Summary of Contents for bonitron M3528
- Page 1 Model M3528 Charger Module A6 and K8 Chassis 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
1.1. Who Should Use This Manual ......................7 1.2. Purpose and Scope ........................... 7 1.3. Manual Revision ..........................7 Figure 1-1: M3528 Charger in the A6 Chassis ...................... 7 1.4. Symbol Conventions Used in this Manual and on Equipment ............8 PRODUCT DESCRIPTION ......................9 2.1. - Page 5 6.3.2. CE Conformity ............................34 6.4. Branch Circuit Protection and Wire Sizing..................34 Table 6-4: M3528 Power Wiring Sizes and Fusing ..................... 35 6.5. Dimensions and Mechanical Drawings..................35 Figure 6-1: A6 Chassis Dimensional Outline ....................... 35 Figure 6-2: K8 Chassis Dimensional Outline ....................... 36 APPENDICES ..........................
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Page 7: Introduction
1.2. URPOSE AND COPE This manual is a user’s guide for the model M3528 charger module. It will provide the user with the necessary information to successfully install, integrate, and use the M3528 with battery or capacitive energy storage systems. -
Page 8: Symbol Conventions Used In This Manual And On Equipment
M3528 1.4. YMBOL ONVENTIONS SED IN THIS ANUAL AND ON QUIPMENT Earth Ground or Protective Earth AC Voltage DC Voltage 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
User’s Manual RODUCT ESCRIPTION Bonitron’s M3528 charger is a voltage limited current source used to charge higher voltage batteries, ultracapacitor or double layer capacitor energy storage strings. Variable frequency drive systems can require energy storage to back up power for mission critical or continuous processes. -
Page 10: General Specifications
URRENT ATING The current rating indicates the maximum charging current for the M3528 in DC Amps. This rating is directly represented by a 3-digit value. For instance, the rating for a 10ADC M3528 is indicated as 010. Note the maximum charging current for C class charger is 5ADC. -
Page 11: General Precautions And Safety Warnings
User’s Manual 2.4. ENERAL RECAUTIONS AND AFETY ARNINGS • IGH VOLTAGES MAY BE PRESENT • EVER ATTEMPT TO OPERATE THIS PRODUCT WITH THE ENCLOSURE COVER REMOVED • EVER ATTEMPT TO SERVICE THIS PRODUCT WITHOUT FIRST DISCONNECTING POWER TO AND FROM THE UNIT •... - Page 12 M3528 This page left blank intentionally...
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Page 13: Installation Instructions
NSTALLATION NSTRUCTIONS The M3528 has an open type chassis construction. It is intended to be part of a larger variable frequency drive system, and will require different hardware for interconnection based on the installation. An appropriate enclosure may need to be provided to protect personnel from contact and the system from damage. - Page 14 ONNECTIONS An isolation transformer should be used with the M3528AC models to prevent the rectifier section of the M3528 charger from supplying power to the drive. The AC Line connections should be made to the output of the isolation transformer. The AC Line connections are not available on the M3528DC models.
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Page 15: Control Interface And I/O Wiring
ONTROL NTERFACE AND IRING Control wiring allows for remote enabling and monitoring of the M3528. Inputs can be a dry contact using an internally generated, isolated supply, or an external 24VDC signal. Table 3-3: User I/O Connections With 3528C2 or 3528C3 Boards... -
Page 16: Typical Configurations
M3528 3.5. YPICAL ONFIGURATIONS Figure 3-1: M3460 Ultracapacitor System CHOPPER... - Page 17 User’s Manual Figure 3-2: M3460 Battery System...
- Page 18 M3528 Figure 3-3: M3534 Ultracapacitor System...
- Page 19 User’s Manual Figure 3-4: M3534 40A Battery System...
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Page 21: Operation
In Input Follow mode, the M3528 is in Equalize mode as long as the Equalize input is active. In Timeout mode, a pulse may be used to put the M3528 into Equalize mode and an internal timer will remove the M3528 from Equalize mode after two hours. If the Equalize input stays high for more than two hours, the 3528 will return to the normal full voltage after two hours. - Page 22 M3528 Table 4-1: Equalize Mode Selection Jumper Details 3528C2 3528C3 UMPER OSITION UMPER UMPER Timeout Input Follow 4-1: E IGURE QUALIZATION IMING HART...
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Page 23: I/Oand Features
User’s Manual 4.3. EATURES Control and monitoring signals are available on the terminal strips marked TB3 and TB4 of the control boards. These are suitable for remote operation of the system. Figure 4-2: 3528C2 Control Board Layout NC NO NC NO INV NORM R102 R103... - Page 24 M3528 Figure 4-3: 3528C3 Control Board Layout 3 2 1 5 4 3 2 1 NC NO NC NO ENABLE 3528C3 POWER OVERTEMP CURRENT LIMIT NORM CHARGE EQUALIZE 1 2 3 4 5 6 7 1 2 3...
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Page 25: Input Terminals - Tb3
The internal supply is capable of supplying 50mA at 24VDC. It is intended to be used for the inputs of the M3528 locally, and should not be used as any other source. There is not sufficient power to serve as signaling for the output terminals. -
Page 26: Indicators
Ready TB4 - 3 4.3.3. NDICATORS The LED indicators are located on the front panel of the M3528 charger, and can be used to monitor the operation of the charger. 4.3.3.1. OWER This light illuminates green the M3528 internal power supply is operating properly. -
Page 27: Operational Adjustments
THE FINAL VOLTAGE WILL NOT BE KNOWN • HE FULL VOLTAGE SETTING CANNOT BE SET ABOVE THE RECTIFIED M3528. INPUT OF THE The full voltage setting can be adjusted with R37 on the 3528C2 board or R41 on the 3528C3 board. Adjusting the potentiometer clockwise increases the voltage setting and adjusting the potentiometer counter-clockwise decreases the voltage setting. -
Page 28: Equalize Voltage Adjustment
M3528 4.4.2. QUALIZE OLTAGE DJUSTMENT MPROPER SETTING OF THE EQUALIZE VOLTAGE SETTING CAN CAUSE OVERCHARGING OVERHEATING AND OR HYDROGEN GAS PRODUCTION AND RELEASE HIS CAN LEAD TO BATTERY DAMAGE EXPLOSIONS PROPERTY DANGER! DAMAGE AND DEATH OLLOW BATTERY BANK RECOMMENDATIONS FOR PER CELL FULL VOLTAGES AND PROCEDURES The equalize voltage is factory preset for 2.5% increase above full voltage... -
Page 29: Start-Up Procedures, Maintenance, & Troubleshooting
Verify proper wiring and ensure the disconnect or contactor between the M3528 and battery bank is open. Apply input power to M3528 and activate the Enable Input. (see Section 4.3.1.2.) Verify the output voltage of the M3528 is appropriate for the battery bank being used. -
Page 30: Start-Up Procedure For Use With Capacitors
Apply input power to M3528 and activate the Enable Input (see Section 4.3.1.2.) Verify the output voltage of the M3528 is appropriate for the storage bank being used. This can be done by measuring the DC voltage at the inside terminals to the Storage Bus fuse block inside the M3528. -
Page 31: Troubleshooting
CTION Check incoming voltage. If no voltage, check input fuses within the charger. If the incoming fuses are blown, contact Bonitron for assistance No Panel Indicators Lit before replacing fuses. This can be an indication of further damage to the charger. -
Page 32: Technical Help - Before You Call
The AC line to line voltage on all 3 phases • The DC bus voltage • KVA rating of power source • Source configuration Wye/Delta and grounding This information will help us support you much more quickly. Please contact us at (615) 244-2825 or through www.bonitron.com... -
Page 33: Engineering Data
460 - 480VAC 400VDC 480VDC 540VDC 554VDC 575 - 600VAC 500VDC 600VDC 675VDC 692VDC 6.2. FFICIENCY OWER ONSUMPTION Table 6-3: M3528 Watt Loss Chart TANDBY ODEL HARGING PERATION 5 Amp 300W maximum 10 Amp 300W maximum 20 Amp 600W maximum... -
Page 34: Certifications
ABORATORIES ISTING The M3528 is UL Listed under UL-508C standards for use with ultracapacitors for Land H voltage classes. The M3528 is UL Listed under UL-1017 for use with battery banks for L and H voltage classes. CE C 6.3.2. -
Page 35: Dimensions And Mechanical Drawings
User’s Manual Table 6-4: M3528 Power Wiring Sizes and Fusing INIMUM IRCUIT RANCH ECOMMENDED ODEL ROTECTION USING IELD IRING LASS ELAY IZES 10A DC Input A60Q40 5A AC Input A60Q10 10 AWG 10A AC Input A60Q15 20A AC Input A60Q25 Note: C class AC chargers does not include DC output fuses. - Page 36 M3528 Figure 6-2: K8 Chassis Dimensional Outline 11.1in [28.2cm] MINIMUM 5.00in [12.70cm] 20.00in 19.30in [50.80cm] [49.02cm] 8.12in [20.62cm]...
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Page 37: Appendices
HOOSING AN NPUT There are two input types of M3528 chargers, AC input or DC input. For M3534 20A and 40A ride-thru systems connecting to a single drive, the DC input charger can be used. For all other ride-thru systems, the AC input charger with an isolation transformer is recommended. - Page 38 M3528 NOTES...
- Page 40 D_M3528_CMAN_ vACDC_CEUL_00i 01/23/2018 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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