bonitron M3645P, Reference Manual

Page 1: ...Web www bonitron com Tel 615 244 2825 Email info bonitron com Model M3645P Regenerative DC Bus Power Supply 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: ...17 3 4 1 Power Wiring 17 Table 3 1 Transformer Ratings 18 Table 3 2 Power Terminal Specifications 30 Amp Unit M10 Chassis 19 Table 3 3 Power Terminal Specifications 50 Amp Unit M11 Chassis 19 Table 3 4 Power Terminal Specifications 100 Amp Unit M12 Chassis 19 Figure 3 2 Power Connections 20 Figure 3 3 Connection Locations 20 Table 3 5 Power Terminal Specifications 150A 225A and 300A Unit M15 Chass...

Page 5: ...Input Output Connections 35 4 5 1 Local I O 24V Supply TB2 1 TB2 5 35 4 5 2 Enable Input TB2 2 35 4 5 3 Fault Recall Input TB2 3 35 4 5 4 Input COM TB2 4 35 4 5 5 Ready Output TB2 6 35 4 5 6 Overtemperature Output TB2 7 36 4 5 7 Output COM TB2 8 36 4 6 Startup 36 4 6 1 Pre power Checks 36 4 6 2 Startup Procedure and Checks 36 4 6 3 Cooling Fan 36 5 MAINTENANCE AND TROUBLESHOOTING 37 5 1 Periodic T...

Page 6: ...6 3 Watt Loss 42 6 4 Certifications and RoHS 42 6 5 Fuse Selection 43 Table 6 6 Fuse Current Rating Requirements 43 Table 6 7 Fuse Voltage Rating Requirements 43 6 6 Dimensions and Mechanical Drawings 44 Figure 6 1 M3645P M10 Chassis Dimensional Outline 44 Figure 6 2 M3645P M11 Chassis Dimensional Outline 45 Figure 6 3 M3645P M12 Chassis Dimensional Outline 46 Figure 6 4 M3645P M15 Dimensional Out...

Page 7: ... successfully install and use the M3645P modules in your application In the event of any conflict between this document and any publication and or documentation related to the application the latter shall have precedence 1 3 MANUAL VERSION AND CHANGE RECORD The initial release of the M3645P manual is Rev 00a Update to Section 7 on the sizing and energy savings in Rev 00b Updated to include KIT 364...

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 CAUTION Heat or burn hazard Identifies a statemen...

Page 9: ...C bus into the AC line to limit the rise in bus voltage and prevent overvoltage faults While regenerating the M3645P will automatically fold back in an overcurrent condition or shut down in the event that unsafe conditions are detected With the optional digital display the current status of the M3645P is shown and fault records are stored along with a lifetime count of regenerative energy Up to tw...

Page 10: ...er represents the maximum continuous DC current Amps the regen module can regenerate The M10 M11 M12 frame sizes are capable of handling a 50 overload above this current rating for 60 seconds The M15 frame size is capable of a 25 overload above this current rating for 60 seconds MODULE IDENTIFIER This single letter code is added to the model number to indicate if the line regen is made up of separ...

Page 11: ... x 11 3 x 10 6 M12 100A Open Chassis 24 0 x 12 0 x 12 1 M15 300A Open Chassis 26 0 x 13 9 x 11 1 M15 Reactor 300A Open Chassis 17 9 x 18 8 x 15 2 See Section 6 5 for chassis mounting and dimensional outlines DISPLAY Two display options are available Table 2 4 Option Codes OPTION CODE DESCRIPTION D Digital Diagnostic Display L Basic LED Indicators NOTE The KIT 3645DD external display is only compat...

Page 12: ... DC Input Current 30 300A continuous 150 of rating 60 second overload for M10 M11 M12 chasses 125 of rating 60 second overload for M15 chassis Control Voltage Internal Indicators Power Regen Fault Optional 4 line character display Inputs Enable 24VDC 5mA Fault Recall 24VDC 5mA Outputs Ready 200VDC 100 mA Operating Temp 0 to 40OC Storage Temp 20O to 65OC Humidity Below 90 non condensing Atmosphere ...

Page 13: ...RODUCT SHOULD BE INSTALLED ON A NON FLAMMABLE SURFACE WITH CLEARANCES OF AT LEAST TWO INCHES IN ALL DIRECTIONS ALWAYS ALLOW AMPLE TIME FOR THE UNIT TO COOL BEFORE ATTEMPTING SERVICE ON THIS PRODUCT BEFORE ATTEMPTING INSTALLATION OR REMOVAL OF THIS PRODUCT BE SURE TO REVIEW ALL DRIVE AND OR RESISTIVE LOAD DOCUMENTATION FOR PERTINENT SAFETY PRECAUTIONS INSTALLATION AND OR REMOVAL OF THIS PRODUCT SHO...

Page 14: ...M3645P 14 This page intentionally left blank ...

Page 15: ...hich the product was purchased 3 3 MOUNTING 3 3 1 M3645P DC BUS REGENERATIVE POWER SUPPLY The installation site for the M3645P power supply should be chosen with several considerations in mind When mounting regen units in an enclosure power dissipation should be taken into account Refer to Section 6 3 Watt Loss for details The unit requires a minimum clearance of two 2 inches in all directions aro...

Page 16: ... Figure 3 1 M3645P Mounting Orientation Figure 3 1A Figure 3 1D HORIZONTAL SURFACE UP UP BONITRON Figure 3 1B Figure 3 1E UP HANGING UNDERSIDE Fig B UP BONITRON Figure 3 1C UP PARALLEL TO FLOOR BONITRON BONITRON ...

Page 17: ...he panel The display is secured to the panel with a screw in each corner The unit requires a minimum clearance of one 1 inch in all directions around it The unit should not be exposed to falling debris or condensation The 12 foot cable provided with the display must be attached to TB5 on the control board of the M3645P and to TB3 on the ASM 3645D3 on the rear of the display See Figure 3 12 Once th...

Page 18: ...A 2 5 C30 33 kVA 2 0 L50 22 kVA 6 0 E50 38 kVA 3 4 H50 44 kVA 3 0 C50 55 kVA 2 4 L100 44 kVA 6 3 E100 75 5 kVA 3 6 H100 87 5 kVA 3 1 C100 109 5 kVA 2 5 L150 75 kVA 5 0 E150 125 kVA 6 0 H150 150 kVA 4 0 L225 100 kVA 5 0 E225 170 kVA 6 0 H225 200 kVA 4 0 L300 131 kVA 4 4 E300 226 5 kVA 2 5 H300 262 kVA 2 2 Do not connect to a generator For further details contact Bonitron The AC line connections sho...

Page 19: ...r AC drive manual or AC drive technical support department for assistance with this connection 3 4 1 4 GROUNDING Using the ground stud provided ground the chassis in accordance with local codes Typically the wire gauge will be the same as is used to ground the attached drive Table 3 2 Power Terminal Specifications 30 Amp Unit M10 Chassis TERMINALS FUNCTION ELECTRICAL RATINGS WIRE SIZE MINIMUM WIRE...

Page 20: ...e should be selected to match or exceed the voltage rating of the unit Field wiring for terminals will be copper 75 C wire only Figure 3 2 Power Connections NO CONNECTION L1 L2 L3 GND 3ØAC INPUT DC BUS Figure 3 3 Connection Locations USER I 0 POWER CONNECTIONS ...

Page 21: ... 4 lb in A2 B2 C2 AC line outputs 300 A 350 kcmil 350 kcmil 275 lb in DC DC DC bus inputs 300 A 350 kcmil 350 kcmil 275 lb in GND Ground 3 AWG 1 0 50 lb in Notes L1 L2 L3 AC control power and A2 B2 C2 AC line output are phase sensitive switching the order of phases to any of the inputs may result in damage to the regen L1 is the same phase as A1 L2 is the same phase as A2 L3 is the same phase as A...

Page 22: ...M3645P 22 Figure 3 5 M3645P 150A 225A and 300A Connection Locations ...

Page 23: ...disable the drive in the event of an Overtemperature Fault Otherwise an overload condition may result in catastrophic failure Table 3 6 I O Terminal Specifications TERMINAL FUNCTION ELECTRICAL SPECIFICATIONS MIN WIRE AWG MAX WIRE AWG TORQUE TB2 1 24V 24VDC to TB2 5 18 16 2 2 lb in TB2 2 Enable Input 24VDC 5mA 18 16 2 2 lb in TB2 3 Fault Recall Input 24VDC 5mA 18 16 2 2 lb in TB2 4 Input COM COM to...

Page 24: ... Figure 3 6 M3645P Enable Input Using Internal Power Supply TB2 24V 1 2 3 4 5 6 7 8 ENABLE FAULT RECALL Figure 3 7 M3645P Enable Input Using External Power Supply TB2 24V 24V 1 2 3 4 5 6 7 8 ENABLE FAULT RECALL ...

Page 25: ...ls should have a low impedance path back to the grid No reactors should be connected upstream of the unit without consulting Bonitron for instructions The AC feed to the VFDs should be left disconnected The DC terminals should be connected to a fixed bus of one or more VFDs This should never be connected to a switching source such as the braking resistor terminals on some drives The DC terminals s...

Page 26: ...M3645P 26 Figure 3 8 M3645P 30A 50A 100A Power Wiring Disconnect Isolation Transformer if used REGEN 3 M 3 DC DC INVERTER M3728 RESISTIVE PRECHARGE DC IF NEEDED DC IN OUT ...

Page 27: ...User s Manual 27 Figure 3 9 M3645P 150A 225A and 300A Power Wiring ...

Page 28: ... Figure 3 10 M3645P Multiple Drives Field Wiring Diagram M 3 Disconnect Isolation Transformer if used REGEN 3 M 3 M 3 DC DC DC DC DC DC INVERTER INVERTER INVERTER M3728 RESISTIVE PRECHARGE DC IF NEEDED DC IN OUT ...

Page 29: ...User s Manual 29 Figure 3 11 M3645P Connection with KIT 3645DD External Panel Mounted Display USER I 0 POWER CONNECTIONS ...

Page 30: ...M3645P 30 This page intentionally left blank ...

Page 31: ...mation about the present status of the unit as well as records of faults and energy throughput 4 2 2 LEDS Red yellow and green LEDs indicate the status of the unit 4 2 2 1 POWER GREEN INDICATOR The green LED indicates that the unit is powered on 4 2 2 2 REGEN ACTIVE YELLOW INDICATOR The yellow LED indicates that the unit is actively regenerating power back to the line 4 2 2 3 NOT READY RED INDICAT...

Page 32: ... SCREEN This screen allows the user to reset the record of energy regenerated by the unit This screen also displays the firmware version present on the unit Up Energy Records screen Enter Confirm reset 4 3 4 FAULTS SCREEN This screen shows the present fault state of the unit scrolling through all faults detected if any Left Metering screen Right Metering screen Down Fault Records screen 4 3 5 FAUL...

Page 33: ...ES FAULT Solid Unit is not Enabled 1 Fast Feedback Undervoltage 2 Fast Overtemperature 3 Fast DC Overvoltage 4 Fast Differential Overvoltage 5 Fast Sync Loss 1 Slow IGBT Driver 2 Slow Phase Overcurrent 3 Slow Phase Loss 4 Slow DC Undervoltage 5 Slow Regen Power On Precharge Not Complete 6 Slow Frequency Detect Failure Note Slow 1 blink per second Fast 3 blinks per second 4 4 1 FEEDBACK UNDERVOLTAG...

Page 34: ...tantaneous overcurrent on one of the AC legs This fault will latch until cleared by toggling the Enable Input If this fault does not clear it typically indicates that damage to the unit has occurred 4 4 7 PHASE 1 3 OVERCURRENT These faults indicate that the current the unit is regenerating into one leg of the AC line has exceeded a safe operating level This is likely due to voltage distortion on t...

Page 35: ...ommon when activated When not activated they will appear open 4 5 1 LOCAL I O 24V SUPPLY TB2 1 TB2 5 This pin supplies 24V a maximum of 100mA which can be used to drive the user inputs 24V is on TB2 1 and 24V Common is on TB2 5 4 5 2 ENABLE INPUT TB2 2 This input enables the unit to regenerate Faults are reset on a rising edge of this input Note that the unit will not regenerate unless this input ...

Page 36: ...erify continuity of all input fuses prior to applying power Check for exposed conductors that may lead to inadvertent contact Check for any debris shavings trimmings etc that may cause shorts or obstruct ventilation on unit 4 6 2 STARTUP PROCEDURE AND CHECKS After completing pre checks and recommended checks for connected equipment you may apply power to the system The Power indicator on the front...

Page 37: ...1 for your unit If the power light will not come on check any overcurrent devices or disconnects upstream of the unit If the power lamp will not come on it is likely that the unit is damaged and needs to be repaired 5 3 2 READY OUTPUT WILL NOT CLOSE The Ready output indicates that the module is enabled and in a ready condition When the power is applied to the module the Ready output will normally ...

Page 38: ...stor module match the power connections 5 3 5 FEEDBACK UNDERVOLTAGE Reset the M3645P by toggling the enable input 4 5 2 If the fault returns contact Bonitron for assistance 5 3 6 OVERTEMPERATURE Check the ambient temperature If the temperature is above 40 C the unit may not be able to cool properly at full load Ensure that there is adequate clearance and airflow in the area where the Regen is inst...

Page 39: ...reset by toggling the enable input 4 5 2 If the fault cannot be cleared or occurs frequently the unit may be damaged Contact Bonitron for assistance If two M3645P units are operated in parallel IGBT faults may indicate that the parallel combination is undersized for the application 5 3 11 PHASE OVERCURRENT This fault can be cleared by toggling the enable input 4 5 2 If it occurs frequently there m...

Page 40: ...NTACT US If technical help is required please have the following information available when contacting Bonitron 615 244 2825 or email to info bonitron com Model number of unit Serial number of unit Name of original equipment supplier if available Record the Line to Line voltage on all 3 phases Record the DC bus voltage immediately after the AC voltage Brief description of the application Drive and...

Page 41: ...LOSS CONT PEAK CONT PEAK M3645P E030 M10 30A 45A 25 0HP 37 5HP 180W M3645P E050 M11 50A 75A 41 7HP 62 6HP 265W M3645P E100 M12 100A 150A 83 4HP 125 2HP 470W M3645P E150T M15 150A 225A 125 0HP 187 5HP 2980W M3645 E150R M15 300W M3645P E225T M15 225A 335A 187 5HP 279 2HP 2980W M3645 E225R M15 300W M3645P E300T M15 300A 375A 250 0HP 312 5HP 2980W M3645 E300R M15 300W Table 6 3 Ratings and Specificati...

Page 42: ...ether on the same DC bus Table 6 5 Derating Regens in Parallel INDIVIDUALM3645P CURRENT RATING NUMBER IN PARALLEL DC REGEN CURRENT FOR TWO M3645P IN PARALLEL CONT PEAK 100A 2 200A 270A 300A 2 600A 675A 6 3 WATT LOSS Tables 6 1 thru 6 4 list the maximum continuous watt loss generated When installing units in an additional enclosure consideration should be given to internal temperature rise The watt...

Page 43: ...d 6 7 when initially constructing the system Note AC fuses must be J type or equivalent Table 6 6 Fuse Current Rating Requirements MODEL NUMBER AC DC FUSE CURRENT RATING M3645P x030 40A M3645P x050 60A M3645P x100 125A M3645P x150T 175A M3645P x225T 250A M3645P x300T 350A Table 6 7 Fuse Voltage Rating Requirements SYSTEM VOLTAGE AC FUSE VOLTAGE RATING DC FUSE VOLTAGE RATING 230 240VAC 240VAC 350VD...

Page 44: ...M3645P 44 6 6 DIMENSIONS AND MECHANICAL DRAWINGS Figure 6 1 M3645P M10 Chassis Dimensional Outline ...

Page 45: ...User s Manual 45 Figure 6 2 M3645P M11 Chassis Dimensional Outline ...

Page 46: ...M3645P 46 Figure 6 3 M3645P M12 Chassis Dimensional Outline ...

Page 47: ...User s Manual 47 Figure 6 4 M3645P M15 Dimensional Outline ...

Page 48: ...M3645P 48 Figure 6 5 M3645 M15 Line Reactor Dimensional Outline ...

Page 49: ...e 6 6 KIT 3645DD External Display Dimensional Outline 5 00 127 0 mm 7 50 190 5 mm 6 83 173 5 mm 4 13 104 8 mm 7 00 177 8 mm 19 4 8 mm 4 50 114 3 mm 25 6 4 mm 25 6 4 mm R 13 R3 2 mm R 13 R3 2 mm n 19 n4 8 mm 19 4 8 mm CUTOUT ...

Page 50: ...M3645P 50 6 7 BLOCK DIAGRAM Figure 6 7 Typical Customer Application ...

Page 51: ...ere T is torque measured in lb ft 1 0 lb ft 1 355818 Nm WK2 is the total inertial load to be decelerated lb ft2 1 0 lb ft2 0 04214011 kg m2 ΔN is the change in rotational speed rpm 308 is a constant ton is time required to decelerate the load s CALCULATE MOTOR POWER Calculating the power HP regenerated 𝑃 𝑇𝑁𝑚𝑎𝑥 5252 Where Nmax is the maximum rotational speed rpm The constant 5252 has units of lb ft...

Page 52: ...e cost of energy must be known With these application variables the following calculation may be made to determine the cost savings CALCULATE SAVINGS PER YEAR Calculating total savings per year in dollars 𝑆 𝐶𝑃 0 746 𝑘𝑊 𝐻𝑃 𝐷𝐻𝑡𝑜𝑛 𝑡𝑐𝑦𝑐𝑙𝑒 Where S is Savings per year C is the cost in dollars per kW P is the regenerated power D is the number of days the system is operated H is the number of hours per da...

Page 53: ...User s Manual 53 NOTES ...

Page 54: ...M3645P 54 ...

Page 55: ......

Page 56: ...D_M3645P_CMAN_vall_00f 10 27 2017 521 Fairground Court Nashville TN 37211 USA Tel 615 244 2825 Fax 615 244 2833 Web www bonitron com Email info bonitron com ...