Eaton XV Supercapacitors Complete Guide

Eaton XV Series Supercapacitors: Full Technical Description of Cylindrical Plug in Double Layer Capacitors

Introduction: Breakthroughs and Applications of Supercapacitors Technology

Balancing power density and energy density has always been a challenge for engineers in modern power electronic systems. Traditional batteries provide high energy density but limited power output, while traditional capacitors can provide high power but have limited energy storage capacity. The Eaton XV series supercapacitor, also known as an electrochemical double layer capacitor (EDLC), is an innovative device designed to address this contradiction.

The XV series supercapacitor adopts a cylindrical plug-in packaging, combined with an electrochemical double-layer capacitor structure and high-performance materials, which can provide excellent performance in a wide range of application scenarios from microampere level lasting for several days to ampere level lasting for milliseconds. This article provides a comprehensive analysis of the technical characteristics, specification parameters, and application guidelines of XV series 300F to 600F capacitors based on Eaton's official data manual.

Chapter 1 Product Overview and Technical Features

1.1 What is a supercapacitor?

Supercapacitors are energy storage devices that fall between traditional electrolytic capacitors and rechargeable batteries. It stores energy by forming a double layer of electrolyte ions on the electrode surface, rather than relying on chemical reactions. This physical energy storage mechanism endows supercapacitors with a unique combination of performance:

Ultra high capacitance value: up to Farad level, far exceeding traditional capacitors

Extremely low equivalent series resistance: achieving high power density

Ultra long cycle life: up to hundreds of thousands of charge and discharge cycles

Wide working temperature range: suitable for harsh environments

1.2 Core Features of XV Series

The Eaton XV series supercapacitors have the following significant advantages:

Ultra long service life: working at room temperature for over 10 years

Ultra low ESR: Achieving high power density to meet the requirements of pulse current applications

Large capacitance value: provides high energy density and extends backup time

Long cycle life: minimal performance degradation after 500000 charge and discharge cycles

UL certification: compliant with safety standards, suitable for industrial applications

1.3 Main application areas

The XV series supercapacitors are widely used in the following scenarios:

Hybrid battery/fuel cell system: serving as a power buffer, providing peak power and extending the lifespan of the main battery

High pulse current applications: such as motor drives, industrial tools, communication equipment

UPS/Backup Power Supply: Provides brief maintenance power during power outages to ensure secure data storage

Chapter 2 Technical Specifications and Performance Parameters

2.1 Basic electrical parameters

The basic specifications of the XV series 300F to 600F models are as follows:

Parameter specification values

Capacitor range 300 F to 600 F

Working voltage 2.7 V

Surge voltage 2.85 V

Capacitor tolerance -5% to+10%

Working temperature range -40 ° C to+65 ° C

Expand the working temperature range from -40 ° C to+85 ° C (requires derating to 2.3 V @+85 ° C)

2.2 Standard Product Models and Parameters

Model: Capacitor (F) Maximum Initial ESR (m Ω) Maximum Continuous Current (A) Peak Current (A) Maximum Leakage Current (mA) Maximum Power (W) Storage Energy (Wh) Typical Mass (g)

XV3550-2R7307-R 300 4.5 20 160 0.6 100 0.30 60

XV3560-2R7407-R 400 3.2 26 220 0.8 570 0.41 72

XV3585-2R7607-R 600 2.6 33 320 1.3 790 0.60 108

Parameter definition explanation:

Capacitance, ESR, and leakage current: all measured according to IEC 62391-1 standard at+20 ° C

Maximum continuous current: based on a temperature rise of 15 ° C

Peak current: The formula for calculating the peak current in 1 second is: 1/2 x operating voltage x capacitor/(1+DC ESR x capacitor)

Leakage current: measured after being powered on for 72 hours at+20 ° C

Maximum power: Calculation formula=Operating voltage ²/(4 × DC ESR)

Energy storage: Calculation formula=189 × capacitance × operating voltage ²/3600

2.3 Performance Stability

XV series supercapacitors maintain excellent performance stability under various stress conditions:

Maximum variation of conditional parameters

Lifetime test (maximum operating voltage and temperature, 1500 hours): capacitance change ≤ 20%

ESR variation ≤ 200%

Charge discharge cycle ¹ (500000 times), capacitance change ≤ 20%

ESR variation ≤ 200%

Storage life (uncharged, -40 ° C to+65 ° C, 1500 hours), capacitance change ≤ 20%

ESR variation ≤ 200%

Storage life (uncharged, ≤ 30 ° C, 3 years), capacitance change ≤ 5%

ESR variation ≤ 10%

¹ Cycle condition: Cycle between the maximum operating voltage and 50% of the maximum operating voltage at room temperature

Chapter 3 Mechanical Dimensions and Installation Guidelines

3.1 Overall dimensions

The XV series supercapacitors adopt cylindrical plug-in packaging, with the following size parameters:

Model diameter D (mm) length L ± 1.0 (mm) pin spacing

XV3550-2R7307-R 35 53 standard plug-in type

XV3560-2R7407-R 35 63 standard plug-in type

XV3585-2R7607-R 35 87.5 standard plug-in type

Structural features:

Cylindrical aluminum shell packaging with insulation sleeve

Dual pin plug-in design, suitable for PCB through-hole installation

There is an explosion-proof valve at the bottom (in compliance with safety certification requirements)

Clear polarity markings (negative electrode with stripe markings)

3.2 Installation precautions

Ensure that the pins are correctly inserted into the PCB through holes and pay attention to the polarity direction

It is recommended to use support glue or fixing clamps to assist in fixation, especially for long size models

Avoid applying mechanical stress to the components after installation

Maintain sufficient ventilation space around the device to facilitate heat dissipation

Chapter 4 Selection Guide and Model Naming Rules

4.1 Analysis of Model Naming Rules

The XV series models follow the following naming conventions:

XV 35 60 - 2R7 407 - R

Example explanation of the meaning of code snippets

XV series code XV series supercapacitor

35 size reference - diameter 35 mm diameter

60 size reference - length 63 mm length

2R7 voltage (R represents decimal point) 2.7 V

407 capacitance value encoding 40 × 10 μ F=400 F

R Standard Product Identification Standard Product

4.2 Selection considerations

When choosing a suitable XV series supercapacitor, the following factors should be considered:

1. Requirement for capacitance value

300F: Suitable for short-term backup and pulse assistance

400F: Balance energy and power, universal selection

600F: Applications that require longer backup time or higher energy storage

2. ESR requirements

Low ESR means higher power output capability

The 600F model has the lowest ESR (2.6 m Ω) and is suitable for high pulse current applications

3. Working voltage

Standard working voltage 2.7V

85 ° C high temperature environment requires derating to 2.3V for use

4. Temperature environment

Standard working temperature: -40 ° C to+65 ° C

Expansion work: -40 ° C to+85 ° C (derating)

5. Space limitations

Select the appropriate length model (53mm, 63mm, or 87.5mm) based on the available height of the PCB

Chapter 5 Welding Guidelines and Process Requirements

5.1 Wave soldering process curve

The XV series supercapacitors support wave soldering technology, and the recommended temperature curve is as follows:

Standard tin lead solder and lead-free solder in the process stage

Preheating and immersion at 100 ° C

Preheating time maximum 60 seconds maximum 60 seconds

Preheat to maximum temperature difference of 160 ° C, maximum 160 ° C

Peak temperature (Tp) 220 ° C-260 ° C 250 ° C-260 ° C

Peak time (tp) maximum 10 seconds (maximum 5 seconds per peak) maximum 10 seconds (maximum 5 seconds per peak)

Minimum cooling rate~2 K/s, typical~3.5 K/s, maximum~5 K/s, minimum~2 K/s, typical~3.5 K/s, maximum~3.5 K/s

25 ° C to 25 ° C total time 4 minutes 4 minutes

5.2 Manual Welding

Temperature:+350 ° C

Time: 4-5 seconds (using a soldering iron)

Attention: Manual welding is generally not recommended. If manual operation is required, time and temperature must be strictly controlled

5.3 Cleaning Guide

Although it is recommended to avoid cleaning circuit boards as much as possible, if cleaning is necessary, the following principles should be followed:

Cleaning method: static soaking or ultrasonic soaking

Cleaning solution: Standard circuit board cleaning solution

Cleaning time: no more than 5 minutes

Maximum temperature:+60 ° C

Subsequent processing: Thoroughly rinse and dry the circuit board

Important reminder: The cleaning treatment of supercapacitors should follow the same principles as aluminum electrolytic capacitors.

Chapter 6 Application Design and Performance Optimization

6.1 Basic Circuit Design Considerations

1. Voltage balance

When multiple supercapacitors are used in series, voltage balance must be considered. Due to differences in capacitance and leakage current among capacitors, the voltage of each individual unit may be uneven after series connection. Suggest adopting the following balance method:

Passive balancing: Parallel balancing resistors, resistance selection needs to balance balancing effect and static power consumption

Active balancing: using a dedicated voltage balancing IC, suitable for applications that require high efficiency

2. Overvoltage protection

Supercapacitors are sensitive to overvoltage, and working voltage exceeding the rated value can accelerate aging and even lead to failure. In the design, it should be ensured that:

The charging circuit has precise voltage control

Consider the impact of temperature changes on voltage

Monitor the voltage of each individual cell in a series configuration

3. Current limitation

Although supercapacitors can withstand high peak currents, continuous overcurrent can cause overheating. The current limiting circuit should be designed based on the continuous current and peak current parameters in the data manual.

6.2 Thermal Management

The performance and lifespan of XV series supercapacitors are closely related to their operating temperature

High temperature effects: accelerate water evaporation and electrolyte decomposition, leading to capacitance decay and increased ESR

Low temperature effect: ESR increases, power output capability decreases

Hot design suggestions:

Avoid approaching high heating elements

Ensure sufficient ventilation

If necessary, use forced cooling

Transient temperature rise considering peak power applications

6.3 Life Estimation Model

The lifespan of supercapacitors is influenced by both voltage and temperature. You can refer to the following simplified model for life estimation:

Basic formula: L=L ₀× 2 ^ ((T ₀ - T)/10) × 2 ^ ((V ₀ - V)/0.1)

among which

L: Estimated lifespan

L ₀: Life under rated conditions (room temperature, rated voltage)

T ₀: Rated temperature (usually room temperature)

T: Actual working temperature

V ₀: Rated voltage

V: Actual working voltage

6.4 PCB Layout Suggestions

Pin pads: Ensure that the pad size is sufficient to support soldering and mechanical stress

High current wiring: For wiring carrying continuous current, it should be wide enough to reduce resistance and temperature rise

Heat dissipation design: Consider increasing the copper foil area on the PCB to assist in heat dissipation

Mechanical fixation: For long size models, it is recommended to add fixing clips or glue reinforcement

Chapter 7: Safe Use and Authentication Information

7.1 UL certification

The XV series supercapacitors have obtained UL certification and comply with relevant safety standards. Certification information can be queried in product labels and UL databases.

7.2 Safety precautions

1. Polarity protection

Supercapacitors have polarity, reverse charging may cause damage or even explosion

Anti reverse protection should be added in circuit design

2. Overvoltage protection

Strictly prohibit exceeding the surge voltage (2.85V)

When used in series, voltage balance must be ensured

3. Mechanical stress

Avoid excessive vibration and impact

Prevent pins from being subjected to force

4. Failure modes

Supercapacitors typically exhibit open circuits or severe parameter degradation during failures

Redundancy design should be considered in critical applications

7.3 Storage Requirements

Temperature range: -40 ° C to+65 ° C

Humidity: Avoid high humidity environments

Storage status: Short circuit storage or empty state is recommended

Long term storage: Storing for more than 3 years may cause parameter changes, and retesting is required before use

Chapter 8 Packaging and Labeling

8.1 Packaging Information

Standard packaging: 20 pieces per box

Packaging method: anti-static tray or tape (depending on specific model)

Storage conditions: room temperature, dry environment

8.2 Product Identification

The following information is printed on the casing of each XV series supercapacitor:

Manufacturer (Eaton)

Capacitance value (F)

Maximum operating voltage (V)

Series code or model

Polarity Mark (Negative)