Bonitron, Inc. Industrial Electronics for Power Quality and Ride-Thru Solutions

 
Bonitron,
 
Inc.
 
20141103
 
Dedicated
 
to
 
engineering
 
quality
 
industrial
 
electronics
 
since
 
1962!
 
Power
 
Quality
 
Problems
 
with
 
VFD’s
 
 
VFD DC Bus
 
C
apacitors
 
D
rain
 
A
lmost
 
I
mmediately
 
No
 S
ag
 C
orrection
 B
uilt
 
In
 
6
 
P
ulse
 
F
ront
 
E
nds
 
H
ave
 
N
o
 
B
oost
 
C
apability
 
Maintaining 
F
ull
 
L
oad
 
A
nd
 
P
ower
 
Kinetic
 
B
uffering
 
C
auses
 
S
peed
 And Torque
 
C
hanges
 
5
 
D
r
i
v
e
 
R
i
d
e
 
T
h
r
u
 
C
a
p
a
b
i
l
i
t
i
e
s
 
 
Returning Utility Power Or Input AC Can Cause Surges
 
Utility Power Outages
 
Understanding
 
Ride-
Thru
 
Bonitron
 
UPD
 
Ride-
Thru
 
systems
 
are
 
designed
 
for
 
AC
 
drive
 
systems
 
that
 
use
 
a
 
fixed
 
DC
 
bus,
 
such
 
as
 
AC 
variable
speed drives
 
(VSD). 
Unfortunately,
 VSDs
 
are quite
 
susceptible
 
to fluctuations in
 
incoming
 
AC line 
power, 
such
 
as
voltage sags
 
and
 
complete outages
 
from the
 
utility.
 
Bonitron UPD
 
Ride-
Thru
 
systems
 
provide 
the 
security
 
of
 
“riding
through”
 
these
 
events
 by holding up a drives DC bus allowing for motor constant speed and torque
.
 
3
 
Current Industry Ride Thru Solutions
V
F
D
A
C
 
U
t
i
l
i
t
y
 
I
n
p
u
t
 
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n
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n
e
 
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l
e
 
C
o
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r
s
i
o
n
 
U
P
S
 
S
e
r
i
e
s
 
R
i
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e
 
T
h
r
u
 
S
o
l
u
t
i
o
n
s
 
A
C
 
L
i
n
e
 
U
t
i
l
i
t
y
/
U
P
S
 
V
F
D
I
n
p
u
t
.
 
U
P
D
 
A
C
 
3
 
P
h
a
s
e
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u
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p
u
t
 
t
o
 
D
r
i
v
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P
S
 
A
C
 
O
u
t
p
u
t
 
t
o
 
V
F
D
B
a
t
t
e
r
i
e
s
R
e
c
t
i
f
i
e
r
C
h
a
r
g
e
r
 
Uninterruptible
 
Power
 
for
 
Drives
 
5
 
Bonitron
 
UPD
 
Advantages
 
Maintain
s
 
S
peed
 
and
 
T
orque
 for Critical Applications
 
During
 
an
 
AC
 
L
ine
 
S
ag
 
or
 
O
utage
, Critical Application VFDs Remain at Full Capability
 
Simple
 
R
etrofit
 
or
 
I
nitial
 
I
nstallation
 
Uses
 
D
rive’s
 
E
xisting
 
DC
 
B
us
 
C
onnection
 Terminals
Non-
intrusive
 
to
 
V
ariable
 
F
requency
 
D
rive
: WARRANTY SAFE
 
Increased
 
R
eliability
 
Parallel
 
C
onfiguration
 to Drive
Local
 
to Drive I
nstallation
 
P
rotects
 
F
rom
 
E
xternal
 
and
 
I
nternal
 
P
lant
 
G
rid
 
F
aults
 
Increased
 
E
fficiency
 
In Parallel Standby Mode, Bonitron UPD Systems and Modules Use Less Static Power Than On-line Series Drive Backups
Higher
 
E
fficiency
 
D
uring
 
B
ackup,
 
L
onger
 
D
urations
 
F
rom
 
E
nergy
 
S
torage
 
Storage
 
Options
 
VRLA B
attery
 
B
anks
 Are Sized to The Specific AC Line Outage kW Requirement and Time Required
Shorter AC Line 100% Outage Times Can Use Maintenance Free Ultracapacitor Energy Storage
 
1
1
0
0
 
Bonitron
 
Uninterruptable Power For Drives
 
 
AC-DC Conversion Single Voltage Regulator Booster - Sags
DC-
DC
 
Conversion Voltage Regulator Booster
 
with
 
E
nergy
 
S
torage
 and Charger – 100% Outages
 
Single Unit Required 
Only
No
 
E
nergy
 
S
torage
 
N
ecessary
 
 
 
0.5-2 Seconds 100% AC Line Outage
Bonitron
 
Voltage
 
Booster
 M3460R
Charging
 
System
Ultracapacitor
 Energy Storage
Ultracapacitor 
Safety
 
Discharge
 
3 Seconds to 30 Minutes,
Energy Storage Ultracapacitors or Batteries, Time and kW Dependent
3-15 Seconds, Energy Storage, kW Dependent with M3460B
Bonitron
 
Voltage
 
Booster
 M3460B
Charging
 
System
Batter
y Energy Storage
 
7
 
UP
D Systems & Modules
 
Long Term AC Line 
Outages
 
5
0
%
 
S
a
g
s
,
 
1
0
0
%
 
S
i
n
g
l
e
 
P
h
a
s
e
 
O
u
t
a
g
e
 
Short Term AC Line Outages
 
V
o
l
t
a
g
e
 
R
e
g
u
l
a
t
o
r
 
B
o
o
s
t
e
r
 
O
n
l
y
 
Energy
 
Storage
 
Options
 
Ultracapacitors
 
15
 
Batteries
 
Electrolytic
 
Capacitors
 
180
V M
odule
 
48
V M
odule
 
12
V
 
VRLA 
B
attery
 
700
V
 
A
ssembly
Short
 
Term 
O
utages
Low
 
kW
 
D
rives
Short
 
Term 
O
utages
Low to 
High
 
kW
 
D
rives
 
Up
 
to
 
15
 minute
full
 outage
Long
 
Term O
utages
Low to High kW
 
D
rives
 
Critical Process Protection
 
9
 
P
P
l
l
a
a
n
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t
 
 
B
B
a
a
c
c
k
k
u
u
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S
y
y
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m
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&
&
 
 
R
R
e
e
d
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d
a
a
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n
c
c
y
y
 
Solution selection is usually dependent on the critical nature of an application. In critical applications,
Solution selection is usually dependent on the critical nature of an application. In critical applications,
several levels of plant process and drive/motor protection are required. “Redundancy Levels”.
several levels of plant process and drive/motor protection are required. “Redundancy Levels”.
This is common in applications such as Semiconductor and Data Center HVAC VFD Systems where no
This is common in applications such as Semiconductor and Data Center HVAC VFD Systems where no
change in speed or torque of the associated motor can occur. The drawing illustrates N+3 Redundancy
change in speed or torque of the associated motor can occur. The drawing illustrates N+3 Redundancy
 
P
P
o
o
w
w
e
e
r
r
 
 
D
D
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r
r
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b
u
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U
P
P
S
S
 
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P
l
l
a
a
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n
t
t
 
 
G
G
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n
n
S
S
e
e
t
t
 
Process Level
Process Level
VFD Backup
VFD Backup
undefined
 
Critical Process Protection
Critical Process Protection
 
Bonitron
 
UPD
 
Systems
 
1-Second
 
100%
 
Outage
,
 
6
0
kW
Ultracapacitor Energy Storage
 
2
-Second
 
50% Sags, 
250
kW
 
1-Second
 
100%
 
Outage
,
 150kW
,
Double Bay Enclosure with
Ultracapacitor Energy Storage
 
2
2
4
4
 
4 Minutes 100% Outage
, 
200
kW
 and
Battery Energy Storage Enclosure
 
15
-Second
s, 230VAC
 
100%
Outage
,
 
30
kW
 Battery
Energy Storage
undefined
 
Dedicated
 
to
 
Designing
and
 
Manufacturing
Quality
 
Industrial
 
Electronics
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Bonitron, Inc. has been dedicated to engineering quality industrial electronics since 1962. They specialize in addressing power quality problems with VFDs and offer ride-thru solutions to maintain speed and torque during AC line sags or outages. Their UPD systems provide a reliable solution for AC drive systems, improving efficiency and reliability while protecting from external and internal grid faults. Learn about the current industry ride-thru solutions and the advantages of Bonitron's UPD systems.


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  1. Bonitron, Inc. Dedicated to engineering quality industrial electronics since 1962! 20141103

  2. Power Quality Problems with VFDs Drive Ride Thru Capabilities VFD DC Bus Capacitors Drain Almost Immediately No Sag Correction BuiltIn 6 Pulse Front Ends Have No Boost Capability Maintaining Full Load And Power Kinetic Buffering Causes Speed And Torque Changes Utility Power Outages Returning Utility Power Or Input AC Can Cause Surges 5

  3. Understanding Ride-Thru Bonitron UPD Ride-Thru systems are designed for AC drive systems that use a fixed DC bus, such as AC variable speed drives (VSD). Unfortunately, VSDs are quite susceptible to fluctuations in incoming AC line power, such as voltage sags and complete outages from the utility. Bonitron UPD Ride-Thru systems provide the security of riding through these eventsby holding upa drives DC bus allowing for motorconstantspeedandtorque. 3

  4. Current Industry Ride Thru Solutions Online UPS Series Ride Thru Solutions Excessive Energy Used During Normal Operation Due to Passing All AC Power to VFD Input. Series Solution. Supplies All AC Line Voltage. Point of Failure During Normal Operation Series VFD AC Input Ride Thru Solutions Line Interactive UPS Becomes Active and Uses Batteries with AC Line Momentary Brownouts. During Normal Operation, Outputs a Square Wave Creating Excessive Wear and Tear on Associated Motors Has A Voltage Regulating Transformer For Low Voltage Brownout Events Most of The Units Available Have to Switch to Battery Momentarily When Making Transformer Voltage Adjustments During Brownouts, Which Reduce Battery Life Over Time UPS AC Output to VFD Batteries AC Utility Input Rectifier VFD AC Line Utility/UPS VFD Input. UPD AC 3 Phase Output to Drive Standby UPS Charger For Non-critical Applications. Lowest Level of UPS Protection Inverter Only Operatives as Long as The Outage Event Lasts and Batteries Remain Charged. Online Double Conversion UPS AC Line Sag Corrector Corrects for Sags and Partial AC Line Losses. No Full Outage Capability Series Solution. Point of Failure During Normal Operation Flywheels Bearing Changeouts Create Excessive Downtime Requires Batteries for Storing Flywheel Energy VFD Active Front Ends Cycles of Ride Thru Only. Can Not Handle Extended Outage Ride Thru Specifications

  5. UninterruptiblePowerforDrives UPD Advantages 5

  6. Bonitron UPD Advantages Maintains Speed and Torque for Critical Applications During an AC Line Sag orOutage, Critical Application VFDs Remain at Full Capability Simple Retrofit or Initial Installation Uses Drive s Existing DCBusConnection Terminals Non-intrusive toVariableFrequencyDrive: WARRANTY SAFE IncreasedReliability Parallel Configuration to Drive Localto Drive Installation Protects From External andInternalPlant GridFaults IncreasedEfficiency In Parallel Standby Mode, Bonitron UPD Systems and Modules Use Less Static Power Than On-line Series Drive Backups Higher Efficiency DuringBackup,LongerDurationsFromEnergyStorage StorageOptions VRLA BatteryBanks Are Sized to The Specific AC Line Outage kW Requirement and Time Required Shorter AC Line 100% Outage Times Can Use Maintenance Free Ultracapacitor Energy Storage 1 10 0

  7. BonitronUninterruptable Power For Drives UPD Systems & Modules AC-DC Conversion Single Voltage Regulator Booster -Sags DC-DC Conversion Voltage Regulator Boosterwith Energy Storage and Charger 100% Outages 50% Sags, 100% Single Phase Outage Single Unit Required Only No Energy StorageNecessary Voltage Regulator Booster Only Short Term AC Line Outages 0.5-2 Seconds 100% AC Line Outage BonitronVoltage BoosterM3460R ChargingSystem Ultracapacitor Energy Storage Ultracapacitor Safety Discharge Long Term AC Line Outages 3 Seconds to 30 Minutes, Energy Storage Ultracapacitors or Batteries, Time and kW Dependent 3-15 Seconds, Energy Storage, kW Dependent with M3460B Bonitron Voltage Booster M3460B ChargingSystem Battery Energy Storage 7

  8. EnergyStorageOptions Batteries Ultracapacitors Electrolytic Capacitors 12V VRLA Battery Up to 15 minute full outage Low to High kW Drives Long Term Outages 180V Module 48V Module Short Term Outages Low to High kW Drives 700V Assembly Short Term Outages Low kW Drives 15

  9. Critical Process Protection Plant Redundancy Power Distribution UPS Process Level VFD Backup Plant Gen Set Plant Backup Systems & Redundancy Solution selection is usually dependent on the critical nature of an application. In critical applications, several levels of plant process and drive/motor protection are required. Redundancy Levels . This is common in applications such as Semiconductor and Data Center HVAC VFD Systems where no change in speed or torque of the associated motor can occur. The drawing illustrates N+3 Redundancy

  10. Critical Process Protection What is a Critical Process? Critical Process Backup Reasons Personnel Safety Can Be Compromised if the Associated Process Motor Losses Power and Becomes Erratic Any Slight Deviation in Motor Speed or Torque Can Create Scrap Product and Expensive Production Loses or Cleanup Loss of Security System Power Can Allow Intrusion Into High Security Areas Loss of Power to Equipment s Personnel Safety Features Can Create Hazzard to Workers Perishable Products can Be Lost During AC Line Loss that Can Trip Refrigeration Compressor VFDs/Motors Critical Process Examples Data Centers Environmental Systems Backup Critical Data Can Be Lost if Environmental Systems Are Lost and Data Servers Overheat Semiconductor Cleanroom Air Handlers & Machine Tool Chill Water *Cleans Rooms Must Remain Free of Environmental Particulates or Expensive Semiconductor Wafers are Discarded *Machine Tools for Wafer Etching Must maintain Constant Chill Water Cooling Due to High-Speed Operation Lubrication Systems *High Speed Turbines Can Burn up Without Constant Lubrication Safety Systems *Robotics Multi Axis Systems Lose Reference Causing Damage to Mechanical Components or Surrounding Equipment *Hoists & Cranes Can Drop Load Security Gates *Power to Security Access Areas is Cut During Breach Attempts *Chemical and Toxic Exhaust Ventilation *Loss of Ventilation and Exhaust Fans can Create Personnel Hazzard from Toxic Gases

  11. Bonitron UPD Systems 1-Second 100% Outage, 60kW Ultracapacitor Energy Storage 1-Second 100% Outage, 150kW, Double Bay Enclosure with Ultracapacitor Energy Storage 4 Minutes 100% Outage, 200kW and Battery Energy Storage Enclosure 2-Second 50% Sags, 250kW 15-Seconds, 230VAC 100% Outage, 30kWBattery Energy Storage 2 24 4

  12. DedicatedtoDesigning and Manufacturing Quality Industrial Electronics

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