Flight Systems Inc. 634 VR634B-A Voltage Regulator Installation Guide

Below you will find brief information for Voltage Regulator 634 VR634B-A. This guide will help you with installation, setup, and troubleshooting. The Voltage Regulator 634 VR634B-A is designed for use on 50/60 Hz brushless alternators and has features such as frequency compensation, overvoltage shutdown, an automatic exciter circuit, and an EMI filter. You will also learn about the different parts and connections, including the exciter field, power and sensing input, and frequency roll off. This guide will also cover important safety information relating to installing and servicing the Voltage Regulator.

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INSTALLATION

Model 634

VOLTAGE REGULATOR

GENERAL INFORMATION

The VR634B-A Voltage Regulator is built for use on 50/60 Hz brushless alternators. This AVR includes frequency compensation, over voltage shutdown, an automatic exciter circuit, and an EMI filter.

ELECTRICAL SPECIFICATIONS

Dc Output Power:

4 Adc at 63 Vdc continuous,

7 Adc at 100 Vdc (700W) forcing one minute

(at 240 Vac input).

Exciter Field Dc Resistance:

15 to 100 Ohms

Sensing Input:

220v Position: 190-240 Vac, Single phase, 50/60 Hz ±5%

110v Position: 100-120 Vac, Single phase, 50/60 Hz ±5%

Voltage Adjust Range:

220v Position: 170-265 Vac

120v Position: 90-132 Vac.

Regulation Accuracy:

Better than ± 1.0% no load to full load.

Response Time:

Less than 1.5 cycles for ± 5% change in sensing voltage.

EMI Suppression:

Internal EMI filter

Overexcitation Shutdown:

Power to fields STOPS when exciter voltage greater than 100 Vdc

Voltage Build-up:

Automatic voltage build-up with 5 Vac minimum residual

Operating Temperature:

-40° C to + 80°C

MOUNTING

The regulator may be mounted in any position. Use the Voltage Regulator itself as a template

Weight:

15 oz. (0.45 kg) Net.

FUSE

The fuse is part of the Voltage regulator

Use Bussman Model T5AH250

FIELD FLASHING

WARNINGS

Only qualified personal should install & service this AVR.

The resistance of the exciter must be from 15 to 100 Ohms.

Do not use Meggers they damage the AVR.

When a new regulator is installed for the first time, the polarity of residual magnetism may be incorrect or the magnitude low. If the generator does not build-up voltage after startup, shut down the engine and do the following:

OVER EXCITATION SHUTDOWN a.

With the engine STOPPED, apply a dc voltage of not more than 12Vdc, for 3 sec. to terminals F- & F+ in series with a current limiting resistor

If the exciter field voltage exceeds 100

Vdc, the regulator removes the field current of 3-5 ohms & 100 Watts on the fields.

after a time delay. At 135 Vdc, the field voltage is totally removed within 0.2

Start the engine and measure voltage at regulator leads 3 and 4 if is greater seconds.

than 6 volts, voltage build-up should be successful.

Repeat procedure

After shutdown, reset the regulator by stopping and restarting the engine.

if less than 6 Volts is measured.

VOLTAGE ADJUST RHEOSTAT (VAR)

Adjust with a screwdriver potentiometer on AVR to change generator output voltage.

moving rheostat CW increases generator voltage.

If repeating steps 1 and 2 does not result in generator voltage build-up, replace the voltage regulator.

When using remote voltage adjust rheostat

(VAR), the VAR wire on the regulator should be cut and the rheostat connected to wire ends. A 1 k ohm 1/2 watt rheostat is adequate for most applications.

See connection Diagrams

Volt selector

Switch

PRELIMINARY SET-UP

To prevent damage to the regulator, complete the following steps before proceeding with system start-up: a. Verify that the voltage regulator conforms with the generator system requirements.

Ensure that the regulator is correctly connected to the generator.

See connection Diagrams c.

Set the regulator VAR fully CCW before

starting

SYSTEM START-UP a.

Start the prime mover and bring up to rated speed. Voltage should buildup. If a minimum of 5 Vac residual is not present, you must flash the fields.

Fuse

Stab.

Adjust

Voltage

Adjust b.

Adjust internal VAR rheostat on AVR for normal generator output voltage.

EXCITER FIELD POWER CIRCUIT (regulator wires F+ & F-).

Connect the regulator wire F+ to the exciter field F+ terminal, and regulator wire F- to exciter field F- terminal.

Generator

120 V

Generator

POWER & SENSING INPUT (regulator wires 3

& 4)

15 to 100 Ohms

Connect as shown in side diagrams.

Power for the exciter field and regulator

HZ HZ F+ F3 4 VAR VAR circuitry is taken from the generator output.

Input Voltage

120 VOLTS on 120 v Position

1 K Ohm 1/2 W external VAR

If Used

HZ HZ F+ F3 4

Input Voltage

200 to 277 volts

FREQUENCY ROLL OFF

Hz & Hz Together For

50 HZ USE

At 60 Hz ROLL OFF FREQUENCY starts 55 Hz.

At 50 Hz ROLL OFF FREQUENCY starts 45 Hz.

The Regulator comes factory set for 60 Hz use.

Short wires marked Hz. for 50 Hz use.

Hz & Hz Together For

50 HZ USE

Be sure to insulate the connection. Dist. by Flight Systems Inc. www.flightsystems.com

VAR VAR

1 K Ohm 1/2 W external VAR

If Used

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Key features

Frequency Compensation
Overvoltage Shutdown
Automatic Exciter Circuit
EMI Filter
Voltage Adjust Range
Regulation Accuracy
Response Time
EMI Suppression
Overexcitation Shutdown
Voltage Build-up

Frequently asked questions

The Hz shorting wires are used to adjust the regulator for 50 Hz operation. If the regulator is set for 60 Hz, the frequency roll off will start at 55 Hz. For 50 Hz operation, shorting the Hz wires will adjust the frequency roll off to start at 45 Hz.

The VAR rheostat is used to adjust the generator output voltage. Moving the rheostat clockwise increases the generator voltage, while moving it counter-clockwise decreases the generator voltage.

If the generator does not build-up voltage after startup, shut down the engine and follow the steps outlined in the WARNINGS section of the manual. This may involve flashing the fields by applying a DC voltage to the F+ and F- terminals.

Connect the regulator wire F+ to the exciter field F+ terminal, and regulator wire F- to the exciter field F- terminal. Be sure to use the correct polarity.

The frequency roll off is the point at which the voltage regulator starts to reduce the output voltage. This is a safety feature that prevents the generator from producing excessive voltage at high frequencies.