:: i

TM-610 021478

Revised 121180 Revised 050586

,

OPER 3 1

?#A”’ AND MAINTENANCE MANUAL

with I 1 ”

ILLUSTRATED PARTS LIST

PART NO. MODEL NO. RATING

483379- 1

483379-2

483379-3

483379-4

4833794

483379-6

483379-7

for

GATE BOXES

G8M 60-I 60 WA --’

GBM 90-l 90 kVA

GBM 60-l 60 kVA

GBL 60-l 60 kVA

GBM 60-l 60 kVA

GBM 90-l 90 kVA

G8M 60-l 60 kVA i’

HOBART BROTHERS COtiPANY’ : ‘/

POWER. SYSTEMS DIVI~Io~~,~~ “b , ,’ 8 TROY, OHIO 45373

j “~~~~ih~ j ’ , /

U.S.A.

- -

-s-

-r

G&

y-

- - .a

- *.

_ -

-_

--

-

-

. . -4 ..-.-..-- ._.-.........- ----

:, 1,

t

ELECTRIC SHOCK can kill. Do not touch live electrical parts.

ELECTRIC ARC FLASH can injure &yes burn skin cause equipment damage and : 1. ignite combustible material. Do not use power cables to: ' I' '

break load, alnd prevent tools from causing short circuits.

IMJ#&f& PHASE CONNECTION, #A~ALLELING, OR USE can damage this and attached IN equipment.

IM.&ANT: - Protect all operating personnel. Read, understand, and follow all instructiohs in the Operating/Instruction Manual before installing, operating, or-servicing the equipment. available for future use by all operators.

Keep the manual

A. 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.

SHOCK PREVENTION

Bare conductors, electrically-live

or terminals in the output circuit, or ungrounded, 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. equipment, do not work in damp areas.

When inspecting or servicing

dry wood, Stand on a dry rubber mat or

use insulating gloves when dampness or sweat cannot be avoided. Keep clothing dry, and never work alone.

1. 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, and other a plicable

!I codes.

disconnect switch or circuit breaker must A power

e Check the nameplate for volta e,

f frequency,

located at the equipment.

only 3-phase power is availab e, and phase requirements. If

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 this makes the equipment frame electrically HOT, which can cause a fa;aF -slimk.-- --P-P

Alwa s to t K

connect the grounding lead if supplied in a power line cable, e grounded switch box or building ground.

separate groundin lead. If not provided, use a

of the grounding B Ensure that the current (am erage)

ead will be adequate for the worst F capacity

situation. ault cusrent

details. Refer to the National Electrical Code ANSI/NFPA 79 for

Do not remove plug ground prongs. Use correctly mating : receptacles.

2. Output Cables and Terminals

Inspect cables frequently for damage to the insulation and the connectors. not overload

Re lace or repair cracked or worn cables immediately. : Do ca les. i

:

energized. Do not touch output terminal while equipment is :

j)

. I’ :I , ,

3. Service and Maintenance

Instruction 910082 Feb 25186 Revised

Page 1

b; Lock switch OPEN (or remove line fuses) so that power cannot be turned/ON accidentally.

FI -

Fi ma Ul-l

1.

c. Disconnect power to equipment if it is out of service.

d. If troubleshooting must be done with the unit : another person present who is trained in turning

providing or call: iTI

'for first. aid.

EXPLCSION PREVENTICNI'I'

Electrical Short Circuits and Overloads

Overloaded or shorted equipment can become hot enough to cause fires either by self destruction or causing nearby combustibles to ignite. For electrically-powered equipment, in particular, input protection to remove short circuited or heave 3

rovide Primary

equipment from the line. y overloaded

2. Batteries

Batteries may explode and/or give off flammable hydro en and arcing from a ruptured battery can cause fires an 8 ad%Eioni?" acid failures. When servicing, do not smoke, cause sparking, or use open flame near the battery.

3. 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 e uipment may cause fuel expansion overflow. Remove all spilled fuel 9 that penetrates the unit, After clean-up,

MMEDIATELY, including any

fumes away with compressed air. open equipment doors and blow

il. TC -

Ca Pi Ne

i. BC -

IC.FUME PREVENTION

bon monoxide - Engine exhaust fumes can kill and cause health problems. e or vent the exhaust fumes to a suitable exhaust duct or outdoors. ar locate engine exhausts near intake ducts of air conditioners.

ILY INJURY PREVENTION

E % eq ar

F. ME -

Fi / 2 .

ious injury can result from- contact with fans inside some equipment. I t DOWN such equipment for inspection and routine maintenance. When

/

ipment is in o eration use extreme care in doing necessary troubleshooting! adjustment. E o not remove guards while equipment is operating.

ICAL AND FIRST AID TREATMENT

st aid facilities and a qualified first aid person should be available each shift for immediate treatment of all injury victims. Electriq ck victims should be checked by a ph sician and taken to a hospital, ediately if any abnormal signs are o served. 2:

EMERGENCY FIRST AID

short circuits, combustible of batteries and fuel, or

C&l physician immediately. Seek additional assistance and use First Aid techniques recommended by American Red Cross until medical help arrives.

if available, and have victim lie Remove victim* if not

priferably mouth-to-mouth. If massage. Cq$q&rgency Rescue - _I_-

I

fq? e@~wmTdRFTC- ---*- _._ I- __ _I

B.,. .-.. 9:; -;& :I& 1 !I lz IL !irecautlona~ .L aoels on the equi

ii? ent monthly. Order and

.~L-___

abels that cannot be easily rea . -.--.--l-__l"._ ------_-L-

Page 2 Instruction 910082 Revised Feb 25186

TM-61 0

1: I

INTRODUCTION

1. Scope

I contains operating an instructions for a series of AC Gate Boxes manufactured by Ho-

Company, Power Troy, Ohio 45373, U.S.A.

2.’ ,&kpose ’

I I ” ,

’ The purpose of the manual is to provide information and instructions to experienced operators, electricians and technicians who have not previously been exposed to this equipment. The manual is not intended to be a text- book on electricity or electronics.

3. Arrangement

The manual is divided into 6 chapters. Each chapter is divided into sections as required. Each section begins with page 1, and each page is identified by chapter, section and page number in the lower outside corner. Illustration

numbering is also grouped by sections.

When a reference is made to material which is located in the same section, the material is identified by paragraph location only; example: (Para. 1, A). When referenced material appears in a different section, it is identified by

chapter, section and paragraph location; example: (2-l; Para. 1, A). The same method applies to illustrations which are identified by figure numbers; examples: (Fig. 8), or (2-l; Fig. 8).

4. Service Information

If you have any questions concerning your Hobart Power Systems Division equipment, you are invited to contact our Service Department by mail, telephone or TWX .

Write: Hobart Brothers Company Power Systems Division

Service Department Troy, Ohio 45373.

U.S.A.

Call: Area Code. (513) 339-6011

Extension 4276

TWX : 81 o-456-2907

June 12180 Revised

..- 1:

TABLE OF CONTENTS

SUBJECT CHAPTER/SECTION PAGE

Introduction 1

1-o 1

l-l 1

1

1

1

1

3

4

4

4

5

5

5

5

9

9

IO

10

10 /

10

10

IO

j2

: I

Desd \p ‘i,‘n,$peration

li( h.il~ I S)e;cr-i,ption’

1. General

2. Identification

3. Detailed Description

A. Metal Enclosure

B. Indicating Lights

C. Transformer

D. Disconnect Switch

E. Interior Panel Assembly

(1) Control panel assembly

(a) Panel

(b) Overload module

(c) Memory and time delay module

(d) Over-under-voltage module

(e) Power supply system

(f) Fuse-interlock relay

(g) Plug-interlock relay

(h) Test-bank switch

(k) Fault lights test switch

(m) Reset switch

(n) Fuses

(p) Safety switch

.I 0 (q) Receptacle connector

Feb 14178 i

TM-610

1’

* , ‘I f:ik i,: i I

! Contedts /

Page 1

TM-610 I I

:; TABLE OF CONTENTS (CONTINUED)

,SUBJECT ’ CHAPTER/SECTION

(r) Contactor monitor board 1

, I (41, Contactor control circuit resistor

l-l

1 /i~llll I (t) Remote control terminal board

’

,I 1’11 I (2) Load contactor

I , ” ,

(3) Rectifier

(4) Overload transformers and resistors

I F. Spare Lamp and Fuse Board

G. Support Frame

H. Optional Test Box

J. Test Receptacle Connector Kit

K. Optional Mounting Support

Preparation for Use

1. Receipt of Equipment

2. Installation

A. Mounting

B. Input Cable

C. Output Cable

D. Control Leads

E. Grounding

3. Preoperational Check

Operation

1. General

2. Remote Control Box

3. Disconnect Switch and Box Door Operation

l-2

l-3

A. Disconnect Switch Operation 0

Page 2

PAGE

12

12

12

13

13

14

14

14

15

15

15

1

1

1

1

1

t 1

1

4

4

::

’ SUB;ECT

B. Door Operation

: I

TABLE OF CONTENTS (CONTINUED)

CHAPTER/SECTION PAGE

, l-3

‘, C, ‘To Defeat Interlock Syste

1 j/ l~~i’h 1 i ITY ’

; ‘4. Prepaiation for Power Delivery

,;,,) i’;“” Door is Open

/I bl I

5. Power Delivery I 1 ”

,

6. Disconnect Power

Servicing

Maintenance

1. General

2-o

2-l

2. Lubrication

3. Parts Replacement

4. Lamps and Fuses

Inspection/Check

1. General

2-2

2. Inspection Details

Adjustment/Test

1. Adjustment

2-3

2. Test

A. Preparation for Test

B. Test Procedures

’ 3. Test Overload Protective System t

Repair 2-4

1. General

Troubleshooting 3-o

Procedures 3-l

.I !

.I# 44

,I. General ‘w/l :

/

,li ; ill11 ’

Feb 14178 / {

i /

TM-610

,I

:I

Page 3

w TM-610

:: TABLE OF CONTENTS (CONTINUED)

SUBJECT CHAPTER/SECTION PAGE

2. Troubleshooting Chart 1 I

A.

3-l 1

1

B.’ U~,of, Troubleshooting Chart I ,

1

1 ” 3. Equipment for Troubleshooting 1

4. Safety

5. Test Values

Illustrated Parts List

Introduction 4-l

4-o

1

2

1

1. General 1

2. Purpose

3. Arrangement 1

4. Explanation of Parts List 1

A. Contents 1

B. Parts List Form 1

1

(1) Figure-Item No. Column 1

(2) Hobart Part Number Column 2

(3) Nomenclature Column 2

(4) Eff (Effective) Column

(5) Units Per Assembly Column

2

2

5. Reference Designator Index Manufacturer’s Codes

2

I 1 4-2

1. Explanation of Manufacturer’s (Vendor) Code List 1

4-3 1 Parts List

1. Explanation of Parts List Arrangement 1

2. Symbols and Abbreviations .I

,# 4

I ‘u/l :

C ntents P

Page 4

‘,I TABLE OF CONTENTS (CONTINUED)

SUBJECT CHAPTER/SECTION

Nymerical Index

]/I !,&& I planation of Numerical IndeL\ii’i I

4-4

Optiqntrl~iElquipment 5-o ’

I , ” ,

Manufacturer’s Literature 6-O

CHAPTER/ FIGURE SECTION NUMBER

l-l 1

l-l 2

l-l 3

l-l 4

l-l 5 l-l 6

l-l 7

l-l a l-l 9 l-l 10

l-2

l-2 l-2

l-3

l-3 l-3

l-3

2-1

’ 2-l 2-l

2-3 2-3

2-3

Dee 1 l/B0 Revised

1 2

3

1

2 3

4

1 2

3

1

2 3

1

2

1

LIST OF ILLUSTRATIONS

TITLE

Gate Box

Specifications and Characteristics Indicating Lights and Controls

Gate Box Interior

Interior Panel Assembly

Control Panel Assembly

Transformer-Rectifier Assembly

Transformer-Rectifier Connection Diagram

Contactor Monitor Board Spare Lamp and Fuse Block

Typical Installation

Mounting Dimensions

Cable Entry and Connection Provisions

Typical Customer-Furnished Remote Control Box

Disconnect Switch and Door Handles

Locking Mechanism Disabling Levers

Control Panel Assembly

Lamp Chart Fuse Chart Spare Lamp and Fuse Block

Test Box Control Panel Assembly Typical Customer-Furnished Remote Control Box

Control Panel Assembly Troubleshooting Chart (4 Sheets) ; I

/ I, Reference Designator Index illlb ’ I

1 I

TM-610

PAGE

1

1

1

1

PAGE

NO.

2 3

4

6 7

a 11 11 13 14

2

3 4

1

2

3

5

1 2

2

1 3

4

c 3’

Page 5

‘, ,I

CHAPTER/ FIGURE SECTION NUMBER

; ’ 4-3 4-3 // F-1

3 I

’ 4

4-3 5 / 4-3 6

LIST OF ILLUSTRATIONS (CONTINUED)

TITLE

Gate Box Interior Interior Pa&l IAssembly

Control Panel ‘Assembly Transformer and Mounting

Contents I

Page 6

TM-610

PAGE

NO.

2 4

6

a

IO

12

I m I I I I TM-610

1: I

1. General

CHAPTER 1. DESCRIPTION/OPERATION

SECTION 1. DESCRIPTION

This manual provides the information required to install, operate, and maintain a series of gate boxes manufactured

,$&$-@‘ower Systems Division yf jj$pq rt Brothers Company, Troy, Ohio 45373 U.S.A.

; The 400 Hz AC gate boxes covered in this manual are listed by part number as follows: /( 1’11 I 4833791 defines a unit with 575!vblt AC input, and 115/200 volt AC output at 60 kVA.

1 483379-2 defines a unit with 575 volt AC inp,ut, and 115/200 volt AC output at 90 kVA.

483379-3 defines a unit identical to 483379-I except for cable-retaining devices. On this unit, the standard input

cable BX connector and the output cable horn have been deleted and replaced with hole-filler covers. 483379-4 defines a unit with 115/200 volt AC input, and 115l200 volt AC output at 60 kVA.

483379-5 defines a unit identical to 483379-I except for an aluminum enclosure. *

483379-6 defines a unit identical to 483379-2 except for a 60 kVA label. 483379-7 defines a unit identical to 483379-I except for the addition of output controls on the cabinet door.

Each gate box consists of a metal enclosure which houses a large step-down transformer (except 4833794) and

electrical equipment required to monitor and control the output circuit. Power delivery to an aircraft is controlled

by a customer-furnished remote control station.

The gate box is supported by a welded steel frame which provides clearance for routing input, output and control

cables through openings in the floor of the enclosure.

Optional mounting supports are available from Hobart Power Systems Division. One mounting support facilitates

wall mounting the gate box on a Jet-Way passenger ramp.

2. Identification

The units covered in this manual are identical in size and appearance. Exact identification is possible only by con-

sulting the identification plate located inside the cabinet door.

3. Detailed Description

A detailed description of parts used in the construction of the gate box is given below. Main assemblies, or func-

tional groups are listed and components of each assembly or group are then described.

A. Metal Enclosure

The enclosure (6, Fig. I) which houses and protects electrical components is a Hoffman, NEM,A 12 box. The

box is designed for use in outdoor areas and is described as rainproof. The box is equipped with a hinged door

which will swing outward a full 180 degrees. The door is equipped with a three point closing mechanism which

interlocks with a flange mounted disconnect switch operating mechanism located at the right of the door. These two mechanisms, working in conjunction with each other, provide the following safety features:

I 1. Prevent opening of door when disconnect switch is ON. /

2. Prevent switching disconnect switch to ON position unless door is closed and handle is in locked position.

3. Prevent opening of door unless a screwdriver is used to release door handle.

The interior of the box is cooled by a convection flow of air over the transformer and other electrical com-

ponents. Air enters through an opening in the bottom of the box and exhausts through a large opening in the

top. A hood type cover (I, Fig. I) is mounted above the top opening. The cover is flanged downward and ex-,

tends beyond the edges of the upwardly flanged opening to prevent entrance of blowing rain while still,allow-

0 ing a good flow of air. The large opening in the bottom of the box is cov,&ecl by a sheet of expanded,mejal.

,IlIIi~ ’ o’j,u,,.ij: /i I On later production models, a terminal strip (7, Fig. 4) is bolted inside the cabinet on the left side daneI. Thi/s

Bstation terminal str-provides a convenient connecting point for the user’s internal wiring. -~~~~~

Dee 1 l/B0 Revised :L l-l

Page 1

TM-610

X Used on 483379-7 only

!

1. Vent cover 5. Indicating lights (four)

2. Disconnect switch handle 6. NEMA 12 enclosure 3. Door handle x7. Load contactor controls 4. Support

Gate Box

Fig&e 1

w I 1 TM-610

‘: 483379-i, -3, -5, -7 483379-2, -6 4833794

Physical’ ,

(60 kVA) (90 kVA) (60 kVA)

Weight (approx.) 575 pounds (261 kg) 725 pounds (329 kg) 320 pounds (145 kg)

Height (pvepll) 50 inches (1270 mm) 50 inches (1270 mm) 50 inches (1270 mm)

Width (overall)

Dwj$ $jh& )

29 inches (737 ,mrri) 18 inches 1(4bil/ Irjm)

,29 inches (737 mm) 29 inches (737 mm)

18 inches (457 mm) 18 inches (457 mm)

Ele,ct@raf I ! ’

Input Voltage (AC) 575 575 115/200

Frequency (Hz) 400 400 400 Phase 3 3 3

output

Voltage (AC) 115/200 115/200 115/200

Frequency (Hz) 400 400 400

Phase 3 3 3 Capacity 48 kw, 60 kVA, 173 Amps 72 kW, 90 kVA, 261 Amps 48 kw, 60 kVA, 173 Amps

Transformer Not Used

Input 575 V AC, 60.8 Amps, 3 Phase, 575 V AC, 91.9 Amps, 3 Phase, N/A 400 Hz, 60 kVA Continuous 400 Hz, 91.5 kVA Continuous Duty Duty

output 115/200 V AC, 173.2 Amps, 115/200 V AC, 261 Amps, N/A 3 Phase, Full Wave, 60 kVA 3 Phase, Full Wave, 90 kVA

Connection Primary - Delta Primary - Delta N/A Secondary - 4 Wire Wye Secondary - 4 Wire Wye,

Specifications and Characteristics

Figure 2

B. Indicating Lights

Indicating lights (Fig. 3) are mounted in the gate box door.

The three red lights are identical and indicate fault conditions in output circuits. Each light hasjan

identifying nameplate.

The single amber light glows when 115/200-V AC power is available in the box.

On 483379-7 only, a green indicator light glows when the contactor is closed.

NOTE: Spare lamps and fuses are mounted on a block which is focated on the box door near ;

indicating lights (see Para. 3, F and Fig. IO). / ! ’ , / I,

&- -IL ~ , -:------7:&j&y;.l

1 1 I Dee 1 l/B0 Revised l-l 1

Page 3

, Indicator Lights

Pushbuttons

X Used on 483379-7only

TM-610

!PSD-02231

Indicating Lights and Controls

Figure 3

C. Transformer

The 575-volt AC transformer (3, Fig. 4) is mounted on the floor of the enclosure. Its weight is supported by

the channel frame (4, Fig. 1) under the box. The delta connected primary windings of the transformer receive

575~volts AC power from the power source at terminals HI, H2 and H3. The four-wire, wye secondary wind-

ings deliver 115/2,00 volts AC at terminals X0 (Neutral), Xl (A), X2 (B), and X3 (C). (See Fig. 2 for trans-

former ratings.)

D. Disconnect Switch

The AC input disconnect switch (1, Fig. 4) is mounted on the interior panel near the upper right corner.

ltlfeatures an operating mechanism which interlocks with door latching components to prevent opening the box door unless the disconnect switch operating lever is first placed in OFF position. The operating!

mechanism also prevents turning the switch ON when the box door is open. This is a three-pole, non-auto- matic SW&b.

E. Int&ior Panel Assembly

The interior panel assembly (Figure 5) consists of electrical components mounted on a No. 11 gauge, steel

panel (4, Fig. 5). The panel is attached to the rear of the box by four studs and nuts. ! I

0 /

iIll “I ’ I ,

(8 l-l

a

1 ! Revised Dee II/80 /

P ge4 i .,

TM-610

(1) Control panel assembly (see Fig. 6)

: \ (a) Panel

4 ‘,S The control panel (1 ,~i&.i 5) is hinged to provide access to components mounted on the back side

8 and components mounted behind it on the interior panel. It provides mounting facilities for con-

/( 1-l I trols and safety deviices. The panel is secured in closed position by two captive, adjustable grip ’ latches (6, Fig. 6). ”

(b) Overload module

The overload module (24, Fig. 6) is a solid-state device designed to interpret signals from the trans- formers (3, Fig. 5) and to send a signal to the memory and time delay module (21, Fig. 6) when an overload condition exists in the output circuit. A pull-apart electrical connector is mounted on the

overload module. It provides a quick-disconnect facility for all wiring to the module.

The overload module is equipped with a hermetically-sealed, reed-type relay, the contacts of which

are normally open. The solid-state circuitry is designed to close the relay contacts when the output current in ANY phase reaches 125% of normal, rated value. The closed relay sends a signal to the

memory and time delay module. This signal gates the overload SCR (silicon-controlled rectifier) in the module and interrupts the load contactor holding circuit, allowing the load contactor to open.

The following is a list of overload module characteristics:

NOTE: The overload protective system will function when any phase carries 123% to 127% of rated

load. All times are plus or minus 25% and are nonadjustable.

At 125% load the module will function in 5 minutes. At 150% load the module will function in 16 seconds.

At 200% load the module will function in 4 seconds.

NOTE: Gate box components and the aircraft are protected against over and underfrequency by

protective devices in the power source (generator set) which function to cut off power to

the box in the event of a fault.

(c) Memory and time delay module

The memory and time delay module (21, Fig. 6) is sometimes called the protective monitor module

because it receives and acts upon signals from protective devices - namely, the overload and over-

undervoltage modules.

The memory and time delay module is a solid-state device with a hermetically-sealed; reed-type relay.

The printed circuit board includes SCRs (silicon-controlled rectifiers) which act as relays when trig- gered by signals from fault sensing devices. The board includes four memory circuits and a 4 to 12

second time delay circuit. Each memory circuit is connected to a corresponding sensing circuit (over- load, overvoltage, etc.).

Feb 14178

TM-610

1. Disconnect switch

2. Disconnect switch operating handle

3. Transformer 4. Load contactor

u

idI ’ , # 4

l-l

Pa$e 6 -

Gate Box Interior

Figure 4

LPSD-0183 i

5. Interior panel

6. Control panel

7. Terminal strip

TM-61 0

1. ‘Control panel assembly 4. Interior panel 2. Overload burden resistor 5. Silicon rectifier 3. Overload sensing transformer 6. Load contactor

Interior Panel Assembly

Figure 5

t Feb 14178

Page 7

23-

6:

* 1. Heat sink

* 2. Zener diode

* 3. Power supply resistor, 10 ohms, 25 watts

* 4. Load contactor hold circuit resistor, 20 ohms, 25 watts

5. Plug interlock relay

6. Fuse interlock relay

7. Test bank switch

8. Captive screw fastener

9. Fault light test switch

IO. Power supply fuse, 1 ampere

11. Protective system reset switch

12. Load contactor hold circuit fuse, 2 amperes

* Mounted on back of panel

TM-610

13. Test receptacle

*14. Terminal strip, internal connections

‘15. Terminal strip, remote control connections

16. Plexiglass cover

17. Contactor monitor board

* 18. Blocking diode

19. Contactor disable switch / 20. Locking pin

21. Memory and time delay board

22. Over-undervoltage board

“23. Power supply transformer-rectifier

24. Overload board

l- i

Page 8

Control Panel Assembly

Figure 6

r I TM-610 I I

All of the circuits are connected to the module relay coil, and any circuit 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 con-

tactor to ope’n. All circuits,,except the undervoltage circuit, function immediately to open the load

contactor. A time del ,y~system is designed into the under-voltage circuit to prevent nuisance opening

of the contactor und til 6!7& hdit,ions of momentary under-voltage in the generator output. An under-

voltage condition which continues uninterrupted for a period of 4 to 12 seconds (depending upon ad-

justment) will causelthe time delay circuit to open the load contactor. Each of the three circuits is

connected to a corresponding indicating light (Fig. 3) 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 (11, Fig. 6) is pushed to break the module 12-V DC circuit, and allow the relay to return to normal, CLOSED position.

(d) Over-undervoltage module

The over-undervoltage module (22, Fig. 6) is connected to output leads between the transformer and

load contactor. This solid-state module senses any abnormal condition of voltage and signals the solid-state circuitry of the memory and time delay module (21, Fig. 6) to open load contactor and

disconnect output to the aircraft. Trip values are adjustable, however, adjustments should be made ONLY under laboratory conditions.

On 483379&this module- is.connected between the input disconnect switch and the load contactor.

Trip values for the over-undervoltage module are as follows:

Overvoltage trips at 130 V to 134 V. Undervoltage’trips at 192 V or below.

Undervoltage trip time d&y 5%&ds (factory set)

NOTE: Switch (11, Fig. 6) must be pushed after a fault to reset PrOteCtiVe system.

(e) Power supply system

12-V DC power required for operation of the protective system originates from the 115-V AC,

400-Hz, C phase output of the gate box.

The power supply system consists of a transformer-rectifier assembly (23, Fig. 6), Zener diode (2),

and resistor (3). These components are mounted on the back side of the hinged control panel.

The Zener diode is mounted in a heat sink for cooling.

The transformer (3, Fig. 7) steps-down 115-V AC to approximately 24-V AC. The diode-bridge

rectifier (2) then converts 24-V AC to a pulsating 24-V DC. A 3 uF, 50-V capacitor (1) prevents

pulses from reaching zero. Rectifier output is further smoothed and reduced to 12-V\DC by a Zener

diode (2, Fig. 6) and resistor (3, Fig. 6). A terminal board (4, Fig. 7) provides connections for trans- former input and rectifier output leads.

The 115-V AC side of the power supply system is protected by a l-amp fuse (IO. Fig. 6).

A connection diagram of the transformer-rectifier assembly only is provided in Fig. 8: See com- plete connection diagrams in Chapter 6.

,

June 12180 Revised

Page 9

TM-610

:(f) Fuse-interlock relay

The functio’n of the fuse-interlock relay (6, Fig. 6) is to interrupt the load contactor holding coil

circuit and remove the load in case of a blown fuse (10, Fig. 6) in the protective monitor power

! supply circuit. I ,

,I 1 IThe function of the plug-interlock relay (5, Fig. 6) is to cause the output load contactor to open in

thelevent the cable plug conneckor becomes accidentally disconnected from the aircraft during power / delivery, or if an attempt is made to deliver power when the output cable is not connected to the air-

craft. Twenty-eight-volt, direct current for operation of the relay is supplied from the aircraft either through an on-board transformer-rectifier, or from a twenty-eight-volt, electrical system. Connection

from the aircraft to the interlock relay is made through terminal E, or F on the output cable plug connector.

(h) Test-bank switch

This sp st toggle switch (7, Fig. 6) provides a means of by-passing the plug-interlock relay when sup- plying power to a load bank for test purposes, or to an aircraft not equipped with a plug-interlock

system. Without the switch, the load contactor could not be held in closed position for these pur-

poses.

For supplying power to a test (load) bank, the switch is placed in (UP) TEST BANK position. For

supplying power to an aircraft the switch must be in (DOWN) AIRCRAFT position.

(k) Fault lights test switch

The test switch (9, Fig. 6) is a pushbutton snap type. It connects 12-V DC power directly to all

fault lights (Fig. 3) for testing the lamps.

A blocking diode (18, Fig. 6) is used in the light testing circuit. It is mounted on quick-connect termi-

nals on the terminal board (14, Fig. 6).

‘This diode is required to prevent an overload signal from following the test circuit and turning ON

over and undervoltage indicating lights when no voltage fault exists.

NOTE: Similar blocking diodes for over-undervoltage lights are mounted IN the over-undervo’ltage

module (22, Fig. 6).

(m) Reset switch

, A pushbutton switch (11, Fig. 6), identical to the fault light switch, is used to reset the protective monitor system and turn OFF fault indicating lights after a fault condition has caused the protective

system to function.

, (n) Fuses

A l-amp cartridge type fuse (10, Fig. 6) protects the 12-V power SUPPLY SYstem.

A similar 2-amp fuse (12, Fig. 6) protects load contactor operating circui)s. /

1 d~l”i~ ’

1 1

Pa$e 10

1. Capacitor 2. Rectifier

3. Transformer 4. Terminal board

Trancfnrmpr.R.PFtifiPr Accnmhlv

’ -1. .___ Figure 7 _ a.~_~~-

NOTE: RECTIFIER ASSEMBLED AT THIS END. J{

RECT. NOTE: RECTIFIER

F, ASSEMBLED AT THIS END.

“;;(’ I-+

- AC -

115V. AC INPUT 115V. AC INPUT

BLACK

BLACK I / - psicEZ]

TM-610

NOTE: See Diagram in Chapter 6 for connection of Zener diode, resistor and transformer-

rectifier in DC power supply ;system.

Dee 1 l/80 Revised

/ 1

I

Transformer-Rectifier Conntictioh Dia r

Figure 8 ,A fll ’ *

1 1 /

i, Page 11

l-l 1 Pige 12

I w

TM-610

,(p) Safety switch

The switch (19, Fig. 6) functions to,open and disable the load contactor operating circuit and thus

: prevent its closing by operation of a remotely located pushbutton switch. This feature allows an

’ I

electrician to disable the outp ]//I l,~/h($rj (20, Fig. 6) with ball dete

tcircuit and work with output cable in relative safety. A safety lock pull ring is mounted in a guard bracket beside the switch to add

extra’safety and prevent inadvertent actuation of the switch.

// I’)! I To disable the circuit, pull thk safety pin and push switch toggle LEFT to DISABLE position. IN-

SERT safety pin.

WARNING: BE SURE DISCONNECT SWITCH (1, Fig. 4) IS OFF BEFORE WORKING ON ANY COMPONENTS INSIDE THE BOX. OTHERWISE, LETHAL ELECTRICAL SHOCK HAZARD EXISTS.

(4)

(r)

(4

(t)

Receptacle connector

A receptacle connector (13, Fig. 6) is for attachment of a test box (2-3; Fig. 1). Leads are connected

to A, B, C phases and N neutral (ground). The connector is protected by a cap which is attached to

the panel by a chain to prevent loss.

Contactor monitor board

The contactor monitor board (Fig. 9) provides mounting for three light emitting diodes (2, Fig. 9).

Each diode is connected to a single output phase and emits a red light when the phase is energized.

If all three phase lights (A, B, and C) in an output circuit are off, it indicates that the load contactor for the output circuit is open. These lights are also helpful in troubleshooting. For example, if only

two lights are glowing when the contactor is closed, it indicates that one set of contacts in the load contactor is defective and the load contactor should be replaced. If one of the three phase lights re-

mains on when the contactor is open, it indicates that the load contactor contacts for that phase

are stuck, fused together, or otherwise defective and the load contactor should be replaced.

A 10,000 ohm, 10 watt resistor (4) is connected in series with each light emitting diode to reduce

voltage to a value (approximately 1 volt) which will not destroy the diode.

A 400 PRV, 1.5-A silicon diode (3) is connected in parallel with each light emitting diode. This pro-

tection is necessary because the light emitting diode has a near zero peak reverse voltage capacity.

Contactor control circuit resistor

A 20-ohm, 25-watt resistor (4, Fig. 6) is connected in series with components of the load contactor

operating circuit to protect relays, etc., in the event that phase C contacts in the load contactor

should fail to close when remote control box ON button is pushed.

Remote control terminal board

This terminal board (15, Fig. 6) is mounted at the lower edge of the control panel. It has eight,

90 deg., female terminals for connecting remote control box leads. Terminals are protected by a Plexiglass cover (16).

TM-610

I 0 CONTACTOR MONITOR BOARD AY 402935 01

1. Connector 3. Silicon diode, 400 PVR, 1.5 amp

2. Light emitting diode 4. Resistor, 10,000 ohm, 10 watts

Contactor Monitor Board Figure 9

(2) Load contactor

The load contactor (6, Fig. 5) serves to connect and disconnect gate box output power to, or from, the

output cable. The contactor is a sealed unit containing five sets of contacts. The three larger sets conduct

three-phase output. A smaller set is connected in series with the AC protective circuit and supplies 400-Hz

AC to the rectifier (5, Fig. 5) when the load contactor is closed. Another small set of contacts (normally

closed) serve to by-pass an economizer resistor in the load contactor and allow a high voltage to load con-

tactor coil for initial closing. These contacts then open and a reduced voltage is supplied to the coil

through the economizer resistor. Current is conducted to the contactors by cables which pass through

current transformers (3, Fig. 5). These transformers supply a reduced value current to the overload

module. A 16.6-ohm, 25-watt resistor (2, Fig. 5) is connected across each of the transformers.

(3) Rectifier

The silicon rectifier (5, Fig. 5) receives 400-Hz AC from phase C of the generator output and converts

it to a pulsating, direct current for energization of the load contactor holding coil only. This DC coil-

holding circuit is controlled indirectly by controlling the 400-Hz AC to the rectifier. Any time an over- load or over-undervoltage monitor functions to open the memory and time delay relay, the rectifier’s AC circuit is opened. Consequently no DC power is then available to the load contactor coil and the 1

load contactor opens. ! ’ : I

h~1’1 ’ ,

1 I

‘I r’lyl, iI: i I

14 /

Page 13

TM-610

(4) ,Overldad transformers and resistors

Three transformers (3, Fig. 5) are mounted on the interior panel behind the control panel. Each trans-

former senses voltage in an, individual output cable and supplies a reduced voltage signal to the overload

i iyg$y;e;(24n Fig-~c)- ’ ji~lhii’l’

.’ ‘An overload burden resistor (2, Fig. 5) is connected across each transformer. On the 90 -kVA units, the value

pflthis resistor is 16.6 ohms, 25 watts. On the 60 kVA units, the value of this resistor is25,ohms, 25 watts. 1

. . ,. ” /

F. Spare Lamp and Fuse Board

Spare lamps and fuses are provided on a board (see Fig. IO) which is mounted on the gate box door. Three each of 12-V and 120-V indicator lampsare mounted at the top rear of the board. Three each of the I-A and

2-A fuses are mounted in holders on the lower half of the board. A label provides easy identification of lamps

and fuses.

G. Support Frame

Spare Lamp and Fuse Block

Figure 10

The box sits on a support frame (4, Fig. 1) of welded steel channels. The frame allows access for routing cables through the bottom of the box, and allows entry of air for convection cooling.

TM-610

*: H. O’ptional!Test Box

I An optional test box is available for testing the internal circuitry of the gate box. The test box, part number

483347, is covered by Operation and Maintenance Manual, TM-575. : I ,

,,~~J~~$e.$t Receptacle Connector Kid,,I\i’i i

,I 1 ,!F,or those gate boxes not originally equipped with a test box power receptacle connector, a kit is now avail- able. The kit includes all parts required to use 575-V AC gate box input for operation of a test box. Ordering

part number for kit is 483346. /

K.

L.

Optional Mounting Support 1

An optional mounting support, part number 483435, is available for wall mounting the gate box on a Jet-Way passenger ramp.

Integral Controls

On gate box number 483379-7 only, contactor control pushbuttons and an indicator light are added to the

fault lights mounted on the enclosure door. Refer to Figure 3. The CLOSE pushbutton closes the output load

contactor for power delivery, and the OPEN pushbutton opens it. The indicator light labeled CLOSE glows

green when the load contactor is closed, and goes out when it is opened.

Dee 1 l/80 Revised

1 Page 15

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TM-610

‘, ‘,

, SECTION 2. PREPARATION FOR USE

1. Receipt of Equipment

Check the equipment received against, The shipping papers to make certain that the shipment is complete. Check for shipping damag$,(f t, he e UI q ‘p ment has been damaged in transit, notify the carrier at once and damages. If you require assistance,with a damage claim or if the shipment is in error, furnish full in-

I’ ,I

fymation to Hobart Brothers Company at the address given in the Introduction of this manual. , .

, It is recommended that the unit be uncrated as close to the installation site as possible. Use care in uncrating to

avoid damaging the equipment with tools.

2. Installation

The gate box may be installed outdoors without further protection. The heat vent opening and top cover are de-

signed to be rainproof.

Figure 1 illustrates a typical gate box installation using the optional mounting support, Hobart part number

483435. This support is designed for wall mounting the unit on a Jet-Way passenger ramp.

A. Mounting

The gate box may be mounted on a customer-furnished frame or on the optional mounting support illustrated in Fig. 1. The optional mounting support has its bottom flanges predrilled to match the mounting holes in the

base of the gate box. The hole patterns for mounting the gate box base and the optional mounting support are illustrated in Fig. 2.

B. Input Cable

WARNING: MAKE CERTAIN POWER TO BOX CANNOT BE TURNED ON. OTHERWISE, <LETHAL ELECTRICAL SHOCK HAZARD EXISTS.

Route input cable under gate box and through BX connector provided (Fig. 3). Connect input cables to dis ‘connect switch as shown in Installation Connection Diagram, Chapter 6.

C. Output Cable

Route the loose end of output cable assembly through cable horn (Fig. 3) and to load contactor. Connect

cable A, B, C, and N as shown in Installation Diagram (Chapter 6). Connect small interlock lead (No. 12 wire

or larger) to terminal E, F located below control panel.

I ’ D. Control Leads /

Route control leads through cable horn (Fig. 3) in bottom of box and up to control terminal panel (I-l ;

15, Fig. 6). Identify leads and connect to panel according to Installation Connection Diagram, Chapter 6. ’

Locate remote control box according to company regulations. Some types may be secured to output cable

assembly near plug connector.

1

Feb 14178

TM-610

., ,j?@ dl Iii i

1-2

P&e 2

1. Gate box

2. Optional mounting support

Typical Installation,

Figure 1

I 1 TM-610

7

f

x inch diameter (4holesI

8 inches (203mm)

32inches (813mm)

Integral Base Mounting

7

/-

x inch diameter (6 holes)

4- 7 I 13% inches (349mm)

I 13s inches (349mm)

j+--’

;,_i 34 inches (864mm)

Optional Wall Mounting

Using 483435 Bracket

9 16inch diameter

-+ I

31 inches (787mm) lpsD-01841

Pedestal Mounting

Using484141 Pedestal 1 ‘(

Gate Box Mounting Dimensions idI ‘I ‘;’ , ’ ’

Figure 2 /

TM-610

Switch 7

Rectifier Mount With Neutral and EF Terminals.

Ground Lug.

-Case i I

Remote Canfroi Terminals

f Grounding Point

8X Connector * (Input Cable)

Cable Horn * (Output Cable and Control Lsads) IpsD-01811

*Alternate cable entry provisions are available for convenience of installation.

Cable Entry and Connection Provisions

Figure 3

E. Grounding

Ground the box in accordance with National Electrical Code, or in compliance with local code using thi

ground lug or the’alternate grounding point illustrated in Figure 3.

WARNING: DO NOT OPERATE BOX WITHOUT ADEQUATE GROUNDING. OTHERWISE, LETHAL ELECTRICAL SHOCK HAZARD EXISTS.

3. Preoper&tional Check I

A. Test i

The gate box has been tested completely at the factory prior to shipment, and testing at installation is

not,required. However, if testing is desired, refer to 2-3; Para. 2.

B. Check All Wiring

.t Check all wiring for proper connection and terminals for security. Check;following: : ‘1 , I’!,

u/l i Jbh

(1) ‘Input wiring ,11(1”/ ’ .

1 t 1 r’ljhir: <i I

1-2 yevised Jtine 12/8 io ’ 1

Page 4 I,

TM-610

(2) Load contactor output cable

(3) Remote control box wiring

: ’ (4) Test bank switch (I-1 ; 7, Fi .,6! in Al RCRAFT position.

] I/ I!jbiJ: ;,i ’ C.

’ a~l,ri I Wheti all wiring has been determined to be safe, close gate box door and secure. Place disconnect switch in ON

,I 1, I position.

I

1 I , .

1 D. Turn (0.N source of input power. The AMBER indicating light (l-l; Fig. 3) on door and RED light (l-3; 4,

Fig. 1) on control box should GLOW to fndicate power is available.

E. Check operation of load contactor and remote control box.

WARNING: DO NOT TOUCH CABLE PLUG WHEN CHECKING LOAD CONTACTOR. LETHAL

ELECTRICAL SHOCK HAZARD EXISTS.

(1) Press remote control box ON pushbutton,(l3; 1, Fig. 1).

(2) Contactor should close and control box indicating light (l-3; 3, Fig. 1) should glow GREEN as long as

ON pushbutton is held.

(3) Release ON pushbutton. Contactor should open and GREEN indicating light should go OFF because the

output cable is not connected to an aircraft and no DC power is available for holding the plug-interlock relay closed.

NOTE: On 483379-7, the same check can be made using the pushbuttons mounted on the front door.

I& /

i Dee 1 J-180 &-vised

-~ Page 5

- -

- -r

- -.

.-

TM-610

:; SECTION 3. OPERATION

1. General

I

Power delivery from the gate box is controlled by a customer-furnished, remotely located control box. ,i:On

/4S337$-7,-fh&ame controls are m

2; l/@/&$~ bntt-01 80~

nted on the enclosure door. .<

’

// b! I A typical control box is illustrate iI. in Figure 1. There are several types of boxes available. Some are intended for

, attachment to the output cable near the plug connector. All boxes have similar indicating lights and pushbutton

switches, but some have only the contactor closed light without the input power light.

i Dee 1 II80 Revised

3.CONTACTOR ‘CLOSED INDICATING LIGHT

4.lNPUT POWER INDICATING LIGHT

Typical Customer-Furnished Remote’~Confrol t!$ox ’

Figure 1 ,dJ,ll ‘iI ’ !I

,

1 I I*, 1/j,, if ,j I

I I’-3 /

Page 1

TM-610

3. Disconnect Switch and;5ox Door Operation

A. Disconnect Switch Operation I

The sw@ch,handle (1, Fig. 2) can be operated DNLY when the box door is closed and locked. Switch positions are p(ainlymarked on the switch operati g’handle and handle mounting base. The switch is ON when handle is i,n,,&&&ion and RED portion of ha&/$ k no b ’ IS s owing. The BLACK portion of the knob is seen when h the handle is in’DOWN position and the switch is’OFF.

,/ bl I 8. Door Operation

I , I.

/

The door can be opened only when the disconnect switch handle is in OFF position.

(1) Place disconnect switch handle (1, Fig. 2) in OFF position.

(2) Insert blade of a screwdriver in defeater pin (2) slot and turn COUNTERCLOCKWISE about a quarter- turn. Hold pin in this position while turning handle (3) toward edge of door to UNLATCH.

,

UNLOCK

OPEN -

uk

-2

-3

,_-. ‘- 1. Disconnect switch operating handle 2. Defeater pin

3. Door handle

I;3

P A ge 2

\ Disconnect Switch and Door Handles Figure 2 ----L-- -~~!~ ’

I

41\‘i~ ’ , i 1

Feb 14178 /

w TM-610

:;

d. To Defeat Interlock System When Door is OPEN

(I) If door handle is accidentally locked while door is OPEN, LIFT locking lever (1, Fig. 3) to UNLATCH

! 1 handle. ,

\,/I l$E/%: ; I/ !2) T o

while operating handle as desired. // Fll I

is OPEN, hold locking lever extension (2, Fig. 3) DOWN

WARNING: EXERCISE EXTREME CARE WHEN SWITCH IS ON. LETHAL ELECTRICAL SHOCK HAZARD .EXISTS.

Feb 14178

1

- -_ 1. Door handle locking lever

.

2. Switch handle locking lever extension

Locking Mechanism Disabling Levers Figure 3 ; !

._,

/ __I’-

/

1 6 t

illlh ’ , i

/ 1 1

/

w

I , TM-610 I I

,;

4. Preparation for Power Delivery

Before attempting to deliver power to an aircraft, check following:

A.

NOTE: For power delivery to a test bank or to an aircraft not equipped with 28.5-V DC interlock

7 “s$stem, place test-bank switch in TEST BANK position. 1 ”

6. Contactor disable toggle switch (19, Fig. 4) must be in ON position (toggle pointing to RIGHT) and safety

pin (20) installed.

C. Check fault indicating light lamps (in door) by pressing test switch (9, Fig. 4).

D. ’ Close gate box door and LOCK handle.

E. Place disconnect switch handle in ON (up) position.

F. No fault indicating lights should be ON.

5. Power Delivery

To deliver power to an aircraft, proceed as follows:

A. Insert output cable plug in aircraft receptacle. Be SURE connectors are fully mated and secure.

8. Check RED indicating light (4, Fig. 1) in remote control box to make certain power is available.

C. Press ON pushbutton switch (1, Fig. 1). GREEN light (3) will glow immediately and remain ON to indi- cate that the load contactor is closed and power is available at aircraft.

NOTE: In the event that load contactor is OPENED by an overload or abnormal voltage condition,

the reset switch (11, Fig. 4) must be pushed to turn OFF indicating light on gate box door

and return protective system to normal.

Check for cause of fault and correct before continuing operation.

6. Disconnect Power

WARNING: DO NOT DISCONNECT CABLE PLUG WHEN POWER IS ON. LETHAL ELECTRICAL

SHOCK HAZARD EXISTS. ALSO, OPENING CONNECTOR UNDER LOAD CAUSES I ARCING AND PITTING OF CONNECTOR PARTS.

/

A. Press OFF switch pushbutton (2, Fig. 1). Green indicating light (3) will go off, indicating load contactor

has opened and power has been disconnected from the aircraft.

B. Disconnect output cable plug from aircraft.

TM-610

/ 23-

l 1. Heat sink

* 2. Zener diode

* 3. Power supply 10 ohms, 25 resistor, watts

* 4. Load hold circuit resistor, 20 ohms, contactor 25 watts

5. Plug interlock relay

6. Fuse interlock relay 17. Test bank switch

8. Captive screw fastener

9. Fault light test switch

10. Power supply fuse, 1 ampere

11. Protective system reset switch 12. Load contactor hold circuit fuse, 2 amperes

l Mounted on back of panel .-. ~~~ ~~~-

13. Test receptacle

*14. Terminal strip, internal connections

*15. Terminal strip, remote control connections 16. Plexiglass cover

17. Contactor monitor board

*18. Blocking diode

19. Contactor disable switch 20. Locking pin I

21. Memory and time delay board

22. Over-undervoltage board

*23. Power supply transformer-rectifier 24. Overload board

Feb 14178

Control Panel Assembly! !I ’ :/

Figure 4 ,1111’/~ / *

f

i ‘, l’ldl, il’ ,i ’

1 I'-3

/ Page 5

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-- --

.A

TM-610

CHAPTER 2. SERVICING

SECTION 1. MAINTENANCE : I

,I;il&y

,

I I;#,!ji’,’

// F IPI T e gate box requires no maintenance, as such, and should operate for long periods without attention.

1 , . . , 2. Lubrication

No lubrication is required.

3. Parts Replacement

There are no high mortality parts which require periodic replacement, repair or attention.

4. Lamps and Fuses

Lamps and fuses which may require replacement are listed in Figures 1 and 2.

The spare lamp and fuse board is illustrated in Figure 3. Labels on the board provide identification data.

Order new replacement spare lamps and fuses as soon as spares are used.

Light

identification Location

Lamp

Manufacturer

Lam,p (bulb)

Number

Fault lights (all) Gate box door (l-2; Fig. 3) Lamp Industry

Trade Number

12PS8

Power available Gate box door (l-2; Fig. 3) Lamp Industry

Trade Number

12OPSS

NOTE: “Lights” on contactor monitor boards (l-2; 2. Fig. 9) are LED (light emitting diodes). See parts

list, Chapter 4. !

“Contactor CLOSE Gate box door (I-2; Fig. 3) Lamp Industry 1 iOPS8 Trade Number

,

*Used on 483379-T only. ~~~ ---;== ----

Lamp Chart /-- /’ l..., Figure 1

-. ._

Dee 1 l/80 Revised 1 1 I 9-l

‘8 Page 1

Protective monitor

system

Contactor hold

circuit

lqcation

Control panel

(l-4; 10, Fig. 41

Control panel

(l-4; 11, Fig. 4)

Size

2-Amp

1 -Amp

TM-610

Type

AGC (3AG)

AGC (3AG)

Fuse Chart

Figure 2

Spare Lamp and Fuse Block

Figure 3

TM-610

SECTION 2. INSPECTION/CHECK

1. General

requires a minimum of inspection and checking. It is suggested that inspections and checks be co- with those performed on b#e p ower source (generator set). However, it is understandable that a gate

a high volume of traffic will require more frequent inspection than one with moderate usage.

2. /r&&on Details I , .

WARNING: BE SURE INPUT POWER IS OFF. OTHERWISE, LETHAL ELECTRICAL SHOCK

A.

B.

C.

D.

E.

F.

G.

HAZARD EXISTS. 1

Place disconnect switch handle in OFF position and open door.

Inspect ALL lead connections and terminals for security.

Visually inspect all components and connections for discoloration and evidence of overheating.

Inspect all attaching hardware for security.

Inspect door gaskets for defects which could cause leakage.

Use test box to test and check operation of protective systems in accordance with 2-3, Para. 2.

Inspect all switches for proper positioning before closing door.

NOTE: When securing door after inspection, be sure gaskets fit properly.

H. Close door and lock. Place disconnect switch handle in ON (up) position.

i Feb 14178

Page 1

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1.

2. ;

/

TM-610

i SECTION 3. ADJUSTMENT/TEST

Adjustment

has no electrical or components which require adjustment.

Test ’ ,/I I

I , A test box (Fig. I) is required for testing the gate box on location.

A. Preparation for Test

It is assumed that remote control box and output cable are properly connected to gate box.

(I) Place gate box disconnect switch handle in OFF position and open door.

(2) Place circuit breakers (1 and 2, Fig. 1) in OFF position.

(3) Set knob (5) to 115-Volt position.

(4) Attach optional test box cable, part number 483584, to test receptacle connector (13, Fig. 2) on control

panel and to receptacle on rear panel of test box.

1.

2.

3.

i Feb 14178

Output Circuit Breaker Input Circuit Breaker

Voltmeter

Test Box

Figure 1

4. 115-Volt Input Connector 5. Variable Power Transformer Knob

I 1 TM-61 0

(5) $onnect test box input power as follows: I

CAUTION: USE ONLY ONE SOURCE OF INPUT POWER. OTHERWISE, THE TEST BOX WILL

B’E SERIOUSLY DAMAGED.

(ax 115;V AC input power connect,ion, ,

osrtion a mobile, 115-V 1 l;d

AC generator set (self-propelled, etc.) near the gate box. Open receptacle

// cover on test box and connect generator set output cable plug to test box input receptacle (4,

\‘I! I Fig. 1).

Operate generator set to prod&e 115-V AC at output cable. Panel lights on test box will glow.

(b) 575-V AC input power connection

Connect optional test box 575-V AC input cable (part number 483583) to 575-V AC receptacle in gate box and to receptacle on rear panel of test box. Panel lights on test box will glow.

’ (6) Place input circuit breaker (2, Fig. 1) in ON position. Voltmeter (3) will indicate 115 Volts.

B. Test Procedures

I

NOTE: On 483379-7, door-mounted controls may be substituted for remote controls called for in all procedures.

(1) Place output circuit breaker (1, Fig. 1) in ON position. Power available light on gate box will glow.

(2) With generator set running and test box properly connected, the power available indicating light (l-l;

Fig. 3) on gate box door should be ON. Power available light (I-3; 4, Fig. 1) in each remote control light should be ON. If not, check lamps (see 2-1; Fig. 1).

(3) Place test bank switch (7, Fig. 2) in TEST BANK position to by-pass plug-interlock relay and allow load contactor to be closed for testing.

(4) Press and hold test switch (9, Fig. 2). All fault lights (l-l; Fig. 3) on gate box door should glow, indi-

cating that the 12-V power supply transformer, rectifier, etc., are functioning properly; that the memory

and time delay module is functional; and that fault indicating lamps are good. Release test switch.

(5) Check load contactor circuit as follows:

(a) Press remote control box ON switch (1, Fig. 3).

(b) Indicating light (3, Fig. 3) should glow to indicate that load contactor is CLOSED. It also indicates

that rectifier, fuse-interlock relay, and all components of load contactor hold circuit are functioning

properly.

i \

(c) Observe light emitting diode lights on contactor monitor board (1-I ; Fig. 9). If all lights are glowing

it indicates that contacts for all phases (A, B, C) are closed properly. If one or more lights do not

glow, first check light emitting diode. If diode is good, the contactor is defective.

’ (d) Press remote control box OFF pushbutton (2, Fig. 3).

(e) Indicating light (3, Fig. 3) should go OFF to indicate load contactor is OPEN.

, (f) All light emitting diode lights should be OFF. If one or more lights continue to glow, it indicates

that load contactor contacts are stuck or not opening properly. ,ll 1 I ‘iI ’ !

Page 2

TM-610

I 2 3 4 5 6

L \

i63 I \ \

I 2 L: i..

20 I9 \ 1

I8 I7

8 / .

H9

#IO

/I6

* 1. Heat sink

* 2. Zener diode

* 3. Power supply resistor, 10 ohms, 25 watts

* 4. Load hold circuit resistor, 20 ohms, contactor 25 watts

5. Plug interlock relay 6. Fuse interlock relay

7. Test bank switch

’ 8. Captive screw fastener

9. Fault light test switch

10. Power supply fuse, 1 ampere 11. Protective system reset switch 12. Load contactor hold circuit fuse, 2 amperes

13. Test receptacle

*14. Terminal strip, internal connections

*15. Terminal strip, remote control connections

16. Plexiglass cover

17. Contactor monitor board

* 18. Blocking diode

19. Contactor disable switch

20. Locking pin /

21. Memory and time delay board

22. Over-under-voltage board *23. Power supply transformer-rectifier

24. Overload board _----- --- -

./ Control Panel Assembly’;

!

Figure 2 ill11 ’ I

I; , /

Feb 14178 1 1

i /

Page 3

o- R

TM-610

I. ON SWITCH

2. OFF SWITCY

3.CONTACTOR CLOSED ~t&X+,TING

4. INPUT POWER iNNE;TlNG

Typical Customer-Furnished Remote Control Box

Figure 3

(6) Test overvoltage protective circuitry

,(a) Use remote control box to CLOSE load contactor.

’ (b) If test box input voltage is not already 115 V AC, adjust with knob (5; Fig. I). /

--~- -~~

(c) While observing voltmeter(3j turn knob (5) SLOWLY CLOCKWISE to increase voltage. A----

‘(d) At some voltage value between 130 V AC and 134 V AC, the over-undervoltage module and memory and time delay module should function to OPEN load contactor and turn ON overvoltage indicating light (l-l; Fig. 3).

.I (e) Adjust voltage to normal 115 V AC and press reset switch (11, Fig. 2) to turn OFF fault light and

,j# 4

t u/l :

reset protective system. /

ill11 I \ 6

, I’/,

I

I

/1 f/J,! i/ ,j ’

2-3 Feb 14/7 L ’ / Pa e4 A

w ‘ , I TM-610

(7) Test,;undervoltage protective circuitry

Before starting this check, let us. understand the sequence of events which should happen when voltage

is reduced to 102 V or lower. At some value between 102 V and 93 V, the undervoltage sensing module

should function to activate the undervoltage time delay circuit in the memory and time delay module. 1 Five seconds (normal factory septing) after the time delay circuit is activated (if the undervoltage condi-

i 11 ,ibif/: ;i tion continues), it should fuh’~’ c Ion to open the memory and time delay module relay which, in turn, will 1 open load contactors and &op power delivery. As a result of this action, the undervoltage indicating

,/ 111 I light (I-l; Fig. 3) will be yrned ON.

1 , ” /

/ A stopwatch, or sweep-second-hand watch is required for this check. Proceed as follows:

(a) Use remote control box to CLOSE load contactor and reduce voltage to 105 V AC. Undervoltage protective system should not function.

(b) Reduce voltage in steps of 1 V, with a delay of at least 5 seconds between steps. Restart stopwatch or note position of sweep-second-hand each time voltage is reduced. At some voltage value between

102 V and 93 V, and approximately 5 seconds after a new voltage setting is made, the load contactor

should be opened and the undervoltage indicating light should be turned on by the step-by-step ac-

tion of the undervoltage sensing circu’it, time delay circuit, and memory and time delay relay. Under-

voltage indicating light should be turned ON.

(c) Increase voltage to normal 115 V AC, and press reset switch (11, Fig. 2) to turn OFF undervoltage indicating light and reset protective system.

(8) Turn off generator power to test box and disconnect cable plug from test box. Disconnect test box output

cable from gate box.

(9) Place test bank switch (7, Fig. 2) in AIRCRAFT position for normal power delivery to an aircraft.

(IO) Close gate box door and place disconnect switch lever in ON position.

3. Test Overload Protective System

This test is not normally performed on location because a load bank is required, and also because of the difficulty

in applying an accurate load.

It is recommended that the overload module be tested under laboratory conditions.

The overload protective system should function to open the load contactor when the output circuit is carrying

any one of the following loads:

60 kVA unit: 216 Amps, 75 kVA or 60 kW 90 kVA unit: 325 Amps, 112 kVA or 90 kW

i Feb 14178

Page 5

--

-.

- -

-a--

- ;. .

-

-;

TM-610

;

SECTION 4. REPAIR

1. General

WARNING: MAKE CERTAIN THAT PGWER IS OFF AND CANNOT BE TURNED ON ACCIDENTALLY. 1

I/j I&$ !/j OTHERWISE, LETH$l& ECTRICAL SHOCK HAZARD EXISTS.

Re air wil; consist primarily of parts replacement. // 111 I

, I ,

, Protective circuits are designed as easily replaced modules with quick disconnect connectors, etc., and should be

replaced as complete assemblies.

Use connection diagrams in Chapter 6 when replacing electrical components.

If cables are disconnected from the stepdown transformer for any reason, wrap new connections with insulating

tape: EPR, self-amalgamating tape, 1 inch wide by 0.020 thick. Stretch tape approximately 30% when applying,

and overlap each turn 50%. This tape is manufactured by Rotunda in 30 foot (9.1 metre) rolls as catalog No.

2515 and is available from Hobart as part No. 46271.

.I ! ’

. June 12/80 Revised i

1 I - _.._ -~ _.-- - - / Page 1

‘, CHAPTER 3. TROUBLESHOOTING

TM-610

SECTION 1. PROCEDURES

3 1. General

: 1 9

of checking and eliminating possible causes of trouble until the exact the best place to start looking for the cause of a trouble in a circuit

is at the source of power. Continue testing and checking the circuit, step-by-step, in an orderly manner, until /( 1’11 I

thecause of trouble is located,. See applicable connection diagrams and schematic diagrams.

B. This section provides information useful rn diagnosing and correcting certain troubles which cause unsatis- factory operation or failure of the ,equipment.

C. Minor troubles may be remedied by the operator; however, major repairs must be undertaken by experienced

mechanics and electricians only.

I 2. Troubleshooting Chart (See Figure 2)

-- .-

A. Description

The troubleshooting chart lists information under three headings:

(I) Trouble, symptom and condition

(2) Probable cause

(3) Test, check and remedy

B. Use of Troubleshooting Chart

(1) The troubleshooting chart is designed to provide maintenance and repair personnel with a time-saving guide for locating the source of a trouble.

(2) Schematic and connection diagrams are provided in Chapter 6.

(3) Electrical component symbols, which are used on schematic diagrams, are also used in the, troubleshooting chart (in parentheses after the item name) to help maintenance personnel identify parts on the schematic diagrams.

(4) ALWAYS check circuit fuses and the position of switches first in troubleshooting. The incorrect position-

ing of a switch may cause a condition which could be misinterpreted as a fault. ! I

3. Eauioment for Troubleshootina

A good quality multi-scale voltohmmeter and a test box are important tools for good troubleshooting.

4. Safety

WARNING: EXERCISE EXTREME CARE TO AVOID CONTACT. WITH HIGH VOLTAGE LEADS AND : ’

.I COMPONENTS. LETHAL ELECTRICAL SHOCK HA#ZAR,D EXISTS.

,j4@ , /

‘U/l : 4 illlh ’ I )ii

, I’/, i ti’/J,, ir’ ,I ’

June 12/80 Revised t 1 311

i /

Page 1

1 I

‘,

5. Test Values ’ j

TM-610

Overload relay trips at dny value above 125% of rated load in 5 minutes or less.

1(6Q b)!fA unit: 216 Amps,’ 75 kVi+ qr,6Cl kW)

;,(qw+ unit: 325 Amps, 112 kV&$gO kW)

Overvdlt?qqjrFuit functions at 130 to 134, V AC, resets at 125 V AC.

’ , ”

Undewoltage circuit functions at 102 to 93 V AC, resets at 110 V AC.

Undervoltage time delay circuit functions in 4 to 12 seconds (is factory set at 5 seconds).

#ii ’ 3-l

1 Page 2

TM-610

/ 23-

* 1. Heat sink

* 2. Zener diode 13. Test receptacle

* 3. Power supply resistor, 10 ohms, 25 watts * 4. Load contactor hold circuit resistor, 20 ohms, 25 watts

5. Plug interlock relay

6. Fuse interlock relay

I 7. Test bank switch

8. Captive screw fastener

9. Fault light test switch 10. Power supply fuse, 1 ampere

1,l. Protective system reset switch 12. Load contactor hold circuit fuse, 2 amperes

*14. Terminal strip, internal connections

*15. Terminal strip, remote control connections

16. Plexiglass cover

17. Contactor monitor board

*I 8. Blocking diode

19. Contactor disable switch /

20. Locking pin I

21. Memory and time delay board

22. Over-undervoltage board “23. Power supply transformer-rectifier

24. Overload board

1 I c TM-610

‘,

TROUBLE, SYMPTOM ’

AND CONDITION PROBABLE CAUSE TEST, CHECK, AND REMEDY

’ LOAD CONTACTOR CONTROL CIRCUIT I I

is operated from remote stations, any troubles will be detected first at a station. Before the gate box as a source c/filbtouble, check the remote control box thoroughly by checking in-

switches, and circuitry. It is assumed’that all external sources of trouble (generator set, etc.)

haye been eliminated before using thp chart. I

1. Amber indicating light

(DS701) on gate box

door does not glow when

it is known that power is available at gate box

” ,

A. Lamp burned out

B. Disconnect switch (S726) OFF

or defective

input. C. Transformer (T721) defective

2. Indicating light (DS721 on remote control box

does not glow when it is known that power is

1 NOTE: The light is either not, receiving power, or some component in the light

circuit is OPEN.

A. Relay in memory and time delay module (K728) (21, Fig. 1) OPEN

available at gate box. Lamp is good. Load

contactor will not close.

3. Load contactor (K701)

(l-l; 4, Fig. 4) will not

close when remote ON button is pushed.

Contactor closed light (DS721) is ON.

I

3-1

Q ,age4

A. Check lamp and replace (see l-l ; Fig. 3).

B. Check switch. ,Replace if defective.

C. Check transformer windings. Replace if

defective.

B. Blown fuse (F702) (12, Fig. 1)

in load contactor circuit

C. Contactor disable switch (S721) (19, Fig. 1) in DISABLE position

or defective

B. Defective coil in load contactor (K701) (1-I ; 4, Fig. 4)

B. Use terminals Y and X to test coil.

Resistance should be approximately 660 ohms., If coil is defective, replace ,#’

’ : I

cornpIe,?@ Ikid contactor. .

Troubleshooting,Chart (Sheet 1 of 4) I ’ / Revised Dee 11180 i

Figure 2 /

A. Check as follows:

(1) The relay may have been opened by

a fault condition in the output

circuit. Press reset switch (S710)

(11, Fig. 1).

(2) Check resistance across terminals 10 and 11 on memory and time

delay module receptacle connector (J71 I)., If resistance is infinite, in-

dicating an OPEN relay, replace

module (K728) (21, Fig. 1).

B. Check and replace fuse. ’

C. Check switch. Position properly, or

replace if defective.

NOTE: If power-available light is ON, it eliminates from suspicion several components

which could prevent contactor closing (see Trouble 2 above). ’ . .

A. Defective silicon rectifier

(CR7011 (l-l; 2, Fig. 7) A. Check rectifier output. Should be a

pulsating 115-V DC. Replace rectifier if defective.

TM-610

TROUBLE, SYMPTOM

AND CONDITION PROBABLE CAUSE TEST, CHECK, AND REMEDY

LQAD:CQNTACTOR CONTROL CIRCUIT (CONTINUED)

])/I ‘1)Yrhi’lJ’ !,I/

,3. Load contactor (K701)

’ b!l1 I

C. Defective contacto’r close relay

,I(?-1;4, Fig. 4) will not

close when remote ON

(K728) (l-l ; 4, Fig. 5) ”

button is pushed. Con-

tactor closed light (DS721) is ON. (Con-

tinued)

C. Check relay coil and contacts. Replace

relay if defective.

4. Load contactor will

close but OPENS as

soon as control box

ON button is re-

leased.

A. A component in the load con:

tactor hold circuit is defective

(1) Output cable not properly plugged into aircraft

A. Check as follows:

(1) Connect output cable plug to aircraft

receptacle securely so that com-

ponents are fully mated.

(2) Defective E and F terminals

,’ in cable plug connector or

receptacle

(2) Inspect plug and receptacle thoroughly.

Repair or replace as required.

(3) Aircraft not supplying 28.5 V

DC to plug-interlock relay

(3) Check aircraft onboard equipment to

make certain that aircraft will accept power and return 28.5-V DC power to terminals E or F on output terminal panel.

(4) Defective plug-interlock relay

(K707) (6, Fig. 1)

(4) If contactor will remain closed when

test bank switch (S701) (7, Fig. 1) is

in TEST-BANK position, replace plug-

interlock relay.

(5) Small contacts in load con- (5) Connect a jumper lead’between termi- tactor (K701) not functioning nals 1 and 2 on load contactor (see

to connect power to fuse- connection diagram, Chapter 6). If

interlock relay (K720) load contactor will now remain closed,

I I

replace complete load contactor. /

CAUTION: DO NOT OPERATE UNIT WITH ANY COMPONENT(S) JUMPERED EXCEPT FOR TESTING.

B. Fuse (F701) (10, Fig. 1) blown,

preventing fuse-interlock relay

closing

B. Check fuse and replace if blown.

Dee 1 l/80 Revised Troubleshooting Chart (Sheet 2 of 4) ;

Figure 2 3-1

Page 5

m I 1 ,. .

TM-610

‘,

TROUBLE ‘SYMPTOM ’ AND CONDITION PROBABLE CAUSE TEST, CHECK, AND REMEDY

LOAD CONTACTOR CONT

5. Load contactor opens

during power delivery.

No fault lights are ON.

3-1

b age 6

IL CIRCUIT (CbNTlNUED, ,

C. ~;~%Ja6f@$(erlock relay

,I.

I , . .

D. A component of the 12-V DC power supply is defective

(I) Defective transformer

(T719) (23, Fig. 1)

(2) Defective rectifier (C R736) (23, Fig. 1)

(3) Defective capacitor (C707) (l-l; 1, Fig. 7)

(4) Open resistor (R704) (3, (4) Check resistor and replace if defec- Fig. 1) tive.

(5) Defective Zener diode

(CR739) (2, Fig. 1)

A. Output cable has been accidentall\ disconnected from aircraft

B. If load contactor cannot be closed for operation, a compo- nent in the contactor operating circuit has failed

Troubleshooting Chart (Shee Figure 2

C. Check as follows:

(1) Be sure power is available for operat-

ing relay. Press test switch (S727)

(9, Fig. 1). If fault lights do NOT

glow, look for trouble in 12-V DC

power supply system (see Trouble 4, C below). lflights glow, proceed to step (2). ,

(2) Check fuse-interlock relay coil and contacts. Replace relay if defective.

D. If fault lights do NOT glow when test

switch is pushed, check 12-V DC

system.

(I) Check transformer primary and

secondary windings. If defective, replace transformer.

(2) Rectifier output should be a pul- sating 24-V DC. Replace if defective.

(3) A defective capacitor will allow power supply output to reach zero volts. Check capacitor and replace

if defective.

(5) Check diode. Replace if defective.

A. Reconnect cable plug securely and pro-

ceed with power delivery.

B. Check load contactor operating circuit

in accordance with TROUBLES 1 thru

4 above.

t ! Revised Dee 11180 1 /

TM-610

TROUBLE, SYMPTOM

AND CONDITION PROBABLE CAUSE TEST, CHECK, AND REMEDY

Load contactor opens

during power delivery.

Overvoltage indicating

light (DS727) is ON.

Goad contactor opens

during power delivery.

Undervoltage indicating

light (DS727) is ON.

9 Dee 1 l/80 Revised

A.

B.

C.

A.

B.

A.

B.

’ I’ et-load condition has caused ~!&!&tactor to open

dne of the resistors (R727, R728,

R729) is open circuited (see

I-l ; 2,, Fig. 5)

Defective overload module

(K721)

A temporary condition of over-

voltage may have signaled over-

undervoltage module to open contactor

Defective over-undervoltage

module (K727) (22, Fig. I)

A temporary condition of under-

voltage (lasting more than 5

seconds) may have activated

the under-voltage protective

circuit

Defective over-undervoltage

module (K727)

Troubleshooting Chart (Shea ‘.__ Figure 2 _.-_

A.

8.

-

C.

A.

B.

A.

B.

Open gate box door and press reset

switch (11, Fig. 1). Correct condition

that caused overload.

An open resistor will cause higher than

normal voltage signal to overload module

(K721). Check resistor and replace as

required.

A load bank is required for checking

overload module. (Refer to 2-3; Para. 3.) Replace module (K721) if defective.

Open gate box door and press reset

switch (11, Fig. I). With disconnect

switch in ON position, check voltage

in each phase at test receptacle con-

nector (J712) (13, Fig. I). If voltage

is abnormally high, correct condition

before operating gate box.

Use test box to test overvoltage pro-

tective circuitry. Refer to 2-3; Para. 2, A and B. Replace module (K727)

if defective.

Open gate box door and press reset

switch (11, Fig. 1). With disconnect

switch in ON position, check voltage

in each phase at test receptacle (J712)

(13, Fig. 1). If voltage is abnormally

low, correct condition before operating

gate box.

Use test box to test undervoltage

circuitry. Refer to 2-3; Para. 2, A

and B. Replace module (K727) if

defective. /

- -

-c-

i_-

.

TM-610

CHAPTER 4. ILLUSTRATED PARTS LIST

SECTION 1. INTRODUCTION

1. General

Parts List identifi,esi#&ribes, and illustrates main assemblies, subassemblies, and detail parts of _

of Gate Boxes manufactured by Hobart Brothers Company, Power Systems Division, Troy, Ohio 45373.

/I c-’ I I 1 ” I

2, Purpose

The purpose of this list is to provide parts identification and descriptive information to maintenance and provision-

ing personnel for use in provisioning, requisitioning, purchasing, storing, and issuing of spare parts.

3. Arrangement

Chapter 4 is arranged as follows:

Section 1 - Introduction

Section 2 - Manufacturer’s Codes

Section 3 - Parts List

Section 4 - Numerical Index

4. Explanation of Parts List

A. Contents

The parts list contains a breakdown of the equipment into assemblies, subassemblies, and detail parts. All parts of the equipment are listed except:

(1) Standard hardware items (attaching parts) such as nuts, screws, washers, etc., which are available com- mercially.

(2) Bulk items such as wire, cable, sleeving, tubing, etc., which are also commercially available.

(3) Permanently attached parts which lose their identity by being welded, soldered, riveted, etc., to other parts, weldments, or assemblies.

B. Parts List Form

This form is divided into five columns. Beginning at the left side of the form and proceeding to the right,

columns are identified as follows: 1 /

(1) FIGURE-ITEM NO. Column

This column lists the figure number of the illustration applicable to a particular parts list and also identifies each part in the list by an item number. These item numbers also appear on the illustration.

Each item number on an illustration is connected to the part to which it pertains by a leader line. Thus

the figure and item numbering system ties the parts lists to the illustrations and vice versa; The figure and

’ index numbers are also used in the numerical index to assist the user in finding the illustration of a part

when the part number is known. I ! ’ ‘: /

June 12/80 Revised

1

I I 411 3

Page 1

TM-610

(2) ‘HOBART PART NUMBER Column

ALL part numbers appearing in thiscolumn are Hobart numbers. In all instances where the part is a pur-

chased item, the vendor’s identifying five-digit code and his part number will appear in the NOMENCLA-

TURFi coiumn. Vendor by Hobart will be identified as such in the NOMEN-

column. In case not have an identifying part number for a purchased part, the

II reflect No Number and the vendor’s number will be shown in

the NOMENCLATURE column. Parts manufactured by Hobart reflect no vendor code or part number in

tht ‘NGMENCLATURE column. !, I

(3) NOMENCLATURE Column

The item identifying name appears in this column. The indenture method is used to indicate item re- lationship. Thus, components of an assembly are listed directly below the assembly and,indented one space. Vendor codes and part numbers for purchased parts are shown in this column. Hobart modifica- tion to vendor items is also noted in this column.

(4) EFF (Effective) Column

This column is used to indicate the applicability of parts to different models of equipment. When more

than one model of equipment is covered by a parts list, there are some parts which are used on only one

model. This column is used for insertion of a code letter A, B, etc., to indicate these parts and to

identify the particular model they are used on. Uncoded parts are used on all units.

Parts in this list are coded as follows:

Parts coded A are used on 483379-l only. Parts coded B are used on 483379-2 only.

Parts coded C are used on 483379-3 only.

Parts csded D are used on 483379-4 only.

Parts coded E are used on 483379-5 only.

Parts coded F are used on 483379-6 only. Parts coded G are used on 483379-7 only.

(5) UNITS PER ASSEMBLY Column

This column indicates the quantity of parts required for an assembly or subassembly in which the part appears. This column does-not~ne=sarily reflect the total used in the complete enditem---- ---- .~

5. Reference Designator Index

The reference designators listed in Figure 1 are the same as those used on the connection and schematic diagrams

furnished in Chapter 6.

Each reference designator is cross-referenced to the Figure and Item number of that item in the Illustrated Parts

List, Section 4-3.

RkF. LOC.

DES. ITEh

Cy$ll I CR706 CR707

CR708 CR721

CR722 CR723

CR736 CR737

CR739

1 I

13

26

26

26 26

26 26

1

21

23

DS701 8,9, 10

DS706 5,6,7 DS726 5,6,7 DS727 5,6.7

F701 F702

F707

F708

14

14

35

35

K701 11 K707 13 K720 10 K721 4 K727 7 K728 8

R704 2

R705 3 R712 26 R713 26- R714 26

R727 6,7 iR728 6,7 R729 6,7

s701

s710

sj21

S726 S727

17

15

17

20

15

I

ION

FIG.

5

4

5 5

5 5 5 5

5

5

5

2

2

2

2

5

5

5 5

4

5 5 5

5

5

5

5

5 5 5

4

4

4

5 5

5

4

5

Dee 11 I80 Revised

lr REF.

: DES. T

4 ~t,!&4

T705 T706

1 T719 T721

LOC, ITEk

Al

5 5

5

1

12,13

-ION

FIG.

Reference Designator lndek

Figure 1 ill ’

REF.

DES.

T

TM-610

LOC ITEF

ION

FIG.

- -

-r-

.

SECTION 2. MANUFACTURER’S CODES

1. Explanation of Manufacturer’s (Vehdor) Code List

CODE VENDOR’S NAME AND ADDRESS

00779 AMP Inc. P. 0. Box 3608 Harrisburg, Pennsylvania 17105

Anchor Rubber Company

840 S. Patterson Blvd.

Dayton, Ohio 45402

02231

02660

03743

04713

05277

08108

09332

120992

13103

codes with names and addresses for suppliers of purchased parts

with the Federal Supply Codes or Manufacturer’s Catalog-

ing Handbook H4-1, and are arranged in numerical order. Vendor codes are inserted in the nomenclature column

qIo#t& parts list directly following the item name and description. In case a manufacturer does not have a vendor

code, the full name of the manufacturer will be listed in the nomenclature column.

I

TM-61 0

1

Feb 14178

Amphenol Corporation 2801 S. 25th Avenue

Broadview, Illinois 60153

Appleton Electric Company 1713 W. Wellington Avenue

Chicago, Illinois 60657

Motorola Semiconductor Products Inc. 5005 East McDowell Rd.

Phoenix, Arizona 85008

Westinghouse Electric Company

Semi & Conductor Dept.

Youngwood, Pennsylvania 15697

Lamp Industry Designations and Abbreviations for Lamps

Aerofast Inc.

P. 0. Box 324

Wheaton, Illinois 60187

Hewlett Packard P. 0. Box 38289

San Francisco, California 94138

Thermalloy Company Inc.

P. 0. Box 34829 2021 W. Val[ey View Lane

Dallas, Texas 75234 ;; -,Ir,)I.; ,-I

, ,I’/,

, 1 $‘lj,,.$ ,I ’

// F 4-2 /

‘, Page 1

CODE .>

14280

24248

27‘191

28520

44655

50603

70611

71400

73559

77342’

,#,,I& ’ 4-

f Page 2

1 TM-610

VENDOR’S NAME AND ADDRESS

Square D Company Distribution Equipment Div.

1601 Mercer Rd. Lexington, Kentucky 40505

Magnetic Components Inc.

290 Fischer St.

Costa Mesa, California 92627

South Chester Corporation

South Company Division 3rd Street & Governor Printz Boulevard Lester, Pennsylvania 19113

Cutler-Hammer Inc.

Power Distribution & Control Div.

4201 N. 27th Street

Milwaukee, Wisconsin 53216

H EYCO Heyman Manufacturing Company

1000 Michigan Avenue

Kenilworth, New Jersey 07033

Ohmite Manufacturing Company

3601 W. Howard Street Skokie, Illinois 60076

H.B. Electrical Mfg. Co. Inc. 1125 National Pky. Mansfield, Ohio 44906

Ark-Les Switch Corporation

51 Water

Watertown, Massachusetts 02172

Bussman Mfg. Division of McGraw & Edison Company

2536 W. University Street

St. Louis, Missouri 63017

Carling Electric Inc.

505 New Park Avenue

West Hartford, Connecticut 061 IO

American Machine & Foundry Company

Potter & Brumfield Division

1200 E. Broadway P. 0. Box 522

Princeton, Indiana ;47570 !I

! Revised June 12/8b ’

CODE ;

80368

89110

89373

91637

91929

97520

98410

June 12180 Revised

VENDOR’S NAME AND ADDRESS

Sylvania Electric Products Inc. 730 Third Avenue

,

I I;d,[ii”’

New York, New York 10017

Jaymar Terminal Boards, Inc.

I 1 25-27 Brutus Street

” I Weedsport, New York 13166

AMP Inc.

155 Park Street Elizabethtown, Pennsylvania 17022

United States Rubber Company

Detroit, Michigan

Dale Electronics Inc. P. 0. Box 609

Columbus, Nebraska 68601

Honeywell Inc. Building Controls and Components Group

Micro Switch Division

Freeport, Illinois 61032

Basler Electric Company P. 0. Box Rt. 143 Highland, Illinois 62249

E.T.C. Inc. 990 E. 67th Street Cleveland, Ohio 44103

TM-610

Page 3

.-

SECTION 3. PARTS LIST

1. Exolanation of Parts List Arransement

TM-610

will appear on a left-hand page and the applicable parts list will Unless the list is unusually long, the user will be able to look at the illustra-

ti n and read the parts list without turning a page. /I crli I

?. Symbols and Abbreviations

I ,

”

The following is a list of symbols and abbreviations used in the parts list.

*

A, or AMP - AC -

AR -

DC - Fig. -

hd. -

hex -

Hz -

I.D. - IN -

kVA -

~~~ IJF- No. -

NHA -

PRV - PSI -

Ref - TM - T-R -

V-

Item not illustrated ampere alternating current

as required

direct current

Figure head

hexagon Hertz (cycles-per second)

inside diameter inch

kilovolt-ampere

microfarad

number next higher assembly

peak reverse voltage pounds per square inch reference (the item has been listed previously) Technical Manual

transformer-rectifier

volt (when used as a prefix to a five-digit number, indicates vendor code)

NOTE: An item which does not reflect an index number is an assembly which is not illustrated in its assembled -, state, or it is similar (right-hand, left-hand, top, etc.) to an item which is illustrated.

~~ _-.-~

1 Feb 14178

Page 1

w I 1 TM-610

575-Volt Gate Box

Figure 1

!

,Ibl’i~ ’ .

t Revised Dee 1 II8 /

FIGLRE : HJBART

ITEM NO. PART NO.

l- 483379-l : 1 2 '. 483379-2

I

483379-5

1

2

3

4

5

6 7

8

9

10

11

12

13 *

*

* *

*

Y’

*

* * * t

483379-6

483379-7

No Number

483028-I

483028-2

483390

77A-1022

77A-1153

77A-1020

77B-1025-15 77B-1025-3

77B-1025-5

77B-1025-4

483435

77B- 1025-6

77B-1025-7

No Number

No Number 402987

484141

484966

484967 484968

484969 484970 48497 1 485327

Dee 1 l/80 Revised

I I TM-610

NOMENCLATURE UNITS

1234567 EFF

‘BOX, GATE, 575 V ASSEMBLY (60 KVA)

Bf)T;GATE, 575 V ASSEMBLY (90 KVA)

1;#? I ’ X GATE, 575 V ASSEMBLY (60 KVA) PEDESTAL

MOUNTING NO INPUT OR OUTPUT

BOX, GATE, 575 V ASSEMBLY (60 KVA) LESS

!, TRANSFORMER, 225 A CIR. BRKR. _- ..- BOX, GATE, 575 V ASSEMBLY (6Ol<yAT_wlTH

ALUMlNtiM BOX BOX, GATE, 575 V ASSEMBLY (90 KVA WITH

60 KVA LABEL) BOX, GATE, 575 V ASSEMBLY (60 KVA) WITH , PUSHBUTTONS . BOX, STEEL, NEMA 12 ASSEMBLY (For Details

See Fig. 2) . LIGHT, PILOT, FAULT, ASSEMBLY (For Details

See Fig. 2) . LIGHT, PILOT, POWER AVAILABLE, ASSEMBLY

(For Details See Fig. 2) . SUPPORT, MOUNTING, ASSEMBLY (For Details

See Fig. 2) . KIT, MECHANISM, CLOSING, DOOR (For Details

See Fig. 3) . KIT, MECHANISM, OPERATING (For Details See

Fig. 4) . KIT, MECHANISM, OPERATING (For Details See

Fig. 4)

. NAMEPLATE, OVERLOAD

. NAMEPLATE, OVERVOLTAGE

. NAMEPLATE, POWER AVAILABLE

. NAMEPLATE, UNDERVOLTAGE

. SUPPORT, MOUNTING (WALL)

. NAMEPLATE, CLOSE

. NAMEPLATE, OPEN

. CONTROL GROUP (For Details See Fig. 2)

. GATE BOX INTERIOR (For Details See Fig 3)

NAMEPLATE, HOBART

: SUPPORT, MOUNTING (PEDESTAL)

. NAMEPLATE, RATING

. NAMEPLATE, RATING

. NAMEPLATE, RATING

. NAMEPLATE, RATING

. NAMEPLATE, RATING

. NAMEPLATE, RATING

. NAMEPLATE, RATING

A

B

C

D

E

F

G

ABCEFG

D

G /

G

G

A B C!

D E F

G

per ASSY

REF

REF

REF

REF

REF

REF

REF

1

3

1

1

1

1

1

1

1

1

1 REF

2

1 REF

REF

1 REF

1 1

1

1 1 1 1

TM-610

Box Assembly

Figure 2

/ ! ’ / I,

illi / I 1

Revised Dee 1 I/ /

; FIGURE HOBART

ITEM NO. PART NO.

2- , 1 1 No Number

\77D-1147

,( !‘#I I

/ 2

3

4

5

6 7

8

9 10

7’7D-1037

, 485322

483405A

483408A

483390 483028-I 77A-1026-I

77A-1028-1

No Number 483028-2

77A-1026-2

77A-1028-2 No Number 77A-1027 403091-7

No Number 77A-1036-I

15

16

17.

18

. BOX, ALUMINUM

!. 1 BOX, STEEL

. COVER, OPENING, TOP, ASSEMBLY

. DUCT, AIR, ASSEMBLY

. SUPPORT, MOUNTING ASSEMBLY

. LIGHT, PILOT, FAULT, ASSEMBLY

. . LENS (RED) V14280, No. R-9

. . BASE, 17 AMPS, 12 V. V14280, No. KP-32

. . LAMP, 12 PSB. VO8108

. LIGHT, PILOT, POWER AVAILABLE, ASSEMBLY

. . LENS (AMBER) V14280, No. A-9

. . BASE, .025 ‘AMPS, 120 V. V14280, No. KP-38

. . LAMP, 120 PSB VO8108

. . CAP VI4280 CLASS 9001, TYPE KU-27

. PLUG, HOLE V28520, No. P-1500

. CONTROL GROUP (For NHA See Fig. I)

. . PUSHBUTTON, CONTACTOR CLOSE V14280, No. KR-2B-HI3

77A-1036-2

77A-1167

483028-3

77A-1026-3 77A-1028-2

. . PUSHBUTTON, CONTACTOR OPEN

V14280, No. KR-2R-HI3 . . CAP, PROTECTIVE, PUSHBUTTON

V14280, CLASS 9001, TYPE KU7

. . LIGHT, CONTACTOR CLOSE ASSEMBLY

. . . LENS (GREEN) V14280, No. G-9

. . . BASE, .025 AMPS, 120 V. V14280,

No. KP-38 400613-12 . . . LAMP, 120 PSB VO8108 77A-1027 . . . CAP V14280, CLASS 9001, TYPE KU-27

,

Dee 1 l/80 Revised ‘I i

NOMENCLATURE

;I 234567 EFF

BOX;STEEL, NEMA 12 ASSEMBLY (For NHA See

!Etz

‘l,,‘i ’ re 1) 2 *

X, STEEL ABCDF

E

G

G

G

G

G

G G

G

G

G /

TM-610

UNITS

per ASSY

REF

1

1

1

1

1

1 3 3

3

3

1

1

1 1

4 2

REF

Page 5

:;

I

I ,

c’. #

-

-

TM-610

FIG’bRE : ::

HOBART

ITEM NO. PART NO. 1234567

3- No Number

a

400613-I 1 /I ‘I/ I

, 400613-12

,

*

*

*

*

*

*

*

*

w

*

*

*

*

*

0

*

*

UJ

+

*

5 483235

6 483236

7 W-l 1434

8 w-11166-1 9 W-l 1166-9

IO 77A-1022

11 77A-1023

12 77B-1151

13 77B-1154

14 483400

15

16

401911-8

6OA- 1000

400533

IOOGH-117

No Number

W-l 0079-7

W-9760-1 88 W-9760-189 W-9760-1 90

W-9648-303

w-9350-21 7

W-9648-308

W:9648-304 w-9350-21 7 W-9648-308

W-9648-305 w-9350-21 3

W-9648-308

W-9648-306

w-9350-205 W-9648-307

W-9350-206

8

Dee ?I /80 ‘-Revised

1 TM-610

NOMENCLATURE UNITS

per ASSY

GATE BOX INTERIOR (For NHA See Figure I)

. P4NE,L,:INTERlOR ASSEMBLY (For Details See Fig. 4)

. ,P $., INTERIOR ASSEMBLY (For Details See Fig. 4)

. B D, MTG., FUSES & LAMPS ASSEMBLY

. . LAMP, PILOT LIGHT, 12 PSB, V80368

. .!LAMP, PILOT LIGHT, 120 PSB, v80368

. . LABEL, SPARE FUSES & LAMPS

. . BOARD, MiG., FUSES & LAMPS

. . FUSE, HOLDER V71400 No. 4407

. . FUSE, AGC 2A, FAST BLOW

. . FUSE, AGC IA, FAST BLOW ’ . KIT, MECHANISM, CLOSING DOOR VI4280

CLASS 9423, TYPE M4 . KIT, MECHANISM, CLOSING DOOR VI4280

CLASS 9423, TYPE M3

. TRANSFORMER, 60 KVA (For Details See Fig. 6)

. TRANSFORMER, 90 KVA (For Details See Fig. 6)

. CHANNEL, MTG. TRANSFORMER (For Details

See Fig. 6) . STRIP, TERMINAL V88223, No. 441-8

. LUG GROUND

. NAMEPLATE, GROUND HORN & CABLE CLAMP ASSEMBLY (For Details

’ See Fig. 6) . TRANSFORMER & MObNTING (For Details See Fig. 6)

CONNECTOR, BX (For Details See Fig. 6)

: CABLE ASSY, POWER ELECTRICAL (No. 101) CABLE ASSY, POWER ELECTRICAL (No, 102)

: CABLE ASSY, POWER ELECTRICAL (No. 103) CABLE ASSY, POWER ELECTRICAL (No. 104)

: CABLE ASSY, POWER ELECTRICAL (No. 104)

. CABLE ASSY, POWER ELECTRICAL (No. 104)

CABLE ASSY, POWER ELECTRICAL (No. 105)

: CABLE ASSY, POWER ELECTRICAL (No. 105) CABLE ASSY, POWER ELECTRICAL (No. 105)

: CABLE ASSY, POWER ELECTRICAL (No. 106) . CABLE ASSY, POWER ELECTRICAL (No. 106)

CABLE ASSY, POWER ELECTRICAL (No. 106)

: CABLE ASSY, POWER ELECTRICAL (No. 107) CABLE ASSY, POWER ELECTRICAL (No. 107)

: CABLE ASSY, POWER ELECTRICAL (No. 108)

. CABLE ASSY, POWER ELECTRICAL (No. 108)

EFF

ACDEG

BF

ACEG

BF

ABCEFG

ABDFG

ABQi=G ABCE,FG ABCEFG ABCEFG

ACEG-

BF D,

ACEG

BF

D ACEG

BF D

ACEG B!

ACDEG BF

REF

1 1

1

3

3

1 1

6 3 3

1

1 REF

1 1 1

1

1

1

1

1 1

1 1 1

1 1

1

1

1

Page 7

TM-610

! interior Panel Assembly i I I hi

Figure 4 illi ’ I

I

FlGbRE ’

:;

HdBART

ITEM NO. PART NO. 1234567

4-

8 9

10 11

12

13

14

15 16

17

18

19

20

21

483415 483416

483417

1483401

483380 ’ ICZ-148

481959-1

481959-2 481958 40191 I-3 483413 404518

483436 404065-2

402119-8

DW-1704 W- 11097-8

AW-626

A-25

77A-1021

77B-1152

778-l 024

77A-1153

77A-1020

Dee 1 l/80 Revised

i

w 1

NOMENCLATURE

PANEL, INTERIOR ASSEMBLY (For Details See Fig. 3)

. PANEL,‘INTERIOR

. BFJ;&l$ET, MTG., RIGHT ASSEMBLY

. BRACKEf, MTG., LEFT ASSEMBLY

. P

.P

NEL, CONTROL ASSEMBLY (For Details See Fig. 5)

.RhNSFORMER, CURRENT V14831, No. E-6170

. RESISTOR, OVERLOAD ASSEMBLY 16.6 OHMS

. RESISTOR, OVERLOAD ASSEMBLY 25 OHMS

. BRACKET, MOUNTING, RESISTOR

. BLOCK, TERMINAL V88223, No. 441-3

. BRACKET, MOUNTING, RECTIFIER

. CONTACTOR, LOAD V50603 No. HB200B

. LABEL, PHASE

. RECTIFIER, SILICON V04713, No. SDAl0270-1

. SCREW, 1/4-20x J-1/2, HHC, ST.

. BUSHING, INSULATING

. SCREW, 318-16 x 2, HHC, ST.

. BUSHING, INSULATING

. WASHER, INSULATING

. KIT, MECHANISM, HANDLE V14280, CLASS 9422,

TYPE Al

. BREAKER, CIRCUIT V14280, TYPE FAL 36000,

100 A. 600 V. AC, 3 POLE

. BREAKER, CIRCUIT V14280, TYPE KAL 36000,

225 A. 600 V. AC, 3 POLE

. KIT, MECHANISM, OPERATING V14280, CLASS 9422, TYPE RN-1

I KIT, MECHANISM, OPERATING V14280; CLASS 9422, TYPE RP-1

TM-610

UNITS

per EFF ASSY

REF

1

1 1

1

3 ACDEG 3

BF 3

3 3 1 1

1 1

1

1 1

1

4

1

AB-C%% 1

D 1

ABCEEd 1

D 1

Page 9

8,

27.

!5 16

TM-610

I \ \ \ \ \ 28 I7 2L- I9 -26-L I

.I Control Panel Assembly ,, ! ’ :

8 Figure 5 / li illlh ’ I /

4-3 I

Page IO /

I ‘8

w

TM-610

I

FIGSURE HOBART

ITEM NO.’ PART NO.

5- 48&80-F+ 1

121 ; ,’ 480887A W-454 1 B

I,ltd\i’i ‘2 w-4541 c

‘387738A

,I5 C’ I I 402037-g

6 1 7

8 9

* *

IO

11 *

12

13

14 *

*

15

16 17

18 19 20 21 22

23

24

25

26 *

27

* 28 76A-1123-1

i 29 482257

30 77A-1010

31

I , s2

33

34

*

’ 401556

482038 387736B 16DA-4052-O 363771-5 363770-I 16DA-4004A-10

16DA-4253-1

400785-7 76A-1115

16DA-4004A-3

402658

W-l 1166-9

W-l 1166-1

76A-1118

403336 402662 401564-5

400480-2 401937-4

1 CZ-93B

483026

ICZ-271-9

410539 401937-2

482935 404424 401564-l

77A-1011

483039

48338 1 401564-4

401566-I 1

w-11166-1

40008 1

May 5/86 Revised

1234567

NOMENCLATURE UNITS

per EFF ASSY

: PANEL, CONTROL ASSY (For NHA See Fig. 4)

. TRANSFORMER, SUPPLY, POWER, ASSEMBLY

.+ESISTOR, IO 0HM, 25 W V44655, No. 0363

I;~~EsISTOR, 20 OHM, 25 w V44655, NO. 0364B

REF

1 1

1

. BOAFiD, OVERLOAD, 12 V., ASSEMBLY 1

I * GROMMET, RUBBER V02231, No. AGW-4211 2 ” (. MOUNT, SHOCK, RUBBER V89373, No. B-323 20

. BOARD, OVER-UNDERVOLTAGE, ASSEMBLY 1

. BOARD, MEMORY&TIME DELAY, ASSEMBLY 1

. SOCKET, RELAY VO2660, No. 77-MIP-I.1 2

. SLEEVING, PLASTIC, l/8 I.D. 8

. SLEEVING, PLASTIC, 3/16 I.D. 2

. RELAY, FUSE INTERLOCK, ASSEMBLY V77342,

No. KAP-14DY 1

. RETAINER, SPRING, RELAY 2

. RIVET, BLIND, DOMED HEAD, ST 4

. LATCH, ADJUSTABLE GRIP V24248, No. 48-99-126-11 2

. RELAY, PLUG INTERLOCK ASSEMBLY V77342,

No. KAP-14DG 1

. HOLDER, FUSE V71400, No. HKP-HH 2

. FUSE, AGC IA 1

. FUSE, AGC 2A 1

. SWITCH, SNAP, PUSHBUTTON V27191

No. SA35BCB34-9 2 . RING, LOCKING, SWITCH V91929, No. TS10020 2 . SWITCH, TOGGLE V73559, No. 2GK71-73 2 . HOUSING, SOCKET, CONNECTOR V89110, No. l-480438-0 1 . TERMINAL, QUICK CONNECT VOO779, No. 41274 2 . STRIP, TERMINAL V98410, No. 35018-3526 1 . DIODE, SILICON V05277, No. IN4820 1 . HEAT, SINK DIODE, ZENER V13103, No. 6423 1 . DIODE, ZENER 50 WATTS V04713, No. IN3314A 1 . TERMINAL, FEMALE 90° V70611, No. 3000825 8 . STRIP, TERMINAL V98410, No. 35008-3526 2 . BOARD, MONITOR, CONTACTOR 1 . . DIODE, LIGHT EMITTING, RED V120992, No. 5082-4655 3 . HOUSING, SOCKET, CONNECTOR V89110,

No. l-480270-0 1 . PIN, SWITCH DISABLE V09332, No. C5-1.3R 1 . GUARD, SWITCH TOGGLE i 1 . RECEPTACLE, PANEL, CONTROL VO2660

No. MS3 102A-18-20P 1 . CAP & CHAIN ASSEMBLY VO2660, No. 9760-18 I . COVER, PLEXIGLASS 1 . PANEL, CONTROL 1 . HOUSING, SOCKET, CONNECTOR V89110

No. l-480287-0 :2 . TERMINAL, SOCKET V891 IjO, No. 6q619-1 I -

. FUSE, AGC 2 A I ‘j

. RETAINER; FUSE, IN-LINE ,llll / 1 6

G, “I * Gj r’/, Ji iI’ ,I ’

I 1 413

Page 11

TM-610

03

I.

.h Transformer and Mounting 0

Figure 6 /

Page 12

FIG’LRE I :;

HOBART ITEM NO. PART NO.

6-

, 4 5

6 7

8

No Number

77B-1151

r77B-1154

483400

IOOGH-117

IOOGH-121

7J-422-O

IOOGH-118 W-l 0079-7 483492

&h,,ljl~ ’ Dee 3 l/80 Revised

i

NOMENCLATURE

1234567

‘TRANSFORMER & MOUNTING (For NHA See

, ~ANSFORMER, 60 KVA, v97520, NO. ~~-16365-00 ~ANSFORMER, 90 KVA, v97520, NO. BE-16269-00

. CHANNEL, MOUNTING TRANSFORMER

!, ) HORN &CABLE CLAMP ASSEMBLY

. . BRACKET

. . CLAMP

. . HORN ASSEMBLY

. CONNECTOR, BX V03743, No. 7486

. COVER, INPUT&OUTPUT

TM-610

UNITS

per EFF ASSY

REF 1 --ACEG 1

1 BF 1

ABGEFG 2 -ABDEG 1

1

1

1 yPBPFG 1

c... 4

TM-610

1.

‘, SECTION 4. NUMERICAL INDEX

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 fetter A would be located at or near.‘the top of the index list. Likewise a part number 9 would be listed near

,/I #$$i of the list and far below ah&-t number 1000. The figure number and item number location of the part

’ IS directll/,opposite the part. If the part is used in more than one place, each location is listed commencing with

(, t#e first location the part is liste ‘r’-,

1

, NUMERICAL INDEX

PART NUMBER

A-25

AW-626

BOX, ASSEMBLY

DW-1704

GATE BOX INTERIOR

LAMP

TRANSFORMER &MOUNTING

W-l 0079-7

W- 11097-8 W-l 1166-1

W-l 1166-9

W-l 1434

W-4541 B

w4541c

w-9350-205

W-9350-206

w-9350-21 3 w-9350-21 7

W-9648-303

W-9648-304

+ W-9648-305

/ W-9648-306

W-9648-307

W-9760-1 88 W-9760-1 89

W-9760-1 90 ’ ICZ-148

ICZ-271-9 1 CZ-93B IOOGH-117

June 12/80 Revised

FIGURE AND

ITEM NUMBER

4-18 0

4-17

l-l

2-o

4-15

1-o 3-o 2-7

2-10

3-o 6-O

6-7 3-o

1-16 5-o 3-8 5-o 3-9 3-7

5-2

5-3

3-o

3-o

3-o

3-o

3-o

3-o

3-o

3-o

3-o i

3-o

3-o

3-o 4-5 5-23 5-21

6-O ’ /

/

itlit I / I

/ Page 1

PART NUMBER

IOOGH-118

IOOGH-I?1 , 16DA-4

IGDA-tfj

0 '-3;

&d2 "lllb (

16DA-4052-0

16DA-&&I' ,

363770-I

3631)71-5

386781 387736B

387738A 400480-2

430533

400613-I 1 400613-12

400785-7

401556 401561-I 401564-4 401564-5

401566-I 1 40191 l-3 40191 I-8

401937-2 401937-4

402037-g

402119-8 402658 402662

402987

403091-7 403336

404065-2

404424

404518

410539

481958

481959~1

48 1?59-2

482d38 482257

482935

483026 483028- 1

483028-i

,# 4 ‘Ill umerical Inhex

4-4

Pa)e 2

NUMERICAL INDEX (CONTINUED)

FIGURE AND

ITEM NUMBER

1

I i;,,,(‘i’

6-6 64

5-13

5-10

5-9

5-11

5-o

5-o 5-l

5-8 5-4 5-19

3-o 3-3

3-4

5-o

5-6 5-27 5-34 5-18

5-o 4-9 3-15

5-25

5-20 5-5

4-14 5-14 5-17

I-O

2-o

5-16

4-13

5-o

4-l 1

5-24

4-8

4-6

4-7

5-7

5-29

5-26

5-22 2-o l-2

I-O 2-o

I ,

TM-610

‘,

I

PART NUMBE’R

483039

483234 I

\lj@f~~ (

$1 gg;;:;

483379-3

483379-4

483379-5 483379-6

483380

483381

483390

483400

483401 483405A 483408A 483413

4834 15

483415-I 4834 15-2

483416

483417

483435 483436

483492 484141

484966

484967

484968

484969

484970

484971 7J-422-O

76A-1115

) 76A-1118

, 76A-1123-I I

77A-1010

t

77A-1011

77A-1020

77A-1021 ’ 77A-1022

‘77A-1023 77A-1026-I

.I

,c 4 ‘j/l i Dec’l l/80 Revised

i

1 NUMERICAL INDEX (CONTINUED)

FIGURE AND

ITEM NUMBER

5-32

3-o 3-5

3-6

I-O I I " I I-O

I-O

I-O

I-O

I-O

5-o ) 4-4

5-33 24

6-3 3-14

4-3

2-2 2-3 4-10

4-o 3-l

3-2

4-l

4-2

I-IO 4-l 2 6-8

I-O

I-O 1-o

I-O

I-O

I-O

1-O 6-5

5-12

5-15

5-28

5-30

5-31

I-O 4-19 3-10 l-4 3-l 1

2-5

TM-610

Page 3

I

PART NUMBER

: 1

;;;:;Jgg;, ) ,;

77A-1628-l ’

77A-i 025+21 / 77A-1153 ’

,

778-l 024

778-l 025-4 778-l 025-3 77B-1025-5 778-1025-15

778-l 151

778-l 152

778-l 154

77D-1037

77D-1147

8OA- 1000

1 I TM-610

NUMERICAL INDEX (CONTINUED)

FIGURE AND > ITEM NUMBER

2-8 2-11

1 t ” I

2-6 2-9 4-21 1-5

4-o 1-9 l-7

l-8 1-6

6-l 3-12

4-20

6-2 3-13

2-o

2-I

3-16

The following .part numbers were added to up-date the numerical index:

W-l 1166-I 5-35

400081 5-36

400613-12 2-17

483028-3 I-O

483379-7 1-o

485322 2-1

485327 I-O

77A-1026-3 2-15

77A-1027 2-18

77A-1028-2 2-16

77A-1036-I 2-12

77A-1036-2 2-13

77A-1167 2-14

77B-1025-6 I-11

77B-1825-7 l-12

I

Pjge 4 /

1

NAME : 1

CHAPTER 5. OPTIONAL EQUIPMENT

PART NUMBER MANUAL NUMBER

Ji// Idbi*/ !,i Mpunting Bracket l jtliii’r’ ~483435 :

,( 1, ,I , Test Box 48334KC TM-575 ’

I , ~~ ” I

, Test Box Harness

(575-Volt Input Cable) 483583

Test Box Harness

(I 15-Volt Output Cable) 483584

Kit, 575-Volt Receptacle Connector 483633

Feb 14178

i

TM-610

Page 1

--

-.

-_

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CHAPTER 6. MANUFACTURER‘S LITERATURE

Hobart Diagraps:

’ i&k25 - Gate Box Schematic

,/ bl I 1

( ,483441 - Control Panel Connection ” I

483442 2 Interior Panel Connection

48i443 - Installation Connection

Hobart Diagrams for 483379-4 only:

484514 - Gatk Box Schematic

484515 - Interior Panel Connection _

484516 - Installation Connection

Hobart Diagrams for 483379-7 only:

485323 - Gate Box Schematic

485324 - Interior Panel Connection

TM-610

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II& l-l/80 Revised I

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