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bonitron M3645P Reference Manual

Regenerative dc bus power supply
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Model M3645P
Regenerative DC Bus Power Supply
Customer Reference Manual
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Web: www.bonitron.com
Tel: 615-244-2825
Email: info@bonitron.com

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David Szurek
February 25, 2025

I want to regenerate a Kollmorgen AKD2G 24 amp brushless servo drive. What do you suggest?

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Summary of Contents for bonitron M3645P

  • Page 1 Model M3645P Regenerative DC Bus Power Supply 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.

  • Page 4: Table Of Contents

    Figure 3-8: M3645P 30A, 50A, 100A Power Wiring ................26 Figure 3-9: M3645P 150A, 225A, and 300A Power Wiring ..............27 Figure 3-10: M3645P Multiple Drives Field Wiring Diagram ............... 28 Figure 3-11: M3645P 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: M3645P Screen Tree ......................32 4.4. Faults ............................33 Table 4-1: Blink Codes .......................... 33 4.4.1. Feedback Undervoltage ....................33 4.4.2.
  • Page 6 Table 6-7: Fuse Voltage Rating Requirements ..................43 6.6. Dimensions and Mechanical Drawings ..................44 Figure 6-1: M3645P M10 Chassis Dimensional Outline ............... 44 Figure 6-2: M3645P M11 Chassis Dimensional Outline ............... 45 Figure 6-3: M3645P M12 Chassis Dimensional Outline ............... 46 Figure 6-4: M3645P M15 Dimensional Outline ..................

  • Page 7: Introduction

    1.2. URPOSE AND COPE This manual is a user’s guide for the Model M3645P regenerative DC bus power supply. It provides you with the necessary information to successfully install and use the M3645P 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

    M3645P 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

    M3645P rectifies the AC line and supplies power to the load. During a braking event, as the DC bus rises above the AC line peak, the M3645P 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

    RECHARGE PTION ODEL UMBER The base model number for all regenerative DC bus power supply units is M3645P. OLTAGE ATING A code letter represents the 3-phase AC line input voltage to the power supply 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 NOTE: The KIT 3645DD external display is only compatible with “L” versions of the M3645P regenerative DC bus power supply. Only a single display can be used for each M3645P. The M3645P is unable to power more than a single display.

  • Page 12: General Specifications Chart

    M3645P 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 M3645P This page intentionally left blank...

  • Page 15: Installation Instructions

    The M3645P must be properly oriented for proper heat flow through the unit. The M3645P 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 M3645P Figure 3-1: M3645P 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 M15 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 M3645P and to TB3 on the ASM 3645D3 on the rear of the display. See Figure 3-12.
  • Page 18 E300 226.5 kVA 2.5% H300 262 kVA 2.2% Do not connect to a generator. For further details, contact Bonitron. The AC line connections should have short-circuit current protection. Recommended fuses are listed in Section 6.5. 150A, 225A, 300A U 3.4.1.2.
  • Page 19 Never attach the DC bus input of the M3645P 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.
  • Page 20 M3645P Ground 6 AWG 50 lb-in Notes: All power wire should be selected to match or exceed the voltage rating of the unit. ° Field wiring for terminals will be copper 75 C wire only. Figure 3-2: Power Connections L1 L2 L3 + NO CONNECTION 3ØAC INPUT...
  • Page 21 A2. L3 is the same phase as A3. All power wire should be selected to match or exceed the voltage rating of the unit. ° Field wiring for terminals will be copper 75 C wire only. Figure 3-4: M3645P 150A, 225A, and 300A Power Connections...
  • Page 22 M3645P Figure 3-5: M3645P 150A, 225A, and 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 M3645P units in parallel. Note: since the Overtemperature Fault cannot shut down the power supply directly, the Overtemperature output should be used to disable the drive in the event of an Overtemperature Fault.
  • Page 24 M3645P Figure 3-6: M3645P Enable Input Using Internal Power Supply Figure 3-7: M3645P 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 a M3645P unit with generic VFDs. There are many other configurations that may be applied, providing basic connection criteria are maintained, including: • The AC terminals should have a low impedance path back to the grid.
  • Page 26 M3645P Figure 3-8: M3645P 30A, 50A, 100A Power Wiring...
  • Page 27 User’s Manual Figure 3-9: M3645P 150A, 225A, and 300A Power Wiring...
  • Page 28 M3645P Figure 3-10: M3645P Multiple Drives Field Wiring Diagram...
  • Page 29 User’s Manual Figure 3-11: M3645P Connection with KIT 3645DD, External Panel Mounted Display...
  • Page 30 M3645P This page intentionally left blank...

  • Page 31: Operation

    4.1. UNCTIONAL ESCRIPTION The M3645P regenerative DC bus power supply enables energy being generated by an overhauling motor to be efficiently returned to the power grid. It also supplies power to one or more drives through their DC bus terminals.

  • Page 32: Digital Display Operation

    M3645P 4.3. IGITAL ISPLAY PERATION These screens display information about the M3645P on units equipped with digital displays. 4.3.1. ETERING CREEN This screen displays the present DC bus voltage, DC bus current, power being supplied or regenerated, and how long the unit has been powered on since shipment.

  • Page 33: Faults

    This fault indicates that the unit’s DC bus feedback circuitry has failed. This fault will latch until manually cleared by toggling the Enable Input. If this fault does not clear, it typically indicates that damage to the M3645P has occurred and must be repaired.

  • Page 34: Dc Overvoltage

    M3645P DC O 4.4.3. VERVOLTAGE This fault indicates that the DC voltage on the bus has exceeded 1000V. This fault latches until manually cleared. 4.4.4. IFFERENTIAL VERVOLTAGE This fault indicates that the DC bus is more than 200V higher than the AC line peak.

  • Page 35: Regen Power-On/Precharge Not Complete

    User’s Manual 4.4.10. EGEN OWER RECHARGE OMPLETE These faults indicate that the unit has been powered on in the last ten seconds. This fault will clear automatically. If this fault does not clear, it typically indicates that damage to the unit has occurred. 4.4.11.

  • Page 36: Overtemperature Output - Tb2-7

    Otherwise damage to the power supply may result. The M3645P will continue to rectify incoming voltage and operate with the temperature switch open. Continued operation with the temperature switch open can cause dangerous...

  • Page 37: Maintenance And Troubleshooting

    5.3. ROUBLESHOOTING There are no user serviceable parts within the M3645P. 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

    If the unit is operating in current limit, it may be undersized for the application. ▪ If the M3645P is connected to the AC line through a transformer, the transformer may not be large enough to handle the regenerated currents. See section 3.4.1.1 for transformer sizing instructions.

  • Page 39: Differential Overvoltage

    If the fault cannot be cleared, or occurs frequently, the unit may be damaged. Contact Bonitron for assistance. If two M3645P 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

    If the fault cannot be cleared, or occurs frequently, the unit may be damaged. Contact Bonitron for assistance. 5.3.15. REQUENCY ETECT AILURE Power the M3645P down and check all incoming AC and DC fuses or overcurrent devices. – B 5.3.16. ECHNICAL EFORE 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):...

  • Page 41: Ngineering Ata

    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 M3645P-L030 14.4HP 21.6HP 180W M3645P-L050 24.0HP 36.0HP 265W M3645P-L100 100A 150A 48.0HP 72.0HP 470W M3645P-L150T 2980W...

  • Page 42: Derating Parallel Units

    M3645P models with 30A, 50A, and 100A ratings are listed under UL508C, file number E204386. The M3645P 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

    M3645P 6.6. IMENSIONS AND ECHANICAL RAWINGS Figure 6-1: M3645P M10 Chassis Dimensional Outline...
  • Page 45 User’s Manual Figure 6-2: M3645P M11 Chassis Dimensional Outline...
  • Page 46 M3645P Figure 6-3: M3645P M12 Chassis Dimensional Outline...
  • Page 47 User’s Manual Figure 6-4: M3645P M15 Dimensional Outline...
  • Page 48 M3645P Figure 6-5: M3645 M15 Line Reactor Dimensional Outline...
  • Page 49 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

    M3645P 6.7. LOCK IAGRAM Figure 6-7: Typical Customer Application...

  • 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

    M3645P 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 M3645P...
  • Page 56 D_M3645P_CMAN_vall_00f 10/27/2017 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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