Industrial Power Electronics & DC Systems

Heavy-Duty Battery Charger Solutions

Engineered 6-Pulse & 12-Pulse Thyristor (SCR) Float-Cum-Boost Chargers (FCBC), Dual Redundant DC Systems, and High-Frequency SMPS Rectifiers designed for continuous duty in power generation, substations, oil & gas, and heavy manufacturing.

Auto Float / Boost Mode Silicon Dropper Diode Circuit Dual 100% Redundant (1+1) Ripple < 1% RMS Filtering
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Engineered Systems

Industrial Battery Charger Portfolio

Designed to deliver uninterrupted DC power to critical control systems while maximizing battery life cycle and preventing thermal runaway.

Thyristorized FCBC Systems

Heavy-duty 6-pulse or 12-pulse full-wave SCR bridge with digital microcontroller firing control for seamless Float to Boost transition.

  • Constant Voltage / Constant Current (CV/CC)
  • Automatic Float to Boost Mode on Discharge
  • Galvanic Isolation via Double-Wound Transformer

Dual Redundant (1+1) FCBC

Dual 100% capacity rectifiers operating in parallel load-sharing or auto-standby mode with automatic bus-coupler failover logic.

  • Zero DC Bus Interrupt During Charger Swap
  • Independent AC Mains Feeds & DC Isolation
  • Compliant with State & Central Grid Norms

Silicon Dropper Diode Circuit

Automated multi-stage silicon power diode regulation circuit that clamps load voltage within strict limits (±1%) while the battery is on high boost charge.

  • Protects Sensitive DC Relays & Trip Coils
  • Automatic Multi-Step Contactor Switching
  • Heavy Aluminum Extruded Heat Sinks

Modular SMPS Rectifier Racks

High-efficiency (>95%) switched-mode power supplies (SMPS) with hot-pluggable N+1 rectifier modules for compact telecommunication applications.

  • Hot-Swappable 48V / 50A / 100A Modules
  • Active Power Factor Correction (PFC > 0.99)
  • Built-in Low Voltage Disconnect (LVD)

Solar Hybrid DC Power Plants

Combines grid AC thyristor charging with high-voltage MPPT solar controllers for remote sub-stations and telecom towers requiring hybrid green power.

  • Priority Logic: Solar > Battery > Grid
  • Reduces Grid Diesel Genset Runtime by 70%
  • Remote Telemetry via 4G / RS-485 Modbus

Ni-Cd & LiFePO4 Compatible Profiles

Custom programmable charging curves optimized for Nickel-Cadmium pocket plate cells and high-density Lithium Ferro Phosphate battery strings.

  • Precise Cell Temperature Compensation (PTC)
  • High Equalize / Commissioning Charge Voltages
  • Can-Bus / RS485 Lithium BMS Interfacing
Engineering Datasheet

Technical Specifications & Design Ratings

Manufactured in strict conformance with IS 4540, IEC 60146, IEEE 485, and CE certifications.

Parameter 24V / 48V DC Systems 110V DC Substation Systems 220V DC Power Station Systems
Input AC Supply 230V 1-Ph / 415V 3-Ph ± 15% (50Hz) 415V AC ± 15%, 3-Phase 3-Wire / 4-Wire 415V AC ± 15%, 3-Phase 3-Wire / 4-Wire
Nominal Output Voltage 24V DC / 48V DC 110V DC (Float: 123V, Boost: 135V) 220V DC (Float: 247V, Boost: 270V)
Current Capacity Range 20A up to 300A Continuous 25A up to 500A Continuous 50A up to 800A Continuous
Rectifier Topology Full-Wave 6-Pulse SCR Bridge 6-Pulse / Optional 12-Pulse SCR Bridge 12-Pulse SCR Bridge with Isolation Tx
Voltage Regulation ± 1.0% from No-load to Full-load ± 0.5% with Active Dropper Diode ± 0.5% with Multi-Stage Dropper Diode
Ripple Voltage Filter < 2% RMS without battery < 1% RMS without battery < 1% RMS (meets IEEE 485 standards)
Standard Protections AC Phase Reversal, Under/Over Voltage, DC Overvoltage, Overcurrent Limit, Earth Leakage (Positive/Negative Ground Fault Detector), Heat Sink Overtemperature, Short Circuit High-Rupture Fusing.
Enclosure Protection IP31 / IP42 Floor Standing IP42 / IP54 Sheet Steel Cubicle IP54 Heavy Industrial Control Panel
Deployment Footprint

Built for Critical Infrastructure

Powering switchgear tripping circuits, emergency controls, and SCADA systems across mission-critical sites throughout India.

Substations & Utilities

110V & 220V Dual FCBC panels delivering reliable DC power to circuit breaker trip coils, distance protection relays, and RTU telemetry.

Thermal & Hydro Power Plants

Continuous lubrication oil pump power, turbine governor control, and fail-safe black-start emergency DC operation.

Oil, Gas & Petrochemicals

Explosion-resistant, corrosion-treated DC charger cubicles for distributed control systems (DCS), emergency shut-down (ESD), and telemetry.

Telecom Central Offices

High-reliability -48V DC rectifier bays powering national fiber optic backbones, GSM base stations, and edge networking hubs.

The Engineering Difference

Generic Market Rectifiers vs. Northern EPES Standards

Why electrical consultants and utility transmission boards trust Northern EPES chargers for critical DC sub-stations.

Design Parameter Generic Market Chargers Northern EPES Engineered
Isolation Transformer ❌ Aluminum wound or low Class-B insulation ✅ Double-Wound 99.9% Pure Electrolytic Copper (Class H)
DC Output Ripple ❌ Poor filtering (> 3% RMS), cooks battery electrolytes ✅ LC Choke-Capacitor Filtered (< 1% RMS), preserves battery life
Dropper Diode Regulation ❌ Manual resistor or absent (damages sensitive loads) ✅ Automatic multi-stage silicon diode bank with dynamic clamping
Earth Fault Detection ❌ Basic indicator lamp only ✅ Active solid-state Positive & Negative ground leakage monitoring
Enclosure & Longevity ❌ Flimsy 1.2mm sheet, design life < 5 years ✅ 2.0mm CRCA Industrial Cubicle, 20+ Years Continuous Design Life
Technical FAQs

Frequently Asked Questions

Answers to critical engineering queries regarding battery charger sizing, FCBC operation, and dropper diode systems.

What is the difference between Float and Boost charging modes?
In Float mode, the charger supplies continuous trickle current to compensate for self-discharge while simultaneously delivering 100% of the continuous DC load current to the connected plant. In Boost mode (triggered automatically after a power outage or deep discharge), the charger temporarily raises its DC output voltage to rapidly recharge the battery bank to 90%+ capacity within a scheduled timeframe (typically 8 to 12 hours) before reverting smoothly to Float.
Why is a Silicon Dropper Diode Circuit necessary in an FCBC panel?
During Boost charging, the voltage applied to a 110V nominal battery bank can reach up to 135V DC. If this elevated voltage reaches delicate electronic protection relays, PLCs, or trip coils, it can permanently damage them. A Silicon Dropper Diode Circuit automatically steps in between the charger/battery bus and the load bus, dropping the excess 15V-25V to ensure that connected load equipment always receives a stable 110V ±1% DC supply.
When should I specify a Dual FCBC (1+1) configuration?
Dual FCBC systems are mandatory in electrical transmission substations (66kV, 132kV, 220kV, 400kV), power generating stations, and nuclear facilities where power failure cannot be tolerated for even a microsecond. In a Dual FCBC setup, one charger operates on load while the second sits on hot standby (or both share load). If either rectifier undergoes routine maintenance or encounters a component fault, the system switches seamlessly with zero voltage drop.
Can Northern EPES chargers be integrated with SCADA / Smart Grid networks?
Yes. All Northern EPES industrial battery chargers come equipped with standard RS-485 Modbus-RTU communication ports and optional IEC 61850 / Ethernet SNMP interfaces. Operators can monitor Float/Boost mode status, AC input voltage, DC bus voltage, battery current, earth leakage resistance, and comprehensive fault alarm logs in real time from their central control room.
Direct Manufacturing & Supply

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