bonitron M3645 User manual

Web: www.bonitron.com ● Tel: [phone] ● Email: [email protected]m
Model M3645
Line Regen
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 o
ver 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

M3645
4
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: Typical M3645 Line Regen...................................................................................................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 ............................................................................................................10
Figure 2-1: Example of M3645 Part Number Breakdown .....................................................................10
Table 2-1: Voltage Ratings ....................................................................................................................10
Table 2-2: 300A Identifier......................................................................................................................10
Table 2-3: Chassis Styles .......................................................................................................................11
Table 2-4: Option Codes ........................................................................................................................11
2.3. General Specifications Chart......................................................................................................12
Table 2-5: General Specifications..........................................................................................................12
2.4. General Precautions and Safety Warnings .................................................................................13
3. INSTALLATION INSTRUCTIONS................................................................................................15
3.1. Environment ...............................................................................................................................15
3.2. Unpacking................................................................................................................................... 15
3.3. Mounting ....................................................................................................................................15
3.3.1. M3645 Line Regen Mounting...........................................................................................15
Figure 3-1: M3645 Mounting Orientation..............................................................................................16
3.3.2. M3645-x300R Line Reactor Mounting ............................................................................17
3.3.3. KIT 3645DD, External Display Mounting .......................................................................17
3.4. Wiring and Customer Connections.............................................................................................17
3.4.1. Power Wiring....................................................................................................................17
Table 3-1: Transformer Ratings.............................................................................................................18
Table 3-2: Power Terminal Specifications - 30 Amp Unit –M10 Chassis............................................19
Table 3-3: Power Terminal Specifications - 50 Amp Unit –M11 Chassis............................................19
Table 3-4: Power Terminal Specifications - 100 Amp Unit –M12 Chassis..........................................19
Figure 3-2: 30A, 50A, 100A Power Connections ..................................................................................20
Figure 3-3: 30A, 50A, 100A Connection Locations ..............................................................................20
Table 3-5: Power Terminal Specifications - 300 Amp Unit –M15 Chassis..........................................21
Figure 3-4: 300A Power Connections....................................................................................................21
Figure 3-5: 300A Connection Locations................................................................................................22
3.4.2. I/O Wiring.........................................................................................................................23
Table 3-6: M3645 30A, 50A, 100A User I/O Terminal Specifications .................................................23
Figure 3-6: M3645 30A, 50A, 100A User I/O Diagram ........................................................................23
Figure 3-7: M3645 Enable Input Using Internal Power Supply.............................................................24
Figure 3-8: M3645 Enable Input Using External Power Supply............................................................24
3.5 Typical Configurations...............................................................................................................25
Figure 3-9: M3645 30A, 50A, 100A Regen Power Wiring ...................................................................26
Figure 3-10: M3645 300A Regen Customer Power Wiring...................................................................27
Figure 3-11: M3645 Multiple Drives / Regens Field Wiring Diagram..................................................28
Figure 3-12: M3645 Connection with KIT 3645DD, External Panel Mounted Display........................29
4. OPERATION..............................................................................................................................31
4.1. Functional Description ...............................................................................................................31
4.2. Features....................................................................................................................................... 31

Table of Contents
5
4.2.1. Digital Display..................................................................................................................31
4.2.2. LEDs.................................................................................................................................31
4.2.3. Buttons.............................................................................................................................. 31
4.3. Digital Display Operation...........................................................................................................32
4.3.1. Metering Screen................................................................................................................32
4.3.2. Energy Records Screen..................................................................................................... 32
4.3.3. Reset Energy Records Screen...........................................................................................32
4.3.4. Faults Screen.....................................................................................................................32
4.3.5. Fault Records Screen........................................................................................................32
Figure 4-1: M3645 Screen Tree .............................................................................................................32
4.4. Faults ..........................................................................................................................................33
Table 4-1: Blink Codes ..........................................................................................................................33
4.4.1. Feedback Undervoltage ....................................................................................................33
4.4.2. Overtemperature ...............................................................................................................33
4.4.3. DC Overvoltage................................................................................................................33
4.4.4. Differential Overvoltage...................................................................................................33
4.4.5. Sync Loss..........................................................................................................................34
4.4.6. IGBT Driver......................................................................................................................34
4.4.7. Phase 1-3 Overcurrent ......................................................................................................34
4.4.8. Phase Loss.........................................................................................................................34
4.4.9. DC Undervoltage..............................................................................................................34
4.4.10. Regen Power-On/Precharge Not Complete......................................................................34
4.4.11. Frequency Detect Failure..................................................................................................34
4.5. Input / Output Connections.........................................................................................................35
4.5.1. Local I/O +24V Supply- TB2-1 & TB2-5 ........................................................................35
4.5.2. Enable Input - TB2-2........................................................................................................35
4.5.3. Fault Recall Input -TB2-3.................................................................................................35
4.5.4. Input COM -TB2-4...........................................................................................................35
4.5.5. Ready Output - TB2-6 ......................................................................................................35
4.5.6. Overtemperature Output - TB2-7......................................................................................35
4.5.7. Output COM - TB2-8 .......................................................................................................35
4.6. Startup......................................................................................................................................... 36
4.6.1. Pre-power Checks.............................................................................................................36
4.6.2. Startup Procedure and Checks..........................................................................................36
4.6.3. Cooling Fan.......................................................................................................................36
5. MAINTENANCE AND TROUBLESHOOTING...............................................................................37
5.1. Periodic Testing..........................................................................................................................37
5.2. Maintenance Items......................................................................................................................37
5.3. Troubleshooting..........................................................................................................................37
5.3.1. POWER LED is not on, or Digital Display is not active:.................................................37
5.3.2. READY output will not close...........................................................................................37
5.3.3. Unit will not respond to ENABLE command...................................................................37
5.3.4. Drive trips on DC Bus Overvoltage during braking.........................................................37
5.3.5. Feedback Undervoltage ....................................................................................................38
5.3.6. Overtemperature ...............................................................................................................38
5.3.7. DC overvoltage on Regen.................................................................................................38
5.3.8. Differential Overvoltage...................................................................................................39
5.3.9. Sync Loss..........................................................................................................................39
5.3.10. IGBT Driver......................................................................................................................39
5.3.11. Phase Overcurrent............................................................................................................. 39

M3645
6
5.3.12. Phase Loss.........................................................................................................................39
5.3.13. DC Undervoltage..............................................................................................................39
5.3.14. Regen Power-On/Precharge Not Complete......................................................................39
5.3.15. Frequency Detect Failure..................................................................................................40
5.3.16. Technical Help –Before you contact us...........................................................................40
6. ENGINEERING DATA................................................................................................................41
6.1. Ratings Charts.............................................................................................................................41
Table 6-1: Ratings and Specifications –230 - 240VAC ........................................................................41
Table 6-2: Ratings and Specifications –380 - 415VAC ........................................................................41
Table 6-3: Ratings and Specifications –460 - 480VAC ........................................................................41
Table 6-4: Ratings and Specifications –575 - 600VAC ........................................................................41
6.2. Derating Parallel Regens ............................................................................................................42
Table 6-5: Derating Regens in Parallel ..................................................................................................42
6.3. Watt Loss....................................................................................................................................42
6.4. Certifications and RoHS............................................................................................................. 42
6.5. Fuse Selection.............................................................................................................................43
Table 6-6: Fuse Current Rating Requirements.......................................................................................43
Table 6-7: Fuse Voltage Rating Requirements ......................................................................................43
6.6. Dimensions and Mechanical Drawings......................................................................................44
Figure 6-1: M3645 M10 Chassis Dimensional Outline..........................................................................44
Figure 6-2: M3645 M11 Chassis Dimensional Outline..........................................................................45
Figure 6-3: M3645 M12 Chassis Dimensional Outline..........................................................................46
Figure 6-4: M3645 M15 Dimensional Outline.......................................................................................47
Figure 6-5: M645-x300R Line Reactor Dimensional Outline................................................................48
Figure 6-6: KIT 3645DD, External Display Dimensional Outline.........................................................49
6.7. Block Diagram............................................................................................................................50
Figure 6-7: M3645 30A, 50A, 100A Functional Block Diagram...........................................................50
7. APPENDIX.................................................................................................................................51
7.1. Application Notes....................................................................................................................... 51
7.1.1. Sizing the Line Regeneration Unit....................................................................................51
7.1.2. Calculating Energy Savings..............................................................................................52

User’s Manual
7
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 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 M3645 line regen. It provides you with the
necessary information to successfully install and use the M3645 modules in your
application.
In the event of any conflict between this document and any publication and/or
documentation related to the application, the latter shall have precedence.
1.3. MANUAL VERSION AND CHANGE RECORD
Figure 3-8 and Table 6-5-were updated in Rev 01k.
Figures 3-7, 3-8, and 6-4 were updated in Rev 01l.
Figure 3-8 was updated in Rev 01m.
Table 2-2 was updated in Rev 01n.
Updates were made to Section 6.2 and Table 6-5 in Rev 02a.
Updates to Figures 3-7 and 6-4 were made in Rev 02b.
Updates to drawing numbers and chassis dimensional drawings in Rev 02c.
Updated to include KIT 3645DD and M15 frame size in Rev 02d.
Update to Figure 3-9, Sections 6.2, and 6.6 were made in Rev 02e.
Update to Table 6-1 in Rev 02f.
Figures 3-9 and 3-11 were updated in Rev 02g.
Figure 1-1: Typical M3645 Line Regen

M3645
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
Regenerated voltage occurs when the speed of the motor exceeds the set speed on the
drive. This can be due to braking or an overhauling load. In applications with extended
braking times, high horsepower, or where frequent regeneration occurs, the M3645 line
regen is the economical solution for controlling regenerative voltage. While resistor
solutions waste regenerated energy as heat, the Bonitron M3645 line regen returns the
regenerated energy back to the input AC line.
The M3645 line regen synchronizes to the frequency of the incoming power line, allowing
it to automatically adapt to 50Hz or 60Hz input. As the DC bus rises above the AC line
peak, the M3645 redirects current from the DC bus into the AC line to limit the rise in bus
voltage and prevent overvoltage faults. The M3645 is current limiting and will
automatically fold back or shut down in the event that unsafe conditions are detected.
With the optional digital display, the current status of the M3645 is shown and fault records
are stored along with a lifetime count of regenerative energy.
Up to two line regen units can be run in parallel for high-power applications.
2.1. RELATED PRODUCTS
LINE REGEN
M3545 Single Phase or Three Phase Line Regen (<15A)
REGENERATIVE POWER SUPPLY
M3645P Regenerative DC Bus Power Supply (<375A)
EXTERNAL PANEL MOUNTED DIGITAL DISPLAY
KIT 3645DD External Display Kit (compatible only with “L” M3645 regen)
COMMON BUS DIODES
M3345CBM Sharing Diode
BRAKING RESISTORS
M3575R Standard Duty Braking Resistors (<30A)
M3775R Various Duty Load Banks (<1600A)
BRAKING TRANSISTORS
M3452 Heavy Duty Braking Transistor (<1600A)
M3575T Standard Duty Braking Transistor (<600A)
M3675T Low HP Braking Transistor (<10A)

M3645
10
2.2. PART NUMBER BREAKDOWN
Figure 2-1: Example of M3645 Part Number Breakdown
Base Model Number
The base model number for all line regen units is M3645.
VOLTAGE RATING
A code letter represents the 3-phase AC line input voltage to the regen module. The
voltage rating must be selected for the system voltage that will be applied. See Table
2-1 for available voltage ratings.
Table 2-1: Voltage Ratings
RATING CODE
VOLTAGE
L
230 - 240VAC
E
380 - 415VAC
H
460 - 480VAC
C
575 - 600VAC
CURRENT RATING
A 3-digit number represents the maximum continuous DC Current (Amps) the regen
module can regenerate.
The M10, M11, M12 frame sizes are capable of handling a 50% overload above this
current rating for 60 seconds. The M15 frame size is capable ofa 25% overload above
this current rating for 60 seconds.
300A IDENTIFIER
This single letter code is omitted except for 300A models.
Both a line reactor module and a line regen module are required for 300A models. A
single letter code is used for 300A model line regens to designate the line reactor and
the line regen.
Table 2-2: 300A Identifier
CODE
MODEL
DESCRIPTION
R
M3645-x300R
Line Reactor Module
T
M3645-x300T-M15
Line Regen Module
T
300A IDENTIFIER
CURRENT RATING
OPTIONS
VOLTAGE RATING
BASE MODEL NUMBER
CHASSIS STYLE
M3645
H
300
M15
D

User’s Manual
11
CHASSIS STYLE
The chassis style is determined by the current rating, and is represented by an
alphanumeric code as defined in Table 2-2. See Section 6.5 for chassis mounting and
dimensional outlines.
Table 2-3: Chassis Styles
CHASSIS CODE
CURRENT
DESCRIPTION
SIZE (H X WX D)
M10
30A
Open Chassis
20.0”x 10.0”x 10.1”
M11
50A
Open Chassis
22.0”x 11.3”x 10.6”
M12
100A
Open Chassis
24.0”x 12.0”x 12.1”
M15
300A
Open Chassis
26.0” x 13.9” x 11.1”
M15 Reactor
300A
Open Chassis
17.9” x 18.8” x 15.2”
See Section 6.5 for chassis mounting and dimensional outlines.
OPTIONS
Two display options are available.
Table 2-4: Option Codes
OPTION CODE
DESCRIPTION
D
Digital Diagnostic Display
L
Basic LED Indicators
NOTE: The KIT 3645DD external display is only compatible with “L” versions of the
M3645 line regen. Only a single display can be used for each line regen. The line
regen is unable to power more than a single display.

M3645
12
2.3. GENERAL SPECIFICATIONS CHART
Table 2-5: General Specifications
PARAMETER
SPECIFICATION
AC Line Voltage
Voltage Rating
50 or 60 Hz
Voltage Min
Voltage Max
L
207 VAC
253 VAC
E
342 VAC
418 VAC
H
414 VAC
506 VAC
C
518 VAC
600 VAC
DC Input Current
30-300A, continuous
150% of rating, 60 second overload for M10,
M11, M12 chasses
125% of rating, 60 second overload for M15
chassis
Control Voltage
Internal
Indicators
Power
Regen
Fault
Optional 4 line character display
Inputs
Enable 24VDC - 5mA
Fault Recall 24VDC –5mA
Outputs
Ready 200VDC - 100 mA
Operating Temp
0 to +40OC
Storage Temp
-20Oto +65OC
Humidity
Below 90%, non-condensing
Atmosphere
Free of corrosive gas or conductive dust

User’s Manual
13
2.4. GENERAL PRECAUTIONS AND SAFETY WARNINGS
DANGER!
HIGH VOLTAGES MAY BE PRESENT!
NEVER ATTEMPT TO OPERATE THIS PRODUCT WITH THE ACCESS
DOORS OR COVERS OPENED!
NEVER ATTEMPT TO SERVICE THIS PRODUCT WITHOUT FIRST
DISCONNECTING POWER TO AND FROM THE UNIT!
FAILURE TO HEED THESE WARNINGS MAY RESULT IN
SERIOUS BODILY INJURY OR DEATH!
CAUTION!
THIS PRODUCT WILL GENERATE HIGH AMBIENT TEMPERATURES
DURING OPERATION.
THIS PRODUCT SHOULD BE INSTALLED ON A NON-FLAMMABLE
SURFACE WITH CLEARANCES OF AT LEAST TWO INCHES IN ALL
DIRECTIONS.
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 DRIVE AND/OR RESISTIVE
LOAD 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.

M3645
14
This page intentionally left blank

User’s Manual
15
3. INSTALLATION INSTRUCTIONS
CAUTION!
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 M3645regen modules should be accomplishedfollowing 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
start-up of this product to the equipment supplier or system integrator.
3.1. ENVIRONMENT
The module should be installed in an area protected from moisture and falling debris.
Buildup of dust or debris may cause poor performance and possibly a failure.
Operating in a wet environment can pose a shock hazard. The recommended
temperature range for operating this module is 0 to +40C.
Device shall be installed in a Pollution Degree 2 environment.
3.2. UNPACKING
Upon receipt of this product, please verify that the product received matches the
product that was ordered and that there is no obvious physical damage to the unit. If
the wrong product was received or the product is damaged in any way, please contact
the supplier from which the product was purchased.
3.3. MOUNTING
3.3.1. M3645 LINE REGEN MOUNTING
The installation site for the M3645 line regen should be chosen with several
considerations in mind:
When mounting regen units in an enclosure, power dissipation should be taken
into account. Refer to Section 6.3 Watt Loss for details.
The unit requires a minimum clearance of two (2) inches in all directions around it
when not mounted near a heat source. Heat sources may increase necessary
clearances.
Unit should not be exposed to falling debris or condensation.
Once the installation site has been selected as outlined above, the unit should be
mounted in place.
The M3645 must be properly oriented for proper heat flow through the unit. The M3645
must be mounted with the rear surface of the unit to the mounting surface. The unit
may be mounted vertically (Figure 3-1D), or with its backplane down and parallel to
the ground (Figure 3-1A).
Do Not mount the unit on the underside of a mounting surface as shown in Figure 3-
1B.
Do Not mount the unit in a horizontal position with its side parallel to the mounting
surface or floor as shown in Figure 3-1C.
Do Not mount the unit in an upside-down position, as shown in Figure 3-1E.
Refer to Table 2-3: Chassis Styles to determine the chassis for the unit. Mounting
dimensions and provisions vary by unit chassis. See Figure 3-1 for mounting
orientation information and Section 6.6 for dimensional drawings.

M3645
16
Figure 3-1: M3645 Mounting Orientation
Figure 3-1A
Figure 3-1D
HORIZONTAL SURFACE
UP
UP
BONITRON
Figure 3-1B
Figure 3-1E
UP
HANGING UNDERSIDE
Fig B
UP
BONITRON
Figure 3-1C
UP
PARALLEL TO FLOOR
BONITRON BONITRON

User’s Manual
17
3.3.2. M3645-X300R LINE REACTOR MOUNTING
The installation of the M3645-x300R line reactor should be chosen with several
considerations in mind:
The M3645-x300R line reactor is only required when using the 300A rated
M3645 in the M15 chassis.
When mounting the line reactor in an enclosure, power dissipation should be
taken into account. Refer to Section 6.3 Watt Loss for details.
The unit requires a minimum clearance of two inches (2”) in all directions around
it when not mounted near a heat source. Heat sources may increase necessary
clearances.
Unit should not be exposed to falling debris or condensation.
The unit can be mounted in any orientation.
Once the installation site has been selected as outlined above, the unit should be
mounted in place. See Section 6.6 for dimensional drawings.
3.3.3. KIT 3645DD, EXTERNAL DISPLAY MOUNTING
The KIT 3645DD external display is comprised of the display board assembly (ASM
3645D3) and a 12 foot long cable (CBL 3660DD4-DI12). The installation should be
chosen with several considerations in mind:
The external display requires a cutout from the front panel. See Figure 6-6 for the
dimensional requirements for the cutout.
The display will attach to the front of the panel. The display is secured to the
panel with a screw in each corner.
The unit requires a minimum clearance of one (1) inch in all directions around it.
The unit should not be exposed to falling debris or condensation.
The 12 foot cable provided with the display must be attached to TB5 on the
control board of the M3645 and to TB3 on the ASM 3645D3 on the rear of the
display. See Figure 3-12.
Once the installation site has been selected as outlined above, the unit should be
mounted in place. See Section 6.6 for dimensional drawings.
NOTE: The KIT 3645DD is only compatible with “L” versions of the M3645 line regen.
Only a single display can be used for each line regen. The line regen is unable to
power more than a single display.
3.4. WIRING AND CUSTOMER CONNECTIONS
Be sure to review all pertinent AC drive and system documentation as well as the
information listed below before proceeding. Connection points and terminal numbers
of the AC drive will be found in the documentation provided with those units. See
Tables 3-1 thru 3-6 and Figures 3-2 thru 3-8 for connection details.
3.4.1. POWER WIRING
CAUTION!
Only qualified electricians should perform and maintain the interconnection
wiring of this product. All wiring should be in accordance with local codes.
DANGER!
Do NOT daisy chain the AC, DC, or ground connections between multiple
regen units. Each regen should have separate power and ground
connections.

M3645
18
Where possible, minimize the wire length between the regen and the
drive. The wire length should not exceed 10 feet.
Avoid routing and bundling theregen AC/DC wire with the drive AC PWM
motor output wiring.
3.4.1.1. 3-PHASE AC INPUT
Do not installchokes or reactors between the regen and the power source
besides the M3645-x300R. If the AC drive requires a line reactor, the
regen should be connected to the utility grid side.
If an isolation transformer is to be used, the regen AC input MUST be
connected to the same point as the drive AC input. The transformer
should meet the ratings shown in Table 3-1.
Table 3-1: Transformer Ratings
Model
Minimum kVA
Maximum
Impedance
L30
13.5 kVA
5.0%
E30
23 kVA
2.9%
H30
26.5 kVA
2.5%
C30
33 kVA
2.0%
L50
22 kVA
6.0%
E50
38 kVA
3.4%
H50
44 kVA
3.0%
C50
55 kVA
2.4%
L100
44 kVA
6.3%
E100
75.5 kVA
3.6%
H100
87.5 kVA
3.1%
C100
109.5 kVA
2.5%
L300
131 kVA
4.4%
E300
226.5 kVA
2.5%
H300
262 kVA
2.2%
C300
327.5 kVA
1.7%
Do not connect to a generator. For further details, contact Bonitron.
The regen units are not phase sensitive.
The AC line connections should have short-circuit current protection.
Recommended fuses are listed in Section 6.5.
3.4.1.2. INTER-MODULE WIRING FOR 300A ONLY
For M3645 rated for 300A an individual line reactor must be used in
front of each M3645-x300T transistor module. See Figure 3-10 for
wiring diagram.
The user must wire both the control AC wiring from the M3645-x300R
line reactor to the M3645-x300T transistor module.
The control wiring must be connected to the utility side of the M3645-
x300R and is phase sensitive.

User’s Manual
19
DANGER!
The AC control wiring to the M3645-x300T is phase sensitive. If the AC
control wiring is not in phase with power wiring catastrophic damage to
equipment will result.
3.4.1.3. DC BUS INPUT
The DC bus input may be connected to the DC bus of an AC drive, the
DC output of a diode sharing unit, or to a common DC bus. If a reactor
or choke are being used in the bus, make sure the actual connection is in
parallel with filter capacitors of the drive/inverter.
DANGER!
Never attach the DC bus input of the M3645 to braking terminals on the AC
drive, commonly marked “BR”. These terminals are intended for use with an
external resistor, and are not directly connected to the bus filter capacitors of
the drive. Damage may occur if these terminals are used.
Please refer to your AC drive manual or AC drive technical support department
for assistance with this connection.
3.4.1.4. GROUNDING
Using the ground stud provided, ground the chassis in accordance with
local codes. Typically, the wire gauge will be the same as is used to
ground the attached drive.
Table 3-2: Power Terminal Specifications - 30 Amp Unit –M10 Chassis
TERMINALS
FUNCTION
ELECTRICAL
RATINGS
WIRE SIZE
MINIMUM
WIRE SIZE
MAXIMUM
TORQUE
L1, L2, L3
AC line outputs
30A
8 AWG
2 AWG
32 lb-in
DC+, DC-
DC bus inputs
30A
8 AWG
2 AWG
32 lb-in
GND
Ground
10 AWG
1/0
50 lb-in
Table 3-3: Power Terminal Specifications - 50 Amp Unit –M11 Chassis
TERMINALS
FUNCTION
ELECTRICAL
RATINGS
WIRE SIZE
MINIMUM
WIRE SIZE
MAXIMUM
TORQUE
L1, L2, L3
AC line outputs
50A
4 AWG
2/0
120 lb-in
DC+, DC-
DC bus inputs
50A
4 AWG
2/0
120 lb-in
GND
Ground
8 AWG
1/0
50 lb-in
Table 3-4: Power Terminal Specifications - 100 Amp Unit –M12 Chassis
TERMINALS
FUNCTION
ELECTRICAL
RATINGS
WIRE SIZE
MINIMUM
WIRE SIZE
MAXIMUM
TORQUE
L1, L2, L3
AC line outputs
100A
1 AWG
2/0
120 lb-in
DC+, DC-
DC bus inputs
100A
1 AWG
2/0
120 lb-in
GND
Ground
6 AWG
1/0
50 lb-in
Note: All power wire should be selected to match or exceed the voltage rating of the unit.
Field wiring for terminals will be copper 75°Cwire only.

M3645
20
Figure 3-2: 30A, 50A, 100A Power Connections
NO CONNECTION
L1 L2 L3 + - GND
3ØAC INPUT DC BUS
Figure 3-3: 30A, 50A, 100A Connection Locations
USER
I/0
POWER CONNECTIONS
AC
SENSE