STAMFORD AVR CONVERSION INSTRUCTIONS Fitting AS440 AVR in place of SX440 AVR. * Read all instructions carefully before starting this conversion. * Check that all the parts listed below are included with this conversion ki Depending upon the type of machine being converted, not all the parts listed will be required ‘* No specialised tools are necessary. Contents: Tem. Description. PartNo. iy. | check 1 _[ Conversion instructions (this sheet) | SP_SX440_AS440_07.0701.68 | 1 2 [AS440 AVR 000-2440 zl '3__[ AS440 AVR specification sheet | TD_AS440 AVR_11.06_03_GB cl ‘4 | Terminal biock (6-way) “450-15489 a 5 _| Fixing Screw '005-04068. Hl ‘6 | Grommet (003-25161 1 7 [AVR adjustment label E00-14064 1 | AVR adjusting tool 00-10032 A ‘9 | Cabie-tie (052-4503 5 I SAFETY WARNING, Service and fault-finding procedures present hazards which can result in injury or death Only personnel qualified to perform electrical land mechanical service who are familiar with the equipment should carry out these procedures. WARNING Ensure ongine starting circuits are disabledand the generator is electrically olated before commencing service of maintenance procedures. 'solate any anti-condensation heater supply. @ itis essential that all instruments are regularly checked for safely, and any connection leads, probes or clips checked to ensure that they are Suitable forthe voltage levels being tested © Never attempt to test a generator when the ‘engine is running (LIVE) unless there is another ‘competent person present who can switch off the power supply and shut down the generator in.an emergency. @ Never expose electrical components with the ower on (LIVE) without creating a safe working area around you. Make sure you have made all other persons, in the immediate area, fully aware of what you are doing. © These instructions have been written for use with the AVR specification as originally supplies with the generator.CONVERSION PROCEDURE STEP 1 Removing the $x440 AVR. 1.1 Remove the appropriate covers to gain full access to the AVR and its mounting plate. 1.2. Make sure that all the existing AVR connection leads (Fig 1) are clearly identified. v 1.3 _ Disconnect all the leads from the SX440 AVR 1.4 Unscrew the 4 AVR fixings and remove the AVR. Keep the screws for use with the new AVR. Fig 1: Existing AVR wiring. OOO pore stator STEP 2. pProparing the new AS440 AVR. poincin nascar Bas aera 2 a paroupecrraeedond Link) Link ( Link terminals 8-22 Frequency Link for the correct frequency of ‘operation (50Hz or 60H), © Link the required stability setting, (Select the 'FAST’ setting in the correct, kW/rating range ~ see AS440 AVR specification sheet for details.) d. Tum the AVR ‘Output Voltage Control {0 its minimum position (fully ant- clockwise). Note that the output voltage will need to be set to the Link (c) required level when installation is Stability completed. See 'Step 53° SelectionSTEP 3 Fitting the new As44o AVR. Fig 3a : Fitting the new AVR and grommet AVR mounting plate 3.1 Insert the grommet [item 6] into the mounting plate ‘as shown in Fig 3a, AS440 AVR 3.2 Mount the new AS440 AVR [item 2] using the four fixing screws as shown in Fig 3a. 3.3 Fixthe 6-way terminal block {item 4] to the rear of the mounting plate using the fixing screw [item 5] as shown in Fig 3b. Fig 3b : Fitting the 6-way terminal block. 6-way terminal block [item 4] AVR mounting plate 4x fixing screws Remove one cable-tie and route existing hamess as shown in Fig 3b. Pass leads marked P2, 3, F1 (or X or X+) ‘and F2 (or XX or XX.) through the grommet ready to connect to the AVR. New route of e: wiring harness Pass any accessory leads through the ‘grommet ready to connect to the AVR. STEP 4 reconnecting. 41 Connect leads to the new AS440 AVR [item 2] as shown in Fig 4. Pass all these leads through the grommet [item 6] Lead P3 to AVR terminal 7 Lead P2 to AVR terminal 8 Lead F4 (or X or X+) to AVR terminal F1 Lead F2 (or XX or XX-) to AVR terminal F2 Reconnect the Hand-Trimmer leads (if used) to AVR terminals 1 and 2. Reconnect the Droop input leads (if used) fo AVR terminals S1 and $2. Reconnect the Accessory input leads (if used) to AVR terminals A1 and A2. © 42 Connect leads 2 and 3 to the 6-way terminal block [item 4] as shown in Fig 4 (These leads are not used by the new AVR and should not be connected to any equipment. ) 43. Secure all wiring with cable-tie(s) provided [ item 9 },Fig 4: New wiring for the AS440 AVR. [eeecoeeece] Si aan 50 FREQUENCY ‘¢'5% |See 2.1.b SELECTION © 60a Dia [See 2.1.b MAIN STATOR sTaBUTY C i CONNECTIONS SELECTION Bo 2] ‘S1S2A1A2 * O908 [| | C= to Power-ractor | Lt —— CONTROLER (when fitted) mi gr (when fitted) 5.1 Check all wiring connections 52 The AVR has been factory set and might not be adjusted to sult your particular requirements. Before adjusting the AVR read the AS440 AVR Specification Sheet item 3} 5.3 Before starting the generator set its tecommended that you turn the generator ‘output voltage control to its minimum position (ie. fully counter-clockwise). Adjustment of the generator voltage (and other settings if necessary) should be made using the AVR. ‘adjustment too! [tem 8] provided. 5.4 Start the generator set and check correct operation of the new AVR. Make any adjustments while observing any local or national safety regulations and procedures. 5.5 _Refitall covers and make safe, STEP 5 Finat check & adjustments. ro you. orator: Make sure you have made all other persons in the immediate area fully aware of what you are doing, ‘Make sure you have read and understand the AVR Specification Sheet Make sure you fully understand all the other operating and safety instructions conceming the generator set and its installation, STAMFORD BARNACK ROAD ‘STAMFORD LINCOLNSHIRE ENGLAND PE9 2NB