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Hobart GPU-600 Series, Operation And Maintenance Manual

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OM-2244 / Operation and Maintenance Manual 
DCS-600/ Series 500075/ Solid State Transformer-Rectifiers 

 

 

December 15, 2014 

Chapter 4-2 

Page 4 

 

Code 

 

Vendor’s Name and Address 

71400 

Cooper Bussmann Inc.

 

114 Old State Road 

Ellisville, MO 63021-5942

 

72619 

Dialight Corporation 
1501 State Rte 34 S 
Farmingdale, NJ 07727-3932 

74400 

Hobbs Corporation 
1034 East Ash Street 
PO Box 19424 
Springfield, IL  62794-9424 

74542 

Hoyt Electrical Instruments 
23 Meter ST. 
Concord, NH 03303-1894 

74545 

Hubbell Inc 
Wiring Device Div 
185 Plains Road 
Milford, CT 06460 

74829 
 

Ilsco Corp. 
4730 Madison Rd. 
Cincinnati, OH  45227-1426 

75418 

Kysor Industrial Corporation 
1 Madison Ave  
Cadillac, Michigan 49601-9784 

75915 

Littelfuse, Inc. 
8755 W Higgins Road Ste 500 
Chicago, IL 60631 - 2701 

77342 

TYCO Electronics Corporation 
8010 Piedmont Triad Pkwy 
Greensboro, NC 27409 

78388 

Woodward Controls Inc. 
6250 W Howard St                
Niles, Il 60714-3433 

8A334 

Cummins Bridgeway LLC  
2297 SW Blvd Ste K 
Grove City, OH 43123-1822 

8T246 

Whitesell RO & Associates, Inc. 
7009 CORPORATE WAY  
Dayton, OH 45459-4238 

81483 

International Rectifier Corp 
233 Kansas St.   
El Segundo, CA 90245 

Code 

 

Vendor’s Name and Address 

81703 

Mulberry Metal Products Inc. 
2199 Stanley Terrace 
Union , NJ 07083-4399 

82866 

Research Products Corp. 
P.O. Box 1467 
1015 E. Washington Ave. 
Madison, WI 53701 

86797 

Rogan Corp 
3455 Woodhead Dr. 
Northbrook, IL 60062-1812 

9Y826 

Marsh Electronics Inc. 
1563 S. 101st  St. 
Milwaukee, WI  53214-4032 

91637 

Vishay Dale Electronics Inc. 
1122 23RD St. 
Columbus, NE  68601-3647 

91929 

Honeywell International Inc. 
DBA Honeywell 
11 W. Spring St. 
Freeport, IL 61032-4316 

94222 
 
 

Southco Inc. 
210 N. Brinton Lake Rd. 
Concordville, PA  19331 

97520 

Basler Electric Company 
Route 143 
Highland, IL 62249-1074 

 

 

 

 

 

Summary of Contents for GPU-600 Series

Page 1: ...Operation and Maintenance Manual with Illustrated Parts List for GPU 600 3 Phase Solid State Transformer Rectifiers Series 500082 6xx 28 5 Volts 600 Amps OM 2244 12 15 2014 Rev A ...

Page 2: ......

Page 3: ...fied by chapter section and page number which are located in the lower outside corner When information located in another portion of the manual is referred to its location is identified by a chapter section paragraph or figure number For example see Section 2 3 Paragraph 1 a refers to information located in Chapter 2 Section 3 Paragraph 1 a If a chapter and section are not indicated in a reference...

Page 4: ...GSE equipment immediately contact our Service Department by mail telephone FAX or E Mail Write Aviation Ground Equipment Corp 53 Hanse Avenue Freeport NY 11520 Call Inside U S A Canada 800 758 0044 Call From Foreign Countries 516 546 0003 516 546 0198 FAX inside U S A E Mail technicalsupport aviationgroundequip com sales aviationgroundequip com Web Page www aviationgroundequip com ...

Page 5: ...an 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 w...

Page 6: ...ire And Explosion Prevention Fire and explosion are caused by electrical short circuits combustible material near this equipment or unsafe operating conditions Overloaded or shorted equipment can become hot enough to cause fires by self destruction or by causing nearby combustibles to ignite For electrically powered equipment provide primary input protection to remove short circuited or heavily ov...

Page 7: ...DCS 600 Series 500082 Solid State Transformer Rectifiers December 15 2014 Safety Warnings Page 3 7 Equipment Precautionary Labels Inspect all precautionary labels on the equipment monthly Order and replace all labels that cannot be easily read ...

Page 8: ...OM 2244 Operation and Maintenance Manual DCS 600 Series 500082 Solid State Transformer Rectifiers December 15 2014 Safety Warnings Page 4 This page intentionally left blank ...

Page 9: ... for the GPU 1 1 1 Safety Features 1 1 3 Theory of Operation 1 1 4 Detailed Description of GPU 600 Components 1 1 4 Section 2 Preparation for Use Storage or Shipping 1 2 1 Receipt and Inspection of Equipment 1 2 1 Unpacking the Unit 1 2 1 Operating Location Selection 1 2 1 Input Cable Selection 1 2 1 Installation 1 2 2 Preparation for Storage 1 2 6 Preparation for Shipment 1 2 6 Section 3 Operatio...

Page 10: ...leshooting 2 1 2 Voltages of Interest 2 1 3 SCR Malfunction Instructions 2 1 3 Troubleshooting Tables 2 1 5 Section 2 Calibration and Test of PC Control Board 2 2 1 General 2 2 1 Circuit Board Components 2 2 1 Test Procedure 2 2 5 Circuit Board Calibration 2 2 6 Section 3 Scheduled Maintenance 2 3 1 General 2 3 1 Maintenance Schedule 2 3 1 Inspection During Operation 2 3 2 Preparation for Internal...

Page 11: ...ntroduction 4 1 1 General 4 1 1 Purpose 4 1 1 Arrangement 4 1 1 Explanation of Parts List 4 1 1 Numerical Index 4 1 3 Explanation of Numerical Index 4 1 3 Section 2 Manufacture s Codes 4 2 1 Explanation of Manufacture s Vendor Code List 4 2 1 Section 3 Illustrated Parts List 4 3 1 Explanation of Parts List Arrangement 4 3 1 Symbols and Abbreviations 4 3 1 Figure 1 Final Assembly 4 3 2 Figure 2 Int...

Page 12: ...OM 2244 Operation and Maintenance Manual DCS 600 Series 500082 Solid State Transformer Rectifiers December 15 2014 Table of Contents Page 4 Chapter 5 Manufacture s Literature Appendix A ...

Page 13: ...28 5 VDC 600 A DCS600S60208 Stationary 208 230 460 60 Hz 28 5 VDC 600 A DCS600S50380 Stationary 220 380 50 Hz 28 5 VDC 600 A DCS600S50380CE Stationary Y 220 380 50 Hz 28 5 VDC 600 A DCS600B60208 Bridge 220 230 460 60Hz 28 5 VDC 600 A DCS600B60380 Bridge 220 380 60HZ 28 5 VDC 600 A Figure 1 Series 500082 Transformer Rectifier Part Number Descriptions 2 Optional Equipment Appendix A Chapters 1 throu...

Page 14: ...rs December 15 2014 Chapter 1 1 Page 2 1 Mounting Base 2 Rear Wheels 3 Front Caster 4 Front Control Panel 5 Rear Panel Not Shown 6 Cable Hanger 7 Top Panel 8 Side Panel Right Side Shown 9 Cable Storage Basket Option Only 10 Output Cable 11 Pull Handle 12 AC Power Receptacle 1 2 3 4 6 7 8 10 11 12 ...

Page 15: ...mps 600 600 600 Duty Cycle 100 100 100 Kilowatts 17 1 17 1 17 1 PHYSICAL DIMENSIONS Model Length overall Width case Width overall Height w o cable basket Weight overall Trailer 45 7 inches 116 1 cm 24 1 inches 61 3 cm 33 inches 83 8 cm 35 inches 88 8 cm 650 lbs 295 kg Stationary 35 1 inches 89 2 cm 24 1 inches 61 3 cm 33 inches 83 8 cm 29 3 inches 74 5 cm 600 lbs 272 kg Bridge 36 inches 91 cm 24 1...

Page 16: ... output is floating isolated from chassis ground eliminating any grounding problems between the load and the chassis ground CAUTION Capacitor charge can injure Allow capacitors to discharge fully and verify capacitor discharge with voltmeter before touching the capacitor circuitry 7 Detailed Description of GPU 600 Components a Front Panel Control Components See Figure 4 1 Front Panel The GPU opera...

Page 17: ...Panel 2 Convenience Receptacle 115 VAC Shown 3 Starting Current Control 4 Receptacle Fuse 5 DC Voltmeter M2 6 Overload Overvoltage Light red 7 DC Ammeter 8 Input Power Light amber 9 Output Contactor Light green 10 Input Power On Off Switch 11 Output Contactor Close On Off Switch Figure 4 Front Panel Assembly of GPU 600 1 2 3 4 6 5 8 9 10 11 7 ...

Page 18: ...Figure 4 Item 9 green This light is connected across the coil of the output contactor so it turns on when that contactor has been energized 10 Input Power On Off Switch Figure 4 Item 10 This switch turns the input contactor on and off The control transformer T2 supplied power to the input contactor coil through this switch and fuse F8 The input contactor connects the input power to the power trans...

Page 19: ...gy in the circuitry Typical response time is about 25 milliseconds 4 Thermal Overload Protection Normally Closed open on over temperature The control board turns off the SCR firing or gate pulses when the S5 overload thermostat item 18 in Figure 5 opens The power supply cannot produce any DC output until the S5 thermostat cools enough to automatically reset close c Main Transformer Figure 5 Item 1...

Page 20: ...16 2 11 9 8 10 13 15 14 4 6 3 12 17 18 19 20 1 Power Transformer T1 2 Capacitors C15 C16 C17 3 28 5 VDC Output Contactor K2 4 Pre load Resistor Assembly R2 R3 R4 5 Choke L1 6 Control Transformer T2 7 Interior Panel 8 Fuse Block F2 through F7 9 Printed Circuit Board A1 10 Line Contactor K1 11 Front Panel 12 Voltage Changeover Board 13 SCR Heat Sink Assembly 14 Fan Blade 15 Fan Motor B1 16 Feedback ...

Page 21: ... Voltage 12 TP7 24 V Non regulated Voltage 13 TP14 Null at 0 A DC TP R38 14 R60 Overload Limit TP20 15 R109 28 V DC Output Calibration TP13 16 R101 5 V Reference Volt Adjustment TP19 17 R102 Voltage Slope Adjustment TP17 18 TP19 Reference Volt Test Point R101 19 TP17 Voltage Slope Test Point R102 20 TP15 Common PC Board Volts 21 TPF SCR Gate Pulse Timer 22 TPE Gate Timer Output Phase 2 23 TPD Gate...

Page 22: ...un only when necessary to prevent overheating A MOV voltage surge suppressor RV1 6 Figure 4 is installed across the receptacle terminals to reduce voltage surge problems to the load equipment and the power source f Output Contactor Circuitry Output contactor K2 Figure 5 Item 3 is operated by the output contactor ON OFF switch S2 Figure 4 Item 11 Placing this switch momentarily in the TOP spring lo...

Page 23: ... state printed circuit board 9 Figure 5 provides a properly timed and sequenced turn on signal to the silicon controlled rectifiers that must be conducted to provide the desired output If the output voltage is too high or if the output current is above the limit set by controls such as the R13 starting potentiometer the control board delays the SCR turn on signal to allow less SCR device conductio...

Page 24: ...5 7 7 8 9 10 4 2 2 1 Rectifier Heat Sink 2 SCR Mounting Clamp 3 Silicon Rectifier CR1 through CR6 4 SCR Heat Sink 5 Overload Thermostat S5 6 Fan Turn on Thermostat S4 7 Rectifier Mounting Insulator 8 Feedback Shunt Not Shown R12 9 Positive Base Silicone Diode CR7 10 Surge Suppressors A2 A3 11 Pin Spring Figure 7 SCR Heat Sink Assembly of GPU 600 ...

Page 25: ...ner until the unit has been put into service and determined to be operating correctly 3 Operating Location Selection For best operating characteristics and longest unit life select an installation site that is not exposed to high humidity dust high ambient temperature flooding or corrosive agents Moisture can condense on electrical components causing corrosion or shorting circuits Dirt on componen...

Page 26: ...Table 5 Installation A ITW GSE GPU requires no additional preparation in order to supply power to an aircraft It needs only to have its input cable connected to an appropriate source of power and its output cable connected to an aircraft Proceed as follows for putting the GPU unit into service WARNING The method of installation conductor size and over current protection shall conform to the requir...

Page 27: ...main transformer On the right is the control transformer which has different taps for the various input voltages 1 Make sure the GPU is not connected to the electrical service 2 Remove the top cover 3 Locate the items pictures in Figure 2 4 Refer to Sheet 6 of the schematic diagram which is located in Chapter 5 of this manual 5 Verify that the configuration matches the appropriate diagram on the s...

Page 28: ...ground conductor to the stud provided adjacent to the contactor WARNING To help protect against electrical shock from line voltage or static discharge make sure the GPU is grounded Figure 3 Input Contactor NOTE After connecting the input cables it is recommended that ITW GSE 904021 urethane coating be sprayed on the connections at the contactor to protect these connections from corrosion fungus an...

Page 29: ...hrough the side panel and under the cable clamp 2 Connect the positive output lead to the positive output terminal of Output Contactor K2 3 Connect the negative output lead to Ammeter Shunt R11 4 Tighten the cable clamp Figure 4 Output Connections f Check GPU No Load Operation A no load check should be made before the GPU is connected to an aircraft Proceed as follows 1 Replace the top panel 2 App...

Page 30: ...rage When storing the unit for 30 days or less prepare as follows 1 Use moisture absorbing chemicals where excessive dampness is a problem However the unit must be completely packaged and sealed if moisture absorbing chemicals are to be effective Seal all openings Use a waterproof vapor proof material that is strong enough to resist puncture damage 2 Store the unit in a building which is dry and w...

Page 31: ... opening of input fuses or repeated functioning of the overload trip circuitry indicates a misapplication a faulty main component or an improper connection or load Correct the problem by following the instructions in Chapter 2 before attempting to operate the power supply Be certain that a input disconnect means is readily accessible between the power input source and this DC power supply You may ...

Page 32: ...y should continue to deliver power until the S2 switch is placed in the down OFF position or one of the other control functions turn the unit OFF 4 Voltmeter a Verify on the M2 DC voltmeter 1 1 3 Figure 4 that the DC output voltage level is correct If not turn off power supply disconnect your load and refer to Service Chapter 2 for instructions 5 Output Current Limit a If the DC ammeter continuous...

Page 33: ...it Calibration service and repair are to be done by ITW GSE Service Department personnel authorized distributors of ITW GSE equipment or trained qualified electronic technicians If you have any questions concerning your ITW GSE equipment immediately contact our Service Department by mail telephone FAX or E Mail Write Aviation Ground Equipment Corp 53 Hanse Avenue Freeport NY 11520 Call Inside U S ...

Page 34: ... experience 3 Printed circuit board output troubles should be pinpointed only to determine if the problem is a board calibration problem or a PC board failure problem Failure of PC board requires replacement of the board Field repair attempts are not recommended 4 Always check circuit fuses circuit breakers and the position of switches first in troubleshooting The incorrect positioning of a switch...

Page 35: ...f a need arises that would indicate the need for field adjustments please contact the factory The only exception is R109 which adjusts the 28 V output level If necessary use this control to increase the output voltage slightly to compensate for the voltage drop in a long output cable 5 SCR Malfunction Instructions a SCR Failure Symptoms SCR failure is not common When they do fail they generally do...

Page 36: ...t only breaks down to a shorted condition when voltage is applied by reconnecting one device at a time c Troubleshooting Excessive Output Ripple An open gate or an open SCR cannot be checked with a VOM If an SCR is not firing the AC ripple current will increase across the filter capacitors but that will not blow fuses Follow these steps to locate a bad SCR 1 Connect an oscilloscope across the unfi...

Page 37: ...28 5 VDC the SCR or that circuit has failed 6 Troubleshooting Tables Trouble Symptom Condition Probable Cause Test Check and or Remedy Machine Will Not Operate 1 Machine will not start a The input power is turned OFF at remote disconnect switch Turn the power ON at remote disconnect switch b Blown fuse in remote disconnect switch Replace blown fuse If fuse blows frequently determine and remedy the...

Page 38: ... value correct this condition as is necessary to provide proper voltage input to the machine b Breaker incorrect size or type or fuse Refer to Section 1 2 Figure 1 for input current requirements Make sure the breaker is appropriate for a high inrush current use a breaker designed for motor starting applications c Links on voltage changeover board incorrectly connected Check appropriate voltage cha...

Page 39: ...n and secure as required c Starting current potentiometer R13 open Replace potentiometer 3 Fan not operating also see causes and remedies under Machine will not start a Blown fuse F1 Replace fuse b Fan control thermostat defective Place a jumper wire across the overheated thermostat If fan then runs replace thermostat Note A properly operating fan thermostat will turn on the fan at 100 F and keep ...

Page 40: ...ighten GPU Will Not Turn Off 1 Contactor fails to open a Contacts sticking in contactor Clean contacts or replace contactor whichever is needed No Voltage Output 1 Unit on but no output voltage a Protective circuit tripped Determine and correct cause of trip Then reset and restart unit b Component failure in protective circuit Find the defective component and replace it c Control circuit board fai...

Page 41: ...replace defective SCR heat sink assembly if oscilloscope shows faulty SCR devices Replace PC control boards if oscilloscope shows no gate pulse and the PC control board inputs and controls are proper except for output Trouble Symptom Condition Probable Cause Test Check and or Remedy Output Contactor Fault 1 Output contactor will not close a Defective output switch S2 With the unit turned off place...

Page 42: ...actor will not stay closed a Defective output switch S2 With the unit turned off place a jumper between terminals 1 and 3 on S2 Turn S1 on and place S2 in Close position If output contactor stays closed after S2 is released S2 is defective Replace b Defective output contactor auxiliary contacts K2 With the unit turned off place a jumper between terminals NO 3 and NO 4 on output contactor Turn S1 o...

Page 43: ...ne if the circuit board is operating properly ITW GSE recommends calibration of the PC board at the factory but the calibration procedure is included in this section Part 4 in case field calibration is necessary Faulty control boards should be returned to the manufacturer for repair WARNING Electric shock and arcs can kill or injure Use caution to inspect or test the printed circuit control board ...

Page 44: ...OM 2244 Operation and Maintenance Manual DCS 600 Series 500082 Solid State Transformer Rectifiers December 15 2014 Chapter 2 2 Page 2 Figure 2 GPU Circuit Board Components ...

Page 45: ...OM 2244 Operation and Maintenance Manual DCS 600 Series 500082 Solid State Transformer Rectifiers December 15 2014 Chapter 2 2 Page 3 Figure 3 GPU Circuit Board Test Points and Controls ...

Page 46: ...se 1 TP13 Actual Output Voltage 28 5 or 14 25 R109 28 5 V or R110 14 V TP14 Null at zero output current provides amplified load amp reading for comparison with overload limit TP20 and starting amperage limit TP21 set by R13 control on front panel R38 TP15 PC Board Common TP17 Voltage Slope Test Point R102 TP19 Reference Volt Test Point R101 TP20 Overload Limit R60 TP21 Starting Current R13 front p...

Page 47: ... Point 15 TP15 Connect the negative voltmeter lead to either of those test points TEST STEP TEST POINT TEST CONDITION VOLTAGE MEASUREMENT TEST DESCRIPTION 1 TP5 Open circuit no load 15 VDC 5 Checks voltage regulator output set by U4 2 TP6 Open circuit no load 15 VDC 5 Checks voltage regulator output set by U5 3 TP7 Open circuit no load 24 VDC 10 Checks unregulated control voltage needed for 1 and ...

Page 48: ...tput volts set by R110 in 14 VDC mode 11 TP20 6 5 VDC Checks R60 overload current setting 12 TPL Standard load Near zero 0 002 V Optional test Checks overload light DS2 and circuit functioning Q10 TPL Overload 12 to13 VDC Table 2 GPU Circuit Board Tests 4 Circuit Board Calibration Equipment Requirements Calibration requires the following equipment a load bank able to pull 2200 amps at 28 5 volts t...

Page 49: ...The test point voltage should be 0 000 0 005 VDC d Adjust R38 offset null adjust for the proper reading 8 Adjust the voltage reference a Move the positive voltmeter lead to TP19 b The voltage should be 5 00 0 010 VDC c Adjust R101 reference adjust for the proper reading 9 Check the over voltage adjustment When an over voltage occurs the output contactor should open and the red Overload light shoul...

Page 50: ...o make sure the unit is not current limiting c The output voltage should be 22 0 to 25 0 VDC d Adjust R115 max amp adjust for proper output voltage 12 Check overload trip point When an overload occurs the output contactor should open and the red Overload light should turn on a Increase the load at the load bank to make sure the overload turns on between 2125 and 2200 amps b Adjust R60 overload adj...

Page 51: ...ment to an authorized service shop for ITW GSE equipment or to qualified electronic technicians 2 Maintenance Schedule As required Daily 8 hrs 1 month 200 hrs 3 months 600 hrs 6 months 1200 hrs EXTERIOR CABLES Inspect equipment X Inspect AC input cables X Check cable connections internal X CONTROLS AND INSTRUMENTS Check voltmeter functioning X Check ammeter functioning X Check fan thermostat opera...

Page 52: ...diately if a possible dangerous fault is discovered The front panel input contactor switch does not remove input power from all components Be sure capacitors are discharged before you touch b Observe the front panel voltmeter and make sure the voltage is zero If the voltage is not zero the capacitors still hold a charge indicating a problem with the connection to the preload resistors c Observe ge...

Page 53: ...eck for normal operation 6 Lubrication No lubrication is required except for the fan motor The fan motor incorporates a sleeve bearing and therefore requires periodic lubrication a Lubrication Schedule The following table shows the fan motor manufacturer s recommendations for lubricating the motor Type of Duty Usage Starts Per Hour Usage Hours Per Day Lubrication Interval years Light 0 4 starts 0 ...

Page 54: ... upward from the rear bearing The front bearing has a similar tube Use these tubes to oil the bearings Figure 3 Fan Motor Oil Locations 7 Inspection Records Since the fan lubrication is so infrequently you should keep track of the lubrications using the chart below or some similar record Inspection Date Fan Motor Oiled circle Y or N Inspection Notes Y N Y N Y N Y N Y N Y N Y N Y N Y N Y N ...

Page 55: ...ntact the Service Department for authorization It is rarely necessary to return a failed GPU since the unit uses plug in type assemblies throughout its systems For warranty information refer to the warranty statement at the front of this manual or contact the ITW GSE Service Department When ordering parts from your ITW GSE Distributor be sure to include all pertinent information from the unit s id...

Page 56: ...e danger of electric shock always make sure that the input power is turned off at the source and cannot be inadvertently turned back on before working inside the GPU a Lights The light bulbs are accessible from the front by unscrewing the lens Light Unit Bulb Type Input Power On Standard Type 120 MB 120 V 025 A T 2 1 2 Units with CE marking Type 757 28 V 08 A Output Contactor Closed All Type 757 2...

Page 57: ...duce any output voltage If this switch fails in the closed position the GPU will not shut down if the heat sink gets too hot This switch opens when the temperature reaches 190 5 F and closes when the temperature falls back down to 172 8 F Both of these switches can be tested using an ohmmeter and a heat gun To replace a thermostat unplug the wires and then remove the two screws that hold it Reconn...

Page 58: ...ce an SCR you will need a 903878 Force Indicator Gauge This gauge shown in Figure 1 measures the deflection of the flat spring on top of the SCR as the screws are tightened The gauge consists of two metal plates that are free to rotate about a common point where they are fastened together When this gauge is placed on a flat surface so that it makes three point contact the sheet metal plates rotate...

Page 59: ...2244 Operation and Maintenance Manual DCS 600 Series 500082 Solid State Transformer Rectifiers December 15 2014 Chapter 3 1 Page 5 Figure 2 SCR Mounting Components Figure 3 Measuring the Spring Deflection ...

Page 60: ...ere the diode attaches to the heat sink 4 Tighten the nuts evenly until they are finger tight 5 Tighten each screw in 1 4 turn increments using the correct size hex key 6 Place the Force Indicator Gauge firmly against the top spring as shown in Figure 3 Be sure both ends and the center are in firm contact with the spring 7 Tighten the screws in 1 4 turn increments until the gauge shows correct ali...

Page 61: ...re parts 3 Arrangement Chapter 4 is arranged as follows Section 1 Introduction Section 2 Manufacturer s Codes Section 3 Illustrated Parts List 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...

Page 62: ...or part number in the NOMENCLATURE column 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 also listed in this column when applicable ITW GSE modification to vendor items i...

Page 63: ...nged in alphanumerical sequence FIGURE ITEM NO ITW GSE PART NO 5 4 16DA2162 7 12 16DA954 012 2 4 180065 2 2 180294B 3 180358 2 3 180480 5 8 180914 5 9 180914 3 181565 2 201015 2 10 201016 6 5 201673 004 3 6 280023 7 9 280023 1 5 282658 6 13 283066 001 4 8 283322 1 4 283323 6 14 286432 001 1 10 286441 5 3 286607 001 3 3 286810 001 6 4 286810 001 1 12 287460 5 12 287460 6 10 287460 1 15 287547 001 F...

Page 64: ...41 7 4 369642 2 400234 003 5 400613 003 5 400613 006 5 5 400641 012 5 7 400642 003 2 400647 005 5 400647 008 6 8 400663 5 401532 002 1 6 402025 002 6 2 402037 027 5 16 402658 FIGURE ITEM NO ITW GSE PART NO 5 14 402670 7 10 402832 003 3 403091 008 5 11 403189 5 403955 017 7 7 404044 006 5 404172 002 5 404172 003 5 404277 5 404335 5 15 404336 2 404915 001 5 6 405072 002 2 6 405129 001 7 3 405139 7 2...

Page 65: ...aintenance Manual DCS 600 Series 500082 Solid State Transformer Rectifiers December 15 2014 Chapter 4 1 Page 5 FIGURE ITEM NO ITW GSE PART NO 4 6 83B1101 2 W11166 009 6 W11166 011 3 10 W9760 066 FIGURE ITEM NO ITW GSE PART NO ...

Page 66: ...OM 2244 Operation and Maintenance Manual DCS 600 Series 500082 Solid State Transformer Rectifiers December 15 2014 Chapter 4 1 Page 6 This page intentionally left blank ...

Page 67: ...witzerland CH 6300 0CYC7 Western Rubber Supply 7888 Marathon Dr Ste Livermore CA 94550 9314 0E8J0 Emka Inc 1961 Fulling Mill Rd Middletown PA 17057 3125 0HZP9 Diesel Radiator Co 1985 Janice Ave Melrose Park IL 60160 1008 0MR72 Henkel Corp 26941 Cablot Rd Suite 124 Laguna Hills CA 92653 7007 0TSE6 Infineon Technologies Industrial Power Inc 1050 US HWY 22 Lebanon NJ 08833 4208 00779 Tyco Electronics...

Page 68: ...es Inc DBA Hughes Peters 8000 Technology Blvd Huber Heights OH 45424 1573 2B664 All Phase Electric Supply Co 1620 W Main St P O Box 149 Springfield OH 45501 0149 Code Vendor s Name and Address 2N562 Power Transmission Sales Inc 531 Washington P O Box 229 Chagrin Falls OH 44022 0229 23803 N T N Bearing Corp of America 191 Sheree Blvd Ste 101 Exton PA 19341 1265 24161 Gates Corporation 900 S Broadwa...

Page 69: ...54 4125 56289 Sprague Electric Company 678 Main St Sanford MA 04073 7003 57330 Remke Industries Inc 310 Chadick Drive Wheeling IL 60090 6039 Code Vendor s Name and Address 57347 Wall Industries Inc 5 Watson Brook Rd Exeter NH 03833 4589 57733 Stewart Warner Corporation 333 Ludlow St Stamford CT 06902 6987 59656 Dean Technology Inc DBA CKE 1000 Lucerne Road Lucernemines PA 15754 0211 6S553 Wes Gard...

Page 70: ...CO Electronics Corporation 8010 Piedmont Triad Pkwy Greensboro NC 27409 78388 Woodward Controls Inc 6250 W Howard St Niles Il 60714 3433 8A334 Cummins Bridgeway LLC 2297 SW Blvd Ste K Grove City OH 43123 1822 8T246 Whitesell RO Associates Inc 7009 CORPORATE WAY Dayton OH 45459 4238 81483 International Rectifier Corp 233 Kansas St El Segundo CA 90245 Code Vendor s Name and Address 81703 Mulberry Me...

Page 71: ... symbols and abbreviations used in the parts list Item not illustrated A or AMP Ampere AC Alternating current AR As required DC Direct current Fig Figure Ft lb Foot pounds Hd Head Hex Hexagon Hz Hertz cycles per second I D Inside diameter IN Inch KVA Kilovolt ampere UF Microfarad Number Number NHA Next higher assembly N m Newton meters PRV Peak reverse voltage PSI Pounds per square inch Ref Refere...

Page 72: ...OM 2244 Operation and Maintenance Manual DCS 600 Series 500082 Solid State Transformer Rectifiers December 15 2014 Chapter 4 3 Page 2 Figure 1 Final Assembly of GPU 600 Power Supply 1 2 3 4 6 7 ...

Page 73: ...t 28 V 20 ft 1 Other Lengths Available 7 288356 Handle Assembly A G 1 288284 Handle 5 th Wheel A G 1 288281 Latch 5 th Wheel A G 1 288298 001 Grip Foam A G 2 8 288362 001 Cover Protective Changeover Board A C F J L 1 288362 002 Cover Protective Changeover Board B E G H K 9 78B1130 Nameplate Identification 1 10 286441 Label General 1 11 288866 Label Service 1 12 287460 Label Danger High Voltage D E...

Page 74: ...OM 2244 Operation and Maintenance Manual DCS 600 Series 500082 Solid State Transformer Rectifiers December 15 2014 Chapter 4 3 Page 4 Figure 2 Internal Components Part 1 ...

Page 75: ...9 001 Block Fuse 1 W11166 009 Fuse Fast Blow AGC 1 A 250 V 6 83A1105 Label Fuse 1 7 287637 Motor Fan 1 8 288305 002 Rectifier Output SCR Assembly See Figure 7 1 9 406991 Blade Fan 1 10 201016 Shroud Fan 1 288322 Label Warning Fan 1 400234 003 Tag Instructions 2 201015 Bracket Mounting Fan Shroud 2 11 288303 001 Block Fuse 1 400647 005 Fuse 5 A 1 288363 Label Precautionary Fan Fuse 1 12 408567 Rela...

Page 76: ...OM 2244 Operation and Maintenance Manual DCS 600 Series 500082 Solid State Transformer Rectifiers December 15 2014 Chapter 4 3 Page 6 Figure 3 Internal Components Part 2 ...

Page 77: ...tor Mylar 014 2 Wide B E G H K 4 361052 009 Clamp Mounting Capacitor A C F J 3 361052 009 Clamp Mounting Capacitor B E G H K 4 788732 Cover Capacitors CE E H 1 3 286810 001 Output Contactor 28 5 VDC 1 4 589561 Transformer Power A F J 1 180358 Transformer Power B E G H K 1 181565 Transformer Power C 1 5 Panel Interior Assembly See Figure 6 Ref 6 280023 Feedback Shunt See Figure 7 Ref 7 487050 005 R...

Page 78: ...OM 2244 Operation and Maintenance Manual DCS 600 Series 500082 Solid State Transformer Rectifiers December 15 2014 Chapter 4 3 Page 8 1 2 3 4 5 6 7 8 Figure 4 Base Assembly ...

Page 79: ... Base Ay A E 1 288321 002 Base Ay F K 1 1 288262 Base Mounting GPU 1 2 288282 Support Caster 5 th Wheel A E 1 288349 Spacer 5 th Wheel A E 1 3 288283 Catch Latch A E 1 4 288297 001 Kit Caster A E 1 5 288353 Brake 5 th Wheel A E 1 6 83B1101 Tire Symmetrical Ball Bearing 10 A E 2 7 288251 Axle Mounting Wheels A E 1 486143 002 Spacer Black Pipe A E 2 8 283322 Bracket Output Cable 2 489971 Spacer Outp...

Page 80: ...OM 2244 Operation and Maintenance Manual DCS 600 Series 500082 Solid State Transformer Rectifiers December 15 2014 Chapter 4 3 Page 10 Figure 5 Front panel Assembly 1 4 5 7 8 10 9 11 G P U 600 14 ...

Page 81: ...57 28 V 08 A E H 1 404172 002 Lens Light Pilot Amber V72619 1 9 180914 Base Light Pilot 1 400613 003 Lamp Type 757 28 V 08 A 1 404172 003 Lens Light Pilot Green V72619 261193300 1 10 405365 001 Switch Toggle 1 11 403189 Switch Toggle 3 Position V91929 312TS 1 12 287460 Label Danger High Voltage Not Shown 1 13 288365 Nameplate ITW GSE GPU 1 14 402670 Receptacle 3 Wire 125 V 15 A A C F J 1 404277 Co...

Page 82: ...OM 2244 Operation and Maintenance Manual DCS 600 Series 500082 Solid State Transformer Rectifiers December 15 2014 Chapter 4 3 Page 12 Figure 6 Interior Panel Assembly shown with bridge mount option ...

Page 83: ...286810 001 Contactor 28 5 VDC 1 5 201673 004 Diode Assembly on line contactor 1 6 406392 001 Transformer Control A F J 1 406392 002 Transformer Control B C G K 1 406247 002 Transformer Control 1 406247 003 Transformer Control E H 1 406484 Label Fuse 4 400 S 5 Amp 250 V 1 W11166 011 Fuse Fast Blow AGC V71400 AGC 2 1 7 Grounding Screws 1 4 20 Hardware 3 8 400663 Contactor Line A C F G J 1 288733 001...

Page 84: ...ion and Maintenance Manual DCS 600 Series 500082 Solid State Transformer Rectifiers December 15 2014 Chapter 4 3 Page 14 1 2 3 12 7 6 8 8 9 10 11 4 5 2 2 Figure 7 SCR Output Rectifier Assembly of GPU 600 Power Supply ...

Page 85: ...ssembly GPU 600 Ref 1 288277 Heat Sink Rectifier 1 2 405140 001 Clamp Mounting 6 3 405139 Rectifier Silicon Cont 6 4 369642 Heat Sink SCR 6 5 288304 Heat Sink SCR Top 6 6 287929 001 Thermostat Overload 1 7 404044 006 Thermostat Fan Turn On 1 8 369641 Insulator Mounting Rectifier 2 9 280023 Shunt 1200 A 50 mV Assembly 1 10 402832 003 Diode Silicon Positive Base 1 11 367634A 003 Suppressor Surge Ass...

Page 86: ...OM 2244 Operation and Maintenance Manual DCS 600 Series 500082 Solid State Transformer Rectifiers December 15 2014 Chapter 4 3 Page 16 This page intentionally left blank ...

Page 87: ...hapter 5 Manufacturer s Literature Diagram Number Diagram Description 288326 Rev 0 Outline Dimensional Installation 288367 Rev 11 Diagram Schematic Connection Contact ITW GSE if copies of these drawings are not with this manual Refer to Appendix A for specific information on GPU 600 Solid State Transformer Rectifier optional equipment ...

Page 88: ...OM 2244 Operation and Maintenance Manual DCS 600 Series 500082 Solid State Transformer Rectifiers December 15 2014 Chapter 5 1 Page 2 This page intentionally left blank ...

Page 89: ...600 Solid State Transformer Rectifier This chart contains the description part number and document number of the option feature There is also a column to identify which option feature is contained in this Appendix Option Features Available Description Part Number Document Number In This Section Kit Cable Tray 288360 TO 274 Plug Locking Fits 50 Hz Aux 288582 001 Kit Cable Interlock GPU 400 600 2906...

Page 90: ... accumulation of lint or excessive dirt will interfere with normal ventilation c Chemical fumes flammable or explosive gases d Nuclear radiation e Steam salt 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 o...

Page 91: ...es 500082 Solid State Transformer Rectifiers December 15 2014 Appendix A Page 3 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 ...

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