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Hobart POWER MASTER Operation And Maintenance Manual With Illustrated Parts List

Solid state frequency converter
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OM-2065
110190
032993
Operation
Maintenance Manual
and
Illustrated Parts List
with
for
P
W
M
O
ER
ASTER
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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Summary of Contents for Hobart POWER MASTER

  • Page 1 Maintenance Manual Illustrated Parts List with ASTER 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.
  • Page 2 This page intentionally left blank...
  • Page 3 Safety Instructions and Warnings for Electrical Power Equipment WARNING ELECTRIC SHOCK can KILL. Do not touch live electrical parts. ELECTRIC ARC FLASH can injure eyes, burn skin, cause equipment damage, and ignite combustible material. DO NOT use power cables to break load and prevent tools from causing short circuits.
  • Page 4 c. 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 the supervisor and discontinue use of the equipment until its safety has been assured. Repairs should be made by qualified personnel only.
  • Page 5 EMERGENCY FIRST AID Call physician immediately. Seek additional assistance. 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 Electrical Shock, turn off power. Remove victim; if not breathing, begin artificial respiration, preferably mouth-to-mouth.
  • Page 6 This page intentionally left blank. Page iv Instructions 910082 Rev 1/90...

  • Page 7: Table Of Contents

    OM-2065 / Operation and Maintenance Manual 90SB51 / Spec. 7015-3 / Frequency Converter Table of Contents Chapter-Section . Page Chapter 1. Description/Operation Section 1. Description 1-1.1 1. General 1-1.1 a. Mountings for the Solid State Converter ..... . . 1-1.1 b.
  • Page 8 OM-2065 / Operation and Maintenance Manual 90SB51 / Spec. 7015-3 / Frequency Converter Section 3. Operation 1-3.1 1. Start-Up Procedure with No Load on Converter Unit 1-3.1 2. Start-Up Procedure with Converter Unit Connected to an Aircraft 1-3.11 3. Door Interlock Switch 1-3.1 4.
  • Page 9 OM-2065 / Operation and Maintenance Manual 90SB51 / Spec. 7015-3 / Frequency Converter Section 5. Capacitor Test Procedure 3-5. 1 1. Taking Resistance Measurements on Capacitors 3-5. 1 Chapter 4. Illustrated Parts List Section 1. Introduction 4-1. 1 1. General 4-1.
  • Page 10 OM-2065 / Operation and Maintenance Manual 90SB51 / Spec. 7015-3 / Frequency Converter List of Figures Chapter-Section . Page Chapter 1. Description/Operation Frequency Converter Unit ........1-1. 2 Specifications and Capabilities .
  • Page 11 Examples: (Fig. 8) , or (2-l; Fig. 8). 4. Service Information If you have any questions concerning your Hobart Brothers Company, Power Systems Group equipment, you are invited to contact our Service Department by mail, telephone, or FAX. Write:...
  • Page 12 OM-2065 / Operation and Maintenance Manual 90SB51 / Spec. 7015-3 / Frequency Converter This page intentionally left blank Introduction Nov 01/90 Page viii...

  • Page 13: Chapter 1. Description/Operation

    115/200-V AC, 3-phase, 400-Hz electrical systems. This converter unit is identified by Specification Number 7015-3, and is manufactured by Hobart Brothers Company, Ground Power Division, Power Systems Group, Troy, Ohio 45373. See Figure 2 for specifications and capabilities for a basic, or stationary converter.

  • Page 14: Frequency Converter Unit

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

  • Page 15: Theory Of Operation

    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 aircraft, eliminating the costly need for operating the aircraft’s auxiliary power unit.

  • Page 16: Inverter

    OM-2065 / Operation and Maintenance Manual 90SB51 / Spec. 7015-3 / Frequency Converter Block Diagram of Converter Figure 3 b. Inverter The inverter employed in this system is a step wave-form inverter. This inverter uses harmonic neutralization, which results in the elimination of all harmonic distortion below the eleventh harmonic without filtering.

  • Page 17: Alarms

    OM-2065 / Operation and Maintenance Manual 90SB51 / Spec. 7015-3 / Frequency Converter When an overload condition develops, wherein the load exceeds the unit’s power rating by 25%, the unit will run for approximately 5 minutes before shutting down. For a 50% overload, the unit will turn off after approximately 10 seconds.
  • Page 18 OM-2065 / Operation and Maintenance Manual 90SB51 / Spec. 7015-3 / Frequency Converter ALARM I monitors a series of current sensors. This device will sense a current in excess of normal in the transistorized bridge and will turn the entire unit off. These sensors will react only to an imminent failure of the transistors and not to an overload on the unit.

  • Page 19: Description Of Front Panel Controls

    OM-2065 / Operation and Maintenance Manual 90SB51 / Spec. 7015-3 / Frequency Converter The AMPcard allows for adjustments to the output voltage as well as to the load compensation. The VOLTAGE potentiometer allows an operator to adjust the output voltage in excess of +/- 15%.
  • Page 20 OM-2065 / Operation and Maintenance Manual 90SB51 / Spec. 7015-3 / Frequency Converter (6) OUTPUT VOLTMETER This meter (7) , in conjunction with the VOLTAGE SELECTOR SWITCH, (7) measures output voltage on all three phases, with an accuracy of +/-2%. Two test jacks (8) are provided next to the voltmeter for measuring voltage with a more accurate meter if that is required during service.

  • Page 21: Converter Cabinet

    OM-2065 / Operation and Maintenance Manual 90SB51 / Spec. 7015-3 / Frequency Converter c. Converter Cabinet The cabinet which houses the converter apparatus and circuitry consists of a sturdy welded aluminum frame to which a one- piece 16-gauge sheet metal cover (3, Fig. 1) is fastened, and to which a flat metal sheet is attached to form the bottom of the cabinet.

  • Page 22: Remote Pushbutton Station Connection (Optional)

    OM-2065 / Operation and Maintenance Manual 90SB51 / Spec. 7015-3 / Frequency Converter e. Remote Push-button Station Connection (Optional) (1) Description Each unit is provided with START/STOP buttons on the control panel. When the unit is mounted under a bridge these controls are often out of reach of the operator on the ground. Therefore, the units may be equipped for remote START/STOP stations (See 281338 in Chapter 6) .

  • Page 23: Section 2. Preparation For Use

    (c) Remove the pallet from the unit. 4. Preparation for Use A Hobart converter unit requires no additional preparation in order to supply power to an aircraft. It needs only to have its input connected to an appropriate source of power, and then have its output cable connected to the aircraft.

  • Page 24: Select An Adequate Source Of Input Power

    For this installation, the remote control pushbutton station that is used may be provided by the customer, or it may be purchased from Hobart Brothers Company. When purchased from Hobart Brothers, this optional item is available as Part Number 281338.

  • Page 25: Install Output Cable

    OM-2065 / Operation and Maintenance Manual 90SB51 / Spec. 7015-3 / Frequency Converter (3) Turn switch on AMP card to MAINT position. (4) Close all doors tightly to enable interlock switches. (5) Open the access door and Turn on input circuit breaker. All lights and LED’s (except OUTPUT POWER light) should glow.
  • Page 26 OM-1065 / Operation and Maintenance Manual 90SB51 / Spec. 7015-3 / Frequency Converter This page intentionally left blank. Chapter 1-2 Nov 01/90 Page 4...

  • Page 27: Control Panel

    OM-2065 / Operation and Maintenance Manual 90SB51 / Spec. 7015-3 / Frequency Converter Section 3. Operation 1. Start-Up Procedure with No Load on Converter Unit a. Apply rated input power to the converter unit from the input power (disconnecting means). The green INPUT POWER indicating light on control panel will come on.
  • Page 28 OM-2065 / Operation and Maintenance Manual 90SB51 / Spec. 7015-3 / Frequency Converter This page intentionally left blank Chapter 1-3 Nov 01/90 Page 2...

  • Page 29: Chapter 2. Servicing

    All servicing and repair work including testing and calibration, should be referred to the Service Department of Hobart Brothers Company, or to an authorized service shop of Hobart Brothers ground power equipment, or trained, qualified electronic technician.

  • Page 30: Component Torque Values

    Questions concerning the operation, repair, and/or servicing of this equipment should be directed to the Service Department of Hobart Brothers Company (See Introduction, page 1) . When making such an inquiry, be sure to provide the service department with the model number, serial number, and approximate date of receipt of the equipment.

  • Page 31: Chapter 3. Troubleshooting

    The solid state converter is designed to be as easy to troubleshoot as it is to operate and maintain. As mentioned in the previous chapter, all calibrations, servicing and repair work is to be done by Hobart Brothers Service Department personnel, authorized distributors of Hobart Brothers ground power equipment, or trained, qualified electronic technicians.

  • Page 32: Card Cage

    OM-2065 / Operation and Maintenance Manual 90SB51 / Spec. 7015-3 / Frequency Converter 2. Procedure for Restoring Unit to Operation After a Fault Fault shutdowns are indicated on ALARM I, II and III. Following a fault shutdown of the unit, the fault alarm is reset by pushing the STOP/RESET button on the control panel.

  • Page 33: Control Panel

    OM-2065 / Operation and Maintenance Manual 90SB51 / Spec. 7015-3 / Frequency Converter d. OC ( 125%)- Overcurrent (125% Load) Fault When the alarm indicator light marked OC (125%) comes on, this indicates that an overload exceeding 125% lasted approximately 5 minutes before activating the alarm. Reset the alarm and restart the unit.
  • Page 34 OM-2065 / Operation and Maintenance Manual 90SB51 / Spec. 7015-3 / Frequency Converter g. IMB/GND When the indicator light marked “IMB/GND” on ALARM III comes on, this indicates that a load imbalance of at least 10% exists between output phases or one of the output phases is grounded. Check to see where the imbalance is, then balance the load as much as possible or check and remove ground on output phase.
  • Page 35 OM-2065 / Operation and Maintenance Manual 90SB51 / Spec. 7015-3 / Frequency Converter Section 2. Troubleshooting Charts Fault Indicators Trouble, Sympton and Condition Probable Cause Test, Check, And Remedy 1. Input circuit breaker will not a. Front or rear door open Close door(s).
  • Page 36 OM-2065 / Operation and Maintenance Manual 90SB51 / Spec. 7015-3 / Frequency Converter Fault Indicators - (cont.) Trouble, Sympton and Condition Probable Cause Test, Check, And Remedy 7. Ø LOSS - Phase-Loss on a. Input voltage on one or Check input(s) voltage. (See ALARM II more input phases below para.

  • Page 37: Base Pulse For Transistor Sw1

    OM-2065 / Operation and Maintenance Manual 90SB51 / Spec. 7015-3 / Frequency Converter Section 3. “SOFT-START” Instructions 1. General Following major repair such as: • Transistor Replacement • Wire Harness Repair or Replacement • Transformer Replacement or Repair • Card Cage Replacement It is recomended that a SOFT-START procedure be followed before restarting the unit to minimize possibilities of damage to the unit if other unrepaired problems still exist in the unit.

  • Page 38: Unfiltered Output Waveform

    OM-2065 / Operation and Maintenance Manual 90SB51 / Spec. 7015-3 / Frequency Converter i. Disconnect output filter capacitors (All colored wires). j. Turn on input voltage. k. Apply 12 volts DC to bus. l. After pushing the RESET and START buttons, remove ALARM II, otherwise the unit will shutdown from undervoltage.

  • Page 39: Transistor Module

    OM-2065 / Operation and Maintenance Manual 90SB51 / Spec. 7015-3 / Frequency Converter Section 4. Transistor Module Test Procedure 1. Taking Resistance Measurements on the Transistor Module a. Before taking resistance measurements, make certain that the transistor being checked is removed (disconnected) from all other circuitry.

  • Page 40: Taking Transistor Module Resistance Measurements

    OM-2065 / Operation and Maintenance Manual 90SB51 / Spec. 7015-3 / Frequency Converter Taking Transistor Module Resistance Measurements (Placement of Ohmmeter Leads) Figure 2 Direction (Polarity) of Measurement & Approx. Values of Resistance for a Good Transistor Volts/ Collector- Collector- Base- Base- Manufacturer...
  • Page 41 OM-2065 / Operation and Maintenance Manual 90SB51 / Spec. 7015-3 / Frequency Converter Section 5. Capacitor Test Procedure 1. Taking Resistance Measurements on Capacitors a. Before taking resistance measurements, make certain that the capacitor being checked is discharged (check with voltmeter) and removed (disconnected) from all other circuitry. b.
  • Page 42 OM-2065 / Operation and Maintenance Manual 90SB51 / Spec. 7015-3 / Frequency Converter This page intentionally left blank Chapter 3-5 Nov 01/90 Page 2...

  • Page 43: Chapter 4. Illustrated Parts List

    Thus the figure and item numbering system ties the parts lists to the illustrations and vice versa. (2) “HOBART PART NUMBER” Column Part numbers appearing in this column are Hobart numbers. These are the numbers to which a customer should refer when purchasing replacement parts, or identifying a part for servicing or replacement.
  • Page 44 OM-2065 / Operation and Maintenance Manual 90SB51 / Spec. 7015-3 / Frequency Converter (3) “NOMENCLATURE” Column The item identifying name appears in this column. The indenture method is used to indicate item relationships. Thus, components of an assembly are listed directly below the assembly name and indented one space.
  • Page 45 OM-2065 / Operation and Maintenance Manual 90SB51 / Spec. 7015-3 / Frequency Converter Section 2. Parts List Explanation of Parts List Arrangement The parts list is arranged so that the illustration will appear on a lefthand page and the applicable parts list will appear on the opposite right-hand page.
  • Page 46 OM-2065 / Operation and Maintenance Manual 90SB51 / Spec. 7015-3 / Frequency Converter This page intentionally left blank Chapter 4-2 Nov 01/90 Page 2...

  • Page 47: Ac/Ac Converter

    AC/AC Converter Figure 1 Nov 01/90 Chapter 4-2 Page 3...

  • Page 48: Main Frame & Cover Assembly

    OM-2065 / Operation and Maintenance Manual 90SB51 / Spec. 7015-3 / Frequency Converter Main Frame & Cover Assembly Figure 2 Chapter 4-2 Nov 01/90 Page 4...
  • Page 49 OM-2065 / Operation and Maintenance Manual 90SB51 / Spec. 7015-3 / Frequency Converter NOMENCLATURE FIGURE & HOBART ITEM NO. PART NO. 1 2 3 4 5 6 7 —- MAIN FRAME & COVER ASSY. 282491 . BRACKET, MTG. , DOOR INTERLOCK 77A-1000-2 .

  • Page 50: Ac/Ac Converter (Front Components And Main Transformers)

    AC/AC Converter (Front Components and Main Transformers ) Figure 3 Chapter 4-2 Nov 01/90 Page 6...
  • Page 51 OM-2065 / Operation and Maintenance Manual 90SB51 / Spec. 7015-3 / Frequency Converter NOMENCLATURE FIGURE & HOBART ITEM NO. PART NO. 1 2 3 4 5 6 7 No Number AC/AC CONVERTER, INTERIOR, FRONT 281464 . TRANSFORMER, MAIN ASSY. 281133 .

  • Page 52: Ac/Ac Converter (Rear Components)

    OM-2065 / Operation and Maintenance Manual 90SB51 / Spec. 7015-3 / Frequency Converter AC/AC Converter (Rear Components ) Figure 4 Chapter 4-2 Nov 01/90 Page 8...
  • Page 53 OM-2065 / Operation and Maintenance Manual 90SB51 / Spec. 7015-3 / Frequency Converter NOMENCLATURE FIGURE & HOBART ITEM NO. PART NO. 1 2 3 4 5 6 7 No Number AC/AC CONVERTER, INTERIOR, REAR 180637 . CHOKE, AIR CORE ASSY.
  • Page 54 OM-2065 / Operation and Maintenance Manual 90SB51 / Spec. 7015-3 / Frequency Converter This page intentionally left blank. Chapter 4-2 Nov 01/90 Page 10...
  • Page 55 OM-2065 / Operation and Maintenance Manual 90SB51 / Spec. 7015-3 / Frequency Converter NOMENCLATURE FIGURE & HOBART ITEM NO. PART NO. 1 2 3 4 5 6 7 (Continued) 282651 . FUSEHOLDER 405093-3 . FUSE, 1-A, 600-V 406392-2 . TRANSFORMER, CONTROL 408744 .
  • Page 56 OM-2065 / Operation and Maintenance Manual 90SB51 / Spec. 7015-3 / Frequency Converter Front Door Assembly Figure 5 Chapter 4-2 Nov 01/90 Page 12...

  • Page 57: Front Door Assembly

    OM-2065 / Operation and Maintenance Manual 90SB51 / Spec. 7015-3 / Frequency Converter NOMENCLATURE FIGURE & HOBART ITEM NO. PART NO. 1 2 3 4 5 6 7 282489 . FRONT DOOR ASSEMBLY 282486 . LABEL, CONTROL W-9917-20 . METER, HOUR 282480 .
  • Page 58 OM-2065 / Operation and Maintenance Manual 90SB51 / Spec. 7015-3 / Frequency Converter P.C. Card Cage Assembly Figure 6 Chapter 4-2 Nov 01/90 Page 14...

  • Page 59: Card Cage Assembly

    OM-2065 / Operation and Maintenance Manual 90SB51 / Spec. 7015-3 / Frequency Converter NOMENCLATURE FIGURE & HOBART ITEM NO. PART NO. 1 2 3 4 5 6 7 281235 P.C. CARD CAGE ASSEMBLY 180498 . BOARD, ALARM, I ASSEMBLY, A1 180499 .
  • Page 60 OM-2065 / Operation and Maintenance Manual 90SB51 / Spec. 7015-3 / Frequency Converter This page intentionally left blank. Chapter 4-2 Nov 01/90 Page 16...
  • Page 61 OM-2065 / Operation and Maintenance Manual 90SB51 / Spec. 7015-3 / Frequency Converter 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.
  • Page 62 OM-2065 / Operation and Maintenance Manual 90SB51 / Spec. 7015-3 / Frequency Converter FIG/ITEM PART NUMBER FIG/ITEM PART NUMBER 3-22 281235 3-10 408333 6-10 281246 4-24 408333 2-32 281317-1 6-12 408333 2-33 281318-1 3-24 408335 4-11 281319 408337 281464 4-16 408341 282480 408343...
  • Page 63 OM-2065 / Operation and Maintenance Manual 90SB51 / Spec. 7015-3 / Frequency Converter FIG/ITEM PART NUMBER 4-37 7J-422-0 77A-1000-2 77A-1036-3 77A-1036-4 5-12 82B-1066-6 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 W-10827-44 4-28 W-10827-54 W-9917-20 Nov 01/90 Chapter 4-3 Page 3...
  • Page 64 OM-2065 / Operation and Maintenance Manual 90SB51 / Spec. 7015-3 / Frequency Converter This page intentionally left blank Chapter 4-3 Nov 01/90 Page 4...
  • Page 65 “HOBART PART NUMBER” Column Part numbers appearing in this column are Hobart numbers. These are the numbers to which a customer should refer when purchasing spare parts, or identifying a part for servicing or replacement.
  • Page 66 OM-2065 / Operation and Maintenance Manual 90SB51 / Spec. 7015-3 / Frequency Converter Hobart Part Maint. Number Description Level Quanity 408501 RECTIFIER MODULE 408493 FUSE, 300A, 700V. 408567 RELAY, 24VAC 408350 RELAY, 24 VDC. 408341 CAPACITOR, 40 MFD. , 330V.
  • Page 67 OM-2065 / Operation and Maintenance Manual 90SB51 / Spec. 7015-3 / Frequency Converter Chapter 5. Optional Equipment At present, no optional equipment has been designed or manufactured for Specification 7015-3 Nov 01/90 Chapter 5-1 Page 1...
  • Page 68 OM-2065 / Operation and Maintenance Manual 90SB51 / Spec. 7015-3 / Frequency Converter This page intentionally left blank Chapter 5-1 Nov 01/90 Page 2...
  • Page 69 OM-2065 / Operation and Maintenance Manual 90SB51 / Spec. 7015-3 / Frequency Converter Chapter 6. Manufacturer’s Literature Hobart Diagrams 282575 Schematic & Connection (6 Sheets) 281027 Outline, Connections Unusual Service Conditions Warranty Nov 01/90 Chapter 6-1 Page 1...
  • Page 70 OM-2065 / Operation and Maintenance Manual 90SB51 / Spec. 7015-3 / Frequency Converter This page intentionally left blank Chapter 6-1 Nov 01/90 Page 2...
  • Page 83 OM-2065 / Operation and Maintenance Manual 90SB51 / Spec. 7015-3 / Frequency Converter Connections Outline - 281027 Figure 7 Nov 1/90 Chapter 6-1 Page 15...
  • Page 84 OM-2065 / Operation and Maintenance Manual 90SB51 / Spec. 7015-3 / Frequency Converter This page intentionally left blank. Chapter 6-1 Nov 1/90 Page 16...
  • Page 85 OM-2065 / Operation and Maintenance Manual 90SB51 / Spec. 7015-3 / Frequency Converter Unusual Service Conditions This information is a general guideline and cannot cover all possible conditions of equipment use. The specific local environments may be dependent upon conditions beyond the manufacturer’s control. The manufacturer should be consulted if any unusual conditions of use exist which may affect the physical condition or operation of the equipment.
  • Page 86 OM-2065 / Operation and Maintenance Manual 90SB51 / Spec. 7015-3 / Frequency Converter This page intentionally left blank Unusual Service Conditions Nov 01/90 Page 2...

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