.

OM-200
08248 1

INSTRUCTION MANUAL

for

DC Voltage Regulator

Part No. 485972

Hobart Brothers Company

Power Systems Division
Troy, Ohio 45373
U.S.A.
 SAFETY-.INSTRUCTIONS
AND WARNINGS FOR ELECTRICAL POWER EQUIPMENT .---.
--.-
.llYL>.

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

ELECTRIC ARC FLASH can injure eyes burn skin cause equipment damage and 1
ignite combustible material. Do not use power cables to'
/ .break lo,a+!
and prevent tools from causing short circuits.
I
IMPROPER PHASE CONNECTION, PARALLELING, OR USE can damage this and attached'
equipment. I
KPORTANT: - Protect all operating personnel. Read, understand and follow:
1: '
all instructions in the Operating/InstructionMar&l before
installing, operating, or‘servicxng the equipment. Keep the manual
available for future use by all operators. 2
GENERAL
Equipment that supplies electrical power can'cause serious injury or death, j
or damage to other equipment or property. The operator must strictly I /
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-poweredequipment, j
other practices apply to engine-driven equipment, and some practices to;both.:
SHOCK PREVENTION
i
Bare conductors, or terminals in the output circuit, or ungrounded, j
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 j
proper safety clothing, procedures, and test equipment. I
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 I
dry wood, use insulating gloves when dampness or sweat cannot be avoided. ;
Keep clothing dry, and never work alone. I
1. Installation and Grounding of Electrically Powered Equipment ' I I

Equipment driven by electric motors (rather than by diesel or gasoline '

engines) must be installed and maintained in accordance with the National!
Electrical Code, ANSI/NFPA 70 and other a plicable codes. A poweri i:
disconnect switch or circuit &eaker must.ge located at the equipment.
Check the nameplate for volta e, frequency, and phase requirements.' If {
only 3-phase power is availabfe, connect any single- hase rated equipment
to only two nres of the 3-phase line. DO NOT CONNEET the equipment I
grounding conductor (lead) to the third live wire of the 3-phase line, as
this makes the equipment frame electrically HOT, -e--p,
which can cause a fata=
snoclc.- I
Alwa s connect the grounding lead if supplied in a power line cable
to tx e grounded swi.iEkdboxor b&ding ground. If not provided, usb'a i
separate groundin Ensure that the current (am erage) capaci!y
of the grounding !zead will be-adequate for the worst i!
ault current ,
situation. Refer to the National Electrical Code ANSI/NFPA 70 for
details. Do not remove plug ground prongs. Use correctly mating ;
receptacles.
2. Output Cables and Terminals
i
Inspect cables frequently for damage to the insulation and the I
connectors. Re lace or repair cracked or worn cables immediately. IDo
not overload cag les. Do not touch output terminal while.equipment Fs
energized. I
3. Service and tiintenance I

L-----_----_- 1
Instruction 910082 Page 1
Feb 25/86 Revised
 Before inspecting or servicing electrically-powered equepment,. /' -.
;--takethe--fullow$ng-precautions: ____-.------ - . .--
, .--' j I- 7/-.
~-~--a.----
Shut-OFF-;.~l-poweFat--t-h**~~nnac~~n -svi-tch-or--li/ne(breakere.-
I before inspecting or servicing the equ!?
pment.
I b. Lock switch OPEN (or remove line fuses) so that power cannot be
I
turned ON accidentally.
I c. Disconnect power to equipment if it is out of service.
I
I d. If troubleshooting must be done with the unit ener ized, have
I another person presen ; ho is trained in turning oP f the equipment
I n for first aid.
and providing or call13
I
IC . FIRE AND EXPLOSION PREVENTION
I
I Fire and explosion are caused by electrical short circuits, combustible
material near engine exhaust piping, misuse of batteries and fuel, or
I UII 23afe operating-or fueling cbnditions.
I
I 1. Electrical Short Circuits and Overloads
I Overloaded or shorted equipment can become hot enough to cause fires
I either by self destruction or causing nearby combustibles to ignite.
I For electrically-poweredequipment, in particular, rovide primary ,
input protection to remove short circuited or heaviEy overloaded
I equipment from the line.
I 2. Batteries _
I
Batteries may explode and/or give off flammable hydro en
I and arcing from a ru tured battery can cause fires an% ad%?$on??" acid
failures. When serVIcing, do not smoke, cause sparking, or use open
I flame near the battery.
I
I 3. Engine Fuel
I
Use only approved fuel container or fueling system. Fires and
explosions can occur if the fuel tank is not grounded prior to or during
I fuel transfer. Shut unit DOWN before removing fuel tank cap. Do not
completely fill tank, because heat from the a uipment may cause fuel.
expansion overflow. Remove all spilled fuel 4MMEDIATELY, includin any
that penetrates the unit. After clean-up, open equipment doors an% blow
fumes away with compressed air.
I
D. IC FUME PREVENTION I
bon monoxide.--Engine exhaust fumes can kill and cause health problems. ;
e or vent the exhaust fumes to a suitable exhaust duct or outdoors.
'er locate engine exhausts near intake ducts of air conditioners. I
I 1
E. -BC lILY INJURY PREVENTION I
I
,ious inju can result from contact with fans inside some equipment.' I
I
I x equipment for inspection and routine maintenance. When
",;.t DOWN.suc
ec .ipmentis in o eration use extreme care in doing necessary troubleshootin
ar adjustment. Eo not remove guards while equipment is operating.
; I
P. lICALAND FIRST AID TREATMENT I
I
I
'st aid facilities and a qualified first aid person should be available f
1 ' each shift for immediate treatment of all injury victims. Electric
I ck victims should be checked by a ph sician and taken to a hospital
I mediatelyif any abnormal signs are oBserved. ;
I
1
EMERGENCY FIRST AID i
.l physician immediately. Seek additional assistance and use First Aid i
:hnlquesrecommended by American Red Cross until medical help arrives. ;
a BREATHING IS DIFFICULT g%ve oxy en, if available, and have victim lie
Iw FOR ELECTRICAL SHO& turn oP f power. Remove victim* if not
!e z;hing, begin artificial'respiration preferably mouth-to-mouth. If
able pulse. begin external hea& massage. Call Emergency Rescue
utad immediately.
I
ftFI-PMENlf-PR& ..- --_
isp,
ect aII geca tlonaly iaozls on the equirnt rnon~h~yI-Order and
L---rep ceall- beli that cannot be easily rea
Page 2 Instruction 910082
 I I

OPERATION AND MAINTENANCE MANUAL OM-200

FOR D.C. VOLTAGE REGULATOR 485972

CHAPTER 1. DESCRIPTION/OPERATION

SECTION 1. DESCRIPTION

1. Genera 1 Description i4
A. The 485972 regulator is designed to provide 2% regulation with 500
millisecond recovery time on 28.5 volt self-excited D.C. generators, 1
requiring no more than 7 amperes shunt field excitation.

The regulator controls the output voltage of the generator by

switching a power transistor in series with the generator field al-
ternately on and off, varying the average fie.ld power by varying
the ratio of transistor on and off time. Means are also available
for current limiting and line drop compensation.

B. The voltage regulator consists of ten (10) basic interconnected

circuits. They are:

(1) Voltage Detection Circuit

(2) Voltage C omparison Circuit
(3) Summing Applifier Circuit
(4) Pulse Width Modulator Circuit
12; pi;chAn; Transistor Circuit
.am in ircuit
(7) Current Limit Circuit
(8) Line Drop Compensator Circuit
(9) Voltage Hold-Up (12V) Circuit
(10) Voltage Build Up Circuit

C. Any deviation of the generator voltage from its set, regulated

level is sensed by the voltage detection and voltage compa~rison
circuits. A signal is fed from the comparison circuit to the
summing amplifier where the signal is modified, (if necessary) to
account for 1 ine drop compensation or current 1 imiting. This
modified signal is then fed to the pulse width modulator circuit
causing the output pulses driving the power transistor.fo vary
in such a manner as to bring the generator voltage back to its
previously set level.

D. Operating power for the above circuits is supplied by the genera-

tor output. The generator output voltage is fed to an emitter-
follower regulator (consisting of 42, VR2, R3 and C7), this re-
gulator limits the supply voltage to a safe level, acceptable to
the components it powers. Two integrated ci rcui t (1 C) regu’lators
(US, U6) are powered from the emitter-follower regulator. The IC’s
are used where a stable, lower voltage is required.

.
. PAGE 1
 OPERATION AND MAINTENANCE MANUAL OM-200
FOR D.C. VOLTAGE REGULATOR 485972

2. Circuit Descriptions

A. Voltage Detection Circuit 1;

I

This circuit consists of Capacitors C5, C9; Resistors, R13, R14; and a
Potentiometer R33. The resistors and potentiometer form a simple voltage ,
divider network where the voltage at the potentiometer wiper is merely a
portion of the generator output voltage. The capacitors reduce the
effect of generator commutator ripple and brush arcing.

The output of the Voltage Detection Circuit is thus a filtered DC voltage

p,roportional to the generator output.

B. Voltage Comparison Circuit

The voltage comparison circuit consists of a unity gain difference amp-

lifier and constant voltage reference source.

The difference amplifier consists of Resistors R15, R18, R19, R20 and Gp
Amp Ul. The output of the difference amplifier is the signal at the non-
inverting input minus the signal at the inverting input, times the gain
of the amplifier. The voltage at the inverting input is fed by a voltage
divider network (R5, R34) and an 8 volt regulator source; always holding
the voltage to this input constant. The voltage at the non-inverting in-
put is the signal from the voltage detection circuit. Since the gain of :::.
the amplifier is unity (set by the resistors), the output is the difference
between these two input signals.

C. Summing Amplifier Circuit

The Summing Amplifier consists of Resistors R21, R22, R23, R24, R25, R26
and Op-Amp Ul. The resistors set the gain of the amplifier; unity. The
output of the summing amplifier is the sum of the signals at the non-
inverting input, minus the sum of the signals at the inverting input.

The signals at the non-inverting input are the outputs of the Voltage
Comparison Circuit and the Current Limiting Circuit. The signals at the
inverting input are the outputs of the Line Drop Compensation Circuit and
the Voltage Holdup Circuit.

The function of the Summing Amplifier is to modify the signal derived by

the Voltage Comparison Circuit in such a manner as to allow the regulator
to provide line drop compensation, current limiting and voltage holdup.

D. Pulse Width Modulator Circuit

The pulse Width Modulator Circuit (PWM) is comprized of a triangle wave

generator and a voltage comparator circuit.

l-l AUG. 24/81

PAGE 2
 OPERATION AND MAINTENANCE MANUAL OM-200
FOR D.C. VOLTAGE REGULATOR 485972

The triangle wave generator consists of Capacitors Cl, C2, C3; Resistors
Rll, R30; and two IC’s U3, U4. The square wave output of U3 (555 Timer)
is integrated by an Inv rting Hex Buffer U4 to produce the triangle wave.
Capacitor Cl sets the f r equency of the triangle wave and Resistors R30
and Rli are sized to give symmetrical.rise and fal-1 times of the.wave.-’
Capacitors C2, C3 are for power supplying bypassing. This triangle wave ,
is fed to the non-inverting input (through R29) of the voltage comparator.

The voltage comparator circuit consists of Resistors R4, R16, R29 and
Comparator U2. The signal at the non-inverting input is the generated
triangle wave. The signal at the inverting input is the DC level voltage
from the output of the Summing Amplifier. As the positive sloping edge
of the triangle wave exceeds the DC level voltage, the comparator turns
on. The comparator remains on until the negative sloping edge of the
triangle wave falls below the DC level voltage,turning the comparator off.

The duty cycle of the output pulse train is adjustable by increasing or

decreasing the DC level voltage. As the DC level increases, the duty
cycle of the output pulses decreases.

The output of the Pulse Width Modulator Circuit is connected to the

Dar1 ington Power Transistor, 43. As the duty cycle of the PWM decreases,
the average on time of the transistor decreases. Resistor R4 limits the
available current to acceptable levels for U4 and the transistor.

E. Switching Transistor Circuit

The Switching Transistor Circuit consists of Diode CR1 and Darlington

Power Transistor 43. Transistor Q3 is connected in series with the gen-
erator shunt fields; collector to generator field lead, emitter to gen-
erator negative.

The base drive to the transistor is supplied by the Pulse Width Modulator
Circuit. As the duty cycle of the PWM increases, the average on time
of the transistor in turn increases. In this manner, varying the ‘tran-
sistor on and off times, varies the average generator field power.

Diode CR1 is a “Flyback” diode shunt across the generator exciter fields.
When transistor Q3 turns off, the current through the exciter fields is
maintained by flowing through the diode.

F. Damping Ci rcui t

The damping circuit consists of Capacitor C4 and Resistor R7. The damp-
ing circuit detects changes in the generator output and feeds a transient
current to the Pulse Width Modulator Circuit in such a manner as to oppose
the sensed change.

The function of the Damping Circuit is to prevent oscillation and reduce

the transient response time following load changes.
l-l
AUG 24/81

_.. PAGE 3
 OPERATION AND MAINTENANCE MANUAL OM-200
FOR D.C. VOLTAGE REGULATOR 485972

G. Current Limit Circuit

The current limit circuit )cons’ists of a single stage transistor amplifier

and a voltage comparator ci rkui t. The driving signal to the transistor
amplifier is obtained by sensing the voltage drop across the generator
interpole winding. The amplifier circuit consists of Resistors Rl, R2, R6;-: ,
Potentiometer R31, ~32; Capacitors ~8, C6 and Transistor Ql.

When the generator current reaches a level such that the interpole voltage
exceeds the threshold voltage of the transistors emitter-base junction, the
transistor conducts. Capacitor ~8 reduces the effect of brush arcing
and commutator ripple. Resistor R6 1 imits the base current to a safe
level, as Rl, R2 and R31 limit the collector current to acceptable levels.
The voltage gain of the amplifier is controlled by Potentiometer R32.
The output voltage developed at C6 is proportional to the generator load
current.

The voltage developed at ~6 is fed to the non-inverting

input of the com-
-- .._
parator circuit (through Ul used as a unity gain,‘hfgh impedance amplifier).
The comparator circuit consists of Resistors R27, ~28, R10 and Comparator
u2. A reference voltage (set by a potentiometer from the control panel)
is fed to the inverting input. When the voltage ,(pr_oportional
---. to current)
____
exceeds the ~01 tage of the reference (inverting $npuc) i--t&. comparator turns
on. This signal is fed to the Summing Amplifier.

Once the pre-set value of current is reached, the Current Limit Circuit
causes the regulator to decrease the generator voltage in such a manner
that this value of current is not exceeded.

H. Line Drop Compensation Circuit

The Line Drop Compensation Circuit consists of Diodes CR2, CR3 and Op-Amp
Ul. A portion of the voltage developed in the transistor amplifier of
the Current Limiting Circuit (wiper of R31) is fed through a unity gain
amplifier (for high impedance) to the input of the Summing Amplifier.
Diodes CR2, CR3 limit the maximum voltage signal from the Line .Drop
Compensator Circuit to approximately 1.4 Volts.

The Line Drop Compensator Circuit causes the regulator to increase the
generator voltage with load such that the voltage at the load end of the
generator output cables remains constant despite the load cable voltage
drop.

I. Voltage Hold-Up Circuit

The Voltage Hold-Up Circuit consists of Resistors, R8, R9, R12, R17;
Diode VRl and Comparator U2.

The Non-inverting input of the comparator is held constant by Zener Diode

VRl. Resistor R12 limits the current to the diode to safe levels.

-‘l-l AUG 24-181.-..-

- .

‘.
-PAGE 4
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 OPERATION AND MAINTENANCE MANUAL OM-200
FOR D.C. VOLTAGE REGULATOR 485972

Resistors R8, R17 form a voltage divider network across the 27V regu-
lator ci rcui t. This portion of voltage is fed to the inverting input.
As the generator vol tagjeiIfalls towards zero, the regulated-. -27V fol lows
the generator voltage. When the generator voltage fall s to approxi-
mately 12V, the comparator turns on. Resistor R27 is sized to limit
the current through the comparator to a safe level. When the comparator t
turns on, the signal is fed to the Summing Amplifier.

The function of the Voltage Hold-Up Circuit is to limit the voltage to

which the generator can fall when in the current limit mode. Should the
voltage fall below 12 volts, the output contactor.would open, de-ener-
gizing the load.

J. Voltage Build-Up Circuit

The Voltage Build-Up Circuit consists of Relay Kl, Capacitor Cl0 and
Voltage Regulator ~6. When the generator is rotating at or near normal
operating speed, voltage build up begins from residual magnetism. This -*-
residual voltage biases the transistor full on. This causes full gener-
ator voltage to be applied to the shunt field and the resulting self
excitation increases the generator voltage. When the output voltage of
~6 reaches the pull-in voltage of the relay, the contacts open al lowing.5+s--
the regulator to assume the controlling operation.

AUG 24/81 l-l

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 OPERATION AND MAINTENANCE MANUAL OM-200
FOR D.C. VOLTAGE REGULATOR 485972
._.__.- - -. .
..-

l-l AUG 24/81

PAGE 6
 id.:.-
I I

OPERATION AND MAINTENANCE MANUAL OM-200

FOR D.C. VOLTAGE REGULATOR 485972

SECTION 2. ADJUSTMENTS

1. General
i4
There are three multi-turn potentiometers and one single turn potentiometer
which are factory set for proper generator operating characteristics.
Should re-adjustment become necessary, please refer to the following:

A. 28.5 Volt Adjustment

The regulating voltage in the 28.5 volt range is determined by the

position of the wiper arm of the Potentiometer R33, clockwise (CW)
rotation decreases the voltage level that the unit operates. Con-
versely counterclockwise (CCW) rotation increases the voltage level.
Any adjustment of this potentiometer will affect the operation of the
14 Volt range (if supplied).

B. 14 Volt Adjustment

The adjustment of the potentiometer, R34, should be made only after

28.5 Volt range has been
the set. If the unit is equipped with the
optional 14 volt output, set the -vo&$ge range switch in the 14 Volt
position. Clockwise rotation decreases the voltage level, counter-
clockwise increases the voltage level.

Adjustment of this potentiometer will not affect the 28.5 Volt

regulating range.

C. Line Drop Compensation

Line drop compensation allows the voltage at the load end of the out-
put cable to remain constant despite the voltage drop associated with
the output cable. Clockwise rotation of the line drop compensation
Potentiometer R31, increases compensation. This- potentiometer should
be set for flat regulation of voltage at the load end when delivering
rated load current.

D. Current Limiting

The current limiting Potentiometer R32, must be adjusted in conjunction

with the current limiting rheostat located on the control panel of the
unit. Set the dial on the current limiting rheostat to 600 amps. With
a loadbank, apply 800A-900A load.
Clockwise rotation-of R32 wi 11 cause
output current to fall off. Counterclockwise rotation will cause out-
put current to rise. Potentiometer R32 should be adjusted such that the
output current matches the dia 1 setting of the front pane 1 rheostat.

This adjustment is factory set and should not normally need adjusting
in the field.

AUG 24/81 l-2

PAGE 1
 OPERATION AND MAINTENANCE MANUAL OM-200
FOR D.C. VOLTAGE REGULATOR 485972

l-2
AUG 24;81

PAGE 2
 OPERATION AND MAINTENANCE MANUAL OM-200
FOR D.C. VOLTAGE REGULATOR 485972

SECTION 3. TROUBLESHOOTING

1. Genera 1 i4

Troubleshooting is an orderly process of checking and eliminating possible

causes of trouble until the exact cause of a trouble is found.

2. Troubleshooting Chart

The troubleshooting chart lists information in the following manner:

Trouble
Possible Cause
Remedy

The information contained in the following list is not all possible

causes of failures. If the cause of a trouble is an uncommon one and
cannot be located by use of the list, the individual circuits must be
completely checked.

A. Generator voltage wi 11 not bui Id up to normal.

(I) Voltage b ui Id-up circuit relay (Kl) normally closed contacts
open. Replace relay.
(2) Generator residual voltage too low. Flash exciter fields with
“Push To Bui Id Up Voltage” switch.

B. Generator voltage builds up until relay actuates; then fa.lls back.

(1) Integrated circuit U4 failed. Replace U4.
(2) Integrated circuit U3 failed. Replace U3.

C. Generator voltage builds up to dangerously high levels. Flashing

relay (Kl) does not actuate.
(1) Voltage regulator U6 failed. Replace ~6.
(2) Relay Kl defective. Replace Kl.
.(3) Capacitor Cl0 shorted. Replace ClO.

D. Generator voltage builds up to a dangerously high level; flashing

relay (Kl) actuates, but voltage is not controllable with voltage
adjusting potentiometer R33.

(1) Transistor 43 shorted. Replace 43.

(2) Integrated Circuit Ul fai led. Replace Ul .-‘y
(3) Integrated circuit U2 fai led. Replace U2.
(4) Capacitor C5 shorted. Replace C5.
(5) Voltage comparison potentiometer R33 open. Replace R33.

- .----
AUG 24/8f
-

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OPERATION AND MAINTENANCE MANUAL OM-200
FOR D.C. VOLTAGE REGULATOR 485972

E. Generator voltage is unstable, oscillates.

(1) Capacitor C4 shorted.'! Replace C4.

(2) Capacitor Cg open. Repl'ace Cg.

F. Generator voltage falls off when load is applied.

(1) Transistor Ql shorted. Replace Ql.
(2) Current limit rheostat (front panel) shorted. Replace rheostat.

AUG 24181

PAGE 2