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UNDERVOLTAGE SOLUTIONS

Process availability and uptime are the watchwords of a profitable business. Reliability is the key to constant production.  Sags, dips, outages, and transients on the power grid can cause variable frequency drives (VFDs) to trip off-line. This can stop your process and damage your product or equipment. The cost of repair, lost product, and lost productivity can be staggering. Now you can protect your VFDs from power fluctuations from the utility or within the plant with Bontron’s Ride-Thru Solutions.

Conventional methods, such as automatic restart and kinetic buffering, do not allow the VFD to continue operating at full power. Many drives today claim some type of “Ride-Through”, and have been tested to meet SEMI-F47 specifications, however they cannot actually “Ride-Thru” voltage sags over 15% without losing control of the process. Most processes cannot tolerate changes in speed or power output without loss or damage. However, Bonitron’s Ride-Thru systems allow your VFD to maintain full power through sags and outages so your process never sees a disturbance. Bonitron defines Ride-Thru as having no effect on motor speed or torque. In addition, a parallel power path does not affect system reliability. Other solutions, such as UPS, are in-line and can actually reduce system reliability.

Bonitron’s Ride-Thru Modules allow your VFDs to meet or exceed:

  • SEMI-F47
  • Samsung Power Vaccine
  • IEC 61000-4-34

Features

  • Cascade Boost Switching
  • Hook directly to Drive DC bus connections
  • Parallel Connection
  • On Line Test – Without impacting process
  • Low standby power consumption

 

Advantages

  • Low Bus Ripple
  • Connects to all VFD’s easily
  • Exceptional Reliability
  • No impact on main process in standby
  • No heat loss in standby
  • Small Footprint

Benefits

  • Increased Process Availability
  • Low Maintenance
  • Little impact on facility requirements

 

3 Levels of Protection are Available:

Short Term 50% Sag
The most common type of power disturbance is the least costly to protect against. Sags of up to 50% on all three phases can be protected with Bonitron’s Ride-Thru Boost Modules.
 
Short Term 100% Outage
Complete outages up to 20 seconds can occur during utility reclosures or power source switching. Bonitron’s solution pairs our Boost Modules with electrolytic or supercapacitor energy storage to give an outage solution that requires no maintenance or replacement for 10+ years.

Long Term 100% Outage
Long term outages can range from 20 seconds to 15 minutes to allow for manual generator starts or other power source changes. Batteries are used with specially designed Boost Modules to hold up the VFD until power can be restored, or a system shutdown can be completed.

 


M3345
The charts below represent the most cost effective Ride-Thru protection coverages and are determined as system power in kW by sag or outage duration.

Ride-Thru Options S3460SR S3534SR S3460BR S3460UR S3534EC S3534CR S3534BR S3534UR

Bonitron Short Term 50% Sag Solutions solve over 95% of power quality events. There is no energy storage so the unit is smaller and costs less. Bonitron Short Term 50% Sag Solutions have a long life expectancy, no maintenance, use IGBT switching technology , and allow the drive to exceed SEMI-F47 specifications. Short Term 50% Sag Solutions are for 3-Phase symmetrical sags. Bonitron Boost Regulator Modules regulate the DC bus during a voltage sag. As the incoming voltage level drops, the Boost Regulator becomes “active” to boost the rectified DC up to the minimum level needed by the drive.

S3534SR Ride-Thru System

- 5 to 50kW Drives
- 2 Second 50% Sag
- Complete System


The Bonitron S3534SR Boost Regulator System regulates the DC bus during a voltage sag. As the incoming voltage level drops, the Boost Regulator becomes “active” to boost the rectified DC up to the minimum level needed by the drive.

S3460SR Ride-Thru System

- 50 to 1300kW Drives
- 2 Second 50% Sag
- Complete System


The S3460SR is used with 50 to 1300kW drives. Like the S3534SR, the Bonitron S3460SR Boost Regulator System regulates the DC bus during a voltage sag. As the incoming voltage level drops, the Boost Regulator becomes “active” to boost the rectified DC up to the minimum level needed by the drive.

M3534R Boost Regulator Module

- 5 to 50kW Drives
- 2 Second 50% Sag


The M3534R Boost Regulator regulates the DC bus inverter during a voltage sag event. As the incoming voltage level drops, the M3534R becomes “active” in order to boost the rectified DC up to the minimum level needed by the inverter. For 100% outage applications the M3534R becomes an energy reservoir voltage regulator when used in conjuction with Bonitron batteries or capacitors.

M3460R Boost Regulator Module

- 50 to 1300kW Drives
- 2 Second 50% Sag
- UL Listed

The M3460R Boost Regulator provides 2 seconds of sag Ride-Thru capability for 3-phase voltage sags up to 50%, enabling the associated VFD to far exceed SEMI-47 specifications for industrial equipment. The use of IGBT switching technology and the absence of batteries in the M3460R results in low maintenance and long life expectancy. The capability to load test the Ride-Thru and drive while on-line increases confidence in system reliability.

M3532 Sag Buffer Ride-Thru (24VDC)

- Improved uptime-

The Bonitron 24 VDC Sag Buffer Module can help equipment ride through irritating and costly sags, while helping provide an orderly shutdown in a more sustained power loss. Using maintenance-free ultracapacitors, the unit can provide anywhere from 700ms to 10 seconds of holdup (load dependent).

 

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Short Term 100% Outage

Bonitron Short Term 100% Outage Solutions provide protection from short-term AC line voltage sags and outages by using our standard boost technology to regulate energy from a capacitor bank. Short Term 100% Outage Solutions are cost effective - buy only the protection you need! Capacitor models have a 10+ year life-span and can withstand 100,000 Ride-Thru events! Models rated up to 2 seconds allow time for switch reclosures and include a M3528 Capacitor Charger.

S3534EC Electrolytic Capacitor Bank

- Fractional to 3kW Drives
- 0.6 Second 100% Outage
- Electrolytic capacitor energy storage reservoirs with soft precharge

- Complete System

Bonitron S3534EC Systems provide protection from short-term AC line voltage sags and outages for up to 3kW drives by using our standard boost technology to regulate energy from a capacitor bank. S3534EC Systems have a 10+ year life-span and can withstand 100,000 Ride-Thru events!

S3534CR Electrolytic Capacitor Ride-Thru System

- 3 to 12kW Drives
- 2 Second 100% Outage
- Electrolytic capacitor energy storage reservoirs

- Complete System

Bonitron S3534CR Systems provide protection from short-term AC line voltage sags and outages for 3 to 12kW drives. Using Bonitron's standard boost technology, the unit regulates energy from a capacitor bank. S3534CR Systems are rated up to 2 seconds to allow time for switch reclosures.

S3534UR Ultracapacitor Ride-Thru System

- 5 to 50kW Drives
- 2 Second 100% Outage
- Ultra capacitor energy storage reservoirs

- Complete System

Bonitron S3534UR Systems provide protection from short-term AC line voltage sags and outages for 5 to 50kW drives. Using Bonitron's standard boost technology, the unit regulates energy from a capacitor bank. S3534UR Systems are rated up to 2 seconds to allow time for switch reclosures.

S3460UR Ultracapacitor Ride-Thru System

- 50 to 1300kW Drives
- 2 Second 100% Outage
- Ultra capacitor energy storage reservoirs

- Complete System

Bonitron S3460UR Systems provide protection from short-term AC line voltage sags and outages for 50 to 1300kW drives. Using Bonitron's standard boost technology, the unit regulates energy from a capacitor bank.

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Long Term 100% Outage

Bonitron Long Term 100% Outage Solutions provide protection from long-term AC line voltage outages for up to 15 minutes with the use of batteries. This allows enough time for multiple generator restarts or an orderly shutdown. Bonitron Long Term Solutions regulate battery bank voltage and boost it to the drive bus level as it drops during discharge to solve the “voltage drop” problem associated with many other battery bank solutions used in backup situations. The systems are complete and include: Charger, Isolation Transformer, Booster and Batteries. An optional battery bypass can be installed so the system will continue to run during an outage event, even if a single battery fails.

S3534BR Battery Ride-Thru SystemType-1

- 5 to 50kW Drives
- 1 Minute 100% Outage


Bonitron S3534BR Systems provide protection from long-term AC line voltage outages for up to 30 seconds with the use of batteries. S3534BR Systems regulate battery bank voltage and boost it to the drive bus level as it drops during discharge to solve the “voltage drop” problem associated with many other battery bank solutions used in backup situations.

S3460BR Battery Ride-Thru SystemType-1

-
50 to 1100kW Drives
- 15 Minute 100% Outage


Bonitron S460BR Systems provide protection from long-term AC line voltage outages for up to 15 minutes with the use of batteries. S460BR Systems regulate battery bank voltage and boost it to the drive bus level as it drops during discharge to solve the “voltage drop” problem associated with many other battery bank solutions used in backup situations.

M3534B Battery Voltage Regulator Module

- 5 to 50kW Drives
- 90 Second 100% Outage


When used with a battery bank, the M3534B Battery Voltage Regulator provides DC bus support for up to 15 minutes during a 100% power outage as well as AC line voltage sags for AC drive systems using VFDs. The M3534 solves the “voltage drop” problem associated with battery banks in back-up situations by regulating the battery bank voltage and boosting it as it drops. An optional battery bypass will allow the system to continue running during an outage event, even if a battery fails.

M3460B Battery Voltage Regulator Module

- 50 to 1100kW Drives
- Up to 15 Minute 100% Outage
- UL Listed

When used with a battery bank, the M3460B Battery Voltage Regulator provides DC bus support for up to 15 minutes during a 100% power outage as well as AC line voltage sags for AC drive systems using VFDs. The M3534 solves the “voltage drop” problem associated with battery banks in back-up situations by regulating the battery bank voltage and boosting it as it drops. An optional battery bypass will allow the system to continue running during an outage event, even if a battery fails.

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M3460UC Ultracapacitor Bank Add-on for Existing M3460R Modules

The M3460UC is an enclosed ultra capacitor energy storage cabinet with charger module. By adding the M3460UC to an existing M3460R Ride-Thru Module, a 100% outage for a full 0.5, 1, 2, or 3 second spec can be achieved. This would cover virtually all short term power quality issues and exceed SEMI-F47 specifications. Ultra caps require no maintenance and have a 10+ year life with over 100,000 cycles!

M3528B Battery Module

The M3528B is a 108V or 120V Battery Bank designed to provide emergency power during 100% power outages for industrial applications. The M3528B is used with the M3528 Charger and M3534R Boost Regulator as part of a complete Ride-Thru System for fixed bus, variable frequency drives.

 

 

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M3522 Ultracapacitor Regulator

The M3522 is a bidirectional current source designed to move energy between ultracapacitor storage banks and DC bus systems for drive system backup, Ride-Thru, electric vehicle systems, cyclical loads, and other high energy storage applications. The integrated charger can be adjusted and controlled to capture regenerated energy or maintain a float charge. 4:1 voltage boost allows full use of your ultracapacitor bank storage and reduces capacitor count, making a smaller, more cost effective system.

M3528 Ultracapacitor / Battery Charger

The M3528 Charger can charge strings of batteries or ultra capacitors to voltages required for industrial and commercial applications. AC or DC input is available, along with separate float and equalization charge levels. The charger is current limited and designed for use in integrated storage and backup systems, but can also be used in bench or mobile systems.

M3628 Ultracapacitor Discharger

Large capacitor banks store huge amounts of energy and can be a hazard when systems are shutdown for system maintenance. The M3628 system discharges capacitor banks to safe working levels quickly, allowing work on the system to begin in seconds, rather than hours.

 

 

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M3528D Open Cell Bypass

The M3528D bypasses an open battery used in series high voltage battery strings. When used with Bonitron voltage boosters, the diode allows current to bypass the open battery while the booster compensates for the drop in voltage. The M3528D indicates which battery is bad so that only the bad battery needs to be replaced.

M3528M2 Battery String Monitor

If a battery discharges too far, individual cells may change polarity, causing permanent damage to the battery, reducing its lifetime. Batteries, capacitors, and any other system can be damaged by the voltage rising too high. The M3528M2 voltage monitor is designed to monitor DC voltage levels and signal the user if the voltage departs a set range.

M3528M4 Battery Cell Monitor

The M3528M4 monitors a series of 12V batteries and signals the user if one or more of the batteries’ voltages fall below the undervoltage set point, exceeds the overvoltage set point, a blown fuse, or over temperatures exist.

 

 

M3660DM Ride-Thru Display Monitoring System

The M660DM gives users real time information about system functions and monitors present values of the bus and line voltages, currents, and records power quality and Ride-Thru events, including time, duration, and voltage levels.

 

 

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Diode Sharing

M3534D Diode Sharing Modules

- Up to 50kW -
- Isolate drives while sharing common Ride-Thru bus


Bonitron’s M3534D Diode Sharing Modules are used with the M3534 Series and provide blocking diodes that isolate the drives from each other while still establishing a shared, common Ride-Thru bus. This can be used on equally sized and loaded drives within a system, allowing the use of a single boost regulator with more than one drive.

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