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Web: www.bonitron.com ● Tel: 615-244-2825 ● Email: [email protected]

Model M3460

Ride-Thru

Enclosed Voltage Regulator

Customer Reference Manual

Summary of Contents for M3460

Page 1: ...Web www bonitron com Tel 615 244 2825 Email info bonitron com Model M3460 Ride Thru Enclosed Voltage Regulator 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: ...6 Table 3 3 User I O Connections with 3660I4 Board 16 Figure 3 1 M3460R I O Terminal connection 17 Figure 3 2 M3460B I O Terminal connection 18 3 5 Typical Configurations 20 Figure 3 2 M3460R Typical Configuration without Energy Storage 20 Figure 3 3 M3460R Typical Configuration with Electrolytic Capacitor Storage Bank 21 Figure 3 4 M3460R Typical Configuration with Ultracapacitor Storage Bank 22 ...

Page 5: ...Dimensions and Mechanical Drawings 48 Figure 6 1 M3460 E1 Enclosure Dimensional Outline 48 Figure 6 2 M3460 E2 Enclosure Dimensional Outline 49 Figure 6 3 M3460 E3 Enclosure Dimensional Outline 50 Figure 6 4 M3460 E4 Enclosure Dimensional Outline 51 Figure 6 5 M3460 E5 Enclosure Dimensional Outline 52 7 APPENDICES 53 7 1 M3460 Installation Considerations 53 7 2 Specifying an Ultracapacitor Storage...

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Page 7: ...E This manual is a user s guide for the model M3460 ride thru voltage regulator It will provide the user with the necessary information to successfully install integrate and use this 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 REVISION T...

Page 8: ...R DANGER 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 CAUTION Heat or burn hazard Identifi...

Page 9: ...ll Bonitron ride thru products connect in parallel with the drive thus increasing system availability and reliability The M3460 regulates incoming voltage to the DC bus of the variable frequency drive This allows the drive to ride through these events while maintaining motor speed and torque without experiencing drive shutdown ADVANTAGES Reliability Parallel connection to AC system M3460 maintenan...

Page 10: ...able 2 1 System Voltage Rating Codes RATING CODE NOMINAL VOLTAGE AC LINE DRIVE BUS L 230 VAC 325 VDC E 380 415 VAC 540 585 VDC H 460 VAC 650 VDC POWER RATING The power rating indicates the maximum power in kilowatts that can safely be handled by the M3460 and is represented by a 3 digit value based on the nominal DC system voltage rating and the maximum output current rating of the M3460 For insta...

Page 11: ...DC Power Rating 25 250 kW Inactive Power Consumption 200W Duty Cycle Full Load 1 Sag Outage Duration 2 seconds Enclosure Rating NEMA 1 Enclosure Operating Temperature 0 to 40ºC Storage Temperature 20 to 65 ºC Humidity Below 90 non condensing Atmosphere Free of corrosive gas and conductive dust Table 2 4 M3460B General Specifications PARAMETER SPECIFICATION Input DC Voltage 200 540 VDC Output DC Vo...

Page 12: ...ICE ON THIS PRODUCT INSTALLATION AND OR REMOVAL OF THIS PRODUCT SHOULD ONLY BE ACCOMPLISHED BY A QUALIFIED ELECTRICIAN IN ACCORDANCE WITH NATIONAL ELECTRICAL CODE OR EQUIVALENT REGULATIONS 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 F T H I S P R O D U C T B E S U R E T O R E V I E W A L L S Y S T E M D O C U M E N T A T I O N F O R P E R T I N E N T S A F E T Y P R ...

Page 13: ...eld wiring may be provided on the top right surface of the enclosure if desired 3 The unit will require a minimum clearance of two 2 inches in all directions around it when mounted near a non heat source 4 The mounting surface should be clean and dry The maximum ambient operating temperature of the M3460 should not exceed 40 C Temperatures above this can cause overheating during operation The stan...

Page 14: ...s the connection details listed below before proceeding Table 3 1 M3460R Power Wiring Connections TERMINAL DESIGNATION FUNCTION WIRING SPECIFICATION CONNECTION TORQUE AC Line L1 L2 L3 AC Input 600 VAC 3 8 stud 150 lb in Storage Bus DC Input 600 VAC Existing Diode SCR Check Device Datasheet Drive Bus DC Output 600 VAC 3 8 stud 150 lb in Ground 600 VAC 5 16 stud 75 lb in Table 3 2 M3460B Power Wirin...

Page 15: ...k can be made to any two of the AC line connections so that the existing fuses can be used for protection Please note that one terminal will not be connected See Figure 3 4 3 4 1 2 STORAGE BUS CONNECTIONS If an electrolytic capacitor bank is used with the M3460R the input can be attached directly to the diode bus bars marked Storage Bus External fusing between the capacitor bank and the M3460R is ...

Page 16: ... 3660I4 interface board Refer to the KIT 3660DD5 manual for operational and functional details 3 4 2 1 CONNECTIONS WITH DD5 DIGITAL DISPLAY Table 3 3 User I O Connections with 3660I4 Board 3660I4 TERMINAL FUNCTION ELECTRICAL SPECIFICATIONS WIRE AWG TORQUE USER INPUTS TB15 1 24V Common 5 VDC 25 mA 16 2 1 lb in TB15 2 Input Common TB15 3 Spare TB15 4 Ride Thru Test RT Test Input TB15 5 Ride Thru Ena...

Page 17: ...9 I O CONNECTIONS COURTESY 24V RIDE THRU EN RIDE THRU TEST INPUT COM COURTESY COM FAULT 1 FAULT 2 RT ACTIVE OUTPUT COM TERMINAL FUNCTION TB 1 Courtesy 24V TB 2 Ride Thru ENABLE TB 3 Ride ThrU TEST TB 4 Input COM TB 5 Courtesy COM TB 6 Fault 1 TB 7 Fault 2 TB 8 Ride Thru Active RTA TB 9 Output COM ...

Page 18: ... 14 15 16 17 18 19 20 21 22 CHARGER I O SIGNALS TERMINAL FUNCTION TB 1 Courtesy 24V TB 2 Charger ENABLE TB 3 Charger Equalize EQ TB 4 Ride Thru ENABLE TB 5 Ride Thru TEST TB 6 Input COM TB 7 Courtesy COM TB 8 Fault 1 TB 9 Fault 2 TB 10 Ride Thru Active RTA TB 11 Output COM TB 12 Storage Undervoltage NO TB 13 Storage Undervoltage COM TB 14 Charger READY signal TB 15 Charger charginh signal TB 16 Ch...

Page 19: ...ENABLE CH EQUALIZE DISCHARGE SPARE OUTPUT COM OUTPUT COM RT ENABLE RT TEST TB11 TB8 TB6 1 1 1 TB5 TB1 TB4 2 3 4 1 2 3 4 1 2 3 4 TB2 1 3 L2 L1 L3 TB13 4 1 6 8 1 1 TB12 4 1 COURTESY 24V CH ENABLE CH EQUALIZE RT ENABLE RT TEST SPARE INPUT COM 24V COM SPARE 1 N O SPARE 2 N O FAULT 1 N O FAULT 2 N O RT ACTIVE OUTPUT COM RT BYPASS RT NORMAL CH BYPASS CH NORMAL DISCH BYPASS DISCH NORMAL SPARE 1 SPARE 2 T...

Page 20: ... FROM THE SAME FEED TRANSFORMER CONNECTED DOWNSTREAM 2 IF LINE CHOKES ARE USED RIDE THRU MUST BE 1 INVERTER AND RIDE THRU SHOULD BE POWERED NOTES CHOPPER BRAKING INTERNAL VFD INVERTER BRAKING RESISTOR DISCONNECT DRIVE FEED AC CHOKES LINE GROUND FAULT SENSING DISCONNECT RIDE THRU M3460R CHOPPER DRIVE BUS STORAGE BUS STORAGE BUS ...

Page 21: ...ED DOWNSTREAM 2 IF LINE CHOKES ARE USED RIDE THRU MUST BE 1 INVERTER AND RIDE THRU SHOULD BE POWERED NOTES CHOPPER BRAKING INTERNAL VFD INVERTER BRAKING RESISTOR DISCONNECT DRIVE FEED AC CHOKES LINE GROUND FAULT SENSING DISCONNECT RIDE THRU M3460R CHOPPER DRIVE BUS STORAGE BUS STORAGE BUS RESISTOR DISCHARGE ELECTROLYTIC CAPACITORS WITH PRECHARGE ASM 3534EC ...

Page 22: ...SENSING M3528AC CHARGER ULTRA CAP ENERGY STORAGE BANK DISCONNECT RIDE THRU M3460R CHOPPER DRIVE RIDE THRU DISCONNECT AUX CONTACT BUS STORAGE BUS STORAGE BUS M 3 ISOLATION TRANSFORMER FROM THE SAME FEED TRANSFORMER CONNECTED DOWNSTREAM 2 IF LINE CHOKES ARE USED RIDE THRU MUST BE 1 INVERTER AND RIDE THRU SHOULD BE POWERED NOTES L1 L2 ASM 3460PS IS LOWER THAN PCC VOLTAGE 3 ASM 3460 PS WILL BE USED IF...

Page 23: ...h Battery Storage Bank DISCONNECT DRIVE DRIVE FEED AC BANK STORAGE BATTERY ENERGY 3460B CHOPPER CHOKES LINE CHOPPER BRAKING INTERNAL VFD INVERTER BRAKING RESISTOR GROUND FAULT SENSING DISCONNECT BATTERY RIDE THRU DISCONNECT BUS M 3 STORAGE BUS M3528AC CHARGER ISOLATION TRANSFORMER ...

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Page 25: ...itor bank for full outage protection 4 3 OPERATION MODES AND CONFIGURATION 4 3 1 NORMAL OPERATION During normal operation the M3460 will monitor the output DC bus When the output DC bus voltage goes below the DC bus threshold voltage the M3460 will become active and regulate the output DC bus and attached drive to the DC bus threshold voltage As the input voltage drops more current is required to ...

Page 26: ...reens 4 4 2 LEDS Red yellow and green LEDs indicate the status of the ride thru Red indicates a fault has occurred The display will indicate the nature of this fault Yellow indicates that the ride thru or the charger is active Green indicates that the display is receiving power from the ride thru system 4 4 3 BUTTONS The function of each button depends on the active screen For menu screens enter s...

Page 27: ...dicator is moved using the up and down buttons If a line on the menu represents another screen that screen may be accessed with the enter key The cancel button will return the display to the previous screen Figure 4 1 Screen Menu Tree ANALOG STATUS FAULT MAIN MENU RECORDS MENU ACTIONS MENU RIDE THRU EVENTS FAULT RECORDS STATISTICS INDIV EVENTS RIDE THRU TEST THRESHOLD CHECK CHARGER EQUALIZE CONFIG...

Page 28: ...and right simultaneously will clear any resettable faults Up Show previous fault Down Show next fault Left Status screen Right Analog screen Left Right Clear faults Enter Main menu Cancel Status screen 4 5 3 ANALOG SCREEN This screen displays the present values of four of the eight system voltages and currents One set shows storage voltage storage current output voltage and output current the othe...

Page 29: ... menu Cancel ride thru events menu 4 5 4 1 1 2 INDIVIDUAL EVENTS This screen displays the time and duration of one of the thirty most recent ride thru events Up Display a more recent event Down Display an older event Enter Show the voltage records for the presently selected event Cancel Ride Thru Events menu 4 5 4 1 1 2 1 RIDE THRU EVENT VOLTAGES This screen displays the voltages recorded for the ...

Page 30: ...LIZE From this screen the user may set how long the charger should stay in equalize mode for Up Increment digit Down Decrement digit Left Right Move cursor Enter Confirm time Cancel Actions menu 4 5 4 3 CONFIGURATION MENU From this screen the user may set the present time select what status values are to be displayed on the Status screen and set the status screen timeout value Up Down Move cursor ...

Page 31: ... Each fault activates one of the two fault outputs Some faults disable either the ride thru or charger until they are reset See Table 4 1 to determine which properties apply to each fault Table 4 1 KIT 3660DD5 Faults FAULT DESCRIPTION FAULT 1 FAULT 2 LATCH RIDE THRU DISABLE CHARGER DISABLE Output Undervoltage x Storage Undervoltage x x Configurable Storage Overvoltage x x x Ride Thru Not Ready x P...

Page 32: ...time set in the Super menu This is probably due to a blown fuse or incorrect wiring 4 6 8 RIDE THRU ACTIVE TIME This fault indicates that the ride thru has remained active for longer than the maximum safe time as set in the Super menu 4 6 9 STORAGE IMBALANCE This fault indicates that the voltage on one of the individual storage modules has risen to an unsafe level 4 6 10 STORAGE OVERTEMP This faul...

Page 33: ...e This input enables the ride thru TB 5 RT Test This input initializes a test cycle of the ride thru TB 6 Input COM This is the common used with all user inputs TB 7 24V COM This is the common to the courtesy 24V supply This must be connected to the Input Com if the courtesy 24V is used to drive the inputs 4 7 1 2 USER OUTPUTS FOR M3460B TB 8 Fault 1 NO This output closes to Output Com when there ...

Page 34: ...on used with all user inputs TB 5 24V COM This is the common to the courtesy 24V supply This must be connected to the Input Com if the courtesy 24V is used to drive the inputs 4 7 1 4 USER OUTPUTS FOR M3460R TB 6 Fault 1 NO This output closes to Output Com when there is no class 1 fault TB 7 Fault 2 NO This output closes to Output Com when there is no class 2 fault TB 8 RT Active This output close...

Page 35: ...nough to allow the drive to operate at full power Therefore it s useful to set the DC bus threshold voltage setting above this value Generally the DC bus threshold voltage should be set at 10 below the nominal DC bus level Use the following formula to calculate this value Vdc Vac 2 0 9 An actual on site check may be performed to determine the loaded DC bus level as well as the amount of ripple pre...

Page 36: ...TLY M3460B MODELS Checking the DC bus threshold voltage setting directly requires disconnecting the M3460B DC bus from the drive DC bus while the battery bank supplies power to the M3460B 1 Monitor the output DC bus of the M3460B 2 Disconnect the M3460B DC bus from the drive DC bus 3 The M3460B should now be active and the voltage at the M3460B output DC bus is the threshold setting 4 8 3 DETERMIN...

Page 37: ...oltage 100VDC from this reading shows that the actual DC bus threshold voltage setting is 585VDC 4 8 4 ADJUSTING THE DC BUS THRESHOLD VOLTAGE SETTING Adjustment of R7 on the 3460C1 control board see Figure 4 2 is used to adjust the DC bus threshold voltage setting Adjusting the pot in a clockwise direction will raise the setting Alternately a counter clockwise adjustment of the pot will lower the ...

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Page 39: ...ive light should turn ON when the M3460R starts to operate The DC bus will hold at the DC bus threshold voltage setting momentarily while the filter capacitors drain 8 With the M3460R and drive power off connect the DC bus of the M3460R to the DC bus of the drive 9 Turn on power to the drive and ensure it is working properly without any fault the drive must be ON before applying power to the Ride ...

Page 40: ...rrent to the attached drive 11 Load the drive as much as practical and turn off AC power to the drive The display status should be boosting DC bus voltage should hold at threshold boost level Motor should not lose speed or torque DC bus current should flow from M3460B to drive Drive input current should decrease The Display will show Time limit fault at the end of the event The M3460B and drive sy...

Page 41: ... series caps would indicate a change in value in one cap and would constitute a more detailed out of circuit capacitance check A difference of 5 is allowed at time of production Testing the capacitors in the unit requires trained personnel and should only be attempted observing appropriate safety and arc flash precautions when working on live high voltage equipment DANGER HIGH VOLTAGES ARE PRESENT...

Page 42: ...nents If cleaning is needed Remove power and allow all voltages to drain Check for residual voltages with meter Clean affected areas with rag brush or denatured alcohol depending on the type of contamination Once area is clean and dry reapply power 5 4 4 FANS Bonitron estimates fan life to be longer than 20 years in a properly adjusted M3460B in a clean cool environment 4 years under constant runn...

Page 43: ...Thru Ready light is OFF or Ride Thru Ready output is open Check Enable Input Check IGBT fuses Check 3460M6 board jumpers Precharge Complete light is OFF or Precharge Complete output is open Check Enable Input Check 3460M6 jumpers Check Drive Bus voltage level Voltage Fault output is open Check input fuses Check Drive Bus level Check jumpers on 3460M6 board Overtemperature output is open Check jump...

Page 44: ... the 15V wires going to the current sensors CAUTION 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 5 6 TECHNICAL HELP BEFORE YOU CALL If possible please have the following information when calling for technical help Exact model numb...

Page 45: ...415 VAC 485 VDC 100 VDC 460 VAC 585 VDC 100 VDC Table 6 3 M3460R Minimum Input Voltages SYSTEM VOLTAGE MINIMUM AC INPUT VOLTAGE MINIMUM DC INPUT VOLTAGE IUV LEVEL MINIMUM DC INPUT REQUIRED FOR PRECHARGE COMPLETE PCC 230 VAC 115 VAC 160 VDC 270 VDC 380 415 VAC 190 VAC 265 VDC 445 487 VDC 460 VAC 230 VAC 320 VDC 540 VDC Minimum AC input power required after PCC for full power operation with energy s...

Page 46: ...table for use on a circuit capable of delivering not more than 18 000 RMS symmetrical amperes 700 volts maximum when protected by recommended fuses Table 6 6 M3460B Model Specifications for 230 480 VAC Systems DC BUS CURRENT BACKPLATE SIZE CIRCUIT CONFIGURATION RECOMMENDED FUSE RATING SCCR RATINGS DRIVE BUS STORAGE BUS 85 A R10 1 stage 80 A 700 V 125 A 700 V 10 kA 127 A R9 2 stage 125 A 700 V 175 ...

Page 47: ... DC bus current rating of the M3460 The field wiring sizes listed in Tables 6 7 6 8 ensure a 10V drop for wire lengths of 100 feet and are compatible with the recommended steady state circuit branch protection fusing listed The wire gauge selected for field wiring to the M3460 should be equal to or greater than that listed in Tables 6 9 6 10 Use copper wiring rated 75 C or equivalent for field wir...

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Page 49: ...D_M3460_D_CMAN_vall_00a 4 17 2020 49 Figure 6 2 M3460 E2 Enclosure Dimensional Outline ...

Page 50: ...D_M3460_D_CMAN_vall_00a 4 17 2020 50 Figure 6 3 M3460 E3 Enclosure Dimensional Outline ...

Page 51: ...D_M3460_D_CMAN_vall_00a 4 17 2020 51 Figure 6 4 M3460 E4 Enclosure Dimensional Outline ...

Page 52: ...D_M3460_D_CMAN_vall_00a 4 17 2020 52 Figure 6 5 M3460 E5 Enclosure Dimensional Outline ...

Page 53: ...e systems will need to be backed up separately with AC UPS systems or logic power backup systems like 24VDC buffers 3 Most drives have control and cooling power supplies that are connected to the DC bus of the drive These will be backed up by the M3460 Some larger frame AC drives require consistent AC power to keep operating as they have fans that get power directly from the AC line In this case t...

Page 54: ...ackup 3 Determine the maximum current required to support the load at minimum voltage 4 Specify the capacitor to be evaluated 5 Estimate the losses for each capacitor 6 Determine the minimum number of capacitors per series string required for the minimum voltage 7 Add capacitors in series for outage energy 8 Determine if parallel strings are required to provide outage energy These are the definiti...

Page 55: ...l number of joules required is JOut 75kW 2s 150kJ 7 2 2 MINIMUM CAPACITOR BANK VOLTAGE There is a minimum voltage level that must be maintained at the end of the discharge during backup An M3460R has for a 460VAC nominal system a minimum input voltage of 320VDC Therefore the final discharge voltage of the capacitor bank 𝑉𝑒𝑛𝑑 should be 320 VDC These data are available in the specifications for the ...

Page 56: ... 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 of stored energy that cannot be used and will remain in the capacitor bank Since there can be significant terminal voltage drop at the end of the discharge cycle due to 𝐸𝑠𝑟 it is best to use the terminal voltage of the capaci...

Page 57: ... required more energy then capacitors can be added in series and the calculations redone as in 7 2 1 If the charge voltage exceeds the maximum input voltage for the M3460R then the minimum series string combination should be used in parallel and the process repeated 7 3 STEERING DIODE SHARING WITH A BONITRON M3460 RIDE THRU Diode sharing is used to decrease the cost of implementing M3460 modules t...

Page 58: ...rents 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 filter Individual input harmonic filters or line chokes can cause unequal potentials with respect to earth 4 The M3460 connection should be downstream of any input line filter Input line filters cause lower DC bus levels If a M3460 is placed upstream the Ride T...

Page 59: ...D_M3460_D_CMAN_vall_00a 4 17 2020 59 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 60: ...of the variable frequency drive the input rectifier bridge of the variable frequency drive is in parallel with the M3460R input rectifier bridge There are two diodes in parallel from the DC bus to the AC line for each connection Figure 7 2 M3460R Typical Configuration without Energy Storage CHOPPER BRAKING INTERNAL VFD INVERTER BRAKING RESISTOR DISCONNECT DRIVE DISCONNECT RIDE THRU M3460R CHOPPER ...

Page 61: ... or currents that may enter the DC bus of the M3460R through one bridge and return to the AC source through the other bridge Figure 7 3 M3460R Typical Configuration with Current Flow CHOPPER BRAKING INTERNAL VFD INVERTER BRAKING RESISTOR DISCONNECT DRIVE DISCONNECT RIDE THRU M3460R CHOPPER DRIVE BUS STORAGE BUS STORAGE BUS AC FEED ...

Page 62: ...edance should be added to the negative connection of the ride thru to the drive This prevents the circulation current from being sustained after a sag event The M3460RD is not required in all installations however determining the requirement is difficult due to the variables involved with the physical installation Using the M3460RD does not reduce the Ride Thru capacity for the system and is recom...

Page 63: ...SENSING M3528AC CHARGER ULTRA CAP ENERGY STORAGE BANK DISCONNECT RIDE THRU M3460R CHOPPER DRIVE RIDE THRU DISCONNECT AUX CONTACT BUS STORAGE BUS STORAGE BUS M 3 ISOLATION TRANSFORMER FROM THE SAME FEED TRANSFORMER CONNECTED DOWNSTREAM 2 IF LINE CHOKES ARE USED RIDE THRU MUST BE 1 INVERTER AND RIDE THRU SHOULD BE POWERED NOTES L1 L2 ASM 3460PS IS LOWER THAN PCC VOLTAGE 3 ASM 3460 PS WILL BE USED IF...

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Page 65: ...D_M3460_D_CMAN_vall_00a 4 17 2020 65 NOTES ...

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