In the event any component manufacturer has warranted its component to HOBART and will not deal directly with a first user then HOBART will cooperate with the first user in the presentation of a claim to such manufacturer. Under NO circumstances does HOBART assume any liability for any warranty claim against or warranty work done by or in behalf of any manufacturer of the foregoing components.
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 2 Sept 1/90 c. Service and Maintenance (1) 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.
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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.
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OM-2003 Table of Contents SUBJECT CHAPTER/SECTION PAGE Warning List Of Effective Pages Introduction 1. General 2. Scope 3. Purpose 4. Contents 5. Format A. Paragraphing and Outlining B. Page Numbering 6. How to Use the Manual A. General B. How to Locate Information (1) Table of Contents (2) List of Illustrations (3) References...
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OM-2003 Chapter 2. Description And Operation SUBJECT CHAPTER/SECTION PAGE Section 1. Description 1. General 2. Special Features 3. Optional Equipment 4. Detailed Description A. General B. Main Transformer C. Control Transformer D. Auxiliary Power Circuitry E. Output Contactor Circuitry F. Output Filter Circuitry G.
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OM-2003 Chapter 3. Servicing SUBJECT CHAPTER/SECTION PAGE Section 1. Maintenance 1. General 2. Inspection 3. Lubrication 4. Parts Replacement A. Minor electrical components B. Major Electrical Components Section 2. Inspection Check and Repair 1. General 2. Exterior Cables and Connections A.
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OM-2003 SUBJECT CHAPTER/SECTION PAGE Section 4. Troubleshooting 1. General 2. Troubleshooting A. Description B. Use of the Troubleshooting Chart 3. Equipment for Troubleshooting 4. Safety 5. Voltages of Interest 6. SCR Malfunction Instructions A. Normal SCR Malfunction Conditions B. Severe SCR Malfunction Conditions C.
OM-2003 Introduction 1. General This Introduction is intended to give the reader a better understanding of how to use the manual properly. The manual can be very helpful to you if you will READ THIS INTRODUCTION FIRST. READ AND UNDERSTAND THE MANUAL BEFORE ATTEMPTING TO OPERATE, INSTALL, OR REPAIR THIS EQUIPMENT.
OM-2003 b. Page Numbering Page numbers do not run consecutively throughout the manual. Each page is identified by the Chapter/Section number in which is appears, and by a page number within the Chapter/Section. Therefore, the first page in each Section is page 1. These identifying numbers appear in the lower, outside corner of each page.
A special connector for the two output leads and the ground lead may be required when delivering power directly to an aircraft. 7. Service If you have any questions concerning your Hobart Ground Power Division equipment, you are invited to contact our service department by mail, telephone, or FAX. Write:...
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Additional copies may be obtained at a small cost per copy by writing to: Hobart Brothers Company, Power Systems Group, Troy, Ohio Supply the owner’s manual no. (OM-2003) plus the model, specification, a serial numbers of your equipment.
OM-2003 Section 2. installation 1. Location 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 of circuits. Dirt on components helps retain this moisture in addition to providing a conducting material.
OM-2003 NOTE: After connecting the input cables, it is recommended that Hobart # 904021 urethane coating be sprayed on the connections at the fuse block to protect these connections from corrosion, fungus, and contamination. Spraying these connections will also reduce the potential for arcing from dirt and condensation.
OM-2003 CAUTION For safety and to assure adequate ventilation, be sure to replace cabinet top. 5. Output Leads Use your applicable electrical code to determine the minimum size output cable you need. If the cable voltage drop is too large with the minimum size cable, use a larger size cable. For example, the 90 C rated insulation, 4/0 cable in a 40 C ambient needed for 400 A DC may have to be larger for carrying that amperage over 200 feet with less than 4.5 Volts cable drop.
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Specifications and Capabilities Table in Figure 2. Unless a definite specification design or group of designs is to be described, this book will generally refer to this equipment as a GPU-400 power supply or power supply. See Figure 1 for a descriptive drawing showing the major components or sub- assemblies generally present in the design.
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3. Caster 9. Front Access Panel 4. Front Panel 10. Rear Access Door 5. Rear Panel 11. Lifting Yoke 6. Cable Hanger 12. Power Receptacle General Assembly of GPU-400 Power Supply (6732A/6732B Shown) Figure 1 October 7/91 Revised Page 2...
OM-2003 h. Various internal components such as the main primary input fuses (12, Fig. 3), preload resistors (6, Fig. 3), main transformer (1, Fig. 3), filter capacitors (4, Fig. 3) with the bus bar (5, Fig. 3) at the front, filter reactor (7, Fig. 3), two (8, 9, Fig. 3) output contactors, control transformer (10, Fig. 3), and 1A control fuse block (15, Fig.
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OM-2003 Specifications and Capabilities Figure 2 October 7/91 Revised Page 4...
3. Optional Equipment The GPU-400 unit can be used to provide a 14-V DC output by installing a 14-V DC Option Kit (Part No. 489017) and an additional set of output cables. Also available is a Snow Shield Option Kit (Part No.
OM-2003 c. Control Transformer (10, Fig.3) The small control transformer located on the rear of the inside baffle (3, Fig. 3) or lifting eye plate provides 115 V AC to the K1 (14, Fig. 3) input contactor coil, input contactor light A (12, Fig. 4), and S1 (11, Fig.
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8. Deleted 19. Fan Motor 9. 28 V-DC Contactor 20. Control Transformer Fuse 10. Control Transformer 21. Ammeter Shunt 11. Right Side Panel 22. Main Input Fuses Internal Components for GPU-400 (6732A/6732B Shown) Figure 3 October 7/91 Revised Page 7...
OM-2003 The power supply is typically supplied with a 0 to 1600 Amp scale DC ammeter M1 (21, Fig. 4) which measures the millivolt drop across the R11 meter shunt (20, Fig. 3) that corresponds to the scale calibration. The scale range is so much more than the rated output because the R13 starting current potentiometer (8, Fig.
OM-2003 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 “pcb” control delays the SCR turn-on signal to allow less SCR device conduction time for a correspondly lower output. Conversely, if the output voltage is too low, the SCR turn-on signal is delivered earlier in the possible conduction time for each SCR thereby allowing more power to be supplied because of the longer conduction time.
OM-2003 Section 2. Operation 1. General This section contains information for safe and efficient operation of the equipment. Operating instructions are presented in step-by-step sequence of procedures to be followed in supplying 28 V DC to an aircraft or similar load. WARNING Electric shock and fire can kill! Read and understand all operating instructions before attempting to operate the equipment.
OM-2003 4. Voltmeter a. Verify on the M2 DC voltmeter (7, Fig. 1) that the DC output voltage level is correct. If not, turn off power supply, disconnect your load, and refer to Service, Chapter 3 for instructions. 5. Output Current Limit (1) If the DC ammeter continuously reads more than 400 A DC after start-up, immediately turn R13 current limit control (10, Fig.
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OM-2003 1. Front Panel 9. Red Overload Trip Light, DS2 2. Hole Plug 10. Start Current Potentiometer, R13 3. Control Fuse, F1 (15A) 11. Green Output Contactor Light, DS3 4. Input ON-OFF Switch, S1 12. Auxiliary Power Receptacle, 115V AC 5.
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OM-2003 Chapter 3. Servicing Section 1. Maintenance 1. General To be certain the DC power supply set is ready for operation at all times, it must be inspected and maintained systematically so that defects may be discovered and corrected before they result in serious damage or failure of the equipment.
OM-2003 4. Parts Replacement a. Minor electrical components (1) Lamps and fuses are mortality type items which require simple periodic replacement. (2) Switches, meters, contactors and fan motor in the power supply fall into the category of parts which can be expected to fail at infrequent, irregular intervals. Instructions for repair and replacement of these parts are obvious.
OM-2003 Section 2. Inspection Check And Repair 1. General This section describes inspections and checks to be performed in conjunction with Inspection/Check Schedule, Figure 1. For satisfactory service, keep the power supply clean, dry, and well ventilated. At the prescribed intervals or more often as necessary, disconnect the power supply from the input power source and wipe and blow out all dirt and other foreign materials from the internal components, including the fan blades.
OM-2003 c. Control Thermostats The fan thermostat is open until operating temperature is reached. If the fan comes on immediately on a cold unit, the thermostat is probably shorted. If the fan fails to come on before the S5 overload thermostat trips open, the fan thermostat is faulty or the wiring is opened.
OM-2003 4. Major Components Check and Repair a. Main Power Transformer No replacement parts are available for the main transformer. The replacment power transformer part number for your specification number is given in the replacement parts list in Chapter 4. This part and most of the major component parts can best be replaced at the factory or a factory authorized repair facility.
OM-2003 If the flyback diode is shorted, (a rare occurrence) replace it with the same type of device (see Chapter 4 - Replacement Parts) taking care to torque the nut to the stud with 4.2 to 5.2 foot. pounds (5.7 to 7.05 newton meters). If the SCR bridge has one or more SCR devices showing a short circuit or low ohmmeter reading, it is recommended that the GPU400 power supply be sent to the factory or an authorized repair station for repair.
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OM-2003 (3) Check snubber printed circuit boards on the right side of the SCR heatsink assembly for shorted or broken leads and for signs of overheating. (4) Check the SCR gate leads for breaks or short circuits and correct any problems found before retesting.
Consideration should be given to returning the GPU-400 DC power supply to the factory or an authorized repair facility if your recheck of the GPU-400 does not find the cause of the difficulty. Field repair of the PC control board is not recommended.
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OM-2003 Printed Circuit Control Board Test Points Figure 1 April 30/91 Revised Page 2...
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OM-2003 TEST POINTS VOLTAGE & CIRCUIT DESCRIPTION OF TEST CONDITIONS 1. TP5 (10) to TP3 (8).* a. + 15 VDC +/- 5% . Test Checks (+) voltage regulator performed with open circuit output set by u4. and no load. 2. TP6 (11) to TP3 (8) a.
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OM-2003 TEST POINTS VOLTAGE & CIRCUIT DESCRIPTION OF TEST CONDITIONS 11. TP20 (26) to TP3 (8) a. 6 +/- .5 VDC. Test Checks R60 (14) overload performed with open current trip-out setting circuit. 12. TPL (27) to TP3 (8) a. .002V. Test performed with Checks trip-out light (Q10) and open circuit, not tripped.
OM-2003 Section 4. Troubleshooting 1. General Troubleshooting is an orderly process of checking and eliminating possible causes of trouble until the exact cause of a trouble is found. As a rule, the best place to start looking for the cause of a trouble in a circuit is at the source of power.
OM-2003 3. Equipment for Troubleshooting A good quality multi-scale voltohmmeter is the only instrument required for troubleshooting. However, for checking certain erratic, intermittent, or phase relationship problems, a good oscilloscope is strongly recommended. 4. Safety WARNING High voltage - electric shock and fire can kill! Exercise extreme care to avoid contact with high voltage leads and components which could cause serious shock and injury if touched when troubleshooting or operating the equipment.
OM-2003 c. SCR tests or checks (1) If nothing is found defective on the board the next step is to go to the SCRs. First of all 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 no fuses blow.
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OM-2003 Trouble, Symptom, Condition Probable Cause Test, Check, And/or Remedy Machine Will Not Operate 1. Machine will not start. a. Input power turned OFF at Turn power ON at Remote Remote Disconnect Switch. Disconnect Switch. b. Blown fuse in Remote Replace blown fuse.
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OM-2003 Trouble, Symptom, Condition Probable Cause Test, Check, And/or Remedy Machine Will Not Operate (Continued) Contactor operates and blows c. Links on voltage Check appropriate voltage line fuses. changeover board changeover diagram in Chapter incorrectly connected. 8 for proper link positions. Make correction as necessary.
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OM-2003 Trouble, Symptom, Condition Probable Cause Test, Check, And/or Remedy Unit Trips Out After Starting (Continued) 1. Fan not operating (also see a. Blown fuse (F1) on front Replace fuse. See that power causes and remedies under panel of machine. receptacle is not overloaded.
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OM-2003 Trouble, Symptom, Condition Probable Cause Test, Check, And/or Remedy Power Supply On: No Voltage Output 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 Find the defective component protective circuit.
The Illustrated Parts List identifies, describes, and illustrates main assemblies, subassemblies, and detail parts of two Series of GPU-400 SCR Phase controlled, DC power supplies manufactured by Ground Power Group, Hobart Brothers Company, Troy, Ohio. These power supplies are identified as Series 6732A, 6732B and 6732C.
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(2) “HOBART PART NUMBER” Column ALL part numbers appearing in this column are Hobart numbers. In all instances where the part is a purchased item, the vendor’s identifying five digit code and his part number will appear in the “NOMENCLATURE”...
OM-2003 Section 2. Manufacturer’s Codes 1. Explanation of Manufacturer’s (Vendor) Code List The following list is a compilation of vendor codes with names and addresses for suppliers of purchased parts listed in this publication. The codes are in accordance with the Federal Supply Codes for Manufacturer’s Cataloging Handbook H4-1, and are arranged in numerical order.
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OM-2003 Code Vendor’s Name And Address 72619 Amperex Electronic Corporation Dialight Div., 203 Harrison Place, Brooklyn, New York 11237 74545 Hubbell Harvey Inc., 584 Derby Milford Rd., Orange, CT 06477 74559 Carlingswitch Inc., 505 New Park Avenue, West Hartford, CT 06110 77166 Pass and Seymour, P.O.
OM-2003 Section 3. Parts List 1. 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 righthand page. Unless the list is unusually long, the user will be able to look at the illustration and read the parts list without turning a page.
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OM-2003 General Assembly: GPU-400 (6732A/6732B Shown) Figure 1 April 30/93 Page 2...
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OM-2003 Front Panel Assembly Figure 4 April 30/93 Page 12...
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OM-2003 NOMENCLATURE UNITS FIGURE HOBART ITEM NO. PART NO. 1234567 ASSY 489053 PANEL, FRONT ASSY (For NHA See Fig. 1) ACEFHKNPR 489056 PANEL, FRONT ASSY. (For NHA See Fig. 1) 489522-1 PANEL, FRONT ASSY. (For NHA See Fig. 1) 181598 PANEL, FRONT ASSY.
OM-2003 Section 4. Numerical Index 1.Explanation of Numerical Index The purpose of this index is to assist the user in finding the illustration and description of a part when the part number is known. Part numbers are arranged in alpha-numerical sequence. Thus, any part number beginning with the letter A would be located at or near the top of the index list.
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OM-2003 PART NUMBER FIGURE AND ITEM NUMBER PART NUMBER FIGURE AND ITEM NUMBER 402670 487930-1 402670 1-16 487952 3-11 402832-3 1-13 487972 4-31 403056-7 1-41 487979 4-26 403091-2 487991 4-27 403091-4 488025 4-10 403189 1-56 488071 4-15 403247 2-14 488071 1-25 403765-2 1-13...
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OM-2003 PART NUMBER FIGURE AND ITEM NUMBER PART NUMBER FIGURE AND ITEM NUMBER 1-23 AAW-1199 S-6732A-1 S-6732A-2 S-6732A-3 S-6732A-4 S-6732A-5 S-6732B-1 S-6732B-2 S-6732B-3 S-6732B-4 S-6732B-5 S-6732B-6 S-6732C-1 S-6732C-2 S-6732C-3 S-6732C-4 S-6732C-5 S-6732C-6 S-7011-2 1-21 W-10386-10 W-10386-10 1-21 W-10386-13 W-10386-13 1-21 W-10386-9 W-10386-9 W-11097-6...
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OM-2003 Chapter 5. Optional Equipment Optional Equipment available for use with GPU-400 is listed below. OPTION PART NO. MANUAL Kit, 14-V DC Option 283532 TO-156 Kit, Snow Shield Assembly 489518 TO-166 Kit, Riser 284389-1 TO-230 January 29/92 Revised Page 1...
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OM-2003 Chapter 6. Manufacturer’s Literature DIAGRAMS FOR 6732A-1/6732B-1/6732C-1 489040 6732A-1/6732B-1/6732C-1 Schematic 489041 6732A-1/6732B-1 Connection 487987 6732A-1/6732B-1 Voltage Changeover 283528 6732C-1 Connection 283519 6732C-1 Voltage Changeover DIAGRAMS FOR 6732A-2/6732B-2/6732C-2 489043 6732A-2/6732B-2/6732C-2 Schematic 489042 6732A-2/6732B-2 Connection 488070 6732A-2/6732B-2 Voltage Changeover 283529 6732C-2 Connection 283520 6732C-2...
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OM-2003 DIAGRAMS FOR 6732B-6/6732C-6 489040 6732A-6/6732B-6/6732C-6 Schematic 489041 6732A-6/6732B-6 Connection 488388 6732A-6/6732B-6 Voltage Changeover 283528 6732C-6 Connection 283521 6732C-6 Voltage Changeover DIAGRAMS FOR 7011A-1/7011A-2 181597 7011A-1/7011A-2 Schematic 283527 7011A-1/7011A-2 Connection 283521 7011A-1/7011A-2 Voltage Changeover January 29/92 Revised Page 2...
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OM-2003 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.
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