Instruction Manual

Installation
Operation
Maintenance

Voltage Regulator
K65-12B and K125-10B

Publication
351-01057-00 B (09/19/2014)

Kato Engineering, Inc. | P.O. Box 8447 | Mankato, MN USA 56002-8447 | Tel: 507-625-4011
[email protected] | www.KatoEngineering.com | Fax: 507-345-2798
 Table of Contents
Introduction............................................................... 3
Foreword..................................................................................... 3
Safety Instructions....................................................................... 3
General Information................................................... 3
General....................................................................................... .3
Specifications.............................................................................. 4
Installation..................................................................6
Mounting..................................................................................... 6
Connections................................................................................ 7
Operation.................................................................. 13
General..................................................................................... 13
Preliminary Setup...................................................................... 13
System Startup.......................................................................... 13
Adjustments.............................................................................. 15
Field flashing................................................................. 15
Frequency roll-off adjustment........................................ 15
Stability (STB)............................................................... 16
Voltage (VLT ADJ) adjustment.......................................16
Factory voltage adjust range calibration adjustment..... 16
Parallel drop (DRP) compensation................................ 16
Options..................................................................................... 16
Remote voltage adjust................................................... 16
Excitation disable........................................................... 17
VAR/PF control.............................................................. 17
Manual voltage control.................................................. 17
Operational Test....................................................................... 17
Maintenance............................................................. 19
Note: Because of rapid changes in designs
Preventive................................................................................. 19
and processes and the variability of Kato Troubleshooting........................................................................ 19
Engineering’s products, information in this
manual must not be regarded as binding
and is subject to change without notice.

Page 2
Introduction

Foreword
This manual contains instructions for installing, operating and
maintaining Kato Engineering K65-12B and K125-10B voltage
regulators.

Safety Instructions
In order to prevent injury or equipment damage, everyone involved
in installation, operating and maintenance of the equipment described
in this manual must be qualified and informed of the current safety
standards that govern his or her work. The following paragraphs define
warnings, cautions, and notes as they are used in this manual:

Warning: Warnings identify an installation, operating or maintenance

procedure, practice, condition, or statement that, if not strictly followed,
could result in death or serious injury to personnel.

Caution: Cautions identify an installation, operating or maintenance

procedure, practice, condition, or statement that, if not strictly followed,
could result in destruction of or damage to equipment or serious
impairment of system operation.

Note: Notes highlight an installation, operating or maintenance

procedure, condition, or statement and are essential or helpful but are not
of known hazardous nature as indicated by warnings and cautions.

General Information Warning: To avoid personal injury or

equipment damage, only qualified people
should perform the procedures described in
General this manual.
The K65-12B and K125-10B Voltage Regulators are contained in an
Warning: Use meggers and high-potential
encapsulated plastic case. The regulator controls the DC exciter field
test equipment with extreme care. Incorrect
power of conventional, 50 or 60 Hz brushless genera­tors.
use can damage components.
Regulation is provided by sensing the generator output voltage,
converting it to a DC signal and comparing the signal to a reference
voltage signal. An error signal is developed and used to control the DC
field power in order to maintain a constant generator output.
The regulator includes frequency compensation with selectable slope,
inverse time over-excitation shutdown, solid-state build-up circuitry,
single-phase or three-phase voltage sensing, single-phase or three-
phase shunt, or permanent magnet power input, and parallel droop
compensation, and an accessory input. The accessory input provides
compatibility with accessories such as a var/power factor controller.

Page 3
 Specifications
Refer to Table 1 for the electrical specifications. Refer to Table 2 for the
physical specifications:
Specification K65-12B K125-10B
12 Adc @ 65 Vdc maximum 10 Adc @ 125 Vdc maximum
Output power (with a 240 continuous. continuous.
Vac Input): 25 Adc @ 125 Vdc forcing for 10 20 Adc @ 250 Vdc forcing for
seconds. 10 seconds.
100 to 280 Vac, single-phase 50 180 to 280 Vac, single-
to 400 Hz, or 63 to 105 Vac; three- phase or three-phase, 50 to
AC input power:
phase, 50 to 400 Hz, 1092 VA 400 Hz, 1750 VA maximum
maximum continuous burden continuous burden
90 to 140 Vac, 50/60 or 400 Hz; 90 to 140 Vac, 50/60 Hz;
AC sensing voltage:
single- or three-phase. single- or three-phase.
External voltage adjust
10k ohm, 2 W, potentiometer 10k ohm, 2 W, potentiometer
rheostat:
Regulation accuracy: ±0.5% Average responding ±0.5% Average responding
±1% voltage variation for a 40° C ±1% voltage variation for a
Voltage drift:
(104° F) change. 40° C (104° F) change.
Response time: < 4 milliseconds < 4 milliseconds
1 or 2 V/Hz jumper selectable with 1 or 2 V/Hz jumper selectable
Frequency compensation: knee adjustable from 45 Hz to 65 with knee adjustable from 45
Hz. Hz to 65 Hz.
EMI suppression: Internal filter Internal filter
Internal provisions for
Internal provisions for automatic
automatic voltage build-up
Voltage Build-Up: voltage build-up from generator
from generator residual
residual voltages as low as six Vac.
voltages as low as six Vac.
Overexcitation protection
Overexcitation protection starts
starts timing at 180 Vdc ±5%
timing at 90 Vdc ±5% and takes
and takes the output to zero
Overexcitation shutdown: the output to zero in greater than
in greater than 30 seconds.
30 seconds. The output can be 125
The output can be 250 Vdc
Vdc for greater than 10 seconds.
for greater than 10 seconds.

1 A or 5 A, <10 VA, adjustable from 1 A or 5 A, <10 VA, Adjustable

Droop 0 to 10% at rated input current, 0.8 from 0 to 10% at rated input
power factor current, 0.8 power factor

UL recognized per Standard

UL Recognized per Standard 508,
508, UL File NO. E97035.
UL recognized/CSA UL File NO. E97035. CSA certified
CSA certified per Standard
certified per Standard CAN/CSA-C22.2 No.
CAN/CSA-C22.2 No. 14-95,
14-95, CSA File No. LR 23131
CSA File No. LR 23131

Table 1: Electrical specifications

Page 4
 Specification K65-12B and K125-10B

Conforms to:
Radiated Emissions............... EN50081-2
Radiated Immunity:
Electric field..................... EN61000-4-3 (10 V/m
Conducted....................... EN61000-4-6 (10 VRMS)
Conducted Emissions............ EN50081-2 (EN55011, Class A)
CE conformity ESD Immunity ����������������������� EN50082-2 (4 kV contact, 8 KV air)
EFT Immunity........................ EN50082-2 (2 kV coupling clamp)
Magnetic Immunity................ EN50082-2 (30ARMS, 50 Hz)
Safety.................................... EN61010-1
(When enclosed within a suitable steel enclosure attached the
generator)

Operating and storage

-40° C (-40° F) to +70° C (+158° F).
temperature:
Shock: Withstands up to 20 g in each of three mutually perpendicular axes.
Withstands the following accelerations at the stated frequency:
Vibration:
0.5 g; 18 to 2000 Hz
Weight: Approximately 1.1 kg (2.5 lbs.)

Table 2: Physical specifications

Page 5
Installation
Mounting
The regulator may be mounted in any position. Refer to Figure 1 for
overall dimensions. The regulator may be mounted directly on the
generator set using UNF 1/4-20 or equivalent hardware. Select the
proper hardware to withstand any expected shipping/transportation and
operating conditions.

Figure 1: Outline drawing

Page 6
Connections
Before connecting the K65-12B and K125-10B into your system, review
the terminal descriptions provided in Table 3, the internal adjustments
provided in Table 4, and the typical interconnection diagrams shown in
Figures 2-6.
Terminal number Terminal description
Upper Terminal Strip
CH GND Chassis ground connection
2 Auxiliary input from var power factor controller
3 Auxiliary input from var power factor controller
Connect to 7 to use internal voltage adjust, no
4
connection for external voltage adjust
5 1 A current transformer
5a 5 A current transformer
6 Current transformer common
6a Common connection for selectable features
Connect Remote Adjust from 7 to 6a, connect to 4 for
7
internal voltage adjust
Connect to 6a to select 1v/Hz underfrequency slope
8
(Not 810-34334-00)
9 Connect to 6a to select 3 phase sensing
Lower Terminal Strip
20 Phase C sensing input
22 Phase A sensing input
24 Phase B sensing input
26 3-phase power input
28 1-phase or 3-phase power input
30 1-phase or 3-phase power input
F1 Field +
F2 Field -
Table 3: Terminal descriptions

Adjustment Adjustment description

DRP Voltage droop adjust
FAC CAL is a factory voltage adjust range calibration.
FAC CAL
No customer adjustment is required.
VLT ADJ Multi-turn voltage adjust
UF Underfrequency knee adjust (Not 810-34334-00)
STB Stability adjust

Table 4: Internal adjustments

Page 7
 NOTES:
1 IF 1A. SEC CCCT IS USED, CONNECT TO TERMINAL 5 INSTEAD OF 5a. (VAR/PFC & EL CANNOT BE USED WITH 1A. CCCT).
2 IF EXTERNAL VAR IS NOT USED, JUMPER 4 TO 7.
3 FOR 2 x V/HZ, REMOVE CONNECTION TO TERMINAL 8. (1 x V/HZ CONNECTION IS SHOWN).
4 IF EL, VAR/PF, DSLC AND/OR BE3-25A ARE NOT USED, JUMPER 2 TO 3.

VAR NOTE:
10 K IS VOLTAGE RESISTANCE INCREASES TO INCREASE VOLTAGE.
STANDARD CW ADJUST

2 3

VR
4 7 6a 8 9
CH
GND 28 30 26 F1 F2 2 3 22 24 20 6 5a 5

* IF POWER IS REMOVED ** 1
FROM BE3-25A AFTER 4

SYNCHRONIZING, THE
CIRCUIT BETWEEN VR1 &
VR2 MUST BE CLOSED.
BE3- 25A DSLC
VR1 30
*
** IF POWER SOURCE IS VR4 VR3 VR2 31
POLARITY
UNGROUNDED, JUMPER MUST
JUMPER
BE TIED FROM 28 TO 24. * IF POWER
IN "A"
POSITION FROM BE
SYNCHR
CIRCUIT BE
EL
PMG POWER IS SHOWN. F2 C 2 EXCITATION VR2 MUS
E1 E3
1 PHASE POWER MAY BE LIMITER
F1 L 1
FROM PMG, GENERATOR, OR EL-200
OTHER SOURCE. 3 PHASE PMG
POWER, WHEN AVAILABLE, IS ** IF POWE
USED WITH K65-12B ONLY. UNGROUNDE
VAR/PFC BE TIED FRO
C A 2 SCP-250
(11) PM1 PM1 E1 E3
1 PHASE POWER

120 V : K65-12B 1 J K
3 PHASE PMG POWER

240 V : K125-10B
(12) PM2 PM2 or PM4
(REGULATOR 52/B PMG PO
IS 120 VOLT
(13) PM3 SENSING ONLY)
1 PHASE
ALTERNATE LABELING FOR SOME APPLICATIONS 52/b (AUX CONTACT FROM PM
X1 X2 X1 X2
IN CIRCUIT BREAKER) OTHER SOUR
DISABLES SCP-250
F1 (+) WHEN GENERATOR POWER, W
IS NOT OPERATING USED WIT
H1 H2 H1 H2 IN PARALLEL WITH
F2 (-) UTILITY
FROM GENERATOR

ØA ØA (11) PM1
3 PHASE PMG POWER
TO LOAD

ØB ØB
CCCT (12) PM2
5A. SEC 1
ØC ØC

(13) PM3
SHOWN CONNECTED ALTER
FOR A-B-C PHASE
ROTATION. FOR A-C-B
ROTATION, REVERSE
CCCT SECONDARY.
Figure 2: Regulator connections (three phase)

Page 8

SHOWN
 NOTES:
1 IF 1A. SEC CCCT IS USED, CONNECT TO TERMINAL 5 INSTEAD OF 5a. (VAR/PFC & EL CANNOT BE USED WITH 1A. CCCT).
2 IF EXTERNAL VAR IS NOT USED, JUMPER 4 TO 7.
3 FOR 2 x V/HZ, REMOVE CONNECTION TO TERMINAL 8. (1 x V/HZ CONNECTION IS SHOWN).
4 IF EL, VAR/PF, DSLC AND/OR BE3-25A ARE NOT USED, JUMPER 2 TO 3.

VAR NOTE:
10 K IS VOLTAGE RESISTANCE INCREASES TO INCREASE VOLTAGE.
STANDARD CW ADJUST

2 3

VR
4 7 6a 8 9
CH
GND 28 30 26 F1 F2 2 3 22 24 20 6 5a 5

* IF POWER IS REMOVED ** 1
FROM BE3-25A AFTER 4

SYNCHRONIZING, THE
CIRCUIT BETWEEN VR1 &
VR2 MUST BE CLOSED.
BE3- 25A DSLC
VR1 30
*
** IF POWER SOURCE IS VR4 VR3 VR2 31
POLARITY
UNGROUNDED, JUMPER MUST
JUMPER
BE TIED FROM 28 TO 20.
IN "A"
POSITION

EL
PMG POWER IS SHOWN. F2 C 2 EXCITATION
E1 E3
1 PHASE POWER MAY BE LIMITER
F1 L 1
FROM PMG, GENERATOR, OR EL-200
OTHER SOURCE. 3 PHASE PMG
POWER, WHEN AVAILABLE, IS
USED WITH K65-12B ONLY.

VAR/PFC
C A 2 SCP-250
(11) PM1 PM1 E1 E3
1 PHASE POWER

120 V : K65-12B 1 J K
3 PHASE PMG POWER

240 V : K125-10B
(12) PM2 PM2 or PM4
(REGULATOR 52/B
IS 120 VOLT
(13) PM3 SENSING ONLY)
ALTERNATE LABELING FOR SOME APPLICATIONS 52/b (AUX CONTACT
X1 X2
IN CIRCUIT BREAKER)
DISABLES SCP-250
F1 (+) WHEN GENERATOR
IS NOT OPERATING
H1 H2 IN PARALLEL WITH
F2 (-) UTILITY
FROM GENERATOR

ØA ØA TO LOAD

ØB ØB
CCCT
5A. SEC 1
ØC ØC

SHOWN CONNECTED
FOR A-B-C PHASE
ROTATION. FOR A-C-B
ROTATION, REVERSE
CCCT SECONDARY.
Figure 3: Regulator connections (single phase)

Page 9
 NOTES:
1 IF 1A. SEC CCCT IS USED, CONNECT TO TERMINAL 5 INSTEAD OF 5a. (VAR/PFC & EL CANNOT BE USED WITH 1A. CCCT).
2 IF EXTERNAL VAR IS NOT USED, JUMPER 4 TO 7.
3 FOR 2 x V/HZ, REMOVE CONNECTION TO TERMINAL 8. (1 x V/HZ CONNECTION IS SHOWN).

VAR NOTE:
10 K IS VOLTAGE RESISTANCE INCREASES TO INCREASE VOLTAGE.
STANDARD CW ADJUST

2 3

VR
4 7 6a 8 9
CH
GND 28 30 26 F1 F2 2 3 22 24 20 6 5a 5

** 1

** IF POWER SOURCE IS
UNGROUNDED, JUMPER MUST
BE TIED FROM 28 TO 24.

PMG POWER IS SHOWN.

1 PHASE POWER MAY BE
FROM PMG, GENERATOR, OR
OTHER SOURCE. 3 PHASE PMG
POWER, WHEN AVAILABLE, IS
USED WITH K65-12B ONLY.

(11) PM1 PM1

1 PHASE POWER

120 V : K65-12B
3 PHASE PMG POWER

240 V : K125-10B
(12) PM2 PM2 or PM4
(REGULATOR
IS 120 VOLT
(13) PM3 SENSING ONLY)
ALTERNATE LABELING FOR SOME APPLICATIONS
PT'S IF X1 X2 X1 X2
NEEDED
F1 (+)

H1 H2 H1 H2
F2 (-)
FROM GENERATOR

ØA ØA
TO LOAD

ØB ØB
CCCT
5A. SEC 1
ØC ØC

SHOWN CONNECTED
FOR A-B-C PHASE
ROTATION. FOR A-C-B
ROTATION, REVERSE
CCCT SECONDARY.

Figure 4: Regulator connections (simple three phase)

Page 10
 NOTES:
1 IF 1A. SEC CCCT IS USED, CONNECT TO TERMINAL 5 INSTEAD OF 5a. (VAR/PFC & EL CANNOT BE USED WITH 1A. CCCT).
2 IF EXTERNAL VAR IS NOT USED, JUMPER 4 TO 7.
3 FOR 2 x V/HZ, REMOVE CONNECTION TO TERMINAL 8. (1 x V/HZ CONNECTION IS SHOWN).

VAR NOTE:
10 K IS VOLTAGE RESISTANCE INCREASES TO INCREASE VOLTAGE.
STANDARD CW ADJUST

2 3

VR
4 7 6a 8 9
CH
GND 28 30 26 F1 F2 2 3 22 24 20 6 5a 5

** 1

** IF POWER SOURCE IS
UNGROUNDED, JUMPER MUST
BE TIED FROM 28 TO 20.

PMG POWER IS SHOWN.

1 PHASE POWER MAY BE
FROM PMG, GENERATOR, OR
OTHER SOURCE. 3 PHASE PMG
POWER, WHEN AVAILABLE, IS
USED WITH K65-12B ONLY.

(11) PM1 PM1

1 PHASE POWER

120 V : K65-12B
3 PHASE PMG POWER

240 V : K125-10B
(12) PM2 PM2 or PM4
(REGULATOR
IS 120 VOLT
(13) PM3 SENSING ONLY)
ALTERNATE LABELING FOR SOME APPLICATIONS
X1 X2

F1 (+)

H1 H2
F2 (-)
FROM GENERATOR

ØA ØA TO LOAD

ØB ØB
CCCT
5A. SEC 1
ØC ØC

SHOWN CONNECTED
FOR A-B-C PHASE
ROTATION. FOR A-C-B
ROTATION, REVERSE
CCCT SECONDARY.
Figure 5: Regulator connections (simple single phase)

Page 11
Figure 6: Cross-current compensation

Page 12
Operation
General
Table 5 provides system start-up procedures for the K65-12B and
K125-10B voltage regulators. Symptoms of problems occurring
during start-up that arise from incorrect regulator adjustment and
certain generator system problems that resemble faulty regulation are
included together with possible solutions. Simplifying the system by
eliminating components, such as remote adjust potentiometers and
other non-essential items can be helpful in the troubleshooting process.
Adjustments, options, and an operational test are included in the
paragraphs after the table.

Preliminary Setup
To prevent damage to the regulator, ensure that the regulator has been
installed and connected in accordance with the installation procedures
before proceeding with the system start-up.

System Startup
Refer to Table 5 for starting up the system

Page 13
 Procedure Symptom Remedy
1. Perform the preliminary
N/A N/A
set-up.

a. Flash field. (Except

with PMG)
2. Start prime mover and b. Remove power for 1
a. Voltage does not build-up
bring up to rated speed. minute to allow the over
excitation circuit to reset.
c. Troubleshoot.

b. Voltage builds up and then

a. Troubleshoot.
decays

3. Slowly adjust VLT ADJ a. Check generator output

or external voltage adjust a. Voltage does not build up for shorted or excessive
rheostat until voltage to rated value load.
reaches nominal. b. Troubleshoot.

b. Voltage high and

a. Troubleshoot.
uncontrollable

a. Check generator output

for shorted or excessive
load. Adjust STB with no
4. Apply and remove load to Generator response too slow load applied.
check stability. or is hunting (oscillating)
b. Check stability of
governor system.
c. Troubleshoot.

a. Check that prime mover

is up to speed.
b. Check that voltmeter is
connected at the same
5. Check regulation under point as the regulator
normal operating Poor regulation sensing.
conditions.
c. Use an average sensing
voltmeter (not a RMS
sen­sing).
d. Troubleshoot.

6. Reduce generator a. Check that all wiring is

Generator output voltage in accordance with the
frequency. Generator
does not decrease at desired installation procedures
output should decrease
frequency
from this point. b. Adjust UF control.

Table 5: System startup

Page 14
Adjustments
For location of the adjustments referenced in the following paragraphs,
refer to Figure 1.

Field Flashing (only for units with no PMG) Caution: Do not flash the field with the
generator in motion. The regulator may be
When the regulator is operated with the generator for the first time, the
damaged.
polarity of the residual magnetism may not be correct or of sufficient
magnitude. If the generator residual voltage is less than 6 Vac for the
K65-12B or 12 Vac for the K125-10B at terminals 26 and 28, shut down
the prime mover and proceed with the following steps:
(1) With the prime mover at rest, apply a DC source (ungrounded), of
not more than 24 Vdc, to terminals F1 (positive) and F2 (negative) in
series with a limiting resistor. Use 1 ohm of resistance for each volt
from the DC power source with a power rating of least one 1 watt per
ohm.
Example: If using a 24 Vdc source, use a 24-ohm, 24-watt resistor.
(2) Allow the field to be flashed for approximately 10 seconds before
removing the DC source.
(3) If voltage build-up does not occur after performing steps (1) and (2),
verify the polarity of the DC source used in steps (1) and (2) and re-
perform.

Frequency roll-off (knee) adjustment (Not on 810-34334-00)

The underfrequency knee can be set for 45 to 60 Hz operation as
described in the following paragraphs.
(1) .Adjust the underfrequency potentiometer (UF) fully CCW.
(2) Set the generator to the desired frequency
(3) Adjust the Voltage Adjust (internal or external) for nominal generator
voltage.
(4) Adjust the underfrequency potentiometer (UF) CW until the voltage
begins to decrease.
(5) Adjust the underfrequency potentiometer (UF) CCW until the
voltage just returns to the value set in Step 3.
(6) The underfrequency “knee” is now set just below the nominal
operating frequency. Further rotation in the CCW direction will
lower the frequency at which underfrequency compensation begins.
(7) Connecting a jumper from terminal 8 to terminal 6a will provide an
underfrequency slope of 1 X V/Hz. No connection to terminal 8 will
result in an underfrequency slope of 2 X V/Hz.

Page 15
 Stability (STB) adjustment
Use an oscilloscope or other voltage-recording device if an optimal
stability setting is desired. Adjust the stability setting with the generator
at no load. Good response can be obtained with the following procedure.
(1) Rotation of the STB control in the clockwise (CW) direction will
slow re­sponse time.
(2) Rotation of the STB control in the counter-clockwise (CCW)
direction will speed response time. If rotated too far CCW, the
generator voltage may oscillate (hunt).
(3) Rotate the front panel STB control CCW until the system just begins
to oscillate and then rotate CW just past the point where oscillation
occurred.
Voltage (VLT ADJ) adjustment
(1) Installation of a jumper across terminals 4 and 7 allows the internal
VLT ADJ adjustment to vary the generator nominal voltage over the
operating range.
(2) Remove the jumper between terminals 4 and 7 and connect a 10k
ohm external voltage adjust potentiometer across terminals 6 and
7 to allow operation of the external voltage adjust potentiometer.
The internal voltage adjustment should be set fully CW for proper
operation of the external adjustment.

Caution: The factory calibration (FAC CAL) Factory voltage adjust range calibration adjustment
adjustment is intended for use by factory
With the voltage regulator operating on a generator, adjust the calibration
technicians only. The factory voltage adjust
range calibration adjustment can be used if
potentiometer fully ccw and the voltage adjust potentiometer fully CW.
the factory calibration has been disturbed. Adjust the calibration potentiometer CW until the generator voltage is
144 ±1 Vac. Adjust the voltage adjust CCW and verify the generator
voltage is less than 90 Vac. The unit is calibrated and the calibration
potentiometer can be sealed.
Parallel droop (DRP) compensation
Variable parallel droop compensation levels can be obtained by adjusting
the droop potentiometer. CW rotation increases the amount of droop for
a given condition.

Options
The K65-12B and the K125-10B may be equipped with the following
options to enhance operational characteristics. Characteristics of these
options are defined in the following paragraphs:

Remote voltage adjust

Connect a 10k ohm potentiometer from terminals 6 to 7, remove the
jumper from terminal 4 to 7 and adjust the internal voltage adjust
potentiometer fully clockwise to allow operation of a remote voltage
adjust.

Page 16
Excitation disable
This option provides for disabling of the excitation system by removal
of power from the voltage regulator. A switch removing voltage from
terminals 26, 28 and/or 30 will remove power.

Var/PF control
This option allows the K65-12B and the K125-10B to either regulate the
volt-amps reactive (var) or power factor while the generator is connected
to an infinite or utility bus. The var/PF option (Model Number SCP250G-
50 for 50-Hz operation or SCP250G-60 for 60-Hz operation) supplies a
DC signal into the K65-12B & K125-10B terminals 2 and 3 to regulate
to the SCP250 var or power factor setting.

Manual voltage control

This option provides a manual back-up channel for manually controlling
the generator output during generator start-up and commissioning or in
the unlikely event that the voltage regulator should fail. Manual voltage
controller models MVC-300 (if exciter field current does not exceed 7
amps) or the MVC-112 are suitable for use with the either the K65-12B
or the K125-10B.

Operational Test
To operationally test any K65-12B or the K125-10B, perform the
following steps:
a. Connect the voltage regulator as shown by Figure 7, and apply 120
Vac.
b. Adjust the VLT ADJ control fully counterclockwise (CCW).
Result: Observe that the lamp is OFF.
c. Adjust the front panel VLT ADJ control clockwise (CW).
Result: Observe that the lamp is now ON.
d. Adjust the front panel VLT ADJ control until the lamp just goes out.
Regulator operation is satisfactory if the above results are obtained.
Stability, however, must be tested with the regulator operating while
connected to the generator.

Page 17
Figure 7: Operational test setup

Page 18
Maintenance
Preventive Maintenance
Inspect the voltage regulator periodically to ensure that it is clean
and free from accumulations of dust and moisture. Be sure that all
connections are clean and tight.

Troubleshooting
In case of failure or defective operation of the unit, Table 6 is provided
to aid in the determination of the cause and the possible solution.
Simplifying the system by eliminating components, such as remote
adjust potentiometers and other non-essential items can be helpful in the
troubleshooting process.

Symptom Possible Cause Remedy

a. Flash field. (except with PMG)
a. No voltage or incorrect b. Verify wiring.
voltage to power input at
Voltage does not build terminals 26, 28 or 30 c. Check fuses supplying power.
up. d. Replace regulator.
Shutdown regulator power for 1 minute
b. Overexcitation circuit is
then restart. Watch for high field
shutting off regulator
vol­tage.
Verify single or three phase sensing is
a. Single or three phase applied to 20, 22 and/or 24 and verify
Voltage builds up and jumper incorrect connection from upper terminal 6a to 9
then decays. is correct.
b. Defective regulator. Replace regulator.

Page 19
 Verify single or three phase sensing is
a. Single or three phase applied to 20, 22 and/or 24 and verify
jumper incorrect connection from terminal 6a to 9 is
correct.
b. Internal or external voltage Adjust VLT ADJ control and/or external
adjustments are improperly voltage adjust rheostat. Verify proper
set connection from 4 to 7.
Verify the generator is rotating at
c. The regulator is operating
the proper frequency. Verify proper
Voltage does not build up on the underfrequency curve
adjustment of the underfrequency pot.
to rated value.
d. Faulty regulator Replace regulator.
e. Terminals 2 and 3 are not a. Jumper terminals 2 and 3.
jumpered and there is no
device connected to these b. Connect var/PF controller or other
terminals device to terminals 2 and 3.

f. Jumpers are set for single-

Install a jumper between terminals 6a
phase sensing and three
and 9.
-phase voltage is applied
Voltage does not build g. Voltage adjust pot not in
up to rated value. use and terminals 4 and 7 Install jumper.
(continued) are not jumpered

a. No sensing input Verify wiring.

Verify whether single or three phase

Voltage high and b. Single or three phase sensing is applied to 20, 22 and/or 24
uncontrollable. jumper incorrect and verify connection from terminal 6a
to 9 is correct.
c. Faulty regulator Replace regulator.
d. Voltage adjust pot in use
and terminals 4 and 7 are still Remove jumper.
jumpered
a. Improper front panel STB Re-adjust front panel STB adjustment,
adjustment as described in section 3.
Generator response too
slow or hunting. b. Improper governor setting Adjust governor.
c. Faulty regulator. Replace regulator.
a. Low prime mover speed Verify prime mover speed.
Poor regulation.
b. Faulty regulator Replace regulator.
Remove the connection jumper
No specific symptom; between terminal 28 and 20 (single-
Cross-grounding of circuitry
random loss of control phase sensing) or 24 (three-phase
sensing)
a. CT input is reversed. Correct CT input connections.
Improper droop.
a. Output increases b. CT input improperly con-
based on the amount of nected to the one ampere or
Correct CT input connections.
current and the droop pot five ampere input terminals,
setting. or is shorted out

b. Too much or too little

droop.
c. Sensing Input connected
Correct sensing input connections.
c. Improper droop out of phase.
characteristics.
 Kato Engineering Support
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and model number for your machine in the email subject line.
Field Service [email protected]
Parts [email protected]
Remanufacturing [email protected]
Warranty/Quality Assurance [email protected]

Kato Engineering, Inc. | P.O. Box 8447 | Mankato, MN USA 56002-8447 | Tel: 507-625-4011
[email protected] | www.KatoEngineering.com | Fax: 507-345-2798