Advantages of Bonitron Regenerative Braking Solutions

In almost every industry, the old saying “time is money” stands true. This saying is no more true than in the world of Industrial Automation. Processes that require frequent stops or continuous braking create a harsh environment for variable frequency drives (VFDs), causing overvoltage faults that stop production.

Integrators are forced to sacrifice valuable time for functionality to create a system that operates properly. Bonitron Line Regeneration models are designed to provide continuous energy regeneration, giving the integrator extreme flexibility to push your process as fast as possible. This increases each line’s production by allowing the customer to stop as fast and as often as you want with no process downtime.

To size our regenerative solution, take the horsepower of your VFD and match it to the horsepower of one of our Line Regen models listed below.

The time it takes to complete your process determines the amount of profit made. When variable speed drive systems are required to brake, excess energy is generated that must be removed or the drive system can lose control of the process due to an overvoltage fault.

Bonitron’s Line Regeneration modules and Regenerative DC Bus Power Supplies give you the ability to expand the braking capabilities of your standard 6-pulse VFDs. Bonitron Line Regen models replace the traditional braking transistor and resistor option.

Instead of dissipating braking energy as heat in a resistor, Line Regen solutions return this energy to the power grid. This reduces demand from the utility, which equates to ample energy savings. Bonitron Regenerative solutions are delivered ready to install with no programming or extra components needed. Access to the VFDs DC terminals and a return 3-phase connection to the AC line are the only installation requirements.  It automatically synchronizes to the frequency of the incoming power line, allowing automatic adaptation to 50Hz or 60Hz. Being efficient and small enough to be integrated into the drive cabinet, eliminates excess resistor wiring, panel space and cooling costs.

Most panels contain multiple VFDs. Each VFD requires their own set of required components: reactor, fusing, breaker and conduit. Implementing the use of a common DC bus system removes the need of components for each individual VFD such as AC breakers, AC fusing, reactor and AC conduit. Removal of these components results in extreme reduction in costs, watts loss, installation time and panel space.

Bonitron’s Regenerative Power Supply rectifies the AC line, supplying DC power to operate VFDs. During a braking event, as the DC bus rises above the AC line peak, the Regenerative Power Supply also redirects current from the DC bus into the AC line to limit the rise in bus voltage and prevent overvoltage faults.

Utilize the Regenerative Power Supply to create a common DC Bus connection that drastically reduces the cost of the panel. To size properly simply add the horsepower of all VFDs to be connected to the common bus and apply a Regenerative Power Supply that rated to the cumulative horsepower.  Use Bonitron’s Regen Cost Savings Calculator to estimate your annual cost savings.

For more information on this or other Bonitron solutions, call your French Gerleman Account Manager or contact us.

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