Revised 063094 OPERATION AND MAINTENANCE MANUAL with ILLUSTRATED PARTS for LIST 37.5 kva and 60 kva SYNCHRONOUS MOTOR DRIVEN GENERATOR SETS 400-Hz, 115/200-V AC, 3-Phase SPECIFI- CATION MODEL NUMBER INPUT VOLTS INPUT HERTZ OUTPUT POWER RATING (KVA) RATED SPEED (RPM) 6182A-1 37F-H61 230 / 460 60 37.5 1200 6182A-2 37F-H61 208 / 380 60 37.5 1200 6182A-3 37F-H61 575 60 37.5 1200 6183A-1 37F-H51 220 / 380 50 37.5 1500 6184A-1 60F-H61 230 / 460 60 60 1200 6184A-2 60F-H61 230 / 460 * 60 60 1200 6184A-3 60F-H61 208 / 380 60 60 1200 6184A-4 60F-H61 575 60 60 1200 6185A-1 60F-H51 220 / 380 50 60 1500 6185A-2 60F-H51 415 50 60 1500 * Delta Output HOBART BROTHERS COMPANY Airport Systems Group Troy, Ohio 45373 U.S.A.
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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. IMPROPER PHASE CONNECTION, PARALLELING, OR USE can damage this and attache equipment. Important: Protect all operating personnel. Read, understand, and follow all instructions in the Operating/Instruction Manual before installing, operating, or servicing the equipment. Keep the manual available for future use by all operators. 1. General Equipment that supplies electrical power can cause serious injury or death, or damage to other equipment or property. The operator must strictly observe all safety rules and take precautionary actions. Safe practices have been developed from past experience in the use of power source equipment. While certain practices below apply only to electrically-powered equipment, other practices apply to engine-driven equipment, and some practices to both. 2. Shock Prevention Bare conductors, or terminals in the output circuit, or ungrounded, electrically-live equipment can fatally shock a person. Have a certified electrician 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 wood, use insulating gloves when dampness or sweat cannot be avoided. Keep clothing dry, and never work alone a. Installation and Grounding of Electrically Powered Equipment Equipment driven by electric motors (rather than by diesel or gasoline engines) must be installed and maintained in accordance with the National Electrical Code, ANSI/NFPA 70, or 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. Always 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. Ensure 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/NFPA 70 for details. Do not remove plug ground prongs. Use correctly mating receptacles. b. Output Cables and Terminals Inspect cables frequently for damage to the insulation and the connectors. Replace or repair cracked or worn cables immediately. Do not overload cables. Do not touch output terminal while equipment is energized. June 30/94 Revised Safety Warnings Page 1
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. (1) Before inspecting or servicing electrically-powered equipment, take the following precautions: (2) Shut OFF all power at the disconnecting switch or line breaker before inspecting or servicing the equipment. (3) Lock switch OPEN (or remove line fuses) so that power cannot be turned on accidentally. (4) Disconnect power to equipment if it is out of service. (5) If troubleshooting must be done with the unit energized, have another person present who is trained in turning off the equipment and providing or calling for first aid. 3. 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. a. Electrical Short Circuits and Overloads 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 overloaded equipment from the line. b. Batteries Batteries may explode and/or give off flammable hydrogen gas. Acid and arcing from a ruptured battery can cause fires and additional failures. When servicing, do not smoke, cause sparking, or use open flame near the battery. c. Engine Fuel Use only approved fuel container or fueling system. Fires and explosions can occur if the fuel tank is not grounded prior to or during fuel transfer. Shut unit DOWN before removing fuel tank cap. DO NOT completely fill tank, because heat from the equipment may cause fuel expansion overflow. Remove all spilled fuel IMMEDIATELY, including any that penetrates the unit. After clean-up, open equipment doors and blow fumes away with compressed air. 4. 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 of air conditioners. 5. Bodily Injury Prevention Serious injury can result from contact with fans inside some equipment. Shut DOWN such equipment for inspection and routine maintenance. When equipment is in operation, use extreme care in doing necessary trouble-shooting and adjustment. Do not remove guards while equipment is operating. Safety Warnings Page 2 June 30/94 Revised
6. Medical and First Aid Treatment 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. IMPORTANT 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. If no detectable pulse, begin external heart massage. CALL EMERGENCY RESCUE SQUAD IMMEDIATELY. 7. Equipment Precautionary Labels Inspect all precautionary labels on the equipment monthly. Order and inspect all labels that cannot be easily read. June 30/94 Revised Safety Warnings Page 3
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Introduction This manual contains operation and maintenance information for a series of 400-Hertz generator sets manufactured by Hobart Brothers Company, Power Systems Division, Troy, Ohio 45373. This manual is not intended to be a textbook on electricity or electronics. Its primary purpose is to provide information and instructions to experienced operators, electricians, and mechanics who have never seen or operated this equipment. It is the intent of this 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. The manual is divided into six chapters. Each chapter is divided into as many sections as required. Each new section starts with page 1. Each page is identified 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, and paragraph, or figure number. For example, (See 2-3, Para. B) refers to information located in Chapter 2, Section 3, Paragraph B. If a Chapter and Section are not indicated in a reference, the referenced material is located in the same section as the reference, Example, (See Para. B). In addition to operation and maintenance instructions, the manual contains an illustrated parts list in Chapter 4, and connection and schematic diagrams in Chapter 6. Content of the manual is arranged as follows: Chapter 1. Description/Operation Chapter 2. Servicing Chapter 3. Troubleshooting Chapter 4. Illustrated Parts List Chapter 5. Optional Equipment Chapter 6.Manufacturer s Literature June 30/94 Revised Introduction Page 1
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Table of Contents Safety Warnings Introduction Table of Contents Subject Chapter/Section Page Chapter 1. Description / Operation 1-1 1 Section 1. Description 1-1 1 1. General 1-1 1 2. Orientation 1-1 1 3. Optional Equipment 1-1 1 4. Identification 1-1 4 5. Special Features 1-1 4 6. Detailed Description 1-1 4 a. Motor-Generator Assembly.................... 1-1.............. 5 b. Control Cabinet.............................. 1-1.............. 5 (1) General 1-1 5 (2) Generator Monitor Tray 1-1 7 (3) Generator Protection Tray 1-1 9 (4) Voltage Regulator Tray 1-1 12 (5) Motor And Generator Control Pushbutton Panels 1-1 13 (6) Front Panel 1-1 13 c. Interior Panel (Ref. 7, Fig. 4).................... 1-1............. 13 (1) Contactors 1-1 13 (2) Motor Control Transformer 1-1 13 (3) Generator Control And Plug-Interlock Relays 1-1 13 (4) Aircraft - Test Bank Switch 1-1 16 (5) Motor Overload Relay And Transformer 1-1 16 (6) Rectifier 1-1 16 (7) Power Supply (12-V DC) 1-1 16 (8) Wiring Harness 1-1 18 (9) Current Transformer Panel Assembly 1-1 18 d. Test Panel................................... 1-1............. 19 e. Cabinet Fan................................. 1-1............. 19 7. Conduits and Connectors 1-1 23 June 30/94 Revised Table of Contents Page 1
Subject Chapter/Section Page 8. Frame And Sheet Metal Covers And Air Ducts 1-1 23 9. Options 1-1 25 a. General..................................... 1-1............. 25 b. Second Output (Part Number 485211)............ 1-1............. 25 c. Convenience Receptacle Panel Assembly, 60-HZ.. 1-1............. 25 d. Phase Failure Relay........................... 1-1............. 27 e. Alternate Voltage Kit.......................... 1-1............. 27 f. Trailer....................................... 1-1............. 27 g. Transformer-Rectifier......................... 1-1............. 28 h. T-R Mounting Package........................ 1-1............. 28 i. Convenience Receptacle Panel Assembly, 50-HZ....................................... 1-1............. 28 Section 2. Preparation For Use 1-2 1 1. Uncrating 1-2 1 2. Inspection/Check 1-2 1 3. Lubrication 1-2 1 4. Generator Set Mounting Installation 1-2 1 a. Location.................................... 1-2............. 1 b. Mounting.................................... 1-2............. 1 (1) General 1-2 1 (2) Mounting Cautions 1-2 1 (3) Recommended Mounting Instructions 1-2 2 (4) Mounting Kit 1-2 2 (5) Mounting Procedures 1-2 2 (6) Alternate Mounting Method 1-2 2 5. Wiring the Generator Set 1-2 4 a. Preparation for Wiring......................... 1-2............. 4 (1) Input Voltage Requirements 1-2 4 (2) Cable Horns and Clamps 1-2 5 (3) Cable Size Selection for Input Power 1-2 5 b. Input Wiring................................. 1-2............. 6 (1) Protection 1-2 6 (2) Cable Terminations 1-2 6 (3) Cable Routing 1-2 6 (4) Cable Connections and Armature Rotation Direction 1-2 6 (5) Grounding 1-2 6 (6) Check for Proper Phase Sequence Connection 1-2 7 c. Output Wiring................................ 1-2............. 8 (1) Output Cable Assembly 1-2 8 (2) Cable Selection 1-2 8 (3) Cable Connection 1-2 8 (4) Second Output 1-2 8 Table of Contents Page 2 June 30/94 Revised
Subject Chapter/Section Page 6. Wiring for Alternate Input Voltages 1-2 10 a. General..................................... 1-2............. 10 b. Motor Stator Terminal Board................... 1-2............. 10 c. Motor Overload Relay Heater Elements.......... 1-2............. 11 d. Motor Control Transformer Alternate Connections................................. 1-2............. 13 e. Convenience Receptacle Panel Assembly (Option). 1-2............. 14 f. Checks and Procedures Following Voltage Changeover................................. 1-2............. 14 Section 3. Operation 1-3 1 1. General 1-3 1 2. Preparation for Power Delivery with AUTOMATIC Voltage Regulation 1-3 1 a. Safety...................................... 1-3.............. 1 b. Position Switches and Controls................. 1-3.............. 1 (1) Front Panel 1-3 1 (2) Generator Monitor Tray 1-3 1 (3) Generator Protection Tray 1-3 1 (4) Voltage Regulator Tray 1-3 4 (5) Interior Panel 1-3 5 3. Power Delivery with Automatic Voltage Control 1-3 5 4. Preparation for Power Delivery with MANUAL Voltage Control 1-3 5 5. Power Delivery with MANUAL Voltage Control 1-3 7 6. Discontinue Power Delivery 1-3 7 7. Optional Equipment Operation 1-3 7 a. Second Output Circuit......................... 1-3.............. 7 b. Convenience Receptacle Panel Assembly........ 1-3.............. 7 c. Trailer...................................... 1-3.............. 7 d. Transformer Rectifier......................... 1-3.............. 8 Chapter 2. Servicing 2-1 1 Section 1. Maintenance 2-1 1 1. General 2-1 1 2. Inspection 2-1 1 3. Lubrication 2-1 1 4. Parts Replacement 2-1 1 a. Replacements of Lamps and Fuses.............. 2-1.............. 2 b. Replacement of Minor Electrical Components..... 2-1.............. 2 June 30/94 Revised Table of Contents Page 3
Subject Chapter/Section Page Section 2. Inspection Check And Repair 2-2 1 1. General 2-2 1 2. Exterior Cables and Connections 2-2 1 a. Input and Output Cables....................... 2-2............. 1 b. Cable Connections........................... 2-2............. 1 3. Controls and Instruments 2-2 1 a. Voltmeter and Ammeter....................... 2-2............. 1 b. Indicating Lights............................. 2-2............. 1 (1) Protective Monitor Indicating Lights 2-2 1 (2) Motor and Generator Control Indicating lights 2-2 1 c. Overvoltage Protection Circuit.................. 2-2............. 3 d. Undervoltage Protection Circuit................. 2-2............. 3 e. Underfrequency Protection Circuit.............. 2-2............. 3 f. Overload Protection Circuit..................... 2-2............. 3 g. Ammeter Accuracy........................... 2-2............. 3 h. Voltmeter Accuracy........................... 2-2............. 3 i. Internal Wiring and Connections................. 2-2............. 4 j. General Overall Inspection...................... 2-2............. 4 4. Motor Generator 2-2 4 a. Rotor Bearings............................... 2-2............. 4 b. Motor-Generator Temperature.................. 2-2............. 4 5. Check Electrical Components 2-2 4 Section 3. Adjustment / Test 2-3 1 1. General 2-3 1 2. Test Panel 2-3 1 3. Testing The Generator Set 2-3 1 a. Pre-Operational Test Procedures................ 2-3............. 1 b. Operational Test Procedures................... 2-3............. 3 c. Optional Equipment Testing.................... 2-3............. 10 4. Motor-Generator Testing 2-3 11 a. General..................................... 2-3............. 11 b. Motor and Generator Stator Windings............ 2-3............. 11 (1) Preparation for test 2-3 11 (2) Check generator stator winding resistance 2-3 11 (3) Check motor stator winding resistances 2-3 12 c. Motor and Generator Rotor Windings............ 2-3............. 12 (1) Preparation For Test 2-3 12 (2) Test Generator Rotor Fields on Series 6183A, Series 6184A and Series 6185A Units 2-3 12 (3) Test Motor Rotor Field on Series 6183A, Series 6184A and Series 6185A Units 2-3 13 (4) Test Motor Rotor Field - Generator Rotor Field on Series 6182A Units 2-3 13 Table of Contents Page 4 June 30/94 Revised
Subject Chapter/Section Page d. Test Exciter Rotating Field..................... 2-3............. 13 e. Test Exciter Stationary Fields.................. 2-3............. 13 f. Check Micro Switches......................... 2-3............. 13 g. Rotor Bearings............................... 2-3............. 13 5. Diode Test 2-3 15 6. Adjustments 2-3 15 a. Adjust Undervoltage Time Delay................ 2-3............. 15 b. Adjust Manual Voltage Control Variable Resistor.. 2-3............. 16 c. Adjust 12-V DC Power Supply.................. 2-3............. 18 d. Adjust Voltage Regulator...................... 2-3............. 18 Section 4. Removal/Installation of Motor-Generator Covers 1. General 2-4 1 2. Generator End Covers 2-4 1 a. Removal.................................... 2-4.............. 1 b. Installation................................... 2-4.............. 1 3. Motor End Covers 2-4 1 a. Removal.................................... 2-4.............. 1 b. Installation................................... 2-4.............. 1 Section 5. Motor-Generator Servicing and Repair 2-5 1 1. General 2-5 1 2. Motor-Generator Removal and Installation 2-5 1 a. Removal.................................... 2-5.............. 1 b. Installation.................................. 2-5.............. 5 3. Electrical and Mechanical Repair 2-5 5 a. General..................................... 2-5.............. 5 b. Cabinet..................................... 2-5.............. 5 (1) Sheet Metal Repair 2-5 5 (2) Frame and Structural Repair 2-5 6 c. Wiring the Unit After Repair or Parts Replacement. 2-5.............. 6 Section 6. Overhaul of Electrical Equipment and Motor-Generator 2-6 1. Electrical Equipment 2-6 1 2. Motor-Generator Overhaul 2-6 1 a. General..................................... 2-6.............. 1 b. Remove Sheet Metal Covers and Ducts.......... 2-6.............. 1 c. Disassembly, General......................... 2-6.............. 1 d. Disassemble Motor-Generator.................. 2-6.............. 1 e. Cleaning.................................... 2-6.............. 6 June 30/94 Revised Table of Contents Page 5
Subject Chapter/Section Page f. Inspection................................... 2-6............. 6 (1) Bearings 2-6 6 (2) Fan 2-6 8 (3) Armature (Rotor) Assembly 2-6 8 (4) Motor, Generator and Exciter Stators 2-6 8 g. Assemble Motor-Generator..................... 2-6............. 8 3. Remove and Install Exciter Rotor Without Removing Armature 2-6 15 a. Removal.................................... 2-6............. 15 b. Installation.................................. 2-6............. 15 Chapter 3. Troubleshooting 3-1 1 Section 1. Troubleshooting Procedures 3-1 1 1. General..................................... 3-1............. 1 2. Troubleshooting 3-1 1 a. Description.................................. 3-1............. 1 (1) Trouble, Symptom, and Condition 3-1 1 (2) Probable cause 3-1 1 (3) Test, Check, and/or Remedy 3-1 1 b. Use of the Troubleshooting Chart............... 3-1............. 1 3. Equipment for Troubleshooting 3-1 2 4. Safety 3-1 2 5. Parts Replacement 3-1 2 6. Test Values 3-1 2 7. Check Connections and Leads 3-1 3 Chapter 4. Illustrated Parts List 4-1 1 Section 1. Introduction 4-1 1 1. General 4-1 1 2. Purpose 4-1 1 3. Arrangement 4-1 1 4. Explanation of Parts List 4-1 1 a. Contents.................................... 4-1............. 1 b. Parts List Form.............................. 4-1............. 1 (1) FIGURE-ITEM NO. Column 4-1 2 (2) HOBART PART NUMBER Column 4-1 2 (3) NOMENCLATURE Column 4-1 2 (4) REC. SPARES column 4-1 2 (5) EFF (Effective) Column 4-1 2 (6) UNITS PER ASSEMBLY Column 4-1 2 Table of Contents Page 6 June 30/94 Revised
Section 2. Manufacturer s Codes 4-2 1 1. Explanation of Manufacturer s (Vendor) Code List 4-2 1 Section 3. Parts List 4-3 1 1. Explanation of Parts List Arrangement 4-3 1 2. Symbols and Abbreviations 4-3 1 Section 4. Numerical Index 4-4 1 1. Explanation of Numerical Index 4-4 1 Chapter 5. Optional Equipment Chapter 6. Manufacturer s Literature Unusual Service Conditions June 30/94 Revised Table of Contents Page 7
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Chapter 1 Description / Operation Section 1. Description 1. General The generators covered by this manual are identified by Series Numbers 6182A, 6183A, 6184A and 6185A. These generator sets are manufactured by Hobart Brothers Co., Power Systems Division, Troy, Ohio 45373. All generator sets are electric drive stationary units, fiowever each may be made mobile by mounting on an optional four-wheel trailer. Unqualified information throughout the manual will apply to all generator sets. Information which applies to a specific machine will be qualified as such. Each machine is identified in Para. 4., Identification. Specifications and capabilities for each series are contained in Fig. 2. For purposes of simplification and to avoid confusion when referring to the generator, which is a component of the subject Generator Set, the end item covered by this manual will hereafter be referred to as the set. All sets are identical in outward appearance because they share the same frame, control box, sheet metal covers, etc. All sets produce 400-HZ, 115/200-V, 3-phase output power for serving the electrical system of parked aircraft or for powering other equipment requiring 400-HZ service. The only difference in the four sets covered here are in the internal electrical components required for either 37.5KVA or 60-KVA output rating and for their input power requirements of either 50-HZ or 60-HZ and optional voltages such as 220-V, 380-V, etc. NOTE: When we speak of 50HZ or 60HZ we will always be referring to drive motor input requirements. All generators covered by the manual produce 400HZ output power. As stated above, the general physical configuration of all machines is the same. A welded steel frame provides mounting facilities for a control cabinet and a combination motor-generator complete the unit. 2. Orientation To avoid confusion in the location of components, the control cabinet is located at the FRONT of the unit. Left and right are determined by looking at the unit from the REAR. The motor-generator is mounted with the generator end on the LEFT, the motor on the RIGHT. Cooling air enters on the LEFT or generator end and exits on the RIGHT or motor and fan end. 3. Optional Equipment Some options, by their size, function, etc., lend themselves to inclusion in the basic manual. They are: Phase Reversal Relay (See Para. 9, D) Second Output (See Para. 9, B) Convenience Receptacle (See Para. 9, C) Alternate Voltage Kit (See Para. 9, E) Transformer-Rectifier and Mounting Kit (See Para. 9, G and H) Options covered by separate manuals are: Four-Wheel Trailer (See TM-268A in Chapter 8) Transformer-Rectifier (See TM-597 in Chapter 8) June 30194 Revised l-1 Page 1
3 ""'i 3/4 Front View 3/h Rear View Front View Top View Motor Driven Generator Set Figure 1 l-1 Page 2 June 30/94 Revised
PHYSICAL SPECIFICATIONS STATIONARY 6162A-1, 6182A-2 6183A-1 6184A-1, 6184A-2 6185A-I UNITS 6182A-3 6184A-3, 6184A-4 6185A-2 Weight 2785 lb. 2900 lb. 3125 lb. 3185 lb. (1283 Kg) (1315 Kg) (1417 Kg) (1445 Kg) Length 60 in. 60 in. 60 in. 60 in. (1524 mm) (1524 mm (1524 mm (1524 mm Width 40 in. 40 in. 40 in. 40 in. 1016 mm) 1016 mm) 1016 mm) 1016 mm) Height 46 in. 46 in. 46 in. 46 in. 1168mm 1168 mm 1168 mm 1168 mm UNITS WITH TRAILER Weight 3200 lb. 3315 lb. 3540 lb. 3600 lb. (145lKg.) (I 503 Kg.) (I 605 Kg.) (1632 Kg.) Length 71 in. 71 in. 71 in. 71 in. (1803.4 mm) (1803.4 mm) (1803.4 mm) (I 803.4 mm) Width 64-518 in. 64-518 in. 64-518 in. 64-518 in. (1641 mm) (1641 mm) (1641 mm) (1641 mm) Height 57-314 in. 57-3/4 in. 57-314 in. 57-314 in. (1467 mm) (1467 mm) (1467 mm) (1467 mm) GENERATOR 37F-H61 and 37F-H51 UNITS 60F-H61 and 60F-H51 UNITS VOLTS LOAD HERTZ KILO- POWER DUTY OVERLOAD AMPS WAlTS FACTOR CYCLE CAPACITY 115/200 108 400 30.8 100% 125% of rated load 115/200 173 400 48.8 100% 125% of rated load Specifications and Capabilities Figure 2 June 30/94 Revised l-1 Page 3
4. ldentif ication Generator sets covered by the manual are listed below with their Specification Number, Model Number and Characteristics. For clarification, it should be noted here that a plain four-digit Series number (i.e. 6182A) does not identify a complete machine. It rather represents a group of parts used in ALL 6182A Series machines. To identify a complete functional machine, a dash number suffix (i.e. -1, -3, etc.) must be added to the Series number (i.e. 6182A-1). Dash numbers, added to the Series number, identify certain characteristics of a machine which set it apart from others in a Series. A Series number plus a dash number becomes a Spec (specification) number which completely identifies a machine without options. Optional equipment such as a trailer, special instruments, etc. which are usable on more than one Series of machines are identified by a six digit part number and must be ordered by part number. There is no single number which identifies a machine and an option or options. When an option or options are part of your purchase, applicable Instruction Manuals will be included in your Basic Manual under Manufacturer s Data, Chapter 8. Otherwise options are covered here. 5. Special Features Generator sets have many special features which are described more fully under the assemblies in which they appear. Some features are listed as follows: a. The backward tilted mounting position of instruments and controls allows easier reading and operation from a normal standing position. b. A hinged Plexiglass cover provides protection for instruments and controls allows easy access to them. C. Split-winding motor starting is used to simplify the starting sequence and to reduce weight, maintenance and bulk normally associated with Wye-Delta starting, and to provide closed transition starting rather than open transition as in Wye-Delta starting. d. Controls and instruments, as well as the voltage regulator, are mounted in pull-out, drawer type trays which allow easy access to equipment mounted in them. e. A test panel with connections to various test points throughout the electrical circuitry is located inside the control cabinet door. The test panel provides safe, convenient test points for checking equipment performance and for troubleshooting. f. A solid-state, adjustable voltage regulator provides automatic voltage regulation and line drop compensation The generator protective monitor system consists of solid-state devices (printed circuit boards) which provide maintenance-free operation and quick, easy removal and installation if replacement should become necessary. h. The complete generator set is designed to be weatherproof. 6. Detailed Description A detailed description of the parts which are used to build the generator set is given here. Main assemblies are listed by part name. Components of each assembly are then described. An attempt will be made to describe each item in a way which will be the most helpful to operators and maintenance personnel. 1-l Page 4 June 30/M Revised
a. Motor-Generator Assembly The motor-generator (Fig. 3) was designed with two main goals in mind. First, to eliminate excessive weight and bulk, and second, to maintain quality, performance and overload capacity. Comparing this motor-generator to previous designs clearly indicates that both goals have been reached. The drive motor, generator and exciter are combined in a single, compact, brushless unit. Both motor and generator are three-phase synchronous type. This design incorporates motor, generator and exciter stator windings in a common stator housing. Rotating field windings for motor and generator, and the exciter armature are mounted on a common shaft which is supported at each end by permanently lubricated ball bearings. Generator connection is four-wire wye with grounded neutral. The motor is connected in delta for lower voltages, 208-V to 230-V input, in wye for higher voltages, 380-V and up. The normal AC output of the exciter is changed to DC for excitation of both the motor and generator. Six diodes, mounted on the generator revolving field spider are provided to make the AC to DC change. Two normally CLOSED Micro switches also mounted on the generator revolving field spider are connected across the diodes to disable them and prevent excitation of the motor and generator during motor start-up. This design provides better starting characteristics because less power (amperage) is required for starting when motor and generator fields are NOT excited. Since micro switches are sensitive to centrifugal force, they OPEN when armature speed reaches near normal speed and allow excitation to reach motor and generator fields for normal operation. Motor starting is accomplished by the split-winding or part-winding method in which only half of the motor stator windings are used for starting. After the motor has reached operating speed, the other half of windings are automatically connected for normal running. A centrifugal, vane type fan mounted by a hub on the armature shaft at the motor end provides air circulation throughout the motor-generator. Air is drawn in at the generator end and is circulated over and around all windings. Air is then discharged from the motor end and is conducted by a sheet metal duct arrangement to an outlet at mounting frame level. b. Control Cabinet (7) General The control cabinet (Fig. 4) is mounted on the frame at the front of the unit. It consists of a weather proof enclosure which houses all electrical controls, protective devices and monitoring instruments. Two drawer type, slide-out trays (1 and 3) are mounted in the upper part of the cabinet. These trays contain instruments, controls and protective devices. The front panels of these trays are tiled backward at an angle for improved visibility from a standing position in front of the control cabinet. A third tray (9) without a front panel, contains the voltage regulator and is mounted in the lower compartment to the left of the interior panel. All trays slide in and out easily for adjustment or inspection of internal components. Quick-disconnect wiring connectors allow quick removal and replacement. Trays are supported by slides and nylon rollers which are mounted on the sides of trays and tray compartments. Slides and rollers mate to form a rigid support for trays and to prevent downward tipping when trays are at the limit of the outward travel. A gravity-type retainer latch on each compartment slide prevents the tray from being accidentally pulled from a compartment before the latch is released. The two top trays are retained in their compartments by screw driver operated, adjustable grip latches. June 30/94 Revised 1-l Page 5
1 2 3 4 5 \ \ I -6-7 -7-6 d b 1. Motor Stator Windings 7. Diode 2. Armature Shaft 8. Bearing Cap 3. Generator Stator Windings 9. Spacer 4. Stator Housing 10. Ball Bearing 5. Bearing Bracket 11. Fan 6. Micro Switch (not illustrated) 12. Excciter Fields 13. Exciter Rotating Armature 14. Key Washer 15. Round Nut 16. Fan Hub 17. Fan Housing Motor-Generator Figure 3 1-l Page 6 June 30194 Revised
A hinged Plexiglass cover (6) provides protection for trays while allowing observation of instruments, etc. Motor START-STOP and generator ON-OFF switches and indicating lights are panel mounted just below the trays (See 4, and 10, Fig. 4). Space is provided for mounted an optional second output control panel (5). A single door with key-lock handle provides access to electrical components mounted in the large lower compartment of the cabinet. In addition to the voltage regulator tray, the interior panel is located here. All wiring to and from the panel is routed through quick-disconnect connectors. Cable hangers (11) are mounted on each side of the cabinet. (2) Generator Monitor Tray The generator monitor tray (1, Fig. 4 and Fig. 5) contains generator output monitoring instruments and controls. a. Wiring Harness A wiring harness (1, Fig. 5) with receptacle connector mates with another wiring harness which has a plug connector. These mating connectors provide a quick-disconnect point for all wiring to and from the tray. b. Automatic-Manual Voltage Controls Items covered here are the switch (2), rectifier (4), variable rheostat (7), and variable resistor (6). Automatic or manual control of the generator output voltage is selected by a 4p dt, two-position, toggle switch (2). The generator set is normally operated with the switch in AUTOMATIC position. in this position the switch serves to connect the voltage regulator (Ref. Fig. 4, Item 9) in the exciter field circuit for automatic regulation of the generator output voltage. When the switch is in AUTOMATIC position, all manual voltage controls are disconnected. When the switch is placed in MANUAL position, it serves to disconnect the voltage regulator from the exciter field circuit and connect the manual control rheostat (7, Fig. 5) in its place. Current to the exciter field is the supplied through a rectifier (4), variable resistor (6), and controlled by the rheostat (7). Voltage may be adjusted by turning the rheostat knob (8) clockwise to increase voltage and counterclockwise to reduce voltage. The variable resistor (6) is used to adjust the effective voltage range controlled by the rheostat. c. Excitation De-Energize Relay (EDR) This relay (3, Fig. 5) performs a dual function. It prevents energization of the exciter field and operation of the generator until the motor has reached operating speed. It also stops generator output by removing excitation from the generator and motor fields when the motor STOP switch button is pushed, or when any motor shutdown device functions. d. Ballast Resistors Two, 50-ohm, loo-watt resistors (5) are connected in the exciter field circuit and act as ballast. They are connected in parallel and function during both automatic and manual operation. e. Ammeter The ammeter (9) is a special rectifier type with voltmeter movement and rectangular 4-l/2 inch face. A zero adjusting screw is accessible through a hole just below the instrument in the front panel of the tray. June 30194 Revised l-1 Page 7
1 2 3 4 5 6 1. Generator Monitor Tray 6. Plexiglass Cover 2. Front Panel 7. Interior Panel 3. Generator Protection Tray 8. Test Panel 4. Generator Control Pushbutton 9. Voltage Regulator Panel (No. 1 Standard) IO. Motor Control Pushbutton 5. Generator Control Pushbutton Panel Panel (No. 2 Standard) 11. Cable Hangers Control Cabinet Figure 4 l-l Page 8 June 30/94 Revised
f. Voltmeter The voltmeter (12) is also a rectifier type with rectangular 4-i/2 inch face. It also has a zero adjustment screw accessible through a hole in the front panel. The same voltmeter is used on all units. Its scale marking range is 0 to 300-VAC. The voltmeter indicated phase-to-phase (A-B, B-C, or C-A) generator output voltage as determined by the position of the meter selector switch (11). g. Meter Selector Switch The meter selector switch (11) is a six-position rotary type. It provides a means of selecting and determining which phase amperage or voltage is indicated on the voltmeter and switch phase amperage or load is indicated on the ammeter. Switch positions and equivalent phases monitored by the voltmeter and ammeter are silkscreened on the tray front panel. (See Sect. 1-3, Fig. 2) (3) Generator Protection Tray The generator protection tray (3, Fig. 4 and Fig. 6) contains electrical devices designed to protect the aircraft and generator against damage which could result from overvoltage, undervoltage, underfrequency, etc. A series of indicating lights on the front panel warn the operator when a fault condition exists and also identifies the fault. a. Voltage And Frequency PC Boards The over-undervoltage board (3) and underfrequency board (4) are solid-state devices which receive their signals directly from output circuits. These boards (or modules) sense any abnormal condition of voltage or frequency and signal the solid-state circuitry of the memory and time delay board (2) to open the load contactor and disconnect the generator from the load. Voltage and frequency values at which the boards send a signal are adjustable, however, adjustments must be make ONLY under laboratory conditions. The frequency sensing board is connected for sensing underfrequency. The over-frequency circuitry is not used because it is required only in engine-driven generator sets. A synchronous motor cannot run faster than its designed speed. In this case 1200 RPM for 60-HZ motors and 1500 RPM for 50-HZ motors. A solid-state overload signaling device (Ref. 4, Fig. 12) is also connected to the memory and time delay board (2, Fig. 6) and performs a function similar to the voltage and frequency sensing modules. See Para. 6, C, (1 l), (c) for more specific and detailed information regarding overload device. Factory adjusted trip values for protective circuits are as follows: Overvoltage trips at 130-V to 134-V; resets at 125-V Undervoltage trips at 93-V to 102-V; resets at 11 O-V Underfrequency trips at 375-HZ to 385-HZ Undervoltage time delay (adjustable) 4 to 12 seconds (set at 5 seconds) Overload circuit trips at any value over 125% rated load capacity in 5 minutes, 150% load in 30 seconds, and 200% in 4 seconds. b. Memory and Time Delay Board The memory and time delay board (2, Fig. 6) is sometimes called the protective monitor module. It is a solid-state device with a hermetically-sealed, reed-type relay. The printed circuit board or card is connected to a corresponding sensing circuit in the over-undervoltage board, underfrequency board and overload board. June 30/94 Revised 1-l Page 9
6 1. Wiring Harness 7. Manual voltage control rheostat 2. Automatic-manual voltage control switch 8. Knob 3. Excitation deenergization relay (EDR) 9. Ammeter 4. Rectifier 10. Adjustable grip latch 5. Ballast resistor, 50-ohm, loo-watt 11. Voltmeter-ammeter selector switch 6. Manual control resistor, 50-ohm, loo-watt 12. Voltmeter Generator Monitor Tray Figure 5 1-l Page 10 June 30/94 Revised
12 11 10 9 8 7 6 5 I I I \I I I I HOBART I GENERATOR PROTECTION 1. Fuse-interlock relay 2. Memory and time delay board 3. Over-undetvoltage board 4. Undetfrequency board 5. Reset switch 6. Test switch 7. Hole plug 8. Overload indicating light 9. Underfrequency indicating light 10. Undervoltage indicating light 11. Overvoltage indicating light 12. Fuse, 2-Amp 13. Adjustable grip latch 14. Terminal Board 15. Wiring harness Generator Protection Tray Figure 6 June 30/94 Revised l-l Page 11
All circuits are connected to the module relay coil, and any one of the circuits can energize the coil to open the relay contacts. Thus, when a sensing device energizes any one of the module circuits, the module relay is also energized to break the load contactor holding circuit and allow the load contactor to open. All circuits, except the undervoltage circuit, function immediately to open the load contactor. A time delay system is designed into the undervoltage circuit to prevent nuisance opening of the output. An undervoltage condition which continues un interrupted for a period of 4 to 12 seconds (adjustable) will cause the time delay circuit to open the load contactor. Each of the four circuits is connected to a corresponding indicating light (8 through 11) which is turned on when a fault occurs. The module relay will remain energized (OPEN) and the light will remain On until the reset switch (5) is pushed to break the module 12-V DC circuit, and allow the relay to return to normal, CLOSED position. The overvoltage, undervoltage and underfrequency circuits are self-explanatory and function when one of those faults exist. NOTE: The overload circuit is activated at any value over 125% rated load on the generator [See Para. 6, C, (11)I (c)l c. Indicating Lights (12-15, Fig. 6) Four identical RED indicating lights (8, 9, 10, and 11) are mounted on the front panel of the tray. Their function is to indicate to the operator the abnormal condition which caused the protective monitor system to function and open the load contactor. An indicating light will remain ON until the reset switch (5) is pushed. d. Reset And Test Switches The reset switch (5) and test switch (6) are identical pushbutton switches. The reset switch is used to break the 12-V DC protective system circuit and allow the system to return to normal after a fault condition has caused the system to function. Pushing the switch turns off any indicating light(s) which may be on and allows memory and time delay board relays to reset. The test switch is used to apply 12-V DC directly to all SCR (silicon controlled rectifier) memory circuits for testing each circuit in the memory and time delay PC Board and for testing lamps (bulbs) in their respective indicating lights on the tray front panel. e. Fuse And Fuse-Interlock Relay The function of the fuse-interlock relay (1) is to interrupt the load contactor holding coil circuit and remove the load in case the 12-V protective system operating circuit is disabled by a blown fuse (12). f. Terminal Board The terminal board (14) provides wiring connection points between quick-disconnect connectors on PC Boards, internal components and the wiring harness (15). g. Wiring Harness A wiring harness (15) with receptacle connector mates with another wiring harness which has a plug connector. These mating connectors provide a quick connect-disconnect point for all wiring to and from the tray. (4) Voltage Regulator Tray The voltage regulator (9, Fig. 4 and Fig. 7) is mounted in a pull-out tray similar to the generator monitor and protection trays with the exception that it has no front panel. However, it is protected by the cabinet lower compartment door. l-l Page 12 June 30/94 Revised
The regulator is a solid-state device designed to provide automatic voltage regulation of generator output at the aircraft. It will maintain a constant voltage to within plus or minus 1% of the preset value. The regulator controls output voltage by varying the field power of the exciter as required by load conditions. For details, Static Voltage Regulator, Operation and Maintenance Manual No. TM-759, in Chapter 8. (5) Motor And Generator Control Pushbutton Panels Pushbutton controls for motor and generator are mounted on small separate panels (4 and 10, Fig. 4) just below the trays. (See Fig. 8 and 9). Each pushbutton panels contains two momentary contact switches and an indicating light. Panel components are identical with exception of the indicating light color. Motor RUNNING light is AMBER, contactor CLOSED light is GREEN. When an optional second generator is ordered, a second generator output panel No. 2 is mounted directly to the right of the No. I control panel. (See 5, Fig. 4). (6) Front Panel (Ref. 2, Fig. 4) A fluorescent light (1, Fig. 10) at the top of the front panel provides illumination for instruments and controls mounted in trays. It is controlled by a toggle switch (3). A time totalizing meter (hourmeter) (2) records actual running time and is useful in maintenance scheduling as well as recording total operating time. It is operated by 12-V DC from the generator protection circuit and is turned ON when the motor has reached operating speed and the start-run timer switches have closed. A terminal board (4) is mounted on the back of the panel. Two openings are provided for trays. c. Interior Panel (Ref. 7, Fig. 4) The interior panel (Fig. 11) is mounted on the back panel of the control cabinet. Although it is located in the control cabinet it is not considered to be a part of the cabinet assembly. (7) Contactors Three identical electromagnetic switches or relays that are identified as contactors by the manufacturer are located on the interior panel. The contactor is a sealed unit. Main contacts are 3 p st. N.O. Auxiliary contacts open before main contacts when coil voltage is, removed. Two contactors (17 and 18) function as motor switches. One (18) connects input power to half of motor stator windings for motor starting. After normal motor operating speed has been reached, the second contactor (17) connects the second half of stator windings for running. Both contactors of course remain closed for normal operation. The third contactor (7) serves to connect and disconnect generator output power to or from a load (aircraft, etc.) and is identified as the load contactor. (2) Motor Control Transformer The step-down transformer (5) is used to reduce motor input power to 115~VAC for operation of motor and generator controls. Multiple input taps provide connections for various input voltages from 208-V to 575-V. (3) Generator Control And Plug-Interlock Relays These relays (9 and 10) are magnetic coil operated, enclosed, plug-in type, and are identical except their coil voltage ratings. The generator control relay (9) is energized when the contactor CLOSE switch (See Fig. 9) is pushed. Its purpose is to by-pass the CLOSE switch and connect power for holding the load contactor closed and operating the contactor CLOSED indicating light when the CLOSE switch is released. The relay is de-energized when the OPEN switch is pushed. The plug interlock relay (10, Fig. 11) is energized by 28.5~VDC from the aircraft being serviced. Its purpose is to interrupt the load contactor holding circuit and disconnect generator output in the event that the output cable plug should be accidentally disconnected at the aircraft. This relay also prevents power delivery if the output cable is not properly connected. June 30194 Revised 1-l Page 13
I I I I :0 I I 10 I I t I0 I I I 0 0: 0 0 I 0 I 01 1 f 2 0 8 0 3 4 5 1. Resistor (1000 ohms, 25 watts) 11. Receptacle connector 2. Regulator rheostat 12. Fuse (5 amp) 3. Cable length compensation rheostat 13. Fuseholder 4. Cable size compensation rheostat 14. Receptacle connector 5. On-Off switch, line drop compensation 15. Sensing and preamplifier 6. Chassis assembly, line drop compensation chassis assembly 7. Receptacle connector 16. High-phase sensing board assembly 8. Damping circuit gain potentiometer 17. Reactor 9. Receptacle connector 18. Chassis 10. Damping circuit rate potentiometer 19. Terminal board Voltage Regulator (Top View) Figure 7 l-l Page 14 June 30194 Revised
Motor Control Pushbutton Panel Figure 8 NO. 1 GENERATOR CONTACTOR c START OPEN CLOSED Generator Control Pushbutton Panel Figure 9 June 30/94 Revised l-l Page 15
1. Flourescent light 3. Toggle switch 2. Time totalizing meter (hourmeter) 4. Terminal board Front Panel Figure 10 (4) Aircraft - Test Bank Switch This toggle switch (8) is provided to by-pass the plug interlock relay for servicing an aircraft not equipped with an interlock system, or for supplying power to a load bank used in generator testing. (5) Motor Overload Relay And Transformer Any input voltage change necessitates a change in overload relay heater* elements. I I Three current transformers located on the power input panel (15) lower input current in each input line to a lesser value of definite ratio (500A to 5A) for operation of the motor overload relay (14). The relay is an automatic reset, ambient compensated, bimetallic, thermal, overcurrent type. The reduced current is connected to heater elements in the relay. A set of contact in the relay are connected in series with the motor control transformer (5) which supplies power for operation of motor-generator controls and contactors. Any condition of overload in any input line causes a heater element (elements) to OPEN relay contacts and thus stop the motor by disconnecting the source of power for holding contactors closed. Heater elements must be matched to input voltage (See Sect. l-2, Fig. 15) (6) Rectifier This silicon rectifier (2, Fig. 11) converts 115-VAC output of the motor control transformer (5) to direct current for operation of all contactor (7, 17 and 18) coils which require DC for operating and holding contacts closed. (7) Power Supply (12-DC) The 12-DC power supply (13) is a compact unit which contains a step-down transformer, printed circuit board, etc. required to change 115-VAC input to 12-V DC output. 12-V DC is used for operation of the protective system relay, lights, etc. and the hourmeter. Power from this source is also used by the optional transformer-rectifier. l-l Page 16 June 30/94 Revised
1 23 4 5 6 18-16 1. Voltage regulator (Not part of interior panel) 2. Rectifier 3. Terminal board 4. Wiring harness 5. Motor control transformer 6. Transformer panel assembly 7. Load contactor 8. Aircraft-test bank switch 9. Generator control relay 10. Plug interlock relay Il. E and F leads terminal 12. Neutral terminal 13. Power supply 14. Motor overload relay 15. Motor input terminal panel 16. Wiring harness 17. Motor run contactor 18. Motor start contactor Interior Panel Figure I I June 30194 Revised I-I Page I7