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Author Topic: Orcon CV 1600 rectifier burning wires to the diode block Brant Veilleux Film Handler Posts: 23 From: Chicago, IL, USA Registered: Dec 2004 posted 07-03-2007 11:18 AM                        I am trying to troubleshoot a screen 800 miles away and am getting limited information. Wondering if anyone has run across something similar or may have a part #. This is an Orcon II console. Like the subject line states the rectifier is an Orcon CV 1600 The symptoms are: 1) The leads to the Diode block are burning and are being replaced every 4 - 6 days. The diodes have been checked and are good. Voltage and amperage output is within operating limits. 2) The large capacitor on the rectifier is split. I figure replacing this would be an obvious start. Though, I can not make out a replacement part # or specs in any of the 1600 Orcon / ORC manuals I have found online. I am also wondering if there may be underlying cause beside the fact that the machine is almost as old as I am. Any ideas or information would be appreciated.  |  IP: Logged Jack Ondracek Film God Posts: 2348 From: Port Orchard, WA, USA Registered: Oct 2002 posted 07-03-2007 01:58 PM                        Which leads are you talking about... coming from the transformer or the bulb? If you've been replacing the wires for awhile, somebody might have used something too small and you're now copying from a past mistake. That lamphouse is rated up to 80 amps. What are you running? This might be the book for your console. It's in the manuals section. http://www.film-tech.com/warehouse/wareview.php?id=378&category=2 According to that, your caps are 4500mFd at 150Vdc. If they're as old as you say, they probably needed replacing years ago. You can get caps like that from places like Mouser and Newark Electronics. Both companies have online catalogs.  |  IP: Logged Mark Gulbrandsen Resident Trollmaster Posts: 16657 From: Music City Registered: Jun 99 posted 07-03-2007 02:26 PM                     Oh come on 800 miles is nothing! Get yer ass in the car and get over there! I know techs that have droven further just to re-set a circuit breaker. Is the replacement wire large enough for the current level? What type of crimps or lugs are U using? This rectifier was I believe built by LP associates and they are still making them for Strong or did until recently but they are still making them under the LP name. They were always pretty good rectifiers, age doesn't matter with this stuff. In fact the rectifier is the best part in that console . Mark  |  IP: Logged Gordon McLeod Film God Posts: 9532 From: Toronto Ontario Canada Registered: Jun 99 posted 07-03-2007 03:03 PM                     Is this the leads from the heatsinks to the caps or the leads on the diodes If it is the leads on the caps I suspect they put wire there rather than the piece of nichrome that was used to limit the inrush current  |  IP: Logged Brant Veilleux Film Handler Posts: 23 From: Chicago, IL, USA Registered: Dec 2004 posted 07-03-2007 08:14 PM                        The leads to the diodes coming from the transformer are what are being replaced. Apparently, the diode block is getting abnormally hot. From what I have been told they are being replaced with the same AWG as used in the other identical rectifiers at the site that do not exhibit the problem. I am fairly confident that it isn’t as simple as that. The Lamphouse is pulling ~65 amps with a 1600 watt bulb. I am wondering if a bad capacitor might be the cause of this. quote: Mark Gulbrandsen ... age doesn't matter with this stuff. I agree. Providing it was taken care of during it's lifetime. quote: Gordon McLeod If it is the leads on the caps I suspect they put wire there rather than the piece of nichrome that was used to limit the inrush current This is interesting. I wasn't aware that copper wire wasn't used for the leads on the caps. Good to know but the leads to the caps haven't been replaced in this situation. Thanks for all the help!  |  IP: Logged Mark Gulbrandsen Resident Trollmaster Posts: 16657 From: Music City Registered: Jun 99 posted 07-03-2007 09:49 PM                     Check the current draw on each side of the brige. It should be pretty well balanced. If not then at least knowning which side the heavier draw is on might isolate or lead you to the problem. Mark  |  IP: Logged Gordon McLeod Film God Posts: 9532 From: Toronto Ontario Canada Registered: Jun 99 posted 07-03-2007 10:22 PM                     Is this a 3 phase or a single phase rectifier I have on the single phase ones had issues where the blocking diode has failed and a failed boost circuit caused main diode failures On the 3 phase disconnect the diodes and measure that one has the same output voltage on each tap Also put a current clamp on meter on the diode leeds and measure the current that they are conducting Also check the blowers that they are cooling the stack well enough  |  IP: Logged Brant Veilleux Film Handler Posts: 23 From: Chicago, IL, USA Registered: Dec 2004 posted 07-07-2007 10:12 AM                        So I spoke with a tech from the area that made a service call and got some more information. The issue is the leads to caps. They have been replaced with copper. Anyone have a place to get nichrome? I have a feeling the issue is more than that but it would be a good place to start. Thanks.  |  IP: Logged Gordon McLeod Film God Posts: 9532 From: Toronto Ontario Canada Registered: Jun 99 posted 07-07-2007 04:08 PM                     If a tech visited the theatre did they measure the current being conducted on each lead?  |  IP: Logged Scott Christopher Film Handler Posts: 69 From: Adelaide, South Australia Registered: Apr 2001 posted 07-08-2007 04:14 AM                     "2) The large capacitor on the rectifier is split. I figure replacing this would be an obvious start" Yep, change the capacitor.  |  IP: Logged

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