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Rotating Rectifier - Test
Rotating Rectifier - Test
Rotating Rectifier - Test
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i02443225
Table 1
TOOLS NEEDED
Part Number Tool Quantity
6V-7070 Multimeter 1
Illustration 1 g00613957
(1) Positive Rectifier Block
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Note: Verify part number 9Y-0916 rectifier block date code as 0503 or greater. Refer to illustration 2. Rectifiers
with a date code of 0503 and greater contain an internal varistor (CR7). Follow testing procedures with internal
varistor (CR7).
Illustration 2 g01229622
(6) Date code
Improper test equipment can fail and present a high voltage shock
hazard to its user.
Make sure the testing equipment is designed for and correctly operated
for high voltage and current tests being made.
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Do not start the engine or move any of the controls if there is a "Do Not
Operate" or similar warning tag attached to the start switch or controls.
Procedure - Rectifier
The following procedure tests all six diodes within the 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. Place the black test lead on the positive "+" rectifier terminal. Place the red test lead on the following
rectifier terminals: "AC1" (3) , "AC2" (4) and "AC3" (5) . All readings on the meter should be between
0.4 and 1.0.
3. Place the red test lead on the negative "-" rectifier terminal. Place the black test lead on the following
rectifier terminals: "AC1" (3) , "AC2" (4) and "AC3" (5) . All readings on the meter should be between
0.4 and 1.0.
4. Place the red test lead on the positive "+" rectifier terminal. Place the black test lead on the following
rectifier terminals: "AC1" (3) , "AC2" (4) and "AC3" (5) . In all cases, the meter should read "OL"
(overload).
5. Place the black test lead on the negative "-" rectifier terminal. Place the red test lead on the following
rectifier terminals: "AC1" (3) , "AC2" (4) and "AC3" (5) . In all cases, the meter should read "OL"
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(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, "Winding - Test" and Testing and Adjusting, "Insulation - Test".
Perform these tests.
Note: For a failed rectifier block, refer to the "Diode Block Troubleshooting Guide", Table 3. The "Diode
Block Troubleshooting Guide" consists of a list of items to consider when troubleshooting a failed diode
block and/or external varistor (CR7). The purpose of this list is to find a cause for the diode block and/or
varistor (CR7) failure which may be external to the exciter system. The purpose of this list is NOT to
troubleshoot "no voltage output" from the generator.
6. Install leads.
Terminal connections - 2.35 N·m (20.8 lb in) to 3.36 N·m (29.7 lb in)
9Y-0916 Rectifier Assembly (mounting to heatsink) - 4.07 N·m (36 lb in) to 5.54 N·m (49 lb in)
NOTICE
Do not over-torque. Applying torques greater than the listed torques
may cause damage to the components.
The following procedure tests the ability of the normal state of the varistor (CR7). If any meter reading does not
fall within the given ranges, replace the rectifier block.
Note: The rectifier block is polarity sensitive. Damage to equipment may result in reverse polarity testing.
3. If the megohmmeter is not capable of reading DC voltage, hook up a 1000 VDC voltmeter across the
negative and positive terminals.
4. On the megohmmeter, select and apply 1000 VDC to the varistor (CR7).
Note: Do not apply voltage to the varistor (CR7) for greater than 3 seconds..
If the readings are greater than 600 VDC, the varistor (CR7) is OPEN.
If the readings are less than 450 VDC, the varistor (CR7) is SHORTED or DEGRADED.
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Note: Do not over torque. Applying torques greater than the listed torques may cause damage to the
components.
Terminal connections - 2.35 N·m (20.8 lb in) to 3.36 N·m (29.7 lb in)
Note: If the varistor (CR7) is found to be defective, the varistor (CR7) most likely failed due to a transient
voltage surge on the main rotor winding. Varistor failure is not usually a component failure. Root causes of
varistor (CR7) failure include:
Loss of main rotor field due to voltage regulator failure, diode rectifier failure, or other events
Illustration 3 g00610240
Three Diode Rectifier Block (two pieces)
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Illustration 4 g00613971
Three Diode Rectifier Block (two pieces)
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.
a. Place the red test lead on the negative "-" terminal. Place the black test lead on the following
rectifier terminals: "AC1" (3) , "AC2" (4) and "AC3" (5) . All readings on the meter should be
between 0.4 and 1.0.
b. Place the black test lead on the negative "-" terminal. Place the red test lead on the following
rectifier terminals: "AC1" (3) , "AC2" (4) and "AC3" (5) . In all cases, the meter should read "OL"
(overload).
a. Place the red test lead on the positive "+" rectifier terminal. Place the black test lead on the
following rectifier terminals: "AC1" (3) , "AC2" (4) and "AC3" (5) . In all cases, the meter should
read "OL" (overload).
b. Place the black test lead on the positive "+" rectifier terminal. Place the red test lead on the
following rectifier terminals: "AC1" (3) , "AC2" (4) and "AC3" (5) . All readings on the meter
should be between 0.4 and 1.0.
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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, "Winding - Test" and Testing and Adjusting, "Insulation - Test". Perform these
tests.
Note: For a failed rectifier block, refer to the "Diode Block Troubleshooting Guide", Table 3. The "Diode Block
Troubleshooting Guide" consists of a list of items to consider when troubleshooting a failed diode block and/or
external varistor (CR7). The purpose of this list is to find a cause for the diode block and/or varistor (CR7)
failure which may be external to the exciter system. The purpose of this list is NOT to troubleshoot "no voltage
output" from the generator.
Note: This configuration contains an externally mounted varistor (CR7) block. Refer to Testing and Adjusting,
"Varistor - Test" section of this document. Perform the tests in the "Diode Block Troubleshooting Guide".
Table 2
Diode Block Troubleshooting Guide
Measurement OK/Failed
Check For
External varistor
A shorted external varistor can cause diode block failure
(CR7) check - OK
due to overcurrent.
or Failed?
A failed diode block can cause the external varistor to
fail due to the loss of the main rotor circuit, overheat,
and then become an open circuit.
Exciter end
physical General conditions
inspection?
Loose or missing wires.
Heat transfer compound under diode block.
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Operating mode at
Stand alone operation.
time of failure?
Stable load, loading up, shutting down, engine startup?
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Time of day?
Utility voltage stable?
Operating
parameters at time Confirm kW load and kVAR load.
of failure?
Power factor, line current per phase, generator voltage.
Copyright 1993 - 2017 Caterpillar Inc. Thu Nov 02 2017 08:12:48 GMT-0400 (Hora estándar oeste, Sudamérica)
All Rights Reserved.
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