KIPOR POWER CO., LTD.

BRUSHLESS
THREE PHASE
A LT E R N A T O R

KFS
 CONTENTS

1. SAFETY CAUTION 1

2. DESCRIPTION 2

3. STORAGE 5

4. INSTALLATION AND ADJUSTMENT 6

5. INSPECTION AND OPERATION 8

6. TROUBLESHOOTING 10

7. MAINTENANCE AND OVERHAUL 13

8. PARALLELING OPERATION 14

9. THYRISTOR OR SCRLOADING 15

10. NOTICE 16

11. WIRING CONNECTIONS 17

12. WIRING SCHEMATIC DIAGRAM 21

13. RECTIFIER ASSEMBLY REMOVAL 23

14. VOLTAGE REGULATOR 26

1. SAFETY CAUTION 2. DESCRIPTION

Please remember safety first. If you are not sure of the instructions or KFS series three phase A.C synchronous brushless generator is a new
procedures, seek qualified help before continuing. generation brushless generator.
Our generators may be combined with diesel engine (internal-combus-tion

This service manual emphasises the safety precautions necessary during the engine) to make fixed or movable electrical power. It is suited for commercial
buildings, hospitals, factories, farms, fields, etc. as power and lighting. The
installation, operation, and maintenance of your generators.
generating set may be used for the prime power or stand by.
KFS series generator are of unique design, advanced construction, excellent
1. The lifting eyes on the generator are designed to support the generator only.
performances, reliable operation, easy use, small volume and light weight.
Do not lift a complete generator set (engine) by means of lifting eyes on the
Features:
generator. Personal injury or damage to the equipment may result. 1. KFS series generator are manufactured in accordance with NEMA ODP type. It
2. Do not apply any force to the generator fan. Never BAR OVER the engine- consists of main generator, AC brushless exciter, rotating rectifiers, AVR, conduit
generator set by using the fan. Failure to comply with these safety procedures box, etc.
could result in severe injury to personnel or damage to the equipment. 2. Class H or Class F insulation system.
3. Before any service work is done, disconnect all power sources, and lock out all 3. The frame is made by steel plate. The design of stator lamination is unique. If

controls to prevent an unexpected start-up of the generator set. necessary, 12 leadwires may be supplied.

4. Proper grounding in compliance with local and national electrical codes must 4. Main rotor apply the single piece 4-pole saliant pole lamination, coupled with
die cast or welding damping winding, field winding to form a unirotor construction.
be provided.
The field winding is layer wound with thermo setting epoxy for high mechanical
5. Whenever the generator is running, always assume and proceed as if voltage
and electrical integrity.
is present. Residul voltage is present at the generator terminals, and at the
Perfomance
regulator panel connections, even with the regulator fuse removed. Caution must 1. KFS series generator may be operated continuly at rated load under following
be exercised, or serious personal injury or death can result. conditions.
6. Whenever solvents, cleaners, or flammable liquids are present, adequate (1) Ambient. Air temperature 40 , well vantilation marin use, 45
ventilation must be available to avoid fire, explosion, and health hazards. Always (2)Elevation 1000m over sea level
avoid breathing vapors and suitable personal protective equipment to prevent 2. Electrical performances

personal injuries (head, eyes, face, feet, hand, respirator, etc.) (1) Steady voltage regulation 1.0%

7. Special caution must be taken during trouble shooting since protective covers (2) Transient voltage regulation +20%,-15%(60%In,cos =0.4 lag)
(3) Adjustable voltage range 95-105% Un
and safety devices may be removed or disabled to gain access and make tests.
(4) Waveform distortion at no-load, 5%(line voltage)
(5) Starting motor ability (no-load, three phase, 4p, cage motor)

- - - -
 Generator Motor capacity Rotating Assembly
Up to 40kW 0.7Pn Exciter Field Exciter Armature Main Field Main Armature
(stator) (rotor) (rotor) (stator)
50.64.75kW 30kw L1
(+) (+)
90.120kW 55kw DC DC
(in) (in) L2
150.200.250kW 75kw (-)
3 Phase AC (out)
(-)
3 Phase AC (out)

320kW 110kw L3
Rotating Rectifier Assembly
3 Phase - Full Bridge

Principle of operation: Exciter Field Power

(DC out) Input Power - Single Phase
Our generators are a brushless, self excited, externally voltage regulated, Automatic
(Shunt Powered Regulator)
Voltage
Regulator
synchronous AC generator. The generator is made up of six major components: Sensing Input - Single Phase
3 Phase (Optional)
main stator (armature), main rotor (field), exciter stator (field), exciter
rotor(armature), rectifier assembly, and voltage regulator. In understanding the FIGURE 1 Circuit Diagram

above terminology, note the following: stators are stationary, rotors rotate, a field
is an electrical input, and an armature is an electrical output. These system
components are electrically interconnected as shown in figure 1 and physically
located as shown in figure 2.
Main Stator Main Rotor
Main Staor
AC Output (Field)
Cooling Fan
Rotary Rectifier

The generator's exciter consists of a stationary field and a rotating armature.

The stationary field (exciter stator) designed to be the primary source of the Drive
Disc

generator's residual magnetism. This residual magnetism allows the exciter rotor
(armature) to produce AC voltage even when the exciter stator (field) is not
powered. This AC voltage is rectified to DC by the rotating rectifier assembly and
fed directly to the main rotor (field). As the generator shaft continues to rotate, the
Fig 7 Rotary Rectifier Assembly
main rotor (field) induces a voltage into the generator's main stator (armature).

At rated speed, the main stator's voltage produced by the residual magnetism
Bearing

of the exciter allows the automatic voltage regulator to function. The regulator
provides voltage to the exciter resulting in a build-up of generator terminal voltage.
This system of using residual magnetism eliminates the need for a special field
flashing circuit in the regulator. After the generator has established the initial
FIGURE 2 Generator Layout Diagram
residual voltage, the regulator provides a controlled DC field voltage to the exciter
stator resulting in a controlled generator terminal voltage.

- - - -
3. STORAGE 4. INSTALLATION AND ADJUSTMENT

In the event that the generator is not to be installed on its prime mover 1. Generator must be mounted at the clean, dry and well ventilation place. The
immediately, it is recommended that the unit be stored in a cleaned, dry area prime mover and generator should be installed on a public frame, never put them
which is not subject to rapid changes in temperature and humidity. on the cement floor, and ensure the public frame undeformed.
2. Single bearing generators
In the event of long term storage, the generator should be tested cleaned and Single bearing units are provided a SAE flywheel housing adapter and flexible
dried as required, before being put into service. See the maintenance section of drive discs to match the engine. Close tolerances are maintained in the
this manual for further information. manufacture of the generator to promote ease of alignment.
Special steel drive discs are bolted the shaft. In some case spacer are used to
achieve the proper XG dimension. Holes are provided in the periphery of the
coupling discs which correspond to tapped holes in the engine flywheel. The
outside diameter of the drive discs fit in a rabbet in the flywheel so that
concentricity is assured.

CAUTION
Grade 12.9 place to the flywheel. Do not use spring gasket, they will cause
stress bolt and gasket rising, and may resuly in disc failure.
The SAE flywheel housing adapter and the engine flywheel housing are
designed to match each other, with no further alignment necessary.
Shims may be necessary under the generator feet to insure a solid mounting.
Do not force the feet to an uneven mounting surface, serious problems could
result.

- - - -
ENDPLAY TEST PROCEDURES:
After the generator has been assembled to the engine, check for endplay of the 5. INSPECTION AND OPERATION
assembled set. Using a suitable lever, force the engin flywheel forward so that the
crankshaft is pressed against its thrust bearing. When force is removed, the
1. Inspection
engine crankshaft should remain in position. Apply force in the opposite direction
(1)Though the generator, AVR and auxilar devices are solid and well insulated, if
forcing the crankshaft towards the generator, and observe if the crankshaft
the generator was stored for longtime it might be moistened, and should be
remains in this position after force has been removed. Refer to the engine manul
inspected carefully before operation.
for proper or recommended endplay. If the crankshaft springs away in either
direction after force has been removed, it is an indication that the generator shaft (2) Measure the insulating resistance of windings against the ground by

is not moving freely, and normal life of the thrust bearing could be impaired. ohmmeter if the value is less than 2 M in cold condition, the generator should
Probable couse of this problem are: be dried. Caution: At measuring, the electronic elements and capacitor should be
shorted, and AVR, should be disconnected to avoid damage.
1. Improper XG dimension of either the generator or the engine flywheel, or both. (3) Make sure all connecting joints are tight and contact well.
Generator bearing may be bottoming out in its bearing bracket. (4) Be sure the frame is properly grounded, and ground wire should be same as
the size of leadwires.
2. Misalignment:
(5) Be familiar with the rated data of nameplete before operation.
(1) Improper seating of generator drive discs in the engine flywheel.
(2) Improper mating of the generator frame to the engine flywheel housing.
2. Voltage adjustment
(3) Set sub-base is not true. Generator and or engine feet require shims. See
mounting instructions. In general, the generator was carefully inspected and tested in operation before it
left the factory, and the normal voltage has been corrected, so it is not necessary
3. Two bearing generators. to adjust. If necessary, the setting potentiometer of voltage may be adjusted
If generator couples with engine by flange rabbet, it is easy to mount. If it again. If the external potentiometer is used for remote control, it also can be
coupled by other way, should pay more attention to installation, it may be adjusted to set the voltage. The details of wiring diagram are as Fig. 1 Fig. 2
necessary to shim the generator feet for proper support and alignment. Aligning
the generator and engine as accurately as possible will reduce vibration, increase
3. AVR. wiring
bearing life, and minimize coupling wear.
The wirning diagram is shown as Fig.1.Fig.2.The end 3 and 4 of AVR are also
connected to the 190V-240V, but there is a plug wire that should be put in the
50Hz or 60Hz position.

- - - -
4. Operation.
6. TROUBLESHOOTING
After inspection and adjustment have been made, and no trouble is found, the
generator can run normally and generate the electricity. In order to keep
generator run well, please remember following notices; SYMPTOM1: Generator produces no voltage or abnormal voltage

(1) Before starting the prime mover the generator output must be disconnected (1) Regulator fuse blown Check all wiring, if there is no problem; replace

from the load. bad fuse, and start the unit again.
(2) Voltmeter damaged Verify the panel meter with multi-meter or other
(2) Check the speed and adjust to the rated RPM, the voltage of generator will
meter that is known to be accurate.
get to normal value, then close the main circuit breaker to the load. The genset
(3) Defective voltmeter Check the meter in time, replace bad meter.
speed may be changed under load, and frequency may be lower than the normal
(4) Loose the connecting Check the connecting plug, make sure all joints
frequency, check and adjust the speed as necessary.
plug of AVR. tight and contact good.
(3)Before shut down the genset, remove load and turn off the main circuit breader. (5) Surge suppressor short Check the surge suppressor and eliminate the
This is especially important, or the loss of residue magnetism can result. circuit short circuit or replace bad one.

(4) If starting up the generator for first time or the generator stored for long time, (6) Defective diodes Take down the diodes and test them by multimeter.

generator may be loss of the residue magnetism, and voltage can not built up, Replace the bad diode.

should charge to F+ and F- with DC 12V voltage, the + touch to F+(Red) and (7) Lost residue magnetism Connect a 12V battery to the exciter field, the + of

the - touch to F-(Black) for 15-20 seconds. Caution: the generator must be stud bettery to the F+(red lead),and the - to the F-
(black lead) for abort 15 to 20 second. Caution:
still during charging the magnetism, or AVR. may be damaged.
The generator should be stayed still during flashing.
(5) Three phase AC. generator should be operated at balanced load. Should pay
(8) Incorrect connect Check carefully, and correct the wiring refer to the
more attention to the load and the balance of current to prevent the generator
wiring diagram.
loaded on the single phase or serious unbalancing condition, or the AVR and
(9) Exciter field break Clean, twist and weld the broken wire. Wrap this
generator can be damaged.
place with insulating material.

- - - -
(10) Loose joints or poor Clean and tight the joints again. SYMPTOM2: Generator voltage fluctuation

contact
(1) Incorrect speed Verify speed with tachometer or frequency meter.
(11) Atmature winding of Find the failure place, clean, weld and wrap it.
(2) Unstable speed Verify governor stability.
generaor break
(3) AVR stability Adjust AVR stability. Refer to AVR manual.
(12) Armature winding of Short circuit will couse the serious heating, should
(4) Defective/ loose conne- Inspect all wiring for loose or dirty connectins.
generator short circuit replace the winding.
cting
(13) Armature winding of Locate the failure and replace the winding.
(5) Defective diodes, surge Test generator with constant excitation (12V
exciter break or short
suppressor, or generator battery test).
circuit
windings.
(14)Incorrect speed Verfy speed with tachometer or frequency meter.
(6) Remote voltage adjust Check operation of rheostat. Refer to AVR,
(15) AVR protective shut- Correct the problem and adjust AVR. Refer to AVR.
rheostat (if used). manual.
down circuits manual.
(7) Defective AVR Replace the AVR. Refer to AVR manual.
(16) AVR inoperative Adjust or replace the AVR. Refer to AVR manual.
(8) Defective bearing of Replace worn bearing. Check bearing carrier for
w o r n b e a r i n g c a r r i e r wear Replace as necessary.
causing an uneven air gap.

SYMPTOM3: Generator over heated

(1) Overload
Pay attention to currentmeter at times.
Alert the load does not exceed the name plate
rating of the generator.
(2) Ventilation flue blocked Blow the interior (dust.dirt) off the generator.
(3) Armature winding of Replace the damaged winding.
generator short circuit

- - - -
7. MAINTENANCE AND OVERHAUL 8. PARALLELING OPERATION

1. Maintenance. Our generators are suitable for paralleling operation at electricity net or other
(1) Installed in the dry, clean, ventilating place, and prevent the direct contact of generators as full damping winding, can ensure operation properly. If necessary,
wind driven dirt, rain, snow and sunlight. costomer can take note of it in order. Consult with the factory for further
(2)Take note of the ventilation and heating of generator at times, and the current
information relative to parallel operations.
and voltage mustn't exceed the rating data.
(3) Not operate at the place full of water vapor, dust and flammable gas.
(4) In general, maintenance intervals will depend upon operating conditions.
Routine overhaul should be made frequently.

2. Major overhaul
(1) Measure insulating resistance with 500V Megohm meter. If the reading is less
than 2M , the generator should be dried. (Must disconnect AVR. with generator
during measuring)
(2) Replace the grease in bearing housing, and clean the surface of two shield
bearing, or replace the bearing.
(3) Clean the interior of generator by blowing, and take care of all the junctions.
(4) Inspect all living parts, and make sure joint nut tight and contact well.

3. Overhaul attention.
(1) Take care of the disassembled parts, and avoid to bump each other or missing.
(2) Should lightly place main parts such as rotor, stator, bracket, etc. to prevent
damage.
(3) In order to reassemble easily, should make the mark for the disconnected
wiring, and avoid wrong connecting.
(4) Disasse, bled bearing and bearing cap should be covered by clean paper to
prevent dirt, and replace the dirty grease.
(5) After the generator reassembled, rotate the rotor slowly, ensure there are not
abnormal sound and halt.
(6) The bracket screws should be driven crosswise can't drive the screws one by
one.

- - - -
9. THYRISTOR OR SCR LOADING 10. NOTICE

Solid state electronic control devices which utilize thyristor or SCR firing circuits 1. AVR. wiring can't be connected wrong. The terminal 3 4 and mains input are
(such as variable frequency induction motor control precision motor speed connected to the tapped and line of generator winding. It is used for 200 volt, if
controls, no break powered battery charges etc.) may introduce higher used for 400volt, the AVR, would be damaged.
harmonics which adversely affect, or totally distort the normal wave of generator. 2. The terminal 6 and 7 of AVR, should be shorted with jumper wire, if the
This creates additional heat in the generator windings and may cause the external potentiometer is used for remote adjusting voltage, the potentiometer
generator to overheat. Problems which can occur are not limited to the generator. would be connected to the 6 and 7, or the AVR, may be damaged without
poor wave shape may adversely effect the thyristor devices, the equipment they connecting.
provided power and any other connected load. Please contact the factory for 3. Boost exciting must use the 12V battery, and the generator must be stopped.
application assistance. Using 24V battery or boosting the excitation in rotating, the AVR would be
damaged.
4. The generator runs at 50Hz or 60Hz , should ensure the wiring right, or
maybe affect AVR, working.
5. Before shut down the generating set, first turn off the output switch, then speed
down the engine.
6. Take care of the contact of the plug and sockets, ensure them close contacting
each other.
7. If the generator can't built up, first of all, look for the causes, such as: fuse;
wirings; residue voltage, etc. Please don't adjust the potentiometer and boosting
excitation before known the causes.
8. If the engine runs at idle speed, please don't adjust the potentiometer and
boost excitation.
9. Adjusting the voltage and stability potentiometer, please use small screw-driver
and rotate slowly.

- - - -
11. WIRING CONNECTIONS HIGH WYE CONNECTION

VOLTAGE (HIGH WYE)

Wiring of the generator and accessories should be done in accordance with Hz L-L L-N
60 480 277
good electrical practices.
460 266
Follow government, industry and association standards. 440 254
416 240
The generator conduit box construction allows cable entry from multiple sides. 380 219
A hole saw or other appropriate tool may be used to provide for conduit entrance. 50 416 240
400 231
Protect the interior of the generator from shavings when drilling or sawing. An
380 219
approved connector must be used in conjunction with the conduit. To minimize
the transmission of vibration, it is essential that flexible conduit be used for all
electrical entrance to the generator conduit box. LOW WYE CONNECTION

Refer to the connection diagram supplied with the generator and/or the proper
diagrams shown in this manual. Install all inter-component and external wiring in
Hz L-L L-N
accordance with national and local electrical codes. The neutral in the following 60 240 139
connection diagrams shown below may be either grounded (earthed) or left 230 133
220 127
above ground potential (floating). See national and local codes and/or the system
208 120
distribution wiring schematic diagram for the proper connection of the neutral. 190 110
The following connection diagrams are shown for twelve lead generators. The 50 208 120
200 115
lead generators have the same terminal designations except for leads T10, T11,
190 110
and T12. These three leads are internally connected inside the generator and
brought out as a single lead (TO). The lead generators can only be connected in
a wye configuration. HIGH DELTA CONNECTION

VOLTAGE (HIGH DELTA)

Hz L-L L-N
60 277 139
240 120
50 240 120
220 110
200 100

- - - -
 LOW DELTA CONNECTION
HIGH ZIG ZAG -- SINGLE PHASE CONNECTION
VOLTAGE (LOW DELTA)
Hz L-L L-N
VOLTAGE (HIGH ZIGZAG)
60 120 NA
Hz L-L L-N
110 NA
60 480 240
110 NA
460 220
50 100 NA
50 415 208
380 190

DOUBLE DELTA -- SINGLE PHASE CONNECTION

VOLTAGE (DOUBLE DELTA)

Hz L-L L-N
60 240 120 DEDICATED SINGLE PHASE CONNECTION
220 110
50 220 110
VOLTAGE (DEDICATED)
Hz L-L L-N
60 240 120
220 110
50 220 110
200 100

LOW ZIG ZAG -- SINGLE PHASE CONNECTION

VOLTAGE (LOW ZIGZAG)

Hz L-L L-N
60 480 120
460 110
50 415 110
380 100

- - - -
 Main Generator (4 Leads) U

12. WIRING SCHEMATIC DIAGRAM V

Exciter Field
Main Stator (12 Leads) 1. Run at 50Hz. The jump wire to F+ (Red)

50Hz . Run at 60Hz. the jump wire Fuse

F- (Black) 10A 240V
to 60 Hz.
Adjust Voltage Exciter Field Remote
Potentiometer
Clockwise Boosting
F+ 2. CB- & CB+ Should be short circuit
(Red)
1 2
F- except that need inserting CT for
(Black) boosting.
3
F+
Voltage Regulator

F- 60 Com 50 CB CB F-
7 Hz Hz - F+ 4 6 7 3 240 480
+
6 Fuse
E1
4
50
60 Hz 5A 240V
4 T4 T2 T1(u)
Fig 4 APR 125-5 wiring schematic diagram (Three phase)
T8 T5 T2(v)

Adjust Stability 3 T6 T9 T3(w)

Closkwise Stabiliey Rise T10T11T12(N)

(More Time for Reaction) 280 360Connect Board

Fig 3 Wiring Schematic Diagram (Three phase) 1. Open parallel-single switch for Se350 APR125-5 or Xr2002
Voltage Regulator
Main Stator (4 Leads) parallel operation and close it for
7 6 4 3
single operation.
Adjust Voltage
Potentiometer
2
Adjust Voltage Exciter Field
2. Adjust voltage potentiometer is 7
APM 2000 6
Clockwise Boosting F+ supplied with AVR. Parallel
(Red) 1A
Running Module
F- 5A 1
K
(Black) C
3 U N W V
3
F+ 3
F+
F-
F-
Voltage Regulator

7
7
6
6
4 V
4
50 4
50 5A 240V
60 60 Hz Elec. Mutual Inductor
Hz
Fuse
Main Generator
W
4
3
Closkwise Stabiliey Rise U
(More Time for Reaction)

Remote Potentiometer Fig 5 Parallel Operation Schematic Diagram

If the remote potentiometer is used for adjusting voltage should open the short
jumper wire between 6 and 7 . and insert the potentiometer.
Fuse In SE350 Booster
- - - -
 Forward Reverse
Termianal End
13. RECTIFIER ASSEMBLY REMOVAL (+)
Anode
(-)
Cathode

The rectifier assembly cannot be removed until the opposite drive end bearing
Stud End
(-) (+)
bracket and bearing have been removed (see bearing removal procedure).
Cathode Anode
Remove the three exciter rotor leads from the heat sinks and the two main rotor
leads from the main rotor posts (see Figures 7). Remove the screws securing the Fig 6 Polarity of Bipolar Tube

rectifier assembly and pull the assembly free from the shaft.
Diode Testing
If the generator is close coupled to an engine, it may be necessary to bar over A

the engine in order to gain access to a given area of the rectifier assembly. Never
A A
use the generator's fan as a fulcrum to accomplish this. Use the engine
manufacturer's recommended practice to manually turn over the engine. To
prevent possible injury to personnel, and damage to the equipment, ensure that
C D
the engine cannot start during this procedure.
A
Remove the two main rotor leads and the three exciter rotor leads from the B B

rectifier assembly (figure 7). The rectifier assembly is now electrically isolated
from the generator. The diodes remain mounted and the diode leads remain B B
A

connected to the terminal posts. Using an ohmmeter or a battery light continuity 430 FRAME 280-360 FRAME

tester, place on test probe on the diode lead terminal post. In succession, touch A Connect With Rotator of Exciter B Connect With Rotator of Main Pole
C Red (+) Lead Wire of Surging Eliminator D Black (-) Lead Wire of Surging Eliminator
the other test probe to the lead screw hole in each heat sink. Reverse the probes
and repeat the procedure. You have now tested the three diodes connected to Fig 7 Rotary Rectifier Assembly
this terminal post in both the forward and reverse direction. Repeat the procedure
using the other diode terminal post.

- - - -
 When the positive test probe is connected to the diode's anode and the
negative test probe is connected to the diode's cathode (forward biased), the 14. VOLTAGE REGULATOR
diode will switch on and conduct electricity (figure 6). This is observed by a low
resistance reading when using an ohm meter or the lighting of the bulb when Instruction:
using a battery light continuity tester Reversing the test leads (reverse biased) will The voltage regulator is a partly-sealed electronic regulator; it controls the output
result in the diode switching off and no electricity will be conducted. The results of voltage of the AC brushless generator by adjusting the magnetic current of the
these tests should indicate one of three conditions: exciter.

There is no easy method to determine remaining life in the other diodes. To avoid
Characteristic Voltage regulator
possible continued failures, it is recommended that the entire rectifier assembly
Check and input voltage 190~240Vav
be replaced rather than replacing individual diodes.
Power input 500VA
1. Good diode: Will have a much greater resistance in one direction than the Power output (continuous) 73Vde, 3.5Ade (255W)
other. Typical reverse biased resistance will be 30,000 ohms or greater, while Power output (strong excitation) 105Vde, 5A (525W)
forward biased resistance will be less than 10 ohms. The battery-light tester will (240VAC voltage input)
have the light on in one direction and off in the other. Voltage regulator 1.0%

2. Shorted condition: Ohmmeter reading will be zero, or very low in both Remote voltage adjusting range If connected with 2000 rheostat, 10%;

directions. The continuity tester will have the light on in both directions. If connected with 1000 rheostat, 5%
Frequency compensation Available
3. Open condition: Ohmmeter will have a maximum (infinity) reading in both
Turnover frequency Running at 60Hz, 54~61Hz;
directions. Continuity tester light will be off in both directions.
Running at 50Hz, 45~51Hz
Diode failure after a 25 hour run-in period is generally traceable to external Running temperature -40~60
causes such as a lightning strike, reverse current, line voltage spikes, etc. all 6 Storage temperature -65~85
diodes are essentially in the same circuit. When a diode is stressed to failure. Power consumption 8W at most
Voltage instauration Voltage regulator upbuilds the voltage autom-
atically if remanence voltage down to 10Vac
Electromagnetic disturbance Inner electromagnetic disturbance filter (EMI filter)

- - - -
 To avoid personal injury or equipment damage, please Turnover frequency selection (V/Hz)
WARNING
turn to dealer or agency for installation, operation or 1. Select 50Hz or 60Hz by using the jumper wires, the turnover frequency is
maintenance. between 54Hz and 61Hz while the potentiometer stays at 60Hz, and 4551Hz at
60Hz.
Never use a megohm meter or high pressure to 2. In 60Hz type, the turning point has been pre-setted at 58Hz; in 50Hz type, the
CAUTION measure or to push the connection of the generator and turning point has been pre-setted at 48Hz.
regulator, so does the booster. 3. To change the turning point: first, adjust the engine speed to the rated speed
Installation (50Hz or 60Hz); second, set the voltage value to your requirement; third, screw
It can be installed at any even surface of the generator, the installation size clockwise until the voltage return to the rated value; finally, adjust the speed to
shown as in fig.1. the rated speed.

Starting procedure
Power circuit of the exciter
Connect F in the booster to the generator terminal F or F1; F in the booster Initial adjustment
connect to terminal F or F2 of the generator. Typical connecting diagram is 1. Be sure that the connection of the booster and generator is OK. Refer to the
shown in fig.2. connecting diagram enclosed with the generator.
2. Turn the potentiometer counterclockwise to the smallest voltage value.
Check for the input circuit 3. Turn the remote adjust potentiometer (if used) to the middle position.
Terminal 3 and 4 are available in this task. The booster needs 190240Vac input. 4. Screw the stability clockwise to the highest level.
See in fig.2. 5. Connect the positive polar of 100V DC voltmeter to F1, negative polar to F2, or
Fuse use an appropriate AC voltmeter connects to the generator extension line.
A 4A, 250V-5*20mm fuse is provided by the regulator.

Voltage adjustment
Output voltage is adjustable by using the screw potentiometer, output will Installation size
90.4
increase if turns the potentiometer clockwise. If a remote adjust potentiometer is 59.7 2-4.8
41.9
used, please remove the jumper wires between the terminal 6 and 7, and install a
24.1
2000 1/2W (min.) potentiometer (See fig.2), which will provide a 10% voltage
change on the standard value. (make sure the voltage change of the 2000 1/2W Turnover Frequency 58.7
3-9.6
POT is 5%).
6.6 7.9
Stability adjustment
1. Stability will increase if clockwise screws the potentiometer, and the respond Stability Adjustment Voltage Adjustment

time of the generator prolongs; respond time will reduce if screws Fig.1

counterclockwise.
2. Two small jumper wires on the booster should be reserved totally. (Fig.2)

- - - -
 Troubleshooting
416 - 480V or 208 - 240V wye connecting diagram

T1
T9 Trouble Cause Salvation
General T2
T7 The voltage is below 10V in the Check the wiring refers to the
T3

3
terminal 3 and 4 connecting diagram

No output remanence voltage

F1 F8
cw Too long time of acceleration of Magnetizing refers to the manual;
4
rated speed Reduce the acceleration time;
2000
1/2 W
Pause the power supply of the
booster after it reaches the rated speed
3 F+ F- 7 6 4 50 60 3 F+ F- 7 6 4 50 60
Hz Hz Hz Hz No connection of the down-lead F1 and F2 Connect them
Voltage of input terminal(3,4):190-240VAC Power input down-lead hasn't connected Connect the lead
Fuse snapped or no fuse Replace the fuse
Trouble in the regulator Replace it
Start the system
Trouble in the generator Refer to the generator manual
1. Start the generator with no load to the rated speed; the voltage will upbuild the
Wrong connection Check the wiring connection
minimum value (actual level relies on the connection state.). If it doesn't upbuild

Low output voltage

according to the diagram
the voltage, please refer to the section of magnetizing in the relative manual.
Too low voltage after adjusting Adjust the potentiometer clockwise
2. Slowly adjust the voltage to its rated value, if remote adjust is needed, please
until to the required voltage
adjust the rheostat to help the generator reach its needed voltage.
3. Turn counterclockwise to adjust the stability till the voltmeter shows instable, Too low voltage after adjusting the Adjust the remote control potentiometer

then turn clockwise slowly to control the potentiometer until the generator reaches remote control voltage clockwise until to the required voltage

its stability. Trouble in the regulator Replace it

4. Pause the power supply of the booster for about 1~2seconds.
5. Check whether the generator is in its stable state or not, if not, please keep
adjusting; if it cannot keep stability, increase the stability a bit and pause the
booster again. This step should repeat and repeat until the system reach and
keep its stability.

- - - -
High output Too high voltage after adjusting Adjust the potentiometer counter
voltage -clockwise until to the required voltage

Too high voltage after adjusting Adjust the remote control potentiom
the remote control voltage counterclockwise until to the
required voltage
High output Trouble in the regulator Replace it
voltage,
nonadjustable
Remote control Voltage adjusting wires reversed Reconnect them
voltage reversal

Output voltage
Improper setting of the stability Adjust the stability potentiometer
vibration
adjustment clockwise until the vibration stops
Bad efficiency Trouble in the regulator Replace it
of regulation

Running of 570 type

jumper wire must be cut off

- -