X-Pact® High Current

The X-Pact^® High Current switch-mode rectifiers enable customized, module-based DC power supply for electrolytic coating processes, including galvanizing, tinning, chromating, and stainless steel lines. They increase energy efficiency, reduce CO₂ emissions, and improve plant availability.

Additionally, X-Pact^® High Current delivers maximum process-oriented power supply performance, strengthening our customers' competitiveness. Leveraging advanced technologies such as pulse plating, these rectifiers enable surface design options that cannot be achieved with traditional thyristor DC systems.

X-Pact® High Current switch-mode power supply units

Improved surface quality
Increased wear resistance
Variable/adjustable hardness
Enhanced corrosion resistance
Possibility of multi-layer deposition
Faster coating process
Reduction of so-called "paint cracks"
Decreased risk of "hydrogen embrittlement"

Our expertise in the field of metallurgical plant engineering provide the foundation for our holistic concept for IGBT-based power supply used in electrolytic processing lines.

X-Pact^® High Current switch-mode rectifier boast high energy efficiency levels (more than 94 percent) over the entire working range, enables the highest level of process-oriented power supply and reduce the costs of installation, commissioning and maintenance.

In the event of a failure of modules or towers, other modules take over automatically, which significantly increases availability compared to the previous systems that are based on individual towers.

High energy efficiency: up to 40% energy savings
Enhanced plant performance (residual ripple, control speed, control accuracy, cos phi)
Alternative operating modes (pulse mode, reverse pulse mode)
High availability thanks to a modular design
Efficient troubleshooting and monitoring
Fewer and more cost-eﬀective spare parts
Easy expandable for capacity increases

Pulse/pulse reverse plating for surface design Avoidance of quality limitations Square AC for improved cleaning results Control options for enhanced plant performance

Pulse/pulse reverse plating for surface design
Technological advantages, e.g. for electrolytic tinning lines

With pulse plating/pulse reverse plating, it is possible to achieve a multitude of technological advantages of the coating and to improve the quality and properties of the plated layer in terms of edge grits, dendrites, adjustable roughness values, multi-layer coating, oil adhesion improvement, and strip cleaning.
Avoidance of quality limitations
Technological advantages, e.g. for the electrolytic galvanizing process

Hydrogen absorption can be prevented, eliminating associated quality issues such as material failure and surface defects. This advancement allows for the treatment of high-strength steel grades (Rm>500<2000MPa).
Square ac for improved cleaning results
Technological advantages, e.g. for stainless steel lines

The square AC option (variable 5-60 Hz) enables improved cleaning results and a more homogeneous surface treatment with consistent properties. Passivation of pole plates is not required, and there is no need to alternate the cleaning frequency or change the DC poles (every hour).

Switched-mode power supplies, along with the option of square AC, also enable further cleaning effects that were impossible with conventional thyristor technology:

H₂ and O₂ take effect at same time and same surface area with improved cleaning force by synergy

Discharge of explosive gas (H₂ und O₂) with AC is nearly zero

Tenside activity is higher with AC

AC pattern and frequency could be adjusted in a wide range

Low-energy technology

Efficient cleaning system

Low gas generation

Modular system
Control options for enhanced plant performance
Technological advantages, e.g. for electrolytic tinning lines

Switch-mode rectifiers show significantly better control accuracy, control cycle time, wave shape control and especially lower residual ripple (less than 5% and even less than 3% or 1% independent of the operating point). The ripple of an thyristor device without filter amounts is closed ro 7% at full modulation.

The power factor over the entire working range is better than 95%.