CONFIDENTIAL INFORMATION

of Basler Electric, Highland, IL. It is loaned forconfidential use, subject to return on request, andwith the mutual understanding that it will not beused in any manner detrimental to the interest ofBasler Electric.

Publication:

9 1687 00 991

© 1997-2000, Basler Electric, Highland, IL 62249First Printing November 1986

Revision E June 2000ECO: 9609

INSTRUCTION MANUALFOR

VOLTAGE REGULATORModel: APR 63-5

BASLER ELECTRIC, BOX 269, HIGHLAND, IL 62249 PHONE 618/654-2341 FAX 618/654-2351

INTRODUCTION

The Basler APR 63-5 Voltage Regulator is aCSA/UL approved unit contained in an encap-sulated plastic case. The regulator controlsthe dc exciter field power of conventional, 50or 60 hertz brushless generators that have a63 Vdc field to regulate the output voltage.

Regulation is provided by sensing the genera-tor output voltage, converting it to a dc signaland comparing the signal to a reference volt-age signal. An error signal is developed andused to control the dc field power in order tomaintain a constant generator output.

SPECIFICATIONS

Certification: UL Listed, CSA Certified

DC Output Power: 5.0 Adc @ 63 Vdc (315W) maximum continuous, 8.5 Adc @ 105 Vdc(893 W) one minute forcing.

Exciter Field DC Resistance: 12.6 ohms mini-mum, 100 ohms maximum.

AC Input Power: 190 to 277 Vac ±10%, single-phase, 50/60 Hz. Burden: 650 VA.

AC Sensing Input: 190 to 240 Vac (240 Vtap), 380 to 480 Vac (480 V tap), single-phase,50/60 Hz. Burden: 5 VA maximum.

Voltage Adjust Range (Internal):170 to 264Vac (240 V tap) or 340 to 528 Vac (480 V tap).

External Voltage Adjust Rheostat: 1,000ohms, 2 W (supplied as an optional item).

Voltage Build-Up: Internal and automatic fromgenerator residual voltage (6 Vac minimum).

Overexcitation Shutdown: Output power re-moved under the following conditions: Exciterfield voltage exceeds 100 ±5 Vdc for a timeinversely proportional to voltage magnitude,or instantaneously if voltage exceeds 135 ±5Vdc.

Operating Temperature: –40°C (–40°F) to+60°C (+140°F).

Storage Temperature: –65°C (–85°F) to+85°C (+185°F)

FUSES

Install 5 A, 250 V, high interrupting capacity,fast-blowing fuses in lines 3 and 4. See inter-connection diagrams.

MOUNTING

The regulator may be mounted in any position.Refer to the outline drawing for dimensions.The regulator may be mounted directly on thegenerator set using ¼” hardware. Select theproper hardware to withstand any expectedshipping or transportation conditions.

C O M

6 0HZ

5 0HZ

CB-

C B +

F-

F+

4

6

7

3

2 4 0

4 8 0

F R E Q

S T A B

V O L T

R

Basler E lect r icHigh land, I l l ino is

S O L I D - S T A T E

V O L T A G E R E G U L A T O R

Power: 190-277 Vac650VA

Sensing: 240, 480 Vac

Output: 63 Vdc 5AOper. Freq. 50/60 Hz

M o d e l : A P R 6 3 - 5

R4.75(121)

5.66(144)

0.45(12)

0.90(23)

1.58(40)

3.16 (80)

1.35(34)

1.68 (43)

NOTE: ALL DIMENSIONS ARE IN INCHES (MILLIMETERS)

11-18-97D2717-07

APR 63-5 Outline Diagram

0.53(13.49)

0 .81(20.64)

0 .125(3.18)

0 .25(6.35)

NOTE: ALL D IMENSIONS ARE IN INCHES (MILL IMETERS)

0 .625(15.88)

0 .625(15.88)

1 .094(27.78)

06-06-00

D2717-08.vsd

0 .375(9.53)

External Voltage Adjust Potentiometer(Optional), Basler P/N 17727

00

10 20 30 40 50 60

20

40

60

80

100

120

FREQUENCY (HZ. )

(% F

RO

M N

OM

INA

L)

GE

NE

RA

TO

R O

UT

PU

T

" C O R N E R F R E Q U E N C Y "

60H Z

50H Z

D2717-0511-18-97

Frequency Compensation Curves

OVEREXCITATION SHUTDOWN

If the exciter field voltage exceeds 100 ±5 Vdc,the regulator automatically removes the fieldcurrent after a time delay. The time delay isinversely proportional to the magnitude of thedetected overvoltage condition. At approxi-mately 135 ±5 Vdc, the field voltage is removedinstantaneously. Refer to the following figure.

Upon detection of overexcitation and the re-sulting field voltage shutdown, the regulatorwill not reset or return to an operational condi-tion until the generator output drops to lessthan 6 Vac for 10 seconds minimum.

TIM

E D

ELA

Y (

SE

CO

ND

S)

F IELD VOLTS (dc)

1

2

34568

10

20

3040506080

100

70

200

300400500

80 90 100 110 120 130 140 150

135 5+-1 1 - 1 8 - 9 7D 2 7 1 7 - 0 6

Typical Inverse TimeDelay Characteristic Curves

REGULATOR CONTROLS

FREQ CONTROL

This control prevents generator and regulatordamage by dropping the generator output volt-age when the generator frequency drops.

a. Set generator RPM to desired frequencyroll-off.

b. Adjust FREQ control until voltage startsto drop off.

c. Speed up generator to rated speed. Volt-age should be at nominal.

STAB CONTROL

This control allows the generator responsetime (and thus voltage stability) to be adjusted.Use an oscilloscope or other voltage record-ing device to set this control.

a. Rotation of STAB control CW will slowvoltage response time.

b. Rotation of STAB control CCW will speedresponse time. If rotated too far, genera-tor voltage will hunt (oscillate).

c. Rotate STAB control CW just past pointwhere voltage oscillation occurs.

VOLT CONTROL

Rotation of VOLT control CW will increase gen-erator output voltage.

Removing jumper (terminals 6 and 7) and con-necting external potentiometer (1,000 ohms,2 watts) allows a ±10% adjustment of voltagerange with nominal set by VOLT control.

INTERCONNECTION

Refer to the following interconnection dia-grams.

a. Connect the jumper from COM to eitherthe 50 Hz or 60 Hz terminal dependingupon the generator frequency.

b. Remove the jumper and connect termi-nals CB– and CB+ to the CBS 305 inputs(if used). If the CBS 305 is not being used,leave the jumper in place.

c. If an external voltage adjust control isbeing used, connect the potentiometer toterminals 6 and 7 as shown. If not, con-nect a jumper between terminals 6 and 7.

d. Connect the exciter field to terminals F+and F–. Be sure to observe polarity.

e. Connect the input power to the genera-tor stator to provide power to terminals 3and 4. Fuse both leads. Install the op-tional shutdown switch, if desired.

f. Connect the sensing input to either 240or 480 depending on voltage. The sens-ing should be connected line-to-line.

4802403764F+F-CB+CB-50

COM60

APR 63-5VOLTAGE REGULATOR

}

3

TO CBS 305(OPTIONAL)

C W

EXTERNALVOLTAGEADJUST

FIELD

A

B

C

22

GEN

1

250V, 5A, FAST BLOWING,HIGH INTERRUPTINGCAPACITY FUSES.

REMOVE JUMPER IFCBS 305 IS USED.

JUMPER FOR 60HZOR 50HZ.

1 2

3

SHUTDOWNSWITCH

HZHZ

11-18-97D2717 -09

4

TERMINAL 6 TO TERMINAL 7.IS NOT BEING USED, JUMPERIF EXTERNAL ADJUST RHEOSTAT

4

240 Vac, 1-Phase Interconnection Diagram

4802403764F+F-CB+CB-50

COM60

APR 63-5VOLTAGE REGULATOR

}

3

TO CBS 305(OPTIONAL)

C W

EXTERNALVOLTAGEADJUST

FIELD

A

B

C

N

22

480VGEN

1

250V, 5A, FAST BLOWING,HIGH INTERRUPTINGCAPACITY FUSES.

REMOVE JUMPER IFCBS 305 IS USED.

JUMPER FOR 60HZOR 50HZ.

1 2

3

SHUTDOWNSWITCH

HZHZ

11-18-97D2717 -10

4IS NOT BEING USED, JUMPERIF EXTERNAL ADJUST RHEOSTAT

TERMINAL 6 TO TERMINAL 7.

4

480 Vac Interconnection Diagram

4802403764F+F-CB+CB-50

COM60

APR 63-5V O L T A G E R E G U L A T O R

}

3

TO CBS 305(OPTIONAL)

C W

EXTERNALVOLTAGEADJUST

FIELD

A

B

C

22

GEN

1

250V, 5A, FAST BLOW, HIGHINTERRUPTING CAPACITY FUSES.

REMOVE JUMPER IF CBS305 IS USED.

JUMPER FOR 60HZOR 50HZ.

1 2

3

S H U T D O W NS W I T C H

HZHZ

ISOLATIONTRANSFORMER

4E1

3

11-18-97D2717-11

4IS NOT BEING USED, JUMPERIF EXTERNAL ADJUST RHEOSTAT

TERMINAL 6 TO TERMINAL 7.

4

Isolation Transformer Interconnection Diagram

OPERATION

The following system operation proceduresprovide instructions for adjusting the APR 63-5 Voltage Regulator.

CAUTION

Meggers and high potential test equipmentmust not be used. Incorrect use of suchequipment could damage the semiconduc-tors contained in the regulator.

PRELIMINARY SETUP

To prevent damage to the regulator, completethe following steps before proceeding withsystem startup.

a. Verify that the voltage regulator specifi-cation conforms with the generator sys-tem requirements.

b. Ensure that the regulator is correctlyconnected to the generator. See inter-connection diagram.

c. Install fuses per FUSES paragraph.

During periods of prime mover idling, use theexcitation shutdown switch.

SYSTEM STARTUP

a. Start the prime mover and bring it up torated speed. Voltage should build up. If aminimum residual of 6 Vac is not present,perform field flashing.

b. Slowly adjust VOLT control until voltagereaches nominal value. If used, adjustremote voltage adjust to set generatoroutput to exact value desired.

c. Apply and remove load to check stability.Adjust per STAB CONTROL paragraphif voltge is unstable.

d. Reduce generator frequency (speed) to55 Hz (on 60 Hz systems) or 45 Hz (on50Hz systems). Check that generatoroutput decreases from this point. If it doesnot, adjust per FREQ CONTROL para-graph.

ACCESSORY EQUIPMENT

Power Isolation Transformer - BE 18674 001

Parallel Compensation - APM2000 and Cur-rent Transformer

Manual Voltage Control - MVC-300

Current Boost System - CBS305 and CurrentTransformer

OPERATIONAL TEST

a. Connect the test setup as shown belowand apply 240 Vac as shown.

b. Adjust the VOLT control fully CCW. Ob-serve that the lamp is not lit.

c. Adjust the VOLT control fully CW. Ob-serve that the lamp is lit.

d. Adjust the VOLT control until the lampjust goes out.

C O M

60HZ

50HZ

CB-

CB+

F-

F+

4

6

7

3

240

480

F R E Q

S T A B

V O L T

R

Basler Electr icHighland, I l l inois

SOL ID-STATE

V O L T A G E R E G U L A T O R

Power: 190-277 Vac650VA

Sensing: 240, 480 Vac

Output: 63 Vdc 5AOper. Freq. 50/60 Hz

Mode l : APR 63 -5

R

240 VACJ2

J1

J3

10 OHMS

10 W100 W

LIGHT BULB

1 1 - 1 8 - 9 7D 2 7 1 7 - 1 2

Operational Test Setup

FIELD FLASHING

When the regulator is operated with the gen-erator for the first time, the polarity of residualmagnetism may not be correct or the magni-tude may not be enough. If the generator doesnot build up, shut down the prime mover andproceed as follows.

a. With the prime mover at rest, apply a dcsource (not grounded) of not more than48 Vdc to terminals F+ and F– in serieswith a limiting resistor. Use 1 ohm of re-sistance for each volt from the dc sourcewith a power rating of at least 1 watt pervolt.

b. Allow approximately 30 seconds beforeremoving the dc source.

c. Start the prime mover and measure thevoltage at the regulator leads 3 and 4. Ifthe voltage is greater than 6 Vac, voltagebuildup should occur. Repeat flashing ifless than 6 Vac residual is measured.