bonitron M3452 EIP User manual

Web: www.bonitron.com ● Tel: [phone] ● Email: [email protected]
Model M3452 EIP/PDP
Heavy Duty Braking Transistor
with EtherNet / IP®or PROFIBUS®DP
Communications
K6, K9, K10, M14, T10 Chassis
R7EIP, R7PDP Options
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

M3452 vR7 EIP/PDP
4
1. INTRODUCTION..........................................................................................................................7
1.1. Who Should Use...........................................................................................................................7
1.2. Purpose and Scope........................................................................................................................ 7
1.3. Manual Version ............................................................................................................................ 7
Figure 1-1: Typical M3452-R7 ................................................................................................................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: M3452 Part Number Breakdown.........................................................................................10
Table 2-1: Control Voltage Rating.........................................................................................................10
Table 2-2: Available Braking Current Ratings.......................................................................................11
Table 2-3: DC Bus Voltage Rating ........................................................................................................11
Table 2-4: Chassis Codes.......................................................................................................................11
Table 2-5: Control Option Codes...........................................................................................................12
2.3. General Specifications................................................................................................................12
Table 2-6: General Specifications..........................................................................................................12
2.4. General Precautions and Safety Warnings .................................................................................13
3. INSTALLATION INSTRUCTIONS................................................................................................15
3.1. Product Inspection......................................................................................................................15
3.2. Site Selection..............................................................................................................................15
3.3. Mounting ....................................................................................................................................15
3.4. Wiring and Customer Connections.............................................................................................16
3.4.1. Power Wiring ..............................................................................................................................16
Table 3-1: Power Wiring Specifications ................................................................................................16
3.4.2. I/O Wiring ...................................................................................................................................17
Table 3-2: I/O Terminal Block Specifications: R7 Control Board.........................................................17
3.4.3. DC Control Wiring......................................................................................................................17
Figure 3-1: Customer Connections in K6 Chassis .................................................................................18
Figure 3-2: Customer Connections in K9 Chassis .................................................................................19
Figure 3-1: Customer Connections in K10 Chassis................................................................................20
Figure 3-2: Customer Connections in M14 Chassis...............................................................................21
Figure 3-3: Customer Connections in T10 Chassis................................................................................22
3.5. Typical Configurations...............................................................................................................23
Figure 3-4: Master Stand-Alone Hookup...............................................................................................23
Figure 3-5: Master with Slave(s) Hookup..............................................................................................23
Figure 3-6: I/O Hookup with R7 EIP/PDP Communication ..................................................................24
Figure 3-7: Braking Transistor Customer Connections..........................................................................25
Figure 3-8: 24VDC Power Connection..................................................................................................26
4. OPERATION..............................................................................................................................27
4.1. Functional Description ...............................................................................................................27
4.2. Features....................................................................................................................................... 27
4.2.1. Indicators.....................................................................................................................................27
Table 4-1: Fault Conditions Table..........................................................................................................27
4.2.2. Terminal Strip I/O .......................................................................................................................28
4.2.3. Master / Slave Control (200 Amp to 1600 Amp) ........................................................................28
4.2.4. Fieldbus I/O.................................................................................................................................30
Figure 4-1: M3452R7 Memory Map......................................................................................................30
Table 4-2 PROFIBUS Network Length.................................................................................................33
Table 4-3 D-Sub Pin Signal Description................................................................................................35
Figure 4-2: PROFIBUS Connector ........................................................................................................35

Table of Contents
5
Figure 4-3: PROFIBUS Address Switches ............................................................................................36
Table 4-4: PROFIBUS Diagnostic Table...............................................................................................38
Figure 4-4: Screen shot of Home Page...................................................................................................41
Figure 4-5: Screen shot of Password Configuration Page......................................................................42
Figure 4-6: Screen shot of Network Configuration Page .......................................................................43
Figure 4-7: Screen shots of Test Page....................................................................................................48
Table 4-5: Diagnostic Table...................................................................................................................50
4.3. Startup......................................................................................................................................... 51
4.3.1. Pre-Power Checks .......................................................................................................................51
4.3.2. Startup Procedure and Checks.....................................................................................................51
4.4. Operational Adjustments............................................................................................................52
5. MAINTENANCE AND TROUBLESHOOTING...............................................................................53
5.1. Periodic Testing..........................................................................................................................53
5.2. Maintenance Items......................................................................................................................53
5.3. Troubleshooting.......................................................................................................................... 53
5.3.1. Green Control Power light not illuminated .................................................................................53
5.3.2. Amber DC Bus light not on.........................................................................................................54
5.3.3. Blown DC bus fuse......................................................................................................................54
5.3.4. Fan runs constantly......................................................................................................................54
5.3.5. Fan doesn’t run............................................................................................................................54
5.3.6. Control Ready contacts won’t close ............................................................................................55
5.3.7. Power Stage Ready contacts won’t close ....................................................................................55
5.3.8. Module over-temp, or module seems too hot..............................................................................55
5.3.9. Drive trips on overvoltage...........................................................................................................56
5.3.10. Red Braking light flickers ...........................................................................................................56
5.3.11. Red Braking light stays on all the time........................................................................................57
5.3.12. Master Unit appears to function properly, but Slave Units do not seem to follow the Master....57
5.3.13. Attached Drive Will Not Precharge.............................................................................................57
5.4. Technical Help –before you call................................................................................................57
6. ENGINEERING DATA................................................................................................................59
6.1. Ratings Charts.............................................................................................................................59
Table 6-1: Module Ratings: 230 –240 VAC Drives (375 VDC Setpoint).............................................59
Table 6-2: Module Ratings: 380 –415 VAC Drives (620 VDC Setpoint).............................................60
Table 6-3: Module Ratings: 460 –480 VAC Drives (750 VDC Setpoint).............................................61
Table 6-4: Module Ratings: 575 –600 VAC Drives (940 VDC Setpoint).............................................62
Table 6-5: Module Ratings: 690 VAC Drives (1090 VDC Setpoint).....................................................63
6.2. Watt loss.....................................................................................................................................63
Table 6-6: Watt Loss..............................................................................................................................63
6.3. Certifications ..............................................................................................................................63
6.4. UL 508A Short Circuit Current Rating ......................................................................................63
6.5. Fuse/Circuit Breaker Sizing and Rating ..................................................................................... 63
6.6. DC Bus Link Length Limits.......................................................................................................64
Table 6-7: Maximum Inductance for DC Link Cable ............................................................................64
Figure 6-1: DC Link...............................................................................................................................64
6.7. Resistor Link Length Limits.......................................................................................................65
6.8. Dimensions and Mechanical Drawings......................................................................................65
Figure 6-2: M3452 K6 Chassis Dimensional Outline Drawing .............................................................65
Figure 6-3: M3452 K9 Chassis Dimensional Outline Drawing .............................................................66
Figure 6-4: M3452 K10 Chassis Dimensional Outline Drawing ...........................................................67
Figure 6-5: M3452 M14 Chassis Dimensional Outline Drawing...........................................................68
Figure 6-6: M3452 T10 Chassis Dimensional Outline Drawing............................................................69
6.9. Block Diagrams..........................................................................................................................70
Figure 6-7: Block Diagram (All 200A thru 1200A and 1600A in T10 Chassis)....................................70

M3452 vR7 EIP/PDP
6
Figure 6-8: Block Diagram (1600A in M14 Chassis) ............................................................................70
7. APPENDICES.............................................................................................................................71
7.1. Application Notes....................................................................................................................... 71
7.1.1. Sizing your braking requirements................................................................................................71
7.1.2. Common Bus Application Note ..................................................................................................73
7.1.3. Bonitron Line Regeneration Modules .........................................................................................74

User’s Manual
7
1. INTRODUCTION
1.1. WHO SHOULD USE
This manual is intendedfor 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 M3452 Heavy Duty Braking Transistor. It
will provide the user with the necessary information to successfully install, integrate,
and use the M3452 Heavy Duty Braking Transistor in a variable frequency AC drive
system.
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
The “D” Control Voltage and “L” Braking Current Ratings were added in Rev 02.
DC bus information was expanded in Rev 02a.
Dimensional outlines and connection drawings were updated in Rev 02b.
I/O Hookup drawings and link length limits were updated in Rev 02c.
The T10 Chassis was added in Rev 02d.
Rev 02e has minor text edits.
Figure 3-5 was updated in Rev 02f.
The manual template was updated in Rev 02g.
Figure 3-5 was updated in Rev 02h.
Updated Section 6.3 Certification in Rev 02i.
Section 3.4 was updated in Rev 02j.
Added Altitude to table 2-6 in Rev 02k.
Updated Table 3-1 in Rev 02m.
Figure 1-1: Typical M3452-R7
K9 CHASSIS
M14 CHASSIS

M3452 vR7 EIP/PDP
8
1.4. SYMBOL CONVENTIONS USED IN THIS MANUAL AND ON
EQUIPMENT
Earth Ground or Protective Earth
AC Voltage
DC Voltage
DANGER!
DANGER: Electrical hazard - Identifies a statement that indicates
a shock or electrocution hazard that must be avoided.
DANGER!
DANGER: Identifies information about practices or circumstances
that can lead to personal injury or death, property damage, or
economic loss.
CAUTION!
CAUTION: Identifies information about practices or circumstances
that can lead to property damage, or economic loss. Attentions
help you identify a potential hazard, avoid a hazard, and
recognize the consequences.
CAUTION!
CAUTION: Heat or burn hazard - Identifies a statement regarding
heat production or a burn hazard that should be avoided.

User’s Manual
9
2. PRODUCT DESCRIPTION
Bonitron M3452 heavy duty braking transistors are used with AC drives to allow full power
braking and eliminate overvoltage faults. This permits controlled braking and dramatically
shortens motor stopping time.
The M3452 works with variable frequency drives(with DC bus connections) to monitor the
DC bus. If overvoltage occurs, the M3452 shunts the excess energy through an external
braking resistor to prevent overvoltage faults.
The need for regenerated voltage control occurs in applications where the frequency of
an AC motor at times exceeds that of its variable frequency drive. In this case, the motor
acts as a generator. The energy generated by the motor must be dissipated as heat or
returned to the power line. If this energy is not controlled, the motor may run with high
peak voltages, the energy may be dissipated as heat in the motor, or the drive may trip on
an over-voltage condition.
The R7 option allows for Master/Slave operation to be changed on the fly in multiple
module systems to allow for fault redundancy in the control sections for critical
applications.
The R7E option includes all the functions of the R7 option, while adding extended status
I/O as well as the bus discharge feature. This can be used to drain a capacitor bank for
quicker servicing at power down. This can be an issue with drive systems that have large
capacitor banks or use oversized capacitor banks for power dip immunity. Under normal
circumstances, these banks can take excessive amounts of time to reach safe working
levels. The bus discharge feature allows the braking system to be used as the bleeder
resistor, and brings the bus voltage down much quicker.
The EIP / PDP options (available on 200A units and above) work in conjunction with the
R7E option to provide those functions via an RJ45 / DB9 plug to an EtherNet / PROFIBUS
device. The power supply for the EtherNet / PROFIBUS I/O module is isolated (3000VDC)
from the DC bus.
2.1. RELATED PRODUCTS
The M3452 series is one of several overvoltage solutions offered by Bonitron. Below
are a few related products, including braking resistors that are used in conjunction with
the M3452 series.
BRAKING TRANSISTORS
•Like the M3452 heavy duty braking transistors, Bonitron M3575T and M3675T
standard duty braking transistors work with variable frequency drives (with DC
bus connections) to monitor the DC bus. If overvoltage occurs, the M3575T or
M3675T shunts the excess energy through an external braking resistor to
prevent overvoltage faults. The M3575T series is rated up to 600A peak / 20%
duty, while the M3675T series is rated up to 10 A peak / 20% duty.
BRAKING RESISTORS
•Bonitron offers resistor solutions to complement its braking transistor selection.
The M3575R series is rated up to 32 A peak / 20% duty, while the M3775R series
is rated up to 1600 A / 100% duty. Custom resistors are also available.

M3452 vR7 EIP/PDP
10
LINE REGENERATION
•Bonitron is famous for its industry-leading line regeneration solutions. The
Bonitron M3645 line regen returns regenerative energy back onto the AC line
instead of dissipatingthe energy as heat in aresistor, and is ideal for applications
with high duty cycles, frequent deceleration, or where heat from a resistor may
be an issue. The M3645 line regen features an interactive digital display with
event logging.
Please contact your AC drive distributor or visit our website at www.bonitron.com for
more information on these additional products.
2.2. PART NUMBER BREAKDOWN
Figure 2-1: M3452 Part Number Breakdown
BASE MODEL NUMBER
The base model number for all heavy duty braking transistors is M3452.
CONTROL VOLTAGE RATING
The control voltagerating indicates the voltage levelto be used to supply control power
to the unit. Most units utilize the AC line voltage supplied to the drive system.
However, this is not required. Other AC voltage sources can be used if desired. Refer
to the unit specifications to determine the voltage source. The control voltage is
indicated by a code letter.
Table 2-1: Control Voltage Rating
CONTROL VOLTAGE
RATING CODE
VOLTAGES
U
115 –120 VAC
L
230 –240 VAC
E
380 –415 VAC
H
460 –480 VAC
C
575 –600 VAC
D
24 VDC
BRAKING CURRENT RATING
The braking current rating indicates the maximum current level that can safely be
handled by the M3452 heavy duty braking transistor.
M3452
U
600
C
K6
-
R7PDP
BASE MODEL NUMBER
CONTROL VOLTAGE
BRAKING CURRENT
*DC BUS VOLTAGE
CHASSIS STYLE
CONTROL OPTION
-

User’s Manual
11
The braking current rating is indicated by a 3 or 4-digit number. For example, 300
would indicate a braking current tating of 300 Amps maximum.
Table 2-2: Available Braking Current Ratings
AVAILABLE CURRENT RATINGS (ADC)
200, 300, 600, 800, 1200, 1600
*DC BUS VOLTAGE
This code is used only if different from the control voltage rating.
Omit this position if control voltage is the same as Nominal AC line voltage.
The DC bus voltage indicates the voltage regulation level of the DC bus if the control
voltage input does not correspond to the actual drive bus being controlled.
The DC bus voltage uses the codes L, E, H, C, and Y as defined in Table 2-3.
Table 2-3: DC Bus Voltage Rating
VOLTAGE
RATING CODE
VOLTAGES
(Nominal AC Line / DC Bus Trigger Level)
L
230 –240 VAC Line / 375 VDC
E
380 –415 VAC Line / 620 VDC
H
460 –480 VAC Line / 750 VDC
C
575 –600 VAC Line / 940 VDC
Y
690 VAC Line / 1090 VDC
Nxxxx
Special (xxxx VDC)
Nxxxx is used only for custom trigger levels.
Contact Bonitron before specifying Nxxxx.
CHASSIS STYLE
The chassis style code represents the chassis type and size of the heavy duty braking
transistor.
Table 2-4: Chassis Codes
CHASSIS
CODE
CURRENT
(AMPS)
TYPE
DIMENSIONS
(H”X W”X D”)
K6
200-600
Open Chassis
20.00 x 7.12 x 10.50
K9
800
Open Chassis
20.00 x 9.05 x 10.25
K10
1200
Open Chassis
20.00 x 10.00 x 10.50
M14
1600
Open Chassis
28.00 x 13.90 x 14.60
T10
1600
Open Chassis
30.60 x 10.12 x 19.20
CONTROL OPTIONS
A code following a dash in this position denotes that the indicated option is installed
within the heavy duty braking transistor. See Table 2-5 below for a list of available
options. Please contact Bonitron if you have any other special requirements.

M3452 vR7 EIP/PDP
12
Table 2-5: Control Option Codes
CONTROL OPTION CODE
DESCRIPTION
R7EIP
R7E unit with EtherNet communications
R7PDP
R7E unit with PROFIBUS communications
2.3. GENERAL SPECIFICATIONS
Table 2-6: General Specifications
PARAMETER
SPECIFICATION
DC Bus Voltage
375 –1090 VDC
DC Braking
Current
200 –1600 ADC
Control Voltage
Single Phase, 115, 230, 380, 460, 575 VAC ±10% 50/60 Hz 70 VA
24 VDC ±10%
Indicators
DC Bus
Control Power
Active Braking
Logic I/O
Inputs –dry
contact
Outputs –Max 140 VAC/200 VDC
at 100mA
R7
Enable
Master/Slave
Select
Fault Reset
Control Ready
Master/Slave Status
Power Stage Ready
Instantaneous Overcurrent
R7E
DC Bus Discharge
Logic Power OK
Not IGBT Shorted
Not Overtemp
Not Blown Fuse
Control I/O
R7
R7E
Sharing Control Signal
Operating Temp
0to 40C
Storage Temp
-20to 65C
Humidity
Below 90%, non-condensing
Atmosphere
Free of corrosive gas or conductive dust
Altitude
Up to 1000 Meters (3000 feet) above sea level*
*Units must be derated by 2% for every 300 meters (1000 feet) above 1000 meters (3000 feet) sea level.

User’s Manual
13
2.4. GENERAL PRECAUTIONS AND SAFETY WARNINGS
DANGER!
▪HIGH VOLTAGES MAY BE PRESENT!
▪NEVER ATTEMPT TO SERVICE THIS PRODUCT WITHOUT FIRST DISCONNECTING
FROM THE INCOMING AC POWER AND DC BUS.
▪ALWAYS ALLOW ADEQUATE TIME FOR RESIDUAL VOLTAGES TO DRAIN
BEFORE ATTEMPTING SERVICE.
▪BEFORE ATTEMPTING INSTALLATION OR REMOVAL OF THIS PRODUCT,BE
SURE TO REVIEW ALL AC DRIVE DOCUMENTATION FOR PERTINENT SAFETY
PRECAUTIONS.
▪INSTALLATION AND/OR REMOVAL OF THIS PRODUCT SHOULD ONLY BE DONE
BY A QUALIFIED ELECTRICIAN IN ACCORDANCE WITH NATIONAL ELECTRICAL
CODE OR EQUIVALENT REGULATIONS.
▪FAILURE TO HEED THESE WARNINGS MAY RESULT IN SERIOUS
BODILY INJURY OR DEATH.
CAUTION!
▪THIS PRODUCT WILL GENERATE HEAT DURING OPERATION.
▪THIS PRODUCT SHOULD BE INSTALLED ACCORDINGLY ON NON-FLAMMABLE
SURFACES WITH CLEARANCES OF AT LEAST TWO INCHES IN ALL DIRECTIONS.
▪ALWAYS ALLOW AMPLE TIME FOR THE UNIT TO COOL BEFORE ATTEMPTING
SERVICE ON THIS PRODUCT.
▪ALWAYS BE SURE THE BRAKING CAPACITY OF THE CHOPPER AND LOAD BANK
DOES NOT EXCEED THE CAPACITY OF THE CONNECTED DRIVE!
▪REVIEW THE APPLICATION NOTE IN SECTION 7OF THIS MANUAL FOR
INFORMATION ABUT COMMON DC BUS SYSTEMS.
Important Notice about Drives with DC Link Chokes!
▪DURING BRAKING SITUATIONS,ENERGY STORED IN A DRIVE’S DC LINK
CHOKES CAN CREATE EXTREME OVER-VOLTAGE CONDITIONS FOR DYNAMIC
BRAKING CONTROL MODULES.TO AVOID THESE CONDITIONS,DC
CONNECTIONS FROM RESISTIVE BRAKING CONTROL MODULES TO THE DRIVE
SYSTEM MUST ALWAYS BE MADE DIRECTLY IN PARALLEL WITH THE DRIVE’S
FILTER CAPACITORS.THESE MODULES SHOULD NEVER BE CONNECTED IN
SERIES WITH A DRIVE’S DC LINK CHOKES.
▪BE SURE TO REVIEW THE PERTINENT AC DRIVE DOCUMENTATION TO ENSURE
THAT THE PROPER CONNECTIONS ARE USED.
▪CONTACT THE DRIVE MANUFACTURER OR EQUIPMENT SUPPLIER FOR
ASSISTANCE WITH DRIVE CONNECTIONS.
ANY QUESTIONS RELATING TO APPLICATION, INSTALLATION, OR
SERVICE SAFETY SHOULD BE DIRECTED TO THE EQUIPMENT SUPPLIER.

M3452 vR7 EIP/PDP
14
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User’s Manual
15
3. INSTALLATION INSTRUCTIONS
DANGER!
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 M3452 dynamic brake module should be accomplished
following the steps outlined below. Be sure to refer to all other pertinent system
documentation 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. PRODUCT INSPECTION
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.
3.2. SITE SELECTION
The installation site for the module should be chosen with several considerations in
mind:
▪All units require adequate protection from the elements.
▪Adequate clearance should be allowed for easy access to terminals and
adjustments. This will facilitate inspection and maintenance.
▪Sufficient circulation of clean, dry air should be provided. Ambient
temperatures should not exceed +40°C (+104°F) nor be less than 0°C (+32°F)
and non-condensing. Ambient air should not be contaminated with harmful
chemical vapors or excessive dust, dirt, or moisture.
▪The unit will require a minimum clearance of six (6) inches above and below it
to allow for proper airflow for cooling. Avoid mounting the unit with its air intake
near heat sources.
3.3. MOUNTING
Once the installation site has been selected as outlined above, and the mounting holes
drilled and mounting studs or anchors installed, the dynamic brake module is ready to
be hung in position. Be sure all mounting hardware is tightened securely.
Refer to Section 6.6 of this manual to determine the correct mounting dimensions and
provisions for the unit.

M3452 vR7 EIP/PDP
16
3.4. WIRING AND CUSTOMER CONNECTIONS
3.4.1. POWER WIRING
DANGER!
Only qualified electricians should perform and maintain the
interconnection wiring of this product. All wiring should be done in
accordance with local codes.
Wire size should be selected in accordance with local codes, according to the
current rating of the braking transistor. Use copper conductors rated 75°C.
In general, the wire type should be selected by the nominal system AC
voltage and the current rating of the module.
Table 3-1: Power Wiring Specifications
CHASSIS
TERMINAL
CONNECTION
TORQUE
K6
DC+, DC-, RES+, RES-
3/8” stud
192 lb-in
K9
DC+, DC-, RES+, RES-
1/2" stud
300 lb-in
K10
DC+, DC-, RES+, RES-
1/2" stud
300 lb-in
M14
DC+, DC-, RES+, RES-
Bus Bar
N/A
T10
DC+, DC-, RES+, RES-
Bus Bar
N/A
3.4.1.1. DC BUS CONNECTION
As a general rule of thumb, 30 feet (10m) is the maximum total buswork
or cable that the chopper should be mounted from the drive. This means
that the actual installation distance should be 15 feet (5m), as the cable
must go out and back. If you must connect the choppers farther away,
see Section 6.6.
The braking transistor must be connected directly to the DC bus filter
capacitors of the drive.
Figure 3-9 is an example of the terminals that may be available in your
installation. Not all of the terminals may be on your drive. Refer to the
drive manufacturer's manual or technical documents to locate the proper
terminals. Your drive will have different terminal markings depending on
manufacturer and drive series.
Ensure that the polarity of the connection is correct. Incorrect polarity will
effectively short the DC bus of the drive, and can cause severe damage
to the drive, load resistor, and the Bonitron braking transistor.
The proper terminals to attach the braking transistor are marked + and -
on Figure 3-9.
The terminals marked BR+ and BR- are intended for the internal braking
transistor. If the Bonitron external braking transistor is hooked to the
terminals, the braking transistor will not operate properly. In some cases,
it may cause drive failure.
The terminals marked X and Y are intended for connection of a DC link
choke. If the Bonitron braking transistor is connected to the terminals
marked "X" and "-" in Figure 3-9, switching resonances caused by the DC
link choke will destroy the braking transistor. If the Bonitron braking
transistor is connected between X and Y, the drive will not operate.

User’s Manual
17
If the braking transistor is connected to the terminals marked "A" and "B"
in Figure 3-9, switching resonances caused by the lack of filter
capacitance during precharge will destroy the braking transistor.
3.4.1.2. RESISTOR CONNECTION
The polarity of the resistor connections is not critical; however, it is critical
that the resistor be connected to the proper terminals. Improper hookup
can lead to the resistor being connected directly across the DC bus, which
will cause severe overheating and drive stress.
3.4.1.3. GROUNDING REQUIREMENTS
All units come equipped with either a ground terminal or ground stud that
is connected to the module chassis. Ground the chassis in accordance
with local codes. Typically, the wire gauge will be the same as is used to
ground the attached drive.
3.4.2. I/O WIRING
NOTE!
Terminal strip I/O is prewired to the modular I/O module, and is listed here
only for reference. All I/O operations should be carried out using the
network interface.
Table 3-2: I/O Terminal Block Specifications: R7 Control Board
TERMINAL
FUNCTION
ELECTRICAL
SPECIFICATIONS
(MAX)
MIN
WIRE
AWG
MAX
WIRE
AWG
TORQUE
TB1-1
Control Voltage
L1
24V (+)
24V –3A *
24V –8A *
120V –0.6A
230V –0.3A
460V –0.16A
575V –0.15A
16
10
4.5 lb-in
TB1-2
Control Voltage
L2
24V (-)
24V –3A *
24V –8A *
120V –0.6A
230V –0.3A
460V –0.16A
575V –0.15A
16
10
4.5 lb-in
TB2-11&12
Control Signal I/O
Analog
(Note: This signal does not
appear on the network)
18
12
4.5 lb-in
* 24V –3A for 200A thru 1200A units. 24V –8A for 1600A units.
3.4.3. DC CONTROL WIRING
M3452-Dxxx units have 24VDCfor control power. This connection is on ASB
3452I5 TB1 with positive in Terminal 1 and negative in Terminal 2. See
Figure 3-9.

M3452 vR7 EIP/PDP
18
Figure 3-1: Customer Connections in K6 Chassis
CUSTOMER I / 0
CONNECTION
RES+ RES- DC BUS- DC BUS+

User’s Manual
19
Figure 3-2: Customer Connections in K9 Chassis
CUSTOMER I / 0
CONNECTION

M3452 vR7 EIP/PDP
20
Figure 3-1: Customer Connections in K10 Chassis
RES.
RES.
CUSTOMER I / 0
CONNECTION
DC BUS-
RES.+
RES.-
DC BUS+