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It works almost everywhere as long as you have sufficient airflow in the space you are placing the rectifier in.
It is easier to install as it does not have to be connected to the ship’s existing water-cooling system.
As there is no water in the appliance, an air-cooled rectifier does not run the risk of freezing if the temperature drops below zero degrees Celsius in the space it is placed in.
No risk for condensation inside the appliance as no cold water is run through a heat sink. (In a water-cooled rectifier, the humidity in the air can cause condensation on the heat sink, which can lead to water leaking into the hardware.)
CONS
Air is not as efficient in transporting heat as water. Hence, to properly cool the rectifier, the airflow needs to be high. Especially if the ambient temperature is high. If the ambient temperature increases out of the specification – i.e., gets too high – the rectifier might stop due to overheating.
Bad air quality can have a negative impact on the performance of the rectifier and might result in the inlet air filter having to be changed more frequently. If the air quality is very poor, it can even cause the rectifier to break down.
WATER-COOLED RECTIFIER – PROS AND CONS
PROS
Water-cooling is a more efficient cooling method since the thermal resistance is much lower between the heat sink and water tubes as opposed to the heat sink and forced air.
Water has a much higher energy density compared to air hence less volume is needed.
Cooling power is solely dependent on water temperature and water flow, which means that even if the ambient temperature around the rectifier is very high, the rectifier can still operate as normal.
CONS
Availability of cooling water circuit needed.
Water-cooled rectifiers run a risk of freezing if placed in a space where the temperature can fall below zero degrees Celsius.
Obvious risk for condensation issues if the heat sink in the rectifier is colder than the ambient temperature.
To avoid risk of freezing damage as well as condensation issues it is absolutely necessary to control the water flow. Let the water flow in case of risk for freezing damages and stop the flow in case of risk for condensation issues.
Since the LT system sometimes contains sediment that might clog the water tubes, a strainer might be needed, which must be cleaned regularly.
CONCLUSION
Regardless of whether you choose an air-cooled or a water-cooled rectifier, the environmental requirements for the rectifier’s performance are the same. They operate in the same environment and feed the same load. The only difference is that the heat generated inside the rectifier is removed by using either forced air or water as cooling media.
Making sure your rectifier has a modular design is also crucial, as it ensures easy troubleshooting and maintenance if anything were to go wrong. From an operational perspective, this is especially important. Because if one module malfunctions or breaks down, the remaining modules will compensate for the output lost from the malfunctioned component. If this were to occur, the rectifier will keep operating – albeit at a reduced capacity – thanks to the remaining modules’ built-in redundancy. This is of great help when troubleshooting the system. But more importantly: it is of great value for the ballast water management system owner, as they can continue to load and unload their cargo.
How Rectifier Chooses Water Cooling Or Air Cooling？
Typically there are three methods of cooling methods of rectifiers, air cooling, water cooling and oil cooling. Here we introduce the advantages and disadvantages of water cooling and air cooling:
For high power DC power supply, the environment condition is not good such as with corrosive fumes, much dust, very high environment temperature, requires high IP rating, water cooling is more suitable.
Like some special environments and sub-tropical climate areas, such as electroplating, anodizing, electrolysis etc. environment, we generally recommend water cooling rectifier.
1) Water cooling Rectifier:
The heat generated by the power semiconductor components inside rectifier will be dissipated through circulated cooling water, cold water(lower than 35℃) goes into the rectifier cooling loop and get hoter water out, through this circulation, the heat is dissipated to keep the rectifier running normally.
Advantages of water cooling:
A. Less maintenance needed, no need to change cooling fans like air cooling;
B. Rectifier with lower cost;
C. Better cooling performance under high ambient temperature, up to 50℃;
D. Better cooling effect for high power rectifier;
E. Cabinet sealed, suitable for corrosive environment;
F. Higher IP rating;
G. Low noise from rectiifer;
H. Smaller size.
Disadvantages:
Need user to provide suitable cooling water or we could provide water chiller together on request.
Cooling water quality requirement:
Better to provide purified deioned water for the rectifier, especially for high voltage rectifiers.
If could not provide deioned water, the water quality must meet below requirement:
Item
Value
Remarks
Water quality
PH: 6～8
Resistivity ≥20KΩcm
Hardness<8 dH
Particle≤0.25mm
Suspended solid≤30mg/L
Water is not corrosive, dirty
Does not contain acids or salt
Inlet Water Temperature
20-35℃
To prevent condensation, the water must not be too cold. The ideal temperature is between ambient temperature and 35℃(not below dew point)
Inlet Water Pressure
0.3MPa-0.5MPa
Water flow
According to rectifier power, the inlet water and outlet water temperature difference is 5℃-10℃.
Connection of Cooling Water:
Use adaptive cooling water pipe and connectors to connect to the inlet and outlet interface on the rectifier. Below pictures are for example:
2) Forced air cooling Rectifier:
Advantages:
A. Convenient use, needn't extra work on the cooling system;
B. Suitable for low power rectifier
Disadvantages:
A. In most conditions, price is higher than water cooling.
B. Cooling performance is not as good as water cooling under very high ambient temperature above 40℃.
C. Higher noise from the rectifier.
D. The IP rating is lower, because of heat exhange between rectiifer inside and outside, the corrosive fumes and dusts may enter the rectifier and will shorten the
lifespan of the fans and other parts.
E. Need more maintenance work for the dust clearance.
F. Because the cooling fans are mechanical parts, after some years, they need to be replaced.
G. Bigger size than water cooling rectifier.
If users prefer to air cooing for corrosive applications, we recommend rectifiers put in a separate area or room isolated from the plating cells to avoid corrosion and dust. Like the picture:
Air & liquid cooled rectifiers
Rectifiers from Littelfuse
Rectifiers are electrical devices used to convert alternating current (AC) into direct current (DC). They are commonly used in power supply systems to provide a steady DC voltage for various applications. Rectifiers can be categorized into two main types based on their cooling methods: liquid-cooled rectifiers and air-cooled rectifiers.
Liquid-Cooled Rectifiers
Liquid-cooled rectifiers utilize a cooling system that involves circulating a liquid coolant, such as water or oil, to dissipate heat generated during the rectification process. The rectifier components, such as diodes and transformers, are typically immersed or in direct contact with the coolant. The coolant absorbs the heat and carries it away from the rectifier, maintaining a suitable operating temperature.
Liquid cooling is commonly applied in high-power rectifier systems where the heat dissipation requirements are significant. The high thermal conductivity of liquids enables efficient heat transfer, allowing the rectifier to handle large power loads. Liquid cooling is often found in industrial applications.
Air-Cooled Rectifiers
Air-cooled rectifiers, on the other hand, rely on the surrounding air for heat dissipation. They utilize cooling fins or heat sinks attached to the rectifier components to increase the surface area and enhance airflow. As the rectifier operates, the heat generated is transferred to the fins, and the circulating air carries away the heat, keeping the rectifier within acceptable temperature limits.
Link to Kehong
Air cooling is typically employed in lower-power rectifier applications, where the heat dissipation requirements are relatively lower. It is commonly used in consumer electronics, small-scale power supplies, and low to medium power industrial applications.
Choosing the right cooling type
The choice between liquid cooling and air cooling depends on several factors, including the power rating, operating conditions, and cost considerations. Liquid cooling is favored when dealing with high-power rectifiers that generate significant amounts of heat, as it provides better cooling efficiency. However, it requires additional infrastructure, such as coolant circulation systems and maintenance, which can increase the overall cost. Air cooling, on the other hand, is more cost-effective and simpler to implement but may have limitations in dissipating heat for high-power applications.
Our technical power electronics specialists are happy to advise you on the right cooling method, taking into account the the specific requirements of the rectifier system, and factors such as power rating, operating environment, reliability, and cost efficiency.
Rectifiers are electrical devices used to convert alternating current (AC) into direct current (DC). They are commonly used in power supply systems to provide a steady DC voltage for various applications. Rectifiers can be categorized into two main types based on their cooling methods: liquid-cooled rectifiers and air-cooled rectifiers.Liquid-cooled rectifiers utilize a cooling system that involves circulating a liquid coolant, such as water or oil, to dissipate heat generated during the rectification process. The rectifier components, such as diodes and transformers, are typically immersed or in direct contact with the coolant. The coolant absorbs the heat and carries it away from the rectifier, maintaining a suitable operating temperature.Liquid cooling is commonly applied in high-power rectifier systems where the heat dissipation requirements are significant. The high thermal conductivity of liquids enables efficient heat transfer, allowing the rectifier to handle large power loads. Liquid cooling is often found in industrial applications.Air-cooled rectifiers, on the other hand, rely on the surrounding air for heat dissipation. They utilize cooling fins or heat sinks attached to the rectifier components to increase the surface area and enhance airflow. As the rectifier operates, the heat generated is transferred to the fins, and the circulating air carries away the heat, keeping the rectifier within acceptable temperature limits.Air cooling is typically employed in lower-power rectifier applications, where the heat dissipation requirements are relatively lower. It is commonly used in consumer electronics, small-scale power supplies, and low to medium power industrial applications.The choice between liquid cooling and air cooling depends on several factors, including the power rating, operating conditions, and cost considerations. Liquid cooling is favored when dealing with high-power rectifiers that generate significant amounts of heat, as it provides better cooling efficiency. However, it requires additional infrastructure, such as coolant circulation systems and maintenance, which can increase the overall cost. Air cooling, on the other hand, is more cost-effective and simpler to implement but may have limitations in dissipating heat for high-power applications.Our technical power electronics specialists are happy to advise you on the right cooling method, taking into account the the specific requirements of the rectifier system, and factors such as power rating, operating environment, reliability, and cost efficiency.
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