Kutai electronics EA06 User manual

KUTAI ELECTRONICS INDUSTRY CO., LTD.
TEL : [phone] FAX : [phone] Website : www.kutai.com.tw
Headquarters : No.3, Ln. 201, Qianfu St., Qianzhen Dist., Kaohsiung City 80664, Taiwan
EA06
Generator Automatic Voltage Regulator
Operation Manual
Suitable for Single or Three Phase Self Excited Brushless Generator
Compatible replacement for Mecc Alte UVR6
* All manufacturer names and numbers are used for reference purpose only
and do not imply that any part is the product of these manufacturer.

___________________________________________________________________________________________
2EA06
SECTION 1 : SUMMARY
EA06 is equipped with 3 separate sensing inputs (1-2,
3-4, 5-6 terminals R.S.T phase), which can survey from
single up to three phase voltages and check the
average voltage from Y, YY or wiring accordingly to
the generator requirement or user preference.
The AVR is equipped with adjustable under frequency
protection and over voltage protection to prevent
generator from overloading and over excitation.
The 3 LED each represents (Green) normal operation,
(Red) under frequency and (Yellow) over excitation.
The built in EMS filter helps to prevent possible
interference from the AVR to the generator.
SECTION 2 : SPECIFICATION
Sensing Input (1-2, 3-4, 5-6)
EMI Suppression
Voltage 100 290 Vac / 270 520 Vac
Internal electromagnetic interference filtering
1 or 3 phase, selectable by wiring
Frequency 50/60 Hz
Static Power Dissipation
Max.5 watts
Power Input (+, 2)
Voltage 50 280 Vac
Over Excitation Protection
Frequency 50/60 Hz
25 55 Vdc @ 0.1 20 sec
Excitation Output (+ , –)
Under-Frequency Knee Point Thermal Drift
Voltage Max. 63 Vdc @power input 220 Vac
Adjustable range 42 62 Hz
Current Continuous 6A
Intermittent 7A for 10 secs.
Voltage Thermal Drift
Resistance 10 100 ohms
Less than 3% at temperature range -40 to +70 ˚C
Fuse Spec. Slow blow 5 x 20mm S505-6.3A / 250V
Environment
External Voltage Adjustment
Operating Temperature -40 to +60 ˚C
Max. +/- 5% @ 100K ohms 1/2 watt potentiometer
Storage Temperature -40 to +80 ˚C
Relative Humidity Max. 95%
Voltage Regulation
Vibration 1.5 Gs @ 5 –30 Hz
Less than +/- 1% ( with 4% engine governing )
5.0 Gs @ 30 –500 Hz
Build Up Voltage
Dimensions
5 Vac 25 Hz residual volts at power input terminal
150.0 (L) x 115.0 (W) x 41.0 (H) mm
Soft Start Ramp Time
Weight
4 seconds +/- 10%
440 g +/- 2%
ATTENTION
1. AVR can be mounted directly on the engine, genset,
switchgear, control panel, or any position that will not
affects operation. For dimension reference, please see
Figure 1.
2. All voltage readings are to be taken with an
average-reading voltmeter Meggers and high-potential
test equipment must not be used. Use of such
equipment could damage the AVR.
3. Secure all wiring connection. Do not install AVR at a
placewith high vibrations to prevent loose connections.
For safety do not touch the heat sink while in operation.
4. Improper setting of under-frequency protection could
cause the output voltage of the unit to drop or become
unstable under with changes in load. Avoid making any
changes to the U/F setting unless necessary.
41.0
20.587.0
115.0
122.0 150.0
4
3210B
+
6
5
EA06
5.3
Figure 1 Outline Drawing

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EA06 3
SECTION 3 : WIRING / ADJUSTMENTS
3.1 Field Excitation Wiring 「+, –」
3.1.1 Connect AVR terminal「+」to field「+」, connect
AVR terminal「–」to the field「–」.
NOTE
The Exciter field resistance is between 10 100
ohm.
3.1.2 If field resistance is less than 10 ohm when
generator is under full load and the field voltage
is under the maximum output, please series a
suitable wattage (W) resistor to have the overall
field resistance to equal to 10 100 ohm.
3.2 Sensing / Power Input「1-2, 3-4, 5-6」
3.2.1 Total of 3 sets of independent sensing inputs,
each input voltage equals to 120 / 240V (Center),
can be series into Y or to connect to the
generator output (3 Phases) for example R-T, T-S,
S-R, or joint connected into a single phase
sensing (See Figure 2 to 13).
3.2.2 Terminal +, 2 is the AVR power input, voltage
range from 50 280V.
3.3 Frequency Selection (60 Hz)
When the 2 terminals marked as 60 Hz on the AVR is
bridged, the system frequency is 60 Hz. In the contrary,
when bridge is removed the system frequency is 50
Hz.
3.4 External Voltage Adjustment VR
Connect a 100K Ohms 1/2W voltage rheostat at VR
terminals to enable a +/- 5% voltage adjustment from
rated voltage.
*The terminals must be bridged when the external
voltage adjustment function is none required.
3.5 Terminals B, 0 can remain not connected
3.6 VOLT. Voltage Adjustment
User can adjust the generator voltage by rotating the
「VOLT 」potentiometer on the AVR. Rotate the
potentiometer clockwise to increase voltage and
decreasing when rotate counterclockwise. The voltage
adjust rate is less than 1% when the power factor
equals to 1 to 0.8 (PF 1 to 0.8) and frequency variation
within 6%.
3.7 STAB. Stability Adjustment
3.7.1 Slowly and precise adjustment of 「STAB」
potentiometer can change the respond time
between the AVR and generator. Inadequate
adjustment will cause voltage instability and over
adjusting will cause sudden overly voltage
variation under heavy load.
3.7.2 Analogue type multi voltmeter is suggested when
adjusting the voltage stability. Adjust the
「STAB」potentiometer until the pointer on the
multi voltmeter is oscillating to its minimal.
3.8 Circuit Protection
3.8.1 AMP. Over Excitation Protection Adjustment
(Overload protection)
Set the 「AMP」Overload protection value (25 to
55 Vdc) according to the generator maximum
excitation voltage. When over excitation occurs
wait for 20 seconds then decrease the generator
voltage to 30 to 50 Vac. When the Over
excitation protection is activated the yellow LED
will illuminate, the higher the over excitation
value is the shorter delay time becomes. The
generator will require stopping operation to reset.
3.8.2 Hz. Under Frequency Protection Adjustment
Hz. Is used to set the under frequency
protection knee point. When the generator
frequency declines to setting point, the generator
voltage will also decrease in the same time to
prevent high excitation current from damaging
the AVR or the exciter, adjustment procedure :
Adjustment procedure :
(1) Start generator and let voltage build up.
(2) Adjust engine frequency to the appropriate
low frequency value.
(3) Slowly adjust Hz. Potentiometer until the red
LED illuminates.
SECTION 4 : OPERATION PROCEDURE
4.1 Please confirm the follow condition before
starting the generator :
4.1.1 Starting Setting
(1) Confirm if the AVR specification conforms to
the system requirements ?
(2) Confirm the AVR wiring ?
(3) Confirm correct frequency selected ?
(4) Confirm the generator rated voltage with the
AVR sensing input ?
(5) Adjust 「VOLT 」potentiometer fully
counterclockwise?
Adjust「STAB」potentiometer to the center
position?
Adjust「AMP」potentiometer fully clockwise?

___________________________________________________________________________________________
4EA06
Figure 2 Manual Field Flash
4.1.2 Starting Generator
(1) Reconfirm all setting and wiring.
ATTENTION
The AVR reading AC voltage are all average
value.
(2) Start generator and adjust to rated frequency.
The first measured voltage value should be
under the rated voltage. If not, then reconfirm
the start setting.
(3) Slowly adjust 「VOLT」potentiometer to the
rated voltage, at this time the generator
voltage may become unstable. Adjust the
「STAB.」potentiometer anticlockwise, until
the oscillation stabilizes. Over adjustment
may cause short oscillation when load applied
or load type varies.
SUGGESTION
Adjust the 「STAB.」potentiometer to the point
where the oscillation occurs and then adjust the
potentiometer counterclockwise by 1/6 of
rotation.
(4) If voltage can not be adjusted or to the rated
value, please check to see if the generator
frequency is too slow (Under frequency
protection activated). If residual voltage is
below 5 Vac, then please execute field
flashing to help build up the residual voltage.
(5) Make sure the generator and AVR are both
under normal operation conditions.
(6) The voltage adjustable range should be +/-
1% under no load or full load. If the adjustable
range in not within such range, please check
the below :
A. Generator under frequency (Lower than low
frequency protection knee point).
B. Severely deformed generator output wave
form.
C. Capacitive load over ratio (Power factor in
lead).
D. Change the AVR and restart.
E. Under over excitation voltage protection
(Overload protection).
SECTION 5 : FIELD FLASHING
When the regulator is installed correctly but the
generator is failed to generate power. Besides carbon
brushes were worn out, here are two possible causes
below.
5.1 The polarity of field is inverse
Solution：Exchange the connection of F+ and F-.
5.2 The residual voltage is less than 5 Vac,
Solution 1：
5.2.1 Shut down generator, disconnect the wiring
between AVR and generator then flash the field.
Flashing duration = 3 seconds. (See wiring in
Figure 2)
Resistor 3 –5 ohms for full wave AVR
Resistor 5 –10 ohms for half wave AVR
Warning!! Over field flashing may damage
the field winding of generator.
5.2.2 Restart generator and measure the residual
voltage by AC Voltmeter, if it is still less than 5
Vac, repeat the previous process, after several
times, the residual voltage still cannot be built,
Kutai EB500 is strongly recommended, see
Figure 2.
Field
SWR
-+
V
F+F-
BATT.
~
G
~
T
S
R
5.3 Maintenance
Regular maintenance to make sure the AVR surface is
clean and free from oil or moisture. All connection
terminals and wirings must be firmly tightened and no
signs of visible oxidation or erosion.
WARNING
Overly field flashing may damage the AVR or
generator excitation winding.
Please make sure you have read and understand
the contents of the instruction manual prior to
installation. Incorrect wiring connection may
result in irreversible damage to the product and
other equipments.

___________________________________________________________________________________________
EA06 5
1
1
1
2
645 3
N
S
R
N
T
5
624 3
2
65 4 3
T
S
R
S
R
N
T
-0 B34 2 15
6++B -0
VR
60HZ 60HZ
VR
N
Field
winding
Auxiliary
-
+
Auxiliary
+B0
winding
VR
-60HZ
S
R
N
T
B + -0
VR
60HZ
Field
+
-
winding
Auxiliary
-
Field
+
T
S
R
S
R
N
T
B5
64 3 2 1 0
Field -
+
+ - 60HZ
VR
B12 05
64 3 + - 60HZ
+
-
Field
VR
-
Field
+
4B
R
35
64 02 1
N
+ - 60HZ
VR
-
Field
+
T
65
R
60HZ
13 2 -0 B +
NT+
Field -
VR
S S
+
Field -
5
6
R
124 3 +B0
NT
S
VR
-60HZ
winding
Auxiliary
12
65 4 3
S
R
N
T
B + -0
VR
60HZ
winding
Auxiliary
-
Field
+3~5Ω
20w +
Figure 3 3 phase 120 / 240 Vac
Figure 4 3 phase 120 / 240 Vac With auxiliary winding
1
1
1
2
645 3
N
S
R
N
T
5
624 3
2
65 4 3
T
S
R
S
R
N
T
-0 B34 2 15
6++B -0
VR
60HZ 60HZ
VR
N
Field
winding
Auxiliary
-
+
Auxiliary
+B0
winding
VR
-60HZ
S
R
N
T
B + -0
VR
60HZ
Field
+
-
winding
Auxiliary
-
Field
+
T
S
R
S
R
N
T
B5
64 3 2 1 0
Field -
+
+ - 60HZ
VR
B12 05
64 3 + - 60HZ
+
-
Field
VR
-
Field
+
4B
R
35
64 02 1
N
+ - 60HZ
VR
-
Field
+
T
65
R
60HZ
13 2 -0 B +
NT+
Field -
VR
S S
34
65 012
VR
60HZ
-B +
R
S
T
N
Field -
+
T
N
R
S+
34
65 02 1 60HZ
-B +
VR
Field -
winding
34
6560HZ
1 02 -B +
VR
R
S
T
NAuxiliary
-
+
Field
3
T
45
6
N
R
S+
60HZ
012 -+B
Auxiliary
winding
VR
Field -
+
65 1234 B0
VR
60HZ
-
R
T
S
N+
-
Field
winding
345
602 1
VR
60HZ
-B +
R
S
T
NAuxiliary
Field
+
-
T
N
R
S
Auxiliary
winding
35 4
6012 60HZ
-B +
VR
+
-
Field
+
T
65
N
124 3 B0
R
S
VR
-60HZ
+
-
Field
Figure 5 3 phase 240 / 277 Vac
Figure 6 1 phase 120 / 240 Vac With auxiliary winding
34
65 012
VR
60HZ
-B +
R
S
T
N
Field -
+
T
N
R
S+
34
65 02 1 60HZ
-B +
VR
Field -
winding
34
6560HZ
1 02 -B +
VR
R
S
T
NAuxiliary
-
+
Field
3
T
45
6
N
R
S+
60HZ
012 -+B
Auxiliary
winding
VR
Field -
+
65 1234 B0
VR
60HZ
-
R
T
S
N+
-
Field
winding
345
602 1
VR
60HZ
-B +
R
S
T
NAuxiliary
Field
+
-
T
N
R
S
Auxiliary
winding
35 4
6012 60HZ
-B +
VR
+
-
Field
+
T
65
N
124 3 B0
R
S
VR
-60HZ
+
-
Field
34
65 012
VR
60HZ
-B +
R
S
T
N
Field -
+
T
N
R
S+
34
65 02 1 60HZ
-B +
VR
Field -
winding
34
6560HZ
1 02 -B +
VR
R
S
T
NAuxiliary
-
+
Field
3
T
45
6
N
R
S+
60HZ
012 -+B
Auxiliary
winding
VR
Field -
+
65 1234 B0
VR
60HZ
-
R
T
S
N+
-
Field
winding
345
602 1
VR
60HZ
-B +
R
S
T
NAuxiliary
Field
+
-
T
N
R
S
Auxiliary
winding
35 4
6012 60HZ
-B +
VR
+
-
Field
+
T
65
N
124 3 B0
R
S
VR
-60HZ
+
-
Field
Figure 7 1 phase 120 / 240 Vac
Figure 8 3 phase 120 / 240 Vac With auxiliary winding
34
65 012
VR
60HZ
-B +
R
S
T
N
Field -
+
T
N
R
S+
34
65 02 1 60HZ
-B +
VR
Field -
winding
34
6560HZ
1 02 -B +
VR
R
S
T
NAuxiliary
-
+
Field
3
T
45
6
N
R
S+
60HZ
012 -+B
Auxiliary
winding
VR
Field -
+
65 1234 B0
VR
60HZ
-
R
T
S
N+
-
Field
winding
345
602 1
VR
60HZ
-B +
R
S
T
NAuxiliary
Field
+
-
T
N
R
S
Auxiliary
winding
35 4
6012 60HZ
-B +
VR
+
-
Field
+
T
65
N
124 3 B0
R
S
VR
-60HZ
+
-
Field
R
T
N
S
-
+
VR
2
64 35
winding
+B1 0 - 60HZ
Auxiliary
Field
Figure 9 3 phase 120 / 240 Vac
Figure 10 3 phase 380 / 480 Vac With auxiliary winding
Delta winding
Delta winding
Delta winding

___________________________________________________________________________________________
6EA06
+
6
R
T
N
S
34 25 B01 -
VR
60HZ
Field -
+
1
N
T
S
R
5
624 3
Field
+
Auxiliary
+B0
winding
-60HZ
VR
-
N
S
T
R
B4 35
602 1
+
-60HZ +
VR
Field -
4
4
S
Field
S
winding
Auxiliary
T
N
01345 2
6
5C 4 5
-+B 60HZ
VR
+
313A SR7
Terminal
5
6
T
N
45C
Auxiliary
winding
R
S
N
T
R
4
65 023 1
5C 4 5
60HZ
-
-B +
VR
1
3
3A
-
Field
+
Terminal
SR7
R
5
6
S
T
R
N
45C
Field
+
60HZ
B -+2 013
53A 3
VR
Terminal
SR7
1
- -
Field
+
60HZ
2 13 B + -0
53A 3
VR
Terminal
SR7
1
Figure 11 3 phase 380 / 480 Vac
Figure 12 3 phase ≥ 480 Vac With auxiliary winding
1
N
T
S
R
5
624 3
Field
+
Auxiliary
+B0
winding
-60HZ
VR
-
N
S
T
R
B4 35
602 1
+
-60HZ +
VR
Field -
4
4
S
Field
S
winding
Auxiliary
T
N
01345 2
6
5C 4 5
-+B 60HZ
VR
+
313A SR7
Terminal
5
6
T
N
45C
Auxiliary
winding
R
S
N
T
R
4
65 023 1
5C 4 5
60HZ
-
-B +
VR
1
3
3A
-
Field
+
Terminal
SR7
R
5
6
S
T
R
N
45C
Field
+
60HZ
B -+2 013
53A 3
VR
Terminal
SR7
1
- -
Field
+
60HZ
2 13 B + -0
53A 3
VR
Terminal
SR7
1
Figure 13 3 phase ≥ 480 Vac
EA06 For Replacing Mec Calte SR7 Diagram
1
N
T
S
R
5
624 3
Field
+
Auxiliary
+B0
winding
-60HZ
VR
-
N
S
T
R
B4 35
602 1
+
-60HZ +
VR
Field -
4
4
S
Field
S
winding
Auxiliary
T
N
01345 2
6
5C 4 5
-+B 60HZ
VR
+
313A SR7
Terminal
5
6
T
N
45C
Auxiliary
winding
R
S
N
T
R
4
65 023 1
5C 4 5
60HZ
-
-B +
VR
1
3
3A
-
Field
+
Terminal
SR7
R
5
6
S
T
R
N
45C
Field
+
60HZ
B -+2 013
53A 3
VR
Terminal
SR7
1
- -
Field
+
60HZ
2 13 B + -0
53A 3
VR
Terminal
SR7
1
1
N
T
S
R
5
624 3
Field
+
Auxiliary
+B0
winding
-60HZ
VR
-
N
S
T
R
B4 35
602 1
+
-60HZ +
VR
Field -
4
4
S
Field
S
winding
Auxiliary
T
N
01345 2
6
5C 4 5
-+B 60HZ
VR
+
313A SR7
Terminal
5
6
T
N
45C
Auxiliary
winding
R
S
N
T
R
4
65 023 1
5C 4 5
60HZ
-
-B +
VR
1
3
3A
-
Field
+
Terminal
SR7
R
5
6
S
T
R
N
45C
Field
+
60HZ
B -+2 013
53A 3
VR
Terminal
SR7
1
- -
Field
+
60HZ
2 13 B + -0
53A 3
VR
Terminal
SR7
1
Figure 14 1 phase 120 / 240 Vac
Figure 15 1 phase 120 / 240 Vac With auxiliary winding
1
N
T
S
R
5
624 3
Field
+
Auxiliary
+B0
winding
-60HZ
VR
-
N
S
T
R
B4 35
602 1
+
-60HZ +
VR
Field -
4
4
S
Field
S
winding
Auxiliary
T
N
01345 2
6
5C 4 5
-+B 60HZ
VR
+
313A SR7
Terminal
5
6
T
N
45C
Auxiliary
winding
R
S
N
T
R
4
65 023 1
5C 4 5
60HZ
-
-B +
VR
1
3
3A
-
Field
+
Terminal
SR7
R
5
6
S
T
R
N
45C
Field
+
60HZ
B -+2 013
53A 3
VR
Terminal
SR7
1
- -
Field
+
60HZ
2 13 B + -0
53A 3
VR
Terminal
SR7
1
1
N
T
S
R
5
624 3
Field
+
Auxiliary
+B0
winding
-60HZ
VR
-
N
S
T
R
B4 35
602 1
+
-60HZ +
VR
Field -
4
4
S
Field
S
winding
Auxiliary
T
N
01345 2
6
5C 4 5
-+B 60HZ
VR
+
313A SR7
Terminal
5
6
T
N
45C
Auxiliary
winding
R
S
N
T
R
4
65 023 1
5C 4 5
60HZ
-
-B +
VR
1
3
3A
-
Field
+
Terminal
SR7
R
5
6
S
T
R
N
45C
Field
+
60HZ
B -+2 013
53A 3
VR
Terminal
SR7
1
- -
Field
+
60HZ
2 13 B + -0
53A 3
VR
Terminal
SR7
1
Figure 16 1 phase 380 / 480 Vac
Figure 17 1 phase 380 / 480 Vac With auxiliary winding
※Use only the replacement fuses specified in this user manual.
※Appearance and specifications of products are subject to change for improvement without prior notice.