{"id":230,"date":"2010-12-27T03:36:16","date_gmt":"2010-12-27T03:36:16","guid":{"rendered":"https:\/\/www.enerpro-inc.com\/vr31-3-stage-auxiliary-generator-voltage-and-current-regulator\/"},"modified":"2021-10-01T15:58:13","modified_gmt":"2021-10-01T15:58:13","slug":"vr31-3-stage-regulator","status":"publish","type":"page","link":"https:\/\/www.enerpro-inc.com\/locomotive-and-rail-products\/vr31-3-stage-regulator\/","title":{"rendered":"VR31 3-Stage Auxiliary Generator Voltage and Current Regulator"},"content":{"rendered":"[et_pb_section fb_built=&#8221;1&#8243; fullwidth=&#8221;on&#8221; _builder_version=&#8221;3.22.7&#8243; background_image=&#8221;https:\/\/www.enerpro-inc.com\/wp-content\/uploads\/2019\/03\/Freight-Train.jpg&#8221; global_colors_info=&#8221;{}&#8221;][et_pb_fullwidth_header title=&#8221;VR31 3-Stage Charge Auxiliary Generator Regulator&#8221; _builder_version=&#8221;3.29.2&#8243; background_color=&#8221;rgba(38,142,197,0.79)&#8221; custom_padding=&#8221;28px||28px|&#8221; z_index_tablet=&#8221;500&#8243; title_text_shadow_style=&#8221;preset1&#8243; title_text_shadow_color=&#8221;rgba(0,0,0,0.14)&#8221; text_shadow_style=&#8221;preset1&#8243; text_shadow_color=&#8221;rgba(0,0,0,0.25)&#8221; global_colors_info=&#8221;{}&#8221;][\/et_pb_fullwidth_header][\/et_pb_section][et_pb_section fb_built=&#8221;1&#8243; _builder_version=&#8221;3.22.3&#8243; global_colors_info=&#8221;{}&#8221;][et_pb_row column_structure=&#8221;3_5,2_5&#8243; _builder_version=&#8221;3.25&#8243; background_size=&#8221;initial&#8221; background_position=&#8221;top_left&#8221; background_repeat=&#8221;repeat&#8221; global_colors_info=&#8221;{}&#8221;][et_pb_column type=&#8221;3_5&#8243; _builder_version=&#8221;3.25&#8243; custom_padding=&#8221;|||&#8221; global_colors_info=&#8221;{}&#8221; custom_padding__hover=&#8221;|||&#8221;][et_pb_text _builder_version=&#8221;3.29.2&#8243; global_colors_info=&#8221;{}&#8221;]\n<p><span>Enerpro\u2019s VR31 3-Stage charge auxiliary generator voltage regulator module is a direct replacement for the VR10 &#8211; VR16 EMD auxiliary generator voltage regulator modules used in EMD auxiliary generator equipped locomotives (prior to SD70Ace and SD70M-2). The VR31 provides battery manufacturer recommended three-stage battery charging profile\u00a0for longer battery life, faster charging, reduced water consumption and compatibility with flooded lead acid (FLA) and valve regulated lead-acid (VRLA).\u00a0 The VR31 is compatible with both ac and dc auxiliary generators.<\/span><\/p>\n[\/et_pb_text][et_pb_text _builder_version=&#8221;3.29.2&#8243; background_size=&#8221;initial&#8221; background_position=&#8221;top_left&#8221; background_repeat=&#8221;repeat&#8221; custom_padding=&#8221;||0px|||&#8221; global_colors_info=&#8221;{}&#8221;]\n<h3>Key Features<\/h3>\n<ul>\n<li>Direct Replacement for EMD VR10 \u2013 VR16<\/li>\n<li>Three-stage Battery Charging<\/li>\n<li>Longer Battery Life<\/li>\n<li>Reduced Failure to Start Events<\/li>\n<li>Faster Charging<\/li>\n<li>Reduced Water Consumption<\/li>\n<li>Simple Installation<\/li>\n<li>Compatible with FLA and VRLA Batteries<\/li>\n<li>Compatible with both AC and DC Aux Generators<\/li>\n<\/ul>\n[\/et_pb_text][\/et_pb_column][et_pb_column type=&#8221;2_5&#8243; _builder_version=&#8221;3.25&#8243; custom_padding=&#8221;|||&#8221; global_colors_info=&#8221;{}&#8221; custom_padding__hover=&#8221;|||&#8221;][et_pb_image src=&#8221;https:\/\/www.enerpro-inc.com\/wp-content\/uploads\/2019\/08\/VR31-vert.jpg&#8221; alt=&#8221;3-Stage Battery Charger VR31&#8243; align_tablet=&#8221;center&#8221; align_phone=&#8221;&#8221; align_last_edited=&#8221;on|desktop&#8221; _builder_version=&#8221;3.27.3&#8243; width=&#8221;70%&#8221; border_width_all=&#8221;1px&#8221; border_color_all=&#8221;rgba(51,51,51,0.09)&#8221; box_shadow_style=&#8221;preset1&#8243; box_shadow_color=&#8221;rgba(0,0,0,0.06)&#8221; global_colors_info=&#8221;{}&#8221;][\/et_pb_image][et_pb_text _builder_version=&#8221;3.29.2&#8243; text_font=&#8221;||||||||&#8221; text_line_height=&#8221;2.2em&#8221; width=&#8221;100%&#8221; global_module=&#8221;131455&#8243; saved_tabs=&#8221;all&#8221; global_colors_info=&#8221;{}&#8221;]\n<p><a href=\"\/downloads\/locomotive\/PD773-VR31-Product-Data-Guide.pdf\" target=\"_blank\" rel=\"noopener noreferrer\"><img loading=\"lazy\" decoding=\"async\" src=\"https:\/\/www.enerpro-inc.com\/wp-content\/uploads\/2019\/04\/PDF-icon22h.png\" width=\"17\" height=\"22\" alt=\"\" class=\"wp-image-29508 alignnone size-full\" \/>\u00a0Product Guide<\/a><br \/>\n<img loading=\"lazy\" decoding=\"async\" src=\"https:\/\/www.enerpro-inc.com\/wp-content\/uploads\/2019\/04\/PDF-icon22h.png\" width=\"17\" height=\"22\" alt=\"\" class=\"wp-image-29508 alignnone size-full\" \/><\/a><a href=\"\/downloads\/locomotive\/OP-0116-VR31-Troubleshooting-Guide.pdf\" target=\"_blank\" rel=\"noopener noreferrer\"> Troubleshooting Guide<\/a><a href=\"\/downloads\/locomotive\/PD773-VR31-Product-Data-Guide.pdf\" target=\"_blank\" rel=\"noopener noreferrer\"><br \/>\n<img loading=\"lazy\" decoding=\"async\" src=\"https:\/\/www.enerpro-inc.com\/wp-content\/uploads\/2019\/04\/PDF-icon22h.png\" width=\"17\" height=\"22\" alt=\"\" class=\"wp-image-29508 alignnone size-full\" \/><\/a><a href=\"\/downloads\/locomotive\/M2101-VR31-Mechanical-Drawing.pdf\" target=\"_blank\" rel=\"noopener noreferrer\">\u00a0Mechanical Drawing<\/a><a href=\"\/downloads\/locomotive\/PD773-VR31-Product-Data-Guide.pdf\" target=\"_blank\" rel=\"noopener noreferrer\"><\/a><\/p>\n<p><a href=\"\/downloads\/locomotive\/PD773-VR31-Product-Data-Guide.pdf\" target=\"_blank\" rel=\"noopener noreferrer\"><\/a><\/p>\n[\/et_pb_text][et_pb_sidebar area=&#8221;et_pb_widget_area_2&#8243; _builder_version=&#8221;3.26&#8243; global_colors_info=&#8221;{}&#8221;][\/et_pb_sidebar][\/et_pb_column][\/et_pb_row][et_pb_row _builder_version=&#8221;3.25&#8243; global_colors_info=&#8221;{}&#8221;][et_pb_column type=&#8221;4_4&#8243; _builder_version=&#8221;3.25&#8243; custom_padding=&#8221;|||&#8221; global_colors_info=&#8221;{}&#8221; custom_padding__hover=&#8221;|||&#8221;][et_pb_toggle title=&#8221;Technical Details&#8221; icon_color=&#8221;#268ec5&#8243; _builder_version=&#8221;3.26.7&#8243; title_text_color=&#8221;#000000&#8243; title_font=&#8221;||||||||&#8221; title_font_size=&#8221;20px&#8221; body_font=&#8221;||||||||&#8221; background_color=&#8221;#ffffff&#8221; custom_padding=&#8221;2vw|3vw|2vw|3vw|true|true&#8221; border_radii=&#8221;on|10px|10px|10px|10px&#8221; box_shadow_style=&#8221;preset1&#8243; box_shadow_color=&#8221;rgba(0,0,0,0.12)&#8221; global_colors_info=&#8221;{}&#8221;]\n<p><strong>Overview<\/strong><\/p>\n<p>The advent of locomotive automatic engine stop and start systems has brought the benefits of decreased fuel consumption and air emissions but also increased the demands on starting batteries. The much more frequent discharge-charge cycles combined with constant voltage VR10- VR16 voltage regulators has resulted in much shorter battery life, battery plate sulfation, and reduced charge capacity. The operational impact is increased failure to start events and more frequent battery replacements. The VR31 solves these problems by providing battery manufacturer recommended 3-stage battery charging.<\/p>\n<p><strong>VR31 module<span>\u00a0<\/span><br \/><\/strong>The VR31 module is a direct replacement for the VR10-16 series auxiliary generator voltage regulators. Locomotives equipped with the DVR300 voltage regulator require an additional mounting cage and wiring harness adapter for installation. The VR31 uses auxiliary generator voltage feedback, like the VR10, but also uses battery current feedback to provide optimum battery charging. The current sensor provides feedback required to limit current at the start of the charge cycle and to determine when the battery is 95% charged for transition to the float stage. VR31 design incorporates several failure mode protection features that ensure high operational reliability.<\/p>\n<p><strong>Shorted PWM Transistor Protection<span>\u00a0<\/span><br \/><\/strong>At high engine speed, the auxiliary generator will produce dangerously high voltage if the PWM transistor or the bootstrap transistor becomes shorted or if either transistor is turned on continuously due to a component failure. In this event, an over-voltage comparator trips the panel mounted circuit breaker if the auxiliary generator voltage exceeds the over-voltage trip threshold.<\/p>\n<p><strong>Loss of Current Feedback Protection<span>\u00a0<\/span><br \/><\/strong>If the current sensor fails or the current signal to the VR31 becomes shorted or open, the VR31 immediately transitions to the 72V float voltage. A current sensor fault LED on the VR31 illuminates and an output signal is sent to the locomotive. This fail-safe feature protects the battery from overcharging while still allowing the locomotive to operate until the next maintenance cycle.<\/p>\n<p><strong>EBCS-3 Current Sensor<span>\u00a0<\/span><br \/><\/strong>The EBCS-3 current sensor is installed on the BTN battery cable directly behind the knife switch. By providing isolated battery current feedback to the VR31, the system is able to provide proper charging regardless of load switching. The EBCS-3 is powered from nominal 74V output of the Auxiliary Generator and has built in failure detection and fail-safe circuitry.<\/p>\n<p><strong>Three-Stage Charge Profile<br \/><\/strong>Air pollution regulations and high fuel costs have made locomotive operators shut down idling locomotives much more frequently than in the past. This change in locomotive operation has resulted in premature loss of battery capacity and more frequent cell failure rate. These problems are caused by the single-stage charge profile provided by conventional chargers. With single-stage charging, the initial current immediately after engine start is limited only by generator output and battery circuit resistance. Most locomotive battery charging circuits incorporate a current limiting resistor to reduce the charge current. Even with this resistor, the initial current can greatly exceed the battery manufacturer\u2019s recommended maximum charging current and shorten battery life. The single-stage charger transitions from the high initial first-stage current when the battery voltage rises to reach the nominal voltage setpoint of 74 V. The single-stage charger then maintains constant nominal 74 V on the battery until the engine is shut down. According to battery experts, 74 V is insufficient to convert all of the battery\u2019s active material during the engine run time if the engine is shut down several times per day. The result is a progressive loss of capacity.<\/p>\n<p>The three-stage charge profile produced by the VR31 regulates the first, or Bulk Stage, current to 90 Amps. In the second, or Absorption Stage, the rectifier voltage is regulated to typically 78 V for an FLA battery and 76V for VRLA. This elevated voltage converts the maximum amount of active battery material while equalizing the charge in each cell, thus minimizing sulfation and capacity loss. In the third, or Float Stage, the VR31 reverts to a constant-voltage regulation mode (nominally 72 V).<\/p>\n<p><strong>Bulk Stage<\/strong><br \/>After engine start, the unit enters the 90 A constant-current Bulk Stage. The battery behaves as a capacitor in that the constant charging current results in battery voltage increasing linearly with time. The Bulk Stage ends when the voltage reaches a converter-imposed limit of 78 V (FLA) or 76 V (VRLA).<\/p>\n<p><strong>Absorption Stage<\/strong><br \/>The constant voltage Absorption Stage begins with the battery charged to about 80% total capacity. The Absorption Stage current decays exponentially with time from the initial 90 A until it reaches one of two Float Stage thresholds. The transition to the Float Stage occurs when one of two conditions are met:<\/p>\n<ol>\n<li>The Absorption Stage current decays to typically 25 A, or<\/li>\n<li>The total charge reaches approximately 95% capacity.<\/li>\n<\/ol>\n<p>Forcing the Absorption\/Float transition to occur as a function of charge assures that a shorted cell or other battery defect will not result in continuous operation at elevated voltage.<\/p>\n<p><strong>Float Stage<\/strong><br \/>During the regulated 72V Float Stage, the battery current gradually decays to the steady-state self-discharge current. This maintains a full battery charge as long as the engine is running.<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" src=\"https:\/\/www.enerpro-inc.com\/wp-content\/uploads\/2019\/08\/3stageVR31.jpg\" width=\"600\" height=\"293\" alt=\"\" class=\"wp-image-132079 alignnone size-full\" srcset=\"https:\/\/www.enerpro-inc.com\/wp-content\/uploads\/2019\/08\/3stageVR31.jpg 600w, https:\/\/www.enerpro-inc.com\/wp-content\/uploads\/2019\/08\/3stageVR31-300x147.jpg 300w\" sizes=\"(max-width: 600px) 100vw, 600px\" \/><\/p>\n<p><strong>System Block Diagram<\/strong><\/p>\n<p><strong><img loading=\"lazy\" decoding=\"async\" src=\"https:\/\/www.enerpro-inc.com\/wp-content\/uploads\/2019\/08\/3stageVR31-b.jpg\" width=\"600\" height=\"278\" alt=\"\" class=\"wp-image-132083 alignnone size-full\" srcset=\"https:\/\/www.enerpro-inc.com\/wp-content\/uploads\/2019\/08\/3stageVR31-b.jpg 600w, https:\/\/www.enerpro-inc.com\/wp-content\/uploads\/2019\/08\/3stageVR31-b-300x139.jpg 300w\" sizes=\"(max-width: 600px) 100vw, 600px\" \/><\/strong><\/p>\n[\/et_pb_toggle][\/et_pb_column][\/et_pb_row][\/et_pb_section][et_pb_section fb_built=&#8221;1&#8243; module_class=&#8221;customfooter&#8221; _builder_version=&#8221;3.26&#8243; background_color=&#8221;#2A2A2A&#8221; min_height=&#8221;458px&#8221; custom_padding=&#8221;||0px|||&#8221; global_module=&#8221;131558&#8243; saved_tabs=&#8221;all&#8221; global_colors_info=&#8221;{}&#8221;][et_pb_row column_structure=&#8221;1_5,1_5,1_5,1_5,1_5&#8243; _builder_version=&#8221;4.9.3&#8243; width=&#8221;90%&#8221; max_width=&#8221;1440px&#8221; global_colors_info=&#8221;{}&#8221;][et_pb_column type=&#8221;1_5&#8243; _builder_version=&#8221;3.26&#8243; global_colors_info=&#8221;{}&#8221;][et_pb_text module_id=&#8221;customfoot&#8221; _builder_version=&#8221;3.29.2&#8243; text_text_color=&#8221;#ffffff&#8221; text_font_size=&#8221;13px&#8221; text_line_height=&#8221;1.9em&#8221; header_4_text_color=&#8221;#ffffff&#8221; header_4_font_size=&#8221;16px&#8221; header_4_line_height=&#8221;1.2em&#8221; global_colors_info=&#8221;{}&#8221;]\n<h4 class=\"title\">UNITED STATES<\/h4>\n<p>Enerpro, Inc.<br \/> Global Headquarters<br \/> 99 Aero Camino<br \/> Goleta, CA 93117<\/p>\n<p><a href=\"mailto:info@enerpro-inc.com\" target=\"_blank\" rel=\"noopener noreferrer\">info@enerpro-inc.com<\/a><br \/> <a href=\"https:\/\/www.enerpro-inc.com\/\" target=\"_blank\" rel=\"noopener noreferrer\">https:\/\/www.enerpro-inc.com<\/a><\/p>\n<p>Tel: (805) 683-2114<br \/> Fax: (805) 964-0798<\/p>\n[\/et_pb_text][\/et_pb_column][et_pb_column type=&#8221;1_5&#8243; _builder_version=&#8221;3.26&#8243; global_colors_info=&#8221;{}&#8221;][et_pb_text module_id=&#8221;customfoot&#8221; _builder_version=&#8221;3.27.4&#8243; text_text_color=&#8221;#ffffff&#8221; text_font_size=&#8221;13px&#8221; text_line_height=&#8221;1.9em&#8221; header_4_text_color=&#8221;#ffffff&#8221; header_4_font_size=&#8221;16px&#8221; header_4_line_height=&#8221;1.2em&#8221; global_colors_info=&#8221;{}&#8221;]\n<h4 class=\"title\">CANADA<\/h4>\n<p>ICT Power Company Inc.<br \/>1220 Corporate Dr.<br \/>Burlington, ON L7L 5R6<br \/>Canada<\/p>\n<p><a href=\"mailto:sales@ictpower.com\" target=\"_blank\" rel=\"noopener noreferrer\">sales@ictpower.com<\/a><br \/><a href=\"http:\/\/www.ictpower.com\/\" target=\"_blank\" rel=\"noopener noreferrer\">http:\/\/www.ictpower.com<\/a><\/p>\n<p>Tel: 905.631.8494<br \/>Fax: 905.631.8495<\/p>\n[\/et_pb_text][\/et_pb_column][et_pb_column type=&#8221;1_5&#8243; _builder_version=&#8221;3.26&#8243; global_colors_info=&#8221;{}&#8221;][et_pb_text module_id=&#8221;customfoot&#8221; _builder_version=&#8221;4.10.7&#8243; text_text_color=&#8221;#ffffff&#8221; text_font_size=&#8221;13px&#8221; text_line_height=&#8221;1.9em&#8221; header_4_text_color=&#8221;#ffffff&#8221; header_4_font_size=&#8221;16px&#8221; header_4_line_height=&#8221;1.2em&#8221; min_height=&#8221;312px&#8221; custom_margin=&#8221;0px||||false|false&#8221; custom_padding=&#8221;7px||0px|||&#8221; global_colors_info=&#8221;{}&#8221;]\n<h4 class=\"title\">SCANDINAVIA<\/h4>\n<p>MPE Cathodic AS<br \/>P. O. Box 74<br \/>N1581 Rygge, Norway<br \/>Marine &amp; Offshore<br \/>Jotun <strong>ICCP<\/strong> Specialists<\/p>\n<p><a href=\"mailto:emil@mpecathodic.no\" target=\"_blank\" rel=\"noopener noreferrer\">emil@mpecathodic.no<\/a><br \/><a href=\"mailto:%20roy@mpecathodic.no\" target=\"_blank\" rel=\"noopener noreferrer\">roy@mpecathodic.no<\/a><br \/><a href=\"http:\/\/www.mpecathodic.no\/\" target=\"_blank\" rel=\"noopener noreferrer\">http:\/\/www.mpecathodic.no<\/a><br \/>Tel: +47 69 23 29 00<br \/>Fax: +47 69 23 29 01<br \/>Mob: +47 95 11 81 82<\/p>\n[\/et_pb_text][\/et_pb_column][et_pb_column type=&#8221;1_5&#8243; _builder_version=&#8221;3.26&#8243; global_colors_info=&#8221;{}&#8221;][et_pb_text module_id=&#8221;customfoot&#8221; _builder_version=&#8221;3.27.4&#8243; text_text_color=&#8221;#ffffff&#8221; text_font_size=&#8221;13px&#8221; text_line_height=&#8221;1.9em&#8221; header_4_text_color=&#8221;#ffffff&#8221; header_4_font_size=&#8221;16px&#8221; header_4_line_height=&#8221;1.2em&#8221; global_colors_info=&#8221;{}&#8221;]\n<h4 class=\"title\">UNITED KINGDOM<\/h4>\n<p>Andrew Chettle<br \/> Power Products International Limited<br \/> Commerce Way<br \/> Edenbridge<br \/> Kent TN8 6ED<\/p>\n<p><a href=\"mailto:%20%20sales@ppi-uk.com\" target=\"_blank\" rel=\"noopener noreferrer\">sales@ppi-uk.com<br \/> <\/a><a href=\"http:\/\/www.ppi-uk.com\/\" target=\"_blank\" rel=\"noopener noreferrer\">http:\/\/www.ppi-uk.com<\/a><br \/> Tel: 01732 866424<br \/> Fax: 01732 866399<\/p>\n[\/et_pb_text][\/et_pb_column][et_pb_column type=&#8221;1_5&#8243; _builder_version=&#8221;3.26&#8243; global_colors_info=&#8221;{}&#8221;][et_pb_text module_id=&#8221;customfoot&#8221; _builder_version=&#8221;3.27.4&#8243; text_text_color=&#8221;#ffffff&#8221; text_font_size=&#8221;13px&#8221; text_line_height=&#8221;1.9em&#8221; header_4_text_color=&#8221;#ffffff&#8221; header_4_font_size=&#8221;16px&#8221; header_4_line_height=&#8221;1.2em&#8221; global_colors_info=&#8221;{}&#8221;]\n<h4 class=\"title\">ITALY, SLOVENIA, SLOVAKIA, CZECH REPUBLIC<\/h4>\n<p>Bruno Passerini<br \/>G.P.S. \u2013 Green Power Solutions SRL<br \/>Via Venezia 34D<br \/>10088 Volpiano \u2013 Torino<br \/>Italy<\/p>\n<p><a href=\"mailto:%20info@gpsemi.it\" target=\"_blank\" rel=\"noopener noreferrer\">info@gpsemi.it<\/a><br \/><a href=\"http:\/\/www.gpsemi.it\/\" target=\"_blank\" rel=\"noopener noreferrer\">http:\/\/www.gpsemi.it<\/a><br \/>Tel: +39 011 9882251<br \/>Fax: +39 011 9881358<\/p>\n[\/et_pb_text][\/et_pb_column][\/et_pb_row][et_pb_row column_structure=&#8221;1_4,1_4,1_4,1_4&#8243; _builder_version=&#8221;4.9.3&#8243; width=&#8221;90%&#8221; max_width=&#8221;1440px&#8221; global_colors_info=&#8221;{}&#8221;][et_pb_column type=&#8221;1_4&#8243; _builder_version=&#8221;3.26&#8243; global_colors_info=&#8221;{}&#8221;][et_pb_text module_id=&#8221;customfoot&#8221; _builder_version=&#8221;3.29.2&#8243; text_text_color=&#8221;#ffffff&#8221; text_font_size=&#8221;13px&#8221; text_line_height=&#8221;1.6em&#8221; header_4_text_color=&#8221;#ffffff&#8221; header_4_font_size=&#8221;16px&#8221; header_4_line_height=&#8221;1.2em&#8221; global_colors_info=&#8221;{}&#8221;]\n<h4 class=\"title\">TECHNICAL SUPPORT<\/h4>\n<p>Design Support<br \/>\nIn-Service Support<br \/>\nToll Free: (877) 648-2114<br \/>\n(805) 683-2114<br \/>\n<a href=\"mailto:support@enerpro-inc.com\">support@enerpro-inc.com<\/a><\/p>\n<p><a href=\"\/enerpro-sales-policy-2015\/\" target=\"_blank\" rel=\"noopener noreferrer\">Sales Policy<\/a><br \/>\n<a href=\"https:\/\/www.enerpro-inc.com\/support\/rma-policy\/\" target=\"_blank\" rel=\"noopener noreferrer\">RMA Policy<\/a>[\/et_pb_text][\/et_pb_column][et_pb_column type=&#8221;1_4&#8243; _builder_version=&#8221;3.26&#8243; global_colors_info=&#8221;{}&#8221;][et_pb_text module_id=&#8221;customfoot&#8221; _builder_version=&#8221;4.9.3&#8243; text_text_color=&#8221;#ffffff&#8221; text_font_size=&#8221;13px&#8221; text_line_height=&#8221;1.9em&#8221; header_4_text_color=&#8221;#ffffff&#8221; header_4_font_size=&#8221;16px&#8221; header_4_line_height=&#8221;1.2em&#8221; global_colors_info=&#8221;{}&#8221;]\n<h4 class=\"title\">HONG KONG, MACAU, CHINA (PRC)<\/h4>\n<p>Jane Lu<br \/>Tackoh Enterprises (HK)<br \/>Room 1604, Arion Commercial Centre<br \/>2-12 Queen\u2019s Road, West<br \/>Hong Kong<\/p>\n<p><a href=\"mailto:janelu2000@yahoo.com\" target=\"_blank\" rel=\"noopener noreferrer\">janelu2000@yahoo.com<\/a><br \/><a href=\"http:\/\/www.shjdn.com\/\" target=\"_blank\" rel=\"noopener noreferrer\">http:\/\/www.shjdn.com<\/a><br \/>Tel: 852 2543 0186<br \/>Fax: 852 2542 2114<br \/>Mob: 852 9379 8172<\/p>\n[\/et_pb_text][\/et_pb_column][et_pb_column type=&#8221;1_4&#8243; _builder_version=&#8221;3.26&#8243; global_colors_info=&#8221;{}&#8221;][et_pb_text module_id=&#8221;customfoot&#8221; _builder_version=&#8221;4.9.3&#8243; text_text_color=&#8221;#ffffff&#8221; text_font_size=&#8221;13px&#8221; text_line_height=&#8221;1.9em&#8221; header_4_text_color=&#8221;#ffffff&#8221; header_4_font_size=&#8221;16px&#8221; header_4_line_height=&#8221;1.2em&#8221; global_colors_info=&#8221;{}&#8221;]\n<h4 class=\"title\">SOUTH AMERICA<\/h4>\n<p>Andes Controls, Power and Automation<br \/>Cristi\u00e1n Ladisla Bohn<br \/>Av. Holanda 099, Oficina 1101<br \/>Providencia, Santiago, Chile<\/p>\n<p><a href=\"mailto:contact@andescpa.com\">contact@andescpa.com<\/a><br \/><a href=\"http:\/\/andescpa.com\/\">http:\/\/andescpa.com\/<\/a><br \/>Tel: +56 2 2306 6202<\/p>\n[\/et_pb_text][\/et_pb_column][et_pb_column type=&#8221;1_4&#8243; _builder_version=&#8221;3.26&#8243; global_colors_info=&#8221;{}&#8221;][et_pb_text module_id=&#8221;customfoot&#8221; _builder_version=&#8221;3.27.4&#8243; text_text_color=&#8221;#ffffff&#8221; text_font_size=&#8221;13px&#8221; text_line_height=&#8221;1.9em&#8221; header_4_text_color=&#8221;#ffffff&#8221; header_4_font_size=&#8221;16px&#8221; header_4_line_height=&#8221;1.2em&#8221; global_colors_info=&#8221;{}&#8221;]\n<h4 class=\"title\">THAILAND, MALAYSIA, VIETNAM, PHILIPPINES<\/h4>\n<p>Akom Chantakhun<br \/> CBC International Limited<br \/> 56\/12-13 Soi Prayasuren 45<br \/> Samwatawantok, Klongsamwa<br \/> Bangkok, 10510<br \/> Thailand<\/p>\n<p><a href=\"mailto:akom@cbcinter.co.th\" target=\"_blank\" rel=\"noopener noreferrer\">akom@cbcinter.co.th<\/a><br \/> <a href=\"http:\/\/www.cbcinter.com\/\" target=\"_blank\" rel=\"noopener noreferrer\">http:\/\/www.cbcinter.com<\/a><br \/> <a href=\"http:\/\/www.cbcinter.co.th\/\" target=\"_blank\" rel=\"noopener noreferrer\">http:\/\/www.cbcinter.co.th<br \/><\/a><strong><\/strong><strong><\/strong>Tel: 662 902 6106-9<br \/> Fax: 662 914-3009<\/p>\n[\/et_pb_text][\/et_pb_column][\/et_pb_row][\/et_pb_section]\n","protected":false},"excerpt":{"rendered":"<div class=\"ems_right\"><img loading=\"lazy\" decoding=\"async\" class=\" size-full wp-image-225\" src=\"https:\/\/www.enerpro-inc.com\/wp-content\/uploads\/2010\/12\/vr31-1.png\" alt=\"\" border=\"0\" width=\"213\" height=\"345\" srcset=\"https:\/\/www.enerpro-inc.com\/wp-content\/uploads\/2010\/12\/vr31-1.png 213w, https:\/\/www.enerpro-inc.com\/wp-content\/uploads\/2010\/12\/vr31-1-185x300.png 185w\" sizes=\"(max-width: 213px) 100vw, 213px\" \/><br \/><a href=\"https:\/\/www.enerpro-inc.com\/wp-content\/uploads\/2010\/12\/PD773_C_VR31_Product_Data_Guide.pdf\" target=\"_blank\" rel=\"noopener noreferrer\">Product Guide<\/a><br \/><a href=\"https:\/\/www.enerpro-inc.com\/wp-content\/uploads\/2010\/12\/M2101_VR31_ASSEMBLY_v2.pdf\" target=\"_blank\" rel=\"noopener noreferrer\">Mechanical Drawing<\/a><\/div>\n<p style=\"text-align: left\">Enerpro\u2019s VR31 Auxiliary Generator Three-Stage Charge Voltage Regulator Module is a direct replacement for the VR10 &#8211; VR16 EMD auxiliary generator field controllers used in EMD Auxiliary Generator equipped locomotives (prior to SD70Ace and SD70M-2). The VR31 provides battery manufacturer recommended three-stage battery charging profile&nbsp;for longer battery life, faster charging, reduced water consumption and compatibility with flooded lead acid (FLA) valve regulated lead-acid (VRLA) and lithium-ion batteries.&nbsp; A novel solid-state circuit replaces a problematic bootstrap contactor to power-up the generator from residual magnetism. The VR31 is compatible with both ac and dc auxiliary generators.<\/p>\n<p><strong><br \/>KEY FEATURES<\/strong><\/p>\n<ul>\n<li>Three-stage Battery Charging<\/li>\n<li>Longer Battery Life<\/li>\n<li>Reduced Failure to Start Events<\/li>\n<li>Faster Charging<\/li>\n<li>Reduced Water Consumption<\/li>\n<li>Simple Installation<\/li>\n<li>Compatible with Flooded Lead Acid, Valve <br \/>Regulated Lead Acid, and Lithium-ion Batteries<\/li>\n<li>Compatible with both AC and DC Aux Generators<\/li>\n<\/ul>\n<p>&nbsp;<\/p>\n","protected":false},"author":1,"featured_media":0,"parent":29731,"menu_order":2,"comment_status":"closed","ping_status":"closed","template":"","meta":{"_et_pb_use_builder":"on","_et_pb_old_content":"<div class=\"ems_right\"><img class=\" size-full wp-image-225\" src=\"https:\/\/www.enerpro-inc.com\/wp-content\/uploads\/2010\/12\/vr31-1.png\" alt=\"\" border=\"0\" width=\"213\" height=\"345\" \/><br \/><a href=\"https:\/\/www.enerpro-inc.com\/wp-content\/uploads\/2010\/12\/PD773_C_VR31_Product_Data_Guide.pdf\" target=\"_blank\" rel=\"noopener noreferrer\">Product Guide<\/a><br \/><a href=\"https:\/\/www.enerpro-inc.com\/wp-content\/uploads\/2010\/12\/M2101_VR31_ASSEMBLY_v2.pdf\" target=\"_blank\" rel=\"noopener noreferrer\">Mechanical Drawing<\/a><\/div> <p style=\"text-align: left;\">Enerpro\u2019s VR31 Auxiliary Generator Three-Stage Charge Voltage Regulator Module is a direct replacement for the VR10 - VR16 EMD auxiliary generator field controllers used in EMD Auxiliary Generator equipped locomotives (prior to SD70Ace and SD70M-2). The VR31 provides battery manufacturer recommended three-stage battery charging profile\u00a0for longer battery life, faster charging, reduced water consumption and compatibility with flooded lead acid (FLA) valve regulated lead-acid (VRLA) and lithium-ion batteries.\u00a0 A novel solid-state circuit replaces a problematic bootstrap contactor to power-up the generator from residual magnetism. The VR31 is compatible with both ac and dc auxiliary generators.<\/p> <p><strong><br \/>KEY FEATURES<\/strong><\/p> <ul> <li>Three-stage Battery Charging<\/li> <li>Longer Battery Life<\/li> <li>Reduced Failure to Start Events<\/li> <li>Faster Charging<\/li> <li>Reduced Water Consumption<\/li> <li>Simple Installation<\/li> <li>Compatible with Flooded Lead Acid, Valve <br \/>Regulated Lead Acid, and Lithium-ion Batteries<\/li> <li>Compatible with both AC and DC Aux Generators<\/li> <\/ul> <p>\u00a0<\/p>   <p>{tab=System Description|dark grey}<\/p> <p><strong><strong>Overview<\/strong> <br \/><\/strong>The advent of locomotive automatic engine stop and start systems has brought the benefits of decreased fuel consumption and air emissions but also increased the demands on starting batteries. The much more frequent discharge-charge cycles combined with constant voltage VR10- VR16 voltage regulators has resulted in much shorter battery life, battery plate sulfation, and reduced charge capacity. The operational impact is increased failure to start events and more frequent battery replacements. The VR31 solves these problems by providing battery manufacturer recommended 3-stage battery charging.<\/p> <p><strong><strong>VR31 module<\/strong> <br \/><\/strong>The VR31 module is a direct replacement for the VR10-16 series auxiliary generator voltage regulators. Locomotives equipped with the DVR300 voltage regulator require an additional mounting cage and wiring harness adapter for installation. The VR31 uses auxiliary generator voltage feedback, like the VR10, but also uses battery current feedback to provide optimum battery charging. The current sensor provides feedback required to limit current at the start of the charge cycle and to determine when the battery is 95% charged for transition to the float stage. VR31 design incorporates several failure mode protection features that ensure high operational reliability.<\/p> <p style=\"padding-left: 30px;\"><strong><strong>Shorted PWM Transistor Protection<\/strong> <br \/><\/strong>At high engine speed, the auxiliary generator will produce dangerously high voltage if the PWM transistor or the bootstrap transistor becomes shorted or if either transistor is turned on continuously due to a component failure. In this event, an over-voltage comparator trips the panel mounted circuit breaker if the auxiliary generator voltage exceeds the over-voltage trip threshold.<\/p> <p style=\"padding-left: 30px;\"><strong>Loss of Current Feedback Protection <br \/><\/strong>If the current sensor fails or\u00a0the current\u00a0signal to the VR31 becomes shorted or open, the VR31 immediately transitions to the 72V float voltege.\u00a0A current sensor fault light on the VR31 also lights and\u00a0an output signal is sent to the locomoitve. This fail-safe feature protects the battery from overcharging while still allowing the locomotive to operate until the next maintenance cycle.<\/p> <p><strong><strong>EBCS-2 Current Sensor<\/strong> <br \/><\/strong>The\u00a0EBCS-2 current sensor\u00a0is installed on the BTN battery cable directly behind the knife switch. By providing isolated battery current feedback to the VR31, the system is able to provide proper charging irregardless of load switching. The EBCS-2 is powered from nominal 74V output of the Auxilliary Generator and has built in failure detection and fail-safe circuitry.<\/p> <p>{tab=3-Stage Charging|dark grey}<\/p> <p><strong>THREE-STAGE CHARGE PROFILE <\/strong><br \/>Air pollution regulations and high fuel costs have made locomotive operators shut down idling locomotives much more frequently than in the past. This change in locomotive operation has resulted in premature loss of battery capacity and more frequent cell failure rate. These problems are caused by the single-stage charge profile provided by conventional chargers. With single-stage charging, the initial current immediately after engine start is limited only by generator output and battery circuit resistance. Most locomotive battery charging circuits incorporate a current limiting resistor to reduce the charge current. Even with this resistor, the initial current can greatly exceed the battery manufacturer\u2019s recommended maximum charging current and shorten battery life. The single-stage charger transitions from the high initial first-stage current when the battery voltage rises to reach the nominal voltage setpoint of 74 V. The single-stage charger then maintains constant nominal 74 V on the battery until the engine is shut down. According to battery experts, 74 V is insufficient to convert all of the battery\u2019s active material during the engine run time if the engine is shut down several times per day. The result is a progressive loss of capacity.<\/p> <p>The three-stage charge profile produced by the VR31 regulates the first, or Bulk Stage, current to 90 Amps. In the second, or Absorption Stage, the rectifier voltage is regulated to typically 78 V for an FLA battery and 76V for VRLA. This elevated voltage converts the maximum amount of active battery material while equalizing the charge in each cell, thus minimizing sulfation and capacity loss. In the third, or Float Stage, the VR31 reverts to a constant-voltage regulation mode (nominally 72 V).<\/p> <p><strong>Bulk Stage<\/strong> <br \/>After engine start, the unit enters the 90 A constant-current Bulk Stage. The battery behaves as a capacitor in that the constant charging current results in battery voltage increasing linearly with time. The Bulk Stage ends when the voltage reaches a converter-imposed limit of 78 V (FLA) or 76 V (VRLA).<\/p> <p><strong>Absorption Stage<\/strong> <br \/>The constant voltage Absorption Stage begins with the battery charged to about 80% total capacity. The Absorption Stage current decays exponentially with time from the initial 90 A until it reaches one of two Float Stage thresholds. The transition to the Float Stage occurs when one of two conditions are met:<\/p> <ol> <li>The Absorption Stage current decays to typically 25 A, or<\/li> <li>The total charge reaches approximately 95% capacity.<\/li> <\/ol> <p>Forcing the Absorption\/Float transition to occur as a function of charge assures that a shorted cell or other battery defect will not result in continuous operation at elevated voltage.<\/p> <p><strong>Float Stage<\/strong> <br \/>During the regulated 72V Float Stage, the battery current gradually decays to the steady-state self-discharge current. This maintains a full battery charge as long as the engine is running.<\/p> <p><img class=\" size-full wp-image-228\" src=\"https:\/\/www.enerpro-inc.com\/wp-content\/uploads\/2010\/12\/3-Stage_Charging.png\" alt=\"\" border=\"0\" width=\"600\" height=\"293\" \/><\/p> <p>{tab=System Block Diagram|dark grey}<\/p> <p><img class=\" size-full wp-image-229\" src=\"https:\/\/www.enerpro-inc.com\/wp-content\/uploads\/2010\/12\/VR31-block-diagram.png\" alt=\"\" border=\"0\" width=\"600\" height=\"278\" \/><\/p> <p>{\/tabs}<\/p>","_et_gb_content_width":"","footnotes":""},"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v22.6 - https:\/\/yoast.com\/wordpress\/plugins\/seo\/ -->\n<title>3-Stage Locomotive Battery Charger - Enerpro-Inc Power Electronics<\/title>\n<meta name=\"description\" content=\"VR31 3-Stage Battery Charger provides battery manufacturer recommended three-stage battery charging profile for longer battery life, faster charging,\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/www.enerpro-inc.com\/locomotive-and-rail-products\/vr31-3-stage-regulator\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"3-Stage Locomotive Battery Charger - 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