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

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1 INSTRUCTIONS FOR REMOVAL OF GROUND FAULT PROTECTION DEVICE FROM HOBART GENERATOR SETS SPECIFICATION NUMBERS HOBART BROTHERS COMPANY Power Systems Division Troy, Ohio 45373

3 INSTRUCTIONS FOR REMOVAL OF GROUND FAULT PROTECTION FOR GENERATOR SPECIFICATION NUMBERS 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 Numbers and covered by Hobart Manual TM-764. 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. 2. Preparation for Removal of Ground Fault Device WRNING: 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.,. _-.Aug Page...1.i

4 3. Generation Protection Tray TO-163 A. B. Remove tray to facilitate making changes. 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) 840 Red-Yellow from the Ground Fault Light (DS41) to the Test Pushbutton (S30). (3) Yellow-Black from the main receptacle (52) terminal 810 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 #5 (5th from rear of tray). (Cut wire flush with rear of receptacle.) (5) 815 Black-Red from the terminal block station #5 (5th from rear of tray) to the Memory and Time Delay Relay plug (P5) pin f13. (Cut wire flush with rear of plug.) (6) #16 Black-Red from the terminal block station #5 (5th from rear of tray) to the Underfrequency Relay plug (P15) pin #8. (Cut wire flush with rear of plug.) (7) W32 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 G;. t j Page 2 (1) Use label #9 from enclosed sheet of labels (85C-1009) to cover the i words GROUND FAULT on front of tray... ~~..-. Reinstall tray to original position and lock--in-place..- --Aug 13185

5 12 II IO HOBART I I GENERATOR FfWTECTlON k Location of Label ii Fuse-Interlock Relay Memory And Time Delay Board Over-Undervoltage Board Underfrequency Board Reset Switch Test Switch Ground Fault.IndicatingLight 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 Gener.ator Protection Tray Figure 1.Aug 13;85 Page 3

6 . TO Interior Panel A. Remove the following wires. Refer to Diagram Clip wire ties as necessary to remove wires. (1) 812 Black-Red from Ground Fault Relay (K13) (cut wire at splice) to 2nd station from right on terminal block TBl. (2) f13 Red-Blue from Ground Fault Relay (K13) (cut wire at splice) to first station on right on terminal block TBl. (3) ii52 Blue-Orange from Ground Fault Auxiliary Relay (K49) terminal 83 to 8th station from left on terminal block TBl. (4) 1153 Yellow-Black from Ground Fault Auxiliary Relay (K49) terminal 82 to 5th station from right on terminal block TBl. (5) #54 Orange-Black from Ground Fault Auxiliary Relay (K49) terminal 1111 to 7th station from bottom on terminal block TB2. (6) ii55 Red-Yellow from Ground Fault Auxiliary Relay (K49) terminal #lo to 9th station from top on terminal block TB3. (7) Yellow-Black from the Generator Protection Tray Receptacle (537) terminal #lo to 5th station from right 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 2nd station from right 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 #37 to 5th station from right 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 2nd station from right 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 TB2. 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. Page 4 AuglT185

7 c. Remove the following parts. Refer to Figure 2 and Diagram (1) Remove the Resistor Assembly (7.5 ohm, 5 watt) which is connected from the neutral (N) output terminal (and routed through the Ground 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 ii27 to test point jack f229. (2) Yellow-Black from the Top Test Point Plug (P34) terminal #37 to test point jack D. Remove the following parts. Refer to Figure 3, Items 1 & 2. Two test point jacks #229 and #234. 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 (85C-1009) onto the test point panel. (1) Apply label i'/l to the location shown on the Label Application Outline (2) Apply label #2 to the location shown on the Label Application Outline : (3) Apply label 113 to the location shown on the Label Application Outline ,. (4) Apply--label--#4 to- the-loca-tion shown on the-label -Application..Outlin~..~~ Aug 13' page 5

8 (5) Apply label #5 to the location shown on the Label Application Outline (6) Apply label #6 to the location shown on the Label Application Outline (7) Apply label #7 to the location shown on the Label Application Outline (8) Apply label 88 to the location shown on the Label Application Outline TestInstructions. 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 all 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 TM-764 and replace with new Operating Manual OM 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:

9 I 23 u I3 12 II Voltage regulator (not part of interior panel) Rectifier Terminal Board Wiring Harness Motor Control Transformer Transformer Panel Assembly Load Contactor Aircraft-Test Bank Switch Generator Control Relay Plug Interlock Relay 11. "E" and "F" Leads Terminal 12. Neutral Terminal 13. Power Supply (12-VDC) 14. Auxiliary Ground Fault Relay. 15. Main Ground Fault Relay 16. Motor Overload Relay 17. Motor Input Terminal Panel 18. Wiring Harness 19. Motor Run Contactor 20. Motor Start Contactor. Aug _._ p&e...7,i

10 IL <., I..- -., m c I *-, a -...a w -e _. -..ztr~~ - a-. ---ci I.m I.* I , e-v a C , I..-. s i I I \ 2 1. Test Point Jack Test Point Jack Identification Nameplate /.,.. Test Panel Figure 3,Page 8 Aug 13185

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

TO-161 073085 INSTRUCTIONS FOR REMOVAL OF GROUND FAULT PROTECTION DEVICE FROM HOBART GENERATOR SETS SPECIFICATION NUMBER 6184-3..-.-.._. HOBART BROTHERS COMPANY Power Systems Division Troy, Ohio 45373