Kutai electronics EA440 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
EA440
Generator Automatic Voltage Regulator
Operation Manual
Self ExcitedAutomatic Voltage Regulator
Compatible with Newage SX440*
* All manufacturer names and numbers are used for reference purpose only
and do not imply that any part is the product of these manufacturer.

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2EA440
SECTION 1 : SPECIFICATION
Sensing Input
Quadrature Droop Input
Voltage 190 –264 Vac, 1 phase 2 wire
Burden 10 ohms
Frequency 50 / 60 Hz, selectable
Max. input 0.33 A
Max. sensitivity 0.07 A for 5% droop (PF=0)
Excitation Output
Voltage Max. 90 Vdc @ power input 207 Vac
Analogue Voltage Input
Current Continuous 4A
Input Resistance 1K ohm
Intermittent 10A for 10 secs.
Max. Input +/- 5 Vdc
Resistance Min. 15 ohm
Sensitivity 1V for 5% generator volts
External Voltage Adjustment
Under Frequency Protection
Max. +/- 8% @ 1K ohm 1 watt potentiometer
Set point 95% Hz
Slope 170% down to 30 Hz
Voltage Regulation
Less than +/- 1% ( with 4% engine governing )
Voltage Thermal Drift
Less than 3% at temperature range -40 to +70 ˚C
Build Up Voltage
5 Vac residual volts at power input terminal
Environment
Operating Temperature -40 to +70 ˚C
Soft Start Ramp Time
Storage Temperature -40 to +85 ˚C
2 seconds +/- 10%
Relative Humidity Max. 95%
Vibration 3.3 Gs @ 100 2K Hz
Static Power Dissipation
Max.12 watts
Dimensions
150.0 (L) x 135.0 (W) x 48.0 (H) mm
Weight
418 g +/- 2%
115.0
135.0
130.0 150.0
21.5
48.0
5.5
STABILITY
DROOP
TRIM
VOLT
UFRO
LED C B A
C-A < 90KW
C-B < 90-550KW
B-A < 550KW
Resistor
ATTENTION
1. AVR can be mounted directly on the
engine, genset, switchgear, control
panel, or any position that will not affect
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. 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.
Figure 1 Outline Drawing

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EA440 3
SECTION 2 : WIRING
2.1 K1, K2 : Field input external switch terminals.
Linked for normal operation.
2.2 P2, P3 : External power input terminals.
2.3 3, 2 : Sensing input terminals.
2.4 1, 2 : External VR terminals. Linked for useless.
2.5 X,XX : X connect to field (+), XX connect to field
(-).
2.6 S1, S2 : Droop CT input terminal.
2.7 A1, A2 : VAR/PF controller input.
2.8 A, B, C : Link A, C for under 90 KW.
Link B, C for 90 550 KW.
Link A, B for over 550 KW.
2.9 J1 J8 : Jump select terminals, 2-3, 4-5, 6-7.
please refer to Figure 2 and Figure 3.
SECTION 3 : ADJUSTMENT
3.1 Voltage Adjustment
The generator output voltage can be altered by
adjustment of the volt VR on the AVR board, or by the
external trimmer (1K ohm) if fitted.
(1) The terminals 1&2 must be linked if no hand
trimmer.
(2) Before start the generator, please turn the Volt
trimmer on the AVR board fully anticlockwise Turn
the external trimmer to midway position.
(3) Turn the stability trimmer on the AVR board to
midway position.
(4) Connect a voltmeter to generator output voltage
terminals.
(5) Start generator set and run on no load at nominal
frequency 50 53 Hz or 60 63 Hz.
(6) If the red Led is illuminated, refer to the under
frequency roll off adjustment.
(7) Carefully turn volt trimmer clockwise until rated
voltage is reached.
3.2 Stability Adjustment
If a replacement AVR has been fitted or re-setting of
the stability control is required, turn the stability trimmer
slowly clockwise until the output voltage is steady, on
or off load.
3.3 Droop Adjustment
Generator intended for parallel are fitted with a
quadrature droop CT with provides a power factor
dependent signal for the AVR. The CT is connected to
S1, S2 on the AVR. The Droop adjustment is normally
present in the works to give 5% voltage droop at full
load zero power factor. Clockwise increases the
amount of CT signal injected into the AVR and
increases the droop with lagging power factor. With the
control fully anticlockwise there is no droop.
Figure 2 Bypass Drawing
Figure 3 Wiring Drawing

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4EA440
Figure 4 Manual Field Flash
3.4 Trim Adjustment
An auxiliary input is provided to connect to A1, A2. It is
designed to accept DC +/- 5V.Turn the TRIM trimmer
fully anticlockwise has no effect, Clockwise it has
maximum effect.
SECTION 4 : 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.
4.1 The polarity of field is inverse
Solution：Exchange the connection of F+ and F-.
4.2 The residual voltage is less than 5 Vac,
Solution 1：
4.2.1 Shut down generator, disconnect the wiring
between AVR and generator then flash the field.
Flashing duration = 3 seconds. (See wiring in
Figure 4)
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.
4.2.2 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 4.
Field
SWR
-+
V
F+F-
BATT.
~
G
~
T
S
R
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.
SECTION 5 : PARALLEL FUNCTION
5.1 Parallel Compensation
5.1.1 When it is required to operate the regulator in
parallel with an isolated or utility bus, in addition
to the regulator provisions, a 10VA current
transformer (CT) is required ( See Figure 3 ). The
CT is connected in a generator line and should
deliver from 1 amperes secondary current at
rated load.
5.1.2 The phase relationship of CT signal to the
regulator sensing voltage must be correct or the
system will not parallel properly. The CT must be
installed in the line of the three phase generator
that does not supply sensing to the regulator.
5.2 Reactive Droop Compensation
5.2.1 For reactive droop compensation, connect the
CT to it’s respective regulator as shown on
Figures 3.
5.2.2 A unit-parallel switch shorts the parallel CT
secondary to prevent any droop signal from
being injected into the regulating system during
single unit operation. The switch may not be
required on parallel droop compensation
applications where a voltage drop is not
objectionable.

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EA440 5
SECTION 6 : TROUBLE SHOOTING
SYMPTOM
POSSIBLE CAUSES
SOLUTIONS
Voltage does not
build up
Engine speed is too low
Please refer to the Generator Manual
wires are not connected well
Please refer to Figure 2
Defective Generator
Please refer to the Generator Manual
Low output voltage
External VR broken
Check wiring and testing VR
Terminal 1&2 not linked
Please linked terminal 1&2
Terminal 3&2 no sensing input
Please refer to Figure 2
Under frequency
Please refer to the Generator Manual
Defective Generator
Please refer to the Generator Manual
Over output voltage
AVR adjustment not well
Please refer to voltage adjustment page
Defective Generator
Please refer to the Generator Manual
※Appearance and specifications of products are subject to change for improvement without prior notice.