bonitron M3575T, Customer Reference Manual

Page 1: ...Web www bonitron com Tel 615 244 2825 Email info bonitron com Model M3575T Standard Duty Braking Transistor Customer Reference Manual ...

Page 2: ...design develop and manufacture the quality industrial electronic systems demanded in today s market A strong academic background supported by continuing education is complemented by many years of hands on field experience A clear advantage Bonitron has over many competitors is combined on site engineering labs and manufacturing facilities which allows the engineering team to have immediate access ...

Page 3: ...Below is a sampling of Bonitron s current product offering WORLD CLASS PRODUCTS Undervoltage Solutions Overvoltage Solutions Uninterruptible Power for Drives DC Bus Ride Thru Voltage Regulators Chargers and Dischargers Energy Storage Braking Transistors Braking Resistors Transistor Resistor Combo Line Regeneration Dynamic Braking for Servo Drives Common Bus Solutions Portable Maintenance Solutions...

Page 4: ...s 14 3 5 Wiring and Customer Connections 14 3 5 1 Power Wiring 14 Table 3 1 Power Wiring Specifications 15 3 5 2 Control Interface Wiring 16 Table 3 2 Control Interface Wiring Specifications 16 3 6 Typical Configurations 17 Figure 3 2 Typical Power Interconnection Diagram 17 Figure 3 3 Customer Connections 18 4 OPERATION 19 4 1 Functional Description 19 4 2 Features 19 4 2 1 Indicators 19 4 2 2 Te...

Page 5: ... 6 1 M3 Chassis Dimensional Outline Drawing 29 Figure 6 2 M4 Chassis Dimensional Outline Drawing 30 Figure 6 3 B5 Chassis Dimensional Outline Drawing 31 Figure 6 4 B7 Chassis Dimensional Outline Drawing 32 Figure 6 5 MTW 3575 CVR 30U Conduit Cover Dimensional Outline 33 Figure 6 6 MTW 3575 CVR 30 Conduit Cover Dimensional Outline 33 6 8 Block Diagram 34 Figure 6 7 Block Diagram 34 7 APPENDIX 35 7 ...

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Page 7: ... documentation related to the AC drive system the latter shall have precedence 1 3 MANUAL VERSION AND CHANGE RECORD Additional models were added in rev 07 of this manual A new setpoint option and additional dimensional outlines were added in rev 07a Connection drawings were updated in rev 07b Wiring specifications were updated in rev 07c Updates to the Indicators were made in rev 07d The manual te...

Page 8: ...tifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss CAUTION CAUTION Identifies information about practices or circumstances that can lead to property damage or economic loss Attentions help you identify a potential hazard avoid a hazard and recognize the consequences CAUTION Heat or burn hazard Identifies a statement regard...

Page 9: ...ndard AC drive with a fixed DC bus These modules have been designed for use with remotely mounted resistive loads such as the model M3575R or M3775RK resistive load modules For higher duty cycle applications consider the M3452 series of braking transistor modules 2 2 PART NUMBER BREAKDOWN Figure 2 1 Example of M3575T Part Number Breakdown BASE MODEL NUMBER The Base Model Number M3575T indicates th...

Page 10: ...H X W X D M3575T L15 M3 12 75 x 3 00 x 8 70 M3575T L30 M3 12 75 x 3 00 x 8 70 M3575T L60 M4 12 75 x 4 00 x 8 70 M3575T L125 B5 17 75 x 5 50 x 8 00 M3575T L150 B5 17 75 x 5 50 x 8 00 M3575T L200 B7 17 75 x 7 00 x 8 00 M3575T L300 B7 17 75 x 7 00 x 8 00 M3575T L600 B7 17 75 x 7 00 x 8 00 400VAC MODEL NUMBER CHASSIS DIMENSIONS H X W X D M3575T E15 M3 12 75 x 3 00 x 8 70 M3575T E30 M3 12 75 x 3 00 x 8...

Page 11: ...ng Drive Voltage For use with 230VAC 400VAC and 460VAC drive systems Control Power Derived from DC bus voltage 100 400VDC required for 230VAC drives 320 800VDC required for 400VAC drives 450 800VDC required for 460VAC drives Braking Current 15 600A Use Bonitron M3452 for applications requiring 600 Amps Turn on Voltage 375VDC for 230VAC drives 620VDC for 400VAC drives 750VDC for 460VAC drives Maxim...

Page 12: ... N E N T S A F E T Y P R E C A U T I O N S IN S T A L L A T I O N A N D O R R E M O V A L O F T H I S P R O D U C T S H O U L D O N L Y B E A C C O M P L I S H E D B Y A Q U A L I F I E D E L E C T R I C I A N I N A C C O R D A N C E W I T H NA T I O N A L EL E C T R I C A L CO D E O R E Q U I V A L E N T R E G U L A T I O N S ATTENTION A T T E N T I O N Important Notice about drives with DC link ...

Page 13: ...n of the Model M3575T standard duty braking transistor module should be accomplished following the steps outlined below Be sure to refer to your AC drive s instruction manual as you perform these steps Please direct all installation inquiries that may arise during the installation and startup of this braking product to your supplier or system integrator Once the installation site has been selected...

Page 14: ...stive braking modules Actual connection points and terminal numbers for the AC drive module will be found in the documentation provided with the drive Be sure to review all pertinent drive and system documentation as well as the power connection notes listed below before proceeding WARNING Only qualified electricians should perform and maintain the interconnection wiring of this product All wiring...

Page 15: ... value which can be found in Table 6 1 in Section 6 of this manual 3 5 1 1 DC BUS CONNECTION WARNING DC bus polarity must be correct Connecting the DC bus with the polarity reversed will cause damage to the equipment As a general rule 30 feet 10m is the maximum total buswork or cable that the chopper should be mounted from the drive This means that the actual installation distance should be 15 fee...

Page 16: ...ked A and B in Figure 3 2 switching resonances caused by the lack of filter capacitance during precharge will destroy the braking transistor 3 5 1 2 RESISTOR CONNECTION The polarity of the resistor connections is not critical however it is critical that the resistor be connected to the proper terminals Improper hookup can lead to the resistor being connected directly across the DC bus which will c...

Page 17: ...User s Manual 17 3 6 TYPICAL CONFIGURATIONS Figure 3 2 Typical Power Interconnection Diagram ...

Page 18: ... Precharge 2 X Y DC Link Choke 1 BR BR Internal Brake Transistor connection Not Used Load Bank Resistor Bonitron Braking Transistor DC RES DC RES Notes 1 Precharge connections may not be external 2 Choke may be internal to drive A B DC Bus Filter Capacitors Output Inverter ...

Page 19: ...work on Always check the DC bus with a working voltmeter before servicing equipment as the DC bus light may be broken 4 2 1 2 ACTIVE BRAKING The red indicator illuminates when the chopper IGBT is on When the drive is idle this light should not be on During braking this light will be on or flashing depending on the amount of braking energy 4 2 2 TERMINAL STRIP I O See Figure 3 1 4 2 2 1 STATUS CONT...

Page 20: ...e Braking indicator is OFF any significant current flow could indicate incorrect connections or damaged equipment Immediately turn off all power to avoid possible load bank overheating and or other equipment damage if current flow is indicated Note Depending on the type of measuring equipment used small currents could just be noise pickup and could be ignored Check status contacts to ensure they a...

Page 21: ...is that may have gotten on any of the circuit boards 5 3 TROUBLESHOOTING WARNING Lethal voltages exist in these systems Before attempting checks or repair follow all precautions to ensure safe working conditions including lockout tagout procedures and verifying safe working voltages with proper meters Do not rely on the DC Bus indicator to ensure a safe condition ATTENTION Only qualified personnel...

Page 22: ...until the heatsink cools to 80 F If the ambient temperature is above 80 F the fan may run continuously A constantly running fan does not indicate a problem with the module If the heatsink temperature is below 80 F the thermostat may be damaged This will not affect DC bus regulation 5 3 4 FAN DOESN T RUN The fan only runs when the braking module heatsink is hot If the heatsink is above 110 F then t...

Page 23: ...ule If it never illuminates check the connections to the DC bus of the drive system Check the DC bus voltage and make sure the bus voltage at the braking module exceeds the trip point of the module i e 750VDC for a 460VAC nominal system See Table 2 1 If the Active Braking light comes on check the wiring to the load bank and check the current to the load bank with a clamp on current meter If the wi...

Page 24: ...e chassis sticker for the part number Refer to Section 2 2 of this manual and verify that the sticker information represents the correct part number for your application and voltage levels Remove and replace as required Main control board has gone bad Module needs to be sent in for repair 5 3 10 ATTACHED DRIVE WILL NOT PRECHARGE Verify the polarity of the connection to the DC filter capacitors of ...

Page 25: ...00HP 0 70Ω B7 M3575T E15 400VAC 15A 3 87A 20 12 5HP 41 25Ω M3 M3575T E30 30A 7 75A 20 25HP 20 50Ω M3 M3575T E75 75A 19 36A 20 63HP 8 25Ω M4 M3575T E125 125A 32 27A 20 100HP 5 00Ω B5 M3575T E150 150A 38 73A 20 125HP 4 10Ω B5 M3575T E200 200A 51 64A 20 165HP 3 10Ω B7 M3575T E300 300A 77 46A 20 240HP 2 00Ω B7 M3575T E600 600A 154 92A 20 530HP 1 10Ω B7 M3575T H15 460VAC 15A 3 87A 20 15HP 50 00Ω M3 M35...

Page 26: ...575T L200 25 W 120 W M3575T L300 25 W 150 W M3575T L600 25 W 300 W 400VAC MODEL NUMBER CONTROL POWER WATT LOSS HEATSINK WATT LOSS M3575T E15 25 W 10 W M3575T E30 25 W 20 W M3575T E75 25 W 45 W M3575T E125 25 W 75 W M3575T E150 25 W 100 W M3575T E200 25 W 120 W M3575T E300 25 W 150 W M3575T E600 25 W 300 W 460VAC MODEL NUMBER CONTROL POWER WATT LOSS HEATSINK WATT LOSS M3575T H15 25 W 10 W M3575T H3...

Page 27: ...FWP 125 M3575T L150 FWP 150 M3575T E150 FWP 150 M3575T H150 FWP 150 M3575T L200 FWP 200 M3575T E200 FWP 200 M3575T H200 FWP 200 M3575T L300 FWP 300 M3575T E300 FWP 300 M3575T H300 FWP 300 M3575T L600 FWP 600 M3575T E600 FWP 600 M3575T H600 FWP 600 6 6 DC BUS LENGTH LIMITS The distance that the chopper is mounted from the main DC bus filter capacitors within the drive is limited by the amount of in...

Page 28: ...C Link Cable MODEL AMPERAGE MAXIMUM INDUCTANCE 3575T x15 15 A 1000uH 3575T x30 30 A 650uH 3575T x60 60 A 350uH 3575T x75 75 A 350uH 3575T x125 125 A 750uH 3575T x150 150 A 750uH 3575T x200 200 A 620uH 3575T x300 300 A 275uH 3575T x600 600 A 70uH ...

Page 29: ...User s Manual 29 6 7 DIMENSIONS AND MECHANICAL DRAWINGS Figure 6 1 M3 Chassis Dimensional Outline Drawing 7 7 12 12 75 3 76 2mm 304 8mm 323 85mm 195 58mm ...

Page 30: ...M3575T 30 Figure 6 2 M4 Chassis Dimensional Outline Drawing 7 7 12 75 12 1 75 4 101 6mm 44 45mm 323 85mm 304 8mm 195 58mm ...

Page 31: ...User s Manual 31 Figure 6 3 B5 Chassis Dimensional Outline Drawing ...

Page 32: ...M3575T 32 Figure 6 4 B7 Chassis Dimensional Outline Drawing 17 75 16 75 7 5 7 75 177 8mm 127mm 425 45mm 450 85mm 196 85mm ...

Page 33: ...User s Manual 33 Figure 6 5 MTW 3575 CVR 30U Conduit Cover Dimensional Outline 2 60 1 57 1 15 60 Figure 6 6 MTW 3575 CVR 30 Conduit Cover Dimensional Outline 1 63 3 07 2 75 ...

Page 34: ...M3575T 34 6 8 BLOCK DIAGRAM Figure 6 7 Block Diagram ...

Page 35: ...ts for the mechanical load are determined multiply the horsepower by the scaling factor of 746 W hp to determine the wattage required For instance with a 400hp system the peak braking power may be 600hp In this case the peak power required would be 746 Braking brake hp P watts hp P brake 447600 746 600 7 1 1 2 PEAK AMPERAGE The peak amperage of the braking cycle can be determined by dividing the p...

Page 36: ...o a stop Check this rating against the modules duty cycle rating and if it is higher than rated go to the next higher rated module If a duty cycle is required over 50 please call for assistance with your application 7 1 1 5 CONTINUOUS RATING The continuous rating is listed for long term heating calculations should the unit be installed in an area where heat dissipation is an issue The rating is ba...

Page 37: ...nd system documentation as well as the status connection notes in Table 3 2 before proceeding The connection diagrams shown below assume the use of the model M3575R resistive load module The actual load module used may vary Refer to the drive system documentation for details on the actual load module used ATTENTION Please note that the status contact within the M3575T remains CLOSED until a fault ...

Page 38: ...M3575T 38 Figure 7 1 Typical Status Contact Wiring with Input Contactor ...

Page 39: ...User s Manual 39 Figure 7 2 Typical Status Contact Wiring with Drive Interlock Control ...

Page 40: ...be necessary to limp along until repairs or swap outs can occur Even though the modules are well suited for use in these systems the following modes of operation could arise or exist and are not allowed 1 Do not connect the dynamic braking transistor module on the rectifier side of a DC link choke The connections must always be made to the inverter drive side directly to the DC bus capacitors Duri...

Page 41: ...User s Manual 41 NOTES ...

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Page 44: ...D_M3575T_CMAN_VALL_07j 09 27 2016 521 Fairground Court Nashville TN 37211 USA Tel 615 244 2825 Fax 615 244 2833 Web www bonitron com Email info bonitron com ...