FORCED AIR COOLED ALTERNATOR MOUNTED RECTIFIER

FOR DIESEL ELECTRIC LOCO

INTERNAL TEST REPORT

INDEX
Sr. No.

Title

Page

01

CONTINOUS DUTY TEMPERATURE RISE TEST

02

02

CURRENT DISTRIBUTION TEST

03

03

VOLTAGE /LIGHT LOADTEST

04

04

TEST ON INDICATING & FUNCTIONAL UNITS

04

05

INSULATION TEST

04

06

VISUAL & DIMENSIONAL CHECK

05

Testing Date:- 05/11/2012

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1.CONTINOUS DUTY TEMPERATURE RISE TEST IN "N" CONDITION:

Hirect SR. NO.:2012K/24/13
D.M.W P.O. NO.: 21/13/3001/1/761843 Dt.24/07/2012
Type: TRSR 510/3800 RDSO SPEC.NO: MP.O.24.02.20(Rev.00)April 2009.
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FORCED AIR COOLED ALTERNATOR MOUNTED RECTIFIER

FOR DIESEL ELECTRIC LOCO

INTERNAL TEST REPORT

Test Conditions :1. Full Load Condition
2. Blower Inlet Opening
3. Circuit Conditions
4. Initial condition
5. Shunt Rating
6. Cooling

:
:
:
:
:
:

3800Adc (47.5mV)
100%
All diodes in circuit.
Cold.
6000A / 75 mV.
By External blower

(Temperature record of Diode base in C)

Reverse Polarity (FRONT)
Diode Colour
C
Diode Colour
No.
code
No.
code

Diode
No.

Normal Polarity (BACK)

Colour
C
Diode Colour
code
No.
code

D1

63

D10

68

D19

64

D28

66

D2

63

D11

69

D20

65

D29

65

D3

62

D12

67

D21

62

D30

72

D4

58

D13

63

D22

63

D31

D5

60

D14

62

D23

60

D32

D6

61

D15

61

D24

60

D33

D7

62

D16

62

D25

64

D34

D8

68

D17

60

D26

63

D35

60
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63
/
20
65
13
L
S63
K
Pa
61
ge
2

D9

65

D18

61

D27

68

D36

BUSBAR TEMPERATURE : (in C)

(U)AC1:53C
(V)AC2: 53 C
(W)AC3: 53C

+VE: 51C

-VE: 50C

CALCULATION OF Tj OF THE HOTTEST DIODE :Case Temperature of the hottest diode

No. MR (30) (Recorded)
=
72o C
Max. Average Current through the diode D30

(3800*1.2/6)/3

Hirect SR. NO.:2012K/24/13

D.M.W P.O. NO.: 21/13/3001/1/761843 Dt.24/07/2012
Type: TRSR 510/3800 RDSO SPEC.NO: MP.O.24.02.20(Rev.00)April 2009.
Page 2 of 5

62

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FORCED AIR COOLED ALTERNATOR MOUNTED RECTIFIER

FOR DIESEL ELECTRIC LOCO

INTERNAL TEST REPORT

=
=
=

RMS Value of the diode

253.33
253.33*1.73

438.26A
Power loss in the diode
=
Junction Temp.of the diode@ 23 o C ambient
=
o
Junction Temp.of the diode@ 60 C ambient
=
Rated Junction Temp. of the diode at 160 o

282.55W
72+ (282.55*0.065) = 73.36 o C
73.36 +(60-23) = 110.36 o C

Hence diode is safe

2.CURRENT DISTRIBUTION TEST:

DIODE
D1
D2
D3
D4
D5
D6
D7
D8
D9
D10
D11
D12
D13
D14
D15
D16
D17
D18

Reverse Polarity (FRONT)

(Iav)

230
207
205
198
222
220
240
243
215
203
216
235
236
240
245
232
210
225

Mean Value
Max. Recorded.
Min. Recorded.
Max.. unbalance.
Min.. unbalance.
Permissible limits
Mean Value
Max. Recorded.
Min. Recorded.
Max.. unbalance.
Min.. unbalance.
Permissible limits
Mean Value
Max. Recorded.
Min. Recorded.
Max.. unbalance.
Min.. unbalance.
Permissible limits

213.66
230
198
7.64%
-7.32%
20%
225.33
243
203
7.84%
-9.90%
20%
231.33
240
210
3.74%
-9.22%
20%

SHUNT: 6000 Amps / 75 mV

Idc:
3800 Amps / 47.5mV

DIOD
E
D19
D20
D21
D22
D23
D24
D25
D26
D27
D28
D29
D30
D31
D32
D33
D34
D35
D36

Normal Polarity (BACK)

(Iav)

235
215
200
215
220
226
228
234
206
221
223
235
210
222
196
192
225
215

Mean Value
Max. Recorded.
Min. Recorded.
Max.. unbalance.
Min.. unbalance.
Permissible limits
Mean Value
Max. Recorded.
Min. Recorded.
Max.. unbalance.
Min.. unbalance.
Permissible limits
Mean Value
Max. Recorded.
Min. Recorded.
Max.. unbalance.
Min.. unbalance.
Permissible limits

3. VOLTAGE SHARING: At light load

A.C. Input
Volts
Amps
U-V phase

U phase

Arm Voltages
Volts
Between+Ve,U

D.C. Output
Volts
Amps
595

1190

10.8

Hirect SR. NO.:2012K/24/13

D.M.W P.O. NO.: 21/13/3001/1/761843 Dt.24/07/2012
Type: TRSR 510/3800 RDSO SPEC.NO: MP.O.24.02.20(Rev.00)April 2009.
Page 3 of 5

218.5
235
200
7.55%
-8.46%
20%
12
214.5
/
235
31
/
206
20
9.55%
13
L
-3.96%
S
20%
K
Pa
210
ge
225
3
192
12
7.14%
/
31
-8.57%
/
20%
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FORCED AIR COOLED ALTERNATOR MOUNTED RECTIFIER

FOR DIESEL ELECTRIC LOCO

INTERNAL TEST REPORT

888

9.3

Between +Ve,V

590

V-W phase

V phase

Between +Ve,W

590

888

9.2

Between -Ve,U

590

W-U phase

W phase

Between -Ve,V

590

888

9.3

Between -Ve,W

595

4. TEST ON INDICATING & FUNCTIONAL UNITS:

FUSE FAILURE DISPLAY TEST :
Status
All 36-nos. micro-switch N/O contact shorted manually and
respective fuse failure LED glows

OK

5. INSULATION TEST WITH MEGGAR 1000 V

Terminals
Input &output shorted
w.r.t. Earth
Auxillary circuit
shorted w.r.t. Earth

IR (Before di-electric)
In M
>200 M

Di-electric test
(for 1 minute)
3.0 KV
1.5 KV

>200 M

IR (after Di-electric)
in M
>200 M
>200 M

6.VISUAL & DIMENSIONAL CHECK

The rectifier assembly was examined for general workmanship mounting etc. and
found OK.
Sr.no
.

Description

In drawing
(mm)

Actual Measured
(mm)

Hirect SR. NO.:2012K/24/13

D.M.W P.O. NO.: 21/13/3001/1/761843 Dt.24/07/2012
Type: TRSR 510/3800 RDSO SPEC.NO: MP.O.24.02.20(Rev.00)April 2009.
Page 4 of 5

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FORCED AIR COOLED ALTERNATOR MOUNTED RECTIFIER

FOR DIESEL ELECTRIC LOCO

INTERNAL TEST REPORT

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

Rectifier Frame height

Width
Depth
Mounting hole
Mounting hole
Mounting hole
Mounting hole
Mounting hole
DC Bus Bar Centre to Centre
DC Bus Bar Centre to Centre
Total Height
Radius (R)

970
1450
497
190
375
310
375
190
55
35
1037
R721

971
1451
496.7
190.8
376
311.2
374.8
190.8
55.3
35.4
1038
R721.5

For HIND RECTIFIERS LTD.

E (Testing)

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M (Production)

Hirect SR. NO.:2012K/24/13

D.M.W P.O. NO.: 21/13/3001/1/761843 Dt.24/07/2012
Type: TRSR 510/3800 RDSO SPEC.NO: MP.O.24.02.20(Rev.00)April 2009.
Page 5 of 5

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