Customer Reference Manual
Model M3345D
Diode Sharing Module
Web: www.bonitron.com ● Tel: 615-244-2825 ● Email: info@bonitron.com
Bonitron, Inc.
Bonitron, Inc.
Nashville, TN
An industry leader in providing solutions for AC drives.
ABOUT BONITRON
Bonitron designs and manufactures quality industrial electronics that improve the reliability of
processes and variable frequency drives worldwide. With products in numerous industries, and
an educated and experienced team of engineers, 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.
The Bonitron engineering team has the background and expertise necessary to design, develop,
and manufacture the quality industrial electronic systems demanded in today’s market. A strong
academic background supported by continuing education is complemented by many years of
hands-on field experience. A clear advantage Bonitron has over many competitors is combined
on-site engineering labs and manufacturing facilities, which allows the engineering team to have
immediate access to testing and manufacturing. This not only saves time during prototype
development, but also is essential to providing only the highest quality products.
The sales and marketing teams work closely with engineering to provide up-to-date information
and provide remarkable customer support to make sure you receive the best solution for your
application. Thanks to this combination of quality products and superior customer support,
Bonitron has products installed in critical applications worldwide.
2
Bonitron, Inc.
Undervoltage Solutions
Overvoltage Solutions
Uninterruptible Power for Drives
(DC Bus Ride-Thru)
Voltage Regulators
Chargers and Dischargers
Energy Storage
Braking Transistors
Braking Resistors
Transistor/Resistor Combo
Line Regeneration
Dynamic Braking for Servo Drives
Common Bus Solutions
Portable Maintenance Solutions
Single Phase Power Supplies
3-Phase Power Supplies
Common Bus Diodes
Capacitor Formers
Capacitor Testers
Power Quality Solutions
Green Solutions
12 and 18 Pulse Kits
Line Regeneration
AC DRIVE OPTIONS
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. Below is a sampling of
Bonitron’s current product offering.
WORLD CLASS PRODUCTS
3
M3345D
1. INTRODUCTION ..........................................................................................................................7
1.1. Who Should Use ........................................................................................................................... 7
1.2. Purpose and Scope ........................................................................................................................ 7
1.3. Manual Version and Change Record ............................................................................................ 7
Figure 1-1: Typical M3345D-90N2 ........................................................................................................ 7
1.4. Symbol Conventions Used in this Manual and on Equipment ..................................................... 8
2. PRODUCT DESCRIPTION / FEATURES ........................................................................................9
2.1. Related Docs / Products ................................................................................................................ 9
2.2. Part Number Breakdown .............................................................................................................. 9
Figure 2-1: Example of M3345D Part Number Breakdown .................................................................... 9
Table 2-1: DC Bus Amps Codes .............................................................................................................. 9
Table 2-2: Chassis Codes ....................................................................................................................... 10
2.3. General Specifications ................................................................................................................ 10
Table 2-3: General Specifications Chart ................................................................................................ 10
2.4. General Precautions and Safety Warnings ................................................................................. 11
3. INSTALLATION INSTRUCTIONS ................................................................................................13
3.1. Environment ............................................................................................................................... 13
3.2. Unpacking ................................................................................................................................... 13
3.3. Mounting .................................................................................................................................... 13
3.4. Wiring and Customer Connections ............................................................................................. 13
3.4.1. Power Wiring .................................................................................................................................... 13
Table 3-1: Power Wiring Specifications ................................................................................................ 13
3.5. Typical Configurations ............................................................................................................... 15
Figure 3-1: Typical Field Wiring ........................................................................................................... 15
4. OPERATION ..............................................................................................................................17
4.1. Functional Description ............................................................................................................... 17
4.2. Startup ......................................................................................................................................... 17
4.2.1. Pre-Power Checks ............................................................................................................................. 17
4.2.2. Startup Procedure and Checks ........................................................................................................... 17
4.3. Operational Adjustments ............................................................................................................ 17
5. MAINTENANCE AND TROUBLESHOOTING ...............................................................................19
5.1. Troubleshooting .......................................................................................................................... 19
5.1.1. Drive will not Precharge .................................................................................................................... 19
5.1.2. Circulating currents between drives .................................................................................................. 19
5.1.3. Heatsink gets excessively hot ............................................................................................................ 19
5.1.4. Drive Voltage too high or drive trips on over-voltage ....................................................................... 19
5.1.5. Drive Overvoltage on one Drive but not on another Drive ............................................................... 19
5.1.6. Overheating ....................................................................................................................................... 19
5.2. Technical Help – before you call ................................................................................................ 19
6. ENGINEERING DATA ................................................................................................................21
6.1. Ratings Charts ............................................................................................................................. 21
Table 6-1: M3345D Diode Module Load Ratings ................................................................................. 21
Table 6-2: M3345D Diode Modules Fuses ............................................................................................ 21
6.2. Dimensions and Mechanical Drawings ...................................................................................... 22
Figure 6-1: Typical “F” Chassis ................................................................................................ ............. 22
Figure 6-2: Typical “H” Chassis ............................................................................................................ 22
Figure 6-3: Typical “J” Chassis.............................................................................................................. 23
Figure 6-4: Typical “L” Chassis ............................................................................................................. 24
Figure 6-5: Typical “N” Chassis ............................................................................................................ 25
Figure 6-6: Typical “P” Chassis ................................................................................................ ............. 26
Figure 6-7: Typical “P2” Chassis ........................................................................................................... 27
4
Table of Contents
7. APPENDICES .............................................................................................................................29
7.1. Application Notes ....................................................................................................................... 29
7.2. Sizing .......................................................................................................................................... 29
7.3. Use with Line Regens ................................................................................................................. 29
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M3345D
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User’s Manual
1. INTRODUCTION
1.1. WHO SHOULD USE
This manual is intended for use by anyone who is responsible for integrating, installing,
maintaining, troubleshooting, or using this equipment.
Please keep this manual for future reference.
1.2. PURPOSE AND SCOPE
This manual is a user’s guide for the Model M3345D Diode Sharing Module. It will
provide the user with the necessary information to successfully install, integrate, and
use the M3345D module in a variable frequency AC drive system.
In the event of any conflict between this document and any publication and/or
documentation related to the AC drive system, the latter shall have precedence.
1.3. MANUAL VERSION AND CHANGE RECORD
Revisions 02c and 02d have minor format changes. Product data is unchanged.
Update to the manual template in Rev 02e.
Figure 3-1 and Table 6-1 were updated and Section 7.3 was added in Rev 02g.
Figure 1-1: Typical M3345D-90N2
7
M3345D
Earth Ground or Protective Earth
AC Voltage
DC Voltage
DANGER!
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.
CAUTION!
CAUTION: Identifies information about practices or
circumstances that can lead to property damage, or economic
loss. Attentions help you identify a potential hazard, avoid a
hazard, and recognize the consequences.
CAUTION!
CAUTION: Heat or burn hazard - Identifies a statement regarding
heat production or a burn hazard that should be avoided.
1.4. SYMBOL CONVENTIONS USED IN THIS MANUAL AND ON
EQUIPMENT
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User’s Manual
RATING CODE
DC BUS AMPS
04
4
10
10
30
30
60
60
90
90
200
200
BASE MODEL
DRIVE DC BUS AMPS
CHASSIS STYLE
MAXIMUM # OF DRIVES
M3345D
60 P 4
2. PRODUCT DESCRIPTION / FEATURES
Bonitron’s M3345D Diode Sharing Modules are designed to offer a low cost solution for
sharing regeneration or dynamic braking for multiple drives. Traditionally, a common DC
bus for the drives and regen modules has required that the drives be connected to a
common bus power supply. If the drives are directly connected to the AC line, the parallel
input bridges can cause circulating currents. This causes overheating and shortened drive
life. The M3345D modules provide blocking diodes that isolate the drives from each other
while establishing a shared, common regen bus. This eliminates circulating currents with
parallel input bridges.
Please see the Application Notes in Section 7 for additional information.
2.1. RELATED DOCS / PRODUCTS
M3345 Line Regen Module
M3345CBM (Common Bus Modules)
M3460D Diode Sharing Modules (Used with Bonitron M3534 and M3460 Ride-Thru
Modules)
2.2. PART NUMBER BREAKDOWN
Figure 2-1: Example of M3345D Part Number Breakdown
BASE MODEL NUMBER
The Base Model Number for these Diode Modules is M3345D.
DC BUS AMPS
The DC Bus Amps Rating indicates the current rating of each individual drive.
The DC Bus Amps Rating is entered directly into the part number and will be either 2
or 3 digits.
Table 2-1: DC Bus Amps Codes
9
M3345D
CHX CODE
TYPE AND SIZE (H X W X D)
F
8.0 x 12.5 x 5.5”
H
8.5 x 8.5 x 5.5”
J
8.5 x 15.0 x 5.5”
L
13.0 x 12.0 x 8.0”
N
14.0 x 15.0 x 8.0”
P
15.0 x 24.0 x 8.0”
PARAMETER
SPECIFICATION
Voltage
230VAC, 460VAC, 575VAC
(Please consult with Bonitron regarding special
requirements)
Current
0 – 200ADC
Connections
Drive DC bus
DC bus to Regen from Diode Module
Fusing
Individual bus connections
DC bus to Regen
Operating Temperature
0°C to +40°C
Storage Temp
-2°C to + 65°C
Humidity
Below 90% non-condensing
Atmosphere
Free of corrosive gas and dust
CHASSIS STYLE
The Chassis Style is determined by the configuration of the module. This is not a
selection, but an indicator of the chassis size.
Table 2-2: Chassis Codes
MAXIMUM # OF DRIVES
The Maximum Number of Drives that can be connected in this configuration.
2.3. GENERAL SPECIFICATIONS
Table 2-3: General Specifications Chart
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User’s Manual
DAN G ER !
HI GH VO LT AGE S M AY B E PR ES ENT !
NE VER AT TEM PT TO S ERV I CE THI S P ROD UC T WI T HO UT
FI RS T D IS CONNE CT ING POWE R T O AN D F ROM T H E UNIT.
ALWAYS ALL OW ADE Q UATE TIME FOR RES IDU AL
VO LT AG ES TO D RA IN BE F OR E RE M OV IN G THE
EN CLOSU RE COVE R.
FAILURE TO HEED THESE WARNINGS MAY
RESULT IN SERIOUS BODILY INJURY OR DEATH!
CAU T ION !
CO MPO NE NT S WIT HI N T H I S PR ODU CT GET HO T DU R IN G
OP ER AT I ON .
ALWAYS AL LOW AM P LE TI ME FOR T HE UNI T T O C OO L
BE FORE AT TE M PT ING S E RV IC E O N T HI S PRO DU CT .
BE F OR E ATTE MP TIN G I NST ALL AT I ON OR REMO VAL OF
TH IS PRO DU CT, B E S URE TO REV IE W AL L DR IV E AND/O R
RE SI ST I VE L OA D DO CU M ENT AT IO N FOR P ER TIN ENT
SAFE TY PR ECAUT IONS.
IN ST ALL AT I ON AND /OR REM O VA L OF THI S PROD UCT
SH OU LD ON LY B E AC CO M P LI SH ED B Y A QU AL IFI E D
EL EC TRI CI AN I N A CC ORDA NC E W IT H NAT I ON AL
EL EC TRI CA L COD E O R E QU IV AL ENT RE GU L AT IO NS.
2.4. GENERAL PRECAUTIONS AND SAFETY WARNINGS
ANY QUESTIONS AS TO APPLICATION, INSTALLATION, OR SERVICE
SAFETY SHOULD BE DIRECTED TO THE EQUIPMENT SUPPLIER.
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M3345D
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User’s Manual
WARNING!
Only qualified electricians should perform and maintain the
interconnection wiring of this product. All wiring should be done in
accordance with local codes.
CHASSIS
TERMINAL
TORQUE
F, H, J
Regen terminal +/-
182 lb-in
Drive terminal +/-
20 lb-in
L, N, P
Regen terminal +/-
182 lb-in
Drive terminal +/-
182 lb-in
3. INSTALLATION INSTRUCTIONS
3.1. ENVIRONMENT
All units require adequate protection from the elements. Open frame modules
must be mounted within enclosures of suitable rating for the environment.
Adequate clearance should be allowed for easy access to terminals and
adjustments. This will facilitate inspection and maintenance.
Sufficient circulation of clean, dry air should be provided. Ambient temperatures
should not exceed +40°C (+104°F) nor be less than 0°C (+32°F) and noncondensing. Ambient air should not be contaminated with harmful chemical vapors
or excessive dust, dirt, or moisture.
3.2. UNPACKING
Upon receipt of this product, please verify that the product received matches the
product that was ordered and that there is no obvious physical damage to the unit. If
the wrong product was received or the product is damaged in any way, please contact
the supplier from which the product was purchased.
3.3. MOUNTING
The modules are intended to be mounted in a protective enclosure. The unit will
require a minimum clearance of three (3) inches around it to allow for proper airflow
for cooling.
Refer to Section 6 of this manual to determine the correct mounting dimensions and
provisions for the unit.
3.4. WIRING AND CUSTOMER CONNECTIONS
3.4.1. POWER WIRING
Wire size should be selected in accordance with local codes, according to the current
rating of the braking load. In general, the wire type should be selected by the nominal
system AC voltage and the current rating of the module.
Table 3-1: Power Wiring Specifications
13
M3345D
3.4.1.1. REGEN CONNECTION
3.4.1.2. DRIVE CONNECTION
3.4.1.3. GROUNDING REQUIREMENTS
The DC bus input should be connected to the DC input of the Regen
module.
Make sure that the DC bus connection polarity is correct. Improper
polarity connections risk damaging drive equipment if energized.
Some drives have a connection to an internal braking transistor. Do
NOT use this connection. Connect only to the DC bus terminals.
Make sure that the DC bus connection polarity is correct. Improper
polarity connections risk damaging drive equipment if energized.
All units come equipped with either a ground terminal or ground stud
that is connected to the module chassis. Ground the chassis in
accordance with local codes. Typically, the wire gauge will be the same
as is used to ground the attached drive.
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User’s Manual
DC ( - )
DC ( + )
TYPICAL M3345D
DRIVE 1 DC ( - )
DRIVE 2 DC ( - )
DRIVE 3 DC ( - )
DRIVE 3 DC ( + )
DRIVE 2 DC ( + )
DRIVE 1 DC ( + )
L1 L2
L3
AC LINE
NEG.
REGEN
REGEN
POS.
TYPICAL
MOTOR AND DRIVE
DC BUS
AC LINE
A B C
+ -
MODEL 3345 REGEN
POWER
A B C
AC LINE
+ -
DC BUS
MODEL 3345 REGEN
POWER
DC BUS
A B C
+
AC LINE
-
MODEL 3345 REGEN
POWER
1 2 43
5
6
31 2 4
5
6
31 2 4
5
6
*MASTER/SLAVE &
STATUS I/O
60A, 90A & 120A ONLY
*MASTER
*SLAVE1
*SLAVE2
T1
T2
T3
GND
DC BUS
L1L2L3
DRIVE 3
DRIVE 2
DC BUS
L3L1L2
T3
GND
T1
T2
L3
DC BUS
DRIVE 1
L2
L1
T2
GND
T3
T1
MOTOR AND DRIVE
TYPICAL
MOTOR AND DRIVE
TYPICAL
Dwg: 950175 Rev: 20080515
3.5. TYPICAL CONFIGURATIONS
Figure 3-1: Typical Field Wiring
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M3345D
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User’s Manual
4. OPERATION
4.1. FUNCTIONAL DESCRIPTION
The Diode Sharing Module isolates the DC bus connections of multiple drives to isolate
the AC bridges of the drives. This insures that the input bridges of each drive do not
supply power to other drives in the network, or allow circulating currents between
drives. These currents can cause bridge overheating and damage to the drives.
4.2. STARTUP
4.2.1. PRE-POWER CHECKS
Insure that all connections are tight, DC bus polarity is correct, and that the
drives are connected to the proper terminals. Check for exposed conductors
that may lead to inadvertent contact or shorting. Insure that the current rating
of the module is suitable for the application.
4.2.2. STARTUP PROCEDURE AND CHECKS
Check each drive + and – connection, and make sure they are correct.
Cross connection of the drive buses can cause catastrophic damage to
the drives or the Ride-Thru Module.
Make sure the incoming line voltage is within tolerance of the drive
system and the M3345 Diode Sharing Module.
Apply power to the drive system.
4.3. OPERATIONAL ADJUSTMENTS
There are no adjustments necessary to these modules.
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M3345D
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User’s Manual
5. MAINTENANCE AND TROUBLESHOOTING
Repairs or modifications to this equipment are to be performed by Bonitron approved
personnel only. Any repair or modification to this equipment by personnel not approved
by Bonitron will void any warranty remaining on this unit.
5.1. TROUBLESHOOTING
5.1.1. DRIVE WILL NOT PRECHARGE
Verify that the DC bus connections on the drive and on the M3345D DC bus
terminals.
5.1.2. CIRCULATING CURRENTS BETWEEN DRIVES
Make sure the connections are correct between the drives and the Common
Bus Module.
5.1.3. HEATSINK GETS EXCESSIVELY HOT
Make sure that the connections are correct. Heat can be caused by
circulating currents between the drives.
5.1.4. DRIVE VOLTAGE TOO HIGH OR DRIVE TRIPS ON OVER-VOLTAGE
Make sure that the fuses are not blown. Check voltage across the
M3345D fuses and replace fuses if voltage is >1V.
Check blocking diodes for failure.
Verify that voltage is 0.5 - 2V across the M3345 diode which should be
regenerating energy.
5.1.5. DRIVE OVERVOLTAGE ON ONE DRIVE BUT NOT ON ANOTHER
DRIVE
Check the fuses on the M3345D. A blown fuse will not let the drive
5.1.6. OVERHEATING
Check that if the unit has a fan that it is working properly. If there is any
debris or object blocking the fan clear this immediately.
Check the heatsink, diodes, and fuses for being covered if they are covered
in dust or dirt. If the unit is dirty wipe it down thoroughly.
5.2. TECHNICAL HELP – BEFORE YOU CALL
If possible, please have the following information when calling for technical help:
Serial number of unit
Name of original equipment supplier
Brief description of the application
Drive and motor hp or kW
The line to line voltage on all 3 phases
The DC bus voltage
kVA rating of power source
Source configuration Wye/Delta and grounding
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M3345D
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User’s Manual
PART NUMBER
NUMBER
OF
DRIVES
NOMINAL HP
TOTAL DRIVE
BUS
CURRENT
M3345D
CONT. OUTPUT
CURRENT
M3345D
PEAK OUTPUT
CURRENT
230V
460V
575V
M3345D-04F6
6
1.5 hp
3 hp
4 hp
4 A
20 A
24 A
M3345D-10H3
3
3 hp
5 hp
6 hp
10 A
30 A
30 A
M3345D-10J6
6
3 hp
5h p
6 hp
10 A
30 A
60 A
M3345D-30H3
3
10 hp
20 hp
25 hp
30 A
30 A
90 A
M3345D-30J6
6
10 hp
20 hp
25 hp
30 A
30 A
180 A
M3345D-60L2
2
20 hp
40 hp
50 hp
60 A
50 A
120 A
M3345D-60L3
3
20 hp
40 hp
50 hp
60 A
50 A
180 A
M3345D-60P4
4
20 hp
40 hp
50 hp
60 A
100 A
240 A
M3345D-60P6
6
20 hp
40 hp
50 hp
60 A
100 A
360 A
M3345D-90N2
2
30 hp
60 hp
75 hp
90 A
100 A
180 A
M3345D-90N3
3
30 hp
60 hp
75 hp
90 A
100 A
270 A
M3345D-200P2
2
100 hp
200 hp
250 hp
200 A
200 A
400 A
PART NUMBER
BUS FUSE
WATT LOSS
M3345D-04F6
ATM-4
56W
M3345D-10H3
ATM-10
84W
M3345D-10J6
ATM-10
84W
M3345D-30H3
A60Q30
84W
M3345D-30J6
ATM-30
84W
M3345D-60L2
FWP-60
140W
M3345D-60L3
FWP-60
140W
M3345D-60P4
FWP-60
280W
M3345D-60P6
FWP-60
280W
M3345D-90N2
FWP-100
280W
M3345D-90N3
FWP-100
280W
M3345D-200P2
FWP-200
560W
6. ENGINEERING DATA
6.1. RATINGS CHARTS
Table 6-1: M3345D Diode Module Load Ratings
Table 6-2: M3345D Diode Module Fuses and Watt Loss
21
M3345D
Dwg: 020035 Rev: 20020125
6.2. DIMENSIONS AND MECHANICAL DRAWINGS
Figure 6-1: Typical “F” Chassis
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User’s Manual
Dwg: 980121 Rev: 20001018
Figure 6-2: Typical “H” Chassis
23
M3345D
Dwg: 980124 Rev: 20001018
Figure 6-3: Typical “J” Chassis
24
User’s Manual
Dwg: 980209 Rev: 20001018
Figure 6-4: Typical “L” Chassis
25
M3345D
Dwg: 980210 Rev: 20060125
Figure 6-5: Typical “N” Chassis
26
User’s Manual
Dwg: 970179 Rev: 20051014
Figure 6-6: Typical “P” Chassis
27
M3345D
Dwg: 080221 Rev: 20080519
Figure 6-7: Typical “P2” Chassis
28
User’s Manual
7. APPENDICES
7.1. APPLICATION NOTES
The diode modules include fusing, heatsinks, and diodes mounted on a backplate.
High speed semiconductor fuses are included for the protection of the drives and diode
modules.
Two applications are ideal for regen sharing:
1. Several drives, each producing a small amount of regenerated energy and
sharing a line regen module large enough to handle the sum total amount of
regenerated energy.
2. Multiple drive applications which have regeneration occuring on only one drive at
a time (an example is an overhead crane system which is lifting or only moving in
one axis at a time).
7.2. SIZING
The M3345D is selected based on the maximum DC regen current per drive. This will
generally be based on the size of the largest drive in the application. Bonitron does
not recommend sharing more than 200 amps of regen current. Applications involving
more than 200 amps of regen should be reviewed with Bonitron Engineering. Custom
configurations may be designed for specialized applications or high volumes.
Example: System has two (2) 50hp drives and one (1) 25hp drive.
The largest drive is 50hp.
From Table 6-1 select the 90 amp module for 3 drives, the M3345D-90N3.
7.3. USE WITH LINE REGENS
The M3345 is the only line regen that should be used with the M3345D diode sharing
module.
The M3345D should not be used with the M3545 or the M3645 series of line regens.
Several drives on the same DC bus that do not share the same ground will result in
common mode noise which will cause Overvoltage and IGBT Desat faults in the
M3545 or the M3645. For the M3545 and M6545 line regens use of the M3345CBM
common bus diode sharing module is recommended.
29
M3345D
NOTES
30
D_M3345D_CMAN_VALL_02f 09/15/2014
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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