SENR5833-05

February 2002

Specifications
Systems Operation
Testing and Adjusting
Digital Voltage Regulator
 i01658146

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or
pictorially presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,
work method or operating technique that is not specifically recommended by Caterpillar is used,
you must satisfy yourself that it is safe for you and for others. You should also ensure that the
product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job. Caterpillar dealers have the most current information available.

When replacement parts are required for this

product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
 3
Table of Contents

Table of Contents
Specifications Section
Electrical ................................................................. 4
Dimensions ............................................................. 6

Systems Operation Section

General Information ................................................ 7
Display and Keypad ................................................ 8
Startup Profile Function ........................................ 10
Loading and Stopping Profile ................................ 11
Voltage Regulation ................................................ 12
Line Loss Compensation ...................................... 12
Reactive Voltage Droop ........................................ 13
Cross Current Compensation ............................... 13
KVAR Regulation .................................................. 14
Power Factor Regulation ....................................... 15
Parameters ........................................................... 17
Fault Classifications .............................................. 28
Fault Codes ........................................................... 30
Remote Communication ....................................... 33
Customer Options ................................................. 33

Testing and Adjusting Section

Testing and Adjusting
General Information .............................................. 37
Service Tools ........................................................ 37
Startup Procedure ................................................ 38
Parameter Viewing and Configuring Procedure .... 38
Fault Handling ....................................................... 39
Fault Handling for Earlier Digital Voltage
Regulators ........................................................... 41
Troubleshooting .................................................... 43
No Voltage - Troubleshoot ..................................... 44
Low Voltage - Troubleshoot ................................... 46
High Voltage - Troubleshoot .................................. 48
Unstable Voltage - Troubleshoot ........................... 50
Inaccurate Display - Troubleshoot ......................... 51
Reverse Power Shutdown or Reverse VAR Condition
- Troubleshoot ..................................................... 52
Improper PF Regulation or KVAR Regulation -
Troubleshoot ....................................................... 53
Watchdog Alarm - Troubleshoot ............................ 54
Loss of Frequency Shutdown - Troubleshoot ........ 55
Instantaneous Trip Shutdown - Troubleshoot ........ 55
Wiring Diagrams ................................................... 57

Index Section
Index ..................................................................... 67
4
Specifications Section

Specifications Section
i01041627

Electrical
SMCS Code: 4467
Table 1
Specifications
Regulation 0.25% from no load to full load.
Regulator temperature drift Less than 0.5% for any 40 C (72 F) change over the ambient operating temperature range.
Configurable Volts/Hz Two slope ranges adjustable from 1 to 10 V/Hz. See the Regulation Characteristic Illustration.
characteristic
Regulator response time Maximum of 10 milliseconds.
Regulator sensing True RMS 3-phase sensing is standard. Single phase sensing is available. Variable sense
range: 90 to 600 volts.
Regulator stability The regulator responds to the fundamental component of the sensed voltage and remains
stable for total harmonic distortion of the generator output voltage waveform, up to 20%.
Telephone influence factor Less than 50. Complies with MIL STD 461C Part 9 and VDE 0875 level N.
(TIF)
Fine voltage adjust range ± 10% of regulator sensing voltage.
Regulator voltage gain (Line Adjustable from 0 to 10%.
loss compensation)
Fault detection and Diagnostics identify operation outside of programmed limits. Specific fault information is
identification available even after the unit has been powered down.
Regulator start-up voltage Meets ISO8325-3 class G2 specifications.
Harmonic tolerance The digital voltage regulator maintains precise control of the generator output with up to 20%
harmonic distortion in the generator output voltage.
Reactive droop adjustment Adjustable from 0 to 10%.
Overexcitation protection Shuts off generator output when excitation current exceeds normal operating currents for 15
seconds or instantaneous shutoff if output is shorted.
Ambient operating −40 C (−40 F) to +70 C (+ 158 F).
temperature
Storage temperature range −40 C (−40 F) to +85 C (+ 185 F).
Power dissipation 5 watts at idle, 55 watts at rated output.
Shock Withstands up to 20 g’s.
Vibration Withstands 4.5 g’s at frequencies between 18 and 2000 Hz in three mutually perpendicular
planes.
Salt spray Meets MIL-STD-810C, method 509.1.
Sealing Withstands up to 35 kPa (5.08 psi).
Weight 5 kg (11 lb).
Electromagnetic Meets 89/336/EEC Electromagnetic Compatibility Directive.
compatibility
Power supply 24 ± 6 volt DC power supply required (0.5 amp).
 5
Specifications Section

g00538141
Illustration 1
Regulation Characteristic Illustration

Table 2
Summary of Operating Parameters
Power Input Output Rating Sensing Reactive Exciter Field
Droop Resistance
Input
Voltage Generator V Freq. VA Max. Min. V Max. Max. Max. Min. Max.
Regulator Type Hz Conti- Forcing VA Vol- VA Ohms Ohms
Rating nuous Bur- tage Bur-
den den
V A V A per
Ø
120 Volt PM/SE 70-120 50-240 1500 48 12 84 21 79/124 1 5 1 3 10
3Ø
240 Volt PM/SE 70-120 50-240 1500 48 12 84 21 125/249 1 5 1 3 10
3Ø
480 Volt PM/SE 70-120 50-240 1500 48 12 84 21 250/600 1 5 1 3 10
3Ø
6
Specifications Section

i01041622

Dimensions
SMCS Code: 4467

g00538091
Illustration 2
Dimensions Of The Digital Voltage Regulator
(The dimensions are referenced to centerlines.)
(A) 119.9 mm (4.72 in) (E) 150.6 mm (5.93 in)
(B) 88.9 mm (3.50 in) (F) 9.9 mm (0.39 in)
(C) 9.9 mm (0.39 in) (G) 191.5 mm (7.54 in)
(D) 140.7 mm (5.54 in) (H) 266.4 mm (10.49 in)
 7
Systems Operation Section

Systems Operation Section The digital voltage regulator is a microprocessor

based voltage regulator. The main purpose of
the digital voltage regulator is to regulate output
i01041637 voltage of a generator which is used with an
engine generator set. Service personnel can modify
General Information (configure) certain regulation characteristics. The
modifications will allow the engine generator set
SMCS Code: 4467 performance to be optimized. The digital voltage
regulator can also integrate into one package many
options that were previously panel mounted. The
options include KVAR/PF controller, overexcitation
protection, fault detection, overvoltage protection,
undervoltage protection, diode monitor, reverse
power relay and system parameter monitoring.

The configurable parameters of the digital voltage

regulator are listed below.

• Voltage versus frequency (V/Hz) characteristic

• Fine voltage level adjustment
• Droop adjustment
• Overvoltage trip point with adjustable trip time
• Undervoltage trip point with adjustable trip time
• Gain
• Single-phase or three-phase true RMS sensing
• Underfrequency trip point
• Knee frequency
g00538257
Illustration 3
• Performance gains
Digital Voltage Regulator
(1) Display • Generator set parameters
(2) Keypad
(3) J1 connector • Minimum voltage
(4) Screw terminals
• Diode monitor ripple level
Display (1) of the digital voltage regulator, shows
numbers that represent different parameters of the
• Reverse VAR trip time
digital voltage regulator system. Keypad (2) is used
to change the information that is shown on display
• Reverse power trip point with adjustable trip time
(1). J1 connector (3) is used to join the digital
voltage regulator to a personal computer. Screw
• Optional KVAR level
terminals (4) are used to join the digital voltage
regulator to the generator and various customer
• Optional power factor level
options. The protective functions that the digital voltage
regulator provides are listed below.

• Overvoltage protection
• Undervoltage protection
• Loss of sensing
• Rotating diode monitor
8
Systems Operation Section

• Overexcitation protection Display (1) and keypad (2) are used to select
and manipulate parameter values that control the
• Reverse VAR detection operation of the digital voltage regulator. Display
(1) of the digital voltage regulator has four digits.
• Underfrequency protection A colon in the display indicates that the number
showing is a parameter code. If a colon is not
• Instantaneous field over current trip present, then the number showing is a parameter
value. A decimal point in the display is used to
• Optional reverse power relay indicate the precision of the parameter value.

• Loss of frequency Keypad (2) has three keys. The keys are listed
below.
The digital voltage regulator can be set up for
a specific application by using the configurable • Function key (3)
parameters. Parameters are preset at the factory.
Parameters may need to be adjusted in order • Scroll down key (4)
to meet the specific requirements of a site. The
digital voltage regulator also detects faults and sets • Scroll up key (5)
the appropriate alarm or caution. Certain system
parameters can also be monitored on the display of Display (1) has two modes, parameter code mode
the digital voltage regulator. and parameter value mode. Function key (3) is used
to toggle back and forth between the two modes.
Scroll down key (4) and scroll up key (5) are used
i01041625
to decrease and increase the parameter number or
Display and Keypad value number that is showing on display (1).
Table 3
SMCS Code: 4467
Parameter Code Parameter Value
:01 0480
0481
0482
0483
:02 0001
0002
0003
0004
:03 0004
g00538863
Illustration 4 0003
Display And Keypad
0002
(1) Display
:04 0100
(2) Keypad
(3) Function key 0099
(4) Scroll down key 0100
(5) Scroll up key
0101
Note: For a list of parameter codes and the
corresponding range of values, see System The operation of display (1) and keypad (2) can
Operation, “Parameters”. be described as a table. Pressing function key (3)
toggles the display back and forth between the
two columns of the table (parameter code and
parameter value). If a colon is present, the display
is in parameter code mode. If a colon is not present,
the display is in parameter value mode.
 9
Systems Operation Section

Pressing a scroll up key (5) or scroll down key (4) If scroll up key (5) is pressed, the display moves
will increase or decrease the display to the next (scrolls) up to the next parameter code, “:02”.
number within a column. Use of the scroll keys Again, the colon is on. This is the entry point for
cannot cause the display to change columns of the parameter code :02.
table.
Then, if scroll down key (4) is pressed, the display
In order to configure a parameter code (change the moves (scrolls) down to the preceding parameter
value), follow the procedure below. code, “:01” again.

1. Select the desired parameter code by pressing If scroll down key (4) is pressed again, the display
scroll key (4) or (5). moves (scrolls) to the highest parameter code,
“:96”.
2. Access the parameter value by pressing function
key (3). Note: When scroll key (4) or (5) is held down for
more than five seconds, the display will scroll
3. Select the desired parameter value by pressing rapidly. Otherwise, the display changes at the rate
scroll key (4) or (5). of one parameter per second.

4. Enter the chosen value into the memory of the

digital voltage regulator by pressing function key
(3).

Example

g00538865
Illustration 6
Example Illustration - Display Shows Value Of “0480”

Note: The value of some parameter codes is only

for viewing by the user. Such parameters are not
configurable. See System Operation, “Parameters”.
Illustration 5
g00538864 View the value. Then, press function key (3) in order
to return the display to showing parameter codes.
Example Illustration - Display Shows Parameter Code Of :01
(1) Display If function key (3) is pressed, the display changes
(2) Keypad to show the value “0480” of parameter code :01.
(3) Function key Notice that the colon is off. The value of parameter
(4) Scroll down key code :01 can now be changed (configured).
(5) Scroll up key
If scroll up key (5) is pressed, the display moves
(scrolls) up to the next value, “0481”. The colon
This example is a demonstration of scrolling and
selection of parameter codes. Also the scrolling and remains off.
configuration of values is demonstrated.
Then if scroll down key (4) is pressed, the display
After the digital voltage regulator is powered up moves (scrolls) down to the preceding value, “0480”
(battery voltage applied) parameter code “:01” is again.
shown on the display. The engine does not have
to be running for the digital voltage regulator to To enter (configure) a new value for a parameter
show parameter codes. The colon indicates that a code, scroll the display until the desired new value
is showing, then press function key (3). Now, the
parameter code is being shown.
new value is entered into the memory of the digital
The user has the option of pressing function key (3), voltage regulator. The display returns to showing
the parameter codes.
scroll down key (4), or scroll up key (5).
10
Systems Operation Section

i01041659

Startup Profile Function

SMCS Code: 4467

g00538913
Illustration 7
Startup Profile Function Illustration

The parameters that are related to the startup profile The startup profile function sets up the volts
function are listed below. per hertz profile (V/Hz) during startup only. The
digital voltage regulator will begin to build voltage
01 – Generator Output Voltage following a 1:1 volts per hertz profile after the
configurable underfrequency point (parameter
03 – Generator Type :10) has been reached. When the speed reaches
the knee frequency point (parameter :06), the
06 – Knee Frequency loading/stopping profile takes effect. The startup
profile function will not be initiated again unless
10 – Underfrequency Point the frequency drops below the underfrequency
point (parameter :10). The underfrequency point is
defaulted to 25 Hz, with a range of 20 to 40 Hz. This
is the same underfrequency setpoint used by the
loading/stopping setpoint. The startup V/Hz slope is
set to 1. The startup V/Hz slope is not adjustable.
A V/Hz slope of 1 indicates that a change of 1%
voltage will result for every 1% of frequency change.
The knee frequency point is the point above which
the digital voltage regulator will regulate to the
voltage specified by the generator output voltage
parameter. The generator type selects whether the
frequency being detected is the actual generator
output frequency (SE) or one of the permanent
magnet (PM) frequencies.
 11
Systems Operation Section

i01041640

Loading and Stopping Profile

SMCS Code: 4467

g00538141
Illustration 8
Illustration Of The Loading And Stopping Profile

The parameters that are related to the loading and Voltage regulators are generally of the volts
stopping profile are listed below. per hertz type or the constant voltage type.
The digital voltage regulator can perform as a
01 – Generator Output Voltage constant voltage regulator or a volts per hertz type
regulator depending on user configuration. Volts
03 – Generator Type per hertz type regulators are commonly used with
reciprocating internal combustion engine driven
06 – Knee Frequency generator sets because they provide an automatic
means for the engine to recover from a large block
07 – Decreasing V/Hz Slope 1 load. In the digital voltage regulator, the block load
recovery performance is configurable so that it may
08 – Decreasing V/Hz Slope 2 be field optimized for each specific application.

09 – Minimum Voltage When the generator is running and if a large load is

applied, the frequency and voltage will drop. The
10 – Underfrequency Point loading/stopping function minimizes the amount
of time that it takes the engine and generator
to recover and increases the ability to pick up
large loads. After the knee frequency has been
reached on startup, this function will modify the
voltage reference based upon the frequency of the
generator.
12
Systems Operation Section

As a large load is applied, the engine speed i01073831

will begin to drop (frequency decreases). As the
frequency decreases below the knee frequency, Voltage Regulation
the voltage reference will decrease on a Volts/Hz
slope according to the decreasing slope 1 SMCS Code: 4467
value (parameter :07). If the frequency decrease
continues beyond the knee frequency minus 5 The parameters that are related to voltage regulation
Hz, then the voltage reference will decrease on are listed below.
a Volts/Hz slope according to the decreasing
slope 2 value (parameter :08) until the minimum :01 – Generator Output Voltage
voltage level (parameter :09) is reached. The digital
voltage regulator will try to regulate the generator :02 – Ratio of Output Voltage to Sensing Voltage
output voltage at the minimum voltage, unless the
underfrequency point (parameter :10) is reached :03 – Generator Type
where the generator output voltage will decrease to
a minimum value. :06 – Knee Frequency

As the engine recovers from the load increase, :16 – Integral Gain
the voltage will increase in the reverse order as it
decreased, unless the frequency dropped below :17 – Proportional Gain
the underfrequency point. If the frequency dropped
below the underfrequency point, the startup profile Once startup has been achieved and the generator
will be used for the recovery. output frequency is above the knee frequency, the
regulator will normally act to keep the generator
In some applications it is desirable to maintain output voltage constant. As changes in generator
a constant voltage at the possible sacrifice of a loading cause the voltage to sag or rise, the
larger frequency dip during load transients. The regulator will automatically adjust generator
digital voltage regulator can accommodate these excitation to maintain the output voltage as set by
applications if the knee frequency (parameter :06) parameter :01. If loading causes the generator
is configured for a lower value than normal. The frequency to drop below the knee frequency,
actual value will depend on the specific application. the loading and stopping profile as previously
When used in this application, the load transients described will be followed. See System Operation,
must be kept small in order to allow the engine to “Loading And Stopping Profile”.
recover without dropping below the knee frequency.
A remote voltage adjust rheostat may be used
When a large block load is switched on to the to fine tune the generator output voltage. When
system, the engine speed temporarily decreases used, the active value of voltage reference may be
as the engine produces the additional power adjusted ±10% about the value set in parameter :01.
requirement by burning more fuel. If the regulator is
set to act as a volts per hertz type, it will reduce the i01073865
output voltage according to the slope of the V/Hz
curve. The reduction in voltage reduces the power Line Loss Compensation
requirement of the load, thus allowing the engine to
recover faster for a given block load. If the regulator SMCS Code: 4467
is set to act as a constant voltage type, the regulator
will not reduce the output voltage for a change in In some installations where a single generator is
speed (addition of block load). Therefore, it will used with long feeder lines to the load, it may be
take the engine a longer time to regain speed and advantageous to provide line loss compensation.
supply the total power requirement of the load. If the Line loss compensation is commonly referred to
regulator is set to act as a constant voltage type, as IR compensation. In this mode, a CT must be
care must be taken to keep block load applications provided in order to measure the generator current.
small enough so that the engine can recover in
acceptable time. The parameters that are related to line loss
compensation are listed below.

:01 – Generator Output Voltage

:02 – Ratio of Output Voltage to Sensing Voltage

:03 – Generator Type

 13
Systems Operation Section

:04 – Rated Generator Output Current :22 – Droop/CCC Select (only on part number
155-xxxx and later)
:05 – CT Voltage at Rated Generator Current
:30 – Droop Percentage
:06 – Knee Frequency
When generators operate in parallel, two primary
:15 – Voltage Gain (Line Loss Compensation) objectives are for the generators to share both
the real power requirements and the reactive
:16 – Integral Gain power requirements of the system electrical load.
The engine governors will control sharing of the
:17 – Proportional Gain real power requirements (kW) and the voltage
regulator will control sharing of the reactive power
Current flowing through a long cable conductor requirements (KVAR) of the total system load. If the
causes a voltage drop due to the resistance of output voltage of one generator is slightly higher
the wire. Therefore, the voltage at the load end of than the other generators, it will supply lagging
the conductor will be lower than at the generator reactive current to the other generators connected
end due to the voltage drop along the conductor. in the group. This current will circulate between
This condition is commonly referred to as line generators, possibly causing ampere overloading.
losses. In order to improve the power quality, the One method of minimizing this effect is to cause
digital voltage regulator can compensate for this an individual generator’s output voltage to sag, or
phenomenon. As generator load increases, the “droop”, in proportion to the lagging reactive current
regulator will cause the output voltage to rise slightly flow from it as measured with a current transformer
at the generator terminals in order to compensate (CT). For proper reactive load sharing, the regulator
for line losses. Voltage gain (parameter :15) controls must know the rated generator output current
the amount of compensation. It should be adjusted (parameter :04), the CT voltage at rated generator
to yield a constant voltage at the location of the current (parameter :05) and the desired percentage
load. of output voltage droop (parameter :30) when the
generator is at rated reactive output current.
If line loss compensation is desired, droop
percentage (parameter :30) should be set to zero, As reactive lagging generator output current
as the two functions are counteracting. If a CT is increases, the regulator will cause the output
provided but line loss compensation is not desired, voltage to droop (lower the voltage) proportionally. If
voltage gain (parameter :15) must be set to zero. the measured reactive output current is leading, the
output voltage will rise. In either case, this action will
tend to reduce the reactive current for better KVAR
i01074092
sharing with other units. The droop percentage
Reactive Voltage Droop (parameter :30) controls how much the generator
output voltage will vary for a given amount of
SMCS Code: 4467 reactive current. It is important that the connected
CT polarity is correct for the voltage to droop with
Parameters that are related to voltage regulation lagging current flow. The line loss compensation
with reactive droop are listed below. voltage gain (parameter :15) function can adversely
affect load sharing. For reactive droop to work
:01 – Generator Output Voltage properly, parameter :15 should be set to zero.

:02 – Ratio Of Output Voltage To Sensing Voltage i01074156

:03 – Generator Type Cross Current Compensation

:04 – Rated Generator Output Current SMCS Code: 4467

:05 – Current Transformer (CT) Voltage At Rated Parameters related to voltage regulation with cross
Generator Current current compensation (CCC) are listed below.

:06 – Knee Frequency :01 – Generator Output Voltage

:15 – Voltage Gain :02 – Ratio of Output Voltage to Sensing Voltage

:16 – Integral Gain :03 – Generator Type

:17 – Proportional Gain :04 – Rated Generator Output Current

:05 – CT Voltage At Rated Generator Current

14
Systems Operation Section

:06 – Knee Frequency Beginning with regulator part numbers 155-xxxx

and newer, another parameter was added to
:15 – Voltage Gain signal the digital voltage regulator when the CT
is measuring differential compensation current or
:16 – Integral Gain normal generator line current. Parameter :22 is used
to notify the regulator that CCC is in effect, and
:17 – Proportional Gain to turn off the features that would be erroneous in
that configuration. When parameter :22 is set to a
:22 – Droop/CCC Select (only on part number “1” (CCC selected), the reverse VAR detection and
155-xxxx and later) optional reverse power fault detection are turned
OFF, as well as the ability to view all current related
:30 – Droop Percentage parameters, such as parameters :52, :53, :54, :56,
:57, and :58. If any current related parameters are
Cross current compensation is often used to selected for display when CCC mode is selected,
minimize circulating current flow between the the value for these parameters will read zero.
generators which are connected in parallel. The
advantage of this operating mode is that all
i01073672
generators contribute to establish the same output
voltage to the load. A utility voltage connection
is not necessary to do so. Operation is similar to
KVAR Regulation
the reactive voltage droop mode except that the SMCS Code: 4467
secondary circuits of the current measuring CT’s
of all generators are interconnected in a series Note: KVAR regulation is an optional feature.
string. Each generator is initially adjusted in order
to provide the same output voltage via parameter Parameters that are related to KVAR regulation are
:01. When all generators share the same current, listed below.
in magnitude and phase (according to their CT
ratio), there will be no significant voltage output on :01 – Generator Output Voltage
the secondary of any generator CT. If one of the
generators carries more current or the current that :02 – Ratio Of Output Voltage To Sensing Voltage
the generator carries is lagging or leading relative
to the others, a net difference voltage signal will :03 – Generator Type
be created on the burden resistor for that CT. If
that generator is supplying more reactive (lagging) :04 – Rated Generator Output Current
current than other generators, the phase polarity
and the magnitude of the signal returned to the :05 – CT Voltage At Rated Generator Current
digital voltage regulator will be such to cause a
slight decrease in the generated voltage, reducing :31 – PF/KVAR Select
the amount of reactive current. Less reactive (or
more leading) current will cause the generator :33 – KVAR Reference
voltage to rise. The net result is that the generated
voltage and the output current of each generator :36 – Paralleling Integral Gain
is trimmed toward an operating point where all
generators will share the same load current in :37 – Paralleling Proportional Gain
proportion to their CT ratio, with the little or no
circulating current between them. Parameter :30 Note: Parameters :36 and :37 are only available on
controls the amount of individual generator voltage part number 155-xxxx or newer.
droop (or rise) for a given amount of CT signal.
When the generator is connected in parallel with
However, because the CT secondary circuits are all an infinite bus (utility), the voltage of the generator
interconnected, the CT signal seen by any individual is controlled by the infinite bus. The voltage of the
regulator is not representative of the actual current generator will change as the infinite bus voltage
flowing in that particular generator. Any display changes. It is not possible to control the system
or calculations that might use that signal as if voltage when the generator is connected to an
it were the actual generator current will provide infinite bus. In this instance, it is necessary for the
erroneous results. This is the case with the digital digital voltage regulator to regulate the reactive
voltage regulator on all models with part numbers power output which is supplied by the generator.
of 130-xxxx or older (smaller prefix number). There are two methods for regulating the reactive
power output.
 15
Systems Operation Section

• KVAR Regulation Parameters that are related to PF regulation are

listed below.
• Power Factor (PF) Regulation
:01 – Generator Output Voltage
Note: KVAR stands for Kilo-Volt-Ampere-Reactive,
which is the unit of measurement for reactive power. :02 – Ratio Of Output Voltage To Sensing Voltage

When the digital voltage regulator is in the KVAR :03 – Generator Type
operating mode, it regulates so that the generator
produces a constant value of reactive power :04 – Rated Generator Output Current
(KVARs), regardless of the real power output of
the generator. In this case, the generator power :05 – CT Voltage At Rated Generator Current
factor will change when the real power output of the
generator changes. A current transformer (CT) is :31 – PF/KVAR Select
necessary for this mode to work.
:32 – PF Reference
The KVAR mode is active when parameter :31 is set
to a logic 1, and the external switch on terminal 41 :33 – KVAR Reference
is closed indicating that the generator is connected
in parallel with utility lines. In KVAR mode, the :36 – Paralleling Integral Gain
generator will supply a constant amount of KVARs
to the system as set in parameter :33 (or a remote :37 – Paralleling Proportional Gain
rheostat), regardless of the real power (kW) output
of the generator set. The generator will supply real :38 – PF Switch Point
power (kW) to the system as determined by the
engine governor and/or load sharing device. It is Note: Parameters :36, :37 and :38 are only available
common that utility loads are too reactive (low power on part number 155-xxxx or newer.
factor), which can cause ampere overloading of the
system due to large reactive current requirements. When the generator is connected in parallel with
In the KVAR mode, the generator can supply a fixed an infinite bus (utility), the voltage of the generator
amount of KVARs to the system to provide a less is controlled by the infinite bus. The voltage of the
reactive load, which will improve the power factor generator will change as the infinite bus voltage
of the load and reduce the ampere demand on the changes. It is not possible to control the system
system. voltage when the generator is connected to an
infinite bus. In this instance, it is necessary for the
A remote PF/KVAR adjust rheostat may be digital voltage regulator to regulate the reactive
connected in the KVAR mode. When in the KVAR power output which is supplied by the generator.
mode (parameter :31 set to 1), the remote rheostat There are two methods for regulating the reactive
adjustment will override the setting for parameter power output.
:33.
• KVAR Regulation
For stable operation of the generator in the KVAR
regulating mode, the generator must be connected • Power Factor Regulation
to a utility or system that is much larger than the
generator. When the tie breaker is closed to the Note: KVAR stands for kilo-Volt-Ampere-Reactive,
utility, use the external control switch contact at which is the unit of measurement for reactive power.
regulator terminal 41, via the gen/utility 52/a aux
contact, to enable the KVAR mode. When the When the digital voltage regulator is in the power
terminal 41 contact logic is open, the regulator factor operating mode, it regulates so that the
will be in a voltage control operating mode with generator produces a constant power factor,
or without droop or line loss compensation as regardless of the real power output of the generator.
previously described. In this case, the reactive current will change when
the real power output of the generator changes. A
current transformer (CT) is necessary for this mode
i01073755
to work.
Power Factor Regulation
SMCS Code: 4467

Note: The power factor (PF) regulation is an optional

feature.
16
Systems Operation Section

Operation of the power factor mode has changed a PROM ID 1.05 Power Factor
number of times, each time to improve the behavior
at low levels of real current. The first change took
Operation
place when the PROM ID (parameter :91) changed
When parameter :31 is set to zero, and the external
to 1.03. This is also coincident with the new fault
switch on terminal 41 is closed, the regulator
parameter methods. The second change took
will start up in the KVAR mode and will regulate
place when the regulator part number changed to
according to the KVAR reference level which is set in
155-xxxx and PROM ID changed to 1.05.
parameter :33. When the real current measurement
is equal to or above the percentage which is set
Original Power Factor Operation in parameter :38, the regulator will switch to the
power factor control mode of operation. Thus, the
When parameter :31 is set to zero, and the external generator set needs to provide a significant amount
switch on terminal 41 is closed, the regulator will of real kW power before the digital voltage regulator
operate in power factor control mode. The regulator will regulate in the power factor mode. In the power
assumes the generator is connected to an infinite factor mode the generator will supply a varying
bus, so that the voltage cannot be changed. In amount of reactive power (KVARs) based upon the
power factor mode the generator will supply a real power output (kW) of the generator to obtain
varying amount of reactive power (KVARs) based the desired power factor set in parameter :32 (or a
upon the real power output (KW) of the generator remote rheostat). When the real current output of the
to obtain the desired power factor set in parameter generator becomes 5% less than the percentage
:32 (or a remote rheostat). configured in parameter :38, the controller will
switch back to regulating only KVARs as described
PROM ID 1.03 Power Factor above. The actual switch-back point has hysteresis.
For further information see the detailed explanation
Operation for parameter :38.

When parameter :31 is set to zero, and the external A remote PF/KVAR adjust rheostat may be
switch on terminal 41 is closed, the regulator will connected in the power factor operating mode.
start up in the KVAR mode supplying 0 KVAR. When When in the power factor mode (parameter :31
the real current measurement is equal to or above set to zero), the remote rheostat adjustment will
10% of rated generator output current, the regulator override the PF reference in parameter :32, but at
will switch to the power factor control mode of levels of current below the PF/KVAR switch point,
operation. The rated generator output current is the KVAR reference will be as set by parameter
parameter :04. Thus, the generator set needs to :33. For stable operation of the generator in the
provide a significant amount of real kW power power factor regulating mode, the generator must
before the digital voltage regulator will regulate be connected to a utility or system that is much
in the power factor mode. The start up value of larger than the generator. When the tie breaker is
0 KVAR is a fixed value and cannot be adjusted. closed to the utility, use the external control switch
While the measured real current is below 10%, the contact at regulator terminal 41, via the gen/utility
remote rheostat input will be ignored. Once the real 52/a aux contact, to enable the power factor mode.
generator output current exceeds 10%, the power When the terminal 41 contact logic is open, the
factor will then be regulated according to parameter regulator will be in a voltage control operating mode
:32 (or a remote rheostat). In power factor mode the with or without droop or line loss compensation as
generator will supply a varying amount of reactive previously described.
power (KVARs) based upon the real power output
(KW) of the generator to obtain the desired power
factor set in parameter :32 (or a remote rheostat).
When the real current output of the generator
decreases to 5% or less of the rated generator
output current, the controller will switch back to
regulating only KVARs as described above. The
switch-back point has hysteresis to avoid ringing.
 17
Systems Operation Section

i01041643

Parameters
SMCS Code: 4467

Parameter Table
Table 4
PARAMETERS
Parameter Title Type Units Range Default
Of Value Value
01 Generator Output Voltage Program Volts 0080 - 9999 0480(1)
02(2) Ratio Of Output Voltage To Sensing Voltage Program - 001.0 - 100.0 001.0
03 Generator Type Program - 0000 - 0004 0004
04 Rated Generator Output Current Program Amps 0000 - 9999 0600
05(2) CT Voltage At Rated Generator Current Program Volts 01.00 - 05.00 05.00
06 Knee Frequency Program Hz 045.0 - 065.0 050.0
07 Decreasing Volts/Hz Slope 1 Program Volts/Hz 001.0 - 010.0 002.0
08 Decreasing Volts/Hz Slope 2 Program Volts/Hz 001.0 - 010.0 002.0
09 Minimum Voltage Program % 050.0 - 100.0 050.0
10 Underfrequency Point Program Hz 020.0 - 040.0 025.0
11 Overvoltage Trip Point Program % 0105 - 0140 0140
12 Overvoltage Trip Time Program Seconds 0002 - 0030 0002
13 Undervoltage Trip Point Program % 0060 - 0095 0060
14 Undervoltage Trip Time Program Seconds 0030 - 0120 0030
15 Voltage Gain (IR Compensation) Program % 000.0 - 010.0 0000
16(3) Integral Gain Program - 001.0 - 020.0 006.0
17(4) Proportional Gain Program - 001.0 - 020.0 005.0
18 Single Phase Sensing Select Program - 0000, 0001 0000
(0 = three phase, 1 = single phase)
19 Diode Monitor Trip Point Program Amps 001.0 - 010.0 002.0
20 Reverse VAR Trip Time Program Seconds 000.1 - 009.9 000.5
21 Reverse VAR Fault Selection Program - 0000 - 0002 0002
22 Droop/CCC Select (0 = Droop, 1 = CCC) Program - 0000, 0001 0000
30 Droop Percentage Program % 000.0 - 010.0 0000
31(5) PF/KVAR Select (0 = PF, 1 = KVAR) Program - 0000, 00001 0000
32(5) PF Reference Program - 00.60 - 01.10 01.00
33(5) KVAR Reference Program Per Unit 00.00 - 01.00 0000
34 Reverse Power Trip Point Program % 000.0 - 020.0 010.0
35 Reverse Power Trip Time Program Seconds 000.0 - 020.0 010.0
36(5) Paralleling Integral Gain Program - 000.1 - 030.0 003.3
37(5) Paralleling Proportional Gain Program - 000.1 - 009.9 001.3
38(5) PF Switch Point Program % 0010 - 0025 0015
(continued)
18
Systems Operation Section

(Table 4, contd)
PARAMETERS
Parameter Title Type Units Range Default
Of Value Value
50 Generator Output Frequency View Hz - -

51 Generator Output Voltage View Volts - -

52 Generator Output Current View Amps - -

53 Generator Reactive Output Current View Amps - -

54 Generator Real Current View Amps - -

55 Exciter Field Current View Amps - -

56(5) Three Phase Kilowatts (“KE” and later) View kW - -

57(5) Power Factor (PF) View - - -

58(5),(6) Three Phase KVAR (“KE” and later) View - - -

60 Hours View Hours - -

70(5),(7) Voltage Adjust View - 0000 - 0200 0100
71(5),(7) PF/KVAR Adjust View - 0000 - 0200 0100
90 Password Program - 0000 - 9999 0200
91 Software ID View - - -

92 Latest Fault View - - 0000

93 Previous Fault View - - 0000
94 Fault Clear Switch - - -

95(8) Alarm Fault View - - -

96 Shutdown Fault Reset Switch - - -

(1) Default value for the output voltage is different depending on the regulator sensing voltage. If the regulator is designed for 120 volts sensing,
then the default output voltage is 4160 volts. All other sensing types have the default output voltage set to 480 volts.
(2) Digital voltage regulators with earlier software (“KD” and earlier) have one less digit to the right of the decimal point.
(3) Earlier versions had a range of 0001-099.9 and default value of 002.0.
(4) Earlier versions had a range of 0001-099.9 and default value of 003.0.
(5) This is an optional feature.
(6) New parameter on serial number prefix “KE” and later digital voltage regulators.
(7) Parameter only available for adjustment through the serial link. See System Operation, “Parameters”, topic Parameter Descriptions for
more details.
(8) Parameter is only available on earlier software versions (“KD” and earlier).

General Information Not all parameters are configurable. Some

parameters are only used as meters meant for
Parameters are pieces of information which are viewing or monitoring purposes. Some parameters
used within the memory of the digital voltage act like a switch that activates a digital voltage
regulator. Each parameter has a specific range of regulator function. Parameters :01 through :49 are
values. Parameters tell the digital voltage regulator configurable parameters and can be changed.
how to operate. Service personnel can configure Parameters :50 through :79 are monitor or view
certain parameters to the requirements of a specific parameters and can only be viewed. Parameters
site. Configuration changes the value of a particular :90 through :99 are system parameters which
parameter. There is an upper and lower limit for are primarily alarm/fault parameters for the entire
the value of each parameter. The limits can not be system.
exceeded.
 19
Systems Operation Section

Each parameter is assigned a specific two digit If the generator output voltage is more than 700
code. These parameters can be shown on the VAC, then use the transformer ratio of the sensing
display of the digital voltage regulator. Parameters transformers. For example, if the generator output
are preceded by a colon. The value of each voltage is 4160 VAC and the sensing transformers
parameter can also be shown on the display of the are 4200:120, the voltage ratio is 35 (4200 divided
digital voltage regulator. The parameter value is a by 120).
four digit number and is not preceded by a colon.

Proper activation of the keypad is necessary to

view or configure the values of the parameters. See
System Operation, “Display And Keypad”. Also,
see Testing And Adjusting, “Parameter Viewing And
Configuring Procedure”.

Parameter Descriptions
Parameter :01 – Generator Output Voltage. This
is the voltage expected (desired) at the generator
output terminals. Modify this parameter in order
to adjust the normal generator output voltage. A
remote voltage adjust rheostat will provide a ±10% g00551383
Illustration 9
voltage adjustment range from the value entered for
generator output voltage. Typical Nameplate On Digital Voltage Regulator

Parameter :02 – Ratio Of Output Voltage To Another method to find the ratio is by performing
Sensing Voltage. This is the ratio of the generator the following measurement.
output voltage to the regulator sensing voltage. The
generator output voltage appears at the terminals 1. Remove wires 26 and 30 from regulator terminals
of the generator. The regulator sensing voltage 26 and 30 in order to eliminate the possibility for
appears at terminals 20, 22, and 24 of the digital overvoltage. Remove the wire from B- in order to
voltage regulator. In order to determine the ratio of avoid fault code 803.
output voltage to sensing voltage if the generator
output is less than 700 VAC, divide the generator 2. Start the engine and run at rated speed (high
output voltage by the voltage range on the digital idle).
voltage regulator ID nameplate. The number
actually used for the voltage range listed on the 3. Measure residual generator output voltage.
digital voltage regulator ID nameplate varies with
the frequency (Hz) of the generator. The numbers 4. Measure voltage across terminals 20 and 22 of
used for the different digital voltage regulator the digital voltage regulator.
voltage ranges are listed below.
5. Shut down the engine.
• If the range is 79-124 use 100 volts for 50 Hz or 6. Voltage ratio is equal to measured generator
120 volts for 60 Hz.
output voltage divided by measured voltage
across terminals 20 and 22.
• If the range is 125-249 use 200 volts for 50 Hz
or 240 volts for 60 Hz.
Note: On occasion, it may be necessary to flash
the field in order to get enough residual voltage for
• If the range is 250-600 use 400 volts for 50 Hz this test.
or 480 volts for 60 Hz.

For example, if the generator output voltage is 480 Parameter :03 – Generator Type. This relates to the
volts and the digital voltage regulator voltage range type of generator which the digital voltage regulator
is 125-249 and the frequency of the generator is controlling. This is required for the digital voltage
is 60 HZ, then the ratio is 480 divided by 240 regulator to properly measure the output frequency
which equals 2. The below method may also work of the generator. The digital voltage regulator
for generators below 700 VAC depending on the measures frequency using two of the PM power
connection diagram employed. inputs (26 and 30). The generator frame size is
indicated on the nameplate which is located on the
outside of the generator terminal box.
20
Systems Operation Section

I – rated generator output current per phase (value

NOTICE entered for parameter :04)
Additional components (potential transformers) are re-
quired when the digital voltage regulator is set for SE W – the number of times each generator wire goes
operation. If the SE generator and the digital voltage through the droop CT window
regulator are not connected properly, the digital volt-
age regulator can be permanently damaged. R – ohms of CT burden resistor

N – number of wires going through the droop CT

In a self-excited application (SE), the PM power
inputs to the digital voltage regulator must be T – CT turns ratio or (ICT primary) / (ICT secondary)
connected to power transformers. Two power
transformers are required to be connected in O – total number of generator output wires per
an ungrounded open delta configuration. Each phase, of which some or all may go through the
transformer must be capable of supplying 1200 VA. droop CT.
The PM inputs must not exceed 120 VAC line to
line. For example, if the generator has a 480 VAC C – generator output voltage connection: 1 for high,
output, use 4:1 transformers. The transformers must 2 for low. Four or six lead generators can only be
be fused on the primary side. 1 (high). Ten or twelve lead generators connected
in series are also 1 (high). Ten or twelve lead
Table 5
generators connected in parallel are considered
Parameter Code :03 - Generator Type 2 (low voltage). Twelve lead generator connected
in delta are considered 2 (low voltage). Six lead
Parameter Exciter Frame Gen Engine
generators connected in delta are still considered
Value Type Size Poles Speed
1 (high).
0 SE All All All
Another method to determine the value for
1 PM 440 6 1000/1200
parameter :05 is listed below.
2 PM 440 4 1500/1800
1. Start and run the generator set at full load
3 PM 580-820 6 1000/1200
(available loading).
4 PM 580-820 4 1500/1800
2. Select and monitor parameter :52 (generator
output current).
Parameter :04 – Rated Generator Output Current.
This parameter is set to the nameplate rated output
3. If the value monitored on parameter :52 is not
current of the generator at 0.8 power factor. This is
approximately equal (± 5%) to the actual current
the 100% maximum rating, including the real and
on phase “B”, then adjust parameter :05 up or
reactive currents. The digital voltage regulator does
down until the current monitored is equal to the
not use this parameter to limit current. However, the
actual current.
parameter must be set properly for the paralleling
and line loss compensation functions in order to
Note: Increasing parameter :05 will lower the value
operate correctly. The rated generator output current
of parameter :52. Decreasing parameter :05 will
is indicated on the nameplate. The nameplate is
increase the value of parameter :52.
located on the outside of the generator terminal box.
Parameter :06 – Knee Frequency. For a visual
Parameter :05 – CT Voltage At Rated Generator
description see System Operation, “Startup Profile
Current. The voltage that the digital voltage
Function”. Also, see System Operation, “Loading
regulator will have at the droop current transformer
And Stopping Profile”. This parameter is set in hertz
(CT) input at rated generator current. This entry is
(Hz). For better stability, it is recommended that
used for droop, line loss compensation, KVAR/PF
this setting be 0.2 to 1.0 Hz below the operating
control, and calculation of the monitoring parameters
frequency. For voltage sensitive applications, it may
:52, :53, :54, :56, :57, and :58. The parameter must
be desirable to set the value lower still.
be set properly for the monitoring, paralleling, and
line loss compensation functions in order to operate
Parameter :07 – Decreasing V/Hz Slope 1. For a
correctly. The value can be calculated by using the
visual description see System Operation, “Loading
following formula.
And Stopping Profile”. This parameter is set in %
voltage change per % frequency change.
Vct=(I × W × R × N) / (T × O × C)

Vct – CT Voltage At Rated Generator Current

 21
Systems Operation Section

Parameter :08 – Decreasing V/Hz Slope 2. For a Note: The undervoltage trip point and undervoltage
visual description see System Operation, “Loading trip time prevent the engine/generator from
And Stopping Profile”. This parameter is set in % operating in an undervoltage condition for an
voltage change per % frequency change. extended time. The minimum voltage (parameter
:09) is the lowest operating voltage where it is
Parameter :09 – Minimum Voltage. For a visual expected that the engine/generator will recover
description see System Operation, “Loading And from a large load application. Setting the minimum
Stopping Profile”. This parameter is set in volts as a voltage above the undervoltage trip point (parameter
percentage of rated voltage (% of parameter :01). :13) eliminates most of the undervoltage protection.

Note: The undervoltage trip point and undervoltage Parameter :15 – Voltage Gain (Line Loss
trip time prevent the engine/generator from Compensation). This parameter increases the
operating in an undervoltage condition for an voltage reference to compensate for voltage drops
extended time. The minimum voltage (parameter in the wires (resistance) from the generator to the
:09) is the lowest operating voltage where it is load. This drop is dependent on the amount of
expected that the engine/generator will recover current flowing through the wires. The value is
from a large load application. Setting the minimum entered in percentage of generator output voltage
voltage above the undervoltage trip point (parameter (parameter :01). Reactive droop (parameter :30)
:13) eliminates most of the undervoltage protection. may have an effect on the voltage reference in
the opposite direction. Either voltage gain or
Parameter :10 – Underfrequency Point. For a voltage droop may be used. However, both of the
visual description see System Operation, “Startup parameters should not be used simultaneously. One
Profile Function”. See also System Operation, or both of these parameters should always be zero.
“Loading And Stopping Profile”. This parameter is See System Operation, “Voltage Regulation”. See
set in hertz (Hz). also System Operation, “Line Loss Compensation”.
This feature requires the presence of a droop
Parameter :11 – Overvoltage Trip Point. If the current transformer.
voltage is more than this value for a period of time
greater than the overvoltage trip time, then an Parameter :16 – Integral Gain. This parameter
overvoltage shutdown fault will occur. This point is changes the transient performance of the digital
set in % of generator output voltage (parameter :01). voltage regulator when in voltage control mode.
See also parameter :12. This feature is intended to This is preset at the factory for the generator and
operate like an ANSI 59 protective relay. should not be adjusted unless the resulting effect is
fully understood. An incorrect adjustment may make
Parameter :12 – Overvoltage Trip Time.The time, the output voltage overshoot or oscillate. Increasing
in seconds, required that the output voltage must this value may improve regulation accuracy but
be greater than the overvoltage trip point before can cause it to be more unstable. The shorter the
tripping an overvoltage shutdown fault. See also generator time constant the higher this parameter
parameter :11. should be set. Hunting may be experienced if the
gain is too low. This parameter should generally be
Parameter :13 – Undervoltage Trip Point. If the set within the range of 1.0 to 9.0.
voltage is less than this value for a period of time
greater than the undervoltage trip time, then an Parameter :17 – Proportional Gain. This parameter
undervoltage shutdown fault will occur. This point changes the transient performance of the digital
is set in % of generator output voltage (parameter voltage regulator when in voltage control mode.
:01). See also parameter :14. This protection is not This parameter is preset at the factory for the
enabled when the optional excitation disable switch generator and should not be adjusted unless the
is closed or when the running/operating profile is resulting effect is fully understood. Increasing this
not in effect. This feature is intended to operate like value will improve the response of the regulator to
an ANSI 27 protective relay. load changes but may cause voltage overshoot or
become unstable. This parameter should generally
Parameter :14 – Undervoltage Trip Time. The time, be set within the range of 1.0 to 9.0. This parameter
in seconds, required that the output voltage must should be close to the value for parameter :16.
be lower than the undervoltage trip point before
tripping an undervoltage shutdown fault. See also
parameter :13.
22
Systems Operation Section

Parameter :18 – Single Phase Sensing Select. If Parameter :22 – Droop/CCC Select. This parameter
single phase sensing is required, set this value to is used to select between voltage regulation/droop
1. The default setting is 0 for three phase sensing. and cross current compensation (CCC) modes
This is required to regulate the proper voltage. when operating in voltage control mode. When CCC
When single phase sensing is selected, all KVAR/PF mode is selected, parameters :52, :53, :54, :56, :57,
features are disabled, including viewing of monitor and :58 are disabled as well as the reverse power
functions :56, :57, and :58. On 155-xxxx part fault code 705 and reverse VAR fault codes 604
number regulators, when single phase sensing is and 704. This parameter has no effect on the KVAR
selected, all KVAR/PF, reverse VAR, and reverse or PF modes of operation and is ignored when
power features are disabled, including viewing of terminal 41 is closed to terminal 50, thus enabling
monitor functions :56, :57, and :58. the optional KVAR or PF regulation mode. This
parameter was added on regulator part numbers
Parameter :19 – Diode Monitor Trip Point. This 155-xxxx and newer.
parameter sets the allowable amount of field current
variation (ripple) before the digital voltage regulator Parameter :30 – Droop Percentage. See System
detects a possible bad rotating diode. If the value Operation, “Reactive Voltage Droop Function”.
is exceeded for a period of five seconds, a rotating See also System Operation, “Cross Current
diode shutdown fault will occur. Initially, this value Compensation”. This parameter defines generator
should be set to the no-load field current monitored output voltage droop, in percent, at rated generator
on parameter :55. Lower the value (increase reactive current. The parameter is effective only
sensitivity) in order to lower the allowable current when in voltage droop mode (see parameter :22).
difference. Raise the value (decrease sensitivity) in Generator rated current is defined by parameter :04
order to raise the allowable current difference. and parameter :05. Either voltage gain or voltage
droop may be used but both should not be used
Parameter :20 – Reverse VAR Trip Time. This simultaneously. One or both of these parameters
parameter represents the time, in seconds, required should always be zero. This parameter has no
to trip the reverse VAR faults (fault codes 604 and effect on the KVAR or PF modes of operation and is
704). This protective fault is defined as 0.4 Per Unit ignored when terminal 41 is closed to terminal 50,
or greater leading KVARs. Entering a longer time will which enables the optional KVAR or PF regulation
allow for compensation of added loads. The system mode. This feature requires the presence of a droop
settle time for added loads depends on the size current transformer. Note that with leading reactive
of the added load. See also parameter :21. This current, the voltage will rise rather than droop.
parameter was added on regulator part numbers
155-xxxx and newer. This feature is intended to Parameters :31 through :38 apply only to the
operate like an ANSI 40 protective relay. digital voltage regulators with the optional
KVAR/PF and reverse power functions. All the
Parameter :21 – Reverse VAR Fault Selection. This features require the presence of a droop current
parameter configures the digital voltage regulator’s transformer. Several notes for this option are
action when subjected to a reverse VAR condition. listed below.
This fault may be configured to be a shutdown
fault, an alarm fault, or to be disabled (no fault). • The KVAR/PF option is not operable if the 52/a
When parameter :21 is set to 0, detection of the contacts are not closed (shorting terminal 41 to
reverse VAR fault is disabled. This disables fault 50). Parameters :4 and :5 must be configured
code 604 and fault code 704. When parameter :21 correctly for proper operation in KVAR/PF mode.
is set to 1, the fault is treated as an alarm fault. This
enables the fault code 604, while disabling the fault • The reverse power function is not active unless
code 704. When parameter :21 is set to 2, the fault the KVAR/PF mode is enabled or unless the droop
is treated as a shutdown fault. This enables the mode is selected in parameter :22.
fault code 704, while disabling the fault code 604.
See also fault code 604 and fault code 704. This • If the droop current transformer (CT) is connected
parameter was added on part numbers 155-xxxx in a cross current compensation (zero droop)
and newer. configuration and 52/a contacts are closed (thus
enabling the PF/KVAR controller), the regulator
will not operate properly and will trip out with
various faults (usually, the reverse VAR fault).
Properly located contactors may be used to allow
the setup of both configurations so that either one
can be used at any given time.
 23
Systems Operation Section

• If the KVAR/PF mode is enabled when the When a remote adjustment rheostat is connected at
generator is connected to an isolated load (not regulator terminals 44 and 45, and parameter :31
connected to a utility), then an unstable operating is set to 1 (selecting KVAR regulation), the rheostat
condition exists because it is not possible to will have a full range of adjustment of the KVAR
regulate voltage and power factor (or KVAR) reference. The range of adjustment will be 0.0 to
simultaneously. 1.0 Per Unit. The KVAR reference (parameter :33)
value will not be modified, but will be ignored and
• If single phase sensing is selected (parameter not used.
:18), all PF/KVAR optional features will be disabled
as well as monitoring functions :56, :57, and :58. On regulators with part number 155-xxxx and newer
this value is used in power factor mode as well.
Parameter :31 – PF/KVAR Select (optional When in PF control mode (parameter :31 is set to
feature). This parameter selects whether power zero), the value entered in parameter :33 will be
factor (PF) or KVARs will be regulated when the used as the KVAR reference when the generator
PF/KVAR mode is activated by applying 24 volts real current level is below that defined by the PF
DC to the VAR/PF enable input at regulator terminal switch point (parameter :38). See System Operation,
41 (Always use terminal 50 for the 24 volts DC “KVAR Regulation” for more detail. See also System
source). Set parameter :31 to 0 for PF control. Set Operation, “Power Factor Regulation”.
parameter :31 to 1 for KVAR control. The default for
parameter :31 is 0. Parameter :34 – Reverse Power Trip Point. If the
generator is subjected to a reverse power level
Parameter :32 – PF Reference (optional feature). greater than this value for a period of time greater
When power factor (PF) control is active, the value than the reverse power trip time, a reverse power
entered for this parameter is used as the reference shutdown fault will occur. This value is set in percent
for regulation. Power factor is the ratio of real of rated real power (KW). See also parameter :35.
power (KW) divided by apparent power (KVA) of This feature requires the PF/KVAR mode switch at
the generator. The value range of this parameter regulator terminal 41 to be enabled or the droop /
is adjustable from 0.6 (lagging) to 1.1, where 1.1 CCC mode (parameter :22) to be set as droop (0)
represents a leading power factor of 0.9. When the on units with that parameter available. This feature is
remote adjustment rheostat is used for manually intended to operate like an ANSI 32 protective relay.
adjusting the power factor, the setting of parameter
:32 will not be modified, but will be ignored and Parameter :35 – Reverse Power Trip Time. The
not used. See System Operation, “Customer time, in seconds, required that the generator be
Options”. The PF/KVAR switch at terminal 41 must subjected to a reverse power level greater than the
be enabled, and the real generator output must be reverse power trip point before tripping a reverse
above the level defined by parameter :38 for this power fault (fault code 705). See also parameter :34.
feature to operate. See System Operation, “Power
Factor Regulation” for more details and for the Parameter :36 – Paralleling Integral Gain (optional
history of changes to this feature. feature). This parameter changes the transient
performance of the digital voltage regulator only
Parameter :33 – KVAR Reference (optional when in KVAR or power factor mode. This is preset
feature). When KVAR control is active, the value at the factory for the generator and should not
entered for this parameter is used as the reference be adjusted unless the resulting effect is fully
for KVAR regulation. This value is entered as per understood. Increasing this parameter will improve
unit KVARs, with an adjustment range of 0.0 to 1.0. the regulation accuracy but possibly more unstable.
The PF/KVAR mode switch at regulator terminal 41 It should be set similarly to parameter :37. This
must be enabled for this feature to operate. parameter was added on regulator part numbers
155-xxxx and newer.
The digital voltage regulator defines 1 Per Unit
KVARs as 100% of rated KVARs, where rated KVARs Parameter :37 – Paralleling Proportional Gain
is equal to 0.6 of rated generator KVA. This fixed (optional feature). This parameter changes the
definition is based on the fact that most generators transient performance of the digital voltage regulator
are rated for their KW capacity at 0.8 power factor, only when in KVAR or power factor mode. This is
which defines the ratio to overall KVA capacity. preset at the factory for the generator and should
Parameters :01 and :04 define rated generator KVA. not be adjusted unless the resulting effect is fully
By definition, KVA2 = KW2 + KVAR2. Therefore, at understood. Increasing this parameter will make the
full rated conditions and with a power factor of 0.8, generator more responsive to reactive load changes
where KW/KVA = 0.8, the KVARs will be 0.6 times but possibly more unstable. This parameter should
rated KVA. be set similarly to parameter :36. This parameter
was added on regulator part numbers 155-xxxx
and newer.
24
Systems Operation Section

Parameter :38 – PF Switch Point (optional Parameter :53 – Generator Reactive Output
feature). Power factor cannot be calculated or Current (view only). This parameter is the digital
regulated at low power levels, so the regulator must voltage regulator calculated reactive portion of
have a default control until an appropriate level the generator “B” phase output current. It is the
is reached. This parameter is the amount of real reactive portion of the current represented in
current, as a percent of rated generator current, parameter :52. For units with parameter :22, this
that is needed before power factor (PF) mode monitor will read zero if the digital voltage regulator
becomes active when PF mode is selected. Until is operated in cross current compensation mode.
the real current reaches this point, the unit will run For older models, this monitor will not be correct if
in KVAR mode using parameter :33 for a reference. the digital voltage regulator is connected in cross
After the generator has switched to power factor current compensation mode. This feature requires
control, if the real current falls 5% below the value the presence of a droop current transformer. See
set for this parameter, the digital voltage regulator parameters :04, :05, and :22.
will switch from the power factor control back into
KVAR control. This 5% hysteresis is built in to Parameter :54 – Generator Real Output Current
prevent ringing, or unstable operation. Parameter (view only). This parameter is the calculated real
:33 must be set to an appropriate level to ensure a portion of the generator output current. It is the real
smooth transition to PF mode. The rated generator portion of the current represented in parameter
current is as defined in parameters :04 and :05. This :52. For units with parameter :22, this monitor
parameter was added on regulator part numbers will read zero if the digital voltage regulator is
155-xxxx and newer. operated in cross current compensation mode. For
older models, this monitor will not be correct if
Parameter :50 – Generator Output Frequency the digital voltage regulator is connected in cross
(view only). This parameter is the output frequency current compensation mode. This feature requires
of the generator as calculated by the digital voltage the presence of a droop current transformer. See
regulator. It is based on the measured frequency parameters :04, :05, and :22.
of AC power input to the digital voltage regulator
(PMG terminals 26 and 30), and the generator type Parameter :55 – Exciter Field Current (view only).
(parameter :03), SE or PM. This parameter is the measured exciter field current
(in amps) at the output of the digital voltage
Parameter :51 – Generator Output Voltage (view regulator.
only). This parameter is the true RMS output
voltage as measured by the voltage input of the Parameter :56 – Kilowatts (view only). This
digital voltage regulator (after the sensing voltage parameter is the digital voltage regulator calculated
transformers if present). The value is the average measurement of the generator output in kilowatts.
of all three sensing voltage inputs unless single This function is only available on the PF/KVAR
phase sensing is selected. The value is based on optional version and when 3 phase sensing is
parameters :01 and :02. selected. The accuracy depends upon proper
adjustments to parameter :04 and parameter :05. For
Parameter :52 – Generator Output Current units with parameter :22, this monitor will read zero
(view only - total current). This parameter is the if the digital voltage regulator is operated in cross
measured generator output current in amps of the current compensation mode. For older models,
“B” phase. The accuracy depends upon proper this monitor will only operate when the KVAR/PF
adjustments to parameter :04 and parameter :05. control mode is enabled. This feature requires the
For units with parameter :22, this monitor will read presence of a droop current transformer. Monitoring
zero if the digital voltage regulator is operated parameter :56 was previously providing only single
in cross current compensation mode (parameter phase (phase “B”) information for KW. Effective with
:22 is set to 1). For older models, this monitor will serial number prefix “KE” and later, digital voltage
not be correct if the digital voltage regulator is regulator parameters :56 and :58 now provide three
connected in cross current compensation mode. phase information on KW and KVAR. However,
This feature requires the presence of a droop there is only one current transformer (CT) and the
current transformer. See parameters :04, :05, and three phase information is based on a balanced
:22. three phase load. If the load is unbalanced, the
error will be proportional to the unbalance. See also
parameters :04, :05, and :22.
 25
Systems Operation Section

Parameter :57 – Power Factor (view only). The Parameter :70 – Voltage Adjust (optional feature).
value of this parameter is the digital voltage This parameter is available only through the serial
regulator calculated ratio of real power (KW) divided communications port. It is designed to allow a
by apparent power (KVA), or the cosine of the angle remote control device (PLC) to modify the regulated
between those two. This function is only available voltage level reference by up to ±10% from the
on the KVAR/PF optional version and when 3 phase value set in parameter :01. The minimum value,
sensing is selected. The accuracy depends upon 0 (zero), will decrease the regulated voltage level
phase load balance and proper adjustments to by 10%. The maximum value of 200 will increase
parameter :04 and parameter :05. For units with the voltage level by 10%. A value of 100 will leave
parameter :22, this monitor will read zero if the the voltage level reference unchanged. The value
digital voltage regulator is operated in cross current of parameter :01 does not change. The internal
compensation mode. For older models, this monitor voltage reference value changes. The value of
will only operate when the KVAR/PF control mode parameter :70 is stored in computer memory but
is enabled. This feature requires the presence of not in non-volatile memory. This feature allows the
a droop current transformer. See also parameters remote control device to repeatedly send a new
:04, :05, and :22. reference voltage value to parameter :70 without
risk of wearing out the non-volatile memory storage
Parameter :58 – KiloVARs (view only). This device. The value of parameter :70 will default to
function is only available on the PF/KVAR optional 100 (zero offset) on each re-application of +24 VDC
version when 3 phase sensing is selected. This power to “B+” and “B-”. It will also reset to 100 (no
parameter is the digital voltage regulator calculated offset) upon generator shutdown (defined as zero
measurement of the generator output in KVARs. frequency). When the generator is restarted, it will
There is only one current transformer (CT) and three remain at 100 (no offset) until modified from the
phase information is based on a balanced three serial communications link. See System Operation,
phase load. If the load is unbalanced, the error will “Remote Communications”. This parameter was
be proportional to the unbalance. This parameter added on regulator part numbers 155-xxxx and
has been added effective with serial number prefix newer.
“KE” and later units. The accuracy depends upon
phase load balance and proper adjustments to If a remote voltage adjust rheostat is present, it will
parameter :04 and parameter :05. For units with work in conjunction with the value of parameter :70.
parameter :22, this monitor will read zero if the The position of the remote voltage adjust rheostat is
digital voltage regulator is operated in cross current internally converted to a percentage offset similar to
compensation mode. For older models, this monitor that described above. The percentage offset from
will only operate when the KVAR/PF control mode the rheostat is added to the percentage offset from
is enabled. This feature requires the presence of parameter :70 to create a combined offset. The net
a droop current transformer. See also parameters result will be limited to a maximum total deviation of
:04, :05, and :22. ±10% from the setting of parameter :01.

Parameter :60 – Hours (view only). This parameter Parameter :71 – PF/KVAR Adjust (optional
is the number of hours that a measurable frequency feature). This parameter is available only through
has been applied to the AC power input of the the serial communications port. It is designed to
digital voltage regulator. This will typically occur allow a remote control device (PLC) to provide the
when the generator is operated above 15% normal regulation reference for control of power factor (PF)
rpm. Time is accumulated in 0.25 hours and shown or KVARs when that operating mode is active. The
in full hours only. reference value (PF or KVAR) to be modified is
determined by parameter :31. The actual reference
to be modified can be from either parameter :32
(PF) or :33 (KVARs), or from the remote PF/KVAR
adjust rheostat, if provided. Note, however, when
parameter :31 is configured for PF operation and
the PF switch point (parameter :38) has not been
reached, no remote adjustment of the KVAR level
is possible. Remote adjustment is only possible
when the PF switch point (parameter :38) has been
reached. See the description of KVAR/PF operation
for further clarification. This parameter was added
on regulator part numbers 155-xxxx and newer.

The numeric value range of parameter :71 is 0 - 200.

It will act as a ± offset to the value of the selected
reference as calculated in the following manner.
26
Systems Operation Section

• In the KVAR mode (parameter :31 set to 1), the If the generator installation is intended to be
offset is calculated as: monitored and controlled by a programmable logic
controller (PLC) using serial communications to
KVAR Offset = (Parameter :71)/100 - 1. parameter :71, it is recommended that parameter
:32 (PF) or :33 (KVAR) (whichever is intended to be
This offset is combined with the existing KVAR remotely controlled) be consistently set to 1.0 PF
reference using signed addition, then limited so that or 0.0 KVARs, and that a manual PF/KVAR remote
the resulting effective reference will be between 0 adjust rheostat not be connected. If a manual
(zero) and 1.0 (maximum rated KVARs). Refer to the remote adjustment rheostat is required, it should
explanation of parameter :33. A numeric value of be disconnected with a control relay when the PLC
parameter :71 larger than 100 will therefore cause serial communications control is active so that the
an increase in lagging KVARs. A value less than 100 known numeric value stored in parameter :32 or
will reduce lagging KVARs. A value of 100 will cause :33 is used for the offset calculation. The remote
no offset change. The range of parameter :71 is PLC will then have a consistent numeric means to
such that the serial communications control device control the PF or KVARs regardless of the position
can adjust the KVARs over the entire operating of the rheostat. The exact expressions that the PLC
range, regardless of the setting of parameter :33 would need to calculate are listed below.
or the remote PF/KVAR adjust rheostat (if one is
present). • Parameter :71 KVAR = 100 x (1 + Desired_PU_KVARs
- Parameter :33)
• In the PF mode (Parameter :31 set to zero), the
offset is calculated as: • Parameter :71 PF = 100 x (1- (Desired_PF -
Parameter :32) / 0.4)
PF Offset = 0.4 x (1 - (Parameter :71)/100)
If the above recommendations are followed
This offset is combined with the existing PF (Parameter :33 = 0.0, Parameter :32 = 1.0, no
reference using signed addition, then limited so that remote rheostat), values between 100 to 200 will set
the resulting effective reference will be between 0.6 KVARs from 0 to 1.0 per unit and values between
(minimum lagging PF) and 1.1 (maximum PF, 0.9 200 to 75 will set the effective PF reference from
leading). Refer to the explanation of parameter :32. 0.6 to 1.1.
A numeric value of parameter :71 less than 100 will
therefore increase the PF, making it less lagging Parameter :90 – Password. The Password function
(more leading). A value greater than 100 will reduce operates as a lockout to help prevent accidental
it (more lagging). A value of 100 will cause no offset modification of other parameter settings. When
change. The range of parameter :71 is such that the parameter :90 is set to “0009”, no other parameters
serial communications control device can adjust the can be modified from the keypad or serial
PF over the entire operating range only if parameter communication link (including parameters :70 and
:32 or the remote PF/KVAR adjust rheostat (if one is :71). When parameter :90 is set to any other value,
present) is set for a PF of or between 0.7 and 1.0. all configurable parameters may be modified from
Adjustment of PF is still possible when parameter either the keypad or serial communications link.
:32 is set outside 0.7 to 1.0 but the full range is
not available. Parameter :91 – Software ID (PROM ID) (view
only). Software ID (PROM ID) (view only). This
The value of parameter :71 is stored in computer parameter is the number or version of the software
memory but not in non-volatile memory. This allows within the digital voltage regulator, used for a factory
the remote control device to repeatedly send a guided reference.
new reference PF/KVAR value to parameter :71
without risk of wearing out the non-volatile memory
storage device. Parameter :71 will default to 100
(zero offset) on each re-application of +24 VDC
power to “B+” and “B-”. It will also reset to 100 (no
offset) upon generator shutdown (defined as zero
frequency). When the generator is restarted, it will
remain at 100 (no offset) until modified from the
serial communications link.
 27
Systems Operation Section

Parameter :92 – Latest Fault. This parameter Parameter :96 – Shutdown Fault Reset. This
contains the fault code of the most recently parameter acts like a switch to reset an active fault.
declared, or current, fault that has occurred after Resetting an active fault will allow the digital voltage
the last fault was reset. It may contain either alarm regulator to begin regulation again and stop the
or shutdown faults. If a shutdown fault is active (has display from flashing the fault code. In order to
not been reset) and an additional fault occurs, the activate this function, select parameter :96 on the
additional fault will be ignored. However, if an alarm display and press the function key. The display will
is active (has not been reset) and an additional flash three more times and then return parameter
shutdown fault occurs, the alarm code will be moved :01. Note, that if there is no active fault, the display
into the Previous Fault location (parameter :93) and will flash three times and remain at parameter :96.
the new shutdown fault will be stored in the Latest This parameter applies to all alarm and resettable
Fault location (parameter :92). When no active fault shutdown faults, fault codes 6xx and 7xx. In order
is present (any previous fault has been reset) and to reset non-resettable shutdown faults (800 level),
parameter :94 is activated, the value of parameter power-down the digital voltage regulator (remove
:92 is moved to :93 while leaving zero in :92. The 24 VDC from “B+/B-” inputs). Resetting an active
fault code is retained during power-down and fault does not affect the contents of parameters :92
power-up of the digital voltage regulator. For earlier and :93. Active resettable shutdown faults may also
digital voltage regulators, see System Operation, be reset using the Fault Reset input terminal, see
“Parameters”, the topic Parameter Exceptions. System Operation, “Customer Options”. For earlier
digital voltage regulators, see System Operation,
Parameter :93 – Previous Fault. This parameter “Parameters”, the topic Parameter Exceptions.
contains the fault code for the previous fault
(both alarm and shutdown faults) that was stored NOTICE
in parameter :92. There is an exception. This When a shutdown fault code is reset, the digital volt-
parameter may contain an active alarm if an age regulator will begin operation again. If the gener-
active alarm was present in parameter :92 and a ator is being driven, it will begin to regulate according
shutdown fault occurred. When the parameter :92 to engine /generator speed and the regulation mode
is cleared using the fault clear function (parameter selected.
:94), or a new fault is declared, the fault code
stored in parameter :92 is moved to this location
(parameter :93), and any previous fault code Parameter Exceptions For Earlier
stored in this location will be lost. The fault code is
retained during power-down and power-up of the Digital Voltage Regulators
digital voltage regulator. For earlier digital voltage
regulators, see System Operation, “Parameters”, The chart lists the serial number break between the
the topic Parameter Exceptions. earlier and the current fault parameters. All digital
voltage regulator part numbers starting with 116
Parameter :94 – Fault Clear. This parameter acts (116-xxxx) and some of the regulator part numbers
like a switch to clear fault codes from the latest fault starting with 130 (130-xxxx) use the earlier fault
(parameter :92) and the previous fault (parameter parameters. The current fault parameters will be
:93) locations. In order to activate this function, implemented on all versions of the digital voltage
select parameter :94 on the display and press the regulator built after March 1996. Another method
function key. Each time the fault clear function is to determine if a digital voltage regulator uses the
used, the display will flash three times, the fault current fault parameters is to check the PROM ID
code stored in parameter :92 is moved to parameter (parameter :91). A value of 1.03 or greater indicates
:93, and the display returns to parameter :01. If use of the current alarm/fault parameters.
there is a fault code in the previous fault location
(parameter :93), it will be lost since the value from Note: Alarm and fault troubleshooting is discussed
the latest shutdown fault will now occupy that in Testing And Adjusting, “Fault Handling For Earlier
location. The fault codes stored in parameters :92 Digital Voltage Regulators”.
and :93 cannot be cleared until the active fault has
been reset. For earlier digital voltage regulators,
see System Operation, “Parameters”, the topic
Parameter Exceptions.

Parameter :95 – Alarm Fault. Parameter :95 is

not used. For earlier digital voltage regulators,
see System Operation, “Parameters”, the topic
Parameter Exceptions.
28
Systems Operation Section

Table 6 Parameter :95 – Alarm Fault. This parameter

Earlier Fault Parameter
contains the fault code of the first alarm fault that
Serial Number Break occurred since this parameter was cleared. If
any additional alarm faults occur, they are not
Digital Voltage Regulator Earlier Fault Parameter recorded until the existing alarm fault is cleared.
Part Number Serial Number The code is retained during power-down and
130-3471 LBNBA1-0123 power-up of the digital voltage regulator. When an
alarm fault occurs, the corresponding fault code
130-3472 LBNBB1-0301 is automatically flashed on the display. The alarm
130-3473 LBNBC1-0176 code information shown on the display flashes until
the fault clear parameter :94 is activated. When no
130-3474 LBNBD1-0190 alarm fault is present, parameter :95 is zero. The
130-3475 LBNBE1-0392 regulator will continue to operate when an active
alarm fault exists.
130-3476 LBNBF1-0238
Parameter :96 – Shutdown Fault Reset. This
Parameter :92 – Latest Fault. This parameter parameter acts like a switch to reset a shutdown
contains the fault code of the shutdown fault that fault so that the digital voltage regulator can begin
first occurred since this parameter was reset. If operation again. This parameter only applies
any additional shutdown faults occur, they are not to resettable shutdown faults. In order to reset
recorded until the existing fault is reset. The fault non-resettable shutdown faults, power-down the
code is retained during power-down and power-up digital voltage regulator by removing 24 VDC from
of the digital voltage regulator. When a shutdown “B+/B-” inputs. When a shutdown fault code is
fault occurs, the corresponding fault code is reset, the digital voltage regulator is able to begin
automatically flashed on the display. Any information operation again. Resetting a fault code also stops
shown on the display flashes until the shutdown the display from flashing. Resetting does nothing
fault reset parameter :96 is activated. When no fault to the latest fault parameter :92) or the alarm
is present and parameter :92 is cleared, the value fault parameter :95). In order to reset a resettable
of parameter :92 is zero. shutdown fault code, select parameter :96 on the
display and press the function key. Parameter :96
Parameter :93 – Previous Fault. This parameter performs the same function as the external fault
contains the fault code for the last shutdown reset switch. See the Customer Options diagram in
fault that was reset and cleared. When an active Testing And Adjusting, “Wiring Diagrams”.
shutdown fault (parameter :92) is reset and cleared,
the fault code is moved to this location (parameter i01041629
:93). The fault code is retained during power-down
and power-up of the digital voltage regulator. An Fault Classifications
active shutdown fault is reset using the fault reset
switch or the parameter :96. It is cleared and moved SMCS Code: 4467
into parameter :93 using the fault clear parameter
:94. There is a degree of severity that is attached to
every fault. There are four classes of faults which
Parameter :94 – Fault Clear. This parameter acts the digital voltage regulator will annunciate.
like a switch to clear fault codes from the latest fault
parameter :92 and the alarm fault parameter :95. • Alarm Fault
Each time the fault clear function is used, the alarm
fault parameter :95 is cleared to zero and the value • Resettable Shutdown Fault
in the latest fault parameter :92 is moved to the
previous fault parameter :93. If there is a fault code • Non-Resettable Shutdown Fault
in the previous fault parameter :93, it will be lost
since the value from the latest fault will now occupy • Severe Fault
that location. Clearing a fault code also stops the
display from flashing. Clearing DOES NOT RESET
shutdown faults. Before clearing an alarm/fault,
check parameters :92 and :95 to see if an active
fault is present, as this may aid in troubleshooting.
To clear a fault code, select parameter :94 on the
display and press the function key.
 29
Systems Operation Section

Alarm Fault Non-Resettable Shutdown Fault

Alarm faults indicate a condition that will not inhibit Non-Resettable shutdown faults indicate a condition
the function of the digital voltage regulator and the where the digital voltage regulator cannot be
generator set. Alarm faults have fault codes in the safely run. Non-resettable shutdown faults have
600’s range. A condition such as a partial internal fault codes in the 800’s range. Conditions such as
memory failure is an alarm fault. The generator set sensing loss and frequency loss are non-resettable
continues to operate at a normal level. When an shutdown faults. The generator set continues to
alarm fault occurs, the fault code will flash on the operate, but at a reduced level too low to sustain
display of the digital voltage regulator. Pressing load (excitation voltage of 3.0 VDC or less at F1
the function key toggles the display to show the and F2). When a non-resettable shutdown fault
parameter for the latest fault. The user can then occurs, the fault code will flash on the display of the
investigate the various parameters of the digital digital voltage regulator. Pressing the function key
voltage regulator through the keypad and display. toggles the display to show “:92”, the parameter for
All information that is shown on the display will be the latest faults. The user can then investigate the
flashing. Alarm faults must be reset before another various parameters of the digital voltage regulator
alarm fault can be declared. However, a successive through the keypad and display. All information that
shutdown fault will override an alarm fault, and is shown on the display will be flashing. In order
move the alarm fault code to the previous fault to reset a non-resettable shutdown fault, remove
location. In order to clear an alarm fault, see System power from the digital voltage regulator (remove 24
Operation, “Parameters”. VDC from “B+”/“B-” inputs).

Resettable Shutdown Fault Severe Fault

Resettable shutdown faults indicate a condition Severe faults indicate the existence of a condition
where the digital voltage regulator or the generator which would be dangerous if not harmful to run
set exhibit a degradation of power generation the digital voltage regulator. Severe faults have
performance. Resettable shutdown faults have fault codes in the 900’s range. An example of a
fault codes in the 700’s range. Conditions such severe fault is fault code 901 which indicates that
as undervoltage and overvoltage are resettable the internal memory of the digital voltage regulator
shutdown faults. The generator set continues to is not functioning properly. The memory contains
operate, but at a reduced level too low to sustain parameter data that is read each time the digital
load (excitation voltage of 3.0 VDC or less at F1 voltage regulator is powered-up (24 VDC applied
and F2). When a resettable shutdown fault occurs, to “B+”/“B-” inputs). The parameters configure the
the fault code will flash on the display of the digital digital voltage regulator to the specific generator
voltage regulator. Pressing the function key toggles set. When a severe fault occurs, the fault code will
the display to show “:92”, the parameter for the flash on the display of the digital voltage regulator.
latest faults. The user can then investigate the Also, the keypad will be disabled (the keys will have
various parameters of the digital voltage regulator no effect on the digital voltage regulator and the
through the keypad and display. All information external shutdown fault reset will have no effect on
that is shown on the display will be flashing. In the digital voltage regulator). A severe fault cannot
order to reset a resettable shutdown fault, activate be reset. These faults occur at power-up or when
parameter :96 or the fault reset switch. See System writing a new value to EEPROM memory. Severe
Operation, “Customer Options”. After the fault is faults cause the digital voltage regulator to prohibit
reset, the display will stop flashing and return to power generation. The digital voltage regulator must
parameter :01, but parameter :92 will still contain be replaced.
the fault code. The digital voltage regulator will
immediately begin to regulate voltage again. In
order to clear the fault code, use parameter :94.
30
Systems Operation Section

i01041632 Note: An additional fault (fault code 901) exists.

Fault code 901 indicates a significant failure of the
Fault Codes internal memory that stores current parameter data.
This fault can only occur at power-up and when
SMCS Code: 4467 making changes to configurable parameter values.
This is a shutdown fault, and the digital voltage
Table 7
regulator will prohibit power generation. Fault code
Active Shutdown Faults (Parameter :92) 901 is classified as a severe fault. This fault code
can not be reset. Therefore, the digital voltage
Fault Description Classification(1)
Code regulator must be replaced.

0000 No Fault Present - Note: Parameter :95 only appears on the earlier
701 Undervoltage Resettable Shutdown Fault
digital voltage regulator. Parameter :95 shows an
alarm fault. See System Operation, “Parameters” in
702 Overvoltage Resettable Shutdown Fault order to determine the serial number break.
703 Overexcitation Resettable Shutdown Fault
A fault is a condition that does not conform (an
704 Reverse VAR(2) Resettable Shutdown Fault abnormal condition) to the rules (program) by
which the digital voltage regulator operates. Some
705 Reverse Power Resettable Shutdown Fault
examples of a fault are listed below.
801 Instantaneous Trip Non-Resettable Shutdown
Fault Undervoltage – Generator voltage is less than
802 Loss Of Sensing Non-Resettable Shutdown
specified for too long a time.
Fault
Overexcitation – The measured field current is too
803 Loss Of Frequency Non-Resettable Shutdown high for too long a time.
Fault
(1) Resettable shutdown faults are reset by selecting parameter When a fault occurs, the digital voltage regulator
:96 (shutdown fault reset) on the display and pressing the automatically flashes the corresponding fault code
function key or with the fault reset switch (external attachment) on the display and takes the necessary preventive
or through J1 connector. Non-resettable shutdown faults are
reset by powering down the digital voltage regulator (removing
action. For shutdown faults, the digital voltage
24 VDC). regulator disables the output to the exciter. While a
(2) The digital voltage regulator looks for 0.4 and greater leading fault is present, the fault code information shown
power factor for shutdown. on the display will be flashing. If a shutdown fault
occurs, the shutdown fault MUST BE RESET in
Table 8 order for the digital voltage regulator to begin
Alarm Faults (Parameter :95) operation again. The method to reset a shutdown
fault depends upon the classification of the fault.
Fault Description Classification(1) When a fault code is reset, the display will stop
Code
flashing. The digital voltage regulator will begin
0000 No Fault Present - generator output regulation again, according to
generator/engine speed and the mode selected.
601 Internal Memory Failure Alarm Fault For more information, see System Operation, “Fault
602 Internal Watchdog Failure Alarm Fault Classifications”.
603 Rotating Diode Fault Alarm Fault Fault code 601 – Internal Memory Failure. This
604 Reverse VAR(2)(3) Alarm Fault fault is an alarm fault. The EEPROM failed during
(1)
a read action.
Alarm faults are cleared by selecting parameter :94 (fault clear)
on the display and pressing the function key.
(2) The digital voltage regulator looks for 0.4 and greater leading Note: Reset the fault. Clear the fault. If the alarm
power factor for shutdown. reoccurs, check all parameter values between 1
(3) Available only on part numbers 155-xxxx and newer. and 38 by using the function keys on the face of the
digital voltage regulator or remote communications.
Each fault is assigned a unique three digit code This refreshes the programmed values and should
that is called the fault code. Fault codes are the eliminate the alarm condition. If the alarm persists,
values of parameter :92. Parameter :92 shows the verify that proper grounding, shielding, and
latest fault. electromagnetic noise reduction practices have
been followed in the installation before replacing
the digital voltage regulator.
 31
Systems Operation Section

Fault code 602 – Internal Watchdog Failure. This Fault code 701 – Undervoltage. This fault is a
fault is an alarm fault. A microprocessor watchdog resettable shutdown fault. The digital voltage
is intended to detect when the microprocessor gets regulator detected that the generator voltage
"lost" and to restart the microprocessor again. The has been less than the undervoltage trip point
watchdog alarm indicates that the digital voltage (parameter :13) for the amount of time specified by
regulator just came out of a watchdog-induced the undervoltage trip time (parameter :14). This fault
microprocessor restart. is disabled when the excitation disable switch at
terminal 42 has been enabled and when the digital
Note: A possible cause is electro magnetic voltage regulator is in the startup profile. Refer to
interference (EMI). It may be necessary to provide System Operation, “Customer Options”. See also
shielded cable, grounded on one end, for all System Operation, “Startup Profile Function”.
potentiometers. Another possible cause is the
battery voltage being too low (less than 18 Note: This fault may be caused by a decline in
VDC). See watchdog alarm, fault code 602. Refer utility voltage or incorrect parameter settings. Check
to Testing And Adjusting, “Watchdog Alarm - parameters :01, :02, :06, :13, and :30. This fault
Troubleshoot”. also may be caused by the remote voltage adjust
potentiometer setting being too low.
Fault code 603 – Rotating Diode. Check the diodes
as per the generator service manual. This fault is Fault code 702 – Overvoltage. This fault is a
a resettable shutdown fault. The digital voltage resettable shutdown fault. The digital voltage
regulator detects that the variation (ripple) of exciter regulator detected that the generator voltage
field current exceeds the diode monitor trip point has been greater than the overvoltage trip point
(parameter :19) for a period of five seconds. A large (parameter :11) for the amount of time specified by
variation in the exciter field current will occur if a the overvoltage trip time (parameter :12).
rotating diode fails, shorted or open. This may also
occur with good diodes under varying loads if the Note: This fault may be caused by an increasing
diode monitor trip point is set too low (too sensitive). utility voltage or incorrect parameter settings. Check
parameters :01, :02, :09, :11, and :15. This fault
Note: For troubleshooting purposes it is useful to may also be caused by the remote voltage adjust
know that this alarm fault is often followed by an potentiometer setting being too high.
overexcitation shutdown fault. If an overexcitation
shutdown fault (fault code 703) is found in Fault code 703 – Overexcitation. This fault is
parameter :92, check parameter :93 (or the alarm a resettable shutdown fault. The digital voltage
parameter :95 if it exists) for the presence of the regulator has measured that the exciter field current
rotating diode monitor alarm code. has been at a high current level for too long a
time. If field current is not removed, high current
Fault code 604 – Reverse VAR (only available on may cause permanent overheating damage to the
155-xxxx and later regulators). This fault is an regulator, generator, or wiring. When exciter field
alarm fault. The fault code 604 will occur when the current is greater than 12 amps, the digital voltage
digital voltage regulator detects 0.4 Per Unit or regulator will shut off the exciter field current and
greater leading reactive power for a time greater declare a fault after a timeout determined by the
than the value entered in reverse VAR trip time excitation current level.
(parameter :20). This fault is only active if parameter
:21 is set to 1, which means that reverse VAR fault This shutdown will occur between 14 and 120
selection is set to an alarm. The fault code 604 will seconds after the detection of a sustained
not be active if parameter :22 is set to 1, which overcurrent in the field circuit, depending on the
means that droop/CCC select is set to CCC. level of overexcitation.

Note: A current measuring CT must be present Note: Possible causes are the loss of all three
for this feature to operate. Possible causes for phases of sensing, failed diodes, short in exciter
erroneous 604 codes are incorrect CT/PT polarity or stator or rotor, short in the main rotor, or a
large circulating currents due to incorrect voltage downstream line/load fault.
droop adjustment. See Testing And Adjusting,
“Reverse VAR Shutdowns - Troubleshoot”.
32
Systems Operation Section

Fault code 704 – Reverse VAR. This fault is a Note: Possible cause is a short in the exciter stator.
resettable shutdown fault. A Reverse VAR fault This fault code can also be generated due to high
code will occur when the digital voltage regulator levels of electromagnetic noise. The noise can be
detects 0.4 Per Unit or greater leading reactive present on the wires or in the cabinet were the
power for greater than 0.5 seconds. For regulator regulator is mounted. See Testing And Adjusting,
part numbers of 155-xxxx and newer, 0.4 Per Unit “Instantaneous Trip Shutdown - Troubleshoot”.
or greater leading reactive power must be detected
for a time longer that the reverse VAR trip time Fault code 802 – Loss Of Sensing. This fault is a
(parameter :20) to activate this fault. This fault will non-resettable shutdown fault. The digital voltage
shutdown the digital voltage regulator and remove regulator detects that one of the sense inputs
excitation to the field. The fault output driver can (terminals 20, 22, 24) has been open (disconnected)
be used to activate the shunt trip of the generator or shorted to another input.
circuit breaker to remove the generator set from the
system to provide protection against a sustained Note: Possible causes are blown customer fuse
reverse VAR condition. For regulators with part or faulty wiring. A severe load imbalance may
number 155-xxxx and newer, this fault is only active also cause this fault to occur. If the digital voltage
if parameter :21 is set to 2 (reverse VAR fault regulator sees a 20% voltage unbalance between
selection is set to shutdown) and will not be active phases for 750 ms or longer, it will generate the loss
if parameter :22 is set to 1 (droop/CCC select is of sensing shutdown fault.
set to CCC).
Fault code 803 – Loss Of Frequency. This fault is
Note: A current measuring CT must be present a non-resettable shutdown fault. The digital voltage
for this feature to operate. Possible causes for regulator detects that there is no AC frequency
erroneous 704 codes are incorrect CT/PT polarity or present for 200 msec while the measured voltage
large circulating currents due to incorrect voltage is greater than 50% of nominal. The frequency
droop adjustment. See Testing And Adjusting, is measured from the PM inputs, NOT from the
“Reverse VAR Shutdowns - Troubleshoot”. sensing inputs.

Fault code 705 – Reverse Power. This fault is Note: Another possible cause is electro magnetic
a resettable shutdown fault. The digital voltage interference (EMI). It is necessary to provide
regulator detected that the generator real power shielded cable, grounded on one end, for all
output has been greater than the reverse power customer optional wiring. This fault may also be
trip point (parameter :34) for the amount of time caused by a microprocessor restart after the digital
specified by the reverse power trip time (parameter voltage regulator has obtained rated voltage.
:35). This fault only considers the real portion of the See Testing And Adjusting, “Loss of Frequency
generator output. This shutdown fault is active only Shutdown - Troubleshoot”.
when the auxiliary contact (terminal 41) is closed
in order to enable the PF/KVAR operating mode. Fault code 901 – Digital Voltage Regulator Memory
There is an exception. On regulators with part Failure. This fault is a severe fault. The EEPROM
number 155-xxxx and newer it is active in voltage device, within the digital voltage regulator, failed the
regulation/droop and PF/KVAR operating modes power-up test and the digital voltage regulator will
but not active in cross current compensation mode no longer function properly. The EEPROM stores the
(parameter :22 set to 1). parameter values of all the program parameters.
This fault can also occur after writing (storing) a
Note: Possible causes for erroneous 705 codes are new parameter value if the EEPROM device has
incorrect CT/PT polarity, the engine/generator set just failed.
shed (removed) load but the breaker did not shunt
trip, or parameter :35 (reverse power trip time) was Note: The EEPROM will no longer accept new
set too low for the loading scheme. values. This means that the EEPROM is inoperable
and the digital voltage regulator must be replaced.
Fault code 801 – Instantaneous Trip. This fault is
a non-resettable shutdown fault. The digital voltage
regulator detects that the exciter field current is
greater than approximately 28 amps. If this occurs,
the digital voltage regulator instantaneously shuts
off the exciter field current.
 33
Systems Operation Section

i01041650 For the DVRVIEW supporting software and

documentation, see Digital Voltage Regulator
Remote Communication Software - 3.5" Disks, LERX5100. This reference
includes a manual and a software. In order to obtain
SMCS Code: 4467 a copy of the manual only, order Digital Voltage
Regulator Software - User Manual Only, LERX5662.
The digital voltage regulator has the capability to The manual also contains the software protocol
communicate with a remote personal computer or used to communicate with the digital voltage
programmable logic controller. The J1 connector of regulator. The protocol is very simple and can be
the digital voltage regulator provides a RS422 port implemented in switchgear or office equipment to
necessary for communication. The RS422 port is a provide customized communication with the digital
5-wire communication media including a wire pair voltage regulator.
for Receive, a wire pair for Transmit, and a common
Signal Ground. For noise immunity, it is required An RS422 to RS232 (computer serial port) converter
that the wire pairs be twisted and shielded. The is available from the Caterpillar Parts Department.
shield(s) should be grounded at the remote end of Use part number 131-7416 Converter Control. The
the cable only. The common signal ground is NOT a converter comes with a regulated power supply
bonding ground and should not be grounded to the and a wiring harness to connect the converter to
case or frame. It is to be connected to the RS422 the digital voltage regulator. A standard serial cable
device Signal Ground connection point. Cable must be provided to connect the converter to a PC.
length should be limited to 1000 meters maximum If connecting to a modem, it may be necessary to
for the RS422 signal wiring. use a null modem cable or adapter on the RS232
side of the converter. RS232 wiring should be
An isolated, regulated power supply is also required limited to 15 m (50 ft).
for the remote communication port to operate. The
digital voltage regulator is optically isolated from the
communications port to ensure complete isolation i01041600
of voltage levels. In order to maintain this isolation,
power for the communications circuitry must be Customer Options
provided from outside the regulator. The supply may
be from 8.55 VDC to 10.35 VDC where 9 VDC is SMCS Code: 4467
considered nominal and should be able to source
100 mA of current. This voltage is measured at Fault Shutdown Output Driver
the voltage regulator. If the supply is provided in a
remote location, ensure that the voltage present at The fault shutdown driver is intended to provide an
the regulator is still above 8.55 VDC (preferably at 9 external signal to operate a circuit breaker shunt
VDC or slightly above). trip and other alarm lights and/or horns in the event
of a shutdown fault. The fault shutdown driver is
A windows program is available to communicate normally pulled low (sinking up to 100 mA). When
with the digital voltage regulator. The program is a fault occurs the output driver will open, allowing
called DVRVIEW. For proper connection of the the output to go high, to +24 VDC.
digital voltage regulator to the personal computer,
see Testing And Adjusting, “Wiring Diagrams”, the Note: The output driver is “pull down” only. It
illustration Remote Communications. will not source current when a fault occurs. Use
input terminal 50 for a current source. Refer to
DVRVIEW allows the user to perform the following the Customer Options illustration in Testing And
operations. Adjusting, “Wiring Diagrams”.

• Viewing and modifying the parameters in a This method was chosen as a safety feature to
windowed PC environment protect against loss of battery voltage which will
also cause the regulator to cease operation and,
• Sending a “recipe” of parameters to the digital therefore, the generator voltage to collapse.
voltage regulator

• Saving the existing digital voltage regulator

Alarm Output Driver
settings to a recipe file
The alarm driver is intended to provide an external
signal to operate alarm lights and/or horns in the
event of an alarm fault condition. The alarm driver
is normally pulled low (sinking up to 100 mA).
When an alarm occurs, the output driver will open,
allowing the output to go high, to +24 VDC.
34
Systems Operation Section

Note: The output driver is “pull down” only. It Utility 52/a Contacts
will not source current when a fault occurs. Use
input terminal 50 for a current source. Refer to The generator 52/a auxiliary contact is closed only
the Customer Options illustration in Testing And when the generator breaker is closed. The utility
Adjusting, “Wiring Diagrams”. 52/a auxiliary contact is closed only when the
breaker which ties the generator to the utility is
Note: The alarm output and fault shutdown output closed. When BOTH of these breakers are closed
drivers may change state during engine cranking, the generator is assumed to be operating in parallel
indicating a false alarm or shutdown fault condition. to the utility grid. This will activate (enable) the
If the “B+”/“B-” inputs to the digital voltage regulator PF/KVAR mode when connected as shown in the
are supplied from the engine cranking batteries, it is wiring diagrams for this manual. It will also enable
likely that insufficient voltage will be present during the reverse power fault if it is not already enabled.
cranking. Therefore, during cranking the state of the See description of parameter :34 in Systems
fault shutdown output driver may change. The fault Operation, “Parameters”. See also descriptions of
shutdown output driver should be ignored until the fault codes 604, 704, and 705 in Systems Operation,
crank terminate speed has been reached. “Fault Codes”.

Excitation Disable Remote Voltage Adjust Rheostat

The excitation disable switch is intended to provide The remote voltage adjust rheostat inputs are
a method of disabling the regulator field output provided to allow the use of a 10 kOhm rheostat
(F1 and F2) in a manner which is safe for the to remotely adjust the regulated voltage level.
regulator internal components. This feature is Increasing the resistance at the input causes the
activated by shorting terminal 42 to terminal 50. voltage to increase from the level configured in
Refer to the Customer Options illustration in Testing parameter :01. Turning the remote voltage adjust
And Adjusting, “Wiring Diagrams”. Activation of rheostat will not change the value displayed in
the excitation disable switch will also disable the parameter :01. However, it will modify an internal
undervoltage shutdown fault. reference which will cause the generator output
voltage to change in proportion to the rheostat
NOTICE movement. The range of the remote voltage rheostat
The generator will always have residual voltage still re- adjustment is limited to a ±10% change in output
maining; therefore, it is important to stop the generator voltage from the value set in parameter :01. When
set if downstream maintenance is to be performed. installing the remote voltage adjust rheostat, always
use shielded cable. See parameter :70 for an
explanation of using the voltage adjust rheostat in
Fault Reset conjunction with the serial communications control.

The fault reset contact is provided as a method to

reset a resettable shutdown fault through the use
of an external switch. This operation is equivalent
to using parameter :96 in the user interface.
Operating the fault reset contact (momentarily
shorting terminal 43 to terminal 50) will reset a
resettable fault and allow the voltage to build again.
However, on the "original" fault handling versions,
the display will still show the flashing fault and the
fault will remain in the active position in memory. On
the "new" fault handling versions, the display will
stop flashing, return to showing “:01”, and the fault
will remain in the active fault parameter :92. The
fault reset contacts should never be continuously
shorted together. A momentary contact is all that is
necessary to reset the fault.
 35
Systems Operation Section

Remote PF/KVAR Adjust Rheostat Communication Port PF/KVAR

The remote PF/KVAR adjust rheostat inputs are
Adjust
provided to allow the use of a 10 kOhm rheostat Beginning with part number 155-xxxx regulators, a
to remotely adjust the regulated PF or KVAR level.
convenient PF and KVAR adjust method is available
Connecting a rheostat to this input causes the local
via the communications port on the optional
values which are programmed in parameters :32 PF/KVAR models only. The adjustment parameter
and :33 to become inactive. See description for
is available as parameter :71. The adjustment
parameters :32 and :33 for detailed explanation.
parameter cannot be seen from the display on the
Varying the remote PF/KVAR rheostat will not digital voltage regulator. This parameter allows full
change the values displayed in parameters :32
range of PF or KVAR adjustment depending on
and :33. However, it replaces the internal reference
which mode is active (via parameter :31 selection).
which controls PF or KVAR regulation depending on Further details on the operation of this parameter
which mode is selected in parameter :31. Increasing
are discussed in System Operation, “Parameters”.
the resistance when in power factor mode causes
Refer to parameter :71, PF/KVAR adjust. Writing a
the power factor to become more lagging, with a value to this parameter location will NOT cause a
range of 0.9 power factor leading to 0.6 power
write to the EEPROM and will not be saved during
factor lagging. Increasing the resistance when in
a loss of power. This parameter was added to aid
KVAR mode causes the lagging KVAR reference
in wire reduction so that automatic adjustments can
to increase, with a range of 0.0 to 1.0 Per Unit.
be made by customer supplied equipment for PF
When installing the remote PF/KVAR adjust rheostat,
or KVAR correction by utilizing a communications
always use shielded cable. See parameter :71 for
interface already present. Adjustments made to this
an explanation of using the PF/KVAR adjust rheostat
parameter will not be effective unless the regulator
in conjunction with serial communications control.
is operating in the PF/KVAR control mode with
terminal 41 closed.
Application Note
Remote voltage adjust and PF/KVAR adjust
Remote Installation Notes
rheostats should be installed with shielded cable.
When the digital voltage regulator is remotely
The shield drain wire should be connected to installed from the generator, special care should
terminal 45 of the digital voltage regulator and be
be given in the installation process to ensure
insulated from all other circuits, including Earth
proper engineering procedures are followed to
ground. prevent electromagnetic noise from reducing the
performance of the regulator. While the digital
Communication Port Voltage Adjust voltage regulator has been designed to meet the
89/336/EEC Electromagnetic Compatibility Directive,
Beginning with part number 155-xxxx regulators, poor wiring practices can generate electromagnetic
a convenient voltage adjust method is available noise levels much greater than the levels the
via the communications port. The voltage adjust regulator was designed to accomodate. When
parameter is available as parameter :70 but cannot remote mounting the regulator, the sensing wires,
be seen from the display on the digital voltage PMG wires, and F1 and F2 exciter field wires
regulator. This parameter allows ±10% voltage should each be routed in their own separate tray or
adjustment around the nominal value of voltage conduit. The optional customer wiring should be
entered in parameter :01. Further details on the separated from all other signals in a control wiring
operation of this parameter are discussed in the conduit only. The voltage sensing wires attached to
System Operation, “Parameters”. Refer to parameter terminals 20, 22, and 24 should be twisted together.
:70, voltage adjust. Writing a value to this parameter The F1 and F2 exciter field wires should also be
location will NOT cause a write to the EEPROM twisted together. The droop current transformer
and will not be saved during a loss of power. This burden resistor, R1, should be mounted within 3 m
parameter was added to aid in wire reduction so (10 ft) of the regulator. If this is not possible, use
that automatic voltage adjustments can be made by two burden resistors, each with twice the nominal
customer supplied equipment for voltage matching resistance of R1, and locate one at the regulator
during synchronizing by utilizing a communications and one at the droop current transformer.
interface already present.
36
Systems Operation Section

Manual Voltage Control

An optional manual voltage control may be used
to provide a backup method for controlling the
generator output voltage in case of failure of the
digital voltage regulator. This device will manually
adjust the output voltage by controlling the current
flow to the exciter stator (L1). The manual voltage
control has a mode selector switch and a voltage
adjust dial. The selector switch can be set to
MAN, OFF, or AUTO. When the switch is in the
MAN position, the generator output voltage is
controlled by the manual control by varying the
amount of current to the exciter stator via the
voltage adjust dial. When the switch is in the OFF
position, no current will flow to the exciter stator and
the generator output voltage will be zero. In the
AUTO position, the manual voltage control will be
bypassed, and the generator output voltage will be
controlled by the digital voltage regulator.

Note: The manual voltage control must not be

installed in a location that is subject to engine
vibrations or directly to outside weather.

Note: When the manual voltage control is operating

in the “MAN” mode, it is not necessary for the digital
voltage regulator to be connected to the generator.
If the digital voltage regulator remains installed and
powered on during manual control, it will annunciate
the loss of frequency fault (fault code 803) since the
PM input is disconnected and the regulator will no
longer be able to sense the frequency.
 37
Testing and Adjusting Section

Testing and Adjusting

Section When servicing or repairing electric power gener-
ation equipment:

Testing and Adjusting • Make sure the unit is either locked out or
tagged DO NOT OPERATE.

i01041639 • Remove all fuses.

General Information • Make sure the generator engine is stopped.
SMCS Code: 4467 • Make sure all batteries are disconnected.
• Make sure all capacitors are discharged.

Do not connect generator to a utility electrical dis- • Make sure residual voltage in the rotor, stator
tribution system unless it is isolated from the sys- and the generator is discharged.
tem. Electrical feedback into the distribution sys-
tem can occur and could cause personal injury or Failure to do so could result in personal injury or
death. death.

Open and secure main distribution system switch,

or if the connection is permanent, install a dou- i01041654
ble throw transfer switch to prevent electrical feed-
back. Some generators are specifically approved
Service Tools
by a utility to run in parallel with the distribution
SMCS Code: 0785
system and isolation may not be required. Always
check with your utility as to the applicable circum-
stances.

When the engine-generator, or any source to

which the engine-generator is synchronized to, is
operating, voltages up to 600V are present in the
control panel.

Do not short these terminal with line voltage to

ground with any part of the body or any conduc-
tive material. Loss of life or injury could result
from electrical shock or injury from molten met- Illustration 10 g00241203
al.
6V-7070 Caterpillar Digital Multimeter

Caterpillar Digital Multimeters can be used to

measure voltage, resistance or current up to 10
amperes. Rectifiers can also be checked by
using the diode function. See Special Instruction,
SEHS7734, “Use Of The 6V-7070 And 6V-7800
Multimeter” for the correct operation of the 6V-7070
Digital Multimeter.
38
Testing and Adjusting Section

i01041642

Parameter Viewing and

Configuring Procedure
SMCS Code: 4467-NQ

g00538441
Illustration 11
8T-0900 AC/DC Clamp-On Ammeter

The 8T-0900 Ammeter may be used to measure

current up to 1200 amperes. When you are
measuring line current on multiple lead units,
measure the current in each conductor per phase Illustration 12
g00538863
and add the currents together. See Special Display And Keypad
Instruction, SEHS8420, “Using the 8T900 AC/DC
(1) Display
Clamp-On Ammeter 0651” for the correct operation
of the 8T-0900 Ammeter. (2) Keypad
(3) Function key
(4) Scroll down key
i01041658
(5) Scroll up key
Startup Procedure
Note: Before performing this procedure, study the
SMCS Code: 4467 list of parameters in order to determine the desired
parameter code and the corresponding range of
1. Connect the digital voltage regulator. Refer to values. Refer to System Operation, “Parameters”.
Testing And Adjusting, “Wiring Diagrams” for a The value of some parameter codes is only for
proper illustration. Take care to follow notes and viewing by the user and may not be configurable.
observe polarities.
Note: While performing this procedure, it will be
2. Apply battery power only to the digital voltage convenient to have the entire list of parameters
regulator. Verify that all of the parameters are available. See System Operation, “Parameters”.
properly adjusted for the application.
1. Select the parameter code.
3. Start the engine. Make the final adjustments, as
required. Press scroll up key (5) and scroll down key (4)
until the desired parameter code is showing on
4. Record all settings. display (1). Remember that parameter codes are
always preceded by a colon.

2. View the value of the parameter.

Press function key (3) to view the value of the

chosen parameter code of Step 1. Remember
that values are not preceded by a colon.

Note: The following Steps do not apply to parameter

codes that are not configurable. Press function key
(3) and the display will return to showing parameter
codes as in Step 1.

3. Select a new value.

 39
Testing and Adjusting Section

Press scroll up key (5) or scroll down key (4) until 3. Check the status of the latest fault.
the desired new value is showing on display (1).
a. Check if a new alarm has been logged in
4. Configure a new value. parameter :92. Parameter :92 describes the
latest fault.
With the desired new value showing, press the
function key (3). The new value is now entered Expected Result: A new alarm has been
into the memory of the digital voltage regulator. logged in parameter :92.
The display returns to showing parameter codes
as in Step 1. Results:

i01041634
• OK: A fault or alarm has occurred and has
been reset. Troubleshoot the problem using
Fault Handling the code in parameter :92 and the service
manual (or clear the alarm). Go to Testing
SMCS Code: 4467 And Adjusting, “Fault Handling”, section
Fault Clearing.
Note: For earlier digital voltage regulators go to
Testing And Adjusting, “Fault Handling For Earlier • NOT OK: No new alarm has occurred.
Digital Voltage Regulators”. STOP.

4. Check the status of the fault.

Fault Identification
a. Check the display on the digital voltage
1. Check the excitation. regulator.
a. Use a multimeter across the exciter field b. Check the status of the fault output.
outputs F1 and F2. A multimeter should be
set for VDC. Another way to verify that the Expected Result: The display on the regulator
regulator is providing excitation is by looking is flashing or the fault output is off. When fault
at parameter :55. Parameter :55 describes output is off, a fault is active.
excitation current.
Results:
Expected Result: The regulator is providing
excitation to the generator. • OK: A shutdown fault has occurred and
is active. No new alarms/faults will be
Results: detected until this fault is reset. Go to Step
5.
• OK: Go to Step 2.
• NOT OK: Refer to Testing And Adjusting,
• NOT OK: Go to Step 4. “Troubleshooting”. STOP.
2. Check the status of the alarm. 5. Check the shutdown fault log.
a. Check the display on the digital voltage a. Check the number logged in the shutdown
regulator. fault log. The shutdown fault log is described
by parameter :92. Check the flashing number
b. Check the status of the alarm output. on the display.
Expected Result: The display on the digital Expected Result: The number starts with a
voltage regulator is flashing or the alarm 6 (6xx).
output is off. When alarm output is off, an
alarm is active. Results:
Results:

• OK: An alarm has occurred. The alarm is

active. No new alarms will be detected until
the fault has been reset. However, fault
detection is still enabled. Go to Step 5.

• NOT OK: Go to Step 3.

40
Testing and Adjusting Section

• OK: The number starts with a 6 (6xx). An • OK: The number starts with a 8 (8xx). A
alarm has occurred. This will not shut down non-resettable fault has occurred which is
the digital voltage regulator. The alarm resettable only after removing all power to
is resettable without removing power by the digital voltage regulator, troubleshooting
activating either parameter :96, the external and correcting the problem, and reapplying
fault reset switch contact, or by cycling the power. Follow troubleshooting
the 24 VDC. Follow the troubleshooting procedures in the service manual for the
procedures in the service manual for fault code shown in parameter :92 and
the alarm code shown in parameter :92. any active alarm code in parameter :93.
Continue the procedures until the alarm has Hardware output driver(s) is/are reset, unit
been reset. is operational, display returns to :01, and
the fault is still logged in the latest fault
• NOT OK: The number does not start with a log, parameter :92. If an active alarm was
6 (6xx). Go to Step 6. present when the fault was received, then
it will be found in the previous fault log,
6. Check the shutdown fault log (continued). parameter :93. The display stops flashing to
indicate all alarms and faults are reset. New
a. Check the number logged in the shutdown alarms/faults may be detected again. Go
fault log. The shutdown fault log is described to Testing And Adjusting, “Fault Handling”,
by parameter :92. Check the flashing number section Fault Clearing.
on the display.
• NOT OK: A number is logged in shutdown
Expected Result: The number starts with a fault log, parameter code :92 or is flashing
7 (7xx). in the display starting with a 9 (9xx). This
indicates a severe fault has occurred and
Results: the unit must be replaced. STOP.

• OK: The number starts with a 7 (7xx). A Fault Clearing

resettable fault has occurred. This fault
is resettable without removing power by
An alarm/fault has occurred and has been reset.
activating either the shutdown fault reset The digital voltage regulator is fully operational,
parameter :96, the external fault reset
the alarm/fault is reset but not cleared. A 6xx, 7xx,
switch, or by cycling the 24 VDC. Follow
or 8xx is logged in the fault log, parameter :92. If
the troubleshooting procedures in the another alarm/fault is received, it will be logged
service manual for the fault code shown
in parameter :92 and the original contents of
in parameter :92 and any possible active
parameter :92 will be shifted to parameter :93.
alarm shown in parameter :93. Note, that if
the engine is running when the fault is reset,
In order to clear the alarm/faults, select parameter
the digital voltage regulator will provide
:94 on the display and press the function key. The
excitation to the generator. Continue the regulator screen blanks briefly and returns to “:01”.
procedures until the fault has been reset.
Fault value in parameter :92 is moved to parameter
:93 and parameter :92 is cleared to “0000”.
• NOT OK: The number does not start with a
7 (7xx). Go to Step 7.
Note: If another alarm/fault has occurred, the new
number will be logged in parameter :92. No change
7. Check the shutdown fault log (continued). will occur to parameter :93. Return to Testing
And Adjusting, “Fault Handling”, section Fault
a. Check the number logged in the shutdown
Identification, Step 1.
fault log. The shutdown fault log is described
by parameter :92. Check the flashing number
Note: In order to clear the previous fault (parameter
on the display.
:93), select parameter :94 on the display and
pressing the function key. Parameter :93 is cleared
Expected Result: The number starts with an
to “0000”. Parameter :92 remains at 0000 and the
8 (8xx).
display returns to “:01”. STOP.
Results:
 41
Testing and Adjusting Section

i01041633 a. Check the display on the digital voltage

regulator.
Fault Handling for Earlier
Digital Voltage Regulators b. Check the status of the alarm output.

SMCS Code: 4467 Expected Result: The display on the regulator

is flashing or the alarm output is off (open
The chart lists the serial number break between circuit). When alarm output is off, an alarm
the earlier fault parameters and current fault is active.
parameters. All digital voltage regulator part
numbers starting with 116 (116-XXXX) and some Results:
of the regulator part numbers starting with 130
(130-XXXX) use the earlier alarm/fault handling • OK: Go to Testing And Adjusting, “Fault
procedures. The current fault parameters/procedure Handling For Earlier Digital Voltage
is implemented on all versions of the digital voltage Regulator”, section Alarm Clearing (For
regulator built after March 1996. Another method Earlier Digital Voltage Regulator).
to determine if a digital voltage regulator uses the
current alarm/fault handling procedures is to check • NOT OK: Go to Step 3.
the PROM ID (parameter :91). A value of 1.03 or
greater indicates use of the current alarm/fault 3. Check the alarm fault log.
parameters/procedures.
a. Check the status of the alarm fault log. The
Table 9 alarm fault log is described by parameter :95.
Earlier Fault Parameter
Serial Number Break Expected Result: The alarm fault log shows
“0000”.
Regulator Earlier Fault Parameter
Part Number Serial Number Results:
130-3471 LBNBA0001-0123
• OK: The alarm fault log shows “0000”. No
130-3472 LBNBB0001-0301 new alarm has occurred. STOP.
130-3473 LBNBC0001-0176
• NOT OK: Go to Testing And Adjusting,
130-3474 LBNBD0001-0190 “Fault Handling For Earlier Digital Voltage
130-3475 LBNBE0001-0392
Regulator”, section Alarm Clearing (For
Earlier Digital Voltage Regulator).
130-3476 LBNBF0001-0238
116-XXXX All
4. Check the status of the fault.

a. Check the display on the digital voltage

Fault Identification (For Earlier regulator.
Digital Voltage Regulator) b. Check the status of the fault output.
1. Check the excitation. Expected Result: The display on the regulator
is flashing or the fault output is off (open
a. Use a multimeter across the exciter field circuit). When fault output is off, a fault is
outputs F1 and F2. A multimeter should active.
be set for VDC. Another way to verify that
the regulator is providing excitation to the Results:
generator is by looking at parameter :55.
Parameter :55 describes excitation current. • OK: A shutdown fault has occurred and is
active. No new faults will be detected until
Expected Result: The digital voltage regulator active shutdown fault is reset. Go to Step 5.
is providing the excitation to the generator.
• NOT OK: Go to Testing And Adjusting,
Results: “Troubleshooting”.

• OK: Go to Step 2. 5. Check the shutdown fault log.

• NOT OK: Go to Step 4.

2. Check the status of the alarm.
42
Testing and Adjusting Section

a. Check the number logged in the shutdown Results:

fault log. The shutdown fault log is described
by parameter :92. Check the flashing number • OK: The number starts with an 8 (8xx). A
on the display. non-resettable fault has occurred. This fault
is resettable only after removing all power to
Expected Result: The number starts with a the digital voltage regulator, troubleshooting
7 (7xx). and correcting the problem, and reapplying
the power. Go to Testing And Adjusting,
Results: “Fault Handling For Earlier Digital Voltage
Regulator”, section Fault Clearing (For
• OK: The number starts with a 7 (7xx). A Earlier Digital Voltage Regulator).
resettable fault has occurred. It can be
reset without removing power by activating • NOT OK: The number logged in the
either shutdown fault reset, parameter :96 shutdown fault log, parameter :92 or
or the external fault reset switch. The fault flashing on the display starts with a 9 (9xx).
can also be reset by cycling the power to A severe fault has occurred. The unit must
24 VDC power inputs (“B+”/“B-”). Note, be replaced. STOP.
that if the engine is running when the fault
is reset the digital voltage regulator will Alarm Clearing (For Earlier Digital
provide excitation to the generator when the
fault is reset. Go to Step 6. Voltage Regulator)
• NOT OK: Go to Step 7. An alarm has occurred but the digital voltage
regulator is still operational. No new alarms will be
6. Check the status of the shutdown fault reset. recorded until the present alarm is cleared. A 6xx
number is flashing on the display and logged in the
a. Select parameter :96 which describes alarm fault log, parameter :95. Troubleshoot per the
shutdown fault reset. Depress the function key specific alarm description in service manual.
in order to reset the fault.
Note: If power is removed with an active fault, upon
Expected Result: Shutdown fault reset has power-up the display will stop flashing. However, the
been activated. fault will remain in the alarm fault log, parameter :95.

Results: If you want to reset and clear the alarm, clear the
alarm/fault by selecting parameter :94 on the display
• OK: Shutdown fault reset has been and pressing the function key. The digital voltage
activated. The fault output driver is reset regulator screen should blank briefly, stop flashing
and the unit is operational. The display and return to parameter :94. The Alarm Fault Log
continues to flash and the fault is still in parameter :95 should be cleared to “0000” and
logged in the shutdown fault log, parameter the alarm driver output should be reset. This also
:92. A flashing display indicates a fault affects the values in parameters :92 and :93.
in the shutdown fault log, parameter :92.
New faults may be detected again. Go to Fault Clearing (For Earlier Digital
Testing And Adjusting, “Fault Handling For
Earlier Digital Voltage Regulator”, section Voltage Regulator)
Fault Clearing (For Earlier Digital Voltage
Regulator). A shutdown fault has occurred. A 7xx or 8xx number
is flashing on the display. A 7xx or 8xx number is
• NOT OK: Shutdown fault reset has not been logged in the shutdown fault log, parameter :92.
activated. Go to Step 5. Troubleshoot per the specific fault description.

7. Check the shutdown fault log. Note: If power is removed with an active fault, upon
power-up the display will stop flashing. However,
a. Check the number logged in the shutdown the fault will remain in the shutdown fault log,
fault log. The shutdown fault log is described parameter :92.
by parameter :92. Check the flashing number
on the display. Reset a 7xx fault by selecting parameter :96 and
depress the function key to reset the fault. Reset
Expected Result: The number starts with an an 8xx fault by removing all power to the digital
8 (8xx). voltage regulator, troubleshooting and correcting
the problem, and reapplying the power.
 43
Testing and Adjusting Section

After the fault has been reset, clear the alarm/fault

by selecting parameter code :94 on the display
and pressing the function key. The digital voltage
regulator screen should blank briefly, stop flashing
and return to parameter :94.

The alarm/fault log in parameter :95 should be

cleared to “0000”. The fault value in parameter :92
is moved to parameter :93 and parameter :92 is
cleared to “0000”.

Note: In order to clear previous fault (parameter

:93), select parameter :94 on the display and press
the function key. Parameter :93 is cleared to “0000”.
Alarm log parameter :95 is also cleared to “0000”
again.

i01041696

Troubleshooting
SMCS Code: 4467
Table 10
Common Troubleshooting Procedures(1)(2)
Problem Troubleshooting Procedure
Reverse Power Shutdown Check CT polarity.
Check connections to the digital voltage regulator terminals 5 and 6.
No Voltage Check for the fault codes. Correct the fault codes.
(50 ACV or Less) Determine if DC voltage is properly connected (“B+”/“B-”).
Check for loose sensing or PM wires.
Check for blown PM fuses.
Determine if underfrequency setpoint (parameter :10) is too high.
Temporarily disconnect battery from the digital voltage regulator. Then, connect battery to
the regulator. Restart the regulator.
Check terminal 42. Battery voltage (24 VDC) should not be present. (Excitation disable
circuit)
Check rotating diodes on the generator.
Low Voltage Check for the fault codes. Correct the fault codes.
(Residual to Less Than Rated Determine if generator output voltage setpoint (parameter :01) is set too low.
Output Voltage) Determine if droop setpoint (parameter :30) is set to zero. Droop setpoint should be 0.
Check parameter :03 for correct generator type.
Determine if parameter :06 is less than the expected generator operating frequency.
Check parameter :02 for the correct PT ratio. Check that parameter :02 is not doubled.
Check that one PM fuse is not blown.
Check rotating diodes on the generator.
High Voltage Check for the fault codes. Correct the fault codes.
(Voltage Higher Than Range Check parameter :02 for the correct PT ratio. Check that parameter :02 is not too low.
Allows) Check that parameter :15 (IR Compensation) is set to zero.
Determine if the generator output voltage setpoint (parameter :01) is set too high.
Determine if the minimum voltage setpoint (parameter :09) is set too high.
Unstable Voltage Check for the fault codes. Correct the fault codes.
(Voltage Fluctuation Greater Remove the remote voltage adjust rheostat.
Than 0.25%) Disconnect droop current transformer.
Check for loose wiring.
Check rotating diodes on the generator.
Initial Voltage Overshoot Check parameter :03 for correct generator type.
(1) A regulator may fail to perform correctly if it is not properly connected. A regulator may also fail if there is a failure of downstream
equipment, such as diodes.
(2) It is possible to get an unexplained reverse VAR fault if the CT is connected backward. Check the CT connection if this fault occurs.
44
Testing and Adjusting Section

This section provides troubleshooting procedures

for generator voltage problems that are related to
the digital voltage regulator.

Note: Before starting to troubleshoot, check the part

number to determine if the digital voltage regulator
being used is proper for the application. The
part number label on the digital voltage regulator
indicates the sensing voltage range and whether or
not the regulator is the optional KVAR/PF model.
Refer to the following chart.
Table 11
Digital Voltage Regulator Application Chart
Regulator Version Voltage Range Early Part Number Former Part Current Part
Number Number
Basic 79 to 124 Volt 116-7480 130-3471 155-3831
3 phase sensing
Basic 125 to 249 Volt 3 phase sensing 116-7481 130-3472 155-3832
Basic 250 to 600 Volt 3 phase sensing 116-7482 130-3473 155-3833
KVAR/PF 79 to 124 Volt 116-7483 130-3474 155-3834
Optional Version 3 phase sensing
KVAR/PF 125 to 249 Volt 3 phase sensing 116-7484 130-3475 155-3835
Optional Version
KVAR/PF 250 to 600 Volt 3 phase sensing 116-7485 130-3476 155-3836
Optional Version

i01041690 Expected Result: The display should contain

a number.
No Voltage - Troubleshoot
Results:
SMCS Code: 4467-035
• OK: Proceed to Step 4.
1. Check for the proper version of the regulator.
• NOT OK: No number is present on the
a. Check the part number of the digital voltage display. Proceed to Step 3.
regulator. Refer to the chart in Testing And
Adjusting, “Troubleshooting”. Check whether 3. Check the DC voltage.
the digital voltage regulator is proper for the
application. a. Check for proper DC voltage from terminal
“B+” to “B-”. The acceptable voltage range
Expected Result: The digital voltage regulator is 18 VDC to 32 VDC.
is proper for the application.
Expected Result: The sufficient DC voltage
Results: is present.
• OK: Go to Step 2. Results:
• NOT OK: Install the proper digital voltage
regulator. STOP.

2. Check the status of the display.

a. Stop the generator set.

b. Observe the display on the digital voltage

regulator.
 45
Testing and Adjusting Section

• OK: The sufficient DC voltage is present. d. Restart the engine.

Remove the DC power wires from terminals
“B+” and “B-” for 30 seconds. Reconnect e. Check the PM inputs (26, 28, and 30) of the
the DC power wires to the “B+” and “B-” digital voltage regulator. Measure the AC
terminals. If the display of the regulator voltage between terminals 26 to 28, 28 to 30,
is still blank, the regulator is faulty. Then, and 26 to 30.
the regulator needs to be replaced. If
this condition has occured, verify that the f. If the digital voltage regulator is connected as
correct burden resistor or the rheostat a self-excited regulator, check if the power
is connected between the droop current transformers are properly wired as an open
transformer and the regulator. If no resistor delta configuration for the according wiring
is present, the regulator was destroyed diagrams. Check if the power transformers
because of high current on the CT input. are properly sized in order to provide a
Refer to Testing And Adjusting, “Wiring minimum of 1200 VA each.
Diagrams”. STOP.
Expected Result: The proper voltage is
• NOT OK: The sufficient DC voltage is not approximately 95 VAC for 60 Hertz generator
present. Repair the supply voltage wiring, sets and 79 VAC for 50 Hertz generator sets.
fuses and circuit breakers, if necessary. The voltage must be stable. Voltages up to
STOP. 120 VAC, 60 HZ are acceptable.

4. Verify the proper configuration of the Results:

parameters.
• OK: The voltage is correct. Go to Step 6.
Parameters :10 or :13 must not be set too high.
• NOT OK: The voltage is incorrect or
a. If the underfrequency point (parameter :10) unstable. PM stator or PM rotor is damaged.
is set too close to the nominal operating Troubleshoot the PM unit. Replace the faulty
frequency, then the voltage may not build. component. STOP.
Look for an undervoltage fault code. If the
code is found, try the default value. 6. Check the sensing inputs.

b. If the undervoltage trip point (parameter :13) a. Check the sensing inputs between the digital
is set too close to the nominal operating voltage regulator terminals 20 to 22, 22 to 24,
voltage, the voltage regulator may shutdown and 20 to 24.
and report an undervoltage fault code. Try
the default value. Expected Result: All 3 readings should be
balanced and with proper PT ratio to the
c. Display the number in parameters :92, :93, output voltage.
and :95 (if present). A display of “0000”
indicates no faults. If a fault code is present, Result:
see System Operation, “Parameters”.
• OK: All three readings are balanced. Go
Expected Result: The problem has been to Step 7.
resolved.
• NOT OK: The readings are unbalanced.
Results: Check all connections to the regulator.
Check all connections to the output
• OK: The problem has been resolved. STOP. terminals. Make sure that proper potential
transformers are installed, if applicable.
• NOT OK: The problem has not been Check the neutral connection. Check for
resolved. Proceed to Step 5. the correct phase rotation. STOP.

5. Check the PM inputs. 7. Check the generator set.

a. Turn the engine off. a. Turn the engine off.

b. Check that all of the digital voltage regulator b. Disconnect all accessory wiring from terminals
connections are tight and properly made per 3, 5, 6, 7, 40, 41, 42, 43, 44, 45, and 50.
the appropriate wiring diagram. Remove the serial data link, if installed.

c. Check PM fuses (connecting to terminals 26 c. Start the generator set and operate at “No
and 30 of the digital voltage regulator). Load”.
46
Testing and Adjusting Section

Expected Result: The generator set operates i01041688

properly.
Low Voltage - Troubleshoot
Results:
SMCS Code: 4467-035
• OK: The generator set operates properly.
There is a problem with an accessory which 1. Check for the proper version of the regulator.
has been disconnected. Proceed to Step 8.
a. Check the part number of the digital voltage
• NOT OK: The generator set does not regulator. Refer to the chart in Testing And
operate properly. Proceed to Step 9. Adjusting, “Troubleshooting”. Check whether
the digital voltage regulator is proper for the
8. Check the accessory. application.

a. Reconnect one accessory. Operate the Expected Result: The digital voltage regulator
generator set again at “No Load”. Continue is proper for the application.
this process of reconnecting one accessory
at a time until the faulty accessory is found. Results:

Expected Result: The problem has been • OK: Go to Step 2.

resolved.
• NOT OK: Install the proper digital voltage
Results: regulator. STOP.

• OK: The problem has been resolved. STOP. 2. Check the status of the display.

• NOT OK: The problem has not been a. Stop the generator set.
resolved. Proceed to Step 9.
b. Observe the display on the digital voltage
9. Check the exciter output voltage. regulator.

a. Start the generator set. Expected Result: The display should contain
a number.
b. Measure the voltage from F1 to F2.
Results:
Expected Result: The proper voltage is from
6 to 14 VDC at no load. • OK: Proceed to Step 4.
Results: • NOT OK: No number is present on the
display. Proceed to Step 3.
The 3 possible results are listed below.
3. Check the DC voltage.
• The voltage is present for a short time, but
trails off to or near zero. Shut the generator a. Check for proper DC voltage from terminal
down. Megger the exciter stator and rotor. “B+” to “B-”. The acceptable voltage range
Check the rotating diodes. is 18 VDC to 32 VDC.

• The voltage between F1 and F2 is near zero Expected Result: The sufficient DC voltage
immediately after the generator set starts. is present.
Stop the generator set. Remove the wires
F1 and F2 from the digital voltage regulator. Results:
Restart the generator set. Measure the
voltage from F1 to F2 on the digital voltage
regulator.

• The voltage between F1 and F2 is near

zero immediately after the generator set
starts and after Step 5 has been thoroughly
completed. The digital voltage regulator is
faulty. The digital voltage regulator needs
to be replaced.
 47
Testing and Adjusting Section

• OK: The sufficient DC voltage is present. • NOT OK: The problem has not been
Remove the DC power wires from terminals resolved. Proceed to Step 5.
“B+” and “B-” for 30 seconds. Reconnect
the DC power wires to the “B+” and 5. Check the PM inputs.
“B-” terminals. If the regulator display is
still blank, the regulator is faulty. Then, a. Turn the engine off.
the regulator needs to be replaced. If
this condition has occured, verify that b. Check that all of the digital voltage regulator
the correct burden resistor or rheostat connections are tight and properly made per
is connected between the droop current the appropriate wiring diagram.
transformer and the regulator. If no resistor
is present, the regulator was destroyed c. Check PM fuses (connecting to terminals 26
because of high current on the CT input. and 30 of the digital voltage regulator).
Refer to Testing And Adjusting, “Wiring
Diagrams”. STOP. d. Restart the engine.

• NOT OK: The sufficient DC voltage is not e. Check the PM inputs (26, 28, and 30) of the
present. Repair the supply voltage wiring, digital voltage regulator. Measure the AC
fuses and circuit breakers as necessary. voltage between terminals 26 to 28, 28 to 30,
STOP. and 26 to 30.

4. Verify the proper configuration of the f. If the digital voltage regulator is connected as
parameters. a self-excited regulator, check if the power
transformers are properly wired as an open
Pay particular attention to parameters :01, :02, delta configuration for the according wiring
and :30. diagrams. Check if the power transformers
are properly sized in order to provide a
a. If the rated voltage, parameter :01 is minimum of 1200 VA each.
increased, the output voltage will increase.
Expected Result: The proper voltage is
b. If the sensing transformer ratio, parameter :02 approximately 95 VAC for 60 Hertz generator
is decreased, the output voltage will increase. sets and 79 VAC for 50 Hertz generator sets.
The voltage must be stable. Voltages up to
c. If the voltage droop, parameter :30 is 120 VAC, 60 HZ are acceptable.
increased, the output voltage will decrease as
the generator output current increases. Try Results:
the default value.
• OK: The voltage is correct. Go to Step 6.
d. If generator type is set incorrectly, the
regulator may operate constantly in the under • NOT OK: The voltage is incorrect or
frequency curve. Check parameter :50 and unstable. PM stator or PM rotor is damaged.
compare actual frequency to verify. Troubleshoot the PM unit. Replace the faulty
component. STOP.
e. If the current transformer is installed or wired
incorrectly (reverse polarity) and voltage gain 6. Check the sensing inputs.
(parameter :15) is greater than zero, the
output voltage will decrease as the generator a. Check the sensing inputs between the digital
output current increases. Reverse the wires voltage regulator terminals 20 to 22, 22 to 24,
on terminal 5 and terminal 6. and 20 to 24.

f. Display the number in parameters :92, :93, Expected Result: All 3 readings should be
and :95 (if present). A display of “0000” balanced and with proper PT ratio to the
indicates no faults. If a fault code is present, output voltage. The PT ratio should match
see System Operation, “Parameters”. parameter :02 in most cases.

Expected Result: The problem has been Result:

resolved.
• OK: All three readings are balanced. Go
Results: to Step 7.

• OK: The problem has been resolved. STOP.

48
Testing and Adjusting Section

• NOT OK: The readings are unbalanced. 2. Check the status of the display.
Check all connections to the regulator.
Check all connections to the output a. Stop the generator set.
terminals. Make sure that proper potential
transformers are installed, if applicable. b. Observe the display on the digital voltage
Check the neutral connection. Check for regulator.
the correct phase rotation. STOP.
Expected Result: The display should contain
7. Check the generator set. a number.

a. Turn the engine off. Results:

b. Disconnect all accessory wiring from terminals • OK: Proceed to Step 4.

3, 5, 6, 7, 40, 41, 42, 43, 44, 45, and 50.
Remove the serial data link, if installed. • NOT OK: No number is present on the
display. Proceed to Step 3.
c. Start the generator set and operate at “No
Load”. 3. Check the DC voltage.

Expected Result: The generator set operates a. Check for proper DC voltage from terminal
properly. “B+” to “B-”. The acceptable voltage range
is 18 VDC to 32 VDC.
Results:
Expected Result: The sufficient DC voltage
• OK: The generator set operates properly. is present.
There is a problem with an accessory which
has been disconnected. Reconnect one Results:
accessory. Operate the generator set again
at “No Load”. Continue this process of • OK: The sufficient DC voltage is present.
reconnecting one accessory at a time until Remove the DC power wires from terminals
the faulty accessory is found. STOP. “B+” and “B-” for 30 seconds. Reconnect
the DC power wires to the “B+” and
• NOT OK: The generator set does not “B-” terminals. If the regulator display is
operate properly. The digital voltage still blank, the regulator is faulty. Then,
regulator is faulty. The digital voltage the regulator needs to be replaced. If
regulator needs to be replaced. this condition has occured, verify that
the correct burden resistor or rheostat
is connected between the droop current
i01041681
transformer and the regulator. If no resistor
High Voltage - Troubleshoot is present, the regulator was destroyed
because of high current on the CT input.
SMCS Code: 4467-035 Refer to Testing And Adjusting, “Wiring
Diagrams”. STOP.
1. Check for the proper version of the regulator.
• NOT OK: The sufficient DC voltage is not
a. Check the part number of the digital voltage present. Repair the supply voltage wiring,
regulator. Refer to the chart in Testing And fuses and circuit breakers as necessary.
Adjusting, “Troubleshooting”. Check whether STOP.
the digital voltage regulator is proper for the
application. 4. Verify the proper configuration of the
parameters.
Expected Result: The digital voltage regulator
is proper for the application. Pay particular attention to parameters :01, :02,
and :15.
Results:
a. If the rated voltage, parameter :01 is
increased, the output voltage will increase.
• OK: Go to Step 2.
b. If the sensing transformer ratio, parameter :02
• NOT OK: Install the proper digital voltage is increased, the output voltage will decrease.
regulator. STOP.
 49
Testing and Adjusting Section

c. If the voltage gain (line loss compensation), • NOT OK: The voltage is incorrect or
parameter :15 is increased, the output voltage unstable. PM stator or PM rotor is damaged.
will increase when the generator output Troubleshoot the PM unit. Replace the faulty
current increases. Try the default value. component. STOP.

d. If generator type is set incorrectly, the 6. Check the sensing inputs.

regulator may operate constantly in the under
frequency curve. Check parameter :50 and a. Check the sensing inputs between the digital
compare actual frequency to verify. voltage regulator terminals 20 to 22, 22 to 24,
and 20 to 24.
e. Display the number in parameters :92, :93,
and :95 (if present). A display of “0000” Expected Result: All 3 readings should be
indicates no faults. If a fault code is present, balanced and with proper PT ratio to the
see System Operation, “Parameters”. output voltage.

Expected Result: The problem has been Result:

resolved.
• OK: All three readings are balanced. Go
Results: to Step 7.

• OK: The problem has been resolved. STOP. • NOT OK: The readings are unbalanced.
Check all connections to the regulator.
• NOT OK: The problem has not been Check all connections to the output
resolved. Proceed to Step 5. terminals. Make sure that proper potential
transformers are installed, if applicable.
5. Check the PM inputs. Check the neutral connection. Check for
the correct phase rotation. STOP.
a. Turn the engine off.
7. Check the generator set.
b. Check that all of the digital voltage regulator
connections are tight and properly made per a. Turn the engine off.
the appropriate wiring diagram.
b. Disconnect all accessory wiring from terminals
c. Check PM fuses (connecting to terminals 26 3, 5, 6, 7, 40, 41, 42, 43, 44, 45, and 50.
and 30 of the digital voltage regulator). Remove the serial data link, if installed.

d. Restart the engine. c. Start the generator set and operate at “No
Load”.
e. Check the PM inputs (26, 28, and 30) of the
digital voltage regulator. Measure the AC Expected Result: The generator set operates
voltage between terminals 26 to 28, 28 to 30, properly.
and 26 to 30.
Results:
f. If the digital voltage regulator is connected as
a self-excited regulator, check if the power • OK: The generator set operates properly.
transformers are properly wired as an open There is a problem with an accessory which
delta configuration for the according wiring has been disconnected. Reconnect one
diagrams. Check if the power transformers accessory. Operate the generator set again
are properly sized in order to provide a at “No Load”. Continue this process of
minimum of 1200 VA each. reconnecting one accessory at a time until
the faulty accessory is found. STOP.
Expected Result: The proper voltage is
approximately 95 VAC for 60 Hertz generator • NOT OK: The generator set does not
sets and 79 VAC for 50 Hertz generator sets. operate properly. The digital voltage
The voltage must be stable. The voltage must regulator is faulty. The digital voltage
be stable. Voltages up to 120 VAC, 60 HZ are regulator needs to be replaced.
acceptable.

Results:

• OK: The voltage is correct. Go to Step 6.

50
Testing and Adjusting Section

i01041694 • OK: The sufficient DC voltage is present.

Remove the DC power wires from terminals
Unstable Voltage - “B+” and “B-” for 30 seconds. Reconnect
Troubleshoot the DC power wires to the “B+” and
“B-” terminals. If the regulator display is
SMCS Code: 4467-035 still blank, the regulator is faulty. Then,
the regulator needs to be replaced. If
1. Check for the proper version of the regulator. this condition has occured, verify that
the correct burden resistor or rheostat
a. Check the part number of the digital voltage is connected between the droop current
regulator. Refer to the chart in Testing And transformer and the regulator. If no resistor
Adjusting, “Troubleshooting”. Check whether is present, the regulator was destroyed
the digital voltage regulator is proper for the because of high current on the CT input.
application. Refer to Testing And Adjusting, “Wiring
Diagrams”. STOP.
Expected Result: The digital voltage regulator
is proper for the application. • NOT OK: The sufficient DC voltage is not
present. Repair the supply voltage wiring,
Results: fuses and circuit breakers as necessary.
STOP.
• OK: Go to Step 2.
4. Verify the proper configuration of the
• NOT OK: Install the proper digital voltage parameters.
regulator. STOP.
Pay particular attention to parameters :06, :10,
2. Check the status of the display. :16, and :17.

a. Stop the generator set. a. If parameter :06 is set too close to the nominal
operating frequency, then the voltage could
b. Observe the display on the digital voltage become unstable. Try the default setting.
regulator.
b. If parameter :10 is set too close to the nominal
Expected Result: The display should contain operating frequency, then the voltage could
a number. become unstable. Try the default setting.

Results: c. Some combinations of the gain parameters

:16 and :17 may cause unstable operation.
• OK: Proceed to Step 4. Try the default settings.

• NOT OK: No number is present on the d. Display the number in parameters :92, :93,
display. Proceed to Step 3. and :95 (if present). A display of “0000”
indicates no faults. If a fault code is present,
3. Check the DC voltage. see System Operation, “Parameters”.

a. Check for proper DC voltage from terminal Expected Result: The problem has been
“B+” to “B-”. The acceptable voltage range resolved.
is 18 VDC to 32 VDC.
Results:
Expected Result: The sufficient DC voltage
is present. • OK: The problem has been resolved. STOP.
Results: • NOT OK: The problem has not been
resolved. Proceed to Step 5.

5. Check the PM inputs.

a. Turn the engine off.

b. Check that all of the digital voltage regulator

connections are tight and properly made per
the appropriate wiring diagram.
 51
Testing and Adjusting Section

c. Check PM fuses (connecting to terminals 26 • NOT OK: The readings are unbalanced.
and 30 of the digital voltage regulator). Check all connections to the regulator.
Check all connections to the output
d. Restart the engine. terminals. Make sure that proper potential
transformers are installed, if applicable.
e. Check the PM inputs (26, 28, and 30) of the Check the neutral connection. Check for
digital voltage regulator. Measure the AC the correct phase rotation. STOP.
voltage between terminals 26 to 28, 28 to 30,
and 26 to 30. 7. Check the generator set.

f. If the digital voltage regulator is connected as a. Turn the engine off.

a self-excited regulator, check if the power
transformers are properly wired as an open b. Disconnect all accessory wiring from terminals
delta configuration for the according wiring 3, 5, 6, 7, 40, 41, 42, 43, 44, 45, and 50.
diagrams. Check if the power transformers Remove the serial data link, if installed.
are properly sized in order to provide a
minimum of 1200 VA each. c. Start the generator set and operate at “No
Load”.
Expected Result: The proper voltage is
approximately 95 VAC for 60 Hertz generator Expected Result: The generator set operates
sets and 79 VAC for 50 Hertz generator sets. properly.
The voltage must be stable. Voltages up to
120 VAC, 60 HZ are acceptable. Results:

Results: • OK: The generator set operates properly.

There is a problem with an accessory which
• OK: The voltage is correct. Go to Step 6. has been disconnected. Reconnect one
accessory. Operate the generator set again
• NOT OK: The voltage is incorrect or at “No Load”. Continue this process of
unstable. PM stator or PM rotor is damaged. reconnecting one accessory at a time until
Troubleshoot the PM unit. Replace the faulty the faulty accessory is found. STOP.
component. STOP.
• NOT OK: The generator set does not
6. Check the sensing inputs. operate properly. The digital voltage
regulator is faulty. The digital voltage
a. Check the sensing inputs between the digital regulator needs to be replaced.
voltage regulator terminals 20 to 22, 22 to 24,
and 20 to 24.
i01041685

b. If the digital voltage regulator has been

located in a switchgear cabinet, ensure that
Inaccurate Display -
no wiring is located in the same cable tray Troubleshoot
with the generator output wires or any other
high voltage or high current wiring. The digital SMCS Code: 4467-035
voltage regulator should be separated from
the circuit breaker by a metal, grounded plate Note: This section refers to parameters :50 through
or by large physical distance. The digital :58.
voltage regulator should never be located in
the same cabinet as a medium voltage circuit Note: If you change a parameter, you must exit the
breaker. parameter before the change of the parameter will
take effect.
Expected Result: All 3 readings should be
balanced and with proper PT ratio to the 1. Check the wiring.
output voltage. The PT ratio should match
parameter :02 in most cases. a. Stop the generator set.

Result: b. Check the wiring.

• OK: All three readings are balanced. Go Expected Result: The wiring is correct.
to Step 7.
Results:

• OK: Go to Step 2.
52
Testing and Adjusting Section

• NOT OK: The CT polarity or PT polarity Note: If the generator set neutral is connected to
is incorrect. Reverse the polarity. See the ground or a neutral bus, then measure the neutral
proper wiring diagram for details. Refer to current. If a significant amount of circulating current
Testing And Adjusting, “Wiring Diagrams”. is present, it may cause incorrect readings. A
STOP. harmonic analysis is recommended in order to help
determine the nature of the problem.
2. Check the parameter values.
Note: It is normal for the accuracy to be reduced at
a. Start the generator set and load with 25% levels below 15% of rated load. The digital voltage
to 50% of rated load. Use 0.8 power factor regulator is sensitive to the size of CT. The droop
inductive load, if at all possible. current transformer should be sized in order to
provide no more than 5 VAC (RMS) at full rated load
b. Check the values in parameters :04 and :05. but not less than 3.5 VAC either. Proper sizing will
significantly aid the accuracy at lower power levels.
Note: Parameter :52 (current) provides the measured
value of the current in the B phase only.
i01041691

c. Measure the ampere load on the B phase. Reverse Power Shutdown

d. Measure the signal voltage level at regulator or Reverse VAR Condition -
terminals 5 and 6.
Troubleshoot
e. Verify that it is in correct proportion to load
SMCS Code: 4467-035
amperes and agrees with the settings of
parameters :04 and :05.
1. Check the wiring.
Expected Result: Any parameters show
a. Stop the generator set.
negative numbers.
b. Check the wiring.
Results:
Expected Result: The wiring is correct.
• OK: If any parameters show negative
numbers, a CT or PT polarity is incorrect
Results:
or the phase rotation is wrong. Verify the
polarity and the rotation. STOP.
• OK: Go to Step 2.
• NOT OK: Go to Step 3. • NOT OK: CT polarity or PT polarity is
incorrect. The incorrect polarity may
3. Check the value of the generator output
generate erroneous faults. Reverse the
current.
polarity. See the proper wiring diagram for
details. Refer to Testing And Adjusting,
a. Compare the value of parameter :52 to the
“Wiring Diagrams”. STOP.
actual generator current.
2. Check the parameter values.
Expected Result: Parameter :52 reads less
than the actual generator current, which was
a. Start the generator set and load with 25%
measured by another meter.
to 50% of rated load. Use 0.8 power factor
inductive load, if at all possible.
Results:
b. Check value in parameters :04 and :05.
• OK: Parameter :52 reads less than the
actual generator current, which was
Note: Parameter :52 (current) provides the measured
measured by another meter. Slowly
value of the current in the B phase only.
decrease parameter :05 until the currents
match.
c. Measure the ampere load on the B phase.
• NOT OK: Parameter :52 reads more than d. Measure the signal voltage level at regulator
the actual generator current which is
terminals 5 and 6.
measured by another meter. Slowly increase
parameter :05 until the currents match.
 53
Testing and Adjusting Section

e. Verify that it is in correct proportion to load i01041684

amperes and agrees with the settings of
parameters :04 and :05. Improper PF Regulation
Expected Result: Any parameters show
or KVAR Regulation -
negative numbers. Troubleshoot
Results: SMCS Code: 4467-035

• OK: If any parameters show negative 1. Check the wiring.

numbers, a CT or PT polarity is incorrect
or the phase rotation is wrong. Verify the a. Stop the generator set.
polarity and the rotation. STOP.
b. Check the wiring.
• NOT OK: Go to Step 3.
Expected Result: The wiring is correct.
3. Check the value of the generator output
current. Results:

a. Compare the value of parameter :52 to the • OK: Go to Step 2.

actual generator current.
• NOT OK: The erroneous regulation may be
Expected Result: Parameter :52 reads less observed if the CT polarity or PT polarity
than the actual generator current, which was is incorrect. Reverse the polarity. See the
measured by another meter. proper wiring diagram for details. Refer to
Testing And Adjusting, “Wiring Diagrams”.
Results: STOP.

• OK: Parameter :52 reads less than the 2. Check the parameter values.
actual generator current, which was
measured by another meter. Slowly a. Start the generator set and load with 25%
decrease parameter :05 until the currents to 50% of rated load. Use 0.8 power factor
match. inductive load, if at all possible.

• NOT OK: Parameter :52 reads more than b. Check the values in parameters :04 and :05.
the actual generator current which is
measured by another meter. Slowly increase Note: Parameter :52 (current) provides the measured
parameter :05 until the currents match. value of the current in the “B” phase only.

Note: It is normal for the accuracy to be reduced c. Measure the ampere load on the “B” phase.
at levels below 15% of rated load. In these cases,
the digital voltage regulator may observe a 0.4 d. Measure the signal voltage level at regulator
Per Unit leading KVAR due to unbalanced cross terminals 5 and 6.
current compensation networks. The digital voltage
regulator is sensitive to CT sizing. The droop current e. Verify that it is in correct proportion to load
transformer should be sized to provide no more amperes and agrees with the settings of
than 5 VAC (RMS) at full rated load but not less parameters :04 and :05.
than 3.5 VAC either. Proper sizing will significantly
aid the accuracy at lower power levels. Expected Result: Any parameters show
negative numbers.
Note: If the digital voltage regulator is part number
155-xxxx or newer, check the value in parameter Results:
:20. If the value is very small, try increasing it until
the problem is eliminated. • OK: If any parameters show negative
numbers, a CT or PT polarity is incorrect
or the phase rotation is wrong. Verify the
polarity and the rotation. STOP.

• NOT OK: Go to Step 3.

3. Check the parameter values (continued).

a. Check the value in parameter :52.

54
Testing and Adjusting Section

Expected Result: Parameter :52 reads less • NOT OK: The problem has not been
than the actual generator current, which was resolved. Verify the CT sizing. The digital
measured by another meter. voltage regulator is sensitive to the CT
sizing. The droop current transformer
Results: should be sized to provide no more than
5 VAC (RMS) at full rated load but not
• OK: Parameter :52 reads less than the less than 3.5 VAC either. Proper sizing
actual generator current, which was will significantly aid the accuracy at lower
measured by another meter. Slowly power levels. Go to Step 6.
decrease parameter :05 until the currents
match. 6. Check the generator set.

• NOT OK: Parameter :52 reads more than a. Turn the engine off.
the actual generator current which is
measured by another meter. Slowly increase b. Disconnect all accessory wiring from terminals
parameter :05 until the currents match. 3, 5, 6, 7, 40, 41, 42, 43, 44, 45, and 50.
Remove the serial data link, if installed.
4. Check the parameter values (continued).
c. Start the generator set and operate at “No
a. On units with part numbers of 130-xxxx and Load”.
older, check the value in parameter :16 and
:17. Some combinations of gain parameters Expected Result: The generator set operates
:16 and :17 may cause unstable operation. properly.
Try the default settings.
Results:
b. On units with part numbers of 155-xxxx and
newer, check the value in parameters :36 and • OK: The generator set operates properly.
:37. Some combinations of Gain parameters There is a problem with an accessory which
:36 and :37 may cause unstable operation. has been disconnected. Reconnect one
Try the default settings. accessory. Operate the generator set again
at “No Load”. Continue this process of
c. If the problem only exists at low power levels, reconnecting one accessory at a time until
check the value in parameter :38. Try raising the faulty accessory is found. STOP.
the value. This is not valid for the earlier
digital voltage regulator, which does not have • NOT OK: If the generator set neutral is
parameter :38. connected to ground or a neutral bus, then
measure the neutral current. If a significant
Expected Result: The problem has been amount of circulating current is present, it
resolved. may cause improper operation. A harmonic
analysis is recommended in order to help
Results: determine the nature of the problem.

• OK: The problem has been resolved. STOP. i01041695

• NOT OK: The problem has not been Watchdog Alarm -

resolved. Go to Step 5.
Troubleshoot
5. Verify the CT sizing.
SMCS Code: 4467-035
a. Remove the remote PF/KVAR adjust rheostat.
A 602 alarm is a watchdog alarm. A watchdog
b. Retry the operation of the generator set. alarm can be generated during engine cranking. In
order to prevent this alarm, a separate constant 24
Expected Result: The problem has been VDC supply to the regulator should be provided.
resolved. If a constant 24 VDC supply is not available, then
remove all battery power to the regulator during
Results: engine cranking in order to prevent the 602 alarm.

• OK: The problem has been resolved. STOP.

 55
Testing and Adjusting Section

i01041687 Note: It is also possible to get the loss of frequency

shutdown fault (fault code 803), if a fault is reset
Loss of Frequency Shutdown on a self excited generator connection with the
- Troubleshoot generator still spinning. Always stop the generator
before resetting faults when using a self excited
SMCS Code: 4467-035 connection.

1. Check the wiring. i01077455

a. Turn the engine off. Instantaneous Trip Shutdown

b. Check the PM wiring. - Troubleshoot
Expected Result: The wiring is correct. SMCS Code: 4467-035

Results: Instantaneous trip shutdown is fault 801.

Note: Electromagnetic noise spikes can create

• OK: Go to Step 2.
an erroneous instantaneous trip. Such spikes are
often the result of breaker closure. If the digital
• NOT OK: The CT polarity or PT polarity voltage regulator or any wiring to the digital
is incorrect. Reverse the polarity. See the
proper wiring diagram for details. Refer to voltage regulator is in close proximity to a circuit
Testing And Adjusting, “Wiring Diagrams”. breaker (particularly a medium voltage breaker),
STOP. this condition may occur. Uninterrupted power
systems (UPS), motor drives, and other equipment
2. Check the accessory. that generates electromagnetic interference (EMI)
spikes or switches large currents must also be
a. Disconnect all accessory wiring from terminals avoided. Install the digital voltage regulator in the
3, 5, 6, 7, 40, 41, 42, 43, 44, 45, and 50. generator terminal box or in another location away
Remove the serial data link, if installed. from the offending equipment.

b. Start the generator set and operate at “No 1. Check the wiring.
Load”.
a. Stop the generator set.
Expected Result: The generator set operates
properly. b. Check the wiring.

Results: Expected Result: The wiring is correct.

Results:
• OK: The generator set operates properly.
There is a problem with an accessory which
has been disconnected. Reconnect one • OK: Go to Step 2.
accessory and operate the generator set
again at “No Load”. Continue this process • NOT OK: Shorted F1 and F2 wires will
of reconnecting one accessory at a time cause the instantaneous trip shutdown fault.
until the faulty accessory is found. STOP. Megger the exciter stator. See the proper
wiring diagram for details. Refer to Testing
And Adjusting, “Wiring Diagrams”. STOP.
• NOT OK: The generator set does not
operate properly. Temporarily disconnect
and then reconnect the battery voltage 2. Check the accessory.
to the regulator. If proper AC voltage is
present at terminals 26 and 30, and the a. Disconnect all accessory wiring from terminals
fault is still present, the regulator is faulty. 3, 5, 6, 7, 40, 41, 42, 43, 44, 45, and 50.
Replace the regulator. Remove the serial data link, if installed.

Note: Shielded cable should be provided for all b. Start the generator set. Operate the generator
remote adjustment potentiometers. Connect the set with the same conditions that caused the
shield drain wire to regulator terminal 45. Insulate problem previously.
the wiring shield from touching all other objects,
including Earth ground. This will eliminate the Expected Result: The generator set operates
possibility of induced voltages (EMI spikes) causing properly.
an intermittent shutdown.
Results:
56
Testing and Adjusting Section

• OK: The generator set operates properly.

There is a problem with an accessory which
has been disconnected. Reconnect one
accessory. Operate the generator set again.
Continue this process of reconnecting
one accessory at a time until the faulty
accessory is found. STOP.

• NOT OK: The generator set does not

operate properly. Go to Step 3.

3. Check the nearby equipment.

a. Identify nearby equipment that could generate

EMI spikes.

b. Move the digital voltage regulator and the

wiring to a temporary location away from
the offending equipment and operate the
generator again.

Expected Result: The problem has been

resolved.

Results:

• OK: The problem has been resolved. Find

a new permanent home for the digital
voltage regulator away from the offending
equipment. Shielded wiring should always
be used for rheostat inputs when the
regulator and/or rheostat are located off the
generator. Connect the shield drain wire to
regulator terminal 45. Insulate the wiring
shield from touching all other objects,
including Earth ground.

• NOT OK: The digital voltage regulator is

being subjected to other sources of EMI. On
methods to reduce EMI, refer to Systems
Operation, “Customer Options”, section
Remote Installation Notes.

i01041698

Wiring Diagrams
SMCS Code: 4467; 7566
 57
Testing and Adjusting Section

4/6 Lead

g00539494
Illustration 13
58
Testing and Adjusting Section

4/6 Lead With Sensing Isolation

Transformer

g00539496
Illustration 14
 59
Testing and Adjusting Section

10/12 Lead

g00539518
Illustration 15
60
Testing and Adjusting Section

10/12 Lead With Sensing Isolation

Transformer

g00539520
Illustration 16
 61
Testing and Adjusting Section

10/12 Lead With Self-Excitation

g00539521
Illustration 17
62
Testing and Adjusting Section

Manual Control

g00539523
Illustration 18
 63
Testing and Adjusting Section

Customer Options

g00539524
Illustration 19
64
Testing and Adjusting Section

Remote Communications

g00539526
Illustration 20

The new 131-7416 Converter Control includes

the converter, power supply and the harness. The
harness is serviced separately.
 65
Testing and Adjusting Section

Single Phase Sensing - PM

g00586883
Illustration 21
66
Testing and Adjusting Section

Single Phase Sensing - SE

g00586885
Illustration 22
 67
Index Section

Index
C I

Cross Current Compensation ................................ 13 Important Safety Information ................................... 2

Customer Options.................................................. 33 Improper PF Regulation or KVAR Regulation -
Alarm Output Driver ........................................... 33 Troubleshoot ........................................................ 53
Application Note................................................. 35 Inaccurate Display - Troubleshoot ......................... 51
Communication Port PF/KVAR Adjust ............... 35 Instantaneous Trip Shutdown - Troubleshoot ........ 55
Communication Port Voltage Adjust .................. 35
Excitation Disable .............................................. 34
Fault Reset......................................................... 34 K
Fault Shutdown Output Driver............................ 33
Manual Voltage Control...................................... 36 KVAR Regulation................................................... 14
Remote Installation Notes.................................. 35
Remote PF/KVAR Adjust Rheostat.................... 35
Remote Voltage Adjust Rheostat ....................... 34 L
Utility 52/a Contacts ........................................... 34
Line Loss Compensation ....................................... 12
Loading and Stopping Profile ................................ 11
D Loss of Frequency Shutdown - Troubleshoot ........ 55
Low Voltage - Troubleshoot ................................... 46
Dimensions.............................................................. 6
Display and Keypad ................................................. 8
Example ............................................................... 9 N

No Voltage - Troubleshoot ..................................... 44

E

Electrical.................................................................. 4 P

Parameter Viewing and Configuring Procedure .... 38

F Parameters ............................................................ 17
General Information ........................................... 18
Fault Classifications............................................... 28 Parameter Descriptions ..................................... 19
Alarm Fault......................................................... 29 Parameter Exceptions For Earlier Digital Voltage
Non-Resettable Shutdown Fault ........................ 29 Regulators........................................................ 27
Resettable Shutdown Fault ................................ 29 Parameter Table................................................. 17
Severe Fault....................................................... 29 Power Factor Regulation ....................................... 15
Fault Codes ........................................................... 30 Original Power Factor Operation........................ 16
Fault Handling ....................................................... 39 PROM ID 1.03 Power Factor Operation ............. 16
Fault Clearing..................................................... 40 PROM ID 1.05 Power Factor Operation ............. 16
Fault Identification .............................................. 39
Fault Handling for Earlier Digital Voltage
Regulators ........................................................... 41 R
Alarm Clearing (For Earlier Digital Voltage
Regulator) ........................................................ 42 Reactive Voltage Droop ......................................... 13
Fault Clearing (For Earlier Digital Voltage Remote Communication ........................................ 33
Regulator) ........................................................ 42 Reverse Power Shutdown or Reverse VAR Condition
Fault Identification (For Earlier Digital Voltage - Troubleshoot ...................................................... 52
Regulator) ........................................................ 41

S
G
Service Tools ......................................................... 37
General Information........................................... 7, 37 Specifications Section ............................................. 4
Startup Procedure ................................................. 38
Startup Profile Function......................................... 10
H Systems Operation Section ..................................... 7

High Voltage - Troubleshoot................................... 48

T

Table of Contents..................................................... 3
Testing and Adjusting ............................................ 37
Testing and Adjusting Section ............................... 37
Troubleshooting ..................................................... 43

Unstable Voltage - Troubleshoot............................ 50

Voltage Regulation ................................................ 12

Watchdog Alarm - Troubleshoot ............................ 54

Wiring Diagrams .................................................... 57
10/12 Lead ......................................................... 59
10/12 Lead With Self-Excitation......................... 61
10/12 Lead With Sensing Isolation Transformer.. 60
4/6 Lead ............................................................. 57
4/6 Lead With Sensing Isolation Transformer .... 58
Customer Options .............................................. 63
Manual Control................................................... 62
Remote Communications................................... 64
Single Phase Sensing - PM ............................... 65
Single Phase Sensing - SE................................ 66

©2002 Caterpillar
All Rights Reserved Printed in U.S.A.