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Model 5012 Secondary SCR 12 Pulse

The Model 5012 is a secondary SCR, 12 pulse, single transformer, DC power supply (rectifier) used for e-coat and other higher current applications requiring lower output AC RMS ripple and reduced input harmonics. The Model 5012 is a part of the Series 50 rectifier product line, which also includes the Model 506, a secondary SCR, 6 pulse system used for e-coating, anodizing, and other industrial DC powered applications. The Models 5012 and 506 are available in air or water cooled configurations. The Series 50 rectifiers are available in a NEMA 1, NEMA 2, or NEMA 4X enclosure.

Input AC Voltage: 208V to 600V

Output DC Voltage: 100V-1,000V

Output DC Current Range: 100A to 5,000A.

For additional information on both the Model 5012 and Model 506, Please see our Series 50 Product Page

Features & Benefits
Technical Specs

General Specifications

Guide Specifications

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Features & Benefits

  • 12 Pulse System
  • High Efficiency
  • Ultra Low Output Ripple
  • Air or Water Cooled Flexability
  • Domestic and International Voltage Capability
  • Tight Voltage and Current Regulation
  • Selectable DC Overload Retry

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Technical Specs

  • Input Line Variation: +/- 5% from nominal (+/- 10% optional)
  • Efficiency: 95% typical, size dependant
  • Output Voltage Regulation: +/- 0.5%
  • Output Current Regulation: +/- 0.5%
  • AC RMS Output Ripple at Full Voltage and Current: 3%
  • Optional AC RMS Output Ripple at Full Current: 1% operating at 25% to 100% output voltage

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  • E-Coating
  • Magnet Charging
  • Superconducting Magnet Charging and Discharging
  • Electro-Chemical Applications
  • Testing / Lab
  • Other Industrial DC Powered Systems

  • Why would I need a 12 pulse rectifier?

  • The Model 5012 is a 12 pulse rectifier used in higher current applications requiring lower output AC RMS ripple and reduced input harmonics. In larger e-coating applications where the operating voltage is >300VDC and the operating current is >1500 amps DC, the Model 5012 is often the best solution. With building power coordination, the Model 5012 design meets IEEE 519 for 5% current THD (total harmonic distortion).

  • What size rectifier do I need?

  • Rectifier sizing is influenced by many variables including, part size, anode cell square footage, chemical / paint characteristics and process time. The chemical / paint or the DC powered system supplier usually recommends the rectifier size required for the application.

  • Which is better...air or water-cooling?

  • The environment where the rectifier will be placed usually determines the best type of cooling. For harsh, corrosive, or high temperature environments, water-cooling is best suited.

  • Do I need a ripple filter?

  • Ripple is the small AC RMS voltage occurring in a DC component as an unavoidable byproduct of rectification. Ripple filtering is a combination of inductance and capacitance used to reduce the level of ripple. Ripple filtering is required on most paint and chrome processes where a decorative or good finish is required. Filtering is also required for strict regulation or AC sensitive loads. In all metal finishing applications, consult your paint or chemical supplier for the desired maximum output ripple requirement. Compared to a 6 pulse rectifier design providing 5% AC RMS output ripple at full voltage and current, the Model 5012’s 12 pulse design provides 3% AC RMS output ripple at full voltage and current. An optional filter may be added to the 12 pulse design to achieve 1% AC RMS output ripple at full current, when operating at 25% to 100% output voltage.

  • Which leg of the rectifier is grounded?

  • The rectifier output is isolated allowing either leg to be grounded per process requirements.

  • Can I control or monitor the rectifier with my PLC?

  • Yes. As an option, Controlled Power Company offers a single channel computer interface card for controlling or monitoring the rectifier. The computer interface card can be configured for 0 to 10 volt, 0 to 5 volt or 4 to 20 milliamp signals. One card is required for each signal to be controlled or monitored. Additional options for control and monitoring include Ethernet, Device Net and other digital communication methods. Consult Controlled Power Company for details.

  • How can I reduce the floor space needed for rectifiers used in my process?

  • Controlled Power Company is able to custom design rectifier cabinets for limited floor space or single side access. We are also able to provide multiple rectifiers in a single enclosure.

  • Do I need a separate feeder transformer for the rectifier?

  • The rectifier does not require a separate feeder transformer; however, the rectifier will introduce noise, transients and harmonics on the lines that may interfere with other equipment. A K-rated transformer is recommended.

  • When do I need a DC switch?

  • A DC switch is used for output isolation and may be configured for various applications. When down time is unacceptable, DC switches on the normal production unit and a standby unit provide a quick means of switching between the two and isolating the unit not in use to provide safety for repair personnel. When multiple rectifiers are operated in parallel to obtain higher current levels, each unit may have a DC switch. The DC switch provides isolation in the event of a rectifier failure. The failed unit may be safely repaired while running reduced production with the other unit(s). For multi zone operation, a standby unit may have a DC switch selectable to any zone. A DC switch may also be configured to switch one rectifier between multiple tanks. See Option #13000.

  • How can I increase my rectifier’s output current?

  • A second Series 50 rectifier may be connected in parallel. The parallel control option will allow both units to equally share the load current. Some changes to the existing unit may be required.