IGBT plating rectifier for electroplating zinc copper chrome gold nickel 1000A2000A3000A5000A10000A 12V Switch mode rectifiers for plating Introduction Switch mode rectifier for plating is a series ofswitchmode rectifiers designed to meet all surface treatment requirementsof metals and plastics. As a technology specialist in power supplies,Website:http://www.gprectifier.com, Green Power provide wide range of power solutions for various electroplating process, including for nickel plating line, copper plating, zinc plating, gold plating, silver plating, chrome plating, hard chrome plating, tin plating, cadmium plating. Based on high speed IGBT PWM technology, Green Power IGBT plating rectifiers provide high efficiency and performance with module structure and compact size, meet all process requirements and guarantee the user excellent results.We have the best power supply for your electroplating applicationElectroplating rectifiers provide reliable and stable DC power supply for various electroplating process covering metal plating and plastic plating, plating on brass, bronze, steel and more, used for barrel plating, rack plating and continuous plating line. Typical types including igbt plating rectifier 1000A 15V, plating rectifier 2000A 12V, copper plating rectifier 1500A 12V, current rectifiers for plating 3000A 12V, gold plating rectifier 500A 12V, ac to dc rectifier 5000A 12V, used plating rectifiers 300A, 100A 12V etc. 12V power supplies. Why Green Power's switch mode power supplies replace SCR rectifier? Green Power's Switch mode power supplies have many advantages over SCR rectifier, therefore, they are now more and more used for electroplating process to replace SCR rectifier. The main advantages of Green Power pulse plating rectifiers over thyristor rectifiers include but not limited to:Same high reliability as SCR rectifier, long time 7 days 24 hours continuous runningHigh conversion efficiency, power saving at least 15% than SCR rectifier. E.g for 1000A 12V plating rectifier, suppose 6300 hours running time one year, saving power 18613kwh than SCR rectifier.Not affected by power fluctuation, 100% output, don't need extra capacityIGBT rectifier adopts AC-DC-AC-DC topology, 3 phase AC is firstly converted to DC, which has capacitors for energy charging and discharging, it will suppress power fluctuation, so rectifiers don't need bigger capacity than actual use. SCR rectifier doesn't have energy buffer function, it is affected directly by the grid power fluctuation, so it always keep much extra capacityand increase user's investment cost.Pulse output needs less plating time, customer feedback 40% shorter time needed for platingModular design:Rectifier won't break down: in case of one module failed, the rectifier continue working with reduced powerLess downtime and easy recovering:plug-in structure, replace module directly, downtime is shorten to minimum, this reduces potential high cost of your plant stop and increase your plant's availability.Current expansion available:thanks to the modular design and supporting parallel connection, if you need more power, you only need to add more modules.Reduce current rating to save power: if you don't need all modules working, you can switch off some modules, rectifier can work at lower rating.Less floor space occupied: the rectifiers can be built on top of each other, making them easy to fit into your plant's design, optimizingfloor space.Easy to install and maintain: each rectifier consists of up to ten modules and naturally two or more stacks can be connected to allow higher currents (40kA) and voltages (200V DC).Separate output or parallel running output available: you can let the rectifier module separate output to connect to more tanks, or parallel connecting to get higher current for one tank.Compact size, modular structure, e.g. air cooling 1000A 12V size only 450*560*300mm, weight is only 58kg. much less size and weight than SCR rectifier, don't need forklift 1000A 12V air cooling 2000A 12V air coolingLow pollution to grid, power factor>0.93Lower costfor the same specificationComparison chartThyristor rectifierGreen Power switchingpower supplyEfficiencylowhigh88% (typ.)Power factorbadhigh>0.93SizebigsmallAt least 1/2 smaller than SCR typeWeightheavylightRegulation speedslowhighResponse time to load variationslowvery highvery high (≈1ms)Accuracyacceptablevery high1/1000 of max current or voltageShift phaseyesnoParallelability (multi-tower)very difficulteasy in current and voltage modeLosses at no load /Vout ONhighlowLosses at no load /Vout OFFhighlowReverse speedvery slowFast in both voltage and current modefastest in both voltage and current modeTechnology-the core of rectifier reliability 1. 20+ years R&D and engineering experience, exported to 30+ countries, including USA, Germany, UK, India, Pakistan, Israel, Chile etc. 2. High-tech company 3. Our own patent and software copyrights 4. Our own know-how through 20+ years experience 5. DSP Digital control: Ensures 20+ years reliable high control accuracy; Protection self diagnosis and alarm protection type automatically on touch panel, easy for troubleshooting 6. Touch panel HMI: installed on rectifier or away distance for remote monitoring; Full information of the rectifier running status on touch panel; All operations on touch panel 7. Modular design: Module separate output, in case of one broken, others continue working to support rectifier won't break down; Support direct output parallel connection; Compact size, less floor area occupied; easy to integrate with your equipment. 8. Unique insulation design 9. Unique heat dissipation design Quality-the basis of process reliability We provide top quality, high reliability, low fault rate of rectifiers, ensuring your electroplating line smooth continuous running.Components used are all good quality and excellent performance: 1. Control board: DSP digital control, 20+ years high control accuracy, not like analog control, accuracy will reduce after some time. 2. Cabinet: use 2mm thick strong cold-rolled steel plate or aluminum coated zinc plate. 3. High frequency transformer: Nanocrystalline material as transformer core, high efficiency saving power, long time reliable running. 4. Bus bar: red copper bus bar, the purity of copper is 99.9%, tin plated, not like others may use brass or aluminum inside. 5. Cooling fan: use Taiwan or Japan brand high quality fan, with lifespan 100,000 hours under 25℃. 6. Touch panel: control and display all parameters on one panel for local use or remote monitor, say goodbye to separate controls. easy for troubleshooting, while there is protection, it will show protection type automatically. 7. Capacitor: Taiwan brand reliable capacitors. 8. IGBT: Germany or Japan brand. 9. SMPS: Taiwan brand. 10. Rectifier diode module: good quality brand. 11. Current sensor: good quality brand. 12. Cables, wires, screws: good qualitybrands. Production craftwork: Using 3D design software for design, well trained workers, have uniform installation and wiring regulation. Use well trained professional workers have higher wages than not professional workers. Strict quality control process Full load factory testing: Digital PCB board reliability testPCB board function testRectifier function testRectifier protection testTouch panel function testCommunication testFull load power testTemperature rise testMain technical parameters 1.Cooling options: Air cooling IGBT rectifier Water cooling IGBT rectifier2.Available Interfaces with PLC: Analogue 0-10VAnalogue 4-20mARS485(MODBUS)RS232Profibus-DPProfinet3.Operation Modes: Manual (through touch panel or remote control)Automatic (timer setting, process step setting available)4.Protections: The rectifier provides the following protections, user could set rectifier stop delay time and stop or not stop rectifier in case of protections.Protection typeProtection valueRectifier actionShort circuit protectionAlarm Rectifier stop immediatelyOver/under input voltage protectionNominal input voltage+/-10%Alarm Could set stop or not stop rectifierDriving protection/Alarm, rectifier stop immediatelyOver heat protection85℃Alarm Could set stop or not stop rectifierOver current protectionRated output current+100AAlarm Could set stop or not stop rectifierOver voltage protectionRated output voltage+2VAlarm Could set stop or not stop rectifier5.Technical Parameters: Input voltageSingle phase 220VAC for rectifier below 3kw. 3 phase 230VAC, 380VAC, 415VAC, 440VAC, 480VAC, 550VAC, 600VAC 50-60HzOutput DC currentUp to 50kAOutput DC voltageUp to 500VOutput regulation range0-100% of max currentor voltageControl accuracy 1/1000 of max current or voltage Operation Mode Constant current and constant voltage, constant powerRipple <3% on requestEfficiency>90% (typ.) @ rated load >92% (>= 100VDC) @rated loadDegree of ProtectionIP30 for air cooling IP44, IP54 for water cooling on requestPower factor>0.93 @ rated loadInsulation gradeBWorking mode100% 24 hours continuous runningAlarm typeAudible and visual alarm6.Process control parameters: Input to rectifier:Output from rectifier:Set currentSet voltageOn/OffStart/stopSet control mode (CC/CV, local/remote)Set run timeSet pulse timeSet manual/autoEmergency stopSet rectifier-stop delay timeActual currentActual voltageActual powerRun signalRun mode(CC/CV, Local/remote)Alarm signalAlarm causeRun timeAmpere hourWater pressure(for water cooling)Communication status7.Operation Conditions Location: indoor use onlyAmbient temperature: 0℃～+40℃Relative humidity: ≤90% (relative to 20±50℃).Power requirement: AC nominal voltage+/-10%, 3 phase 4 line, 3 phase imbalance less than 5％, and meet national electricity quality standard.Water input temperature(water cooling): 20-35℃Altitude: less than 2,000 meters.There shouldn't be excessive amount of dust, explosive and corrosive gas in the air.The installation place should be without severe vibration, the vertical gradient shouldn't exceed 5%.The seismic intensity of the installation site is less than 7 on the Richter scale.Saturated vapor pressure: daily average value is less than 2.2×10-3M pa, monthly average value is less than 1.8 10-3Mpa.
