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User’s Manual

 

35 

5. 

S

TART

-

UP

,

 

M

AINTENANCE

,

 AND 

T

ROUBLESHOOTING

 

5.1.  S

TART

-

UP 

/

 

F

IELD 

T

EST 

P

ROCEDURE 

 

1. 

Ensure the M3534 has been properly installed and is disabled. 

2. 

Ensure the M3534 DC bus is disconnected from the drive DC bus. 

3. 

Ensure the drive is operating properly with the M3534 disconnected. 

4. 

Apply power to the input of the M3534 and observe the following conditions: 

 

DC bus voltage should rise 

 

Power light should be ON 

 

Overtemperature light should be OFF 

 

Ride-Thru Active light should be OFF 

 

All status outputs are in the expected state.  If there are faults on the system, 
check the configuration of the status output jumpers.  

5. 

Enable the M3534 with either the enable input or the digital display. 

6. 

Initiate the test mode with the Test input or display panel.   

 

The DC bus should rise for as long as the test is performed.   

7. 

Turn off the power to the M3534 and watch the DC bus voltage fall.  The M3534 
will become active. 

 

The Ride-Thru Active light should turn ON when the M3534 starts to operate. 

 

The DC bus will hold at the DC bus threshold voltage setting momentarily 
while the filter capacitors drain. 

8. 

With the M3534 and drive power off, connect the DC bus of the M3534 to the 
DC bus of the drive. 

9. 

Turn on power to the M3534 and the attached drive. 

10. 

Monitor  the  DC  bus  voltage  and  current  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  put  the  M3534  into  Test  mode  by 
activating the Test input or using the display panel. 

 

DC bus voltage should rise to the test boost level. 

 

Motor should not lose speed or torque. 

 

DC bus current should flow from M3534 to drive. 

 

Drive input current should decrease. 

The M3534 and drive system should now be ready to be put into service. 

 

    

 

CAUTION! 

I

F THE OUTPUT 

DC

 BUS DROPS BELOW 

70%

 THE 

M3534

 WILL HAVE TO GO THROUGH 

PRE

-

CHARGE AGAIN

. 

5.2.  M

AINTENANCE 

I

TEMS

 

The M3534 is designed to require no maintenance.  However, Bonitron recommends 
a yearly test of the system in order to ensure the system is functioning properly.  If the 
system is equipped with displays, then the cycle counters should indicate the number 
of events since the last reset.  If there are more than 10 events per month, the DC bus 
threshold voltage setting should be checked and/or adjusted.   

 

 

Содержание M3534-I3

Страница 1: ...Web www bonitron com Tel 615 244 2825 Email info bonitron com Model M3534 I3 Ride Thru Voltage Regulator Customer Reference Manual ...

Страница 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 ...

Страница 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...

Страница 4: ... Control Interface and I O Wiring 15 Table 3 4 User I O Basic Connections with 3534I3 Board 16 Table 3 5 User I O Connections with DP10 Display 16 Figure 3 1 M3534 Interconnections with DP10 17 3 5 Typical Configurations 18 Figure 3 2 M3534R without Energy Storage 18 Figure 3 3 M3534R with Electrolytic Capacitor Storage Bank 19 Figure 3 4 M3534R with Ultracapacitor Storage Bank 20 Figure 3 5 M3534...

Страница 5: ...ng 38 Table 6 6 M3534R 20A Derating Values 38 Table 6 7 M3534R 40A Derating Values 38 6 3 Efficiency Power Consumption 39 6 4 Branch Circuit Protection and Wire Sizing 39 Table 6 6 Minimum Input Power Wiring Sizes and Fusing 39 6 5 Dimensions and Mechanical Drawings 40 Figure 6 1 M3534 A5 Chassis Dimensional Outline 40 Figure 6 2 M3534 K7 Chassis Dimensional Outline 41 Figure 6 3 M3534 K9 Chassis ...

Страница 6: ...M3534 6 This page intentionally left blank ...

Страница 7: ...any publication and or documentation related to the AC drive system the latter shall have precedence 1 3 MANUAL REVISION Options were updated in Rev 00a Notations added to connectors in Figures 3 2 3 3 3 4 3 5 and 3 6 in Rev 00b The manual template was updated in Rev 00c Figures 3 4 and 3 5 were updated in Rev 00d Figure 6 5 was updated in Rev 00e Updates were made to Section 4 4 for the Enable In...

Страница 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...

Страница 9: ...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 M3534 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 use existing AC feed wiring...

Страница 10: ...tage Rating Codes RATING CODE NOMINAL VOLTAGE AC LINE DRIVE BUS L 230VAC 325VDC E 380 415VAC 540 585VDC H 460VAC 650VDC POWER RATING The power rating indicates the maximum power in kilowatts that can safely be handled by the M3534 and is represented by a 3 digit value based on the nominal DC system voltage rating and the maximum output current rating of the M3534 For instance the rating code for a...

Страница 11: ...3 GENERAL SPECIFICATIONS Table 2 3 General Specifications PARAMETER SPECIFICATION Input AC Voltage 208 480 VAC Input DC Voltage 200 585 VDC Output DC Voltage 265 650 VDC DC Bus Current Rating 20 85 ADC Power Rating 6 50 kW Inactive Power Consumption 40 W Duty Cycle Full Load 1 Sag Outage Duration 2 seconds 60 seconds Enclosure Rating Open Operating Temperature 0 to 40ºC Storage Temperature 20 to 6...

Страница 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 ...

Страница 13: ...the system if other components cause excessive heat buildup in the enclosure 3 2 UNPACKING Inspect the shipping crate and M3534 for damage Notify the shipping carrier if damage is found 3 3 MOUNTING Mounting dimensions can be found in Section 6 1 Remove the M3534 from the shipping crate and mount it in the desired location using the mounting slots and holes and diameter studs or bolts Mounting har...

Страница 14: ...onnections TERMINAL DESIGNATION FUNCTION WIRING SPECIFICATION CONNECTION TORQUE AC LINE L1 L2 L3 AC Input 600 VAC 12 4 AWG Box Connection 32 lb in STORAGE BUS DC Input 600 VAC 12 4 AWG Box Connection 32 lb in DRIVE BUS DC Output 600 VAC 12 4 AWG Box Connection 32 lb in Ground 600 VAC 10 lug ring or spade 15 lb in Main power connections should be made with copper wire use compression fitting lugs W...

Страница 15: ...e to do so can cause severe 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 3 DRIVE BUS CONNECTIONS The M3534 must have a DC bus connection directly to the DC bus filter capacitors within the drives Connections cannot be made through the braking terminals or with ...

Страница 16: ...e on a different module than the M3534 They are made to the 3660I3 interface module Refer to the KIT 3660DD4 manual for operational and functional details 3 4 2 3 CONNECTIONS WITH DP10 ANALOG DISPLAY When the M3534 is used with the DP10 analog display the interconnections are made through TB5 on the 3534I3 board and TB1 on the 3660D1 board Table 3 5 User I O Connections with DP10 Display 3660D1 TE...

Страница 17: ...ure 3 1 M3534 Interconnections with DP10 TB5 TEST RTR 8 7 6 5 4 3 2 1 3534I3 10 9 COM 15V RTA OT 3660D1 J1 B A TB4 V TB1 8 7 6 5 4 3 2 1 COM TEST PCC RTR RTA VF OT 1 2 3 4 5 RESET NRESET AMBER RED RED GREEN GREEN GREEN VF ...

Страница 18: ...M3534 18 3 5 TYPICAL CONFIGURATIONS Figure 3 2 M3534R without Energy Storage ...

Страница 19: ...User s Manual 19 Figure 3 3 M3534R with Electrolytic Capacitor Storage Bank ...

Страница 20: ... LINE 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 ...

Страница 21: ...User s Manual 21 Figure 3 5 M3534B 40A with Battery Storage Bank ...

Страница 22: ...M3534 22 This page intentionally left blank ...

Страница 23: ...ge protection 4 3 OPERATION MODES AND CONFIGURATION 4 3 1 NORMAL OPERATION During normal operation the M3534 will monitor the output DC bus When the output DC bus voltage goes below the DC bus threshold voltage the M3534 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 maintain the same outpu...

Страница 24: ... through discrete I O points located on the 3534I3 board Figure 4 1 3534I3 Interface Board Layout 10 OT RTR RTA TEST COM 15V TB5 9 8 7 6 5 4 3 2 1 TB4 6 5 4 3 2 1 ENABLE DISABLE TB1 1 2 3 4 TB2 1 2 3 4 5 6 7 8 TB3 1 2 J3 NC NO READY OUTPUT ACTIVE OUTPUT J2 NO NC J1 NC NO ...

Страница 25: ...User s Manual 25 Figure 4 2 3534I3 I O Diagram ...

Страница 26: ...M3534 26 Figure 4 3 3534R2 Control Board Layout 1 2 3 4 5 6 TB1 3 2 1 TB2 6 5 4 3 2 1 TB3 R40 5 4 3 2 1 TB5 2 1 TB4 NC NO NC NO J2 J1 PWR OT RTA 3534R2 ...

Страница 27: ...User s Manual 27 Figure 4 4 3534R3 Control Board Layout PWR OT RTA 2 1 TB7 4 3 2 1 2 1 NC NO NO NC J3 J2 TB5 TB6 4 3 2 1 4 3 2 1 6 5 TB4 TB3 TB2 TB1 1 2 2 3 1 3534R3 R35 ...

Страница 28: ...E CORRECTLY IF THE UNIT IS NOT PROPERLY CONFIGURED PAY SPECIAL ATTENTION TO THIS CONFIGURATION AS THIS CAN CAUSE THE UNIT TO NOT PROTECT THE DRIVE IN THE CASE OF A POWER SAG OR OUTAGE 4 4 1 2 TEST INPUT TB5 6 10 The Test input is used to make the M3534 go into Test mode Connect the internal supply 15V positive at TB5 10 to the test input at TB 5 6 to go into Test mode When the DP10 display is used...

Страница 29: ...eady output has 3700 Vrms Input Output isolation 4 4 2 4 RIDE THRU ACTIVE TB5 5 DP10 DISPLAY This output is pulled to the internal supply common when the M3534 is currently regulating the output DC bus of the system This indicates a power sag or outage on the main AC input power of the attached drive or that a drive input fuse has opened This output will also be pulled to the internal supply commo...

Страница 30: ...3534 is unloaded or lightly loaded this light may not illuminate 4 4 4 3 OVERTEMP The Overtemperature light will illuminate red when the temperature of the heatsink or the inductor has risen to an unsafe level This light will remain illuminated until the temperature returns to a safe level The M3534 will be inhibited and will not function while in an overtemperature condition 4 4 5 DISPLAY OPTIONS...

Страница 31: ...There are two remote inputs to control the activity of the M3534 Enable and Test They allow remote initiation of these inputs but the digital display system allows the M3534 to be tested locally DIGITAL DISPLAY OUTPUTS There are two outputs that can be configured for various indications on the digital display DEFAULT OPERATION When the M3534 is ordered with the KIT 3660DD4 digital display the fact...

Страница 32: ...may overheat and not be available in the event of an actual sag or outage The M3534 DC bus threshold voltage setting is determined by the drive installation Consult the manufacturers specifications on the attached drive and make sure that the DC bus threshold voltage is above this value For instance many 460 480VAC input drives have an undervoltage trip point of 400VDC This may allow the drive to ...

Страница 33: ...eshold voltage setpoint for approximately one second while the M3534 input filter capacitor discharges The DC bus will then continue to drop 4 Read the DC bus voltage as it is being maintained This is the DC bus threshold voltage setting 4 5 2 DETERMINING THE DC BUS THRESHOLD VOLTAGE SETTING USING THE TEST MODE The DC bus threshold voltage setting may be checked with the drive connected using the ...

Страница 34: ...tage 100VDC from this reading shows that the actual DC bus threshold voltage setting is 585VDC 4 5 3 ADJUSTING THE DC BUS THRESHOLD VOLTAGE SETTING Adjustment of R40 on the 3534R2 control board or R35 on the 3534R3 control board see Figures 4 2 4 3 is used to adjust the DC bus threshold voltage setting Adjusting the pot in a clockwise direction will raise the setting Alternately a counter clockwis...

Страница 35: ...ld voltage setting momentarily while the filter capacitors drain 8 With the M3534 and drive power off connect the DC bus of the M3534 to the DC bus of the drive 9 Turn on power to the M3534 and the attached drive 10 Monitor the DC bus voltage and current 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 put t...

Страница 36: ...luctuates During Test Mode Check DC bus threshold voltage setting and test boost level Overvoltage shutdown can occur if settings are too high causing an oscillation effect Lower threshold level and retry Stays in Test Mode Check to make sure test input is properly configured and not active Precharge Overheated Not enough time between power up power down during testing Pre charge can only be done ...

Страница 37: ...C Table 6 3 M3534R Minimum Input Voltages SYSTEM VOLTAGE MINIMUM AC INPUT VOLTAGE MINIMUM DC INPUT VOLTAGE IUV LEVEL 230 VAC 115 VAC 160 VDC 380 415 VAC 190 VAC 265 VDC 460 VAC 230 VAC 320 VDC Minimum AC input for full power output operation without energy storage Minimum DC input for full power output operation with energy storage Table 6 4 M3534B Battery Bank Typical Values SYSTEM VOLTAGE MINIMU...

Страница 38: ...e is 1 at full rated load Fuses recommended for use with the M3534 are Gould Shawmut A70QS series Buss FWP series or equivalent semiconductor fuses Suitable for use on a circuit capable of delivering not more than 100 000 rms symmetrical amperes with10ms time constant 700 volts maximum when protected by recommended fuses 6 2 DERATING Table 6 6 M3534R 20A Derating Values PERCENT SAG PERCENT LOAD CU...

Страница 39: ...ent for 2x surge capability The recommended minimum current rating for the power source fusing is listed in Table 6 6 based on the DC bus current rating of the M3534 The maximum rating of the steady state power source fusing should be 225A for cabinets with disconnects The field wiring sizes listed in Table 6 6 ensure a 10V drop for wire lengths of 100 feet and are compatible with the recommended ...

Страница 40: ...M3534 40 6 5 DIMENSIONS AND MECHANICAL DRAWINGS Figure 6 1 M3534 A5 Chassis Dimensional Outline ...

Страница 41: ...User s Manual 41 Figure 6 2 M3534 K7 Chassis Dimensional Outline ...

Страница 42: ...M3534 42 Figure 6 3 M3534 K9 Chassis Dimensional Outline ...

Страница 43: ...User s Manual 43 Figure 6 4 M3534 A9 Chassis Dimensional Outline ...

Страница 44: ...77 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 n 4 8 mm 19 4 8 mm CUTOUT Figure 6 6 DP10 Display Cutout and Mounting Dimensions 6 00 152 4mm 5 00 127mm 4 10 22 14mm 5 10 129 54mm 4x R 125 3 18mm 4x R 125 3 18mm 5 50 25 6 35mm 4 50 114 3mm 25 6 35mm 4x Ø 188 4 78mm 20 5 08MM 20 5 08MM CUTOUT ...

Страница 45: ...trol system that requires backup to allow the drive to keep operating like sensors or external commands from PLC or relay logic These 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 M3534 Some larger fra...

Страница 46: ...eptable for full power backup 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 energ...

Страница 47: ... bank 𝑉 should be 320 VDC These data are available in the specifications for the specific M3534R by nominal system voltage 7 2 3 PEAK CURRENT The peak current from the capacitor bank will occur at the minimum voltage This can be estimated from the equation I P V For our example I 75kW 320Vdc 235A 7 2 4 CAPACITOR SPECIFICATIONS At this point a specific capacitor s characteristics can be used It is ...

Страница 48: ... 𝑉 for this calculation V V I Esr V 46V 235A 0 01Ω 43 7V For our example the minimum number of caps in a series string would be n V V 320V 43 7V 8 7 2 6 AVAILABLE JOULES At this point the available maximum joules for the string can be calculated V n V 𝑉 8 46𝑉 368𝑉 The capacitor voltage at the end of the discharge 𝑉 will be given by V V n I Esr V 320V 8 235A 0 01Ω 338V The total capacitance of the ...

Страница 49: ...7 1 is a block diagram of a diode sharing example Below are some basic guidelines for using diodes in this manner for M3534 applications 9 Drives should have equivalent DC bus levels as would be found on equal size drives of a common manufacturer 10 Drives should be on same AC feed and grounding There must be no isolation transformers between the drives and or M3534 modules Different feeds may hav...

Страница 50: ...M3534 50 Figure 7 1 Diode Sharing Example VFD BRAKING RESISTOR DISCONNECT DC BUS MODEL M3460 M3534 DC OUTPUT M 3 VFD BRAKING RESISTOR M 3 ...

Страница 51: ...User s Manual 51 NOTES ...

Страница 52: ...M3534 52 ...

Страница 53: ...User s Manual 53 ...

Страница 54: ...M3534 54 ...

Страница 55: ......

Страница 56: ...D_M3534_vRB_00L 12 17 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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