rated temperature, but other temperatures and even Ceramic capacitors are not polarized and therefore can be used
room temperature may be used. This step reforms the cut edges in AC applications. The low DF and high capacitance stability of
and any damaged spots on the anode foil and covers any bare Class 1 and 2 are especially suited to AC and RF applications. By
aluminum with aluminum oxide dielectric. Aging acts as burn- comparison, aluminum electrolytic capacitors are polarized and
in and reduces or eliminates early life failures (infant mortals). cannot withstand voltage reversal in excess of 1.5 V. While non-
Low, initial DC leakage current is a sign of effective aging. polar aluminum electrolytics are available for momentary-duty
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AC applications like motor starting and voltage-reversing ignition that can accompany aluminum electrolytic capacitor
applications, the high DF of aluminum electrolytic capacitors – failures in large high-voltage banks of 10 or more capacitors.
from 2% to 150% – causes excess heating and short life in most Cornell Dubilier now provides special aluminum electrolytic
AC applications. capacitors with improved self-healing to deliver the needed
reliability for these applications.
Ceramic capacitors are generally no more reliable than aluminum
electrolytic capacitors because aluminum electrolytics self
heal. Since high-capacitance ceramic capacitors may develop SOLID TANTALUM CAPACITORS
micro-cracks, aluminum electrolytic capacitors are preferred Like aluminum electrolytic capacitors solid tantalum capacitors
for high capacitance values. However, small sizes of aluminum are polar devices (1 V maximum reverse voltage), having distinct
electrolytic capacitors may have limited life due to dry out, and positive and negative terminals and are offered in a variety of
so consider reliability in your choice for applications operating styles. Case styles include both molded and conformal-coated
at high temperatures, over 65 ºC. versions of radial, axial and surface mount configurations.
Typical capacitance values are from 0.1 µF to 1000 µF in voltage
FILM CAPACITORS ratings from 2 V to 50 V. Typical maximum capacitance-voltage
Film capacitors offer tight capacitance tolerances, very combinations are approximately 22 µF at 50 V for leaded styles
low leakage currents and small capacitance change with and 22 µF at 35 V for surface mount. Strengths are temperature
temperature. They are especially suited to AC applications stability, volumetric efficiency and compatibility with all
through their combination of high capacitance and low DF that automated assembly systems. Weaknesses are the limited
permits high AC currents. However, they have relatively large voltage and capacitance ranges and a short-circuit failure mode
sizes and weights. accompanied by catching fire.
The popular polymers used for plastic-film dielectric capacitors The operating temperature range is –55 ºC to 85 ºC at rated
are polyester and polypropylene. The popular polymer for voltage; +85ºC to 125 ºC with linear voltage derating to 2/3
SMT devices is polyphenylene sulfide (PPS). While film/foil rated voltage. The typical capacitance change over the entire
construction is often used for small capacitance values – less range is less than ±5%. Thus aluminum electrolytic capacitors
than 0.01 µF – and for high-current applications, metallized-film have a much broader voltage and capacitance ranges than solid
is usually preferred because it gives smaller size, lower cost and tantalum capacitors but perform worse at cold temperature.
is self healing. Film capacitors are general-purpose capacitors
for through-hole applications and have special uses for tight- Solid tantalum capacitors are generally considered more reliable
tolerance, AC voltage, high voltage and snubbing. than aluminum electrolytic capacitors because solid tantalum
capacitors do not wear out. Their failure rate decreases with time,
Polyester film capacitors operate from –55 ºC to 85 ºC at rated while aluminum electrolytic capacitors wear out by drying out.
voltage; 85 ºC to 125 ºC with linear voltage derating to 50% As a practical matter, dry-out only affects the smallest capacitors
rated voltage. The typical capacitance change over the entire operating in high-temperature environments. Larger aluminum
range is less than –5% +15% with ±1% from 0 ºC to 50 ºC. electrolytics do not dry out in the 10 to 20 years expected of
Capacitance values are readily available up to 10 µF with special most applications, and the open-circuit, dry-out failure is benign
large sections to 100 µF. Generally available voltages are 50 to compared to solid-tantalum’s short circuit failure mode.
1000 Vdc and 35 to 600 Vac. AC current handling is limited by
polyester’s high-temperature DF of about 1%. PARAMETRIC CHARACTERIZATION
Polypropylene film capacitors operate from is –55 ºC to 85 ºC
CIRCUIT MODEL
at rated voltage; 85 ºC to 105 ºC with linear voltage derating
Capacitance occurs when two electrical conductors are
to 50% rated voltage. The typical capacitance change over the
separated by an insulator, the dielectric. A capacitor is an
entire range is less than +2% –4% with ±1% from –20 ºC to 60 ºC.
electronic component optimized to deliver capacitance. The
Capacitance values are readily available up to 65 µF with special
capacitance in µF is:
large sections to 1000 µF. Generally available voltages are 100 to
3000 Vdc and 70 to 500 Vac. AC current handling permits use in
motor-run and other continuous duty AC applications. C = 8.855(10–8)(n-1)εA/d
Compared to aluminum electrolytic capacitors, film capacitors Where n is the number of plates or electrodes, ε is the dielectric
take the lead in high voltage, AC voltage and tight tolerance constant, A is the plate surface area in cm² and d is the thickness
applications. Aluminum electrolytics excel in capacitance and of the dielectric between the plates in cm. Dielectric constant is
energy storage. However, there is growing use of power film the multiplier increase in capacitance that the dielectric delivers
capacitors as replacements for aluminum electrolytic capacitors compared to a vacuum. The dielectric constant for aluminum
as dc-link, bus capacitors in high-voltage inverter power systems. oxide is about 8.
While generally power film capacitors are more than four times
the price for capacitance as aluminum electrolytic capacitors, The equivalent circuit on the next page models the aluminum
film capacitors are perceived as more reliable because failures electrolyic capacitor’s normal operation as well as overvoltage
are relatively benign and without the incidence of explosion and and reverse-voltage behavior.
5
20 to 50 nH for screw-terminal types, and up to 200 nH for axial-
leaded types. It increases with terminal spacing.
Ls Rs
Resistance Rp is the equivalent parallel resistance and accounts
for leakage current in the capacitor. It decreases with increasing
capacitance, temperature and voltage, and it increases while
Rp D C voltage is applied. Typical values are on the order of 100/C MΩ
with C in µF, e.g. a 100 µF capacitor would have an Rp of about
1 MΩ.
Zener diode D models overvoltage and reverse voltage behavior.

Equivalent Circuit Application of overvoltage on the order of 50 V beyond the
capacitor’s surge voltage rating causes high leakage current
and a constant-voltage operating mode quite like the reverse
Capacitance C is the equivalent capacitance and it decreases conduction of a zener diode. Application of reverse voltage much
with increasing frequency. Common values range from 1 µF to beyond 1.5 V causes high leakage current quite like the forward
1 F, a six-decade range. conduction of a diode. Neither of these operating modes can be
maintained for long because hydrogen gas is produced by the
Resistance Rs is the equivalent series resistance, and it decreases capacitor, and the pressure build up will cause failure.
with increasing frequency and temperature. It increases with
rated voltage. Typical values range from 10 mΩ to 1 Ω, and Rs is The table below expresses capacitor parameters for the series
inversely proportional to capacitance for a given rated voltage. equivalent-circuit model shown schematically on the left. From
this table Capacitance C, Dissipation Factor DF, Equivalent
Inductance Ls is the equivalent series inductance, and it is Series Resistance Rs, Impedance Z, Inductance Ls, Self-Resonant
relatively independent of both frequency and temperature.
Frequency fo and Voltage are explored more fully in the next
Typical values range from 10 nH to 30 nH for radial-leaded types,
section.
Parameter Unit Symbol Formula Approximately
Capacitance farads (F) C
Capacitive Reactance ohms (Ω) Xc 1/(2πfC) Z
Current amperes (A) I C(dV/dt), Vz/Z
Dissipation Factor none DF Rs/Xc, 2πfCRs, tan(δ), cot(Θ) PF
Energy Joules (J) E ½CV²
Equivalent Series Resistance ohms (Ω) Rs DF/(2πfC)
Frequency hertz (Hz) f
Impedance ohms (Ω) Z [Rs²+(Xc–XL)²]½ Xc
Inductance henries (H) Ls
Inductive Reactance ohms (Ω) XL 2πfLs
Loss Angle degrees (°) δ tan-1(DF)
Phase Angle degrees (°) Θ cot-1(DF)
Power watts (W) P I²Rs
Power Factor none PF Rs/Z, sin(δ), cos(Θ) DF
Quality Factor none Q Xc/Rs, 1/DF, cot(δ), tan(Θ) 1/PF
Self-Resonant Frequency hertz (Hz) fo 1/[2π(LC) ] ½
Voltage volts (V) V Vc=IXc, Vz=IZ

Volt-Amperes V-A VA IVz, I²Z
limits given in the specification. It is the range of ambient

PARAMETERS temperatures for which the capacitor has been designed to
operate continuously. Largely the formation voltage sets the
TEMPERATURE RANGE high-temperature limit. Higher formation voltages permit
higher operating temperatures but reduce the capacitance. The
Operating temperature range low-temperature limit is set largely by the cold resistivity of the
The Operating Temperature Range is the temperature range electrolyte. The higher cold resistivity increases the capacitor’s
over which the part will function, when electrified, within the ESR 10 to 100 fold and reduces the available capacitance.
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Typical temperature ranges are –20 ºC to 55 ºC, –25 ºC to 85 ºC, Small radial-lead capacitors have inductance of less than 20 nH.
–40 ºC to 85 ºC, –55 ºC to 85 ºC, –40 ºC to 105 ºC, –55 ºC to 105 ºC Larger capacitors have more inductance according to terminal
and –55 ºC to 125 ºC. spacing. See INDUCTANCE.
Storage Temperature Range DISSIPATION FACTOR (DF)

The Storage Temperature Range is the temperature range Dissipation factor is the measurement of the tangent of the loss
to which the part can be subjected unbiased, and retain angle (tan δ) expressed as a percentage. It is also the ratio of
conformance to specified electrical limits. It is the range of the ESR to the capacitive reactance and is thus related to ESR by
ambient temperatures over which the capacitor may be stored this equation:
without damage for short periods. For long periods of storage
keep capacitors at cool room temperatures and in an atmosphere DF = 2πfC(ESR)/10,000
free of halogen gases like chlorine and fluorine that can corrode
aluminum. Storage temperature ranges are from –55 ºC to the Where DF is a unit-less number expressed in percent, test
upper limit of the operating-temperature ranges. frequency f is in Hz, capacitance C is in µF and ESR is in Ω.
CAPACITANCE DF Measurement
The measurement of DF is carried out at +25 ºC, 120 Hz, and
Rated Capacitance no voltage bias, with a maximum 1 Vac signal voltage free
The rated capacitance is the nominal capacitance and it is of harmonics. The value of DF is temperature and frequency
specified at 120 Hz and a temperature of 25 ºC. The rated dependent.
capacitance is also the capacitance marked on the unit.
DF Temperature Characteristics
Capacitance Tolerances The dissipation factor decreases with increasing temperature.
Capacitance tolerance is the permitted minimum and maximum DF declines about 50% from 25 ºC to the high-temperature limit,
capacitance values expressed as the percentage decrease and but increases more than 10 fold at the low-temperature limit.
increase from the rated capacitance, ΔC/C. Typical capacitance The DF of the better devices rated –55 ºC increases less than 5
tolerances are ±20%, –10% +50%, and –10% +75%. Tighter times at –40 ºC.
tolerances are more readily available in high voltage capacitors,
e.g., above 150 V, but tolerances tighter than ±10% are generally DFlf, defined in the next paragraph, varies little with temperature
not available. Note that tighter tolerance parts may meet other and ESRhf, also in the next paragraph, increases 10 to 100 times
tolerance requirements and are readily substitutable. from 25 ºC to the low-temperature limit. The increase in DF at
cold temperatures is set by the ESRhf.
The capacitance varies with temperature and frequency. This
variation itself is also dependent on the rated voltage and DF Frequency Characteristics
capacitor size. The dissipation factor varies with frequency at high frequencies.
DF can be modeled as below:
Capacitance Measurement
For aluminum electrolytic capacitors, capacitance is measured DF = DFlf + 2πfC(ESRhf )/10,000
as the capacitance of the equivalent series circuit at 25 ºC in a
measuring bridge supplied by a 120 Hz source free of harmonics Where DF is the total dissipation factor in percent, DFlf is the
with maximum AC signal voltage of 1 Vac and no bias voltage. low-frequency dissipation factor in percent, ESRhf is the high-
frequency ESR in Ω, f is the test frequency in Hz and C is the
Capacitance Temperature Characteristics capacitance in µF at the test frequency. DFlf results from the
The capacitance varies with temperature. This variation itself is power lost by the applied electric field in orienting the molecules
dependent to a small extent on the rated voltage and capacitor of the aluminum oxide dielectric. ESRhf results from the resistive
size. Capacitance increases less than 5% from 25 ºC to the high- losses in the foils, connections and the electrolyte/separator pad.
temperature limit. For devices rated –40 ºC capacitance declines The electrolyte/separator pad resistance usually dominates and
up to 20% at –40 ºC for low-voltage units and up to 40% for high- its resistance varies little with frequency. DFlf ranges from about
voltage units. Most of the decline is between –20 ºC and –40 ºC. 1.5% to 3%. ESRhf ranges from 0.002 to 10 Ω and decreases with
For devices rated –55 ºC capacitance typically declines less than increasing temperature.
10% at –40 ºC and less than 20% at –55 ºC.
The DF equation above shows that DF is constant for low
Capacitance Frequency Characteristics frequencies and crosses over to increasing-DF, constant-ESR, at a
The effective capacitance decreases as frequency increases. crossover frequency inversely proportional to capacitance. Since
Self-resonance is reached typically below 100 kHz depending high-capacitance capacitors have low crossover frequencies,
on capacitance. At self-resonance the device is resistive and DF increases more with increasing frequency than for lower-
beyond it is inductive. The termination style (i.e., axial, radial, capacitance capacitors.
screw-terminal) will influence the inductive characteristics.
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EQUIVALENT SERIES RESISTANCE (ESR)
The equivalent series resistance (ESR) is a single resistance Low-Temperature Impedance
representing all of the ohmic losses of the capacitor and Low-temperature impedance is the capacitor’s 120 Hz
connected in series with the capacitance. impedance measured at the low-temperature limit. It is usually
expressed as a multiple of the device’s 25 ºC impedance.
ESR Measurement
For aluminum electrolytic capacitors, ESR is measured as the Z Low-Temperature Measurement
resistance of the equivalent series circuit at 25 ºC in a measuring For low-temperature impedance measurement, place the
bridge supplied by a 120 Hz source free of harmonics with capacitors in a chamber set to the low-temperature limit ±2 ºC.
maximum AC signal voltage of 1 Vac and no bias voltage. Measure impedance at 120 ±5 Hz using any suitable method
providing an accuracy of ±2 ½ %. After temperature stabilization,
ESR Temperature Characteristics make the measurements quickly using as small as practical an
The high-frequency ESR declines with increasing temperature. It AC measuring voltage in order that it will not cause heating of
declines about 35% to 70% from 25 ºC to the high-temperature the capacitors. Assure that the capacitors have reached thermal
limit, but increases more than 10 fold at the low-temperature stability by demonstrating that two successive measurements
limit. The ESR of devices rated –20 ºC or –40 ºC can increase taken at 15 minute intervals show no change.
more than 100 times at –40 ºC.
Z Temperature Characteristics
DFlf has a positive temperature coefficient of 0.4 %/°C; so, it Impedance typically decreases less than 5% from 25 ºC to the
varies little with temperature, but ESRhf increases 10 to 100 high-temperature limit but increases up to 10 times to the low-
times from 25 ºC to the low-temperature limit. The increase in temperature limit.
ESR at cold temperatures is set by the ESRhf.
Z Frequency Characteristics
ESR Frequency Characteristics The frequency characteristics of impedance are dictated by the
Like DF, the ESR varies with frequency. Rewriting the DF contributions from capacitive reactance (1/(2πfC)), inductive
equation above, ESR can be modeled as below: reactance (2πfL) and from resistive losses in the electrolyte. A
typical impedance-versus-frequency curve is below. The low
ESR = 10,000(DFlf )/(2πfC) + ESRhf point is at the self-resonant frequency, and the impedance is
equal to the ESR at that frequency.
Expressing the ideas in ESR terms, at low frequencies the
ESR declines steadily with increasing frequency and crosses
over to constant ESR at a frequency inversely proportional to
capacitance. This crossover is typically below 10 kHz. The ESR
of high-capacitance capacitors changes little with increasing Impedance and ESR vs. Frequency
100
frequency because high-capacitance causes them to have low
crossover frequencies. The ESRhf ranges from 0.002 Ω for large,
screw-terminal capacitors to 10 Ω for miniature devices. 10
Impedance/ESR (Ω)
Z
IMPEDANCE (Z) Xc
1
For aluminum electrolytic capacitors impedance is actually
impedance magnitude. It is the ratio of voltage to current at XL
ESR
a given frequency and is related to the capacitor’s capacitance, 0.1
ESR and series inductance as follows:
Z = [(ESR)² + (1/(2πfC) – 2πfLs)²]½ 0.01

10 100 1000 10000 100000 1000000
Frequency (Hz)
Where Z is impedance in Ω, ESR is equivalent series resistance in
Ω, f is frequency in Hz, C is capacitance in F and Ls is equivalent
DC LEAKAGE CURRENT (DCL)
series inductance in H.
DC Leakage Current is the DC current flowing through the
capacitor with the rated voltage applied. The value of leakage
Z Measurement current depends on the voltage applied, the charging period
For aluminum electrolytic capacitors, Z is measured as the and capacitor temperature.
impedance magnitude of the equivalent series circuit at 25 ºC
in a measuring bridge supplied by a variable frequency source
capable of delivering an AC signal voltage of 1 Vac free of DCL Method of Measurement
harmonics from 10 Hz to 100 kHz. Impedance measurements are Measure leakage current at 25 ºC with the rated voltage applied
mostly for typical performance curves and for low-temperature through a protective resistance of 1000 Ω in series with the
limit measurements. capacitor in the measuring circuit. Five minutes after the
8
application of voltage, the leakage current is not to exceed the
DC Leakage vs Voltage, 4700 µF 450 V
maximum value indicated in the specification. 10
DCL Temperature Characteristics

Typical temperature characteristics are shown below:
DC Leakage (mA)
1
DC Leakage vs Temperature, 8600 µF 100 V 85 ºC

1
0.1
25 ºC
DC Leakage (mA)
100% V
0.01
0.1
90 95 100 105 110 115 120
Percent Rated Voltage
90% V
VOLTAGE WITHSTANDING
Rated DC Voltage
0.01 Rated DC voltage is the nominal voltage marked on the capaci-
25 35 45 55 65 75 85
tor, and it is the maximum peak voltage including ripple volt-
Temperature (ºC)
age that may be applied continuously between the terminals
and over the rated temperature range. Higher rated voltage ca-
pacitors may be substituted for lower rated voltage capacitors
DC Leakage vs Temperature, 4700 µF 450 V
1 as long as case size, DF, and ESR ratings are also compatible.
Rated Surge Voltage

Rated surge voltage is the maximum DC overvoltage to which
DC Leakage (mA)
the capacitor may be subjected at 25 ºC for short periods not

0.1
100% V exceeding approximately 30 s at infrequent intervals of not less
than 5 min.
Surge voltage Measurement

90% V
Subject the capacitors to their rated surge voltage at normal
room temperature and through a 1000 Ω ±10% resistor (except
0.01
25 35 45 55 65 75 85
for capacitances of 2500 µF and up, use a higher value resistor
Temperature (ºC) calculated as 2,500,000/C Ω ±10% where C is the capacitance
in µF). Cycle the voltage ½ minute on followed by 4½ minutes
off during which each capacitor is discharged through the
DCL Voltage Characteristics charging resistor or equal resistor. Repeat the cycles for 120 h.
The leakage current value drops rapidly as the applied voltage Post test requirements are for DCL, ESR and DF to meet initial
decreases below the capacitor’s rated voltage. The effect of requirements and for there to be no evidence of mechanical
voltage derating on the leakage current is shown next. damage or electrolyte leakage. Electrolyte residue with no
droplets or visible flow is permitted.
DC Leakage vs Voltage, 8600 µF 100 V
100
Reverse Voltage
Aluminum electrolytic capacitors are polarized and must be
10 connected in the correct polarity. They can withstand reverse
voltages up to 1.5 V. Higher reverse voltage can cause failure
DC Leakage (mA)
by pressure build up and rupture of the capacitor’s safety vent

1 structure. Non-polar and semi-polar devices are available that
85 ºC can withstand reverse voltage.
0.1
25 ºC Transient Overvoltage
Aluminum electrolytic capacitors can generally withstand
extreme overvoltage transients of limited energy. Application of
0.01
90 95 100 105 110 115 120
overvoltage more than about 50 V beyond the capacitor’s surge
Percent Rated Voltage
voltage rating causes high leakage current and a constant-
voltage operating mode quite like the reverse conduction of
9
a zener diode. The capacitor may fail short if the electrolyte diameter. For larger cases with high ripple current, verify the
cannot take the voltage stress, but even if it can, this operating temperature rise by requesting samples with thermocouples
mode cannot be maintained for long because hydrogen gas imbedded in the cores.
is produced by the capacitor, and the pressure build up will
cause failure. However, special designs are available that use Cornell Dubilier Thermal Pak, screw-terminal capacitors have
the overvoltage, zener-clamping effect to successfully protect controlled, low thermal resistance from core to case. You can
equipment from overvoltage transients such as lightning strikes. predict temperature rise using the Thermal Resistance Chart
later in this section or by using the thermal-resistance/expected-
Capacitors used as bus capacitors in large, high-voltage life model available on the website, http://www.cde.com.
capacitor banks are less capable of withstanding overvoltage
transients because the high energy and low source impedance Ripple Current Temperature Characteristics
of the capacitor bank can prevent a momentary partial discharge Rated ripple current can be increased for operating temperatures
from self healing and cause it to become a runaway short- less than rated temperature. Multipliers are shown in the
circuit failure. For high-voltage capacitor-bank applications use specifications. Generally the multipliers are derived based on
capacitors proven for that use. maximum core temperature (Tc), rated temperature (Tr) and
ambient temperature (Ta) as
RIPPLE CURRENT
Ripple Temperature Multiplier = [(Tc – Ta)/(Tc – Tr)]½
Ripple current is the AC current flowing in the capacitor. It’s called
ripple current because the associated AC voltage rides like ripple Counting on multipliers for temperatures below 60 ºC and for
on water on the capacitor’s DC bias voltage. The ripple current more than 1½ times rated ripple current is risky. High ripple
heats the capacitor and the maximum permitted ripple current is currents can cause shorter operating lives than expected
set by how much can be permitted and still meet the capacitor’s because as the capacitor ages its ESR increases and causes more
load life specification. Too much temperature rise will cause the heating for the same ripple current. This accelerates wearout.
capacitor to exceed its maximum permitted core temperature
and fail quickly, but operation close to the maximum permitted Ripple Current Frequency Characteristics
core temperature dramatically shortens expected life. The load Rated ripple current can be adjusted for operation at frequencies
life specifications for aluminum electrolytic capacitors operating other than 120 Hz. Multipliers are shown in the specifications.
at maximum permitted core temperature are typically 1000 Generally the multipliers are derived based on expected ESR
to 10000 hours. That’s a load life of six weeks to a year and a change with frequency; however, as discussed above, ESR is
seventh and not long enough time for most applications. a complex function of temperature, capacitance and rated
voltage as well as frequency. So it is difficult to create ripple-
Ripple current ratings usually assume that the capacitor is frequency multiplier tables that accurately model the frequency
convection cooled and that the entire can is in contact with dependence. For high-ripple current applications verify ESR at
air. A convection coefficient of 0.006 W/ºC/in² predicts the frequencies of interest and calculate total power dissipated.
temperature rise from air to the case, and the core temperature
is assumed to be the same as the case temperature. The power INDUCTANCE
dissipated is the ripple current squared times the ESR. Often the
25 ºC, 120 Hz maximum ESR is used, but since ESR decreases at Inductance is the equivalent series inductance, and it is relatively
elevated temperatures, less than maximum ESR may be used to independent of both frequency and temperature. Typical values
calculate power dissipated. range from 2 to 8 nH for SMT types, 10 nH to 30 nH for radial-
leaded types, 20 to 50 nH for screw-terminal types, and up to
Here’s an example. Suppose you wanted the ripple-current 200 nH for axial-leaded types. These low values are achieved by
rating for a 4700 µF, 450 V capacitor in a 3 inch (76 mm) diameter tab location and the intrinsic, low inductance of the dielectric
and 5 5/8 inches (143 mm) long can and the maximum ESR at contact geometry. The capacitor element has typical inductance
25 ºC and 120 Hz is 30 mΩ. The can area – not including the of less than 2 nH.
terminal end – is 60.1 in² (388 cm²). The thermal conductance is
(0.006)(60.1) = 0.36 W/ºC. For a 10 ºC temperature rise the case SELF RESONANT FREQUENCY
may dissipate 3.6 W. So the permitted ripple current with an ESR
of 30 mΩ is 11 A. If you assume that the ESR would decrease The self-resonant frequency is the frequency at which the
35% by 85 ºC, then the maximum ripple current can be 13.6 A. capacitive reactance (1/(2πfC)) equals the inductive reactance
(2πfL). Because the capacitive reactance is 180 degrees out of
With large-can capacitors, like the one in this example, neglecting phase with the inductive reactance, the two reactances subtract
the temperature rise from the case to the core can seriously out, and the remaining impedance is purely resistive and is
overstate the ripple current capability. With some constructions equal to the ESR at that frequency. Above self resonance the
the core is 3 to 5 ºC per watt of ripple power hotter than the device is inductive. In aluminum electrolytic capacitors the self-
case. So the total temperature rise would be more than double resonant frequency typically occurs at less than 100 kHz. The
the intended 10 ºC with rated ripple current and maximum ESR. self-resonant frequency is equal to 1/[2π(LC)½]. It occurs at a
It is generally safe to assume that the core temperature is the frequency higher than expected based on 120 Hz capacitance
same as the case temperature for capacitors smaller than 25 mm because capacitance decreases with increasing frequency.
10
The self resonant frequency can decrease with increasing VIBRATION WITHSTANDING CAPABILITY
temperature from capacitance increase.
Aluminum electrolytic capacitors can generally withstand
DIELECTRIC ABSORPTION 10 g vibration forces. Limits are shown in the specifications.
Adjust the procedure below as required by the individual type
Dielectric absorption may be observed as the reappearance of a specifications.
voltage across a capacitor after the terminals have been shorted
for a brief period and the short removed. This characteristic is To test vibration resistance, clamp the capacitors to a vibrating
important in RC timing circuits, triggering systems and phase platform and subject them to a simple harmonic motion having
shift networks. For aluminum electrolytic capacitors dielectric maximum peak-to-peak amplitude of 0.06 inches and maximum
absorption will allow up to 10% recovery of the charging voltage acceleration of 10 g or 15 g as specified. Vary the frequency of
between 100 s and 1000 s at 25 °C, and is more pronounced at vibration linearly between 10 and 55 Hz. Traverse the entire
higher temperatures. Maximum dielectric absorption can be frequency range in 1 minute. Unless specified otherwise, vibrate
obtained by charging capacitors for 1 hour at rated voltage and the capacitors for 1½ hours with the direction of motion being
discharging through a dead short for 1 minute. Subsequent parallel to the axis of the capacitor, then place the capacitors
measurements over time can be made with a high impedance so that the direction of motion is perpendicular to the axis and
micrometer. continue vibration for 1½ hours. During the last ½ hour of test
connect the capacitor to a capacitance meter and observe for a
With high-voltage aluminum electrolytic capacitors rebound 3-minute period.
voltages of 40 to 50 V are possible. While such voltages are not
a safety hazard, they can certainly cause sparking and create There will be no evidence of loosening of the capacitor element
a frightening distraction if the terminals are shorted by a tool within the container when shaken by hand following the test.
during installation. Conductive tape and wire shorting straps Also there will be no indication of intermittent contact, open or
can be supplied for the faint of heart. The tradeoff is extra cost shorting during the 3-minute observation period.
and the labor to remove them.
SAFETY CONSIDERATIONS
INSULATION AND GROUNDING
Pressure-Relief Vent
With non-solid electrolyte aluminum electrolytic capacitors the During operation of an aluminum electrolytic capacitor with
aluminum cases connect to the negative terminals by contact non-solid electrolyte, gas pressure normally increases. This
with electrolyte. The resulting isolation resistance may vary gas is mostly hydrogen and excess pressure is avoided by
from a few ohms to a few thousand ohms. For axial leaded permeation of the gas through the capacitor’s seal. But in cases
capacitors and flatpacks the case is connected to the negative like application of overvoltage, reverse voltage, AC voltage or
lead. If objects contacting the cases are to be at a potential capacitor failure, excess pressure can cause the capacitor to
other than the negative terminal’s potential, use capacitors with explode. To reduce the risk of explosion aluminum electrolytic
insulating sleeves. capacitors are usually equipped with pressure-relief vent
structures. These safety vents are intended to rupture and
The plastic insulation can withstand 3000 Vdc or 2500 Vac, 60 Hz release the gas pressure. After rupture the capacitor has limited
for 1 minute applied between the case and a ¼ inch wide metal life because it loses electrolyte and dries out.
foil placed around the sleeve. For stud-mounting, apply the
voltage between the mounting plate and the case, and mount Be careful not to interfere with the operation of the vent, for
the capacitor with an approved nylon nut and clearance hole. instance by mounting measures such as clamps, glue or potting
compounds. In the case of large capacitors with the capacitor
Insulation resistance is no less than 100 MΩ after 2 minutes elements secured by thermoplastic potting, don’t mount them
electrification with 100 volts applied between the foil and the with the safety vents down as the potting may flow when the
capacitor case. capacitors overheat and block the vents.
In rare cases for capacitors mounted alone and more often

ELEVATION AND EXTERNAL PRESSURE for capacitors in multiple-unit parallel capacitor banks a fully
functioning pressure relief device may not react in time. This
Not relevant for capacitors with solid electrolyte. Aluminum
could be from extreme overload or ignition of gas inside the
electrolytic capacitors can operate to 80,000 feet and pressures
capacitor through sparking caused by breakdown. Protect
as low as 3 kPa. Maximum air pressure depends on the size
personnel from possible rupture of high-energy capacitors with
and style of the capacitor. Exceeding the maximum value
shielding, and be sure to use substantial shielding when testing
can damage the capacitor by crushing the case, opening the
the pressure-relief vent. Examples of appropriate shielding
pressure-relief vent or causing a short circuit.
for testing are ¼-inch thick steel or ½-inch polycarbonate
enclosures with one end open to redirect the explosion rather
than contain it.
11
Test the capacitor’s pressure-relief capability by applying voltage overheating, overpressure, and dielectric breakdown. This can
or current using one of the following three methods: result in associated open-circuit or short-circuit failures and
rupture of the capacitor’s pressure-relief vent.
A. Subject the capacitor to AC current according to the rated
capacitance as below: Flammability
Aluminum electrolytic capacitors contain materials which can
Rated Capacitance Test Current catch fire and support combustion when contacted by flames.
µF Aac, 60 Hz Flammable parts include plastic parts, insulating sleeves, paper,
up to 3000 1 to 100 and the electrolytes. Most capacitors will pass the needle-flame
3,000 to 20,000 85 to 150 test requirements of UL 94V-O and not support combustion to
above 20,000 100 to 175 the requirements of Category B or C.
B. For a capacitor rated 150 Vdc and above, apply 110 to 125 Vac, In rare cases the capacitor may self-ignite from heavy overload
60 Hz through a 5 Ω ±10% series, current-limiting resistor. or capacitor defect. Hydrogen in the capacitor can ignite if
sparking occurs during capacitor failure. In critical applications
C. Subject the capacitor to reverse polarity, DC voltage sufficient such as mining applications consider providing fire-resistant
to allow a current from 1 to 10 A to flow. shields.

The excess internal pressure will be relieved without violent
expulsion of the capacitor element or cover or ignition of CAPACITOR BANK CONFIGURATIONS
surrounding material. To demonstrate non-ignition, wrap the
case loosely with two layers of cheese cloth which must not PARALLEL
ignite during test. A short or open circuit is not a failure of the Capacitors may be connected in parallel for increased
test. capacitance and ripple-current capability.
Contact with Electrolyte Bus Structure

The electrolyte in non-solid electrolytic capacitors is a When connecting capacitors in parallel, design the connecting
biodegradable liquid based on a stable solvent with a high bus with these features in mind. For minimum series inductance
boiling point as the main ingredient. The most common use a laminated-bus or strip-line structure. For example, have
solvent is ethylene glycol (EG). Dimethylformamide (DMF) and one plane of the circuit board as the plus connection and another
gammabutyrolactone (GBL) may be used in capacitors rated plane as the minus connection to all capacitors. Path resistance
–55 °C. The electrolyte includes an acid base system and other to each capacitor should be equal to assure equal current
chemicals. The electrolyte is chemically neutral and contains no sharing. While ripple current divides among the capacitors in
PCBs or halogenated compounds. It has low toxicity but you proportion to capacitance values for low-frequency ripple, high-
should avoid contact with the skin or eyes and avoid prolonged frequency ripple current divides in inverse proportion to ESR
inhalation. A Material Safety Data Sheet is available for the values and path resistance.
electrolyte solvent base material.
Fusing
Immediately treat contact with electrolyte by rinsing exposed In order to fuse the individual capacitors, include a slow-start
area with water. If electrolyte contacts eyes, flush for 10 minutes circuit at equipment turn-on, and fuse each capacitor at twice
with running water. Seek medical attention if any symptoms its expected, maximum ripple current. The slow-start circuit can
persist. Avoid inhalation of electrolyte vapors or dust particles. be a resistor in series with the capacitors that is shorted after
If vapors are present, ventilate the room. Smoke from burning initial charging.
electrolyte is irritating but does not contain dioxins or similar
toxic substances. If electrolyte gets on clothing, wash it off with SERIES
water. Capacitors may be connected in series for increased voltage
withstanding.
Charge-Discharge
Frequent, rapid charge and discharge of aluminum electrolytic Voltage Sharing
capacitors not designed for such service can damage the During charging the voltage on each capacitor connected in
capacitors by overheating and overpressure or breakdown series is proportional to the inverse of the actual capacitance,
with consequent failure by open or short circuit. For charge- but upon reaching final voltage, the voltage on each capacitor
discharge applications use capacitors designed for that use. is proportional to the inverse of the capacitor’s leakage current.
Of course in a series string there is only one leakage current and
Polarity – Reverse Voltage the capacitors with a propensity for higher leakage current will
Check the polarity of each capacitor both in circuit design get less voltage. Since leakage current increases with applied
and in mounting. Polarity is marked on the capacitor. While voltage, less voltage results in higher leakage resistance, and the
the capacitors can withstand continuous application of 1.5 V voltages tend to equalize. However, voltage distribution will not
reverse voltage, exceeding that can damage the capacitor by be uniform, and to assure that no capacitor is subjected to more
12
than its rated voltage, use higher rated voltage capacitors or a
balancing scheme such as balancing resistors, discussed next.
Assist voltage sharing stability by using capacitors from the
same manufacturing lot and mounting them to operate at the
same temperature.
Balancing Resistors
The difference in leakage currents in μA for two capacitors in
series at rated temperature can be estimated as 0.0015CVb Series - parallel array, no center connection
where C in μF is rated capacitance of each capacitor and Vb in Series - parallel array, no center connection
Vdc is the bus voltage across the two series capacitors. Using this Advantages: If one capacitor fails short then the capacitor
estimation enables selecting a value of balancing resistance for in series with it also fails, but other capacitors in the bank are
each capacitor as follows: unaffected. If balancing resistors are not used, high leakage
current of one capacitor affects only a single pair of capacitors.
R = (2Vm – Vb)/(0.0015CVb) The independent, series pairs permit fusing.
Where R in MΩ is the balancing resistance, Vm is the maximum Disadvantages: With balancing resistors the construction
voltage you'll permit on either capacitor, and Vb is the maximum is more complex; many resistors need to be fitted, and the
bus voltage across the two capacitors. additional resistors cost more.
For three or more capacitors in series use the following where n NON-POLAR AND MOTOR START
is the number of capacitors in series:
CAPACITORS
R = (nVm – Vb)/(0.0015CVb)
If two, same-value, aluminum electrolytic capacitors are
connected in series with the positive terminals or the negative
PARALLEL/SERIES terminals connected together, the resulting single capacitor is
Capacitors connected as shown below with a common
a non-polar capacitor equal in capacitance to half of the rated
connection between multiple series combinations have these
capacitance of either of the original pair. The two capacitors
considerations.
rectify the applied voltage and act as if they had been partially
bypassed by diodes. However, at all levels of AC voltage the
apparent capacitance is half of the rated capacitance as you
would expect for capacitors connected in series. The nonlinear
performance produces distortion where non-polar aluminum
electrolytic capacitors are used in audio AC applications.
In non-polar aluminum electrolytic capacitors and motor-start

aluminum electrolytic capacitors a second anode foil substitutes
Parallel-series array with common center connection for the cathode foil to achieve a non-polar capacitor in a single
Parallel-series array with common center connection
case. These are available for momentary-duty AC applications
Advantages: As the number of capacitors in parallel increases like motor starting and voltage-reversing applications, but the
the capacitance at the top tends to equal the capacitance at the high DF of aluminum electrolytic capacitors – from 2% to 150%
bottom. This improves voltage balance during transients. Also – causes excess heating and short life in most AC applications.
the leakage current at the top tends to equal the leakage current
at the bottom, so voltage balance improves during steady- Aluminum electrolytic, motor-start capacitors are non-polar and
state conditions. Finally, only two balancing resistors need be designed for intermittent operation in starting single-phase
considered, and the top and bottom may be so well matched as induction motors or for other brief AC applications such as
to eliminate the need for balancing resistors. motor-run capacitors in electric door openers.
Disadvantage: If one capacitor fails short, the other half of the

bank gets the entire bus voltage, so other capacitors will fail too RELIABILITY AND LIFETIME
unless the shorted capacitor blows open. Thus one capacitor Aluminum electrolytic capacitors are quite reliable largely
failure can cause failure of the entire bank. because of their effective, self-healing mechanism. While wear-
out is the most common failure mode, most such failures are
SERIES/PARALLEL gradual conversions to open circuits as the units become more
Capacitors connected as shown below with multiple series and more resistive.
combinations in parallel have these considerations. This
configuration is the clear choice when balancing resistors are
not used.
13
Failure Modes calculated service-life capability at temperatures near room
temperature. Use these predictions with caution because it is
Early-Life Failures not validated by life test results.
Early-life failures, infant mortals are mostly short-circuit failures
from weaknesses in the aluminum oxide dielectric. Incidence Often Mv is neglected, and values for the other variables
can be reduced with extended aging or burn-in. calculated service-life capability at temperatures near room
Random Failure Rate temperature. Use these predictions with caution because it is
The following formula accurately fits failure rates for Cornell not validated by life test results. change by case size. Typical
Dubilier aluminum electrolytic capacitors reported on billions values for Lb are 1000 to 2000 h for miniature types, 2000 to
of unit hours of field life data in large volume applications with
multiple levels of voltage and temperature stress. 10,000 h for snap-in types and 2000 to 20,000 h for large-can
screw terminal types. Lb can be greater than the rated load life
y = 4000,000NVa3C½2(Ta-Tm)/10⁄(LbVr²)
because no ripple is applied and because it’s typical life rather
y = random failure rate in FIT than minimum. Often Tm is 95 ºC when rated temperature is 85
N = number of capacitors in the array ºC and is 108 to 110 ºC when it’s 105 ºC.
Va = applied voltage in Vdc
C = capacitance of one capacitor in F Mv based on life tests for Cornell Dubilier capacitor types is:
Ta = actual core temperature in °C Mv = 4.3-3.3Va/Vr
Tm = maximum permitted core temperature in °C where Va is applied voltage and Vr is rated voltage. Values for
Lb = base life in hours at Tm and Vr Lb and Tm are:
Vr = rated voltage in Vdc Type Lb Tm
Wear-Out 330 12000 h 108 °C
Wear-out failures are mostly open-circuit failures from loss of
electrolyte or ESR increase from other causes. In the case of large 401C/101C 8000 h 108 °C
capacitors enduring high levels of ripple current, the increasing 300/301 6000 h 108 °C
ESR can cause overheating and short-circuit failures as wear-out 380L/LX 5000 h 95 °C
failures.
381L/LX 5000 h 110 °C
Operating Life
Onset of wear-out is determined mainly by the capacitor’s size 400C/500C/500R 7500 h 98 °C
and average operating temperature. Operating voltage has some 420C/520C 12000 h 103 °C
effect. For capacitors operating at moderate temperatures the 450C/550C 15000 h 108 °C
operating life doubles for each 10 ºC that operating temperature
DCMC 5000 h 95 °C
is reduced. Operating life can be expressed as
MLSG/MLSG-S 7500 h 125 °C
Lop = MvLb2[(Tm – Ta)/10]
MLSH 5000 h 125 °C
Where
Lop is the expected operating life in h, SLP 4500 h 110 °C
Mv is a unitless voltage multiplier for voltage derating, SLPX 4500 h 90 °C
Lb is the expected operating life in h for full rated volt-
THA 3000 h 85 °C
age and temperature,
Tm is the maximum permitted internal operating tem- THAS 3000 h 105 °C
perature in ºC, and
Determining Operating Life
Ta is the actual capacitor internal operating tempera-
Determine expected operating life by calculating the capacitor’s
ture in ºC.
expected operating temperature, Ta, and then use the operating-
Most manufacturers use this model to predict operating life; life formula. The operating temperature is the expected average
however, values for Mv, Lb and Tm vary both by capacitor type ambient temperature plus temperature rise from ripple current
and by manufacturer. For case diameters larger than 25 mm with and leakage current. Leakage-current power is small compared
significant ripple current, take into account the temperature rise to ripple-current power and can be neglected. Measure
of the capacitor element over its case. temperature rise from ripple current using sample capacitors
with thermocouples installed at the core hotspot, or calculate
Some makers appear to calculate operating life saying that
temperature rise from dissipated power. If you calculate the
expected lifetime doubles with less that a 10 °C drop in
power, do so at each significant ripple frequency and add the
temperature. The expectation that life doubles for each 10 °C
powers together for total power. Use the Thermal Resistance
reduction is well demonstrated by life tests and is consistent with
Chart to determine temperature rise. It’s equal to power
the Arrhenius equation of chemical activation and the activation
multiplied by thermal resistance.
energy for aluminum electrolytic capacitors. However, there is
another school of thought that says the reaction rate at cooler Calculating power at a frequency other that 120 Hz requires
temperatures slows more than predicted by the Arrhenius knowing the ESR at the new frequency. You may infer the ESR
equation because only a growingly smaller portion of the value from the ripple-current frequency multipliers for each
molecules have the activation energy needed to break existing type.
chemical bonds and form new ones. This collision theory puts ESRf = ESR120/Mf²
a prefactor in the Arrhenius equation that enables much longer
Where ESRf = ESR at a frequency f, ESR120 = ESR at 120 Hz and Mf
= Frequency multiplier for frequency f.
14
Or you may calculate the new ESR using the equation in ESR Lop = (1.44)(5000)2[(95 – 57)/10]
Frequency Characteristics. Using that equation to solve for = 100,300 h
ESRhf and including 3% for DFlf,,
And actual ESRs are typically 70% of limit so you could argue that
ESRf = ESR120 – 39800(f – 120)/fC the total power is 1.6 W. Thus the temperature rise would be 5
ºC, the core temperature, 55 ºC, and the operating life, 115,000 h.
Where ESR is in mΩ, f is in Hz and C is in µF. Although 3% is at However, it is more accurate to use the maximum limit because
the high end for DFlf, it fits with ESR120 which is a maximum limit that takes into account the ESR increase over life.
for the ESR at 120 Hz.
The example lower left shows the iterative approach. If a higher
Besides knowing ESR at the new frequency you also need to core temperature gives the operating life you require, you are
know the ESR at a new temperature, the expected operating done.
temperature. For Cornell Dubilier capacitors with electrolytes
rated to –40 ºC this table shows representative ratios of ESR at If the math needed to calculate operating life seems burdensome,
elevated temperatures to ESR at 25 ºC. take cheer. You can shortcut the calculations and consider more
mounting and cooling options by using our Java applet on our
Rated Capacitor Temperature website, http://www.cde.com.
Voltage 45 °C 65 °C 85 °C
Transient Over-Temperature
Vdc Ratio to ESR at 25 °C
As said, life of aluminum electrolytic capacitors generally
Up to 150 82% 77% 77% doubles for each 10 ºC that the core temperature is reduced.
200 to 300 75% 70% 70% The core is the hottest spot at about the center of the capacitor.
However, as a capacitor heats up toward its maximum permitted
350 & 450 70% 60% 60%
core temperature, the rules change. At temperatures above the
500 61% 49% 45% maximum core temperature and by 125 ºC for most types the
Here’s an illustration to unify this information: Consider the electrolyte can be driven from capacitor element and the ESR
earlier example, a 4700 µF, 450 V capacitor in a 3 inch (76 mm) can increase as much as 10 times. By this mechanism, transient
diameter and 5 5/8 inches (143 mm) long can with a maximum over-temperature or over-current can permanently increase the
ESR at 25 ºC and 120 Hz of 30 mΩ. Suppose that the capacitor is ESR and make the capacitor unusable. Be alert to this possibility
used as a bus capacitor in a motor-drive inverter, and the ripple in high-temperature and high-ripple applications, and pay extra
current consists of 11 A at 360 Hz and 6.5 A at 8000 Hz. And the attention to system cooling.
average applied voltage, the bus voltage, is 390 Vdc. Load Life Test
First calculate the ESRs at the two frequencies. While you Place the capacitors in a circulating air oven set to the upper
would use one or the other of the methods above to calculate temperature limit, 85 ºC, 105ºC or 125 ºC, ±3 ºC. Apply a DC
ESR, here we’ll use both to illustrate. If the capacitor is a Type voltage and an AC ripple voltage. Adjust the AC voltage to cause
DCMC, the frequency multiplier for 360 Hz is 1.13. Thus the current equal to the rated ripple current to flow and adjust the
360 Hz ESR is 30/1.13² or 23.5 mΩ. Or using the ESR Frequency DC voltage such that the peak voltage equals the capacitors’
Characteristics equation, the 360 Hz ESR is [30 – 39800(360- rated voltage. Apply the voltage for the rated load-life period –0
120)/360/4700] or 24.4 mΩ. Similarly at 8000 Hz the ESRs +6 h. Upon completion allow the capacitors to stabilize at 25 ºC
calculate to be 19.5 and 21.6 mΩ. for 24 h or more. The capacitors will meet the specified post-test
limits for capacitance, ESR and DCL.
Next calculate the total power. At 360 Hz it’s (11²)(0.0244) or 2.9
W. At 8000 Hz it’s (6.5²)(0.0216) or 0.9 W. That’s a total power of EIA Ripple Life Test, EIA IS-479
3.8 W. Conduct the wear-out lifetime test per EIA Interim Standard 479.
The highlights of that test are as follows:
Then calculate the core hot-spot temperature. From the
Thermal Resistance Chart the thermal resistance for free Apply ripple current at 120 Hz or adjust to maintain the same
power dissipation if performed at another frequency. Set DC
convection cooling is 3.07 ºC/W. So the temperature rise is (3.8)
(3.07) or 14 ºC. If the ambient temperature were 50 ºC, the corebias voltage equal to rated voltage minus peak applied AC
temperature would be 64 ºC. voltage. Set ambient temperature to 85 ± 2 ºC with airflow less
than 0.5 m/s. Periodic test interval ≤ 1000 h. Sample size is 10
Now predict operating life capability using the Operating Life or more. Mount capacitors horizontally and spaced 25 mm or
equation. The voltage multiplier, Mv is [4.3 – 3.3(390/450)] or more. Choose any temperature ≤ 85 ºC for measurements, and
1.44. Operating life is make all measurements at that temperature. End of Lifetime is

Lop = (1.44)(5000)2[(95 – 64)/10] ≤ the time when 10% or more of the sample have
= 61,700 h capacitance < 80% initial value or
But if the core temperature is 64 ºC, the ESR would have ESR > 200% initial requirement or
decreased about 40%. The new total power would be 0.6(3.8) or DCL > initial value or
2.3 W. The new temperature rise would be (3.07)(2.3) or 7 ºC, and there is evidence of mechanical damage or
the core temperature would be 57 ºC. Recalculating operating leakage of electrolyte.
life with the lower core temperature gives. 10% of sample may fail short or open and not be counted.
15
Voltage Derating the core to the bottom much more effectively than out the sides.
Voltage derating is expressed as the percentage that the applied You can take advantage of this heat path by mounting the ca-
voltage is less than rated voltage, e.g., a 450 V capacitor operat- pacitors directly to a metal chassis. In many case sizes this can
ing at 400 V would have 11% voltage derating. double the permitted ripple current for the same temperature
rise.
Aluminum electrolytic capacitors made with formation voltages
at least 35% higher than rated voltage and with rated tempera- Mounting can be by using capacitors with mounting studs and
tures of 85 ºC or higher, don’t require much voltage derating. In screwing the capacitors directly to the plate or it can be by
applications operating at less than 45 ºC no derating is needed, pressing the capacitors against a plate using the interconnect-
and with up to 75 ºC, 10% is sufficient. For higher temperatures ing bus structure. Cornell Dubilier furnishes silpad inserts at the
and with high ripple current, 15% or 20% is appropriate. Since bottom of the capacitors for this application. The silpads create
operating life continues to increase for further derating, military smooth bottoms by eliminating the steps at the sleeve rollovers.
and space applications use 50% voltage derating. The thermal resistance between the can and the underlying
plate for capacitors merely sitting on the plate is about 2.5 ºC/W.
Photoflash capacitors may be used at full rated voltage at nor- This decreases to less than 1 ºC/W if the capacitors are pressed
mal room temperatures because they are designed for such in place. Recommended vertical mounting force is 100 pounds.
duty. Strobe capacitors benefit from at least 10% voltage de- A Java applet is available on the Cornell Dubilier website which
rating because their continuous operation makes them run hot. permits you to explore cooling options and directly see the af-
fect on operating life. Go to http://www.cde.com.
SHELF LIFE Thermal Resistance

In large-can capacitors there can be significant temperature
Aluminum electrolytic capacitors stored for more than 5 to 10 rise from the case to the core, the hottest spot at the center of
years may have increased levels of DC leakage current. Check if the capacitor. For Cornell Dubilier Thermal Pak screw-terminal
DCL meets application requirements before placing in service. capacitors use the following thermal resistance data to deter-
Recondition high DCL units by applying rated voltage through mine temperature rise from power dissipated. As an illustration,
1,000 Ω resistor for 30 minutes. consider 20 amps of ripple current at 120 Hz in a 3 x 5 5/8 case
with a maximum ESR of 20 mΩ. The hot, typical ESR would be
Shelf life is a measure of how the capacitors will withstand stor- about half that or 10 mΩ, and the power dissipated would be
age for long times especially at high temperature. To test shelf I²Rs, 20²x0.01 or 4 W. For the DF case code the table shows that
life place the capacitors in an oven set to the shelf-life test tem- the thermal resistance from core to bottom of the can is about
perature –0 +3 ºC for the shelf-life test period. Upon comple- 0.41 ºC/W. That varies a little depending on how the capacitor
tion of the test stabilize the capacitors at 25 ºC for 24 h or more. is cooled, but 0.41 ºC/W predicts a temperature rise of 1.6 ºC for
Apply the rated voltage for 30 minutes, then verify the post test 4 W. The free-convection cooling column shows a total thermal
limits. Unless otherwise specified the capacitance, DCL and ESR resistance of 3.07 ºC/W for air on all sides and 1.02 ºC/W for the
will meet initial requirements. capacitor pressed against a large metal plate or chassis. The 3.07
ºC/W predicts a temperature rise of 12.3 ºC, and 1.02 ºC/W pre-
COOLING AND THERMAL RESISTANCE dicts 4.1 ºC.
Cooling Strategies
Cornell Dubilier screw-terminal capacitors conduct heat from
16
Thermal Resistance °C/W Thermal Pak Screw Terminal Aluminum Electrolytic Capacitors
Free Convection 200 lfm Airflow
Case Case Size Air on Side & End Air & Metal Chassis Air on Side & End Air & Metal Chassis
Code D x L (in)
Core to Case to air Total Core to Case to Total Core to Case to air Total Core to Case to air Total
bottom bottom air bottom bottom
AK 1 3/8 X 1 5/8 1.67 17.12 18.78 1.68 3.29 4.97 1.66 12.19 13.86 1.68 3.08 4.76
AA 1 3/8 X 2 1/8 1.70 13.72 15.42 1.74 3.13 4.87 1.70 9.80 11.50 1.74 2.90 4.64
AH 1 3/8 X 2 5/8 1.72 11.49 13.21 1.78 2.99 4.77 1.72 8.23 9.94 1.77 2.73 4.51
AB 1 3/8 X 3 1/8 1.72 9.91 11.63 1.80 2.86 4.66 1.71 7.12 8.83 1.79 2.59 4.38
AJ 1 3/8 X 3 5/8 1.69 8.73 10.43 1.81 2.74 4.55 1.69 6.29 7.99 1.80 2.46 4.25
AC 1 3/8 X 4 1/8 1.66 7.82 9.48 1.81 2.63 4.44 1.66 5.65 7.32 1.79 2.33 4.13
AD 1 3/8 X 4 5/8 1.62 7.09 8.71 1.80 2.52 4.32 1.62 5.14 6.76 1.78 2.22 4.00
AE 1 3/8 X 5 1/8 1.58 6.49 8.07 1.79 2.42 4.21 1.58 4.72 6.30 1.76 2.12 3.88
AF 1 3/8 X 5 5/8 1.53 5.99 7.52 1.77 2.33 4.10 1.53 4.37 5.90 1.74 2.02 3.76
EA 1 3/4 X 2 1/8 1.03 10.40 11.43 1.05 1.90 2.96 1.03 7.43 8.46 1.05 1.79 2.84
EH 1 3/4 X 2 5/8 1.06 8.77 9.83 1.09 1.84 2.93 1.06 6.28 7.34 1.09 1.71 2.80
EB 1 3/4 X 3 1/8 1.08 7.61 8.68 1.13 1.77 2.90 1.08 5.47 6.55 1.12 1.64 2.76
EJ 1 3/4 X 3 5/8 1.08 6.73 7.82 1.15 1.72 2.87 1.08 4.86 5.94 1.15 1.57 2.72
EC 1 3/4 X 4 1/8 1.08 6.06 7.13 1.17 1.66 2.83 1.08 4.39 5.47 1.16 1.51 2.67
ED 1 3/4 X 4 5/8 1.07 5.51 6.58 1.19 1.61 2.79 1.07 4.01 5.08 1.17 1.45 2.62
EE 1 3/4 X 5 1/8 1.05 5.07 6.12 1.19 1.55 2.75 1.05 3.70 4.75 1.18 1.39 2.57
EF 1 3/4 X 5 5/8 1.03 4.69 5.72 1.20 1.50 2.70 1.03 3.43 4.47 1.18 1.34 2.52
BA 2 X 2 1/8 0.78 8.89 9.67 0.80 1.45 2.24 0.78 6.35 7.14 0.80 1.37 2.17
BH 2 X 2 5/8 0.81 7.53 8.34 0.84 1.40 2.24 0.81 5.40 6.21 0.83 1.32 2.15
BB 2 X 3 1/8 0.83 6.55 7.38 0.87 1.36 2.23 0.83 4.71 5.54 0.87 1.27 2.13
BJ 2 X 3 5/8 0.84 5.82 6.66 0.90 1.32 2.22 0.84 4.20 5.04 0.89 1.22 2.11
BC 2 X 4 1/8 0.85 5.24 6.09 0.92 1.28 2.20 0.85 3.80 4.65 0.91 1.18 2.09
BD 2 X 4 5/8 0.84 4.78 5.63 0.93 1.25 2.18 0.84 3.48 4.33 0.93 1.14 2.07
BE 2 X 5 1/8 0.84 4.40 5.24 0.95 1.21 2.16 0.84 3.22 4.06 0.94 1.10 2.04
BF 2 X 5 5/8 0.83 4.09 4.92 0.96 1.18 2.14 0.83 3.00 3.83 0.94 1.06 2.01
CH 2 1/2 X 2 5/8 0.52 5.80 6.32 0.53 0.89 1.42 0.52 4.16 4.68 0.53 0.85 1.38
CB 2 1/2 X 3 1/8 0.54 5.07 5.61 0.56 0.87 1.43 0.54 3.65 4.19 0.56 0.82 1.38
CJ 2 1/2 X 3 5/8 0.55 4.53 5.08 0.58 0.85 1.43 0.55 3.27 3.82 0.58 0.80 1.38
CC 2 1/2 X 4 1/8 0.56 4.10 4.66 0.60 0.83 1.43 0.56 2.98 3.54 0.60 0.78 1.38
CD 2 1/2 X 4 5/8 0.57 3.47 4.04 0.64 0.79 1.43 0.57 2.55 3.11 0.63 0.74 1.37
CD 2 1/2 X 5 1/8 0.57 3.47 4.04 0.64 0.79 1.43 0.57 2.55 3.11 0.63 0.74 1.37
CF 2 1/2 X 5 5/8 0.57 3.23 3.80 0.65 0.78 1.43 0.57 2.38 2.95 0.64 0.72 1.36
DB 3 X 3 1/8 0.37 4.10 4.47 0.39 0.61 0.99 0.37 2.95 3.33 0.39 0.58 0.97
DJ 3 X 3 5/8 0.39 3.67 4.06 0.41 0.59 1.00 0.39 2.66 3.04 0.41 0.56 0.97
DC 3 X 4 1/8 0.40 3.34 3.73 0.43 0.58 1.01 0.40 2.43 2.82 0.42 0.55 0.97
DC 3 X 4 5/8 0.40 3.34 3.73 0.43 0.58 1.01 0.40 2.43 2.82 0.42 0.55 0.97
DE 3 X 5 1/8 0.41 2.85 3.26 0.46 0.56 1.02 0.41 2.09 2.50 0.45 0.53 0.98
DF 3 X 5 5/8 0.41 2.66 3.07 0.47 0.55 1.02 0.41 1.96 2.37 0.46 0.51 0.98
DP 3 X 5 7/8 0.41 2.58 2.99 0.47 0.55 1.02 0.41 1.91 2.32 0.47 0.51 0.98
DG 3 X 8 5/8 0.40 1.95 2.35 0.52 0.49 1.01 0.40 1.47 1.87 0.51 0.45 0.96
FC 3 1/2 X 4 1/8 0.30 2.79 3.09 0.32 0.43 0.75 0.30 2.03 2.33 0.31 0.41 0.72
FD 3 1/2 X 4 5/8 0.30 2.58 2.88 0.33 0.42 0.75 0.30 1.88 2.19 0.33 0.40 0.73
FE 3 1/2 X 5 1/8 0.31 2.40 2.71 0.34 0.42 0.76 0.31 1.76 2.07 0.34 0.39 0.73
FF 3 1/2 X 5 5/8 0.31 2.24 2.56 0.35 0.41 0.76 0.31 1.66 1.97 0.35 0.39 0.74
FP 3 1/2 X 5 7/8 0.31 2.18 2.49 0.36 0.41 0.77 0.32 1.61 1.93 0.36 0.38 0.74
FG 3 1/2 X 8 5/8 0.31 1.67 1.98 0.40 0.37 0.78 0.31 1.26 1.58 0.40 0.34 0.74
17
Thermal Resistance °C/W Thermal Pak Screw Terminal Aluminum Electrolytic Capacitors
500 lfm Airflow 1000 lfm Airflow
Air on Side & End Air & Metal Chassis Air on Side & End Air & Metal Chassis
Case Case Size Core to Core to Core to Core to
Code D x L (in) bottom Case to air Total bottom Case to air Total bottom Case to air Total bottom Case to air Total
AK 1 3/8 X 1 5/8 1.66 7.83 9.49 1.68 2.75 4.43 1.66 5.62 7.29 1.68 2.46 4.14
AA 1 3/8 X 2 1/8 1.70 6.31 8.02 1.73 2.53 4.26 1.70 4.56 6.26 1.73 2.22 3.95
AH 1 3/8 X 2 5/8 1.72 5.33 7.05 1.76 2.35 4.11 1.72 3.87 5.59 1.76 2.04 3.79
AB 1 3/8 X 3 1/8 1.71 4.64 6.35 1.78 2.19 3.97 1.71 3.39 5.11 1.77 1.88 3.65
AJ 1 3/8 X 3 5/8 1.69 4.13 5.82 1.78 2.05 3.83 1.69 3.04 4.73 1.76 1.75 3.52
AC 1 3/8 X 4 1/8 1.66 3.73 5.39 1.77 1.93 3.70 1.66 2.76 4.42 1.75 1.64 3.39
AD 1 3/8 X 4 5/8 1.62 3.41 5.03 1.75 1.82 3.57 1.62 2.54 4.16 1.72 1.54 3.27
AE 1 3/8 X 5 1/8 1.58 3.15 4.73 1.72 1.73 3.45 1.58 2.36 3.93 1.70 1.46 3.15
AF 1 3/8 X 5 5/8 1.53 2.93 4.46 1.69 1.64 3.33 1.53 2.20 3.73 1.66 1.38 3.04
EA 1 3/4 X 2 1/8 1.03 4.79 5.83 1.05 1.61 2.66 1.03 3.46 4.50 1.05 1.45 2.49
EH 1 3/4 X 2 5/8 1.06 4.08 5.14 1.09 1.51 2.60 1.06 2.97 4.03 1.08 1.35 2.43
EB 1 3/4 X 3 1/8 1.08 3.57 4.65 1.12 1.43 2.55 1.08 2.62 3.69 1.11 1.26 2.37
EJ 1 3/4 X 3 5/8 1.08 3.20 4.28 1.14 1.36 2.50 1.08 2.36 3.44 1.13 1.19 2.32
EC 1 3/4 X 4 1/8 1.08 2.91 3.99 1.15 1.29 2.44 1.08 2.16 3.24 1.14 1.13 2.27
ED 1 3/4 X 4 5/8 1.07 2.67 3.74 1.16 1.23 2.39 1.07 2.00 3.07 1.14 1.07 2.21
EE 1 3/4 X 5 1/8 1.05 2.48 3.54 1.16 1.18 2.33 1.05 1.87 2.92 1.14 1.02 2.16
EF 1 3/4 X 5 5/8 1.03 2.32 3.35 1.15 1.13 2.28 1.03 1.76 2.79 1.13 0.97 2.11
BA 2 X 2 1/8 0.78 4.10 4.88 0.79 1.25 2.04 0.78 2.97 3.75 0.79 1.14 1.93
BH 2 X 2 5/8 0.81 3.50 4.32 0.83 1.18 2.01 0.81 2.55 3.36 0.83 1.07 1.89
BB 2 X 3 1/8 0.83 3.08 3.91 0.86 1.13 1.99 0.83 2.26 3.09 0.86 1.01 1.86
BJ 2 X 3 5/8 0.84 2.77 3.61 0.88 1.07 1.96 0.84 2.05 2.89 0.88 0.95 1.83
BC 2 X 4 1/8 0.85 2.52 3.37 0.90 1.03 1.93 0.85 1.88 2.73 0.89 0.91 1.80
BD 2 X 4 5/8 0.84 2.33 3.17 0.91 0.99 1.90 0.84 1.75 2.59 0.90 0.87 1.77
BE 2 X 5 1/8 0.84 2.17 3.01 0.92 0.95 1.87 0.84 1.64 2.48 0.91 0.83 1.74
BF 2 X 5 5/8 0.83 2.03 2.86 0.93 0.91 1.84 0.83 1.55 2.38 0.91 0.80 1.71
CH 2 1/2 X 2 5/8 0.52 2.70 3.22 0.53 0.78 1.31 0.52 1.97 2.49 0.53 0.71 1.24
CB 2 1/2 X 3 1/8 0.54 2.39 2.93 0.55 0.75 1.30 0.54 1.76 2.29 0.55 0.68 1.23
CJ 2 1/2 X 3 5/8 0.55 2.16 2.71 0.58 0.72 1.30 0.55 1.60 2.15 0.57 0.65 1.23
CC 2 1/2 X 4 1/8 0.56 1.98 2.54 0.59 0.70 1.29 0.56 1.48 2.04 0.59 0.63 1.22
CD 2 1/2 X 4 5/8 0.57 1.72 2.29 0.62 0.65 1.27 0.57 1.31 1.88 0.62 0.58 1.20
CD 2 1/2 X 5 1/8 0.57 1.72 2.29 0.62 0.65 1.27 0.57 1.31 1.88 0.62 0.58 1.20
CF 2 1/2 X 5 5/8 0.57 1.62 2.19 0.63 0.63 1.26 0.57 1.24 1.81 0.62 0.56 1.19
DB 3 X 3 1/8 0.37 1.94 2.31 0.39 0.53 0.92 0.37 1.42 1.80 0.38 0.49 0.88
DJ 3 X 3 5/8 0.39 1.76 2.14 0.40 0.52 0.92 0.39 1.30 1.69 0.40 0.47 0.88
DC 3 X 4 1/8 0.40 1.62 2.02 0.42 0.50 0.92 0.40 1.21 1.61 0.42 0.46 0.88
DC 3 X 4 5/8 0.40 1.62 2.02 0.42 0.50 0.92 0.40 1.21 1.61 0.42 0.46 0.88
DE 3 X 5 1/8 0.41 1.42 1.83 0.45 0.47 0.92 0.41 1.08 1.49 0.44 0.43 0.88
DF 3 X 5 5/8 0.41 1.34 1.76 0.46 0.46 0.92 0.41 1.03 1.44 0.45 0.42 0.87
DP 3 X 5 7/8 0.41 1.31 1.72 0.46 0.46 0.92 0.41 1.01 1.42 0.46 0.41 0.87
DG 3 X 8 5/8 0.40 1.05 1.45 0.50 0.39 0.89 0.40 0.83 1.23 0.48 0.36 0.84
FC 3 1/2 X 4 1/8 0.30 1.36 1.65 0.31 0.38 0.69 0.30 1.02 1.31 0.31 0.35 0.66
FD 3 1/2 X 4 5/8 0.30 1.27 1.57 0.32 0.37 0.69 0.30 0.96 1.26 0.32 0.34 0.66
FE 3 1/2 X 5 1/8 0.31 1.20 1.51 0.34 0.36 0.70 0.31 0.91 1.22 0.33 0.33 0.67
FF 3 1/2 X 5 5/8 0.31 1.14 1.45 0.35 0.35 0.70 0.31 0.87 1.19 0.34 0.33 0.67
FP 3 1/2 X 5 7/8 0.32 1.11 1.43 0.35 0.35 0.70 0.32 0.86 1.17 0.35 0.32 0.67
FG 3 1/2 X 8 5/8 0.32 0.91 1.22 0.39 0.31 0.70 0.32 0.72 1.04 0.38 0.28 0.66
18
Thermal Resistance Chart °C/W Snap-in Aluminum Electrolytic Capacitors
Free Convection 200 lfm Airflow 500 lfm Airflow 1000 lfm Airflow
Case Case Size core to case to core to case to core to case to core to case to
Code DxL(mm) case air total case air total case air total case air total
H01 22 x 25 7.92 22.46 30.38 7.90 13.05 20.96 7.89 8.31 16.20 7.87 5.78 13.64
H02 22 x 30 8.13 20.02 28.15 8.11 11.75 19.87 8.09 7.58 15.67 8.06 5.34 13.41
H03 22 x 35 8.33 18.15 26.48 8.31 10.78 19.08 8.28 7.05 15.32 8.24 5.04 13.28
H04 22 x 40 8.51 16.69 25.20 8.48 10.03 18.51 8.44 6.65 15.09 8.39 4.83 13.22
H05 22 x 50 8.83 14.56 23.39 8.79 8.97 17.75 8.73 6.12 14.85 8.66 4.56 13.22
J01 25 x 25 6.11 18.99 25.10 6.10 11.04 17.14 6.08 7.03 13.11 6.06 4.89 10.95
J02 25 x 30 6.32 17.01 23.33 6.30 9.99 16.29 6.28 6.44 12.72 6.25 4.54 10.79
J03 25 x 35 6.52 15.49 22.00 6.49 9.20 15.69 6.46 6.01 12.47 6.42 4.30 10.72
J04 25 x 40 6.70 14.29 20.99 6.67 8.59 15.26 6.63 5.70 12.32 6.58 4.13 10.71
J45 25 x 45 6.87 13.32 20.19 6.83 8.11 14.94 6.78 5.46 12.24 6.72 4.02 10.73
J05 25 x 50 7.03 12.54 19.57 6.98 7.73 14.71 6.92 5.27 12.20 6.85 3.93 10.78
K01 30 x 25 4.28 14.84 19.12 4.26 8.63 12.89 4.25 5.50 9.74 4.22 3.82 8.04
K02 30 x 30 4.46 13.40 17.86 4.44 7.87 12.31 4.41 5.08 9.49 4.38 3.58 7.96
K03 30 x 35 4.63 12.27 16.91 4.61 7.29 11.90 4.57 4.77 9.34 4.53 3.41 7.94
K04 30 x 40 4.80 11.38 16.18 4.77 6.84 11.61 4.73 4.54 9.26 4.67 3.29 7.96
K45 30 x 45 4.96 10.66 15.62 4.92 6.49 11.41 4.87 4.37 9.23 4.80 3.21 8.01
K05 30 x 50 5.12 10.07 15.19 5.07 6.21 11.28 5.00 4.23 9.24 4.92 3.15 8.07
A01 35 x 25 3.19 11.98 15.18 3.18 6.97 10.15 3.16 4.44 7.60 3.14 3.09 6.22
A02 35 x 30 3.35 10.89 14.24 3.33 6.40 9.73 3.31 4.13 7.43 3.28 2.91 6.18
A03 35 x 35 3.51 10.03 13.53 3.48 5.96 9.44 3.45 3.89 7.34 3.40 2.78 6.18
A04 35 x 40 3.66 9.34 13.00 3.62 5.62 9.24 3.58 3.72 7.30 3.52 2.69 6.22
A45 35 x 45 3.80 8.78 12.58 3.76 5.35 9.10 3.70 3.59 7.29 3.64 2.63 6.27
A05 35 x 50 3.94 8.32 12.26 3.89 5.13 9.02 3.82 3.49 7.31 3.74 2.59 6.33
A06 35 x 63 4.26 7.46 11.72 4.19 4.75 8.94 4.09 3.34 7.43 3.98 2.54 6.53
A08 35 x 80 4.63 6.76 11.39 4.52 4.48 9.00 4.38 3.26 7.64 4.23 2.54 6.78
A10 35 x 105 5.03 6.19 11.21 4.87 4.30 9.17 4.69 3.24 7.93 4.49 2.59 7.08
N04 40 x 40 2.90 7.84 10.74 2.87 4.71 7.58 2.82 3.12 5.94 2.77 2.25 5.02
N05 40 x 50 3.15 7.03 10.18 3.10 4.33 7.43 3.04 2.94 5.98 2.96 2.18 5.14
N06 40 x 63 3.45 6.34 9.79 3.37 4.03 7.41 3.28 2.83 6.11 3.17 2.14 5.31
N08 40 x 80 3.79 5.78 9.57 3.68 3.83 7.50 3.54 2.77 6.31 3.39 2.15 5.54
N10 40 x 105 4.18 5.33 9.51 4.02 3.70 7.71 3.83 2.77 6.60 3.63 2.19 5.83
B05 50 x 50 2.20 5.25 7.45 2.15 3.23 5.38 2.09 2.19 4.27 2.01 1.61 3.62
B06 50 x 63 2.44 4.79 7.23 2.37 3.04 5.40 2.27 2.11 4.39 2.17 1.59 3.76
B08 50 x 80 2.72 4.41 7.14 2.61 2.90 5.52 2.48 2.08 4.56 2.34 1.60 3.94
B09 50 x 92 2.90 4.24 7.14 2.76 2.86 5.62 2.60 2.09 4.69 2.44 1.61 4.06
B10 50 x 105 3.07 4.12 7.18 2.90 2.83 5.74 2.72 2.10 4.81 2.53 1.63 4.17
PROCESS CONSIDERATIONS
Temperature and Duration
SOLDERING Strictly adhere to soldering conditions for temperature, duration
and minimum distance of solder from body. Don’t contact
Preheat insulating sleeve or other plastic parts with a soldering iron or
Don’t exceed the maximum storage temperature while molten solder. Reflow solder only SMT types, and then only
preheating the capacitors. If this cannot be avoided, contact
one reflow cycle. Contact the supplier if more than one reflow
the supplier first. is necessary.
19
Care after Soldering Fumigation Warning
Do not exert any mechanical force like bending, straightening, International shipments of electronic equipment are often in
twisting or tilting of capacitors after soldering into a printed wooden crates, and these crates may be fumigated with methyl
circuit board. bromide gas during shipment to control insect infestation.
Also, some factories such as flourmills are routinely fumigated
Handling Assembled Devices with this gas. Methyl bromide can penetrate cardboard boxes,
During transport and handling of assembled devices do not vinyl bags and other packaging materials used to protect the
misuse capacitors as a handle. Ensure that capacitors are equipment. Methyl bromide can also penetrate the seals of
protected from physical damage during mounting of printed aluminum electrolytic capacitors; cause corrosion and cause
circuit boards into assemblies or during stacking. open-circuit capacitor failure after the equipment is put into
service.
Halogenated-Solvent Cleaning
Halogenated hydrocarbon solvents (CFC) are ozone depleting Beginning in 2005 methyl bromide use has been limited to
chemicals harmful to the environment. Such solvents can applications with EPA Critical Use Exemptions for specific
penetrate the capacitors’ seals and cause corrosion and failure agricultural and food-processing use.
when voltage is applied, and so use them to clean aluminum
electrolytic capacitors only to the limited conditions given by To protect aluminum electrolytic capacitors against such failures
the component supplier and then only as a last resort. Solvent- use capacitors proven to be able to withstand fumigation
proof miniature capacitors and capacitors with epoxy endseals or individually sealed to prevent penetration of the methyl
are available for limited use with halogenated solvents. bromide gas. Screw terminal capacitors with rubber vent plugs
are the most susceptible type.
Aqueous Cleaning
Water with a mild detergent may be used to clean aluminum
electrolytic capacitors. However, immediately dry the capacitors
MOUNTING
in hot air at about 85 ºC for 5 or more minutes but not hotter
than the capacitors’ maximum storage temperature. Water Mounting Position
can become trapped beneath the sleeve which may not be Aluminum electrolytic capacitors have longer operating lives
dispelled by evaporation at room temperature. Water can be at lower ambient temperatures; so, put the capacitors at the
trapped under the sleeve and cause hydration and discoloration coolest place on the board. Ensure that aluminum electrolytic
of the aluminum cases; although this does not affect capacitor capacitors are away from hot components like power resistors,
operation. power transistors or diodes and transformers. Adequately
space components apart for cooling air to circulate. Ensure
that aluminum electrolytic capacitors are away from hot
Alcohol Cleaning
components like power resistors, power transistors or diodes
Alcohol solvents like isopropanol, methanol, ethanol and
and transformers. Adequately space components apart for
propanol have no harmful affects on aluminum electrolytic
cooling air to circulate. This is especially important when high
capacitors. While they are fine for cleaning, they are not very
ripple current or charge/discharge loads are applied.
effective in removal of commercial soldering fluxes.
Mount screw-terminal capacitors upright with terminals up or
Cleaning Precautions horizontally with pressure-relief vent plug at the 12-O’clock
The capacitor’s insulating sleeve may re-shrink or crack if position; so, the least amount of electrolyte will be expelled if
rapidly heated to above 100 ºC just after cleaning. If the solder the vent operates. Do not mount upside down with terminals
flux contains chlorine as many active flux types do, frequently down as this may reduce the operating life and could impair the
regenerate or replace the cleaning solvent to avoid damaging operation of the pressure-relief vent.
the capacitors. Cleaning solvents may swell the insulating
sleeves and affect the legibility of marking if applied too long or Place the capacitors so that a person working on the equipment
with too high mechanical forces or temperatures. would be protected from the hot vapor in the event that a vent
was to operate.
Potting and Gluing
Be certain that varnishing, coating, lacquering, embedding and Horizontal Mounting
gluing near the capacitors’ seals are halogen free. And be sure One maker of high voltage screw terminal aluminum electrolytic
all constituent parts including base material, thinners, binders, capacitors reports that if mounted horizontally, the positive
reacting agents, propellants and additives are halogen free. If terminal should be above the negative terminal to avoid
the printed circuit board has been cleaned with halogenated corrosion. This is not needed with Cornell Dubilier capacitors,
solvent, be sure it’s fully dry before installation of capacitors. but if you advocate better safe than sorry, you can mount the
When gluing, don’t apply glue to the full capacitor circumference, capacitor with the vent plug at the 11-O’clock position, so the
and don’t cover the capacitors’ pressure-relief vent with potting positive terminal would be higher.
or glue.
For high-ripple-current applications of screw terminal aluminum
electrolytic capacitors with extended paper, horizontal moun-
20
ting shortens the lifetime. With heating from ripple current require correct-polarity installation in the circuitry. To ensure
the electrolyte in such capacitors may bleed from the winding, correct mounting and identification of the polarity, put a clear
and puddle along the side of the can where there is no paper + and/or – on the board layout marking. If the circuit voltage
to wick it back into the winding. If the ripple current is low can reverse polarity or is unknown, consider using non-polar
(less than half of rated 85 ºC current), this is not an issue. But capacitors. Disadvantages are that non-polar capacitors are
if the ripple current is high, the effect is accelerated due both larger and more expensive.
to the increasing temperature driving the electrolyte out faster
and to the drying of the wet paper where it is crushed into the Printed-Circuit Board Precautions
can bottom. The drying of the paper can thermally insulate Avoid positioning holes in places where parts of a capacitor
the element causing it to get hotter and the can bottom to get could be on the other side and be touched by molten solder.
cooler. This can actually turn into a thermal runaway condition Because the can and sometimes extra terminals of an aluminum
that can greatly reduce the capacitor lifetime, sometimes by as electrolytic capacitor have resistive connections to the negative
much as 90%. terminal through the electrolyte, don’t locate tracks or lands
under upright capacitors, don’t permit metal capacitor parts
The possible solutions are 1) to mount such capacitors upright, other than active terminals to contact conductive tracks or other
2) use Thermal Pak construction with extended cathode foil, 3) components, and leave dummy pins voltage free.
use rilled construction with the element secured by dimples in
the can wall, or use potted construction where the element is Handling Terminals
anchored with pitch. If the capacitor is upright, the electrolyte Before handling a capacitor be sure it is sufficiently discharged.
is able to readily wick back into the winding, and the thermal To avoid damaging the capacitor, don’t bend rigid terminals,
contact and ESR do not degrade significantly. Thermal runaway and be sure to clamp the terminals during cutting or bending to
does not occur, and the expected lifetime is achieved. avoid excess stress on terminations, welds and capacitor seals.
Don’t use extra force to insert capacitors. If they cannot be
If a Thermal Pak extended-cathode capacitor is mounted inserted easily, correct the problem. Discard capacitors showing
horizontally, the thermal insulation does not occur because signs of mechanical damage.
the thermal contact never degrades. However, the lifetime
may still be somewhat shortened because of electrolyte loss. Screw-Terminal Torque
Life reduction may be more than 10% with rated 85 ºC ripple. Excess torque during tightening screws into terminals may affect
Because the thermal contact does not degrade, there is no the performance of the capacitor or damage the terminal. The
thermal runaway. following torque settings are recommended. Be certain that at
least six screw threads are engaged.
If a potted construction capacitor is mounted horizontally,
Terminal Recommended Torque
increased heating does not occur because the electrolyte does
not readily escape the winding, and the thermal contact never 10–32, Low Post 25 in-lb, 2.8 N-m
degrades. Potted construction has limited availability because 10–32, High Post 25 in-lb, 2.8 N-m
of environmental issues and is currently not available in Cornell ¼–28, Low Post 50 in-lb, 5.6 N-m
Dubilier capacitors. ¼–28, High Post 60 in-lb, 6.8 N-m
Small M5 Post 25 in-lb, 2.8 N-m
Position of the Pressure-Relief Vent
M5 Post 30 in-lb, 3.4 N-m
Aluminum electrolytic capacitors with liquid electrolyte have
pressure-relief vents. The vents are scored lines or patterns on M6 Low Post 50 in-lb, 5.6 N-m
the end or side of the cans or rubber plugs in the molded tops. M6 High Post 60 in-lb, 6.8 N-m
Vents are designed to rupture, release gas and electrolyte vapor,
and prevent possible explosion from pressure build up during Screw-Terminal Current Rating
capacitor abuse, e.g. overvoltage, reverse voltage or application For normal operation the maximum recommended continuous
of AC voltage. AC currents for screw terminals are as tabulated below.
Terminal Maximum Current
Provide adequate clearance for proper operation of the pressure-
10–32, Low Post 30 Aac
relief vent. The following distances are a guide.
10–32, High Post 30 Aac
Nominal Case Diameter Space around pressure relief device
¼–28, Low Post 50 Aac
< 16 mm > 2 mm
¼–28, High Post 50 Aac
> 16 mm to < 40 mm > 3 mm
Small M5 Post 30 Aac
> 40 mm > 5 mm
M5 Post 35 Aac
Mount the capacitors with the vents up to reduce the amount of M6 Low Post 50 Aac
electrolyte expelled if a vent operates. M6 High Post 60 Aac
Polarity indication
Aluminum electrolytic capacitors are normally polarized and
21
The ripple current ratings may exceed the currents listed DISPOSAL OF CAPACITORS
here. Terminals can withstand continuous currents of more
than double the maximum currents listed if you assure gas- Aluminum electrolytic capacitors with non-solid electrolyte
tight connections to avoid formation of aluminum oxide. Use principally include high-purity aluminum foils, capacitor paper,
Belleville washers and a commercial electrical joint compound, electrolyte, aluminum case, cover and sealing parts (phenolic,
e.g. Penetrox A, and tighten the terminals to the recommended thermoplastic, rubber and phenolic board), insulating sleeve
torque for the washers. (polypropylene, polyester or polyvinylchloride) and, perhaps,
safety-vent plugs made of synthetic rubber. If incinerated, be
Mounting-Stud Torque certain that the temperature is more than 1200 ºC. Disposal is
Screw-terminal, capacitors are available with threaded permitted in appropriate landfills.
mounting studs on the can bottoms, and nylon nuts are
available for insulated mounting. The following torque settings
are recommended.
Nylon Nut Thread Recommended Torque

M8 25 in-lb, 2.8 N-m
M12 75 in-lb, 8.5 N-m
Notice and Disclaimer: All product drawings, descriptions, specifications, statements, information and data
(collectively, the “Information”) in this datasheet or other publication are subject to change. The customer
is responsible for checking, confirming and verifying the extent to which the Information contained in this
datasheet or other 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 any guarantee, warranty, representation
or responsibility of any kind, expressed or implied. Statements of suitability for certain applications are based
on the knowledge that the Cornell Dubilier company providing such statements (“Cornell Dubilier”) has
of operating conditions that such Cornell Dubilier company regards as typical for such applications, but
are not intended to constitute any guarantee, warranty or representation regarding any such matter – and
Cornell Dubilier specifically and expressly disclaims any guarantee, warranty or representation concerning
the suitability for a specific customer application, use, storage, transportation, or operating environment.
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 Cornell Dubilier with reference to the use of any Cornell Dubilier products is given
gratis (unless otherwise specified by Cornell Dubilier), and Cornell Dubilier assumes no obligation or liability
for the advice given or results obtained. Although Cornell Dubilier strives to apply the most stringent quality
and safety standards regarding the design and manufacturing of its products, in light of 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 or other appropriate protective measures) 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 indicated in such warnings, cautions and notes, or that other safety measures may not be
required.
22

Tables: Aluminum Electrolytic Capacitor Overview

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Aluminum Electrolytic Capacitor Application Guide

Other Types of Capacitors Comparison 4

Characterization and Circuit Model 5 TABLES PAGE

Temperature Range 6 Capacitor Parameter Formulas 6

Capacitance 7 Base Lives and Max Core Temperatures 14

Dissipation Factor (DF) 7 Thermal Resistance Screw Terminal Capacitors 17

Equivalent Series Resistance (ESR) 8 Thermal Resistance for Snap-in Capacitors 19

Impedance (Z) 8 Pressure Relief Device Clearance 21

Low-Temperature Impedance 8 Screw Tightening Torque for Screw Terminals 21

DC Leakage Current (DCL) 8 Maximum Currents for Screw Terminals 21

Voltage Withstanding 9 Tightening Torque for Nylon Mounting Nuts 22

Insulation and Grounding 11

Elevation & External Pressure 11

Vibration Withstanding Capability 11

Capacitor Bank Configurations 12

Non-Polar and Motor Start Capacitors 13

Reliability and Lifetime 13

Cooling and Thermal Resistance 16

Rubber Gasket Rubber Gasket

Thermal Pak Construction Rilled Construction

Etching involves pulling the aluminum foil on rollers through a

The typical temperature range for aluminum electrolytic

Zener diode D models overvoltage and reverse voltage behavior.

Voltage volts (V) V Vc=IXc, Vz=IZ

limits given in the specification. It is the range of ambient

Storage Temperature Range DISSIPATION FACTOR (DF)

Z = [(ESR)² + (1/(2πfC) – 2πfLs)²]½ 0.01

DCL Temperature Characteristics

DC Leakage vs Temperature, 8600 µF 100 V 85 ºC

Rated Surge Voltage

the capacitor may be subjected at 25 ºC for short periods not

Surge voltage Measurement

by pressure build up and rupture of the capacitor’s safety vent

In rare cases for capacitors mounted alone and more often

Contact with Electrolyte Bus Structure

In non-polar aluminum electrolytic capacitors and motor-start

Disadvantage: If one capacitor fails short, the other half of the

SHELF LIFE Thermal Resistance

Nylon Nut Thread Recommended Torque

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