Hobart TM416 Operation And Maintenance Instruction Manual

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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OPERATlON,MAlNTENANCE,AND OVERHAULMANUALTM-416

MOTOR-DRIVEN GENERATORSET,SERIES 5503AAND 5507A

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OPERATION, MAINTENANCE, AND OVERHAUL MANUAL TM-416

MOTOR-DRIVEN GENERATOR SET, SERIES 5503A AND 5507A

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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

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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

1-o

1

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1

2

5

37

38

l-2

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6

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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

3-o 1

3-l 1

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4-o

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4-2

Content:

Page 3

.-

I’ I

p!mq

1

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

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Feb 27p6

.

I’ --- .-

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_--.-

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m

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

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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

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Protective Relay Trcy (Dual Output Illustrated)

15

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8 Generat,?r Schematic, Diograrr (S inglei Output!

17

Feb 27/?‘6

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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

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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

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

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

3-1

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

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

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

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

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

2

5

8

10

12

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

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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Hobart TM416 Operation And Maintenance Instruction Manual

Hobart TM416 Operation And Maintenance Instruction Manual

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