Power-Tronics XR5C Series Manual Download | Manualshive

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Conversion From Older Shunt-Wound Voltage

Regulation to Modern Solid-State Voltage Regulation

It is possible to use the XR5C Universal Voltage regulator with older Shunt-Wound
exciters that originally had manual, mechanical, or series solid-state voltage regulators
by converting the wiring as in the diagrams below. If the generator will not build up after
conversion, try switching your F+ and F- leads at the regulator and try starting up again.

NOTE:

Armature brushes

MUST BE ISOLATED

from the field leads for
proper operation!

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Summary of Contents for XR5C Series

Page 1: ...temperature All major electronic components are not encapsulated to facilitate repair while all sensitive components are encapsulated to protect them from contamination and moisture PLC and automated Genset control is possible with the XR5C by simply adding an optional inexpensive digital interface module This capability makes the XR5C suitable for automated or unattended installations or large sc...

Page 2: ...enerators 7 Hookup Connection A 8 Parallel Configuration for Connection A 9 Hookup Connection B 10 Parallel Configuration for Connection B 11 Hookup Connection C 12 Parallel Configuration for Connection C 13 Initial Setup and Commissioning 14 Optional Power Tronics Add On Modules 15 Conversion From Shunt Wound to Solid State Regulation 16 Internal Fuse Replacement 17 Application Troubleshooting 18...

Page 3: ...perly installed the XR5C Universal 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 design specifications and protect both itself and the generator should a fault situation arise ...

Page 4: ...A B or C from the chart below Exciter Field Resistance 42Ω Exciter Full Load Voltage 125VDC Use connection A See Page 8 Exciter Field Resistance 21Ω Exciter Full Load Voltage 63VDC Use connection B See Page 10 Exciter Field Resistance 10 5Ω Exciter Full Load Voltage 32VDC Use connection C See Page 12 Note about Field Resistance When measuring field resistance on a brushless generator simply measur...

Page 5: ...rator To determine your full load exciter field voltage use the following formula EExc EGen Conf EGen Output EBattery 2 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...

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 XR5C has proprietary filtering circuitry in its sensing stage that is largely unaffected by generator load Beca...

Page 8: ... For use on 480V systems either connect the regulator to the winding center taps T7 and T9 See Page 6 or use a 480 240V step down transformer rated at 1KVA Connecting the input of the XR5C to 2 different legs of the generator as shown in the diagram below will result in greater regulation accuracy than when connecting line neutral NOTE It is not necessary to jumper terminals 7 and 8 if not using t...

Page 9: ...istance a bit at a time until satisfactory droop is achieved CT should be sized at 25 35VA burden XR5C Specialty Series Universal Voltage Regulator 240VAC MAX Secondary Voltage 100K 2W Unit Parallel Switch Reactive Droop Adjustment 3Ω 100W CT Rating XXX 5A 25 35VA Transformer Rating XXX 240V 1KVA Regulator On Off Switch Rate for Primary Voltage 10A Setup Tips Isolation Transformer is recommended f...

Page 10: ... to the unit will result For use on 480V systems either connect the regulator to the winding center taps T7 and T9 See Page 6 or use a 480 240V step down transformer rated at 750VA Connecting the input of the XR5C to 2 different legs of the generator as shown in the diagram below will result in greater regulation accuracy than when connecting line neutral NOTE It is not necessary to jumper termina...

Page 11: ...istance a bit at a time until satisfactory droop is achieved CT should be sized at 25 35VA burden XR5C Specialty Series Universal Voltage Regulator 240VAC MAX Secondary Voltage 100K 2W Unit Parallel Switch Reactive Droop Adjustment 3Ω 100W CT Rating XXX 5A 25 35VA Transformer Rating XXX 240V 750VA Regulator On Off Switch Rate for Primary Voltage 10A Setup Tips Isolation Transformer is recommended ...

Page 12: ...ither connect the regulator to the winding center taps T7 to T0 See Page 6 or use a 480 120V step down transformer rated at 500VA Preferred for superior regulation accuracy Connecting the input of the XR5C to 2 different legs of the generator through a transformer will result in greater regulation accuracy than when connecting line neutral as shown in the diagram below NOTE It is not necessary to ...

Page 13: ...he resistance a bit at a time until satisfactory droop is achieved CT should be sized at 25 35VA burden XR5C Specialty Series Universal Voltage Regulator 120VAC MAX Secondary Voltage 100K 2W Unit Parallel Switch Reactive Droop Adjustment 3Ω 100W CT Rating XXX 5A 25 35VA Transformer Rating XXX 120V 500VA Regulator On Off Switch Rate for Primary Voltage 10A Setup Tips Isolation Transformer is recomm...

Page 14: ...You may notice unsteady or pulsating voltage If so turn the Stability adjustment clockwise until the pulsation stops As you turn the stability adjustment the terminal voltage will rise Always keep your voltage within 10 of the desired setpoint with the voltage adjustment pot 8 Place the generator on line and observe the frequency and voltage 9 If the generator is being paralleled measure the droop...

Page 15: ...DC 25ADC Static Exciter ABF10 Automatic Battery Flash Module Adds Automatic Battery Flash to installations with low residual or requiring guaranteed buildup EIM1020VM External Interface Card Allows the XR5C to be controlled externally by virtually any digital load sharing controller VAR controller genset controller or digital governor controller MOP1224HD Motorized Potentiometer Allows the XR5C to...

Page 16: ...e the XR5C Universal Voltage regulator with older Shunt Wound exciters that originally had manual mechanical or series solid state voltage regulators by converting the wiring as in the diagrams below If the generator will not build up after conversion try switching your F and F leads at the regulator and try starting up again NOTE Armature brushes MUST BE ISOLATED from the field leads for proper o...

Page 17: ...rt Number BK GDB 5A Fuse Replacement Procedure Refer to the image above for easy reference Remove the 4 screws located on the front of the aluminum mounting can to allow removal of the can Remove the aluminum mounting can from the circuit card Use a continuity tester or multimeter to test the fuses A good fuse will read continuity or 0Ω resistance Replace open fuses then replace and re tighten all...

Page 18: ...generator 4 Non linear Inverter 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 Inverter load or wrong selection for regulator hookup 11 Exciter fields are reversed 12 Wrong selection of regulator wir...

Page 19: ...reen status light is not on do not continue this test 6 SLOWLY turn the internal voltage adjustment CW until the incandescent light bulb turns fully on 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 the regulator has an i...

Page 20: ...ww power tronics com warranty Submit Online at www power tronics com warranty Problem Description 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 Z...

Page 21: ...nd 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 v Overheating...

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