bonitron M3460 Customer Reference Manual
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bonitron M3460 Customer Reference Manual

Ride-thru enclosed voltage regulator
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Model M3460
Ride-Thru
Enclosed Voltage Regulator
Customer Reference Manual
●
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Web: www.bonitron.com
Tel: 615-244-2825
Email: info@bonitron.com

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  • Page 1 Model M3460 Ride-Thru Enclosed 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 of Contents 1. INTRODUCTION........................6 1.1. Who Should Use This Manual ...................... 7 1.2. Purpose and Scope ........................7 1.3. Manual Revision ........................... 7 Figure 1-1: M3460R in E1 Chassis and M3460B in E2 Chassis .............. 7 1.4. Symbol Conventions Used in this Manual and on Equipment ............. 8 2.
  • Page 5 Minimum Series String ........................56 7.2.6. Available Joules ..........................56 7.3. Steering Diode Sharing with a Bonitron M3460 Ride-Thru ............57 Figure 7-1: Diode Sharing Example ....................... 59 7.4. Sag Only Installations & Circulating Currents ................60 Figure 7-2: M3460R Typical Configuration without Energy Storage ............ 60 Figure 7-3: M3460R Typical Configuration with Current Flow ............
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  • 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

    D_M3460_D_CMAN_vall_00a 4/17/2020 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! DANGER: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or...

  • 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

    D_M3460_D_CMAN_vall_00a 4/17/2020 Table 2-2: Chassis Size Codes 3460B 3460R IMENSIONS HASSIS 30.00” x 24.00” x 13.00 85-127 A 36.00” x 24.00” x 13.00” 85 A 170 A 40.00” x 24.00” x 13.00” 127-170A 48.00” x 24.00” x 13.00” 255-425 A 60.00”...

  • Page 12: General Precautions And Safety Warnings

    D_M3460_D_CMAN_vall_00a 4/17/2020 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

    The maximum ambient operating temperature of the M3460 should not exceed 40C. Temperatures above this can cause overheating during operation. The standby heat production of the M3460 is quite low, but can generate significant heat during boosting. This is only of concern with the M3460B models because the M3460R run time of 2 seconds will not allow the system to reach thermal equilibrium, and should not cause thermal issues.

  • Page 14: Wiring And User Connections

    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 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: Control Interface And I/O Wiring

    IRING Control wiring allows for remote enabling, testing, and monitoring of the M3460. All units are equipped with the 3660DD5 digital display interface, all connections are made to the 3660I4 interface board. Refer to the KIT 3660DD5 manual for operational and functional details.
  • Page 17 D_M3460_D_CMAN_vall_00a 4/17/2020 Figure 3-1: M3460R I/O Terminal connection I/O CONNECTIONS ERMINAL UNCTION TB – 1 Courtesy + 24V TB – 2 Ride-Thru ENABLE TB – 3 Ride-ThrU TEST TB – 4 Input COM TB – 5 Courtesy COM TB – 6 Fault 1 TB –...
  • Page 18 D_M3460_D_CMAN_vall_00a 4/17/2020 Figure 3-2: M3460B I/O Terminal connection I/O CONNECTIONS 9 10 11 12 13 14 15 16 17 18 19 20 21 22 CHARGER I/O SIGNALS UNCTION ERMINAL TB – 1 Courtesy + 24V TB – 2 Charger ENABLE TB –...
  • Page 19 D_M3460_D_CMAN_vall_00a 4/17/2020 Figure 3-3: 3660I4 Board Layout TB16 RT BYPASS RT NORMAL CH BYPASS CH NORMAL DISCH BYPASS DISCH NORMAL SPARE 1 SPARE 2 COURTESY 24V CH ENABLE CH EQUALIZE RT ENABLE TB15 RT TEST SPARE 2 3 4 1 2 3 4 1 2 3 4 INPUT COM 24V COM...

  • Page 20: Typical Configurations

    D_M3460_D_CMAN_vall_00a 4/17/2020 3.5. T YPICAL ONFIGURATIONS Figure 3-2: M3460R Typical Configuration without Energy Storage CHOPPER...
  • Page 21 D_M3460_D_CMAN_vall_00a 4/17/2020 Figure 3-3: M3460R Typical Configuration with Electrolytic Capacitor Storage Bank CHOPPER ASM 3534EC ELECTROLYTIC CAPACITORS WITH PRECHARGE DISCHARGE RESISTOR...
  • Page 22 D_M3460_D_CMAN_vall_00a 4/17/2020 Figure 3-4: M3460R Typical Configuration with Ultracapacitor Storage Bank CHOPPER...
  • Page 23 D_M3460_D_CMAN_vall_00a 4/17/2020 Figure 3-5: M3460B Typical Configuration with Battery Storage Bank...
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  • Page 25: 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 26 D_M3460_D_CMAN_vall_00a 4/17/2020 The interface board accepts digital and analog signals from the ride-thru system and the user, and processes them before sending them to the display board via CANbus. The interface board provides an isolated power supply to the display board, as well as an isolated serial connection.
  • Page 27 D_M3460_D_CMAN_vall_00a 4/17/2020 & M 4.5. CREENS AVIGATION Many screens are menus allowing access to other screens, or lists presenting a number of options. The presently selected item on the menu is indicated by a ‘>’ character. This selection indicator is moved using the up and down buttons. If a line on the menu represents another screen, that screen may be accessed with the enter key.
  • Page 28 D_M3460_D_CMAN_vall_00a 4/17/2020 4.5.1. TATUS CREEN Upon system start, after a set period of inactivity, or during certain events, the system transitions to the Status screen. The status screen displays the present ride-thru and charger state, and two system voltages or currents. The variables displayed will be those selected by the user in the Configuration menu.
  • Page 29 D_M3460_D_CMAN_vall_00a 4/17/2020 4.5.4.1. ECORDS MENU From this screen, the user may select viewing ride-thru event records or fault records. Up/Down: Move cursor Enter: Make selection Cancel: Main menu 4.5.4.1.1. VENTS From this screen, the user may select whether to view event statistics or individual event records.
  • Page 30 D_M3460_D_CMAN_vall_00a 4/17/2020 4.5.4.2.1. On this screen, the user is instructed to press and hold the enter button to perform a ride-thru test. The test will end when the button is released. The system transitions to the Status screen for the duration of the test.
  • Page 31 D_M3460_D_CMAN_vall_00a 4/17/2020 4.5.4.3.2. TATUS IMER On this screen, the user may set how long the system will wait after the last button press before returning to the Status screen. If this time is set to 0 seconds, the Status screen timer is disabled, and the system will not leave the present screen without external stimulus.
  • Page 32 D_M3460_D_CMAN_vall_00a 4/17/2020 the ride-thru to prevent damage to the storage bank. If capacitors are used, the system will start-up with this fault, but can be reset after the capacitor bank is charged above the Storage Undervoltage level. 4.6.3. TORAGE VERVOLTAGE This fault indicates that the storage voltage has risen above the level set in the Super menu.
  • Page 33 D_M3460_D_CMAN_vall_00a 4/17/2020 4.7. ONNECTIONS The 3660DD5 requires several connections to operate. These are identified as either power connections or user connections. The power connections are typically done to monitor the AC line and drive Bus voltage. The user connections are typically done to enable the unit as well as monitor status and faults.
  • Page 34 D_M3460_D_CMAN_vall_00a 4/17/2020 (FOR M3460R) 4.7.1.3. NPUTS TB-1 (Courtesy 24V) This provides an isolated 24V, which may be used to drive the user inputs. TB-2 (RT Enable) This input enables the ride-thru. TB-3 (RT Test) This input initializes a test cycle of the ride-thru. TB-4 (Input COM) This is the common used with all user inputs.

  • Page 35: 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 36: Determining The Dc Bus Threshold Voltage Setting Directly (M3460R 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 37: Adjusting The Dc Bus Threshold Voltage Setting

    D_M3460_D_CMAN_vall_00a 4/17/2020 3. Monitor the DC bus voltage while the M3460 is in Test mode. This is the DC bus test voltage setting. The DC bus test voltage setting is approximately 50-100V higher than the DC bus threshold voltage setting.
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  • Page 39: Start-Up, Maintenance And Troubleshooting

    D_M3460_D_CMAN_vall_00a 4/17/2020 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 40: M3460B Start-Up / Field Test Procedure

    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...
  • Page 41 100% rated voltage, and caps run full ripple current at 1% duty. With typical operating conditions of 35°C, caps running at 75% rated voltage, and a duty cycle of one event per month, Bonitron recommends the capacitors be checked or replaced every 20 years.

  • Page 42: Capacitor Testing Procedure

    Once area is clean and dry, reapply power. 5.4.4. F 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 43: Troubleshooting

    D_M3460_D_CMAN_vall_00a 4/17/2020 5.5. 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 44: 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 45: Engineering Data

    D_M3460_D_CMAN_vall_00a 4/17/2020 NGINEERING 6.1. R ATINGS Table 6-1: M3460 kW Ratings DC B 230VAC 380-415VAC 460VAC URRENT YSTEM YSTEM YSTEM OLTAGE OLTAGE OLTAGE 85 A 25 kW 43 kW 50 kW 127 A 38 kW 65 kW 75 kW 170 A...
  • Page 46 D_M3460_D_CMAN_vall_00a 4/17/2020 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 2-stage 125 A, 700 V 200 A, 600 V...

  • Page 47: Efficiency / Power Consumption

    D_M3460_D_CMAN_vall_00a 4/17/2020 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. 6.3. B RANCH IRCUIT ROTECTION AND IZING The following information is supplied for assistance in selecting the appropriate field wiring sizes and power source fuse ratings for the M3460: •...

  • Page 48: Dimensions And Mechanical Drawings

    D_M3460_D_CMAN_vall_00a 4/17/2020 6.4. D IMENSIONS AND ECHANICAL RAWINGS Figure 6-1: M3460-E1 Enclosure Dimensional Outline...
  • Page 49 D_M3460_D_CMAN_vall_00a 4/17/2020 Figure 6-2: M3460-E2 Enclosure Dimensional Outline...
  • Page 50 D_M3460_D_CMAN_vall_00a 4/17/2020 Figure 6-3: M3460-E3 Enclosure Dimensional Outline...
  • Page 51 D_M3460_D_CMAN_vall_00a 4/17/2020 Figure 6-4: M3460-E4 Enclosure Dimensional Outline...
  • Page 52 D_M3460_D_CMAN_vall_00a 4/17/2020 Figure 6-5: M3460-E5 Enclosure Dimensional Outline...

  • Page 53: 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 54 D_M3460_D_CMAN_vall_00a 4/17/2020 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 55: Energy Required For Outage

    D_M3460_D_CMAN_vall_00a 4/17/2020 7.2.1. E 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 56: Capacitor Specifications

    D_M3460_D_CMAN_vall_00a 4/17/2020 7.2.4. C APACITOR PECIFICATIONS At this point, a specific capacitor's characteristics can be used. It is best to use the values that are listed at end of life for the capacitor to make sure that the storage system is sized for the eventual degradation of performance over time. The critical points to use are ������...

  • Page 57: 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.
  • Page 58 DC bus levels. If a M3460 is placed upstream, the Ride-Thru DC bus can be higher than the drive bus, and current can flow through the M3460 during normal operation. This can cause constant activity and overheating. It may be necessary to lower the threshold for these applications.
  • Page 59 D_M3460_D_CMAN_vall_00a 4/17/2020 Figure 7-1: Diode Sharing Example BRAKING RESISTOR BRAKING RESISTOR DC BUS DISCONNECT MODEL M3460/M3534 OUTPUT...

  • Page 60: Sag Only Installations & Circulating Currents

    D_M3460_D_CMAN_vall_00a 4/17/2020 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 61 D_M3460_D_CMAN_vall_00a 4/17/2020 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. Figure 7-3: M3460R Typical Configuration with Current Flow BRAKING RESISTOR...
  • Page 62 D_M3460_D_CMAN_vall_00a 4/17/2020 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 63 D_M3460_D_CMAN_vall_00a 4/17/2020 Figure 7-4: M3460R Typical Configuration with Ultracapacitor Storage Bank CHOPPER...
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  • Page 65 D_M3460_D_CMAN_vall_00a 4/17/2020 NOTES...
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