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

Model M3645

Line Regen

Customer Reference Manual

Summary of Contents for M3645

Page 1: ...Web www bonitron com Tel 615 244 2825 Email info bonitron com Model M3645 Line Regen 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 o ver 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: ...g 17 Table 3 1 Transformer Ratings 18 Table 3 2 Power Terminal Specifications 30 Amp Unit M10 Chassis 19 Table 3 3 Power Terminal Specifications 50 Amp Unit M11 Chassis 19 Table 3 4 Power Terminal Specifications 100 Amp Unit M12 Chassis 19 Figure 3 2 30A 50A 100A Power Connections 20 Figure 3 3 30A 50A 100A Connection Locations 20 Table 3 5 Power Terminal Specifications 300 Amp Unit M15 Chassis 21...

Page 5: ... Output Connections 35 4 5 1 Local I O 24V Supply TB2 1 TB2 5 35 4 5 2 Enable Input TB2 2 35 4 5 3 Fault Recall Input TB2 3 35 4 5 4 Input COM TB2 4 35 4 5 5 Ready Output TB2 6 35 4 5 6 Overtemperature Output TB2 7 35 4 5 7 Output COM TB2 8 35 4 6 Startup 36 4 6 1 Pre power Checks 36 4 6 2 Startup Procedure and Checks 36 4 6 3 Cooling Fan 36 5 MAINTENANCE AND TROUBLESHOOTING 37 5 1 Periodic Testin...

Page 6: ...tt Loss 42 6 4 Certifications and RoHS 42 6 5 Fuse Selection 43 Table 6 6 Fuse Current Rating Requirements 43 Table 6 7 Fuse Voltage Rating Requirements 43 6 6 Dimensions and Mechanical Drawings 44 Figure 6 1 M3645 M10 Chassis Dimensional Outline 44 Figure 6 2 M3645 M11 Chassis Dimensional Outline 45 Figure 6 3 M3645 M12 Chassis Dimensional Outline 46 Figure 6 4 M3645 M15 Dimensional Outline 47 Fi...

Page 7: ...d any publication and or documentation related to the application the latter shall have precedence 1 3 MANUAL VERSION AND CHANGE RECORD Figure 3 8 and Table 6 5 were updated in Rev 01k Figures 3 7 3 8 and 6 4 were updated in Rev 01l Figure 3 8 was updated in Rev 01m Table 2 2 was updated in Rev 01n Updates were made to Section 6 2 and Table 6 5 in Rev 02a Updates to Figures 3 7 and 6 4 were made i...

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: ... the rise in bus voltage and prevent overvoltage faults The M3645 is current limiting and will automatically fold back or shut down in the event that unsafe conditions are detected With the optional digital display the current status of the M3645 is shown and fault records are stored along with a lifetime count of regenerative energy Up to two line regen units can be run in parallel for high power...

Page 10: ...tinuous DC Current Amps the regen module can regenerate The M10 M11 M12 frame sizes are capable of handling a 50 overload above this current rating for 60 seconds The M15 frame size is capable of a 25 overload above this current rating for 60 seconds 300A IDENTIFIER This single letter code is omitted except for 300A models Both a line reactor module and a line regen module are required for 300A mo...

Page 11: ...11 3 x 10 6 M12 100A Open Chassis 24 0 x 12 0 x 12 1 M15 300A Open Chassis 26 0 x 13 9 x 11 1 M15 Reactor 300A Open Chassis 17 9 x 18 8 x 15 2 See Section 6 5 for chassis mounting and dimensional outlines OPTIONS Two display options are available Table 2 4 Option Codes OPTION CODE DESCRIPTION D Digital Diagnostic Display L Basic LED Indicators NOTE The KIT 3645DD external display is only compatibl...

Page 12: ...DC Input Current 30 300A continuous 150 of rating 60 second overload for M10 M11 M12 chasses 125 of rating 60 second overload for M15 chassis Control Voltage Internal Indicators Power Regen Fault Optional 4 line character display Inputs Enable 24VDC 5mA Fault Recall 24VDC 5mA Outputs Ready 200VDC 100 mA Operating Temp 0 to 40OC Storage Temp 20O to 65OC Humidity Below 90 non condensing Atmosphere F...

Page 13: ...RODUCT SHOULD BE INSTALLED ON A NON FLAMMABLE SURFACE WITH CLEARANCES OF AT LEAST TWO INCHES IN ALL DIRECTIONS ALWAYS ALLOW AMPLE TIME FOR THE UNIT TO COOL BEFORE ATTEMPTING SERVICE ON THIS PRODUCT BEFORE ATTEMPTING INSTALLATION OR REMOVAL OF THIS PRODUCT BE SURE TO REVIEW ALL DRIVE AND OR RESISTIVE LOAD DOCUMENTATION FOR PERTINENT SAFETY PRECAUTIONS INSTALLATION AND OR REMOVAL OF THIS PRODUCT SHO...

Page 14: ...M3645 14 This page intentionally left blank ...

Page 15: ...om which the product was purchased 3 3 MOUNTING 3 3 1 M3645 LINE REGEN MOUNTING The installation site for the M3645 line regen should be chosen with several considerations in mind When mounting regen units in an enclosure power dissipation should be taken into account Refer to Section 6 3 Watt Loss for details The unit requires a minimum clearance of two 2 inches in all directions around it when n...

Page 16: ... Figure 3 1 M3645 Mounting Orientation Figure 3 1A Figure 3 1D HORIZONTAL SURFACE UP UP BONITRON Figure 3 1B Figure 3 1E UP HANGING UNDERSIDE Fig B UP BONITRON Figure 3 1C UP PARALLEL TO FLOOR BONITRON BONITRON ...

Page 17: ... of the panel The display is secured to the panel with a screw in each corner The unit requires a minimum clearance of one 1 inch in all directions around it The unit should not be exposed to falling debris or condensation The 12 foot cable provided with the display must be attached to TB5 on the control board of the M3645 and to TB3 on the ASM 3645D3 on the rear of the display See Figure 3 12 Onc...

Page 18: ... kVA 5 0 E30 23 kVA 2 9 H30 26 5 kVA 2 5 C30 33 kVA 2 0 L50 22 kVA 6 0 E50 38 kVA 3 4 H50 44 kVA 3 0 C50 55 kVA 2 4 L100 44 kVA 6 3 E100 75 5 kVA 3 6 H100 87 5 kVA 3 1 C100 109 5 kVA 2 5 L300 131 kVA 4 4 E300 226 5 kVA 2 5 H300 262 kVA 2 2 C300 327 5 kVA 1 7 Do not connect to a generator For further details contact Bonitron The regen units are not phase sensitive The AC line connections should hav...

Page 19: ...und stud provided ground the chassis in accordance with local codes Typically the wire gauge will be the same as is used to ground the attached drive Table 3 2 Power Terminal Specifications 30 Amp Unit M10 Chassis TERMINALS FUNCTION ELECTRICAL RATINGS WIRE SIZE MINIMUM WIRE SIZE MAXIMUM TORQUE L1 L2 L3 AC line outputs 30A 8 AWG 2 AWG 32 lb in DC DC DC bus inputs 30A 8 AWG 2 AWG 32 lb in GND Ground...

Page 20: ...M3645 20 Figure 3 2 30A 50A 100A Power Connections NO CONNECTION L1 L2 L3 GND 3ØAC INPUT DC BUS Figure 3 3 30A 50A 100A Connection Locations USER I 0 POWER CONNECTIONS AC SENSE ...

Page 21: ...4 4 lb in A2 B2 C2 AC line outputs 300A 350 kcmil 350 kcmil 275 lb in DC DC DC bus inputs 300A 350 kcmil 350 kcmil 275 lb in GND Ground 3 AWG 1 0 50 lb in Notes L1 L2 L3 AC control power and A2 B2 C2 AC line output are phase sensitive switching the order of phases to any of the inputs may result in damage to the regen L1 is the same phase as A1 L2 is the same phase as A2 L3 is the same phase as A3...

Page 22: ...M3645 22 Figure 3 5 300A Connection Locations ...

Page 23: ...3 6 M3645 30A 50A 100A User I O Terminal Specifications TERMINAL FUNCTION ELECTRICAL SPECIFICATIONS MIN WIRE AWG MAX WIRE AWG TORQUE TB2 1 24V 24VDC to TB2 5 18 16 2 2 lb in TB2 2 Enable Input 24VDC 5mA 18 16 2 2 lb in TB2 3 Fault Recall Input 24VDC 5mA 18 16 2 2 lb in TB2 4 Input COM COM to TB2 2 3 18 16 2 2 lb in TB2 5 24V COM COM to TB2 1 18 16 2 2 lb in TB2 6 Ready Output NO 250V 150 mA 18 16 ...

Page 24: ...4 Figure 3 7 M3645 Enable Input Using Internal Power Supply TB2 24V 1 2 3 4 5 6 7 8 ENABLE FAULT RECALL Figure 3 8 M3645 Enable Input Using External Power Supply TB2 24V 24V 1 2 3 4 5 6 7 8 ENABLE FAULT RECALL ...

Page 25: ... AC input should maintain a low impedance path back to the grid No reactors should be connected upstream of the regen unit without consulting Bonitron for instructions The DC input should be connected to a fixed bus whether from a common bus supply or from the output of a VFD This should never be connected to a switching source such as the braking resistor terminals on some drives The DC input sho...

Page 26: ...M3645 26 Figure 3 9 M3645 30A 50A 100A Regen Power Wiring CHOPPER BRAKING INTERNAL VFD INVERTER EXTERNAL RESISTOR M 3 3 Disconnect Isolation Transformer if used REGEN DC DC Line Reactor if used ...

Page 27: ...User s Manual 27 Figure 3 10 M3645 300A Regen Customer Power Wiring ...

Page 28: ... DC M3345CBM DRIVE 1 DC DRIVE 2 DC DRIVE 3 DC DRIVE 3 DC DRIVE 2 DC DRIVE 1 DC L3 L2 L1 AC LINE NEG REGEN REGEN POS DRIVE 1 CHOPPER BRAKING INTERNAL INVERTER DC DRIVE 2 CHOPPER BRAKING INTERNAL INVERTER DC DRIVE 3 CHOPPER BRAKING INTERNAL INVERTER DC REGEN REGEN DC DC DC DC ...

Page 29: ...User s Manual 29 Figure 3 12 M3645 Connection with KIT 3645DD External Panel Mounted Display USER I 0 POWER CONNECTIONS ...

Page 30: ...M3645 30 This page intentionally left blank ...

Page 31: ...EATURES 4 2 1 DIGITAL DISPLAY The optional display is a four line eighty character LCD which shows information about the present status of the regen as well as records of faults and energy throughput 4 2 2 LEDS Red yellow and green LEDs indicate the status of the regen 4 2 2 1 POWER GREEN INDICATOR The green LED indicates that the unit is powered on 4 2 2 2 REGEN ACTIVE YELLOW INDICATOR The yellow...

Page 32: ...RGY RECORDS SCREEN This screen allows the user to reset the record of energy regenerated by the unit This screen also displays the firmware version present on the unit Up Energy Records screen Enter Confirm reset 4 3 4 FAULTS SCREEN This screen shows the present fault state of the unit scrolling through all faults detected Left Metering screen Right Metering screen Down Fault Records screen 4 3 5 ...

Page 33: ... Fast Differential Overvoltage 5 Fast Sync Loss 1 Slow IGBT Driver 2 Slow Phase Overcurrent 3 Slow Phase Loss 4 Slow DC Undervoltage 5 Slow Regen Power On Precharge Not Complete 6 Slow Frequency Detect Failure Note Slow 1 blink per second Fast 3 blinks per second 4 4 1 FEEDBACK UNDERVOLTAGE This fault indicates that the M3645 s DC bus feedback circuitry has failed This fault will latch until manua...

Page 34: ... due to line noise These faults will latch until cleared by toggling the Enable input 4 4 8 PHASE LOSS These faults indicate that the Regen has lost voltage on one or more of the AC line phases These faults clear automatically when voltage is reestablished If these faults do not clear it typically indicates that a line fuse has failed 4 4 9 DC UNDERVOLTAGE This fault indicates that the DC voltage ...

Page 35: ...s case faults must be cleared by cycling power to the Regen 4 5 3 FAULT RECALL INPUT TB2 3 For units with no digital display the last fault record can be retrieved by disabling the regen unit and activating this input The last fault code will blink out until the unit is re enabled For units with a digital display this input has no function 4 5 4 INPUT COM TB2 4 All user inputs are common to this t...

Page 36: ...tem The Power indicator on the front panel should illuminate The fan should start then stop within ten seconds Enable the M3645 by placing 24VDC on the Enable input Table 3 6 or Table 3 7 for 300A units The status contact should be closed after a 2 second delay which is an indication that unit is ready for operation Observe the current on the digital display or with a current clamp for systems wit...

Page 37: ...come on check any overcurrent devices or disconnects upstream of the regen If the power lamp will not come on it is likely that the regen is damaged and needs to be repaired 5 3 2 READY OUTPUT WILL NOT CLOSE The Ready output indicates that the module is enabled and in a ready condition When the power is applied to the module the Ready output will normally close after a startup delay of approximate...

Page 38: ... 1 for transformer sizing instructions With 300A units confirm that the phase rotation of the AC control power connections between the reactor and the transistor module match the power connections 5 3 5 FEEDBACK UNDERVOLTAGE Reset the M3645 by toggling the enable input 4 5 2 If the fault returns contact Bonitron for assistance 5 3 6 OVERTEMPERATURE Check the ambient temperature If the temperature ...

Page 39: ...conjunction with a Precharge Not Complete fault this indicates that control power to the unit has been reset No actual sync loss condition has occurred 5 3 10 IGBT DRIVER This fault can be reset the M3645 by toggling the Enable input 4 5 2 If the fault cannot be cleared or occurs frequently the unit may be damaged Contact Bonitron for assistance If two M3645 units are operated in parallel IGBT fau...

Page 40: ...assistance 5 3 15 FREQUENCY DETECT FAILURE Power the M3645 down and check all incoming AC and DC fuses or overcurrent devices 5 3 16 TECHNICAL HELP BEFORE YOU CONTACT US If technical help is required please have the following information available when contacting Bonitron 615 244 2825 or email to info bonitron com Model number of unit Serial number of unit Name of original equipment supplier if av...

Page 41: ...0W Table 6 3 Ratings and Specifications 460 480VAC MODEL NUMBERS CHASSIS STYLE DC REGEN CURRENT POWER MAX CONT WATT LOSS CONT PEAK CONT PEAK M3645 H030 M10 30A 45A 28 8HP 43 2HP 180W M3645 H050 M11 50A 75A 48 0HP 72 0HP 265W M3645 H100 M12 100A 150A 96 0HP 144 0HP 470W M3645 H300T M15 300A 375A 288 0HP 360 0HP 2980W Table 6 4 Ratings and Specifications 575 600VAC MODEL NUMBERS CHASSIS STYLE DC REG...

Page 42: ... each of the listed regen units When installing regen units in an additional enclosure consideration should be given to internal temperature rise The watt loss rating in these tables is based upon the maximum continuous regen capability of each unit Applications that do not utilize the full capacity may be calculated by using the percentage of loading for the individual unit The M3645 is more than...

Page 43: ... Use Tables 6 6 and 6 7 when initially constructing the system Note AC fuses must be J type or equivalent Table 6 6 Fuse Current Rating Requirements MODEL NUMBER AC DC FUSE CURRENT RATING M3645 x030 40A M3645 x050 60A M3645 x100 125A M3645 x300 350A Table 6 7 Fuse Voltage Rating Requirements SYSTEM VOLTAGE AC FUSE VOLTAGE RATING DC FUSE VOLTAGE RATING 230 240VAC 240 VAC 350 VDC 380 480VAC 600 VAC ...

Page 44: ...M3645 44 6 6 DIMENSIONS AND MECHANICAL DRAWINGS Figure 6 1 M3645 M10 Chassis Dimensional Outline ...

Page 45: ...User s Manual 45 Figure 6 2 M3645 M11 Chassis Dimensional Outline ...

Page 46: ...M3645 46 Figure 6 3 M3645 M12 Chassis Dimensional Outline ...

Page 47: ...User s Manual 47 Figure 6 4 M3645 M15 Dimensional Outline ...

Page 48: ...M3645 48 Figure 6 5 M645 x300R Line Reactor Dimensional Outline ...

Page 49: ...e 6 6 KIT 3645DD External Display Dimensional Outline 5 00 127 0 mm 7 50 190 5 mm 6 83 173 5 mm 4 13 104 8 mm 7 00 177 8 mm 19 4 8 mm 4 50 114 3 mm 25 6 4 mm 25 6 4 mm R 13 R3 2 mm R 13 R3 2 mm n 19 n4 8 mm 19 4 8 mm CUTOUT ...

Page 50: ...M3645 50 6 7 BLOCK DIAGRAM Figure 6 7 M3645 30A 50A 100A Functional Block Diagram ...

Page 51: ...ere T is torque measured in lb ft 1 0 lb ft 1 355818 Nm WK2 is the total inertial load to be decelerated lb ft2 1 0 lb ft2 0 04214011 kg m2 ΔN is the change in rotational speed rpm 308 is a constant ton is time required to decelerate the load s CALCULATE MOTOR POWER Calculating the power HP regenerated 𝑃 𝑇𝑁𝑚𝑎𝑥 5252 Where Nmax is the maximum rotational speed rpm The constant 5252 has units of lb ft...

Page 52: ...e cost of energy must be known With these application variables the following calculation may be made to determine the cost savings CALCULATE SAVINGS PER YEAR Calculating total savings per year in dollars 𝑆 𝐶𝑃 0 746 𝑘𝑊 𝐻𝑃 𝐷𝐻𝑡𝑜𝑛 𝑡𝑐𝑦𝑐𝑙𝑒 Where S is Savings per year C is the cost in dollars per kW P is the regenerated power D is the number of days the system is operated H is the number of hours per da...

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

Page 54: ...M3645 54 ...

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Page 56: ...D_M3645_CMAN_vall_02f 07 12 2016 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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