PM500 v1.

2
Voltage Regulator
Installation, Operation and
Maintenance Manual

A Regal Brand
 Introduction
The PM500 is an encapsulated electronic voltage regulator intended for use with the Marathon PMG system
and most Marathon AC generators. The PM500 controls the output of a brushless AC generator by
regulating the DC current input to the exciter field. The PM500 is designed as a three phase or single phase
true RMS sensing regulator that is capable of accepting analog voltage adjustment input. The PM500 is UL
Recognized and UL Certified for Canada – Component per UL File E222903. The PM500 bears the CE mark
for the European Union.

Specifications
Sensing Input 175 - 600Vac, True RMS, 60/50Hz, 3 Phase/1 Phase
Power Input 175 - 260Vac, 300Hz PMG, 60/50Hz Shunt
Power Output, Continuous 85Vdc at 3.5Adc with 240Vac input power
Power Output, Forcing 170Vdc at 7Adc for 10 sec. with 240Vac input power
Fuse 5 x 20mm S505-5A, Slow Blow Type
Voltage Regulation ± 0.25%, with 4% engine governing
Excitation Resistance 9 ohms, minimum
Over Excitation Protection Excitation exceeds 190Vdc or 7Adc for more than 10 seconds
Manual Voltage Adjustment Range ± 20% with 2000 ohm rheostat
± 10% with 1000 ohm rheostat
Analog Voltage Input A1 & A2 ± 20% with 0-10Vdc or ± 5Vdc bias
Under Frequency Factory Setting 58Hz preset for 60Hz operation and 48Hz preset for 50Hz operation
Voltage Build-up Voltage build up from input voltage ≥ 5Vac at 25Hz.
Response Time <1 Cycle
Weight 16.6 oz.
Operating Temperature -40°C to +60°C
Storage Temperature -40°C to +85°C
Power Dissipation 12 watts, maximum
Size 5.9” L x 5.3” W x 2.2” H
Thermal Drift 0.05% / °C change in AVR ambient temperature
Electromagnetic Compatibility Tests
Immunity
IEC61000-4-2 - Electrostatic Discharge
IEC61000-4-3 - Radiated RF
IEC61000-4-4 - Electrical Fast Transient
IEC61000-4-5 - Surge
IEC61000-4-6 - Conducted RF
IEC61000-4-11
Emission
EN61204-3 - Conducted RF
CISPR 22
IEC61000-3-2 - Harmonic IEC
IEC61000-3-3 - Flicker IEC

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 Installation

TO PREVENT PERSONAL INJURY OR EQUIPMENT DO NOT megger or high-pot the generator with the regula-
DAMAGE, ONLY QUALIFIED PERSONNEL SHOULD tor connected. DO NOT high-pot the regulator. All voltage
INSTALL, OPERATE OR SERVICE THIS DEVICE. readings are to be taken with an rms voltmeter.

MOUNTING
The PM500 is mounted through a keyed hole in the
generator conduit box and secured with a plastic
mounting nut.

The PM500 should be mounted directly to the

conduit box panel with the rubber gasket positioned
between the outside of the conduit box panel and the
mounting nut.

Protect front panel adjustment pots by installing clear

or black plastic cover.

Mounting nut torque is 26 – 43 lbf-in.

Refer to the Figure 1 for dimensions. Figure 1

Wiring and Connections

EXCITER FIELD POWER CIRCUIT Connect regulator terminals P1 & P2 to generator
leads that will provide 240Vac output. No capacitor is
The exciter field resistance must be ≥ 9 ohms. used with the PM500 in shunt mode.
If the exciter field resistance is less than 9 ohms and
Refer to Figure 3 for typical connection points.
the full load field current does not exceed 3.5 amps,
add a resistor in series of sufficient wattage to increase
the total resistance to 9 ohms.

Connect the generator F+ (F1) field lead to the regu-

lator F+ terminal. Connect the generator F- (F2) field
lead to the regulator F- terminal. Refer to Figure 3 for
typical connection points.

POWER INPUT CIRCUIT

The PM500 is designed to be powered by a PMG and
capacitor. A 7.5µƒ capacitor is connected in parallel
between the PMG leads and the regulator power input
terminals.

The regulator power input terminals are labeled

P1 and P2. Connect leads from P1 and P2 to the
capacitor terminals.
Figure 2

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Wiring and Connections (cont’d)

Figure 3a – Three Phase

Figure 3b – Single Phase

SENSING CIRCUITS 3 Phase Sensing

Sensing input range is 175 - 600Vac. DIP switch SW1 Connect PM500 terminal E1 to output lead L1, E2 to
and SW2 must be set appropriately. Refer to Figures output lead L2 and E3 to output lead L3.
3a & 3b for typical connections.
If used in a paralleling application, a paralleling CT
Single Phase Sensing will be required in the generator B phase. Paralleling
CT must be sized to provide either a 1A or 5A signal
Connect PM500 terminal E1 to output lead L1 and E2
when the generator is under full load.
to output lead L2. PM500 terminal E3 is jumpered to
E2.

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 Wiring and Connections (cont’d)
DIP SWITCH PROGRAMMING PROTECTION FUNCTIONS
Eight DIP switches located on the back of the The PM500 has built in protection functions for
regulator must be set appropriately for correct Over Excitation, Under Frequency and Over Voltage
regulator operation and generator control. Refer to Protection.
Figure 4.
Over Excitation
Switches 1 & 2 set the regulator sensing range. The Over Excitation function protects the PM500
and generator components in the event the excitation
Switches 3 – 8 Configure multiple functions: 3 or system demands excessive levels of voltage and/or
Single Phase Sensing, Frequency, Over Excitation current to maintain output.
Protection, kW Range and Paralleling CT Range.
The Over Excitation function will trip when excitation
SW1 : OFF SW2 : OFF Volts ≤ 280Vac output exceeds 190Vdc or 7Adc for more than 10 sec.
SW1 : OFF SW2 : ON Volts ≤ 480Vac with 220Vac input power.
SW1 : ON SW2 : ON Volts ≤ 600Vac
The Over Excitation O/E LED on the front panel
OFF ON will be illuminated when the PM500 when the Over
SW3 : 3 Phase Sensing 1 Phase Sensing Excitation system has tripped. Replace the fuse on the
SW4 : 60 Hz 50 Hz back panel if required and inspect the generator. The
SW5 : O/E Protect On O/E Protect Off PM500 will reset when power is cycled
SW8 : CT 1A CT 5A
Under Frequency
SW6 : OFF SW7 : OFF < 90kW Under Frequency protection allows the generator
SW6 : ON SW7 : OFF 90 - 500kW voltage to decrease when the output frequency drops
SW6 : ON SW7 : ON > 500kW below the Roll-Off point. This reduces the load on the
engine, allowing engine RPM to recover. This is normal
operation and no reset is required.

Figure 4

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Operating Adjustments
Six adjustable potentiometers are accessible on the factory preset at 57Hz for 60Hz operation and at
front panel of the PM500. These are: VOLT, STAB, 47Hz for 50Hz operation.
U/F, DIP, DROOP and TRIM.
When the U/F LED on the front panel it lit, the PM500
is operating in Under Frequency mode.

To change the roll-off point, first verify that the gen-set

is operating at the intended speed and voltage.
Figure 6
Fixed Engine RPM
VOLTAGE ADJUST (VOLT) On most new engines (Tier 4i and up), the engine
Set Point speed is fixed at 1800RPM or 1500RPM.
Output voltage may be adjusted via the VOLT poten-
tiometer on the front panel of the regulator. The set Adjust the roll-off point by block loading the genera-
point range is 175 - 600Vac. tor and observing the U/F LED on the front panel. To
ensure the generator maintains voltage under a given
Remote Voltage Adjust block load, adjust U/F potentiometer until the U/F LED
A 2000 ohm, 2 watt rheostat may be connected to VR1 remains off during the block load test.
and VR2 - replacing the factory jumper, providing a
±10% voltage adjustment range. Terminals A1 & A2 Adjustable Engine RPM
may not be used when a rheostat is installed. Adjust engine speed to the new roll-off point. Verify
that the output voltage still matches the intended set-
Analog Voltage Adjust point voltage.
Regulator terminals A1 & A2 may be connected to the
analog output of a gen-set controller. The allowable Next, adjust the U/F potentiometer clockwise until the
voltage input range is 0-10Vdc or ± 5Vdc will provide voltage starts to drop off, then slightly adjust the poten-
a 20% range. Jumper VR1 & VR2 when analog voltage tiometer counterclockwise until the voltage returns to
adjustment terminals are used. rated voltage. Re-adjust engine speed to rated speed.

TRIM ADJUST (TRIM) U/F DIP ADJUST (DIP)

The analog bias range is adjusted via the TRIM potenti- When Under Frequency (U/F) protection is activated,
ometer on the front panel. Set the TRIM potentiometer the voltage dip follows a linear Volts / Hertz curve.
fully clockwise to provide a ± 20% adjustment range. The voltage dip ratio may be adjusted via the DIP
potentiometer with an adjustable range of 3-10V/Hz.
DROOP ADJUST (DROOP) The default setting is full clockwise for 10V/Hz.
Requires a 1A or 5A CT in the B Phase.
DIP switch SW8 must be set appropriately. STABILITY ADJUST (STAB)
Stability is the ability of the generator to respond to
In a paralleling system, the PM500 adjusts the genera- load changes. Decreasing the stability setting allows
tor output voltage when the B phase current leads or the generator to respond faster to load changes. If the
lags the B phase voltage. stability setting is too low, the generator voltage will
tend to hunt under steady state conditions.
The adjustment range may be preset via the DROOP
potentiometer. The default setting is full counter clock- Correct stability adjustment must be conducted while
wise for minimum range. Maximum range is ±7% at the generator is operating unloaded.
1.7 PF lagging to 0.7 PF leading.
Adjust the STAB potentiometer clockwise until the
UNDER FREQUENCY ROLL-OFF ADJUST (U/F) voltage becomes unstable, then slightly adjust coun-
The Roll-Off point is the frequency at which the gen- terclockwise (Approximately 1/5 turn) until the voltage
erator output voltage is allowed to decrease and is becomes stable.

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 Warnings & Cautions
IMPORTANT INFORMATION
Please Read Carefully
This document is not intended to provide operational instructions. Appropriate Marathon Electric instructions provided with the
generator and precautions attached to the generator should be read carefully prior to installation, operations and/or maintenance of the
equipment. Injury to personnel or generator failure may be caused by improper installation, maintenance or operation.

The following and information is supplied to you for your protection and to provide you with many
years of trouble free and safe operation of your Marathon Electric product:

• Buyer shall be solely responsible for determining the adequacy of the product for any and all uses to which Buyer shall
apply the product. The application by Buyer shall not be subject to any implied warranty of fitness for a particular purpose.
• For safety, Buyer or User should provide protective guards over all shaft extensions and any moving
apparatus mounted thereon. The User is responsible for checking all applicable safety codes in his area and providing
suitable guards. Failure to do so may result in bodily injury and/or damage to equipment.
• Hot oil can cause severe burns. Use extreme care when removing lubrication plugs.
• Disconnect power and lock out drive equipment before working on a generator.
• Always keep hands and clothing away from moving parts.
• The lifting eyes on the generator are not to be used to lift the entire generator set. Only the generator may be safely
lifted by the lifting eyes. Do not use the conduit box for lifting or support of the generator.
• Install and ground the generator per local and national codes.
• Discharge all capacitors before servicing the generator.
• Misapplication of a generator in a hazardous environment can cause fire or an explosion and result in serious injury.
• Never attempt to measure the temperature rise of a generator by touch. Temperature rise must be measured by
thermometer, resistance, imbedded detector or thermocouple.
• Operation of a generator at higher than its nameplate ratings may result in fire, damage to equipment or serious injury
to personnel.
• Do not apply any force to the generator fan when rotating the generator rotor.
• Generators should not be operated faster than their rated speed.
• The following statement is only applicable to high voltage generators (above 5000 V). A grounding strap is supplied
from the generator neutral to ground. This grounding strap not only bleeds off any voltage potential on the main stator
after the high potential test, but also bleeds off any static charge that can build-up on the main stator during shipment
and storage. THIS GROUND STRAP IS NOT A PERMANENT PART OF THE GENERATOR CONSTRUCTION. REMOVE
THIS GROUND STRAP ONLY AFTER A PERMANENT GROUND IS INSTALLED ON THE GENERATOR MAIN STATOR
(not supplied by Marathon Electric), OR THE GENERATOR FINAL INSTALLATION IS COMPLETE.
• Mounting bolts should be routinely checked to ensure that the unit is firmly anchored for proper operation.
• Consult qualified personnel with questions. All electrical repairs must be performed by trained and qualified personnel only.
• For inverter applications, follow the inverter manufacturer’s installation guidelines.
• Make sure the generator is properly secured and aligned before operation.
• When installing the generator, insure that loose parts or tools do not fall inside the generator.
• When connecting the generator, be sure to follow the correct wiring diagram for the desired voltage. Insure that the
voltage regulator is connected per the wiring diagram.

RESALE OF GOODS
In the event of the resale of any of the goods, in whatever form, Resellers/Buyers will include the following language in a conspicuous place
and in a conspicuous manner in a written agreement covering such sale:
The manufacturer makes no warranty or representations, express or implied, by operation of law or otherwise, as to the
merchantability or fitness for a particular purpose of the goods sold hereunder. Buyer acknowledges that it alone has deter-
mined that the goods purchased hereunder will suitably meet the requirements of their intended use. In no event will the
manufacturer be liable for consequential, incidental or other damages. Even if the repair or replacement remedy shall be deemed
to have failed of its essential purpose under Section 2-719 of the Uniform Commercial Code, the manufacturer shall have no liability
to Buyer for consequential damages.

Resellers/Buyers agree to also include this entire document including the cautions and warnings above in a conspicuous place and in a
conspicuous manner in writing to instruct users on the safe usage of the product.

This information should be read together with all other printed information supplied by Marathon Electric.

For more information contact: Regal Beloit America, Inc., 100 E. Randolph St., Wausau, WI 54401
Phone: 715-675-3311 or Fax: 715-675-8026

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100 E. Randolph Street A Regal Brand
PO Box 8003
Wausau, WI 54402-8003 U.S.A.
PH: 715-675-3359
FAX: 715-675-8026

www.marathonelectric.com

©2019 Regal Beloit Corp GPN056 v1.2 100/11-19/FS Printed in the U.S.A.