Hobart 7015-3 Operation And Maintenance Manual With Illustrated Parts List Download | Manualshive

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Summary of Contents for 7015-3

Page 1: ...d Parts List for POWER MASTER Solid State Frequency Converter Specification Number 7015 3 Rated Output 90 kVA 115 200 V 3 PHASE 400 Hz 415 V 3 Phase 50 Hz Input Model Number 90SB51 Hobart Brothers Company Airport Systems Group Ground Power Equipment Troy Ohio 45373 U S A ...

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Page 3: ...e 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 a Installation and Grounding of Electrically Powered Equipment Equipment driven by electric motors rather than by die...

Page 4: ...t circuited or heavily overloaded equipment from the line b Batteries Batteries may explode and or give off flammable hydrogen gas Acid and arcing from a ruptured battery can cause fires and additional failures When servicing do not smoke cause sparking or use open flame near the battery c Engine Fuel Use only approved fuel container or fueling system Fires and explosions can occur if the fuel tan...

Page 5: ...For Electrical Shock turn off power Remove victim if not breathing begin artificial respiration preferably mouth to mouth If no detectable pulse begin external heart massage CALL EMERGENCY RESCUE SQUAD IMMEDIATELY 7 Equipment Precautionary Labels Inspect all precautionary labels on the equipment monthly Order and replace all labels that cannot be easily read EMERGENCY FIRST AID Instructions 910082...

Page 6: ...This page intentionally left blank Page iv Instructions 910082 Rev 1 90 ...

Page 7: ...ock Circuit 1 1 9 e Remote Pushbutton Station Connection Optional 1 1 10 Section 2 Preparation For Use 1 2 1 1 Receipt and Inspection of Equipment 1 2 1 2 Unpacking the Unit 1 2 1 3 Mounting the Unit 1 2 1 4 Preparation for Use 1 2 1 a Select an Adequate source of Input Power 1 2 2 b Install Input Conductors in Converter 1 2 2 c Install Cable for Remote Control START STOP Pushbutton Station If Use...

Page 8: ... Restoring Unit to Operation After a Fault 3 1 2 a UV Undervoltage Fault 3 1 2 b OV Overvoltage Fault 3 1 2 c OC SH Overcurrent Short Fault 3 1 2 d OC 125 Overcurrent 125 Load Fault 3 1 3 e OC 150 Overcurrent 150 Load Fault 3 1 3 f 0 LOSS Phase Loss 3 1 3 g IMB GND 3 1 3 h DC Fuse 3 1 4 i A B C D Inverter Sections 3 1 4 Section 2 Troubleshooting Charts 3 2 1 Section 3 SOFT START Instructions 3 3 1...

Page 9: ...m 4 1 1 Section 2 Parts List 4 2 1 1 Explanation of Parts List Arrangement 4 2 1 2 Symbols and Abbreviations 4 2 1 Section 3 Numerical Index 4 3 1 1 Expalination of Numerical Index 4 3 1 Section 4 Spare Parts 4 4 1 1 Explanation of Spare Parts 4 4 1 Chapter 5 Optional Equipment Chapter 6 Manufacturer s Literature Unusual Service Conditions OM 2065 Operation and Maintenance Manual 90SB51 Spec 7015 ...

Page 10: ...ulse for Transistor SW1 3 2 1 Base Pulse for Transistor SW2 3 2 1 Unfiltered Output Waveform 3 2 2 Filtered Output Waveform 3 2 2 Transistor Module 3 4 1 Taking Transistor Module Resistance Measurements 3 4 2 Resistance Values for Transistor Module 3 4 2 Chapter 4 Illustrated Parts List AC AC Converter 4 2 2 Main Frame Cover Assembly 4 2 4 AC AC Converter Front Components and Main Transformers 4 2...

Page 11: ...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 See 2 l para lA The same method applies to illustrations which are identif...

Page 12: ...This page intentionally left blank OM 2065 Operation and Maintenance Manual 90SB51 Spec 7015 3 Frequency Converter Introduction Nov 01 90 Page viii ...

Page 13: ...stem it consumes only the energy necessary and in the amount required If no aircraft is being serviced no power is required and thus none is generated or consumed 2 Efficiency The converter unit provides power to an aircraft at an efficiency of 94 95 or better with 1 voltage regulation at the aircraft Since the unit is used in the vicinity of an aircraft being serviced expensive 400 Hz cabling is ...

Page 14: ...panel 2 Front Door Assembly 3 Cabinet 4 Rear Door 5 Card Cage Window Frequency Converter Unit Figure 1 OM 2065 Operation and Maintenance Manual 90SB51 Spec 7015 3 Frequency Converter Chapter 1 1 Nov 01 90 Page 2 ...

Page 15: ... conform to your LOCAL electrical code which may vary from the National Electrical Code Specifications and Capabilities Figure 2 2 Theory of Operation This Hobart converter is a state of the art solid state 60 or 50 Hz to 400 Hz frequency converter It employs all silicon semi conductors and CMOS digital logic This converter is specifically designed to supply clean reliable ground power to an aircr...

Page 16: ...ardless of pulse width variation Because of the elimination of the lower harmonics the output filter is very simple c Transformers Each inverter transformer has three AC output windings These windings are connected in series with the windings from the other inverters to yield a low distortion output Each leg of the three phase system is comprised of one winding from each of the six transformers d ...

Page 17: ...is located at the FRONT of the unit LEFT and RIGHT are determined by looking at the unit from the FRONT 4 Detailed Description a Controls and Control Circuits All control boards are concentrated in the card cage a portion of which is visible from the front of the unit through a small window located just beneath the control panel See 5 Fig 1 All control circuits are solid state and employ CMOS tech...

Page 18: ...itional adjustment is not necessary The potentiometer for these thresholds are in the alarm cards and are not easily accessible All of the lights on ALARM I and II cards are red and have a latching circuit which allows for an investigation even after the cause of a fault has disappeared ALARM III has 3 green indicators signaling the presence of the internal voltages 6V and 12V and the integrity of...

Page 19: ...C converter which provides regulated 6V and 6V from an input of 70V This output is used to drive all of the transistors with the emitter connected to the 600V bus To drive the rest of the transistors POWER SUPPLY II provides sets of floating 6V sources 4 Driver Cards The driver cards receive width modulated pulse signals from the comparator card and amplify these signals from logic power level to ...

Page 20: ...time and will record up to 9999 9 hours on five revolving drums The hourmeter operates whenever voltage is available at the output terminals of the converter 9 KILOWATT HOUR METER The kilowatt hour meter 2 as its name implies measures total power usage from the converter The kilowatt hour meter operates only when the converter is delivering power to a load 1 Hour meter 6 Meter Selector switch 2 Ki...

Page 21: ...ear interior section of the converter d Bridge Interlock Circuit For safety and to prevent damage to equipment the converter can be interlocked with the bridge drive circuitry in such a way that the bridge can not be moved on the apron while the converter is operating This is done to prevent the bridge from pulling the output cable from the airplane or driving over the cable Each converter is equi...

Page 22: ...tation may be mounted on the bridge boggie or a special output cable plug may be provided which has START STOP buttons or on off toggle switches mounted in the plug 2 Installation Remove the yellow jumper wire between terminals 7 9 of TB2 connect remote START STOP Push button as in Figure 7 and check operation NOTE If remote START STOP push buttons are disconnected terminals 7 9 of TB2 have to be ...

Page 23: ... full information about the claim NOTE Save the shipping container until the unit has been put into service and determined to be operating correctly When the unit is lifted into place under a bridge for mounting it should be supported by two 2 x 6 wooden planks extending the full length of the unit to prevent damage to the underside of the unit Take necessary measures to ensure that no water can r...

Page 24: ...in electrical functions and wiring to the Hobart item described above Make certain that the electrical power supply service disconnecting means is off before connecting input cables to the power supply service d Install Input Cable at Electrical Power Supply Service After turning off disconnect switch intended for supply to the unit connect the unit s input connectors to the disconnect switch Conn...

Page 25: ...is off g Install Output Cable The AC output terminal panel is located behind the rear door of the unit 1 Open the rear door and loosen the cable clamp screws at the cable horn 2 Route cable through cable horn and clamp and upward to the terminal board NOTE Conductor size recommended for AC output is 2 0 size 60 90 kVA Use No 12 size for control E and F terminals Large cables A B C N should be equi...

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Page 27: ...e converter check that the three green lights on ALARM III are ON and that the green INPUT POWER light is ON at the control panel b Check the functioning of all alarms by putting the TEST RESET switch in the TEST UP position and then in the RESET DOWN position c Place the NORMAL MAINT switch on the AMP card in the NORMAL UP position d Push the START button and keep it depressed for approximately o...

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Page 29: ...eful to avoid blowing debris where it could cause harm or injury carefully clean dust from the interior of the converter by blowing low pressure compressed air into the interior first from the bottom of the unit and then from the top b Clean heat sinks and printed circuit boards using compressed air or a soft brush c Inspect input and output terminal blocks for evidence of overheating due to loose...

Page 30: ...ce department for authorization It is often unnecessary to return a failed piece of equipment since this equipment uses plug in type assemblies throughout its systems Replacement assemblies for systems covered by this manual are usually in stock at the factory and available for immediate shipment For details on the warranty which covers this equipment refer to the warranty statement in the rear of...

Page 31: ...turned on the three green lights on ALARM III should be ON The DC FUSE light when ON indicates that the fuse is not blown The 12V light when ON indicates that all control boards are powered The 6V light when ON indicates that the DC to DC converter in the POWER SUPPLY I is working properly Do not apply power to the unit if any of the circuit boards are removed When input power is turned on the lig...

Page 32: ...dicated by OV light on ALARM II disconnect the load and restart the unit after resetting the alarm Check the output voltage Since response to an overvoltage condition is instantaneous there may not be time to read output voltage on the panel voltmeter Attempt to adjust the voltage downward by turning the potentiometer on the AMP card counterclock wise If no effect is seen replace the AMP card Sinc...

Page 33: ... the indicating light marked Ø LOSS on ALARM II comes on this indicates that the input voltage on one or more phases is less than specification See Chapter 1 Fig 2 If during a period of normal converter operation converter on and powering an aircraft a short term loss of input power occurs the phase loss fault will be activated and latched When input power is restored the red indicator light will ...

Page 34: ...blown Various sections have to be checked till fault is diagnosed and corrected Refer to troubleshooting charts later in this chapter i A B C D E F NOT USED ON THIS UNIT INVERTER SECTIONS When an indicating light for an inverter section on ALARM I comes on this indicates an excessive current draw through one transistors heat sink assembly Check for a cause of the excessive load See Troubleshooting...

Page 35: ...en interconnecting wires from these transformers to card cage connection Replace transformer and or repair wires 4 OC SH Overcurrent Short Circuit on ALARM II a Short circuited outputs Phase to phase or phase to neutral more than 200 overload Remove short or reduce load See para 2C on restoring to operation 5 OC 125 Overcurrent by 125 on ALARM II a Load exceeds 125 of rated current more than 5 min...

Page 36: ...ts on ALARM I Inspect all transistors and replace if found defective shorted SOFT START unit as described in Sect 3 before restarting 10 A B C D E F not used on ALARM I a Inverter section A B C D overcurrent due to excessive current Remove excess load reset and start b Shorted output Remove short reset and restart c Shorted transistor s Replace defective items SOFT START the unit as described in S...

Page 37: ...e NORMAL MAIN switch to MAIN position d Apply full rated input voltage to the unit All lights except OUTPUT POWER which is connected to output should illuminate e After pressing the STOP RESET and START in that order buttons remove ALARM II card immediately otherwise the unit will shutdown from undervoltage f With an oscilloscope observe base emitter pulses of all 24 transistors and compare them t...

Page 38: ... and STOP buttons Also verify the operation of the voltage ramp up circuitry p Reconnect the output filter caps Repeat above steps and compare to Figure 4 If the waveform is not smooth check output filter capacitors C17 C34 according to Section 5 q Remove DC power supply connected in step H above r Check the DC capacitors C7 C16 according to Section 5 s Reconnect the DC bus fuse F3 and DC filter f...

Page 39: ...ues of resistance for a good transistor are shown in Figure 3 When taking these resistance measurements take particular note of which company manufactures the transistor as values vary between manufacturers NOTE A DIGITAL ohmmeter may be used to check transistors by using the X1 scale or DIODE CHECK scale if so equipped However measured resistance values may be quite different from those shown in ...

Page 40: ...20 1200 V 100 A infinity 7 100 100 For taking these resistance measurements use an ANALOG ohmmeter set to X1 scale If unsure of output polarity verify with another voltmeter Values shown are approximate and are measured with the transistor removed from all other circuitry Resistance Values for Transistor Module Figure 3 Taking Transistor Module Resistance Measurements Placement of Ohmmeter Leads F...

Page 41: ...and the meter to capacitor terminal For AC capacitors such as C17 C34 polarity of meter connections is not important e Good capactiors will show some resistance followed by decay falling to or near infinity as the capacitor takes a charge f Bad capacitors will show low to no resistance short circuit or infinite resistance open circuit No charging of the capacitor will be noted NOTE A DIGITAL ohmme...

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Page 43: ... 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 five 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...

Page 44: ...hich are used only on 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 on which they are used Since this manual covers only one model of equipment the effectivity column is not used in this manual 5 QTY Quantity Column Numbers in this column indicate the quantity of parts required for an assembly or subassembly in whi...

Page 45: ... AR as required DC direct current Fig Figure hd head hex hexagon Hz Hertz cycles per second I D inside diameter IN inch kVA kilovolt ampere uF microfarad No number NHA next higher assembly OM Owners Manual PRV peak reverse voltage PSI pounds per square inch Ref reference the item has been listed previously T R transformer rectifier V volt when used as a prefix to a five digit number indicates vend...

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Page 47: ...AC AC Converter Figure 1 Nov 01 90 Chapter 4 2 Page 3 ...

Page 48: ...Main Frame Cover Assembly Figure 2 OM 2065 Operation and Maintenance Manual 90SB51 Spec 7015 3 Frequency Converter Chapter 4 2 Nov 01 90 Page 4 ...

Page 49: ...82490 BRACKET LIGHT FLOURESCENT 4 15 282506 SUPPORT TRANSFORMERS FRONT ASSY 1 16 280573 PANEL MTG FRONT 1 17 402037 9 GROMMET RUBBER 5 18 280675 BRACKET MTG CARD CAGE 2 19 280555 TOP HOOD HEAT SINK 4 20 280706 SIDE RIGHT HOOD HEAT SINK 8 21 280960 COVER BOTTOM 1 22 280570 FRAME END ASSY 2 23 282499 PANEL MTG REAR 1 24 180539 2 CORD NYLON 4 25 408700 1 LABEL AC OUTPUT 1 26 83A 1112 LABEL L1 1 27 83...

Page 50: ...AC AC Converter Front Components and Main Transformers Figure 3 Chapter 4 2 Nov 01 90 Page 6 ...

Page 51: ... 1000 V 4 18 403955 1 VARISTOR METALOXIDE 1 19 282574 1 RELAY FAULT 1 20 408352 SOCKET RELAY 3 21 408585 RETAINER RELAY SPRING 3 22 281235 CARD CAGE PC BOARD ASSY For Details See Fig 5 1 23 181705 BOARD AUXILIARY POWER SUPPLY 1 24 408335 FUSEHOLDER 1 25 W 10083 34 FUSE 25 A 600 V 2 26 280656 CLAMP CAPACITOR 2 27 408737 BRACKET MTG RESISTOR 2 28 280759 CONNECTOR MOTHER BOARD 12 29 280698 1 CONNECTO...

Page 52: ...AC AC Converter Rear Components Figure 4 OM 2065 Operation and Maintenance Manual 90SB51 Spec 7015 3 Frequency Converter Chapter 4 2 Nov 01 90 Page 8 ...

Page 53: ...IER 3 14 408374 CAPACITOR 1 uF 1000 V 1 15 408346 RESISTOR 2 OHM 3 WATT 1 16 408341 CAPACITOR 40 uF 330 V 18 17 280673 SWITCH NORMALLY CLOSED 2 18 280643 BOARD SUPPRESSOR 1 19 408463 TRANSFORMER AUX POWER SUPPLY 1 20 408373 VARISTOR METAL OXIDE 1 21 280966 CIRCUIT BREAKER 600 V 225 A 1 22 No Number SENSOR KILOWATT HOUR COUNTER 1 Part of Kilowatt Hour Meter Assembly along with Item 10 Fig 4 and Ite...

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Page 55: ...PACER AIRCORE 12 36 100GH 121 BRACKET MTG CABLE CLAMP 1 37 7J 422 0 CLAMP CABLE 2 38 181461 COVER OUTPUT 1 39 W 10079 5 CONNECTOR BX STRAIGHT 1 40 181460 COVER INPUT 1 41 280767 CLIP GROUND 4 42 280800 LUG GROUND 1 43 282652 BARRIER END FUSEHOLDER 1 Not Illustrated OM 2065 Operation and Maintenance Manual 90SB51 Spec 7015 3 Frequency Converter Nov 01 90 Chapter 4 2 Page 11 ...

Page 56: ...Front Door Assembly Figure 5 OM 2065 Operation and Maintenance Manual 90SB51 Spec 7015 3 Frequency Converter Chapter 4 2 Nov 01 90 Page 12 ...

Page 57: ...0V 1 6 77A 1036 3 PUSHBUTTON OPERATOR 1 7 77A 1036 4 PUSHBUTTON OPERATOR 1 8 408362 SWITCH VOLTAGE SELECTOR 1 9 408361 METER OUTPUT VOLTAGE 1 10 403397 JACK INSULATED TIP 1 11 402946 JACK INSULATED TIP 1 12 82B 1066 6 LIGHT PILOT Red 1 400613 6 LAMP 120V 1 13 280910 DOOR FRONT 1 14 280661 DOOR PLEXIGLASS 1 15 83B 1079 LABEL WARNING 1 Revised Chapter 4 2 March 26 93 Page 13 OM 2065 Operation and Ma...

Page 58: ...P C Card Cage Assembly Figure 6 OM 2065 Operation and Maintenance Manual 90SB51 Spec 7015 3 Frequency Converter Chapter 4 2 Nov 01 90 Page 14 ...

Page 59: ...BLY A5 10 6 7 181706 BOARD POWER SUPPLY 1 A12 1 8 180493 BOARD POWER SUPPLY II A11 1 9 408728 RAIL FRONT 2 10 281246 PLATE SIDE RT 1 11 280212 BACKPLANE MOTHER BOARD ASSY 1 12 408333 FAN 120VAC Shown as Item 10 of Fig 3 1 13 408729 RAIL REAR 2 14 408731 RAIL GUIDE CARD 26 15 280171 COVER TOP 1 16 408734 BRACKET MTG 4 17 408732 STRIP INSULATING 2 18 408733 INSERT THREADED 2 19 181294 PLATE SIDE LT ...

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Page 61: ... 3 29 280698 1 2 20 280706 2 7 280746 3 32 280747 3 28 280759 4 41 280767 4 42 280800 2 29 280806 2 30 280807 5 13 280910 4 9 280957 2 21 280960 2 5 280963 3 15 280965 4 21 280966 3 2 281133 Section 3 Numerical Index 1 Explanation of Numerical Index The purpose of this index is to assist the user in finding the illustration and description of a part when the part number is known Part numbers are a...

Page 62: ... 34 406392 2 3 25 408319 3 9 408320 3 3 408323 3 13 408329 FIG ITEM PART NUMBER 3 10 408333 4 24 408333 6 12 408333 3 24 408335 4 5 408337 4 16 408341 4 2 408343 4 15 408346 4 29 408349 4 26 408350 4 8 408351 3 20 408352 4 30 408352 5 9 408361 5 8 408362 4 20 408373 4 14 408374 4 19 408463 3 4 408493 4 7 408494 3 7 408500 4 13 408501 3 34 408517 3 17 408518 4 27 408567 4 3 408584 3 21 408585 4 31 ...

Page 63: ...036 4 5 12 82B 1066 6 5 5 82B 1066 7 2 31 83B 1079 5 15 83B 1079 2 26 83A 1112 2 27 83A 1113 2 28 83A 1114 4 39 W 10079 5 4 6 W 10827 44 4 28 W 10827 54 5 2 W 9917 20 OM 2065 Operation and Maintenance Manual 90SB51 Spec 7015 3 Frequency Converter Nov 01 90 Chapter 4 3 Page 3 ...

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Page 65: ...ment When more than one model of equipment is covered by a parts list there are some parts which are used only on one model This column is used for insertion of the Specification Number to indicate these parts and to identify the particular model on which they are used UNCODED PARTS ARE USED ON ALL MODELS SPECIFICATIONS d MAINTENANCE LEVEL Column This column is used to determine the appropriate le...

Page 66: ...ACITOR 3100 MFD 450 V BC 2 400613 6 LAMP 120V 120MB ABC 3 77A 1036 3 PUSHBUTTON OPERATOR BC 1 77A 1036 4 PUSHBUTTON OPERATOR BC 1 408361 METER OUTPUT VOLTAGE ABC 1 180501 BOARD OSCILLATOR AMP ASSEMBLY A3 ABC 1 180497 BOARD COMPARATOR ASSEMBLY A4 ABC 1 181704 BOARD DRIVER ASSEMBLY A5 10 ABC 1 181706 BOARD POWER SUPPLY 1 A12 ABC 1 180493 BOARD POWER SUPPLY II A11 ABC 1 408411 COVER DUST ABC 1 408323...

Page 67: ...onal Equipment At present no optional equipment has been designed or manufactured for Specification 7015 3 OM 2065 Operation and Maintenance Manual 90SB51 Spec 7015 3 Frequency Converter Nov 01 90 Chapter 5 1 Page 1 ...

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Page 69: ...rature Hobart Diagrams 282575 Schematic Connection 6 Sheets 281027 Outline Connections Unusual Service Conditions Warranty OM 2065 Operation and Maintenance Manual 90SB51 Spec 7015 3 Frequency Converter Nov 01 90 Chapter 6 1 Page 1 ...

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Page 83: ...Connections Outline 281027 Figure 7 Nov 1 90 Chapter 6 1 Page 15 OM 2065 Operation and Maintenance Manual 90SB51 Spec 7015 3 Frequency Converter ...

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Page 85: ...flammable or explosive gases Nuclear radiation Steam salt laden air or oil vapor Damp or very dry locations radiant heat vermin infestation or atmospheres conducive to fungus growth Abnormal shock vibration or mechanical loading from external sources during equipment opera tion Low and or high ambient temperatures 2 Operation at Voltages above or below rated voltage Frequency other than rated freq...

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