Bonitron M3452 EIP Bedienungsanleitung

Web: www.bonitron.com ● Tel: 615-244-2825 ● Email: [email protected]

Model M3452 EIP/PDP

Heavy Duty Braking Transistor

with EtherNet / IP®or PROFIBUS®DP

Communications

K6, K9, K10, M14, T10 Chassis

R7EIP, R7PDP Options

Customer Reference Manual

Bonitron, Inc.

Nashville, TN

An industry leader in providing solutions for AC drives.

ABOUT BONITRON

Bonitron designs and manufactures quality industrial electronics that improve the reliability of

processes and variable frequency drives worldwide. With products in numerous industries, and

an educated and experienced team of engineers, Bonitron has seen thousands of products

engineered since 1962 and welcomes custom applications.

With engineering, production, and testing all in the same facility, Bonitron is able to ensure its

products are of the utmost quality and ready to be applied to your application.

The Bonitron engineering team has the background and expertise necessary to design, develop,

and manufacture the quality industrial electronic systems demanded in today’s market. A strong

academic background supported by continuing education is complemented by many years of

hands-on field experience. A clear advantage Bonitron has over many competitors is combined

on-site engineering labs and manufacturing facilities, which allows the engineering team to have

immediate access to testing and manufacturing. This not only saves time during prototype

development, but also is essential to providing only the highest quality products.

The sales and marketing teams work closely with engineering to provide up-to-date information

and provide remarkable customer support to make sure you receive the best solution for your

application. Thanks to this combination of quality products and superior customer support,

Bonitron has products installed in critical applications worldwide.

Bonitron, Inc.

AC DRIVE OPTIONS

In 1975, Bonitron began working with AC inverter drive specialists at synthetic fiber plants to

develop speed control systems that could be interfaced with their plant process computers. Ever

since, Bonitron has developed AC drive options that solve application issues associated with

modern AC variable frequency drives and aid in reducing drive faults. Below is a sampling of

Bonitron’s current product offering.

WORLD CLASS PRODUCTS

Undervoltage Solutions

Overvoltage Solutions

Uninterruptible Power for Drives

(DC Bus Ride-Thru)

Voltage Regulators

Chargers and Dischargers

Energy Storage

Braking Transistors

Braking Resistors

Transistor/Resistor Combo

Line Regeneration

Dynamic Braking for Servo Drives

Common Bus Solutions

Portable Maintenance Solutions

Single Phase Power Supplies

3-Phase Power Supplies

Common Bus Diodes

Capacitor Formers

Capacitor Testers

Power Quality Solutions

Green Solutions

12 and 18 Pulse Kits

Line Regeneration

M3452 vR7 EIP/PDP
4 
 
1. INTRODUCTION..........................................................................................................................7 
1.1. Who Should Use...........................................................................................................................7 
1.2. Purpose and Scope........................................................................................................................ 7 
1.3. Manual Version ............................................................................................................................ 7 
Figure 1-1: Typical M3452-R7 ................................................................................................................7 
1.4. Symbol Conventions Used in this Manual and on Equipment.....................................................8 
2. PRODUCT DESCRIPTION............................................................................................................9 
2.1. Related Products........................................................................................................................... 9 
2.2. Part Number Breakdown ............................................................................................................10 
Figure 2-1: M3452 Part Number Breakdown.........................................................................................10 
Table 2-1: Control Voltage Rating.........................................................................................................10 
Table 2-2: Available Braking Current Ratings.......................................................................................11 
Table 2-3: DC Bus Voltage Rating ........................................................................................................11 
Table 2-4: Chassis Codes.......................................................................................................................11 
Table 2-5: Control Option Codes...........................................................................................................12 
2.3. General Specifications................................................................................................................12 
Table 2-6: General Specifications..........................................................................................................12 
2.4. General Precautions and Safety Warnings .................................................................................13 
3. INSTALLATION INSTRUCTIONS................................................................................................15 
3.1. Product Inspection......................................................................................................................15 
3.2. Site Selection..............................................................................................................................15 
3.3. Mounting ....................................................................................................................................15 
3.4. Wiring and Customer Connections.............................................................................................16 
3.4.1. Power Wiring ..............................................................................................................................16 
Table 3-1: Power Wiring Specifications ................................................................................................16 
3.4.2. I/O Wiring ...................................................................................................................................17 
Table 3-2: I/O Terminal Block Specifications: R7 Control Board.........................................................17 
3.4.3. DC Control Wiring......................................................................................................................17 
Figure 3-1: Customer Connections in K6 Chassis .................................................................................18 
Figure 3-2: Customer Connections in K9 Chassis .................................................................................19 
Figure 3-1: Customer Connections in K10 Chassis................................................................................20 
Figure 3-2: Customer Connections in M14 Chassis...............................................................................21 
Figure 3-3: Customer Connections in T10 Chassis................................................................................22 
3.5. Typical Configurations...............................................................................................................23 
Figure 3-4: Master Stand-Alone Hookup...............................................................................................23 
Figure 3-5: Master with Slave(s) Hookup..............................................................................................23 
Figure 3-6: I/O Hookup with R7 EIP/PDP Communication ..................................................................24 
Figure 3-7: Braking Transistor Customer Connections..........................................................................25 
Figure 3-8: 24VDC Power Connection..................................................................................................26 
4. OPERATION..............................................................................................................................27 
4.1. Functional Description ...............................................................................................................27 
4.2. Features....................................................................................................................................... 27 
4.2.1. Indicators.....................................................................................................................................27 
Table 4-1: Fault Conditions Table..........................................................................................................27 
4.2.2. Terminal Strip I/O .......................................................................................................................28 
4.2.3. Master / Slave Control (200 Amp to 1600 Amp) ........................................................................28 
4.2.4. Fieldbus I/O.................................................................................................................................30 
Figure 4-1: M3452R7 Memory Map......................................................................................................30 
Table 4-2 PROFIBUS Network Length.................................................................................................33 
Table 4-3 D-Sub Pin Signal Description................................................................................................35 
Figure 4-2: PROFIBUS Connector ........................................................................................................35 

Table of Contents
 5 
Figure 4-3: PROFIBUS Address Switches ............................................................................................36 
Table 4-4: PROFIBUS Diagnostic Table...............................................................................................38 
Figure 4-4: Screen shot of Home Page...................................................................................................41 
Figure 4-5: Screen shot of Password Configuration Page......................................................................42 
Figure 4-6: Screen shot of Network Configuration Page .......................................................................43 
Figure 4-7: Screen shots of Test Page....................................................................................................48 
Table 4-5: Diagnostic Table...................................................................................................................50 
4.3. Startup......................................................................................................................................... 51 
4.3.1. Pre-Power Checks .......................................................................................................................51 
4.3.2. Startup Procedure and Checks.....................................................................................................51 
4.4. Operational Adjustments............................................................................................................52 
5. MAINTENANCE AND TROUBLESHOOTING...............................................................................53 
5.1. Periodic Testing..........................................................................................................................53 
5.2. Maintenance Items......................................................................................................................53 
5.3. Troubleshooting.......................................................................................................................... 53 
5.3.1. Green Control Power light not illuminated .................................................................................53 
5.3.2. Amber DC Bus light not on.........................................................................................................54 
5.3.3. Blown DC bus fuse......................................................................................................................54 
5.3.4. Fan runs constantly......................................................................................................................54 
5.3.5. Fan doesn’t run............................................................................................................................54 
5.3.6. Control Ready contacts won’t close ............................................................................................55 
5.3.7. Power Stage Ready contacts won’t close ....................................................................................55 
5.3.8. Module over-temp, or module seems too hot..............................................................................55 
5.3.9. Drive trips on overvoltage...........................................................................................................56 
5.3.10. Red Braking light flickers ...........................................................................................................56 
5.3.11. Red Braking light stays on all the time........................................................................................57 
5.3.12. Master Unit appears to function properly, but Slave Units do not seem to follow the Master....57 
5.3.13. Attached Drive Will Not Precharge.............................................................................................57 
5.4. Technical Help –before you call................................................................................................57 
6. ENGINEERING DATA................................................................................................................59 
6.1. Ratings Charts.............................................................................................................................59 
Table 6-1: Module Ratings: 230 –240 VAC Drives (375 VDC Setpoint).............................................59 
Table 6-2: Module Ratings: 380 –415 VAC Drives (620 VDC Setpoint).............................................60 
Table 6-3: Module Ratings: 460 –480 VAC Drives (750 VDC Setpoint).............................................61 
Table 6-4: Module Ratings: 575 –600 VAC Drives (940 VDC Setpoint).............................................62 
Table 6-5: Module Ratings: 690 VAC Drives (1090 VDC Setpoint).....................................................63 
6.2. Watt loss.....................................................................................................................................63 
Table 6-6: Watt Loss..............................................................................................................................63 
6.3. Certifications ..............................................................................................................................63 
6.4. UL 508A Short Circuit Current Rating ......................................................................................63 
6.5. Fuse/Circuit Breaker Sizing and Rating ..................................................................................... 63 
6.6. DC Bus Link Length Limits.......................................................................................................64 
Table 6-7: Maximum Inductance for DC Link Cable ............................................................................64 
Figure 6-1: DC Link...............................................................................................................................64 
6.7. Resistor Link Length Limits.......................................................................................................65 
6.8. Dimensions and Mechanical Drawings......................................................................................65 
Figure 6-2: M3452 K6 Chassis Dimensional Outline Drawing .............................................................65 
Figure 6-3: M3452 K9 Chassis Dimensional Outline Drawing .............................................................66 
Figure 6-4: M3452 K10 Chassis Dimensional Outline Drawing ...........................................................67 
Figure 6-5: M3452 M14 Chassis Dimensional Outline Drawing...........................................................68 
Figure 6-6: M3452 T10 Chassis Dimensional Outline Drawing............................................................69 
6.9. Block Diagrams..........................................................................................................................70 
Figure 6-7: Block Diagram (All 200A thru 1200A and 1600A in T10 Chassis)....................................70 

M3452 vR7 EIP/PDP

Figure 6-8: Block Diagram (1600A in M14 Chassis) ............................................................................70

7. APPENDICES.............................................................................................................................71

7.1. Application Notes....................................................................................................................... 71

7.1.1. Sizing your braking requirements................................................................................................71

7.1.2. Common Bus Application Note ..................................................................................................73

7.1.3. Bonitron Line Regeneration Modules .........................................................................................74

User’s Manual

1. INTRODUCTION

1.1. WHO SHOULD USE

This manual is intendedfor use by anyone who is responsible for integrating, installing,

maintaining, troubleshooting, or using this equipment with any AC Drive System.

Please keep this manual for future reference.

1.2. PURPOSE AND SCOPE

This manual is a user’s guide for the Model M3452 Heavy Duty Braking Transistor. It

will provide the user with the necessary information to successfully install, integrate,

and use the M3452 Heavy Duty Braking Transistor in a variable frequency AC drive

system.

In the event of any conflict between this document and any publication and/or

documentation related to the AC drive system, the latter shall have precedence.

1.3. MANUAL VERSION

The “D” Control Voltage and “L” Braking Current Ratings were added in Rev 02.

DC bus information was expanded in Rev 02a.

Dimensional outlines and connection drawings were updated in Rev 02b.

I/O Hookup drawings and link length limits were updated in Rev 02c.

The T10 Chassis was added in Rev 02d.

Rev 02e has minor text edits.

Figure 3-5 was updated in Rev 02f.

The manual template was updated in Rev 02g.

Figure 3-5 was updated in Rev 02h.

Updated Section 6.3 Certification in Rev 02i.

Section 3.4 was updated in Rev 02j.

Added Altitude to table 2-6 in Rev 02k.

Updated Table 3-1 in Rev 02m.

Figure 1-1: Typical M3452-R7

K9 CHASSIS

M14 CHASSIS

M3452 vR7 EIP/PDP

1.4. SYMBOL CONVENTIONS USED IN THIS MANUAL AND ON

EQUIPMENT

Earth Ground or Protective Earth

AC Voltage

DC Voltage

DANGER!

DANGER: Electrical hazard - Identifies a statement that indicates

a shock or electrocution hazard that must be avoided.

DANGER!

DANGER: Identifies information about practices or circumstances

that can lead to personal injury or death, property damage, or

economic loss.

CAUTION!

CAUTION: Identifies information about practices or circumstances

that can lead to property damage, or economic loss. Attentions

help you identify a potential hazard, avoid a hazard, and

recognize the consequences.

CAUTION!

CAUTION: Heat or burn hazard - Identifies a statement regarding

heat production or a burn hazard that should be avoided.

User’s Manual

2. PRODUCT DESCRIPTION

Bonitron M3452 heavy duty braking transistors are used with AC drives to allow full power

braking and eliminate overvoltage faults. This permits controlled braking and dramatically

shortens motor stopping time.

The M3452 works with variable frequency drives(with DC bus connections) to monitor the

DC bus. If overvoltage occurs, the M3452 shunts the excess energy through an external

braking resistor to prevent overvoltage faults.

The need for regenerated voltage control occurs in applications where the frequency of

an AC motor at times exceeds that of its variable frequency drive. In this case, the motor

acts as a generator. The energy generated by the motor must be dissipated as heat or

returned to the power line. If this energy is not controlled, the motor may run with high

peak voltages, the energy may be dissipated as heat in the motor, or the drive may trip on

an over-voltage condition.

The R7 option allows for Master/Slave operation to be changed on the fly in multiple

module systems to allow for fault redundancy in the control sections for critical

applications.

The R7E option includes all the functions of the R7 option, while adding extended status

I/O as well as the bus discharge feature. This can be used to drain a capacitor bank for

quicker servicing at power down. This can be an issue with drive systems that have large

capacitor banks or use oversized capacitor banks for power dip immunity. Under normal

circumstances, these banks can take excessive amounts of time to reach safe working

levels. The bus discharge feature allows the braking system to be used as the bleeder

resistor, and brings the bus voltage down much quicker.

The EIP / PDP options (available on 200A units and above) work in conjunction with the

R7E option to provide those functions via an RJ45 / DB9 plug to an EtherNet / PROFIBUS

device. The power supply for the EtherNet / PROFIBUS I/O module is isolated (3000VDC)

from the DC bus.

2.1. RELATED PRODUCTS

The M3452 series is one of several overvoltage solutions offered by Bonitron. Below

are a few related products, including braking resistors that are used in conjunction with

the M3452 series.

BRAKING TRANSISTORS

•Like the M3452 heavy duty braking transistors, Bonitron M3575T and M3675T

standard duty braking transistors work with variable frequency drives (with DC

bus connections) to monitor the DC bus. If overvoltage occurs, the M3575T or

M3675T shunts the excess energy through an external braking resistor to

prevent overvoltage faults. The M3575T series is rated up to 600A peak / 20%

duty, while the M3675T series is rated up to 10 A peak / 20% duty.

BRAKING RESISTORS

•Bonitron offers resistor solutions to complement its braking transistor selection.

The M3575R series is rated up to 32 A peak / 20% duty, while the M3775R series

is rated up to 1600 A / 100% duty. Custom resistors are also available.

M3452 vR7 EIP/PDP

LINE REGENERATION

•Bonitron is famous for its industry-leading line regeneration solutions. The

Bonitron M3645 line regen returns regenerative energy back onto the AC line

instead of dissipatingthe energy as heat in aresistor, and is ideal for applications

with high duty cycles, frequent deceleration, or where heat from a resistor may

be an issue. The M3645 line regen features an interactive digital display with

event logging.

Please contact your AC drive distributor or visit our website at www.bonitron.com for

more information on these additional products.

2.2. PART NUMBER BREAKDOWN

Figure 2-1: M3452 Part Number Breakdown

BASE MODEL NUMBER

The base model number for all heavy duty braking transistors is M3452.

CONTROL VOLTAGE RATING

The control voltagerating indicates the voltage levelto be used to supply control power

to the unit. Most units utilize the AC line voltage supplied to the drive system.

However, this is not required. Other AC voltage sources can be used if desired. Refer

to the unit specifications to determine the voltage source. The control voltage is

indicated by a code letter.

Table 2-1: Control Voltage Rating

CONTROL VOLTAGE

RATING CODE

VOLTAGES

115 –120 VAC

230 –240 VAC

380 –415 VAC

460 –480 VAC

575 –600 VAC

24 VDC

BRAKING CURRENT RATING

The braking current rating indicates the maximum current level that can safely be

handled by the M3452 heavy duty braking transistor.

M3452

600

R7PDP

BASE MODEL NUMBER

CONTROL VOLTAGE

BRAKING CURRENT

*DC BUS VOLTAGE

CHASSIS STYLE

CONTROL OPTION

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