Nidec Leroy-Somer R180 Instruction Manual

R180
AVR
Installation and maintenance

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Installation and maintenance
R180
AVR
5599 en -
SAFETY MEASURES
Before using your machine for the rst time,
it is important to read the whole of this
installation and maintenance manual.
All necessary operations and interventions
on this machine must be performed by a
qualied technician.
Our technical support service will be pleased
to provide any additional information you
may require.
The various operations described in this
manual are accompanied by recommenda-
tions or symbols to alert the user to potential
risks of accidents. It is vital that you unders-
tand and take notice of the following warning
symbols.
Warning symbol for an operation capable
of damaging or destroying the machine
or surrounding equipment.
Warning symbol for general danger to
personnel.
Warning symbol for electrical danger to
personnel.
All servicing or repair operations perfor-
med on the AVR should be undertaken by
personnel trained in the commissioning,
servicing and maintenance of electrical
and mechanical components.
When the generator is driven at a
frequency below 28 Hz for more than 30
seconds with an analogue AVR, its AC
power supply must be disconnected.
WARNING
This AVR can be incorporated in a EC-
marked machine.
This manual is to be given to the end
user.
© - We reserve the right to modify the
characteristics of this product at any time in
order to incorporate the latest technological
developments. The information contained in
this document may therefore be changed
without notice.
This document may not be reproduced in
any form without prior authorisation.
All brands and models have been registered
and patents applied for.
WARNING
This manual concerns the alternator AVR which you have just purchased.
We wish to draw your attention to the contents of this maintenance manual.

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CONTENTS
1 - GENERAL DESCRIPTION.................................................................................................4
2 - AVR PARAMETERS...........................................................................................................5
3 - TECHNICAL SPECIFICATION...........................................................................................6
4 - MAIN FUNCTION OF THE AVR .........................................................................................7
4.1 - Connection diagram for low voltage range.....................................................................7
4.2 - Connection diagram for high voltage range with droop powered by AREP.....................8
4.3 - Connection diagram for high voltage range with droop powered by PMG...................... 9
5 - AVR SETTINGS................................................................................................................10
6 - TROUBLESHOOTING CHART........................................................................................ 11
7 - MULTIMETER TEST ........................................................................................................12
8 - STATIC TEST PROCEDURE ...........................................................................................13
8.1 - Test equipment ............................................................................................................13
8.2 - Connection ..................................................................................................................13
8.3 - Test procedure.............................................................................................................14
9 - DIMENSIONS...................................................................................................................15
10 - SPARE PARTS ..............................................................................................................16
10.1 - Designation ...............................................................................................................16
10.2 - Technical support service ..........................................................................................16
Disposal and recycling instructions

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1 - GENERAL DESCRIPTION
The R180 is a fully solid-state automatic
voltage regulator (AVR) which is used for
excitation of a brushless alternator powered
by a Permanent-Magnet (PMG) exciter or
by auxiliary windings.
The alternator voltage between phases V-W
is sampled, processed and converted to a
direct current value. This signal is compared
to the reference value which is internally
generated depending upon the voltage
setting. The comparison is made by a PID
controller, which controls the alternator
excitation. The power circuit uses a pulse
width modulated (PWM) IGBT circuit to
adjust the eld current, which gives a good
dynamic/transient response.
It takes a 1 and 5 A signal from a droop
current transformer in U phase to give a
voltage droop which allows the alternator to
operate in parallel.
The R180 has an accessory input, which
can be used as a remote potentiometer
terminal when connected to a 1 KΩ
potentiometer or takes ± 4.5 VDC in order to
change the terminal voltage.
It has an under frequency voltage roll-off
function to prevent alternator overuxing in
the event of underspeed operation. The
AVR has a potentiometer for setting the
knee-point for under frequency roll-off and
a 50 Hz/60 Hz selection jumper. This jumper
makes it easy to select the AVR frequency
for a 50 Hz/60 Hz alternator.
The AVR output is limited to 6 A. This limiter
is delayed type so that it does not interfere
with eld forcing. In the event of loss of the
sensing input, the AVR provides 9 A DC
excitation current for 5 seconds and
reduces the excitation current.
The R180 is triggered from the alternator
remanent voltage.

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2 - AVR PARAMETERS
UFRO selection link
Open - 60 Hz operating mode.
Closed - 50 Hz operating mode.
UFRO potentiometer
45 Hz to 55 Hz in 50 Hz mode.
55 Hz to 65 Hz in 60 Hz mode.
Voltage
The working voltage is set by the
potentiometer marked “V”.
Droop
The quadrature droop is set by the
potentiometer marked “Droop”.
Auxiliary input and external potentio-
meter range
The auxiliary input range is set by the
potentiometer marked “Acc”. This
potentiometer sets the maximum voltage
range for the external potentiometer or the
auxiliary input range.
Stability
This potentiometer is used to set the
alternator output voltage stability. Turning it
clockwise increases the speed. The setting
is reached when the stability potentiometer
position (set CW) allow to be at the starting
of a voltage instability, then set the
potentiometer 1 turn below (set CCW).
Indications
- Over Excitation limit
- Loss of sensing voltage
- UFRO
0V

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3 - TECHNICAL SPECIFICATION
1 Sensing input 3-ph/2-ph - 220/230/240/380/400/415 volts for
50 Hz
3-ph/2-ph - 208/240/277/380/416/440/480 Volts for
60 Hz
2 Voltage range High 300 V to 530 V
3 Voltage range Low 180 V to 310 V
4 Droop 1 and 5 A AC in U phase
5 Droop range 8% droop at 0.8 PF
6 PMG input power Continuous: 240 V RMS +10%
Momentary 5 s: 240 V RMS + 30
Up to 240 Hz
7 AREP input power Continuous: 250 V peak+10%
Momentary 10 s: 350 V peak +5% - Up to 75 Hz
8 Excitation current 6 A DC continuous
9 A for 5 seconds (short-circuit operation)
9 Regulation ± 1% at AVR sensing terminals
10 Maximum excitation limit 6 A DC (factory setting)
11 Maximum excitation limit
delay
30 sec. (factory setting)
12 Under frequency protection 48.5 Hz/58.5 Hz for 50 Hz/60 Hz operation
13 Slope 1.2X (120%) V/Hz
14 Remote potentiometer 1 kOhm for ± 10% adjustment
15 Accessory Input ± 4.5 VDC for ±15%
16 Loss of sensing Shuts down after 5 sec. when sensing open
17 Weight 500 g approximate
18 Dimensions 140 mm x 115 mm x 70 mm
19 Temperature range -25ºC to +70ºC
20 Storage temperature range -40ºC to +80ºC
21 Thermal drift 0.5% for 20ºC change
22 Fuse FST 10A 250V

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4 - MAIN FUNCTION OF THE AVR
4.1 - Connection diagram for low voltage range
0V

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AVR
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4.2 - Connection diagram for high voltage range with droop powered by AREP
0V

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4.3 - Connection diagram for high voltage range with droop powered by PMG
0V

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5 - AVR SETTINGS
WARNING! TO PREVENT ELECTRIC
SHOCK AND PERSONAL INJURY, CARE
MUST BE TAKEN NOT TO TOUCH LIVE
PARTS.
CAUTION! ADJUSTMENTS MUST BE
DONE CAREFULLY AND GRADUALLY
WHILE THE ALTERNATOR IS RUNNING
OTHERWISE THE SYSTEM MAY
EXPERIENCE FLUCTUATIONS.
- VOLT : Full CCW
- STAB : Centre of travel
- UFRO : Select 50 Hz or 60 Hz mode
Start-up
- Check all settings are as per the paragraph
“Initial Settings”.
- Start the prime mover and bring the
alternator up to rated speed (rpm).
- The voltage at the terminals will show
voltage build-up.
- Adjust the voltage at the terminals using
the voltage adjustment potentiometer.
- If oscillations are seen on the voltmeter
(A.C.) indicating the alternator terminal
voltage, gradually turn the “STABILITY”
trimmer on the R180 clockwise and stop
turning it at the position where the
oscillations disappear.
- If oscillations are not seen on voltage
build-up, turn the “STABILITY” trimmer
anticlockwise till oscillations appear and
then slightly turn it clockwise to remove
any oscillation. This will help tune the
controller and alternator time constants.
- Set the Ufro knee point at 47.5 Hz for 50 Hz
or 57 Hz for 60 Hz.
- If an external voltage adjustment
potentiometer is required, stop the alternator
and connect a 1 kOhm potentiometer in
place of the link at terminals A1 and A2.
- If droop is required, connect the droop
current transformer at terminals Q1 and Q2.

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6 - TROUBLESHOOTING CHART
Symptom Cause Action
No voltage
build-up
Fuse links blown Change the fuse links.
Low residual voltage across
X1 and X2 terminals
Run alternator at correct rpm. If the problem
persists, disconnect the AVR and connect a
24 VDC battery between F1 and F2. This action
will increase the residual voltage.
Reconnect AVR.
Incorrect wiring Check the wiring complies with the wiring diagram
and repair if necessary.
Voltmeter defective Replace the voltmeter
Faulty AVR Replace the AVR
Voltage too high Incorrect voltage setting Set the voltage to the required value
Faulty AVR Replace the AVR
Low voltage External potentiometer link
open
Connect link or potentiometer as necessary
Loss of sensing voltage Connect as per the diagram
Prime mover rpm falls Set rpm
Incorrect
regulation
Prime mover rpm falls Set rpm
Highly distorted non-linear
load
Reduce non-linear load
Alternator running on very low
P. F.
P.F. correction required
Unbalanced load Redistribute the load equally over all three phases.
Faulty AVR Replace the AVR
Rotating diodes failed Replace the diodes
Droop connected Remove droop connection if not needed
Voltage unstable Incorrect wiring Check and repair the wiring. Make sure that the
contacts are screwed in tightly
Stability setting incorrect Adjust the stability potentiometer
Voltage builds-up
but collapses/
erratic behaviour
Incorrect wiring Check and repair the wiring. Make sure that the
contacts are screwed in tightly
Incorrect circuit board settings Set as per instructions in the manual

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7 - MULTIMETER TEST
WARNING
The freewheel diode can be tested by a
digital multimeter in diode tester mode.
Connect the red lead to F2 and the black
lead on the multimeter to F1. The multimeter
will display 0.4 V to 0.6 V in diode test mode
if the freewheel diode is OK. 0 V or OL on the
multimeter indicates a faulty freewheel
diode.
IGBT Tab is connected to +DC bus and A1 is
connected to -DC bus on the AVR.
These two connections can be used to test
the IGBT and input bridge connected at X1,
X2, Z1 and Z2.
Connect the multimeter black lead to IGBT
Tab.
Connect the red lead to X1.
The multimeter will display 0.4 V to 0.6 V
Connect the red lead to X2.
The multimeter will display 0.4 V to 0.6 V
Connect the red lead to Z1.
The multimeter will display 0.4 V to 0.6 V
Connect the red lead to Z2.
The multimeter will display 0.4 V to 0.6 V
Connect the red lead to A1 and
connect the black lead to X1.
The multimeter will display 0.4 V to 0.6 V
Connect the black lead to X2.
The multimeter will display 0.4 V to 0.6 V
Connect the black lead to Z1.
The multimeter will display 0.4 V to 0.6 V
Connect the black lead to Z2.
The multimeter will display 0.4 V to 0.6 V
If the multimeter displays 0 V or OL in diode
test, the bridge rectier diodes are faulty.
If the fuses are open, X1 and Z2 will display
OL in diode test mode.
If IGBT Tab and F1 display 0 ohm, the IGBT
is faulty.
Sensing input resistance test
Resistance between V and A1:
1.3 MΩ approx.
Resistance between L1 and A1:
1 MΩ approx.
Resistance between L2 and A1:
1 MΩ approx.
Resistance between W and A1:
1.3 MΩ approx.

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8 - STATIC TEST PROCEDURE
8.1 - Test equipment
- 3-phase variac
- AC/DC voltmeter
- 100 Watt bulb
- 1 K potentiometer
- 250 V/110 V transformer
8.2 - Connection
- Connect the 100 W bulb between the F1
and F2 terminals on the AVR
- Connect the 110 V transformer output to
X1 and X2 on the AVR
- Connect the 250 V end of the transformer
to U and N on the variac
- V output on the variac to V terminal on
the AVR
- W on the variac to W terminal on the AVR
- Connect the 1 KΩ potentiometer to A1
and A2

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8.3 - Test procedure
1. Build-up test
To test build-up, start the variac at 0 volts
and set the output voltage to around 5 VAC
between X1 and X2. If the AVR is OK, the DC
voltmeter will display a stable value between
terminals F1 and F2 on the AVR which will
increase as the input power increases.
2. Voltage control test
The default AVR voltage setpoint is around
415 VAC. The bulb should remain ON for a
supply voltage level below the setpoint i.e.
around 415 VAC and should turn OFF when
the input voltage is increased above the
setpoint by the variac. The bulb transition
will be gradual because the AVR is stable.
3. External potentiometer test
Connect the 1 K potentiometer between
terminals A1 and A2. The external
potentiometer will allow the setpoint to drop
to 330 V from 415 V (minimum and maximum
positions). This can be veried by the
voltage control test described above.
4. UFRO test
Set the variac output voltage to 400 VAC.
The bulb will up light because the setpoint is
415 V. Now turn on the switch which is
connected to the 50 Hz/60 Hz input. The
bulb will gradually go OFF due to the change
in the UFRO setpoint. If the switch is turned
OFF the bulb will light up again. In 60 Hz
mode the UFRO LED will light up.
5. Sensing loss test
Open connection W on the AVR terminal
and start the AVR at 400 V. The sensing loss
LED will light up and the bulb will be ON for
5 sec and then switch OFF.
6. Stability test
The bulb dimming rate during the voltage
control test depends upon the AVR stability
setting. At minimum stability, the bulb will
switch ON and OFF around the voltage
setpoint. A higher stability setting will
decrease the speed of bulb dimming and
brightening.
7. Voltage range
The AVR voltage range can be checked by
performing a voltage control test for V
potentiometer min and V potentiometer
max. This test gives the approximate voltage
range values.
8. UFRO test
The UFRO factory setpoint is around
47.5 Hz. Set the variac output to 410 VAC.
Turn the UFRO potentiometer clockwise
until the UFRO LED turns ON. One more
clockwise turn of the UFRO potentiometer
will gradually switch OFF the bulb.

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147
115
90
56.5
11 16
117
159
142
Installation and maintenance
R180
AVR
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9 - DIMENSIONS
TOP VIEW
SIDE VIEW

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10 - SPARE PARTS
10.1 - Designation
Description Type Code
AVR R180 5089747
10.2 - Technical support service
Our technical support service will be
pleased to provide any additional
information you may require.
For all spare parts orders or technical
support requests, send your request to
[e-mail] or your
nearest contact, whom you will nd at
www.lrsm.co/support indicating the type
and the code number of the AVR.
To ensure that our products operate correctly
and safely, we recommend the use of
original manufacturer spare parts.
In the event of failure to comply with this
advice, the manufacturer cannot be held
responsible for any damage.

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Disposal and recycling instructions
We are committed limiting the
environmental impact of our activity. We
continuously monitor our production
processes, material sourcing and products
design to improve recyclability and minimise
our environmental footprint.
These instructions are for information
purposes only. It is the user’s responsibility
to comply with local legislation regarding
product disposal and recycling.
Waste & hazardous materials
The following components and materials
require special treatment and must be
separated from the alternator before the
recycling process:
- electronic materials found in the terminal
box, including the automatic voltage
regulator (198), current transformers (176),
interference suppression module (199) and
other semi-conductors.
- diode bridge (343) and surge suppressor
(347), found on the alternator rotor.
- major plastic components, such as the
terminal box structure on some products.
These components are usually marked with
information concerning the type of plastic.

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[e-mail] www.lrsm.co/support
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Our worldwide service network of over 80 facilities is at your service.
This local presence is our guarantee for fast and efcient repair, support and
maintenance services.
Trust your alternator maintenance and support to electric power generation experts.
Our eld personnel are 100% qualied and fully trained to operate in all environments
and on all machine types.
We have a deep understanding of alternator operation, providing the best value
service to optimise your cost of ownership.
Where we can help:
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5599 en
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