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Instructions: Voltage Regulator Kr4Ffx/Ffmx and Kr7Ffx/Ffmx
Instructions: Voltage Regulator Kr4Ffx/Ffmx and Kr7Ffx/Ffmx
Instructions: Voltage Regulator Kr4Ffx/Ffmx and Kr7Ffx/Ffmx
INSTRUCTIONS
FOR
Basler Electric Power Systems Group
Phone 618 654-2341 VOLTAGE REGULATOR Fax 618 654-2351
Route 143 Box 269 http://www.basler.com
Highland IL 62249 USA
KR4FFX/FFMX and KR7FFX/FFMX info@basler.com
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9 1610 00 101/9 1606 00 101 and 9 1611 00 101/9 1607 00 101
INTRODUCTION Electromagnetic Interference (EMI) Filtering and that the 50 Hz connection is made.
Refer to Figure 3. (3) With the regulator properly connected into
The Basler KR Series Voltage Regulators
the system (Figure 4), bring the generator up to
precisely control the output voltage of an ac PHYSICAL SPECIFICATIONS rated frequency (50 Hz).
electric generating system by controlling the Operating Temperature: -40( C (-40( F) to (4) While watching the generator voltmeter,
amount of current supplied to the exciter (or
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+60( C (+140(F). adjust the Internal Voltage Range Adjustment
generator) field. The KR Series Voltage
Storage Temperature: -65( C (-85( F) to +85( until the nominal generator voltage is obtained.
Regulators contain built-in Electromagnetic
C (+185( F). (Voltage increases with CW rotation.)
Interferenc e (EMI) filtering and an
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underfrequency roll-off characteristic. Weight 6.0 lbs. (2.7 kg) net. 7.0 After the internal Voltage Range Adjustment
lbs. (3.2 kg) shipping. has been properly set, the External Voltage
ELECTRICAL SPECIFICATIONS
Vibration: Withstands the following:5 Adjust Rheostat will provide a voltage
Input Power Requirements adjustment of ±10% of nominal (both 50 and 60
to 26 Hz at 1.2 g. 27 to 52 Hz at 0.036 inch
KR4FFX/FFMX: 120 to 139 Vac (nom.), double amplitude. 53 to 260 Hz at 5.0 g. Hz systems).
11, 60 Hz, 300 VA. 100 to 127 Vac (nom.), 11, Stability Adjustment
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Shock: Withstands 20 g in each
50 Hz, 300 VA. This screwdriver adjustment adjusts the system
of three mutually perpendicular planes.
KR7FFX/FFMX: 208 to 277 Vac (nom.), stability by controlling the amount of feedback
Mounting The unit is designed to
11, 60 Hz, 840 VA. 220 to 240 Vac (nom.), 11, that is applied to the Sensing and Gating
operate when mounted directly on a diesel or
50 Hz, 840 VA. Circuitry. Normally, it is factory preset near the
turbine driven generator system. The unit can
Input Sensing Requirements extreme clockwise (CW) position. This setting
also be mounted in switchgear or control
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50 Hz, 11: 100-110/220-230- panels.
normally assures good stability, but tends to
240/380-400-415/500 Vac, ±10%, 60 Hz, 11; slow the response time of the generator. If
Accessories rotated counterclockwise (CCW), the system
120-139/208-240/416-480/520-600 Vac, ±10%.
The KR Series Voltage Regulator is designed response time becomes faster. However, if
Input Sensing Burden to be compatible with any of the following listed rotated too far CCW, the generator voltage may
10 VA per phase accessories and equipment.
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oscillate (hunt). It should then be rotated CW
Power Output 1. VAR/Power Factor Controller (SCP 250) well above the point where oscillating occurred.
KR4FFX/FFMX: 2.5 A @ 63 Vdc max- 2. Series Boost Option The system voltage stability is most critical at
imum continuous. 3.5 A @ 90 Vdc 1 minute 3. Current Transformers (CT2 through CT50) no-load. If a setting is desired that provides the
forcing (120 Vac input). 4. Minimum/Maximum Excitation Limiter (EL fastest possible voltage response with good
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KR7FFX/FFMX: 3.5 A @ 125 Vdc max- 200) generator stability, an oscilloscope or some
imum continuous. 5.0 A @ 180 Vdc 1 minute 5. Auto-Synchronizer (BE3-25A) load transient voltage recording device should
forcing (240 Vac input). 6. Auto-Synchronizer (BE1-25A) be used.
7. Line Drop Compensator (LDC 300)
Field Resistance Sensing Transformer Reconnection
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Regulation Accuracy voltage of the regulated generator voltage. and 500; ±10%
±1% from no-load to full-rated load and 5% When connected as shown in Figure 4, The transformer is normally factory connected
frequency variation. adjustment of the rheostat to maximum to the 120 Vac tap and must be reconnected to
Thermal Stability resistance (CCW) will obtain minimum another tap before operation if a voltage other
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±1% voltage variation for a 40(C (104(F) generator voltage output. Maximum generator than the 120 Vac sensing is used.
change within the operating range. voltage output is obtained by turning the rheo- Reconnection is facilitated through the use of
stat clockwise (CW) to the minimum resistance solderless connectors. Figure 4 shows the
Power Dissipated sensing transformer location and the voltage
position.
<20 watts at maximum continuous rating. tap identification.
Voltage Range Adjustment
Underfrequency Operational Threshold This screwdriver adjustment is factory set to INSTALLATION
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54 Hz nominal in 60 Hz systems (see Figure 1). establish the nominal ranges of sensing General
44 Hz nominal in 50 Hz systems (see Figure 2). voltages associated with 60 Hz operation. If 60 The Regulator must be connected to the
Regulator Response Hz sensing is used, this control will not generator system as instructed in this section
<17 milliseconds in 60 Hz systems. normally need adjustment. and as shown in the basic interconnection
<20 milliseconds in 50 Hz systems. When nominal 50 Hz sensing voltages are diagram (Figure 5).
Frequency Compensation required, this control is used to establish the Input Power (Terminals 3 and 4)
Variable. Frequency roll-off is preset at the desired nominal sensing voltage. This is done The voltage regulator operates on a power
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factory for 48.5 Hz (50 Hz systems) and 58.5 in the following manner. input voltage applied to terminals 3 and 4. If
Hz (60 Hz systems). Either V/Hz or 2 V/Hz can (1) Set the External Voltage Adjust Rheostat the correct voltage is not available at the
be selected. Refer to Figures 1 and 2. to the middle of its adjustment range. generator, or if the field flashing circuit is
(2) Ensure that the appropriate sensing grounded, a power isolation transformer must
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voltage connection is made (refer to Figure 4) be used. The transformer is not furnished with
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Because the regulator output leads are not OPERATION
from the Basler Electric Company. connected to any part of the system except the This section contains operation procedures.
The KR Voltage Regulators contain filter generator field, they are not filtered. Since EMI Before operating, ensure that the regulator is
capacitors that are internally connected is present on these leads, it may be necessary connected into the system as shown on the
between terminal 3 and the chassis and to observe precautions with regard to the lead interconnection diagram (Figure 5). Even
between terminal 4 and the chassis. Each installation. Optimum results will be obtained momentary operation with an incorrect
capacitor is rated at 370 Vac. When using when the field leads are kept as short as connection can damage the regulator or other
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these regulators with generators whose output possible and shielded. Effective shielding can control equipment.
is above 370 Vac, ensure that the voltage be achieved by routing both leads through a
Field Flashing
between terminal 3 and ground and terminal 4 standard 0.5 inch diameter conduit. Not more
and ground does not exceed 370 Vac. The than one or two feet of the field leads should be
CAUTION!
voltage across the regulator's filter capacitors unshielded. If the regulator is installed on the
Do not attempt to flash the machine when
can exceed 370 Vac on an ungrounded generator frame, it is possible to achieve
generating system when the line-to-line voltage satisfactory results with short, unshielded it is rotating.
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exceeds 370 Vac. leads.
When the Voltage Regulator is operated with
Example (Figure 6): On a 480 Vac generating External Voltage Adjust Rheostat
the generator for the first time, the polarity of
system with an ungrounded neutral lead and The voltage adjust rheostat (Terminals 6 and 7)
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residual magnetism may not be correct or of
regulator chassis, if the KR7FFX regulator input is furnished with the voltage regulator for sufficient magnitude. If the generator does not
power (terminals 3 and 4) is obtained line-to- remote mounting and wiring. It should be 175 build up after start-up, check for 6 volts or more
neutral (277 Vac), and then a ground occurs on ohms and 2 watts minimum. residual at the regulator terminals TB1-3 and
one of the other two generator lines, 480 Vac
MOUNTING TB1-4. If the voltage is below 6 volts, shut
will be applied across one of the voltage
The Voltage Regulator may be mounted in any down the prime mover and proceed as follows:
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regulator filter capacitors.
position. However, it should be vertically 1. With the prime mover at rest, connect a
On this same system with the same conditions,
mounted to obtain optimum cooling. The Reg- limiting resistor of 25 to 30 ohms in series with
but with the regulator connected phase-to-
ulator can be mounted in any location where the field (terminals F+ and F-).
phase (T7 and T9) at the generator's Wye con-
the ambient temperature does not exceed the 2. Observe polarity and apply a dc source
nection tie point (240 Vac) the voltage across
operational limits. Due to its rugged construc- (non-grounded) of not more than 12 Vdc, to the
the regulator's filter capacitors would have been
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tion, the Regulator can be mounted directly on series circuit of the field and resistor.
reduced to 366 Vac.
the generator. Mounting hardware should be 3. Allow approximately 3 seconds before
If the line-to-line voltage of the generating removing the dc source.
selected based upon the vibration and shock
system is reduced to 416 Vac, the voltage 4. With the voltage regulator power input
expected to be encountered during shipping/
across the regulator's filter capacitors is disconnected (terminals 3 and 4), start the
transport and normal operation. Refer to Figure
reduced to 318 Vac. prime mover and measure the voltage at the
7 for the outline drawing of the unit which pro-
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The power input leads are EMI filtered. In most vides overall and mounting dimensions. generator terminals. If the generator output is
applications, securing the regulator with a good less than 6 volts, repeat steps 1 through 3. If
ACCESSORY ITEMS
metal-to-metal bond ensures a reduction in the voltage is greater than 6 volts, voltage
interference to acceptable limits. As in all Voltage Shutdown Switch build-up should occur. Stop the prime mover
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interference reduction situations, it is necessary The system can be equipped with a switch to and reconnect the regulator input power.
to maintain a good electrical connection allow the removal of the excitation in case of an Preliminary Operation
between the filter ground and the system emergency or when the generator prime mover
Verify that all wiring is properly and securely
ground. A good electrical power ground is not must be operated at reduced speed. This
connected (Refer to Figure 5).
necessarily a good interference ground. switch must always be placed in the input
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Ground leads should be as short as possible, power line that is connected to the regulator at System Checkout
preferably of a copper braid whose width is 1/5 terminals 3 and 4. Perform the following steps to ensure the
of the length. For applications involving radio proper operation of the regulator initial
reception, additional improvement can be operation.
CAUTION!
noticed by connecting the system to earth Step 1. Start the prime mover and bring up to
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power ground. This is because the filter provide for the parallel operation of two or If necessary refer to the troubleshooting chart.
capacitors are connected between the line more generators. (b) No Voltage Build-up. If this condition
and the regulator case. occurs, field flashing may be required.
Manual Voltage Control
(c) Undervoltage. If this condition occurs,
A Manual Voltage Control is available for use adjust the External Voltage Adjust Rheostat. If
Output Power (Terminals F+ and F-) with the voltage regulator to provide a manual not corrected, refer to the troubleshooting chart.
The dc resistance of the exciter field winding backup that is independent of the voltage (d) Voltage Builds Up and Then Collapses.
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must be at least the minimum value specified in regulator. If this condition occurs, stop the prime mover
the Electrical Specifications. If the field Excitation Support System and determine the cause by referring to the
resistance is less than this value, a series troubleshooting chart.
In brushless exciter applications, no source of
resistor is required to increase the field (e) Oscillating Voltage. If this condition
power is available for field forcing during short
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resistance. This additional resistance is occurs, rotate the Stability Adjustment Poten-
circuit and large motor starting conditions. The
required to limit the regulator field current tiometer (R15) to correct. If the voltage
addition of an Excitation Support System will
forcing because excessive current may damage continues to oscillate and the Stability
prevent the collapse of excitation by providing
the regulator semiconductors. This resistance Adjustment (R15) has no effect, refer to the
constant voltage to the regulator for all load
must not be of such a value as to restrict the troubleshooting chart.
conditions and short circuits.
excitation at full load.
not available, repair wiring. If the sensing
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Step 3. Adjust the External Voltage Adjust Troubleshooting Chart
Rheostat for nominal generator output voltage. voltage is proper, proceed to Step 2.
Common generator system malfunctions and
Step 4. Apply a load to the generator. the appropriate repair procedures are listed in Step 2. Check for defective voltmeter. If
the following paragraphs. voltmeter is defective, replace voltmeter. If
Step 5. Verify that voltage regulation is within
voltmeter is not defective, proceed to Step 3.
±1%. If it is not, refer to the troubleshooting Voltage Does Not Build up to Rated Value
chart. Step 1. Check for low residual voltage (less Step 3. If the above steps fail to correct the
than 6 volts). If low residual voltage exists, malfunction, replace the regulator.
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Step 6. Alternately remove and apply the load
several times to determine if the generator flash the field in accordance with Field Poor Stability (Hunting).
voltage is stable. Flashing. If residual voltage is normal, proceed Step 1. Verify that the frequency is stable. If
to Step 2. the frequency is unstable, consult with the
MAINTENANCE AND TROUBLESHOOTING
Step 2. Check that Shutdown Switch is closed governor manufacturer. If the frequency is
Preventive Maintenance
and that fuses are intact. If Shutdown Switch is stable, proceed to Step 2.
The only preventive maintenance required on closed and fuses are intact, proceed to Step 3. Step 2. Check the adjustment of the Stability
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the KR Series Voltage Regulators is to
Step 3. Check that prime mover is up to Adjustment (R15). If adjusting the Stability
periodically check that the connections between
speed. If prime mover is operating at rated Adjustment does not correct the malfunction,
the Regulator and system are clean and tight
speed, proceed to Step 4. proceed to Step 3.
and that the air flow is not obstructed by
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accumulations of dirt and dust. Step 4. Verify that generator output is not Step 3. Verify that the no-load field voltage is
shorted or heavily loaded. If output is not not below rated. If the no-load field voltage is
Corrective Maintenance
shorted, proceed to Step 5. below rated, refer to Installation, Output Power
The KR Series Voltage Regulators are
Step 5. Verify that wiring and external Voltage (Terminals F+ and F-), and change the field
designed for ease of repair by the replacement
Adjust Rheostat is not defective. If wiring is series resistance. If the no-load field voltage is
of major parts, such as the transformers,
an
defective, repair or replace wiring. If rheostat is at rated, proceed to Step 4.
heatsinks, or the printed circuit board.
defective, replace rheostat. If wiring and Step 4. Verify generator/exciter operation. If
Warranty and Repair Service
rheostat are not defective, proceed to Step 6. generator/exciter operation is improper, contact
The Basler KR Series Voltage Regulators are generator/exciter manufacturer. If generator/
Step 6. Verify that all wiring is correctly
warranted against defective material and exciter operation is proper, proceed to Step 5.
connected at power input terminals 3 and 4 and
workmanship for 18 months from the date of
that input power is of correct value. If power
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Step 5. If the above steps fail to correct the
shipment from our factory. Units submitted for
input is low or not present, repair wiring. If malfunction, replace the voltage regulator.
warranty repair should be returned to the
power input is present, proceed to Step 7. Poor Regulation.
factory in Highland, Illinois, freight prepaid, with
a complete description of the installation and Step 7. Verify that connections at terminals F+ Step 1. Verify that the field voltage/current
the reported problem. Pre-arrangement with and F- are correct. If connections are incorrect, requirements at full load are not in excess of
repair wiring. If connections are correct,
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either the nearest Basler Sales Office or with the maximum regulator output capability. If
the factory will assure the fastest possible turn proceed to Step 8. regulator limits are being exceeded (per
around time. Step 8. Verify that correct sensing tap has Specifications), consult with the factory for a
Functional Testing been selected. If wrong sensing tap has been suitable model. If regulator limits are not
selected, reconnect to proper tap. If correct tap exceeded, proceed to Step 2.
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Step 4. Connect the regulator to a 120 Vac, 60 Voltage Adjust Rheostat. If wiring is defective, Step 4. Check for waveform distortion due to
Hz. source. Note that the light bulb will flash repair wiring. If rheostat is defective, replace harmonic content in generator output voltage.
momentarily when the voltage is applied. rheostat. If connections are proper and not (Regulator senses average voltage, meter may
defective and rheostat is not defective, proceed be indicating RMS value.) If waveform
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Step 6. At the regulating point, a small change at terminals E1 and E3 and that the proper taps
are used. If sensing voltage is not available, If Unit/Parallel is in an incorrect position, place
in the External Voltage Adjust Rheostat should
correct wiring. If sensing voltage is proper, switch into proper position. If Unit/Parallel
turn the light bulb on or off.
proceed to step 2. switch is in proper position, proceed to Step 6.
Step 7. This test may not reveal a stability
Step 2. Replace the voltage regulator. Step 6. Verify generator/exciter operation. If
problem.
generator/exciter operation is improper, contact
Step 8. Before installing the regulator back into Voltage High and Controllable with Voltage generator/exciter manufacturer. If generator/
the system, connect the regulator sensing Adjust Rheostat exciter operation is proper, proceed to step 7.
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transformer back to the original tap selected. Step 1. Verify that the sensing voltage is
Step 7. If the above steps fail to correct the
available at terminals E1 and E3 and that the
malfunction, replace the voltage regulator.
proper taps are used. If the sensing voltage is
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110
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60
40 40
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30 30 40
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Figure 1. 50 Hz Frequency Compensation Figure 2. 60 Hz Frequency Compensation Figure 3. Typical Suppression of Conducted EMI
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KR-FX/KR-FFX VOLTAGE REGULATOR
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380 220 100
400 230 110 500
6
50 HZ* 500 415 240 OHMS
1 2 3
6 7 3 4 E1 E3 F+ F-
CW 4
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GENERATOR CHASSIS 1
GENERATOR B
D2779-06 C
02-27-98
N
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Figure 4. Sensing Transformer Connections + -
T4 3 4
416 VAC
OR
480 VAC
T7 NOTES:
318 VAC
OR 1. Power matching transformer is required if appropriate input voltage is not available at
366 VAC
generator terminals. If field or flashing circuit is grounded, an isolation transformer is
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208 VAC
OR
also required.
240 VAC
T10 2. Internal sensing transformer is provided with taps. It is shipped connected to the 120
T12 T11 Volt tap. If voltage other than 120 V is required, connect wire to applicable tap.
3. The exciter field dc resistance must be at least that listed in the Specifications. If not,
a series resistor must be added so that the total resistance is at least this value.
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T9 T8 4. Shutdown switch allows removal of field excitation. If switch is not used, a temporary
T6 120 VAC T5 switch should be installed during initial operation.
OR
139 VAC 5. The regulator contains an internal relay for voltage buildup. If flashing is required,
refer to Field Flashing. If permanent field flashing is desired, connect as shown and
T3 T2 limit flashing current to <50% of no-load field current. Diode rating: 15 A, 600 PIV.
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1.00
(25.4)
KR-FX OR KR-FFX VOLTAGE REGULATOR
2.015
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(51.18)
D2779-10
10-16-98
6 7 3 4 E1 E3 F+ F-
5.10
7.10 (129.5)
(180.34)
6.50 5.25
(165.10) (133.35)
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EXTERNAL
VOLTAGE
ADJUST LIGHT
RHEOSTAT BULB
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