bonitron M3612EC User manual

Web: www.bonitron.com ● Tel: [phone] ● Email: [email protected]m
Model M3612EC
Common DC Bus High Ripple Capacitor
with Cooling
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

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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 M3612EC Capacitor Bank .......................................................................................7
2. PRODUCT DESCRIPTION............................................................................................................9
2.1. Related Products........................................................................................................................... 9
2.1.1. Common Bus Diodes ........................................................................................................................9
2.1.2. Common Bus Filtering......................................................................................................................9
2.1.3. Common Bus Power Supplies...........................................................................................................9
2.1.4. Braking and Overvoltage Protection.................................................................................................9
2.2. Part Number Breakdown ..............................................................................................................9
Figure 2-1: Example of Part Number Breakdown....................................................................................9
Table 2-1: Voltage Rating......................................................................................................................10
Table 2-2: Capacitance Ratings..............................................................................................................10
2.3. General Specifications................................................................................................................10
Table 2-4: General Specifications Chart ................................................................................................10
2.4. General Precautions and Safety Warnings .................................................................................11
3. INSTALLATION INSTRUCTIONS................................................................................................13
3.1. Environment ...............................................................................................................................13
3.2. Unpacking................................................................................................................................... 13
3.3. Mounting ....................................................................................................................................13
3.3.1. Mounting the M3612EC Capacitor Bank........................................................................................13
Figure 3-1: M3612EC Mounting Orientation.........................................................................................13
3.4. Wiring and Customer Connections.............................................................................................14
3.4.1. Power Wiring..................................................................................................................................14
Table 3-1: Power Connection Specifications .........................................................................................14
Figure 3-2: Power Connections..............................................................................................................15
3.5. Typical Configurations...............................................................................................................17
Figure 3-3: M3612EC Capacitor Bank Field Wiring Diagram Option 1 ...............................................17
Figure 3-4: M3612EC Capacitor Bank Field Wiring Diagram Option 2 ...............................................17
4. OPERATION..............................................................................................................................19
4.1. Functional Description ...............................................................................................................19
4.2. Startup......................................................................................................................................... 19
4.2.1. Pre-Power Checks...........................................................................................................................19
4.2.2. Startup Procedure and Checks ........................................................................................................19
5. MAINTENANCE AND TROUBLESHOOTING...............................................................................21
5.1. Periodic Testing..........................................................................................................................21
5.2. Maintenance Items......................................................................................................................21
5.3. Troubleshooting..........................................................................................................................21
5.3.1. Attached drive does not come on....................................................................................................21
5.3.2. Overheating.....................................................................................................................................21
5.3.3. Blown Input Fuses or Circuit Breakers...........................................................................................21
5.4. Technical Help –Before you call or email.................................................................................22
6. ENGINEERING DATA................................................................................................................23
6.1. Ratings Charts.............................................................................................................................23
Table 6-1: Ratings Table........................................................................................................................23
6.1.1. Ripple Current.................................................................................................................................23

Table of Contents
5
Table 6-2: Ripple Current and Fuse Table .............................................................................................23
6.2. Watt Loss....................................................................................................................................23
Table 6-3: Full Load Watt Loss .............................................................................................................23
6.3. Dimensions and Outlines............................................................................................................23
Table 6-4: Chassis Dimensions for M3612EC Module..........................................................................23
Figure 6-1: M3612EC K7 Chassis Dimensional Outline .......................................................................24
6.4. Block Diagrams..........................................................................................................................24
Figure 6-2: Functional Block Diagram ..................................................................................................24
7. APPLICATION NOTES...............................................................................................................25
7.1. Application Considerations ........................................................................................................25
7.1.1. Drives..............................................................................................................................................25
7.2. System Voltage and Source Impedance .....................................................................................25
NOTES ...................................................................................................................................................27

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User’s Manual
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1. INTRODUCTION
1.1. WHO SHOULD USE
This manual is intended for use by anyone who is responsible for integrating, installing,
maintaining, troubleshooting, or using this equipment with any 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 M3612EC Capacitor Bank. It will provide
you with the necessary information to successfully install and use the M3612EC
module 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
Rev01 of this manual contains clarified specs and updated drawings.
Rev02 of this manual contains updated drawings, part numbers, and rating
information.
The placement of the field connections was modified in Rev 03.
The manual template was updated in Rev 03a.
Updates to Section 2-1 Related Products in Rev 03b.
Figure 1-1: Typical M3612EC Capacitor Bank

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User’s Manual
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2. PRODUCT DESCRIPTION
The M3612EC is a filter capacitor bank for a common DC bus drive systems. The drives
can be either servo or variable frequency drives intended for use with common bus
capacitors.
2.1. RELATED PRODUCTS
2.1.1. COMMON BUS DIODES
M3345CBM Common Bus Sharing Diodes
Allows power sharing between drives, while isolating input bridges
M3345D Common Bus Isolation Diodes
Provides blocking diodes that isolate drives from each other, while
still establishing a shared, common DC bus
2.1.2. COMMON BUS FILTERING
M3612RC Common Bus Snubber
High frequency filter that limits spikes and ringing in DC bus systems
caused by inverter switching, supply noise, bus reactance, and other
such sources
2.1.3. COMMON BUS POWER SUPPLIES
M3712 Single Phase Power Supply
Power 3-Phase drives via the DC bus from a single-phase source
without de-rating the drive
M3713SC 3-Phase Power Supply with Pre-charge
Six pulse diode bridge with pre-charge that can serve as the main
power supply for common DC bus systems.
Multiples can be used to serve as 12 or 18 pulse building blocks.
2.1.4. BRAKING AND OVERVOLTAGE PROTECTION
M3452 and M3575T Modules add resistive dynamic braking to DC bus
systems and VFDs.
M3645 Modules are standalone line regeneration modules to add
dynamic braking to DC bus systems and VFDs.
2.2. PART NUMBER BREAKDOWN
Figure 2-1: Example of Part Number Breakdown
BASE MODEL NUMBER
VOLTAGE RATING
CAPACITANCE
CHASSIS
M3612EC
L
280
K7

M3612EC
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BASE MODEL NUMBER
The Base Model Number for these Capacitor Banks is M3612EC.
VOLTAGE RATING
A 1-digit code represents the AC system voltage tothe M3612EC module. The voltage
rating must be selected for the system voltage that will be applied.
Table 2-1: Voltage Rating
RATING CODE
SYSTEM VOLTAGE
L
230 - 240VAC
H
460 - 480VAC
CAPACITANCE
A 3-digit code represents the nominal capacitance in.
Table 2-2: Capacitance Ratings
RATING CODE
NOMINAL CAPACITANCE (UF)
070
7,000
280
28,000
CHASSIS
The Chassis for the M3612EC is determined by the capacitance.
Table 2-3: Chassis Codes
CAPACITANCE (UF)
CHASSIS CODE
DIMENSIONS (HX WX D)
28,000
K7
20.00 x 7.12 x 10.30
2.3. GENERAL SPECIFICATIONS
Table 2-4: General Specifications Chart
PARAMETER
SPECIFICATION
Input voltage
230VAC & 480VAC 3Ø, 60 Hz
Capacitance tolerance
± 20% (M) at +25C
Leakage current
I=0.12CV (uA) or 30ma whichever is smaller
Rated ripple current multiplier
+45C
+65C
+85C
+105C
2.45
2.12
1.73
1.00
Operating temperature
-10C to +50C
Humidity
Below 90% non-condensing
Atmosphere
Free of corrosive gas and conductive dust

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2.4. GENERAL PRECAUTIONS AND SAFETY WARNINGS
DANGER!
HIGH VOLTAGES MAY BE PRESENT!
NEVER ATTEMPT TO OPERATE OR SERVICE THIS EQUIPMENT
WITH ACCESS DOORS OR COVERS OPENED!
FAILURE TO HEED THESE WARNINGS MAY RESULT IN
SERIOUS BODILY INJURY OR DEATH!
DANGER!
HIGH TEMPERATURES MAY BE GENERATED BY THIS EQUIPMENT
DURING NORMAL OPERATION!
THIS EQUIPMENT SHOULD BE INSTALLED ON A NON-
FLAMMABLE SURFACE IN A WELL VENTILATED AREA WITH A
MINIMUM OF 2INCHES OF CLEARANCE ALL AROUND.
LETHAL VOLTAGES CAN EXIST IN UNIT AFTER POWER HAS
BEEN REMOVED.ALLOW 5MINUTES FOR CAPACITOR BANKS
TO DISCHARGE,AND ENSURE THERE ARE LESS THAN 40VDC
ON THE DC BUS BEFORE ATTEMPTING SERVICE.
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.
ANY QUESTIONS AS TO APPLICATION, INSTALLATION, OR SERVICE
SAFETY SHOULD BE DIRECTED TO THE EQUIPMENT SUPPLIER.

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User’s Manual
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3. INSTALLATION INSTRUCTIONS
WARNING!
Installation and/or removal of this product should only be performed by a
qualified electrician in accordance with National Electrical Code or local codes
and regulations.
Proper installation of the Power Supply Modules should be accomplished 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 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 or storing this module is 0C to +40C.
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. MOUNTING THE M3612EC CAPACITOR BANK
The installation site for the module should be chosen with several
considerations in mind:
The unit requires a minimum clearance of two (2) inches in all directions
around it when mounted near a non-heat source.
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 M3612EC must be properly oriented
for proper heat flow through the units. The M3612EC must be mounted
with the rear surface of the unit to the mounting surface. Unit should be
mounted vertically as shown in Example A of Figure 3-1.
Do Not mount the unit upside-down or on the underside of a
mounting surface as shown in Example B of Figure 3-1.
Do Not mount unit in a horizontal position with its side parallel to the
mounting surface or floor as shown in Example C of Figure 3-1.
Figure 3-1: M3612EC Mounting Orientation
HORIZONTAL TO FLOOR
Example A
HORIZONTAL SURFACE VERTICAL SURFACE
UP
UP
Example B Example C
HANGING UNDERSIDE
UP
Dwg: 070131 Rev: 20070225

M3612EC
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3.4. WIRING AND CUSTOMER CONNECTIONS
Be sure to review all AC Drive and system documentation for attached equipment as
well as the information listed belowbefore proceeding. Connection points and terminal
numbers of the AC Drive will be found in the documentation provided with those units.
See Table 3-1 and Figure 3-2 for connection details.
3.4.1. POWER WIRING
WARNING!
Only qualified electricians should perform and maintain the
interconnection wiring of this product. All wiring should be done in
accordance with local codes.
DANGER!
This unit contains substantial capacitance and can maintain lethal
voltages for a long time after power is removed! Ensure that the
DC bus level has dropped below 40VDC before attempting to work
on or with this unit!
Table 3-1: Power Connection Specifications
MODEL
CONNECTOR
TORQUE
M3612EC-L280
#4AWG - 500Kcmil (AL/CU)
375 in-lbs
M3612EC-H070
#4AWG - 500Kcmil (AL/CU)
375 in-lbs

User’s Manual
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Figure 3-2: Power Connections
Dwg: 090051 Rev: 20120605

M3612EC
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3.4.1.1. MAIN DC INPUT
“DC─“ and “DC+” should be connected to the DC bus terminals of the
power supply. Ensure the polarity of the connection is correct, as this can
cause severe damage to the capacitor bank. Refer to your drive and
power supply manuals for the exact location of this connection.
3.4.1.2. OUTPUT TO VFD
“DC─“ and “DC+” should be connected to the DC bus terminals of the
VFD. Ensure the polarity of the connection is correct, as this can cause
severe damage to the drive. Refer to your drive manual for the exact
location of this connection.
This link should be fused in accordance with the drive manufacturer’s
recommendations. If the M3612EC is installed in the same cabinet as
the VFD, DC link fusing may not be necessary. Semiconductor fuses
such as the A70Q or FWP are recommended for this purpose.
Do not connect the output of the M3612EC to the braking terminals of the
drive. This can also cause severe damage to the drive.
3.4.1.3. GROUNDING CONSIDERATIONS
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.
Refer to your local codes and standards for installation guidelines.
3.4.1.4. FAN POWER
The fan has a current draw of ½A and will need an 115VAC, 15W power
supply. See Figure 3-2 for location of fan hook-up.

User’s Manual
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3.5. TYPICAL CONFIGURATIONS
Figure 3-3: M3612EC Capacitor Bank Field Wiring Diagram Option 1
Dwg: 080476 Rev: 20120605

M3612EC
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Figure 3-4: M3612EC Capacitor Bank Field Wiring Diagram Option 2
Dwg: 090050 Rev: 20120605

User’s Manual
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4. OPERATION
4.1. FUNCTIONAL DESCRIPTION
The M3612EC is a capacitor bank with an integral bleeder to build a DC bus if bus
filter capacitance is required.
4.2. STARTUP
This section covers basic checks and procedures that may be used when performing
a startup with a M3612EC.
4.2.1. PRE-POWER CHECKS
Ensure that all connections are tight and that all wiring is of the proper
size and rating for operation.
Verify continuity of all input fuses.
Ensure that the polarity of the DC link to the attached drive is correct.
Check for exposed conductors that may lead to inadvertent contact.
Check for any debris, shavings, trimmings, etc that may cause shorts or
obstruct ventilation on unit.
Perform the pre-power checks required for the attached drive.
4.2.2. STARTUP PROCEDURE AND CHECKS
After completing pre-checks and recommended checks for connected
equipment, you may apply power to the system.
Check bus voltage to make sure it is within the capacitance bank
specification.
The attached drive should then be started up according to its instructions.

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