Heavy Duty Low Loss Rectifier Transformers

Anodizing Rectifier | Electroplating Rectifier

Introduction

POWER is a name known for reliability and continuous improvement in the field of Electroplating Rectifiers using vertical, copper strip wound, rolling contact type voltage regulators. We are also manufacturing Industrial Servo Voltage Stabilizers, Automatic Voltage Controllers, Servo Stabilizers, Anodizing Rectifiers, Electro Coloring Transformers, Distribution Transformers, Isolation Transformers, Variable DC or AC Power Supplies and Voltage regulators. Rectifier transformer is an equipment that converts AC into DC supply. Power make Silicon Rectifiers are widely used in Electroplating, Anodizing, Hydrogenation and all other electrochemical processes. These are tailor made, covering a wide range from 200 Amps to 30000 Amps at different output DC voltages as per requirement.

Salient Features of POWER Electroplating Rectifier

Inspite of best efforts, no state electricity board can ensure constant voltage to the customer because of long and inadequate distribution lines and irregular load pattern on distribution transformers. Generally Voltage is low during day time and high during night hours. Moreover on holidays, peak hours, rainy days and when agricultural and industrial load is switched off, the voltage rises sharply which is more dangerous.

Electroplating Rectifier

Brief Specifications

Input Voltage 380- 440 Volts, 3-Phase 50Hz. AC supply or any other voltage.
Output Voltage
DC variable from zero to maximum rated voltage.
Output Current
Rated maximum DC current.
Temperature Rise
Less than 45°C above ambient at the top of the oil.
Efficiency
Depends on voltage current rating of rectifier.
Ripple Content
Less than 5%.
Insulation
‘A’ class for oil cooled.

Starting Circuitry - POWER Electroplating Rectifier

AC Input

POWER Electroplating Rectifiers are designed for three phase, 50Hz AC input supply and are suitable for operation at any voltage between 380-440 Volts in India and can be designed for 60Hz AC and any other voltage available. Input to the Rectifier Transformer should be connected through a proper protective device, to provide positive protection to personnel and the system which is not included in our scope of supply and has to be procured separately.

DC Output

The DC output is continuously and steplessly variable from zero to the full rated voltage for any input voltage between 380-440 Volts and for any load between zero to its rated full load. The ripple content in the output is less than 5% and these units are very much suitable for all special processes such as Chrome Plating or Hard Chrome Plating where low ripple content is necessary.

Inner view of Rectifier

Rectifier

Circuits & Components - POWER Electroplating Rectifier

The circuit employed in POWER Electroplating Rectifier is simple. Input 3Phase 415V supply is given to Vertical, Copper Strip Wound, Rolling Contact type Voltage Regulator, which in turn supplies a variable voltage to the primaries of a three phase, double wound, Delta / Double star connected transformer. The secondary of the transformer is connected to Hexa-Phase connected rectifier using Silicon Diodes. The output is obtained from the Rectifier and the star points of the transformer through an Interphase Transformer. Moving Coil Voltmeter and Ammeter with shunt are provided to measure the output voltage and output current.

Onload Voltage Regulator

POWER Electroplating Rectifiers are equipped with Vertical, Copper Strip Wound, Rolling Contact type Voltage Regulator. These voltage regulators are ± type, wound with heavy section of electrolytic grade rectangular copper strip and fitted with Carbon Rollers. POWER Voltage Regulators have higher efficiency of approximately 99% and are suitable for continuous duty cycle. Self lubricating Carbon Roller Assemblies offer more reliability and trouble free performance of the equipment. In POWER Voltage regulators Carbon Rollers move on both sides of the coil to give ± 440V or ± 230Volts. We design Rectifier Transformers in “Q” connection in which the regulator current is half the line current so losses are less and life is much more.

Vertical Voltage Regulator

Double Wound Transformer

Metering

Good quality of Voltmeter and Ammeter are provided on a separate panel to indicate the DC output voltage and current. Ammeter is used in conjunction with shunt fitted inside the tank.

Control

We use Motorized on load voltage regulator in our Electroplating Rectifier. Output Voltage / Current can be varied by pressing Raise / Lower switch fitted in Control Panel. We also provide ‘T Handle’ which can be used in case of failure of Motor circuit.

Construction

Voltage Regulator, Transformer, Diodes etc. are fitted in a common frame and housed in same or separate sheet steel tanks. Absolutely new radiators are provided for better cooling. Rectifier Transformer is painted with EPOXY paint, which is resistant to acidic environment in electroplating plant. We use new IS 335 grade Transformer Oil from Silvassa which provides better cooling and in turn increases life of Electroplating Rectifier.

Silicon Diode

Silicon Diode

Shunt

Onload Voltage regulator

Double Wound Transformer

Double Wound Transformer is a conventionally designed step down transformer and confirming to IS 2026 as regards the temperature rise and insulations are concerned. These transformers are wound with multiple strips of electrolytic prime grade copper strip to minimize power losses. RectifierTransformers are designed liberally as per capacity and are ideally suitable for marginal overloading conditions. Combination of double primary winding in transformer and double output from voltage regulator help us to form “Q” connection in which the regulator current is half the line current so losses are less and life is much more. Cooling ducts are provided to keep the hotspot temperature as low as possible. Coils are dried in electric oven and rigid connection support and coil clamping are provided to ensure high short circuit strength. We use very high quality 0.27mm to 0.3mm thick CRGO core, so no load losses becomes very less in our Electroplating Rectifiers.

Interphase Transformer

Connected between the two star points of the secondary of the step down transformer. It increases the rating of the diodes.

Carbon Roller Assembly

Carbon Roller Assembly

Silicon Diodes

Diodes are arranged in Six Phase Circuit. We use absolutely new diodes in our Rectifiers. Diodes are tested in house and similar PIV batch diodes are used in one equipment for equal load sharing and reducing the power loss of diodes. We use diodes up to 50% more in capacity for better durability.

Optional attachments

Constant voltage controller (CVC) We offer CVC electronic attachment with Rectifier transformer, which will maintain constant output voltage as per setting automatically, irrespective of input voltage or load variation.
Constant current controller (CCC) We offer CCC electronic attachment with Rectifier transformer, which will maintain constant output current as per setting automatically, irrespective of input voltage variation.

Warrantee & Customer support

POWER's Electroplating Rectifiers are warranted for 5 years against any manufacturing defect. Inorder to ensure complete customer satisfaction, we provide excellent customer service to our clients. We also offer friendly technical assistance for new installation where highly qualified engineers will attend your quiries.

Advantages as compared to thyristor controlled electroplating Rectifier

Rolling contact type

Thyristor controlled

Why the regulator control is superior to thyristorised control in rectifier?

Comparison between POWER make and dimmer type Electroplating Rectifiers

POWER Electroplating Rectifier

Power Electroplating Rectifier

Electroplating Rectifier with Dimmer

Electroplating Rectifier with Dimmer

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