Basler AVC63-12 User manual

Publication: Rev First Printing 06/2001 Copyright
9 3372 00 991 A Revised 08/2001 2001
Basler Electric
Phone [phone]
Route 143 Box 269
Highland IL 62249 USA
Power Systems Group
Fax [phone]
http://www.basler.com
[email protected]
INSTRUCTIONS
FOR
AUTOMATIC VOLTAGE REGULATOR
AVC63-12 AND AVC125-10
INTRODUCTION
The AVC63-12 and AVC125-10 Voltage
Regulators are contained in encapsulated plastic
cases. The regulators control the amount of dc
excitation to the exciter field of conventional
brushless synchronous generators.
Regulation is provided by sensing the generator
output voltage, converting it to a dc signal and
comparing thesignaltoareference voltage signal.
An error signal is developed and used to control
the dc field power in order to maintain a constant
generator output.
The regulator includes frequency compensation
with selectable slope, inverse-time overexcitation
shutdown, solid-state build-up circuitry, single-
phase or three-phase voltage sensing, single-
phaseorthree-phaseshunt, orpermanent magnet
generator power input, parallel droop compen-
sation, and an accessory input. The accessory in-
putprovidescompatibilitywithaccessoriessuchas
a var/powerfactor controllers or excitation limiters.
ELECTRICAL SPECIFICATIONS
Power Output
AVC63-12: 12 Adc @ 63 Vdc maximum con-
tinuous. 24 Adc @ 125 Vdc forcing for 10
seconds. Minimum field resistance: 5.25
$
.
AVC125-10: 10 Adc @ 125 Vdc maximum
continuous. 20 Adc @ 250 Vdc forcing for 10
seconds. Minimum field resistance, 12.5
$
.
Input Power Requirements
Single- or three-phase, 50 to 400 Hz
AVC63-12: 90 to 153 Vac, 1092 VA
maximum continuous burden.
AVC125-10: 180 to 264 Vac, 1750 VA maxi-
mum continuous burden.
Sensing Input Voltage and Frequency
Single- or three-phase. Sensing voltage option
A: 90 to 139 Vac, sensing voltage option B:
180 to 264 Vac. Sensing frequency option 1:
50 or 60 Hz nominal, sensing frequency option
2: 400 Hz nominal. (For more style/option
information see Table 4.)
Input Sensing Burden
Less than 1 VA.
Auxiliary Input
± 3Vdc for usewith SCP250 VAR/PF Controller
or EL200 Min/Max Excitation Limiter.
External Voltage Adjust Rheostat
10k ohm, 2 W potentiometer.
Regulation Accuracy
±0.5%ofvoltagesetpoint,averageresponding.
Voltage Drift
±0.5% voltage variation for a 40°C (104°F)
change.
Response Time
< 4 milliseconds.
Frequency Compensation
One or two V/Hz jumper selectable with knee
adjustable from 45 to 65 Hz for 50/60 Hz units
and 300 to 430 Hz for 400 Hz units. Reference
Figure 1 for 60 Hz and Figure 2 for 400Hz
sensing models. (Figures are not in numerical
order to conserve space in this document.)
EMI Suppression
Internal filter. (See CE Conformity below.)
Voltage Build-Up
Provisions for automatic voltage build-up from
generator residual voltages as low as: 6Vac for
AVC63-12 and 12 Vac for AVC125-10 units.
Overexcitation Shutdown
Overexcitationshutdownprotectionreducesthe
output voltage to zero for the following voltages
in the times shown. Other voltages and times
arebased on inverse time characteristic curves
as shown in Figures 3 and 4.
AVC63-12:
125 Vdc ±10% in approximately 10 seconds.
210 Vdc ±10% in approximately 1 second or
less.
AVC125-10:
250 Vdc ±10% in approximately 10 seconds.
370 Vdc ±10% in approximately 1 second or
less.
Droop/Line Drop Compensation
<10 VA adjustable from 0 - 10% of rated input
current, 0.8 power factor. (LDC compensates
for voltage drop due to line reactance and
reactive components of the load current only.)
Agency Approvals
UL Recognized per Standard 508, UL File No.
E97035.
CSA Certified per Standard CAN/CSA-C22.2
No. 14-95, CSA File No. LR 23131
CE Conformity. Conforms to:
Radiated Emissions ........EN50081-2.
Radiated Immunity:
Electric field ..... EN61000-4-3 (10 V/m).
Conducted .... EN61000-4-6 (10 VRMS).
Conducted Emissions ......EN50081-2.
(EN55011, Class A).
ESD Immunity ............. EN50082-2
(4 KV contact, 8 KV air).
EFT Immunity ............. EN50082-2
(2 KV coupling clamp).
Magnetic Immunity ......... EN50082-2
(30ARMS, 50 Hz).
Safety: ..................EN61010-1.
Operating and Storage Temperature
-40°C to +70°C (-40°F to +158°F).
Relative Humidity
95% non-condensing
Shock
Withstands 20 g in each of three mutually
perpendicular planes.
Vibration
Withstands the following accelerations at the
stated frequency: 4.5 g; 18 to 2000 Hz.
Weight
Approximately 1.1 kg (2.5 lbs.)
INSTALLATION
The regulator may be mounted in any position.
Refer to the outline drawing (Figure 5). The
regulator may be mounted directly on the
generator set using UNF 1/4-20 or equivalent
hardware. Select the proper hardware to
withstandanyexpectedshipping/transportation
and operating conditions.
CONNECTIONS
Before connecting the AVC63-12 or the
AVC125-10 into your system, review the
terminal descriptions provided in Table 1, the
internal adjustments provided in Table 2, and
the diagrams shown in Figures 6 through 8.
Table 1. Terminal Descriptions
Term.
Number Term. Description
Upper Term. Strip
CH GND Chassis ground connection
2Auxiliary Input from var
Power Factor Controller
3Auxiliary Input from var
Power Factor Controller
4Connect to 7 to use internal
voltage adjust, no
connection for external
voltage adjust
5 1 Amp Current Transformer
5a 5 Amp Current Transformer
6 Current Transformer
Common
6a Common connection for
selectable features
7Connect Remote Adjust
from 7 to 6a, connect to 4
for internal voltage adjust
8Connect to 6a to select
1v/Hz underfrequency slope
9Connect to 6a to select 3
phase sensing
Lower Term. Strip
20 Phase C sensing input
22 Phase A sensing input
24 Phase B sensing input
26 3-phase power input
28 1-phase or 3-phase power
input
30 1-phase or 3-phase power
input
F1 Field +

CAUTION
Do not flash the field with the
generator in motion. Regulator
damage may result.
CAUTION
The factory calibration (FAC CAL)
adjustment is intended for use by
factory technicians only. The
following procedure can be used if
the factory calibration has been
disturbed.
F2 Field -
Table 2. Internal Adjustments
Adjust. Adjustment. Description
DRP Voltage Droop Adjust
FAC CAL FAC CAL is a factory voltage
adjust range calibration. No
customer adjustment is
required.
VLT ADJ Multi-Turn Voltage Adjust
UF Underfrequency Knee Adjust
STB Stability Adjust
OPERATION
General
Table3providessystemstart-upproceduresfor
the AVC63-12 and AVC125-10 Voltage Reg-
ulators.Symptomsofproblemsoccurringduring
start-up that arise from incorrect regulator
adjustment and certain generator system
problems that resemble faulty regulation are
included together with possible solutions.
Simplifying the system by eliminating
components, such as remote adjust poten-
tiometers and other non-essential items can be
helpful in the troubleshooting process. Ad-
justments, options, and an operational test are
included in the paragraphs after the table.
Preliminary Set-Up
Topreventdamagetotheregulator,ensurethat
the regulator has been installed and connected
in accordance with the paragraphs in
Instal-
lation
and Connections before proceeding with
the system start-up.
System Start-Up
Refer to Table 3 for system start-up.
ADJUSTMENTS
Field Flashing
When the regulator is operated with the
generator for the first time, the polarity of the
residual magnetism may not be correct or of
sufficient magnitude. If generator residual
voltage is less than 6 Vac for the AVC63-12 or
12 Vac for the AVC125-10 at terminals 26,28
and/or 30 shut down the prime mover and
proceed with the following steps:
1. With the prime mover at rest, apply a dc
source (ungrounded), of not more than 24
Vdc, to terminals F1 (positive) and F2
(negative) in series with a limiting resistor.
Use one (1) ohm of resistance for each volt
from the dc power source with a power
rating of least one (1) watt per ohm.
EXAMPLE: If using a 24 Vdc source, use
a 24-ohm, 24-watt resistor.
2. Allow the field to be flashed for approx-
imatelytensecondsbeforeremovingthedc
source.
3. If voltage build-up does not occur after
performing steps (1) and (2), verify the
polarity of the dc source used in steps (1)
and (2) and re-perform.
Frequency Roll-Off (UF Knee) Adjustment
The underfrequency knee (roll-off) is typically
set below the nominal system frequencies.
When the generators speed falls below the
knee set point of the regulator, generator
voltage is reduce proportional to the speed of
the machine. To adjust the underfrequency
knee, follow the steps below:
(1) Adjust the generator frequency for nominal
frequency (50, 60, or 400 Hz).
(2) Adjust the underfrequency potentiometer
(UF) CCW.
(3) AdjusttheVoltageAdjustpotentiometerfor
nominal generator voltage.
(4) Adjust the underfrequency potentiometer
(UF) CW until the voltage begins to decrease.
(5) Adjust the underfrequency potentiometer
(UF) CCW until the voltage just returns to the
value set in Step 3.
(6) The underfrequency knee is now set just
belowthenominaloperatingfrequency. Further
rotationintheCCWdirectionwilllowertheknee
frequency set point at which underfrequency
compensation begins.
(7) Connecting a jumper from terminal 8 to
terminal 6a will provide an underfrequency
slope of 1 P.U. V/Hz. No connection to
terminal8willresult inanunderfrequency slope
of 2 P.U. V/Hz. The slope can also be selected
on the 400Hz models. However, the actual
V/Hz curve is approximately 1 P.U. or 2 P.U.
depending if the terminal 8 is jumpered to 6a or
not.
Stability (STB) Adjustment
An oscilloscope or other voltage-recording
device should be used if an optimal stability
setting is desired. Adjust the stability setting
with the generator at no load. Good
response can be obtained with the following
procedure.
(1) Rotation of the front panel STB control in
theclockwise(CW)directionwillslowresponse
time.
(2) Rotation of the front panel STB control in
the counter-clockwise (CCW) direction will
speed response time. If rotated too far CCW,
the generator voltage may oscillate (hunt).
(3) Rotate the front panel STB control CCW
until the system just begins to oscillate and
then rotate CW just past the point where
oscillation occurred. Apply various amounts of
loadstodetermineproperstabilityperformance.
Voltage (VLT ADJ) Adjustment
(1) Installation of a jumper across terminals 4
and 7allows the internal (front panel) VLT ADJ
adjustment to vary the generator nominal
voltage over the operating range.
(2) Remove the jumper between terminals 4
and 7and connect a 10k ohm external voltage
adjust potentiometer across terminals 6a and 7
to allow operation of the external voltage adjust
potentiometer. Theinternalvoltageadjustment
should be set fully CW for proper operation of
the external adjustment. It should be noted, as
the external potentiometer resistance in-
creases, generator voltage also increases.
Factory Calibration (FAC CAL) Adjustment
(1) With the voltage regulator operating on a
generator, adjust the calibration potentiometer
fully CCW and the external voltage adjust
potentiometer fully CW. Adjust the FAC CAL
potentiometer CW until the generator voltage
reaches the desired maximum voltage setting.
The unit is calibrated and the calibration
potentiometer can be sealed.
Parallel Droop Compensation
Variableparalleldroopcompensationlevels can
be obtained by adjusting the droop poten-
tiometer. CW rotation increases the amount of
droop for a given condition.
Line Drop Compensation
When the sensing input CT connections are
swapped to provide LDC, the droop adjustment
becomes the LDC adjustment.
OPTIONS
The AVC63-12 and AVC125-10 may be
equipped with the following options to enhance
operational characteristics. Characteristics of
these options are defined in the following para-
graphs.
Remote Voltage Adjust
Connect a 10k ohm, 2 watt potentiometer from
terminals 6a to 7, remove the jumper from
terminal 4 to 7 and adjust the internal voltage
adjustpotentiometerfullyCWtoallowoperation
of a remote voltage adjust.
Excitation Disable
This option provides for disabling of the
excitation system by removal ofpower from the
voltage regulator. A switch removing voltage
from terminals 26, 28 and/or 30 will remove
power.
Excitation Limiter
This EL200 option provides an initial fast acting
limit of the field current at a pre-selected level.
Once the field current has changed to the
selected level, the output provides a signal to
the regulator to change the excitation.
Var/PF Control
This option allows the AVC63-12 and the
AVC125-10toregulatethevarandpowerfactor
while the generator is connected to an infinite
orutility bus. The var/PF option(Model Number
SCP250G-50 for 50-hertz operation or
SCP250G-60 for 60-hertz operation)supplies a
dc signal into the AVC63-12 and AVC125-10
terminals2and3to regulate theSCP250 var or
power factor setting. (See Figure 7 for inter-
connection diagram.)
Current Boost System
WiththisCBS212option,ifthegeneratoroutput
voltage drops below the preset operation point
due to a short or large motor starting, the
current boost function detects the voltage drop.
The function then provides full current boost to
the generator exciter until the voltage returns to
a level just above the operation point.
Manual Voltage Control
This option provides amanualback-up channel
for manually controlling the generator output
duringgeneratorstart-upandcommissioningor
in the unlikely event that the voltage regulator
should fail. Manual voltage controller model
MVC-112 is suitable for use with the either the
AVC63-12or the AVC125-10voltageregulator.

Table 3. System Start-Up
1. Perform the preliminary set-up.
2. Start prime mover and bring up to rated
speed.
If the voltage does not build up:
a. Flash Field
b. Remove power for 1 minute to allow
the overexcitation circuit to reset.
3. Slowly adjust VOLT adjustment or external
voltageadjust rheostatuntilvoltagereaches
nominal.
If the voltage does not build up to the rated
value, check the generator output for a
shorted or excessive load.
4. Apply and remove load to check stability.
If the generator response is too slow or is
hunting (oscillating):
a. Check generator output for shorted
or excessive load. Adjust STB with
no load applied.
b. Check stability of governor system.
5. Check regulation under normal operating
conditions.
If the regulation is poor:
a. Check that the prime mover is up to
rated speed.
b. Check that the voltmeter is
connected at the same point as the
regulator sensing.
c. Use an average sensing voltmeter
(not an RMS sensing voltmeter).
6. Reduce generator frequency. Generator
output should decrease from this point.
If the generator output voltage does not
decrease at desired frequency:
a. Check that all the wiring is in
accordance with the connection
diagrams provided in these
instructions.
b. Adjust FREQ control.
OPERATIONAL TEST
This test is designed to test all eight models of
the AVC63-12 and AVC125-10. See Table 4 for
appropriate testing voltages and frequencies.
To operationally test any AVC63-12 or AVC125-
10, perform the following steps.
a. Connect the voltage regulator as shown by
Figure 9 and apply appropriate voltages.
b. Adjust the front panel VLT ADJ control fully
counterclockwise (CCW).
RESULT: Observe that the lamp is OFF.
c. Adjust the front panel VLT ADJ control
clockwise (CW).
RESULT: Observe that the lamp is now ON.
d. Adjust the front panel VLT ADJ control until
the lamp just goes out.
Regulator operation is satisfactory if the above
resultsareobtained. Stability,however,mustbe
tested with the generator and regulator in
operation.
MAINTENANCE
Preventive Maintenance
A periodic inspection should be made of the
voltage regulator to ensure that it is clean and
free from accumulations of dust and moisture.
Be sure that all connections are clean and tight.
Troubleshooting
In case of failure/defective operation of the unit,
simplifying the system by eliminating com-
ponents, such as remote adjust potentiometers
and other non-essential items can be helpful in
the troubleshooting process.
Table 4. Testing Parameters
Input
Sensing
Model Power Vac Freq.
AVC63-12A1 120 120 50/60
AVC63-12A2 120 120 400
AVC63-12B1 120 240 50/60
AVC63-12B2 120 240 400
AVC125-10A1 240 120 50/60
AVC125-10A2 240 120 400
AVC125-10B1 240 240 50/60
AVC125-10B2 240 240 400
0
50
100
150
200
250
20 25 30 35 40 45 50 55 60 65
Frequency In Hertz
Terminal Voltag
e
Ideal 1 PU/Hz
Ideal 2 PU/Hz
Figure 1. 60 Hertz Frequency Compensation
0
50
100
150
200
250
150 200 250 300 350 400 450
Fre
q
uenc
y
in Hertz
Terminal Voltage in Volts
Ideal 2 PU/Hz
Ideal 1 PU/Hz
Figure 2. 400 Hertz Frequency Compensation
5.500
0.593
.281 DIA. HOLE
(4 PL)
6.01
D2590-30.vsd
06-20-01
0.438
STB
VLT ADJ
UF KNEE
FAC CAL
DRP
23455a66a789
F2F1302826242220
0.438
7.500
2.96
0.438
0.438
CH
GND
.750
.51 DIA.
(4 PL)
8.01
Figure 5. Outline Drawing

AVC63-12
or
AVC125-10
23455a66a78
20 22 24 26 28 30 F1 F2
9
CH
GND
RR
Chassis
Ground
2
5
KTK 20 AMP
KTK 20 AMP
1
3
9SHOWN WITH 3-PHASE PMG.FOR SINGLE PHASE
PMG
,
OMIT A-PHASE CONNECTION TO TERMINAL 26.
10K
PMG
GEN
52
A
A
B
B
C
C
9
6
Sensing Power Output
AVC63-12
or
AVC125-10
23455a66a78
20 22 24 26 28 30 F1 F2
9
CH
GND
RR
Chassis
Ground
2
5
KTK 20 AMP
KTK 20 AMP
1
3
1
2
3
5
6
4
CONNECT 2 AND 3 TO SCP250 VAR/PF AND El200
CONTROLLERS AS SHOWN IN FIGURE 7. SHORT
WHEN NOT USED.
REQUIRED FOR 3-PHASE SENSING. ALSO
REFERENCE NOTE 2.
POWER STEPDOWN TRANSORMER REQUIRED
IF GENERATOR VOLTAGE DOES NOT MATCH THE
REGULATOR INPUT POWER RANGE.
SENSING STEPDOWN TRANSFORMER REQUIRED
IF GENERATOR VOLTAGE DOES NOT MATCH THE
SENSING VOLTAGE RANGE IDENTIFIED BY THE
VOLTAGE REGULATOR'S STYLE NUMBER.
REFERENCE STYLE CHART.
10K
GEN
52
A
B
C
6
D2590-34.wmf
09-2-0-01
4
7ABC ROTATION SHOWN.
8LDC COMPENSATES FOR VOLTAGE DROP DUE TO
LINE REACTANCE AND REACTIVE COMPONENTS
OF THE LOAD CURRENT ONLY.
For Line Drop Compensation,
reverse the CT inputs.
8
55a6
Sensing Power Output
CONNECT 6aTO9 FOR 3-PHASE SENSING,
OPEN FOR 1-PHASE SENSING.
CONNECT 6aTO8 FOR 1V/Hz, REMOVE
FOR 2V/Hz UNDERFREQUENCY SLOPE.
CONNECT REMOTE VOLTAGE ADJUST FROM
6a TO 7, REMOVE LINK 4-7 IF FITTED WITH A
REMOTE ADJUST.
CONNECT TO TERMINAL 5 FOR 1 AMP CT. .CONNECT TO TERMINAL 5a FOR 5 AMP CT
Figure 6. Typical Interconnection Diagram
DC Output Voltage
210 230 250 270 290 310 330 350
1
10
100
Shutdown Region
Time In Seconds
Figure 4. AVC125-10 Overexcitation Shutdown Characteristics
L
C
2
3
Part of
AVC63-12
or
AVC125-10
Part of
EL200
P0009-25.vsd
06-26-01
A
CPart of
SCP250
NOTE: AVC Units may be connected to
either the EL200 or the SCP250 using the
terminals as shown in place of this series
interconnection. See the unit Instruction
Manuals for more information.
Figure 7. AVC Interconnection Diagram
70 90 110 DC Output Voltage 130 150 170 190 210 230
Time In Seconds
1
10
100
Shutdown Re
g
ion
Figure 3. AVC63-12 Overexcitation Shutdown Characteristics
GEN 1
GEN 2
5 or 5A
6
AVC
0.1
0.1
CT
CT
LOAD
CCC
ENABLE
CONTACT
5 or 5A
GEN 3
0.1
CT
P0009-26.vsd
08-10-01
5 or 5A
52b
1
52
1
52
2
52b
2
52b
3
52
3
AVC
AVC
6
6
Figure 8. Cross-Current Compensation
F1 F2 28 30 20 22
AVC63-12
AND
AVC125-10
D2590-33.vsd
06-15-01
10
ohm
In
p
ut
Power
100 W
Lam
p
2426
23 5 66a785a 9
4
CH
GND
Sensin
g
Volta
g
e
Figure 9. Operational Test Set-Up