Kutai electronics EA05A User manual

EA05A
Generator Automatic Voltage Regulator
Operation Manual
Kaohsiung : No.3, Lane 201, Chien Fu ST., Chyan Jenn Dist., Kaohsiung, TAIWAN
Tel : + 886-7-8121771 Fax : + 886-7-8121775
URL : http://www.kutai.com.tw Email : servi[email protected]ai.com.tw
Self Excited Automatic Voltage Regulator
5 Amp AVR For General Generators

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2EA05A
1. INTRODUCTION
Sensing Inpu
uu
ut
Voltage 220 / 380 / 440 VAC, 1 phase2 wire
DIP switch selectable
Frequency 50 / 60 Hz, DIP switch selectable
Power Input
Voltage 100 ~ 300 VAC, 1 phase 2 wire
Output
Voltage Max. 90 VDC @ 240 VAC input
Current Continuous 5A
Intermittent 7A for 10 sec
Resistance Min. 15 ohm Max. 100 ohm
Voltage Regulation
< ± 0.5% ( with 4% engine governing )
Voltage Build-up
Residual voltage at AVR terminal > 5 VAC
Thermal Drift
0.03% per °C change in AVR ambient
External Volts Adjustmen
± 7% with 1K ohm 1 watt trimmer
EMI Suppression
Internal electromagnetic interference filtering
Unit Power Dissipation
Max. 8 watt
Under Frequency Protection (Factory Setting)
60 Hz system presets knee point at 55 Hz
50 Hz system presets knee point at 45 Hz
Soft Start Ramp Time
3 sec.
Dimensions
101mm L * 69mm W * 47.5mm H
Weight
183g ± 2%
2. WIRING
When generator supply is over load, N phase will be
different with the sharing load by 3 phases (load
imbalance). Hence, the voltage from N phase to 3
phases (R.S.T.) will be altered. When the rated
voltage of the traditional single input’s AVR is above
220V, it will increase the voltage drift rate by using N
phase as the detective input. It will also cause the
voltage imbalance.
EA05A can improve the above situation, and
increase the generator’s rated voltage usage space,
such as 380V, 440V. We can all detect by the
“phase voltage”.
1. When the rated phase voltage of the generator is
220VAC, the input terminals B, C and sensing
terminals A, C can join together (as show as
figure3. It’s the original setting).or connect
independent.(as show as figure2).
2. When the rated phase voltage of the generator is
380V, 440V, the input terminals B, C and sensing
terminals A, C must separate connect the wiring
(as show as Figure 4 or figure 5). The voltage
between B and C must not be over 300 VAC.
3. F+ F- terminals connect to the generator field. (J
and K)
FEXT.VR is the potentiometer (1KΩ1W). These two
terminals must be by-pass when external
potentiometer is needless.
P.S. : A, B, C, F+ F- the usage of wire gauge are
AWG16 or 1.25 mm2 85°C above 600V.
The EXT.VR connection wires must be made of
isolated wiring.
3. ADJUSTMENTS
The voltage setting for 220V/380V/440V and the
frequency setting for 50/60HZ is show in figure7.
Please check the voltage/frequency selector setting
is correct before start the generator.
CAUTION :
THE GENERATOR OR AVR MAY BE DAMAGED
IF THE VOLTAGE / FREQUENCY SELECTOR
SETTING IS INCORRECT.
UFRO DIP:
Close - please refer to solid curre in Figure8.
Open - please refer to dotted curre in Figure8.

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EA05A 3
1. Before you turn on the generator, please turn the
voltage adjustment and stability adjustment full
anti-clockwise. After the generator is on and run
stably, turn the voltage adjustment clockwise to
reach the required out voltage. (If there is an
external potentiometer, turn the external
potentiometer to the middle position before adjust
internal voltage potentiometer.)
2. Adjust “Stability Adjustment” clockwise slowly to
change the feedback time between AVR and the
generator. If the adjustment is too big, it might
cause the voltage instable. If too small, the load
voltage will change too much at heavy load. Our
suggestion is to trace by the multi-meter DCV. To
adjust “stability adjustment”, you just need to
make the multi-meter waving smaller. It can also
improve the full load’s voltage drift rate.
4. FIELD FLASHING
When the regulator is operated with the generator for
the first time, the polarity of residual magnetism may
be reversed or too small to achieve the necessary
build-up voltage for the regulator. If reversing the field
connections does not induce build-up, and the residual
voltage is less than the specified value of 5 Vac, shut
down the Prime-mover and proceed with the following
steps :
1. With the Prime-mover at rest and the regulator’s
field output wires disconnected, apply a DC
source ( NOT grounded ) of not more than 3~12
Vdc with Positive to F+ and Negative to F-, in
series with a current-limiting resistor of 3~5 ohms
20 watt. (The set battery is a suitable source.)
2. Allow approximately 3 seconds before removing
the DC source.
3. With the voltage regulator disconnected ( wires 3
and 4 ), start the prime mover and measure the
“ residual ” voltage available at the auxiliary
winding. If this voltage is greater than 5 Vac,
reconnect voltage regulator, and voltage build-up
should be successful. If less than 5 Vac is
measured, repeat field flashing procedure.
4. If repeating steps a. and b. does not result in
generator voltage build-up, and residual is
greater than 5 Vac, replace voltage regulator.
5. TROUBLE SHOOTING
SYMPTOM CAUSE CORRECTION
Engine speed is too low. Please refer to the Generator Manual.
Residual voltage is too low.
Please refer to the section introduction of
excite.
B,C,F+,F- wires are not connected well. Please refer to Figure 2 ~ Figure 5.
Voltage does not
build up
Defective Generator. Please refer to the Generator Manual.
The input wiring of A,B,C are not correct.
Please refer to Figure 2 ~ Figure 5.
Check the external potentiometer. Check wiring and potentiometer.
Under frequency. Please refer to the Generator Manual.
The exciter does not match the AVR. Please refer to the Generator Manual.
Out voltage low
The voltage / frequency selector setting
is not correct.
Please refer to Figure 7.
Fuse blown The exciter flash is too large or wiring
doesn’t connect well.
Please refer to the Generator Manual.
Please refer to Figure 2 ~ Figure 5.
A,C terminals are not connect or wiring
incorrect.
Please refer to Figure 2 ~ Figure 5.
Out voltage high
The voltage / frequency selector setting
is not correct.
Please refer to Figure 7.
Out voltage instable
Stability Adjustment doesn’t adjust well.
Please refer to the section introduction of
Adjustment.
P.S. Please use the fuse of the original plant.

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4EA05A
6. FIGURE AND SIZE
ON
123
3
ON
1 2
220V/60HZ
220V/50HZ
N
R
S
T
G
~
Field
CB A F+ F-
1 32
ON
U/F STAB VOLT UFRO
DIP
1000 OHM
EXT. VR
Frequency
Selector
Volt /
Field
~
G
380V/60HZ
380V/50HZ
STAB
U/F
321
ON
VOLT
C
321
ON
BF- F+
A
ON
R
T
S
N
31 2
UFRO
DIP
1000 OHM
EXT. VR
Frequency
Selector
Volt /
Field
220V/60HZ
220V/50HZ
21 3
ON
21 3
ON
STAB
U/F VOLT
B
CF-
F+
A
R
T
S
N
3
ON
1 2
~
G
UFRO
DIP
1000 OHM
EXT. VR
Frequency
Selector
Volt /
Figure 1 Figure 2
Figure 3 Figure 4
UFRO
DIP

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EA05A 5
2 31
ON
220V/60HZ
21 3
220V/50HZ
ON
380V/50HZ 380V/60HZ
31 2
ON
31 2
ON ON
440V/50HZ 440V/60HZ
ON
11 2 32 3
Figure 5
Flash with Battery
Figure 6
Figure 7
Figure 8 Figure 9
GENERATOR OUTPUT VOLTAGE GENERATOR OUTPUT VOLTAGE
SOFT START (V/Sec)
1
0
FREQUENCY (HZ)
10 20 40 30 50 60 0
2
60HZ
( % OF MONINAL)
80
20
40
60
50HZ
120
100
( % OF MONINAL)
80
20
40
60
120
100
321
Field
ON
440V/60HZ
440V/50HZ
ON
1
1
STAB
U/F
32
VOLT
CB
32
A F+ F-
ON
R
T
S
N
~
G
UFRO
DIP
1000 OHM
EXT. VR
Frequency
Selector
Volt /