bonitron M3545P User manual

Web: www.bonitron.com ● Tel: [phone] ● Email: [email protected]
Model M3545P
Regenerative
DC Bus Power Supply
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

M3545P
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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 M3545P Regenerative Power Supply.......................................................................7
1.4. Symbol Conventions Used in this Manual and on Equipment.....................................................8
2. PRODUCT DESCRIPTION............................................................................................................9
2.1. Related Products...........................................................................................................................9
2.2. Part Number Breakdown ..............................................................................................................9
Figure 2-1: Example of M3545P Part Number Breakdown.....................................................................9
Table 2-1: Voltage Ratings ....................................................................................................................10
Table 2-2: Chassis Styles .......................................................................................................................10
Table 2-3: Option Codes ........................................................................................................................10
2.3. General Specifications Chart......................................................................................................11
Table 2-4: 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
Figure 3-1: M3545P Mounting Orientation ...........................................................................................14
3.4. Wiring and Customer Connections.............................................................................................15
3.4.1. Power Wiring......................................................................................................................15
Table 3-1: Power Terminal Specifications.............................................................................................16
Figure 3-2: M3545P Power & I/O Connection Location .......................................................................16
3.4.2. I/O Wiring...........................................................................................................................17
Table 3-2: M3545P I/O Wiring..............................................................................................................17
Figure 3-3: M3545P I/O Diagram..........................................................................................................17
3.5. Typical Configurations...............................................................................................................17
Figure 3-4: M3545P Power Wiring........................................................................................................18
Figure 3-5: M3545P Multiple Drives Field Wiring Diagram.................................................................19
4. OPERATION..............................................................................................................................21
4.1. Functional Description ...............................................................................................................21
4.2. Features....................................................................................................................................... 21
4.2.1. Indicator LEDs....................................................................................................................21
4.3. Faults ..........................................................................................................................................21
4.3.1. Operational Faults...............................................................................................................21
Table 4-1: Blink Codes ..........................................................................................................................22
4.3.2. System Faults......................................................................................................................22
Table 4-2: System Faults........................................................................................................................22
4.4. User I/O Connections .................................................................................................................22
4.4.1. N/C (TB-6)..........................................................................................................................22
4.4.2. Input COM (TB-7)..............................................................................................................22
4.4.3. Fault Recall (TB-8).............................................................................................................22
4.4.4. Output Com (TB-9).............................................................................................................23
4.4.5. Ready (TB-10) .................................................................................................................... 23
4.5. Startup......................................................................................................................................... 23
4.5.1. Pre-power Checks............................................................................................................... 23

Table of Contents
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4.5.2. Startup Procedure and Checks ............................................................................................23
4.5.3. Cooling Fan.........................................................................................................................23
5. MAINTENANCE AND TROUBLESHOOTING...............................................................................25
5.1. Periodic Testing..........................................................................................................................25
5.2. Maintenance Items......................................................................................................................25
5.3. Troubleshooting.......................................................................................................................... 25
5.3.1. POWER LED is not on.......................................................................................................25
5.3.2. READY output will not close.............................................................................................25
5.3.3. Over Voltage fault on Drive or Regen................................................................................25
5.3.4. Overtemperature Fault ........................................................................................................26
5.3.5. IGBT Desat Fault................................................................................................................26
5.3.6. Phase Loss Fault..................................................................................................................26
5.3.7. Fuses fail on power on........................................................................................................26
5.4. Technical Help –Before you contact us..................................................................................... 26
6. ENGINEERING DATA................................................................................................................27
6.1. Ratings Charts.............................................................................................................................27
Table 6-1: Ratings and Specifications –230 - 240VAC ........................................................................27
Table 6-2: Ratings and Specifications –460 - 480VAC ........................................................................27
6.2. Derating Parallel M3545P ..........................................................................................................27
Table 6-3: Derating M3545P in Parallel ................................................................................................27
6.3. Watt Loss....................................................................................................................................27
6.4. Certifications ..............................................................................................................................28
6.4.1. UL 61800-5-1......................................................................................................................28
6.4.2. RoHS...................................................................................................................................28
6.5. Fuse Selection............................................................................................................................. 28
Table 6-4: Fuse Current Rating Requirements.......................................................................................28
6.6. Dimensions and Mechanical Drawings ......................................................................................29
Figure 6-1: M3545P M4 Chassis Dimensional Outline .........................................................................29
7. APPENDIX.................................................................................................................................31
7.1. Application Notes.......................................................................................................................31
7.1.1. Sizing the M3545P..............................................................................................................31
7.1.2. Calculating Energy Savings................................................................................................32