R450 Operation and Troubleshooting

Automatic voltage
regulator R450

1
AVR R450
 R450 Operation and Troubleshooting

 Visual checks

 R450 Inputs

 Meter checks

 Paralleling user

 Possible root cause of AVR failures (Electrical faults)

 Fault tree

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AVR R450
 Visual Checks

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AVR R450
 R450 Operation and Troubleshooting

4
AVR R450
 R450 Operation and Troubleshooting

X2 Z1

X1 Z2
ST3 External
F+ F-
Frequency select

UVW
ST4 Remote voltage
adjustment potentiometer
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AVR R450
 R450 Operation and Troubleshooting

 Check that all terminals have been properly plugged

and wired correctly.
 Check the selectors selections according to the
generator set specifications
–Frequency
–Rated voltage
–Alternator type
–Excitation mode
Options
Check secondary of the CT (Droop CT is XXX:1 amp)

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AVR R450
 R450 Troubleshooting

• Check configuration before

start-up
 Remote voltage pot. input
 Dial selector settings

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AVR R450
 R450 Troubleshooting

Picture shows a functional

Metal Oxide Varistor (MOV)
Mov’s function:
 Protect against overvoltage,
in general MOV’s are damaged
by overvoltage issue and blow
out (see pic below). In this case
the AVR needs to be replaced
• MOV

Polyruethane
cracked &
MOV’s technical data: MOV blown
MOV
250 VAC 72 Joules Blown
Max 354 Volts DC
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AVR R450
 R450 Inputs Details

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AVR R450
 R450 Troubleshooting

• Current
Parallel CT transformer
Input for machines in parallel operation, connection S1 and S2.
• Make sure the CT is installed on U Phase

Diagnostic information:
 Input resistance measurement using multimeter should be less than 0.5 Ω.
 CT connected wrong
 If not, faulty AVR

Possible cause of failure:

Input shorted
Open circuit
Installation procedure not followed correctly

 If measurement correct, the investigation needs to be focus on the genset

 For more details (see installation form)

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AVR R450
 R450 Troubleshooting

• External potentiometer External Pot. Input

 Input resistance measurement should be around 1,4 KΩ (measurement

made with a multimeter in Ω setting), pot disconnected

 If measurement is correct, the investigation needs to be focused on the

genset
If not, AVR is bad

*Input characterics: 470Ω, 0.5W min: adjustement range +-5% (Range

limited by internal voltage potentiometer P2)

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AVR R450
 R450 Troubleshooting

• 50HZ-60HZ EXT FREQ control External Frequency Select

 Using a multimeter with jumper

disconnected
Resistance measurement should be
around 1,9 MΩ (measurement made
with a multimeter in Ω setting)
If not, AVR is bad

 If the measurement is correct, the

investigation needs to be focused on
the genset

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AVR R450
 R450 Troubleshooting

• Fuses check

 Make sure the two fuses are in

place
 If they are clearly blown, replace

Fuses type: 250Volts 10 Amps

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AVR R450
 Meter Checks

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AVR R450
 R450 Troubleshooting

Make sure both fuses F1 & F2

Fuse open
F2 are good!
• Test Procedure:

 Meter set to Ω position

F1 Incorrect: open
Replace fuse
Fuse OK
F2
Correct: close to 0Ω
Fuse is OK

F1
AVR R450
15
 R450 Troubleshooting
.OL Opened circuit

• Check IGBT free wheel diode

 Meter set on diode test
 Measurement must be done between F+ and F-

 The test must be carried out in both positions (Multimeter

probe reversed on terminal)
Diode voltage threshold

Pic shows correct values

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AVR R450
 R450 Troubleshooting

Paralleling
W
V
U

USERS

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AVR R450
 CT 1A&5A Installation Procedure
• The purpose of this instruction is to define the marking, positioning and verification
for
the proper CT connection (measuring, protection and parallel operation).
There are 3 phases :
 Identification label positioning
 CT positioning
 Connection verification

• Label Application
Identify the transformer by applying a color label with an arrow
and mark P1 on the transformer. The label must be applied by
the cableman. 3 colors corresponding to CT are as follows:
Green label : parallel operation CT (ref in CT diagram 04)
White label : protection CT (ref 5P5 / 5P10) P1
Orange label : measuring CT (ref CL1 / CL0,5 ; 3 pcs per unit)

Stick the label on so that the arrow is oriented to P1 side. Then

roll out and stick the rest of the label on the transformer

P2

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AVR R450
 CT 1A&5A installation Procedure
• CT Positioning
The CT must be installed during wiring so that the arrow is oriented to the
neutral bar (except contraindication on the BF), it means the P1 side to the
neutral.

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AVR R450
 CT 1A&5A installation procedure
• Connection verification:
Within the « VMV » principle (Verify Make Verify), the assembler verifies
visually, proper orientation of the CT (color code + arrow toward the
neutral). In addition, the operator measures the value of CT with a clamp
meter. To do this, make a loop between the CTs. Connect the black
wires to each other and blue wires to each other. Then connect the 1st
blue wire to last black wire to close the loop. It is on this wire you make
the measurement with clamp meter (see the diagram below).

CT CT CT

Clamp meter 20
AVR R450
 CT 1A&5A installation procedure
The CT measurement is a comparative measurement. First of all, determine the voltage with the
right connection then reverse 2 wires and remake the measurement (see the diagram below).

TI TI TI

Clamp meter
The alternator is correct if the value measured in the correct connection is inferior to one
obtained in connection with 2 reversed wires.

This is an order of values to be measured :

Machine type Correct connection value Wrong connection value
462 VL 12 1 to 17 mV 42 mV to 1 V
472 M 7 5 to 30 mV 40 mV to 1,2 V
472 M 8 10 mV 250 mV
472 S 5 1 to 80 mV 0,3 to 1 V
491 M 5 3 mV 0,9 V
491 L 10 15 mV 160 mV
501 VL 10 1 mV 150 mV
501 M 6 1 mV 130 mV
501 M 7 4 to 300 mV 0,7 to 2 V 21
AVR R450
 Electrical Fault Investigation

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AVR R450
 Electrical Faults
CT installed is not correct, out of specification, Possible effects: Internal components on AVR, could
Represent 3.62% of returns issue on R448 cause irreversible damaged
Resistance
CT connection not implemented correctly Possible effects: Internal components on AVR, could
cause irreversible damaged
Resistance
Wrong connection on X2 Z1 and X1 Z2 Possible effects: MOV’s could be damaged, due to
Represent 8.96% of returns issue on R448 overvoltage issue.

Wrong connection on E+ and E- Possible effects: Internal components on AVR, could

Represent 2.13% of returns issue on R448 cause irreversible damaged
Resistance

External potentiometer connected with the machine’s Possible effects: Internal components on AVR, could
enclosure ground cause irreversible damaged
Represent 1.92 % of returns issue on R448 Internal power supply

Fuse metalic support, damaged Possible effects: Bad contact, therefore intermittent
Represent 2.99% of returns issue on R448 trip on AVR would occurs

Loss of residual magnetism on the exciter field, if Possible effects: Internal components on AVR, could
the technician do not follow the procedure correctly cause irreversible damaged
and reverse the polarity E+ and E- using a battery. IGBT failure
Represent 1.28% of returns issue on R448

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AVR R450
 Electricals faults

Alternator’s not paralleled correctly Possible effects: Wrong voltage applied on the AVR
inputs UVW, will damaged the MOV on the AVR due
to overvoltage issue

Voltage applied on the AVR heat sink Possible effects: Internal components on AVR, could
cause irreversible damaged IGBT

Bad connection with mat’N lok connector or faston Possible effects: unstable condition - could cause
version on the exciter field terminal irreversible failure of IGBT

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AVR R450
 R450 Fault Tree

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AVR R450
 Fault Tree
Voltage drop too High on load impact
Yes
Check GENSET load applied, No Reduce load
might be too high, is it correct?
Yes
Check CT position Reinstalled CT on U
and make sure is Phase (see Yes
installed on U phase, No installation Check quadrature
No
is it correct? procedure) droop setting P4 Makes P4
Yes potentiometer, is it adjustment
Is the CT Wired No Makes wiring correct?
correctly? S1and S2 modification (see Yes Makes selector
adjustment.
Yes installation Check the LAM function No LAM 2U/F
procedure) setting on selector, is it
50HZ/60HZ or
Check stator resistance set correctly? Auto adaptative
windings (see testing Yes LAM
procedure and
50HZ/60HZ
resistance value on No Replace AVR
manual installation) Repair alternator
Yes
Yes
Check wiring on voltage
detection U/V/W 3
Phases, single phase V
No Makes wiring Run GENSET and
modification monitor
and W, is it correct?
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AVR R450
 Fault Tree
Voltage too low
Yes
Check GENSET speed, is it correct? No Makes speed
(50HZ 1500 RPM – 60HZ 1800 RPM) adjustment
Yes Yes No
Check CT position Check AVR’s wiring, Makes AVR wiring
Installed CT on U
and make sure is No is it correct? modification
Phase (see installation
installed on U phase, Yes
is it correct?
manual) No Makes P1 or external
Check P1 or external
Yes potentiometer potentiometer
Check windings adjustment in order to
No Replace the exciter field position, is it correct? get 400 V at 50HZ or
resistance value on
the exciter field, is it
(see exciter field Yes 480V at 60HZ
resistance value Check the LAM function
correct? (field provided in installation setting on selector and No
windings) manual) frequency selected, is it set
Makes selector
Yes correctly?
adjustment. LAM
No Yes 2U/F 50HZ/60HZ
Check rotating diodes
(see procedure on the
Replace rotating Replace AVR or Auto adaptative
manual installation), are diodes LAM 50HZ/60HZ
they correct? Yes
Yes Replace revolving
field (see procedure Run GENSET and
Check revolving field
resistance value, is it No and Rotor resistance monitor
correct? value in manual)
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AVR R450
 Fault Tree
Voltage too high
Yes
Check GENSET speed, is it correct? No Makes speed
(50HZ 1500 RPM – 60HZ 1800 RPM) adjustment
Yes Yes
Check exciter field Replace exciter field
Check
Check CTrotating
position No (see resistance value
No resistance, is it
anddiodes
make (see
sure is Replace rotating correct? (field
and procedure on
installed on Uinphase,
procedure the diodes windings)
manual installation)
installation manual),
is it correct? Yes Makes AVR’s
are they correct?
Check AVR’s selectors, is
No selectors
Yes it correct? modification
Check electrical wiring
for voltage sensing No Yes Makes P1 or external
U/V/W for 3 phases or
Makes wiring Check P1 or external No potentiometer
V/W for single phase ,
modification potentiometer adjustment in order to
is it correct? get 400 V at 50HZ or
position, is it correct?
480V at 60HZ
Yes No Yes
Measure voltage sensing Makes wiring
modification Replace AVR
on U/V/W 380 Volts or
220 Volts, is it correct? Yes
Yes Replace revolving
field (see procedure Run GENSET and
Check revolving field
resistance value, is it No and resistance value monitor
correct? in manual)
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AVR R450
 Fault Tree
No Voltage at start-up
Yes Makes wiring
Check rotating diodes (see No Replace rotating Check exciter polarity No modification
procedure on the manual diodes connection, is it according to
installation), are they correct? correct? diagram
Yes Yes Yes
Replace stator, (see
Check stator resistance No procedure and
Check External No Makes
potentiometer wiring, wiring
windings, is it correct? resistance value on the insure ground is not modification
manual installation) connected. Is it correct?
Yes Yes
Check exciter armature No replace exciter armature
resistance windings, is it (see procedure and
Check Green light in No Makes wiring
running condition, is it modification
correct? (field windings) resistance value on the
correct?
manual installation)
Yes Yes
Replace revolving fld ,
Check revolving fld No (see procedure and Shunt/AREP: Check No
resistance, is it residual voltage, is it Apply field forcing
resistance value in the
correct? manual) correct? procedure on E+
Yes and E- using diode
Check AVR’s power No Makes wiring Yes and battery (4 to
supply wiring, X1X2- modification. According 12V) (see manual)
Z1Z2, is it correct?
to alternator type AREP- Replace AVR
SHUNT-PMG
Yes Yes
Check the voltage ≤7%
No Makes wiring modification, Run GENSET and
of UN, is it correct? alternator couple monitor
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AVR R450
 Fault Tree
Voltage Unstable
Yes
Check drive system stability, look for No Correct motor
speed oscillation…, is it correct? instability
Yes
Check load, is it
No Correct load
balanced? unbalance
Yes Makes P2
Yes Check P2 (Sability No adjustment, till
Check windings potentiometer), is it stability being
resistance value on the No Replace exciter field (see set correctly? reached
exciter field, is it resistance value and Yes
procedure in installation
correct?
manual)
Check the selector No Modify selector
50HZ or 60HZ according to
application selected frequency used
Yes 50HZ or 60HZ
Check rotating diodes
Yes
No Try to switch from
(see procedure in Replace rotating Check selector Normal No Normal to Fast
manual), are they diodes Yes mode
or Fast recovery
and either
correct? selected. Is it correct?
recovery mode
Yes Yes Yes
Check all No Insure proper Replace AVR
connections: tight,
connection
fully engauged Run GENSET and
correctly? monitor
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AVR R450
 Fault Tree
Response too slow on load impact
Yes
Check drive system stability, is it No Correct motor
correct? unstability
Yes
Check load, is it
No Correct load
balanced? unbalance
Yes Makes P2
Check P2 (Sability No adjustment, till
potentiometer), is it
stability is reached
set correctly?
and response time Run GENSET and monitor
Yes acceptable
Check the selector No
50HZ or 60HZ
Modify selector
application selected according to frequency
Yes used 50HZ or 60HZ
Check selector Normal
or Fast recovery mode No Try to switch from
selected. Is it correct?
Yes Normal to Fast and
either recovery mode
Yes
Replace AVR
Yes
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AVR R450
 Fault Tree
Voltage correct unloaded, too LOW loaded Replace revolving
Yes field (see
Check revolving field procedure and
Measure voltage using a Yes resistance value in
multimeter on the AVR resistance, is it correct?
between E+ and E-, No the manual)
make sure the system is Yes
unloaded Check selector Normal Try to switch from
or Fast recovery mode Normal to Fast
No Measure voltage using a Measure voltage using a selected. Is it correct? No and either
multimeter between E+ multimeter between E+
Yes recovery mode
and E-. AREP/PMG and E-. AREP/PMG No
<10V is it correct? >15V is it correct?
Replace AVR
Yes Yes
Check drive system Check rotating diodes
Yes
stability speed, look No No Replace
Correct (see procedure in the rotating
for speed
speed manual), are they Run GENSET and
oscillation…, is it diodes
correct? monitor
correct?
Yes Yes
Check the selector Check windings resistance
50HZ or 60HZ No Modify selector
value on the exciter field, is
No
according to Replace
application selected in it correct?(see procedure
frequency used exciter
function of your needs. and resistance value in
Is it correct? 50HZ or 60HZ
manual)
Yes Yes
Replace the exciter
armature (see exciter
Check resistance value on the No armature resistance
exciter armature, is it correct? value in the manual)
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AVR R450
 Fault Tree
Voltage loss while operating
Yes
Check drive system stability, look for No Correct motor
speed oscillation…, is it correct? instability
Yes Replace revolving
Check load, is it
No Correct load field (see
balanced? unbalance procedure and
Yes
Yes No resistance value in
Check revolving field the manual)
Check windings resistance, is it correct?
Replace the exciter field ,
resistance value on the No
exciter field, is it (see procedure and Yes
resistance value in
correct? (field
manual) Check MOV protection
No Replace AVR,
windings) on the AVR, is it correct perform diodes
Yes check.
Replace the exciter Yes
Check resistance value No armature, (see procedure
on the exciter armature, and resistance value in Replace AVR
is it correct? manual) Yes
Yes
Check rotating diodes
(see procedure in the No Replace rotating
manual), are they diodes
correct? Run GENSET and
monitor
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AVR R450
 Fault Tree
Ustable VAR control (Parallel operation)
Yes
Check CT position Reinstalled CT on U
and make sure is No Phase (see installation
installed on U phase, procedure)
Yes
is it correct?
Yes Check AVR’s selectors, is
No Makes AVR’s
selectors
Check electrical wiring it correct?
modification
for voltage sensing No Makes wiring Yes
U/V/W for 3 phases or Adjust P4
V/W for single phase ,
modification Check P4 potentiometer No potentiometer in order
is it correct? (quadrature droop) to divide currents and
position is it correct? balance between
Yes alternators
Measure voltage Yes
sensing on U/V/W No Make alternator
380 Volts or 220 wiring modification Replace AVR
Volts, is it correct?
Yes Yes
Perform voltage
Check voltage balance No balancing procedure
using multimeter
between alternators, is it (see parallel mode in
correct? manual) Run GENSET and
Yes monitor
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AVR R450
 Fault Tree
Overload condition RED LIGHT and GREEN LIGHT turns ON after 90S, this state
cannot be RESET, the engine need to be turned OFF
Yes
Check GENSET speed, is it correct? No Makes speed
(50HZ 1500 RPM – 60HZ 1800 RPM) adjustment
Yes Yes No
If CT installed check CT Check AVR’s wiring, Makes AVR wiring
position and make sure No is it correct? modification
is installed on U phase, Relocate CT on U
is it correct? Phase Yes No Makes P3 adjustment
Check P3 (excitation 110% of In Current
Yes potentiometer) setting for excitation in order to
Check windings No Replace the exciter field 110% In, is it correct? get the RED LIGHT
off in normal running
resistance value on (see exciter field
Yes condition
the exciter field, is it resistance value Does the current excitation
correct? provided in installation exceed 110% In for more No Correct over
manual) than 90S? Is it correct excitation
Yes operation?
Check rotating No Yes Makes wiring
diodes (see Replace rotating AVR detect loss of sensing modification on
procedure in the diodes for more than 1s in SHUNT- No voltage detection
AREP mode and 10 s in (U V W)
manual), are they
PMG mode, is it correct AVR’s POT needs to
correct? Replace revolving operation? be configured with
Yes field (see procedure Yes factory setting
Check revolving field No and resistance value before restart. Run
resistance, is it correct? in manual) Replace AVR GENSET and
AVR R450 monitor 35
 Fault Tree
Overload condition RED LIGHT turns ON only after 1S for AREP/SHUNT and 10S in PMG mode
during both LOSS OF SENSING OR CURRENT excitation reaches the MAXIMUM
Yes

Check GENSET speed, is it correct? (50HZ No Makes speed

1500 RPM – 60HZ 1800 RPM) adjustment

Yes Yes No
If CT installed check CT Check AVR’s voltage Makes AVR’s voltage
position and make sure detection wiring, is it detection wiring
No
is installed in U phase, is correct? modification
Relocate CT on U Phase
it correct? Yes
Yes
Stop and restart the No
No engine.
Check windings Replace the exciter field the AVR still in fault
resistance value on the (see exciter field state?
exciter field, is it correct? resistance value
provided in manual) Yes
Yes Replace AVR
No
Check rotating diodes AVR’s POT needs to be
(see procedure in the Replace rotating diodes configured with factory
manual), are they setting before restart.
correct? Run GENSET and then
apply settings according
Replace revolving field
Yes to the engine, Run and
(see procedure and
monitor
No resistance value in
Check revolving field
manual)
resistance, is it correct?
36
AVR R450
 Fault Tree

Light Indications
AVR with power
Power ON supply, in normal
operation states
Green light ON
Over excitation
counter counting
down
Green light Flashes
Excitation current exceeding 110%
In (nominal amps) for more than 90
s
Overload and short OR
Excitation current at the maximum
circuit conditions value for more than 10s
Red light ON OR
AVR detects loss of sensing for
more than 1s in SHUNT-AREP
mode and 10 s in PMG mode

Excitation current is exceeding

110% In for less than 90 s
OR
Red light Flashes current excitation reached the
maximum value for less than 10 s
OR
AVR detect loss of sensing for
less than 1s in SHUNT-AREP
mode and 10 s in PMG mode37
AVR R450