Manual Generador Kato

Manual Package
Installation • Operation • Maintenance

Drawings & Parts List
Customer: Maestranza Diesel S.A.
Customer P.O.: ENE018.322/12
Project: 1.6MW, 380V, 50Hz, 80C
Kato Serial Number: 28469
Kato Engineering Inc.

P.O. Box 8447
Mankato, MN USA
56002-8447
Tel: 507-625-4011
Fax: 507-345-2798
Email: katoengineering@lsusa.com
www.kato-eng.com
Page 1
Publication Number: 350-05013-00
Publication Date: July 1994
Bearing Lubrication Instructions

For Generator or Motor
Serial Number Model Number Type Number
28469 Gen AA28819000 28819
Motor
Where grease fittings and grease relief valve are mounted into bearing housing, remove cover from exciter
end of unit for access to fittings.
Replenish the bearings using the amounts of grease listed below and at intervals shown in running time hours
or months, whichever comes first. Do not overfill. Wipe excess grease from internal parts of unit.
Use a high quality NLGI electric motor bearing grease (Lithium Base) with extreme pressure additives which
will lubricate satisfactorily over a range from the lowest ambient temperature expected to +250F.
GREASE BASE MATERIAL Lithium
Outboard or Exciter End Drive End

Bearing Number
012-92659-15 012-92659-16
Replenish Interval in Running Time
200 200
Replenish Interval in Months
12 12
Replenish Amount in Ounces
0.15 0.15
P.O. Box 8447, Mankato, MN 56002-8447, (507) 625-4011 Fax (507) 345-2798 www.kato-eng.com
Publication # 350-05010-00 Publication Date: April 1994
Revised: January, 2010
INSTRUCTION
MANUAL
FOR
SPLIT ROLLER BEARINGS
P.O. Box 8447, Mankato, MN 56002-8447, (507) 625-4011 Fax (507) 345-2798 www.kato-eng.com
1
Table of Contents
Introduction 3
General 4
Lubrication 5
Bearing Replacement and Disassembly 5
Initial Grease Fill Chart 8
Bearing Replacement, Assembly 9
Periodic Maintenance 12
Field Service of Split Roller Bearings 13
Anti Brinelling Device 14
Torque Chart 16
2
Introduction
Foreword
This manual contains instructions for installing, operating and maintaining split roller bearings in
Kato Engineering generators. This specific bearing maintenance must be performed by an individ-
ual fully trained to perform maintenance on this split roller bearing.
Lubrication information, electrical connection drawings, dimensional drawings and parts listings for
your model are contained in the manual package as supplementary information and are the specific
source of information for making connections and ordering replacement parts. Information about
optional components of your generator may also be contained as a supplement.
Please read this manual and all included manuals in its entirety before unpacking, installing,
and operating your generator. If your manual came on a CD, read all the files included on the
CD.
Safety instructions
In order to prevent injury or equipment damage, everyone involved in installation, operating and
maintenance of the generator described in this manual must be qualified and trained in the current
safety standards that govern his or her work.
While “common-sense” prevention of injury or equipment damage cannot be completely defined by any
manual (nor built into any piece of equipment), the following paragraphs define warnings, cautions, and notes
as they are used in this manual:
Warning: Warnings identify an installation, operating or maintenance procedure, practice, condition, or state-
ment that, if not strictly followed, could result in death or serious injury to personnel.
Caution: Cautions identify an installation, operating or maintenance procedure, practice, condition, or state-
ment that, if not strictly followed, could result in destruction of or damage to equipment or serious impairment
of system operation.
Note: Notes highlight an installation, operating or maintenance procedure, condition, or statement and are
essential or helpful but are not of known hazardous nature as indicated by warnings and cautions.
Ratings/description
Nameplates, which are located on the side of the generator, include serial and model number as
well as rating information and bearing and lubrication information.
3
INSTRUCTION SUPPLEMENT
FOR KATO Generators Fitted With Split Roller Bearings
GENERAL
This instruction covers the installation and removal of split roller bearings in Kato Generators. Refer to your
generator manual for maintenance schedules.
Figure 1
Exploded View of Split Roller Bearing
The picture above shows an exploded view of a split roller bearing. Note the names of the
parts and be familiar with them. Use this page for reference as needed while performing the
maintenance on the bearing.
4
1. LUBRICATION
Replenishment - For periodic replenishment of lubri-
cation, refer to the Bearing Lubrication Plate mounted
on your unit. If your unit does not have a Lubrication
Plate, Contact Kato Engineering Parts Department
for a replacement. Very stiff greases which tend to
channel or very soft greases which may churn at high
speed should not be used. We use and recommend
Mobilith SHC 220.
NOTE: Do not mix synthetic and non-synthetic

greases. Mixing greases may result in rapid
failure of the grease by setting up hard or break-
down
Figure 2
2. BEARING REPLACEMENT, Loosen Bolts
DISASSEMBLY
NOTE: It may be necessary to remove the exciter/

PMG to do maintenance on your bearing, espe-
cially if the complete bearing has to be changed.
Also, for units without an anti brinelling bracket,
some disassembly may be required to remove
internal bearing parts. The pictures being used
in these procedures are for reference only. They
may not match your unit. If they do not match,
use them as a guide, adapting them for your
needs. Use good shop safety procedures.
A. To remove drive end bearing, proceed as follows:
1. Remove exciter and drive end covers.
2. Place wood or fiber protective strips Figure 3

between the generator field poles and the Remove PMG Rotor
bottom of the stator. These strips must be of
such thickness and strength as to minimize CAUTION
downward movement of the rotor if it rests on TAKE SUITABLE PRECAUTIONS TO PREVENT
the stator. INJURY TO FINGERS CAUSED BY THE STATOR
FRAME BEING FORCIBLY ATTRACTED TO PER-
3. Disconnect alternator field leads. Remove MANENT MAGNETS ON PILOT ROTOR.
the exciter armature and PMG retaining
bolts. Thread two 5/8 threaded stock 4. Remove clips securing exciter field leads
through the PMG rotor into the shaft as to the exciter frame, generator frame and
shown in figure 3. generator endbell.
Remove the PMG rotor. The rotor should 5. Connect a hoist to the lifting eyes on the
be removed by grasping the inside magnets exciter stator and remove the exciter stator
and then pulling quickly and sharply straight mounting bolts. Remove the exciter stator
back, overcoming the magnetic pull off the from the endbell, being careful not to dam
PMG rotor to the PMG armature. Take care age stator or rotor windings.
not to cock the PMG when pulling it off. See figures 4 & 5.
Place the PMG in a clean area, or seal it in
plastic to avoid contamination with metal
particles. See Figures 2 & 3.
5
Figure 6
Figure 4 Remove Exciter Armature
Remove Bolts
7. Place a sling about the drive end of the
6. Remove the exciter armature and rotating shaft and attach the sling to an overhead
rectifier as follows: crane or hoist. Put enough pressure on the
sling to hold the shaft level.
a. Disconnect alternator field leads from the See figure 7.
positive (+) and negative (-) terminals located
on the heat sinks of the rotating rectifier
assembly.
Figure 7
Sling Placement
8. Remove the bolts holding the two halves

of the flanged bearing cap together. Take
out the bolts holding the flanged bearing cap
to the endbell and remove the two halves.
Since the cartridge cannot move axially on
Figure 5 the drive end bearing, the flanged cap halves
Remove Exciter Stator must be tilted out of the recess in the end
bell. See figures 8, & 9.
b. Using a hoist and strap, remove exciter
armature and rotating rectifier. See figure 6.
Figure 8
6
Figure 9 Figure 11
Removing Clamping Rings
9. Remove the joint screws from the housing;
remove the two halves of the housing. Leave 14. If the sling is to be removed, make sure
the outer race in the housing. See figure 10. that the wood or fiber strips are in position
between the generator field and stator.
B. To remove the exciter end bearing, proceed as fol-

lows: Note: Remove exciter per previous steps.
1. Place a strap around the exciter end of the

shaft and lift enough to take the pressure off
the bearing.
2. Remove the bolts holding the flanged

bearing cap to the endbell; slide the bearing
assembly out so that the cap is clear of the
recess in the endbell
Figure 10
Removing Housing 3. Remove the joint screws from the cap;
remove the two halves of the cap.
10. Pull the outer seal off the shaft. Clean it
and set it aside. 4. Remove the joint screws from the housing;
remove the two halves of the housing. Leave
11. Remove the jointing clips from the roller the outer race in the housing.
cage; remove the roller cage.
5. Slide the seals out of the way. Do not
12. Carefully measure the position of the remove them unless they are to be replaced.
inner race on the shaft so that the new inner
race can be placed in exactly the same 6. Remove the jointing clips from the roller
position. Measure from a specific surface on cage; remove the roller cage.
the coupling or shaft step.
7. Measure and record the position of the
13. Remove the screws from the clamping inner race on the shaft. Measurement should
rings. Remove the clamping rings and the be accurate within 0.015". Kato Engineering
inner race. See figure 11. can be contacted for the measurement re
corded during assembly.
8. Remove the screws from the clamping

rings. Remove the clamping rings and inner
race.
9. If the sling is to be removed, make sure

that the strips are in position between the
generator field and stator.
7
Note: Initial grease fills only. Do not use for periodic regreasing.
Table 1
Split bearing grease initial fill chart
(Shaft size measured at end of drive end)
8
3. BEARING REPLACEMENT, ASSEMBLY Note: The inner race and the clamping rings are
matched sets and are not interchangeable. They
To assemble a bearing, proceed as follows: are stamped with identifying numbers. Make sure
the numbers match and are facing the same di-
Note: Clean the parts and shaft with solvent to rection. The clamping ring stamps will face away
remove any oil. from the inner race on both sides.
1. Apply a light coat of O-ring lubricant to the o-rings

in the ID of the seal. See figure 12.
Figure 14
Match Numbers and Direction
Figure 12
Lube ID of Inner Seal
2. Install the inner seal onto the shaft. Use a square

to get the correct position. See figure 13.
Figure 15
Placing inner race
4. There should be a gap at the joints of the inner

race. Some gap in each joint helps insure good seat-
ing. The gaps should be even, It may be helpful to
place shim stock in the gaps to keep them even, and
remove them before final tightening. If the measured
Figure 13 gap is outside the range of 0.05" to 0.020, contact
Install Inner Seal Kato Engineering.
3. Place the two halves of the inner race at the cor- 5. Verify the shoulders of the clamp collars face each
rect position on the shaft. A light tap with a rawhide or other. Fit the clamping rings with their joints rotated
rubber hammer may be required to spring the races between 30o and 90° from the joints in the inner race.
over the shaft. Hold together with plastic ties or a Partially tighten all four clamping screws equally.
hose clamp temporarily. Consult the measurements Strike each clamping ring with a soft mallet about 90O
taken during disassembly. The drive end race and from the parting line to ensure the proper seating of
non drive end race must be placed exactly where the the clamping rings. Tighten bolts and strike with mal-
original race had been. See figures 14 & 15. let again. Fully tighten bolts to torque value specified
on page 15. See figure 16.
9
7.Inject sufficient grease to fill the grease passages
of the roller bearing cage. Refer to Table 1 for grease
amounts. See figure 18.
Figure 18
Figure 16 Grease the bearing rollers
Install Clamping Rings
8. Place the cage around the inner race, matching
6. Tap down each half of the inner race and clamping the race halves. Insert the jointing clips.
rings all around the shaft, placing a fiber or hardwood
block between hammer and bearing parts. Retighten Note: Some units will have Allen screws. See
screws. Repeat until the screws are fully tight. Make page 16 for torque specification.
sure that the rings are hard against the race shoul-
ders all around. The total gap is not critical provided Verify the grease is evenly distributed between the
the shaft is within the required tolerance. rollers and the cage, and the joint clips remain in
position by rotating the cage on the race five times.
Make sure the placement of the inner race is the See figures 19 and 20.
same measurement as recorded earlier. Also, lubri-
cate the bores and the seal area of the outer seal
and install. See figure 17.
Figure 19
Insert joint clips or Allen screws
Figure 17
On drive end, Positioning must be exact
10
Figure 21
Fill grease passages
Figure 20
Installing roller cage
9. Inject sufficient grease to fill the grease passages. Grease hole

Fill each half of the cartridge with grease. See Table
1 for grease amounts. See figure 21.
10. After the cartridge has grease in it, tap and slide
in the outer race. Repeat for the bottom half. See
figure 22.
11. Assemble the cartridge with races installed.

Tighten the four split screws to set the outer races in
position. Tighten and torque the twelve Allen head No grease hole
race locking screws to secure the outer races. Disas-
semble the cartridge.
Figure 22
Install outer race
11
12. Assemble the two halves of the cartridge around
the bearing cage and seals. (The outer race halves
should be in the housing halves). Tighten the four
joint screws, making sure the end faces are flush.
13. Tighten in an X pattern to torque spec, refer to

page 15 for torque spec.
Figure 24
Assemble bearing housing
4. RECOMMENDED MAINTENANCE
Replenishment - For periodic replenishment of lubri-

cation, refer to the Bearing Lubrication Plate mounted
on your unit. If your unit does not have a Lubrication
Figure 23 Plate, Contact Kato Engineering Parts Department
Lubricate Spherical Seating for a replacement.
Very stiff greases which tend to channel or very soft

14. Rotate the cartridge five times to ensure proper greases which may churn at high speed should not
seating. Make sure the anti-rotation pin is on top. be used. We use and recommend Mobilith SHC 220.
15. Lubricate the spherical seating all the way around NOTE: Do not mix synthetic and non-synthetic
with MolyKote or similar. greases. Mixing greases may result in rapid
failure of the grease by setting up hard or break-
16. Allow the spherical seating to self-align while down.
tightening the flange bolts. Then loosen the flange
bolts on the top housing and at the split line. Note: Caution:
If working on both bearings, loosen flange and Kato Engineering strongly advises rotating idle
split line bolts on both drive end and non drive units, especially those subject to vibration, at
end. Rotate the shaft at least five revolutions to allow least 1/2 turn each week to keep a film of grease
the cartridge to align. Fully tighten the bolts to torque between the roller and the race. This will help
spec, refer to page 15 for torque spec. prevent bearing damage and brinelling.
Caution: Tightening the flange halves without

ensuring the cartridge alignment will result in Every 12,000 hours or 3 years of operation
premature bearing failure.
Remove the upper flange cap and the upper outer
Note: the cap screws or bolts holding the bearing race and remove the old grease. Inspect the bearing,
assembly to the end bell on the exciter end each re-pack with grease as indicated in table 1.
have a lock washer and a hardened flat metal Re-torque the roller bearing cage if it is equiped with
washer. These screws must not be allowed to Allen screws.
bottom out in their holes.
See the generator manual for complete maintenance
Verify all the bolts are torqued to the proper levels instructions.
when assembling the generator, refer to page 15.
12
5. FIELD SERVICE OF SPLIT ROLLER BEARINGS 5. Prepare and lubricate the roller cage per previous
instructions.
This section is for bearing maintenance when a
full shop disassembly is not possible. Refer to 6. Install the cage first, then roll in the cartridge. Add
Chapter 3 for full procedures. Torque all bolts and Molykote to spherical seat only.
screws per page 15. Be sure to safely support
generator parts while working on them. 7. Roll the cartridge to verify ease of rotation.
Drive end bearing 8. Ensure the lower cartridge is seated squarely to

eliminate a cocked bearing. Place a straight edge
Disassemble across the cartridge and flange to check for even
seating.
1. Set a jack to support the shaft, be sure to center
the jack on the shaft. Protect the shaft surface with 9. Slowly lower the shaft to allow the bearing to take
hardwood or brass, etc. the rotor weight. Recheck that the lower cartridge is
still seated squarely.
2. Check the torque of the lower bearing flange.
Insure bearing lower half is secure. 10. Install the upper cartridge. Install, tighten and
torque the split line screws.
3. Remove the upper flange.
11. Install the upper cap. Leave loose if working on
4. Remove the upper cartridge. the opposite end.
5. Place the dial indicator on the shaft so as to mea- Non drive end bearing
sure the upward force on the shaft.
1. Loosen the PMG and remove.
6. With a jack or a Kato lifting device, raise the shaft
.020”, (insure the jack is sufficient to support the rotor 2. Reinstall the PMG bolts to the shaft for saftey.
during work).
3. Move the exciter to the rear, no need to remove it
7. Roll out the lower cartridge to expose the bearing from the shaft.
cartridge roller. Inspect.
4. Work within the constraints of the exciter frame,
8. Remove the roller. Inspect in cage. making sure the shaft is supported during bearing
disassembly.
9. Inspect and disassemble the inner race. Remove
the screws and collar. Take care not to drop the in- 5. Tighten and torque the bearing bolts after comple-
ner race. tion of ODE and DE assembly.
10. Inspect the grease seals. Replace if necessary.

Bearing removal, inspection and maintenance is the
Use a hose clamp to squeeze and remove pins. same as the drive end.
Prep and assemble
1. Install the inner race and torque. (Measurements

from shaft center line or race line.)
2. Prepare the cartridge. Clean and lubricate. Re-

move, clean, and reinstall the outer race per instruc-
tions.
3. Clean the shaft, seals and rollers, inspect for dam-

age.
4. Reinstall and re-lubricate the rollers or replace with

new parts.
13
Optional Anti-Brinelling Device
Lifting Block
Figure 25
Optional anti-brinnelling device, note brass lifting block
Prior to start up, bolts MUST be loosened three or four turns. Verify clearance to
brass lifting block, see figure 25 and 26.
FAILURE TO DO SO MAY CAUSE DAMAGE TO THE EQUIPMENT
To block rotor for transportation, tighten both screws indicated above to 25 ft/lbs.
Total rise in shaft is about .005"-.010"
14
Optional Anti-Brinelling Device
Figure 26
Lifting Bolts
15
Torque Specifications for Split Roller Bearings
5" shaft bearings

TORQUE SPECIFICATION
BOLT SIZE HEX WRENCH SIZE IN/LBS FT/LBS N/m
CLAMP COLLAR 1/4-28 X 1 S.H.C.S. 3/16 120.0 10.0 13.6
ROLLER CAGE* #10-32 X 3/8 LOW HEAD 3/32 29.3 2.4 3.3
CARTRIDGE PUSHER SCREWS #10-24 X 3/4 S.S. 3/32 40.0 3.3 4.5
CARTRIDGE ASSEMBLY BOLTS 1/4-20 X 1 S.H.C.S. 3/16 108.0 9.0 12.2
LOCATING PIN (BOLT) 3/8-16 X 1/2 S.H.C.S. 5/16 396.0 33.0 44.7
FLANGE ASSEMBLY BOLTS 5/8-11 X 2 1/2 S.H.C.S. 1/2 1,908.0 159.0 215.6
VIBRATION BRACKET 3/8-16 X 1 5/8 S.H.C.S. 5/16 396.0 33.0 44.7
FLANGE MOUNTING BOLTS 7/8 (GRADE 8) COARSE NA 5,448.0 454.0 615.6
5.5" shaft bearings

TORQUE SPECIFICATION
CLAMP COLLAR 5/16-24 X1 S.H.C.S. 1/4 240.0 20.0 27.1
ROLLER CAGE* 1/4-20 X 3/8 LOW HEAD 3/16 68.4 5.7 7.7
CARTRIDGE PUSHER SCREWS #10-24 X 3/4 S.S. 3/32 40.0 3.3 4.5
16
FLANGE ASSEMBLY BOLTS 5/8-11 X 2 1/2 S.H.C.S. 1/2 1,908.0 159.0 215.6
VIBRATION BRACKET 3/8-16 X 1 5/8 S.H.C.S. 5/16 396.0 33.0 44.7
FLANGE MOUNTING BOLTS 7/8 (GRADE 8) COARSE NA 5,448.0 454.0 615.6
6" shaft bearings

TORQUE SPECIFICATIONS
CLAMP COLLAR 5/16-24 X 1 S.H.C.S. 1/4 240.0 20.0 27.1
ROLLER CAGE* 1/4-20 X 1/2 LOW HEAD 3/16 68.4 5.7 7.7
CARTRIDGE PUSHER SCREWS 1/4-20 X 1/2 S.S. 1/8 108.0 9.0 12.2
FLANGE ASSEMBLY BOLTS 3/4-10 X 3 S.H.C.S. 5/8 3,384.0 282.0 382.4
FLANGE MOUNTING BOLTS 1 (GRADE 8) COARSE NA 8,184.0 682.0 924.8
NOTE: ALL VALUES REPRESENT DRY OR LIGHTLY OILED, IF THEY ARE HEAVILY OILED REDUCE TORQUE RATING BY 10%
*The NYLOK™ patch incorporated into the threads is a thread locking compound. According to the screw manufacturer, any screw with NYLOK
embedded into the threads can be re-used up to 5 times. In the event of inspection or change out, re – use the screws if spares are not available
We strongly recommend using new screws if available
Field Installation Split Roller Bearing Checklist
BEFORE DISMANTLING
Technician's Name: ___________________ Technician's Company: _________________
Serial Number: _______________________ # Hours ran: _________________________
Date: _______________________________ Site Location: ________________________
Check cleanliness of insulation on Exciter End
Vibration recorded by site operation
Visual Estimation of Axial Movement of the rotor in

operation
ENGINE STOPPED, COUPLING GUARD REMOVED
Location of Magnetic center, relative to the seal face

WHEN BOTH BEARINGS ARE OPENED ( TOP CASING AND TOP CARTRIDGE REMOVED)
Dimension between center of roller and center of lower part Drive End :
of out race, for both bearings Non Drive End :
Slowly rotate the generator and visually check the rollers Roller Condition:
and cage condition, record Cage Condition:
Record grease amount in bearings and grease color
Type of seal present? ALUMINUM RACE BRONZE RACE

WHEN THE INNER RACE IS REMOVED FROM THE SHAFT
Measure the shaft diameter where the race was mounted.

Measure at 3:00 and 9:00 and 12:00 and 6:00 at (2)
locations under the race (Ex.: 4.999 - 3 digits)
Visual aspect of the shaft under the race
If Inner race removed / replaced Inner race NOT removed / replaced

Record the gap with a feeler gage between the
Inner race removed / replaced
two halves of the inner race tightened on the shaft
Gap Measurement: ____________________
All screws are torqued with a torqued wrench

WHEN THE BEARINGS ARE PARTIALLY REASSEMBLED, NOT HAVING THE UPPER PART OF THE CASING AND
CARTRIDGE ON YET
Rotate slowly by hand for 5 turns or with turbine slowly
REMAINING REASSEMBLY
The rotor can be rotated smoothly and quietly by hand
AFTER ALIGNMENT, BUT BEFORE THE GUARD IS INSTALLED
Location of Magnetic center, relative to the seal face

DURING OPERATION
Check cleanliness of insulation on Exciter End
Vibration recorded by site operation
ALL PARTS REMOVED AND REPLACED FROM BEARINGS MUST BE RETURNED TO KATO WITH IDENTIFICATION
S/N and Site Name: ____________________________________

DE or ODE: ___________________________________________
17
Number of hours on turbine: ______________________________
Date and Name of Service Tech: __________________________
Instruction Manual
Publication 350-01001-00, 09/29/11
Installation • Operation • Maintenance
Standard AC generator
Single or two-bearing
Drive-end air discharge
Kato Engineering Inc.

P.O. Box 8447
Mankato, MN USA
56002-8447
Tel: 507-625-4011
Fax: 507-345-2798
Email: katoengineering@emerson.com
www.kato-eng.com
Page 1
Table of Contents
Introduction......................................................... 4
Foreword............................................................................4
Safety instructions..............................................................4
Ratings/description............................................................ 4
Construction and Operating Principles............ 5
Stator................................................................................. 5
Rotor.................................................................................. 5
Bearings.............................................................................5
Connection boxes.............................................................. 6
Excitation system............................................................... 6
Optional PMG system........................................................ 7
Other options..................................................................... 7
Installation........................................................... 8
Receiving inspection.......................................................... 8
Unpacking and moving...................................................... 8
Location............................................................................. 8
Base design....................................................................... 8
Assemble to prime mover, alignment................................ 8
Two-bearing alignment............................................ 9
Two-bearing close-coupled alignment................... 11
Single-bearing alignment....................................... 18
Foot deflection................................................................. 23
Doweling.......................................................................... 23
Electrical connections...................................................... 23
Space heaters................................................................. 23
Note: Because of rapid changes in designs Inspection before startup................................................. 24
and processes and the variability of Kato
Engineering’s products, information in this
Operation........................................................... 25
manual must not be regarded as binding Initial startup: generators w/auto & manual control.......... 26
and is subject to change without notice. Initial startup: generators w/auto control only................... 25
Restoring residual magnetism/field flashing.....................26
The image on the front cover is representa- Continuous operation....................................................... 27
tive only. Several variations are available
within the range of generators covered
Idling................................................................................. 28
within this manual. Parallel operation..............................................................28
Page 2
Maintenance.......................................................30
Schedules........................................................................30
Maintenance procedures................................................. 32
Visual inspection methods of windings.................. 32
Cleaning................................................................ 33
Insulation resistance tests at low voltage.............. 34
Dry out procedures............................................... 36
Bearing lubrication................................................ 36
Rectifier tests........................................................ 37
Disassembly..................................................................... 39
Overall disassembly............................................... 39
Exciter armature and PMG removal...................... 40
Bearing removal.................................................... 42
Assembly..........................................................................42
Bearing installation................................................ 42
Overall assembly................................................... 43
Exciter armature and PMG installation.................. 43
Storage............................................................................ 44
Troubleshooting Guide.....................................45
Appendices........................................................48
List of equipment required for installation
and maintenance............................................................. 48
Main part location............................................................. 49
Torque chart..................................................16-17
Page 3
Introduction
Foreword
This manual contains instructions for installing, operating and
maintaining Kato Engineering AC brushless revolving field generators.
These generators are manufactured in many sizes and ratings and with
various options.
Note: For specific lubrication instructions, Lubrication information, electrical connection drawings, dimensional
always refer to the bearing lubrication sheet drawings and parts listings for your model are contained in the manual
that came with your manual or the lube plate package as supplementary information and are the specific source of
on the generator. information for making connections and ordering replacement parts.
Information about optional components of your generator may also be
contained as a supplement.
Please read this manual and all included manuals in its entirety before
unpacking, installing, and operating your generator. If your manual
came on a CD, read all the files included on the CD.
Safety instructions
In order to prevent injury or equipment damage, everyone involved in
installation, operating and maintenance of the generator described in this
manual must be qualified and trained in the current safety standards that
govern his or her work.
While “common-sense” prevention of injury or equipment damage

cannot be completely defined by any manual (nor built into any piece
of equipment), the following paragraphs define warnings, cautions, and
notes as they are used in this manual:
Warning: Warnings identify an installation, operating or maintenance

procedure, practice, condition, or statement that, if not strictly followed,
could result in death or serious injury to personnel.
Caution: Cautions identify an installation, operating or maintenance

procedure, practice, condition, or statement that, if not strictly followed,
could result in destruction of or damage to equipment or serious
impairment of system operation.
Note: Notes highlight an installation, operating or maintenance

procedure, condition, or statement and are essential or helpful but are not
of known hazardous nature as indicated by warnings and cautions.
Ratings/description
Nameplates, which are located on the side of the generator, include
serial and model number as well as rating information and bearing and
lubrication information.
Page 4
Construction and Operating Principles
Stator
The stator consists of the supporting frame, core, and armature windings.
The stator core is made from laminations, thin sheets of electrical steel,
which are stacked and held in place by steel endrings and support
bars. The rings and bars are welded to or are part of the steel frame.
Base mounting plates are welded to the bottom of the frame. The base
mounting plates allow the assembly to be mounted on the genset base.
The windings (coils) are constructed of layered and insulated copper

wire. The coils are inserted in the core slots, connected together, and
the entire assembly is vacuum-pressure impregnated with resin. Stator
leads terminate in standard connection lug or strap terminals for ease of
connection to the load.
Rotor
The main rotor assembly is the revolving field. It consists of windings
in a core, which is in turn mounted on a steel shaft. The exciter armature
assembly and optional permanent magnet generator (PMG) rotor are also
mounted on the shaft as are the fan(s) and other optional accessories.
The core consists of laminations, thin sheets of electrical steel, which are
stacked together. The core makes the salient poles (four, six, eight or 10).
With six or more poles, the poles are typically attached to a center hub.
The rotor windings consists of insulated magnet wire wound around

each pole. V-blocks between each pole keep the rotor windings in place.
Damper windings consist of copper or aluminum rods that are inserted
through each pole surface and are brazed to copper or aluminum damper
end plates at each end of the lamination stack. The end plates are brazed
to adjacent poles to form a continuous damper winding. The ends of the
windings are supported with bars or aluminum pole shoes. The rotor
either has resin applied during the winding process or is vacuum-pressure
impregnated with resin.
The shaft is made from high-strength rolled or forged steel and machined
to accommodate all the rotating generator components. Keyways in
the shaft ensure precise positioning of the rotor, exciter armature, and
optional PMG rotor as well as drive couplings. On the exciter side, the
shaft has a slot or hole in its centerline for running the revolving field
leads to the rectifier.
Bearings Note: For specific lubrication instructions,

The generator may contain either one or two bearings. Bearings are always refer to the bearing lubrication sheet
typically ball or roller type and are regreaseable bearings, which contain that came with your manual or the lube plate
fill and drain ports for easy lubrication. Sleeve bearings are optional on the generator.
on some designs. A supplementary instruction will be included in
Page 5
the manual package for sleeve bearings if they are applicable to this
generator. Some smaller generators may use heavy duty double shielded
bearings, which are typically used on smaller generators and are greased
for life.
Connection boxes
The main lead connection box houses the load lead terminals. In
addition, the generator may have auxiliary connection boxes for
connecting temperature detector outputs, space heater connectors, and
sensing outputs.
Excitation system
The excitation system consists of the exciter stator assembly and the
exciter armature assembly:
The exciter stator assembly consists of windings in a core. The core is

made from steel laminations that are stacked and welded together. The
main exciter stator coils are placed in slots in the core and form alternate
north and south poles. The entire assembly is either mounted to the end
bracket or mounted in a frame, which is mounted to the end bracket. The
stator is a stationary field, which is powered by the voltage regulator.
The assembly consists of two subassemblies: the exciter armature and

the rotating rectifier. The exciter armature assembly contains steel
laminations that are stacked and keyed on the shaft or on to a sleeve,
which is keyed to the generator shaft. A three-phase winding is inserted
into slots in the laminations. The coils are held in place by insulating
wedges. The coil extensions are braced with tape. Output leads from the
winding are connected to the rotating rectifier assembly.
The rotating rectifier is a three-phase full wave bridge rectifier,

converting the AC from the exciter armature to DC, which is transferred
to the revolving field windings. Two aluminum steel plates, each
containing three rotating rectifier diodes, are mounted on each side of
an insulating hub to form the negative and positive terminals. The plates
also act as heat sinks for the diodes.
Excitation system functional overview: Exciter field control is

established by the strength of the exciter field current developed by
the voltage regulator system. The DC voltage and current levels of the
exciter field signal from the voltage regulator varies depending upon the
generator output voltage and the loading of the output lines (see Figure
1).
Page 6
Power input
Voltage
regulator
Output leads
Main stator
PMG stator Exciter stator (armature)
(armature) (field)
Main rotor (DC) Prime mover
Shaft
PMG rotor
(field)
Rectifier
Exciter
armature (AC)
Figure 1: Overview of excitation system

(with an optional PMG)
Optional PMG system

The permanent magnet generator (PMG) system consists of the PMG
stator and PMG rotor:
The PMG stator is a stationary armature and is located within the stator
assembly that also contains the exciter stator or is a separate stator
mounted next to the exciter stator. The PMG stator consists of steel
laminations. The laminations are held in place by steel compression rings
and are welded to the frame bars of the exciter-PMG frame. The PMG
windings are placed in slots in the laminations. Insulating wedges are
inserted at the top of each slot to hold the coils in position.
The PMG rotor consists of rectangular permanent magnets and cast pole
tips secured to a steel hub with nonmagnetic stainless steel bolts. The
PMG rotor is keyed to the shaft and secured with a nut and lock washer.
PMG system overview: The PMG system functions as a pilot exciter,

providing power to the automatic voltage regulator power supply. The
PMG is an AC generator that uses permanent magnets in the rotor instead
of electromagnets to provide the magnetic field (see Figure 1).
Other options
Other options include, but are not limited to, space heaters, filters, and
temperature sensing devices.
Page 7
Installation
Warning: Be alert at all times when Receiving inspection
installing, operating and maintaining the Before accepting a shipment, examine the packaging for any sign of
generator. Avoid contact with the uninsulated damage that might have occurred during transit. Report any damage to
metal parts of the generator. Most injuries the transportation company and Kato Engineering.
occur from faulty ground connections on
portable electrical equipment and failure to Unpacking and moving
ground stationary equipment.
If the generator is received during cold weather, reduce condensation on
Test all portable devices frequently to cold surfaces and failure due to wet windings by allowing the generator
prove that a solid electrical circuit exits to reach room temperature before removing the protective packing.
from the metal frame though the grounding
conductor, in the electrical cord, to the Unpack the generator carefully to avoid scratching painted surfaces. Do
grounding contact in the attachment plug. not remove the protecting lubricant from the shaft end or drive plates.
Do not use electrical equipment with frayed, Inspect for loosely mounted components and the presence of moisture.
burned or damaged cords. Always take Inspect to make certain foreign material, such as crating nails, loose
extreme care when moving the generator. bolts or packing material, which may have fallen into the machine during
Be careful to not strike objects or personnel. unpacking, is removed. If damage is noted, determine the extent of
damage and immediately notify the transportation company claims office
Apply lifting force to structural points
specifically provided for lifting. Do not use and Kato Engineering. Be sure to give complete and accurate details
the enclosure lifting holes to lift the whole when reporting damage.
unit. Use lifting means adequate for the
weight. Observe lifting notices attached Move the generator by attaching an overhead hoist to the eyebolts
to the generator. Failure to observe these installed on the generator frame or by lifting the generator from
instructions can result in injury and damage underneath the skid with a forklift.
to the generator.
Single-bearing generators are shipped with the exciter rotor assembly
Caution: Do not attempt to transport a removed from the shaft and a support mounted across the drive discs to
single-bearing generator without maintaining
support the rotor.
proper rotor support and with the exciter
rotor assembly removed. Failure to observe
this warning can result in equipment Location
damage. Install the generator in an area so it complies with all local and industrial
regulations. Locate it in a clean, dry, well-vented area or area that is
Caution: Blocking or restriction of normal air suitable for the generator enclosure. Make sure it is easily accessible for
flow into or out of the generator may cause inspection and maintenance.
damage to the electrical windings.
Check winding insulation resistance before placing the generator in
operation (see the maintenance section).
Protect generators operating intermittently in very damp locations with

space heaters. Slowly warm generators placed in operation after being
subjected to very low temperatures to prevent excessive condensation.
Base design
The type of base to be used will depend upon the nature of the
installation site. However, the generator base must be rigid, level, and
free from vibration. Mounting holes must be larger than the fasteners to
allow for alignment.
Page 8
Assemble to prime mover, alignment
Follow either the two-bearing alignment (if your generator model has
two bearings but no adapter to bolt to an engine flywheel housing),
two-bearing close-coupled alignment (if your generator model has two
bearings and an adapter for bolting to a flywheel housing), or single-
bearing alignment (if your generator has one bearing and drive plates).
Consult the factory for belt or gear drive alignment).
Two-bearing alignment
Follow the tolerances specified by the coupling manufacturer when they
are less than described in this manual.
Use shims, if necessary, between the mounting pad and the base to
properly level and align the generator to the prime mover.
Install the coupling(s) on the generator and engine drive shafts in

accordance with coupling manufacturer installation procedures. Use a
straight edge and a thickness gauge for rough alignment as shown in
Figure 2. Check for angular and parallel alignment as follows:
Straight edge
Notes: Mounting of the indicators must

allow complete rotation of the prime mover.
Thickness gauge Use dial indicators that are rigid so indicator

Figure 2: Rough alignment sag won’t be a factor. Using the shortest
offset distance of the indicator bracket will
Angular alignment: Fasten a dial indicator to one of the coupling halves, reduce the effects of indicator droop or sag.
and scribe the position of the dial button on the face of the opposite
coupling half as shown in Figure 3. Rotate both shafts simultaneously, During alignment, you may also need to
keeping the finger or button on the indicator at the reference mark on the compensate for engine expansion due to
coupling hub. Note the reading on the indicator dial at each one quarter heating. Generator expansion is generally
revolution. not considered a factor.
If the genset is moved to a different

A variation of readings at different positions will indicate how the location, check alignment before startup.
machine needs to be adjusted to obtain a maximum misalignment of
0.001 inch for each inch of the coupling hub’s radius, total indicator Caution: Do not pry on the generator fan.
runout. Place or remove slotted shims from under the front or rear engine
or generator mounting pads and/or shift the front or back half of one Caution: Generators equipped with sleeve
component from side to side until the components are properly aligned. oil bearings must have oil added to the
Tighten the mounting bolts, and recheck alignment. bearing prior to rotation. See the bearing
manual.
Page 9
Dial indicator
Figure 3: Angular alignment
Parallel alignment: Fasten a dial indicator to one of the coupling halves,

and scribe the position of the dial button on the top of the opposite
coupling half as shown in Figure 4. Rotate both shafts simultaneously,
keeping the finger or button on the indicator at the reference mark on the
coupling hub. Note the reading on the indicator dial at each one quarter
revolution. A variation of readings at different positions will indicate how
the machine needs to be adjusted to obtain a maximum misalignment of
0.002 inch. Place or remove slotted shims from under all of the engine
or generator mounting pads and/or shift one component from side to side
until the components are properly aligned. Tighten the mounting bolts,
and recheck alignment.
Dial indicator
Figure 4: Parallel alignment
Page 10
Two-bearing close-coupled alignment Notes: Mounting of the indicators must
Check the engine flywheel housing pilot’s radial and face runout by allow complete rotation of the prime mover.
mounting a dial indicator and measuring the flywheel to the flywheel
housing as shown in Figure 5. See Table 1 for maximum allowable Use dial indicators that are rigid so indicator
runout. sag won’t be a factor. Using the shortest
offset distance of the indicator bracket will
reduce the effects of indicator droop or sag.
Flywheel
During alignment, you may also need to
Dial indicator compensate for engine expansion due to
pointer for radial Flywheel housing
heating. Generator expansion is generally
runout
not considered a factor.
If the genset is moved to a different

location, check alignment before startup.
Shaft Caution: Do not pry on the fan.
Caution: Generators equipped with sleeve

oil bearings must have oil added to the
bearing prior to rotation. See the bearing
manual.
Dial indicator pointer for

face runout
Figure 5: Flywheel housing check
SAE housing Housing inside Allowable

number dia. runout (TIR)
6 10.500 0.002
5 12.375 0.003
4 14.250 0.003
3 16.125 0.004
2 17.625 0.004
1 20.125 0.005
0.5 23.000 0.005
0 25.500 0.006
00 31.000 0.007
Table 1: Maximum allowable

flywheel housing runout (inches)
Page 11
Check the engine flywheel’s radial and face runout by mounting a dial
indicator and measuring the flywheel housing to the flywheel as shown
in Figure 6. See Table 2 for maximum allowable runout.
Flywheel
Flywheel housing
Dial indicator pointer
for radial runout
Shaft
Dial indicator
pointer for face
runout
Figure 6: Flywheel check
Pilot Allowable
diameter runout (TIR)
6.5 0.002
7.5 0.002
8 0.002
10 0.003
11.5 0.003
14 0.004
16 0.005
18 0.005
21 0.006
24 0.007
Table 2: Maximum allowable fly-

wheel runout (inches)
Page 12
Check the generator adapter’s radial and face runout by mounting a
dial indicator on the generator shaft or coupling as shown in Figure 7.
The maximum radial and face runout on the generator adaptor must not
exceed 0.010 inch.
Adapter
for radial runout
Shaft
Dial indicator
pointer for face
runout
Figure 7: Generator adapter check
Check the generator coupling’s radial and face runout by mounting

a dial indicator to the generator adapter as shown in Figure 8. The
maximum radial and face runout on the coupling must not exceed 0.003
inch.
Adapter
Shaft
Dial indicator
pointer for face
runout
Dial indicator
pointer for radial
runout
Figure 8: Generator coupling check
Page 13
Install the portion of the coupling that fits into the engine flywheel
following the manufacturer’s recommended procedures and in
accordance with engine manufacturer’s specifications. Check the
coupling’s radial and face runout by mounting a dial indicator to the
engine flywheel housing as shown in Figure 9. The maximum radial and
face runout on the coupling must not exceed 0.004 inch.
Flywheel
Flywheel housing
Dial indicator
pointer for face
runout Shaft

for radial runout
Figure 9: Engine coupling check
Measure and record the engine crank shaft endplay and generator
endplay. Set the engine endplay to the manufacturer’s recommended
position for alignment. Verify the generator end-float is set at a position
of one half of the measured distance or at a position that will allow
full thermal growth of the generator shaft when operated at rated
temperatures.
Mount the generator on the skid, and move the generator to within 0.010
inch of the engine. Place two 0.010-inch shims in the horizontal
(9 o’clock and 3 o’clock) positions between the generator adapter
and the engine flywheel housing. Raising the rear, exciter end of the
generator as necessary, place two 0.010-inch shims in the vertical (6
o’clock and 12 o’clock) positions between the generator adapter and
the engine flywheel housing. This will give a good starting point for
alignment. Remove the vertical shims at this time. (If necessary, mark
holes to be drilled on the base, and remove the generator at this time.)
Page 14
Mount a dial indicator on the generator shaft or half coupling to the
flywheel radial surface for parallel alignment as shown in Figure 10.
Mount a dial indicator on the flywheel coupling to the face of the
generator half coupling for angular alignment as shown in Figure 10.
Align the engine by rotating the prime mover in 90-degree increments
and measuring total indicator runout. Tighten the generator to the base
before taking each set of readings. Raise or lower the generator by
adding or removing shims under the machined feet.
Flywheel

for parallel alignment Flywheel housing
Shaft

for angular alignment
Figure 10: Alignment check
Following the final generator adjustment and runout check, remove Note: Clearances between the adaptor
the horizontal shims from the adaptor flywheel housing, and move the pilot and the flywheel housing recess are
generator all the way to the adaptor. Then tighten the fasteners. Recheck designed to meet the tolerance of 0.001 to
alignment. Make sure angularity (face) total indicated runout does not 0.015 inches.
exceed 0.001 inch per inch of generator shaft diameter and parallel
(radial) total indicated runout does not exceed 0.003 inch.
Torque the fasteners to the value shown in Table 3.
Page 15
ASTM and SAE Torque Values
Specific Drawings, OMS, BOMS supercede this generic table.
Grade 5
SCREW Grade 2 Grade 5 GASKETED COVERS Grade 8
SIZE Foot-Pounds Newton-Meter Foot-Pound Newton-Meter Foot-Pound Newton-Meter Foot-Pound Newton-Meter
Ft-Lbs Tol N-M Tol Ft-Lbs Tol N-M Tol Ft-Lbs Tol N-M Tol Ft-Lbs Tol N-M Tol
#4-40 4* 0.4
#6-32 8* 0.9
#8-32 14 * 1.6
#10-24 20 * 2.3
#10-32 23 * 2.6
1/4-20 4 1 6 1 8 2 11 3 5 1 7 2 10 2 14 3
5/16-18 8 2 11 2 17 3 24 4 10 2 14 3 25 5 34 7
3/8-16 15 3 20 4 31 6 42 8 12 2 16 3 40 10 54 14
7/16-14 24 5 32 6 50 10 65 13 70 15 95 20
1/2-13 36 7 50 10 75 ** 15 100 20 24 5 32 6 100 20 135 27
9/16-12 55 10 75 14 110 20 150 25 150 30 200 40
5/8-11 75 12 100 17 150 25 200 20 200 40 275 55
3/4-10 130 25 175 24 260 50 350 70 370 50 500 70
7/8-9 145 20 195 28 425 60 575 80 600 60 800 80
1.0-8 190 22 250 30 650 75 875 100 900 90 1200 120
1 1/8-7 265 27 350 35 790 80 1075 100 1200 120 1650 160
1 1/4-7 375 40 500 55 1100 120 1500 150 1750 180 2400 250
1 3/8-6 490 50 650 70 1450 150 1950 200 2300 230 3100 300
1 1/2-6 625 60 850 90 1750 180 2350 250 3000 300 4000 400
* Inch-pounds
SCREW Set Screws Brass Screws Stainless Screws Grade B Top Lock Nuts
#4-40 4* 0.4 5* 0.6
#6-32 8* 0.9 10 * 1.1
#8-32 20 * 2.3 16 * 1.8 21 * 2.4
#10-24 18 * 2 24 * 2.7
#10-32 34 * 3.8 33 * 2.9 33 * 3.7
1/4-20 6 1 9 2 5 1 7 2 6 1 8 2 6 1 8 1
5/16-18 13 2 18 3 9 2 12 2 11 2 15 3 11 2 15 3
3/8-16 23 2 31 6 16 3 22 4 21 4 28 5 18 2 24 3
7/16-14 36 5.14 50 10 26 5 35 7 33 7 45 9 28 4 38 5
1/2-13 50 10 70 14 35 7 45 9 45 9 60 12 44 ** 6 60 12
9/16-12 55 10 70 13 60 11 80 15
5/8-11 110 18 145 24 85 14 115 19 100 17 140 23
3/4-10 180 35 240 46 120 23 160 31 130 25 180 35
7/8-9 430 60 580 82 205 30 280 40
1.0-8 580 70 790 90 300 35 400 45
1 1/8-7 430 45 590 60
1 1/4-7 550 60 750 80
1 3/8-6 700 70 950 100
1 1/2-6 930 100 1250 130
* Inch-pounds
** For Electrical Lugs use 44 Ft-lbs (60 N-M) See Fig 4 and Fig 5
Table 3: Recommended lubricated torque values. (If no lubricant is used, increase values by 25%.)
Page 16
Metric Torque Values
Grade 8.8
SCREW Grade 4.8 to 6.8 Grade 6.9 to 8.8 GASKETED COVERS Grade 10.9
M4 x .70 1.1 1.5 2 2.7 2.9
M5 x .80 2.3 3.1 4 5.3 6
M6 x 1.00 4 1 5.2 1 7 1 9.3 2 4 1 5 1 10 2 14 3
M7 X 1.00 6.5 1 8.7 2 11 1 15 3 16 5 34 7
M8 x 1.25 10 2 13 3 18 2 24 5 11 2 15 4 25 10 54 14
M10 x 1.50 20 4 27 5 32 4 43 9 13 3 18 4 47 15 95 20
M12 x 1.75 34 7 45 9 58 7 77 15 19 4 26 5 83 20 135 27
M14 x 2.00 54 10 72 13 94 10 125 23 132 30 200 40
M16 x 2.00 80 13 108 18 144 13 192 32 196 40 275 55
M18 x 2.50 114 22 152 29 190 22 253 50 269 50 500 70
M20 x 2.50 162 23 216 30 260 23 347 50 366 60 800 80
M22 x 2.50 202 23 269 31 368 23 491 55 520 90 1200 120
M24 x 3.00 245 25 327 33 470 25 627 65 664 120 1650 160
M27 x 3.00 360 40 480 52 707 40 943 100 996 180 2400 250
M30 x 3.50 500 50 667 70 967 50 1289 130 1357 230 3100 300
Grade 2 Grade 5 Grade 8

ASTM & SAE grade markings
Class 8.8 Class 10.9

Metric grade markings
1-NM = 0.737 ft-lbs. = 8.85 in-lbs.
Page 17
Notes: Mounting of the indicators must Single-bearing alignment
allow complete rotation of the prime mover. Before assembling the generator to the prime mover, remove the exciter
cover and adapter cover. Remove the blocking holding the drive discs to
Use dial indicators that are rigid so indicator the adapter. Also make sure the generator bearing end clearance is not
sag won’t be a factor. Using the shortest less than the total engine crankshaft axial movement plus 1/16 inch. The
offset distance of the indicator bracket will generator is shipped from the factory with 1/8-inch minimum bearing
reduce the effects of indicator droop or sag.
end clearance. (This dimension is recorded on the Factory Recorded
Dimensions sheet, packaged with the generator.)
During alignment, you may also need to
compensate for engine expansion due to
heating. Generator expansion is generally Measure the distance from the end of the exciter shaft extension to the
not considered a factor. bearing housing on the endbracket (dimension A in Figure 11). This
dimension is recorded on the Factory Recorded Dimensions sheet,
If the genset is moved to a different packaged with the generator. If the dimensions do not match, move the
location, check alignment before startup. rotor axially relative to the stator until the dimensions are equal.
Caution: Do not pry on the generator fan.
Endbracket
Caution: Generators equipped with sleeve
oil bearings must have oil added to the
bearing prior to rotation. See the bearing Bearing Exciter field
manual.
Shaft extension
Figure 11: Generator coupling check
Page 18
Check the engine flywheel housing pilots’s radial and face runout by
mounting a dial indicator and measuring the flywheel to the flywheel Caution: Never grind the OD of drive
housing as shown in Figure 5. See Table 1 for maximum allowable discs or attempt to drill out the holes. If the
runout. dive discs do not fit properly, use different
discs or a different flywheel.
Check the engine flywheel’s radial and face runout by mounting a dial
indicator and measuring the flywheel housing to the flywheel as shown
in Figure 6. See Table 2 for maximum allowable runout.
Measure the generator drive plate diameter (dimension S of Figure 12)

and flywheel bore diameter (dimension B of Figure 13). Drive plate
diameter must not be greater than the flywheel bore diameter. Also check
to make sure the hole centers match (dimension W of Figure 12 and
dimension C of Figure 13).
Measure the axial distance from the surface on the generator adapter
to the outside surface on the drive disc coupling plates (dimension Y
in Figure 12). This dimension is recorded on the Factory Recorded
Dimensions sheet, which was packaged with the generator. If the
dimensions do not match, move the rotor axially relative to the stator
until the dimensions are equal.
Adaptor
Drive Y
plates
Fan
Shaft
S A
W
Bolt holes
Figure 12: Single bearing generator drive plate

and adaptor
Page 19
Caution: The number and thickness Measure the axial distance from the machined surface on the engine
of drive discs are specified for torque flywheel housing the bottom of the flywheel drive disc recess
requirements. Do not remove drive discs (dimension G in Figure 13). Make sure the difference between
to compensate for spacing. dimensions Y (of Figure 12) and G are less than 1/32 inch. If G is
more than Y, install additional spacers between the drive discs and the
generator hub. If Y is more than G, remove spacers between the drive
discs and generator hub.
Tapped
bolt holes
C B
Flywheel G
Figure 13: SAE flywheel and adapter

Install the generator to the engine. Make sure the drive discs seat in
the recess of the flywheel housing. Secure the generator to the engine
(drive discs to flywheel, adapter to flywheel housing), and the base. Use
lock washers on all bolts. Torque the adapter and drive discs in a criss-
cross pattern to the values in Table 3.
Ensure that the bolts in the flywheel do not bottom out. If they are too
long or cannot be tightened with a socket or box wrench, use 1/4 to 3/8-
inch long spacers inserted in the bolts as shown in Figure 14 to increase
the clearance between the bolt head and the flywheel.
Lock washer
Bolt
Spacer
Drive hub
Drive plates
Flywheel
Figure 14: Disc-to-flywheel installation
Page 20
Occasionally, there is insufficient clearance to install the bolts that Note: The generator with sheet metal fans
fasten the drive discs to the engine flywheel, and the fan will have to be and cast fan hubs is shipped from the
temporarily moved to accommodate this. This situation will typically factory with the fan 1/2 to 3/4 inch from the
occur with several types of generators: fan baffle and clear of the inside adaptor
for optimum air flow through the exhaust
• With the three-frame units that have an aluminum fan, loosen the fan screen.
hub bolts to move the fan. After installing the drive disc-to-flywheel
bolts, move the fan back so the rotor-side edge is flush with the air
opening and the minimum distance between the windings and the
fan is 3/8 inch. Torque the fan hub bolts to 75 ft-lbs.
• With sheet metal fans with cast hubs that are in turn mounted on the
drive hub, mark the drive hub as closes as possible to the fan hub.
Loosen the two set screws, the fan clamping bolt, and the fan bolts.
Wedge the fan open, and move it out of the way (See Figure 15).
After attaching the drive discs-to-fly wheel bolts, align the fan hub
to the mark to move the fan back to its original position. Ensure
the key is fully in place under the fan hub and positioned so the set
screw will press on the key. Tighten the fan hub clamping bolt and
the set screws. Install the fan bolts and torque them according to
Table 3.
Fan
Drive discs
Fan bolts
Keyway Set screw
Key
Bolt holes
Alignment mark on
drive hub
Fan hub bolt
Fan hub
Figure 15: Moving sheet metal fans
Page 21
After installing the drive disc-to-flywheel bolts, check the runout of the
generator shaft by placing the base of a dial indicator on the generator
frame and positioning of the probe on the shaft as shown in Figure 16.
If the total indicated runout exceeds 0.003 inch, remove the drive discs
bolts, and rotate the generator relative to the engine flywheel. Reinstall
the bolts, and check the runout again.
Recheck the shaft-end-to-bearing-housing distance (dimension A in

Figure 11).
Mount the brushless exciter armature assembly to the generator shaft

(as described in the assembly procedures below).
Adapter
Fan
Shaft
Drive plates
Drive hub
Figure 16 Runout check
Page 22
Foot deflection Warning: The space heaters are designed
After alignment, check for foot deflection or “soft foot” condition on to be energized when the generator is
each shim location to eliminate distortion of the generator frame. Do shut down. They are hot enough to cause
this by loosing one mounting bolt at a time and checking deflection skin burns. Terminals for power at the
after retightening. Deflection at the shim location from shims under space heaters are live during operation.
Disconnect power to the space heaters
compression to a loosened condition must not exceed 0.003 inch.
before removing the generator covers.
Doweling
In case the mounting bolts loosen during operation, doweling will
prevent movement of the generator. Dowel as follows:
Check the alignment after the generator has been in operation for at least
48 hours. If alignment is not satisfactory, realign.
Drill holes through the footpads and into the base in two mounting pads
opposite each other. Drill the holes slightly smaller than the dowel pin.
Ream the holes to the proper diameter for the pin. Clean out chips, and
install the pins.
Electrical connections
If the generator was subjected to a rapid change in temperature, freezing
or wet conditions during shipment or storage, measure the insulation
resistance of each winding and dry the generator, if necessary, as
described in the maintenance section below.
Make all electrical connections (main load, temperature monitoring

device, space heater, AVR) in accordance with local regulations and
national/international electrical code requirements. Check the electrical
diagrams provided with the generator or manual. The main terminals
need to be properly spaced for the load connections. Refer to Table 3 for
the proper torque values for the connections.
On larger generators grounding points are provided for properly

grounding the system to the generator frame. The grounding wire must
be sized to national/international code requirements.
Space heaters
When the generator has optional space heaters to prevent water
condensation during long periods of downtime, connect the space heaters
so they start when the generator is turned off and stop when the generator
is switched on. Some generators with space heaters have thermostats.
The thermostat should be set above the dewpoint. Refer to the electrical
diagrams for the space heater characteristics.
Page 23
Caution: Do not pry on the fan. Inspection before startup
After electrical connections have been made, perform the following
checks:
• Check all the connections to the electrical diagrams provided.
Note: For specific lubrication instructions, • Secure all covers and guards.
always refer to the bearing lubrication sheet
that came with your manual or the lube plate • Turn the rotor slowly with the appropriate starting mechanism (bar
on the generator.
the engine or flywheel) through one revolution to see if the rotor
turns freely.
• Check the bearings to see they are properly lubricated.
• Determine the direction of the engine rotation, and make sure that it
matches the rotation of the generator.
• Make sure the power requirements comply with the data on the
generator nameplate.
• Make sure that the engine-generator set is protected with an adequate

engine governor and against excessive overspeed.
• Make sure the output of the generator is protected with an overload

protection device, such as circuit breakers or fuses, sized in
accordance with national/international electrical code and local
electrical code standards. Fuses need to be sized using the lowest
possible current rating above the full-load current rating (115% of
rated current is commonly recommended).
• Remove tools and other items from the vicinity of the generator.
Page 24
Operation Caution: Do not actuate the auto-manual
switch with the full load applied to the
generator. Whenever possible, stop the
generator before switching.
Initial startup: generators with both automatic and
manual voltage control
1. Disconnect the generator output from the load by opening the main
circuit breaker.
2. Turn the manual voltage adjust rheostat fully counterclockwise.
3. Put the auto-manual switch in the manual position.
4. Start the prime mover, and bring the set to rated speed. Turn the
manual voltage adjust rheostat to reach rated voltage. Close the
output circuit breaker, and apply load in steps until the rated load is
reached. Adjust the manual adjust rheostat as necessary to obtain the
desired output voltage.
5. Gradually reduce load, and adjust the rheostat accordingly until no

load is reached. Open the circuit breaker, and stop the prime mover.
6. Actuate the auto voltage rheostat. Then start the genset, and bring it
to rated speed. Adjust the voltage to the desired value.
7. Close the output circuit breaker. Then check the generator voltage
and voltage regulation. Apply load in steps until the rated load is
reached.
8. Check for vibration levels at no load and rated load. A slight increase
is normal. As the load is maintained for 2-3 hours, the vibration
levels will gradually increase and reach a final level.
Initial startup: Generators with automatic voltage control

only (generator has an automatic voltage regulator (AVR)
with no auto-manual switch)
1. Disconnect the generator output from the load by opening the main
circuit breaker.
2. Turn the voltage adjust rheostat fully counterclockwise. Start the

prime mover, and bring the set to rated speed. Turn the voltage adjust
rheostat to obtain the desired voltage.
3. Close the output circuit breaker, and apply load in gradual steps until
the rated load is reach. Note the voltage regulation with the changes
in load steps.
4. Check for vibration levels at no load and rated load. A slight increase
is normal. As the load is maintained for 2-3 hours, the vibration
levels will gradually increase and reach a final level.
Page 25
Restoring residual magnetism/field flashing
The direct current necessary to magnetize the revolving field is obtained
from the exciter. Upon starting the generator, current and voltage is
induced into the exciter by the magnetic lines of force set up by residual
Note: If the polarity of the exciter is reversed magnetism of the exciter field poles. Residual magnetism of the exciter
by flashing the field, it may be corrected by field poles may be lost or weakened by a momentary reversal of the field
interchanging the battery leads. connection, a strong neutralizing magnetic field from any source, or non-
operation for a long time. If the generator fails to generate voltage after
it has come up to rated speed, it may be necessary to restore residual
magnetism.
To restore the small amount of residual magnetism necessary to begin the

voltage build up, connect a 12 or 24-volt battery to the exciter field coil
circuit and flash as follows:
1. Open the output circuit breaker, and stop the engine.
2. Disconnect the exciter field coil wires EF1 at the terminal EF1 and
EF2 at the terminal EF2, and connect the battery positive lead to the
field coil lead EF1.
3. Flash the field by touching the battery lead to the field coil circuit
terminal EF2.
4. Disconnect the battery leads.
5. Reconnect the field coil lead EF1 to terminal EF1, and reconnect the
field coil lead EF2 to terminal EF2.
6. Start the generator, and check for voltage build up. Reflash if
the generator output voltage does not build up, or flash with the
generator running, the field coil wires connected to the regulator, and
a 3-amp or larger diode off the positive terminal of the battery per
Figure 17.
- 12 or 24 V
battery
+
3 amp or
larger diode F- Voltage
F+ regulator
EF2 EF1
Figure 17: Field flashing setup with the field wires

connected to the regulator
Page 26
Continuous operation Caution: Operating the unit beyond name-
Operate the generator within the nameplate values . If the generator is plate values may cause equipment damage
operated below the rated power factor and voltage, decrease the kVA to or failure.
prevent overheating of the field and stator windings. Consult the factory
for derating factors if the application requires the unit to be operated
beyond nameplate values.
Rotor overheating may occur when the generator is carrying excessive

unbalanced loads. Negative sequence currents flowing in the field pole
face cause the rotor heating. For a general guide to the allowable phase
unbalance, see Figure 18, Guide to allowable phase unbalance (which is
based on a 10% equivalent negative sequence current).
100
Min. current in any phase (% of rated)
80
Allowable
unbalance
60
Excessive
40 unbalance
20
0 20 40 60 80 100
Max. current in any phase (% of rated)
Figure 18: Guide to allowable phase unbalance
The guide is used in the following manner: Find the point where the
vertical line (determined by the maximum current in any of the phases
and expressed in percent of rated current) crosses the horizontal line
(determined by the minimum current in any of the phases and expressed
in percent of rated current). Ensure the point where these two lines
intersect is within the permissible allowable unbalance region for safe
operation of the generator.
Loss of field excitation can result in the unit operating out of

synchronization with the system when operating is parallel. This has the
effect of producing high currents in the rotor, which will cause damage
very quickly. Protective relays should be considered to open the circuit
breaker.
Page 27
Caution: Refer to the voltage regulator Idling
manual for complete details and possible Unless the voltage regulator has V/Hz protection built in, having the
additional instructions. Damage to the rotat- generator set in operating mode while idling the engine can cause
ing diodes, generator, and voltage regulator permanent equipment damage. If engine adjustments require that
can be caused if the regulator is operated the engine be run at idle speed and the regulator does not have V/Hz
improperly.
protection, make the generator regulating system inoperative during
idling by one of the following methods:
When the generator is provided with a voltage shutdown switch, be sure

the switch is set to the idle position while the engine is running at idle
speed.
Where the generator set is provided with field circuit breakers, set the
Caution: Do not make connections or other- circuit breaker to the off position while the generator is running at idle
wise make contact with the generator leads speed.
or other devices connected to them unless
the genset is stopped and the phase leads
Where the generator set is provided with an automatic/manual control
are grounded.
switch that has an off position, switch it to off while the engine is
running at idle speed.
Where the generator set does not have any of the above options, remove
the wires from the voltage regulator input power terminals when the
engine is running at less than rated speed.
Parallel operation
For the generator to operate in parallel with a system in operation, the
phase sequence of the generator must be the same as that of the system.
Use transformers to reduce the voltage to an acceptable level, and then
use a phase rotation meter or incandescent lamp method, described in
electrical machinery handbooks, for a phase sequence check.
The output voltage at the paralleling point must be the same as each
instant, which requires that the two voltages be of the same frequency,
same magnitude, same rotation, and in coincidence with each other.
Voltmeters indicate whether the voltage magnitude is the same, and

frequency meters indicate whether the frequencies are the same. Whether
the voltages are in phase and exactly at the same frequency is indicated
by a synchroscope or by synchronizing lamps.
A synchroscope can be used to indicate the difference in phase angle

between the incoming machine and the system. The generator can be
paralleled by using incandescent lamps connected as shown in Figure 19.
The voltage rating of the series lamps must equal the voltage rating of the
transformer-low voltage winding.
Each prime mover in the system must have the same speed regulating
characteristics, and the governors must be adjusted to give the same
speed regulation as determined by applying load that is proportional to
the full load rating of the generator.
Page 28
System bus
Load Synchronizing
switch lamps
Load lines from the incoming generator
Figure 19: Synchronizing paralleled generators with test lamps

The voltage regulator must include paralleling circuitry. In addition, the
voltage, droop settings and the V/Hz regulation characteristics must be
the same for all the voltage regulators. This will allow the generators to
properly share reactive loads.
If cross-current compensation is used, paralleling current transformers

must give the same secondary current.
Current transformer secondary windings provide reactive kVA droop

signal to the voltage regulator. Accidental reversal of this electrical
wiring will cause the voltage to attempt to rise with load rather than
droop. If this occurs during paralleling, stop the unit and reverse the
wires at the voltage regulator terminals.
If the set is provided with a unit/parallel switch, set the switch to the
parallel position on the unit being synchronized.
Synchronize the generator by adjusting the speed (frequency) slightly

higher than the system. Observe the synchroscope or the lamps. The
lamps should fluctuate from bright to dark at the rate of one cycle every
2 to 3 seconds. When the generator is in phase (the lights will be dark),
close the circuit breaker. Immediately after closing the breaker, measure
the line current kVAR of the generator. The readings must be within
the rating of the unit. A high ammeter reading accompanied by a large
kW reading indicates faulty governor control. A high ammeter reading
accompanied by a large kVAR unbalance indicates problems with the
voltage regulator. Adjusting the cross current or voltage droop rheostat
should improve the sharing of kVAR.
To shut down the generator operating in parallel, gradually reduce the

kW load by using the governor to reduce speed. When kW load and
line current approach 0, open the generator circuit breaker. Operate
the generator unloaded for several minutes to dissipate the heat in the
windings. Refer to the prime mover manual for shutdown and cool-down
procedures.
Page 29
Maintenance
Schedules
Warning: Do not service the generator
A regular preventive maintenance schedule will ensure peak
or other electrical machinery without de-
performance, minimize breakdowns and maximize generator life. The
energizing and tagging the circuits as out of
service. Dangerous voltages are present, schedule listed below is a guide for operating under standard conditions.
which could cause serious or fatal shock. Specific operating conditions may require reduced or increased
maintenance intervals. Also, if there is a different or more specific
schedule for your generator than the schedule provided below, it will be
included as a supplement to the manual package.
Every day
Visually check generator bearing housings for any sign of oil seepage.
Check the operating temperatures of the generator stator windings.
Check the control panel voltmeter for proper stability and voltage output.
Monitor the power factor and generator loading during operation.
With generators that have sleeve oil bearings, check the operating
temperatures and sight glass levels (if applicable).
Note: For specific lubrication instructions,
always refer to the bearing lubrication sheet
Every week
that came with your manual or the lube plate
on the generator. Visually inspect the bearing exterior for dirt, and clean if necessary.
Inspect any generator air filters for build up of contaminants, and clean or
replace as required
Every 2000 Hours or 6 months of operation

Remove generator outlet box cover. Visually inspect the stator output
leads and insulation for cracking or damage. Check all exposed electrical
connections for tightness. Check transformers, fuses, capacitors, and
lightning arrestors for loose mounting or physical damage. Check all lead
wires and electrical connections for proper clearance and spacing.
Clean the inside of the outlet box, air screens, bearing housings, and air
baffles with compressed air and electrical solvent if needed.
With generators that have ball or roller bearings, check machine

vibrations and bearing condition with a spectrum analyzer or shock
pulse.
Regrease the regreaseable-type bearings. With generators that have

sleeve oil bearings, inspect bearing oil for proper levels and clarity.
Page 30
Every 8000 hours or 1 year of operation
Check insulation resistance to ground on all generator windings,
including the main rotating assembly, the main stator assembly, the
exciter field and armature assemblies, and the optional PMG assembly.
Check the space heaters for proper operation.
Check the rotating rectifier connection tightness.
With generators that have sleeve oil bearings, replace the bearing oil.
Every 20,000 hours or 3 years of operation

With generators that have sleeve oil bearings, perform a sleeve bearing
inspection to include the removal of the upper bearing housing and
bearing liner to inspect the liner, shaft journal, and seal surfaces for wear
or scoring.
Remove the endbrackets, and visually inspect the generator end windings
for oil or dirt contamination. Excessive contamination may necessitate
surface cleaning with compressed air and electrical solvent.
Inspect the fan and fan hub for damage.
Every 30,000 hours or 5 years of operation

(Contact Kato Engineering for assistance)
Disassemble the generator (this includes rotor removal).
Clean the generator windings using either (depending upon the severity
of contamination) 1) compressed air and electrical solvent or 2) de-
greaser and high pressure hot water wash. Dry the windings to acceptable
resistance levels (see the dry out procedure).
Inspect the rotor shaft bearing journals for wear or scoring.
With generators that have ball or roller bearings, replace the bearings.
With generators that have sleeve bearings, replace the bearing liners and
oil seals.
Page 31
Maintenance procedures
Visual inspection methods of windings
Electric machines and their insulation systems are subjected to
mechanical, electrical, thermal and environmental stresses that give rise
to many deteriorating influences. The most significant of these are the
following:
Thermal aging: This is the normal service temperature deteriorating

influence on insulation.
Over temperature: This is the unusually high temperature of operation

caused by conditions such as overload, high ambient temperature,
restricted ventilation, foreign materials deposited on windings, and
winding faults.
Overvoltage: This is an abnormal voltage higher than the normal service

voltage, such as caused by switching or lightning surges or non-linear
loads. Operating above rated nameplate voltage will reduce insulation
life.
Contamination: This deteriorates electrical insulation by 1) conducting

current over insulated surfaces 2) by attacking the material to reduce
electrical insulation quality or physical strength, or by 3) thermally
insulating the material so the generator operates at higher than normal
temperatures. Such contaminants include water or extreme humidity, oil
or grease including unstable anti-wear and extreme pressure lubricants,
conducting and non-conducting dusts and particles, industrial chemicals
such as acids, solvents, and cleaning solutions.
Physical damage: This contributes to electrical insulation failure by

opening leakage paths through the insulation. Physical damages can be
caused by physical shock, vibration, over-speed, short-circuit forces or
line starting, out-of-phase paralleling, erosion by foreign matter, damage
by foreign objects and thermal cycling.
Ionization effects: Ionization (corona), which may occur at higher

operating voltages, is accompanied by several undesirable effects such as
chemical action, heating, and erosion.
To achieve maximum effectiveness, a direct visual inspection program

initially to those areas that are prone to damage or degradation caused
by the influences listed above. The most suspect areas for deterioration
or damage are 1) ground insulation, which is insulation intended to
isolate the current carrying components from the non-current bearing
components, and 2) support insulation, which includes blocks and slot
wedges and are usually made from compressed laminates of fibrous
materials, polyester, or similar felt pads impregnated with various types
of bonding agents. Check for the following:
Page 32
Deterioration or degradation of insulation from thermal aging:
Examination of coils reveal general puffiness, swelling into ventilation
ducts, or a lack of firmness of the insulation, suggesting a loss of bond
with consequent separation of the insulation layers from themselves or
from the winding conductors or turns.
Abrasion: Abrasion or contamination from other sources, such as Warning: When using cleaning solvents,
ensure adequate ventilation and user
chemicals and abrasive or conducting substances, may damage coil and
protection.
connection surfaces.
Cracking: Cracking or abrasion of insulation may result from prolonged

or abnormal mechanical stress. In stator windings, looseness of the
bracing structure is a certain sign of such phenomena and can itself cause
further mechanical or electrical damage if allowed to go unchecked.
Erosion: Foreign substances impinging against coil insulation surfaces

may cause erosion.
Cleaning
Exterior: Wipe loose dirt from the exterior with a clean, lint-free cloth.
Remove stubborn accumulations of dirt with a detergent or solvent
that won’t damage the paint or metal surfaces. Use a vacuum to clean
ventilating ports.
Windings, assembled machines: Where cleaning is required at the

installation site and complete disassembly of the machine is unnecessary
or not feasible, pick up dry dirt, dust or carbon with a vacuum cleaner to
prevent the redistribution of the contaminant. A small non-conducting
nozzle or tube connected to the vacuum cleaner may be required to reach
dusty surfaces or to enter into narrow openings. After most of the dust
has been removed, a small brush can be affixed to the vacuum nozzle to
loosen and allow removal of dirt that is more firmly attached.
After the initial cleaning with a vacuum, compressed air may be used to
remove the remaining dust and dirt. Compressed air used for cleaning
must be clean and free of moisture or oil. Air pressure or velocity must
be adequately controlled to prevent mechanical damage to the insulation.
Disassembly of the machine and more effective cleaning by a qualified
Kato technician may be required if the above described field service
cleaning procedures do not yield effective results.
Windings, disassembled machines: Take an initial insulation resistance

reading on the machine to check electrical integrity. The high pressure
hot water wash method of cleaning, which sprays a high velocity
jet of hot water and water containing a mild detergent, is normally
effective in cleaning windings, including those subjected to flooding
or salt contamination. Use multiple sprays with clean water to remove
or dilute the detergent following the detergent spray. Dry the machine
until acceptable insulation resistance values are obtained at room
temperature. See the insulation resistance procedures below for minimum
recommended values.
Page 33
Caution: The insulation resistance tests are Electrical contacts: Clean electrical contacts, switch contacts and
usually made on all or parts of an armature terminals with an approved contact cleaner. Do not file contacts.
or field circuit to ground. They primarily
indicate the degree of contamination of the Insulation resistance tests at low voltage
insulating surfaces or solid insulation by Insulation tests are conducted for two reasons: to discern existing
moisture and other conducting influences weakness or faults or to give some indication of expected service
and will not usually reveal complete or reliability. Insulation resistance tests are based on determining the current
uncontaminated ruptures. through the insulation and across the surface when a DC voltage is
applied. The leakage current is dependent upon the voltage and time of
Note: The insulation resistance value
increases with decreasing winding
application, the area and thickness of the insulation, and the temperature
temperatures. All readings must be and humidity conditions during the test.
corrected to winding temperatures. Use
Table 4 for converting megger readings to Refer to the following electrical measurement procedures for testing
other temperatures (e.g., 100 megohms at detail. Contact Kato Engineering or refer to IEEE Standard. 432-1992
50º C is converted to 170 megohms: 1.7 x when more extensive insulation tests are required
100).
When checking insulation resistance with a megger, first verify the
Winding ground path. Connect one test lead to a ground point. Then connect
Temp Conversion the second test lead to another ground location to prove the ground
(ºC) factor connection. Once the ground path has been proven, the second test lead
10 0.23 can be connected to the leads of the component to be tested.
20 0.37
30 0.6
40
Exciter field (stator) and PMG armature (stator)
1
50 1.7
60 2.7 1. Disconnect the exciter leads from the terminals in the terminal box or
70 4.5 the voltage regulator.
80 7.5
90 14
100 23 2. Connect exciter leads to one clamp of 500-volt megger, and connect
110 38 the other clamp to the exciter field frame.
120 61
Table 4: Temperature conversion 3. Apply 500 V from the megger, and measure the resistance reading
factor for resistance readings after 1 minute. The reading must be a minimum of 50 megohm. If it
is not, refer to the cleaning or dry out procedures.
Warning: Never apply the megger to the
rotating rectifier, the voltage regulator, or 4. Ground the exciter field leads to the exciter field frame for several
generator accessories (e.g., temperature minutes after the megger has been disconnected. This will allow the
detectors, space heaters). voltage build up to be properly discharged.
Note: New generators should measure 5. Repeat steps 1-4 for the PMG armature (stator).
about 100 megohms minimum of insulation
resistance when meggered. Generators that Exciter armature
read 50 megohms or less should be dried
out according to the dry out procedures 1. Disconnect the exciter armature leads from the rotating rectifiers.
here. Generators with insulation resistance
readings of 10 megohms or less should be 2. Connect the leads of the exciter armature to one clamp of a 500-volt
investigated. megger, and connect the other clamp to a suitable connection on
exciter sleeve or shaft.
Page 34
3. Apply 500 V from the megger, and measure the resistance reading Winding rated Insulation
after 1 minute. The reading must be a minimum of 50 megohms. If it voltage (V)* resistance test
is not, refer to the cleaning or dry out procedures. direct voltage
(V)
4. Ground the exciter leads to the exciter sleeve or shaft after
<1000 500
disconnecting the megger. This will allow the voltage build up to be
properly discharged. 1000-2500 500-1000
2501-5000 1000-2500
Main rotor 5001-12000 2500-5000
>12000 5000-10000
1. Disconnect the generator field leads from the positive and negative
terminals of the rotating rectifier assembly. Table 5
Guidelines for DC voltages to be
2. Connect the positive and negative leads to one clamp of the megger, applied during insulation resistance
and connect the other clamp to the shaft. tests
3. Apply voltage from the megger, and measure the resistance reading
a
Rated line-line voltage for three-phase
after 1 minute. The reading must be a minimum of 50 megohms. If it ac machines, and line-to-ground voltage
is not, refer to the cleaning or dry out procedures. (See Table 5). for single-phase machines, and rated
direct voltage for dc machines or field
4. Ground the field leads to the shaft after disconnecting the megger for windings.
a minimum of 1 minute. This will allow the voltage build up to be
properly discharged.
Main stator
1. Disconnect power connections and all control apparatus from the

generator terminals.
2. Measure insulation resistance of each phase separately with the two

other phases shorted to the frame.
3. Use a megger connected between the lead(s) of the phase to be

measured and generator frame. The minimum 1-minute insulation
resistance must not be less than 50 megohms. (See Table 5).
Caution: Do not apply heat too rapidly. It
could damage the windings.
4. Ground the leads to the frame after the 1-minute megger test. This
will allow the voltage build up to be properly discharged.
Page 35
Caution: Do not apply heat too rapidly. It Dry out procedures
could damage the windings. If the insulation resistance readings are below the recommended mini-
mum values specified previously, use one of the dry out procedures
described below. Select the procedure based on the size and location
of the unit, available equipment, and experience of personnel. Before
drying, remove the voltage regulator, and cover all inlet and discharge
openings. Provide an opening at the top of the machine, preferably at the
fan end, for moisture to evaporate.
Drying with external heat: Place heat lamps, space heaters (in addition
to the ones already supplied) or a steam pipe near the windings. Monitor
winding temperatures. Raise winding temperature gradually at a rate
of 10-20° F (-12° to -6° C) per hour up to 200° F (93° C). Measure
insulation resistance at 1-hour intervals. Typically the insulation
resistance will slowly drop while the temperature is coming up, and then
gradually increase and level out.
Drying with AC current in the armature: Short circuit the generator

terminals. Provide DC excitation to the brushless exciter field winding.
Insert a current transformer and an ammeter to read full load current.
Run the generator at rated speed. Apply excitation to the exciter field
until rated current is developed. Monitor winding temperatures until they
stabilize. Continue running until insulation resistance values level off.
Monitor winding temperatures. Raise winding temperature gradually at a
rate of 10-20° F (-12° to -6° C) per hour up to 200° F (93° C). Measure
insulation resistance at 1-hour intervals. Typically, the insulation
resistance will slowly drop while the temperature is coming up and then
gradually increase and level out.
Note: For specific lubrication instructions, Bearing lubrication

always refer to the bearing lubrication sheet Shielded or sealed ball bearings: Shielded or sealed ball bearings are
that came with your manual or the lube plate factory packed with lubricants and generally can be operated several
on the generator. years without requiring replenishment or change of the grease. If
repacking the grease is necessary, disassemble the machine, clean the
bearings, and repack the bearings about 1/2 full using a high quality ball
bearing grease, which must be capable of lubricating satisfactorily over a
temperature range of the lowest ambient temperature to 250º F (121o C).
Regreaseable ball or roller bearings: In applications where regreaseable

bearings are used, grease fill fittings and relief valves are incorporated
into the bearing housing. Lubricate the bearings in accordance with the
lubricating instructions attached to the generator.
Sleeve bearings: Lubricate the bearings in accordance with the

lubricating instructions attached to the generator and the bearing
lubrication instructions, which are provided in the manual package as
supplementary material.
Page 36
Rectifier tests
If a failure of a rectifier is suspected, remove the exciter cover. Remove
the nut and washer holding the rectifier in the heat sink, and remove the
diode lead wire. Lift the rectifier from the heat sink (see figure 20 for
an overview). Test the entire rectifier with an ohmmeter or test lamp as
follows:
Negative
Positive
Positive
Figure 20: Rectifier
Ohmmeter: Connect the ohmmeter leads across the rectifier in one

direction (see Figure 21). Note the meter reading. Reverse the leads, and
note the meter reading. The meter should indicate a low resistance when
the leads are across the rectifier in one direction and a high resistance
when the leads are across the rectifier in the opposite direction. A low
resistance in both directions indicates a short. A high resistance in both
directions indicates an open rectifier.
Cathode
Ohmmeter
Anode
Reverse Standard
diode diode
Figure 21: Testing the rotating rectifier with an

ohmmeter
Page 37
Test lamp: Connect the leads of a test lamp, consisting of standard
flashlight batteries and a flashlight and built, as shown in Figure 22,
across the rectifier in one direction. Then reverse the leads. The light
should light in one direction but not the other. If the light lights in both
directions, the rectifier is shorted. If the light does not light in either
direction, the rectifier is open.
Figure 22 Test lamp
Replace defective rectifiers with rectifiers of the same operating

characteristics as rectifiers installed in the generator at the factory. Order
rectifiers by part number, including the model and type of exciter as well
as the generator serial number.
Surge protectors may be included on the rotating rectifier assembly.

Disconnect one lead of the surge protector, and connect the leads of an
ohmeter or makeshift test lamp, consisting of standard flashlight batteries
and a flashlight and built as shown in Figure 22, across the surge
protector in either direction.. If the light comes on, the surge protector
is defective. Order surge protectors by part number, including the model
and type of exciter as well as the generator serial number. Following
replacement, make sure that the revolving field, exciter armature, and
rotating diode leads are properly secured.
Page 38
Disassembly Note: The following procedures are meant
to be a general guide. Procedures for your
Overall disassembly unit may vary.
1. Remove the terminal box cover, and disconnect the load leads and
all other leads. Tag the leads to ensure they are correctly connected Warning: Ensure the generator has stopped
and is de-energized before disassembly.
when the generator is reassembled.
Warning: Use a hoist and slings or chains
2. Remove the bolts securing the generator to the base and prime to support components during removal. Use
mover, and move the generator to an area that allows sufficient room lifting devices that are selected for generator
for disassembly. component weights. Be extremely careful
not to damage components.
3. Remove the coupling or drive plates.
4. Remove the exciter cover.
5. Remove the clips securing the exciter field leads to the exciter frame
and endbracket. Disconnect the leads and remove the exciter frame/
stator and/or exciter-PMG frame/stator.
6. Remove the (optional) PMG and exciter armature as described

below.
7. Support the shaft. Remove the exciter-end endbracket bolts, and

remove the endbracket. Tap lightly with a rubber or fiber mallet
to loosen the endbracket if necessary. Repeat with the drive-end
endbracket (if applicable).
8. Remove the fan from the hub where applicable. If necessary, make
sure to mark the location of the fan for reinstallation.
9. Float out the rotor (see Figure 23). First attach a pipe over the shaft Warning: Make sure the pipe is strong
on the drive end. Attach slings around the pipe on one end and enough to support the weight of the rotor
around the shaft on the opposite end. Lift up the rotor, and move it and that it does not have rough edges on
out, resting the rotor as the slings are moved down the pipe for the the inside, which could damage the shaft.
next lifting stage.
Caution: To prevent tension on the shaft,
put the slings around the largest shaft step
possible.
Caution: Make sure the rotor does not

rest on the stator during the stages of
movement. Make sure the rotor does not hit
the stator.
Page 39
Figure 23: Floating the rotor
Exciter armature and PMG removal (see Figure 24)

1. Remove the exciter cover.
2. Remove the retaining bolt and washer.
3. Disconnect the field wires on the rotating rectifier assembly.
4. If the generator has a PMG rotor, pull it off separately using hand
Warning: Pull the PMG off straightly. The
force. Wrap the PMG rotor in plastic to avoid contamination with
assembly may pull toward other steel
components. Be careful that your fingers or metal filings. Note: Some inboard PMG assemblies use a locknut to
hands do not get pinched. secure the PMG rotor. See figure 26. To remove the PMG rotor with
a lock nut:
a) On the lockwasher, pry up the tab that is bent down in a notch of

the locknut. Then unscrew the locknut with a spanner wrench,
Caution: Ensure the generator field wires and remove the lockwasher.
are flat in the wireway so they don’t tear
during pulling. Do not pull on the edges of b) Pull the PMG rotor straight back. Take care not to cock the PMA
the heat sinks or on the exciter armature when pulling it off.
windings.
c) Wrap the PMG rotor in plastic to avoid contamination with metal
filings.
5. Slowly pull the armature assembly off of the generator shaft. If the
exciter can not be pulled off by hand, use a hydraulic jack as shown
in Figure 25.
6. Remove the key from the keyway in the generator shaft.
Page 40
PMG aligning
pin Hole in sleeve for field
wires (some models
PMG may have a slot) Retaining
Retaining Rectifier
washer
Retaining Field leads
bolts
A B Wire slot
Keyway
A B
PMG
Key
rotor
aligning Exciter arma- Shoulder
Exciter armature
ture
sleeve A-A end view of B-B cutaway view
exciter of shaft
Wire slot
Figure 24: Exciter armature assembly
Bolt holes
Shoulder
Key
Keyway
Plate
Figure 25: Pulling the armature assembly
Hydraulic jack
Exciter sleeve Threaded rod
Locknut
Figure 26: PMG rotor with locking nut
Lock washer and tab
Page 41
Bearing removal
1. Remove the endbracket(s) to expose the bearing(s).
2. Use a puller to remove the bearing from the shaft end with a cap. If
the bearing is going to be used again, make sure the puller supplies
pressure only against the bearing inner ring (see Figure 26).
Puller against Cap to protect shaft end

bearing
Caution: Make sure all components are

clean before assembly.
Note: Torque fasteners to the values speci-

fied in Table 3 unless otherwise specified.
Outer ring Inner ring
Figure 27: Pulling the bearing
Assembly
Bearing installation (done prior to installing the rotor)
1. Heat the bearing to 220º F (104o C) - 250º F (121o C) in a clean oven
or with an induction heater.
2. Start the heated bearing on the shaft. Then use a fiber or soft metal
tube to tap the bearing into place.
3. Ensuring that pressure is applied only to the bearing inner ring,

press the bearing onto the shaft until the inner ring seats against the
bearing shoulder on the shaft. Assemble the rest of the generator after
the bearing has cooled.
Page 42
Overall assembly
1. Float in the rotor until the rotor and stator laminations line up.
Position the rotor such that a full pole face is at the bottom.
2. Install the endbrackets. Support the rotor during installation. Put an

corrosion inhibitor on the bare mating surfaces to prevent rust.
3. Install the exciter armature and optional PMG as described below.
4. Install the covers.
5. Install the coupling or drive plates.
6. Reconnect the load leads and exciter leads.
Exciter armature and PMG installation (see Figure 24)

1. Clean the shaft and inside of the exciter sleeve.
2. Place the key in the slot in the shaft.
3. Lay the generator field wires flat in the wireway with the wire ends
protruding past the end of the shaft.
Caution: Do not pound on the rectifier or
armature windings.
4. Position the exciter armature assembly in line with the shaft, and turn
the assembly to the position where the keyway in the exciter sleeve is
in line with the key in the generator shaft.
5. With hand force, push the exciter armature assembly over the shaft,
so the end of the sleeve is against the shoulder on the shaft. When
it is part of the way onto the shaft, start the field lead wires through
the wire hole or slot in the exciter sleeve. It may be necessary to tap
lightly on the exciter sleeve in order to move the assembly over the
key. Use a fiber or rubber mallet. If installation is still a problem, use
a heat gun to expand the exciter sleeve.
6. Connect the exciter armature wires to the rectifier terminals.
7. If the generator has a PMG, place it onto the end of the exciter
sleeve. Make sure it is aligned with the pin slot in the end of the
exciter sleeve.
8. Install the retaining washer and bolt, and torque (60 ft-lbs for a 1/2-
inch diameter bolt; 200 ft-lbs for a 3/4-inch diameter bolt).
9. Install the exciter frame/stator and/or exciter-PMG frame/stator.

Install the clips securing the exciter field leads to the exciter frame
and endbracket and connect the leads.
Page 43
Note: To measure air gap, measure com- 10. Measure the air gap between the exciter armature and exciter field
pletely around the gap between the exciter and between the PMG rotor and PMG stator. If the air gap of the
armature and exciter field with a feeler armature is less than specified in Table 5 or if the air gap of the PMG
gauge. Keep the gauge at the tightest point, is less than 0.020 inch, check 1) generator-engine alignment, 2)
and turn the generator over to measure the check for bearing wear, 3) check for misalignment of the armature,
air gap as the rotor turns. PMG or stator.
Caution: Do not pry on the fan.
Exciter armature Minimum air gap
diameter (in.) (in.)
5 3/4 0.014
9 7/8 0.014
12 1/2 0.018
16 1/4 0.035
Table 5: Exciter air gap
11. Install the exciter cover.
Warning: If necessary, remove the covers Storage

around the space heaters to reduce the risk If the generator is not installed in its operating location as soon as
of fire. received, store it in a clean, dry area, not subject to vibrations or sudden
temperature or humidity changes. Make sure the storage area temperature
Caution: Grease used in ball and roller
bearing generators is subject to time is between 10º F (-12o C) and 120º F (49o C) and the relative humidity is
deterioration. Before placing the unit into less than 60%. If possible, storage should be in an ambient temperature
service after long-term storage, check the of approximately normal room temperature. Protect the shaft from
bearings for corrosion, and replace the corrosion by applying an anti-corrosion agent. Cover the unit with a
grease. durable cover.
Prepare units that cannot be stored in a temperature and humidity

controlled area as follows:
Install desiccant bags in the exciter cover and inside the end bells.
Vacuum seal the unit in a covering of plastic or other material designed

for that purpose.
Adequately tag the generator to ensure that preservative greases and

desiccant bags are removed before the unit is placed in operation.
If space heaters are supplied, energize them to keep condensation from

the windings.
For storage longer than 2 months, rotate the shaft a minimum of 10

revolutions every 60 days.
When the unit is taken out of storage, check the insulation resistance on
all windings. (See the maintenance section).
Page 44
Troubleshooting Guide
(corrective maintenance)
Between regular preventive maintenance inspections, be alert for any Warning: Problems left uncorrected can
signs of trouble. Correct any trouble immediately. See Table 6 for result in injury or serious damage, which can
symptoms, causes and remedies. result in costly repairs and downtime.
Symptom Cause Remedy

No Voltage Open voltage regulator, circuit breaker or Check. Reset the circuit breaker or replace
fuses fuses if open.
Overvoltage, undervoltage, or overload Check for the cause of the abnormal condition.
devices tripped (when protective devices Correct any deficiencies. Reset devices.
are incorporated into the circuit) Check the generator nameplate for nominal
operating values.
Open circuit in exciter field Check continuity of shunt field and leads
to voltage control. (Use ohmmeter or
wheatstone bridge) If open in field coils,
remove exciter field assembly and return
assembly to factory for repair.
Loss of residual magnetism in exciter Restore residual magnetism or flash field. When
field poles the voltage regulator is a model that requires
flashing, install an automatic field flashing
system.
Open circuit in stator windings Check for continuity in the windings. Return the
generator to the factory for repair if open.
Malfunction of automatic voltage See troubleshooting of voltage regulator.
regulator Correct deficiencies.
Short-circuited generator output leads Clear lead to restore voltage buildup.
Open in rotating rectifiers Check rotating rectifiers, and replace if
open.
Open in generator field Check for continuity and return rotor to
factory for repair if field coils are open.
Shorted or grounded surge protector Check for shorts or grounds. Replace .
Shorted or grounded rotating rectifier Check for shorts grounds. Replace or repair.
Shorted or grounded exciter armature Check for shorts or grounds. Replace or repair.
Low voltage Shorted leads between the exciter armature Test and repair.
and generator field
Incorrect stator connections Check the connections, and reconect
Page 45
Low voltage Improper adjustment of voltage adjust Adjust rheostat.
(cont.) rheostat
Excessive load Reduce load. With three-wire, single-phase and
four-wire, three-phase generators, the load on
each leg must be as evenly balanced as possible
and must not exceed the rated current on any leg.
Line loss Increase the size of the line wire.
High resistance connections (hot) Make better connections.
Shorted main or exciter field Test the field coils for possible short by
checking resistance with an ohmmeter or
resistance bridge. Return the rotor assembly
to the factory for repair if field coils are shorted.
Low power factor Reduce inductive (motor) load. Some AC
motors draw approximately the same
current regardless of load. Do not use
motors of larger horsepower rating than
is necessary to carry the mechanical
load.
Weak field due to operating in a warm Improve the ventilation of the generator.
temperature Field current can be increased providing
the generator temperature rating
stamped on the nameplate is not
exceeded.
Defective rectifiers in rectifier assembly Check rectifier assembly. Replace
(stationary) defective fuses or rectifiers.
Excessive load Reduce load to rated value.
Defective bearing Replace the bearing.
Improper speed of engine driven Check and correct deficiencies.
generator set due to defective governor,
ignition system, or carburetor
Voltage regulator not operating properly Check the regulator. Adjust, repair or replace.
Fluctuating Prime mover speed fluctuating Check frequency and voltage of incoming
voltage power when the generator set is motor
driven. Check engine governor on
engine-driven generator sets.
Loose internal or load connections Tighten all connections.
Generator overloaded Reduce load to rated value.
DC excitation voltage fluctuating Trace DC excitation circuit. Correct any
defects.
Overspeed Correct speed of prime mover.
High voltage Improper adjustment of voltage adjust Adjust rheostat and/or voltage regulator.
rheostat or voltage regulator
Page 46
Overheating Clogged ventilating screens and air Clean all screens and air passages.
passages
Dry or defective bearings Replace defective bearings.
Coupling misaligned Align the generator set.
Generator field coils shorted or Test field coils for shorts. Replace
grounded shorted rotor or return it to the factory for
repair.
Unbalanced load or overload, low PF Adjust load to nameplate rating.
Vibrations Defective or dry bearings Replace defective bearings.
Misalignment of generator and prime Align the generator set.
mover
Generator not properly mounted Check mounting. Correct defective
mounting.
Transfer of vibration from another Isolate the generator set from the source of
source vibration by installing vibration dampeners
between generator set base and foundation.
Table 6: Troubleshooting
Page 47
Appendices
List of equipment required for installation and maintenance:
Test equipment Notes

Ammeter Clamp-on, 0 to 500 amp range for measuring of electrical current.
Multimeter Digital, for measuring voltage, current, frequency and resistance.
Thermometer For measuring temperature in Celsius
Megger To measure insulation resistance.
Resistive Bridge To measure resistance of windings.
Special tools
Bearing puller For changing bearing.
Exciter puller For pulling exciter armature
Standard tools
Cable tool Crimping
Flashlight As required
Grease gun For lubricating bearings
Hammer Soft-faced
Lamp (incandescent) Safety light
Screwdrivers Standard, sized as required
Screwdrivers Phillips, sized as required
Wrench Adjustable, 12-inch
Wrench Torque 0 to 100 ft-lb
Wrench set Allen, 1/8 to 1/2 inch
Wrench set Socket, 1/4 to 1 Inch with 3/8 and 1/2 inch drive
Wrench set Standard, open-end/box-end combination sized 1/4 to 1 inch
Vacuum Electric with nonmetallic nozzle
Materials
Air Compressed, dry.
Corrosion inhibitor Nox-Rust VC #10 Oil or equivalent
Covering material Waterproof desiccant bags for protection from
moisture during long-term equipment storage
Detergent As required for cleaning
Gloves Chemical-protective
Gloves Electrical-protective
Heaters Space Heater, for eliminating excess moisture in damp areas and dry
out of motor or generator windings
Plastic Protection for long-term storage
Rags As required for cleaning
Water Warm and clean, for cleaning
Tags Warning and cautions
Page 48
Main part location
Exciter cover
Exciter stator
Lead connection
box
Drip proof Rectifier

cover
Fan
Adapter
Exciter
armature
Endbracket
Rotor
Coupling Stator windings

hub
Feet
Bearing
Page 49
FOR
INRUSH CURRENT
REDUCTION MODULE
ICRM-7, ICRM-15
INTRODUCTION
The Inrush Current Reduction Module (ICRM) prevents damage to a protected voltage regulator during power-up
by limiting inrush current to a safe level. Without inrush protection, the inrush current is limited only by the level of
the power source impedance. The lower the impedance, the greater the risk of damaging the regulator from
excessive inrush current. Devices with a pulse-width modulated (PWM) power stage are especially vulnerable to
high inrush current due to a large amount of capacitance inherent to the design. However, voltage regulators that
use SCR-type power stages do not require the protection of an ICRM since these regulators do not have a large
amount of capacitance in the power stage.
When a voltage regulator with a PWM power stage is energized, the ICRM limits the inrush current by adding a
high level of resistance in series with the voltage regulator power input. Once the inrush current subsides, the
series resistance diminishes quickly to allow nominal, steady-state current flow.
APPLICATION
Applications where a voltage regulator is powered by a permanent magnet generator (PMG), auxiliary winding, or
generator output (shunt fed) usually do not require the protection of an ICRM. These sources usually have a
higher source impedance which inherently minimizes inrush current. Also, these sources are typically connected
directly to the voltage regulator with no interposing relays, contactors, or switches. If this is the case, then no
inrush occurs since the source voltage ramps up to its rated value.
However, if rated or near rated voltage is applied to the voltage regulator, then some amount of inrush current is
expected and an ICRM should be considered. Typically, voltage regulators in these applications receive power
from a station service bus that is switched by a relay or contactor. Applications where a PWM type voltage
regulator is powered by a low-impedance source need an ICRM to minimize the amount of inrush current.
To summarize, if the voltage that powers the voltage regulator ramps up to nominal as the generator comes up to
rated speed, then an ICRM is not needed. If this is not the case, an ICRM should be used. If you are unsure
whether your application requires an ICRM, contact Basler Electric Technical Sales Support for assistance.
ICRM Versions
Two versions of the ICRM are available. Each version is uniquely suited to protect a specific family of Basler
Electric products. Table 1 lists each ICRM model, its part number, and the compatible products.
Table 1. ICRM Cross-Reference

Model Number Part Number Compatible Products
ICRM-7 9387900103 DECS-100
ICRM-15 9387900104 AVC63-12, AVC125-10, DECS-200
CAUTION
If operating power is removed from an energized ICRM, a minimum interval of
five minutes should elapse before operating power is restored. This cool-down
interval allows the ICRM to regain its ability to limit inrush current.
SPECIFICATIONS
The following electrical and physical specifications, type tests, and certifications apply to the ICRM.
Publication Revision First Printing: 02/05 Copyright

9387900990 A Revised: 08/05 2005
Electrical Specifications
Input Voltage: 90 to 277 Vac, 90 to 300 Vdc
Input Frequency: dc, 50 to 420 Hz
Input Current
ICRM-7: 9 Aac
ICRM-15: 18 Aac
Power Dissipation: 25 W
Physical Specifications
Temperature
Operating: –25 to 70°C (–13 to 158°F)
Storage: –40 to 70°C (–40 to 158°F)
Dimensions: Refer to Figure 1
Weight: 227 g (8 oz)
Type Tests
Dielectric: Withstands 2,000 Vac for one minute in accordance with IEC 60255-5.
Shock: Withstands 15 G in three perpendicular planes in accordance with IEC 60255-21-1.
Vibration: Tested in accordance with IEC 60255-21-2. Withstands 2 G in each of three mutually
perpendicular axes, swept over the range of 10 to 500 Hz for a total of six sweeps, 15
minutes each sweep.
Humidity: Qualified to IEC 68-1, IEC 68-2-28.
Certifications
UL Recognition: cURus recognition per UL Standard 508 and CSA Standard C22.2 No. 14.
CE Qualification: This product meets or exceeds the standards required for distribution in the European
community.
INSTALLATION
The ICRM may be installed in any environment where the conditions do not exceed the capabilities listed in the
Specifications section.
Mounting
For maximum cooling, the ICRM should be mounted on a vertical surface and oriented so that the ventilation
holes are located at the top and bottom of the unit.
CAUTION
Case may become hot during operation.
Figure 1 shows the ICRM mounting dimensions. Mounting dimensions are identical for both ICRM models.
Dimensions are shown in inches with millimeters in parenthesis.
Connections
Figure 2 illustrates typical connections for an application using single-phase operating power. The ICRM is not
phase sensitive. Figure 3 illustrates typical connections for an application using three-phase operating power.
Table 2 lists the terminal connections for each voltage regulator that is compatible with the ICRM.
Table 2. ICRM Terminals Cross-Reference
ICRM Output Terminals
Voltage Regulator A-OUT B-OUT C-OUT
AVC63-12, AVC125-10 26 28 30
DECS-100 3 4 5
DECS-200 C2 C3 C4
Page First Printing: 02/05 Revision Publication
2 Revised: 08/05 A 9387900990
Wiring requirements are subject to the specifications of the voltage regulator. Refer to the appropriate device
instruction manual for wire sizing, fuse recommendations, and terminal designations.
TROUBLESHOOTING
The ICRM contains no serviceable components. Replacement of the ICRM is recommended in the event of a
failure.
If the protected device is not receiving operating power, check the following:
• Verify that the ICRM connections between the power source and voltage regulator are correct.
• Confirm that the voltage supplied by the power source is sufficient to energize the voltage regulator.
If operating power is applied to the input terminals of the ICRM but voltage is not present at the output terminals,
remove operating power, disconnect all ICRM wiring, and perform the following procedure.
1. Connect a suitable ohmmeter across the A-IN and A-OUT terminals. The resistance measured across the IN
and OUT terminals should be approximately 2.0 ohms for the ICRM-7 and 0.5 ohms for the ICRM-15. If an
open circuit or short circuit is detected, the ICRM should be replaced.
2. Repeat Step 1 for the B-IN and B-OUT pair of terminals and the C-IN and C-OUT pair of terminals.
Figure 1. ICRM Dimensions
Publication Revision First Printing: 02/05 Page

9387900990 A Revised: 08/05 3
Figure 2. Typical ICRM Connections, 1-Phase Operating Power
Figure 3. Typical ICRM Connections, 3-Phase Operating Power
Page First Printing: 02/05 Revision Publication

4 Revised: 08/05 A 9387900990
INSTRUCTION MANUAL
for
DECS-100
Digital Excitation Control System
Publication: 9 2875 00 991

Revision: E 03/04
INTRODUCTION
This instruction manual provides information about the operation and installation of the DECS-100
Digital Excitation Control System. To accomplish this, the following information is provided.
C General Information and Specifications
C Human-Machine Interface
C Functional Description
C Installation
C BESTCOMS Communication Software
C Troubleshooting
WARNING!
To avoid personal injury or equipment damage, only qualified personnel should
perform the procedures in this manual.
Lethal voltage is present at the rear panel when the unit is energized. Rear
panel connections should be made only when the unit is de-energized.
CAUTION
The Manual mode excitation level must be evaluated prior to enabling this
feature. If the level of excitation current is inappropriate for the generator, severe
damage to the generator may occur.
Improper PID numbers will result in poor system performance or system
damage.
When applying operating power to the DECS-100 for programming purposes,
observe the precautions called out in Section 4, Installation, Preliminary Setup.
When programming the DECS-100 without the generator spinning, the
connections to DECS-100 terminals F+ and F– should be removed.
Before uploading a settings file, remove operating power from the DECS-100,
disconnect the field wiring from terminals F+ and F–, and re-apply operating
power to the DECS-100.
NOTE
Be sure that the DECS-100 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 unit.
DECS-100 Introduction i
First Printing: March 2001
Printed in USA
Copyright © 2004 Basler Electric, Highland, IL 62249 USA
March 2004
CONFIDENTIAL INFORMATION
of Basler Electric, Highland, IL. It is loaned for confidential use, subject to return
on request, and with the mutual understanding that it will not be used in any
manner detrimental to the interest of Basler Electric.
It is not the intention of this manual to cover all details and variations in equipment, nor does this
manual provide data for every possible contingency regarding installation or operation. The availability
and design of all features and options are subject to modification without notice. Should further
information be required, contact Basler Electric.
BASLER ELECTRIC
ROUTE 143, BOX 269
HIGHLAND, IL, 62249 USA
http://www.basler.com, info@basler.com
PHONE 618-654-2341 FAX 618-654-2351
ii DECS-100 Introduction
PRODUCT REVISION HISTORY
The following information provides a historical summary of the changes made to the DECS-100
embedded firmware, hardware, and BESTCOMS software. The corresponding revisions made to this
instruction manual (9 2875 00 991) are also summarized. Revisions are listed in chronological order.
Firmware
Version and Date Change
1.09.XX, 01/01 • Initial release
1.11.XX, 07/01 • Enabled the protection function during the first five seconds of
operation.
• Modified the OEL setpoint scale factor to be compatible with
BESTCOMS version 1.03.00.
• Added the scale factor for per unit gain.
• Established minimum voltage regulation at 30 percent of nominal
sensing voltage.
1.12.XX, 03/02 • Added register to detect CT type.
BESTCOMS for
Windows® OS
1.03.XX, 08/01 • Changed OEL scale from 100 to 1,000 to match the change in
firmware version 1.11.01.
• Changed OEL default setting from 1 to 15.
• Changed the default for all protection functions to enabled.
• Added support for French regional settings.
1.04.XX, 04/02 • Made BESTCOMS compatible with all older firmware versions.
• Added support for all regional settings.
• Enabled reading of secondary CT Value for units with firmware version
1.12.01 and higher.
• Simplified the Analysis screen.
• Added feature to calculate and send voltage matching reference for
different generator and bus PT ratios.
• Changed minimum Ki setpoint from 0 to 0.01.
BESTCOMS for
Palm OS®
1.02.XX, 08/01 • Added a Check for New Version button to the Contact Basler screen
• Added a date/time stamp to the “Save to File” names
• Added version checking
1.03.XX, 04/02 • Added password protection

• Improved version checking function
DECS-100 Introduction iii

Hardware
E, 01/01 • Initial release
F, 05/01 • Deepened potting shell
G, 10/01 • Began supplying mounting screws
H, 02/02 • SIL-PADS were added between some power components and the heat
sinks.
• Added manufacturing origin to the rear label.
J, 07/02 • Revised EEPROM
K, 02/03 • Replaced transistor Q8B1 with an improved part
L, 03/03 • Incremental improvements to firmware and BESTCOMS
M, 01/04 • Improved flash memory retention
Manual
Revision and Date Change
None, 03/01 • Initial release
A, 03/01 • In Section 5, BESTCOMS Software for the Windows® Operating

System and Section 6, BESTCOMS Software for the Palm OS®
Platform, Step 2 of Installing BESTCOMS was revised to reflect the
addition of an auto-start utility for the DECS-100 CD-ROM.
B, 08/01 • Added Embedded Software subsection to Section 5, BESTCOMS

Software for the Windows Operating System.
• Corrected various minor errors throughout the manual.
C, 05/02 • Revised the torque specification for the mounting screws supplied with
the unit.
• In Section 5, BESTCOMS Software for the Windows® Operating
System and Section 6, BESTCOMS Software for the Palm OS®
Platform, text and illustrations were revised to accommodate software
enhancements.
D, 01/03 • Revised Voltage Matching Time Adjustment Range from 0 to 300

seconds to 1 to 300 seconds through manual.
• Corrected figure number references in Sections 5 and 6.
E, 03/04 • Added Operating Power Considerations During DECS-100

Programming to Section 4, Installation, Preliminary Setup.
• Added caution box regarding application of operating power during
DECS-100 programming to Section 5, BESTCOMS for Windows® OS
and Section 6, BESTCOMS for Palm OS®.
• Corrected CT ratio setting range stated in Section 5.
iv DECS-100 Introduction
CONTENTS
A detailed table of contents is provided at the start of each manual section. The manual sections are
ordered as follows.
Section 1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Section 2 Human-Machine Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Section 3 Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Section 4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Section 5 BESTCOMS Software for the Windows® Operating System . . . . . . . . . . . . . . 5-1
Section 6 BESTCOMS Software for the Palm OS® Platform . . . . . . . . . . . . . . . . . . . . . . 6-1
Section 7 Maintenance and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
DECS-100 Introduction v
SECTION 1 • GENERAL INFORMATION
TABLE OF CONTENTS
SECTION 1 • GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
MODEL AND STYLE NUMBER DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Style Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Operating Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Generator Voltage Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Generator Current Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Bus Voltage Sensing (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Accessory Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Communication Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Contact Input Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Common Alarm Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Field Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
AVR Operating Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
FCR (Manual) Operating Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Var Operating Mode (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
PF Operating Mode (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Parallel Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Field Overvoltage Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Field Overcurrent Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Generator Overvoltage Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Soft-Start Function (AVR Mode Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Voltage Matching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Metering (BESTCOMS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Type Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Physical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
UL Recognition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
CSA Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
CE Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Patent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Figures
Figure 1-1. DECS-100 Style Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Figure 1-2. Typical V/Hz Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
DECS-100 General Information i

SECTION 1 • GENERAL INFORMATION
GENERAL
The Basler Digital Excitation Control System (DECS-100) is an electronic, solid-state, microprocessor based
control device. The DECS-100 regulates the output voltage of a brushless, ac generator by controlling the
current into the generator exciter field. Input power to the DECS-100 can be from a multi-pole, high-frequency,
permanent magnet generator (PMG) or from the generator output when used as a conventional, shunt-excited,
excitation system.
The DECS-100 is supplied in an encapsulated package designed for behind-the-panel mounting. The
DECS-100 is held in place by thread-forming screws that thread into its plastic shell. Front panel indicators
(LEDs) annunciate DECS-100 status and system conditions. DECS-100 connections are made through
quarter-inch, quick-connect terminals on the rear panel. A 9-pin DB-9 type connector on the rear panel
provides communication between the DECS-100 and an IBM compatible PC.
FEATURES
DECS-100 units have the following features and capabilities.
C Four control modes: automatic voltage regulation (AVR), manual or field current regulation (FCR), power
factor (PF) regulation, and reactive power (var) regulation.
C Programmable stability settings.
C Soft start and voltage buildup control with an adjustable ramp in AVR control mode.
C Overexcitation (OEL) limiting in AVR, var, and PF control modes.
C Underfrequency (volts/hertz) regulation.
C Three-phase or single-phase generator voltage (rms) sensing/regulation in AVR mode.
C Single-phase bus voltage (rms) sensing.
C Single-phase generator current sensing for metering and regulation purposes.
C Field current and field voltage sensing.
C One analog input for proportional remote control of the setpoint.
C Five contact sensing inputs for system interface.
C One common output relay for alarm indication and trip functions.
C Four protection functions (field overvoltage, field overcurrent, generator overvoltage, and loss of sensing).
C Generator paralleling with reactive droop compensation and reactive differential compensation.
C Rear RS-232 communication port for personal computer communication using BESTCOMS Windows®
based software for fast, user-friendly, setup and control.
MODEL AND STYLE NUMBER DESCRIPTION
General
DECS-100 electrical characteristics and operational features are defined by a combination of letters and
numbers that make up the style number. The model number, together with the style number, describe the
options included in a specific device, and appear on a label affixed to the rear panel. Upon receipt of a
DECS-100, be sure to check the style number against the requisition and the packing list to ensure that they
agree.
Style Number
Style number identification chart Figure 1-1 defines the electrical characteristics and operational features
available in the DECS-100.
DECS-100 General Information 1-1

Figure 1-1. DECS-100 Style Chart
For example, if the style number was A15, the device would have the following characteristics and operating
features.
A . . . . No var or power factor control
1 . . . . Voltage matching
5 . . . . 5 ampere CT secondary
SPECIFICATIONS
DECS-100 electrical and physical specifications are listed in the following paragraphs.
Operating Power Bus Voltage Sensing (Optional)–continued

Voltage: 88 to 250 Vac, single-phase or 50 Hertz Sensing
three-phase (L-L) Range 1: 100 Vac (85 to 132 Vac)
Frequency Range: 50 to 400 Hz Range 2: 200 Vac (190 to 220 Vac)
Burden: 650 VA Range 3: 400 Vac (380 to 440 Vac)
Terminals: 3, 4, 5 Range 4: N/A
Voltage Buildup: from a minimum of 6 Vac 60 Hertz Sensing
Generator Voltage Sensing Range 1: 120 Vac (85 to 132 Vac)
Type: 1-phase/3-phase, 4 ranges Range 2: 240 Vac (170 to 264 Vac)
Burden: <1 VA per phase Range 3: 480 Vac (340 to 528 Vac)
Terminals: E1, E2, E3 Range 4: 600 Vac (540 to 660 Vac)
50 Hertz Sensing Accessory Input
Range 1: 100 Vac (85 to 132 Vac) Voltage Range: –3 Vdc to +3 Vdc
Range 2: 200 Vac (190 to 220 Vac) Setpoint Range: –30% to +30% shift
Range 3: 400 Vac (380 to 440 Vac) Burden: 1 kS
Range 4: N/A Terminals: A, B
60 Hertz Sensing
Communication Port
Range 1: 120 Vac (85 to 132 Vac)
Range 2: 240 Vac (170 to 264 Vac) Interface: Full duplex RS-232
Range 3: 480 Vac (340 to 528 Vac) Connection: Rear panel DB-9 connector
Range 4: 600 Vac (540 to 660 Vac) Baud: 4800
Data Bits: 8
Generator Current Sensing Parity: None
Type: 1-phase (B-phase), 50/60 Hz Stop Bit: 1
Style X1X: 1 Aac maximum continuous
Contact Input Circuits
Style X5X: 5 Aac maximum continuous
Burden: <0.1 VA Type: Dry Contact
Terminals: CT1, CT2 Wetting Voltage: 13 Vdc (supplied by DECS-100)
Terminal Assignments for Standard Functions
Bus Voltage Sensing (Optional) Unit/Parallel Control: 52L, 52M
Type: 1-phase, 4 ranges Raise: 6U, 7
Burden: <1 VA per phase Lower: 6D, 7
Terminals: B1, B3
1-2 DECS-100 General Information

Contact Input Circuits–continued FCR (Manual) Operating Mode
Terminal Assignments for Optional Functions Adjustment Range: 0 to 7 Adc
Var/PF Enable: 52J, 52K Increment: 0.1 A
Voltage Matching: VM, VMC
Var Operating Mode (Optional)
Common Alarm Output Adjustment Range: 100% to –100%
Type: Form A Increment: 0.1%
Rated Load: 7 Aac/Adc continuous
PF Operating Mode (Optional)
Make: 30 Aac/Adc, carry for 0.2 sec
Adjustment Range: 0.6 lead to 0.6 lag
Break: 7 Aac/0.1 Adc
Increment: 0.001
Operating Voltage: 240 Vac/250 Vdc maximum
Terminals: AL1, AL2 Parallel Compensation
Modes: Reactive Droop and Reactive
Field Output
Differential (cross-current)t
Field Resistance: 5 S minimum
Droop Adjust Range: 0 to 10%
Terminals: F+, F–
Increment: 1%
Continuous Rating: 63 Vdc, 7 Adc
t Burden can exceed 1 VA if external resistors are
10 Second Forcing Rating added to the CT circuit.
200 Vac Power Input: 135 Vdc, 15 Adc
Field Overvoltage Protection
110 Vac Power Input: 90 Vdc, 10 Adc (9 S field)
75 Vdc, 15 Adc (5 S field) Pickup Range: 0 to 250 Vdc
Time Delay: 10 seconds (fixed)
AVR Operating Mode
Field Overcurrent Protection
Adjustment Range: See Generator Voltage Sensing
Voltage Regulation: ±0.25% over load range at Pickup
rated power factor and Range: 0 Adc to 15 Adc
constant generator frequency. Increment: 0.001 Adc
±0.5% with 3-phase sensing Time Delay
and shunt power at 40% THD Range: 0 to 10 seconds
of the voltage waveform (due Increment: 1 second
to a 6 SCR load).
Temperature Drift: ±0.5% for a 40°C change Generator Overvoltage Protection
V/Hz Characteristic: Slope from 0 to 3PU is adjust- Pickup 100% to 120% of system
able in 0.01PU increments. voltage setting
Transition (Corner) frequency Increment: 1.0%
is adjustable from 40 to 65 Hz. Time Delay: 0.75 seconds (fixed)
See Fig. 1-2 for V/Hz curves.
Response Time: Within 1 cycle Soft Start Function (AVR Mode Only)
Time Adjust Range: 1 to 7,200 seconds
Increment: 1 second
Voltage Matching
Accuracy: Generator rms voltage is
matched with the bus rms
voltage to within ±0.5% of the
generator voltage.
Time Adjustment
Range: 1 to 300 seconds
Increment: 0.01 seconds
Metering (BESTCOMS)
Generator Voltage
Range: 10 V to 79 kV
Accuracy: ±0.5% (at 25°C)
Generator Current
Range: 0.04 to 3,000 A (1 A CTs)
0.2 to 15,000 A (5 A CTs)
Accuracy: ±0.5% (at 25°C)
Figure 1-2. Typical V/Hz Curves
DECS-100 General Information 1-3

Metering (BESTCOMS)–continued UL Recognition
Frequency Recognized per Standard 508, UL File E97035
Range: 40 to 65 Hz
CSA Certification
Accuracy: ±0.2 Hz (at 25°C)
Certified per Standard CAN/CSA-C22.2, Number 14-
Field Voltage
95, CSA File LR23131-139
Range: 0 to 200 V
Accuracy: ±5.0% (at 25°C) CE Compliance
Field Current Emissions
Range: 0 to 20 A CISPR11/EN55011, Level A
Accuracy: ±0.5% (at 25°C) Electrostatic Discharge (ESD)
Bus Voltage IEC 1000-4-2/EN 61000-4-2, Level B
Range: 10 V to 79 kV Radiated Susceptibility
Accuracy: ±0.5% (at 25°C) IEC 1000-4-3/EN 61000-4-3, Level A
Auxiliary DC Input Electrical Fast Transient
Range: –3 V to +3 V IEC 1000-4-4/EN 61000-4-4, Level B
Accuracy: ±0.5% (at 25°C) Radio Frequency–Conducted
Power (Apparent, Real, and Reactive) IEC 1000-4-6/EN 61000-4-6, Level A
Range: 0 to 99 MVA, MW, Mvar Power Frequency–Magnetic
Accuracy: ±3.0% (at 25°C) IEC 1000-4-8/EN 61000-4-8, Level A
Power Factor Dielectric
Range: –1.0 to –0.6, +0.6 to +1.0 IEC 255
Accuracy: ±0.02 at rated current (25°C)
Phase Angle Patent
Range: 0 to 360 degrees U.S. Patent Number 5294879
Accuracy: ±2.0 degrees (at 25°C)
Environment
Operating Temperature
DECS-100: –40°C to 70°C
(–40°F to 158°F)
Storage Temperature
DECS-100: –40°C to 85°C
(–40°F to 185°F)
CD-ROM: 0°C to 50°C
(32°F to 122°F)
Type Tests
Shock: 20 Gs in 3 perpendicular
planes
Vibration: 1.2 Gs at 5 to 26 Hz
0.914 mm (0.036") double
amplitude at 27 to 52 Hz
5 Gs at 53 to 500 Hz
Salt Fog: Tested per MIL-STD-810E
Physical
Weight
Unit: 1.10 kg (2.42 lb)
Shipping: 1.31 kg (2.88 lb)
Shipping Carton Dimensions (W x H x D)
Single Unit: 299 mm x 79 mm x 146 mm
(11.75" x 3.125" x 5.75")
48 Units: 841 mm x 653 mm x 352 mm
(33.13" x 25.69" x 13.88")
1-4 DECS-100 General Information

SECTION 2 • HUMAN-MACHINE INTERFACE
TABLE OF CONTENTS
SECTION 2 • HUMAN-MACHINE INTERFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
FRONT PANEL INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
COMMUNICATION PORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Figures
Figure 2-1. DECS-100 Front Panel Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Figure 2-2. DECS-100 Communication Port Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Tables
Table 2-1. DECS-100 Front Panel Indicator Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
DECS-100 Human-Machine Interface i

SECTION 2 • HUMAN-MACHINE INTERFACE
GENERAL
The DECS-100 human-machine interface (HMI) consist of front panel indicators and a rear panel
communication port.
FRONT PANEL INDICATORS

DECS-100 front panel indicators consist of seven red LEDs. Figure 2-1 shows the front panel indicators for
the DECS-100. Table 2-1 describes the function of each front panel indicator.
Figure 2-1. DECS-100 Front Panel Indicators
Table 2-1. DECS-100 Front Panel Indicator Descriptions

Indicator Description
Overexcitation Shutdown This LED lights when the Overexcitation Protection feature is enabled
and the field voltage exceeds 100 Vdc for 10 seconds. The DECS-
100 will shutdown when an overexcitation condition is detected. The
Overexcitation Shutdown LED will light for 5 seconds when the
DECS-100 is powered up following an overexcitation shutdown.
Generator Overvoltage This LED lights when generator output voltage exceeds the
adjustable setpoint for 0.75 seconds. When a generator overvoltage
condition exists, the DECS-100 output contacts close and the DECS-
100 shuts down (if hardware shutdown is enabled). The Generator
Overvoltage LED will light for 5 seconds when the DECS-100 is
powered up following a generator overvoltage shutdown.
DECS-100 Human-Machine Interface 2-1

Indicator Description
Loss of Generator Sensing This LED lights when a loss of generator sensing voltage is detected.
When a loss of sensing condition occurs, the DECS-100 output
contacts close. Depending on the protective action selected, the
DECS-100 will either shutdown or transfer to Manual mode. The Loss
of Generator Sensing LED will flash for 5 seconds when the DECS-
100 is powered up following a loss of generator sensing shutdown.
Overexcitation Limiting This LED lights when the field current exceeds the programmed
overexcitation limit. It stays lit until the overexcitation condition
ceases or the overexcitation time delay expires and the DECS-100
shuts down. The Overexcitation Limiting LED will flash for 5 seconds
when the DECS-100 is powered up following an overexcitation
limiting shutdown.
Var/P.F. Mode Active This LED lights to indicate that the DECS-100 is operating in the
optional Var or Power Factor mode of control. Var/Power Factor
control is enabled through BESTCOMS software and when the 52J/K
contact input is open.
Manual Mode Active This LED lights when the DECS-100 is operating in Manual mode.
Manual mode is enabled through BESTCOMS software.
Underfrequency Active This LED lights when the generator frequency decreases below the
underfrequency setpoint and the DECS-100 is regulating on the
selected volts per hertz curve.
COMMUNICATION PORT
The 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 DECS-100. Figure 2-2 illustrates the location of the
communication port.
Programming requires a standard 9-pin serial communication
cable connected between the DECS-100 and an IBM-compatible
PC or handheld computer operating with BESTCOMS software.
BESTCOMS software is a Microsoft Windows®-based communi-
cation software package that is supplied with the DECS-100. A
detailed description of BESTCOMS software is provided in
Section 5, BESTCOMS Software for the Windows® Operating
System.
WARNING!
Lethal voltage is present at the rear panel when the unit is
energized. Rear panel connections should be made only
when the unit is de-energized.
Figure 2-2. DECS-100

Communication Port Location
2-2 DECS-100 Human-Machine Interface
SECTION 3 • FUNCTIONAL DESCRIPTION
TABLE OF CONTENTS
SECTION 3 • FUNCTIONAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
DECS-100 FUNCTION BLOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Analog Input Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Bus Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Generator Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Phase B Line Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Accessory Input (Auxiliary Adjust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Field Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Field Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Contact Input Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Raise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Var/Power Factor Control (52J/K) Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Parallel Generator Compensation (52L/M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Voltage Matching Control Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
RS-232 Communication Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Microprocessor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Power Input Stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Power Amplifier Stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Front Panel Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Relay Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
DECS-100 OPERATING FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Automatic Voltage Regulation Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Var Control Mode (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Power Factor Control Mode (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Reactive Droop Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Underfrequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Overexcitation Shutdown (Field Voltage) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Generator Overvoltage Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Loss of Generator Sensing Shutdown or Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Overexcitation Limiting (Field Current) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Soft Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Voltage Matching (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Figures
Figure 3-1. Simplified Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
DECS-100 Functional Description i

SECTION 3 • FUNCTIONAL DESCRIPTION
INTRODUCTION
This section describes how the DECS-100 functions and explains its operating features. To ease
understanding, DECS-100 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 DECS-100 Function Blocks.
DECS-100 operating features include four operating modes, four protective functions, startup provisions,
reactive droop compensation, underfrequency compensation, and optional voltage matching. A detailed
description of each operating feature is provided in the paragraphs under the heading of DECS-100 Operating
Features.
Figure 3-1. Simplified DECS-100 Block Diagram
DECS-100 FUNCTION BLOCKS

The following paragraphs describe each of the function blocks illustrated in Figure 3-1. The function of each
block is explained along with the operation of all function block inputs and outputs.
Analog Input Circuits

Seven analog voltage and current inputs may be sensed and brought to the DECS-100 input.
Bus Voltage
C-phase and A-phase bus voltages are monitored at terminals B3 and B1 on units that include Voltage
Matching. Nominal voltages of up to 600 Vac may be sensed at these terminals. Voltage monitored at this
input is scaled and conditioned before being applied to the input of the analog-to-digital converter (ADC). This
bus voltage signal applied to the ADC is used to calculate the Rms value of the bus voltage across phases
C and A (Bus VC-A).
DECS-100 Functional Description 3-1

Generator Voltage
Generator voltage is monitored at terminals E1 (A-phase), E2 (B-phase), and E3 (C-phase). Nominal voltages
of up to 600 Vac 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. Likewise, the
voltage signal from phase C and B (VC-B) of the generator is used by the ADC to calculate the Rms value of
generator voltage across phases C and B. The Rms value of generator phase B to phase A voltage (VB-A) is
calculated by the microprocessor from the phase C to phase A signal (VC-A)and the phase C to phase B (VC-B)
signal.
Additionally, the generator phase C to phase A (VC-A) signal is applied to a filtered zero cross detector circuit.
This signal is applied to the microprocessor and is used to calculate generator frequency.
Phase B Line Current

The phase B line current (IB) signal is developed through a customer supplied current transformer (CT) and
monitored through terminals CT1 and CT2. Depending on the option selected, current up to 1 ampere (style
number xx1) or 5 amperes (style number xx5) rms may be monitored at these terminals. The current
monitored at these terminals is scaled and conditioned by an internal current transformer and active circuitry
for use by the ADC. The signal applied to the ADC is used to calculate the rms value of phase B line current.
Additionally, the phase angle between phase B line current and phase C to phase A generator voltage is
calculated for use during Droop and Var/Power Factor operation.
Accessory Input (Auxiliary Adjust)

This input allows adjustment of the DECS-100 regulation setpoint by the application of a positive or negative
dc voltage across terminals A and B. Positive voltage applied to terminal A with respect to terminal B will
cause the active mode setpoint to increase. Voltage from –3 to +3 Vdc may be applied to this input. The circuit
induces a 1,000-ohm burden on the dc source. The Application of a ±3 Vdc signal corresponds to a ±30
percent change in setpoint.
Field Voltage
Voltage (VFIELD) across the regulator field output terminals, F+ and F–, is monitored, scaled, and
conditioned before being applied to the ADC. This signal is used to calculate the dc value of field voltage
for use in system protection.
Field Current
Current (IFIELD) through the main power output switch is converted to a proportional voltage level. This voltage
signal is scaled and conditioned before being applied to the input of the ADC. The result is used to calculate
the dc value of field current for use in the Manual mode of operation as well as protection of the system.
Contact Input Circuits

Five contact input circuits powered from an internal 13 Vdc power supply provide input control from user-
supplied, isolated, dry-type contacts.
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.
Var/Power Factor Control (52J/K) Option

Closing a contact across terminals 52J and 52K disables var/power factor control. An open contact enables
the DECS-100 to control the generator reactive power in either the var or the power factor mode. The contact
3-2 DECS-100 Functional Description

has no effect when this function is not enabled in the software. For more information, see Parallel Generator
Compensation (52L/M) and Voltage Matching Control Option.
Parallel Generator Compensation (52L/M)
Closing a contact across terminals 52L and 52M disables parallel operation. An open contact enables parallel
operation and the DECS-100 operates in reactive droop compensation mode.
If the Var/Power Factor Control option is present and is enabled in the software, the 52J/K input has priority.
Therefore, if the 52J/K and the 52L/M inputs are both open, the system operates in var/power factor mode.
For more information, see Voltage Matching Control Option.
Voltage Matching Control Option
If the Voltage Matching option is enabled in the software, closing a contact across terminals VM and VMC
causes the DECS-100 to operate in the voltage matching mode. An open contact disables voltage matching.
Voltage matching is also disabled when either the 52J/K or 52L/M inputs are open.
RS-232 Communication Port

The communication port provides the interface for user programming (setup) of the DECS-100. Connection
is made to the female RS-232 (DB-9) connector with a user-supplied, standard 9-pin cable. The
communication port is optically isolated and is powered from a transformer-isolated supply.
Microprocessor
The microprocessor is the heart of the DECS-100 and performs measurement, computation, control, and
communication functions by the use of its embedded programming and the nonvolatile settings stored in its
memory.
Power Input Stage

Input power applied to terminals 3, 4, and 5 is rectified and filtered before being applied to the power amplifier
and the power supply. Input power may be single-phase or three-phase in the range of 88 to 250 Vac at a
frequency of 50 to 400 hertz.
The input power source should be properly fused for the application.
Power Supply
The internal switch-mode power supply receives power from the power input stage and supplies power at the
required dc voltage levels to the internal circuitry of the DECS-100.
Power Amplifier Stage

The power amplifier receives power from the power input stage and supplies a controlled amount of power
to the exciter field via terminals F+ and F–. The amount of power supplied to the exciter field is based on
gating pulses received from the microprocessor. The power amplifier uses a solid state power switch to
provide the required power to the exciter field. Power amplifier output to the field is rated up to 63 Vdc at 7 Adc
continuous and 135 Vdc at 15 Adc for 10 seconds.
Front Panel Indicators

Seven front panel LED indicators light to indicate various protective functions and operating modes. Section
2, Human-Machine Interface provides more information about the front panel indicators.
Relay Output
A common alarm output contact is provided through terminals AL1 and AL2. This normally open, form A
contact annunciates alarm or trip conditions. The relay output is non-latching.

DECS-100 OPERATING FEATURES
The following paragraphs describe the characteristics of each DECS-100 operating feature.
Operating Modes
The DECS-100 provides up to four modes of operation selectable through BESTCOMS software. Automatic
voltage regulation mode and Manual mode are standard features. Var and Power Factor modes are an option.
Automatic Voltage Regulation Mode

In Automatic Voltage Regulation (AVR) mode, the DECS-100 regulates rms generator output voltage. This
is accomplished by sensing generator output voltage and adjusting dc output excitation current to maintain
voltage at the regulation setpoint. The regulation setpoint is adjusted by the Raise and Lower contact inputs,
the Accessory input, or through BESTCOMS software. The regulation point may also be modified by the
Droop function or the Underfrequency function under certain conditions.
Manual Mode
In Manual mode, also known as Field Current Regulation (FCR) mode, the DECS-100 maintains dc excitation
current at a set level. The current-level setpoint is adjustable from 0 to 7 Adc in 0.1 Adc increments by the
Raise and Lower contact inputs, the optional Accessory input, or through BESTCOMS software.
CAUTION
The Manual mode excitation level must be evaluated prior to enabling this
feature. If the level of excitation current is inappropriate for the generator, severe
damage to the generator may occur.
Var Control Mode (Optional)

In Var Control mode, the DECS-100 maintains generator vars (volt-amperes, reactive) at a set level when
paralleling with an infinite bus. The DECS-100 calculates generator vars by using the sensed generator output
voltage and current quantities. It then adjusts the dc excitation current to maintain vars at the setpoint. Var
control is enabled and disabled through BESTCOMS software. When the software is turned on, var control
is enabled or disabled through the Var/Power Factor Control (52J/K) contact input circuit. The var setpoint is
adjustable from 100 percent absorb to 100 percent generate through the Raise and Lower contact inputs, the
optional Accessory input, or through BESTCOMS software.
Power Factor Control Mode (Optional)

In Power Factor Control mode, the DECS-100 maintains generator power factor at a set level when paralleling
with an infinite bus. The DECS-100 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 BESTCOMS software. When the software is
turned on, it is enabled or disabled through the Var/Power Factor Control (52J/K) contact input circuit. The
power factor setpoint is adjustable between 0.6 lag and 0.6 lead through the Raise and Lower contact inputs,
the optional Accessory input, or through BESTCOMS software.
Reactive Droop Compensation

The DECS-100 provides a reactive droop compensation feature to assist in the sharing of reactive load during
parallel generator operation. When this feature is enabled, the DECS-100 calculates the reactive portion of
the generator load using the sensed generator output voltage and current quantities and then modifies the
voltage regulation setpoint accordingly. A unity power factor generator load results in almost no change in
generator output voltage. A lagging power factor generator load (inductive) results in a reduction of generator
output voltage. A leading power factor generator load (capacitive) results in an increase of generator output
voltage. Droop is adjustable up to 10 percent with rated, nominal B-phase line current (1 ampere or 5 amperes
applied through terminals CT1 and CT2) and 0.8 power factor. The droop feature is enabled and disabled

through the Parallel Generator Compensation contact input circuit (terminals 52L and 52M). Droop is also
disabled when operating in var or power factor control modes.
Underfrequency
When generator frequency drops below the selected knee frequency setpoint, the voltage setpoint is
automatically adjusted by the DECS-100 so that generator voltage follows the selected PU (per unit) V/Hz
curve. When operating on the selected PU V/Hz curve, the UNDERFREQUENCY ACTIVE indicator lights on
the front panel and in BESTCOMS. Underfrequency control is disabled below 12 hertz. The knee frequency
is adjustable from 40 to 65 hertz in 0.1 hertz increments and the PU V/Hz curve may be set at a slope of 0
to 3 in 0.01 steps through BESTCOMS software. A slope of 0 effectively disables the underfrequency function.
The DECS-100 has a minimum regulation point of approximately 30 percent of the nominal setpoint.
Protection
The DECS-100 includes four protective functions: overexcitation shutdown, generator overvoltage shutdown,
loss of generator sensing shutdown or transfer, and overexcitation limiting. Each function has a corresponding
front panel indicator that lights when the function is active. An active function is also annunciated through
BESTCOMS software.
Overexcitation Shutdown (Field Voltage)

This function is enabled or disabled through BESTCOMS software. When enabled, if field voltage exceeds
the adjustable field overvoltage setpoint for 10 seconds, the OVEREXCITATION SHUTDOWN indicator on
the front panel and in BESTCOMS lights, the relay output closes, and the DECS-100 shuts down. When the
DECS-100 is powered up following an overexcitation shutdown, the OVEREXCITATION SHUTDOWN
indicator will light for 5 seconds. The Field Overvoltage setpoint is adjustable from zero to 250 Vdc in integer
steps.
Generator Overvoltage Shutdown

The DECS-100 monitors the sensed generator output voltage. If it exceeds the adjustable Generator
Overvoltage setpoint of the nominal setpoint for 0.75 seconds, the GENERATOR OVERVOLTAGE indicator
lights on the front panel HMI and in BESTCOMS, the relay output closes, and the DECS-100 shuts down.
When the DECS-100 is powered up following a generator overvoltage shutdown, the GENERATOR
OVERVOLTAGE indicator will light for 5 seconds. The Generator Overvoltage setpoint is adjustable from 100
to 120 percent in integer steps.
Loss of Generator Sensing Shutdown or Transfer

The DECS-100 monitors the sensed generator output voltage and takes protective action if a loss of sensing
voltage is detected. A loss of sensing voltage is detected during the following conditions.
C The sensed voltage is less than 50 percent of the rated voltage (one-phase or three-phase sensing).
C A total loss of any phase occurs (three-phase sensing).
C The voltage difference between any phase (line-to-line) and the three-phase average exceeds 20 percent
of nominal (three-phase sensing).
A time delay of zero to 25 seconds is adjustable through BESTCOMS software. This delays the protective
action in order to allow field forcing in applications that do not sense B-phase generator current. The default
time delay setting is 10 seconds.
BESTCOMS software allows the selection of one of two protective actions for a loss of sensing. Either a
complete shutdown or a transfer to Manual mode may be selected.
If shutdown is selected and a loss of sensing occurs, the LOSS OF GENERATOR SENSING indicator on the
front panel and in BESTCOMS lights, the relay output closes, and the DECS-100 shuts down after the
adjustable time delay expires. When the DECS-100 is powered up following a loss of generator sensing
shutdown, the LOSS OF GENERATOR SENSING indicator will light for five seconds. However, if the loss of
sensing conditions still exists, the DECS-100 will not shut down due to loss of sensing until the soft-start time
delay and the loss of sensing time delay expires.
If transfer to Manual is selected and a loss of sensing occurs, the relay output closes, and the DECS-100
transfers to the Manual mode of operation after the adjustable time delay expires. The DECS-100 will remain

in this mode of operation until switched via BESTCOMS. Prior to selecting transfer to Manual on loss of
sensing, it is necessary to determine an appropriate Manual (FCR) mode setpoint level to be transferred to.
An inappropriate excitation level could result in severe damage to equipment.
This function is disabled when the frequency decreases below 12 hertz or when a generator short circuit
condition is detected. A generator short-circuit is determined when the B-phase CT current exceeds three
times the per unit value. Loss of sensing shutdown or transfer is not active during the soft-start time.
Overexcitation Limiting (Field Current)

The DECS-100 field current limit is adjustable from 0 to 15 amperes in 0.1 ampere increments with an
adjustable time delay that has a range of 0 to 10 seconds in 1 second increments. Both settings are made
through BESTCOMS software. When the overexcitation limit is exceeded, the OVEREXCITATION LIMITING
indicator on the front panel and in BESTCOMS lights. When the adjustable time delay expires, the relay output
closes and the DECS-100 shuts down. When the DECS-100 is powered up following overexcitation limiting,
the OVEREXCITATION LIMITING indicator will light for 5 seconds.
Soft Start
The DECS-100 also incorporates an adjustable soft start feature that controls the time for generator voltage
or field current to ramp to the regulation setpoint. The ramp rate is adjustable from 1 to 7,200 seconds in 1
second increments through BESTCOMS. The underfrequency feature is also active during soft start and takes
priority in control of the generator voltage in an effort to minimize voltage overshoot.
Voltage Matching (Optional)

Voltage matching is useful when the PT ratios in an application are not matched exactly. The DECS-100
voltage matching option automatically matches the rms generator output voltage with the rms bus voltage prior
to synchronizing. The DECS-100 compares and matches the generator voltage with the bus voltage by
adjusting the dc excitation current. As long as the values of generator and bus voltage (applies to the DECS-
100 voltage sensing inputs) are within the same range, voltage matching can be achieved. (Refer to Section
1, General Information, Specifications for the four generator and bus sensing voltage ranges.) for Voltage
matching is automatically disabled if bus voltage is not within 10 percent of the nominal sensing range
selected. The voltage matching option is enabled and disabled through BESTCOMS software. When enabled
in BESTCOMS, voltage matching is enabled or disabled through external contacts connected to the voltage
matching contact input circuit. Using BESTCOMS to enter the generator PT ration and bus PT ratio will
automatically compensate for the offset. The voltage matching speed setting is adjustable from 1 to 300
seconds in 0.01 second increments. This setting changes the rate at which the DECS-100 matches the
generator input level with the bus input level.

SECTION 4 • INSTALLATION
TABLE OF CONTENTS
SECTION 4 • INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
DECS-100 Terminations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Bus Voltage Sensing Inputs (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Generator Voltage Sensing Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Phase B Line Current Sensing Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Accessory Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Raise and Lower Contact Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Var/Power Factor Control Contact Input (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Parallel Generator Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Parallel Control and Var/PF Control Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Voltage Matching (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Power Supply Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Chassis Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Power (Field) Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Relay Output (Alarm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Communication Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
DECS-100 Connections for Typical Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
INSTALLATION FOR CE COMPLIANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
PRELIMINARY SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Operating Power Considerations During DECS-100 Programming . . . . . . . . . . . . . . . . . . . . . 4-13
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Figures
Figure 4-1. DECS-100 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Figure 4-2. Cutout and Drilling Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Figure 4-3. DECS-100 Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Figure 4-4. RS-232 Port Pin Assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Figure 4-5. Personal Computer to DECS-100 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Figure 4-6. Typical Connections for PMG Application with ABC Rotation and Three-Phase Sensing . . 4-8
Figure 4-7. Typical Connections for PMG Application with ABC Rotation and Single-Phase Sensing . . 4-9
Figure 4-8. Typical Connections for Shunt Application with ABC Rotation and Three-Phase Sensing 4-10
Figure 4-9. Typical Connections for Shunt Application with ABC Rotation and Single-Phase Sensing 4-11
Figure 4-10. Cross-Current (Reactive Differential) Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Figure 4-11. Operating Power Connections for DECS-100 Programming (Input Voltage >120 Vac) . . 4-13
Tables
Table 4-1. Bus Voltage Sensing Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Table 4-2. Generator Voltage Sensing Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Table 4-3. 52L/M and 52J/K Control Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Table 4-4. Communication Port Pin Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
DECS-100 Installation i
SECTION 4 • INSTALLATION
GENERAL
DECS-100 Digital Excitation Control Systems are delivered in sturdy cartons to prevent shipping damage.
Upon receipt of a system, 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 the
Basler Electric Regional Sales Office, your Sales Representative or a Sales Representative at Basler Electric,
Highland, Illinois.
If the unit is not installed immediately, store it in the original shipping package in a moisture and dust free
environment.
MOUNTING
The DECS-100 is normally located in the generator conduit box. It is designed for behind the panel mounting
and requires a cutout for front panel viewing. Supplied mounting hardware consists of six #12 thread-forming
screws that pass through mounting holes in the conduit box and thread into the plastic shell of the DECS-100.
The recommended torque range for the steel mounting screws is 4.07 to 4.52 newton-meters (36 to 40 inch-
pounds). The unit must be mounted where the ambient temperature does not exceed the allowable
environmental conditions called out in Section 1, General Information, Specifications. DECS-100 package
dimensions are shown in Figure 4-1. Cutout and drilling dimensions are shown in Figure 4-2. Drawing
dimensions are shown in inches and millimeters (in parenthesis).
DECS-100 Installation 4-1

Figure 4-1. DECS-100 Dimensions
4-2 DECS-100 Installation

Figure 4-2. Cutout and Drilling Dimensions

CONNECTIONS
DECS-100 connections are dependent on the application and excitation scheme. Incorrect wiring may result
in damage to the unit. Check the part number to ensure that you have the correct unit before connecting and
applying power.
NOTE
Be sure that the DECS-100 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, connect a separate
lead from the ground bus to each DECS-100 unit.
DECS-100 Terminations
DECS-100 units have two types of interface terminals (Figure 4-3). One type is quarter-inch, quick-connect
terminals and the other is a 9-pin DB9 connector. All terminals are located on the rear of the unit. The quarter-
inch, quick-connect terminal labels are located on the rear of the case. Wires performing common functions,
such as voltage sensing leads, should be grouped together. The 9-pin DB-9 type connector is used for
temporary interface with both IBM compatible PCs and hand-held computers.
Figure 4-3 shows the terminal connections located on the rear panel of the DECS-100. Except as noted
above, connections should be made with minimum wire size of 14 AWG.
Figure 4-3. DECS-100 Terminals

Bus Voltage Sensing Inputs (Optional)
The bus voltage sensing terminals are labeled B1 and B3. These terminals are used only on units that include
the Voltage Matching option. The bus input is not phase sensitive to generator sensing. Table 4-1 lists the
terminal assignments for bus voltage sensing.
Table 4-1. Bus Voltage Sensing Terminals
Bus Voltage Phase Terminal
A B1
C B3
Generator Voltage Sensing Inputs

The generator voltage sensing terminals are labeled E1, E2, and E3. The DECS-100 comes equipped for
three-phase sensing as standard. Single-phase sensing 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 4-2. Generator Voltage Sensing Terminals
Generator
Sensing Phase Terminal
A E1
3-Phase B E2
C E3
A E1
1-Phase
C E2, E3
Phase B Line Current Sensing Input

Generator line current is stepped down through a user-supplied current transformer (CT). Secondary current
from that transformer is applied to terminals labeled CT1 and CT2.
Accessory Input
The accessory input voltage terminals are labeled A and B and accept a maximum signal of ±3 Vdc. Positive
voltage applied to terminal A with respect to terminal B causes the active mode setpoint to increase.
Raise and Lower Contact Inputs

Remote setpoint adjustment may be accomplished by connecting a single-pole, double-throw (SPDT), spring
return, center-off switch to the terminals labeled 6U, 7, and 6D. To connect this switch, the center pole, or
common terminal, must be connected to terminal 7. The other two terminals are connected to terminals 6U
and 6D.
This remote adjust switch may be mounted up to 150 feet away from the DECS-100 when using twisted,
shielded cable. Only dry, ungrounded switching contacts should be applied to the Raise and Lower contact
inputs.
Var/Power Factor Control Contact Input (Optional)

A customer-supplied enable/disable contact for this function connects to the terminals labeled 52J and 52K.
Only dry, ungrounded switching contacts should be applied to the Var/Power Factor Control contact input.

Parallel Generator Compensation
A customer-supplied enable/disable contact for this function connects to the terminals labeled 52L and 52M.
Only dry, ungrounded switching contacts should be applied to the Parallel Generator Compensation contact
input.
Parallel Control and Var/PF Control Inputs

User-supplied contacts at terminals 52L and 52M determine whether AVR or Droop mode is active. Terminals
52L and 52M typically connect to a 52b auxiliary contact of the generator breaker. User-supplied contacts at
terminals 52J and 52K control whether var or power factor correction is active or disabled. Terminals 52J and
52K typically connect to the auxiliary contacts of the utility tie breaker. Table 4-3 lists the operating modes
achieved for the different 52L/M and 52J/K contact states. A closed state indicates a continuous contact
closure and an open state indicates a continuous open-circuit.
Table 4-3. 52L/M and 52J/K Control Modes

DECS-100 Operating Mode 52L/M 52J/K Generator Operating Mode
AVR mode active, no droop, optional closed closed Single unit/stand-alone

var/PF mode disabled
Droop mode active, optional var/PF open closed Paralleled to the utility grid (droop) or
mode disabled two or more generators islanded
(droop or CCC)
Var/PF mode active open open Paralleled to utility grid
Voltage Matching (Optional)

A customer-supplied enable/disable contact for this function connects to the terminals labeled VM and VMC.
Only dry, ungrounded switching contacts should be applied to the Voltage Matching contact input.
NOTE
Voltage matching is disabled when either the 52J/K or 52L/M contact inputs are
opened.
Power Supply Inputs

Power input terminals are labeled 3, 4, and 5. Single-phase or three-phase power may be applied. Single-
phase power may be applied to any two of the three terminals.
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 (Alarm)

The common alarm relay output contact may be accessed at the terminals labeled AL1 AND AL2.

Communication Port
The RS-232 port on the rear panel uses a DB-9
female connector. Figure 4-4 Illustrates the pin
assignments of the communication port and Table 4-
4 Identifies the RS-232 connector pin functions. A
standard communication cable terminated with a
DB-9 male connector is used for PC interface with
the DECS-100 as shown in Figure 4-4.
Figure 4-4. RS-232 Port Pin Assignments
Table 4-4. Communication Port Pin Functions

Pin Function Name Direction
1 N/C — N/A
2 Transmit Data TXD From DECS-100
3 Receive Data RXD To DECS-100
4 N/C — N/A
5 Signal Ground GND N/A
6 N/C — N/A
7 N/C — N/A
8 N/C — N/A
9 N/C — N/A
Figure 4-5. Personal Computer to DECS-100 Connections
DECS-100 Connections for Typical Applications

Figures 4-6 through 4-9 illustrate typical applications using the DECS-100. Figure 4-6 shows an application
where DECS-100 operating power is derived from a permanent magnet generator (PMG) and three-phase
voltage sensing is applied to the DECS-100. Figure 4-7 shows another PMG application but with single-phase
voltage sensing. Figure 4-8 shows an application where DECS-100 operating power is derived from the
generator output (shunt application) and three-phase voltage sensing is applied to the DECS-100. Figure 4-9
shows another shunt application but with single-phase sensing.
Figure 4-10 shows a typical connection diagram for two paralleled generators operating in cross-current
compensation (reactive differential) mode. The resistors shown have a value of 0.1 ohms. This is a typical
value that can be used to set the burden. (Ensure that the resistor power rating is adequate for the
installation.)
4-8
DECS-100 WITH VOLTAGE MATCHING
FIELD INPUT SENSING VAR/PF PARALLEL EXTERNAL AUX. VOLTAGE
OUTPUT POWER CTB VOLTAGE GROUND BUS CONTROL CONTROL ADJUST ALARM ADJUST MATCHING
F- F+ 3 4 5 CT1 CT2 E3 E2 E1 GND B1 B3 52J 52K 52L 52M 6D 7 6U AL 1 AL 2 A B VM VMC
4 5
10 10
52b S3
S2 S1
A B C
1 2 10 9 10
7
3
10
6
NOTES:
7 1 Required only for optional Var/PF control. Var/PF is active with
8
10
52b open. Var/PF is inactive with 52b closed.
10
2 Parallel control and droop active with S2 open, inactive with S2
closed.
3 S1 (SPDT, spring-return to center-off position) adjusts DECS-
PMG
10 52 100 setpoint.
+ 4 Normally-open output contact closes for customer alarm or trip.
A
10 CTB
GEN B 5 Analog input voltage between +/- 3 Vdc provides adjustment of
11 voltage sepoint (optional feature).
C
D2881-09 6 External fuses should be Bussman type KTK-10 or equivalent.
05-10-02
Generator Utility
Side Side 7 Sensing potential transformer is required if line voltage exceeds
660 Vac.
8 3-phase PMG is shown. For 1-phase PMG, omit B-phase
connection.
9 Optional voltage matching control input. Voltage matching is
active with S3 closed, inactive with S3 open.
10 Item not supplied by Basler Electric.
11 When generator rotation is ACB, the connections shown for

CTB should be reversed.
Figure 4-6. Typical Connections for PMG Application with ABC Rotation and Three-Phase Sensing
DECS-100 Installation
4 5
10 10
52b S3
S2 S1
A B C
1 2 10 9 10
7
3
10
6 NOTES:
7
8 1 Required only for optional Var/PF control. Var/PF is active with
10 52b open. Var/PF is inactive with 52b closed.
10
closed.
PMG 3 S1 (SPDT, spring-return to center-off position) adjusts DECS-

10 52 100 setpoint.
+ 4 Normally-open output contact closes for customer alarm or trip.
A
10 CTB
GEN B 5 Analog input voltage between +/- 3 Vdc provides adjustment of
C
voltage sepoint (optional feature).
D2881-11 6 External fuses should be Bussman type KTK-10 or equivalent.
05-10-02
Generator Utility
Side Side 7 Sensing potential transformer is required if line voltage exceeds
660 Vac.
8 3-phase PMG is shown. For 1-phase PMG, omit B-phase
connection.
Figure 4-7. Typical Connections for PMG Application with ABC Rotation and Single-Phase Sensing
4-9
4-10
4 5
10 10
52b S3
S2 S1
A B C
1 2 10 9 10
7
6 3
10
NOTES:
8
1 Required only for optional Var/PF control. Var/PF is active with
7
11 10 2 Parallel control and droop active with S2 open, inactive with S2
closed.
100 setpoint.
10 52 4 Normally-open output contact closes for customer alarm or trip.
+
A
10 CTB 5 Analog input voltage between +/- 3 Vdc provides adjustment of
GEN B voltage sepoint (optional feature).
12
C 6 External fuses should be Bussman type KTK-10 or equivalent.
D2881-10
05-10-02
Generator Utility 7 Sensing potential transformer is required if line voltage exceeds
Side Side 660 Vac.
8 3-phase transformer is shown. For 1-phase transformer, omit B-
phase connection.
11 Power potential transformer is required if line voltage exceeds

the specified power input limits.
Figure 4-8. Typical Connections for Shunt Application with ABC Rotation and Three-Phase Sensing
4 5
10 10
52b S3
S2 S1
A B C
1 2 10 9 10
7
6 3
10 NOTES:
8
1 Required only for optional Var/PF control. Var/PF is active with
7
11 10
closed.
100 setpoint.
10 52 4 Normally-open output contact closes for customer alarm or trip.
+
A
10 CTB 5 Analog input voltage between +/- 3 Vdc provides adjustment of
GEN B voltage sepoint (optional feature).
12
C 6 External fuses should be Bussman type KTK-10 or equivalent.
D2659-18
05-10-02
Generator Utility 7 Sensing potential transformer is required if line voltage exceeds
Side Side 660 Vac.
8 3-phase transformer is shown. For 1-phase transformer, omit B-
phase connection.
11 Power potential transformer is required if line voltage exceeds

the specified power input limits.
Figure 4-9. Typical Connections for Shunt Application with ABC Rotation and Single-Phase Sensing
4-11
CT
GEN 1
0.1
CTB1
CTB2
DECS-100
CCC LOAD
DECS-100 ENABLE
0.1 CONTACT
CTB1
CTB2
D2880-16
05-19-00
GEN 2
CT
Figure 4-10. Cross-Current (Reactive Differential) Connections
INSTALLATION FOR CE COMPLIANCE

The following paragraphs describe the mounting and wiring requirements for a CE (European Community)
compliant installation.
Mounting
The DECS-100 must be mounted inside a grounded, metal enclosure (conduit box). An access panel should
cover the opening for the front panel display.
Wiring
Wiring connected to the terminals listed below must be shielded. Each shield should be terminated to ground
on the outside of the conduit box.
C Current sensing terminals CT1 and CT2

C Relay output terminals AL1 and AL2
C Var/Power Factor control contact input terminals 52J and 52K
C Parallel generator compensation terminals 52L and 52M
C Raise and lower contact input terminals 6U, 6D, and 7
C Accessory input voltage terminals A and B
C Voltage matching contact input terminals VM and VMC
PRELIMINARY SETUP
WARNING!
Lethal voltage is present at the rear panel when the unit is energized. Rear panel
connections should be made only when the unit is de-energized.
Before starting the generator and DECS-100 for the first time, proceed as follows.

1. Tag and disconnect all wiring to the DECS-100. Be sure to insulate the wire terminals to prevent a
short circuit.
2. Start the prime mover and perform all engine governor adjustments.
3. After all initial governor adjustments have been made, shut down the prime mover.
4. Connect only the DECS-100 power input terminals to an auxiliary power source. Before applying
DECS-100 operating power, observe the precautions noted in Operating Power Considerations During
DECS-100 Programming.
5. Perform all initial DECS-100 settings by connecting a PC or handheld operating with BESTCOMS to
the rear communication port of the DECS-100 and save all new settings.
6. Remove power from the DECS-100.
7. Connect the rest of the DECS-100 leads using the tagged identification.
8. Start the prime mover/generator and perform the final adjustments at rated speed and load.
9. After the initial startup, the DECS-100 should not require any further adjustments unless there is a
change in the system.
Operating Power Considerations During DECS-100 Programming

Due to its pulse-width modulated (PWM) power stage, the DECS-100 operating power input has a substantial
amount of capacitance. High inrush current can be experienced upon DECS-100 power-up when a “solid”
power source is used. When powering the DECS-100 for programming with voltage greater than 120 Vac,
high inrush current may damage the unit. Therefore, during programming, DECS-100 operating power should
be within the range of 30 to 120 Vac (50/60 Hz).
CAUTION
When programming the DECS-100 without the generator spinning, the
connections to DECS-100 terminals F+ and F– should be removed.
If it is necessary to perform programming with applied operating power over 120 Vac, a current-limiting resistor
must be connected between the power source and DECS-100 (Figure 4-11). A resistor rated at 20 ohms and
20 watts may be used to limit the inrush current to a safe level. During the duration of the inrush current (about
one cycle), the resistor power rating will be exceeded. Once the inrush has passed, the resistor power
dissipation level will be minimal. If desired, a 10 ohm, 50 watt resistor may be used instead.
Figure 4-11. Operating Power Connections for

DECS-100 Programming (Input Voltage >120 Vac)
These special operating considerations are to be observed only during DECS-100 programming. Applications
where the DECS-100 is powered from the generator output (shunt powered) or a permanent magnet generator
(PMG) are still valid within the constraints given in Section 1, General Information, Specifications.
ADJUSTMENTS
All adjustments are made using external switching, or with BESTCOMS software via the rear panel
communication port. See Sections 5 and 6 for more information regarding setting adjustments with
BESTCOMS software.

SECTION 5 • BESTCOMS SOFTWARE FOR THE
WINDOWS® OPERATING SYSTEM
TABLE OF CONTENTS
SECTION 5 • BESTCOMS SOFTWARE FOR THE WINDOWS® OPERATING SYSTEM . . . . . . . . . . 5-1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Installing BESTCOMS-DECS100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Connecting the DECS-100 and PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
STARTING BESTCOMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Establishing Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
CHANGING SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
SENDING AND RECEIVING SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Sending Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Receiving Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Saving Settings to DECS-100 Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
SETTING DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
System Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Setting Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Setpoint Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Startup Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Control Gain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Control Gain Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
AVR Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
FCR Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
PF Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
VAR Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Protection Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Protection Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Metering, Operation and Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Operation Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Alarm/Status Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
PID DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
PID Calculation Based on Input Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Adding to the PID List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Removing a PID List Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Retrieving Existing Data from the PID List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
SETTINGS FILES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Printing Settings Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Saving Settings Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Uploading Settings Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
PASSWORD PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Changing the Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
TERMINATING COMMUNICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
EMBEDDED FIRMWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Updating the Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
DECS-100 BESTCOMS for Windows® OS i

Figures
Figure 5-1. Basler Electric Folder Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Figure 5-3. System Configuration Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Figure 5-2. BESTCOMS Title and Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Figure 5-4. Communication Port Menu Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Figure 5-5. Password Dialog Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Figure 5-6. Communication Initiation Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Figure 5-7. Wait Dialog Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Figure 5-8. System Configuration Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Figure 5-9. Setting Adjustments Screen, Setpoint Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Figure 5-10. Setting Adjustments Screen, Startup Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Figure 5-11. Control Gain Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Figure 5-12. Analysis Screen, AVR Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Figure 5-13. AVR Setpoint Dialog Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Figure 5-14. Analysis Screen, FCR Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Figure 5-15. FCR Setpoint Dialog Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Figure 5-16. Analysis Screen, PF Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Figure 5-17. PF Setpoint Dialog Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Figure 5-18. Analysis Screen, VAR Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Figure 5-19. Var Setpoint Dialog Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Figure 5-20. Protection and Relay Settings Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Figure 5-21. Metering, Operation, and Alarms, Operation Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Figure 5-22. Metering, Operation, and Alarms, Alarm/Status Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Figure 5-23. PID Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Figure 5-24. User Information Dialog Box for Settings List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Figure 5-25. Settings Upload Dialog Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Figure 5-26. Password Dialog Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Figure 5-27. DECSLoad Menu Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Figure 5-28. Software Uploading Advisory Dialog Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Figure 5-29. DECS-100 Embedded Program Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Figure 5-30. Retrieved DECS-100 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Figure 5-31. Settings File Reminder Dialog Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Figure 5-32. Open Dialog Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Figure 5-33. File Transfer Progress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Figure 5-34. DECS-100 Information After Upload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Tables
Table 5-1. DECS-100 Stability Range Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Table 5-2. Analysis Screen Tab Combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
ii DECS-100 BESTCOMS for Windows® OS

WINDOWS® OPERATING SYSTEM
INTRODUCTION
BESTCOMS-DECS100 software provides the communication link between the DECS-100 and the user. All
DECS-100 settings are entered through BESTCOMS and all metering values (updated about once every
second) are read through BESTCOMS. PID (Proportional + Integral + Derivative) software within BESTCOMS
enables the user to establish proper PID parameters based on a specified generator and/or exciter time
constants. Within BESTCOMS, DECS-100 settings can be saved in a computer file and used later to configure
other units with the same settings.
INSTALLATION
BESTCOMS-DECS100 software operates with IBM compatible personal computers (PCs) using Microsoft®
Windows® 95, Windows® 98, or Windows NT® operating systems. The minimum recommended operating
requirements are listed below.
C IBM compatible PC, 486DX2 or faster (100 MHz or higher microprocessor is recommended)
C CD-ROM Drive
C One available serial port
Installing BESTCOMS-DECS100
BESTCOMS-DECS100 software contains a setup utility that installs the program on your PC. An uninstall
utility is loaded with the program that can be used to remove BESTCOMS from your PC if desired. Use the
following procedure to install BESTCOMS-DECS100.
1. Insert the CD-ROM into the PC CD-ROM drive.
2. When the DECS-100 Setup and Documentation CD menu appears, click the Install button for the
BESTCOMS PC Program. The setup utility automatically installs BESTCOMS-DECS100 on your PC.
When BESTCOMS is installed, a Basler Electric

folder is added to the Windows® program menu.
This folder is accessed by clicking the Start button
and pointing to Programs. As illustrated in Figure
5-1, the Basler Electric folder contains icons for Figure 5-1. Basler Electric Folder Contents
the BESTCOMS-DECS100 program and a utility
to remove BESTCOMS.
Connecting the DECS-100 and PC

Connect a communication cable between the rear RS-232 connector of the DECS-100 and the appropriate
communication port of the PC. Refer to Figure 2-2 for the location of the DECS-100 RS-232 connector and
Figure 4-5 for the required connections between the DECS-100 and a PC.
STARTING BESTCOMS
BESTCOMS is started by clicking the Windows®

Start button, pointing to Programs, the Basler CAUTION
Electric folder, and then clicking the BESTCOMS- When applying operating power to the DECS-100
DECS100 icon. At startup, a dialog box with the for programming purposes, observe the precau-
program title and version number is displayed briefly tions called out in Section 4, Installation, Prelimi-
(Figure 5-2). After this dialog box is displayed, the nary Setup.
System Configuration screen is displayed (Figure
5-3).
DECS-100 BESTCOMS for Windows® OS 5-1
Figure 5-2. BESTCOMS Title and Version Figure 5-3. System Configuration Screen
Establishing Communication
Communication between BESTCOMS and the
DECS-100 must be established before viewing
metering values or reading or changing settings.
BESTCOMS screen settings are updated only after
communication is opened or the communication
settings have been changed.
Open the DECS-100 communication port by clicking
on Communications on the menu bar, hovering the
mouse pointer over Open Comm Port, and clicking Figure 5-4. Communication Port Menu Selection
RS-232 Port. Figure 5-4 illustrates the menu
selections for opening the DECS-100 communication
port.
When RS-232 Port is selected, the Password dialog box of Figure 5-5 appears and prompts you to enter a
password. Each DECS-100 is delivered with “decs” as the default password. See the Password Protection
sub-section for information about changing the password.
After the correct password is entered, the Communication Initiation screen of Figure 5-6 is displayed. Select
Comm 1, Comm 2, Comm 3, or Comm 4 as the active communication port on your PC and click the Initialize
button. BESTCOMS initializes communication by obtaining the configuration settings from the DECS-100.
NOTE
BESTCOMS may display the dialog box of Figure
5-7 when initializing DECS-100 communication,
obtaining DECS-100 configuration settings, or
performing other tasks. It’s important to wait until
the box disappears before trying to execute
Figure 5-5. Password Dialog Box communication commands. Issuing commands
while the Wait dialog box is present may disrupt
communication between BESTCOMS and the
DECS-100.
Figure 5-7. Wait Dialog Box
Figure 5-6. Communication Initiation Screen
5-2 DECS-100 BESTCOMS for Windows® OS

CHANGING SETTINGS
Settings are arranged into six groups.
C System Configuration C Analysis
C Setting Adjustments C Protection/Relay
C Control Gain C Metering/Operation
Each setting group has a corresponding button (shown in Figure 5-3) that can be selected to access that
group of settings. The six setting groups can also be accessed by clicking Screens on the menu bar and then
selecting the desired setting group from the list. Once a setting group is accessed, the individual settings of
the group can be viewed and changed.
A setting is changed by clicking within the setting field and typing the new setting. The range limits of a setting
can be viewed by double-clicking the setting. Once all desired setting changes have been made on a setting
group screen, the settings must be sent to the DECS-100 before viewing other screens. Otherwise, the
settings changes will be lost. Settings changes can be sent to the DECS-100 by clicking the SendToDECS
button. Settings can also be sent to the DECS-100 by clicking Communications on the menu bar and clicking
Send To DECS.
SENDING AND RECEIVING SETTINGS

When communication is enabled, DECS-100 settings can be sent or received through BESTCOMS.
Sending Settings
Settings changes are sent to the DECS-100 by clicking the SendToDECS button. This causes the selected
setting displayed on the current settings screen to become the DECS-100 setting. Settings can also be sent
to the DECS-100 by clicking Communications on the menu bar and clicking Send To DECS. Additionally,
a setting can be sent by pressing the Enter key after the new value is typed in. The SendToDECS button must
be clicked or the Enter key must be pressed after each setting change to ensure that all settings are sent to
the DECS-100. See Saving Settings to DECS-100 Memory for information about retaining DECS-100 settings
after operating power is removed.
Receiving Settings
DECS-100 settings are retrieved by clicking the GetFromDECS button. This causes the current settings of
the DECS-100 to be displayed on the settings screen. Settings can also be received from the DECS-100 by
clicking Communications on the menu bar and clicking Get From DECS.
Saving Settings to DECS-100 Memory

Settings are saved in nonvolatile memory (EEPROM). In the event of a power loss, these are the settings that
are active at power up. If settings are changed and sent to the DECS-100, but not sent to EEPROM, the
changed settings are lost if DECS-100 operating power is lost. When exiting BESTCOMS or closing
communication, you are asked if you want to save the settings to EEPROM. This question is asked even if
no settings changes were made.
When communication is enabled, setting changes are saved to EEPROM by clicking the EEPROM button.
The opportunity to save settings to EEPROM is also given through a dialog box when exiting BESTCOMS or
closing communication.
SETTING DEFINITIONS
Each of the six setting groups has a corresponding BESTCOMS screen. The settings of each screen are
categorized by one or more tabs. In the following paragraphs, settings are arranged and defined according
to the organization of the BESTCOMS screens and tabs.
System Configuration
The System Configuration screen consists of one tab labeled System Settings. Click the Configure button
to access the System Configuration screen or click Screens on the menu bar and click System
Configuration.
System Settings
System settings are shown in Figure 5-8 and are described in the following paragraphs.
Figure 5-8. System Configuration Screen
Sensing Voltage. This setting is used to configure the DECS-100 for either single-phase or three-phase
sensing voltage.
Generator Frequency. This setting is used to select a nominal system operating frequency of 50 hertz or 60
hertz.
Limiter Mode. Selecting OEL enables the DECS-100 Overexcitation Limiter and selecting None disables it.
Regulator Sensing Voltage (V). The nominal, ac generator voltage obtained from the generator sensing
transformer is entered in this setting field. Voltages within the ranges of 100 to 140 Vac, 200 to 280 Vac, or
400 to 560 Vac may be entered in 0.1 Vac increments. A setting of 600 Vac is also possible.
Regulator Sensing Current (A). This setting field reads and displays the nominal output of the current
transformer (CT) that supplies the DECS-100 with B-phase generator line current. This value (1 or 5) must
be manually entered for units with a firmware version lower than 1.12.01.
Version Numbers. These two version numbers are read-only. They indicate the BESTCOMS software version
and the DECS-100 embedded software version. If a DECS-100 version number is not shown, then the PC
and BESTCOMS has not communicated with the DECS-100. The DECS-100 version number is indicated only
when communication between the DECS-100 and BESTCOMS occurs.
Generator PT Ratio. The ratio of the generator sensing transformer is entered in this setting field. This ratio
allows the voltage displayed through BESTCOMS to match the actual generator output voltage. A ratio of 1
to 150 may be entered in increments of 0.01.
Generator CT Ratio. The ratio of the generator B-phase current transformer is entered in this setting field. This
ratio allows the current displayed by the DECS-100 to match the actual B-phase generator output current. A
ratio of 1 to 3000 may be entered in increments of 0.1.
Bus PT Ratio. This setting field is used to enter the bus potential sensing transformer ratio. This ratio allows
the bus voltage to be displayed through BESTCOMS. A ratio of 1 to 150 may be entered in 0.01 increments.

Setting Adjustments
The Setting Adjustments screen consists of two tabs: Setpoint and Startup.
Setpoint Tab
The Setpoint tab settings of the Setting Adjustments screen are shown in Figure 5-9. Each setting of the
Setpoint tab is described in the following paragraphs.
Figure 5-9. Setting Adjustments Screen, Setpoint Tab

Automatic Voltage Regulator (AVR) - AVR Setpoint (V). This setting field is used to enter the desired generator
output terminal voltage. The AVR setpoint value range depends on the regulator sensing voltage and band
setting.
Fine Voltage Adjustment - Band Setting (%). The Band Setting determines the minimum and maximum
adjustment allowed to the AVR Setpoint (as a percentage of the Regulator Sensing Voltage setting (see Figure
5-8)). Band Setting values are entered as a percentage of the regulator sensing voltage setting over a range
of 0 to 15 percent in 0.1 percent increments.
Droop - Setpoint (%). This setting controls the reactive droop compensation feature of the DECS-100. The
setpoint value determines the amount of change permitted in the generator voltage setpoint when the
DECS-100 responds to a reactive load. The setpoint value is adjustable from 0 to 10 percent in increments
of 0.01 percent. The setpoint is based on a 0.8 power factor load.
Field Current Regulator (FCR) - FCR Setpoint (A). This setting defines the field current setpoint when
operating in Manual mode. The FCR Setpoint field accepts a value of 0 to 7 Adc in increments of 0.01 Adc
Reactive Power Control (VAR) - VAR Setpoint (% of rated). The VAR Setpoint determines the level of
generator vars maintained by the DECS-100 when operating in Var Control mode. Values from -100 to +100
percent in 1.0 percent increments may be entered in the VAR Setpoint field.
Power Factor Control (PF) - PF Setpoint. The PF Setpoint determines the level of generator power factor
maintained by the DECS-100 when operating in Power Factor Control mode. PF Setpoint values are
adjustable from -0.6 to -1 (1) or 0.6 to +1 in 0.001 increments.
Startup Tab
The Startup-tab settings of the Setting Adjustment screen are shown in Figure 5-10. Each setting of the
Startup tab is described in the following paragraphs.

Figure 5-10. Setting Adjustments Screen, Startup Tab
Startup Control - Gen Soft Start Time (sec). This setting defines the time limit for the generator soft-start
voltage ramp time. The soft-start time minimizes generator voltage overshoot and can be set from 1 to 7,200
seconds in 1 second increments.
Voltage Matching - Speed (sec). This setting determines how quickly the generator voltage is adjusted by the
DECS-100 to match the bus voltage. The Speed setting is adjustable from 1 to 300 seconds in 0.01
increments.
Underfrequency Setting - Corner Frequency (Hz). The Corner Frequency setting defines the value of
frequency that causes the DECS-100 to adjust the voltage setpoint so that the generator voltage follows the
selected volts per hertz slope. A value of 40 to 65 hertz can be entered in this setting field in 0.01 increments.
Underfrequency Setting - Slope (Volts/Hz). The slope for generator underfrequency protection is selected with
this per-unit setting. A slope setting of 0 to 3.00 can be entered in increments of 0.01.
Control Gain
The Control Gain screen consists of one tab labeled Control Gain. Click the Gain button to access the Control
Gain screen or click Screens on the menu bar and click Control Gain.
Control Gain Tab
Control gain settings are shown in Figure 5-11 and are described in the following paragraphs.
Stability Range. This setting selects one of 20 preset stability ranges within the DECS-100. A guide for
selecting the stability range is provided in Table 5-1. A setting of 21 enables the entry of custom stability
settings through the BESTCOMS PID window. Information about the PID window is provided later under the
heading of PID Window. When the Stability Range is set at 21, the PID button may be selected to access the
PID window. A Stability Range setting of 1 through 20 disables the PID button and prevents access to the PID
window.
AVR/FCR - Proportional Gain KP. This setting selects the proportional constant (KP) stability parameter. The
DECS-100 supplies a value that is equivalent to KP multiplied by the error between the voltage setpoint and
the actual generator output voltage. KP values of 0 to 1,000 may be entered in increments of 0.01.
Observe the following guidelines when tuning the KP value. If the transient response has too much overshoot,
then KP should be decreased. If the transient response is too slow, then KP should be increased.

Figure 5-11. Control Gain Screen
Table 5-1. DECS-100 Stability Range Settings

Time Constants
Generator Stability
Size Generator (T’do) Exciter (Texc) Range
SMALL 1.0 0.17 1
1.5 0.25 2
2.0 0.33 3
2.5 0.42 4
3.0 0.50 5
3.5 0.58 6
4.0 0.67 7
4.5 0.75 8
5.0 0.83 9
5.5 0.92 10
6.0 1.00 11
6.5 1.08 12
7.0 1.17 13
7.5 1.25 14
8.0 1.33 15
8.5 1.42 16
9.0 1.50 17
9.5 1.58 18
10.0 1.67 19
LARGE 10.5 1.75 20

AVR/FCR - Integral Gain KI. This setting selects the integral constant (KI) stability parameter. The DECS-100
supplies a value that is equivalent to KI multiplied by the integral of the error between the voltage setpoint and
the actual generator output voltage. KI values of 0.01 to 1,000 may be entered in increments of 0.01.
Increasing the value of KI decreases the time required to reach steady state.
AVR/FCR - Derivative Gain KD. This setting selects the derivative constant (KD) stability parameter. The
DECS-100 provides an output value that is equivalent to KD multiplied by the derivative of the error between
the voltage setpoint and the actual generator output voltage. KD values of 0 to 1,000 may be entered in
increments of 0.01.
Increasing the value of KD reduces transient response ringing.
AVR/FCR - AVR<=Loop Gain Kg=>FCR. This setting adjusts the loop-gain level of the PID algorithm. Loop
Gain values of 0 to 1,000 may be entered for AVR and FCR operation in increments of 0.01.
VAR/PF - PF Integral Gain KI. This setting adjusts the integral gain and determines the characteristic of the
DECS-100 dynamic response to a changed PF setting. PF KI values of 0 to 1,000 may be entered in
increments of 0.01.
VAR/PF - Var Integral Gain KI. This setting adjusts the integral gain and determines the characteristic of the
DECS-100 dynamic response to a changed var setting. Var KI values of 0 to 1,000 may be entered in
increments of 0.01.
VAR/PF - VAR<=Loop Gain Kg=>PF. This setting adjusts the loop-gain level of the PI algorithm for var or
power factor control. Loop Gain values of 0 to 1,000 may be entered for var and power factor operation in
increments of 0.01.
OEL - Integral Gain KI. This setting controls the rate at which the DECS-100 responds during an
overexcitation event. KI values of 0 to 1,000 may be entered in increments of 0.01.
OEL - Loop Gain Kg. This setting adjusts the coarse loop-gain level of the PID algorithm for the over-excitation
limiting function. Loop Gain values of 0 to 1,000 may be entered in increments of 0.01.
Analysis
Click the Analysis button or click Screens on the Menu bar and click Analysis to view the Analysis screen.
The Analysis screen consists of four tabs: VAR, PF, AVR, and FCR. Each of the tabs displays four metered
sensing values and has five alarm signal indicators. Metered sensing values include Vrms (rms voltage), Ifd
(dc field current), reactive power (vars), and power factor (PF). Alarm signal indicators include Overexcitation
Shutdown, Generator Overvoltage, Loss of Generator Sensing, Overexcitation Limiting, and Underfrequency
Active.
The operating status and control mode of the DECS-100 determine which tabs of the Analysis screen are
enabled and can be accessed by the user. Table 5-2 lists the DECS-100 operating status and control modes
that enable the four tabs of the Analysis screen.
Table 5-2. Analysis Screen Tab Combinations

Control Mode Operating Status Tab Enabled
AVR OFF AVR
AVR PF AVR, PF
AVR VAR AVR, VAR
FCR N/A FCR
Control mode and operating status selections are made at the Operation tab of the BESTCOMS Metering
screen and are discussed later in this section.

AVR Tab
Figure 5-12 illustrates the settings, sensing values, and alarm signal indicators of the AVR tab. The settings
of the AVR tab make it possible to increment and decrement the AVR setpoint of the DECS-100.The sensing
values and alarm signal indicators of the AVR tab are also displayed by the other tabs of the Analysis screen.
Figure 5-12. Analysis Screen, AVR Tab

Voltage Step Response - AVR Setpoint (V) (Nominal). This read-only field indicates the AVR setpoint. (The
AVR setpoint is set by using the Setpoint tab of the Setting Adjustments screen). The voltage displayed in the
AVR Setpoint field is selected by clicking the adjacent button. Clicking this button sends the AVR Setpoint
value to the DECS-100 and changes the color of the button from gray to red.
Voltage Step Response - Increment of AVR Setpoint (V). These two fields indicate the increase that occurs
to the AVR setpoint when the corresponding Increment button is clicked. The "% increase" field is used to set
and indicate the percentage that the AVR setpoint is increased when the Increment button is clicked. The
"AVR Setpoint =" field indicates the value of voltage that corresponds to the “% increase” field. Any setpoint
value within range or higher than the setpoint value can be typed into the “AVR Setpoint =”field, which updates
the “% increase” field. The AVR setpoint changes to this value when the adjacent button is clicked. When
clicked, the Increment button changes from gray to red to indicate that the AVR setpoint has increased to the
value in the “AVR Setpoint =” field.
Voltage Step Response - Decrement of AVR Setpoint (V). These two fields indicate the change that will occur
to the AVR setpoint when the corresponding Decrement button is clicked. The "% decrease" field is used to
set and indicate the percentage (0 to 10%) that the AVR setpoint is decreased when the Decrement button
is clicked. The "AVR Setpoint =" field indicates the value of voltage that corresponds to the "% decrease" field.
Any setpoint value within range or lower than the setpoint value can be typed into the “AVR Setpoint =” field,
which updates the “% decrease” field. The AVR setpoint changes to this value when the adjacent button is
clicked. When clicked, the Decrement button changes from gray to red to indicate that the AVR setpoint has
decreased to the value in the “AVR Setpoint =” field.
Voltage Step Response - Meter Value. This field and the dial pointer indicate the value of the selected AVR
setpoint. When the AVR setpoint is changed by clicking the increment, decrement, or setpoint button, the
meter value field and dial pointer indicate the new setpoint value. A new AVR setpoint can be typed directly
into the Meter Value field or selected by dragging the dial pointer to the desired value. The new value is sent
to the DECS-100 by clicking the Send button.

Voltage Step Response - Current Setpoint. The active
DECS-100 setpoint (adjusted by using any of the
previously mentioned methods) is displayed in this field.
To return the AVR setpoint to the nominal setting, the
button adjacent to the “AVR Setpoint (V) (Nominal)” field
should be clicked. If the AVR tab is left to view other
tabs or screens without returning the AVR setpoint to
nominal, the dialog box of Figure 5-13 appears. The
AVR setpoint is returned to nominal by clicking Yes. The
AVR setpoint is maintained at the current value by Figure 5-13. AVR Setpoint Dialog Box
clicking No.
FCR Tab
Figure 5-14 illustrates the settings, sensing values, and alarm signal indicators of the FCR tab. The settings
of the FCR tab make it possible to increment and decrement the FCR setpoint of the DECS-100. The sensing
values and alarm signal indicators of the FCR tab are also displayed by the other tabs of the Analysis screen.
Figure 5-14. Analysis Screen, FCR Tab
Field Current Step Response - FCR Setpoint (A). This read-only field indicates the FCR setpoint. (The FCR
setpoint is set by using the Setpoint tab of the Setting Adjustments screen). The current displayed in the FCR
Setpoint field is selected by clicking the adjacent pushbutton. Clicking this button sends the FCR Setpoint
value to the DECS-100 and changes the color of the pushbutton from gray to red.
Field Current Step Response - Increment of FCR Setpoint (A). These two fields indicate the increase that
occurs to the FCR setpoint when the corresponding Increment button is clicked. The "% increase" field is used
to set and indicate the percentage (0 to 10%) that the FCR setpoint is increased when the Increment button
is clicked. The "FCR Setpoint =" field indicates the value of current that corresponds to the “% increase” field.
Any setpoint value within range or higher than the setpoint value can be typed into the “FCR Setpoint =” field,
which updates the “% increase” field. The FCR setpoint changes to this value when the adjacent button is
clicked. When clicked, the Increment button changes from gray to red to indicate that the FCR setpoint has
increased to the value in the “FCR Setpoint =” field.

Field Current Step Response - Decrement of FCR Setpoint (A). These two fields indicate the change that will
occur to the FCR setpoint when the corresponding Decrement button is clicked. The "% decrease" field is
used to set and indicate the percentage that the FCR setpoint is decreased when the Decrement button is
clicked. The "FCR Setpoint =" field indicates the value of current that corresponds to the "% decrease" field.
The FCR setpoint changes to this value when the adjacent button is clicked. When clicked, the Decrement
button changes from gray to red to indicate that the FCR setpoint has decreased to the value in the "FCR
Setpoint =" field.
Field Current Step Response - Meter Value. This field and the dial pointer indicate the value of the selected
FCR setpoint. When the AVR setpoint is changed by clicking the increment, decrement, or setpoint button,
the meter value field and dial pointer indicate the new setpoint value. A new FCR setpoint can be typed
directly into the “Meter Value” field or selected by dragging the dial pointer to the desired value. The new value
is sent to the DECS-100 by clicking the Send button.
Field Current Step Response - Current Setpoint. The
active DECS-100 setpoint (adjusted by using any of the
To return the FCR setpoint to the nominal setting, the
button adjacent to the “FCR Setpoint (A) (Nominal)” field
should be clicked. If the FCR tab is left to view other
tabs or screens without returning the FCR setpoint to
nominal, the dialog box of Figure 5-15 appears. The
FCR setpoint is returned to nominal by clicking Yes. The
AVR setpoint is maintained at the current value by Figure 5-15. FCR Setpoint Dialog Box
clicking No.
PF Tab
Figure 5-16 illustrates the settings, sensing values, and alarm signal indicators of the PF tab. Each setting of
the PF tab is described in the following paragraphs.
Figure 5-16. Analysis Screen, PF Tab
Power Factor Step Response - Power Factor Setpoint (Nominal). This read-only field indicates the PF
setpoint. (The PF setpoint is set by using the Setpoint tab of the Setting Adjustments screen.) The value
displayed in the FCR Setpoint field is selected by clicking the adjacent pushbutton. Clicking this button sends
the PF setpoint value to the DECS-100 and changes the color of the pushbutton from gray to red.

Power Factor Step Response - Increment of PF Setpoint. This field indicates the new PF setpoint that is
established when the corresponding increment button is clicked. Any setpoint value within range or higher
than the existing setpoint value can be typed into the “Increase PF Setpoint =” field. The PF setpoint changes
to this value when the adjacent button is clicked. When clicked, the Increment button changes from gray to
red to indicate that the PF setpoint has increased to the value in the “Increase PF Setpoint =” field.
Power Factor Step Response - Decrement of PF Setpoint. This field indicates the new PF setpoint that is
established when the corresponding decrement button is clicked. Any setpoint value within range or lower than
the existing setpoint value can be typed into the “Decrease PF Setpoint =” field. The PF setpoint changes to
this value when the adjacent button is clicked. When clicked, the Decrement button changes from gray to red
to indicate that the PF setpoint has decreased to the value in the “Decrease PF Setpoint =” field.
Power Factor Step Response - PF Value. This field and the dial pointer indicate the value of the selected PF
setpoint. When the PF setpoint is changed by clicking the increment, decrement, or setpoint button, the meter
value field and dial pointer indicate the new setpoint value. A new PF setpoint can be typed directly into the
“PF Value” field or selected by dragging the dial pointer to the desired value. The new value is sent to the
DECS-100 by clicking the Send button.
Power Factor Step Response - Current Setpoint. The
active DECS-100 setpoint (adjusted by using any of the
To return the PF setpoint to the nominal setting, the
button adjacent to the PF Setpoint (Nominal) field
should be clicked. If the PF tab is left to view other tabs
or screens without returning the PF setpoint to nominal,
the dialog box of Figure 5-17 appears. The PF setpoint
is returned to nominal by clicking Yes. The PF setpoint
is maintained at the current value by clicking No.
Figure 5-17. PF Setpoint Dialog Box
VAR Tab
Figure 5-18 illustrates the settings, sensing values, and alarm signal indicators of the VAR tab. Each setting
of the VAR tab is described in the following paragraphs.
Figure 5-18. Analysis Screen, VAR Tab

Reactive Power Step Response - VAR Setpoint (%) (Nominal). This read-only field indicates the var setpoint.
(The var setpoint is set by using the Setpoint tab of the Setting Adjustments screen.) The value displayed in
the “VAR Setpoint” field is selected by clicking the adjacent button. Clicking this button sends the var setpoint
value to the DECS-100 and changes the color of the pushbutton from gray to red.
Reactive Power Step Response - Increment of VAR Setpoint (%). This field indicates the increase that occurs
to the FCR setpoint when the corresponding Increment button is clicked. The “Increase VAR Setpoint =” field
is used to set and indicate the percentage that the var setpoint is increased to when the Increment button is
clicked. Any setpoint value (expressed as a percent of nominal) within range or higher than the existing
setpoint value can be typed into the “Increase VAR Setpoint =” field. The var setpoint changes to the new
value when the adjacent button is clicked. Clicking this button sends the var setpoint value to the DECS-100
and changes the color of the pushbutton from gray to red.
Reactive Power Step Response - Decrement of VAR Setpoint (%). This field indicates the decrease that
occurs to the FCR setpoint when the corresponding Decrement button is clicked. The “Decrease VAR
Setpoint =” field is used to set and indicate the percentage that the var setpoint is decreased to when the
Decrement button is clicked. Any setpoint value (expressed as a percent of nominal) within range or lower
than the existing setpoint value can be typed into the “Decrease VAR Setpoint =” field. The var setpoint
changes to the new value when the adjacent button is clicked. Clicking this button sends the var setpoint value
to the DECS-100 and changes the color of the pushbutton from gray to red.
Reactive Power Step Response - Meter Value. These fields and the dial pointer indicate the value of the
selected var setpoint. When the var setpoint is changed by clicking the increment, decrement, or setpoint
button, the meter value fields and dial pointer indicate the setpoint value. A new var setpoint, expressed as
a kvar value or a percentage of nominal, can be typed directly into either Meter Value field or selected by
dragging the dial pointer to the desired value. The new value is sent to the DECS-100 by clicking the Send
button.
Reactive Power Step Response - Current Setpoint (%).
The active var setpoint (adjusted by using any of the
To return the var setpoint to the nominal setting, the
button adjacent to the “VAR Setpoint (%) (Nominal)”
field should be clicked. If the VAR tab is left to view
other tabs or screens without returning the VAR setpoint
to nominal, the dialog box of Figure 5-19 appears. The
var setpoint is returned to nominal by clicking Yes. The
var setpoint is maintained at the current value by Figure 5-19. Var Setpoint Dialog Box
clicking No.
Protection Settings
The Protection Settings screen consists of one tab labeled Protection. Click the Protection button to access
the Protection screen or click Screens on the menu bar and click Protection/Relay.
Protection Tab
Protection settings are shown in Figure 5-20 and are described in the following paragraphs.
OEL - Current Level (A). The value of current in this field determines the excitation level that will cause the
DECS-100 to issue an overexcitation limit alarm. A current level of 0 to 15 A may be entered in 0.001
increments. When the level of field current increases above the value of this field, the OVEREXCITATION
SHUTDOWN LED on the front panel lights and the OEL time delay starts timing down.
OEL - Alarm Time Delay (sec). The value of this field determines the time delay between when the DECS-100
recognizes an overexcitation condition and the DECS-100 Alarm output (terminals AL1, AL2) closes. A time
delay of 0 to 10 seconds may be entered in 1 second increments.

Figure 5-20. Protection and Relay Settings Screen
OEL - Hardware Shutdown. If the Hardware Shutdown feature is enabled and an overexcitation condition
exists for the duration of the Alarm Time Delay, the DECS-100 will stop excitation when the Alarm output
closes. Disabling the Hardware Shutdown feature prevents the DECS-100 from removing field excitation when
the Alarm Time Delay expires and the Alarm output closes.
Field Overvoltage - Voltage Level (Vdc). The value in this field is adjustable from 0 to 250 Vdc and determines
the field voltage level that will cause the DECS-100 to issue an overexcitation limit alarm. When the field
voltage increases above the value of this field for 10 seconds, the OVEREXCITATION SHUTDOWN LED on
the front panel lights.
Field Overvoltage - Alarm. If the Alarm is enabled and a field overvoltage condition exists for 10 seconds, the
DECS-100 Alarm output (terminals AL1, AL2) will close. Disabling the Alarm prevents the Alarm output from
closing when a field overvoltage condition exists.
Field Overvoltage - Hardware Shutdown. When Hardware Shutdown is enabled, the DECS-100 will remove
field excitation when a field overvoltage condition exists for 10 seconds.
Loss of Sensing Voltage - LOS Option. One of two DECS-100 responses can be selected for a loss of sensing
voltage condition. Selecting Shutdown Regulator will cause the DECS-100 to remove field excitation when
loss of sensing voltage occurs. Selecting Transfer To FCR will cause the DECS-100 to transfer to FCR mode
when a loss of sensing voltage occurs.
Loss of Sensing Voltage - Time Delay (sec). The value of this field determines the time delay between when
a loss of sensing voltage is recognized and the DECS-100 responds according to the Hardware Shutdown
and LOS Option options selected. A time delay of 0 to 25 seconds may be entered in 1 second increments.
Loss of Sensing Voltage - Hardware Shutdown. Enabling Hardware Shutdown will cause the DECS-100 to
remove field excitation when a loss of sensing voltage occurs. Disabling Hardware Shutdown prevents the
DECS-100 from removing excitation during a loss of sensing voltage.
Generator Overvoltage - Voltage Level (%). The value of this field is expressed as a percentage and
determines the level of generator voltage required to initiate a generator overvoltage condition. An overvoltage
percentage value of 100 to 120 percent may be entered in 1 percent increments. A generator overvoltage
condition lights the GENERATOR OVERVOLTAGE LED on the front panel and closes the Alarm output at
DECS-100 terminals AL1 and AL2.

Generator Overvoltage - Hardware Shutdown. Enabling Hardware Shutdown will cause the DECS-100 to
remove field excitation when the generator overvoltage setting is exceeded. Disabling Hardware Shutdown
prevents the DECS-100 from removing excitation during a generator overvoltage condition.
Metering, Operation and Alarms

The Metering, Operation and Alarms screen is viewed by clicking the Metering button or by clicking Screens
on the Menu bar and clicking Metering/Operation. Information displayed on the Metering, Operation and
Alarms screen can be frozen by clicking the Metering button while viewing the screen or by clicking Metering
on the Menu bar and clicking Disable Metering. Metering can be resumed by clicking the Metering button or
by clicking Metering on the Menu bar and clicking Enable Metering. The Metering, Operation and Alarms
screen consists of two tabs: Operation and Alarm/Status.
Operation Tab
Operation tab metering values, setpoint values, and control functions are illustrated in Figure 5-21.
Figure 5-21. Metering, Operation, and Alarms, Operation Tab
Gen Voltage (V). These metering values report the status of the VA-B, VC-B, VC-A, and VAVG generator voltages.
The reported values are the product of the voltage sensed at terminals E1, E2, and E3 and the generator PT
ratio. All metering values are updated once each second. When single-phase sensing is used (System
Configuration screen, Sensing Voltage) and the DECS-100 sensing voltage terminals (E1, E2, and E3) are
connected as shown in Figures 4-7 or 4-9, all of the generator voltage metering values will be identical.
Gen Current (A). This metering value indicates the level of the B-phase generator current. This value is the
product of the current input to CT1 and CT2 and the CT ratio. Generator current is monitored through
DECS-100 terminals CT1 and CT2.
Gen Frequency (Hz). This metering value indicates the frequency of the monitored generator voltage.
Field Voltage (V). This metering value indicates the value of voltage being supplied from the DECS-100 output
(terminals F+ and F-) to the generator field.
Field Current (A). This metering value indicates the amount of current flowing from the DECS-100 output
(terminals F+ and F-) to the generator field.

Bus Voltage (V). This metering value indicates the amount of bus voltage present at the utility side of the tie
circuit breaker. The displayed value is the product of the voltage sensed at terminals B1 and B3 and the bus
PT ratio.
Phase Angle (Degree). This metering value indicates the phase angle difference (in degrees) between the
generator voltage and the generator current.
Aux DC Input (V). This metering value indicates the level of dc control voltage applied from a remote device
to DECS-100 terminals A and B. The displayed value correlates to the generator voltage setpoint.
Apparent Power (VA). This value is the calculated product of the metered generator voltage (VAVG), PT ratio
(entered at the System Configuration screen), metered generator current (Ib), CT ratio (entered at the System
Configuration screen), and the square root of 3. See Equation 5-1.
VA= VAVG × IB × 3 Equation 5-1
Real Power (W). This value is the calculated product of the metered generator voltage(VAVG), PT ratio (entered
at the System Configuration screen), metered generator current (Ib) CT ratio (entered at the System
Configuration screen), square root of 3, and the cosine of the metered phase angle. See Equation 5-2.
W = VAVG × I B × 3 × cos∅ Equation 5-2

Reactive Power (var). This value is the calculated product of the metered generator voltage(VAVG), PT ratio
(entered at the System Configuration screen), metered generator current (Ib) CT ratio (entered at the System
Configuration screen), square root of 3, and the sine of the metered phase angle. See Equation 5-3.
var = VAVG × I B × 3 × sin∅ Equation 5-3
Power Factor. This value is the calculated result of dividing the Real Power (W) value by the Apparent Power
(VA) value. See Equation 5-4.
PF = W ÷ VA Equation 5-4
Operating Status. The Operating Status controls and indicators include three buttons and three corresponding
indicators. Operating Status buttons are labeled PF, VAR, and OFF. Clicking the PF button changes the color
of the adjacent PF indicator to green and causes the DECS-100 to maintain the desired power factor
regulation point. The power factor regulation point can be set within the range of 0.6 lead to 0.6 lag. Clicking
the VAR button changes the color of the adjacent VAR indicator to green and causes the DECS-100 to
maintain the desired var regulation point. The var regulation point can be set within the range of 100 percent
absorb to 100 percent generate. Clicking the OFF button changes the color of the adjacent OFF indicator to
red and disables power factor and var regulation.
Operation of the Operating Status controls is determined by the status of the contacts connected across the
DECS-100 Var/PF Control terminals (52J, 52K). When these contacts are open, the Operating Status controls
are enabled. Closing the contacts at terminals 52J and 52K disables the Operating Status controls and
interrupts regulation of vars or power factor until the contacts are opened again.
Setpoint - Voltage (V). This setting field can be used to enter the desired generator output terminal voltage.
The voltage setpoint can also be entered at the Setting Adjustments screen, Setpoint tab, Automatic Voltage
Regulator (AVR) - AVR Setpoint (V). The background color of this field is green when operating in AVR mode
and power factor and var regulation is disabled.
Setpoint - Current (A). This setting defines the field current setpoint when operating in FCR mode. The current
setpoint can also be entered at the Setting Adjustments screen, Setpoint tab, Field Current Regulator (FCR)
- FCR Setpoint. Current values from 0 to 7 Adc may be entered in increments of 0.01 Adc. The background
color of this field is green when operating in FCR mode.
Setpoint - Var (% of nom.). This setting determines the level of generator vars maintained by the DECS-100
when operating in var mode. The var setpoint can also be entered at the Setting Adjustments screen, Setpoint
tab, Reactive Power Control (VAR) - VAR Setpoint (% of nom.). The background color of this field is green
when the DECS-100 is operating in AVR mode and is regulating the var setpoint.

Setpoint - Power Factor. This setting determines the level of power factor regulation maintained by the
DECS-100. The power factor setpoint can also be entered at the Setting Adjustments screen, Setpoint tab,
Power Factor Control (PF) - PF Setpoint. Power Factor setpoint values are adjustable from -0.6 to -1 (1) or
0.6 to +1 in 0.001 increments. The background color of this field is green when the DECS-100 is operating
in AVR mode and is regulating the power factor setpoint.
Voltage Matching. The Voltage Matching controls and indicators consist of two buttons and two adjacent
indicators. Clicking the ON button changes the color of the adjacent ON indicator to green and enables voltage
matching by the DECS-100. When Voltage Matching is enabled, the DECS-100 automatically adjusts the field
current to match the generator output voltage with the bus voltage prior to synchronizing. In order for Voltage
Matching to be enabled, the following conditions must be met.
C The Parallel Generator Compensation Contacts (terminals 52L and 52M) must be shorted.
C The DECS-100 Voltage Matching input must be shorted (terminals VM and VMC).
C Var/PF control must be disabled by shorting terminals 52J and 52K (open breaker).
C The DECS-100 must be operating in AVR mode.
Clicking the OFF button changes the color of the adjacent OFF indicator to red and disables the voltage
matching function.
Control Mode. Clicking the AVR button changes the color of the adjacent AVR indicator to green and enables
the AVR operating mode. When operating in AVR mode, the DECS-100 regulates the generator output voltage
at the AVR setpoint. Clicking the FCR button changes the color of the adjacent FCR indicator to green and
enables the FCR operating mode. When operating in FCR mode, the DECS-100 maintains the field current
at the FCR setpoint. Enabling the FCR mode turns off Voltage Matching.
Fine Adjustment. Raise and Lower buttons control the fine adjustment of the operating setpoint. These buttons
perform the same function as closing the appropriate set of contacts connected to the External Adjust
terminals (6D and 7 to decrease, 6U and 7 to increase) of the DECS-100. For AVR mode, each click of the
Raise button increases the voltage setpoint 0.01 volts; each click of the Lower button decreases the voltage
setpoint 0.01 volts. The minimum and maximum limits for fine adjustment of the voltage setpoint are controlled
by the Regulator Sensing Voltage setting (System Configuration screen) and the Fine Voltage Adjustment -
Band setting (Setting Adjustments screen). Fine adjustment of the voltage setpoint can be
increased/decreased no higher/lower than the Regulator Sensing Voltage setting plus/minus the Band setting.
For example, a Regulator Sensing Voltage setting of 100 volts and a Band setting of 10 percent allows the
Fine Adjustment function to increase the voltage setpoint to a maximum of 110 volts and decrease the voltage
setpoint to a minimum of 90 volts. For Var, PF, or FCR modes, the Raise and Lower buttons provide fine
adjustment over the entire adjustment range.
Alarm/Status Tab
The Alarm/Status tab indicators provide the status of DECS-100 protection functions, control modes, and
contact inputs. Alarm/Status tab indicators are illustrated in Figure 5-22 and are described in the following
paragraphs.
Protection Alarms. Five Protection Alarm indicators provide the status of DECS-100 protection functions.
Alarm indicators include Overexcitation Shutdown, Overexcitation Limiting, Underfrequency, Generator
Overvoltage, and Loss of Generator Sensing. When a DECS-100 protection function detects an alarm
condition, the appropriate indicator changes from black to red.
Control Status. Two Control Status indicators indicate when the VAR/PF and Manual modes are active. The
Manual Mode Active indicator changes from black to red when the FCR control mode is active. The VAR/PF
Mode Active indicator changes from black to red when the DECS-100 is operating in AVR mode and
correction of power factor or vars is selected.
Switch Status. Three Switch Status indicators indicate when the DECS-100 control inputs are open or closed.
The 52JK switch open indicator changes from black to red when the user-supplied contacts at terminals 52J
and 52K are closed. When this control input is open, selection of PF or VAR mode can be made on the
Operation tab of the Metering, Operation, and Alarms screen. The 52LM switch closed indicator changes from
black to red when the user-supplied contacts at terminals 52L and 52M are closed. When this control input
is closed, parallel control and droop is inactive. The VM switch closed indicator changes from black to red

when the user-supplied contacts at terminals VM and VMC are closed. When this control input is closed, the
Voltage Matching function is active.
Figure 5-22. Metering, Operation, and Alarms, Alarm/Status Tab
Metering Signal. The Metering Signal indicator of the Alarm/Status tab flashes to indicate when metering is
active. A number beside the indicator tracks how many times the metering and status indicators have been
updated. When the Metering button is clicked or Metering on the Menu bar is clicked followed by Disable
Metering, the Metering Signal indicator stops flashing, the metering update counter stops incrementing, and
the metering functions stop being updated.
PID DATA
BESTCOMS-DECS100-32 enables generator stability to be set through the automatic calculation of PID
parameters. PID stands for Proportional, Integral, Derivative. The word proportional means that the response
of the DECS-100 output is proportional or relative to the amount of change that is observed. Integral means
that the DECS-100 output is proportional to the amount of time that a change is observed. Integral action
eliminates offset. Derivative means that the DECS-100 output is proportional to the required rate of excitation
change. Derivative action avoids excitation overshoot.
BESTCOMS automatically calculates PID values after the user selects the generator frequency, generator
time constant (T'do), and exciter time constant (Texc). With BESTCOMS, the user may generate new PID
numbers, add to a PID list file, and update the AVR gain settings in the Control Gain or Step Response
screens.
The PID window (Figure 5-23) is accessed by clicking the PID button. The PID button can be clicked only
when the Stability Range setting of the Control Gain screen is set at a value of 21. (A setting of 21 enables
the entry of custom stability settings through the PID window.) Then, when a field of the Control Gain screen
is changed or selected, the PID button changes from gray to yellow and the button can be clicked to view the
PID window. After the PID numbers are modified, calculated, and updated, the PID window is closed by
clicking the Update Setting Screen button. The modified PID values are then shown on the Control Gain
screen.

Figure 5-23. PID Window
PID Calculation Based on Input Values

The available range for the exciter time constant depends on the value entered for the generator time
constant. (The default value for the exciter time constant is the generator time constant divided by 6.) The
generator time constant value selected must be in the range of 1.00 to 15.00 seconds and in 0.05 increments.
When the generator time constant value is 1.00, the available exciter time constant range is 0.03 to 0.50 in
0.01 second increments. When the generator time constant value is 15.00, the available exciter time constant
range is 0.30 to 3.00 in 0.01 second increments.
For example, when T'do is set at 2.0 seconds, Texc is 0.33. After specifying the input values, a set of PID
parameters (output data) is generated automatically. If T'do is set at 5.00 seconds, then Texc is 0.83 seconds.
The calculated KP is 155.47, KI is 138.72, KD is 48, and Kg is 1.
PID parameters can be directly removed from, added to, or modified in the PID List Data. PID parameters may
also be saved into a file (pidlist.dat).
Adding to the PID List
CAUTION
Improper PID numbers will result in poor system performance or system damage.
PID parameters can be added to a list and recalled for operation and comparison. To add to the list, type a
name for the generator (or other appropriate information) in the generator information box. Select the
generator time constant. Observe the PID gain parameters in the Field Output Data fields. If these gain
parameters are appropriate, click the Add to PID List button. Check for the new parameters by pulling down
the PID List (click the down arrow). The new gain and time constant parameters should be displayed.
Removing a PID List Record

PID parameters can also be removed from the list. To remove a list (record), pull down the PID List and select
the record or list so that the gain and time constant parameters are displayed. Click the Remove Record
button and the listed record is deleted.
Retrieving Existing Data from the PID List
To retrieve existing data, pull down the PID List and select the record or list so that the gain and time constant
parameters are displayed and highlighted. Click the Get from a List button and the listed record input and
output data displays in the boxes.

SETTINGS FILES
BESTCOMS software enables you to print a list of DECS-100 settings, save DECS-100 settings to a file, and
open a settings file and upload those settings to a DECS-100. A settings file may also be opened and edited
within any text editing software.
Printing Settings Files

A printout of DECS-100 settings can be useful for record keeping or comparison purposes. DECS-100 settings
are printed by clicking the print icon or clicking File on the Menu bar and then clicking Print. When the print
command is given, a print dialog box prompts you to select a printer. Once the printer is selected, a second
dialog box (Figure 5-24) provides the opportunity to add a title, unit information, and comments to the settings
list. Each entry is limited to a maximum of 54 characters. After this information is entered, OK is clicked and
the report is printed.
Saving Settings Files

Saving DECS-100 settings to a file for uploading to other DECS-100 units saves setup time when configuring
multiple units to the same configuration. A settings file can also be created in BESTCOMS without being
connected to a DECS-100. The settings of the desired screens can be changed and these settings can then
be saved to a file. Once a settings file is created, it can be edited using any text editing software, and then
saved for uploading.
Figure 5-24. User Information Dialog Box for Settings List
A settings file is created by clicking the save icon or by clicking File on the Menu bar and then clicking Save.
When the file command is given, a dialog box asks if you want to save the current settings into a DECS-100
data file. Clicking Yes displays a Save As dialog box where the settings are assigned a file name and then
saved. All DECS-100 settings files are automatically given a .de1 extension by BESTCOMS.
Uploading Settings Files

A DECS-100 settings file downloaded from a DECS-100 or created within BESTCOMS can be uploaded to
multiple DECS-100 units. Only a DECS-100 settings file with a .de1 extension can be uploaded to a
DECS-100 unit. Before uploading a file, communication must be initiated with the DECS-100 that is to receive
the settings. Refer to the paragraphs labeled Starting BESTCOMS, Establishing Communication.

CAUTION
Before uploading a settings file, remove operating power from the DECS-100,
disconnect the field wiring from terminals F+ and F–, and re-apply operating
power to the DECS-100.
The upload process is started by clicking the open icon or clicking File on the menu bar and then clicking
Open. A dialog box is then displayed (Figure 5-25) reminding you that the DECS-100 should be off-line before
uploading settings. Clicking Yes loads the settings into DECS-100 memory.
Figure 5-25. Settings Upload Dialog Box
PASSWORD PROTECTION
Password protection guards against unauthorized changing or viewing of DECS-100 settings. A single
password protects all DECS-100 settings. The DECS-100 is delivered with a default password of decs. Once
the password is changed, it should be stored in a secure location. If the user-defined password is lost or
forgotten, BESTCOMS-DECS100-32 must be reloaded to restore the default password.
Changing the Password
NOTE
A password change can be made only after communication between BESTCOMS
and the DECS-100 is established.
A new password can be programmed by performing the following steps.

1. Click Communications on the menu bar and click
Password Change on the drop-down menu. The Change
Password dialog box of Figure 5-26 appears.
2. Type the current password in the "Enter your access
password" field of the Change Password dialog box and
press the Enter key on your keyboard.
3. Another dialog box will appear with instructions for making
the password change. Click the OK button and type a new
password (8 alphanumeric characters, maximum) in the
"Enter your new password" field.
4. Press the Enter or Tab key on your keyboard to advance
the cursor into the field labeled "Re-enter your new
password". Type the new password again to confirm the
changed password and press the Enter key. When the
Enter key is pressed, the new password is enabled and a
dialog box appears to remind you to keep your password
in a secure location. Figure 5-26. Password Dialog Box

TERMINATING COMMUNICATION
DECS-100 communication is terminated by clicking on Communications on the menu bar, and clicking Close
Comm Port. You are asked if you want to save the settings to EEPROM. This question is asked even if no
changes were made to the DECS-100 settings. When you execute the Close command (with a Yes or No to
save settings to EEPROM), communication with the DECS-100 is terminated. If you choose to exit
BESTCOMS (by clicking File on the menu bar and then Exit) without first closing communication, you are still
given the opportunity to save the settings to EEPROM.
EMBEDDED FIRMWARE
Embedded firmware is the operating program that controls the actions of the DECS-100. The DECS-100
stores firmware in nonvolatile flash memory that can be reprogrammed through the RS-232 communication
port. It is not necessary to replace EPROM chips when replacing the firmware with a newer version.
Updating the Firmware

Future enhancements to DECS-100 functionality may make a firmware update desirable. DECS-100
embedded firmware can be updated by performing the following steps.
CAUTION
If power is lost or communication is interrupted during file transfer, the DECS-
100 will not recover and will cease to be operational.
NOTE
Communication must be closed prior to uploading embedded firmware to the
DECS-100. Refer to the Terminating Communication subsection for information
about closing DECS-100 communication.
1. Connect a communication cable between the rear RS-232 connector of the DECS-100 and the
appropriate communication port of your PC.
2. Click DECSLoad on the BESTCOMS menu bar and click Uploading Embedded Software (Figure 5-27).
If this menu selection is grayed out, you’ll need to close DECS-100 communication. Refer to the
Terminating Communication subsection for information about closing DECS-100 communication.
Figure 5-27. DECSLoad Menu Selection
When Uploading Embedded Software is clicked, a dialog box (Figure 5-28) is displayed that advises
you to disconnect the DECS-100 generator and bus connections and save the DECS-100 settings in a
file before proceeding with firmware uploading. Firmware uploading may replace some user-adjusted
settings with factory-default settings.

Figure 5-28. Software Uploading Advisory Dialog Box
3. Click Yes to proceed with software uploading. When Yes is clicked, the Communication Initiation screen
(Figure 5-6) appears. Select the active communication port for your PC and click the Initialize button.
BESTCOMS obtains the configuration settings from the DECS-100 and saves all settings. When the
saving of settings is complete, the DECS-100 Embedded Program Loader of Figure 5-29 appears.
Figure 5-29. DECS-100 Embedded Program Loader
4. Click the Get Device Information button. The DECS-100 Embedded Program Loader retrieves and
displays the DECS-100 model number, style number, serial number, and application program version
number in the left-hand column (Figure 5-30).
Figure 5-30. Retrieved DECS-100 Information
5. Click the Start Transfer Data button to proceed with software uploading. The dialog box of Figure 5-31
appears and recommends that your DECS-100 settings be saved in a file that can be uploaded to the
DECS-100 after the embedded firmware is updated.

Figure 5-31. Settings File Reminder Dialog Box
Clicking No allows you to exit the upload process so that a DECS-100 settings file can be created. Refer
to the Settings Files subsection for information about creating a settings file.
Clicking Yes continues with the upload process and displays the Open dialog box of Figure 5-32. The
Open dialog box is used to locate and select the appropriate file for uploading to the DECS-100. Only files
with a .S19 extension are displayed in the Open dialog box.
Figure 5-32. Open Dialog Box
6. Select the appropriate file for uploading and click the Open button to start the file transfer. A dialog box
(Figure 5-33) indicating the progress of the file transfer is displayed.
Figure 5-33. File Transfer Progress
Once the transfer is complete, the device information is displayed in the right-hand column of the DECS-
100 Embedded Program Loader (Figure 5-34). The displayed program version number indicates the
version and date of the firmware just loaded.

Figure 5-34. DECS-100 Information After Upload
7. Close the DECS-100 Embedded Program Loader. BESTCOMS loads the default settings, loads the saved
settings, and checks the settings.

PALM OS® PLATFORM
TABLE OF CONTENTS
SECTION 6 • BESTCOMS SOFTWARE FOR THE PALM OS® PLATFORM . . . . . . . . . . . . . . . . . . . 6-1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Installing BESTCOMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Connecting the DECS-100 and Handheld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
STARTING BESTCOMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
BESTCOMS OPERATING MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
On-Line Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Off-Line Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
BESTCOMS MAIN SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Navigating Through the Setting Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Changing Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Alarm and Contact Input Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
System Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Regulation and Voltage Matching Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Operating Mode Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Fine Voltage Adjust Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Firmware and BESTCOMS Version Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Basler Electric Contact Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
BESTCOMS FILE OPERATIONS SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Creating a Settings File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Sending a Settings File to the DECS-100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Reading Settings from the DECS-100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Deleting User-Created Settings Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
PASSWORD PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Changing the Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Figures
Figure 6- 1. Welcome Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Figure 6- 2. Select Destination Directory Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Figure 6- 3. Modules Selection Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Figure 6- 4. Select a User Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Figure 6- 5. Installation Complete Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Figure 6- 6. Main Menu BESTCOMS Icon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Figure 6- 7. Password Entry Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Figure 6- 8. BESTCOMS Startup Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Figure 6- 9. Mode Selection Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Figure 6- 10. Settings Selection Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Figure 6- 11. Downloading Progress Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Figure 6- 12. File Operations Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Figure 6- 13. BESTCOMS Main Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Figure 6- 14. Setting Change - Part 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Figure 6- 15. Setting Change - Part 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Figure 6- 16. Alarm/Contact Status Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Figure 6- 17. System Status Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Figure 6- 18. About BESTCOMS Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Figure 6- 19. Contact Basler Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Figure 6- 20. Main Drop-Down Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Figure 6- 21. New Password Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
DECS-100 BESTCOMS for Palm OS® i

Tables
Table 6-1. BESTCOMS Settings Group Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
ii DECS-100 BESTCOMS for Palm OS®

PALM OS® PLATFORM
INTRODUCTION
BESTCOMS software for the Palm OS® platform provides a portable communication link between the DECS-
100 and the user. BESTCOMS enables you to use a Palm OS® handheld or personal digital assistant (PDA)
to view and change DECS-100 settings and create settings files that can be uploaded to DECS-100 units.
INSTALLATION
BESTCOMS software for the Palm OS platform has the following minimum recommended installation and
operating requirements.
! IBM-compatible personal computer (PC)
" 486DX2 or faster microprocessor
" Microsoft® Windows® 95, 98, Me, or NT 4.0 operating system
" CD-ROM drive
" One available serial port
" Palm™ Desktop software, version 3.0.1 or later
! Palm OS® handheld
" Palm OS version 3.3 or later
! HotSync® cable
Installing BESTCOMS
BESTCOMS software for the Palm OS® platform is comprised of a series of files that run as a single
application on your handheld. A setup utility on the CD supplied with the DECS-100 automatically loads the
files into the Palm™ Desktop application Install Tool on your PC. BESTCOMS is then installed on your
handheld when you perform your next HotSync® operation.
Use the following procedure to install BESTCOMS on your handheld.
NOTE
The Palm™ Desktop software supplied with your handheld must be installed on
your PC before the BESTCOMS setup utility is run.
Your handheld must have a unique identification number in order for the
installation of BESTCOMS to be successful. This is accomplished by performing
a HotSync® operation before installing BESTCOMS.
Installing this version of BESTCOMS software will overwrite all existing DECS-100
settings files. Make a written record of all desired DECS-100 settings before
installing BESTCOMS.
Some settings in this version of BESTCOMS may not be compatible with DECS-
100 firmware version 1.09.09. (Information about checking the firmware version
is provided in the BESTCOMS Version Information sub-section.) To obtain the
latest version of DECS-100 firmware, contact Basler Electric. (Information about
viewing contact information for Basler Electric is provided in the Basler Electric
Contact Information sub-section.)
BESTCOMS is compatible only with USA regional numeric settings.
DECS-100 BESTCOMS for Palm OS® 6-1

1. Insert the BESTCOMS installation CD into the
CD-ROM drive of your PC.
2. When the DECS-100 Setup and
Documentation CD menu appears, click the
Install button for the BESTCOMS Palm OS®
Program. The setup utility starts and displays
the Welcome screen of Figure 6-1. Click the
Next> button to view the Select Destination
Directory screen of Figure 6-2.
Figure 6-1. Welcome Screen
Figure 6-2. Select Destination Figure 6-3. Modules Selection Screen

Directory Screen
3. Accept the default installation location by clicking Next> or change the location to the desired folder and
click Next>. The Modules Selection screen (Figure 6-3) appears.
4. Select all of the BESTCOMS files for installation by clicking the Select all button. Click the Next> button
to proceed to the Select a User screen of Figure 6-4.
5. Click the check box next to the desired user or click the Select all button to make BESTCOMS available
to all users. Click the Next> button to complete the installation. The Installation Complete screen (Figure
6-5) appears and confirms that BESTCOMS was installed successfully. Click the Quit button to exit the
setup utility.
Figure 6-4. Select a User Screen Figure 6-5. Installation Complete Screen
6. Connect your handheld and PC using a HotSync® cable or cradle and perform a HotSync® operation
to load BESTCOMS on your handheld.
Connecting the DECS-100 and Handheld

Communication between the DECS-100 and your handheld requires the proper connections. A readily
available data cable can be used to connect your handheld to the DECS-100. If a data cable isn’t available,
a 9-pin, male-to-male, null-modem adaptor can be connected in series with a HotSync® cable.
6-2 DECS-100 BESTCOMS for Palm OS®

STARTING BESTCOMS
BESTCOMS is started by tapping the BESTCOMS icon on the main menu (Figure 6-6) of your handheld. The
screen of Figure 6-7 appears and prompts you to enter the password. The DECS-100 is delivered with a
password of decs. If an incorrect password is entered or the Cancel button is tapped, a message will appear
and notify you that an invalid password was selected. Tapping the Ok button exits BESTCOMS and returns
you to the main menu (Figure 6-6). Entering the correct password and tapping OK displays the BESTCOMS
startup screen (Figure 6-8) followed by a screen (Figure 6-9) asking you to select the desired operating mode.
CAUTION
When applying operating power to the DECS-100 for programming purposes,
observe the precautions called out in Section 4, Installation, Preliminary Setup.
Figure 6-6. Main Menu BESTCOMS Icon Figure 6-7. Password Entry Screen
Figure 6-8. BESTCOMS Startup Screen Figure 6-9. Mode Selection Screen

BESTCOMS OPERATING MODES
BESTCOMS has two modes of operation: On-Line and Off-Line. On-Line mode enables direct communication
with the DECS-100. In On-Line mode, DECS-100 settings can be viewed and changed, and system alarms
and status indicators can be verified. The Off-Line mode can be used to view and edit settings files when your
handheld is not connected to the DECS-100. The handheld can then be connected to the DECS-100 and the
settings file uploaded.
The following paragraphs describe how each BESTCOMS operating mode is accessed.
On-Line Mode
NOTE
Ensure that the handheld is connected to the DECS-100 with the correct cable
before attempting to work in the On-Line mode. If the communication cable is not
connected, the handheld may lock up and require a soft reset.
Tapping the On-Line button (Figure 6-9) establishes communication between BESTCOMS and the DECS-100.
When communication is established, BESTCOMS downloads the settings from the DECS-100 so that they
can be viewed and edited on your handheld. The screen shown in Figure 6-11 is displayed when BESTCOMS
is downloading settings from the DECS-100.
Off-Line Mode
Tapping the Off-Line button (Figure 6-9) displays a screen (Figure 6-10) that asks you to select either the
factory-default DECS-100 settings (Default button) or a user-created settings file (Open button) from a list of
settings files stored on your handheld.
Tapping the Default button causes BESTCOMS to retrieve the factory-default settings from your handheld so
that they can be viewed and edited. A screen similar to the one shown in Figure 6-11 is displayed while
BESTCOMS retrieves the factory-default settings.
Tapping the Open button displays the File Operations screen of Figure 6-12. One of 10 user-created settings
files or the factory-default settings file can be selected from the list displayed on this screen. When the settings
file name is tapped, the settings are retrieved. A screen similar to the one shown in Figure 6-11 is displayed
while BESTCOMS retrieves the factory-default settings or user-created settings file. When the settings file has
been retrieved, a dialog box appears and confirms that the settings were loaded. Tapping the Ok button
displays the main screen shown in Figure 6-13.
More information about the File Operations screen is provided in the BESTCOMS File Operation Screen
subsection.
Figure 6-10. Settings Selection Screen Figure 6-11. Downloading

Progress Screen
Figure 6-12. File Operations Screen Figure 6-13. BESTCOMS Main Screen
NOTE
The Save to DECS button of the main screen (Figure 6-13) is not always present.
It is displayed only in On-Line mode when settings have been changed but not
saved to the DECS-100. If BESTCOMS is exited (either by turning off the
handheld or switching to another application) without tapping the Save to DECS
button, setting changes are not saved in the DECS-100 and may be erased if the
DECS-100 loses operating power.
The Save to DECS button does not appear when using BESTCOMS in Off-Line
mode.
BESTCOMS MAIN SCREEN

The BESTCOMS main screen of Figure 6-13 is the gateway to other BESTCOMS screens where you can
make settings changes, view the status of DECS-100 alarms and outputs, view system parameters, the
BESTCOMS version level, and contact information for Basler Electric customer service.
Navigating Through the Setting Groups

DECS-100 settings are divided into the seven groups/screens listed below. Each setting group/screen is
accessed from the BESTCOMS main screen.
C Configuration
C Settings
C Control
C Limiter
C AVR/FCR Gain
C Protection
C Var/PF Gain
A group of settings is accessed by tapping the group name listed on the main screen. A summary of the
individual settings available at each screen is provided in Table 6-1.

Table 6-1. BESTCOMS Settings Group Summary
Configuration Screen AVR/FCR Gain Screen

Sensing Mode Stability Range
Sensing Frequency Mode AVR Kp
Rated Sensing Voltage AVR Ki
Generator PT Ratio AVR Kd
Generator CT Ratio AVR Td
Bus PT Ratio AVR Kg
Limiter Mode FCR Kg
Fine Voltage Adjustment Band
Settings Screen
Protection Screen
Voltage Setpoint (AVR)
Field Current Setpoint (FCR) Overexcitation Voltage Enabled
Var Setpoint OEL Shutdown Enabled
PF Setpoint LOS Transfer to FCR Enabled
OEL Shutdown Time Delay
Generator OV Shutdown Enabled
LOS Shutdown Enabled
Control Screen Field OV Shutdown Enabled
Soft Start Time Generator Overvoltage Level
Underfrequency Kneepoint Field Overvoltage Level
Volts/Hertz Slope LOS Time Delay
Voltage Matching Speed LOS Balance Level
Droop Setpoint LOS Imbalance Level
Generator Short-Circuit Level
Limiter Screen Var/PF Screen

Overexcitation Limiter Var Ki
OEL Ki Var Kg
OEL Kg PF Ki
PF Kg
Changing Settings
When a setting screen is selected and displayed, the description for each setting is listed in the Item column,
the value for each setting is listed in the Value column, and the range for the highlighted setting is listed in the
Settings Range box.
To change a setting, highlight the desired setting by tapping it. Ensure that the cursor is on the Change to: line
and enter the new value in the Graffiti ® writing area of your handheld. In the example of Figure 6-14, the
Control screen Soft Start Time setting of 20 seconds is being replaced with a new setting of 50 seconds. Once
the new value is entered in the Change to: line, the Update button is tapped to send the setting to the DECS-
100. When the handheld confirms the DECS-100 setting change, the handheld emits a two-tone beep, the
new setting is displayed in the Value column, and the Save to DECS button appears in the lower, right-hand
corner of the screen. (Figure 6-15).

Figure 6-14. Setting Change - Part 1 Figure 6-15. Setting Change - Part 2
Multiple changes can be made before saving the DECS-100 settings. Settings are saved by tapping the Save
to DECS button on any of the screens that display the button.
Alarm and Contact Input Status

The Alarm/Contact Status screen (Figure 6-16) is accessed from the BESTCOMS main screen (Figure 6-13).
Tap the arrow (–) on the Other Pages: line and then select Front Panel Alarms from the drop-down menu.
The Alarms portion of this screen displays the status of the DECS-100 front panel LEDs. An alarm condition
is indicated by a checked box (:). The Contact Status section indicates whether the DECS-100 52LM, 52JK,
and Voltage Matching contact inputs are open or closed. To refresh the status of the Alarm/Contact Status
screen indicators, tap the Update button. To return to the main screen, tap the Back icon ( ).
System Status
The System Status screen shown in Figure 6-17 is accessed from the main screen (Figure 6-12) by tapping
the arrow on the Other Pages: line and then tapping System Status. The System Status screen displays the
current mode setting beside or below each Mode button. Note that the voltage matching and var/power factor
mode settings will not appear on the System Status screen if your DECS-100 does not have those optional
features.
Figure 6-16. Alarm/Contact Figure 6-17. System Status Screen

Status Screen

Regulation and Voltage Matching Buttons
Tapping the Reg. Mode button toggles between Field Current Regulation (FCR) mode and Automatic Voltage
Regulation (AVR) mode.
Tapping the VM Mode button toggles the voltage matching function between the On and Off state. The
example of Figure 6-18 shows a DECS-100 operating in the AVR mode with voltage matching disabled.
Note that voltage matching cannot be enabled unless the following conditions are met.
C The DECS-100 must be equipped with the voltage matching option.
C The Parallel Generator Compensation contacts (terminals 52L and 52M) must be shorted.
C The DECS-100 Voltage Matching input (terminals VM and VMC) must be shorted.
C Var/PF control must be disabled by shorting terminals 52J and 52K (open breaker).
C The DECS-100 must be operating in AVR mode.
Operating Mode Buttons

The Operating Mode segment of the System Status screen (Figure 6-18) has three buttons labeled OFF, PF,
and VAR. These buttons will not appear if the DECS-100 isn’t equipped with the var/power factor control
option. Tapping the PF button places the DECS-100 in the power factor operating mode and causes a
checked box (:) to appear below the PF button. Tapping the VAR button places the DECS-100 in the var
operating mode and causes a checked box to appear below the VAR button. Tapping the Off button disables
power factor and var regulation and places a checked box below the OFF button. The example of Figure 6-18
shows that power factor and var regulation are disabled.
Operation of the Operating Mode controls is determined by the status of the contacts connected across the
DECS-100 Var/PF Control terminals (52J, 52K). When these contacts are open, the Operating Status controls
are enabled. Closing the contacts at terminals 52J and 52K disables the Operating Status controls and
interrupts regulation of vars or power factor until the contacts are opened again.
Fine Adjust Buttons

Fine adjustments to the operating setpoint are made by tapping the Raise and Lower buttons of the System
Status screen (Figure 6-18). In AVR mode, an arrow serves as a reminder of which button was last tapped.
A single tap of the Raise or Lower buttons increments or decrements the generator voltage by 0.1 volts. In
Var, PF, or FCR mode, the Raise and Lower buttons allow fine adjustment over the entire adjustment range.
To return to the main screen, tap the Back icon.
Firmware and BESTCOMS Version Information

The “i” button, located in the upper right-hand corner of the main screen (Figure 6-13), can be tapped to view
the About screen (Figure 6-18). When operating in Off-Line mode, the About screen displays only the
BESTCOMS version number. When operating in On-Line mode, the About screen displays the BESTCOMS
version number and the DECS-100 firmware version number. Tapping the Hide Splash Screen box prevents
the BESTCOMS startup screen from appearing when BESTCOMS is started. Tapping the “i” button on the
About screen displays a message stating that BESTCOMS is compatible only with USA regional numeric
settings. For example, integers and fractions are separated by periods instead of commas. Tapping the Back
icon in the upper right-hand corner of the screen returns you to the main screen.
Basler Electric Contact Information

Tapping the Contact Basler button on the About screen (Figure 6-18) displays the Contact Basler screen of
Figure 6-19. This screen lists the contact information for Basler Electric customer service. Tapping the Back
icon returns you to the main screen shown in Figure 6-13.

Figure 6-18. About BESTCOMS Screen Figure 6-19. Contact Basler Screen
BESTCOMS FILE OPERATIONS SCREEN

The File Operations screen (Figure 6-12) displays a list of 10 user-created settings files and one factory-
default settings file. When less than 10 user-created settings files exist, placeholders labeled “–empty–“
occupy unused locations in the list. Tapping the name of a user-created file or the default settings file loads
the file settings into BESTCOMS.
A drop-down menu is accessed by tapping the arrow (–) on the File Actions line. Selections from the drop-
down menu enable you to create a settings file, send a settings file to the DECS-100, retrieve settings from
the DECS-100, and delete user-created settings files from the file list on the File Operations screen.
Creating a Settings File

A settings file can be created with BESTCOMS in either On-Line or Off-Line mode. In On-Line mode, the
existing DECS-100 settings can be downloaded from the DECS-100 and then modified to create a settings
file. The factory-default settings or a user-created settings file can be retrieved and modified in either On-Line
mode or Off-Line mode to create a new settings file. When editing of the settings is complete, the following
steps are used to save the settings file with a unique name.
1. On the BESTCOMS main screen, tap the arrow (–) on the Other Pages: line.
2. Select File Operations from the drop-down menu and then tap the Open button in the “Which
Settings?” dialog box to access the File Operations screen.
3. Tap the arrow (–) on the File Actions: line of the File Operations screen.
4. Select SAVE to file from the drop-down menu.
5. Use the handheld Graffiti® writing area to enter a name for the file. Up to 50 alphanumeric characters
can be used. Note that no more than approximately 13 characters are shown in the Save As: field when
entering a file name.
Sending a Settings File to the DECS-100

An existing settings file can be sent to the DECS-100 by using the following procedure.
1. On the BESTCOMS main screen, tap the arrow (–) on the Other Pages line.
3. Select the desired settings file from the list on the File Operations screen to load the settings into
BESTCOMS.
4. Tap the Ok button to acknowledge that the settings were loaded.
5. Repeat Steps 1 and 2 to access the File Operations screen.

6. Tap the arrow (–) on the File Actions: line and select SEND to DECS from the drop-down menu.
7. Ensure that the proper data cable is connected between the DECS-100 and your handheld.
8. Tap the Ok button in the “Connect Cable” dialog box to send the file.
9. Tap the Ok button to acknowledge that the settings were sent to the DECS-100.
10. To save the settings in DECS-100 memory, tap the Save to DECS button which is accessible from any
of the BESTCOMS screens.
11. Tap Ok to acknowledge that the settings were saved to DECS-100 memory.
Reading Settings from the DECS-100

DECS-100 settings are read into BESTCOMS on your handheld by performing the following steps.
3. Tap the arrow (–) on the File Actions: line and then select SEND to DECS from the drop-down menu.
4. Ensure that the proper data cable is connected between the DECS-100 and your handheld.
5. Tap the Ok button in the Connect Cable dialog box to read the DECS-100 settings into BESTCOMS.
6. Once the settings are read, tap the Ok button to acknowledge that the DECS-100 settings were read
into BESTCOMS.
Deleting User-Created Settings Files

Perform the following steps to delete a user-created settings file.
3. Tap the arrow (–) on the File Actions line and then select DELETE saved file.
4. Tap the name of the settings file that you want to delete.
5. Tap the Delete button to remove the selected settings file from your handheld.
PASSWORD PROTECTION
Password protection guards against unauthorized changing or viewing of DECS-100 settings. A single
password protects all settings. The DECS-100 is delivered with a default password of decs. Once the
password is changed, it should be stored in a secure location. If the user-defined password is lost or forgotten,
BESTCOMS must be reloaded to restore the default password.
Changing the Password

A new password can be programmed by performing the following steps.
1. Access the Main drop-down menu (Figure 6-20) by tapping the title bar of the main screen. Older
versions of BESTCOMS may require that you tap the Menu icon on your handheld screen to access
the Main drop-down menu.
2. Select Change Password from the Main drop-down menu.
3. When prompted, enter the desired password and tap OK. The BESTCOMS password is not case-
sensitive; either lower-case or upper-case alphanumeric characters are acceptable. When OK is
tapped, the new password is activated and BESTCOMS displays the new password. In the example
of Figure 6-21, a password of 123 was entered.
4. Tap OK to return to the BESTCOMS main screen.

Figure 6-20. Main Drop-Down Menu Figure 6-21. New Password Screen

SECTION 7 • MAINTENANCE AND TROUBLE-
SHOOTING
TABLE OF CONTENTS
SECTION 7 • MAINTENANCE AND TROUBLE-SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Generator Voltage Does Not Build . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Low Generator Output Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
High Generator Output Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Poor Voltage Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Generator Output Unstable (Hunting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
OVEREXCITATION SHUTDOWN Indicator is Annunciating . . . . . . . . . . . . . . . . . . . . 7-4
LOSS OF GENERATOR SENSING Indicator is Annunciating . . . . . . . . . . . . . . . . . . . 7-4
OVEREXCITATION LIMITING Indicator is Annunciating . . . . . . . . . . . . . . . . . . . . . . . 7-5
UNDERFREQUENCY ACTIVE Indicator is Annunciating . . . . . . . . . . . . . . . . . . . . . . . 7-5
No Droop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
No Voltage Matching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
DECS-100 Maintenance and Troubleshooting i

SECTION 7 • MAINTENANCE AND TROUBLE-
SHOOTING
PREVENTIVE MAINTENANCE
The only preventive maintenance required on the DECS-100 is to periodically check that the connections
between the DECS-100 and the system are clean and tight. DECS-100 units are manufactured using state-of-
the-art, surface-mount technology. As such, Basler Electric recommends that no repair procedures be
attempted by anyone other than Basler Electric personnel.
TROUBLESHOOTING
If you do not get the results that you expect from the DECS-100, first check the programmable settings for the
appropriate function. Use the following troubleshooting procedures when difficulties are encountered in the
operation of your excitation system.
Generator Voltage Does Not Build

Step 1. Verify that all wiring is properly connected. Refer to Figures 4-6 through 4-10.
If wiring is improperly connected or loose, reconnect wiring properly.
If wiring connections are correct, proceed to Step 2.
Step 2. Verify that the generator is spinning at rated speed.
If the generator is not up to rated speed, increase generator speed to the rated value.
If the generator is spinning at rated speed, proceed to Step 3.
Step 3. For PMG power, check for correct input power to the DECS-100. Refer to Section 1, General
Information, Specifications for input power requirements.
If voltage is not present, refer to the generator manual for repair procedures (PMG system only).
If voltage is present, proceed to Step 4.
Step 3a. If the DECS-100 is being shunt powered (non-PMG) mode, verify that the residual voltage applied
to the power input is at least 6 Vac.
If the applied voltage is less than 6 Vac, refer to the generator manual and flash the generator field.
If the applied voltage is 6 Vac or greater, proceed to Step 4.
Step 4. Verify that no fuses are open.
Replace any open fuses.
If no fuses are open, proceed to Step 4.
Step 5. Verify that the front panel OVEREXCITATION SHUTDOWN indicator is not lit.
If the front panel OVEREXCITATION SHUTDOWN indicator (field voltage) is lit, check the
generator and/or load conditions. Interrupt input power or shut down the generator for a minimum
of one minute.
If the front panel OVEREXCITATION SHUTDOWN indicator is not lit, proceed to Step 6.
Step 6. Verify that the front panel OVEREXCITATION LIMITING indicator is not lit.
If the front panel OVEREXCITATION LIMITING indicator is lit, check the generator and load
conditions. Also check the field current limit setpoint for the correct level. Interrupt input power or
shut down the generator for a minimum of 1 minute.
DECS-100 Maintenance and Troubleshooting 7-1

If the front panel OVEREXCITATION LIMITING indicator is not lit, proceed to Step 7.
Step 7. Verify that the DECS-100 soft start settings are correct. Too long of a soft start setting may give the
appearance of no buildup.
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 DECS-100 unit.
If replacing the DECS-100 unit does not correct the malfunction, then the generator is defective.
Consult with the generator manufacturer.
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. Verify that the underfrequency knee setpoint is not greater than the generator frequency.
If the underfrequency setpoint is too high, adjust the setpoint below the rated generator frequency.
If the underfrequency setpoint is correct, proceed to Step 3.
Step 3. Verify that the generator is spinning at rated speed.
If the generator is not up to rated speed, increase the generator speed to the rated level.
If the generator is spinning at rated speed, proceed to Step 4.
Step 4. For PMG power, check for correct input power to the DECS-100. Refer to Section 1, General
Information, Specifications for input power requirements.
If the DECS-100 input voltage is low, refer to the PMG manual for PMG repair (PMG system only).
If the voltage is at the required level, proceed to Step 5.
Step 4a. If the DECS-100 is being shunt powered (non-PMG), verify that the power potential transformer (if
used) has the correct turns ratio, is sized properly, and is supplying the correct voltage level to the
power input.
If the turns ratio of the power potential transformer is incorrect, is sized too small, or is not supplying
the correct input power, replace the power potential transformer.
If the power potential transformer is correct, proceed to Step 5.
Step 5. Verify that the sensing potential transformer (if used) has the correct turns ratio and is operating
correctly.
If the turns ratio of the sensing potential transformer is incorrect, replace the sensing potential
transformer.
If the sensing potential transformer is operating correctly, proceed to Step 6.
Step 6. Verify that the front panel OVEREXCITATION LIMITING indicator is not lit.
If the front panel OVEREXCITATION LIMITING indicator is lit, check the generator and/or load
conditions. Also check the field-current limit setpoint for the correct level. Interrupt input power or
shut down the generator for a minimum of one minute.
If the front panel OVEREXCITATION LIMITING indicator is not lit, proceed to Step 7.
Step 7. Low generator output voltage may occur when operating in droop mode with an inductive load.
7-2 DECS-100 Maintenance and Troubleshooting

If the low voltage condition is not caused by the droop function, proceed to Step 8.
Step 8. Verify that the voltage setpoint is not being modified by application of voltage to the optional
Accessory Input.
If the low voltage condition is not caused by voltage applied to the Accessory Input, proceed to Step
9.
High Generator Output Voltage
Step 1. Verify that the voltage adjustment is not set too high.
If the voltage adjustment is too high, adjust it to the correct setpoint.
If the voltage adjustment is correct, proceed to Step 2.
Step 2. Verify that the sensing potential transformer (if used) has the correct turns ratio.
If the turns ratio of the sensing potential transformer is incorrect, replace the sensing potential
transformer with the correct one.
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. Verify that the voltage setpoint is not being modified by application of voltage to the optional
Accessory Input.
If the high voltage condition is not caused by voltage applied to the Accessory Input, proceed to
Step 5.
Poor Voltage Regulation

Step 1. Verify that the case of the DECS-100 is properly grounded.
If the DECS-100 is not properly grounded, connect a dedicated ground wire to the quarter-inch
fast-on connector labeled GND on the rear of the DECS-100 case.
If the DECS-100 is properly grounded, proceed to Step 2.
Step 2. Check for grounded field leads.
If the field leads are grounded, isolate them from ground.
If the field leads are not grounded, proceed to Step 3.
Step 3. If the DECS-100 is powered from a PMG, check for grounded PMG leads.
If the PMG leads are grounded, isolate them from ground.
If the PMG leads are not grounded, proceed to Step 4.
Step 4. Verify that the generator frequency is not dropping below the DECS-100 underfrequency setpoint
when load is applied to the generator.
If the generator frequency is dropping below the underfrequency setpoint, reduce the setpoint if
possible. Also check the prime mover and generator for proper sizing in relation to the applied load.
If poor regulation is not related to DECS-100 underfrequency operation, proceed to Step 5.

Step 5. Verify that regulation is not being affected by normal droop operation.
If droop operation is not affecting regulation, proceed to Step 6.
Step 6. Replace the DECS unit.
Generator Output Unstable (Hunting)

Step 1. Verify that the governor for the prime mover is operating properly.
If the governor is not operating properly, troubleshoot using the manufacturer's suggested
procedures.
If the governor is operating properly, proceed to Step 2.
Step 2. Verify that the sensing and input power leads are connected securely.
If the sensing or input power leads are not connected securely, tighten the connections.
If the sensing or input power lead connections are secure, proceed to Step 3.
Step 3. Verify that the DECS-100 Stability Range is set to the proper range.
If the Stability Range setting is incorrect, reset the Stability Range.
If the Stability Range setting is correct, proceed to Step 4.
Step 4. Verify that the Stability Level is properly set.
If the Stability Level is not properly set, reset the Stability Level.
OVEREXCITATION SHUTDOWN Indicator is Annunciating

Step 1. 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 2.
Step 2. Verify that the generator exciter field voltage requirements are compatible with the DECS-100.
If the exciter field voltage requirements are not compatible with the DECS-100, contact Basler
Electric Customer Service for recommendations.
If the exciter field voltage requirements are compatible with the DECS-100, proceed to Step 3.
Step 3. Replace the DECS-100.
If replacing the DECS-100 does not correct the malfunction, proceed to Step 4.
Step 4. Refer to the generator manual. Generator is defective.
LOSS OF GENERATOR SENSING Indicator is Annunciating

Step 1. Verify that the voltage sensing leads are properly connected.
If the sensing leads are not properly connected, correct the connections.
If the sensing lead connections are correct, proceed to Step 2.
Step 2. For single-phase sensing, verify that E2 and E3 are connected.
If E2 and E3 are not connected, connect them both to phase C sensing voltage.
If E2 and E3 are properly connected, proceed to Step 3.
Step 3. Verify that the sensing potential transformer (if used) has the correct turns ratio and is functioning
properly.

If the sensing potential transformer has the wrong turns ratio or is malfunctioning, replace it.
If the sensing potential transformer is correct and functioning properly, proceed to Step 4.
Step 4. Verify that the generator output voltage is present on all phases.
If the generator is missing a phase, refer to the generator manual. Generator is defective.
If generator output voltage is balanced on all phases, proceed to Step 5.
Step 5 Replace the DECS-100.
OVEREXCITATION LIMITING Indicator is Annunciating

Step 1. 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 2.
Step 2. Verify that the DECS-100 output (field) current limit is not set too low.
If the output current limit setpoint is too low, adjust for the proper setting.
If the output current limit is set properly, proceed to Step 3.
Step 3. Verify that the generator exciter field current requirements are compatible with the DECS-100.
If the generator exciter field current requirements are not compatible with the DECS-100, contact
Basler Electric Customer Service for recommendations.
If the generator exciter field current requirements are compatible with the DECS-100, proceed to
Step 4.
Step 4. Replace the DECS-100.
If replacing the DECS-100 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.
If the underfrequency setpoint is incorrect, adjust it to the correct value.
No Droop
Step 1. Verify that the DECS-100 52L/M contact input is open.
If the 52L/M contact input is not open, it must be opened to enable the droop function.
If the 52L/M contact input is open, proceed to Step 2.
Step 2. Verify that the DECS-100 52J/K contact input (if present) is closed or the Var/PF function is
disabled via BESTCOMS. Var/PF operation must be disabled for droop operation. If var/PF
operation is disabled, proceed to Step 3.
Step 3. Verify that the DECS-100 droop setting is not adjusted to 0% droop.
If the droop setting is adjusted to 0% droop, increase the setpoint above 0%.
If the droop setting is adjusted to above 0%, proceed to Step 4.
Step 4. Check for an open in the circuit connected to DECS-100 CT1 and CT2.

If there is an open circuit, repair as necessary.
If there is no open circuit, proceed to Step 5.
Step 5. Verify that all connections are correct according to Figures 4-6 through 4-9.
If connections are incorrect, correct the problem.
If connections are correct, proceed to Step 6.
Step 6. Verify that the load being applied to the generator for droop testing is not purely resistive.
If only a resistive load is being applied to the generator, apply an inductive load and retest.
If the load being applied to the generator is inductive, proceed to Step 7.
Step 7. Verify that your DECS-100 is compatible with the current sensing transformer (1 A or 5 A
secondary) being used. For example, a current sensing transformer with a 1 ampere output rating
would produce very little droop if your DECS-100 has a 5 ampere current transformer input. Refer
to Figure 1-1 of Section 1, General Information to check the current transformer input of your
DECS-100.
If the current transformer input is incorrect, replace the current sensing transformer or the
DECS-100 for compatibility.
If the current transformer input is correct, proceed to Step 8.
Step 8. If the above steps fail to correct the malfunction, replace the DECS-100 unit.
No Voltage Matching
Step 1. Verify that the Voltage Matching option was purchased and is enabled in the software.
If not enabled, use the BESTCOMS software to turn on voltage matching.
If voltage matching is enabled, proceed to Step 2.
Step 2. Verify that all connections are correct according to Figures 4-6 through 4-9 as required for the
Voltage Matching option of the DECS-100.
If the interconnection is incorrect, reconnect according to the appropriate interconnect diagram.
If the interconnection is correct, proceed to Step 3.
Step 3. Verify that the DECS-100 VM/VMC contact input is closed.
If the VM/VMC contact input is open, it must be closed to enable voltage matching.
If the VM/VMC contact input is closed, proceed to Step 2.
Step 4. Check for correct utility reference voltage on DECS-100 terminals B1 and B3.
If the interconnection is incorrect, reconnect according to the appropriate interconnect diagram.
If the interconnection is correct, check for open system fuses.
Verify that the potential sensing transformer, if used, is connected to DECS-100 terminals B1 and
B3.
If potential sensing transformer connections are correct, proceed to Step 5.
Step 5. Verify that the generator output voltage setpoint is within 10 percent of the measured utility bus
voltage.
If the setpoint is too low or too high, adjust the setpoint to the appropriate level.
If the setpoint is correct, proceed to Step 6.
Step 6. If the above steps fail to correct the Voltage Matching malfunction, replace the DECS-100.

4/10/2012 CERTIFIED FOR: MAESTRANZA DIESEL SA; PO #: ENE018.322/12; PROJECT NAME: ; KATO SN: 28469;

Manual Generador Kato

Încărcat de

Informații document

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

Manual Generador Kato

Încărcat de

Drepturi de autor:

Formate disponibile

Manual Package

Installation • Operation • Maintenance

Customer: Maestranza Diesel S.A.

Customer P.O.: ENE018.322/12

Project: 1.6MW, 380V, 50Hz, 80C

Kato Serial Number: 28469

Kato Engineering Inc.

Bearing Lubrication Instructions

Serial Number Model Number Type Number

28469 Gen AA28819000 28819

GREASE BASE MATERIAL Lithium

Outboard or Exciter End Drive End

SPLIT ROLLER BEARINGS

Bearing Replacement and Disassembly 5

Initial Grease Fill Chart 8

Bearing Replacement, Assembly 9

Field Service of Split Roller Bearings 13

Anti Brinelling Device 14

NOTE: Do not mix synthetic and non-synthetic

NOTE: It may be necessary to remove the exciter/

A. To remove drive end bearing, proceed as follows:

1. Remove exciter and drive end covers.

2. Place wood or fiber protective strips Figure 3

8. Remove the bolts holding the two halves

B. To remove the exciter end bearing, proceed as fol-

1. Place a strap around the exciter end of the

2. Remove the bolts holding the flanged

8. Remove the screws from the clamping

9. If the sling is to be removed, make sure

1. Apply a light coat of O-ring lubricant to the o-rings

2. Install the inner seal onto the shaft. Use a square

4. There should be a gap at the joints of the inner

9. Inject sufficient grease to fill the grease passages. Grease hole

11. Assemble the cartridge with races installed.

13. Tighten in an X pattern to torque spec, refer to

Replenishment - For periodic replenishment of lubri-

Very stiff greases which tend to channel or very soft

Caution: Tightening the flange halves without

Drive end bearing 8. Ensure the lower cartridge is seated squarely to

10. Inspect the grease seals. Replace if necessary.

Prep and assemble

1. Install the inner race and torque. (Measurements

2. Prepare the cartridge. Clean and lubricate. Re-

3. Clean the shaft, seals and rollers, inspect for dam-

4. Reinstall and re-lubricate the rollers or replace with

FAILURE TO DO SO MAY CAUSE DAMAGE TO THE EQUIPMENT

5" shaft bearings

5.5" shaft bearings

6" shaft bearings

Vibration recorded by site operation

Visual Estimation of Axial Movement of the rotor in

Location of Magnetic center, relative to the seal face

Record grease amount in bearings and grease color

Type of seal present? ALUMINUM RACE BRONZE RACE

Measure the shaft diameter where the race was mounted.

Visual aspect of the shaft under the race

If Inner race removed / replaced Inner race NOT removed / replaced

All screws are torqued with a torqued wrench

Rotate slowly by hand for 5 turns or with turbine slowly

The rotor can be rotated smoothly and quietly by hand

AFTER ALIGNMENT, BUT BEFORE THE GUARD IS INSTALLED

Location of Magnetic center, relative to the seal face

Check cleanliness of insulation on Exciter End

Vibration recorded by site operation