EA05A

Generator Automatic Voltage Regulator

Operation Manual

Self Excited Automatic Voltage Regulator

5 Amp AVR For General Generators

Headquarters : No.3, Lane 201, Chien Fu ST., Chyan Jenn Dist., Kaohsiung, TAIWAN
Tel : + 886-7-8121771 Fax : + 886-7-8121775 URL : http://www.kutai.com.tw
 1. INTRODUCTION
Sensing Input External Volts Adjustment
Voltage 220 / 380 / 440 VAC, 1 phase2 wire 7% with 1K ohm 1 watt trimmer
DIP switch selectable
Frequency 50 / 60 Hz, DIP switch selectable EMI Suppression
Internal electromagnetic interference filtering
Power Input
Voltage 100 ~ 300 VAC, 1 phase 2 wire Unit Power Dissipation
Max. 8 watt
Output
Voltage Max. 63 VDC @ 220 VAC input Under Frequency Protection (Factory Setting)
Max. 90 VDC @ 240 VAC input 60 Hz system presets knee point at 55 Hz
Current Continuous 5A 50 Hz system presets knee point at 45 Hz
Intermittent 7A for 10 sec Soft Start Ramp Time
Resistance Min. 15 ohm Max. 100 ohm 3 sec.
Voltage Regulation Dimensions
< ± 0.5% ( with 4% engine governing ) 101mm L * 69mm W * 47.5mm H
Voltage Build-up Weight
Residual voltage at AVR terminal > 5 VAC 183g ± 2%
Thermal Drift
0.03% per °C change in AVR ambient

2. WIRING 3. F+, F- terminals connect to the generator field. ( J

and K )
When generator supply is over load, N phase will be
FEXT.VR is the potentiometer (1KΩ 1W). These two
different with the sharing load by 3 phases (load
terminals must be by-pass when external
imbalance). Hence, the voltage from N phase to 3
potentiometer is needless.
phases (R.S.T.) will be altered. When the rated
voltage of the traditional single input’s AVR is above
P.S. : A, B, C, F+, F- the usage of wire gauge are
220V, it will increase the voltage drift rate by using N
AWG16 or 1.25mm 85°C above 600V.
2
phase as the detective input. It will also cause the
voltage imbalance.
The EXT.VR connection wires must be made of
isolated wiring.
EA05A can improve the above situation, and
increase the generator’s rated voltage usage space,
such as 380V, 440V. We can all detect by the 3. ADJUSTMENTS
“Phase voltage”.
The voltage setting for 220V / 380V / 440V and the
frequency setting for 50/60HZ is show in Figure7.
1. When the rated phase voltage of the generator is
Please check the voltage/frequency selector setting
220VAC, the input terminals B, C and sensing
is correct before start the generator.
terminals A, C can join together (as show as
Figure3. It’s the original setting).or connect
CAUTION :
independent.(as show as Figure2).
The generator or AVR may be damaged if the
2. When the rated phase voltage of the generator is
voltage / frequency selector setting is incorrect.
380V, 440V, the input terminals B, C and sensing
terminals A, C must separate connect the wiring
UFRO DIP:
(as show as Figure 4 or Figure 5). The voltage
Close - please refer to solid curve in Figure8.
between B and C must not be over 300 VAC.
Open - please refer to dotted curve in Figure8.

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2 EA05A
1. Before you turn on the generator, please turn the 1. With the Prime-mover at rest and the regulator’s
voltage adjustment and stability adjustment full field output wires disconnected, apply a DC
anti-clockwise. After the generator is on and run source ( NOT grounded ) of not more than 3~12
stably, turn the voltage adjustment clockwise to VDC with Positive to F+ and Negative to F-, in
reach the required out voltage. (If there is an series with a current-limiting resistor of 3~5 ohms
external potentiometer, turn the external 20 watt. (The set battery is a suitable source.)
potentiometer to the middle position before adjust
2. Allow approximately 3 seconds before removing
internal voltage potentiometer.)
the DC source.
2. Adjust “Stability Adjustment” clockwise slowly to
3. With the voltage regulator disconnected ( wires 3
change the feedback time between AVR and the
and 4 ), start the prime mover and measure the
generator. If the adjustment is too big, it might
“ residual ” voltage available at the auxiliary
cause the voltage instable. If too small, the load
winding. If this voltage is greater than 5 VAC,
voltage will change too much at heavy load. Our
reconnect voltage regulator, and voltage build-up
suggestion is to trace by the multi-meter DCV. To
should be successful. If less than 5 VAC is
adjust “stability adjustment”, you just need to
measured, repeat field flashing procedure.
make the multi-meter waving smaller. It can also
improve the full load’s voltage drift rate. 4. If repeating steps a. and b. does not result in
generator voltage build-up, and residual is
4. FIELD FLASHING greater than 5 VAC, replace voltage regulator.

When the regulator is operated with the generator for WARNING

the first time, the polarity of residual magnetism may This Automatic Voltage Regulator is not
be reversed or too small to achieve the necessary equipped with loss-Sensing Protection
build-up voltage for the regulator. If reversing the field function / Over Excitation Protection. An
connections does not induce build-up, and the residual additional Over-Voltage Protection device for
voltage is less than the specified value of 5 VAC, shut load may be required to avoid possible
down the Prime-mover and proceed with the following damage to the equipment or severe personal
steps : injury or death.

5. TROUBLE SHOOTING
SYMPTOM CAUSE CORRECTION
Voltage does not Engine speed is too low. Please refer to the Generator Manual.
build up Residual voltage is too low. Please refer to the section introduction of
excite.
B,C,F+,F- wires are not connected well. Please refer to Figure 2 ~ Figure 5.
Defective Generator. Please refer to the Generator Manual.
Out voltage low The input wiring of A,B,C are not correct. Please refer to Figure 2 ~ Figure 5.
Check the external potentiometer. Check wiring and potentiometer.
Under frequency. Please refer to the Generator Manual.
The exciter does not match the AVR. Please refer to the Generator Manual.
The voltage / frequency selector setting Please refer to Figure 7.
is not correct.
Fuse blown The exciter flash is too large or wiring Please refer to the Generator Manual.
doesn’t connect well. Please refer to Figure 2 ~ Figure 5.
Out voltage high A,C terminals are not connect or wiring Please refer to Figure 2 ~ Figure 5.
incorrect.
The voltage / frequency selector setting Please refer to Figure 7.
is not correct.
Out voltage instable Stability Adjustment doesn’t adjust well. Please refer to the section introduction of
Adjustment.

P.S. Please use the fuse of the original plant.

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EA05A 3
6. FIGURE AND SIZE

N
R
S G
T
~

Field

U/F
220V/50HZ
ON
STABILITY
C B A F+ F-
12 3 Volt /
VOLTS
Frequency

123
ON
Selector
220V/60HZ
UFOR ON
DIP

12 3
1000 OHM
EXT. VR

U/F STAB VOLT UFRO

DIP

Figure 1 Figure 2

N N
R R
S G S G
T
~ T
~

Field Field

220V/50HZ 380V/50HZ
ON ON
C B A F+ F- C B A F+ F-
123 Volt / 123 Volt /
Frequency Frequency
123

123
ON

ON

Selector Selector
220V/60HZ 380V/60HZ
ON ON

12 3 12 3
1000 OHM 1000 OHM
EXT. VR EXT. VR

U/F STAB VOLT UFRO U/F STAB VOLT UFRO

DIP DIP

Figure 3 Figure 4

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4 EA05A
 N Field
R
S G
T
~ 3~5 OHM SWITCH

DIODE

BATT.
Field

440V/50HZ
ON
C B A F+ F- C B A F+ F-
123 Volt / Volt /
Frequency

123
Frequency
123

ON
ON

Selector Selector
440V/60HZ
ON

123 1000 OHM

1000 OHM
EXT. VR EXT. VR

U/F STAB VOLT UFRO U/F STAB VOLT UFRO

DIP DIP

Figure 5 Flash with Battery

Figure 6

220V/50HZ 220V/60HZ 380V/50HZ 380V/60HZ 440V/50HZ 440V/60HZ

ON ON ON ON ON ON

12 3 12 3 12 3 12 3 12 3 12 3

Figure 7

120 120
GENERATOR OUTPUT VOLTAGE

GENERATOR OUTPUT VOLTAGE

100 100
( % OF MONINAL)

( % OF MONINAL)

80 80
50HZ
60HZ

60 60

40 40

20 20

0 10 20 30 40 50 60 0
1 2
FREQUENCY (HZ) SOFT START (V/Sec)

Frequency Compensation Curves Soft Start Curve

Figure 8 Figure 9

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EA05A 5