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Series 50 Rectifier

The Series 50 is a secondary SCR, single transformer, DC power supply (rectifier) used for e-coating, anodizing, and other industrial DC powered applications. The Series 50 rectifiers include two (2) product models: 506 and 5012. The Model 506 is a 6 pulse rectifier that provides reliable, regulated power and is selected for most applications. The Model 5012 is a 12 pulse rectifier used in higher current applications requiring lower output AC RMS ripple and reduced input harmonics. Both models 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 to 1,000V

Output DC Current Range: 500A to 5,000A

Features & Benefits
Technical Specs

General Specifications

Guide Specifications

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Features & Benefits

  • High Efficiency
  • Air or Water Cooled Flexibility
  • Domestic and International Voltage Capability
  • Low Ripple
  • 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 : 5% (Model 506); 3% (Model 5012)
  • Optional AC RMS Output Ripple at Full Current: 5% operating at 25% to 100% output voltage (Model 506) 1% operating at 25% to 100% output voltage (Model 5012)

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

  • 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.

  • What are the differences between the Model 506 and Model 5012 designs and their applications?

  • The Model 506 is a 6 pulse rectifier design used for most DC powered applications. Available with or without optional output filtering to reduce AC RMS ripple, the Model 506 provides reliable, regulated power for applications requiring >100VDC. 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).

  • 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.

  • 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 current output?

  • 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.