Bonitron M3645P Manual de usuario

Web: www.bonitron.com ● Tel: 615-244-2825 ● Email: [email protected]m

Model M3645P

Regenerative DC Bus Power Supply

Customer Reference Manual

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.

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

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

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

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

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

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

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 theDC 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

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

230 - 240VAC

380 - 415VAC

460 - 480VAC

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.

MODULE IDENTIFIER

CURRENT RATING

DISPLAY OPTION

VOLTAGE RATING

BASE MODEL NUMBER

CHASSIS STYLE

M3645P

300

M15

PRECHARGE OPTION

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