Powerexpert has recently completed an important milestone on a multi-year development project. A 438kW, 834ADC, 525V AC-to-DC plasma torch converter retrofit system was successfully designed, developed, manufactured, and commissioned inside a customer’s existing power supply. The system was successfully installed (a true drop-in replacement) and started up. The system is currently running and the customer is making product. This is part of a larger effort for a dual output 2500ADC system where a total of 8 identical retrofit power panels will be provided, and the final phase is expected to start in early 2022.

This retrofit system strengthens the customer’s position that enables them to not only have sustainable and maintainable operation for years to come, but also provides increased performance, diagnostics, reliability, and efficiency.

The machine that uses this equipment is vital to the success of the business, but the down time and cost to completely replace it is not a practical option.  Modernizing the existing installation by reusing all relevant parts of the original equipment and installing new power electronics allows the client to continue to provide consistent product to its growing market without significant down time or heavy total replacement costs.  This makes retrofits an attractive alternative to complete replacement.

The existing system includes several power converters, each mounted on a rack out panel, operating in parallel.  The existing panels will be replaced with drop in replacements, completely redesigned with the latest technology.  The new system will include upgraded protection and diagnostic features, the latest IGBT based technology, a new precharge system, reliable film capacitor technology, upgraded liquid cooling, and a simplified, easy to maintain package.  The retrofit offers flexibility in that the end user can continue to use the existing panels, use a mix of old and new, or completely replace all of the panels with the retrofits.