MX321 AUTOMATIC VOLTAGE

REGULATOR (AVR)
SPECIFICATION, INSTALLATION AND ADJUSTMENTS

General description Technical specification

MX321 is a three phase sensed Automatic Voltage SENSING INPUT
Regulator and forms part of the excitation system for a Voltage 190-264V ac max, 2 or 3 phase
brush-less generator. Excitation power is derived from a Frequency 50-60 Hz nominal
POWER INPUT (PMG)
three-phase permanent magnet generator (PMG), to
Voltage 170-220V ac max, 3 phase, 3 wire
isolate the AVR control circuits from the effects of non- Current 3A/phase
linear loads and to reduce radio frequency interference on Frequency 100-120 Hz nominal
the generator terminals. Sustained generator short circuit OUTPUT
current is another feature of the PMG system. Voltage max 120V dc
Current continuous 3.7 A (see note 1)
The AVR senses the voltage in the main generator winding Intermittent 6A for 10 secs.
and controls the excitation to maintain the generator output Resistance 15 ohms minimum
REGULATION
voltage within the specified limits, compensating for load,
+/- 0.5% RMS with 4% engine governing (see note 2)
speed, temperature and power factor of the generator. THERMAL DRIFT
Three phase RMS sensing is employed for superior 0.02% per deg. C change in AVR ambient (note 3)
voltage regulation. SOFT START RAMP TIME
0.4 - 4 seconds
Adjustable Soft start circuitry is included to provide a TYPICAL SYSTEM RESPONSE
smooth controlled build up of generator output voltage. AVR response 10 ms
Filed current to 90% 80 ms
Machine Volts to 97% 300 ms
A frequency measuring circuit continually monitors the
EXTERNAL VOLTAGE ADJUSTMENT
shaft speed of the generator and provides under-speed +/-10% with 5 k ohm 1 watt trimmer (see note 4)
protection of the excitation system by reducing the UNDER FREQUENCY PROTECTION
generator output voltage proportionally with speed below a Set point 95% Hz (see note 5)
pre-settable threshold. A further enhancement of this Slope 100-300% down to 30 Hz
feature is an adjustable volts per Hertz slope and voltage Max. Dwell 20% volts/S recovery
recovery time, to improve the response of turbo charged UNIT POWER DISSIPATION
engines. 18 watts maximum
ANALOGUE INPUT
Maximum input +/- 5 Vdc (see note 6)
Current limiting may be included to allow control over the Sensitivity 1v for 5% Generator Volts (adjustable)
amount of sustained short circuit current. Input resistance 1k ohm
QUADRATURE DROOP INPUT
Maximum excitation is limited to a safe period by internal 10 ohms burden
shutdown of the AVR output device. This condition remains Max. sensitivity: 0.22 A for 5% droop 0PF
latched until the generator has stopped. Max. input: 0.33 A
CURRENT LIMIT INPUT
The AVR includes an over-voltage protection feature with 10 ohms burden
Sensitivity range: 0.5 – 1A
internal shutdown of the AVR output device, plus the ability
OVER VOLTAGE DETECTOR INPUT
to trip an optional excitation circuit breaker if required. Set point: 300v. Time delay: 1 Sec (fixed)
CB trip coil volts: 10-30 vdc
Provision is made for the connection of a remote voltage CB trip coil resistance: 20-60 ohms
trimmer, allowing the user fine control of the generator's OVER EXCITATION PROTECTION
output. Set point 75 V dc
Time delay 8-15 seconds (fixed)
An analogue input is provided allowing connection to a ENVIRONMENTAL
Vibration 20-100 Hz 50mm/sec
Newage Power Factor controller or other external device
100Hz – 2kHz 3.3g
with compatible output. Operating temperature
0
-40 to +70 C
0
Relative Humidity 0-70 C 95% (see note 7)
The AVR has the facility for droop CT connection, to allow Storage temperature
0
-55 to +80 C
parallel running with other similarly equipped generators.

NOTES 4. Applies to Mod status E onwards. Generator de-rate may

1. Derate linearly from 3.7A at 50°C to 2.7A at 70°C apply. Check with factory.Factory set, semi-sealed,
2. The stated voltage regulation may not be maintained in the jumper selectable.
presence of certain transmitted radio signals. Any change in 5. Any device connected to the analogue input must be fully
regulation will fall within the limits in Criteria B of floating (galvanically isolated from ground), with an
BS.EN.61000-6-2 : 2001. insulation strength of 500V ac.
3. After 10 minutes. 6. Non condensing.

TD_MX321.GB_06.03_03
 DESIGN DETAIL
Over Over -
Voltage voltage
Stator Sensing
Voltage Detector
PMG
Sensing Low Hz
Detection
Droop Potential Dip & Synchronising
Divider & Dwell Circuit
Hand Rectifier Circuit Breaker
Trimmer
Reference Power
Analogue DC Voltage supply
Input Mixer

Level Power
Ramp Detector & Control
Amp
Generator Driver Devices

Current
Limit 3 Phase
Over
Input Rectifier
Stability Excitation
Circuit Detector

Exciter
Field

The main functions of the AVR are: The Low Hz Detector measures the period of each
electrical cycle and causes the reference voltage to be
Potential Divider and Rectifier takes a proportion of the reduced approximately linearly with speed below a
generator output voltage and attenuates it. The potential presettable threshold. The Dip and Dwell circuits
divider is adjustable by the AVR Volts potentiometer and provide adjustments for greater voltage roll off and
external hand trimmer (when fitted). The output from the recovery time. A Light Emitting Diode gives indication
droop CT is also added to this signal. A rectifier converts of underspeed running.
the a.c. input signal into a d.c. signal representing
generator voltage. The Synchronising circuit is used to keep the Ramp
Generator and Low Hz Detector locked to the
The DC Mixer adds the Analogue input signal the Permanent Magnet Generator waveform period.
generator voltage signal.
Power Control Devices vary the amount of exciter field
The 3 Phase Rectifier converts the output of the current current in response to the error signal produced by the
limit CT’s into a dc signal representing generator current. Amplifier.

The Amplifier (Amp) compares the generator voltage or The Circuit Breaker provides circuit isolation of the
current signals to the Reference Voltage and amplifies the control system in the event of an over excitation or over
difference (error) to provide a controlling signal for the voltage condition.
power devices. The Ramp Generator and Level Detector
and Driver infinitely control the conduction period of the The Over Excitation Detector continuously monitors the
Power Control Devices and hence provides the excitation exciter field voltage and turns off the power device if
system with the required power to maintain the generator this rises above the reference leve,l for greater than the
voltage within specified limits. stated time period. An external signal is also provided
to trip the Circuit Breaker
The Stability Circuit provides adjustable negative ac
feedback to ensure good steady state and transient The Over Voltage Detector continuously monitors the
performance of the control system. generator stator voltage and turns off the power device
if this rises above the reference level, for greater than
The Power Supply provides the required voltages for the the stated time period. An external signal is also
AVR circuitry. provided to trip the Circuit Breaker

TD_MX321.GB_06.03_03
 FITTING AND OPERATING (Refer to generator wiring diagram for connection details)

K2 K1 P2 P3 P4 XX X 6 7 8 1 2

Ramp No link 6P50Hz

6P60H Volts
Indicator z
4P50H I Limit
LED z4P60H

3 2 1
z Frequency
UFRO
Selection
MX321 Dip
Rms
Dwell
Stability
Stability
Selection > 550kW
90-550kW Droop
< 90kW Trim
Over V Exc. U V W
E0 E1 B0 B1 CBA S1S2 S1S2
S1S2 A1A2

SUMMARY OF AVR CONTROLS

CONTROL FUNCTION DIRECTION

VOLTS TO ADJUST GENERATOR OUTPUT VOLTAGE CLOCKWISE INCREASES OUTPUT VOLTAGE

STABILITY TO PREVENT VOLTAGE HUNTING CLOCKWISE INCREASE THE DAMPING EFFECT
UFRO TO SET THE UFRO KNEE POINT CLOCKWISE REDUCES THE KNEE POINT FREQUENCY
DROOP TO SET THE GENERATOR DROOP TO 5% AT 0PF CLOCKWISE INCREASES THE DROOP
TRIM TO OPTIMISE ANALOGUE INPUT SENSITIVITY CLOCKWISE INCREASES THE GAIN OR SENSITIVITY
EXC TO SET THE OVER EXCITATION TRIP LEVEL CLOCKWISE INCREASES THE TRIP LEVEL
DIP TO SET THE HZ RELATED VOLTAGE DIP CLOCKWISE INCREASES THE DIP
DWELL TO SET THE HZ RELATED RECOVERY TIME CLOCKWISE INCREASES THE RECOVERY TIME
I LIMIT TO SET THE STATOR CURRENT LIMIT CLOCKWISE INCREASES THE CURENT LIMIT
OVER V TO SET THE OVER VOLTAGE TRIP LEVEL CLOCKWISE INCREASES THE TRIP LEVEL
RAMP TO SET THE NO LOAD VOLTAGE RAMP UP TIME CLOCKWISE INCREASES THE VOLTAGE RAMP TIME

ADJUSTMENT OF AVR CONTROLS

If a replacement AVR has been fitted or re-setting of
VOLTAGE ADJUSTMENT the VOLTS adjustment is required, proceed as
follows:
The generator output voltage is set at the factory, but can 1. Before running generator, turn the VOLTS control
be altered by careful adjustment of the VOLTS control on fully anti-clockwise.
the AVR board, or by the external hand trimmer if fitted. 2. Turn remote volts trimmer (if fitted) to midway
Terminals 1 and 2 on the AVR will be fitted with a shorting position.
link if no hand trimmer is required. 3. Turn STABILITY control to midway position.
4. Connect a suitable voltmeter (0-300V ac) across
WARNING! Do not increase the voltage above the rated line to neutral of the generator.
generator voltage. If in doubt, refer to the rating plate 5. Start generator set, and run on no load at nominal
mounted on the generator case. frequency e.g. 50-53Hz or 60-63Hz.
6. If the red Light Emitting Diode (LED) is illuminated,
WARNING! Do not ground any of the hand trimmer refer to the Under Frequency Roll Off (UFRO)
terminals, as these could be above earth potential. Failure adjustment. Continued…..
to observe this could cause equipment damage.

TD_MX321.GB_06.03_03
 FITTING AND OPERATING (Refer to generator wiring diagram for connection details)
7. Carefully turn VOLTS control clockwise until rated TRIM ADJUSTMENT continued
voltage is reached. The dc signal applied to this input adds to the AVR sensing
8. If instability is present at rated voltage, refer to stability circuit. A1 is connected to the AVR 0 volts. Positive on A2
adjustment, then re-adjust voltage if necessary. increases excitation. Negative on A2 decreases excitation.
9. Voltage adjustment is now completed. The TRIM control allows the user to adjust the sensitivity of
STABILITY ADJUSTMENT the input. With TRIM fully anti-clockwise the externally
The AVR includes a stability or damping circuit to provide applied signal has no effect. Clockwise it has maximum
good steady state and transient performance of the effect.
generator. Normal setting is fully clockwise when used with a Newage
A jumper link selector is provided to optimise the Power Factor Controller.
response of the stability circuit to various size generators. OVER EXCITATION (EXC) ADJUSTMENT
The link should be positioned as shown in the diagram This adjustment is set and sealed in the works and should
according to the kW rating of the generator. not be tampered with. An over excitation condition is
The correct setting of the Stability adjustment can be indicated by the illumination of the red LED which also
found by running the generator at no load and slowly indicates under-speed running and over-volts.
turning the stability control anti-clockwise until the The generator must be stopped to reset an over-excitation
generator voltage starts to become unstable. The trip.
optimum or critically damped position is slightly clockwise DIP ADJUSTMENT
from this point (i.e. where the machine volts are stable This feature is mostly used when the generator is coupled
but close to the unstable region). to turbo charged engines with limited block load
UNDER FREQUENCY ROLL OFF (UFRO) acceptance. The feature works by increasing the V/Hz
ADJUSTMENT slope to give greater voltage roll off in proportion to speed.
The AVR incorporates an underspeed protection circuit With the DIP control fully anti-clockwise, the generator
which gives a volts/Hz characteristic when the generator voltage will follow the normal V/Hz line as the speed falls
speed falls below a presettable threshold known as the below nominal. Turning the DIP control clockwise provides
"knee" point. The red Light Emitting Diode (LED) gives greater voltage roll off aiding engine recovery.
indication that the UFRO circuit is operating. DWELL
The UFRO adjustment is preset and sealed and only This feature is mostly used when the generator is coupled
requires the selection of 50 or 60Hz and 4 pole or 6 pole, to turbo charged engines with limited block load
using the jumper link as shown in the diagram. acceptance. The feature works by introducing a delay
For optimum setting, the LED should illuminate as the between speed recovery and voltage recovery and allows a
frequency falls just below nominal, i.e. 47Hz on a 50Hz greater DIP setting without instability. With the DWELL
system or 57Hz on a 60Hz system. control fully anti-clockwise, the generator voltage will follow
DROOP ADJUSTMENT the V/Hz line. Turning the DWELL control clockwise
Generators intended for parallel operation are fitted with increase the delay time between speed recovery and
a quadrature droop C.T. which provides a power factor voltage recovery.
dependent signal for the AVR. The C.T. is connected to CURRENT LIMIT (I LIMIT) ADJUSTMENT
S1, S2 on the AVR, (see generator wiring diagram for This feature is mostly used to limit short circuit current or to
details). The DROOP adjustment is normally preset in provide a current limit on motor starting. To use this
the works to give 5% voltage droop at full load zero feature, current limit CT’s of the correct ratio need to be
power factor. connected to the AVR S1 S2 terminals. There is an internal
Clockwise increases the amount of C.T. signal injected time limit of 10 seconds. Consult the factory before using
into the AVR and increases the droop with lagging power this feature.
factor (cos Ø). With the control fully anti-clockwise there OVER VOLTAGE (OVER V) ADJUSTMENT
is no droop. This adjustment is set and sealed in the works and should
not be tampered with. An over voltage condition is
TRIM ADJUSTMENT indicated by the illumination of the red LED which also
An analogue input (A1 A2) is provided to connect to the indicates under-speed running and over-excitation.
Newage Power Factor Controller or other devices. It is The generator must be stopped to reset an over-voltage
designed to accept dc signals up to +/- 5 volts. trip.
RAMP
WARNING! Any devices connected to this input must be The AVR includes a soft start or voltage ramp-up circuit to
fully floating and galvanically isolated from ground, with control the rate of voltage build up, when the generator
an insulation capability of 500V ac. Failure to observe runs up to speed. This is normally pre-set and sealed to
this could result in equipment damage. give a voltage ramp-up time of approximately 3 seconds. If
required, this can be adjusted between the limits defined in
the specification.

PO Box 17 • Barnack Road • Stamford • Lincolnshire • PE9 2NB

© 2003 Newage International Limited. Tel: 00 44 (0)1780 484000 • Fax: 00 44 (0)1780 484100
Reprinted with permission of N.I. only. Website: www.newage-avkseg.com
Printed in England. TD_MX321.GB_06.03_03