Droop R2 R1 Q2 Q1 F2 F1 N W V

A1 A2
FUSE

V AC S UF OE SL UF OE

R150

50 Hz 60 Hz

R150

A.V.R.
Installation and maintenance
 Electric Power Generation Installation and maintenance 5384 en - 2017.07 / e

R150
A.V.R.

This manual concerns the alternator A.V.R. which you have just purchased.
We wish to draw your attention to the contents of this maintenance manual.

SAFETY MEASURES

Before using your machine for the first time,

it is important to read the whole of this
installation and maintenance manual. All servicing or repair operations
performed on the AVR should be
All necessary operations and interventions undertaken by personnel trained in the
on this machine must be performed by a commissioning, servicing and main-
qualified technician. tenance of electrical and mechanical
components.
Our technical support service will be pleased
to provide any additional information you
may require.

The various operations described in this When the generator is driven at a

manual are accompanied by recommen- frequency less than 28 Hz for more than
dations or symbols to alert the user to 30 seconds with an analogic regulator,
potential risks of accidents. It is vital that you the AC power must be disconnected.
understand and take notice of the following
warning symbols.
WARNING
WARNING This A.V.R. can be incorporated in a
machine marked C.E.
Warning symbol for an operation capable This manual is be given to the end user.
of damaging or destroying the machine
or surrounding equipment.
© - We reserve the right to modify the
characteristics of its products at any time in
order to incorporate the latest technological
developments. The information contained in
this document may therefore be changed
Warning symbol for general danger to without notice.
personnel.
This document may not be reproduced in
any form without prior authorization.
All brands and models have been registered
and patents applied for.
Warning symbol for electrical danger to
personnel.

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R150
A.V.R.

CONTENTS

1 - GENERAL DESCRIPTION..................................................................................................4

2 - OPERATION OF THE A.V.R................................................................................................4

3 - TECHNICAL SPECIFICATION............................................................................................5

4 - MAIN FUNCTION OF THE A.V.R........................................................................................6

5 - A.V.R. ADJUSTMENTS.......................................................................................................7

5.1 - V-TRIM: V...................................................................................................................... 7

5.2 - FRO: UF .......................................................................................................................7
5.3 - STAB: S ........................................................................................................................ 7
5.4 - EXC LIMIT: OE .............................................................................................................7
5.5 - QUADRATURE DROOP: DROOP ...............................................................................7
5.6 - ACCESSORY (DC INPUT): AC ....................................................................................7

6 - A.V.R. CONTROLS.............................................................................................................. 7

7 - TROUBLE SHOOTING CHART..........................................................................................8

8 - MULTIMETER CHECKS.....................................................................................................9

9 - STATIC TEST PROCEDURE............................................................................................10

10 - DIMENSIONS.................................................................................................................. 11

11 - SPARE PARTS................................................................................................................ 12

11.1 - Designation............................................................................................................... 12
11.2 - Technical support service..........................................................................................12

Disposal and recycling instructions

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R150
A.V.R.
1 - GENERAL DESCRIPTION The AVR has the facility for droop CT
The Automatic voltage regulator (AVR) is a connection, which is required for equal
compact, high performance encapsulated KVAR load sharing during parallel oper-
unit. The AVR incorporates latest technology ation.
and efficient semiconductor to achieve a
high degree of miniaturization when applied 2 - OPERATION OF THE A.V.R.
to 3Ø and 1Ø AC brushless generator within The AVR derives its power supply from the
its input and output limits, the unit offers line to neutral terminal of the AC Generator,
excellent reliability. at level of 277V AC rms at 50Hz or 60Hz.
The AVR supplies DC excitation to the The sensing voltage, which is the regulated
exciter field of a brushless generator to keep voltage, is derived from line to line (for 3 Ø)
the terminal voltage within close limits from and line to neutral (for 1Ø). The AVR forms
NO-LOAD to FULL LOAD. an important part of the close loop system
The recovery time on sudden loading is comprising of the generator field, generator
likely to be around 0.5 sec. to recover 98% armature and the AVR.
of the rated voltage. Please note that the The AVR first builds up the generator voltage
transient performance like voltage dip and from its residual levels. When the generator
recovery time are mainly decided by the is loaded, the sensed voltage goes down
generator and exciter design parameters. and generates the error voltage, which is
Best performance from the regulator can be required to drive the closed loop system.
obtained by keeping full load excitation The AVR contains high gain amplifier, ramp
around 60V DC. and pedestal circuitry. Depending upon the
The generator employs true average value of the amplifier voltage (either high or
sensing circuit, dV/dt snubber and special low) the ramp intersects the amplified
filters circuits to cope with NON-LINEAR voltage at a point, which is early or late in the
loading like battery charger, DC drives etc. half cycle. At the intersection point a firing
The voltage regulation is guaranteed only pulse is produced to trigger the power
for linear loading. Severely distorting NON- device.
LINEAR loads can cause regulation When the power device is triggered early in
problem. the half cycle, more voltage is let into the
AVR is tested prior to dispatch through a field and when triggered late in the half
quality plan, for standard voltage and cycle, less voltage is let in to the field.
frequency. In order to reduce the generator voltage at
R 150 type AVR is provided with two lower speed, a signal inversely proportional
accessory input terminals A1 & A2. Injecting to the speed is fed as an extra input. At
±4.5V DC in these terminals will change the higher speeds the voltage reduces more
generator voltage by ±10%. than proportional with the speed.
Excitation power is derived from the main R150 type AVR carries two additional
generator ouptut winding. terminals A1 & A2. These terminals could be
Soft start circuitry is included which provides used for accepting a DC control signal
a smooth control on build up of generator (isolated) from external controllers like
output voltage. APFC, Auto Synchronizer, etc.
A frequency roll off circuit continually It is important that the DC signal injected
monitors the generator, under speed should be electrically isolated from the line
protection by reducing the generator output terminals.
voltage proportionally with speed below a
threshold.

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R150
A.V.R.
3 - TECHNICAL SPECIFICATION 16) Closed loop response: typically 0.5sec
1) Sensing input to recover to 98% of the set voltage for a
- Voltage: 240 V AC ±10% for 1 phase, field forcing ratio of 1:2.
380 V up to 480 V AC ±10% for 3 phase, 2 17) Sense Loss protection: voltage should
line sensing AVR Senses true average of collapse, when the sensing circuit is open.
the line to line waveform. Use Resistor 18) Over excitation protection: 10V DC to
(SMD) network for trouble free sensing & 85V DC.
control of sensed voltage / regulation. Set point : 60 V DC
2) Input power 19) Fuse for protection: 6 Amps, 240 Volts
- Voltage: 415V for 3 phase and 240V for 1 AC.
phase
- Frequency: 50/60 Hz 20) All potentiometers: multi-turn except
Droop pot (Droop-single turn)
3) Output power
- Voltage: 105 V DC at 240V AC Input 21) Sealing of Potentiometers: except V –
- Current: trim pot all pots are sealed.
• 6 Amps DC Continuous 22) Frequency roll off indicator: LED
• 8 Amps for 30sec. (when allowed by field provided (UF).
resistance)
23) Sense Loss indicator: LED provided (SL).
4) Operating temperature: -20ºC to +70ºC
24) Over excitation indicator: LED provided
5) Storage temperature: -40ºC to +80ºC (OE).
6) Voltage adjustment: min ± 10% of rated 25) Protection on the devices: Suitable R-C
voltage. Snubber to be provided for the device used
7) Stability adjustment: adjustable to get to protect this from surge.
Steady state Stability good transient 26) Potting/ Encapsulation Details: the
response. components on the AVR should be
8) Remote Voltage adjustment: to get completely encapsulated with suitable PU
±10% of set terminal voltage (with 2W / resin compound to absorb transients /
2.5W , 1 Watt pot). vibrations while in operation.
9) Droop for parallel operation: 4% droop for 27) Excitation details of alternator: (typical)
5 Amps from «U» phase. - Full load:
• Excitation Voltage: 40 to 50 Volts
10) Auxiliary input A1 & A2: ±4.5V DC will
• Excitation Current: 2.5 to 5.0 Amps
give change in terminal voltage by ±10%.
28) Terminal marking: refer drawing
11) Under frequency roll - off adjustment:
available below 46 Hz for 50 Hz & below 29) AVR Testing: Burn in test, Thermal
56 Hz for 60 Hz. cycling, Static test, Voltage variation check,
Build up test, FRO check, Stability check,
12) Voltage Build up: ≥ 2 Volts (L-N)
QDC check, Remote voltage check, DC
13) Voltage regulation: ± 0.8% at AVR input voltage check.
terminals.
30) Dimension:
14) Thermal drift: ± 1% for 30º C change in - Overall: 135 x 110 x 47.5 (in mm)
temperature. - Mounting: 115 x 90 (in mm)
- Mounting hole dia: 9 (in mm)
15) Response time: less than 50 milli
seconds. 31) Weight: 320 gms

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R150
A.V.R.

4 - MAIN FUNCTION OF THE A.V.R.

The AVR derives its power supply from line to neutral terminals of the ac generator at a level of
240V AC at 50/60Hz. The sensing voltage which is regulated is derived from the line to line
terminals of the generator.
CONNECTION DIAGRAM OF 3PH TRIDENT BRUSHLESS AC GENERATOR FOR AVR MODEL R 150
STATOR : 6 wires (T1 to T6 identification)

MAIN FIELD
T1 T2 T3
EXCITER U1 V1 W1

Armature
Varistor

Delta
connection

T4 T5 T6
Exciter field U2 V2 W2
+ -
Rotating rectifiers
black or blue

P2
red or white

8 S2

connection
TI04
7 S1 P1

Star
blue
2K/2.5K (1W)
green
yellow
8 7
optional ST1 ST2

Droop R2 R1 Q2 Q1 F2 F1 N W V
Options:
Q1 & Q2: CT for parallel operation TI04 (remove ST2)
A1 A2

FUSE R1 & R2: 2K/2K5, 1W external potentiometer (remove ST1)

A1 & A2: isolated voltage ±4.5 VDC
V AC S UF OE SL UF OE

R150

50 Hz 60 Hz

The AVR first builds up the generator At the intersection point, a firing pulse is
voltage from its residual voltage to rated produced to trigger the power device.
voltage.
When the generator is loaded, the sensed
voltage goes down and generates the error
signal, which is required to drive the closed
loop system.
Depending upon the value of the amplified Only qualified person should replace /
voltage, the ramp intersects the amplified operate on AVR.
voltage at the point which is early or late in Do not increase the voltage beyond the
the half cycle. rated voltage.

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R150
A.V.R.

5 - A.V.R. ADJUSTMENTS oscillation). Too far clockwise rotation will

result in sluggish response and sometimes
5.1 - V-TRIM: V oscillations also.
This feature is provided for voltage Factory default setting is slightly more
adjustment up to ±12% of rated voltage than critical damping (around mid way).
through a potentiometer. Turn the POT
clockwise to increase voltage and vice 5.4 - EXC LIMIT: OE
versa, after reaching the nominal speed. This feature is provided to protect the Exciter
Provision is made for connecting external Field from over exciting through a
potentiometer in the AVR for remote voltage potentiometer. Turn clockwise to increase
adjustment. the Excitation limit. This pot is initially set for
5.2 - FRO: UF 60% rating of the AVR. If the full load exc.
requirement is less, then run & load the
This feature is provided to protect the AC
generator to its full load & rotate the pot
generator from the sustained low speed
ACW till the RED LED lights.
operation through a potentiometer. AVR will
Factory default setting at 60%.
reduce the voltage proportional to the speed
below the set value. The procedure to set
the FRO pot is as follows:
5.5 - QUADRATURE DROOP:
First run the generator at full speed (50Hz)
DROOP
turn FRO by few turns clockwise, ensure A potentiometer is provided to adjust the
voltage does not increase. Now turn the droop for parallel operation of AC
FRO pot slowly anticlockwise. At a particular Generators. Follow the CT connections as
point Red LED glows and voltage will start to per the AVR connection diagram.
reduce, stop turning the pot at this point and Turn the QDC pot clockwise to increase
turn the pot clockwise by two turns after droop and vice versa.
nominal voltage is restored.
Factory default setting is 46Hz. 5.6 - ACCESSORY (DC INPUT): AC
For 60Hz operation reset the FRO pot to R 150 is provided with two accessory
56Hz as per above procedure. terminals A1 & A2 for injecting ±1.0 to ±4.5V
DC. The variation in terminal voltage will be
5.3 - STAB: S ±10% of the rated voltage.
This feature is provided to arrest the voltage Warning : a screw driver as the «vishay
hunting through a potentiometer. Turn trimmer model 8» type should be used to
clockwise to increase stability (to arrest set the potentiometer.

6 - A.V.R. CONTROLS
SI No Control Function Direction
To adjust the generator Turn clockwise to increase the output
V VOLTS
output voltage voltage
To set the Under frequency Turn clockwise to to reduce the knee
UF UFRO
Knee point point
S STAB To arrest voltage hunting Turn clockwise to increase the stability
OE OVER EXC To set the over excitation limit Turn clockwise to increase the limit
DROOP DROOP To set voltage droop Turn clockwise to increase the droop
AC ACC (DC i/p) It is used for Auto synchronization Turn clockwise to increase the gain

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R150
A.V.R.

7 - TROUBLE SHOOTING CHART

Symptom Cause Action
No voltage Fuse blown Check &replace
build up Low residual across U and N If the residual voltage of the Generator at rated
terminal speed is less than 2.5V AC (L-N), then disconnect
the Regulator and connect a 24V DC Battery
keeping F1 as positive and F2 as Negative.
Connecting a free wheel Diode (BY 127)
Right across the field with Diode Cathode to F1 &
Anode to F2 during field flashing will help restoring
the residual voltage.
CAUTION:
Remove the diode (BY-127) after field flash.
24V battery positive must be connected to F1 only
and negative to F2.
Reverse connection will Blow out Diode BY127
instantaneously.
Incorrect wiring Check wiring
Rotating diodes and /or fuse Check and replace
failed
Panel voltmeter defective Check and correct
AVR defective Replace after conducting static test
(repeated fuse blowing)
Grounded exciter field Check and correct
High voltage Loose, or no connection to ‘U’ Check and correct
build up terminal of the Regulator
AVR defective Conduct static test and replace if necessary
Low voltage Low prime mover speed Check and correct
build up Sensloss is in circuit Check and correct
AVR defective Replace AVR
Voltage oscillation Incorrect stab-pot sealing Turn clockwise still Hunting is arrested
Prime mover speed hunting Check and adjust governor
Load hunting, fluctuates Check and correct
rapidly
High percentage of non linear Check and reduce the non linear load
load
High reactance in generator Consult generator manufacturer
(during non linear loading)
Poor regulation The exciter field’s requirement Wrong selection or very low P.f load. Check and
is higher than 105V DC correct.
Prime mover speed dips Adjust governor and reduce active load
too much on load (kW load)

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R150
A.V.R.

8 - MULTIMETER CHECKS Resistance between U&N1 should give

Equipment: Digital Multimeter. 200kW to 260kW. Open circuit indicates AVR
failure.
Select Diode mode in digital multimeter.
Resistance between F1 & F2 (keeping com- In static test lamp will not turn OFF or when
mon of multimeter jack to F1 of the AVR connected to generator it will produce cei-
should give 0.4 to 0.6kW, and reverse keep- ling voltage (for 1Ø ONLY).
ing common of multimeter jack to F2 of the Resistance between N&F1 should be very
AVR should give INFINITY). low or ZERO ohms. If it is open lamp will not
ZERO indicates power device failure in both glow when static test is conducted.
the cases. No further tests (static test or dy-
namic tests) are allowed, and it will lead to
rapture of fuse.
Resistance between F2 & U (both sides)
should be 180kW.
Resistance between F2 & V (Keeping com-
mon of the multimeter to ‘V’ of the AVR
should show about 2.2M ohms in 10MW
range and reverse keeping common of the
Multimeter to F2 of the AVR should give
15 Mega ohms.
ZERO indicates power device failure in both
the cases. No further tests (static test or dy-
namic tests) are allowed, and it will lead to
rapture of fuse.
Resistance between U&V should give
300kW to 400kW. Open circuit indicates
AVR failure. In static test lamp will not turn
OFF or when connected to generator it will
produce ceiling voltage (for 3Ø ONLY).

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R150
A.V.R.

9 - STATIC TEST PROCEDURE

For 3-phase circuit

AVR (3Ø)
Model: R150

F2 F1 N W V
ACV
0-500V

F1 R

LAMP F2

WITH NEUTRAL
415V, 3Ø, 50Hz,
100W
Y
230V
F3 B

N
VARIAC
8A, 415V

STATIC TEST CONNECTION DIAGRAM OF 3Ø AVR

This should be attempted only after 5. It is difficult to prescribe a static test for
ascertaining that the regulator has passed checking the stability, as it is best found in
all multimeter checks. Connect the regulator closed loop test. However healthy regulator
to three ph variable voltage source as will behave as given below.
shown in diagram 3 phase of this manual.
First keep the ‘STAB’ pot in fully
1. Keep ‘V-TRIM’ in minimum position. anticlockwise. Conduct static test as in 1, 2
& 3, the lamp will GO-OFF rather swiftly at
2. Keep ‘FRO’ in fully maximum position.
360-380V and come again swiftly when the
3. Increase the applied voltage. The lamp voltage is reduced below 360V.
should glow with increasing brightness. At a Now keep ‘STAB’ pot fully clockwise,
voltage around 360-380V the lamp should conduct static test as in 1, 2, & 3 the lamp
GO-OFF slowly. Further increase in voltage should GO-OFF much slower and come
up to 415V should keep the lamp OFF. again much slower. At end of this test keep
Decrease the voltage now to below 360 pot mid-way.
volts the lamp should glow bright again.
If the regulator behaves as said above
4. Turn ‘FRO’ pot anticlockwise the lamp
then the regulator is healthy.
should GO-OFF slowly. Now turn ‘FRO’ pot
clock wise. The lamp should brighten up
again.

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R150
A.V.R.

10 - DIMENSIONS
135 mm

10
A1 A2 Droop R2 R1 Q2 Q1 F2 F1 N W V

FUSE
V AC S UF OE SL UF OE
110 mm

90 mm
R150

10
50 Hz 60 Hz

115 mm

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R150
A.V.R.

11 - SPARE PARTS To ensure correct operation and the safety

of our machines, we recommend the use of
11.1 - Designation
original manufacture spare parts.
Description Type Code
In the event of failure to comply with this
A.V.R. R150 5014127 ad­vice, the manufacturer cannot be held
res­ponsible for any damage.
11.2 - Technical support service
Our technical support service will be
pleased to provide any additional informa-
tion you may require.

When ordering spare parts, you should in­

dicate the type and code number of the
regulator.

Address your enquiry to your usual contact.

Our extensive network of service centres

can dispatch the necessary parts without
delay.

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R150
A.V.R.
Disposal and recycling instructions All materials listed above need special
We are committed to limit the environmental treatment to separate waste from
impact of our activity. We continuously reclaimable material and should be handed
survey our production processes, material to specialized disposal companies.
sourcing and products design to improve The oil and grease from the lubrication
recyclability and diminish our footprint. system should be considered as a hazardous
These instructions are for information waste and has to be handled according to
purposes only. It is the user responsibility to local legislation.
comply with local legislation regarding
product disposal and recycling.

Recyclable materials
Our alternators are mainly built out of iron,
steel and copper materials, which can be
reclaimed for recycling purposes.
These materials can be reclaimed through a
combination of manual dismantling,
mechanical separation and melting
processes. Our technical support depar-
tment can provide detailed directions on
products dismounting upon request.

Waste & hazardous materials

The following components and materials
need a special treatment and need to be
separated from the alternator before the
recycling process:
- electronic materials found in the terminal
box, including the Automatic Voltage
Regulator (198), Current Transformers
(176), interference suppression module
(199) and other semi-conductors.
- diode Bridge (343) and Surge suppressor
(347), found on the alternator rotor.
- major plastic components, such as the
terminal box structure on some products.
These components are usually marked with
plastic type information.

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R150
A.V.R.

14