Model M3452 - Bonitron, Inc.

1 Web: Tel: 615-244-2825 Email: Model M3452 Combination Braking Module with Integrated Transistor and Resistor 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.

2 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.

3 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 M3452 Complete 4 1. INTRODUCTION .. 7 Who Should Use .. 7 Purpose and Scope .. 7 Manual Version an d Change Record.

4 7 Figure 1-1: Typical M3452 Complete Module .. 7 Symbol Conventions Used in this Manual and on Equipment .. 8 2. PRODUCT DESCRIPTION / FEATURES .. 9 Related Products .. 9 Part Number Breakdown .. 9 Table 2-1: Part Number Breakdown .. 9 Table 2-2: AC Voltage Rating .. 9 Table 2-3: Resistors .. 10 Table 2-4: Chassis Codes .. 10 General Specifications .. 10 Table 2-5: Specifications .. 10 General Precautions and Safety Warnings .. 11 3. INSTALLATION INSTRUCTIONS .. 13 Environment .. 13 Unpacking .. 13 13 Mounting the M3452 .. 13 Figure 3-1: Prohibited Mounting Arrangement .. 14 Figure 3-2: Recommended Placement and Required Minimum Mounting Clearances .. 14 Wiring and Customer Connections .. 15 Power Wiring .. 15 Figure 3-3: TS1 Termination Information .. 15 Table 3-1: Power Wiring Specifications .. 15 Table 3-2: DC Bus Wiring Specifications .. 16 Typical Configurations .. 17 Figure 3-4: Field Connections.

5 17 4. OPERATION .. 19 Functional Description .. 19 Features .. 19 Indicators .. 19 Crowbar Circuit .. 19 Startup .. 19 Pre-Power Checks .. 19 Startup Procedure and Checks .. 20 Operational Adjustments .. 20 5. MAINTENANCE AND TROUBLESHOOTING .. 21 Periodic Testing .. 21 Maintenance Items .. 21 Troubleshooting .. 21 Control power light not illuminated .. 21 DC bus light not illuminated .. 21 Blown DC bus fuse .. 22 Fan runs constantly .. 22 Fan doesn t run .. 22 Module over-temp, or module seems too hot .. 23 Table of Contents 5 Drive trips on overvoltage .. 23 Braking light flickers .. 23 Braking light stays on all the time .. 23 Technical Help before you call .. 24 6. ENGINEERING DATA .. 25 Ratings Charts .. 25 Table 6-1: Model Ratings .. 25 Turn On Voltages .. 25 Table 6-2: Turn-on Voltages .. 25 Certifications .. 26 UL 508A Short Circuit Current Rating .. 26 Fuse/Circuit Breaker Sizing and Rating.

6 26 Dimensions and Mechanical Drawings .. 27 Figure 6-1: Enclosure Dimensional Outline (Styles B & C ) .. 27 Block Diagrams .. 28 Figure 6-2: Block Diagram .. 28 7. APPLICATION NOTES .. 29 Sizing your Braking Requirements .. 29 Horsepower to Watts .. 29 Peak 29 Ohmic Value .. 29 Duty Cycle .. 30 Continuous Rating .. 30 Common Bus Application Note .. 30 Bonitron Line Regeneration Modules .. 31 M3452 Complete 6 This page intentionally left blank. User s Manual 7 1. INTRODUCTION 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. PURPOSE AND SCOPE This manual is a user s guide for the Model M3452 Complete Braking Module. It will provide the user with the necessary information to successfully install, integrate, and use the M3452 Complete Braking Module in a variable frequency AC drive system.

7 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. MANUAL VERSION AN D CHANGE RECORD Model ratings were updated in Rev 05c of this manual. Fusing information was updated in Rev 05d of this manual. Block diagram was updated in Rev 05e of this manual. The manual template was updated in Rev 05f of this manual. Figure 1-1: Typical M3452 Complete Module M3452 Complete 8 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.

8 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 / FEATURES Bonitron's Complete Braking Module provides drive protection from overvoltage faults and allows for full power braking. The Complete Braking Module works with any AC drive system that uses a fixed DC bus by shunting the excess energy through a load resistor. Regenerative braking occurs when an induction motor is decelerating or the shaft of the motor is being overhauled by a load. In this case, the motor acts as a generator, and causes the DC bus of the Variable Frequency Drive to rise. If the DC bus voltage is not controlled, the VFD will trip on DC Bus Overvoltage and stop regulating the motor speed. The regenerated energy must be dissipated as heat or returned to the power line.

9 Dissipating this heat may be impractical in applications with more frequent regeneration. In these applications, the higher cost of the Bonitron M3645 Line Regen as compared with resistive braking is quickly offset because the regenerated energy, which is returned to the AC line with near unity power factor, can be used to power other equipment. RELATED PRODUCTS The M3575T Standard Duty Braking Transistor Module offers 15 to 600 hp braking capability at a 20% duty cycle. The M3452 Heavy Duty Braking Transistor Module is compatible with a number of other Bonitron modules, which may be required to meet overall system operational requirements. The M3575R represents a line of enclosed Resistive Load Modules rated up to 150hp peak. The M3775RK represents another line of Resistive Load Banks rated up to 3 megawatts. PART NUMBER BREAKDOWN Table 2-1: Part Number Breakdown BASE Model NUMBER The Base Model Number for the Complete Braking Module is M3452 .

10 VOLTAGE RATING The Voltage Rating indicates the AC voltage level for the drives in the system. Table 2-2: AC Voltage Rating RATING CODE NOMINAL AC LINE L 230 VAC H 460 VAC C 575 VAC M3452 H 9 C BA S E MO D E L NU M B E R CO N T R O L VO L T A G E RE S I S T O R S CH A S S I S ST Y L E R050 RE S I S T A N C E M3452 Complete 10 RESISTORS The Resistor Quantity is indicated by a numeric code. Table 2-3: Resistors RATING CODE RESISTOR QUANTITY 2 2 Resistors 3 3 Resistors 6 6 Resistors 8 8 Resistors 9 9 Resistors CHASSIS SIZE The Chassis code represents the chassis size of the Complete Braking Module. Table 2-4: Chassis Codes CHASSIS CODE RESISTORS TYPE DIMENSIONS (H X W X D) B 2, 3, 6 Type 1 x C 8, 9 Type 1 x RESISTANCE The Resistance is indicated by an R followed by the 3-digit number representing the ohmic value of the internal load bank. GENERAL SPECIFICATIONS Table 2-5: Specifications PARAMETER SPECIFICATION Connections Input AC line Drive DC Bus Ground Input AC Line 230, 460, 575 VAC Single Phase; Rated Voltage 10%; 50/60 Hz Operating Temp 0 to 50 C Storage Temp -20 to + 65 C Humidity Below 90 % non-condensing Atmosphere Free of corrosive gas and conductive dust User s Manual 11 GENERAL PRECAUTIONS AND SAFETY WARNINGS DANGER!