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Revised

OM-105 032581 050286

OPERAb!!ON AND MAINTENANCE WITH ILLUSTRATED for PARTS

MANUAL

LIST

GATE

BOXES

FART

NO.

MODEL

NO.

RATING 140kVA

482934A-1 Addendum 2 482934A-2 482934A-4 482934A-5 482934A-6 Addendum1

GBM-140-2

GBM;l40--2 GBM-140-Z GRM-30-2 GBM-90-2

140kVA 140kVA 30kVA 90kVA '

Hobart Brothers Company Power Systems Division Troy, Ohio 45373 U.S.A.

ELECTRIC SHOCK can kill.

Do not touch live electrical parts.

ELECTRIC ARC FLASH can injure eyes burn skin cause equipment damage and ignite combustible material. Do not use power cables to break load and prevent tools from causing short circuits. IMPROPER PHASE CONNlXTION,~~ARALLELING,OR USE can damage this and attached ! equipment. IMPORTANT: - Protect all operating personnel. Read, understand, and follow all instructions in the Operating/Instruction Manual before installing, operating, or servicing the equipment. Keep the manual available for future use by all operators. A. GENERP;L Equipment that supplies electrical power can cause serious injury or death, or damage to other equipment or property. The.operator must strictly observe all safety rules and take precautionary actions. Safe practices have been developed from past experience in the use of power source equipment. While certain practices below apply only to electrically-powered equipment, other practices apply to engine-driven equipment, and some practices to both. SHOCK PREVENTION Bare conductors, or terminals in the output circuit, or ungrounded, electrically-live equipment can fatally shock a person. Have a certified electrician verify that the equipment is adequately grounded and learn what terminals and parts are electrically HOT, Avoid hot spots on machine. Use proper safety clothing, procedures, and test equipment. The electrical resistance of the body is decreased when wet, permitting dangerous currents to flow through it. When inspecting or servicing equipment, do not work in damp areas. 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 driven by electric motors (rather than by diesel or gasoline engines) must be installed and maintained in accordance with the National Electrical Code, ANSIiNFPA 70, and other a plicable codes. A power disconnect switch or circuit breaker must 1e located at the equipment. Check the nameplate for volta e, frequency, and phase requirements. If f e, connect any single-phase rated equipment only 3-phase power is availab to only two wires of the 3-phase line. 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; ---awhich can cause a fataf -irEEk.Alwa s connect the grounding lead if supplied in a power line cable, to tK e grounded switch box or building ground. If not provided, use a separate groundin lead. Ensure that the current (am erage) capacity of the grounding fead will be adequate for the worst Fault current -situation. Refer to the National Electrical Code ANSI/NFPA 70 for details. Do not remove plug ground prongs- Use correctly mating receptacles. 2. Output Cables and Terminals 1 Inspect cables frequently for damage to the insulation and the connectors. Re lace or repair cracked or worn cables immediately. Do not overload ca1les. Do not touch output terminal while equipment $s energized. 3. Service and Maintenance :

,._____Thissqui~~~~thpmaintainednoon-d-~~c~t~~~al_and_me~h.ani_c_a_l:.~___-~

condition to avoid hazards stemming from disrepair. Report any' equipment defect or safet hazard to the supervisor and discontinue: i~--its-safetyiras been a--ssured-;----Repairs------__-! - ---use--of--the--erv* should be ma e y qualified personnel only. ._ -..." .._ -..._.I - .._._ . _^.______ --_-_.---_-__. .-c Instruction 910082 Page 1 Feb 25/86 Revised

* -t. 1 .. , \ rc / //

, --I / /p

: ;1 J-

Beforeinspecting or servicing electrically-powered equibent, /,,-A '--...-,, #take the follow+n8 precautions: ,____-j ..-, -. -b. __ -( ,M ~!.Ua~~_sh_u_t_oFF$14 power at the disconnecting switch orli'ne&eaker I *, before inspecting or servicing the equipment. I Lock switch OPEN (or remove line fuses) so that power cannot be turned ON accidentally. ! ! c. Disconnect power to equipment if it is out of service. 1 d. If troubleshooting must be done with the unit ener ized, have j another person present who is trained in turning oi! f the equipment and providing or call'ng for first aid. P I RE AND EXPLOSION PREVENTION FI / Fi re and explosion are caused by electrical short circuits combustible ma terial near engine exhaust pi ing, misuse of batteries a&d fuel, or I itlons. un.+afeoperating or fueling conii

/ b*

1. j Electrical Short Circuits and Overloads I 1 Overloaded or shorted equipment can become hot enough to cause fires either by self destruction or causing nearby combustibles to ignite. 1 For electrically-powered equipment, in particular, rovide primary , / input protection to remove short circuited or heave 3 y overloaded 1 equipment from the line. 1 2. 1 Batteries I ,1 Batteries may explode and/or give off flammable hydro / and arcing from a ru tured battery can cause fires an cing, do not smoke, cause sparking, or use open j failures. When servi! 1 flame near the battery. 3. i Engine Fuel

! I

I I

[ Use only approved fuel container or fueling system. Fires and explosions can occur if the fuel tank is not grounded pr,iorto or during i ! fuel transfer. Shut unit DOWN before removing fuel tank cap. Do not ! completely fill tank, because heat from the e uipment may cause fuel i expansion overflow. Remove all spilled fuel 4MMEDIATELY, includin any ; i that penetrates the unit. After clean-up, open equipment doors an3 blow I I fumes away with compressed air. TOLIC 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. BODILY INJURY PREVENTION i Sebious injury can result from contact with fans inside some equipment. Shut DOWN such equipment for inspection and routine maintenance. When equipment is in o eration use extreme care in doing necessary troubleshootingj and adjustment. 8o not remove guards while equipment is operating. MEDICAL AND FIRST AID TREATMENT F&t aid facilities and a qualified first aid person should be available for each shift for immediate treatment of all injury victims. Electric shock victims should be checked by a ph sician and taken to a hospital immediately if any abnormal signs are oBserved. 1 EMERGENCY FIRST AID Ca#l physician immediately. Seek additional assistance and use First Aid techniques recommended by American Red Cross until medical help arrives. IF;BREATHING IS DIFFICULT give oxy en if available, and have victim lie down. FOR ELECTRICAL SHOk, turn of f iower. Remove victim; .if not breathing, begin artificial respiration, preferably mouth-to-mouth. If noidetectable pulse, begin external heart massage. Call Emergency Rescue Sqiuadimmediately. -EQ~-~TIQ~XaBY_LABELs_____ ins ect all recautionary iaoels on the equirnt i._. __, .x.e % bels that cannot be easily rea PJace-all._ Page 2 monthly,-~%Z?iiid-~ ---I- ._ -__. ; / I.

--^ ~--.. _^ __" .__ Instruction 910082 Revised Feb 25/86

I ADDENDUM to 1

OPEtATION

AND MAINTENANCE for

MANUAL

OM-105

90,kVA 1 I
1.

GATE BOX, Part No. 482934A-6 Model No. GMB-90-2

GENERAL This addendum provides the information necessary to increase the coverage of OM-105 to include the 9OkVA Gate Box, Part No. 482934A-6. All information in the manual that applies to 482934A-4 also applies to this unit, except for the differences listed below.

2.

PAGES AFFECTED The addition of these units affects the following pages: A. COVER PAGE, add: 482934A-6 B. l-l, GBM-90-2 90 kVA AND CHARACTERISTICS 482934A-6 1204 pounds (546 kg) 51 inches (2195 mm) 42 inches (1067 mm) 19 inches (483 mm) TABLE, Figure 2:

page 3, add to SPECIFICATIONS PHYSICAL

Weight Height Width Depth ELECTRICAL INPUT Voltage (AC) Frequency (Hz) Phase OUTPUT Voltage (AC) Frequency (Hz) Phase Capacity (Total) TRANSFORMER INPUT

575 400 3

115/200 400 3 72 kW, 90 kVA, 260 Amps

575 V AC, 91.9 Amps, 3 Phase, 400 Hz, 91.5 kVA Continuous duty

OUTPUT

117/203 V AC, 256 Amps, 3 Phase, Full wave 90 kVA Primary: Delta

CONNECTION

Secondary: 4-wire Wye Sept 28182 Page 1

C.

2-3, Page 6, TEST OVERLOAD the following:

PROTECTIVE

SYSTEM, add to list of units with Amps, kVA or kW ratings,

90 kVA unit, 325 Amps, 112 kVA or 90 kW 3. ILLUSTRATED PARTS LIST

i4
with the following exceptions:

In the Illustrated Parts List, Chapter 4, all parts coded B apply to 482934A-6 A. B. C. D. E. F. G. Figure 3, item 11 for 482934A-6 Figure 3, item 12 for 482934A-6 Figure 4, item 26 for 482934A-6 Figure 4. item 27 for 482934A-6 Figure 6, item 1 for 482934A-6 Figure 6, item 2 for 482934A-6 should be 77B-1154 should be 48557 1 should be 77B-1152 should be 77A-1153 should be 77B-1154 should be 485571 INDEX, 4-4, page 4:

Add the following numbers to NUMERICAL Part Number 48557 1 77B-1152 77A-1153 77B-1154

Fig. and Item No. 3-l 1 4-26 4-27 3-11

Page 2

Sept 28/82

ADDENDUM
to

OPERATION

AND MAINTENANCE for

MANUAL

OM-105

140kVA

GATE BOX, Part No. 4829 36A-1 Model No. GMB-140-2

1.

General This addendum provides the information necessary to increase the coverage of OM-105 to include the 140-kVa Gate Box, in the manual that applies Part NO. 482934A-1. All information to 482934A-4 also applies to 'this unit,except for the ' differences listed below. 482934A-1 does not include List Parts List, Chapter 4,all parts with the following exceptions: should be 485308 be 482933A to 482934A-1 , coded B 24V. Remote Pushbuttons.

2. Illustrated

Parts

In the Illustrated apply to 482934A-1 A. Figure B. Figure C. Figure D. Figure

4-O for 482934A-1 4,item

4 for 482934A-1 28-31

should

4, items

Do Not pretain

5-O for 48.2934&-1 should

be 482933A be W-454lB and

E. Figure 5,item 2 for 482934A-1 should W-4541C Resistor, 20 OHM, 25W. F. Add the following Part Number 485308 482933A 482933A w-4541c 3. Manufacturer's Hobart Diagrams numbers to NUMERICAL

INDEX,4-4,P,age

Fig and Item No. 4-o 4-4 5-o 5-2 Literature 6-O

for 482934A-1

485301-Schematic,Gate Box 485302-Connection,Interior Panel 485303-Connection,Control Panel 485427-Connection,Installation Page 1 May 2/86

4. Service

Information concerning to contact your Hobart our Service Power Systems Div. Department by mail,

If you have any questions equipment,you are invited telephone or TWX.

i4

Write:

Hobart Brothers Company Power Systems Division Service Department Troy,Ohio 45373 U.S.A.

Call:

Area Code Extension

(513) 339-6000 4276

TWX :

810-456-2907

May

2/86

Page

OM-105

INTRODUCTION 1. Scope This manual contains operating and kaintenance instructions for a series of AC Gate Boxes manufactured by Ho-

bart Brothers Company, Power Systems Division, Troy, Ohio 45373, U.S.A. 2. Purpose The purpose of the manual is to provide information and instructions to experienced operators, electricians and technicians who have not previously been exposed to this equipment. The manual is not intended to be a textbook on electricity or electronics. 3. Arrangement The manual is divided into 6 chapters. Each chapter is divided into 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-I; 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 . Write: Hobart Brothers Company Power Systems Division Service Department Troy, Ohio 45373 U.S.A. Call: Area Code (513) Extension 4276 TWX: 81 o-456-2907 339-6011

Mar 25181

Introduction Page l/2

1
SUBJECT Introduction Description/Operation Description 1. 2. General Detailed Description A. B. C. D. E. Metal Box Indicating Lights and Controls Transformer Disconnect Switch Interior Panel Assembly (1) Control panel assembly (a) (b) (c) (d) (e) (f) (g) (h) (k) (m) (n) (p) (q) (r) Mar 25181 Panel Overload module

1
CHAPTER/SECTION

OM-I 05

TABLE OF CONTENTS

i4

1-o l-l

1 1
1

1 1

4 5 5 5 5 5 5 9 9 10 10 IO 12 12 12 12 12 13 13 Contents Page 1

Memory and time delay module Over-undervoltage module Power supply system Fuse-interlock relay Plug-interlock relay Test bank switch Fault lights test switch Reset switch Fuses Safety switch Receptacle connector Contactor monitor board

m I I
TABLE OF CONTENTS SUBJECT (s) Terminal boards Remote control t&mjnal board

1 I
(CONTINUED) CHAPTER/SECTION l-l

OM-105

PAGE 14 14 14 14 14 14 15/16 15116 15116 15116

(t)
(2) (3) (4) (5) F. G. H. J. Installation 1. 2. 3. 4. General

Load contactor Rectifier Overload transformers and resistors Contactor close relays

Spare Lamp and Fuse Board Support Frame Test Box (Option) Test Receptacle Connector Kit 1-2

1 1 2 8 2 3

Preparation for Installation Box Installation Wiring A. B. C. Input Cables Output Cable Assemblies Control Leads

3 3 4 4 4 4 4 1-3 1 1 1 Mar 25181

5. 6.

Grounding Test and Check After Installation A. B. General Double Check All Wiring

Operation 1. 2. Contents Page 2 General Remote Control Box

[d
OM-105 TABLE OF CONTENTS SUBJECT 3. Disconnect Switch and Box Door Operation A. B. C. 4. 5. 6. Servicing Maintenance 1. 2. 3. 4. General Lubrication Parts Replacement Lamps and Fuses 2-2 Disconnect Switch O/&rtion Door Operation To Defeat Interlock When Door Is Open (CONTINUED) CHAPTER/SECTION 1-3 PAGE 2 2

Preparation For Power Delivery Power Delivery To An Aircraft Disconnect Power 2-o 2-l

Inspection/Check 1. 2. General Inspection Details

Adjustment/Test 1. 2. Adjustment Test A. B. 3. Preparation For Test Test Procedures

2-3

2 6 2-4 l/2 l/2 3-o 1 Contents Page 3

Test Overload Protective System

Repair 1. General \

Troubleshooting Mar 25181

I
TABLE OF CONTENTS SUBJECT Electrical 1. 2. General Troubleshooting Chart A. B. 3. 4. 5. Description Use of Troubleshooting Chart (CONTINUED) CHAPTER/SECTION 3-1

OM-105

PAGE 1 1 1 1 1 1 I 1 2

i4

Equipment for Troubleshooting Safety Test Values 4-o 4-1

Illustrated Parts List Introduction 1. 2. 3. 4. General Purpose Arrangement Explanation of Parts List A. B. Contents Parts List Form (1) (2) (3) (4) (5) (6) 5. Figure-Item No. Column Hobart Part Number Column Nomenclature Column Rec. Spares Column EFF (Effective) Column Units Per Assembly Column

1 1 1 1 1 ( 1 1 1 1 2 2 2 2 2 2

Reference Designator Index 4-2

Manufacturers Codes 1. Contents Page 4 Explanation of Manufacturers (Vendor) Code List

1 1 Mar 25181

OM-105

TABLE OF CONTENTS SUBJECT Parts List , f 1. 2. rahgement Explanation of Parts List A 1 Symbols and Abbreviations

(CONTINUED) CHAPTER/SECTION 4-3 PAGE 1 1 1 4-4 1 1 5-o 6-O 112 l/2 ,

Numerical Index 1. Explanation of Numerical Index

Optional Equipment Manufacturers Literature

LIST OF ILLUSTRATIONS CHAPTER/ SECTION l-l 1-I l-l l-l 1-I l-l l-l I-1 1-I 1-I 1-2 l-2 1-2 1-3 1-3 l-3 l-3 2-l 2-1 2-l 2-2
1

FIGURE NUMBER
1

PAGE TITLE Typical Gate Box Specifications and Characteristics Controls and Indicators Gate Box Interior Interior Panel Control Panel Transformer-Rectifier Assembly Transformer-Rectifier Connection Diagram Contactor Monitor Board Spare Lamp and Fuse Block Typical Installation Mounting Dimensions Output Cable Horns Remote Control Box Disconnect Switch and Door Handles Locking Mechanism Disabling Levers Control Panel Lamp Chart Fuse Chart Spare Lamp and Fuse Block No Illustrations
1

NO. 2 3 4 6 7 8 11 11 13 15116 1 2 3

2 3 4 5 6 7 8 9 10
1

2 3

2 3

2 2

Mar 25181

Contents Page 5

OM-105

LIST OF ILLUSTRATIONS CHAPTER/ SECTION 2-3 2-3 2-3 2-4 3-1 3-1 4-1 4-2 4-3 4-3 4-3 4-3 4-3 4-3 4-4 1 2 1 FIGURE NUMBER 1 a 3 Test Bob ; , Control Panel Remote Control Box No Illustrations

(CONTINUED) PAGE TITLE NO.


1

3 4

Control Panel Troubleshooting Chart (4 sheets) Reference Designator Index No Illustrations 575 Volt Gate Box Box Assembly Gate Box Interior Interior Panel Assembly Control Panel Assembly Transformer and Mounting No Illustrations

3 4 thru 718 314

2 4 6 8 10 12

Contents Page 6

Mar 25181

OM-I 05

CHAPTER

1. DESCRIPTION/OPERATION 1. DESCRIPTION

SECTION 1. General

.;, The gate box (Fig. 1) covered by t il IS manual consists of a metal enclosure which houses a large step-down transformer and electrical equipment required to monitor and control two independent output circuits. Each output circuit may be operated by a customer furnished remotely located control station. The unit is designed to accept 575-V AC, 400-Hz, 3-phase power from a distant generator and step it down to 115/200-V AC power usable by an aircraft. The concept of transmitting higher voltage than required, then reducing it at the point of use allows transmission of power greater distances from the source without the disadvantage of high voltage drop inherent in the transmission of 115-V AC. The box is supported by a welded steel frame which provides clearance for routing cables through apenings in the floor of the box. An optional support bracket is available at nominal cost from Hobart Power Systems Division for wall mounting the unit on a Jet-Way passenger ramp (see 1-2; Fig. 1). An optional pedestal mount is available which raises the gate box 18 inches (457 mm) above its mounting pad. (See Fig. 2 for gate box specifications and capabilities.) (See l-3; Para. 3, A and B, for door opening instructions.) ,2 Detailed Description A detailed description of parts used in the construction of the gate box is given below. Main assemblies, or functional groups are listed and components of each assembly or group are then described. A. Metal Box The steel enclosure (6, Fig. 1) which houses and protects electrical components is a Hoffman, NEMA 12 box. The box is designed for use in outdoor areas and is described as rainproof. The box is equipped with a hinged door which will swing outward a full 180 degrees. The door is equipped with a three point closing mechanism which interlocks with a flange mounted disconnect switch operating mechanism located at the right of the door. These two mechanisms working in conjunction with each other provide the following safety features: 1. 2. Prevent opening of door when disconnect switch is ON. Prevent switching disconnect switch to ON position unless door is closed and handle is in locked position. Prevent opening of door unless a screwdriver is used to release door handle.

3.

The interior of the box is cooled by a convection flow of air over the transformer and other electrical components. Air enters through an opening in the bottom of the box and exits through a large opening in the top. A hood type cover (1, Fig. 1) is mounted above tht top opening. The cover is flanged downward and extends beyond the edges of the upwardly flanged opening to prevent entrance of blowing rain while still allowing a good flow of air. The large opening in the bottom of the box is covered by a sheet of expanded metal. Mar 25/81 l-l Page 1

OM-105

-3

1. 2. 3.

Vent cover Disconnect switch handle Door handle Typical Gate Box Figure 1

4. 5. 6.

support Indicating lights (five) Nema 12 enclosure

I-1 Page 2

Mar 25181

&

OM-105

, f I I ! Physical 482934A-2, (140 kVA) Weight Height Width Depth Electrical Input Voltage (AC) Frequency (Hz) Phase output Voltage (AC) Frequency (Hz) Phase Capacity (Total) Transformer Input 575 V AC, 143 Amps, 3 Phase, 400 Hz, 142.3 kVA, Continuous Duty output 1171203 V AC, 398 Amps, 3 Phase, Full Wave, 140 kVA Connection Primary: Delta Secondary: 4 Wire Wye 575 V AC, 60.8 Amps, 3 Phase, 400 Hz, 60 kVA, Continuous Duty 1171203 V AC, 17 1 Amps, 3 Phase, Full Wave, 60 kVA Primary: Delta Secondary: 4 Wire Wye 115/200 400 3 112 kW, 140 kVA, 398 Amps 115/200 400 3 24 kW, 30 kVA, 171 Amps 575 400 3 575 400 3 1434 pounds (640 kg) 51 inches (2195 mm) 42 inches (1067 mm) 19 inches (483 mm) -4 482934A-5 (30 kVA) 1050 pounds (476 kg) 51 inches (2195 mm) 42 inches (1067 mm) 19 inches (483 mm)

Specifications and Characteristics Figure 2

Mar 25181

l-l

Page 3

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1 I

OM-105

B.

Indicating Lights and Controls Refer to Figure 3. All gate boxes covered in this manual have four red fault lights and one amber POWER AVAILABLE light mounted on the door. In addition to these five lights, the gate box identified as 482934A-2 is equipped with local controls for each,o,utput circuit which are also mounted on the door. These consist of a black contactor CLOSE pushbutton s&&h, a red contactor OPEN pushbutton switch, and a green contactor CLOSElight which glows when the load contactor is closed.

These four switches and two lights are used on 482934A-2 only.

ICIRCUIT II

These five lights are used on_/ all Gate Boxes. Controls and Indicators Figure 3 l-l Page 4 Mar 25/81

OM-105

- NOTE- Spare lamps and fuses are mounted on a block which is located on the box door near indicating lights (see Para. 2r F and Fig. 10). C. Transformer The575-V

i 4

AC transformer (3, Fig. 4) is mounted on the right side of the control box floor. Its weight is sup,

ported by the channel frame (4, Fig. 1) under the box. The delta connected primary windings of the transformer receive 575-V AC power from the power source at terminals Hl, H2 and H3. The four-wire, wye secondary windings deliver 115/200-V 2 for transformer ratings.) D. Disconnect Switch The 575-V AC input disconnect switch (1, Fig. 4) is mounted on the interior panel near the upper right corner. It features an operating mechanism which interlocks with door latching components to prevent opening the box door unless the disconnect switch operating lever is first placed in OFF position. The operating mechanism also prevents turning the switch ON when the box door is open. The switch is a three-pole, nonautomatic rated at 600-V AC. E. Interior Panel Assembly The interior panel assembly (Figure 5) consists of electrical components mounted on a No. 10 gauge, 33-inch by 39-inch steel panel (4, Fig. 5). The panel is attached to the rear of the box by eight (1) Control panel assembly (a) Panel The control panel (1, Fig. 5) is hinged to provide access to components mounted on the back side and components mounted behind it on the interior panel. It provides mounting facilities for controls and safety devices. The panel is secured in closed position by two captive, adjustable grip latches (7, Fig. 6). (b) Overload module Two overload modules (22 and 24, Fig. 6), one for each output circuit are mounted on the control panel. The upper module (24) provides overload protection to output circuit No. 1. The lower module serves output No. 2. The overload module (22 and 24, Fig. 6) is a solid-state device designed to interpret signals from the AC at terminals X0 (Neutral), X1 (A), X2 (B), and X3 (C). (See Fig.

studs and nuts.

transformers (2 and 9, Fig. 5) and to send a signal to the memory and time delay module (5, Fig. 6) when an overloaded condition exists in an output circuit. A pull-apart electrical connector is mounted on the overload module. It provides a quick-disconnect facility for all wiring to the module. The overload module is equipped with a hermetically-sealed, reed-type relay, the contacts of which are normally open. The solid-state circuitry is designed to close the relay contacts when the output current in ANY phase reaches 125% of normal, rated value. The closed relay sends a signal to the memory and time delay module. This signal gates the overload SCR (silicone-controlled rectifier) in the module and interrupts the load contactor holding circuit, allowing the load contactor to open.

Mar 25181

l-l

Page 5

OM-105

I I I I I I I I I

6,

-3

1. 2. 3.

Disconnect switch Disconnect switch operating handle Transformer Gate Box Interior

4. 5. 6.

Load contactors Interior panel Control panel

l-l Page 6

Figure 4 Mar 25/81

OM-105

*2 rkquired on eah transformer for 482934A-5. 1. 2. *3. 4. 5. 6. 7. 8. 9. IO. Control panel assembly Overload sensing transformer, Output No. 2 Overload burden resistor, Output No. 2 Panel Load contactor, Output No. 2 Siljcon rectifier, Output No. 2 Load contactor, Output No. 1 Silicon rectifier, Output No. 1 Overload sensing transformer, Output No. 1 Overload burden resistor, Output No. 1

,Ipso-o2361

11. Contactor close relays (2) Interior Panel Figure 5 Mar 25181
l-l

Page 7

OM-105

16

._

1. Diode heat sink 2. Zener diode 3. DC power supply resistor (on back of panel) 4. Over-undervoltage module 5. Memory and time delay module (protective module) 6. Fuse interlock relay 7. Control panel captive screw fastener 8. Plug interlock relay 9. Power supply fuse, 1 Amp 10. Load contactor hold circuit fuse (2 Amp) 11. Protective system reset switch 12. Fault lights test switch

13. Test-bank switch 14. Terminal board (three) (on back of panel) 15. Blocking diode 16. Contactor monitor 17. Plexiglass cover 18. Remote controls connection terminal board 19. Safety pin 20. Contactor disable switch 21. Test receptacle 22. Overload module, No. 2 23. DC power supply transformer-rectifier 24. Overload module, No. 1 assembly

Control Panel Figure 6 l-l Page 8 Mar 25181

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OM-105

The following is a list of overload module characteristics: I t I NOTE: The overload d rdfective system will function when any phase carries 123% to 127% of rated load. All times are plus or minus 25% and are nonadjustable.

At 125% load the module will function in 5 minutes. At 150% load the module will function in 16 seconds. At 200% load the module will function in 4 seconds. NOTE: Gate box components and the aircraft are protected against over and underfrequency by protective devices in the power source (generator set) which function to cut off power to the box in the event of a fault. (c) Memory and time delay module The memory and time delay module (5, Fig. 6) is sometimes called the orotective monitor module because it receives and acts upon signals from protective devices - namely, the overload and overundervoltage modules. The memory and time delay module is a solid-state device with a hermetically-sealed, reed-type relay. The printed circuit board includes SCRs (siliconcontrolled rectifiers) which act as relays when triggered by signals from fault sensing devices. The board includes four memory circuits and a 4 to 12 second time delay circuit. Each memory circuit is connected to a corresponding sensing circuit (overload, overvoltage, etc.). All of the circuits are connected to the module relay coil, and any circuit can energize the coil to open the relay contacts. Thus, when a sensing device energizes any one of the module circuits, the module relay is also energized to break the load contactor holding circuit and allow the load contactor to open. All circuits, except the undervoltage circuit, function immediately to open the load contactor. A time delay system is designed into the undervoltage circuit to prevent nuisance opening of the contactor under conditions of momentary undervoltage in the generator output. An undervoltage condition which continues uninterrupted for a period of 4 to 12 seconds (depending upon adjustment) will cause the time delay circuit to open the load contactor. Each of the four circuits is connected to a corresponding indicating light (Fig. 3) which is turned on when a fault occurs. The module relay will remain energized (OPEN) and the light will remain ON until the reset switch (11, Fig. 6) is pushed to break the module 12-V DC circuit, and allow the relay to return to normal, CLOSED position. (d) Over-undervoltage module The over-undervoltage module (4, Fig. 6) is connected to output leads between the transformer and load contactors. This solid state module sensesany abnormal condition of voltage and signals the solid-state circuitry of the memory and time delay module (5, Fig. 6) to open load contactors and disconnect output to the aircraft. Trip values are adjustable, however, adjustments should be made ONLY under laboratory conditions. Trip values for the over-undervoltage module are as follows:

Mar 25/81

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Page 9

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m I 1

1
1

OM-105

Overvoltage trips at 130 V to 134 V. Undervoltage trips at 102 V or below.. Under-voltage trip time delay 5 s cqnds (factory set) d NOTE: (e) Switch (11, Fig. 6) must be pushed after a fault to reset protective system.

Power supply system 12-V DC power required for operation of the protective system originates from the 115-V AC, 400-Hz, C phase output of the gate box. The power supply system consists of a transformer-rectifier The Zener diode is mounted in a heat sink for cooling. The transformer (3, Fig. 7) steps-down 115-V AC to approximately 24-V AC. The diode-bridge rectifier (2) then converts 24-V AC to a pulsating 24-V DC. A 3 mfd, 50-V capacitor (1) prevents pulses from reaching zero. Rectifier output is further smoothed and reduced to 12-V DC by a Zener diode (2, Fig. 6) and resistor (3, Fig. 6). A terminal board (4, Fig. 7) provides connections for transformer input and rectifier output leads. The 115-V AC side of the power supply system is protected by a 2-Amp fuse (9, Fig. 6). A connection diagram of the transformer-rectifier plete connection diagrams in Chapter 6. assembly only is provided in Fig. 8. See comassembly (23, Fig. 6), Zener diode

(2). and resistor (3). These components are mounted on the back side of the hinged control panel.

(f)

Fuse-interlock relay A fuse-interlock relay (6, Fig. 6) is provided for each output circuit. Theleft relay serves No. 1 output circuit. The right relay is for No. 2 circuit. The function of the fuse-interlock relay is to interrupt the load contactor holding coil circuit and remove the load in case of a blown fuse (9, cuit. Fig. 6) in the protective monitor power supply cir-

(g) Plug-interlock relay Plug-interlock relays (8, Fig. 6) are located directly below fuse-interlock relays. The left relay serves No. 1 output circuit. The right is for No. 2 circuit. The function of the plug-interlock relay is to cause the output load contactor to open in the event the cable plug connector becomes accidentally disconnected from the aircraft during power delivery, or if an attempt is made to deliver power when the output cable is not connected to the aircraft. Twenty-eight-volt, direct current for operation of the relay is supplied from the aircraft either through an on-board transformer-rectifier, or from a twenty-eight-volt, electrical system. Connection from the aircraft to the interlock relay is made through terminals E and F on the output cable plug connector.

l-l

Mar 25181

Page 10

OM-105

I\

1. 2.

Capacitor Rectifier Transformer-Rectifier


Figure 7 _.

3. 4. Assembly
1-

Transformer Terminal board

NOTE: RECTIFIER ASSEMBLED AT THIS END.

IISV. AC INPUT

BLACK BLACK

~psD-0225~

NOTE:

See Diagram in Chapter 6 for connection of Zener diode, resistor and transformerrectifier in DC power supply system. Transformer-Rectifier Connection Diagram

Figure 8 Mar 25/81

m I
I (h) Test-bank switch A test-bank switch (13, Fig. 6) is provided for each output circuit. The left switch is for the No. 1 output circuit. The right switch is for No. 2 circuit. The sp st toggle switch provides a Teans of by-passing the plug-interlock relay when supplying power to a load bank for test purposes, bti 10 an aircraft not equipped with a plug-interlock system. Without the switch, the load contactor could not be held in closed position for these purposes. For supplying power to a test (load) bank, the switch is placed in (UP) TEST BANK position. For supplying power to an aircraft the switch must be in (DOWN) AIRCRAFT (k) Fault lights test switch The test switch (12, Fig. 6) is a pushbutton snap type. It connects 12-V DC power directly to all fault lights (Fig. 3) for testing the lamps. Two blocking diodes (15, Fig. 6) are used in the light testing circuit - one in-each overload circuit. They are mounted on quick-connect terminals on the center terminal board (14, Fig. 6). These diodes are required to prevent an overload signal from following the test circuit and turning ON over and undervoltage indicating lights when no voltage fault exists. NOTE: Similar blocking diodes for over-undervoltage lights are mounted IN the over-undervoltage module (4, Fig. 6). position.

1
I

OM-I 05

(m) Reset switch A pushbutton switch ( 11, Fig. 6), identical to the fault light switch, is used to reset the protective monitor system and turn OFF fault indicating lights after a fault condition has caused the protective system to function. (n) Fuses A I-Amp cartridge type fuse (9, Fig. 6) protects the 12-V power supply system. A similar 2-Amp fuse (IO, Fig. 6) protects load contactor operating circuits. (p) Safety switch A safety toggle switch (20, Fig. 6) is provided for each output circuit. The left switch is in the No. 1 output circuit. The right switch is in No. 2 circuit. The switch functions to open and disable the load contactor operating circuit and thus prevent its closing by operation of a remotely located pushbutton switch. This feature allows an electrician to disable one or both output circuits and work with output cable in relative safety. A safety lock pin (19, Fig. 6) with ball detent and pull ring is mounted in a guard bracket above each switch to add extra safety and prevent inadvertent actuation of the switch. To disable a circuit. pull the safety pin and push switch toggle LEFT to DISABLE safety pin. WARNING: BE SURE DISCONNECT ON ANY COMPONENTS position. INSERT

SWITCH (1, Fig. 4) IS OFF BEFORE WORKING INSfDE THE 80X. Mar 25/81

I-1

Page 12

OM-105 (q) Receptacle connector A receptacle connector (21, Fig. 6) is for attachment of a test box (2-3; Fig. 1). Leads are connected to A, B, ,, C phases and N neutral (ground). The connector is protected by a cap which is chain attached to the panel to prevent loss. (r) Contactor monitor boafd; , A contactor monitor board (16, Fig. 6) is provided for each output circuit. The left board monitors No. 1 output circuit, the right board monitors No. 2 circuit. Each contactor monitor board (Fig. 9) provides mounting for a series of light emitting diodes (2, Fig. 9). Each diode is connected to a single output phase and emits a red light when the phase is energized. If all three phase lights (A, 8, and C) in an output circuit are off, it indicates that the load contactor for that circuit is open. These lights are also helpful in troubleshooting. For example, if only two lights in a circuit are glowing when the contactor is closed, it indicates that one set of contacts in the load contactor is defective and the load contactor should be replaced. If one of the three phase lights remains on when the contactor is open, it indicates that the load contactor contacts for that phase are stuck, fused together, or otherwise defective and the load contactor should be replaced. A 10,000 ohm, 10 watt resistor (4) is connected in series with each light emitting diode to reduce voltage to a value (approximately 1 volt) which will not destroy the diode.

A 400 PRV, 1.5-A silicone diode (3) is connected in parallel with each light emitting diode. This protection is necessary because the light emitting diode has a near zero peak reverse voltage capacity.

..

0
I

I0
1. Connector

CONTACTOR MON I TOR BOARD AY 482935

3. Silicon diode, 400 PVR, 1.5 Amp 4. Resistor, 10,000 ohm, 10 watts Contactor Monitor Board Figure 9

2. Light emitting diode

Mar 25181

l-l

Page 13

OM-I 05

(s) Terminal boards Three terminal boards (14, Fig. 6) are mounted on the rear side of the control panel. Each board has 12 terminals which provide connectipn facilities for leads to and from the panel assembly. (t) Remote control terminal boar-b r This terminal board (18, Fig. 6) is mounted at the lower edge of the control panel. It has eight, 90 deg., female terminals for connecting remote control box leads. Terminals are protected by a Plexiglass cover (17). (2) Load contactor Load contactors (5 and 7, Fig. 5) are mounted near the lower left corner of the interior panel. The upper load contactor (7) serves No. 1 output circuit. The lower contactor (5) is in No. 2 circuit. No. 1 contactor is mounted on a higher bracket than No. 2 which positions it nearer to the front of the box and allows better cable arrangement and routing. The load contactor serves to connect and disconnect gate box output power to, or from, an output cable. The contactor is a sealed unit containing five sets of contacts. The three larger sets conduct three-phase output. A smaller set is connected in series with the AC protective circuit and supplies 400-Hz AC to the rectifier (6 and 8, Fig. 5) when the load contactor is closed. Another small set of contacts (normally closed) serve to by-pass an economizer resistor in the load contactor and allow a high voltage to load contactor coil for initial closing. These contacts then open and a reduced voltage is supplied to the coil through the economizer resistor. Current is conducted to the contactors by cables which pass through current transformers (2 and 9, Fig. 5). These transformers supply a reduced value current to the overload module. A resistor (3 and IO, Fig. 5) is connected across each of the transformers. (3) Rectifier A silicon rectifier (6 and 8, Fig. 5) is mounted on each of the load contactor brackets. The rectifier receives 400-Hz AC from phase C of the generator output and converts it to a pulsating, direct current for energization of the load contactor holding coil only. This DC coil-holding circuit is controlled indirectly by controlling the 400-Hz AC to the rectifier. Any time an overload or over-undervoltage monitor functions to open the memory and time delay relay, the rectifiers AC circuit is opened. Consequently no DC power is then available to the load contactor coil and the load contactor opens. (4) Overload transformers and resistors Six transformers (2 and 9, Fig. 5) are mounted on the interior panel behind the control panel. The three transformers (9) on the left are in the No. 1 output circuit. Transformers (2) on the right are for No. 2 circuit. Each transformer sensesvoltage in an individual output cable and supplies a reduced voltage signal to the overload module (22 or 24, Fig. 6). A burden resistor (3 and 10, Fig. 5) is connected across each transformer. (5) Contactor close relays This relay (11, Fig. 5) permits operation of the 115 V DC contactor coil circuit by the 24 V DC remote control pushbutton circuit. When the remote CONTACTOR When this circuit is completed, it closes the load contactor. One relay is used in each output circuit. 1-I Page 14 CLOSE pushbutton is pushed, 24 V DC energizes the relays coil and closes its contacts, which are wired into the load contactors coil circuit.

Mar 25181

w
1
OM-105

F.

Spare Lamp and Fuse Board Spare lamps and fuses are provided on a board (see Fig. 10) which is mounted on the gate box door. Three each of 12-V and 120-V indicator lamps are mounted at the top rear of the board. Three each of the I-A and 2-A fuses are mounted in holpefs on the lower half of the board. A label provides easy identification of lamps and,fuses.

-.
Spare Lamp and Fuse Block

G.

Support Frame The box sits on a support frame (4, Fig. 1) of welded steel channels. The frame allows access for routing cables through the bottom of the box, and allows entry of air for convection cooling.

H.

Test Box (Option) An optional test box is available for testing the-internal circuitry of the gate box. The test box,. part number 483347-2 is covered by Operation and Maintenance Manual, TM-575.

J.

Test Receptacle Connector Kit For those gate boxes not originally equipped with a test box power iecep;;lcle connector, a kit is now available. The kit includes all parts required to use 575-V AC gate box input for operation of a test box. Ordering part number for kit is 483346.

Mar 25/81

I-l

Page 15/l 6

1
SECTION 2. INSTALLATION 1. General

OM-105

The gate box may be installed outdoors without further protection. The heat vent opening and cover in the top are designed to be rainproof. Figure,1 illustrates a typical installation using the optional mounting support, Hobart part number 483470. This sci pport is designed for wall mounting the unit on a Jet-Way passenger ramp. Also available is the optional pedestal mount, Hobart part number 484139, which raises the gate box 18 inches (457 mm) above its mounting pad.

1482934

1. 2.

Gate box Optional mounting support Typical Installation

Mar 25/81

Figure 1 l-2 Page 1

OM-105 2. Preparation for Installation Cable horns and clamps for output cable assemblies are provided in the bottom of the box. A 6X input cables is also provided. No hole cutting is required. Refer to Section 4, Operation, for disconnect switch and door opening instructions. i I 3. Box Installation j connector for

The gate box may be mounted on a customer-furnished frame, or on the optional mounting support illustrated in Figure 1. The hole patterns for mounting the gate box base and the optional supports are illustrated in Figure 2.
z( llmm) (4 haled dia.

Gate Box Base -$IImm~dia.

(6 helee)

I
I
40$ inches (IO36mm) Optional Wall Mounting Support

13% incha (349mm)

I33 ioehea(349mm)

-+

+-7

,$(14mm)dia. (4 holes)

I-

Be3 inchee(984mm) 4 Optional Pedestal Mounting

Mounting Dimensions Figure 2 1-2 Page 2 Mar 25181

OM-105 4. Wiring A. Input Cables WARNING: MAKE CERTAIN POWER TO BOX CANNOT BE TURNED ON.

Route input cables under gateibklx and through BX connector provided. Connect input cables to disconnect switch as shown in Installation Connection Diagram, Chapter 6. B. Output Cable Assemblies Route the loose end of No. 2 output cable assembly through cable horn (Fig. 3) and to No. 2 load contactor which is the lower contactor. Connect cable A, B, C, and N as shown in Installation Diagram (Chapter 6). Connect small interlock leads (No. 12 wire or larger) to terminals E and F on contactor bracket. Repeat the above procedures for No. 1 cable assembly.

[ 482934

Output Cable Horns Figure 3 Mar 25181 I-2 Page 3

1
C. Control Leads

OM-105

Route control leads through their respective cable horns, No. 1 and No. 2, in bottom of box and up to control terminal panel (l-l; 18, Fig. 6). Identify leads and connect to panel according to Installation Connection Diagram, Chapter 6. Locate remote control boxes accordingitd Company regulations. Some types may be secured to output cable assembly near plug connector. 5. Grounding Ground the box in accordance with National Electrical Code, or in compliance with local code. Convenient grounding points are labeled on the step-down transformer base. WARNING: 6. DO NOT OPERATE BOX WITHOUT ADEQUATE GROUNDING.

Test and Check After Installation A. General The gate box has been tested completely at the factory prior to shipment, and testing at installation should not be required. However, if testing is desired, refer to 2-3; Para. 2. B. Double Check All Wiring Check all wiring for proper connection and terminals for security. Check following: (1) 575-V input wiring (2) (3) Load contactor output cables Remote control boxes wiring position.

(4) Test bank switches (1-I; 13, Fig. 6) in AIRCRAFT C.

When all wiring has been determined to be safe, close gate box door and secure. Place disconnect switch in ON position.

D.

Turn ON source of input power (575-V AC). The AMBER indicating light (l-l, Fig. 3) on door and AMBER light (l-3, Fig. 1) on each control box should GLOW to indicate power is available. Check operation of load contactors and remote control boxes. WARNING: DO NOT TOUCH CABLE PLUGS WHEN CHECKING LOAD CONTACTORS.

E.

(1) Press remote control box CLOSE pushbutton (I-3, Fig. 1). (2) Contactor should close and control box indicating light should glow as long as CLOSE pushbutton is held. (3) Release CLOSE pushbutton. Contactor should open and indicating light should go OFF because the output cable is not connected to an aircraft and no DC power is available for holding the plug-interlock relay closed. I-2 Page 4 Mar 25/81

OM-105 SECTION 3. OPERATION IGeneral All gate boxes may be operated from either of two remotely located, customer-furnished, control boxes; however, each control box will operate only one output circuit. The gate box identified as Hobart &aQ number 482934A-2 remote-control capability. 2. Remote Control Box A typical control box is illustrated in Figure 1. There are several types of boxes. Some are intended for attachment to the output cable near the plug connector. All boxes have similar indicating lights and pushbutton switches. has local controls mounted on its door, in addition to

/-Pushbutton (Block)

L 1 1
I
OPEN

/-Pushbutton (Red)

/-Light (Amber)

/-Light (Clear)

Remote Control Box (Typical) (Not part of Gate Box) Mar 25181 Figure 1 l-3 Page 1

I
3. Disconnect Switch and Box Door Operation A. Disconnect Switch Operation

OM-105

The switch handle (1, Fig. 2) can be operated ONLY when the box door is closed and locked. Switch positions are plainly marked on the switch opera&b handle and handle mounting base. The switch is ON when handle is in UP position and RED portion of handle knob is showing. The BLACK portion of the knob is seen when the handle is in DOWN position and the switch is OFF. B. Door Operation The door can be opened only when the disconnect switch handle is in OFF position. (1) Place disconnect switch handle (1, Fig. 2) in OFF position. (2) Insert blade of a screwdriver in defeater pin (2) slot and turn COUNTERCLOCKWISE about a quarter-

turn. Hold pin in this position while turning handle (3) toward edge of door to UNLATCH.

OPEN

1. 2. 3.

Disconnect switch operating handle Defeater pin Door handle

Disconnect Switch and Door Handles Figure 2 1-3 Page 2 Mar 25181

C.

To Defeat Interlock When Door Is OPEN

(1)

If door handle is accidentally locked while door is OPEN, LIFT locking lever (1, Fig. 3) to UNLATCH handle.

(2) To operate disconnect SW itiCH handle when door is OPEN, hold locking lever extension (2, Fig. 3) DOWN while operating handle as desired., WARNING: EXERCISE EXTREME CARE WHEN SWITCH IS ON.

1. 2.

Door handle locking lever Switch handle locking lever extension

Locking Mechanism Disabling Levers Figure 3

Mar 25181

I-3 Page 3

OM-105 4. Preparation For Power Delivery Before attempting to deliver power to an aircraft, check following: A. Test-bank switches (13, Fig. 4) must be in Al RCRAFT position. NOTE: For power delivery to a test b&&or to an aircraft not equipped with 28.5-V DC interlock system, place test-bank switches in TEST BANK position.

B.

Contactor disable toggle switches (20, Fig. 4) must be in ON position (toggle pointing to RIGHT) and safety pins (19, Fig. 4) installed. WARNING: EXERCISE EXTREME CAUTION IS OPEN; LETHAL ELECTRICAL WHEN GATE BOX IS ENERGIZED SHOCK HAZARD EXISTS. AND DOOR

C. D. E. F. G. H. 5.

With gate box door open, defeat the interlock on the switch handle and raise the handle to the ON position. Check fault lights in door with test switch (13, Fig. 4). Turn OFF fault lights with reset switch (12). Position switch handle down to OFF position. Close gate box door and LOCK handle. Place disconnect switch handle in ON (up) position. No fault lights in door should be ON.

Power Delivery To An Aircraft CAUTION: AN INTERLOCK NETWORK IS BUILT INTO THE GATE BOX OUTPUT CIRCUITS ,

TO SATISFY CERTAIN INTERNAL 707 AIRCRAFT. FOR SERVICING HAVE THIS A JUMPER GATE BOX, BETWEEN THE SAME

WIRING REQUIREMENTS OF THE BOEING THE 707, THE OUTPUT CABLE MUST NOT F IN THE CABLE PLUG. ARE USED WITH SUITABLE (WITHOUT JUMPERS)

PINS E AND CABLES ALSO.

FOR USE ON OTHER AIRCRAFT

To deliver power to an aircraft, proceed as follows: NOTE: On 482934A-2, local controls on the door may be substituted for remote controls called for

in all procedures. A. B. C. Insert output cable plug(s) in aircraft receptacle(s). Be SURE connectors are fully mated and secure. Check POWER AVAILABLE indicating light in remote control box to make certain power is available.

Press CLOSE pushbutton switch (Fig. 1). CLOSE light should glow immediately and remain ON to indicate that the load contactor is closed and power is available at aircraft. NOTE: In the event that a load contactor is OPENED by an overload or abnormal voltage condition, the reset switch (11, Fig. 4) must be pushed to turn,OFF indicating light on gate box door and return protective system to normal. Check for cause of fault and correct before continuing operation.

I-3 Page 4

Mar 25181

OM-I 05

6.

Disconnect Power A. Press OPEN switch pushbutton. OPEN indicating light should go off, indicating load contactor has opened and power has been disconnected from the aircraft. B. i ; Discqnnect output cable plug(s) #ram aircraft. WARNING: DO NOT DISCONNECT A CABLE PLUG WHEN POWER IS ON.

Mar 25181

OM-105

6
A

23

1. Diode heat sink 2. Zener diode 3. DC power supply resistor (on back of panel) 4. Over-undervoltage module 5. Memory and time delay module (protective module) 6. Fuse interlock relay 7. Control panel captive screw fastener 8. Plug interlock relay 9. Power supply fuse, 1 Amp 10. Load contactor hold circuit fuse (2 Amp) 11. Protective system reset switch 12. Fault lights test switch

13. Test-bank switch 14. Terminal board (three) (on back of panel) 15. Blocking diode 16. Contactor monitor 17. Plexiglass cover 18. Remote controls connection terminal board 19. Safety pin 20. Contactor disable switch 21. Test receptacle 22. Overload module, No. 2 23. DC power supply transformer-rectifier 24. Overload module, No. 1 assembly

Control Panel Figure 4


l-3

Mar 25/81

Page 6

m I
CHAPTER SECTION i 4 1. General 1

1
1

OM-105

2. SERVICING

1. MAINTENANCE

The gate box requires no maintenance, as such, and should operate for long periods without attention. 2. Lubrication No lubrication is required. 3. Parts Replacement There are no high mortality parts which require periodic replacement, repair or attention. 4. Lamps and Fuses Lamps and fuses which may require replacement are listed in Figures 1 and 2. The spare lamp and fuse board is illustrated in Figure 3. Labels on the board provide identification data. Order new replacement spare lamps and fuses as soon as spares are used.

Light Identification Fault lights (all) Location Gate box door (I-l; Fig. 3)

Lamp Manufacturer Lamp Industry Trade Number

Lamp (bulb) Number 12PSB

Power available

Gate box door (I-l ; Fig. 3)

Lamp Industry Trade Number Lamp Industry Trade Number

120PSB

* Contactor close

Gate box door (l-l ; Fig. 3)

120PSB

NOTE:

Lights on contactor monitor boards (I-l ; 2, Fig. 9) are LED (light emitting diodes). See parts list, Chapter 4. I

* Used on 482934A-2

only. Lamp Chart Figure 1

Mar 25181

2-l Page 1

w I

OM-I 05

Item Pro&ted

i 4 Location Size Type

Protective monitor system Contactor hold circuit

Control panel ,!I-3; 9, Fig. _ 4) _ Control panel (I-3; IO, Fig. 4)

I-Amp

AGC (3AG)

2-Amp

AGC (3AG)

Fuse Chart Figure 2

12V LAMPS I2 PSB SPARE FUSES IA FUSES 8 INDICATOR

12OV LAMPS 120 PSB LAMPS 2.A FUSES

Spare Lamp and Fuse Holder Block Figure 3 2-I Page 2 Mar 25181

OM-I 05

SECTION 2. INSPECTION/CHECK General The gate box requires a minimum bfi iplspection and checking. It is suggested that inspections and checks be coordinated! with those performed on the power source (generator set). However, it is understandable that a gate box handling a high volume of traffic will require more frequent inspection than one with moderate usage. Inspection Details WARNING: A. B. C. D. E. F. G. BE SURE INPUT POWER IS OFF.

Place disconnect switch handle in OFF position and open door. Inspect ALL lead connections and terminals for security. Visually inspect all components and connections for discoloration and evidence of overheating. Inspect all attaching hardware for security. Inspect door gaskets for defects which could cause leakage. Use test box to test and check operation of protective systems in accordance with 2-3, Para. 2. inspect all switches for proper positioning before closing door. NOTE: When securing door after inspection, be sure gaskets fit properly.

H.

Close door and lock. Place disconnect switch handle in ON (up) pos.ition.

Mar 25181

2-2 Page 112

OM-I 05

SECTION 3. ADJUSTMENT/TEST 1. Adjustment The gate box has no electrical or mechanical components which require adjustment. 2. Test ,

A test box (Fig. I) is required for testing the gate box on location. A. Preparation for Test It is assumed that both remote control boxes and output cables are properly connected to gate box. (1) (2) Place gate box disconnect switch handle in OFF position and open door. Place circuit breakers (I and 2, Fig. 1) in OFF position.

(3) Set knob (5) to 115-Volt position. (4) Attach optional cable part number 483584 to test receptacle connector (22, Fig. 2) on control panel and to receptacle on rear panel of test box.

1. Output Circuit Breaker 2. Input Circuit Breaker 3. Voltmeter Test Box Figure 1 Mar 25181

4. 115-Volt

Input Connector

5. Variable Power Transformer Knob

2-3 Page 1

m
I

OM-105

(5) Connect test box input power as follows: (a) 115-V AC input power connection Position a mobile, 115-V AC generator set (self-propelled, etc.) near the gate box. Open receptacle cover on test box and coflnact generator set output cable plug to test box input receptacle (4, Fig. 1). Operate generator set to produce 115-V AC at output cable. Panel lights on test box will glow. (b) 575-V AC input power connection Connect optional test box 575-V AC input cable (part number 483583) to 575-V AC receptacle in gate box and to receptacle on rear panel of test box. Panel lights on test box will glow. WARNING: USE ONLY ONE SOURCE OF INPUT POWER. (3) will indicate 115 volts.

(6) Place input circuit breaker (2, Fig. 1) in ON position. Voltmeter B. Test Procedures NOTE:

On 482934A-2, door mounted controls may be substituted for remote controls called for in all procedures.

(1) Place output circuit breaker (1, Fig. 1) in ON position. Power available light on gate box will glow. (2) With generator set running and test box properly connected, the power available indicating light (l-l; Fig. 3) on gate box door should be ON. Power available light in each remote control light should be ON. If not, check lamps. (3) Place test bank switches (13, Fig. 2) in TEST BANK position to by-pass plug-interlock relays and , allow load contactors to be closed for testing. (4) Press and hold test switch (12, Fig. 2). All fault lights (I-l ; Fig. 3) on gate box door should glow, indicating that the 12-V power supply transformer, rectifier, etc., are functioning properly; that the memory and time delay module is functional; and that fault indicating lamps are good. Release test switch. (5) Check each load contactor circuit separately. After steps (a) through (f) below have been completed for one load contactor circuit, repeat for the other circuit. (a) Press remote control box CLOSE switch (Fig. 3). (b) Indicating light should glow to indicate that load contactor is CLOSED. It also indicates that rectifier, fuse-interlock relay, and all components of load contactor hold circuit are functioning properly. (c) Observe light emitting diode lights on contactor monitor board (1-I; Fig. 9). If all lights are glowing it indicates that contacts for all phases (A, B, C) are closed properly. If one or more lights do not glow, first check light emitting diode. If diode is good, the contactor is defective.

2-3 Page 2

Mar 25181

OM-105

24

7 / Y8 /9 /

23

22
SUPPLY IA

10
2

71

b!%u

TEST

FAULT LIGHTT BANK TEST BANK

-11
I2

2oA I -/
/CDNTACTOi-

\ 1

13

\ 14

1. Diode heat sink 2. Zener diode 3. DC power supply resistor (on back of panel) 4. Over-undervoltage module 5. Memory and time delay module (protective module) 6. Fuse interlock relay 7. Control panel captive screw fastener 8. Plug interlock relay 9. 10. 11. 12. Power supply fuse, 1 Amp Load contactor hold circuit fuse (2 Amp) Protective system reset switch Fault lights test switch Control Panel Figure 2 Mar 25181

13. Test-bank switch 14. Terminal board (three) (on back of panel) 15. Blocking diode 16. Contactor monitor 17. Plexiglass cover 18. Remote controls connection terminal board 19. Safety pin 20. Contactor disable switch 21. Test receptacle 22. Overload module, No. 2 23. DC power supply transformer-rectifier 24. Overload module, No. 1 assembly

2-3

Page 3

OM-105 (d) Press remote control box OPEN pushbutton. (e) (f) Indicating light should go OFF to indicate load contactor is OPEN, All light emitting diode lights should be OFF. If one or more lights continue to glow, it indicates that load contactor contacts arestuck or not opening properly.
i I

Pushbutton (Black)

OPEN /-Pushbutton (Red)

/-Light (Amber)

/-Light (Clear)

Remote Control Box (Typical) (Not part of Gate Box) 2-3 Page 4 Figure 3 Mar 25/81

OM-105

(6) Test overvoltage protective circuitry (a) Use remote control I I(b) If test box input voltage is not already 115-V AC, adjust with knob(5, (c) While observing voltmeter (3), turn knob (5) SLOWLY CLOCKWISE Fig. 1). or,es to CLOSE load contactors.

to increase voltage.

(d) At some voltage value between 130-V AC and 134-V AC, the over-undervoltage module and memory and time delay module should function to OPEN load contactors and turn ON overvoltage indicating light (l-l; (e) Fig. 3).

Adjust voltage to normal 115-V AC and press reset switch (11, Fig. 2) to turn OFF fault light and reset protective system.

(7) Test undervoltage protective circuitry Before starting this check, let us understand the sequence of events which should happen when voltage _ is reduced to 102-V or lower. At some value between 102-V and 93-V, the undervoltage sensing module should function to activate the undervoltage time delay circuit in the memory and time delay module. Five seconds (normal factory setting) after the time delay circuit is activated (if the under-voltage condition continues), it should function to open the memory and time delay module relay which, in turn, will open load contactors and stop power delivery. As a result of this action, the under-voltage indicating light (l-l; Fig. 3) will be turned ON.

A stopwatch, or sweep-second-hand watch is required for this check. Proceed as follows: (a) Use remote control boxes to CLOSE load contactors, and reduce voltage to 105-V AC. Undervoltage protective system should not function. (b) Reduce voltage in steps of 1 V, with a delay of at least 5 seconds between steps. Restart stopwatch or note position of sweep-second-hand each time voltage is reduced. At some voltage value between 102-V and 93-V, and approximately 5 seconds after a new voltage setting is made, the load contactor should be opened and the undervoltage indicating light should be turned on by the step-bystep action of the under-voltage sensing circuit, time delay circuit, and memory and time delay relay. Undervoltage indicating light should be turned ON. (c) Increase voltage to normal 115-V AC, and press reset switch (11, Fig. 2) to turn OFF undervoltage indicating light and reset protective system. (8) Turn off generator power to test box and disconnect cable plug from test box. Disconnect test box output cable from gate box. (9) Place test bank switches (13, Fig. 2) in AIRCRAFT (10) position for normal power delivery to an aircraft.

Close gate box door and place disconnect switch lever in ON position..

Mar 25/81

2-3 Page 5

OM-105

3.

Test Overload Protective System This test is not normally performed on location because a load bank is required, and also because of the difficulty in applying an accurate load. It is recommended that the overload modulp be tested under laboratory conditions. The overload protective system should function to open the load contactor when the output circuit is carrying any one of the following loads: 30 kVA unit: 106.6 Amps, 37.5 kVA, or 30 kW 140 kVA unit: 497.5 Amps, 175 kVA, or 140 kW

2-3 Page 6

Mar 2,5/81

OM-105

SECTION 4. REPAIR 1. General WARNING: BEFORE WORKIN AND CANNOT BE GN ANY COMPONENT, UdNED MAKE CERTAIN THAT POWER IS OFF

ON ACCIDENTALLY.

Repair will consist primarily of parts replacement. Protective circuits are designed as easily replaced modules with quick disconnect connectors, etc., and should be replaced as complete assemblies. Use connection diagrams in Chapter 6 when replacing electrical components. If cables are disconnected from the stepdown transformer for any reason, wrap new connections with insulating tape: EPR, self-amalgamating tape, 1 inch wide by 0.020 thick. Stretch tape approximately 30% when applying, and overlap each turn 50%. This tape is manufactured by Rotunda in 30 foot (9.1 metre) rolls as catalog No. 2515 and is available from Hobart as part No. 46271.

Mar 25181

2-4 Page If2

OM-105

CHAPTER

3. TROUBLESHOOTING 1. ELECTRICAL

SECTION 1. General A.

; Troubleshooting is an orderly I process of checking and eliminating possible causes of trouble until the exact cause of a trouble is found. As a rule, the best place to start looking for the cause of a trouble in a circuit is at the source of power. Continue testing and checking the circuit, step-by-step, in an orderly manner, until , the cause of trouble is located. See applicable connection diagrams and schematic diagrams.

B.

This section provides information useful in diagnosing and correcting certain troubles which cause unsatisfactory operation or failure of the equipment.

C.

Minor troubles may be remedied by the operator; however, major repairs must be undertaken by experienced mechanics and electricians only.

2.

Troubleshooting Chart A. Description The troubleshooting chart (Figure 3) lists information under three headings: (1) Trouble, symptom and condition (2) Probable cause (3) Test, check and remedy B. Use of Troubleshooting Chart (1) The troubleshooting chart is designed to provide maintenance and repair personnel with a time-saving guide for locating the source of a trouble.

(2) A schematic diagram and connection diagrams are provided in Chapter 6.

(3)

Electrical component symbols, which are used on schematic diagrams, are also used in the troubleshooting chart (in parentheses after the item name) to help maintenance personnel identify parts on the schematic diagrams.

(4) ALWAYS check circuit fuses and the position of switches first in troubleshooting. The incorrect positioning of a switch may cause a condition which could be misinterpreted as a fault. 3. Equipment for Troubleshooting A good quality multi-scale voltohmmeter and a test box are important tools for good troubleshooting. 4. Safety WARNING: EXERCISE EXTREME CARE TO AVOID OR OPERATING CONTACT WITH HIGH VOLTAGE LEADS AND WHEN ~. 3-I Page 1

COMPONENTS

WHICH COULD CAUSE SERIOUS SHOCK AND INJURY THE EQUIPMENT.

IF TOUCHED -

TROUBLESHOOTING Mar 25181

OM-105 5. Test Values Overload relay trips at any value above 125% rated load in 5 minutes or less. Overvoltage circuit functions at 130 to 134 V AC, resets at 125 V AC. I 6 Undervoltage circuit functions at 102 to 93 V AC, resets at 110 V AC. Undervoltage time delay circuit functions in 4 to 12 seconds (is factory set at 5 seconds).

3-l Page 2

Mar 26181

OM-105

1. Diode heat sink 2. Zener diode 3. DC power supply resistor (on back of panel) 4. Over-undervoltage module 5. Memory and time delay module (protective module) 6. Fuse interlock relay 7. Control panel captive screw fastener 8. Plug interlock relay 9. Power supply fuse, 1 Amp 10. Load contactor hold circuit fuse (2 Amp) 11. Protective system reset switch 12. Fault lights test switch Control Panel Figure 1 Mar 25/81

13. Test-bank switch 14. Terminal board (three) (on back of panel) 15. Blocking diode 16. Contactor monitor 17. Plexiglass cover 18. Remote controls connection terminal board 19. Safety pin 20. Contactor disable switch 21. Test receptacle 22. Overload module, No. 2 23. DC power supply transformer-rectifier 24. Overload module, No. 1 assembly

3-1 Page 3

rz
TROUBLE, SYMPTOM PROBABLE CONTROL I CIRCUIT I CAUSE AND CONDITION LOAD CONTACTOR NOTE:

OM-I 05

TEST, CHECK, AND REMEDY

If the gate box is operated from remQt$rstations, any troubles will be detected first at a station. Before condemning the ,gate box as a source of trouble, check the remote control box thoroughly by checking indicating lamps, switches, and circuitry. It is assumed that all external sources of trouble (generator set, etc.) have been eliminated before using this chart.

1.

Amber indicating light (DS701) on gate box door does not glow when it is known that power is available at gate box input.

A. B.

Lamp burned out Disconnect switch (S726) OFF or defective Transformer (T721) defective

A. B.

Check lamp and replace (see l-l;

Fig. 3).

Check switch. Replace if defective.

C.

C.

Check transformer windings. Replace if defective.

2.

Amber indicating light (DS702 or DS703) on remote control box does not glow when it is known that power is available at gate box. Lamp is good. Load contactor will not close.

NOTE:

The light is either not receiving power, or some component in the light-- ._ circuit is OPEN. A. Check as follows:

A.

Relay in memory and time delay module (K728) (5, Fig. 1) OPEN

(I)

The relay may have been normally opened by a fault condition in the output circuit. Press reset switch (S710) (11, Fig. 1).

(2) Check resistance across terminals 10 and 11 on memory and time delay module receptacle connector (J711). If resistance is infinite, indicating an OPEN relay, replace module (K728) (5, Fig. 1). B. Blown fuse (F702) (10, Fig. 1) in load contactor circuit C. Contactor disable switch (S721 or S722) (20, Fig. 1) in DISABLE position or defective C. Check switch(es). Position properly, or replace if defective. B. Check and replace fuse.

3.

Load contactor (K701 or K702) (l-l ; 4, Fig. 4) will not close when remote ON button is pushed. Power available light (DS702 or DS703) is ON.

NOTE:

If power-available light is ON, it eliminates from suspicion several components which could prevent contactor closing (see Trouble 2 above).

A.

Fuse (F701) (9, Fig. 1) blown, preventing fuse-interlock relay closing

A.

Check fuse and replace if blown.

Page 4

I rouoresnooring Lnart (sneer I Figure 2

OT 4~

Mar 25/81

w I

OM-I 05

TROUBLE, SYMPTOM AND CONDITION LOAD CONTACTOR 3. (Continued) CONTROL B.

PROBABLE CIRCUIT I I

CAUSE

TEST, CHECK, AND REMEDY

(CONTINUED) B. Check as follows: (1) Be sure power is avai!able for operating relay. Press test switch (S727) (12, Fig. 1). If fault lights do NOT glow, look for trouble in 12-V DC power supply system (see Trouble 3, C below). If lights glow, proceed to step (2). (2) Check fuse-interlock relay coil and contacts. Replace relay if defective.

Defective fuse-interlock relay (K720 or K726) (6, Fig. 1)

C.

A component of the 12-V DC power supply is defective (1) Defective transformer (T719) (23, Fig. 1)

C.

If fault lights do NOT glow when test switch is pushed, check 12-V DC system. (1) Check transformer primary and secondary windings. If defective, replace transformer.

(2)

Defective rectifier (CR736) (23, Fig. 1)

(2)

Rectifier output should be a pulsating 24-V DC. Replace if defective.

(3)

Defective capacitor (C707) (l-l; 1, Fig. 7)

(3) A defective capacitor will allow power supply output to reach zero volts. Check capacitor and replace if defective.

(4) Open resistor (R704) (3, Fig. 1) (5) Defective Zener diode (CR739) (2, Fig. 1) D.

(4) Check resistor and replace if defective. (5) Check diode. Replace if defective.

D.

Defective silicon rectifier (CR701 or CR702) (l-l, 6 and 8, Fig. 5)

Check rectifier output. Should be a pulsating 115-V DC. Replace rectifier if defective.

E.

Defective coil in load contactor (K701 or K702) (l-l ; 4, Fig. 4)

E.

Use terminals Y and X to test coil. Resistance should be approximately 600 ohms. If coil is defective, replace complete load contactor.

F.

Defective contactor close relay (K729 or K732)

F.

Check relays (l-l; if defective.

11, Fig. 5). Replace

Mar 25181

Troubleshooting Chart (Sheet 2 of 4) Figure 2

3-1 Page 5

OM-I 05

TROUBLE,

SYMPTOM PROBABLE CONTROL CIRCUIT A. CAUSE TEST, CHECK, AND REMEDY

AND CONDITION LOAD CONTACTOR 4.

(CONTINUED) I A. Check as follows:

Load contactor will close but OPENSas soon as control box ON button is released.

A compo kerh in the load contactor hold circuit is defective (1) Output cable not properly plugged into aircraft

(1) Connect output cable plug to aircraft receptacle securely so that components are fully mated.

(2)

Defective E and F terminals in cable plug connector or receptacle

(2)

Inspect plug and receptacle thoroughly. Repair or replace as required.

(3) Aircraft not supplying 28.5-V DC to pluginterlock relay

(3) Check aircraft onboard equipment to make certain that aircraft will accept power and return 28.5-V DC power to terminals E or F on output terminal panel.

(4)

Defective plug-interlock relay (K707 or K708) (8, Fig. 1) is defective

(4)

If contactor will remain closed when test bank switch (S701 or S702) (13, Fig. 1) is in TEST-BANK position, replace plug-interlock relay.

(5) Small contacts in load contactor (K701 or K702) not functioning to connect power to fuse-interlock relay (K720 or K726)

(5) Connect a jumper lead between terminals 1 and 2 on load contactor (see connection diagram, Chapter 6). If load contactor will now remain closed, replace complete load contactor.

CAUTION:

DO NOT OPERATE

UNIT WITH ANY COMPONENT(S)

JUMPERED

EXCEPT FOR TESTING.,

5.

Load contactor opens during power delivery. No fault lights are ON.

A.

Output cable has been accidentally disconnected from aircraft

A.

Reconnect cable plug securely and proteed with power delivery.

B.

If load contactor cannot be closed for operation, a component in the contactor operating circuit has likely failed.

B.

Check load contactor operating circuit in accordance with TROUBLES 4 above. 1 thru

3-I Page 6

Troubleshooting Chart (Sheet 3 of 4) Figure 2

Mar 25181

1
TROUBLE, SYMPTOM PROBABLE CAUSE

OM-I 05

AND CONDITION PROTECTIVE SYSTEM

TEST, CHECK, AND REMEDY

1 I 1. Load cot&actor opens during power delivery. Overload indicating light (DS706 or DS707) is ON. B. One of the resistors (R727, R728, R729 for No. 1 circuit, or R730, R731, R732 for No. 2 circuit) is open circuited (see l-l ; 3 and 10, Fig. 5). C. Defective overload module (K721 or K722) C. A load bank is required for checking overload module. (Refer to 2-3; Para. 3.) Replace module (K721 or K722) if defective. 2. Load contactor opens during power delivery. Overvoltage indicating light (DS727) is ON. A. A temporary condition of overvoltage may have signaled overundervoltage module to open contactor. A. Open gate box door and press reset switch (11, Fig. 1). With disconnect switch in ON position, check voltage in each phase at test receptacle connector (J712) (21, Fig. 1). If voltage is abnormally high, correct condition before operating gate box. B. Defective over-undervoltage module (K727) (4, Fig. 1) B. Use test box to test overvoltage protective circuitry. Refer to 2-3; Para. 2, A and B. Replace module (K727) if defective. 3. Load contactor opens during power delivery. Undervoltage indicating light (DS726) is ON. A. A temporary condition of undervoltage (lasting more than 5 seconds) may have activated the undervoltage protective circuit. A. Open gate box door and press reset switch (11, Fig. 1). With disconnect switch in ON position, check voltage in each phase at test receptacle (J712) (21, Fig. 1). If voltage is abnormally low, correct condition before operating gate box. B. Defective over-undervoltage module (K727) B. Use test box to test undervoltage circuitry. Refer to 2-3; Para. 2, A and B. Replace module (K727) if defective. B. An open resistor will cause higher than normal voltage signal to memory and time delay module (K728). Check resistor and replace as required. A. An overload condition has caused load contactor to open. A. Open gate box door and press reset switch (11, Fig. 1). Correct condition that caused overload. ,

Mar zb/81

Troubleshooting Chart (Sheet 4 of 4) Figure 2

3-1 Page 718

OM-105 CHAPTER 4. ILLUSTRATED I. PARTS LIST

SECTION 1. General

INTRODUCTION

The Illustrated Parts List identifies!, dlescribes, and illustrates main assemblies, subassemblies, and detail parts of a 575 V. Gate Box manufactured by Hobart Brothers Company, Power Systems Division, Troy, Ohio 45373. 2. Purpose The purpose of this list is to provide parts identification and descriptive information to maintenance and provisioning personnel for use in provisioning, requisitioning, purchasing, storing, and issuing of spare parts. 3. Arrangement Chapter 4 is arranged as follows: Section 1 - Introduction Section 2 - Manufacturers Codes Section 3 - Parts List Section 4 - Numerical Index 4. Explanation of Parts List A. Contents The parts list contains a breakdown of the equipment into assemblies, subassemblies, and detail parts. All parts of the equipment are listed except: (1) Standard hardware items (attaching parts) such as nuts, screws, washers, etc., which are available commercially. (2) Bulk items such as wire, cable, sleeving, tubing, etc., which are also commercially available.

(3) Permanently attached parts which lose their identity by being welded, soldered, riveted, etc., to other parts, weldments, or assemblies. B. Parts List Form This form is divided into six columns. Beginning at the left side of the form and proceeding to the right, columns are identified as follows: (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 lists to the illustrations and vice versa. The figure and index numbers are also used in the numerical index to assist the user in finding the illustration of a part when the part number is known.

Mar 25181

4-1 Page 1

OM-105 (2) HOBART PART NUMBER Column

ALL part numbers appearing in this column are Hobart numbers. In all instances where the part is a purchased item, the vendors identifying five-digit code and his part number will appear in the NOMENCLATURE column. Vendor parts which are modified by Hobart will be identified as such in the NOMENCLATURE column. In case H bart does not have an identifying part number for a purchased part, the HOBART PART NUMBE r3 dolumn will reflect No Number and the vendors number will be shownin the NOMENCLATURE column. Parts manufactured by Hobart reflect no vendor code column. or part number in the NOMENCLATURE (3) NOMENCLATURE Column

The item identifying name appears in this column. The indenture method is used to indicate item relationship. Thus, components of an assembly are listed directly below the assembly and indented one space. Vendor codes and part numbers for purchased parts are shown in this column. Hobart modification to vendor items is also noted in this column. (4) REC. SPARES Column When there is an entry in this column, it shows the quantity of that item recommended for spares to support ONE end item. (5) 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 the particular model they are used on. Parts in this list are coded as follows: Uncoded parts are used on all models. Parts coded A are used on 482934A-2 Parts coded 8 are used on 482934A-4 Parts coded C are used on 482934A-5 (6) UNITS PER ASSEMBLY Column only. only. only.

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. 5. Reference Designator Index The reference designators listed in Figure 1 are the same as those used on the connection and schematic diagrams furnished in Chapter 6. Each reference designator is cross-referenced to the Figure and Item number of that item in the Illustrated Parts List, Section 4-3.

4-1 Page 2

Mar 25181

OM-105

REF. DES. c 707 CR 701 CR 702 CR 706 CR 707 CR 708 CR 709 CR 710 CR 711 CR 721 CR 722 CR 723 CR 724 CR 725 CR 726 CR 736 CR 737 CR 738 CR 739 DS 701 DS 706 DS 707 DS 721 DS 723 DS 726 DS 727 F 701 F 702 K 701 K 702 K 707 K 708 K 720 K 721 K 722 K 726 K 727 K 728 K 729 K 732

LOCATION ITEM FitG.

REF. DES.

LOCATION ITEM FIG.

REF. DES.

LOCATION ITEM FIG.

1 10 16

5 4 4 5 5 5 5 5 5

R 704 R 712 R 713 R 714 R 715 R 716 R 717 R 727 R 728 R 729 R 730 R 731 R 732 R 733 R 734 R 735 R 736 R 737 R 738 s 701

2 25 25 25 25 25 25 6 6 6 6 6 6 6 6 6 6 6 6 16 16 14 11 12 16 16 26 14 5 5 5 5 5 5 1 11

5 5 5 5 5 5 5 4 4 4 4 4 4 4 4 4 4 4 4

25 25 25 25 25 25 1 20 20 22

5 5 5 5 5 5 5 5 5 5

8,9
5,6,7 5,6,7 14, 15, 16 14, 15, 16 5,6,7 5,6,7 13 13 9 9 12 12 9 3 3 9 6 7 28 28 5 5 4 4 5 5 5 5 5 5 5 5 4 4

s 702. s 710 s711 S712 S721 S 722 S 726 S 727 T 704 T 705 T 706 T 707 T 708 T 709 T 719 T721

Mar 25181

Reference Designator Index Figure 1

4-1 Page 314

OM-I 05 SECTION 1. 2. MANUFACTURERS CODES

Explanation of Manufacturers (Vendor) Code List The following list is a compilation of vendor codes with names and addresses for suppliers of purchased parts listed in this publication. The codes are in accordance with the Federal Supply Codes or Manufacturers Cataloging Handbook H4-1, and are arranbeQ 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. CODE 00779 VENDORS NAME AND ADDRESS

AMP Inc. P. 0. Box 3608 Harrisburg, Pennsylvania 17105 Anchor Rubber Company 840 S. Patterson Blvd. Dayton, Ohio 45402

02231

02660

Amphenol Corporation 2801 S. 25th Avenue Broadview, Illinois 60153 Appleton Electric Company 1713 W. Wellington Avenue Chicago, Illinois 60657

03743

04713

Motorola Semiconductor Products Inc. 5005 East McDowell Rd. Phoenix, Arizona 85008

05277

Westinghouse Electric Company Semi & Conductor Dept. Youngwood, Pennsylvania 15697

08108

Lamp Industry Designations and Abbreviations for Lamps

09332

Aerofast Inc. P. 0. Box 324 Wheaton, Illinois 60187 Thermalloy Company Inc. P. 0. Box 34829 2021 W. Valley View Lane Dallas, Texas 75234

13103

14280

Square D Company Distribution Equipment Div. 1601 Mercer Rd. Lexington, Kentucky 40505

Mar 25181

4-2 Page 1

I
CODE 14831

1
VENDORS NAME AND ADDRESS Magnetic Components Inc. 290 Fischer St. Costa Mesa, California 92627

OM-105

24248

South Chester Corporation South Company Division 3rd Street & Governor Printz Boulevard Lester, Pennsylvania 19113

27191

Cutler-Hammer

Inc.

Power Distribution & Control Div. 4201 N. 27th Street Milwaukee, Wisconsin 53216 28520 H EYCO Heyman Manufacturing Company 1000 Michigan Avenue Kenilworth, New Jersey 07033 44655 Ohmite Manufacturing Company 3601 W. Howard Street Skokie, Illinois 60076 50603 H. B. Electrical Mfg. Co. Inc. 1125 National Pky. Mansfield, Ohio 44906 54860 Hewlett Packard 5303 Stevens Creek Blvd. Santa Clara, California 95050 Ark-Les Switch Corporation 51 Water Watertown, Massachusetts 02172 71400 Bussman Mfg. Division of McGraw & Edison Company 2536 W. University Street St. Louis, Missouri 63017 73559 Carling Electric Inc. 505 New Park Avenue West Hartford, Connecticut 77342 061 IO

70611

American Machine & Foundry Company Potter & Brumfield Division 1200 E. Broadway P. 0. Box 522 Princeton, Indiana 47570

4-2 Page 2

Mar 25181

OM-105

CODE 80368

VENDORS

NAME AND ADDRESS

Sylvania Electric Products Inc.

i6
89110 '

730 Third Avenue New York, New York AMP Inc.

10017

155 Park Street Elizabethtown, Pennsylvania 17022 89373 United States Rubber Company Detroit, Michigan 91637 Dale Electronics Inc. P. 0. Box 609 Columbus, Nebraska 68601 91929 Honeywell Inc. Building Controls and Components Group Micro Switch Division Freeport, Illinois 61032 Basler Electric Company P. 0. Box Rt. 143 Highland, Illinois 62249 98410 E.T.C. Inc. 990 E. 67th Street Cleveland, Ohio 44103

97520

Mar 25181

4-2 Page 314

OM-105

SECTION 1. Explanation of Parts List Arrangement

3. PARTS LIST

The parts list is arranged so that th illustration will appear on a left-hand page and the applicable parts list will appear on the opposite right-hand i a&. Unless the list is unusually long, the user will be able to look at the illustration and read the parts list without turning a page. 2. Symbols and Abbreviations The following is a list of symbols and abbreviations used in the parts list.

*
A, or AMP AC AR DC -

Item not illustrated ampere alternating current as required direct current Figure head hexagon Hertz (cycles-per second) inside diameter inch kilovolt-ampere microfarad number next higher assembly peak reverse voltage pounds per square inch reference (the item has been listed previously) Technical Manual transformer-rectifier volt (when used as a prefix to a five-digit number, indicates vendor code)

Fig. hd. hex Hz I.D. kVA IN PF No. NHA PRV -

PSI Ref TM T-R vNOTE:

An item which does not reflect an index number is an assembly which is not illustrated in its assembled state, or it is similar (right-hand, left-hand, top, etc.) to an item which is illustrated. ,

Mar 25181

4-3 Page 1

OM-105

only

575 Volt Gate Box 4-3 Page 2 Figure 1 Mar 25181

I
OM-105

NOMENCLATURE FIGURE ITEM NO. lHOBART PART NO. 482934A-2 482934A-4 482934A-5 1234567 BOX, GATE, ASSY, 140 KVA WITH 24 V. Lpc L & REMOTE PUSHBUTTONS BO s , GATE, ASSY, 140 KVA WITH 24 V. REMOTE PUSHBUTTONS BOX, GATE, ASSY, 30 KVA WITH 24 V. REMOTE PUSHBUTTONS TRANSFORMER
1

UNITS REC SPARES EFF per ASSY

A B

REF REF

AND 60 KVA C REF 1 4 ASSEMBLY 1 ASSEMBLY (For Details


1

No Number 483028-I 483028-2 483020 77A-1022 77A-1020 77A- 1153

. BOX, ASSEMBLY See Fig. 2)

(For Details See Fig. 2) ASSEMBLY (For Details

. LIGHT, PILOT, FAULT,

. LIGHT, PILOT, POWER AVAILABLE, (For Details See Figure 2) . SUPPORT, MOUNTING, See Figure 2) . KIT, MECHANISM, See Figure 3) . KIT, MECHANISM, Figure 4) . KIT, MECHANISM, Figure 4) . NAMEPLATE, . NAMEPLATE, . NAMEPLATE, . . . . CLOSING,

DOOR (For Details


1

OPERATING OPERATING

(For Details See A,B (For Details See


c 1 1 1 1 1 1 1

6 7 8 9 10

77B-1025-1 77B-1025-3 77B-1025-5 77 B-l 025-2 77B-1025-4 402987 No Number 483470 484139 79A-1004 79A-1005 77B-1025-6 77B-1025-7

CIRCUIT

1 OVERLOAD

OVERVOLTAGE POWER AVAILABLE

* * ** **

NAMEPLATE, CIRCUIT 2 OVERLOAD NAMEPLATE, UNDERVOLTAGE NAMEPLATE, HOBART GATE BOX INTERIOR (For Details See Figure 3) (WALL) (PEDESTAL) A A A A 2

REF REF REF 1 1 4 2

11 12 13 14 15

SUPPORT, MOUNTING : SUPPORT, MOUNTING . NAMEPLATE, . NAMEPLATE, . NAMEPLATE, . NAMEPLATE, CIRCUIT CLOSE OPEN

Cl RCUIT 1

**

Optional item must be ordered separately.

Mar 25/81

4-3 Page 3

OM-I 05

Q Q 0 Q\ -
-2

only

t PSO-0242

Box Assembly Figure 2


4-3

Mar iSI

Page 4

OM-105 NOMENCLATURE FIGURE ITEM NO. 21 2 3 4 5 6 7 8 9 10 11 12 13 HOBART PART NO. No Number 485562 77D-1019 483231 A 483225A 483020 483028-I 77A-1026-1 77A-1028-I 400613-I 1 483028-2 77A-1026-2 77A-1028-2 400613-12 77A-1027 77A-1036-I 77A-1036-2 77A-1167 483028-I 0 77A-1026-3 77A-1028-3 77A-1027 400613-I 5 1234567 BOX ASSEMBLY (For NHA See Figure 1) A B,C REC SPARES EFF UNITS per ASSY REF 1 1 1 1 1 4 1 5 1 1 1 1 1 5 1 5 A OPEN A A A No. G9 No. KP-34 5 * 2 4 2 1 1 1 1 2 ,

. ox, STEEL, NEMA 12 ASSEMBLY .x dk, STEEL, NEMA 12 ASSEMBLY . COVER, OPENING, TOP, ASSEMBLY . DUCT, Al R, ASSEMBLY . SUPPORT, MOUNTING ASSEMBLY . LIGHT, PILOT, FAULT, ASSEMBLY . . . . . LENS (RED) VI4280 No. R-9 . BASE, 17 AMPS., 12 V. V14280, No. KP-32 . LAMP, 12 PSB. VO8108 LIGHT, PILOT, POWER AVAILABLE, ASSY . . LENS (AMBER) V14280, No. A-9 . . BASE, .025 AMPS., 120 V. V14280, No. KP-38 . . LAMP, 120 PSB VO8108 CLASS 9001, TYPE KU-27 . . CAP VI4280 . PUSHBUTTON, V14280, CONTACTOR, CLOSE No. KR-2BH13

. PUSHBUTTON, CONTACTOR, V14280, NO. KR-2RH13 . CAP, PROTECTIVE, . LIGHT, CONTACTOR, . . LENS (GREEN) . . CAP VI4280 CLASS 9001, TYPE KU7

PUSHBUTTON CLOSED ASSEMBLY

14 15 * 16

V14280,

. . BASE, .073 AMPS., 24 V. V14280, . . LAMP, 24 PSB VO8108

CLASS 9001, TYPE KU-27

Mar 25181

4-3 Page 5

id eil

OM-105

-T-l

Gate Box Interior Figure 3 4-3 Page 6 Mar iSi

w I
FIGURE ITEM NO. 31 HOBART PART NO. No Number 485558 685630 483234 400613-I 400613-12 483235 483236 W-l 1434 W-l 1166-1 W-11166-9 77A-1022 10 11 77A-1023 778-1018 77B-1151 12 483221 485635 * x * * * * 8 IOOGH-117 No Number W-l 0079-7 80A-1000 400533 403091-7 40191 l-8 1 1234567 . TAVEL, . PANEL, INTERIOR INTERIOR See Figure 4)

OM-I 05

NOMENCLATURE REC SPARES (For NHA See Figure 1) ASSEMBLY ASSEMBLY (For Details A,B (For Details C EFF

UNITS per ASSY REF 1 1 1 3 3 1 1 6 3 3 1 1 A,B C AS3 (For Details C (For Details 2 1 1 1 2 1

GATE BOX INTERIOR

See Figure 4) . BOARD, MTG. FUSES & LAMPS ASSEMBLY . . LAMP, PILOT LIGHT, 12 PSB, V80368 . . LAMP, PI LOT LIGHT, 120 PSB, V80368 . . LABEL, SPARE FUSES & LAMPS . . BOARD, MTG., FUSES & LAMPS . . FUSE, HOLDER V71400 No. 4407 . . FUSE, AGC 2A, FAST BLOW . . FUSE, AGC IA, FAST BLOW . KIT, MECHANISM, CLOSING DOOR VI4280 CLASS 9423, TYPE M4 . KIT, MECHANISM, CLOSING DOOR VI4280 CLASS 9423, TYPE M3 . TRANSFORMER, 140 KVA (For Details See Figure 6) . TRANSFORMER (For Details See Figure 6) (For Details . CHANNEL, MTG. TRANSFORMER See Figure 6) . CHANNEL, MTG. TRANSFORMER See Figure 6) . HORN &CABLE See Figure 6) . TRANSFORMER Figure 6) . CONNECTOR . LUG, GROUND . NAMEPLATE, . PLUG, HOLE GROUND V28520, No. DP-1500 No. 38008-63 V98410, & MOUNTING (For Details See CLAMP ASSEMBLY

REF No. 7486 1 12 2 1

BOX V03743,

. STRIP, TERMINAL

Mar 25181

4-3 Page 7

OM-105

26

d
I 9 ) .!@ \ 27 -2 -4 24-

Interior Panel Assembly Figure 4 4-3 Page 8 Mar 25/81

OM-I 05 NOMENCLATURE FIGURE ITEM NO. 4HOBART PART NO. 485558 485630 48300 1 483002 483003A 485557 5 6 ICZ-148 404402-I 404402-8 7 8 9 IO 11 12 13 14 15 * 16 38932 1 48562 1 38692 1 485310 404518 404065-2 402 119-8 DW-1704 W- 11097-8 AW-626 A-25 485311 483436 485309 404518 404065-2 402119-8 DW-1704 W-l 1097-8 AW-626 A-25 485312 483436 77A-1021 77B-1024 402261-13 27 28 29 30 * * 31 Mar 25/81 77A-1020 16DA-4004A-3 16DA-4253-1 16DA-4052-0 484689-l 484690-2 370891 REC 1234567 PANEL, PANEL, INTERIOR INTERIOR ASSEMBLY ASSEMBLY (For NHA See Fig. 3) (For NHA See Fig. 3) SPARES EFF AB C UNITS per ASSY REF REF 1 1 1

1 &%T~~;!I~GHT . BRACKET; . PANEL, CONTROL Fig. 5) . TRANSFORMER, . RESISTOR, V91637, V91637,

ASSEMBLY ASSEMBLY CURRENT WATT 50 OHMS WATT RESISTOR RESISTOR TRANSFORMER 1 6 C A,B C (For Details See

MTG:: LEFT ASSEMBLY

1
V14831, No. E-6170 6 A,B 6 6 12 6 6 6 1 1 1 2 2 1 1 6 1 1 1 1 1 2 2 1 1 CONTACTOR V14280, 1 TYPE KAL 36000, 1 TYPE FAL 36060, 1 V14280,
1

'

OVERLOAD,

16.6 OHMS

No. RH-25,20 No. RH-25,20 MOUNTING MOUNTING MOUNTING

. RESISTOR, OVERLOAD, . BRACKET, . BRACKET, . BRACKET,

. BRACKET, MOUNTING CONTACTOR ASSY . . CONTACTOR, LOAD V50603, No. HB200B . . RECTIFIER, SILICON V04713, No. SDAl0270-2 . . SCREW, 1/4-20x l-1/2, HHC, ST. . . BUSHING, INSULATING . . SCREW, 318-16 x 2, HHC, ST. BUSHING, INSULATING : : WASHER, INSULATING . . BRACKET, MOUNTING CONTACTOR . . LABEL, PHASE . BRACKET, MOUNTING CONTACTOR ASSY . . CONTACTOR, LOAD V50603, No. HB200B RECTIFIER, SILICON V04713, No. SDA10270-2 : : SCREW, l/4-20 x l-1/2, HHC, ST. . . BUSHING, INSULATING . . SCREW, 3/8-16x 2, HHC, ST. . . BUSHING, INSULATING . . WASHER, INSULATING . . BRACKET, MOUNTING . . LABEL, PHASE

17 18 19 20 21 22 23 24 * 25 26

6 1 1

. KIT, MECHANISM, HANDLE CLASS 9422, TYPE Al . BREAKER, . BREAKER, CIRCUIT CIRCUIT V14280, V14280, 225 A. 600 V. AC, 3 POLE 60 A. 600 V. AC, 3 POLE . KIT, MECHANISM,

A,B c

1 1

OPERATING

CLASS 9422, TYPE RP-1 . RELAY, CONTACTOR, No. KAP-14DG . RETAINER, . SLEEVING, . SLEEVING, SPRING, PLASTIC, . SOCKET, RELAY CLOSE V77342, RELAY l/8 I.D.

I.

VO2660, No. 77-MIP-11

PLASTIC, 3/16 I.D.

. MOUNT, SOCKET, RELAY 4-3 Page 9

w I I

OM-105

32

21 22

-2

-4

ii3

34

IO 11

------------

23

31 -.

pi5zzq

Control Panel Assembly Figure 5 4-3 Page IO Mar 25181

1
I FIGURE ITEM NO. 51 1 2 3 4 5 6 7 * * 8 HOBART PART NO. 485557 1234567 PANEL, CONTROL TRANSFORMER, 387738~ 402037-g 401556 482038 387736B 16DA-4052-0 484689-l 484690-2 16DA-4004A-10 16DA-4253-1 400785-7 11 12 13 * * 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 * 34 * 76A-1115 16DA-4004A-3 402658 W-l 1166-9 W-l 1166-I 76A-1118 403336 402662 401937-3 400480-2 401937-2 1CZ-93B 483026 1CZ-27 1-9 410539 401937-2 482935 401564-I 76A-1123-I 482257 77A-1010 404875 483039 485556 40 1564-4 401566-I 401564-5 404424 1 . MOUNT, SHOCK, RUBBER V89373, No. B-323 ASSEMBLY 1 1 . BOARD, OVER-UNDERVOLTAGE, ASSY (For NHA See Fig. 41 SUPPLY, POWER, ASSEMBLY 1 1 1

m I

1
I

OM-105 UNITS REC SPARES EFF per ASSY REF 1 1 2 3 28 1 1 4 16 4 V77342, 1 , 2 4 8 2


1

NOMENCLATURE

. BOARD, MEMORY &TIME DELAY, ASSEMBLY . SOCKET, RELAY VO2660, No. 77-MIP-11 . SLEEVING, PLASTIC, l/8 I.D. . SLEEVING, PLASTIC, 3/16 I.D. . RELAY, FUSE INTERLOCK, ASSEMBLY No. KAP-14DY . RETAINER, . RIVET, SPRING, RELAY BLIND, DOMED HEAD, ST

9 IO *

. LATCH, ADJUSTABLE GRIP V24248, No. 48-99-126-11 . RELAY, PLUG INTERLOCK ASSEMBLY V77342, No. KAP-14DG . HOLDER, FUSE V71400, No. HKP-HH . FUSE, AGC IA . FUSE, AGC 2A . SWITCH, SNAP, PUSHBUTTON No. SA35BCB34-9 . RING, LOCKING, . SWITCH, TOGGLE . STRIP, TERMINAL . TERMINAL, . STRIP, TERMINAL . DIODE, SILICON . DIODE, . HEAT, SINK DIODE, . TERMINAL, SWITCH V73559, V98410, V98410, V05277, ZENER V91929, No. TS10020 No. 2GK71-73 No. 35005-3526 VO0779, No. 41274 No. 35008-3526 No. IN4820 V13103, V04713, V70611, No. 6423 No. IN3314A No. 3000825 V27191

5 5 2
1

QUICK CONNECT

2
1

ZENER 50 WATTS FEMALE 90 V98410,

. STRIP, TERMINAL

No. 35008-3526 2 V89110, 2 2 2


1 1

. BOARD, MONITOR, CONTACTOR . HOUSING, SOCKET, CONNECTOR No. l-480270-0

. PIN, SWITCH DISABLE V09332, No. C5-1.3R . GUARD, SWITCH TOGGLE . RECEPTACLE, PANEL, CONTROL VO2660 No. MS3102A-18-20P . CAP & CHAIN ASSEMBLY . COVER, PLEXIGLASS . PANEL, CONTROL . HOUSING, SOCKET, CONNECTOR No. l-480287-0 . TERMINAL, SOCKET V89110, . HOUSING, SOCKET, CONNECTOR No. l-480438-0 . DIODE, LIGHT EMITTING, No. 5082-4655 V891 IO VO2660, No. 9760-13

1 3 52 V89110,

No. 60619-I

RED V54860, 6 6 4-3 Page 11

May

I/86

Revised

OM-105

Transformer and Mounting Figure 6 4-3 Page 12 Mar 25/81

m I
I

1 I

OM-105

NOMENCLATURE FIGURE ITEM NO. 61 HOBART PART NO. No Number 77B-1018 77B-1151 2 48322 1 485635 IOOGH-117 3 4 5 IOOGH-121 7J-422-O IOOGH-118 1234567 TRANSFORMER Ffgiy 3) . TRANSFORMER, No. BE15861-001 . TRANSFORMER, No. BE-l 6365-001 . CHANNEL, . CHANNEL, MTG. TRANSFORMER MTG. TRANSFORMER CLAMP ASSEMBLY 60 KVA V97520.
1, c

UNITS REC SPARES EFF per ASSY

& MOUNTING 140 KVA

(For NHA See REF

V97520, 1 A,B 1
1

A,B c

2 2 2 1 2 1

. HORN &CABLE . . BRACKET . . CLAMP

. . HORN ASSEMBLY

Mar 25181

4-3 Page 13114

OM-105

SECTION 4. NUMERICAL 1. Explanation of Numerical Index

INDEX

The purpose of this index is to assist the user in finding the illustration and description of a part when the part is known. Part numbers are arrang d, in alpha-numerical sequence. Thus, any part number beginning with the letter A would be located at or nea r the top of the index list. Likewise a part number 9 would be listed near the end of the list and far below a part number 1000. The figure number and item number location of the part is directly opposite the part. If the part is used in more than one place, each location is listed commencing with the first location the part is listed. NUMERICAL INDEX FIGURE AND ITEM NUMBER 4-15 4-23 AW-626 DW-I 704 GATE BOX INTERIOR TRANSFORMER W-l 0079-7 W-l 1097-8 w-11166-1 W-11166-9 W-l 1434 W-454 1 B ICZ-148 1CZ-27 1-9 1CZ-93B 16DA-4004A-3 16DA-4004A-IO 16DA-4052-0 16DA-4253-1 IOOGH-117 IOOGH-118 IOOGH-121 370891 386781 &MOUNTING 4-14 4-22 4-12 4-20 1-o 3-o 3-o 6-O 3-o 4-13 4-21 3-7 5-o 3-8 5-o 3-6 5-2 4-5 5-22 5-20 4-28 5-12 5-9 4-30 5-8 4-29 5-10 3-o 6-O 6-5 6-3 4-31 5-1

PART NUMBER A-25

Mar 25181

Numerical Index 4-4 Page 1

w I
NUMERICAL INDEX

I
(CONTINUED) FIGURE AND ITEM NUMBER 4-8 5-7

OM-105

PART NUMBER 386921 387736B 387738A 389321 400480-2 400533 400613-I 400613-I 400613-15 400785-7 401556 401564-I 401564-4 401564-5 401566-I 1 40191 I-8 401937-I 401937-2 401937-3 402037-g 402 119-8 402261-13 402658 402662 402987 40309 1-7 403336 404065-2 404402-I 404402-8 404424 404518 404875 410539 482038 482257 482934A 482935 48300 1 483002 483003A 1 2

5-3 4-7 5-18 3-o 2-7 3-2 2-10 3-3 2-o 5-o 5-5 5-26 5-33 5-34 5-o 3-o 5-19 5-24 5-17 5-4 4-11 4-19 4-o 5-13 5-16 1-o 3-o 5-l 5 4-18 4-10 4-6 4-o 5-o 4-9 4-I 7 5-30 5-23 5-6 5-28 1-o 5-25 4-I 4-2 4-3

Numerical Index 4-4 Page 2

Mar 25181

OM-105 NUMERICAL INDEX (CONTINUED) FIGURE AND PART NUMBER 483020 483026 483028-I 483028-2 483028-I 0 483039 48322 1 483225A 483231 A 483233 483234 483235 483236 483436 483470 484139 484689-l 484690-2 485309 485310 485311 485312 485556 485557 485558 485562 485621 485630 485635 7J-422-O 76A-1115 76A-1118 76A-1123 77A-1010 77A-1020 77A-1021 77A-1022 ITEM NUMBER I-3 2-4 5-21 I-2 2-o 1-o 2-o 2-o 5-31 3-12 6-2 2-3 2-2 6-O 3-o 3-4 3-5 4-o I-II 1-o 4-o 5-o 4-o 5-o 4-o 4-o 4-I 6 4-24 5-32 4-4 3-1 2-1 4-o 3-o 4-o 3-o 6-O 6-4 5-11 5-14 5-27 5-29 l-5 4-o 4-18 I-4 3-9 Mar 25/81 Numerical Index 4-4 Page 3

w I
NUMERICAL INDEX

1
(CONTINUED) FIGURE AND

OM-I 05

PART NUMBER 77A-1023 77A-1026-1 77A-1026-2 77A-1026-3 77A-1027 77A-1028-I 77A-1028-2 77A-1028-3 77A-1036-I 77A-1036-2 77A-1157 77A-1167 77B-1018 778-l 024 77B-1025-I 77B-1025-2 77B-1025-3 778-l 025-4 77B-1025-5 77B-1025-6 77B-1025-7 77B-1151 77D-1019 79A-1004 79A- 1005 80A-1000 ,

ITEM NUMBER

i4

3-10 2-5 2-8 2-14 2-11 2-I 6 2-6 2-9 2-15 2-l 2 2-13 1-o 2-o 3-11 6-I 4-l 9 I-6 I-9 I-7 I-IO I-8 I-14 I-15 3-o 6-O 2-o 1-12 1-13 3-o

Numerical Index 4-4 Page 4

Mar 25181

&g I I
CHAPTER

I I
EQUIPMENT

OM-105

5. OPTIONAL

NAME Wall Mounting Bracket Pedestal Mount Test Box Test Box Harness (575-Volt Input Cable) i ;I

PART NUMBER 483470 484139 483347-2

MANUAL

NUMBER

TM-575

483583

Test Box Harness (115-Volt Output Cable) Receptacle Connector 483584 483633

Kit, 575-Volt

5-o Page II2

m
r I
CHAPTER

I I
LITERATURE

OM-I 05

6. MANUFACTURERS

Hobarf: Diagrams for 482934A-2

iiI485567

- Schematic, Gate Box

485568 - Connection, Interior Panel 485554 - Connection, Control Panel 485427 - Connection, Installation

Hobart Diagrams for 482934A-4 485553 - Schematic, Gate Box 485555 - Connection, Interior Panel 485554 - Connection, Control Panel 485427 - Connection, installation

Hobart Diagrams for 482934A-5 485631 - Schematic, Gate Box 485632 - Connection, Interior Panel 485554 - Connection, Control Panel 485427 - Connection, Installation

Mar 25181

6-O Page II2

5726 HI HZ H3

T7

0 I

575V INPUT

0 sI!ezls

LEGEND

c707

CAPACITOR,

24V T-R, 3MFD,

50V DC

CR701 ,CR702 CR706-CR711 CR721-CR726 CR736 CR737,CR738 CR739 CR736 u,

RECTIFIER, LOPD CONTACTOR DIODE, LIGHT EMITTING DIODE. FLY- BACK. LED RECTIFIER, 24V i-R DIODE, OVERLOAD FAULT LIGHT DIODE, ZENER. 15V

J I
T707 I I Al ,?.A2 I T

DS701 DS702,DS703 DS706, DS707 05721 ,05723 DS722.DS724 OS726 DS727 F701 F702

INDICATOR, POWER AVAILABLE, AMBER. LOCAL INDICATOR. WWER AVAILABLE, AMBER, REMOTE INDICATOR, OVERLOAD FAULT, RED INDICATOR, CONT CLOSED, GREEN. LOCAL INDICATOR. CONT CLOSED, CLEAR, REMOTE INDICATOR, OVERVOLTAGE FAULT INDICATOR. UNDERVOLTAGE FAULT FUSE, 24V POWER SUPPLY, IA FUSE, LOAD CONTACTOR. 2A

J704 3709 J7Il J712 J713

, J705 3710

RECEPTACLE, OVERLOAD BOARD RECEPTACLE, CONTACTDR MONITOR BOARD RECEPTACLE, MEMORY 8 TIME DELAY BOARD RECEPTACLE, SYSTEMS TEST RECEPTACLE, OVER-UNDERVOLTAGE BOARD

K701 K707 K720 K721 K727 K726 K729

,K702 ,K705 ,K726 ,K722

,K732

LOAD CONTACTOR RELAY, PLUG INTERLOCK RELAY, FUSE INTERLOCK RELAY, OVERLOAD, S. S RELAY, OVER-UNDERVOLTAGE, S S RELAY, MEMORY 8 TIME DELAY, SS RELAY, CONTACTOR CLOSED

P704

,P705

2 P713 K726 1 P704 5727 19 91P705 1

*p7o

PLUG, PLUG, PLUG, PLUG,

OVERLOAD BOARD CONTACTOR MONITOR BOARD MEMORY 8 TIME DELAY BOARD OVER-UNDERVOLTAGE BOARD

R704 R712-A717 R727-R732

RESISTOR, 24V T-R. IODHM. 25W RESISTOR, VOLTAGE DROPPING, IQOOO OHM, IOH RESISTOR,OL BURDEN,166 OHM,25W (90KVAl RESISTCf?.OL ,BURDEN,25OtIM ,25W i60KVA 1

CR7Om

%721

%; lS702 5711 I $715


TC 4-L. NO

v 1
K702 K732

S712 s713 5714

,S716 ,s717 ,S716

Z26 S727 (727 CR737 :i J[ CR739

ss722

T704-T709

L-L
6 7

5722

::::

TRANSFORMER, TRANSFORMER, TRANSFORMER,

CURRENT, OVERLOAD 24V T-R 3 PWASE

J71 I

NOTE. WHEN GATE @OX IS USED FOR THE BOEING 707, THE CONTACTOR INTERLOCK CIRCUITRY WILL OPERATE PROPERLY ONLY ElY USING AN AIRCRAFT CABLE WITHOUT AN E B F JUMPER K728

HOBART BROTHERS CO. TROY,OHlO 45373 USA

T,TLE DIAWV4.SMEMATI
I

P711

;711

-.

4
1 r

:_ ::

,-. ,- .-.

-I L------J OS701 I

l,

L-?. t-n,

a mrv., cl.

.a,,

1 &$&.P*,.

-2,rarn .,..m ^^.... .^_^^ .-. ., -- .- --...-.-,. #DE, LIGHT EMITTING --- --^I LED -R IllOUt, UVERWAD FAULT LIGHT DIODE, ZENER. I%! 5701 c707 --Ii-

OS701 OS702,OS703 0s706.0s707

INDICATOR, WWER AVAILABLE. AMBER, LOCAI INDICATOR. POWER AVAILABLE, AMBER, REM01 INDICATOR. OVERLOAD FAULT, RED INDICATOR, CONT CLOSED, CLEAR, REMOTE INDICATOR, OVERVOLTAGE FAULT INDICATOR, UNOEVOLTAGE FAULT

!
T707 T7OB Al .i.A2 81 .+,B2 I

F7Ol F702

FUSE, 24V POWER SUPPLY, IA. FUSE, LOAD CONTACTOR, 2A.

J704, J705 5709. J7lO ; J7ll 5712 i J713

RECEPTACLE, OVERLOAD BOARD RECEPTACLE, CDNTACTOR MONITOR BOARD RECEPTACLE, MEMORY B TIME DELAY BOARD RECEPTACLE, SYSTEMS TEST RECEPTACLE, OVER-UNDERVOLTAGE BOARD

1 : j R704

K70l K702 K70+, K706 K720. K726 ;;;$K722

K72B K729,

K732

LOAD CONTACTOR RELAY, PLUG INTERLOCK RELAY, FUSE INTERLOCK RELAY, OVERLOAD, S. S. RELAY, OVER-UNDERVOLTAGE, S S. RELAY, MEMORY B TIME OELAY, SS. RELAY, CONTACTOR CLOSED

P704, P705 : ;;pf$ P7lO

P713

PLUG, PLUG, PLUG, PLUG,

OVERLOAD BOARD CONTACTOR MONITOR BOARD MEMORY 8 TIME DELAY BOARD OVER-UNDERVOLTAGE BOARD

R704 R712-R717 R727-R732 K726 Ii702 P7D4 k si P705 r

RESISTOR, 24V T-R, IOOHM, 25W. RESISTOR, VOLTAGE DROPPING. IQ00 OHM, IO\ RESISTOR,OL..BURDEN,l6.6 OHM.25W (SO KVA RESISTCf?,OL .BUROEN.E5OHM, 25W i60KVA.l

S701,5702 S71D S7ll,S713 STl2,S714 S72l ,S722 S726 S727 P704 y7 ,727 CR737 :! I I CR73E 7y P705

SWITCH, TEST BANK SWITCH,PUSHBUTTDN,RESET,PRDT SYSTEM SWITCH,PUSHEUTTON,CONT. CLOSE.REMOTE SWITCH,PUSHEUTTON,CDNT OPEN, REMOTE SWITCH, CONTACTOR DISABE SWITCH.DISCDNNECT SWlTCH;PUSHBUTTON.TEST, PROT SYSTEM

T704-T709 T7lS T72l

TRANSFORMER, TRANSFORMER, TRANSFORMER,

CURRENT, 24V T-R 3 PHASE

OVERLOAD

P7ll

:a-r-

2-s kI&

NOTE: WHEN GATE BOX IS USED FOR THE BOEING 707, THE CONTACTOR INTERLOCK CIRCUITRY WILL OPERATE PROPERLY ONLY BY USING AN AIRCRAFT CABLE WITHOUT AN E B F JUMPER.

HOBART BROTHERSCO. TROY,OHIO 45373 USA.

4
P7ll

TITLE

01 AGRAM. SCHEM4TI (

-i-lI

% E
__ __..... _~..-......... .._ -. -_-...-_-.. . . .-

r
I

Ir

: : ._

I : _

/ !

6E CLOSE-OPEN STATION FOR CIRCUIT 2 OUTPUT n CLOSE-OPEN STATION FOR CIRCUIT I OUTPUT I TERYINAL BLOCK FOR CONNECTING TERMINAL ELECTRICAL EQUIPMENT , FUf+NlSHED BY CUSTOMER CONTROL PANEL I

5726

CBA

575u INWT

INTERIOR PANEL OF OAT2 BOX.

CIRCUIT I OUTPUT CABLE

__

-----CIRCUIT 2 OUTPUT CABLE -

WIRE FURNISHED BY HOBART NO. 12 WIRE OR LAROER CABLE, SIZED BY OTHERS

BROS. CO.

LEGEND

05702, DS703 DS721, OS722

INDICATOR, POWER AVAILABLE, AMBER, REMOTE INDICATOR, CONTACTOR CLOSED, CLEAR, REMOTE

K701, K702

LOAD CONTACTOR

HOBART BROTHERSCO. TROY,OHIO 45373 USA.


TITLE DI AGm, oNI% -.

S7II.SII3 5712, S714 S726

SWITCH, PUSHBUTTON, CONTACTOR CLOSE, REMOTE SWITCH, PUSHBUTTON, CONTACTOR OPEN, REMOTE SWITCH, DISCONNECT

INSTALLATION GATE BOX

575V

5726 T704

T7

HI

QI

575V INPUT

H2

0 ziYf!Ez

H3

LEGEND

c707

CAPACITOR.

24V T-R, 3MFD,

50

DC

CR736 K727

CR701, CR702 CR706-CR71 I CR721-CR726 CR736 CR737, CR738 CR739 u,

RECTIFIER. Lo40 CONTACTOR DIODE, LIGHT EMITTING DIODE. FLY- BACK. LED RECTIFIER, 24V i-R DIODE, OVERLOAD FAULT LIGHT DIODE. ZENER. 15V

DS701 DS70Z,DS703 DS706.DS707 DS72l.DS722 05726 OS727

F701 F702

FUSE. 24V POWER SUPPLY, IA FUSE, LOAD CONTACTOR. EA

J704, J705 J709.J710 J711 J712 J713

RECEPTACLE, OVERLOAD BOARD RECEPTACLE, CONTACTOR MONITOR BOARD RECEPTACLE, MEMORY a TIME DELAY BOARD RECEPTACLE, SYSTEMS TEST RECEPTACLE, OVER-UNDERVOLTAGE BOARD

R704 5~A3 :iz--4,,?,6 8/,:P705

K701.K702 K707, K70B K720, K726 K721, K722 K727 K728 K729, K732

LOAD CONTACTOR RELAY, PLUG INTERLOCK RELAY, FUSE INTERLOCK RELAY, OVERLOAD, S. S RELAY, OVER-UNDERVOLTAGE, S S. RELAY. MEMORY a TIME DELAY, ss RELAY, CONTACTOR CLOSED

R7I5+ KRO K701 I

P704, P705 P709, P710 P71 I P713

PLUG, PLUG, PLUG, PLUG,

OVERLOAD BOARD CONTACTOR MONITOR BOARD MEMORY 8 TIME DELAY BOARD OVER-UNDERVOLTAGE BOARD

R7I6+

R7,7+

H704 R712-R717 R727-R738

RESISTOR, E4V T-R, IO OHM, 25W RESISTOR, VOLTAGE DROPPING, IQ(Kx, OHM, ,Oyl RESISToR.OL ,BURDEN. 50 OHM,25W (15 KVA:

S701,5702 s7io s711,5713 5712.S714 S721 ,S722 5726 5727

SWITCH, TEST BANK SWITCH,PUSHBUTTON,RESET,PROT SYSTEM SWITCH.PUSHEUTTON.CONT. CLOSE,REMOTE SWITCH,PUSHBUTTDN,CCNT OPEN,REMOTE SWITCH, CONTACTOR DISABE SWITCH.DISCONNECT SWITCH, PUSHBUTTON,TEST, PROT SYSTEM

T7CI+T709 1719 T721 (727

TRANSFORMER.CURRENT.OVERLOAD TRANSFORMER, 24V T-R TRANSFORMER, 3 PHASE

NOTE WHEN GATE BOX IS USED FOR THE BOEING 707, THE CONTACTOR INTERLOCK CIRCUITRY WILL OPERATE PROPERLY ONLY BY USING AN AIRCRAFT CA8LE WITHOUT AN E 8 F JUMPER

HOBART BROTHERS CO. TROY,OHlO 45373 USA


TITLE

DIAGRAM,SC3iEMATI C

-4

L--&---------L--;----L------------l----;;=<, t ,c:>:

L
/I/,

* ---IE

/II*

I,,,

j,,,,,,,,,,,,,,,, rr--------

Unusual

Service

Conditions

This information is a general guideline and cannot cover all possible conditions of equipment use. The specific local environments may be dependent upon conditions beyond the manufacturers control. The manufacturer should be consulted if any unusual conditions of use exist which may affect the physical condition or operation of the equipment. Among such conditions are :

1. Exposure to:
a. Combustible, explosive, abrasive or conducting dusts. b. Environments where the accumulation of lint or excessive dirt will interfere with normal ventilation. c. Chemical fumes, flammable or explosive gases. d. Nuclear radiation. e. Steam, sat&laden air, or oil vapor. f. Damp or very dry locations, radiant heat, vermin infestation, or atmospheres conducive to fungus growth. g. Abnormal shock, vibration or mechanical loading from external sources during equipment operation. h. Abnormal axial or side thrust imposed on rotating equipment shafts. i. Low and/or high ambient temperatures.

2. Operation at:
a. Voltages above or below rated voltage. b. Speeds other than rated speed. c. Frequency other than rated frequency. d. Standstill with rotating equipment windings energized. e. Unbalanced vottages. 1. Operation at loads greater than rated.

3. Operation where low acoustical noise levels are required. 4. Operation with:
a. Improper fuel, lubricants or coolant. b. Parts or elements unauthorized by the manufacturer. c. Unauthorized modifications.

5. Operation in poorly ventilated areas.

November 16/90 Revised

Unusual Service Conditions Page 1

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