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OM-433021784 – Original051094 – Revision

Operation and Maintenance Manual with

Illustrated Parts Listfor

Transformer-Rectifier

28.5 Volts DC, 1500 Amperes

Model TR-1528

Series 487750

ITW GSE GroupHobart Ground Power

Troy, Ohio 45373U.S.A.

OM-433 / Operation and Maintenance ManualTR-1528/ Series 487750/ 28.5 VDC Transformer-Rectifier

February 17, 1984 Safety WarningsPage 1

S A F E T Y IN S T R U C TI O N S A N D W A R NIN G S F O R E L E C T R IC A L P O W E R E Q U IP M E N T

WARNING

E L EC T R IC SH O C K can K IL L. Do not touch live electrical par ts.

E L EC T R IC A R C F LA S H can inj ure eyes, burn skin, cause equipment damage, and i gni te combus ti blematerial . D O N O T use power cabl es to break l oad and prevent tools from causing shor t cir cui ts.

I M P R O P E R P H A S E C O N N E C TI O N , P A R A L L E LIN G , O R U S E can damag e thi s and attachedequi pment.

Important: - Protec t a l l operatin g pers o nnel . R e a d, u nders tand, and f ollo w al l instr u cti o ns in theO perating/ I nstructi o n Manua l b e fore instal l ing, operati n g, or servic in g t he equipment . K e e p them a nual avai lable for future use by al l ope rator s.

A G E N E R A L

Equi pment that suppli es el ectrical power can cause ser ious inj ury or death, or dama ge to other equipment orproperty. The operator must strictly observe all safety rul es and take prec auti onary acti ons. Safe practi ceshave bee n develope d from past experience in the use of power source equipm ent. Whil e certai n practicesbel ow apply onl y to electri cally power ed equi pment, other practices apply to engine-driven eq ui p ment, and someprac tices to both.

B SH O C K PR E V E N TI O N

Bare conductors, or termi nals i n the output circuit, or unground ed, electri cally live equipme nt can fatallyshock a person. Have a cer tifi ed el ectrician verify that the equipm ent i s adequately groun ded and l earn whatterminal s and parts are el ectricall y H O T. Avoid hot spots on machi ne. Use proper safety cl othi ng,procedures, and test equipme nt.

The electri cal resis tance of the body is decreased when wet, permi tti ng dangerous curr ents to fl owthrough i t. When i nspecti ng or servicing equipment, do not work in damp areas. Stand on a dry rubber mat ordry wood, use insul ati ng gloves when dampness or sweat cannot be avoided. Keep clothi ng dry, and neverwork al one

1. Installatio n and Gr o u n din g of Electrical ly Po w ere d Eq u i p m e nt

Equi pment driven by elec tric motors (rather than by di esel or gasoli ne engi nes) must be ins talled andmaintai ned in accordance wi th the Nati onal Electrical Code, ANS I/NFPA 70, or other applicable codes . Apower disconn ec t swi tch or circui t breaker must be l ocated at the equipme nt. Check the na mepl ate forvoltage, frequency, and phase requi reme nts. If onl y 3-phase power is avail abl e, connect any singl e-phaserated equipm ent to onl y two wires of the 3-phase li ne. D O N O T C O N N E C T the equipme nt groundingconductor (lead) to the third live wire of the 3-phase li ne, as this makes the equipme nt frame electri callyH O T, which can cause a fatal shock.

Always connect the grounding l ead, i f suppli ed i n a power li ne cabl e, to the grounded switch box orbuildi ng ground. If not provi ded, use a separate groundi ng lead. Ensure that the cur rent (amperage)capacity of the groundi ng lead will be adequate for the worst faul t current si tuati on. Refer to the NationalElectrical Code ANSI/NFPA 70 for details. Do not remove plug groun d prongs. Use correctly matingreceptacles.



2. Output Cables a n d Ter mi nals

Inspect cabl es freque ntl y for damage to the i nsul ati on and the connectors. Repl ace or repai r crackedor worn cabl es imm edi ately. Do not overload cabl es. Do not touch output termi nal while equi pment isenergized.

3. Service an d Mai ntenance

Thi s equi pment must be mai ntained in good electri cal and mechanical condi ti on to avoi d hazardsstemmi ng fro m dis repai r. Report any equi pment defect or safety hazard to the supervi sor and disconti nueuse of the equi pment until its safety has been assured. Repairs should be ma de by qualifi ed personnelonl y.

Before i nspecti ng or servi ci ng electrically power ed equi p ment, take the following precauti ons:

a. Shut O F F all power at the disc onnec ti ng swi tch or l ine breaker before i nspecti ng or servicing theequi pment.

b. Lock s wi tch O P E N (or remove line fuses) so that power cannot be turned on accidentally.c. Disc onnect power to equi pment i f it is out of servic e.d. If troubles hooti ng must be done with the unit energi zed, have another person present who

is trai ned in turning off the equi pme nt and providi ng or cal l ing for firs t ai d.

A FIR E A N D E X P L O SI O N P R E V E N TIO N

Fire and expl osion are caused by el ect rical short ci rcui ts, co mbusti ble materi al near engi ne exhaustpipi ng, misuse of batter ies and fuel , or unsafe operati ng or fuel ing conditi ons.

1. Electric al S h ort C ircui ts an d Ov erloa ds

Overl oaded or shor ted equi pment can become hot enough to cause fires by sel f-destructi on or bycausing nearby com bus ti bles to i gni te. For elec trically powered equip ment, provide pr imary i nputprotec ti on to remove short ci rcui ted or heavily overl oaded equi pment from the li ne.

2. Ba tt eries

Batteri es may expl ode and/or give off fl ammable hydrogen gas. Acid and arcing from a rupturedbattery can cause fires and additi onal failur es. When servici ng, do not smoke, cause sparki ng, or use openflame near the battery.

3. E ngine F uel

Use onl y approved fuel container or fueling sys tem. Fires and explosions can occur if the fuel tank isnot grounded pri or to or during fuel transfer . Shut uni t D O W N before removi ng fuel tank cap. D O N O Tcompletel y fill tank, bec ause heat from the equip ment may cause fuel expansi on overfl ow. Remove allspilled fuel IM M E D IA T E L Y , i ncludi ng any that penetrates the unit. After clean-up, open equipm ent doorsand bl ow fumes aw ay wi th compressed air.

D. T O XIC FU M E P R E V E N T I ON

Carbon mon oxide - Engine exhaust fumes can kill and cause health problems. Pipe or vent the exhaustfumes to a suitabl e exhaust duct or outdoors. Never l ocate engine exhausts near i ntake ducts of ai rcondi ti oners.



E. B OD I L Y IN J U R Y P R E V E N TI ON

Serious i njury can res ult from contact wi th fans i nsi de some equipme nt. Shut D O W N such equipment forinspecti on and routi ne maintenance. When equi pment i s in operati on, use extreme care i n doi ng necessarytroubl e-shooti ng and adjustme nt. Do not remove guards whil e equipm ent i s operati ng.

F. M E D IC A L A N D F I R S T A ID T R E A T M E N T

First aid faciliti es and a qualifi ed first aid person should be avail abl e for each shi ft for immedi ate treatment ofall inj ury victims. El ec tric shock victims should be checked by a physici an and taken to a hospital imm edi ately i fany abnormal signs are observed.

EMERGENCY FIRST AIDCal l p h y s i c i a n immedia te ly . Seek addi t ional assista n c e . U se Firs t Aid tec h n i q u e s

rec o m m e n d e d by America n R e d C ros s until medical hel p arrives.

IF B R E A T H IN G IS D I F FICULT , give oxy g e n , i f avai lable, a n d h ave vic ti m l ie d o w n. F O R E L E C T R I C A LSH O C K , tur n off p o wer. R emov e vic tim; i f n o t breathin g, b e gin artificial res pirat ion, preferably mouth- to -m o u t h. I f n o dete ctable puls e, be g i n exter nal hear t ma ss a ge. C A L L E M E R G E N C Y R E S C U E S Q U A DI M M E D I A T E L Y .

G. E Q U IP M E N T PR E C A U TI O N A R Y L A B E L S

Inspect all precauti onary l abels on the equi pment m onthl y. Order and i nspect all label s that cannot beeasily read.



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Apil 20, 1989Revised

IntroductionPage 1

INTRODUCTION

1. Scope

Thi s manual contai ns information and instructi ons for a 28.5-V DC Transformer-Recti fi er, manufacturedby Hobart Brothers Co mpa ny, Power Systems Group, Troy, Ohio 4537 3, U.S.A.

2. Purpose

The manual’ s pur pose i s to provide i nformation and inst ructi ons to experi enced operators, el ectrici ans,and mechanics who have never seen or operated this machine. The man ual is not i ntende d to be atextbook on el ec tricity , nor el ectronics.

3. Contents

The manual is di vi ded into 3 chapters. Each chapter is di vi ded into as many secti ons as required.Each new secti on begi ns wi th page 1, and each page is i dentifi ed by chapter, secti on and pag enumber, loc ated in the l ower outsi de cor ner . Illustrati on nu mbering is also grouped by secti ons.

When a reference i s made to materi al which is l ocated in the same secti on, the materi al is i denti fi ed byparagraph locati on only; example: (Para.1, A). When referenced materi al appe ars in a di fferent secti on, itis identi fi ed by chapter , secti on and paragraph locati on; exa mple: (2- 1, Para. 1, A). The same methodappl ies to illustrati ons which are i dentifi ed by fi gure numbers; exampl es: (Fig. 8) , or (2-1, Fig. 8).

4. Customer Service

If you have any questions conc erning your Hobart Power Systems Group equipment, you are i nvited tocontac t our Servic e Department by mail, telephon e or FAX.

W rite: Hob art B rothe r s C o m p any

P o w e r Sy ste m s Gr o u p

Servic e D e p a rt m e n t

Troy , Ohi o 45373

U.S.A.

Cal l : A rea C o d e (513) 332-5 060

F A X : (513) 339-4219



IntroductionPage 2




Table of ContentsPage 1

Table of Contents

SUBJECT CHAPTER/SECTION PAGE

WARNING

INTRODUCTION

CHAPTER 1 DESCRIPTION/OPERATIONSECTION 1. DESCRIPTION 1-1 1

1. Ge ner al 1-1 12. Tra n s f or m er- Recti f ier Asse m bl y 1-1 1

A. Contro l P a nel Ass e m b l y 1-1 2B. Electric al C o m p o n e nts 1-1 4

(1 ) Loa d C ontactor 1-1 4(2 ) Transfor m er 1 -1 4(3) Heat Sink A ss e m b l y 1-1 4(4 ) Overl oa d m o d ule 1-1 5(5 ) Overvo l tage m o dule 1-1 5(6) Base 1-1 5

SECTION 2. PREPARATION FOR USE 1-2 11. Ge ner al 1-2 12. Inspec tion 1-2 13. Installatio n 1-2 1

A. Genera l 1-2 1B . M o u ntin g 1-2 1C. C o n n e c t i o n 1-2 2

(1) In p u t 1-2 2(2) Output 1-2 3

CHAPTER 2 SERVICINGSECTION 1. MAINTENANCE 2-1 1

1. Ge ner al 2-1 12. Lubr ica tio n 2-1 13. Inspec tio n 2-1 14. C lean ing 2-1 2





SECTION 2. ADJUSTMENT/TEST 2-2 11. Ge ner al 2-2 12. Test 2-2 1

A. Pre par a tio n fo r T est 2-2 1B. O per a ti o nal Te s t Pro ce dure 2-2 1(C ) Tes t Si l icon D io des 2-2 3

3. A dj ustm e n t 2-2 4A . Line -Drop C o m pensat io n 2-2 4B. A m m e ter S hunt 2-2 4C . R a n g e o f C ur r e nt Li miti n g Rheosta t 2 -2 5

SECTION 3. TROUBLESHOOTING 2-3 11. Ge ner al 2-3 12. Tr o ubleshootin g C har t 2 -3 1

A. Descri p tio n 2-3 1B . H o w t o U se Troubleshoot i n g C hart 2 -3 1

3. Eq u ipm e nt for Trouble s h o o tin g 2-3 14. Safe t y 2 -3 15. Parts R e p l a ce m e nt 2-3 26. C he ck C o n n ecti o ns an d L ea ds 2-3 27. Schemat ic Diagra m 2-3 2

SECTION 4. REPAIR 2-4 11. Ge ner al 2-4 12. R e m o v al a n d Ins tal lat i o n 2-4 1

A. R e m o v a l Pro c e d ur es 2-4 1B. I nstallatio n P r o c e dure s 2-4 1

3. Parts R e p l a ce m e nt 2-4 2A. Acce s s 2-4 2B. Part s R e m o val 2-4 2

(1) Modules 2-4 2(2) Miscel laneous par ts 2 -4 2

C. Part s Ins ta l la t ion 2-4 2D . Fa n Instal la tio n 2-4 2

4. W ork m a n s h i p 2-4 25. C o n n e c t i o n D i a gra m s 2-4 2





CHAPTER 3 ILLUSTRATED PARTS LIST

SECTION 1. INTRODUCTION 3-1 11. Ge ner al 3-1 12. Purpos e 3-1 13. A rrang e m e nt 3-1 14. Ex planati o n o f Pa rts Lis t 3-1 1

A. Contents 3-1 1B . Parts List For m 3-1 1

SECTION 2. MANUFACTURER’S CODES 3-2 11. Expla na t ion of Manufa c turer’s ( V e n d or) Code List 3-2 1

SECTION 3. PARTS LIST 3-3 11. Ex planati o n o f Pa rts Lis t A rra nge m e nt 3-3 1

SECTION 4. NUMERICAL INDEX 3-4 11. Ex planati o n o f N u m erical In de x 3-4 1

UNUSUALSERVICE CONDITIONS



Description 1-1Page 1

CHAPTER 1 DESCRIPTION/OPERATION

SECTION 1. DESCRIPTION

1. General

The Transformer-Recti fi er, hereafter referred to as a T-R, is a compact, enclosed, power -supply unitempl oyi ng a transformer and semiconductor di ode compon ents to conver t 200-Vol t, 400-Hz input to28.5-Vol t DC output power (see Figure 1). It has many uses including aircraft servicing, which mayrequire hi gh current output for short periods of time, and constant duty power supply appli cati onswhich require a regulated vol tage output at a lesser cur rent rate.

2. Transformer-Rectifier Assembly

The T-R consists of six main assembli es plus side panels and top, which make up the weatherproofenclosur e. Termi nal boards, cabl es, and other misc ell aneous items complete the assembly. Mainassem blies are i dentifi ed as foll ows:

Tra nsformer

Pa ne l Front

B a s e

T o p Heat Sink

C over Ter m i nal

For purposes of orientati on, the control panel is consi dered to be at the F R O N T of the T-R. The l oadcontactor is at the front and the fans are at the R E A R . R IG H T and L E F T are determined by observingthe uni t from a positi on at the R E A R . Thus the output terminal s are on the LE F T si de.

The T-R is desi gned to convert the output of a 115/200-Vol t AC, 400-Hz, 3-phase gen erator toregulated 28.5-Vol t DC, primaril y for operation and/or testing of aircraft on-board elect rical equipment.AC i nput vol tage is reduced by a transformer assembly and chan ged to DC by a 24-di ode rectifi eridenti fi ed as a heat sink assembly . The uni t rati ng is 1500 Amperes. Refer to Figure 2 forspecificati ons and capabiliti es.

Output voltage is adj ustable and controll ed by a soli d-state, li ne- drop and current-limiti ng m odule.Output current i s also adjus table, and i s control led by the sam e modul e, howev er these capabiliti es arepossi ble only whe n the T-R is connec ted to a Hobart generator set. The l atter capa bi l i ty all ows theoperator to adjust output current to as littl e as 700 Amperes when required for soft-starting an aircraft ,or other limited current applicati ons.

Soli d state current and voltage sensing modules serv e to protect the T-R and aircraft by disconnecti ngthe load under condi ti ons of overload and/or undervoltage. Thermostati c s wi tches provide protecti onagai ns t over heati ng. Two 200-Vol t AC, motor-driven fans provide cooli ng for i nternal compo nents.Air is drawn in over the heat si nks and discharged at the rear.




Transformer-Rectifier (28.5-V DC)

Figure 1

A. Contro l P a nel Ass embly

Refer to Figure 3. The control panel (14) serves a dual functi on. It provides a mo unting panel forinst ruments and controls, and when hinged downwar d, serves as a door for access to i nter nalcomponents. Four screws (1) sec ure the panel i n closed posi ti on. Louvers (2) on each side of thepanel admi t air to the fans. An ins trum ent li ght (4), control led by a toggle s witch (12), providesilluminati on for controls and instrume nts. DC power for operati on of the l ight is suppli ed by thegenerator set engi ne circui t thr ough a 2-Ampere fuse (10) . A three-positi on toggl e s witch (8)controls operati on of a l oad contactor in the i nput circuit. The s wi tch i s spri ng l oaded in the top O Nor s tart positi on.

An indicati ng li ght (7) gl ows green when the l oad contactor is cl osed to i ndi cate that 28.5 VoltsDC is avai lable at the output termi nals . A fuse (11) protects the 115-Vol t A C load contactoroperati ng circuit.

Max imum output current may be adj usted from 700 Amper es to 1500 Amperes by a rheostat (5).A toggle switch (9) controls operati on of the rheostat, whi ch is functi onal onl y when the s wi tch isin O N positi on. Vol tage and current i n the output circui t is indicated by a DC voltmeter (3) and aDC ammeter (6).




TRANSFORMER-RECTIFIER

Part Number 487750

Model Number TR-1528

PHYSICAL

Overall dimensions

Le ngt h 34 inche s (864 m m )Widt h 20 3/8 inc he s (518 m m )Height 13 1/8 inc hes ( 3 3 3 m m )Mount in g di m e n s i o ns 24-1/8 X 16 inche s (613 X 406 m m )

center t o cent er . Four 3/8-16 in c ht a p pe d mount ing h o l e s

W eight approximate ly 300 p o u n d s (136 kg) |

ELECTRICAL

Input

Li ne volts 200 Volts A CC ycles per s e c o n d 400 H zAmpere s 136 A m p eresKi lowat ts 50 k W

Output

V olts 28.5 Vol ts D C L o a d Rat ing 1500 A m p e resM a xi m u m o u t put rat ing 2000 A m p e r e s fo r 5 minutes, 2500

A mpe re s for 30 secondsCurrent l imit ing (Soft-Start C apabi li ty ) 1500 Amperes to 700 A m p e r es

mi ni m u mKi lowat ts (steady state load ) 42 k W

Recommende d output cable size for normal aircraft servicin g is 4/ 0.

Specifications and Capabilities

Figure 2




Other items are mou nted on the i nner surface of the control panel and are not visibl e unless thepanel is opened. A resis tor (15) is conn ected in the l oad contactor holdi ng circui t to limi t currentfl ow to approximately 0.5 Amper e. Another resistor (16) provides a mea ns of adj usti ng the curr entlimiti ng rang e of the rheostat (5). A di ode-bridge recti fi er (17) provides DC pow er for operati on ofthe l oad contactor . The l ine-drop compensati on and current limiti ng mod ule (18) contai ns solidstate circuitr y which i nterprets signals from curr ent transformer s i n the A C input circuit and sends asignal to the Hobar t generator-set voltage regulator which causes it to regulate generator outputvoltage to a value whi ch will resul t i n a T-R output of 28.5 Volts DC. Under normal operati ngcondi ti ons the signal from the cur rent limi ti ng transformer does not enter the mo dule ci rcui try.When soft-star t (limi ted output current) is requi red, the current limiti ng signal is allowed to enter themod ule by placing the control swi tch (9) i n the O N positi on. The signal to the voltage regulator isthen control led by the current limiti ng rheos tat (5) so that the regul ator l imits generator output to aval ue which will produce no more current i n the T-R output than that sel ected by the curr entlimiti ng rheostat.

B. Electric al C o m p o n e nts

Electrical compo nents of the T-R, other than the control panel which was described above, areillustrated i n Figures 4 through 6. A brief description of the function of each component i s givenhere. Theory of operation will be covered in the description where necessary.

(1) Loa d C ontactor

The load contactor (5, Fig. 4) is a sealed uni t similar to the one used on a Hob ar t generatorset. It contai ns four sets of contacts and an operati ng coil. The three larger sets of contactsconduct the i nput pow er to the trans former. A small , auxiliary set is connected in the 115-Vol tinput holdi ng circui t to the rec tifi er (17, Fig. 3), which suppli es direc t current for energizati on ofthe l oad contactor operati ng coil . In operati on, the l oad contactor is clos ed by holdi ng thecontac tor control s witch (8, Fig. 3) in spri ng-loaded O N (up) positi on mo mentarily . In thispositi on the s witch connec ts 115-Volt AC power direc tly to the recti fi er (17, Fig. 3) , which i nturn suppli es DC power to the contactor operati ng coil and cl oses all contacts i n the l oadcontactor. When the control s witch (8, Fig. 3) is rel eased, it auto maticall y returns to center ONpositi on and 115-Vol t current is mai ntai ned to the rec tifier , i ndirec tly , throug h a resistor (15,Fig. 3) and the auxili ary contacts i n the l oad contac tor. Thi s cir cui t is arrang ed in such aman ner that i n case an overloaded conditi on devel ops , the 115-Volt i nput to the recti fi er is leaddirectly to ground through a rel ay in the over load mo dule. The load contactor is thus opene dbecause the holdi ng circui t has ac tually been shor t-circui ted. The resis tor (15, Fig. 3) limitscurrent fl ow in the holdi ng circui t to 0.5 Ampere and thus prev ents damage to anycompo nents.

(2) Transformer

The primary coils of the transformer (6, Fig. 4) consi st of three sets of doubl e windi ngs. Thereare 12 secondary windi ngs, 6 connected in wy e, and 6 conn ected in del ta . Normal i nputvoltage is 200 Vol ts A C and normal output before being rectifi ed is approximately 21 Vol ts DC.Output vol tage of the transformer (and the T-R) is determined and control led by adj usti nginput voltage to the transformer.

(3) Heat S ink Assembly

The heat sink assembly consists of two heat sink subassembli es (2 and 7, Fig. 4) mounte don two cross me mber supports and attached by brackets and Hx Hd SF-Tap scr ews.Observed from the rear of the T-R, the positive heat sink is on the RIG H T and the negati veon the L E FT.




Each heat si nk subassembly consists of a fan, a thermostatic switch, 12 diodes, and the heat sinkwhich i s a secti on of multi - fi nned, al uminu m extrusion, 25 i nches (635 mm) l ong. The fan assembl y(10, Fi g. 4) is mounted on the rear of the heat si nk. A five-bl ade, 4-1/4-i nch (108 mm) di a. fan drawscool ing ai r over the di odes at a rate of 190 cubic feet per minute at 5300 RPM. The fan motor is ratedat 200 Vol ts AC, 400 Hz. Input power is 33 Watts, 0.3 Ampere. The thermostatic switch (1, Fig. 4)mounted on the front end of the heat sink, performs a functi on simil ar to an overload rel ay. The s witchcauses the l oad contactor to OPEN by i nterrupti ng the contac tor hol ding circui t when an overl oad (orother faul t) condi ti on causes am bi ent temper ature to rise to approximately 230 Deg. F (110 Deg. C) .The swi tch cl oses at approximatel y 210 Deg. F (99 Deg. C).

Two hexagon bars (11, Fi g. 6), threaded at each end, serve as bus bars to conduct current fro m thepositive ( ri ght) heat si nk to the positi ve terminal on the l eft si de of the T-R. The bars pass throughholes i n the negati ve heat sink and are protected from shor ti ng by scr ew-mounted, i nsulati ng pl ates.Bars are threaded into the positi ve heat sink body and further secur ed by alumi nu m nuts. Twoalumi num nuts on the l eft end of the forward bar are used to attach one of the l eads to the DCammeter. The other ammeter l ead is attached to the same bar on the other side of the negati ve heatsink by a screw. The porti on of the bar betwe en the l ead attac hi ng poi nts serv es as a shunt for theammeter. The shunt is adjustable by chan gi ng the l ocati on of the two alu mi nu m nuts.

Two hexagon bars (4, Fig. 6) similar to the positi ve bars, but shorter , are attached to the negati ve heatsink i n the same mann er as the positive bars. They conduct curr ent to the neg ati ve output terminal .Each diode i s attached to the heat si nk by an assembled washer nut.

(4) Over load module

The over load mod ule (20, Fig. 3) contai ns soli d state circuitry which i nterprets signals from threecurrent transformers (11, Fig. 4) and func ti ons to close a rel ay whe n an over-load conditi on i sdetec ted in the T-R m ain circuit. The normally open rel ay contac ts are connec ted to the l oadcontactor 115-Volt AC holdi ng circui t so that whe n relay contac ts are closed by an over load condi ti on,the l oad contactor holdi ng circuit i s short -circuited and the l oad contactor opens for l ack of hol dingpower. T-R output power is thus automatically disconn ected. Rel ay contacts return to normally openpositi on when the overload is r emoved by l oad contactor holdi ng circui t when it is short-circuited. DCpower fro m the generator’s engine circuit provides operati ng power for the overload rel ay: 12 VoltsDC is required for par t numb er 487750-1. Thi s circui t is protec ted by a 2-Ampere fuse (10). The l oadcontac tor 11-Vol t operati ng ci rcui t is protected by another 2-Ampere fuse (11).

(5) Overvol tage module

The overvol tage m odule (19, Fig. 3) is another protective device wi th solid s tate circuitry which causesa normally C L OS E D relay to O P E N under a condi ti on of overvoltage in the T-R output circui t. Therel ay is connected in the ground circui t of the 115-Vol t A C load contac tor holdi ng circui t. When anovervoltage conditi on causes the relay to OPE N , the l oad contac tor holdi ng circuit i s broken and thecontac tor opens automaticall y to shut off the T-R.

(6) Base

The T-R base consis ts of a metal pl ate m ounted on (4) spac ers. Four 3/8-16 tapp ed mounti ng hol esin the base (spacers) are l ocated 16 inches by 24-1/8 i nches (406mm by 613mm), center to center.




1. Screw2. Air inlet louver3. DC voltmeter4. Instrument light5. Current limiting rheostat6. DC ammeter7. Contactor CLOSED indicating light8. Contactor control switch9. Current limiting control switch10. Fuse (2A) (DC circuit)

11. Fuse (2A) (115-V AC circuit)12. Light Switch13. Hinge14. Panel15. Resistor (200 Ohm, 25 Watt)16. Resistor (100 Ohm, 100 Watt)17. Rectifier, silicon18. Line-drop compensation and current limiting module19. Board, overvoltage20. Board, PC overload

Control Panel AssemblyFigure 3




1. Thermal overload relay2. Negative heat sink3. Output terminals4. Transformer current limiting5. Load contactor6. Transformer

7. Positive heat sink8. Diode leads9. Bus bars10. Fan11. Overload current transformer12. Line drop CT

T-R Components (Front and Rear Views)Figure 3




1. Thermal overload relay2. Negative heat sink3. Positive output terminals4. Negative output terminals5. Negative diode6. Fan

7. Current limiting transformer8. Overload current transformer9. Load contactor10. Positive heat sink11. Positive diode

T-R Components (Side Views)Figure 5




1. Fan2. Load contactor3. Negative heat sink4. Negative output bus5. Positive output bus6. Ammeter shunt7. Contactor

8. Control panel9. Thermal overload relay10. Overvoltage module11. Positive heat sink12. Current transformer13. Bracket resistors14. Current transformer

T-R Components (Top View From Front)Figure 5



Preparation 1-2Page 1

SECTION 2. PREPARATION FOR USE

1. General

The T-R requires no speci al preparati on for use, other than inspecti on; mou nting, as required; and/orconnecti on, as required.

2. Inspection

A. Inspect exterior for shippi ng da mage such as broken l ights or instrument l enses, dam agedsheet metal , etc.

B. Open the front control panel and rear access panel by loosening screw-type fasteners.

C. Inspect i nteri or for forei gn material s such as rags, shi pping papers , etc.

3. Installation

A. Ge neral

When the T-R i s suppl ied as part of a generator set, it is properl y mounte d and conn ec ted.

B. M o u nti n g

T-R mounting suppor ts, com plete with hardwar e, are avail abl e i n kit form from Hobart BrothersCo mpa ny at a nomi nal cost. These kits provide T-R mou nti ng arrange m ents for truck or trail ermo unted generators as well as self-propel led. If the rec omme nded kit is not to be used, proceedas fol lows:

(1) Sel ect a l ocati on i n which the T-R package will not i nterfere wi th service and mai ntenanceoperati ons required for the vehi cle, or generator set on which it is mounted. Many Hobar tself-propell ed generator sets provide a mou nti ng space on the right side of the driverscompartment; on rear fenders, or behi nd the dri vers com partme nt.

(2) Mou nt the T-R so that the front panel is easily vi sibl e and accessibl e for adj ustm ent. A cl eararea at both front and rear shoul d be provided so that access panels may be opened fully andeasily.

(3) Provide mounting holes i n solid material to accomodate 3/8 in.-16 screws, and locate the m24-1/8 inc hes by 16 inches (613mm by 406mm), center to center. The 24-1/8 inc h (613mm)dime nsi on i s lengthwise of the T-R. Al so provide for air fl ow to trans former coils through the42 slots i n the base.

(4) If mo unting is on a soli d steel plate, provi de an access hole for i nput cables to the T-R,di rectly under or near the hol e near the contactor (1-1: 7, Fi g.6).

(5) Posi ti on the T-R in i ts mou nted positi on and ali gn mou nti ng holes. A ttach with 3/8-16screws and lock washers.




C. C o n n ect ion

All units are furni shed with control l eads and a DC suppl y lead connected to an ei ght-pinconnector. The mati ng receptacl e, wi th wiri ng harness attached, i s furnished wi th the T-R mou nti ngkit descri bed in para. 3. B. above. Connect the wiri ng harness as shown on the generator set’sconnecti on diagram and pl ug i n the T-R control connector (P403 on T-R connecti on di agram).

(1) Input (4877 50-1)

As stated abov e, i nput l eads are connected when the T-R i s suppli ed as part of a generatorset. If input connecti on i s required, proceed as fol lows :

(a) Sel ect a conveni ent point i n the generator output circui t B E T W E E N the generator andthe l oad contactor for attachi ng size No. 2 cabl es to output phases A , B, and C. ManyHobart generator sets are equi pped wi th a conveni ent terminal bl ock for thi s purpos e.

(b) Me asure the distance betwee n the connecti on poi nt and the i nput termi nal board onthe T-R to determi ne length of cable requi red.

(c) Fabricate cables wi th terminati ons. Route cabl es through the bottom of the T-R andconnect to contactor (1-1; 5, Figure 4) . Input terminals are not i dentifi ed A ,B, and C oncontactor. Viewing the T-R from the front panel , the “A” terminal of the contactor is at thetop, “B” is the middle termi nal and “C” is the bot tom terminal. The fans will not functi onproper ly unless “A” phase is connected to termi nal “A” etc. Conn ect i nput l ead fromphase A to terminal A, B to B, etc. A l arge neutral N l ead is not required; however, a No.10 wire shoul d be connected from the generator N terminal (or l ead) to the ground studon the T-R base (See Connecti on Diagram). The blac k lead in the T-R with a plasti ccovered terminal must also be connected to the groun d stud. Verify that the fans areblowi ng ai r out the exhaust ports of the T-R on the back si de.

NOTE : When the TR (487750-1) is instal led by the cus tomer, it is necessary to removejumper l ead on termi nal strip i n generator vol tage regulator. Follow inst ructi ons on platelocated near termi nal s trip. Refer to Generator Set Manu al .

Input Connect ion D iagram

Figure 1



(2) O utput

T-R output cables are not normally suppli ed unless specifically ordered. For normalaircraft servi ce, use 4/0 size cable for positive and negative (see Figur e 2) . For otherapplicati ons where lar ge l oads are i nvolved, i t is reco mmended that two, or even three4/0 cables are used.

Output Cable Insta l la t ionFigure 2



Operation 1-3Page 1

SECTION 3. OPERATION

1. Preparation for DC Power Delivery

Start, and prepare the generator set for power deli very the same as for 400-Hz use. If it is necessary tosupply both 28.5-Vol t DC and 400-Hz power at the same time, refer to Para. 4 bel ow.

2. DC Power Delivery

A. Connect DC output cable pl ug connector to aircraft rec eptacle connector . Be sure goo d connecti on i smad e.

B. Operate generator-set control s, as instruc ted by the applicabl e manual , to produce 115- Vol t AC,400-Hz output.

C. If ill uminati on is required at the T-R control panel, turn i nstrument li ght (4, Fig. 1) ON with switch(12) .

D. If current-limiting is required for soft-start ing an aircraft, position control s as follows:

(1) Plac e current limiti ng control switch (9, Fi g.1) i n the ON positi on.

(2) Adjus t rheostat (5) to the star ti ng amperage recommended by the engi nemanufacturer.

E. If power delivery is to be a l oad bank, or to an applicati on where full l oad capaci ty is desired, placethe current limiti ng control switch (9) i n the O F F posi ti on. The T-R will then have a l oad capaci ty of2000 Amperes for fi ve minutes , or 2500 Amperes for 30 seconds .

F. Close the T-R load contac tor to deliver power to the output cables by mo me ntarily holdi ng thecontactor control switch (8) i n the top, O N posi ti on until the i ndicati ng l ight (7) glows. Release thes witch and allow i t ti return to center , ON positi on.

G. Apply a l oad of 1000 Amperes and observe voltmeter (3). If vol tage i s not 28.5 Vol ts DC, ope n thecontrol panel and use rheostat (1, Fig.2) l ocated on the li ne-drop and current limiti ng mo dul e (4) toadjust. Loosen locknut (2) and tur n adjusting screw C L O C K WI SE to i ncrease vol tage. TurnC O U N T E R - C LO C K WI S E to decrease vol tage. Adj ust output to 28.5 Volts DC. Ti ghten locknut andcl ose control pan el .

H. Reme mber that an overload, overvol tage, or overheati ng will cause the l oad contactor to di sconnectthe l oad and turn O F F the i ndi cati ng li ght (7, Fig. 1). If shut-down occurs, check for the condi ti on thatcaused it and reme dy it before res tarti ng the T-R.

WARNING: DO NOT DISCONNECT CABLE WHILE POWER IS ON.LETHAL ELECTRICAL SHOCK HAZARD EXISTS. ALSO, OPENINGTHE CONNECTOR UNDER LOAD CAUSES ARCING AND PITTING



Operation 1-3Page 2






Operation 1-3Page 3

3. Discontinue Power Delivery

A. Plac e contactor control switch (8, Fig. 1) in the O F F positi on.

B. Disconnec t output cabl e at aircraft.

C. Operate generator-set controls as instructed in applicabl e manual.

4. Simultaneous 28.5-Volt DC and 400-Hz AC Power Delivery

If both 28.5-Volt DC and 400-Hz A C power must be deliver ed at the same time, the fol lowing rules andprecauti ons M U S T be obs erved.

1. Rheostat2. Nut3. Screw4. Line drop and current limiting module

T-R Output Voltage AdjustmentFigure 3

A. Plac e DC current limi ti ng swi tch i n the O F F positi on. This will elimi nate the soft-star t feature ofthe T-R, but will prevent AC vol tage fro m droppi ng low enough to trip the A C load contactor.

B. Li ne-drop compe nsati on on the T-R must be R E D U C E D or turned D O W N compl etel y to preventthe AC load contac tor from being open ed by an overvol tage conditi on.

C. Readjus t AC li ne-dr op comp ens ati on on the voltage regul ator using cabl e l ength and cable si zecompens ati on rheostats so that A C voltage, as i ndi cated on the vol tmeter, does not exceed118-Vol t A C whe n the DC l oad i s 500 Amperes. (See line-drop compensation adjustmentinstructi ons i n the Generator Set Manual, Chapter 2).

If higher DC vol tage is needed, adj ust the li ne-dr op compensati on (on T-R f ront panel ) asrequi red. Observe AC vol tage whil e making thi s adjustment to make certain that it does not goT O O HI G H with DC load.



Operation 1-3Page 4

D. Duri ng simultane ous, conti nuo us operati on, l oads on ei ther cir cuit are limited onl y by thecapaciti es of the respecti ve circui ts; however, the combi ned l oads shoul d not exceed the ratedcapaci ty of the gener ator set. For exampl e, a balanced load on a 90-kVA generator set coul dbe 60-kVA, A C and 20-kW, DC.



Maintenance 2-1Page 1

CHAPTER 2. SERVICING

SECTION 1. MAINTENANCE

1. General

To make certai n the transformer-rec tifier i s ready for operation at all times, i t must be inspected andmaintai ned sys tematically and regularl y so that any defec ts will be di scovered and correc ted before thayresul t i n serious dam age or complete fail ure of the equipm ent.

2. Lubrication

The T-R requires no lubricati on.

3. Inspection

A periodic i nspecti on schedule should be established and mai ntained. If the T-R i s part of a generatorset, i nspecti ons should be schedul ed to coi ncide with similar i nspecti ons for the parent machi ne. Inspectas foll ows:

A. Open the front control panel . Remove the top cover. (Rear panel and si de may be removed after thetop is removed).

B. Inspect l eads and cabl es for deteriorated or da maged ins ulati on.

C. Check all accessible termi nals and connectors for security.

D. Visually ins pect all components, termi nals, etc., for discolorati on and evidence of overheati ng causedby loose connec ti ons , etc..

E. Check both fuses loc ated on the control panel .

4. Cleaning

Use dry , compressed ai r to clean the i nterior of the T-R each time it is ins pec ted.

WARNING: STOP OPERATION IMMEDIATELY IF A SERIOUS OR POSSIBLEDANGEROUS FAULT IS DISCOVERED.

WARNING: BE SURE NO INPUT POWER CAN REACH THE T-R. LETHALELECTRICAL SHOCK HAZARD EXISTS.



Maintenance 2-1Page 2




Adjustment 2-2Page 1

SECTION 2. ADJUSTMENT/TEST

1. GeneralThi s Secti on contai ns i nformati on for testi ng and adjusti ng the T-R after major parts replacement, orrepair.

2. TestThe following tes t procedures may be used for testi ng the T-R fol lowing repai r, or for checkingperformanc e.

A. Pre par a tio n fo r T est

(1) Connect the T-R to a l oad bank using two each, si ze 4/0 cabl es from each output terminal to theload bank rather than single 4/0 cabl es ordi narily used for aircraft service.

NOTE: It is recomm ende d that thi s hi gher capacity output cable arrangement be used for applicati onswhere very lar ge loads are connec ted to the T-R.

(2) Check di ode leads. Make certai n they are not touchi ng bus bars.

(3) Make certain that each transformer bus has cl earance between windi ngs and other busi ng.

B. O pe ra ti o nal Te s t Pr oce dure

(1) Star t generator set and adj ust vol tage to 115/200 Volts AC.

(2) Operate the T-R by placing s witch (1-3; 8, Fig. 1) i n top ON positi on momentari ly, thenrelease. The green indicati ng li ght shoul d glow to i ndi cate power is avail abl e at outputterminal s.

(3) Observe the vol tmeter (3). It shoul d i ndi cate approx. 28.5-Volts DC. Attach a master vol tmeterand compare meter readi ng. Vol tmeter should be accurate to withi n plus or minus 2%.

(4) Observe operati on of fans and check directi on of rotati on. Air i ntake is at control panel end (front).Exhaus t is at (fan) end (rear). If fan rotati on i s incorrect, reverse the connecti on of any two faninput l eads.

(5) Check adj us tment of ammeter shunt.

(a) Adj ust the l oad bank to apply a l oad of E X A C T L Y 500 Amperes. Use a reliable masterammeter.

(b) Observe the T-R ammeter (1-3; 6, Fi g. 1) . A t 70 deg. F (21 deg. C) ambient temperature, theshunt should be adj usted to produce an indicated 450 Amperes on the ammeter. This rul e foradj us ti ng the shunt was sel ec ted to provide a more accurate readi ng through the enti reammeter scal e range of 0 to 250 0 Amper es.




NOTE: The alumi num bus bar, a porti on of whi ch serves as a shunt, is sensitive to both ambi enttemperature, and current-i nduced thermal changes. Thi s means that under sustained heavy loads theammeter readi ng could change considerably from the readi ng indi cated at the begi nni ng of a powerdelivery period. The ambi ent temp erature selected for a true ammeter readi ng i s 70 deg F (21 deg C). Ithas been determi ned that a temp erature change of 9 deg F (approx. 3 deg C) will change the ammeterreading 2%. An increase in temperature results in an increase in i ndicated amperage, and a decreasein temperature decreas es the amperage reading. As a rule-of-thumb for approx conversi ons, eachdegree of temp erature change resul ts i n a change of 1 ampere i n the i ndi cated amperage, whe n theload i s in the 500-Ampere range.

(c) If adjustment i s required, refer to Ammeter Shunt Adjustment, Para. 3, B.

Ammeter Shunt AmbientTemperature Deg. F / Deg. C T-R Indicated Amperes True Amperes

60 / 1670 / 2180 / 2790 / 32

100 / 38110 / 43120 / 49

440450460470480490500

500500500500500500500

Ammeter Shunt Temperature Chart

Figure 1

(6) Plac e current limiti ng control switch (1-3; 9, Fig. 1) i n the O F F positi on. Adj ust line dropcompe nsati on to minimu m (See 1-3; Fig. 2) . Loosen nut (2) and turn screw (3) fully CCW.Tighten nut.

(7) Wi th 500-Amp ere l oad, observe the generator set ammeter. Input current to the T-R should beapprox. 44 Amperes . Observe DC output voltage on T-R voltmeter . Indicated voltage shoul d beapprox . 26.5-Volts DC with l ine-dr op compensati on set to minimu m.

(8) Increase l oad to 1000 Amp eres, and adjus t the l ine-dr op compensati on (See 1-3; Fi g. 2). Loosennut (2) and turn adj usti ng screw (3) CW until 28.5-Volts DC i s i ndicated on the vol tmeter. Ti ghtennut (2).

(9) Check current limiti ng rheostat and resistor adjustm ent.

(a) Wi th current-limiti ng swi tch (1-3; 9, Fig.1) in the O F F positi on, apply a l oad of 1500Amperes to the T-R.

(b) Place current-limiti ng switch (9) in the O N posi ti on.

(c) Observe ammeter (6) whil e operati ng the rheos tat (5) . If output amper age can becontrolled through a range of 700 to 1500 Amp eres, the resis tor (16) is properly adj us ted.The poi nter which is attached to the rheostat knob is properl y adj usted i f it points to thesame amp erage val ue on the di al as that indicated on the ammeter.

(d) If output current cannot be controll ed through a range of 700 to 1500 Amp eres, or if thepoi nter i ndicates a value other than that shown on the ammeter , adjus tment is requiredrefer to Para. 3, C, for procedures.




(10) Test overvoltage mod ul e

(a) Plac e current limiti ng s wi tch (1-3; 9, Fig. 1) i n the O F F posi ti on. Operate s wi tch (8) to clos ethe load contactor . No load is required.

(b) Observe T-R output voltmeter and gradually i ncrease A C i nput voltage by adj usti ng thegenerator set voltage control rheostat.

(c) Overvol tage module should functi on to open the T-R load contactor when output vol tagereaches 32 to 34 Volts DC. Mod ul e shoul d functi on i n 2 to 10 seconds after tri p vol tage isreached.

(11) Test themal overload thermostati c s wi tches (1-1; 1, Fi g. 4) .

(a) Remove DC circuit fuse (1-1; 10, Fig. 3).

NOTE : Removi ng the fuse prevents operati on of overload modul e

(b) Appl y a 2500-Ampere l oad.

NOTE: If thi s load exceeds the capaci ty of the power suppl y (generator set), reduce the i nputvoltage to maintai n 2500-Amper e load.

(c) Thermostati c s wi tches should functi on to open the l oad contactor i n l ess than 20 seconds.

(12) Replace the DC circui t fuse and all ow T-R to cool 15 to 20 minutes, or until exhaust air is thesame te mperature as ambi ent i ntake air.

(13) Test overl oad m odule.

(a) Use a j umper l ead to short-out the thermostat s wi tches.

(b) Appl y a sustained minimum load of 2250 Amperes to the T-R. The overl oad m odule shouldfuncti on to open the l oad contactor within 5 minutes.

NOTE:

1. An output l oad of 2500 Amperes DC will cause the overload mod ule to functi on i n approx. 30seconds.

2. A line current ( input) of 182 Amperes is required to produce 8.25-Vol ts A C acros s the burdenresistors for this test.

(c) Remove the jumper lead ac ross the thermostat switches.

C A UTI ON : D O N OT M A IN TA IN 2500 - A M P E R E L OA D F O R M OR E TH A N 2 MIN U T E S . DA MA G ETO E Q U I P M E N T MAY R E S U LT.

C A UTI ON : D O N OT R U N THIS T E S T F O R M ORE T H A N 7 MIN U T E S .




C. Tes t Sil icon D io de s

(1) Disconnect di ode leads.

(2) Use a good quali ty ohmmeter (preferabl y one having a mid-scal e value of approx . 50 ohms ) tomeasure resis tance values.

(3) Zero the i nstrument on the RX 1 scale.

(4) Take and note a reading by pl acing ei ther ohmmeter l ead on the threaded end of the di odeand the other lead on the diode lead.

(5) Reverse the ohmmeter l eads on the di ode, take and note another reading.

(6) The di ode may gen erally be considered good if:

O ne r ea din g is infinite or very h igh. The ot h e r rea d i n g is extre m e l y low.

NOTE: An acceptable low ohmic val ue or range cannot be given because ohmm eter readi ngs may v arybetween meters, or even between diodes wi th the same rati ng.

3. AdjustmentA. Li ne-Drop C o m pensat ion

Adjustment procedures, which were outlined i n a previous Section, are repeated here.

(1) Apply a 1000-Ampere DC load to the T-R.

(2) Open control panel.

(3) Refer to 1-3; Fig. 2 and loosen nut (2) . Adjust screw (3) to produce a vol tmeter readi ng of 28.5-Volts DC. Turn screw CW to i ncrease voltage; C C W to decrease voltage.

(4) Tighten nut (2) when adjustment i s completed.

B. A m m e ter S hunt

No adj ustment of the shunt shoul d be requi red unl ess it has been di sassembl ed.

(1) Apply a load of exactly 500 Amperes . Use a rel iable ammeter to make cer tai n the l oad is 500Amperes.

(2) Indi cated amperage as observed on the T-R ammeter shoul d be 450 Amperes. Use chart Fig. 1,and Par a. 2, B , (5) (6) to compensate for ambient temperature.

(3) Stop all operati ons; T-R and generator set . Remove T-R top, and repos iti on adj usti ng nuts (4,Fi g. 2) to adj ust shunt. Lengthe n the shunt to i ncrease the ammeter reading. S horten the shuntto decr ease the reading. Tighten the adjusti ng nuts.

C A UTI ON : D O N OT A P P LY A M E G G E R O R A N Y H IGH P OT E N TI A L T E S T E QU I P M E N T IN A N YM A N N E R T H AT S U BJ E C T S T H E SILIC O N DIO D E S A N D OTH E R C O M P O N E N T S TO A B N O R -M A L VO LTA G E S . S IL ICON D I O D E S M U S T B E ISO L A TED O R S H OR T ED WITH E X T R E M E LYSH O R T L E A D S . S U C H T E S T S M U S T BE MA D E U N D E R T H E S U P E RVIS I ON O F A FAC TO R YRE P R ES E N TA TIV E.




(4) Star t the generator set and reapply load to check ammeter readi ng.

(5) Turn both generator set and T-R O F F and repeat step (3) if further adjustment is required.

(6) Ins tall T-R top after adj us tment i s satis fac torily compl eted.

C. Rang e of C ur r e nt Li miti n g Rheosta t

Thi s adjustment shoul d be required only if the resi stor is repl aced or i f the adjustment i s tamp eredwith.

(1) Turn all power O F F.

(2) Open the control panel and use a reliable ohmmeter to check resistance across current-limiti ng,range-adjusti ng resistor (1, Fig. 3) . Resi stance should be 40 Ohms. If not, l oosen the adjusti ngband (2) and sli de it toward the end of the resistor where the band lead i s connected, to i ncreaseresis tance. S li de the oppos ite directi on to decrease resistance. When a resistance of 40 Ohmsis indicated, tighten the band clamping screw. Clos e the control panel.

(3) Wi th current-limiti ng swi tch O F F, appl y a l oad of 1500 Amperes to the T-R.

(4) Turn current-limiti ng switch O N . Observe ammeter (1-3; 6, Fig. 1) and operate the current-limiti ngrheostat (5) throughout its compl ete range. Output current should be control lable fro m 700 to 1500Amperes.

(5) Rotate rheostat to obtai n an ammeter readi ng of 1000 Amp eres. Observe am perage i ndicated bythe rheostat knob pointer. If the poi nter does not i ndicate 100 0 Amperes, on the dial, l oos en thepoi nter attachi ng setscrew and posi ti on the poi nter to i ndicate exactly 1000 Amp eres. Tightensetscrew.

WARNING: DO NOT ADJUST WHILE THE GENERATOR IS RUNNING.LETHAL ELECTRICAL SHOCK HAZARD EXISTS.




1. Ammeter lead2. Lead attaching screw3. Ammeter shunt the portion of aluminum rod

between screw (2) and nuts (4)]

4. Adjusting Nuts5. Ammeter Lead

Ammeter Shunt AdjustmentFigure 2




1. Resistor2. Slide Band

Current-Limiting Range AdjustmentFigure 3



Troubleshooting 2-3Page 1

SECTION 3. TROUBLESHOOTING

1. General

Troubl eshooti ng i s an orderl y process of checking and elimi nati ng possible causes of trouble until theexact cause of a trouble i s found. As a rul e, the best pl ace to s tar t l ooking for the cause of a trouble in acircui t is at the sourc e of power. Continue testing and checking the circuit, s tep-by-step, i n an orderlyma nner, until the cause of the troubl e is l ocated. See the schematic and connecti on diagrams located atthe rear of this ma nual.

2. Troubleshooting ChartA. Descri p tio n

The troubl eshooti ng chart lists i nformati on und er three headi ngs:

(1) Trouble , s y m pt o n, and c onditi o n

(2) Probable c a u s e

(3) Te st, che ck, an d re m e d y

B. H o w t o U se Troubleshoot i n g C hart

Read the trouble symptoms and conditions before proceeding to causes and remedies. For example,at the begi nning of the troubl eshooti ng char t, the first trouble listed is “Transformer-Recti fi erinoperati ve. Load contactor will N O T close” . If the l oad contac tor WIL L close, then obviously this isnot your symptom and condition. Proceed to the next troubl e and sympto m directl y below untilsymptoms and conditions corresponding to your situation are found. Look to the right under “ProbableCause”, and “Test, Check, and Remedy” to fi nd vari ous thi ngs which could cause the troubl e and whatyou should do to check and reme dy them.

3. Equipment for TroubleshootingA good quality multi-scal e voltohmmeter is the onl y instrument required for troubleshooting. A t least twojumper l eads with alligator , or simil ar cli ps, will be required.

4. Safety

WARNING: EXERCISE EXTREME CARE TO AVOID CONTACT WITH H IGHVOLTAGE LEADS AND COMPONENTS. LETHAL ELECTRICAL HAZARDEXISTS.

C A UTI ON : D O N OT A P P LY A M E G G E R O R A N Y H IGH P OT E N TI A L T E S T E QU I P M E N T IN A N YM A N N E R T H AT S U BJ E C T S T H E SILIC O N DIO D E S A N D OTH E R C O M P O N E N T S TO A B N O R -M A L VO LTA GES. S IL ICON D I O D E S MU S T B E IS O L A T E D O R S H OR TE D WITHE X T R E M E LY S H OR T LE A D S . S U C H T E S T S M U S T BE MA D E U N D E R T H E S U P E RVIS I ONO F A FA C TO R Y R E PR E S EN TA TIV E.




5. Parts ReplacementTo lessen end ite m do wn time and to get a faul ty machi ne back i n servic e as qui ckly as possi bl e, theblack-box concept of parts replacement is reflected i n the troubleshooting chart. For example, if acompo nent i n the li ne-drop and current limi ti ng modul e i s defective, repl ace the compl ete m odule andreturn the defective module to the factory for repair or exchan ge.

Asse m b lies w h i c h le n d th e m selve s t o this c o nce p t are :

Line -drop an d current-l i mi ti n g m oduleO verloa d m oduleO ve r v ol ta ge m o d ule

6. Check Connections and LeadsA L W A Y S make a check of connecti ons and l eads to a comp onent suspected of bei ng faulty. Wi th theexcepti on of a few instances, we will assume that connecti ons and wiri ng have always been checked firs tand that power has not been lost as a res ul t of defective wiring or conn ec ti ons.

7. Schematic DiagramRefer to the sche mati c di agram (rear of this manual ) for the el ectri cal locati on of compo nents andtheir rel ati ons to each other.




TROUBLE, SYMPTOM ANDCONDITION

PROBABLE CAUSE TEST, CHECK, AND/ORREMEDY

A. N o input p o w e r f rom A Cpower source (generator-set)

A. C h e c k voltage a t contactor ( S e e1-1 , Fig.4, ite m 5 ). Inpu t should wil lbe 200-V A C l i n e -t o-l ine . Ch eckvol t a ge fro m line C to ground termina l st u d o n base . I f not a p pr ox .115-V AC, correc t faul t in T-Rg r o u n d circuit. (A l s o see Trouble 8 )

B. Fus e (11, Fig. 1) defect ive B. R emov e and inspect fuse.R e place i f defective.

C . D efective loa d contactorcontrol s witc h (8 , F ig. 1)

C . C h e ck volta ge a t control s w i t c htermina l (brown-red wire ) whi leh o l d i n g s w i t c h in top O N posit ion.I f vol tage is not a p pr o x. 11-V AC,replace switch .

D . D efective diode-br id g erectifier (17, Fi g.1)

D. C heck recti fier D C o utpu t vo l t ageat o u t put termi nals (blue -red wi res).H o ld co nt a c t o r c o n tr o l switc h in to pO N p o sition w hile test ing. I f volta g eis no t a pprox. 100 -V D C , replac e th erectif ier.

E. Relay in overvoltagemodule (5 , F ig. 4)defective

E. With switch held in ON posit ion,check vol tage at terminal T (brown-white wire) on overvoltage module.I f voltage is not approx.115-V AC, replace ‘overvol tagemodule .

F. Defect ive (open-circuited)thermostat ic switch (1, Fig.4)for

F. Check thermostat ic switchescontinuity. I f e i ther switch is opencircuited, replace.

1. Transformer- rectifi erin operat ive. Loa d contactor N O Tclose.

G. Load contactor coi ldefective (13, Fig. 4)

G. Check load contactor coi l resi -s tance between terminals X l andX2. (See connect ion diagram at rearof manual) . Zero resistanceindicates a short-circuit . Very high(inf inite) resistance indicates anopen c i rcui t . Replace complete loadcontactor i f coi l is defective.

Troubleshooting Chart(Sheet 1 of 4)

Figure 2






A. Defective control switch (8,Fig. 1)

A. Place switch in center ONposit ion. Check voltage at switch(S403) (See connect ion diagram). I fthere is no voltage, replace switch.

B. Defective resistor (15, Fig.1 )

B. Place control switch (&Fig. 1) incenter ON posi t ion and checkvoltage at resistor (15, Fig. 1) outputend (orange-black wire). I f resistoris open or short circuited, replace.

2 . Load contactor c losesnormal ly . Opens as soon ascontrol switch is released.

C. Smal l contacts in loadcontactor defect ive

C. With control switch (8, Fig. 1) heldin top ON posit ion to keep loadcontactor c losed, check vol tage atterminal No.2 (red-white wire) onload contactor. I f no voltage isindicated, replace complete loadcontactor.

A. Short circuited condit ion inload contactor holding circuit .

A. Check al l leads in this circuit fordamaged insulat ion and short ing.Check al l terminals and connect ionsfor short ing. Repair as required.

3. Fuse (11, F ig. 1) b lows whenload contactor swi tch is operatedto ON position.

B. Defect ive relay (contactsclosed) in overload module

B. Disconnect p lug connector onoverload module. I f contactor wi l lnow c lose and remain c losedwithout blowing fuse, replaceover load module .

4. Output voltage is unsteady.Green indicat ing l ight bl inks.

A. Voltage regulator on 200-VAC power source requiresadjustment.

A. Refer to the generator-setinstruct ion manual . Adjust RATEpotentiometer on voltage reg. tostabi l ize output voltage. Voltage issteady when indicat ing l ight ceasesto blink

5. Normal output vol tage (28.5 VDC) decreases as load increases.Current l imit ing switch in OFFposit ion.

A. Line-drop and currentlimiting module (18, Fig. l) , orl inedrop current t ransformerdefective

A. Apply a load of 1000A to the T-Rcheck input voltage at the contactorat a load of lOOOA, the inputvoltage, l ine-to-l ine, should beapprox. 220-V AC. I f input vol tage ISthat , the l inedrop module andcurrent t ransformer are OK and thetrouble is in the main transformerand heat sink (rectifier) circuit.Proceed to step B below.


Figure 2






A. (CONTINUED) If input voltage is only 200-V AC, thetrouble is in the l ine-drop moduleand current transformer circuit .Check as fo l lows:

(1) Line-drop current trans-former defect ive

(1) Use an ohmmeter to check the,transformer. Replace i f open orshort circuited.

(2) Line-drop and current-l imit ing module (18, Fig. 1)defective

(2) I f l ine-drop current transformerchecked good in test A, (1) above,Replace l ine-drop and current-l imit ing module.

B. Defect in t ransformer andrectif ier circuit

B. I f l ine-drop circuitry was provento be good in check A, above, checkas fo l lows:

(1) Defect ive transformer (1) Check a l l input and outputconnect ions to the t ransformer.Use an ohmmeter to checktransformer windings. Repair orreplace as required.

5 . (CONTINUED)

(2) Defect ive diodes or diodeconnections

(2) Check al l diodes for open orshort-circuited condit ion. Check al lconnections. Check instal lat ion ofdiodes ( torque values).NOTE: Torque West inghouse d iodesto 25 foot-lbs . . Torque Internat ionaldiodes to 13-l /2 foot- lbs. (threadslubricated with Penetrox) . Checkfactory for other manufacturer ’sdiodes. Replace diodes and/orcorrect instal lat ion and connectionsas required.

A. Module not receiv ing DCpower

A. Check and correct as fo l lows:6. Over load module does notoperate

(1) Fuse (10, Fig. 1) defective (1) Fuse (10, Fig. 1) defective (1)Place instrument l ight switch (12) inON posi t ion. I f instrument l ight doesnot operate, check fuse. Replace i fdefective.


Figure 2






6 . (CONTINUED) (2) Defect in DC circuit (2) Check wir ing and connect ionsfrom DC power source to over loadmodule. Repair as required.

A. An open resistor isa l lowing higher than normalvol tage to enter the over loadmodule .

A. Check each resistor . Replace asrequired.

7. Overload module operates toopen load contactor when nooverload exists.


Figure 2



Repair 2-4Page 1

SECTION 4. REPAIR

1. General

Repair of the trans former-rectifier will consist primarily of parts replacement. The onl y rotating parts in theuni t are the two cool ing fans and the only other moving parts are s wi tches , relays, rheostats , and meters.

2. Removal and Installation

It is suggested that if extensive repairs are to be made to a T-R which is mo unted on a mo bil e machinesuc h as a self-propelled generator-set, etc., the uni t be removed and placed on a workbenc h or othersupporti ng structur e.

A. R e m o v a l Pro c e d ur es

WARNING: MAKE CERTAIN INPUT POWER CANNOT REACH THE T-R.LETHAL ELECTRICAL SHOCK HAZARD EXISTS.

(1) Disconnect DC cabl es at output termi nal s.

(2) Open the control panel and di sconnect three A C i nput l eads at the contactor (1-1; 4, Fig.5).

WARNING: IF THE MOBILE GENERATOR SET IS TO BE OPERATED WHILET-R IS REMOVED, ALSO DISCONNECT T-R SUPPLY LEADS AT THEGENERATOR SET TERMINAL BOARD.

(3) Disconnect pl ug connector P403. See connecti on di agrams at the rear of thi s manual .

(4) Remove four (3/8-16) mounti ng screws which attach the T-R to the mo bil e unit.

(5) Attach a lifti ng hoist and car efully lift the T-R. Li fti ng hol es are accessible whe n plug buttonsare removed in sides of the top. Be sure all l eads are free and do not become entangl ed.Move the uni t to a workbench or cl ear worki ng area.

B. Installatio n P r o c e dures

Ins tal lati on procedures are contai ned in 1-2; Par a. 3.

3. Parts Replacement

A. Acce s s

All par ts, which might normally require repl acement, are easily accessi ble by openi ng the front andrear hi nged access panels. Output di odes are accessible by rem ovi ng the housing top.



Repair 2-4Page 2

B. Part s R e m o v al

(1) M o d ules

The overload, and line-drop and current-limiti ng modules are equipped wi th quick-di sconnect l eadconnectors so that i nput and output l ead i dentificati on for these uni ts is not a probl em.

Identi fy and mark leads to the overvoltage mod ule before removal .

(2) Misc el laneous par ts

C. Part s Ins tal la tion

Chec k new parts physicall y and electrically, i f possible, befor e installation.

(1) Posi ti on parts carefull y in mou nti ng l ocati on and attach securely.

(2) Be certai n all leads are connected properl y. If any doubt exists, refer to the applicabl econnecti on diagram located at the rear of thi s manual .

(3) If i t is nec essary to repl ace any of the diodes mounte d on the heat sinks (1-1; 5 and 11, Fi g. 5) ,torque the Westi nghouse di odes to 25 foot-lbs ., or the Internati onal Recti fier diodes to 13-1/2 foot-lbs. For other man ufacturer’s diodes, contact the factory at the address given in the Introducti onof thi s manual for i nstall ati on torque requirements.

NOTE: The tor que val ue for these di odes is a criti cal requi rement. The torque requirements varywidel y among the various suppliers of these di odes and, i n addi tion, the suppli ers change. Therefore,it is impr acticable to provi de torque values for all di odes in this manua l .

(4) If the bus bar s (1-1; 4 and 11, Fig. 6) and aluminum nuts, which secur e them, are removed for anyreason, they must be torque d in place at i nstall ati on to 20 to 25 l b.-feet (27 to 34 N-m). Themo unting face of each al uminu m nut and the thr eads on the bus bars must be coated wi thPenetrox or an equival ent heat sink com pou nd at installati on.

D. Fa n Instal la tio n

If fan blades rotate i n the wrong directi on, reverse connecti on of any T W O fan i nput l eads.

4. Workmanship

Perform all repairsi n accordanc e with good electrical repai r practices . All interconnecting lead connec ti onsto com pon ents must be m ade wi th proper wire terminati ons. Route all l eads neatl y and secure wi th ti es,cl amps, etc.

5. Connection Diagrams

A compl ete set of connecti on di agrams are i ncluded in the rear of thi s manual . When reconn ecti ng wi resto a compo nent, use the connecti on di agrams to make certain connecti ons are made correctly .



Parts List Introduction 3-1Page 1

CHAPTER 3. ILLUSTRATED PARTS LIST

SECTION 1. INTRODUCTION

1. General

The Illus trated Parts Lis t identifies , describes, and i l lus trates mai n assemblies , subassemblies , and detailparts of the Transformer-Recti fi ers manufactur ed by Hobart Brothers Comp any, Pow er Syst ems Group,Troy, Ohio, 45373. These sets are i dentifi ed as Part Number 4877 50-1.

2. Purpose

The purpose of this lis t is to provi de parts i dentifi cati on and descri pti ve i nformation to maintenance andprovisi oni ng personn el for use in provisioni ng, requisiti oning, purchas ing, stori ng, and i ssui ng of spareparts.

3. Arrangement

Chapter 3 i s arrange d as follows:

Secti o n 1 - IntroductionSec tion 2 - Manufa c turer ’ s CodesSecti o n 3 - Part s ListSecti o n 4 - N u m eric al I ndex

4. Explanation of Parts List

A. Contents

The par ts lis t contai ns a break down of the equi pme nt i nto assembli es, subassembl ies, and detailparts. All parts of the equip ment are li sted except:

(1) Stand ard hardware i tems (attaching parts) such as nuts, screws , washers , etc. , whi ch areavailabl e commercially.

(2) Bulk items such as wi re, cable, sl eeving, tubi ng, etc., which are also commercially avail abl e.

(3) Perma nently attached parts which l ose their i dent i ty by bei ng wel ded, soldered, riv- eted, etc.,to other par ts, wel dments , or assembl ies.

B. Parts List Form

Thi s form i s divi ded i nto six columns. B eginni ng at the l eft side of the form and proceeding to the ri ght,col umns are i dentifi ed as follows:



Parts List Introduction 3-1Page 2

(1) FI GU R E-I T E M N O. C olu m n

Thi s column lis ts the fi gure nu mber of the illustrati on appl icable to a particul ar parts list and al soidentifi es each par t in the lis t by an i tem numb er . These ite m nu mbers also appear on theillustrati on.

Each item num ber on an illustrati on is connec ted to the part to which i t per tai ns by a leader line.Thus the figur e and ite m numbering system ti es the parts lists to the illustrati ons and vice versa.The fi gure and index nu mbers are also used in the num erical i ndex to assist the user i n fi nding theillus trati on of a part when the part number i s known.

(2) “ H O B A R T P A R T N U M B E R ” C o l u m n

A L L part numbers appe aring i n this column are Hobart numbers. In all instances where the par tis a purchased item, the vendor’ s i dentifyi ng fivedi gi t code and hi s part number will appear i n the“NOMENCLATURE” column.

Vendor parts whi ch are modifi ed by Hobart will be i dentifi ed as such in the “NO MENCLATURE”column. In case Hob art does not have an i denti fyi ng part number for a purchas ed part, the“HOBART PART NUMBER” column will reflect “No Number” and the vendor’s numb er will beshown in the “NOMENCLATURE” col umn. Par ts manufactured by Hobart refl ect no vendor codeor part number i n the “NOMENCLATURE” column.

(3) “ N O M E N C L A T U R E ” C olu m n

The i tem i dentifyi ng na me appears i n thi s col umn. The indenture method is used to i ndi cate i temrel ati onshi p. Thus, compon ents of an assembly are listed direc tly bel ow the assem bly and i ndente done space. Vend or codes and part numbers for purchased parts are s hown in thi s col umn. Hobartmo di ficati on to vendor items is also noted in this column.

(4) “ EF F” (Effective) Co lum n

Thi s column is used to i ndicate the applicability of parts to different models of equipme nt. Whenmore than one model of equipm ent i s covered by a par ts list, there are some par ts which are usedon onl y one model . Thi s colum n i s used for i nsertion of a code letter “A”, “B”, etc., to i ndicate theseparts and to i denti fy the particul ar model they are used on. Par ts i n thi s manual are coded asfol lows:

Part s c o de d “A” are use d o n Spe cs 4877 50-1 only.Part s co de d “B” are use d o n Spe c s 487 750-2 only.Part s c o de d “C” are use d o n Spe cs 4877 50-3 only.Part s c o de d “D” are use d o n Spe cs 4877 50-4 only.

(5) “ U N I T S P E R A S S E M B L Y ” C o l u m n

Thi s column indi cates the quantity of parts required for an assembly or subassembly in which thepar t appears. This col umn does not necessarily refl ect the total used in the complete end item.



Manufacture’s Code 3-2Page 1

SECTION 2. MANUFACTURER’S CODES

1. Explanation of Manufacturer’s (Vendor) Code List

The following lis t is a compil ati on of vendor codes with names and addresses for suppliers of purchasedparts listed i n thi s publicati on. The codes are i n accordance with the Federal Supply Codes forMa nufactur er’ s Catal ogi ng Handb ook H4-1, and are arrange d in numeri cal order. Vendor codes areinser ted i n the nomenclatur e colum n of the parts list di rectl y followi ng the ite m na me and descripti on. Incase a m anufacturer does not have a vendor code, the full nam e of the manufactur er will be lis ted i n thenomenclature colum n.

CODE VENDOR’S NAME AND ADDRESS

04713 Motorola S emiconductor In c., Products S ector, 5005 E. Mc DowellRoad, Ph oen ix, Arizona 85008

0810 8 Lamp Industry, For Us e With Industry Designations & Abbreviationsfor Lamps

13445 Cole-Hersee Company, 20 Old Colony Avenue, Boston, Massachusetts02127

14101 Sprague Electric Company, 300 W. National, Vandalia, Ohio 45377

14859 Metals & Controls, Inc. Control Products Group, 300 North Main,Versailles, Kentucky 40383

4465 5 Ohmit e Manufacturing Company, 3601 Wes t Howard Street, Skokie,Illinois 60076

56365 Square “D” Company, Executive Plaza, Park Ridge, IL 60067

6074 1 Triplett Electrical Instrument Company, Harmon Road, Bluffton,Ohio 45817

71400 Bussman Manufacturing, Division of McGraw-Edison Compan y,2536 W. University Street, St. Louis , Missouri 63017

72619 Dialight Div., 60 Stewart Avenue, Brooklyn, New York 11237

73559 Carlingswitch Inc., 505 New Park Avenue, West Hartford, CT 06110

74063 Hartman Electrical Manufacturing Div., P. O. Box 8, Mansfield,Ohio 44901

83774 Midwest Elect ric Products, 2114 North Arsenal Avenue, Indianapolis,Indiana 46218



Manufacture’s Code 3-2Page 2

8615 1 Genisco Technology Corp oration, Illinois Division, 9367 William Street,Rosemont , Illinois 60018

9020 1 Mallory Capacitor Company, 3029 E. Washington Street , P.O. Box 372,Indianapolis , Indian a 46206

90763 United-Carr Div., 4258 N. Cicero, Chicago, Illinois 60640

91929 Hon eywell, Inc., Building Controls & Components Group, Micro SwitchDivis ion , Chicago an d Sp rings Street, Freep ort, Illinois 61032

9270 2 IMC Magnetics Corp oration, Eastern Divis ion, 570 Main Street,Westbury, New York 11591


May 10, 1994Revised

Illustrated Parts List 3-3Page 1

SECTION 3. PARTS LIST

1. Explanation of Parts List Arrangement

The par ts lis t is arranged so that the illustrati on will appe ar on a l eft-hand pag e and the applicable parts listwill appear on the opposi te r ight-hand page. Unl ess the lis t is unusually l ong, the user will be able to l ookat the ill ustrati on and read the parts list without turni ng the pag e.


May 10, 1994Revised


Transformer -Rect i f i e r AssemblyFigure 1


May 10, 1994Revised


FI GU R E H O B A R T N O M E N C L A T U R E UNITS/I T E M N O. P A R T N O . 1234 567 EFF A S S Y1- 0 4877 50-1 T R A N S F O R M E R - R E C T I FI ER A S S E M B L Y , A 1

28.5 V O L T D C4877 50-2 T R A N S F O R M E R - R E C T I FI ER A S S E M B L Y , B 1

28.5 V O L T D C4877 50-3 T R A N S F O R M E R - R E C T I FI ER A S S E M B L Y , C 1

28.5 V O L T D C

1 487752-1 . NAMEPLA TE , ID AB 1487752-2 . NAMEPLA TE , ID C 1

2 389525 . NAMEPLA TE , OVERLOAD 13 180719-1 . TRANSFORMER - RECTIFIER A Y . A 1

180719-2 . TRANSFORMER - RECTIFIER A Y . B 1

180719-3 . TRANSFORMER - RECTIFIER A Y . C 14 487744 . . TRANSFORMER ASSEMB LY 15 487736-1 . . PANEL, FRONT ASSY. (For Detail s See Fi g. 2) A 1

487736-2 . . PANEL, FRONT ASSY. (For Detail s See Fi g. 2) B 1487736-3 . . PANEL, FRONT ASSY. (For Detail s See Fi g. 2) C 1

6 487896 . . BASE ASSEMBLY 17 3892 75A-3 . . . BASE 18 487739 . . . BRACKET, CONTACTOR 19 404518 . . . CONTACTOR 110 1CZ-148 . . . TRANSFORMER, CURRENT 4

11 487740 . . . BRACKET, RESISTORS 212 402935-4 . . . RESISTOR, TYPE RH, 5 WATT 313 402956 . . . TRANSFORMER, CURRENT 114 487738 . . TOP ASSEMB LY 115 487734 . . PANEL, REAR 1

16 487737 . . PANEL, SIDE 117 487900 . . HEAT SINK ASSEMBLY 118 389229 . . . BRACKET, HEAT SINK 419 389226 . . . BUS BAR, ALUMINUM 220 389225 . . . BUS BAR, ALUMINUM 2

*21 389251 . . . INSULATOR, BUS BA R 222 389252 . . . HEAT SINK ASSEMBLY, POSITIVE 123 83B-1098-1 . . . . THERMOSTAT 124 3893 3 . . . . BRACKET, THERMOSTAT 125 W-10931-3 . . . . DIODE, S ILICON, 275 A ., POSITIVE BASE 12

26 403692 . . . . FAN, HEAT SINK, V92702, MODEL BT2206F-0-1 127 389530 . . . . HEAT SINK, ALUMINUM 128 389253 . . . HEAT SINK ASSEMBLY, NEGATIVE 1*29 8RT-336 . . . . THERMOSTAT, V1485 9, TYPE 2040 0L 1*30 389333 . . . . BRACKET, THERMOSTAT 1

*31 W-10933-3 . . . . DIODE, S ILICO N, 275 A ., NEGATIVE BASE 12

* NOT ILLUSTRATED


May 10, 1994Revised




May 10, 1994Revised


FI GU R E H O B A R T N O M E N C L A T U R E UNITS/I T E M N O. P A R T N O . 1234 567 EFF A S S Y

1- 0 C O N TIN U E D32 403692 . . . . FAN, HEAT SINK, V92702, MODEL BT- 2206F-0-1 133 389262 . . . . HEAT SINK, ALUMINUM 134 389249 . . . SUPPORT, HEAT SINK 235 389426 . . PLATE, TERMINAL, BUS BA R 236 389427 . . INSULATOR, BUS BAR 136 389427 . . INSULATOR, BUS BAR 137 389556 . . COVER, TERMINAL ASSEMBLY 138 389524 . . NAMEPLATE, LIFTING YOKE 239 A-897-1 . . NAMEPLATE, NEGATIVE 140 A-896-1 . . NAMEPLATE, POSITIVE 1*41 4015 63-2 . . HOUS ING, P IN CONNECTOR 1*42 430278 . . GROMMET 143 487763 . . CLAMP, CABLE 1

* NOT ILLUSTRATED


May 10, 1994Revised


Cont ro l Pane l AssemblyFigure 2


May 10, 1994Revised


FI GU R E H O B A R T N O M E N C L A T U R E UNITS/I T E M N O. P A R T N O . 1234 567 EFF A S S Y2- 0 4877 36-1 P A N E L A S S E M B L Y , C O N T R O L A 1

(For N H A See Fig . 1 )487736-2 P A N E L A S S E M B L Y , C O N T R O L B 1

(For N H A See Fig . 1 )487736-3 P A N E L A S S E M B L Y , C O N T R O L C 1

(For N H A See Fig . 1 )

1 487735 . PANEL FRONT 42 389523 . BOARD, LINE DROP & LIMIT ASSY AB 1

284590 . BOARD, LINE DROP & LIMIT ASSY C 13 4015 64-4 . HOUSING, SOCKET, CONNECTOR, V89110, 2

1-480288-0

4 4053 65-1 . SWITCH, TOGGLE, SPST, V7355 9, NO. 2GL6 1 25 38952 2B . BOARD, OVERVOLTAGE 16 W-8063A-3 . VOLTMETER, DC, S INGLE SCA LE 0-50, V60741 17 389521 . CAPACITOR ASSEMBLY 18 403189 . SWITCH, TOGGLE, 3 POSITION, 2 POLE, 1

V91929, NO. 312TS1-599 389803 . LABEL, INSTRUCTIO NS 110 402157 . RHEOSTAT, 150 WATT, 75 OHM, V44655, AB 1

MODEL L402218 . RHEOSTAT C 1

11 BW-920 . INDICATOR, AMP HR. SEL., K NOB ASSY. 112 W-11113-5 . SCREW, MACH., RD-HD, #10-32 X ¼ 213 TRE-242 . NAMEPLATE, STARTING CURRENT AB 1

284589 . NAMEPLATE, STARTING CURRENT C 114 82B-1047 . LIGHT, PANE L, 12V , V56365 1

15 4055 06-1 . RESISTOR, VARIABLE, OHMITE 116 400078 . BRACKET, MOUNTING RESISTOR, V44655, NO. 12 217 W-9746-4 . RESISTOR, 25 WATT, F IXED TYPE 118 4040 65-2 . RECTIFIER, SILICON, V047 13, NO. 5DA-1027 0-2 119 W-8061A-13 . AMMETER, DC, SINGLE SCA LE 0-2500, V60741 1

20 422241 . SPACER, TIMER1 121 3877 38A . BOARD, P C OVERLOAD 122 2834 94-2 . ADAPTER, CIRCUIT BREAKER B 123 402658 . FUSEHOL DER, V71400, NO. HKP AC 224 W-11166-1 . FUSE, FAST BLOW, AGC, 2 AMP A C 2

25 HF-2518-7 . LIGHT, GREEN, V7261 9, NO. 2613 10-119 1*26 W-11242-29 . WASHER, FLAT, #6 127 40952 7-5 . BREAKER, CIRCUIT B 228 410539 . TERMINAL, FEMALE, 90 DEG. A C 429 4806 38-3 . GUARD, LIGHT & SWITCH A C 3

*30 3895 35-1 . SUPPORT, ROPE, HINGED DOO R 131 BW-917 . KNOB, RHE OSTAT, AMP HR SELE CTO R A C 1

* NOT ILLUSTRATED


May 10, 1994Revised




April 20, 1989Revised

Unusual Service ConditionsPage 1

SECTION 4. NUMERICAL INDEX

1. Explanation of Numerical IndexThe purpose of this i ndex is to assis t the user in fi ndi ng the ill ustrati on and descripti on of a part when thepart number is known. Part nu mbers are ar ranged in al pha-num erical sequenc e. Thus, any numb erbegi nni ng with the l etter “A” would be located at or near the top of the i ndex list. Li kewise a part numb er“9" woul d be lis ted near the end of the list and far bel ow a part number ”1000". The fi gure num ber anditem nu mber l ocati on of the part is listed di rectl y opposite the part. If the part is used in more than oneplac e, each locati on i s listed commenc i ng wi th the first locati on the part is listed.

PART NUMBER FIGURE & ITEM NUMBER

A-896 1-26A-897-1 1-29BW-916 2-18HF-1466 2-0HF-2407 2-8HF-2518-7 2-4TRE-242 2-19W-10051-10 1-19W-10931-3 1-8W-10933-3 1-13W-11166-1 2-7W-2974-E 2-29W-8061A-13 2-5W-8063A-3 2-6W-9746-4 2-311CZ-148 1-3416DA-1997- 12 1-243877 38A 2-243895 22B 2-9389225 1-4389226 1-3389229 1-2389249 1-16389251 1-5389252 1-0389253 1-0389262 1-153892 75A-3 1-32389333 1-12, 1-7389426 1-21389427 1-22389503 1-18389517 2-15389521 2-263895 22B 2-9389523 2-11389524 1-27389525 2-32




PART NUMBER FIGURE & ITEM NUMBER

389530 1-10389535 1-23389556 1-25389803 2-16400078 2-28400400 2-104015 63-4 2-344015 64-3 2-124015 64-4 2-134015 66-11 2-14402157 2-204029 35-4 1-38402956 1-36403189 2-3403692 1-9, 1-44040 65-2 2-17404518 1-35410539 2-25422241 2-33430278 1-204806 38-2 2-27487734 1-31487735 2-14877 36-1 2-0487737 1-30487738 1-1487740 1-37487744 1-04877 50-1 1-0487752 2-30487763 1-28487900 1-050GHP-20 6 2-226FW-3167 1-178RT-336 1-1182B-1047 2-2183A-1110- 1 1-40

8401

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‘CAPACITOR 20 MFD, 30V DC ‘CAPACITOR, 40 MFD, 250V DC REACTOR, FILTER 400 CYCLE DIODE, SILICON 400 PRV, 1.5 WATT POTENTIOMETER 25q 25W. RELAY FORM 1B DIODE ZENER, 9.1~.$-WATT

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UNUSUAL SERVICE CONDITIONSThi s informati on i s a general gui del ine and cannot cover all possibl e condi ti ons of equipment use. The specifi clocal environments may be depend ent upon condi ti ons beyond the manufacturer’ s control. The manufactur ershould be consul ted i f any unusual condi ti ons of use exi st which may affec t the physi cal condi ti on or operati onof the equip ment.

Amon g such condi ti ons are:

1. Exposure to:

A. Co mbustibl e, explosive, abr asi ve or cond uc ti ng dusts.

B. Environme nts where the accumul ati on of li nt or excessive dirt will i nterfere wi th normal ventila- ti on.

C. Chemical fumes , fl ammabl e or expl osive gases .

D. Nuclear radi ati on.

E. Steam, sal t-l aden air , or oil vapor.

F. Damp or very dry l ocati ons, radiant heat, vermin i nfestati on, or atmosp heres conduc ive to fun- gusgrowth.

G. Abnormal shock, vibr ati on or mecha ni cal l oadi ng fro m external sources duri ng equi pment operati on.

H. Abnormal axial or side thr ust impos ed on rotati ng equi p ment shafts.

I. Low and/or high a mbient temperatur es.

J. Hi gh electro magn eti c fiel ds.

2. O p e ra t ion at:

A. Voltages above or bel ow rated vol tage.

B. Speeds other than rated speed.

C. Frequ ency other than rated frequ ency.

D. Standstill wi th rotati ng equipment windi ngs energized.

E. Unbal anced vol tages.

F. Operati on at l oads greater than rated.

3. O p e ra t ion w her e l o w ac oust ical noise levels are required .

4. O p e ra t ion wi th :

A. Improper fuel , l ubricants or cool ant.

B. Parts or el ements unauthori zed by the manufacturer.

C. Unauthori zed modi ficati ons.

5. Operat ion in poorly venti late d areas.

operation and maintenance manual illustrated parts … · trouble-shooting and adjustment. ... the...

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