Droop R2 R1 Q2 Q1 F2 F1 N W V

A1 A2
FUSE

V
AC S UF OE SL UF OE

R150

50 Hz 60 Hz

R150

AVRs
Installation and maintenance
 Electric Power Generation Installation and maintenance 5384 en - 2018.01 / g

R150
AVRs

This manual concerns the alternator AVR which you have just purchased.
We wish to draw your attention to the contents of this maintenance manual.

SAFETY MEASURES

Before using your machine for the first time,

it is important to read the whole of this
installation and maintenance manual. All servicing or repair operations
performed on the AVR should be
All necessary operations and interventions undertaken by personnel trained in the
on this machine must be performed by a commissioning, servicing and main-
qualified technician. tenance of electrical and mechanical
components.
Our technical support service will be pleased
to provide any additional information you
may require.

The various operations described in this When the generator is driven at a

manual are accompanied by recom- frequency below 28 Hz for more than 30
mendations or symbols to alert the user to seconds with an analogue AVR, its AC
potential risks of accidents. It is vital that power supply must be disconnected.
you understand and take notice of the
following warning symbols.
WARNING
WARNING This AVR can be incorporated in a EC-
marked machine.
Warning symbol for an operation capable This manual is to be given to the end
of damaging or destroying the machine user.
or surrounding equipment.

© - We reserve the right to modify the

characteristics of this product at any time in
order to incorporate the latest technological
developments. The information contained in
Warning symbol for general danger to this document may therefore be changed
personnel. without notice.

This document may not be reproduced in

any form without prior authorisation.
All brands and models have been registered
Warning symbol for electrical danger to and patents applied for.
personnel.

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R150
AVRs

CONTENTS

1 - GENERAL DESCRIPTION..................................................................................................4

2 - OPERATION OF THE AVR..................................................................................................4

3 - TECHNICAL SPECIFICATION............................................................................................5

4 - MAIN FUNCTION OF THE AVR..........................................................................................6

5 - AVR SETTINGS................................................................................................................... 7

5.1 - V-TRIM: V...................................................................................................................... 7

5.2 - FRO: UF .......................................................................................................................7
5.3 - STAB: S ........................................................................................................................ 7
5.4 - EXC LIMIT: OE .............................................................................................................7
5.5 - QUADRATURE DROOP ..............................................................................................7
5.6 - A1&A2 DC VOLTAGE INPUTS: AC ..............................................................................7

6 - AVR CONTROLS................................................................................................................. 7

7 - TROUBLESHOOTING CHART...........................................................................................8

8 - MULTIMETER CHECKS.....................................................................................................9

9 - STATIC TEST PROCEDURE............................................................................................10

10 - DIMENSIONS.................................................................................................................. 11

11 - SPARE PARTS................................................................................................................ 12

11.1 - Designation............................................................................................................... 12
11.2 - Technical support service..........................................................................................12

Disposal and recycling instructions

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R150
AVRs
1 - GENERAL DESCRIPTION The AVR has the facility for droop CT
The R150 automatic voltage regulator connection, which is required for equal
(AVR) is a compact, high-performance KVAR load sharing during parallel operation.
encapsulated unit. It incorporates the latest
technology and efficient components to 2 - OPERATION OF THE AVR
achieve a high degree of miniaturisation The AVR is powered by the line-to-neutral
when applied to a 3-phase and 1-phase AC terminal of the AC generator, with 277 VAC
brushless generator, within its input and rms at 50 Hz or 60 Hz. The sensing voltage,
output limits. The unit offers excellent which is the regulated voltage, is based on
reliability. line-to-line (for 3-phase) and line-to-neutral
The AVR provides DC excitation to the (for 1-phase). The AVR forms an important
exciter field of a brushless generator to keep part of the closed loop system comprising
the voltage within the approximate operating the generator field, generator armature and
limits from NO-LOAD to FULL LOAD. the AVR.
The typical recovery time in the event of The AVR first builds up the generator voltage
sudden loading is around 0.5 sec. to recover from its residual levels. When the generator
98% of the rated voltage. Transient is loaded, the sensed voltage decreases
performance such as voltage dip and and generates an error voltage, which is
recovery time is mainly determined by the required in order for the closed loop system
generator and exciter design parameters. to work.
Optimum AVR performance can be obtained The AVR contains a high gain amplifier,
by keeping full-load excitation to around ramp and a pedestal circuit. Depending
60 VDC. upon the value of the amplifier voltage
The generator uses a true average sensing (either high or low) the ramp intersects the
circuit, dV/dt snubber and special filter amplified voltage at a point, which is either
circuits to manage NON-LINEAR loads early or late in the half-cycle. At this
such as battery chargers, DC motors, etc. intersection point a starting pulse is
Voltage regulation is only guaranteed for produced to trigger the power device.
linear loads. Severely distorting NON- When the power device is triggered early in
LINEAR loads can cause regulation the half-cycle, more voltage is transmitted to
problems. the field and when triggered late in the half-
Each AVR is tested prior to dispatch as part cycle, less voltage is transmitted to the field.
of a quality plan, for standard voltage and In order to reduce the generator voltage at
frequency. low speed, a signal inversely proportional
The R150 AVR is provided with two to the speed is generated as an extra input.
accessory input terminals A1 and A2. At higher speeds the voltage decreases at a
Injecting ± 4.5 VDC into these terminals will faster rate than in proportion with the speed.
change the generator voltage by ± 10%. The R150 AVR has two additional terminals
The AVR allows a shunt power supply from A1 and A2. These inputs can be used to
the generator output voltage. connect an external control signal from
A soft-start circuit is included which provides controllers such as APFC, Auto
smooth control of the build-up of generator Synchronizer, etc.
output voltage. It is important that the DC power supply
A frequency roll-off circuit continuously should be electrically isolated from the line
monitors the generator underspeed terminals.
protection by reducing the generator output
voltage in proportion with the speed below a
threshold.

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R150
AVRs
3 - TECHNICAL SPECIFICATION 16) Closed loop response: typically 0.5 sec
1) Sensing input to recover 98% of the defined voltage for a
- Voltage: 240 VAC ± 10% for 1-phase, field forcing ratio of 1:2.
380 V to 480 VAC ± 10% for 3-phase, 2-line 17) Sensing loss protection: the voltage
sensing. The AVR senses the true average should disappear when the sensing circuit is
of the line-to-line waveform. Use the resistor open.
(SMD) network for trouble-free sensing and 18) Overexcitation protection: 10 VDC to
control of sensed voltage/regulation. 85 VDC.
2) Input power Setpoint : 60 VDC.
- Voltage: 415 V for 3-phase and 240 V for 19) Protection fuse: 6 A, 240 VAC.
1-phase
- Frequency: 50/60 Hz 20) Potentiometer sealing: except for the
V-trim potentiometer, all potentiometers are
3) Output power sealed.
- Voltage: 105 VDC at 240 VAC input
- Current: 21) Frequency roll-off indicator: LED
• 6 A DC provided (UF).
• 8 A for 30 sec. (when allowed by the field 22) Sensing loss indicator: LED provided
resistance) (SL).
4) Operating temperature: -20ºC to +70ºC 23) Overexcitation indicator: LED provided
5) Storage temperature: -40ºC to +80ºC (OE).
6) Voltage setting: min ± 10% of rated 24) Protection on the devices: suitable R-C
voltage. snubber to be provided for the device used
to protect against voltage surges.
7) Stability setting: can be adjusted to obtain
a correct transient response in steady state. 25) Potting/Encapsulation details: the
8) 2 to 2.5 kOhm external setting components on the AVR should be
potentiometer for 1 Watt to get a voltage completely encapsulated with suitable PU
setting range of ± 10%. resin compound to absorb transients/
vibrations during operation.
9) Quadrature droop setting for parallel
operation: 4% droop for an output current 26) Alternator excitation details: (typical)
from the 5 A CT placed on the U phase. - Full load:
• Excitation voltage: 40 to 50 V
10) Auxiliary inputs A1 and A2: ± 4.5 VDC • Excitation current: 2.5 to 5.0 A
will change the voltage by ± 10%.
27) Terminal marking: see diagram
11) Under frequency roll-off setting:
available below 46 Hz for 50 Hz and below 28) AVR testing: dielectric test, thermal
56 Hz for 60 Hz. cycling, Static test, voltage variation check,
U/F curve, stability check, field excitation
12) Voltage build-up: ≥ 2 V (L-N). limit, external voltage setting check, DC
13) Voltage regulation: ± 0.8% at the AVR input voltage check.
terminals. 29) Dimensions:
14) Thermal drift: ± 1% for a 30ºC change in - Overall: 135 x 110 x 47.5 (mm)
temperature. - Mounting: 115 x 90 (mm)
- Mounting hole dia: 9 (mm)
15) Response time: less than 50 ms.
30) Weight: 320 g

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R150
AVRs

4 - MAIN FUNCTION OF THE AVR

The AVR is powered by the line-to-neutral terminals of the AC generator with 240 VAC at
50/60 Hz. The regulated sensing voltage is based on the generator line-to-line terminals.

STATOR: 6 wires (T1 to T6 identification)

MAIN FIELD
T1 T2 T3
EXCITER U1 V1 W1

Armature
Varistor

Delta
configuration

T4 T5 T6
Exciter field U2 V2 W2
+ -
Rotating rectifiers
black or blue

P2
red or white

8 S2

configuration
TI04
7 S1 P1

Star
blue
2K/2.5K (1W)
green
yellow
8 7
Options:
optional ST1 ST2 Q1 and Q2: CT for parallel operation TI04 (remove ST2)
R1 and R2: 2/2.5 kOhm external potentiometer (remove ST1)
Droop R2 R1 Q2 Q1 F2 F1 N W V A1 and A2: isolated voltage ± 4.5 VDC
A1 A2

FUSE
V
AC S UF OE SL UF OE

R150 Depending upon the value of the amplified

voltage, the ramp intersects the amplified
voltage at a point which is early or late in the
half-cycle.
At this intersection point, a starting pulse is
produced to trigger the power device.
50 Hz 60 Hz

The AVR builds up the generator voltage

from its residual voltage to rated voltage.
When the generator is loaded, the sensed Only qualified personnel should replace/
voltage decreases and generates an error work on the AVR.
signal, which is required in order for the Do not increase the voltage beyond the
closed loop system to work. rated voltage.

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R150
AVRs

5 - AVR SETTINGS result in a sluggish response and possibly

also oscillations.
5.1 - V-TRIM: V The factory default setting is slightly
This function is provided for setting the voltage higher than critical damping (around
up to ± 12% of rated voltage by means of a halfway).
potentiometer. Turn the potentiometer
clockwise to increase the voltage and vice 5.4 - EXC LIMIT: OE
versa, once the rated speed has been This function is provided to protect the Exciter
reached. Field from overexciting by turning a
It is also possible to connect an external potentiometer clockwise to increase the
potentiometer. excitation limit. It is factory-set at 105 V. The
5.2 - UF - Under frequency knee point red LED lights up when the ceiling has been
setting reached for more than 10 s.
This function is provided to protect the 5.5 - QUADRATURE DROOP
AC generator from sustained low speed This potentiometer is used to adjust the
operation through a potentiometer. The AVR voltage droop to balance the reactive load in
will reduce the voltage in proportion with the parallel operation. Follow the instructions for
speed below the defined value. The procedure connecting the CT (current transformer)
for setting the UF potentiometer is as follows: which is essential for this function, as per the
First run the generator at full speed (50 Hz) AVR connection diagram.
and turn the UF potentiometer by a few turns Turn the potentiometer clockwise to increase
clockwise, making sure that the voltage does % droop and vice versa.
not increase. Now turn the UF potentiometer
slowly anticlockwise. At a particular point the 5.6 - A1&A2 DC VOLTAGE
red LED glows and the voltage will start to INPUTS: AC
decrease. Stop turning the potentiometer at
this point and turn the potentiometer clockwise These accessory terminals A1 and A2 are
by two turns after rated voltage is restored. used to inject ± 1.0 to 4.5 VDC. The variation
The factory default setting is 46 Hz. in terminal voltage will be ± 10% of the rated
voltage.
For 60 Hz operation, the knee point position is
set to 56 Hz. Warning: A “Vishay spectrol model 8”
type screwdriver should be used to adjust
5.3 - STAB: S the potentiometer.
This function is provided to stop voltage
hunting by means of a potentiometer. Turn
clockwise to increase stability (to stop
oscillation). Turning too far clockwise will

6 - AVR CONTROLS
No. Control Function Direction
V VOLTS Sets the generator output voltage Turn clockwise to increase output voltage
UF UFRO Sets the Under frequency knee point Turn clockwise to reduce the knee point
S STAB Stops voltage hunting Turn clockwise to increase stability
OE OVER EXC Sets the overexcitation limit Turn clockwise to increase the limit
DROOP DROOP Sets voltage droop Turn clockwise to increase the droop
AC ACC (DC i/p) Used for Auto synchronization Turn clockwise to increase the gain

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R150
AVRs

7 - TROUBLESHOOTING CHART
Symptom Cause Action
No voltage Fuse blown Check and replace
build-up Low residual voltage across U If the generator’s residual voltage at rated speed
and N terminals is less than 2.5 VAC (L-N), disconnect the AVR
and connect a 24 VDC battery, keeping F1 as
positive and F2 as negative.
Connecting a freewheel diode (BY 127) across
the field with the diode cathode to F1 and the
anode to F2 during field flashing will help restore
the residual voltage.
WARNING:
Remove the diode (BY-127) after field flashing.
The 24 V battery positive terminal must only be
connected to F1 and the negative to F2.
Swapping the connection will cause diode BY127
to explode instantly.

Incorrect wiring Check wiring

Rotating diodes and/or fuse Check and replace
failed
Voltmeter on the front Check and correct
defective
AVR defective Replace after performing a static test
(repeated fuse blowing)
Earthed exciter field Check and correct
High voltage Loose or missing connection Check and correct
build-up to AVR U terminal
AVR defective Perform a static test and replace if necessary
Low voltage Low prime mover speed Check and correct
build-up Sensing loss in circuit Check and correct
AVR defective Replace the AVR
Voltage oscillation Incorrect stability Turn clockwise until hunting stops
potentiometer sealing
Prime mover speed hunting Check and adjust the controller
Load hunting, fluctuates Check and correct
rapidly
High percentage of non-linear Check and reduce the non-linear load
loads
High reactance in generator Consult the generator manufacturer
(during non-linear loading)
Incorrect The exciter field’s requirement Wrong selection or very low P.F. load. Check and
regulation is higher than 105 VDC correct.
Prime mover speed drops too Adjust the controller and reduce the active load
much when on load (kW load)

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R150
AVRs

8 - MULTIMETER CHECKS The resistance between U and N1 should be

Equipment: Digital multimeter. between 200 kW and 260 kW. Open circuit
indicates AVR failure.
Select Diode mode on the digital multimeter.
The resistance between F1 and F2 (with the During a static test, the lamp will not turn
multimeter jack common applied to F1 of the OFF or, when connected to the generator, it
AVR) should be between 0.4 and 0.6 V, and will produce a ceiling voltage (for 1-phase
vice versa (with the multimeter jack ONLY).
common applied to F2 of the AVR) should The resistance between N and F1 should be
give INFINITY. very low or ZERO ohms. If the circuit is
ZERO indicates a power device failure in open, the lamp will not glow when the static
both cases. No further tests (static or test is performed.
dynamic) are allowed, as they would lead to
the fuse blowing.
The resistance between F2 and U (both
sides) should be 180 kW.
The resistance between F2 and V (with the
multimeter jack common applied to the AVR
V terminal should be approximately 2. 2 MW
in the 10 MW range and vice versa (with the
multimeter jack common applied to the AVR
F2 terminal) should be 15 MW.
ZERO indicates power device failure in both
cases. No further tests (static test or dynamic
tests) are allowed, as they would to the fuse
blowing.
The resistance between U and V should
be 300 kW to 400 kW. Open circuit indicates
AVR failure. During a static test the lamp will
not turn OFF or, when connected to the
generator it will produce ceiling voltage (for
3-phase ONLY).

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R150
AVRs

9 - STATIC TEST PROCEDURE

For 3-phase circuit

AVR (3-PH)
Model: R150

F2 F1 N W V
VAC
0-500 V

F1 R

LAMP F2

415 V, 3Ø, 50 Hz,

WITH NEUTRAL
100 W
Y
230 V
F3 B

N
VARIAC
8 A, 415 V

STATIC TEST CONNECTION DIAGRAM OF 3-PH AVR

This test should only be attempted after 5. It is difficult to prescribe a static test for
making sure that the AVR has passed all checking the stability, as this is more easily
multimeter checks. Connect the AVR to the detected during closed loop tests. However, a
three-phase variable voltage source as healthy AVR will behave as described below.
shown in diagram for 3-phase installation in
First keep the ‘STAB’ potentiometer in the fully
this manual.
anticlockwise position. Perform the static test
1. Keep ‘V-TRIM’ in the minimum position. as described in steps 1, 2 and 3. The lamp will
go out fairly quickly at 360-380 V and come on
2. Keep UF in the fully maximum position.
again quickly when the voltage is reduced to
3. Increase the applied voltage. The lamp below 360 V.
should glow increasingly brightly. At a voltage Now keep the ‘STAB’ potentiometer fully
of around 360-380 V. The lamp should go out clockwise, and perform the static test as in 1,
slowly. Increase the voltage again up to 2, and 3. The lamp should go out much more
415 V. The lamp should stay OFF. slowly and come on again much more slowly.
Decrease the voltage to below 360 V. The At the end of this test reset the potentiometer
lamp should glow brightly again. in the middle position.
4. Turn the UF potentiometer anticlockwise;
If the AVR behaves as described above
the lamp should go out slowly. Now turn
then the regulator is healthy.
the UF potentiometer clockwise. The lamp
should glow brightly again.

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R150
AVRs

10 - DIMENSIONS
135 mm

10
A1 A2 Droop R2 R1 Q2 Q1 F2 F1 N W V

FUSE
V
110 mm

90 mm
AC S UF OE SL UF OE

R150

10
50 Hz 60 Hz

115 mm

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R150
AVRs

11 - SPARE PARTS
11.1 - Designation
Description Type Code
AVR R150 5014127

11.2 - Technical support service

Our technical support service will be
pleased to provide any additional
information you may require.

For all spare parts orders or technical

support requests, send your request to
[email protected] or your
closest contact, whom you will find at
www.lrsm.co/support indicating the type
and the code number of the AVR.

To ensure that our products operate correctly

and safely, we recommend the use of
original manufacturer spare parts.

In the event of failure to comply with this

advice, the manufacturer cannot be held
responsible for any damage.

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R150
AVRs
Disposal and recycling instructions
We are committed limiting the
environmental impact of our activity. We
continuously monitor our production
processes, material sourcing and products
design to improve recyclability and minimise
our environmental footprint.
These instructions are for information
purposes only. It is the user’s responsibility
to comply with local legislation regarding
product disposal and recycling.

Waste & hazardous materials

The following components and materials
require special treatment and must be
separated from the alternator before the
recycling process:
- electronic materials found in the terminal
box, including the automatic voltage
regulator (198), current transformers (176),
interference suppression module (199) and
other semi-conductors.
- diode bridge (343) and surge suppressor
(347), found on the alternator rotor.
- major plastic components, such as the
terminal box structure on some products.
These components are usually marked with
information concerning the type of plastic.

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R150
AVRs

14
 Service & Support

Our worldwide service network of over 80 facilities is at your service.

This local presence is our guarantee for fast and efficient repair, support and
maintenance services.
Trust your alternator maintenance and support to electric power generation experts.
Our field personnel are 100% qualified and fully trained to operate in all environments
and on all machine types.
We have a deep understanding of alternator operation, providing the best value
service to optimise your cost of ownership.
Where we can help:
Design
•Consulting & specification
•Maintenance
contracts

Life Extension
•Reconditioning Start-up
•System upgrade
•Commissioning
•Training

Optimisation
•Monitoring Operation
•System audit •Genuine spare parts
•Repair services

Contact us:
Americas: +1 (507) 625 4011
Europe & Rest of the world: +33 238 609 908
Asia Pacific: +65 6250 8488
China: +86 591 88373036
India: +91 806 726 4867
Middle East: +971 4 811 8483 Scan the code or go to:

[email protected] www.lrsm.co/support
 www.leroy-somer.com/epg

Linkedin.com/company/Leroy-Somer
Twitter.com/Leroy_Somer_en
Facebook.com/LeroySomer.Nidec.en
YouTube.com/LeroySomerOfficiel

5384 en - 2018.01 / g