Kutai electronics EA440 Operation Manual

KUTAI ELECTRONICS INDUSTRY CO., LTD.

TEL : [phone] FAX : [phone] Website : www.kutai.com.tw
Headquarters : No.3, Ln. 201, Qianfu St., Qianzhen Dist., Kaohsiung City 80664, Taiwan

Self Excited Automatic Voltage Regulator

Compatible with Newage SX440*

* All manufacturer names and numbers are used for reference purpose only

and do not imply that any part is the product of these manufacturer.

EA440

Generator Automatic Voltage Regulator

Operation Manual

Sensing Input

Quadrature Droop Input

Voltage 190 – 264 Vac, 1 phase 2 wire

Burden 10 ohms

Frequency 50 / 60 Hz, selectable

Max. input 0.33 A

Max. sensitivity 0.07 A for 5% droop (PF=0)

Excitation Output

Voltage Max. 90 Vdc @ power input 207 Vac

Analogue Voltage Input

Current Continuous 4A

Input Resistance 1K ohm

Intermittent 10A for 10 secs.

Max. Input +/- 5 Vdc

Resistance Min. 15 ohm

Sensitivity 1V for 5% generator volts

External Voltage Adjustment

Under Frequency Protection

Max. +/- 8% @ 1K ohm 1 watt potentiometer

Set point 95% Hz

Slope 170% down to 30 Hz

Voltage Regulation

Less than +/- 1% ( with 4% engine governing )

Voltage Thermal Drift

Less than 3% at temperature range -40 to +70 ˚C

Build Up Voltage

5 Vac residual volts at power input terminal

Environment

Operating Temperature -40 to +70 ˚C

Soft Start Ramp Time

Storage Temperature -40 to +85 ˚C

2 seconds +/- 10%

Relative Humidity Max. 95%

Vibration 3.3 Gs @ 100  2K Hz

Static Power Dissipation

Max.12 watts

Dimensions

150.0 (L) x 135.0 (W) x 48.0 (H) mm

Weight

418 g +/- 2%

115.0

135.0

130.0

150.0

21.5

48.0

5.5

STABILITY

DROOP

TRIM

VOLT

UFRO

LED

C B A

C-A < 90KW
C-B < 90-550KW
B-A < 550KW

Resistor

ATTENTION

1. AVR can be mounted directly on the
engine, genset, switchgear, control
panel, or any position that will not affect
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. Improper setting of under-frequency
protection could cause the output
voltage of the unit to drop or become
unstable under with changes in load.
Avoid making any changes to the U/F
setting unless necessary.

Figure 1 Outline Drawing

SECTION 1 : SPECIFICATION

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2 EA440

Figure 2 Bypass Drawing

Figure 3 Wiring Drawing

SECTION 2 : WIRING

2.1 K1, K2 : Field input external switch terminals.
Linked for normal operation.

2.2 P2, P3 : External power input terminals.

2.3 3, 2 : Sensing input terminals.

2.4 1, 2 : External VR terminals. Linked for useless.

2.5 X,XX : X connect to field (+), XX connect to field
(-).

2.6 S1, S2 : Droop CT input terminal.

2.7 A1, A2 : VAR/PF controller input.

2.8 A, B, C : Link A, C for under 90 KW.

Link B, C for 90  550 KW.
Link A, B for over 550 KW.

2.9 J1  J8 : Jump select terminals, 2-3, 4-5, 6-7.
please refer to Figure 2 and Figure 3.

SECTION 3 : ADJUSTMENT

3.1 Voltage Adjustment

The generator output voltage can be altered by
adjustment of the volt VR on the AVR board, or by the
external trimmer (1K ohm) if fitted.

(1) The terminals 1&2 must be linked if no hand

trimmer.

(2) Before start the generator, please turn the Volt

trimmer on the AVR board fully anticlockwise Turn
the external trimmer to midway position.

(3) Turn the stability trimmer on the AVR board to

midway position.

(4) Connect a voltmeter to generator output voltage

terminals.

(5) Start generator set and run on no load at nominal

frequency 50  53 Hz or 60  63 Hz.

(6) If the red Led is illuminated, refer to the under

frequency roll off adjustment.

(7) Carefully turn volt trimmer clockwise until rated

voltage is reached.

3.2 Stability Adjustment

If a replacement AVR has been fitted or re-setting of
the stability control is required, turn the stability trimmer
slowly clockwise until the output voltage is steady, on
or off load.

3.3 Droop Adjustment

Generator intended for parallel are fitted with a
quadrature droop CT with provides a power factor
dependent signal for the AVR. The CT is connected to
S1, S2 on the AVR. The Droop adjustment is normally
present in the works to give 5% voltage droop at full
load zero power factor. Clockwise increases the
amount of CT signal injected into the AVR and
increases the droop with lagging power factor. With the
control fully anticlockwise there is no droop.

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EA440 3

Figure 4 Manual Field Flash

Field

SWR

-

+

V

F+F-

BATT.

~

G

~

T

S

R

WARNING

Overly field flashing may damage the AVR or
generator excitation winding.

Please make sure you have read and understand
the contents of the instruction manual prior to
installation. Incorrect wiring connection may
result in irreversible damage to the product and
other equipments.

3.4 Trim Adjustment

An auxiliary input is provided to connect to A1, A2. It is
designed to accept DC +/- 5V.Turn the TRIM trimmer
fully anticlockwise has no effect, Clockwise it has
maximum effect.

SECTION 4 : FIELD FLASHING

When the regulator is installed correctly but the
generator is failed to generate power. Besides carbon
brushes were worn out, here are two possible causes
below.

4.1 The polarity of field is inverse

Solution：Exchange the connection of F+ and F-.

4.2 The residual voltage is less than 5 Vac,
Solution 1：

4.2.1 Shut down generator, disconnect the wiring
between AVR and generator then flash the field.
Flashing duration = 3 seconds. (See wiring in
Figure 4)

Resistor 3 – 5 ohms for full wave AVR
Resistor 5 – 10 ohms for half wave AVR

Warning!! Over field flashing may damage

the field winding of generator.

4.2.2 Restart generator and measure the residual
voltage by AC Voltmeter, if it is still less than 5
Vac, repeat the previous process, after several
times, the residual voltage still cannot be built,
Kutai EB500 is strongly recommended, see
Figure 4.

SECTION 5 : PARALLEL FUNCTION

5.1 Parallel Compensation

5.1.1 When it is required to operate the regulator in
parallel with an isolated or utility bus, in addition
to the regulator provisions, a 10VA current
transformer (CT) is required ( See Figure 3 ). The
CT is connected in a generator line and should
deliver from 1 amperes secondary current at
rated load.

5.1.2 The phase relationship of CT signal to the
regulator sensing voltage must be correct or the
system will not parallel properly. The CT must be
installed in the line of the three phase generator
that does not supply sensing to the regulator.

5.2 Reactive Droop Compensation

5.2.1 For reactive droop compensation, connect the

CT to it’s respective regulator as shown on

Figures 3.

5.2.2 A unit-parallel switch shorts the parallel CT
secondary to prevent any droop signal from
being injected into the regulating system during
single unit operation. The switch may not be
required on parallel droop compensation
applications where a voltage drop is not
objectionable.

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4 EA440

SYMPTOM

POSSIBLE CAUSES

SOLUTIONS

Voltage does not

build up

Engine speed is too low

Please refer to the Generator Manual

wires are not connected well

Please refer to Figure 2

Defective Generator

Please refer to the Generator Manual

Low output voltage

External VR broken

Check wiring and testing VR

Terminal 1&2 not linked

Please linked terminal 1&2

Terminal 3&2 no sensing input

Please refer to Figure 2

Under frequency

Please refer to the Generator Manual

Defective Generator

Please refer to the Generator Manual

Over output voltage

AVR adjustment not well

Please refer to voltage adjustment page

Defective Generator

Please refer to the Generator Manual

SECTION 6 : TROUBLE SHOOTING

※ Appearance and specifications of products are subject to change for improvement without prior notice.

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EA440 5