New Age EA440 User manual

EA440
Generator Automatic Voltage Regulator
Operation Manual
Self Excited Automatic Voltage Regulator
Compatible with Newage SX440*
* Use for reference purpose only and not a genuine Newage product.

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2EA440
1. SPECIFICATION
Sensing Input
Voltage 190 ~ 264 VAC, 1 phase 2 wire
Frequency 50 / 60 Hz, selectable
Output
Voltage Max. 90 VDC @ 207 VAC
Current Continuous 4A
Intermittent 10A for 10 sec.
Resistance Min. 15 ohm
Voltage Regulation
< ± 1% ( with 4% engine governing )
Voltage Build-up
Residual voltage at AVR terminal > 5 VAC
Thermal Drift
0.05% per
°
C change in AVR ambient
External Volts Adjustment
±8% with 1K ohm 1 watt trimmer
Unit Power Dissipation
Max. 12 watt
Under Frequency Protection (Factory Setting)
Set point 95% Hz
Slope 170% down to 30 Hz
Soft Start Ramp Time
2 sec.
Analogue Input
Sensitivity 1V for 5% generator volts
Input Resistance 1K ohm
Max. Input ± 5 VDC
Quadrature Droop Input
Burden 10 ohm
Max sensitivity 0.07 A for 5% droop (PF=0)
Max. input 0.33 A
Dimensions
150mm L * 135mm W * 40mm H
Weight
418g ± 2%
2. WIRING
1. K1, K2 : Field input external switch terminals.
Linked for normal operation.
2. P2, P3 : External power input terminals.
3. 3, 2 : Sensing input terminals.
4. 1, 2 : External VR terminals. Linked for useless.
5. X,XX : X connect to field (+), XX connect to field (-).
6. S1, S2 : Droop CT input terminal.
7. A1, A2 : VAR/PF controller input.
8. A, B, C : Link A, C for under 90KW.
Link B, C for 90 ~ 550KW.
Link A, B for over 550KW.
9. J1~J8 : Jump select terminals, 2-3,4-5,6-7. please
refer to Figure 2 and Figure 3.
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 (1KΩ) 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 ~ 53Hz or 60~63Hz.
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.

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EA440 3
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 fullyanticlockwise there is no droop.
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.
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 no more than 3~12
VDC with Positive to X and Negative to XX, 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. Disconnect the AVR AC power input terminals
and restart the generator, re-measure the
residual voltage. If this voltage is greater than
5VAC, reconnect voltage regulator, and voltage
build-up should be successful. If measured less
than 5VAC, repeat steps 1 and 2.
4. If residual voltage is greater than 5VAC, but AVR
still unable to build up voltage, please replace
with another AVR.
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.
5. PARALLEL FUNCTION
5.1 Parallel Compensation
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.
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
1. For reactive droop compensation, connect the
CT to it’s respective regulator as shown on
Figures 3.
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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4EA440
6. TROUBLE SHOOTING
SYMPTOM CAUSE CORRECTION
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
Out voltage low 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
Out voltage high AVR adjustment not well Please refer to voltage adjustment page
Defective Generator Please refer to the Generator Manual
※
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.
STAB
DROOP
TRIM
UFRO
LED
High Temperature
VOLT
C B A
C-A < 90KW
C-B 90-550KW
B-A > 550KW
Figure 1 Outline Drawing
UNITS : mm
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.
Figure 2 Bypass Drawing Figure 3 Wiring Drawing