Technical Document CS-0508A Produced by the Electrical Rebuilder’s Association www.electricalrebuilders.org Soci” 6G Rectifiers Simplified Choosing the correct rectifier has never been as important as it is with the Ford 6G series alternators. This guide will attempt to explain the characteristics that separate the different part numbers. Ford has used no less than 12 different rectifiers on 6G’s through 2006. Four of them fit large frame, 135 amp units, and eight of them fit small frame 105/110 amp units. Differences include stator configuration (delta or wye), clock-position of the thru-bolts in relation to the B+ post, diode rating and diode type. By consolidating some numbers, the aftermarket has narrowed the choices to three for the large-frame and six for the small-frame. Large-Frame Rectifiers – 149mm diameter body Clock | Diodes | Config Notes Ref # Used in Transpo | Regitar | Rand R 8 Wye FR602 | RF12 | 32.602 7795, 8253, 8315 R 8 Wye 2mm lower profile | FR604 8478 2mm lower profile i 8 Wye Avalanche Diodes FR60S 8408 Table 1 — Large-Frame Rectifiers as of 04/2008 Small-Frame Rectifiers – 136mm diameter body Clock | Diodes | Config Notes Ref # Used in Transpo | Regitar | Rand R 8 Wye FR600 |RF10 | 32.600 | 7788,7796,7797,7798,7799,8252 8261, 8262 R 8 Wye | Avalanche Diodes | FR603 | RF10A | 32.602 | 8316, 8317 L 8 Wye FR601 |RF11 = | 32.601 | 8250, 8260 R 6 Delta FR606 | RF13 | 32.606 R 6 Delta | 3.3mf HD Capacitor | FR607 | RF13 | 32.607 | 8254, 8256, 8259, 8263, 8266, 8268 L 6 Delta FR608 |RF15 | 32.608 | 8260, 8264 Table 2 — Small-Frame Rectifiers as of 04/2008 Up through the early 1990’s, almost every stator was wound with three phases in either a delta or wye configuration, all visually identifiable. Then Ford brought out the 3G series in 1991, with stators which were wound with open phases. The connections that make them wye-configuration were inside the lead frame of the rectifier and were not visible. All 3G and 4G rectifiers are wye-configured, at least through 2006. All large-frame 6G rectifiers are wye-configured. However, Ford used both wye- and delta-configured rectifiers on the small-frame. All delta-configured rectifiers have six diodes. Most wye-configured rectifiers have eight diodes, but be aware that Ford used a wye-configured rectifier with only six diodes on a few applications. If you replace this rectifier, be sure to replace it with a wye-configured rectifier. Created by Wes Grueninger and Bob Thomas for the Electrical Rebuilder’s Association – © 2008, Electrical Rebuilder’s Association — All rights 1 reserved. No portion of this guide may be reproduced in any way, or stored in any electronic retrieval system without the prior written consent of the Electrical Rebuilder’s Association. Technical Document CS-0508A Produced by the Electrical Rebuilder’s Association www.electricalrebuilders.org DELTA-Configured 6-Diodes Up through the 2006 model year, XR8U-10300-CE is a 6G small- Up through the 2006 model year, most all 6-diode rectifiers are frame alternator and the rectifier all 8-diode rectifiers are used with used with 6-lead, single-wound is wye, but it has only 6 diodes 12-lead double-wound stators stators and are Delta configured. and a 12-lead tan stator. There and are Wye configured. There are a few exceptions – are a few other units where Ford (see panel to immediate right) early on used this rectifier, but the alternator was superseded to a Delta 6-diode rectifier type with a 6-lead tan stator. 6-diode rectifier 6-diode rectifier 8-diode rectifier One lead per phase Two leads per phase Two leads per phase Diodes Diodes Diodes Neg Pos Neg Pos Neg Pos Wye ey Wye Connector Connector Delta-Connected Stator and Diodes Wye-Connected Stator and Diodes Wye-Connected Stator and Diodes Figure 1 — Rectifier and Stator Configurations Created by Wes Grueninger and Bob Thomas for the Electrical Rebuilder’s Association – © 2008, Electrical Rebuilder’s Association — All rights y) reserved. No portion of this guide may be reproduced in any way, or stored in any electronic retrieval system without the prior written consent of the Electrical Rebuilder’s Association. Technical Document CS-0508A Produced by the Electrical Rebuilder’s Association www.electricalrebuilders.org It should also be noted that, up through the Delta Lead Wye Lead 2006 model year, all stators used with wye- Configuration Configuration configured rectifiers are double-wound and have six double-wire leads. All stators used with delta-configured rectifiers are single- wound and have six single-wire leads. (see Figure 1) Swapping stators will cause problems in the output curve and may result in serious performance problems on the vehicle, even though they may seem to work OK on a test bench. Always be sure to match the correct stator with the correct rectifier. See Figure 2 for rectifier testing points that will allow you to determine Figure 2 — Rectifier Test Points which configuration rectifier you are working on. Two different battery-post positions have been used. To simplify this, we’ll call them left and right. With the battery post straight up at 12:00, there will be a thru-bolt position either to the right side at 1:00 or to left side at 11:00 (see Figure 3). , Some 6G rectifiers utilized standard diodes Clocked Left Clocked Right in various ratings from 50 to 70 amps. ersue ere Thrucbot However, others were manufactured with Position’ *esnon avalanche diodes. In applications utilizing avalanche diodes, Ford removed voltage- spike protection devices from some electronic modules. If the application calls for a rectifier with avalanche diodes, it is imperative that they be used. The use of a standard-diode rectifier in those applications could cause damage to electronic modules. On OE rectifiers, avalanche diodes can be identified by their color, either green or blue. Notice that standard diodes are used to Figure 3 — Rectifier Clocking Positions rectify the wye-connection on these OE rectifiers, but be aware that some aftermarket manufacturers have used avalanche diodes on the wye-connection. One small-frame 6G rectifier utilizes a 3.3mf capacitor, a higher rating than other rectifiers. This is for enhanced voltage- spike suppression. If the application calls for this rectifier, it is important to use it. Ford did not use avalanche diodes in this rectifier. Created by Wes Grueninger and Bob Thomas for the Electrical Rebuilder’s Association – © 2008, Electrical Rebuilder’s Association — All rights 3 reserved. No portion of this guide may be reproduced in any way, or stored in any electronic retrieval system without the prior written consent of the Electrical Rebuilder’s Association.