Green Power IGBT Switch mode rectifiers for plating have the advantages of Europe quality, Europe technology, power saving more than 20%, modular design, compact size, high power factor,less plating time, not affected by input power fluctuation.
IGBT Rectifier for electroplating zinc copper chrome gold nickel
1000A 12V, 1000A 18V, 2000A 12V, 3000A 15V, 5000A 15V, 5000A 24V, 10000A 12V, 20000A 12V, 10000A 24V, 25000A 12V
IGBT Plating Rectifier video on Youtube:
1. Switch Mode Rectifiers for Plating Introduction
Switch mode rectifier for plating is a series of switch mode rectifiers designed to meet all surface treatment requirementsof metals and plastics. As a technology specialist in power supplies, Green Power provides wide range of power solutions for various electroplating process, including for nickel plating, 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 provides high efficiency and performance with module structure with compact size, meeting all process requirements and guarantee the user excellent results.
2. We have the best power supply for your electroplating application
Electroplating rectifiers provide reliable and stable DC power supply for various electroplating process covering metal plating and plastic plating, plating on brass, bronze, steel etc., 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. power supplies.
3. Why Green Power's switch mode power supplies could replace SCR rectifier?
The main advantages of Green Power pulse IGBT plating rectifiers over thyristor rectifiers(SCR) include but not limited to:
● Same high reliability as SCR rectifier, long time 7 days 24 hours continuous running
● High conversion efficiency, power saving at least 17% than SCR rectifier. E.g for 1000A 12V plating rectifier, suppose 6300 hours running time one year, saving power 18,613kwh than SCR rectifier.
● Not affected by power fluctuation, 100% output, don't need extra capacity
IGBT 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 keeps much extra capacity and increase user's investment cost.
● Pulse output needs less plating time, customer feedback 40% shorter time needed for plating
● Modular design, the advantages of modular design:
Rectifier won't break down: in case of one module failure, the rectifier continues working with reduced power
Less downtime and easy recovering: plug-in structure, replacing module directly, downtime is shorten to minimum, this reduces potential high cost of your plant stop and increase your plant's availability and productivity.
Current expansion available: thanks for the modular design and supporting parallel connection, if you need more power, you only need to add more modules.
Less floor space occupied: the rectifiers can be built on top of each other(rack mounted), making them easy to fit into your plant's design, optimizing floor 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 (up to 40kA) and voltages (up to 200V DC).
Separate output or parallel running output available: you can let the rectifier modules with separate outputs to be connected to more tanks, or in parallel connecting to get higher current for one tank.
● Compact size, modular structure, e.g. air cooling 1000A 12V size only 525*600*310mm, weight is only 58kg. much less size and weight than SCR rectifier, don't need forklift
 |  |
| 1000A 12V air cooling | 2000A 12V air cooling |
● Low pollution to grid, power factor>0.94
● Lower cost for the same specification
Overview of IGBT rectifier advanteages
| Comparison of IGBT rectifier and SCR rectifier | ||
| Green Power IGBT Rectifier | SCR Rectifier | |
| Power semiconductor | IGBT | SCR |
| Voltage regulation mode | PWM modulation | SCR Phase shift |
| Cost for same specs | Lower | High |
| Working frequency | 10-20KHz | 50-60Hz |
| Average efficiency (full load) | >90% | <75% |
| Power saving | yes, about 17% saving from SCR | no |
| Effect by power fluctuation | Less | More |
| Plating time | Less, about 40% saving from SCR | no saving |
| Power factor (full load) | ≥0.94 | ≤0.78 |
| Noise | Low | High |
| Regulation speed | High | Slow |
| Response time to load variation | very high ≈1ms | Slow |
| Accuracy | Very high, 1/1000 of max current or voltage | acceptable |
| Shift phase | no | yes |
| Parallel ability(multi-tower) | Easy, in CC or CV mode, modular design | very difficult |
| Loss at no load/Vout ON | Low | High |
| Loss at no load/Vout OFF | Low | High |
| Reverse speed | Fast in CC or CV mode | Very slow |
| Ripple change | Independent to output voltage, keeping constant in all output voltages | Ripple increases when output voltage reduces, with bad influence to electroplating quality |
| Size | Small | Big |
| Weight | Light | Heavy |
Customer feedback about our IGBT rectifier over SCR Rectifier:
4. Green Power Technology-the core of rectifier reliability
20+ years R&D and engineering experience, exported to 30+ countries, including USA, Germany, UK, India, Pakistan, Israel, Chile etc.
High-tech company
Our own patent and software copyrights
Our own know-how through 20+ years experience
DSP Digital control: Ensures 20+ years reliable high control accuracy; Protection self diagnosis and alarm protection type automatically on touch panel, easy for troubleshooting
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
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.
Unique insulation design
Unique heat dissipation design
5. Green Power 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 quality brands.
Production craftwork:
Using 3D design software for design, well trained workers, with uniform installation and wiring regulation.
By well-trained professional workers at higher wages.
Full load factory testing:
Digital PCB board reliability test
PCB board function test
Rectifier function test
Rectifier protection test
Touch panel function test
Communication test
Full load power test
Temperature rise test
6. Main technical parameters
1). Cooling options:
 |  |
| Air cooling IGBT rectifier | Water cooling IGBT rectifier |
2). IGBT plating rectifier Available Interfaces with PLC:
3). IGBT plating rectifier Operation Modes:
Automatic (timer setting, process step setting available)
4). IGBT plating rectifier Protections:
The rectifier provides the following protections, user could set rectifier stop delay time, and stop / not stop rectifier in case of protections.
| Protection type | Protection value | Rectifier action |
Short circuit protection | Alarm | |
Over/under input voltage protection | Nominal input voltage+/-10% | Alarm |
Driving protection | / | Alarm, rectifier stop immediately |
Over heat protection | 85℃ | Alarm |
Over current protection | Rated output current+100A | Alarm |
Over voltage protection | Rated output voltage+2V | Alarm |
5). IGBT plating rectifier Technical Parameters:
Input voltage | Single phase 220VAC for rectifier below 3kw. |
Output DC current | Up to 50kA |
Output DC voltage | Up to 500V |
Output regulation range | 0-100% of max currentor voltage |
Control accuracy | 1/1000 of max current or voltage |
Operation Mode | Constant current and constant voltage, constant power |
Ripple | <3% on request |
Efficiency | >90% (typ.) @ rated load |
Degree of Protection | IP30 for air cooling |
Power factor | >0.93 @ rated load |
Insulation grade | B |
Working mode | 100% 24 hours continuous running |
Alarm type | Audible and visual alarm |
6). IGBT plating rectifier process control parameters:
| Input to rectifier: | Output from rectifier: |
|
|
7). IGBT plating rectifier Operation Conditions
Power requirement: AC nominal voltage+/-10%, 3 phase 4 line, 3 phase imbalance less than 5%, and meet national electricity quality standard.
There shouldn't be excessive amount of dust, explosive and corrosive gas in the air.
The seismic intensity of the installation site is less than 7 on the Richter scale.
Saturated vapor pressure: daily average value is less than 2.2X10-3M pa, monthly average value is less than 1.8×10-3Mpa.
Looking for IGBT Plating Rectifier for electroplating zinc copper chrome gold nickel? Ours with power saving 20%, module type, small size, easy maintenance. 1000a 2000a 3000a 5000a 10000a 12v etc. Green Power Technology is one of the professional manufacturers and suppliers. We have been dedicated to this field for over 20 years and already exported products to India, USA, Germany, etc. Equipped with a productive factory, we warmly welcome you to buy our high quality products made in China at competitive price, or try our customized service.
