Académique Documents
Professionnel Documents
Culture Documents
August 2001
Specifications
Systems Operation
F
Troubleshooting
Testing and Adjusting
VR6-B Voltage Regulator O
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CCB1-Up (Generator Set)
9EP1-Up (Generator Set)
8NS1-Up (Generator Set)
9ES1-Up (Generator Set)
BCW1-Up (Generator Set)
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The meaning of this safety alert symbol is as follows:
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Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or
pictorially presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The
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warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,
work method or operating technique that is not specifically recommended by Caterpillar is used,
you must satisfy yourself that it is safe for you and for others. You should also ensure that the
product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
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measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job. Caterpillar dealers have the most current information available. For a list of the most
current publication form numbers available, see the Service Manual Contents Microfiche, REG1139F.
Table of Contents
Specifications Section
Electrical ................................................................. 4
Dimensions ............................................................. 5
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Manual Voltage Control ......................................... 10
Voltage Droop Control .......................................... 11
Series Boost ......................................................... 12
Power Factor Regulation and KVAR Regulation ... 13
Troubleshooting Section
Symptom Procedures
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Low Voltage .......................................................... 14
High Voltage ......................................................... 17
Unstable Voltage ................................................... 20
Index Section
Index ..................................................................... 43
4
Specifications Section
Specifications Section
i01499340
Electrical
SMCS Code: 4467
Table 1
Specifications
Regulator Regulation Less than ±1% of voltage setpoint from no load to full load
Characteristics
Response time Maximum of 4 milliseconds
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Voltage drift Less than ±1% steady state
Temperature drift Less than ±1% for any 40 C (104.0 F) change over the operating temperature range
Sensing voltage True RMS three-phase sensing is standard. Single phase sensing is available. The
variable sensing range is 180 to 264 VAC for 60 Hz. The variable sensing range
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is 150 to 220 VAC for 50 Hz.
Stability The regulator responds to the main component of the sensed voltage and remains
stable for total harmonic distortion of the generator output voltage waveform, up
to 20%.
Regulation Volts/Hz The characteristic is linearly proportional to frequency. 1 V/Hz characteristic can be
characteristic selected by placing the jumper between terminals 6A and 8. 2 V/Hz characteristic
can be selected by removing the jumper between terminals 6A and 8. These
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characteristics provide matched engine/generator performance for improved block
load performance.
Knee frequency The knee frequency is adjustable from 45 Hz to 65 Hz. Refer to the Testing and
Adjusting, “Knee Frequency - Adjust” for more information.
Adjustment Voltage adjust +10% to -25% of regulator sensing voltage
Characteristics range
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Reactive droop Adjustable from 0 to 10% at rated input current and 0.8 power factor. Either a 1
adjustment Ampere current transformer (CT) or a 5 Amperes CT can be used with a VA<10.
External Voltage 10 kOhm, 2 Watts
Adjust Rheostat
Protection For Overexcitation The protection shuts off the generator output when excitation current exceeds normal
operating currents for 30 seconds at 90 VDC ± 5%.
Power Power dissipation Maximum 50 watts at rated output
Characteristics
Input 180 to 264 VAC, single-phase or three-phase on 50 Hz or 60 Hz applications
90 to 120 VAC, three-phase, on 100 Hz to 240 Hz permanent magnet (PMG)
applications. Maximum of 3125 VA.
240 VAC, single-phase, on 100 Hz to 240 Hz permanent magnet (PMG) applications.
Maximum of 3125 VA.
Output 12 Amperes DC at 65 VDC maximum continuous
(with a 240 VAC 25 Amperes DC at 125 VDC forcing for 10 seconds
Input)
Temperature Ambient operating −40 C (−40 F) to +70 C (+ 158 F).
Range
Storage −40 C (−40 F) to +70 C (+ 158 F).
Physical Weight 1.1 kg (2.4 lb).
Specifications
Shock Withstands up to 20 g’s.
Vibration Withstands 0.5 g’s at frequencies between 18 and 2000 Hz in three mutually
perpendicular planes.
(continued)
5
Specifications Section
(Table 1, contd)
Specifications
Conformity Electromagnetic Meets 89/336/EEC Electromagnetic Compatibility Directive.
compatibility Contains internal EMI suppression filter.
UL UL 508 certified
CSA Certified per Standard CAN/CSA-C22.2 No. 14-95, CSA File No. LR 23131
CE Conforms to the following standards:
Radiated Emissions EN50081-2
Radiated Immunity (electric field) EN61000-4-3 (10 V/m)
Radiated Immunity (conducted) EN61000-4-6 (10 VRMS)
Conducted Emissions EN50081-2 (EN55011, Class A)
ESD Immunity EN50082-2 (4 KV contact, 8 KV air)
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EFT Immunity EN50082-2 (2 KV coupling clamp)
Magnetic Immunity EN50082-2 (30ARMS, 50 Hz)
Safety EN61010-1
i01502056
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Dimensions
SMCS Code: 4467
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g00779068
Illustration 1
Dimensions of the VR6 Voltage Regulator
(A) 212.75 mm (8.376 inch) (C) 161.95 mm (6.376 inch) (E) 87.4 mm (3.441 inch)
(B) 190.50 mm (7.500 inch) (D) 139.70 mm (5.500 inch)
6
Specifications Section
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3 Auxiliary input from VAR/PF Controller
4 This terminal is used in conjunction with
terminal 7 for selecting internal voltage
adjustment. Place the jumper between
terminals 4 and 7 for using internal voltage
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adjustment. Remote voltage adjustment
requires a jumper between terminals 6A
and 7.
5 1 Ampere Current Transformer (CT)
5A 5 Ampere Current Transformer (CT)
6 Common for the Current Transformer
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6A Common connection for selectable features
7 This terminal is used in conjunction with
terminal 4 for selecting external voltage
adjustment. Place the jumper between
terminals 4 and 7 for using internal voltage
adjustment. Remote voltage adjustment
requires a jumper between terminals 6A
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and 7.
8 Connect terminal 8 to terminal 6A in order
to select a 1 V/Hz underfrequency slope.
9 Connect terminal 9 to terminal 6A in order
to select three-phase sensing.
20 Sensing input on phase C
22 Sensing input on phase A
24 Sensing input on phase B
26 Three-phase power input
28 Single-phase power input or three-phase
power input
30 Single-phase power input or three-phase
power input
F1 Positive field lead
F2 Negative field lead
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Systems Operation Section
General Information
SMCS Code: 4467
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g00778919
Illustration 2
Typical Block Diagram of SR4B Generator with VR6 Voltage Regulator
(1) Generator lines (three-phase output (6) Main rotor
voltage) (7) Exciter rotor
(2) Generator lines (sensing voltage and AC (8) Exciter stator
power) (9) Three-phase rectifiers
(3) VR6 voltage regulator (10) Permanent magnet stator
(4) Jumper (11) Permanent magnet
(5) Main stator (12) Generator lines (DC excitation voltage)
This manual covers the VR6 voltage regulator The regulator senses the generator voltage through
which is used on 4/6 and 10/12 lead self-excited the generator sensing leads (2). The sensing leads
generators and permanent magnet generators. The are connected to the following terminals: 20, 22,
VR6 regulator is typically located in the generator and 24. The sensed voltage is then compared to a
terminal box. The regulator may also be located in reference voltage. The reference voltage value is
the marshalling box. set by the voltage adjust rheostat on the regulator.
The reference voltage value may also be set by an
The VR6 voltage regulator (3) keeps the generator external voltage adjust rheostat.
output voltage constant with changing loads. The
voltage regulator controls the DC voltage and
current that is supplied to the exciter stator (8).
8
Systems Operation Section
When the regulator senses a decrease in output • Factory calibration of the voltage adjustment
voltage due to an increase in load, the regulator range (15)
will increase the DC voltage at wires (12). This
increases the magnetic field in the exciter stator • Voltage adjustment (16)
(8). The increased magnetic field in the exciter
stator increases the AC voltage and current, which • Knee frequency adjustment (17)
is induced in the exciter rotor (7). This increased
three-phase AC voltage from the exciter rotor • Stability adjustment (18)
causes more AC current to flow. The three-phase
ACV is then rectified to DCV by the three-phase full The factory calibration of the voltage adjustment
wave rectifier (9). The increased DC output from the range (15) should not be adjusted by the user.
bridge rectifier is carried to the main rotor (6) by For the other adjustments, refer to the Testing and
conductors, which are routed through a passage Adjusting Section within this manual.
in the generator shaft. Increased current through
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the main rotor increases the magnetic field of the The excitation circuit can be disabled by removing
generator. The increased magnetic field induces a the power from the VR6.
larger AC voltage into the main stator 5. Therefore,
the three-phase AC voltage (1) increases until the The VR6 voltage regulator can operate in one of
voltage regulator no longer senses a decreased the following modes:
output voltage.
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• three-phase sensing
When the voltage regulator senses an increase
in output voltage due to a decrease in load, the • single-phase sensing
regulator will decrease the DC voltage to the exciter.
A decrease in generator voltage will occur due to For three-phase sensing, place the jumper between
similar responses, as described above. terminals 6A and 9. Sensing leads (2) should
be connected to terminals 20, 22 and 24 for
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three-phase sensing.
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is above the adjusted knee frequency, the regulator
and 3. Terminals 2 and 3 should be jumpered if the
maintains the generator voltage at the reference
KVAR/PF controller is not used.
voltage.
If an external voltage adjust rheostat is used, there
should be no jumper between terminals 4 and 7. V/Hz Slope
An external voltage adjust rheostat is connected
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between terminals 6A and 7. If an internal voltage If the generator frequency drops below rated
adjust rheostat is used, place the jumper between frequency, the regulator will regulate the voltage to
terminals 4 and 7. a lower reference voltage. This helps the engine to
recover quickly during block loading. The reference
If a 1 Ampere droop current transformer (CT) voltage is proportional to the generator frequency.
is used, the CT should be connected between There are two slopes that can be selected: 1 V/Hz
terminals 5 and 6. If a 5 Ampere droop current and 2 V/Hz. The jumper between terminals 6A and
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transformer (CT) is used, the CT should be 8 creates a 1 V/Hz slope. In order to select a 2
connected between terminals 5A and 6. V/Hz slope, remove the jumper between terminals
6A and 8.
In order to create a 1 V/Hz underfrequency slope,
place the jumper between terminals 6A and 8. Droop
Leave these terminals unconnected for a 2 V/Hz
underfrequency slope. When a generator set operates in parallel with
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Features Stability
SMCS Code: 4467
Because of a time delay from the moment when
the regulator senses a change in voltage to the
Sensing Voltage moment when the generator voltage is increased
or decreased, the generator voltage can become
The sensing voltage is the three-phase AC voltage unstable (or hunt). The time delay varies. This delay
at terminals 20, 22 and 24. The ratio of the sensing depends on time constants for the exciter and the
voltage to the generator voltage depends on the generator. The stability circuit slows the response of
following conditions: the regulator in order to stabilize the voltage. The
stability adjustment is used in order to ensure that
• The connection point of the sensing leads to the the regulator responds as quickly as possible, while
generator leads still keeping the voltage stable.
i01502082 i01502094
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2. Remove the jumper between terminals 4 and 7.
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potentiometer are fragile. The wiring, which is
connected to remote mounted potentiometer, should
not have a diameter larger than 18 gauge. A wire
with a larger diameter is not recommended. The
wire should be 600 Volt class with 90 C (194.0 F)
insulation. When the remote potentiometer is
mounted at a long distance from generator set, a Illustration 4 g00779092
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shielded cable may be necessary in order to isolate
Manual Voltage Control Panel
the signal from noise.
(1) Switch (OFF, AUTO, and MAN positions)
(2) Voltage control rheostat
(3) Fuse
i01502107
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g00779093
Illustration 5
Voltage Droop Control (Typical Example)
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(1) Voltage droop transformer T1 (3) Main stator (5) VR6 voltage regulator
(2) Lead (4) Voltage droop rheostat
There are two primary requirements for parallel In order to minimize an ampere overloading, an
operation: individual generator output voltage droops in
proportion to the lagging reactive current flow. The
• Generators should share the real power reactive current flow is measured with a current
requirements of the electrical load. transformer (CT). As reactive generator output
current increases, the regulator will cause the output
• Generators should share the reactive power voltage to lower proportionally. If the measured
requirements of the electrical load. reactive current is leading, the output voltage will
rise. In either case, this action will tend to reduce
The engine governors will control sharing of the real the reactive current for better sharing of KVAR with
power requirements (kW). The voltage regulator will other units.
control sharing of the reactive power requirements
(KVAR) of the total system load. Occasionally, The following items are required in order to provide
one generator output voltage is slightly higher the voltage droop function:
than the other generators. This will supply lagging
reactive current flow to the other generators that • 1 Ampere CT or 5 Ampere CT (1)
are connected in the group. The lagging reactive
current flow will circulate between generators. This • wiring harness
could possibly cause an ampere overloading.
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Systems Operation Section
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i01502293
Series Boost
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SMCS Code: 4467
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g00779203
Illustration 6
Typical Example of a Series Boost Module
Series boost allows the self-excited generators Series boost consists of the series boost module
to stay on the line (approximately 10 seconds) and current transformers (CT).
when there is a short in the generating circuits or
in the load circuits. Therefore, circuit breakers in Voltage sensing and power are applied to the series
the load distribution system get a chance to trip in boost module from the voltage sensing terminals
sequence. When circuit breakers trip in sequence, 20, 22, and 24 of the regulator.
there is less chance for a loss of power to all of the
electrical system.
13
Systems Operation Section
When the sensed voltage is within normal limits, an Note: The generator does NOT control power factor.
electrical signal is sent to the gate of a triac which Power factor is determined by the load.
is located in the series boost module. This triac
short circuits the current transformer. This prevents The voltage regulator can be used with an external
any series boost during normal operation. device (KVAR/PF controller) in order to control one
of the generator output parameters, such as KVAR
If there is a short circuit that causes the voltage at and PF. When the voltage regulator is in the power
the regulator sensing terminals to drop to a low factor mode and when the KVAR/PF controller is in
value, the control signal to the gate of the triac will the power factor mode, the generator produces a
be turned off. Current from the current transformer constant power factor, regardless of the real power
will be rectified. This current will be applied directly output of the generator. In this case, the reactive
to the exciter stator. This field current will be enough current will change when the real power output
to give at least three times full load current into of the generator changes. A 5 Amperes current
a short circuit. After approximately ten seconds, transformer is necessary for any mode of operation
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a timer within the series boost module will again to work, except for the disabled mode.
cause a control signal to be applied to the gate
of the triac. The triac will short circuit the current When the voltage regulator is in the KVAR operating
transformer. Current flow to the exciter stator will be mode and when the KVAR/PF controller is in the
zero, until the short circuit is corrected. KVAR operating mode, the generator produces
a constant value of reactive power (KVARs),
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regardless of the real power output of the generator.
i01535320
In this case, the generator power factor will change
Power Factor Regulation and when the real power output of the generator
changes. A 5 Amperes current transformer is
KVAR Regulation necessary for any mode of operation to work,
except for the disabled mode.
SMCS Code: 4467
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When the generator is connected in parallel with
an infinite bus (utility), the voltage of the generator
is controlled by the infinite bus. The voltage of the
generator will change as the infinite bus voltage
changes. It is not possible to control the system
voltage when the generator is connected to an
infinite bus. In this instance, it is necessary for the
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PF = KW / KVAR,
KW – kilowatts
KVAR – Kilo-Volt-Ampere-Reactive
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CHECK THE VOLTAGE ADJUST RHEOSTAT
A. Turn off the genset. A. Turn off the genset.
B. Check for loose terminals. B. Check if there is the jumper between terminals
4 and 7.
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C. Check for corroded terminals.
Expected Result:
D. Check for proper connections between the
voltage regulator and the generator. There is a jumper that is placed between terminals
4 and 7.
Expected Result:
Results:
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All initial checks show no problems.
• YES – If a remote voltage adjust rheostat is NOT
Results: used, the jumper is properly installed. Proceed
to test step 5.
• YES – There are no loose terminals or corroded
terminals. The connections are correct. Proceed
• YES – If a remote voltage adjust rheostat is used,
to test step 2. the jumper should be removed from terminals
4 and 7. In this case, the rheostat should be
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• NO – One or more of initial checks shows a connected to wires 6A and 7. Proceed to test
problem. step 4.
Repair: Tighten loose terminals. Replace
• NO – There is no jumper between terminals 4 and
corroded terminals. If the connections are 7. The regulator may go into the overexcitation
incorrect, connect the wiring properly according shutoff.
to the wiring diagram.
Repair: Verify the wiring schematics. Install the
STOP. jumper in accordance with the wiring schematic.
Test Step 2. CHECK METERS STOP.
A. Start the genset. Test Step 4. CHECK THE RESISTANCE
OF THE REMOTE VOLTAGE ADJUST
B. Run the genset at no load. RHEOSTAT
C. Ensure the accuracy of the voltmeter. If you are A. Disconnect the wires from terminals 6A and 7.
reading the voltage from the control panel, check
that voltage with a multimeter. B. Measure the resistance of the remote voltage
adjust rheostat while the rheostat is being
Note: Take the voltage readings on terminals 20, 22 adjusted over the operating range.
and 24 at the regulator.
Expected Result:
Expected Result:
The resistance should be between 0 kOhm and 10
Meters are accurate. ± 0.5 kOhm.
15
Troubleshooting Section
Results: Results:
• YES – The resistance increases smoothly within • YES – The jumper is installed when the VAR/PF
the specified range. Proceed to test step 5. controller is not used. There is no jumper between
terminals 2 and 3 when the VAR/PF controller is
• NO – The resistance is not within the specified used. Proceed to test step 7.
value. The resistance jumps to a high value when
the rheostat is adjusted. • NO – The connections are not correct.
Repair: Replace the remote voltage adjust Repair: Place the jumper according to the wiring
rheostat. schematic.
STOP. STOP.
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Test Step 5. CHECK THE SENSING Test Step 7. CHECK CONNECTIONS FOR
CONNECTIONS THE DROOP CURRENT TRANSFORMER
(CT)
A. Check if there is a jumper between terminals
6A and 9. A. Stop the genset.
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Note: If you are using three-phase sensing, B. For a 1 Amperes CT, verify that the connections
terminals 6A and 9 should be jumpered. If you are are to terminals 5 and 6.
using single-phase sensing, this jumper should be
removed. C. For a 5 Amperes CT, verify that the connections
are to terminals 5A and 6.
Expected Result:
Note: For troubleshooting purposes, it is possible to
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The jumper may be installed or the jumper may not operate the voltage regulator when the droop CT is
be installed, based on the phase sensing selection. disconnected. However, the droop CT secondary
wires must be connected together.
Results:
D. Verify that the polarity connection of the droop
• YES – The jumper is installed between CT is connected to terminal 6.
terminals 6A and 9 for three-phase sensing. For
single-phase sensing, the jumper is not installed Expected Result:
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Test Step 6. CHECK CONNECTIONS FOR Repair: If it was impossible to verify, stop the
THE VAR/PF CONTROLLER genset and reverse the lead connections. Perform
this step again. If the connections were backward,
A. If the VAR/PF controller is used, verify whether connect the droop CT wires correctly.
there is no jumper between terminals 2 and 3.
STOP.
B. If the VAR/PF controller is not used, place the
jumper between terminals 2 and 3. Test Step 8. CHECK THE VOLTAGE
INPUTS ON A PERMANENT MAGNET
Expected Result: GENERATOR
The jumper has been placed accordingly. A. Check the voltages between the following
terminals:
• 26 and 28
16
Troubleshooting Section
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A. Make sure that the generator set is off.
Repair: There is no power which is coming
from the permanent magnet generator to the B. If the generator uses Power Transformers (PT)
voltage regulator. Correct the wiring according to to step down the generator output voltage to
schematics. Refer to the Testing and Adjusting, the sensing voltage, check the sensing voltage
“Wiring Diagrams”. If the measured voltages are range. The sensing voltage range should lie
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balanced, but the voltages are between 20 VAC between the following limits:
and 89 VAC, replace the PM exciter rotor.
• 180 V to 264 V on 60 Hz gensets
STOP.
• 150 V to 220 V on 50 Hz gensets
Test Step 9. CHECK THE VOLTAGE
INPUTS ON A SELF-EXCITED C. Verify that sensing wires 20, 22, and 24
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GENERATOR are connected correctly. Wire 20 should be
connected to T3 phase. Wire 22 should be
A. Check the voltages between the following connected to T1 phase. Wire 24 should be
terminals: connected to T2 phase.
The generator voltage is lower than the nominal The voltage should be adjustable between 180
voltage. The generator voltage is steady. and 264 V for 60 Hz operation. The voltage should
be adjustable between 150 and 220 V for 50 Hz
Results: operation.
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Repair: Add the load to the genset. If the
voltage still oscillates, turn off the genset. • NO – The regulator does not perform the
Reset the voltage regulator. Start the genset adjustment to operating voltage, as described
again and run at no load. Add load to the above.
generator. If the voltage oscillates again, go to the
Troubleshooting, “Unstable Voltage”. If the voltage Repair: Check diodes. Refer to the appropriate
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is no longer low, the problem has been fixed. Operations and Maintenance Manual for the
particular generator. If the problem has not been
STOP. eliminated, replace the voltage regulator.
STOP.
18
Troubleshooting Section
Test Step 2. CHECK METERS Repair: Verify the wiring schematics. Install the
jumper in accordance with the wiring schematic.
A. Start the genset.
STOP.
B. Run the genset at no load.
Test Step 4. CHECK THE RESISTANCE
C. Ensure the accuracy of the voltmeter. If you are OF THE REMOTE VOLTAGE ADJUST
reading the voltage from the control panel, check RHEOSTAT
that voltage with a multimeter.
A. Disconnect the wires from terminals 6A and 7.
Note: Take the voltage readings on terminals 20, 22
and 24 at the regulator. B. Measure the resistance of the remote voltage
adjust rheostat while the rheostat is being
Expected Result: adjusted over the operating range.
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Meters are accurate. Expected Result:
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to test step 3. Results:
• NO – The meters’ readings do not match. • YES – The resistance increases smoothly within
the specified range. Proceed to test step 5.
Repair: Troubleshoot the metering circuit. Verify
the schematic for the metering circuit. Verify • NO – The resistance is not within the specified
whether the meters are connected correctly. value. The resistance jumps to a high value when
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the rheostat is adjusted.
STOP.
Repair: Replace the remote voltage adjust
Test Step 3. CHECK CONNECTIONS OF rheostat.
THE VOLTAGE ADJUST RHEOSTAT
STOP.
A. Turn off the genset.
Test Step 5. CHECK THE SENSING
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There is a jumper that is placed between terminals Note: If you are using three-phase sensing,
4 and 7. terminals 6A and 9 should be jumpered. If you are
using single-phase sensing, this jumper should be
Results: removed.
Repair: Connect the jumper in accordance with C. Verify that sensing wires 20, 22, and 24
the phase sensing selection. are connected correctly. Wire 20 should be
connected to T3 phase. Wire 22 should be
STOP. connected to T1 phase. Wire 24 should be
connected to T2 phase.
Test Step 6. CHECK CONNECTIONS FOR
THE DROOP CURRENT TRANSFORMER Expected Result:
(CT)
The sensing voltage is correct. The sensing wires
A. Stop the genset. are connected properly.
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C. For a 5 Amperes CT, verify that the connections connections are correct. Proceed to test step 8.
are to terminals 5A and 6.
• NO – The sensing voltage is NOT correct and/or
Note: For troubleshooting purposes, it is possible to the sensing wires are NOT connected properly.
operate the voltage regulator when the droop CT is
disconnected. However, the droop CT secondary Repair: Install a PT with correct ratios. Connect
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wires must be connected together. the sensing wires to correct terminals.
• YES – The connections are correct. Proceed to C. Read the output voltage from the control panel.
test step 7.
Expected Result:
• NO – The connections are not correct or the
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connections are impossible to verify. The generator voltage is higher than the nominal
voltage. The generator voltage is steady.
Repair: If it was impossible to verify, stop the
genset and reverse the lead connections. Perform Results:
this step again. If the connections were backward,
connect the droop CT wires correctly. • YES – The generator voltage is still high but
steady. Proceed to test step 9.
STOP.
• NO – The generator voltage oscillates. The
Test Step 7. VERIFY THE SENSING voltage goes very high. Then, the voltage goes
VOLTAGE very low.
A. Make sure that the generator set is off. Repair: Add the load to the genset. If the
voltage still oscillates, turn off the genset.
B. If the generator uses Power Transformers (PT) Reset the voltage regulator. Start the genset
to step down the generator output voltage to again and run at no load. Add load to the
the sensing voltage, check the sensing voltage generator. If the voltage oscillates again, go to
range. The sensing voltage range should lie the Troubleshooting, “Voltage Regulator”. If the
between the following limits: voltage is no longer high, the problem has been
fixed.
• 180 V to 264 V on 60 Hz gensets
STOP.
• 150 V to 220 V on 50 Hz gensets
20
Troubleshooting Section
The generator frequency is above 5% of the rated A. Turn off the genset.
frequency.
B. Check for loose terminals.
Results:
C. Check for corroded terminals.
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• YES – The frequency is above the rated
frequency. In this case, the voltage will be higher D. Check for proper connections between the
than the rated voltage. voltage regulator and the generator.
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Adjusting, “Knee Frequency - Adjust”. All initial checks show no problems.
STOP. Results:
• NO – The generator frequency is same as the • YES – There are no loose terminals or corroded
rated frequency. The high voltage problem still terminals. The connections are correct. Proceed
exists. Proceed to test step 10. to test step 2.
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Test Step 10. CHECK THE REGULATOR • NO – One or more of initial checks shows a
problem.
A. Adjust the operating voltage range by using the
voltage adjustment. Refer to the Testing and Repair: Tighten loose terminals. Replace
Adjusting, “Voltage - Adjust”. corroded terminals. If the connections are
incorrect, connect the wiring properly according
Expected Result: to the wiring diagram.
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Expected Result: circuit from the attachments, which can cause
voltage to become unstable.
Engine speed is stable.
If the problem has not been resolved, proceed
Results: to test step 6.
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• YES – Engine speed is stable. Proceed to test Test Step 6. CHECK THE REGULATOR
step 4.
A. Adjust the operating voltage range by using the
• NO – When the engine speed is unstable, the voltage adjustment. Refer to the Testing and
frequency will be also unstable. The unstable Adjusting, “Voltage - Adjust”.
frequency causes the voltage to become unstable
as well. Expected Result:
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Repair: Troubleshoot the engine RPM. Refer to The voltage should be adjustable between 180
the appropriate engine service manual. and 264 V for 60 Hz operation. The voltage should
be adjustable between 150 and 220 V for 50 Hz
STOP. operation.
• YES – The voltage is stable. Add the load to Repair: Check diodes. Refer to the appropriate
the generator. If the voltage remains stable, the Operations and Maintenance Manual for the
problem has been resolved. Otherwise, proceed particular generator. If the problem has not been
to test step 5. eliminated, replace the voltage regulator.
Results:
i01534468
Remote Voltage Control • YES – The problem has been eliminated. STOP.
F
STOP.
B. Turn the remote voltage adjust rheostat in a fully
counterclockwise direction.
i01534470
C. Measure the resistance between terminals 6A
and 7. Voltage Droop Control
O
D. Turn the remote voltage adjust rheostat in a fully SMCS Code: 4467-038
clockwise direction.
Test Step 1. CHECK THE DROOP CIRCUIT
E. Measure the resistance between terminals 6A
and 7. A. Turn off the genset.
Expected Result:
Results:
First, voltage increases rapidly to a very high value.
• YES – Resistance lies within specified range. Then, the voltage goes to a very low value.
Proceed to test step 2.
Results:
• NO – Resistance is outside specified range.
• YES – The voltage acts, as described above.
Repair: Check if the wires are broken. Check for
the wires that are shorted to ground. Check for Repair: Stop the genset. Switch wires to terminals
bad solder joints. 5 and 6 for a 1 Ampere current transformer
(CT). Switch wires to terminals 5A and 6 for a 5
STOP. Ampere CT. Start the genset and run the genset
at no load.
Test Step 2. CHECK THE REMOTE
VOLTAGE ADJUST RHEOSTAT STOP.
A. Reconnect the remote voltage adjust rheostat • NO – The voltage is within specified range.
to the voltage regulator. Proceed to test step 2.
Expected Result: C. Start the genset and run the genset at no load.
F
STOP. “Wiring Diagrams”.
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i01534471
Expected Result:
Results:
STOP.
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Testing and Adjusting 5. Rotate stability adjustment (1) CW just past the
point at which oscillation occurred.
Section
Note: If the voltage remains stable when the
adjustment is fully CCW, leave the adjustment
fully CCW. This gives the fastest response to load
Testing and Adjusting changes.
i01502445 i01502538
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g00779264 g00779323
Illustration 7 Illustration 8
VR6 Voltage Regulator VR6 Voltage Regulator
(1) Stability adjustment (1) Voltage adjustment
An oscilloscope or other voltage recording device Rotate the voltage adjustment (1) in the clockwise
should be used if an optimal stability setting is direction in order to increase the voltage. Rotate
desired. Rotate stability adjustment (1) in the the voltage adjustment (1) in the counterclockwise
clockwise (CW) direction if you need to slow the direction in order to decrease the voltage.
response time. Rotate stability adjustment in the
counterclockwise (CCW) direction if you need When the jumper is installed between terminals 4
to speed the response time. If the adjustment is and 7, the nominal voltage of the generator can
rotated too far in a CCW direction, the generator be varied over the operating range by using the
voltage may oscillate or the voltage may hunt. voltage adjustment (1).
Good response can be obtained with the following In order to use an external voltage adjust rheostat,
procedure: perform the following procedure:
2. Run the generator at no load. 2. Remove the jumper between terminals 4 and 7.
3. Rotate stability adjustment (1) CW until the 3. Connect an external voltage adjust rheostat
voltage becomes stable. across terminals 6A and 7. The rheostat is rated
at 10 kOhm.
4. Rotate stability adjustment (1) CCW until the
system just begins to oscillate.
25
Testing and Adjusting Section
Note: On some gensets, the voltage adjust rheostat 6. Connect a jumper from terminal 8 to terminal 6A
is located on the control panel. in order to provide an underfrequency slope of 1
V/Hz. No connection to terminal 8 will result in an
4. Turn the voltage adjustment (1) in a fully underfrequency slope of 2 V/Hz.
clockwise direction in order for the external
adjustment to operate properly.
Operation at 50 Hz
i01502616 1. Adjust the generator frequency for 50 Hz.
Knee Frequency - Adjust 2. Turn the knee frequency adjustment (1) fully
counterclockwise (CCW) or until voltage does
SMCS Code: 4467-025 not increase with further turning.
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3. Turn the voltage adjustment (2) until the voltage
is at 200 VAC.
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5. Turn the knee frequency adjustment (1) CCW
until the voltage just returns to 240 VAC. The
knee frequency is now set just below the nominal
operating frequency.
Operation at 60 Hz
1. Adjust the generator frequency for 60 Hz.
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Illustration 10
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VR6 Voltage Regulator g00779405
Illustration 11
(1) Droop adjustment
VR6 Voltage Regulator
(1) Factory calibration adjustment
Variable levels of parallel droop compensation can (2) Voltage adjustment
be obtained by adjusting the droop potentiometer
(1). Clockwise rotation increases the amount of
droop for a given condition. NOTICE
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8. Verify that the voltage on 20-22-24 is between Self-excited generators may lose the residual
156 VAC and 180 VAC. The unit is calibrated. magnetism that normally exists in the exciter field
(L1) and the main field (L3). Residual magnetism
9. Seal the factory calibration adjustment (1). is necessary to start the generation process. The
magnetism can be restored by flashing exciter field
(L1) with direct current. A 12 VDC battery can be
i01585330
used to supply the direct current.
Exciter Field - Flash
NOTICE
SMCS Code: 4470-025 Do not flash permanent magnet pilot excited (PMPE)
generators. Damage to the generator set can occur.
F
• Static Flashing (stopped engine)
• Dynamic Flashing (running engine)
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Static Flashing (Stopped Engine)
Table 4
TOOLS NEEDED
Tool Quantity
12 VDC Battery 1
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1. Stop the engine.
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g00614470
Illustration 13
Dynamic Flashing Circuit
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(1) Battery (≤ 12 VDC)
(2) Diode
(3) Red test lead “+”
(4) Black test lead “-”
Table 5
TOOLS NEEDED
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Part Number Tool Quantity
6V-7070 Digital 1
Multimeter
9P-5153 Diode 1
(MR-504)
Dynamic 1
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Flashing Circuit
5. Hold the red lead of the dynamic flashing circuit 1. Connect the voltage regulator according to
to terminal “F1”. Illustration 14.
6. Monitor the voltmeter. Touch the black lead to 2. Apply the AC power source to the voltage
terminal “F2” of the dynamic flashing circuit. regulator. The AC power source is 240 V ± 5%.
29
Testing and Adjusting Section
3. Turn the voltage adjustment (3) in a fully 10. Slightly reduce the frequency of the genset.
counterclockwise direction. The light should Generator voltage should decrease proportionally
decrease in intensity as the voltage adjustment is with the frequency. Otherwise, readjust the knee
turned CCW. After 10 to 15 seconds at maximum frequency again.
intensity, light bulb (7) should go OFF.
11. Increase the frequency to the rated frequency.
4. Turn the voltage adjustment in a fully clockwise
direction. The light should increase in intensity
i01502837
as the voltage adjustment is turned CW. The light
bulb (7) should go ON. Wiring Diagrams
5. Slowly turn the voltage adjustment CCW until the SMCS Code: 4467; 7566
light goes OFF.
F
The following wiring diagrams are shown below:
Expected Result: The light bulb (7) operates, as
described above.
Results:
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• “NO”: The light bulb (7) reacts differently. Replace
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Note: Knee frequency (4) should be adjusted during
generator’s operation.
i01534466
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Table 6
No. of Generator Leads Excitation Voltage Sensing No. of Illustration
10/12 Permanent Magnet (PM) three-phase 15
Self-Excited (SE) single-phase 16
three-phase 17
4/6 PM three-phase 18
SE single-phase 19
three-phase 20
Medium Voltage PM three-phase 21
F
SE single-phase 22
three-phase 23
Attachments
VAR/PF controller 24
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Series Boost Module 25
Cross Current Compensation 26
three-phase sensing.
Remove the jumper between terminals 6A and 9 for single-phase sensing.
Note 3 Connect terminals 2 and 3 to the VAR/PF controller. Short terminals 2 and 3 when the VAR/PF controller
is not used.
Note 4 For three-phase voltage sensing, connect the wiring to the secondary winding. Phase rotation with transformer
T1 is important.
Connect terminal 22 to the PT on T1. Connect terminal 24 to the PT on T2. Connect terminal 20 to the PT on T3.
Note 5 Sensing input voltage is rated at 25 VA.
Note 6 The shunt is rated for 100 mV at full rated field current.
Note 7 Use twisted, shielded cables.
31
Testing and Adjusting Section
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g00779533
Illustration 15
(CR1-CR6) Rotating rectifiers (L4) Main stator
(CR7, CR8) Surge suppression diodes (L5) PM exciter stator
(E1) Positive heat sink (M) Rotating permanent magnet
(E2) Negative heat sink (R2) Remote level rheostat
(L1) Exciter field (stator) (R5) Suppression resistor
(L2) Exciter armature (rotor) (RFA) Revolving field assembly
(L3) Revolving field (main rotor) (T1) Voltage droop transformer (option)
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g00779534
Illustration 16
(CR1-CR6) Rotating rectifiers (L1) Exciter field (stator) (R2) Remote level rheostat
(CR7, CR8) Surge suppression diodes (L2) Exciter armature (rotor) (R5) Suppression resistor
(E1) Positive heat sink (L3) Revolving field (main rotor) (RFA) Revolving field assembly
(E2) Negative heat sink (L4) Main stator (T1) Voltage droop transformer (option)
F
O
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g00779536
Illustration 17
(CR1-CR6) Rotating rectifiers (L1) Exciter field (stator) (R2) Remote level rheostat
(CR7, CR8) Surge suppression diodes (L2) Exciter armature (rotor) (R5) Suppression resistor
(E1) Positive heat sink (L3) Revolving field (main rotor) (RFA) Revolving field assembly
(E2) Negative heat sink (L4) Main stator (T1) Voltage droop transformer (option)
F
O
O
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g00779538
Illustration 18
(CR1-CR6) Rotating rectifiers (L4) Main stator
(CR7, CR8) Surge suppression diodes (L5) PM exciter stator
(E1) Positive heat sink (M) Rotating permanent magnet
(E2) Negative heat sink (R2) Remote level rheostat
(L1) Exciter field (stator) (R5) Suppression resistor
(L2) Exciter armature (rotor) (RFA) Revolving field assembly
(L3) Revolving field (main rotor) (T1) Voltage droop transformer (option)
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O
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g00779539
Illustration 19
(CR1-CR6) Rotating rectifiers (L1) Exciter field (stator) (R2) Remote level rheostat
(CR7, CR8) Surge suppression diodes (L2) Exciter armature (rotor) (R5) Suppression resistor
(E1) Positive heat sink (L3) Revolving field (main rotor) (RFA) Revolving field assembly
(E2) Negative heat sink (L4) Main stator (T1) Voltage droop transformer (option)
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O
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g00779540
Illustration 20
(CR1-CR6) Rotating rectifiers (L1) Exciter field (stator) (R2) Remote level rheostat
(CR7, CR8) Surge suppression diodes (L2) Exciter armature (rotor) (R5) Suppression resistor
(E1) Positive heat sink (L3) Revolving field (main rotor) (RFA) Revolving field assembly
(E2) Negative heat sink (L4) Main stator (T1) Voltage droop transformer (option)
F
O
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g00779542
Illustration 21
(CR1-CR6) Rotating rectifiers (L4) Main stator
(CR7, CR8) Surge suppression diodes (L5) PM exciter stator
(E1) Positive heat sink (M) Rotating permanent magnet
(E2) Negative heat sink (R2) Remote level rheostat
(L1) Exciter field (stator) (R5) Suppression resistor
(L2) Exciter armature (rotor) (RFA) Revolving field assembly
(L3) Revolving field (main rotor) (T1) Voltage droop transformer (option)
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g00779543
Illustration 22
(CR1-CR6) Rotating rectifiers (L1) Exciter field (stator) (R2) Remote level rheostat
(CR7, CR8) Surge suppression diodes (L2) Exciter armature (rotor) (R5) Suppression resistor
(E1) Positive heat sink (L3) Revolving field (main rotor) (RFA) Revolving field assembly
(E2) Negative heat sink (L4) Main stator (T1) Voltage droop transformer (option)
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O
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g00779544
Illustration 23
(CR1-CR6) Rotating rectifiers (L1) Exciter field (stator) (R2) Remote level rheostat
(CR7, CR8) Surge suppression diodes (L2) Exciter armature (rotor) (R5) Suppression resistor
(E1) Positive heat sink (L3) Revolving field (main rotor) (RFA) Revolving field assembly
(E2) Negative heat sink (L4) Main stator (T1) Voltage droop transformer (option)
VAR/PF Controller
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O
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g00779545
Illustration 24
(CR1-CR6) Rotating rectifiers (L1) Exciter field (stator) (R2) Remote level rheostat
(CR7, CR8) Surge suppression diodes (L2) Exciter armature (rotor) (R5) Suppression resistor
(E1) Positive heat sink (L3) Revolving field (main rotor) (RFA) Revolving field assembly
(E2) Negative heat sink (L4) Main stator (T1) Voltage droop transformer (option)
41
Testing and Adjusting Section
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O
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Illustration 25
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Illustration 26
Index
D P
F
Electrical.................................................................. 4
Exciter Field - Flash............................................... 27 S
Dynamic Flashing (Running Engine) ................. 28
Static Flashing (Stopped Engine) ...................... 27 Series Boost .......................................................... 12
Specifications Section ............................................. 4
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Stability - Adjust..................................................... 24
F Symptom Procedures ............................................ 14
Systems Operation Section ..................................... 7
Features .................................................................. 9
Droop ................................................................... 9
Knee Frequency................................................... 9 T
Overexcitation Protection ..................................... 9
Reference Voltage................................................ 9 Table of Contents..................................................... 3
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Sensing Voltage ................................................... 9 Testing and Adjusting ............................................ 24
Stability ................................................................ 9 Testing and Adjusting Section ............................... 24
V/Hz Slope ........................................................... 9 Troubleshooting Section ........................................ 14
G U
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H V
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three-phase sensing......................................... 36
Cross Current Compensation ............................ 42
Medium voltage permanent magnet generators
with three-phase sensing ................................. 37
Medium voltage self-excited generators with
single-phase sensing ....................................... 38
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Medium voltage self-excited generators with
three-phase sensing......................................... 39
Series Boost Module.......................................... 41
VAR/PF Controller.............................................. 40
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All Rights Reserved Printed in U.S.A.