vR504A
DETAILEDINSTRUCTIONSHEET
PTo3st9l
ot z g *
PI
F2
Pg
o Q OO '
llanufactured
by : P0WER-TR0N|C$,
lNC.
Cor^pus
Christi,Texas
regulator
wasdesigned
TheVR504Avoltage
to flll a universal
rolein
replacing
oldermechanical
andelectronic
as well as thenewestdigital
ln usetoday.lt alsocanbeusedto controlmuchlarger
voltageregulators
static excltensfoundin olderbrushtypegenerators,
Because
the VR504A
hasbeendesigned
for sucha universalrole,it has
someverydifferentoneratlng
characteristics
thanthe otherregulators
that areconsidered
the standardindustryfare,
TheVR504A
is designed
to let the installeractuallyadjustthe
characteristics
of the regulatorto matchthe requirements
of the
potentiometers
generator,
Thisis accomplished
by uslngadjustment
powerto the
locatedonthe regulatorandselectingthe incoming
are
reslstors0r specialreactors0r transformers
regulator.Nodr0pping
needed,
.5pe*h/rnofe.'Never
useadlgitalvoltmeter
tosetupagenerator
or
voltage
regulator.
lt will notindicate
realflickersor fluctuations
and
will notEivea truevoltage
reading
eitherondc0r acwhenfluctuations
present.
are
Onlyusea vanetypevoltmeter
0ngenerators
llll
Thereis a special
reason
thattherearen0identifications
of positions
0r
printed
functions
onthecaseof thevoltage
regulator.
Thisis doneto
present
insurethattheinstruction
sheetis
uponeachinstallation.l
Installationandmounting: TheVR504A
regulator
1sdesigned
to
ln h0stileenvlronments,
operate
butfor thelongest
llfe andbest
it
operation,should
bemounted
in thecleanest
andmostvibration
free
p0ssible
package
location
suchasthemeter
or lnsidea switchboard.
Hinimumfield resistancevalues: l0 ohms
at 120vac
input,
20
ohmsat 240vacinput.
!-
Flaximumoutput amperage:5 amps
dc,Higher
amperes
canbe
withoptional
obtained
adaptors.
usea multiconductor
RFI and induced voltages: Never
cordto hook
upthisregulator,
Useloose
wlringora shielded
cahle
withonlyoneend
c0nnected
to ground,
of theshielding
l'lagnetic interfenence: Donotmount
thlsregulator
nearanystrong
f leldssuchaswlthln6 lnches
magnetlc
of hlghcurrent
conduct0rs
0r
placed
nextt0 a magnetlc
f ieldsuchasanexclter
fleld0ra pmgexclter
nouslng.
Highvoftage protectionof outputof generutor:Themosr
common
failureof all voltage
regulators
ls hlghanduncontrollahle
protection
voltage
0rn0voltage
at all, Theonlyabsolute
against
htgh
voltage
is avoltage
sensing
relay,These
relays
areavailahle
thrumost
generator
service
companl
es,
Lowspeedoperationof generator: lf warm
ilp0rc*oldown
of
thegenerator
engine
is desired,
a run/ idleswitchshould
in
beplaced
serieswiththelnputvoltage
0f theregulator.
Thlsswltchcanalsobe
usedasanemergency
shutdownfor thegenerator
voltage.Damage
to the
regulator
andgenerator
canresultfromlowrpmoperatlon
of the
generator.
is designed
to havean
Incoming suppfy voltage: Thisregulator
yourinputv0ltage,
you
ashighas250vac,T0determine
inputvoltage
knowwhatthefull loadexcitervoltage
is, lf the
should
of thegenerator
voltage
ls lessthan32volts,thebestinputvoltage
will
full loadexciter
f 20vac,lf thefull loadexcltervoltage
is above
f2
besomewhere
around
volts,aninputvoltage
of somewhere
around
220vacis recommended
,
is unknown,
waysto makean
lf theexcltervoltage
thereareseveral
guess
asto whatit is. lf thef ieldresistance
ls lowerthanl5
educated
it mayindlcate
ohms,
thattheexciteris of thelowvoltage
fype,Another
voltage
theexclten
is to runthegenerator
at ratedrpm
wayto determine
connect
a 12vdcbatteryt0 theexciterf ields.lf the
andmomentarily
is t00hlghor cornect,
theexciterhasa lowvoltage
outputvoltage
lf the0utputvoltage
requirement,
is toolow,theexciteris 0f thehigher
reguirement.
voltage
test,butshould
serveto giveyouanideaof where
Thisis nota foolproof
at theexciterf ieldsshould
to start.Thedcvoltage
bechecked
withthe
generator
at ratedspeed
wlthn0loadandthenduringfull loadcondltions.
will n0thavea residual
voltage
hlghenough
to
a generator
Sometlmes
of thelinevoltage,
Thisusually
occurs
onlowvoltage
meatea buildup
instead0f
the120
lf so,slmplyinput220voltsto theregulator
exciters.
ly reguired,
voltsnormal
is for settingthe
Regulator ildiustment Pl: Thisadjustment
is
When
thevoltageregulator
desired
outputvoltageof thegenerator,
Thisis normal
f irst installed
andrunup,thevoltage
sh0uld
hepulslng,
thePI adJustment
ls below80vac,whlchis thevoltage
thatls
because
requlred
fer thehuildup
clrcultto dlsengage,
Fl is adJusted
When
ahove
wlll eitherstopor begln
to become
mildlyerratic.
80vac,thepulsation
perfectly
will become
setupat thistlme.
It is veryrarethatthevoltage
to about8098
of whatyouwouldlikeyouroutput
Adjusttheoutputvoltage
to be.Otheradjustments
will bedoneat thistime.Thevoltage
voltage
will riseandfall astheseotheradJustments
aremade.Keep
thevoltage
in the8098
range
withP1,
Regufator adjustment P2: Note: Thls adjustment is not
ls for correctlng
a voltagerlsewhich
normallyused.ThtsadJustment
speed
is
occurs
0nveryiowvoltage
exciters
whentheenglne
sometimes
governor
reduced
duringshutdownor sloppy
operation.
lf anundeslrable
riseoccurs
voltage
during
thesecondltlons,
whichwlll be I to 5 volts,
cw in smallincrements
turntheP2adjustment
to correcttheemor,As
whenP2is fullycw,
P2ls adjusted,
thevoltage
wlll lower,Sometimes
generator
of the
will notadjustto full outputevenwith
thelinevoltage
fullycw. Thlsis dueto overcompensating
0f the
thePI adJustment
voltage
regulator,
Tocomect
this,slowfyadjustPJcw untiltheline
voltage
ls at thedeslred
level,lt is bestnotto usethisadjustment
absolutely
necessary.
All PZadjustment
holesareplugged
andto
unless
plug,
pair
pliers
pinch
the
usea
of needle
nose
and
thelocking
refirove
plug
push
plug
oneachsideof the
and
the
upandoutof the
brackets
hole,
adjustment
RegulatoradjustmentP3: Thisadjustment
is used
to match
the
reactance
tlme0f thegenerator
wlththeoutput0f thevoltage
regulator.
regulator
is reacting
toofast,thelinevoltage
will be
lf thevoltage
for its ownvoltage
triesto overcompensate
erraticastheregulator
Toslowdownthereactance
timeof theregulator
to matchthe
changes,
tlmeof thegenerator,
veryslowlyturnPi cw untilthevoltage
reactance
will rise,
withnof llcker,AsyouturnPi cw,thevoltage
becomes
steady
withPl. When
thevoltage
is smooth
nearthe80?d
range
keepthevoltage
levelwithPl
thevoltage
upto thedesired
andthereis nof licker,adJust
youare
thevoltagefor about2 minutes,ff nof lickeroccurs,
andobserve
adjustPJcw
onllne,ff a flickeris noticed,
readyto placethegenerator
a little more.
Trouble shooting
running
Ho build up of voltage: Withgenerator
at operating
speed,
checktheresldual
voltageat,I and2 0ntfreVR504A
terminalboard,The
voltage
sh0uld
hemorethan3,5voltsac. lf thevoltage
ls belowthis
theexciterf ieldsfr0mtheregulat0r
value,remove
andmomenlarily
apply
l2vdcto themwhilethegenerator
is running
at speed,
Thevoltage
at I
increase
to a muchhlgher
valueduring
thistest, lf the
and2should
doesnotIncrease
to a muchhigher
all wiringand
voltage
value,check
for 0pencircuits.Alsomakesurethat
fuslngthatleadt0 theregulat0r
potentiometers
during
thistestthatall of theadjustment
aresetfully
cw andthattheoutputdcf leldvoltage
at 2 and3 alsoIncreases
asthis
thatthevoltage
wouldindicate
regulator
is functioning
correctly,
After
potentiometers
tl^ris
test,setall adJustment
fullyccw.
regulator
increases
duringthe
lf thevoltage
at I and2 onthevoltage
at 2 and3 doesnotincnease,
thiswouldindlcate
test,andthedcvoltage
is damaged
0r defective.
thattheregulator
diclnotinrease0nthegenenator
whentheexciter
ff thelinevoltage
problem
to the l2 vdc,thereis aninternal
in the
f ieldswerec0nnected
generator
suchasanopenexciterfleld0r shorted
0r opendiodes
In the
rectiflerbankor openrotor,
the l2 vdcfromtheexciterfieldsandreAfterthlstest,disconnect
thef ieldleadsto theregulator,
connect
l{akesurethattheleadthatwas
c0nnected
t0 theposltlve
0f the l2 voltsis connected
to 3 andthelead
to negative
thatwasc0nnected
ls connected
to 2 onthevoltageregulator,
goahead
upto spe-ed.
lf theIinevoltage
is pulsing,
and
Runthegenerator
aspreviously
described,
lf thereis nobuildupand
setuptheregulator
theresidual
voltage
at I and2 ls still t0olow,change
to
theinputv0ltage
240vacwhlchshould
double
theresldual
voltage
at I and2, lf when
vac
upwlth a24$ lnput,lf theresldual
ls stlll toolowfor build
ho0ked
f lashing
circuitwill haveto beinstalled,
up,thenanexternal
\*
cw.with
l'linorflickering of voltage: Pi isnotsetfarenough
generator
froml0ad,sl0wlyturnP3cwuntilflickerlng
dlsconnected
5tops.
Yoltage is high and uncontrollable: voltage
regulator
is
defective
0r theexciterfleldls grounded,
for thlsis that
Another
reason
exceeds
theexciteramperage
therating0f thevoltage
regulator,
Intermittentflashesor glitchesin voltage Loose
c0nnection
t0 regulator
aclnputor a defectlve
exclterf leldwitha carbon
or
Intermlttent
In
leld
track
open f
c0llor loosecomponents
ln thevoltage
regulator
dueto excessive
vibration.
loading
of generator
leads
or
Voltage rises ruithload: Unbalanced
to beadjusted
morecw,
Pi needs
toofarcw,adjustccw
Yoltage falls off rith load: PJis adjusted
droop
is satlsfactory.
untilvoltage
\v-'
Yoltagc rises too muchduring shut dorn: P2needs
to be
adJusted
cwto correct
therlse.TurnJustenough
to correct
therlse,
Voltage rill not adjust to louer values: Inputwiringto
regulator
voltage
is supplied
thrua cordorcable
thatls unshielded.
Use
wiringorshielded
cables.
loose
If yound adviceor tshnical assistance
CAII:
(512)ffi1-9382
ll hourhotline
generator
Troubleshmt
anddetermine
if
youhave
apneratorfailureor if the
voltry regulator
faild.
Datermine
inputvoltEeandfield
voltapfor theYR504A
r4ulator
andinstall.
$etall diustments
ccr*
$tartpneratorandrunuptoratedspffid.
Adjust
Pl until808 ofratd
voltapis remhd.
pulsations
harestoppdandthev0ltry
bmames
steady,
Yoltffiwill riseasPJis
turned
cw,Fsep
voltryin ranpwithPt.
Remsre
lmdfromgenerator
andlower
volt@
Snerat0rrpmslightly,0bserve
in voltage
astherpmis
for aninmease
TocorrmtavoltaEe
rise,adjust
lowered.
PZcwin smallinrements
untiltherise
P2isdiusted,
stops,
thevoltry
{ When
will lowar.Kmpthevoltryin ranpwith
Pl.) Besuretoreturntherpmtoratlng
before
eachtest.
TurnPl cwuntllpulslngvoltap
bemm*steady
or slightlyamatic.
Applyloadandobsrvevoltqe, lf it rises
onloding,setP3morecrY,lf it falls
whenloding,setPJmoreccw,
generutor
Place
vR50{A
ETECTRONICVOTTAGEREGUI.ATOR
t20 0n 2t0 uRc
'I
STARTUP PROCEDURE
3 AI{D4 IF THISREGULATOR
INSIALL A JI'I,IPERBETT'EEN
FIELD.32
IS TOBEUSEDOiI A LOT'VOLTAGEEXCITER
votTs oRrEss.
If,PUT VOLTAGE
OUTPUr VOLTAGEF+
}IAIINUN DC AIIPERABE
FPEQUEf,C?
VOLTAGE DROOP
NEGULATIOXAGCUTACY
st?E
ilEta||T
oo To 250 v*c
.6 TOtos DC
5 AOC / 25 ADC lflTH A504
45 TO 70 HZAA'USTABLE TO IOT
LESE TIIAT I' OF SETTIXG
6 l i . rs t f ,. r 21i l .
6 02.
HOOKUP
VITH OPTIOT{AL
A5O.TADAPTOR.
RED
5 ANO6 IF IIIOEXTERIIAL
INSTALTA JUHPERBETWEEN
rS USED.
2.000_0HEYoLTAGEAIUUSTT{ENT
FIETDSAREIN 6OOD
IiAKE SURETHATTHEEXCITER
ANDI{AVEIIIOCONTACT
WITHGROUND
COilDITION
OR
OTHER
CIRCUITRY.
30 AIIP FUSE
YITI{ I20 VOLTSFOREI(CITERS
OF
D. SUPPLYTI{EREGULATOR
52 VOLTSORLESS.SUPPIYTHEREGUTATOR
YITH 2{O
OF32 VOttS ORI{ORE.
volTs FoR EXCITERS
120 VOLTINPUT
YILL
I{OTE:AS AtUUSfHEilTSAREI{ADE,THEVOLTAGE
TOOOT
RAISEA}IDLOSER,XEEPTHEVOLTAGEATUUSTED
VOTTAGE
VITII PI" WIIEiIFIRSTINSTALLED
OFDESIRED
TI{EVOLTAGEWILLruLSE I,TIITILPI IS TURiIEDCW. I.IAKE
VER,Y
SLOYLYI
ALL ATI'USTMENTS
I.
ATT'I'STI.IENT
POTSFUTLYCCU.
TURNALL YOLTAGE
2.
Rt,I{ UP TOSPEED,
DOIiIOTIDLE.
$TARTGEI.IERATOR,
5.
YOLTAGEIS
TURHPI CY UHTILEO' OFDESIREO
OBTAII{ED.
4.
IF THEVT}LTA6EIS STABTEAI.IDIIOTPI,LSATING,
TURI{PI CW UNTILTHEDESIRED
YOLTAGEIS
NOOTHER
ATUUSTTIENT
YILL BEilEEOEO.
REACHED.
\-
tF THEVoLTAGEts puLsAilNo. vERy slovlv ruRtrl
P3 CY UNTILTllE PUtSATlOtrlSTOpS,(XEEPVOLTAGE
DOESNOTSTOP,
tN RAI{GES|TH Pt }, lF PULSATTON
YILL ITIOT
THISREGUTATOR
BESUITABLEFORTHE
APPLlCATlOl,l.
qIJESTIONS
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GA[.[.:
POWER-TRONICS,'INc.
CORPUSCHNISTI.TEI(AS
(5r2) EEr-9382
Et
ort:rg,