bonitron M3528M2 User manual

Web: www.bonitron.com ● Tel: [phone] ● Email: [email protected]m
Model M3528M2
Voltage Monitor Module
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

M3528M2
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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 M3528M2.........................................................................................................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
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. Environment...............................................................................................................11
3.2. Unpacking ..................................................................................................................11
3.3. Mounting.....................................................................................................................11
3.4. Wiring and Customer Connections.............................................................................11
Figure 3-1: Typical Interconnection Diagram..............................................................................12
3.4.1. Power Wiring.....................................................................................................................12
3.4.2. I/O Wiring..........................................................................................................................12
Table 3-1: Wiring Specifications .................................................................................................13
4. OPERATION ............................................................................................................... 15
4.1. Functional Description................................................................................................15
4.2. Features.....................................................................................................................15
4.2.1. Connectors........................................................................................................................15
4.2.2. Jumpers ............................................................................................................................16
Table 4-1: Setpoint Range Jumper Configurations ....................................................................16
4.2.3. Potentiometers..................................................................................................................17
Table 4-2: Setpoint Adjustment Sensitivity.................................................................................17
Figure 4-1: Front View ................................................................................................................18
5. MAINTENANCE AND TROUBLESHOOTING ...................................................................... 19
5.1. Troubleshooting..........................................................................................................19
6. ENGINEERING DATA ................................................................................................... 21
6.1. Ratings Charts............................................................................................................21
Table 6-1: M3528M2 Ratings Chart............................................................................................21
Table 6-2: Recommended Settings............................................................................................21
6.2. Dimensions and Mechanical Drawings .......................................................................21
Figure 6-1: M3528M2 Chassis Dimensional Outline ..................................................................21
NOTES........................................................................................................................................21

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User’s Manual
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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 DC energy
storage system.
Please keep this manual for future reference.
1.2. PURPOSE AND SCOPE
This manual is a user’s guide for the Model M3528M2 Voltage Monitor Module. It
will provide the user with the necessary information to successfully install, integrate,
and use the M3528M2.
In the event of any conflict between this document and any publication and/or
documentation related to the DC storage system, the latter shall have precedence.
1.3. MANUAL VERSION AND CHANGE RECORD
CE requirements for the M3528M2 are met in Rev 01.
Wiring Specs were corrected and terminology was clarified in Rev 01a.
The manual template was updated in Rev 01b.
Figure 1-1: Model M3528M2

M3528M2
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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.

User’s Manual
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2. PRODUCT DESCRIPTION
The need for DC voltage monitoring arises in applications where a system voltage may
otherwise rise or fall to an unsafe value. If a battery discharges too far, individual cells
may change polarity, causing permanent damage to the battery and reducing its lifetime.
Batteries, capacitors, and any other system can be damaged by the voltage across them
rising too high. The M3528M2 voltage monitor is designed to monitor DC voltage levels
and signal the user if the voltage departs a set range.
2.1. RELATED PRODUCTS
This product is designed for use with any DC energy storage system, including super
capacitors and battery systems, such as the M3534 and M3460 Ride Thru Systems.
Contact your distributor for more information.
2.2. PART NUMBER BREAKDOWN
BASE MODEL NUMBER
The Base Model Number, M3528, indicates that the unit is related to charger
modules. ‘M’ specifies a monitor board, and ‘2’ specifies this particular unit.
There are no special options at this time.
2.3. GENERAL SPECIFICATIONS
Table 2-1: General Specifications Chart
PARAMETER
SPECIFICATION
Power
24VDC ± 10%, 30 mA
Monitor Voltages
10-100VDC, 50-500VDC, 100-850VDC
Latch Reset Control Voltage
24VDC
Outputs
Overvoltage & undervoltage :
Form C Solid State Relay,
250V, 100mA, 35 Ω
Storage Temp
-20ºC to +65ºC
Ambient Operating Temp Range
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

M3528M2
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2.4. GENERAL PRECAUTIONS AND SAFETY WARNINGS
DANGER!
HIGH VOLTAGES MAY BE PRESENT!
FAILURE TO HEED THESE WARNINGS MAY RESULT
IN SERIOUS BODILY INJURY OR DEATH!
CAUTION!
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 DOCUMENTATION OF ALL
CONNECTED DEVISES 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
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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 M3528M2 Voltage Monitor Module should be
accomplished following the steps outlined below. Please direct all installation and start
up inquiries regarding this product to your supplier or system integrator.
3.1. ENVIRONMENT
The installation site should be dry and clean without extreme temperatures.
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
The unit is mounted with a standard DIN rail clip attached to the back of the
enclosure. Refer to Figure 6-1 to determine the correct mounting dimensions for
your unit.
3.4. WIRING AND CUSTOMER CONNECTIONS
This section provides information about the field connection of the DC bus and signal
inputs to the M3528M2 Voltage Monitor Module.
Be sure to review all pertinent system documentation as well as the power wiring
information in Section 3.4.1 before proceeding.
For the maximum wire size accepted by the individual field connection terminals,
refer to Table 3-1. Wire types and sizes should be chosen in accordance with
national and local electrical codes to meet the voltage and current levels present for
your application.
Figure 3-1 shows a typical interconnection of the M3528M2 with a DC voltage source
and I/O signals.

M3528M2
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Figure 3-1: Typical Interconnection Diagram
OVER
VOLTAGE
NC P NO VOLTAGE NC P NO
TB4
RESET
OV UV
+ - + - + -
24Vdc
POWER
+ -
MONITOR
VOLTAGE
+
+
UNDERVOLTAGE LATCH
OVERVOLTAGE LATCH
850V RANGE
500V RANGE
UNDERVOLTAGE
HYSTERESIS
UNDERVOLTAGE
SET POINT
OVERVOLTAGE
OVERVOLTAGE
SET POINT
HYSTERESIS
M3528M2
VOLTAGE MONITOR
TB3 TB2
TB1
123456 4321 1 2
2 1
UNDER
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.
3.4.1. POWER WIRING
The power connector supplies control power to the internal circuitry with
power. The system must be supplied with at least 30 mA at 24VDC to
guarantee correct functioning.
3.4.2. I/O WIRING
The I/O connectors connect the unit to an external voltage to be monitored,
and to external signals used to indicate the state of the monitor voltage.
Dwg: 080327 Rev: 20110510

User’s Manual
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Table 3-1: Wiring Specifications
TERMINAL
FUNCTION
ELECTRICAL
SPECIFICATIONS
MIN
WIRE
AWG
MAX
WIRE
AWG
TORQUE
TB1-1
Monitor Input -
0-850VDC to TB1-2
18
10
4.4 lb-in
TB1-2
Monitor Input +
0-850VDC common to TB1-1
18
10
4.4 lb-in
TB2-1
Power Input +
+24VDC to TB2-2
18
16
2.2 lb-in
TB2-2
Power Input -
24VDC common to TB2-1
18
16
2.2 lb-in
TB3-1
Overvoltage Latch Reset
Input +
+24VDC to TB3-2
18
16
2.2 lb-in
TB3-2
Overvoltage Latch Reset
Input -
24VDC common to TB3-1
18
16
2.2 lb-in
TB3-3
Undervoltage Latch Reset
Input +
+24VDC to TB3-4
18
16
2.2 lb-in
TB3-4
Undervoltage Latch Reset
Input -
24VDC common to TB3-3
18
16
2.2 lb-in
TB4-1
Overvoltage Output NC
350VDC/ 120 mA max
18
16
2.2 lb-in
TB4-2
Overvoltage Output COM
350VDC/ 120 mA max
18
16
2.2 lb-in
TB4-3
Overvoltage Output NO
350VDC/ 120 mA max
18
16
2.2 lb-in
TB4-4
Undervoltage Output NC
350VDC/ 120 mA max
18
16
2.2 lb-in
TB4-5
Undervoltage Output COM
350VDC/ 120 mA max
18
16
2.2 lb-in
TB4-6
Undervoltage Output NO
350VDC/ 120 mA max
18
16
2.2 lb-in

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User’s Manual
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4. OPERATION
4.1. FUNCTIONAL DESCRIPTION
The M3528M2 Module monitors a DC voltage connected to the input terminals.
The module has two voltage setpoints, one each for the overvoltage and
undervoltage, which are set by the user via potentiometers. While the monitored
voltage remains within the setpoint range, both relays are energized. When the
monitored voltage reaches either setpoint, that channel’s output relay will de-
energize, triggering whatever signaling device the user connects to it. By default, the
output relay will return to its energized state when the monitor voltage returns to
within the range between setpoints, accounting for hysteresis. However, the
module’s jumpers can be configured so that the output change will latch until a latch
reset signal is received, the latch jumper is removed, or power is disconnected from
the board.
4.2. FEATURES
4.2.1. CONNECTORS
4.2.1.1. TB1 –1&2 (MONITOR)
The monitor connector accepts the input voltage which is to be
monitored by the unit. The monitor connector is rated for 850VDC.
4.2.1.2. TB2 –1&2 (POWER)
The power connector accepts 24VDC to supply power to the voltage
monitor board.
4.2.1.3. TB3 –1&2 (OVERVOLTAGE LATCH RESET)
The isolated latch reset connector accepts a 24VDC overvoltage latch
reset signal. When a latch reset signal is received, any latch on the
overvoltage channel is cleared.
4.2.1.4. TB3 –3&4 (UNDERVOLTAGE LATCH RESET)
The isolated latch reset connector accepts a 24VDC undervoltage latch
reset signal. When a latch reset signal is received, any latch on the
undervoltage channel is cleared.
4.2.1.5. TB4–1-3 (OVERVOLTAGE SIGNAL OUTPUT)
The overvoltage signal output connector is connected to a form C relay.
This connector can be used to establish or break an electrical
connection when the monitored voltage crosses its overvoltage set
point.
When the monitor voltage exceeds the overvoltage set point, the
overvoltage relay de-energizes. If the overvoltage channel is not set to
latch by the latch jumper, the overvoltage relay returns to its energized
state when the monitor voltage drops to below the overvoltage set point
minus the overvoltage hysteresis value. If the channel is set to latch,
the overvoltage relay only re-energized when a latch reset signal is
received, the latch jumper is removed, or power is cut to the board.

M3528M2
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4.2.1.6. TB4 –4-6 (UNDERVOLTAGE SIGNAL OUTPUT)
The undervoltage signal output connector is connected to a form C
relay. This connector can be used to establish or break an electrical
connection when the monitored voltage crosses its undervoltage set
point.
When the monitor voltage falls below the undervoltage set point, the
undervoltage relay de-energizes. If the undervoltage channel is not set
to latch by the latch jumper, the undervoltage relay returns to its
energized state when the monitor voltage rises above the undervoltage
set point plus the undervoltage hysteresis value. Else, the undervoltage
relay only re-energizes when a latch reset signal is received, the latch
jumper is removed, or power is cut to the board.
4.2.2. JUMPERS
4.2.2.1. RANGE (850V,500V)
Jumpers 850V and 500V control the ranges in which the setpoints for
the overvoltage and undervoltage outputs can be configured. The
voltage ranges for different combinations of these jumpers may be seen
in Table 4-1: Setpoint Range Jumper Configurations. Please ensure
that the voltages connected to the system remain within the range
determined by the range jumper settings, or correct system operation is
not guaranteed, and damage to the monitor board may result.
Table 4-1: Setpoint Range Jumper Configurations
MONITOR RANGE
850V
500V
100-850V
ON
-
50-500V
OFF
ON
10-100V
OFF
OFF
4.2.2.2. OUTPUT LATCHING (LATCH 1&2)
When the monitor voltage reaches one of the two setpoints and that
channel’s output switches, the new output can be set to either latch, or
to return to its energized state when the monitor voltage returns to within
its hysteresis range. If a channel is set to latch by having the
appropriate jumper in place, once the relay switches the output will hold
its new state regardless of changes in the monitor voltage. The latch
can be cleared by sending a latch reset signal to the appropriate
channel, removing the latch jumper, or cutting power to the board. If a
channel’s latch jumper is open, that output will not latch, and will instead
return to its energized state when the monitor voltage returns to the set
range.

User’s Manual
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4.2.3. POTENTIOMETERS
4.2.3.1. SETPOINT (SET 1&2)
The setpoint for each output channel is controlled by adjusting a
potentiometer. The adjustment range for the setpoints is determined by
the jumper settings, shown in Table 4-1.
Turn the setpoint potentiometers clockwise to increase the setpoint
voltages, and counter-clockwise to decrease them. The approximate
adjustment in volts-per-turn is shown in Table 4-2.
Table 4-2: Setpoint Adjustment Sensitivity
MONITOR RANGE
VOLTS PER TURN
10 –100V
5V
50 –500V
25V
100 –850V
50V
4.2.3.2. HYSTERESIS (HYST 1&2)
If the outputs are not set for latching operation as described in sections
4.2.1.3 and 4.2.1.4, the reset voltage is set with these pots. This means
that once an output changes, it resets at a different input level. This
hysteresis prevents rapid switching between output states in cases that
the input voltage is very close to a set point.
The hysteresis range for each channel is controlled by adjusting a
potentiometer. The hysteresis range can be set to between 3% and
100% of the maximum setpoint range as determined by the jumper
settings in Table 4-1.
Turn the hysteresis potentiometers clockwise to increase the hysteresis
range, and counterclockwise to decrease it.
For overvoltage, increasing the hysteresis causes the reset point to go
down. For example, if the setpoint is 100V, turning the hysteresis pot
clockwise will make the reset voltage decrease from 100V to 0V.
For undervoltage, increasing the hysteresis causes the reset point to go
up. For example, if the setpoint is 100V, turning the hysteresis pot
clockwise will make the reset voltage increase from 100V to the
maximum voltage as selected by the jumpers.

M3528M2
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Figure 4-1: Front View
Dwg: 080333 Rev: 20080812

User’s Manual
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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.
OUTPUT SWITCHES UPON VOLTAGE REACHING SETPOINT,BUT DOES NOT
SWITCH BACK WHEN VOLTAGE RETURNS TO SET RANGE
Ensure that the output latch jumpers are open. Reduce the hysteresis value by
turning the hysteresis potentiometers counter-clockwise.
OUTPUT NEVER SWITCHES
Ensure that the ranging jumpers are correctly set for the voltage being tested. Turn
the appropriate setpoint potentiometer counterclockwise a full twenty turns, and then
clockwise a full twenty turns, until the signal switches.
OUTPUT SWITCHES RAPIDLY
Check the monitor signal for noise. Increase the hysteresis of the switching output.
OUTPUT WILL NOT LATCH
Ensure that the latch jumpers are connected appropriately.
OUTPUT WILL NOT RESET
Ensure that the monitor voltage is below the set point. Check the wiring of the latch
reset connector. Check that the voltage of the latch reset signal is 24VDC. Remove
and replace the latch jumper.

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