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bonitron M3534B, Customer Reference Manual

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

 

 
 
 
 
 
 
 
 
 
 
 
 
 

 

 
 
 
 
 
 
 
 
 

Legacy Model M3534R-RY 

20A DC Bus Ride-Thru 

for Variable Frequency AC Drives 

 
 

 

 

Customer Reference Manual 

Summary of Contents for M3534B

Page 1: ...Web www bonitron com Tel 615 244 2825 Email info bonitron com Legacy Model M3534R RY 20A 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 Solutions...

Page 4: ...Interconnection with Existing Drive System 17 4 OPERATION 19 4 1 Functional Description 19 Figure 4 1 Basic 20A M3534R RTM Internal Power Flow Circuit Diagram 19 4 2 Features 20 4 2 1 Signal I O 20 Table 4 1 Control Signal Details 3534R2 Control Board for Standard Models 21 Table 4 2 Control Board Control Signal Details for Modules with DP10 I3 Option 21 Table 4 3 Status Signal Component Details 3...

Page 5: ...ecommended Input Power Wiring Sizes And Power Source Fusing 34 Table 6 4 Input Power Wiring Sizes and Fusing 34 6 4 Dimensions and Mechanical Drawings 35 Figure 6 1 M3534R Control Module A5 Chassis Dimensional Outline 35 6 5 Supplemental Drawings 36 6 5 1 Schematics 36 Figure 6 2 3534R2 TB5 Status Signal 36 Figure 6 3 3534I3 Control and Status Signal 36 7 APPENDICES 37 7 1 Drive Ride Thru Selectio...

Page 6: ...M3534R 20A 6 This page intentionally left blank ...

Page 7: ...duced through 2009 It will provide the user with the necessary 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 R...

Page 8: ...entifies 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 rega...

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: ...WER RATING KW The Power Rating indicates 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 12kW RTM is 012 CHASSIS STYLE The 20 amp Model M3534R RTM com...

Page 11: ...ime Less than 100 milliseconds Inactive Power Usage Less than 15W Fault Status Indicators Power PWR Overtemp OT Ride Thru Active RTA 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 contacts availa...

Page 12: ... 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: ...ON The installation site for the module should be chosen with several considerations in mind The unit has a Type 1 rating 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 allo...

Page 14: ...tem for field connection points within that system The DC bus should always be connected directly to the drive output capacitor bank Connecting upstream of the DC bus inductors may cause damage to the drive and Ride Thru module Typical Field Connection terminal layouts for the M3534R RTM are shown in Figures 3 1 and 3 2 Figure 3 3 shows a typical power interconnection of the M3534R Ride Thru Modul...

Page 15: ...ns may be made across TB3 5 and TB3 6 of the ASB 3534R2 Control Board Torque terminal screws to 2 lb in max See Figures 3 2 and 4 2 3 4 2 2 DISABLE INPUT CONNECTIONS Disable input connections may be made across TB4 1 Positive and TB4 2 Negative of the ASB 3534R2 Control Board Torque terminal screws to 2 lb in max See Figures 3 2 and 4 2 For units utilizing the DP10 Option connect at I3 TB4 6 and 5...

Page 16: ...M3534R 20A 16 Figure 3 1 A5 Chassis Field Connection Terminal Layout Figure 3 2 A5 Internal Layout with I3 Interface Dwg 120211 and 120213 Rev 20120621 ...

Page 17: ...User s Manual 17 3 5 TYPICAL CONFIGURATIONS Figure 3 3 Typical 20 Amp M3534R Interconnection with Existing Drive System Dwg 080455 Rev 20100903 ...

Page 18: ...M3534R 20A 18 This page intentionally left blank ...

Page 19: ...e RTM bus down with it 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 onl...

Page 20: ... Open position Refer to the ASB 3534R2 Control Board layout drawing in Figure 4 2 for the locations of each of the components listed in Tables 4 1 thru 4 6 4 2 1 3 ASB 3534R2 STATUS OUTPUT CONFIGURATION JUMPERS FOR MODELS WITH DP10 OPTION I3 BOARD Fault Signals are available on the 3534I3 board FOR STANDARD MODELS The purpose and setting for each of the configuration jumpers provided on the ASB 35...

Page 21: ...V 3kV Isolation Terminal TB4 6 5 State Jumper Selectable Table 4 3 Status Signal Component Details 3534R2 Control Board for Standard Models BOARD FAULT STATUS COMPONENTS FAULT STATUS SIGNAL COMPONENT ID OVERTEMP OT RIDE THRU ACTIVE RTA 3534R2 Jumper J1 J2 Relay Contact Ratings 1 Amp at 24VDC 5 Amp at 115 VAC 1 Amp at 24VDC 5 Amp at 115 VAC Indicator LD2 LD3 Control Board Terminations TB5 5 3 TB5 4...

Page 22: ...ATES PWR OT RTA OT J1 RTA J2 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 in normal condition ON OFF OFF O X X O Power on in Overtemp condition 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 INDICATORS 4 2 2 1 ASB 3534R2 CONTROL BOARD The ASB 3534R2 ...

Page 23: ...r 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 K2 This indicator is ON and the relay is energized when ride through activity is present must have a minimum of 0 25 amps load current 4 2 2 2 ASB 3534I3 INTERFACE BOARD Figure 4 ...

Page 24: ...E OR CABINET DOOR SYSTEM STATUS DISPLAY AND TEST MODULE The Ride Thru Diagnostic Display Panel provides visual indication of the Ride Thru module s operating status Currently there are 3 DPxx display panel configurations The most common combinations of features are detailed in Table 4 7 and Figure 4 5 The monitored functions include POWER RIDE THRU ACTIVE and OVERTEMP In addition this panel provid...

Page 25: ...vel Bonitron typically sets the DC bus threshold to be approximately 10 below nominal level For example Bonitron sets all 460VAC systems to hold the 640VDC bus to 585VDC Refer to the inverter documentation for details on adjusting its under voltage trip setting if the factory default setting is other than 15 below nominal DC bus level 4 3 2 STARTUP PROCEDURE AND CHECKS 1 De sensitize or disable in...

Page 26: ...e Thru module becomes active to regulate the DC bus voltage to the Threshold setpoint voltage 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 rip...

Page 27: ...ring 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 READ THE DC BUS METER AND SUBTRACT THE BOOST VOLTAGE When the...

Page 28: ... 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 Adjustment pot R40 on the 3534R2 control board see Figure 4 2 is used to set the Threshold voltage level Adjusting the pot in a clockwise direction will rai...

Page 29: ...ening the AC disconnect to the Ride Thru module if equipped Refer to Section 4 4 1 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 u...

Page 30: ...de 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 ...

Page 31: ...on recommends the capacitors be checked or replaced every 20 years 5 2 1 2 CLEANING Cleaning cycle depends entirely upon the surrounding environment and the quality of air inside cabinet Cleaning off dust debris or chemical build up on high voltage bus bars or other exposed components may be necessary If cleaning is needed 1 Remove power and allow all voltages to drain 2 Check for residual voltage...

Page 32: ... Check for constant current on the negative or positive DC bus links Check for missing phase in drive power feed Check for low line level Check temp sensors on IGBT heatsink Check activity record too much activity may cause overtemp Check precharge network for overheating cause of low bus and constant activity TEST won t work Check DC bus level too high causes no test activity Check blown fuse LED...

Page 33: ...ESHOLD MIN AT FULL LOAD NOMINAL 208VAC 265 VDC 255 VDC 290 VDC 230VAC 285 VDC 275 VDC 320 VDC 380 400 415VAC 485 VDC 475 VDC 535 565 VDC 460VAC 585 VDC 575 VDC 640 VDC Table 6 2 Notes The Min at Full Load column in the table above lists the minimum voltage level at which the DC bus will be maintained when the RTM is active This is usually about 90 of the nominal DC bus level and 7 10V below the TH...

Page 34: ...wiring sizes and power source fuse ratings for the model M3534R Cabinet Mounted and Open chassis 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 4 Input Power Wiring Sizes and Fusing SYSTEM HP SYSTEM...

Page 35: ...User s Manual 35 6 4 DIMENSIONS AND MECHANICAL DRAWINGS Figure 6 1 M3534R Control Module A5 Chassis Dimensional Outline Dwg 120209 Rev 20120619 ...

Page 36: ...M3534R 20A 36 6 5 SUPPLEMENTAL DRAWINGS 6 5 1 SCHEMATICS Figure 6 2 3534R2 TB5 Status Signal Figure 6 3 3534I3 Control and Status Signal Dwgs 060165 Rev 20090615 and 090364 Rev 20091230 ...

Page 37: ...S FOR DRIVE RIDE THRU SYSTEMS The following items should be considered when installing a Bonitron Ride Thru 1 Inverter logic voltage must be backed up Most 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 ...

Page 38: ...m Bonitron can source complete capacitor cabinets or individual capacitors This section gives some instruction for sizing and specifying these storage devices The process described below is a good way to estimate the capacitor bank required Since the discharge characteristic of a capacitor bank with a constant power load is a nonlinear differential equation optimizing the capacitor bank selection ...

Page 39: ...eginning of discharge 𝑉𝐶𝑎𝑝𝐸𝑛𝑑 The capacitor string voltage at the end of the discharge 𝑉𝐶𝑎𝑝𝑀𝑎𝑥 Maximum charge voltage for the 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 o...

Page 40: ...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 of ...

Page 41: ... 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 42: ...ual size drives of a common manufacturer see Figure 7 2 b If positive and negative busses are different potentials the standard precharge may overheat and the Ride Thru may be constantly active 2 Drives should be on same AC feeder in same cabinet or close proximity a Different feeds may have different potentials and may cause circulating currents or ground faults 3 Drives should have a common line...

Page 43: ...User s Manual 43 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 44: ...M3534R 20A 44 NOTES ...

Page 45: ...User s Manual 45 ...

Page 46: ...M3534R 20A 46 ...

Page 47: ......

Page 48: ...D_M3534R_CMAN_v20Aall_03a 03 17 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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