bonitron M3675T User manual

Web: www.bonitron.com ● Tel: [phone] ● Email: in[email protected]
Model M3675T
Braking Transistor
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

M3675T
4
This page intentionally left blank.

Table of Contents
5
1. INTRODUCTION..........................................................................................................................7
1.1. Who Should Use...........................................................................................................................7
1.2. Purpose and Scope........................................................................................................................7
1.3. Manual Version and Change Record............................................................................................7
Figure 1-1: Model M3675T....................................................................................................................................7
2. PRODUCT DESCRIPTION............................................................................................................9
2.1. Related Products...........................................................................................................................9
2.2. Part Number Breakdown ..............................................................................................................9
Figure 2-1: Example of M3575T Part Number Breakdown ...................................................................................9
Table 2-1: Control Voltage Rating Chart .............................................................................................................10
2.3. General Specifications................................................................................................................10
Table 2-2: General Specifications Chart...............................................................................................................10
2.4. General Precautions and Safety Warnings .................................................................................11
3. INSTALLATION INSTRUCTIONS................................................................................................13
3.1. Environment ...............................................................................................................................13
3.2. Unpacking................................................................................................................................... 13
3.3. Mounting ....................................................................................................................................13
3.4. Wiring and Customer Connections.............................................................................................13
3.4.1. Power Wiring............................................................................................................................13
Table 3-1: Power Wiring Specifications...............................................................................................................14
3.5. Typical Configuration.................................................................................................................14
Figure 3-1: Typical Chassis Interconnection Diagram.........................................................................................14
4. OPERATION..............................................................................................................................15
4.1. Functional Description ...............................................................................................................15
Table 4-1: Turn-On and Turn-Off Setpoints ........................................................................................................15
4.2. Features....................................................................................................................................... 15
4.2.1. Indicators..................................................................................................................................15
5. MAINTENANCE AND TROUBLESHOOTING...............................................................................17
5.1. Troubleshooting..........................................................................................................................17
5.1.1. Green dc bus power led does not come on ...............................................................................17
5.1.2. Red active braking led stays on or flashes during motoring operation.....................................17
5.1.3. Drive trips on over-voltage or self-limits its decel rate.............................................................17
6. ENGINEERING DATA................................................................................................................19
6.1. Ratings Chart..............................................................................................................................19
Table 6-1: Module Ratings...................................................................................................................................19
6.2. Dimensions and Mechanical Drawings ......................................................................................20
Figure 6-1: M3675T Chassis Dimensional Outline Drawing...............................................................................20
NOTES..................................................................................................................................................................20

M3675T
6
This page intentionally left blank.

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 3675T Braking Transistor. It will provide
the user with the necessary information to successfully install, integrate, and use the
M3675T.
In the event of any conflict between this document and any publication and/or
documentation related to the AC drive system, the latter shall have precedence.
1.3. MANUAL VERSION AND CHANGE RECORD
Minor format changes were added in Rev 02d.
Features were changed in Rev 02e.
Minor format changes were added in Rev 02f.
Voltage rating U was added in Rev 02g.
Updates to indicators were added in Rev 02h.
The manual template was updated in Rev 02i.
Figure 1-1: Model M3675T

M3675T
8
This page intentionally left blank.

User’s Manual
9
2. PRODUCT DESCRIPTION
The need for braking control occurs in applications where the frequency of an AC motor
at times exceeds that of the variable frequency drive controlling it. When this happens,
the motor acts as a generator. The energy produced in these circumstances may cause
the drive to trip on an over-voltage condition or cause the motor to build up heat or run
with an excessively high volts/Hertz ratio. This regenerated energy must either be
dissipated or returned to the power line. For applications where this condition occurs
infrequently, dissipating the energy as heat through a Braking Transistor can be the
most cost-effective solution.
The Model M3675T series of braking products is designed to provide dynamic braking
control for applications utilizing a standard AC drive with a fixed DC bus. These
modules have been designed for use with remotely mounted dynamic loads such as the
M3675R-H100C or M3575R series of Dynamic Load Modules.
2.1. RELATED PRODUCTS
Like the M3675T, the Bonitron M3575T is a Standard Duty Braking Transistor that is
rated for applications that require higher current. The M3575T is rated up to 600A
peak at 20% duty cycle.
For applications that require high duty cycles, the Bonitron M3452 Heavy Duty
Braking Transistor is rated for continuous duty.
The M3575R series of Dynamic Load Modules are available for use with the M3675T
Braking Transistors or with the drive’s integral braking control module.
2.2. PART NUMBER BREAKDOWN
Figure 2-1: Example of M3575T Part Number Breakdown
BASE MODEL NUMBER
The Base Model Number, M3675T, indicates that the unit incorporates the braking
transistor and its control circuitry only. An external braking resistor is required for
proper function of the braking module.
AC DRIVE VOLTAGE RATING
The AC Voltage Rating of the braking unit should match the input AC line voltage to
the AC drive used with the braking module. The AC Drive Voltage is indicated by a
code letter.
M3675T
H
10
BASE MODEL NUMBER
DC CURRENT RATING
AC DRIVE VOLTAGE RATING

M3675T
10
Table 2-1: Control Voltage Rating Chart
RATING CODE
LINE VOLTAGE INPUT
U
115 VAC
L
230 VAC
E
380 VAC
H
460 VAC
DC CURRENT RATING:
The DC Current Rating indicates the maximum DC current level safely handled by
the braking unit. All M3675T modules are rated for a maximum of 10 Amps DC at
20% duty cycle.
2.3. GENERAL SPECIFICATIONS
Table 2-2: General Specifications Chart
PARAMETER
SPECIFICATION
Adjustments
Factory calibrated –no field adjustments necessary
Connections
Drive DC Bus
Resistors
Enclosure
TYPE-1
Panel Indicators
DC Bus
Active Braking
Braking Current
10 Amps DC maximum
Peak Horsepower
2.5 hp (for 115VAC drives)
5.0 hp (for 230VAC drives)
7.5 hp (for 380VAC drives)
10.0 hp (for 460VAC drives)
Duty Cycle
20% Maximum braking
Maximum On-Time
15 seconds
Storage Temp
-20ºC to +65ºC
Humidity
Below 90% non-condensing
Atmosphere
Free of corrosive gas and dust

User’s Manual
11
2.4. GENERAL PRECAUTIONS AND SAFETY WARNINGS
DANGER!
HIGH VOLTAGES M AY BE PRES ENT!
FAILURE TO HEED THESE WARNINGS MAY
RESULT IN SERIOUS BODILY INJURY OR DEATH!
CAUTION!
THIS PRODUCT GENERATES HEAT DURING OPERATION .
THIS PRODUCT SHOULD B E INSTALLED ACCORDIN GLY ON
NON-FLAMMABLE SURFACES W ITH CLEARANCES OF AT
LEAST TWO INCHES IN ALL DIRECTIONS.
NO USER-SERVICEABLE PARTS ARE CONTAINED WITHIN
THIS PRODUCT.INOPERABLE UNITS SHOULD BE
REPLACED OR RETURNED FOR EVALUATION AND /OR
REPAIR BY QUALIFIED TECHNICIANS.
BEFORE ATTEMPTING INSTALLATION OR REMOVAL OF
THIS PRODUCT,BE SURE TO REVIEW ALL DRIVE AND/OR
RESISTIVE LOAD DOCUM ENTATION FOR PERTINENT
SAFETY PRECAUTIONS.
INSTALLATION AND /OR REMOVAL OF THIS PRODUCT
SHOULD ONLY BE ACCOM PLIS HED BY A QU ALIFI ED
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.

M3675T
12
This page intentionally left blank.

User’s Manual
13
3. INSTALLATION INSTRUCTIONS
WARNING!
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 Model M3675T Braking Transistor should be accomplished
following the steps outlined below. Be sure to refer to your AC drive’s instruction manual
as you perform these steps. Please direct all installation inquiries that may arise during
the installation and startup of this braking product to your supplier or system integrator.
3.1. ENVIRONMENT
The installation site for the module should be chosen with several considerations in
mind:
The mounting surface must be non-flammable, as the unit may generate high
ambient temperatures during typical operation.
The unit will require a minimum clearance of two inches in all directions around it.
The unit will require adequate protection from the elements.
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
Once the installation site has been selected as outlined above, the unit should be
mounted in place using two ¼ inch diameter bolts or studs. Refer to Figure 6-1 to
determine the correct mounting dimensions for your unit.
3.4. WIRING AND CUSTOMER CONNECTIONS
This section provides information pertaining to the field connection of the DC bus
inputs to the M3675T Braking Transistor. Actual connection points and terminal
numbers for the AC drive module will be found in the documentation provided with
the drive. Be sure to review all pertinent drive and system documentation as
well as the power wiring information in Section 3.4.1 before proceeding.
3.4.1. POWER WIRING
WARNING!
Only qualified electricians should perform and maintain the
interconnection wiring of this product. All wiring should be done in
accordance with local codes.
WARNING!
DC bus polarity must be observed! Connecting the DC bus with the
polarity reversed will cause damage to the equipment!
For the maximum wire size accepted by the individual field connection
terminals, refer to Table 3-1: Power Wiring Specifications. Wire types and

M3675T
14
sizes should be chosen in accordance with national and local electrical
codes to meet the voltage and current levels present for your application.
Minimum load resistance requirements listed in Table 6-1: Module Ratings
in the Engineering Section of this manual MUST be followed when selecting
a dynamic load for use with the M3675T unit.
Figure 3-1 shows a typical interconnection of the M3675T with the M3575R
Resistor Module. For interconnection with other load modules, refer to the
documentation supplied with them.
Table 3-1: Power Wiring Specifications
TERMINAL
MIN WIRE
AWG
MAX WIRE
AWG
TORQUE
DC+, DC─, RES+, RES─
16
12
8 lb-in
Ground
16
12
8 lb-in
3.5. TYPICAL CONFIGURATION
Figure 3-1: Typical Chassis Interconnection Diagram
BONITRON
DRIVE
BRAKING
GND
DC BUS
MODEL 3675
DC +
RES. +
RES. - DC -
Dwg: 070247 Rev: 20070925

User’s Manual
15
4. OPERATION
4.1. FUNCTIONAL DESCRIPTION
The M3675T Module controls the bus voltage of a variable frequency drive by
transferring energy to a resistor.
When the drive’s DC bus voltage exceeds a fixed setpoint, the Braking Transistor’s
control electronics turns on an IGBT transistor connecting a dynamic load across the
DC bus. When the DC bus drops below another threshold, the IGBT turns off.
Table 4-1: Turn-On and Turn-Off Setpoints
RATING CODE
LINE VOLTAGE INPUT
TURN-ON SETPOINT
TURN-OFF SETPOINT
U
115VAC
190VDC
180VDC
L
230VAC
375VDC
350VDC
E
380VAC
620VDC
600VDC
H
460VAC
750VDC
725VDC
4.2. FEATURES
4.2.1. INDICATORS
4.2.1.1. DC BUS
The DC Bus indicator illuminates when the voltage between the DC+
and DC- terminals is greater than 50VDC.
CAUTION!
Do not use this light as an indication that the DC bus is safe to work
on! Always check the DC bus with a working voltmeter before
servicing equipment, as the DC bus light may be broken!
4.2.1.2. ACTIVE BRAKING
This indicator illuminates when the chopper IGBT is on. When the drive
is idle, this light should not be on. During braking, this light will be on or
flashing, depending on the amount of braking energy.
This light will also be on if the Bus Discharge input is active.

M3675T
16
This page intentionally left blank.

User’s Manual
17
5. MAINTENANCE AND TROUBLESHOOTING
5.1. TROUBLESHOOTING
If a problem occurs on start-up or during normal operation, refer to the problems
described below. If a problem persists after following the steps below, contact the
product supplier or your system integrator for assistance.
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.
5.1.1. GREEN DC BUS POWER LED DOES NOT COME ON
Ensure proper DC Bus voltage at input terminals to the unit. If proper DC
Bus voltage is present, return unit for repair or replace unit.
5.1.2. RED ACTIVE BRAKING LED STAYS ON OR FLASHES DURING
MOTORING OPERATION
Ensure that the voltage rating of M3675T is the same as the AC Drive. If
the voltage rating is the same, ensure that the line voltage to the AC Drive is
correct. If line voltage is abnormally high or low, the unit may require
special calibration adjustments. Contact the product supplier or your
system integrator for assistance. If correct line voltage is present on the AC
Drive and the M3675T module is rated for the same line voltage as the AC
Drive, return unit for repair or replace unit.
5.1.3. DRIVE TRIPS ON OVER-VOLTAGE OR SELF-LIMITS ITS DECEL RATE
Ensure that the Green DC Bus Power LED is ON (see above).
Ensure that the proper dynamic load value is connected to the M3675T unit
and that the maximum current rating is not exceeded.
Most AC drives are capable of 150-200% output. If the AC Drive continues
to trip and the application has been thoroughly reviewed, contact Bonitron.

M3675T
18
This page intentionally left blank.

User’s Manual
19
6. ENGINEERING DATA
6.1. RATINGS CHART
See Table 6-1 below for the ratings for all M3675T modules currently available.
Units are rated for 20% duty or 2A RMS. If your module is not listed below, please
contact your supplier or systems integrator for this information.
Table 6-1: Module Ratings
PART
NUMBER
DRIVE
VOLTAGE
MAX
DC AMPS
MAX
BRAKING
MINIMUM
LOAD
M3675T-U10
115VAC
10A
2.5hp
19
M3675T-L10
230VAC
10A
5.0hp
38
M3675T-E10
380VAC
10A
7.5hp
62
M3675T-H10
460VAC
10A
10.0hp
75

M3675T
20
6.2. DIMENSIONS AND MECHANICAL DRAWINGS
Figure 6-1: M3675T Chassis Dimensional Outline Drawing
Dwg: 070246 Rev: 20070924