Superior Electric STABILINE WHR5206 User manual

213709-203 Rev. A
EC96068
INSTRUCTIONS
for
STABILINE ®
Automatic Voltage Regulator
WHR5206
Single Phase
240 X 208 Volt
Superior Electric reserves the right to make engineering changes on all its products. Such refinements may affect
information given in the instructions. Therefore, USE ONLY THE INSTRUCTIONS THAT ARE PACKED WITH THE
PRODUCT.
WARNING: High voltages are present inside this unit during operation. Do not operate this unit unless all
covers are in place. Installation and servicing should only be done by qualified personnel.

2
TABLE OF CONTENTS
SECTION PAGE SECTION PAGE
1.0 INSPECTION ................................................ 2
1.1 UNPACKING ......................................... 2
2.0 DESCRIPTION.............................................. 2
2.1 GENERAL ............................................. 2
2.3 THEORY OF OPERATION ................... 2
3.0 INSTALLATION ............................................ 2
3.1 MECHANICAL INSTALLATION ............ 2
3.2 ELECTRICAL INSTALLATION.............. 2
4.0 START UP..................................................... 3
5.0 OPERATION ................................................. 3
5.1 CONTROL MODULE ASSEMBLY ........ 3
5.2 SETTING OUTPUT VOLTAGE AND
SENSITIVITY POTENTIOMETERS...... 3
5.3 REMOTE SENSING.............................. 4
6.0 MAINTENANCE ............................................ 5
7.0 TROUBLESHOOTING.................................. 5
8.0 RATING ......................................................... 7
9.1 POWER RATINGS................................ 7
9.3 GENERAL SPECIFICATIONS .............. 7
9.0 REPLACEMENT PARTS .............................. 8
9.1 ORDERING ........................................... 8
9.2 CONTROL MODULE ASSEMBLY ........ 8
9.3 POWER COMPONENTS ...................... 9
9.4 REPLACEMENT BRUSH ASSEMBLY.. 9
10.0 SCHEMATIC ................................................. 10
1.0. INSPECTION
1.1. UNPACKING
When unpacking the unit, examine it carefully for any
shipping damage. The "Damage and Shortage"
instructions packed with the unit outlines the procedure
to follow if any parts are missing or damaged.
2.0. DESCRIPTION
2.1. GENERAL
WHR5206 STABILINE®Automatic Voltage Regulators
are single phase, 240 X 208 volt, fast acting
electromechanical regulators. These units have an
analog electronic control section and a power section
consisting of a motor driven POWERSTAT®Variable
Transformer and a buck-boost transformer.
Advantages of all WHR Series voltage regulators
include high efficiency (99% typical), high overload
capacity and low impedance. These voltage regulators
are insensitive to the magnitude and power factor of the
load, and have little to no effect on system power factor.
This means these regulators can be used with any type
load.
2.2. THEORY OF OPERATION
These units regulate AC voltage by automatically
adjusting POWERSTAT®Variable Transformers to
maintain constant output voltage.
The solid-state control unit detects output voltage, and
continually compares it with output and accuracy
settings selected by the user. If the output is out of
specifications, the control unit drives the POWERSTAT
variable transformer by means of a synchronous motor,
to the required new position.
3.0. INSTALLATION
3.1. MECHANICAL INSTALLATION
The regulators are designed for bench or rack
mounting. When mounting the unit, allow a minimum
clearance of 4 inches (100 mm) behind and above the
unit for proper ventilation.
Note: When rack mounting a WHR Series regulator, it is
recommended that support be provided for the rear of
the unit.
3.2. ELECTRICAL INSTALLATION
All WHR regulators are designed to be hard-wired to the
input power and the load using copper wire. When these
units increase low input voltage to give nominal output
voltage, the input current is substantially higher than the
output current. Maximum rated input and output
currents are given in the enclosed rating chart. Select a
wire size that is adequate to carry the maximum rated
current as specified by local and national code
requirements.
The terminals for input and output connections are
located on the rear of the regulator. A ground stud is
provided on the chassis of the unit. The terminals for
making the input and output connections are on a
terminal panel. The input terminals are labeled L1 and
L2-NEUT. The load connection terminals are labeled T1
and T2-NEUT.
The ground terminal must be connected to a
suitable earth ground to reduce the chance of
electrical shock.

3
4.0. START UP
Set the Output Voltage Range toggle switch on the
control module to either the 240 or the 208 volt position
to match your application. Use the 240 volt position for
220 and 230 volt systems. The Output Voltage
Adjustment and the Sensitivity potentiometers are set at
the factory for nominal output voltage and approximately
1% accuracy, and should not be readjusted until the
voltage regulator is initially energized.
After all input and output connections are completed
and checked, ensure the chassis panel(s) are in
position and tightly fastened.
Energize the regulator power source. The voltmeter
should indicate the output voltage (approx. 240 or 208
volts), and the POWER pilot lamps and the CONTROL
pilot lamps should be lit. This indicates the voltage
regulator is operating properly.
5.0. OPERATION
5.1. CONTROL MODULE ASSEMBLY
5.1.1. General
The control modules contain the circuitry that sense the
output voltage and determine if correction is needed. On
rack models the control module is the front panel and
the components mounted to it. When correction is
required this circuit sends a raise or lower signal to the
motor driven variable transformers. To eliminate
accidental tampering of the control module settings a
cap is provided to cover the control potentiometers.
5.1.2. Power Pilot Lamps (A1-LP1)
The POWER lamp on the control assembly lights when
power is present for the motor. This indicates the
voltage regulator is energized.
5.1.3. Control Pilot Lamps (A1-LP2)
The CONTROL lamp lights when the control assembly
sense voltage is energized. The control sense voltage
must be energized for automatic correction of voltage
changes to occur.
5.1.4. Analog Voltmeters (A1-M1)
The front panel meter shows the output voltage. This is
the voltage being sensed by the control module. If
remote sensing is used the meter will read the remote
voltage being produced on the remote sense terminals.
5.1.5. Output Voltage Range Toggle Switches
(A1-S1)
With these switches in the OFF position, the control
sense voltage is disconnected and the control pilot lamp
is not illuminated. In this position automatic correction
for voltage changes will not take place and any change
in input voltage will be reflected in output voltage. The
switch should be placed in either the 240 or 208 position
to energize the control assembly sense voltage and
allow automatic correction of voltage changes.
5.1.6. Output Voltage Potentiometers
This potentiometer sets the output voltage. The
adjustment range is approximately ± 10% of selected
nominal output voltage.
5.1.7. Sensitivity Potentiometers
This potentiometer adjusts the voltage regulator’s output
accuracy and therefore set how much the output voltage
will change before the unit will correct.
5.1.8. Fuses (A1-F1 to A1-F4)
The four fuses located on the control module protect the
motor and sense power lines. If the POWER or
CONTROL lights are not lit, and all control settings are
proper, check for a blown fuse.
5.2. SETTING OUTPUT VOLTAGE AND
SENSITIVITY POTENTIOMETERS
5.2.1. Energize Regulator
Energize the regulator power source. The pilot lamps
should light, indicating that the voltage regulator is
energized and that the control unit is on. If necessary,
move the OUTPUT VOLTAGE RANGE switch to the
desired nominal output voltage position. The voltmeters
will indicate the output voltages.
5.2.2. Set Output
Adjust the output voltage if necessary by turning the
OUTPUT VOLTAGE potentiometer. Clockwise will
increase the voltage and counterclockwise will decrease
the output voltage. The voltmeter will indicate the
changes.
5.2.3. Set Sensitivity
The sensitivity must be adjusted if the voltage regulator
hunts (the motor driven variable transformer sections of
the regulator continually cycles back and forth) or if the
regulator allows too great a change from the set voltage
before correction occurs.
Turning the SENSITIVITY control clockwise increases
the sensitivity to maximum (± 0.5% output voltage
accuracy). For maximum sensitivity, turn the
SENSITIVITY control clockwise to the point where the
POWERSTAT begins to hunt. Turn the control
counterclockwise (CCW) until the hunting stops. Turn
the control an additional 1/8 turn CCW.

4
5.3. REMOTE SENSING
Normally, the voltage WHR series regulators sense and
regulate the voltage at the regulator's output terminals.
In some cases better control can be obtained by
regulating the voltage at another point, such as at the
end of long lines between the regulator and the load.
This is known as remote sensing.
If remote sensing is desired, remove the jumper wire
connecting terminal 1 to terminal 3 and the jumper wire
connecting terminal 2 to terminal 4 on the remote
sensing terminal strip at the rear of the unit. These
jumpers are wht/red and wht/grn respectively. This will
disconnect the control module sense terminals from the
output terminals of the regulator. Connect remote
sensing wires corresponding to the output load voltage
to terminals 3 and 4 on the remote sensing terminal
strip.
The sense voltage must be controlled by the
voltage regulator. If the control is not sensing a voltage
controlled by the regulator’s output, the POWERSTAT
connected to that control unit will drive to the end of its
travel when it attempts to correct the voltage it is not
controlling. This will result in incorrect output voltages.

5
6.0. MAINTENANCE
To ensure maximum life of the equipment, the following
should be part of an annual maintenance program.
Warning
De-energize unit before performing maintenance.
Voltages are present inside this unit which can
cause injury. Therefore, only personnel qualified to
service electrical equipment should perform
maintenance on this unit.
6.1. Vacuum the voltage regulator inside and out to
remove accumulated dirt, which could lead to
overheating or insulation failure.
6.2. Tighten all electrical connections, particularly all
power wiring to, and in, the unit.
6.3. Inspect all variable transformer brushes and
commutators for signs of wear or pitting. Replace as
required. See diagram below.
Do not attempt to clean a commutator with an
abrasive such as sandpaper or a file. This will ruin the
soft precious metal plating on the commutator and will
shorten the life of the unit. It is normal for commutators
to become black due to carbon brush tracking. If a
commutator is to be cleaned, use denatured alcohol and
a soft cloth.
6.4. Inspect the variable transformer drive belts,
sprockets, gears, cams, etc. for signs of slippage or
wear and adjust as required.
6.5. Check the variable transformer radiator(s) (the
die cast part that holds the brush assembly) for signs of
slippage, and see if all brushes driven by the same
motor are aligned with each other. The alignment of the
radiator and brushes depends on the setscrews that
hold the variable transformer center tube(s) to the shaft
and the setscrews that hold the radiator to the center
tube. Adjust and tighten as needed.
6.6. Lubrication of the WHR Series voltage regulator
is not required since it has been lubricated at the factory
for its lifetime.
7.0. TROUBLESHOOTING
WHR Series voltage regulators will provide long, reliable
service with little attention. Unless the unit is
overloaded, there is little likelihood of component failure.
Warning
Voltages are present inside this unit which can
cause injury. Therefore, only personnel qualified to
service electrical equipment should perform
trouble-shooting procedures on this unit.
If the regulator fails to operate correctly, the following
checks will help locate and correct the problem. Refer to
the schematic, rating chart and replacement parts list for
further information.
7.1. Check the load connected to the voltage regulator
to be sure the unit's output current rating is not being
exceeded.
7.2. See if the POWER pilot lamps are on. If a lamp is
not on, there is no power to the voltage regulator, or
fuses F1 & F2 (POWER LIGHT MOTOR) on that control
module are blown, or the lamp has burned out. Check
the POWER LIGHT MOTOR fuses (F1 and F2). Check
the power input to the unit to be sure the voltage is
within the range specified for the selected output
voltage.
7.3. Check the output voltmeters. If a meter shows
zero output voltage, check the input line, control module
fuses F3 and F4 (CONTROL fuses), remote sense
wiring if applicable, and input connections. If so
equipped, check position of input circuit breaker and
manual bypass switch.
7.4. Check the CONTROL pilot lamps. If one is not lit,
check the VOLTAGE RANGE switch to be sure it is on
and check for blown CONTROL fuses (F3 and F4). If
applicable, check the remote sense wiring.
7.5. If the motor hunts (cycles continuously), readjust
the SENSITIVITY control.
7.6. If a motor drives a POWERSTAT variable
transformer to one end of its travel, and the voltage
decreases when it should increase or increases when it
should decrease, check to see if the input and output
power connections to the voltage regulator are
reversed. If applicable, check the remote sense wiring.
If the unit has been reworked or repaired, check to see
if the leads driving the motor have been reversed.
A1-TB1-2 and A1-TB1-3 provide the motor power to
lower and raise the motor with A1-TB1-1 being the
common for both AC voltages.
7.7. If the motor continues to hum or buzz after the
OUTPUT VOLTAGE RANGE switch is turned off, the
solid-state switch controlling the motor may be

6
defective. De-energize the input line to the voltage
regulator, and replace the control board.
7.8. If the motor has driven to one end or does not
drive at all, check to ensure the motor drive is
functioning correctly. Refer to the unit's schematic
diagram to complete the following steps:
De-energize the input line to the voltage regulator; place
the OUTPUT VOLTAGE RANGE switch in the center
(off) position, and remove POWER LIGHT-MOTOR
fuses F1 and F2 on each control module.
Apply 115 volts AC between terminals A1-TB1-1 and
A1-TB1-2 on the control module, or to the
corresponding terminals at the motor board terminal
strip (TB1). These nine junction terminal strips are
connected point-for-point. The motor should turn the
variable transformer counter clockwise (viewed from
top) so as to lower the output voltage until it reaches the
end of its travel, where the limit switch will prevent
further rotation in that direction.
Apply 115 volts between terminals A1-TB1-1 and
A1-TB1-3 should run the motor in the opposite direction
until a limit switch stops the motor at the end of travel.
If the motor operates successfully in this test the
problem may be with the control board.
7.9. Inspect the POWERSTAT Variable Transformer
brush(s) and commutator(s) for signs of wear or
damage. The brush assemblies on the variable
transformer section will not need replacement under
normal conditions. When excessive brush wear or
commutator damage occurs, it is usually the result of an
overload. If either condition exists, the POWERSTAT
Variable Transformer section or the brush must be
replaced or repaired. Check the load to be sure the
output current rating of the voltage regulator is not being
exceeded.
Do not attempt to clean a commutator with an
abrasive such as sandpaper or a file. This will ruin the
soft precious metal plating on the commutator surface
and will shorten the life of the unit. It is normal for
commutators to become black due to carbon brush
tracking. If a commutator is to be cleaned, use
denatured alcohol and a soft cloth.
7.10. Check the variable transformer radiator(s) (the
die cast part that holds the brush assembly) for signs of
slippage, and see if all brushes driven by the same
motor are aligned with each other. The alignment of the
radiator and brushes depends on the setscrews that
hold the variable transformer center tube(s) to the shaft
and the setscrews that hold the radiator to the center
tube. Adjust and tighten as needed.

7
8.0. RATING
8.1. POWER RATINGS
The WHR5206 ratings are shown below:
INPUT:
VOLTAGE: 240 X 208
FREQUENCY: 50/60 Hz X 50/60 Hz
MAX CURRENT: 31 X 31
RANGE: -17% to +17% of Selected Output
CONNECTION: Single Phase, 2 Wire
OUTPUT:
VOLTAGE: 240 X 208
MAX CURRENT: 25 25
MAX kVA 6.0 X 5.2
CONNECTION: Single Phase, 2 Wire
GENERAL SPECIFICATIONS
Electrical:
Output Accuracy Adjustable from ±0.5% to ±3%
Response Time 0.025 seconds at 60 Hz,0.030 seconds at 50 Hz
Load Capacity 100% rated continuous
200% rated 60 seconds
400% rated 3 seconds
600% rated 1 second
800% rated 0.5 second
1000% to 2500% 1/2 cycle inrush
Load Power Factor 0 lagging to 0 leading
Load Crest Factor 6 Max (I peak / I RMS)
Efficiency 99% typical, at full load
Heat Generated BTU (typical) = 35 x rated kVA
Harmonic Distortion Less than 1% added
Surge Withstand Capability 6000 volts per IEEE C62.41, location category B
Impedance 1% typical
Environmental:
Service Conditions Units are housed in 19 inch rack enclosures, intended for indoor use under
usual service conditions.
Temperature
Operating Average ambient temperature for any 24 hour period not to exceed 30°C
(86°F), and maximum temperature not to exceed 40°C (104°F). Average
ambient temperature for any 24 hour period may be increased to 40°C
(104°F),and the maximum temperature may be increased to 50°C (122°F),if
the load is decreased to 90%of standard rating. Minimum temperature is 0°C
(32°F).
Storage -40°C to +70°C (-40°F to +158°F)
Humidity (Operating and Storage) 10 to 75% average relative humidity for any 7 day period, and maximum
relative humidity not to exceed 95% non-condensing.
Altitude
Maximum Altitude Derating
6,600 Ft.(2,000 meters) No de-rating
10,000 Ft.(3,000 meters) load to 95%,ambient 30°C (86°F)
Operating
15,000 Ft.(4,500 meters) load to 90%,ambient 20°C (68°F)
Storage 50,000 Ft.(15,000 meters)max

8
9.0. REPLACEMENT PARTS
9.1. ORDERING
This manual covers the WHR5206 STABILINE®
Automatic Voltage Regulator. It is impractical to provide
a full list of replacement parts. To order a part not listed
in this manual, provide the unit model number, serial
number, and date code. Reference the part by
schematic reference symbol, description and part
number if available.
9.2. CONTROL MODULE ASSEMBLY
The control module used in the WHR5206 STABILINE®
Automatic Voltage Regulator is shown below. Other
WHR Series regulators have similar control modules but
some of the parts are different with different part
number. Do not use this is manual for any unit other
then the one it was intended for.
REAR VIEW
RACK MOUNT CONTROL MODULE ASSEMBLY (A1)
Standard
Reference Symbol Part Description Part Number
A1 CONTROL MODULE 219452-004
A1-A1 CONTROL BOARD 227412-005
A1-F1,F2,F3,F4 FUSE, 1A, 250V 104364-003
A1-LP1,LP2 LIGHT, INDICATOR, GREEN 227571-001
A1-M1 VOLTMETER 212917-002
A1-S1 SWITCH, ROCKER SPDT ON/OFF/ON 227572-001

9
9.3. POWER COMPONENTS
The parts listed below are for the WHR5206 STABILINE®Automatic Voltage Regulator power section.
Reference Symbol Part Description Part Number
B1 MOTOR, AC 228870-002
R1 & C1 RC NETWORK 228978-001
S1,S2 SWITCH 058743-001
T1 POWERSTAT, VARIABLE TRANSFORMER 229095-001
REPLACEMENT BRUSH ASSEMBLY FOR T1 056135-002
T1
including B1, C1, R1, S1, S2 ASSEMBLY, VARIABLE TRANSFORMER AND MOTOR DRIVE 229091-001
T2 TRANSFORMER, BUCK-BOOST 229086-001
9.4. REPLACEMENT BRUSH ASSEMBLY
Each POWERSTAT®Variable Transformer contains a durable brush assembly. These assemblies are designed to
reduce the need for attention or replacement; however, because these are moving parts that rely on contact friction to
operate properly, an annual inspection is suggested. Refer to the maintenance section of this manual for details. The
replacement brush assembly is listed along with its corresponding POWERSTAT Variable Transformer in the power
component section.

10
10.0. SCHEMATIC (For reference only, use full size supplied with unit)

11
11.0. DIMENSIONS
Enclosures
Note: All dimensions are inches [millimeters]

12
Available Coast-To-Coast and Internationally
Voltage Control Components
POWERSTAT ®Variable Transformers
LUXTROL ®Lighting Controls
5-WAY ®Binding Posts
SUPERCON ®Electrical Connectors
Power Quality Solutions
STABILINE ®Automatic Voltage Regulators
STABILINE ®Transient Voltage Surge
Suppressors
STABILINE ®Uninterruptible Power Supplies
STABILINE ®Power Conditioners
Voltage Control Components are available worldwide
through an extensive Authorized Stocking Distributor
network. These Distributors offer literature, technical
assistance and a wide range of models off-the-shelf for
fastest possible delivery and service.
STABILINE Power Quality Solutions are available
worldwide through an extensive Authorized Distributor
and Reseller network, which offer literature, technical
assistance and a select range of models off-the-shelf for
fastest possible delivery and service.
In addition, Superior Electric Manufacturer’s Representatives are available to provide prompt attention to customer
needs. Call or fax for ordering and application information or for the address of the closest Manufacturer’s
Representative, Authorized Distributor or Reseller.
Telephone and Fax Numbers
Telephone [phone]
Fax: [phone]
Customer Service: 860-585-4500 Ext. 4750
Product Application 860-585-4500 Ext. 4755
Toll-Free (in U.S.A. and Canada only)
Telephone [phone]
Fax: [phone]
Customer Service: 1-800-787-3532 Ext. 4750
Product Application: 1-800-787-3532 Ext. 4755
383 Middle Street •Suite 105 • Bristol, CT 06010
www.superiorelectric.com
The right to make engineering refinements on all products is reserved. Dimensions and other details are subject to change.
213709-203A manual,WHR5206(f).doc