Ensuring Continuous SMT Production with Preen Industrial UPS Solutions

Power continuity and power quality are essential for semiconductor packaging, testing, and Surface Mount Technology (SMT) production. Even a brief power disturbance can interrupt production, reduce yield, and increase operating costs.

To support a multinational manufacturer with facilities in different countries, Preen delivered customized power quality solutions based on local grid conditions. APS Series Static Solid-State Voltage Regulators were installed with datacenter UPS systems to stabilize voltage in the United States, Mexico, and Malaysia. For the customer's Vietnam facility, where grid instability posed a greater challenge, multiple high-load SMT lines were protected by AEU Series Industrial High-Power UPS Systems.

The Vietnam project spans three buildings across multiple floors. A centralized architecture allows one high-power UPS to protect two SMT production lines, supporting a total load of 520 kW with 15 minutes of battery backup. From system design and structural assessment to onsite commissioning, Preen delivered the entire project as a turnkey solution.

The Challenge: Millisecond Power Interruptions Can Stop Production

Modern SMT lines integrate screen printers, high-speed pick-and-place machines, reflow ovens, and inline AOI systems into a continuous automated process. Even a millisecond power interruption can halt production.

• Reflow oven interruptions can stop conveyor movement during soldering, exposing PCBs and components to uneven heating that often results in immediate batch scrap.
  
  

• Poor power quality, including voltage sags, harmonic distortion, and transient surges, accelerates wear on precision motors and sensors, reducing placement accuracy and overall production yield.
  
  

For high-volume SMT manufacturing, a reliable industrial UPS has become an essential part of production infrastructure.

Three Engineering Challenges
The Vietnam facility presented three major engineering challenges.

1. High Power Demand: one UPS was designed to protect two SMT lines with a combined load of 520 kW, requiring high system capacity, efficient thermal management, and fast transient response.
   
   

2. Multi-Floor Deployment: critical equipment was distributed across multiple buildings and floors, requiring a flexible architecture with localized fault isolation.
   
   

3. Structural loading limits: each UPS required 160 batteries to provide 15 minutes of backup time. Every battery rack weighed 10,600 kg (10.6 metric tons), making structural load assessment a key part of the installation.

AEU Series: High-Reliability Power Quality & Protection

Designed for demanding industrial environments, the AEU Series Industrial UPS delivers continuous power protection through four key technologies.

• Zero-Transfer Online Double-Conversion: the online double-conversion topology isolates critical loads from utility power. During a utility failure, battery backup is activated with zero transfer time, keeping chip shooters, reflow ovens, and AOI systems operating without interruption.
  
  
• ±1% Voltage Regulation: the system provides ±1% output voltage accuracy and maintains ±2% voltage deviation under 100% unbalanced loads. It also isolates harmonics and transient surges to protect sensitive equipment and improve production stability.
  
  
• 12.5% Higher Load Capacity With A Wide Input Voltage Range: With a unity power factor (PF = 0.9), the AEU-33600TT delivers up to 540 Kw, 12.5% higher capacity than conventional PF = 0.8 systems, providing sufficient margin for the 520 kW application while reducing CAPEX.
  Its ultra-wide 285–498 V input voltage range minimizes unnecessary battery discharge during grid fluctuations, extending battery life.
  
  
• Smart Battery Management: Programmable self-diagnostics, temperature compensation, and a smart BCB-BOX provide continuous battery monitoring and physical isolation during battery faults. Accurate runtime estimation can extend battery service life by up to 30%.

Turnkey Engineering From Design to Commissioning

Beyond equipment supply, Preen provided complete turnkey engineering services throughout the project.

• Structural Assessment: Preen performed onsite structural calculations and floor load-bearing analysis during the design stage. Battery layouts were optimized to distribute weight safely across upper-floor installations.
  
  
• Independent Fault Isolation: Each UPS independently protects two SMT lines. Maintenance or service on one UPS does not affect other production lines, improving plant availability and operational flexibility.
  
  
• Comprehensive Validation: Every AEU UPS undergoes incoming inspection of critical imported components, a 72-hour full-load burn-in test, and parallel circulating current testing during Factory Acceptance Testing (FAT). After installation, Site Acceptance Testing (SAT) verifies system performance under simulated power failures and overload conditions.

Tailored Solutions for Global Precision Manufacturing

Power interruptions and poor power quality directly affect production efficiency, product yield, and operating costs.

From APS Series Static Solid-State Voltage Regulators installed in the United States, Mexico, and Malaysia to AEU Series Industrial High-Power UPS Systems protecting multi-floor SMT production lines in Vietnam, Preen delivers power quality solutions tailored to regional grid conditions.

With proven engineering expertise and global turnkey execution, Preen helps manufacturers maintain stable operations and maximize production uptime.