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User’s Manual

29

5.

M

AINTENANCE AND

T

ROUBLESHOOTING

Repairs or modifications to this equipment are to be performed by Bonitron approved
personnel only. Any repair or modification to this equipment by personnel not approved
by Bonitron will void any warranty remaining on this unit.

5.1. P

ERIODIC

T

ESTING

The Bonitron Ride-Thru is designed to be low maintenance. While the amount of ride-
thru time does not depend on energy storage devices that degrade over time, Bonitron
still recommends a yearly test of the system in order to ensure the electronics package
is operating. The following steps can be taken to ensure reliability and give comfort
that the system is still able to ride-thru a sag event.

5.1.1. P

ERIODIC

M

AINTENANCE

P

ROCEDURES FOR

M3534R

M

ODULE

W

ITHOUT

O

PTIONAL

D

ISPLAY

P

ANEL

1. Monitor boost module LEDs.



PWR LED should be ON.



RTA LED should be

OFF.



OT LED should be

OFF

.

2. Verify DC bus voltage level.



Ride-Thru bus should be about 5

– 15V DC below the Inverter bus.

3.

Verify “Threshold” by opening the AC disconnect to the Ride-Thru
module (if equipped). Refer to Section 4.4.



The DC bus voltage should drop until it reaches the threshold.



Ride-Thru Active LED should begin to flash.



DC bus should hold for a second at the threshold.



This threshold level should be approximately 10-12% below the
nominal loaded inverter bus.

Each Bonitron Ride-Thru should be tested under load during initial start up to
verify the functionality of the test circuit and that the test does not negatively
affect the process. However, Bonitron recommends that, if the process is
critical, the test cycle be initiated only during a shutdown to avoid unforeseen
problems.

4. Verify switching circuits by causing a TEST cycle while running the

inverter at full load.



Ride-Thru DC bus current should flow during the 2-second test
cycle.



Inverter input current should drop.



Ride-Thru DC bus voltage should rise above the threshold. (+17% if
lightly loaded, less if fully loaded.)



Inverter DC bus voltage should rise above the threshold. (+17% if
lightly loaded, less if fully loaded.)



Ride-Thru Active LED should turn

ON.



Motor speed should remain constant.



Active cycle counter (if used) should count test cycles.

This completes the maintenance procedure.

5.1.2. P

ERIODIC

M

AINTENANCE

P

ROCEDURES FOR

M3534R

M

ODULE

W

ITH

O

PTIONAL

DP10

D

ISPLAY

P

ANEL

1. Check Active cycle counters.

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Summary of Contents for Legacy M3534R-RY

Page 1: ...Web www bonitron com Tel 615 244 2825 Email info bonitron com Legacy Model M3534R RY 40 85 Amp DC Bus Ride Thru for Variable Frequency AC Drives 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 Solution...

Page 4: ...del Disable Relay 12 Figure 3 5 Typical Control and Status Connections with I3 Interface 13 3 5 Typical Configurations 14 Figure 3 6 Typical M3534R Interconnection with Existing Drive System 14 Figure 3 7 Typical 85 Amp A9 Chassis M3534R Parallel Wiring Diagram 15 4 OPERATION 17 4 1 Functional Description 17 Figure 4 1 Basic 40A 85A M3534R RTM Internal Power Flow Circuit Diagram 17 4 2 Features 18...

Page 5: ...4 6 4 Dimensions and Mechanical Drawings 35 Figure 6 1 24kW Ride Thru K7 Chassis Dimensional Outline 35 Figure 6 2 M3534R 50kW A9 Chassis Dimensional Outline 36 6 5 Supplemental Drawings 37 Figure 6 3 3534R3 TB5 Status Signal 37 Figure 6 4 3534R Status Signal Schematics 37 Figure 6 5 3534I3 Control and Status Signal 38 6 6 Recommended Spare Parts 38 Table 6 4 Example of PCB Serial Sticker 38 Table...

Page 6: ...M3534R 40 85A vi This page intentionally left blank ...

Page 7: ... information to successfully install integrate and use the M3534R module in a variable frequency AC drive system In the event of any conflict between this document and any publication and or documentation related to the AC drive system the latter shall have precedence 1 3 MANUAL VERSION AND CHANGE RECORD DP10 details were clarified in Rev 02a of this M3534R 40A 24kW to 85A 50kW manual The 20A 12kW...

Page 8: ...Identifies 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 re...

Page 9: ...e from nominal voltage of less than 50 and duration of less than 2 seconds The model M3534R DC Bus Ride Thru Control module provides sufficient ride through capability to handle these types of voltage sags 2 1 RELATED PRODUCTS S3534UR AND S3534BR SERIES RIDE THRU MODULES Adding ultracapacitor UR or battery BR energy storage allows M3534R modules to maintain loads under 100 outage conditions M3460 ...

Page 10: ...the maximum power in kilowatts that can safely be handled by the M3534R RTM during outage durations of 2 seconds This rating is directly represented by a 3 digit value based on the nominal DC system voltage rating and the maximum output current rating of the RTM For instance the rating code for a 24kW RTM is 024 CHASSIS STYLE The 40A Model M3534R RTM comes in the K7 chassis while the 85A Model M35...

Page 11: ...ss than 100 milliseconds Inactive Power Usage Less than 25W Fault Status Indicators Power PWR Overtemp OT Ride Thru Active RTA Ride Thru Ready RTR Power Connections 3 Phase AC Line Input Ground DC Bus Output External Energy Reservoir or Bus Support Module Control Inputs 24V input initiates TEST cycle 24V input disables BOOST mode Status Outputs OT relay contacts available on all models RTA relay c...

Page 12: ...D B E I N S T A L L E D A C C O R D I N G L Y O N N O N F L AM M A B L E S U R F A C E S W I T H C L E A R A N C E S O F A T L E A S T T W O I N C H E S I N A L L D I R E C T I O N S AL W A Y S A L L O W A M P L E T I M E F O R T H E U N I T T O C O O L B E F O R E A T T E M P T I N G S E R V I C E O N T H I S P R O D U C T BE F O R E A T T E M P T I N G I N S T A L L A T I O N O R R E M O V A L O...

Page 13: ...CTION The installation site for the module should be chosen with several considerations in mind The unit has an open chassis and will therefore require some protection from the elements Conduit access for field power wiring is provided through the bottom surface of the enclosure and for control status through the top The unit will require a minimum clearance of two 2 inches above and below it to a...

Page 14: ...IN WIRE AWG MAX WIRE AWG TORQUE LB IN L1 L2 L3 AC Input 600VAC 12 4 32 lb in Storage Bus DC Input 600VAC 12 4 32 lb in DC Bus DC Output 600VAC 12 4 32 lb in GND Ground 600VAC 18 10 20 lb in 3 4 1 POWER WIRING RTM TO DRIVE INTERCONNECTIONS Illustrations and a table are provided to assist with the field connection of the M3534R Ride Thru Module to an existing AC drive system Also be sure to refer to...

Page 15: ... 20 lb in maximum 85 Amp units The DC Bus Output connections are made at the output terminals at DC Connections can be made using 6 AWG wire These terminals will accept 12 4 AWG wire Torque all terminal screws to 32 lb in maximum For ALL Parallel Units If connection to drive cap bank is less than 3 feet a 25uH choke is recommended to decrease high frequency ripple currents between RTM and drive Co...

Page 16: ... DP10 option is installed I3 board the Disable Input is at TB4 5 6 3 4 2 3 FAULT STATUS MONITORING CONNECTIONS FOR STANDARD MODELS 40 and 85 Amp units On the ASB 3534R3 Control Board See Figures 3 3 and 3 4 To monitor the OVERTEMP Fault Relay connect across TB5 2 OT and TB5 4 Common To monitor the RIDE THRU ACTIVE Relay connect across TB5 3 RTA and TB5 4 Common 3 4 2 4 FAULT STATUS MONITORING CONN...

Page 17: ...User s Manual 11 Figure 3 1 Typical K7 Chassis Field Connection Terminal Layout Figure 3 2 Typical A9 Chassis Field Connection Terminal Layout Ground Ground On side wall ...

Page 18: ...M3534R 40 85A 12 Figure 3 3 K7 Chassis Standard Model Disable Relay Figure 3 4 A9 Chassis Standard Model Disable Relay 24V DISABLE Relay TEST Status 24V DISABLE Relay TEST Status ...

Page 19: ...User s Manual 13 Figure 3 5 Typical Control and Status Connections with I3 Interface TB 5 Display Panel TB 4 Disable RTR RTA C J1 C J2 ...

Page 20: ...M3534R 40 85A 14 3 5 TYPICAL CONFIGURATIONS Figure 3 6 Typical M3534R Interconnection with Existing Drive System Note Typical 40 Amp model shown Dwg 060304 Rev 20071205 ...

Page 21: ...User s Manual 15 Figure 3 7 Typical 85 Amp A9 Chassis M3534R Parallel Wiring Diagram Note Special Option C must be purchased for sharing to work properly Dwg 060189 Rev 20070806 ...

Page 22: ...M3534R 40 85A 16 This page intentionally left blank ...

Page 23: ...t Once the DC bus drops below a preset low limit threshold the RTM will become active When this occurs the RT ACTIVE front panel LED will illuminate the internal RTA relay contact will change states the cooling fan will begin running in order to cool the internal IGBT heatsink and the DC bus level will be supported by the RTM The RT ACTIVE LED and internal relay will be ON only while the RTM is ac...

Page 24: ...e or at rest Please refer to Table 4 1 for details 4 2 1 3 ASB 3534R3 STATUS OUTPUT CONFIGURATION JUMPERS FOR STANDARD MODELS The purpose and setting for each of the configuration jumpers provided on the ASB 3534R3 RTM Control board is described below Each output is jumper selectable to provide Normally Open NO or Normally Closed NC dry contact outputs Each contact is in its Normal condition while...

Page 25: ...24VDC 20mA 1kV Isolation 22 16 Table 4 2 Control Signal Connection Details for Models with DP10 I3 Option BOARD TERMINAL TYPE FUNCTION ELECTRICAL SPECIFICATIONS MIN WIRE AWG MAX WIRE AWG TORQUE LB IN 3534I3 Phoenix plug TB4 Disable 15 24VDC 20mA 3kV Isolation 22 16 2 lb in Table 4 3 Status Signal Component Details for Standard Models BOARD STATUS COMPONENTS STATUS SIGNAL COMPONENT ID OVERTEMP OT R...

Page 26: ...Control Board RTM STATUS CONDITION INDICATORS JUMPER POSITIONS CONTACT STATES PWR OT RTA OT J2 RTA J3 LD1 LD2 LD3 N C N O N C N O Power off or P S failure OFF OFF OFF X O X O Power on DC bus OK ON OFF OFF O X X O Power on Overtemp ON ON OFF X O X O Power on Ride Thru Active ON OFF ON O X O X NOTES X contact is closed under stated conditions O contact is open under stated conditions 4 2 2 INDICATOR...

Page 27: ...hin the M3534R RTM Control module This indicator directly tracks the activity of Over Temp status output relay K2 This indicator is ON and the relay is de energized when an Over Temp condition is present LD3 RTA RIDE THRU ACTIVE The LD3 RTA indicator shows when the M3534R RTM Control module is actively supporting the DC bus This indicator directly tracks the activity of RTA status output relay K3 ...

Page 28: ... Selects N O or N C contact for the disable DIS signal With J3 in the N O position the boost module will be disabled if there is 15 24VDC on the disable input terminals TB4 The TB4 connector provides a field connection point for Disable Ready and Active signals Signals are isolated up to 3000V Ready available on TB4 3 J1 post and 4 common 350VDC 120mA max Active available on TB4 1 J2 post and 2 co...

Page 29: ...e driven from the 3534I2 board or the 3660M1 board depending on application parameters Each of these boards uses a voltage divider connected across the DC bus to drive the panel meter The Voltmeter will read slightly lower than the drive bus when idle 4 2 3 2 BUS CURRENT METER The Bus Current Meter indicates the positive DC bus current supplied by the Ride Thru module For voltage isolated panels t...

Page 30: ...voltage trip point of 15 below nominal DC bus levels Some inverters can be reprogrammed to change this trip level Bonitron typically sets the DC bus threshold to be approximately 10 below nominal level For example Bonitron sets all 460VAC systems to hold the 640V DC bus to 585VDC Refer to the inverter documentation for details on adjusting its under voltage trip setting if the factory default sett...

Page 31: ... Generally the Threshold level should be set at 10 15 below the nominal DC bus level If running on single phase system threshold and battery levels may need to be lowered to prevent excessive activity An actual on site level setting must be determined by the loaded DC bus level as well as the amount of ripple present on the DC bus The Ride Thru Module should not become active during normal everyda...

Page 32: ...ms 2 PUSH THE TEST BUTTON Push the Test button while monitoring the DC bus voltage On modules so equipped the Test button is located on the module s control display front panel For modules without a control display front panel a normally open momentary switch should be installed to serve as a test switch for this procedure Refer to applicable field wiring diagrams for switch connection points 3 RE...

Page 33: ...reshold voltage should be set to approximately 10 below the nominal DC bus under normal load or 15 below unloaded bus level Coordinate to be above the associated inverter s under voltage trip level and below normal line level Most inverters have an under voltage trip point lower than 15 below the nominal DC bus Some inverters can be reprogrammed to change this trip level as needed For 40 85 Amp un...

Page 34: ...ll increase the setpoint value This adjustment pot is factory preset However field calibration of this setpoint may be necessary if the AC line level is more than 7 below the nominal AC requirement listed on the RTM module nameplate Contact Bonitron Inc for additional information as needed ...

Page 35: ... to Section 4 4 The DC bus voltage should drop until it reaches the threshold Ride Thru Active LED should begin to flash DC bus should hold for a second at the threshold This threshold level should be approximately 10 12 below the nominal loaded inverter bus Each Bonitron Ride Thru should be tested under load during initial start up to verify the functionality of the test circuit and that the test...

Page 36: ...flash DC bus should hold for a second at the threshold This threshold level should be approximately 10 12 below the nominal loaded inverter bus Each Bonitron Ride Thru should be tested under load during initial start up to verify the functionality of the test circuit and that the test does not negatively affect the process However Bonitron recommends that if the process is critical the TEST cycle ...

Page 37: ...d outgoing fuses Check normal DC bus voltage If the DC bus is normally too high the DC bus test setpoint may not raise the output voltage RTA Always On Check DC bus threshold voltage setting Ride Thru Active Output Never Comes On or Attached Drive Trips On Outages Check Enable input Check DC link to attached drive Initiate Test Mode If the test does not raise the DC bus and or the Ride Thru Active...

Page 38: ...llowing information when calling for technical help Exact model number of affected units Serial number of unit Name and model number of attached drives Name of original equipment supplier Brief description of the application The AC line to line voltage on all 3 phases The battery bank voltage The DC Bus voltage KVA rating of power source Source configuration Wye Delta and grounding This informatio...

Page 39: ...e the dimensional outlines in Section 6 4 For higher ratings batteries can be added and 85 Amp units can be paralleled Table 6 2 Model M3534R Ride Thru Module Voltage Levels AC INPUT VOLTAGE DC BUS VOLTAGE LEVELS THRESHOLD MIN AT FULL LOAD NOMINAL 208VAC 265VDC 255VDC 290VDC 230VAC 285VDC 275VDC 320VDC 380 400 415VAC 485VDC 475VDC 565VDC 460VAC 585VDC 575VDC 640VDC The Min at Full Load column in t...

Page 40: ...assis Ride Thru systems Wire size must be coordinated with circuit protection devices and IR drop of wire It is NOT necessary to size wire for continuous duty Maximum allowed duty cycle for the M3534R Ride Thru is one 2 second run every 4 minutes Table 6 3 Input Power Wiring Sizes and Fusing SYSTEM KW RIDE THRU DC BUS CURRENT RATING MIN SOURCE FUSING SEMICONDUCTOR RECOMMENDED FIELD WIRING SIZES MC...

Page 41: ...User s Manual 35 6 4 DIMENSIONS AND MECHANICAL DRAWINGS Figure 6 1 24kW Ride Thru K7 Chassis Dimensional Outline Dwg 120210 Rev 20120619 ...

Page 42: ...M3534R 40 85A 36 Figure 6 2 M3534R 50kW A9 Chassis Dimensional Outline Dwg 120220 Rev 20120626 ...

Page 43: ...User s Manual 37 6 5 SUPPLEMENTAL DRAWINGS Figure 6 3 3534R3 TB5 Status Signal Figure 6 4 3534R Status Signal Schematics Dwgs 060165 Rev 20090615 and 070001 Rev 20090624 ...

Page 44: ... Each printed circuit board has a serial sticker i e 3534R3H10 125 Please refer to Table 6 5 below Please include every character when ordering spare PCBs to help ensure a proper order Parts should be ordered by the responsible party through your local distributor or system integrator NOTE Spare circuit boards are available for companies who have active personnel with training certificates on file...

Page 45: ...Green lens cap 1 LD RED LENS L05 Amber lens cap 1 LD RED LENS L05 W Neoprene Washer 3 Table 6 6 Spare Parts List for 67hp 50kW 85 Amp Unit PART NUMBER DESCRIPTION QTY ASB 3534R3 x Control PCB 1 ASB 3534P3 1 Power Chopper PCB 1 ASB 3534I3 Optional Interface Board 1 FS FWP 100 FWP 100B Semiconductor Fuse 2 LD AMB LENS L05 Red lens cap 1 LD GRN LENS L05 Green lens cap 1 LD RED LENS L05 Amber lens cap...

Page 46: ...M3534R 40 85A 40 This page intentionally left blank ...

Page 47: ... new Inverters derive logic supply from DC bus Install UPS on circuits with AC feed 2 Any control or Interlock relays must be backed up Test Relays at half voltage for dropout Use DC relays on logic supply Install UPS on circuits with AC feed 3 Determine the maximum motor voltage needed To ensure Threshold level is sufficient to supply motor Most inverters automatically compensate RMS to motor 4 V...

Page 48: ...required Since the discharge characteristic of a capacitor bank with a constant power load is a nonlinear differential equation optimizing the capacitor bank selection is an iterative process A general estimate of needs must be used to build a capacitor bank and then the actual values must be cross checked to make sure they are suitable There are several steps in the process The capacitor bank wil...

Page 49: ...capacitor 𝑉𝑒𝑛𝑑 Lowest voltage the capacitor bank can reach 𝑉𝑇𝑒𝑟𝑚𝐸𝑛𝑑 Terminal voltage of an individual capacitor during discharge 7 4 1 ENERGY REQUIRED FOR OUTAGE The total energy required for the event must be calculated first Using the following equation the total number of joules required for the outage can be calculated JOut Psys Tout We will use a specification of 100 hp for a 2 second outage ...

Page 50: ...e 𝑉𝐶𝑎𝑝𝑀𝑎𝑥 Maximum charge voltage for the capacitor A general rule is to use 95 of the value listed on the datasheet for a reasonable margin For our example we will use the following values 𝐸𝑠𝑟 01Ω 𝐶𝑒𝑜𝑙 132F 𝑉𝐶𝑎𝑝𝑀𝑎𝑥 46V 7 4 5 MINIMUM SERIES STRING From 𝑉𝑐𝑎𝑝𝑀𝑎𝑥 we can calculate the minimum series string of capacitors that will be required by the voltage rating Below this voltage there is an amount o...

Page 51: ... delivered to the load is given by JAvailable 1 2 Ctot 𝑉𝐶ℎ𝑎𝑟𝑔𝑒 2 𝑉𝐶𝑎𝑝𝐸𝑛𝑑 2 JAvailable 1 2 16 5F 368V2 338V2 175kJ The equivalent 𝐸𝑠𝑟 of the string is given by Esrtot nstring Esr nparallel Esrtot 8 0 01Ω 1 0 08Ω The total extraction losses of the string is given by JLossTot Esrtot IPeak 2 Tout JLossTot 0 08Ω 235A2 2s 9kJ Now the total required energy can be compared JOut JLossTot JAvailable 150kJ 9...

Page 52: ...d be found on equal size drives of a common manufacturer 2 Drives should be on same AC feed and grounding There must be no isolation transformers between the drives and or M3534 modules Different feeds may have different potentials and may cause circulating currents or ground faults 3 If line chokes or harmonic filters are used all the drives should be connected to the output of a single choke or ...

Page 53: ...User s Manual 47 Figure 7 1 Diode Sharing Example VFD BRAKING RESISTOR DISCONNECT DC BUS MODEL M3460 M3534 DC OUTPUT M 3 VFD BRAKING RESISTOR M 3 ...

Page 54: ...M3534R 40 85A 48 NOTES ...

Page 55: ......

Page 56: ...D_M3534R_CMAN_v40A24kWand85A50kWall_03a 03 18 2015 521 Fairground Court Nashville TN 37211 USA Tel 615 244 2825 Fax 615 244 2833 Web www bonitron com Email info bonitron com ...

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