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Basler Electric’s
Convection -Cooled Bridge Replacement
for Aging Alterrex™ Water-Cooled Rectifiers

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Basler Offers New High Power Convection-Cooled Bridges for GE Alterrex Systems

Water-cooled excitation systems were developed in the early 1970s to provide DC to the generator field for the large GE Alterrex generator systems. The system consisted of an AC rotating exciter providing a three phase output connected to multiple remote stationary diode rectifier bridges.

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Larger generators requiring higher field amperages often had three or more water-cooled bridges connected in parallel with N+ 1 redundancy in the event of bridge failure. To isolate a defective bridge and allow maintenance, each bridge included a five-pole manual disconnect switch to isolate the AC input and DC output.

Today, 30-40 years later, the water-cooled mechanism to cool the power semiconductors have deteriorated to the point where water leaks are prevalent in the Alterrex system. Elbow and tube leaks are typical issues, along with Teflon carbonizing that leads to eventual isolation of the rectifier bridge, requiring repair. For some plants, two or more leaks may be common in a year’s time.

Existing technology leaves you:

  • Tired of water leaks and plumbing repairs
  • Coping with nuisance field grounds due to water leaks
  • Dealing with obsolete parts
  • Fearing long lead times/ down times
Aging Water-Cooled Rectifier
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Alterrex™ - 1960's Technology
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Drop in Replacement Solution Offering Convenience and Reliability
 

The solution is new technology. High-performance heat sink extrusions for maximum heat efficiency are combined with high ampere semiconductors that are arranged in a three phase full wave configuration utilizing convection-cooled semiconductors in lieu of the water-cooled semiconductors of the past. Convection-cooled bridges eliminate the maintenance and headaches associated with deionizing water, corroded plumbing and even fans.

The new Basler convection-cooled bridge is specifically designed to be located in the same mounting location as the existing water-cooled rectifier bridges. Basler Electric offers several combinations for consideration. In each case, it is intended that the original water cooled rectifier bridge would be replaced with Basler Electric's convection cooled rectifier bridge.

The options consist of:

Basler’s Convection-Cooled Technology Solution -
move your mouse over to see a side view of the bridge
  1. Continue to utilize the original 5 pole disconnect switch. This would require flex bus to connect the new rectifier bridge to the existing 5 pole disconnect switch. - Click here for a summary of the “switch utilized” features
  2. Replace the original 5 pole disconnect switch with a new 2000A 5 pole disconnect switch that already is designed to interconnect via bus bar connections to the new convection cooled rectifier bridge. -
    Click here for a summary of the “switch replacement” features
  3. For those applications that do not intend to isolate the rectifier bridge via the 5 pole switch but want to eliminate potential issues in the future, a solid link bus bar panel can be provided in lieu of the switch. This solid link panel will mount in the same location as the switch and will connect to the bridge via bus bar.
     
Thermal data on convection cooled rectifier
Actual thermal data on the convection cooled rectifier system
 

Save Money and Time

The Basler “Drop-in Replacement” solution eliminates the need to make a prohibitive expenditure for a complete static exciter changeout and offers a fast 8 week product delivery to meet emergency needs.

Other options include a replacement door mounted interface panel housing DC meters, temperature indicators, and pilot light, if required.

For more information, see Application Note EX-ALT_BRDG - Convection-cooled DECS-400 retrofit solutions for the water-cooled Alterrex main field stationary bridges and

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Special Features as Standard

  • 6 RTDS per bridge for monitoring
  • 3 in line power interrupt fuses
  • Shunt for each bridge for monitoring bridge current
  • 1600 dc amp bridge, with 1800 amp maximum continuous capability
  • No Fans- convection cooled, designed 50° C ambient (See thermal data at left)
  • Qty (6) 5700 amp capacity diodes
  • 3500 V snubbers for the power semiconductors
     
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Three phase diode bridge rectifier and five pole switch drawing

Three phase diode bridge rectifier and five pole switch in the Basler convection-cooled solution
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Application Note EX-ALT2 -Dual DECS-400 system and “drop-in” convection-cooled rectifier bridges for existing Alterrex water-cooled bridges

Summary flyers detailing the major features of the:

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Return to Power Plant Operators page or view more solutions for - Excitation Systems - Synchronous Motor Control and Protection - Rotating Exciter Diode Replacement - Power System Stabilizers - Protective Relays - Automatic Synchronizers - Energy Storage Devices for Shunt Breaker Trip - Motor Operated Potentiometer Replacements

For more information, contact Technical Support or your local sales representative
 


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