Related Manuals for bonitron M3460
Summary of Contents for bonitron M3460
- Page 1 Model M3460 Ride-Thru Voltage Regulator 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
Table 3-3: User I/O Connections with 3460M6 Board ................16 Table 3-4: User I/O Connections with 3660D1 Board ................17 Figure 3-1: M3460 Interconnections with DP10 ..................17 3.5. Typical Configurations ....................... 18 Figure 3-2: M3460R Typical Configuration without Energy Storage ............ 18 Figure 3-3: M3460R Typical Configuration with Electrolytic Capacitor Storage Bank ...... - Page 5 Table 6-10: M3460B Input Power Wiring Sizes and Fusing ..............45 6.5. Dimensions and Mechanical Drawings ..................46 Figure 6-1: M3460-R10 Chassis Dimensional Outline ................46 Figure 6-2: M3460-R9 Chassis Dimensional Outline ................47 Figure 6-3: M3460-R11 Chassis Dimensional Outline ................48 Figure 6-4: M3460-R2 Chassis Dimensional Outline ................
- Page 6 Minimum Series String ........................54 7.2.6. Available Joules ..........................54 7.3. Steering Diode Sharing with a Bonitron M3460 Ride-Thru ............55 Figure 7-1: Diode Sharing Example ....................... 56 7.4. Sag Only Installations & Circulating Currents ................57 Figure 7-2: M3460R Typical Configuration without Energy Storage ............ 57 Figure 7-3: M3460R Typical Configuration with Current Flow ............
-
Page 7: Introduction
1.2. P URPOSE AND COPE This manual is a user’s guide for the model M3460 ride-thru voltage regulator. It will provide the user with the necessary information to successfully install, integrate, and use this in a variable frequency AC drive system. -
Page 8: Symbol Conventions Used In This Manual And On Equipment
M3460 1.4. S 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! -
Page 9: Product Description
All Bonitron ride-thru products connect in parallel with the drive, thus increasing system availability and reliability. The M3460 regulates incoming voltage to the DC bus of the variable frequency drive. This allows the drive to “ride through” these events while maintaining motor speed and torque without experiencing drive shutdown. -
Page 10: Documents
The power rating indicates the maximum power in kilowatts that can safely be handled by the M3460 and is represented by a 3-digit value based on the nominal DC system voltage rating and the maximum output current rating of the M3460. For instance, the rating code for a 100kW M3460 is 100. -
Page 11: General Specifications
User’s Manual Table 2-2: Chassis Size Codes 3460B 3460R IMENSIONS HASSIS 28.00” x 16.00” x 13.50” 85 A 85-127 A 34.00” x 16.00” x 13.50” 127-170 A 170 A 44.00” x 15.25” x 13.50” 255-425 A 52.00” x 24.00” x 12.50” 255-340 A USING The M3460R comes with internal fusing. -
Page 12: General Precautions And Safety Warnings
M3460 2.4. G ENERAL RECAUTIONS AND AFETY ARNINGS • IGH VOLTAGES MAY BE PRESENT • EVER ATTEMPT OPERATE THIS PRODUCT WITH THE ENCLOSURE COVER REMOVED • EVER ATTEMPT TO SERVICE THIS PRODUCT WITHOUT FIRST DISCONNECTING POWER TO AND FROM THE UNIT •... -
Page 13: Installation Instructions
NSTALLATION NSTRUCTIONS The M3460 has an open frame 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 Wire sizing should be appropriate for the current being carried. System ratings are listed in Section 6.1. M3460 ride-thru units only provide full currents for a limited amount of time. Therefore, wire heating is not as much a concern as mechanical strength.
-
Page 15: Control Interface And I/O Wiring
3.4.1.3. RIVE ONNECTIONS The M3460 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 precharge resistors or DC link chokes between the output of the M3460 and the DC bus capacitors in the drive. Consult the manufacturers' documentation or contact Bonitron for further assistance. -
Page 16: Table 3-3: User I/O Connections With 3460M6 Board
Refer to the KIT 3660DD5 manual for operational and functional details. DP10 A 3.4.2.3. ONNECTIONS WITH NALOG ISPLAY When the M3460 is used with the DP10 analog display, the interconnections are made through TB6 and TB7 on the 3460M6 board and TB1 on the 3660D1 board. -
Page 17: Table 3-4: User I/O Connections With 3660D1 Board
TB1 – 5 Pre-Charge Complete (PCC) TB1 – 6 Test TB1 – 7 Local I/O Supply - 15 VDC, 50 mA TB1 – 8 Local I/O Supply + Figure 3-1: M3460 Interconnections with DP10 3660D1 TEST 24V+ 3460M6 SIG COM 24V COM... -
Page 18: Typical Configurations
M3460 3.5. T YPICAL ONFIGURATIONS Figure 3-2: M3460R Typical Configuration without Energy Storage CHOPPER... -
Page 19: Figure 3-3: M3460R Typical Configuration With Electrolytic Capacitor Storage Bank
User’s Manual Figure 3-3: M3460R Typical Configuration with Electrolytic Capacitor Storage Bank CHOPPER ASM 3534EC ELECTROLYTIC CAPACITORS WITH PRECHARGE DISCHARGE RESISTOR... -
Page 20: Figure 3-4: M3460R Typical Configuration With Ultracapacitor Storage Bank
M3460 Figure 3-4: M3460R Typical Configuration with Ultracapacitor Storage Bank CHOPPER... -
Page 21: Figure 3-5: M3460B Typical Configuration With Battery Storage Bank
User’s Manual Figure 3-5: M3460B Typical Configuration with Battery Storage Bank... - Page 22 M3460 This page intentionally left blank...
-
Page 23: Operation
During a power quality event the internal DC bus of the VFD drops. When this level meets the DC bus threshold voltage of the M3460, power is delivered through blocking diodes to hold up the voltage in the VFD bus. The M3460 regulates and boosts the input voltage to the drive at a constant voltage. -
Page 24: I/O, Features, And Displays
M3460 This mode is activated by the Test input. Refer to Section 4.4.1.2 for details on configuring this input. 4.4. I/O, F EATURES ISPLAYS Full status monitoring is available through discrete I/O points located on the 3460M6 board. Most of the I/O can be configured for different modes of operation with jumpers. -
Page 25: Input Terminals - 3460M6 Tb7
4.4.1.1. NABLE NPUT The Enable input is used to allow the M3460 to operate. This signal can be configured for either enable or disable operation. This input operation is configured with jumper JP15. The input operation is set to "Enable" with JP15 set to "NO", and the M3460 will operate when 24VDC is applied to the input. -
Page 26: Output Terminals - 3460M6 Tb5, Tb6
4.4.2.1. EADY This output closes when the M3460 is ready to operate and has no faults. This indicates the Enable input is active, the precharge is complete, and all the stage fuses are intact. This can be used as a general status indication. - Page 27 4.4.2.6. CTIVE This output will close when the M3460 is regulating the output DC bus of the system. This indicates that the power input on the connected equipment has sagged or failed. This output will also close when the unit is put into Test mode with the Test input, assuming the attached drive is loaded.
-
Page 28: Local I/O Power Supply - Tb6 - 1, 9
M3460 can operate again after a 4 second delay. If jumper J1 is ON the M3460 will operate as long as the DC bus is below the DC Bus Threshold voltage during a power quality event, or as long as the "Test"... -
Page 29: Test Timer Selection
CTIVE The Ride-Thru Active light will illuminate while the M3460 is regulating the DC bus or when the M3460 is put into Test mode. If the M3460 is unloaded or lightly loaded, this light may not illuminate. – 3460C1 - LD1 4.4.6.6. -
Page 30: Fan Timer
The Output Undervoltage fault will happen if the DC bus is approximately 35V below the threshold setting. If the DC bus drops 35V below the threshold setting, the light will go out. This is an indication the M3460 is not regulating the DC bus and an undervoltage fault on the attached equipment is possible. - Page 31 IGITAL ISPLAY The KIT 3660DD5 digital display has many features and control modes that can be used to monitor, test and log information about the M3460 and its activity. Below are basic operation instructions. Please refer to the KIT 3660DD5 manual for detailed instructions and configuration information.
-
Page 32: Dc Bus Threshold Voltage Setting
OLTAGE ETTING The DC bus threshold voltage is the voltage at which the M3460 maintains the DC bus during a power quality event. Whenever the output DC bus voltage drops below the DC bus threshold voltage setting, the M3460 becomes active to regulate the DC bus to the setpoint voltage. -
Page 33: Determining The Dc Bus Threshold Voltage Setting Directly (M3460B Models)
SING THE The DC bus threshold voltage setting may be checked with the drive connected using the test input to put the M3460 in Test mode. This raises the DC bus voltage approximately 50-100V above the actual DC bus threshold voltage setting, and is a fair indication of how the system is set. -
Page 34: Adjusting The Dc Bus Threshold Voltage Setting
EVEL DJUSTMENT This output indicates that the input voltage to the M3460 has dropped below a preset threshold. This is generally used when a storage device must be protected from over discharge. The default level for this output is dependent on the nominal system voltage, and is listed in Table 6-3 and Table 6-4. -
Page 35: Start-Up, Maintenance And Troubleshooting
User’s Manual TART AINTENANCE AND ROUBLESHOOTING 5.1. M3460R S TART IELD ROCEDURE Ensure the M3460R has been properly installed and is disabled. Ensure the M3460R DC bus is disconnected from the drive DC bus. Ensure the drive is operating properly with the M3460R disconnected. Apply power to the input of the M3460R and observe the following conditions: •... -
Page 36: M3460B Start-Up / Field Test Procedure
M3460 • I M3460R F THE IS ACTIVE FOR LONGER THAN THE TIMEOUT SETTING IT WILL SHUT DOWN SWITCHING AND THE BUS WILL DROP TO THE NORMAL LEVEL • I M3460R F THE OUTPUT BUS DROPS BELOW WILL HAVE TO GO... -
Page 37: Maintenance Items
The M3460 uses high quality aluminum electrolytic capacitors and is designed for long life without maintenance. While a typical inverter may require capacitor replacement after a certain time due to the heavy ripple currents, the M3460 typically is in a standby mode waiting for a power disturbance, and by design has 50% more capacitance than needed. -
Page 38: Capacitor Testing Procedure
• Once area is clean and dry, reapply power. 5.3.4. Bonitron estimates fan life to be longer than 20 years in a properly adjusted M3460B in a clean cool environment, 4 years under constant running conditions with high ambient temperatures. -
Page 39: Troubleshooting
User’s Manual 5.4. T ROUBLESHOOTING Below are suggestions on how to check some common issues. If you continue to have problems after going over this list, please contact Bonitron. Table 5-1: Troubleshooting Guide CTION YMPTOM ▪ Check incoming power. No lights are ON ▪... -
Page 40: 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 41: Engineering Data
User’s Manual NGINEERING 6.1. R ATINGS Table 6-1: M3460 kW Ratings 575VAC DC B 230VAC 380-415VAC 460VAC YSTEM URRENT YSTEM YSTEM YSTEM OLTAGE OLTAGE OLTAGE OLTAGE 85 A 25 kW 43 kW 50 kW 60 kW 127 A 38 kW... -
Page 42: Table 6-5: M3460R Model Specifications For 230 – 480 Vac Systems
M3460 Table 6-5: M3460R Model Specifications for 230 – 480 VAC Systems ECOMMENDED SCCR DC B ACKPLATE IRCUIT ATING ONFIGURATION ATINGS URRENT AC L RIVE 85 A 2-stage 80 A, 700 V 125 A, 600 V 127 A... -
Page 43: Efficiency / Power Consumption
Suitable for use on a circuit capable of delivering not more than 18,000 RMS symmetrical amperes, 1000 volts maximum when protected by recommended fuses. 6.2. E FFICIENCY OWER ONSUMPTION All M3460 modules are 93% efficient or better at full load. Power consumption in standby mode is less than 200W. -
Page 44: Certifications
6.3. C ERTIFICATIONS 6.3.1. NDERWRITERS ABORATORIES ISTING Standard M3460 models with L, E, and H voltage ratings are UL listed under file E204386. 6.3.2. CE C ONFORMITY Compliance with the Low Voltage Directive and Electromagnetic Compatibility Directive has been demonstrated using harmonized European Norm (EN) standards published in the Official Journal of the European Communities. -
Page 45: Table 6-9: M3460R Input Power Wiring Sizes And Fusing
The wire gauge selected for field wiring to the M3460 should be equal to or greater than that listed in Tables 6-9 & 6-10. • Use copper wiring rated 75°C or equivalent for field wiring terminals. -
Page 46: Dimensions And Mechanical Drawings
M3460 6.5. D IMENSIONS AND ECHANICAL RAWINGS Figure 6-1: M3460-R10 Chassis Dimensional Outline 15.25IN 0.75IN [387.4MM] [19.0MM] 0.75IN Ø0.50IN [19.0MM] [Ø12.7MM] 27.25IN 28.00IN [692.2MM] [711.2MM] 26.50IN [673.1MM] 13.45IN 14.50IN [341.6MM] [368.3MM] 16.00IN [406.4MM] MOUNTING FOOTPRINT... -
Page 47: Figure 6-2: M3460-R9 Chassis Dimensional Outline
User’s Manual Figure 6-2: M3460-R9 Chassis Dimensional Outline 15.25IN [387.4MM] 0.75IN [19.0MM] 0.75IN Ø0.50IN [19.0MM] [Ø12.7MM] 16.15IN [410.2MM] 16.90IN [429.3MM] 32.50IN [825.5MM] 33.25IN [844.6MM] 34.00IN [863.6MM] 16.35IN [415.3MM] 14.50IN 13.25IN [368.3MM] [336.5MM] 16.00IN [406.4MM] MOUNTING FOOTPRINT... -
Page 48: Figure 6-3: M3460-R11 Chassis Dimensional Outline
M3460 Figure 6-3: M3460-R11 Chassis Dimensional Outline 15.25IN [387.4MM] 0.75IN 0.75IN [19.0MM] [19.0MM] Ø0.50IN [Ø12.7MM] 18.75IN [476.2MM] 19.50IN [495.3MM] 44.00IN [1117.6MM] 43.25IN 42.50IN [1098.6MM] [1079.5MM] 23.75IN [603.2MM] 14.50IN 13.50IN [368.3MM] [342.9MM] 16.00IN [406.4MM] MOUNTING FOOTPRINT... -
Page 49: Figure 6-4: M3460-R2 Chassis Dimensional Outline
User’s Manual Figure 6-4: M3460-R2 Chassis Dimensional Outline 23.25IN 0.75IN [590.6MM] [19.0MM] 0.75IN Ø0.50IN [19.0MM] [Ø12.7MM] 12.75IN [323.8MM] 13.50IN [342.9MM] 51.25IN [1301.8MM] 52.00IN [1320.8MM] 37.75IN 50.50IN [958.9MM] [1282.7MM] 11.14IN 22.50IN [283.0MM] [571.5MM] 24.00IN [609.6MM] MOUNTING FOOTPRINT... -
Page 50: Figure 6-5: Dd5 Digital Display Cutout And Mounting Dimensions
M3460 Figure 6-5: DD5 Digital Display Cutout and Mounting Dimensions 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... -
Page 51: Appendices
ONSIDERATIONS There are several things to take in to account when backing up a drive system. The M3460 is designed to back up the power section of an AC drive, and does so within the DC link of the drive. - Page 52 M3460 process. A general estimate of needs must be used to build a capacitor bank and then the actual values must be cross checked to make sure they are suitable. There are several steps in the process. The capacitor bank will be comprised of capacitors connected in series for voltage support, with one or more strings in parallel to support the energy requirements.
-
Page 53: Energy Required For Outage
User’s Manual 7.2.1. NERGY EQUIRED FOR UTAGE The total energy required for the event must be calculated first. Using the following equation, the total number of joules required for the outage can be calculated: ∗ T We will use a specification of 100 hp. for a 2 second outage for this example. For instance, a 100 hp drive outage for 2 seconds would be = 100hp ∗... -
Page 54: Minimum Series String
M3460 ������ = .01٠�� 132F ������ �� = 46V ������������ 7.2.5. INIMUM ERIES TRING From �� , we can calculate the minimum series string of capacitors that ������������ will be required by the voltage rating. Below this voltage, there is an amount of stored energy that cannot be used, and will remain in the capacitor bank. -
Page 55: Steering Diode Sharing With A Bonitron M3460 Ride-Thru
For Ride-Thru applications, the energy is allowed to pass from the M3460 to the drives, but is blocked from the drives to the M3460. Figure 7-1 is a block diagram of a diode sharing example. Below are some basic guidelines for using diodes in this manner for M3460 applications. -
Page 56: Figure 7-1: Diode Sharing Example
M3460 5. Ground Fault sensing should be done upstream at common point of line connection. Figure 7-1: Diode Sharing Example BRAKING RESISTOR BRAKING RESISTOR DC BUS DISCONNECT MODEL M3460/M3534 OUTPUT... -
Page 57: Sag Only Installations & Circulating Currents
User’s Manual 7.4. S & C NSTALLATIONS IRCULATING URRENTS The topology of the M3460R voltage boost module incorporates a six diode full wave three phase rectifier bridge. When the M3460R is connected to the DC bus of the variable frequency drive, the input rectifier bridge of the variable frequency drive is in parallel with the M3460R input rectifier bridge. -
Page 58: Figure 7-3: M3460R Typical Configuration With Current Flow
M3460 The current will follow the path with the least resistance, this can cause “circulation currents”, or currents that may enter the DC bus of the M3460R through one bridge and return to the AC source through the other bridge. - Page 59 User’s Manual If the circulation current shown above in Figure 7-2 is established and remains during standby operation, the highlighted SCR/Thyristor in Figure 7-3 can remain on and overheat due to the continuous current flow. If the circulating current situation is not corrected the SCR may be permanently damaged and fail.
-
Page 60: Figure 7-4: M3460R Typical Configuration With Ultracapacitor Storage Bank
M3460 Figure 7-4: M3460R Typical Configuration with Ultracapacitor Storage Bank CHOPPER... - Page 61 User’s Manual NOTES...
- Page 62 M3460...
- Page 64 D_M3460 _CMAN_ 02/20/2018 521 Fairground Court ● Nashville, TN 37211 ● USA Tel: (615) 244-2825 ● Fax: (615) 244-2833 ● Web: www.bonitron.com ● Email: info@bonitron.com...
Need help?
Do you have a question about the M3460 and is the answer not in the manual?
Questions and answers