The XR500D is a universal voltage regulator designed for generator technicians. It incorporates selectable frequency ranges and precise voltage regulation regardless of load or temperature. The electronic circuitry automatically adjusts to the generator exciter without manual stability corrections. It can be controlled externally and used with optional modules from earlier models. The specifications include voltage and frequency ranges, regulation ability, output ratings, and physical dimensions. It provides three wiring configurations depending on the exciter field resistance and voltage ratings. Instructions are given for installation, setup, troubleshooting, fuse replacement, and filling out an installation form. The two-year warranty covers parts and workmanship but has exclusions such as overheating, physical damage, or unauthorized repairs.
The XR500D is a universal voltage regulator designed for generator technicians. It incorporates selectable frequency ranges and precise voltage regulation regardless of load or temperature. The electronic circuitry automatically adjusts to the generator exciter without manual stability corrections. It can be controlled externally and used with optional modules from earlier models. The specifications include voltage and frequency ranges, regulation ability, output ratings, and physical dimensions. It provides three wiring configurations depending on the exciter field resistance and voltage ratings. Instructions are given for installation, setup, troubleshooting, fuse replacement, and filling out an installation form. The two-year warranty covers parts and workmanship but has exclusions such as overheating, physical damage, or unauthorized repairs.
The XR500D is a universal voltage regulator designed for generator technicians. It incorporates selectable frequency ranges and precise voltage regulation regardless of load or temperature. The electronic circuitry automatically adjusts to the generator exciter without manual stability corrections. It can be controlled externally and used with optional modules from earlier models. The specifications include voltage and frequency ranges, regulation ability, output ratings, and physical dimensions. It provides three wiring configurations depending on the exciter field resistance and voltage ratings. Instructions are given for installation, setup, troubleshooting, fuse replacement, and filling out an installation form. The two-year warranty covers parts and workmanship but has exclusions such as overheating, physical damage, or unauthorized repairs.
The XR500D is a universal voltage regulator designed for generator technicians. It incorporates selectable frequency ranges and precise voltage regulation regardless of load or temperature. The electronic circuitry automatically adjusts to the generator exciter without manual stability corrections. It can be controlled externally and used with optional modules from earlier models. The specifications include voltage and frequency ranges, regulation ability, output ratings, and physical dimensions. It provides three wiring configurations depending on the exciter field resistance and voltage ratings. Instructions are given for installation, setup, troubleshooting, fuse replacement, and filling out an installation form. The two-year warranty covers parts and workmanship but has exclusions such as overheating, physical damage, or unauthorized repairs.
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XR500D
Universal Voltage Regulator
The XR500D is a unique voltage regulator that is designed specifically for Professional Electrical Generator Service and Repair Technicians. The XR500D is the newest upgrade for all UVR and XR series voltage regulators and incorporates selectable frequency ranges for voltage roll off during under frequency operation and precise voltage regulation regardless of load and ambient temperature. The XR500D incorporates patented electronic circuitry that automatically adjusts itself to the generator exciter and does not require manual stability correction. The XR500D can be externally controlled with a PLC or Genset controller by simply adding an optional interface module. All major electronic components are not encapsulated so that they can easily be repaired while all sensitive components are encapsulated to protect them from contamination. The XR500D can be used with all optional modules that were available for use with the earlier models of Power-Tronics regulators.
Specifications Input Voltage: Frequency: Voltage Regulation: Parallel Operation Output Voltage: Maximum Continuous Output: Minimum Field Resistance: Min Residual Build up Voltage: Under Frequency Protection: Physical Size: Weight: Repairable: Internal Protection: External Voltage Adjustment: System Operating Indicator: Optional Static Exciter Modules Optional External Controls 120 / 208 or 240acv 50 or 60hz +/- .25% From NL to FL Yes 0-52vdc @ 120vac input 0-105vdc @ 240vac input 0-210vdc @ 240vac input 5adc 10.5 @ 52vdc output 21 @ 105vdc output 42 @ 210vdc output 3.5vac Yes, VPH reduction 4.75 x 6 x 1 in. 7 oz Yes Fuses, cartridge type Yes Yes Yes Yes
Caution: Read this Installation Manual carefully.
Warning: Do not use digital equipment to read voltage, Hz, or amperage during this installation. Use only Analog sensing equipment! Failure to do so may result in damage to equipment or in personal injury! Make sure that all setup is done off line. Always wear eye protection and NEVER hold the regulator in your hand when energized. The XR500D is a Universal Voltage Regulator that can be configured several different ways to fit differing applications. Before selecting a wiring configuration for the regulator, you must know certain pieces of information about the generator and exciter to be successful in determining the correct hookup for the regulator. Show below is a guide to determine the correct connection of the regulator: Exciter field resistance is more than 40 ohms and exciter full load voltage is rated at 125vdc or less. (Use connection A) Exciter field resistance is more than 21 ohms and exciter full load voltage is rated at 63vdc or less. (Use connection B) Exciter field resistance is more than 10 ohms and exciter full load voltage is rated at 32vdc or less. (Use connection C) If this generator is going to operate at a speed lower than 50/60 Hz, a disconnect or switch should be placed in series from the generator stator to terminal #1 and #2 on the XR500D.
Connection A
Generator
A B 208-240vac C F+ F-
For 480vac, either use a transformer with a 240vac secondary or center tap the generator windings. At T7 and T8.
N 208-240vac Do not connect the input of the voltage regulator to DPE or auxiliary windings!
1 2 3 4 5 6 7 8
Remote Voltage Adjustment 100K @ 1w
XR500D Universal Voltage Regulator
Note: It is not necessary to jumper 7 and 8 terminals if not using the Remote Voltage Adjustment!
Connection B
If this generator is going to operate at a speed lower than 50/60 Hz, a disconnect or switch should be placed in series from the generator stator to terminal #1 and #2 on the XR500D.
Generator
A B 208-240vac C FF+
For 480vac, either use a transformer with a 240vac secondary or center tap the generator windings. At T7 and T8.
N 208-240vac
2 3 4 5 6 7 8
Do not connect the input of the voltage regulator to DPE or auxiliary windings!
Remote Voltage Adjustment 100K @ 1w
XR500D Universal Voltage Regulator
Note: It is not necessary to jumper 7 and 8 terminals if not using the Remote Voltage Adjustment!
Connection C
If this generator is going to operate at a speed lower than 50/60 Hz, a disconnect or switch should be placed in series from the generator stator to terminal #1 on the XR500D.
Generator
A B 208-240vac C FF+
For 480vac,use a transformer with a 120vac secondary.
120-139vac
1 2 3 4 5 6 7 8
Do not connect the input of the voltage regulator to DPE or auxiliary windings!
Remote Voltage Adjustment 100K @ 1w
XR500D Universal Voltage Regulator
Note: It is not necessary to jumper 7 and 8 terminals if not using the Remote Voltage Adjustment!
Installation and setup
1. 2. Install the regulator and wire up to the correct wiring diagram. Turn the internal voltage control and stability control 15 or more turns counter clockwise (left). This procedure is necessary in case the original factory settings have been altered.
Frequency Selection Remove jumper for 50Hz operation. This products default setting is 60Hz. (Pull up to remove) Internal voltage adjustment System indicator light
3. 4. 5. 6.
If you are using a remote voltage adjustment, set it at 50% of adjustment. Start up the prime mover and bring up to operating speed and turn on the regulator switch. (if used) Set the internal voltage adjustment to the desired voltage setting for the generator output Place the generator on line and observe the frequency and voltage.
Application Troubleshooting Problem: No Voltage Pulsating Voltage Flickering Voltage High Voltage Voltage Drop on Load Low Voltage Poor Voltage Regulation No Voltage Control
Possible Cause: 1. Residual input voltage to the voltage regulator is below 3.5vac or fuses are open in the regulator. 2. Unbalanced generator load. 3. Open exciter field or defective generator. 4. Non linear load or defective connection in exciter field. 5. Open diode in exciter or shorted rotor in generator. 6. Loose component in voltage regulator. 7. Loose wiring connections. 8. Input voltage to regulator is too low. 9. Exciter field is grounded. 10. Non linear load or wrong selection for regulator hookup. 11. Exciter fields are reversed. 12. Wrong selection of regulator wiring configuration. 13. Defective voltage regulator. 14. SCR or Inverter drive effecting generator waveform. 15. Regulator needs external flashing circuit. 16. Isolation transformer is too small.
17. Isolation transformer is needed. 18. Exciter fields are not isolated from other circuits. 19. Input and field circuit are being fed by a common cable or conduit. 20. Incorrect hookup or wiring.
Fuse Replacement
Fuses, 20 x 5mm, 5 amp @ 250vac
Frequency Selection
Remove the 2 screws located on the front of the mounting can near the terminal board. Loosen the 2 screws located on the front of the mounting can near the voltage and stability adjustment holes. (DO NOT REMOVE!) Partially separate the top of the regulator printed circuit card from the mounting housing. (Separate just enough to reach and replace the fuses) Replace open fuses and re-tighten all screws. Fuse size is 20mm x 5mm, 5 amps @ 250vac. (DO NOT REPLACE WITH ANY OTHER TYPE OR RATING OF FUSE! SEVERE DAMAGE AND PERSONAL INJURY COULD RESULT BY DOING SO!)
Installation form It is very important that you fill out this form completely when installing a voltage regulator. This form serves as a history record on the application. This form also contains the information needed by Power-Tronics, Inc., for repair and troubleshooting of any product you may be having problems with.
Product Serial Number Date of Installation Type of Generator Brush type Brushless Wired for Volts Phase [] []
Other options
Model #
AC Stator Information Hz Generator Configuration: Lead Exciter/Rotor Information Exciter field resistance Exciter field volts vdc Description of problem with product or generator @ F+ / F@ Slip Rings
Your phone number Your fax number Your email address
Name: Ship to Address: Ship to City, State, Zip:
PRODUCT WARRANTY Power-Tronics, Inc., assumes no liability for damages due to incorrect voltage or other voltage related damages resulting from either output of the generator or input to the generator exciter system. These problems should be protected with external devices provided by the customer such as fuses, surge suppressors, over/under voltage and frequency controls. Power-Tronics, Inc., warranties only parts and workmanship of this product for a period of 2 years from the original date of purchase from Power-Tronics, Inc. Under warranty, Power-Tronics, Inc. will replace, exchange or repair the defective product without labor or parts cost to the customer. Remaining warranty of the original product will be transferred to the replaced or repaired product. To obtain warranty, a copy of the original purchase receipt must be sent in with the defective product, which clearly shows the purchase date and serial number of the defective part. A repair request form must be sent in with the product before repairs will begin. You can obtain this form through contacting PowerTronics, Inc.. Send repairs to: Power-Tronics, Inc., 2802 Cobbler Ln., Kerrville Texas USA 78028. Send in repairs only by UPS or FedEx.
Any one of the following conditions will void the warranty:
Overheating of the power supply resistor on the printed circuit card. Overheating of the SCR or freewheeling diode. Physical damage to the printed circuit card, housing or components. Unauthorized repair or alteration of printed circuit card. Installation by anyone other than a qualified professional generator service technician. Conductive or corrosive contamination of the circuit card. Removal of our company identification from the product. Removal of any conformal coating of the printed circuit card or components. Overheating of foil on the printed circuit card. Inappropriate or infeasible application Use with any external device other than manufactured by Power-Tronics, Inc.
No other warranty is expressed or implied.
Bench Check Instructions
1. 2. 3. 4. 5. Wire up the regulator as shown in figure A. Connect up a 120 volt 50 to 150 watt light bulb to the F+ and F- Terminals. Adjust the internal voltage pot fully CCW (25 turns) or until a click is heard. Input 120vac into the regulator at #1 and #2. (Fuse this input with fuses rated at 120 volts or higher and not more than 5 amps ac) Observation: The green status light should be on and the light bulb across F+ and Fshould be off. If the green status light is not on, the internal fuses are blown in the regulator or there is internal damage to the regulator! If the green status light is not on, do not continue this test! 6. 7. 8. Turn the internal voltage adjustment CW until the light bulb across F+ and F- turns fully on, then adjust the internal voltage adjustment CCW until the light bulb is off. Remove the 120vac from the regulator. Connect up the regulator in configuration B and perform all of the previous steps again. In this mode, the light bulb will only glow at half brilliance!
9.
If you were able to successfully perform all of these tests, the regulator is good.
120 vac
F+
F-
Figure A 1 2 3 4 5 6 7 8
120 vac
F-
F+
Figure B 1 2 3 4 5 6 7 8
Parallel Connections For The XR500D Universal Voltage Regulator (Connection A)
Generator
xx/5a CT
A B C Reactive droop adjustment
1Kva transformer for maximum output amperage.
240vac 3 ohm, 100w Regulator off/on
Unit / Parallel switch
Exciter field
XR500D For stand-alone operation, close the Unit/Parallel switch.
If the voltage raises during motor loading, reverse the current transformer leads. Remote voltage adjustment 100k, 1/2w
10
Parallel Connections For The XR500D Universal Voltage Regulator (Connection B)
Generator
xx/5a CT
A B C Reactive droop adjustment
750va transformer for maximum output amperage.
240vac 3 ohm, 100w Regulator off/on
Unit / Parallel switch
Exciter field
XR500D For stand-alone operation, close the Unit/Parallel switch.
If the voltage raises during motor loading, reverse the current transformer leads. Remote voltage adjustment 100k, 1/2w
11
Parallel Connections for the XR500D Universal Voltage Regulator when used with the SE350 Static Exciter Module.
A Generator xx/5 CT
B C Reactive droop adjustment
5kva transformer for maximum output amperage.
240vac 3 ohm, 100w Exciter field
Unit / Parallel switch
AC1 AC2 F+
F-
Regulator off/on Gray Red White
SE350
XR500D For stand-alone operation, close the Unit/Parallel switch.
If the voltage raises during motor loading, reverse the current transformer leads. Remote voltage adjustment 100k, 1/2w
12
Parallel Connections for the XR500D Universal Voltage Regulator when used with the SE450 Static Exciter Module.
A Generator xx/5 CT
B C Reactive droop adjustment
5kva transformer for maximum output amperage.
240vac 3 ohm, 100w Exciter field
Unit / Parallel switch
AC1 AC2 F+
F-
Regulator off/on Gray Red White
SE450
XR500D For stand-alone operation, close the Unit/Parallel switch.
If the voltage raises during motor loading, reverse the current transformer leads. Remote voltage adjustment 100k, 1/2w
13
Conversion Diagram To Change From Older Shunt Wound Voltage Regulation To Newer Solid State Voltage VR, UVR And XR Universal Voltage Regulators.
Original Wiring Shunt Field F1 Interpole ARM
F2
Rheostat Or Voltage Regulator
A1
A2
Main Rotor C1 C2
Converted Wiring Voltage Regulator F+ and F-
Shunt Field F1 Interpole ARM A1 A2 F2
Switch polarity if buildup does not occur
Main Rotor C1 C2 14
Optional AFM500X Auto Flash Connection Diagram
AFM500X shown connected to an XR or UVR series Power-Tronics voltage regulator in the AUTO FLASH configuration.
1 2 4 5 6 3
XR500C XR500D XR500C-400 UVR501 UVR501-400 UVR500
AFM500X shown connected to an XR or UVR series Power-Tronics voltage regulator in the BATTERY FLASH configuration.
1 2 1 2 5 6 3
XR500C XR500D XR500C-400 UVR501 UVR501-400 UVR500
B+ 12/24vdc 10, 100w resistor
PB switch, fuel or oil pressure, speed switch or relay contact. Note: Battery negative must be connected to the generator neutral and not to the F- of the exciter!
