PowerMaster 500048A-301, 500048A-302, 500048A-312, 500048A-311 Operation And Maintenance Manual With Illustrated Parts List

OM-2089A

9-21-00

Operation and Maintenance Manual

with

Illustrated Parts List

for

Series 500048A

45 kVA

Solid State Frequency Converters

Hobart Brothers Company

Ground Power Division

Troy, Ohio 45373

U.S.A.

WARRANTY

HOBART BROTHERS COMPANY TROY, OHIO 45373

GROUND POWER DIVISION

1. Hobart Brothers Company (hereinafter called HOBART) warrants that each new and unused Hobart Ground Power

Equipment, (hereinafter called the PRODUCT) is of good workmanship and is free from mechanical defects,
provided that (1) the PRODUCT is installed and operated in accordance with the printed instructions of HOBART,
(2) the PRODUCT is used under the normal operating conditions for which it is designed, (3) the PRODUCT is not
subjected to misuse, negligence or accident, and (4) the PRODUCT receives proper care, lubrication, protection,
and maintenance under the supervision of trained personnel.

2. This warranty expires 15 months after shipment by HOBART to the first user, or 12 months after installation,

whichever first occurs.

3. This warranty does not apply to: primary and secondary switch contacts, cable connectors, carbon brushes, fuses,

bulbs, and filters unless found to be defective prior to use.

4. Hobart DOES NOT WARRANT THE FOLLOWING COMPONENTS: Engines (gasoline or diesel),storage

batteries, engine starters generators, alternators, regulators, governors, tires, axles,transmissions, and cable
retrieving devices. Many of the foregoing components are warranted directly by the manufacturer to the first user
and serviced by a worldwide network of distributors and others authorized to handle claims for component
manufacturers. A first user’s claim should be presented directly to such an authorized component service outlet.
In the event any component manufacturer has warranted its component to HOBART and will not deal directly with
a first user then HOBART will cooperate with the first user in the presentation of a claim to such manufacturer.
Under NO circumstances does HOBART assume any liability for any warranty claim against or warranty work done
by or in behalf of any manufacturer of the foregoing components.

5. This warranty is extended by HOBART only to the purchaser of new PRODUCTS from HOBART or one of its

authorized distributors. The PRODUCTS purchased under this warranty are intended for use exclusively by the
buyer and his employees and by no other persons and, therefore, there shall be no third party beneficiary to this
warranty.

6. A claim of defects in any PRODUCT covered by this warranty is subject to HOBART factory inspection and

judgment. HOBART’S liability is limited to repair of any defects found by HOBART to exist, or at HOBART’S option
the replacement of the defective product, F.O.B. factory, after the defective product has been returned by the
purchaser at its expense to HOBART’S shipping place. Replacement and exchange parts will be warranted for the
remainder of the original Warranty, or for a period of ninety (90) days, whichever is greater.

7. UNDER NO CIRCUMSTANCES whatsoever shall HOBART and its authorized distributors be liable for any special

or consequential damages, whether based on lost goodwill, lost resale profits, work stoppage impairment of other
goods or otherwise, and whether arising out of breach of any express or implied warranty, breach of contract,
negligence or otherwise, except only in the case of personal injury as may be required by applicable law.

8. Continued use of the PRODUCT(S) after discovery of a defect VOIDS ALL WARRANTIES.

9. Except as authorized in writing, this warranty does not cover any equipment that has been altered by any party

other than HOBART.

10. THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HERE OF.

HOBART MAKES NO WARRANTIES, EXPRESSED OR IMPLIED, OF MERCHANTABILITY OR FITNESS FOR
A PARTICULAR PURPOSE.

11. HOBART neither assumes nor authorizes any person to assume for HOBART any liability in connection with the

PRODUCTS sold, and there are no oral agreements or warranties collateral to or affecting this written Warranty.

This warranty and all undertakings of HOBART thereunder shall be governed by the laws of the State of Ohio,
United States of America.

AT ALL TIMES, SAFETY MUST BE CONSIDERED AN IMPORTANT FACTOR IN THE INSTALLATION,

SERVICING AND OPERATION OF THE PRODUCT, AND SKILLED, TECHNICALLY QUALIFIED

PERSONNEL SHOULD ALWAYS BE EMPLOYED FOR SUCH TASKS.

WARNING

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

Safety Warnings and Cautions

WARNING

IMPORTANT

1.

General

Equipment that supplies electrical power can cause serious injury or death, or damage to other
equipment or property. The operator must strictly observe all safety rules and take precautionary
actions. Safe practices have been developed from past experience in the use of power source
equipment. While certain practices below apply only to electrically-powered equipment, other practices
apply to engine-driven equipment, and some practices to both.

2.

Shock Prevention

Bare conductors, terminals in the output circuit, or ungrounded, electrically-live equipment can fatally
shock a person. Have a certified electrician verify that the equipment is adequately grounded and learn
what terminals and parts are electrically HOT. Avoid hot spots on machine. Use proper safety clothing,
procedures, and test equipment. The electrical resistance of the body is decreased when wet,
permitting dangerous currents to flow through it. When inspecting or servicing equipment, do not work
in damp areas. Stand on a dry rubber mat or dry wood, and use insulating gloves when dampness or
sweat cannot be avoided. Keep clothing dry, and never work alone.

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

ELECTRIC ARC FLASH can injure eyes, burn skin, cause equipment damage,

and ignite combustible material. DO NOT use power cables to break load and
prevent tools from causing short circuits.

IMPROPER PHASE CONNECTION, PARALLELING, OR USE can damage
this and attached equipment.

Protect all operating personnel. Read, understand, and follow all instructions in
the Operating/Instruction Manual before installing, operating, or servicing the
equipment. Keep the manual available for future use by all operators.

a. Installation and Grounding of Electrically Powered Equipment

This equipment must be installed and maintained in accordance with the National Electrical Code,
ANSI/NFPA 70, or other applicable codes. A power disconnect switch or circuit breaker must be
located at the equipment. Check the nameplate for voltage, frequency, and phase requirements. If
only 3-phase power is available, connect any single-phase rated equipment to only two wires of the
3-phase line. DO NOT CONNECT the equipment grounding conductor (lead) to the third live wire of
the 3-phase line, as this makes the equipment frame electrically HOT, which can cause a fatal
shock.

Always connect the grounding lead, if supplied in a power line cable, to the grounded switch box or
building ground. If not provided, use a separate grounding lead. Ensure that the current (amperage)
capacity of the grounding lead will be adequate for the worst fault current situation. Refer to the
National Electrical Code ANSI/NFPA 70 for details. Do not remove plug ground prongs. Use
correctly mating receptacles.

September 21, 2000 Saftey Warnings

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PoWerMaster ADV / Series 500048A / Solid State Converter

b. Output Cables and Terminals

Inspect cables frequently for damage to the insulation and the connectors. Replace or repair
cracked or worn cables immediately. Do not overload cables. Do not touch output terminal while
equipment is energized.

Service and Maintenance

3.

This equipment must be maintained in good electrical condition to avoid hazards stemming from
disrepair. Report any equipment defect or safety hazard to the supervisor and discontinue use of the
equipment until its safety has been assured. Repairs should be made by qualified personnel only.
Before inspecting or servicing this equipment, take the following precautions:

a. Shut off all power at the disconnecting switch or line breaker before inspecting or servicing the

equipment.

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

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

d. If troubleshooting must be done with the unit energized, have another person present who is trained

in turning off the equipment and providing or calling for first aid.

4.

Fire And Explosion Prevention

Fire and explosion are caused by electrical short circuits, combustible material near this equipment, or
unsafe operating conditions. Overloaded or shorted equipment can become hot enough to cause fires
by self destruction or by causing nearby combustibles to ignite. For electrically-powered equipment,
provide primary input protection to remove short circuited or heavily overloaded equipment from the
line.

5.

Bodily Injury Prevention

Serious injury can result from contact with live circuit components inside this equipment. Shut DOWN
this equipment for inspection and routine maintenance. When equipment is in operation, use extreme
care in doing necessary troubleshooting and adjustment.

6.

Medical and First Aid Treatment

First aid facilities and a qualified first aid person should be available for each shift for immediate
treatment of all injury victims. Electric shock victims should be checked by a physician and taken to a
hospital immediately if any abnormal signs are observed.

EMERGENCY

FIRST AID

7.

Equipment Precautionary Labels

Inspect all precautionary labels on the equipment monthly. Order and replace all labels that cannot be
easily read.

Safety Warnings September 21, 2000
Page 2

Call physician immediately. Seek additional assistance. Use First Aid
techniques recommended by American Red Cross until medical help
arrives.
IF BREATHING IS DIFFICULT, give oxygen, if available, and have victim lie
down. FOR ELECTRICAL SHOCK, turn off power. Remove victim; if not
breathing, begin artificial respiration, preferably mouth-to-mouth. If no
detectable pulse, begin external heart massage. CALL EMERGENCY
RESCUE SQUAD IMMEDIATELY.

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

Introduction

This manual contains operation and maintenance information for Hobart PoWerMaster ADV® solid
state frequency converters manufactured by Hobart Brothers Company, Ground Power Division, Troy,
Ohio 45373.

This manual is not intended to be a textbook on electricity or electronics. Its primary purpose is to
provide information and instructions to experienced operators, electricians, and mechanics who have
never operated this equipment. It is the intent of this manual to guide and assist operators and
maintenance people in the proper use and care of the equipment.

Use of the manual should not be put off until a trouble or need for help develops. Read the instructions
before starting the unit. Learn to use the manual and to locate information contained in it. Its style and
arrangement are very similar to commercial aircraft manuals.

The manual is divided into five chapters plus an appendix. Each chapter is divided into as many
sections as required. Each new section starts with page 1. Each page is identified by chapter, section
and page number, which are located in the lower, outside corner. When information located in another
portion of the manual is referred to, its location is identified by a chapter, section, and paragraph or
figure number.

For example: “(see Section 2-3, Paragraph 1.a.)” refers to information located in Chapter 2, Section 3,
Paragraph 1.a. If a chapter and section are not indicated in a reference, the referenced material is
located in the same section as the reference, for example: “(see Paragraph 1.a.).”

The Appendix is the last section. Its contains a list of available options that may be purchased with that
unit. Items on the list with check marks next to them, have been added to the standard unit per the
customers order. Literature for each option follows. The Appendix will help control the information in
the manual: making it unique to the unit purchased.

In addition to operation and maintenance instructions, the manual contains an illustrated parts list in
Chapter 4, and a collection of manufacturer’s literature and supplemental information in Chapter 5.

Contents of the manual is arranged as follows:

Chapter 1. Description/Operation

Chapter 2. Servicing/Troubleshooting

Chapter 3. Overhaul/Major Repair

Chapter 4. Illustrated Parts List

Chapter 5. Manufacturer’s Literature

Appendix A Options

September 21, 2000 Introduction

Page 1

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

If you have any questions concerning your Hobart Ground Power equipment, immediately contact our
Service Department by mail, telephone or FAXX.

Write: Hobart Brother Company

Ground Power Division

Service Department

1177 Trade Square East

Troy, Ohio 45373

U.S.A.

Call Inside U.S.A.: [phone] (Parts)

[phone] (Service)

Call From Foreign Countries: [phone] (Parts)

[phone] (Service)

FAXX Inside U.S.A. [phone]

FAXX From Foreign Countries: [phone]

Introduction September 21, 2000
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PoWerMaster ADV / Series 500048A / Solid State Converter

Table of Contents

Chapter 1. Description / Operation Chapter/Page #

Section 1. Description 1-1/1

General 1-1/1
Optional Equipment - Appendix A 1-1/1
Orientation 1-1/1
Mountings for the Converter 1-1/1
Safety Features 1-1/4
Bridge Interlock Circuit 1-1/4
Converter Cabinet (See Figure 2) 1-1/5
Theory of Operation (See Figure 5) 1-1/5
Model 101 Control System 1-1/11
Event Records/Fault Monitoring 1-1/11
Detailed Description of Converter Components 1-1/13

Section 2. Preparation for Use, Storage or Shipping 1-2/1

Receipt and Inspection of Equipment 1-2/1
Unpacking the Unit 1-2/1
Installation 1-2/1
Input Cable Size and Temperature Requirements 1-2/1
Preparation for Storage 1-2/8
Preparation for Shipment 1-2/8

Section 3. Operation 1-3/1

General 1-3/1
Basic Converter Operation 1-3/1

September 21, 2000 Table of Contents

Page 1

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

Chapter 2. Servicing / Troubleshooting

Section 1. Troubleshooting 2-1/1

General 2-1/1
Model 101 Control Monitoring (See Fig 1) 2-1/2
Troubleshooting Procedures 2-1/12

Section 2. Calibration 2-2/1

Test Preparation 2-2/1
Calibration (See Figure 2) 2-2/2

Section 3. Scheduled Maintenance 2-3/1

General 2-3/1
Scheduled Maintenance Procedure 2-3/1

Chapter 3. Overhaul / Major Repair

Unscheduled Repair 3-1/1

General 3-1/1
Service Information and Factory Repair 3-1/1
Workmanship 3-1/2
Converter Bridge Mount Removal and Installation 3-1/2
Component Removal and Replacement 3-1/4
PC Board Removal and Replacement 3-1/9

Table of Contents March 16/98
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PoWerMaster ADV / Series 500048A / Solid State Converter

Chapter 4. Illustrated Parts List

Section 1. Introduction 4-1/1

General 4-1/1
Purpose 4-1/1
Arrangement 4-1/1
Explanation of Parts List 4-1/1

Section 2. Manufacturer’s Codes 4-2/1

1. Explanation of Manufacturer’s (Vendor) Code List 4-2/1

Section 3. Illustrated Parts List 4-3/1

Explanation of Parts List Arrangement 4-3/1
Symbols and Abbreviations 4-3/1

Section 4. Numerical Index 4-4/1

1. Explanation of Numerical Index 4-4/1

Chapter 5. Manufacturer’s Literature

Appendix A

September 21, 2000 Table of Contents

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PoWerMaster ADV / Series 500048A / Solid State Converter

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Table of Contents September 21, 2000
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OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

Chapter 1. Description / Operation

Section 1. Description

1. General

The PoWerMaster ADV Solid State Frequency Converters covered by this manual are manufactured
by Hobart Brothers Company, Ground Power Division, Troy, Ohio 45373. These converters are
designed to provide 45 kVA power for maintenance and startup of aircraft having 115/200-V AC,
3-phase, 400-Hz electrical systems.

The number 500048A identifies the “model or series” of the converter. The part number is followed by
a different dash number which separates the basic units available. The criteria for number of power
rating, outputs, and contactors on a converter change with each dash number. Figure 1 uses the part
number to identify the variations possible covered by this manual.

Part & Dash Number Output (kVA) Outputs Contactor(s) Input Voltage

500048A-301 45 One One 400/480

500048A-302 45 Two Two 400/480

500048A-311 45 One One 208

500048A-312 45 Two Two 208

Series 500048A Converters Part Number Descriptions

Figure 1

The Hobart PoWerMaster ADV is designed to service aircraft equipped with No-Break Power Transfer
(NBPT). Advanced electronic circuitry allows the unit to automatically synchronize with onboard power
during NBPT, providing successful transfers every time.

2.

Optional Equipment - Appendix A

Chapters 1 through 5 of this Operation and Maintenance Manual identifies only the basic version of a
45 kVA Series 500048 converter. A list of optional equipment which make this manual unique to the
generator set that you have purchased, appears in Appendix A. An example of items located Appendix
A would be the trailer mount configuration.

3.

Orientation

To avoid confusion in the location of components, for these horizontally mounted units, the control
panel is considered to be at the right front of the unit. Left and right are determined by looking at the
unit from the front.

4.

Mountings for the Converter

The ADV converter must be mounted horizontally in one of three ways:

·

Under a passenger boarding bridge.

·

On a trailer to make it mobile.

·

On a floor stand.

September 21, 2000 Chapter 1-1

Page 1

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

Hobart PoWerMaster®ADV Solid State Frequency Converter

Chapter 1-1 September 21, 2000
Page 2

Figure 2

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

PHYSICAL

Enclosure NEMA 3R or IEC IP 54

Weight (approx.)

Bridge Mount Unit 1100 Lb (499 kg)

Bridge Mount Unit

w/ 208 Input

1300 Lb (590 kg)

Trailer Mount Unit 1860 Lb (843.7 kg)

Trailer Mount Unit

w/ 208 Input

2060 Lb (934.4 kg)

Size

Bridge Mount Unit 22.5" high x 70.5" wide x 50.1" deep (572 mm x 1791 mm x 1273 mm)

Trailer Mount Unit

Towbar Raised

Trailer Mount Unit

Towbar Lowered

81" long x 56" wide x 56.5" high

(2049 mm x 1422 mm x 1435 mm)

119.2" long x 56" wide x 56.5" high

(3029 mm x 1422 mm x 143.5 mm)

ELECTRICAL

Acoustical noise Less than 65 dBA @ 1.5 m high, 2 m distance

Operating temperature -40º to +55º C (-40º to +131º F)

Storage temperature -40º to +60º C (-40º to +140º F)

Relative humidity 10 to 100% non-condensing

INPUT

45 kVA Unit 45 kVA Unit w/ 208V input

Voltage (nominal) 400 / 460 208

Frequency (Hz) 50 / 60

Amperes (rated load) 60/48 125

Voltage Range (max) 340-530 VAC 208

Starting Current

Power Factor

Less than 100% full load input current

More than 0.98 lagging from 10% to full load

Specifications and Capabilities

Figure 3

September 21, 2000 Chapter 1-1

Page 3

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

ELECTRICAL

Output

Voltage 115/200-V AC

Power rating 45 kVA (36 kW continuous)

Amperes (at rated load, per power ratings) 130 - A

Frequency 400-Hz

Overload trips at 125% after 10 min. at 150% after 30 sec. at 200% after 10 sec.

Shorted output shutdown Immediate

Duty cycle 100%

Total harmonic distortion (THD) Less than 3%

Individual harmonic distortion (IHD) Less than 2%

DC content Less than 100-mV

Voltage modulation Less than 0.05 rms

Frequency drift +/- 0.05%

Phase displacement 120 +/- 1.5º

Transient performance Meets Mil Std 704E, Figure 5

Voltage adjustment range +/- 15% of rated voltage

Phase voltage balance (with balanced load) Less than 2% of rated line/neutral voltage

Voltage unbalance (10% unbalanced load on one

phase)

Voltage regulation Less than 1% from no load to rated load

Crest factor 1.414+/- 0.07

Line drop compensation

Frequency modulation

Less than 3-V (meets Mil Std 704E, Figure 1 and

ARP-1940, 3.1.5.10)

Automatic, up to 8% of rated voltage at maximum

rated load

Less than +/- 0.25% of the period of output voltage

wave

Specifications and Capabilities Electrical

5.

Safety Features

The Hobart control system provides the highest available level of protection and safety for the operator,
the aircraft, and the converter itself. The ADV performs complete diagnostic testing upon each startup
and continuous monitoring of all critical circuits and operating electrical values, and automatically shuts
down the converter in order to minimize risks to the user, aircraft, and converter.

See Section 2-1 Troubleshooting, for details on the types and levels of protection provided by the
control system.

6.

Bridge Interlock Circuit

For safety, and to prevent damage to equipment, the converter can be interlocked with the bridge drive
circuitry so that the bridge cannot be moved on the apron while the converter is operating. This is done
to prevent the bridge from pulling the output cable from the airplane or driving over the cable.

Chapter 1-1 September 21, 2000
Page 4

Figure 4

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

7. Converter Cabinet (See Figure 2)

The cabinet which houses the converter apparatus and circuitry is a NEMA 3R or IEC IP 54 enclosure,
which means that it is weather resistant. It consists of a sturdy welded steel frame to which an
aluminum enclosure fastens at the sides and top. Aluminum front and rear doors are hinged to permit
opening the unit for easy access to serviceable components. Both the front and back doors open
upward.

8.

Theory of Operation (See Figure 5)

a. Input Rectifier (See Figure 6)

The input rectifier consists of a three phase thyristor/rectifier bridge which is phase angle regulated
during startup providing a soft start of the converter. This limits the inrush current to less than the
full rated value of the converter. During normal operation the thyristor/rectifiers operate at full
conduction to behave as a standard 3-phase bridge rectifier. The bridge produces an unregulated
DC voltage (approximately 650 volts) which is passed through a filter before it is applied to the
inverter. The converter is protected against input line voltage surges by a three phase voltage
snubber network connected across the AC input of the bridge and two voltage suppressers across
the DC output of the rectifier bridge.

September 21, 2000 Chapter 1-1

Simplified Block Diagram of Converter

Figure 5

Page 5

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

Input Thyristor/Rectifier Circuit

Figure 6

Input Filter Circuit and DC Bus Capacitor Bank

Chapter 1-1 September 21, 2000
Page 6

Figure 7

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

b. Input Filter and DC Bus Capacitor Bank (See Figure 7)

The input filter consists of two filter inductors and a bank of capacitors to provide the inverter with a
low ripple DC voltage. One inductor is in the positive output of the rectifier bridge and one is in the
negative output of the rectifier bridge. The capacitor bank consists of electrolytics and high
frequency film capacitors connected in parallel but strategically located to utilize the advantages of
each fully. The high frequency film capacitors exhibit low capacitance, extremely low series
inductance but high ripple current and are mounted directly across the inverter IGBTs with a low
inductance bus; the electrolytic capacitors which have high capacitance but low ripple current
capabilities are remotely located and serve as energy storage and input rectifier filter for the DC
bus. Because of the limited voltage rating of electrolytic capacitors, two capacitors are connected in
series with a voltage balancing resistor across each capacitor to achieve a 900 volt capability.

c. Discharge Circuit

The discharge circuit consists of a high power low value resistor that will discharge the DC bus to 30
volts in less than 6 seconds. An IGBT (Insulated Gate Bipolar Transistor) switches a resistor across
the bus upon command from the IPC board. Red indicating lamps located on the bus discharge
board and the signal conditioning boards indicate the presence of voltage (greater than 8 volts)
across the bus.

September 21, 2000 Chapter 1-1

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OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

Chapter 1-1 September 21, 2000
Page 8

Inverter Section Circuit

Figure 8

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

d. Inverter and Output Filter Section (See Figure 8)

The inverter section consists of three pairs of high power IGBTs (6 total) connected in a three phase
array; each pair consists of two in series IGBT’s across the bus forming one output phase of the
three phase output. Each pair is Advanced Pulse-Width-Modulated to synthesize a low harmonic
400 hertz 280 volt output voltage line to line. This three phase pulse-width-modulated output is
connected to an OUTPUT FILTER that smoothes the output voltage by reducing the higher order
switching harmonics. The result is three line to line 400 hertz voltages that contain less than 3%
distortion. The Output Filter (OF) consists of three inductors, one in series with each output phase,
and three banks of capacitors connected line to line (delta) across the output of the inductors. This
junction is the output of the inverter.

September 21, 2000 Chapter 1-1

Output Transformer Circuitry

Figure 9

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Chapter 1-1 September 21, 2000
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OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

9. Model 101 Control System

The Model 101 Control System performs complete diagnostic testing upon each startup and continuous
monitoring of all critical circuits and operating electrical values. Functions of the converter are selected
through the control panel of the Model 101. Specifically, the Model 101 performs the following:

a. Checks all critical components prior to supplying 400-Hz power.

b. Monitors all critical operating parameters during operation.

c. Signals a fault and indicates a potential problem if parameters approach critical levels during

operation.

d. Diagnoses and identifies the cause of a fault.

e. Causes the converter to automatically shut down if factory-set output parameters or output

characteristics fall outside predetermined safe limits.

f. Measures power flow for billing purposes if desired. Stores history of up to 200 power cycles at the

gate.

g. Logs data into its own memory for downloading to an external computer through the control serial

port

h. Provides an advanced and easy-to-use interface between the operator and the converter..

10.

Event Records/Fault Monitoring

The Hobart PoWerMaster ADV Model 101 Control System performs complete diagnostic testing upon
each startup and continuous monitoring of all critical circuits and operating electrical values. If the
control system senses a problem with one of the circuits or if one of the electrical values exceeds its
safe operating limit, the control will indicate an event record. These records allow the converter to
continue operation or will indicate a fault and will shut the converter down, depending on the severity of
the condition. The two types of event records are Warnings and Faults.

a. Warnings result when a problem is detected which does not interfere with the proper operation of

the converter. The warning will be displayed on the front panel and the machine will continue to
operate normally. An event record will be recorded.

b. Faults occur when any of the fault limits are exceeded, when an internal problem occurs, or under

certain conditions that would cause injury to personnel or damage to an aircraft or the converter.
These limits are preset at the factory. A fault indication signifies a condition severe enough to
discontinue all output power and shut the converter down. After the recognition of a Fault the
control system will immediately shut down, the red fault lamp will illuminate and the appropriate fault
message will appear in the display. An Event Record will be stored to troubleshoot the problem.

When a Fault occurs that may cause damage to the unit, an event record will be recorded and the
breaker will automatically be tripped.

(1) See Section 2-3, Troubleshooting for a list of fault levels, their possible causes, and corrective

actions.

September 21, 2000 Chapter 1-1

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OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

1. 400 Hz POWER ON push button

2. OUTPUT VOLTAGE ADJUSTMENT push button

3. BYPASS ON lamp

4. EF PRESENT lamp

5. PHASE SELECT push button

6. OUTPUT VOLTAGE display

7. INPUT POWER lamp

8. FAULT lamp

9. OUTPUT 1 lamp

10. OUTPUT 2 lamp

11. OUTPUT 1 ON push button

Chapter 1-1 September 21, 2000
Page 12

12. OUTPUT 2 ON push button

13. OUTPUT 1 OFF push button

14. OUTPUT 2 OFF push button

15. OUTPUT CURRENT display

16. FAULT CODE display

17. SET POINT UP AND DOWN ADJUSTMENT
push buttons

18. LINE DROP COMPENSATION ADJUSTMENT
push button

19. 400 Hz POWER OFF push button

Control Panel

Figure 10A

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

11. Detailed Description of Converter Components

a. Control Panel (See Figures 10A and 10B)

The function of each of the controls and indicators are as follows:

(1) 400 Hz POWER ON push button (1, Figure 10)

Pressing this push button turns the converter on and readies the machine to deliver 400 Hz
power.

NOTE: Pressing the 400 Hz POWER ON push button will power the converter only, but will NOT close output

contactor(s) to provide output power to the aircraft.

(2) OUTPUT VOLTAGE ADJUSTMENT push button

To adjust the output voltage, depress and hold the OUTPUT VOLTAGE ADJUSTMENT push
button (2) and use the proper arrow key (17).

Note: This adjustment can be disabled if the keypad disable switch is in the “disable” position (see

Sect. 1-3, Para. J).

(3) “EF” BYPASS ON lamp

CAUTION

DO NOT use the EF BYPASS unless the output cables are connected to an
aircraft or an approved load bank.

These lamps indicate that EF BYPASS (Sect. 1-3; 2 and 3, Figure 2), has been turned on for
that output. Once the EF BYPASS is activated, the need for a returned EF Signal from the
aircraft is disabled, therefore allowing 400 Hz power to be sent uncontested to the output
cables(s). Because “Live” unattended output cables are possible, the EF BYPASS is to be
used for aircraft not equipped with EF circuitry or maintenance use only.

(4) EF PRESENT lamp

The presence of the EF signal(s) returning to the converter is displayed with illumination of
one or both of the EF Present lamps in the EF STATUS box.

(5) PHASE SELECT push button

With each press of this push button, either the A, B, C, or AVG. voltage lamp will light. The
OUTPUT VOLTAGE display (6) and the OUTPUT CURRENT display (15) will show the real
time value of the phase selected or the average of the group.

(6) OUTPUT VOLTAGE display

Displays the output voltage value of the converter at the output connection of the converter.

(7) INPUT POWER lamp

The green INPUT POWER lamp indicates the presence of input power. The input power
lamp flashes during converter self test.

(8) FAULT lamp

The red FAULT lamp indicates that a fault is detected by the control system.

(9) OUTPUT 1 lamp

The amber OUTPUT 1 lamp indicates the presence of power at the output 1 terminal of the
converter.

September 21, 2000 Chapter 1-1

Page 13

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PoWerMaster ADV / Series 500048A / Solid State Converter

1. 400 Hz POWER ON push button

2. OUTPUT VOLTAGE ADJUSTMENT push button

3. BYPASS ON lamp

4. EF PRESENT lamp

5. PHASE SELECT push button

6. OUTPUT VOLTAGE display

7. INPUT POWER lamp

8. FAULT lamp

9. OUTPUT 1 lamp

10. OUTPUT 2 lamp

11. OUTPUT 1 ON push button

Chapter 1-1 September 21, 2000
Page 14

12. OUTPUT 2 ON push button

13. OUTPUT 1 OFF push button

14. OUTPUT 2 OFF push button

15. OUTPUT CURRENT display

16. FAULT CODE display

17. SET POINT UP AND DOWN ADJUSTMENT
push buttons

18. LINE DROP COMPENSATION ADJUSTMENT
push button

19. 400 Hz POWER OFF push button

Control Panel

Figure 10B

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

(10) OUTPUT 2 lamp

The amber OUTPUT 2 lamp indicates the presence of power at the output 2 terminal of the
converter.

(11) OUTPUT 1 ON push button

Depressing this push button will deliver 400 Hz power to the corresponding contactor,
providing the 400 Hz POWER push button (1) is turned on.

(12) OUTPUT 2 ON push button

Depressing this push button will deliver 400 Hz power to the corresponding contactor,
providing the 400 Hz POWER push button (1) is turned on.

(13) OUTPUT 1 OFF push button

Depressing this push button will cancel 400 Hz power to the corresponding contactor.

(14) OUTPUT 2 OFF push button

Depressing this push button will cancel 400 Hz power to the corresponding contactor.

(15) OUTPUT CURRENT display

Displays the output current to the aircraft.

(16) FAULT CODE display

When a fault is detected by control system, the fault codes to troubleshoot the problem will be
displayed here. See Section 2-1 for a complete list of Warning and Fault codes.

(17) SET POINT UP AND DOWN ADJUSTMENTS push buttons

These UP and DOWN push buttons increase or decrease the output voltage or the line drop
compensation values. Simply press one of these push buttons while simultaneously pressing
either one of the corresponding master push buttons for output voltage or line drop
compensation.

(18) LINE DROP COMPENSATION ADJUSTMENTS push button

To adjust the line drop compensation value, depress and hold the LINE DROP
COMPENSATION ADJUSTMENTS push button while simultaneously pressing a SET POINT
UP AND DOWN ADJUSTMENTS push button (17). The line drop compensation value, in
percentage, will be shown in the FAULT CODE display (16).

(19) 400 Hz OFF push button

Shuts off output power. Pressing this push button opens all output contactor(s), if closed, and
turns the converter off.

NOTE: If 400 Hz power is on and only one contactor is closed, pressing the corresponding OUTPUT OFF push

button will open the contactor and disconnect 400 Hz power from the aircraft. If 400 Hz power is on and
2 contactors are closed, turningoffoutput 1 or output 2 will not turnoff 400 Hz power to both contactors.

September 21, 2000 Chapter 1-1

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PoWerMaster ADV / Series 500048A / Solid State Converter

b. Printed Circuit Boards (See Figure 11)

The 45 kVA units have 7 printed circuit (PC) boards in various locations inside the converter. The
functions of each PC board are as follows.

(1) Modulator PC Board A3 (MOD)

The modulator PC board generates the pulse-width modulated switching patterns that
produce the output voltage sine wave. It has circuitry to produce a stable output voltage,
voltage ramp-up and ramp down, soft start, no break power transfer NBPT, active transistor
diagnostics, output voltage/output current monitoring, and fault detection.

(2) Driver PC Board A5

The Driver PC board translates the input drive signal from the modulator board into an
optically isolated drive signal for each of the six IGBT power modules.

(3) Input Power Control Board A4 (IPC)

The IPC Board monitors the AC input voltage, AC input frequency, and power supply voltages
within the converter. It provides drive signals for the thyristor/rectifier modules, Bus Discharge
PC Board, and the Booster PC Board (if present). The IPC Board has circuitry to produce a
stable DC Bus voltage, soft start, self diagnostics, fault detection, and door interlock
monitoring.

(4) Signal Conditioning Board A6 (SCB)

The Signal Conditioning PC Board senses and converts signals to low level DC values for use
by the Control PC Board, Input Power Control PC Board, and Modulator PC Boards. The
signals sensed are neutral current, output current, output voltage, DC Bus voltage, main
transformer I.D. resistor, and transformer temperature sensor. In addition, the following
signals are generated: average current, average power, average voltage. Each of these
circuits are digitally adjustable.

(5) Control Board A2 (CTL)

The Control Board serves as the primary user interface displaying: voltage, current, fault, and
EF data. It has circuitry to monitor and tests critical circuits in the converter prior to and
during operation. This PC board also has circuitry to provide system diagnostics, output
voltage and current monitoring, run time and diagnostic data storage, and external serial data
communications.

(6) I/O (input/output) Board A1 (IOB)

The I/O Board serves as the converter interface to the outside world. It processes the EF,
interlock, bridge, and operator pendent signals to and from the converter.

(7) Bus Discharge PC Board A7

The Bus Discharge PC Board discharges the main DC bus at a controlled rate on command
from the IPC Board.

Chapter 1-1 September 21, 2000
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OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

1. Modulator PC Board A3

2. Driver PC Board A5

3. Signal Conditioning PC Board A6

4. Input Power Control PC Board A4

September 21, 2000 Chapter 1-1

5. Control PC Board A2

6. Input/Output PC Board A1

7. Bus Discharge PC Board A7

PC Board Location

Figure 11

Page 17

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PoWerMaster ADV / Series 500048A / Solid State Converter

c. Components Inside Front Door (See Figure 12)

(1) Circuit Breaker CB1

The input power lines are wired into this circuit breaker. The external circuit breaker lever that
operates the breaker switch utilizes a cable that pushes the breaker switch up (on) or down
(off).

(2) Voltage suppressers RV1, RV2, RV3

These three voltage suppressers are designed to help protect against input voltage spikes,
including lightning induced, on the AC input lines.

(3) Fuse F3

This fuse protects the control transformer secondary circuit. Its size and rating is FNQ 2A,
125-V.

(4) Input/Control Transformer

This transformer steps the input voltage down to 115-V AC for operation of the converter’s
control circuits and other circuits requiring this voltage.

(5) Hour meter M3

This component monitors the amount of time 400 Hz power is generated in hours.

(6) Door Interlock Switch S7

Immediately shuts down the converter when the door is opened. Can be bypassed for
maintenance purposes only. See Sect. 2-2; Figure 1 to bypass switch.

(7) 115V AC Power Supply Hold-Up Capacitor (C42)

This capacitor enables the converter to withstand a 50 millisecond power interruption — micro
break. The capacitor will discharge into the input circuitry to maintain power to the control
system.

(8) DC Bus Capacitor Bank C1-C11

The DC capacitor bank, input filter reactors, and a number of other components provide

filtering of the rectified AC input voltage. The bank consists of eleven 50-m F, 900-V capacitors

connected by an integrated bus system.

(9) Air Filter — Hobart Brothers Replacement Part No. 283159-003

CAUTION

To maintain a uniform air flow through the Power Module Heatsink, the air filter
MUST be in place at ALL TIMES during operation of the converter.

Aside from proper air-flow, the air filter (9, Figure 12) helps provide clean air for circulation.

Chapter 1-1 September 21, 2000
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PoWerMaster ADV / Series 500048A / Solid State Converter

1. Circuit Breaker CB1

2. Voltage suppressers RV1, RV2, RV3

3. Fuse F3

4. Input/Control Transformer T1

5. Hour meter M1

September 21, 2000 Chapter 1-1

6. Door Interlock Switch S7

7. 115V AC Power Supply Hold-Up Capacitor (C42)

8. DC Bus Capacitor Bank C1-C11

9. Air Filter

Components Inside Front Door

Figure 12

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PoWerMaster ADV / Series 500048A / Solid State Converter

d. Heat Sink Panel Assembly Details (See Figure 13)

(1) IGBT (Insulated Gate Bipolar Transistor) Power Modules

The six IGBT power modules (PM1 - PM6) provide the actual switching which produces the

·

output voltage sine wave from the filtered DC voltage, under control of the modulator and
driver PC Boards.

(2) Power Module Thermal Switch S4

This switch is located on the heat sink assembly. The Modulator PC board monitors the
thermal switch to detect overheating.

(3) Voltage Surge suppressers RV4 - RV5

These suppressers are connected across the rectified input to protect the SCR-Diode
Modules from internal voltage surges.

(4) SCR-Diode Rectifier Modules CR1 - CR3

These modules are used as a soft start mechanism. They limit the inrush current to control
the start up of the machine.

(5) Input Step-down Power Supply PS1

This switching type power supply draws 115V AC from the input /control transformer and
converts it to +12V DC. The output is directed to control logic power supply.

(6) Power Supply Load Resistor R1

Provides a constant “load” on the input step-down and control logic power supplies.

(7) Control Logic Power Supply PS2

The 12V DC input from the step down power supply is fed into this control logic power supply
in order to achieve a +12, -12, and +5V DC output. These three outputs feed the Input Power
Control PC Board, which disperse to other PC Boards.

(8) Heat Sink

The heat sink used provides cooling for the power components listed in Figure 13.

Chapter 1-1 September 21, 2000
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PoWerMaster ADV / Series 500048A / Solid State Converter

1. IGBT PM1 - PM7

2. Power Module Thermal Switch S4

3. Voltage Surge suppressers RV6 - RV7

4. SCR-Diode Modules SCR1 - SCR3

September 21, 2000 Chapter 1-1

5. Input Step-down Power Supply PS1

6. Resistor, Power Supply Load R1

7. Control Logic Power Supply PS2

8. Heat Sink

Heat Sink Panel Assembly

Figure 13

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PoWerMaster ADV / Series 500048A / Solid State Converter

e. Components Inside Rear Door (See Figure 14)

(1) Output Contactor(s) K1 AND K2

The converter may have either one or two output contactors, depending on the requirements
of the customer. Each contactor is a sealed unit which contains a magnetic operating coil and
four sets of contacts. The three larger contacts conduct 3-phase AC voltage output. The I/O
PC Board monitors the smaller, fourth set of contacts to verify proper operation of the
contactors.

(2) Output Current Sensing Transformers CT1- CT7

The cables which conduct output power to each converter output pass through a set of three
current transformers. These current transformers monitor the output load current in each of
the three output phases, detect the magnitude of current flowing from the converter to its load
and supply a reduced value current signal to the Signal Conditioning PC board.

Neutral Line Current Sensing Transformer CT4

To detect excessive current through the neutral line, the neutral line current transformer
senses the current and continually sends a signal to the Signal Conditioning PC board.

(3) Fan Motor Start Capacitor C13

This component limits the inrush of current to the fan motor upon start up.

(4) Terminal Block TB4

Provides a connection point for the cooling fan and the Fan Motor Start Capacitor with power
coming from the Fan Inverter PC Board

(5) Cooling Fan B1

The aluminum panel on the bottom side of the unit has an air intake and an exhaust opening.
Air enters the unit through louvers located near the front right, circulates throughout the unit,
then leaves through the louvers next to the output cables.

(6) Three Phase AC Filter Inductors L1 - L3

These inductors, when working in conjunction with the AC filter capacitors, is a filter for the
Pulse Width Modulated voltage produce by the inverter.

(7) DC Filter Inductors L4 - L5

These inductors work with the electrolytic capacitors (10) to smooth the DC current leaving
the SCR Modules.

(8) DC Bus Capacitor Discharge Resistor R3

This 50 ohm 125 watt resistor works in conjuction with the Bus Discharge PC Board (Figure

14), to completely drain the Electrolytic DC Capacitors (10) in less than a second. The two
instances that trigger this immediate discharge are:

(1) Opening either canopy door during POWER ON.
(2) Fault occurances.

(9) Electrolytic DC Capacitors C6 - C11

These capacitors work in conjunction with the DC Filter Inductors to filter the DC voltage from
the SCR Modules.

Chapter 1-1 September 21, 2000
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PoWerMaster ADV / Series 500048A / Solid State Converter

1. Output Contactor(s) K1- K2

2. Output Current CT1 - CT7 and Neutral
Sensing CT4 Transformers

3. Fan Motor Start Capacitor C13

4. Fan Terminal Block TB4

5. Cooling Fan B1

6. Three Phase AC Filter Inductors L1 - L3

7. DC Filter Inductors L4 - L5

8. DC Bus Capacitor Charging Resistor R3

September 21, 2000 Chapter 1-1

9. Electrolytic DC Capacitors C14 - C19

10. AC Filter Capacitor C22 - C33

11. Door Interlock Switch S2

12. Output/Main Transformers T2

13. 12 Station Terminal Strips TB1 - TB3

14. Terminal Strip TB5

15. Input Transformer (208V input units only)
(Not Shown)

Components Inside Rear Door

Figure 14

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PoWerMaster ADV / Series 500048A / Solid State Converter

(10) AC Filter Capacitor C1 - C12

The AC capacitor bank and the output filter reactors provide filtering of the output voltage sine
wave.

(11) Door Interlock Switch S2

The converter cannot be turned on unless both doors are closed securely, and will shut down
immediately upon opening either door.

(12) Output/Main Transformers T2

One output transformer transforms the output from the inverter section into the desired
115/200-V AC output voltage. Transformer contains three input and three output windings.

(13) 12 Station Terminal Strips TB1 - TB3

These three terminal strips connect the ADV to the outside world. Bridge Interlock circuitry,
EF circuitry and other external airport communications are maintained here.

(14) Terminal Strip TB5

Connection Point for Transformer Temperature sensor.

·

Connects the Unit Identification Resistor—different resistor for 90 kVA and 125 kVA.

·

(15) Input Transformer (208V input units only)

Transforms nominal input voltage of 208 up to internal working voltage.

Chapter 1-1 September 21, 2000
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PoWerMaster ADV / Series 500048A / Solid State Converter

Section 2. Preparation for Use, Storage or Shipping

1. Receipt and Inspection of Equipment

The converter has been thoroughly inspected and tested at the factory and prepared for shipment in
accordance with standard industrial practices for safe shipment. Upon receiving this equipment, inspect
it as follows.

a. Visually inspect the shipping crate for damage. If any damage is detected, request that the carrier

agent inspect the shipment and note the damage on the delivery receipt. This is for your protection.

b. If there is no obvious damage to the shipping crate, unpack the unit as follows:

2.

Unpacking the Unit

a. Remove crate, leaving unit on pallet for lifting it into place for mounting. Take care to avoid damage

to the equipment if bars, hammers, etc. are used in unpacking. Remove all unused hardware from
the unit.

b. Visually inspect the unit for evidence of external damage such as damaged sheet metal, scratches,

dents, etc. Check also for loose connections and components. If the equipment has been damaged
in transit, file a claim for damage at once. If you require assistance with a damage claim, furnish
Hobart Brothers Company with full information about the claim.

NOTE: Save the shipping container until the unit has been put into service and determined to be operating cor-

rectly.

3.

Installation

A Hobart converter requires no additional preparation in order to supply power to an aircraft. It needs
only to have its input cable(s) connected to an appropriate source of power and its output cable(s)
connected to an aircraft. Proceed as follows for putting the converter unit into service.

WARNING

The method of installation, conductor size, and over-current protection shall
conform to the requirements of the local electrical code, the national electrical
code, or other national codes, as applicable. All installation wiring and machine
reconnection shall be done by qualified persons.

4.

Input Cable Size and Temperature Requirements

Figures 1 and 2 show input cable size and temperature requirements for converter units covered by
this manual. This information is from the U.S. National Electrical Code ANSI/NFPA 70, 1933 Edition.
Install this equipment per the latest edition, available from the National Fire Protection Association, 470
Atlantic Avenue, Boston, MA 02210.

September 21, 2000 Chapter 1-2
Revised: 2/1/01 Page 1

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

INPUT

45-kVA

VOLTAGE

120 Amperes

208

#1 AWG (50 mm2)

COPPER

64 Amperes

380

#4 AWG (25 mm2)

COPPER

55 Amperes

460

#6 AWG (16 mm2)

COPPER

Values given in this chart assume that 90º C rated cables will be used, with typical wire sizing per chart
310-16 of the 1999 National Electrical Code. Wire sizes should be verified by a qualified electrician and
should conform to local electrical codes. This chart assumes operation at 50º C ambient temperature. Total
input cable weight is limited to 250-lbs (113.4 kg) on trailer mounted converters.

Input Cable Size Requirements - Cables Rated at 90º C

Figure 1

INPUT

45-kVA

VOLTAGE

120 Amperes

208

2/0 AWG (70 mm2)

COPPER

64 Amperes

380

#3 AWG (35 mm2)

COPPER

55 Amperes

460

#4 AWG (25 mm2)

COPPER

Values given in this chart assume that 75º C rated cables will be used, with typical wire sizing per chart
310-16 of the 1999 National Electrical Code. Wire sizes should be verified by a qualified electrician and
should conform to local electrical codes. This chart assumes operation at 50º C ambient temperature. Total
input cable weight is limited to 250-lbs (113.4 kg) on trailer mounted converters.

Input Cable Size Requirements - Cables Rated at 75º C

Figure 2

Chapter 1-2 September 21, 2000
Page 2 Revised: 2/1/01

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

a. Cable Entry Locations

Input and output cable entrance shall be made through the cable entrance hole(s) provided in the
converter cabinet. Consult our Service Department if problems arise.

b. Install Input Cables at Power Supply Service

Before connecting input cables to the power supply service, check voltage, amperage and phase
ratings of the service. Make certain that the capacity of the service is adequate for the power
requirements of the unit being connected to it. Make certain also that the service used as the
source of input power is grounded. Refer and conform to your local electrical code when selecting
and installing power supply service.

Make sure electrical service is off. Connect the input power cables to the input power source, and
connect the grounding conductor to a proper ground.

c. Install Input Cables in Converter Circuit Breaker Box (Figure 3)

(1) Make sure electrical service is off.

(2) Open the front door of the unit by turning all three latches counterclockwise with an 8 mm allen

wrench

(3) Route the cable up through the hole in the base and then through the cable clamp located below

the circuit breaker CB1.

(4) Using a 3/8 inch allen wrench, connect input cable leads securely to terminals L1, L2, and L3 on

circuit breaker.

(5) Using a 5/16 inch allen wrench, connect the ground wire securely to the ground lug located

below the circuit breaker.

(6) Pull the excess cable downward through the clamp in the base, and tighten the clamp around the

cables. Leave just enough slack in the cables so there is no strain on them. Avoid damage to
cable insulation.

September 21, 2000 Chapter 1-2
Revised: 2/1/01 Page 3

Circuit Breaker Connections

Figure 3

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

1. 400 Hz POWER ON push button

2. OUTPUT VOLTAGE ADJUSTMENT push button

3. BYPASS ON lamp

4. EF PRESENT lamp

5. PHASE SELECT push button

6. OUTPUT VOLTAGE display

7. INPUT POWER lamp

8. FAULT lamp

9. OUTPUT 1 lamp

10. OUTPUT 2 lamp

11. OUTPUT 1 ON push button

Chapter 1-2 September 21, 2000
Page 4 Revised: 2/1/01

12. OUTPUT 2 ON push button

13. OUTPUT 1 OFF push button

14. OUTPUT 2 OFF push button

15. OUTPUT CURRENT display

16. FAULT CODE display

17. SET POINT UP AND DOWN ADJUSTMENT
push buttons

18. LINE DROP COMPENSATION ADJUSTMENT
push button

19. 400 Hz POWER OFF push button

Control Panel

Figure 4

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

(7) Close and latch the front door of the unit.

d. Check Converter No-Load Operation (See Figure 4)

A no-load check should be made before the output cables are connected to the converter and to a
load. Proceed as follows.

(1) Make certain that both converter doors are tightly closed and latched.

(2) Apply input power to the converter from the input power source; throw circuit breaker handle on

converter to on position. The green INPUT POWER lamp (7) will flash for several seconds and
then illuminate.

(3) Press the 400 Hz POWER ON push button (1). At this time the unit output voltage is displayed

on the control panel (6).

(4) Press the control panel 400 Hz POWER OFF push button (19). The INPUT POWER lamp

remains illuminated.

(5) Check optional remote START/STOP controls and bridge interlock feature for proper operation.

(6) Shut off power at the input power source. The INPUT POWER lamp (7) will shut off.

September 21, 2000 Chapter 1-2
Revised: 2/1/01 Page 5

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PoWerMaster ADV / Series 500048A / Solid State Converter

e. Install Output Cable and Remote START/STOP Controls (Figures 5 and 6)

Each output cable and remote control used enters the converter through a cable clamp in the
bottom panel. These cables are connected directly to the terminals of the output contactor and to
the appropriate terminals of the 12-station terminal strips located on the base of the converter inside
the rear door. Use the terminal strips for 28-V DC interlock (EF signal) and the remote control
lines.

NOTE: To determine appropriate cable size for single output configurations, consult your local electrical code;

for dual outputs, an industry standard aircraft cable is recommended. Use No. 12 AWG for interlock sig
nal (E and F terminals). Output cable leads (A,B,C,N) should be equipped with terminals suited for the
3/8" diameter terminal stud. Interlock signal (E and F) and remote control leads should be equipped
with terminals suited for a 5/16" diameter terminal stud.

NOTE: If the output cable is installed in conduit, the conduit must be non-ferromagnetic, such as aluminum.

(1) Open the rear door of the unit by turning all three latches counterclockwise with an 8 mm allen

wrench.

(2) Loosen the cable clamp screws at the cable horn that is mounted in the bottom panel.

(3) Route output and remote control cables through the cable horn and clamp and pull enough of

this cable through to allow working space.

-

a. Machines with 1 or 2 Contactors (Figure 5)

WARNING

· The output contactors can be seen inside the rear door on the far left. Each terminal stud

on the contactor is identified by an identification plate. Each cable should be identified by a
band-type marker. Connect cable lead “A” to terminal marked “A”, “B” to terminal “B”, and
“C” to terminal “C” on the appropriate contactor (see Figure 4). Tighten terminal nuts
securely using a “six point” 9/16 inch wrench.

Turning wrench or socket sizes that do not fit securely may cause personal
injury. Damage to hardware damage may also occur.

·

Three 12-station terminal strips (Figure 6) are located just inside the rear door of the unit in
front of the output contactors. Connect interlock leads “E” and/or “F” to the terminal marked
“EF” for the corresponding output connected in the previous step.

·

At the rear of the unit, connect the three remote control leads to the terminals for each
corresponding output.

·

Pull the excess cable out through the clamp assembly and out of the unit, tighten the clamp
around the cables. Leave just enough slack in the cables so that there is no strain on them.
Avoid damage to cable insulation.

·

Close and latch the rear door of the unit.

·

The converter is now ready for service. See Section 1-3, Operation, for operating
instructions.

Chapter 1-2 September 21, 2000
Page 6 Revised: 2/1/01

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PoWerMaster ADV / Series 500048A / Solid State Converter

Output Contactor(s) Connection

Figure 5

EF Signal and Remote START/STOP Control Connections

Figure 6

September 21, 2000 Chapter 1-2
Revised: 2/1/01 Page 7

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PoWerMaster ADV / Series 500048A / Solid State Converter

5. Preparation for Storage

a. General

(1) The unit should be prepared for storage before installation or as soon as possible after being

removed from service.

(2) The unit should be stored in a building which is dry and which may be heated during winter

months.

(3) Moisture absorbing chemicals are available for use where excessive dampness is a problem.

However, the unit must be completely packaged and sealed if moisture absorbing chemicals are
to be effective.

b. Temporary Storage

When storing the unit for 30 days or less, prepare as follows:

(1) Use moisture absorbing chemicals where excessive dampness is a problem. However, the unit

must be completely packaged and sealed if moisture absorbing chemicals are to be effective.
Seal all openings. Use a waterproof, vapor proof material which is strong enough to resist
puncture damage from air pressures.

(2) Store the unit in a building which is dry and which may be heated during winter months.

c. Long Time Storage

(1) To protect the converter’s components, the complete unit should be packaged, using moisture

proof packaging and sealing material. Place containers of moisture absorbing chemicals, such as
silica gel, in the unit before packaging.

(2) Store the unit in a building which is dry and which may be heated during winter months.

6.

Preparation for Shipment

During long shipments, the converter unit’s retaining hardware may become loosened by vibration,
jolting, etc. Check this hardware periodically during the shipment to make certain that retaining
hardware is secure.

Chapter 1-2 September 21, 2000
Page 8 Revised: 2/1/01

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

Section 3. Operation

IMPORTANT

1.

General

This section contains basic instructions for safe, efficient equipment operation. Operating instructions
are presented in step-by-step sequence for supplying 400-Hz power to an aircraft.

2.

Basic Converter Operation

The following operating instructions explain basic converter operation from the control panel.

a. Pre-Start Up Inspection

(1) Make certain that both converter doors are tightly closed. The unit is equipped with two door

interlock switches: S7 on the front door and S2 on the back door. Opening either door will disable
the unit. Therefore both doors must be closed to operate the unit. This feature is included for the
safety of the user.

(2) Make Sure the Air Filter — Hobart Brothers Replacement Part No. 283159-003 — is in place.

The air filter helps provide clean air for circulation. More importantly though, its presence in
the air intake system provides uniform air flow through the power module heat sink (Figures
12 and 13). With a missing air filter, the air will flow through the bottom of the heat sink only,
leaving some of the internal power supplies (IGBTs) to cool improperly. The air filter MUST

be in place at ALL TIMES during operation of the converter.

b. Startup Procedure (See Figure 1)

The following steps will turn the machine on so that variables on the control panel can be checked
without power delivery to an aircraft.

Before attempting to operate the converter, read this entire section to become
fully familiar with how the converter operates.

CAUTION

Use output cable(s) of proper size and length for this specific converter’s power
output rating.

(1) Connect output cable plug connector(s) to aircraft receptacle(s). Be sure connectors are mated

fully and securely.

(2) Raise circuit breaker handle beside the control panel to the ON position.

(3) Apply rated input power to the converter from the input power source. The green INPUT POWER

lamp (7) on the control panel will flash for several second and then illuminate.

WARNING

Care must be taken not to bypass the door interlock switches. High voltages
are present inside the converter, and FATAL SHOCK could result.

(4) Press the 400 Hz POWER ON push button (11) to turn machine on without power delivery.

However 400 Hz power is now present within the machine. To turn the machine off anytime
hereafter, simply press the 400 Hz POWER OFF push button (19).

September 21, 2000 Chapter 1-3

Page 1

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

1. 400 Hz POWER ON push button

2. OUTPUT VOLTAGE ADJUSTMENT push button

3. BYPASS ON lamp

4. EF PRESENT lamp

5. PHASE SELECT push button

6. OUTPUT VOLTAGE display

7. INPUT POWER lamp

8. FAULT lamp

9. OUTPUT 1 lamp

10. OUTPUT 2 lamp

11. OUTPUT 1 ON push button

Chapter 1-3 September 21, 2000
Page 2

12. OUTPUT 2 ON push button

13. OUTPUT 1 OFF push button

14. OUTPUT 2 OFF push button

15. OUTPUT CURRENT display

16. FAULT CODE display

17. SET POINT UP AND DOWN ADJUSTMENT
push buttons

18. LINE DROP COMPENSATION ADJUSTMENT
push button

19. 400 Hz POWER OFF push button

Control Panel

Figure 1

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

(5) Output voltage (voltage to be delivered to an aircraft) must be checked the first time the

converter is turned on. If it is necessary to change the factory set value, press and hold the “Set
Output Voltage” push button (2) while simultaneously depressing the up/or down push button
(17) until the output voltage display (6) changes to the appropriate voltage value.

This new output voltage value need only be set once; the voltage level will remain the same
for all future operations of the converter, even when the unit is turned off or disconnected from
input power. It may, however, be changed as often as desired.

c. Immediate Output Power Delivery

400 Hz power will not be delivered to the aircraft until at least one of the output contactors has been
closed. This can be done whether the converter is turned on or not, as long as the green INPUT
POWER lamp (7) is glowing and not flashing. To do this:

(1) Apply rated input power to the converter from the input power source.

(2) Raise circuit breaker handle beside the control panel to the ON position. The green INPUT

POWER lamp (7) on the control panel will flash for several second and then illuminate.

(3) Press OUTPUT 1 ON (11) and/or OUTPUT 2 (12) ON push button. The corresponding yellow

lamps, the OUTPUT 1 lamp (9) and OUTPUT 2 lamp (10) will glow.

If the output cable from the converter is connected properly to the aircraft, an EF DC interlock
signal (EF signal) will be sent back to the converter to allow the converter to operate as
normal.

d. Line Drop Compensation Setting (See Figure 1)

Line drop compensation must be set the first time the converter is operated. Line drop
compensation allows the converter to automatically make allowance for the voltage drop caused by
the resistance of long output cables.

When operating under no-load, the line drop compensation will be zero therefore the output voltage
display (6) will read 115 voltage.

When operating the converter under a load with drop compensation is present the output voltage
display (6) will read the voltage at the output contactor. The value displayed should read high
because it is taking into consideration how much extra voltage needed to compensate for power lost
through the output cables.

To check the drop compensation percentage value, simply press the LINE DROP
COMPENSATION push button (18). The value given, which appears in the Fault Code display (16),
will be the percentage of voltage over normal (115 Volts) the converter is supplying to the output
contactors. From the contactors, the voltage gradually decreases through resistance over the
length of the cable. As a result, the line drop in voltage will not effect the desired value of 115 volts
at the aircraft.

Once the line drop compensation is set, that factor value will remain the same for future operations
of the converter, unless the output cable size is changed. Turning the unit off or disconnecting from
input power will not affect the line drop compensation values. It may however be changed as often
as desired.

September 21, 2000 Chapter 1-3

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OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

To determine if the compensation factor should be changed, perform the following steps:

(1) One Output

a. Turn on all available electrical devices on the aircraft. The aircraft should be drawing the

maximum possible amount of current from the converter without exceeding the unit’s
maximum power rating.

b. Have an assistant measure the voltage being delivered to the aircraft through the No. 1 output

at the aircraft end of the cable.

c. If the value measured above does not match the desired voltage value, press and hold the

LINE DROP COMPENSATION ADJUSTMENT push button (18) while simultaneously
depressing the SET POINT UP OR DOWN ADJUSTMENT push buttons (17) on the control
panel to change the compensation factor. Have the assistant report when the measured value
matches the desired value.

(2) Two Output

a. If the converter has more than one output, setting the line drop compensation factor for the

first output synchronizes the line drop compensation for the second output automatically.

b. To check the line drop compensation for a multi-output converter, press the LINE DROP

COMPENSATION ADJUSTMENT push button (18).

e. Phase Select

Press the PHASE SELECT push button (5) to check the current and voltage values of phase A, B,
or C or to check the average of all three.

f. Operating Procedure

Since the converter is a solid state unit, rather than a rotating, engine/generator type, the unit
requires no intervention once it is running normally (i.e., no fuel, oil, etc. is needed). If the control
system senses a problem, the fault light on the control panel will illuminate and take the appropriate
action automatically.

g. Discontinued Power Delivery

Taking output power away from either output is as easy as pressing the OUTPUT 1 OFF (13) and/or
OUTPUT 2 OFF (14) push button(s). The corresponding yellow lamps, the OUTPUT 1 lamp (9) and
OUTPUT 2 lamp (10) will no longer glow. However the converter will still be turned on with 400 Hz
power still available for future use.

WARNING

Never disconnect an output cable while output power is on. SHOCK HAZARDS
EXIST!

On a single output unit, if the output cable is inadvertently disconnected from the aircraft while the
converter is operating, the converter will shut off.

On a multiple-output converter, if at least one output cable is disconnected to an aircraft, the
converter will operate and deliver power only through the connected output(s). If both the cables
are accidentally disconnected from the aircraft while the converter is in operation, the converter will
shut off. However, if at least one cable remains connected to an aircraft, the converter will continue
to operate and deliver power through that one cable; only the disconnected cable(s) will stop
delivering output power. This feature is included for the safety of the user and should not be used as
an alternate method of discontinuing output power to an aircraft.

Chapter 1-3 September 21, 2000
Page 4

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

h. Unit Shut Down

To discontinue power delivery and shut the unit down at one time, press the 400 Hz POWER OFF
push button (19).

i. shutdown Procedure (See Figure 1)

To stop power delivery to one of the outputs, press the appropriate remote control STOP push
button for that output. To turn all outputs and the converter off, either press the control panel 400
Hz POWER OFF push button (19, or press all remote control STOP push buttons on each remote
connected to the converter. The amber OUTPUT POWER lamp(s) (9 or 10) will shut off when no
power is being delivered through any of the corresponding outputs.

WARNING

Never disconnect an output cable while output power is on.

(1) Be sure 400 Hz power is not being delivered through output cables.

(2) Disconnect the output power delivery cable(s) from the aircraft.

Shut off power at the input power source, if desired. The green INPUT POWER lamp (7) will
shut off. It is not necessary to discontinue input power between operations of the converter.
When the unit is not delivering output power, it uses only a small amount of input power and
may be left connected to input power indefinitely.

j. EF BYPASS switches (See Figure 2)

WARNING

The converter may have as many as two separate outputs. The EF BYPASS output setting, which
can only be changed while the converter is not running, permits a qualified technician to set the
output mode for each of the outputs to either “NORMAL” or to “EF BYPASS".

The “NORMAL” setting for each output is for delivery of power to an aircraft.

The “EF BYPASS" setting bypasses the normal EF signal checking and permits the checking of
various converter parameters which would normally only be accessible while the signal is present
(i.e., when an output is connected to an aircraft). An output cannot be switched to EF bypass mode
while an EF signal is present for that output; additionally, if an EF signal is applied while the
converter is in EF bypass mode (e.g., by connecting an output cable to an aircraft), the unit will
automatically switch that output to normal mode. Be aware that if EF bypass mode is selected, it is
possible to deliver voltage to an output cable whether or not that cable is connected to an aircraft or
load bank. Exercise extreme caution when selecting EF bypass mode.

The EF BYPASS push button switches (1 and 2, Figure 2) are located on the bottom left of the
control PC Board. These two push buttons are used to toggle between normal and EF BYPASS
mode. The control panel will indicate the EF BYPASS status (3, Figure1) for each output.

(1) EF ByPass/Normal Mode (See Figure 2)

These two push buttons switches are spring assisted for momentary contact; meaning they do
not lock in or out. Just press the push button in to change the setting and press again to go
back.

The push button for output 1 is the top most of the two. The push button for output 2 is the
bottom switch of the two.

Output cables are “LIVE” when the EF BYPASS mode is selected. Exercise
extreme caution or FATAL SHOCK may result.

September 21, 2000 Chapter 1-3

Page 5

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

Chapter 1-3 September 21, 2000
Page 6

1. KEY PAD DISABLE Switch

2. #1 EF BYPASS push button

3. #2 EF BYPASS push button

Figure 2

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

a. Open the front door of converter using an 8 mm allen wrench.

b. Reach inside and depress either of the two BYPASS/NORMAL push button switches to

change the setting for that output.

c. Close and latch the front door.

k. KEYPAD DISABLE switch

Once the operator sets the output voltage and line drop compensation values for the ADV, it is
possible to lock both values to restrict change from the operator at the control panel. The KEYPAD
DISABLE toggle switch (1, Figure 2), located above the EF BYPASS push button switches (2 and 3)
on the Control PC Board, will prevent these values from being changed. Once triggered, the
OUTPUT VOLTAGE ADJUSTMENT push button (2, Figure 1) and LINE DROP COMPENSATION
ADJUSTMENT push button (18, Figure 1) on the control panel will be disabled.

If this switch is pointed towards the PC Board, then the two control panel push buttons are disabled.

(1) Open the front door of converter using an 8 mm allen wrench.

(2) Reach inside and toggle the KEYPAD DISABLE switch. The switch is located on the Control

Panel PC Board above the EF BYPASS push button switches.

(3) Toggle the switch towards the Control PC Board to activate the switch and disable the OUTPUT

VOLTAGE ADJUSTMENT and LINE DROP COMPENSATION ADJUSTMENT push buttons.

(4) Close and latch the front door.

September 21, 2000 Chapter 1-3

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PoWerMaster ADV / Series 500048A / Solid State Converter

This page intentionally left blank.

Chapter 1-3 September 21, 2000
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OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

Chapter 2. Servicing / Troubleshooting

Section 1. Troubleshooting

1. General

The troubleshooting information provided in this section is limited to procedures for determining the
cause of faults, and for restoring the converter to operation after faults develop which shut off the unit.

Calibration, service, and repair is to be done by Hobart Ground Power Service Department personnel,
authorized distributors of Hobart Ground Power equipment, or trained qualified electronic technicians.

If you have any questions concerning your Hobart Ground Power, contact our Service Department by
mail, telephone, FAX or E-Mail.

Write: Hobart Ground Power

Service Department

1177 Trade Square East

Troy, Ohio 45373

U.S.A.

In U.S.A. Call: [phone] (Parts)

[phone] (Service)

From Foreign Countries Call: [phone] (Parts)

[phone] (Service)

FAX Toll Free inside U.S.A.: [phone]

[phone]

E-Mail [e-mail]

WWW hobartgroundpower.com

September 21, 2000 Chapter 2-1

Page 1

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

2. Model 101 Control Monitoring (See Fig 1)

The Hobart PoWerMaster ADV Model 101 Control performs complete diagnostic testing upon each
startup and continuous monitoring of all critical circuits and operating electrical values. If the control
senses a problem with one of the circuits or if any of the electrical values exceeds its safe operating
limit, the Model 101 Control will shut the converter down, or may allow the converter to continue
operation depending on the severity of the condition.

a. Warnings

Warnings are displayed when irregular conditions exist that are not necessarily a threat to the
converter, aircraft, or personnel exist. The converter will continue to operate normally and will
display the warning in the Fault Code Display (See Figure 1).

An EF By-pass warning typically occurs when an output cable is removed from an aircraft before
that output is turned off. EF warnings are stored in memory, as part of an event record, and can be
used to indicate patterns of improper operation.

b. Faults

Faults result when any of the fault limits are exceeded, when an internal problem occurs, or under
certain conditions that would cause injury to personnel or damage to an aircraft or the converter.
The PoWerMaster ADV displays a “Fault Code” (1-3, Fig. 1, Item 17) and the “Fault Lamp” (1-3,
Fig. 1, Item 8) will illuminate to alert the operator that something has gone wrong during operation.
Faults are also stored in memory as an event records. The fault limits and conditions are preset at
the factory.

c. Fault Codes (See Fig. 1)

The numbers that appear in the Fault Code display (1-3, Fig. 1, Item 17) are used for
troubleshooting the PoWerMaster ADV.

To read the four digit fault code properly, it must be understood that the first two digits represent
one half of the fault code and the last two digits represent the other half.

· The two digits on the left side of the Fault Code represent the Command.

·

The two digits on the right side of the Fault Code represent the Fault Condition.

(1) Commands

The ongoing operations conducted by the ADV are driven by the list of commands in figure 1. The
control PC board communicates these commands to all of the PC boards in the converter. The first
half of the fault code identifies the command that was present when the fault occurred, as well as
the PC board which was commanded.

(2) Fault Condition

The two numbers located on the right side of the four digit fault code make up the ADV Fault. This
half of the fault code identifies the detected Fault as well as the PC Board which detected it.

Chapter 2-1 March 16/98
Page 2

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

Fault Code Quick Reference Chart V1.01

1 EF 1 NOT PRESENT WARNING

EF

2 EF 2 NOT PRESENT WARNING

EF

n 1 CONTACTOR 1 NOT PRESENT WARNING

WARNINGS

COMMANDS

UNKNOWN COMMAND 00
ADV SELF TEST 01
CTL LAMP TEST 02
IPC STATUS CHECK 04
SCB STATUS CHECK 05
MOD STATUS CHECK 06
IOB STATUS CHECK 07
CTL STATUS CHECK 08
IPC INPUT VOLTAGE TEST 11
IPC SYSTEM POWER SUPPLY TEST 12
IOB AUX POWER SUPPLY TEST 13
CTL ID CHECK 15
IPC ID CHECK 16
IOB CONTACTOR CHECK 17
CTL MEMBRANE CHECK 18
CTL REPORT CONFIG 22
IOB PENDENT CHECK 26
IPC TEST DOOR SWITCHES 27
IPC 12 PULSE OVERHEAT TEST 28
CTL OVERHEAT TEST 29
MOD OVERHEAT TEST 30
IPC BUS DISCHARGE PCB TEST 32
IPC DISCHARGE BUS 33
IPC BUS VOLTAGE TEST 34
CTL TEST FOR NO OUTPUT 39
MOD DRIVER TEST 41
MOD IGBT A PAIR TEST 42
MOD IGBT B PAIR TEST 43
MOD IGBT C PAIR TEST 44
ADV STANDBY 52
ADV RAMP UP 54
IPC TEST FOR BUS SHORT 57
IPC RAMP TO MINIMUM 59
IPC RAMP TO 25 PERCENT 61
IPC RAMP TO 50 PERCENT 63
IPC RAMP TO FULL OUTPUT 67
MOD RAMP TO FULL OUTPUT 79
SCB TEST OUTPUT FREQUENCY 82
CTL TEST OUTPUT 85
ADV 400HZ ON 87
ADV SHUTDOWN 93
ADV FAULT SHUTDOWN 99

COMMANDS FAULTS

Fault Code

See Operation and Maintenance Manual
for detailed troubleshooting procedures.

Co

n 2 CONTACTOR 2 NOT PRESENT WARNING

Co

o r DOOR OPEN WARNING

do

FRONT PANEL ADJUST DISABLE WARNING

. 00 INVALID FAULT
. 04 IPC BUS SHORT FAULT
. 06 IPC SELF TEST FAULT
. 07 IPC REAR DOOR SWITCH TRIP FAULT
. 08 IPC FRONT DOOR SWITCH TRIP FAULT
. 09 IPC POS 5VDC FAULT
. 10 IPC POS 12VDC FAULT
. 11 IPC NEG 12VDC FAULT
. 13 IPC DISCHARGE BOARD FAULT
. 14 IPC DISCHARGE FAULT
. 15 IPC 12 PULSE OVERHEAT FAULT
. 16 IPC SCR FAULT
. 17 IPC BUS VOLTAGE LOW FAULT
. 18 IPC BUS VOLTAGE HIGH FAULT
. 19 IPC INPUT VOLTAGE TOO HIGH FAULT
. 20 IPC INPUT VOLTAGE TOO LOW FAULT
. 21 IPC INPUT PHASE LOSS FAULT
. 23 IPC COMM FAULT
. 27 SCB SELF TEST FAULT
. 28 SCB OUTPUT OVER FREQ FAULT
. 29 SCB OUTPUT UNDER FREQ FAULT
. 30 SCB COMM FAULT

34 MOD DRIVER BOARD 2 FAULT
. 35 MOD SELF TEST FAULT
. 36 MOD NBPT CURRENT TRIP FAULT
. 37 MOD VBUS OVER VOLTAGE FAULT
. 38 MOD DRIVER BOARD FAULT
. 39 MOD IGBT PAIR A FAULT

40 MODIGBTPAIRA2FAULT
. 41 MOD IGBT PAIR B FAULT

42 MODIGBTPAIRB2FAULT
. 43 MOD IGBT PAIR C FAULT

44 MODIGBTPAIRC2FAULT
. 45 MOD OUTPUT SHORT CIRCUIT FAULT
. 47 MOD HEATSINK OVERTEMP FAULT
. 48 MOD TRANSFORMER OVERTEMP FAULT
. 49 MOD NBPT FAULT
. 50 MOD COMM FAULT
. 51 MOD VCESAT FAULT
. 57 CTL SELF TEST FAULT
. 58 CTL TRANSFORMER ID FAULT
. 59 CTL RS232 FAULT
. 60 CTL OUTPUT OVER VOLTAGE FAULT
. 61 CTL OUTPUT UNDER VOLTAGE FAULT
. 62 CTL OUTPUT 1 OVERLOAD FAULT

. 65 CTL OUTPUT 2 OVERLOAD FAULT
. 68 CTL MACHINE OVERLOAD FAULT
. 72 CTL OUTPUT VOLTAGE IMBALANCE FAULT
. 73 CTL MEMORY FAULT
. 74 CTL UNBALANCED LOAD FAULT
. 75 CTL MEMBRANE FAULT
. 79 IOB SELF TEST FAULT
. 80 IOB AUX24 FAULT
. 81 IOB EF 1 VOLTAGE TOO HIGH FAULT
. 82 IOB EF 1 VOLTAGE TOO LOW FAULT
. 83 IOB EF 2 VOLTAGE TOO HIGH FAULT
. 84 IOB EF 2 VOLTAGE TOO LOW FAULT
. 89 IOB REMOTE 1 FAULT
. 90 IOB REMOTE 2 FAULT
. 91 IOB CONTACTOR SENSE FAULT
. 92 IOB COMM FAULT
. 93 IOB CONTACTOR 1 CONTACTS STUCK FAULT
. 94 IOB CONTACTOR 2 CONTACTS STUCK FAULT
. 99 ADV COMM FAULT

FAU LT S

12/99P/N 286377

September 21, 2000 Chapter 2-1

Commands and Faults list

Figure 1

Page 3

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

d. Self Test

When input power is first applied or after a fault has been reset, the converter performs a complete
self diagnostic of its internal circuitry. The input power lamp will flash for several seconds indicating
self test is in process.

During a self test, the converter will perform ADV Commands “01.” through “52.” (ADV SELF TEST
through ADV STANDBY ). The converter performs each test one at a time and in the order listed.
When a fault is detected during self test, the current Command and detected Fault are indicated in
the Fault Code display (1-3, Figure 1, Item 16).

By referencing the Fault Code chart (Figure 1), the converter state and exact nature of the fault can
be determined. Not only is the failed test identified, but the tests that passed are also known. The
tests are ordered such that failures which can cause misleading symptoms ( ex. bad power supply )
are checked first. This method yields a high degree of troubleshooting accuracy.

e. Ramp Up

When an operator presses an ON button to apply power to an aircraft, the converter performs a
number of commands to perform an orderly ramp up. During ramp up, the converter also performs
self diagnostics. The output contactor will only close when the output power is within specifications.

During ramp up, the converter will perform ADV Commands “54.” through “87.” (ADV RAMP UP
through ADV 400Hz ON). The converter performs each command one at a time and in the order
listed. When a fault is detected during ramp up, the current Command and detected Fault are
indicated in the Fault Code display (1-3, Figure 1, Item 16).

By referencing the Fault Code chart (Figure 1), the converter state and exact nature of the fault can
be determined. During ramp up, not only is the failed command identified, but the commands that
passed are also known. The commands are ordered such that failures which can cause misleading
symptoms are checked first. When the fault is reset, the converter will perform a self test and will
often detect the fault again revealing additional information. This method yields a high degree of
troubleshooting accuracy.

Chapter 2-1 September 21, 2000
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OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

f. 400 Hz Operation

While applying power to an aircraft, the converter continually monitors all critical circuits and
operating electrical values.

During 400 Hz operation, the converter continually performs ADV Command “87” (ADV 400Hz ON).
When a fault is detected during 400Hz operation, this Command and the detected Fault are
indicated in the Fault Code display (1-3, Figure 1, Item 16).

By referencing the Fault Code chart (Figure 1), the converter state and exact fault can be
determined. When the fault is reset, the converter will perform a self test and will often detect the
fault again revealing additional information. This method yields a high degree of troubleshooting
accuracy.

g. Fault Code Charts/Tables :

Figure 1 contains a quick reference chart. This chart is also located inside the front door of the
converter.

A complete troubleshooting chart is located on Page 8 of this section.

September 21, 2000 Chapter 2-1

Page 5

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

h. Troubleshooting examples:

(1) Example 1:

The converter is operating and delivering power to an aircraft when the front door of the
converter is opened. The unit shuts down and the red fault lamp on the control illuminates.
The fault code display indicates an “87.08”.

Command

ADV 400 Hz ON

Fault

IPC FRONT DOOR

SWITCH TRIP FAULT

Fault Code

The numerals “87.” on the left of the fault code display indicates that the machine was
operating, and delivering 400Hz power when the fault occurred.

The numerals “.08” on the right of the fault code display indicates that the IPC PC board
detected a front door switch trip during operation.

Chapter 2-1 March 16/98
Page 6 Revised 1/4/99

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

(2) Example 2:

Now with the door still open, the fault is reset by pressing the 400 Hz Off button on the front
panel. The Input Power lamp begins to flash to indicate self test in process. After a couple of
seconds, another fault occurs and the fault code display now indicates an “27.08”.

Command

IPC TEST DOOR SWITCHES

Fault

IPC FRONT DOOR

SWITCH TRIP FAULT

Fault Code

The numerals “27.” on the left of the fault code display indicates that the machine was
executing a self test and that the IPC PC board was testing the door switches.

The “27.” also indicates that that tests “01.” through “26.” passed and that therefore the power
supplies, contactors, remote pendents, etc., are ok.

COMMANDS

SELF
TEST

UNKNOWN COMMAND 00 -----PASSED
ADV SELF TEST 01 -----PASSED
CTL LAMP TEST 02 -----PASSED
IPC STATUS CHECK 04 -----PASSED
SCB STATUS CHECK 05 -----PASSED
MOD STATUS CHECK 06 -----PASSED
IOB STATUS CHECK 07 -----PASSED
CTL STATUS CHECK 08 -----PASSED
IPC INPUT VOLTAGE TEST 11 -----PASSED
IPC SYSTEM POWER SUPPLY TEST 12 -----PASSED
IOB AUX POWER SUPPLY TEST 13 -----PASSED
CTL ID CHECK 15 -----PASSED
IPC ID CHECK 16 -----PASSED
IOB CONTACTOR CHECK 17 -----PASSED
CTL MEMBRANE CHECK 18 -----PASSED
CTL REPORT CONFIG 22 -----PASSED
IOB PENDENT CHECK 26 -----PASSED

IPC TEST DOOR SWITCHES 27 -----FAILED

IPC 12 PULSE OVERHEAT TEST 28
CTL OVERHEAT TEST 29
MOD OVERHEAT TEST 30
IPC BUS DISCHARGE PCB TEST 32
IPC DISCHARGE BUS 33
IPC BUS VOLTAGE TEST 34
IPC BOOSTER BOARD TEST 36
IPC BOOSTER IGBT TEST 37
CTL TEST FOR NO OUTPUT 39
MOD DRIVER TEST 41
MOD IGBT A PAIR TEST 42
MOD IGBT B PAIR TEST 43
MOD IGBT C PAIR TEST 44
ADV STANDBY 52

The numerals “.08” on the right of the fault code display indicates that the IPC PC board
detected a front door switch trip during self test.

The door is now properly latched. The 400 Hz Off button is pressed to reset the fault. The
Input Power lamp flashes for several seconds to indicate self test. The input power lamp then
illuminates continuously to indicate the converter is now ready for use.

September 21, 2000 Chapter 2-1

Page 7

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

Troubleshooting Table

ADV Commands

Fault

Code

00.__

01._ _ ADV SELF TEST All boards go to self test mode.

02._ _ CTL LAMP TEST CTL turn on all front panel lights.

03._ _

04._ _ IPC STATUS CHECK IPC check PC board status.

05._ _ SCB STATUS CHECK SCB check PC board status.

06._ _ MOD STATUS CHECK MOD check PC board status.

07._ _ IOB STATUS CHECK IOB check PC board status.

08._ _ CTL STATUS CHECK CTL check PC board status.

09.__

10.__

11._ _ IPC INPUT VOLTAGE TEST IPC test input voltage within limits.

12._ _ IPC SYSTEM POWER SUPPLY TEST IPC test system power supplies within limits.

13._ _ IOB AUX POWER SUPPLY TEST IOB test aux power supply within limits

14.__

15._ _ CTL ID CHECK CTL detect main transformer rating.

Name Description

16._ _ IPC ID CHECK IPC detect 12 pulse transformer presence.

17._ _ IOB CONTACTOR CHECK IOB detect contactors.

18._ _ CTL MEMBRANE CHECK CTL check front switch panel for shorts.

19.__ `

20.__

21.__

22._ _ CTL REPORT CONFIG

23.__

24.__

25.__

26._ _ IOB PENDENT CHECK IOB check for stuck pendent buttons.

27._ _ IPC TEST DOOR SWITCHES IPC test door switches for closed position.

28._ _ IPC 12 PULSE OVERHEAT TEST IPC test 12 pulse transformer for overheat.

29.__

Chapter 2-1 September 21, 2000
Page 8

CTL display kVA rating, 6 or 12 pulse config.,

and number of contactors.

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

Troubleshooting Table

ADV Commands

Fault

Code

30._ _ MOD OVERHEAT TEST

33._ _

32._ _ IPC BUS DISCHARGE PCB TEST IPC test bus discharge PC board.

33._ _ IPC DISCHARGE BUS

34._ _ IPC BUS VOLTAGE TEST IPC test bus voltage.

35.__

36.__

37.__

38.__

39._ _ CTL TEST FOR NO OUTPUT CTL test for output voltage = 0.

40.__

41._ _ MOD DRIVER TEST MOD test driver PC board.

42._ _ MOD IGBT A PAIR TEST MOD test IGBT pair A for shorts.

43._ _ MOD IGBT B PAIR TEST MOD test IGBT pair B for shorts.

Name Description

MOD test heatsink and main transformer for

overheat.

IPC command bus discharge PC board to

discharge.

44._ _ MOD IGBT C PAIR TEST MOD test IGBT pair C for shorts.

45.__

46.__

47.__

48.__

49.__

50.__

51.__

52._ _ ADV STANDBY All boards go to stand-by mode.

53._ _ ADV RAMP UP All boards go to ramp-up mode.

54.__

55.__

56.__

57._ _ IPC TEST FOR BUS SHORT IPC test D.C. Bus for short circuit.

58.__

September 21, 2000 Chapter 2-1

Page 9

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

Troubleshooting Table

ADV Commands

Fault

Code

59._ _ IPC RAMP TO MINIMUM

60.__

61._ _ IPC RAMP TO 25 PERCENT

62.__

63._ _ IPC RAMP TO 50 PERCENT

64._ _

65._ _

66.__

67._ _ IPC RAMP TO FULL OUTPUT

68.__

69.__

70.__

71.__

Name Description

IPC ramp SCR duty cycle to minimum bus

voltage.

IPC ramp SCR duty cycle to 25 percent duty

cycle

IPC ramp SCR duty cycle to 50 percent duty

cycle

IPC ramp SCR duty cycle to full output duty

cycle

72.__

73.__

74.__

75.__

76.__

77.__

78.__

79._ _ MOD RAMP TO FULL OUTPUT MOD ramp 400Hz voltage to full.

80.__

81.__

82._ _ SCB TEST OUTPUT FREQUENCY SCB test 400Hz frequency within limits

83.__

84.__

85._ _ CTL TEST OUTPUT CTL test 400Hz voltage within limits.

86.__

Chapter 2-1 September 21, 2000
Page 10

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

Troubleshooting Table

ADV Commands

Fault

Code

87._ _ ADV 400HZ ON All boards go to 400Hz on mode.

88.__

89.__

90.__

91.__

92.__

93._ _ ADV SHUTDOWN All boards shutdown (normal shutdown).

94.__

95.__

96.__

97.__

98.__

99._ _ ADV FAULT SHUTDOWN All boards shutdown (abnormal shutdown).

Name Description

September 21, 2000 Chapter 2-1

Page 11

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

Troubleshooting Table

Faults

Fault

Code

__.00

__.01

__.02

__.03

__.04 IPC BUS SHORT FAULT Shorted SCR Replace SCR

__.05

__.06 IPC SELF TEST FAULT IPC Board failed self test Replace IPC Board

IPC REAR DOOR SWITCH TRIP FAULT Rear door is open

__.07

IPC FRONT DOOR SWITCH TRIP FAULT Front door is open

__.08

__.09 IPC POS 5VDC FAULT Power Supply PS2 is defective Replace PS2

__.10 IPC POS 12VDC FAULT Power Supply PS1 is defective Replace PS1

__.11 IPC NEG 12VDC FAULT Power Supply PS2 is defective Replace PS2

__.12

IPC DISCHARGE BOARD FAULT Discharge Board is defective

__.13

IPC DISCHARGE FAULT Discharge Board is defective

__.14

IPC 12 PULSE OVERHEAT FAULT Filter Clogged

Name Possible Cause(s) Corrective Action

Close and latch rear door

Interlock switch is defective

Interlock switch is defective

Discharge Resistor is open

Discharge Resistor is open

Replace interlock switch S2

Close and latch front door

Replace interlock switch S7

Replace Discharge Board A7

Replace Discharge Resistor R3

Replace Discharge Board A7

Replace Discharge Resistor R3

Clean or Replace Filter

__.15

__.16 IPC SCR FAULT SCR shorted or open Replace SCR

IPC BUS VOLTAGE LOW FAULT SCR open

__.17

__.18 IPC BUS VOLTAGE HIGH FAULT Improper No Break Power Transfer Check output cable and load

IPC INPUT VOLTAGE TOO HIGH FAULT Input voltage too high

__.19

IPC INPUT VOLTAGE TOO LOW FAULT Input voltage too low

__.20

Fan is inoperative

Defective thermal switch in 12 pulse
transformer

Input power control board defective

Input Power Control Board defective

Input Power Control Board defective

Check fan

Replace thermal switch

Replace SCR

Replace IPC board A4

Check input source, correct as
necessary

Replace Input Power Control Board
A4

Check input source, correct as
necessary

Replace Input Power Control Board
A4

Chapter 2-1 September 21, 2000
Page 12

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

Troubleshooting Table

Faults

Fault
Code

IPC INPUT PHASE LOSS FAULT Loss of input phase detect

__.21

__.22

__.23

__.24

__.25

__.26

__.27

__.28 SCB OUTPUT OVER FREQ FAULT Modulator Board defective Replace Modulator Board A3

__.29 SCB OUTPUT UNDER FREQ FAULT Modulator Board defective Replace Modulator Board A3

__.30

__.31

__.32

__.33

__.34

__.35 MOD SELF TEST FAULT Modulator Board failed self test Replace Modulator Board A3

__.36

__.37 MOD VBUS OVER VOLTAGE FAULT Faulty No Break Power Transfer Reset and restart converter

__.38 MOD DRIVER BOARD FAULT Defective Driver Board Replace Driver Board

__.39 MOD IGBT A FAULT Phase A IGBT defective Replace PM1 & PM2

__.40

__.41 MOD IGBT B FAULT Phase B IGBT defective Replace PM3 & PM4

__.42

__.43 MOD IGBT C FAULT Phase C IGBT defective Replace PM5& PM6

__.44

__.45

__.46

IPC COMM FAULT Comm fault on Input Control Board Replace Input Power Control Board

SCB SELF TEST FAULT Signal Conditioning Board failed self

SCB COMM FAULT Comm fault on Signal Conditioning

MOD NBPT CURRENT TRIP FAULT High current No Break Power Transfer Check output cable and load

MOD OUTPUT SHORT CIRCUIT FAULT Shorted output Check output cable and load

MOD HEATSINK OVERTEMP FAULT Filter clogged

Name Possible Cause(s) Corrective Action

Check input source, correct as
necessary

Input Power Control Board defective

test

Board

Replace Input Power Control Board
A4

A4

Replace Signal Conditioning Board A6

Replace Signal Conditioning Board A6

Reset and restart converter

Reset and restart converter

Clean or replace filter

__.47

September 21, 2000 Chapter 2-1

Fan inoperable

Defective Thermal Switch

Check fan

Replace switch S4

Page 13

Fault

Code

__.48

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

Troubleshooting Table

Faults

Name Possible Cause(s) Corrective Action

MOD TRANSFORMER OVERTEMP
FAULT

Filter clogged

Fan inoperable

Clean or replace filter

Check fan

Defective Thermal Switch

__.49 MOD NBPT FAULT Improper No Break Power Transfer Reset and restart converter

__.50 MOD COMM FAULT Comm fault on Modulator Board Replace Modulator Board A3

MOD VCESAT FAULT High current No Break Power

__.51

__.52

__.53

__.54

__.55

__.56

__.57 CTL SELF TEST FAULT Control Board failed self test Replace Control Board A2

__.58

__.59 CTL RS232 FAULT RS232 Comm fault Replace Control Board A2

__.60

CTL TRANSFORMER ID FAULT Transformer ID resistor is missing,

CTL OUTPUT OVER VOLTAGE FAULT Voltage set too high

Transfer.

Shorted Output

Defective IGBT

Defective Driver board

open, or incorrect value

Line drop comp. Set too high

Signal Conditioning BD. defective

Replace switch S5

Reset and restart converter

Check output cable and load.
Reset and restart converter

Replace IGBT pair

Replace Driver board

Replace resistor R4

Reset and restart converter

Reset and restart converter

Replace Signal Conditioning BD. A6

CTL OUTPUT UNDER VOLTAGE FAULT Voltage set too low

__.61

__.62 CTL OUTPUT 1 OVERLOAD FAULT Overload on Output 1 Reset and restart converter

__.63

__.64

__.65 CTL OUTPUT 2 OVERLOAD FAULT Overload on Output 2 Reset and restart converter

__.66

__.67

__.68 CTL MACHINE OVERLOAD FAULT Load over rating of converter Reset and restart converter

__.69

__.70

Chapter 2-1 September 21, 2000
Page 14

Modulator Board defective

Signal Conditioning BD. Defective

Modulator Board defective

Replace Modulator Board A3

Reset and restart converter

Replace Signal Conditioning BD. A6

Replace Modulator Board A3

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

Troubleshooting Table

Faults

Fault
Code

__.71

CTL OUTPUT VOLT. IMBALANCE FAULT Load is Unbalanced

Name Possible Cause(s) Corrective Action

Reset and Restart Converter

__.72

__.73 CTL MEMORY FAULT Control Board is defective Replace Control Board

CTL UNBALANCED LOAD FAULT Load is unbalanced

__.74

CTL MEMBRANE FAULT Button held on during self test

__.75

__.76

__.77

__.78

__.79 SELF TEST FAULT I/O Board failed self test Replace I/O Board A1

__.80 AUX24 FAULT I/O Board fuse blown Replace I/O Board fuse

IOB EF 1 VOLTAGE TOO HIGH FAULT EF Voltage being sent from aircraft on

__.81

IOB EF 1 VOLTAGE TOO LOW FAULT EF Voltage being sent from aircraft on

__.82

IOB EF 2 VOLTAGE TOO HIGH FAULT EF Voltage being sent from aircraft on

__.83

Modulator Board is defective

Signal Conditioning Board defective

Output cable is defective

Button stuck on control membrane

Output 1 to the converter on TB1-6to
N is too high

Output Cable is Defective

Output 1 to the converter on TB1-6to
N is too low

Output Cable is Defective

Output 2 to the converter on TB1 - 12
to N is too high

Replace Modulator Board A3

Replace Signal Conditioning Bd. A6

Reset and restart converter

Check output cable

Reset and restart converter

Replace membrane switch panel S1

Reset and restart converter

Check Output Cable

Reset and restart converter

Check Output Cable

Reset and restart converter

IOB EF 2 VOLTAGE TOO LOW FAULT EF Voltage being sent from aircraft on

__.84

__.85

__.86

__.87

__.88

IOB REMOTE 1 FAULT Button held down during self test

__.89

September 21, 2000 Chapter 2-1

Output Cable is Defective

Output 2 to the converter on TB1 - 12
to N is too low

Output Cable is Defective

Stuck button or open wire on remote
for output #1

Check Output Cable

Reset and restart converter

Check Output Cable

Reset and restart converter

Repair or replace remote push
buttons.

Page 15

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

Troubleshooting Table

Faults

Fault

Code

IOB REMOTE 2 FAULT Button held down during self test

__.90

__.91 IOB CONTACTOR SENSE FAULT Contactor coil open Replace Contactor

__.92

__.93

__.94

__.95

__.96

__.97

__.98

__.99 ADV COMM FAULT Converter comm fault Replace control board A2

IOB COMM FAULT

IOB CONTACTOR 1 CONTACTS STUCK
FAULT

IOB CONTACTOR 2 CONTACTS STUCK
FAULT

Name Possible Cause(s) Corrective Action

Reset and restart converter

Stuck button or open wire on remote
for output #2

Comm fault on I/O board

Contactor on output #1 stuck closed Replace output K1 contactor

Contactor on output #2 stuck closed Replace output K2 contactor

Repair or replace remote pushbuttons.

Replace I/O board (A1)

Chapter 2-1 September 21, 2000
Page 16

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

Converter Protective Output Faults

Over Voltage Trips at 125 volts after a 1-second time delay

Under Voltage Trips at any value between 60 volts and 104 volts after a

Over Frequency Trips at any value between 430-Hz and 440-Hz after a

Under Frequency Trips at any value between 350-Hz and 365-Hz after a

Overloads Trips in approximately 10 minutes at 125% load on either

Fault Limits are described above and are detailed in the Fault Code Chart earlier in the chapter.

3.

Troubleshooting Procedures

The remainder of this section provides further explanation of the troubleshooting information given in
the preceding table. When necessary, detailed testing procedures are given to help determine which of
several possible components may be in need of repair or replacement. Actual removal and
replacement instructions are given in Chapter 3.

Trips at 140 volts in 160 milliseconds
Trips at 180 volts in 50 milliseconds

8-second time delay. Trips immediately at any voltage
below 60 volts.

14-second time delay. Trips immediately at any
frequency above 440-Hz.

14-second time delay. Trips immediately at any
frequency below 350-Hz.

output or overall converter rating.
Trips in approximately 30 seconds at 150% load on either
output or overall converter rating.
Trips in approximately 10 seconds at 200% load on either
output or overall converter rating.

NOTE: There are no procedures listed for testing or replacing individual components on any PC board. Inop-

erative PC boards cannot be repaired in the field, but must be replaced as a complete unit. PC boards
may be returned to the factory for replacement. Contact Hobart Brothers service for parts and replace­ment instructions.

WARNING

High voltages may be present inside the converter cabinet, even when the unit
is off. Exercise extreme caution when testing and replacing components or
FATAL SHOCK may result.

Before testing any components inside the converter, always make certain that the DC bus is fully
discharged. In certain circumstances, such as a failure of the DC bus discharge PC board, the DC bus
may not be discharged when the converter shuts down. Several hundred volts may still be present at
the bus.

Test the DC bus with a voltmeter to be sure that it is fully discharged. The bus can be tested using test
jacks TP1 and TP2 (2-3, Figure 1) on the upper left corner of the signal conditioning board inside the
front door. If the bus is not discharged, close the converter door, wait at least 15 minutes, and test it
again. Do not perform any work inside the converter while the DC bus remains charged.

a. Door Switch Fault

The converter is equipped with two door interlock switches: S7 on the front door and S2 on the back
door. Opening either door will disable the unit. Therefore both doors must be closed to operate the
unit. If a door interlock fault occurs, follow the procedure below to determine the cause and restore
the converter to normal operation.

September 21, 2000 Chapter 2-1

Page 17

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

(1) Make sure both the front and back converter doors are tightly closed and all six latches are

fastened. To fasten the latches, turn each one clockwise with an 8 mm (5/16 inch) Allen wrench
until it stops.

(2) Press the control panel 400Hz OFF button to reset the converter.

(3) Restart the converter normally and attempt to deliver output power.

(4) If this fault reoccurs, one or both of the door interlock switches may be faulty. To test the

switches, follow these steps:

a. Disconnect input power from the converter.

WARNING

High voltages may be present inside the converter cabinet, even when the unit
is off. Exercise extreme caution when testing and replacing components or
FATAL SHOCK may result.

b. Open the front and back doors by turning all three latches counterclockwise with an 8 mm

Allen wrench. Exercise extreme caution while the doors is open, as high voltages may be
present, even when the unit is off.

c. Test the DC bus with a voltmeter to be sure that it is fully discharged. The bus can be tested

using test jacks TP1 and TP2 on the upper left corner of the signal conditioning board inside
the front door. If the bus is not discharged, close the converter door, wait at least 15 minutes,
and test it again. Do not perform any work inside the converter while the DC bus remains
charged. See Figure 1 for the proper test points.

d. Check the continuity of each door interlock switch with an ohmmeter. When the doors are

open, the switch contacts will also be open, and there should be approximately 100-W or more

across the terminals.

e. Press and hold the white post in front of each switch and measure the continuity. The switch

contacts will be closed, and there should be no resistance across the terminals.

f. If a switch is faulty, it must be replaced. See Chapter 3 for replacement procedures.

b. Output Current Overload Fault

If an output current fault occurs, follow the procedure below to determine the cause and restore the
converter to normal operation.

(1) Make sure the aircraft is not placing a load on the converter greater than the unit’s power rating.

Turn off unnecessary accessories on the aircraft. Check for a shorted output or output cable.

(2) Press the control panel 400Hz OFF button to reset the converter.

(3) Restart the converter normally and attempt to deliver output power.

c. Neutral Line Current Fault

A neutral line current fault may be caused by unequal loading of the output phases by the aircraft, or
one or two open or shorted phases in the output cable or at the aircraft. If a neutral line current fault
occurs, follow the procedure below to determine the cause and restore the converter to normal
operation.

(1) Make sure the aircraft is not placing an excessive load on one output phase. The loads placed on

each phase should be nearly equal. Check the output cable, aircraft plug, and contactor
connections, and repair as necessary.

(2) Press the control panel 400Hz OFF button to reset the converter.

(3) Restart the converter normally and attempt to deliver output power.

Chapter 2-1 September 21, 2000
Page 18

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

Section 2. Calibration

IMPORTANT

As explained in Section 1-1, the Model 101 control permits monitoring and testing of critical circuits
prior to and during operation. After major repair, major parts replacement, or overhaul, the Model 101
Controls will perform a thorough analysis of converter circuits. If adjustments are required, calibrations
may be made from inside the front door of the converter using the Signal Conditioning P.C. Board.

1.

Test Preparation

a. Calibration adjustments must be made while the front door is open and the converter is sending

output power. All test measurements can be taken behind the front door of the converter or at the
ends of the output cables. It is not necessary to have access to the back door for calibration
purposes. Make sure the back door is tightly closed. The unit is equipped with two door interlock
switches: S7 on the front door and S2 on the back door (See Figure 1). Opening either door will
prevent the unit from operating therefore, S7 (front) must be bypassed while performing
measurements inside the front of the unit (Figure 4)

Before attempting to make tests and adjustments on the converter, READ THIS
ENTIRE SECTION to become familiar with the proper procedures.

WARNING

High voltages may be present inside the converter cabinet even when the unit is
off. Exercise extreme caution when taking measurements or FATAL SHOCK
may result.

September 21, 2000 Chapter 2-2

Door Interlock Switches (S2 & S7)

Figure 1

Page 1

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

b. To bypass S7, open front door by turning all three latches counterclockwise with an 8mm allen

wrench.

c. Test the DC bus (1, Figure 3) with a voltmeter to be sure that it is fully discharged. The bus can be

tested using test jacks TP1 and TP2 on the upper left corner of the signal conditioning board inside
the front door. If the bus is not discharged, close the converter door, wait at least 15 minutes, and
test it again. While the DC bus remains charged.

d. Press the end of the white post behind (Figure 1), switch until it locks into place. S7 is now

bypassed and will allow the converter to operate while the front door is open.

e. Apply rated input power. Do not perform any work inside the converter from the input power source.

The green INPUT POWER lamp (7, Figure 2) on the control panel will illuminate.

f. Use output cable of proper size and length for the converter’s power output rating. Connect output

cable plug connectors from all available outputs to aircraft receptacle(s) or load bank(s). Be sure
connectors are mated fully and securely. Make a general inspection of all wiring and terminals.

WARNING

Never disconnect an output cable while output power is on.

2.

Calibration (See Figure 2)

The Model 101 Control provides automatic and continuous monitoring of numerous critical electrical
operating values.

WARNING

Exercise extreme caution while performing calibrations. FATAL SHOCK OR
PERMANENT DAMAGE TO EQUIPMENT may result if proper procedures and
precautions are not taken.

If a qualified technician, after measuring various voltage or current values with his own testing
equipment, discovers that the readings he obtained do not match the values displayed by the Model
101 Control, he may change the calibration of the unit to bring the displayed values into agreement with
the measured values. This procedure should be performed especially after major repair, major parts
replacement, and overhaul.

CAUTION

Only QUALIFIED personnel using ACCURATE test equipment should perform
calibrations. Otherwise PERMANENT DAMAGE to the converter could result.

Chapter 2-2 September 21, 2000
Page 2

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

1. 400 Hz POWER ON push button

2. OUTPUT VOLTAGE ADJUSTMENT push button

3. BYPASS ON lamp

4. EF PRESENT lamp

5. PHASE SELECT push button

6. OUTPUT VOLTAGE display

7. INPUT POWER lamp

8. FAULT lamp

9. OUTPUT 1 lamp

10. OUTPUT 2 lamp

11. OUTPUT 1 ON push button

September 21, 2000 Chapter 2-2

12. OUTPUT 2 ON push button

13. OUTPUT 1 OFF push button

14. OUTPUT 2 OFF push button

15. OUTPUT CURRENT display

16. FAULT CODE display

17. SET POINT UP AND DOWN
ADJUSTMENT push buttons

18. LINE DROP COMPENSATION
ADJUSTMENT push button

19. 400 Hz POWER OFF push button

Control Panel

Figure 2

Page 3

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

1

4

5

6

3

Current LEDs

9

8

72

Signal Conditioning Board

Figure 3

a. Voltage Calibration Procedure (See Figure 3)

The voltage settings on this converter are calibrated at the factory however onsight adjustments
may be made using the following procedure..

To begin the calibration procedure, the converter must be ON and a load must be present. The
following calibrations are to be performed on the Signal Conditioning Board (Figure 3) which is
located inside the front door (Figure 4). The SCB has a series of LEDs that indicate which signal is
being calibrated. The LEDs VA, VB, and VC are used to indicate that the output phase A, B, and C
voltages are being adjusted.

(1) Turn the converter on, and place a load on any of the converter outputs.

Chapter 2-2 September 21, 2000
Page 4

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

WARNING

(2) Press and hold the “POT (potentiometer) SELECT” push button (9) for 3 seconds until the “IA1”

LED (3) illuminates.

(3) Depress and release the “POT SELECT” push button repeatedly until the “VA” LED illuminates.

(4) Using a properly calibrated voltage meter, place one voltmeter lead into the"NEUTRAL" test point

(3) and the other lead into the “PHASE A” (6) test point. Turn on the voltmeter.

(5) Check that the control panel displays PHASE A (5, Figure 2); use the control panel “PHASE

SELECT” push button if needed. When power is being delivered, the voltage reading on the
voltmeter should match the voltage reading on the control panel (6, Figure 2).

(6) If the voltmeter and the control panel readings match, PHASE A calibration is complete.

(7) If the voltmeter and the control panel readings do not match, use the “ADJUST UP” (8) and

”ADJUST DOWN” (7) push buttons until the readings match.

(8) Repeat the above procedure for PHASE B (5) and PHASE C (4).

(9) When finished performing voltage calibration, Press and hold the “POT SELECT” push button (9)

for 3 seconds until all LED’s turn OFF.

b. Current Calibration Procedure (See Figure 3)

The amperage settings on this converter are calibrated at the factory however onsight adjustments
may be made using the following procedure.

High voltages will be present inside the converter cabinet when the unit is on.
Exercise extreme caution when taking measurements or FATAL SHOCK may
result.

To begin the calibration procedure, the converter must be ON and a load must be present. The
following calibrations are to be performed on the Signal Conditioning Board (SCB)(Figure 3) which
is located inside the front door (Figure 4). The SCB has a series of LEDs that indicate which signal
is being calibrated. The LEDs IA1, IB1, and IC1 are used to indicate that the phase A, B, and C
current for output 1 is being adjusted. The LEDs IA2, IB2, and IC2 are used to indicate that the
phase A, B, and C current for output 2 is being adjusted.

WARNING

A reliable and accurate ammeter is needed to complete this calibration.

a. Turn the converter on, and place a load on the outputs of interest.

WARNING

High voltages will be present inside the converter cabinet when the unit is on.
Exercise extreme caution when taking measurements or FATAL SHOCK may
result.

September 21, 2000 Chapter 2-2

Page 5

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

b. Press and hold the “POT (potentiometer) SELECT” push button (9) for 3 seconds until the

“IA1” LED (3) illuminates. This LED identifies that the PHASE A current for output 1 can now
be calibrated.

c. Using a properly calibrated ammeter, place one end of a cable clamp onto the PHASE A,

output 1 cable. Turn on the ammeter.

d. Check that the control panel displays PHASE A (5, Figure 2); use the “PHASE SELECT”

button (5) if needed. When power is being delivered, the amperage reading on the control
panel (6, Figure 2) should match the amperage reading on the ammeter.

e. If the ammeter and the control panel amperage readings match, calibration is complete.

f. If the ammeter and the control panel amperage readings do not match, use the “ADJUST

UP”(8) and “ADJUST DOWN” (7) buttons to change the control panel reading until both
values ,match.

g. Depress and release the “POT SELECT” push button (9) repeatedly until the next desired

signal for calibration is indicated.

h. Repeat the above 6 steps (b - f) to calibrate for each signal to be calibrated..

i. When finished performing calibration, depress and hold the “POT SELECT” push button (9)

for 3 seconds until all LED’s turn OFF.

and Door Interlock Switch Location

Chapter 2-2 September 21, 2000
Page 6

Signal Conditioning Board

Figure 4

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

Section 3. Scheduled Maintenance

1. General

The Hobart PoWerMaster ADV Frequency Converter is designed to be as maintenance free as
possible. Therefore there are few maintenance requirements. Field maintenance of the converter
should be done only by qualified service personnel, and should be limited to cleaning and inspection of
the unit and its components, and the replacement of lamps and fuses. All servicing and repair work,
including testing and calibration, should be referred to the Service Department of Hobart Brothers
Company, or to an authorized service shop of Hobart Brothers ground power equipment, or to qualified
electronic technicians.

2.

Scheduled Maintenance Procedure

The converter should be cleaned and inspected once every six months, or more frequently if operating
conditions warrant it. Proceed as follows with cleaning and inspection.

a. Turn off input power at the source. Make sure that power cannot be inadvertently turned back on.

WARNING

High voltage may be present inside the converter cabinet, even when the unit is
off. Exercise extreme caution or FATAL SHOCK may result.

b. Open the front and rear doors by turning all six latches counterclockwise with an 8 mm Allen

wrench. Exercise extreme caution while the doors is open, as high voltages may be present, even
when the unit is off.

c. Test the DC bus with a voltmeter to be sure that it is fully discharged. The bus can be tested using

test jacks TP1 and TP2 on the upper left corner of the signal conditioning board (Figure 1) inside the
front door. If the bus is not discharged, close the converter door, wait at least 15 minutes, and test it
again. Do not perform any work inside the converter while the DC bus remains charged. See Figure
1 for the proper test points.

d. Carefully clean dust from the interior of the converter by blowing low pressure compressed air into

the interior from the bottom of the unit first and then from the top.

WARNING

Wear eye protection and be careful to avoid blowing debris where it could cause
harm or injury.

e. Air Filter — Hobart Brothers Replacement Part No. 283159-003

The air filter helps keep clean air inside for circulation. More importantly though, its presence in the
air intake compartment provides uniform air flow through the power module heat sink (Figures 12
and 13). With a missing air filter, the air will flow through the bottom of the heat sink only, leaving
some of the internal power supplies (IGBTs) to cool improperly. For these cooling purposes, the air
filter MUST be in place while the converter is in operation.

If the filter need to be cleaned, flush with water and recoat the filter with Research Products
Corporation’s RP Super Filter Coat Adhesive.The filter (located on the bottom left side of the
converter in front) should also be inspected regularly for cleanliness. This chemical, which will
increase the effectivity of the filter by 10%, can be found by calling Research Products Corporation
at [phone]. The name of a local suppler of their products will be furnished.

The air filter should be replaced annually. It can only be removed from outside the machine.

September 21, 2000 Chapter 2-3

Page 1

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

f. Clean heat sinks and printed circuit boards using compressed air or a soft brush.

g. Inspect terminal blocks for evidence of overheating due to loose electrical connections.

h. Inspect electrical and mechanical connections for tightness. Inspect closely all compression-type

connectors.

i. Inspect printed circuit boards for evidence of overheating, such as burned resistors or capacitors.

Note that the printed circuit boards are coated with a fungus and moisture-proof coating which turns
brown on hot components. This is a normal occurrence, especially on resistors exceeding 1-watt in
rating.

j. Check and inspect all front panel components, including indicator lamps.

k. Inspect the long hinge at the front and rear of the unit. If these hinges stick and are difficult to

operate, spray hinges with a good silicone spray lubricant.

l. Inspect all wiring, leads, and cables. Inspect for cuts, abrasions, and signs of deterioration and

overheating. Inspect leads for broken strands at terminals.

m.Check to be sure that the fan is operational and does not exhibit excess bearing wear. The unit

contains one fan hidden in the center, located behind the IPC (Input Control PC Board). Removal of
the Input Control and Signal Conditioning PC Boards is required to inspect the fan, as it cannot be
seen from either door access.

n. After inspection has been completed, close and latch the front and rear doors, and turn on input

power at the source.

Te st P oi n t 1

Te st P oi n t 2

Test Points - Signal Conditioning Board

Chapter 2-3 September 21, 2000
Page 2

Figure 1

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

Chapter 3. Overhaul / Major Repair

Unscheduled Repair

1. General

Repair of the converter will consist primarily of parts replacement. Most of the components used in the
converter cannot be disassembled and repaired, and must be replaced if faulty. Additionally,
inoperative PC boards cannot be repaired in the field, but must be replaced as a complete unit. PC
boards may be returned to the factory for replacement. Contact Hobart Brothers service for parts and
replacement instructions.

2.

Service Information and Factory Repair

Questions concerning the operation, repair, and/or servicing of this converter should be directed to the
Service Department of Hobart Brothers Company. When making such an inquiry, be sure to provide
the service department with the model number, serial number, and approximate date of receipt of the
unit. If it is deemed necessary to return the unit to the factory for servicing, contact the Service
Department for authorization. It is often unnecessary to return a failed converter since the unit uses
plug-in type assemblies throughout its systems. Replacement assemblies for systems covered by this
manual are available for shipment. For details on the warranty which covers this unit, refer to the
warranty statement on the back of the cover page of this manual or contact the Hobart Service
Department.

When ordering parts from your Hobart Brothers Company Distributor, be sure to include all pertinent
information from the unit’s identification plate: Specification No., Model No., and unit rating.

If you have any questions concerning your Hobart Ground Power equipment, immediately contact our
Service Department by mail, telephone or FAX.

Write: Hobart Brother Company

Ground Power Division

Service Department

1177 Trade Square East

Troy, Ohio 45373

U.S.A.

In U.S.A. Call: [phone] (Parts)

From Foreign Countries Call: [phone] (Parts)

FAX: [phone]

September 21, 2000 Chapter 3-1

[phone] (Service)

[phone] (Service)

[phone] Toll Free in U.S.A.

Page 1

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

3. Workmanship

Perform all repairs in accordance with good electrical repair practices. All interconnecting lead
connections to components must be made with proper wire termination’s. Route all leads neatly and
secure with wire ties, cable clamps, etc.

This converter was designed to use metric hardware wherever possible, however, some of its
purchased components, such as contactors, switches, transformers..., may have standard sizes
(S.A.E.). Hobart Brothers does not recommend the use of standard size tools on metric hardware or
vise versa. Where mentioned, use only the hardware sizes reference in this manual.

CAUTION

Use only metric tools to loosen or tighten metric hardware, and as well, use only
standard size tools to loosen or tighten standard size hardware. These
fundamental practices will help to avoid insufficient tightening and rounding off
corners. Use only the tools that are specified,.

CAUTION

When reassembling parts on this converter, use only the same size hardware as
what is originally fastened to the part. The “preferred” hardware for this unit is
metric.

4.

Converter Bridge Mount Removal and Installation

If extensive repairs are to be made to a unit which is mounted on a trailer or boarding bridge, it is
suggested that the unit be removed and placed on a solid supporting structure of some kind.

WARNING

High voltages may be present inside the cabinet, even when the unit is off.
Exercise extreme caution or FATAL SHOCK may result.

a. Turn off input power at the source. Make sure that power cannot be inadvertently turned back on.

b. Open the front door by turning all three latches counterclockwise with a 8mm allen wrench.

c. Test the DC bus (Figure 1) with a voltmeter to be sure that it is fully discharged. The bus can be

tested using test jacks TP1 and TP2 on the upper left corner of the signal conditioning board inside
the front door. If the bus is not discharged, close the converter door, wait at least 15 minutes, and
test it again. Do not perform any work inside the converter while the DC bus remains charged.

d. Disconnect the three AC input leads at terminals L1, L2, and L3 of circuit breaker CB1 and the

grounding wire at the grounding lug (Figure 2).

e. Loosen the clamp in the base and pull the input cable from the clamp.

f. Pull the input cable from the unit.

g. Close and latch the front door, and open the rear door.

h. Loosen the cable clamp on the bottom panel so as to remove the output, EF signal, and remote

control cables from the unit.

Chapter 3-1 September 21, 2000
Page 2

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

Te st P oi n t 1

Te st P oi n t 2

DC Bus Test Points

Signal Conditioning PC Board

(Front Door)

Figure 1

September 21, 2000 Chapter 3-1

Circuit Breaker
Grounding Lug

Figure 2

Page 3

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

i. Disconnect the output cables from the output contactors or transformer. Disconnect EF signal and

any remote control leads from the terminal strips near the rear of the unit.

j. Be sure all leads are free and do not become entangled.

k. Attach a lifting hoist or forklift to the bottom of unit and remove the mounting screws or bolts which

attach the converter to its mounting.

l. Carefully lower the converter

m.Move the unit to a clear working area where it can be placed on a solid supporting structure.

n. Installation is in the reverse order of removal. See Section 1-2, Installation and Setup, for additional

information on installing the converter.

Component Removal and Replacement

5.

Many of the components in the converter are easily replaced when necessary. Section 1-1 provides a
description of the major components used in the unit, while Figures 11 - 14 of Section 1-1 show the
location of the components used in the converter.

a. Preparation

Before removing or replacing any component, follow these steps:

(1) Turn off input power at the source. Make sure that power cannot be inadvertently turned back on.

WARNING

High voltages may be present inside the cabinet, even when the unit is off.
Exercise extreme caution or FATAL SHOCK may result.

(2) The converter draws a small amount of input power even when the unit is off. Components and

PC boards throughout the unit can be permanently damaged if anything is removed or replaced
while input power is present. Therefore, always make sure input power is off before removing or
installing any parts inside the unit.

(3) Open the front door by turning all three latches counterclockwise with a 8mm allen wrench.

(4) Test the DC bus with a voltmeter to be sure that it is fully discharged. The bus can be tested

using test jacks TP1 and TP2 (Figure 1) on the upper left corner of the signal conditioning board
inside the front door. If the bus is not discharged, close the converter door, wait at least 15
minutes, and test it again. Do not perform any work inside the converter while the DC bus
remains charged.

Chapter 3-1 September 21, 2000
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OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

b. Component Removal and Replacement

(1) DC Capacitors

The only capacitors which may need to be replaced under normal use are those that make up
the DC capacitor bank. This bank is located behind the front door near the center of the unit.
After determining which capacitor is defective, proceed as follows to remove and replace it.

a. Open the rear door by turning all three latches counterclockwise with an 8 mm allen wrench.

b. Remove the two PC boards from the front of the DC capacitor bank.

c. Remove the resistors, four or six depending on the unit, that are connected across the two

vertical bus bars that are attached to the capacitors.

d. Remove the bus bars from the capacitor bank.

WARNING

Capacitors are POLARITY SENSITIVE. Make certain that capacitors are
installed EXACTLY as they were previously installed.

e. Remove defective capacitor and replace it.

f. Installation is in the reverse order of removal. Make certain that components are installed

exactly as they were previously installed, and make certain that screws and nuts are tightened
securely. The mounting face of each aluminum terminal stud, but not the threads of the
capacitors, must be coated with Penetrox or an equivalent anti-oxidation compound at
installation.

(2) Output Contactors

One or two output contactors may be used in all models of the ADV converter.

a. Output Contactors K1- K2

Refer to Section 1-1; Figure 14. Output contactors are mounted on bracket on the left side of
the unit behind the rear door. Each is fastened with three 8 mm keps screws. To remove
and install this contactor, follow these steps:

·

Open the rear door by turning all three latches counterclockwise with an 8 mm allen
wrench.

·

Clearly label each of the leads connected to the contactor and disconnect each one.

·

Loosen, but do not remove, the three screws which hold the contactor in place, then slide
up and to the left until the contactor can be removed.

Installation is in the reverse order of removal. If necessary, verify connections by referring to
pertinent connection diagram.

(3) Control Panel

a. Open the front door by turning all three latches counterclockwise with an 8 mm Allen wrench.

b. The control panel PC Board is fastened to the back side of the control panel. Reach in

through the door cearly label each of the leads connected to the contactor. Then carefully
detach the many leads that are attached to the control panel PC Board.

c. While holding onto the control panel PC Board, unfasten the 10 screws that hold the control

panel onto the unit.

d. Slowly pull the control panel, with PC Board attached, out of the unit from the outside.

Installation is in the reverse order of removal. If necessary, verify wiring by referring to the
pertinent connection diagram.

September 21, 2000 Chapter 3-1

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OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

(4) Cooling Fan

Refer to Section 4-3; Figure 7 to view the various components of the cooling fan assembly,
and proceed as follows to remove and install the fan.

a. Open the front door by turning all three latches counterclockwise with an 8 mm allen wrench.

b. Remove the airduct plenum panel with the Input Control PC Board and Signal Conditioning

P.C. Board attached.

c. Clearly label each of the leads connected to both printed circuit boards and disconnect each

one.

d. Use a socket wrench with 10 mm socket to remove the six screws that hold the panel in

place.

e. Behind the airduct panel resides the cooling fan. Use a socket wrench with 10 mm socket to

remove the four screws that mount the cooling fan.

f. Detach the wiring from the fan.

g. Carefully pull out the fan and mounting plate.

h. Remove the fan from the mounting bracket panel by removing the four M4-0.7 X 7 mm

pan-head cross-recess screws, along with the M4 flat washers, and lock washers that attach
the fan to the mounting bracket.

Installation is in the reverse order of removal. If necessary, verify wiring by referring to
pertinent connection diagram.

If fan blades rotate in the wrong direction, reverse connection of any two fan input leads.

(5) Input SCR/Diode Module

Section 1-1; Figure 13 shows the location of the power module assembly.

a. Open the front door by turning all three latches counterclockwise with an 8 mm allen wrench.

b. Remove the capacitor bank assembly (C1 - C11) using an 8 mm socket.

c. Remove the input SCR/Diode Module (SCR1 - SCR6) using an 8 mm socket.

d. Installation is in reverse order as shown above. Figure 3 shows the torque values

recommended by the manufacturer for the rectifier modules used in this converter. Rectifier
torque values are shown in inch-pounds (inch-lbs), Newton-meters (NM), and
centimeter-kilograms (cm-kg).

Location

Case to Heat Sink 44 inch-lbs 5 NM 51 cm-kg

Terminal, M6 Screws 53 inch-lbs 6 NM 61 cm-kg

Input Rectifier Torque Requirements

Figure 3

Torque Values

Chapter 3-1 September 21, 2000
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OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

(6) IGBT - Power Modules

Section 1-1; Figure 13 shows the location of the IGBTs.

a. Open the front door by turning all three latches counterclockwise with an 8 mm allen wrench.

b. Remove the capacitor bank assembly (C1 - C11) using an 10 mm socket.

c. Remove the IGBTs(PM1 - PM7) as needed using an 10 mm socket.

d. Installation is in reverse order as shown above. Figure 4 of this chapter shows the torque

values recommended for the IGBTs. Power module torque values are shown in inch-pounds
(inch-lbs), Newton-meters (NM), and centimeter-kilograms (cm-kg).

Location

Case to Heat Sink 27 inch-lbs 3.0 NM 31 cm-kg

Terminal, M4 Screws 17 inch-lbs 1.9 NM 20 cm-kg

Terminal, M6 Screws 27 inch-lbs 3.0 NM 31 cm-kg

IGBT - Power Module Torque Values

Figure 4

(7) Resistors

a. DC Bus Discharge Resistor

The DC bus discharge resistor, R3, is positioned vertically on the right side of the unit behind
the rear door. It is fastened with a long, threaded bar through its centers. To remove and
replace this resistor, follow these steps:

·

Open the rear door by turning all three latches counterclockwise with an 10 mm alien
wrench.

·

Disconnect the two leads by gently pulling the connector away from the resistor.

·

Using a 10 mm wrench, remove the nut, lock washer, and flat washer at the top end of the
long threaded bar.

·

Slide the bar out from the unit while holding the resistor to prevent it from falling.

·

Installation is in the reverse order of removal. If necessary, verify connections by referring
to the pertinent connection diagram.

Torque Values

b. DC Capacitor Bank Resistors

Refer to Figure 4, Section 4-3 to see location of the four capacitor bank resistors. Any one of
these resistors can be removed, simply by removing the two 10-32 X 5/8" pan-head
cross-recess screws and the washers which attach the resistor to the vertical DC capacitor
bus bars. Installation is in the reverse order of removal.

September 21, 2000 Chapter 3-1

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OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

(8) Switches

a. Door Interlock Switches

The converter is equipped with two door interlock switches: S7 on the front door and S2 on
the back door. To remove and replace a switch, follow these steps:

Open the front or rear door by turning all three latches counterclockwise with a 8mm allen

·

wrench.

Disconnect the two leads from the switch.

·

Remove the two screws holding the switch to the frame of the converter.

·

Installation is in the reverse order of removal. Make sure that the leads are connected to

·

the “COMMON” and “N.O.” terminals. If necessary, verify connections by referring to the
pertinent connection diagram.

b. Power Module Thermal Switch

One small thermal switch is located on the heat sink beside the power modules, which are
behind the DC Capacitors inside the front door. To remove and replace a switch, follow these
steps:

Open the front door by turning all three latches counterclockwise with a 8mm allen wrench.

·

Remove the DC Capacitor system (Sect. 1-1; 8, Figure 12).

·

· Remove the buss bar located behind the DC Capacitors.

· Disconnect the two leads from the faulty switch.

· Remove the two small screws on each side of the switch.

· Installation is in the reverse order of removal.

c. Transformer Thermal Switches

The main transformer has a thermal switch, tucked in the coils of its windings, that detects
overheating and sends a signal to the Control PC board. The thermal switch has two wire
leads. These wire leads are connected to a terminal strip attached to the large bar beside the
transformer.

To remove and replace one of these switches, carefully pull upward on the switch that is
tucked in the coils of the transformer, then disconnect the thermal switch wire leads from the
small terminal strip. Installation is in the reverse order of removal.

(9) Transformers

Except for physical damage, it is improbable that the main transformer or many other
transformers in this unit will fail. In the unlikely event of failure, it is not recommended that
attempts be made to remove and replace the main transformer in the field. Call the Hobart
Brothers Service Department for assistance.

a. Output/Main Transformer

In the event that the main transformer fails, contact the Hobart Service Department for
assistance.

b. Input Transformer (208V input units only)

In the event that the main transformer fails, contact the Hobart Service Department for
assistance.

Chapter 3-1 September 21, 2000
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OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

c. Input Control Transformer

The Control Transformer (1-1; 4, Figure 12) is located directly behind the control panel.
Proceed as follows to remove and replace the control transformer.

Clearly label each of the leads connected to the control transformer and disconnect each

·

one.

Remove the four M10 keps-nuts which attach the control transformer to the cabinet frame.

·

Remove the control transformer.

·

Installation is in the reverse order of removal. If necessary, verify connections by referring

·

to the pertinent connection diagram.

6.

PC Board Removal and Replacement

The 45 kVA converter has 7 printed circuit (PC) boards in various locations inside (Figure 6). They are:

Model 101 Control PC Board

·

Driver PC Board

·

Modulator PC Board

·

DC Bus PC Board

·

I/O (Input/Output) PC Board

·

· Signal Conditioning PC Board

· Input Power Control (IPC) PC Board

Section 1-1 figure 11provides a description and location of each board. Before inspecting, removing, or
replacing any of the boards, follow these steps:

WARNING

(1) Turn off input power at the source. Make sure that power cannot be inadvertently turned back on.

The converter draws a small amount of input power even when the unit is off. Components
and PC boards throughout the unit can be permanently damaged if anything is removed or
replaced while input power is present. Therefore, always make sure input power is off before
removing or installing any parts inside the unit.

(2) Open the front door by turning all three latches counterclockwise with an 8 mm allen wrench.

(3) Test the DC bus (Figure 1) with a voltmeter to be sure that it is fully discharged. The bus can be

tested using test jacks TP1 and TP2 on the upper left corner of the signal conditioning board
inside the front door. If the bus is not discharged, close the converter door, wait at least 15
minutes, and test it again. Do not perform any work inside the converter while the DC bus
remains charged. See Figure 1 for the proper test points.

(4) Remove and replace each board as follows.

a. Model 101 Control PC Board

The Model 101 Control PC Board (A2) is mounted on the back of the control panel (4, Figure 6).
The board is mounted on six round aluminum spacers and fastened with six M7 x .7 x 16 keps
machine screws. To remove and replace this board, follow these steps:

(1) Open the front door by turning all three latches counterclockwise with an 8 mm allen wrench.

(2) Reach in through the door. Clearly label each of the cables connected to the Model 101 Control

PC Board, then disconnect each one by gently pulling the plug away from the board.

High voltages may be present inside the cabinet, even when the unit is off.
Exercise extreme caution or FATAL SHOCK may result.

September 21, 2000 Chapter 3-1

Page 9

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

1. Modulator PC Board

2. Driver PC Board

3. Input Power Control PC Board

4. Signal Conditioning PC Board

Chapter 3-1 September 21, 2000
Page 10

5. Model 101 Control PC Board

6. I/O (input/output) PC Board

7. Bus Discharge PC Board

PC Board Location

Figure 6

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

(3) While holding onto the control panel PC Board, unfasten the 10 screws that hold the control

panel onto the front of the unit.

(4) Slowly pull the control panel, with PC Board attached, out of the unit.

(5) Steady the assembly on a smooth clean surface, and unfasten the six keps screws that secure

the two pieces.

Installation is in the reverse order of removal. If necessary, verify wiring by referring to the
pertinent connection diagram.

b. Modulator PC Board

The Modulator PC board (A3) is located on the far left side (beside) the Driver PC board behind the
front door. (1, Figure 6). The board has four keps nuts tightening it to aluminum spacers that are
fasten to an internal panel. To remove and replace this board, follow these steps:

(1) To gain access to this PC board, open the front door by turning all three latches

counterclockwise with an 8 mm allen wrench.

(2) Clearly label each of the cables connected to the PC board, then disconnect each one by gently

pulling the plug away from the board.

NOTE: When removing the Modulator PC board, carefully guide it around the Driver PC board to avoid inadver

tent damage to either board.

(3) Steady the board with one hand and remove the eight keps nuts (8 mm ) that hold the board

down.

Installation is in the reverse order of removal. If necessary, verify wiring by referring to the
pertinent connection diagram.

c. Driver PC Board

The Driver PC board (A5) is beside the Modulator PC Board to the right (2, Figure 6). The board
has eight keps nuts (8 mm ) tightening it to aluminum spacers that are fasten to an internal panel..
To remove and replace this board, follow these steps:

(1) To gain access to this PC board, open the front door by turning all three latches

counterclockwise with an 8 mm allen wrench.

(2) Clearly label each of the cables connected to the PC board, then disconnect each one by gently

pulling the plug away from the board.

(3) Steady the board with one hand and remove the eight keps nuts (7 mm ) that hold the board

down.

Installation is in the reverse order of removal. If necessary, verify wiring by referring to the
pertinent connection diagram.

d. DC Bus Discharge PC Board

The DC bus discharge PC board (A13) is located above of the DC capacitor bank behind the rear
door. (8, Figure 6). The board has four keps nuts tightening it to aluminum spacers that are fasten
to an internal panel. To remove and replace this board, follow these steps:

(1) To gain access to this PC board, open the rear door by turning all three latches counterclockwise

with an 8 mm allen wrench.

(2) Clearly label each of the cables connected to the PC board, then disconnect each one by gently

pulling the plug away from the board.

(3) Steady the board with one hand and remove the four keps nuts (7 mm) that hold the board down.

Installation is in the reverse order of removal. If necessary, verify wiring by referring to the
pertinent connection diagram.

-

September 21, 2000 Chapter 3-1

Page 11

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

e. Input/Output (I/O) Board

(1) The I/O PC Board is located behind the rear door, mounted against an interior panel beside the

output connections (7, Figure 6). The board has seven keps nuts tightening it to aluminum
spacers that are fastened to an internal panel. To remove and replace this board, follow these
steps:

(2) To gain access to this PC board, open the rear door by turning all three latches counterclockwise

with an 8 mm allen wrench.

(3) Clearly label each of the cables connected to the PC board, then disconnect each one by gently

pulling the plug away from the board.

(4) Steady the board with one hand and remove the seven keps nuts (7 mm) that hold the board

down.

Installation is in the reverse order of removal. If necessary, verify wiring by referring to the
pertinent connection diagram.

f. Signal Conditioning PC Board

(1) The Signal Conditioning PC Board is located behind the front door, mounted against a hinged

interior panel that sits in front of the Input Control PC Board. (5, Figure 6). The board has eight
keps nuts tightening it to aluminum spacers that are fastened to the hinged internal panel. To
remove and replace this board, follow these steps:

(2) To gain access to this PC board, open the front door by turning all three latches

counterclockwise with an 8 mm allen wrench.

(3) Clearly label each of the cables connected to the PC board, then disconnect each one by gently

pulling the plug away from the board.

(4) Steady the board with one hand and remove the eight keps nuts (7 mm) that hold the board

down.

Installation is in the reverse order of removal. If necessary, verify wiring by referring to the
pertinent connection diagram.

g. Input Control PC Board (IPC)

The Input Control PC Board is located behind the Signal Conditioning Board mounted against an
interior panel in the center of the unit (4, Figure 6). In fact, the Signal Conditioning Board must be
out of the way, but not removed, to service the IPC PC Board. The IPC board has eight keps nuts
tightening it to aluminum spacers that are fastened to an internal panel. To remove and replace this
board, follow these steps:

(1) To gain access to this PC board, open the front door by turning all three latches

counterclockwise with an 8 mm allen wrench.

(2) Remove the 8 mm screw that fastens down the HINGED Signal Conditioning Board panel.

Swing the Signal Conditioning PC Board panel out of the way. DO NOT REMOVE THIS
BOARD.

(3) Clearly label each of the cables connected to the IPC board, then disconnect each one by gently

pulling the plug away from the board.

(4) Steady the board with one hand and remove the eight keps nuts (7 mm) that hold the board

down.

Installation is in the reverse order of removal. If necessary, verify wiring by referring to the
pertinent connection diagram.

Chapter 3-1 September 21, 2000
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OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

Chapter 4. Illustrated Parts List

Section 1. Introduction

1. General

The Illustrated Parts List identifies, describes, and illustrates main assemblies, subassemblies, and
detail parts of a Diesel Engine-Generator Set manufactured by Hobart Brothers Company, Ground
Power Division, Troy, Ohio.

2.

Purpose

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

. 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 commercially.

(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.

a. Parts List Form

This form is divided into six columns. Beginning at the left side of the form and proceeding to the
right, columns are identified as follows:

(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.

September 21, 2000 Chapter 4-1

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PoWerMaster ADV / Series 500048A / Solid State Converter

(2) HOBART PART NUMBER Column

All part numbers appearing in this column are Hobart numbers. In all instances where the part
is a purchased item, the vendor’s identifying five-digit code and his part number will appear in
the “NOMENCLATURE” column. Vendor parts which are modified by Hobart will be identified
as such in the “NOMENCLATURE” column. In case Hobart does not have an identifying part
number for a purchased part, the “HOBART PART NUMBER” column will reflect “No Number”
and the vendor’s number will be shown in the “NOMENCLATURE” column. Parts
manufactured by Hobart will reflect no vendor or part number in the “NOMENCLATURE”
column.

(3) AIRLINE PART NUMBER Column

This column will appear blank. Eleven character spaces have been reserved for filling in part
numbers that may have been assigned by individual airlines.

(4) NOMENCLATURE Column

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

(5) 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. Since this manual
covers only one generator set specification, this column is not used in this manual.

Parts coded “A” are usable on Part Number 500048A-301 only.

Parts coded “B” are usable on Part Number 500048A-302 only.

Parts coded “C” are usable on Part Number 500048A-311 only.

Parts coded “D” are usable on Part Number 500048A-312 only.

(6) 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 necessarily reflect the total used in the complete end
item.

Chapter 4-1 September 21, 2000
Page 2

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

Section 2. Manufacturer’s Codes

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

The following list is a compilation of vendor codes with names and addresses for suppliers of
purchased parts listed in this publication. The codes are in accordance with the Federal Supply Codes
for Manufacturer’s Cataloging Handbook H4-1, (CAGE CODES) and are arranged in numerical order.
Vendor codes are inserted in the nomenclature column of the parts list directly following the item name
and description. In case a manufacturer does not have a code, the full name of the manufacturer will be
listed in the nomenclature column.

Code Vendor’s Name and Address Code Vendor’s Name and Address

00779 Amp Inc.

2800 Fulling Mill Rd.
P.O. Box 3608
Harrisburg, PA 17105-3608

054W1 Talema Electronic Inc.

3 Industrial Park Dr.
P.O. Box 306
Saint James, MO 65559

05YB3 Acon Inc.

22 Bristol Dr.
South Easton, MA 02375

0H8R0 Magnetics

200 10TH St.
P.O. Box 391
Butler, PA 16003-0391

0MR72 Power Devices Inc.

26941 Cablot Rd
Suite 124
Laguna Hills, CA 92653-7006

1AA44 Collmer Semiconductor Inc.

C/O NA-NA Co.
14368 Protopn Rd.
Dallas, TX 75244-3511

1E045 Austin Hardware and Supply Co.

10220 E. 65TH St.
P.O. Box 9550
Kansas City, MO 64133-5205

1W134 Eaton Corp.

4201 N. 27TH Ave.
Milwaukee, WI 53216-1807

24446 General Electric Co.

3135 Easton Tpke.
Fairfield, CT 06431

27410 Harris Corp.

1025 Nasa Blvd.
Melbourne, FL 32919

27694 Connectron Inc.

12 Industrial Dr.
South Amboy, NJ 08879

28520 Heyco Molded Products Inc.

1800 Industrial Way N.
P.O. Box 517
Toms River, NJ 08755

38151 Marathon Electric Mfg. Co.

100 E. Randolph St.
P.O. Box 8003
Wausau, WI 54401-2568

3A054 McMaster Carr Supply Co.

9630 Norwalk Blvd.
Santa Fe Springs, CA 90670-2932

44655 Heico Ohmite LLC

3601 W. Howard St.
Skokie, IL 60076-4014

1E222 Furnas Electric Co.

Richmond, VA 23200

September 21, 2000 Chapter 4-2

56365 Square D Company

1415 S. Roselle Rd.
Palatine, IL 60067-7337

Page 1

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

Code Vendor’s Name and Address Code Vendor’s Name and Address

57347 Wall Industries Inc.

5 Watson Brook Rd.
Exeter, NH 03833

5P059 Tech Products Corp.

2348 Sandridge Dr.
Dayton, OH 45439

66844 Powerex Inc.

E. Hillis St.
Youngwood, PA 15697-1176

62292 EBM Industries Inc.

110 Hyde Rd.
P.O. Box 4009
Farmington, CT 06034-4009

67529 All-Phase Electric Supply Co.

875 Riverview Dr.
P.O. Box 67
Benton Harbor, MI 49022-0067

6H359 Hobbs Div., of Stewart Warner Corp.

Highway 6
Spring Valley, IL 61362

S7023 Bossard LTD Fasteners

Steinhauserstrasse 70
Zug
Switzerland, CH-6300

6Y440 Micron Technologies Inc.

8000 S. Federal Way
Boise, ID 83707

74829 Ilsco Corp.

4730 Madison Rd.
Cincinnati, OH 45227-1426

79497 Western Rubber Co.

620 E. Douglas
Goshen, IN 46526-4035

91637 Dale Electronics Inc.

1122 23RD St.
Columbas, NE 68601-3647

94222 Southco Inc.

210 N. Brinton Lake Rd.
Concordville, PA 19331

D0024 Semikron International

Sigmundstrasse 200
P.O. Box 820251
Nuerengerg, Germany 90253

Chapter 4-2 September 21, 2000
Page 2

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

Section 3. Illustrated Parts List

1. Explanation of Parts List Arrangement

The parts list is arranged so that the illustration will appear on a left-hand page and the applicable parts
list will appear on the opposite right-hand page. Unless the list is unusually long, the user will be able to
look at the illustration and read the parts list without turning a page.

Symbols and Abbreviations

2.

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

* - Item not illustrated

A, or AMP - Ampere

AC - Alternating current

AR - As required

DC - Direct current

Fig. - Figure

Hd. - Head

Hex - Hexagon

Hz - Hertz (cycles-per-second)

I.D. - Inside diameter

IN - Inch

KVA - Kilovolt-ampere

UF - Microfarad

Number - Number

NHA - Next higher assembly

PRV - Peak reverse voltage

PSI - Pounds per square inch

Ref - Reference (the item has been listed previously)

TM - Technical Manual

T-R - Transformer-rectifier

V - 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.

September 21, 2000 Chapter 4-3

Page 1

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

Chapter 4-3 September 21, 2000
Page 2

PoWerMaster ADV Converter

Figure 1

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

NOMENCLATURE UNITS
FIGURE & HOBART AIRLINE PER
ITEM NO. PART NO. PART NO. 123456 EFF ASSY

1 - 500048A-301 PoWerMaster ADV CONVERTER

45 KVA, SINGLE OUTPUT A 1

500048A-302 PoWerMaster ADV CONVERTER

45 KVA, DUAL OUTPUT B 1

500048A-311 PoWerMaster ADV CONVERTER

45 KVA, SINGLE OUTPUT, 208V INPUT C 1

500048A-312 PoWerMaster ADV CONVERTER

45 KVA, DUAL OUTPUT, 208V INPUT D 1

1 - 1 No Number . FRAME ASSEMBLY (SEE FIG. 2) REF
1 - 2 286416-001 . CIRCUIT BREAKER ACTUATOR

HANDLE AY. (V56365 #9422A3) 1
1 - 3 286411 . CONTROL P.C. BOARD ASSEMBLY 1
1 - 4 286398-002 . MEMBRANE SWITCH PANEL ASSEMBLY 1

1 - 5 82B1066-012 . AMBER PILOT LIGHT ASSEMBLY, 12V

(V56365 #9001-SKP-32A9) A,C 1

* 400613-004 . . BULB, 12V, TYPE 1815, BAYONET BASE,

STYLE T-3-1/4 A,C 1

82B1066-012 . AMBER PILOT LIGHT ASSEMBLY, 12V

(V56365 #9001-SKP-32A9) B,D 2

* 400613-004 . . BULB, 12V, TYPE 1815, BAYONET BASE,

STYLE T-3-1/4 B,D 2

1 - 6 82B1066-001 . RED PILOT LIGHT ASSEMBLY, 12V

(V56365 #9001-SKP-32R9) 1

* 400613-004 . . BULB, 12V, TYPE 1815, BAYONET BASE,

STYLE T-3-1/4 1

1 - 7 82B1066-010 . GREEN PILOT LIGHT ASSEMBLY, 12V

(V56365 #9001-SKP-32G9) 1

* 400613-004 . . BULB, 12V, TYPE 1815, BAYONET BASE,

STYLE T-3-1/4 1

1 - 8 283714-005 . LABEL, 45 KVA 1

1 - 9 286457 . LABEL, TRADEMARK 1

1 - 10 283887 . LABEL, HOBART 2
1 - 11 No Number . FRONT INTERIOR COMPONENTS(SEE FIG. 3) REF
1 - 12 No Number . REAR INTERIOR COMPONENTS(SEE FIG. 5) REF
1 - 13 No Number . CANOPY COMPONENTS (SEE FIG. 10) REF

* 1 - 14 283716 . LABEL, ID 1
* 1 - 15 287460 . LABEL, SHOCK 2
* 1 - 16 286441 . LABEL, GENERAL 2
* 1 - 17 287341 . WIRING HARNESS ASSEMBLY 1

1 - 18 No Number . BOTTOM EXTERIOR COMPONENTS(SEE FIG. 11) REF

* 1- 19 286377 . LABEL, FAULT CODE 1
* 1 - 20 286442 . LABEL, RAINPROOF 1
* 1 -21 282658 . LABEL, WARNING, CLEARANCE 2
* 1 - 22 286475-001 . CABLE SUMMARY, STANDARD 1

September 21, 2000 Chapter 4-3

* NOT ILLUSTRATED

Page 3

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

Chapter 4-3 September 21, 2000
Page 4

Frame Assembly

Figure 2

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

NOMENCLATURE UNITS
FIGURE & HOBART AIRLINE PER
ITEM NO. PART NO. PART NO. 123456 EFF ASSY

2 - No Number FRAME ASSEMBLY REF

2 - 1 287845 . FRAME 1
2 - 2 286354 . BOTTOM FRAME SPACER 1
2 - 3 286376 . INLET RING PANEL 1
2 - 4 283157-003 . IMPELLER INLET RING (V62292 #9621-2-4013) 1
2 - 5 287852 . BASE 1

2 - 6 287836 . COVER, FAN HOLE 1

September 21, 2000 Chapter 4-3

Page 5

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

Chapter 4-3 September 21, 2000
Page 6

Front Interior Components

Figure 3

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

NOMENCLATURE UNITS

FIGURE& HOBART AIRLINE PER

ITEM NO. PART NO. PART NO. 123456 EFF ASSY

3 - No Number FRONT INTERIOR COMPONENTS REF

3 - 1 280807 . LABEL, GROUND 1
3 - 2 285104-001 . GROUNDING LUG (V74829 #TA-250) 1
3 - 3 285315-001 . MOV. SUPPRESSOR (V27410 #V661DA40) 3
3 - 4 287838 . CIRCUIT BREAKER SUPPORT 2
3 - 5 282653 . WIRE TERMINAL (V67529 #FA-T) 3

3 - 6 280966-002 . CIRCUIT BREAKER

(V56365 #KAL-36150-26M) 1

* 286415-001 . ACTUATOR, CIRCUIT BREAKER

(V56365 #9422-CKA30) 1

3 - 7 83A1114 . LABEL, L3 1

3 - 8 83A1113 . LABEL, L2 1
3 - 9 83A1112 . LABEL, L1 1

3 - 10 404960-034 . CONTROL TRANSFORMER, 115V

(V6Y440 #B750-1213-1) 1

3 - 11 W10502-031 . FUSE, 15A 1

3 - 12 285968 . LABEL, FUSE 1
3 - 13 281848-002 . CAPACITOR, 1800UF, 250 VDC 1
3 - 14 402682 . TOGGLE SWITCH 1
3 - 15 286447 . VOLTAGE SELECTION LABEL 1
3 - 16 286448 . METER SUPPORT BRACKET 1

3 - 17 181358 . HOUR METER (V6H359 #80001) 1
3 - 18 287856 . CABLE CLAMP SUPPORT 1
3 - 19 285568 . CABLE CLAMP BRACKET 1
3 - 20 286423 . INPUT CABLE PLATE 1
3 - 21 280673 . DOOR INTERLOCK SWITCH

(V1W134 #SSI2ET10-20Y3) 1

3 - 22 286445 . FRONT DOOR SWITCH SUPPORT 1
3 - 23 No Number . HEATSINK PANEL ASSEMBLY,

(SEE FIGURE 4) REF

3 - 24 287841 . LEFT HAND INPUT FILTER GUIDE 1

* NOT ILLUSTRATED

September 21, 2000 Chapter 4-3

Page 7

OM-2089A / Operation and Maintenance Manual

PoWerMaster ADV / Series 500048A / Solid State Converter

Chapter 4-3 September 21, 2000
Page 8

Heatsink Panel Assembly

Figure 4