3412 Generator Set 4BZ00001-UP(SEBP2785 - 34) - Documentation Page 1 of 10

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Product:  GENERATOR SET 
Model:  3412C GENERATOR SET 4BZ 
Configuration: 3412 Generator Set 4BZ00001-UP 

Testing and Adjusting

SR4B Generator
Media Number -SENR5359-11 Publication Date -01/05/2009 Date Updated -11/05/2009

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"

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(5) Rectifier Terminal "AC3"

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.

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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.

• 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

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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" (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).

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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.

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

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Illustration 3 g00610240

Three Diode Rectifier Block (two pieces)

Illustration 4 g00613971

Three Diode Rectifier Block (two pieces)

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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.

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.

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External varistor A shorted external varistor can cause

(CR7) check - OK or diode block failure due to overcurrent.
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

Measurements?
insulation 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.

Loss of field events due to VR

Voltage regulator
malfunction can cause diode block
functionality?
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.

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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)?

Verify phase rotation is correct by

New installations? 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?
Time of day?
Utility voltage stable?

Was the unit in stable operation,

ALL faults and starting up, shutting down, or
alarms (both logged paralleling (trying to match voltage and
and active)? frequency before shutting the breaker)?

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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 of Confirm kW load and kVAR load.
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.

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All Rights Reserved.
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