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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 

Summary of Contents for XR500B

Page 1: ... 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 ...

Page 2: ...ator 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 ...

Page 3: ...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 t...

Page 4: ... 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 10va...

Page 5: ...iter 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 configurati...

Page 6: ...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 PERSONA...

Page 7: ...ng 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...

Page 8: ...urchase 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 ...

Page 9: ...o 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 ...

Page 10: ...el switch Exciter field Remote voltage adjustment 100k 1 2w 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 ...

Page 11: ...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 ...

Page 12: ...iter 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 ...

Page 13: ...iter 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 ...

Page 14: ...M 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 rsion Diagram To Change From Older Shunt Wound Voltage Regulation To Newer Solid State Voltage VR UVR And XR Universal Voltage Regulators ...

Page 15: ...n 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 Optional AFM500X Auto Flash Connection Diagram ...

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