Power-Tronics XC4-R Manual

Power-Tronics XC4-R Manual

Voltage regulator

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Specifications
Input Voltage:
Frequency:
Voltage Regulation:
Parallel Operation:
Maximum Output Voltage:
Continuous Output Voltage:
Maximum Output Current:
Minimum Field Resistance:
Min Residual Build up Voltage:
Under Frequency Protection:
Physical Size:
Weight:
Fully Encapsulated:
Internal Fuse Type:
Remote Voltage Adjustment:
System Operating Indicator:
Optional Static Exciter Modules:
Optional External Controls:
120 / 208 or 240vac
50 or 60hz
± .75% From NL to FL
No
52vdc @ 120vac input
105vdc @ 240vac input
32vdc @ 120vac input
63vdc @ 240vac input
5adc
8Ω @ 32vdc output
16Ω @ 63vdc output
3.5vac
Yes, Idle speed reduction
4.1 x 2.1 x .75 in.
2.5 oz
Yes
GDB5A @ 250V Fast-Blow
Yes
No
No
No
XC4-R
Commercial Series
Voltage Regulator
The Power-Tronics XC4-R Automatic Voltage
Regulator is the latest upgrade for our commercial
voltage regulator product line! The XC4-R is capable
of replacing other manufacturers' voltage regulators
and can fit into extremely tight enclosures due to its
small size!
The XC4-R is designed as a commercial product, ideal
for installation in standby applications, portable
generators, residential generators, and any application
where the customer demands a simple, reliable, and
durable regulator at a competitive price.
The XC4-R offers greater value with an onboard fuse
to protect against overload or external faults and
optional remote voltage adjustment via panel-mounted
potentiometer!
Simplicity and Reliability are important to the Power-
Tronics brand, and all components used in the
manufacture of our products are high-quality name-
brand and engineered to withstand the continuous
ratings advertised on our products. You can have
confidence with a product designed and manufactured
in the USA and backed by a factory One-Year
Warranty!
Based internally on the XR8 voltage regulator, the
XC4-R offers precise voltage regulation regardless of
the connected load and ambient temperature. It
incorporates an idle-protection circuit that automatically
reduces voltage to prevent excessive rotor heating
when the engine is idled.
The XC4-R uses the XR8's patented electronic circuitry
that automatically matches the regulator's response
time to the generator exciter. This greatly speeds
installation and eliminates guesswork. Because it only
uses 4 wires for connection to the generator, it also
makes quick replacement in the field possible!
To ensure extreme durability and dependability, the
XC4-R is fully encapsulated in a heat-resistant
polyester resin. Because of its strong design and fully
encapsulated packaging, the XC4-R is able to
withstand extreme operating conditions that would
damage most other voltage regulators.
The XC4-R is a direct upgrade for previous XC4, VP4,
VP5, VR50, and VR250 voltage regulators.
© 2022 Power-Tronics, Inc.

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Summary of Contents for Power-Tronics XC4-R

  • Page 1 Because of its strong design and fully encapsulated packaging, the XC4-R is able to withstand extreme operating conditions that would damage most other voltage regulators. The XC4-R is a direct upgrade for previous XC4, VP4, VP5, VR50, and VR250 voltage regulators. © 2022 Power-Tronics, Inc.
  • Page 2: Table Of Contents

    Use with PMGs, DPE, AUX, and Harmonic Winding Generators:......7 240V Hookup Connection:.....................8 120V Hookup Connection:.....................9 Installation on Brush-Type Generators:..............10 Installation Considerations:..................11 Initial Setup and Commissioning:................11 Optional Power-Tronics Accessories:................12 Application Troubleshooting:..................13 Bench Check Procedures:...................14 Installation Warranty Form:..................15 Product Warranty Certificate:..................16 For Technical Support: Visit our website at: www.power-tronics.com...
  • Page 3: Introduction And Functional Description

    The XC4-R contains a time-proven, extremely reliable circuit for build-up functionality, in use for over 25 years. Due to its simplicity, the XC4-R is able to build up generators with residual voltages from 3.5VAC without initial overshoot or excessive delay. The patented circuitry contained in the XC4-R automatically adjusts the regulator to match the generator’s response time, minimizing setup complexity while maximizing load...
  • Page 4: Determining Which Hookup Configuration To Use

    UVR and XR series voltage regulators! Immediate voltage runaway and potentially life-threatening conditions may occur!!! The XC4-R Automatic Voltage Regulator is suitable for 2 different output ranges suitable for use on most brushless generators available on the market from past and present. It is necessary to choose the proper mode of operation for your generator in order to get the best regulation and fastest response time possible.
  • Page 5 R is your measured field resistance. Using the values you just measured and calculated, see the chart on the previous page to determine which connection you should use to connect the XC4-R to your generator. For Example: Measured Field Resistance: 18Ω...
  • Page 6: Common 12-Lead Generator Wiring Diagrams

    Voltage L3 – N: 208V Don’t Use Zig-Zag if Possible. NOTE: L3-N is a “High Leg” NOTE: Derate generator by 1/3 rated 208V instead of 120V! capacity when using this connection! For Technical Support: Visit our website at: www.power-tronics.com Call Us at: (830) 895-4700...
  • Page 7: Use With Pmgs, Dpe, Aux, And Harmonic Winding Generators

    This type of generator generally has a permanent magnet generator mounted on the main shaft along with a brushless exciter and finally the main rotor itself. The XC4-R is a very fast responding regulator (1/2 cycle response time) and low enough burden on the main stator that it can be used on these generators without any need for the PMG input.
  • Page 8: 240V Hookup Connection

    T7 and T9 (See Page 6) or use a 480-240V step-down transformer rated at 500VA. Connecting the input of the XC4-R to 2 different legs of the generator as shown in the diagram below will result in greater regulation accuracy than when connecting line- neutral.
  • Page 9: 120V Hookup Connection

    1980s and many smaller KW portable, truck-mounted, or commercial generators. Most generators using this connection will have a field resistance of 10-15Ω. Note that the maximum input voltage to the XC4-R Automatic Voltage regulator is 139VAC in this configuration! DO NOT input 277VAC into the XC4-R!
  • Page 10: Installation On Brush-Type Generators

    XC4-R. Use of the XC4-R on brush-type generators requires the use of an external varistor across the exciter field or brush riggings. Brush-type generators inherently create reverse EMF conditions and occasional arcing at the brush/ring interface that can quickly damage the XC4-R if the varistor is omitted.
  • Page 11: Installation Considerations

    Mount towards a corner of a metal plate. Corners of mounting plates vibrate less than the center sections will. Less vibration leads to a longer service life. • Do not install the XC4-R in a sealed control box. Free ventilation is required for a long service life. Forced air is not required. •...
  • Page 12: Optional Power-Tronics Accessories

    Optional Power-Tronics Accessories Power-Tronics offers optional accessories and add-on modules for the XC series voltage regulators for specialty applications or troublesome installations. For more information on any of the modules below, visit our online catalog at: www.power-tronics.com HVD2 ABF10 High Voltage Disconnect...
  • Page 13: Application Troubleshooting

    12. Wrong selection of regulator wiring configuration. 13. Defective voltage regulator. 14. SCR or Inverter drive effecting generator waveform. 15. Regulator needs external flashing circuit (Contact Power-Tronics for Assistance). 16. Isolation transformer is too small. 17. Isolation transformer is needed.
  • Page 14: Bench Check Procedures

    If you were able to successfully perform all of these tests, the regulator is good. IF ANY SINGLE STEP FAILED, THE REGULATOR IS DEFECTIVE! 120V 50-150W Incandescent Fuse 5A@250V For Technical Support: Visit our website at: www.power-tronics.com Call Us at: (830) 895-4700...
  • Page 15: Installation Warranty Form

    This form also contains the information needed by Power-Tronics, Inc., for repair and troubleshooting of any product you may be having problems with. Failure to fill out this form during installation will result in a cancellation of your warranty...
  • Page 16: Product Warranty Certificate

    These problems should be protected with external devices provided by the customer such as fuses, surge suppressors, over/under voltage and frequency controls. Power-Tronics, Inc., warranties only parts and workmanship of this product for a period of 1 year from the original date of purchase from Power-Tronics, Inc. Under warranty, Power- Tronics, Inc.

This manual is also suitable for:

Commercial series

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