UENR8784-03

4JAN2023

Special
Instruction

R120 Automatic Voltage

Regulator

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SAFETY.CAT.COM
V S UF OPEN IN 60Hz OE UF SL

R120

V N1 U N F1 F2

R120

AVRs
Installation and maintenance
 Installation and maintenance 5243 en - 2018.01 / k

R120
AVRs

This manual concerns the alternator AVR which you have just purchased.
We wish to draw your attention to the contents of this maintenance manual.

SAFETY MEASURES

Before using your machine for the first time,

it is important to read the whole of this
installation and maintenance manual. All servicing or repair operations
performed on the AVR should be
All necessary operations and interventions undertaken by personnel trained in the
on this machine must be performed by a commissioning, servicing and main-
qualified technician. tenance of electrical and mechanical
components.
Our technical support service will be pleased
to provide any additional information you
may require.

The various operations described in this When the generator is driven at a

manual are accompanied by recom- frequency below 28 Hz for more than 30
mendations or symbols to alert the user to seconds with an analogue AVR, its AC
potential risks of accidents. It is vital that power supply must be disconnected.
you understand and take notice of the
following warning symbols.
WARNING
WARNING This AVR can be incorporated in a EC-
marked machine.
Warning symbol for an operation capable This manual is to be given to the end
of damaging or destroying the machine user.
or surrounding equipment.

© - We reserve the right to modify the

characteristics of this product at any time in
order to incorporate the latest technological
developments. The information contained in
Warning symbol for general danger to this document may therefore be changed
personnel. without notice.

This document may not be reproduced in

any form without prior authorisation.
All brands and models have been registered
Warning symbol for electrical danger to and patents applied for.
personnel.

2
 CONTENTS

1 - GENERAL DESCRIPTION..................................................................................................4

2 - OPERATION OF THE AVR..................................................................................................4

3 - TECHNICAL SPECIFICATION............................................................................................5

4 - MAIN FUNCTION OF THE AVR..........................................................................................6

5 - AVR SETTINGS................................................................................................................... 7

5.1 - V-TRIM (V).................................................................................................................... 7

5.2 - FRO (UF) ...................................................................................................................... 7
5.3 - STAB (S) ......................................................................................................................7

6 - AVR CONTROLS................................................................................................................. 7

7 - TROUBLESHOOTING CHART...........................................................................................8

8 - MULTIMETER CHECKS.....................................................................................................9

9 - STATIC TEST PROCEDURE............................................................................................10

10 - DIMENSIONS.................................................................................................................. 12

Disposal and recycling instructions

3
 Installation and maintenance 5243 en - 2018.01 / k

R120
AVRs
1 - GENERAL DESCRIPTION 2 - OPERATION OF THE AVR
The R120 automatic voltage regulator The AVR is powered by the line-to-neutral
(AVR) is a compact, high-performance terminal of the AC generator, with 240 VAC
encapsulated unit. It incorporates the latest rms at 50 Hz or 60 Hz. The sensing voltage,
technology and efficient components to which is the regulated voltage, is based on
achieve a high degree of miniaturisation line-to-line (for 3-phase) and line-to-neutral
when used with 3-phase and 1-phase AC (for 1-phase). The AVR forms an important
brushless generators within its input and part of the closed loop system comprising
output limits. The unit offers excellent the generator field, generator armature and
reliability. the AVR.

The AVR provides DC excitation to the The AVR first builds up the generator voltage
exciter field of a brushless generator to keep from its residual levels, to the rated value of
the voltage within the approximate operating 415 V for 3-phase and 240 V for 1-phase.
limits from NO-LOAD to FULL LOAD. When the generator is loaded, the sensed
voltage decreases and generates an error
The typical recovery time in the event of
voltage, which is required in order for the
sudden loading is around 0.5 sec. to recover
closed loop system to work.
98% of the rated voltage. Transient
performance such as voltage dip and
The AVR contains a high gain amplifier,
recovery time is mainly determined by the
ramp and a pedestal circuit. Depending
generator and exciter design parameters.
upon the value of the amplifier voltage
Optimum AVR performance can be
(either high or low) the ramp intersects the
obtained by keeping full-load excitation to
amplified voltage at a point, which is either
around 60 VDC.
early or late in the half-cycle. At this
The generator uses a true average sensing intersection point a starting pulse is
circuit, dV/dt snubber and special filter produced to trigger the power device.
circuits to manage NON-LINEAR loads
such as battery chargers, DC motors, etc. When the power device is triggered early in
the half-cycle, more voltage is transmitted to
Voltage regulation is only guaranteed for the field and when triggered late in the half-
linear loads. Severely distorting NON- cycle, less voltage is transmitted to the field.
LINEAR loads can cause regulation
problems. In order to reduce the generator voltage at
low speed, a signal inversely proportional
Each AVR is tested prior to dispatch as part to the speed is generated as an extra input.
of a quality plan, for standard voltage and At higher speeds the voltage decreases at a
frequency. faster rate than in proportion with the speed.
A soft-start circuit is included which provides
smooth control of the build-up of generator
output voltage.
A frequency roll-off circuit continuously
monitors the generator underspeed
protection by reducing the generator output
voltage in proportion with the speed below a
threshold.

4
3 - TECHNICAL SPECIFICATION 15) Overexcitation protection: 10 VDC to
1) Sensing input 85 VDC.
- Voltage: 277 VAC ± 10% for 1-phase, Set point: 60 VDC
415 VAC line-to-line ± 10% for 3-phase, 16) Protection fuse: 4 A, 240 VAC.
2-line sensing. The AVR senses the true
average of the line-to-line waveform. Use 17) Potentiometer sealing: except for the
the resistor (SMD) network for trouble-free V-trim potentiometer, all potentiometers are
sensing and control of sensed voltage/ sealed.
regulation.
18) Frequency roll-off indicator: LED
2) Input power provided (UF).
- Voltage: 277 VAC rms ± 10%
- Frequency: 50/60 Hz 19) Sensing loss indicator: LED provided
(SL).
3) Output power
- Voltage: 95 VDC for 240 VAC Input 20) Overexcitation indicator: LED provided
- Current: (OE).
• 4 A DC 21) Protection on the devices: suitable R-C
• 6 A for 30 sec. (when allowed by the field snubber to be provided for the device used
resistance) to protect against voltage surges.
4) Operating temperature: -20ºC to +70ºC 22) Potting/Encapsulation details: the
5) Storage temperature: -40ºC to +80ºC components on the AVR should be
completely encapsulated with suitable PU
6) Voltage setting: min ± 10% of rated resin compound to absorb transients/
voltage. vibrations during operation.
7) Stability setting: can be adjusted to obtain 23) Alternator excitation details: (typical)
a correct transient response in steady state. - Full load:
8) Under frequency roll-off setting: available • Excitation voltage: 40 to 50 V
below 46 Hz for 50 Hz and below 56 Hz for • Excitation current: 2.5 to 4.0 A
60 Hz. 24) Terminal marking: see diagram
9) Voltage build-up: 2 Volts (L-N) 25) Dimensions:
10) Voltage regulation: ± 1% at the AVR - Overall: 104 x 94 x 40 (mm)
terminals with a THC <5%. - Mounting: 83 (mm)
- Mounting hole dia: 5.5 (mm)
11) Thermal drift: ± 1% for 30ºC change in
temperature. 26) Weight: 185 g

12) Response time: less than 50 ms.

13) Closed loop response: typically 0.5 sec
to recover 98% of the defined voltage for a
field forcing ratio of 1:2.
14) Sensing loss protection: the voltage
should disappear when the sensing circuit is
open.

5
 Installation and maintenance 5243 en - 2018.01 / k

R120
AVRs

4 - MAIN FUNCTION OF THE AVR

The AVR is powered by the line-to-neutral terminals of the AC generator with 240 VAC at
50/60Hz. The regulated sensing voltage is based on the AVR input power.
Note: The wiring diagram below might not
reflect your actual configuration. Refer to
STATOR: 6 wires (T1 to T6 identification)
the Generator Set main wiring schematic.
MAIN FIELD T1 T2 T3
U1 V1 W1

* not connected in delta configuration

Delta configuration
Star configuration
Armature
Varistor

Exciter field
black

T4 T5 T6
red

U2 V2 W2
blue
green
yellow
OE Under UF SL
Over-excitation frequency Sensing loss

V V S UF OPEN IN 60Hz OE UF SL

Voltage

S
Stability

U/F

50 Hz
60 Hz
Frequency

Fuse 4 A
240 V

V N1 U N F1 F2

* Note: for delta configuration (1PH – 3PH), use terminals N and U, short N and N1.

6
The AVR builds up the generator voltage 5.2 - UF - Under frequency knee
from its residual voltage to rated voltage. point setting
When the generator is loaded, the sensed This function is provided to protect the AC
voltage decreases and generates an error generator from sustained low speed
signal, which is required in order for the operation through a potentiometer. The AVR
closed loop system to work. will reduce the voltage in proportion with the
speed below the defined value.
Depending upon the value of the amplified
The procedure for setting the UF
voltage, the ramp intersects the amplified
voltage at a point which is early or late in the potentiometer is as follows:
half-cycle. First run the generator at full speed (50 Hz)
At this intersection point, a starting pulse is and turn UF by a few turns clockwise,
produced to trigger the power device. making sure that the voltage does not
increase. Now turn the UF potentiometer
slowly anticlockwise. At a particular point
the red LED glows and the voltage will start
to decrease. Stop turning the potentiometer
at this point and turn the potentiometer
Only qualified personnel should replace/ clockwise by two turns after rated voltage is
work on the AVR. restored.
Do not increase the voltage beyond the
rated voltage. The factory default setting is 46 Hz.

5 - AVR SETTINGS 5.3 - STAB (S)

This function is provided to stop voltage
5.1 - V-TRIM (V)
hunting by means of a potentiometer. Turn
This function is provided for setting the
clockwise to increase stability (to stop
voltage up to ± 10% of rated voltage by
oscillation). Turning too far clockwise will
means of a potentiometer. Turn the
result in a sluggish response and possibly
potentiometer clockwise to increase the
also oscillations.
voltage and vice versa, once the rated
speed has been reached. The factory default setting is slightly
higher than critical damping (around
The default setting is 415 V ± 2% for
3-phase, 240 V ± 2% for 1-phase. halfway).

6 - AVR CONTROLS
No. Control Function Direction

1 VOLTS Sets the generator output voltage Turn clockwise to increase output voltage

2 STAB Stops voltage hunting Turn clockwise to increase stability

Sets the Under frequency Turn clockwise to to reduce the knee
3 UFRO
knee point point

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 Installation and maintenance 5243 en - 2018.01 / k

R120
AVRs

7 - TROUBLESHOOTING CHART
Symptom Cause Action
No voltage Fuse blown Check and replace
build-up Low residual voltage across U If the generator’s residual voltage at rated speed
and N terminals is less than 2.5 VAC (L-N), disconnect the AVR
and connect a 24 VDC battery, keeping F1 as
positive and F2 as negative.
Connecting a freewheel diode (BY 127) across
the field with the diode cathode to F1 and the
anode to F2 during field flashing will help restore
the residual voltage.
WARNING:
Remove the diode (BY-127) after field flashing.
The 24 V battery positive terminal must only be
connected to F1 and the negative to F2.
Swapping the connection will cause diode BY127
to explode instantly.

Incorrect wiring Check wiring

Rotating diodes and/or fuse Check and replace
failed
Voltmeter on the front Check and correct
defective
AVR defective Replace after performing a static test
(repeated fuse blowing)
Earthed exciter field Check and correct
High voltage Loose or missing connection Check and correct
build-up to AVR U terminal
AVR defective Perform a static test and replace if necessary
Low voltage Low prime mover speed Check and correct
build-up Sensing loss in circuit Check and correct
AVR defective Replace the AVR
Voltage oscillation Incorrect stability Turn clockwise until hunting stops
potentiometer sealing
Prime mover speed hunting Check and adjust the controller
Load hunting, fluctuates Check and correct
rapidly
High percentage of non-linear Check and reduce the non-linear load
loads
High reactance in generator Consult the generator manufacturer
(during non-linear loading)
Incorrect The exciter field’s requirement Wrong selection or very low P.F. load. Check and
regulation is higher than 95 VDC correct.
Prime mover speed drops too Adjust the controller and reduce the active load
much when on load (kW load)

8
8 - MULTIMETER CHECKS The resistance between U and N1 should be
Equipment: Digital multimeter, Type: between 200 kW and 260 kW. Open circuit
MECO or equivalent. indicates AVR failure. During a static test,
the lamp will not turn OFF or, when
Select Diode mode on the digital multimeter.
connected to the generator, it will produce a
The resistance between F1 and F2 (with the
ceiling voltage (for 1-phase ONLY).
multimeter jack common applied to F1 of the
AVR) should be between 0.4 and 0.6 kΩ, The resistance between N and F1 should be
and vice versa (with the multimeter jack very low or ZERO ohms. If the circuit is
common applied to F2 of the AVR) should open, the lamp will not glow when the static
give INFINITY. test is performed.
ZERO indicates a power device failure in
both cases, No further tests (static or
dynamic) are allowed, as they would lead to
the fuse blowing.
The resistance between F2 and U (both
sides) should be 180 kΩ.
The resistance between F2 and V with the
multimeter jack common applied to the AVR
V terminal should be approximately 2.2 MW
in the 10 MW range and vice versa (with the
multimeter jack common applied to the AVR
F2 terminal) should be 15 MW.
ZERO indicates a power device failure in
both cases, No further tests (static test or
dynamic tests) are allowed, as they would to
the fuse blowing.
The resistance between U and V should
be between 300 kW and 400 kW. Open
circuit indicates AVR failure. During a static
test, the lamp will not turn OFF or, when
connected to the generator, it will produce a
ceiling voltage (for 3-phase ONLY).

9
 Installation and maintenance 5243 en - 2018.01 / k

R120
AVRs

9 - STATIC TEST PROCEDURE

For 3-phase circuit

AVR (3-PH)
Model: R120

VAC
0-500 V

415 V, 3PH, 50 Hz,

LAMP

WITH NEUTRAL
100 W
230 V

VARIAC
8A, 415 V

STATIC TEST CONNECTION DIAGRAM OF 3-PH AVR

This test should only be attempted after 5. It is difficult to prescribe a static test for
making sure that the AVR has passed all checking the stability, as this is more easily
multimeter checks. Connect the AVR to the detected during closed loop tests. However,
three-phase variable voltage source as a healthy AVR will behave as described
shown in diagram 3 in this manual. below.
1. Keep ‘V-TRIM’ in the minimum position. First keep the ‘STAB’ potentiometer in the
fully anticlockwise position. Perform the
2. Keep UF in the fully maximum position.
static test as described in steps 1, 2 and 3.
3. Increase the applied voltage. The lamp The lamp will go out fairly quickly at 360-
should glow increasingly brightly. At a 380 V and come on again quickly when the
voltage of around 360-380 V the lamp voltage is reduced to below 360 V.
should go out slowly. Increase the voltage Now keep the ‘STAB’ potentiometer fully
again up to 415 V. The lamp should stay clockwise, and perform the static test as in
OFF. 1, 2, and 3. The lamp should go out much
Decrease the voltage to below 360 V. The more slowly and come on again much more
lamp should glow brightly again. slowly. At the end of this test reset the
potentiometer in the middle position.
4. Turn the UF potentiometer anticlockwise;
the lamp should go out slowly. Now turn the If the AVR behaves as described above
UF potentiometer clockwise. The lamp then it is in good working order.
should glow brightly again.

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10 - DIMENSIONS
94 mm

82 mm

V S UF OE UF SL

OPEN IN 60Hz

52 mm
R120

FUSE

104 mm
2 x holes Ø 5.5
x 83 mm

V N1 U N F1 F2

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 Installation and maintenance 5243 en - 2018.01 / k

R120
AVRs
Disposal and recycling instructions
We are committed limiting the
environmental impact of our activity. We
continuously monitor our production
processes, material sourcing and products
design to improve recyclability and minimise
our environmental footprint.
These instructions are for information
purposes only. It is the user’s responsibility
to comply with local legislation regarding
product disposal and recycling.

Waste & hazardous materials

The following components and materials
require special treatment and must be
separated from the alternator before the
recycling process:
- electronic materials found in the terminal
box, including the automatic voltage
regulator (198), current transformers (176),
interference suppression module (199) and
other semi-conductors.
- diode bridge (343) and surge suppressor
(347), found on the alternator rotor.
- major plastic components, such as the
terminal box structure on some products.
These components are usually marked with
information concerning the type of plastic.

12
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may not be used without permission.