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Testing and Adjusting

SR5 Electric Power Generation
Media Number -KENR5284-04 Publication Date -01/05/2014 Date Updated -07/05/2014

i02467522

Rotating Rectifier - Test

SMCS - 4465-081

Half Wave (Three-Diode) Rectifier and Varistor Heat Sink

Assembly for 1800 Frame Family
Components

Illustration 1 g00610240
Three-Diode Rectifier Block (two pieces)

with Varistor
Illustration 2 g00613971
Three-Diode Rectifier Block (two pieces)

Illustration 3 g01342087

The rotating half wave rectifier/varistor heat sink assemblies are pre-balanced. No
additional balancing is required prior to installing the assembly on the generator. Balance
is obtained using a balancing nut and bolt combination. Some assemblies may contain one
or several balance bolt and nut combinations while others may contain none. Do not add or
remove bolts and nuts to a new assembly in an attempt to balance it.
Test Interval

During routine maintenance, scheduled maintenance, or whenever there is need to

access the rotating generator components

Whenever it is suspected that the generator may have been exposed to transient
voltage activity. Transient voltages can be caused by lightning strikes, or after the
generator has been manually paralleled, or when a reverse power condition has
occurred.

Whenever there has been failure of any other excitation system component such as
the voltage regulator, exciter stator, or exciter rotor.

After every 2000 operating hours.

After every 1000 operating hours when the generator has been exposed to a harsh
operating environment. Harsh operating environments include aggregate sites and
sites with sustained elevated ambient temperatures, etc.

All leads, terminals, and connections should be inspected for damage and correct torque.

All test measurements should be documented to establish trending data.

Rectifier Diode Test Procedure

A true RMS digital multimeter and an IR thermometer are needed in order to measure
voltage, resistance, current up to 10 amperes, or temperature. Rectifier diodes can be
checked by using the diode function.

An insulation tester (megohmmeter) is needed in order to measure the insulation resistance

of the main armature, main field, exciter armature, and exciter field.

The following procedure tests all three diodes within a block. Check the positive rectifier
block and the negative rectifier block. If any meter reading does not fall within the given
ranges, replace the rectifier block.

1. Set the digital multimeter on the diode range. Remove all leads from the rectifier
block.

2. To test the positive rectifier block, follow these steps:

a. Place the black test lead on the positive "+" rectifier diode module terminal.

b. Place the red test lead on the following rectifier terminals: "AC1", "AC2" and "AC3".

Note: All meter readings should be between 0.4 VDC and 1.0 VDC.

c. Place the red test lead on the positive "+" rectifier terminal.

d. Place the black test lead on the following rectifier terminals: "AC1", "AC2" and
"AC3". In all cases, the meter should read "OL" (overload).

3. To test the negative rectifier block, follow these steps:

a. Place the red test lead on the negative "-" rectifier diode module terminal.
 b. Place the black test lead on the following rectifier terminals: "AC1", "AC2" and
"AC3".

Note: All meter readings should be between 0.4 VDC and 1.0 VDC.

c. Place the black test lead on the negative "-" rectifier diode module terminal.

d. Place the red test lead on the following rectifier terminals: "AC1", "AC2" and "AC3".

Note: In all cases, the meter should read "OL" (overload).

Note: A shorted diode can cause damage to the exciter rotor. If a diode is shorted,
check the exciter rotor. Refer to the Testing and Adjusting, KENR5284, "Winding -
Test" and the Testing and Adjusting, "Insulation - Test" sections for more testing
information. Perform the tests that are shown in "KENR5284".

e. Install new star washers on the bolts that are used in order to secure the lead
terminals to the rectifier diode module positive (+) and negative (-) terminals. The
star washers must be installed directly under the bolt head. Install all leads to the
rectifier diode modules. Torque the screws for the connections to between 2.35
N·m (20.8 lb in) and 3.35 N·m (29.7 lb in).

External Varistor Test

Refer to the "Varistor Test" section of this document for test procedures. If any meter
reading does not fall within the given range, replace the heat sink assembly. Refer to the
"Removal/Installation Instructions" section.

Removal/Installation Instructions

Use the following instructions in order to remove and in order to replace the rotating heat
sink assembly. DO NOT attempt to replace any individual component of the rotating heat
sink assembly.

1. Remove all of the necessary sheet metal in order to gain access to the rotating heat
sink assembly.

2. Remove the exciter rotor. Remove the main rotor leads from rectifier diode modules
and the varistor module. DO NOT reuse any of the star washers that are removed
from the modules. Discard them.

3. Cut any necessary wire ties and remove the wire ties.

4. Remove the bolts that secure the rotating heat sink assembly to the rotor shaft.

5. Be careful not to damage the exciter rotor lead insulation or the main rotor lead
insulation. Gently pull the heat sink assembly straight back from main rotor shaft.
Guide the exciter rotor and the main rotor leads through the heat sink assembly.

6. Inspect the exciter rotor lead terminals and main rotor lead terminals for fatigue or
loose wire strands. As is necessary, replace the terminals. Use the same type of
terminals as were originally installed.

7. Be careful not to damage the exciter rotor lead insulation or the main rotor lead
insulation during installation. Guide the leads through new heat sink assembly.
 8. Align the new rotating heat sink assembly with the holes in rotor shaft.

Note: If the new heat sink assembly is pre-wired, some lead terminations may need to
be loosened in order to move the leads to allow easier installation. DO NOT loosen the
varistor terminal nuts.

9. Apply thread lock compound to the bolts. Install the bolts. Torque the bolts according
to Table 1.

Table 1
BOLT TORQUE

Bolt Size Torque

5/16 inch
35.4 N·m (26 lb ft)

3/8 inch
55.8 N·m (41.2 lb ft)

10. Inspect exciter rotor and main rotor lead insulation for damage. Correct as necessary.

11. Reinstall exciter rotor and main rotor leads on rectifier diode module.

12. Install new star washers on varistor module terminal posts. The star washer shall be
placed between the terminal post and the lead terminal.

13. Reinstall leads to varistor module.

14. Avoid introducing sharp bends in any lead or at any connection. Torque all lead
terminal connections according to Table 2.

Table 2
TERMINAL TORQUE

Terminal Torque

Rectifier Diode Module Screws 2.35 N·m (20.8 lb in) to

3.35 N·m (29.7 lb in)

Rectifier Diode Module Bolts 5.7 N·m (50.4 lb in) to

8.1 N·m (71.7 lb in)

Varistor Module 1.4 N·m (12.4 lb in) to

2.0 N·m (17.7 lb in)

15. Refer to Illustration 1. Install new wire ties as necessary in order to secure all of the
lead wires. Install all of the sheet metal that was removed in order to gain access to
rotating heat sink assembly.

Discrete Diode Test

Check the Bridge Diodes for the 1400 Frame and 1600 Frame Generator

Illustration 4 g01327476

1. In order to perform this diode check, the diodes must be isolated, that is, they must be
disconnected. Refer to Illustration 4.

Illustration 5 g01327478

2. Attach a battery and a light to each diode in both directions in order to test the diode.
Refer to Illustration 5.
 3. Replace the diodes that illuminate the light bulb when wired in both directions.

Check the Windings and Rotating Diodes by use of Separate Excitation

NOTICE
During this procedure, make sure that the generator is
disconnected from any external load and inspect the
terminal box to check that the connections are fully
tightened.

1. Stop the unit, disconnect and isolate the CDVR wires.

Illustration 6 g01327528

Illustration 7 g01327530

2. There are two ways of creating an assembly with separate excitation. Assemble one of
the following test circuits.

Note: The voltage from a 12 volt battery or a 24 volt battery is too high with regard to
the required excitation voltage when running at rated engine speed. A variac or a
rheostat must be used in order to adjust the required excitation current for the
nominal voltage at no load. Refer to Illustration 6. Refer also to Illustration 7.
 As an alternative, a 12 volt battery that is directly connected may be used if running
the engine at low idle speed. Refer to "Dynamic" flashing.

Both these systems should have characteristics which are compatible with the
machine field excitation power. Refer to the nameplate.

3. Run the generator at the recommended speed that is used during normal operations.

4. Gradually increase the exciter field current by adjusting the rheostat or the variac and
measure the output voltages on "L1- L2 - L3", checking the excitation voltage and
current at no load and on load. Refer to the machine nameplate or ask for the factory
test report.

5. When the output voltage is at its rated value and is balanced within 1% for the rated
excitation level, the machine is in good working order. The fault therefore comes from
the CDVR or its associated wiring (that is sensing or auxiliary windings).

Full Wave Rectifier and Rectifier/Varistor Rotating Heat

Sink Assembly
Refer to the "Varistor - Test" section of this document for information about testing
procedures.

1800 Generators Only

The full wave rectifier module including its internal varistor and the external varistor
module should be inspected and should be tested according to the following guidelines:

All leads, terminals, and connections should be inspected for damage and correct torque.

All test measurements should be documented to establish trending data.

Rectifier Diode Test

The following procedure tests each of the six diodes within the rectifier diode module. If
any meter reading does not fall within the given ranges, replace the heat sink assembly. If
needed refer to the "Removal/Installation" instructions.

High voltage may be present. The power source must be

disconnected before working on the equipment. Failure to
disconnect the power source could result in injury or death.
Verify that the equipment is not energized before performing
any maintenance. This work must be performed by trained
personnel with correct tools and procedures. Bodily contact
with electrical potential will cause personal injury or death.

1. Remove all leads from the rectifier diode module.

2. Set the digital multimeter to the diode range.

 3. Place the black test lead of the multimeter on the positive "+" rectifier diode module
terminal.

4. Place the red test lead of the multimeter on each of the following rectifier diode
module terminals. Begin with "AC1", then "AC2", and finally "AC3".

Note: All of the meter readings must be between 0.4 VDC and 1.0 VDC.

5. Place the red test lead on the negative "-" rectifier diode module terminal.

6. Place the black test lead of the multimeter on each of the following rectifier diode
module terminals. Begin with "AC1", then "AC2", and finally "AC3".

Note: All of the meter readings should be between 0.4 VDC and 1.0 VDC.

7. Place the red test lead of the multimeter on the positive "+" rectifier diode module
terminal.

8. Place the black test lead of the multimeter on each of the following rectifier diode
module terminals. Begin with "AC1", then "AC2", and finally "AC3".

Note: In all cases, the meter should read "OL"(overload).

9. Place the black test lead of the multimeter on the negative "-" rectifier diode module
terminal.

10. Place the red test lead of the multimeter on each of the following rectifier diode
module terminals. Begin with "AC1", then "AC2", and finally "AC3".

Note: In all cases, the meter should read "OL" (overload).

Note: A shorted diode can damage the exciter rotor. If a diode is shorted, then check
the exciter rotor. Refer to the Testing and Adjusting, KENR5284, "Winding - Test" and
the Testing and Adjusting, "Insulation - Test" sections for more testing information.
Perform the tests that are shown in "KENR5284".

11. Install all of the leads to the rectifier diode module. Torque the screws. The torque for
the connections can range from 2.35 N·m (20.8 lb in) to 3.35 N·m (29.7 lb in).

Rotating Heat Sink Assembly Removal/Installation Instructions - 1800

Frame Generators Only

Use the following instructions in order to remove and in order to replace the rotating heat
sink assembly. DO NOT attempt to replace any individual component on the rotating heat
sink assembly.

1. Label the wires in order to ensure correct wiring upon installation.

2. Remove wires from terminals.

3. Remove mounting bolts.

4. Remove heat sink assembly.

5. Replace heat sink assembly.

 6. Apply 9S-3263 Thread Lock to bolts. Install the bolts. Torque the bolts according to
Table 3.

Table

Table 3
Bolt Size Torque

5/16 inch
35.4 N·m (26 lb ft)

3/8 inch
55.8 N·m (41 lb ft)

7. Inspect the exciter rotor lead insulation and the main rotor lead insulation for
damage. Correct as necessary.

8. Install the exciter rotor leads and the main rotor leads on the rectifier diode module.

9. Install new star washers on the varistor module terminal posts. The star washer shall
be placed between the terminal post and the lead terminal.

10. Install the leads to the varistor module.

11. Avoid introducing sharp bends in any lead or at any connection. Torque all of the lead
terminal connections according to Table 4.

Table 4
TERMINAL TORQUE

Terminal Torque Rectifier Diode Module 2.35 N·m (20.8) -

3.35 N·m (30 lb in)

Varistor Module 1.4 N·m (12.3910 lb in) -

2 N·m (17.7 lb in)

12. Install new wire ties as necessary in order to secure all of the lead wires.

13. Install all of the sheet metal that was removed in order to gain access to rotating the
heat sink assembly.

Rectifier Assembly Troubleshooting Checklist

Table 5
Package S/N:

Factory Claim Number

DSN

Dealer Contact - Name and Phone

External varistor check Installed (Y / N) -

 Megohmmeter measurement
(VDC) -

Condition (Good/Bad) -

Megohmmeter measurement
Internal varistor check (VDC) -

Condition (Good/Bad) -

AC1 AC2 AC3

Forward Biased Check - Pos.

(VDC) -

Forward Biased Check - Neg.

Diode check (VDC) -

Reverse Biased Check - Pos.

(VDC) -

Reverse Biased Check - Neg.

(VDC) -

Insulation test results

Exciter Rotor check (Megohms) -

Winding test results (Ohms) -

Insulation test results

Main Rotor check (Megohms) -

Winding test results (Ohms) -

Other Failed Parts (Regulator, Exciter Stator, Exciter

Rotor, etc.)

Failure Analysis Root Cause/Time Line of event

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