Kutai electronics EA16 Operation Manual

EA16

Generator Automatic Voltage Regulator

Operation Manual

Universal 16Amp Self Excited Automatic Voltage Regulator

for use in 220 / 380 / 440 / 480 VAC brushless generators

with paralleling compatibility

Headquarters : No.3, Lane 201, Chien Fu ST., Chyan Jenn Dist., Kaohsiung, TAIWAN
Tel : + 886-7-8121771 Fax : + 886-7-8121775 URL : http://www.kutai.com.tw

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2 EA16

1. SPECIFICATION

Sensing Input

Voltage 170 ~ 510 VAC, Single Phase 2 wires
Voltage is DIP Switch selectable
Frequency 50/60 Hz, DIP Switch selectable

Power Input

Voltage 60 ~ 300 VAC, Single Phase 2 wires

Output

Voltage Max. 90 VDC @ 240 VAC input
Current Continuous 16A
Intermittent 20A for 10 sec
Resistance Min. 5 ohm

Voltage Regulation

< ± 0.5% ( with 4% engine governing )

Voltage Build-up

Residual voltage at AVR terminal > 5 VAC

Thermal Drift

0.03% per °C change in AVR ambient

Load Current Compensation
1A or 5A Max. 7% @ PF0.5 DIP Switch Selectable

Analogue Voltage Input

Max. ±5VDC. ±10% @ ±3VDC

Over Excitation Protection

Max Output DCV 95% 20sec

External Volts Adjustment

± 5% with 2K ohm 1 watt trimmer

Unit Power Dissipation

Max. 10 watt

Under Frequency Protection ( Factory Setting )

50/60 Hz DIP SW selectable

Soft Start Ramp Time

2 sec.

Dimensions

156mm L * 106mm W * 43mm H

Weight

450g ± 2%

The EA16 AVR is an update of the EA15A AVR. It is similar to the original EA15A in power and voltage
sensing capabilities but with new enhanced paralleling functions; the user can now select the CT inputs either
1 & 5 Amp or use new A1 & A2 analogue signal inputs terminals for use with PLC paralleling controls. It has
new over-voltage excitation safety circuits to prevent damage caused by the accidental detachment of the
sensing wires or irregularities on the generator’s excitation circuits.

High Temperature

ATTENTION

1. AVR can be mounted directly on the engine,
genset, switchgear, control panel, or any position
that will not affects operation. For dimension
reference, please see Figure 1.

2. All voltage readings are to be taken with an
average-reading voltmeter Meggers and
high-potential test equipment must not be used.
Use of such equipment could damage the AVR.

3. Secure all wiring connection. Do not install AVR at a
place with high vibrations to prevent loose
connections. For safety do not touch the heat sink
while in operation.

4. Fuse specification : 16A / 250V slow blow type.

5. Terminal："Fast-On" terminals 6.35mm (1/4 inch) &
With 4mm crimping terminal.

Figure 1 Outline Drawing

UNIT :

mm

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EA16 3

2. CONNECTION TERMINAL

1. P1, P2： Power Input Terminals from 60 to
300VAC 50/60Hz -16A rated.

2. F+, F−：Maximum Output current 16A.

3. VS1, VS2：Voltage sensing input terminals, Volts
selected using DIP SW1 for 220V or 400V.

4. K, L：Load Current Compensation (Droop), CT
secondary current input selected by using DIP
SW 1A or 5A (If droop not used leave terminals
open).

5. VR1, VR2：External Voltage trim use, 2K Ohms 1
watt trimmer for ±5% voltage adjustment. Keep
terminals shorted when not in use.

6. A1, A2：Analogue Voltage Input terminals used
for Power Factor correction from a external PLC­The PLC controls provides a DC voltage signal to
adjust the generator voltage. Max. Adjustment
range is ±5VDC. Keep terminals open when not
used.

7. DIP Switch

SW1：OFF 220VAC (170 to 260VAC)
ON 400VAC (340 to 510VAC)

SW2：OFF CT Secondary Input 1A
ON CT Secondary Input 5A

SW3：OFF Generator Frequency 60Hz,
52 ~ 61Hz Adjustment

ON Generator Frequency 50Hz,
42 ~ 51Hz Adjustment

SW4：OFF Over excitation protection enabled
ON Over excitation protection disabled

8. LED Indicator

U/F：Under Frequency Indicator
O/E：Over Excitation Indicator

3. ADJUSTMENT AND SETTING

1. TRIM works together with a bias voltage applied
to terminals A1 and A2. This signal is supplies by
an external Power Factor Paralleling PLC. Use
the TRIM potentiometer to adjust the DC voltage
input that controls the level of the generator’s
output voltage. When set counter-clockwise the
control level is zero, and if moved clockwise the
maximum control range is 10%. The signal
connected to A1 and A2 can be unipolar (0,+) or
bipolar (+,−). Check with the manufacture of the
Paralleling control PLC.

2. DROOP：Select switch K or L pending on the
secondary current of the CT that you are using.
Voltage droop works when the CT and the AVR
senses that the output of the generator voltage
and current waveforms are out of synch and the
AVR droops the output voltage of the generator
to correct it.

3. STAB：If the generator output voltage oscillate,
adjusting the STAB potentiometer will stabilize
the output voltage, over adjustment will result in
high voltage variation when load is applied. Use
an analog type multimeter when making this
adjustment. Connect the meter to terminals F+
and F− and slowly adjust STAB potentiometer to
the point when the pointer stops moving.

4. VOLT：Move to set the generator output voltage.
Set DIP Switch 1 to the generator working
voltage.

Set SW1 to OFF (220V) for use from 170 to 260V
Set SW1 to ON (400V) for use from 340 to 510V

When using and external VR set it to the central

position and adjust the AVR VOLT trim to the
rated voltage.

NOTE

If the external VR is not used, short terminal
VR1 and VR2.

5. U/F：Under Frequency protection setting.

At 60Hz U/F factory set at 55Hz
At 50Hz U/F factory set at 45Hz

To adjust the U/F setting, select the correct

system frequency, start engine and adjust engine
speed to the required U/F frequency (for
example 55Hz or 45Hz), slow adjust U/F
potentiometer until the U/F red LED turn ON,
returning the engine speed to normal turn the
LED off.

Function of the Under Frequency trim pot：

● During start up or shutdown, the engine speed

changes going over or under its rated RPM (Hz).
This AVR has an Under Frequency circuit to
protect the AVR and exciter; you do not need to
disconnect the AVR when idling the engine.

● If load is higher than the generator’s capacity, the

Under Frequency activates, reducing the
generator’s voltage preventing generator
overload.

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4 EA16

6. Over Excitation Protection：

● This AVR has over Excitation Protection
preventing the generator from working under
unusually high excitation. Excitation Protection
includes generator overload, accident removal of
sensing wires, and incorrect voltage setting.
When problems occur, the AVR will gradually
shutdown the excitation voltage to the minimum
residual voltage. If the O/E LED turn ON and
stays ON, you need to reset the AVR by shutting
the engine for 10 seconds. When working the
generator in parallel this protection is not required,
the user can disable this function by switching
DIP switch SW4 to ON position, vice versa.

4. NOTICE OF USE

1. Installation Notice：(Refer to Figure 2 and 4).

● Only, a trained professional can Installation,
calibrate and inspections this AVR.

● Install this AVR inside the generator enclosure
away from moisture, corrosion and from any easy
to reach area.

2. Generator Operation Notice：

● During operation, the temperature on the surface
of the AVR can reach higher the 60 °C / 140°F.

● “DANGER” When the AVR is working never
touch or ground the heat sink on the AVR. The
AVR heat sink is an electrically live terminal.

A warning sticker is in place on top of the heat

sink.

5. FIELD FLASHING

When operating this AVR for the first time, the
polarity of the residual magnetism may be reversed
or too weak to achieve the necessary build-up on
the regulator. If reversing the field connections does
not induce build-up, and the residual voltage is less
than 5 VAC, shut down the Prime-mover and
proceed with the following steps：

1. Stop the generator and disconnect the field wires

(F+ and F−), apply a DC Voltage using a
batteries positive terminal to F+ and the negative
terminal to F−, using a current-limiting resistor of
3~5 ohms 20 watt.

2. Allow approximately 3 seconds before removing

the battery.

3. Disconnect the AVR AC power input terminals
and restart the generator, re-measure the
residual voltage. If this voltage is greater than
5VAC, reconnect voltage regulator, and voltage
build-up should be successful. If measured less
than 5VAC, repeat steps 5.1 and 5.2.

4. If repeating steps 5.1 and 5.2 does not result in
generator voltage build-up, and residual is
greater than 5VAC, replace with a new voltage
regulator.

CAUTION

Over excite may damage the AVR or the
exciter.

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EA16 5

EA16A

EXT. VR

K

A1

VR1 VR2

Field

P2P1 VS1F- VS2F+

A2

L

GEN

T

R
S

N

Figure 3 220V Connection

P1

VR1

EXT. VR

Field

GEN

VR2

A1

A2

VS1F+P2 F- KVS2 L

R

T
N

S

Field

EXT. VR

VR1P1VR2

A2

A1

VS1F-P2 F+ LVS2 K

GEN

T
N

S

R

EA16A

EA16A

GEN

EXT. VR

K

VR1 VR2

A1

F+P2P1 VS1F- VS2A2L

T
N

R
S

EA16A

Field

Figure 2 Paralleling Connection Figure 4 380 / 480V Connection

Field

EXT. VR

EA16

VR2VR1

A2

A1

F- VS1P1 P2 F+ LVS2 K

GEN

T
N

S

R

Aux.

Winding
60~300v

Figure 5 Auxiliary Winding

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6 EA16

6. TROUBLE SHOOTING

SYMPTOM CAUSE CORRECTION

Residual voltage below 5VAC Reference from 5. Field Flashing
F+, F− polarity reversed F+ and F− reverse the connection
F+, F−, P1, P2, VS1, VS2 not

connected

Reference from Figure 3 and 4 connection

Burnt fuse Change fuse 16A 250V
Ext. Switch (Breaker) not turned on Switch on (ON)

Voltage does not

build up

Engine RPM under speed Increase engine speed / frequency above25HZ
Poor adjustment is made Read start procedure carefully and adjust again
U/F protection activated Increase generator speed

Out voltage low

U/F activated / Incorrect voltage
selection

Read user’s manual to select correct voltage

Poor adjustment is made Read start procedure carefully and adjust again

Out voltage high

Incorrect voltage selection Read user’s manual to select correct voltage
Poor adjustment is made Read start procedure carefully and adjust again

Out voltage instable

Field voltage requirement lower
the rang of regulator

Inquire our distributor to solve

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Use only original supplied spare protection fuse for fuse replacement.

※

Please accept our sincere apology if any modification in performance, specification or appearance is
made without prior notice.