Power-Tronics XR500B User manual

XR500B
Universal Voltage Regulator
The XR500B is a unique voltage
regulator that is designed specifically
for Professional Electrical Generator
Service and Repair Technicians.
The XR500B incorporates patented
electronic circuitry that allows an
installer to match the regulator to many
differing configurations of exciters
without special transformers or inline
resistors.
The XR500B can be externally
controlled with a PLC or Genset
controller by simply adding an optional
interface module.
Specifications
Input Volts: 120 / 208 or 240acv
Frequency: 50 or 60hz
Voltage Regulation: +/- 1% From NL to FL
Parallel Operation Yes
Output Volts: 0-52vdc @ 120vac input
0-105vdc @ 240vac input
0-210vdc @ 240vac input
Maximum Continuous Output: 5adc
Minimum Field Resistance: 10.5Ω@ 52vdc output
21Ω@ 105vdc output
42Ω@ 210vdc output
Min Residual Build up Volts: 3.5vac
Physical Size: 4.75 x 6 x 1 in.
Weight: 7 oz
Repairable: Yes
Internal Protection: Fuses
External Voltage Adjustment: Yes
System Operating Indicator: Yes
Optional Static Exciter Modules Yes
Optional External Controls Yes

2
Caution: Read this Installation
Manual carefully.
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! Make sure that all setup is done
off line. Always wear eye protection and never hold the regulator in your hand when
energized.
The XR500B is a Universal Voltage Regulator that can be configured several different
ways to fit differing applications. Before selecting a wiring configuration for the
regulator, you must know certain pieces of information about the generator and exciter
to be successful in determining the correct hookup for the regulator. Show below is a
guide to determine the correct connection of the regulator:
•Exciter field resistance is more than 40 ohms and exciter full load voltage is
rated at 125vdc or less. (Use connection A)
•Exciter field resistance is more than 21 ohms and exciter full load voltage is
rated at 63vdc or less. (Use connection B)
•Exciter field resistance is more than 10 ohms and exciter full load voltage is
rated at 32vdc or less. (Use connection C)
1 2 3 4 5 6 7 8
N
Generator
AØ
BØ
CØ
Do not connect the
input of the
voltage regulator
to DPE or auxiliary
windings!
!
F+
F-
208-240vac
208-240vac
Connection A
XR500B Universal Voltage Regulator
Note:
It is not necessary to jumper 7 and 8
terminals if not using the Remote
Voltage Adjustment!
Remote
Voltage
Adjustment
100K @ 1w
If this generator is going to operate at a speed lower than 50/60 Hz, a
disconnect or switch should be placed in series from the generator stator
to terminal #1 and #2 on the XR500B.
For 480vac, either use a
transformer with a 240vac
secondary or center tap the
generator windings. At T7 and
T8.

3
1 2 3 4 5 6 7 8
N
Generator
AØ
BØ
CØ
Do not connect the
input of the
voltage regulator
to DPE or auxiliary
windings!
!
F+
F-
208-240vac
208-240vac
Connection B
XR500B Universal Voltage Regulator
Note:
It is not necessary to jumper 7 and 8
terminals if not using the Remote
Voltage Adjustment!
Remote
Voltage
Adjustment
100K @ 1w
1 2 3 4 5 6 7 8
N
Generator
AØ
BØ
CØ
Do not connect the
input of the
voltage regulator
to DPE or auxiliary
windings!
!
F+
F-
120-139vac
208-240vac
Connection C
XR500B Universal Voltage Regulator
Note:
It is not necessary to jumper 7 and 8
terminals if not using the Remote
Voltage Adjustment!
Remote
Voltage
Adjustment
100K @ 1w
If this generator is going to operate at a speed lower than 50/60 Hz, a
disconnect or switch should be placed in series from the generator stator
to terminal #1 and #2 on the XR500B.
If this generator is going to operate at a speed lower than 50/60 Hz, a
disconnect or switch should be placed in series from the generator stator
to terminal #1 on the XR500B.
For 480vac,use a transformer
with a 120vac secondary.
For 480vac, either use a
transformer with a 240vac
secondary or center tap the
generator windings. At T7 and
T8.

4
Installation and setup
1. Install the regulator and wire up to the correct wiring diagram.
2. Turn the internal voltage control and stability control 15 or more turns counter
clockwise (left). This procedure is necessary in case the original factory settings
have been altered.
3. If you are using a remote voltage adjustment, set it at 50% of adjustment.
4. Start up the prime mover and bring up to operating speed and turn on the
regulator switch. (if used)
5. Set the internal voltage adjustment to the desired voltage setting for the
generator output. If the generator voltage is unsteady or flickering, adjust the
stability adjustment clockwise (right) until the voltage is steady and the green
light is not pulsating. During this adjustment, be sure to keep the generator
voltage within 10vac of the original setting with the internal voltage adjustment.
6. Place the generator on line and observe the frequency and voltage.
Internal
voltage
adjustment
Stability
adjustment

5
Application Troubleshooting
Problem: Possible Cause
No Voltage 1 3 5 7 9 11 13 15 20
Pulsating Voltage 4 5 6 12 16
Flickering Voltage 6 7 14 4
High Voltage 6 7 8 9 12 13 17 18 20
Voltage Drop on Load 5 8 10 12 16
Low Voltage 5 8 12 13
Poor Voltage Regulation 2 4 10 12 13 16
No Voltage Control 13 19 20
Possible Cause:
1. Residual input voltage to the voltage regulator is below 3.5vac or fuses are open in the regulator.
2. Unbalanced generator load.
3. Open exciter field or defective generator.
4. Stability adjustment is not properly adjusted.
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. Stability adjustment is set too far clockwise.
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.

6
19. Input and field circuit are being fed by a common cable or conduit.
20. Incorrect hookup or wiring.
Fuse Replacement
•Remove the 2 screws located on the front of the mounting can near the
terminal board.
•Loosen the 2 screws located on the front of the mounting can near the
voltage and stability adjustment holes. (DO NOT REMOVE!)
•Partially separate the top of the regulator printed circuit card from the
mounting housing. (Separate just enough to reach and replace the fuses)
•Replace open fuses and re-tighten all screws.
•Fuse size is 20mm x 5mm, 5 amps @ 250vac. (DO NOT REPLACE WITH
ANY OTHER TYPE AND RATING OF FUSE! SEVERE DAMAGE AND
PERSONAL INJURY COULD RESULT BY DOING SO!)

7
Installation 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.
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:

8
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 purchase receipt 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 through 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.
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 on any external device other than manufactured by Power-Tronics, Inc.
No other warranty is expressed or implied.

9
Bench Check Instructions
1. Wire up the regulator as shown in figure A.
1. Connect up a 120 volt 50 to 150 watt light bulb to the F+ and F- Terminals.
2. Adjust the internal voltage and stability pots fully CCW (25 turns) or until a click is heard.
3. Input 120vac into the regulator at #1 and #2. (Fuse this input with fuses rated at 120 volts
or higher and not more than 5 amps ac )
4. Observation: The green status light should be on and the light bulb across F+ and F-
should be off. If the green status light is not on, the internal fuses are blown in the regulator
or there is internal damage to the regulator! If the green status light is not on, do not
continue this test!
5. Turn the internal voltage adjustment CW until the light bulb across F+ and F- turns fully on,
then adjust the internal voltage adjustment CCW until the light bulb is very dim.
6. Adjust the stability adjustment CW until the light bulb begins to brighten up.
7. Turn both of the internal voltage and stability pots fully CCW (25 turns ) or until a click is
heard.
8. Remove the 120vac from the regulator.
9. Connect up the regulator in configuration B and perform all of the previous steps again. In
this mode, the light bulb will only glow at half brilliance!
10. If you were able to successfully perform all of these tests, the regulator is good.
120 vac
F+
F-
1 2 3 4 5 6 7 8
120 vac
F+
F-
1 2 3 4 5 6 7 8
Figure A
Figure B

10
1 2 3 4 5 6 7 8
A
B
C
Generator
XR500B
6 ohm, 100w
Unit / Parallel
switch
Reactive droop
adjustment
Exciter field
Remote voltage
adjustment
100k, 1/2w
Parallel Connections
For The
XR500B Universal Voltage Regulator
(Connection A)
xx/5a CT
1Kva
transformer
for
maximum
output
amperage.
240vac
For stand-alone operation, close the Unit/Parallel
switch.
If the voltage raises during motor loading, reverse the
current transformer leads.
Regulator off/on
+
-

11
1 2 3 4 5 6 7 8
A
B
C
Generator
XR500B
6 ohm, 100w
Unit / Parallel
switch
Reactive droop
adjustment
Exciter field
Remote voltage
adjustment
100k, 1/2w
Parallel Connections
For The
XR500B Universal Voltage Regulator
(Connection B)
xx/5a CT
750va
transformer
for
maximum
output
amperage.
240vac
For stand-alone operation, close the Unit/Parallel
switch.
If the voltage raises during motor loading, reverse the
current transformer leads.
Regulator off/on
+
-

12
1 2 3 4 5 6 7 8
A
B
C
Generator
AC1 AC2 F+ F-
SE350
White
Red
Gray
XR500B
6 ohm, 100w
Unit / Parallel
switch
Regulator off/on
Reactive droop
adjustment
Exciter field
Remote voltage
adjustment
100k, 1/2w
Parallel Connections for the XR500B Universal
Voltage Regulator when used with the SE350 Static
Exciter Module.
xx/5 CT
5kva
transformer
for
maximum
output
amperage.
240vac
For stand-alone operation, close the Unit/Parallel
switch.
If the voltage raises during motor loading, reverse the
current transformer leads.

13
1 2 3 4 5 6 7 8
A
B
C
Generator
AC1 AC2 F+ F-
SE450
White
Red
Gray
XR500B
6 ohm, 100w
Unit / Parallel
switch
Regulator off/on
Reactive droop
adjustment
Exciter field
Remote voltage
adjustment
100k, 1/2w
Parallel Connections for the XR500B Universal
Voltage Regulator when used with the SE450 Static
Exciter Module.
xx/5 CT
5kva
transformer
for
maximum
output
amperage.
240vac
For stand-alone operation, close the Unit/Parallel
switch.
If the voltage raises during motor loading, reverse the
current transformer leads.

14
ARM
Main
Rotor
Shunt Field
Interpole
A1
A2
F1
F2
C2
C1
Rheostat
Or
Voltage
Regulator
ARM
Main
Rotor
Shunt Field
Interpole
A1
A2
F1
F2
C2
C1
Voltage Regulator
F+ and F-
Switch polarity if
buildup does not
occur
Original Wiring
Converted Wiring
Conversion Diagram To Change From Older Shunt Wound Voltage Regulation To Newer
Solid State Voltage VR, UVR And XR Universal Voltage Regulators.

15
XR500B
XR500B-400
UVR501
UVR501-400
UVR500
AFM500X shown connected to an XR or UVR
series Power-Tronics voltage regulator in the
AUTO FLASH configuration.
AFM500X shown connected to an XR or UVR
series Power-Tronics voltage regulator in the
BATTERY FLASH configuration.
B+ 12/24vdc
6
2
5
1
4
3
XR500B
XR500B-400
UVR501
UVR501-400
UVR500
6
2
5
1
10Ω, 100w resistor
PB switch, fuel or oil pressure,
speed switch or relay contact.
Note: Battery negative must be
connected to the generator neutral and
not to the F- of the exciter!
2
3
1
Optional AFM500X Auto Flash Connection Diagram