DESIGN DETAIL

SX440 AUTOMATIC VOLTAGE

REGULATOR (AVR)
SPECIFICATION, INSTALLATION AND ADJUSTMENTS

General description Technical specification

SX440 is a half-wave phase-controlled thyristor type INPUT
Automatic Voltage Regulator (AVR) and forms part of the Voltage 190-264V ac
excitation system for a brush-less generator. Frequency 50-60 Hz nominal
Phase 1
Wire 2
In addition to regulating the generator voltage, the AVR OUTPUT
circuitry includes under-speed and sensing loss Voltage max 90V dc at 207V ac input
protection features. Excitation power is derived directly Current continuous 4A dc
from the generator terminals. Intermittent 6A for 10 secs
Resistance 15 ohms minimum
Positive voltage build up from residual levels is ensured REGULATION
by the use of efficient semiconductors in the power +/- 1% (see note 1)
circuitry of the AVR.
THERMAL DRIFT
0.04% per deg. C change in AVR ambient (note 2)
The AVR is linked with the main stator windings and the
exciter field windings to provide closed loop control of the TYPICAL SYSTEM RESPONSE
output voltage with load regulation of +/- 1.0%. AVR response 20ms
Filed current to 90% 80 ms
In addition to being powered from the main stator, the Machine Volts to 97% 300ms
AVR also derives a sample voltage from the output
EXTERNAL VOLTAGE ADJUSTMENT
windings for voltage control purposes. In response to this
+/-10% with 1 k ohm 1 watt trimmer (see note 3)
sample voltage, the AVR controls the power fed to the
exciter field, and hence the main field, to maintain the UNDER FREQUENCY PROTECTION
machine output voltage within the specified limits, Set point 95% Hz (see note 4)
compensating for load, speed, temperature and power Slope 170% down to 30 Hz
factor of the generator.
UNIT POWER DISSIPATION
A frequency measuring circuit continually monitors the 12 watts maximum
BUILD UP VOLTAGE
generator output and provides output under-speed
4 Volts @ AVR terminals
protection of the excitation system, by reducing the output ANALOGUE INPUT
voltage proportionally with speed below a pre-settable Maximum input +/- 5V dc (see note 5)
threshold. A manual adjustment is provided for factory Sensitivity 1v for 5% Generator Volts (adjustable)
setting of the under frequency roll off point, (UFRO). This Input resistance 1k ohm
can easily be changed to 50 or 60 Hz in the field by push- QUADRATURE DROOP INPUT
on link selection. 10 ohms burden
Max. sensitivity: 0.07 A for 5% droop 0PF
Provision is made for the connection of a remote voltage Max. input: 0.33A
ENVIRONMENTAL
trimmer, allowing the user fine control of the generator's Vibration 20-100 Hz 50mm/sec
output. 100Hz – 2kHz 3.3g
o
Operating temperature -40 to +70 C
o
An analogue input is provided allowing connection to a Relative Humidity 0-70 C 95% (see note 6)
o
Newage Power Factor controller or other external devices Storage temperature -55 to +80 C
with compatible output. NOTES
1. With 4% engine governing.
The AVR has the facility for droop CT connection, to allow 2. After 10 minutes.
3. Applies to Mod status S onwards. Generator de-rate
parallel running with other similarly equipped generators. may apply. Check with factory.
4. Factory set, semi-sealed, jumper selectable.
5. Any device connected to the analogue input must be
fully floating (galvanically isolated from ground), with an
insulation strength of 500V ac.
6. Non condensing.

TD_SX440 AVR_03.05_03_GB
 DESIGN DETAIL

Voltage
Sensing
Generator

Droop Potential
Divider &
Hand Rectifier
Trimmer Suppression

Low Hz Synchronising Low Pass

Sensing Detection Circuit Filter
Loss
Detector
Reference Power
Voltage supply

Analogue Level Power

DC Ramp Detector & Control
Input Amp
Mixer Generator Driver Devices

Exciter
Stability Field
Circuit

The main functions of the AVR are: The Stability Circuit provides adjustable negative ac
feedback to ensure good steady state and transient
Potential Divider and Rectifier takes a proportion of the performance of the control system.
generator output voltage and attenuates it. The potential
divider is adjustable by the AVR Volts potentiometer and The Low Hz Detector measures the period of each
external hand trimmer (when fitted). The output from the electrical cycle and causes the reference voltage to
droop CT is also added to this signal. An isolating be reduced approximately linearly with speed below
transformer is included allowing connection to various a presettable threshold. A Light Emitting Diode gives
winding configurations. A rectifier converts the a.c. input indication of underspeed running.
signal into d.c. for further processing.
The Synchronising circuit is used to keep the Ramp
The Sensing Loss Detector is an electronic changeover Generator and Low Hz Detector locked to the
switch, which normally connects the Amplifier (Amp) to generator waveform period.
the Voltage Sensing input and automatically changes
over to the Power input when the normal sensing voltage The Low Pass Filter prevents distorted waveforms
is lost. affecting the operation of the AVR control circiut

The DC Mixer adds the Analogue input signal the Power Control Devices vary the amount of exciter
Sensing signal. field current in response to the error signal produced
by the Amplifier.
The Amplifier (Amp) compares the sensing voltage to the
Reference Voltage and amplifies the difference (error) to Suppression components are included to prevent
provide a controlling signal for the power devices. The sub cycle voltage spikes damaging the AVR
Ramp Generator and Level Detector and Driver infinitely components and also to reduce the amount of
control the conduction period of the Power Control conducted noise on the generator terminals..
Devices and hence provides the excitation system with
the required power to maintain the generator voltage The Power Supply provides the required voltages
within specified limits. for the AVR circuitry.

TD_SX440 AVR_03.06_03_GB
 FITTING AND OPERATING

K1 K2 P2 P3 P4 XX X 3 2 2 1
Note. If replacing an existing SX440, position the
links and connections the same as the original
Trim A1 SX440.
K1-K2 A2
Power isolation link S1 If up grading to an SX440 refer to generator wiring
(normally fitted)
Droop diagram for connection details.
S2

1
Volts 2 Note. There are two terminals marked ‘2’
3 Sensing they are connected, either one or both can
SX440 4 links be used.
5 standard
6
7
positions
Frequency Stability 8
Selection Selection
Warning: Electrical shock can cause injury or death.
Stability Ensure that all personnel operating, servicing,
Indicator > 550kW maintaining or working near this equipment are fully
LED 50Hz 90-550kW aware of the emergency procedures in case of accidents.
UFRO 60Hz < 90kW Before removing the protective covers to carry out
service maintenance or repair, ensure that the engine is
50 C 60 CBA
inhibited and the generator is electrically isolated.

SUMMARY OF AVR CONTROLS

CONTROL FUNCTION DIRECTION

VOLTS TO ADJUST GENERATOR OUTPUT VOLTAGE CLOCKWISE INCREASES OUTPUT VOLTAGE

STABILITY TO PREVENT VOLTAGE HUNTING CLOCKWISE INCREASE THE DAMPING EFFECT
UFRO TO SET THE UFRO KNEE POINT CLOCKWISE REDUCES THE KNEE POINT
FREQUENCY
DROOP TO SET THE GENERATOR DROOP TO 5% AT 0PF CLOCKWISE INCREASES THE DROOP
VTRIM TO OPTIMISE ANALOGUE INPUT SENSITIVITY CLOCKWISE INCREASES THE GAIN OR SENSITIVITY

ADJUSTMENT OF AVR CONTROLS

VOLTAGE ADJUSTMENT CAUTION
1. Before running generator, turn the VOLTS control
The generator output voltage is set at the factory, but can fully anti-clockwise.
be altered by careful adjustment of the VOLTS control on 2. Turn remote volts trimmer (if fitted) to midway
the AVR board, or by the external hand trimmer if fitted. position.
Terminals 1 and 2 on the AVR will be fitted with a shorting 3. Turn STABILITY control to midway position.
link if no hand trimmer is required. 4. Connect a suitable voltmeter (0-300V ac) across
line to neutral of the generator.
CAUTION Do not increase the voltage above the rated 5. Start generator set, and run on no load at nominal
generator voltage. If in doubt, refer to the rating plate frequency e.g. 50-53Hz or 60-63Hz.
mounted on the generator case. 6. If the red Light Emitting Diode (LED) is illuminated,
refer to the Under Frequency Roll Off (UFRO)
CAUTION Do not ground any of the hand trimmer adjustment.
terminals as these could be above earth potential. Failure 7. Carefully turn VOLTS control clockwise until rated
to observe this could cause equipment damage. voltage is reached.
8. If instability is present at rated voltage, refer to
If a replacement AVR has been fitted or re-setting of the stability adjustment, then re-adjust voltage if
VOLTS adjustment is required, proceed as follows: necessary.
9. Voltage adjustment is now completed.

TD_SX440 AVR _03.06_03_GB

 FITTING AND OPERATING
STABILITY ADJUSTMENT TRIM ADJUSTMENT

The AVR includes a stability or damping circuit to provide An analogue input (A1 A2) is provided to connect to the
good steady state and transient performance of the Newage Power Factor Controller or other devices. It is
generator. designed to accept dc signals up to +/- 5 volts.

The correct setting can be found by running the generator CAUTION Any devices connected to this input must be
at no load and slowly turning the stability control anti- fully floating and galvanically isolated from ground, with
clockwise until the generator voltage starts to become an insulation capability of 500 Vac. Failure to observe
unstable. this could result in equipment damage.

The optimum or critically damped position is slightly The dc signal applied to this input adds to the AVR
clockwise from this point (i.e. where the machine volts are sensing circuit. A1 is connected to the AVR 0 volts.
stable but close to the unstable region). Positive on A2 increases excitation. Negative on A2
decreases excitation.
OPTIMUM RESPONSE SELECTION
The TRIM control allows the user to adjust the
The stability selection ‘jumper’ should be correctly linked, sensitivity of the input. With TRIM fully anti-clockwise
A-B, B-C or A-C at the bottom of the board for the frame the externally applied signal has no effect. Clockwise it
size of the generator, (see drawing). has maximum effect.

UNDER FREQUENCY ROLL OFF (UFRO) Normal setting is fully clockwise when used with a
ADJUSTMENT Newage Power Factor Controller.

The AVR incorporates an underspeed protection circuit

which gives a volts/Hz characteristic when the generator
speed falls below a presettable threshold known as the
"knee" point.

The red Light Emitting Diode (LED) gives indication that

the UFRO circuit is operating.

The UFRO adjustment is preset and sealed and only

requires the selection of 50 / 60Hz using the jumper link.

For optimum setting, the LED should illuminate as the

frequency falls just below nominal, i.e. 47Hz on a 50Hz
system or 57Hz on a 60Hz system.

DROOP ADJUSTMENT
Skill requirements of personnel
Generators intended for parallel operation are fitted with a Service and maintenance procedures should only
quadrature droop C.T. which provides a power factor be carried out by experienced, qualified,
dependent signal for the AVR. The C.T. is connected to engineers/technicians, familiar with the
S1, S2 on the AVR. procedures and the equipment.
Before any intrusive procedures are carried out,
The DROOP adjustment is normally preset in the works ensure that the engine is inhibited and the
to give 5% voltage droop at full load zero power factor. generator is electrically isolated.
Clockwise increases the amount of C.T. signal injected
into the AVR and increases the droop with lagging power
factor (cos Ø). With the control fully anti-clockwise there
is no droop.

Barnack Road • Stamford • Lincolnshire • PE9 2NB

© 2006 Cummins Generator Technologies Tel: 00 44 (0)1780 484000 • Fax: 00 44 (0)1780 484100
Limited.
TD_SX440 AVR_03.06_04_GB
Printed in England.