Rectifier Clinic
Craig Henry
J P Tech, Inc.
P.O. Box 863
East Troy, WI 53120
Phone: 262/642-7671
E-mail: craigh@[Link]
Website: [Link]
Rectifier Ripple
There often seems to be some confusion Tapswitch Rectifiers—These rectifiers equivalent level of plating or coating with-
concerning ripple in a plating, anodiz- will usually produce ripple of 5 percent or out ripple.
ing or coating environment. What is it? less for the full range of output as long as
Where does it come from? Does it cause they are in good repair and the three tap- How Do You Reduce Ripple?
problems? How do we deal with it? The switches are set at the same level.
answers will vary based on the type of Powerstat Rectifiers—These rectifiers Assuming you need or prefer an SCR rec-
rectifier, how the rectifier is used and the will also usually produce ripple of 5 percent tifier and do not run it at full output, you
process in which it is used. or less for the full range of their output. will need to add some sort of filter choke to
While both the tapswitch and powerstat reduce the ripple. To obtain the proper size
rectifiers are durable, they are limited in filter choke it will be necessary to deter-
What is Ripple? mine the range of your voltage output.
their use due to size and sophistication
Simply stated, ripple is the percentage of restrictions. If you want to keep your volt- For instance, if you have a 12 VDC rec-
AC current that is passed through by a rec- age and/or amperage constant during the tifier, and you operate between 2 and 12
tifier on the way to the process. For exam- length of a cycle or control the rectifier VDC you will need a larger filter choke
ple, if the voltage at the tank measures 10 with a computer, then an SCR rectifier will than if you operate between 7 and 10 VDC,
VDC (volts DC) and 3 VAC (volts AC) the be your choice. because you will be compressing a larger
ripple is 30 percent. If you measure 6 VDC SCR Rectifiers—The amount of ripple segment of the AC that is passed through.
and .5 VAC the ripple is 8.33 percent, and at low voltage outputs may be 100% or In addition, if your process is extremely
so on. Because the primary function is to more, but as the voltage is turned up ripple ripple-sensitive and you require a ripple
produce a controllable DC current for the decrease to 5% at full rated output. Since so level below 1 percent through most of the
propagation of ions within a tank, the more few platers or coaters run their rectifiers at voltage range of the rectifier, you will need
AC that is passed the less effectively the full output for the entire cycle, ripple will a larger and more expensive filter choke.
rectification becomes. be higher during those times of lower volt- The choke portion is typically a wound
It is important to measure the voltage as age output. steel coil, elliptical in cross-section, that
close to the load as possible, because there Switchmode Rectifiers—These high- fits over the rectifier bus and reduces a
is usually less ripple at the tank than at the speed switching rectifiers are built to portion of the AC sine wave inductively.
rectifier. Plus, you really want to know how provide low ripple across the full range of If your process typically runs between
much AC is at the load. voltage output. Unfortunately, they are cur- 20–100 percent of the full output of the
The voltages can be measured with a rently limited in size to around 1000 amps rectifier and you can accommodate a ripple
device as sophisticated as an oscilloscope and 12 VDC. level of up to 5 percent, the choke may be
or as simple as an analog multi-meter. For Malfunction Rectifiers—Regardless of sufficient.
accurate readings, be sure that the meter type, a component failure or other malfunc- The filter portion is comprised of a
has been calibrated and you have a clean tion can cause any rectifier to exceed the capacitor bank sized to the output voltage
connection where you measure. If you are specified levels of ripple. and amperage of the rectifier. If you require
measuring a high-voltage operation, such low ripple for all levels of output in your
as e-coating, be very careful not to touch process, you will need this filter in addition
the voltage source with your body, as seri- Does Ripple Cause Problems? to the choke portion. Very small rectifiers
ous injury or death can occur. If you are an electro-coater, or if you plate may often get by with only a filter.
chrome, nickel, or precious metals, you are
Where Does Ripple Come From? probably already aware of the susceptibil- How Can I Keep Track of Ripple?
ity of your processes to problems associ-
Different types of rectifiers pass different ated with ripple. Inconsistent coating, Many rectifier manufacturers, as well
amounts of ripple. If you have a single burning, rupture, or reduced deposition as after-market suppliers, provide ripple
phase rectifier you can expect to have rates may all accompany high levels of meters to obtain constant feedback, often
ripple of 50 percent or more regardless of AC and be causing you scrap, rework, and with alarms, to track ripple levels. These
the type of rectifier or the level of output. unhappy customers. meters allow you to monitor the status of
Because most platers and coaters use In addition to quality related problems, your process and the operating condition of
three phase rectifiers of 220–240 VAC or the efficiency of the process is reduced your rectifier. This will prevent the creation
440–480 VAC, we will look at the pre- proportionately to the level of ripple. This of defective product as well as alert you to
dominant types in use: means you spend more on energy to get an immediate or impending failure of your
rectifier. P&SF
26 Plating & Surface Finishing • M a rch 2004
26 26 3/1/04, 1:49:49 PM