Motor capacitor

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A typical motor start capacitor Motor-Start-Capacitor.jpg
A typical motor start capacitor

A motor capacitor [1] [2] is an electrical capacitor that alters the current to one or more windings of a single-phase alternating-current induction motor to create a rotating magnetic field.[ citation needed ] There are two common types of motor capacitors, start capacitor and run capacitor (including a dual run capacitor). [2]

Contents

Motor capacitors are used with single-phase electric motors [3] :11 that are in turn used to drive air conditioners, hot tub/jacuzzi spa pumps, powered gates, large fans or forced-air heat furnaces for example. [1] A "dual run capacitor" is used in some air conditioner compressor units, to boost both the fan and compressor motors. [1] Permanent-split capacitor (PSC) motors use a motor capacitor that is not disconnected from the motor. [4]

Start capacitors

Simple capacitor-start single-phase motor circuit diagram. Note that starting capacitor is connected in series with auxiliary winding just like in LC circuit. Capasitor-start single-phase motor circuit diagram.svg
Simple capacitor-start single-phase motor circuit diagram. Note that starting capacitor is connected in series with auxiliary winding just like in LC circuit.
Capacitor motor with a speed limiting governor device. Condensatormotor.svg
Capacitor motor with a speed limiting governor device.

Start capacitors lag the voltage to the rotor windings creating a phase shift between field windings and rotor windings. Without the start capacitor, the north and south magnetic fields will line up and the motor hums and will only start spinning when phsically turned, creating a phase shift. A start capacitor stays in the circuit long enough to rapidly bring the motor up to a predetermined speed, which is usually about 75% of the full speed, and is then taken out of the circuit, often by a centrifugal switch that releases at that speed. Afterward the motor works more efficiently with a run capacitor which makes the power factor closer to one.. [1] [5]

Start capacitors usually have ratings above 70 μF, with four major voltage classifications: 125 V, 165 V, 250 V, and 330 V. [1]

Start capacitors above 20 μF are always non-polarized aluminium electrolytic capacitors [6] with non solid electrolyte and therefore they are only applicable for the short motor starting time.

The motor will not work properly if the centrifugal switch is broken. If the switch is always open, the start capacitor is not part of the circuit, so the motor does not start. If the switch is always closed, the start capacitor is always in the circuit, so the motor windings will likely burn out. If a motor does not start, the capacitor is far more likely the problem than the switch.[ citation needed ]

Run capacitors

Some single-phase AC electric motors require a "run capacitor" to energize the second-phase winding (auxiliary coil) to create a rotating magnetic field while the motor is running. [5]

Run capacitors are designed for continuous duty while the motor is powered, which is why electrolytic capacitors are avoided, and low-loss polymer capacitors are used. Run capacitors are mostly polypropylene film capacitors (historically: metallised paper capacitors) and are energized the entire time the motor is running. [1] Run capacitors are rated in a range of 1.5 to 100 μF, with volt classifications of 250, 370 and 440 V. [1]

If a wrong capacitance value is installed, it will cause an uneven magnetic field around the rotor. This causes the rotor to hesitate at the uneven spots, resulting in irregular rotation, especially under load. This hesitation can cause the motor to become noisy, increase energy consumption, cause performance to drop and the motor to overheat. [5]

Dual run capacitors

A dual run capacitor supports two electric motors, with both a fan motor and a compressor motor. It saves space by combining two physical capacitors into one case. The dual capacitor has three terminals, labeled C for common, FAN, and HERM for hermetically-sealed compressor.

Dual capacitors come in a variety of sizes, depending on the capacitance (measured in microfarads, μF), such as 40 plus 5 μF, and also on the voltage. A 440-volt capacitor can be used in place of a 370-volt, but not a 370-volt in place of a 440-volt. [2] The capacitance must remain within 5% of its original value. [2] Round cylinder-shaped dual run capacitors are commonly used for air conditioning, to help in the starting of the compressor and the condenser fan motor. [2] An oval dual run capacitor could be used instead of a round capacitor; in either case the mounting strap needs to fit the shape used. [2]

Labeling

The units of capacitance are labeled in microfarads (μF). Older capacitors may be labeled with the obsolete terms "mfd" or "MFD", which can be ambiguous but are, especially in this context, used for microfarad as well (a millifarad is 1000 microfarads and not usually seen on motors).

Failure modes

A faulty run capacitor often becomes swollen, with the sides or ends bowed or bulged out further than usual; it can then be clear to see that the capacitor has failed, because it is swollen or even blown apart causing the capacitor's electrolyte to leak out. Some capacitors have a "pressure-sensitive interrupter" design that causes them to fail before internal pressures can cause serious injury. One such design causes the top of the capacitor to expand and break internal wiring. [7]

Over many years of use the capacitance of the capacitor drops; this is known as a "weak capacitor". As a result, the motor may fail to start or to run at full power.

When a motor is running during a lightning strike on the power grid, the run capacitor may be damaged or weakened by a voltage spike, thus requiring replacement.

IEC/EN 60252-1 2011 specifies the following levels of protection for motor run capacitors:

Safety issues

Heat

A motor capacitor which is a component of a hot tub circulating pump can overheat if defective. [9] This poses a fire hazard, and the U.S. Consumer Product Safety Commission (CPSC) has received more than 100 reports of incidents of overheating of the motor capacitor, with some fires started. [9]

Toxic

Motor capacitors manufactured before 1978 likely contain polychlorinated biphenyls (PCBs). These are extremely toxic and persistent chemicals with many long-lasting negative human and wildlife health effects. Capacitors were required to be labeled in the U.S. with "No PCBs" or similar language. Capacitors without these labels are suspect.

PCB containing capacitors must be replaced and disposed by consulting local environmental authorities. If these capacitors leak or fail, PCBs can be released into the environment and will very likely result in extremely expensive environmental cleanups, and potentially, lawsuits. There are extensive toxicological reports on PCBs in the research community. U.S. EPA has much information on the correct way to test and manage these toxic chemicals in older capacitors. [10]

Related Research Articles

<span class="mw-page-title-main">Farad</span> SI unit of electric capacitance

The farad (symbol: F) is the unit of electrical capacitance, the ability of a body to store an electrical charge, in the International System of Units (SI), equivalent to 1 coulomb per volt (C/V). It is named after the English physicist Michael Faraday (1791–1867). In SI base units 1 F = 1 kg−1⋅m−2⋅s4⋅A2.

<span class="mw-page-title-main">Commutator (electric)</span> Device for changing direction of current

A commutator is a rotary electrical switch in certain types of electric motors and electrical generators that periodically reverses the current direction between the rotor and the external circuit. It consists of a cylinder composed of multiple metal contact segments on the rotating armature of the machine. Two or more electrical contacts called "brushes" made of a soft conductive material like carbon press against the commutator, making sliding contact with successive segments of the commutator as it rotates. The windings on the armature are connected to the commutator segments.

<span class="mw-page-title-main">Induction motor</span> Type of AC electric motor

An induction motor or asynchronous motor is an AC electric motor in which the electric current in the rotor that produces torque is obtained by electromagnetic induction from the magnetic field of the stator winding. An induction motor therefore needs no electrical connections to the rotor. An induction motor's rotor can be either wound type or squirrel-cage type.

A photoflash capacitor is a high-voltage electrolytic capacitor used in camera flashes and in solid-state laser power supplies. Their usual purpose is to briefly power a flash lamp, used to illuminate a photographic subject or optically pump a laser rod. As flash tubes require very high current for a very short time to operate, photoflash capacitors are designed to supply high discharge current pulses without excessive internal heating.

<span class="mw-page-title-main">Electrolytic capacitor</span> Type of capacitor

An electrolytic capacitor is a polarized capacitor whose anode or positive plate is made of a metal that forms an insulating oxide layer through anodization. This oxide layer acts as the dielectric of the capacitor. A solid, liquid, or gel electrolyte covers the surface of this oxide layer, serving as the cathode or negative plate of the capacitor. Because of their very thin dielectric oxide layer and enlarged anode surface, electrolytic capacitors have a much higher capacitance-voltage (CV) product per unit volume than ceramic capacitors or film capacitors, and so can have large capacitance values. There are three families of electrolytic capacitor: aluminium electrolytic capacitors, tantalum electrolytic capacitors, and niobium electrolytic capacitors.

A motor controller is a device or group of devices that can coordinate in a predetermined manner the performance of an electric motor. A motor controller might include a manual or automatic means for starting and stopping the motor, selecting forward or reverse rotation, selecting and regulating the speed, regulating or limiting the torque, and protecting against overloads and electrical faults. Motor controllers may use electromechanical switching, or may use power electronics devices to regulate the speed and direction of a motor.

<span class="mw-page-title-main">Inrush current</span> Maximal instantaneous input current drawn by an electrical device when first turned on

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<span class="mw-page-title-main">Capacitor types</span> Manufacturing styles of an electronic device

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<span class="mw-page-title-main">Capacitor</span> Passive two-terminal electronic component that stores electrical energy in an electric field

In electrical engineering, a capacitor is a device that stores electrical energy by accumulating electric charges on two closely spaced surfaces that are insulated from each other. The capacitor was originally known as the condenser, a term still encountered in a few compound names, such as the condenser microphone. It is a passive electronic component with two terminals.

<span class="mw-page-title-main">AC motor</span> Electric motor driven by an AC electrical input

An AC motor is an electric motor driven by an alternating current (AC). The AC motor commonly consists of two basic parts, an outside stator having coils supplied with alternating current to produce a rotating magnetic field, and an inside rotor attached to the output shaft producing a second rotating magnetic field. The rotor magnetic field may be produced by permanent magnets, reluctance saliency, or DC or AC electrical windings.

<span class="mw-page-title-main">Ceramic capacitor</span> Fixed-value capacitor using ceramic

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An induction generator or asynchronous generator is a type of alternating current (AC) electrical generator that uses the principles of induction motors to produce electric power. Induction generators operate by mechanically turning their rotors faster than synchronous speed. A regular AC induction motor usually can be used as a generator, without any internal modifications. Because they can recover energy with relatively simple controls, induction generators are useful in applications such as mini hydro power plants, wind turbines, or in reducing high-pressure gas streams to lower pressure.

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<span class="mw-page-title-main">Tantalum capacitor</span> Type of electrolytic capacitor

A tantalum electrolytic capacitor is an electrolytic capacitor, a passive component of electronic circuits. It consists of a pellet of porous tantalum metal as an anode, covered by an insulating oxide layer that forms the dielectric, surrounded by liquid or solid electrolyte as a cathode. Because of its very thin and relatively high permittivity dielectric layer, the tantalum capacitor distinguishes itself from other conventional and electrolytic capacitors in having high capacitance per volume and lower weight.

<span class="mw-page-title-main">Gyrator–capacitor model</span> Model for magnetic circuits

The gyrator–capacitor model - sometimes also the capacitor-permeance model - is a lumped-element model for magnetic circuits, that can be used in place of the more common resistance–reluctance model. The model makes permeance elements analogous to electrical capacitance rather than electrical resistance. Windings are represented as gyrators, interfacing between the electrical circuit and the magnetic model.

<span class="mw-page-title-main">ESR meter</span> Tool for measuring equivalent series resistance of capacitors

An ESR meter is a two-terminal electronic measuring instrument designed and used primarily to measure the equivalent series resistance (ESR) of real capacitors; usually without the need to disconnect the capacitor from the circuit it is connected to. Other types of meters used for routine servicing, including normal capacitance meters, cannot be used to measure a capacitor's ESR, although combined meters are available that measure both ESR and out-of-circuit capacitance. A standard (DC) milliohmmeter or multimeter cannot be used to measure ESR, because a steady direct current cannot be passed through the capacitor. Most ESR meters can also be used to measure non-inductive low-value resistances, whether or not associated with a capacitor; this leads to several additional applications described below.

<span class="mw-page-title-main">Film capacitor</span> Electrical capacitor with an insulating plastic film as the dielectric

Film capacitors, plastic film capacitors, film dielectric capacitors, or polymer film capacitors, generically called film caps as well as power film capacitors, are electrical capacitors with an insulating plastic film as the dielectric, sometimes combined with paper as carrier of the electrodes.

<span class="mw-page-title-main">Capacitive power supply</span> Type of power supply using a capacitor

A capacitive power supply or capacitive dropper is a type of power supply that uses the capacitive reactance of a capacitor to reduce higher AC mains voltage to a lower DC voltage.

<span class="mw-page-title-main">Aluminum electrolytic capacitor</span> Type of capacitor

Aluminum electrolytic capacitors are (usually) polarized electrolytic capacitors whose anode electrode (+) is made of a pure aluminum foil with an etched surface. The aluminum forms a very thin insulating layer of aluminum oxide by anodization that acts as the dielectric of the capacitor. A non-solid electrolyte covers the rough surface of the oxide layer, serving in principle as the second electrode (cathode) (-) of the capacitor. A second aluminum foil called "cathode foil" contacts the electrolyte and serves as the electrical connection to the negative terminal of the capacitor.

References

  1. 1 2 3 4 5 6 7 LA.gov, Louisiana. "Capacitor Sizing Dilemmas (motor capacitors)". LA.gov. Retrieved 2012-01-29.
  2. 1 2 3 4 5 6 JustTheRightAir (Sep 2008). "Round Dual Run Capacitors". justtherightair.com. Archived from the original on 2008-07-12. Retrieved 2008-09-24.
  3. 1 2 Emadi, Ali (2018). Energy-efficient electric motors (3rd ed. rev. and expanded ed.). [Boca Raton]. ISBN   978-1-4200-3081-5. OCLC   1083013923.{{cite book}}: CS1 maint: location missing publisher (link)
  4. Alternating Current Machines. Firewall Media. 2024-02-19. ISBN   978-81-7008-222-4.
  5. 1 2 3 Motor start and motor run capacitors; capacitorguide.com
  6. This link only shows irrelevant types (July 2018) do they even exist? Allied electronics, Aluminium Electrolytic, Quick connect
  7. Regal-Beloit. "AC Capacitors for Motor Run Applications" (PDF). GE Capacitors. Archived from the original (PDF) on 2011-10-26. Retrieved 2011-09-04.
  8. "MotorCap DM AC Film Capacitors for Motor Run Applications" (PDF). Epcos AC, Munich, Germany. Retrieved 2012-04-22.
  9. 1 2 "CPSC, Firms Announce Recall of Infinity and Lifestyle Spas" U.S. CPSC, Washington, DC, CPSC.gov, 2003-12-09, webpage: CP7 Archived 2013-01-08 at the Wayback Machine .
  10. Dan Bench. "Identification, Management, and Proper Disposal of PCB-Containing Electrical Equipment used in Mines" (PDF). U.S. Environmental Protection Agency.