bonitron M3534-I3 User manual

Web: www.bonitron.com ● Tel: [phone] ● Email: [e-mail]
Model M3534-I3
Ride-Thru
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 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

M3534
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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: M3534R in the K7 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: 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 ..................................................................................................... 13
3.4.1. Power Wiring .................................................................................................................................. 13
Table 3-1: M3534 20A Power Wiring Connections ............................................................................... 14
Table 3-2: M3534 40A Power Wiring Connections ............................................................................... 14
Table 3-3: M3534 85A Power Wiring Connections ............................................................................... 14
3.4.2. Control Interface and I/O Wiring .................................................................................................... 15
Table 3-4: User I/O Basic Connections with 3534I3 Board ................................................................... 16
Table 3-5: User I/O Connections with DP10 Display ............................................................................ 16
Figure 3-1: M3534 Interconnections with DP10 .................................................................................... 17
3.5. Typical Configurations ............................................................................................................... 18
Figure 3-2: M3534R without Energy Storage ........................................................................................ 18
Figure 3-3: M3534R with Electrolytic Capacitor Storage Bank ............................................................ 19
Figure 3-4: M3534R with Ultracapacitor Storage Bank ........................................................................ 20
Figure 3-5: M3534B 40A with Battery Storage Bank ............................................................................ 21
4. OPERATION .........................................................................................................................23
4.1. Functional Description ............................................................................................................... 23
4.2. M3534R Operation for Full Outage Protection .......................................................................... 23
4.3. Operation Modes and Configuration .......................................................................................... 23
4.3.1. Normal Operation ........................................................................................................................... 23
4.3.2. Test Mode ....................................................................................................................................... 23
4.4. I/O, Features, and Displays ......................................................................................................... 24
Figure 4-1: 3534I3 Interface Board Layout............................................................................................ 24
Figure 4-2: 3534I3 I/O Diagram ............................................................................................................ 25
Figure 4-3: 3534R2 Control Board Layout ............................................................................................ 26
4.4.1. Input Terminals – 3534I3 TB4 & TB5 ........................................................................................ 28
Table 4-1: 3534I3 Enable Input Logic Jumper Details .......................................................................... 28
4.4.2. Output Terminals – 3534I3 TB5 & TB4 ......................................................................................... 28
Table 4-2: 3534I3 Status Output Signal Logic Jumper Details .............................................................. 29
4.4.3. Local I/O Power Supply – 3534I3 TB5 .......................................................................................... 30
4.4.4. Indicators......................................................................................................................................... 30
4.4.5. Display Options .............................................................................................................................. 30

Table of Contents
5
Table 4-3: Display Panel Configurations ............................................................................................... 30
Figure 4-5: Display Panels ..................................................................................................................... 31
4.5. DC Bus Threshold Voltage Setting ............................................................................................ 32
4.5.1. Determining the DC Bus Threshold Voltage Setting Directly ........................................................ 33
4.5.2. Determining the DC Bus Threshold Voltage Setting Using the Test Mode .................................... 33
4.5.3. Adjusting the DC Bus Threshold Voltage Setting .......................................................................... 34
5. START-UP, MAINTENANCE, AND TROUBLESHOOTING ........................................35
5.1. Start-up / Field Test Procedure ................................................................................................... 35
5.2. Maintenance Items ...................................................................................................................... 35
5.3. Troubleshooting .......................................................................................................................... 36
Table 5-1: Troubleshooting Guide ......................................................................................................... 36
5.4. Technical Help – Before You Call ............................................................................................. 36
6. ENGINEERING DATA ........................................................................................................37
6.1. Ratings ........................................................................................................................................ 37
Table 6-1: M3534 kW Ratings ............................................................................................................... 37
Table 6-2: Factory Setpoints for DC Bus Threshold and Test Boost Voltages ...................................... 37
Table 6-3: M3534R Minimum Input Voltages ....................................................................................... 37
Table 6-4: M3534B Battery Bank Typical Values ................................................................................. 37
Table 6-5: Model Specifications ............................................................................................................ 38
6.2. Derating ...................................................................................................................................... 38
Table 6-6: M3534R 20A Derating Values ............................................................................................. 38
Table 6-7: M3534R 40A Derating Values ............................................................................................. 38
6.3. Efficiency / Power Consumption ................................................................................................ 39
6.4. Branch Circuit Protection and Wire Sizing ................................................................................ 39
Table 6-6: Minimum Input Power Wiring Sizes and Fusing .................................................................. 39
6.5. Dimensions and Mechanical Drawings ...................................................................................... 40
Figure 6-1: M3534 A5 Chassis Dimensional Outline ............................................................................ 40
Figure 6-2: M3534 K7 Chassis Dimensional Outline ............................................................................ 41
Figure 6-3: M3534 K9 Chassis Dimensional Outline ............................................................................ 42
Figure 6-4: M3534 A9 Chassis Dimensional Outline ............................................................................ 43
Figure 6-5: DD4 Display Cutout and Mounting Dimensions ................................................................. 44
Figure 6-6: DP10 Display Cutout and Mounting Dimensions ............................................................... 44
7. APPENDICES ........................................................................................................................45
7.1. M3534 Installation Considerations ............................................................................................. 45
7.2. Specifying an Ultracapacitor Storage Bank for full outage protection with the M3534R .......... 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 ................................................................................................................. 47
7.2.5. Minimum Series String ................................................................................................................... 48
7.2.6. Available Joules .............................................................................................................................. 48
7.3. Diode Sharing with a Bonitron M3534 Ride-Thru ..................................................................... 49
Figure 7-1: Diode Sharing Example ....................................................................................................... 50

M3534
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User’s Manual
7
1. INTRODUCTION
1.1. WHO SHOULD USE THIS MANUAL
This manual is intended for 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 M3534 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
Options were updated in Rev 00a.
Notations added to connectors in Figures 3-2, 3-3, 3-4, 3-5, and 3-6 in Rev 00b
The manual template was updated in Rev 00c.
Figures 3-4 and 3-5 were updated in Rev 00d.
Figure 6-5 was updated in Rev 00e.
Updates were made to Section 4.4 for the Enable Input in Rev 00f.
Update made to revision update of the Interface board in Section 2 in Rev 00g.
Updates to Table titles were made in Section 6 in Rev 00h.
Section 6.2 Derating was added in Rev 00i.
Figure 3-3 DP10 wiring was updated in Rev 00j.
Display options were updated in Rev 00k.
Update to Table 6-7: M3534R 40A Derating Values in Rev 00L.
Figure 1-1: M3534R in the K7 Chassis

M3534
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 M3534 Ride-Thru Voltage Regulator provides protection from power quality
events for variable frequency drives (VFDs) that use a fixed rectifier and DC bus. The
M3534R provides sag protection for up to 2 seconds at 50% line sag on all 3 phases. It
can also provide protection from short term full outages of up to 2 seconds with the addition
of storage systems, such as capacitors. The M3534B, in conjunction with a battery bank,
provides protection for up to 60 seconds during a full outage.
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 M3534 regulates incoming voltage to the DC bus of the variable frequency drive. This
allows the drive to “ride through” these events while maintaining motor speed and torque
without experiencing drive shutdown.
ADVANTAGES
 Reliability
 Parallel connection to AC system
 M3534 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
S3534CR SERIES RIDE-THRU SYSTEMS
Complete systems that use electrolytic capacitor storage for short term power
outages.
S3534UR SERIES RIDE-THRU SYSTEMS
Complete systems that use ultracapacitor storage for short term power
outages.
S3534BR SERIES RIDE-THRU SYSTEMS
Complete systems that use batteries for longer term power outages.
M3460 SERIES RIDE-THRU MODULES
Voltage regulators used for sag or outage protection of higher power systems.
M3528 BATTERY AND ULTRACAPACITOR CHARGERS
Chargers for high voltage storage strings.
M3628 ULTRACAPACITOR SAFETY DISCHARGERS
Automatic discharge for large capacitor storage banks for safety and quick
maintenance entry.

M3534
10
2.1.2. DOCUMENTS
Please refer to the KIT 3660DD4 manual when this unit is equipped with the
DD4 Digital Display option. 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
BASE MODEL NUMBER
The base model number for all ride-thru modules in this series rated for 2 second
operation is M3534R. The base model number for all ride-thru modules in this series
rated for 60 second operation is M3534B.
SYSTEM VOLTAGE RATING
The M3534 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
C
ODE
NOMINAL VOLTAGE
(AC LINE / DRIVE BUS)
L 230VAC / 325VDC
E 380-415VAC / 540-585VDC
H 460VAC / 650VDC
POWER RATING
The power rating indicates the maximum power in kilowatts that can safely be handled
by the M3534 and is represented by a 3-digit value based on the nominal DC system
voltage rating and the maximum output current rating of the M3534. For instance, the
rating code for a 50kW M3534 is 050.
CHASSIS SIZE
Four open type 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 W X D) M3534R M3534B
A5 18.6” x 5.1” x 9.4” 20A -
K7 20.0” x 7.4” x 10.3” 40A -
K9 20.0” x 9.1” x 10.3” - 40A
A9 22.1” x 8.7” x 10.3” 85A -
BASE MODEL NUMBER
SYSTEM VOLTAGE RATING
POWER RATING
M
3534R
050
H I3
INTERFACE
A9
CHASSIS SIZE

User’s Manual
11
INTERFACE
The Interface selection indicates the M3534 is able to utilize the DP10 and DD4
display options. All current M3534 ride-thru modules have the I3 interface option.
For legacy M3534 modules go to www.bonitron.com or contact Bonitron for the
legacy customer manual.
2.3. GENERAL SPECIFICATIONS
Table 2-3: General Specifications
P
ARAMETER
SPECIFICATION
Input AC Voltage 208 – 480 VAC
Input DC Voltage 200 – 585 VDC
Output DC Voltage 265 – 650 VDC
DC Bus Current Rating 20 – 85 ADC
Power Rating 6 –50 kW
Inactive Power Consumption <40 W
Duty Cycle (Full Load) 1%
Sag/Outage Duration 2 seconds – 60 seconds
Enclosure Rating Open
Operating Temperature 0 to +40ºC
Storage Temperature -20 to +65 ºC
Humidity Below 90% non-condensing
Atmosphere Free of corrosive gas and conductive dust

M3534
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2.4. GENERAL PRECAUTIONS AND SAFETY WARNINGS
DANGER!
 HIGH VOLTAGES MAY BE PRESENT!
 NEVER ATTEMPT TO OPERATE THIS PRODUCT WIT
H THE
ENCLOSURE COVER REMOVED!
 NEVER ATTEMPT TO SERVICE THIS PRODUCT WIT
HOUT FIRST
DISCONNECTING POWER TO AND FROM THE UNIT.
 ALWAYS ALLOW ADEQUATE TIME FOR RE
SIDUAL 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.
 BE F O R E A T T E M P T I N G I N S T A L L A
T I O N O R R E M O V A L O F
T H I S P R O D U C T , B E S U R E T O R E V I E W A
L L S Y S T E M
D O C U M E N T A T I O N F O R P E
R T I N E N T S A F E T Y
P R E C A U T I O N S .
 NO U S E R -S E R V I C E A B L E P A R T S A R
E C O N T A I N E D
W I T H I N T H I S P R O D U C T . IN O P E R A B L E U N I T S S H O U
L D
B E R E P L A C E D O R R E T U R N E D F O R R E P A I R .
 THIS PRODUCT DOES NOT PROVIDE MOTOR OVERLOAD
PROTECTION
.
ANY QUESTIONS AS TO APPLICATION, INSTALLATION, OR SERVICE
SAFETY SHOULD BE DIRECTED TO THE EQUIPMENT SUPPLIER.

User’s Manual
13
3. INSTALLATION INSTRUCTIONS
The M3534 has an open type chassis construction. It is intended to be part of a larger
variable frequency drive system, and will require different hardware for interconnection
based on the installation. An appropriate enclosure may need to be provided to protect
personnel from contact and the system from damage. The enclosure may also need to
protect the equipment from the installation environment.
Please read this manual completely before designing the drive system or enclosure layout
to ensure all required elements are included.
3.1. ENVIRONMENT
The maximum ambient operating temperature of the M3534 should not exceed 40C.
Temperatures above this can cause overheating during operation.
The standby heat production of the M3534 is quite low, but can generate significant
heat during boosting. This is only of concern with the M3534B models because the
M3534R run time of 2 seconds will not allow the system to reach thermal equilibrium,
and should not cause thermal issues.
Non-condensing, filtered air may be required to cool the system if other components
cause excessive heat buildup in the enclosure.
3.2. UNPACKING
Inspect the shipping crate and M3534 for damage.
Notify the shipping carrier if damage is found.
3.3. MOUNTING
Mounting dimensions can be found in Section 6.
1. Remove the M3534 from the shipping crate and mount it in the desired location
using the mounting slots and holes and ¼” diameter studs or bolts. Mounting
hardware is not supplied with the M3534.
2. If supplied, install the display panel in an appropriate location.
3.4. WIRING AND USER CONNECTIONS
Review this entire section before attempting to wire the M3534.
3.4.1. POWER WIRING
DANGER!
THE M3534 CAN 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 M3534. 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.

M3534
14
Table 3-1: M3534 20A Power Wiring Connections
TERMINAL
DESIGNATION FUNCTION WIRING
SPECIFICATION CONNECTION TORQUE
AC LINE
L1 L2 L3 AC Input 600 VAC #10 lug
ring or spade 20 lb-in
STORAGE BUS
+ - DC Input 600 VAC 14-8 AWG
Box Connection
15 lb-in
DRIVE BUS
- + DC Output
600 VAC #10 lug
ring or spade 20 lb-in
Ground 600 VAC #10 lug
ring or spade 15 lb-in
Table 3-2: M3534 40A Power Wiring Connections
TERMINAL
D
ESIGNATION
FUNCTION WIRING
SPECIFICATION CONNECTION TORQUE
AC LINE
L1 L2 L3 AC Input 600 VAC #10 lug
ring or spade 20 lb-in
STORAGE BUS
+ - DC Input 600 VAC 12-4 AWG
Box Connection
32 lb-in
DRIVE BUS
- + DC Output
600 VAC #10 lug
ring or spade 20 lb-in
Ground 600 VAC #10 lug
ring or spade 15 lb-in
Table 3-3: M3534 85A Power Wiring Connections
TERMINAL
D
ESIGNATION
FUNCTION WIRING
SPECIFICATION CONNECTION TORQUE
AC LINE
L1 L2 L3 AC Input 600 VAC 12-4 AWG
Box Connection
32 lb-in
STORAGE BUS
+ - DC Input 600 VAC 12-4 AWG
Box Connection
32 lb-in
DRIVE BUS
- + DC Output
600 VAC 12-4 AWG
Box Connection
32 lb-in
Ground 600 VAC #10 lug
ring or spade 15 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.
These units can provide high surge currents for a limited amount of time;
therefore wire heating is not as much a concern as mechanical strength.
3.4.1.1. AC LINE (L1 L2 L3) CONNECTIONS
The AC input to the M3534 can temporarily reach up to 200% of the
normal input current during a power quality event. Size the upstream
current protection devices accordingly, so that the incoming AC will not
be interrupted by the temporary power draw.

User’s Manual
15
During a power quality event, the AC input to the drive will not be drawing
current. Sizing the incoming AC feed to supply both the drive and the
M3534 simultaneously is not necessary. Even though the input current
during a power quality event may be higher than the normal input current,
this temporary overload is allowed by most codes without upsizing the
normal AC feed bus.
Due to the increased currents in the AC feed during a power quality event,
the total IR drop of the incoming AC feed should be considered to make
sure the voltage doesn't dip too low.
If line chokes are to be used in the system, the M3534 must be installed
on the load side of these chokes. This minimizes the possibility of
circulating currents through the M3534 and converter section of the VFD.
There is no need to connect the AC line to the M3534 if an ultracapacitor
or battery bank is being used. See Figure 3-5.
3.4.1.2. STORAGE BUS (+ -) CONNECTIONS
If a storage module is used, such as ultracapacitors or batteries, the input
from this module is made at the Storage Bus terminals.
Make sure the polarity is correct for the connection, 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. DRIVE BUS (- +) CONNECTIONS
The M3534 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 M3534 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 the connection, 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.
3.4.1.4. 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.
3.4.2. CONTROL INTERFACE AND I/O WIRING
Control wiring allows for remote enabling, testing, and monitoring of the
M3534. Inputs can be a dry contact using an internally generated, isolated
supply, or an external 15-24VDC signal.

M3534
16
Outputs are individual contacts with a jumper to choose the logic state desired.
3.4.2.1. CONNECTIONS FOR BASE CONFIGURATION
Table 3-4: User I/O Basic Connections with 3534I3 Board
3534I3
TERMINAL FUNCTION ELECTRICAL
SPECIFICATIONS
WIRE
AWG TORQUE
TB4 – 5 Enable / Disable - 24 VDC, 15 mA
16 AWG 2.1 lb-in
TB4 – 6 Enable / Disable +
TB4 – 3 Ride-Thru Ready (RTR)
24 VDC, 15 mA
TB4 – 4
TB4 – 1 Ride-Thru Active (RTA)
TB4 – 2
3.4.2.2. CONNECTIONS WITH DD4 DIGITAL DISPLAY
When the DD4 digital display is used, some user connections to the
digital display interface are made on a different module than the M3534.
They are made to the 3660I3 interface module.
Refer to the KIT 3660DD4 manual for operational and functional details.
3.4.2.3. CONNECTIONS WITH DP10 ANALOG DISPLAY
When the M3534 is used with the DP10 analog display, the
interconnections are made through TB5 on the 3534I3 board and TB1 on
the 3660D1 board.
Table 3-5: User I/O Connections with DP10 Display
3660D1
T
ERMINAL
3534I3
TERMINAL FUNCTION ELECTRICAL
SPECIFICATIONS
WIRE
AWG TORQUE
TB1 – 1 TB5-3 Overtemperature (OT)
15 VDC, 15 mA
16 AWG 2.1 lb-in
TB1 – 2 N/U Voltage Fault (VF)
TB1 – 3 TB5-5 Ride-Thru Active (RTA)
TB1 – 4 TB5-4 Ride-Thru Ready (RTR)
TB1 – 5 N/U Pre-Charge Complete (PCC)
TB1 – 6 TB5-6 Test
TB1 – 7 TB5-9 Local I/O Supply - 15 VDC, 50 mA
TB1 – 8 TB5-10 Local I/O Supply +

User’s Manual
17
Figure 3-1: M3534 Interconnections with DP10
TB5
TEST
RTR
8 7 6 5 4 32 1
3534I3
10 9
COM
+15V
RTA
OT
3660D1
J1
BA
TB4
V+
TB1
8
7
6
5
4
3
2
1
COM
TEST
PCC
RTR
RTA
VF
OT
1
2
3
4
5
RESET
NRESET
AMBER
RED
RED
GREEN
GREEN
GREEN
VF

M3534
18
3.5. TYPICAL CONFIGURATIONS
Figure 3-2: M3534R without Energy Storage

User’s Manual
19
Figure 3-3: M3534R with Electrolytic Capacitor Storage Bank

M3534
20
Figure 3-4: M3534R with Ultracapacitor Storage Bank
M3628T DISCHARGER
M3628R
CHOPPER
BRAKING
INTERNAL
VFD
INVERTER
BRAKING
RESISTOR
DISCONNECT
DRIVE
FEED
AC
CHOKES
LINE
GROUND
FAULT
SENSING
M3528AC CHARGER
ULTRA CAP
ENERGY STORAGE
BANK
DISCONNECT
RIDE-THRU
+
-
+
-
DRIVE
RIDE-THRU DISCONNECT
AUX. CONTACT
BUS
M
3
ISOLATION TRANSFORMER
+
-
STORAGE BUS STORAGE BUS
M3534R
CONNECTED DOWNSTREAM. IF LINE CHOKES ARE USED, RIDE-THRU MUST BE FROM THE SAME FEED TRANSFORMER. INVERTER AND RIDE-THRU SHOULD BE POWERED
2. 1.
NOTES~ ~
FUSES ONLY NEEDED
WITH 85A MODELS.