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TM-439
021676
Revised 052176
Revised 070676 Revised 011877
Revised 111577 Revised 021778
OPERATION AND MAINTENANCE MANUAL
with
ILLUSTRATED PARTS LIST
for
37%KVA AND 60-KVA !’
SYNCHRONOUS MOTOR-DRIVEN
400-HZ GENERATOR SETS
SERIES 45768, MODEL NO. 3210-50 60-KVA
SERIES 4713B, MODEL NO. 3210 60-KVA
SERIES 48208, MODEL NO. 3209-50 37.5-KVA
SERIES 491OC, MODEL NO. 3209 37.5-KVA
Manufactured by
Hobart Brothers Company pgwer Systems Division
Troy, Ohio 45373
U.S.A.
bLECTRIC SHOCK can kill. Do not touch live electrical parts. .
ELECTRIC ARC 'FLASH can injure eyes burn skin cause equipment damage and : I ignite combustible material. Do not use power cabies to
break load and prevent tools from causing short circuits.
IMPROPER PHASE CONNECTION, PARALLELING, OR USE can damage this and attached equipment.
IMPORTANT: - Protect all operating pers.onnel. Read, understand, and follow. all instructions in the Operating/Instruction Manual before installing,
. operating,, or-servicing the equipment.
available for future use by all operators. Keep the manual
GENERAL
Equipment that supplies electrical power can cause serious injury or death, or damage to other equipment or property. The operator must strictly observe all safety rules and take precautionary actions. Safe practices have been developed from past experience in the use of power source equipment. While certain practices below apply only to electrically-powered equipment, other practices apply to engine-driven equipment, and some practices to both.
SHOCK PREVENTION
Bare conductors, or terminals in the output circuit, or ungrounded, electrically-live equipment can fatally shock a person. Have a certified electrician verify that the equipment is adequately grounded and learn what terminals and parts are electrically HOT. Avoid hot spots on machine. Use proper safety clothing, procedures, and test equipment.
The electrical resistance of the body is decreased when wet, permitting dangerous currents to flow through it. equipment, do not work in damp areas.
When inspecting or servicing Stand on a dry rubher mat or
dry wood., use insulating gloves when dampness or sweat cannot be avoided. Keep clothing dry, and never work alone.
1. Installation and Grounding of Electrically Powered Equipment
Equipment driven by electric motors (rather than by diesel or gasoline engines) must be installed and maintained in accordance with the National Electrical Code, ANSI/NFPA 70, and other applicable codes. A power disconnect switch or circuit breaker must be located at the equipment.
' Check the nameplate for volta e, only 3-phase power is availab e, B
frequency, and phase requirements. If connect any single-phase rated equipment
to only two wires of the 3-phase line. DO NOT CONNECT the equipment grounding conductor (lead) to the third live mire of the 3-phase line, as this makes the equipment frame electrically HOT, which can cause a fata- shoclr.- _I---- - Alwa s connect the grounding lead to K
if supplied in a power line cable, t e grounded switch box or building round.
separate groundin If not provided, use a
of the grounding K lead. ead will
Ensure that t e current (am erage) capacity ii F ault current
;
situation. be adequate for the worst
details. Refer to the National Electrical Code ANSI/NFPA 70 for 1
Do not remove plug ground prongs. Use correctly mating receptacles.
2. Output Cables and Terminals
Inspect cables frequently for damage to the insulation and the connectors. not overload
Re lace or repair cracked or worn cables immediately. ;Do ca les. fl
energized. Do not touch output terminal while equipment fs
/ 3. Service and Maintenance ,i
i 8. .- _ . -. +--- This equipment must be maintained'in ood
, condition to avoid h azards stemming 9 electrical and mechanical; -- -----
equipment defect or safet rom disrepaiYYX@oitFy
1 hazard to the supervisor and discontinue :
~‘ --v'e---. -~~~~-~~.~~~~~ualif;~d personnel only. &.+&a ~&+.-.s-&#y-&s-b~~~ ,a.ssu~e&. .-&ap.&~s-.--'.. "..... -_
t., -" ._. _- .,- ..,, I- .- .-.. - ." _ "_ ,.
--I.-- ---.-- .-.".._- .-.-. ___-..-__--- __.., __ Instruction 910082 Feb 25186 Revised
Page 1
FI -
Fi ma Ull
1.
2.
3.
i D. TC -
Ca .
ti: v
E. BO -
“,E -4 ar
I in
$
6
-I,_ ! before inspecting or servicing the equipment.
b. Lock switch OPEN (or remove line fuses) so that power cannot be turned ON accidentally.
c. Disconnect power to equipment if it is out of service. , d. If troubleshooting must be done with the unit ener ized, have
another person present who is trained in turning o fi and providing or calling for first,aid.
f the equipment
E AND EXPLOSION PREVENTION
e and explosion are caused by electrical short circuits, combustible erial near engine exhaust 'pi ing, misuse of batteries and fuel, or afe operating or fueling con itions. is
Electrical Short Circuits and Overloads
Overloaded or shorted equipment can become hot enough to cause fires either by self destruction or causing nearby combustibles to ignite. For electrically-powered equipment, in particular,
3 rovide primary
input protection to remove short circuited or heave y overloaded equipment from the line.
Batteries
Batteries may explode and/or give off flammable hydro en and arcing from a ruptured battery can cause fires an 3 ad%;;ioniy a=id failures. When servicing, do not smoke, cause sparking, or use open flame near the battery.
Engine Fuel
Use only approved fuel container or fueling system. Fires and explosions can occur if the fuel tank is not grounded prior to ;; g:ing fuel transfer. Shut unit DOWN before removing fuel tank cap. completely fill tank, because heat from the e uipment may cause fuel expansion overflow. Remove all spilled fuel 8 MMEDIATELY,- including any that penetrates the unit. After clean-up, fumes away with compressed air.
open equipment doors and blow
IC FUME PREVENTION
bon monoxide - Engine exhaust fumes can kill and cause health problems. e or vent the .exhaust fumes to a suitable exhaust duct or outdoors. er locate engine exhausts near intake ducts of air conditioners.
ILY INJURY PREVENTION I
ious injury can result from contact with fans inside some equipment. I t DOWN such equipment for inspection and routine maintenance. When
!
ipment is in o eration use extreme care in doing necessary troubleshooting; adjustment. ii o not remove guards while equipment is operating.
! i
ICAL AND FIRST AID TREATMENT E 5
st aid facilities and a qualified first aid person should be available ! ! -. each shift for immediate treatment of all injury victims. ck victims should be checked by a ph
Electric I ;
.ediately if any abnormal signs are o served. g sician and taken to a hospital ! I
EMERGENCY FIRST AID
,i i
Page 2 Instruction 910082 Revised Feb 25/86
INTRODUCTION
This manual contains operation and maintenance information for a group of 37.5-KVA and 60-KVA synchronous, motor-driven 400iHz Generator Sets, manufactured by; Hobart Brothers Company, Power Systems Division, Troy,
Ohio 45373.,All machines covered by the manual will be identified in the Description Section (l-l) by specification numbers ,and characteristics.
The manual is in no way intended to be a text book on electricity or electronics. Its primary purpose is to provide
information and instructions to experienced operators, electricians, and mechanics who have never seen or operated
these generator sets. It is the intent of the manual to guide and assist operators and maintenance people in the proper
use and care of the equipment.
Use of the manual should not be put off until a trouble or need for help develops. Read the instructions before starting
the unit. Learn to use the manual and to locate information contained in it. Its style and arrangement are very similar
to commercial aircraft manuals. Each page is identified in the lower outside corner by the chapter and section number in which it appears. Each new section starts with page 1.
In addition to operation and maintenance instructions, the manual contains an illustrated parts list in Chapter 4. Con-
nection and schematic diagrams, and a collection of ma,nufacturer’s literature are included in Chapter 6.
Content of the manual is arranged as follows:
Chapter 1. Description/Operation
Chapter 2. Servicing
Chapter 3. Trouble Shooting
Chapter 4. Illustrated Parts List Chapter 5. Optional Equipment
Chapter 6. Manufacturer’s Literature
If you have any questions concerning your unit, you are invited to contact the Hobart Power Systems Division Service
Department by mail, telephone or TWX at:
Hobart Brothers Company
Power Systems Division
Service Department
Troy, Ohio 45373
U.S.A.
Telephone: Area Code (513) 339-6276
TWX: 810-456-2907
Jan 18/77 Revised Introduction
Page 1’ ----_
TABLE OF CONTENTS
SUBJECT CHAPTER/SECTION PAGE
Description/Operation 1-o
Description l-l
1. General
2. Orientation
3. Identification
A. Specification Numbers
B. Motor Ratings and Special Characteristics of Each Generator Set
(1) Series 4576B
(2) Series 4713B
(3) Series _ h -. h
(4) Series 4910C
4. Detailed Description
A. Canopy 5
B. Motor-Generator 6
C. Control Box, Voltage Regulator and Power Module
(1) Control box
(a) Generator output monitors (meters)
(b) Voltage regulator rheostat 8
(c) Motor control switch 8
(d) Generator control switch 8
(e) Panel light 10
(f) Indicating light
(g) Manual voltage control rheostat
(h) Operating mode control switch
(k) Convenience output receptacle
FEB 16176
10
10
10
10
Contents
Page 1
I
TABLE OF CONTENTS (CONTINUED)
CHAPTER/SECTION
l-l
SUBJECT PAGE
10
10
(2) ,lnterior panel
(a) Protective relays
(b) Resistors 12
12 (c) Rectifiers ’
(d) Plug-interlock relay
(e) Test bank switch
12
12
12
12
12
(3) Voltage regulator
(4) Power module panel assembly
(a) Ammeter current transformers
(b) Line-drop current transformers 12
(c) Load contactor 13
13 (d) Terminal studs
D. Motor Switch Box 14
E. Motor Switch Panel Assembly
(1) Motor switches
(a) Motor main switch
14
15
15
(b) Motor start switch 15
(c) Motor run , 4 17
(d) Start-run interh “ bar 17
(2) Time delay relays
(a) Time delay relay (25~seconds)
18
18
(b) Time delay relay (5-seconds) 18
18
18
18
18
19
(3) Transformers
(4) Control relay
(5) Motor exciter field rectifier and resistor
(6) Changeover connection links
(7) Motor overload protection system
FEB 16176 ’ Contents
Page 2
TABLE OF CONTENTS (CONTINUED)
SUBJECT CHAPTER/SECTION PAGE
F. Drip-Proof Panel
6. Special Equipment
l-l
A. Ungrounded Neutral 19
B. Power Factor Correction Capacitor Box 19
6. Optional Equipment 1 22
A. Trailer 22
23 B. Reverse Phase Relay
Preparation for Use
1. Inspection
2. Lubrication
3. Installation
A. Location 1
B. Mounting 1
(1) General
(2) Mounting cautions
(3) Recommended mounting instructions 2
(a) Mounting surface 2
(b) Pad mounting
(c) Leveling pads .
(4) Vibration trouble shooting
C. Wiring the Generator Set
(I) Power input wiring
(2) Grounding 7
(3) Connecting output cable 8
l-2
19
19
1
1
1
1
1
1
2
2
3
3
3
FEB 16176 Contents
Page 3
TABLE OF CONTENTS (CONTINUED)
SUBJECT CHAPTER/SECTION
D. Remote Controls l-2
(1) General
(2) Connecting remote controls
(3) Disconnect remote controls
Operation
1. General
2. Preparation for Power Delivery with Automatic
Voltage Regulation
A. General
B. Position Switches and Controls
(1) Motor switch box
(2) Control box
3. Power Delivery with Automatic Voltage Regulation
4. Preparation for Power Delivery with Manual Voltage Control
5. Power Delivery with Manual Voltage Regulation
6. Discontinue Power Delivery
l-3
PAGE
8
8
9
Contents FEB 16176
Page 4 Revised Jan 18177
TABLE OF CONTENTS (CONTINUED)
SUBJECT CHAPTER/SECTION PAGE
Servicing’ 2-o
Maintenance 2-l
. 1.' General
2. Inspection
3. Lubrication
4. Parts Replacement
5. Motor Switch Repair
A. Preparation
B. Recondition Switch Contacts
C. Replace Switch Contacts
D. Auxiliary Contacts
(1) Recondition auxiliary contacts
(2) Replace auxiliary contacts
Inspection/Check
1. General
2. Exterior Cables and Connections
A. Input and Output Cables
B. Cable Connections
2-2
FEE! 16176
Jan 18177 Revised
1
1
1
1
1
1
2
3
3
4
4
4
4
Contents
Page 5
TABLE OF CONTENTS (CONTINUED)
SUBJECT,
3. Controls and Instruments
A. Voltmeter, Ammeter and Frequency Meter
B. Indicating Lights
C. Overvoltage Sensing Relay
D. Undervoltage Sensing Relay
E. Motor Switch Contacts
3
3
F. Motor Switch Interlock Rocker Bar
G. Voltmeter Accuracy
4
4
H. internal Wiring and Connections 4
J. General Overall Inspection
4. Motor-Generator
A. Rotor Bearings
B. Motor-Generator Temperature
Adjustment/Test
1. General
2. Testing the Generator Set
A. Pre-operational Test Procedures
B. Operational Test Procedures
3. Adjusting the Generator Set
A. Adjust Motor Switch Contacts
B. Adjust Motor Switch Interlock Bar
C. Adjust Motor Start Time Delay Relays
(1) 25-second time delay relay adjustment
(2) 5-second time delay relay adjustment
Contents FEB 16176
Page 6
CHAPTER/SECTION
2-2
PAGE
1
1
1
3
5
5
5
5
2-3 1
1
1
1
4
6
6
6
8
8
9
1 i
TABLE OF CONTENTS (CONTINUED)
SUBJECT CHAPTER/SECTION PAGE
D. Generator Undervoltage Time Delay Relay
Adjustment 2-3
E. Voltage Regulator Adjustment
F. Generator Overload Relay Adjustment
Trouble Shooting
Electrical
1. General
2. Trouble Shooting Chart
3-6
3-l
A. Description
B. Use of the Trouble Shooting Chart
3. Equipment for Trouble Shooting
4. Safety
5. Fault and Effect Chart
Illustrated Parts List
introduction
1. General
2. Purpose
3. Arrangement
4. Explanation of Parts List
FEB 16176
4-o
4-l
10
11
II
1
1
1
1
1
1
1
2
2
Contents
Page 7
TABLE OF CONTENTS (CONTINUED)
SUBJECT, CHAPTER/SECTION
A. Contents 4-l
B. Parts List Form
(I) “Figure-Item No.” Column
(2) “Part Number” Column
(3) “Nomenclature” Column
(4) “Eff” (effectivity) Column
(5) “Units per Assembly” Column 2
Manufacturer’s Codes 4-2
1. Explanation of Manufacturer’s (Vendor) Code List
Parts List 4-3
1. Explanation of Parts List Arrangement
- ,2. Symbols and Abbreviations 4 .-
1
1
Numerical Index _ .--__ 4-4
3 Y Explanation of Numerical Index Optio~~~~~~~~~~~~~~~~‘-‘ --
570 /i __- ._
I Manufacturer’s Literature
CHAPTER/ FIGURE SECTION NUMBER
l-l
l-l
l-l
l-l
l-l
l-l l-l
l-l l-l
l-l
l-l
l-l
I l-l
Contents
Page 8
1 Generator Set 2
2 Specifications and Capabilities 3 3 Motor-Generator Exploded View 7 4 Control Box, Voltage Regulator and Power Module Assembly 8 5 Control Box 9 6 Interior Panel 11 7 Power Module Panel 13
8 Motor Switch Box 14 9 Motor Switch Panel 16
10 Motor Switch (Typical) (Main) 17 11 Drip-Proof Panel 20 12 Capacitor Box 21 13 Trailer-Mounted Generator Set 22
6-O LIST OF ILLUSTRATIONS
TITLE
’ i
PAGE
1
2
2
2
1
1
PAGE
NO.
FEB 16176
Revised Jan 18177
CHAPTER/ FI’GURE
SECTION NUMBER
1-2, 1 Locating Generator Insulating Pads
l-2 2 Motor Stator Link Connections
l-2 3 Motor Control Transformer Connections for 208-Volts
l-2 4 Motor Control Transformer Connections for 220-Volts or 230-Volts
l-2 5 Motor Control Transformer Connections for 380-Volts or 460-Volts
l-2 6 Motor Input Lead Turns Chart
l-2 7 Generator Output Terminal Panel
l-2 8 Motor and Generator Remote Controls Connections
l-3 1 Operating Controls and Instruments 2-3
2-l 1 Fuse Chart 2
2-l 2 Lamp Chart 2
2-l 3 Motor Switch (Typical) (Main) 3
2-2 1 Inspection/Check Schedule 2
2-3 1 Operating Controls and Instruments 2-3
2-3 2 Switch Interlock Bar Adjustment 7
2-3 3 Time Delay Relay (Motor Switch) 9
2-3 4 Undervoltage Time Delay Relay 10
3-l
3-l
4-3 1 Generator Set
4-3 2 Canopy Assembly
4-3 3 Motor-Generator Group Without Canopy
4-3 4 Motor Switch Box Assembly
4-3 5 Motor Switch Panel Assembly
4-3 6 Drip-Proof Panel Assembly
4-3 7 Motor-Generator Group
4-3 8 Control Box Assembly 4-3 9 Interior Panel Assembly
4-3 10 Voltage Regulator Box Group 4-3 11 Magnetic Amp Regulator
4-3 12 Power Module Assembly 4-3 13 Mounting Frame 4-3 14 Capacitor Box Group
FEB 16176
Jan 18/77 Revised
TITLE
PAGE
NO.
1 Motor-Generator Fault and Effect Chart 2
2 Trouble Shooting Chart (Sheet 1 thru 6) 3-8
-. 26 L
LIST OF ILLUSTRATIONS (CONT’D)
Contents
Page 9
CHAPTER 1. DESCRIPTION/OPERATION
SECTION 1. DESCRIPTION
1. General
All generator sets covered by the manual are self-contained, stationary units. They are identical in outward appear-
ance, mainly because they share the same sheet metal housing which is identified as a canopy (see Fig. 1). Any gen-
erator set may be mounted on a four-wheel trailer when the optional trailer is specified. All generator sets produce a
400-Hz, 115/200-V, 3-phase output for serving the electrical system of a parked’aircraft when the onboard gen-
erators are not running. Output power capacity of generator sets is either 37.5-KVA, or 60-KVA. Drive motor in-
put power requirements are either 50-Hz or 60-Hz. Motor input voltage requirements may also vary. (See Fig. 2 and Para. 3, B for identification of machines and their characteristics.)
The general physical configuration of all machines is the same. A combination motor-generator is mounted in a
welded, steel frame. The control box, power module, and voltage regulator are designed into a removable unit
mounted at the rear of the generator set. The motor switch box is mounted at the front end of the machine.
All components will be described later in this Section.
2. Orientation
For purposes of orientation and to avoid confusion in the location of components, the motor switch end (motor
end) of the generator set is identified as the FRONT. The control box is at the REAR end. Left and right are de-
termined by looking at the machine from the REAR. The fan exhaust duct is on the LEFT side.
3. Identification
A. Specification Numbers
Generator sets can best be identified by their specification number. A basic four digit series number i.e. (4713)
plus a dash number (-1, -2, etc) make up the specification (Spec.) number. The series number may or may not
’ have a letter suffix i.e. (4713B). The letter indicates an update or improvement in the series. To completely iden-
tify a machine, the series number plus a dash number (4713B-1) is required. This number is the specification
(Spec) number. Model numbers, although used frequently by Sales people, are too general for positive identifica-
tion.
To positively identify a machine, look at the identification plate mounted on the control box instrument panel. The complete specification number is stamped on this plate.
Refer to Fig. 2 and to information listed under Para. 3, B for ratings and various special features of your
machine.
FEB 16176 l-l
Page 1
I -
Canopy Closed
1 2 3 4 4 5 6 7
Canopy
Open
10
1. Motor switch box 6. Voltage regulator box 2. Motor 7. Control box 3. Drip-tight panel 8. Canopy 4. Access doors 9. Power module box 5. Generator 10. Frame
Generator Set
Figure 1
?:I FEB 16176
Page 2
* See Para. 3, B.
I SERIES
4576B 4713B 4820B 491 oc
PHYSICAL
(Stationary,) Weight approx.
Length
Width Height
(With Optional Trailer) Weight approx.
Length
Width
Height
4670 Ibs (2118 kg) 4670 Ibs (2118 kg) 4200 Ibs (1905 kg) 4200 Ibs (1905 kc 97 inches (2464 mm) all units 40 inches ’ (1064 mm) all units 54 inches (1372 mm) all units
5020 Ibs (2277 kg) 5020 Ibs (2277 kg) I 4750 Ibs (2155 kg) 4750 Ibs (2155 kc
107 inches (2718 mm) all units 62 inches (1575 mm) all units 67 inches (I 702 mm) all units
MOTOR
Cycles per second (,Hz) Phase Volts
Amperes
Horsepower Rated Speed (RPM)
50 60 50 60
3 3 3 3 * * * * * * * *
75 75 50 50
1500 1200 1500 \ 1200
GENERATOR
Output power rating (KVA) 60 60 37.5 37.5
Volts 115/200 115/200 115/200 115/200
Amperes (rated load) 173 173 108 108
Cycles per second (Hz) 400 400 400 400
Kilowatts (KWI 48 48 30 30
Power factor (PF) 0.8 0.8 0.8 0.8 Duty cycle 100% 100% 100% 100%
Operating Speed (RPM) 1500 1200 1500 1200 Overload capacity 125% of 125% of 125% of 125% of
rated load rated load rated load rated load
Phase 3 0
3 3 3
Specifications and Capabilities
Figure 2
Feb 16176 Jan 18/77 Revised
l-l
Page 3
B. Motor Ratings and Special Characteristics of Each Generator Set
(I) Series 45768
(a) Spec. 4576B-1
‘Motor rating 380 Volts, 94,Amps
(b) Specs. 4576B-2
Motor rating 220 Volts, 161 Amps
(2) Series 47138
(a) Spec. 4713B-1
Motor rating 460 Volts, 77 Amps
(b) Spec. 4713B-2
Motor rating 230 Volts, 154 Amps
(cl Sec. 47138-3
Motor rating 460 Volts, 77 Amps Special feature - ungrounded neutral (See Para. 5, A)
(d) Spec. 47138-4
Motor rating 230 Volts, 154 Amps Special feature - ungrounded neutral
(e) Spec. 47138-5
Motor rating 460 Volts, 77 Amps Special feature - Capacitor box for power factor correction (See Para. 5, B)
(f) Spec. 47138-6
Motor rating 230 Volts, 154 Amps Special feature - Capacitor box for power factor correction
(g) Spec. 4713B-7
Motor rating 208 Volts, 170 Amps, NOT reconnectable
I
(h) Spec. 4713B-8
Motor rating 380 Volts, 94 Amps, NOT reconnectable
(3) Series 4820B
(a) Spec. 4820B-1
Motor rating 380 Volts, 63 Amps
(b1 Spec. 4820B-2
Motor rating 220 Volts, 109 Amps
l-l
Page 4
Revised Jan 18177
.
4.
I I
(4) Series 491 OC
(a) Spec. 491OC1
Motor rating 460 Volts, 52 Amps
(b) Spec. 491OC2
Motor rating 230 Volts, 103 Amps
(c) spec. 491OC3
Motor rating 460 Volts, 52 Amps Special feature - ungrounded neutral
(d) Spec. 491OC4
Motor rating 230 Volts, 103 Amps Special feature - ungrounded neutral
(e) Spec. 491OC5
Motor rating 460 Volts, 52 Amps Special feature - ungrounded neutral
(f) Spec. 4910G6
Motor rating 230 Volts, 103 Amps Special feature - Capacitor box for power factor compensation
(g) Spec. 4910G7
Motor rating 575 Volts, 42 Amps Special feature - Capacitor box for power factor compensation
(h) Spec. 491OC8
Motor rating 208 Volts, 115 Amps (NOT reconnectable)
(j) Spec. 491OC9
Motor rating 208 Volts, 115 Amps (NOT reconnectable) Special feature - Capacitor box for power factor compensation
Detailed Description
A description of components used to build a generator set is given here. Main assemblies are listed by part name. Functional electrical parts for the assembly or group are then listed with a brief description of their function. Information applies generally to all machines. Information which applies only to a specific machine or machines will be qualified or identified as such.
A. Canopy
The canopy (8, Fig. 1) is a sheet metal housing designed to protect mechanical and electrical components of the generator set. It is attached to the main frame and sub-frame by machine screws. Two folding-hinged doors are provided on each side for access to the motor-generator and other internal components. Hinged doors are provided on each end for access to the motor switch on the front end and control box on the rear end.’
Feb 16176 May 21/76 Revised July 6/76 Revised
l-l Page 5
Nov 15/77 Revised
B. Motor-Generator (Se,e Fig. 3)
The drive motor and generator are combined in a single, compact, brushless unit. Both motor and generator
are three-phase synchronous type. The rotor assembly (or armature) consists of a single shaft upon which are mounted separate revolving fields for the motor, generator and the two exciters. Exciter revolving fields and 6-diode rectifiers are located near the’shaft ends. On 50-Hz motors only, two Micro switches are mounted on the motor exciter rectifier. These switches are normally CLOSED during start-up and are OPENED by cen-
trifugal force when operating speed has been reached. Their purpose is to short out the motor exciter recti-
fier during start-up to improve the starting torque characteristics of the 50-Hz motor. These switches also pro-
tect diodes against blow-out during start-up.
Generator output voltage is controlled by an outside voltage regulator which controls power in the exciter
stator field circuit. A centrifugal, vane type fan is mounted on the rotor shaft between motor and generator revolving fields. The fan draws cooling air over all internal windings. Air enters the motor-generator at each
end and is discharged through a single duct at the center of the unit.
The motor and generator stator windings with their respective exciter windings are installed in separate hous-
ings. The two housings are installed over each end of the rotor assembly and bolted together at the center of
the unit. Bearings and shaft ends are covered by flat bearing caps and gaskets. Flat washers provide a means
of adjusting rotor end play.
A threaded hole is provided in each end of the rotor shaft for attaching a lifing eye used in positioning or lift-
ing the rotor. A threaded hole is also provided in each of the stator housings.
The output of the generator is three-phase. The phases may be identified as phase A, B, and C, as, in fact, they are on schematic and connection diagrams. However, a fourth lead must be considered in a three-phase system.
This lead is identified as N (neutral) or ground. Later in the manual when we speak of line-to-neutral voltage,
we mean the voltage value between one of the phases and ground. Line-to-line is the voltage value between one phase and another phase. Current (amperage) value can only be expressed as a per-line value.
C. Control Box, Voltage Regulator, and Power Module Assembly.
This assembly (Fig. 4) is mounted on the main frame at the rear of the generator set. The control box is
mounted on a sub-frame at a convenient height for operating controls and observing instruments. The voltage
regulator is mounted directly behind the control box. The power module is mounted in the sub-frame below
the control box. A removable sheet metal cover provides access to power module components.
(1) Control box.
The control box (Fig. 5) consists of a sheet metal enclosure which houses controls and electrical equip-
ment. Operating controls and instruments are mounted on a front panel which hinges downward to pro-
vide access to internal components. It also houses an interior panel (Fig. 6) which is mounted vertically at
the rear of the box. All control box components except the ammeter are identical in all machines.
l-l
Page 6
FEB 16176
1.
Fan
gu
ard
2.
Mo
tor
stat
or
3.
Arm
atu
re
(ro
tor)
4.
Rec
tifi
er
bas
e
5.
Insu
lato
r p
late
6.
Co
nn
ecto
r b
ar
7.
Dio
de
8.
Dio
de
9.
Bra
cket
, sw
itch
10.
Mic
ro s
witc
h
11.
Bal
l b
eari
ng
12.
Gen
erat
or
stat
or
13.
Exc
iter
C
ove
r
15.
Ret
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16.
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ket
17.
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rin
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ap
18.
Exc
iter
win
din
gs
19.
Insu
lato
r
20.
Po
lep
iece
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24
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ox
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ust
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25.
Mo
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26.
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,_Control box -
Power module A
:..
-I
~
iVoltage regulator
E3
p, i
:
Output terminal
Control Box, Voltage Regulator, and Power Module Assembly
Figure 4
board
(a) Generator output monitors (meters) (See Fig. 5)
Generator output is monitored by three instruments; a frequency meter 3, a voltmeter 7, and an ammeter 9. The frequency meter is a resonant-reed type and indicates the frequency of the generator output’in the range of 380 to 420 Hz (cycles-per-second). The voltmeter indicates phase-to-phase (A-
B, B-C, or C-A), or phase-to-neutral (A-N) output voltage as determined by the position of the line
switch (15). The ammeter indicates the alternating current output, or “load” on the generator in each
of the three phases (A, B, or C) as selected by the meter switch (14). Ammeters used on 37.5-KVA
units (Series 4820B and 4910C) have a range of 0 to 150-A. Those used on 60-KVA units (Series
4576B and 4713B) have a range of 0 to 250-A.
(b) Voltage regulator rheostat
This rheostat (8) is connected directly to the voltage regulator (See Fig. 4) and provides a means of
adjusting output voltage when operating in automatically controlled voltage mode (switch (4, Fig. 5)
in AUTO position). After the desired generator output voltage’has been selected by turning the rheo-
stat knob (clockwise to increase voltage, or counterclockwise to decrease), the value selected will be
maintained automatically by the static voltage regulator.
(c) Motor control switch
The motor is started and stopped by operating START and STOP push button switches (12).
(d) Generator control switch
Generator output is controlled by pushbutton switches (16). Pushing the ON button closes the load
contactor and makes power available at the output cable. Pushing the OFF button opens the bad
contactor and disconnects output power. ’ I
l-l
Page 8
FEB 16175
,
16
1.
2.
3. 4.
5.
6. 7.
8.
115-V receptacle fuse (15-A) Panel fastener
Frequency meter
Operating mode switch Panel light switch
Panel light
Voltmeter
Voltage control rheostat (Automatic voltage regulator) Ammeter 9.
10. Convenience receptacle (I 15-V. 400-Hz).
11. Motor indicating light (Amber)
12. Motor START-STOP switch. 13. Manual voltage control rheostat. 14. Meter selector switch
15.’ Line switch
16. Generator load contactor control switch
17. Load contactor indicating light (Green)
Control Box Figure 5
FEB 16176 l-l
Page 9
,‘. .
,-- .-. - ,*_ _ . _
(e) Panel light
An instrument panel light (6) is controlled by a toggle switch (5).
(f) Indicating light
An indicating light (11) glotis amber when the drive motor is RUNNING. Another light (17) glows green when the load contactor is CLOSED and power is available.
(g) Manual voltage control rheostat
This rheostat (13) controls generator output voltage when operating in MANUAL control mode.
(h) Operating mode control switch
This is a two-position toggle switch (4) used to select either AUTOMATIC or MANUAL control of
generator output voltage. In AUTO mode, output voltage is initially adjusted by rheostat (8) and then
automatically maintained by the voltage regulator. In MANUAL mode, output voltage must be con-
stantly observed and adjusted as required by using rheostat (13).
(k) Convenience output receptacle
Two, dual-output convenience output receptacles (IO) are located on each side of the control box.
They provide 115-V, 400-Hz power for small tools and lights.
CAUTION: BE SURE TOOL OR LIGHT IS RATED FOR 400-HZ BEFORE USING.
These outlet circuits are protected by 15-A fuses (1).
(2) Interior panel (Fig. 6)
The interior panel is mounted inside the control box on the box rear panel. It is accessible by opening the
hinged instrument panel at the front of the box.
(a) Protective relays
The overvoltage relay (I), undervoltage relay (2). underfrequency relay (4) and overload relay (5)
provide protection to the generator and load (aircraft) against abnormal conditions of voltage, fre- quency and load.
Overvoltage and underfrequency relays function at once to break the load contactor holding circuit
and open the load contactor when an overvoltage or underfrequency condition exists.
The undervoltage relay is connected to a time delay relay (11) which opens the load contactor if the
undervoltage condition continues uninterrupted for 5 seconds. This arrangement prevents nuisance tripping of the load contactor caused by a momentary condition of undervoltage.
The overload relay (5) is a thermal type and starts functioning to open the load contactor when the
load exceeds 125% of rated load.
l-l
Page 10
FEB 16176
FEB 16176
__’
1. Overvoltage relay ~.y.
2. Undervoltage relay
3. Contactor hold circuit resistor (100 ohm, 25-Watt)
4. Underfrequency relay 5. Overload relay
6. Manual voltage range adjusting resistor (250 ohm, 100 Watt)
7. Overload adjusting resistor (50 ohm, 100 Watt)
8. Generator exciter field rectifier
9. Terminal boards
10. Load contactor hold circuit rectifier
11. Undervoltage time delay relay
12. Test bank switch 13. Plug-interlock relay.
Interior Panel
Figure 6
Page 11
(b) Resistors
The resistors (3, 6, and 7) are mounted on the interior panel.
The adjustable resistor (6) is used to adjust the range of the manual voltage adjusting rheostat (13,
Fig. 5).
The other adjustable resistor (7) is for adjusting the trip point of the overload relay (5, Fig. 6).
A smaller non-adjustable resistor (3) serves to, protect components of the load contactor hold circuit in the event of diode failure in the rectifier (10).
(c) Rectifiers
The diode rectifier (8) converts generator’1 15-VAC output to DC for generator exciter field exci- tation when operating in MANUAL voltage control mode.
The other rectifier (10) converts 115-VAC to DC for operation of the load contactor hold circuit.
(d) Plug-interlock relay.
The function of the plug interlock relay (13) is to cause the output load contactor to open in the
event the cable plug connector becomes accidentally disconnected from the aircraft during power de-
livery, or if an attempt is made to deliver power when the output cable is not connected to the air-
craft. Twenty-eight-volt, direct current for operation of the relay is supplied from the aircraft either
through an on-board transformer-rectifier, or from a twenty-eight-volt, electrical system. Connection
from the aircraft to the interlock relay is made through terminals E and F on the cable connectors.
(e) Test bank switch
A single-pole, single-throw toggle switch (12) provides a means of by-passing the plug-interlock relay
(13) when supplying power to a load bank, or to an aircraft not equipped with a plug-interlock sys-
I
tern. Switch must be in AIRCRAFT position for normal operation andin TEST.BANK position~to
supply power to a load bank, or aircraft not equjpped with a 28.5-V interlock systemzmmP _ ~~ ~_~ __ ~~~ ~~~~ ~-~.~
(3) Voltage regulator
The 225-Watt static voltage regulator (See Fig. 4) is mounted directly behind the control box. It is de-
signed to provide 1% voltage regulation with 0.2 second recovery time for all loads up to 100% of rated load at rated power factor on 3-phase, 4-wire, 4OO-Hz generators (alternators) with ratings up to 75-
KVA.
For detailed information refer to Instruction Manual for 225-Watt Static Regulator, No. 430293 in Chap-
ter 6, Manufacturers Literature.
(4) Power module panel assembly (Fig. 7)
The power module panel assembly is mounted directly below the control box and is accessible by re- moving a sheet metal cover.
Power module assemblies are identical on all machines except for a difference in ammeter current trans- formers required for 37.5-KVA and 60-KVA machines.
(a) Ammeter current transformers
The three ammeter current transformers (2) lower the output load current to a lesser value of definite ratio which will operate the ammeter movement without damage. The ammeter dial scale is graduated
and numbered so that the ammeter pointer will indicate the true load current value rather than the
metermovement value. 37.5-KVA machines and 60-KVA machines require different transformers.
(b) Line-drop current transformers.
The three line-drop current transformers (4) detect the magnitude of current flowing from generator
to load and feed a signal to the voltage regulator. The regulator interprets the signal and alters exciter field current as required to maintain a constant predetermined voltage at the load.
l-l
Page 12 --- FEB 16176
Revised Nov 15177
I I
(c) Load contactor
The load contactor (3) is a sealed unit and contains four sets of functional contacts. The three larger sets conduct three-phase generator output to the output terminals (1) and cable when the generator
ON button (16, Fig 5) is pushed. The contactor is OPENED automatically under abnormal voltage, frequency, or overload conditions.
A small set of contacts in the load contactor allow the undervoltage relay and timer to function only
when the motor is running and the load contactor is closed.
(d) Terminal studs
Output terminal studs (1) provide connections for the three-phase output A, 8, C, and ground N. Ter-
minal studs (5) provide for plug-interlock leads E and F.
I
1. Output terminals (A, B, C, N)
2. Ammeter current transformers
3. Load contactor
4. Line drop current transformers
5. Plug-interlock terminals (E and F)
Power Module Panel Figure 7
FEB 16176 l-l
Page 13
D. Motor Switch Box (Fig. 8)
The motor switch box is a sheet metal, cabinet like enclosure which houses the motor switch panel. The box
is mounted at the front (motor) end of the generator set.
A hinged front panel provides easy access to motor switch components. An hourmeter which records operating time is mounted in the hinged panel. ,Five revolving drums in the hourmeter record running time up to 9999.9
hours. An indicating light mounted below the hourmeter glows RED to warn operators when power is ON and it is dangerous to touch any internal components.
E. Motor Switch Panel Assembly
The motor switch panel assembly (Fig. 9) is ‘mounted vertically at the rear of the switch box. It consists of
switches and other electrical components required to start and control motor operation.
NOTE: Motor START and STOP pushbutton switches are located on the generator control box panel at the rear of the unit. They are described in Para 4, C, (I), (c) and (d). ,
Hourmeter
l-l
Page 14
Motor Switch Box Figure 8
. Indicating
light (red)
FEB 16176
(1) Motor switches
Three motor switch assemblies are used to start and run the motor. They are identified as the main switch
(8), the start switch (12). and the run switch (14). The main switch is directly connected to the incoming power source and is closed at al) times when the motor is ON. The start switch is closed only while the
motor is starting. The run switch is closed only while the motor is operating at rated speed.
The function of the mainswitch assembly is to disconnect all incoming power from the motor stator and
eliminate a dangerous “hot” motor condition which would exist if only start and run switches were used.
The purpose of the start switch is to provide a “wye” input connection to the motor stator windings for low speed torque at less current input.
The function of the run switch is to provide a “delta” input connection to the motor stator windings for
synchronous running.
The three switches are very similar in construction and operation.
(a) Motor main switch
The main switch (8, Fig. 9). which is the largest of the three, has three sets of stationary contacts (3,
Fig. IO) and three sets of movable contacts (5) which are clamp mounted on a bearing (7) supported
shaft (8). A core (12) is attached to the shaft in such a manner that when the magnetic coil (1) is
energized, it attracts the core and pulls it into the center of the coil. The core is thus moved to rotate
the shaft and close the contacts. The contacts are held in closed position as long as the switch coil is
energized. When the coil circuit is broken, the contacts are opened immediately by gravity and spring
loading. Stationary contacts are equipped with blowout coils to dampen, blowout, and minimize arc-
ing which may result from closing or opening the contacts. Each set of contacts is equipped with an arc shield (2, Fig. 10) which is easily removable for contact servicing. The main switch has a small set
of contacts (4) which are closed when the main switch contacts close. These contacts apply a holding
current to the switch coil circuitry which allows the START switch button to be released after the
main switch closes.
(b) Motor start switch
The motor start switch (12, Fig. 9) is very similar to the main motor switch (8) described above, ex-
cept it is smaller, and has no auxiliary contacts. Mechanical and electrical operating characteristics
are the same. The start switch is energized to close at the same time the main switch is closed to pro-
vide a “wye” starting connection to the motor stator windings.
FEB 16/76 l-l
Page 15
6 / \\
1. .
2.
3.
4.
5.
6. 7.
8.
.Time delay relay (25 sec.) Time delay relay (5 sec.)
Transformer
Fuse, IOA
Overload relay
Line input leads
Overload sensing coils
Main motor switch
9. Changeover connection links
IO. Control relay
11. Switch interlock bar
12. Motor start switch
13. Motor exciter field rectifier
14. Motor run switch
15. Motor exciter field resistor (250 ohm, 100 watt
Motor Switch Panel
Figure 9
’ i
1-I
Page 16
--
1. Magnetic coil 7. Shaft bearing
2. Arc shield 8. Movable contact mounting shaft 3. Stationary contact 9. Movable contact mounting bracket 4. Auxiliary contacts IO. Core adjusting screw
5. Movable contacts 11. Stationary core ‘6. Contact attaching screw 12. Movable core
Motor Switch (Typical) (Main)
Figure IO
(c) Motor run switch
The motor run switch (14, Fig. 9) is identical to the start switch. After the motor reaches operating
speed with the stator windings in “wye” connection, the start switch opens and the run switch closes to connect the motor stator windings in “delta” connection for synchronous running. The main switch remains closed during this operation.
(d) Start-run interlock bar
The interlock bar (11, Fig. 9) is designed to mechanically prevent the motor start switch and run
switch from closing or being closed at the same time. ’ I
FEB 16176 l-l
Page 17 ,,’
(2) Time delay relays
These relays time the operation of the start and run switches.
(a) Time delay relay (25 seconds)
This is a double-pole, double-throw, 120-V AC relay (1, Fig. 9). It has an adjustable time delay range of from 5 seconds to 50 seconds. For this application it is adjusted for a time delay of twenty-five
seconds between energization of the relay coil and actuation of the contacts. The relay coil is ener-
gized when the start switch closes. After a delay of twenty-five seconds, the relay contacts actuate to
OPEN the start switch circuit and CLOSE,the run switch circuit. This time delay allows the motor to
reach full speed before the run switch is CLOSED.
(b) Time delay relay (5 seconds)
This relay (2) is identical to the time delay relay described above. However, it is adjusted for a 5-
second time delay. Its function is to connect 115-V to the rectifier (13) through resistor (15). The
rectifier then supplies DC to the motor exciter field. This relay also prevents closing of the load con-
tactor before the motor reaches operating speed.
c (3) Transformers.
The transformer (3) reduces input line voltage to approximately 115-VAC for operation of relays,motor
switch coils, and other electrical components. The secondary circuit of the transformer is protected by a
10-A fuse (4).
NOTE: If the motor input voltage is changed it will be necessary to change transformer connections.
(See 1-2, Fig. 3,4, and 5).
(4) Control relay
The coil of this relay (IO) is energized when the motor START button is pushed. The relay contacts then
supply power directly to motor switch coils when the START button is released.
All 115-V power for timers, switch coils, etc. must pass through the control relay contacts.
(5) Motor exciter field rectifier and resistor
The rectifier (13) supplies DC excitation to the motor exciter stationary field. The resistor (15) is used to _...
adjust AC input power to the rectifier and thereby adjust motor excitation and power factor.
(6) Changeover connection links
These connection links (9) provide a convenient means of changing motor stator lead connections for var-
ious input voltage.
NOTE: Refer to (l-2; Fig. 2) for proper connection for specified voltages.
I-1
Page 18
FEB 16176
(7) Motor overload protection system
Three current transformers (7) lower the three-phase input current to a lesser value of definite ratio
(5OOlA to 5-A) for operation of the overload relay (5). The relay is an automatic reset, thermal over-
current type. The reduced current is connected to heater elements in the relay. Relay contacts are con-
nected in series with the control transformer (3) which supplies power for operation of motor switches. Any condition of overload in any phase causes a heater element to open a set of relay contacts and thus
stop the motor by disconnecting the source of power for holding motor switches closed.
NOTE: Overload relay heaters must be checked when input voltage value is changed. The number of
turns of wire lead (6) required through transformers (7) must also be checked and changed if
necessary. (See 1-2; Fig. 6)
F. Drip-Proof Panel (Fig. 11)
The sheet metal structure identified as a drip-proof panel assembly is a box-like housing mounted on the
motor-generator stators. In addition to providing extra protection for the motor-generator it provides terminal
boards for connecting motor and generator stator leads, motor and generator exciter leads, and for remote
generator and motor controls.
The stator leads terminal board is located on the right side panel. Remote control and exciter terminal boards
are mounted on the rear panel.
5. Special Equipment
Generator sets having special equipment were identified in Para. 3, B.
The special equipment or features will be described here.
A. Ungrounded Neutral
On machines with ungrounded neutral, a 3-MFD, 660-V capacitor witli connecting cable is used between the
generator NEUTRAL circuit and generator frame instead of the usual ground cable. This capacitor installation
provides a “floating” neutral and serves to insulate the generator set from the aircraft and to discharge any AC
‘voltage build-up.
B. Power Factor Correction Capacitor Box.
The capacitor box (Fig. 12) is mounted between main frame rails below the voltage regulator box. The box
contains six, 34 MFD capacitors which are connected to generator output leads. Connections are made at the
power module. Capacitors are connected in triple parallel delta.
The function of the capacitor installation is to reduce the excitation (revolving field power) required for a
given load, thus increasing the load capacity of the generator and also permitting a greater overload. The
capacitor installation tends to maintain a leading power factor load and prevents voltage drop and overheating
under heavy load. Another advantage is a reduced voltage demand on the voltage regulator at all loads.
’ i
FEB 16176 l-l
Page 19
c
1. Side panel 5.
2. Top panel 6.
3. Front panel 7. 4. Side panel
Drip-Proof Panel
Figure 11
Stator leads terminal board
Terminal boards
Rear panel
’ i
l-l
Page 20
FEB 16176 ‘.
1. Cover
2. Capacitor (34 MFD) (6 used)
3. Capacitor box 4. Grommet
Capacitor Box
Figure 12
FEB 16176 1-I
Page 21
6. Optional Equipment
Presently available optional equipment for generator sets covered by this manual is listed here in the main text. If
additional options become available they will be added in Chapter 5, Optional Equipment.
Options can no longer be tied to a certain machine by a modification to the Spec. number, or dash number added to the Spec. number. They must be ordered separately by name and part number.
I A. Trailer
I Any generator set in the Series covered by the manual may be mounted on a trailer when specified (see Fig. 13). Detailed information on the trailer (part number W-4460B-26) may be found in the trailer instruction --.------ manual TO-1 15.
,, .-.-
l-l
Page.22
Trailer-Mounted Generator Set
Figure 13
Revised Jan 18177
B. Reverse Phase Relay
The reverse’phase relay, or “phase sequence relay” (part number 4043891, is located below the starter switch. It is connected in the motor power input circuit to prevent motor starting if input power is connected in a reverse phase sequence. Briefly, it prevents the motor from running backward.
‘Basic components of this relay are: a set of shunt’coils, a pivoted copper disc, and a snap-action switch with a set of NO-NC contacts which are connected in series with the motor starting circuit. When input power is connected in the proper phase’sequence, the disc is rotated in a direction to close the contacts and allow the motor to start. If the phase sequence is reversed, the disc is rotated in the opposite direction to open the con- taizts and prevent starting the’motor.
(See Connection Diagram No. 482201 and Schematic Diagram No. 482202 in Chapter 6.)
Jan 18177 Revised 1-I
Page 23
SECTION 2. PREPARATION FOR USE
1. Inspection
Inspect the unit thoroughly prior to operation.
A. ‘Inspect for shipping damage.
B. Inspect all electrical connections for security.
C. Inspect cables and wire leads for damaged insulation, abrasions, etc.
2. Lubrication
No prestart lubrication is required. The motor-generator rotor bearings are permanently lubricated and sealed.
3. Installation
A. Location
Unless the location site has been definitely determined, the following things should be considered in the selection.
(1) The site should be well ventilated and free from exposure to high humidity, dust, or corrosive fumes. The
unit should be clear of jet engine intake or exhaust.
(2) Provide a clear area around the complete unit which is sufficiently large to allow working on any compo-
nent comfortably.
(3) If possible, position the unit so that the fan exhaust is in the same direction as prevailing winds or jet
engine blast.
(4) Try to keep power input and output cables as short as possible.
B. Mounting
(I) General
No “hard and fast” rules for mounting the generator set can be given because they may vary, depending
upon the users requirements and facilities. Common sense must be used in all installations to achieve a firm mounting which is free from vibration and which does not place undue stress on the skid (mounting
frame) and motor-generator.
(2) Mounting cautions
Before recommending how to mount the generator set, we believe you should first be cautioned about
how NOT to mount it.
CAUTION: (1) DO NOT BOLT THE MACHINE TO AN UNEVEN FLOOR, PAD, OR PEDESTAL.
THIS CAN-USE DAMAGING STRESSES IN THE FRAME AND MOTO-R-GENER-
ATOR.
FEB 16176 l-2 ~
Page 1
(2) DO NOT SET (AND OPERATE) THE MACHINE LOOSELY ON AN UNEVEN SUR-
FACE. THIS CAN RESULT IN AN UNSTABLE THREE-POINT SUSPENSION AND
CAUSE VIBRATION.
Most all cases of vibration are caused by mounting the generator set on an uneven floor surface.
(3) Reco’mmended mounting instructions
(a) Mounting surface
The single most important thing in generator mounting is the mounting surface. Whether the machine
is mounted on a cement floor, or on a pedestal, the mounting surface should be level and smooth so
that the full length of the skid can contact the cement.
(b) Pad mounting
It is recommended that some type of insulating pad be used between the skid and mounting surface
in all installations.
Resilient pads placed between the skid and the floor may help to compensate for slight unevenness in the mounting surface, and also insulate the skid from the floor to reduce vibration. Hobart pads No.
389945 can be used with or without bolts from skid to floor. (See Fig. 1).
(c) Leveling pads
An alternate method to the plain pad installation described above is one involving the use of self-
contained leveling mounts such as “Unisorb Level-Rites” or equivalent. These mounts will compen- sate for a greater degree of floor unevenness than plain insulating pads.
Pads equally spaced from ends of frame
Locating Generator Insulating Pads
Figure 1.
l-2
Page 2
FEB 16176
(d) Instructions for use of insulating pads
Whatever pad components are selected, these rules should be observed.
(aa) Support the skid at six or eight evenly spaced points, along each side of mounting frame. (See
Fig. 1).
(bb)Avoid solid contact between skid and floor.
(cc) Mount L shaped brackets along outside of frame to prevent unit from “walking”.
(4) Vibration trouble shooting
Because of the complex nature of vibration and resonance, it may be necessary to change the type and location of mounts to achieve the best results on a particular machine.
C. Wiring the Generator Set
(1) Power input wiring
WARNING: ALWAYS BE SURE THE POWER SOURCE IS TURNED OFF WHEN WORKING ON IN-
PUT LEADS OR CONNECTIONS.
CAUTION: MAKE CERTAIN THAT INPUT POWER IS CORRECT FOR THE GENERATOR SET.
AND BE CERTAIN THAT THE GENERATOR SET IS PROPERLY CONNECTED AND PREPARED FOR THE INPUT POWER BEING USED.
Refer to Fig. 2 for motor stator link connections.
Refer to Figs. 3,4, and 5 for control transformer connections.
Refer to Fig. 6 for number of input lead turns through overload coils.
Refer to Parts List Chap. 4 for motor overload relay heater element numbers.
Use cable size which will meet National Electric Code or your local Code for the input power being used.
It is recommended that a disconnect switch and a circuit breaker be used in the circuit ahead of the motor switch.
Route cables through back of motor switch box and to input terminals at the upper right corner of the
motor switch panel. Cut a cable entry hole in the lower left canopy panel as required, or as is necessary.
FEB 161% J2
Page 3
A 3A
2A IA 2B
0 2A IA
. ..
112
Page 4
38
lB
STATOR LINKS 208,220, 8 230V CONNECTIONS ., :
STATOR LINKS
380 B 460V CONNECTION
Motor Stator Link Connections
Figure 2
FEB 16176
BLACK-WHITE
BLACK-YELLOW r
. T14
BROWN -RED
BROWN -RED
208V CONNECTION
BROWN-RED J I RED - BLACK
Motor Control Transformer Connections for 208-V Figure 3
BLACK- WHITE
I BLACK- YELLOW
I
-,., ,~,
T I4
BROWN -RED RED-BLACK
-- *
Motor Control Transformer Connections for 220-V and 230-V
Figure 4 1 i
Jan 18177 Revised 1-i
Page 5 _-~
1-2
Page 6
BLACK-WHITE F
BLACK-YELLOW
Motor Control Transformer-Connections for 380-V and 460-V
Figure 5
4576B-1 4576B-2 47138-l. 3, and 5 4713B-2,4, and 6 4713B-7
4820B-1 4820B-2 491OC-1,3, and 5
Motor Input Lead Turns Chart Figure 6
Revised-Jan 18/77
I D-4
.
If input leads are identified, connect lead Ll to terminal Ll ; connect L2 to L2, and L3 to L3.
Proper,rotation of the motor is CLOCKWISE when viewed from the front, motor end. (See arrow on
stator housing.) If input leads are not identified, connect at random and use a phase rotation meter to
determine proper phase sequence. If out of phase, change any two input leads to correct. If a phase rota-
tion meter is not available, check for correct rotation as follows:
(a) Make certain that it is safe to turn on power and start motor. (Open canopy side doors).
(b) Make certain no tools or other foreign materials are in or on the unit.
(c) Turn ON remotely located disconnect switch or circuit breaker so power will be available at motor switch. Indicating light (l-l, Fig. 4) will glow RED when power is available.
(d) Press the motor START button (Ref. l-l, Fig. 5, item 12).0bserve and note the direction of motor rotation.
(e) Allow the motor to reach FULL OPERATING SPEED (approximately 30 seconds), then press the
motor STOP button and turn OFF the disconnect switch.
WARNING: DO NOTPRESSTHESTOPBUTTON OR INTERRUPTTHESTARTCYCLEBEFORE
THE MOTOR HAS REACHED OPERATING SPEED AND SHIFTED TO RUN
(DELTA) CONNECTION.
(f) If rotation was CLOCKWISE, motor is properly connected. If rotation was COUNTERCLOCKWISE,
reverse the positions of ANY TWO of the three input cables. This will connect the motor properly for
CLOCKWISE rotation.
NOTE: Motor rotation must be checked each time the generator set is moved or reconnected to a
power source.
For generator sets equipped with optional reverse phase relay: The motor will not start if
input leads are not connected in proper phase sequence.
, (2) Grounding
(a) If a four-conductor, rubber-covered input cable is used, connect the green lead to the generator set
main frame.
(b) If a three-conductor, rubber-covered input cable is used, it is necessary to ground the equipment with a separate conductor. This wire may be bare or insulated. Recommended wire size is No. 2. Ground
wire must make a good electrical connection between the main frame and a water pipe, earth, or the
ground connection of the power source.
(c) When conduit or flexible armored cable is used for input, provide adequate ground as in Para. (b)
above. Also ground the conduit, or armor of the cable.
(d) Connect a ground wire or strap between the motor-generator and the main frame to insure that the
motor is properly grounded to the frame.
WARNING: PROPER GROUNDING IS VERY IMPORTANT TO ASSURE FULL PROTECTION
TO THE OPERATOR AND OTHER PERSONNEL IN THE EVENT OF INSULATION
FAILURE OR ACCIDENTAL SHORTING OF THE POWER SUPPLY.
FEB 16176 i-i -.
Page 7
(3) Connecting output cable.
The generator output terminal board is mounted on the back side of the power module. It is equipped
with a hinged, clear plastic, protective cover. (See Fig. 7).
(a) Open left rear canopy doors.
(b) Cut a cable exit hole in lower right canopy panel as required.
(c) Route cable and connect to terminal board. Connect “A” lead to “A” terminal, “B” to “B” etc.
Cohnect small interlock lead(s) to “E” and/or “F”. Be sure all connections are secure.
NOTE: Generator to aircraft cable should not exceed 60 feet.
WARNING: DO NOT USE PLUG-IN CABLE ENTENSIONS TO EXTEND LENGTH OF OUTPUT
CABLE.
D. Remote Controls
(1) General
The generator set is wired to accommodate remote control stations for control of the motor and generator output load contactor. Terminal boards are mounted on the rear panel of the drip-proof panel (I-l, Fig.
11). It will be necessary to remove canopy top and drip-proof panel top to reach these terminal board.
The machine is shipped with jumper leads properly installed for regular operation without remote controls.
,’
_ .-.- r--l
L!l 43
CnP(
Generator Output Terminal Panel
Figure 7
l-2-.
Page 8
FEB_~6176
(2) Connecting remote controls.
(a) Remove canopy top and drip-proof panel cover.
(b) Route remote control leads to terminal boards (See Fig. 8). Protect leads against chaffing and insula- tion damage.’
(c) Remove jumper leads and connect remote controls as illustrated in Fig. 8.
(3) Disconnect remote controls
If remote controls are disconnected and removed, be sure to reinstall jumper leads.
MOTbR GENERATOR
STOP START . OFF
I I
I 1
.I ; .; 1 .I I
I I I I ” I I
-
Motor and Generator Remote Controls Connections Figure 8
1 i
FEB 16176 1-2
Page 9~
,
SECTION 3. OPERATION
1. General
This section contains information for the safe and efficient operation of the equipment. Operating instructions are
presented in a step-by-step sequence of procedures to be followed in supplying 400-Hz power to an aircra’ft.
NOTE: Read ALL of the operating instructions before attempting to operate the equipment.
CAUTION:
WARNING:
MAKE CERTAIN THAT ANY JUMPER LEADS, ETC., USED IN TESTING OR CHECKING, ARE
REMOVED.
BE SURE ALL COVERS, PANELS, DOORS, ETC.,ARE PROPERLY IN PLACE AND PROPERLY
FASTENED.
2. Preparation for Power Delivery with Automatic Voltage Regulation
A. General
(1) Make certain that no tools, rags, or other foreign materials are in or on the unit.
(2) Be sure the remotely located, input disconnect switch is ON.
B. Position Switches and Controls
Position (or check) switches and controls as follows:
(1) Motor switch box
The indicating light (l-l; Fig. 4) will glow RED when input power is available to motor start switch.
(2) Control box (see Fig. 1)
(a) If lighting is required, turn instrument panel light switch (5) ON.
(b) Place operating mode control switch (4) in AUTO position.
(c) Open control box hinged panel and place test bank switch (29) in A!R_CRAFTpo&ion. ~~~ ~~~
(d) Check generator overload relay (22). Push reset button to reset.
(e) If automatic voltage regulator rheostat (8) has been tampered with, set at mid-range position.
NOTE: Rheostat (8) was set at factory for 115-VAC, line-to-neutral output.
FEB 16176
Nov 15177 Revised
1-3
Page 1
! ? 3 43,678 9 2 1
16
.-
1. 2.
3.
4. 5.
6. 7.
8.
115-V receptacle fuse (15-A)
Panel fastener Frequency meter
Operating mode switch
Panel light switch Panel light
Voltmeter Voltage control rheostat
(Automatic voltage regulator) Ammeter 9.
10. Convenience receptacle (115-V. 400-Hz).
11. Motor indicating light (Amber) 12. Motor START-STOP switch
13. Manual voltage control rheostat
14. Meter selector switch 15. Line switch
16. Generator load contactor control switch 17. Load contactor indicating light (Green)
Operating Controls and Instruments
Figure 1 (sheet 1 of 2)
1-3
Page 2
FEB 16176
I8 'Q
I / I \ \
J 4, / hL
27 26 25
18. Overvoltage relay 19. Undervoltage relay
20. Contactor hold circuit resistor (100 ohm, 25-watt) 21. Underfrequency relay
22. Overload relay
23. Manual voltage range adjusting resistor (250 ohm, 100 watt)
24. Overload adjusting resistor (50 ohm, 100 watt) 25. Generator exciter field rectifier
26. Terminal boards
27. Load contactor hold circuit rectifier
28. Undervoltage time delay relay
29. Test bank switch 30. Plug-interlock relay
Operating Controls and Instruments
Figure 1 (sheet 2 of 2) ’ i
FEB 16176 1-3
Page 3
3. Power Delivery with Automatic Voltage Regulation
Operation with automatic voltage regulation is the normal method of supplying power to an aircraft. (See Figure 1)
A. Press the motor switch (12) START button, momentarily. The indicating light (11) should glow at once. Al-
low approximately 30 seconds for the motor to reach operating speed and the generator to produce power.
WARNING: DO NOT ABORT A START WHILE THE MOTOR SWITCH IS IN START POSITION EXCEPT IN CASE OF EMERGENCY. OPENING ENERGIZED START CONTACTS CAN CAUSE DAN-
GEROUS ARCING AND WILL REDUCE CONTACT LIFE.
B. Observe the generator output voltage as indicated on the voltmeter (7). This voltage must be 115 V, line-to-
neutral. If voltage is not 115 V, use the rhedstat (8) to adjust to proper value. Turn the rheostat knob CLOCK-
WISE to INCREASE voltage and COUNTERCLOCKWISE to DECREASE. Use the meter switch (14) to check voltage in each phase.
C. Observe frequency meter (3). Indicated frequency must be 400 Hz.
D. Connect generator output cable plug connector to aircraft. Make certain the plug and receptacle connectors are securely and fully mated.
E. Press generator on-off switch (16) ON button. Indicating light (17) glows to indicate the load contactor is CLOSED and power is available at the aircraft. If the indicating light should “go out” as soon as the ON
button is released, it indicates that 28.5-V DC holding current is not being supplied from the aircraft to the plug interlock relay. Correct the condition and again press the ON button.
F. It is recommended that the operator check output voltage and current in each of the three phases early in the
power delivery run. Use the meter switch (14) to select the phase. Use the line switch (15) to select line-to-line or line-to-neutral voltage. If the load is changing, it is good operating practice to observe the instruments
until load conditions stabilize.
G. A condition of overvoltage, undervoltage, underfrequency, or overload in the output circuit will automatically open the load contactor and disconnect load. Determine cause of load contactor opening and correct. Over-
load relay (22) must be manually reset. When fault has been corrected, proceed with power delivery.
4. Preparation for Power Delivery with Manual Voltage Control (See Figure 1)
Power delivery, using manual means for controlling the generator output voltage, is basically an emergency oper-
ation and should be used only in case of voltage regulator failure, or for testing the unit. Preparation for power
delivery with manual voltage control is exactly the same as for automatic control except:
A. Place the automatic-manual switch (4) in MANUAL position. This will disconnect the voltage regulator from
the exciter field circuit and connect the manual control rheostat (13) into the circuit.
B. Set the rheostat (13) knob to near mid-range position.
5. Power Delivery with Manual Voltage Regulation
Power delivery procedures are the same as for delivery with automatic control except:
J-3
Page 4
FEB 16176
A. Regulate the output voltage to 115 V by controlling the exciter voltage and current with the manual control rheostat (1,3). Turn the knob CLOCKWISE to increase voltage and COUNTERCLOCKWISE to decrease vol-
tage.
NOTE: Set manual control rheostat (13) at mid-range before start-up to prevent an overvoltage or under- -. voltage trip.
6. Discontinue Power Delivery (See Figure 1)
A. Press the red OFF pushbuttonswitch (16), and hold until the indicating light (17) goes off. This indicates that the load contactor has opened and power is no longer being delivered to the output cable.
B. Disconnect the power delivery cable from the aircraft.
WARNING: NEVER DISCONNECT A POWER CABLE WHILE POWER IS ON. I
C. The motor is stopped by pressing the STOP switch (12) to open the run and main motor switches. The indi- cating light (11) should go OFF, indicating that input power has been removed from the motor.
’ I
Jan 18177 Revised I-3
Page 5
CHAPTER 2. SERVICING
SECTION 1. MAINTENANCE
1. General
To make certain the generator set is ready for operation at all times, it must be inspected and maintained sys- tematically so that defects may be discovered and corrected before they result in serious damage or failure of the
equipment. Defects discovered during operation of the unit should be noted for future correction to be made as
soon as operation has ceased.
CAUTION: STOP OPERATION IMMEDIATELY IF A SERIOUS AND POSSIBLY DANGEROUS FAULT IS DISCOVERED.
WARNING: MAKE CERTAIN THE SOURCE OF MOTOR POWER IS TURNED OFF BEFORE PROCEEDING WITH ANY INSPECTION OR MAINTENANCE OPERATION WHICH COULD BRING PERSON-
NEL IN CONTACT WITH HIGH VOLTAGE OR REVOLVING EQUIPMENT.
2. Inspection
A periodic inspection schedule should be established and maintained. A suggested inspection/check schedule is pro-
vided in 2-2, Figure 1; however, it may be changed as required to meet varying operation conditions and environ-
ment. See 2-2, Inspection/Check for inspection and check procedures.
3. Lubrication
The generator set requires no lubrication. Motor-generator bearings are permanently lubricated and sealed at man-
ufacture. However, bearing replacement is recommended after 5000 hours of operation.
NOTE: The optionaltrailer requires lubrication. Instructions will be found inthe instruction manual, TO-1 15.
4. Parts Replacement
A. Replacement of Lamps and Fuses
Replacement of mortality items such as lamps, fuses, etc., requires no special instructions except the new
items should be installed securely and with good electrical contact. See Fig. 1 for fuse sizes, location, etc., and
see Fig. 2 for lamp identification.
B. Replacement of Minor Electrical Components
No special instructions are required to items such as relays, instruments, small switches and other controls. Re-
placement of such items is a matter of disconnecting all wiring attached to the item, removing attaching hard- ware, taking out the defective item, placing a new item in proper position to mount with the same hardware
and completing the installation by connecting the wiring as noted at removal or in accordance with the appli-
cable connection diagram. Some items such as time delay relays, etc., may require adjustment before proceed-
ing with normal operation of the generator set. Refer to 2-3, Adjustment/Test for testing and adjusting procedures.
Jan 18177 Revised
Page 1
Protection For Location
Motor control On motor
circuit control transformer
Convenience On control box
receptacle circuit front panel
Voltage regulator Voltage regulator
Symbol
FIO
Fll, F12
Fl
Size
M LD-5A
AGC-15A
NAG-2A
Fuse Chart Figure 1
Light Identification Location I
Lamp (bulb) Number
Control panel
illuminating
Motor ON indicating
Load contactor CLOSED indicating
Motor input
power ,ON indicating
Control box (see 1-I ; 6, Fig. 5)
Control box
(see l-l; 11, Fig. 5)
Control box (see l-l ; 17, Fig. 5)
Motor switch box
(see l-l ; Fig. 8)
6S6
(120-v, 6 watt)
120MB (neon)
NE51H (neon)
NE51H
(neon)
5. Motor Switch Repair (See Fig. 3)
Lamp Chart Figure 2
Motor switch contacts may require replacement every four to six months, depending upon operating conditions
and environment. Unavoidable arcing during motor starting and stopping causes wear and damage to switch con-
tacts.
WARNING: ALWAYS MAKE CERTAIN THAT INCOMING POWER IS OFF BEFORE MAKING ANY CLOSE
INSPECTION OR DOING ANY WORK ON MOTOR SWITCHES.
2-1
Page 2
FEB 16176
A. Preparation
Motor switches are more accessible for repair, replacement, and adjustment if the front panel is removed from
the motor switch box. Remove as required.
B. Recondition Switch Contacts
(1) Remove arc shields (2,,Fig. 3) for better access to contacts.
(2) If contacts show signs of only moderate burning or pitting, they may be reconditioned temporarily by “dressing” with a flat mi,lled file. It is not necessary to remove all traces of burning or pitting. File to ob-
tain approximately 90 per cent or more good, clean, contact surface, If contacts are badly burned,
proceed to step C.
1. Magnetic coil 7. Shaft bearing
2. Arc shield 8. Movable contact mounting shaft
3. Stationary contact 9. Movable contact mounting bracket
4. Auxiliary contacts 10. Core adjusting screw
5. Movable contacts 11. Stationary core
6. Contact attaching screw 12. Movable core
Motor Switch (Typical) (Main) Figure 3 1 i
FEB 16176 2-1
Page 3
C. Replace Switch Contacts
(1) Remove attaching cap screws (6, Fig. 3) and remove switch contacts (3 and 5). There are a total of 18
contacts used in the three motor switches. Contacts on the main switch are larger and are attached by 2
screws each. Start and run switch contacts are smaller and are attached by a single screw each.
(2) Install all new contacts (six required) in any one switch’ (main, run, or start) but do not tighten attaching screws securely. Close the switch manually by pushing the movable core (12) into coil (1) until the con-
tacts meet. Align each pair of contacts to meet evenly along their parallel contact surfaces, then tighten
attaching screws securely. The three sets of contacts must meet at the same instant. If they do not meet
simultaneously, loosen the four screws which clamp the movable contact holder (9) to the shaft (8) and
retighten to pull the holder in the desired direction. The holder will be “pulled” in the direction of the
screws being tightened. If perfect alignment and contact cannot be accomplished by the above methods,
it is permissible to bend the movable contact holder slightly. Repeat the above installation instructions for each switch. After installation of new contacts, the interlock rocker must be checked for proper adjust-
ment. Refer to 2-3, Para. 3, B.
D. Auxiliary Contacts
The auxiliary contacts (4, Fig. 3) on the main switch supply holding power to the switch coil (I) when the
motor START switch button is released. These contacts are OPEN when the main switch contacts are OPEN.
They are not subject to the same high voltage and current as the larger switch contacts, and therefore, re-
placement is required less often.
(I 1 Recondition auxiliary contacts
If auxiliary contacts are only darkened and slightly pitted, they may be cleaned and reconditioned.
(a) Dampen a clean, lint-free cloth with a good-quality, commercial contact cleaner. Several brands are
available in pressurized cans.
(b) Insert cloth between contacts and pull back and forth while contacts are held in closed position.
(2) Replace auxiliary contacts
If contacts are badly burned and pitted, replace the contact set (4, Fig. 3).
(a) Remove.the two stationary contacts by removing the attaching nuts, washers, and screws.
(b) Remove the movable contact assembly by removing the attaching nuts, washers, screws, and clamps
which mount it on the shaft.
(c) Install two new stationary contacts so that they are pointed straight upward perpendicularly and
parallel to each other. Tighten attaching hardware partially. Use attaching hardware and clamps to
mount the movable contact assembly on the shaft. Push the movable core into the coil so that the
contacts meet. Reposition the movable contact assembly, and the stationary contacts, if necessary, to
get good alignment between the two sets of contacts. Both sets of contacts must close at the same
time. It is permissible to bend the STATIONARY contact mounts slightly to get simultaneous closing and good alignment.
(d) Be sure all attaching parts are securely tightened and that contact adjustment is not changed.
2-I
Page 4
FEB 16176
Jan 18177 Revised 2-1
Page 5
2-1
Page 6
Jan 18177
SECTION 2. INSPECTION/CHECK
1. General
This,section describes inspections and checks to be performed in conjunction with Inspection/Check Schedule,
Figure 1.
2. Exterior Cables and Connections
A. Input and Output Cables
Observe general condition of motor input cables and generator output cables. Inspect for cuts and abrasions in the insulation which could cause a short circuit. Visually inspect the output cable plug connector for physical
damage.
B. Cable Connections
Check all input and output cable connections for tightness and security.
WARNING: TURN THE SOURCE OF INPUT POWER OFF WHEN CHECKING THESE CONNECTIONS.
3. Controls and Instruments
A. Voltmeter, Ammeter and Frequency Meter
Observe these instruments at each generator “start-up” to make certain they are operating. If one of the in-
struments is suspected of being inaccurate, check it against a master, or test instrument.
B. Indicating Lights
(1) Motor and generator indicating lights
Check these lights at each “start-up”. The motor indicating light should glow amber as soon as the START
button is pushed. The generator light glows green when the load contactor is closed. Replace the lamp if
any light should fail to glow under operating conditions.
(2) Input power indicating light
Be sure that input power indicating light, located on motor switch box, is operating at all times when
power is ON.
FEB 16176
-
EX
TE
RIO
R
CA
BL
ES
Insp
ect
gen
erat
or
ou
tpu
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s
Insp
ect
mo
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cab
les
Ch
eck
cab
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on
nec
tio
ns
CO
NT
RO
LS
A
ND
IN
ST
RU
ME
NT
S
Ch
eck
volt
met
er
Ch
eck
amm
eter
Ch
eck
freq
uen
cy
met
er
Ch
eck
all
ind
icat
ing
lig
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Ch
eck
ove
rvo
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e re
lay
Ch
eck
un
der
volt
age
rela
y
Ch
eck
volt
age
reg
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Ch
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all
mo
tor
switc
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on
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s
Ch
eck
mo
tor
switc
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nte
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rock
er a
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Ch
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volt
met
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accu
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C
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C. Overvoltage Sensing Relay
To check the operation of the overvoltage sensing relay (Section 1-3, Fig. 1, item 18), proceed as follows:
(I)
(2)
(3)
(4)
Start motor by pressing START switch (Section 1-3, Fig. 1, item 12).
Open control box instrument panel and place test bank switch (29) in TEST BANK position.
Place operating mode switch (4) in MANUAL position.
Close contactor by pushing generator ON switch (16).
WARNING: AVOID CONTACT WITH END OF OUTPUT CABLE - IT WILL BE “HOT”.
(5) Increase the generator output voltage gradually by turning the rheostat knob (13) slowly clockwise. Ob-
serve the voltage indicated on the voltmeter and note the voltage at which the load contactor OPENS.
The relay should function to open the contactor at an indicated voltage of 130 V to 134 V. The over-
voltage relay is not adjustable and must be replaced if it does not function within the specified voltage
range.
U-5) Adjust generator voltage to normal 115-V output.
D. Undervoltage Sensing Relay
Check operation of undervoltage sensing relay (Section 1-3, Fig. 1, item 19) as follows:
(1) Repeat steps (I) thru (4) in Para. C above.
(2) Lower the generator voltage in steps of 1 V each by turning the transformer knob (Section 1-3, Fig. 1, item 13) counterclockwise. Wait at least 12 seconds between steps to allow the time delay to function
after the undervoltage relay has tripped. Observe the voltage indicated on the voltmeter and note the vol-
tage at which the load contactor OPENS. The relay should function to open the contactor at an indicated
voltage of 103V to 92V. The relay is not adjustable and must be replaced if it does not function within
the specified voltage range.
(3) Adjust generator voltage to normal 115 V.
E. Motor Switch Contacts
WARNING: MAKE CERTAIN THAT THE OUTSIDE POWER SOURCE IS TURNED OFF.
(1) Open switch access panel (I-l ; Fig. 4)
(2) Visually inspect all switch contacts for burned and pitted contact surfaces. If the contacts are badly burned and pitted, they must be replaced. If contact surfaces can be cleaned and smoothed with a flat,
milled file to obtain 90 per cent or more good contact surface, the contacts need not be replaced (see 1-3,
Fig. 3).
FEB 16176
Nov 15177 Revised
2-2
Page 3
(3) Operate each of the three switches (main, start, and run) manually, one at a time. Observe the closing of
the three sets of contacts in each switch. If the three sets of contacts do not close at the same instant, ad-
just in accordance with instructions in 2-3; Para. 3,A.
(4) Chec,k all contacts and lead terminals for secure mounting.
F. Motor Switch Interlock Rocker Bar
The motor switch, interlock, rocker bar should be checked each time the motor switches are inspected, re-
paired, or replaced.
WARNING: MAKE CERTAIN THE OUTSIDE POWER SOURCE IS TURNED OFF.
(I) Manually close the start switch by pressing movable core (Ref. Section 2-3; Fig. 2, item E) into coil (M)
as far as it will go.
(2) Use a thickness gage to measure the clearance between the top end of the interlock bar (L) and the ad-
justing screw (G). Clearance should be approximately l/32 inch (0.031).
(3) Manually close the run switch by pressing movable core (E) into coil (M) as far as it will go.
(4) Repeat step 2 above except measure the clearance between the bottom end of the interlock bar and screw
(Cd.
(5) If clearances are correct and approximately the same, interlock bar adjustment is correct. If clearances are
not correct, adjust the interlock bar in accordance with Section 2-3; Para. 3, B, (1) through (3).
G. Voltmeter Accuracy (See Section 1-3, Fig. 1)
(I) Open the control box hinged panel and connect a master voltmeter of known accuracy to voltmeter
terminals.
(2) Start the motor and compare the unit voltmeter reading to the master reading. At normal output of 115V,
the voltmeter must not vary from the master meter reading by more than plus or minus 2% of full scale.
H. Internal Wiring and Connections
WARNING: MAKE CERTAIN INPUT POWER IS TURNED OFF.
(1) Open all canopy doors. Open starter switch box and control box panels.
(2) Visually inspect all wiring, leads, and cables. Inspect for cuts, abrasions, and signs of deterioration and
overheating. Inspect stranded leads for broken strands at terminals. Repair or replace any faulty wiring.
(3) Check all connections and connectors for security. Tighten all loose connections.
2-2
Page 4
FEB 16176 h.
J. General Overall Inspection
Inspect the entire generator set thoroughly while canopy doors are open for wiring and connections inspec-
tion.
(1) Clean the entire unit with dry rags and d,ry, low-pressure air so that any broken welds, cracks, deformation
or other evidence of damage may be observed.
(2) Check all attaching hardware for adequate tightness.
4. Motor-Generator
A. Rotor Bearings
(1) Open canopy doors.
(2) Start motor.
(3) Check both rotor bearings. Use a stethoscope, or long metal rod to listen for unusual bearing sounds. If
using a metal rod, place one end on a bearing housing and hold the other end near the ear. Hold the rod
with three fingers and use the index finger and thumb to form a “sounding chamber” between the rod and ear. Do not allow the rod to touch the ear. Listen for clicks, whines, or pounding which would indicate a
defective bearing. Send the unit to overhaul if in doubt of bearing serviceability.
NOTE: Do not misinterpret a “crackling” sound, caused by grease cavitation, as a defective bearing sound. A cavitation noise may be especially noticeable in new bearings.
B. Motor-Generator Temperature
Check the temperature of the motor-generator discharge air at the duct outlet.in the side of the canopy. Use an accurate thermometer. After one hour operation at full load in an ambient temperature of 90 deg F (32 deg C), the discharged air-temperature should not exceed 133 deg F (56 deg C).
FEB 16176
Jan 18/77 Revised 2-2
Page 5
;.
L. ’
SECTION 3. ADJUSTMENT/TEST
1. General
Adjustment and test procedures are most applicable to testing the generator set after repair, replacement of parts
or overhaul.
2. Testing the Generator Set
A. Pre-operational Test Procedures
Perform the following tests, checks, and operations before starting the generator set.
WARNING: MAKE CERTAIN THAT INPUT POWER IS OFF.
(I)
(2)
Open canopy doors and hinged access panels
Input and output wiring connections
(a) Connect the generator set to a load bank. The load bank should have single phase testing capability.
Use individual cables on each output terminal. Cables should be same length as those to be used in service. Length should not exceed 60 feet (18 m).
(b) If the motor is reconnected to a power source, make certain it is connected for proper rotation direc-
tion [see 1-2; Para. 3, C, 1, (a) thru (f).]
(c) Check connection of remote control boxes. If remote controls are not used, be sure jumpers are pro-
perly installed (see 1-2, Fig. 8).
(3)
(4)
(5)
Check adjustment of motor switch contacts and interlock bar (see Para. 3, A and B).
Check to make certain the unit is properly grounded. Check for ground lead on “N” terminal.
Check motor-generator rotor shaft end play. Should be l/32 inch to 3/32 inch (0.79 mm to 2.38 mm).
NOTE: Excessive end play - over 3/32 inch (2.38 mm) is preferable to NO rotor shaft end play.
(6) Check number of lead turns through each motor overload transformer (l-l ; 7, Fig. 9) for input power
rating being used. Refer to 1-2, Fig. 6.
(7)
Check for proper element in motor overload relay. (Refer to Chap. 4)
Check connections to motor control transformer for input power being used. Refer to 1-2, Figs. 3,4,
and 5.
(8) Remove motor stator lead connecting links (I-l ; 9, Fig. 9), so that motor switches, etc. may be checked
under power without starting the motor.
Locate links so that they won’t become lost.
1 i
FEB 16176 2-3
Jan 18177 Revised Page 1
8 9
I 15
\ -I 14 13
1.
2.
3.
4.
5.
6.
7.
8.
115-V receptacle fuse (15-A)
Panel fastener
* Frequency meter
Operating mode switch
Panel light switch
Panel light
Voltmeter Voltage control rheostat
(Automatic voltage regulator)
Ammeter
,,..__
Operating Controls and Instruments
Figure 1 (sheet 1 of 2)
IO. Convenience receptacle (115-V, 400-Hz)
11. Motor indicating light (Amber)
12. Motor START-STOP switch
13. Manual voltage control rheostat
14. Meter selector switch
15. Line switch 16. Generator load contactor control switch 17. Load contactor indicating light (Green)
9.
pz=-10 , , L 1
F-11
-12
.,. _
2-3
Page 2
FEB 16176
18. Overvoltage relay
19. Undervoltage relay
20. Contactor hold circuit resistor (100 ohm, 25-watt)
21. Underfrequency relay
22. Overload relay
23. Manual voltage range adjusting resistor (250 ohm, 100 watt)
24. Overload adjusting resistor (50 ohm,100 watt)
25. Generator exciter field rectifier 26. Terminal boards
27. Load contactor held circuit rectifier
28. Undervoltage time delay relay
29. Test bank switch
30. Plug-interlock relay
Operating Controls and Instruments Figure 1 (sheet 2 of 2)
FEB 16176 2-3
Page 3
B. Operational Test Procedures
(1) Place remote input circuit breaker or switch in ON position.
WARNING: EXERCISE CARE IN TESTING BECAUSE THE SWITCH BOX AND PANEL ASSEMBLY
WILL BE “HOT”.
(2) Use voltmeter to check output voltage of control transformer (l-l; 3, Fig. 9). Voltage should be 1 IO to
120 V AC across terminals Xl and X3 on transformer.
(3) Check operation of instrument panel light (6, Fig. I), and motor input indicating light (l-l; Fig. 4).
(4) Check operation of start switch time delay relay (l-l ; 1, Fig. 9). A stop watch or sweep-second-hand
watch is required for this test.
(a) Press motor START pushbutton. Main switch (l-l ; 8, Fig. 9) and start switch (12) should close at
once.
(b) The time delay relay should function to OPEN ,the start switch and CLOSE the run switch, 20 to 25
seconds after the START button is pushed. Switch shifting action may be heard and observed.
(c) Press motor STOP pushbutton.
(d) If the relay does not function within the above time range, adjust in accordance with instructions in
Para. 3, C, (1).
(5) Check operation of 5-second time delay relay (l-l ; 2, Fig. 9). This is similar to check (4) above.
(a) Connect a voltmeter so that voltage may be observed at terminal “1” on 5-second time delay relay when contacts close.
(b) Press the motor START pushbutton to close the main and start switches.
(c) Start timing the excitation application relay the instant the shift from start to run is made. The 5-
second relay should function within 4 to 6 seconds and a voltage of 115-V AC should appear on the
test voltmeter.
(d) Press motor STOP pushbutton.
(e) If the relay does not function within the time range, adjust in accordance with instructions in Para.
3, c, (2).
(6) Open remote switch or circuit breaker to remove input power to motor switch box. Reinstall motor stator
links which were removed in step (Para. 2, A, (8) ) above. Refer to 1-2, Fig. 2 for proper connection for input power being used.
(7) “Flash” generator exciter field by momentarily apply in 24-VDC to RED and YELLOW lead terminals
on drip proof canopy front panel. Apply POSITIVE to RED and NEGATIVE to YELLOW.
(8) Turn ON input power to motor switch box.
2-3
Page 4
FEB 16176 ’
I (9)
(IO)
(II)
(12)
(13) Place auto-manual switch in AUTO position and check automatic mode voltage range.
(14) Check convenience receptacles and fuses.
I (I 5)
I (16)
I (17)
(18)
I (19) Check operation of remote motor and generator controls if used.
With test bank switch (29) in TEST BANK position, apply l/3 to l/2 load and allow unit to run 20 to 30 min- -__ utes. Increase to full load and check motor power factor. Should be 0.95 leading to 1 0 PF at full ~~ ~.L._ -~~- load. Power
factor is adjustable by using motor exciter field resistor (1-I ; 15, Fig. 7).
(20) With full load on generator, adjust overload resistor (24, Fig. 1) to give 4-1/2-V across overload relay heater element.
(21) Check voltage regulation. Voltage regulator should maintain voltage within plus or minus 1% on loads up to full load.
(22) Check voltmeter (7) against master meter. Error must not exceed 2%ifull scale .
FEB 16176 \.
Nov 15177 Revised
2-3
Page 5
r
Place test bank switch (29, Fig. 1) in TEST BANK position, and place operating mode switch (4) in ~~~ -___ ~~ ~____ ~~ ~~~.~-~.. ~~~~ MANUAL position. .__ _ . _
Start ‘motor and check motor ON indicating light (11).
At NO LOAD on motor, check motor power factocshould be 0.8 PF leading.
If power factor is incorrect, use motor exciter field resistor (l-l ; 15, Fig. 9) to adjust.
Check manual mode maximum and minimum voltage range.
(a) Turn manual voltage adjusting rheostat (13, Fig. 1) to its full CLOCKWISE position. Indicated vol-
tage should exceed 140-VAC.
(b) Turn manual voltage adjusting rheostat to its full COUNTERCLOCKWISE position. Indicated vol-
tage should be less than IOO-VDC.
(a) Turn automatic voltage control rheostat (8, Fig. 1) to full CLOCKWISE position. Indicated voltage should exceed 132-VAC.
(b) Turn control rheostat to full COUNTERCLOCKWISE position. Voltage should be IOO-VAC or less.
NOTE: Receptacles are 115-VAC, 400-Hz.
With test bank switch (29, Fig. ?) jn TESTBA_N_K_positiqn,~press generator DN button. Contactor should close and remain closed.
Place test bank switch in Al RCRAFT position. Contactor should OPEN, indicating that plug-interlock relay is functioning.
Connect-a source of 24-VDC to terminal “F” on output terminal board (See 1-2, Fig. 7). With test bank
switch in Al RCRAFT position press generator ON button. Contactor should close and remain closed. If it does ~~~~-~~- ~~~- not remain closed, the plug-interlock relay is defective.
Disconnect source of 24-VDC.
(23) Check ammeter (9) against master meter. Error must not exceed 4% full scale.
(24) Operate at 125% load for 5 minutes. Overload relay (22) should not trip.
(25) Chec,k operation of protective relays. Trip points are as,follows:
Overvoltage relay
Undervoltage relay
Undervoltage timer Underfrequency relay
Overload relay
Trips at 130-I 34-VAC Trips at 92-l 03-VAC
Trips at 4-6 seconds
Trips at 375-385 Hz. Trips at any load above 125% rated load.
Trip time depends upon size of load.
(26) Check phase reversal relay if used (optional equipment).
(a) Disconnect input power and reverse any two input leads at motor switch box.
(b) Reconnect power and attempt to start motor. Motor should NOT start.
(c) Disconnect input power and reconnect input leads properly.
(d) Reconnect input power.
3. Adjusting the Generator Set
A. Adjust Motor Switch Contacts (See Fig. 2)
Switch contacts should be checked, and adjusted if necessary, each month and anytime switch components are
replaced.
WARNING: MAKE CERTAIN INPUT POWER IS TURNED OFF.
(1) Check each switch (main, start, and run) by operating manually to determine if the three poles (switch contacts) are closing at the same instant, and meeting evenly, that is, making contact along their parallel
surfaces.
(2) If one or two contacts are lagging, they may be adjusted to make contact sooner by loosening the movable
contact, mounting bracket screw (J) and tightening screw (K).
NOTE: Remember, the contact will be moved in the direction of the bracket screw tightened.
(3) If a satisfactory adjustment cannot be attained by the above method, it is permissible to bend the mov-
able-contact mounting bracket slightly.
B. Adjust Motor Switch Interlock Bar (See Figure 2)
The function of this bar is to mechanically prevent the START and RUN switches from closing at the same
time.
If START and RUN switches have been replaced, repaired, or adjusted, the interlock bar must be checked and
adjusted if necessary. Adjust as follows: ’ I
2-3
Page 6
FEB 16176
8’
A Screw, core adjusting G
B Locknut, core adjusting screw H
C Bracket, core J
D Bracket, adjusting screw mounting K
E Core L
F Locknut, bar adjusting screw M
Switch Interlock Bar Adjustment Figure 2
Screw, bar adjusting
Clearance Front adjusting screw Rear adjusting screw
Interlock bar
Holding coil
FEB 16176 2-3
Page 7
I
(1) Adjust both the START switch and RUN switch core adjusting screws.
(a) Loosen locknut (B) and turn screw (A) in clockwise until the point just touches core (E) when the
core bracket (C) is resting against the adjusting screw mounting bracket (D).
(b) When screw (A) point touches core (E), continue turning screw two full turns clockwise. Tighten
locknut (B).
(2) Loosen bar adjusting screw locknuts (F) and back out each screw (G) until the screw point is flush with its mounting bracket, then turn each screw (G) in CLOCKWISE four full turns and tighten locknuts (F).
(3) Push the run switch coil core (E) into the coil (M) as far as it will go and hold in this position. Check clear- ance between the interlock bar (L) and the head of the adjusting screw at (H). Clearance should be ap- proximately 0.030 inch (0.79 mm). Press the start switch core into its coil and recheck clearance between interlock bar and adjusting screw head. If further adjustment is necessary, adjust screw(s) (G) and (A) to ob- tain desired clearance. Iclosing
_ . ~~~~.~~ ~~
C. Adjust Motor Start Time Delay Relays
Motor start time delay relays are properly adjusted when the equipment’leaves the.factory, however; the vibra- *’
tions of shipping, etc., sometimes make readjustment necessary. If a relay is replaced, the new relay must be
checked and adjusted.
(1) 25-second time delay adjustment
The adjustment of this relay (I-l ; 1, Fig. 9) determines the length of time that the motor is in wye con-
nection for starting. The purpose of this time delay is to allow the motor to reach operating speed before
switches are shifted to delta connection for normal synchronous running.
WARNING: EXERCISE CARE TO AVOID TOUCHING A “HOT” LEAD, CONNECTION, OR COMPO- NENT DURING ADJUSTING PROCEDURES.
(a) Press the motor START switch button to close the main and start switches.
(b) Use a stopwatch, or sweep-second-hand watch, to determine the elapsed, time between the instant
the start button is pushed and the start and run switches are actuated to shift from wye to delta con-
nection: The start switch (l-l ; 12, Fig. 9) will OPEN and the,run switch (l-l ; 14, Fig. 9) will CLOSE. The elapsed time between pushing the START button and the closing of the run switch should be 20
to 25 seconds - preferably 25 seconds.
NOTE : Although the above times are realistic and good for most normal conditions, it is possible
that they may have to be extended in special instances. The important thing to remember is
that the motor MUST reach operating speed before the 25-second time delay functions to
cause motor switches to shift from “start” to run”. An operator can quickly learn to deter- mine when operating speed is reached by the sound of the motor-generator. As long as the
sound is increasing in frequency, the motor is accelerating. When sound frequency becomes
steady, operating speed has been reached. The time delay relay should function approxi-
mately ten seconds AFTER normal speed is reached.
i
2-3
Page 8
FEB 16176
(c) Press the motor STOP switch button.
(d) If the time delay recorded above is not within the prescribed range, turn the adjusting knob, located
in the top cover of the relay, CLOCKWISE to increase time delay or COUNTERCLOCKWISE to de-
crease time delay. The knob is graduated from 5 seconds to 50 seconds, however, do not depend upon graduations completely for an accurate setting. See Fig. 3.
(e) Repeat steps (a) through (d) until a satisfactory adjustment has been achieved.
(2.) 5-second time delay relay adjustment
The purpose of this relay (l-l ; 2, Fig. 7) is to apply power to the motor exciter field rectifier 5-seconds
after switches have shifted from wye to delta connection, and to supply exciter field excitation for syn- chronous running.
(a) Press motor START button.
(b) Use a stopwatch or sweep-second-hand watch to determine elapsed time between the moment motor
switches shift from “start” to “run” and the moment power is applied to the motor exciter rectifier.
This time delay should be approximately 5-seconds.
(c) Press the motor STOP switch button.
(d) If the time delay is not approximately 5 seconds, turn the adjusting knob, located in the top cover of
the relay, CLOCKWISE to increase time delay, or COUNTERCLOCKWISE to decrease time delay.
(See Fig. 3)
(e) Repeat steps (a) through (e) until a satisfactory adjustment has been completed.
Time Delay Relay (Motor Switch) Figure 3
’ 1
FEB 16176 2-3
Page 9
D.
I
Decrease time delay
Generator Undervoltage Time Delay Relay Adjustment
This time delay relay’(28, Fig. I), sometimes called a timer, is connected in the generator protective circuit. It
is identified as a “G-V Controls” relay. This relay provides a 5-second delay between receiving a signal from
the undervoltage sensing relay (?9) and the time it functions to open the load contactor to disconnect output
power. This delay prevents nuisance tripping of the load contactor under conditions of momentary undervol- tage in the output system.
(I) Place operating mode control switch (4) in MANUAL position. Place test bank switch (29) in TEST
BANK position. . -
(2) With generator running, press generator ON switch. Use manual voltage control rheostat (13) to quickly lower voltage to 90-V. The time delay relay should function within 4 to G-second after voltage is set to
90-V to open the load contactor.
(3) If adjustment is necessary proceed as follows:
The adjusting screw is located in the top of the relay and visible when looking down at the top of the
relay body (see Fig. 4). Turn the adjusting screw CLOCKWISE to DECREASE time delay and COUNTER-
CLOCKWISE to INCREASE time delay-After a COUNTERCLOCKWISE (backing the screw outward) ad-
justment, always press down on the screw firmly, but carefully, until the screw tip touches the diaphragm. Turn the screw only a little at a time.
Undervoltage Time Delay Relay
Figure 4
2-3
Page 10
FEB 16176
Revised Nov 15177
NOTE: 1. It may be noted that the direction of rotation for adjustment of this relay is exactly opposite to
the 5-second and 25-second motor-switch relay requirement.
2. To obtain best accuracy, the relay heating element should be allowed to cool approximately 15 minutes between checks.
(4) Repeat steps (2) through (4) until a satisfactory adjustment has been made.
E. Voltage Regulator Adjustment
Generator output voltage in automatic mode is adjusted by a rheostat (8, Fig. 1) mounted on the control box
panel. Turn the knob CLOCKWISE to INCREASE voltage, and turn COUNTERCLOCKWISE to DECREASE.
For other voltage regulator information, refer to Instructions for No. 430293 Voltage Regulator located in
Chapter 6.
F. Generator Overload Relay Adjustment
(1) With generator running at full load, check voltage across the relay (22, Fig. 1) heater element. Voltage
should be 4-I/2 Volts.
(2) To adjust this voltage move slider band on resistor (24) until proper voltage on relay heater element is obtained.
FEB 16176 2-3 ,
Page 11
CHAPTER 3. TROUBLE SHOOTING
SECTION 1. ELECTRICAL
1. General
A. Trouble shooting is an orderly process of checking and eliminating possible causes of trouble until the exact
cause of a trouble is found. As a rule, the best place to start looking for the cause of a trouble in a circuit is at
the source of power. Continue testing and checking the circuit, step-by-step, in an orderly manner, until the
cause of trouble is located. See connection diagrams and schematic diagrams in Chapter 6.
B. This section provides information useful in diagnosing and correcting certain troubles which cause unsatis-
factory operation or failure of the equipment.
- C. Minor troubles may be remedied by the operator; however, major repairs must be undertaken by experienced mechanics and electricians only.
2. Trouble Shootina Chart (See Fiaure 2)
A. Description
The trouble shooting chart lists information under three headings:
(1) Trouble, Symptom and Condition
(2) Probable cause
(3) Test, Check, and/or Remedy
B. Use of the Trouble Shooting Chart
(1) The trouble shooting chart is designed to provide maintenance and repair personnel with a time-saving
guide for locating the source of a trouble.
(2) Probable causes and remedies are listed in a step-by-step sequence which will insure power for testing in
all instances where input or output power may be used.
(3) Generator and motor troubles should be pinpointed only when the unit is stopped, since stator leads and
wiring must be disconnected for most tests.
(4) Always check circuit fuses, circuit breakers and the position of switches first in trouble shooting. The in-
correct positioning of a switch may cause a condition which could be misinterpreted as a fault.
(5) Electrical component symbols, which are used on schematic diagrams, and their legends to identify com- ponents, are also used in the trouble shooting chart (in parentheses after the item name) to help main-
tenance personnel identify parts on the schematic diagrams.
3. Equipment for Trouble Shooting
A good quality multi-scale voltohmmeter is the only instrument required for trouble shooting. However, for check-
ing motor-generator windings a double bridge or “Kelvin” bridge must be u&l and NOT a “Wheatstone” bridge.
Connection and schematic diagrams are also required.
FEB 16176
Jan 18/77 Revised
3-I
Page 1
4. Safety
WARNING: EXERCISE EXTREME CARE TO AVOID CONTACT WITH HIGH VOLTAGE LEADS AND COM- PONENTS WHICH COULD CAUSE SERIOUS SHOCK AND INJURY IF TOUCHED WHEN
TROUBLE SHOOTING OR OPERATING THE EDUIPMENT.
5. Fault and Effect Chart
Figure 1 lists faults which may occur in the’motor or generator and their resultant effects on the motor and/or gen-
erator. This chart may help pinpoint strictly motor and generator troubles.
GENERATOR
1. Open circuited winding Motor will run with decreased power NONE, except decreased output pow-
er potential caused by reduced motor
2. Short circuited
MOTOR STATOR
1. Open circuited winding
Motor will run, heat, and probably “burn out” diodes in exciter;
Motor will continue to run, single
phase, with high input current and
low power. Motor WILL NOT START if stopped.
NONE, except NO VOLTAGE OUT-
PUT if diodes are “burned out”.
NONE, except low current output.
2. Short circuited winding Motor will run single phase. WILL
HEAT. Will probably trip overload
NONE, except low current output.
GENERATORROTOR
1. Open circuited winding
2. Short circuited winding NONE, except low power if exciter
diodes are “burned out”.
NO VOLTAGE OUTPUT.
NO VOLTAGE OUTPUT.
GENERATOR STATOR
1. Open circuited winding Will operate until parallel windings in
one phase are burned out by overload,
then operate single phase.
2. Short circuited winding
Motor-Generator Fault and Effect Chart
Figure 1 (Sheet 1 of I) ’ I
3-l
Page 2
FEB 16176
TROUBLE, SYMPTOM,
AND CONDITION PROBABLE CAUSE TEST, CHECK, AND/OR REMEDY
MOTOR POWER INPUT CIRCUIT ;
B. No input power to switch box. B. Restore power as follows:
(1) Remote disconnect (1) Reset switch to ON position.
(2) Remote line fuse “blown”, (2) Check fuse and replace. Check or circuit breaker OPEN circuit breaker and reset.
C. Defective overload relay (K5, C. Turn input power OFF and check
relays as follows:
(1) Relay contacts dirty, (1) Inspect contacts. Clean, or re-
place relay as required.
D. Control transformer (T14) D. With input power ON, check vol- tage at terminals Xl and X3 on
control transformer. Voltage shoulc
be approximately 115 V AC. If vol- tage is abnormal, transformer is
defective. Replace.
1. Motor will not start when A. Defective START switch A. Turn input power OFF. Operate START button is pushed. (S26) or STOP switch (S27). and visually inspect START and Amber indicating light does STOP switch contacts. Clean, re- NOT glow. Power ON in- pair or replace switch assembly. dicating light glows. Turn circuit breaker ON.
2. Motor will ,not start when A. Defective control relay A. If control relay contacts do not START button is pushed. close when 115-VAC is applied tc Amber light (DSI 6) glows relay coil, replace control relay and start switch (K20)
closes momentarily.
B. Defective main switch (K19) B. Check coil resistance. If zero or in-
finity replace coil.
C. Defective main switch (K19) C. Inspect auxiliary contacts. Repair auxiliary (small) contacts. or replace as required.
itch (K19) auxil- D. Check and adjust as required.
(See 2-1, Para. 5, D, (1) and 2)
Trouble Shooting Chart (Sheet 1 of 6) Figure 2
1 i
FEB 16176 3-I
Page 3
:.i
TROUBLE, SYMPTOM, AND CONDITION PROBABLE CAUSE TEST, CHECK, AND/OR REMEDY
MOTOR POWER INPUT CIRCUIT (c~NT’D.)
pushed. START switch
(K20) will not,close. B. Start switch (K20) actuating
coil defective.
B. Check coil resistance. Replace if
4. Motor starts. Motor switches. Shift to “RUN”
either too soon or too late.
A. 25-second time delay relay A. Adjust relay (M7) in accordance (M7) requires adjustment. with (2-3; Para, 3, C, (1) ).
5. Motor switches will not A. 25-second time delay relay A. Replace relay (M7)
sh/ft to RUN. Run switch (M7) defective.
(K2l) will not close. B. Defective coil in Run B. Check coil and replace if
Motor runs. Lacks power
under load.
A. No excitation to motor ex- A. Check and repair as follows:
(1) Defective 5second time
delay relay (M8)
(2) Defective motor field
power adjusting resistor
(1) Check operation of 5-second relay (M8) Replace if defectiw
(2) Check resistor (R 14). Replace
if defective.
(3) Defective motor field
power rectifier (CR4).
(3) Check diodes in rectifier (CR4)
Replace diodes, or complete
rectifier if defective.
(4) Defective motor exciter (4) Check motor exciter field re-
sistance. If windings are open or shorted, send machine to
overhaul.
Trouble Shooting Chart (Sheet 2 of 6)
Figure 2
3-1 FEB 16176
Page 4
TROUBLE, SYMPTOM,
AND CONDITION PROBABLE CAUSE TEST, CHECK, AND/OR REMEDY
MOTOR EXCITATION CIRCUIT (CONT’D.)
MOTOR
reststance.
reduced power.
A. Check input cables between input
circuit breaker and source of
power. Repair as required.
B. Motor stator winding is open B. Check motor stator windings or short circuited.
3. Motor switches operate nor- A. Open circuit in motor stator A. See remedy 2, B, directly above. mally. Motor will not start.
4. Motor starts. Will not reach A. One input’phase is partially A. Check as follows AFTER turn- operating speed. ing input power OFF at remote
disconnect.
(1) Loose connection in (I) Check all input connections to motor switch panel.
(2) Open, dirty, or burned
motor switch contacts. (2) Inspect and check all motor
switch contacts. Refer to 2-2,
Para. 3, E, (1) thru (3)
(3) Defect in motor stator (3) Disconnect motor stator leads
at motor switch panel and check resistances. If a stator
winding is found to be defec-
tive, replace motor stator.
5. Motor stops in power de- A. Power supply failure. A. Check power source. livery run. Amber indicating
light goes out. B. Remote circuit breaker B. Locate and correct cause of trip-
ping before resuming operation
C. Motor overload relay has C. Check as follows:
(1) If motor housing is hot, locate cause and correct before re-
suming operation.
NOTE. Loss of motor field excita- A tion shows up as very high input
overload relays.
Trouble Shooting Chart (Sheet 3 of 6)
Figure 2
FEB 16176 3-l
Page 5
TROUBLE, SYMPTOM,
AND CONDITION PROBABLE CAUSE TEST, CHECK, AND/OR REMEDY
GENERATOR EXClTATiON CIRCUIT
MAL voltage in MANUAL
mode (I), Defective operating mode
control switch (Sl )
(2) Defective voltage regu-
(1) Make certain switch (Sl) is
supplying power to the vol-
tage regulator (VRI)
(2) If the generator produces
proper voltage in MANUAL mode and NOT in AUTO-
MATIC mode, replace volta(
2. Very low voltage in all gen- A. Defective component in MAN- A. Check as follows:
erator phases in MANUAL UAL voltage control circuit. mode. NORMAL voltage in
AUTOMATIC mode. (1) Defective operating mode (1) Be sure switch (Sl ) is con- control switch (Sl ). netting DC power to resis-
tor (R41) and overload rela!
(2) Defective manual control (2) Check diodes in rectifier (CR
rectifier (CR3). Replace diodes or complete
rectifier if defective.
(3) Defective exciter field (3) Check resistor and replace if (manual) resistor. (RI 1). defective.
(4) Defective manual control (4) Check rheostat (R61). RepIs rheostat (R61). if defective.
3. Voltage loL;/ in both AUTO- A. Defective operating control A. Check switch (9). Replace if
B. Defective overload adjusting B. Check both. Replace if defective resistor (R41) and overload
C. Defective generator exciter C. Check resistance of windings (L2 Send to overhaul if defective.
D. Defective exciter revolving
field windings (G2); exciter D. Send to overhaul for checks and
Trouble Shooting Chart (Sheet 4 of 6)
Figure 2
3-I FEB 16176
Page 6
TROUBLE, SYMPTOM,
AND CONDITION PROBABLE CAUSE TEST, CHECK, AND/OR REMEDY
GENERATOR OUTPUT CONTROL CIRCUIT
CLOSE when ON switch (&I) is pushed.
til 5-second time delay relay (M8)
has been actuated.
B. Defective generator ON or OFF B. Check switch contacts and mechan-
switch (S21 or S22) ism. Replace if defective.
C. If there is no AC voltage at terminal
“2” on the relay (M8) when genera-
tor ON button is held in closed
position, replace 5-second time de-
D. Overload relay (K3) tripped.
E. One of the protective devices
D. Manually reset.
E. Check across the contacts of the
following to determine power
carrying capability.
(1) Overvoltage relay (Kg) (2) Underfrequency relay (Kl 1)
(3) Undervoltage time delay relay
(4) Overload relay (K3) Replace
any defective protective device.
F. Load contactor rectifier (CR6) F. Check diodes in rectifier. Replace
diodes or rectifier (CR6) if defec-
G. Load contactor (Kl ) coil G. Check coil resistance. Replace com-
plete load contactor (Kl) if coil is “open” or “shorted”.
2. Load contactor CLOSES A. Generator output cable not A. Connect cable plug to aircraft re-
when generator ON switch properly plugged into aircraft. ceptacle. Be sure they mate se-
is pushed. DPENS when
switch is released.
B. Aircraft not supplying 28.5- B. Check aircraft on-board equipment
VDC to plug interlock relay to make certain aircraft will accept
power. 28.5-VDC power must be
available to “E” and/or “F” circuit!
in generator output cable.
C. Defective generator output
cable or plug connector
C. Inspect cable and plug terminals
thoroughly to make certain that
“E” and/or “F” circuits are good.
Trouble Shooting Chart (Sheet 5 of 6) Figure 2
’ i
FEB 16176
Jan 18177 Revised
3-l
Page 7
TROUBLE, SYMPTOM,
AND CONDITION PROBABLE CAUSE
GENERATOR OUTPUT CONTROL CIRCUIT(CONT’D.)
GENERATORCONTROL
1. Generator output voltage can- A. Defective voltage control
not be controlled in AUTO- rheostat (R72)
MATIC mode
B. Voltage regulator (VRI)
defective.
;ENERATOR
TEST, CHECK, AND/OR REMEDY
A. Use ohmmeter to check rheostat
(R72). Replace if defective.
NOTE: Rheostat should have a
range of 0 to 1500 ohms.
B. Replace voltage regulator.
2. Single phase output.
3. Generator overheats.
4. Unbalanced output.
EXTERNAL LOAD
1. Unbalanced load.
CIRCUIT troubles above.
B. Generator rotor windings B. Check winding resistance.
open or short circuited.
C. Generator stator windings C. Check winding resistance
open or short circuited.
A. Open or short circuit in A. Check winding resistance
generator stator windings.
A. Loose connection causing A. Inspect all connections for dis-
coloration caused by overheating. Tighten all connections.
B. Improper or blocked B. Inspect for rags, etc. in air dis-
C. Stator windings short cir- C. Check windings resistance
A. Loose connection in output A. Check all connections for loose-
ness and discoloration. Tighten
all connections
B. Open or short circuited gen- B. Check stator windings resistance.
A. Unbalanced load in aircraft. A. Check aircraft circuit for defects.
B. Defective connection in out- B. Check cable plug and aircraft re-
put circuit. ceptacle connectors.
C. Break or cut in output cable. C. Inspect. Repair or replace as re-
quired. .A
Trouble Shooting Chart (Sheet 6 of 6) Figure 2
Page 8
FEB 16176
Revised Jan 18177
CHAPTER 4. ILLUSTRATED PARTS LIST
1.
I
2.
3.
I
4.
SECTION 1. INTRODUCTION
General
The Illustrated Parts List identifies, describes, and illustrates main assemblies, sub-assemblies, and detail parts of the 400-Hz, synchronous motor-driven generator sets, manufactured by
Hobart Brothers Compan~PowerSystems .Division, Troy,-Ohio 45373. The generator sets are identified by the specifications-with series numbers 4576B, 4713B, 4826B and 4SlBC. ._
-Purpose
The purpose of the list is to provide parts identification and descriptive information to mainte- nance and provisioning personnel for use in provisioning, requisitioning, purchasing, and issuing of spare parts.
Arrangement
Chapter 4 is arranged as follows:
Section 1 - Introduction Section 2 - Manufacturer’s Codes Section 3 - Parts List
Section 4 - Numerical Index
Explanation of Parts List
A. Contents
The parts list contains a breakdown of the equipment into assemblies, subassemblies, and detail parts. All parts of the equipment are listed except:
(1) Standard hardware items (attaching parts) such as nuts, screws, washers, etc., which are available commercially.
(2) Bulk items such as wire, cable, sleeving, tubing, etc., which are also commercially available.
(3) Permanently attached parts which??% theirjdentity by being welded, soldered, riveted, etc., to other parts, weldments, or assemblies.
B. Parts List Form
This form is divided into five columns. Beginning at the left side of the form and proceed- ing to the right, columns are identified as follows:
(I) “FIGURE-ITEM NO.” Column
This column lists the figure number of the illustration applicable to a particular parts list and also identifies each part in the list by an item number. These item numbers also appear on the illustration. Each item number on an illustration is connected to the part to which it pertains by a leader line. Thus the figure ayd item numbering system ties the parts list to the illustration and vice versa.
Feb.16176
Jan 18177 Revised
4-l
Page 1
-
4-1
Page 2
(2)
(3)
(4)
(5)
“PART NUMBER” Column
All part numbers appearing in this column are Hobart numbers. If a Hobart number has not been assigned to a part, “NO NUMBER” will appear in the column and a vendor number (size description for hardware) will be listed in the NOMENCLATURE column.
“NOMENCLATURE” Column
The item identifying.name appears in this column. The indenture method is used to indicate item relationship. Thus, components of an assembly are listed directly below the assembly and indented one space. Sizes, ratings, or vendor part numbers may also appear in this column. ,
“EFF” (Effectivity) Column
This column is used to indicate applicability of parts when two or more models of equipment are covered by the parts list. code letters are used to indicate parts which are used only on a certain model, or models. Parts in this list are coded as follows:
Uncoded parts are usable on all models. Parts coded “A” are usable on Specs 4576B-1 only. Parts coded “B” are usable on Specs 4576B-2 only. Parts coded “C” are usable on Specs 4713B-1 only. Parts coded “D” are usable on Specs 4713B-2 only. Parts coded “E” are usable on Specs 4713B-3 only. Parts coded “F” are usable on Specs 4713B-4 only. Parts coded “G” are usable on Specs 4713B-5 only. Parts coded “H” are usable on Specs 4713B-6 only. Parts coded “J” are usable on Specs 4713B-7 only. _. ~.-.- ~~~ Parts coded “K” are usable on Specs 4820B-1 only. Parts coded “L” are usable on Specs 4820B-2 only. Parts coded “M” are usable on Specs 491OC-1 only. Parts coded “N” are usable on Specs 491 OC-2 only. Parts coded “P” are usable on Specs 491 OC-3 only. Parts coded “0” areusable on Specs 491OC4 only. Parts coded “R” are usable on Specs 491OC5 only. Parts coded “s” are usable on Specs 491OC6 only.
Parts coded “T” are usable on Specs 491 OC-7 only. Parts coded “U” are usable on Specs 491OC8 only.
Parts coded “V” are usable on Specs 4713B-8 only.
Parts coded “W” are usable on Specs 491OC-9 only.
“UNITS PER ASSEMBLY” Column
This column indicates the quantity of parts required for an assembly or subassembly in which the Part appears. This column does not necessarily reflect the total used in the complete end item.
Revised Jan 18177
SECTION 2. MANUFACTURER’S CODES
1. .-Expfanation of Manufacturer’s (Vendor) Code List
The following list is a compilation of vendor codes with names and addresses for suppliers of purchased parts listed in this publication. The codes are in accordance with the Federal Supply Codes for Manufacturer’s Cataloging Handbook H4-1, and are arranged in numerical order. Vendor codes,are inserted in the nomenclature column of the parts list directly following the item name and description. In case a manufacturer does not have a vendor code, the full name of the manu- facturer will be ‘listed-in the-nomenclature column.
CODE VENDOR’S NAME AND ADDRESS
00779 AMP Inc. P. 0. Box 3608 Harrisburg, Pennsylvania 17105
01121 Allen-Bradley,Company 1201 South 2nd Street Milwaukee, Wisconsin 53204
02231 Anchor Rubber Company 840 S. Patterson Blvd. Dayton, Ohio 45402
02660
03743
04009
Amphenol Corporation 2801 South 25th Avenue Broadview, Illinois 60153
Appleton Electric Company 1713 W. Wellington Avenue Chicago, Illinois 60657
Arrow-Hart & Hegeman Electric Company 103 Hawthorne Street Hartford, Connecticut 06106
04713 Motorola, Inc. Semiconductor Products Division Phoenix, Arizona 85008
14655 Cornell &‘Dubilier Electric Corp. 50 Paris Street Newark, New Jersey 07101
14831 Magnetic Components Inc. 290 Fischer Street Costa Mesa, California 92627
16053
Feb.16176
.,
Pepka Spring Company 810 South Waugh Kokomo, Indiana 46901
4-2
Page 1
CODE
24248
26992
27191
31356
44655
58849
60038
60741
71400
71785
72765
73559
4-2
VENDOR’S NAME AND ADDRESS
South Chester Corporation South Company Division 3rd and Governor Printz Blvd. Lester, Pennsylvania 19113
Page 2
Hamilton Watch Company Columbia &West End Avenue Lancaster, Pennsylvania 17604
C,utler-Hammer Inc. Power Distribution & Control Division 4201 North 27th Street Milwaukee, Wisconsin 53216
J-B-T Instruments, Inc. 424 Chapel Street P.O.Box18~8 New Haven, Connecticut 06508
Ohmite Manufacturing Company 3601 West Howard Street Skokie, Illinois 60076
Syntron Company 1938 Black Street Homer City, Pennsylvania 15748
Timken Roller Bearing Company 1835 Dueber Avenue SW Canton, Ohio 44706
Triplett Electrical Instruments Company Harmon Road Bluffton, Ohio 45817
Bussmann Mfg. Division of McGraw-Edison Company 2536 W. University Street St. Louis, Missouri 63017
Cinch-Jones Mfg. Company 1026 South Homan Avenue Chicago, Illinois 60624
Drake Manufacturing Company 4626 North Olcott Avenue Harwood Heights, Illinois 60656
Carling Electric, Inc. 505 New Park Avenue Hartford, Connecticut 06110
Feb.1 6176
CODE VENDOR’S NAME AND ADDRESS
74063 Hartman Electric Manufacturing Company P. 0. Box 8 Mansfield, Ohio 44901
76062
77342
79470
80368
81074
81091
88223
88601
89616
89873
90763
Feb.1 6176
Kurz-Kasch Inc. 1421 South Broadway Dayton, Ohio 45401
Marlin-Rockwell Company Division Thompson Ramo Wooldridge Inc. 1002 Chandler Street Jamestown, New York 14701
American Machine & Foundry Company Potter & Brumfield Division 1200 E. Broadway, P.O. Box 522 Princeton, Indiana 47570
Western Rubber Company 620 East Douglas Goshen, Indiana 46526
Sylvania Electric Products Inc. 730 Third Avenue New York, New York 10017
Holub Industries, Inc. 414 Hi-Center Sycamore, Illinois 60178
Pass & Seymour Inc. Solvay Station Syracuse, New York 13209
Jaymar Terminal Boards, Inc. 25-27 Brutus Street Weedsport, New York 13166
Westinghouse Electric Corp. Transformer Division Sharpsville Avenue Sharon, Pennsylvania 16146
United States Rubber Company Consumer Industrial & Plastics Products Division Mishawaka, Indiana 46544
Cortland Industries, Inc. 4545 West Cortland Street Chicago, Illinois 60618
United-Carr Inc. 4258 North Cicero Chicago, Illinois 60640 1 i
4-2
Page 3
CODE
91929
93929
93993
98403
98410
4-2
VENDOR’S NAME AND ADDRESS
Honeywell Inc. Building Controls & Components Group Micro Switch Division Freeport, Illinois’61032
G-V Controls Inc. 81 Okner Parkway
’ Livingston, New Jersey 07039
Midwest Electric Products Inc. Box 910 Mankato, Minnesota 56001
Agastat Division Elastic Stop Nut Corporation 1027 Newark Avenue Elizabeth, New Jersey 07207
E.T.C. Inc. 990 East 67th Street Cleveland, Ohio 44103
Feb.1 6176
Page 4
SECTION 3. PARTS LIST
1. Explanation of Parts List Arrangement
The parts list is arranged so that the illustration will appear on a left-hand page and the applicable parts list will appear on the opposite right-hand,page. Unless the list is unusually long, the user will be able to look at the illustration and read the parts list without turning a page.
2. Symbols and Abbreviations
The following is a list of symbols and abbreviations used in the parts list.
* - Item not illustrated A, or AMP - ampere
AC - alternating current AR - as required DC - direct current
Fig. - Figure hd. - head hex - hexagon Hz - Hertz (cycles-per-second)
I.D. - inside diameter .. ,,,!.N - inch
:‘WA - kilovolt-ampere MFD - microfarad
NO. - number NHA - next higher assembly PRV - peak reverse voltage
PSI - pounds per square inch Ref - reference (the item has been listed previously) SA - sub-assembly TM - Technical Manual T-R - transformer-rectifier
v - volt (whenused as a prefix to a five-digit number, indicates vendor code)
NOTE: An item which does not reflect an index number is an assembly which is not illustrated in its assembled state, or it is similar (right-hand, left-hand, top, etc.) to an item which is illustrated.
Feb.16176 4-3
Page 1
_-
--
\
_.
FIGURE HOBART
ITEM NO. PART NO.
I -
k I.
NOMENCLATURE .
UNITS
per 1234567 EFF ASSY.
connectable, motor rating 208 Volts, 115 Amps.) u
l-
I
I Specs47138-8 GENERATOR SET,
Model 3210 (with 380 Volt input) 1 i V
Specs 491OC9 GENERATOR SET, Model 3209
Jan 18177 Revised (with 208 Volt input, not reconnectable, and
Feb 17178 Revised power factor correction capacitors for output) W
-t.. .-.
.I”.., .,,, .,.- .; ‘/ _, +:j? ,, . 7
4-3
Page 3
Specs 45768-l GENERATOR SET,
Model No. 3210-50 (with 380 Volt input)
Specs 4576B-2 GENERATOR SET, Model No. 3210-50 (with 220 Volt input) Specs 4313B-1 GENERATOR SET,
Model No. 3210 (with 460 Volt input)
Specs 47138-2 GENERATOR SET,
Model No. 3210 (with 230 Volt input)
Specs 47138-3 GENERATOR SET,
Model No. 3210 (with 460 Volt input and
ungrounded neutral)
Specs 4713B-4 GENERATOR SET,
Model No. 3210 (with 230 Volt input and
ungrounded neutral)
Specs 4713B-5 GENERATOR SET,
Model No. 3210 (with 460 Volt input and
power factor correction capacitors for output)
Specs 4713B-6 GENERATOR SET,
Model No. 3210 (with 230 Volt input and
power factor correction capacitors for output)
Specs 4713B-7 GENERATOR SET (with 208 Volt input)
Specs 4820B-1 GENERATOR SET, Model No. 3209-50 (with 380 Volt input)
Specs 48208-2 GENERATOR SET,
Model No. 3209-50 (with 220 Volt input)
Specs 491OC1 GENERATOR SET, Model No. 3209 (with 460 Volt input) Specs 491OC2 GENERATOR SET,
Model No. 3209 (with 230 Volt input)
Specs 491OC3 GENERATOR SET,
Model No. 3209 (with 460 Volt input and
ungrounded neutral)
Specs 491OC-4 GENERATOR SET,
Model No. 3209 (with 230 Volt input and ungrounded neutral)
Specs 491OC5 GENERATOR SET,
Model No. 3209 (with 460 Volt input and
power factor correction capacitors for output)
Specs 491OC6 GENERATOR SET,
Model No. 3209 (with 230 Volt input and
power factor correction capacitors for output) Specs 4919C7 GENERATOR SET, Model, No. 3209 (with 575 Volt input, motor’ rating 575 Volts, 42 Amps.) Specs 491OC8 GENERATOR SET, Model No. 3209 (with 208 Volt input, not re
A
B
C
D
E
F
G
H
J
K
L
M
N
P
Q
R
S
T
-.
4-3
Page 4
Revised’ Jan 18177
FIGURE HOBART
ITEM NO. PART NO.
NOMENCLATURE
1234567
I- 1 HF-2727 . EYE, LIFTING 2 50NH-787 . CANOPY ASSEMBLY (For details, see Fig. 2) 3 No Number . MOTOR &GENERATOR GROUP (WITHOUT
CANOPY) (For details, see Fig. 3)
4 W-4460B-26 . TRAILER GROUP (For details, see TO-1 15) 5 No Number . MOUNTING FRAME (For details, see Fig. 13)
Jan 18177 Revised
EFF
UNITS
per ASSY
1
1
4-3
Page 5
3
-21
6
Canopy Assembly
Figure 2
4-3 Revised Jan 18177
Page 6
FIGURE
ITEM NO.
1
?
3
4
2-
*
*
*
8
*
*
5
6
7
8
9
IO
11
12
13
14
15
16
17
18
19
20
21
HOBART
PART NO.
50NH-787
50NH-774
50NH-775
50NH-776
5JB-984
5JB-985
H F-584
50NH-778
6OFC-622
6OFC-620
60GHP-234
50NH-796
75GH-323
50NH-765
50NH-810
50NH-784
75NH-334
50NH-797
50N H-786
1 OOGH-683
3DW-248
1 OOGH-685
50NH-800
50NH-807
50NH-790
50NH-791
50NH-792
50NH-793
50NH-794
50NH-792
60GH-145
DWP-982
50NH-622
480366
402987
Jan 18177 Revikd
NOMENCLATURE
1234567
CANOPY ASSEMBLY (For NHA
See Fig. 1)
. PANEL, END, CANOPY SA
. . PANEL, END
. . DOOR, RIGHT, SA
. . ,CAM V24248, No. 17012-15
. . SPRING V24248, No. 17011-15
. . SPACER
. . DOOR, LEFT, SA
. . HANDLE, LATCH, SA
. . SPACER
LATCH, DOOR : >p_NEL, LEFT FRONT & RIGHT REAR ‘. ~~ ~~_~-.-.- . GUIDE, DOOR
. TOP, CANOPY, SA
. PANEL, SIDE, LEFT
. DOOR, FRONT & REAR, ASSEMBLY
. BLOCK, HINGE, DOOR
. PANEL, LEFT, CENTER, SA
. PANEL, LEFT, REAR, & RIGHT FRONT
. HANDLE, LATCH, SA
. LATCH, DOOR
. SPACER, DOOR LATCH
. PANEL, RIGHT, CENTER
. PANEL, SIDE, RIGHT
. TRACK, RIGHT, TOP, SA
. . ANGLE
. . TRACK
. TRACK, LEFT, TOP, SA
. . ANGLE
. . TRACK
. HOOK, DOOR, END, CANOPY
. HANGER, CABLE
. PLATE, REINFORCING, CABLE HANGER
. STIFFENER, PANEL, CENTER
. NAMEPLATE, HOBART
UNITS
per ASSY.
REF
2
1
1
4
4
4
1
2
2
2
2
8
1
1
4
8
1
2
8
8
8
1
1
1
1
2
1
1
2
4
4
4
2
2
4-3
-. Page 7
‘.
,
Motor Generator Group Without Canopy
Figure 3
Revised Jan 18/77 4-3
Page 8
FIGURE HOBART
ITEM NO. PART NO.
3-
1 382501-25
2
3 ** 4
5 481051-I
9 *
10
11
12
‘No Number
382501-26
382501-27
382501-28
382501-29
382501-30
382501-31
382501-32
382501-33
382501-34
382501-35
50NH-703-0
No Number . MOTOR GENERATOR GROUP (For Details, See Fig. 7)
481063-I . BOX CONTROL, REGULATOR AND POWER
481063-2
481051-2
No Number
381090
481061-I
481061-2
481062
A-98
No Number
60GH-92
50NH-743
I I
NOMENCLATURE
1234567 EFF
MOTOR GENERATOR GROUP WITHOUT CANOPY
(For NHA, See Fig. 1)
. BOX ASSEMBLY, MOTOR SWITCH (For Details
See Fig. 4)
. BOX ASSEMBLY, MOTOR SWITCH (For Details,
See Fig. 4)
. BOX ASSEMBLY, MOTOR SWITCH (For Details,
See Fig, 4)
. BOX ASSEMBLY, MOTOR SWITCH (For Details,
See Fig. 4)
. BOX ASSEMBLY, MOTOR SWITCH (For Details,
See Fig. 4)
. BOX ASSEMBLY, MOTOR SWITCH (For Details,
See Fig. 4)
. BOX ASSEMBLY, MOTOR SWITCH (For Details,
See Fig. 4)
. BOX ASSEMBLY, MOTOR SWITCH (For Details,
See Fig. 4)
. BOX ASSEMBLY, MOTOR SWITCH (For Details,
See Fig. 4)
. BOX ASSEMBLY, MOTOR SWITCH (For Details,
See Fig. 4)
. BOX ASSEMBLY, MOTOR SWITCH (For Details,
See Fig. 4)
. PANEL, DRIP-PROOF ASSEMBLY (For Details,
See Fig. 6)
MPR
NQS
K
L
CEG
BDFH
A
J
T
uw
V
MODULE ASSEMBLY KLYNPQRSW
. BOX CONTROL, REGULATOR AND POWER
MODULE ASSEMBLY ABCDEFGHJV
. . BOX ASSEMBLY, CONTROL (For Details, See
Fig. 8) KLMNPQRSW
. . BOX ASSEMBLY, CONTROL (For Details, See
Fig. 8) ABCDEFGHJV
. . BOX GROUP, REGULATOR (For Details, See
Fig. IO)
. . SUPPORT, MOUNTING (For Details, See Fig. 13)
. . MODULE ASSEMBLY, POWER (For Details,
See Fig. 12) &l-M NPaR-s&
. . MODULE ASSEMBLY, POWER (For Details,
See Fig. 12) ABCDEFGHJV
. . COVER, POWER MODULE
. NAMEPLATE, ARROW
. CAPACITOR BOX GROUP (For Details, See
Fig. 14)
. YOKE, LIFTING (For Details, See Fig. 13)
FRAME ASSEMBLY, MOUNTING (For Details,
. See Fig. 13) ii
GHRSW
UNITS
per ASSY
REF.
** Item 4 is an assembly of Items 5,6,7,8 and 9.
Jan 18177 Revised
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4-3
Feb 17l78 Revised Page 9
\
\
4-3
Page IO
Motor Switch Box Assembly
Figure 4
Revised Jan 18/77
*
FIGURE HOBART
ITEM NO. ,PART NO.
4- 382501 -25
382501-26
382501-27
382501-28
382501-29
382501-30
382501-31
382501-32
382501-33
382501-34
382501-35
1 HF-530
W-l 1250
W-991 7-20
50NH-384
W-l 0079-g
1 OONH-264
382103
IOONH-261A
75NH-22
482199-1
482199-2
482 199-3
482199-Q
482199-5
482199-6
482199-7
482 199-8
482199-g
482199-10
482199-12
8 IOOGH-216-3
9 400847-3
10 402018 *
386075 *
404389-I *
481568
9
Jan 18/77 Revised
Feb 17178 Revised
NOMENCLATURE
1234567 EFF
BOX ASSY, MOTOR SWITCH (For NHA See Fig. 3)
BOX ASSY, MOTOR SWITCH (For NHA See Fig. 3)
BOX ASSY, MOTOR SWITCH (For NHA See Fig. 3)
BOX ASSY; MOTOR SWITCH (For NHA See Fig. 3)
BOX ASSY, MOTOR SWITCH (For NHA See Fig. 3)
BOX ASSY, MOTOR SWITCH (For NHA See Fig. 3)
BOX ASSY, MOTOR SWITCH (For NHA See Fig. 3)
BOX ASSY, MOTOR SWITCH (For NHA See Fig. 3)
BbX ASSY, MOTOR SWITCH (For NHA See Fig. 3)
BOX ASSY, MOTOR SWITCH (For NHA See Fig. 3)
BOX ASSY, MOTOR SWITCH (For NHA See Fig. 3)
. KNOB, FASTENING, PANEL
. WASHER, V24248, STYLE 7PT, No. 10014-I 1
. METER, HOUR V26992, No.SG-77140/130
. PANEL, HINGED, ASSEMBLY
. CONNECTOR, CONDUIT, 3” V03743, No. 7488
. COVER, INSPECTION, HOLE
. WRAPPER, BOX, MOTOR SWITCH, ASSEMBLY
. PANEL, REAR ASSEMBLY
. PANEL, FRONT ASSEMBLY
. SWITCH ASSY, MOTOR (For Details See Fig. 5)
. SWITCH ASSY, MOTOR (For Details See Fig. 5)
. SWITCH ASSY, MOTOR (For Details See Fig. 5)
. SWITCH ASSY, MOTOR (For Details See Fig. 5)
. SWITCH ASSY, MOTOR (For Details See Fig. 5)
. SWITCH ASSY, MOTOR (For Details See Fig. 5)
. SWITCH ASSY, MOTOR (For Details See Fig. 5)
. SWITCH ASSY, MOTOR (For Details See Fig. 5)
. SWITCH ASSY, MOTOR (For Details See Fig. 5)
. SWITCH ASSY, MOTOR (For Details See Fig. 5)
SWITCH ASSY, MOTOR (For Details See Fig. 5)
: CHAIN SUPPORT, HINGED PANEL
. LIGHT, WARNING, RED V72765, No. 5200-233-32
. NAMEPLATE, CAUTION - INPUT POWER ON
. ADAPTER, HOUR METER
. RELAY, REVERSAL PHASE V01121, No. 812-AAB-5
. PLATE, MOUNTING RELAY
MPR
NQS
K
L
CEG
BDFH
A
J
T
uw
V
MPR
NQS
K
L
CEG
BDFH
A
J
T
uw
V
F
F
UNITS
per ASSY
REF
REF
REF
REF
REF
REF
REF
REF
REF
REF
REF
2
2
1
1
1
3
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
4-3
Page 11
,
Motor Switch Assembly
Figure 5
4-3
Page 12
Revised Jan 18177
FIGURE
ITEM NO.
5-
1 *
2 *
3
4 *
5
6
7
8
9
10
11
12
13
14
15
16
17
18 *
19
20
21
22 *
23
HOBART
PART NO.
482199-1
482199-2
482 199-3
482199-4
482199-5
482199-6
482199-7
482199-8
482199-g
482199-10
482199-12
404060-3
W-9350-76
40191 I-8
w-9350-77
40065 1
16DA-42524
w-9350-75
400MS-18
400669
400670
DATA No. 2210A
50MS-28
W-9407-1 98
W-9648-257
W-9760-1 34
W-9760-1 35
W-9760-1 36
402956
50MS-696
200MS-146
1 OONM-97
1 OONM-98
1 OOMS-122-1
200MS-132A
IOONM-94
1 OOMS-21
1 OONM-95
W-799C-66
50MS-60
1
1
1
OONM-96
OOMS-122-O
OONM-92
OOMS-132
OOMS-383
Jan 18/77 Revised
Feb 17/78 Revised
NOMENCLATURE
1234567 EFF
SWITCH ASSY, MOTOR (For NHA See Fig. 4)
SWITCH ASSY, MOTOR (For NHA See Fig. 4)
SWITCH ASSY, MOTOR (For NHA See Fig. 4)
SWITCH ASSY, MOTOR (For NHA See Fig. 4)
SWITCH ,AkY, MOTOR (For NHA See Fig. 4)
SWITCH ASSY, MOTOR (For NHA See Fig. 4)
SWITCH ASSY, MOTOR (For NHA See Fig. 4)
SWITCH ASSY, MOTOR (For NHA See Fig. 4)
SWITCH ASSY, MOTOR (For NHA See Fig. 4)
SWITCH ASSY, MOTOR (For NHA See Fig. 4)
SWITCH ASSY, MOTOR (For NHA See Fig. 4)
. RELAY, TIME DELAY V98403, No. 7012ADA2M
. CABLE No. 182
. STRIP, TERMINAL V88223, No. 441-8
. CABLE No. 181
. FUSEHOLDER, WESTINGHOUSE ADD-A-PART
No. 257A574GOl
. FUSE, MDL, 5 AMP V71400, No. MDL
CABLE, No. 180
: ARM, ROCKER
. TRANSFORMER V88601, TYPE MTA
No. 332B635A37, Frame No. 1730
. TRANSFORMER V88601, TYPE MTA
No. 332B635A22, Frame No. 1730
. COIL, NVR
HOLDDOWN COIL
: CABLE, Ll, L2, L3
. CABLE, Ll, L2, L3
ABCDEFGHKL
MNPQRST
. CABLE, Ll, L2, L3
. CABLE, Ll, L2, L3
. CABLE, Ll, L2, L3
. TRANSFORMER, CURRENT V93993, No. 6CT-15
. CONTACT ASSY, AUXILIARY, MOVABLE
. WASHER, BLOWOUT COIL
. CYLINDER, COIL, BLOWOUT
. INSULATOR, COIL, BLOWOUT
. HOLDER, ARC SHIELD
. COIL BLOWOUT
. SHIELD, ARC ASSEMBLY
. . SIDE, SHIELD
. . BACK, SHIELD
. . SPRING V16053, No. 66
. . GUIDE, END (1 R.H. and 1 L.H.)
. . PLATE, SHIELD
. HOLDER, ARC SHIELD
. CONTACT
. POST, CONTACT, STATIONARY
. MOUNT, DOUBLE, MOVABLE CONTACT, ASSY
CEGKMPR 3
AV 3
T 3
3
1
BDFHJ
6
3
3
9
3
3
2
1
1
2
1
9
6
12
3
MPR
NQS
K
L
CEG
BDFH
A
J
T
uw
V
UNITS
per ASSY
REF
REF
REF
REF
REF
REF
REF
REF
REF
REF
REF
2
1
2
1
4-3
Page 13
FIGURE HOBART
ITEM NO. PART NO.
5- 24
25
26
27 *
28
29
30
31
32
33 *
34
35
36
37
38
39 *
*
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63 *
*
*
*
*
lOOMS-14
2dOMS-138
200MS-135A
400M.S72
w-9350-74
400MS-63
4OJ-90
400MS58
363769-3
50MS-696
1 OOMS-36
w-9350-73
40191 I-5
200MS-145
200MS-143
400589-5
16DA-1626-4
200MS-140
60GHP-424
400MS-62
50MS-472
400MS-23A
400MS-19
400MS-17
FW-3294B
400MS-9
1 OOMS-358
1 OOMS-6
IOOMS-141
IOOMS-117
lOOMS-137
DATA-l 330A
1 OOMS-349
404065-l
1 OOMS-382
200MS-116
6FW-557A
1 OOMS-146
W-2974-F
400078
400092
400097
400098
1 OOMS-79
w-9234-1 45
w-9234-1 12
W-9760-4
W-9648-226
W-9760-5
4-3
Page 14
NOMENCLATURE
1234567
. CLAMP, SHAFT
. BEARING, SUPPORT, SHAFT
. SHAFT, ARMATURE, MAGNETIC, CONTACTOR
. STRAP, CONNECTING, MOVABLE CONTACT
. CABLE No. 184 anb No. 185
. BUS, ANGLE
. LINK, CHANGEOVER
. BUS, JUMPER, CONTACTOR TO CHANGEOVER
. INSULATOR, SHAFT
. CONTACT, AUXILIARY, MOVABLE ASSY
. CONTACT, AUXILIARY, STATIONARY, ASSY
. CABLE No. 183
. STRIP, TERMINAL V88223, No. 441-5
. STOP, MOVABLE, MAGNETIC YOKE
. YOKE, MAGNETIC, MOVABLE, ASSY
. STRIP, TERMINAL V98410, No. 38012-3820
. RELAY V77342, No. PR-2271-1
. YOKE, MAGNETIC STATIONARY
. CLAMP, CABLE
. BRACKET, CABLE
. SUPPORT, SINGLE, BEARING
SHAFT, ARMATURE, LINE SWITCH
: SLEEVE, ROCKER ARM
. SUPPORT, ROCKER ARM
. STRAP, CONNECTING MOVABLE CONTACT
. BUS, CONNECTING CONTACTOR
. CYLINDER, COIL, BLOWOUT
. WASHER, COIL BLOWOUT
. YOKE, MAGNETIC, MOVABLE ASSEMBLY’
. STOP, MOVABLE, MAGNETIC YOKE
. YOKE, MAGNETIC, STATIONARY ASSEMBLY
. COIL, NVR
. BUS, STUD TO BLOWOUT COIL
. RECTIFIER, SILICON V04713, No. SDA 10270-I
. MOUNT, SINGLE, MOVABLE CONTACT ASSY
. CONTACT
COIL, BLOWOUT
: SHIELD, ARC
. RESISTOR V44655, No. 0960B
. BRACKET MTG., RESISTOR V44655, No. 12
. NAMEPLATE, Ll
. NAMEPLATE, L2
. NAMEPLATE, L3
. INSULATOR, CYLINDER, COIL
. CABLE, No. 104, No. 105, No. 106
. CABLE, No.1 10
. CABLE, MOTOR STATOR EXTENSION
. CABLE, GENERATOR STATOR EXTENSION
UNITS
per EFF ASSY
14
1
1
6
2
9
6
3
6
1
2
1
1
1
1
1
1
1
1
1
2
2
1
2
6
1
6
12
2
2
2
2
3
1
6
12
6
6
1
2
1
1
1
6
3
1
12
ABCDEFGHJV 12
. CABLE, GENERATOR STATOR EXTENSIONI KLMNYQRSTUW 12
Revised Jan ‘I 8177
Revised Feb 17178
FIGURE
ITEM NO.
*5-
HOBART
PART NO.
w-9350-75 . CABLE, No. 111
64 482200
65 403330-O
w
*
9
*
w
66
403330-I . RELAY, OVERLOAD V01121, No. 816, Heater
403330-2 . ,RELAY, OVERLOAD V01121, No. 816, Heater
403330-3 . RELAY, OVERLOAD V01121, No. 816, Heater
4033304 . RELAY, OVERLOAD V01121, No. 816, Heater
403330-5 . RELAY, OVERLOAD V01121, No. 816, Heater
404612-3
4046 12-4
404612-5
4046 12-6
W-9407-1 98
W-9648-257
W-9760-1 34
W-9760-1 35
404389-I
404389-2
404389-3
Jan 18177 Revised
NOMENCLATURE
1234567
UNITS
per EFF ASSY
ABCDGHJKLM
N RSTUVW
. PANEL, @lOTOR SWITCH
. RELAY, OVERLOAD V01121, No. 816, Heater
Element No. N-17 K
Element No. N-15 MNPQRST
Element No. N-18 AV
Element No. N-19 BCDEFGH
Element No. N-16 uw
Element No. N-20 J
ELEMENT, HEATER V01121, No. N-16
(Mounted in Item 65) (For 220 V input)
ELEMENT, HEATER V01121, No. N-17
(Mounted in Item 65) (For 380 V input)
ELEMENT, HEATER VO1121, No. N-18
(Mounted in Item 65) (For 380 V input)
ELEMENT, HEATER V01121, No. N-19
(Mounted in Item 65) (For 220 V input)
CABLE (For 220 V input)
CABLE (For 230 V input)
CABLE (For 220 V input)
CABLE (For 230 V input)
CABLE (For 380 V input)
CABLE (For 460 V input)
CABLE (For 380 V input)
RELAY, PHASE, REVERSAL (Option) VO1121,
No. 812-AAB5
K
L
BV
A
A
CEG
K
MPR
L
DFHNQS
B
RELAY, PHASE, REVERSAL (Option) VOI 121,
No. 812-AAC5
RELAY, PHASE, REVERSAL (Option) VOI 121,
No. 812-AAA5
1
1
1
1
1
1
1
1
3
3
3
3
3
3
3
3
3
3
3
1
1
1
4-3
Page 15 Feb 17178 Revised
Drip-Proof Panel Assembly
Figure 6
4-3
Page 16
Revised Jan 18/77
FIGURE HOBART
ITEM NO. PART NO.
6- 50NH-703-0
*
1
2
3
4
5
6 7
8
9
10
11
12
13
14
15
50NH-832
50NH-435
401911-5
50NH-436
380435
40191 l-8
w-9701 -4
50NH-978
50NH-977
50NH-976
50NH-979
50NH-827
No Number
No Number
No Number
No Number
50NH-828
Jan 18177 Revised 4-3
I I
NOMENCLATURE
1234567 EFF
PANEL, ASSEMBLY, DRIP-PROOF
(For NHA, see Fig. 3)
STRIP, INSULATING
NAMEPLATE, REMOTE-START-STOP
STRIP, TERMINAL V88223, No. 441-5
NAMEPLATE, REMOTE, ON-OFF
TOP, PANEL, DRIP-PROOF
STRIP, TERMINAL V88223, No. 441-8
STRIP, TERMINAL V71785, No. 4-150
PANEL, DRIP-PROOF RIGHT
PANEL, DRIP-PROOF, REAR
- PANEL, DRIP-PROOF, FRONT
PANEL, DRI,P-PROOF, LEFT
BOARD, ASSEMBLY, TERMINAL
. SCR@Y.~3/8-16 x 2 HHC (STEEL)
. WASHER, FLAT 3/8 (STEEL)
. WASHER, LOCK, 3/8 (STEEL)
. NUT, HEX HD. 3/8-16 (STEEL)
. BOARD
UNITS
per ASSY
Ref
1
1
2
1
1
1
1
1
1
1
1
1
24
24
24
24
1
Page 17
1”
1.. ~_ ~~ -- ,/’
Motor Generator Group
Figure 7
Revised Jan 18/77
Page 18
FIGURE HOBART
ITEM NO. PART NO.
7- No Number
1
2
_- ‘-
3
4
5
6
7
8
9
IO
11
12
13
14
15 ’
16
17
18
19
20 *
*
z:
23 *
50 NH-130
380524-2
380527-2
380524-l
380527-I 380527-5
381649-l
382432-l
380376-l
50NH-1015-1
380943
5BJ-32
5BJ-32
5BJ-34
5BJ-33
5BJ-35
20RT-352-1
20RT-353-l
380942
403982
W-10072-1
380526-2
380530-4
380526-l
380530-l
50NH-54
50NH-840
H F-879
DW-883
DW-882A
DATA-2033
50NH-43
50NH-42
W-l 0079-3
MOTOR-GENERATOR GROUP
(For NHA, see Fig. 3)
. GUARD, FA.N
. HOUSING & STATOR ASSY. (MOTOR)
. . HOUSING & STATOR ASSY. (MOTOR)
. HOUSING & STATOR ASSY. (MOTOR)
. HOUSING & STATOR ASSY. (MOTOR) HOUSING & STATOR ASSEMBLY (MbiO’R)
. ARMATURE ASSEMBLY
. ARMATURE ASSEMBLY
. ARMATURE ASSEMBLY
. ARMATURE ASSEMBLY
Ref
1
AB 1
CDEFGHJV 1
KL 1
MNPQRSUW 1 T
. . EXCITER ASSEMBLY, BRUSHLESS
. . EXCITER ASSEMBLY, BRUSHLESS
. . EXCITER ASSEMBLY, BRUSHLESS
. . .BASE ASSEMBLY, MOUNTING
. . .PLATE, INSULATING
. . .BAR, BUS, CONNECTING DIODES
. . .DIODE, POSITIVE V58849, No.92429-AF
AB
CDEFGHJV
KL
MNPQRSW
ABCGHJ
ABCGHJ
DEFKLV
. . .DIODE, NEGATIVE V58849, No.92429-CF
. . .BRACKET, MOUNTING, MICRO SWITCH
. . .SWITCH, MICRO V91929, No. BZ-2RD
. BEARING V76062, No.310~SFFC
. HOUSING & STATOR ASSY. (GENERATOR)
. HOUSING 81 STATOR ASSY. (GENERATOR)
. HOUSING & STATOR ASSY. (GENERATOR)
. HOUSING & STATOR ASSY. (GENERATOR)
. COVER, HOUSING, EXCITER
. COVER, SCREEN
ABCGHJ
ABCGHJ
AB
CDEFGHJV
KL
MNPQRSW
. WASHER, RETAINING, BEARING
. GASKET
. CAP, BEARING
. FIELD
INSULATION
. POLE PIECE
. CONNECTOR, BOX, STRAIGHT,3/4, V03743,
No. 7289V (One required for generator, two re-
quired for motor)(To be used with flexible metallic
electrical conduit)
W-l 0088-3
w- 10079-5
. CONNECTOR, BOX, 90’ V03743, No. 7382V
(To be used with flexible metallic electrical conduit)
. CONNECTOR, BOX, l’/, V03743, No. 7484 (Four
required on motor)(To be used with flexible metallic
electrical conduit)
50NH-641 . CONDUIT, ELECTRICAL (MOTOR-GENERATOR)
387 168 PLATE, WASHER, HOUSING
386635A . PAD, VIBRATION, TOP
386634A PAD, VIBRATION, BOTTOM ’ i
50NH-642 . ADAPTER, CONDUIT
Feb 17178 Revised
NOMENCLATURE
1234567 EFF
UNITS
per ASSY.
1
1
1
1
1
2
1
1
2
3
3
2
2
2
1
1
1
2
2
2
2
2
2 SETS
8
8
3
2
6
1
4
4
8
2
4-3
Page 19
.-
--
481051-I
481051-2
402658
W-l 1166-4
H F-530
W-l 1250
W-9916-10
402826
FW-1312
IODH-534
480641
IOONH-330-0
W-8 105A-4
H F-745
16DA-2 162
W-9712-6
8-
1
2
3 *
4
5
6
7
8
9
IO
11
12
13
14
15
16
17
18
19
20
21’
22
23
24
25
26
27 d
28
29
30
31
32
33
34 3%
*
Jan 18177 Revised
W-8095A-8
W-8095A-4
481054
481056
481057
400847-2
50MS-209
DW-4691-1
481052
30GH-322
402157
IOJ-178
HF-1459
400400
15GH-433
W-10051-6
H F-478
DW-4691-2
1 ODH-664
7J-597-6
HF-2518-9
FW-3399
IOOGH-216-2
401864
50NH-642
FIGURE HOBART
ITEM NO. PART NO.
Feb 17178 Revised
NOMENCLATURE UNITS
per
1234567 EFF ASSY.
BOX ASSEMBLY, CONTROL
(For NHA, see Fig. 3) KLMNPQ@W Reef
BOX ASSEMBLY, CONTROL
(For NHA, see Fig. 3) -A@QEFGHJVR’EF
. HOLDER, FUSE V71400, No. HKP-HH 2
. FUSE, AGC, 15A 2
. KNOB, FASTENING, HINGED PANEL 2
. WASHER V24248, STYLE 7PT, No.10014-11 2
. METER, FREQUENCY, V31356, No. 36-FX 1
. SWITCH, AUTOMATIC-MANUAL, LZPDT,
V27191, No. 8926K425 1
. SWITCH, PANEL LIGHT, DPST VO4009,
No. 80600 1
. NAMEPLATE, LIGHT, PANEL, ON-OFF 1
. NAMEPLATE, AUTOMATIC, MANUAL 1
. LIGHT, PANEL V81091, No. 1339, Mt.Strap No.1354 1
. VOLTMETER, O-300, AC V60741, No. 331 LH 1
. NAMEPLATE, REGULATOR RHEOSTAT 1
. KNOB, RHEOSTAT V44655, No. 5150 2
. RHEOSTAT, REGULATOR V44655,
Model No. H, 1500 Ohm, 25 W. 1
. AMMETER V60741, No. 331 LH ABCDEFV 1
. AMMETER V60741, No. 331 LH GHJKL 1
. PANEL, HINGED, ASSEMBLY 1
. PANEL, FRONT 1
. WRAPPER, CONTROL BOX, ASSY. 1
. LIGHT, PILOT, AMBER V72765, No.,5200-233-323 1
. SWITCH, START-STOP ASSEMBLY 1
. NAMEPLATE, MOTOR 1
. PANEL, INTERIOR (For Details, see Fig. 9) 1
. PANEL, REAR 1
. RHEOSTAT, MANUAL, 75 OHM, 150 W V44655,
Model No. L 1
. NAMEPLATE, FIELD RHEOSTAT 1
. SWITCH, METER, SELECTOR, VO4009, No.81579 1
. SWITCH, LINE DPDT V73559, No.2GL61 “TABS” 1
. NAMEPLATE, METER SELECTOR SWITCH 1
. CLAMP, WIRE V81074, No. EC-7 2
. SWITCH, ON-OFF, ASSEMBLY 1
. NAMEPLATE, GENERATOR 1
. NAMEPLATE, 400 CYCLE 2
. NAMEPLATE, RECEPTACLE 2
. LIGHT, PILOT, GREEN 1
. RECEPTACLE, DUPLEX 2
. CHAIN, SUPPORT, HINGED DOOR 2
. NAMEPLATE, RATING 1
. ADAPTER, CONDUIT ’ I
2
4-3 -_
.-\. y>- -
-Page ~21_
i6
Interior Panel Assembly
Figure 9 ’ I
4-3
Page 22
Revised Jan I%/77
FIGURE ITEM NO.
9- 481052
1 -
2
3
4
5 6
7
8
9
383766 ,. RELAY, OVERVOLTAGE 1 ODH-845-0 . RELAY, UNDERVOLTAGE IODH-847-2 . RELAY,UNDERFREQUENCY 400540-3 . RELAY, OVERLOAD V01121, No. NN-1 W-2974-F . RESISTOR V44655, No. 0960B, 250 Ohm, 100 W
W-2974-L . RESISTOR V44655, No. 0959,50 Ohm, 100 W
400078 . BRACKET, MOUNTING, RESISTOR V44655, No.12
404065-I . RECTIFIER, SILICON V04713, No. SDA 10270-I
IODH-696-3 . RELAY, TIME DELAY V93929, Type TF-10
IO 11
12
13
14
75NH-110
IOOGH-142
403336
FW-1312 387725 - ---- 16DA-4052-0
36377 1-5
16DA-4004A-3
PANEL ASSEMBLY, INTERIOR (For NHA, see Fig. 8)
115 Volt Heater
15
. BRACKET, MOUNTING, RELAY
. BRACKET, MOUNTING, SWITCH
. RING, LOCKING, SWITCH V91929, No. TS10020
. SWITCH, TOGGLE VO4009, No. 80600-BJ
. BRACKET, MOUNTING, SOCKET, RELAY
. SOCKET, RELAY VO2660, No. 77-MIP-11
. SLEEVING, PLASTIC -
. RELAY, PLUG, INTERLOCK, 24 V. V77342,
No. KAP-14DG
16 16DA-4253-1 . SPRING, RETAINER, RELAY V77342, No. 2OC206
17 40191 I-20 . SPRING, TERMINAL V88223, No. 441-20
18 W-4541 D . RESISTOR, V44655, No. 0368
19 481053 . PANEL, INTERIOR
HOBART PART NO. 1234567
Jan 18177 Revised
NOMENCLATURE
’ i
EFF
UNITS
per ASSY.
Ref 1 1 1 1 1
1
4
2
4-3
I%&@ \
Regulator Box Group
Figure IO ’ i
4-3
Page 24 Revised Jan I%/77
FIGURE HOBART
ITEM NO. PART NO.
IO-
*
1
2
3
4
5
NOMENCLATURE
1234567
No Number
50NH-829
430278
50NH-831
430293
50NH-830
50NH-834
50NH-707
50 NH-708
Jan I%/77 Revised
BOX, REGULATOR, GROUP
(For NHA, Sde Fig. 3)
. BOX, STATIC, EXCITER, ASSEMBLY
. . GROMMET, RUBBER V89616, No. TPR-1812
. . PANEL, FRONT
. .,REGULATOR, MAGNETIC, AMP
(For Details, see Fig. 11)
. . BOX, S.A.
. SUPPORT, SLIDING ASSEMBLY
. . BASE, MOUNTING
. . SUPPORT, S.A.
’ i
EFF
UNITS
per ASSY.
Ref
1
1
1
Page 25
4-3
Page 26
Magnetic Amp Regulator
Figure 11
Revised Jan I%/77
FIGURE HOBART
ITEM NO. PART NO.
II- 430293
1 1 cz- 134A
2 ICZ-132
3 430297
1 CZ-62
*
4
5
6 +
400034
-4O~ll35
FW-1507
1 CZ-22 B
400033
7 3C$63
8 1 CZ-60
9 430191 IO 1 CZ-35B 11 40 1563-3 12 401564-3
13 ICZ-156 14 W-9746-2
15 1 cz-74
16 401563-2
17 401564-2
18
19
20
430222
430183
430224
1 CZ-63
21 1 CZ-64
22 401563-2
23 401564-2
24
25
26
27
28
29
430223
16DA-2016-4
W-2974-L
W-l 1434
W-l 1166-I
430189
1 CZ-226
Jan 18177 Revised
NOMENCLATURE
1234567 EFF
REGULATOR, MAGNETIC, AMP
(For NHA, see Fig. IO)
. REACTOR, REGULATOR, 300 VA
Chicago Electronic Engineering Co.
. TRANSFORMER, POWER, 300 VA
Chicago’Electronic Engineering Co.
. AMPLIFIER, FIRSTSTAGE SA
. . REACTOR, FIRST STAGE
Chicago Electronic Engineering Co.
. . TUBE, HOLDER V71785, No. 7XBl
. . TUBE, COVER V71785, No. 754
. . GROMMET, RUBBER V79497, No. 61068
. . BOARD, TERMINAL, FIRST STAGE ASSEMBLY
. . TUBE, 6627, CBS HYTRON 928/WA OR EQUIV.
V80368. No. JANOB2WA
. . CHOKE, FILTER, FIRST STAGE
Chicago Electronic Engineering Co., E-3661LA
. . TRANSFORMER, DAMPING
Chicago Electronic Engineering Co., No. E-3196A
. . CHASSIS, FIRST STAGE
. . INSULATOR, PLATE
. . HOUSING, PIN CONNECTOR VO0779, No.l-480386-0
. . ‘HOUSING, SOCKET CONNECT.OR, \t.
No. 1-480285-O r-t
. . INSULATOR
. . RESISTOR, 750,25 W V44655, No.0203
. . INSULATOR
. . HOUSING, PIN CONNECTOR VO0779, No.l-480284-0
. . HOUSING, SOCKET CONNECTOR VO0779,
No. 1-480283-O
. SENSING, HIGH PHASE SA
. . INSULATOR, BOARD
. . BOARD, HIGH PHASE SENSING ASSEMBLY
. . CHOKE, HIGH PHASE FILTER, Chicago Electronic
Engineering Company, No. E-3661-A
. . TRANSFORMER, HIGH PHASE, Chicago Electronic
Engineering Company, No. E-3712
. . CONNECTOR, PIN HOUSING VO0779, No.l-480284-0
. . CONNECTOR, SOCKET HOUSlbiG VO0779,
No. l-480283-0
. . CHASSIS, HIGH PHASE SENSING
. RELAY V77342, No. PR2286-1
. RESISTOR, 50 OHM, 100 WATT, V44655, No. 0959
. BASE, FUSE, BUSS No. 4407
. FUSE, BUSS No. 3 AG-2
. CABINET, REGULATOR
. PANEL, CONTROL ASSEMBLY / I
UNITS
per ASSY.
Ref
1
1
1
1
‘1
4
3
1
4-3
Page 27
’ I
4-3
Page 28
Revised Jan I%/77
FIGURE HOBART
ITEM NO. PARTNO. 1234567 EFF
ll- 30 w-9712-31
31 w-97 12-29
32 lCZ-152
33 1 cz-75
34 1 cz-97
. . RHEOSTAT, MODEL SHALO 5000
. . OHM, 25 WATT V44655, Model “H”
. . RHEOSTAT, MODEL SHALO, 750 OHM,
25 WATT, V44655, Model “H”
. . NAMEP.LATE
. .NAMEPLATE, TERMINAL STRIP
. . REACTOR, LINE DROP, COMPENSATION
Chicago Electronic Engineering Co., No. E-3963
35 402660-20 . .TERMINAL STRIP V71785, No. 20-141
36 1 cz-70 . .SWITCH, LINE DROP COMPENSATION
ON-OFF V27191, No. 7610 K2
37 W-9746-l
38 1 cz-129
39 1 CZ-128
. . RESISTOR, 50 OHM, 25 WATT, V44655, No. 0200D
. .INSULATOR, RESISTOR
. .RHEOSTAT, TRIPLE TANDEM, 250 OHM, 25 WATT,
TAPER WOUND V44655, No. 45403 40
41 W-l 1597
ICZ-105
. .KNOB, POINTER, V75376, No. S-292-31
. .RHEOSTAT, TRIPLE TANDEM 10 OHM, 25 WATT
V44655, No. H-lo-F2-T3 42
*
43
44
45
46
47
48
49
50
401865 . .NAMEPLATE, LINE COMPENSATION
16DA-1997-4 . .BUTTON, PLUG V90763, No. SS-48152
W-l 1535 . .TERMINAL, FANNING STRIP V71785, No.20-161-L
W-l 1534 . .CAE?LE, CLAMP V71785, No. CC-161-12
16DA-1997-3 _ .BUTTON, PLUG V90763, No. SS-48192
ICZ-101 . .NAMEPLATE, ADJUST
1 cz-74 . .INSULATOR, EPOXY MICA .012
W-9026-9 . .RESISTOR V44655,3000 OHM, 10 WATT
400032 , .BRACKET, MTG. RESISTOR V44655, No. 5
430188 , .PANEL, CONTROL
Jan 18177 Revised
1. --
NOMENCLATURE
UNITS
per ASSY. !
2
1 :
1
1
3
1 . .
;. 1
3
1
1 -.
2
1
1
3
1
1
1
1 3 I
1 1
2 j
1 ‘j
4-3
Page 29
--
‘L-1
4
-31
i
14
-34
t
FIGURE
ITEM NO.
12- 481061-I
1
2
3
4
5
6. 7
I 8
9
IO
11
12
13
14
15 16
17
18
19
20
21
22
23
i4
25
26
27
28
29
30
HOBART
PART NO. 1234567
481061-2
381081
381082
381083
381084
75GH-48
75GH-47
75GH-46
75GH-51
15GH-519-I
15GH-519-2
400589-5
401911-8
75GH-566
75GH-49
75GH-50
W-l 1278-5
5CW-2127
IOOGH-112
5cw-975
5CW-976A
W-l 1242-10
W-l 1254-6
W-l 1097-8
w-9549-1 9
DW-1704
A-25
W-l 1242-5
W-l 1254-4
W-l 1278-7
AW-626
ICZ-148
W-l 1097-22
W-l 1263-6
W-l 0079-5
50NH-815
381086
W-l 1097-3
W-l 1242-12
TRY-154-1
TRY-174-3
NOMENCLATURE
MODULE ASSY., POWER
(For NHA, see Fig. 3)
MODULE ASSY., POWER
(For NHA, see Fig. 3)
. COVER, OUTPUT TERMINAL
KLMNPQRSW’ Ref
. . COVER, OUTPUT TERMINAL
. .,HINGE, COVER
. BRACKET, MTG., COVER, OUTPUT TERMINALS
. NAMEPLATE, C
. NAMEPLATE, B
. NAMEPLATE, A
. NAMEPLATE, N
. TRANSFORMER, CURRENT
. TRANSFORMER, CURRENT
. STRIP, TERMINAL V98410, No. 38012-3820
. STRIP, TERMINAL V88223, No. 441-8
. CONTACTOR V74063, No. A-874C
. NAMEPLATE, E
. NAMEPLATE, F
. NUT, 3/8-16, HEX, ST.
. BUSHING
. TERMINAL, OUTPUT
. BUSHING, INSULATOR
. WASHER, INSULATOR
. WASHER, 31% FL. ST.
. WASHER, LOCK, 3/8, ST.
. SCREW, 3/%-16x 2, HHCS, ST.
. STUD
. BUSHING
. WASHER, INSULATOR V89873
. WASHER, l/4, FL., ST.
. WASHER, l/4, LOCK, ST.
. NUT, l/4, l/4 HEX, ST.
. BUSHING
. TRANSFORMER, CURRENTV14831, No. E-6170
. SCREW, 3/8-16 x 2, HHCS, ST.
. WASHER, LOCK, 318, ST.
. CONNECTOR, CONDUIT, l-1/4
. BAR, BUS
. BOX, POWER MODULE
. SCREW, 3/%-16x l-1/4 HHC, ST.
. WASHER, FLAT, l/2, ST.
. CAPACITOR V14101, No. 200P1868,3MFD,660 V.
. BRACKET, MTG., CAPACITOR V14101, Type
AABCDEFGHJV Ref
1
1
1
1
1
1
1
1
XLMNPQRSW 3 ABCDEFGHJV 3
1
1
1
1
1
14
4
4
4
8
18
17
7
2
2
12
4
4
4
4
3
1
1
2
3
1
1
1
EFPQ 1
3-36-l 61, No. 2OOP1823 EFPQ 1
Revised Jan I%/77
Feb 17178 Revised
UNITS . .
.-- per EFF ASSY.
4-3
Page 31
Mounting Frame
Figure 13
4-3
Page 32
Revised Jan 18177
.
FIGURE HOBART
ITEM NO. PART’NO.
13- ‘No Number
1 60GH-92
2 50NH-743
3 381090
4 No Number
NOMENCLATURE
1234567
MOUNTING FRAME (For NHA, See Fig. I)
. YOKE ASSEMBLY, LIFTING
. FRAME ASSEMBLY, MOUNTING
. SUPPORT, MOUNTING, CONTROL BOX,
REGULATOR &POWER MODULE
. CAPACITOR BOX GROUP (Mounted inside of
Mounting Fiame) (For Details, See Fig. 14)
EFF
UNITS
per ASSY
REF
REF
REF
1
GHRSW REF
Jan 18177 Revised Feb 17178 Revised
4-3
Page 33
4-3
Page 34
Capacitor Box Grou’p
Figure 14
’ i.
Revised Jan 18177
NOMENCLATURE
FIGURE HOBART
ITEM NO. PART NO. 1234567 EFF
UNITS
per ASSY.
14- No Number CAPACITOR BOX GROUP
(For NHA, see Fig. 3)(Mounted inside of
Mounting Frame) GHRSW Ref
1 50NH-1196 . LID, BOX, CAPACITOR GHRSW 1 2 404877 . CAPACITOR, V14655,34 MFD, 400 CYC., 220 V. GHRSW 6 3 50NH-1193 . BOX; CAPACITOR :;; GHRSW 1 4 402037-g . GROMMET, RUBBER V02231, No. AGW-4211 GHRSW 2
Jan 18/77 Revised
Feb 17178 Revised
4-3
Page 35
SECTION 4. NUMERICAL INDEX
1. Explanation of Numerical Index
The purpose of this index is to assist the user in finding the illustration and description of a part when the part
number is known. Part numbers are arranged in alpha-numerical sequence. Thus, any part number beginning with
the letter “A” would be located at or near the top of the index list. Likewise a part number “9” would be listed
near the end of the list and far below a part number “1000”. The figure number and item number location of the
part is directly opposite the part. If the part is used in more than one place, each location is listed commencing
with the first location the part is fisted.
NUMERICAL INDEX
PART NUMBER
A-25
A-98
AW-626
BOX GROUP REGULATOR
CAPACITOR BOX GROUP
DATA-1330A
DATA-2033
DATA-221 OA
DW-4691-I
DW-4691-2
D W-882A
D W-883
DW-1704
DWP-982
FW-1312
FW-1507
FW-3294B
FW-3399
HF-1459
H F-251 8-9
H F-2727
H F-478
H F-530
H F-584
H F-745
H F-879
MOUNTING FRAME
MOTOR& GENERATOR GROUP
MOTOR GENERATOR GROUP
NUT
SCREW
TRY-154-I
TRY-174-3
WASHER, FLAT
Jan 18177
FIGURE AND
ITEM NUMBER
12-24
3-o
12-28
3-6
3-10
13-4
5-51
7-18
5-7
B-20
8-29
7-17
7-16
12-23
2-21
8-6
9-12
11-5
5-44
8-33
8-25
8-32
l-l
8-28
4-I
8-3
2-o
8-11
7-15
1-5
1-3
3-3
6-14
6-11
12-o
12-o
6-12 i
Numerical Index
44 Page 1
PART NUMBER
WASHER, COCK
W-10051-6
W-10072-1
w- 10079-3
w- 10079-5
W-l 0079-g
W- 10088-3
W-l 1097-3
W-l 1097-B
W-l 1097-22
W-l 1166-I
W-l 1166-4
W-l 1242-5
W-l 1242-10
W-l 1242-12
W-l 1250
W-l 1254-4
W-l 1254-6
W-l 1263-6
W- 11278-5
W-l 1278-7
W-l 1434
W-l 1534
W-l 1535
W-l 1597
W-2974-F
W-2974-L ’
W-44608-26
W-454 1 D
W-799C-66
W-8095A-4
W-8095A-8
W-8105A-4
W-9026-9
w-9234- 112
w-9234-1 45
w-9350-73
w-9350-74
w-9350-75
W-9350-76
w-9350-77
W-9407-1 98
w-9549- 19
Numerical Index
4-4 Page 2
NUMERICAL INDEX (CONTINUED)
FIGURE AND
ITEM NUMBER
6-13
8-O
7-I 1
7-o
7-o
12-o
4-o
7-o
12-34
12-21
12-30
11-28
8-2
12-25
12-19
12-35
4-o
8-O
12-26
12-20
12-31
12-14
12-27
II-27
11-44
1 l-43
II-40
9-5
5-58
9-6
11-26
I-4
9-18
5-o
8-O
8-14
B-10
II-48
5-o
5-o
5-o
5-o
5-o
5-o
5-o
5-o
5-9
12-22
Jan 18177
PART NUMBER
W-9648-226
W-9648-257
w-9701 -4
W-97 12-6
w-971 2-29
w-9712-31
W-9746-l
W-9746-2
W-9760-4
W-9760-5
W-9760- 134
W-9760-135
W-9760-1 36
W-9916-10
W-99 17-20
ICZ-101
ICZ-105
ICZ-128
ICZ-129
ICZ-132
1 CZ-134A
ICZ-148
ICZ-152
ICZ-156
1 CZ-22-B
1 CZ-35B
1 CZ-60
1 CZ-62
1 CZ-63
1 CZ-64
1 cz-70
1 cz-74
1 cz-75
1 cz-97
IODH-534
IODH-664
1 ODH-696-3
IODH-845-0
1 ODH-847-2
IOJ-178
IOOGH-I 12
IOOGH-142
IOOGH-216-2
IOOGH-216-3
1 OOG H-683
1 OOG H-685
Jan 18177
NUMERICAL INDEX (CONTINUED)
FIGURE AND
ITEM NUMBER
5-o
5-o
6-6
8-13
II-31
II-30
11-37
II-14
5-o
5-o
5-o
5-o
5-o
8-4
4-2
II-46
II-41
1 I-39
11-38
II-2
11-I
12-29
II-32
1 I-13
II-6
II-10
II-8
II-3
11-7
II-20
1 I-21
11-36
11-15
11-47
11-33
11-34
8-7
830
9-9
9-2
9-3
8-24
12-16
9-11
8-34
4-8
2-13 / i
2-o
Numerical Index
4-4
Page 3
PART NUMBEh
lOOMS-14
IOOMS-I 17
1 OOMS-122-O
IOOMS-I 22-I
lOOMS-132
lOOMS-137
IOOMS-141
IOOMS-146
IOOMS-21
1 OOMS-36
1 OOMS-349
1 OOMS-358
1 OOMS-382
1 OOMS-383
1 OOMS-6
1 OOMS-79
IOONH-261A
IOONH-264
1 OON H-330-0
IOONM-92
IOONM-94
IOONM-95
1 OONM-96
1 OONM-97
IOONM-98
15G H-433
15GH-519-I
15GH-519-2
16DA-1626-4
16DA-1997-3
16DA-1997-4
16DA-2016-4
16DA-2162
16DA-4004A-3
16DA-4052-0
16DA-4252-4
16DA-4253-1
20RT-352-1
20RT-353-1
200MS-116
200MS-132A
200MS135A
200M.S138
200MS-140
200MS-143
200MS-145
200MS-146
Numerical Index 4-4
Page 4
NUMERICAL INDEX (CONTINUED)
FIGURE AND
ITEM NUMBER
5-24
5-49
5-21
5-15
5-o
5-50
5-48
5-57
5-17
5-33
5-52
5-46
5-54
5-23
5-47
5-63
4-6
4-4
8-9
5-22
5-o
5-18
5-20
5-13
5-14
8-27
12-8
12-o
5-38
II-45
11-o
1 I-25
8-12
9-15
9-14
5-4
9-I 6
7-7
7-8
5-55
5-16
5-26
5~25
5-39
5-36
‘5-35 ’ I 5-12
Jan 18177
PART NUMBER
3DW-248 2-14
30GH-322
363769-3
363771-5
380376-I
380435
380524-I
380524-2
380526- 1
380526-2
380527-I
380527-2
380527-5
380530-I
380530-4
380942
380943
381081
381082
381083
381084
381086
381090
381649-1
382103
382432-l
382501-25
382501-26
382501-27
382501-28
382501-29
382501-30
382501-31
382501-32
38250 1-33
382501-34
382501-35
383766
386075
386634~
386635A
387168
387725
405-90
400MS17
400MS-18
400MS19
Jan 18177 Feb 17178 Revised
NUMERICAL INDEX (CONTINUED)
FIGURE AND
ITEM NUMBER
8-22
5-31
9-o
7-o
6-4
7-o
7-2
7-o
7-I 2
7-o
7-o
7-o
7-o
7-o
7-9
7-o
12-o
1
1
1
1
2-I
2-2
2-3
2-33
3-7
1. 3-3
7-3
4-5
7-o
3-I
3-o
3-o
3-o
3-o
3-o
3-o
3-o
3-o
3-o
3-o
9-I
4-o
7-23
7-22
7-21
9-13
5-29
5-43 5-5 Ii
5-42
Numerical Index
4-4 Page 5
NUMERICAL INDEX (CONTINUED)
I PART NUMBER
400MS-23A,
400MS-58
400MS-62
400MS-63
400MS-72
400MS-9
400032
400033
400034
400035
400078
400092
400097
400098
400400
400540-3
400589-5
400651
400669
400670
400847-2
400847-3
40 1563-2
401563-3
40 1564-2
401564-3 ’
401864
401865
401911-5
401911-B
40191 I-20
402018
402037-g
402157
402658
402680-20
402826
402956
402987
, 403330-O
403330-I
FIGURE AND
ITEM NUMBER
Numerical Index 4-4
Page 6
5-41
5-30
5-o
5-28
5-27
5-45
II-49
11-o
11-o
11-4
5-59
9-7
5-60
5-61
5-62
8-26
9-4
5-37
12-9
5-3
5-6
5-o
8-I 8
4-9
11-22
11-16
II-II
II-17
II-23
II-12
8-O
II-42
5-34
6-2
5-2
6-5
12-10
9-17
4-10
14-4
8-23
8-1
II-35
8-5
5-10
2-o
,5-65
5-o
Jan 18177
NUMERlCALlNDEX(CONTINUED)
-
PARTNUMBER
403330-2
403330-3
403330-4
403330-5
403336
403982
404060-3
404065-I
404389-I
404389-2
404389-3
404612-3
404612-4
404612-5
404612-6
404877 430183
430188
430189
430191
430222
430223
430224
430278
430293
430297
480366
460641
481051-I
481051-2
481052
481053
481054
481056
481057
481061-I
481061-2
481062
481063-I
481063-2
481568
482199-1
482199-2
482199-3
482199-4
482199-5
482199-6 ~~ .-__-
Jan 18177
Feb 17/78 Revised
FIGUREAND
ITEMNUMBER
5-o
5-o
5-o
5-o
9-o
7-10
5-I
5-53
9-8
4-o
5-66
5-o
5-o
5-o
5-o
5-o
5-o
14-2 II-18
II-50
11-29
II-9
11-o
II-24
1 I-19
1 o-o
IO-2
11-o
2-o
8-8
3-5
3-o
8-21
9-19
8-15
8-16
8-17
3-8
3-o
3-9
3-4
3-o
4-o
4-o
4-o
4-o
4-o
4-o hi
4-o
Numerical Index
,
PART NUMBER
482199-7
482199-B
482199-9 482199-l-O
482199-12
482200
5BJ-32
5BJ-33
5BJ-34
5BJ-35
5CW-2127
5cw-975
5CW-976A
5JB-984
5JB-985
50MS-28
50MS209
50MS-472
50MS-60
50MS-696
50NH-130
50NH-1015-I
50NH-1193
50NH-1196
50N H-384
50NH-42
50N H-43
50NH-435
50NH-436
50NH-54
50NH-622
50NH-641
50NH-642
50NH-703-0
50NH-707
50NH-708
50N H-743
50NH-765
50NH-774
50NH-775
50NH-776
50NH-778
50N H-784
50N H-786
50N H-787
Numerical Index 4-4 Page 8
NUMERICAL INDEX (CONTINUED)
FIGURE AND
ITEM NUMBER
4-o
4-o
4-o
4-o 4-o
5-64
7-o
7-5
7-4
7-6
12-15
12-17
12-18
2-o
2-o
5-8
8-19
5-40
5-19
5-I 1
5-32
7-I
7-o
14-3
14-I
4-3
7-20
7-19
6-1
6-3
7-I 3
2-o
7-o
7-o
8-O
3-2
IO-4
1 o-5
3-12
13-2
2-8
2-o
2-I
2-2
2-3
2-l 0
2-12
I-2
Jan 18177
PART NUMBER
50NH-790
50NH-791
50NH-792
50NH-793
50NH-794
50NH:796
50NH-797
50NH-800
50N H-807
50NH-810
50NH-815
50N H-827
50NH-828
50N H-829
50NH-830
50NH-831
50NH-832
50NH-834
50N H-840
50NH-976
50NH-977
50NH-978
50NH-979
6FW-557A
6OFC-620
6OFC-622
60GH-145
60GH-92
60GHP-234
60GHP-424
75GH-323
75GH-46
75GH-47
75G H-48
75GH-49
75G H-50
75GH-51
75GH-566
75NH-1 IO
75NH-22
75NH-334
Jan 18177
NUMERICAL INDEX (CONTINUED)
FIGURE AND
ITEM NUMBER
2-o
2-I 7
2-18
2-20
2-o
2-19
2-6
2-11
2-15
2-I 6
2-9
12-32
6-O
6-15
1 o-o
IO-3
IO-I
6-O
1 o-o
7-14
6-9
6-8
6-7
6-10
5-56
2-o
2-4
2-o
3-11
13-I
2-5
5-o
2-7
12-6
12-5
12-4
12-12
12-13
12-7
12-I 1
9-10
4-7
2-o
’ i
Numerical Index
44
Page 9
’ I
CHAPTER 5. OPTIONAL EQUIPMENT
Optional equipment supplied with your generator set is indicated by the part number of the option and the instruction
manual number opposite the option name.
OPTION NAME PART NUMBER TO- NUMBER
Trailer W-4460B-26 TO-1 15
Reverse Phase Relay 404389
Jan 18177 Revised 5-o
Page 1
CHAPTER 6. MANUFACTURER’S LITERATURE
Voltage Regulator Hobart Instruction Manual
430293
Hobart Diagrams
Generator Connection Diagram
Schematic’Diagram
Motor Switch Connection Diagram
481065
482202
482201
’ i
Jan 18177 Revised 6-O
Page 1
INSTRUCTIONS
.Installation
.Operation *Maintenance
225 WATT STATIC REGULATOR 430293
Designed as a Control of A.C. generator output voltages for generators with capacities up to '75 KVA.
MOTOR GENERATOR CORPORATION
(Hobart Brothers Affiliate)
Troy, Ohio
J-22663 hi
’ i
SECTION 1 - INTRODUCTION
1. Purpose ............................. . ...............
2. General Description .................................
3. Detailed Description tif Circuits ....................
4. Sequence of Operation ...............................
SECTION 2 - INSTALLATION
5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 OPERATION
7. ............................................. 7
Adjustments .........................................
SECTION 4 MTN’IENANCE
9. ............................................. 9
List ..........................................
Block Diagram ........................... 11
Operating Voltages 13
Trouble ....................................... 15
6
HOBART STATIC REGULATOR
SECTION I - INTRODUCTION
1. PURPOSE
The Hobart Static Regulator ,is disigned to provide 1% voltage regulation with .2 second recovery time for all loads up to 100% of rated load at rated poster factor on 3 phase, 4 wire, 120/208 volt, 400 cycle alternators with ratings up to 75 KVA. The static Regulator provides field power for the Ro- tary Exciter except on starting, and provides ‘regulation by varying the field power of the Rotary Exciter as required by load conditions. The maximum continuous rating of the regulated static exci- ter is 1.5 amperes at 150 volts DC.
2. GENERAL DESCRIPTION
The static regulator consists of 7 basic interconnected circuits. These are:
a. The voltage detector circuit,
b. The comparison circuit. C. The first or input .stage, full wave, single phase, magnetic amplifier. d. The second or power stage, full wave, single phase magnetic amplifier. e. The damping cir:;uits. f. The line voltage drop compensation circuit.
g. The voltage Buildup circuit.
All of the components of these circuits are mounted on a single chassis with the exception of the voltage control rheostat and the line drop compensation current transformers. All external connec- tions are made through a terminal strip at the bottom of the front of the chassis.
Any deviation of the alternator voltage from the regulated voltage is sensed by the voltage detector and comparison circuits. A signal is fed from the comparison circuit into the first stage magnetic amplifier, amplified, and fed into the power stage magnetic ‘amplifier. The power stage nagnetic amp-
lifier changes the Rorary Exciter field power enough to return the alternator voltage to its regu- lated value. The voltage at which the alternator is regulated may be adjusted with the voltage ad- justment rheostat. A line drop compensating circuit is provided, and may be set with control knobs on the front of the chassis to provide regulated voltage at the ends of the power cables.
3. DETAILED DESCRIPTIONS OF CIRCUITS
a. The Voltage Detector Circuit - The voltage detector circuit consists of 3 single phase trans- formers (TlA, TlB, Tic), 4 rectifiers CRlA, CRIB, CRlC, CRlD) with L-section filters (Cl, L4, RX, ABCD) and 4 blocking diodes (CR2 - A, R, C,D). One side of each of the three-transformer primaries is
common. The transformer primaries are connected as. a 3 phase, 4 wire Y, to the alternator output
voltage. Each of the transformer secondaries has two taps, one of which is a center-tap. The three
secondary center-taps are joined together. Each of the other taps leads to a diode of rectifier CRID
to form a 3 phase, half-wave rectifier connection. The filtered output of this half-wave rectifier
is proportional to the average line to neutral 3 phase alternator R.M.S. voltage.
Each.transformer secondary also feeds a full-wave center-tap single phase rectifier (CRlA, CRIB, CRlc) . The filtered output voltage of each of these single phase rectifiers iS ProPortional to the
line to neutral voltage of a different phase of the alternator. The positive sides of the filtered
output voltages of the four rectifiers (CRlA, CRlB, CRlC, CRlD) are common at a point (A ) through blocking diodes (CRBA, CR2B, CR2C, CR2D). The blocking diodes prevent the flow of current from one of the four rectifiers into the filter circuit of any other rectifier. The negative sides of the rectifiers are common at a point (B-) with the center-taps of all three transformer second- aries. The output of the voltage detector circuit is filtered DC and feeds the comparisoncircuit
(A . B-).
‘Ihe functions of the detector circuit are to provide a filtered DC voltage proportional to the AC output voltage of the alternator, and to sense the highest phase voltage of the 3 phases. The 3 ,.- phase half-wave rectifier (CRlD) senses the average phase voltage, and the 3 full-wave rectifiers (CRlA, CRIB, CRlC) sense the individual phase voltages. If the three phase voltages are equal, the 1) half-wave 3 phase rectifier voltage is slightly higher than any of the three full-wave single phase rectifier voltages and controls the DC output voltage of the detector circuit. lf the three phase voltages are ,not equal, the highest of the full-wave,,rectifier voltages will be higher than the half- wave, A phase, or average, rectifier voltage, and will control the output voltage of the detector circuit. The output of the voltage detector circuit is thus a filtered DC voltage proportional to the highest line to neutral voltage of the alternator.
b. The Comparison Circuit - The comparison circuit consists of 3 fixed resistors (R4. R5, R6),
a potentiometer (Rl) and a voltage reference tube (Vl). The components are connected together to
form a voltage reference bridge. The DC output voltage (A , B-) from the voltage detector circuit
is applied to this bridge in such a manner that a voltage signal proportional to the difference be- tween the detector voltage and the reference voltage appears between the positive side of the refer- ence tube and the potentiometer slider. ‘l’his voltage signal is also a function of the position of
the slider on the potentiometer.
‘Ibe function of the comparison circuit is to compare part of the DC output voltage of the detector circuit with a fixed DC reference voltage and provide a control sigaal proportional to their differ- ence to the input stage magnetic amplifier. It is in this circuit that the voltage at which the al-
ternator regulates is established. Varying the position of the slider on the potentiometer in the comparison bridge changes the fraction of the voltage which is compared to the reference voltage, &d so varies the control signal of the first stage magnetic amplifier. This affects the output of the
power stage magnetic amplifier, and affects alternator voltage.
C. The First or Input Stage Pull-Save Single Phase Magnetic Amplifier - The input stage magnetic amplifier consists of a single phase saturable reactor (SRl), a single phase full-wave rectifier (CR3), a stablizing feed back network(Ri3. C3, R8), and a filter (C2. Ll). The saturable reactor has two laminated cores with a separate load winding (1) (2) (3) (4) on each core. A stabil-
izing winding. (7) (8). a damping winding (9) (10). and a control winding (5) (6), link both cores.
The load windings are connected with the rectifiers to the alternator, line-to-neutral voltage to provide a full-wave single phase self-saturating reactor. Power is supplied to the load windings
from one phase of the 3 phase.alteana’tor. The. stabilizing winding is connected to the output of the Regulator through a Resistor and Capacitor and provides sufficient degenerative feed back to stabilize the amplifier. The output of the input stage magnetic amplifier is fi.‘: tt!led and fed
through a variable resistor (RlO) into the, control winding of the 1 phase power stage full-wave mag- netic amplifier:
The current in the control winding of the input stage magnetic amplifier controls the saturation of the reactor core, controlling the inductence of the load windings and thus controlling the impedance of the load windlags. This determines the load current of the magnetic amplifie‘r. The character- istics of the material in the cores of the saturable’rkactor are such.that a very small change in DC control current causes a great change in the load current of the magnetic amplifier.
The first stage magnetic amplifier receives its control signal from the comparison circuit, ampli- fies it, and feeds the amplified signal into the control winding of the power stage 1 phase full-wave magnetic amplifier.’
d. The Second or Power Stage 1 phase FullYWave Magnetic Amplifier - The power stage magnetic, amplifier consists of 1 saturable react&, a full-wave, single phase power rectifier (CR5). and 1 transformer.
2
.
Each saturable reactor has 2 load windings (1) (2) (3) (4) on separate cores, a control winding (7-8) linking both cores, and a bias winding (5-6) linking both cores.
The saturable reactors are connected with the 1 phase full-wave rectifier to form a 1 phase self-
saturating magnetic amplifier. The power transformer primary is connected to the alternator out-
put. The secondary of the transformer supplies power to the 1 phase self-saturating reactor circuit.
The control winding of the saturable reactor is energized by the output current of the first stage magnetic amplifier.
The bias winding is energized by the output of the sensing circuit and is in series with the compari- son circuit.
The saturation of the power stage 1 phase reactor is controlled by the current flowing in its control winding from the first stage magnetic amplifier and by the amount of current flowing in its bias’ windings. With the bias current constant, an increase in the control current saturates the reactor cores, decreasing the impedance of the 3 phase reactor to the applied voltage. The load current in- creases, is rectified by the 1 phase full-wave power rectifier, and is fed into the field of the ro- tary Exciter, increasing the alternator voltage.
e. Ihe Damping Circuit - The damping circuit consists of a transformer (TV. a variable resis- tor (R9). and a winding (9, lo), on the input stage magnetic amplifier. The primary (3,4) of the damping transformer is connected through the variable resistor to the output of the static regulator. The secondary (1.2) of the transformer is connected to a damping winding on the input stage magnetic amplifier.
The damping circuit detects changes in the output of the static regulator and feeds pulses of energy opposing the signal causing the-change into the first stage magnetic amplifier. The damping circuit
affects only the transient operation of the system and prevents hunting, oscillation. and excessive overshoot in regulating action. The damping effect may be increased by decreasing the resistance of the variable resistor in series with the damping transformer primary winding. Increasing damping improves stability, hut results in longer response times in voltage regulation. Decreasing damping shortens response time but results in poorer stability and in hunting.
f. The Line Voltage Drop compensating Circuit - The line drop compensation circuit consists of
a current transformer (CTl. CT2. cT3,) on each phase of the load lines, a fixed inductance (L2A. L2B, L2C) and variable resistance (R2A, R2B. RX) in each of the three phase lines leading to the detec- tor circuit, a toggle switch (Sl) for by-passing the line drop compensation, a variable resistance (R15A, R15B. R15C) in series with each current transformer, and a fixed resistance in parallel with
each cur rent transformer. Each of the three current transformers has its secondary connected
through a variable resistor to the fixed inductance and another variable resistor.
The current transformers detect the magnitude and power factor of current flowing through the power lines from the alternator to the load. The current transformers feed a signal into the resistance
and inductance ahead of the detector circuit which opposes the alternator voltage being sensed by the detector circuit. The voltage actually received by the detector circuit is therefore lower than
the actual alternator voltage by an amount proportional to the magnitude and power factor of the load current, and therefore proportional to the voltage drop in the lines. The regulator output in- creases slightly so that the alternator output voltage is equal to the regulated voltage plus the voltage drop in the lines. The load voltage is then equal to the regulated voltage. The variable resistances may be adjusted to match exactly the impedance of the power lines carrying the alternator load current.
g. Voltage Build-up Circuit - The voltage build-up circuit consists of a relay with normally closed
contacts shorting across the load windings of the 2nd stage magnetic amplifier reactor. When the
3
. _. __ .- ..-
machine is started, the voltage generated from residual magnetism is rectified by the output rectifier (CB4) and fed into the fields of the brushless exciter, causing the exciter vol-e and hence the alternator voltage to increase. 8hen the exciter output resis to a level sufficient to Cause the alternator voltage to be high enough to power the regulator, the relay coil, connected in the regulator sensing circuit, becomes energized and actuates the relay. The relay contacts shorting the amplifier windings open, allowing the amplifier to control the exciter field current. The regulator then supplies all,power required by the exciter field to maintain the alternator voltage at its regulated value.
4. SEQUENCE OF OPERATION
a. Starting- when the machine is started, the rotary exciter is excited through the voltage build up relay, and the output rectifier from A.C. voltage generated by residual magnetism. As the rotary exciter voltage increases, alternator excitation increases and the alternator voltage builds up. The detector circuit of !he regulator receives this voltage, rectified and filters it, and feeds it into the comparison ‘lrcuit. When the voltage vecomes high enough, the build up relay opens the contacts across the reactor load coils. The DC output voltage of the detector circuit is not high enough to cause the OB2 voltage reference tube to fire and start conducting current until the alternator voltage reaches about two-thirds of its regulated level. Unit1 the reference tube starts to conduct, the comparison circuit is badly unbalanced in such a manner that a high current flows in the control winding of the first stage magnetic amplifier. The saturable reactor of the first stage magnetic amplifier is saturated by this high control current. The DC output current of the first stage magnetic amplifier flows into the control winding of the second stage magnetic amplifier, and is high enough to saturate the reactor of the second stage magnetic amplifier. The load winding of second stage magnetic amplifier then presents a low impedance to the alternator voltage, and the rectified output current of the amplifier flows into the rotary exciter field. This results ina,
a further increase in alternator voltage.
When the alternator voltage reaches about two-thirds of its regulated value, the DC output voltage of the detector circuit becomes high enough for the 0~~ voltage reference tube to conduct current at
J
This establishes the reference.voitage. As the alternator voltage cpntinues to --/’
a constant voltage. increase. the detector circuit output voltage increases, but the voltage of the reference tube re-
mains constant. The control winding of the first stage magnetic amplifier is connected between the reference voltage and a part of the detector voltage. As the detector voltage increases, the volt-
age across the control winding decreases and the control current decreases. The reactor of the
first stage magnetic amplifier de-saturates. The rectified load current of the first stage mag- netic amplifier, flowing in the control winding of the second stage magnetic amplifier, decreases. As the control current of the second stage magnetic amplifier decreases, the reactor of that stage becomes less saturated. As the reactor desaturates, the inductance and hence the impedance presented by the load windings of the second stage reactor to the three phase alternator voltage increases. The rectified load current flowing in the exciter field from the second stage magnetic amplifier is limited by the increasing impedance of the reactor. When the alternator voltage reaches the regs ulated voltage, the rectified three phase voltage in the sensing circuit is such that the voltage across the first stage amplifier control winding is just enough to cause the output of the second stage amplifier to excite the exciter sufficiently to maintain the regulated voltage.at alternator no load. The characteristics of the magnetic amplifiers are such that the voltage across the first stage control winding should be very nearly zero at alternator no load.
‘Ihe voltage at which the alternator is regulated may be varied by varying the position of the slider of the ‘Volts Adjustor? potentiometer. This increases or decreases the potential of one terminal of the control winding of the first stage magnetic amplifier. Since the other terminal of the first stage control winding is connected to the reference voltage, this causes the control current of the first stage amplifier to change. Increasing the potential of the potentiometer slider with respect to the detection circuit negative causes the regulated voltage to decrep?e. Decreasing the poten- tial of the slider with respect to’ the detector circuit negative causes the regulated voltage to in- 1 crease.
b. Regulating, Load Applied, - When a load is applied to the alternator, the alternator voltage decreases. When the alternator voltage decreases, the rectified three phase voltage in the sensing
circuit decreases. The potential of one side of the control winding of the first stage magnetic amplifier is directly proportional to the detector circuit DC voltage, which in turn is directly proportional to the alternator voltage. The potential of the other side of the first stage amplifier
control winding is the constant potential of the first stage amplifier changes in such a manner as to cause the first stage reactor to become more saturated. This allows the rectified load current
of the first &age amplifier, flowing through the second stage control winding, to increase end sat- urate the r,eactor of the second stage amplifier. As the second stage reactor saturates, its impedance decreases and the rectified loadScurrent flowing into the field of the rotary exciter increases. The alternator voltage increases until the voItage,returns to its regulated value.
c. Regulating, Load Removed - When a load is removed from the alternator, the alternator voltage rises. The rectitied three phase voltage in C,he sensing circuit also rises. When the sensing circuit voltage rises, the potential of one side of the first stage amplifier control winding rises, while the potential of the other side of the winding remains at the constant potential of the refer- ence voltage. The control current in the first stage magnetic amplifier changes in such a manner as to desaturate the first stage reactor. The output of the first stage amplifier decreases, causing the second stage reactor to desaturate. This causes the DC output of the second stage amplifier to
decrease. The field current of the rotary exciter is decreased and the alternator voltage returns to its regulated level.
5
’ i
SECTION 2 - INSTALLATION
5. MGUNTING
The Hobart Static Reguiator may be mounted in any Regulator should be carefully be inserted and, secured. The
placed in position, open top and bottom
6. CONNECTIONS
.’ ,1
position without impairing its operation. The the mounting holes aligned, and the bolts should must ,be left unobstructed to allow air circulation.
All electrical connections are made through a 20, station terminal strip at the bottom of the front of the exciter chassis. The connection diagrams are included at the back of this manual. The connection diagrams should be referred when connecting a Static Regulator to an alternator.
(F 8 F-1 (cm). m2. m3) To Tl. T2, T3 Rl. R2. R3
To rotary exciter field To current transformers. To the alternator neutral connection. To the 3 phase alternator output voltage, To the ‘voltage control rheostat, be sure middle terminal of rheostat goes to R2. Rl goes to left terminal facing shaft of rheostat.
6
SECTION 3 - OPERATION
-.
7. GENERAL
Operating the static regulator involves very little when all components are functioning normally. Ihe only operations ‘that need be performed are on starting. There are only 6 cdjustments which can be made on the regulator, 5 of which are made at the factory. r)nce placed in operation, the regula- tor should require little further attention. ,
8. ADJUSTMENTS
There are 6 adjustments which can be made on the static regulator. of these 6 adjustments, only the
voltage control rheostat setting need be changed in normal operation of the regulator. All of the
other adjustments are set at the factory and should not need changing.
a. Voltage Control - The voltage at which the alternator regulates may be controlled by a small rheostat on the control panel of tne machine Rotating the rheostat knob to--the right (clock-
wise) increases alternator Voltage. Rotating the rheostat knob to the left (counter-clockwise) de- creases the alternator voltage. The alternator is regulated at what ever voltage it is set with the voltage control rheostat. Same directions apply to units equipped with screwdriver type rheostats.
h. Line Voltage Drop Compensation Gain - Adjustments of the line compensation magnitude are made
with the knob marked ‘Ft. Compensation’ on the right side of the static regulator terminal panel. ‘Ihe knob dial is calibrated in approximate cable length in feet. The ‘Ft. Compensation’ knob con-
trols a rheostat which limits the current flowing in the compensation circuit. The setting of the
rheostat resistance determines the magnitude of the compensation. Rotating the ‘Ft. Compensation*
knob to the left (counter-clockwise) decreases the magnitude of the compensation. Changing the ‘Ft. ’
Compensation’ knob controls only the magnitude of the compensation and has very little affect on the compensation phase.
C. Line Voltage Drop Compensation Phase.- The compensation circuit must be adjusted to match not
only the voltage drop in the power cables to the load but must also be adjusted to match the phase of the voltage drop. This is done by adjusting the relative magnitude of reactive and resistive compensation with the ‘Cable Size’ knob. This knob is calibrated in ‘cable sizes and controls a
variable resistance in series with a fixed reactance. The power factor of the compensation circuit
is varied by varying the resistance and leaving the reactance constant. Rotating the knob to the right (clockwise) increases the resistive component of the compensation circuit. Rotating the
‘Cable Size’ knob to the left (counter-clockwise) decreases the resistive component of compensation.
d. Damping Gair. Adjustment - The gain adjustment for the damping circuit is a 5000 ohm variable
resistance (R9) in series with the primary of the damping ,transformer. lhis resistor is in the
form of a screwdriver potentiometer with a locking nut. It is located on the left side of the terminal
panel of the static regulator and is marked ‘damping’. Turning the potentiometer screw to the
the right (clockwise) increases the resistance, decreasing the system damping and making the system less stable. Turning the adjustment screw to the left (counter-clockwise) decreases the resistance, increasing the stability of the exciter but slowing the system response. If the system is oscilla- tory, stability may be achieved by decreasing the resistance of this resistor. The resistance should not be set at zero or very low values as this will allow enough current to flow in the cir-
cult to damage the damping transformer primary. lhis resistance is set at the factory to give sat- isfactory system transient resoonse. It will not ordinarily require additional adjustment.
e. Interstage Amplifier Coupling Resistor - The interstage amplifier coupling resistor is a
variable resistor (~10) in series with the control winding of the second stage magnetic amplifier.
It tapers the signal coming from the first stage magnetic amplifier to the second stage amplifier. It decreases the gain of the two-stage amplifier and helps to stabilize the system.
-?
Turning the adjustmerit screw to the right (clockwise) increases the resistance of this resistor, resulting in a decreased system gain and increased stability. Turning the adjustment screw to the left (counterrclockwise) results in increased sy&em,gain and decreased stability. Regulation improves as the system gain is increased., within limits of stability. The coupling resistor is set to its proper value at the factory and should not need further adjustment.
f. Setting the Line Drop Compensation - The procedure for setting the line voltage drop compen- sation adjustments for good regulation is as follows:
1. Turn the line compensation switch on and set the ‘Ft. Compensation’ and ‘Cable Size’ control knobs to the dial settings corresponding to the length and size of.the cables on the machine.
2. Adjust the alternator voltage to the desired regulating voltage at no load, measuring the voltage at‘ the load end of the leads with a remote voltmeter.
3. Load the machine with the largest available 3-phase inductive load of rated power fac- tor not exceeding rated load. If the voltage at the load rises or droops more than one percent, de- crease or increase the setting of the ‘Ft. Compensation’knob until the regulation is flat.
4. Load the machine with the largest available 3-phase unity power factor load not ex- ceeding rated load. If the voltage at the load rises or droops more than one percent at full 1oadJ adjust the ‘Cable Size’ setting until flat regulation is attained. If it is necessary to adjust the ‘Cable Size’ setting, repeat step 3 above. -7
g. The Rate Control Resistor - lhe rate control resistor is a 5000 ohm variable resistor (R13) through which the stabilizing winding @U-7,8) of the first stage amplifier is capacitively coupled to the regulator current output to provide a negative feedback during transient operation. The magni- tude and phase of this negative feedback are controlled by the rate control resistor. Increasing the resistance of this resistor makes the system less stable, but shortens the response time. De- creasing the-‘resistance of this resistor makes the system more stable, but increases the system response time. This resistance should not be decreased to zero, for this may, in some machines, result in system instability due to phase shift effects. This resistance is set at the factory to give satis- factory system response and should not require additional adjustment.
SECTION 4 - MAINTENANCE
9. QNERAL
The Hobart static regulator is so designed that all of its components are operated will within their ratings at rated regulator maximum output. There are few moving parts in the regulator to wear out
and give mechanical trouble. The ,static regulator should require little maintenance for long and
trouble free operation. It is true, however, that in ar@ system containing a large number of elec-
tronic components there will in time be a certain number of component failures. The parts list,
trouble chart ,and list of component .operating voltages are intehded as aids in locating and replacing any components which fail.
.
. ,
.
9
.
QUANTITY
3 12 3 4 4 3 4 1 1 1 1 I 1 1 1 1 1 1 1 1 1 1 4 1 1 3 1
PARTS LIST
&AWING SYMBOL DESCRIPTION OF PART
TlA, TlB, TlC CRlA, CRlB. CRiC CRlD
L3A, B, C, D, ClA, ClB, ClC, ClD R3A. R3B, R3C, R3D CR2A, CRZB, CRZC, CR2D R4 R5 R6 Vl RI R? c2 c3 c4 CR3 SRl Ll RlO l3 R9 CR4 SR2 CR5 T2 R13
Sensing Transformer Diodes, .?5 =.inp, 400 volt peak inverse Diodes, .75 amp, 600 volt peak inverse Filter ,chikes, .6Ii, ICE-63 Filter capacitor, .5 mid., 400 volt Filter resistor, SOOO’ohm, 10 watt Blocking diode .75 amp, 400 volt peak inverse Resistor, 5000 ohm, 10 watt Resistor, 1750 ohm, 10 watt Resistor, 3000 ohm, 10 watt OB2/WA cold cathode voltage reference tube Potentiometer, 1500 ohm, 25 watt Resistor, 750 ohm, 25 watt .5 mfd. capacitor Capacitor, 40 mfd., 250 volt . 5 mfd. capacitor Rectifier, full-wave, sinele phase, 400 PIV, .75 amp Saturable reactor, single phase, full-wave, ICZ-62 Filter choke, .3H., ICE-58 Resistor, variable, 500 ohm, 25 watt Transformer, damping, X5-60 Resistor, variable, 5000 ohm, 25 watt Diodes, 600 PIV, .75 amp Reactor, saturable, single phase, ful?-wave 400 volt PIV Diode Transformer,, power 5000 ohm, Model H, screw driver adjustable locking
potentiometer CTl, CT2, CT3 R2A, R2B, R2C L2A. L2B. L2C Sl RlSA, R15B. R15C Rc R8A R8B
c5
Current transformer Rheostat, triple tandem assembly Reactance Switch, toggle 3 phase, 3 PST Rheostat, Triple Tandem Assembly Relay 50 ohm, 100 watt fixed resistor 50 ohm, 100 watt slidewire resistor Capacitor, 5 mfd., 250 WVDC
\
IO ’ i
BLOCK DIAGRAM EXPLANATION
A. LINE DROP COMPENSATION CIRCUIT
The line drop’compensation circuit makes it possible to maintain the desired load voltage when the load is at the end of long power cables. ‘l’his circuit detects load magnitude and power. factor and causes the alternator voltage to increase with increasing load so that the alternator
1 voltage equals the desired regulated voltage plus the voltage drop of the lines.
B. VOLTAGE DETECTOR CIRCUIT
The input to the voltage detector circuit is 3 phase, 4 wire voltage, tapped directly off the
alternator output. Ihe output is a filtered D.C. voltage directly proportional to the highest line to neutral voltage of the alternator.
lbe voltage detector circuit receives the 3 phase. 4 wire alternator voltage, steps up each phase voltage with a transformer, rectifies and filters each of the stepped up phase voltages, compares the 3 rectified phase voltages with each other and with an average phase voltage, and feeds the highest of these 3 rectified voltages into the voltage comparison circuit.
C. VOLTAGE COMPARISON CIRCUIT
‘Die input to the voltage comparison circuit is a filtered D.C. voltage proportional to the highest line to neutral voltage of the alternator output voItage. The nutput is a D.C. voltage equal to the difference between a constant reference voltage and a part of the input voltage to the comparison circuit.
The voltage comparison circuit receives a D.C. voltage proportional to the highest alternator phase voltage, compares part of it to a fixed D.C. reference voltage and applies the difference to the control coil of the first stage magnetic amplifier. The regulating voltage is established in this circuit.
D. FIRST STAGE MAGNETIC AMPLIFIER
‘Ihe’first stage magnetic amplifier has a power input and a control input. The power input is single phase line to line alternator voltage. The control input is the D.C. output of the volt-
age comparison ‘circuit. The output is a filtered D.C. voltage proportional to its D.C. control voltage.
This stage receives a D.C. control voltage from the voltage comparison circuit. It amplifies
this voltage and feeds it into the control tindings of the second or power Stage amplifier.
E. SECOND STAGE MAGNETIC AMPLIFIER
The second stage magnetic amplifier has a control input and a power input. The power input
receives 1 phase power from the alternator. The control input is the D.C. output of the first stage magnetic amplifier. ‘Die output is a D.C. voltage proportional to the cnntrol voltage.
This stage obtains 1 phase A.C. power from the alternator output, rectifies it with a full- wave 1 phase rectifier, and delivers D.C. power to the rotary exciter field. The amount of power supplied by the second stage magnetic amplifier to the,exciter fields depends on the con- trol signal received from the first stage magnetic amplifier, which in turndepends on the con- trol signal obtained from the voltage comparison circuit.
F. DAMPING CIRCUIT
The damping circuit detects changes in the output of the static regulator and feeds a signal
back into the first stage magnetic amplifier in such a direction as to oppose the change. This
circuit stabilizes the system and prevents oscillation and excessive transient overshoot of al- ternator voltage when, loads are suddenly applied to or removed from the alternator.
G. FIELD APING CIRCUIT
The field flashing circuit allows the system to build up from residual magnetism. When volt-
age is built up, the exciter field is energized from the regulator, which thereafter provides the exciter field power.
12
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/
The operating voltages listed in this table were recorded with the ICZ-150 regulator operating on a 30 KW synchronous drive alternator. The alternator was operating at no load and was regulated by the regulator at 120/208 volts, 4 wire, 3 phase, 400 cycles. There will be some variation from unit to unit, but no drastic differences. A volt-ohmeter with a.c. scales of 5000 ohms per volt and d.c. scales of 20,000 ohms per volt was used.
NORMAL OPERATING VOLTAGES
Component Drawing Component Name Where Voltage Was observed Symbol
Cl, A, B, C Capacitor, ..5 mfd 400~ Cl,D Capacitor, .5 mfd 400,~ c2 Capacitor, .5 mfd 400~ c3 Capacitor, .40mfd 250~ c4 Capacitor, .5 mfd 400~ CRlA, B, C Diodes. 400~. .75 Amp CRlD Diodes, 6oOv,. 75 Amp
CR2. A, B, C Diodes, 4OOv, .75 Amp CRXD Diodes, 4OOv,. 75 Amp CR3 Rectifier Bridge CR3 Diodes, 4OOv, .75 Amp CR4 Rectifier, 1.5 Amp Bridge CR4 Diodes, 600~. .75 Amp CR5 Diode, 400~. .75 Amp Ll Choke, .3 henry L3,A.B,C Choke, .6 henry L3D Choke, .6 henry Rl Potentiometer, 1500 ohm
Rl Potentiometer, 1500 ohm Rl Potentiometer, 1500 ohm R3. A, B. C Resistor, 5000 ohm 10 watt R3l-l Resistor, 5000 ohm 10 watt R4 Resistor, 5000 ohm 10 watt R5 Resistor. 1750 ohm 10 watt R3 Resistor, 3000 ohm 10 watt R7 Resistor, 750 ohm 25 watt R9 Rheostat. 5000 ohm 25 watt RlC Rheostat. 500 ohm 25 watt R13 Rheostat, 5000 ohm 25 watt RC Relay Coil. SRl 1st Stage Reactor SRl 1st Stage Reactor SRl 1st Stage Reactor SR2 2nd Stage Reactor SR2 2nd Stage Reactor SR2 2nd Stage Reaclbor SR2 2nd Stage Reactor Tl,A,B,C Transformer, Sensing Tl, A,B,C Transformer, Sensing Tl, A, B, C Transformer, Sensing Tl,A,B,C Transformer, Sensing Tl, A, B, C Transformer, Sensing
13
Across Capacitor Across Capacitor Across Capacitor Across Capacitor Across Capacitor Across Diodes.2 in series Across Diodes Across Diodes Across Diodes output Across each diode Bridge Output Across each diode Across diode Across Choke Across Choke Across Choke Terminal Rl-R3 Terminal Rl-R2 Terminal RZ-R3 Across Resistor Across Resistor Acms Resistor Across Resistor Across Resistor Across Resistor Across Rheostat Across Rheostat Across Rheostat Across Coil Coil 1-2 Coil 3-4 Coil 5-6 Coil l-2 Coil 3-4
Coil 5-6 Coil 7-8 Coil l-2 Coil 3-4 Coil 4-5 Coil 5-6 Ceil 3-6
Voltage
178 volts D.C. 195 volts D.C, 58.5 volts D. C 29.5 volts D.C 81 volts D.C. 180 volts D.C. 188 volts D.C. 7.8 volts D. C. .75 volts B.C. 58.5 volts D. C. 30 volts D.C. 41 volts D.C. 21 volts D.C. . 1 volt D.C. 13 volts D.C. 1 volt D.C. 1.25 volts D.C. 44 volts D.C. 17 volts D. C. 27 volts D.C. 178 volts D.C. 90 volts D.C. 81 volts D.C. 53 volts D.C. 93 volts D.C. 38 volts D.C. 13 volts D.C. 20 volts D. C. 1.8 Volts A.C. 105 volts D. C. 125 volts A.C. 125 volts A.C. 5.8 volts A. C. .8 voltsD. C. volts AC .8 volts D. C. voltsAC 1.35 volts D.C. .8 volts D.C. 120 volts A.C. 210 volts A.C. 170 volts A. C. 45 volts A.C.
425 volts ‘A. C.
-_. ..: ‘,
NORMAL OPERATING VOLTAGES '7
Component Drawing Component Name Where Voltage Voltage
Ssmbol Was observed
T2 Transformer. power Coil Hl-HZ 120 volts A.C.
T2 Transformer, Power Cbil Xl-X2 310 volts A.C.
T3 Transformer, Damping Coil 3-4 .75 volts A.C.
OB2WA Voltage Reference Tube ,Across Tube 108 volts D.C.
’ i
14 .J
Symptom
Alternator
voltage builds up to a dan- gerously high level. Flashing relay does not operate.
Alternator
Voltage Builds up to a dan- erously high level. Relay does operate
Alternator will not build up to proper voltage
Circuit
Voltage Build. up
Voltage Build Up
Voltage Detector
Voltage Detector
Voltage Detector Voltage Detector
Voltage Comparison
Voltage Comparison
Voltage Comparison
TROUBLE CHART
part Name
Relay
Relay
Resistor, 5000 ohm 10 watt capacitor, Jmfd
Choke, .6 henry 3 phase half Wave Rectifier
Resistor, 1750 ohm 10 watt Rheostat, 1500 ohm 25 watt
OB2 reference tube
First stage amplifier 1st stage reactor
First stage amplifier 1st stage reactor
Second stage amplifier 2nd stage reactor
second stage amplifier Rectifier
Voltage Comparison
Voltage Comparison
1st stage amplifier
2nd Stage amplifier
Voltage build up
Voltage build up
Resistor, 3000 ohm 10 watt Capacitor, .5mfd
Capacitor, .5mfd
Rectifier
Diode
Relay
Part Dwg. Symbol
RC,NO, NC
RC,NO, NC
R3D
ClD
L3D CRlD
R5
Rl
OB2WA
SRl
SRl
SR2
CR4
R6
c4
c2
CR4
CR5
’ i RC,NO ,NC
Fa .lure
Relay Coil open or Shorted Relay Arm- ature not moving freely Resistor open Capacitor shorted Choke open Diode shorted
Resistor
open Rheostat open or one terminal disconnected.
Open; not conducting at proper voltage. Winding l-2 or 3-4 shorted
Winding 5-6 open Winding open or shorted one diode open
Open
Shorted
Shorted
One diode shorted Diode open
Normally * closed con-t ‘tacts not
making prop- erly.
Remedy
Replace Relay
Check to see if armature is binding Replace Resistor Replace capacitor Replace choke Replace diode; check transformers TlA, B, C for damage.
Replace ree istor Replace if failed. Reconnect if one ter- minal open. Replace tube
Replace reactor
Replace reactor Replace reactor Replace diode
Replace
resistor Replace capacitor Replace capacitor Replace diode Replace diode Clean con-
tacts; make sure contacts are making.
15
‘IROUBLE CHART
Qmton
Poor regulation under load
Voltage buiIds up but regu- lator will not take over. Relay clicks in end out.
System unstable
C
Voltage is one phase Above 130 volts line to neutral with unbal-
anced load.
Circuit Part NtMIe
Voltage Comparison Resistor, 5000 ohm io watt
First stage amplifier Capacitor, 4Omfd 250 Volt
First stage amplifier Rectifier
First stage amplifier 1st stage reactor
First stage amplifier Rheostat, 5000 ohm 25 watt
First stage amplifier Choke L-l First stage amplifier Resistor, 750 ohm R-7 First stage amplifier Rheostat, 5006 ohm R-lo
25 watt First stage amplifier 1st stage reactor Second stage amplifier 2nd stage amplifier
SRl SR2
First stage amplifier
First stage amplifier
First stage amplifier
Damping
Damping
Voltage Comparison
Voltage Detector
Voltage Detector
Voltage Detector Voltage Detector
Choke First stage reactor First stage reactor Damping transformer
Rheostat 5000 ohm 25 watt
Capacitor, .5mfd
Part Dwg.
Fgmbl
R4
c3
CR3
SRI
R13
L-l
SRl
SRl T3
R9
c4
Transformer
Capacitor, .5mfd
Diode Diode
TlA, B. C
CIA, B, C
CRlA, B, C CRBA. B, C
Failure Remedy
Resistor open Replace resistor
open or Rep1 ace shorted capacl tor one diode open Replace or shorted diode Winding l-2.3-4 Replace or 7-8 open reactor Rheostat open Replace
rheostat
Choke coil open Replace choke Resistor open Replace resistor Rheostat open Replace
rheostat Coil 5-6 shorted Replace reactor eoll 7-8 open P&place reactor or shorted
Choke coil shorted Replace choke Coil 9-10 open or shorted CoiI 7-6 shorted Either winding open or shorted Rheas tat open o,r set wrong
Capacitor open
Any coil shorted or open Capacitor s horted Shorted diode Shorted diode
Replace reactor &pIace reactor Replace transformer RepIace rheo- stat or ad- just rheostat to proper value. Replace capacitor
Replace transformer Replace capacitor Replace diode Replace diode
TROUBLE CHART
Smpton Circuit Part Name
Line Drop Line Compensation Current transformer compensation not as much ,Line Compensation Choke as should Line Compensation Rheostat, 250 ohm be Triple tandem
Line Compensation Resistor, 50 ohm 25 watt
Part Dwg. Symbol
CTI, ,3
L2A. B. C .R15
R14
~. _ _... -_
Remedy Failure
Open or shorted Replace current
coil transformer Shorted coil Replace choke Open rheostat Replace
rheostat
Resistor Replace
shorted resistor
BLOCK
DIAGRAM
REGULATOR
HOBART
F
r
LINE DROP
COWE IRA- H
AMPLIFIER
AMPiiFlER
EXCITER ,
6
1
TION
I
r- #
L
0
FIELD '-I-
,-
--
LEA
i2/i9/62
/-‘Group .
and Index No.
1
2.
4"
5
. . 6 . 7
B 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
. 28
29 30 31 32 33
Part Number
I
43029j 430187 430297 icz-62 400034, 400035 Fd-1507 lCZ-228 lCZ-229 lCZ-93B . 16DA-4372-2 w-go26-g w-go26-13 w-go26-5 lCZ-186 lCZ-94A 400258-l 400033 1cz-63 ICZ-60 430191 lCZ-35B 401563-3 401564-3 1cz-156 \J-9746-2 lCZ-74 401563-2 401564-2 lCZ-134A lCZ-132 430222 430223 401564-2 401563-2 lcz-64 1cZ-63
PAFiTS LIST'
J+3=93
NOMENCLATURE Units
Per 12394567 a Assembly
Static Voltage Regulator Assembly
Regulator Assembly - Voltage, static ...................... 1 , Cabinet - Regulator . ......... ..*.*.w**~d..* ............. 1
. Amplifier Assembly - First stage ........................ 1
.. Reactor - First stage ........................ ..*o*.*. . 1
.. Holder - Tube ......................................... 1
.. Cover - Tube ........................................... 1'
.. Grommet - Rubber ...................................... 2
.. Board Assembly - Terminal, first stage ................ 1
... Board - Terminal . .*.****i*.**..; ....................
... Diode - Silicon, .75A, 4OOV, PIV .................... t
... Capacitor - .5!QIJ, 4OOV .............................. 2 .
.... Resistor L 3000 ohm, 10 watt ........................ 1'
... Resistor - 5000 ohm, 10 watt ........................ i
... Resistor - 1750 ohm, 10 watt ........................ 1
... Capacitor ........................................... 1.
... Diode - Silicon, .75A, Goov, PiV .................... 4
... Capacitor - 5MFD, 250WDC ............................. 1
.. Tube .................................................. 1.
.. Choke - Filter ........................................ 1
.. Transformer - Damping ................................. 1
... Chassis - First stage ................................. 1' Plate - Insulator
. . . ..................................... 1
.. Housing - Pin connector ............................... 1
.. Housing - Socket connector t .. .......................... 1
.. Insulator .................................. ..s****k ... 1
.. Resistor - 750 ohm, 25 watt . ..*., ...................... 1
.. Insulator ............................................. 1
.. Housing - Pin connector ...................... ..***A.* . 1 .
.. Housing - Socket connector ............................ 1'
. Reactor - Regulator, 300VA .............................. 1
. Transformer - Power, 300VA .............................. 1
. Chassis Assembly - Sensing, high phase ..; ............... 1
.. Chassis - High phase sensing .......................... 1
.. Housing - Socket connector ............................ 1
.. Housing - Pin connector ........... ..**e.****i** ....... 1
.. Transformer - tiiGh phase ..............................
. . Choke - High phase filter .............................
.
. , ’ i
1.
‘.
Group and Index No.
430224 34 lCZ-94A 35 lcz-93B 36 430182
37 16DA-4372-.2
38 w-go26-13 > 39
40 I 41
---.m--w--
-m-----e-
430183 m-226 lCZ-102 W-97'12-31 w-9712-29 lCZ-152 lCZ-75 lCZ-97 402680-20 . lCZ-70 W-9746-1 lCZ-129 < lCZ-128 w-11597 lCZ-105 lcz-98 16DA-1997-4 w-11535 W-11534 160A-1997-3 lCZ-101 . lCZ-74 w-9026-g 400032 16DA-2016-4 w-2974L w-11434 w-11166-1
’ 42. 43 44 45 46 47 48
49
;i!
. 52
;;
- 2: 64
65 66
67
,Part Number
c
,PARTS LlST
430293
~NOMENCLATURE
12'3 4 567
Units
per Assembly
Static Voltage Regulator Assembly .(Cont'd)
.
.
.
.
.
. . .
.
.
.
.
.
.
.
.
. l
.
.
a*
.
;
.
.
�.
.
.
.
.
.
.
.
.
.
.
.
. Board Assembly - Righ phase sensing ................... 1
. . Diode - Silicon, bOOV, PIV (marked ii!) ............... 6
. . Diode - Silicon, 4OOV, .PIV .... ..- .................... 16
.. Board - Pin .........................................
. . Capacitor,- .5HFD, 400V ............................. t
............................ Resistor - 5000 ohm', 10 watt 4
. . Sleeving - Temflex, 105'C, size 15 .................. 10"
. . Wire - Solid, copper, tinned, #20 ................... 14"
. Insulator - Board ..................................... 1 Panel Assembly - Control, regulator ... .................. 1, ; Panel - Control ....................................... 1' .. Rheostat - 5000 ohm, 25 watt .......................... 2
. Rheostat - .750'0hm, 25! watt .*.......................i. 1
. Nameplate ............................................. 1
. Nameplate - Terminal Strip ............................ 1
. Reactor - Line drop compensation ...................... 3
. Strip.,- Terminal ...................................... 1
. Switch - Line drop compensation, on-off ............... 1
. Resistor - 50 ohm, 25 watt ............................ 3
. Insulator . Resistor .................................. 1
.'Rheostat . 250 ohm, 25 watt, triple tandem ............ 1
. knob - Pointer ........................................ 2
. Rheostat . lo-ohm, 25 watt, triple tamdem ............. 1
. Nameplate - Line Compensation ......................... 1
. Button . Plug ......................................... 3
. Terminal - Fanning strip .............................. 1
. Clamp . Cable ......................................... 1
. Button- -Plug *...* ..................................... 1
.. Nameplate ,- Adjust .................................... 1.
. Insulator - Epoxy mica .012 ........................... 3
. Resistor - 3000 ohm, 10 watt .......................... 1
. Bracket - Mounting, resistor .......................... 2 Relay ................................................... 1
Resistor . 50 ohm, 100 watt ............................. 2
Base . Fuse ............................................. 1
Fuse .................................................... 1
’ i
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