MTS Systems ADVR-12 User manual

ADVR-12
Hybrid Universal Analog
Digital Voltage Regulator
Operation Manual
4501 NW 27 Ave
Miami Florida 33142
305.634.1511
Adapter plugs for Digital Regulator
Self Excited Automatic Voltage Regulator
For use in Brushless SHUNT, PMG and Auxiliary Winding
Basler* AVC63-12, AVC125-10, CATERPILLAR*
12B & K125-10B, Leroy Somer* 202-8634 regulators
*For reference purposes only and does not imply that any part listed
is the product of the manufacturer.

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2ADVR-12
1. SUMMARY
The ADVR-12 is a totally new hybrid 12 Amp
universal voltage regulator with a comparable
footprint as the Basler* AVC63-12 and AVC125-10,
CAT* VR6, KATO* K65-12B and K125-10B, and the
Leroy Somer* 202-8634, and many other. To
simplify installation, voltage sensing without PT’s up
to 520 volts was added, also new DIP & TRIM
adjustment compatible with many automatic
paralleling and PF controllers in the market. The
new CPU design makes the ADVR-12 exceedingly
stable, however keeping the analog power circuit for
fast response.
2. SPECIFICATION
Sensing Input 1 or 3 Phase
Voltage 220 / 440VAC 50 / 60Hz
(SW5 Selectable)
180 ~ 260VAC @ 220VAC
330 ~ 520VAC @ 440VAC
Power Input 1Ø or 3Ø
Voltage 100 ~ 300VAC, 40 ~ 500Hz
Output 63VDC @ 110VAC input
125VDC @ 220VAC input
Output
Current Continuous 12ADC
Maximum 25ADC for 10 sec
Frequency
50 / 60Hz (SW4 Selectable)
40 ~ 51Hz @ 50Hz Preset 47Hz
50 ~ 61Hz @ 60Hz Preset 57Hz
Voltage Regulation
< ± 0.5% ( with 4% engine governing )
Voltage Build-up
Residual voltage at AVR terminal > 6 VAC @ 25Hz
Thermal Drift
0.03% per °C change in AVR ambient
Over Excitation Protection
60% of Input Voltage
External Volts Adjustment VR
10K ohm 0.5 watt trimmer
Excitation Resistance
> 10 ohm
Current Compensation
1 or 5A > 0.2VA
Max ±7% @ P.F ±0.5
Analogue Voltage Input
Un0 ~ 10% @ ±5VDC <2mA
Respond Time
< 1 Cycle
Unit Power Dissipation
Max. 12 watt
Dimensions
214mm L * 163mm W * 45.7mm H
Weight
1130g ± 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
place with high vibrations to prevent loose
connections. For safety do not touch the heat sink
while in operation.
4. Fuse specification：12.5A/500V VF blow type.
Outline and Drilling Diagram
Figure 1
UNIT
S
:
mm

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ADVR-12 3
3. DIP SWITCH ADJUSTMENT (SW)
KW
SW <90KW
90~500KW >500KW
1 OFF ON ON
2 OFF OFF ON
SW ON OFF
3 O/E Deactivated O/E Activated
4 50Hz 60Hz
5 440V 220V
ATTENTION
When 60Hz frequency setting is selected on a
50Hz generator, it could result in under voltage.
When 50Hz frequency setting in selected on a
60Hz generator, it could result in over excitation
current when stopping the generator and cause
sever damage to the generator or AVR.
After adjusting SW1 or 2, the STAB must be
recalibrated to ensure maximum performance.
All adjustment of SW must be conducted when
engine is not in operation.
4. ADJUSTMENT
4.1 VOLT
●Voltage setting adjusting the genset rated output
voltage.
●When SW5 is “OFF” (220V) adjustable range is
175 ~ 260VAC.
●When SW5is “ON” (440V) adjustable range is
350 ~ 520VAC.
●When terminal 7 & 4 are bridged together, volt
adjust is done only on the regulator VOLT pot. But
when using a external 10k volt pot connect to
terminals 7 & 6a and opening terminals 7 & 4
makes the pot on the regulator useless.
ATTENTION
AVR AC voltage readings are all average value.
4.2 STAB
●Adjust STAB fully clockwise, the generator voltage
will begin to fluctuate, whereas if adjust fully
counterclockwise the voltage becomes stable.
●The correct stability setting is at a knee point,
where the voltage is stable yet on the brink of
becoming unstable.
●If Stability is over adjusted, it can result in high
voltage fluctuation when load is connected.
4.3 U/F
Under frequency protection adjustment. When
generator frequency falls below the knee point, the
under frequency protection circuit will begin to
intervene and voltage and frequency begin to
decrease in linear descend. Coordinate with the DIP
switch SW4 frequency selection 50/60Hz.
When selecting 50Hz the adjustable range is from
40 to 51Hz and the factory presets at 47Hz.
When selecting 60Hz the adjustable range is from
50 to 61Hz and the factory presets at 57Hz.
4.4 U/F LED
When under frequency protection is activated, the
RED LED will light up.
4.5 DIP
When under frequency protection is activated, the
voltage droop ratio is adjusted via the DIP VR. The
adjustable range is 3 ~ 10 V/Hz.
4.6 DROOP
Droop adjustment. When paralleling, the AVR
compensate the input rating and voltage shifting
basis on load current, through internal circuit
calculation and increase or decrease the voltage.
When phase current lag the voltage, it decreases
original voltage setting and if the phase current lead
the voltage then it increases the original voltage
setting. The increase and decrease range can be
preset by the DROOP adjustment.
4.7 TRIM
Analogue voltage Input sensitivity. When terminal 2
and 3 is added with a DC input (0 ~ ±5V), the TRIM
is used to adjust the influence level from the DC
input to the rated voltage. If the TRIM potential (POT)
is adjusted fully counter-clockwise, and then the
additional signal will not cause any influence. On the
contrary if the TRIM is adjusted fully clockwise, then
the additional signal will produce a maximum effect.
4.8 O/E
The protection is enabled by selecting DIP SW 3 to
OFF position (Protection disabled when DIP SW 3
select to ON). The O/E voltage setting is at 125VDC
±5V. If generator excitation voltage exceeds the
setting the AVR will shutdown the excitation output
and illuminate the O/E LED. To reset the protection,
stop generator for 30 seconds before restart. The
higher the excitation voltage the faster the AVR
enables the protection from 0.1 ~ 20 seconds.
If O/E is disabled, (DIP SW 3 to OFF position) the
AVR does not shutdown the generator excitation
output but only illuminate the O/E LED.

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4ADVR-12
5. CONNECTION TERMINAL
PIN NO. NOTES
CH GND Ground
2Analogue voltage input
3
4
For onboard voltage adjustment 4 & 7
Shorted
For external voltage adjustment (Connect
10Kohm VR to 6a &7) 4& 7Open
5CT (Current Transformer) 1A input
5a CT (Current Transformer) 5A input
6CT (Current Transformer) common
6a Bridge selection common
7
For onboard voltage adjustment 4 & 7
Shorted
For external voltage adjustment (Connect
10Kohm VR to 6a &7) 4& 7Open
8Null
99 & 6a Open for single phase sensing
20 R phase sensing input
22 S phase sensing input
26 3Ø power input
28 1Ø or 3Ø power input
30 1Ø or 3Ø power input
F1 Positive + excitation output
F2 Negative −excitation output
5.1 Manual excitation / Flash (None PMG
system)
A newly assembled generator, a exciter with
incorrect polarity or with field residual voltage less
than 6VAC, please disconnect the AVR wiring
connection with engine at rest and follow the steps
below :
●Series a limiting resistor at F1 (Positive) & F2
(Negative) and apply a DC input (Do not exceed
24VDC). The resistance is 1ohm per volt with 1
watt per volt at power.
For example : If the DC input is 24VDC with
24ohm the resistor should be 24 watt.
●Remove DC power input from exciter after 5
seconds.
●Reconnect wiring.
●Start up engine, and if the measured residual
voltage is still below 6Vac, repeat step 1 and 2.
5.2 Under frequency protection Knee point
setting
50Hz adjustable range 40 ~ 51Hz
Factory preset at 47Hz
60Hz adjustable range 50 ~ 61Hz
Factory preset at 57Hz
Adjustment steps as follow :
●From DIP select generator frequency.
●Startup generator and adjust to rated speed.
●Adjust UF VR to maximum (Clockwise), adjust
voltage to rated.
●Decrease engine speed to required knee point
activation frequency.
●Slowly ad SW4 just UF VR counterclockwise until
voltage begins to decrease (UF LED illuminates).
The under frequency protection only activate
when generator frequency falls under the knee
point setting, to prevent AVR from over excitation
and causing damage. The V/Hz decrease margin
is adjusted via DIP VR.
5.3 Wiring
1. Power Input (26, 28, 30)
●Terminals 26, 28, 30 are for 3 phase power input
and terminals 28, 30 are for single phase power
input. The input voltage 100 ~ 300VAC, 40 ~ 500Hz
from PMG, Auxiliary winding, generator power input.
●If a switch is required to shutdown the excitation
output, add a switch at terminals 26, 28, 30 to
shut down AVR power.
2. Sensing Input (20, 22, 24)
●20, 22 are used for single phase sensing input.
●In a single phase sensing, terminals 9, 6a need to
be opened. Terminals 22, 24 need to be shorted
and connect sensing input to terminals 20, 22,
incorporating the DIP SW5 voltage setting.
●In a 220V SHUNT type generator, the power input
and sensing input can be combined together.

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ADVR-12 5
3. Analogue Voltage Input (2, 3)
●Terminal 2 & 3 are Analogue Voltage Input, for
connecting to remote voltage control (Paralleling
Controller) of Var / PFC (Power Factor Controller).
●When TRIM is adjust to maximum, entering
±5VDC will effectively change the generator’s
rated voltage by 10%, and if adjust to minimum,
the analogue voltage input becomes ineffective.
4. Droop Compensation (5, 5a, 6)
●When paralleling, connecting a N : 1A CT at
terminal 5 & 6 or connection a N : 5A CT at
terminal 5a & 6 enables DROOP VR to adjust the
generator voltage droop rate (Adjust clockwise to
increase).
The CT must never install on the same phase as
the sensing input (Terminal 20 & 22).
●Circuit Voltage Compensation.
If CT input signal is reversed (K, L), it can
become current compensation for the generator
output, therefore the generator will voltage
increase with the load current. The increase ratio
is adjusted via the DROOP VR (Adjust clockwise
to increase).
5. External VR (7, 6a)
●Terminal 4 & 7 must be shorted if external voltage
adjustment is not required.
●When external voltage adjustment is required,
connect one 10K ohm 1/2W VR to terminal 7 &
6a (The onboard VR then becomes ineffective).
WARNING
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.
Figure 2 Single Phase Sensing
22 & 24 Shorted, 20 & 22 Input (6a & 9 Open) Figure 3 Auxiliary Winding Single Phase 28 & 30, 3 Phase 26, 28 & 30
Figure 4 PMG
Single Phase 28 & 30, 3 Phase 26, 28 & 30 Figure 5 Voltage Adjustment Without External VR 4 & 7 Shorted
With External VR (6a & 7) 4 & 7 Open

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6ADVR-12
Figure 6 CT Input
5 & 6 for 1Amps, 5a & 6 for 5Amps
ADVR-12 Testing Procedure :
1.Setup ADVR-12 as shown in Figure 7. and switch
SW5 to OFF position.
2.Turn VOLT VR fully counterclockwise then
connect to power. Lamp should be off at this time.
3.Slowly adjust VOLT VR clockwise, the lamp will
illuminate, then adjust counterclockwise the lamp
should turn off.
4.If lamp is constantly illuminating or unable to
illuminate then change to another AVR.
Figure 7 AVR Testing Wiring Diagram
Figure 8 PMG Wiring Diagram
If generator rated voltage differs from ADVR-12 :
sensing voltage, add PT1
CT = 1A connect to 5 & 6, CT = 5A connect to 5a & 6
Figure 9 AUX. Wiring Diagram
If generator rated voltage differs from ADVR-12 :
sensing voltage, add PT1
power input voltage, add PT2
CT = 1A connect to 5 & 6, CT = 5A connect to 5a & 6
※Use only original supplied spare protection fuse for fuse replacement.
※Please accept our sincere apology if any modification in performance, specification or appearance is
made without prior notice.

T7
T8
PMG
Almost all Cat generators even if they work at 480/277v are sensing at 240Volts
So be careful how you set up Voltage sensing on the ADVR-12 SW -5
T9
Use Jumper for 3 Phase sensing
Open for single Phase sensing
Terminals 2 & 3 are normally not
used. But come in handy if you
need to correct PF.
SW1 & SW2 SET GENERATOR SIZE (see Manual)
SW3 OFF (Over Excitation Protection ON SW3 ON (Over Excitation Removed)
SW4 OFF (60Hz) ON (50Hz)
SW5 OFF (220V) ON (480 V) Sensing
When using Single Phase Sensing
Jumper 22 and 24 and remove
Jumper from 6a to 9
L1
L2
L3
Connect 10k Ohm remote voltage
adjust from 6a to 7 and remove bridge
from 4 and 7. Keep bridge when using
internal voltage adjust
6a
7
10k
CT
1A 5A

No more then 300Vac on
the power input terminals
T7
L1
Almost all Cat generators even if they work at 480/277v are sensing at 240Volts
So be careful how you set up Voltage sensing on the ADVR-12 SW -5
T8
T9
Use Jumper for 3 Phase sensing
Open for single Phase sensing
Terminals 2 & 3 are normally not
used. But come in handy if you
need to correct PF.
SW1 & SW2 SET GENERATOR SIZE (see Manual)
SW3 OFF (Over Excitation Protection ON SW3 ON (Over Excitation Removed)
SW4 OFF (60Hz) ON (50Hz)
SW5 OFF (220V) ON (480 V) Sensing
When using Single Phase Sensing
Jumper 22 and 24 and remove
Jumper from 6a to 9
L2
L3
Connect 10k Ohm remote voltage
adjust from 6a to 7 and remove bridge
from 4 and 7. Keep bridge when using
internal voltage adjust
6a
7
10k
CT
1A 5A

Terminals 2 & 3 are normally not
used. But come in handy if you
need to correct PF.
SW1 & SW2 SET GENERATOR SIZE (see Manual)
SW3 OFF (Over Excitation Protection ON SW3 ON (Over Excitation Removed)
SW4 OFF (60Hz) ON (50Hz)
SW5 OFF (220V) ON (480 V) Sensing
When using Single Phase Sensing
Jumper 22 and 24 and remove
Jumper from 6a to 9
Connect 10k Ohm remote voltage
adjust from 6a to 7 and remove bridge
from 4 and 7. Keep bridge when using
internal voltage adjust
6a
7
10k
CT
1A 5A
L1
L2
Remove Jumper from 6a to 9
for Single Phase sensing
240/120Vac
Field

Set SW 1 & 2 to Proper Genset Size
Set SW 3 to OFF Activate O/E -- ON Deactivate (when Paralleling) O/E
Set SW 4 to OFF for 60 Hz ON for 50 Hz
Set SW 5 to OFF Cat genset always sense at 220 V
P12 = 12 Pin Plug
P6 = 6 Pin Plug
Adupter plugs for digital regulator