USER MANUAL
Integration Kit
BKIT – MCINT
BKIT – MCIHT
Integration Kit for:
Maxwell Technologies
®
Ultracapacitor Cells
© 2013 Maxwell Technologies, Inc.
®
1011158.5
1. Introduction
This integration kit is intended to provide all the necessary hardware and instructions to
interconnect 2, 4 or 6 series connected ultracapacitors. This kit includes printed circuit
boards (PCBs) with voltage management circuitry, buss bars, washers, rivets and retaining
nuts. For optimal implementation, we recommend to use an even number of cells with this
kit.
Each individual cell voltage is monitored by the voltage management circuitry, which protects
each cell from entering an over voltage condition. If any cell does experience an over voltage
condition, an LED will illuminate and the active circuitry will begin to discharge that cell.
Once the cell is back within nominal operating voltage limits, the LED will extinguish.
This manual is current at time of printing. Please visit
www.maxwell.com
for the latest
product updates and information.
For illustrative purposes the integration kit with active PCBA is shown throughout this
document.
2. Unpacking
The integration kit contains the following items.
BKIT-MCINT (P/N 106927)
Integration Kit with active PCBA
Part No.
Description
Qty
129363
Active PCBA
3
107414
Buss bar
5
108541
Washers
12
103996
M12-1.75 nuts
12
105003
Rivets
3
BKIT-MCIHT (P/N 108320)
Integration Kit with passive PCBA
Part No.
Description
Qty
106826
Passive PCBA
3
107414
Buss bar
5
108541
Washers
12
103996
M12-1.75 nuts
12
105003
Rivets
3
Note: Cables, cable lugs, and aluminum washers are not included in this kit.
3. Installation
3.1
3.1.1
Preparing buss bar connection
Apply joint compound (not included) to capacitor surfaces that will come in contact with the
buss bar. Use a highly conductive aluminum-aluminum antioxidant.
For example,
Noalox® Anti-Oxidant Compound available from IDEAL is a viable choice. There are
many other vendors that supply equivalent compounds.
Apply joint compound to the buss bar
only
on the side that will come in contact with the
capacitor.
3.1.2
User Manual – Integration Kit – Doc. No. 1011158.5
© 2013 Maxwell Technologies, Inc.
®
Page 1
3.1.3
3.2
Ensure any excess joint compound does not contact the top of the buss bar or come in
contact with the voltage management circuitry as this may affect the circuitry performance.
Assembling connections
Notes:
For optimal implementation, we only support and recommend the use of an even
number of cells with this kit. These instructions show the assembly of six cells connected in
series.
3.2.1
Place a buss bar over the threaded terminal at
one end of the first pair of cells (Figure 2)
with antioxidant facing towards capacitor. Note
the polarity of the terminals of each cell, e.g.
in Figure 2, A: positive terminal, B: negative
terminal.
Figure 2
3.2.2
Place a washer over each threaded terminal
on top of buss bar. (Figure 3)
Note:
For
optimal electrical connection, it is critical to
use the provided washer on every single cell,
per the explanation in step 3.2.6, below.
Figure 3
3.2.3
Thread a nut onto each threaded terminal and
hand tighten. (Figure 4)
Figure 4
User Manual – Integration Kit – Doc. No. 1011158.5
© 2013 Maxwell Technologies, Inc.
®
Page 2
3.2.4 Repeat steps 3.2.1 to 3.2.3 on one side of each of the remaining pairs of cells. (Figure
5)
Figure 5
3.2.5
Turn the cells around so that the threaded terminals opposite to terminals A - F are
facing you. Place buss bars over the middle pairs of threaded terminals (marked H, I, J
and K in Figure 6), with antioxidant facing towards capacitor.
Figure 6
3.2.6
Place lugs attached to power cables (1/0 AWG cables shown in Figure 7) over the
remaining two threaded terminals of the cells at the ends of the series and an
aluminum washer(s) over each lug. (Figure 7, G and L). It is important to use a
lug plus an aluminum washer that together have a combined thickness of 3.2 ± 1.0
mm. This prevents the voltage management boards (which are attached in the
following step) from being stressed due to uneven stack up of the elements bolted to
the cell.
Figure 7
User Manual – Integration Kit – Doc. No. 1011158.5
© 2013 Maxwell Technologies, Inc.
®
Page 3
3.2.7
Place a voltage management board over each pair of threaded terminals as shown in Figure
8, with the printed circuit board components facing away from the capacitor.
Make sure that the buss bar and power cable connections are
below
the voltage
management board.
Figure 8
3.2.8
Note:
The voltage management board is polarized.
J1 on the board is positive; J3
is negative.
Ensure correct polarities of capacitor terminal and voltage management
board are connected. (Figure 9)
Figure 9
User Manual – Integration Kit – Doc. No. 1011158.5
© 2013 Maxwell Technologies, Inc.
®
Page 4
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