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Testing and Adjusting

SR4B Generators
Media Number -SENR5359-13 Publication Date -01/10/2014 Date Updated -10/10/2014

i02443225

Rotating Rectifier - Test

SMCS - 4465-081

Table 1
TOOLS NEEDED
Part Number Tool Quantity
6V-7070 Multimeter 1

243-3134 (1) Tester Group 1

(1) Or equivalent.

Illustration 1 g00613957
(1) Positive Rectifier Block

(2) Negative Rectifier Block

(3) Rectifier Terminal "AC1"

(4) Rectifier Terminal "AC2"

(5) Rectifier Terminal "AC3"

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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

Personal injury or death can result from improper troubleshooting and

repair procedures.

The following troubleshooting and repair procedures should only be

performed by qualified personnel familiar with this equipment.

Personal injury or death can result from high voltage.

When power generation equipment must be in operation to make tests

and/or adjustments, high voltage and current are present.

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.

When servicing or repairing electric power generation equipment:

Make sure the unit is off-line (disconnected from utility and/or

other generators power service), and either locked out or tagged
DO NOT OPERATE.

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Make sure the generator engine is stopped.

Make sure all batteries are disconnected.

Make sure all capacitors are discharged.

Shut off engine and remove key before performing maintenance or

repair work. Failure to do so may result in personal injury due to
inadvertant machine operation.

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.

Do not connect generator to a utility electrical distribution system

unless it is isolated from the system. Electrical feedback into the
distribution system can occur and could cause personal injury or death.

Open and secure main distribution system switch, or if the connection is

permanent, install a double throw transfer switch to prevent electrical
feedback. Some generators are specifically approved by a utility to run
in parallel with the distribution system and isolation may not be
required. Always check with your utility as to the applicable
circumstances.

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.

Procedure - Internal Varistor (CR7)

Note: Verify 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).

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.

1. Remove all leads from the rectifier block.

2. Place the megohmmeter test leads on the rectifier block as follows:

Place the BLACK test lead on the negative "-" terminal.

Place the RED test lead on the positive "+" terminal.

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..

5. Megohmmeter readings should be between 450 VDC and 600 VDC.

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.

6. Install leads. Apply the following torques.

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:

Incorrect paralleling or loss of synchronism

Reverse VAR or reverse power event

Loss of main rotor field due to voltage regulator failure, diode rectifier failure, or other events

High ambient temperature (or other application error)

Large sudden load application

Three Diode Rectifier Block

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.

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

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).

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

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

Diode checks? Diode short or open.

Internal varistor (CR7) OK or Failed.

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.

Exciter rotor winding resistance and insulation

Measurements?
resistance measurement
Main field rotor winding resistance and insulation
resistance measurement.
Record ambient temperature when taking winding
resistance readings.
Record generator stator and rotor metal temperature
when taking winding resistance readings.

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Voltage regulator Loss of field events due to VR malfunction can cause

functionality? diode block failure.
Under certain conditions, startup with shorted diode
block can cause damage to certain voltage regulators.
Voltage sensing is correctly connected and functional.
Voltage sensing potential transformer fuses and wiring
for medium voltage and high voltage systems.
If applicable, B-phase current transformer (droop VAR
sensing).
Is the VAR pf control enabled as soon as the main
breaker is shut (parallel operation only)? The VAR
control setpoint should not be zero.
After a loss of sensing, inspect and test the diode block
before restarting the unit.

Operating mode at
Stand alone operation.
time of failure?
Stable load, loading up, shutting down, engine startup?

Load swings, motor starting, surges or transients?

Engine operation OK or not?
List all faults and warnings from generator, engine, and
switchgear.
Parallel to other generator(s)?

New installations? Verify phase rotation is correct by wiring inspection and

instrument measurement.
How is VAR shared? Droop or cross current
compensation or kVAR or pf controller? Is the VAR
share working correctly?
How is real load (kW) shared. Is the load sharing
working correctly?
Is the paralleling control functioning correctly
(including dead bus closure).
Is the load sharing control functioning correctly.
Parallel to utility?

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Time of day?
Utility voltage stable?

ALL faults and

Was the unit in stable operation, starting up, shutting
alarms (both
down, or paralleling (trying to match voltage and
logged and active)?
frequency before shutting the breaker)?

Confirm that every engine shutdown or voltage regulator

shutdown will open the main generator output breaker.
How much time does it take to get the breaker open?
Confirm kVAR or Power factor set point for voltage
regulator(s).
Check set point and correct operation of reverse VAR
and reverse kW relays.
Check set point and correct operation of minimum
excitation limiter.
Check set point and correct operation of maximum
excitation limiter.
Check set point and correct operation of loss of field
protection.

Operating
parameters at time Confirm kW load and kVAR load.
of failure?
Power factor, line current per phase, generator voltage.

Voltage regulator output current at the time of failure?

(if available)
Cross check the kW, kVAR, line current and power
factor . Do the instruments make sense?
Cross check generator package instruments against
switchgear or other readings to confirm Instrument
performance if necessary.

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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