351-02020-01A

INSTRUCTION MANUAL
Diode Fault Detector
for Series Redundant Brushless Exciters
Description Installation Operation
Maintenance Parts Description

Made By:
Rockwell Automation Kato Engineering

P.O. Box 8446

Mankato, MN 56002-8447
(507) 625-4011
Fax. (507) 345-2798

DANGER
ONLY QUALIFIED PERSONNEL FAMILIAR WITH THE CONSTRUCTION AND
OPERATION OF THIS EQUIPMENT AND THE HAZARDS INVOLVED SHOULD
INSTALL, ADJUST, OPERATE AND /OR SERVICE THIS UNIT. READ AND
UNDERSTAND THIS MANUAL IN ITS ENTIRETY BEFORE PROCEEDING. FAILURE
TO OBSERVE THIS PRECAUTION COULD RESULT IN SEVERE BODILY INJURY OR
LOSS OF LIFE.

DANGER
THE USER IS RESPONSIBLE FOR CONFORMING TO THE NATIONAL ELECTRIC
CODE AND ALL OTHER APPLICABLE LOCAL CODES. WIRING, GROUNDING,
DISCONNECTS, AND OVERCURRENT PROTECTION ARE PARTICULARLY
IMPORTANT. FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN
SEVERE BODILY INJURY OR LOSS OF LIFE.

DANGER
SUBSEQUENT STEPS REQUIRE ROTATING PARTS AND/OR ELECTRICAL CIRCUITS
TO BE EXPOSED. STAY CLEAR IF UNIT MUST BE RUNNING OR DISCONNECT AND
LOCKOUT AND TAG POWER SOURCE IF CONTACT MUST BE MADE. FAILURE TO
OBSERVE THESE PRECAUTIONS COULD RESULT IN SEVERE BODILY INJURY OR
LOSS OF LIFE.

WARNING
IF LIFTING OF EXCITER IS REQUIRED, DO NOT PULL AT AN ANGLE ON LIFTING
EYES. THE LIFTING EYES ARE FOR THE UNIT ONLY AND NOT FOR THE
COMPLETE SET. FAILURE TO OBSERVE THESE PRECAUTIONS COULD RESULT IN
BODILY INJURY.

Table of Contents

SECTION 1: Introduction and Description

1.1.
1.2.
1.3.

1.4

Introduction
General Description
Construction and Mounting
1.3.1. Diode Fault Detector (DFD) Versions and Application
1.3.2. Input Connections
1.3.3. Output Connections
1.3.4. Installation Instructions
1.3.4.1 508-00118-31, -32 Detectors
1.3.4.2 508-00118-33 Detectors
Description of Operation
1.4.1. DFD Circuit Overview
1.4.2. DFD Output Signals

SECTION 2: Initial Inspection, Storage and Alignment

2.1.
2.2.

Receiving Inspection
Alignment and Adjustments

SECTION 3: Maintenance
3.1
3.2
3.3

Periodic Maintenance
Replacement
Insulation Resistance

SECTION 4: Troubleshooting
4.1.
4.2.
4.3.
4.4.
4.5.
4.6.

Diode Fault Alarm

Troubleshooting General Method
Wire Continuity Test
Checkout of Signal Wires to Ground Detector
Functional Check of Diode Fault Detector
Replacement Part Numbers

TABLE OF FIGURES AND ILLUSTRATIONS

Figure 1: Diode Fault Detector Mounting on Brushless Exciter Rotors

Figure 2: Block Diagram of Detector AC and DC Connections on Diode Wheel
Figure 3: Complete Diode Wheel Assembly (6A6 and 7A6 type exciter designs)
Figure 4: Diode Wheel Assembly Inboard Side (6A6 and 7A6 type exciter designs)
Figure 5: Diode Wheel Assembly Outboard Side (6A6 and 7A6 type exciter designs)
Figure 6: Diode Fault Detector Outline of Mounting and Connections
Figure 7: Diode Fault Detector Mounting Face View (Photo)
Figure 8: Diode Fault Detector Top View and Output Connections to Ground Detector System
(Photo)
Figure 9: Diode Fault Detector Connection Example to DC Buss (Photo of 6A6 and 7A6 type
exciter designs)
Figure 10: Diode Fault Detector AC Connection Example and Wire Harness Securing in Diode
Wheel Groove (Photo of 6A6 and 7A6 type exciter designs)
Figure 11: Complete Diode Wheel Assembly (7A7 and 9A4 type exciter designs)
Figure 12: Diode Wheel Assembly Inboard Side (7A7 and 9A4 type exciter designs)
Figure 13: Diode Wheel Assembly Outboard Side (7A7 and 9A4 type exciter designs)
Figure 14: Block Diagram of Diode Fault Detector / Field Ground Detector
Figure 15: Diode Fault Detector Alarm Logic

1. INTRODUCTION AND DESCRIPTION

1.1 Introduction
This manual describes the Diode Fault Detector used on brushless exciters with series redundant diodes on the diode
wheel used mainly on 2 pole synchronous generators. The instruction book covers the general description,
construction, installation, operation, initial inspection, maintenance, troubleshooting and renewal parts.

1.2 General Description

The Diode Fault Detector is used in conjunction with a field ground detector system (see separate instruction book)
to detect faulty diodes in a series redundant brushless exciter system. The brushless excitation system consists of a
high frequency AC generator complete with a rotating, series redundant diode assembly and a lead assembly that
connects the DC diode bridge output to the field windings of the main generator. The Diode Fault Detector is a
electronic module mounted underneath the rim of the diode assembly hub or wheel between the wheel and the
armature of the exciter as shown in Figure 1.
The module connects to the AC and DC connections of the rectifier bridge and monitors the forward voltage drop of
the series redundant diodes within the rectifier bridge. It is also powered from the DC connections. If a diode fails
open or shorted , the forward voltage drop of the cells in that leg changes with respect to the other legs of the bridge.
This creates a ripple in the forward voltage balance which is detected in the module. When the ripple exceeds a
preset threshold, the module sends a fault signal to the field ground detector transmitter (see separate instruction
book) located diametrically opposite the Diode Fault Detector. The transmitter in turn sends the alarm signal to a
stationary receiver unit. The receiver sends this alarm signal to a remote device such as the brushless exciter voltage
regulator which provides a fault signal to the user.
A block diagram of how the Diode Fault Detector connects to the exciter and ground detector system is shown
in Figure 14 (found in section 1.4.).

DIODE FAULT DETECTOR

RED
AC CONNECTION LINKS

DIODE WHEEL ASSEMBLY

AC CONNECTION RING

WIRE HARNESS GROOVE

DFD OUTPUT CONNECTIONS

TO GROUND DETECTOR
TRANSMITTER
GREEN

(CUT AWAY VIEW)

FIGURE #1a: DIODE FAULT DETECTOR MOUNTING
(6A6 AND 7A6 TYPE EXCITER ROTOR DESIGNS)

DIODE FAULT DETECTOR

RED

DIODE WHEEL ASSEMBLY

AC CONNECTION LINKS
AC CONNECTION RING

DFD OUTPUT CONNECTIONS

TO GROUND DETECTOR
TRANSMITTER

WIRE HARNESS GROOVE

GREEN
SPACER

(CUT AWAY VIEW)

FIGURE #1b: DIODE FAULT DETECTOR MOUNTING
(7A7 AND 9A4 TYPE BRUSHLESS EXCITER ROTORS)

1.3 Construction and Mounting

The Diode Fault Detector (DFD) is consists electronic components mounted to printed circuit boards and a heat sink
which are encapsulated in a high strength molded potting compound. The Detector has 2 holes for mounting to the
face of the diode assembly as shown in Figures 3 to 6.

1.3.1.

DFD Versions and Application

As of the date of this publication there are 4 models of Diode Fault Detectors. These models are used for
various DC buss operating voltages and different diode wheel mechanical arrangements. The following list
gives the Kato Engineering part number and associated application information.
508-00118-32, 508-00118-34:
These 2 models are used on exciters with an output operating voltage range of 20 to 278 VDC. They
mount on 6A6 style exciters (with the smaller diode wheel). The 34 Detector incorporates a special
harness for mounting to diode wheels which do not have the harness groove (also the smaller 6A6 style
diode wheels).
508-00118-31:
This model is used on exciters with an output operating voltage range of 32 to 390 VDC. They mount
on 7A6 style exciters utilizing the smaller diameter diode wheel.
508-00118-33:
This model is used on exciters with an output operating voltage range of 60 to 525 VDC. They mount
on 7A7 and 9A4 style exciters utilizing the larger diameter diode wheel.

1.3.2.

Input Connections
The Detector receives input signals from the AC and DC terminals of the diode bridge via the wire
harnesses (one on each side of the Detector). Each wire harness contains 3 pairs of leads for connection to
each pair of diodes. One lead of the pair connects to AC heatsink and other lead (DC lead) is routed
through the diode wheel opening for that heatsink and connects to the DC buss. The A and C leads are
encased in a harness and are routed in a groove in the diode wheel rim on the inboard side of the diode
wheel (figures 3, 4, and 6). The length of the leads in the harness are sized to assure connection lead
lengths match the mechanical arrangement of the correct AC phase. The leads must be connected to the
proper phase to avoid noise pickup from magnetic fields from the diode currents. The wires of the
harnesses are routed through the diode wheel openings as shown in Figure 2.
The DC leads are connected to the DC buss ring as shown in Figure 3 and 5.
The AC leads of the Detector are connected to the AC heatsink assembly under one of the bolts securing the
U shaped AC connection leads to the heatsinks. AC lead connection locations are shown in figures 3, 4,
11 and 12. For lead assembly and torque of the bolts for U connectors refer to the brushless exciter
instruction book.

DIODE FAULT MONITOR

ARMATURE PHASE CONNECTIONS, B-, C-, AARMATURE PHASE CONNECTIONS, C+, A+, B+
C DC
C AC

C+

A+
BL

DC BUS RING

B-

B DC
B AC
A DC
A AC

B+

BL

POSITIVE POLARITY HARNESS

A-

C-

AC HEAT
SINK

DC BUS RING

NEGATIVE POLARITY HARNESS

DIODE WHEEL HUB

LAYOUT OF TOP VIEW OF DIODE WHEEL (RIM NOT SHOWN)

WIRE COLOR CODE

Y
O
ORANGE
R
G GREEN
W
BL BLUE
B

YELLOW
RED
WHITE
BLACK

Figure 2: Block Diagram Of Detector AC And DC Connections On Diode Wheel

1.3.3.

Output Connections
Two leads from the Ground Detector Transmitter (red and green) are routed to the Diode Fault Detector
along the outboard face of exciter AC connection ring (see Figure 1) or in a groove at the ID of the diode
wheel rim. These leads are connected to the DFD output terminals as shown in detail B of Figures 3, 4,
11 and 12. After the leads are connected to the Detector, they are secured to the U connector near the
Detector with glass cord and air dry varnish (Figure 1). The leads are then routed along the connection
ring face (in nearly all cases these leads will be pre-routed).

1.3.4.

Installation Instructions
Installation of these models is basically the same in that they all mount under the rim of the diode wheel
(see Figure 1). They are also similar in that they contain a harness that distributes around the wheel and
connects across the series redundant diode assemblies located between the spokes of the wheel.
At the time of this publication there were 4 models of Diode Fault Detectors as listed in section 1.3.1.
Normally these Detectors will be mounted on the diode wheels at the factory. However, if field
installation is required the following sections will provide the instructions necessary for successful
installation or replacement of the Detector. Removal of the Detector which exists on the diode wheel is
as simple as disconnecting all of the leads connected to the potted Diode Fault Detector module and
removing the module along with the wire harness (which is potted right into the module).
NOTE: Care should be taken when removing the RED and GREEN wires from the DFD. These
wires will remain and be re-used and must not be damaged (these wires connect the DFD
to the Ground Detector System and are difficult to replace if damaged).
Refer to section 1.3.4.1. for installation instructions on the 508-00118-31 and 32 Detectors. Refer to
section 1.3.4.2. for installation instructions on the 508-00118-33 Detectors.
Tools Required:
v 3/8 torque wrench (small head is best) and 7/16 short socket
v 1/4 small open end or combination wrench
v screwdriver (medium flat tip for #8 screw)
v wire harness installation tool (provided along with the DFD)
v Loctite 242 or equivalent threadlocker
v Wire cutter, stripper, and crimping tools for 22AWG wire lugs
v Wire lugs (provided with the DFD)
v allen wrench to fit 1/4 x 20 socket head bolts
v nylon installation tools (provided with DFD for harness installation of 31 and 32 Detectors)
Kato Engineering part numbers: 172-60000-17
172-60000-18

GROOVE IN DIODE WHEEL RIM ID

DIODE WHEEL ASM.

DIODE WHEEL RIM

LEADS TO
AC/DC HEATSINKS

FAN

ASSURE MONITOR IS SEATED AGAINT RIM I.D.

DIODE FAULT MONITOR

MODULE

RED

OUTPUT TERMINAL ( + )

OUTPUT TERMINAL ( - )

DC AC
DC AC
A
C
DC AC
B

DIODE WHEEL ASM.

DC BUS
RING

CONNECTION
LEADS

TERM./
SCREW

DIODE FAULT
MONITOR

AC HEAT SINK
INSULATION

GREEN

LEADS FROM GROUND

DETECTOR TRANSMITTER

#1/4-20x1.5 MOUNTING SCREWS (2)

FLAT WASHER, LOCK WASHER

FACE VIEW

SIDE VIEW

AC
HEAT SINK
SLIDE HARNESS INTO GROOVE
UNDERNEATH SLOT INSULATION
MAY NEED TO LOOSEN AC CONNECTORS

SIDE VIEW OF RIM NEAR AC HEAT SINK

Figure 6: Diode Fault Detector Outline of Mounting and Connections

1.3.4.1.

508-00118-31, -32 Style Detectors

Installation of these Detectors requires: installation of the wire harness, connection of the leads from
the Ground Detection System (GDS) to the DFD output terminals, mounting of the DFD module, and
termination of the sensing leads encased in the wire harness.
** Wire Harness Installation:
Installation of the wire harness on this type of DFD requires the wire harness to be wedged into a
groove located on the ID of the diode wheel. Installation of this wire harness is facilitated through the
use of the nylon installation tools provided in the package along with the DFD. The tools and their
associated Kato part numbers are listed in the above section under the heading Tools Required.
To install the harness, first locate the DFD module on the spoke face of the diode wheel rim in which
the module will ultimately be secured. Second, using the heavier of the two installation tools, push the
wire harness into the groove between the diode wheel rim and the insulation papers found under the
series diode assembly heatsinks (figures 7 and 10 show proper installation of the wire harness). Care
should be taken when pushing the wire harness into the groove so as not to damage the sensing
wires. The portion of the harness nearest to the DFD module fits quite snugly in the groove.
Therefore, it may be necessary to loosen the AC link nearest to the module in order to get the
harness into the groove without damaging the sensing leads.

Spread the harness out around the diode wheel rim as it is being installed (the lead wires will be
terminated during a later step in this installation process). Do not trim any sensing leads at this
time. The finer of the installation tools can be used to finish off the complete installation of the wire
harness (press the harness totally within the groove). Make sure that the wire harness is total
encased by the groove in the rim the harness should not hang out beyond the edge of the rim
at any point.
** Connecting the Output Leads of the DFD to the GDS:
The next step is to connect the red and green leads which run between the GDS and the DFD. It is
easiest to connect these wires before final mounting of the DFD module is completed. To accomplish
this simply connect the ring lugged red wire to the terminal of the DFD which is closest to the diode
wheel ID (the red wire must be landed on the terminal closest to the edge of the diode wheel rim
the terminal furthest out on the radius).
Next land the lugged green wire on the other terminal of the DFD module (the terminal closest to the
shaft).
The lugs should be installed (if at all possible) with the barrels (crimped portion of the lug) pointing
out radially from the terminals (so that the centrifugal force will not turn the lug and terminal). Refer
to Figure 8 showing these terminations.
Care should be exercised when terminating or landing these leads so that they will not be
damaged or broken these wires are 24AWG stranded wire and can be fragile if mishandled.
Once these leads are terminated the terminals should be secured with a threadlocker (loctite 242 or
equivalent) and sprayed with an air dry varnish.
** Mounting the DFD Module:
At this point the DFD module can be fastened to the diode wheel. The module is secured by (2) 20 x 1 socket head cap screws with flat washers. The screw should be secured with loctite 242
threadlocker or equivalent and torqued to 50 in-lbs. While tightening make sure that the module is
seated tightly against the ID of the diode wheel (slightly pry the module up by inserting a flat tipped
screwdriver between the module and the shaft collar).
Figures 7 and 8 show the installed module as it is mounted to the diode wheel.
** Terminating the Sensing Lead Wires:
Termination of the sensing lead wires is critical. This operation should be done carefully as the
lead wires are exposed to the full electrical and mechanical stresses produced by this rotary
excitation system.
Please refer to figures 3, 4, 5, 7, 9, and 10 for assistance in determining where and how each sensing
lead should be terminated (if replacing a DFD module carefully examine and document the existing
lead termination arrangement). Termination of these lead wires requires trimming each perspective
lead to the proper length (very critical), stripping back the Teflon coated wire, lugging the lead with
the proper type lug (these lugs are shipped in the same package that contains the DFD), and finally
terminating the perspective lead to the proper termination point. Within the package that contains the
DFD module there are 3 different sizes of wire lugs. The smallest ring lugs (number 6 hole) are used
for termination of the leads which connect the DFD to the GDS (this process should already have been
done in previous steps). Also included in this package are ring lugs containing a number 8 size hole
(to be used to terminate the leads to the DC buss bar located on the outboard side of the diode wheel
see figure 5). The remaining wire lugs in this package are the lugs that will be used to terminate the
sensing leads to the AC connection links. These ring lugs contain a hole for securing the lead

directly to the bolts that fasten the AC connection links to the heat sinks of the series redundant diode
assemblies refer to figures 4, 7, and 10.
Termination of the sensing leads is best performed by starting at the DFD module (terminate the
sensing leads closest to the module first then continue around the rim until all leads have been
properly terminated).
The diode wheel rim is the securing surface for all of these sensing leads. When terminating
these leads be sure that when the lead is finally landed in the correct location there is no
possibility for the lead to creep out or extend out in any way beyond the edge of the diode
wheel rim. The diode wheel rim protects the sensing leads from the centrifugal forces
present when the exciter is rotating.
Begin by extending the green wire down below the insulating paper and over the closest AC link
mounting bolt. There is a green sensing wire that extends out from either side of the DFD
module. Refer to Figure 4 to see how these leads are to be connected (the sensing lead wire color
is shown on this figure). Figure 4 does not show the AC connection links. However, the sensing
leads are to be connected under the bolt head and on top of the connection link.
Trim the lead wire so that after the lug is applied, and fastened to the proper connection link, the
lead wire length is not so long that it may creep out from under the diode wheel rim when the unit
is running. It is absolutely necessary that the sensing lead wire does not extend, or have the
potential to extend, out beyond the edge of the diode wheel rim once it is finally terminated
on the AC link. Figure 10 is a photo showing how these wires should look once terminated (this
photo was taken without the AC link in place and was intended to show proper lead length and
how the sensing leads break out of the wire harness only).
The next step is to feed the red and black sensing leads through the diode wheel spoke openings
(windows). They should be fed through the windows in the locations shown on Figure 4. The
sensing leads are shown on this figure and are the red, black, white and yellow leads. After
feeding the leads through the windows, measure and trim the leads. Then feed them back though
the window and strip and lug the lead wire. Feed the lugged wire through the window again as
before and terminate the lead on the DC buss in the proper location (use loctite 242 or equivalent
for securing the #8 screws used to terminate the leads which connect to the DC buss bars). Figure
5 shows how they are to be terminated on the DC buss bars located on the diode wheel rim
outboard side (included in this figure is the color of the sensing lead as well as the proper location
for termination to the DC buss). As before, these leads must be terminated short enough so that
the potential for these leads to extend out beyond the edge of the diode wheel rim is non-existent.
Make sure that the barrels of the lugs lay against the diode wheel rim. This will reduce the
chance of the lug turning under normal centrifugal loads.
Figure 9 is a photo showing termination of a sensing lead to the DC buss bar. In this photo one of
the yellow leads of the DFD is shown terminated along with the black lead from the GDS
transmitter.

** Final Preparation:
Once all of the sensing leads have been properly terminated, the next step is to spray all of
the connection points with an air dry varnish.
At this point the installation of the 508-00118-31 and 508-00118-32 Diode Fault Detectors is
complete.

Figure 7: Diode Fault Detector Mounting Face View (Photo)

Figure 8: Diode Fault Detector Top View and Output Connections to Ground Detector (Photo)

Figure 9: Diode Fault Detector Connection Example to DC Buss

(Photo of 6A6 and 7A6 type exciter designs)

Figure 10: Diode Fault Detector AC Connection Example and Wire Harness Securing in Diode
Wheel Groove (Photo of 6A6 and 7A6 type exciter designs)
1.3.4.2.

508-00118-33 Style Detectors

Installation of this Detector requires: installation of the wire harness, connection of the leads from the
Ground Detection System (GDS) to the DFD output terminals, mounting of the DFD module, and
termination of the sensing leads encased in the wire harness. If this is a replacement of an existing
DFD module then carefully examine and document the installation as it exists. Also, the groove
should be cleaned out thoroughly with a solvent. Cleaning of the groove is required so that the silicon
sealant used to retain the harness will adhere properly to the coating in the groove.
** Wire Harness Installation:
Installation of the wire harness on this type of DFD requires the wire harness to be laid into a groove
located on the ID of the diode wheel. The harness must also be installed in the groove underneath the
series redundant diode assemblies (the harness must be fed between the mounting block of this
assembly and into the groove in some cases loosening of the diode assembly may facilitate
installation of the harness in this location). Centrifugal force exerted on this wire harness while the
exciter is rotating is what will keep it in place.
Spread the harness out around the diode wheel rim as it is being installed (the lead wires will be
terminated during a later step in this installation process). Do not trim any sensing leads at this
time.
Once the harness is laid into the groove, apply 100% clear silicon sealant over the harness and into the
groove, at approximately 4 inch intervals around the diode wheel rim. Apply the silicon sealant so
that there is a bead of sealant approximately in length which fully fills the groove and encases the
harness in that location. Make sure that the wire harness is total encased by the groove in the rim
the harness should not hang out beyond the edge of the rim at any point.

Allow the silicon sealant to skin and dry for about at least an hour before proceeding on with the
installation process.
** Connecting the Output Leads of the DFD to the GDS:
Once the silicon sealant has dried sufficiently to hold the harness in place, the next step is to connect
the red and green leads which run between the GDS and the DFD. It is easiest to connect these wires
before final mounting of the DFD module is completed. To accomplish this simply connect the ring
lugged red wire to the terminal of the DFD which is closest to the diode wheel ID (the red wire must
be landed on the terminal closest to the edge of the diode wheel rim the terminal furthest out
on the radius).
Next land the lugged green wire on the other terminal of the DFD module (the terminal closest to the
shaft).
The lugs should be installed (if at all possible) with the barrels (crimped portion of the lug) pointing
out radially from the terminals (so that the centrifugal force will not turn the lug and terminal). Refer
to Figure 8 showing these terminations.
Care should be exercised when terminating or landing these leads so that they are not damaged
or broken these wires are 24AWG stranded wire and can be fragile if mishandled.
Once these leads are terminated the terminals should be secured with a threadlocker (loctite 242 or
equivalent) and the terminals sprayed with an air dry varnish.
** Mounting the DFD Module:
At this point the DFD module can be fastened to the diode wheel. The module is secured by (2) x
20 x 1 socket head cap screws with flat washers. The screw should be secured with loctite 242
threadlocker or equivalent and torqued to 50 in-lbs. While tightening make sure that the module is
seated tightly against the ID of the diode wheel (slightly pry the module up by inserting a flat tipped
screwdriver between the module and the shaft collar).
Figures 7 and 8 show an installed module as it is mounted to the 6A6 and 7A6 style diode
wheels. The mounting on this larger style diode wheel looks the same except that the rim is
deeper and the module nestles deeper into the rim (the entire DFD back radius fits under the
rim Figure 1 shows this).
** Terminating the Sensing Lead Wires:
Termination of the sensing lead wires is critical. This operation should be done carefully as the
lead wires are exposed to the full electrical and mechanical stresses produced by this rotary excitation
system.
Please refer to figures 12 and 13 for assistance in determining where and how each sensing lead
should be terminated (if replacing a DFD module carefully examine and document the existing lead
termination arrangement). Termination of these lead wires requires trimming each perspective lead to
the proper length (very critical), stripping back the Teflon coated wire, lugging the lead with the
proper type lug (these lugs are shipped in the same package that contains the DFD), and finally
terminating the perspective lead to the proper termination point. Within the package that contains the
DFD module there are 2 different sizes of wire lugs. The smallest ring lugs (number 6 hole) are used
for termination of the leads which connect the DFD to the GDS (this process should already have been
done in previous steps). Also included in this package are ring lugs containing a number 8 size hole
which will be used to terminate the sensing leads contained within the wire harness to the AC and DC
sides of the series redundant diode heatsinks.

The AC sensing leads will all connect on the inboard side of the diode wheel assembly. Figure 11
displays the complete diode wheel assembly and Figure 12 shows, in greater detail, the inboard side of
the diode wheel assembly.
Termination of the sensing leads is best performed by starting at the DFD module (terminate the
sensing leads closest to the module first then continue around the rim until all leads have been
properly terminated).
The diode wheel rim is the securing surface for all of these sensing leads. When terminating
these leads be sure that when the lead is finally landed in the correct location there is no
possibility for the lead to creep out or extend out in any way beyond the edge of the diode
wheel rim. The diode wheel rim protects the sensing leads from the centrifugal forces
present when the exciter is rotating.
Begin by extending the green wire from the wire harness and out to the first heatsink. There is a
green sensing wire that extends out from either side of the DFD module. Refer to Figure 12 to see
how these leads are to be connected (the sensing lead wire color is shown on this figure). Trim
and lug the wire such that when landed the wire will lay on the rim of the diode wheel and not be
too loose to hang out beyond the edge of the diode wheel rim.
It is absolutely necessary that the sensing lead wire does not extend, or have the potential to
extend, out beyond the edge of the diode wheel rim once it is finally terminated on the AC
link.
Next apply loctite 242 or equivalent threadlocker to the #8 screw which will be used to secure the
sensing lead to the heatsink and terminate the lead to the heatsink.
The next step is to feed the red and black sensing leads through the diode wheel spoke openings
(windows). They should be fed through the windows in the locations shown on Figure 12 (these
are the red, black, yellow and white wires). After feeding the leads through the windows, measure
and trim the leads. Then feed them back though the window and strip and lug the lead wire. Feed
the lugged wire through the window again as before and terminate the lead on the DC buss spiders
in the proper location as shown on Figure 13 (again use the loctite 242 or equivalent). As before,
these leads must be terminated short enough so that the potential for these leads to extend out
beyond the edge of the diode wheel rim is non-existent. Make sure that the barrels of the lugs
hang radially outward from the heatsinks. This will reduce the chance of the lug turning
under normal centrifugal loads.
Continue around the rim terminating each sensing wire as shown on figures 12 and 13 using the
same procedure as outlined above.
** Final Preparation:
Once all of the sensing leads have been properly terminated, the next step is to spray all of
the connection points with an air dry varnish.
At this point the installation of the 508-00118-33 Diode Fault Detector is complete.

F
(

1.4 Description of Operation

1.4.1.

Diode Fault Detector Circuit Overview

The Diode Fault Detector senses the forward voltage drop of the series redundant diodes within the rectifier
bridge. Normally the forward voltage drop of each diode is about .7 and 1.2 volts DC or 1.4 to 2.4 volts for both
diodes. When one of the diodes fail either shorted (predominant mode) or open, the forward drop changes
significantly with respect to the other legs. The Detector senses this change by monitoring the filtered AC
component of the composite forward voltage drop signal of all the legs of a given polarity. Referring to block
diagram of the Detector (Figure 14), the following describes the basic circuit elements of the Diode Fault
Detector:
1.

2.
3.
4.

5.
6.

7.

The Detector senses the forward voltage drop of the diodes in positive and negative buss separately. For
each polarity, the Detector receives the signals from the 3 AC phase connections and the DC output buss
(positive or negative). These signals are fed into a high or low value gate (A0) to detect the largest absolute
value of the potential difference as referenced to the DC buss. This is the unfiltered composite forward
voltage drop.
The output of A0 is then limited by the clamping circuit A1, filtered by circuit A2 (band limiting ) , and low
pass filtered by A3 to attenuate high frequency noise and bridge harmonics.
The filtered signal is fed into a high pass filter A4 to obtain the AC coupled ripple voltage or AC component
of the filtered forward voltage drop signal produced by the bridge.
The AC component of the filtered forward voltage drop signal from item 3 is converted to a DC signal by
precision rectifier A5. Circuit A6 is a pure integrating amplifier which provides added noise immunity and
fault detection delay timing to the AC ripple signal.
The resulting AC ripple signal is compared to a preset thresh-hold voltage for alarm, Vref1 or Vref2. When
signal exceeds the thresh-hold, output of the comparator A7 goes low signaling a diode fault condition.
The diode fault signals from the high and low side Detector circuits are passed to a low value gate (LVG), A9
along with a square wave pulse of about 1 to 2 Hz. With a normal condition, the diode fault signals are high
and the LVG , A9 provides a square wave output signaling a normal condition. If either of the diode fault
signals go low, the square wave signal is inhibited and the LVG output stays low indicating a diode fault has
occurred.
Circuit A10 monitors the input DC voltage and provides an inhibit signal when the input voltage is below the
preset threshold (about 32 Vdc for a 31 Detector). When the input DC voltage rises above the threshold ,
A10 goes from high to low (no inhibit). This signal is fed into the high value gate (HVG) A11 along with the
diode fault signal from A9 and it serves as to inhibit the diode fault signal from A9 when high. This prevents
spurious or unpredictable Detector operation when the exciter is operating at low voltage.
The preset threshold for:

508-00118-32, 34 is approx. 20VDC

508-00118-31 is approx. 32VDC
508-00118-33 is approx. 60VDC

This is the level of main field excitation at which the Diode Fault Detector will begin to monitor the status of
the diode wheel and series redundant diodes. It is at this point that the Detector will begin to output a signal
(pulse or continuous output).
8.

HVG, A11 provides the diode fault alarm signal to an external device such is the optical isolator of the
ground detector transmitter. The opto-isolator is connected between Detector DC+ and the output of A11,
thus when A11 is low, the current flows (1 to 2 ma) through the isolator driving it to a high state (diode
fault). The transmitter sends this signal to the receiver which causes the diode fault alarm to go high, 24 Vdc.
When the output current of A11 is 1 to 2 Hz square wave, this indicates a normal condition. The resulting
signal out of the ground detector receiver is a 1 to 2 Hz square wave , 0 to 24 Vdc.
When the diode fault signal at A11 is high, current output to the transmitter is zero. This indicates an
undervoltage condition (from A10) or malfunction condition (under most conditions the current output will

go to zero when a malfunction has occurred). The diode fault signal output from the receiver will be
constant at about 0 Vdc.
9.

Thus, the Diode Fault Detector alarm signal has three states which allows the indication of normal, alarm, or
malfunction / undervoltage condition. These states are summarized in Figure 15. The receiver sends the
diode fault alarm signal along with the generator ground fault alarm signals (see separate instruction book) to
a remote device for indication to user.

DIODE FAULT MONITOR

High Side Monitoring Circuit

ROTATING COMPONENTS

A0

DIODE BRIDGE ASM.

A1

ISO. AMP/
HVG

A5

LIMITER/
FILTERS

A6

AC TO
DC CNV.

A2-A4

A7

K
s+m
VREF1

A9

A8

GEN.
FIELD

LVG

DIODE

LOW SIDE
POWER SUPPLY

VREF2

LIMITER/
FILTERS

A0

A2-A4

AC TO
DC CNV.

K
s+m

A5

A6

Low Side Monitoring Circuit

OPT. ISO.

DIODE
FAULT
SIGNAL
OUTPUT

HVG
DC +

A1
ISO. AMP/
LVG

A11

1 - 2 HZ SQUARE WAVE
NORMAL SIGNAL

DC -

GROUND FAULT DET.

CIRCUIT

COMPARE

DC +
HIGH SIDE
POWER SUPPLY

EXCITER
ARMATURE
AC VOLTS

A7

+
COMPARE

A10 UNDER VOLTAGE

LOCKOUT

RED
DIODE FAULT SIG.

TELEMETRY CIR.

GREEN
FIELD GROUND DETECTOR TRANSMITTER

TELEMETRY CIR.

FIELD GROUND DETECTOR RECEIVER (STATIONARY)

INPUT POWER (24 VDC)

PICK-UP COILS

FIGURE 14: BLOCK DIAGRAM OF DIODE FAULT DETECTOR

/FIELD GROUND DETECTOR

0 TO 24 VDC OUTPUT SIGNALS

FIELD GROUND ALARM
FIELD GROUND DETECTOR MALFUNCTION
DIODE FAULT ALARM.

1.4.2

Diode Fault Detector Output Signals

The Diode Fault Detector is used in conjunction with brushless exciters with series redundant diode bridge
arrangement and the field ground detector (see separate instruction books). The Diode Fault Detector output
signals as transmitted via the Ground Detector System are shown below.
Normal Signal
No Alarm

24 V
0V

1 to 2 Hz Frequency
Diode Fault
Alarm Signal

24 V
0V

Recommended Time Delay to Alarm - 20 Sec to Alarm.

Set to Alarm on less than 4 pulses (.15 sec Min.
Pulse width) in Rolling 20 second Period

Diode Detector
Undervoltage/
Malfunction
Alarm

24 V
0V

Figure 15: Diode Fault Detector Alarm Logic

2. INITIAL INSPECTION, STORAGE AND ALIGNMENT

2.1. RECEIVING INSPECTION
The Diode Fault Detector comes mounted and pre-wired to the diode wheel of the brushless exciter which is
carefully crated for shipment and can withstand most shocks incurred during transit. Before accepting shipment
from the transportation company, examine the crating carefully per exciter instruction book. If the Diode Fault
Detector is shipped as a separate or replacement part unpack and check for damage to the module or wires.
Notify the transportation company claims office and Kato Engineering if damage is found. Be sure to give
complete and accurate details when reporting damage.

2.2. ALIGNMENT AND ADJUSTMENTS

The Diode Fault Detector does not require adjustment or alignment. Some brushless exciter disassembly is
required to access the Diode Fault Detector and ground detector. Remove the exciter end cover, ground
detector mounting cover , exciter fan, and fan baffle per the exciter instruction book. The Diode Fault Detector
will be accessible through the ground detector cover opening and from the back of the exciter (monitor leads).
Mount the Diode Fault Detector to diode wheel per paragraph 1.3. Be sure to use a thread lock adhesive on all
the threaded fasteners of the Detector. Lock exciter fasteners per the exciter instruction book.

3. MAINTENANCE
3.1. PERIODIC MAINTENANCE
The Diode Fault Detector requires no maintenance beyond that required for the exciter to which it is mounted.
Check connections for damage or upset during exciter maintenance. Any connections removed and replaced
should be sprayed with a good quality, air drying insulating varnish.

3.2. REPLACEMENT
If replacement Diode Fault Detector is required refer to section 1.3 for assembly/disassembly.

3.3. INSULATION RESISTANCE

Periodic measurement of the insulation resistance may prevent a serious problem caused by a double ground.
Readings with a 500 volt megger of the combined exciter rotor, diode wheel, Diode Fault Detector, and generator
field may be made. Refer to the exciter instruction book for further information.

3. TROUBLESHOOTING
4.1. Diode Fault Alarm
If a diode fault alarm occurs, the redundant diode will, under normal circumstances, continue to provide
rectification for the leg. The diode may be visually inspected during operation using a strobe light through an
access plate on the end of the exciter to see if there is mechanical damage.
If the exciter continues to function normally, the rectifier assembly may be checked at the next planned outage.
The diodes can then be checked per the exciter instruction book.
If no diodes are found to be faulty. Disconnect the Diode Fault Detector wires and check per paragraph the
following few paragraphs (sections 4.2., 4.3., 4.4., and 4.5.).
Note: If both diodes fail in the same leg then excitation will be lost.

4.2. Troubleshooting General Method

A digital voltmeter with diode check scale, 0 to 50 VDC power supply, and a function generator are useful in
locating problems with the Diode Fault Detector.

4.3. Wire Continuity Test

Disconnect the AC and DC input leads of the Detector and the ground detector output leads. With a digital
multimeter (similar to an 8060 Fluke digital meter) with diode check feature, check the continuity between the AC
and DC leads to determine if there are any wire breaks. The readings will range from 10K ohms to 5 Megohm
and some leads will be polarity sensitive. The magnitude of the reading not important, just determine if any wire
has broken. Check the continuity of the red and green diode wires from the ground detector.

4.4. Checkout of Signal Wires to Ground Detector

Align the ground detector pickup coils. Then apply about 2 mA across the red (plus) and green (minus) lead. It is
recommended that a limiting resister be placed in the circuit to protect from over current. The current must not
exceed 25 mA. With 1 to 2 mA current, the diode fault signal out of the receiver assembly should go high (about
24 VDC). The output signal should go to zero with no current. If it does not respond as described, the ground
detector transmitter circuit is faulty and the transmitter should be replaced.

4.5. Functional Check of Diode Fault Detector

Reconnect the ground detector red and green wires to the Detector. Alternately, the Diode Fault Detector output
terminals may be connected to an ammeter (0 to 10 mA scale). The Diode Fault Detector can be functionally
checked using a variable power supply 0 to 50 VDC (floating / ungrounded). Connect power supply to the DC
buss leads, leave the AC leads connected. A 1 to 2 Hz square wave output current should appear at DFD output
terminals at about 32 VDC on 31 DFDs (20VDC on 32 and 34 DFDs, and approx. 65VDC on 33 DFDs).
Then connect a function generator set for 250 to 400 Hz square or sine wave, 0 to 5V to between one of the AC
leads and the corresponding DC signal lead (this AC lead will have to be disconnected from the exciter AC links
and heatsinks). The function generator is being used here to simulate an AC ripple on the forward voltage drop
thus simulating a failed diode. Measure the function generator output with a digital voltmeter on RMS scale.
Gradually increase the function generator voltage. At about .5 to 1 Vrms, the Diode Fault Detector output or
alarm signal current should change from a square wave signal to a steady 1 to 2 ma signal. Check the other AC

leads in the same manner. If the Detector checks good , contact GE representative for assistance. If the Detector
checks bad, replace with a new one. There are no serviceable parts.

4.6. Replacement Part Numbers

GE Part Number
351A6424P0001
351A6424P0002
351A6424P0003
351A6424P0004

Kato Engineering Part Number

508-00118-31
508-00118-34
508-00118-32
508-00118-33

Operating Range
32 to 390 VDC
20 to 278 VDC
20 to 278 VDC
60 to 525 VDC