PM300 VOLTAGE REGULATOR INSTRUCTION MANUAL INTRODUCTION The PM300 voltage regulator is an encapsulated electronic voltage regulator that controls the output of a brushless AC generator by regulating the current into the exciter field. SPECIFICATION Sensing Power Input Burden Output Power- Continuous Output Power - Forcing(240 Vac Input Power) Regulation Remote Voltage Adjustment Range Frequency Compensation Roll off frequency Operation Operating Temperature Storage Temperature Power Dissipation Size EMI Suppression PM300 REGULATOR 190-240 Vac 50 / 60 Hz 190-240 Vac 250 / 300 Hz 500 VA 63 Vdc at 3.5 Adc (190w) 105 Vdc at 5 Adc (525w) 1 .0% ± 10% with 2000 ohm rheostat ± 5% with l000 ohm rheostat Adjustable 54-61 Hz for 60 Hz 45-51 Hz for 50 Hz Weight6.5 oz. - 40°C to + 60°C - 65°C to + 85°C 8 watts maximum 3.94" L X 2.66” W X 2.20: H Internal Electromagnetic Interference Filter (EMI Filter ) WARNING TO PREVENT PERSONAL INJURY OR EQUIPMENTDAMAGE ONLY QUALIFIED PERSONNEL SHOULD INSTALL, OPERATE, OR SERVICE THIS DEVICE. CAUTION: DO NOT megger or high-pot the generator with the regulator connected. DO NOT high-pot the regulator. MOUNTING The PM300 voltage regulator can be mounted in any plane, following is Figure 1 with the mounting dimensions. FIGURE 1 EXCITER POWER CIRCUIT Connect the regulator wire F+ to the generator F+ or Fl field terminal. Connect the regulator wire F - to the generator F - or F2 field terminal. See Figure 2 for typical connection diagram SENSING CIRCUIT Sensing is achieved through terminals E1 and E 4. The voltage-sensing requirement of the PM300 is 190 to 240 Vac 50/60 Hz. Terminal E4 is common with terminal 4 from power input connection. See Figure 2 for typical connection diagram POWER INPUT CIRCUIT Input power is achieved through terminals 3 and 4. The voltage-input requirement of the PM300 is 190 to 240 Vac 250 / 300 Hz. See Figure 2 for typical connection diagram FUSE A 4 Amp, 250 V, 5 X 20 mm fuse is supplied with the regulator Littelfuse 218004 or Bussman GDC-4A. Marathon Electric Part A-527066), It can be located on the rear face of the voltage regulator. FIGURE 2 VOLTAGE ADJUST The screwdriver adjustable potentiometer adjusts the generator output voltage. Adjustment clockwise increases the generator output voltage. When using a remote voltage adjust rheostat, remove the jumper wire across terminals 6 and 7 and install a 2000 ohm 1/2 watt (minimum) rheostat. This will give ±10% voltage variation from the nominal. (For ±5% voltage variation use a 1000-ohm 1/2-watt rheostat). See Figure 2. STABILITY ADJUST System stability is the ability of the generator to respond to load transients. Decreasing the stability makes the generator less sluggish and faster to respond to toad transients. If the stability of the regulator is decreased too much, the generator will tend to hunt under steady state conditions. The screwdriver adjustable potentiometer adjusts the system stability. Adjustment clockwise increases the stability. Increasing the stability increases the response time of the generator. Conversely, decreasing the stability decreases the response time of the generator. There are two small jumpers on the regulator, see Figure 3. These jumpers must be cut for proper operation of the 570 Frame MagnaMax product. For all other MagnaMax frames these jumpers should be left intact. V/HZ ROLL-OFF FREQUENCY SELECTION The roll off point is the frequency where the generator voltage starts to decrease. This reduces the Kilowatt load to the engine, which allows the engine to recover in speed under any load transient condition. Use jumper to select 50 HZ or 60 Hz. The screwdriver adjustable potentiometer sets the roll-off frequency from 54-61 Hz in the 60 Hz setting or from 45-51 Hz in the 50 Hz setting. FIGURE 3 The PM300 has the roll-off point preset to 58 Hz in the 60 Hz mode and 48 Hz in the 50 Hz mode. To change the roll-off point, adjust engine speed to the desired rated speed. (50 or 60 Hz). Set the voltage to the desired setting at rated speed. Adjust engine speed to the desired roll-off point. Turn the potentiometer counterclockwise until the voltage starts to drop off. Then adjust the potentiometer clockwise until the voltage returns to rated voltage. Re-adjust engine speed to rated speed. STARTUP PROCEDURE PRELIMINARY SET-UP Ensure the voltage regulator is correctly connected to the generator. Refer to the specific connection diagram supplied with the generator. Set the regulator voltage adjust to full counter-clockwise (minimum voltage level). Set the remote voltage adjust (if used) to the center position. Set the stability control full clockwise (maximum stability level). Connect the positive lead of a 100 V D.C. voltmeter to Fl and the negative lead of the voltmeter to F2 or use an appropriate AC voltmeter on the generator output leads. SYSTEM START-UP Start and run the generator at no load and rated speed. The generator voltage should build up to a minimum level. (Actual level is dependent upon connection). If it does not build up, refer to field flashing section in generator manual. Slowly adjust the voltage control until the generator voltage reaches the nominal value. If used, adjust the remote voltage rheostat to set the generator voltage to the exact value desired. Turn the stability adjust counter-clockwise until instability is shown on either of the voltmeters mentioned in the “PRELIMINARY SET-UP” section. With the system operating in an unstable condition, slowly adjust the stability control clockwise until generator stability is reached. Interrupt regulator power for a short time (approximately 1-2 seconds). If the generator remains stable, no further adjustment is necessary. If the generator does not remain stable, increase the stability slightly and interrupt regulator power again. This procedure should be repeated until system stability is reached and maintained. TROUBLESHOOTING Symptom Residual Voltage -No Output Cause No voltage at regulator power input terminals. Action Check wiring diagram for proper connections. Defective PMG Shorted PMG Capacitor Output Voltage Low Output Voltage High Field leads Fl, F2 not connected. Connect field leads Fl, F2. Power input leads not connected. Connect power-input leads 3,4. Blown or missing fuse. Replace fuse. Defective regulator. Replace regulator. Defective generator. Incorrect connections. Consult generator manual. Check wiring diagram for proper connections. Voltages adjust turned down. Rotate voltages adjust CW until desired voltage is reached. Remote voltage adjust is turned down. Rotate remote voltages adjust CW until desired voltage is reached. Defective regulator. Voltages adjust turned too high. Replace regulator. Rotate voltages adjust CCW until desired voltage is reached. Remote voltage adjust is turned too high. Rotate remote voltages adjust CCW until desired voltage is reached. Replace regulator. Output Voltage High - Defective regulator. No Adjustment Remote Voltage Adjust Voltages adjust wired backwards. Operates Backwards Generator Output Stability adjusts not set properly. Voltage Hunting Poor Regulation Defective regulator. Reverse the wiring of the remote voltage adjust. Rotate the stability adjusts in a CW direction until hunting stops. Replace regulator.