How to inspect CBB60 capacitor, CBB65 capacitor and CBB61 capacitor?

How to inspect CBB60 capacitor, CBB65 capacitor and CBB61 capacitor?

Capacitor Inspection Criterion
1. Applicable Scope
This criterion applies to the running capacitor (CBB) put on the single phase asynchronous 
motor manufactured by Lishui Topo Electronic Co., ltd.
2. Standard
Capacitor must comply with the latest version IEC60252&GB3667.
3. Class of Operation
As stipulated in IEC60252, the minimum total life for which the capacitor has been designed at rated duty, voltage, temperature and frequency is: 
Class A- 30 000h 
Class B- 10 000h 
Class C- 3 000h 
Class D- 1 000h
4. Inspection and Testing instruments
The inspection and testing instrument listed as: Capacitor endurance general testing system, capacitor impact testing station, 500V direct current impact testing station, capacitor testing instrument, 20KVA transformer, damp heat testing case, pressure cooker etc.
5. Inspection Procedure
5.1. CBB60, CBB61 capacitor inspection procedure:
Capacitor holistic quality evaluation→visual, marks, certification→fire resistance of the plastic shell (only applicable to plastic shell)→dimension and lead length →termination pressing quality or plug termination quality inspection→measure of capacitor value and tangent of loss angle value→voltage duration test between 2 poles→voltage duration test between pole and shell(only applicable to metal shell)→water cooking test, impact test, duration test→anatomic inspection and analysis→testing report.
5.2. CBB65 capacitor inspection procedure:
Capacitor holistic quality evaluation→visual, marks, certification→dimension termination pressing quality→measure of capacitor value and tangent of loss angle value voltage duration test between 2 poles→voltage duration test between pole and shell (only applicable to metal shell)→impact test, duration test→anatomic inspection and analysis→testing report.
6. Inspection and Testing Requirements
6.1. Capacitor holistic quality evaluation before test
6.1.1. Epoxy resin requirements (it is only limited to CBB60, CBB61)
6.1.2. The whole core of capacitor must be completely sealed with epoxy resin as attached picture 1. The defects showed as picture 2 are prohibited: air leak hole, epoxy resin is not complete: the core is not sealed with epoxy resin or the epoxy resin can’t cover the top of the core etc.
6.1.3. The thickness of epoxy resin sealing on top of capacitor could not be less 5mm, CBB61 capacitor value could not be less than 3mm; and the thickness of epoxy resin sealing on bottom could not be less than 2mm, CBB61 capacitor value could not be less than 1mm.
6.1.4. The height between the epoxy resin plane and the out casing edge could not be over 3mm.
6.1.5. The thickness around the core of CBB60 could not be less 1mm, while the CBB61 could not be less than 0.5mm
6.2. The quality requirements of core
6.2.1. The welding of lead wire must be firm, reliable, burned and burnable.
6.2.2. The thickness of capacitor metal spraying must not be ≥0.5mm, metal spraying layer and core must felt firm.
6.2.3. The protective firm of CBB60 and CBB65 could not be less 15 layers, while CBB61 could not be less 8 layers.
6.2.4. The metallic firm must do not have any oxidation symbol.
6.3. Marks
6.3.1. The capacitor must get the specific certification and make marks on the capacitor.
6.3.2. The capacitor must indicate the model no, rated volume (μF) ,rated voltage(UN), tolerance(%), trademark, production date or batch, climate classification, running class etc.
6.3.3. The printing on the capacitor must comply with “capacitor application and purchase specification” or the confirmative docs.
6.4. Shell requirements (it is only limited to the plastic shell capacitor)
In case plastic shell is required, the material of the shell must be fire-resistance and V-1 grade, one batch one sample is a must.
6.5. Visual requirements
The surface of the capacitor must do not have the defects as nicked, sunk, nasty or rust, with clear marks and correct data.
6.6. Dimension and lead wire requirements (it is only limited to lead wire capacitor)
The dimension and lead wire must comply with “capacitor application and purchase specification” or drawings’ requirements.  
6.7. Lead wire capacitor termination punching quality and plug capacitor connection quality requirements.
6.7.1. Lead wire capacitor termination and its punching quality requirements
6.7.1.1. Punching of termination and its quality must meet the relevant requirements.
6.7.1.2. Termination must be tin plated or nickel plated, the thickness should not ≥ 0.4, and have enough tenacity, the termination could be bent 90° and resume its original position, termination could not break or break off or crack. One batch 3 samples are a must, if fail the test, double the sample.
6.7.1.3. Termination after punching could bear 5kg clog and no break off or move. 5 samples are a must, if fail the test, double the sample.
6.7.1.4. Ensure good connection between termination, the lead wire conductor and the 2 edges of insulator must be clear, the conductor could be seen clearly, there is no any insulator in the lead wire in the parts which hold the lead wore conductor.
6.7.2. The quality requirements of plug type capacitor
6.7.2.1. Plug is normal #250 double straight blade.
6.7.2.2. Plug slice should have no sharp edge, burr and defects that influence the assembling procedure.
6.7.2.3. Material of plug slice should be brass with tin plated or nickel plated, 5%Nacl central salt spray test for 16 hours without red rust, one batch one sample is a must.
6.7.3. The position of termination and lead wire must be sealed by a transparent heat shrink, the position should be seal suitable after shrink, but should not go beyond the outside diameter of termination.

6.8. The measurement of value of capacitor
6.9. Tangent of loss angle value
t gδ≤5×10-3（1KHz）
6.10. The voltage duration test between terminal edges during 2 poles.
The insulation lead by 2 poles should bear 2.0UN A/C tested voltage for 60 seconds, during the test, there should not occur any flashover or bowl over permanently.. After test, a tangent of loss angle value will be made according to clause6.9, and measure the capacitor value according to clause 6.8: △C≤0.5% is qualified.
6.11. Voltage test between lead end and out casing.
Lead end and out casing should bear 2UN+1KV, but should not less 2KV frequency tested voltage for 2 seconds, there should not occur any flashover or bowl over permanently.
6.12. Water cooking test
6.12.1. Measurement of capacitor sample’s value and loss.
6.12.2. Put the CBB60 capacitor sample in boiling water in the electric cooker and continuously cook for 1 hour, and then put the sample into cold water immediately and keep for 1 hour.  After that, keep the sample indoor for 24 hours; repeat this water cooking test for one week. After test, measure the sample’s value and the tangent of loss angle value, the value difference before and after the test should be ΔC≤3%, tangent of loss angle value should be tgδ≤5×10-3（1KHz） .Every vendor’s product should take 3 random samples to take the water cooking test every month.
6.13. Impact test
6.13.1 With 1.5 UN, 2S on and off 2S, 80,000 times repeat test, then measure capacitor value according to clause 6.8, ΔC≤3% is qualified..
6.14. Duration test
6.14.1. Test environment: put the capacitor sample in the water under the highest ambient 
temperature marked on capacitor.
6.14.2. Test method: capacitor continuously electrify test with 1.5 UN: B class: 260 hours, C class: 87 hours.
6.14.3. Evaluation of test results: there should have no any break, flashover or bowl over permanently. After the test, there should have not any drop leak, cooled to ambient temperature, and measure capacitor value accruing to clause 6.8: ΔC≤3% is qualified.
6.15. 500V Direct current impact test (it is only limit to CBB65)
With 500V direct current, 2S on and off 2S, repeat test 5 times, then measure capacitor value 
according to clause 6.8, measure the tangent of loss angle value according to clause 6.9, 5% samples is a must every batch, if defect quantity make up 1% of the total sample, the whole batch must be tested.
6.16. The other test items should meet IEC60252 standard requirements and GB3667 standard requirements.

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