INSTRUCTIONS FOR REMOVAL OF GROUND FAULT PROTECTION DEVICE FROM HOBART GENERATOR SETS SPECIFICATION NUMBER

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1 TO INSTRUCTIONS FOR REMOVAL OF GROUND FAULT PROTECTION DEVICE FROM HOBART GENERATOR SETS SPECIFICATION NUMBER _. HOBART BROTHERS COMPANY Power Systems Division Troy, Ohio U.S.A.

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3 TO-161 INSTRUCTIONS FOR REMOVAL df GROUND FAULT PROTECTION FOR GENERATOR SPECIFICATION NUMBERS '1. Purpose The purpose of this -manual is to provide instructions for removal of the ground fault protection device from the circuitry of Hobart generator sets identified by Specification Number and covered by Hobart Manual OM-395. For removal of the ground fault device, Hobart Brothers Company has available a kit, identified as Hobart Number and containing the wires, labels, and other items which are needed. For proper operation of a generator set after removal of its ground fault device, these instructions must be followed exactly as they are given herein. NOTE: Use the following instructions as a CHECKLIST, checking off in pencil each step in the procedure as that step is performed. L. 3 Preparation for Removal of Ground Fault Device WARNING: ELECTRIC SHOCK CAN KILL! DO NOT TOUCH LIVE ELECTRICAL PARTS. A. Turn OFF the input power to the generator set at its source and make certain that input power cannot be turned ON inadvertently while the ground fault device is being removed.,

4 3. Generation Protection Trav TO~161 A. Remove tray to facilitate making changes. B. Remove the following wires. Refer to Diagram Clip wire ties as necessary to remove wires. (1) 1139 Red-Yellow from the Overload Fault Light (DS36) to the Ground Fault Light (DS41). (2) #40 Red-Yellow from the Ground Fault Light (DS41) to the Test Pushbutton (S30). (3) Yellow-Black from the main receptacle (52) terminal fl0 to the Ground Fault Light (DS41). (Cut wire flush with rear of receptacle.) (4) Black-Red from the main receptacle (52) terminal #26 to the terminal block station f5 (5th from rear of tray). (Cut wire flush with rear of receptacle.) (5) #15 Black-Red from the terminal block station #5 (5th from rear of tray) to the Memory and Time Delay Relay plug (P5) pin fl3. (Cut wire flush with rear of plug.) (6) #16 Black-Red from the terminal block station 115 (5th from rear of tray) to the Underfrequency Relay plug (P15) pin #8. (Cut wire flush with rear of plug.) (7) #32 Yellow-Black from the Memory and Time Delay Relay plug (P5) pin #14 to the Ground Fault Light (DS41). (Cut wire flush with rear of plug.) c. Remove the following part. Refer to Figure 1, Item 7. (1) One HF Ground Fault Pilot Light (DS41). D. Add the following part. Refer to Figure 1. (1) One Hole Plug. Insert in hole previously occupied by the Ground Fault Pilot Light as removed in Step C. (1) above. E. Add the following wire. Refer to Diagram (1) One Red-Yellow Wire Assembly (#40) from the left terminal of Overload Fault Light (DS36) (as viewed from rear of, tray) to the N.O. terminal of the Test Pushbutton (S30). (2) Secure above wire and refasten wire bundles as required with l Wire Ties. F. Add the following label. Refer to Figure 1. (1) Use label #9 from enclosed sheet of labels (85C-1009) to cover the: words GROUND FAULT on front of tray.

5 TO-161 I 2 HOBART I GENERATOR PFiOlECT~ Location of Label # Fuse-Interlock Relay Memory And Time Delay Board Over-Undervoltage Board Underfrequency Board Reset Switch Test Switch Ground Fault Indicating Light Overload Indicating Light 9. Underfrequency Indicating Light 10. Undervoltage Indicating Light 11. Overvoltage Indicating Light 12. Fuse, 2 Amp 13. Adjustable Grip Latch 14. Terminal Board 15. Wiring Harness 1.- Generator Protection Tray Fi~~re-l _.~._..._. _._.._ -. --~-.----~---. _ _ July 3G/85

6 4. Interior Panel A. Remove the following wires. Refer to Diagram Clip wire ties as necessary to remove wires. (1) 112 Black-Red from Ground Fault Relay (K13) (cut wire at splice) to station 1117 on terminal block TBl. (2) #13 Red-Blue from Ground Fault Relay (K13) (cut wire at splice) to station 818 on terminal block TBl. (3) ii52 Blue-Orange from Ground Fault Auxiliary Relay (K49) terminal #3 to station #8 on terminal block TBl. (4) 553 Yellow-Black from Ground Fault Auxiliary Relay (K49) terminal 112 to station f14 on terminal block TBl. (5) #54 Orange-Black from Ground Fault Auxiliary Relay (K49) terminal bll to 7th station from bottom on terminal block TB4. (6) 1155 Red-Yellow from Ground Fault Auxiliary Relay (K49) terminal 1110 to 9th station from top on terminal block TB3. (7) Yellow-Black from the Generator Protection Tray Receptacle (537) terminal HlO to station #14 on terminal block TBl. First disconnect it at the terminal block, and pull wire loose from wire bundle, then cut off wire as close to receptacle as possible. (8) Black-Red from the Generator Protection Tray Receptacle (537) terminal 826 to station #17 on terminal block TBl. First disconnect it at the terminal block, and pull wire loose from wire bundle, then cut off'wire as close to receptacle as possible. (9) Yellow-Black from the Top Test Point Receptacle (534) terminal i/37 to station 1114 on terminal block TBl. First disconnect it at the terminal block, and pull wire loose from wire bundle, then cut off wire as close to receptacle as possible. (10) Black-Red from the Top Test Point Receptacle (534) terminal #27 to' station #17 on terminal block TBl. First disconnect it at the terminal block, and pull wire loose from wire bundle, then cut off'wire as close to receptacle as possible. B. Move the following wire. Refer to Diagram (1) Disconnect Orange-Black wire from Ground Fault Auxiliary Relay (K49) terminal 88 and reconnect it to the 7th station from bottom on terminal block TB4. Cut wire to proper length, and apply quick connect terminal to end of wire which connects to terminal block. (2) Secure above wire and refasten wire bundles as required with l Wire Ties. i

7 .~~ TO-161. C. Remove the following parts. Refer to Figure 2 and Diagram (1) Remove the Resistor Assembly (7.5 ohm, 5 watt) which is conne,cted from the neutral (N) output terminal (and routed through the Ground i Fault Relay sensing transformer) to the ground screw in the bottom of / the control cabinet. (2) Remove the 79B-1157 Ground Fault Relay (Figure 2, Item 15) and the ; Auxiliary Ground Fault Relay (Item 14) and their associated parts, by removing the 2 screws which attach the mounting bracket to the interior panel. D. Add the following part. Refer to Diagram (1) Connect one W cable from the neutral (N) output where the input ground cable is attached. 5. Test Point Panel A. Disconnect the 2 test point plugs (P34 & P35) from the left side of the interior panel. B. Remove the Test Point Panel by removing the 4 screws which mount it to the inside of the control cabinet door. C. Remove the following wires. Refer to Diagram Clip wire ties as necessary to remove wires. (1) Black-Red from the Top Test Point Plug (P34) terminal f27 to test point jack i/229. (2) Yellow-Black from the Top Test Point Plug (P34) terminal ii37 to test point jack D. Remove the following parts. Refer to Figure 3, Items 1 & 2. Two test point jacks i/229 and E. Using the screws removed in Step B above, reinstall the test point panel in the control cabinet door. At the same time, reconnect the ground strap to the lower right hand screw using the IET lock washer. F. Install the following labels from the enclosed sheet of labels (SSC-1009) onto the test point panel. Note that label #3 and label #4 are not used; (1) Apply label i/l to the location shown on the Label Application Outline (2) Apply label 112 to the location shown on the Label Application Outline

8 /.- TO-161 (3) Apply label #5 to the location shown on the Label Application Outline (4) Apply label 116 to the location shown on the Label Application Outline (5) Apply label 87 to the location shown on the Label Application Outline (6) Apply label K8 to the location shown on the Label Application Outline G. Apply label to the location shown on the Label Application Outline Test Instructions A. Reconnect input power. B. Press TEST pushbutton on Generator Protection Tray, and check to make sure that all fault lights illuminate. c. Press RESET pushbutton on Generator Protection Tray, and check to make sure that al-1 fault lights go out. D. Press MOTOR START pushbutton, and make sure that the generator builds up voltage when the motor completes its start. NOTE: Unit is now ready to operate. 7. Update Operating Manual A. Discard original Operating Manual OM-395 dated Jan 1984 and replace with new Operating Manual OM-395 dated Aug ' Service-Information - If you have any questions concerning the removal of the Ground Fault Protection Device from Hobart generator sets, you are invited to contact our Service Department by mail, telephone, or TWX at: Write: Hobart Brothers Company Power Systems Division Service Department Troy, Ohio U.S.A. Telephone: Area Code (513) TWX: _-.-. ^_.. July 30/85

9 I I. fj 17 I i3 i Ii Voltage regulator (not part of 11. interior panel) 12. Rectifier 13. Terminal Board 14. Wiring Harness 15. Motor Control Transformer 16. Transformer Panel Assembly 17. Load Contactor 18. Aircraft-Test Bank Switch 19. Generator Control Relay 20. Plug Interlock Relay 21. "E" and "F" Leads Terminal Neutral Terminal Power Supply (12-VDC) Auxiliary Ground Fault Relay Main-Ground Fault-Relav., Motor Overload Relay Motor Input Terminal Panel Wiring Harness Motor Run Contactor Motor Start Contactor Circuit Breaker, 25-A.--.. Interior Panel Figure 2 --.~. -.-~ ~ _ :... _-_. -.' B E

10 I*.- I-... U._.- - I._ I...-.,- M.....m, ~e..-,..-. W a...~ , , I c I_ I. *-.. U -.. w U... -* \, v I \ 2 1. Test Point Jack Test Point Jack # Identification Nameplate Test Panel Figure.._ _ - _. _ July 30185

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