INSTRUCTION MANUAL

FOR
VOLTAGE REGULATOR Model: DBT63-7
Part Number: 9 3242 00 104

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

INTRODUCTION
This manual provides information concerning the operation and installation of the DBT63-7 Voltage Regulator, 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 QUALIFIED PERSONNEL SHOULD PERFORM THE PROCEDURES PRESENTED IN THIS MANUAL.

CAUTION Meggers and high potential test equipment should be used with extreme care. Incorrect use of such equipment could damage components contained in the device.

DBT 63-7 INTRODUCTION

First Printing: April 1998 Printed in USA 1998, Basler Electric Co., Highland, IL 62249 May 1998

CONFIDENTIAL INFORMATION
OF BASLER ELECTRIC COMPANY, HIGHLAND, IL. IT IS LOANED FOR CONFIDENTIAL USE, SUBJECT TO RETURN ON REQUEST, AND WITH THE MUTUAL UNDERSTANDING THAT IT WILL NOT BE USED IN ANY MANNER DETRIMENTAL TO THE INTEREST OF BASLER ELECTRIC COMPANY.

It is not the intention of this manual to cover all details and variations in equipment, nor does this manual provide data for every possible contingency regarding installation or operation. The availability and design of all features and options are subject to modification without notice. Should further information be required, contact Basler Electric Company, Highland, Illinois.

BASLER ELECTRIC ROUTE 143, BOX 269 HIGHLAND, IL 62249 USA http://www.basler.com, info@basler.com PHONE 618-654-2341
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FAX 618-654-2351

DBT63-7 INTRODUCTION

CONTENTS
SECTION 1 GENERAL INFORMATION.......................................................................... 1-1 General ........................................................................................................ 1-1 Specifications ............................................................................................... 1-1 SECTION 2 INSTALLATION ........................................................................................... 2-1 Mounting ....................................................................................................... 2-1 Interconnection ............................................................................................. 2-2 SECTION 3 OPERATION ................................................................................................ 3-1 General3-1 Preliminary Setup ......................................................................................... 3-1 System Startup ............................................................................................. 3-1 Overexcitation Shutdown.............................................................................. 3-2 Adjustments .................................................................................................. 3-2 Field Flashing......................................................................................... 3-2 Frequency Roll-Off Adjustment.............................................................. 3-2 Stability Adjustment................................................................................ 3-2 Voltage Adjustment ................................................................................ 3-3 Operational Test ........................................................................................... 3-3 SECTION 4 MAINTENANCE ........................................................................................... 4-1 Preventative Maintenance ............................................................................ 4-1 Troubleshooting............................................................................................ 4-1

DBT 63-7 INTRODUCTION

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SECTION 1 GENERAL INFORMATION

GENERAL
The DBT63-7 Voltage Regulator is contained in an encapsulated plastic case. The regulator controls the dc 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 comparing the signal to a reference voltage signal. An error signal is developed and used to control the dc field power in order to maintain a constant generator output.

SPECIFICATIONS
Refer to Table 1-1 for the electrical specifications and to Table 1-2 for the physical specifications of the DBT63-7.

Table 1-1. Electrical Specifications

Output Power (with a 240 Vac Input): Ac Input Power: Ac Sensing Voltage: External Voltage Rheostat: Adjust 7 Adc @ 63 Vdc maximum continuous. 11 Adc @ 100 Vdc forcing for 30 seconds. 180 to 300 Vac, single-phase, 50-180 Hz, <900 VA at 240 Vac. 180-264 Vac, 50/60 Hz; single- or three-phase. A 10K ohm, 2 W, potentiometer . 1%. <1% voltage variation for a 40C (104F) change. Typically <20 mSec; <30 mSec maximum 4 V/Hz, adjustable knee from 45 Hz to 60 Hz. Internal electromagnetic filter (EMI filter). Internal provisions for automatic voltage generator residual voltages as low as 6 Vac. build-up from

Regulation Accuracy: Voltage Drift: Response Time: Frequency Compensation: EMI Suppression: Voltage Build-up: Overexcitation Shutdown:

With input voltage of 240 Vac, trip will occur in greater than 60 sec. when the output voltage is 95 10%. Above 95 Vdc the trip time will be inversely proportional to the voltage. 25 W maximum.

Power Dissipation:

DBT63-7 GENERAL INFORMATION

1-1

Table 1-2. Physical Specifications

Operating and Storage Temperature: Shock: Vibration: -40C (-40F) to +60C (+140F). Withstands up to 15 G's in each of three mutually perpendicular axes. 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.)

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DBT63-7 GENERAL INFORMATION

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

Figure 2-1. DBT63-7 Outline Drawing

DBT63-7 INSTALLATION

2-1

INTERCONNECTION
To 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. For paralleling applications, connect the sensing terminals as shown in Figure 2-4 or 2-5. Refer to the APM 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/PF Controller). f. Short terminals CB+ and CB-. Terminals CB+ and CB- are for connection to CBS 305 (Current Boost System).

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

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

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DBT63-7 INSTALLATION

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

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

DBT63-7 INSTALLATION

2-3

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

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DBT63-7 INSTALLATION

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

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

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

Table 3-1. System Start-up

Procedure 1. Perform the preliminary set-up. 2. Start prime mover and bring up to rated speed. N/A a. Voltage does not build-up. Symptom N/A a. Flash field. b. Troubleshoot. b. Voltage builds up and then decays. 3. Slowly adjust VOLT adjustment or external voltage adjust rheostat until voltage reaches nominal. a. Voltage does not build up to rated value. Troubleshoot. a. Check generator output for shorted or excessive load. b. Troubleshoot. b. Voltage high controllable. 4. Apply and remove load to check stability. and unTroubleshoot. a. Check generator output for shorted or excessive load. b. Check stability of governor system. c. Troubleshoot. 5. Check regulation under normal operating conditions. Poor regulation. a. Check that prime mover is up to speed. b. Check that voltmeter is connected at the same point as the regulator sensing. c. Use an average sensing voltmeter (not an RMS sensing). d. Troubleshoot. Remedy

Generator response too slow or is hunting (oscillating).

DBT63-7 OPERATION

3-1

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

Symptom Generator output voltage does not decrease at desired frequency.

Remedy a. Check that all wiring is in accordance with Section 2. b. Adjust FREQ control.

OVEREXCITATION SHUTDOWN
The overexcitation shutdown is included to remove the regulator output power if the exciter field voltage exceeds 95 10%. After regulator output power is shutdown, the regulator can be reset by decreasing the input voltage to less than 6 Vac for a minimum of 10 seconds. This may be accomplished by stopping the prime mover or by interrupting the regulator input.

ADJUSTMENTS
Field Flashing When the regulator is operated with the generator for the first time, the polarity of the residual magnetism may not be correct or of sufficient magnitude. If the residual voltage at terminals A and C is greater than 6 Vac and voltage build-up has not occurred, replace the regulator. If generator residual voltage is less than 6 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 terminals F1 (positive) and F2 (negative) in series with a limiting resistor. Use one (1) ohm of resistance for each 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 Adjustment The 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 is shown 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.

3-2

DBT63-7 OPERATION

Stability Adjustment An oscilloscope or other voltage recording device should be used if a stability setting is desired that will provide 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 for adjustment of the voltage. The internal VOLT adjustment should be set fully CW for proper operation of the external adjust.

OPERATIONAL TEST
To 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 tested with the generator and regulator operating.

Figure 3-1. Operational Test

DBT63-7 OPERATION 3-3

SECTION 4 MAINTENANCE
PREVENTIVE MAINTENANCE
A periodic inspection should be made of the voltage regulator to ensure that it is clean and free from accumulations of dust and moisture. Be sure that all terminal connections are clean and tight.

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

Table 4-1. Troubleshooting

Symptom Voltage does not build up. Possible Cause a. No voltage or incorrect voltage to power input at terminals A and C. Remedy a. Flash field. b. Verify wiring. c. Check fuses. d. Replace regulator. b. Overexcitation circuit is shutting off regulator. Voltage builds up and then decays. a. Open external voltage adjust rheostat or no connection between terminals 6 and 7. b. Defective regulator. Voltage does not build up to rated value. a. Terminals CB+ and CBare not jumpered. b. Internal or external voltage adjustments are improperly set. c. Faulty regulator. Voltage high and uncontrollable. a. No sensing input. b. Wrong sensing configuration. c. Faulty regulator. Generator response too slow or hunting. a. Improper STAB adjustment. b. Improper governor setting. c. Faulty regulator. Poor regulation. a. Low prime mover speed. Shutdown prime mover then restart. Watch for high voltage. Replace external voltage adjust rheostat or the jumper across terminals 6 and 7. Replace regulator. Install jumper across terminals CB+ and CB-. Adjust VOLT control and/or external voltage adjust rheostat. Replace regulator. Verify wiring. Verify connections to S1 and S2. Replace regulator. Re-adjust STAB adjustment. Adjust governor. Replace regulator. Verify prime mover speed.

DBT63-7 MAINTENANCE

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SECTION 5 MANUAL CHANGE INFORMATION

CHANGES
Substantive changes in this manual to date are summarized in Table 5-1.

Table 5-1. Summary of Changes

Revision A Summary of Changes Added information to the Interconnection procedure in Section 2. Also added new Figures 2-4 and 2-5 to accommodate for the Paralleling Module. Added a new Section 5 Manual Change Information. ECA No. 16730 Date 05-98

DBT63-7 MANUAL CHANGE INFORMATION

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