Web: www.bonitron.com ● Tel: 615-244-2825 ● Email: info@bonitron.com
Model M3460D
Diode Sharing Module
For Ride-Thru Applications
Customer Reference Manual
Bonitron, Inc.
2
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.
Bonitron, Inc.
3
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
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
M3460D
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Table of Contents
5
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 M3460D ....................................................................................................................... 7
1.1. Symbol Conventions Used in this Manual and on Equipment ..................................................... 8
2. PRODUCT DESCRIPTION / FEATURES ........................................................................................9
2.1. Related Products ........................................................................................................................... 9
2.2. Part Number Breakdown .............................................................................................................. 9
Figure 2-1: Example of M3460D Part Number Breakdown ........................................................................ 9
Table 2-1: Chassis Codes ............................................................................................................................. 9
2.3. General Specifications ................................................................................................................ 10
Table 2-2: General Specifications Chart .................................................................................................... 10
2.4. General Precautions and Safety Warnings ................................................................................. 11
3. INSTALLATION INSTRUCTIONS ................................................................................................13
3.1. Product Inspection ...................................................................................................................... 13
3.2. Site Selection .............................................................................................................................. 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 ............................................................................................................... 14
Figure 3-1: Typical Field Wiring for M3460 Booster System ................................................................... 14
4. OPERATION ..............................................................................................................................15
4.1. Functional Description ............................................................................................................... 15
4.2. Features ....................................................................................................................................... 15
4.3. Startup ......................................................................................................................................... 15
4.3.1. Pre-Power Checks............................................................................................................................... 15
4.3.2. Startup Procedure And Checks ........................................................................................................... 15
4.4. Operational Adjustments ............................................................................................................ 15
5. MAINTENANCE AND TROUBLESHOOTING ...............................................................................17
5.1. Troubleshooting .......................................................................................................................... 17
5.1.1. Circulating currents between drives ................................................................................................... 17
5.1.2. Heatsink gets excessively hot or drives do not behave properly during normal operating conditions 17
5.1.3. Ground Faults ..................................................................................................................................... 17
5.2. Technical Help – before you call ................................................................................................ 17
6. ENGINEERING DATA ................................................................................................................19
6.1. Ratings Charts ............................................................................................................................. 19
Table 6-1: M3460D Diode Ratings................................................................ ............................................ 19
6.2. Watt Loss .................................................................................................................................... 19
Table 6-2: M3460D Watt Loss .................................................................................................................. 19
6.3. Dimensions and Mechanical Drawings ...................................................................................... 20
Figure 6-1: Typical “H” Chassis ................................................................................................................ 20
Figure 6-2: Typical “J” Chassis ................................................................................................................. 21
Figure 6-3: Typical “L” Chassis ................................................................................................................ 21
Figure 6-4: Typical “N” Chassis ................................................................................................................ 22
Figure 6-5: Typical “P4” Chassis .............................................................................................................. 23
Figure 6-6: Typical “P6” Chassis .............................................................................................................. 24
Figure 6-7: Typical “P2” Chassis .............................................................................................................. 26
Figure 6-8: Block Diagram Example of a Ride-Thru / Diode Application ................................................ 27
M3460D
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User’s Manual
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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 M3460D Diode Sharing Module. It will
provide the user with the necessary information to successfully install, integrate, and
use the M3460D 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
The part numbering scheme for the M3460D was revised in Rev 01.
CE requirements for the M3460D are met in Rev 02.
Manual template was updated in Rev 02a.
Section 2, Table 3-1, Table 6-1 were updated and Figure 6-8 was included in Rev 02b.
Updated figure 6-7, and dimensions in table 2-1.
Updated product chassis in revision 02d.
Figure 1-1: Typical M3460D
M3460D
8
1.1. SYMBOL CONVENTIONS USED IN THIS MANUAL AND ON
EQUIPMENT
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.
User’s Manual
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2. PRODUCT DESCRIPTION / FEATURES
Bonitron’s M3460D Diode Sharing Modules are designed to offer system integrators a low
cost solution for using a DC Bus Ride-Thru Module (RTM) with multiple fixed bus Variable
Frequency Drives. The modules provide isolation for positive current flow to the drive.
Please see the Application Notes in Section 7 for additional information.
2.1. RELATED PRODUCTS
M3460R Ride-Thru Voltage Regulator provides Sag or Full Outage Protection for
Variable Frequency Drives.
M3460RD Impedance Module for Sag Ride-Thru Applications.
M3345CBM Common Bus Module.
2.2. PART NUMBER BREAKDOWN
Figure 2-1: Example of M3460D Part Number Breakdown
BASE MODEL NUMBER
The Base Model Number for Ride-Thru Diode Sharing Modules for use with M3460
Booster Modules is M3460D.
MAXIMUM # OF DRIVES
A numeral indicates the Maximum Number of Drives allowed in this configuration.
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 2-1: Chassis Codes
CHX CODE
TYPE AND SIZE (H X W X D)
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”
P4
15.0 x 24.0 x 8.0”
P6
15.0 x 24.0 x 8.0”
DRIVE DC BUS AMPS
The Drive DC Bus Amps Rating indicates the current rating of each individual drive.
This Rating is entered directly into the part number and will be either 2 or 3 digits.
M3460D
3 N 90
BASE MODEL NUMBER
MAXIMUM # OF DRIVES
CHASSIS STYLE
DRIVE DC BUS AMPS
M3460D
10
2.3. GENERAL SPECIFICATIONS
Table 2-2: General Specifications Chart
PARAMETER
SPECIFICATION
Voltage
230 VAC, 460 VAC
(Please consult with Bonitron regarding special
requirements)
Current Input Ratings
85, 170, 255, 340, 425
Current (each output)
Up to 90 amps
Maximum Run Time
4 minutes
Connections
Drive DC bus
DC bus to Ride-Thru Module
Fusing
Individual bus connections
Common DC bus
Operating Temperature
5°C to 40°C
Storage Temperature
-20ºC to +65ºC
Humidity
Below 90% non-condensing
Atmosphere
Free of corrosive gas and conductive dust
User’s Manual
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2.4. GENERAL PRECAUTIONS AND SAFETY WARNINGS
DANGER!
▪ HIGH VOLTAGES MAY BE PRESENT!
▪ NEVER ATTEMPT TO SERVICE THIS PRODUCT WITHOUT FIRST
DISCONNECTING POWER TO AND FROM THE UNIT!
▪ ALWAYS ALLOW ADEQUATE TIME FOR RESIDUAL VOLTAGES TO DRAIN
BEFORE REMOVING THE ENCLOSURE COVER!
▪ FAILURE TO HEED THESE WARNINGS MAY RESULT IN SERIOUS
BODILY INJURY OR DEATH!
CAUTION!
▪ CERTAIN COMPONENTS WITHIN THIS PRODUCT MAY GENERATE HIGH
AMBIENT TEMPERATURES DURING OPERATION.
▪ ALWAYS ALLOW AMPLE TIME FOR THE UNIT TO COOL BEFORE ATTEMPTING
SERVICE ON THIS PRODUCT.
▪ BEFORE ATTEMPTING INSTALLATION OR REMOVAL OF THIS PRODUCT, BE
SURE TO REVIEW ALL AC DRIVE DOCUMENTATION FOR PERTINENT SAFETY
PRECAUTIONS.
▪ INSTALLATION AND/OR REMOVAL OF THIS PRODUCT SHOULD ONLY BE
ACCOMPLISHED BY A QUALIFIED ELECTRICIAN IN ACCORDANCE WITH
NATIONAL ELECTRICAL CODE OR EQUIVALENT REGULATIONS.
ANY QUESTIONS AS TO APPLICATION, INSTALLATION OR SERVICE
SAFETY SHOULD BE DIRECTED TO THE EQUIPMENT SUPPLIER.
M3460D
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User’s Manual
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3. INSTALLATION INSTRUCTIONS
3.1. PRODUCT INSPECTION
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.
3.2. SITE SELECTION
• 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. 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.
• The unit will require a minimum clearance of three (3) inches above and below it
to allow for proper airflow for cooling. Avoid mounting the unit with its air intake
near heat sources.
3.3. MOUNTING
Once the installation site has been selected as outlined above, the unit should be
mounted in place.
Mounting holes should be drilled and mounting studs or anchors installed before
positioning the Diode Sharing Module. Once the studs or bolts are in place the module
can be hung in position. Be sure all mounting hardware is tightened securely.
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
WARNING!
Only qualified electricians should perform and maintain the
interconnection wiring of this product. All wiring should be done in
accordance with National Electrical Code or equivalent regulations.
Wire size should be selected in accordance with local codes, according to the
current rating of the braking transistor. 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
CHASSIS
TERMINAL
TORQUE
H, J
Ride-Thru terminal +/-
182 lb-in
Drive terminal +/-
20 lb-in
L, N, P
Ride-Thru terminal +/-
182 lb-in
Drive terminal +/-
182 lb-in
M3460D
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3.4.1.1. RIDE-THRU CONNECTION
The DC bus input should be connected to the output of the Ride-Thru
module.
Make sure that the DC bus connection polarity is correct. Improper
polarity connections carry a high risk of damaging drive equipment if
energized.
3.4.1.2. DRIVE CONNECTION
Some drives have a connection to an internal braking transistor. Do NOT
use this connection. Connect only to the DC bus terminals. See the
operation manual for your drive.
Make sure that the DC bus connection polarity is correct. Improper
polarity connections carry a high risk of damaging drive equipment if
energized.
3.5. TYPICAL CONFIGURATIONS
Figure 3-1: Typical Field Wiring for M3460 Booster System
Dwg: 070327 Rev: 20140729
User’s Manual
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4. OPERATION
4.1. FUNCTIONAL DESCRIPTION
The Diode Sharing Module isolates the DC bus connections of multiple drives to keep
from generating circulation currents in the AC bridges of the drives. This ensures 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. FEATURES
These modules can come with integral fusing for systems that require added protection
of the DC bus.
4.3. STARTUP
4.3.1. PRE-POWER CHECKS
Ensure 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. Ensure that the current
rating of the module is suitable for the application.
4.3.2. STARTUP PROCEDURE AND CHECKS
• Check the DC Bus at the RT+ and RT- links, and make sure the polarities
are correct.
• Check each drive + and – connection, and make sure they are correct.
• Cross connection of the drive busses 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 diode sharing module.
• Apply power to the drive system.
• Load the drive system and check for circulating currents between the
drives using a clamp on ammeter at the drive + and – terminals. This
current should be zero unless the drives are being supplied by the RideThru Module.
4.4. OPERATIONAL ADJUSTMENTS
There are no adjustments necessary to these modules.
M3460D
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User’s Manual
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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. CIRCULATING CURRENTS BETWEEN DRIVES
Make sure the connections are correct between the drives and the Ride-Thru
Module. If one drive is connected to the Ride-Thru Module input, circulating
currents can occur.
5.1.2. HEATSINK GETS EXCESSIVELY HOT OR DRIVES DO NOT BEHAVE
PROPERLY DURING NORMAL OPERATING CONDITIONS
Make sure that the connections are correct. Heat can be caused by
circulating currents between the drives.
Make sure the Ride-Thru Module is not operating in the BOOST mode during
normal conditions. See the Ride-Thru manual for more information on that
equipment.
5.1.3. GROUND FAULTS
When using a diode isolation module with several drives and a single RideThru, some drives may trip on ground faults depending on the ground fault
sensing scheme and sensitivity. If this occurs, a separate ground fault
detector on each motor output may be needed.
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
M3460D
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User’s Manual
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6. ENGINEERING DATA
6.1. RATINGS CHARTS
Table 6-1: M3460D Diode Ratings
PART NUMBER
NOMINAL HP
NUMBER
OF
DRIVES
DRIVE
AMPS
CONT.
CURRENT
RATING
PEAK
HEATSINK
RATING
FUSES
230V
460V
M3460D-3H-10
3 5 3
10
30 A
30 W
ATM-10
M3460D-6J-10
3 5 6
10
30 A
60 W
ATM-10
M3460D-3H-30
10
20 3 30
30 A
90 W
A60Q30
M3460D-6J-30
10
20 6 30
30 A
180 W
ATM-30
M3460D-2L-60
20
40 2 60
50 A
120 W
FWP-60
M3460D-3L-60
20
40 3 60
50 A
180 W
FWP-60
M3460D-4P4-60
20
40 4 60
100 A
240 W
FWP-60
M3460D-6P6-60
20
40 6 60
100 A
360 W
FWP-60
M3460D-2N-90
30
60 2 90
100 A
180 W
FWP-100
M3460D-3N-90
30
60 3 90
100 A
270 W
FWP-100
M3460D-2P2-200
100
200 2 200
200 A
560 W
FWP-200
6.2. WATT LOSS
Watt losses listed are figured at full load. Losses occur and heat is generated only
when the Ride-Thru is active. Ensure that enclosure cooling is adequate based on the
duty cycle of the attached Ride-Thru Module. Maximum duty cycle for M3460 Diode
Sharing Modules is 1%.
Table 6-2: M3460D Watt Loss
PART NUMBER
CONT.
HEATSINK
RATING
PEAK
HEATSINK
RATING
WATT
LOSS
M3460D-3H-10
30 W
30 W
84W
M3460D-6J-10
30 W
60 W
84W
M3460D-3H-30
30 W
90 W
84W
M3460D-6J-30
30 W
180 W
84W
M3460D-2L-60
50 W
120 W
140W
M3460D-3L-60
50 W
180 W
140W
M3460D-4P4-60
100 W
240 W
280W
M3460D-6P6-60
100 W
360 W
280W
M3460D-2N-90
100 W
180 W
280W
M3460D-3N-90
100 W
270 W
280W
M3460D
20
6.3. DIMENSIONS AND MECHANICAL DRAWINGS
Figure 6-1: Typical “H” Chassis
Dwg: 980121 Rev: 20001018
User’s Manual
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Figure 6-2: Typical “J” Chassis
Dwg: 050047 Rev: 20050323
M3460D
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Figure 6-3: Typical “L” Chassis
Dwg: 980209 Rev: 20001018
User’s Manual
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Figure 6-4: Typical “N” Chassis
Dwg: 980210 Rev: 20060125
M3460D
24
Figure 6-5: Typical “P4” Chassis
Dwg: 050046 Rev: 20050323
User’s Manual
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Figure 6-6: Typical “P6” Chassis
Dwg: 010293 Rev: 20011010
M3460D
26
Figure 6-7: Typical “P2” Chassis
Dwg: 080221 Rev: 20080519
User’s Manual
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Figure 6-8: Block Diagram Example of a Ride-Thru / Diode Application
WITH EQUAL LOADS USING DC BOOSTER AND DIODE ISOLATION
AC LINE
REGULATOR
2 SECOND, 50% SAG PROTECTION FOR EQUIVALENT DRIVES
BOOST
3 PHASE
AC LINE
DC LINK
M
DC LINK
M
VFD
VFD
Dwgs: 070241 Rev: 20080604
M3460D
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NOTES
User’s Manual
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D_M3460D_CMAN_VALL_02d 03/04/2019
521 Fairground Court ● Nashville, Tennessee 37211
(615) 244-2825 ● FAX (615) 244-2833 ● www.bonitron.com ● info@bonitron.com
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