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Summary of Contents for bonitron M3645
- Page 1 Model M3645 Line Regen Customer Reference Manual ● ● Web: www.bonitron.com Tel: 615-244-2825 Email: info@bonitron.com...
- Page 2 Bonitron has seen thousands of products engineered since 1962 and welcomes custom applications. With engineering, production, and testing all in the same facility, Bonitron is able to ensure its products are of the utmost quality and ready to be applied to your application.
- Page 3 RIVE PTIONS In 1975, Bonitron began working with AC inverter drive specialists at synthetic fiber plants to develop speed control systems that could be interfaced with their plant process computers. Ever since, Bonitron has developed AC drive options that solve application issues associated with modern AC variable frequency drives and aid in reducing drive faults.
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Page 4: Table Of Contents
Figure 3-9: M3645 30A, 50A, 100A Regen Power Wiring ..............26 Figure 3-10: M3645 300A Regen Customer Power Wiring ..............27 Figure 3-11: M3645 Multiple Drives / Regens Field Wiring Diagram ..........28 Figure 3-12: M3645 Connection with KIT 3645DD, External Panel Mounted Display ......29 4. O ..........................31 PERATION 4.1. - Page 5 4.3.3. Reset Energy Records Screen ................... 32 4.3.4. Faults Screen ........................32 4.3.5. Fault Records Screen ......................32 Figure 4-1: M3645 Screen Tree ......................32 4.4. Faults ............................33 Table 4-1: Blink Codes .......................... 33 4.4.1. Feedback Undervoltage ....................33 4.4.2.
- Page 6 Figure 6-4: M3645 M15 Dimensional Outline ..................47 Figure 6-5: M645-x300R Line Reactor Dimensional Outline ..............48 Figure 6-6: KIT 3645DD, External Display Dimensional Outline ............49 6.7. Block Diagram ..........................50 Figure 6-7: M3645 30A, 50A, 100A Functional Block Diagram............50 7. A ..........................51 PPENDIX 7.1.
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Page 7: Introduction
1.2. URPOSE AND COPE This manual is a user’s guide for the Model M3645 line regen. It provides you with the necessary information to successfully install and use the M3645 modules in your application. In the event of any conflict between this document and any publication and/or documentation related to the application, the latter shall have precedence. -
Page 8: Symbol Conventions Used In This Manual And On Equipment
M3645 1.4. YMBOL ONVENTIONS SED IN THIS ANUAL AND ON QUIPMENT Earth Ground or Protective Earth AC Voltage DC Voltage DANGER: Electrical hazard - Identifies a statement that indicates a shock or electrocution hazard that must be avoided. DANGER! DANGER: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. -
Page 9: Product Description
50Hz or 60Hz input. As the DC bus rises above the AC line peak, the M3645 redirects current from the DC bus into the AC line to limit the rise in bus voltage and prevent overvoltage faults. -
Page 10: Part Number Breakdown
HASSIS TYLE PTIONS Base Model Number The base model number for all line regen units is M3645. OLTAGE ATING A code letter represents the 3-phase AC line input voltage to the regen module. The voltage rating must be selected for the system voltage that will be applied. See Table 2-1 for available voltage ratings. -
Page 11: Table 2-3: Chassis Styles
NOTE: The KIT 3645DD external display is only compatible with “L” versions of the M3645 line regen. Only a single display can be used for each line regen. The line regen is unable to power more than a single display. -
Page 12: General Specifications Chart
M3645 2.3. ENERAL PECIFICATIONS HART Table 2-5: General Specifications ARAMETER PECIFICATION Voltage Rating Voltage Min Voltage Max 50 or 60 Hz 207 VAC 253 VAC AC Line Voltage 342 VAC 418 VAC 414 VAC 506 VAC 518 VAC 600 VAC ... -
Page 13: General Precautions And Safety Warnings
User’s Manual 2.4. ENERAL RECAUTIONS AND AFETY ARNINGS H IGH VOLTAGES MAY BE PRESENT N EVER ATTEMPT TO OPERATE THIS PRODUCT WITH THE ACCESS DOORS OR COVERS OPENED N EVER ATTEMPT TO SERVICE THIS PRODUCT WITHOUT FIRST DISCONNECTING POWER TO AND FROM THE UNIT DANGER! ... - Page 14 M3645 This page intentionally left blank...
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Page 15: Installation Instructions
Once the installation site has been selected as outlined above, the unit should be mounted in place. The M3645 must be properly oriented for proper heat flow through the unit. The M3645 must be mounted with the rear surface of the unit to the mounting surface. The unit may be mounted vertically (Figure 3-1D), or with its backplane down and parallel to the ground (Figure 3-1A). -
Page 16: Figure 3-1: M3645 Mounting Orientation
M3645 Figure 3-1: M3645 Mounting Orientation Figure 3-1A Figure 3-1D BONITRON HORIZONTAL SURFACE Figure 3-1B Figure 3-1E HANGING UNDERSIDE Fig B Figure 3-1C PARALLEL TO FLOOR... -
Page 17: M3645-X300R Line Reactor Mounting
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. -
Page 18: Table 3-1: Transformer Ratings
NTER ODULE IRING FOR For M3645 rated for 300A an individual line reactor must be used in front of each M3645-x300T transistor module. See Figure 3-10 for wiring diagram. The user must wire both the control AC wiring from the M3645-x300R line reactor to the M3645-x300T transistor module. - Page 19 Never attach the DC bus input of the M3645 to braking terminals on the AC drive, commonly marked “BR”. These terminals are intended for use with an external resistor, and are not directly connected to the bus filter capacitors of the drive.
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Page 20: Figure 3-2: 30A, 50A, 100A Power Connections
M3645 Figure 3-2: 30A, 50A, 100A Power Connections L1 L2 L3 + NO CONNECTION 3ØAC INPUT DC BUS Figure 3-3: 30A, 50A, 100A Connection Locations USER SENSE POWER CONNECTIONS... -
Page 21: Table 3-5: Power Terminal Specifications - 300 Amp Unit – M15 Chassis
User’s Manual The AC control wiring to the M3645-x300T is phase sensitive. If the AC control wiring is not in phase with power wiring catastrophic damage to equipment will result. DANGER! Table 3-5: Power Terminal Specifications - 300 Amp Unit – M15 Chassis... -
Page 22: Figure 3-5: 300A Connection Locations
M3645 Figure 3-5: 300A Connection Locations... -
Page 23: I/O Wiring
24VDC supply, or from the internal 24V supply. To use the internal 24V supply, TB2-4 and TB2-5 must be shorted. No additional I/O wiring is required for running multiple M3645 line regens in parallel. Table 3-6: M3645 30A, 50A, 100A User I/O Terminal Specifications... -
Page 24: Figure 3-7: M3645 Enable Input Using Internal Power Supply
M3645 Figure 3-7: M3645 Enable Input Using Internal Power Supply Figure 3-8: M3645 Enable Input Using External Power Supply... -
Page 25: Typical Configurations
ONFIGURATIONS The diagrams shown in Figures 3-9, 3-10, 3-11 illustrate typical connections of the M3645 regen units with generic VFDs. There are many other configurations that may be applied providing a basic connection criterion is maintained such as: The AC input should maintain a low impedance path back to the grid. -
Page 26: Figure 3-9: M3645 30A, 50A, 100A Regen Power Wiring
M3645 Figure 3-9: M3645 30A, 50A, 100A Regen Power Wiring... -
Page 27: Figure 3-10: M3645 300A Regen Customer Power Wiring
User’s Manual Figure 3-10: M3645 300A Regen Customer Power Wiring... -
Page 28: Figure 3-11: M3645 Multiple Drives / Regens Field Wiring Diagram
M3645 Figure 3-11: M3645 Multiple Drives / Regens Field Wiring Diagram... -
Page 29: Figure 3-12: M3645 Connection With Kit 3645Dd, External Panel Mounted Display
User’s Manual Figure 3-12: M3645 Connection with KIT 3645DD, External Panel Mounted Display... - Page 30 M3645 This page intentionally left blank...
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Page 31: Operation
UNCTIONAL ESCRIPTION The M3645 line regen enables energy being generated by an over-hauling motor to be efficiently returned to the power grid. Alternative solutions typically consist of dissipating the returned energy in a resistor or simply allowing the motor to coast uncontrolled to a stop. -
Page 32: Digital Display Operation
M3645 4.3. IGITAL ISPLAY PERATION These screens display information about the M3645 on units equipped with digital displays or those equipped with the KIT 3645DD. 4.3.1. ETERING CREEN This screen displays the present DC bus voltage, DC regen current, regen power, and how long the unit has been powered on since shipment. -
Page 33: Faults
4.4. AULTS The M3645 monitors a number of different fault conditions which prevent the regen from operating. Some faults latch until they are reset by toggling the enable input. Faults that do not latch will automatically clear when the fault condition is no longer present. -
Page 34: Sync Loss
HASE VERCURRENT These faults indicate that the current the M3645 is driving into one leg of the AC line has exceeded a safe operating level. This is likely due to line noise. These faults will latch until cleared by toggling the Enable input. -
Page 35: Input / Output Connections
NABLE NPUT This input enables the M3645. Faults are reset on a rising edge of this input. Note that the unit will not operate unless this input is on. This unit can be jumpered high if the unit does not need remote operation. In this case, faults must be cleared by cycling power to the Regen. -
Page 36: Startup
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. -
Page 37: Maintenance And Troubleshooting
5.3. ROUBLESHOOTING There are no user serviceable parts within the M3645 regen unit. If you are still experiencing problems after you have reviewed this whole section, you may contact Bonitron for additional assistance at (615) 244-2825. -
Page 38: Feedback Undervoltage
5.3.5. EEDBACK NDERVOLTAGE Reset the M3645 by toggling the enable input. (4.5.2) If the fault returns, contact Bonitron for assistance. 5.3.6. VERTEMPERATURE Check the ambient temperature. If the temperature is above 40°C, the unit may not be able to cool properly at full load. -
Page 39: Differential Overvoltage
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 faults may indicate that the parallel combination is undersized for the application. 5.3.11. -
Page 40: Frequency Detect Failure
M3645 If the fault does not clear automatically, power the M3645 down and check all incoming AC and DC fuses or overcurrent devices. Ensure that DC bus voltage is present at the terminals of the regen, at the expected voltage. Check the polarity of the DC bus connections. If the polarity is incorrect the regen will not be able to complete precharge. -
Page 41: Engineering Data
User’s Manual NGINEERING 6.1. ATINGS HARTS Table 6-1: Ratings and Specifications – 230 - 240VAC DC R EGEN URRENT OWER ODEL HASSIS UMBERS TYLE M3645-L030 14.4HP 21.6HP 180W M3645-L050 24.0HP 36.0HP 265W M3645-L100 100A 150A 48.0HP 72.0HP 470W M3645-L300T 300A 375A 144.0HP... -
Page 42: Table 6-5: Derating Regens In Parallel
M3645 models with 30A, 50A, and 100A ratings are listed under UL508C, file number E204386. The M3645 line regen is suitable for use on a circuit capable of delivering not more than 65 kA RMS symmetrical amperes at the rated voltage, when protected by the recommended AC fuses. -
Page 43: Fuse Selection
ELECTION Blown fuses typically indicate a semiconductor device failure or a severe transient. In any case, blown fuses should not be replaced without first consulting Bonitron as catastrophic damage can occur. Use Tables 6-6 and 6-7 when initially constructing the system. -
Page 44: Dimensions And Mechanical Drawings
M3645 6.6. IMENSIONS AND ECHANICAL RAWINGS Figure 6-1: M3645 M10 Chassis Dimensional Outline... -
Page 45: Figure 6-2: M3645 M11 Chassis Dimensional Outline
User’s Manual Figure 6-2: M3645 M11 Chassis Dimensional Outline... -
Page 46: Figure 6-3: M3645 M12 Chassis Dimensional Outline
M3645 Figure 6-3: M3645 M12 Chassis Dimensional Outline... -
Page 47: Figure 6-4: M3645 M15 Dimensional Outline
User’s Manual Figure 6-4: M3645 M15 Dimensional Outline... -
Page 48: Figure 6-5: M645-X300R Line Reactor Dimensional Outline
M3645 Figure 6-5: M645-x300R Line Reactor Dimensional Outline... -
Page 49: Figure 6-6: Kit 3645Dd, External Display Dimensional Outline
User’s Manual Figure 6-6: KIT 3645DD, External Display Dimensional Outline 5.00 R.13 127.0 mm 4.8 mm R3.2 mm 4.8 mm R.13 R3.2 mm 4.13 4.8 mm 104.8 mm 6.83 7.50 CUTOUT 173.5 mm 190.5 mm 7.00 177.8 mm 4.50 114.3 mm 6.4 mm 6.4 mm... -
Page 50: Block Diagram
M3645 6.7. LOCK IAGRAM Figure 6-7: M3645 30A, 50A, 100A Functional Block Diagram... -
Page 51: Appendix
User’s Manual PPENDIX 7.1. PPLICATION OTES 7.1.1. IZING THE EGENERATION The line regeneration unit is sized for the amount of DC bus current, I which it must carry. To obtain the amount of DC bus current needed during deceleration; the load and motor inertias, desired change in RPM, and required stopping time must be known. -
Page 52: Calculating Energy Savings
M3645 7.1.2. ALCULATING NERGY AVINGS The regen directs energy from the mechanical load to the power distribution line, where the energy is available to other connected loads. These units provide system energy savings over dynamic braking kits, because the net energy required from the distribution system is reduced by the regenerated energy. - Page 53 User’s Manual NOTES...
- Page 54 M3645...
- 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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