INSTRUCTION MANUALFOR

VOLTAGE REGULATORModel: DBT63-7

Part Number: 9 3242 00 104

Publication Number: 9 3242 00 994Revision: A 05/98

DBT 63-7 INTRODUCTION i

INTRODUCTIONThis manual provides information concerning the operation and installation of the DBT63-7 VoltageRegulator, part number 9 3242 00 104. To accomplish this, the following is provided.

Specifications

Functional Description

Mounting Information

Operation

Maintenance

WARNING!

TO AVOID PERSONAL INJURY OR EQUIPMENT DAMAGE, ONLY QUALIFIEDPERSONNEL SHOULD PERFORM THE PROCEDURES PRESENTED IN THISMANUAL.

CAUTIONMeggers and high potential test equipment should be used with extreme care. Incorrectuse of such equipment could damage components contained in the device.

ii DBT63-7 INTRODUCTION

First Printing: April 1998

Printed in USA

1998, Basler Electric Co., Highland, IL 62249

May 1998

CONFIDENTIAL INFORMATIONOF BASLER ELECTRIC COMPANY, HIGHLAND, IL. IT IS LOANED FORCONFIDENTIAL USE, SUBJECT TO RETURN ON REQUEST, AND WITH THEMUTUAL UNDERSTANDING THAT IT WILL NOT BE USED IN ANY MANNERDETRIMENTAL TO THE INTEREST OF BASLER ELECTRIC COMPANY.

It is not the intention of this manual to cover all details and variations in equipment, nordoes this manual provide data for every possible contingency regarding installation oroperation. The availability and design of all features and options are subject tomodification without notice. Should further information be required, contact Basler ElectricCompany, Highland, Illinois.

BASLER ELECTRICROUTE 143, BOX 269

HIGHLAND, IL 62249 USAhttp://www.basler.com, info@basler.com

PHONE 618-654-2341 FAX 618-654-2351

DBT 63-7 INTRODUCTION iii

CONTENTS

SECTION 1 GENERAL INFORMATION.......................................................................... 1-1

General ........................................................................................................ 1-1Specifications ............................................................................................... 1-1

SECTION 2 INSTALLATION ........................................................................................... 2-1

Mounting....................................................................................................... 2-1Interconnection ............................................................................................. 2-2

SECTION 3 OPERATION ................................................................................................ 3-1

General3-1Preliminary Setup ......................................................................................... 3-1System Startup ............................................................................................. 3-1Overexcitation Shutdown.............................................................................. 3-2Adjustments.................................................................................................. 3-2

Field Flashing......................................................................................... 3-2Frequency Roll-Off Adjustment.............................................................. 3-2Stability Adjustment................................................................................ 3-2Voltage Adjustment ................................................................................ 3-3

Operational Test ........................................................................................... 3-3

SECTION 4 MAINTENANCE ........................................................................................... 4-1

Preventative Maintenance ............................................................................ 4-1Troubleshooting............................................................................................ 4-1

DBT63-7 GENERAL INFORMATION 1-1

SECTION 1 GENERAL INFORMATIONGENERALThe DBT63-7 Voltage Regulator is contained in an encapsulated plastic case. The regulator controls thedc exciter field power of conventional, 50 or 60 Hz brushless generators.

Regulation is provided by sensing the generator output voltage, converting it to a dc signal and comparingthe signal to a reference voltage signal. An error signal is developed and used to control the dc fieldpower in order to maintain a constant generator output.

SPECIFICATIONSRefer to Table 1-1 for the electrical specifications and to Table 1-2 for the physical specifications of theDBT63-7.

Table 1-1. Electrical Specifications

Output Power (with a 240Vac Input):

7 Adc @ 63 Vdc maximum continuous.

11 Adc @ 100 Vdc forcing for 30 seconds.

Ac Input Power: 180 to 300 Vac, single-phase, 50-180 Hz,

1-2 DBT63-7 GENERAL INFORMATION

Table 1-2. Physical Specifications

Operating and StorageTemperature:

-40C (-40F) to +60C (+140F).

Shock: Withstands up to 15 G's in each of three mutually perpendicularaxes.

Vibration: Withstands the following accelerations at the stated frequency:

1.2 G's from 5 to 26 Hz,

0.036" double amplitude from 26 to 53 Hz,

5.0 G's from 53 to 1000 Hz.

Weight: 0.39 kg (0.85 lbs.)

DBT63-7 INSTALLATION 2-1

SECTION 2 INSTALLATIONMOUNTINGThe regulator may be mounted in any position. Refer to the outline drawing (Figure 2-1). The regulatormay be mounted directly on the generator set using 1/4" hardware. Select the proper hardware towithstand any expected shipping/transportation and operating conditions.

Figure 2-1. DBT63-7 Outline Drawing

2-2 DBT63-7 INSTALLATION

INTERCONNECTIONTo connect the DBT63-7, perform the following procedures.

a. Connect exciter field to terminal F1 and F2 as shown. Be sure to observe polarity.

b. For stand alone applications, connect the sensing terminals as shown in Figure 2-2 or 2-3. Forparalleling applications, connect the sensing terminals as shown in Figure 2-4 or 2-5. Refer to theAPM 300 Instruction Manual for paralleling settings and instructions.

c. Connect terminal 6 and 7 to remote voltage adjust, if used. Short if not used.d. Open terminals S1 and S2 for three-phase sensing.

Short terminals S1 and S2 for single-phase sensing.

e. Short terminals AUX and COM. Terminals AUX and COM are for connection to SCP 250G (VAR/PFController).

f. Short terminals CB+ and CB-. Terminals CB+ and CB- are for connection to CBS 305 (Current BoostSystem).

g. Connect terminals 3 and 4 to generator auxiliary winding terminals 1 and 2. (If there are no generatorauxiliary windings available, connect terminals 3 and 4 to the appropriate generator connections toprovide 240 Vac to terminals 3 and 4.)

Figure 2-2. 240 Vac, Single-Phase, Interconnection Diagram

DBT63-7 INSTALLATION 2-3

Figure 2-3. 240 Vac, Three-Phase, Interconnection Diagram

Figure 2-4. 240 Vac, Single-Phase, With Paralleling Module, Interconnection Diagram

2-4 DBT63-7 INSTALLATION

Figure 2-5. 240 Vac, Three-Phase, With Paralleling Module, Interconnection Diagram

DBT63-7 OPERATION 3-1

SECTION 3 OPERATIONGENERALThe below procedures provide instructions for setting up, starting, operating, and adjusting the DBT63-7Voltage Regulator. Symptoms of problems occurring during start-up that result from incorrect regulatoradjustment and certain generator system problems that resemble faulty regulation, are included togetherwith possible solutions.

PRELIMINARY SET-UPTo prevent damage to the regulator, ensure that the regulator has been installed and connected inaccordance with Section 2 before proceeding with system start-up.

SYSTEM START-UPRefer to Table 3-1 for starting up the system.

Table 3-1. System Start-up

Procedure Symptom Remedy

1. Perform the preliminaryset-up.

N/A N/A

2. Start prime mover andbring up to rated speed.

a. Voltage does not build-up. a. Flash field.

b. Troubleshoot.

b. Voltage builds up and thendecays.

Troubleshoot.

3. Slowly adjust VOLT ad-justment or external voltageadjust rheostat until voltagereaches nominal.

a. Voltage does not build upto rated value.

a. Check generator output forshorted or excessive load.

b. Troubleshoot.

b. Voltage high and un-controllable.

Troubleshoot.

4. Apply and remove load tocheck stability.

Generator response too slowor is hunting (oscillating).

a. Check generator output forshorted or excessive load.

b. Check stability of governorsystem.

c. Troubleshoot.

5. Check regulation undernormal operating conditions.

Poor regulation. a. Check that prime mover isup to speed.

b. Check that voltmeter isconnected at the same pointas the regulator sensing.

c. Use an average sensingvoltmeter (not an RMS sen-sing).d. Troubleshoot.

3-2 DBT63-7 OPERATION

Procedure Symptom Remedy

6. Reduce generator fre-quency. Generator outputshould decrease from thispoint.

Generator output voltagedoes not decrease at desiredfrequency.

a. Check that all wiring is inaccordance with Section 2.

b. Adjust FREQ control.

OVEREXCITATION SHUTDOWNThe overexcitation shutdown is included to remove the regulator output power if the exciter field voltageexceeds 95 10%.

After regulator output power is shutdown, the regulator can be reset by decreasing the input voltage toless than 6 Vac for a minimum of 10 seconds. This may be accomplished by stopping the prime mover orby interrupting the regulator input.

ADJUSTMENTS

Field FlashingWhen the regulator is operated with the generator for the first time, the polarity of the residual magnetismmay not be correct or of sufficient magnitude. If the residual voltage at terminals A and C is greater than 6Vac and voltage build-up has not occurred, replace the regulator. If generator residual voltage is less than6 Vac at terminals A and C, shut down the prime mover and proceed with the following steps:

CAUTION

Do not flash the field with the generator in motion. The regulator may be damaged.

(1) With the prime mover at rest, apply a dc source (ungrounded), of not more than 48 Vdc, to terminalsF1 (positive) and F2 (negative) in series with a limiting resistor. Use one (1) ohm of resistance foreach volt from the dc power source with a power rating of least one (1) watt per ohm.

EXAMPLE: If using a 24 Vdc source, use a 24 ohm, 24 watt resistor.

(2) Allow the field to be flashed for approximately ten seconds before removing the dc source.(3) If voltage build-up does not occur after performing steps (1) and (2), verify the polarity of the dc source

used in steps (1) and (2) and re-perform.

Frequency Roll-Off AdjustmentThe underfrequency adjust is factory preset to reduce generator voltage below 47 Hz.To reset the regulator to the factory setting, perform the following procedures. (The procedure for 50 Hz isshown in parenthesis.)(1) Set prime mover speed for a frequency of 60 Hz (50 Hz).(2) Set voltage adjust for a generator voltage of 240 Vac (200 Vac).(3) Set the prime mover speed for a frequency of 57 Hz (47 Hz).(4) Set UNDER FREQUENCY adjust for a generator voltage of 239 Vac (199 Vac).The regulator should be set to factory default condition.

DBT63-7 OPERATION 3-3

Stability AdjustmentAn oscilloscope or other voltage recording device should be used if a stability setting is desired that willprovide the fastest possible voltage response with good generator stability.

(1) Rotation of the front panel STAB control in the clockwise (CW) direction will slow response time.(2) Rotation of the front panel STAB control in the counter-clockwise (CCW) direction will speed response

time. If rotated too far CCW, the generator voltage may oscillate (hunt).(3) Rotate the front panel STAB control CCW until the system starts oscillating and then rotate CW just

past the point where oscillation occurred.

Voltage Adjustment(1) Installation of a jumper across terminals 6 and 7 allows the internal VOLT adjustment to vary the

generator nominal voltage over the operating range.

(2) The 10K ohm external potentiometer may be connected in place of the jumper and will allow foradjustment of the voltage. The internal VOLT adjustment should be set fully CW for proper operationof the external adjust.

OPERATIONAL TESTTo operationally test any DBT63-7, refer to Figure 3-1 and perform the following steps in the order given:

a. Connect the voltage regulator as shown by Figure 3-1 and apply 240 Vac as shown.

b. Adjust the front panel VOLT control fully counter-clockwise (CCW).RESULT: Observe that the lamp does not light.

c. Adjust the front panel VOLT control fully clockwise (CW).RESULT: Observe that the lamp is now lit.

d. Adjust the front panel VOLT control until the lamp just goes out.Regulator operation is satisfactory if the above results are obtained. Stability, however, must be testedwith the generator and regulator operating.

Figure 3-1. Operational Test

DBT63-7 MAINTENANCE 4-1

SECTION 4 MAINTENANCEPREVENTIVE MAINTENANCEA periodic inspection should be made of the voltage regulator to ensure that it is clean and free fromaccumulations of dust and moisture. Be sure that all terminal connections are clean and tight.

TROUBLESHOOTINGIn case of failure/defective operation of the unit, the following table (Table 4-1) is provided to aid in thedetermination of the cause and the possible solution. Note: Fuse is Schurter FSF 0034.1524.

Table 4-1. Troubleshooting

Symptom Possible Cause Remedy

Voltage does not build up. a. No voltage or incorrectvoltage to power input atterminals A and C.

a. Flash field.

b. Verify wiring.

c. Check fuses.

d. Replace regulator.

b. Overexcitation circuit isshutting off regulator.

Shutdown prime mover thenrestart. Watch for high vol-tage.

Voltage builds up and thendecays.

a. Open external voltageadjust rheostat or no con-nection between terminals 6and 7.

Replace external voltageadjust rheostat or the jumperacross terminals 6 and 7.

b. Defective regulator. Replace regulator.

Voltage does not build up torated value.

a. Terminals CB+ and CB-are not jumpered.

Install jumper across ter-minals CB+ and CB-.

b. Internal or external voltageadjustments are improperlyset.

Adjust VOLT control and/orexternal voltage adjustrheostat.

c. Faulty regulator. Replace regulator.

Voltage high and uncontrol-lable.

a. No sensing input. Verify wiring.

b. Wrong sensingconfiguration.

Verify connections to S1 andS2.

c. Faulty regulator. Replace regulator.

Generator response too slowor hunting.

a. Improper STABadjustment.

Re-adjust STAB adjustment.

b. Improper governor setting. Adjust governor.c. Faulty regulator. Replace regulator.

Poor regulation. a. Low prime mover speed. Verify prime mover speed.

DBT63-7 MANUAL CHANGE INFORMATION 5-1

SECTION 5 MANUAL CHANGE INFORMATIONCHANGESSubstantive changes in this manual to date are summarized in Table 5-1.

Table 5-1. Summary of ChangesRevision Summary of Changes ECA

No.Date

A Added information to the Interconnection procedure in Section 2. Alsoadded new Figures 2-4 and 2-5 to accommodate for the ParallelingModule. Added a new Section 5 Manual Change Information.

16730 05-98

IntroductionTable of Contents Section 1 - General InformationSection 2 - InstallationSection 3 - OperationSection 4 - MaintenanceSection 5 - Manual Change Information