bonitron M3528 Customer Reference Manual Download Page 1

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

Model M3528

Charger Module

A6 and K8 Chassis

Customer Reference Manual

Summary of Contents for M3528

Page 1: ...Web www bonitron com Tel 615 244 2825 Email info bonitron com Model M3528 Charger Module A6 and K8 Chassis 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: ...iring 13 Table 3 1 M3528AC Power Wiring Connections 14 Table 3 2 M3528DC Power Wiring Connections 14 3 4 2 Control Interface and I O Wiring 15 Table 3 3 User I O Connections With 3528C2 or 3528C3 Boards 15 3 5 Typical Configurations 16 Figure 3 1 M3460 Ultracapacitor System 16 Figure 3 2 M3460 Battery System 17 Figure 3 3 M3534 Ultracapacitor System 18 Figure 3 4 M3534 40A Battery System 19 4 OPER...

Page 5: ...elp Before you call 32 6 ENGINEERING DATA 33 6 1 Ratings 33 Table 6 1 M3528 Ratings 33 Table 6 2 Battery Bank Typical Values 33 6 2 Efficiency Power Consumption 33 Table 6 3 M3528 Watt Loss Chart 33 6 3 Certifications 34 6 3 1 Underwriters Laboratories Listing 34 6 3 2 CE Conformity 34 6 4 Branch Circuit Protection and Wire Sizing 34 Table 6 4 M3528 Power Wiring Sizes and Fusing 35 6 5 Dimensions ...

Page 6: ...M3528 6 This page left blank intentionally ...

Page 7: ...tween this document and any publication and or documentation related to the AC drive system the latter shall have precedence 1 3 MANUAL REVISION Rev 00 is the original printing of the M3528 charger CE UL listed manual Output and jumper position drawings were clarified in rev 00a A6 chassis dimensions were corrected in rev 00b Terminology was updated in rev 00c Branch circuit protection and wire si...

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: ...S RIDE THRU MODULES Voltage regulators used for sag or outage protection of higher power systems M3534 SERIES RIDE THRU MODULES Voltage regulators used for sag or outage protection of lower power systems M3628 ULTRACAPACITOR SAFETY DISCHARGERS Automatic discharge for large capacitor storage banks for safety and quick maintenance entry 2 2 PART NUMBER BREAKDOWN Figure 2 1 Example of M3528 Part Numb...

Page 10: ...0 x 8 10 x 11 10 20A 2 3 GENERAL SPECIFICATIONS Table 2 3 General Specifications Chart PARAMETER SPECIFICATION AC Input Voltage 208 575VAC DC Input Voltage 295 650VDC DC Charging Voltage 175 675VDC Bulk Charge Equalize Voltage 2 9 above Charge Voltage Max DC Charging Current 5A 10A 20A Enclosure Rating Open Environmental Indoor use only Maximum operating altitude 2000m or 6500ft Ambient temperatur...

Page 11: ...S PRODUCT MAY GET HOT DURING OPERATION ALWAYS ALLOW AMPLE TIME FOR THE UNIT TO COOL BEFORE ATTEMPTING SERVICE 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 BEFORE ATTEMPTING INSTALLATION OR REMOVAL OF THIS PRODUCT BE SURE TO REVIEW ALL SYSTEM DOCUMENTATION FOR ...

Page 12: ...M3528 12 This page left blank intentionally ...

Page 13: ...ing carrier if damage is found 3 3 MOUNTING Mounting dimensions can be found in Section 6 Remove the M3528 from the shipping crate and mount it in the desired location using the mounting slots and holes and diameter studs or bolts Mounting hardware is not supplied with the M3528 3 4 WIRING AND USER CONNECTIONS Review this entire Section before attempting to wire the M3528 3 4 1 POWER WIRING DANGER...

Page 14: ...ONS An isolation transformer should be used with the M3528AC models to prevent the rectifier section of the M3528 charger from supplying power to the drive The AC Line connections should be made to the output of the isolation transformer The AC Line connections are not available on the M3528DC models CAUTION IT IS RECOMMENDED TO USE A DELTA DELTA ISOLATION TRANSFORMER IF A WYE CONFIGURATION IS USE...

Page 15: ...ENABLING FAILURE TO HEED THIS WARNING COULD RESULT IN DAMAGE TO THE SYSTEM DANGER FOR SYSTEMS THAT HAVE DC STORAGE ALWAYS MEASURE DC VOLTAGES AND FOLLOW PROPER PRECAUTIONS TO ENSURE THEY ARE AT SAFE LEVELS BEFORE MAKING CONNECTIONS 3 4 1 4 GROUNDING REQUIREMENTS All units come equipped with a ground stud that is connected to the module chassis Ground the chassis in accordance with local codes Typi...

Page 16: ...GER 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 L3 ASM 3460PS IS LOWER THAN PCC VOLTAGE 3 ASM 3460 PS WILL BE USED IF THE INPUT DC LEV...

Page 17: ...ONNECT 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 ...

Page 18: ...GROUND FAULT SENSING M3528AC CHARGER ULTRA CAP ENERGY STORAGE BANK DISCONNECT RIDE THRU DRIVE RIDE THRU DISCONNECT AUX CONTACT BUS M 3 ISOLATION TRANSFORMER STORAGE BUS STORAGE BUS M3534R CONNECTED DOWNSTREAM IF LINE CHOKES ARE USED RIDE THRU MUST BE FROM THE SAME FEED TRANSFORMER INVERTER AND RIDE THRU SHOULD BE POWERED 2 1 NOTES FUSES ONLY NEEDED WITH 85A MODELS ...

Page 19: ...User s Manual 19 Figure 3 4 M3534 40A Battery System ...

Page 20: ...M3528 20 This page left blank intentionally ...

Page 21: ...HEATING HYDROGEN GAS PRODUCTION FIRE AND EXPLOSIONS PERFORM THIS PROCEDURE ONLY PER THE INSTRUCTIONS FROM THE BATTERY MANUFACTURER While in Equalize mode the M3528 will charge the attached storage bank to a voltage slightly higher than the full voltage setting This can force long strings of batteries to have a more even charge across cells The equalize voltage is set at the factory to be 2 5 highe...

Page 22: ...M3528 22 Table 4 1 Equalize Mode Selection Jumper Details 3528C2 JUMPER 3528C3 JUMPER JUMPER POSITION MODE J6 J3 ON Timeout OFF Input Follow FIGURE 4 1 EQUALIZATION TIMING CHART ...

Page 23: ...B4 of the control boards These are suitable for remote operation of the system Figure 4 2 3528C2 Control Board Layout TB4 TB3 TB2 TB7 TB6 R102 R107 TB1 R37 R103 J6 LD1 POWER LD2 OVERTEMP LD4 CURRENT LIMIT LD3 CHARGE LD5 EQUALIZE J9 R71 TB5 NC NO NC NO J4 J2 INV NORM J7 J8 1 2 1 2 3 3 2 1 2 4 1 1 2 3 2 3 4 5 3 1 2 1 3528C2 ...

Page 24: ...trol Board Layout TB4 TB3 NC NO NC NO R40 R41 R86 R75 TB6 TB1 TB7 LD6 ENABLE TB5 TB2 J5 J6 LD1 POWER LD2 OVERTEMP LD3 CURRENT LIMIT LD4 CHARGE LD5 EQUALIZE J3 J7 J4 1 2 3 4 5 6 7 1 2 1 2 3 3 2 1 5 4 3 2 1 4 3 2 1 2 1 3528C3 INV NORM ...

Page 25: ...e Both the Enable Input and the Equalize Input must be activated for the charger to operate in Equalize mode 4 3 1 4 INPUT COMMON TB3 5 This terminal is the common for the inputs only If the internal power supply from TB3 1 is used there is no connection to this terminal This common is not connected to ground and should not be connected locally to avoid noise in the control circuits or ground loop...

Page 26: ... of the M3528 charger and can be used to monitor the operation of the charger 4 3 3 1 POWER This light illuminates green the M3528 internal power supply is operating properly 4 3 3 2 OVERTEMP This light illuminates red when the M3528 heatsink is above 65 C 150 F When this light is on the M3528 will not operate This light will turn off when the M3528 heatsink temperature returns to a safe level 4 3...

Page 27: ...ND RELEASE THIS CAN LEAD TO BATTERY DAMAGE EXPLOSIONS PROPERTY DAMAGE AND DEATH FOLLOW BATTERY BANK RECOMMENDATIONS FOR PER CELL FULL VOLTAGES AND PROCEDURES IMPROPER SETTING OF THE FULL VOLTAGE FOR CAPACITORS CAN CAUSE OVERCHARGING AND RESULT IN INTERNAL BREAKDOWN AND DAMAGE TO CAPACITOR BANKS THIS CAN LEAD TO CAPACITOR DAMAGE CATASTROPHIC FAILURE PROPERTY DAMAGE AND DEATH FOLLOW CAPACITOR BANK R...

Page 28: ...RGE CURRENT SPECIFICATIONS CAUTION CHECK STORAGE BANK MANUFACTURER S RECOMMENDATIONS BEFORE APPLYING POWER THE CURRENT LIMIT SETTING SHOULD BE VERIFIED BEFORE CONNECTING TO ANY ENERGY STORAGE BANK THE CURRENT LIMIT SETTING MUST BE CHECKED WITH A DISCHARGED BATTERY BANK IF THE BATTERY BANK IS NOT DISCHARGED THE M3528 CURRENT REQUIRED TO CHARGE THE BATTERY BANK WILL NOT BE THE FULL CURRENT LIMIT SET...

Page 29: ... 4 3 1 2 Verify the output voltage of the M3528 is appropriate for the battery bank being used See Section 4 4 and adjust if necessary 3 Activate the Equalize Input see Section 4 3 1 3 Verify the equalize voltage of the M3528 is appropriate for the battery bank being used See Section 4 4 and adjust if necessary 4 Remove Equalize Input and place a DC current clamp on the output wiring to the batter...

Page 30: ... if necessary 4 Remove Enable Input remove input power from M3528 and allow all voltages to drain to a safe level 5 Replace Storage Bus fuses and place a DC current clamp on the output wiring to the storage bank 6 Apply input power to M3528 ensure the storage bank is discharged and activate the Enable Input 7 Ensure that the charge current is appropriate for the storage bank being used See Section...

Page 31: ...e to check the voltage setpoint and current limits If the unit is enabled and the Current Limit indicator is on the current limit may be set too low Storage Bank will not fully charge Check the input voltage and verify that it is at least 50V higher than the desired charge voltage If the Charge indicator is on repeat the startup procedure to check the voltage setpoint and current limits If the uni...

Page 32: ...ve the following 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 DC bus voltage KVA rating of power source Source configuration Wye Delta and grounding This information will help us s...

Page 33: ...itable for use on a circuit capable of delivering not more than 10 000 RMS symmetrical amperes 600 volts maximum when protected by recommended fuses Suitable for use on a circuit capable of delivering not more than 10 000 RMS symmetrical amperes 480 volts maximum when protected by recommended fuses Table 6 2 Battery Bank Typical Values Not to replace manufacturer s recommendations SYSTEM VOLTAGE M...

Page 34: ... looped around Fair Rite 0444176451 five times through or greater coverage or equivalent shielding must be provided Braided shielded cable can be grounded at the ground terminal on the fuse plate marked All power wiring to the charger must use cables housed in metal conduit or equivalent shielding must be provided 6 3 2 4 CONDUCTED EMC FILTERING To meet CE conformity for conducted emissions a line...

Page 35: ...10 AWG 5A AC Input A60Q10 10A AC Input A60Q15 20A AC Input A60Q25 Note C class AC chargers does not include DC output fuses 6 5 DIMENSIONS AND MECHANICAL DRAWINGS Figure 6 1 A6 Chassis Dimensional Outline 6 25in 15 88cm 17 90in 45 47cm 18 60in 47 23cm 11 25in 28 58cm HANGING UNDERSIDE HORIZONTAL SURFACE MOUNTING INFO HORIZONTAL TO FLOOR UP UP VERTICAL SURFACE UP 6 MIN AIRFLOW AIRFLOW ...

Page 36: ...M3528 36 Figure 6 2 K8 Chassis Dimensional Outline 5 00in 12 70cm 19 30in 49 02cm 20 00in 50 80cm 8 12in 20 62cm 11 1in 28 2cm MINIMUM ...

Page 37: ...t as possible In this mode the Equalize voltage is used to set the target voltage higher than normal This allows the battery bank to slightly overcharge which allows the battery bank to come to full charge more quickly This can be a dangerous practice however as batteries can overheat and or release explosive hydrogen gas permanently damaging the battery bank If this method is used it is critical ...

Page 38: ...M3528 38 NOTES ...

Page 39: ......

Page 40: ...D_M3528_CMAN_ vACDC_CEUL_00i 01 23 2018 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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