bonitron M3460UC User manual

Web: www.bonitron.com ● Tel: [phone] ● Email: in[email protected]
Model M3460UC
Ride-Thru
Enclosed Voltage Regulator
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 syste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

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

M3460
4
1. INTRODUCTION....................................................................................................................7
1.1. Who Should Use This Manual......................................................................................................7
1.2. Purpose and Scope........................................................................................................................ 7
1.3. Manual Revision...........................................................................................................................7
Figure 1-1: M3460UC in E1 Chassis .......................................................................................................7
1.4. Symbol Conventions Used in this Manual and on Equipment.....................................................8
2. PRODUCT DESCRIPTION...................................................................................................9
2.1. Related Products and Documents.................................................................................................9
2.1.1. Products ............................................................................................................................................9
2.1.2. Documents ......................................................................................................................................10
2.2. Part Number Breakdown ............................................................................................................10
Figure 2-1: Example of Part Number Breakdown..................................................................................10
Table 2-1: System Voltage Rating Codes ..............................................................................................10
Table 2-2: Chassis Size Codes ...............................................................................................................10
2.3. General Specifications................................................................................................................11
Table 2-3: M3460UC General Specifications........................................................................................11
2.4. General Precautions and Safety Warnings .................................................................................12
3. INSTALLATION INSTRUCTIONS ...................................................................................13
3.1. Environment ...............................................................................................................................13
3.2. Unpacking................................................................................................................................... 13
3.3. Mounting ....................................................................................................................................13
3.4. Wiring and User Connections..................................................................................................... 14
3.4.1. Power Wiring..................................................................................................................................14
Table 3-1: M3460UC Power Wiring Connections.................................................................................14
3.4.2. Control Interface and I/O Wiring....................................................................................................16
Figure 3-1: M3460UC I/O Terminal connection....................................................................................17
Figure 3-2: M3460UC POWER Terminal connection...........................................................................18
3.5. Typical Configurations...............................................................................................................20
Figure 3-4: M3460UC Typical Configuration with Ultracapacitor Storage Bank.................................20
4. OPERATION .........................................................................................................................21
4.1. Functional Description ...............................................................................................................21
4.2. M3460UC Operation for Full Outage Protection.......................................................................21
4.3. Operation Modes and Configuration..........................................................................................21
4.3.1. Normal Operation ...........................................................................................................................21
4.3.2. Test Mode .......................................................................................................................................21
4.8. DC Bus Threshold Voltage Setting ............................................................................................ 30
4.8.1. Determining the DC Bus Threshold Voltage Setting Using the Test Mode....................................31
4.8.2. Adjusting the DC Bus Threshold Voltage Setting ..........................................................................31
Figure 4-2: 3460C1 Control Board Layout............................................................................................32
5. START-UP, MAINTENANCE AND TROUBLESHOOTING.........................................33
5.1. M3460UC Start-up / Field Test Procedure.................................................................................33
5.2. Maintenance Items......................................................................................................................33
5.2.1. Capacitor Replacement Recommendations.....................................................................................33
5.2.2. Capacitor Testing Procedure...........................................................................................................35
5.2.3. Cleaning..........................................................................................................................................35
5.2.4. Heatsinks.........................................................................................................................................35
5.3. Troubleshooting.......................................................................................................................... 36
Table 5-1: Troubleshooting Guide.........................................................................................................36
5.4. Technical Help –Before You Call .............................................................................................37

Table of Contents
5
6. ENGINEERING DATA ........................................................................................................39
6.1. Ratings........................................................................................................................................39
Table 6-1: M3460 kW Ratings...............................................................................................................39
Table 6-2: Factory Setpoints for DC Bus Threshold and Test Boost Voltages......................................39
Table 6-3: M3460 Minimum Input Voltages .........................................................................................39
Table 6-5: M3460 Model Specifications for 230 –480 VAC Systems..................................................40
6.2. Efficiency / Power Consumption................................................................................................40
6.3. Branch Circuit Protection and Wire Sizing................................................................................40
Table 6-7: M3460 Input Power Wiring Sizes and Fusing......................................................................40
6.4. Dimensions and Mechanical Drawings......................................................................................42
Figure 6-1: M3460-E1 Enclosure Dimensional Outline.........................................................................42
Figure 6-2: M3460-E2 Enclosure Dimensional Outline.........................................................................43
Figure 6-3: M3460-E4 Enclosure Dimensional Outline.........................................................................44
7. APPENDICES........................................................................................................................45
7.1. M3460 Installation Considerations.............................................................................................45
7.2. Specifying an Ultracapacitor Storage Bank for Full Outage Protection With M3460R Models 45
7.2.1. Energy Required for Outage ...........................................................................................................47
7.2.2. Minimum Capacitor Bank Voltage .................................................................................................47
7.2.3. Peak Current....................................................................................................................................47
7.2.4. Capacitor Specifications .................................................................................................................48
7.2.5. Minimum Series String...................................................................................................................48
7.2.6. Available Joules..............................................................................................................................48
7.3. Steering Diode Sharing with a Bonitron M3460 Ride-Thru.......................................................49
Figure 7-1: Diode Sharing Example.......................................................................................................51

M3460
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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 with any AC drive system.
Please keep this manual for future reference.
1.2. PURPOSE AND SCOPE
This maodel M3460UC ride-thru voltage regulator. It
will provide the user with the necessary information to successfully install, integrate,
and use this 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
The initial release of M3460UC voltage regulator is Rev 00a.
Figure 1-1: M3460UC in E1 Chassis

M3460
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.

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2. PRODUCT DESCRIPTION
-thru voltage regulators provide protection from power quality events
for variable frequency drives (VFDs) that use a fixed rectifier and DC bus. The M3460UC
provides protection from short term full outages of up to 2 seconds with the addition of
Ultra capacitor storage system.
Industries with continuous processes can suffer huge losses from equipment downtime,
loss of production, or damaged product when VFDs trip on under-voltage conditions.
Traditional UPS solutions are connected in series, which decreases the overall drive
system reliability. All Bonitron ride-thru products connect in parallel with the drive, thus
increasing system availability and reliability.
The M3460 regulates incoming voltage tothe DC bus of the variable frequency drive. This

without experiencing drive shutdown.
ADVANTAGES
•Reliability
•Parallel connection to AC system
•M3460 maintenance can be done while normal process is on-line
•Works with almost any fixed bus, variable frequency, PWM drive
•Only 2-3 parallel connections
•Can use existing AC feed wiring and breakers
•Instant response
•Bumpless transfer
•Easy commissioning
2.1. RELATED PRODUCTS AND DOCUMENTS
2.1.1. PRODUCTS
S3460UR SERIES RIDE-THRU SYSTEMS
Complete systems that use ultracapacitor storage for short term power
outages.
S3460BR SERIES RIDE-THRU SYSTEMS
Complete systems that use batteries for longer term power outages.
M3534 SERIES RIDE-THRU MODULES
Voltage regulators used for sag or outage protection of lower power systems.
M3528 BATTERY AND ULTRACAPACITOR CHARGERS
Chargers for high voltage storage strings.

M3460
10
2.1.2. DOCUMENTS
Please refer to the KIT 3660DD5 manual for more details about the DD5 Digital
Display. This manual is available at www.bonitron.com or by contacting
Bonitron.
2.2. PART NUMBER BREAKDOWN
Figure 2-1: Example of Part Number Breakdown
- - -
D
Display
SystemVoltage Rating
Power Rating
Chassis Size
M3460UC
H
100
E1
Base Model Number
BASE MODEL NUMBER
The base model number for all ride-thru modules in this series rated for 2 second
operation is M3460UC.
SYSTEM VOLTAGE RATING
The M3460UC is available in several input voltage ratings. This rating is indicated by
a code as shown in Table 2-1.
Table 2-1: System Voltage Rating Codes
RATING
CODE
NOMINAL VOLTAGE
(AC LINE /DRIVE BUS)
L
230 VAC / 325 VDC
E
380 - 415 VAC / 540 - 585 VDC
H
460 VAC / 650 VDC
POWER RATING
The power rating indicates the maximum power in kilowatts that can safely be handled
by the M3460 and is represented by a 3-digit value based on the nominal DC system
voltage rating and the maximum output current rating of the M3460. For instance, the
rating code for a 100kW M3460 is 100.
CHASSIS SIZE
Three enclosed chassis sizes are indicated by a code as shown in Table 2-2. This
chassis size is determined by the current rating of the unit.
Table 2-2: Chassis Size Codes
CHASSIS SIZE CODE
DIMENSIONS (H X WX D)
3460R
E1
30.00
85-127 A
E2

170 A
E4
4
255-425 A
DISPLAY
The M3460UC module is equipped with the DD5 digital display.

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2.3. GENERAL SPECIFICATIONS
Table 2-3: M3460UC General Specifications
PARAMETER
SPECIFICATION
Input AC Voltage
208 480 VAC
Input DC Voltage
200 585 VDC
Output DC Voltage
265 650 VDC
DC Bus Current Rating
85 425 ADC
Power Rating
25 250 kW
Inactive Power Consumption
<200W
Duty Cycle (Full Load)
1%
Sag/Outage Duration
2 seconds
Enclosure Rating
NEMA 1 Enclosure
Operating Temperature
0 to +40ºC
Storage Temperature
-20 to +65 ºC
Humidity
Below 90% non-condensing
Atmosphere
Free of corrosive gas and conductive dust

M3460
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2.4. GENERAL PRECAUTIONS AND SAFETY WARNINGS
DANGER!
•HIGH VOLTAGES MAY BE PRESENT!
•NEVER ATTEMPT TO OPERATE THIS PRODUCT WITH THE
ENCLOSURE COVER REMOVED!
•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 OPENING THE ENCLOSURE.
•FAILURE TO HEED THESE WARNINGS MAY RESULT IN
SERIOUS INJURY OR DEATH!
CAUTION!
•CERTAIN COMPONENTS WITHIN THIS PRODUCT MAY GET HOT
DURING OPERATION.
•ALWAYS ALLOW AMPLE TIME FOR THE UNIT TO COOL BEFORE
ATTEMPTING SERVICE ON THIS PRODUCT.
•INSTALLATION AND/OR REMOVAL OF THIS PRODUCT SHOULD
ONLY BE ACCOMPLISHED BY A QUALIFIED ELECTRICIAN IN
ACCORDANCE WITH NATIONAL ELECTRICAL CODE OR
EQUIVALENT REGULATIONS.
•BEFORE ATTEMPTING INSTALLATION OR REMOVAL OF
THIS PRODUCT ,BE SURE TO REVIEW ALL SYSTEM
DOCUMENTATION FOR PERTINENT SAFET Y
PRECAUTIONS.
•NO USER-SERVICEABLE PARTS ARE CONTAINED
WITHIN THIS PRODUCT.INOPERABLE UNITS SHOULD BE
REPLACED OR RETURNED FOR REPAIR .
•THIS PRODUCT DOES NOT PROVIDE MOTOR OVERLOAD
PROTECTION.
ANY QUESTIONS AS TO APPLICATION, INSTALLATION, OR SERVICE
SAFETY SHOULD BE DIRECTED TO THE EQUIPMENT SUPPLIER.

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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 M3460 ride-thru should be accomplished by following the steps
outlined below. Be sure to refer to the AC drive instruction manual as these steps are
performed. Please direct all installation inquiries that may arise during the installation and
startup of this product to the equipment supplier or system integrator. Please read this
manual completely before designing the drive system or enclosure layout to ensure all
required elements are included.
3.1. ENVIRONMENT
The installation site for M3460 should be chosen with several considerations in mind:
1. The unit has a NEMA 1 enclosure rating and will therefore require some protection
from the elements.
2. Conduit access for field wiring may be provided on the top-right surface of the
enclosure if desired.
3. The unit will require a minimum clearance of two (2) inches in all directions around
it when mounted near a non-heat source.
4. The mounting surface should be clean and dry.
The maximum ambient operating temperature of the M3460 should not exceed 40C.
Temperatures above this can cause overheating during operation.
The standby heat production of the M3460 is quite low because the run time of 2
seconds will not allow the system to reach thermal equilibrium, and should not cause
thermal issues.
3.2. UNPACKING
Inspect the shipping crate and M3460 for damage.
Notify the shipping carrier if damage is found.
3.3. MOUNTING
Mounting dimensions can be found in Section 6.4.
Once the installation site has been selected as outlined above, the unit should be

Mounting holes should be drilled and mounting studs or anchors installed before
positioning the enclosure. Mounting hardware is not supplied.

M3460
14
3.4. WIRING AND USER CONNECTIONS
Review this entire section before attempting to wire the M3460.
3.4.1. POWER WIRING
DANGER!
THE M3460CAN HAVE MULTIPLE POWER SOURCES,INCLUDING THE MAIN AC INPUT,
ENERGY STORAGE SYSTEMS AND THE DC CONNECTION TO THE VFD.
ENSURE THAT ALL SOURCES ARE DISCONNECTED AND LOCKED OUT BEFORE
ATTEMPTING SERVICE OR INSTALLATION.
FAILURE TO HEED THESE WARNINGS MAY RESULT IN SERIOUS INJURY
OR DEATH!
This section provides information pertaining to the field wiring connections of
the M3460. Actual connection points and terminal numbers of the AC drive
system will be found in the documentation provided with the drive system.
Be sure to review all pertinent AC drive system documentation as well as the
connection details listed below before proceeding.
Table 3-1: M3460UC Power Wiring Connections
TERMINAL
DESIGNATION
FUNCTION
WIRING
SPECIFICATION
CONNECTION
TORQUE
Storage Bus
+ -
DC Input
600 VAC
3/8" stud
150 lb-in
Drive Bus
+ -
DC Output
600 VAC
3/8" stud
150 lb-in
Ground
600 VAC
5/16" stud
75 lb-in
Main power connections should be made with copper wire; use compression
fitting lugs. Wire sizing should be appropriate for the current being carried.
System ratings are listed in Section 6.1.
M3460 ride-thru units only provide full currents for a limited amount of time.
Therefore, wire heating is not as much a concern as mechanical strength.

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3.4.1.1. STORAGE BUS (+ -) CONNECTIONS
The M3460UC capacitor bank connections are made at the Storage Bus
fuse blocks at the top of the module.
Make sure the polarity is correct for these connections, as failure to do
so can cause severe damage to the system.
DANGER!
FOR SYSTEMS THAT HAVE DC STORAGE,ALWAYS MEASURE DC VOLTAGES AND
FOLLOW PROPER PRECAUTIONS TO ENSURE THEY ARE AT SAFE LEVELS BEFORE
MAKING CONNECTIONS.
3.4.1.2. DRIVE BUS (+ -) CONNECTIONS
The M3460UC must have a DC bus connection directly to the DC bus
filter capacitors within the drives. Connections cannot be made through
the braking terminals or with precharge resistors or DC link chokes
between the output of the M3460 and the DC bus capacitors in the drive.
Consult the manufacturers' documentation or contact Bonitron for further
assistance.
Make sure the polarity is correct for these connections, as failure to do
so can cause severe damage to the system.
DANGER!
FOR SYSTEMS THAT HAVE DC STORAGE,ALWAYS MEASURE DC VOLTAGES AND
FOLLOW PROPER PRECAUTIONS TO ENSURE THEY ARE AT SAFE LEVELS BEFORE
MAKING CONNECTIONS.
3.4.1.3. GROUNDING REQUIREMENTS
All units come equipped with a 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.

M3460
16
3.4.2. CONTROL INTERFACE AND I/O WIRING
Control wiring allows for remote enabling, testing, and monitoring of the
M3460. All units are equipped with the 3660DD5 digital display interface,
all connections are made to the 3660I4 interface board. See figure 3-1
on the next page.
Refer to the KIT 3660DD5 manual for operational and functional details.

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Figure 3-1: M3460UC I/O Terminal connection
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TERMINAL
FUNCTION
ELECTRICAL
SPECIFICATIONS
WIRE
AWG
Torque
TB 1
Courtesy + 24V
24 VDC, 25 mA
16
4.5 in lbs
TB 2
Charger ENABLE
24 VDC, 25 mA
16
4.5 in lbs
TB 3
Ride-Thru ENABLE
24 VDC, 25 mA
16
4.5 in lbs
TB 4
Ride-Thru TEST
24 VDC, 25 mA
16
4.5 in lbs
TB 5
Input COM
24 VDC, 25 mA
16
4.5 in lbs
TB 6
Courtesy COM
24 VDC, 25 mA
16
4.5 in lbs
TB 7
Fault 1
250 VDC, 120 MA
16
4.5 in lbs
TB 8
Fault 2
250 VDC, 120 MA
16
4.5 in lbs
TB 9
Ride-Thru Active (RTA)
250 VDC, 120 MA
16
4.5 in lbs
TB 10
Output COM
250 VDC, 120 MA
16
4.5 in lbs
TB 11
Spare
TB 12
Storage Undervoltage (NO)
24 VDC, 25 mA
16
4.5 in lbs
TB 13
Storage Undervoltage COM
24 VDC, 25 mA
16
4.5 in lbs
TB 14
Charger READY signal
24 VDC, 25 mA
16
4.5 in lbs
TB 15
Charger charging signal
24 VDC, 25 mA
16
4.5 in lbs
TB 16
Charger output com
24 VDC, 25 mA
16
4.5 in lbs
TB 17
Charger enable signal
24 VDC, 25 mA
16
4.5 in lbs
TB 18
Charger equalize signal
24 VDC, 25 mA
16
4.5 in lbs
TB 19
Charger input com
24 VDC, 25 mA
16
4.5 in lbs
TB 20
AC LINE L1
208-600 VAC
16
4.5 in lbs
TB 21
AC LINE L2
208-600 VAC
16
4.5 in lbs
TB 22
AC LINE L3
208-600 VAC
16
4.5 in lbs

M3460
18
Figure 3-2: M3460UC POWER Terminal connection


19
Figure 3-3: 3660I4 Board Layout
TB15
TB14
J3
TB3
TB7 61
TB9 61 81
INPUT COM SPARE RT OT PCC RTR RTA INPUT COM DISCH OT STORAGE OT IMBALANCE CH ACTIVE CH FAULT CH ENABLE CH EQUALIZE DISCHARGE SPARE OUTPUT COM OUTPUT COM RT ENABLE RT TEST
TB11
+
-
TB8 TB6
1 1
1
TB5 TB1
TB4
2 3 4 1 2 3 4 1 2 3 4
TB2
13 L2 L1L3
+ - + -
TB13
4
1
-
+
68
1
1
TB12
4
1
COURTESY 24V
CH ENABLE
CH EQUALIZE
RT ENABLE
RT TEST
SPARE
INPUT COM
24V COM
SPARE 1 N.O.
SPARE 2 N.O.
FAULT 1 N.O.
FAULT 2 N.O.
RT ACTIVE
OUTPUT COM
RT BYPASS
RT NORMAL
CH BYPASS
CH NORMAL
DISCH BYPASS
DISCH NORMAL
SPARE 1
SPARE 2
TB16

M3460
20
3.5. TYPICAL CONFIGURATIONS
Figure 3-4: M3460UC Typical Configuration with Ultracapacitor Storage Bank
M3628R
CHOPPER
BRAKING
INTERNAL
VFD
INVERTER
BRAKING
RESISTOR
DISCONNECT
DRIVE
FEED
AC
CHOKES
LINE
GROUND
FAULT
SENSING
M5628AC CHARGER
DISCONNECT
RIDE-THRU
M3460UC
CHOPPER
+
-
+
-
DRIVE
RIDE-THRU DISCONNECT
AUX. CONTACT
BUS
STORAGE BUS STORAGE BUS
M
3
+
-
ULTRA CAP
ENERGY STORAGE
BANK