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Hobart TM416 Operation And Maintenance Instruction Manual

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TM-416
022776
Revised 100879
OPERATION, MAINTENANCE, AND OVERHAULMANUAL
with
. ILLUSTRATED PARTS LIST
for
SERIES 5503A AND 5507A
MOTOR-DRIVEN GENERATOR SETS
rated at
200 KVA, 115/200-V AC, 4OO+lz, 3-Phase
Machines c avered.+
60-Hz MOTOR DKIVE-;
Specification No. 5503A-1, Model No. 200F-H61, Single Output
Specification No. 5503A-2, Model No. 200F-H61P, Single Output.
Specification No. 5503A-3, Model No. 200F-H62, Dual Output
Specification No. 5503A-4, Model No. 200F-H62P, Dual Output
Specification No. 5503A-5, Model No. 2OOF-H61, Single Output
5031~ MOTOR DRIVE
Specification No. 5507A-1, Model No. 200F-H51, Single Output
Specification No. 5507A-2, Model No. 2OOF-H51P, Single Output
Specification No. 5507A-3, Made1 Na. 2OOF-H52, Dual Output
Specification No. 5507A-4, Model No. 2OOF-H52P, Dual Output
.’
With Opt iona I
Reverse Phase Re lay, No. 404389
Motor Start Counter kter, No. 403013
Shutdown Timer, No. 403351
Hobart Brothers Company
Power Systems Division
Troy, Ohio 45373
U.S.A.
Ii
SAFETY INSTRUCTIONS AND WARNINGS FOR ELECTRICAL POWER EQUIPMENT
AWAR
ELECTRIC SHOCK can kill. Do not touch live electrical parts.
FUMES AND GASES can be fire and.health hazards. Ventilate all fumes and exhaust gases to the outside.
ELECTRIC ARC FLASH can injure eyes, burn skin, cause equipment damage, and ignite combustible material. Do not
use power cables to break load and be sure tools don’t cause short circuits.
IMPROPER PHASE CONNECTION, PARALLELING, OR USE can damage this and attached equipment.
MOVING PARTS can cause serious injury. Keep clear of moving parts,
IMPORTANT - Protect yourself and others. Read and understand all the instructions in this Operating/Instruction
Manual before installing, operating, or servicing this equipment. Keep this manual available for future
use by all operators.
A. GENERAL
/
Equipment that supplies electrical power can cause serious injury or death, or damage to other equipment or
property, if the operator does not strictly observe all safety rules and take precautionary actions. Safe practices
have developed from past experience in the use of power source equipment. Certain of the practices below apply to
engine driven equipment.
B. SHOCK PREVENTION
Bare conductors, or terminals in the output circuit, or ungrounded, electrically-live equipment can fatally shock a
person. Have a competent electrician verify that the equipment is adequately grounded and learn what terminals
and parts are electrically HOT. Use proper safety clothing, procedures, and test equipment.
The electrical resistance of the body is decreased when wet, thus more easily permitting dangerous currents to flow
through it. When inspecting or servicing equipment, do not work in damp areas without being extremely careful.
Stand on dry rubber mat or dry wood, use insulating gloves that are effective when dampness or sweat cannot be
avoided. Keep your clothing dry and never work alone.
1.
Installation and Grounding of Electrically Powered Equipment - Electrical equipment must be installed
and maintained in accordance with the National Electrical Code, ANSI/NFPA 70, and other applicable codes.
A power disconnect switch or circuit breaker must be located at the equipment. Check the nameplate for voltage,
frequency, and phase requirements. If only 3-phase power is available, connect any single-phase rated equipment 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, which can cause a fatal shock.
--- ---
Be sure to connect the grounding lead, if supplied in a power line cable, to the grounded switch box or building
ground. If not provided, use a separate grounding lead. Be certain that the current (amperage) capacity of the
grounding lead will be adequate for the worst fault current situation. Refer to the National Electrical Code ANSI/
N FPA 70 for details. Do not remove plug ground prongs. Use correct mating receptacles.
2. Output Cables and Terminals - Inspect cables often for damage to the insulation and the connectors. Replace
or repair cracked or worn cables immediately. Do not overload cables. Dol:ot touch output terminal while equip-
ment is energized.
Instruction 910082
Nov 16/82 Revised
Page 1
C.
FIRE AND EXPLOSION PREVENTION
Fire and explosion are caused by electrical short circuits, combustible material near engine exhaust piping, misuse
of batteries and fuel, or unsafe operating or fueling conditions.
1. Electrical Short Circuits and Overloads - ‘Overloaded or shorted equipment can become hot enough to cause
fires either by self destruction or causing nearby combustibles to ignite. Provide primary input protection to re-
move short circuited or heavily overloaded equipment from the line.
2. Battery - Batteries may explode and/or give off flammable hydrogen gas. The acid and arcing from a ruptured
battery can cause fires and additional failures. When servicing, do not smoke, causing sparking, or use open flame
near the battery.
3. Ensine Fuel - Use only approved fuel container or fueling system. Fires and explosions can occur if the fuel
tank is not grounded prior to and during fuel transfer. Shut unit DOWN before removing fuel tank cap. Do not
completely fill tank. Heat from the equipment may cause fuel expansion overflow. Remove all spilled fuel im-
mediately including any that penetrates the unit. After cleanup, open equipment doors and blow fumes away with
compressed air.
D.
E.
F.
TOXIC FUME PREVENTION
Carbon Monoxide - Engine exhaust fumes can kill and cause health problems. Pipe or vent the exhaust fumes to a
suitable exhaust duct or outdoors. Never locate engine exhausts near intake ducts or air conditioners.
BODILY INJURY PREVENTION
Serious injury can result from contact with fans, belts, and pulleys inside the equip’ment. Shut DOWN equipment
for inspection and routine maintenance. When equipment is in operation use extreme care in doing necessary
troubleshooting and adjustment.
MEDICAL AND FIRST AID TRFATMFNT
First 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 physician and taken to a hospital immediately if any
abnormal signs are observed.
Call physician immediately. Seek additional assistance and use First Aid techniques recommended
by American Red Cross until medical help arrives.
IF BREATHING IS DIFFICULT, give oxygen, if available, and have victim lie down. FOR ELEC-
TRICAL 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.
G.
EQUIPMENT PRECAUTIONARY LABELS
3. Service and Maintenance - This equipment must be maintained in good electrical and mechanical condition
to avoid hazards stemming from disrepair. Report any equipment defect or safety hazard to your supervisor and
discontinue use of the equipment until its safety has been assured. Repairs should be made by qualified personnel
only. Shut OFF all pdwer at the disconnecting switch or.line breaker before inspecting or servicing the equipment.
Lock switch OPEN (or remove lin,e fuses) so that power cannot be turned ON accidentally. Disconnect power to
equipment if it is out of service. If troubleshooting must be done with the unit energized, have present another per-
son trained in turning off the equipment and providing or calling for first aid.
EMERGENCY FIRST AID
Inspect all precautionary labels on the equipment monthly. Order and replace all labe/s that cannot be easily read.
Page 2
Instruction 910082
Revised Nov 16/82
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MOTOR-DRIVEN GENERATOR SET, SERIES 5503A AND 5507A
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OPERATION, MAINTENANCE, AND OVEKHAULMANUALTM-416
MOTOR-DRIVEN GENERATOR SET, SERIES 5503A AND 5507A
CHAPTER/
SECTION
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OPERATION, MAINTENANCE, OVERHAUL MANUALTM-416
MOTOR-DRIVEN GENERATOR SET, SER ES 5503A AND 5507A
INTRODUCTION
This manua I contains operation,
maintenance, and overhaul information and instructions
for ZOO-KVA, 400-HZ, Motor-Driven Generator Sets manufactured by Hobart Brothers
Company, Power Systems Division, Troy,, Ohio 45373.
The manual covers two basic Series of generator sets.
One requires 60-Hz input power; the
other requires 50-Hz input.
Various models of each series and some optional equipment are
also covered.
Any information which applies only to a certain model will be qualified, or
identified as such.
The manual is not intended to be a text book on electricity nor electronics.
Its primary
purpose is to provide informat ion and instruct ions to experienced operators, e lectric ians ,
and mechanics who have never seen or operated these particular generator sets.
It is the
intent of the manual to guide and assist operators and maintenance people in the proper
use and care of the equipment.
Use of the manual should not be put off until a trouble or need for help develops. Read
the instructions before starting the unit.
learn to use the manual and to locate information
contained in it.
Its style and arrangement are very similar to commercial aircraft manuals.
Each page is identified in the lower outside corner by the chapter and section number in
which it appears.
Each new section starts with page 1.
In addition to operation and maintenance instructions, the manual contains an illustrated
parts list in Chapter 7, and a collection of manufacturer’s literature and supplemental
information in Chapter 8.
N OTE :
-
When an “output cable ”
is mentioned in the manual, it generally refers to a
multi-conductor cable assembly.
A five-conductor (A, B, C, N, and E or
F) cable is required when de livering power directly to an aircraft. A four-
conductor (A, B, C, and N) cable may be used on a single output machine
when delivering power to a distribution box.
Feb 27/76
Introduct ion
Page 1
OPERATION, MAINTENANCG OVERHAUL MANUALTM-416
MOTOR-DRIVEN GENERATOR SET, SERES 5503A AND 5507A
lntr oduc t ion
Page 2
Feb 27p6
OPERATION, MAINTENANCE, AND OVERHAUL MANUALTM-416
MOTOR-DRiVEN GENERATOR SET, SERIES 5503A AND 5507A
TABLE OF CONTENTS
SUBJECT
Description/Operation
Description
Genera I
Identification
Options
Spec ia I Features
Detailed Description
Trailer Mounted Units
Trailer (Optional)
Preparation for Use
Inspection
Lubrication
lnsta I lation
Start-Run Time Delay Relay Check
Operation
Genera I
Preparation for Power De livery with Automatic
Voltage Regulation
Power Delivery with Automatic Voltage Regulation
Preparation for Power Delivery with Manual
Voltage Control
Power Delivery with Manual Voltage Regulation
Discontinue Power De livery
Delivering Power to a Distribution Panel
Feb 27/76
CHAPTER/SECTION
PAGE
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Contents
Page 1
I I
OPERkTlON, MAINTENANCE, AND OVERHAUL MANUAL TM-416
MOTOR-DRIVEN GENERATOR SET, SERIES 5503A AND 5507A
TABLE CF CONTENTS (CONT’D.)
SUBJECT CHAPTER/SECTlGN
PAGE
OperatSon of Dual-Output Generator Set
l-3
6
Servicing
2-o
1
Maintenance
2-l
General Maintenance
1
Inspection
1
Lubrication
1
Parts Replacement 1
Inspection/Check
2-2 1
General
1
Exterior Cables and Connections
1
Controls and Instruments
1
Motor-Generator
5
Check Slectrical Components
6
Adiustment/Test
2-3
1
General
1
Test Panels .
1
Testing the Generator Set
9
Motor- Generator Test
15
Diode Test
16
Adiusting the Generator Set
17
ii
Contents
Page 2
Feb 27/f6
OPERATION, MAltiTENANCE, AND OVERHAUL MANUAL TM-41’6
MOTOR-DRIVEN GENERATOR SET, SERIES 5503A AND 5507A
TABLE OF CONTENTS (CONT’D.)
SUBJECT
CHAPTER/SECT ION
PAGE
Trouble Shooting
Electrical
General
Trouble Shooting Chart
Equipment for Trouble Shooting
Safety
Fault and Effect Chart
Pmtective Monitor Chart
Test Point Values
Mechanical
General
Rotor Bearing Trouble Shooting
I Removal and Installation
RemovaI/l,nstaf lation
Canopy and ,.Sheet Meta
General
Canopy.Assembly
Major Electrical Components Removal and lnstal Iation
General
Preparation for Removal of Components
Motor Switch Panel Assembly
Motor Switch Relay Panel Assembly
Feb 27/f6
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OPERAT’ION, MAINTENANCE, AND OVERHAUL MANUAL TM-416
MOTOR-DRIVEN-GENERATOR SET, SERIES 5503A AND 5507A
TABLE OF CONTENTS (CONT’D.)
SUBJECT
CHAPTER/SECTION
PAGE
Pushbu’tton SW itch Panel Assembly
Control Box Assembly
Current Transformer Panel Assembly
Contactor Pane I
Motor’Generator
Repairs
Mechanical Repair
General
Canopy
Electrical Repair
General
Motor Switch Repair
Wiring jhe Unit After Repair or Parts Replacement
Overhaul
Canopy and Frame Overhaul
General
Disassemble
Repair
Electrical Equipment and Motor+enerator
Electrical Equipment
Motor-Generator Overhaul
Contents
Page 4
4-2
5-o
5-l
5-2
6-d
6-1
6-2
3
4
5
5
6
1
1
1
1
1
1
1
4
1
1
1
1
1
1
1
1
Feb 27p6
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OPERATIOti, MAINIXNANCE, AND OaRHAUL MANUAL TM-416
MOTOR-DRIVEN GENERATOR SET, SERIES 5503A AND 5507A
SUBJECT
TABLE OF CONTENTS (CONT’D.)
CHAPTER/SECTION
PAGE
Illustra+ed Parts List
Introduction
General
Purpose
Arrangement
Explanaticn of Parts List
Manufacturer’s (Vendor’s) Code List
Explanation of Vendor’s Code List
Parts List
Explanation of Parts List Arrangement
Symbols and Abbreviations
Numerical Index
Explanation of Numerical index
Manufacturer’s Literature
CHAPTER/
FIGURE
PAGE
SECTION NUMBER
TITLE
NO.
l-l
l-l
l-l
1-l
l-1
1-l
LIST OF ILLUSTRATIONS
1 Generator Set
2
Specifications and Copabilities
3 Motor-Generator (5503A Series, 60-Hz)
4 Motor-Generator (5507A Series, 50-Hz)
5
Control Box
*
6
Generator Control Tray
7-o
1
7-l
1
1
1
1
1
1
1
1
1
1
7-2
7-3
7-4 1
1
8-O
1
3
4
6
7
9
11
l-l
7
Protective Relay Trcy (Dual Output Illustrated)
15
l-1
8 Generat,?r Schematic, Diograrr (S inglei Output!
17
Feb 27/?‘6
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I 1
OPERATION,; MAINTEN-AWE, AND OVERHAUL MANUAL TM-416
MOTOR-DRIVEN GENERATOR SET, SEkIES 55C3A AKD 5507A
LIST OF ILLUSTRATIONS (CONT’D.)
CHAPTER/ FIGURE
PAGE
SECTION NUMBER TITLE
NO.
l-1
1-l
l-l
1-l
l-l
l-1
l-l
l-1
l-l
l-l
l-l
l-1
1-l
l-l
l-1
,
9
10
!1
12
13
14
15
16
17
18
19
20
21
22
23
Generator Schematic, Diagram (Dual Output)
Protective MonitorSchematic Diagram
Voltage Regu later Tray
Pushbutton Switch, Panel (Dual Output Illustrated)
Load Contactor Panel, Single Output
Load Contactor Panel, Dual Output
Current Transformer Panel
Output Terminal Panel, Single Output
Output Terminal Pane I, Dual Output
Motor Switch Panel
Motor Switch (Typica;) (Run Switch Illustrated)
Motor Switch Schematic Diagram (Single Output)
Motor Switch Schematic Diagram (Dual Output)
Motor Switch Relay Pane I
Transforrrer and Rectifier
18
19
20
22
24
26
27
29
29
31
32
33
34
35
37
l-2
1
Input Terminals 4
l-3
1
Operating Controls and Instruments (Sheet 1)
2
l-3
1
Operating Controls and Instruments (Sheet 2)
3
l-3 2
Dual-Output Operating Controls.
7
2-l
1
2-l
Lamp Chart
2
Fuse Chart
3
3
2-2 1
Inspection Check Schedule
2
2-3
1
2-3
1
2-3 1
2-3
2
2-3 3
2-3
4
Test Panek (Sheet 1)
Test Pane is (Sheet 2)
Test Panek (Sheet 3)
Test Values, Normal Operation, No Load, Single Output
Test Values, Normal Operation, No Load, Dual Output
Test Values, Normal Operation at Rated Load,
S ing le Output
7
2-3
5 Test Values, Normal Operation at Rated Load,
2-3
6
2-3
7
2-3
8
2-3
9
Dua I Output 8
Remote Control Terminal Boards
11
Mot&,-Generator, and Exciter Stator Test Values
16
Switch Interlock Bar Adjustment
18
Time De lay Relay
ii
22
Contents
Pase 6
Fe b 27176
OPERATION, MAINTENANCE-, AND
MOTOR-DRIVEN GENERATOR SET,
OVERHAUL MANUAL TM-416
SERIES 5503A AkD 5507A
LIST OF ILLUSTRATIONS (CONT’D.)
CHAPTER/
SECTION
/
3-1
3-l
3-l
3-1
3-1
FIGURE
NUMBER
PAGE
TITLE
NO.
.
3-1
6
Motor Switch Schematic Diagram, S ingle Output 3
Motor Switch Schematic Diagram, Dual Output 4
Generator Schematic Diagram (Single Output) 5
Generator Schematic Diagram (Dua I Output) 6
Electrical Trouble Shooting Chart (Sheets 7 through
17)
7 thru 23
Motor-Generator Fault and Effect Chart
(Sheets 1 and 2)
24 and 25
3-1
7
Prokctive Monitor Fault Chart
26
3-2
1
Bearing Trouble Shooting Chart
2
4-l
1
Canopy Assembly, Exploded View 2
4-2
1
Generator Set Without Canopy 2
5-2
1
5-2
2
5-2
3
5-2
4
5-2 5
Motor Switch (Typical) (Run)
Motor Switch Connection Diagram (Ail)
Generator Connection Diagram, S ingie Output
Control Box Connecticn Diagram, Single Output
Generator Control Tray Connection Diagram,
All
3
5
6
7
8
5-2
6
5-2 ’
7
5-2
8
Protective Relay Tray Connection Diagram, Single
output
Current Transformer Pane I Connecticn Diagram (Al I)
Pushbutton Switch Panel Connection Diagram,
Single Output
9
10
5-2
5-2
5-2
5-2
5-2
9
10
11
12
13
14
15
Contactor Panel Connection Diagram, Single Output
Transformer-Rectifier Connection Diagram (All)
Generator Connection Diagram, Dual Output
Control Box Connection Diagram, Dual Output
Prdtective Relay Tray Connection Diagram, Dual
Output
11
12
13
14
15
16
5-2
5-2
6 ---1
Pushbutton Switch Panel Connection Diagram, Dual
ouipui
Contactor Panel Connection Diagram, Dual Output
No Illustrations
’ i
17
18
Feb 27/?‘6
Contents
Page 7
CHAPTER/
F!GURE
SECT ION NUMBER
6-2
1
I
Motor-Generator (Typica I)
2
6-2 2
Bearing Remova I and instal iation Tools
5
6-2
3
Motor, Generator, and Exciter Field Connections
9
6-2 4
Motor, Generator, and Exciter Field Schematic
9
6-2
5
Stator Housing Blocking Arrangement (Typical)
12
6-2
6
Rotor Lifting Arrangement (Typical)
12
6-2 7
Pulling Rotor Bearing into Stator Housing (Typical)
13
6-2
8
Pcsitioning Rotor Shaft Bearing in Housing (Typical)
13
7-3 1
7-3
2
7-3 3
7-3 4
7-3
5
7-3
6
7-3 7
7-3
8
7-3
9
7-3
10
7-3
11
7-3
12
7-3
13
7-3
14
7-3
15
7-3
16
7-3
17
7-3
18
7-3
19
7-3
20
7-3
21
7-3
22
7-3
23
7-3
24
7-3
25
7-3
26
Generator Set
Canopy Assembly
Canopy Assembly
Front Pane I Assembly
Rear Panel Assembly
Rear Pane I Assemb iy
Front Pane I Asse mb iy
Rear Pane I Assemb ly
Rear Panel Assembly
Generator Set Without Canopy
Motor Switch Relay Panel Assembly
Motor Switch Assembly
Current Transformer Pane I Assembly
Contactor & Overload Panel Assembly
Contactor & Overload Panel Assembly
Control Box Assembly
Generator Controls Tray Assembly
Generator Controls Tray Sub-assembly
Protective Relays Tray Assembly
Protective Relays Tray Sub-assembly
Regu iator Tray Assembly
Regulator Tray Sub-assembly
Control Box Group
Pushbutton Pane I Assembly
Generator Group
Frame Group
2
4
6
8
10
12
14
16
18
20
22
24
30
32
34
36
38
40
42
46
48
50
52
54
58
62
Contents
Page 8
Feb 27/76
OPERATION, MAINTENANCE, AND OVERHAUL MANUAL TM-416
MOTOR-DRIVEN GE NE RATOR SET, SE R ES 5503A AND 5507A
LIST OF ILLUSTRATIONS (CONT’D)
TITLE
PAGE
NO.
OPERATION, MAiNTENmAND OVERHAULMANUALTM-416
MOTOR-DRIVEN GENERATOR SET, SERES 5503A AND 5507A
CHAPTER 1. DESCRiPTiON/OPERATiON
TABLE OF CONTENTS
SUBJECT ’
Descr ipt,ion
Genera I
Identification
Opt ions
Specia I Features
Detailed Description
Motor Generator
Control Box
Generator control tray
Generator output monitors
Meter and line switches
Automatic-manual controls
Test panel
Protective re lay tray
Sens ing relays
Protective monitor module
indicating I ights
Plug inter ioc k relay
Test bank switch
Resistor
Feb 27/76 , :
CHAPTER/SECTION
PAGE
l-l
1
1
1
2
5
5
5
8
8
10
10
10
12
12
12
13
13
13
14
ii
14
1-o
Page 1
OPERATION, MAiNTENANCE,AND OVERHAUL MANUAL TM-416
MOTOR-DRIVEN GENERATOR SET, SERES 5503A AND 5507A
TABLE OF CONTENTS (CONT’D)
SUBJECT
CHAPTER/SECT ION
Fuse inter ioc k rk lay
l-l
PAGE
14
Test panel .
14
Connector
14
Protective relay tray summary
16
Voltage regulator tray
16
Test pane I
16
Voltage regulator
16
Pushbutton Switch Pane I
16
instrument lights
16
Motor controls and instruments
20
Generator control switch
21
Convenience outlets
21
Resistor
21
Pushbutton switch pane I summary
Load Contactor Panel, Single Output
21
21
Load contactor and transformers
21
Over load modu ie
23
Rectifier
23
Test pane I
25
Load C ontactor Pane I, Dual Output
25
Ii
Current Transformer Pane I Assembly
25
1-o
Feb 27/76
Page 2
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