SECTION 5516

NP7 - 034
ISSUE 4
(Mod Status A)

SX421 AUTOMATIC VOLTAGE

REGULATOR (AVR)
SPECIFICATION, INSTALLATION AND ADJUSTMENTS

GENERAL DESCRIPTION TECHNICAL SPECIFICATION

The SX421 is a three phase sensed Automatic Voltage SENSING INPUT

Voltage 170-250 V ac max
Regulator (AVR) and forms part of the excitation system for a Frequency 50-60 Hz nominal
brushless generator. Phase 3
Wire 3
In addition to regulating the generator voltage, the AVR circuitry OUTPUT
includes a number of protective features. Excitation power is Voltage max 90 V dc at 207 V ac input
derived directly from the generator terminals. Current Continuous 4 A dc
Transient 6 A for 10 seconds
Field Resistance 15 W minimum
Positive voltage build-up from residual levels is ensured by
the use of efficient semiconductors in the power circuitry of REGULATION (See Note 2) +/- 0.5% RMS
the AVR. THERMAL DRIFT
(after 10 min)
0.5% for 40°C change in AVR ambient
The AVR is linked with the main stator and exciter field windings
to provide closed loop control of the output voltage with load TYPICAL SYSTEM RESPONSE
regulation in the order of +/-0.5% RMS. Field current to 90% 80ms
Machine Volts to 97% 300ms

The AVR senses the output voltage from the main stator EXTERNAL VOLTAGE ADJUSTMENT
+/- 6% with 1 K W trimmer
windings and in response to this controls the power fed to the
exciter field and hence the main field to maintain output voltage UNDER FREQUENCY PROTECTION
within the specified limits, compensating for load, speed, Set Point (See Note 3) 95% Hz
Slope 100-300% down to 30 Hz
temperature, and power factor of the generator.
UNIT POWER DISSIPATION
20 watts maximum
Overvoltages caused by open circuit sensing terminals or
short circuit power device are avoided by overvoltage detection BUILD UP VOLTAGE
circuitry which provides circuit breaker trip signals for circuit 3.5 V ac @ AVR terminals
isolation. (see note 1).
ACCESSORY INPUT
+/- 1V = +/- 5% change in output
A frequency measuring circuit continually monitors the volts @ 415 V
generator output and provides underspeed protection of the QUADRATURE DROOP
excitation system by reducing the generator output voltage Maximum sensitivity (10 W Burden)
proportionally with speed below a presettable threshold. A 0.22A for 5% droop @ 0p.f.
further enhancement of this feature is an adjustable V/Hz slope,
OVER VOLTAGE PROTECTION
to improve frequency recovery time on turbo-charged engines. Set Point 300 V dc
Time Delay (fixed) 1 second
Circuit Breaker Trip Coil Voltage 12-30 V dc
Provision is made for the connection of a remote voltage
C/B Trip Coil Resistance 25-40 W
trimmer, allowing the user fine control of the generator output.
ENVIRONMENTAL
Vibration 20-100 Hz 50mm/sec
Accessories are available for this AVR. Please refer to factory 100 Hz-2 kHz 3.3g
for further details. Relative Humidity 0-60°C 95%
Operating Temperature -40°C to + 70°C
Storage Temperature -55°C + 80°C
NOTES
1. A miniature circuit breaker must be fitted to use the
Overvoltage Protection feature.
2. With 4% engine governing.
3. Factory set, semi-sealed, jumper selectable.
 DESIGN DETAILS

The main functions of the AVR are: Stability Circuit provides adjustable negative ac feedback to
ensure good steady state and transient performance of the
Sensing Resistors take a proportion of the generator output
control system.
voltage and attenuate it. This input chain of resistors includes
the range potentiometer and hand trimmer which adjusts the Power Control Driver controls the conduction period of the
generator voltage. output device. This is achieved by pedestal and ramp control
followed by a level detector and driver stage.
Quadrature Droop Circuit converts the current input into a
voltage which is phase mixed with the sensing voltage. The Power Control Devices and Rectifier vary the amount of
result is a net increase in the output from the sensing network exciter field current in response to the error signals produced
as the power factor lags, causing the reduction in excitation by the main comparator.
needed for reactive load sharing of paralleled generators.
Synchronising Circuit provides a short pulse at the zero
A trimmer allows control over the amount of droop signal. crossing of each cycle and is used to synchronise the Under
Frequency Roll Off (UFRO) and power control circuits to the
RMS Converter is a square law precision rectifier circuit that generator cycle period.
converts the ac signals from the sensing networks into a
composite dc signal representing the mean squared value of UFRO circuit measures the period of each electrical cycle and
the waveform. reduces the reference voltage linearly with speed below a
presettable threshold. A light emitting diode (LED) gives
Offset Control provides an interface between the AVR and
indication of underspeed.
accessories.
Engine Relief (load acceptance) circuit causes greater voltage
Power Supply components consist of zener diodes, dropper
roll off (makes the volts/Hz slope steeper) to aid engine speed
resistors and smoothing to provide the required voltages for
recovery after application of a "block" load.
the integrated circuits.
Overvoltage Monitor continuously monitors the voltage at the
Precision Voltage Reference is a highly stable temperature
generator terminals and provides signals to trip a circuit breaker
compensated zener diode for comparison purposes.
to isolate power from the exciter and AVR if sustained
Main Comparator/Amplifier compares the sensing voltage to overvoltages occur. A one second timer is included in the circuit
the reference voltage and amplifies the difference (error) to to prevent operation during transient overvoltages which are
provide a controlling signal for the power device. normal after load removal.

A miniature circuit breaker must be fitted to use the Overvoltage

Protection feature.
 FITTING AND OPERATING

SUMMARY OF AVR CONTROLS

CONTROL FUNCTION DIRECTION
VOLTS TO ADJUST GENERATOR OUTPUT VOLTAGE CLOCKWISE INCREASES OUTPUT VOLTAGE
STABILITY TO PREVENT VOLTAGE HUNTING CLOCKWISE INCREASES STABILITY OR DAMPING EFFECT
STABILITY SELECTION TO OPTIMISE TRANSIENT PERFORMANCE LINK DEPENDING UPON KW OUTPUT
UFRO TO SET UNDER FREQUENCY ROLL OFF KNEE POINT CLOCKWISE REDUCES THE KNEE POINT FREQUENCY
FREQUENCY SELECTION TO SELECT 'UFRO' CONTROL RANGE LINK DEPENDING ON OPERATING FREQUENCY
DROOP TO SET GENERATOR DROOP TO 5% AT FULL LOAD 0 PF CLOCKWISE INCREASES THE DROOP
TRIM TO MATCH AVR INPUT TO ACCESSORY OUTPUT CLOCKWISE ALLOWS THE ACCESSORY MORE CONTROL OVER AVR
DIP TO SET THE INTIAL FREQUENCY RELATED VOLTAGE DIP CLOCKWISE INCREASES THE VOLTAGE DIP
OVER/V TO SET THE OVERVOLTAGE PROTECTION CUT OFF LEVEL CLOCKWISE INCREASES THE OVERVOLTAGE CUT OFF LEVEL
RMS SET AND SEALED AT FACTORY

The AVR is fully encapsulated to ensure long trouble-free 2) Turn remote volts trimmer (if fitted) to midway position.
operation. It is usually fitted on a panel of the terminal box. It
3) Turn STABILITY control to midway position.
can also be separately fitted in a switchboard.
4) Connect a suitable voltmeter (0-300V ac) across
ADJUSTMENT OF AVR CONTROLS
line to neutral of the generator.
VOLTAGE ADJUSTMENT
5) Start generator set, and run on no load at nominal
The generator output voltage is set at the factory, but can be frequency e.g. 50-53Hz or 60-63Hz.
altered by careful adjustment of the volts control on the AVR
board, or by the external hand trimmer if fitted. Terminals 1 & 2 6) If the red Light Emitting Diode (LED) is illuminated,
on the auxiliary terminal block inside the generator terminal refer to the Under Frequency Roll Off (UFRO)
box will be fitted with a shorting link if no hand trimmer is adjustment.
required.
7) Carefully turn VOLTS control clockwise until rated
voltage is reached.
Do not increase the voltage above the
rated generator voltage. If in doubt, 8) If instability is present at rated voltage, refer to stability
refer to the rating plate mounted on the adjustment, then re-adjust voltage if necessary.
Warning ! generator case.
9) Voltage adjustment is now completed.

STABILITY SELECTION
If a replacement AVR has been fitted or re-setting of the VOLTS
adjustment is required, proceed as follows:- The "jumper" selector lead should be correctly linked for the
frame size of the generator (See diagram above).
1) Before running generator, turn VOLTS control fully
anti-clockwise.
STABILITY ADJUSTMENT controller. It is designed to accept dc signals up to +/- 5 volts.
The AVR includes a stability or damping circuit to provide good The dc signal on this input (A1,A2) adds to or subtracts from
steady state and transient performance of the generator. the AVR sensing circuit, depending on polarity.
The correct setting can be found by running the generator at
no load and slowly turning the stability control anti-clockwise The Trim control allows the user to adjust the sensitivity of the
until the generator voltage starts to become unstable. AVR to the PF controller output.
The optimum or critically damped position is slightly clockwise
from this point (i.e. where the machine volts are stable but close With Trim fully anti-clockwise the PF controller has no effect.
to the unstable region). Clockwise it has maximum effect. Normal setting is fully
clockwise.
FREQUENCY SELECTION
OVER VOLTAGE (OVER V) ADJUSTMENT
The "jumper" selection lead should be correctly linked for the
nominal operating frequency of the generator (see diagram). A miniature circuit breaker is supplied for this feature. It may
be fitted in the generator or supplied loose for fitting in the
UNDER FREQUENCY ROLL OFF (UFRO) ADJUSTMENT control panel.

The AVR incorporates an underspeed protection circuit which The AVR includes over voltage protection circuitry to remove
gives a volts/Hz characteristic when the generator speed falls generator excitation in the event of a short circuit power device
below a presettable threshold known as the "knee" point. or loss of sensing input.

The red Light Emitting Diode (LED) gives indication that the Separate terminals are provided for the over voltage circuit
UFRO circuit is operating, and turning the UFRO control E1, E0 which connect to the generator windings independently
clockwise lowers the frequency setting of the "knee" point and of the AVR sensing terminals. (Typical E1, E0 voltage = 240
extinguishes the LED. Vac).

For optimum setting, the LED should illuminate as the frequency Provision is made for the connection of the circuit breaker to
falls just below nominal, i.e. 47Hz on a 50Hz system or 57Hz break terminals K1, K2, interrupting the power supply to the
on a 60Hz system. exciter field. The addition of this circuit breaker (and leads B0
and B1) causes the AVR power supply to be interrupted
If the red LED is illuminated and no output voltage is present, automatically in the event of an over voltage.
refer to Over Voltage protection adjustment.
The OVER V adjustment is normally set and sealed at the
DIP ADJUSTMENT factory but can be reset on retrofit AVRs. Clockwise increases
the tripping voltage.
The 'DIP' adjustment allows some control over the generator
voltage dip upon the application of load.
Caution ! When the circuit breaker is supplied
This feature is mostly used when the generator is coupled to loose, the AVR is fitted with a link on
turbo-charged engines with limited block load acceptance, and
terminals K1-K2 to enable operation of
operates only when the speed is below the UFRO knee point.
the AVR. When connecting the circuit
The circuit works by increasing the volts/Hz slope to give greater breaker this link must be removed.
voltage roll off in proportion to speed.

With the 'DIP' control fully anti-clockwise the generator voltage In the event of operation of the circuit breaker, indicated by
characteristics will follow the normal V/Hz line as the frequency loss of generator output voltage, manual resetting is required.
falls below nominal. When in the "tripped" state the circuit breaker switch lever
shows "OFF". To reset move the switch lever to the position
Turning the 'DIP' control more clockwise provides greater showing "ON".
voltage dip allowing easier engine recovery.
When fitted in the generator, access to the breaker is gained
DROOP ADJUSTMENT by removal of the AVR access cover.

Generators intended for parallel operation are fitted with a Terminals which are live with the
quadrature droop C.T. which provides a power factor correction
signal for the AVR. The C.T. is connected to S1, S2 on the generating set running are exposed
AVR. when the AVR access cover is removed.
Resetting of the circuit breaker must be
The DROOP adjustment is normally preset in the works to give carried out with the generating set
5% voltage droop at full load zero power factor. Warning ! stationary, and engine starting circuits
Clockwise increases the amount of C.T. signal injected into disabled.
the AVR and increases the droop with lagging power factor
The circuit breaker is mounted on the AVR mounting bracket
(cos Ø).
either to the left or to the right of the AVR depending upon
With the control fully anti-clockwise there is no droop. AVR position. After resetting the circuit breaker replace the
AVR access cover before restarting the generating set. Should
resetting of the circuit breaker not restore the generator to
TRIM ADJUSTMENT normal operation, refer to the Service section in the generator
An auxiliary input is provided to connect to the Power Factor Instruction Manual.

NEWAGE INTERNATIONAL LIMITED

Registered Office and Address:
PO Box 17, Barnack Road, Stamford, Lincolnshire PE9 2NB England.
Telephone: 44 (0) 1780 484000 Fax: 44 (0) 1780 484100 Telex: 32268 Registered in England No. 441273

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