Power-Tronics XC4-R Manuel utilisateur
© 2022 Power-Tronics, Inc.
The Power-Tronics XC4-R Automatic Voltage
Regulator is the latest upgrade for our commercial
voltage regulator product line! The XC4-R is capable
of replacing other manufacturers' voltage regulators
and can fit into extremely tight enclosures due to its
small size!
The XC4-R is designed as a commercial product, ideal
for installation in standby applications, portable
generators, residential generators, and any application
where the customer demands a simple, reliable, and
durable regulator at a competitive price.
The XC4-R offers greater value with an onboard fuse
to protect against overload or external faults and
optional remote voltage adjustment via panel-mounted
potentiometer!
Simplicity and Reliability are important to the Power-
Tronics brand, and all components used in the
manufacture of our products are high-quality name-
brand and engineered to withstand the continuous
ratings advertised on our products. You can have
confidence with a product designed and manufactured
in the USA and backed by a factory One-Year
Warranty!
Based internally on the XR8 voltage regulator, the
XC4-R offers precise voltage regulation regardless of
the connected load and ambient temperature. It
incorporates an idle-protection circuit that automatically
reduces voltage to prevent excessive rotor heating
when the engine is idled.
The XC4-R uses the XR8’s patented electronic circuitry
that automatically matches the regulator's response
time to the generator exciter. This greatly speeds
installation and eliminates guesswork. Because it only
uses 4 wires for connection to the generator, it also
makes quick replacement in the field possible!
To ensure extreme durability and dependability, the
XC4-R is fully encapsulated in a heat-resistant
polyester resin. Because of its strong design and fully
encapsulated packaging, the XC4-R is able to
withstand extreme operating conditions that would
damage most other voltage regulators.
The XC4-R is a direct upgrade for previous XC4, VP4,
VP5, VR50, and VR250 voltage regulators.
Specifications
Input Voltage: 120 / 208 or 240vac
Frequency: 50 or 60hz
Voltage Regulation: ± .75% From NL to FL
Parallel Operation: No
Maximum Output Voltage: 52vdc @ 120vac input
105vdc @ 240vac input
Continuous Output Voltage: 32vdc @ 120vac input
63vdc @ 240vac input
Maximum Output Current: 5adc
Minimum Field Resistance: 8Ω @ 32vdc output
16Ω @ 63vdc output
Min Residual Build up Voltage: 3.5vac
Under Frequency Protection: Yes, Idle speed reduction
Physical Size: 4.1 x 2.1 x .75 in.
Weight: 2.5 oz
Fully Encapsulated: Yes
Internal Fuse Type: GDB5A @ 250V Fast-Blow
Remote Voltage Adjustment: Yes
System Operating Indicator: No
Optional Static Exciter Modules: No
Optional External Controls: No
XC4-R
Commercial Series
Voltage Regulator
2
For Technical Support:
Visit our website at: www.power-tronics.com
Call Us at: (830) 895-4700
Table of Contents
Introduction and Functional Description:....................................................................3
Determining Which Hookup Configuration to Use:....................................................4
Common 12-Lead Generator Wiring Diagrams:..........................................................6
Use with PMGs, DPE, AUX, and Harmonic Winding Generators:..............................7
240V Hookup Connection:.............................................................................................8
120V Hookup Connection:.............................................................................................9
Installation on Brush-Type Generators:.................................................................... 10
Installation Considerations:....................................................................................... 11
Initial Setup and Commissioning:...............................................................................11
Optional Power-Tronics Accessories:........................................................................12
Application Troubleshooting:......................................................................................13
Bench Check Procedures:...........................................................................................14
Installation Warranty Form:.........................................................................................15
Product Warranty Certificate:......................................................................................16
3
For Technical Support:
Visit our website at: www.power-tronics.com
Call Us at: (830) 895-4700
Introduction and Functional Description
Caution: Read This Installation
Manual Carefully and Entirely!
Warning: Do not use digital equipment to read voltage, Hz, or amperage
during this installation. Use only Analog sensing equipment! Failure to do so
may result in damage to equipment or in personal injury!
ALWAYS perform all setup procedures off-line
ALWAYS wear eye protection
ALWAYS strip wire insulation properly or use insulated connectors
ALWAYS use analog metering equipment when setting up the regulator
ALWAYS ensure the regulator receives ample airflow
NEVER hold the regulator in your hand when energized
NEVER install the regulator in a location it can get wet or is exposed to the elements
NEVER mount the regulator over a screw, bolt, rivet, welding seam, or other fastener
NEVER touch exposed components while the unit is in operation
NEVER insert a screwdriver or other object under the regulator cover
NEVER install a switch in the DC portion of the regulator’s wiring
NEVER USE A DIGITAL FREQUENCY METER (It can give a false reading!)
Functional Description
The XC4-R Automatic Voltage Regulator is the result of over 30 years of engineering efforts and offers high-
demand features at a competitive price point. The XC4-R is a proven design and is engineered to greatly
simplify setup while offering extreme reliability in demanding service conditions. When properly installed, the
XC4-R Automatic Voltage Regulator is designed to provide a lifetime of service.
A Generator voltage regulator has several automated tasks it must perform in order to provide reliable, clean,
and regulated electricity. It must build-up the generator, regulate the terminal voltage within its design
specifications, and protect both itself and the generator should a fault situation arise.
The XC4-R contains a time-proven, extremely reliable circuit for build-up functionality, in use for over 25 years.
Due to its simplicity, the XC4-R is able to build up generators with residual voltages from 3.5VAC without initial
overshoot or excessive delay. The patented circuitry contained in the XC4-R automatically adjusts the
regulator to match the generator’s response time, minimizing setup complexity while maximizing load
acceptance and rejection performance. The XC4-R is a precise voltage regulator and is capable of regulating
the terminal voltage of the generator within +/-.75% of its initial set point.
The XC4-R is a fully encapsulated design to resist extreme operating conditions. It also contains a unique idle
protection circuit, which helps to protect the generator rotor and exciter if the engine is idled with the regulator
still energized.
Due to its extreme simplicity, the XC4-R Automatic Voltage Regulator is uncommonly reliable and offers
features and regulation accuracy usually only offered by much more complicated and often much more
expensive regulators.
4
For Technical Support:
Visit our website at: www.power-tronics.com
Call Us at: (830) 895-4700
Determining Which Hookup Configuration to Use
STOP! DO NOT use this product in combination with add-on products
designed for UVR and XR series voltage regulators! Immediate voltage
runaway and potentially life-threatening conditions may occur!!!
The XC4-R Automatic Voltage Regulator is suitable for 2 different output ranges suitable for use
on most brushless generators available on the market from past and present. It is necessary to
choose the proper mode of operation for your generator in order to get the best regulation and
fastest response time possible.
To determine the proper connection for your generator you need to know any two of the
following 3 specifications from the rating plate of your generator:
1: Exciter Field Voltage (in DC Volts) [Generally given in full load Voltage on nameplates]
2: Exciter Field Resistance (in Ohms) [See Note Below]
3: Exciter Field Amperage (in DC Amps) [Generally given in full load Amps on nameplates]
Using the specifications obtained from your generator exciter, select
120V or 240V Hookup from the list below:
• Exciter Field Resistance ≥16Ω & Exciter Full-Load Voltage ≤63VDC
Use 240V Hookup Connection (See Page 8)
• Exciter Field Resistance ≥8Ω & Exciter Full-Load Voltage ≤32VDC
Use 120V Hookup Connection (See Page 10)
Note about Field Resistance:
• When measuring field resistance on a brushless generator, simply measure the
resistance of the exciter field through your field leads with a multimeter.
• When measuring field resistance on a brush-type generator, measure the resistance
through both the field leads as well as directly on the slip rings themselves. The
readings you obtain should ideally be the same, but no more than 1% difference.
If you show more than 1% difference in reading your generator has brush and ring
contact problems and will need cleaning or maintenance before installing the XC4-R.
Failure to correct brush and ring contact problems will result in severe damage to
the voltage regulator as well as possible PERMANENT damage to the slip rings
themselves! NEVER use emery cloth, carborundum stones, “comm sticks”, or
Tuner cleaner to dress or clean slip rings. They will make a bad problem much,
much worse! Only use Garnet or Flint sandpaper and clean with a clean rag soaked
with Acetone for best results!
5
For Technical Support:
Visit our website at: www.power-tronics.com
Call Us at: (830) 895-4700
If you do not have any of the specifications of your generator’s
exciter, or if you don’t know where to start when trying to determine
your exciter specs, please see the section below for instructions on
measuring and calculating your exciter specifications.
• Measure your exciter field resistance using a multimeter on your field leads.
Record this value. If you have a brush-type generator, also take a resistance
reading on your slip rings: the value you obtain on the slip rings should be no
more than 1% difference from the value you obtained through the field leads.
• Next, start and run the generator and apply 12V from a battery through your
field leads and record the AC voltage produced by the generator. To
determine your full load exciter field voltage, use the following formula:
EExc. =
Where EGen.Conf. is your Generator’s configured voltage (e.g.: 120, 208, 240,
480V, etc.), EGen.Output is your recorded output voltage, and EBattery is your battery
voltage (12V usually).
• Next, calculate your maximum exciter field amperage using your measured
field resistance and your calculated exciter voltage using the following formula:
Where I is your maximum exciter field current, E is your calculated field
voltage from the above formula, and R is your measured field resistance.
Using the values you just measured and calculated, see the chart on
the previous page to determine which connection you should use to
connect the XC4-R to your generator.
For Example:
Measured Field Resistance: 18Ω
Battery Voltage: 12V
Generator Configuration: 480V Wye
12V applied to the field yields 189VAC L1-L3.
EExc. =
480
!
!"#
!$
"
∗ 2 = 60.95
EExc. = 60.95VDC (Full-Load Voltage)
This generator would use 240V Connection.
€
EGen.Conf .
EGen.Output
EBattery
"
#
$
$
%
&
'
'
* 2
I=E
R
6
For Technical Support:
Visit our website at: www.power-tronics.com
Call Us at: (830) 895-4700
Common 12-Lead Generator Wiring Diagrams
Series Wye (416/480V 3ø)
Voltage L-L: 416/480V
Voltage L-N: 240/277V
Voltage CT – N: 120/139V
Parallel Wye (208/240V 3ø)
Voltage L-L: 208/240V
Voltage L-N: 120/139V
NOTE: 208V is Standard Voltage
Series Delta (240V 3ø)
Voltage L-L: 240V
Voltage L1/L2-N: 120V
Voltage L3 – N: 208V
NOTE: L3-N is a “High Leg”
208V instead of 120V!
Double-Delta (120/240V 1ø)
Voltage L-L: 240V
Voltage L-N: 120V
Preferred Single-Phase Connection.
Don’t Use Zig-Zag if Possible.
NOTE: Derate generator by 1/3 rated
capacity when using this connection!
7
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Visit our website at: www.power-tronics.com
Call Us at: (830) 895-4700
PMG, DPE Winding, Auxiliary Winding, and
Harmonic/Resonant Winding Use
The XC4-R Automatic Voltage Regulator is compatible with some of these types
of generators but not others. It is necessary to determine which type of generator
you have before proceeding since some styles will connect differently than
others while the XC4-R cannot be used with some of these generators at all.
PMG (Permanent Magnet Generator/Exciter):
This type of generator generally has a permanent magnet generator mounted on the
main shaft along with a brushless exciter and finally the main rotor itself. The XC4-R is
a very fast responding regulator (1/2 cycle response time) and low enough burden on
the main stator that it can be used on these generators without any need for the PMG
input.
To connect the XC4-R to this type of generator, isolate and insulate the PMG leads that
were connected to the original voltage regulator. Measure your field resistance and
proceed with sizing on Page 4.
DPE Winding and Auxiliary Winding:
These generators use an extra winding in the main stator as a power supply for the
voltage regulator in an attempt to give the regulator a clean power source that isn’t
affected by load. The XC4-R has proprietary filtering circuitry in its sensing stage that is
largely unaffected by generator load. Because the regulator isn’t affected by loading,
these types of windings are not needed.
To connect the XC4-R to this type of generator identify, isolate, and insulate the
Auxiliary or DPE wiring that were connected to the original voltage regulator. Measure
your field resistance and proceed with sizing on Page 4.
Harmonic and Resonant Windings:
This type of generator rarely has a voltage regulator, and instead relies on a phase-
shifted “harmonic” winding and a capacitor to adjust the terminal voltage with load.
They often have a brushless “exciter”, but because they operate on harmonics from the
AC waveform, they do not operate like a typical brushless exciter.
Because these generators rely on AC waveform phasing for
their voltage regulation, the XC4-R cannot be used with this
type of generator.
8
For Technical Support:
Visit our website at: www.power-tronics.com
Call Us at: (830) 895-4700
240V Hookup Connection
240V Hookup Connection is a Half-Wave rectified configuration, which allows a
continuous output of 63VDC @ 4A with an input voltage of 240VAC.
This connection is common on most American style brushless generators built since the
1970s. Most generators using this connection will have a field resistance of 18-22Ω.
Note that the maximum input voltage to the XC4-R Automatic Voltage regulator is
240VAC! DO NOT input 277VAC into the XC4-R! Severe damage to the unit will
result! For use on 480V systems, either connect the regulator to the winding center
taps T7 and T9 (See Page 6) or use a 480-240V step-down transformer rated at
500VA.
Connecting the input of the XC4-R to 2 different legs of the generator as shown in the
diagram below will result in greater regulation accuracy than when connecting line-
neutral.
XC4-R Commercial Series
Automatic Voltage Regulator
NOTE:
If the generator is to be operated
below 50/60 Hz, a disconnect
or switch should be installed in
series with the incoming power to
terminals AC1 and AC2 on the
XC4-R.
NEVER install a switch or
breaker on the DC or Exciter
side of the voltage regulator!
Only install a switch or
disconnect on the AC Side of
the regulator!
240VAC
MAX!
Regulator On/Off
Switch
Rate for:
240V @ 10A
100KΩ @ 1/2W
Remote Adjustment Potentiometer
Jumper Pins R1 and R2 if not
using Remote Adjustment
Potentiometer!
FAILURE TO INSTALL
POTENTIOMETER OR
JUMPER MAY RESULT IN
LOW VOLTAGE OUTPUT!
9
For Technical Support:
Visit our website at: www.power-tronics.com
Call Us at: (830) 895-4700
120V Hookup Connection
120V Hookup Connection is a Half-Wave rectified configuration, which allows a
continuous output of 32VDC @ 4A with an input voltage of 120VAC.
This connection is common on most Asian style brushless generators built since the
1980s and many smaller KW portable, truck-mounted, or commercial generators. Most
generators using this connection will have a field resistance of 10-15Ω.
Note that the maximum input voltage to the XC4-R Automatic Voltage regulator is
139VAC in this configuration! DO NOT input 277VAC into the XC4-R! Severe
damage to the unit will result! For use on 480V systems, either connect the regulator to
the winding center taps T7 and T0 (See Page 6) or use a 480-120V step-down
transformer rated at 250VA.
When connecting the input of the XC4-R from center-tap to neutral of the
generator as shown in the diagram always connect AC2 to the generator neutral.
XC4-R Commercial Series
Automatic Voltage Regulator
NOTE:
If the generator is to be operated
below 50/60 Hz, a disconnect
or switch should be installed in
series with the incoming power to
terminals AC1 and AC2 on the
XC4-R.
NEVER install a switch or
breaker on the DC or Exciter
side of the voltage regulator!
Only install a switch or
disconnect on the AC Side of
the regulator!
139VAC
MAX!
Regulator On/Off
Switch
Rate for:
240V @ 10A
100KΩ @ 1/2W
Remote Adjustment Potentiometer
Jumper Pins R1 and R2 if not
using Remote Adjustment
Potentiometer!
FAILURE TO INSTALL
POTENTIOMETER OR
JUMPER MAY RESULT IN
LOW VOLTAGE OUTPUT!
10
For Technical Support:
Visit our website at: www.power-tronics.com
Call Us at: (830) 895-4700
Installation on Brush-Type Generators
The XC4-R Automatic Voltage Regulator is designed primarily for use on
brushless generators, however many smaller commercial and residential style
generators have excitation requirements that are within the capacity of the XC4-R.
Use of the XC4-R on brush-type generators requires the use of an external
varistor across the exciter field or brush riggings. Brush-type generators
inherently create reverse EMF conditions and occasional arcing at the brush/ring
interface that can quickly damage the XC4-R if the varistor is omitted.
XC4-R Commercial Series
Automatic Voltage Regulator
Field Varistor
Required on Brush-
Type Generators.
Power-Tronics
Part # 5R1-44
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