GMG MEP-802A Voltage Regulator Replaces TRC 19580 Instructions

GMG MEP-802A Voltage Regulator Replaces TRC 19580

Instructions

WARNING!

Lethal voltages are present in the MEP-802A/803A instrumentation civil,et when the generator is running. Additionally, 24-30 vol1s DC is present inside the cabinet even is the generator set is turned off and the Dead Crank Switch is in the off position. Do NOT perform work inside the control cabinet with the genre:ator running or if the batteries are connected. Failure to do so may result in serious injury or death.

1. Disconnect the generator from all AC loads. This includes convenience 011tlet connections as well as the load tenninals.
2. Disconnect the NEGATIVE lead from the batteiy and secure the Negative lead away from the battery’s negative terminal. Disconnect any external connection to the generators NATO slave connector.
3. Open the generators control panel door by turning the two ¼ turn fasteners at the top of the access door and carefully lower the door.
4. Label each of the 8 wires connected to the existing (Al) Voltage Regulator using the supplied wire labels. It is imperative this step is done to prevent potential mix up of the wires and damage to the new Voltage Regulator. Labeling can be accomplished by removing one wire at a time from the existing Voltage Regulator and labeling them. Repeat for each of the 8 wires. An alternative to ush1g the supplied labels is to use a black “Sharpie” to label the back of each wire lug.
5. Remove the 4 screws fastening the existing Voltage Regulator to the cabinet wall and remove the existing Voltage Regulator. The generator may have a fuse holdt,r mounted to the lower left comer. Is so the 4th screw can be accessed by removing the fuse cartridge. Discard the 4 mounting screws. New mounting scre”WS supplied with the new voltage regulator will be used to fasten the new Regulator.
6. Position the replacement Voltage and fasten it to the cabinet’s wall usin_gthe 4 supplied mounting screws. Be sure to mount the fuse holder in the lower left if it was removed in the step above. Reinstall the fuse into the fuse bolder a:ftet the 4 screws have been tightened.
7. Attach each of the 8 wires removed and labeled in step 4 to the new Voltage Regulator.
8. Route the two wires at the left end of the regulator along the generator wire harness behind the relays and around in front of the relays. Secure with supplied.
9. Connect the lead Labeled Kl5-l to.terminal 1 of the Kl5 relay socket as shown above. This will be the only wire on Kl 5-1 terminal.
10. Route the other wire along the factory wire harness and connect the lead labeled M7-I to the I terminal on the Oil Pressure Gauge. If unsure which is the “I” terminal com.pare the stenciled wire numbers on the factory harness and see which is labeled with 137Jxx. The letter ”I” is usually embossed in the meter case.
11. Remove the voltage adjustment knob from the existing voltage adjustment e potentiometer. It is securd with two small 5/64″ alien screws.
12. Remove the nut and washer securing the existing voltage adjust the potentiometer to the from panel and pull the potentiometer back thru the hole. Reinstall the lock washer and nut securely. Zip tie the old potentiometer out of the way approximately as show below.
13. Insert the supplied pre-wired potentiometer in the from panel making sure it’s locating pin is lined up with the small hole in the front panel and secure using the supplied nut and lock washer.
14. Check to be sure the new potentiometer is in the middle of it’s operating range. Then re-install the voltage adjusting knob with the knob pointer up and tighten the two 5/64″ allen screws to secure the knob on the potentiometer shaft.
15. Close the front cover and secure the with the two ¼ turn fasteners.
16. Set the new AC Voltage Adjust potentiometer fully counter clockwise.
17. Reconnect the battery cable.
18. Start the generator and adjust the output frequency to be 60 +/-1 Hz.
19. Then adjust the new AC Voltage Adjust potentiometer to achieve 120, 208 or or 240 volts AC depending on how the AM/VM switch (S6) and the Voltage Phase reconnection switch (S8) are set.

Additional information about the Voltage Regulator

1. The regulator will work in generators that have damaged Quad windings as the regulator does not use power from the Quad windings.
2. There are two fuses on the board for protection. One for power into the regulator and one for the output from the regulator. Both are 5mm x 20 mm 3amp slow blow fuses. Under normal circumstance these fuses should not blow. Each is easily replaced if needed.
3. Use of tis regulator eliminates the need for the “Fuse Mod” and the “MOV Mod” if h they are not currently in the generator. If the “Fuse Mod” is installed it can be left installed in the set. The Fuse Mod, if installed is not utilized by the new regulator. Mounting the fuse holder to the new regulator is only done to secure it from accidentally shorting to anything. The MOV, if previously installed on terminals 7 & 8 of the factory Voltage Regulator should not be re-installed.
4. Installation of the regulator does not disconnect any of the existing wiring or components of the generator.
5. Terminals 1, 2, 7 & 8 of the new regulator are only there to secure the unused generators wire harness leads. The connections on those terminals have no bearing on the operation of the-new voltage regulator.

Questions? Feel free to contact me at: [email protected]

Warranty

If the Voltage Regulator fails to perform properly as a result of defects in materials or workmanship within One Year of the date of purchase, the Regulator, at our option, will be repaired, replaced or the original purchase price refunded. The defective Regulator must be shipped back for failure analysis at the buyer’s expense.
Liability is limited to repair or replacement of the Regulator, or a refund of the purchase price of the controller. Buyer assumes all liability for installation and use of the Voltage Regulator.

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