bonitron M3460RD User manual

Web: www.bonitron.com ● Tel: [phone] ● Email: [email protected]m
Model M3460RD
Impedance Module
For Sag Ride-Thru Applications without Energy
Storage
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

M3460RD
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Table of Contents
5
1. INTRODUCTION..........................................................................................................................7
1.1. Who Should Use This Manual......................................................................................................7
1.2. Purpose and Scope........................................................................................................................7
1.3. Manual Revision Record..............................................................................................................7
Figure 1-1: M3460RD-225..........................................................................................................................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 ..............................................................................................................9
Figure 2-1: Example of M3460RD Part Number Breakdown .....................................................................9
2.3. General Specifications.................................................................................................................. 9
Table 2-1: General Specifications Chart......................................................................................................9
2.4. General Precautions and Safety Warnings .................................................................................10
3. INSTALLATION INSTRUCTIONS................................................................................................11
3.1. Product Inspection......................................................................................................................11
3.2. Site Selection..............................................................................................................................11
3.3. Mounting ....................................................................................................................................11
3.4. Wiring and Customer Connections.............................................................................................11
Table 3-1: Field Wiring Connections ........................................................................................................11
3.4.1. Power Wiring......................................................................................................................................11
3.5. Typical Configurations...............................................................................................................13
Figure 3-1: M3460R Typical Configuration without Energy Storage .......................................................13
Figure 3-2: M3460RS Typical Configuration without Energy Storage.....................................................14
4. OPERATION..............................................................................................................................15
4.1. Functional Description ...............................................................................................................15
5. STARTUP,MAINTENANCE AND TROUBLESHOOTING..............................................................17
5.1. Startup......................................................................................................................................... 17
5.1.1. Pre-Power Checks...............................................................................................................................17
5.1.2. Startup Procedure ...............................................................................................................................17
5.2. Maintenance................................................................................................................................17
5.3. Troubleshooting..........................................................................................................................17
5.3.1. Ridethrough System does not hold up the drive during a sag event ...................................................17
5.3.2. Circulating currents between drives or Heatsink in the M3460R gets hot..........................................17
5.4. Technical Help –before you call................................................................................................17
6. ENGINEERING DATA................................................................................................................19
6.1. Ratings Charts.............................................................................................................................19
Table 6-1: M3460RD Impedance Module Ratings....................................................................................19
6.2. Watt Loss....................................................................................................................................19
6.3. Dimensions and Mechanical Drawings......................................................................................19
Figure 6-1: M3460RD Backplate Dimensional Outline ............................................................................19
Figure 6-2: M3460RD-255 Chassis Outline..............................................................................................20
Figure 6-3: M3460RD-425 Chassis Outline..............................................................................................20
7. SAG ONLY INSTALLATIONS &CIRCULATING CURRENTS......................................................21
Figure 7-2: M3460R Typical Configuration without Energy Storage .......................................................21
Figure 7-3: M3460R Typical Configuration with Circulating Current Flow.............................................22
Figure 7-3: M3460R Typical Configuration with Current Flow with affected SCR Highlighted .............23
Figure 7-4: M3460R Typical Configuration with Ultracapacitor Storage Bank........................................24

M3460RD
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User’s Manual
7
1. INTRODUCTION
1.1. WHO SHOULD USE THIS MANUAL
This manual is intendedfor use by anyone who is responsible for integrating, installing,
maintaining, troubleshooting, or using this equipment.
Please keep this manual for future reference.
1.2. PURPOSE AND SCOPE
This manual is a user’s guide for the Model M3460RD Impedance Module. It will
provide the user with the necessary information to successfully install, integrate, and
use the M3460RD 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 REVISION RECORD
The initial release of this manual is Rev 00a.
Figures 6-2 and 6-3 were added in Rev 00b.
Section 2 was updated in Rev 00c.
Figure 1-1: M3460RD-225

M3460RD
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’s M3460RD Impedance Modules are designed to offer system integrators a low
cost solution for using an M3460R Ride-Thru Module (RTM) in systems where there is an
AC input directly to the M3460R module. In some installations, additional impedance in
the negative DC link may be required for proper operation. The M3460RD prevents
circulating currents between the variable frequency drive and the M3460R Ride Thru
Module.
Please see the Application Notes in Section 7 for additional information.
2.1. RELATED PRODUCTS
The M3460RD modules are intended to be used with Bonitron M3460R Ride-Thru
Modules.
2.2. PART NUMBER BREAKDOWN
Figure 2-1: Example of M3460RD Part Number Breakdown
BASE MODEL NUMBER
The Base Model Number for the Impedance Modules for use with M3460R Ride Thru
Modules is M3460RD.
CURRENT RATING
The maximum current rating of the M3460R Ride Thru module is designated by this
value in amperes. M3460R Ride-Thru modules rated 85A-255A should use 255.
M3460R Ride-Thru modules rated 340A-425A should use 425.
2.3. GENERAL SPECIFICATIONS
Table 2-1: General Specifications Chart
PARAMETER
SPECIFICATION
Nominal System Voltage
208 –480VAC
Current Ratings
255A –425A
Maximum Run Time
4 minutes
Storage Temperature
-20ºC to +65ºC
Operating Temperature
5°C to 40°C
Humidity
80% for temperatures up to 31°C decreasing linearly to
50% relative humidity at 40°C
Atmosphere
For indoor use only and free of corrosive gas and dust
Pollution Degree
2
Installation/Overvoltage Category
II
Altitude
2000 m
M3460RD
255
BASE MODEL NUMBER
CURRENT RATING

M3460RD
10
2.4. GENERAL PRECAUTIONS AND SAFETY WARNINGS
DANGER!
HIGH VOLTAGES MAY BE PRESENT!
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!
FAILURETOHEEDTHESEWARNINGSMAYRESULTINSERIOUS
BODILY INJURY OR DEATH!
CAUTION!
CERTAIN COMPONENTS WITHIN THIS PRODUCT MAY GENERATE HIGH
AMBIENT TEMPERATURES DURING OPERATION.
ALWAYS ALLOW AMPLE TIME FOR THE UNIT TO COOL BEFORE ATTEMPTING
SERVICE ON THIS PRODUCT.
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
ACCOMPLISHED BY A 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.

User’s Manual
11
3. INSTALLATION INSTRUCTIONS
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
All units require adequate protection from the elements. Open frame modules
must be mounted within enclosures of suitable rating for the environment.
Adequate clearance should be allowed for easy access to terminals. 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 becontaminated with harmful chemical vapors
or excessive dust, dirt, or moisture.
The unit requires a minimum clearance of three (3) inches in all directions. Avoid
mounting the unit near heat sources.
3.3. MOUNTING
Once the installation site has been selected as outlined above, the unit should be
mounted in place.
Mounting holes should be drilled and mounting studs or anchors installed before
positioning the M3460RD Module. Once the studs or bolts are in place the module
can be mounted. Be sure all mounting hardware is tightened securely.
Refer to Section 6 of this manual to determine the correct mounting dimensions and
provisions for the unit.
3.4. WIRING AND CUSTOMER CONNECTIONS
Table 3-1: Field Wiring Connections
TERMINAL
DESIGNATION
FUNCTION
WIRING
SPECIFICATION
CONNECTION
MAX.
TORQUE
Drive Bus –
DC Connection
to Drive
600VAC
3/8" stud
230 lb-in
3460R Output
Bus –
DC Connection
to M3460R
Module
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 National Electrical Code or equivalent regulations.
Wire size should be selected in accordancewith local codes,according to the
current rating of the M3460R module.
3.4.1.1. DRIVE BUS –CONNECTION
The Drive Bus should be connected to the negative side of the DC Bus
on the Drive. Connecting to the positive side of the Drive carries a high
risk of damaging drive equipment if energized. Some drives have a

M3460RD
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connection to an internal braking transistor. Do NOT use this connection.
Connect only to the DC bus terminals. See the operation manualfor your
drive.
3.4.1.2. M3460R OUTPUT BUS –CONNECTION
The M3460R Output Bus should be connected to the negative side of the
ouput bus on the M3460R module. Connecting to the positive side of the
M3460R Output Bus carries a high risk of damaging drive equipment if
energized.

User’s Manual
13
3.5. TYPICAL CONFIGURATIONS
Figure 3-1: M3460R Typical Configuration without Energy Storage
FROM THE SAME FEED TRANSFORMER.
CONNECTED DOWNSTREAM.
2. IF LINE CHOKES ARE USED, RIDE-THRU MUST BE
1. INVERTER AND RIDE-THRU SHOULD BE POWERED
~NOTES~
CHOPPER
BRAKING
INTERNAL
VFD
INVERTER
BRAKING
RESISTOR
DISCONNECT
DRIVE
FEED
AC
CHOKES
LINE
GROUND
FAULT
SENSING
DISCONNECT
RIDE-THRU
M3460R
CHOPPER
+
-
+
-
DRIVE
BUS
STORAGE BUS
STORAGE BUS
M3460RD
DRIVE
BUS-
M3460R
OUTPUT
BUS-
Dwg: 010175 Rev: 20140502

M3460RD
14
Figure 3-2: M3460RS Typical Configuration without Energy Storage
FROM THE SAME FEED TRANSFORMER.
CONNECTED DOWNSTREAM.
2. IF LINE CHOKES ARE USED, RIDE-THRU MUST BE
1. INVERTER AND RIDE-THRU SHOULD BE POWERED
~NOTES~
CHOPPER
BRAKING
INTERNAL
VFD
INVERTER
BRAKING
RESISTOR
DISCONNECT
DRIVE
FEED
AC
CHOKES
LINE
GROUND
FAULT
SENSING
DISCONNECT
RIDE-THRU
M3460R
CHOPPER
+
-
+
-
DRIVE
BUS
STORAGE BUS
STORAGE BUS
M3460R
CHOPPER
+
-
+
-
DRIVE
BUS
STORAGE BUS
STORAGE BUS
M3460RD
DRIVE
BUS-
M3460R
OUTPUT
BUS-
M3460RD
DRIVE
BUS-
M3460R
OUTPUT
BUS-
Dwg: 140076 Rev: 20140505

User’s Manual
15
4. OPERATION
4.1. FUNCTIONAL DESCRIPTION
The Ride-Thru Impedance Module provides the necessary impedance to prevent the
propagation of circulating currents between the variable frequency drive and the Ride-Thru
Module. Stray circulating currents cause heating in the components of the Ride-Thru and the
variable frequency drive. The addition of the Impedance Module adds a fixed voltage drop in
the negative link in the connection between the boost regulator and the drive. Please see
Section 7 for further details.

M3460RD
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User’s Manual
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5. STARTUP, MAINTENANCE AND TROUBLESHOOTING
5.1. STARTUP
5.1.1. PRE-POWER CHECKS
Ensure that all connections are tight, DC bus polarity is correct, and that the
drive is connected to the proper terminals. Check for exposed conductorsthat
may lead to inadvertent contact or shorting. Ensure that the current rating of
the module is suitable for the application.
5.1.2. STARTUP PROCEDURE
Refer to the M3460 Ride Thru User Manual for the startup procedure of the
Ride Thru system. This can be found online at www.bonitron.com or by
contacting Bonitron.
5.2. MAINTENANCE
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.
5.3. TROUBLESHOOTING
5.3.1. RIDETHROUGH SYSTEM DOES NOT HOLD UP THE DRIVE DURING A
SAG EVENT
Make sure the M3460RD is connected in the negative power return between
the VFD and the M3460R.
Check the polarity of the installation of the M3460RD with respect to the
M3460R and VFD. The anode side of the M3460RD shold be connected to
the VFD and the cathode side should be connected to the M3460RD.
5.3.2. CIRCULATING CURRENTS BETWEEN DRIVES OR HEATSINK IN THE
M3460R GETS HOT
Make sure the connections are correct between the drives and the Ride-Thru
Module. The M3460RD is intended to be used only in the negative power
connection between the M3460R and the VFD.
5.4. TECHNICAL HELP –BEFORE YOU CALL
If possible, please have the following information when calling for technical help:
Serial number of unit
Name of original equipment supplier
Brief description of the application
Drive and motor hp or kW
The line to line voltage on all 3 phases
The DC bus voltage
KVA rating of power source
Source configuration Wye/Delta and grounding

M3460RD
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User’s Manual
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6. ENGINEERING DATA
6.1. RATINGS CHARTS
Table 6-1: M3460RD Impedance Module Ratings
PART NUMBER
CURRENT
RATING
WATT
LOSS
M3460RD-255
255A
370
M3460RD-425
425A
450
6.2. WATT LOSS
Watt losses listed are figured at full load. Losses occur and heat is generated only
when the Ride-Thru is active. Ensure that enclosure cooling is adequate based on the
duty cycle of the Ride-Thru Module attached. Maximum duty cycle for the M3460RD
is 1%. See Table 6-1.
6.3. DIMENSIONS AND MECHANICAL DRAWINGS
Figure 6-1: M3460RD Backplate Dimensional Outline
10.00
6.50
9.50
6.00
.25
.25
4x Ø.22
9.50
6.00
Dwg: 140085 Rev: 20140527

M3460RD
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Figure 6-2: M3460RD-255 Chassis Outline
4 AWG WIRES
Figure 6-3: M3460RD-425 Chassis Outline
2 AWG WIRES
Dwg: 140078 Rev: 20140509, 140077 Rev: 20140509