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VR6 IK65- Adjustment - Troubles hooting

Manual

ReplacesCaterpillar VR6, Kato K65-1 28A Supplied by:4l \r SYSTEMSwww.fl i g h tsystems. co m

CONTENTS:Installation - Pgs 6-12Adjustment - Pgs 13-18Troubleshooting - Pgs 19-2hone tech Support:(US/Gnd) 800 4o3 3728(lntl) 717 932 9900

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lnstallationMountingThe reguiator nray be mounted in any position. Refer to Figure 1 foroverall dimensions. The regulator may be mounted directly on thegenerator set using UNF 1/4-20 or equivalent hardware. Select theproper hardware to withstand any expected shippingitransportation andoperating conditions.

/-.?81 *t&. l"{*Lg,1 {4 Pt-'}

23.4$9465n?*.43S

I

ffi* *,AlVtT,&FJ

Iif

sY* \tr,r,F/iiIo\, /S\'.ttd) ln_6 \\#iil,i ffir-HJ : IUIfl.*\ l#"k2d \q

-----*-*-----=J iFigure 1: Outline drawing

Page 6

7.SfJ*ia

i1I1

IIItI.,,._-i---.--_*s.438

iiIIl"------.439 r a.ss -

@vw ?.e ,a & a @ w

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ConnectionsBefore connecting the K65-128 and K125-108 into;,6111 system^ reviervthe terminal descriptions provided in Table 3, the internal adjustmentsprovided in Table 4, and the typical interconnection diagrams shown inFigures 2-6.

Terminal number Terminal descriptionUpper Terminal Strip

CH GND Chassis ground connectionaL Auxiliary input from var power facior controller

Auxiliary input from var power factor controller4 Connect to 7 to use internal voltage adjusi, noconnection for external voltage adjust

'l A current transformer5a 5 A curreni transformer

Current transformer common6a Common connection for selectable features7 Connect Remote Adjust from 7 to 6a, connect to 4 forinternal voltage adjustF Connect to 6a to select 1vlHz underfrequency slope{Not 810-34334-00)I Connect to 6a to select 3 phase sensing

Lower Terminal Stripzu Phase C sensing input22 Phase A sensing input24 Phase B sensing input

3-phase power input28 1-phase or 3-phase power input?n 1-phase or 3-phase power inputF1 Field +F2 Field -

Table 3: Terminal descriptionsAdjustment Adj ustment description

DRP Voltage droop adjustFAC CAL FAC CAL is a factory voltage adjust range calibration.No customer adjustment is required.VLTADJ Multiturn voltage adjust

iltr Underfrequency knee adjust (Not 81 0-34334-00)STB Stability adjust

Table 4: Internal adjustmentsPageT

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lF 1 A. sEc CCCT Is UsED coNNECT TO TERMINAL 5 INSTEAD oF 5a. (VAR/PFc & EL cANNoT BE UsED WITH I A.CCcr).IF EXTERNAL VAR IS NOT UsED, IUMPER 4 TO 7.FOR 2 X V/HZ, REIV1OVE CONNECTION TO TERMINAL 8. (1 X V/HZ CONNECTION IS SHOWN).

IF EL,VAR/PF,DSLCAND/OR BE3-25A ARE NOT USED,JUMPER 2TO 3-

10K tsnSTANDARD

NOTE:REsISTANCE INCREASES TO INCREAsE VOLTAGE

" IF POWER IS REMOVEDFROM BE3.25A AFTER

SYNCHRONIZING,THECIRCUIT BETWEEN VRl &

VR2 MUST BE CLOSED.

*" IF POWER sOURCE ISUNGROUNDED, JUIMPER MUSI

BE TIED FROM 28 TO 24,

PMG POWER IS 5HOWN.1 PHASE POWER MAY BE

FROM PMG,6ENERATOR, OROTHER SOURCE.3 PHASE PMG

POWER,WHEN AVAILABLE, ISUSED WITH K65-1 28 ONLY

(REGULATORts r 20 voLT

SENSING ONLY)

Figure 2. Regulator connections (three phase)

52lb (AUX CONTACIIN CIRCUIT BREAKER)

DISABLES SCP.25OWHEN GENERATORI5 NOT OPERATINGIN PARALLEL WITH

UTILITY

vR476a89cH (t) (-)GND283026F1F22322242065a5

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lF 1 A. SEC CCCT 15 USED, CONNECT TO TERMINAL 5 INSTEAD OF 5a. (VAR/PFC & EL CANNOT BE USED WITH lA.CCCT).IF EXTERNAL VAR IS NOT USED,JUMPER 4 TO 7.FoR 2 x V/HZ, REI,4OVE coNNEctloN TO TER/vllNAL 8. (l x V/Hz coNNEcTloN 15 SHowN).

IF EL,VAR/PF, DSLC AND/OR BE3.25A ARE NOT USED,JUMPER 2 TO 3.

NOTE:RESISTANCE INCREASES TO INCREASE VOLTAGE0K ts.nSTANDARD

" IF POWER IS REMOVEDFROi\4 BE3-25A AFTER

SYNCHRONIZING,THECIRCUIT BETWEEN VRl &

VR2 MUST BE CLOSED.

"" IF POWER SOURCE ISUNGROUNDED, JUMPER MUST

BE TIED FROI\4 28 TO 20,

PMG POWER IS 5HOWN.I PHASE POWER MAY 8E

FROM PI!1G, GENERATOR, OROTHER SOURCE,3 PHASE PMG

POWER,WHEN AVAILABLE, I5USED WITH K65.'I28 ONLY

(REGULATORls 120 voLT

SENSING ONLY)52lb (AUX CONTACTIN CIRCUIT BREAKER)

DISAELES 5CP.25OWHEN GENERATORIS NOT OPERATINGIN PARALLEL WITH

UTILITY

Figure 3: Regulator connections (single phase)

cH i+) (-)GND 28 30 26 Fr F2

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lF 1 A. SEC CCCT lS USED, CONNECT TO TERMINAL 5 INSTEAD OF 5a. {VAR/PFC & EL CANNOT BE UsED WITH 1 A CCCT).IF EXTERNAL VAR I5 NOT USED,-JUMPER 4 TO 7.FOR 2 x V/HZ. REMOVE CONNECTION To TERMINAL 8. {1 x V/HZ CONNECTION 15 SHOWN).

loK tsJ1STANDARD

"* IF POWER SOURCE 15UNGROUNDED, JUMPER MUST

BE TIED FROM 28 TO 24.

NOTE:RESISTANCE INCRASES TO INCREASE VOLTAGE

cccl54,5EC

PMG POWER I5 SHOWN.1 PHASE POWER MAY BE

FROM PMG,GENERATOR,OROTHER 50URCE.3 PHASE PMG

POWER,WHEN AVAILABLE, ISUSED WITH K65-]28 ONLY

ft*'-{113Y;[fi;\lM2 or PMa

.|-*"- t**

| (11) PMlt=lot4( ttrl er',rz -VII {t 31 PM3}onr*"otr rot,

=I:I

128-'t0B

APPLICATIONS

(REGULATORls t20voLT

SENSING ONLY)PT'S IFNEEDED

;}=SHOWN CONNEFOR A-B.C PHAs

ROTATION. FOR ArROTATION, REVECCCT SECOND,

Figure 4. Regulator connections (simple three phase)

GND 28 30 26 F1 F2

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lF 1 A.SEC CCCT 15 UsED, CONNECT TO TERMINAL s INSTEAD OF 5a. (VAR/PFC & EL CANNOT BE USED WITH 1 A. CCCT)IF EXTERNAL VAR IS NOT USED, JUMPER 4 TO 7.FOR 2 x V/HZ, REMOVE CONNECTIoN TO TERI\4lNAL 8. (l x VIHZ CONNECTION lS SHOWN).

loK rsrtSTANDARD

VOLTAGEADJUST

ANOTE:

RESISTANCE INCREAsES TO INCREASE VOLTAGE

PMG POWER I5 5HOWN,1 PHA5E POWER MAY BE

FROM PMG,GENERATOR,OROTHER 5OURCE.3 PHASE PMG

POWER,WHEN AVAILABLE,ISUSED WITH K65-1 2B ONLY

** IF POWER SOURCE ISU NGROU N DED, J UM PER i\4U57

BE TIED FROM 28 TO 20.

F2 GI

| (11) PMl-lll>)X \ (12) PM2=ll{ | rr:r pw:E Verenrnre

(REGULATOR15 I20 VOLT

SENSING ONLY)

oFzI:o OB

a(SHOWN CONNECTEDFOR A-B-C PHASE

ROTATION. FOR A-C-BROTATION, REVERSECCCT SECONDARY. Figure 5: Reguiator connections (simple single phase)

GND 28 30 26 F1 F2

Pnno 11' -5" il

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S ':r 5cKS,5 *r l{1f.5

5or5*f{S5 or t{13"$

5*r3*f{fi.3 *r li'if.$

*

r'f-r1.*:l'

Figure 6: Cross-current compensation

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OperationGeneralTable 5 provides system start-up procedures for the K65-128 andK125-108 voltage regulators. Symploms of problems occuringduring starl-up that arise from incorrect regulator adjustmenl andcertain generator system problems that resemble faulty regulation areincluded together with possible solutions. Simplifying the system byeliminating components, such as rernote adiust potenriometers andother non-essential items can be helpful in the troubleshooting process.Adjustmerrts, optiorls, and an operalional test are inciuded in theparagraphs after the table.

Preliminary SetupTo prevent damage to the regulatoE ensure that the regulator has beeninstalled and connected in accordance with the installation proceduresbefore proceeding with the system staft-up.

System StartupRefer to'lable 5 for starting up the svstem

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Procedure Symptom Remedy1. Perform the preliminaryset-up. NIA N/A

2. Start prime mover andbring up to rated speed. a. Voltage does not build-up

a. Fiash field. (Exceptwith PMG)b. Remove power for 1minute to allow the overexciiation circuit to resetc. Troubleshoot.

b. Voliage builds up and thendecays a. Troubleshoot.3. Slowly adjust VLTADJor external voltage adjustrheostat untii voltagereaches nominal.

a. Voltage does not build upto rated valuea. Check generator outputfor shofted or excessive

load.

b. Troubleshoot.b. Voltage high anduncontrollable a. Troubleshoot

4. Apply and remove load tocheck stabilitv. Generator response too slowor is hunting (oscillating)

a. Check generator outputfor shorted or excessiveload. Adjust STB with not^^l ^^^ti^ludLr dl-rliilcu.b. Check stability ofgovernor system.c. Troubleshoot.

5. Check regulation undernormal operatingconditions. Poor regulation

a. Check that prime moveris up to speed.b. Check that volimeter isconnected at the samepoint as the regulatorsensing.c. Use an average sensingvoltmeter (not a RMSsensing).d. Troubleshoot.6. Reduce generatorfrequency. Generatoroutput should decreasefrom this point"

Generator output voltagedoes not decrease at desiredfrequency

a. Check that allwiring isin accordance with theinstallation proceduresb. Adjust UF control.

Table 5. System startup

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AdjustmentsFor location of tire acljustments referenced in the following paragraphs,rel-er to Figure 1.Field ]-'lashing (only for units with no PMC)When the regulator is operated lvith tlre generator fbr the frrsf time, thepolarity of the residual nlagnetism may uot be correct or of sufficientmagnitude. If the generator residual voltage is less than 6 Vac for theK65-128 or 12 Vac l-or tire K125-10B al lerminals 26 and 28, shut dor.vnthe prime mover and proceed r,vith the follou,ing steps:(1) With the prine mover at rest, apply a DC source (ungroLrnded), ofnot more than 24 Vdc. to terminals F1 (positive) and F2 (negative; in

series lvith a limiting resistor. Use 1 ohm of resistance for each voltfrom the DC power source with a power rating of least one 1 tvaf[ peroitnr.Example: tf using a 24 Vdc source. use a 24-ohm ,24-watt resistor.(2) A}lorv tire field to ire liashed far approximately'' l0 seconds beforeremoving the DC source.

(3) If voltage build-up does not occur afler performing steps (l ) and (2).verifl'the polaritv ofthe DC source used in steps {1) and (2) and re-perfbrm.Frequency roll-off (knee) adjustment {Not on B l0-34334-00)The underfrequenc)' knee can be set for 45 to 60 Hz operation asdescribed in the l-olloia,ing paragraphs.(1) .Adjust the underliequenc.v potentiomeler (LIF) Illly CCW(2) Set the geuerator to the desired frequency'(3) Adjust tire Voltage Adjust (internal or extelnal) for noininai generator

voltage.(,{) Adjust the underfrequency potentiometet (UF) CW urrtil the voltage

begins to decrease.(5) Adjust tlre underfrequency potentiometer itJF) CCW unti] thevoltagejust returns to the value set in Step 3.(6) The underfrequency' "knee" is nou' setjust below the nominal

operatirrg frequencl,. Further rotation in the CCW direction r.villlower the frequencS,' at rvhich underfrequenlcy colnpensation begins.

(7) Connecting a jumper from tetminal 8 to terminal 5a will provide anunderfiequency slope of 1 X V/Hz. Nct comection to terminal 8 r,villresr.rlt in an underfrequency slope of 2XYlHz.

Caution: Da nat flash the fietd wik thegeneratar in matian. The regulatar may bedamaged.

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Gaution: The factary calibratian (FAC CAL)adjustment is intended far use by factarytechnicians only. The factory voltage adjustrange calibration adjustment can be used ifthe factory calibration has been disturbed.

Stabilitlz (STB) adjustmentUse an oscillosoope or other voltage-recording device if an optimalstability setting is desired. Adjust tlie stabilitv setting with tire generatorat no 1oad. Good response can be obtained with the following procedure.(1) Rotation of the STB control in tl"re clockwise (CW) direction willslorn response time.(2) Rotation of the STB control in the counter-clockrvise (CCW)direction r.vill speed response tirne. If rotated too lar CCW, the

generator voltage ma1'' oscillate (hLrnt).(3) Rotate the front panel S1'B control CCW until the system just begins

to osciltrate and then rotate CWjust past the poinl rvhere oscillationoccnrreci.

Voltage lVt.T AD.l) adjusttnent(1) tnstallation of aiumper across terminals 4 andT allor.r's the intemal

VLT ADJ adjusfirrent to vary the generator nominal voltage over theoperating range.(2) Rernove the juraper between terminals 4 and ? and oonnect a 10k

otun external voltage adjusl potentiometer asross tetminais 6 and7 to allow operation ofthe external voltage adjust potentionreter.The internal voltage adjustrrent should be set fully CW for properoperation of the external adjustment.

Factory voltage adjust range calibration adjustrnentWith the voltage regulator operating on a generator, adjust the calibrationpotentiometer fully ccw and the voltage adjust potentiometer full-v CW.AdjLrst the calibration potentiometer CW until the generator voltage is144 +1 Vac. Adjust the voltage adjust CCW ancl verif the generatorvoltage is less than 90 Vac. Tlie unit is calibrated and the calibrationpotentiometer ca:r be sealed.Parallel droop (DRP) cornpensationVariable parailel droop compensalion levels can be obtained by adjustingthe droop potentiometer. CW rotaticn increases the amount af droop fora given condition.OptionsThe K65-128 and the Kl25-l0B may be equipped rvith the follor.vingoptions to enhance operalional characteristics. Characteristics of theseoptions are defined in the follorving paragraphs:Remote volta*ee adjustConnect a 10k ohrn potentiometer from tenninals 6 to 7, remove thejnmper from terminal 4 ta'/ and adjust tlre inlernal voltage adjustpotentiometer filly clockrvise to allow operation of a remote voltageadjust.

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Excitatiorr disableThis option provicles fbr disabling of the excitation system by removalof power from the voltage regulator. A switch removing voltage fromterminals 26,28 andlor 30 will remove power.VarlPF controlThis option allows the K65-128 and the K125-108 to either regulate thevolt-arnps reactive ivar) or power lactor rvhile the generator is connectedto an infinite or utility bus. The varlPF option (Modei Number SCP250G-50 for 50-Hz operation or SCP250G-60 for 60-Hz opration) suppiies aDC signal into the K65-l28 & K125-108 terminals 2 and 3 to regulateto the SCP250 var ot'power factor setting.Manual voltage controlThis option provides a nranual back-up channel for manually controllingthe generator outprt during generator start-up and commissiouing or inthe urrlikely event tlrat the voltage regulator should fail. Manual voltagecontroller models MVC-300 (if exciter field cunent does nof exceed 7amps) or the MVC-112 arc suitable for use rn'ith the either the K65-12tsor the Ki25-10B.Operational TestTo operationally test an-v K65-128 orthe K125-l0I*" perform thefollowing steps:a. Connect the voltage regulator as shorvn by Figure 7, and apply 124

Vac.

b" Adjust the VUII ADJ control filly counterclockwise (CCW).Reurlt: Observe that tlie lamp is OFF.c. Adjust the front panel VLT ADJ control clockrvise (CW).Result: Obserue that the la:rp is now ON.

d. Adjust the front panel VLT ADJ control until the lamp i Lrst goes out.R.egulator operation is satisfactory if the above results are obtained.Stability, however, must be tested with the regulator operating whileconnected to the generator.

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1*ohr*

Figure 7: Operationaltest setup

KffiS-tr 3*, K$ ffiS-t **

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MaintenancePreventive MaintenanceInspect the voltage regnlator periodically" to ensure that it is cleanand free from accumulations of dust and moisture. Be sure thar allconnections are clean and tisht.Trouhleshootingln case of {ailirre or defective operatioti of the unit, Table 6 is providedto aid in the determination of the cause and the possible solution.Simplifying the systern by elirninatir'rg ccllnponents, suclt as remoteadjust potentiometers and other non-essential items can be helpfirl in thetroubleshooti n g nrocess.

Symptom Possibie Cause Remedy

Voltage does not buildup"

a. No voltage or incorrectvoltage to power input atterminals 26. 28 or 30

a. Flash field. (except with PMG)b. Verify wiring.c. Check fuses supplying power.d. Replace regulator.

b. Overexcitation circuit isshutting off regulatorShutdown regulator power for 1 minutethen restart. Watch for high fieldvoltaoe.

Voltage builds up andihon doc:rrca. Single or three phasejumper incorrect

Verify single or three phase sensing isapplied b 2A, 22 and/or 24 and verifyconnection from upper terminal 6a to 9is correct.

b. Defective regulator. Replace regulator.

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Voltage does not build upto rated value.

a. Single or three phasejumper incorrectVerify single or three phase sensing isapplied to 20,22 andlor 24 and verifyconnection from terminal 6a to I is

b. Internal or external voltageadjustments are improperlyset

Adjust VLTADJ control andlor externalvoltage adjust rheostat. Verify properconnection from 4 to 7

c. The regulator is operatingon the undeffrequency curveVerify the generator is rotating atthe proper frequency. Verify properadjustment of the underfrequency pot.

d. Faulty regulator Replace regulator.e. Terminals 2 and 3 are notjumpered and there is nodevice connected to theseterminals

a. Jumper terminals 2 and 3.b. Connect va#PF controller or otherdevice to terminals 2 and 3"

f. Jumpers are set for stngle-phase sensing and three-phase voltage is applied

Install a jumper between terminals 6aand 9.

Voltage does not buildup to rated value.(continued)g. Voltage adjust pot not inuse and terminals 4 and 7are not jumpered lnstalljumper.

Voltage high anduncontrollable.

a. No sensing input Verify wiring.b. Single or three phasejumper incorrect

Verify whether single or three phasesensing is applied ta 20,22 andlor 24and veriiy connection from terminal 6ato I is correct.c. Faulty regulator Replace regulatord. Voltage adjust pot in useand terminals 4 and 7 are stilliumpered Remove

jumper

Generator response tooslow or hunting.a. lmproper front panel STBadiustment Re-adjust front

panel STB adjustment,as described in section 3.b. lmproper governor setting Adjust governor.c. Faulty regulator. Replace regulator

Poor regulation. a. Low prime mover speed Verify prime mover speed.b. Faulty regulator Replace regulator.No specific symptom;random loss of control Cross-grounding of circuitry

Remove the connection .jumperbetween terminal2S and 20 (single-phase sensing) ar 24 (three-phasesensing)

Table 6: Troubleshooting

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