REDARTI Rack Series High-Frequency IGBT Switch-Mode Plating Rectifiers are our flagship product group, designed to deliver the highest energy efficiency, uninterrupted production and excellent plating quality in modern surface-treatment plants (zinc, nickel, chrome, copper, gold, silver, anodizing, etc.). The Switch-Mode power systems that REDARTI builds with 100% in-house engineering, design and manufacturing give industrial users in Türkiye direct factory spare parts, fast technical service and tailor-made power solutions.
With the evolution of power electronics, IGBT-controlled Switch-Mode systems have become industry's first choice over classic thyristor- and variac-controlled rectifiers. Eliminating the need for a transformer and heavy components thanks to a high 30–35 kHz switching frequency, our systems set a new standard in plant management with their compact rack/tower design (45x45 cm footprint), modular hot-swap capability and real efficiency of up to 95%.
Why IGBT Switch-Mode Technology? A Real Comparison with Classic Systems
The key technical and economic advantages Switch-Mode rectifiers provide in industrial applications:
- Real Energy Savings (10% - 40% Efficiency Gain): In classic thyristor rectifiers, chopping the mains frequency by phase angle causes high iron-copper transformer losses and thyristor/diode voltage drops. In REDARTI Switch-Mode systems, the mains signal is first rectified and then switched by high-speed IGBT transistors at 30–35 kHz, keeping energy losses to a minimum. The energy savings of up to 40% seen in the field are generally achieved by replacing classic thyristor rectifiers that were built non-standard or specified with the wrong voltage in the past.
- Power Factor (Cos φ = 1.00): In classic rectifiers, phase chopping drops the power factor to Cos φ = 0.70–0.85. This draws excess reactive current from the grid, increases the load on the compensation panel and leads to high electricity bills. In REDARTI Switch-Mode rectifiers the power factor is always Cos φ = 1.00 — they do not pollute the grid and eliminate additional compensation costs.
- Low Ripple Factor and Excellent Plating Quality: While classic 6-pulse rectifiers produce 100–300 Hz DC ripple, Switch-Mode systems deliver 60–70 kHz DC. Thanks to the low ripple (<1%), the need for polarised capacitor filters is reduced, plating speed increases, micron thickness is distributed evenly across the plant and electrolyte chemical consumption falls.
- Compact Size and Light Weight: Occupies 75% less floor space (space savings) and is 60% lighter (lower shipping costs and easy installation) than classic heavy transformers.
Modular Design, Flexible Configuration and Automation Options
- Uninterrupted Production (Hot-Swap Modular Architecture): The system consists of independent power modules working in parallel (RED SWC 15/300, RED SWC 15/600, RED CN 500, RED CN 1000, etc.). Even if a module fails, it disconnects itself by tripping its own fuse while the remaining modules keep the bath in production without interruption.
- Flexible Control and Display Alternatives: A digital LCD panel on the unit, an external remote-control box or an industrial colour touchscreen (HMI) based on Siemens PLC is available.
- Unlimited Power and Standard Rack Cabinets: Unlimited production at any required kW and ampere rating (from 100 A to 30,000 A+) in standardised rack cabinet sizes (Rack 3 to Rack 12, 650 mm - 2270 mm height range, 620x560 mm top footprint).
- Full Automation (100% SCADA / PLC Integration): In addition to standard Modbus RTU (RS485), full integration into the PLC and SCADA systems of automatic plating plants via Profibus or Profinet interfaces.
Risks of Far-East Imports vs. REDARTI Local Manufacturing
Today the market offers many Switch-Mode products imported from the Far East and marketed with similar technical specifications. Although they may seem attractively priced at the time of purchase, these units carry serious risks for operators:
- Spare-Part and Service Dead End: When imported units fail, sourcing their custom electronic boards or IGBT modules from abroad can take weeks, bringing plant production to a standstill.
- High Repair and Renewal Costs: When imported units break down, service costs can approach the price of a new unit.
- REDARTI Local Manufacturing Advantage: As a 100% local manufacturer, REDARTI provides a 24/7 original spare-parts stock from its Istanbul factory, module replacement within 30 minutes and expert technical service support. Your production continuity is never put at risk.
Operating Conditions and User Responsibilities
REDARTI Switch-Mode Rectifiers feature all advanced protection hardware, including over-current, short-circuit, high-temperature, phase-loss and over-voltage protection, and are designed to operate trouble-free even in the harshest physical factory conditions. However, for the unit to serve for years at maximum efficiency, the following basic environmental conditions are important:
- Ventilation and Clean Surroundings: Keep the fan intake vents of air-cooled modules unobstructed, leave sufficient air-circulation space around the unit and prevent corrosive acid fumes from being drawn directly into the unit (integrate a clean-air duct if necessary).
- Mains Voltage Stability: Provide a suitable supply panel with communication/surge arresters against excessive voltage spikes on the mains side.
- Periodic Dust and Fan Maintenance: In heavily dusty environments with metal particles, clean the module fans and heat sinks periodically with compressed air.
