Power-Tronics XR5C Series - User Manual

© 2020 Power-Tronics, Inc.
XR5C
Specialty Series
Universal Voltage Regulator
The Power-Tronics XR5C Universal Voltage
Regulator is the latest upgrade to the XR500C
product line and features a strengthened
regulation system and a redesigned rectifier
section to match that of the XR8! The XR5C is
also capable of replacing other manufacturers'
voltage regulators and has optional Static Exciter
Modules to boost its capacity to 30 amps DC!
The XR5C is designed for legacy installations and
specialty applications where tolerance to extreme
waveform distortion is required or installations
where manual tuning of stability is preferred.
Manual stability matching is sometimes required
on applications with severe waveform distortion
due to VFDs, solid-state drives, motor soft-start
systems, UPS loading, or generators with
extremely slow or non-linear magnetic
characteristics. Because the stability is matched
manually, the technician can tune the regulator to
the generating system, allowing the XR5C to
regulate loads that other types of automatic
voltage regulators cannot.
Like the XR500C, the XR5C incorporates an
easily selectable frequency range for voltage roll-
off during under-frequency operation and offers
precise voltage regulation regardless of the
connected load and ambient temperature. All
major electronic components are not
encapsulated to facilitate repair while all sensitive
components are encapsulated to protect them
from contamination and moisture.
PLC and automated Genset control is possible
with the XR5C by simply adding an optional,
inexpensive digital interface module. This
capability makes the XR5C suitable for automated
or unattended installations, or large-scale parallel
operations. The XR5C is compatible with all
previous and current optional modules available
for use with Power-Tronics voltage regulators
making it extremely simple to upgrade an existing
voltage regulator installation.
Specifications
Input Voltage:
120 / 208 or 240vac
Frequency: 50 or 60hz
Voltage Regulation: ± 1% From NL to FL
Parallel Operation Yes
Maximum Output Voltage: 52vdc @ 120vac input
105vdc @ 240vac input
210vdc @ 240vac input
Continuous Output Voltage: 32vdc @ 120vac input
63vdc @ 240vac input
125vdc @ 240vac input
Maximum Continuous Output: 5adc
Minimum Field Resistance: 10.5Ω @ 52vdc output
21Ω @ 105vdc output
42Ω @ 210vdc output
Min Residual Build up Voltage: 3.5vac
Under Frequency Protection: Yes, VPH reduction
Physical Size: 4.75 x 6 x 1 in.
Weight: 7 oz
Repairable: Yes
Internal Protection: Fuses, cartridge type
External Voltage Adjustment: Yes
System Operating Indicator: Yes
Optional Static Exciter Modules Yes
Optional External Controls Yes
Cartridge Fuse Type: GDB 5A @ 250V Fast-Blow
Optional External Potentiometer: 100KΩ @ 2W
External Adjustment Range: ±10% of Terminal Voltage

Power-Tronics XR5C Series Specifications

General

Brand	Power-Tronics
Model	XR5C Series
Category	Controller
Language	English

Summary

XR5 C Voltage Regulator Overview

XR5 C Product Specifications

Detailed technical specifications for the XR5C voltage regulator.

XR5 C General Introduction

Brief overview of the XR5C's purpose and capabilities.

Installation and Functional Description

Critical Installation Warnings and Cautions

Essential warnings and cautions for safe and proper installation.

XR5 C Functional Description

Detailed explanation of the XR5C's operational principles and design.

Determining Generator Hookup Configuration

Hookup Configuration Selection Criteria

Criteria for selecting the correct connection (A, B, or C) based on generator specs.

Field Resistance Measurement Guidelines

Guidelines for accurately measuring exciter field resistance on generators.

Calculating Generator Exciter Specifications

Measuring and Calculating Exciter Voltage

Step-by-step process to measure and calculate exciter field voltage.

Calculating Exciter Field Amperage

Method for calculating maximum exciter field amperage using measured values.

Common Generator Wiring Diagrams

12-Lead Generator Wiring Configurations

Visual diagrams for Series Wye, Parallel Wye, Series Delta, and Double-Delta.

Generator Type Compatibility

PMG, DPE, and Auxiliary Winding Compatibility

Compatibility of XR5C with PMG, DPE, and Auxiliary winding generators.

Harmonic;Resonant Winding Incompatibility

Explanation why XR5C cannot be used with Harmonic/Resonant winding generators.

Connection A Wiring

XR5 C Connection A Wiring Diagram

Wiring diagram for Connection A, used for higher voltage excitation fields.

Connection A Voltage Limits and Transformers

Maximum input voltage and transformer requirements for Connection A.

Parallel Configuration for Connection A

Parallel Hookup Diagram (Connection A)

Diagram for paralleling with XR5C using Connection A.

Parallel Operation Setup Tips

Recommendations for successful parallel operation setup.

Connection B Wiring

XR5 C Connection B Wiring Diagram

Wiring diagram for Connection B, used for 32-63VDC excitation fields.

Connection B Voltage Limits and Transformers

Maximum input voltage and transformer requirements for Connection B.

Parallel Configuration for Connection B

Parallel Hookup Diagram (Connection B)

Diagram for paralleling with XR5C using Connection B.

Parallel Operation Setup Tips

Recommendations for successful parallel operation setup.

Connection C Wiring

XR5 C Connection C Wiring Diagram

Wiring diagram for Connection C, used for low voltage excitation fields.

Connection C Voltage Limits and Transformers

Maximum input voltage and transformer requirements for Connection C.

Parallel Configuration for Connection C

Parallel Hookup Diagram (Connection C)

Diagram for paralleling with XR5C using Connection C.

Parallel Operation Setup Tips

Recommendations for successful parallel operation setup.

Initial Setup and Commissioning

Setup Step-by-Step Procedures

Procedures for initial setup and calibration of the voltage regulator.

Voltage and Stability Adjustment

Guidance on using adjustment pots for voltage and stability tuning.

Connecting to Line and Load Testing

Steps for connecting to the line and observing performance under load.

Optional Power-Tronics Add-On Modules

Static Exciter Modules (SEM250 A;B)

Modules to convert XR5C to a static exciter with higher DC output.

Automatic Battery Flash Module (ABF10)

Module for automatic battery flash for guaranteed buildup.

External Interface Module (EIM1020 VM)

Module for external control via digital signals.

Motorized Potentiometer Module (MOP1224 HD)

Module for external control using pulsed signals or dry contacts.

High Voltage Disconnect Module (HVD2)

Module for passive protection against runaway high voltage.

Shunt-Wound to Solid-State Conversion

Original Shunt-Wound Wiring Diagram

Diagram showing typical original wiring for shunt-wound exciters.

Converted Solid-State Wiring Diagram

Diagram showing converted wiring for modern solid-state regulation.

Fuse Replacement Procedure

Fuse Locations and Specifications

Identification of fuse locations and required fuse type/rating.

Step-by-Step Fuse Replacement

Instructions for safely replacing the XR5C fuses.

Application Troubleshooting Guide

Problem to Possible Cause Correlation

Table mapping common problems to their likely causes.

Comprehensive List of Possible Causes

Detailed list of potential issues and their relation to regulator problems.

Bench Check Procedures

Bench Test Setup (Figure A)

Instructions and diagram for initial bench testing of the regulator.

Alternate Bench Test Setup (Figure B)

Instructions and diagram for a second bench test configuration.

Installation Warranty Form

Warranty Registration Information Fields

Fields required for completing the installation warranty form.

Repair or Warranty Request Details

Information needed for submitting a repair or warranty request.

Product Warranty Terms and Conditions

Warranty Coverage and Duration

Details on the warranty period and what Power-Tronics covers.

Conditions That Void the Warranty

List of actions or conditions that will nullify the product warranty.