bonitron M3452 User manual

Web: www.bonitron.com ● Tel: [phone] ● Email: [email protected]
Model M3452
Combination Braking Module with
Integrated Transistor and Resistor
Customer Reference Manual

Bonitron, Inc.
2
Bonitron, Inc.
Nashville, TN
An industry leader in providing solutions for AC drives.
ABOUT BONITRON
Bonitron designs and manufactures quality industrial electronics that improve the reliability of
processes and variable frequency drives worldwide. With products in numerous industries, and
an educated and experienced team of engineers, Bonitron has seen thousands of products
engineered since 1962 and welcomes custom applications.
With engineering, production, and testing all in the same facility, Bonitron is able to ensure its
products are of the utmost quality and ready to be applied to your application.
The Bonitron engineering team has the background and expertise necessary to design, develop,
and manufacture the quality industrial electronic systems demanded in today’s market. 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

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1. INTRODUCTION............................................................................................................. 7
1.1. Who Should Use...........................................................................................................7
1.2. Purpose and Scope......................................................................................................7
1.3. Manual Version an d Change Record...........................................................................7
Figure 1-1: Typical M3452 Complete Module...............................................................................7
1.4. Symbol Conventions Used in this Manual and on Equipment.......................................8
2. PRODUCT DESCRIPTION /FEATURES ............................................................................. 9
2.1. Related Products..........................................................................................................9
2.2. Part Number Breakdown ..............................................................................................9
Table 2-1: Part Number Breakdown.............................................................................................9
Table 2-2: AC Voltage Rating.......................................................................................................9
Table 2-3: Resistors....................................................................................................................10
Table 2-4: Chassis Codes ..........................................................................................................10
2.3. General Specifications................................................................................................10
Table 2-5: Specifications ............................................................................................................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
3.3.1. Mounting the M3452 ...........................................................................................................13
Figure 3-2: Recommended Placement and Required Minimum Mounting Clearances .............14
3.4. Wiring and Customer Connections.............................................................................15
3.4.1. Power Wiring.......................................................................................................................15
Figure 3-3: Power Termination Information................................................................................15
Table 3-1: Power Wiring Specifications......................................................................................15
Table 3-2: DC Bus Wiring Specifications....................................................................................16
3.4.2. Control Interface Wiring ......................................................................................................16
Figure 3-4: Control Termination Information...............................................................................16
Table 3-3: Control Wiring Specifications ....................................................................................17
3.5. Typical Configurations................................................................................................18
Figure 3-4: Field Connections.....................................................................................................18
4. OPERATION ............................................................................................................... 20
4.1. Functional Description................................................................................................20
4.2. Features.....................................................................................................................20
4.2.1. Indicators.............................................................................................................................20
4.3. Startup........................................................................................................................20
4.3.1. Pre-Power Checks ..............................................................................................................20
4.3.2. Startup Procedure and Checks...........................................................................................21
4.4. Operational Adjustments ............................................................................................21
5. MAINTENANCE AND TROUBLESHOOTING ...................................................................... 22
5.1. Periodic Testing..........................................................................................................22
5.2. Maintenance Items.....................................................................................................22
5.3. Troubleshooting..........................................................................................................22
5.3.1. Control power light not illuminated......................................................................................22
5.3.2. DC bus light not illuminated ................................................................................................22
5.3.3. Blown DC bus fuse..............................................................................................................23
5.3.4. Fan runs constantly.............................................................................................................23
5.3.5. Fan doesn’t run ...................................................................................................................23

Table of Contents
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5.3.6. Module over-temp, or module seems too hot .....................................................................24
5.3.7. Drive trips on overvoltage ...................................................................................................24
5.3.8. Braking light flickers ............................................................................................................24
5.3.9. Braking light stays on all the time........................................................................................24
5.4. Technical Help –before you call.................................................................................26
6. ENGINEERING DATA ................................................................................................... 27
6.1. Ratings Charts............................................................................................................27
Table 6-1: Model Ratings............................................................................................................27
6.2. Turn On Voltages .......................................................................................................27
Table 6-2: Turn-on Voltages.......................................................................................................27
6.3. Certifications...............................................................................................................28
6.4. UL 508A Short Circuit Current Rating.........................................................................28
6.5. Fuse/Circuit Breaker Sizing and Rating ......................................................................28
6.6. Dimensions and Mechanical Drawings .......................................................................29
Figure 6-1: Enclosure Dimensional Outline (Styles “B” & “C”) ...................................................29
6.7. Block Diagrams ..........................................................................................................30
Figure 6-2: Block Diagram..........................................................................................................30
7. APPLICATION NOTES.................................................................................................. 31
7.1. Sizing your Braking Requirements..............................................................................31
7.1.1. Horsepower to Watts...........................................................................................................31
7.1.2. Peak Amperage...................................................................................................................31
7.1.3. Ohmic Value........................................................................................................................31
7.1.4. Duty Cycle...........................................................................................................................32
7.1.5. Continuous Rating...............................................................................................................32
7.2. Common Bus Application Note...................................................................................32
7.3. Bonitron Line Regeneration Modules..........................................................................33

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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 complete braking module. It will
provide the user with the necessary information to successfully install, integrate, and
use the M3452 complete braking module in a variable frequency AC drive system.
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 AN D CHANGE RECORD
Model ratings were updated in Rev 05c of this manual.
Fusing information was updated in Rev 05d of this manual.
Block diagram was updated in Rev 05e of this manual.
The manual template was updated in Rev 05f of this manual.
Section 4.2.2 was removed in Rev 05g of this manual.
Updates to Section 7.2 were made in Rev 05h of this manual.
Section 3 was updated to include info about the status contacts in Rev 05j.
Figure 1-1: Typical M3452 Complete Module

M3452 Complete
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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.

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2. PRODUCT DESCRIPTION / FEATURES
Bonitron's complete braking module provides drive protection from overvoltage faults and
allows for full power braking. The complete braking module works with any AC drive
system that uses a fixed DC bus by shunting the excess energy through a load resistor.
Regenerative braking occurs when an induction motor is decelerating, or the shaft of the
motor is being overhauled by a load. In this case, the motor acts as a generator, and
causes the DC bus of the variable frequency drive to rise. If the DC bus voltage is not
controlled, the VFD will trip on DC bus overvoltage and stop regulating the motor speed.
The regenerated energy must be dissipated as heat or returned to the power line.
Dissipating this heat may be impractical in applications with more frequent regeneration.
In these applications, the higher cost of the Bonitron M3645 line regen as compared with
resistive braking is quickly offset because the regenerated energy, which is returned to
the AC line with near unity power factor, can be used to power other equipment.
2.1. RELATED PRODUCTS
The M3575T standard duty braking transistor module offers 15 to 600HP braking
capability at a 20% duty cycle.
The M3452 heavy duty braking transistor module is compatible with several other
Bonitron modules, which may be required to meet overall system operational
requirements.
The M3575R represents a line of enclosed resistive load modules rated up to 150HP
peak. The M3775RK represents another line of resistive load banks rated up to 3
megawatts.
2.2. PART NUMBER BREAKDOWN
Table 2-1: Part Number Breakdown
BASE MODEL NUMBER
The Base Model Number for the complete braking module is M3452.
VOLTAGE RATING
The voltage rating indicates the AC voltage level for the drives in the system.
Table 2-2: AC Voltage Rating
RATING
CODE
NOMINAL AC LINE
L
230VAC
H
460VAC
C
575VAC
M3452
H
9
C
BASE MODEL NUMBER
CONTROL VOLTAGE
RESISTORS
CHASSIS STYLE
R050
RESISTANCE

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RESISTORS
The resistor quantity is indicated by a numeric code.
Table 2-3: Resistors
RATING CODE
RESISTOR QUANTITY
2
2 Resistors
3
3 Resistors
6
6 Resistors
8
8 Resistors
9
9 Resistors
CHASSIS SIZE
The chassis code represents the chassis size of the complete braking module.
Table 2-4: Chassis Codes
CHASSIS
CODE
RESISTORS
TYPE
DIMENSIONS
(H X WX D)
B
2, 3, 6
Type 1
18.25 x9.50 x 8.50
C
8, 9
Type 1
18.25 x11.50 x 10.50
RESISTANCE
The resistance is indicated by an “R” followed by the 3-digit number representing the
ohmic value of the internal load bank.
2.3. GENERAL SPECIFICATIONS
Table 2-5: Specifications
PARAMETER
SPECIFICATION
Connections
Input AC line
Drive DC Bus
Ground
NO Module Ready
NC Module Ready
Input AC Line
230, 460, 575VAC Single Phase;
Rated Voltage ±10%; 50/60 Hz
Operating Temp
0 to 50C
Storage Temp
-20 to + 65C
Humidity
Below 90 % non-condensing
Atmosphere
Free of corrosive gas and conductive dust

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2.4. GENERAL PRECAUTIONS AND SAFETY WARNINGS
DANGER!
▪HIGH VOLTAGES PRESENT!
▪NEVER ATTEMPT TO OPERATE THIS PRODUCT WIT H THE
ENCLOSURE COVER OPENED!
▪NEVER ATTEMPT TO SERVICE THIS PRODUCT WITHOUT
FIRST DISCONNECTING POWER TO AND FROM THE UNIT.
▪ALWAYS ALLOW ADEQUATE TIME FOR RESIDUAL
VOLTAGES TO DRAIN BEFORE REMOVING THE
ENCLOSURE COVER.VERIFY VOLTAGE ON UNIT WITH
VOLTMETER BEFORE SERVICING.
▪FAILURE TO HEED THESE WARNINGS MAY
RESULT IN SERIOUS BODILY INJURY OR DEATH!
CAUTION!
▪THIS PRODUCT WILL GENERATE HIGH TEMPERATURES
DURING OPERATION.
▪THIS PRODUCT SHOULD BE INSTALLED ACCORDINGLY ON
NON-FLAMMABLE SURFACES WITH CLEARANCES OF AT
LEAST 2” ON THE TOP AND SIDES,AND A MINIMUM OF
6”ON THE FRONT AND BOTTOM.
▪ALWAYS ALLOW AMPLE TIME FOR THE UNIT TO COOL
BEFORE ATTEMPTING SERVICE ON THIS PRODUCT.
▪NO USER-SERVICEABLE PARTS ARE CONTAINED WITHIN
THIS PRODUCT.INOPERABLE UNITS SHOU LD BE
REPLACED OR RETURNED FOR EVALUATION AND /OR
REPAIR BY QUALIFIED TECHNICIANS
▪BEFORE ATTEMPTING INSTALLATION OR REMOVAL OF
THIS PRODUCT,BE SURE TO REVIEW A LL DRIVE AND/OR
RESISTIVE LOAD DOCUM ENTATION FOR PERTINENT
SAFETY PRECAUTIONS .
▪INSTALLATION AND/OR REMOVAL OF THIS PRODUCT
SHOULD ONLY BE ACCOM PLISHED BY A QU ALIFIED
ELECTRICIAN IN ACCOR DANCE WITH NATIONAL
ELECTRICAL CODE OR EQUIVALENT REGULATIONS.
ANY QUESTIONS AS TO APPLICATION, INSTALLATION, OR SERVICE
SAFETY SHOULD BE DIRECTED TO THE EQUIPMENT SUPPLIER.

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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 M3452 complete brake module should be accomplished
following the steps outlined below. Be sure to refer to the AC drive instruction manual as
these steps are performed. Since most start-up difficulties are theresult of incorrect wiring,
every precaution must be taken to assure that the wiring is done as instructed. All items
must be read and understood before the actual installation is started. Please direct all
installation questions that may arise during the installation and startup of this product to
the equipment supplier or system integrator.
3.1. 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.
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
3.3.1. MOUNTING THE M3452
The installation site for the module should be chosen with several
considerations in mind:
•Unit should not be exposed to falling debris or condensation.
•Refer to Figure 3-2 for minimum mounting clearances.
•The M3452 must be properly oriented for proper heat flow through the
units.
•The M3452 must be mounted with the rear surface of the unit to the
mounting surface. Unit should be mounted vertically as shown in
Figure 3-2. Failure to do so can result in overheating and damage to the
unit or surrounding equipment.
•Do Not mount the unit upside-down or on the underside of a mounting
surface as shown in Figure 3-1.
•Do Not mount unit in horizontally with side parallel to the mounting
surface or floor as shown in Figure 3-1.

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•Figure 3-1: Prohibited Mounting Arrangement
Figure 3-2: Recommended Placement and Required Minimum Mounting Clearances

User’s Manual
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3.4. WIRING AND CUSTOMER CONNECTIONS
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.
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.
Figure 3-3: Power Termination Information
AC INPUT
DETAIL A: TS1 TERMINATION INFORMATION
L1
1
DC BUS
L2 +
234
Table 3-1: Power Wiring Specifications
TERMINAL
CONNECTION
TORQUE
WIRE SIZE
L1, L2
#10-32 Phillips Screw
20 lb-in
#18 AWG CU
DC+, DC-
#10-32 Phillips Screw
20 lb-in
See Table 3-2
GND
¼” Stud
10 lb-in
#10-14 AWG CU
3.4.1.1. AC BUS CONNECTION
The AC connection to the drive provides power for the fans and control
circuit of the braking unit. It must be connected for the braking unit to
operate. The amount of AC input power is very low compared to the
capacity of the braking unit. Refer to Section 6 for full power requirements
for each unit.
All AC input power wiring should be a minimum of 18 AWG.
3.4.1.2. DC BUS CONNECTION
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 is being used in the bus, make sure the actual connection is in
parallel with filter capacitors of the drive/inverter.
Make sure that the DC bus connection polarity is correct. Improper
polarity connections carry a high risk of damaging drive equipment if
energized.
Some drives have a connection to an internal braking transistor,
commonly marked B+ or B-. Do not use this connection. Connect only to
the DC bus terminals. Refer to your drive manufacturer’s documentation
or technical support for further information.
Please see Section 7 for further application notes.

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Table 3-2: DC Bus Wiring Specifications
PART NUMBER
MINIMUM WIRE
SIZE
M3452-L2B-R030
14 AWG CU
M3452-L3B-R020
14 AWG CU
M3452-L3B-R030
14 AWG CU
M3452-L6B-R010
12 AWG CU
M3452-L8C-R004
8 AWG CU
M3452-L9C-R007
10 AWG CU
M3452-L9C-R015
14 AWG CU
M3452-H2B-R120
14 AWG CU
M3452-H3B-R075
14 AWG CU
M3452-H6B-R038
14 AWG CU
M3452-H8C-R018
10 AWG CU
M3452-H9C-R025
12 AWG CU
M3452-H9C-R050
14 AWG CU
M3452-H9C-R108
14 AWG CU
M3452-C2B-R120
14 AWG CU
M3452-C3B-R105
14 AWG CU
M3452-C6B-R053
14 AWG CU
M3452-C9C-R035
12 AWG CU
M3452-C9C-R050
14 AWG CU
M3452-C9C-R108
14 AWG CU
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. CONTROL INTERFACE WIRING
Figure 3-4: Control Termination Information

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Table 3-3: Control Wiring Specifications
TERMINAL
FUNCTION
ELECTRICAL
SPECIFICATIONS
MIN WIRE
AWG
MAX WIRE
AWG
TORQUE
LB-IN
TS1-1
Ready Status NO
220VAC/DC, 100mA Max[2]
16
12
5.3 lb-in
TS1-2
Ready Status NC
220VAC/DC, 100mA Max[2]
16
16
5.3 lb-in
TS1-3
Ready Status COM
220VAC/DC, 100mA Max[2]
16
16
5.3 lb-in

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3.5. TYPICAL CONFIGURATIONS
Figure 3-4: Field Connections

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4. OPERATION
4.1. FUNCTIONAL DESCRIPTION
When the drive’s DC bus voltage exceeds a fixed setpoint, the complete braking
module’s control electronics turns on an IGBT transistor connecting the resistor load
across the DC bus. When the DC bus goes down to a lower level, the IGBT turns off.
The braking module may switch at different frequencies, depending on the amount of
braking force or deceleration needed.
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 buswith a working voltmeter before servicing equipment, as the DC
bus light may be broken!
4.2.1.2. CONTROL POWER
This indicator illuminates when control power is applied to the unit and
indicates that the control circuit is functioning.
4.2.1.3. 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.
4.3. STARTUP
WARNING!
Bonitron complete braking modules are designed to be used with stand-alone
or common DC bus drive/inverter systems with bus capacitors. When using
the Bonitron modules on common bus systems, special considerations may
apply. Refer to and review the Application Notes found in Section 7 later in
this manual prior to energizing this type of system!
4.3.1. PRE-POWER CHECKS
Ensure that all connections are tight, DC bus polarity is correct, and that all
customer wiring is of the proper size for operational requirements. Check for
exposed conductors or bare spots that may lead to accidental contact.