VR6 IK65

Installation - Adjustment - Troubles hooting Manual

Replaces Caterpillar VR6, Kato K65-1 28

A
Supplied by:

-vF-FLIGHT
www.fl
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SYSTEMS
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CONTENTS:

g h tsystems. co

Phone tech Support: (US/Gnd) 800 4o3 3728 (lntl) 717 932 9900

Installation - Pgs 6-12 Adjustment - Pgs 13-18 Troubleshooting - Pgs 19-20

lnstallation
Mounting
The reguiator nray be mounted in any position. Refer to Figure 1 for overall dimensions. The regulator may be mounted directly on the generator set using UNF 1/4-20 or equivalent hardware. Select the proper hardware to withstand any expected shippingitransportation and

operating conditions.

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s.438

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Figure 1: Outline drawing
Page 6

Connections
Before connecting the K65-128 and K125-108 into;,6111 system^ revierv the terminal descriptions provided in Table 3, the internal adjustments provided in Table 4, and the typical interconnection diagrams shown in Figures 2-6.

Terminal number
Upper Terminal Strip CH GND
a L

Terminal description

Chassis ground connection Auxiliary input from var power facior controller Auxiliary input from var power factor controller

Connect to 7 to use internal voltage adjusi, no connection for external voltage adjust
'l A current transformer

5a

5 A curreni transformer

Current transformer common

6a
7

Common connection for selectable features Connect Remote Adjust from 7 to 6a, connect to 4 for internal voltage adjust Connect to 6a to select 1vlHz underfrequency slope {Not 810-34334-00)
Connect to 6a to select 3 phase sensing

I
Lower Terminal Strip

zu
22 24

Phase C sensing input

Phase A sensing input

Phase B sensing input 3-phase power input

28
?n
F1

1-phase or 3-phase power input 1-phase or 3-phase power input

Field + Field Table 3: Terminal descriptions

F2

Adjustment
DRP FAC CAL

Adj ustment description

Voltage droop adjust

FAC CAL is a factory voltage adjust range calibration. No customer adjustment is required.

VLTADJ

Multiturn voltage adjust

Underfrequency knee adjust (Not Stability adjust
Table 4: Internal adjustments
81

iltr
STB

0-34334-00)

PageT

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

A.CCcr).

V/HZ CONNECTION

IS SHOWN).

IF EL,VAR/PF,DSLCAND/OR

BE3-25A ARE NOT USED,JUMPER 2TO 3-

10K

tsn

NOTE: REsISTANCE INCREASES TO INCREAsE VOLTAGE

STANDARD

vR476a89 (t) (-) cH GND283026F1F22322242065a5

"
IF POWER IS REMOVED

FROM BE3.25A AFTER SYNCHRONIZING,THE CIRCUIT BETWEEN VRl & VR2 MUST BE CLOSED.

*"

IF POWER sOURCE IS

UNGROUNDED, JUIMPER MUSI

BE TIED FROM 28 TO 24,

PMG POWER

IS

5HOWN.

1 PHASE POWER MAY BE FROM PMG,6ENERATOR, OR OTHER SOURCE.3 PHASE PMG POWER,WHEN AVAILABLE,
USED WITH K65-1 28 ONLY
IS

(REGULATOR

ts r 20 voLT
SENSING ONLY)

52lb (AUX CONTACI

IN CIRCUIT BREAKER) DISABLES SCP.25O WHEN GENERATOR I5 NOT OPERATING IN PARALLEL WITH UTILITY

Figure 2. Regulator connections (three phase)

Page

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

IF EL,VAR/PF, DSLC

coNNEctloN

TO TER/vllNAL 8.

(l x V/Hz coNNEcTloN
2 TO 3.

15

SHowN).

AND/OR BE3.25A ARE NOT USED,JUMPER

r0K ts.n
STANDARD

NOTE:
RESISTANCE INCREASES TO INCREASE VOLTAGE

GND

cH

28 30 26 Fr

i+) (-)
F2

" IF POWER

IS REMOVED

FROi\4 BE3-25A AFTER

SYNCHRONIZING,THE CIRCUIT BETWEEN VRl & VR2 MUST BE CLOSED.

""

IF POWER SOURCE IS

UNGROUNDED, JUMPER MUST

BE TIED FROI\4 28 TO

20,

PMG POWER IS 5HOWN.

PHASE POWER MAY 8E

FROM PI!1G, GENERATOR, OR OTHER SOURCE,3 PHASE PMG POWER,WHEN AVAILABLE, I5

USED WITH

K65.'I28 ONLY

(REGULATOR

ls 120 voLT
SENSING ONLY)

52lb (AUX CONTACT

IN CIRCUIT BREAKER) DISAELES 5CP.25O WHEN GENERATOR
IS NOT OPERATING

IN PARALLEL WITH UTILITY

Figure 3: Regulator connections (single phase)

Page

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

A CCCT).

4 TO 7.

To TERMINAL

8. {1 x

V/HZ CONNECTION

15

SHOWN).

NOTE:

loK tsJ1
STANDARD

RESISTANCE INCRASES TO INCREASE VOLTAGE

GND 28 30 26

F1

F2

"* IF POWER SOURCE 15

UNGROUNDED, JUMPER MUST
BE TIED FROM 28 TO 24.

PMG POWER I5 SHOWN. 1 PHASE POWER MAY BE FROM PMG,GENERATOR,OR OTHER 50URCE.3 PHASE PMG POWER,WHEN AVAILABLE,
USED WITH
IS

K65-]28 ONLY

| (11) PMl

o =
I

t= lo t4
I

ft*'-V
rot,

ttrl er',rz
I {t
PM3

{113Y;[fi; or PMa
\lM2

128 -'t0B

(REGULATOR

ls t20voLT
31

}onr*"otr

.|-*"- t**

SENSING ONLY)
APPLICATIONS PT'S IF

NEEDED

cccl
54,5EC

;}=

SHOWN CONNE FOR A-B.C PHAs

ROTATION. FOR

Ar

ROTATION, REVE
CCCT SECOND,

Figure 4. Regulator connections (simple three phase)

Page 10

lF 1 A.SEC CCCT

15

UsED, CONNECT TO TERMINAL s INSTEAD OF 5a. (VAR/PFC & EL CANNOT BE USED WITH

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

rsrt

NOTE: VOLTAGE ADJUST RESISTANCE INCREAsES TO INCREASE VOLTAGE

STANDARD

A
GND 28 30 26 F1
F2

** IF POWER SOURCE
U

IS

NGROU
BE

DED, J UM PER i\4U57

TIED FROM 28 TO 20.

PMG POWER I5 5HOWN,

1 PHA5E POWER MAY BE

FROM PMG,GENERATOR,OR
OTHER 5OURCE.3 PHASE PMG

POWER,WHEN AVAILABLE,IS
USED WITH K65-1 2B ONLY

(11) PMl

-l ill

>) X

\ (12) PM2 =l ul { | rr:r pw: E Verenrnre

(REGULATOR
15

I20 VOLT

SENSING ONLY)

F2 GI

o
F

: o
I

OB

a(
SHOWN CONNECTED
FOR A-B-C PHASE ROTATION. FOR A-C-B ROTATION, REVERSE CCCT SECONDARY.

Figure 5: Reguiator connections (simple single phase)

Pnno
' -5"

11 il

S ':r 5c
KS,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

Page 12

Operation
General
Table 5 provides system start-up procedures for the K65-128 and

K125-108 voltage regulators. Symploms of problems occuring during starl-up that arise from incorrect regulator adjustmenl and
certain generator system problems that resemble faulty regulation are included together with possible solutions. Simplifying the system by
as rernote adiust potenriometers and other non-essential items can be helpful in the troubleshooting process. Adjustmerrts, optiorls, and an operalional test are inciuded in the paragraphs after the table.

eliminating components, such

Preliminary Setup
To prevent damage to the regulatoE ensure that the regulator has been installed and connected in accordance with the installation procedures before proceeding with the system staft-up.

System Startup Refer to'lable 5 for starting up the svstem

Page 13

Procedure
1. Perform the preliminary set-up. NIA

Symptom
N/A

Remedy

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

Fiash field. (Except with PMG) Remove power for 1 minute to allow the over exciiation circuit to reset Troubleshoot. Troubleshoot. Check generator output for shofted or excessive
load.

b.
c.

b. Voliage builds up and then

decays
3. Slowly adjust VLTADJ

a. a.

or external voltage adjust rheostat untii voltage reaches nominal.

a. Voltage does not build up to rated value

b. Troubleshoot.
b. Voltage high and uncontrollable

a. a.

Troubleshoot Check generator output for shorted or excessive load. Adjust STB with no
t^^l ^^^ti^l rudLr dl-rliilcu.

4. Apply and remove load to

check stabilitv.

Generator response too slow or is hunting (oscillating)

b.

Check stability of governor system.

c. Troubleshoot.
a. b.
5. Check regulation under normal operating Check that prime mover is up to speed. Check that volimeter is connected at the same point as the regulator sensing. Use an average sensing voltmeter (not a RMS sensing). Troubleshoot.

Poor regulation

conditions.

c.
d.

6. Reduce generator frequency. Generator output should decrease from this point"

Generator output voltage does not decrease at desired frequency

a.
b.

Check that allwiring is in accordance with the installation procedures

Adjust UF control.

Table 5. System startup

Page 14

Adjustments
For 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, the polarity of the residual nlagnetism may uot be correct or of sufficient magnitude. If the generator residual voltage is less than 6 Vac for the K65-128 or 12 Vac l-or tire K125-10B al lerminals 26 and 28, shut dor.vn the prime mover and proceed r,vith the follou,ing steps:

Caution: Da nat flash the fietd wik the

generatar in matian. The regulatar may be damaged.

(1) With the prine mover

at rest, apply a DC source (ungroLrnded), of not more than 24 Vdc. to terminals F1 (positive) and F2 (negative; in series lvith a limiting resistor. Use 1 ohm of resistance for each volt from the DC power source with a power rating of least one 1 tvaf[ per oitnr.

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

removing the DC source.

seconds before

(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 reperfbrm.
Frequency roll-off (knee) adjustment {Not on
B

l0-34334-00)

The underfrequenc)' knee can be set for 45 to 60 Hz operation as described 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]

voltagejust returns to the value set in Step 3.

the

(6)

The underfrequency' "knee" is nou' setjust below the nominal operatirrg frequencl,. Further rotation in the CCW direction r.vill lower the frequencS,' at rvhich underfrequenlcy colnpensation begins.

(7) Connecting a jumper from tetminal 8 to terminal 5a will provide an underfiequency slope of 1 X V/Hz. Nct comection to terminal 8 r,vill
resr.rlt

in an underfrequency slope of

2XYlHz.

Page 15

Stabilitlz (STB) adjustment

Use an oscillosoope or other voltage-recording device if an optimal stability setting is desired. Adjust tlie stabilitv setting with tire generator at no 1oad. Good response can be obtained with the following procedure.

(1) Rotation of the STB control in tl"re clockwise (CW) direction will
slorn 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 oscillation
occnrreci.

Voltage lVt.T AD.l) adjusttnent

(1) tnstallation of aiumper

operating range.

across terminals 4 andT allor.r's the intemal VLT ADJ adjusfirrent to vary the generator nominal voltage over the

(2) Rernove

the juraper between terminals 4 and ? and oonnect a 10k otun external voltage adjusl potentiometer asross tetminais 6 and 7 to allow operation ofthe external voltage adjust potentionreter. The internal voltage adjustrrent should be set fully CW for proper operation of the external adjustment.

Gaution: The factary calibratian (FAC CAL)

adjustment is intended far use by factary technicians only. The factory voltage adjust range calibration adjustment can be used if the factory calibration has been disturbed.

Factory voltage adjust range calibration adjustrnent

With the voltage regulator operating on

a generator, adjust the calibration

potentiometer fully ccw and the voltage adjust potentiometer full-v CW. AdjLrst the calibration potentiometer CW until the generator voltage is 144 +1 Vac. Adjust the voltage adjust CCW ancl verif the generator voltage is less than 90 Vac. Tlie unit is calibrated and the calibration potentiometer ca:r be sealed. Parallel droop (DRP) cornpensation Variable parailel droop compensalion levels can be obtained by adjusting the droop potentiometer. CW rotaticn increases the amount af droop for
a given condition.

Options
The K65-128 and the Kl25-l0B may be equipped rvith the follor.ving options to enhance operalional characteristics. Characteristics of these options are defined in the follorving paragraphs: Remote volta*ee adjust Connect a 10k ohrn potentiometer from tenninals 6 to 7, remove the jnmper from terminal 4 ta'/ and adjust tlre inlernal voltage adjust potentiometer filly clockrvise to allow operation of a remote voltage adjust.

Page 16

Excitatiorr disable This option provicles fbr disabling of the excitation system by removal of power from the voltage regulator. A switch removing voltage from terminals 26,28 andlor 30 will remove power. VarlPF control This option allows the K65-128 and the K125-108 to either regulate the volt-arnps reactive ivar) or power lactor rvhile the generator is connected to an infinite or utility bus. The varlPF option (Modei Number SCP250G50 for 50-Hz operation or SCP250G-60 for 60-Hz opration) suppiies a DC signal into the K65-l28 & K125-108 terminals 2 and 3 to regulate to the SCP250 var ot'power factor setting. Manual voltage control This option provides a nranual back-up channel for manually controlling the generator outprt during generator start-up and commissiouing or in the urrlikely event tlrat the voltage regulator should fail. Manual voltage controller models MVC-300 (if exciter field cunent does nof exceed 7 amps) or the MVC-112 arc suitable for use rn'ith the either the K65-12ts
or the Ki25-10B.

Operational Test
To operationally test an-v K65-128 orthe K125-l0I*" perform the

following steps:

a.

Connect the voltage regulator as shorvn by Figure 7, and apply 124

Vac.

b" Adjust the VUII ADJ control filly counterclockwise

Reurlt: Observe that tlie lamp is OFF.

(CCW).

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 while
connected to the generator.

l)ana 17

1*
ohr*

KffiS-tr

3*,

K$ ffiS-t

**

Figure 7: Operationaltest setup

Page

1B

Maintenance
Preventive Maintenance
Inspect the voltage regnlator periodically" to ensure that it is clean and free from accumulations of dust and moisture. Be sure thar all connections are clean and tisht.

Trouhleshooting
ln case of {ailirre or defective operatioti of the unit, Table 6 is provided to aid in the determination of the cause and the possible solution. Simplifying the systern by elirninatir'rg ccllnponents, suclt as remote adjust potentiometers and other non-essential items can be helpfirl in the
troubleshooti
n

g nrocess.

Symptom

Possibie Cause

Remedy

a. Flash field. (except with PMG) a. No voltage or incorrect voltage to power input at terminals 26. 28 or 30
b. Verify wiring.

Voltage does not build

up"

c. Check fuses supplying power.

d. Replace regulator.
b. Overexcitation circuit is shutting off regulator

Shutdown regulator power for 1 minute then restart. Watch for high field
voltaoe. Verify single or three phase sensing is applied b 2A, 22 and/or 24 and verify connection from upper terminal 6a to 9 is correct. Replace regulator.

Voltage builds up and

ihon doc:rrc

a. Single or three phase jumper incorrect b. Defective regulator.

Page 19

a. Single or three phase jumper incorrect

b. Internal or external voltage adjustments are improperly set

Verify single or three phase sensing is applied to 20,22 andlor 24 and verify connection from terminal 6a to I is Adjust VLTADJ control andlor external voltage adjust rheostat. Verify proper connection from 4 to 7 Verify the generator is rotating at the proper frequency. Verify proper adjustment of the underfrequency pot. Replace regulator. a. Jumper terminals 2 and 3. b. Connect va#PF controller or other device to terminals 2 and 3" Install a jumper between terminals 6a

Voltage does not build up to rated value.

c. The regulator is operating on the undeffrequency curve

d. Faulty regulator
e. Terminals 2 and 3 are not jumpered and there is no device connected to these terminals

f. Jumpers are set for stnglephase sensing and three -phase voltage is applied
Voltage does not build up to rated value. (continued) g. Voltage adjust pot not in use and terminals 4 and 7

and 9.

lnstalljumper.

are not jumpered a. No sensing input

Verify wiring. Verify whether single or three phase sensing is applied ta 20,22 andlor 24 and veriiy connection from terminal 6a to I is correct.

Voltage high and

uncontrollable.

b. Single or three phase jumper incorrect

c. Faulty regulator
d. Voltage adjust pot in use and terminals 4 and 7 are still iumpered a. lmproper front panel STB

Replace regulator
Remove jumper Re-adjust front panel STB adjustment, as described in section 3.

Generator response too slow or hunting.

adiustment b. lmproper governor setting c. Faulty regulator. a. Low prime mover speed

Adjust governor. Replace regulator

Verify prime mover speed.

Poor regulation.

b. Faulty regulator

Replace regulator.
Remove the connection .jumper between terminal2S and 20 (singlephase sensing) ar 24 (three-phase sensing)

No specific symptom; random loss of control

Cross-grounding of circuitry

Table 6: Troubleshooting

Page 20