Power-Tronics Commercial Series Manual Download

Page: 12 / 16

For Technical Support:

Visit our website at:

www.power-tronics.com

Call Us at:

(830) 895-4700

Optional Power-Tronics Accessories

Power-Tronics offers optional accessories and add-on modules for the XC series voltage

regulators for specialty applications or troublesome installations. For more information on

any of the modules below, visit our online catalog at:

www.power-tronics.com

ABF10

Automatic Battery Flash

Module

Adds Automatic Battery Flash

to installations with low residual

or requiring guaranteed buildup!

HVD2

High Voltage Disconnect

Adds passive protection for

your generator and connected

equipment from runaway and

high voltage conditions!

Disconnects power to the

voltage regulator instantly in the

event of high voltage!

Potentiometer &

Knob Kit

Part # PK-ECONO

Allows the XC4-R to have a

panel-mounted remote

adjustment knob!

Field Varistor

Part # 5R1-44

Required for use on Brush-

Type generators

Summary of Contents for Commercial Series

Page 1: ... reduces voltage to prevent excessive rotor heating when the engine is idled The XC4 R uses the XR8 s patented electronic circuitry that automatically matches the regulator s response time to the generator exciter This greatly speeds installation and eliminates guesswork Because it only uses 4 wires for connection to the generator it also makes quick replacement in the field possible To ensure ext...

Page 2: ... 12 Lead Generator Wiring Diagrams 6 Use with PMGs DPE AUX and Harmonic Winding Generators 7 240V Hookup Connection 8 120V Hookup Connection 9 Installation on Brush Type Generators 10 Installation Considerations 11 Initial Setup and Commissioning 11 Optional Power Tronics Accessories 12 Application Troubleshooting 13 Bench Check Procedures 14 Installation Warranty Form 15 Product Warranty Certific...

Page 3: ...ly simplify setup while offering extreme reliability in demanding service conditions When properly installed the XC4 R Automatic Voltage Regulator is designed to provide a lifetime of service A Generator voltage regulator has several automated tasks it must perform in order to provide reliable clean and regulated electricity It must build up the generator regulate the terminal voltage within its d...

Page 4: ...your generator exciter select 120V or 240V Hookup from the list below Exciter Field Resistance 16Ω Exciter Full Load Voltage 63VDC Use 240V Hookup Connection See Page 8 Exciter Field Resistance 8Ω Exciter Full Load Voltage 32VDC Use 120V Hookup Connection See Page 10 Note about Field Resistance When measuring field resistance on a brushless generator simply measure the resistance of the exciter fi...

Page 5: ...tor To determine your full load exciter field voltage use the following formula EExc Where EGen Conf is your Generator s configured voltage e g 120 208 240 480V etc EGen Output is your recorded output voltage and EBattery is your battery voltage 12V usually Next calculate your maximum exciter field amperage using your measured field resistance and your calculated exciter voltage using the followin...

Page 6: ...39V Parallel Wye 208 240V 3ø Voltage L L 208 240V Voltage L N 120 139V NOTE 208V is Standard Voltage Series Delta 240V 3ø Voltage L L 240V Voltage L1 L2 N 120V Voltage L3 N 208V NOTE L3 N is a High Leg 208V instead of 120V Double Delta 120 240V 1ø Voltage L L 240V Voltage L N 120V Preferred Single Phase Connection Don t Use Zig Zag if Possible NOTE Derate generator by 1 3 rated capacity when using...

Page 7: ... Measure your field resistance and proceed with sizing on Page 4 DPE Winding and Auxiliary Winding These generators use an extra winding in the main stator as a power supply for the voltage regulator in an attempt to give the regulator a clean power source that isn t affected by load The XC4 R has proprietary filtering circuitry in its sensing stage that is largely unaffected by generator load Bec...

Page 8: ... and T9 See Page 6 or use a 480 240V step down transformer rated at 500VA Connecting the input of the XC4 R to 2 different legs of the generator as shown in the diagram below will result in greater regulation accuracy than when connecting line neutral XC4 R Commercial Series Automatic Voltage Regulator NOTE If the generator is to be operated below 50 60 Hz a disconnect or switch should be installe...

Page 9: ...ither connect the regulator to the winding center taps T7 and T0 See Page 6 or use a 480 120V step down transformer rated at 250VA When connecting the input of the XC4 R from center tap to neutral of the generator as shown in the diagram always connect AC2 to the generator neutral XC4 R Commercial Series Automatic Voltage Regulator NOTE If the generator is to be operated below 50 60 Hz a disconnec...

Page 10: ... excitation requirements that are within the capacity of the XC4 R Use of the XC4 R on brush type generators requires the use of an external varistor across the exciter field or brush riggings Brush type generators inherently create reverse EMF conditions and occasional arcing at the brush ring interface that can quickly damage the XC4 R if the varistor is omitted XC4 R Commercial Series Automatic...

Page 11: ...If installing the XC4 R on a brush type generator verify that the brushes and brush riggings are isolated ungrounded and connected ONLY to the XC4 R 3 Turn the internal voltage control fully counter clockwise left This procedure is necessary in case the original factory settings have been altered Set external remote adjustment potentiometer if used to 50 of its range 4 Start up the prime mover and...

Page 12: ...alog at www power tronics com ABF10 Automatic Battery Flash Module Adds Automatic Battery Flash to installations with low residual or requiring guaranteed buildup HVD2 High Voltage Disconnect Adds passive protection for your generator and connected equipment from runaway and high voltage conditions Disconnects power to the voltage regulator instantly in the event of high voltage Potentiometer Knob...

Page 13: ...d 5 Open diode in exciter or shorted rotor in generator 6 Loose or failed component in voltage regulator 7 Loose wiring connections 8 Input voltage to regulator is too low 9 Exciter field is grounded 10 Non linear Inverter 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 Inverte...

Page 14: ... continue this test 6 VERY SLOWLY turn the internal voltage adjustment CW until the incandescent light bulb turns fully on it will be reduced brightness then adjust the internal voltage adjustment CCW until the light bulb is off 7 Observation You should be able to taper the incandescent light bulb on and off in a relatively smooth manner If the light flashes on or off quickly as if being switched ...

Page 15: ...n History Please be detailed Ship To Address City State Zip Country Company Name Contact Person Telephone Number Email Address Primary Load Please Explain Repair Warranty Request Information Generator Leads Check One 12 10 6 4 3ø 4 1ø 3 Generator Wiring Mode Check One High Wye Low Wye Series Delta Zig Zag Double Delta Single Phase Other Terminal Voltage Residual AC Voltage Rated KW Rated KVA Gener...

Page 16: ...t 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 v Overheating of the power supply resistor s on the printed circuit card v Overheating of the SCR or free...

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