VR6B Manual

VR6-B Service Manual
TABLE OF CONTENTS
1 INTRODUCTION.............................................................................................1-3
1.1 MOUNTING........................................................................................................... 1-3

1.2 WIRING................................................................................................................ 1-3
1.3 ADJUSTMENTS:....................................................................................................1-4
1.4 DROOP CIRCUIT:..................................................................................................1-4
2 SPECIFICATIONS..........................................................................................2-1
3 DIMENSIONS:................................................................................................3-1
4 GENERAL INFORMATION............................................................................4-1
4.1 GENERAL OPERATION..........................................................................................4-1

4.2 REGULATOR FUNCTIONS.......................................................................................4-2
4.2.1 SENSING VOLTAGE..........................................................................................4-2
4.2.2 REFERENCE...................................................................................................4-2
4.2.3 COMPARATOR.................................................................................................4-2
4.2.4 KNEE FREQUENCY..........................................................................................4-2
4.2.5 VOLTS/HZ ADJUSTMENT..................................................................................4-2
4.2.6 DROOP..........................................................................................................4-3
4.2.7 STABILITY.......................................................................................................4-3
4.2.8 POWER SUPPLY..............................................................................................4-3
4.2.9 EXCITATION....................................................................................................4-3
4.2.10 OVEREXCITATION PROTECTION......................................................................4-3
4.3 REGULATOR CONNECTIONS..................................................................................4-3
4.3.1 OPTION CONNECTIONS (12):...........................................................................4-5
4.4 REGULATOR ADJUSTMENTS..................................................................................4-5
5 OPTIONS........................................................................................................5-1
5.1 REMOTE VOLTAGE CONTROL................................................................................5-1

5.2 MANUAL VOLTAGE CONTROL................................................................................5-1
5.3 VOLTAGE DROOP CONTROL..................................................................................5-2
5.4 SERIES BOOST.....................................................................................................5-3
6 INSTALLATION..............................................................................................6-1
1
6.1 CONNECTIONS..................................................................................................6-1
6.1.1 TERMINAL DESCRIPTIONS................................................................................6-1
6.2 INTERNAL ADJUSTMENTS......................................................................................6-2
6.3 CONNECTION DIAGRAMS.......................................................................................6-3
7 SYSTEM START-UP AND ADJUSTMENT....................................................7-1
7.1 PRELIMINARY SET-UP......................................................................................7-1

7.2 INITIAL SYSTEM START-UP..............................................................................7-1
7.3 ADJUSTMENTS..................................................................................................7-1
7.3.1 FIELD FLASHING.............................................................................................7-1
7.3.2 KNEE FREQUENCY ADJUSTMENT......................................................................7-1
7.3.3 STABILITY (STB) ADJUSTMENT........................................................................7-2
7.3.4 VOLTAGE (VLT ADJ) ADJUSTMENT...................................................................7-2
7.3.5 FACTORY VOLTAGE ADJUST RANGE CALIBRATION ADJUSTMENT.........................7-2
7.3.6 PARALLEL DROOP (DRP) COMPENSATION.......................................................7-3
8 MAINTENANCE..............................................................................................8-1
8.1 PREVENTIVE MAINTENANCE...................................................................8-1
9 TROUBLESHOOTING PROCEDURES.........................................................9-1
9.1 OPERATIONAL TEST.............................................................................................9-1

9.2 HIGH VOLTAGE TROUBLESHOOTING PROCEDURE...................................................9-1
9.3 LOW VOLTAGE TROUBLESHOOTING PROCEDURES.................................................9-5
9.4 UNSTABLE VOLTAGE TROUBLESHOOTING PROCEDURE...........................................9-9
9.5 REGULATOR TROUBLESHOOTING PROCEDURE.....................................................9-11
9.6 REGULATOR ATTACHMENT TROUBLESHOOTING....................................................9-13
2
1 Introduction
The VR6-B is designed as an improvement to and replacement for the VR3 and
VR3F. It has the same footprint, same functionality and similar wiring to the
VR3(F) with the added benefit of adjustable knee frequency and stability. More
importantly, it is UL508 Recognized, CSA Certified and is in conformity with CE
for electro-magnetic emissions. The droop adjustment is on the VR6-B
eliminating the need for an external circuit. One regulator model works with SE or
PM generators. The following gives those who are familiar with the VR3(F)
operation a brief overview of the similarities and differences between the VR3(F)
and the VR6-B.
1.1 Mounting
The VR6-B mounts in the same space with the same hardware as the VR3(F).
1.2 Wiring
Note: Detailed wiring diagrams are provided later in this manual.
The terminals on the bottom of the VR6-B are the same as those on the VR3(F).
Sensing leads are connected to 20, 22 and 24, PMG leads to 26, 28 and 30, and
F1 and F2 to the exciter field, exactly as they are to the VR3(F). The only
difference is that when using the VR6-B with an SE generator terminal 20 must
be jumpered to terminal 28, terminal 22 to terminal 30, and terminal 24 to
terminal 26. The jumpers come installed for service. These jumpers must be
removed for use with a PM generator.
When using the VR3(F)SE for single phase sensing a jumper is installed from
terminal 20 to terminal 28. This is not necessary on the VR6-B. Single phase
sensing is not available on the VR3(F)PM. The VR6-B provides single-phase
sensing for SE and PM generators. This is done through connections on the top
terminals discussed below.
There are a number of differences in wiring to the terminals on the top of the
VR6-B. The VR6-B is compatible with the Basler Var/PF Controller Model
Number SCP250G-50 for 50 Hz operation or SCP250G-60 for 60 Hz operation.
This is connected on terminals 2 and 3.
When using a remote voltage adjust rheostat with the VR3(F) you remove the
jumper between 4 and 7 and connect the rheostat between terminals 6 and 7.
For internal voltage adjust on the VR3(F) the jumper is in place from terminal 4 to
terminal 7. On the VR6-B the wiring is similar. The difference is that the remote
voltage adjust rheostat is connected between terminals 6A and 7. The jumper
between terminal 4 and terminal 7 is on for internal voltage adjust and removed
for remote, exactly like the VR3(F).
On the VR3(F) the droop current transformer (CT) circuit is connected between
terminal 5 and terminal 6. On the VR6-B the a 1Amp CT is connected between
3
terminal 5 and terminal 6 or a 5Amp CT is connected between terminal 5A and

terminal 6.
On the VR3F a jumper between terminals 6 and 8 selects a 1 volt/hz slope.
When the jumper is removed a 2 volts/hz slope is selected. On the VR6-B a
jumper from terminal 6A to terminal 8 selects a 1 volt/hz slope. Removing the
jumper selects the 2 volts/hz slope. The jumper comes installed for service.
On the VR3F a jumper between terminal 6 and terminal 10 selected 60 Hz
operation. Removing the jumper selected 50 Hz operation. VR6-B does not need
this feature as it has an adjustable knee frequency. It does not have a terminal
10.
On the VR6-B a jumper between terminal 6A and terminal 9 selects three phase
sensing. When the jumper is removed single-phase sensing is selected.
1.3 Adjustments:
Like the VR3(F) the VR6-B has an internal voltage adjust pot. Unlike the VR3(F)
this pot must be turned fully clockwise to use the remote voltage adjust rheostat.
The VR6-B has a knee frequency adjustment pot and a stability pot that must be
adjusted for correct operation. The VR3(F) does not have these features. See the
Adjustment section of this manual for full instructions on how to use these. The
knee frequency pot allows the knee frequency to be adjusted to match the
frequency of the engine. The stability pot allows adjustment to obtain the quickest
possible response to block loading while maintaining voltage stability at steady
state operation.
1.4 Droop Circuit:

With the VR3(F) and DVR, the droop circuit, consisting of a rheostat and
sometimes a burden resistor, is located external to the regulator. This circuit is
internal to the VR6-B. A droop adjustment is on the regulator. A 1Amp or 5Amp
CT is required to use this feature. 10% droop is possible at full operating current
(i.e. 1Amp for a 1Amp CT and 5Amp for a 5Amp CT) and at rated 0.8 PF. The
maximum droop decreases proportionally to the amount of reactive current
available. Therefore it is important to size the droop transformer for the load the
generator is operating at. When using the VR6-B as a service replacement for
the VR3(F), connect the droop transformer directly to the regulator bypassing the
droop rheostat and any burden resistor.
4
2 Specifications
Refer to Table 1-1 for the electrical specifications and to Table 1-2 for the physical
specifications of the VR6-B.
Table 2-1. Electrical Specifications
Output Power (with a 240 Vac 12 Adc @ 65 Vdc maximum continuous.
Input): 25 Adc @ 125 Vdc forcing for 10 seconds.
AC Input Power: 180 to 264 Vac, single-phase or three-phase, 50/60 Hz;
or 63 to 105 Vac, three-phase, 100 to 240 Hz, PMG,
3125 VA maximum; or 240 Vac, single-phase, 100 to 240
Hz, PMG, 3125 VA.
AC Sensing Voltage: 180 to 264 Vac, 50/60 Hz; single- or three-phase.
External Voltage Adjust Rheostat: 10 kohm, 2 W, potentiometer
Regulation Accuracy: 1% of voltage setpoint
Voltage Drift: 1% voltage variation for a 40C (104F) change.
Response Time: < 4 milliseconds
Frequency Compensation: 1 or 2 V/Hz jumper selectable with knee adjustable from
45 Hz to 65 Hz.
EMI Suppression: Internal filter
Voltage Build-Up: Internal provisions for automatic voltage build-up from
generator residual voltages as low as six Vac.
Overexcitation Shutdown: Overexcitation protection starts timing at 90 Vdc 5%
and takes the output to zero in greater than 30 seconds.
The output can be 125 Vdc for greater than 10 seconds.
Droop 1 A or 5 A, <10 VA, Adjustable from 0 to 10% at rated
input current, 0.8 power factor
Power Dissipation: 50 W maximum.
UL Recognized/CSA Certified UL Recognized per Standard 508, UL File NO. E97035.
CSA Certified per Standard CAN/CSA-C22.2 No. 14-95,
CSA File No. LR 23131
Specifications 1
Table 2-2. Physical Specifications

CE Conformity Conforms to:
Radiated Emissions...............EN50081-2
Radiated Immunity:
Electric field....................EN61000-4-3 (10 V/m
Conducted......................EN61000-4-6 (10 VRMS)
Conducted Emissions............EN50081-2 (EN55011, Class A)
ESD Immunity.......................EN50082-2 (4 KV contact, 8 KV
air)
EFT Immunity........................EN50082-2 (2 KV coupling clamp)
Magnetic Immunity................EN50082-2 (30ARMS, 50 Hz)
Safety:...................................EN61010-1
Operating and Storage -40C (-40F) to +70C (+158F).
Temperature:
Shock: Withstands up to 20 g in each of three mutually perpendicular axes.
Vibration: Withstands the following accelerations at the stated frequency:
0.5 g; 18 to 2000 Hz
Weight: Approximately 1.1 kg (2.5 lbs.)
Specifications 2
3 Dimensions:
(In Inches)
.281 DIA. HOLE
(4 PL)
.51 DIA.
(4 PL) .750
2 3 4 5 5a 6 6a 7 8 9
DRP
FAC CAL
VLT ADJ
UF
STB
8.01
7.500
0.438 20 22 24 26 28 30 F1 F2
2.96
5.500 0.438
D2590-23.vsd
0.593 06-08-00
6.01
Dimensions 1
4 General Information
This manual covers the VR6-B voltage regulator, which is used on 4/6 and 10/12
lead, self-excited and permanent magnet generators. The VR6-B is typically
located in the generator terminal box or the generator set marshalling box.
4 T1
7 1
11 T2
T3
5
8
10 6 2
9 Stability
F2 F1 Adjust 22 24 20 5 6 3
Excitation Power Sensing Droop

(V/Hz) Droop Adjust
Control Supply
Overexcitation Level
Comparator Reference Adjust
Protection
UF Knee Adjust
VR6-B
D2590-29.vsd
01-22-00
6A 8
Jumper
1. Generator Lines (3 phase voltage) 4. Main stator 8. Rectifiers
2. Generator lines (sensing voltage 5. Main rotor 9. Generator line (DC excitation voltage)
AC power) 6. Exciter stator 10. Permanent magnet
3. VR6-B regulator 7. Exciter rotor 11. Permanent magnet stator
4.1 General Operation

The voltage regulator (3) keeps the generator output voltage constant with
changing loads. It does this by controlling the DC voltage that is supplied to the
exciter stator (6). The regulator senses the generator voltage through the
generator sensing leads (2) connected at terminals 20, 22 and 24. The sensed
voltage is then compared to a reference voltage. The reference voltage value is
set by the voltage adjust pot on the regulator, or an external voltage adjust
potentiometer.
If the regulator senses a decrease in generator voltage, below the reference
voltage, it will increase DC voltage to the exciter stator (6). This increases the
magnetic field in the exciter stator (6). The increased magnetic field in the exciter
stator increases the AC voltage and current, which is induced in the exciter rotor
General Information 1
(7). This increased three-phase AC voltage from the exciter rotor (7) causes
more AC current to flow. The three-phase ACV is then rectified to DCV by the
three-phase full wave rectifier (8). The increased DC output from the bridge
rectifier is carried to the main rotor (5) by conductors, which are routed through a
passage in the generator shaft. Increased current through the main rotor (5)
increases the magnetic field of the generator. The increased magnetic field
induces a larger AC voltage into the main stator (4). Therefore, the three-phase
AC voltage (1) increases until the voltage regulator no longer senses a
decreased output voltage.
When the voltage regulator senses an increase in output voltage due to a
decrease in load, the regulator will decrease the DC voltage to the exciter. A
decrease in generator voltage will occur due to similar responses to the regulator
sensing a decrease in output voltage, as described above.
4.2 Regulator Functions

4.2.1 Sensing Voltage
This is the average of the three-phase AC voltage at terminals 20, 22 and 24.
The ratio of the sensing voltage to the generator voltage depends on where the
sensing leads are connected to the generator leads and whether power
transformers (PTs) are used
4.2.2 Reference
The reference voltage is set by the voltage adjust pot on the regulator or an
external voltage adjust potentiometer. This is the desired voltage on the sensing
leads at rated frequency.
4.2.3 Comparator
The comparator circuit in the regulator compares the sensed voltage to the
reference voltage. It creates an error signal if they differ and sends this to the
excitation control.
4.2.4 Knee Frequency
The knee frequency is adjusted by the underfrequency knee adjust on the
regulator. Without the knee frequency feature generator voltage would follow
generator frequency proportionally. With the knee frequency adjustment, if the
generator frequency is above the adjusted knee frequency, the regulator
maintains the generator voltage at the reference voltage.
4.2.5 Volts/Hz Adjustment
To assist the engine in recovering quickly during block loading, if the generator
frequency drops below rated, the regulator will regulate the voltage to a lower
reference voltage. The reference voltage is proportional to the generator
frequency. The slope of that proportionality can be chosen as 1 pu V/Hz or 2 pu
V/Hz through a jumper.
4.2.6 Droop
When operating a generator set in parallel with another generator set, it is
necessary that the output voltages match, to prevent circulating currents. Based
on power factor, droop raises or lowers the reference voltage, to evenly match
the generator sets. This results in a slight lowering of the output voltage. The
droop adjustment regulates how much droop is used.
4.2.7 Stability
Because of a time delay from when the regulator senses a change in voltage to
when the generator voltage is increased or decreased, the generator voltage can
become unstable (or hunt). The time delay varies dependent on exciter and
generator time constants. The stability circuit slows the regulator response
enough to stabilize the voltage. The stability adjust is used to ensure the
regulator responds as quickly as possible while still keeping the voltage stable.
4.2.8 Power Supply
The power for the DC voltage supplied to the exciter comes through terminals 26,
28 and 30 as AC voltage. When using a PM generator, the power comes from the
PMG. When using an SE generator the power comes from the generator sensing
lines. The power circuit rectifies this power to the DC voltage and current
needed.
4.2.9 Excitation
The excitation control adjusts the DC output voltage to the exciter based on the
error signal it receives from the comparator.
4.2.10 Overexcitation Protection
If the reference and comparator circuit ask the excitation control for more DC
excitation voltage than it is rated for a defined period of time, the overexcitation
control will shut the regulator off and it will provide no DC excitation voltage. The
generator set must be turned off for the regulator to reset.
4.3 Regulator Connections
VR6 Regulator
(12) Terminal Strip for Attachments
(13) Droop Adjustment
(14) Factory Voltage Adjust Range Calculation
(15) Voltage Adjust
(16) Knee Frequency Adjust
(17) Stability Adjust
(18) Terminal Strip for Sensing and Power
VR6-B voltage regulator can operate in three-phase sensing or single-phase

sensing mode. For three-phase sensing terminal 6A is connected with a jumper
to terminal 9 (12). For single-phase sensing the jumper is removed. Sensing
leads (2) are connected at terminals 20, 22 and 24 (18) for three-phase sensing
and terminals 20 and 22 for single-phase sensing.
Note: VR6-B regulators are sensitive to A-B-C phase rotation. Connections

should be T1 to 22, T2 to 24 and T3 to 20. Incorrect connections can result
in high circulating currents during parallel operation.
Note: Rated sensing voltage for the VR6-B is 240VAC for 60Hz systems and
200VAC for 50 Hz systems. The sensing voltage can be adjusted +10% or 25%.
Generator taps, sensing lead connection to midpoint generator connections or
PTs must be used to step generator voltage down to regulator range when
generator has a different operating voltage.
On PM generators, leads from PMG (11) are connected to terminals 26, 28 and
30 (18) and provide power to the regulator. On SE generators, terminal 20 is
jumpered to 28, terminal 22 to 30, and terminal 24 to 26. The sensing leads
provide the power.
4.3.1 Option Connections (12):

1. The Var/PF Controller is connected at terminals 2 and 3. Terminals 2 and 3
are jumpered if no Var/PF Controller is used.
2. Terminals 4 and 7 are jumpered if internal voltage adjust is being used. If an
external voltage adjust potentiometer is used this jumper is removed.
3. If a 1 Amp droop current transformer (CT) is used, it is connected between
terminals 5 and 6. If instead, a 5 Amp CT is used, it is connected between
terminals 5A and 6.
4. An external voltage adjust potentiometer is connected between terminals 6A
and 7. If this is used the jumper between terminal 4 and terminal 7 must be
removed.
5. Terminals 6A and 8 are connected for a 1pu V/Hz underfrequency slope. They
are left unconnected for a 2pu V/Hz underfrequency slope.
6. Terminals 6A and 9 are connected for three-phase sensing. They are left
unconnected for single-phase sensing.
4.4 Regulator Adjustments

There are 5 adjustments on the VR6-B. They are:
1. Droop Adjustment (13),
2. Factory Voltage Adjust Range Calibration (14) Not to be adjusted by
customer,
3. Voltage Adjustment (15),
4. Knee Frequency Adjustment (16),
5. Stability Adjustment (17).
See Set-up and Adjustment Section for detailed instructions on how to use these.
The excitation system can be disabled by removal of power from the VR6-B. A
switch removing voltage from terminals 26, 28 and/or 30 will remove power.
5 Options
5.1 Remote Voltage Control

Generator output voltage level can be controlled from a remote location. This is
done by connecting a 10K potentiometer between terminals 6A and 7 on the
voltage regulator, and removing the jumper between terminals 4 and 7. (See
installation section for detailed wiring schematics). This is standard on Caterpillar
Generator Sets with Control Panels.
For an acceptable voltage control, the remote mounted potentiometer must be
10K +5% with three turns and a dielectric strength of 1000 VAC minimum.
The terminals of the remote mounted potentiometer are fragile. The wiring, which
is connected to remote mounted potentiometer, should not have a diameter
larger than 18 gauge. Larger diameter wire is not recommended. The wire should
be 600 volt class with 90oC (194oF) insulation. When mounting remote
potentiometer a long distance from generator set it may be necessary to used
shielded cable to insulate signal against noise.
5.2 Manual Voltage Control
Options 1
The Manual Voltage Control can be used to control generator voltage when there
is a failure in the generator regulator assembly. The manual voltage control will
manually control the current flow to the exciter stator.
The manual voltage control panel has switch (1) and voltage control (2) for the
manual-operating mode. Switch (1) is used to make the selection between
AUTO, MAN and OFF. In the AUTO position, the VR6-B regulator controls the
generator voltage. In the OFF position, the voltage will go to zero. In the MAN
position, generator voltage is controlled by voltage control rheostat (2).
Note: The manual voltage control panel must not be installed in a location that is
subject to engine vibrations or to outside weather.
Note: When the manual voltage control is operating in the manual mode, it is not
necessary for the VR6-B regulator to be connected to the generator. However,
the manual control must remain connected to the generator sensing lines.
Refer to installation diagrams in installation section for detailed connection

schematics.
5.3 Voltage Droop Control

(Put in graphic from installation diagrams similar to the following for the VR3)
Note: Refer to installation diagrams in installation section for detailed schematics

on droop circuit connection. Refer to system set-up and adjustments section for
adjustment information.
Options 2
When generators operate in parallel there are two primary objectives. First, the
generators share the real power requirements of the electrical load. The
generators also share the reactive power requirements of the electrical load. The
engine governors will control sharing of the real power requirements (kW) and
the voltage regulator will control sharing of the reactive power requirements
(kVAR) of the total system load. Occasionally, one generator output voltage is
slightly higher than the other generators. This will supply lagging reactive current
to the other generators that are connected in the group. The lagging reactive
current will circulate between generators. This could possibly cause ampere
overloading. In order to minimize ampere overloading, an individual generators
output voltage droops in proportion to the lagging reactive current flow. The
reactive current flow is measured with a current transformer.
As reactive lagging generator output current increases, the regulator will cause
the output voltage to lower proportionally. If the measured reactive current is
leading, the output voltage will rise. In either case, this action will tend to reduce
the reactive current for better kVAR sharing with other units.
The following items are required in order to provide the voltage droop function:
1Amp or 5 Amp droop transformer (CT1) (1) and wiring harness. The transformer
senses load current in lead T2 (2) of 4/6 lead generators or in lead T8 of 10/12
lead generators. The droop adjustment on the VR6-B provides adjustment of the
droop voltage.
Transformer CT1 and wiring harness are standard on some generators and an
attachment on other generators.
Note: At full rated CT current (1 Amp or 5Amp) the droop adjustment is up to
10%. As the CT current decreases the amount of droop adjustment decreases
proportionally. It is important to size the CT correctly for the load the generator
will be carrying.
5.4 Series Boost
Options 3
6 Installation
The VR6 is typically mounted in the generator terminal box or the generator set
marshalling box. See specific generator set drawings for exact location.
6.1 CONNECTIONS
Before connecting the VR6-B into your system, review the terminal descriptions
provided in Table 6-1, the internal adjustments provided in Table 6-2, and the
typical interconnection diagrams shown in Figures 6-1 through 6-18. When
automatic voltage regulation is used with a permanent magnetic excited
generator, ensure that the jumpers are removed between terminals 20 - 28,
22 - 30, and 24 26.
6.1.1 Terminal Descriptions
Table 6-1. Terminal Descriptions
Terminal Number Terminal Description
Upper Terminal Strip
2 Auxiliary Input from var Power Factor Controller
3 Auxiliary Input from var Power Factor
Controller
4 Connect to 7 to use internal voltage adjust, no
connection for external voltage adjust
5 1 Amp Current Transformer
5a 5 Amp Current Transformer
6 Current Transformer Common
6a Common connection for selectable features
7 Connect Remote Adjust from 7 to 6a,
connect to 4 for internal voltage adjust
8 Connect to 6a to select 1v/Hz
underfrequency slope
9 Connect to 6a to select 3 phase sensing
Lower Terminal Strip
20 Phase C sensing input
22 Phase A sensing input
24 Phase B sensing input
26 3-phase power input
28 1-phase or 3-phase power input
30 1-phase or 3-phase power input
F1 Field +
F2 Field -
Installation 1
6.2 Internal Adjustments
Table 6-2. Internal Adjustments

Adjustment Adjustment Description
DRP Voltage Droop Adjust
FAC CAL FAC CAL is a factory voltage adjust range
calibration. No customer adjustment is
required.
VLT ADJ Multi-turn Voltage Adjust
UF Underfrequency Knee Adjust
STB Stability Adjust
Installation 2
6.3 Connection Diagrams

10K
T1 T2 T3
R2
T0 T8 2
T1
3 1
2 3 4 5 5a 6 6a 7 8 9
VR6-B
L3
CR8
CR7
CR1 CR4
RFA
CR2 CR5
CR3 CR6 20 22 24 26 28 30 F1F2

E1 E2
R5
L2
L1
ABC 10 AMP
L5
S N
M ABC 10 AMP
CR1-6 ROTATING RECTIFIERS 1 CONNECT TO TERMINAL 5 FOR 1 AMP CT,

CR7,8 SURGE SUPPRESSION DIODES CONNECT TO TERMINAL 5a FOR 5 AMP CT.
E1 POSITIVE HEAT SINK
E2 NEGATIVE HEAT SINK 2 CONNECT REMOTE VOLTAGE ADJUST FROM 6a TO
L1 EXCITER FIELD (STATOR) 7 AND REMOVE LINK 4-7 IF FITTED WITH A
L2 EXCITER ARMATURE (ROTOR) REMOTE ADJUST.
L3 ROTATING FIELD (MAIN ROTOR)
L4 STATOR (MAIN STATOR) CONNECT 6a TO 8 FOR 1V/Hz; REMOVE FOR
L5 PM EXCITER STATOR 2V/Hz UNDERFREQUENCY SLOPE.
M ROTATING PERMANENT MAGNET CONNECT 6a TO 9 FOR 3-PHASE SENSING;
R2 REMOTE LEVEL RHEOSTAT OPEN FOR 1-PHASE SENSING.
R5 SUPPRESSION RESISTOR
RFA REVOLVING FIELD ASSY
T1 VOLTAGE DROOP TRANSFORMER 3 CONNECT 2 AND 3 TO SCP250 VAR/PF
(MAY NOT BE SUPPLIED) CONTROLLER. SHORT WHEN NOT USED.
D2590-11.vsd
06-08-00
Figure 6-1 10-12 Lead, PMG, Single-Phase Sensing
Installation 3
10K
T1 T2 T3
R2
T0 T8 2
T1
3 1
2 3 4 5 5a 6 6a 7 8 9
VR6-B
L3
CR8
CR7
CR1 CR4
RFA
CR2 CR5
CR3 CR6
20 22 24 26 28 30 F1 F2
E1 E2
R5
L2
L1
ABC 10 AMP
L5
S N
M ABC 10 AMP
1
CR1-6 ROTATING RECTIFIERS CONNECT TO TERMINAL 5 FOR 1 AMP CT,
CR7,8 SURGE SUPPRESSION CONNECT TO TERMINAL 5a FOR 5 AMP CT.
DIODES
E2 NEGATIVE HEAT SINK 2 CONNECT REMOTE VOLTAGE ADJUST FROM 6a
L1 EXCITER FIELD (STATOR) 7 AND REMOVE LINK 4-7 IF FITTED
TO
L2 EXCITER ARMATURE (ROTOR) WITH
REMOTEA ADJUST.
L3 ROTATING FIELD (MAIN
ROTOR)
T1 VOLTAGE DROOP 3
CONNECT 2 AND 3 TO SCP250 VAR/PF
TRANSFORMER
D2590-12.vsd
06-08-00
Figure 6-2 10-12 Lead, PMG, Three-Phase Sensing
Installation 4
10K
T1 T2 T3
R2
T0 T8 2
T1
3 1
2 3 4 5 5a 6 6a 7 8 9
VR6-B
L3
CR8
CR7
CR1 CR4
RFA
CR2 CR5
CR3 CR6
20 22 24 26 28 30 F1 F2
E1 E2
R5
L2
L1
KTK-12
KTK-12

D2590-13.vsd
06-08-00
Figure 6-3 10-12 Lead, Shunt Excited, Single-Phase Sensing
Installation 5
10K
T1 T2 T3
R2
T0 T8 2
T1
3 1
2 3 4 5 5a 6 6a 7 8 9
VR6-B
L3
CR8
CR7
CR1 CR4
RFA
CR2 CR5
CR3 CR6
20 22 24 26 28 30 F1 F2
E1 E2
R5
L2
L1
KTK-12
KTK-12
KTK-12
1
DIODES
L1 EXCITER FIELD (STATOR) TO
7 AND REMOVE LINK 4-7 IF FITTED WITH
L2 EXCITER ARMATURE (ROTOR) A
REMOTE ADJUST.
ROTOR)
T1 VOLTAGE DROOP 3
TRANSFORMER
D2590-14.vsd
06-08-00
Figure 6-4 10-12 Lead, Shunt Excited, Three-Phase Sensing
Installation 6
10K
T1 T2 T3
R2
T5 T6 2
T4
T1
3 1
2 3 4 5 5a 6 6a 7 8 9
VR6-B
L3
CR8
CR7
CR1 CR4
RFA
CR2 CR5
CR3 CR6
20 22 24 26 28 30 F1 F2
E1 E2
R5
L2
L1
ABC 10 AMP
L5
S N
M ABC 10 AMP

D2590-15.vsd
06-08-00
Figure 6-5 4-6 Lead, PMG, Single-Phase Sensing
Installation 7
10K
T1 T2 T3
R2
T5 T6 2
T4
T1
3 1
2 3 4 5 5a 6 6a 7 8 9
VR6-B
L3
CR8
CR7
CR1 CR4
RFA
CR2 CR5
CR3 CR6
20 22 24 26 28 30 F1 F2
E1 E2
R5
L2
L1
ABC 10 AMP
L5
S N
M ABC 10 AMP
1
DIODES
REMOTE ADJUST.
ROTOR)
T1 VOLTAGE DROOP 3
TRANSFORMER
D2590-16.vsd
06-08-00
Figure 6-6 4-6 Lead, PMG, Three-Phase Sensing
Installation 8
10K
T1 T2 T3
R2
T5 T6 2
T4
T1
3 1
2 3 4 5 5a 6 6a 7 8 9
VR6-B
L3
CR8
CR7
CR1 CR4
RFA
CR2 CR5
CR3 CR6
20 22 24 26 28 30 F1 F2
E1 E2
R5
L2
L1
KTK-12
KTK-12

D2590-17.vsd
06-08-00
Figure 6-7 4-6 Lead, Shunt Excited, Single-Phase Sensing
Installation 9
10K
T1 T2 T3
R2
T5 T6 2
T4
T1
3 1
2 3 4 5 5a 6 6a 7 8 9
VR6-B
L3
CR8
CR7
CR1 CR4
RFA
CR2 CR5
CR3 CR6
20 22 24 26 28 30 F1 F2
E1 E2
R5
L2
L1
KTK-12
KTK-12
KTK-12
1
DIODES
REMOTE ADJUST.
ROTOR)
T1 VOLTAGE DROOP 3
TRANSFORMER
D2590-18.vsd
06-08-00
Figure 6-8 4-6 Lead, Shunt Excited, Three-Phase Sensing
Installation 10
10K
T1 T2 T3
R2
T5 T6 2
T4
T1
3 1
2 3 4 5 5a 6 6a 7 8 9
4
VR6-B
L3
CR8
CR7
CR1 CR4
RFA
CR2 CR5
CR3 CR6 20 22 24 26 28 30 F1 F2
E1 E2
R5
L2
L1
ABC 10 AMP
L5
S N
M ABC 10 AMP
CR1-6 ROTATING RECTIFIERS
CR7,8 SURGE SUPPRESSION DIODES 1 CONNECT TO TERMINAL 5 FOR 1 AMP CT,
E1 POSITIVE HEAT SINK CONNECT TO TERMINAL 5a FOR 5 AMP CT.
L1 EXCITER FIELD (STATOR)
7 AND REMOVE LINK 4-7 IF FITTED WITH A REMOTE ADJUST.
L2 EXCITER ARMATURE (ROTOR)
CONNECT 6a TO 8 FOR 1V/Hz; REMOVE FOR
2V/Hz UNDERFREQUENCY SLOPE.
L4 STATOR (MAIN STATOR)
L5 PM EXCITER STATOR CONNECT 6a TO 9 FOR 3-PHASE SENSING;
M ROTATING PERMANENT MAGNET OPEN FOR 1-PHASE SENSING.
R2 REMOTE LEVEL RHEOSTAT 3 CONNECT 2 AND 3 TO SCP250 VAR/PF
CONTROLLER. SHORT WHEN NOT USED.
3-PHASE VOLTAGE SENSING LEADS - CONNECT TO
4
(MAY NOT BE SUPPLIED) T1 VOLTAGE DROOP TRANSFORMER 240 VOLT SECONDARY OF METERING TRANSFORMERS.
PHASE RELATION WITH TRANSFORMER T1 IS IMPORTANT
CONNECT TERMINAL 22 TO P.T. ON GENERATOR T1
D2590-19.vsd CONNECT TERMINAL 24 TO P.T. ON GENERATOR T2
06-08-00 CONNECT TERMINAL 20 TO P.T. ON GENERATOR T3
Figure 6-9 Medium Voltage, PMG, Single-Phase Sensing
Installation 11
10K
T1 T2 T3
R2
T5 T6 2
T4
T1
3 1
2 3 4 5 5a 6 6a 7 8 9
VR6-B
L3
CR8
CR7
CR1 CR4
RFA
CR2 CR5
CR3 CR6
20 22 24 26 28 30 F1 F2
E1 E2
R5
L2
L1
ABC 10 AMP
L5
S N
M ABC 10 AMP
CR7,8 SURGE SUPPRESSION 1
CONNECT TO TERMINAL 5 FOR 1 AMP CT,
DIODES
7 AND REMOVE LINK 4-7 IF FITTED WITH A REMOTE
L2 EXCITER ARMATURE (ROTOR) ADJUST.
L3 ROTATING FIELD (MAIN CONNECT 6a TO 8 FOR 1V/Hz; REMOVE FOR
ROTOR) 2V/Hz UNDERFREQUENCY SLOPE.
R2 REMOTE LEVEL RHEOSTAT 3
R5 SUPPRESSION RESISTOR CONTROLLER. SHORT WHEN NOT USED.
4 3-PHASE VOLTAGE SENSING LEADS - CONNECT TO
(MAY NOT BE SUPPLIED)T1 VOLTAGE DROOP 240 VOLT SECONDARY OF METERING TRANSFORMERS.
TRANSFORMER PHASE RELATION WITH TRANSFORMER T1 IS IMPORTANT
Figure 6-10 Medium Voltage, PMG, Three-Phase Sensing
Installation 12
10K
T1 T2 T3
R2
T5 T6 2
T4
T1
3 1
2 3 4 5 5a 6 6a 7 8 9
4
VR6-B
L3
CR8
CR7
CR1 CR4
RFA
CR2 CR5
CR3 CR6
20 22 24 26 28 30 F1 F2
E1 E2
R5
L2
L1
KTK-12
POWER TRANSFORMER KTK-12

DIODES
Figure 6-11 Medium Voltage, Shunt Excited, Single-Phase Sensing
Installation 13
10K
T1 T2 T3
R2
T5 T6 2
T4
T1
3 1
2 3 4 5 5a 6 6a 7 8 9
VR6-B
L3
CR8
CR7
CR1 CR4
RFA
CR2 CR5
CR3 CR6
20 22 24 26 28 30 F1 F2
E1 E2
R5
L2
L1
KTK-12
POWER
TRANSFORMER
KTK-12
KTK-12

DIODES
Figure 6-12 Medium Voltage, Shunt Excited, Three-Phase Sensing
Installation 14
1 1
1 CONNECT TO TERMINAL 5a FOR 5 AMP CT. PF VAR 5 kOHMS
CONNECT REMOTE VOLTAGE ADJUST FROM 6a
2 TO
A
REMOTE ADJUST.
CONNECT 6a TO 9 FOR 3-PHASE SENSING; X Y J K S1 S2 S3 P1 P2 P3
OPEN FOR 1-PHASE SENSING.

3 CONTROLLER. SHORT WHEN NOT USED.
USE TWISTED,
4
VAR/PF SCHIELDED-TYPE
SENSING INPUT VOLTAGE IS RATED AT 25 VA.
CONTROLLER CABLES
CR7,8 SURGE SUPPRESSION
DIODES
E2 NEGATIVE HEAT SINK
L1 EXCITER FIELD (STATOR) Basler Part Number
L3 ROTATING FIELD (MAIN 9 1100 00 10X
ROTOR)
L5 PM EXCITER STATOR
M ROTATING PERMANENT MAGNET
R2 REMOTE LEVEL RHEOSTAT
R5 SUPPRESSION RESISTOR 2 1 E1 E3 C B A
T1 VOLTAGE DROOP 4
TRANSFORMER
(MAY NOT BE SUPPLIED)
10K
T1 T2 T3
R2
T0 T8 2
T1
1
3
2 3 4 5 5a 6 6a 7 8 9
VR6-B
L3
CR8
CR7
CR1 CR4
RFA
CR2 CR5
CR3 CR6
20 22 24 26 28 30 F1 F2
E1 E2
R5
L2
L1
KTK-12
KTK-12
D2590-24.vsd
12-12-00 KTK-12
Figure 6-13 VR6-B Interconnected With VAR/PF Controller
Installation 15
10K
T1 T2 T3
R2
T0 T8 2
T2 T1
T3 3 1
2 3 4 5 5a 6 6a 7 8 9
VR6-B
L3
CR8
CR7
CR1 CR4
RFA
CR2 CR5
CR3 CR6 20 22 24 26 28 30 F1F2

E1 E2
R5
L2
KTK-12
L1
KTK-12
KTK-12
4 SPIKE
21 TB1 PN 4 3 SUPPRESSION
3 MODULE
CBS212/CBS212A 1 CONNECT TO TERMINAL 5 FOR 1 AMP CT,
TB2 2 1
CONNECT TO TERMINAL 5a FOR 5 AMP CT.
2 CONNECT REMOTE VOLTAGE ADJUST FROM 6a TO

VOLTAGE SENSING SELECT 7 AND REMOVE LINK 4-7 IF FITTED WITH A
REMOTE ADJUST.
CR1-6 ROTATING RECTIFIERS L5 PM EXCITER STATOR CONNECT 6a TO 8 FOR 1V/Hz; REMOVE FOR
CR7,8 SURGE SUPPRESSION DIODES M ROTATING PERMANENT MAGNET 2V/Hz UNDERFREQUENCY SLOPE.
E1 POSITIVE HEAT SINK R2 REMOTE LEVEL RHEOSTAT CONNECT 6a TO 9 FOR 3-PHASE SENSING;
E2 NEGATIVE HEAT SINK R5 SUPPRESSION RESISTOR OPEN FOR 1-PHASE SENSING.
L1 EXCITER FIELD (STATOR) RFA REVOLVING FIELD ASSY
T1 VOLTAGE DROOP TRANSFORMER
L2 EXCITER ARMATURE (ROTOR) 3
L3 ROTATING FIELD (MAIN ROTOR) (MAY NOT BE SUPPLIED) CONNECT 2 AND 3 TO SCP250 VAR/PF D2590-27.vsd
CONTROLLER. SHORT WHEN NOT USED. 06-08-00
Figure 6-14 VR6-B Interconnected With Current Boost System
Installation 16
10K
T1 T2 T3
R2
T0 T8 2
T1
3 1
2 3 4 5 5a 6 6a 7 8 9
VR6-B
L3
CR8
CR7
CR1 CR4
RFA
CR2 CR5
CR3 CR6 20 22 24 26 28 30 F1 F2
E1 E2
R5
L2
3 SPIKE
SUPPRESSION
4 MODULE KTK-12
L1
KTK-12
KTK-12
F- F+23 24 TAP120 240 F1 F2 4 3 1 CONNECT TO TERMINAL 5 FOR 1 AMP CT,

TB2 2 CONNECT REMOTE VOLTAGE ADJUST FROM 6a TO

MVC-112 7 AND REMOVE LINK 4-7 IF FITTED WITH A
REMOTE ADJUST.
TB1 CONNECT 6a TO 8 FOR 1V/Hz; REMOVE FOR

50/ 100/COM1256332
14 15 16 COM100 CONNECT 6a TO 9 FOR 3-PHASE SENSING;
200 OPEN FOR 1-PHASE SENSING.
3 CONNECT 2 AND 3 TO SCP250 VAR/PF

CR1-6 ROTATING RECTIFIERS L2 EXCITER ARMATURE (ROTOR) R2 REMOTE LEVEL RHEOSTAT

CR7,8 SURGE SUPPRESSION DIODES L3 ROTATING FIELD (MAIN ROTOR) R5 SUPPRESSION RESISTOR
E1 POSITIVE HEAT SINK L4 STATOR (MAIN STATOR) RFA REVOLVING FIELD ASSY
E2 NEGATIVE HEAT SINK L5 PM EXCITER STATOR T1 VOLTAGE DROOP TRANSFORMER
L1 EXCITER FIELD (STATOR) M ROTATING PERMANENT MAGNET (MAY NOT BE SUPPLIED)
D2590-25.vsd
06-08-00
Figure 6-15 VR6-B Interconnected With Manual Voltage Controller
Installation 17
10K
T1 T2 T3
R2
T0 T8 2
T1
3 1
2 3 4 5 5a 6 6a 7 8 9
VR6-B
L3
CR8
CR7
CR1 CR4
RFA
CR2 CR5
CR3 CR6 20 22 24 26 28 30 F1 F2
E1 E2
R5
L2
KTK-12
L1
100 MV
SHUNT
TO ALARM OR
SHUTDOWN
4
CIRCUITS
KTK-12
KTK-12
1211 10 F+ F2 F- E3 E1 1 CONNECT TO TERMINAL 5 FOR 1 AMP CT,

2 CONNECT REMOTE VOLTAGE ADJUST FROM 6a TO

K1 7 AND REMOVE LINK 4-7 IF FITTED WITH A
CONTACTS EXCITER DIODE MONITOR REMOTE ADJUST.

CONNECT 6a TO 9 FOR 3-PHASE SENSING;
OPEN FOR 1-PHASE SENSING.
CR1-6 ROTATING RECTIFIERS L5 PM EXCITER STATOR
CR7,8 SURGE SUPPRESSION DIODES M ROTATING PERMANENT MAGNET 3 CONNECT 2 AND 3 TO SCP250 VAR/PF
E1 POSITIVE HEAT SINK R2 REMOTE LEVEL RHEOSTAT
E2 NEGATIVE HEAT SINK R5 SUPPRESSION RESISTOR
L1 EXCITER FIELD (STATOR) RFA REVOLVING FIELD ASSY
T1 VOLTAGE DROOP TRANSFORMER 4 SHUNT RATED FOR 100 MV AT FULL RATED FIELD CURRENT
L3 ROTATING FIELD (MAIN ROTOR) (MAY NOT BE SUPPLIED)
D2590-26.vsd
06-08-00
Figure 6-16 VR6-B Interconnected With Exciter Diode Monitor
Installation 18
5
4
3
2
Greater than 1 VA SENSING 1
TRANSFORMERS
4 5
1:1
E1 9 3
MAGNETEK
SERIES
BOOST
E2 8
MODULE 2
FIELD
E3
22 F1
24
VR6-B
20 F2
P0004-30.vsd
12-11-00
Figure 6-17 VR6-B Interconnect With Magnetek Series-Boost Module
Installation 19
CT
GEN 1
5 or 5A
0.1
52b
6
VR6-B
CCC
ENABLE
VR6-B
0.1 CONTACT
5 or 5A
52b
6 LOAD
GEN 2
CT
VR6-B
5 or 5A
0.1
52b
6
GEN 2 P0001-18.vsd
CT 07-13-00
Figure 6-18 VR6-B Cross-Current Compensation
Installation 20
7 System Start-Up and Adjustment
7.1 PRELIMINARY SET-UP

To prevent damage to the regulator, ensure that the regulator has been installed
and connected in accordance with Installation Section instructions before
proceeding with the system start-up.
7.2 INITIAL SYSTEM START-UP

Perform the preliminary set-up and installation per Installation Section.
1. Start Prime Mover and bring up to rated speed.
- If voltage does not build-up flash field. If this does not solve problem go
to Low Voltage Troubleshooting Procedures.
- If voltage builds up and then decays go to High Voltage Troubleshooting
Procedure.
2. Make knee frequency adjustment per instructions in Adjustments Section.
3. Make voltage level adjustment per instruction in Adjustment Section. Refer to
Troubleshooting Procedures if voltage does not adjust to desired level.
4. Make stability adjustment per instructions in Adjustment Section. Refer to
Troubleshooting Procedures if you are unable to adjust voltage to a stable
setting.
5. Add load to generator. Refer to Troubleshooting Procedures if problems arise.
6. Reduce generator frequency. Generator voltage should decrease
proportionally with frequency. If this does not happen readjust knee frequency.
Increase frequency to rated.
7.3 ADJUSTMENTS
For location of the adjustments referenced in the following paragraphs, refer to
Installation Section.
7.3.1 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
generator residual voltage is less than 6 Vac at terminals 26,28 and 30 shut
down the prime mover and follow the procedures in the generator manual for
flashing the field.
7.3.2 Knee Frequency Adjustment
The underfrequency knee can be set for 50 (60) Hz operation as described in the
following paragraphs.
1. Adjust the generator frequency for 50 (60) Hz.
2. Adjust the underfrequency potentiometer (UF) fully CCW or until voltage does
not increase with further turning.
3. Adjust the Voltage Adjust for 200 (240) Vac.
4. Adjust the underfrequency potentiometer (UF) CW until the voltage begins to
decrease.
System Start-Up and Adjustment 1

5. Adjust the underfrequency potentiometer (UF) CCW until the voltage just
returns to the value set in Step 3.
6. The underfrequency knee is now set just below the nominal operating
frequency. Further rotation in the CCW direction will lower the frequency at
which underfrequency compensation begins.
7. Connecting a jumper from terminal 8 to terminal 6a will provide an
underfrequency slope of 1 pu V/Hz. No connection to terminal 8 will result in
an underfrequency slope of 2 pu V/Hz.
7.3.3 Stability (STB) Adjustment
An oscilloscope or other voltage-recording device should be used if an optimal
stability setting is desired. Adjust the stability setting with the generator at no
load. Good response can be obtained with the following procedure.
1. Rotation of the front panel STB control in the clockwise (CW) direction will
slow response time.
2. Rotation of the front panel STB control in the counter-clockwise (CCW)
direction will speed response time. If rotated too far CCW, the generator
voltage may oscillate (hunt).
3. If voltage is unstable, rotate the STB control CW until it is stable. Rotate the
front panel STB control CCW until the system just begins to oscillate and then
rotate CW just past the point where oscillation occurred.
7.3.4 Voltage (VLT ADJ) Adjustment
1. Installation of a jumper across terminals 4 and 7 allows the internal (front
panel) VLT ADJ adjustment to vary the generator nominal voltage over the
operating range.
2. Remove the jumper between terminals 4 and 7 and connect a 10k ohm
external voltage adjust potentiometer across terminals 6A and 7 to allow
operation of the external voltage adjust potentiometer. On generator sets with
a Control Panel voltage adjustment, the voltage adjust potentiometer is
located in the Control Panel. The internal voltage adjustment should be set
fully CW for proper operation of the external adjustment.
7.3.5 Factory Voltage Adjust Range Calibration Adjustment
CAUTION
The factory calibration (FAC CAL) adjustment is intended for use by factory
technicians only. The following procedure can be used if the factory calibration
has been disturbed.
1. With the voltage regulator operating on a generator, adjust the calibration

potentiometer fully ccw and the voltage adjust potentiometer fully cw. Adjust
the calibration potentiometer cw until the generator voltage is 272 1 Vac.
Adjust the voltage adjust ccw and verify the generator voltage is between 156
System Start-up and Adjustment 2

and 180 Vac. The unit is calibrated and the calibration potentiometer can be
sealed.
7.3.6 Parallel Droop (DRP) Compensation

Variable parallel droop compensation levels can be obtained by adjusting the
droop potentiometer. CW rotation increases the amount of droop for a given
condition.
System Start-Up and Adjustment 3

8 Maintenance
8.1 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
connections are clean and tight.
Maintenance 1
9 Troubleshooting Procedures
9.1 Operational Test

An operational test can be performed on the VR6-B by following the steps below.
This test ascertains the regulator is providing proper excitation. Stability,
however, must be tested with the generator and regulator in operation.
a. Connect the voltage regulator as shown by Figure 8-1 and apply 240 Vac.
b. Adjust the front panel VLT ADJ control fully counterclockwise (CCW).
RESULT: Observe that the lamp is OFF.
c. Adjust the front panel VLT ADJ control clockwise (CW).
RESULT: Observe that the lamp is now ON.
d. Adjust the front panel VLT ADJ control until the lamp just goes out.
100 W
Lamp
240
Vac
10
ohm
F1 F2 28 26 30 20 22 24
VR6-B
D2590-28.vsd 2 3 4 5 5a 6 6a 7 8 9
06-08-00
Figure 8-1 VR6-B Operational Test Set-Up
9.2 High Voltage Troubleshooting Procedure
1. Check that you are using a meter that is reading correctly. If you are reading
the voltage from the Control Panel check that this is correct with a meter. DO
NOT TAKE THE READING DIRECTLY OFF THE POWER LEADS. Take the
Troubleshooting Procedures 1
reading at a low current customer connection point or at the voltage sensing

leads, correcting this for any power transformers or midpoint connections.
- METER OK Go to step 2
- METER NOT OK Get correct meter, if voltage still high proceed to step
2.
2. Turn genset off. Check that terminal 4 is jumpered to terminal 7 if you are not
using a remote voltage adjust pot.
- USING REMOTE VOLTAGE ADJUST POT OR NOT USING REMOTE
VOLTAGE ADJUST POT AND TERMINAL 4 JUMPERED TO
TERMINAL 7 Go to step 3
- NOT USING REMOTE ADJUST POT AND TERMINAL 4 IS NOT
JUMPERED TO TERMINAL 7. Jumper terminal 4 to terminal 7, go to
step 3.
- Symptom: Voltage goes very high and then very low as the regulator
has gone into overexcitation shut-off.
3. If you are using a remote voltage adjust pot, turn it fully clock-wise.
Disconnect from regulator. Measure resistance at 80 and 82. Resistance
should be between 9.5K and 10.5K.
- RESISTANCE BETWEEN 9.5K AND 10.5K - Go to step 4
- RESISTANCE LOWER THAN 9.5K OR GREATER THAN 10.5K -
Go to Voltage Regulator Attachment Troubleshooting Section,
troubleshoot voltage adjust pot. If voltage still high, go to step 4.
- Symptom: If the resistance is higher than 10.5K , the voltage will be
high. An infinite resistance will result in the voltage going very high and
then very low due to overexcitation.
4. If you are using a single-phase sensing connection, check that the jumper
between terminal 6A and terminal 9 has been removed.
- USING SINGLE PHASE SENSING AND JUMPER BETWEEN
TERMINAL 6A AND TERMINAL 9 REMOVED, OR USING THREE-
PHASE SENSING CONNECTION Go to step 5
- USING SINGLE PHASE SENSING AND TERMINAL 6A AND
TERMINAL 9 ARE JUMPERED Remove jumper, go to step 5.
- Symptom: If you are using single-phase sensing and have the jumper
from 6A to 9 connected for three-phase sensing, the voltage will be
50% higher than desired and the regulator will probably shut-off due to
overexcitation causing a very low voltage.
5. Check that the droop current transformer (CT) connections to terminals 5 and
6 for a 1Amp CT, and terminals 5A and 6 for a 5Amp CT are correct. (If you
cannot trace the wires to ensure they are connected to the right terminal you
may need to check this while the genset is running by reversing the lead
connection and seeing if the situation is corrected)
- DROOP CT WIRES CONNNECTED CORRECTLY Go to step 6
- DROOP CT WIRES CONNECTED INCORRECTLY Connect droop
CT wires correctly, go to step 6.
- Symptom: When the droop CT connections are switched and load is

added, the voltage will go very high and then very low when the
regulator shuts off due to overexcitation.
6. If you are using power transformers (PTs) to step down the generator voltage
to the sensing voltage, check to see that the ratios are correct, including
tolerances, such that the sensing voltage is from 180V-244V for 60Hz or
150V-220V for 50Hz.
- NOT USING PTS OR PT RATIOS CORRECT Go to step 7
- PT RATIOS INCORRECT Install PTs with correct ratios. Go to step 7
7. Check that sensing wires (20, 22 and 24) are connected from correct point,
i.e. generator taps, generator midpoint connections, or T1, T2 and T3,
depending on generator voltage and number of generator leads .
- SENSING WIRES CONNECTED CORRECTLY Go to step 8,
- SENSING WIRES INCORRECTLY CONNECTED Connect sensing
wires correctly, go to step 8.
8. Check that generator connections are correct.
- GENERATOR CONNECTIONS CORRECT Go to step 9
- GENERATOR CONNECTIONS INCORRECT Connect generator
properly, go to step 9.
9. Check that all regulator connections are correct.
- REGULATOR CONNECTION CORRECT Go to step 10
- REGULATOR CONNECTIONS INCORRECT connect regulator
correctly, go to step 10.
10. Run genset at no load.
- GENERATOR VOLTAGE GOES VERY HIGH AND THEN VERY LOW
Go to step 15,
- GENERATOR VOLTAGE OK Go to step 11,
- GENERATOR VOLTAGE HIGH BUT STEADY Go to step 14.
11. Add load to genset. Is voltage still high?
- YES, VOLTAGE GOES VERY HIGH, THEN DROPS TO VERY LOW
Go to step 12,
- YES, VOLTAGE IS HIGH AND STEADY The problem is not the
regulator, but something in the load. Check load for high harmonics.
FINISHED.
- NO FINISHED.
12. Were you able to trace droop CT wires in step 5?
- YES Go to step 15,
- NO - Go to step 13.
13. Turn off genset to reset regulator. Switch droop CT wire connections. Start
genset and run at no load and then add load. Does voltage still go very high
and then very low?
- YES Turn genset off, switch wires back and go to step 15,
- NO, VOLTAGE CORRECT LEVEL Finished.
14. Check generator frequency. Is frequency high? (Ensure in this step that the
frequency is being measured correctly)
- YES Correct frequency and reset knee frequency. Go to step 10.
- NO Go to step 15.
- Symptom If the frequency is high and the knee frequency is not set
correctly, the voltage will increase proportionally to the frequency. If the
frequency is over rated frequency, the voltage will be over rated
voltage.
15. Check Voltage Regulator
9.3 Low Voltage Troubleshooting Procedures
- METER NOT OK Get correct meter, if voltage still low proceed to step
2.
2. Turn genset off. Check that terminal 4 is not jumpered to terminal 7 if you are
using a remote voltage adjust pot.
- NOT USING REMOTE VOLTAGE ADJUST POT AND TERMINALS 4
AND 7 ARE JUMPERED OR USING REMOTE VOLTAGE ADJUST
POT AND TERMINAL 4 NOT JUMPERED TO TERMINAL 7 Go to
step 3
- USING REMOTE ADJUST POT AND TERMINAL 4 IS JUMPERED TO
TERMINAL 7. Remove jumper from terminal 4 to terminal 7, go to
step 3.
- Symptom: Voltage set point is 30% lower if using remote voltage
adjust pot and terminal 4 is jumpered to terminal 7.
3. If you are using a remote voltage adjust pot, turn it fully clock-wise.
Disconnect from regulator. Measure resistance at 80 and 82. Resistance
should be between 9.5K and 10.5K.
- RESISTANCE BETWEEN 9.5K AND 10.5K - Go to step 4
- RESISTANCE LOWER THAN 9.5K OR GREATER THAN 10.5K -
Go to Voltage Regulator Attachment Troubleshooting Section,
troubleshoot voltage adjust pot. If voltage still low, go to step 4.
- Symptom: If the resistance of the voltage adjust pot is to low, this can
prevent the pot from increasing the voltage to the proper setting.
4. If you are using a three-phase sensing connection, check that there is a
jumper between terminal 6A and terminal 9.
- USING THREE PHASE SENSING AND THERE IS A JUMPER
BETWEEN TERMINAL 6A AND TERMINAL 9, OR USING SINGLE-
PHASE SENSING CONNECTION AND JUMPER BETWEEN
TERMINAL 6A AND 9 HAS BEEN REMOVED Go to step 5
- USING THREE PHASE SENSING AND THERE IS NO JUMPER
BETWEEN TERMINAL 6A AND TERMINAL 9 Install jumper between
terminal 6A and 9, go to step 5.
- Symptom: If you are using three-phase sensing and there is no
jumper from 6A to 9, the terminal voltage will be 33% below the
desired setting.
5. If you are not using a VAR/PF Controller, ensure that terminal 2 and terminal
3 are jumpered.
- NOT USING VAR/PF CONTROLLER AND TERMINALS 2 AND 3 ARE

JUMPERED, OR USING VAR/PF CONTROLLER AND TERMINALS 2
AND 3 ARE NOT JUMPERED Go to step 6,
- NOT USING VAR/PF CONTROLLER AND TERMINALS 2 AND 3 ARE
NOT JUMPERED Install jumper between terminals 2 and 3, go to
step 6.
- Symptom: If you are not using a VAR/PF Controller and terminals 2
and 3 are not jumpered the voltage set point will be 7% lower.
6. If you are using power transformers (PTs) to step down the generator voltage
to the sensing voltage, check to see that the ratios are correct, including
tolerances, such that the sensing voltage is from 180V-264V for 60Hz or
150V-220V for 50Hz.
- NOT USING PTS OR PT RATIOS CORRECT Go to step 7
- PT RATIOS INCORRECT Install PTs with correct ratios. Go to step 7
7. Check that sensing wires (20, 22 and 24) are connected from correct point,
i.e. generator taps, generator midpoint connections, or T1, T2 and T3,
depending on generator voltage and number of generator leads .
- SENSING WIRES CONNECTED CORRECTLY Go to step 8,
- SENSING WIRES INCORRECTLY CONNECTED Connect sensing
wires correctly, go to step 8.
8. Check that generator connections are correct.
- GENERATOR CONNECTIONS CORRECT Go to step 9
- GENERATOR CONNECTIONS INCORRECT Connect generator
properly, go to step 9.
9. Check that all regulator connections are correct.
- REGULATOR CONNECTION CORRECT Go to step 10
- REGULATOR CONNECTIONS INCORRECT connect regulator
correctly, go to step 10.
10. Check that the generator is able to run at the voltage desired.
- GENERATOR ABLE TO RUN AT DESIRED VOLTAGE - Go to step 11,
- GENERATOR NOT RATED FOR DESIRED VOLTAGE FINISHED,
You must get another generator or change the desired voltage rating.
- Symptom: If a generator is not rated for a voltage you are trying to set
it at, it may go into saturation and the voltage will stay the same while
you are trying to adjust it up. An indication of this is if the excitation
voltage and current is high at no load.
11. Turn genset on and run at no load. Watch to see if voltage increases quickly
to a very high value and then drops to a very low value.
- VOLTAGE DOES NOT GO HIGH AND THEN VERY LOW - Go to step
12
- VOLTAGE INCREASES QUICKLY TO VERY HIGH VALUE AND THEN
DROPS TO VERY LOW VALUE - Go High Voltage Troubleshooting
Procedure.
- Symptom: When a generator voltage increases to high a level, the
voltage regulator overexcites and turns itself off.
12. Is voltage low?

- NO Go to step 13.
13. Add load to genset. Is voltage low?
- YES The problem is not in the genset, but in the load. Check
harmonics of load. FINISHED
- NO FINISHED
14. Is voltage below 10V?
- YES - Go to step 15,
- NO Go to step 16
15. Separately excite the exciter field per instructions in the generator manual.
Does the generator build voltage?
- YES Go to step 16
- NO FINISHED the regulator is not the problem. Follow procedures
in generator manual for troubleshooting the exciter and rotating diodes.
16. Is the generator PM or SE?
- PM Go to step 17,
- SE Go to step 18,
17. Check voltage between terminals 26 and 28, terminals 26 and 30, and
terminals 28 and 30. Is the voltage between 90Vand 105V AC?
- NO There is no power coming into the regulator from the PMG.
Check PMG and wiring per generator manual.
terminals 28 and 30. Does it match voltages from terminals 20 to 22,
terminals 20 to 24, and terminals 22 to 24?
- NO Something is wrong with the jumpers from terminal 20 to 26,
terminal 22 to 28, and terminal 24 to 30. Check jumpers and replace if
necessary. If voltage correct, go to step 13, if voltage still low, go to
step 19.
19. Check generator frequency and engine rpm. Is frequency or engine rpm low?
(Ensure in this step that the frequency and engine rpm are being measured
correctly.)
- YES Correct frequency and reset knee frequency. If voltage correct
go to step 13. If voltage still low go to step 21.
- NO Go to step 20.
- Symptom If the frequency is low the voltage will be low.
20. If knee frequency is turned up, does voltage go to correct value?
- YES Adjust knee frequency correctly, go to step 13.
- NO Go to step 18
- Symptom: If knee frequency is set to low, voltage will be low.
terminals 22 and 24. Are the voltages balanced?
- NO There is something wrong in the wiring or the generator. Check
wiring and generator manual.
22. Is the sensing voltage correct and the generator voltage incorrect?
- YES The regulator is not the problem. There is something wrong with
the generator taps, PT ratios, generator connections or sensing wire
connections.
- NO Go to step 23.
23. Check the voltage between F1 and F2. Is it unusually high for no load?
- YES Check the rotating diodes per generator manual.
- NO Go to step 24.
24. Check Regulator.
9.4 Unstable Voltage Troubleshooting Procedure
- METER NOT OK Get correct meter, if voltage still unstable proceed to
step 2.
2. Turn genset off. Check all generator and regulator wiring. Pay special
attention to a) sensing circuit from generator connection through any PTs, to
regulator connection at terminals 20, 22 and 24; b) power connections at
terminals 26, 28 and 30 from PMG or jumpered from terminals 20, 22 and 24;
and c) Exciter connections at terminals F1 and F2.
- GENERATOR AND REGULATOR CONNECTIONS OK Go to step 3
- CONNECTION PROBLEM FOUND Fix problem, go to step 3.
- Symptom: A loose wire or solder joint in the sensing circuit, power
supply, or excitation circuit can cause unstable voltage.
3. Turn genset on and run at no load. Is voltage stable?
- YES Go to step 6
- NO Go to step 4
4. Is engine rpm stable?
- YES Go to step 5
- NO The regulator is not the problem, go to engine manual to
troubleshoot for unstable rpm.
- Symptom: If the engine rpm is unstable, the frequency is unstable and
the voltage will follow the frequency.
5. Readjust the stability pot per instructions in this manual.
- VOLTAGE STABLE Go to step 6
- CANNOT STABILIZE VOLTAGE WITH STABILITY POT
ADJUSTMENT Go to step 11.
6. Add load to generator. Is voltage stable?
- YES FINISHED
- NO Go to step 7
7. Check load. Is voltage as stable as could be expected with varying nature of
load?
- YES FINISHED Regulator is not the problem. You will need to
consult with someone about generator sizing and system setup.
- NO Go to step 8.
8. Check engine. Is the rpm stable?
- YES Go to step 9,
- NO Regulator is not the problem, go to engine manual.
9. Is there harmonic distortion in load above 20% or severe notching.
- YES regulator is not the problem. You will need to consult someone
about reducing the harmonics and/or notching of the load.
- NO Go to step 10.
10. Is there noise in the circuit from attachments that would account for the
instability?
- YES - Regulator is not the problem, you will need to consult with
someone to reduce the noise.
- NO Go to step 11,
11. Check Regulator.
9.5 Regulator Troubleshooting Procedure
1. Remove all attachments from generator then go to step 2.

- Voltage Adjust Rheostat (remove and add jumper between terminals 4
and 7)
- Droop CT Attach both wire terminals (5 or 5A and 6) to terminal 5 or
5A.
- VAR/PF Controller (remove and add jumper between terminals 2 and
3)
- RFI Filter
2. Check all wiring. Ensure it is tight, no broken screws, proper connections,
fuses are good, and fuse clips and holders are good.
- WIRING OK go to step 3,
- PROBLEM WITH WIRING fix and go to step 3.
- METER OK Go to step 4,
- METER NOT OK Get correct meter, proceed to step 4.
4. Run genset at no load. Has problem been corrected?
- YES Go to Voltage Regulator Attachment Troubleshooting section,
- NO Go to step 5.
5. Is generator PM or SE?
- PM Go to step 6,
- SE Go to step 7,
6. Measure voltage at terminals 26, 28 and 30. Is it between 70V and 105V?
- YES Go to step 7,
- NO Problem is with PMG, go to generator manual.
7. Measure voltage at terminals 20, 24 and 26. Is it the same as the voltage on
terminals 26, 28 and 30?
- YES Go to step 8,
- NO There is a problem with the jumper from terminal 20 to 26,
terminal 22 to 28, and/or terminal 24 to 30. Find and fix defective
jumper. If this corrects the genset problem, go to step 14. If not, go to
step 8.
8. Continue running at no load. Measure voltage at terminals 20, 22 and 24. Is
the voltage balanced?
- YES Go to step 9,
- NO Go to generator manual.
9. Readjust knee frequency. Does this correct problem?
- YES Go to step 14.
- NO Go to step 10.
10. Continue to run at no load. Is sensing voltage at terminals 20, 22 and 24

stable?
- NO Go to step 11.
11. Readjust stability pot. Does voltage stabilize with stability pot adjustment?
- YES If this solves problem go step 14, if not, go to step 12.
- NO Replace Regulator.
12. Continue to run at no load. Will regulator adjust within range of 180V to 264V
at 60 Hz or 150V 220V at 50 Hz?
- YES Regulator OK, go to step 14.
- NO Go to step 13.
13. Continue to run at no load. Will regulator adjust to operating voltage?
- YES Regulator OK, go to step 14,
- NO Go back to generator manual. Check Cabling and diodes. If
these check out OK, then replace regulator.
CAUTION: DO NOT REPLACE REGULATOR MORE THAN ONE TIME FOR
THE SAME SYMPTOMS AND PROBLEM. IF WHEN REGULATOR IS
REPLACED, THE SAME PROBLEM AND SYMPTOMS PERSIST, IT IS VERY
UNLIKELY THE PROBLEM IS THE REGULATOR. RECHECK PROCEDURES
AND CONTACT YOUR SERVICE REPRESENTATIVE IF NECESSARY.
14. Check attachments per Regulator Attachments Troubleshooting section.
- ATTACHMENTS OK Go back to generator manual
- ATTACHMENTS NOT OK fix them and retest generator.
9.6 Regulator Attachment Troubleshooting
Remote Voltage Adjust Pot

1. Turn pot fully counter-clockwise. Measure resistance between terminals 80
and 82. Resistance should be less than 5. Turn pot fully clockwise. Measure
resistance between terminals 80 and 82. Resistance should be greater than
9.5K and less than 10.5K. Are resistance measurements correct?
- YES Go to step 3
- NO Go to step 2,
2. If resistance levels in step one are not correct, one of the following conditions
exists:
a) wire broken or shorted to ground,
b) bad solder joint,
c) bad pot.
Find the problem and fix it. Go to step 3.
3. Reconnect remote voltage adjust pot and run genset. Does genset operate
correctly?
- YES Go to Droop Circuit troubleshooting section.
- NO Recheck above steps.
Droop Circuit
1. Connect droop circuit ensuring connections are correct.
2. Run genset, add load. Does voltage increase quickly to very high and then go
very low?
- YES Go to step 3,
- NO Go to step 4.
3. Switch wires to terminals 5 and 6 for a 1Amp CT or 5A and 6 for a 5Amp CT.
Run generator at no load. Is problem corrected?
- YES Go to RFI Filter troubleshooting section,
- NO Go to step 4,
4. Check voltage between terminals 5 and 6 for a 1Amp CT or terminals 5A and
6 for a 5Amp CT. Is there a voltage?
- YES Go to RFI Filter troubleshooting section,
- NO CT is bad, replace it.
RFI Filter
1. Reconnect RFI Filter.
2. Start genset. Is there a problem?
- YES replace RFI filter,
- NO Go to KVAR/PF Controller troubleshooting section.
KVAR/PF Controller
1. Reconnect KVAR/PF controller. Remove jumper between terminals 2 and 3.
2. Start genset. Is there a problem?
YES Refer to manufacturers troubleshooting procedures.
NO FINISHED.

VR6B Manual

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

VR6B Manual

Uploaded by

Copyright:

Available Formats

VR6-B Service Manual

1.1 MOUNTING........................................................................................................... 1-3

4.1 GENERAL OPERATION..........................................................................................4-1

5.1 REMOTE VOLTAGE CONTROL................................................................................5-1

7 SYSTEM START-UP AND ADJUSTMENT....................................................7-1

7.1 PRELIMINARY SET-UP......................................................................................7-1

8.1 PREVENTIVE MAINTENANCE...................................................................8-1

9.1 OPERATIONAL TEST.............................................................................................9-1

terminal 5 and terminal 6 or a 5Amp CT is connected between terminal 5A and

1.4 Droop Circuit:

Table 2-2. Physical Specifications

Excitation Power Sensing Droop

4.1 General Operation

4.2 Regulator Functions

4.3 Regulator Connections

VR6-B voltage regulator can operate in three-phase sensing or single-phase

Note: VR6-B regulators are sensitive to A-B-C phase rotation. Connections

4.3.1 Option Connections (12):

4.4 Regulator Adjustments

5.1 Remote Voltage Control

5.2 Manual Voltage Control

Refer to installation diagrams in installation section for detailed connection

5.3 Voltage Droop Control

Note: Refer to installation diagrams in installation section for detailed schematics

5.4 Series Boost

6.2 Internal Adjustments

Table 6-2. Internal Adjustments

6.3 Connection Diagrams

CR3 CR6 20 22 24 26 28 30 F1F2

CR1-6 ROTATING RECTIFIERS 1 CONNECT TO TERMINAL 5 FOR 1 AMP CT,

Figure 6-1 10-12 Lead, PMG, Single-Phase Sensing

Figure 6-2 10-12 Lead, PMG, Three-Phase Sensing

CR1-6 ROTATING RECTIFIERS 1 CONNECT TO TERMINAL 5 FOR 1 AMP CT,

Figure 6-3 10-12 Lead, Shunt Excited, Single-Phase Sensing

Figure 6-4 10-12 Lead, Shunt Excited, Three-Phase Sensing

CR1-6 ROTATING RECTIFIERS 1 CONNECT TO TERMINAL 5 FOR 1 AMP CT,

Figure 6-5 4-6 Lead, PMG, Single-Phase Sensing

Figure 6-6 4-6 Lead, PMG, Three-Phase Sensing

CR1-6 ROTATING RECTIFIERS 1 CONNECT TO TERMINAL 5 FOR 1 AMP CT,

Figure 6-7 4-6 Lead, Shunt Excited, Single-Phase Sensing

Figure 6-8 4-6 Lead, Shunt Excited, Three-Phase Sensing

Figure 6-9 Medium Voltage, PMG, Single-Phase Sensing

Figure 6-10 Medium Voltage, PMG, Three-Phase Sensing

POWER TRANSFORMER KTK-12

CR1-6 ROTATING RECTIFIERS

Figure 6-11 Medium Voltage, Shunt Excited, Single-Phase Sensing

CR1-6 ROTATING RECTIFIERS

Figure 6-12 Medium Voltage, Shunt Excited, Three-Phase Sensing

CONNECT 2 AND 3 TO SCP250 VAR/PF

Figure 6-13 VR6-B Interconnected With VAR/PF Controller

CR3 CR6 20 22 24 26 28 30 F1F2

2 CONNECT REMOTE VOLTAGE ADJUST FROM 6a TO

Figure 6-14 VR6-B Interconnected With Current Boost System

F- F+23 24 TAP120 240 F1 F2 4 3 1 CONNECT TO TERMINAL 5 FOR 1 AMP CT,

TB2 2 CONNECT REMOTE VOLTAGE ADJUST FROM 6a TO

TB1 CONNECT 6a TO 8 FOR 1V/Hz; REMOVE FOR

3 CONNECT 2 AND 3 TO SCP250 VAR/PF

CR1-6 ROTATING RECTIFIERS L2 EXCITER ARMATURE (ROTOR) R2 REMOTE LEVEL RHEOSTAT

Figure 6-15 VR6-B Interconnected With Manual Voltage Controller

1211 10 F+ F2 F- E3 E1 1 CONNECT TO TERMINAL 5 FOR 1 AMP CT,

2 CONNECT REMOTE VOLTAGE ADJUST FROM 6a TO

CONNECT 6a TO 8 FOR 1V/Hz; REMOVE FOR

Figure 6-16 VR6-B Interconnected With Exciter Diode Monitor

Figure 6-17 VR6-B Interconnect With Magnetek Series-Boost Module