Related Manuals for bonitron M3534R Series
Summary of Contents for bonitron M3534R Series
- Page 1 Legacy Model M3534R-RY 20A DC Bus Ride-Thru for Variable Frequency AC Drives 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
M3534R 20A ........................7 NTRODUCTION 1.1. Who Should Use ........................7 1.2. Purpose and Scope........................7 1.3. Manual Version and Change Record ..................7 Figure 1-1: M3534R 20A in A5 Chassis ....................7 1.4. Symbol Conventions Used in this Manual and on Equipment ..........8 ......................9 RODUCT ESCRIPTION... - Page 5 7.4.2. Minimum Capacitor Bank Voltage ....................39 7.4.3. Peak Current ..........................40 7.4.4. Capacitor Specifications ........................ 40 7.4.5. Minimum Series String ......................... 40 7.4.6. Available Joules ..........................41 7.5. Diode Sharing with a Bonitron Ride-Thru ................42 Figure 7-1: Diode Sharing Example ....................43...
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Page 7: Introduction
User’s Manual NTRODUCTION 1.1. W HOULD This manual is intended for use by anyone who is responsible for integrating, installing, maintaining, troubleshooting, or using this equipment with any AC drive system. Please keep this manual for future reference. 1.2. P URPOSE AND COPE This manual is a user’s guide for the 20 Amp Model M3534R 2-Second, 50% DC Bus... -
Page 8: Symbol Conventions Used In This Manual And On Equipment
M3534R 20A 1.4. S 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: Roduct Escription
Long downtimes as well as large and costly production losses have been experienced due to VFD shutdowns caused by these occurrences. Bonitron’s Model M3534 series of DC Bus Ride-Thru Modules (RTM) provide protection from AC line voltage sags and outages for AC drive systems that use a fixed DC bus as with AC PWM VFDs by temporarily storing energy internally and releasing it back into the DC bus when needed. -
Page 10: 2.2. Part Number Breakdown
M3534R 20A 2.2. Part Number Breakdown Figure 2-1: Example of Part Number Breakdown M3534R H 012 DP10 AS E O D E L U M B E R Y S T E M O L T A G E A T I N G O W E R A T I N G H A S S I S... -
Page 11: General Specifications
User’s Manual 2.3. G ENERAL PECIFICATIONS Table 2-2: General Specifications Chart PECIFICATION ARAMETER AC Input Voltage 208 - 480VAC 265 - 585VDC minimum DC Output Voltage 295 - 650VDC nominal Max. DC Output Current Maximum Kilowatt Rating 12kW Maximum Sag Duration 2 seconds Duty Cycle Rating 1% duty rated at 50% voltage with 100% load... -
Page 12: General Precautions And Safety Warnings
M3534R 20A 2.4. G ENERAL RECAUTIONS AND AFETY ARNINGS H I G H V O L T A G E S M A Y B E P R E S E N T N E V E R A T T E M P T T O O P E R A T E T H I S P R O D U C T W I T H T H E E N C L O S U R E C O V E R R E M O V E D ... -
Page 13: Installation Instructions
User’s Manual NSTALLATION NSTRUCTIONS Installation and/or removal of this product should only be performed by a qualified electrician in accordance with National Electrical Code or local codes and regulations. DANGER! Proper installation of the Model M3534R Ride-Thru Module should be accomplished following the steps outlined below. -
Page 14: Wiring And Customer Connections
M3534R 20A 3.4. W IRING AND USTOMER ONNECTIONS This section provides information pertaining to the field wiring connections of the M3534R Ride-Thru Module. Actual connection points and terminal numbers of the AC Drive system will be found in the documentation provided with that system. Be sure to review all pertinent AC Drive System documentation as well as the RTM to Drive Interconnection details listed below before proceeding. -
Page 15: Control Interface Wiring
User’s Manual fuses. (See Figure 3-1.) Connections can be made using 10 AWG wire. Torque terminal screws to 20 lb-in maximum. ROUND Earth ground stud is provided on the chassis for all models. Make the Ground interconnection to Ground stud located on the lower left inner wall of the RTM enclosure. - Page 16 M3534R 20A Figure 3-1: A5 Chassis Field Connection Terminal Layout Figure 3-2: A5 Internal Layout with I3 Interface Dwg: 120211 and 120213 Rev: 20120621...
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Page 17: Typical Configurations
User’s Manual 3.5. T YPICAL ONFIGURATIONS Figure 3-3: Typical 20 Amp M3534R Interconnection with Existing Drive System Dwg: 080455 Rev: 20100903... - Page 18 M3534R 20A This page intentionally left blank...
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Page 19: Operation
UNCTIONAL ESCRIPTION The M3534R series of Ride-Thru Modules (RTMs) employs IGBT switching technology to regulate the inverter DC bus to a preset minimum voltage level. As the incoming AC voltage level drops, the RTM “activates”, boosting a rectified DC voltage up to the minimum DC bus voltage level specified for the inverter, allowing it to “ride through”... -
Page 20: Features
M3534R 20A 4.2. F EATURES 4.2.1. IGNAL 4.2.1.1. C ONTROL NPUTS TANDARD ODELS The DISABLE command is connected to TB4 1&2 of the 3534R2 control board. 24V will inhibit the module from boosting. connection allows normal operation. Use this to prevent excessive battery cycling while system power is normal. - Page 21 User’s Manual J2 – R UMPER CTIVE TATUS UTPUT This jumper allows the user to select the output contact state of Ride-Thru Active status relay K3. This jumper must be set to “Normally Open” (NO) for cabinet systems. Table 4-1: Control Signal Details- 3534R2 Control Board for Standard Models OARD ISABLE 6mA at 24V...
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Page 22: Indicators
M3534R 20A Table 4-5: Control Status Signal Component Specifications ERMINAL LECTRICAL ORQUE UNCTION OARD PECIFICATIONS 120VAC / .5 Amp Phoenix plug Status 2 lb-in 1kV Isolation 24VDC / 20mA Phoenix plug 3534R2 Test 2 lb-in 3kV Isolation 24VDC / 20mA Phoenix plug Disable 2 lb-in... - Page 23 User’s Manual ASB 3534R2 S TATUS NDICATORS The purpose and function of each status indicator provided on the ASB 3534R2 RTM Control board is described below. Please refer to Figure 4- 2 above for the locations of each of the indicators listed below. LD1 –...
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Page 24: Remote Or Cabinet Door System Status Display And Test Module
M3534R 20A signals. Jumpers select the contact of each opto FET relay device. See Section 6 for basic schematic of I/O signals. J1: Selects N.O. or N.C. contact for the Overtemp (OT) signal. With J1 in the “N.O.” position the contact will be made while the module temperature is within specified limits. -
Page 25: Startup
Some inverters can be reprogrammed to change this trip level. Bonitron typically sets the DC bus threshold to be approximately 10% below nominal level. For example, Bonitron sets all 460VAC systems to hold the 640VDC bus to 585VDC. Refer to the inverter documentation for details on adjusting its under voltage trip setting if the factory default setting is other than 15% below nominal DC bus level. -
Page 26: Operational Adjustments
ODEL M3534 R ODULES The "Threshold" voltage level is the voltage at which the Bonitron Model M3534 Ride-Thru module maintains the DC bus during a power dip. Whenever the DC bus level drops to the "Threshold" setpoint, the Ride-Thru module becomes active to regulate the DC bus voltage to the "Threshold"... -
Page 27: Determining Threshold Voltage Setpoint
HRESHOLD OLTAGE ETPOINT OADED YSTEM 1) V ERIFY PROPER INSTALLATION Ensure that the Bonitron Model M3534 Ride-Thru Module has been properly installed and wired according to all applicable system and module wiring diagrams. 2) P TEST USH THE BUTTON Push the "Test" button while monitoring the DC bus voltage. -
Page 28: Adjustment Pots
However, field calibration of this setpoint may be necessary if the AC line level is more than 7% below the nominal AC requirement listed on the RTM module nameplate. Contact Bonitron, Inc. for additional information as needed. -
Page 29: Maintenance And Troubleshooting
ERIODIC ESTING The Bonitron Ride-Thru is designed to be low maintenance. While the amount of ride- thru time does not depend on energy storage devices that degrade over time, Bonitron still recommends a yearly test of the system in order to ensure the electronics package is operating. -
Page 30: Periodic Maintenance Procedures For M3534R Module With Optional Dp10 Display Panel
This threshold level should be approximately 10-12% below the nominal loaded inverter bus. Each Bonitron Ride-Thru should be tested under load during initial start up to verify the functionality of the test circuit and that the test does not negatively affect the process. -
Page 31: Maintenance Items
M3534R typically is in a standby mode waiting for a power disturbance. With typical operating conditions of 35ºC, caps running at 75% rated voltage, and a duty cycle of one sag per month, Bonitron recommends the capacitors be checked or replaced every 20 years. 5.2.1.2. C... -
Page 32: Troubleshooting
M3534R 20A 5.3. T ROUBLESHOOTING Table 5-1: Detailed Troubleshooting Guide YMPTOM CTION No Panel LEDs Check incoming power Replace 3534R2 RTA never ON Check DISABLE command Initiate test cycle or remove power Watch and listen for signs of activity ... -
Page 33: Engineering Data
User’s Manual NGINEERING 6.1. R ATINGS HARTS Table 6-1: Model M3534R Ride-Thru Module Ratings . DC ECOMMENDED UTPUT ATINGS UTPUT ODEL UMBER NPUT (AC I / DC O OWER NPUT UTPUT URRENT M3534R-L006-A5 230 VAC 6kW /8hp A60Q30-2 / A70Q25-2 20 ADC M3534R-E010-A5 400 VAC 10kW /13hp... -
Page 34: Watt Loss
M3534R 20A 6.2. W TANDBY Less than 15 watts for 20 A units Approximately 3 watts for DP Series panels OOST All units are 95% efficient or better at full load. 6.3. F IRCUIT REAKER IZING AND ATING 6.3.1. -
Page 35: Dimensions And Mechanical Drawings
User’s Manual 6.4. D IMENSIONS AND ECHANICAL RAWINGS Figure 6-1: M3534R Control Module A5 Chassis Dimensional Outline Dwg: 120209 Rev: 20120619... -
Page 36: Supplemental Drawings
M3534R 20A 6.5. S UPPLEMENTAL RAWINGS 6.5.1. CHEMATICS Figure 6-2: 3534R2 TB5 Status Signal Figure 6-3: 3534I3 Control and Status Signal Dwgs: 060165 Rev: 20090615 and 090364 Rev: 20091230... -
Page 37: Appendices
7.2. I NSTALLATION ONSIDERATIONS FOR RIVE YSTEMS The following items should be considered when installing a Bonitron Ride-Thru: Inverter logic voltage must be "backed up" Most new Inverters derive logic supply from DC bus Install UPS on circuits with AC feed Any control or Interlock relays must be "backed up"... -
Page 38: Application Notes For M3534R Modules
ANK FOR FULL M3534R OUTAGE PROTECTION WITH THE Bonitron M3534R models can have energy storage devices added to cover complete outages. This involves adding a capacitor bank with an appropriate charging and discharging system. Bonitron can source complete capacitor cabinets or individual capacitors. -
Page 39: Energy Required For Outage
User’s Manual 5. Estimate the losses for each capacitor. 6. Determine the minimum number of capacitors per series string required for the minimum voltage. 7. Add capacitors in series for outage energy. 8. Determine if parallel strings are required to provide outage energy. These are the definitions of the variables we will use in the following equations: ��... -
Page 40: Peak Current
M3534R 20A 7.4.3. URRENT The peak current from the capacitor bank will occur at the minimum voltage. This can be estimated from the equation peak For our example, 75kW = 235A peak 320Vdc 7.4.4. 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. -
Page 41: Available Joules
User’s Manual 7.4.6. VAILABLE OULES At this point, the available maximum joules for the string can be calculated. ∗ V Charge series CapMax �� = 8 ∗ 46�� = 368�� ��ℎ�������� The capacitor voltage at the end of the discharge �� will be given by: ������������... -
Page 42: Diode Sharing With A Bonitron Ride-Thru
M3534R 20A the maximum input voltage for the M3534R, then the minimum series string combination should be used in parallel and the process repeated. 7.5. D IODE HARING WITH A ONITRON Diode sharing is used to decrease the cost of implementing regeneration, braking, or Ride-Thru modules to existing drive systems that are not common bussed. - Page 43 User’s Manual Figure 7-1: Diode Sharing Example BRAKING RESISTOR BRAKING RESISTOR DC BUS DISCONNECT MODEL M3460/M3534 OUTPUT...
- Page 44 M3534R 20A NOTES...
- Page 45 User’s Manual...
- Page 46 M3534R 20A...
- Page 48 D_M3534R_CMAN_v20Aall_03a 03/17/2015 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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