DVR 2000E ® Installation, Operation, and Maintenance Manual
INTRODUCTION This manual provides information concerning the operation and installation of the DVR®2000E, Digital Voltage Regulator. To accomplish this, the following is provided: • General Information and Specifications • Human-Machine Interface • Functional Description • Installation • Software for Windows Operating System • Software for the Palm Operating System Platform • Maintenance and Troubleshooting DVR®2000E presents an electric shock risk.
CONTENTS A table of contents in the front of each section provides detailed information for that section. The sections in this manual are as follows. Section 1 General Information ...............................................................................................................3 Section 2 Human-Machine Interface......................................................................................................7 Section 3 Functional Description ............................................
SECTION 1 • GENERAL INFORMATION TABLE OF CONTENTS S1 ection SECTION 1 • GENERAL INFORMATION ....................................................................................................4 GENERAL ..............................................................................................................................................4 FEATURES ............................................................................................................................................
SECTION 1 • GENERAL INFORMATION S1 ection GENERAL The DVR®2000E is an electronic, solid-state, microprocessor-based control device. The DVR®2000E regulates the output voltage of a brushless, ac generator by controlling the current into the generator exciter field. Input power to the DVR®2000E is from a multi-pole, high-frequency, permanent magnet generator (PMG). The DVR®2000E is supplied in an encapsulated package designed for behind-the-panel mounting.
Operating Power Single-Phase: Frequency Range: Burden: Terminals: Underfrequency (V/Hz) Characteristic: Slope from 1 to 3PU is adjustable in 0.01 increments. Range: 40 to 65 Hz Increment: 0.
Soft-Start Function Time Adjust Range: Increment: Environment Operating Temp.: 2 to 120 seconds 1 second Storage Temp.: Analog (Auxiliary) Input S1 ection Voltage Range: Setpoint Range: Burden: Terminals: -3 Vdc to +3 Vdc -30% to +30% shift 1 k A, B Type Tests Shock: Vibration: Metering Salt Fog: Accuracy of all metering values assumes 25°C, 50/60 Hz and less than 20% THD. 20 Gs in 3 perpendicular planes 1 G at 5 to 26 Hz 0.
SECTION 2 • HUMAN-MACHINE INTERFACE TABLE OF CONTENTS SECTION 2 • HUMAN-MACHINE INTERFACE .................................................................................... 8 GENERAL ....................................................................................................................................... 8 FRONT PANEL CONTROLS AND INDICATORS ........................................................................... 8 INITIAL ADJUSTMENTS ......................................................
SECTION 2 • HUMAN-MACHINE INTERFACE GENERAL The DVR®2000E human-machine interface (HMI) consists of front panel controls and indicators and a rear panel communication port. FRONT PANEL CONTROLS AND INDICATORS S2 ection DVR®2000E front panel controls and indicators consist of 12 red LEDs and three pushbuttons. Figure 2-1 illustrates the front panel controls and indicators of the DVR®2000E. The LEDs indicate control mode and status conditions and are also used when adjusting settings at the front panel.
Table 2-2. DVR®2000E Front Panel Mode Status Indicator Descriptions Indicator Description Overexcitation LED #12 This LED blinks rapidly when the Overexcitation Protection feature is enabled and the field voltage exceeds the setpoint (80 V default) for 15 seconds. The DVR®2000E will shutdown when an overexcitation condition is detected. The Overexcitation LED blinks for 5 seconds when the DVR®2000E is powered up following an overexcitation condition.
After the initial adjustments are made, shutdown the generator and connect the remaining regulator leads. The generator may be started and final adjustments may be performed on the regulator. MAKING SETTINGS CHANGES The following paragraphs describe how the HMI is used to make setting changes. S2 ection Front Panel Operation The LEDs indicate control mode and status conditions and are also used when adjusting settings at the front panel.
1 - 3 Phase Sensing LED #2 This LED blinks slowly when selecting single or three phase sensing via the front panel push buttons. When in this adjustment mode, LED #1 is on if single phase sensing is selected, LED #3 is on if three phase sensing is selected. Coarse Voltage LED #1 This LED blinks slowly when the “Coarse Voltage” level is selected for adjustment via the front panel push buttons. Setting Level Indication Indication of a setting level is provided by the 12 front panel LED indicators.
Table 2-6. Manual Mode (On/Off) Select S2 ection Manual Mode On/Off – LED 3 Blinking Slowly LED MODE 12 N/A 11 N/A 10 N/A 9 N/A 8 N/A 7 N/A 6 N/A 5 N/A 4 N/A 3 N/A 2 ON 1 OFF Table 2-7. Manual Mode (If – Limit) Adjustment Ranges Manual Mode Adjust – LED 4 Blinking Slowly Adjustment Range: 0 to 3 Adc Increment: 0.01 Adc LED Minimum Value Maximum Value 12 2.75 3 11 2.50 2.74 10 2.25 2.49 9 2.00 2.24 8 1.75 1.99 7 1.50 1.74 6 1.25 1.49 5 1.00 1.24 4 0.75 0.99 3 0.50 0.74 2 0.25 0.49 1 0 0.24 Table 2-8.
Table 2-9. VAR Control Adjustment Ranges * VAR Control Adjust – LED 6 Blinking Slowly Maximum Adjustment Range: −100% (absorb) to +100% (generate) Increment: 1.0% LED Minimum Value † Maximum Value † 12 84 100 11 67 83 10 51 66 9 34 50 8 17 33 7 1 16 6 -16 0 5 -33 -17 4 -49 -34 3 -66 -50 2 -83 -67 1 -100 -84 * VAR/PF control is available only on DVR®2000EC. † Minimum and maximum values may differ from the Table 2-9 values if the value has been changed in MARATHON-DVR®2000E-COMS software.
S2 ection Table 2-11. Underfrequency Adjustment Ranges Underfrequency Adjust – LED 7 Blinking Slowly Maximum Adjustment Range: 40 to 65 Hz Increment: 0.1 Hz LED Minimum Value Maximum Value 12 63.0 65.0 11 60.9 62.9 10 58.8 60.8 9 56.7 58.7 8 54.6 56.6 7 52.5 54.5 6 50.5 52.4 5 48.4 50.4 4 46.3 48.3 3 44.2 46.2 2 42.1 44.1 1 40.0 42.0 Table 2-12. Droop Adjustment Ranges Droop Adjust – LED 8 Blinking Slowly Adjustment Range: 0 to 10% Increment: 0.25% LED Minimum Value * Maximum Value * 12 9.25 10.00 11 8.
Table 2-13. Stability Range Selection Settings Stability Range Select – LED 9 Blinking Slowly Adjustment Range per LED: 1 Frame/Poles LED Range Selected 12 N/A 11 N/A 10 N/A 9 N/A Programmable 8 21 1,000/6 7 7 740/6 6 6 1,000/4 5 5 740/4 4 4 570/4 3 3 430/4 2 2 360/4 1 1 * Note: For 280 Frame generators see Section 8, Set-Up From the Computer. Table 2-14. Gain Adjustment Ranges Gain Adjust – LED 10 Blinking Slowly Maximum Adjustment Range: 0.5 to 4.
COMMUNICATION PORT A communication port is located on the rear panel and consists of a female RS-232 (DB-9) connector. The communication port serves as an interface for programming (setup) of the DVR®2000E. Figure 2-2 illustrates the location of the communication port. S2 ection Programming requires a standard 9-pin serial communication cable connected between the DVR®2000E and an IBM-compatible PC or handheld computer operating with MARATHON-DVR®2000ECOMS software.
SECTION 3 • FUNCTIONAL DESCRIPTION TABLE OF CONTENTS SECTION 3 • FUNCTIONAL DESCRIPTION ............................................................................................18 INTRODUCTION..................................................................................................................................18 DVR®2000E FUNCTION BLOCKS.......................................................................................................18 Analog Inputs........................................
SECTION 3 • FUNCTIONAL DESCRIPTION INTRODUCTION This section describes how the DVR®2000E functions and explains its operating features. To ease understanding, DVR®2000E functions are illustrated in the block diagram of Figure 3-1. A detailed description of each function block is provided in the paragraphs under the heading of DVR®2000E Function Blocks.
Generator Voltage Generator voltage is monitored at terminals E1 (A-phase), E2 (B-phase), and E3 (C-phase). Nominal voltages of up to 600Vac may be sensed at these terminals. Voltage applied to these inputs is scaled and conditioned before being applied to the input of the ADC. The voltage signal from phase C and A (VC-A) of the generator is used by the ADC to calculate the rms value of generator voltage across phases C and A.
Raise Closing a contact across terminals 6U and 7 causes the active operating setpoint to increase. This function is active as long as the contact is closed. Lower Closing a contact across terminals 6D and 7 causes the active operating setpoint to decrease. This function is active as long as the contact is closed. Note: If power is removed from the DVR®2000E long enough for it to reset, the settings from the remote raise/lower contacts will be lost.
Front Panel Switches Changes to settings can be made at the front panel using the three pushbutton switches. These push-buttons are labeled Select, Up, and Down. Section 2, Human-Machine Interface provides more information about the front panel switches. The setting is saved when the “SELECT” button is pressed. If no button is pressed for a period of one minute, the regulator saves the new settings and exits the adjustment mode.
Power Factor Control Mode (Optional) In Power Factor Control mode, the DVR®2000E(C) maintains generator power factor at a set level when paralleling with an infinite bus. The DVR®2000E(C) calculates generator power factor using the sensed generator output voltage and current quantities and then adjusts the dc excitation current to maintain power factor at the setpoint. Power factor control is enabled or disabled through the front panel switches, Windows® or Palm OS® software.
Protection The DVR®2000E has the six protective functions listed below: • • • • • • Overexcitation shutdown Generator overvoltage shutdown DVR® overtemperature shutdown Loss of generator sensing shutdown Overexcitation limiting Crowbar shutdown Each function, except Crowbar Shutdown, has a corresponding front panel indicator that lights when the function is active. An active function (except Crowbar Shutdown) is also annunciated through the Windows® or Palm OS® communication software.
Crowbar Shutdown The Crowbar Shutdown Circuit protects the generator rotor from overcurrent damage resulting from a shorted DVR®2000E power switch. During operation, if the field voltage exceeds the setpoint and the power stage receives no gating pulses for 1.5 seconds, the Crowbar Circuit activates and places a short-circuit across the DVR®2000E input power terminals. This protects the generator by blowing the input power fuse and removing operating power from the device.
SECTION 4 • INSTALLATION TABLE OF CONTENTS SECTION 4 • INSTALLATION.....................................................................................................................26 GENERAL ............................................................................................................................................26 MOUNTING .........................................................................................................................................26 CONNECTIONS .............
SECTION 4 • INSTALLATION GENERAL The DVR®2000E is delivered in a sturdy carton to prevent shipping damage. Upon receipt, check the part number against the requisition and packaging list for agreement. Inspect for damage, and if there is evidence of such, immediately file a claim with the carrier and notify your sales representative or a sales representative at Marathon Electric. If the unit is not installed immediately, store it in the original shipping package in a moisture and dust free environment.
S4 ection Figure 4-1.
S4 ection Figure 4-2.
CONNECTIONS DVR®2000E connections are dependent on the application. Incorrect wiring may damage the unit. NOTE Be sure that the DVR 2000E is hard-wired to earth ground with no smaller than 12 AWG copper wire attached to the ground terminal on the rear of the unit case. When the unit is configured in a system with other devices, it is recommended to use a separate lead to the ground bus from each device. ® DVR®2000E Terminations DVR®2000E units have two types of interface terminals (Figure 4-3).
Generator Voltage Sensing Inputs The generator voltage sensing terminals are labeled E1, E2, and E3. A single-phase sensing connection is obtained by connecting the C-phase sensing input to terminals E2 and E3. Table 4-2 lists the terminal assignments for three-phase and single-phase generator voltage sensing. Table 4-1.
Chassis Ground The chassis ground terminal is labeled GND. Power (Field) Output The field output terminals for connection to the generator exciter field are labeled F+ and F-. Relay Output The common alarm relay output contact may be accessed at the terminals labeled AL1 and AL2. The relay output is normally open. Communication Port The RS-232 port on the rear panel uses a DB-9 female connector.
Figure 4-5. Personal Computer to DVR®2000E Connections DVR®2000E Connections for Typical Applications S4 ection Figures 4-6 through 4-9 illustrate typical applications using the DVR®2000E. Figure 4-6 shows an application where the DVR®2000E is connected for three-phase voltage sensing. Figure 4-7 shows an application with singlephase voltage sensing while Figure 4-8 illustrates an application with a single-phase generator.
S4 The DVR®2000E CT connections are reversed from the DVR®2000 ection Figure 4-6.
S4 The DVR®2000E CT connections are reversed from the DVR®2000 ection Figure 4-7.
6 6 S4 ection Figure 4-8.
Figure 4-9. Cross-Current (Reactive Differential) Connections for Two Generators S4 ection CT GEN 1 0.1 CTB1 CTB2 DVR2000E CT LOAD GEN 2 0.1 CTB1 CTB2 CCC ENABLE CONTACT D VR2 0 0 0 E CT GEN N 0.1 CTB1 CTB2 DVR2000E Figure 4-10.
PRELIMINARY SETUP Use caution when working around the rear of the DVR®2000E. Dangerous voltage levels are present at the exposed heatsinks when the unit is energized. Before starting the generator and DVR®2000E for the first time, proceed as follows. a. Tag and disconnect all wiring to the DVR®2000E. Be sure to insulate the wire terminals to prevent a short. b. Start the prime mover and perform all engine governor adjustments. c.
SECTION 5 • MARATHON-DVR®2000E-COMS SOFTWARE FOR WINDOWS® OS Section 5 describes how to program the DVR®2000E with a PC, which requires special software. The software and instructions can be downloaded from the Marathon Electric website at www.marathonelectric.com. Section 5 of this manual appears in its entirety within the PDF file for this manual (Publication GPN019), which is also available from our website.
SECTION 6 • MARATHON – DVR®2000E SOFTWARE FOR THE PALM OS® PLATFORM Section 6 describes how to program the DVR®2000E with a Palm® Pilot (PDA), which requires special software. The software and instructions can be downloaded from the Marathon Electric website at www.marathonelectric.com. Section 6 of this manual appears in its entirety within the PDF file for this manual (Publication GPN019), which is also available from our website.
SECTION 7 • MAINTENANCE AND TROUBLESHOOTING TABLE OF CONTENTS SECTION 7 • MAINTENANCE AND TROUBLE-SHOOTING ....................................................................41 PREVENTATIVE MAINTENANCE .......................................................................................................41 TROUBLESHOOTING .........................................................................................................................41 Generator Voltage Does Not Build ..............................
SECTION 7 • MAINTENANCE AND TROUBLESHOOTING PREVENTATIVE MAINTENANCE The only preventive maintenance required on the DVR®2000E is to periodically check that the connections between the DVR®2000E and the system are clean and tight. DVR®2000E units are manufactured using state-of-the-art, surface-mount technology. As such, Marathon Electric recommends that no repair procedures be attempted by anyone other than Marathon Electric personnel.
If the soft start settings are incorrect, adjust the settings. If the soft start settings have no effect, proceed to Step 8. Step 8. Replace the DVR®2000E unit. If replacing the DVR®2000E unit does not correct the malfunction, then the generator is defective. Low Generator Output Voltage Step 1. Verify that the voltage adjustment is not set too low. If the voltage adjustment is too low, adjust it to the correct setpoint. If the voltage adjustment is correct, proceed to Step 2. Step 2.
If the sensing potential transformer is correct, proceed to Step 3. Step 3. High generator output voltage may occur when operating in droop mode with a capacitive load. If the high voltage condition is not caused by the droop function, proceed to Step 4. Step 4. Replace the DVR®2000E unit. Poor Voltage Regulation Step 1. Verify that the ground terminal of the DVR®2000E is properly grounded.
OVEREXCITATION SHUTDOWN Indicator Is Annunciating Step 1. Verify that the field overvoltage setpoint is adjusted properly. If not properly adjusted, readjust the field overvoltage setpoint. If properly adjusted, proceed to Step 2. Step 2. Check for generator overloading. If the generator is operating with a larger than rated load, shed load. If the generator is operating with a rated or less than rated load, proceed to Step 3. Step 3. Replace the DVR®2000E.
Step 4. Replace the DVR®2000E. If replacing the DVR®2000E does not correct the malfunction, proceed to Step 5. Step 5. Refer to the generator manual. Generator is defective. UNDERFREQUENCY ACTIVE Indicator Is Annunciating Step 1. Verify that the generator is operating at rated speed. If the generator is not operating at rated speed, adjust the generator speed. If the generator is operating at the rated speed, proceed to Step 2. Step 2. Verify that the underfrequency setpoint is correct.
SECTION 8 • SET-UP PROCEDURES TABLE OF CONTENTS SECTION 8 • SET-UP PROCEDURES ......................................................................................................47 SET-UP From the Front Panel ..............................................................................................................47 SET-UP From the Computer ................................................................................................................50 SET-UP For Paralleling .........................
SECTION 8 • DVR®2000E VOLTAGE REGULATOR SET-UP FROM THE FRONT PANEL PROCEDURE The regulator must be powered from an external source into terminals 3 and 4. This power can be from the generator PMG with the engine running or a 120 Vac wall outlet. Ground the regulator with the ground terminal. No other wires should be connected to the regulator at this time.
3.) Press the ‘SELECT’ button one time. LED 3, ‘Manual Mode On/Off’ should now be blinking. Use the ‘UP’ button to move the steady LED to ‘2’ for ‘Manual Mode’ On. Note: For the first time start up of the generator, the ‘Manual Mode’ should be turned on. This is important for higher voltage generators to insure connections are correct before damage is done. For normal operation, the ‘Manual Mode’ must be turned off (LED 1 on steady). 4.) Press the ‘SELECT’ button twice.
8.) Press the ‘SELECT’ button to select LED 4, ‘Manual Mode Adj.’ Press the ‘UP’ button to increase the field current until LED 2 lights. This should increase the generator voltage a small amount. If everything is still okay, continue increasing the field current until the desired generator voltage is reached. Check that all of the voltages are still balanced line to line and line to neutral. 9.) Press the ‘SELECT’ button to select LED 3, ‘Manual Mode On/Off’.
SECTION 8 • DVR®2000E VOLTAGE REGULATOR SET-UP FROM THE COMPUTER FOR SINGLE UNIT OPERATION PROCEDURE The regulator must be powered from an external source into terminals 3 and 4. This power can be from the generator PMG with the engine running or a 120 Vac wall outlet. Before terminals 3 and 4 on the voltage regulator are connected to the PMG, the engine must be set for 1800 RPM for 60 Hz operation or 1500 RPM for 50 Hz operation.
Note: If an ammeter is installed, it is recommended that the B phase CT be connected in series through the regulator CT1 and CT2 terminals. This will provide additional information on the ‘Metering’ screen that can be very useful for any troubleshooting. 6. Click the ‘Settings’ button in the upper tool bar. On the ‘Setpoint’ tab, under ‘Automatic Voltage Regulator (AVR)’ enter the voltage in ‘AVR Setpoint (V)’ that the regulator will see when the generator is operating properly.
15. Click on the ‘Control Mode’ button to change to ‘AVR’ mode (rectangular box to the right of ‘FCR’). The generator should be operating at the desired voltage. Note the field voltage in ‘Voltage (V)’ and field current in ‘Current (A)’ values for future reference. 16. The ‘Field Current (A)’ and ‘Field Voltage (V)’ values will be relatively stable, but moving up and down in small steps. To adjust the gain, click the ‘Gain’ button in the top tool bar.
SECTION 8 • DVR®2000E VOLTAGE REGULATOR SET-UP FOR PARALLELING WITH THE COMPUTER PROCEDURE For generators to parallel properly certain conditions must be met. The governors must be set for the engine speed, response and load sharing to match all units. The regulators must be set to provide matching voltage, droop and response on all units. To parallel generators, set-up one generator set for single unit operation. Insure that a CT is installed on phase B of the generator and connected per Figure 4-6.
Marathon Electric Mfg. Corp. P.O. Box 8003 Wausau, WI 54402-8003 USA Phone: 715.675.3359 Fax: 715.675.8026 www.marathonelectric.
