TM-598

113077

OPERA,TION AND ‘MAINTENANCE MANUAL

with

ILLUSTRATED PARTS LIST

for

TkANSFOFiMER-RECTIFIER

112-VOLTS DC, 400 AMPERES

MODEL NUMBER TR-4012

Part Number 482085A-2

Part Number 482085A-5

(with 24-Volt DC Power Supply)

manufactured by

.I HOBART BROTHERS COMPANY! ’

POWER SYSTEMS DlVlSlOk , ;;

TROY, OHIO 45373 ‘I L I

1

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U.S.A.

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SAFETY INSTRUCTIONS AND WARNINGS FOR ELECTRICAL POWER EQUIPMEAT

ELECTRIC SHOCK can kill. Do not touch live electrical parts.

ELECTRIC ARC FLASH can injure eyes burn skin cause equipment damage and

I l ‘2 1,: ignite co bustible materiaf. Do not use power cables to break lo/$! and prevent tools from causing short circuits.

IMPROPER PHASE CONNECTION, PARALLELING, OR USE can damage this and attached 'I equipment.

IMPORTANT: - Protect all operating personnel. 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

A. GENE=

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.

B. SHOCK PREVENTION

--- - ._ Bare conductors, electrically-live

or terminals in the output circuit, or ungrounded, 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 dan erous

f currents to flow through it.

equ pmeat, do not work in damp areas. When inspecting or seticing Stand on a dry rubber 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 dr2ven 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 a plicable codes. A power disconnect switch or circuit breaker must 1 Check the nameplate for volta e,

e located at the equipment.

only 3-phase power is 9, frequency, and phase requirements. If

availab e, connect to only two nres of the 3-phase line.

any single- hase rated equipment DO NOT CONNECT the equipment

grounding conductor (lead) to the third live wire of the 3-phase line, as this makes the equipment frame electrically HOT, which can cause a fata? -zzimc.- p-e---

Alwa s connect the grounding lead if supplied in a'power line cable, to t e grounded K swiizkdbox or building ground. separate groundin

If not provided, use a

of the grounding fi Ensure that the current (am erage)

! capacity

ault current situation.

ead 211 be adequate for the worst

details. Refer to the National Electrical Code ANSI/NFPA 70 for

Do not remove plug ground prongs. Use correctly mating receptacles.

' 2.

3.

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. 1

energized. Do not touch output terminal while equipment i,s

Service and Maintenance ) '! , ' I'

i This e uipment must be maintained in good electrical and mechanical condit on to avoid hazards stemming from disrepair. 4 Report any equipment defect or safet hazard to the super&.sor and discontinue use of the ejuigment untiP its safety has been assured. Repairs should be ma e y qualified personnel only.

Instruction 910082 fmL ~C1OC n---r --3 Page 1

Before inspecting or servicing electrically-powered equipment, take the following precautions:

FIRE AND EXPLOSION PREVENTION ,

Fire and explosion are caused by electrical short circuits, combustible material near engine exhaust pi in unsafe operating or fueling con it ii P

,, misuse of batteries and fuel, or ons.

Electrical Short Circuits and'overloads

Overloaded or shorted either by self

e uipment destruct 4

can become hot enough to cause fires on or causing nearby combustibles to ignite.

For electrically-powered equipment, in particular, input protection to remove short circuited or heavi

rovide primary

equipment from the line. P y overloaded

.Batteries

Batteries may explode and/or give off flammable hydro en and arcing from a ru failures. When ser T!

tured battery can cause fires an 3 ad%$onze acid cing, do not smoke, cause sparking, cr 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 or during fuel transfer.

. completely fill Shut unit DOWN before removing fuel tank cap. Do not tank,

expansion overflow. because heat from the e uipment may cause fuel Remove all spilled fuel

that penetrates the unit. &ME

After clean-up, DIATELY, including any

fumes away with compressed air. open equipment doors.and blow

D. TOXIC FUME PREVENTION

Carbon monoxide - Engine exhaust fumes can kill and cause health problems. Pipe or vent the exhaust fumes to a suitable exhaust duct or outdoors. Never locate engine exhausts near intake ducts of air conditioners.

E. BODILY INJURY PREVENTION

Serious inju Shut DOWN sue 7:

can result from contact with fans inside some equipment.

equipment is equipment for inspection and routine maintenance. When

in o eration use extreme care in doing necessary troubleshooting

F.

and adjustment. E o not remove guards while equiment is operating.

MEDICAL AND FIRST AID TREATMENT

a. Shut OFF all power at the disconnectin before,inspecting or servicing the equ pment. f

switch or line breaker

b. Lock &itch 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 ano,ther

zed, have

"arid pro d erson prese t'tiho is trained in turning o f the equipment

9 ding or calling for first aid. i?

First 'aid facilities and a qualified first aid person should be available for each shift for immediate treatment of all injury victims. Electric shock vzctims should be checked by a ph sician and taken to a hospital immediately if any abnormal signs are o served. B

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1

Call physician immediately. Seek additional assistance and use First Aid techniques recommended by American Red Cross until medical help arrives.

1 ' IF BREATHING : down.

IS DIFFICULT,_g5ve ------ .- ---- FOR ELECTRICAL SHOCK oxy en,

f if,available, 'a

? d have vie

turn o f power. Remove vie i.m; if not tim lie1 t ',

breathing, begin artificiai'respiration, preferably mouth-to-mouth. 'If I

no detectable pulse, Squad immediately.

begin external heart massage. Call Emergency Rescue

G. EQUIPMENT PRECAUTIONARP'LABELS .,

Ins rep ace all abels that cannot be easily rea

E ect a II precautionary Labels on the equi rnt monthly. Order and

EMERGENCY FIRST AID

._ _ _

TM-598

j INTRODUCTION

1. Scope

This manual contains information and’instr;uctions for a 112-V DC Transformer-Rectifier, manufactured by Ho-

ba’;t ,B$;thers Company, Power SystyS bivision, Troy, Ohio 45373, U.S.A.

2. Purpose

The purpose of the manual is to provide information and instructions to experienced operators, electricians, and

mechanics who have not previously seen or operated this machine. The manual is not intended to be a text book

on electricity, nor electronics.

3. Contents and Arrangement

The manual is divided into 3 chapters. Each chapter is divided into as many sections as required. Each section

begins with page 1, and each page is identified by chapter, section and page number, in the lower outside

corner. Illustration numbering is also grouped by sections.

When a reference is made to material which is located in the same section, the material is identified by paragraph

location only; example: (Para. 1, A). When referenced material appears in a different section, it is identified by

chapter, section and paragraph location: example: (2-l ; Para.1, A). The same method applies to illustrations which

are identified by figure numbers; examples: (Fig. 81, or (2-1; Fig. 8).

4. Service Information

If you have any questions concerning your Hobart Power Systems Division equipment, you are invited to contact

our Service Department by mail, telephone or TWX at:

Hobart Brothers Company Power Sytiems Division

Service Department

Troy, Ohio 45373 U.S.A.

Telephone: Area Code (513) 3396276

TWX : 81 o-456-2907

1 Nov 30177 Introduction

Page 1

___.-. -... . .._.. -. _.. .- .-...

SUbJECT

lntroductipn

w I I TM-598

TABLE OF CONTENTS

lj,“’

I. General I

2. Transformer-Rectifier Assembly’

A. Control Panel Assembly

8. Electrical Components

(I ) Terminal board

(2) Load contactor

(3) Transformer

(4) Heat sink assembly

(5) Overload module

(6) Overvoltage module

(71 Base

(8) Power supply

Preparation for Use

I. General

2. Inspection

/ 3. Installation

A. General

8. Mounting

C. Connection

(I) Input (482085A-2)

(2) Input (482085A-5)

1 Nov 30177

CHAPTER/SECTION PAGE

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Contents

Page 1

:, TABLE OF CONTENTS (CONTINUED)

TM-598

SUBJECT CHAPTER/SECTION PAGE

(3) output 1 *

Operation ‘i.i, 1, ” ( 1, ‘I

I. Preparation for DC Power Delivery

2. DC Power Delivery

3. Discontinue Power Delivery

Servicing

Maintenance

I. General

2. Lubrication

3. Inspection

4. Cleaning

Adjustment/Test

I. General

2. Test

3.

A. Preparation for Test

8. ‘Operational Test Procedures

C. Test Silicon Diodes

Adjustment

A. Ammeter Shunt

B. Overvoltage Trip Point

Troubleshooting

I. General

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2. Troubleshooting Chart

A. Description !

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C+tents

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I 1 TM598

‘,, TABLE OF CONTENTS (CONTINUED)

SUBJECT

1 B. How to Use Troubleshooting Chart

I ’ (1 6”. ~ I> 3. Equipment for Troubleshooting

4.’ Safety I

5. Parts Replacement

CHAPTER/SECTION PAGE

2-3 I

I

1

I

6. Check Connections and Leads

7. Schematic Diagram

Repair 24

I. General

2

2

I

2. Removal and Installation I

A. Removal Procedures I

B. Installation Procedures 1

3. Parts Replacement I

A. Access

8. Parts Removal

C. Parts Installation

D. Fan Installation

4. Workmanship

5. Connection Diagrams

Illustrated Parts List 3-o

Introduction 3-I

I. General

2. Purpose

.I

3. Arrangement

4. Explanation of Parts List

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Contents

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I TM-598

;, TABLE OF CONTENTS (CONTINUED)

SUBJECT CHAPTER/SECTION PAGE

A. Cpntents

8.1 ‘hts List Form

3-I I (

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(I) Figure Item No. colump 1

(2) Hobart Part Number column 2

(3) Nomenclature column ’

(4) Eff (Effective) column

(5) Units Per Assembly column

Manufacturer’s Codes

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

Parts List

1. Explanation of Parts List Arrangement

Numerical Index

I. Explanation of Numerical Index

Coptents

Page 4

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3-3

34

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TM-598

LIST OF ILLUSTRATIONS

CHAPTER/

SECTION , FIGURE NUMBER

PAGE

NO. 3 TITLE

l1”’ ’ Transformer-Rectifier (1 I2 V DC)

Specifications and Capabilities

/ Control Panel Assembly

T-R Components (Front and Rear Views)

T-R Components (Side Views)

T-R Components (Top View from Front)

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I-2

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I Input Connection Diagram

2 Output Cable Installation

I-3 I Control Panel Assembly 2

2-I No Illustrations

2-2

2-2

I Ammeter Shunt Adjustment 2 Overvoltage Adjusting Rheostat

4

5

2-3

2-3

2-3

2-3

T-R Schematic Diagram 3 Control Panel Assembly 4 Troubleshooting Chart (3 Sheets) 5thru7 24-Volt Power Supply 8

24

24

24

24

24

T-R Connection Diagram

Power Module Connection Diagram Control Panel Connection Diagram

Overload Module Connection Diagram

Overvoltage Module Connection Diagram

3-I No Illustrations

3-2 No Illustrations

3-3

3-3

3-3

3-3

Transformer-Rectifier Assembly 2 Power Module Assembly 6 Control Panel Assembly 8 24-Volt Power Supply IO

34 No Illustrations

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TM-598

CHAPTER I. DESCRIPTION/OPERATION

SECTION I. DESCRIPTION 1 9

I. G&ner& I/,“’

The transformer-rectifier, hereafteq referred to as a T-R, is a compact, enclosed, power-supply unit employing a

transformer and semiconductor diode components to convert 200-Volt, 400-Hz input to 112~Volt DC output

1 power (see Fig. I). It has many uses including aircraft servicing, testing, etc.

This manual covers two nearly identical units: part numbers 482085A-2 and -5. The only difference between the units is that the -5 has a 24Volt power supply. This power supply furnishes the 24 Volts DC required to prevent

the generator’s plug-interlock relay from shutting down the generator when the T-R is used as a free-standing unit.

When a 112.Volt T-R is furnished with a generator set, it is hard-wired in at the factory and provision is made to

bypass the generator’s plug-interlock relay and the unit furnished is 482085A-2. If a T-R is furnished to be used

with an existing generator and to be connected PER,MANENTLY to that generator by the user, the unit furnished

is also 482085A-2. However, if a T-R is furnished to be used TEMPORARILY with a generator, or interchangeably

with several generators as a free-standing unit, the 24Volt source is necessary to avoid repeated internal wiring

changes to the generators and the unit furnished is 482085A-5. --- --. -

2. Transformer-Rectifier Assembly

The T-R consists of six main assemblies plus side panels and top, which make up the weatherproof enclosure.

Terminal boards, cables, and other miscellaneous items complete the assembly. Main assemblies are identified

as follows:

Transformer Heat sink (rectifier)

Power module

Control panel

Overvoltage module

Base .

For purposes of orientation, the control panel is considered to be at the FRONT of the T-R. The load contactor

and fans are at the REAR. RIGHT and LEFT are determined by observing the unit from a position at the REAR.

Thus the output terminals are on the LEFT side.

The T-R is designed to convert the output of 115/200-Volt AC, 400.Hz, 3-phase generator to I IZVolts DC,

‘primarily for operation and/or testing of aircraft on-board electrical equipment. AC input voltage is reduced

by a transformer assembly and changed to DC by a 12-diode rectifier identified as a heat sink assembly. At

100% duty (steady operation), the unit is rated at 400 Amperes. Refer to Fig. 2 for specifications and capabili-

ties.

‘Solid state current and voltage sensing modules serve to protect the T-R and aircraft by disconnecting the load

under conditions of overload and/or overvoltage. Thermostatic switches provide protection against overheating.

Two, 200-Volt AC, motordriven fans provide cooling for internal components. Air is drawn in over the heat sinks

and discharged at the power module end.

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TM -598

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Transformer-Rectifier (I 12-V DC) Figure 1

A. Control Panel Assembly

Refer to Fig. 3. The control panel (12) serves a dual function. It provides a mounting panel for instruments

and controls, and when hinged downward, serves as a door for access to internal components. Two captive-

screw type fasteners (I 1 secure the panel in closed position. Louvers (2) on each side of the panel admit air

to the fans. An instrument light (41, controlled by a toggle switch (IO), provides illumination for controls

and instruments. IZVolt DC power for operation of the light is supplied by the generator-set engine circuit

through a 2-Ampere fuse (9). A three-position toggle switch (71 controls operation of a load contactor in the

input circuit The switch is spring loaded in the top ON, or start position.

An indicating light (6) glows green when the load contactor is closed,to indicate that 112.Volt DC is available

at the output terminals. A fuse (8) protects the II5Volt AC, load contactor operating circuit.

A voltmeter (3) indicates T-R output voltage in a range of 0 to 150 Volts DC. The DC ammeter (5) has a range

of 0 to 1200 Amperes.

.I

Other items are mounted on the inner surface of the control panel and are not visible unless the panel is

opened. A resistor (13) is connected in the load contactor holding circuit to limit current flow to approximate-

ly 0.5 Ampere. Another resistor (14) is connected in series with a variable rheostatJI6). The rheostat provides I

a means of adjusting DC input power to the overvoltage module (5, Fig. 4) to allofl,adjustment of the over- ’ b 1 voltage trip point.

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TM-598

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TRANSFORMER-RECTIFIER

Part number .................................................... 482085A-2 and -5

Model,number .................. i ....................................... TR-4012

PH&AL l/,“’ ’

Overall dimensions I

Length.. ....................... . ............................ .34inches(864mml

Width ...................................................... 20.3/4 inches (527 mm)

Height .................................................... 12-7/8 inches (327 mm)

Mounting dimensions ....................... 24-l/8 x I6 inches (613 x 406 mm) center to center.

Four 3/8-I6 inch tapped mounting holes

Weight approximately ........................................... 280 pounds (I 27.0 kg)

ELECTRICAL

Input

Line volts ...................................................... 115/200 Volts AC

Cycles per second ........................................................ 400 Hz

Amperes .......................................................... 132 Amperes

Kilowatts ............................................................ ..44k W

output

Volts ............................................................ 100VoltsDC

Load rating ........................................................ 400 Amperes

Duty cycle ................................. . ........................... 100%

Overload rating ............................................... 1000 Amperes, 30 Sec.

Kilowatts (steady state load) .................................................. 42 kW

Recommended output cable size for normal aircraft servicing .............................. 4/O

Specifications and Capabilities Figure 2

B. Electrical Components

Electrical components of the T-R, other than the control panel which was described above, are illustrated in

Figs. 4 through 6. A brief description of the function of each component is given here. Theory of operation

will be covered in the description where necessary.

(I ) Terminal board

The terminal board (4, Fig. 41 provides connection terminals for thethree-phase II5/200-Volt input.

Since this is a line-to-line installation, a neutral terminal is not requir@d. ‘I ’ I

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TM-598

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(Control Panel Open)

I. Screw fastener

2. Air inlet louver

3. DC voltmeter

4. Instrument panel light

5. DC ammeter

6. Contactor ON indicating light

7. Contactor control switch

8. Fuse (2 A) (I 15-V AC circuit)

9. Fuse (2 A) (12-V DC circuit)

IO. Light switch

II. Hinge

12. Panel

13. Resistor (200 Ohm, 25 Watt)

14. Resistor (250 Ohm, 100 Watt)

15. Diode bridge rectifier

16. Rheostat

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Control Panel Assembly Figure 3

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Nov 30177

(2) Load, contactor

The load contactor (13, Fig. 41 is a sealed unit similar to the one used on a Hobart generator set. It con-

tains four sets of contacts and an operating coil. The three larger sets of contacts conduct the input

power to the transformer. A small, auxiliary set is connected in the II5-Volt input holding circuit to

L the rectifier (15, Fig. 31, which supplies direct current for energization of the load contactor operating

1 ‘$1’ ) coil. In operation, the Ioac(contactor is closed’by holding the contactor control switch (7, Fig. 3) in spring-loaded ON (up) position momentarily. In this position, the switch connects 115Volt AC power

directly to the rectifier (15, Fig. 31, which in turn supplies DC power to the contactor operating coil

and closes all contacts in ih e load contactor. When the control switch (7, Fig. 3) is released, it auto- matically returns to center ON position and 1 I&Volt current is maintained to the rectifier, indirectly,

through a resistor (13, Fig. 31 and the auxiliary contacts in the load contactor. This circuit is arranged

in such a manner that in case an overloaded condition develops, the II5-Volt input to the rectifier is

sent directly to ground through a relay in the overload module. The load contactor is thus opened be

--cause the holding circuit has actually been short circuited. The resistor (13, Fig. 3) limits current flow in the holding circuit to 0.5 Ampere and thus prevents damage to any components.

(3) Transformer

The primary coils of the transformer (6, Fig. 4) consist of three sets of double windings. There are 6

secondary windings; 3 connected in wye, and 3 connected in delta. Normal input voltage is 200 Volts

AC and normal output is approximately I I8 Volts DC at no load. Output voltage gradually decreases

as load is increased. At 400 Amperes load the output voltage is approximately 100 Volts DC.

(4) Heat sink assembly

The heat sink assembly consists of two heat sink subassemblies (2 and 7, Fig. 4) mounted on two cross

member supports and attached by brackets and round head screws. Observed from the rear of the T-R,

the positive heat sink is on the RIGHT and the negative on the LEFT.

Each heat sink subassembly consists of a fan, a thermostatic switch, 6 diodes, and the heat sink which is

a section of multi-finned, aluminum extrusion, 25 inches (635 mm) ‘long. The fan assembly (IO, Fig. 4)

is mounted on the rear of the heat sink. A five-blade, 4-I/4-inch (108 mm1 dia. fan draws cooling air

over the diodes at a rate of 180 cubic feet (5 m3) per minute at 5300 RPM. The fan motor is rated

at 200 Volts AC, 400 Hz. Input power is 33 Watts, 0.3 Ampere. The thermostatic switch (I, Fig. 4)

mounted on the front end of the heat sink, performs a function similar to an overload relay. The

switch causes the load contactor to OPEN by interrupting the contactor holding circuit when an over-

loaded (or other fault) condition causes ambient temperature to rise to approximately 230 deg F (I IO

deg C). The switch closes at approximately 210 deg F (88 deg C).

Two hexagon bars (I I, Fig. 61, threaded at each end, serve as bus bars to conduct current from the

positive (right) heat sink to the positive terminal on the left side of the T-R. The bars pass through holes

in the negative heat sink and are protected from shorting by screw-mounted, insulating plates. Bars are

threaded into the positive heat sink body and funher secured by aluminum nuts. Two aluminum nuts

on the left end of the forward bar are used to attach one of the leads to the DC ammeter. The other

ammeter lead is attached to the same bar on the other side of the negative heat sink by a screw. The

portion of the bar between the lead attaching points serves as a shunt for the ammeter. The shunt

is adjustable by changing the location of the two aluminum nuts.

Two hexagon bars (4, Fig. 6) similar to the positive bars, but shorter, are attached to the negative heat

sink in the same manner as positive bars. They conduct current to the negative output terminal. Each

diode is attached to the heat sink by a washer-nut. 1 ‘i I ’ I

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TM-598

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I. Thermal overload relay 9. Bus bars

2. Negative heat sink

3. Output terminals

4. Input terminal board

5. Overvoltage protective module 6. Transformer

7. Positive heat sink

8. Diode leads

10. Fan

I I. Deleted

12. Overload protective module

13. Load contactor

14. Overload current transformer (Phase Bl

15. Overload current transformer (Phase Al

T-R Components (Front and Rear Views)

Figure 4

I> Nov 30177

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TM-598

I. Thermal overload relay

2. Negative heat sink

3. Positive output terminals 4. Negative output terminals 5. Negative diode

6. Fan

7. Overload current transformer (Phase A)

8. Overload current transformer (Phase C1

9., Input terminal board IO. Positive heat sink

I I. Positive diode 12. Overvoltage module mounting bracket

13. Overload module

1 T-R Components (Side Views) ‘.

Figure 5 I ‘1 ’ I

\ Nov 30177 l-1

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TM-598

1. Fan 2. Load contactor

3. Negative heat sink

4. Negative output terminals

5. Positive output terminals 6. Ammeter shunt

7. Input terminal board

8. Control panel

9. Thermal overload relay

10. Overvoltage module Il. Positive output bus bars 12. Positive heat sink

13. Power supply (24 V DC)

T-R Components (Top View From Front)

Figure 6

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(5)’ Overload module

The overload module (12, Fig. 41 contains solid-state circuitry which interprets signals from three cur-

rent transformers (,I4 and 15, Fig. 4, and 8, Fig. 5) and functions to close a relay when an overload con-

,’ .dition is detected in the T-R main circuit. The normally open relay contacts are connected to the load

I t/l! contactor I ISVolt AC holbing circuit so that when relay contacts are closed by an overload condition,

the load contactor holding circuit is shot-t circuited and the load contactor opens for lack of holding

power. T-R output power,is thus automatically disconnected. Relay contacts return to normally open

position when the overload is removed by load contactor opening. A 200-Ohm, 25-Watt resistor (13,

Fig. 3) limits current flow in the load contactor holding circuit when it is short circuited. Twelve-Volt

DC from the engine circuit provides operating power for the overload relay. This circuit is protected by a

2-Ampere fuse. The load contactor 1 IBVolt operating circuit is protected by another 2-Ampere fuse.

(6) Overvoltage module

The overvoltage module (5, Fig. 4) is another protective device with solid state circuitry,which causes a

normally CLOSED relay to OPEN under a condition of overvoltage in the T-R output circuit. The relay

is connected in the ground circuit of the I I5-Volt AC load contactor holding circuit. When an over-

voltage condition causes the relay to OPEN, the load contactor holding circuit is broken and the con-

tactor opens automatically to shut off the T-R.

(7) Base

The T-R base consists of a metal plate mounted on two steel channel bars which extend the full length

of the plate on each side. Three shorter channel bars are welded at right angles between the frame side

bars to give the plate support and rigidity. Four, 3/8-l 6 tapped mounting holes in the base are located

I6 inches by 24-l/8 inches (406 mm by 613 mm), center to center.

(8) Power supply

Furnished on T-R part number 482085A-5 only. This power supply (13, Fig. 6) furnishes the 24.5 Volts

DC required to prevent the generator’s plug-interlock relay from opening and shutting down the genera-

tor.

i Nov 30177

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TM-598

SECTION 2. PREPARATION FOR USE

1. General

The T-R requires no special preparation for use, other than inspection; mounting, as required; and/or connec-

tion, a required. I 10 7, li,“’

2. Inspection

A. Inspect exterior for shipping damage such as broken lights or instrument lenses, damaged sheet metal, etc.

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

C. Inspect interior for foreign materials such as rags, shipping papers, etc.

3. Installation

A. General

When the T-R is supplied as part of a generator set, it is properly mounted and connected.

8. Mounting --:. k

T-R mounting supports, complete with hardware, are available in kit form from Hobart Brothers Company

at a nominal cost. These kits provide T-R mounting arrangements for truck or trailer-mounted generators

I as well as self-propelled. If the recommended kit is not to be used, proceed as follows:

(1) Select a location in which the T-R package will not interfere with service and maintenance operations required for the vehicle, or-generator set on which it is mounted. Many Hobart self-propelled generator

sets provide a mounting space on the right side of the drivers compartment; on rear fenders, or behind the drivers compartment.

(2) Mount the T-R so that the front panel is easily visible and accessible for adjustment. A clear area at

both front and rear should be provided so that access panels may be opened fully and easily. I.

(3) Provide mounting holes in solid material to accommodate 3/8 in-16 screws, and locate them 24-l/8 .’

inches by 16 inches (613 mm by 406 mm), center-to-center. The 24-l/8 inch (613 mm) dimension is ..

lengthwise of the T-R. Also provide for air flow to transformer coils through the three openings in the

base.

(4) If mounting is on a solid steel plate, provide an access hole for input cables to the T-R, directly under or

near the input terminal board (l-l ; 7, Fig. 6).

(5) Position the T-R in its mounted position and align mounting holes. Attach with 3/8-16 screws and lock-

washers.

%. Connection

(1) Input (482085A2)

.I As stated above, input leads are connected when the T-R is supplied as part of a generator set. If input

connecton is required, proceed as follows: _’ . . 1 hi , I

- . ..a- -. ::_ / . . _..-. ..-e.. . .- ._.. -_-_ 1 -- .._ _d._ - -

-

1 Nov 30/77 l-2

Page 1

TM-598

(a) Select a convenient point in the generator output circuit BETWEEN the generator and the load

contactor’for attaching size No. 2 cables to output phases A, 8, and C. Many Hobart generator

sets are equipped with a convenient terminal block for this purpose.

(b) Measure the distance between the connection point and the input terminal board on the T-R to

dgkermine length of cable required., ’ I 10 ~ It

(c) Fabricate cables with terminations. Route cables through the bottom of the T-R and connect to

terminal board (1-l ; 4, Fig. 41, Input terminals are identified, A, 8, and C. Connect input lead from

phase A to terminal A, 8 to B;,etc. A large neutral N lead is not required; however, a No. 10 wire

should be connected from the generator N. terminal (or lead) to the ground stud on the T-R input

terminal board.

NOTE: When the T-R (482085A-2) is installed by the customer, it is necessary to remove

jumper lead on terminal strip in generator voltage regulator, Follow instructions

on plate located near terminal strip. Refer to generator set manual.

(d) If this T-R is wired into a generator set WITHOUT another T-R, the 70.inch (1778 mm) Brown-

Yellow lead must be connected to a positive 12.Volt DC source (e.g. generator engine circuit). If it

is to be used WITH another T-R, the Brown-Yellow lead may be connected to pin 1 of plug 6PL on

the other T-R (which is 12 Volts DC).

(2) Input (482085A-5)

Since this T-R is to be used as a free-standing unit (see l-l; Para. 1). the customer must connect it to a

receptacle connector which mates with the generator’s output cable plug. This customer-furnished recep-

tacle connector, AN31 14-18, should be mounted on a solid base, in a convenient location, and connected

to the T-R as follows:

(a) Refer to Fig 1. Connect three No. 2 size cables from the T-R input terminal board to the receptacle connector: A to A, 8 to B and C to C, as labeled.

l- 1

Page 2

-11’2 V. TRANS.- RECT. (Tap View)

r-, -/-24V. POWER SUPPLY

400 HZ. GENERATOR

I I

+--NO.2 CABLE

e

INPUT RECEPTACLE

-_ - I ‘i,

Input Connection Diagram

Figure 1 Nov 3Ol77

- .( -_ .. - -.-,- . . -..-” -..._._ .__.__ ._._. . . . .____..____ ._._. _. _.

TM-598

(b) Connect a No. 10 Wire from receptacle terminal N to the ground stud in the T-R.

, (c) Use a jumper wire to connectterminals E and F on the receptacle.

’ ‘@” l(d) Locate the White-Blue 3,’ ire’ (coiled on the power supply in the T-R) and connect it to terminal E

or F on the receptacle.

I ,(e) Connect the Brown-Yellow lead to a positive 12.Volt DC source (e.g. generator engine circuit).

(3) output

T-R output cables are not normally supplied unless specifically ordered. For normal aircraft service,

use 4/O size cable for positive and negative (see Fig. 2). For other applications where large loads are

involved, it is recommended that two, or even three 4/O cables be used.

.

Output Cable Installation

Figure 2

\ Nov 30177 l-2

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TM -598

‘SECTION 3. OPERATION

1. Preparation for DC Power Delivery ,

SM&nd prepare the generator se d’ &power delivery the same as for 409Hz use.

NOTE: 409.Hz, AC power may also be delivered to an aircraft at the ime time 11ZVolts DC is

y: being delivered. However; the combined loads should not exceed the rated capacity of the / generator set.

2. DC Power Delivery

A. Connect DC output cable plug connector to aircraft receptacle connector. Be sure good connection is made.

B. Operate generator-set controls, as instructed by the applicable manual, to produce 115.Volts AC, 400.Hz out-

put.

C. If illumination is required at the T-R control panel, turn instrument light (4, Fig. 1) ON with switch (10).

D. Close the T-R load contactor to deliver power to output cables by momentarily holding contactor control

switch (7) in top, ON position until indicating light (6) glows. Release switch and’allow it to return to center,

ON position.

E. Remember that an overload; overvoltage, or overheating will cause the load contactor to disconnect the load

and turn OFF the indicating light (6). If shutdown occurs, check for condition that caused it and remedy be.

fore restarting the T-R.

3. Discontinue Power Delivery

A. Place contactor control switch (7, Fig. 1) in OFF position.

B. Disconnect output cable at aircraft.

WARNING: DO NOT DISCONNECT CABLE WHILE POWER IS ON. LETHAL ELECTRICAL SHOCK

HAZARD EXISTS. ALSO, OPENING THE CONNECTOR UNDER LOAD CAUSES ARC-

ING AND PITTING OF CONNECTOR PARTS.

C. Operate generator-set controls as instructed in applicable manual.

1 Nov 3Of77 l-3 s

Page 1

(Control Panel Open)

1. Screw fastener

2. Air inlet louver

3. DC voltmeter

4. Instrument panel light

5. DC ammeter 6. Contactor ON indicating light

7. Contactor control switch

8. Fuse (2 A) (115-V AC circuit)

9. Fuse (2 A) (12-V DC circuit)

10. Light switch

11. Hinge

12. Panel 13. Resistor (200 Ohm, 25 Watt) 14. Resistor (250 Ohm, 100 Watt) 15. Diode bridge rectifier

16. Rheostat ,

TM -598

I 1

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Page 2 .

Control Panel Assembly

Figure 1

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Nov 30177

0 m I- TM-598

_ --- - --.

T- ‘. CHAPTER 2. SERVICING

SECTION 1. MAINTENANCE

1. General ,

‘I,’ ( ’ 1”. !I,“’ To make certain the transformer-rectifier is ready for operation at all times, it must be inspected and maintained

systematically and regularly so that any defects will be discovered and corrected before they result in serious dam-

age or complete failure of the equipment

WARNING: STOP OPERATION IMMEDIATELY IF A SERIOUS OR POSSIBLY DANGEROUS FAULT

IS DISCOVERED.

2. Lubrication

The T-R requires no lubrication.

3. Inspection

A periodic inspection schedule should be established and maintained. If the T-R is part of a generator set, in-

spections should be scheduled to coincide with similar inspections for the parent machine. Inspect as follows:

A. Open front control panel and rear access panel. Remove top cover.

WARNING: BE SURE NG INPUT POWER CAN REACH THE T-R. LETHAL ELECTRICAL SHOCK HAiARD EXISTS.

B. Inspect leads and cables for deteriorated or damaged insulation.

C. Check all accessible terminals and connectors for security.

D. Visually inspect all components, terminals, etc., for discoloration and evidence of overheating caused

by loose connections, etc.

E. Check both fuses located on control panel.

4. Cteaning

Use dry, compressed air to clean the interior of the T-R each time it is inspected. _

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TM-598

;; / SECTION 2. ADJUSTMENT/TEST

1. General

This Section contains information for,t,esting and adjusting the T-R after major parts replacement, or repair.

, h ‘& ,’ ’

I I, 2. Test

The following test procedures ma $ be used for testing the T-R following repair, or for checking performance.

, A. Preparation for Test

(1) Connect the T-R to a load bank using two each, size 4/O cables from each output terminal to the load

bank rather than single 4/O cables ordinarily used for aircraft service. I

NOTE: It is recommended that this higher capacity output cable arrangement be used for applications

where very large loads are connected to the T-R.

(2) Check diode leads. Make certain they are not touching bus bars.

(3) Make certain that each transformer bus has clearance between windings and other busing.

6. Operational Test Procedures

(1) Start generator set and adjust voltage to 115/200 Volts AC.

(2) Operate the T-R by placing switch (l-3; 7, Fig. 1) in top ON position momentarily, then release. Green

indicating light should glow to indicate power is available at output terminals.

(3) Observe voltmeter (3). It should indicate approximately 118 Volts DC. Attach a master voltmeter and

compare meter reading. Voltmeter should be accurate to within plus or minus 2%.

(4) Observe operation of fans and check direction of rotation. Air intake is at control panel end (front).

Exhaust is at power module end (rear). If fan rotation is incorrect, reverse the connection of any two fan input leads.

(5) Check adjustment of ammeter shunt.

(a) Adjust the load bank to apply a load of EXACTLY 400 Amperes. Use the load bank ammeter, or a master ammeter.

(b) Observe the T-R ammeter (l-3; 5, Fig. 11. At 70 deg F (21 deg C) ambient temperature, it should indicate 400 Amperes.

NOTE: The aluminum bus bar, a portion of which serves as a shunt, is sensitive to both ambient

temperature, and current-induced, thermal changes. This means that under sustained heavy

loads the ammeter reading could change from the reading indicated at the beginning of a power delivery period.

,

(c) If adjustment is required, refer to Ammeter Shunt Adjustment, Para. 3, A. ’

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\ Nov 30177 i> 2-2

Page 1

TM-598

(6) With 406Ampere load, observe generator-set ammeter. Input current to the T-R should be approximately

136 Amperes. Observe DC output voltage, on T-R voltmeter. Indicated voltage should be approximately

106 Volts DC.

(7) Test overvoltage module 1 /’ I ” ( 1 I”. l1,“.’

(a) Operate switch (7) to close load contactor. No load is required.

(b) Ob,serve T-R output voltmeter!.and gradually increase AC input voltage by adjusting the genera-

/ tor-set voltage control rheostat

(c) Overvoltage module should function to open the T-R load contactor when output voltage reaches

approximately 128 to 132 Volts DC. Module should function in 2 to 10 seconds after trip voltage

is reached.

(8) Test thermal overload thermostatic switches (l-l; 1, Fig. 4)

(a) Use an external switch or jumper lead to disconnect each of the two thermostatic switches. This

test is to make certain switches are connected properly and that they will open the load contactor

in case of overheating.

9-s - -; (b) Load contactor should open when a thermostatic switch is disconnected.

(9) Test overload module

(a) Use a jumper lead to short-out the thermostat switches.

(b) Apply a sustained minimum load of 1000 Amperes to the T-R. The overload module should func-

tion to open the load contactor within 30 seconds.

NOTE: A line current (input) of 328 Amperes is required to produce 9:9 Volts AC across the burden resistors for this test.

‘CAUTION: DO NOT RUN THIS TEST FOR MORE THAN 2 MINUTES.

(c) Remove’jumper lead across thermostat switches.

(10) Test power supply (482085A-5 only)

(a) With 115Volts AC 466HZ input, check output of power supply (l-l; 13, Fig. 6). Should be 24

to 28 Volts DC.

(b) Apply 366Ohm load to T-R output. Voltage should not fatl below 24 Volts DC.

C. Test Silicon Diodes

CAUTION: DO NOT APPLY x MEGGER OR ANY HIGH POTENTIAL TEST EQUIPMENT IN ANY

MANNER THAT SUBJECTS THE SILICON DIODES AND OTHER COMPONENTS TO

ABNORMAL VOLTAGES. SILICON DIODES MUST BE ISOLATED OR SHORTED WITH

.I EXTREMELY SHORT LEADS. SUCH TESTS MUST BE MADE UNDER THE SUPER- ’

VISION OF A FACTORY REPRESENTATIVE. 1 I ‘1, ’ I’

2-h

Page 2

.-. Nov 30177

I m I I TM-598

;:

(I\ Disconnect diode leads.

(2) Use a good quality ohmmeter (preferably one having a mid-scale value of approximately 50 ohms) to

, ‘measure resistance values. , ,’ ‘, I’ ’

’ ’ & : Zero the instrument on th I ’ R X 1 scale.

(4) Take and note a reading $y placing either ohmmeter lead on the threaded end of the diode and the other

‘lead on the diode lead.

(5) Reverse the ohmmeter leads on the diode, take and note another reading.

(6) The diode may generally be considered good if:

One reading is infinite or very high.

The other reading is extremely low.

NOTE: An acceptable low ohmic-value or range cannot be given because ohmmeter readings may vary

between meters, or even between diodes with the same rating. __..-- .z-

3. Adjustment

A. Ammeter Shunt

No adjustment of the shunt should be required unless it has been disassembled.

(1) Apply a load of exactly 400 Amperes. Use a reliable ammeter to make certain the load is 460 Amperes.

(2) Observe indicated amperage on T-R ammeter.

(3) Stop all operations; T-R and generator set Remove T-R top, and reposition adjusting nuts (4, Fig. 1) to adjust shunt. Lengthen the shunt to increase ammeter reading. Shorten the shunt to decrease reading.

Tighten adjusting nuts.

(4) Start generator set and reapply load to check ammeter reading.

(51 Turn both generator set and T-R OFF and repeat step (3) if further adjustment is required.

WARNING: DO NOT ADJUSTWHILE GENERATOR IS RUNNING. LETHAL ELECTRICAL SHOCK

HAZARD EXISTS.

(6) Install T-R top after adjustment is satisfactorily completed.

B. Overvoltage Trip Point

The adjustment of rheostat (1-3; 16, Fig. 1) determines trip point of overvoltage module (l-l; 5, Fig. 4).

.I (1) Open front and rear access panels. I ’

, I L!( L I

1 Nov 30/77 I. 2-2

Page 3

I m I I I I TM-598

1. Ammeter lead 4. Adjusting nuts 2. Lead attaching screw 5. Ammeter lead 3. Ammeter shunt [the portion of aluminum

rod between screw (2) and nuts (411

Ammeter Shunt Adjustment

Figure 1

! ’

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Page 4

, Nov 3Oi77 . ._

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(2) Apply 115/2C6 Volts AC to the T-R.

(3) Operate switch (1-3; 7, Fig. 1) to close load contactor. I 1

, , ‘#) Use a voltmeter to check PC vohage between’ terminals ” G” and “S” on the overvoltage module. Volt-

age should be 28 Volts DC. If not, use rheostat (l-3; 16, Fig. 1) to adjust

(5), Refer to Fig. 2, and loosen locknut (1). Turn adjusting screw (2) CLOCKWISE to increase voltage and

COUNTERCLOCKWISE to decrease Adjust as required until a reading of 28.5 Volts DC is observed on

voltmeter. This adjustment should allow the overvoltage module to open the load contactor at a load of

approximately 128 to 132 Amperes in the output circuit.

(6) Tighten locknut (1) after final adjustment. Remove voltmeter and close access panels.

Overvoltage Adjusting Rheostat

Figure 2

! ’

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1 Nov 30177 2-2

Page 5

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TM-598

;, SECTION 3. TROUBLESHOOTING /

1. General

Troubleshooting is an orderly process of checking and eliminating possible causes of trouble until the exact cause of trouble is found. As a rule, lt'ht?'!best place to stard, 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 iocated. Use Schematic Diagram, Figure 1 , and Connection Diagrams located in Section 2-4.

2. Troubleshooting Chart

A. Description

The troubleshooting chart lists information under three headings:

(1) Trouble, symptom, and condition

(2) Probable cause

(3) Test, check, and remedy

B. How to Use Troubleshooting Chart

Read the trouble symptoms and conditions before proceeding to causes and remedies. For example, at the beginning of the troubleshooting chart, the first trouble listed is "Transformer-rectifier inoperative. Load contactor will NOT close". If the load contactor WILL close, then obviously this is not your symptom and condition. Proceed to the trouble and symptom directly below until symptoms and conditions corresponding to your situation are found. Look to the right under '*Probable Cause", and "Test, Check, and Remedy" to find various things which could cause the trouble and what you should so to check and remedy them.

3. Equipment for Troubleshooting

A good quality multi-scale volt-ohmmeter is the only instrument required a for troubleshooting. At least two jumper leads with alligator, or similar

clips, will be required.

4. Safety

WARNING: EXERCISE EXTREME AND COMPONENTS.

CARE TO AVOID CONTACT WITH HIGH VOLTAGE LEADS LETHAL ELECTRICAL SHOCK HAZARD EXISTS.

.I

1

CAUTION: DO NOT APPLY A MEGGER OR ANY HIGH POTENTIAL TEST EQUIPMENT IN ANY MANNER THAT SUBJECTS THE SILICON DIODES AND OTHER COMPONENTS TO ABNORMAL VOLTAGES. SILICON DIODES MUST!,BE ISOLATED OR SHORTED WITH EXTREMELY SHORT LEADS. SUCH TESTSMUST BE MADE, UNDER'THE' SUPERVISION OF A FACTORY REPRESENTATIVE.

1 Nov 30/77 2-3

Page 1

. -. ..-. _ .I . . .’ . .

JR TM-598

5. Parts Replacement

To lessen end item down time and to get a faulty machine back into service as quickly as possible, the black-box concept of parts replacement is reflected,i'n the troubleshooting ,chart. For example, if a component in the line-d,rppj,,and current limiti gftnddule is defective, replace the complete module and'return the defec't fe module to the factory for repair or I exchange. Assemblies which lend themselves to this concept are:

Overload module

Overvoltage module

6. Check Connections and Leads

ALWAYS make a check of connections and leads to a component suspected of being faulty. With the exception of a few instances, we will assume that connections and wiring have always been checked first and that power has not been lost as a result of defective wiring or connections.

7. Schematic Diagram

Refer to the Schematic Diagram (Fig. 1) for the electrical location of components and their relation to each other.

” ,

i 2-3

Page 2

/ i _

Nov 30/77

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Screw fastener

Air inlet louver

DC voltmeter

Instrument panel light

IDC ammeter Contactor ON indicating light

Contactor control switch

Fuse (2 A) (115 V AC circuit)

(Control Panel Open)

9. Fuse (2 A) (12 V DC circuit)

10. Light switch

11. Hinge

12. Panel

13. Resistor (200 Ohm, 25 Watt)

14. Resistor (250 Ohm, 100 Watt)

15. Diode bridge rectifier

16. Rheostat

Control Panel Assembly

Figure 2

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Page 4

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Nov 30177

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TM-598

,,

TROUBL& SYMPTDM,

CONDITION, PROBA8l.E CAUSE TEST. CHECK, REMEDY

9 /’

, I $8,)’ 1. Transformer-rectifier

l1,“’ A. No input power from AC power A. Check voltage at input terminal board

inoperative. Load soury (generator-set) (see l-l, Fig. 4, item 4). Input should be

contactpr will NOT 200-V AC line-to-line. Check voltage from

, close. line C to ground terminal stud on input

terminal board. If not approximately

115 V AC, correct fault in T-R ground

circuit. (Also see Trouble 8.)

8. Fuse (8, fig. 2) defective 8. Remove and inspect fuse. Replace if

defective.

C. Defective load contactor control C. Check voltage at control switch (7, Fig.

switch (7, Fig. 2) 2) terminal No. 5 (brown-red wire) while holding switch in top ON position. If

voltage is not approximately 115 V AC,

replace switch.

D. Defective diode-bridge rectifier

(15, Fig. 2) D. Check rectifier DC output voltage at out-

put terminals (blue-red and yellow-red

wires). Hold contactor control switch

(7, Fig. 2) in top ON position while testing. If voltage is not approximately

100 V DC, replace the rectifier.

E. Relay in overvoltage module E. With switch (7, Fig. 2) held in ON

(see l-l, Fig. 4, item 5) defective position, check voltage at terminal T

(brown-white wire) on overvoltage

module. If voltage is not approximately

115 V AC, replace overvoltage module.

F. Defective (open-circuited)

thermostatic switch (see l-l, Fig. 4. item 1)

G. Load contactor coil defective

(see l-l, Fig. 4, item 13)

F. Check thermostatic switches for con-

tinuity. If either switch is open circuited,

replace.

G. Check load contactor coil resistance

between terminals Xl and X2. (See 24,

Fig. 2, connection diagram.) Zero resist-

ance indicates a short-circuit. Very

high (infinite) resistance indicates an

open circuit. Replace complete load con- tactor if coil is defective.

! (

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_. -- -- - Nov 30/7/ Troubleshooting Char-t (Sheet 1 of 3)

Figure 3 2-3

Page 5

TROUBLE, SYMPTOM, CONDITION PROBABLE CAUSE TEST, CHECK, REMEDY

2. Load contatioJk&es

normally. Opens as soon

as control switch is re

leased.

y--- .-

3. Fuse (8, Fig. 2) blows

when load contactor

switch is operated to ON

position.

4. Output voltage unsteady.

Green indicating light

blinks.

5. Output voltage decreases

more than normal as

load is increased.

I 2-p

A. Defective cl ontrol switch (7, Fig. 2)

B. Defective resistor (13, Fig. 2)

C. Small contacts in load con-

tactor (see l-l, Fig. 4, item 13)

defective

A. Short circuited condition in

load contactor holding circuit

8. Defective relay (contacts

closed) in overload module

(see l-l, Fig. 4, item 12)

A. Voltage regulator on 200-V AC

power source requires adjust- ment

A. Defect in transformer and

rectifier circuit

(1) Defective transformer

(see l-l, Fig. 4, item 6)

Place switch in center ON position.

Check voltage at switch terminal 5.

(See 2-4, Fig. 1, connection diagram

[brown-red wire.1 1 If there is no voltage,

replace switch.

Place control switch (7, Fig. 2) in center

ON position and check voltage at re-

sistor (13, Fig. 2) output end (orange

black wire). If resistor is open or short

circuited, replace.

With control switch (7, Fig. 2) held in

top ON position to keep load contactor

closed, check voltage at terminal No.

2 (red-white wire) on load contactor.

If no voltage is indicated, replace com-

plete load contactor.

Check all leads in this circuit for

damaged insulation and shorting. Check

all terminals and connections for short-

ing. Repair as required. See Schematic

Diagram, Figure 1.

Disconnect plug connector on over-

load module. If contactor will now

dose and remain closed without bluw-

ing fuse, replace ovedoad module.

Refer to the generator-set instruction

manual. Adjust RATE potentiometer on voltage regulator to stabilize output

voltage. Voltage is steady when indicatin!

light ceases to blink.

Check as follows:

(1) Check all input and output connec-

tions to the transformer. Use an

ohmmeter to check transformer

windings. Repair or replace as

required. !

I ‘! L

Troubleshooting Chart (Sheet 2 of 3)

Figure 3

__ Nov 30177

Page 6

TM-598

TROUBLE, SYMPTOM,

CONDITION PROBABLE CAUSE TEST, CHECK. REMEDY

,j t ,’ 5. (&Znued)

I I’ ’

A. (Continued)

(2)!,Defective diodes or diode

connections (see l-l, Fig.

5, items 5 and 12)

A. (Continued)

(2) Check all diodes for open or short

circuited condition. Check all con-

nections. Check installation of

diodes (torque values).

NOTE: Tqrque Westinghouse diodes

to 25 foot-pounds. Torque

International diodes to 13-l !:

foot-pounds (threads lubri-

cated with Penetrox).

6. Overload module

does not operate

Replace diodes and/or correct in-

stallation and connections as re -- -- j quired.

A. Module not receiving 12-V DC A. Check and correct as follows: power

(1) Fuse (9, Fig. 2) defective (1) Place instrument light switch (10)

in ON position. If instrument light

does not operate, check fuse. Re-

place if defective.

(2) Defect in 12-V DC circuit (2) Check wiring and connections from

12-V DC power source to overload

module. Repair as required.

7. Overload module A. An open resistor (1 RES, 2RES, A. Check each resistor. Replace as required. operates to open load or 3RES. Fig. 11 is allowing contactor when no higher than normal voltage to over1 oad exists. enter the overload module

8.2 Generator shuts down A. Power supply (Fig. 4) is faulty, A. Replace power supply (1-l; 13, Fig. 6). when contactor switch not supplying 24 Volts DC to (8, Fig. 2) is turned generator’s plug-interlock relay on (482085A-5 only).

_. ---- Nov 30/77

!

) ‘! I

Troubleshooting Chart (Sheet 3 of 3) Figure 3

’

’ I’

2-3

Page 7

Res. 11

=3

0) s 6

CONNECTION DIAGRAMS

I 0) f 3

pziEEq

To Input Term.‘?? On input Terminal Board

To L Ground Stud On To Terminals E 8 F On Customer Transformer-Rectifier Furnished Input Receptacle

TM-598 .

.I

1. Mounting Bracket

2. Transformer with Rectifier 3. Filter, 24 Volt

4. Capacitor, 20 F, 150 Volt p 5. Resistor, 200 Ohm, 10 Watt

24.Volt Power Supply (482085A-5 Only)

Figure 4 ! ’

I ‘!, ’ I’

2-d

Page 8

Nov 30177 _..

TM-598

SECTION 4. REPAIR .

1. General '

Repair of the transformer-rectifier will consist primarily of parts replacement. The, only rotating parts in the unit are the two cooling fans and the only other moving, parts are switches and relays.

I 6”. I ”

2. 1 Removal and Installatioh

If extensive repairs 4re to be made on a T-R which is mounted on a mobile machine such as a self'-propelled generator set, etc., it is suggested that unit be removed and placed on.a workbench or other supporting structure.

A. Removal Procedures

WARNING: MARE CERTAIN THAT INPUT POWER CANNOT REACH THE T-R. LETHAL ELECTRIC SHOCK HAZARD EXISTS.

(1) Disconnect D-C cables at output terminals.

(2) Open control panel and disconnect three AC input leads at the terminal board (l-l; 4, Figure 4).

(3) Disconnect Brown-Yellow lead and tag it for reconnection.

(4) Remove four (3/8-16) mounting screws which attach T-R to mobile unit.

(5) Attach a lifting hoist and carefully lift the T-R. Lifting eyes are accessible when plug buttons are removed through holes in side panels. Be sure all leads are free and do not become entangled. Move the unit to a workbench or clear working area.

B. Installation Procedures

Installation procedures are provided in Section l-2, Para. 3.

3. Parts Replacement

A. Access

All parts which might normally require replacement are easily accessible by opening the front and rear hinged access panels. Output diodes are accessible by removing the housing top.

B. Parts Removal

(1) Modules

The overload, line drop, and current limiting modules are equipped with quick-disconnect lead connectors so that input and output lead identification for these units is not a problem.

Identify and mark leads to the overvoltage module before removal.

(2) Miscellaneous parts

Always identify and mark leads before diskonnecting and removing any component not equipped with plug and'ieceptacle connectorsi

Nov 30/77 2-4

Page 1

TM-598

c. Parts Installation

Check' new 'parts physically and electrically, if possible, before installation.

(1) Position part,carefully in mounting location and attach securely. 9

(2,) j&z certain all lead+ 'ire connected properly. If any doubt exists, refer to the applicable connection diagram in this chapter.

4.

5.

(3) If it is necessary/to replace any of the diodes mounted on the heat sinks (l-l; 5'and 11, Figure S), contact the factory at the address given in the Introduction of this manual for installation torque requirements.

NOTE : The torque value for these diodes is a critical require- ment. The torque requirements vary widely among the various suppliers of these diodes, and, in addition, the suppliers change. Therefore, it is impractical to provide torque values for these diodes in the manual.

At installation, threads and mounting face of the replacement diode should be coated with Penetrox or an equivalent heat sink compound.

(4) If the bus bars (l-l; 4 and 11, Figure 6) and aluminum nuts which secure them are removed for any reason, they must be torqued in place at installation to 20 to 25 pound-feet (27 to 34 N-m). The mounting face of each aluminum nut and the threads on the bus bars must be coated with Penetrox or an equivalent heat sink compound at installation.

D. Fan Installation

If fan blades rotate in the wrong direction, reverse connection of ANY TWO fan input leads.

Workmanship

Perform all repairs in accordance with good electrical repair practices. All interconnecting lead connections to components must be made with proper wire terminations. Route all leads neatly and secure with ties, clamps, etc.

Connection Diagrams

A complete set of connection diagrams is included in this section. When reconnecting wires to a component, use the connection diagrams to make certain that connections are made correctly.

Connections provided on the following pages are as follow, in the order that they appear:

DIAGRAM

T-R Connection Diagram Power Module Connection Diagram Control Panel Connection Diagram Overload Module Connection Diagram Overvoltage Module Connection Diagram

DIAGRAM NO. -

38 9802 389800 389801 387738A:.

'

389522d "1 ' I'

/ -

2-4

Page 2

Nov 30/77

. -

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02 b"--- -

RIO l5OA

LEGEND

CAPAClTOR 1.5/35 CAPACITOR 50/25 DIODE POTENTIOMETER 1K OHM, l/2 WA1 TRANSISTOR 2N-3903 TRANSISTOR ZN-3904 TRANSISTOR PROGRAMMABLE UNIJ- RESISTOR 330 OHM, 3-l/4 WATT RESISTOR 1200 OHM, l/2 WATT RESISTOR 4700 OHM, l/2 WATT RESISTOR 5600 OHM, l/2 WATT RESISTOR 22K OHM, l/2 WATT RESISTOR IOK OHM, l/2 WATT RESISTOR 270 OHM, l/2 WATT RESISTOR 470 OHM, l/2 WATT RESISTOR 150 OHM, l/2 WATT RELAY ZENER 22 VOLT

'T

*2N-

!

) ‘!

c

-6027

! / -1

I

.I

_

_ . _. .c_ .-

1. General

( 2.

3.

4.

i

_

1; c

_

CHAPTER 3. ILLUSTRATED PARTS LIST -

SECTION 1. INTRODUCTION

.

T&z Illustrated Parts List ideqtifle&‘describes. and illustrates main assemblies, subassemblies, and detail parts of

the iransformer-Rectifiers, manufactured by Hobart Brothers Company, Power Systems Division, Troy, Ohio

45373, and identified as Part Numbers 482085A-2 and-482085A-5.. \ _ _

Purpose

The purpose of this list is to provide parts identification and descriptive information to maintenance and provision-

ing personnel for use in provisioning, requisitioning, purchasing, storing, and issuing of spare parts.

Arrangement

Chapter 3 is arranged as follows:

Section 1 - Introduction

Section 2 - Manufacturer’s Codes

Section 3 - Parts List

Section 4 - Numerical Index

Exolanation of Parts List

A. Contents

The parts list contains a breakdown of the equipment into assemblies, subassemblies, and detail parts. All parts I

of the equipment are listed except:

(1) Standard hardware items (attaching parts) such as nuts, screws, washers, etc., which are available com- mercially.

(2) Bulk items such as wire, cable, sleeving, tubing, etc., which are also commercially available.

(3) Permanently attached parts which lose their identity by being welded, soldered, riveted, etc., to other

parts, weldments, or assemblies.

Parts List Form

This form is divided into five columns. Beginning at the left side of the form and proceeding to the right,

columns are identified as foiiows:

(1) 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 and item numbering system ties the parts list to the illustration and vice versa. The figure and

index numbers are also used in the numerical index to assist theuser in finding the illustration pf a part

when the part number is known. I ‘1, ’ 1, .- . _

-. - . -.:-.--- -_.- _-.- --.a _-- - . __ 1.. -_ _ ---.--. -- ‘.

1 Nov 30177 ,_ - 3-l

Page 1

.,. ..,

I I

TM-598

;;

I

(2) HOBAR’T PART NUMBER Column

ALL part numbers appearing in this column are Hobart numbers. In all instances where the part is a

1 purchased item the vendor’s identifying five-digit code and his part number will appear in the NOMEN-

, / ‘I,iI ,, :CLATURE column. Vendq(rT p&s which are modified by Hobart will be identified as such in the NO-

‘MENCLATURE column. In case Hobart does not have an identifying part number for a purchased part,

the HOBART PART NUMBER column will reflect No Number and the vendor’s number will be shown

in the NOMENCLATUREcolumn. Parts manufactured by Hobart reflect no vendor code or part num-

ber in the NOMENCLATURE column.

(3) NOMENCLATURE Column

The item identifying name appears in this column. The indenture method is used to indicate item re-

lationship. Thus, components of an assembly are listed directly below the assembly and indented one

space. Vendor codes and part numbers for purchased parts are shown in this column. Hobart modifica-

tion to vendor items,is also noted in this column. ._ .- -

(4) EFF (Effective) Column ,

This column is used to indicate the applicability of parts to different models of equipment. When more than one model of equipment is covered by a parts list, there are some parts which are used on only one

model. This column is used for insertion of a code letter A, B, etc., to indicate these parts and to identify i

the particular model they are used on..Uncoded parts are used on all units. Parts in this list are coded as follows:

I

Parts coded A are used on 482085A.2 only.

Parts coded B are used on 482085A-5 only.

(5) UNITS PER ASSEMBLY Column

f 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.

‘..

i 3:1

Page 2

Nov 3on7

I TM-596

;; - ._ __ . .- _ -i

SECTION 2. MANUFACTURER’S CODES

‘. \

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

The lollowing list is a compilation of, vendor codes with names and addresses for suppliers of purchased parts

&tt&!in this publication. The cod Q

I

s are in accordance with the Federal Supply Codes for Manufacturer’s Catalog- ’

ing 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 manufacturer will be listed in the nomenclature column. / .I:

1.

CODE VENDOR’S NAME AND ADDRESS

04009 Arrow-Hart & Hedgeman Eiectric Company

103 Hawthorne Street ’

Hartford, Connecticut 06106

08106 . Lamp Industry For Use With Industry

Designations and Abbreviations for Lamps

13445 ColeHersee Company

20 Old Coiony Avenue Boston, Massachusetts 02127

14101 Sprague Electric Company

300 W. National

Vandalia, Ohio 45377

i 4859 Metals & Controls, Inc.

Control Products Group

300 North Main

Versailles, Kentucky 40383

27193 Cutler-Hammer, Inc.

Specialty Products Division

4201 N. 27th Street

Milwaukee, Wisconsin 53216

44655 Ohmite Manufacturing Company

3601 W. Howard Street

Skokie, Illinois 60076

60741 Triplett Electrical Instrument Company

Harmon Road

Bluffton, Ohio

’ 71400 Bussman Manufacturing Division of ;

McGraw-Edison Company

2536 W. University Street ,’ St. Louis, Missouri 63017

.I ! .’

;

I ‘!, :’ i’

L j ,;

..-.- -- - _ __,_ - d .-- -. - _._ _ ._ . . .._ _ .- -- -

t Nov 30177 I; 3-2

Page 1

I m r 1 I 1

;; _..

I

CODE VENDOR’S NAME AND ADDRESS

72619

I ’ i/l

74063

a3774

aim

a91 10

90201

90763 United-Carr Inc.

4258 N. Cicero

Chicago, Illinois 60646

91929 Honeywell Inc.

92702

$2

Page 2

TM-596

3

~ I, ” ’

Dialight Corporation

60 Stewart Avenue

Brooklyn, New York 11237

I

Hartman Electrical Manufacturing Company

P. 0. Box a

Mansfield, Ohio 44901

Midwest Electric Products

2114 N. Arsenal Avenue Indianapolis, Indiana 46218

Genisco Technology Corporation

Illinois Division

9367 William Street

Rosemont, Illinois 60018

Amp Inc.

155 Park Street Elizabethtown, Pennsylvania 17022

Mallory Capacitor Company

3029 E. Washington Street

P. 0. Box 372

Indianapolis, Indiana 46206

Building Controls & Components Group

Micro Switch Division

Chicago & Springs Street

Freeport, Illinois 61032

IMC Magnetics Corporation Eastern Division

570 Main Street

Westbury, New York 11591

! ;

I L!, ’ I’

3 Nov 30177 .-

.I

;;

I SECTION 3. PARTS LIST

1. Exolanation of Parts List Arranaement

TM-598

The pa@ 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 p/age. Unless the list is unusually long, the user will be able to look at the illustra-

tion and read the parts list without turning a page.

t Nov 30177

1 [

I ‘!, ’ I

3-3

Page 1

TM-598

. .I

Transformer-Rectifier Assembly

Figure 1

! ’ /

I ‘!, L I’

3-b

Page 2

Nov 30177 -- !,

FIGURE ’

ITEM NO.

l-

I’ I ’ 6”)

1

( 2

3 4

- 5

6

7

a 9 10

.i -11

- <&- .I$

- 13

1’4

15

16

17

18 19

20

21

22

23

24

25 26

> 27 - 28

- 29 4015644

- 30 401565-l - ‘31 401566-l - 32 401563-3

- 33 430278

34 482814

35 389426

;;

HOeART

PART’NO.

4a2085A-2

4a2085A-5

389410

389254

389229

389226

389225

389251

389255

aRT-336

389333

W-10931-3

403692

389530

389256 aRT-336

389333

W-l 0933-3

403692

389262

389249

6FW-3167

389779

389260

389336

389503

389522

401556

389466

w-10051-10

389517

389445

389443

389444 389331

401563-4

NOMENCLATURE

1234567

TR+NSFORMER-RECTIFIER ASSEMBLY, 112 VOLT,

JDC A 1

’ TRANSFORMER-RECTIFIER ASSEMBLY, 112 VOLT,

DC WliH 24-VOLT POWER SUPPLY B 1

I .TOP 1

TM-598

. HEAT SINK ASSEMBLY

. . BRACKET, HEAT SINK

. . ,BUS BAR, ALUMINUM

. . BUS BAR, ALUMINUM

. . INSULATOR, BUS BAR

. . HEAT SINK ASSEMBLY, POSITIVE

. . . THERMOSTAT Vl4859, Type 204OOL

. . . BRACKET, THERMOSTAT

. . . DIODE, SILICON, 275 A., POSITIVE BASE

. * . FAN, HEAT SINK V92702, Model BT220 6F-O-1

. . . HEAT SINK, ALUMINUM

. . HEAT SINK ASSEMBLY, NEGATIVE

. . . THERMOSTAT Vl4859, Type 204OOL

. * . BRACKET, THERMOSTAT

. . . DIODE, SILICON, 275 A., NEGATIVE BASE

. . . FAN, HEAT SINK V92702, Model BT-220 6F&1

HEAT SINK, ALUMINUM

: I SUPPORT, HEAT SINK . SPACER

. TRANSFORMER ASSEMBLY’

. . TRANSFORMER ASSEMBLY, 112 VOLT

. . . EYE, LIFTING

. . . BRACKET, TRANSFORMER

. OVERVOLTAGE ASSEMBLY

. MOUNT, RUBBER

. BRACKET, RELAY

. CLAMP

. STRAP, GROUND

. BOARD ASSEMBLY, TERMINAL

BOARD, TERMINAL OUTPUT : : STRIP, INSULATING

.: BRACKET, TERMINAL BLOCK

. HOUSING, PIN CONNECTOR, MALE VaQllO, No. l-480288-0

. HOUSING, PIN CONNECTOR, FEMALE, VaQllO, No. l-480287-0

. TERMINAL PIN, va9i 10, NO. 61 i la-1 (STRIP)

. TERMINAL SOCKET VaQl 10, No. 61117-l (STRIP)

. HOUSING, PIN CONNECTOR, MALE VaQllO, 1-480286-1

. GROMMET

. POWER MODULE ASSEMBLY (For betails See Fig. 2)

. PLATE, TERMINAL, BUS BAR I’!,

1 4

2

2

2 1

1

1

6

1

1

1

1

1

6

1

1

2 4

1

1

2

4

1

3

1

3

1

1

1

1

1

1

1 19

10

1

1 1;

21

NOT ILLUSTRATED

Nov 30177 3-3

Page 3

,’

I ’ i”. I ”

3-p

Page 4

I ‘!,

TM-598

Nov 30177

FIGURE HOBART

ITEM NO. PART NO.

l-36 ’ - 371 ‘$j - 38

- 39

- 40 ; / 41

42

43

44

45

46

47

48

49

50

51

389427.

400176-4

400830-8

401913-3

389535

16DA-1997-12

369556

A-896-1

389524

482135

A-897-1

389359

482801

389360

389275

389769

- 52 400480-12

53 481578 . POWER SUPPLY 24 VOLTS (For Details See Fig. 4)

NOT ILLUSTRATED

t Nov 30177

TM-598

NOMENCLATURE

1234567

; !NSULATOR, BUS BAR

1, . TERMINAL, RING . TERMINAL, RING

. TERMINAL, RING

,. . ROPE, SUPPORT, HINGED DOOR

. BUTTON, PLUG HOLE

. COVER ASSEMBLY, TERMINAL

. NAMEPLATE, POSITIVE

. NAMEPLATE

. CLAMP, CABLE

. NAMEPLATE, NEGATIVE

. PANEL ASSEMBLY, TERMINAL SIDE

. PANEL ASSEMBLY, REAR

. PANEL ASqEMBLY, SIDE

. BASE

. PANEL ASSEMBLY, CONTROL (For Details See Fig. 3)

. TERMINAL, RECEPTACLE, SERIES 250, VaQllO, LP41729

UN ITS

per EFF ASSY

1

1

1

6

1

2

1

1

1

1

1

1

1

1

1

1

1

B 1

3-3

Page 5

TM-596

Power Module Assembly

Figure 2

I ‘!, L I’

343

Page 6

Nov 3Ol77

.._.. ._ _d .- ._,. I ..__. ..___ _, _.._ -

FIGURE

ITEM NO.

2-

2 ’

3 4

1 5

6

7

-a 9

_ :

‘,; ,

HOBART PART NO.

462814

lCZ-148

402935-5

369321

404518

367738A

401556

40 1563-4

401565-l

482809

. . . -.. 2 ., . _

NOMENCLATURE

1234567

YODULE ASSEMBLY, POWER (For NHA See Fig. 1)

~ 1, . TRANSFORMEh, CURRENT Va6151, E-6170

. RESISTOR, 5 WATT, TYPE RH

I - BRACKET, MOUNTING RESISTOR

. CONTACTOR, V74063, B-301P

. BOARD, P.C. OVERLOAD

. MOUNT, RUBBER

. HOUSING, PIN CONNECTOR

. TERMINAL SOCKET va9i IO, NO. 61 i 18-i

. BRACKET ASSEMBLY, MODULE, POWER *

TM-598

UNITS

per EFF ASSY

REF 4

3 . 3

1

1

4

1

10

1

.I ! ;

NHA NEXT HIGHER ASSEMBLY .) b!, ’ :I

t - NOT ILLUSTRATED

Nov 30177 3-3

Page 7

25

.26

\

>

TM-598

:, ?; )

‘i.

t 33

Page a

Control Panel Assembly

Figure 3

I L!, ’ I

/ Nov 30/77 .-

!#

_ __ - _. . _

FIGURE HOBA’RT

ITEM NO. PART NO.

3-

‘I 2

3

’ 16DW-538-o

403189

/ 4 H F-25 1 a-9

5 W-8061 A-Q

6 W-8063A-5

7 W-l 1166-l

a H F-2407

9 75-532

10 FW-1312

- 11 401564-3

- 12 401564-4

- 13 401566-l 1

- 14 389517

- 15 389804

16 16DA-1997-4

17 W-9712-36

la 389760

19 30GH-1262

- 20 50GHP-206

21 368326-16

22 388328-l 5

23 389807

24 404065-l

25 400078

26 W-2974-F

27 5TW-356-O

28 W-9746-4

29 389433

30 16DA-1997-3

i NHA

NOT ILLUSTRATED

NEXT HIGHER ASSEMBLY

Nov 30177

__ _ - -.. .._ ,_ . ..__ ._._,

I I m I I

NOMENCLATURE

1234567

PANEL ASSEMBLY, CONTROL (For NHA See Fig. 1)

II ’ ‘AANDLE, DooR, SIDE

NAMEPLATE, ON-OFF CONTACTOR

: SWITCH, TOGGLE, 3 POSITION, 2 POLE, V91929,

’ No. 312TSl-59 . LIGHT, INDICATOR V72619, No. 261310-l 19-301

. AMMETER, DC, SINGLE SCALE, O-1200 V60741

. VOLTMETER, DC, SINGLE SCALE O-150 V60741

. FUSE, AGC, 2 AMP FUSEHOLDER V71400, No. HKP

: NAMEPLATE, LIGHT ON-OFF

. SWITCH, TOGGLE, DPST, V27193, No. 732OK3

. HOUSING, SOCKET, CONNECTOR VaQllO,

i-480285-o

. HOUSING, SOCKET, CONNECTOR VaQllO.

1-480288-o . TERMINAL, SOCKET VaQllO

. STRAP, GROUND DOOR

LABEL, INSTRUCTIONS

: BUTTON, PLUG V90763, SS48192

. RHEOSTAT, 25 WATT, 175 OHM, V44655, Model “H”

. BRACKET, MT. RHEOSTAT

. SOCKET, PILOT LIGHT V13445, DL-21

. LAMP, PANEL LIGHT voaioa, NO. 67

. NAMEPLATE, 12 VOLT

. NAMEPLATE, 115 VOLT

. CAPACITOR ASSEMBLY

. RECTIFIER, SILICON VO4713, No. SDAl0270-1

. BRACKET, MTG. RESISTOR V44655, No. 12

. RESISTOR, 250 OHM, V44655, No. 0960B

NAMEPLATE

: RESISTOR, 200 OHM, V44655

. PANEL ASSEMBLY, FRONT

. BUTTON, PLUG V90763, SS-48192

TM-598

UNITS

EFF I&Y

1

4

1

1

1

1

1

2

2

1 1

1

2

30 1

1

1

1

1

1

1

1

1

2

1

2

1

1

1

1

1

3-3

Page 9

TM-598

24-Volt Power Supply

Figure 4

i 3-3

Page 10 c

I ‘1, L :

I

Nov 30177

FIGURE

ITEM NO.

4 5

6 W-9026-2

t Nov 30177

4

HOBART

PART NO.

481578

481579

386781

402460-4

388720

400075-l

NOMENCLATURE

1234567

II POWiR SUPPLY, ,24 VOLT

. BRACKET, MOUNTING, TRANS. & FILTER

. TRANSFOtiMER WITH RECTIFIER, ASSEMBLY

1 . . CAPACITOR, TYPE MTA, 3 pF, 50 V DC, V90201, No. MTA 3D50

. FILTER, 24 V., ASSEMBLY

. . CAPACITOR, 20 vF, 150 V DC Vl4101,

No. TVA-1410 . . RESISTOR, 200 OHM, 10 WAlT V44655 ,

TM-598

---- 5

UNITS

. per :

EFF ASSY

B 1 .

B 1. ‘.

B 1

B 1 :

B 1

B 1

B 1

! !

I ‘!, , ’ I

3-3

Page 11

TM-598

;; 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

numb$r is known. Part numbers are arranged in alpha-numerical sequence. Thus, any number beginning with the

lette& 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 pati is used in more than one place, each location is listed commencing with the

first location the part is listed. ”

NUMERICAL INDEX

FIGURE AND PART NUMBER ITEM NUMBER ’

A-896-1

A-897-1

FW-1312

H F-2407

H F-25 1 B-7

w-10051-10

w-10931-3

W- 10933-3

W-11166-1 W-2974-E

W-8061 A-Q

w-8063A-5

W-9026-2

W-97 12-36 W-9746-4

lcf-148

16DA-1997-12

16D,A-1997-3

16DA-1997-4

16DA-42 10

16DW-538-O

30GH-1262

384935-l

38678 1

38773aA

’ 388328-i 5

3aa32B16

388720

389225

389226

’ 389229

389249

389251

389254

389255

389256

Nov 30/77

l-43

l-46

3-10

3-a

._ 34

l-23 .. r--~. i l-a

l-13

3-7

3-26

3-5

3-6

4-6

3-l 7 3-28

2-l

l-41

330

3-16

3-24

3-2

3-19

3-l

4-2

2-5

3-22 , 3-21

4-4

l-4

l-3

l-2 l-16

l-5

1-O 1,-o [

) $0 ’ I

Numerical Index

34

Page 1

. . . --..-. . .._ _.I.. .-. . . . . . . ..- --. ‘._ -.-.-^ __.,_.. ’ . .

TM-598

PARTNUMBER

389260 ' 389262 I ' '$4' ! :

389275

389321 389331

389333

389336

389359

389410

389426

389427

389433

389443

389444 j

389445

389466

389503

389517

389521

389522

389524

389530

369535 389556 389760

389769

389779

389804

400075

400078

400176-4

4oo4ao-12

400830-a 40155q

401563-3

401563-4

401564-3

401564-4

401565-l

401566-l

401566-11

NUMERICALINDEX (CONTINUED)

FIGUREAND

ITEMNUMBER

l-o

l-15

l-50

2-3 l-27

l-7

l-12

l-la

l-47

l-l

l-35

l-36

3-29

l-25

l-26

l-o

l-22

l-19

l-24

3-14

3-23

l-20

l-42

l-10

l-40

l-42 3-18

l-51

1-o

3-15

4-5

3-25 137

l-52

l-38

l-21

2-6

l-32

l-28

2-7

3-11

l-29

3-12

l-30

2-a

l-31, !:

3-13 I '1, L I’

Numerical Index

314

Page 2

.

'Nov30177

_ _ . _

PART NUMBER

401913-3

4024&q

402935-5

403189

403692,

404518

481578

481579

482085A-2

482085A-5

482135

482801

482809

482814

5TW-356-O

50GHP-206

6FW-3167

7J-532

aRT-336

w .:. - I 1

NUMERICAL INDEX (CONTINUED)

FIGURE AND

ITEM NUMBER

!I,“’ l-39

4-3 2-2

3-3 1-9

l-4

2-4

l-53 4-O 4-l ’

l-o

l-o

l-45

l-48

2-Q

l-34

2-o

3-27

3-20

l-17

3-Q

l-6

l-11

TM-598

! !

) ‘! I ’ ‘I

i Nov 30177 Numerical Index / 3-4

Page 3

I ‘1, L