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Model M3460R Model S3460SR - Tecno Ingenieria Industrial

1. User s Manual Figure 6 3 3460R R11 Chassis Dimensional Outline 2 a E J HUN LL Lil DC BUS 415 VAC LINE INPUT cil 9 O DN DEC 2545 _ ci a E e gt IC E Et Et t Y 2 13 Tran II L a
2. Dwg 050140 Rev 20090514 61 M3460R and S3460SR 62 ATIC Figure 6 2 3460R R10 Chassis Dimensional Outline i 1 1 T 1 Q B ot NOTES RELAY The Ty 2 eX M e d ip D 056 09 0 oar Uta JZ a Dwg 050225 Rev 20090514 DDI DISPLAY INTERFACE BOOSTER TEST RELAY
3. 14 SEE Hal eip n E REDE a Sm vo 4 H Ee pali om o ixi ford E PR ER oin PE H P TL Dwg 050255 Rev 20090514 63 M3460R and S3460SR Figure 6 4 Typical Cabinet Dimensional Outline bw 4 GG ge OVERALL VIEW Table 6 4 Model S3534SR Cabinet Dimensions CODE RATING H x W x D 540 675kW 72 H x 78 x 18 D 720 1350kW 2000mmH x 800mm W x 600mm D 64 Dwg 080369 20080827 mod User s Manual 6 6 RECOMMENDED SPARE PARTS The part numbers listed in Table 6 6 represent the recommended spare parts and the quantities of each used in various Bonitron Model M3460R Boost Regulator Ride thru modules This list is intended for use as a reference if ordering spare parts for the Ride thru modules becomes necessary Please remember to refer to the complete Bonitron part number when ordering parts Each printed circuit board has a serial sticker 3460C1DJ 125 Please refer to Table 6 5 below Including every
4. a DRIVE 1 NOLLVIAHOHNI NOILOATAS ONISNA 39YNOS ANY S3ZIS H3MOd AINVLYOdWI 303 TVNNVW 390N3Y434384 YAWOLSND OL H3J3H SALON H3MOd 91915 E SILVIW3HOS 303 3ON38333M8 YSAWOLSND 30 NOILOAS 33S SNOILdIHOS3Q 303 3ON333338 33 01 5 dO NOIL
5. D M3460R and 534605 CMAN vall 01b 11 11 2010 521 Fairground Court e Nashville Tennessee 37211 615 244 2825 e FAX 615 244 2823 www bonitron com
6. Lin Q NOHLINOS NOILVNYOSNI NOILOATSS ONISNS 393n0S 53215 NIYIM YIMOd LNAdNI ANVLYOdWI TVNNVW SON333338 YAWOLSND OL 33338 SALON SNIMIM H3MOd 91313 YILIN 170A AV IdSIa 41 90996 9910955 SNOILO3NNOO AV IdSIQ WNOILdO OL SNOILO3NNOO SILVIW3HOS YSAWOLSNOD 30 NOLLO3S 33S SNOILdINOS3G 3ON3 343H YIWOLSNI JO NOLLO3S 33S 15 Dwg 090156 Rev 20101015 M3460R and S3460SR ispla ions with DD3 Di de Thru Field Connecti ical Ri T ure 3 7 Fi NOLLO3NNOO HOLIOVdVO POS BUS NEG BUS LON TIIM SNOLLVNIINH3 L ATLNV LSNOO G3SN 38V NMOHS SQHVOS JHL u43 3MOH SISSVHO NO SNIGQN3d3Q AHVA TIIM NMOHS SQNVOB LINDYIO JHL 30 SNOILISOd SHL 31V83dO OL LAdNI TWNOIS NNY SAVH LSNW WALSAS 5 LNdNI ANH ov 8 LNdNI ov 9 1 OW sna sna oa L3 1 DRIVE 1
7. 67Hp ITI ac FEE N X 4 y 30Hp 25Hp 20Hp AND Y AND Y AND Y FAULT ENSI ECIAL REQUIREMENT EEDE ENDED EQUIVALENT IVE Figure 7 4 Typical M3460R Output vs Input Various Loads 120 00 7 100 00 80 00 60 00 40 00 Percent Output Voltage 5 S S S S Sf e 92 d d 9 10 e Dd e S GNA v o o d b b O Percent Input Voltage Input Voltage Output Voltage 100 Load 4 Output Voltge 2 50 Load Output Voltage 25 Load Dwg 080121 Rev 20091012 71 M3460R and S3460SR Figure 7 5 Duration of Voltage Sag in Seconds 0 01 002 0 1 10 100 Samsung Power Vaccine Percent of Equipment Nominal 72 Bonitron 100 Outage User s Manual Figure 7 6 Typical Drive Bus Voltage for 400VAC Systems VDC 740 520 520 520 540 500 420 UNDER VOLTAGE TRIP POWER LOSS 495 TEST BOOST CYCLE END BOOSTER O V SHUTDOWN TEST BOOST CYCLE START SAG EVENT END SAG EVENT START RUNNING LOAD RAMP UP START DRIVE STANDBY 650 OVER VOLTAGE TRIP EXCESSIVE BRAKING ENERGY 540 520 500 BRAKING CLAMP LEVEL BRAKING CYCLE
8. unire Gal altel de ee 1 Figure 1 1 Examples of M3460R S3460SR Ride Thru 1 PRODUCT 2 rece en e ptr ee arvana 3 22 Part Number Breakdown 4 Figure 2 1 Example of Part Number 4 1 4 Table 2 1 System Voltage Rating Codes enne nennen nennen 4 Table 2 2 Chassis Codes for M3460R Models sese enne nre nre 5 Table 2 3 Cabinet Codes for S3460SR 5 Tabl 2 4 Optom Codes iss eese i d e a ip eer 5 2 3 General Sp cifications nsus inson rna aaa erre RAN a nnne 6 Table 2 5 General Specifications Chart E 6 Table 2 6 Voltage Specifications oer e REO ERSTER ete 6 2 4 General Precautions and Safety Warnings ener entren nnns 7 2 5 Integration Recommendations for Battery Power Source Ride Thru Systems 8 INSTALLATION INSTRUCTIONS ceccccccccocoo0000000000000000000000000000000000000000000000000000000000000000000000000000000009 Codec e o get 9 3 22 Unpackin eee tte 9 X2 Cabinet dee whacked echoes e
9. 405 459 486 sw 607 er 648 508 50 675 59 738 RECOMMENDED DC Bus BOOST Boost ao Current BACKPLATE CIRCUIT FUSE RATING Max ay CONFIG dxc DC Bus ATING F1 F2 F4 F5 The input power source must be capable of handling a 2 second current surge at twice the nominal rating for the Ride Thru module Maximum duty cycle is 1 at full rated load Fuses recommended for use with M3460R Ride Thru systems should be Gould Shawmut 7005 series Buss FWP series equivalent semiconductor fuses User s Manual G Suitable for use on a circuit capable of delivering not more than 10 000 rms Symmetrical Amperes 700 volts maximum when protected by recommended fuses 59 M3460R and S3460SR 60 6 2 WATT Loss INACTIVE POWER CONSUMPTION lt 100 Watts for units rated at 160A DC bus load or less lt 200 Watts for units rated at greater than 160A DC bus load All M3460R models are 93 efficient or better full load 50 sag 6 3 CERTIFICATIONS Tested by EPR to exceed Semi 47 specs Standard M3460R models are UL listed 6 4 FUSE CIRCUIT BREAKER SIZING AND RATING The following data is supplied for assistance in selecting the appropriate field wiring sizes and power source fuse ratings for the 3460 Cabinet Mounted and Open chassis Ride Thru systems Wire size must be coordinated with circuit protection devices and
10. 30 Table 4 3 3460M6 Status Output Interface I O Signal Logic Jumper Details 30 Figure 4 1 366001 DP Series LED 1 1 nennen 31 Figure 4 2 366003 Diagram socassa e A EAE nennen ennt 31 Figure 4 3 3460M6 Status Interface Board Layout and Jumper 32 Figure 4 4 36601 Digital Display Board Layout 33 4 2 2 Displays ee eee ea ee i ERU De ae 34 Table 4 4 Diagnostic Display Panel Configurations nennen eene 34 Figure 4 5 Display Panels ee UE De ERR E e RR NER E ee 34 Table 4 5 Manual Control with Enable Signal sse 37 Table 4 6 Manual Control with Disable 1 38 Table 4 8 Automatic Control with Enable Signal sese 38 Table 4 9 Automatic Control with Disable Signal eese 39 4 7 Input Under Voltage Automatic Shutdown truth table sse 39 4 3 Startup Procedure d dite or tiet Ete ie d Pr ta 40 429212 Pre Power CHECKS 5 40 4 3 2 Startup Procedure and Checks 40 4 4 Threshold Voltage and Low Bus Sense Adjustments sse 43 Table 4 10 Factory Setpoints fo
11. 54 Figure 5 3 Diagnostic Signal Connections with and DP10 55 Figure 5 4 Diagnostic Signal Connections with 353412 amp 17 sse 56 Figure 5 5 M3460R Basic Signal Flow with DP Option sse 57 Figure 5 6 M3460R Basic Signal Flow with SCR 58 ENGINEERING DATA eti ten E O E 6 1 Ratings Charts Performance eene eene enne ener 59 Table 6 1 2 second 50 kW Ratings 59 Table 6 2 Model Specifications etsi ee tie e RR eR Re Pedes 59 6 2 Watt Loss Inactive Power nennen ener entrent en 60 6 3 Certifications sisi e ced han e rt io nr to re ore i ud ete E eO E 60 6 4 Fuse Circuit Breaker Sizing And Rating esses ener enne 60 Table 6 3 Input Power Wiring Sizes and Fusing 1 60 M3460R and S3460SR 7 VI 6 5 Dimensions and Mechanical Drawings sess ener ener 61 Figure 6 1 3460R R9 Chassis Dimensional Outline sess 61 Figure 6 2 3460R R10 Chassis Dimensional Outline essen 62 Figure 6 3 3460R R11 Chassis Dimensional Outline sese 63 Figure 6 4 Typical Cabinet Dimensional Outline 64 Table 6 4 Model S3534SR Cabine
12. RUNNING LOAD RAMP UP START DRIVE STANDBY 460 PRECHARGE COMPLETE POWER ON Dwg 070183 Rev 20090921 ov 73 M3460R and S3460SR Figure 7 7 Typical Drive Bus Voltage for 460VAC Systems VDC 520 UNDER VOLTAGE TRIP POWER LOSS 620 TEST BOOST CYCLE END al 710 685 BOOSTER O V SHUTDOWN E TEST BOOST CYCLE START r 620 SAG EVENT END 585 5 EVENT START Es RUNNING LOAD RAMP UP mA 620 600 START DRIVE 640 STANDBY 840 OVER VOLTAGE TRI P _ EXCESSIVE BRAKING ENERGY za 750 BRAKI NG CLAMP LEVEL E BRAKING CYCLE RUNNING LOAD RAMP UP 620 600 START DRI VE 640 STANDBY PRECHARGE COMPLETE 560 POWER ON ov 74 Dwg 070180 Rev 20070808 User s Manual 7 4 QUICK SET UP GUIDE FOR 3460 ULTRA CAP COMPONENT SYSTEMS The following is a brief guide to lead the Ride Thru system integrator to some of the main issues for each of the system components This is NOT meant to replace the service manuals for each of the components 7 4 1 7 4 2 7 4 3 7 4 4 7 4 5 7 4 6 SYSTEM WIRING e Drawing 080384 shows a system basic connection scheme e Drawing 080263 shows an example of Bonitron U cap Cabinet wiring BOOSTER The Booster may include Digital Display which is factory set f
13. 48 Doc 013029 Rev 20030206 5 1 3 User s Manual e Inverter input current should drop e Ride Thru DC bus voltage should rise to 100VDC above the threshold Inverter DC bus voltage should rise to 100VDC above the threshold e Ride Thru Active LED should turn ON Motor speed should remain constant PERIODIC MAINTENANCE PROCEDURES FOR M3460R WiTH OPTIONAL DiAGNOSTIC DiSPLAY PANEL The Bonitron Ride Thru is designed to be low maintenance While the amount of Ride Thru time does not depend on energy storage devices that degrade over time Bonitron still recommends a yearly test of the system in order to ensure the electronics package is operating The following steps can be taken to ensure reliability and give comfort that the system is still able to ride through a sag event 1 Check Active cycle counters More than 10 counts per month may mean the Ride Thru is improperly adjusted Refer to Section 4 4 for adjustment details e Note count for factory records Report count to Bonitron via your local service representative 2 Monitor Front panel LEDs for the DP17 Display Panel Power LED should be ON e Precharge Complete LED should be e Ride Thru Ready LED should be Ride Thru Active LED should be OFF e Voltage Fault LED should be OFF Over temperature LED should be OFF 3 Verify DC bus current meter Meter should read zero amps under normal conditions 4 Verify DC bus volt
14. FIELD WIRING EQUIVALENT RATING TIME DELAY SIZES WIRING SIZES 40 62 85 Amps 70 Amps 2 AWG 67 MCM 62 93 130 Amps 100 Amps 2 AWG 67 80 125 170 Amps 125 Amps 1 AWG 84 MCM 165 250 340 Amps 225 Amps 3 0 AWG 168 MCM 135 187 255 Amps 175 Amps 2 0 ANG 133 MCM 165 250 425 Amps 225 Amps 4 0 250 User s Manual 6 5 DIMENSIONS AND MECHANICAL DRAWINGS Figure 6 1 3460R R9 Chassis Dimensional Outline j NC S 7 9 E E 2 1 1 14 1 25 2 11 DRIVE 4 12 9 d Tol o To To 25 5 25 a a To oJ Et E E D I I Ud ale _ J m 9 S 5 T N y PVA LL
15. Fee J1 IUV RUN 1 amp DISPLAY FAULT 415 OR EE ENABLE FLT 1 FLT2 RUN 2 LATCH INDICATIONS RTO OUV 24V 0 X B lt a 24V lt X Y Temp Batt UV or 2 lt Fault 0 X X Y RTA Time p 1 N re 6 orma _ a 0 7 X N 24V X z N RTR PCC BF or Fault 0 X X N OUV Table 4 7 Automatic Control with Enable Signal 36601 3660D DISPLAY JUMPERS 36601 SIGNAL INPUTS 36601 OUTPUTS PANEL J1 IUV d RUN 1 amp DISPLAY FAULT 415 an jd ENABLE FLT 1 FLT2 RUN 2 LATCH INDICATIONS RTO OUV 24V x OK Normal 4 Fault 24V X E Y Temp Batt UV or 2 lt 0 F X Time 5 24V 5 X N lt 5 OK Normal 5 lt 0 m en 24V X X N RTR PCC BF or Fault 0 X N OUV User s Manual Table 4 8 Automatic Control with Disable Signal 36601 3660D DISPLAY JUMPERS 36601 SIGNAL INPUTS 36601 OUTPUTS PANEL g mm J1 IUV RUN1 amp DisPLAY FAULT 415 OR EE ENABLE FLT 1 FLT2 RUN 2 LATCH INDICATIONS RTO OUV 24V 2 2 OK Normal 0 X lt m Fault 24V X Y Temp Batt UV or 2 5 0 X Time a 2 E 24V E N lt 5 OK Normal 6 a 0 X N 24V X N Fault RTR PCC BF or 0 X X N OUV DISPLAY SCREEN DISABLE RIDE THRU FOR IUV FAULT J1 amp J14 POSITION AUTOMATIC SHUTDOWN ON 36601 INTERF
16. Model M3460R Ride Thru Module RTM and Model S3460SR Ride Thru Cabinet System Customer Reference Manual TEL 615 244 2825 e FAX 615 244 2833 e www bonitron com Bonitron Inc Bonitron Inc An Industry Leader in AC Drive Systems and Industrial Electronics OUR COMPANY Bonitron is an international supplier of power controls designed to improve the performance and reliability of electronic systems and variable frequency drives Located in Nashville Tennessee and founded in 1962 Bonitron has gained a reputation for designing and manufacturing products with the highest possible degree of quality and reliability Bonitron has all the necessary resources in house for complete electronic product development and manufacturing Engineering facilities include a CAD lab for circuit board design and engineering labs for prototype testing and evaluation Production facilities include production areas for circuit board assembly a machine tool and sheet metal shop for chassis fabrication and a systems assembly and checkout area With these assets Bonitron is positioned to be a leader into the future while maintaining first class support for their current customer base Worldwide sales of equipment are generated mainly by reputation and referrals Our customer base includes all of the major drive manufacturers their distributors OEMs end users and many other satisfied companies Equipment is installed throughout the United S
17. If the threshold is too close to the under voltage trip level of the inverter the system may not Ride Thru and under voltage trips will still occur Most inverters have an under voltage trip point of 15 of nominal Some inverters can be reprogrammed to change this trip level Bonitron typically would like the DC bus threshold to be about 10 of the nominal bus For example Bonitron sets all 460VAC systems to hold the DC bus to 585VDC e Refer to your inverter s documentation for details on adjustment of the under voltage trip setting e Refer to Section 4 4 for details on how the Ride Thru DC bus threshold can be changed If equipped with the Ride Thru disconnect turn off and apply power to the System Otherwise go to the Startup Procedure Section 4 3 2 1 e Ensure that the associated inverter is working properly Confirm the under voltage trip point if possible Ensure that the associated inverter is working properly Confirm the under voltage trip point if possible 4 3 2 STARTUP PROCEDURE AND CHECKS 4 3 2 1 CAUTION FoR M3460R WITHOUT DIAGNOSTIC DISPLAY PANEL If Precharge Hold off option is installed begin with step 1 If not installed go directly to step 2 1 If this unit HAS the Precharge Option installed Apply power to the Ride Thru and observe the following conditions DC bus voltage on Ride Thru cap bank does not charge No LEDs should light Turn on the 24V ENABLE signal
18. 24V is removed from the IGBT switch and the switch is turned on Note that this 24V is NOT isolated from cap bank or drive potential See 3628T Manual Figure 3 1 e External temperature sensor on discharge resistor bank is not required because current limited charger cannot output enough power to overheat the discharge resistor e Connect directly to cap bank as shown 080384 See new App notes the M3628T manual for fusing and rms current rating for wire sizing e Discharge time is about 1 min to 50VDC 3 min to about 15VDC If personnel are working on cap bank or boost modules it is recommended to place a shorting bar across cap bank as soon as the discharger lets go and the cap voltage begins to increase due to reforming 7 5 Quick SET UP GUIDE FOR 3460 ELECTROLYTIC CAP COMPONENT SYSTEMS The following is a brief guide to lead the Ride Thru system integrator to some of the main issues for each of the system components This is NOT meant to replace the service manuals for each of the components 7 5 1 SYSTEM WIRING e Drawing 100271 shows a system basic connection scheme e Drawing 100190 shows an example of Bonitron E cap Cabinet wiring 7 5 2 BOOSTER The Booster may include Digital Display which is factory set for automatic control mode which automatically shuts down the boost module to protect ourselves from damage if misapplied misadjusted or some abnormally long sag brown out event occurs Some owners
19. 3460M6 Fault Output board LED 1 NO FAULT should be ON 2 Verify DC bus voltage level e Ride Thru bus should be about 5 15V DC below the Inverter bus 3 Verify Threshold by opening the AC disconnect to the Ride Thru module if equipped Refer to Section 4 4 e The DC bus voltage should drop until it reaches the threshold e Ride Thru Active LED should begin to flash e DC bus should hold for a second at the threshold e This threshold level should be 10 30 volts below the nominal loaded inverter bus To verify Threshold using the test feature refer to step 5 and see the Threshold Voltage Adjustment Procedure in Section 4 4 4 Re apply AC power to Ride Thru after the Pre charge Complete LED turns OFF 400VDC Allow time to pre charge then re verify steps 1 4 e If Power LED will not turn back on turn power off and allow 5 minutes for internal thermistors to cool Then re apply power Each Bonitron Ride Thru should be tested under load during initial start up to verify the functionality of the test circuit and that the test does not negatively affect the process However Bonitron recommends that if the process is critical the test cycle be initiated only during a shutdown to avoid unforeseen problems 5 Verify switching circuits by initiating the Test sequence while running the inverter at full load e Ride Thru should not have AC power when inverter does not e Ride Thru DC bus current should flow during the 2 second test cycle
20. Connections for Cabinets TERMINAL ELECTRICAL MAX WIRE TORQUE TYPE FUNCTION SPECIFICATIONS Edad LB IN Disconnect Switch Disconnect Switch Stud Ring Lug 3 8 Terminal Ring Lug AC Input DC Output Les 600VAC x Amps EH 3 0 150 Ib in Limited by Limited by DC Input 480VDC 600 Amps 10 4 0 150 Ib in Table 3 2 Power Field Wiring Conn for Open Backplates and Cabinets over 125kW TERMINAL ELECTRICAL MAX WIRE TORQUE TYPE FUNCTION SPECIFICATIONS MEE LB IN 3 8 Terminal Ring Lug 3 8 Terminal Ring Lug Stud or 3 8 Terminal Ring Lug 3 8 Terminal Ring lug on rectifier bus bars AC Input Limited by Limited CAA N 100V Amps RingLug Ring Lug ET Ib in Drive Box DC Output 1000V 600 Amps piss by Limited by m ing Lug Ring Lug Limited by Limited by a Cap Bank DC in es Input 1000V 600 Amps E av 75 lb in S g Lug g Lug 13 M3460R and S3460SR Figure 3 4 Typical Cabinet Field Connections 100kW and below 125kW and above p LINE INPUT L2 L3 DC Bus AC LINE oon NEGATIVE L3 GND 11 L2 14 Dwg F39 Field Wiring jpg Rev 20060220 User s Manual ions with M6 Field Connecti IS l Open Chass Ica T ure 3 6 Fi INT 9 ov v anya 9 sna s sna NOILO3NNO
21. Separate MCC breakers 5 19 Figure 3 11 3460M6 Remote Control and Status Signals sse 20 Figure 3 12 Example of Shunt Trip Wiring sese nennen 21 3 42 Control Interface Wiring asisten eR AGRIC ERIGI e 6304 Uere es 22 Table 3 3 Cabinet Systems iiie nene e E ERG ER 23 Table 3 4 Open Backplate ener 23 Table 3 5 Open Backplate Modules with Digital Display sese 23 Figure 3 13 Basic Fault Contact Wiring to Control 23 3 5 Eypical Configurations s mue ee dece en ae nOn Ere S e 24 Figure 3 14 3460R Ride Thru System Configuration 24 Figure 3 15 3460UR Ride Thru System Configuration 2 24 Figure 3 16 3460R Ride Thru System Configuration 21 sse 25 Figure 3 17 3460R Ride Thru System Configuration 23 25 4 Table of Contents OPERATION 4 1 Functional Description ne n enne enr BERE nnne 27 ee Eee e EA ede de E a 28 4 2 1 Indicators Control Signals for Standard Models sse 28 Table 4 1 Control Signal Specifications eene 28 Table 4 2 3460M6 Control Input Interface I O Signal Logic Jumper 5
22. a single Ride Thru See Fig 7 e use of individual input harmonic filters or line chokes can cause unequal potentials with respect to earth 4 connection should be downstream of any input line filter See Figure 7 2 e Input line filters cause lower DC bus levels If a Ride Thru is placed upstream the Ride Thru DC bus will be higher than the drive bus and energy will flow full 69 M3460R and S3460SR time out of the Ride Thru module which may cause constant activity and overheating Special SCR input models are available for applications where a downstream connection point is not available e t may be necessary to lower the threshold for these applications 5 Ground Fault sensing should be done upstream at common point of line connection upstream of line filter if used See Figures 7 2 and 7 3 Figure 7 1 Ride Thru System Configuration 19 BOOST REGULATOR DC LINK lt 3 PHASE 2 SECOND 50 SAG PROTECTION FOR EQUIVALENT DRIVES WITH EQUAL LOADS USING DC BOOSTER AND DIODE ISOLATION Figure 7 2 Diode Sharing With Individual Line Chokes SPECIAL REQUIREMENTS NEEDE ECOMMENDE FC CC SSING DR ITH INDIVIDUAL LINE CHOK 70 Dwg s 070241 20080604 and 080120 Rev 20091105 User s Manual Figure 7 3 Diode Sharing With Equivalent Drives
23. e DC bus should hold for a second at the threshold e This threshold level should be 10 30 volts below the nominal loaded inverter bus To verify Threshold using the test feature refer to step 6 and see Section 4 4 Re apply AC power to Ride Thru after the Pre charge Complete LED turns off 400VDC Allow time to pre charge and then re verify steps 1 4 e If Power LED will not turn back on turn power off and allow 5 minutes for internal thermistors to cool Then re apply power Each Bonitron Ride Thru should be tested under load during initial start up to verify the functionality of the test circuit and that the test does not negatively affect the process However Bonitron recommends that if the process is critical the test cycle be initiated only during a shutdown to avoid unforeseen problems 6 Verify switching circuits by initiating the Test sequence while running the inverter at full load e Ride Thru DC bus current should flow during the 2 second test cycle e Inverter input current should drop e Ride Thru DC bus voltage should rise to approximately 100VDC above the threshold e Inverter DC bus voltage should rise to approximately 100VDC above the threshold Motor speed should remain constant e Active cycle counter should count test cycles 50 User s Manual 5 2 MAINTENANCE ITEMS 5 2 1 CAPACITOR REPLACEMENT RECOMMENDATIONS 5 2 1 1 5 2 1 2 5 2 1 3 CAPACITOR REPLACEMENT CRITERIA Bonitron Model 3460
24. igure 3 17 3460R Ride Thru System Configuration 2 3 PHASE DC LINK 3612 COMMON BUS DC INPUT VFD 3 POWER SUPPLY DC INPUT DC INPUT VFD VFD 3460R BOOSTER ULTRA CAP RESERVOIR CHARGE 0 SL i REGULATOR gt lt gt lt gt lt ISOLATION TRANSFORMER EL MOTOR CONTINUOUS COMMON DC BUS POWER SUPPLY WITH SHORT TERM 100 OUTAGE PROTECTION USING DC BOOSTER WITH ULTRA CAP RESERVOIR Dwg s 070319 080224 Rev 20080604 25 M3460R and S3460SR This page intentionally left blank User s Manual 4 OPERATION 4 1 FUNCTIONAL DESCRIPTION The M3460R Ride Thru module consists of three basic sections the Rectifier section Boost Converter section and Control Power Supply Each of these three sections is described below RECTIFIER SECTION The Rectifier Section of each slave module converts the 3 phase AC line to a nominal DC bus This section contains the input Rectifier Bridge DC bus filter capacitors and pre charge circuitry for standard systems Upon application of power the pre charge circuitry will commence charging the primary bus capacitors through their pre charge resistors e For SCR front end systems upon application of power and a 24V ENABLE command the 3460B3 pre charge circuitry will commence charging the primary bus capacitors through their pre charge resistors Pre charge cannot begin unless the ENABLE command is present Removing the ENABLE command will
25. switch as fast as is needed to keep the DC bus at the preset level When the maximum switching frequency is reached the DC bus will drop When the DC bus drops below 400VDC the run relay will drop out and the bus chopper will stop switching An over voltage condition on the DC bus approximately 750VDC will cause the Ride Thru section to shut down The Ride Thru Section will be re enabled once the DC bus voltage drops below approximately 725VDC If a chopper circuit output fuse should fail an indicator on its corresponding Blown Fuse Detector will be engaged and the Ride Thru Ready signal will turn OFF indicating a fault The Ride Thru will continue to operate at a diminished capacity in this fault condition CONTROL POWER SUPPLY SECTION Control power is derived from the DC bus via the 3460D5 DC DC power supply board Voltage for the RUN and TEST contacts is derived from an isolated supply on the 3460D5 board All control voltages are maintained under all specified sag conditions 27 M3460R and S3460SR 4 2 FEATURES See Section 2 1 for a synopsis of unit features 4 2 1 INDICATORS CONTROL SIGNALS FOR STANDARD MODELS Several control inputs and status outputs are provided for the Ride Thru system With the exception of the disconnect status contact the 3460M6 Status Interface Board receives monitors and reports all of the various Ride Thru system status and control signals Each of these signals is described in detail he
26. tete Da Febr ete 9 32 02 Open Chassis Units cedem ertet ee dee re ede Re Rd dee R E T ER ede Lnd 9 3 32 Moutinho EE 9 33 17 T ato b pe RENA e ege 9 332 Open Chassis Utits eI ESI o EE ED ee etie 9 Figure 3 1 Typical 7 5 Digital Display Panel Mounting Dimensions 10 Figure 3 2 Typical 3 6 and 6 Diagnostic Display Panel and Mounting Dimensions 11 Figure 3 3 Typical 12 Diagnostic Display Panel and Mounting Dimensions 11 3 4 Wiring and Customer nnne ener enn enn en 12 SAN Power Wiring onse autre ie 12 Table 3 1 Power Field Wiring Connections for Cabinets sse 13 Table 3 2 Power Field Wiring Conn for Open Backplates and Cabinets over 125kW 13 Figure 3 4 Typical Cabinet Field Connections 14 Figure 3 5 F39 Cabinet Field Connections essere enne 14 Figure 3 6 Typical Open Chassis Field Connections with 15 Figure 3 7 Typical Ride Thru Field Connections with DD3 Display 16 Figure 3 8 Recommended Ground Fault Sensing essen 17 Figure 3 9 3460 Power Wiring with Disconnects essere nennen 18 Figure 3 10 3460 Power Wiring from
27. the switch is pressed If the 3460C1 test time jumper J4 is set to INT the DC bus sag setpoint will remain raised for 2 seconds If this is done under load time out will occur in 2 seconds The DPxx series display test button may be disabled by placing ASB 3660D jumper J1 in the B position See Fig 4 1 This test provides positive proof of Ride Thru readiness This test is also useful during field calibration of the Threshold Voltage See Section 4 4 STATUS OUTPUTS The 3460M6 Status Interface board provides a pair of output signals 1 local 1 remote for each of the individual Ride Thru status signals as well as for a multiplexed fault output Each pair of contacts is rated at 350VDC 120mA output contacts are jumper selectable for normally open or normally closed conditions to provide proper logic state Local outputs are provided for display purposes and are routed from the 3460M6 via TB6 to the DP Series Diagnostic Display panel Remote outputs are provided for use with a Control Room interface or other control scheme and are routed from the 3460M6 via TB5 Refer to Table 4 3 and Figure 4 2 for details 28 User s Manual VOLTAGE FAULT L VF amp R VF The Voltage Fault signal is generated by the 3460X4 Phase Loss Monitor board and passed to the 3460M6 Status Interface board This contact will OPEN if any single phase of the AC line is missing This output is provided on the 3460M6 mux board for field conn
28. whichever is greater This setpoint should be a minimum of 25V below Threshold to avoid improper OUV fault activity Please note that not all models are wired to utilize the Output Under Voltage fault Table 4 9 below lists the typical factory setpoints for the Threshold Low DC Bus OUV and Test Boost levels for the Model M3460 Ride Thru modules based on the system AC or DC input voltage requirements Be sure to check this manual for each Ride Thru module for specific setpoint levels Table 4 10 Factory Setpoints for Threshold and Test Boost Voltages NOMINAL INPUT MINIMUM INPUT Low DC Bus 230VAC line 1 260VDC 50VDC 4 4 1 DETERMINING THE THRESHOLD VOLTAGE SETPOINT Testing and adjustment of the Threshold voltage setpoint can be performed on systems in either an On line and loaded or an Off line and unloaded condition as described in methods 1 and 2 below Each of the two methods described require that you monitor the DC bus voltage during the testing and adjustment procedures Be sure to read through both adjustment methods completely before attempting any adjustment of the Threshold and Low DC Bus voltage setpoints METHOD 1 DETERMINING THE THRESHOLD VOLTAGE SETPOINT FOR AN ON LINE AND LOADED SYSTEM 1 Verify proper installation e Ensure that the Bonitron Model M3460 Ride Thru module has been properly installed and wired according to all applicable system and module wiring di
29. 10 below the nominal DC bus under load and coordinated to be above the associated inverter s under voltage trip level Most inverters have an under voltage trip point of approximately 1596 below the nominal DC bus under load Some inverters can be reprogrammed to change this trip level as needed Adjustment pot R7 on the 3460C1 Control Board see Figure 4 5 is used to set the Threshold voltage level Adjusting the pot in a clockwise direction will raise the setpoint level by approximately 5 5 volts per revolution of the pot adjustment screw Alternately a counter clockwise adjustment of the pot will lower the setpoint level The Threshold setpoint level can be adjusted to approximately 35VDC of the factory setpoint listed in Table 4 9 Adjustment pot R3 on the 3460D5 Power Supply Board see Figure 4 7 is used to set the Low DC Bus voltage level Adjusting the pot in a clockwise direction will raise the setpoint level by approximately 5 5 volts per revolution of the pot adjustment screw Alternately a counter clockwise adjustment of the pot will lower the setpoint level Be sure to match any adjustment made to the Threshold voltage level Please note that not all models are wired to utilize the Output Under Voltage fault which is used in systems with kinetic buffering signal 45 M3460R and S3460SR After making the adjustments repeat the test from Section 4 4 1 to verify the new setpoint Fine tune the adjustment and ret
30. 10 Normally OPEN N O TB5 7 8 30 User s Manual Figure 4 1 3660D1 DP Series LED Display Test Switch Test Jumper 1 RESET 5 3V 4 21144 1 x ES IR Bed fen oet Jie TESTIRA Je x Cree M3460R and S3460SR Figure 4 3 3460M6 Status Interface Board Layout and Jumper Positions 32 Dwg 090187 Rev 20090923 ITH J ITION SITION INITIATES N THE OSITION JI TIONS 2SITIO THE N C TEST INITIATES 4 4 ITH OLATION IT FC User s Manual Figure 4 4 36601 Digital Display Board Layout NOILISO OLLISO t Va HT HLI HLI 33 Dwg 100031 Rev 20101014 M3460R and S3460SR 4 2 2 DISPLAYS 4 2 2 1 DIAGNOSTIC DISPLA
31. 205 47 M3460R and S3460SR 5 1 2 8 Temporarily remove the full voltage supply When the DC bus drops to the Ride Thru setpoint level the Ride Thru should become active and attempt to keep the DC bus at the setpoint level Reapply full voltage within 2 seconds e If the Ride Thru is active for more than 2 seconds it will shutdown switching and the DC bus will drop to the normal rectified level e If the DC bus drops below 70 the Ride Thru will have to go through pre charge again e The Ride Thru should not be run at full power for more than 6 seconds every 10 minutes e The Drive under voltage shutdown and the maximum motor voltage should be considered for setting the Ride Thru threshold setpoint Refer to Section 44 This completes the test procedure PERIODIC MAINTENANCE PROCEDURES FOR M3460R WiTHOUT OPTIONAL DIAGNOSTIC DISPLAY PANEL The Bonitron Ride Thru is designed to be low maintenance While the amount of Ride Thru time does not depend on energy storage devices that degrade over time Bonitron still recommends a yearly test of the system in order to ensure the electronics package is operating The following steps can be taken to ensure reliability and give comfort that the system is still able to Ride Thru a sag event 1 Monitor 3460C1 Control Board LEDs e LED 6 15V should be LED 7 15V should be ON e LED 4 PCC should be e LED 3 RTR should be ON All other 3460C1 LEDs should be OFF
32. 22 14 2lb in sensing input Fiqure 3 13 Basic Fault Contact Wiring to Control Room MAX EE 20mA 24VDC 20mA 24VDC 120mA 350VDC 120mA 350VDC 120mA 350VDC TB5 amp TB6 TB5 amp TB5 amp TB6 TB5 amp TB6 120mA 350VDC TB5 amp TB6 TB5 amp TB6 120mA 350VDC 120mA 350VDC 20mA 24VDC 20mA 24VDC 120mA 350VDC 120mA 350VDC 1mA 1000VDC TO CONTROL ROOM INVERTER ose 1 j BONI TRON RI DE THRU raur f 5220 4 f raur 1 Dwg 990036 Rev 20011108 23 M3460R and S3460SR 3 5 TYPICAL CONFIGURATIONS Fiqure 3 14 3460R Ride Thru System Configuration 1 AC LINE 3 PHASE 2 SECOND 50 SAG PROTECTION USING DC BOOSTER ONLY Figure 3 15 3460UR Ride Thru System Configuration 2 ULTRA 3460 BOOST ISOLATION TRANSFORMER RESERVOIR REGULATOR FAST DISCHARGE CHARGER 3 PHASE ABOVE 50KW 0 5 2 SECOND 100 OUTAGE PROTECTION USING DC BOOSTER WITH ULTRA CAP RESERVOIR SINGLE CABINET POWERED FROM AC LINE 24 Dwg s 040201 and 040202 Rev 20080604 User s Manual Figure 3 16 3460R Ride Thru System Configuration 21 BOOST REGULATOR gt gt gt gt lt lt lt lt A 41 410 1 SLAVE geo MASTER CONTROL AC LINE 3 PHASE 2 SECOND 50 SAG PROTECTION USING MULTICABINET DC BOOSTERS F
33. 270V 15 of 270 40 5V cap 1 290V cap 2 250V 4 Remove power and replace both capacitors CLEANING t may be necessary to clean off dust debris or chemical build up on high voltage bus bars or other exposed components If cleaning is needed Remove power and allow all voltages to drain Check for residual voltages with meter e Clean affected areas with rag brush or denatured alcohol depending on the type of contamination Once area is clean dry reapply power 51 M3460R and S3460SR 5 3 TROUBLESHOOTING SYMPTOM No LEDs Table 5 1 Troubleshooting Guide Check incoming power Check power supply 3460D5 for all voltages replace if incorrect Check 24V RUN command Check power supply 346005 for all voltages replace if incorrect 15 or 15 LEDs it OK then replace 3460C1 control PCB No RTR No PCC Voltage Fault RTA always ON RTA never ON Blown Fuse LED ON Check for RUN command Check stage fuses look for blown fuse LED on 3460C1 Check 3460M6 interface IF OK replace 3460C1 control PCB Check DC bus level if not OK check pre charge circuits or bus caps Check for RUN command Check stage fuses look for blown fuse LED on 3460C1 Check 3460M6 interface F OK replace 3460C1 control PCB Check input fuses Check 3460 4 phase loss monitor Check 3460M6 interface Check DC bus levels on both sides of diodes Check for overheated pre cha
34. 60C1 Check threshold and test boost level settings Over voltage shutdown can occur if settings are too high on 460V systems causing an oscillation affect Lower threshold level and retry Check for loss of feedback from DC bus to 3460C1 Stays in TEST mode Replace 3460C1 Check DC bus ripple voltage Too much ripple can cause PTCRs to overheat Add parallel pre charge PTCRs Change series pre charge resistance Add fan to cool PTCRs Add isolated bias supply Precharge can only be done consecutive times before overheating can occur 53 M3460R and S3460SR Figure 5 2 Diagnostic Signal Connections with M6 12 and DP17 54 Dwg 080194 Rev 20010112 User s Manual Figure 5 3 Diagnostic Signal Connections with M6 and DP10 5 42 m on ws we E Eee zu w D s L
35. ACE PCB ON IUV FAULT Pos Manual Pos Pos A Manual Pos B Auto 4 2 2 2 4 DD3 DISPLAY JUMPER POSITION DESCRIPTIONS The following jumpers are located on the 36601 interface pcb mounted on the boost module connected to display panel via 16 pin ribbon cable e J2 7 Program enable Off to program during normal operation e J11 Test Mode enable On to enable local or remote test OFF to disable e J1 J14 Control mode selection Pos A for manual shutdown mode Pos B for automatic shutdown mode e J15 Run command logic state Pos A for 24V to enable booster Pos for OV no enable connection to enable booster 4 2 2 2 5 FACTORY SET UP WHEN USING DD3 DISPLAY MODULE RUN COMMAND Factory set for operation without external input command J15 in the B position CoNTROL MODE Factory set for automatic shutdown with IUV disabled from front panel J1 and J14 in the B position and display programmed to ignore IUV for auto shutdown 39 M3460R and S3460SR 4 3 STARTUP PROCEDURE 4 3 1 PRE POWER CHECKS 1 2 4 Ensure the Bonitron Ride Thru has been properly installed as per the instructions in Section 3 of this manual The Ride Thru DC bus threshold must be coordinated with the under voltage trip setting of the inverter If the threshold is too close to the nominal bus the Ride Thru may supply power to the drive continuously and overheat
36. Charger Isolation 001 010 en ieS K enne nnne 45 74 7 B 11576 161872 A NENNEN 76 7 5 Quick Set up Guide for 3460 Electrolytic Cap Component 76 LS gt gt E ces oc R D odia lr ee 76 1 59 27 eet ee reae bet ie or repe feto tee e per Eesti 76 7 5 3 Electrolytic Cap Bank iae erret esee T LAA Blocking Diode ette etes t ein ale fie 77 71355 ACHAT OIG e IH d Nl e M de ade ms 77 7 9 6 e E eed 77 User s Manual 1 INTRODUCTION 1 1 1 2 1 3 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 PURPOSE AND SCOPE This manual is a user s guide for the Model S3460SR and M3460R Ride Thru systems It will provide the user with the necessary information to successfully install integrate and use these 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 p
37. DARD MODELS Booster modules systems status monitoring can be made at TB5 on the 3460M6 interface circuit board See Table 3 4 for technical specifications See Figure 4 2 for interface board M3460R DIGITAL DISPLAY Booster modules control connections can be made at TB2 on the 366012 interface board See Table 3 5 for technical specifications See Figure 4 2 for interface board and suggested wiring For systems using external Ultra Capacitor energy storage AND Digital Display make cap bank voltage monitoring connection to the 3660 2 interface board as shown in Figure 4 4 User s Manual Table 3 3 Cabinet Systems Connect to top of cabinet backplate TERMINAL TERMINAL ELECTRICAL Sak 2 5 Disable input 20mA 24VDC Sak 2 5 Active output 120mA 350VDC MIN WIRE Sak 2 5 Ready output 120mA 350VDC Sak 2 5 Fault output 120mA 350VDC Sak 2 5 Aux output 1A 460VAC Table 3 4 Open Backplate Modules Connect to M3460M6 PCB of Booster Module TERMINAL TERMINAL ELECTRICAL Funcrion TERMINAL ELECTR Phoenix Plug Enable Disable input Fault output Ready output Active output Phoenix Plug PCC Pre charge Complete Phoenix Plug OT 22 14 2lb in Temperature Voltage Fault Table 3 5 Open Backplate Modules with Digital Displa Connect to M366012 PCB of Booster Module TERMINAL TERMINAL ELECTRICAL MAX FEE m 14 SPECS Phoenix Plug Disable 2 Ib in input Phoenix Plug Saprbanicvellage
38. ER The Base Model Number for all Open Chassis Ride Thru Modules is M3460R The Base Model Number for all Enclosed Ride Thru Modules is S3460SR SOURCE VOLTAGE RATING The Model M3460R Ride Thru is available in several input voltage ratings This rating is indicated by a code number as shown in Table 2 1 Table 2 1 System Voltage Rating Codes CODE NoMINAL AC LiNE DC BUS 230VACLie 320 VDC E 400VAC Line 565VDC umm j 460VAC Line 640VDC I p i 575VAC Line 805VDC POWER RATING KW The Power Rating indicates the maximum power in kilowatts that can safely be handled by x3460 models and is directly represented by a 3 digit value based on the nominal DC system voltage rating and the maximum output current rating of the RTM For instance the rating code for a 150kW RTM is 150 User s Manual CHASSIS SIZE OR CABINET TYPE The Model M3460R Ride Thru is available in three open backplate chassis sizes and the 3460 is available in several cabinet styles The size and type is indicated by a code as shown in Tables 2 2 and 2 3 Table 2 2 Chassis Codes for M3460R Models 34 Hx16 Wx14 D asago open chassis backplate M Hx 16 Wx M D 1 or stage open chassis backplate s75kW __ fae Hx16 Wx14 D open chassis backplate gt 1006W Table 2 3 Cabinet Codes for S3460SR Models 52 sZ talix 37 wide x 167 deep Type 12 wal mount cannet x 37 wide x 16 de
39. IR drop of wire It is NOT necessary to size wire for continuous duty Maximum allowed duty cycle for the M3460R Ride Thru is 2 seconds on at full load followed by 200 seconds off Steady state Class J Time Delay or equivalent power source fusing should be used to support the requirement for 2 second 2x surge capability The recommended minimum current rating for the power source fusing is listed in Table 6 3 below based on the DC bus current rating of the Ride Thru module The maximum rating of the steady state power source fusing should be lt 225 amps for cabinets with disconnects The field wiring sizes listed in Table 6 3 below assure a lt 10V drop for wire lengths of lt 100 feet and are compatible with the recommended steady state power source fusing listed The wire gauge selected for field wiring to the Ride Thru should be equal to or greater than that listed in Table 6 3 The maximum wire gauge that can physically be accepted by disconnects within cabinet mounted systems is 4 0 All M3460R units are certified by UL to be suitable for use on a circuit capable of delivering not more than 10 000 RMS symmetrical amperes 700 volts maximum when protected by fuses recommended in Table 6 2 Use copper wiring rated 75 or equivalent for field wiring terminals These devices do not provide motor overload protection Table 6 3 Input Power Wiring Sizes and Fusing SYSTEM RIDE THRU MIN SOURCE RECOMMENDED MCM kW DC Bus CURRENT FUSING CLASS J
40. Most cap cells can be short circuited so ESR determines max available current for one discharge Joules 1 2 x C x V squared or power in watts x time in seconds Capacitance 2 x J V squared 68 7 3 User s Manual BUILD CAP BANK 1 Choose the highest voltage Cap building blocks available 2 Series cap modules so total voltage is above booster minimum input typically 5096 of nominal DC bus and below booster threshold level typically 10 of nominal DC bus 3 Calculate current needed by dividing needed KW by booster minimum input voltage and ensure cap module can supply the current 4 Add parallel strings to increase available current or choose different cap 5 Calculate ESR voltage drop from needed current at minimum voltage and capacitor ESR rating 6 Add worst case ESR drop to the min Ride Thru input voltage This is the minimum cap bank voltage for calculation purposes 7 Calculate available joules between charged cap voltage and the above calculated min cap bank voltage This is the available joules that can be used e Figure initial voltage See Step 2 below booster threshold Figure Capacitance of series or series parallel bank Figure initial joules based on initial voltage and above Farad calculation Figure final voltage See Step 2 above booster minimum Figure final joules based on final voltage and above Farad calculation Find available or usable joules by subtracting final joules St
41. NOT HAVE the Precharge Hold off Option installed Apply power to the Ride Thru and observe the following conditions on the Digital Display panel Power LED should be ON e Ride Thru Active LED should be OFF e Voltage Fault LED should be OFF e The Bus Current Meters should read 0 amps The Bus Voltage Meters should read NOMINAL DC Bus voltage with Input slightly higher than Output 3 Verify Control Room Connections if used Control Room should read the Ride Thru Fault 1 and Fault 2 signals as found in the Section 4 2 e Unplug 36601 connector and insert jumper into plug end to simulate fault See Figure 4 3 for connection details 4 Verify threshold setpoint e Turn off system power and watch the DC bus voltage fall Refer to the Threshold Adjustment procedure in Section 4 4 e Ride Thru Active LED will come ON when the bus drops to the threshold e The DC bus will hold at the threshold momentarily Allow the DC bus to discharge until the PCC LED on the display panel goes OFF Reapply system power 5 Verify system capability Monitor DC bus voltage and DC bus current or inverter AC line current e Initiate the Test sequence See Digital Display manual to navigate to the test screen Ride Thru Active LED on Digital Display should come ON during test 3460C1 Control Board LED 1 TEST should come ON during test Bonitron DC bus voltage should rise to the test boost level e Inverter DC bus should rise to the test boost
42. O HOLIOVdvO n POS BUS NEG BUS AYVA LON THM SNOLLVNIIAS3 L A1LNV LSNOO d3SN 34V NMOHS SQHVOS JHL H3A3MOH SISSVHO NO AHVA TIIM NMOHS SQHNVOS LIN9YI9 JHL JO SNOLLISOd SHL 31V33dO OL LNAdNI 1 5 NOH SAVH LSNW W31SAS 1 49 o o of 3 ee e le SLE Bcc 4 A FI 4 5 BEI e laki O OBE 5 as zs 2 7 gr 5 O oe LL Del Fere Ha CERO do E SS S leo F G 5 n E jose L Le o o 6585555655625 2555655556 o E IR ERR UN HD JO S GR TR RR RR
43. O3S 33S Dwg 090346 Rev 20101015 16 Fiqure 3 8 Recommended Ground Fault Sensing IDE THRU ERTE ED F ES E ra 3E THER CT T CENTE S TIE Dwg 050163 Rev 20080723 User s Manual 17 M3460R and S3460SR Figure 3 9 3460 Power Wiring with Disconnects ME NOTES RIDE THRU SHOUL SFO AME FEED TRA THE 1 INVERTER FROM 18 Dwg 010175 Rev 20070912 THAT RIDE THR ER ONNECT lt VE JE PC F RIDE THR T JSED 5 IF LINE CHOKES OWNS User s Manual Figure 3 10 3460 Power Wiring from Separate MCC breakers SCR KES H F THE LINE T HAVE STE TREA OOSTER IF THE BOC THE ABINET E Dwg 080467 Rev 20081119 19 M3460R and S3460SR Figure 3 11 3460M6 Remote Control and Status Signals ur LI 4 gt lt Y 2 pr
44. R Ride Thru uses high quality aluminum electrolytic capacitors and is designed for long life without maintenance While a typical inverter may require capacitor replacement after a certain time due to the heavy ripple currents the M3460 typically is in a standby mode waiting for a power disturbance and by design has 5096 more capacitance than needed The capacitor manufacturer has given a rating of 11 years MTBF if ambient temp is 50 C capacitors are held at 10096 rated voltage and caps run full ripple current at 196 duty With typical operating conditions of 35 caps running at 75 rated voltage and a duty cycle of one sag per month Bonitron recommends the capacitors be checked or replaced every 20 years The recommended test is to measure the voltage across each series set of capacitors Any voltage difference greater than 1596 between each set of series caps would indicate a change in value in one cap and would constitute a more detailed out of circuit capacitance check A difference of 596 is allowed at time of production CAPACITOR TESTING PROCEDURE 1 Remove power to unit and wait for DC bus to drain 2 Install Gate drive board extension cables to allow the top panel door to open exposing the capacitor bank 3 Re apply power and measure voltage across each cap and make note for future reference e Any voltage difference more than 15 indicates a substantial change capacitance Example DC bus 540V each series cap
45. Ready signals from the system can be combined to provide a pair of multiplexed fault contact outputs If any of the three multiplexed signals indicates a problem the Fault output will OPEN after a 3 second delay This output is provided on the 3460M6 mux board for field connection at TB5 7 8 and for the display panel TB6 1 29 M3460R and S3460SR Table 4 2 3460 6 Control Input Interface Signal Logic Jumper Details 3460M6 CONTROL SIGNAL INPUT LOCAL FIELD INPUTS DESIGNATION REMOTE FACTORY SETTING TERMINALS RUN Command J15 J16 TB7 1 2 Disable Normally CLOSED CLOSED N C Local Table 4 3 3460M6 Status Output Interface I O Signal Logic Jumper Details REMOTE STATUS OUTPUT LOGIC STATE JUMPERS pe IGNAL REMOTE SIG DESIGNATION o JUMPER FACTORY SETTING TERMINALS Local J5 Normally CLOSED N C 6 3 Voltage Fault Remote 46 Normally N O TB5 56 Local J3 Normally CLOSED N C 6 4 Over Temperature Remote Normally OPEN TB5 34 L PCC Local Normally OPEN N O TB6 2 R Remote J8 Normally OPEN N O TB5 9 10 LRTA RTA Local J13 Normally OPEN N O TB6 6 Ride Thru Active T RTR RTA Remote Normally OPEN N O TB5 11 12 L RTR RTR Local Normally OPEN N O TB6 5 Ride Thru Ready RTR Remote Normally OPEN N O TB5 1 2 L LFAULT Local none CLOSED N C TB6 1 Multiplexed Fault R FAULT Remote J
46. Review this entire Section before attempting to wire the Ride Thru module 3 4 1 POWER WIRING High voltages supplied to the Ride Thru include the input AC power and output DC bus These voltages are derived from different sources Each source must be separately disconnected and verified zero potential before servicing N Additionally the Ride Thru internal DC bus retains a hazardous voltage for several minutes after the input power has been disconnected Wait at least five CAUTION minutes after disconnecting power to allow the DC bus to discharge and then verify zero potential before servicing Failure to observe these precautions could result in severe bodily injury or loss of life This section provides information pertaining to the field wiring connections of the M3460R and S3460SR Ride Thru Cabinet System Actual connection points and terminal numbers of the AC Drive system will be found in the documentation provided with that system Be sure to review all pertinent AC Drive System documentation as well as the RTM to Drive Interconnection details listed below before proceeding 3 4 1 1 SYSTEM WiRING RTM To DRIVE INTERCONNECTIONS Several illustrations are provided to assist with the field connection of the 3460 Ride Thru System to an existing AC drive system Also be sure to refer to the documentation supplied with the drive system for field connection points within that system The DC bus must always be directly connected to th
47. Y PANEL OPTIONAL The Ride Thru Diagnostic Display Panel provides visual indication of the Ride Thru module s operating status and also permits a system test to be performed Currently there are several display panel configurations available with various combinations of features as detailed in Table 4 4 and Figure 4 5 Table 4 4 Diagnostic Display Panel Configurations PANEL LEDS amp TEST METERS _ COUNTERS PANEL NUMBER WITCH DiMS pe v v 5 DP17 5 x 12 7 5 x 5 Figure 4 5 Display Panels 2 2 POWER POWER s PRECHARGE PRECHARGE COMPLETE COMPLETE e RIDETHRU RIDETHRU READY READY 1 RIDETHRU ACTIVE RIDETHRU ACTIVE ACTIVE CYCLES VOLTAGE FAULT VOLTAGE FAULT SYSTEM OVERTEMP TEST SYSTEM BUS CURRENT BUS VOLTAGE POWER PRECHARGE COMPLETE O e r 2 RIDETHRU READY TOTAL RTA CYCLES RIDETHRU ACTIVE VOLTAGE FAULT OVERTEMP V NO y ACTIVE CYCLES TEST 34 4 2 2 1 1 4 2 2 1 2 User s Manual SYSTEM LED STATUS DISPLAY BOARD FOR ALL DPxx DISPLAYS The System Status Display module provides visual indication of various system functions The monitored functions include POWER PRECHARGE COMPLETE RIDE THRU READY RIDE THRU ACTIVE VOLTAGE FAULT OVERTEMP addition this mod
48. a 5 Dwg 090292 Rev 20100409 59 M3460R and S3460SR Figure 5 4 Diagnostic Signal Connections with 353412 amp DP17 56 Dwg 090311 Rev 20100614 User s Manual lon Flow with DP Opti igna M3460R Basic S ure 5 5 Fi 57 Dwg 030018 Rev 20090515 M3460R and S3460SR Figure 5 6 M3460R Basic Signal Flow with SCR Bridge Dwg 080461 Rev 20090515 58 6 ENGINEERING DATA 6 1 RATINGS CHARTS PERFORMANCE CURVES Table 6 1 2 second 50 kW Ratings Table C Amps systems systems systems systems systems systems a 4 43 45 47 120 e 65 amp 75 9 0 87 90 10 135 25 125 130 135 141 150 187 340 165 175 180 188 200 250 215 225 235 250
49. adjustable from 440 540 50 o o VOLTAGE 580 500 adjustable from 440 540 640 585 adjustable from 525 625 805 710 adjustable from 650 750 User s Manual 2 4 GENERAL PRECAUTIONS AND SAFETY WARNINGS HIGH VOLTAGES MAY BE PRESENT e NEVER ATTEMPT TO OPERATE THIS PRODUCT WITH THE ENCLOSURE COVER REMOVED NEVER ATTEMPT TO SERVICE THIS PRODUCT WITHOUT FIRST DISCONNECTING POWER TO AND FROM THE UNIT ALWAYS ALLOW ADEQUATE TIME FOR RESIDUAL VOLTAGES TO DRAIN BEFORE REMOVING THE ENCLOSURE COVER FAILURE TO HEED THESE WARNINGS MAY RESULT IN SERIOUS BODILY INJURY OR DEATH DANGER CERTAIN COMPONENTS WITHIN THIS PRODUCT MAY GENERATE HIGH AMBIENT TEMPERATURES DURING OPERATION 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 CAUTION 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 THIS PRODUCT DOES NOT PROVIDE MOTOR OVERLOAD PROTECTION ANY QUESTIONS AS TO APPLICATION INSTALLATION OR SERVICE SAFETY SHOULD BE DIRECTED TO THE EQUIPMENT SUPPLIER M3460R and S3460SR 2 5 INTEGRATION RECOMMENDATIONS FOR BATTERY POWER SOURCE RIDE THRU SYSTEMS To p
50. ady to run automatically upon power up and a 24V command will inhibit boosting TO BYPASS THIS SAFETY FEATURE FOR MODELS WITH DIGITAL DISPLAY e Change display from automatic to manual mode e Place display in Manual control mode by ensuring jumper J14 is in the A or up position e Bypass or remove factory installed jumper wire from Fault 2 output See Section 4 2 4 1 Change external run command from Enable to Disable Factory set for Enable e On the 366012 interface board ensure jumper J15 is in the B or down position The unit will be ready to run automatically upon power up and the external 24V command will inhibit boosting It is strongly recommended that the safety feature not be bypassed f it is bypassed it is strongly recommended that the faults be monitored and action be taken immediately upon receiving these faults User s Manual 3 INSTALLATION INSTRUCTIONS See Installation Considerations in Section 7 3 1 ENVIRONMENT The maximum operating temperature of the Ride Thru system should not exceed 40 C Non condensing filtered air may be required to cool the system 3 2 UNPACKING 3 2 1 CABINET UNITS 1 Inspect the outer packaging of the Ride Thru cabinet for shipping damage Notify the shipping carrier if damage is found 2 Remove the banding and outer packaging from the cabinet e DO NOT remove the hardware securing the cabinet to its pallet 3 Inspect the Ride Thru cabinet for shipping damage or loos
51. age meter e Ride Thru bus should be about 10 35V DC below the Inverter bus 5 Verify Threshold by opening the AC disconnect to the Ride Thru module if equipped Refer to Section 4 4 e The DC bus voltage should drop until it reaches the threshold e Ride Thru Active LED should begin to flash e DC bus should hold for a second at the threshold e This threshold level should be 10 30 volts below the nominal loaded inverter bus To verify Threshold using the test feature refer to step 6 and see Section 4 4 Re apply AC power to Ride Thru after the Pre charge Complete LED turns off 400VDC Allow time to pre charge and then re verify steps 1 4 If Power LED will not turn back on turn power off and allow 5 minutes for internal thermistors to cool Then re apply power Each Bonitron Ride Thru should be tested under load during initial start up to verify the functionality of the test circuit and that the test does not negatively affect the process However Bonitron recommends that if the process is critical the test cycle be initiated only during a shutdown to avoid unforeseen problems 6 Verify switching circuits by initiating the Test sequence while running the inverter at full load e Ride Thru DC bus current should flow during the 2 second test cycle e Inverter input current should drop e Ride Thru DC bus voltage should rise to approximately 100VDC above the threshold 49 M3460R and S3460SR 5 1 4 e Invert
52. agrams Initiate the test sequence while monitoring the DC bus voltage On modules so equipped the Test button is located on the module s control display front panel For modules without a control display front panel a 24VDC signal is needed at 3460M6 TB7 3 amp 4 to initiate test sequence Read the DC bus meter and subtract the Boost voltage When the Test is initiated the Threshold voltage level is Boosted for certain period of time This time interval is dependent upon the setting of jumper J4 on the 3460C1 Control Board With the J4 jumper in the INT position the interval will be approximately 2 seconds With the jumper in the EXT position the Boost will be maintained in real time by the Test for as long as the Test is performed e During this Boost period you should see the DC bus level increase amount that the DC Bus actually increases will depend on the Boost and 44 User s Manual Threshold level adjustments as well as the input voltage and DC bus output current e For example for a Ride Thru system with an input voltage of 460VAC the Threshold voltage level is preset to be 585VDC and the Boost voltage level is factory preset for an increase of 100VDC e Assuming that these preset levels have not been altered initiating the test described above on a lightly loaded system of this nature would cause the DC bus level to rise to 685VDC 585VDC 100VDC Subtracting the Boost v
53. allow the DC bus to discharge When the DC bus reaches its proper level the Boost Converter section will be ready to supply power to the DC bus on demand When the Boost Converter section is needed the Pre charge SCR modules are turned on which provides a path around the pre charge resistors BOOST CONVERTER SECTION The Boost Converter Section regulates the DC bus voltage during line sag conditions to a factory pre set level Under normal line conditions the input AC power is fed through resistors around the rectifier SCR modules to the primary filter capacitors If the AC line voltage sags the rectifier SCR modules turn on and the Boost Converter section becomes active to regulate the bus voltage An internal pot establishes this voltage The voltage is sensed and regulated by the 3460C1 Control Board and pumped up by an IGBT chopper circuit for each stage of the Ride Thru module Each chopper circuit includes 1 DC bus inductor 1 current sensor and 1 IGBT chopper transistor If the DC bus level drops the IGBT chopper transistor is turned on and the DC bus inductor is connected between the primary DC bus and the negative bus The inductor current increases and energy is stored in the inductor until a maximum current is reached At this point the transistor is turned OFF and the energy is transferred to the drive DC bus Each of the DC chopper circuits is phase shifted from the others to minimize peak current demands The boost chopper will
54. and observe the following conditions DC bus voltage on Ride Thru cap bank should quickly rise to the nominal system bus voltage 3460C1 control board LED 6 15V should be 3460 1 control board LED 7 15V should be 3460C1 control board LED 4 PCC should be ON 3460 1 control board LED 3 RTR should be ON All other 3460C1 LEDs should be OFF 3460M6 fault output board LED No Fault should be ON Skip step 2 2 If this unit DOES NOT HAVE the Precharge Option installed Apply power to the Ride Thru and observe the following conditions e DC bus voltage on the Ride Thru cap bank should rise quickly to the nominal system bus voltage 3460C1 Control board LED 6 15V should be ON 3460C1 Control board LED 7 15V should be ON 3460C1 Control board LED 4 PCC should be 40 User s Manual 3460 1 Control board LED RTR should be ON All other 3460 1 LEDs should be OFF 3460M6 Fault Output board LED 1 No Fault should be ON 3 Verify Control Room Connections if used Control Room should read the Ride Thru status signals as found in the Section 4 2 Move jumper positions on 3460M6 to simulate signals See Figure 3 11 for connection details 4 Verify threshold setpoint e Turn off system power and watch the DC bus voltage fall Refer to the Threshold Adjustment procedure in Section 4 4 3460C1 Control board LED 2 RTA will come ON when the bus drops to the thresh
55. character when ordering spare PCBs will help ensure a proper order Parts should be ordered by the responsible party through your local distributor or system integrator Table 6 5 Example of PCB Serial Sticker LAYOUT COMPONENT SERIAL 3 60 ct D 1 71 Table 6 6 Spare Parts List SPARE PARTS LIST 125 150kW 165 200KW 205 250KW CRITICAL PARTS QUANTITY PER PART NUMBER PART DESCRIPTION CC COEATGSPIDESO _ MODULE FSFWe 2008 Buss FWP Type 2008 Fuse Fuse Onion s FWP Type 2808 Fuse Fuse Onion ar005350 4 ould A7008 Type 350A Semicon Fuse Fuse Onion _ 2 FWP Type 400AFuse Fuse Onion FS aroassoo4 fous A7008 Type 5008 Semicon Fuse Fuse opo 8 Fs A70qse00 4 Gould A7008 Type 6008 Semicon Fuse Fuse Onion 5 65 M3460R and S3460SR This page intentionally left blank User s Manual 7 APPLICATION NOTES 7 1 MODEL M3460R INSTALLATION CONSIDERATIONS The following items should be considered when installing a Bonitron Ride Thru module 1 Inverter logic voltage must be backed up Most new Inverters derive logic supply from DC bus and are OK if bus is maintained e Install UPS on circuits with AC control power feed 2 Any control or Interlock relays must be backed e Test Relays at half voltage for dropout Use DC relays o
56. counter is battery powered and therefore does not lose its count during a power outage This counter is not affected by the Reset push button located to the right on the front face of the counter 4 2 2 2 003 DISPLAY UP FOR 3460 BOOST MODULES 4 2 2 2 1 4 2 2 2 2 INPUT COMMANDS ENABLE MODE In this mode an external 24V input command causes the booster to become enabled providing there are no fault conditions A fault condition may shut down the run command to the booster depending on the position of J1 and J14 and the DD3 display setting DISABLE MODE In this mode the booster will become automatically enabled once powered up and all conditions are met An external 24V input command causes the booster to become disabled and no boosting can occur Use this mode if no external run command is used To make external input an enable command place J15 in the A position To make external input a disable command place J15 in the B position TEST MODE In this mode a 24V input will cause the booster output voltage to increase so that the drive rectifier is reversed biased and power will flow from booster proving switching circuits are operational and fuses are intact Test can be initiated by an external contact or from the DD3 display panel To Enable test mode place J11 connecting both pins To Disable test mode place J11 OFF on one pin only CONTROL MODES AUTOMATIC In this mode the processo
57. e 3 Easy testing e Can test system on line take off line for repair or testing without disrupting the process 4 maintenance e Ride Thru time not based on traditional energy storage e Does not degrade after time Uses less than 100 watts when inactive e fans or filters for cabinet 5 Ability to add outage backup Energy storage be added later using either ultra capacitors or batteries 6 Instant response e switchover time e Maintain control of motor speed and torque 7 Easy commissioning e No programming e Can power up down with system on line e Single fine tune level adjustment 8 RF interference Slow switching speeds internally filtered Feeds DC to inverter bus 9 Control Room communications e Single fault contact or complex I O signals M3460R and S3460SR 10 System monitoring e LEDs e Voltage and current monitoring Activity counter 11 Over 15 years of on site experience Over 1 000 Ride Thru units installed Over 10 000 Drives connected e Over 30 companies Over 10 countries 12 Redundancy Most models use multiple stages e Single stage failure only means reduced capability 13 Custom options available Ability to adapt for custom configurations 2 2 PART NUMBER BREAKDOWN Figure 2 1 Example of Part Number Breakdown BASE MODEL NUMBER SOURCE VOLTAGE RATING KW RATING BACKPLATE OR CABINET CODE ADDED OPTIONS SCR OPTION BASE MODEL NUMB
58. e drive output cap bank Connecting upstream of the DC bus inductors may damage both the drive and the Ride Thru unit A typical field connection terminal layout for the S3460SR Cabinet System is shown in Figures 3 4 and 3 5 Additional drawings can be found in Section 6 of this manual N Interconnect wiring of this product should only be performed by a qualified electrician in accordance with National Electrical Code or local codes and WARNING regulations 3 4 1 2 TERMINAL LAYOUT 3 4 1 2 1 POWER CONNECTIONS Use copper conductors rated 75 See Tables 3 1 and 3 2 for details GROUND Make ground connection to ground stud located at top of cabinet AC LiNE INPUT CONNECTIONS Make AC line feed connections to appropriately labeled terminals at top of cabinet See Figures 3 4 and 3 5 DC Bus OUTPUT CONNECTIONS Make drive DC bus connections to appropriately labeled terminals at top of cabinet See Figures 3 4 and 3 5 Always measure DC voltages ensuring that they are at safe levels before making connections DC Bus INPUT CONNECTIONS 12 User s Manual Make capacitor bank connections to rectifier bus bars as shown in Figures 3 6 and 3 7 Use hex wrench to hold bolt while loosening nut with an open end wrench Mount lug through stud onto bus bar Use Hex wrench to hold bolt while tightening nut Always measure DC voltages ensuring that they are at safe levels before making connections Table 3 1 Power Field Wiring
59. e parts Notify the shipping carrier if damage is found 3 2 2 CHASSIS UNITS 1 Inspect the M3460R Ride Thru module crate for shipping damage 2 Remove screws along bottom of the Ride Thru module crate lift cover off 3 Check all equipment for shipping damage broken terminals loose screws loose or missing IC s unseated connectors etc Notify the shipping carrier if damage is found 3 3 MOUNTING 3 3 1 CABINET UNITS 1 Move the cabinet pallet to the desired installation site 2 Remove the hardware securing the cabinet to its pallet 3 Using a crane or hoist connected to the cabinet s lifting eyes remove the cabinet from the pallet and set it in the desired location Secure the Ride Thru cabinet in place Cabinets may be anchored to the floor as necessary Cabinets can be top heavy with the doors open WARNING 3 3 2 CHASSIS UNITS The entire Open Chassis Ride Thru system is mounted on one of three cabinet mountable open chassis aluminum backplates as follows e All 2 stage systems rated for up to 127ADC are mounted on the R10 chassis which measures approximately 28 long by 16 wide by 14 high e 4 stage systems rated at 170ADC are mounted on the R9 chassis which measures approximately 34 long by 16 wide by 14 high e All 4 stage systems rated for 240ADC or above are mounted on the R11 chassis which measures approximately 44 long by 16 wide by 14 hig
60. econds DPxx series display test button may be disabled by placing ASB 3660D jumper J1 in the B position This test provides definite proof of Ride Thru readiness and is also useful during field calibration of the Threshold Voltage AVAILABLE INDICATIONS FOR ALL DPxx DisPLAYS Bus VOLTAGE METER DP17 DP11 The Bus Voltage meter indicates the Ride Thru DC bus voltage The voltmeter is driven from the 353412 board The 353412 board uses a voltage divider connected across the DC bus to drive the panel meter with 300k ohm impedance between the meter and each bus The Voltmeter will read slightly lower than the drive bus when idle Bus CURRENT METER DP17 The Bus Current meter indicates the positive DC bus current supplied by the Ride Thru module The current is sensed by an isolated Hall Effect device and the meter is driven from the 353412 board ACTIVE CYCLES COUNTER DP10 DP11 DP17 The Active Cycles Counter indicates the number of times the Ride Thru module has been active since this counter was last reset The counter is battery powered and therefore does not lose its count during a power 35 M3460R and S3460SR outage The counter may be reset to zero by pressing the Reset push button This button is located to the right on the front face of the counter TOTAL RTA CvcLES COUNTER DP17 The Total RTA Cycles Counter indicates the lifetime total number of times the Ride Thru module has been active The
61. ection at TB5 5 6 and for the display panel at TB6 3 OVER TEMPERATURE L OT amp R OT The Over Temp contact will OPEN if the temperature of any heatsink within the Ride Thru exceeds 130 F This output is provided on the 3460M6 mux board for field connection at TB5 3 4 and for the display panel at TB6 4 PRECHARGE COMPLETE L PCC amp R PCC The Precharge Complete contact will CLOSE when the DC bus has reached the preset pre charge level This output is provided on the 3460M6 mux board for field connection at TB5 9 10 and for the display panel at TB6 2 RIDE THRU ACTIVE L RTA amp R RTA The Ride Thru Active contact will CLOSE if the module is regulating the DC bus voltage under an input voltage sag or TEST condition The local fault monitor will track Ride Thru activity in real time for display purposes if J13 is removed The remote fault monitor will latch for approximately 3 seconds on Ride Thru activity to allow adequate time for the fault to read This output is provided on the 3460M6 mux board for field connection at TB5 11 12 and for the display panel via at TB6 6 RipE THRU READY L RTR amp R RTR The Ride Thru Ready contact will CLOSE when the RUN command is made pre charge is complete and all stage fuses are intact This output is provided on the 3460M6 mux board for field connection at TB5 1 2 and for the display panel TB6 5 MULTIPLEXED FAULT L FAULT amp R FAULT The Voltage Fault Over Temp and Ride Thru
62. ep Type 12 wall mount cabinet c c 24 wide x 18 deep Type 3 R floor mount cabinet 72 tal x 27 5 wide x 18 deep 12 toor mount cabinet 00 2 tall x 54 wide x 18 deep 12 floor mount cabinet D52 2 tall x 78 wide x 18 deep Type 12 floor mount cabinet CAB1 2000mm tall x 800mm wide x 600mm deep NEMA 12 Hoffman Proline ADDED OPTIONS The Model M3460R Ride Thru is available with several add on options if desired The Added Options are indicated by codes as shown in Table 2 4 and are separated by a comma as shown in Figure 2 1 Option Codes are omitted if not required Table 2 4 Option Codes i Model M3520 External Fuse assemblies also available Pre charge hold off np Digital Display Notes Cabinet Systems include the F and options If the SCR Front End Option is desired an S is added after a dash at the end of the part number See Figure 2 1 e The SCR Front End Option is standard on multi cabinet systems M3460R and S3460SR 2 3 GENERAL SPECIFICATIONS Table 2 5 General Specifications Chart PARAMETER SPECIFICATION 3 phase 50 60 Hz Line Vella See Table 2 6 below for tolerance and voltage specs mountable backplates cabinets Table 2 6 Voltage Specifications OUTPUT DC Bus Low DC Bus TOLERANCE NOMINAL TD VOLTAGE VOLTAGE FAULT 495
63. ep e from initial joules Step c OR Contact Bonitron for aid in sizing DIODE SHARING WITH A BONITRON RIDE THRU Diode sharing is used to decrease the cost of implementing regeneration braking or Ride Thru modules to existing drive systems that are not common bussed The use of diodes prevent drive busses from back feeding each other by allowing energy to pass one way only For regenerative applications the energy is allowed to pass from the drive bus to the regen or resistive braking module but is blocked from passing from regen or brake module to the drive For Ride Thru applications the energy is allowed to pass from the Ride Thru module to the drives but is blocked from the drives to the Ride Thru Figure 7 1 is a block diagram example of a Ride Thru diode application Below are some basic guidelines for using diodes in this manner for 50 sag Ride Thru applications 1 Drives should have equivalent DC bus levels as would be found on equal size drives of a common manufacturer See Figure 7 3 e f positive and negative busses are different potentials the standard pre charge may overheat and the Ride Thru may be constantly active 2 Drives should be on same AC feeder in same cabinet or close proximity e Different feeds have different potentials and may cause circulating currents or ground faults 3 Drives should a common line choke or harmonic filter Any input filter should be common to all drives on
64. er DC bus voltage should rise to approximately 100VDC above the threshold Motor speed should remain constant e Active cycle counter should count test cycles PERIODIC MAINTENANCE PROCEDURES FOR M3460R WITH OPTIONAL DIGITAL DISPLAY PANEL The Bonitron Ride Thru is designed to be low maintenance While the amount of Ride Thru time does not depend on energy storage devices that degrade over time Bonitron still recommends a yearly test of the system in order to ensure the electronics package is operating The following steps can be taken to ensure reliability and give comfort that the system is still able to ride through a sag event 1 Check Active cycle counters More than 10 counts per month may mean the Ride Thru is improperly adjusted Refer to Section 4 4 for adjustment details e Note count for factory records Report count to Bonitron via your local service representative 2 Monitor Front panel LEDs for the Digital Display Panel Power LED should be ON e Ride Thru Active LED should be OFF e Fault LED should be OFF 3 Verify DC bus current meter Meter should read zero amps under normal conditions 4 Verify DC bus voltage meter e Ride Thru bus should be about 10 35V DC below the Inverter bus 5 Verify Threshold by opening the AC disconnect to the Ride Thru module if equipped Refer to Section 4 4 e The DC bus voltage should drop until it reaches the threshold e Ride Thru Active LED should begin to flash
65. est as necessary Figure 4 6 Ride Thru Module 3460C1 Control Board Layout THRESHOLD ADJUSTMENT POT R7 BLOWN SIGNAL xr D FUSE OUTPUTS z 5 e pL I THRESHOLD CIRCUIT lo 15V COMMON icis R15 BOOST PRECH GAIN COMPL TEST TI CLOCK CHOPPER FREQUENCY Tu bl 1c11 1012 ic2 20voc pice L R T ACTIVE common D 20VDC 1 3460C1D RIDE THRU CONTROL BOARD by BONITRON Figure 4 7 Ride Thru Module 3460D5 Power Supply Board Layout R3 Low Bus Sense Adjustment Pot ONITRON 0 HUE oot discs C d Lo an 4 BS pug 4 55 09 092 bod LES n ERST T TI CREET Trav el NEXT AVE LD3 UE 23 Bus User s Manual 5 MAINTENANCE AND TROUBLESHOOTING Repairs or modifications to this equipment are to be perfo
66. eter mounting holes e See Section 6 5 for Ride Thru backplate mounting dimensions If a Diagnostic Display panel is not supplied go to step 10 8 Determine where the Diagnostic Display Panel is to be mounted and prepare the site for installation e The Diagnostic Display Panel is provided with an 8 foot long interconnect harness e See Figures 3 1 thru 3 3 in this manual for the Diagnostic Display Panel cutout and mounting dimensions 9 Mount the Diagnostic Display Panel and reconnect the harness to appropriate locations e See step 3 10 See Section 3 4 for basic field wiring procedures Figure 3 1 Typical 7 5 Digital Display Panel Mounting Dimensions DD3 PANEL DIMENSIONS CUT OUT AND FOOTPRINT 4 500 4X 188 4 500 p gt 188 1 H gt 4 Q 188 pem 250 1 188 7 000 7 500 CUTOUT 6 625 7 000 10 Doc 023010 Rev 20070615 User s Manual Figure 3 2 Typical 3 6 and 6 Diagnostic Display Panel and Mounting Dimensions DP02 DP10 P Tu DISPLAY 4555 DISPLAY P ANEL ANEL 2 Sy 9 N T ur D 410 CUTOUT 45 10 Sout E VN Figure 3 3 Typical 12 Diaqnostic Display Panel and Mounting Dimensions DP17 FH o o o E s 11 M3460R and S3460SR 3 4 WIRING AND CUSTOMER CONNECTIONS
67. h See Figures 6 1 through 6 3 1 Remove wood screws securing Ride Thru module backplates to the shipping crate If a Diagnostic Display panel is not supplied go to step 5 M3460R and S3460SR 2 Remove the Diagnostic Display panel from the shipping bracket mounted to the Ride Thru backplate 3 Unplug wire harness from booster to make display harness installation easier The Display panel will be installed later e For DP10 Disconnect the harness from TB6 of the 3460M6 Status Interface board on the Ride Thru module e Figure 3 6 shows the location of the 3460M6 board e For DP17 Disconnect the harness from TB2 TB5 and TB7 of the 353412 display interface board on the Ride Thru module e Figure 3 6 shows the location of the 353412 board e For Disconnect the ribbon cable from TB3 of the 36601 DD3 interface board Figure 3 7 shows the location of the 366012 board 4 Remove display harness from booster e Carefully cut cable ties holding display harness to booster backplate 5 Lift Ride Thru backplate off of crate bottom using the 4 handles f backplate is too heavy eyebolts may be installed in the mounting holes for lifting by mechanical means 6 Stand backplate upright in rack and slide the bottom of the backplate into position at the rear of the rack while balancing the top See Section 6 5 for Ride Thru backplate orientation 7 Secure the Ride Thru backplate to the rack using the backplate s 375 inch diam
68. ized to account for 150 200 inverter starting torque are adequate Remember drive and Ride Thru will not pull power at the same time GROUNDING REQUIREMENTS Earth ground stud is provided on backplate Max torque of 75 in lbs CONTROL INTERFACE WIRING See Figures 3 6 and 3 7 for physical locations 3 4 2 1 3 4 2 2 CONTROL CONNECTIONS S3460SR Cabinet systems common control connections are made at TS1 in top section of the cabinet backplate See Table 3 3 for technical specifications Not all control signals are available at this terminal strip If more detailed status is desired use directions for connecting to the M3460R booster module M3460R STANDARD MODELS Booster modules control connections can be made at TB7 on the 3460M6 interface circuit board See Table 3 4 for technical specifications See Figure 4 2 for interface board and suggested wiring M3460R wirH DIGITAL DISPLAY Booster modules control connections can be made at TB1 on the 366012 interface board See Table 3 5 for technical specifications See Figure 4 2 for interface board and suggested wiring STATUS MONITORING CONNECTIONS S3460SR Cabinet systems status monitoring connections are made at TS1 in top section of the cabinet backplate See Table 3 3 for technical specifications Not all status signals are available at this terminal strip If more detailed status is desired use directions for connecting to the M3460R booster module M3460R STAN
69. jumper preset for INV invert means with input ON switch is OFF Connect 24V output at TS1 to Enable input via an aux contact on the cabinet disconnect switch so that when cabinet is turned off the 24V is removed from the IGBT switch and the switch is turned on Note that this 24V is NOT isolated from cap bank or drive potential See 3628T Manual Figure 3 1 External temperature sensor on discharge resistor bank 15 recommended for E cap systems because the DC link power is NOT limited by a current limiting charging device and there is sufficient power available to overheat the discharge resistor which may in turn blow fuses or cause heat damage to other equipments in the cabinet Connect directly to cap bank as shown in 080384 See new App notes in the M3628T manual for fusing and rms current rating for wire sizing Discharge time is dependent on resistor value and is typically designed for 1 min or less to 50VDC 3 min to about 15VDC unless faster time can be achieved due to small amount of energy stored in E cap bank If personnel are working on cap bank or boost modules it is recommended to place a shorting bar or low ohm resistor 1kohm or less across cap bank as Soon as the discharger lets go and the cap voltage begins to increase due to reforming 77 M3460R and S3460SR This page intentionally left blank NOTES User s Manual M3460R and S3460SR NOTES
70. level Motor should not lose speed or torque DC bus current should flow from Ride Thru to inverter e Inverter input current should decrease This completes the startup procedure for M3460R with Digital Display Panel THRESHOLD VOLTAGE AND Low BUS SENSE ADJUSTMENTS OVERVIEW The Threshold voltage level is the voltage at which the Bonitron Model M3460 Ride Thru module maintains the DC bus during a power sag Whenever the DC bus level drops to the Threshold setpoint the Ride Thru module becomes active to regulate the DC bus voltage to the Threshold setpoint voltage Generally the Threshold level should be set at 10 15 below the nominal DC bus level An actual on site level setting must be determined by the loaded DC bus level as well as the amount of ripple present on the DC bus The Ride Thru module should not become active during normal everyday operation The Threshold level is factory preset on all Bonitron Model M3460 Ride Thru modules These levels are specified in the General Specifications Chart in Section 2 of this manual for each Ride Thru module However some field adjustment of this level may be required to achieve the optimum setpoint level for any given system Doc 4 013012 Rev 20030128 43 M3460R and S3460SR It is important to note that the Ride Thru module s Low DC Bus or Output Under Voltage OUV or Kinetic Buffering KB setpoint is factory preset to 5 below the Threshold voltage
71. m U cap applications e See M3528AC manual Figure 6 3 for basic drawing CHARGER M3528AC 10 amp charger is pre wired to charge automatically upon power up e disable charging connect 24V to relay on inside top of chassis e Connect charger wires cap bank side of blocking diode e Charge time is about 13 minutes 10 amps using Maxwell 165F 48V caps CHARGER ISOLATION TRANSFORMER Transformer can be supplied by Bonitron or by just about any transformer manufacturer e For Ultra cap charging the transformer does not have to be sized for full power charging because it is not a continuous application to charge caps 75 M3460R and S3460SR Charge current cuts back when you get close to full voltage so 10 amps charging to 456V gives about 4 4kW max charge power but average power during charge is only 2 2kW and lasts for about 13 minutes in this case e Fuse transformer input according to local codes with slow blow fuses Expect 13 amps during heaviest part of charge power curve for 10 amp charger e Connect transformer between VFD RT line and charger input so that charger does not supply any drive current during normal operation 7 4 7 DISCHARGER M3628T Discharger is factory set up for auto discharge e Internal jumper preset for INV invert means with input ON switch is OFF Connect 24V output at TS1 to Enable input via an aux contact on the cabinet disconnect switch so that when cabinet is turned off the
72. n T T f 2 2 D C lt T T LI 5 iE 5 c 7 T c L gt E ue E A 5 7 zi z c 2 box P E m o Ie ula _o uz lt t a 4 E E ISOLATED 23V 20 Dwg 080199 Rev 20090923 SALLY E ISOLATED FET DEVICES User s Manual Wirin Figure 3 12 Example of Shunt Tri 1 NAH 1L 3AMN 0gL09NNO0OSIA SI H3MOd 1 I3ZIOH3N3 SI 71109 LNNHS N3HM L3NI8VO 1 NOYLINOE SHL NI LNNHS JHL SSOYIV OVASLL ONILOANNOO d921943N3 30 SI 1 109 AV I3H JHL 440 GSHOLIMS SI H3LH3ANI N3HM LVHL HONS LOdNNOO LOVLNOOD YaMOd NIV LNNHS xnv 4H MOIS dINV L TIVSLLOSN LOH E d ONIYIM dl amp L LNNHS OIH3N39 L3NISVO NYHL 097 21 Dwg 990009 Rev 20010126 M3460R and S3460SR 22 3 4 2 Note 3 4 1 3 3 4 1 4 SOURCE CONSIDERATIONS Input feed must be capable of delivering 2x rated current for 2 seconds 50 sag levels Feeds s
73. n backed up 24vdc logic supply e Install UPS on circuits with AC control power feed 3 Ensure drive does NOT shut down due to drop in AC line voltage Some drives monitor the AC line and shutdown for self protection when the voltage sags Common CNC machines Some drives be programmed to ignore this condition e Consult Drive manufacturer for details e Bonitron Kinetic Buffering option is available if the AC line sag signal can be intercepted 4 Ensure Inverter has a DC bus connection Most Inverters over 5hp have this available e Connection should be directly on the secondary capacitor bank Some large inverters may require a DC bus adaptor kit from the manufacturer 5 Ensure Inverter kinetic buffering or bus follower or regenerative ride through settings are turned off Most inverters can slow the motor speed to compensate for a sagging DC bus which can interact with the Ride Thru system and cause instability Disable this feature when using DC bus ride thru 6 Verify actual AC line voltage and DC bus level Toensure Threshold level is set 10 of nominal DC bus level ensure valleys of ripple do not cause unwanted activity 7 Determine the maximum motor voltage needed To ensure Threshold level is sufficient to supply motor Standard Bonitron models are factory set for 90 of nominal bus levels Most inverters automatically compensate RMS to motor 8 Determine Inverter low bus tri
74. nes cabinet type 7 2 How TO BUILD A HIGH VOLTAGE ULTRA CAP BANK Bonitron booster models 3460R and 3534R can have energy storage devices added to cover complete outages This involves adding a charging circuit and an Ultra capacitor bank Complete capacitor cabinets can be purchased from Bonitron or individual capacitors can be purchased from various manufacturers and then integrated with the existing boost module This app note gives some instruction for building your own cap bank NEED TO KNOW SYSTEM PARAMETERS System Line Voltage to determine DC bus levels System KW to determine needed joules Time of ride through to determine needed joules Calculated joules to determine needed cap bank Minimum DC bus desired determines cap start voltage threshold is typically 10 of nominal DC bus level Minimum Ride Thru Input voltage determines cap end voltage typically 5096 of nominal DC bus for 3460R and 3534R models RULES OF THUMB 1 e Ultra caps do not like constant ripple current so they should NOT be applied directly to an inverter DC bus and should be held at least 1096 below bus level ESR is a major concern at high power levels Ultra caps store 75 of their power in the first 5096 of voltage Some types of capacitors will have a 10 20 decrease in available energy when discharged quickly at high energy levels Max cap current depends on time of discharge C xV T in seconds
75. ntered in applications of modern AC variable frequency drives Bonitron s Ride Thru module provides protection from AC line voltage sags while the Line Regen and Resistive Braking modules provide DC Bus regulation for over voltage due to regenerated voltage Bonitron AC drive modules are available to provide Undervoltage Overvoltage Line Side Load Side Maintenance Power Quality and Green Sustainability solutions These products are compatible with the drives of all major manufacturers and have become the standard in many industries including semiconductor oil and fiber WORLD CLASS PRODUCTS Bonitron has developed over 3000 different modules and systems Bonitron is willing and able to meet the unique specifications the client may request Some Bonitron products include Power Sag Ride Thru Modules Power Outage Ride Thru Modules Line Regen Modules Resistive Braking Modules Modular High Speed Precision AC Inverter Systems Inverter Upgrade Modules Multi motor Multi phase Current Sensors Battery Production Charging Systems Data Acquisition Systems Process Controllers Temperature Control Systems RMS True Reading Digital Voltmeters Ammeters and Frequency Meters iii M3460R and S3460SR 1 INTRODUCTION LL Who Should Use 1 1 25 Purpose and iecore ete ca 1 1 35 Manual
76. of critical drive systems do not want to shut down under any circumstance short of equipment failure as the cost of shutdown is overriding concern e See Section 4 2 2 2 for set up with Digital display and directions to change to manual mode that will allow the boost module to run beyond specified limits e See Figure 4 3 for physical locations of jumpers and Tables 4 5 through 4 8 for Truth Tables e Booster is factory set up for 585VDC threshold for 460VAC system e See Section 4 4 for threshold description 76 7 5 3 7 5 4 7 5 5 7 5 6 User s Manual ELECTROLYTIC CAP BANK Electrolytic caps should be connected in parallel using bus bar or wire capable of up to 600 amps for short duration ESR is fairly important but wire need not be larger than 3 0 E cap bank should be fused to limit energy into boost module Bonitron EC cap bank assemblies have internal blocking diode so no external diode is needed and would not allow charging of E cap bank if used DIODE Blocking diodes are included on each assembly to prevent huge surge currents upon power up 480VAC system surge current for each cap assembly will be about 8 amps peak CHARGING Pre charge capability is built into the cap assemblies built by so there is no need for additional current limited charging module DISCHARGER M3628T Discharger is factory set up for auto discharge Internal
77. old e The DC bus will hold at the threshold momentarily Allow the DC bus to discharge until the 3460C1 Control board LED 4 PCC goes OFF Reapply system power 5 Verify system capability Monitor DC bus voltage and DC bus current or inverter AC line current e Input 24V TEST signal 3460M6 TB7 3 amp 4 See Threshold Adjustment Procedure Section 4 4 e 3460C1 Control Board LED 2 RTA should come ON during test will flash if the load is light stay on if the load is heavy 3460C1 Control Board LED 1 TEST should come ON during test Bonitron DC bus voltage should rise to the test boost level Inverter DC bus should rise to the test boost level Motor should not lose speed or torque DC bus current should flow from Ride Thru to inverter Inverter input current should decrease This completes the startup procedure for M3460R without the Diagnostic Display Panel 4 3 2 2 FOR M3460R WITH DP17 DIAGNOSTIC DISPLAY PANEL If Precharge Hold off option is installed begin with step 1 CAUTION not installed go directly to step 2 1 If this unit HAS the Precharge Option installed Apply power to the Ride Thru and observe the following conditions e DC bus voltage on Ride Thru cap bank does not charge No LEDs should light e Turn on the 24V ENABLE signal and observe the following conditions DC bus voltage on Ride Thru cap bank should quickly rise to the nominal system bus voltage DC b
78. oltage 100VDC from this reading shows that the actual Threshold voltage level is 585VDC e Initiating this test on a heavily loaded system of this nature would also cause the DC bus level to rise However the DC bus would stop rising once current limit is reached NOTE The Boost voltage level is adjustable and is factory preset It is not recommended that this setpoint be altered If this setpoint has been changed from its original factory setting this test method will not be accurate METHOD 2 DETERMINING THE THRESHOLD VOLTAGE SETPOINT FOR AN OFF LINE AND UNLOADED SYSTEM 1 Remove input voltage supply from system e Disconnect the input voltage to the Ride Thru while monitoring the DC bus voltage As the DC bus drops to the Threshold setpoint voltage the Ride Thru module will become active e The Ride Thru will then maintain the DC bus voltage at the Threshold setpoint level for approximately 1 second while the primary capacitor discharges at which point the DC bus will continue to drop e Read the DC bus voltage as it is being maintained This is the Threshold setpoint voltage ADJUST THE SETPOINTS AND REPEAT THE TEST Once the actual Threshold voltage has been determined you can make adjustments if required to achieve the optimum setting for your system The Low DC Bus setpoint should be adjusted to match any Threshold adjustment that is made The Threshold voltage should be set to approximately
79. oom that an operator should go out and check the Ride Thru front panel for more information This signal may be considered a READY signal Both N O and N C contacts are available at the connector FAULT 2 OUTPUT Fault 2 will change states only if Over Temp Input Under Voltage or Active Time faults occur If any of these faults occur and the Ride Thru is in automatic control the run command will be shut down If fault 2 occurs and the display is in manual mode there should be immediate attention given to the Ride Thru system and remotely shutting down the boost function should be considered Both N O and N C contacts are available at the connector Table 4 5 Manual Control with Enable Signal 36601 3660D DISPLAY JUMPERS 36601 SIGNAL INPUTS 36601 OUTPUTS PANEL a J1 IUV RUN 1 amp DISPLAY FAULT J14 J15 OR ENABLE FLT 1 FLT 2 RUN 2 LATCH INDICATIONS RTO OUV 24V X OK Normal R 0 E 2 E LLI g Fault 24V x x Y Temp UV or Z Z 0 X z y RTA Time Z w X N S OK Normal lt lt 0 N 24V x x N RTR PCC BF or Fault 0 X OUV 37 M3460R and S3460SR 38 Table 4 6 Manual Control with Disable Signal 36601 3660D DISPLAY JUMPERS 36601 SIGNAL INPUTS 36601 OUTPUTS PANEL or
80. or automatic control mode which automatically shuts down the boost module to protect ourselves from damage if misapplied misadjusted or some abnormally long sag brown out event occurs Some owners of critical drive systems do not want to shut down under any circumstance short of equipment failure as the cost of shutdown is overriding concern See Section 4 2 2 2 for set up with Digital display and directions to change to manual mode that will allow the boost module to run beyond specified limits e See manual Figure 4 3 for physical locations of jumpers and Tables 4 5 through 4 8 for Truth Tables e Booster is factory set up for 585VDC threshold for 460VAC system See Section 4 4 for threshold description e U cap bank voltage can be monitored by digital display See Section 3 for connection details ULTRA CAP BANK e Ultra caps should be connected in series using bus bar or wire capable of up to 600 amps for short duration ESR is fairly important but wire need not be larger than 3 0 Cap bank ESR is about 70 milliohms e Ultra cap bank should be fused to limit energy into boost module e Use blocking diode so that Ride Thru 640V DC bus does not charge to cap bank BLockiNG DIODE e Blocking diode should be in series with the U cap bank positive connection so that energy can only flow from cap bank to Ride Thru input Connect Anode to cap bank cathode to booster e Diode does not need additional heatsink for short ter
81. p point To ensure Threshold level is above inverter dropout Standard Bonitron models match to standard inverter trip levels of 85 9 Determine Inverter high bus trip point ensure Test level will not over voltage inverter Standard Bonitron models match up to standard inverter overvoltage levels 10 Inverter ground fault circuits e Ride Thru currents may use Inverter bridge neg diodes during operation causing unequal currents e Circuits can be de sensitized or delayed e External ground fault circuits may be added 11 Electrical safety e Ride Thru should not have AC power when inverter does not RT and Inverted should feed from same point 67 M3460R and S3460SR 12 13 14 15 16 17 18 Use shunt trip interlock between Inverter and Ride Thru if RT power is not fed downstream of inverter power switch Remote monitoring of status signals e Logic level signals e Single dry fault contact Input feed should be capable of 2X rated current during the 2 sec 50 dip e RT RMS rating is 1 percent of system KW runs 1 sec out of every 100 sec Most Inverter feeds have been sized for 150 200 surge for motor starting IR drop of wiring e this subtracts from the 50 dip spec Maximum wire sizes allowed into Ride Thru Over sizing wires is not necessary Some models have max sizes on standard disconnect Local wiring codes Ambient temperature e under 40 C Corrosive environment e Determi
82. r 5 Verify system capability Monitor DC bus voltage and DC bus current or inverter AC line current e Initiate the Test sequence See Threshold Adjustment Procedure in Section 4 4 RIDE THRU ACTIVE LED on DP17 Display should come ON during test will flash if the load is light stay on if the load is heavy 3460C1 Control Board LED 1 TEST should come ON during test Bonitron DC bus voltage should rise to the test boost level Inverter DC bus should rise to the test boost level Motor should not lose speed or torque DC bus current should flow from Ride Thru to inverter Inverter input current should decrease This completes the startup procedure for M3460R with Diagnostic Display Panel 4 3 2 3 FoRM3460R WITH DD3 DIGITAL DISPLAY PANEL If Precharge Hold off B3 option is installed begin with step 1 CAUTION f not installed go directly to step 2 1 If this unit HAS the Precharge Hold off Option installed Apply power to the Ride Thru and observe the following conditions No LEDs should light e Turn on the 24V ENABLE signal and observe the following conditions e DC bus voltage on Ride Thru cap bank should pre charge to the nominal system bus voltage e DC bus current should remain at zero e Power LED should be ON 42 Doc 4 013012 Rev 20030128 4 4 User s Manual Ride Thru Active LED should be OFF e Voltage Fault LED should be OFF Skip step 2 2 If this unit DOES
83. r Threshold and Test Boost Voltages eee 44 4 4 1 Determining the Threshold Voltage Setpoint sese 44 Figure 4 6 Ride Thru Module 3460C1 Control Board Layout 46 Figure 4 7 Ride Thru Module 346005 Power Supply Board 46 MAINTENANCE AND TROUBLESHOOTING esssessossoossessoesoossossoesooesoesoesooesossoesooesoesoeseossoesoessossees 47 5 1 Periodic Testing a oce 47 5 1 1 Half Voltage Field Test 47 Figure 5 1 Half Voltage Field Test Hook up sese 47 5 1 2 Periodic Maintenance Procedures for M3460R Without Optional Diagnostic Display Panel 48 5 1 3 Periodic Maintenance Procedures for M3460R With Optional Diagnostic Display Panel 49 5 1 4 Periodic Maintenance Procedures for M3460R With Optional Digital Display Panel 50 2 22 Maintenance teis os ster rd em PUR EU beds e P ep EE 5 5 2 1 Capacitor Replacement Recommendations sss eren 51 5 3 Troubleshooting oin errem loess oo 52 Table 5 1 Troubleshooting Guide sess 52 Figure 5 2 Diagnostic Signal Connections with M6 12 and DP17
84. r monitors temperature active run time and input voltage and can shut down the boost function if these go outside of desired parameters These conditions generate a Fault signal fault 2 and are available for remote notification The Input under voltage IUV meant to protect the battery bank from deep discharge can be disabled from the front panel in cases where process is more important than battery life MANUAL CONTROL MODE In this mode the processor will only monitor the system status and will not shut down the run command In this mode It is recommended that fault signals are monitored and a remote enable or disable signal be used to stop the switching the effort of keeping the module from running outside its specifications Bonitron will ship with the system set up for automatic control Since some applications are of such crucial importance we realize the desire to continue running may outweigh any concerns for the Ride Thru modules or battery bank If your application is this critical you may want to use the manual mode 36 4 2 2 2 3 User s Manual To place the display in the Manual mode so that automatic shutdown does NOT occur place J1 and J14 in the positions To place the display in the Automatic mode place J1 and J14 in the B positions OUTPUT STATUS SIGNALS FAULT 1 Fault 1 will change states if OUV or BF ocour or if RTR amp PCC turn off signaling to the control r
85. re Table 4 1 Control Signal Specifications CONTROL STATUS ACTIVE STATE Enable Input 24VDC 20mA 24VDC to ENABLE and RUN Test Input 24VDC 20mA 24VDC to TEST Jumper selectable see Table 4 Ride Thru Status Outputs Opto FET 350VDC 120mA 3 and Figure 4 2 ENABLE INPUT The Ride Thru may be configured for a 24V ENABLE or DISABLE signal via jumpers J15 and J16 N O position means the booster is enabled when 24V is applied N C position means the booster is disabled with 24V applied The 3460M6 Status Interface board accepts the 24VDC ENABLE DISABLE signal at TB7 1 2 In order to prevent overheating from constant activity the OT signal should be used to remove the ENABLE in case the Booster Module overheats See Figure 4 2 TEST INPUT The Ride Thru accepts a normally open momentary contact for TEST and calibration purposes A TEST button is provided on the DP Series Diagnostic Display Panels for system testing calibration This button connects to the system via TB6 10 of the 3460M6 Status Interface board However a remote contact can also be connected across terminals TB7 3 4 of the 3460M6 Status Interface board by changing jumpers J10 and J17 to Remote Closing the TEST contact will cause the Ride Thru to raise the DC bus level by 100VDC The inverter input current will drop and the Ride Thru current will start If the 3460 1 test time jumper J4 is set to EXT the DC bus sag setpoint will remain raised for as long as
86. recedence MANUAL VERSION Rev 01b clarifies Digital Display data Figure 1 1 Examples of M3460R and S3460SR Ride Thru Models R11 Open Chassis D40 Type 12 Enclosure k 5064556 M3460R and S3460SR This page intentionally left blank User s Manual PRODUCT DESCRIPTION This document describes the Ride Thru components used to provide the DC bus power for AC PWM inverter drives during a power line sag or phase loss situation The Ride Thru module is factory set to become active begin supplying power if the DC bus voltage drops to a preset level The Ride Thru module is designed to operate at its rated load for 2 seconds under the following conditions e A 50 sag in the line voltage on all 3 phases or single phase loss with the other 2 phases remaining at the rated voltage The Ride Thru module s power rating KW must equal that of the drive s being supplied by the unit The Ride Thru feed should have a 2 second 2x surge capability comparable to the surge rating of the drive s The Ride Thru module is designed to operate continuously 24 hours per day 365 days per year 2 1 FEATURES 1 retrofit installation e Use existing wiring Use existing feed breakers e Works with most any Fixed bus PWM drive e Only 5 connections to AC line and 2 to drive DC bus 2 Inexpensive 100 to 200 per kW e Less expensive than other options e Traditional UPS e Flywheel technology e Capacitive energy storag
87. rge circuit Too much activity can cause stage fuse failures overheating and draining of the battery Check threshold level if changed over time adjust level or replace 3460C1 Check RUN command Initiate test cycle or remove power Watch and listen for signs of activity e Check RTA contact and LEDs e Ticking sound when active Check power quality data to confirm sag events should have caused activity to occur f no activity ever replace 3460C1 Check for constant current the negative and positive DC bus links Check temp sensors On SCR heatsink On diode heatsinks On IGBT heatsinks On chokes if used Check pre charge network for overheating cause of constant activity If all OK replace 3460M6 interface PCB Check activity record Too much activity causes overtemp Check stage fuses LED on 3460F fuse PCB will be ON or Fuse Indicator will indicate blown fuse f all stage fuses are OK replace 3460C control 52 User s Manual Blown stage fuses TEST won t work Voltage fluctuates during TEST mode Check for shorted IGBT Replace 3438C2 gate driver if IGBT is bad Check or replace stage choke current sensor Check or replace 3438S stage IGBT snubber Check activity record Too much activity causes fuse fatigue Check DC bus level too high causes test Check blown fuse LED during test if on check stage fuses Check test input to 3460C1 f OK replace 34
88. rmed by Bonitron approved personnel only Any repair or modification to this equipment by personnel not approved by Bonitron will void any warranty remaining on this unit 5 1 PERIODIC TESTING 5 1 1 HALFVOLTAGE FIELD TEST PROCEDURE PRELIMINARY SET UP Refer to Figure 5 1 for steps 1 thru 4 1 Connect a full voltage 3 phase supply through a switch or contactor to both the Drive and the Ride Thru module 2 Connect Ride Thru module DC bus to the Drive DC bus 3 Connect a half voltage 3 phase supply through a switch or contactor to an external diode bridge 4 Connect the external diode bridge to the primary DC bus bars See Figure 3 6 Typical Open Chassis Field Connections for DC bus locations Figure 5 1 Half Voltage Field Test Hook u APPLY POWER IN SEQUENCE AS NOTED IN FIGURE 5 1 5 Turn on the full voltage supply and allow the Ride thru module to pre charge 6 Turn on the half voltage supply THE RIDE THRU IS NOW READY TO TEST 7 Initiate the test sequence e On modules so equipped the Test button is located on the module s Diagnostic Display panel e On modules so equipped the Test button is located on the module s control display front panel e For modules without these provisions a 24VDC signal is needed at 3460M6 TB7 3 amp 4A to initiate test sequence The DC bus should rise for as long as the test is performed If under load a time out will occur in 2 seconds Dwg 013029 Rev 20030
89. rotect the booster and battery from damage due to extreme circumstances the booster module should be shut down under the following conditions e Overtemp Input Undervoltage e Active run time beyond booster rating FOR STANDARD MODELS OR MODELS EQUIPPED WITH A DP SERIES DISPLAY The 24V RUN command should be sent through the Input Under Voltage and Over temp OT contacts on the 3460M6 interface board FOR MODELS EQUIPPED WITH DIGITAL DISPLAY DD3 OPTION The 24V RUN command should be sent through the Fault 2 contact OR e The Fault 2 contact should be monitored and the external run command removed when any Fault 2 occurs OR The display should be set up for automatic control mode where the display automatically shuts down the enable under any of these conditions models should be factory set to automatically shutdown if any of these faults occur Some end users purposely choose to ignore these warnings because the process is the paramount concern TO BYPASS THIS SAFETY FEATURE FOR MODELS WITH M6 INTERFACE e Remove series contacts from external run command loop Remove factory installed wires between enable input and IUV amp OT contacts on 3460M6 board and connect External enable directly to 3460M6 TB7 1 amp 2 Change external run command from Enable to Disable Factory set for Enable On the 3460M6 interface board move jumpers J15 and J16 from the N O position to the N C position The unit will be re
90. t Dimensions 00 11 1 64 Recommended Spare Parts Rd pe aam ec ks 65 Table 6 5 Example of PCB Serial ener 65 Table 6 6 Spare Parts List sse eren ene ennt etre nre desti parei resort 65 APPLICATION NOTES anco eite OT 7 1 Model M3460R Installation Considerations eene 67 7 2 How to Build a High Voltage Ultra Cap Bank seen 68 7 3 Diode Sharing with Bonitron Ride Thru enne 69 Figure 7 1 Ride Thru System Configuration 19 nennen enne enne 70 Figure 7 2 Diode Sharing With Individual Line Chokes sse 70 Figure 7 3 Diode Sharing With Equivalent nennen 71 Figure 7 4 Typical M3460R Output vs Input Various 71 Figure 7 5 Duration of Voltage Sag in Seconds sse nennen 72 Figure 7 6 Typical Drive Bus Voltage for 400VAC Systems VDC sss 73 Figure 7 7 Typical Drive Bus Voltage for 460VAC Systems VDC sss 74 7 4 Quick Set up Guide for 3460 Ultra Cap Component Systems sese 75 ANS System wife ie OR 75 PAD JBOOS eE xus Mq 75 74 35 Ultra Cap Bank toot ote UI M 75 EAA oBlocking Diode o RB ON 75 4 45 CHAR etre tue 75 7 4 6
91. tates as well as in Canada Mexico Costa Rica Argentina Brazil Chile Venezuela Northern Ireland the Netherlands Spain Hungary Israel Turkey China India Indonesia Singapore Taiwan and the Philippines Bonitron Inc TALENTED PEOPLE MAKING GREAT PRODUCTS The engineering team at Bonitron has the background and expertise needed to design develop and manufacture the quality industrial systems demanded by today s client A strong academic background supported by continuing education is complemented by many years of hands on field experience Expertise encompasses a broad range of applications and engineering solutions such as modern power conversion design techniques and microprocessor based controls This insures a solution tailored to the specific needs of the client A clear advantage that Bonitron has over many competitors is combined on site engineering labs and manufacturing facilities This allows the engineering team to have immediate access to and response from testing and manufacturing This not only saves time during prototype development but also is essential to providing only the best quality products AC DRIVE OPTIONS In 1975 Bonitron began working with the AC inverter drive specialists at synthetic fiber plants to develop speed control systems that could be interfaced to their plant process computers Since that time Bonitron has developed AC drive option modules that help overcome many of the problems encou
92. ule provides the system TEST switch required for threshold voltage adjustments and system calibration The functions of each of these indicators are described below PowER LED The green Power LED is ON if power is applied to the system PCC PRECHARGE CoMPLETE LED The green Precharge Complete LED is ON if the DC bus has reached the factory preset pre charge level RipE THRU READY LED The green Ride Thru Ready LED is ON if the module is fully operational and capable of regulating the rated DC bus voltage under the specified power sag conditions RibE THRU ACTIVE LED The amber Ride Thru Active LED is ON if the module is regulating the DC bus voltage under an input line sag condition VOLTAGE FAULT LED The red Voltage Fault LED is ON if any single phase of the AC line input is missing OVER TEMPERATURE LED The red Overtemp LED is ON if the backplate temperature exceeds 130 F TEST SYSTEM SWITCH The Test System push button switch will cause the Ride Thru section to raise the DC bus sag setpoint by approximately 100VDC see Table 4 9 The inverter input current will drop and the Ride Thru current will start If the 3460C1 test time jumper J4 is set to EXT the DC bus sag setpoint will remain raised for as long as the switch is pressed If the 3460C1 test time jumper J4 is set to INT the DC bus sag setpoint will remain raised for 2 seconds f this is done under load time out will occur in 2 s
93. us current should remain at zero Power LED should be ON Precharge Complete LED should be ON Ride Thru Ready LED should be ON Ride Thru Active LED should be OFF Voltage Fault LED should be OFF Overtemp LED should be OFF 3460 6 fault output board LED NO fault should be ON e Skip step 2 Doc 4 013012 Rev 20030128 41 M3460R and S3460SR 2 If this unit does NOT have the Precharge Option installed Apply power to the Ride Thru and observe the following conditions on the DP17 Display panel Power LED should be Precharge Complete LED should be ON Ride Thru Ready LED should be e Ride Thru Active LED should be OFF e Voltage Fault LED should be OFF Overtemp LED should be OFF e The Bus Current Meter should read 0 amps The Bus Voltage Meter should read NOMINAL DC bus voltage 3 Verify Control Room Connections if used Control Room should read the Ride Thru status signals as found in the Section 4 2 Move jumper positions on 3460M6 to simulate signals See Figure 3 11 for connection details 4 Verify threshold setpoint e Turn off system power and watch the DC bus voltage fall Refer to the Threshold Adjustment procedure in Section 4 4 e RIDE THRU ACTIVE LED will come ON when the bus drops to the threshold e The DC bus will hold at the threshold momentarily Allow the DC bus to discharge until the PCC LED on the display panel goes OFF Reapply system powe

Model M3460R Model S3460SR - Tecno Ingenieria Industrial

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