User Manual
Contents
1. 9 9 9 m R5 O R2 O O R115A 81158 4 LW y 22 D42 219 S S 9 118 J1 o lt gt 0 59 L3 D oc wy us R82 d e 17 T D 5 T gt User s Manual 4 OPERATION 4 1 4 2 FUNCTIONAL DESCRIPTION The M3345 Line Regen enables energy being generated by an over hauling motor to be efficiently re2. 1 5 m B LJ LJ er pamm unum ee oe J EO _ 4 2 5 2 8 0 5 0 0 N 5 L f i 6 6 4 00 5 E E 1 5 n 5 ex uj GM S 5 E 8 5 24 13 D SIESIES e 11 03 SSIS Tere ES L 15 00 Dwg 940040 Rev 20080310 39 M3345 40 Figure 6 6 M3345 C Chassis Dimensional Outline 11 22 CONDUIT ACCESS 26 50 25 25 O Cor LO D 2 0 9 E 16 08 JO e GA 10 00 5 O t pur 22 00 T t 0 0 o e e o 6 5 _ amp ake e Oz 2 eek ooj 2 lt
3. 28 5 3 4 Meter showing excessive current when in standby lt 3 rated current 28 5 3 5 Drive trips on DC De a aaa waah ka ene rennen 28 5 3 60 OVERLOAD light en a aa nennen ennt enne 28 5 3 7 CURRENT LIMIT On icti et 28 5 3 8 Technical Help before you call orcinec initieert a t e rennen 29 Gils Ratings Charts ee a tte te eee 31 Table 6 1 Ratings and Specifications 230 31 Table 6 2 Ratings and Specifications 380 32 Table 6 3 Ratings and Specifications 460 00 01 4 33 6 25 Watt L088 eter des et eee i de Et ea oe e ace 34 6 5 Gertitic at los 2 521828 ee emt eee retur sepe een 34 6 4 Fuse Circuit Breaker Sizing and Rating essere 34 Table 6 4 Replacement FUSES 34 6 5 Dimensions and 35 Figure 6 1 M3345 S Chassis Dimensional Outline esee 35 Figure 6 2 M3345 Chassis Dimensional Outline eese enne 36 Figure 6 3 M3345 Chassis Dimensional Outline esee 37 Figure 6 4 M3345 Chassis Dimensional Outline eerte ener enne 37 Figure 6 5 M3345
4. 16 Table 3 2 Power Terminal Specifications 60 amp 90 Amp Chassis 16 Table 3 3 Power Terminal Specifications 120 Amp 16 34 2 16 Table 3 4 I O Terminal Specifications S 1 16 Table 3 5 Terminal Specifications and X Chassis 17 Table 3 6 I O Terminal Specifications Y Z and V Chassis eene 17 Figure 3 2 S Chassis Connections icit eere pepe Tere eene irte tere 17 7 Figure 3 4 V Chx Cont Uh a p pied ie Pp ea ripe eis ipta 18 Eigure 3 5 and petia ieee 18 Figure 3 6 60490 Amp Chx Conn 18 Figure 3 72 120 Amp Chx 18 8 3 5 Typical Conf 10 ettet I Le EL E Peh EE M Da 18 Figure 3 9 M3345 10 120 Amp Single Drive Regen Field Wiring 19 Figure 3 10 M3345 Multiple Drives Regens Field Wiring Diagram 20 Figure 3 11 M3345 Master Slave I O Connection 21 Figure 3 12 Control Board amp Jumper Configuration s
5. 5 Open so 4 n m Masa52AGMEM ss 4 1965 33452 7 Open so 6 4 2 mes 4254 TYPE ss 12 1965 0506098 Open oo 2 n 3345 25 __ 55 12 1965 5 257 Open ss 2 12 1965 an M in this place denotes a Current Meter is included a 0 indicates Current Meter is not included 31 M3345 Table 6 2 Ratings and Specifications 380 Ginesi DC REGEN ODEL NUMBERS STYLE CURRENT CURRENT 345 50 0 Open 10 6 M3345 30BM00 TYPE 13 10 6 7 M33453100 Open 20 6 15 M3345 31BM00 TYPE 13 9 6 15 4 27 45 2 90 Open 30 6 2 4 27 M334532BM00 3 9 6 2 4 27 Masas sAWMEM TYPE 60 55 4 4 1965 3345 5 60 9 45 36 1741 M3345 8ACMFM TYPE 3 06 55 45 a 195 M3345 3AZ FM Open 60 55 45 4 195 Ms345 35WMFM_ 1 90 55 67 1965 3345 55 Open 90 48 67 36 1741 M3345 85CMFM 9 55 67 195 3345 357 _ Open 9 s 67 4 1965 M3345 860VMFM TYPE 120 9 271 M3345 86CMFM TYPE 3 120 89 271 Masas s6z0rM Open 120 89 271 an in this place denotes a Current Meter is included
6. 7 7 Figure 1 1 Typical M3345 Unit in the S and Chassis 2 20 011 01 0 n anane 7 1 4 Symbol Conventions Used in this Manual and on Equipment 8 2 1 Related DOCS nier eripe Ule pt e EN GAK LEA Kh 9 2 2 Part Number Breakdown 9 Figure 2 1 Example of M3345 Part Number Breakdown 9 Table 2 1 Voltage Rating e une Gone 10 Table 2 2 Current Ratings Lets ete mte temet NAN 10 Table 2 3 Chassis Styles Ga NAN GAGANG esses eene 10 2 3 General 5 010 110 11 Table 2 4 General Specifications 11 2 4 General Precautions and Safety Warnings 12 INSTALLATION INSTRUCTIONS toes Res era 5 1 Environment arenen get edet e epo Ie Ete re re nre EET an 13 3 2 npackIng erit reU eret 7 13 3 94 ene rie tee DE ete eta Eo lote pred a eb cede eerie 13 Figure 3 1 M3345 Mounting 14 15 IPOWOPMWirDg e dest 15 Table 3 1 Power Terminal Specifications 10 to 45 Amp Chassis
7. 9 Lo lt 5 5 0 e 5 alellelelelle lt ao ES DIOE 9 120065 Rev 20120308 2 a 0 lt T N N OUTLINE DIMENSIONAL User s Manual Figure 6 7 M3345 X Chassis Dimensional Outline 1 NZ N U 09 gt O y lt nS 52 o 22 e f e Qi Ls fe 21 x 9 OF SS d 3 5 gt peor SIES E ET ECT 4 SIs n 20 El D 8 2 me 5 8 5 14 n LSS IES e e gt e amp 9 gt 51224 15 000 APPROX DIM INCLUDING WIRES 0222 02222777
8. CZZZZ CZZZZZZ 027777711 Dwg 920322 Rev 20080311 41 M3345 Figure 6 8 M3345 Chassis with Fan Dimensional Outline N 2 N i5 QU el p 21 4 iji 65 94 gt SILS on 000 EAE 223 SIS B n Se 5 E l D se Qi 5 2 5 E zt as n 00 SIISJIS POPE EH H gt FER 9 211111 ol z gt 2 2 o te 5 P m 1 rS ex o 5 3 lt 16 42 Dwg 940190 Rev 20080311 User s Manual Figure 6 9 M3345 Y Chassis Dimensional Outline USED ONLY ON MASTER OR SLAVE UNITS Qi qa M3345 Y CHASSIS DIMENSIONAL OUTLINE Dwg 950052 Rev 20070928a 43 M3345 44 Figure 6 10 M3345 Z Chassis Dimensional Outline M3345 Z CHASSIS DIMENSIONAL OUTL
9. 00 2 v oV N393H 9966 ov YALSV N3934 Sree TAGON C HOLON WOIdAL HOLON WOIdAL HOLOW WOIdAL 021 8 06 9 5 1 15 8 16 OV 1 Dwg 950175 Rev 20070522 20 User s Manual Figure 3 9 M3345 Master Slave I O Connection Diagram 2 5 7 6 6 5 5 6 5 SNLWLS 5 0115 OISN JAV IS JAV IS PIE UN 24 N 4 13 1 UN 6 6 5 6 6 5 SNLVLS AAW IS puc SNLVLS O IS N AAV IS ISI SNLVLS O SW d3lsviN 21 Dwg 070129 Rev 20070522 M3345 22 Figure 3 10 Control Board amp Jumper Configuration For Single unit or Master operation J1 amp J2 must be in the M position For Slave operation J1 amp J2 must be in the S position
10. M3345 B Chassi Figure 6 4 06 068 WOLLOG 12 91 75214 v VIO 47 1 11 53014435 ONIN33NION3 SOINOSWYLIN 50115000 51081 2 1500 WOLLOS Zd 14 2265 lt 0161 Dwg 920306 Rev 20080310 38 12 00 User s Manual Fiqure 6 5 M3345 Chassis with Fan Dimensional Outline
11. BRAKING TRANSISTORS e For redundant operation with M3345 or for applications above 270A e M3452 M3575T BRAKING RESISTORS e Used with Braking Transistors e M3575R M37775R 2 2 PART NUMBER BREAKDOWN Figure 2 1 Example of M3345 Part Number Breakdown BASE MODEL NUMBER VOLTAGE RATING CURRENT RATING CHASSIS STYLE CURRENT METER COOLING FAN SPECIAL OPTIONS FREQUENCY M3345 BASE MODEL NUMBER The Base Model Number for all Line Regen Controllers is M3345 VOLTAGE RATING A 1 digit code represents the 32 AC line input voltage to the Regen module voltage rating must be selected for the system voltage that will be applied Table 2 1 Voltage Rating CURRENT RATING A 1 digit code represents the maximum DC current which the Regen module can dissipate This is an absolute maximum rating Table 2 2 Current Ratings o 1OAms 20 Amps 2 90 i20Amps CHASSIS STYLE Table 2 3 Chassis Styles CHASSIS CODE DESCRIPTION SIZE H x W x D S 10 45 Amps Type 1 enclosure 17 75 x 6 00 x 11 00 x Type 13 JIC type wall without fan 17 50 x 16 25 x 8 25 ITUR with fan 17 50 x 18 50 8 25 Open chassis panel without fan 15 00 x 15 10 x 8 50 10 49 Amps mount backplate with fan 15 00 x 18 00 x 8 50 80 90 Amps 16 00 x 20 00 11 00 Type 13 JIC type wall W 60 90 Amps Type 1 enclo
12. 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 AC DRIVE OPTIONS Bonitron Inc 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 Uninterruptible Power for Drives DC Bus Ride Thru Voltage Regulators Chargers and Dischargers Energy Storage Common Bus Solutions Single Phase Power Supplies 3 Phase Power Supplies Common Bus Diodes Power Quality Solutions 12 and 18 Pulse Kits Overvoltage Solutions Braking Transistors Braking Resistors Transistor Resistor Combo Line Regeneration Dynamic Braking for Servo Drives Portable Maintenance Solutions Capacitor Formers Capacitor Testers Green Solutions Line Regeneration M3345 0 7 1 2 Purpose ve 7 1 3 Manual version and change record 7
13. This contact can be used for remote indication of the operation of the unit FOR PARALLELING REGENS The M3345 regeneration units come equipped with Master Slave selectable control boards 60 Amp and 90 Amp units are available for Master Slave operations The S B and X chassis units 60 Amp do not provide I O connections for Master Slave operation It is imperative that when paralleling units one unit be configured as a Master and all others configured as Slaves This will allow for up to 4 Slaves and 1 Master unit to be used in parallel operation Refer to Figure 3 11 for connection diagram Consult with Bonitron if you plan to configure more than units as Slaves on the 60 amp 90 Amp units When a unit is configured as Master the terminals appear as outputs to the other units When the unit is configured as Slave the terminals appear as inputs to the other units The signal is a complex waveform that is not reproducible as an analog input or output The signal is floating with respect to ground and could have a significant potential difference from other references Do not attempt to use these signals for any purpose other than interconnecting Bonitron M3345 units Damage may occur to the WARNING M3345 as well as to the connected equipment 24 User s Manual 4 3 STARTUP This section covers basic checks and procedures that should be used when performing a startup with a M3345 Line Reg
14. 244 2825 e Fax 615 244 2833 e Web www bonitron com e Email infoG bonitron com
15. local codes Typically the wire gauge will be the same as is used to ground the attached drive Table 3 1 Power Terminal Specifications 10 to 45 Amp Chassis TERMINALS FUNCTION ELECTRICAL RATINGS WIRESIZE TORQUE 11 12 13 Power Input 45A 230 460VAC 10 32 screw 20 Ib in DC Bus Input 45A 750VDC 10 32 screw 20 lb in Chassis Ground amp 10 32screw 20 bin Table 3 2 Power Terminal Specifications 60 amp 90 Amp Chassis Temas Raminas Wine Size Table 3 3 Power Terminal Specifications 120 Amp Chassis Eieermca Remmes Wine Size ow ehassis Grund 3 4 2 WIRING M3345 Line Regens come with a status contact See Table 3 6 for Master Slave terminals 3 4 2 1 STATUS CONTACT This is an isolated normally open contact Contact will energize closed upon ready condition of unit Contact is rated for 120V AC DC 2 amps See Section 4 2 4 for more information Table 3 4 I O Terminal Specifications S Chassis TERMINAL FUNCTION ELECTRICAL RATINGS WIRE SizE TORQUE TS1 1 Ready Contaci 2 120V resistive 28 16 AWG Common TS1 2 Ready Contact No Connection TS1 3 ae 2A 120V resistive 28 16 AWG 16 User s Manual Table 3 5 1 0 Terminal Specifications and X Chassis TERMINAL FUN
16. ATTENTION Helps you identify a potential hazard avoid a hazard and recognize the consequences User s Manual 2 PRODUCT DESCRIPTION 2 1 The need for regenerated voltage control occurs when the frequency of an AC motor is greater than the frequency of the AC line or variable frequency drive providing power to the motor In this case the motor acts as a generator The energy generated by a motor must be dissipated or returned to the power source f this energy is not controlled the motor may run with high voltage the energy may be dissipated as heat in the motor or the drive may trip on an overvoltage condition Bonitron s Model 3345 Regen Module is used for regeneration control of any AC drive system that uses a fixed bus system such as the bus system used on AC PWM drives The Regen module can pass the regenerated energy from the DC bus of the drive to the AC line This provides for regulation of the DC bus and prevents the drives from tripping on overvoltage When a dynamic braking resistor is used with a PWM drive the regenerated energy is dissipated as heat and energy is wasted When the Model 3345 Regen Module is used the regenerated energy is returned to the input AC line with near unity power factor Substantial energy savings may occur as the regenerated energy can be used to power other equipment RELATED Docs COMMON BUS SHARING AND ISOLATION DIODES e For applications with multiple drives e M3345D M3345CBM
17. B Chassis with Fan Dimensional Outline eee 38 Figure 6 6 M3345 Chassis Dimensional Outline eene 39 Figure 6 7 M3345 X Chassis Dimensional Outline eese eere 40 Figure 6 8 M3345 X Chassis with Fan Dimensional Outline eee 41 Figure 6 9 M3345 Chassis Dimensional Outline eese ener 42 Figure 6 10 M3345 Z Chassis Dimensional Outline eene 43 6 6 Block rrt e deed eet tree pt dete Per dde E COR 45 Figure 6 11 Line Regen Functional Block Diagram seen 45 TA Application 000 ie EE e caet utere 47 7 1 1 Sizing the Line Regeneration 7 47 7 1 2 Calculating Energy 5 a 47 74 3 Savings Example pata a a e aana eag et ie etie de ce toot eet e e DH ERE RIO 48 M3345 This page intentionally left blank User s Manual 1 INTRODUCTION 1 1 1 2 1 3 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 M3345 Line Regen Control modules It provides you with the necessary information to successfully insta
18. Figure 3 4 V Chx Conn Figure 3 5 X and B Chx Conn 3345C2 000 2 2 2 oo 177 B 9 Hex x th Mm D pasan ts 5 oxo Figure 3 6 60 amp 90 Amp C Chx Conn Figure 3 7 120 Amp C Chx Conn 151 A e O F5 90128 m gt 2 B 1 1 90 r 5 Ale eo r5 6 9 0 L L L CND INPUT B Figure 3 6 Y and Z Chassis Connections e e e 1 Tel Q E A B 6 Y 30 AZ INPUT 3 5 TYPICAL CONFIGURATIONS The diagrams shown in Figures 3 9 thru 3 11 illustrate typical connections of the M3345 Regen units with generic VFDs There are many other configurations that may be applied providing a basic connection criterion is maintained such as e The AC input should maintain a low impedance path back to the grid e No reactors should be conne
19. a 0 indicates Current Meter is not included 32 User s Manual Table 6 3 Ratings and Specifications 460VAC DC REGEN RATED HP ODELNUMBERS 1 BRAKING CONTIN CURRENT CURRENT Yous 3345 408 10 10 9 3345 40 00 Open 10 6 9 3346408000 TYPE 13 10 6 9 Open 5 50 3346418000 3 9 6 18 5 27 M3345 42X 00 Open 59 6 27 5 27 45 428 00 3 30 6 27 5 287 M3345 4AWMFM TYPE 60 55 54 50 1965 M3345 4AY FM Open 60 9 s 44 1741 3345 4 TYPE 3 60 55 54 50 1965 M3345 MAZ FM Open 60 55 54 50 195 Masas asWMEM TYPE 90 55 50 1965 334545 _ Open 90 48 8 4 1741 M3345 45CMFM 3 9 55 50 1965 3345 452 Open 9 55 15 1965 an in this place denotes a Current Meter is included a 0 indicates Current Meter is not included 33 M3345 6 2 6 3 6 4 A NOTE ON HP RATINGS The Braking hp rating is dependent on the transistors diodes snubbers and fuses provided with the module It is a function of the DC bus amp rating and indicates the maximum hp that the module is designed to dissipate Modules are able to provide full Braking hp for at least 60 seconds Modules can provide less than full Brakin
20. contact Bonitron for additional assistance at 615 244 2825 The 3345C2 Control Board has 3 LEDs which may be useful in diagnosing problems with the unit or system The cover may need to be removed in order to access the control board Do not remove any covers with power applied to the unit Refer to Figure 3 12 for location of the LEDs on the circuit board Following is a brief description of the LEDs and indications 5 3 1 POWER LAMP IS OUT Check AC input voltage at fuses Check voltage at output side of fuses Check connection to lamp from PCB 5 3 2 RUN LIGHT IS OUT The RUN LED indicates that the module is enabled and in a ready condition This LED is directly related to the status contact at the I O terminal If the RUN LED is ON the status contact should be closed If the LED is ON and the status contact does not change there is most likely a wiring issue When the power is applied to the module the RUN LED will normally come ON after a startup delay of approximately 2 seconds Thereafter the RUN LED should be ON indicating that the system is ready to operate If the RUN LED fails to come ON one of several faults may be indicated f the OVERLOAD LED is lit or briefly comes on other than at power up refer to Section 5 3 6 f no LEDs are lit remove power and unplug TB2 and measure continuity of the purple and purple tr wires on the connector This should be 0 ohms connection measures open the thermostat is
21. BONITRON Solutions for AC Drives Model M3345 Line Regeneration Module for AC Drives Customer Reference Manual Web www bonitron com Tel 615 244 2825 Email info bonitron com Bonitron Inc Bonitron Inc Nashville TN An industry leader in providing solutions for AC drives ABOUT BONITRON Bonitron designs and manufactures quality industrial electronics that improve the reliability of processes and variable frequency drives worldwide With products in numerous industries and an educated and experienced team of engineers Bonitron has seen thousands of products engineered since 1962 and welcomes custom applications With engineering production and testing all in the same facility Bonitron is able to ensure its products are of the utmost quality and ready to be applied to your application The Bonitron engineering team has the background and expertise necessary to design develop and manufacture the quality industrial electronic systems demanded in today s market A strong academic background supported by continuing education is complemented by many years of hands on field experience A clear advantage Bonitron has over many competitors is combined on site engineering labs and manufacturing facilities which allows the engineering team to have immediate access to testing and manufacturing This not only saves time during prototype development but also is essential to providing only the highest quality products
22. CT BE SURE TO REVIEW ALL DRIVE AND OR RESISTIVE LOAD DOCUMENTATION FOR PERTINENT SAFETY PRECAUTIONS CAUTION INSTALLATION AND OR REMOVAL OF THIS PRODUCT SHOULD ONLY BE ACCOMPLISHED BY 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 12 User s Manual INSTALLATION INSTRUCTIONS Installation and or removal of this product should only be performed by a qualified electrician in accordance with National Electrical Code or local CAUTION codes and regulations Proper installation of the M3345 Regen Modules should be accomplished 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 3 2 3 3 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 40 C UNPACKING Upon receipt of this product please verify that the product received matches the product that was ordered and that there is n
23. CTION ELECTRICAL RATINGS WIRE SIZE TORQUE TB4 1 Eu 2A 120Vresistive 18 12 AWG 4 5 lb in TB4 2 dnd 2A 120V resistive 18 12 AWG 4 5 lb in TB4 3 Ready Contact 2 120V resistive 18 12 AWG 4 5 lb in Common 3 4 2 2 MASTER SLAVE I O Units that are rated 60 amps and greater are provided with Master Slave I O terminals for parallel operation See Figure 3 11 and Section 4 2 5 for more information Reference Table 3 6 when the unit is configured for Master Table 3 6 I O Terminal Specifications Y C W Z and V Chassis TERMINAL FUNCTION ELECTRICAL RATINGS WIRE SIZE TORQUE arcu Master Slave 250V 18 12 AWG 20 Ib in 1512 2 ee gt Master Slave 250V 18 12 AWG 20 Ib in 1814 4 2 Ready Contact 2A 120V resistive 18 12 AWG 20 51 6 6 NO Not standard in the Y chassis Figure 3 2 S Chassis Connections Figure 3 3 Chassis Connections dh Dwgs 070133 070134 Rev 20080313 17 M3345
24. INE 950246 Rev 20000927 User s Manual iagram Block D 45 Regen Funct ine L Figure 6 11 BLOCK DIAGRAM 6 6 a34 sna 5 vaL Nao Dau MW 100 201 8 Laes anaa wma dN LUVLs gt 2 5t 4 aa KR E 21901 EX lt 1 NI s c ONIWIL SI LINN N3HM 31 105 3 4 A LH KE 1 gt waar 31V5 n 5NISN3S LIWT 31 105 ATIVOILdO n 5 5 TE te Alddns 1 55771 0 2 ACT m 8 y pats I NE N S O oo p ON te i 219 v 4 J up ones AO0ST XS sna 4 sasvHd 7 ang Salo 9 e 8 gt n gt 6 EN a 7 TA gt Q 1 LN cs 3 0 4 2 ra D E 5 Wa V 5 50 31nGOMHW 1 Dwg 000253 Rev 20000830 M3345 46 This
25. P 40 45 5 X chx FWP 45 Serre a Y 2 O 50 FWP 60 60 60 600008 FWP 70 FWP 80 90 Amps FWP 100 FWP 100 120 Amps FWP 125 FWP 125 User s Manual 6 5 DIMENSIONS AND MECHANICAL DRAWINGS Figure 6 1 M3345 S Chassis Dimensional Outline ECTS H MODEL 3545 REGEN 5652 6 750 Dc AMPERES Dwg 010074 Rev 20070521 DIM S CRASSIS ENSIONAL OUTLINE 35 M3345 Figure 6 2 M3345 W Chassis Dimensional Outline APPROX 7 00 19 85 1 jj pee o o M3345 REGEN 20 02 9 00 o o o o 1 DIMENSIONAL OUTLINE W CHASSIS 10 00 36 Dwg 060230 Rev 20070521 User s Manual Figure 6 3 M3345 V Chassis Dimensional Outline Z 9 5 S a 14 50 e e e e e e 6 26 00 e 7 00 8 6 e 8 1 10 00 V CHASSIS DIMENSIONAL OUTLINE Dwg 070107 Rev 20070521 37 M3345 Outli Imensiona is D
26. cted upstream of the regen unit without consulting Bonitron for instructions 18 Dwgs 080109 080110 Rev 20080219 and 080108 080130 070135 Rev 20080313 User s Manual The DC input should be connected to a fixed bus whether from a common bus supply or from the output of a VFD This should never be connected to a switching source such as the braking resistor terminals on some drives The DC input should not be connected to an active SCR front end drive without instructions from Bonitron Fiqure 3 7 M3345 10 120 Amp Single Drive Regen Field Wiring Diagram f M 2 CC 7 t3 O 5 7 lt D LI 5 gt 57 Ed ae Q E gt 2 2 5 mlm ol o x de 2 gt gt Site ile ole g je fe a cn EG gt 5 a z _ M 2 5 s O 2 E J gt 2 2 Lo 25 5 E vA EN D AN X NC e SAN m 7 J gt uj 20228 C5 Q LI 2 02 gt M3346 Dwg 010132 Rev 20070521 19 M3345 Diagram irin M3345 Multiple Drives Regens Field Wi Figure 3 8 GSPEEWN IVOIdA L 9 23 15 16 N3934 Sree TAGON 30 00 00 00
27. d with original type Please refer to Table 6 4 in Section 6 4 4 2 2 INTERNAL LINE FILTERING The M3345 series Line Regen incorporates internal filtering on the AC line to remove voltage transients created by the internal transistors It also adds additional filtering to noise and harmonics that may be generated outside of the regen The internal filtering is not intended for filtering external harmonics and if there are any known power quality issues extra attention should be given when startups are performed 23 M3345 4 2 3 INDICATORS 4 2 3 1 CURRENT METERING The M3345 Line Regen may come with an ammeter installed This is an averaging meter which may not deflect the instantaneous current peaks which may be present 4 2 3 2 INDICATOR The M3345 Line Regen comes standard with a neon power lamp This lamp is powered by 2 of the 3 phases feeding the AC input This lamp should not be relied upon for determining if voltage is present Always check for voltage with dependable measuring CAUTION device before attempting service on unit 4 2 4 4 2 5 STATUS CONTACT The M3345 Line Regens come equipped with a status contact which may be integrated into system control I O This contact is normally open and energized closed when ready The contact will open upon any of the following events Loss of AC voltage Loss of any phase Instantaneous change in voltage Overload condition Over temperature
28. e 3 1 M3345 Mounting Orientation HOO 14 OL MINOZIHOH gt ONISNVH 3ovduns 1VOLLH3A V AOVAYNS V LNOZIHOH 2 Dwg 070131 Rev 20070524 14 User s Manual 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 11 for connection details 3 4 1 POWER WIRING Only qualified electricians should perform and maintain the interconnection wiring of this product All wiring should be in accordance with local codes WARNING 3 4 1 1 Where possible minimize the wire length between the Regen and the Drive The wire length should not exceed 10 Avoid routing and bundling the Regen AC DC wire with the Drive PWM motor output wiring 3 PHASE AC INPUT The AC input should be connected to a 3 phase source following the typical guidelines used when sizing for an inverter This will insure sufficient source impedance to return power to the grid Do not install chokes or reactors between the regen and the power source If the AC drive requires a line reactor the Re
29. e distribution system is reduced by the excess energy Additional savings also occur when there is a need to provide air conditioning with a DB 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 55 P 0 746 t T D H kW 47 M3345 48 where Savings Power Hp D Number of days H Number of hours per day t T Percent on time kW _ Cost per kW SAVINGS EXAMPLE A 20 Amp Model M3345 41SMFO has been selected for use in braking a high inertia centrifuge with the following characteristics Calculate the energy savings over a DB kit 20 Hp peak 15 Hp average during T deceleration D 365 days H 10 hours per day 5 on 15 total kW 80 08 per kW using 55 15 0 746 5 15 365 10 0 08 Savings per year is S 1 089 16 Using the regen module the centrifuge customer is also able to reduce the braking time from 5 minutes to 1 5 minutes This results in a 30 increase in throughput for the machine and produces additional cost savings for the customer NOTES User s Manual M3345 D M3345 CMAN vall 05e 03 06 2014 521 Fairground Court e Nashville TN 37211 e USA Tel 615
30. een eene 22 002 421 Functional Description cid 23 4 23 Beatutes ceret e edet debeat tete E Ed 23 4 2 1 lt FUSS eed ie ee a ee i ne eee oe 23 4 22 Internal Lime Filtering ed etre Ae a teed Sates 23 4 233 7 Indicators e coto 24 4 2 4 Status Contact tad sts ect itte ett asta KG een deme 24 7 Table of Contents 4 25 LO borParallelng Regens oie tette tod ee t e e eee eee 24 4 3 Ea 25 4 3 1 Pre power Checks Ee eH pepe eet ette ete 25 4 3 2 Start p Procedure eta e 25 4 3 3 Cooling nane RED m ee ete Ye n pee Eb pie n pU ER Ye pe ate 25 4 4 Operational Adjustmehts EE E Uc atout ets 25 MAINTENANCE AND TROUBLESHOOTING 00000000000000 0000000000 00000000000000 0000000000000000 27 5 Periodic Testing 0 ed HOD visas 27 2 2 Maintenance tems ee a Gaga case 27 3 9 Tro bleshootitig aas de ec Pra Re at ee ae 27 POWER lamps OUt er e eed ete OR dened eer 27 5 3 2 RUN lightis OUt iet 27 5 3 3 Status Contact remains open after 5 second delay
31. either indicating high temperature or is defective Switch opens at 175 F and closes at 140 F on all chassis EXCEPT the Y chassis 27 M3345 5 3 3 5 3 4 5 3 5 5 3 6 5 3 7 where the switch opens at 140 F and closes at 110 F If the unit is cool the switch may be defective Contact Bonitron for service Check the ribbon cable connector to be securely plugged in f thermostat measures OK check the continuity of the wires feeding the 3 phase AC to the control board at TB1 The brown yellow and orange wires should be directly connected to the main input fuses Verify the Dip Threshold as shown in Section 4 4 2 STATUS CONTACT REMAINS OPEN AFTER A 5 SECOND DELAY Check AC input voltage at fuses to be within 10 of nominal voltage If unit appears to be hot allow a few minutes to cool off If status contact does not change try cycling power to the unit METER SHOWING EXCESSIVE CURRENT WHEN IN STANDBY lt RATED CURRENT Measure AC input voltage to be balanced Line to Line f more than 5VAC difference move highest pair to B 8 C Check for harmonics and noise on the AC that may be caused by DC drives welders induction heaters etc See Section 4 4 about adjustments and or contact support at Bonitron DRIVE TRIPS ON DC BUS OVERVOLTAGE Verify status contact if open see Section 5 3 3 Check DC bus voltage at fuses Check DC bus polarity at fuse Check DC bus fuses Ensu
32. en 4 3 1 PRE POWER CHECKS Insure that the frequency of the AC power system is the same as the regen unit Insure that the voltage of the AC power system is the same as the regen unit Insure 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 3 2 STARTUP PROCEDURE AND CHECKS After completing Regen pre checks and recommended checks for connected equipment you may apply power to the system The power indicator on the front panel should illuminate and a small amount of current may be noticed on the ammeter If the cover is open the RUN LED should be illuminated on the 3345C2 control board see Figure 3 12 for location Status contact should be closed after a 2 second delay which is an indication that unit is ready for operation If any of the following conditions exist refer to Troubleshooting in Section 5 3 Front panel lamp off with power applied Status contact still open after 5 seconds Excessive current flow in standby mode If none of the above conditions exist the Regen Unit is now ready to operate and the drive system can be run normally 4 3 8 COOLING FAN A heat sink cooling fan may be supplied as part of the Re
33. g hp for longer times The Continuous hp rating is a function of package style heatsinks and cooling fans This rating is always equal to or less than the Braking hp rating For applications the following must exist Continuous Regen hp rating gt Required hp rating Duty Cycle WaATT Loss Tables 6 1 thru 6 3 list the maximum Watt Loss generated by each of the listed Regen units When installing Regen 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 regen capability of each unit Applications that do not utilize the full capacity may be calculated as follows 746 5 100 Watt Loss Where hp is the average estimated regen horsepower CERTIFICATIONS There are presently no certifications for the M3345 Regen Unit If certification is required check with your integrator and or panel shop for full system certification The M3345 is constructed with industry guidelines and safety taken into consideration If information is required for certification please contact Bonitron with your request FUsE CiRCUIT BREAKER SIZING AND RATING e Only replace fuses with original type and rating e Due to the current limit control capability blown fuses typically indicate internal device failure or severe transient absorption event Table 6 4 Replacement Fuses RATING REPLACEMENT FUSE REPLACEMENT FUSE 30 EET Y Z chx FWP 35 FW
34. gen should be connected to the utility grid side If an isolation transformer is to be used the regen AC input MUST be connected to the same point as the drive AC input Do not connect to a generator unless minimum load at any time exceeds the peak expected regen power The regen units are not phase sensitive Insure that the frequency of the unit is correct when ordered and only use 60Hz units on 60Hz systems 50Hz units on 50Hz systems This frequency is specified when the unit is ordered and cannot be changed in the field Installing 50Hz regen units on 60Hz systems may cause severe damage to the regen unit WARNING 3 4 1 2 DC Bus INPUT The DC bus input may be connected to the DC bus of an AC drive the DC output of a diode sharing unit 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 Never attach the DC bus input of the M3345 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 WARNING 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 15 M3345 3 4 1 3 GROUNDING Using the ground stud provided ground the chassis in accordance with
35. gen unit The fan runs continuously when proper system voltage is present at the Regen unit inputs 4 4 OPERATIONAL ADJUSTMENTS Adjustments made outside of the factory settings can cause poor performance reduced system capability heatsink overheating or even component failures Under severe operating conditions or if the settings have been accidentally or intentionally altered some minor WARNING field adjustment be required Consult Bonitron prior to making any adjustments 25 M3345 26 This page intentionally left blank User s Manual 5 MAINTENANCE AND TROUBLESHOOTING Repairs or modifications to this equipment are to be performed by Bonitron approved personnel only Any repair or modification to this equipment by personnel not approved by Bonitron will void any warranty remaining on this unit 5 1 5 2 5 3 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 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 TROUBLESHOOTING There no user serviceable parts within the M3345 Regen unit If you are still experiencing problems after you have reviewed this whole Section CAUTION YOU may
36. ll and use the M3345 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 MANUAL VERSION AND CHANGE RECORD Ratings Charts are updated in Rev 05a and Rev 05b Unit pictures and chassis dimensions are updated in Rev 050 Torque terminology was changed in Rev 05d Update to the manual template in Rev 05e Figure 1 1 Typical M3345 Unit in the S and B Chassis 77030 4 7 IN amperes 50 M3345 Line Regen TRON BON 2 M3345 1 4 SYMBOL CONVENTIONS USED IN THIS MANUAL AND ON EQUIPMENT Earth Ground or Protective Earth DANGER DANGER WARNING CAUTION CAUTION ATTENTION DANGER Electrical hazard Identifies a statement that indicates a shock or electrocution hazard that must be avoided DANGER Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss WARNING Identifies information about actions or circumstances that will probably lead to property damage personal injury or economic loss CAUTION Identifies information about practices or circumstances that can lead to property damage or economic loss CAUTION Heat or burn hazard Identifies a statement regarding heat production or a burn hazard that should be avoided
37. o 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 MOUNTING The installation site for the module should be chosen with several considerations in mind e When mounting Regen units in an enclosure power dissipation should be taken into account Refer to Section 6 2 Watt Loss for details e The unit requires a minimum clearance of two 2 inches in all directions around it when mounted near a non heat source e 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 M3345 must be properly oriented for proper heat flow through the unit The M3345 must be mounted with the rear surface of the unit to the mounting surface Unit may be mounted vertically or horizontally as shown in Figure 3 1A Do Not mount the unit in an upside down position or on the underside of a mounting surface as shown in Figure 3 1B 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 Refer to Table 2 3 Chassis Styles in Section 2 2 of this manual 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 5 for dimensional drawings 13 M3345 Fiqur
38. page intentionally left blank 7 APPENDIX User s Manual 7 1 APPLICATION NOTES 7 1 1 SIZING THE LINE REGENERATION CONTROL Since the regeneration kit must direct energy from the DC bus back to the power system it is sized for the amount of DC bus current 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 regeneration unit Use the equation below to establish the torque required to decelerate or stop a rotating object T 2 WK AN 3087 where Torque required lb ft wK Total inertia load to be decelerated lb ft AN Change speed rpm t Time to decelerate load sec Calculate the horsepower required at maximum speed TN 5250 where P Power Hp T Torque lb ft calculated above N Maximum shaft speed rpm Determine the DC bus current rating required for the regeneration module IDC P 1 2 for 460vac drives or IDC P 2 4 for 230vac drives where P Power Hp calculated above IDC Regen Amps CALCULATING ENERGY SAVINGS The regeneration kit 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 th
39. r Slave operation Units with current ratings of 10 45 Amps and of 120 Amps will not support ATTENTION Master Slave operation FREQUENCY e If the unit is for use 60Hz systems omit this position e 50Hz in this position indicates the unit is for use 50Hz systems 2 3 GENERAL SPECIFICATIONS CHART Table 2 4 General Specifications PARAMETER SPECIFICATION Input AC Line e Three Phase e Rated Voltage 10 Connections e 50Hz or 60Hz Drive DC Bus e 10096 of rated DC current Ground Greater than 90 100 DC Rating 010 40 C 20 to 465 C ar Below 90 SURGE Non condensing Atmosphere Free of corrosive or conductive gas and dust Power Light Run Status Indicators Current Limit Overload Current Meter M3345 2 4 GENERAL PRECAUTIONS AND SAFETY WARNINGS e HIGH VOLTAGES MAY BE PRESENT e NEVER ATTEMPT TO OPERATE THIS PRODUCT WITH THE ACCESS DOORS OR COVERS OPENED e NEVER ATTEMPT TO SERVICE THIS PRODUCT WITHOUT DANGER FIRST DISCONNECTING POWER TO AND FROM THE UNIT FAILURE TO HEED THESE WARNINGS MAY RESULT IN SERIOUS BODILY INJURY OR DEATH e THIS PRODUCT WILL GENERATE HIGH AMBIENT TEMPERATURES DURING OPERATION e THIS PRODUCT SHOULD BE INSTALLED ON A FLAMMABLE SURFACE WITH CLEARANCES OF AT LEAST TWO INCHES IN ALL DIRECTIONS e ALWAYS ALLOW AMPLE TIME FOR THE UNIT TO COOL BEFORE ATTEMPTING SERVICE ON THIS PRODUCT e BEFORE ATTEMPTING INSTALLATION OR REMOVAL OF THIS PRODU
40. re unit is not overheated Verify proper sizing of regen unit OVERLOAD LIGHT IS FLICKERING The normal state for the OVERLOAD LED is OFF The OVERLOAD LED may flash for a brief moment on power up The OVERLOAD LED indicates that the system DC bus feedback is substantially greater than the DC bus reference signal Under normal operating conditions this occurs when the regenerated power from the drive is greater than the capacity of the regen module When this occurs the DC bus rise will cause the regen module to be temporarily disabled With the module disabled the drive DC bus will continue to rise until the Drive Overvoltage condition causes the drive to trip OFF Once the Overvoltage condition ceases to exist the OVERLOAD LED will turn OFF and the fault condition will be reset Since the drive and regen module have peak rectifier diode modules a substantial line transient on the AC power lines can cause an erroneous OVERLOAD fault even in the standby mode CURRENT LIMIT LiGHT IS ON The normal state for the CURRENT LIMIT LED is OFF An ON state for the CURRENT LIMIT LED indicates that there is greater than 10096 of the maximum limit of instantaneous non filtered regenerated current in any 1 of the 3 AC input line feeds The response of the CURRENT LIMIT LED is much quicker than the averaging DC bus ammeter frequently supplied with the regen module The CURRENT LIMIT LED is informative when the 28 5 3 8 User s Manual s
41. sure 20 00 x 10 00 x 10 50 Z 60 120 Amps Open chassis panel 20 00 11 00 mount backplate 120 Amps Type 1 enclosure 27 00 x 10 00 x 14 50 Type 1 may also be known as bookshelf See Section 6 5 for chassis mounting and dimensional outlines User s Manual CURRENT METER An in this position indicates the inclusion of a DC Regen current meter with the Regen module A 0 in this position will omit the meter A meter is provided as a standard part of all Type 13 JIC chassis modules and Type 1 chassis modules and is optional for all open chassis modules COOLING FAN An in this position indicates the inclusion of a cooling fan with the Regen module A 0 in this position will omit the cooling fan A cooling fan is provided as a standard part of all chassis types except for the B and chassis modules however the cooling fan is an available option for the B and X chassis modules Please note that a Regen module s rating is somewhat dependant on the use of a cooling fan Refer to the tables in Section 6 of this manual to determine if a cooling fan is required for your application SPECIAL OPTIONS e A 0 in this position indicates the unit is not Master Slave selectable e in this position indicates the unit is 60A or higher and is Master Slave selectable Units with current ratings of 60 90 Amps will support Maste
42. turned to the power grid Alternative solutions typically consist of dissipating the returned energy in a resistor or simply allowing the motor to coast uncontrolled to a stop The M3345 Line Regen establishes a reference from the power source connected to the 3 phase input This reference is used to establish the actual rectified DC voltage which is equal to the DC bus of the AC Drive in standby The DC reference allows for conduction back to the AC line with limited rise in DC bus voltage The reference is also used to monitor instantaneous changes in the incoming voltage Instantaneous changes in voltage greater than 15 can create an over power condition for the power semiconductors The M3345 will go into a shutdown mode during such events and resume operation upon return of nominal voltage The M3345 will also go into the shutdown mode upon loss of any phase of the incoming power The M3345 series of Regen Modules come standard with an internal bus structure which allows for regeneration from the drive to the AC Line only Power may be transferred from the AC drive to the regen however the regen will not provide energy to the AC drive FEATURES Fusing Internal line filtering Current metering Power indicator Status contact I O for paralleling 60 90 and 120 Amp units 4 2 1 FUSING The M3345 Line Regen is provided with fusing for the AC input and the DC bus input All fuses are fast semiconductor type and should only be replace
43. ystem operation consists of short but high peak currents An ON state can indicate the presence of short energy surges which may cause an Overload condition TECHNICAL HELP BEFORE YOU CALL If technical help is required please have the following information available when calling 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 29 M3345 30 This page intentionally left blank User s Manual 6 ENGINEERING DATA 6 1 RATINGS CHARTS Table 6 1 Ratings and Specifications 230VAC CHASSIS DC REGEN RATED HP ODEL NUMBERS Ie CURRENT CURRENT INUOUS Ma346 20x700 Open 1 6 23 13 27 3245 208 00 TYPE 10 6 23 m 46 21 00 Open 2 6 45 s 29 65 218 00 3 20 6 45 13 287 0506026000 so es as 79 696602000 Open so 6e 68 13 29 6866020600 Open so 0 68 45 79 Masa5 228M00 TP 6 58 1s 27 Masas22BMF0 TYPE48 so es as 79 3345 22 __ 1 so so 68 68 no 45 2210 Open so so 68 68 nmo Masa52AWMEM TvPE3 6 ss 4 m 1955
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