Web: www.bonitron.com ● Tel: 615-244-2825 ● Email: info@bonitron.com
Model M3645P
Regenerative DC Bus Power Supply
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
M3645P
4
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 M3645P Regenerative DC Bus Power Supply ......................................................... 7
1.4. Symbol Conventions Used in this Manual and on Equipment ..................................................... 8
2. PRODUCT DESCRIPTION ............................................................................................................9
2.1. Related Products ........................................................................................................................... 9
2.2. Part Number Breakdown ............................................................................................................ 10
Figure 2-1: Example of M3645P Part Number Breakdown ................................................................... 10
Table 2-1: Voltage Ratings .................................................................................................................... 10
Table 2-2: Module Identifier .................................................................................................................. 11
Table 2-3: Chassis Styles ....................................................................................................................... 11
Table 2-4: Option Codes ........................................................................................................................ 11
2.3. General Specifications Chart ...................................................................................................... 12
Table 2-5: General Specifications .......................................................................................................... 12
2.4. General Precautions and Safety Warnings ................................................................................. 13
3. INSTALLATION INSTRUCTIONS ................................................................................................15
3.1. Environment ............................................................................................................................... 15
3.2. Unpacking ................................................................................................................................... 15
3.3. Mounting .................................................................................................................................... 15
3.3.1. M3645P DC Bus Regenerative Power Supply ................................................................. 15
Figure 3-1: M3645P Mounting Orientation ........................................................................................... 16
3.3.2. M3645 M15 Line Reactor Mounting ................................................................................ 17
3.3.3. KIT 3645DD, External Display Mounting ....................................................................... 17
3.4. Wiring and Customer Connections ............................................................................................. 17
3.4.1. Power Wiring .................................................................................................................... 17
Table 3-1: Transformer Ratings ............................................................................................................. 18
Table 3-2: Power Terminal Specifications - 30 Amp Unit – M10 Chassis ............................................ 19
Table 3-3: Power Terminal Specifications - 50 Amp Unit – M11 Chassis ............................................ 19
Table 3-4: Power Terminal Specifications - 100 Amp Unit – M12 Chassis .......................................... 19
Figure 3-2: Power Connections .............................................................................................................. 20
Figure 3-3: Connection Locations .......................................................................................................... 20
Table 3-5: Power Terminal Specifications – 150A, 225A, and 300A Unit – M15 Chassis ................... 21
Figure 3-4: M3645P 150A, 225A, and 300A Power Connections ......................................................... 21
Figure 3-5: M3645P 150A, 225A, and 300A Connection Locations ..................................................... 22
3.4.2. I/O Wiring ......................................................................................................................... 23
Table 3-6: I/O Terminal Specifications .................................................................................................. 23
Figure 3-4: M3645P 30A, 50A, 100A User I/O Connections ................................................................ 23
Figure 3-6: M3645P Enable Input Using Internal Power Supply ........................................................... 24
Figure 3-7: M3645P Enable Input Using External Power Supply ......................................................... 24
3.5 Typical Configurations ............................................................................................................... 25
Figure 3-8: M3645P 30A, 50A, 100A Power Wiring ............................................................................ 26
Figure 3-9: M3645P 150A, 225A, and 300A Power Wiring .................................................................. 27
Figure 3-10: M3645P Multiple Drives Field Wiring Diagram ............................................................... 28
Figure 3-11: M3645P Connection with KIT 3645DD, External Panel Mounted Display ...................... 29
4. OPERATION ..............................................................................................................................31
4.1. Functional Description ............................................................................................................... 31
4.2. Features ....................................................................................................................................... 31
Table of Contents
5
4.2.1. Digital Display .................................................................................................................. 31
4.2.2. LEDs ................................................................................................................................. 31
4.2.3. Buttons .............................................................................................................................. 31
4.3. Digital Display Operation ........................................................................................................... 32
4.3.1. Metering Screen ................................................................................................................ 32
4.3.2. Energy Records Screen ..................................................................................................... 32
4.3.3. Reset Energy Records Screen ........................................................................................... 32
4.3.4. Faults Screen ..................................................................................................................... 32
4.3.5. Fault Records Screen ........................................................................................................ 32
Figure 4-1: M3645P Screen Tree ........................................................................................................... 32
4.4. Faults .......................................................................................................................................... 33
Table 4-1: Blink Codes .......................................................................................................................... 33
4.4.1. Feedback Undervoltage .................................................................................................... 33
4.4.2. Overtemperature ............................................................................................................... 33
4.4.3. DC Overvoltage ................................................................................................................ 34
4.4.4. Differential Overvoltage ................................................................................................... 34
4.4.5. Sync Loss .......................................................................................................................... 34
4.4.6. IGBT Driver ...................................................................................................................... 34
4.4.7. Phase 1-3 Overcurrent ...................................................................................................... 34
4.4.8. Phase Loss......................................................................................................................... 34
4.4.9. DC Undervoltage .............................................................................................................. 34
4.4.10. Regen Power-On/Precharge Not Complete ...................................................................... 35
4.4.11. Frequency Detect Failure .................................................................................................. 35
4.5. Input / Output Connections ......................................................................................................... 35
4.5.1. Local I/O +24V Supply- TB2-1 & TB2-5 ........................................................................ 35
4.5.2. Enable Input - TB2-2 ........................................................................................................ 35
4.5.3. Fault Recall Input -TB2-3 ................................................................................................. 35
4.5.4. Input COM -TB2-4 ........................................................................................................... 35
4.5.5. Ready Output - TB2-6 ...................................................................................................... 35
4.5.6. Overtemperature Output - TB2-7 ...................................................................................... 36
4.5.7. Output COM - TB2-8 ....................................................................................................... 36
4.6. Startup ......................................................................................................................................... 36
4.6.1. Pre-power Checks ............................................................................................................. 36
4.6.2. Startup Procedure and Checks .......................................................................................... 36
4.6.3. Cooling Fan....................................................................................................................... 36
5. MAINTENANCE AND TROUBLESHOOTING ...............................................................................37
5.1. Periodic Testing .......................................................................................................................... 37
5.2. Maintenance Items ...................................................................................................................... 37
5.3. Troubleshooting .......................................................................................................................... 37
5.3.1. POWER LED is not on, or Digital Display is not active: ................................................. 37
5.3.2. READY output will not close ........................................................................................... 37
5.3.3. Unit will not respond to ENABLE command ................................................................... 37
5.3.4. Drive trips on DC Bus Overvoltage during braking ......................................................... 37
5.3.5. Feedback Undervoltage .................................................................................................... 38
5.3.6. Overtemperature ............................................................................................................... 38
5.3.7. DC overvoltage ................................................................................................................. 38
5.3.8. Differential Overvoltage ................................................................................................... 39
5.3.9. Sync Loss .......................................................................................................................... 39
5.3.10. IGBT Driver ...................................................................................................................... 39
5.3.11. Phase Overcurrent ............................................................................................................. 39
M3645P
6
5.3.12. Phase Loss......................................................................................................................... 39
5.3.13. DC Undervoltage .............................................................................................................. 39
5.3.14. Regen Power-On/Precharge Not Complete ...................................................................... 39
5.3.15. Frequency Detect Failure .................................................................................................. 40
5.3.16. Technical Help – Before you contact us ........................................................................... 40
6. ENGINEERING DATA ................................................................................................................41
6.1. Ratings Charts ............................................................................................................................. 41
Table 6-1: Ratings and Specifications – 230 - 240VAC ........................................................................ 41
Table 6-2: Ratings and Specifications – 380 - 415VAC ........................................................................ 41
Table 6-3: Ratings and Specifications – 460 - 480VAC ........................................................................ 41
Table 6-4: Ratings and Specifications – 575 - 600VAC ........................................................................ 42
6.2. Derating Parallel Units ............................................................................................................... 42
Table 6-5: Derating Regens in Parallel .................................................................................................. 42
6.3. Watt Loss .................................................................................................................................... 42
6.4. Certifications and RoHS ............................................................................................................. 42
6.5. Fuse Selection ............................................................................................................................. 43
Table 6-6: Fuse Current Rating Requirements ....................................................................................... 43
Table 6-7: Fuse Voltage Rating Requirements ...................................................................................... 43
6.6. Dimensions and Mechanical Drawings ...................................................................................... 44
Figure 6-1: M3645P M10 Chassis Dimensional Outline ....................................................................... 44
Figure 6-2: M3645P M11 Chassis Dimensional Outline ....................................................................... 45
Figure 6-3: M3645P M12 Chassis Dimensional Outline ....................................................................... 46
Figure 6-4: M3645P M15 Dimensional Outline .................................................................................... 47
Figure 6-5: M3645 M15 Line Reactor Dimensional Outline ................................................................. 48
Figure 6-6: KIT 3645DD, External Display Dimensional Outline ......................................................... 49
6.7. Block Diagram ............................................................................................................................ 50
Figure 6-7: Typical Customer Application................................ ............................................................. 50
7. APPENDIX .................................................................................................................................51
7.1. Application Notes ....................................................................................................................... 51
7.1.1. Sizing the Line Regeneration Unit .................................................................................... 51
7.1.2. Calculating Energy Savings .............................................................................................. 52
User’s Manual
7
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 with any AC Drive System.
Please keep this manual for future reference.
1.2. PURPOSE AND SCOPE
This manual is a user’s guide for the Model M3645P regenerative DC bus power
supply. It provides you with the necessary information to successfully install and use
the M3645P modules in your application.
In the event of any conflict between this document and any publication and/or
documentation related to the application, the latter shall have precedence.
1.3. MANUAL VERSION AND CHANGE RECORD
The initial release of the M3645P manual is Rev 00a.
Update to Section 7 on the sizing and energy savings in Rev 00b.
Updated to include KIT 3645DD and M15 frame size in Rev 00c.
Update to Figure 3-9, Sections 6.2, and 6.6 in Rev 00d.
Precharge Option was added in Rev 00e.
Figure 6-5 was updated in Rev 00f.
Figure 1-1: Typical M3645P Regenerative DC Bus Power Supply
M3645P
8
1.4. 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
9
2. PRODUCT DESCRIPTION
Regenerated voltage occurs when the speed of the motor exceeds the set speed on the
drive. This can be due to braking or an overhauling load. In applications with extended
braking times, high horsepower, or where frequent regeneration occurs, the M3645P
regenerative DC bus power supply is the economical solution for controlling regenerative
voltage. While resistor solutions waste regenerated energy as heat, the Bonitron M3645P
returns the regenerated energy back to the input AC line. M3645P also acts as a rectifier,
supplying power to the drive bus during motoring.
The M3645P regenerative DC bus power supply synchronizes to the frequency of the
incoming power line, allowing it to automatically adapt to 50Hz or 60Hz input. Under
normal conditions, the M3645P rectifies the AC line and supplies power to the load. During
a braking event, as the DC bus rises above the AC line peak, the M3645P redirects current
from the DC bus into the AC line to limit the rise in bus voltage and prevent overvoltage
faults. While regenerating the M3645P will automatically fold back in an overcurrent
condition, or shut down in the event that unsafe conditions are detected.
With the optional digital display, the current status of the M3645P is shown and fault
records are stored, along with a lifetime count of regenerative energy.
Up to two 100A M3645P units can be run in parallel for high-power applications.
2.1. RELATED PRODUCTS
COMMON BUS DIODES
• M3345CBM Sharing Diode
EXTERNAL PANEL MOUNTED DIGITAL DISPLAY
• KIT 3645DD External Display Kit (compatible only with “L” M3645P power supply)
BRAKING RESISTORS
• M3575R Standard Duty Braking Resistors (<30A)
• M3775R Various Duty Load Banks (<1600A)
BRAKING TRANSISTORS
• M3452 Heavy Duty Braking Transistor (<1600A)
• M3575T Standard Duty Braking Transistor (<600A)
• M3675T Low HP Braking Transistor (<10A)
THREE PHASE POWER SUPPLIES
• M3713DM Non-Regenerative Power Supply (<375A)
• M3713SC Non-Regenerative Power Supply with Precharge (<375A)
LINE REGEN
• M3545 Single Phase or Three Phase Line Regen (<15A)
• M3645 Heavy Duty Line Regen (<375A)
RESISTIVE PRECHARGE
• M3728 Precharge Module
M3645P
10
2.2. PART NUMBER BREAKDOWN
Figure 2-1: Example of M3645P Part Number Breakdown
BASE MODEL NUMBER
The base model number for all regenerative DC bus power supply units is M3645P.
VOLTAGE RATING
A code letter represents the 3-phase AC line input voltage to the power supply module.
The voltage rating must be selected for the system voltage that will be applied. See
Table 2-1 for available voltage ratings.
Table 2-1: Voltage Ratings
RATING CODE
VOLTAGE
L
230 - 240VAC
E
380 - 415VAC
H
460 - 480VAC
C
575 - 600VAC
Note: C voltage class is only available for regens with current ratings of 100A or
lower.
CURRENT RATING
A 3-digit number represents the maximum continuous DC current (Amps) the regen
module can regenerate.
The M10, M11, M12 frame sizes are capable of handling a 50% overload above this
current rating for 60 seconds. The M15 frame size is capable of a 25% overload above
this current rating for 60 seconds.
MODULE IDENTIFIER
This single letter code is added to the model number to indicate if the line regen is
made up of separate reactor and line regen modules. This module identifier is omitted
in regens with current ratings of 30A, 50A, and 100A.
Both a line reactor module and a line regen module are required for 150A, 225A, and
300A models. A single letter code is used to designate the line reactor and the line
regen.
T
MODULE IDENTIFIER
CURRENT RATING
DISPLAY OPTION
VOLTAGE RATING
BASE MODEL NUMBER
CHASSIS STYLE
M3645P
H
300
M15
D
R
PRECHARGE OPTION
User’s Manual
11
Table 2-2: Module Identifier
CODE
MODEL
DESCRIPTION
R
M3645-x150R
Reactor Module
R
M3645-x225R
Reactor Module
R
M3645-x300R
Reactor Module
T
M3645P-x150T-M15
Line Regen Module
T
M3645P-x225T-M15
Line Regen Module
T
M3645P-x300T-M15
Line Regen Module
CHASSIS STYLE
The chassis style is determined by the current rating, and is represented by an
alphanumeric code as defined in Table 2-3. See Section 6.5 for chassis mounting and
dimensional outlines.
Table 2-3: Chassis Styles
CHASSIS CODE
CURRENT
DESCRIPTION
SIZE (H X W X D)
M10
30A
Open Chassis
20.0” x 10.0” x 10.1”
M11
50A
Open Chassis
22.0” x 11.3” x 10.6”
M12
100A
Open Chassis
24.0” x 12.0” x 12.1”
M15
300A
Open Chassis
26.0” x 13.9” x 11.1”
M15 Reactor
300A
Open Chassis
17.9” x 18.8” x 15.2”
See Section 6.5 for chassis mounting and dimensional outlines.
DISPLAY
Two display options are available.
Table 2-4: Option Codes
OPTION CODE
DESCRIPTION
D
Digital Diagnostic Display
L
Basic LED Indicators
NOTE: The KIT 3645DD external display is only compatible with “L” versions of the
M3645P regenerative DC bus power supply. Only a single display can be used for
each M3645P. The M3645P is unable to power more than a single display.
PRECHARGE OPTION
The internal precharge option is designated by a single letter code R. When the
precharge option is not included this code is omitted.
The internal precharge option allows the M3645P to precharge the connected VFD.
M3645P
12
2.3. GENERAL SPECIFICATIONS CHART
Table 2-5: General Specifications
PARAMETER
SPECIFICATION
AC Line Voltage
Voltage Rating
50 or 60 Hz
Voltage Min
Voltage Max
L
207 VAC
253 VAC
E
342 VAC
418 VAC
H
414 VAC
506 VAC
C
518 VAC
600 VAC
DC Input Current
• 30-300A, continuous
• 150% of rating, 60 second overload for M10,
M11, M12 chasses
• 125% of rating, 60 second overload for M15
chassis
Control Voltage
• Internal
Indicators
• Power
• Regen
• Fault
• Optional 4 line character display
Inputs
• Enable 24VDC - 5mA
• Fault Recall 24VDC – 5mA
Outputs
• Ready 200VDC - 100 mA
Operating Temp
• 0 to +40OC
Storage Temp
• -20O to +65OC
Humidity
• Below 90%, non-condensing
Atmosphere
• Free of corrosive gas or conductive dust
User’s Manual
13
2.4. GENERAL PRECAUTIONS AND SAFETY WARNINGS
DANGER!
• HIGH VOLTAGES MAY BE PRESENT!
• NEVER ATTEMPT TO OPERATE THIS PRODUCT WITH THE ACCESS
DOORS OR COVERS OPENED!
• NEVER ATTEMPT TO SERVICE THIS PRODUCT WITHOUT FIRST
DISCONNECTING POWER TO AND FROM THE UNIT!
• FAILURE TO HEED THESE WARNINGS MAY RESULT IN
SERIOUS BODILY INJURY OR DEATH!
CAUTION!
• THIS PRODUCT WILL GENERATE HIGH AMBIENT TEMPERATURES
DURING OPERATION.
• THIS PRODUCT SHOULD BE INSTALLED ON A NON-FLAMMABLE
SURFACE WITH CLEARANCES OF AT LEAST TWO INCHES IN ALL
DIRECTIONS.
• 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 DRIVE AND/OR RESISTIVE
LOAD 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.
M3645P
14
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User’s Manual
15
3. INSTALLATION INSTRUCTIONS
CAUTION!
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.
Proper installation of the M3645P DC bus power supply modules should be executed
following the steps outlined below. Be sure to refer to the AC drive instruction manual as
these steps are performed. Please direct all installation inquiries that may arise during the
installation and start-up of this product to the equipment supplier or system integrator.
3.1. ENVIRONMENT
The module should be installed in an area protected from moisture and falling debris.
Buildup of dust or debris may cause poor performance and possibly a failure.
Operating in a wet environment can pose a shock hazard. The recommended
temperature range for operating this module is 0 to +40C.
Device shall be installed in a pollution degree 2 environment.
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
3.3.1. M3645P DC BUS REGENERATIVE POWER SUPPLY
The installation site for the M3645P power supply should be chosen with several
considerations in mind:
• When mounting regen units in an enclosure, power dissipation should be taken
into account. Refer to Section 6.3 Watt Loss for details.
• The unit requires a minimum clearance of two (2) inches in all directions around it
when not mounted near a heat source. Heat sources may increase necessary
clearances.
• Unit should not be exposed to falling debris or condensation.
Once the installation site has been selected as outlined above, the unit should be
mounted in place.
The M3645P must be properly oriented for proper heat flow through the unit. The
M3645P must be mounted with the rear surface of the unit to the mounting surface.
The unit may be mounted vertically (Figure 3-1D), or with its backplane down and
parallel to the ground (Figure 3-1A).
Do Not mount the unit on the underside of a mounting surface as shown in Figure 31B.
Do Not mount the unit in a horizontal position with its side parallel to the mounting
surface or floor as shown in Figure 3-1C.
Do Not mount the unit in an upside-down position, as shown in Figure 3-1E.
Refer to Table 2-3: Chassis Styles to determine the chassis for the unit. Mounting
dimensions and provisions vary by unit chassis. See Figure 3-1 for mounting
orientation information and Section 6.6 for dimensional drawings.
M3645P
16
Figure 3-1: M3645P Mounting Orientation
Figure 3-1A
Figure 3-1D
HORIZONTAL SURFACE
UP
UP
BONITRON
Figure 3-1B
Figure 3-1E
UP
HANGING UNDERSIDE
UP
BONITRON
Figure 3-1C
UP
PARALLEL TO FLOOR
BONITRON BONITRON
User’s Manual
17
3.3.2. M3645 M15 LINE REACTOR MOUNTING
The installation of the M3645 M15 line reactor should be chosen with several
considerations in mind:
• The M3645 M15 line reactor is only required when using the 150A, 225A, and
300A rated M3645 in the M15 chassis.
• When mounting the line reactor in an enclosure, power dissipation should be
taken into account. Refer to Section 6.3 Watt Loss for details.
• The unit requires a minimum clearance of two inches (2”) in all directions around
it when not mounted near a heat source. Heat sources may increase necessary
clearances.
• Unit should not be exposed to falling debris or condensation.
• The unit can be mounted in any orientation.
Once the installation site has been selected as outlined above, the unit should be
mounted in place. See Section 6.6 for dimensional drawings.
3.3.3. KIT 3645DD, EXTERNAL DISPLAY MOUNTING
The KIT 3645DD external display is comprised of the display board assembly (ASM
3645D3) and a 12-foot-long cable (CBL 3660DD4-DI12). The installation should be
chosen with several considerations in mind:
• The external display requires a cutout from the front panel. See Figure 6-6 for the
dimensional requirements for the cutout.
• The display will attach to the front of the panel. The display is secured to the
panel with a screw in each corner.
• The unit requires a minimum clearance of one (1) inch in all directions around it.
• The unit should not be exposed to falling debris or condensation.
• The 12-foot cable provided with the display must be attached to TB5 on the
control board of the M3645P and to TB3 on the ASM 3645D3 on the rear of the
display. See Figure 3-12.
Once the installation site has been selected as outlined above, the unit should be
mounted in place. See Section 6.6 for dimensional drawings.
NOTE: The KIT 3645DD is only compatible with “L” versions of the M3645P power
supply. Only a single display can be used for each line regen. The line regen is unable
to power more than a single display.
3.4. WIRING AND CUSTOMER CONNECTIONS
Be sure to review all pertinent AC drive and system documentation as well as the
information listed below before proceeding. Connection points and terminal numbers
of the AC drive will be found in the documentation provided with those units. See
Tables 3-1 thru 3-6 and Figures 3-2 thru 3-8 for connection details.
3.4.1. POWER WIRING
CAUTION!
Only qualified electricians should perform and maintain the interconnection
wiring of this product. All wiring should be in accordance with local codes.
DANGER!
Do NOT daisy chain the AC, DC, or ground connections between multiple
power supply units. Each power supply should have separate power and
ground connections.
M3645P
18
▪ Where possible, minimize the wire length between the Power Supply and
the Drive. The wire length should not exceed 10 feet.
▪ Avoid routing and bundling the Power Supply AC/DC wiring with the Drive
AC PWM motor output wiring.
3.4.1.1. 3-PHASE AC INPUT
Do not install chokes or reactors between the power supply and the power
source. M3645P has an internal 5% line reactor.
If an isolation transformer is to be used, the transformer should meet the
ratings shown in Table 3-1.
Table 3-1: Transformer Ratings
Model
Minimum kVA
Maximum
Impedance
L30
13.5 kVA
5.0%
E30
23 kVA
2.9%
H30
26.5 kVA
2.5%
C30
33 kVA
2.0%
L50
22 kVA
6.0%
E50
38 kVA
3.4%
H50
44 kVA
3.0%
C50
55 kVA
2.4%
L100
44 kVA
6.3%
E100
75.5 kVA
3.6%
H100
87.5 kVA
3.1%
C100
109.5 kVA
2.5%
L150
75 kVA
5.0%
E150
125 kVA
6.0%
H150
150 kVA
4.0%
L225
100 kVA
5.0%
E225
170 kVA
6.0 %
H225
200 kVA
4.0%
L300
131 kVA
4.4%
E300
226.5 kVA
2.5%
H300
262 kVA
2.2%
Do not connect to a generator. For further details, contact Bonitron.
The AC line connections should have short-circuit current protection.
Recommended fuses are listed in Section 6.5.
3.4.1.2. INTER-MODULE WIRING FOR 150A, 225A, AND 300A UNITS
For M3645 rated for 150A, 225A, and 300A an individual line reactor
must be used in front of each line regen module. See Figure 3-10 for
wiring diagram.
The user must wire both the control AC wiring from the line reactor to
the line regen module.
User’s Manual
19
The control wiring must be connected to the utility side of the line reactor
and is phase sensitive.
DANGER!
The AC control wiring to the 150A, 225A, and 300A units is phase sensitive.
If the AC control wiring is not in phase with power wiring catastrophic
damage to equipment will result.
3.4.1.3. DC BUS INPUT
The DC bus input may be connected to the DC bus of a single AC drive
or to a common DC bus. If a reactor or choke are being used in the bus,
make sure the actual connection is in parallel with filter capacitors of the
drive/inverter.
DANGER!
Never attach the DC bus input of the M3645P to braking terminals on the AC
drive, commonly marked “BR”. These terminals are intended for use with an
external resistor, and are not directly connected to the bus filter capacitors of
the drive. Damage may occur if these terminals are used.
Please refer to your AC drive manual or AC drive technical support department
for assistance with this connection.
3.4.1.4. GROUNDING
Using the ground stud provided, ground the chassis in accordance with
local codes. Typically, the wire gauge will be the same as is used to
ground the attached drive.
Table 3-2: Power Terminal Specifications - 30 Amp Unit – M10 Chassis
TERMINALS
FUNCTION
ELECTRICAL
RATINGS
WIRE SIZE
MINIMUM
WIRE SIZE
MAXIMUM
TORQUE
L1, L2, L3
AC line outputs
30 A
8 AWG
2 AWG
32 lb-in
DC+, DC-
DC bus inputs
30 A
8 AWG
2 AWG
32 lb-in
GND
Ground
10 AWG
1/0
50 lb-in
Table 3-3: Power Terminal Specifications - 50 Amp Unit – M11 Chassis
TERMINALS
FUNCTION
ELECTRICAL
RATINGS
WIRE SIZE
MINIMUM
WIRE SIZE
MAXIMUM
TORQUE
L1, L2, L3
AC line outputs
50 A
4 AWG
2/0
120 lb-in
DC+, DC-
DC bus inputs
50 A
4 AWG
2/0
120 lb-in
GND
Ground
8 AWG
1/0
50 lb-in
Table 3-4: Power Terminal Specifications - 100 Amp Unit – M12 Chassis
TERMINALS
FUNCTION
ELECTRICAL
RATINGS
WIRE SIZE
MINIMUM
WIRE SIZE
MAXIMUM
TORQUE
L1, L2, L3
AC line outputs
100 A
1 AWG
2/0
120 lb-in
DC+, DC-
DC bus inputs
100 A
1 AWG
2/0
120 lb-in
M3645P
20
GND
Ground
6 AWG
1/0
50 lb-in
Notes:
All power wire should be selected to match or exceed the voltage rating of the unit.
Field wiring for terminals will be copper 75°C wire only.
Figure 3-2: Power Connections
NO CONNECTION
L1 L2 L3 + -
GND
3ØAC INPUT DC BUS
Figure 3-3: Connection Locations
USER
I/0
POWER CONNECTIONS
User’s Manual
21
DANGER!
The AC control wiring to the 150A, 225A, 300A units is phase sensitive. If
the AC control wiring is not in phase with power wiring catastrophic damage
to equipment will result.
Table 3-5: Power Terminal Specifications – 150A, 225A, and 300A Unit – M15 Chassis
TERMINALS
FUNCTION
ELECTRICAL
RATINGS
WIRE SIZE
MINIMUM
WIRE SIZE
MAXIMUM
TORQUE
L1, L2, L3
AC control power
18 AWG
10 AWG
4.4 lb-in
A2, B2, C2
AC line outputs
300 A
350 kcmil
350 kcmil
275 lb-in
DC+, DC-
DC bus inputs
300 A
350 kcmil
350 kcmil
275 lb-in
GND
Ground
3 AWG
1/0
50 lb-in
Notes:
L1, L2, L3 AC control power and A2, B2, C2 AC line output are phase sensitive, switching the order
of phases to any of the inputs may result in damage to the regen. L1 is the same phase as A1. L2
is the same phase as A2. L3 is the same phase as A3.
All power wire should be selected to match or exceed the voltage rating of the unit.
Field wiring for terminals will be copper 75°C wire only.
Figure 3-4: M3645P 150A, 225A, and 300A Power Connections
M3645P
22
Figure 3-5: M3645P 150A, 225A, and 300A Connection Locations
User’s Manual
23
3.4.2. I/O WIRING
User I/O is connected via TB2 on the internal 3645C2 circuit board. To access
this terminal, the front panels of the unit must be temporarily removed. The
inputs can be driven either from an external 24VDC supply, or from the
internal 24V supply. To use the internal 24V supply, TB2-4 and TB2-5
must be shorted.
No additional I/O wiring is required for running multiple M3645P units in
parallel.
Note: since the Overtemperature Fault cannot shut down the power supply
directly, the Overtemperature output should be used to disable the drive in
the event of an Overtemperature Fault. Otherwise an overload condition may
result in catastrophic failure.
Table 3-6: I/O Terminal Specifications
TERMINAL
FUNCTION
ELECTRICAL
SPECIFICATIONS
MIN WIRE
AWG
MAX WIRE
AWG
TORQUE
TB2-1
+24V
24VDC to TB2-5
18
16
2.2 lb-in
TB2-2
Enable Input
24VDC 5mA
18
16
2.2 lb-in
TB2-3
Fault Recall Input
24VDC 5mA
18
16
2.2 lb-in
TB2-4
Input COM
COM to TB2-2, -3
18
16
2.2 lb-in
TB2-5
24V COM
COM to TB2-1
18
16
2.2 lb-in
TB2-6
Ready Output NO
250V 150 mA
18
16
2.2 lb-in
TB2-7
Overtemp Output NO
250V 150 mA
18
16
2.2 lb-in
TB2-8
Output COM
COM to TB2-6, -7
18
16
2.2 lb-in
Note: Field wiring for terminals will be copper 75°C wire only.
Figure 3-4: M3645P 30A, 50A, 100A User I/O Connections
1 2 3 4 5 6 7 8
M3645P
24
Figure 3-6: M3645P Enable Input Using Internal Power Supply
TB2
24V
1 2 3 4 5 6 7 8
ENABLE
FAULT RECALL
Figure 3-7: M3645P Enable Input Using External Power Supply
TB2
24V
24V
1 2 3 4 5 6 7 8
ENABLE
FAULT RECALL
User’s Manual
25
3.5 TYPICAL CONFIGURATIONS
The diagrams shown in Figures 3-9, 3-10, 3-11 illustrate typical connections of a
M3645P unit with generic VFDs. There are many other configurations that may be
applied, providing basic connection criteria are maintained, including:
• The AC terminals should have a low impedance path back to the grid.
• No reactors should be connected upstream of the unit without consulting Bonitron
for instructions.
• The AC feed to the VFDs should be left disconnected.
• The DC terminals should be connected to a fixed bus of one or more VFDs. This
should never be connected to a switching source such as the braking resistor
terminals on some drives.
• The DC terminals should not be connected to an active front end drive without
instructions from Bonitron.
M3645P
26
Figure 3-8: M3645P 30A, 50A, 100A Power Wiring
Disconnect
Isolation
Transformer
(if used)
REGEN
3
M
3
DC+
DC-
INVERTER
M3728
RESISTIVE
PRECHARGE
DC+
(IF NEEDED)
DC+
IN
OUT
User’s Manual
27
Figure 3-9: M3645P 150A, 225A, and 300A Power Wiring
M3645P
28
Figure 3-10: M3645P Multiple Drives Field Wiring Diagram
M
3
Disconnect
Isolation
Transformer
(if used)
REGEN
3
M
3
M
3
DC+
DC-
DC+
DC-
DC+
DC-
INVERTER
INVERTER
INVERTER
M3728
RESISTIVE
PRECHARGE
DC+
(IF NEEDED)
DC+
IN
OUT
User’s Manual
29
Figure 3-11: M3645P Connection with KIT 3645DD, External Panel Mounted Display
USER
I/0
POWER CONNECTIONS
M3645P
30
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User’s Manual
31
4. OPERATION
4.1. FUNCTIONAL DESCRIPTION
The M3645P regenerative DC bus power supply enables energy being generated by
an overhauling motor to be efficiently returned to the power grid. It also supplies power
to one or more drives through their DC bus terminals.
M3645P synchronizes to the frequency of the attached power line, automatically
adapting to 50Hz or 60Hz. During motoring, the unit acts as a passive six-pulse
rectifier with an internal 5% reactor. As the DC bus rises above the AC line peak, the
unit drives current from the DC bus into the AC line to limit the rise in bus voltage.
During regeneration the unit is self-limiting, and will automatically fold back or shut
down in the event that unsafe conditions are detected.
An optional digital display shows information about the power supply’s present status
and history. Fault records and a lifetime count of energy regenerated are stored. On
units without digital displays, system information is presented via three color LEDs.
4.2. FEATURES
4.2.1. DIGITAL DISPLAY
The optional display is a four-line, eighty-character LCD which shows
information about the present status of the unit, as well as records of faults
and energy throughput.
4.2.2. LEDS
Red, yellow, and green LEDs indicate the status of the unit.
4.2.2.1. POWER (GREEN) INDICATOR
The green LED indicates that the unit is powered on.
4.2.2.2. REGEN ACTIVE (YELLOW) INDICATOR
The yellow LED indicates that the unit is actively regenerating power back
to the line.
4.2.2.3. NOT READY (RED) INDICATOR
The red LED indicates that the unit is not ready to regenerate. The red
LED will be off during normal operation.
On units with a digital display, the red LED will illuminate if a fault has
occurred, or if the unit’s enable input (4.5.2) is not activated. In case of a
fault, the display will indicate the nature of the fault.
On units without a digital display, the red LED turns on solid if the enable
input (4.5.2) is not activated. If any faults are present, the red Not Ready
LED will blink out a code indicating the present fault (Table 4-1).
Note that neither condition will prevent the unit from operating as a power
supply. Only the regeneration functions are affected by faults or the
enable signal.
4.2.3. BUTTONS
Up, down, left, right, cancel, and enter buttons are present on the face of
Regen units equipped with a digital display. The function of each button
depends on the active screen. See Section 4.3 for details.
M3645P
32
4.3. DIGITAL DISPLAY OPERATION
These screens display information about the M3645P on units equipped with digital
displays.
4.3.1. METERING SCREEN
This screen displays the present DC bus voltage, DC bus current, power
being supplied or regenerated, and how long the unit has been powered on
since shipment.
Left: Faults screen
Right: Faults screen
Down: Energy Records screen
4.3.2. ENERGY RECORDS SCREEN
This screen displays the total energy regenerated by the unit since shipment,
along with the total energy regenerated since the user reset the energy count.
Up: Metering screen
Down: Reset Energy Records screen
4.3.3. RESET ENERGY RECORDS SCREEN
This screen allows the user to reset the record of energy regenerated by the
unit. This screen also displays the firmware version present on the unit.
Up: Energy Records screen
Enter: Confirm reset
4.3.4. FAULTS SCREEN
This screen shows the present fault state of the unit, scrolling through all
faults detected, if any.
Left: Metering screen
Right: Metering screen
Down: Fault Records screen
4.3.5. FAULT RECORDS SCREEN
This screen shows a record of a previous fault state, including all faults and
the time since first power-on that the fault state occurred. The display stores
the 50 most recent fault states.
Left: Previous fault in the record
Right: Next fault in the record
Up: More recent fault state
Down: Older fault state
Cancel: Faults screen
Figure 4-1: M3645P Screen Tree
FAULTS METERING
FAULT
RECORDS
ENERGY
RECORDS
ENERGY
RECORDS
RESET
User’s Manual
33
4.4. FAULTS
The M3645P monitors a number of different fault conditions which prevent
regeneration from occurring. Some faults latch until they are reset by toggling the
enable input. Faults that do not latch will automatically clear when the fault condition
is no longer present. Every fault opens the Ready Output contact (4.5.5).
On units with a digital display, the display stores the last 50 fault records (4.3.5). On
units without a digital display only the most recent fault state can be viewed. The unit’s
most recent fault state may be accessed by disabling the unit (4.5.2), then setting the
Fault Recall Input (4.5.3) high. The red Not Ready LED (4.2.2.3) will blink out all the
faults of the most recent fault state, in sequence.
CAUTION!
Faults will not prevent the power supply from operating. Only the
regeneration mode will be disabled during a fault event.
Table 4-1: Blink Codes
FLASHES
FAULT
Solid
Unit is not Enabled
1 Fast
Feedback Undervoltage
2 Fast
Overtemperature
3 Fast
DC Overvoltage
4 Fast
Differential Overvoltage
5 Fast
Sync Loss
1 Slow
IGBT Driver
2 Slow
Phase Overcurrent
3 Slow
Phase Loss
4 Slow
DC Undervoltage
5 Slow
Regen Power-On/Precharge Not Complete
6 Slow
Frequency Detect Failure
Note:
Slow: 1 blink per second
Fast: 3 blinks per second
4.4.1. FEEDBACK UNDERVOLTAGE
This fault indicates that the unit’s DC bus feedback circuitry has failed. This
fault will latch until manually cleared by toggling the Enable Input. If this fault
does not clear, it typically indicates that damage to the M3645P has occurred
and must be repaired.
4.4.2. OVERTEMPERATURE
This fault indicates that the unit has exceeded its safe operating temperature.
This fault will automatically clear when the unit's temperature has returned to
a safe level.
CAUTION!
Note: Since the Overtemperature Fault cannot shut down the power supply
directly, the overtemp output should be used to disable the drive in the event
on an overtemp. Otherwise an overload condition may result in catastrophic
failure.
M3645P
34
4.4.3. DC OVERVOLTAGE
This fault indicates that the DC voltage on the bus has exceeded 1000V. This
fault latches until manually cleared.
4.4.4. DIFFERENTIAL OVERVOLTAGE
This fault indicates that the DC bus is more than 200V higher than the AC
line peak. This fault latches until manually cleared by toggling the Enable
Input.
4.4.5. SYNC LOSS
This fault indicates that the regen has lost synchronization with the AC line.
This fault will automatically clear if sync is reestablished, and will latch if it
cannot. If this fault recurs regularly or fails to clear, it is likely due to line
noise, a blown phase fuse, or an undersized AC source.
4.4.6. IGBT DRIVER
This fault indicates that the unit’s internal transistor drive circuitry has
detected an error. This typically indicates an instantaneous overcurrent on
one of the AC legs. This fault will latch until cleared by toggling the Enable
Input. If this fault does not clear, it typically indicates that damage to the unit
has occurred.
4.4.7. PHASE 1-3 OVERCURRENT
These faults indicate that the current the unit is regenerating into one leg of
the AC line has exceeded a safe operating level. This is likely due to voltage
distortion on the line. These faults will latch until cleared by toggling the
Enable Input.
4.4.8. PHASE LOSS
These faults indicate that the unit has lost voltage on one or more of the AC
line phases. These faults clear automatically when voltage is reestablished.
If these faults do not clear, it typically indicates that a line fuse has failed.
4.4.9. DC UNDERVOLTAGE
This fault indicates that the DC voltage on the bus is less than 100V. This
fault will clear automatically when the voltage rises to an operable level. If
this fault does not clear, it typically indicates that damage to the unit has
occurred.
User’s Manual
35
4.4.10. REGEN POWER-ON/PRECHARGE NOT COMPLETE
These faults indicate that the unit has been powered on in the last ten
seconds. This fault will clear automatically. If this fault does not clear, it
typically indicates that damage to the unit has occurred.
4.4.11. FREQUENCY DETECT FAILURE
This fault indicates that the unit failed to properly detect whether the AC
source is 50 or 60 Hz. This fault latches until power-down.
4.5. INPUT / OUTPUT CONNECTIONS
All the inputs for the unit are rated for 24VDC. All inputs are common to TB2-4. The
inputs are bidirectional, and can be configured to be sinking or sourcing as the
installation requires. It is recommended that inputs be configured as sinking, as this
is more failsafe.
The outputs are MOSFET optocouplers common to TB2-8, and will show a low
resistance (20 Ω) to this common when activated. When not activated, they will appear
open.
4.5.1. LOCAL I/O +24V SUPPLY- TB2-1 & TB2-5
This pin supplies 24V, a maximum of 100mA, which can be used to drive the
user inputs. +24V is on TB2-1 and 24V Common is on TB2-5.
4.5.2. ENABLE INPUT - TB2-2
This input enables the unit to regenerate. Faults are reset on a rising edge
of this input. Note that the unit will not regenerate unless this input is active.
The unit will operate in power supply mode regardless of the state of this
input.
4.5.3. FAULT RECALL INPUT -TB2-3
For units with no digital display, the last fault record can be retrieved by
disabling the unit and activating this input.
The last fault code will blink out until the unit is re-enabled.
For units with a digital display, this input has no function.
4.5.4. INPUT COM -TB2-4
All user inputs are common to this terminal.
4.5.5. READY OUTPUT - TB2-6
This output closes to TB2-8 when the unit is ready to operate. This contact
will open if the system is not enabled, if the system is powered off, or on any
fault condition.
M3645P
36
4.5.6. OVERTEMPERATURE OUTPUT - TB2-7
This output closes to TB2-8 when the unit is not indicating an overtemp fault,
and opens if the unit reaches an unsafe operating temperature. This contact
should be monitored and the drive system shut down in the event of an
overtemp fault. Otherwise damage to the power supply may result.
DANGER!
The M3645P will continue to rectify incoming voltage and operate with the
temperature switch open.
Continued operation with the temperature switch open can cause dangerous
overheating of the M3645P, and can cause permanent damage, and
catastrophic failure.
4.5.7. OUTPUT COM - TB2-8
This terminal is the common to the outputs. It is not common to TB2-4, and
allows the use of a different power supply for outputs if the installation
requires.
4.6. STARTUP
This section covers basic checks and procedures that should be used when
performing a startup with a M3645P regenerative DC bus power supply.
4.6.1. PRE-POWER CHECKS
▪ Ensure that the voltage of the AC power system is the same as the
voltage rating of the unit.
▪ Ensure that all connections are tight and that all wiring is of the proper
size and rating for operation.
▪ Verify continuity of all input fuses prior to applying power.
▪ Check for exposed conductors that may lead to inadvertent contact.
▪ Check for any debris, shavings, trimmings, etc. that may cause shorts or
obstruct ventilation on unit.
4.6.2. STARTUP PROCEDURE AND CHECKS
After completing pre-checks and recommended checks for connected
equipment, you may apply power to the system. The Power indicator on the
front panel should illuminate. The fan should start, then stop within ten
seconds. Attached drive units should also power on.
Enable the unit by placing 24VDC on the “Enable” input. (Table 3-6 or Table
3-7 for 150A, 225A, and 300A units)
The Status Contact should be closed after a 2 second delay, which is an
indication that unit is ready for operation.
Observe the current on the digital display, or with a current clamp for systems
without a digital display. If more than 5 amps are flowing with the attached
drive not operating, go to the Troubleshooting instructions in Section 5.3.
Once the Status output closes, the unit is ready to operate in regen mode,
and the drive system can be run normally.
4.6.3. COOLING FAN
The cooling fan will not run all the time. The fan runs at startup, when the unit
is regenerating, or when the unit’s internal temperature is above a certain
level. If the cooling fan never runs, there may be damage to the fan and the
unit may need repair.
User’s Manual
37
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. PERIODIC TESTING
There are no requirements for periodic testing of these units. It may be beneficial to
repeat start-up procedures and checks when performing routine maintenance.
5.2. MAINTENANCE ITEMS
Check the fan periodically for debris, and blow out with an air hose if it has become
obstructed or not running at full capacity. Power should not be applied when
blowing dust and debris out of unit.
5.3. TROUBLESHOOTING
CAUTION!
There are no user serviceable parts within the M3645P. If you are still
experiencing problems after you have reviewed this whole section, you
may contact Bonitron for additional assistance at (615) 244-2825.
5.3.1. POWER LED IS NOT ON, OR DIGITAL DISPLAY IS NOT ACTIVE:
▪ Check AC input voltage at terminals. Voltage should be within range
specified in Table 2-1 for your unit. If the power light will not come on,
check any overcurrent devices or disconnects upstream of the unit.
▪ If the power lamp will not come on, it is likely that the unit is damaged and
needs to be repaired.
5.3.2. READY OUTPUT WILL NOT CLOSE
The Ready output indicates that the module is enabled and in a ready
condition. When the power is applied to the module, the Ready output will
normally close after a startup delay of approximately 2 seconds. Thereafter,
the Ready output should be closed, indicating that the system is ready to
operate. If the Ready output fails to close, one of several faults may be
indicated.
▪ Make sure the Power LED is on.
If the Fault LED is blinking, refer to Table 4-1, “Blink Codes” to determine
which fault is active, or look at the digital display.
▪ If the Fault LED is on solid, the "Enable" input is not activated.
5.3.3. UNIT WILL NOT RESPOND TO ENABLE COMMAND
▪ Confirm that 24V is present between TB2-2 and TB2-4 (see Figure 3-6).
▪ If the internal 24V supply is being used, confirm that a jumper is present
between TB2-4 and TB2-5.
5.3.4. DRIVE TRIPS ON DC BUS OVERVOLTAGE DURING BRAKING
If an attached drive trips on overvoltage, it typically indicates the M3645P is
not regenerating. There are some simple things that can determine the
cause.
M3645P
38
▪ Make sure the unit has power and is enabled. The "Ready" output will
close if the unit is ready to operate. (4.5.2)
▪ See if there are any faults reported.
▪ Check DC bus voltage at fuses.
▪ Check DC bus polarity at fuses.
▪ Check DC bus fuses for continuity.
▪ Ensure unit is not faulting during operation. Some faults may clear
themselves, such as phase loss, but fault recall will show that they have
occurred. Check the fault records to see if the unit has recorded faults
that would cause the operation to stop regenerating, resulting in a drive
overvoltage.
▪ Confirm that the unit is properly sized. If the braking energy is too high
for the unit to regenerate, the unit will go into current limit, which will result
in an uncontrolled bus voltage rise. The current being regenerated can
be checked with the digital display or with a separate meter in the DC
link. If the unit is operating in current limit, it may be undersized for the
application.
▪ If the M3645P is connected to the AC line through a transformer, the
transformer may not be large enough to handle the regenerated currents.
See section 3.4.1.1 for transformer sizing instructions.
▪ With 150A, 225A, and 300A units, confirm that the phase rotation of the
AC control power connections between the reactor and the transistor
module match the power connections.
5.3.5. FEEDBACK UNDERVOLTAGE
Reset the M3645P by toggling the enable input. (4.5.2)
If the fault returns, contact Bonitron for assistance.
5.3.6. OVERTEMPERATURE
Check the ambient temperature. If the temperature is above 40°C, the unit
may not be able to cool properly at full load. Ensure that there is adequate
clearance and airflow in the area where the Regen is installed.
Check to make sure the fan is operating. The fan will operate for a few
seconds after power up. Cycle power to the unit and listen for the fan
operation. If it does not operate, check for obstruction.
If the unit is cool and still showing an overtemperature condition, contact
Bonitron for assistance.
If an overtemperature fault is listed in the fault log in conjunction with a
Precharge Not Complete fault, this indicates that control power to the unit has
been reset. No actual overtemperature condition has occurred.
5.3.7. DC OVERVOLTAGE
If the M3645P indicates a DC bus overvoltage fault, this typically indicates
incorrect installation or damage to the unit. The M3645P only indicates this
fault if the DC bus registers as over 1000 VDC. For units of L-, E-, or Hvoltage classes this is not generally possible. For units of the C- voltage
class, check all the conditions described in Section 5.3.34.
Confirm that the system topology matches the diagrams shown in section 3
of the manual.
Confirm with a voltmeter that the DC bus polarity matches the markings on
the unit.
User’s Manual
39
This fault may occur if the regen is connected to multiple drives, with blocking
diodes between each drive ant the regen. This topology is not supported.
Please contact Bonitron for possible alternative common bus solutions.
5.3.8. DIFFERENTIAL OVERVOLTAGE
Differential overvoltage can be caused by the same reasons as the DC
Overvoltage. Refer to Section 5.3.7.
5.3.9. SYNC LOSS
Ensure that the overcurrent devices on the incoming AC line are intact.
Ensure that the AC source is properly sized for the application. "Soft" or high
impedance sources can have significant voltage distortion that can cause the
unit to lose sync. You can check for voltage distortion on the incoming AC
line with an oscilloscope and probes of an appropriate voltage class. It will
be important to be watching the AC line when the Sync Loss fault occurs, as
the distortion may not be present all the time, especially when the line is not
loaded.
If a sync loss fault is listed in the fault log in conjunction with a Precharge not
Complete fault, this indicates that control power to the unit has been reset.
No actual sync loss condition has occurred.
5.3.10. IGBT DRIVER
This fault can be reset by toggling the enable input. (4.5.2)
If the fault cannot be cleared, or occurs frequently, the unit may be damaged.
Contact Bonitron for assistance.
If two M3645P units are operated in parallel, IGBT faults may indicate that
the parallel combination is undersized for the application.
5.3.11. PHASE OVERCURRENT
This fault can be cleared by toggling the enable input. (4.5.2)
If it occurs frequently, there may be a voltage imbalance on the incoming AC
line. Ensure that the incoming line voltages are within 3% of each other.
5.3.12. PHASE LOSS
This fault typically means that the incoming power overcurrent devices or
fuses are blown.
Power the unit down and check all fuses and that AC voltage is present at
the terminals of the Regen.
5.3.13. DC UNDERVOLTAGE
This may indicate that overcurrent devices in the DC link may have opened.
Check the AC and DC voltages with an external voltmeter and make sure
they are within specification.
If the voltages are correct, and the fault will not clear, contact Bonitron for
assistance.
5.3.14. REGEN POWER-ON/PRECHARGE NOT COMPLETE
This fault is expected to occur every time the unit powers on. It should clear
automatically within ten seconds.
If the fault does not clear automatically, power the M3645P down and check
all incoming AC and DC fuses or overcurrent devices.
Ensure that DC bus voltage is present at the terminals of the regen, at the
M3645P
40
expected voltage.
If the fault cannot be cleared, or occurs frequently, the unit may be damaged.
Contact Bonitron for assistance.
5.3.15. FREQUENCY DETECT FAILURE
Power the M3645P down and check all incoming AC and DC fuses or
overcurrent devices.
5.3.16. TECHNICAL HELP – BEFORE YOU CONTACT US
If technical help is required, please have the following information available
when contacting Bonitron (615) 244-2825, or email to info@bonitron.com):
• Model number of unit
• Serial number of unit
• Name of original equipment supplier if available
• Record the Line to Line voltage on all 3 phases
• Record the DC bus voltage immediately after the AC voltage
• Brief description of the application
• Drive and motor HP or kW
• KVA rating of power source
• Source configuration Wye/Delta and grounding
User’s Manual
41
6. ENGINEERING DATA
6.1. RATINGS CHARTS
Table 6-1: Ratings and Specifications – 230 - 240VAC
MODEL
NUMBERS
CHASSIS
STYLE
DC REGEN CURRENT
POWER
MAX CONT.
WATT LOSS
CONT.
PEAK
CONT.
PEAK
M3645P-L030
M10
30A
45A
14.4HP
21.6HP
180W
M3645P-L050
M11
50A
75A
24.0HP
36.0HP
265W
M3645P-L100
M12
100A
150A
48.0HP
72.0HP
470W
M3645P-L150T
M15
150A
225A
72.0HP
108.0HP
2980W
M3645-L150R
M15
300W
M3645P-L225T
M15
225A
335A
108.0HP
160.8HP
2980W
M3645-L225R
M15
300W
M3645P-L300T
M15
300A
375A
96.0HP
120.0HP
2980W
M3645-L300R
M15
300W
Table 6-2: Ratings and Specifications – 380 - 415VAC
MODEL
NUMBERS
CHASSIS
STYLE
DC REGEN CURRENT
POWER
MAX CONT.
WATT LOSS
CONT.
PEAK
CONT.
PEAK
M3645P-E030
M10
30A
45A
25.0HP
37.5HP
180W
M3645P-E050
M11
50A
75A
41.7HP
62.6HP
265W
M3645P-E100
M12
100A
150A
83.4HP
125.2HP
470W
M3645P-E150T
M15
150A
225A
125.0HP
187.5HP
2980W
M3645-E150R
M15
300W
M3645P-E225T
M15
225A
335A
187.5HP
279.2HP
2980W
M3645-E225R
M15
300W
M3645P-E300T
M15
300A
375A
250.0HP
312.5HP
2980W
M3645-E300R
M15
300W
Table 6-3: Ratings and Specifications – 460 - 480VAC
MODEL
NUMBERS
CHASSIS
STYLE
DC REGEN CURRENT
POWER
MAX CONT.
WATT LOSS
CONT.
PEAK
CONT.
PEAK
M3645P-H030
M10
30A
45A
28.8HP
43.2HP
180W
M3645P-H050
M11
50A
75A
48.0HP
72.0HP
265W
M3645P-H100
M12
100A
150A
96.0HP
144.0HP
470W
M3645P-H150T
M15
150A
225A
144.0HP
216.0HP
2980W
M3645-H150R
M15
300W
M3645P-H225T
M15
225A
335A
216.0HP
321.6HP
2980W
M3645-H225R
M15
300W
M3645P-H300T
M15
300A
375A
288.0HP
360.0HP
2980W
M3645-H300R
M15
300W
M3645P
42
Table 6-4: Ratings and Specifications – 575 - 600VAC
MODEL
NUMBERS
CHASSIS
STYLE
DC REGEN CURRENT
POWER
MAX CONT.
WATT LOSS
CONT.
PEAK.
CONT.
PEAK
M3645P-C030
M10
30A
45A
36.0HP
54.0HP
180W
M3645P-C050
M11
50A
75A
60.0HP
90.0HP
265W
M3645P-C100
M12
100A
150A
120.0HP
180.0HP
470W
A NOTE ON HP RATINGS
Modules are able to source or regenerate continuous power indefinitely. Modules can
source or regenerate peak power for at least 60 seconds.
Each unit’s current and power specifications must be derated by 2% per degree
Celsius ambient above 40°C.
6.2. DERATING PARALLEL UNITS
Currently, the 100A and 300A frames sizes are able to be used in parallel. The
maximum number that can be safely operated in parallel. Units with different current
ratings should not be in parallel together on the same DC bus. Paralleled units must
be derated by 10% each. The derating for parallel systems is shown in Table 6-5.
Two units are the maximum number that can be safely operated in parallel. Units
with different current ratings should not be in parallel together on the same DC bus.
Table 6-5: Derating Regens in Parallel
INDIVIDUALM3645P
CURRENT RATING
NUMBER IN
PARALLEL
DC REGEN CURRENT FOR
TWO M3645P IN PARALLEL
CONT.
PEAK.
100A
2
200A
270A
300A
2
600A
675A
6.3. WATT LOSS
Tables 6-1 thru 6-4 list the maximum continuous watt loss generated. When installing
units in an additional enclosure, consideration should be given to internal temperature
rise. The watt loss rating in these tables is based upon the maximum continuous regen
capability of each unit. Applications that do not utilize the full capacity may be
calculated by using the percentage of loading for the individual unit.
The M3645P is >98% efficient when fully loaded.
6.4. CERTIFICATIONS AND ROHS
M3645P models with 30A, 50A, and 100A ratings are listed under UL508C, file number
E204386.
The M3645P line regen is suitable for use on a circuit capable of delivering not more
than 65 kA RMS symmetrical amperes at the rated voltage, when protected by the
recommended AC fuses. DC fusing is not required.
All M3645P models are in compliance with Directive 2011/65/EU of the European
Parliament and of the Council of 8 June 2011 on the restrictions of the use of certain
hazardous substances in electrical and electronics equipment (RoHS Directives).
User’s Manual
43
6.5. FUSE SELECTION
Blown fuses typically indicate a semiconductor device failure or a severe transient. In
any case, blown fuses should not be replaced without first consulting Bonitron as
catastrophic damage can occur.
Use Tables 6-6 and 6-7 when initially constructing the system.
Note: AC fuses must be J-type or equivalent.
Table 6-6: Fuse Current Rating Requirements
MODEL
NUMBER
AC / DC FUSE
CURRENT RATING
M3645P-x030
40A
M3645P-x050
60A
M3645P-x100
125A
M3645P-x150T
175A
M3645P-x225T
250A
M3645P-x300T
350A
Table 6-7: Fuse Voltage Rating Requirements
SYSTEM
VOLTAGE
AC FUSE
VOLTAGE RATING
DC FUSE
VOLTAGE RATING
230–240VAC
240VAC
350VDC
380–480VAC
600VAC
700VDC
575–600VAC
600VAC
1000VDC
M3645P
44
6.6. DIMENSIONS AND MECHANICAL DRAWINGS
Figure 6-1: M3645P M10 Chassis Dimensional Outline
User’s Manual
45
Figure 6-2: M3645P M11 Chassis Dimensional Outline
M3645P
46
Figure 6-3: M3645P M12 Chassis Dimensional Outline
User’s Manual
47
Figure 6-4: M3645P M15 Dimensional Outline
M3645P
48
Figure 6-5: M3645 M15 Line Reactor Dimensional Outline
User’s Manual
49
Figure 6-6: KIT 3645DD, External Display Dimensional Outline
5.00
127.0 mm
7.50
190.5 mm
6.83
173.5 mm
4.13
104.8 mm
7.00
177.8 mm
.19
4.8 mm
4.50
114.3 mm
.25
6.4 mm
.25
6.4 mm
R.13
R3.2 mm
R.13
R3.2 mm
n.19
n4.8 mm
.19
4.8 mm
CUTOUT
M3645P
50
6.7. BLOCK DIAGRAM
Figure 6-7: Typical Customer Application
User’s Manual
51
7. APPENDIX
7.1. APPLICATION NOTES
7.1.1. SIZING THE LINE REGENERATION UNIT
The line regeneration unit is sized for the amount of DC bus current, I
DC,
which
it must carry. To obtain the amount of DC bus current needed during
deceleration; the load and motor inertias, desired change in RPM, and
required stopping time must be known. With these application variables, the
following calculations can be made to size the regen. Use the equation below
to establish the torque required to decelerate or stop a rotating object.
CALCULATE MOTOR TORQUE
Calculating the motor torque
Where
T is torque measured in lb·ft.
1.0 lb·ft = 1.355818 Nm
WK
2
is the total inertial load to be decelerated (lb·ft2).
1.0 lb·ft2 = 0.04214011 kg·m2
ΔN is the change in rotational speed (rpm).
308 is a constant
ton is time required to decelerate the load (s).
CALCULATE MOTOR POWER
Calculating the power (HP) regenerated:
Where
N
max
is the maximum rotational speed (rpm).
The constant 5252 has units of lb·ft/min/radian.
CALCULATE DC BUS CURRENT
Calculating the regenerated DC bus current, IDC.
The DC bus current, IDC, is approximated for the following AC line voltages:
For 230 V
AC
systems:
For 380 V
AC
systems:
For 460 V
AC
systems:
For 575 V
AC
systems:
Once I
DC
is known, you will be able to appropriately size the line regen
based upon its current rating.
M3645P
52
7.1.2. CALCULATING ENERGY SAVINGS
The regen directs energy from the mechanical load to the power distribution
line, where the energy is available to other connected loads. These units
provide system energy savings over dynamic braking kits, because the net
energy required from the distribution system is reduced by the regenerated
energy. Additional savings also come from the lack of a need to provide air
conditioning with a dynamic braking kit and from reduced time spent stopping
loads.
To calculate the savings, the regeneration duty cycle, the length of operation,
the regen HP, and the cost of energy must be known. With these application
variables, the following calculation may be made to determine the cost
savings:
CALCULATE SAVINGS PER YEAR
Calculating total savings per year in dollars:
Where
S is Savings per year.
C is the cost in dollars per kW.
P is the regenerated power.
D is the number of days the system is operated.
H is the number of hours per day the system is operated.
ton is the number of seconds per cycle T power is regenerated.
t
cycle
is the total time to complete a cycle.
SAVINGS EXAMPLE
Assume the following values for this example:
C = $0.11 per kW
P = 20HP peak, 15HP average during deceleration
D = 365 days
H = 10 hours per day
t
on
= 5 seconds regen is on
t
cycle
= 15 seconds
Savings:
User’s Manual
53
NOTES
M3645P
54
D_M3645P_CMAN_vall_00f 10/27/2017
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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