Basler Electric AVC63-4 User Manual

FOR

(

)

ANALOG VOLTAGE CONTROLLER

Model AVC63-4 (P/N 9166800136)

Model AVC63-4D

INTRODUCTION

AVC63-4 and AVC63-4D analog voltage controllers regulate
voltage on 50 or 60 hertz brushless generators. The
controllers include frequency compensation, over-excitation
shutdown, solid-state buildup circuitry, and EMI filtering.

AVC63-4 adjustment potentiometers are located on the
terminals and components side of the controller (see Figure

1). AVC63-4D adjustment potentiometers are accessed
through the controller front panel (see Figure 2).

SPECIFICATIONS

Output Power

Maximum Continuous: 4 Adc at 63 Vdc (252 W)
One Minute Forcing: 7 Adc at 100 Vdc (700 W) with

240Vac power input

Exciter Field DC Resistance

15 to 100 Ω

Input Power

Range: 190 - 240 Vac, ±10%, single-phase
Frequency: 50/60 Hz, ±10%
Burden: 500 VA

Sensing Input

190 to 240 Vac, single-phase, 50/60 Hz, ±10%, common
with ac power input

Voltage Adjustment Range

171 to 264 Vac

Regulation Accuracy

Better than ±1.0%, no-load to full-load

Response Time

Less than 1.5 cycles for ±5% changes is sensing voltage

EMI Suppression

Internal electromagnetic interference (EMI) filtering

Overexcitation Shutdown

Field voltage shuts down after time delay if exciter field
voltage exceeds 100 Vdc, ±5%. (See Overexcitation
Shutdown for inverse time delay curve and description.)

Voltage Buildup

Automatic voltage buildup occurs for residual generator
voltages as low as 6 Vac.

Power Dissipation

8 W maximum

Temperature

Operating: –40 to 140°F (–40 to 60°C)
Storage: –85 to 185°F (–65 to 85°C)

Vibration

2 to 27 Hz: 1.3 G
27 to 52 Hz: 0.036 inches, double-amplitude
52 to 1000 Hz: 5 G

Shock

Withstands up to 20 G in each of three mutually
perpendicular axes.

Publication

9166800890

Revision

A

P/N 9166800134

Weight

8 oz (220 g) net

Agency Certification

UL recognized and CSA certified

CONTROLS

AVC63-4 and AVC63-4D controls consist of jumpers and
screwdriver-adjusted potentiometers.

Jumpers

Two jumpers connect to the controller terminals: the Corner
Frequency jumper and the Voltage Adjust Rheostat jumper.
These jumpers are shown in Figure 3.

Corner Frequency Jumper

Analog voltage controllers are delivered with the Corner
Frequency Jumper set for 60 hertz operation. This gives a
corner frequency of 55 hertz. For 50 hertz operation and a
corner frequency of 45 hertz, the Corner Frequency jumper
must be moved to the 50 Hz terminal.

Voltage Adjust Rheostat Jumper

Analog voltage controllers are delivered with the Voltage
Adjust Rheostat jumper connected across terminals 6 and 7.
This enables adjustment of the generator output voltage
through the controller’s internal Voltage Control potenti­ometer. Clockwise rotation of the voltage control increases
generator voltage.

If remote adjustment of the generator output is desired, the
Voltage Adjust Rheostat jumper must be replaced with a
user-supplied rheostat. A 1000 ohm, ½-watt rheostat will
provide adequate voltage adjustment range for most
applications. Figure 8 shows the proper remote rheostat
connections.

Potentiometer Controls

AVC63-4 potentiometer controls are located on the
components and terminals side of the controller and are
shown in Figure 1. AVC63-4D potentiometer controls are
accessible through the controller front panel and are shown
in Figure 2.

INPUT POWER/SENSING INPUT

Power for the exciter field and analog voltage controller is
derived from the generator output. The acceptable power
input range is 171 to 264 Vac and is connected to terminals
3 and 4. Connect wiring as shown in the interconnection
diagram of Figure 8.

EXCITER FIELD POWER CIRCUIT

Controller terminal F+ is connected to the brushless exciter
field positive terminal and controller terminal F– is
connected to the brushless exciter field negative terminal.

If the exciter field dc resistance is less than 15 Ω and the
full-load field current does not exceed the maximum
continuous current rating of the controller, a resistor of

CAUTION

The exciter field dc resistance must be 15 Ω or
greater and less than 100 Ω.

First Printing: 09/03

Revised: 04/07

Copyright

2007

sufficient wattage must be added in series with the field to
increase the total resistance to 15 Ω.

FREQUENCY COMPENSATION

The frequency compensation feature improves system load
pickup performance by restraining voltage recovery until the
frequency has also started to recover. Figures 4 and 5
illustrate the underfrequency characteristics of the AVC63-4
and AVC63-4D.

The corner frequency range is set for 50 hertz or 60 hertz by
connecting the Corner Frequency jumper to the appropriate
terminal. Refer to Controls, Jumpers for details about
selecting the corner frequency range.

The corner frequency setting is adjusted by the
Underfrequency control (potentiometer). Clockwise rotation
of the Underfrequency control increases the corner
frequency and counterclockwise rotation decreases the
corner frequency. If user adjustment of this factory-set
potentiometer is desired, follow the Preliminary Setup and
System Startup procedures.

OVEREXCITATION SHUTDOWN

The overexcitation shutdown feature removes controller
output power, after a time delay, if the exciter field voltage
exceeds 100 Vdc, ±5%. The time delay is inversely
proportional to the magnitude of the detected overvoltage—
up to 135 Vdc. Beyond 140 Vdc, the field voltage is removed
after approximately 2 seconds. Figure 6 shows the over­excitation shutdown time delay characteristic curves.

Once the output power is removed, the controller can be
reset by decreasing the input voltage to less than 10 Vac for
two seconds, minimum. This can be achieved by stopping
the prime mover or by interrupting the controller input power
with a reset switch.

INSTALLATION

Mounting

The AVC63-4 and AVC63-4D controllers may be mounted
on the generator in any convenient position. Figure 7 shows
the outline dimensions and drilling locations. Dimensions are
shown in inches with millimeters in parenthesis.

The recommended mounting hardware is two #8 or M4
screws torqued to 9 inch-pounds (0.9 newton meters).
Nylon-lined locking nuts are recommended when installing
the controller with loose hardware.

Connections

AVC63-4 and AVC63-4D controller terminals consist of
quarter-inch, quick-connect tabs.

Figure 8 shows a typical interconnection diagram for the
AVC63-4 and AVC63-4D controllers.

OPERATING PROCEDURES

The following procedures provide instructions for adjusting
the AVC63-4 and AVC63-4D controllers. Symptoms caused
by certain generator system problems or a faulty controller
are included along with suggested remedies.

CAUTION

Meggers and high-potential test equipment must
not be used. Use of such equipment could damage
the semiconductors contained in the controller.

Preliminary Setup

Complete the following steps before proceeding with system
startup.

1. Verify that the analog voltage controller specifications
conform with the requirements of the generator system.

2. Ensure that the controller jumpers are positioned as

follows.
a. If a remote voltage adjust rheostat will not be used,

ensure that the Voltage Adjust Rheostat jumper is
connected across terminals 6 and 7.

b. If a 55 hertz corner frequency for a 60 hertz system

is desired, connect the Corner Frequency jumper to
the 60 Hz terminal. If a 45 hertz corner frequency
for a 50 hertz system is desired, connect the
Corner Frequency jumper to the 50 Hz terminal.

3. Ensure that the connections between the generator

system and the controller are correct.

4. Install the fuses as shown in Figure 8.

5. Set the controller’s Voltage control fully counter-

clockwise and the remote voltage adjust rheostat (if
used) to the centered position.

6. Adjust the controller’s Stability control fully clockwise.

This provides the most stability and the slowest
response.

7. If user adjustment of the Underfrequency control is

required, start with the potentiometer adjusted to the
fully counterclockwise position. Then, slowly adjust the
potentiometer clockwise to set.

System Startup

NOTE

All voltage readings are to be taken with an
average-reading voltmeter.

1. Perform the steps under Preliminary Setup.

2. Start the prime mover and bring it up to rated speed.

Generator voltage should build up. If it does not build
up, perform the steps under Field Flashing.

3. Slowly adjust the controller’s Voltage control (or remote

voltage adjust rheostat) until the generator voltage
reaches the nominal level.

If the voltage does not build up to the rated level:
a. Check the generator output for excessive load or a

short-circuit.

b. If a minimal residual of 6 volts is not present,

perform the steps under Field Flashing.

4. Apply and remove the generator load to verify stability.

If the generator responds too slowly or hunts
(oscillates):

a. Check the generator output for excessive load or a

short-circuit. Adjust the controller’s Stability control
with no load applied.

b. Check the stability of the governor system.

5. Check regulation under normal operating conditions.

If the regulation is poor:
a. Verify that the prime mover is operating at rated

speed.

b. Verify that the voltmeter is connected to the same

point as the controller sensing.

c. Use an average-sensing voltmeter (not an rms-

sensing voltmeter).

6. Verify the corner frequency setting by slowly reducing

the generator frequency until the generator output
voltage just starts to decrease.

Page 2 First Printing: 09/03

Revised: 04/07

Revision

A

Publication

9166800890