E-Coat or Electrophoretic deposition (EPD), includes a range of industrial processes: electrocoating, cathodic and anodic electrodeposition, and electrophoretic coating and painting. E-Coat is used in many industry including automotive and appliance applications. E-Coat is a paint deposition process in which parts are immersed into wet paint. DC current is then used to attract the paint to the metal surface. The process produces uniform surface coating and high corrosion resistance and is especially effective for complex shapes. American Plating Power E-Coat rectifiers provide high quality DC, exceptional control characteristics, and superior reliability.

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Features

  • Manual and automatic operation
  • SCR control
  • High control dynamics
  • High control accuracy
  • Voltage and current control
  • Ramp function
  • Customized interfacing (analog/digital)
  • Ripple filter
  • Additional filtering for special applications up to 1%

Options

  • Current censity control for uniform coating of small and large batches
  • Sparkless transition
  • Grounding diodes
  • Ah meter for dosage and coating control
  • Field bus connection (Profibus or Interbus S)
  • Process monitoring and logging
  • PLC or programmer control
  • Dosage control for adhesive and pigments

Modular Rectifier Units In Switch-Mode Power Supply Technology And Thyristor Designs For E-Coating

Switch-Mode Power Supply Technology (IGBT And MOSFET Technology)

The KTL Rectifier from American Plating Power is on the cutting edge of technology advancement in DC power supplies. The KTL Rectifier is a modular type, high efficiency, switch-mode, digital rectifier specifically designed for E-Coat applications. The System consists of controls and modular power modules that provide smooth, reliable DC required for today’s E-Coat systems.

Energy Efficiency

  • 95% Efficiency
  • Constant high power factor

Retrofittability

  • Quick and simple module replacement
  • Redundancy

Power Supply

  • 3 x 380 – 480 V

Residual Ripple

  • Constant < 2%

Smaller E-Coat Systems/ Laboratory DC Power Supplies

In addition to DC power supplies used in larger paint lines, American Plating Power also carries lower current power supplies for use in small painting systems and laboratory environments. There are many different sizes and configurations available. Please contact us for more information.

Electrical Specifications:

  • Input Power: 120V 1 Phase or 480V 3 Phase 50/60 Hz Output Voltage: 0 to 400V
  • Output Current: 0 to 3.5A, 0 to 50A
  • Output Ripple: <1%
  • Voltage Regulation: <1%

Thyristor Technology

The classic rectifier is a thyristor based, E-coat rectifier utilizing decades of proven technology and reliability. The rectifier incorporates the classic design of a transformer, thyristors and filter. These designs are more prevalent when powering E-Coat systems over 1000A or output voltages over 500V. All classic thyristor rectifiers are specifically engineered to deliver smooth and reliable DC for E-Coat system environments.

Electrical Specifications:

  • Output Voltages Available: 300V DC-600V DC
  • Available Output Currents: 500A-5000A
  • Available Input Voltages: 380V-600V 3 Phase, 50 or 60Hz
  • AC Input Protection: Thermal Magnetic Circuit Breaker with Shunt Trip and/or AC Safety Contactor
  • Output Ripple: <5% Standard, <2% Optional
  • Voltage Regulation (Voltage control mode) <1%
  • Galvanic Mains Isolation via internal Transformer

Programmable Process Control KTL 1200

The KTL 1200 programmable process controller enables precise voltage, current or layer thickness control (current density control) for cathodic and anodic dip painting processes. In combination with the American Plating Power IGBT rectifier modules, the KTL 1200 ensures a smooth process flow with reproducible painting results.

The hardware principle is shown below in a simplified way:

Features Of The Process Control KTL 1200

The KTL Rectifier system can be configured to provide individual voltage control to multiple anodes or higher current to multiple anodes. The modular system has the flexibility to be configured for single zone, 2 zone or multiple zone configurations. i.e. automotive MAC systems

E-Coat Rectifier Module Gamma L3+

Maintenance and Reliability

Low maintenance (lHigh MTBF) Components and fans

Space Requirement

Compact design (19″ plug-in module)

Electrical Specifications:

  • Output Voltages Available: 400V. 450V, 500V
  • Available Output Currents 125A-1875A
  • Max. Module Output Power: 45kW
  • Available Input Voltages: 380V-400V, 480 VA 3 Phase 50/60 Hz
  • AC Input Protection: Thermal Magnetic Circuit Breaker with Shunt Trip and/or AC Safety Contactor
  • Efficiency: >95% (SiC Based Semi-Conductors)
  • Pf: >.95
  • Output Ripple: <2% (Resistive Load), <1% (E-Coat Operation) Voltage regulation (voltage control mode): <1%
  • Galvanic Mains Isolation via Internal Transformer
  • Digital interface via RJ45 connector, Plug and Play

Single Anode Control

This enables precise control of individual anode cells or pairs in the E- Coat bath.

Amp-Second Counter (KTL-1200)

The amount of charge (in Amp-Sec) is recorded during the coat process and is the basis for controlling the pumps for paste and resin pumps.

Data Documentation

With the help of a data logger, relevant process data can be permanently recorded.

Coating Thickness Control (KTL 1200)

Automatic rectifier voltage adjustment to optimize paint usage and reduce or eliminate rework.

Earth Current Monitoring

Monitoring the ground current is an important prerequisite to ensure operational safety.