The Electrophoretic Rectifier‘s innovative cabinet structure retains all advantages of non-co-phase inverse parallel configurations while introducing critical technical advancements, as exemplified by the air cooled 500A 400V electrophoretic rectifier. This design addresses evolving demands in the electrolytic aluminum industry—particularly high-voltage serial applications—while resolving limitations of traditional vertical (co-phase inverse parallel) architectures. Enhanced safety coefficients surpass conventional systems, coupled with reduced failure rates and simplified maintenance protocols.
Product Applications
The Electrophoretic Rectifier and Plating Rectifier Equipment series are extensively utilized for a wide range of surface treatment applications, delivering precision, efficiency, and reliability. These rectifiers are particularly well-suited for processes such as PCB electroplating, hard chrome coating, and plating with metals like copper, nickel, zinc, gold, and silver. The Rectifier ensures consistent and high-quality results in these applications by providing stable voltage and current control, which is essential for achieving uniform coating thickness and enhanced surface properties.
Field application diagram
Industry application examples
Technology Advantages
Select thyristors with low on-state threshold voltage: thereby reducing power consumption and improving rectification efficiency. Analysis of rectifier cabinet losses reveals that thyristor losses constitute a significant proportion of the total cabinet losses, with the on-state threshold voltage exerting a notable impact on device losses. It is recommended to select thyristor models with a low on-state threshold voltage and stable, reliable performance.Regarding the parallel design of rectifier bridge arms, inherent variations in thyristor characteristics result in discrepancies in the on-state threshold voltages of individual components. This leads to uneven current distribution among parallel branches. To mitigate this, the number of parallel components should be minimized while ensuring current-carrying requirements are met.
The more parallel elements, the greater the conductive imbalance. Therefore, try to select thyristors with large forward average current, reduce the number of parallel elements in the rectifier bridge arm, and improve the current sharing coefficient of the rectifier bridge arm. Use current-sharing reactors for forced current sharing: Between the two thyristors in the same bridge arm, a low-power current-sharing reactor developed by our company is added for forced current sharing. The current-sharing coefficient is as high as 0.96 or above (when the current-sharing reactor is not used, the current-sharing coefficient is 0.85~0.88), which improves the rectification efficiency.
Non-ferrous metal electrolysis, such as copper, zinc and aluminum electrolytic.
Role of Electrophoretic
The electrophoretic rectifier serves as the operational backbone of modern surface treatment systems, delivering voltage regulation within ±0.5% tolerance and current stability below 1% ripple. This precision enables uniform metal deposition critical for functional coatings - automotive electroplating achieves 8-12μm chromium layers with 1,200 HV hardness, while PCB copper plating maintains ±0.8μm thickness consistency across 24-hour production cycles.
Types of Electrophoretic
By Current Regulation Technology
Thyristor-SCR Units: Phase-controlled DC output (0-24V/1,000-50,000A), ±2% ripple for bulk electroplating lines
IGBT Modular Systems: High-frequency switching (5-20kHz), ±0.5% stability for precision anodization (e.g., automotive Al wheels)
Pulse Rectifiers: Adjustable ton/toff (0.1-100ms) for nanostructured coatings (Ni-PTFE composites)
Application-Specific Configurations
Electrophoretic Coating: Constant voltage mode (200-500VDC) with <5μs response for cathodic dip coating
Electrolytic Refining: Current density control (3,000-15,000 A/m²) for Cu/Zn/Ni electrowinning cells
Hybrid Systems: Voltage-current dual mode switching for combined electroplating/passivation cycles
Performance Benchmarks
Efficiency: 92-96% conversion (IGBT vs. 80-85% SCR)
Current Sharing: <2% deviation across 8+ parallel baths (automotive E-coat lines)
Waveform Control: Programmable ripple <1% for medical implant coatings
Industry Implementation
Automotive: 600V/10kA units for body E-coating (18-22μm uniformity)
Electronics: 50V/5kA precision rectifiers for Au/Ni PCB edge connectors
Energy: 1,200VDC systems for Zn-Ni battery foil production
Structural Rationale: Maintains technical hierarchy while embedding operational parameters and industry-specific validation metrics.
Cooling Type for Electrophoresis
Air Cooling:Heat dissipation fan + air duct + comb heat sink
Water Cooling：Built-in water circulation line
Technical Parameters
Type of characteristics
Parameters
Technical Requirements
Input characteristics
Rated input voltage
Three-phase AC380V±10% 50Hz Complies with National Power Quality Standards
Rated input current
AC 340 A
Rated input power
224 KVA
Rated input power Ffactor
COSΦ≥0.95
Output characteristics
Output voltage
DC 0～400V adjustment
Output current
DC 0～500A adjustment
Precision of steady current
≤1%
Precision of stable voltage
≤1%
Displayed precision
1A，1V
Rated output power
≥ 91%
Insulation characteristic
Insulation resistance
Input – Output: ≥5MΩ
Input – Cabinet: ≥5MΩ
Output – Cabinet: ≥5MΩ
Protective characteristics
With self-protection function under non-normal cases such as over-voltage, over-current, overload, short circuit and overheating
Other characteristics
Noise
≤75dB
Running state
Continuous full load run of product
Load level
Level II
Insulation grade of the transformer
Grade B
Weight
770 kg
Optional Models
Application
Model
Output
1.Electroplating, Electrolysis, Electrochemistry, Anodizing, Electrophoresis,Smelting,Electrocasting, Communication and other fields.
KES-11KA/220V
220Vdc/11KA
KES-13.5KA/90V
90Vdc/13.5KA
KES-26KA/123V
123Vdc/26KA
KES-33KA/135V
135Vdc/33KA
KES-41KA/115V
115Vdc/41KA
KES-41KA/300V
300Vdc/41KA
KES-43KA/249V
249Vdc/43KA
2.Aluminum, magnesium, lead, zinc, copper, manganese, bismuth, nickel and other non-ferrous metal electrolysis;
KES-45KA/210V
210Vdc/45KA
KES-40KA/70V
70Vdc/40KA
KES-50KA/45V
45Vdc/50KA
KES-33KA/245V
245Vdc/33KA
KES-42KA/120V
120Vdc/42KA
3.Salt water,potassium salt electrolytic caustic soda, potassium alkali, sodium;
KES-35KA/110V
110Vdc/35KA
KES-43KA/160V
160Vdc/43KA
KES-13.5KA/135V
135Vdc/13.5KA
KES-30KA/150V
150Vdc/30KA
4.Potassium chloride electrolysis to produce potassium chlorate, potassium perchlorate;
KES-15KA/120V
120Vdc/15KA
KES-40KA/45V
45Vdc/50KA
KES-7000A/150V
150Vdc/7KA
KES-48KA/300V
300Vdc/48KA
KES-10KA/100V
100Vdc/10KA
Looking for a air cooled 500A 400V electrophoretic rectifier? Liyuan Haina Rectifier, a professional manufacturer with 27+ years specializing in industrial rectifiers, supplies global clients including the United States, Canada, Britain, Italy, Spain, South Africa, Russia, the UAE, Japan, South Korea, Malaysia, etc. Our advanced factory delivers cost-effective Made-in-China solutions, with competitive prices and customizable options. Contact us for sales inquiries.
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