Power-Tronics AFM500X User manual

© 2012 Power-Tronics, Inc.
The Power-Tronics AFM500X Automatic
Flashing Module is a convenient and
compact optional build up module for all
Power-Tronics UVR and XR series
Universal Voltage Regulators. The
AFM500X offers an automatic flash or
battery flash mode on the same module for
added versatility.
The AFM500X is a unique, automatic
flashing module designed specifically for
generators with very low AC residual
voltage, brush-type generators, and for any
installation where guaranteed buildup is
required. Operation is completely automatic
and installation into a Power-Tronics
regulating system is quick and easy.
The two modes offered by the AFM500X are
automatic flashing and battery flashing.
Automatic flashing uses the existing residual
AC voltage of the generator as a flashing
source, while the battery flashing mode uses
an external battery for it's flashing source.
All inputs are fused to protect any connected
equipment!
Like the rest of our professional line of
products, the AFM500X is fully repairable!
None of the major electronic components
are encapsulated to facilitate prompt repair!
The entire unit is coated in a protective film
to insulate it from any contamination and
moisture that may be present.
The AFM500X Automatic Flashing Module is
compatible with all previous UVR and XR
series Universal Voltage Regulators as well
as select VR series voltage regulators. The
AFM500X is also a very simple upgrade for
installations using older Power-Tronics
BU120/240 or BU500 series buildup
modules!
Specifications
Input Voltage: 120 / 208 or 240vac
Frequency: 50-400Hz
Buildup Pullout Voltage: 85-100vac
Maximum Continuous Output: 5adc
Minimum Field Resistance: 21Ω
Min Residual Build up Voltage: 2vac
Under Frequency Protection: Yes, VPH reduction
Physical Size: 3 x 4 x 1 in.
Weight: 7 oz
Repairable: Yes
Internal Protection: Fuses, cartridge type
AFM500X
Automatic Flashing Module

© 2012 Power-Tronics, Inc.
2
Table of Contents
Introduction and Functional Description:....................................................................3
Determining Which Hookup Configuration to Use:....................................................4
Use With Power-Tronics Optional Static Exciter Modules:........................................5
Automatic Flashing Configuration:..............................................................................6
Battery Flashing Configuration:...................................................................................7
Initial Setup and Commissioning:................................................................................8
Internal Fuse Replacement:..........................................................................................9
Application Troubleshooting:......................................................................................10
Bench Check Procedures:...........................................................................................11
Installation Warranty Form:.........................................................................................12
Product Warranty Certificate:......................................................................................13

© 2012 Power-Tronics, Inc.
3
Introduction and Functional Description
Caution: Read This Installation
Manual Carefully and Entirely!
Warning: Do not use digital equipment to read voltage, Hz, or amperage
during this installation. Use only Analog sensing equipment! Failure to do so
may result in damage to equipment or in personal injury!
ALWAYS perform all setup procedures off-line
ALWAYS wear eye protection
ALWAYS strip wire insulation properly or use insulated connectors
ALWAYS use analog metering equipment when setting up the regulator
ALWAYS ensure the AFM500X receives ample airflow
NEVER hold the AFM500X in your hand when energized
NEVER install the AFM500X in a place it can get wet or is exposed to the elements
NEVER mount the AFM500X over a screw, bolt, rivet, welding seam, or other fastener
NEVER remove the AFM500X backing while the unit is in operation
NEVER insert a screwdriver or other object under the AFM500X
NEVER install a switch in the DC portion of the regulator’s wiring
NEVER touch any exposed part of the AFM500X while in operation
NEVER USE A DIGITAL FREQUENCY METER (It can give a false reading!)
Functional Description
The AFM500X Automatic Flashing Module is a proven design based on industry-standard flashing
procedures and safety policies. The AFM500X provides a very compact automatic flashing or battery
flashing source to any Power-Tronics voltage regulating system quickly, easily, and safely.
When the generator is first energized, the voltage regulator typically begins it's buildup mode where it
brings the generator up to a given point before it goes into it's regulation mode. Sometimes, however, the
generator may have extremely low residual AC voltage or just have a hard time building up. In these
situations, the voltage regulator has a difficult time building up the voltage to a point it can regulate. The
solution in most situations like this is to flash the generator.
The AFM500X provides two modes of flashing: Automatic and Battery. Automatic flashing is often used
on generators with sliprings and brushes and for generators with very low residual AC voltage (typically
less than 3VAC). Battery flashing is more often used on generators with no, or extremely low residual AC
voltage (typically less than 1.5-2VAC) or in installations where a guaranteed buildup is required, such as
hospitals, nursing homes, or correctional facilities.
The AFM500X Automatic Flashing Module is based on time-proven flashing methods and features an
extremely robust and reliable design. Both voltage inputs and battery inputs are fused to protect both the
AFM500X and any connected equipment in the unlikely even of a fault. Because of it's simplicity and
open design, the AFM500X is quickly and easily repaired should the need ever arise.

© 2012 Power-Tronics, Inc.
4
Determining Which Hookup Configuration to Use
STOP! This manual ONLY covers installation of the AFM500X
Automatic Flashing Module! If you are using an optional Static
Exciter Module, the installation of this product does not differ! Refer
to the instructions that came with your optional modules for their
correct wiring hookup.
The AFM500X is configurable for 2 different modes of operation:
Automatic Flashing, and Battery Flashing.
YOU MUST CHOOSE ONE FLASHING METHOD OR THE OTHER!!
NEVER COMBINE THE TWO FLASHING METHODS! SEVERE
DAMAGE WILL RESULT!!!
To determine the proper connection for your generator you need to know the residual
AC voltage of your generator and which type of generator you have.
To determine the residual AC voltage of your generator, run engine with the
voltage regulator turned off and measure the voltage produced at the AC input
terminals of the voltage regulator then refer to the selection chart below:
When you have determined your residual AC voltage, select a Mode
(Automatic or Battery Flash) from the chart below:
•Residual AC voltage is 2VAC or greater, or the generator has only occasional
problems building up voltage. Use Automatic Flash (See Page 7)
•Residual AC voltage is below 2VAC, the generator is a slip ring and brush
type, or guaranteed buildup is required. Use Battery Flash (See Page 8)

© 2012 Power-Tronics, Inc.
5
Use With Power-Tronics Optional Power-Tronics
Static Exciter Modules
The AFM500X Automatic Flashing Module can be used with
Power-Tronics SE350, SE450, SE900 and SEM100A Static
Exciter Modules. When installing the AFM500X in one of
these conditions, you must follow the instructions in this
manual precisely to prevent damage to the AFM500X!
The AFM500X should NEVER be connected directly to
the exciter field when using an optional Static Exciter
Module! Damage to the AFM500X will result!

© 2012 Power-Tronics, Inc.
6
Automatic Flash Configuration
This configuration uses the existing residual AC voltage from the generator stator to
build the terminal voltage to a point that the automatic voltage regulator can take over
and perform its function.
Take special care to follow the wiring directions precisely! DO NOT use the
automatic flash configuration in conjunction with the battery flash configuration!
Note that the maximum input voltage to the AFM500X Automatic Flashing Module
is 240VAC! DO NOT input 277VAC into the AFM500X!Severe damage to the unit
will result! For use on 480V systems, either connect the regulator to the winding center
taps T7 and T8 or use a 480-240V step-down transformer.
NOTE: Wiring from the AFM500X must ALWAYS be connected to the voltage
regulator terminal board regardless of any other optional modules in use!
†Refer to your instructions that came with your Universal Voltage Regulator for the
interconnect diagrams to connect your voltage regulator to your generator.
White
Red
Gray
XR or UVR series Universal Voltage Regulator †
AFM500X

© 2012 Power-Tronics, Inc.
7
Battery Flashing Configuration
This configuration uses an external battery source to build the terminal voltage to a
point that the automatic voltage regulator can take over and perform its function. This
configuration should be used on brush-type generators as well as installations that
require a guaranteed voltage buildup such as hospitals and correctional facilities.
Take special care to follow the wiring directions precisely! DO NOT use the
battery flash configuration in conjunction with the automatic flash configuration!
Note that the maximum input voltage to the AFM500X Automatic Flashing Module
is 240VAC! DO NOT input 277VAC into the AFM500X!Severe damage to the unit
will result! For use on 480V systems, either connect the regulator to the winding center
taps T7 and T8 or use a 480-240V step-down transformer.
NOTE: Wiring from the AFM500X must ALWAYS be connected to the voltage
regulator terminal board regardless of any other optional modules in use!
†Refer to your instructions that came with your Universal Voltage Regulator for the interconnect
diagrams to connect your voltage regulator to your generator.
*Battery Negative must be connected to the generator Neutral or T0 and NOT to F- of the exciter!
White
Red
Gray
XR or UVR series Universal Voltage Regulator †
AFM500X
10Ω, 100W Resistor
Push Button Switch, Fuel or Oil
Pressure Switch, Speed Switch,
or Relay Contact.
Failure to use a switch in this circuit
will result in a discharged battery
when the genset is not running!
*

© 2012 Power-Tronics, Inc.
8
Initial Setup and Commissioning
1. Refer to your voltage regulator’s instruction manual for initial setup and commissioning
of the voltage regulator.
2. If using the Automatic-Flash configuration, follow the initial setup and commissioning
instructions of your voltage regulator as shown in the voltage regulator’s instruction
manual.
3. If using the Battery-Flash configuration, follow the initial setup and commissioning
instructions of your voltage regulator as shown in the voltage regulator’s instruction
manual, except energize or turn on the switch to the AFM500X when you plan to
energize the generator during setup.
4. Observe the buildup operation and verify there is no excessive voltage overshoot and
that the voltage regulator is operating properly.
5. If using the Battery-Flash configuration, always remember to open the switch or relay
contact connected to the AFM500X when shutting the generator down. This will prevent
a drained battery when the generator is stored.
6. When you are satisfied with the buildup performance of the generator, the setup and
commissioning is complete.

© 2012 Power-Tronics, Inc.
9
Fuse Replacement
The AFM500X contains 3 glass cartridge fuses located for quick and convenient
replacement should they blow. To replace the fuses, follow the instructions below.
Fuse size is 20mm x 5mm rated at 5A at 250VAC.
Power-Tronics Part Number: 5R3-403 (Comes as a package of 10 fuses)
Cooper-Bussmann Part Number: BK/GDB-5A
Fuse Replacement Procedure:
(Refer to the image above for easy reference)
•Visually Check each fuse for signs of failure. A melted fuse link or darkened
window will indicate failure. Check each of the 3 fuses for continuity with a
multimeter. They will conduct if good, but will not if open.
•Replace open fuses with exact replacement fuses.
•Fuse size is 20mm x 5mm, 5A @ 250VAC. (DO NOT REPLACE WITH
ANY OTHER TYPE OR RATING OF FUSE! YOU WILL VOID YOUR
WARRANTY AND SEVERE DAMAGE AND PERSONAL INJURY COULD
RESULT BY DOING SO!)
Fuses, 20 x 5mm,
5 amp @ 250vac

© 2012 Power-Tronics, Inc.
10
Application Troubleshooting
Problem: Possible Cause
No Voltage 1 3 5 7 9 11 13 15 20 22
Pulsating Voltage 4 5 6 12 16
Flickering Voltage 4 6 7 14
High Voltage 6 7 8 9 12 13 17 18 20 21
Voltage Drop on Load 5 8 10 12 16
Low Voltage 1 5 8 12 13
Poor Voltage Regulation 2 4 10 12 13 16
No Voltage Control 1 13 19 20 21
Possible Causes:
1. Open or loose connection, poor brush and slip ring contact, fuses are open in the regulator or
AFM500X.
2. Unbalanced generator load.
3. Open exciter field or defective generator.
4. Non linear load or defective connection in exciter field.
5. Open diode in exciter or shorted rotor in generator.
6. Loose component in voltage regulator.
7. Loose wiring connections.
8. Input voltage to regulator is too low.
9. Exciter field is grounded.
10. Non linear load or wrong selection for regulator hookup.
11. Exciter fields are reversed.
12. Wrong selection of regulator wiring configuration.
13. Defective voltage regulator.
14. SCR or Inverter drive effecting generator waveform.
15. Regulator needs external flashing circuit.
16. Isolation transformer is too small.
17. Isolation transformer is needed.
18. Exciter fields are not isolated from other circuits.
19. Input and field circuit are being fed by a common cable or conduit.
20. Incorrect hookup or wiring.
21. Exciter field is grounded.
22. Drained battery (Only applies to Battery-Flash configuration).

© 2012 Power-Tronics, Inc.
11
Bench Check Procedures
NOTE: Testing the AFM500X requires access to a Vari-AC
1. Wire up the AFM500X as shown in Figure A.
2. Connect up a 120 volt 50 to 150 watt light bulb to the #4 and #3 Terminals.
3. Input 120vac from a Vari-AC into the AFM500X at #6 and #5. (Fuse this input with fuses rated at
120 volts or higher and not more than 5 amps ac). Slowly raise the voltage on the Vari-AC to
120VAC.
4. Observation: The light bulb should increase in brightness until you reach approximately 85-
100VAC. At no more than 100VAC, the AFM500X should open the connection to the light bulb
and it should go out. NOTE: Relay chatter during this test is normal!
5. Turn off power to the AFM500X and remove the light bulb from terminals #4 and #3.
6. Connect up the AFM500X as shown in Figure B and perform all of the previous steps again. You
should have the same results as in step 4!
7. If you were able to successfully perform all of these tests, the AFM500X is good.
Figure A
120V 50-150W
Incandescent
120vac
Figure B
12V
Incandescent
120vac

© 2012 Power-Tronics, Inc.
12
Installation Warranty Form
It is very important that you fill out this form completely when installing a voltage
regulator. This form serves as a history record on the application. This form also
contains the information needed by Power-Tronics, Inc., for repair and troubleshooting
of any product you may be having problems with.
Failure to fill out this form during installation will result in a cancellation of
your warranty coverage! Filling out this form takes only minutes but will save
hours or days later on if your product should require service!
Product
Other options
Serial Number
Date of Installation
Type of Generator
Model #
Brush type
[ ]
Brushless
[ ]
AC Stator Information
Wired for
Volts
Phase
Hz
Generator Configuration: Lead
Exciter/Rotor Information
Exciter field
resistance
Ω
@
F+ / F-
Ω
Exciter field volts
vdc
@
Slip Rings
Ω
Description of problem with product or generator
Your phone number
Name:
Your fax number
Ship to Address:
Your email address
Ship to City, State, Zip:

© 2012 Power-Tronics, Inc.
13
PRODUCT WARRANTY
Power-Tronics, Inc., assumes no liability for damages due to incorrect voltage or other voltage
related damages resulting from either output of the generator or input to the generator exciter
system. These problems should be protected with external devices provided by the customer
such as fuses, surge suppressors, over/under voltage and frequency controls.
Power-Tronics, Inc., warranties only parts and workmanship of this product for a period of 2
years from the original date of purchase from Power-Tronics, Inc. Under warranty, Power-
Tronics, Inc. will replace, exchange or repair the defective product without labor or parts cost
to the customer. Remaining warranty of the original product will be transferred to the replaced
or repaired product. To obtain warranty, a copy of the original Installation Warranty Form must
be sent in with the defective product, which clearly shows the purchase date and serial number
of the defective part. A repair request form must be sent in with the product before repairs will
begin. You can obtain this form by contacting Power-Tronics, Inc.
Send repairs to: Power-Tronics, Inc., 2802 Cobbler Ln., Kerrville Texas USA 78028.
Send in repairs only by UPS or FedEx. USPS will NOT deliver to our facility!
Any one of the following conditions will void the warranty:
!Overheating of the power supply resistor on the printed circuit card.
!Overheating of the SCR or freewheeling diode.
!Physical damage to the printed circuit card, housing or components.
!Unauthorized repair or alteration of printed circuit card.
!Installation by anyone other than a qualified professional generator service technician.
!Conductive or corrosive contamination of the circuit card.
!Removal of our company identification from the product.
!Removal of any conformal coating of the printed circuit card or components.
!Overheating of foil on the printed circuit card.
!Inappropriate or infeasible application.
!Use with any external device other than manufactured by Power-Tronics, Inc.
!Failure to fill out the attached warranty card during installation
No other warranty is expressed or implied.