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User’s Manual

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255 Amps

175 Amps

2/0 AWG

340 Amps

225 Amps

3/0 AWG

425 Amps

225 Amps

4/0 AWG

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Summary of Contents for M3460UC

Page 1: ...Web www bonitron com Tel 615 244 2825 Email info bonitron com Model M3460UC 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: ...trol Interface and I O Wiring 16 Figure 3 1 M3460UC I O Terminal connection 17 Figure 3 2 M3460UC POWER Terminal connection 18 3 5 Typical Configurations 20 Figure 3 4 M3460UC Typical Configuration with Ultracapacitor Storage Bank 20 4 OPERATION 21 4 1 Functional Description 21 4 2 M3460UC Operation for Full Outage Protection 21 4 3 Operation Modes and Configuration 21 4 3 1 Normal Operation 21 4 ...

Page 5: ... and Mechanical Drawings 42 Figure 6 1 M3460 E1 Enclosure Dimensional Outline 42 Figure 6 2 M3460 E2 Enclosure Dimensional Outline 43 Figure 6 3 M3460 E4 Enclosure Dimensional Outline 44 7 APPENDICES 45 7 1 M3460 Installation Considerations 45 7 2 Specifying an Ultracapacitor Storage Bank for Full Outage Protection With M3460R Models 45 7 2 1 Energy Required for Outage 47 7 2 2 Minimum Capacitor B...

Page 6: ...M3460 6 This page intentionally left blank ...

Page 7: ...E This manual is a user s guide for the model M3460UC 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...

Page 8: ...ifies 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 statement...

Page 9: ...oming 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 maintenance can be done while normal process is on line Works with almost any fixed bus variable frequency PWM drive Only 2 3 parallel connections Can...

Page 10: ...oltage 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 instance the rating co...

Page 11: ...85 VDC Output DC Voltage 265 650 VDC DC Bus Current Rating 85 425 ADC 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 ...

Page 12: ...ODUCT 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 E C A U T I O ...

Page 13: ... from the elements 2 Conduit access for field 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 c...

Page 14: ...ystem will be found in the documentation provided with the drive system Be sure to review all pertinent AC drive system documentation as well as the connection details listed below before proceeding Table 3 1 M3460UC Power Wiring Connections TERMINAL DESIGNATION FUNCTION WIRING SPECIFICATION CONNECTION TORQUE Storage Bus DC Input 600 VAC 3 8 stud 150 lb in Drive Bus DC Output 600 VAC 3 8 stud 150 ...

Page 15: ...ons cannot be made through the braking terminals or with precharge resistors or DC link chokes between the output of the M3460 and the DC bus capacitors in the drive Consult the manufacturers documentation or contact Bonitron for further assistance Make sure the polarity is correct for these connections as failure to do so can cause severe damage to the system DANGER FOR SYSTEMS THAT HAVE DC STORA...

Page 16: ...remote enabling testing and monitoring of the M3460 All units are equipped with the 3660DD5 digital display interface all connections are made to the 3660I4 interface board See figure 3 1 on the next page Refer to the KIT 3660DD5 manual for operational and functional details ...

Page 17: ... 250 VDC 120 MA 16 4 5 in lbs TB 8 Fault 2 250 VDC 120 MA 16 4 5 in lbs TB 9 Ride Thru Active RTA 250 VDC 120 MA 16 4 5 in lbs TB 10 Output COM 250 VDC 120 MA 16 4 5 in lbs TB 11 Spare TB 12 Storage Undervoltage NO 24 VDC 25 mA 16 4 5 in lbs TB 13 Storage Undervoltage COM 24 VDC 25 mA 16 4 5 in lbs TB 14 Charger READY signal 24 VDC 25 mA 16 4 5 in lbs TB 15 Charger charging signal 24 VDC 25 mA 16 ...

Page 18: ...M3460 18 Figure 3 2 M3460UC POWER Terminal connection ...

Page 19: ...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 TB16 ...

Page 20: ...citor Storage Bank M3628R CHOPPER BRAKING INTERNAL VFD INVERTER BRAKING RESISTOR DISCONNECT DRIVE FEED AC CHOKES LINE GROUND FAULT SENSING M5628AC CHARGER DISCONNECT RIDE THRU M3460UC CHOPPER DRIVE RIDE THRU DISCONNECT AUX CONTACT BUS STORAGE BUS STORAGE BUS M 3 ULTRA CAP ENERGY STORAGE BANK ...

Page 21: ...bilities Refer to Section 7 2 for general guidelines on sizing a capacitor 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 thr...

Page 22: ...ts and faults and menus allowing the user to select actions or access other screens 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...

Page 23: ... 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 MENU SET ...

Page 24: ...ltaneously 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 other set shows th...

Page 25: ...el 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 selected r...

Page 26: ... 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 Enter Make sel...

Page 27: ...t 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 Precharge N...

Page 28: ...e 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 fault indicates th...

Page 29: ... initializes a test cycle of the ride thru TB 5 Input COM This is the common used with all user inputs TB 6 24V COM This is the common to the courtesy 24V supply This must be connected to the nput om if the courtesy 24 is used to drive the inputs 4 7 1 2 USER OUTPUTS FOR M3460UC TB 7 Fault 1 NO This output closes to utput om when there is no class 1 fault TB 8 Fault 2 NO This output closes to utpu...

Page 30: ... 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 present on the DC...

Page 31: ...to the drive if connected 2 Initiate a test with the display 3 Monitor the DC bus voltage while the M3460 is in Test mode This is the DC bus test voltage setting The DC bus test voltage setting is approximately 50 100V higher than the DC bus threshold voltage setting For example for an M3460 with an input voltage of 460VAC the DC bus threshold voltage setting is preset to be 585VDC and the DC bus ...

Page 32: ...460C1 Control Board Layout 1 TB3 TB4 1 LD2 TB1 LD5 TB2 1 TEST INT J4 EXT LD6 15V TB5 1 R7 THRESHOLD LD3 RIDE THRU READY 15V LD7 LD4 COMPLETE PRECHARGE ACTIVE RIDE THRU 3460C1 CONTROL BOARD by BONITRON LD1 BLOWN FUSE J1 T O ...

Page 33: ...with the display or with separate meters Also monitor the AC input current 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 M3460 to drive Drive input current should decrease The Display will s...

Page 34: ...erence greater than 15 between each set of 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 ...

Page 35: ...lean off dust debris or chemical build up on high voltage bus bars or other exposed components 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 2 4 HEATSINKS Dirt can build up on heatsink surfaces degradi...

Page 36: ...tays in Test Mode Check Test Input Ride Thru Ready light is OFF or Ride Thru Ready output is open Check Enable Input Check IGBT fuses Precharge Complete light is OFF or Precharge Complete output is open Check Enable Input Check Drive Bus voltage level Voltage Fault output is open Check input fuses Check Drive Bus level Overtemperature output is open Check jumpers on 3460M6 board Check threshold vo...

Page 37: ...ires 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 4 TECHNICAL HELP BEFORE YOU CALL If possible please have the following information when calling for technical help Exact model number of affe...

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Page 39: ... DC Bus Threshold and Test Boost Voltages SYSTEM VOLTAGE DC BUS THRESHOLD TEST BOOST 230 VAC 285 VDC 50 VDC 380 415 VAC 485 VDC 100 VDC 460 VAC 585 VDC 100 VDC Table 6 3 M3460 Minimum Input Voltages SYSTEM VOLTAGE MINIMUM DC INPUT VOLTAGE IUV LEVEL MINIMUM DC INPUT REQUIRED FOR PRECHARGE COMPLETE PCC 230 VAC 160 VDC 270 VDC 380 415 VAC 265 VDC 445 487 VDC 460 VAC 320 VDC 540 VDC Minimum AC input p...

Page 40: ... standby mode is less than 200W 6 3 BRANCH CIRCUIT PROTECTION AND WIRE SIZING The following information is supplied for assistance in selecting the appropriate field wiring sizes and power source fuse ratings for the M3460 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 M3460 i...

Page 41: ...User s Manual 41 255 Amps 175 Amps 2 0 AWG 340 Amps 225 Amps 3 0 AWG 425 Amps 225 Amps 4 0 AWG ...

Page 42: ...M3460 42 6 4 DIMENSIONS AND MECHANICAL DRAWINGS Figure 6 1 M3460 E1 Enclosure Dimensional Outline ...

Page 43: ...User s Manual 43 Figure 6 2 M3460 E2 Enclosure Dimensional Outline ...

Page 44: ...M3460 44 Figure 6 3 M3460 E4 Enclosure Dimensional Outline ...

Page 45: ...sistent AC power to keep operating as they have fans that get power directly from the AC line In this case there may be special requirements to keep the drive operating 4 Any AC line outage sensing must be disabled in the drive to keep the drive from automatically shutting down on a phase loss 5 Any kinetic buffering option needs to be disabled in the drive This can cause interference with the ope...

Page 46: ...mber 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 definitions of the variables we will use in the following equations 𝐶𝑒𝑜𝑙 Capacitance at end of life 𝐶𝑡𝑜𝑡 Total capacitance of the entire cap bank 𝐸𝑠𝑟𝑡𝑜𝑡 Total equivalent ESR for the entire cap bank 𝐸𝑠𝑟...

Page 47: ...f 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 specific M...

Page 48: ...S 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 capacitors 𝑉𝑇𝑒𝑟𝑚𝐸𝑛𝑑 ...

Page 49: ...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 to existing...

Page 50: ... 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 Thru DC bus can ...

Page 51: ...User s Manual 51 Figure 7 1 Diode Sharing Example VFD BRAKING RESISTOR DISCONNECT DC BUS MODEL M3460 M3534 DC OUTPUT M 3 VFD BRAKING RESISTOR M 3 ...

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

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Page 56: ...D_M3460_D_CMAN_vall_00a 9 1 2020 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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