CONFIDENTIAL INFORMATION of Basler Electric, Highland, IL.

It is loaned for confidential use, subject to return on request, and with the mutual understanding that it will not be used in any manner detrimental to the interest of Basler Electric.

INSTRUCTION MANUAL FOR VOLTAGE REGULATOR Model: APR 63-5

HIGHLAND, IL 62249
60 HZ

Publication: 9 1687 00 991

1997-2000, Basler Electric, Highland, IL 62249 First Printing November 1986 Revision E ECO: 9609 June 2000

BASLER ELECTRIC, INTRODUCTION

BOX 269,

PHONE 618/654-2341
500 400 300 200
50 HZ CB-

FAX 618/654-2351

CB+
R

4.75 (121) 5.66 (144)

F-

Model: APR 63-5

F+

FREQ

Regulation is provided by sensing the generator output voltage, converting it to a dc signal and comparing the signal to a reference voltage signal. An error signal is developed and used to control the dc field power in order to maintain a constant generator output. SPECIFICATIONS Certification: UL Listed, CSA Certified DC Output Power: 5.0 Adc @ 63 Vdc (315 W) maximum continuous, 8.5 Adc @ 105 Vdc (893 W) one minute forcing. Exciter Field DC Resistance: 12.6 ohms minimum, 100 ohms maximum. AC Input Power: 190 to 277 Vac 10%, singlephase, 50/60 Hz. Burden: 650 VA. AC Sensing Input: 190 to 240 Vac (240 V tap), 380 to 480 Vac (480 V tap), single-phase, 50/60 Hz. Burden: 5 VA maximum. Voltage Adjust Range (Internal):170 to 264 Vac (240 V tap) or 340 to 528 Vac (480 V tap). External Voltage Adjust Rheostat: 1,000 ohms, 2 W (supplied as an optional item). Voltage Build-Up: Internal and automatic from generator residual voltage (6 Vac minimum). Overexcitation Shutdown: Output power removed under the following conditions: Exciter field voltage exceeds 100 5 Vdc for a time inversely proportional to voltage magnitude, or instantaneously if voltage exceeds 135 5 Vdc. Operating Temperature: 40C (40F) to +60C (+140F). Storage Temperature: 65C (85F) to +85C (+185F) FUSES Install 5 A, 250 V, high interrupting capacity, fast-blowing fuses in lines 3 and 4. See interconnection diagrams. MOUNTING The regulator may be mounted in any position. Refer to the outline drawing for dimensions. The regulator may be mounted directly on the generator set using hardware. Select the proper hardware to withstand any expected shipping or transportation conditions.
D2717-05 11-18-97 1.094 (27.78)

TIME DELAY (SECONDS)

The Basler APR 63-5 Voltage Regulator is a CSA/UL approved unit contained in an encapsulated plastic case. The regulator controls the dc exciter field power of conventional, 50 or 60 hertz brushless generators that have a 63 Vdc field to regulate the output voltage.

Basler Electric Highland, Illinois

COM

SOLID-STATE VOLTAGE REGULATOR

Sensing: 240, 480 Vac Power: 190-277 Vac 650VA Output: 63 Vdc 5A Oper. Freq. 50/60 Hz

100 80 60 50 40 30 20 10 8 6 5 4 3 2

STAB
7

VOLT

240

D2717-07 11-18-97

0.45 (12) 1.58 (40) 3.16 (80) 0.90 (23)

480

1.35 (34) 1.68 (43)

1
D2717-06 11-18-97

70

80

90

100

110

120

130

140

150

NOTE: ALL DIMENSIONS ARE IN INCHES (MILLIMETERS)

FIELD VOLTS (dc)

+ 135 5 -

APR 63-5 Outline Diagram

Typical Inverse Time Delay Characteristic Curves

REGULATOR CONTROLS

0.625 (15.88)

0.625 (15.88) 0.25 (6.35)

0.53 (13.49)

FREQ CONTROL
This control prevents generator and regulator damage by dropping the generator output voltage when the generator frequency drops. a. Set generator RPM to desired frequency roll-off. Adjust FREQ control until voltage starts to drop off. Speed up generator to rated speed. Voltage should be at nominal.

0.375 (9.53)

0.125 (3.18)

0.81 (20.64)

D2717-08.vsd 06-06-00

NOTE: ALL DIMENSIONS ARE IN INCHES (MILLIMETERS)

External Voltage Adjust Potentiometer (Optional), Basler P/N 17727

120
"CORNER FREQUENCY"

b. c.

GENERATOR OUTPUT (% FROM NOMINAL)

100 80 60
60 HZ 50 HZ

STAB CONTROL
This control allows the generator response time (and thus voltage stability) to be adjusted. Use an oscilloscope or other voltage recording device to set this control. a. b. Rotation of STAB control CW will slow voltage response time. Rotation of STAB control CCW will speed response time. If rotated too far, generator voltage will hunt (oscillate). Rotate STAB control CW just past point where voltage oscillation occurs.

40 20 0 0 10 20 30 40 50 60

FREQUENCY (HZ.) Frequency Compensation Curves

c.

OVEREXCITATION SHUTDOWN If the exciter field voltage exceeds 100 5 Vdc, the regulator automatically removes the field current after a time delay. The time delay is inversely proportional to the magnitude of the detected overvoltage condition. At approximately 135 5 Vdc, the field voltage is removed instantaneously. Refer to the following figure. Upon detection of overexcitation and the resulting field voltage shutdown, the regulator will not reset or return to an operational condition until the generator output drops to less than 6 Vac for 10 seconds minimum.

VOLT CONTROL
Rotation of VOLT control CW will increase generator output voltage. Removing jumper (terminals 6 and 7) and connecting external potentiometer (1,000 ohms, 2 watts) allows a 10% adjustment of voltage range with nominal set by VOLT control. INTERCONNECTION Refer to the following interconnection diagrams. a. Connect the jumper from COM to either the 50 Hz or 60 Hz terminal depending upon the generator frequency.

b.

Remove the jumper and connect terminals CB and CB+ to the CBS 305 inputs (if used). If the CBS 305 is not being used, leave the jumper in place. If an external voltage adjust control is being used, connect the potentiometer to terminals 6 and 7 as shown. If not, connect a jumper between terminals 6 and 7. Connect the exciter field to terminals F+ and F. Be sure to observe polarity. Connect the input power to the generator stator to provide power to terminals 3 and 4. Fuse both leads. Install the optional shutdown switch, if desired. Connect the sensing input to either 240 or 480 depending on voltage. The sensing should be connected line-to-line.

A GEN B C FIELD

ACCESSORY EQUIPMENT

Power Isolation Transformer - BE 18674 001 Parallel Compensation - APM2000 and Current Transformer Manual Voltage Control - MVC-300

2 ISOLATION TRANSFORMER

c.

4 E1 SHUTDOWN SWITCH

Current Boost System - CBS305 and Current Transformer

OPERATIONAL TEST
CW

d. e.

EXTERNAL VOLTAGE ADJUST 1 TO CBS 305 (OPTIONAL)

a. b.

4 3

Connect the test setup as shown below and apply 240 Vac as shown. Adjust the VOLT control fully CCW. Observe that the lamp is not lit. Adjust the VOLT control fully CW. Observe that the lamp is lit. Adjust the VOLT control until the lamp just goes out.
60 HZ

60 HZ

COM

50 HZ

CB-

CB+

F-

F+

240

480

APR 63-5 VOLTAGE REGULATOR

1 JUMPER FOR 60HZ OR 50HZ. REMOVE JUMPER IF CBS 305 IS USED. 2

D2717-11 11-18-97

c. d.

f.

250V, 5A, FAST BLOW, HIGH INTERRUPTING CAPACITY FUSES. IF EXTERNAL ADJUST RHEOSTAT IS NOT BEING USED, JUMPER TERMINAL 6 TO TERMINAL 7.

Isolation Transformer Interconnection Diagram

GEN

A B C
FIELD

OPERATION The following system operation procedures provide instructions for adjusting the APR 635 Voltage Regulator. CAUTION
R

Basler Electric Highland, Illinois

J1
COM 50 HZ CB-

SOLID-STATE VOLTAGE REGULATOR

Sensing: 240, 480 Vac Power: 190-277 Vac 650VA Output: 63 Vdc 5A Oper. Freq. 50/60 Hz
R

J3
CB+

10 OHMS
F-

2
Model: APR 63-5

10 W
F+

100 W LIGHT BULB

SHUTDOWN SWITCH

EXTERNAL VOLTAGE ADJUST 1 TO CBS 305 (OPTIONAL)

Meggers and high potential test equipment must not be used. Incorrect use of such equipment could damage the semiconductors contained in the regulator.
D2717-12 11-18-97

FREQ
4

STAB
7

J2

240 VAC

VOLT

240

480

CW 4

PRELIMINARY SETUP To prevent damage to the regulator, complete the following steps before proceeding with system startup. a. Verify that the voltage regulator specification conforms with the generator system requirements. Ensure that the regulator is correctly connected to the generator. See interconnection diagram. Install fuses per FUSES paragraph.

Operational Test Setup

FIELD FLASHING When the regulator is operated with the generator for the first time, the polarity of residual magnetism may not be correct or the magnitude may not be enough. If the generator does not build up, shut down the prime mover and proceed as follows. a. With the prime mover at rest, apply a dc source (not grounded) of not more than 48 Vdc to terminals F+ and F in series with a limiting resistor. Use 1 ohm of resistance for each volt from the dc source with a power rating of at least 1 watt per volt. Allow approximately 30 seconds before removing the dc source. Start the prime mover and measure the voltage at the regulator leads 3 and 4. If the voltage is greater than 6 Vac, voltage buildup should occur. Repeat flashing if less than 6 Vac residual is measured.

60 HZ

COM

50 HZ

CB-

CB+

F-

F+

240

480

APR 63-5 VOLTAGE REGULATOR

1 JUMPER FOR 60HZ OR 50HZ. 2 250V, 5A, FAST BLOWING, HIGH INTERRUPTING CAPACITY FUSES.

D2717-09 11-18-97

REMOVE JUMPER IF CBS 305 IS USED.

IF EXTERNAL ADJUST RHEOSTAT IS NOT BEING USED, JUMPER TERMINAL 6 TO TERMINAL 7.

b.

240 Vac, 1-Phase Interconnection Diagram

c.
A B C
FIELD

During periods of prime mover idling, use the excitation shutdown switch. SYSTEM STARTUP a. Start the prime mover and bring it up to rated speed. Voltage should build up. If a minimum residual of 6 Vac is not present, perform field flashing. Slowly adjust VOLT control until voltage reaches nominal value. If used, adjust remote voltage adjust to set generator output to exact value desired. Apply and remove load to check stability. Adjust per STAB CONTROL paragraph if voltge is unstable. Reduce generator frequency (speed) to 55 Hz (on 60 Hz systems) or 45 Hz (on 50Hz systems). Check that generator output decreases from this point. If it does not, adjust per FREQ CONTROL paragraph. b. c.

480V GEN

SHUTDOWN SWITCH

b.
EXTERNAL VOLTAGE ADJUST 1 TO CBS 305 (OPTIONAL)

CW 4

c.
7 3 240 480

60 HZ

COM

50 HZ

CB-

CB+

F-

F+

APR 63-5 VOLTAGE REGULATOR

1 JUMPER FOR 60HZ OR 50HZ. 2 250V, 5A, FAST BLOWING, HIGH INTERRUPTING CAPACITY FUSES.

d.
D2717-10 11-18-97

REMOVE JUMPER IF CBS 305 IS USED.

IF EXTERNAL ADJUST RHEOSTAT IS NOT BEING USED, JUMPER TERMINAL 6 TO TERMINAL 7.

480 Vac Interconnection Diagram