TO-212 121890 Instruction Manual for 14-V DC Option Kits Part No. 282565-1 and Part No. 282565-2 For Use With Hobart Series 7003B Jet-Ex 4 Diesel Generator Sets HOBART BROTHERS COMPANY Airport Systems Group Power Systems Division Troy, Ohio 45373 U.S.A.
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TO-212 / Instruction Manual Part No. 282565 / 14-V DC Option Kit 1. Description The 14-V DC option kits covered by this manual, and identified by Hobart numbers 282565-1 and 282565-1, are designed for use with Hobart Jet-Ex 4D generator sets in Series 7003B. Either option kit, when installed and connected into the Jet-Ex 4D unit, makes 14-V DC power available from the existing circuitry of the unit. Part Number 282565-1 identifies the kit that is designed for installation on a Series 7003B generator set with fenders, and Part Number 282565-2 identifies the kit that is designed for installation on a Series 7003B generator set without fenders. The assemblies and items which comprise a kit are as follows: a. 14-V DC load contactor with bus bars and cable. b. 14-V DC control panel assembly. c. 14-V DC overvoltage PC board. d. Wiring for the kit installation, color coded and cut to proper lengths, with terminals attached. Plastic wire ties are also included. e. Mounting hardware (screws, nuts, washers, etc.) f. Hobart connection diagram No. 282573 for 14-V DC option kit. 2. Location of Kit Components a. 14-V Contactor The 14-V contactor (Figure 1) is located at the rear of the Jet-Ex 4D generator set, on the left side of the rectifier assembly, as illustrated in Figure 4. b. Control Panel A small control panel is provided as part of the kit for controlling the 14-V DC circuit. This small control panel is located at the lower center of the larger engine/generator control panel that is located at the rear of the generator set. See Figure 2. 14-V Contactor Figure 1 December 21/90 Page 1
TO-212 / Instruction Manual Part No. 282565 / 14-V DC Option Kit Location of 14-V DC Control Panel Figure 2 Page 2 December 21/90
TO-212 / Instruction Manual Part No. 282565 / 14-V DC Option Kit c. Overvoltage PC Board The 14-V DC overvoltage PC board (Figure 3) is located on the outside of the hinged box that is mounted on the rear of the engine/generator control panel. The 14-V DC overvoltage board mounts using the same mounting holes as the 28-V DC overvoltage board only on the outside of the box. 14-V Overvoltage PC Board Figure 3 3. Field Installation of 14-V DC Option Kit When a Jet-Ex 4D generator set is ordered with the 14-V DC option from Hobart Brothers, this option kit is installed at the factory. However, this option kit may be installed in the field on a Jet-Ex 4D unit previously purchased without this kit. a. Mounting the Contactor Panel Assembly The 14-V contactor (Figure 1) mounts on the left side of the rectifier assembly. Three 1/4-20 X 1/2" hex-head screws are used to mount the contactor. These screws are provided in the kit. b. Mounting the 14-V Control Panel Assembly To mount the 14-V control panel assembly on the engine/generator control panel, first remove the blank plate that is at the lower center of the engine/generator control panel, and fasten the control panel in place with the four 10-24 X 1/2-inch round head screws and the four #10 lock washers which were used to fasten the blank plate. c. Mounting the 14-V Overvoltage PC Board To mount the 14-V DC overvoltage board, open the hinged engine/generator control panel. Remove the three nuts which mount the 28-V overvoltage board to its shock mounts, and mount the three spacers (provided in the kit) in place of the three nuts on the outside of the box which contains the 28-V DC overvoltage board. Then mount the three shock mounts (provided in the kit) on top of the spacers, and mount the 14-V overvoltage board to the shock mounts with the hardware provided. December 21/90 Page 3
TO-212 / Instruction Manual Part No. 282565 / 14-V DC Option Kit d. Mounting the 14-V DC Load Contactor, Buses, Cable and Label Using the hardware that is provided in the kit, as identified below, refer to Figure 6 for performing this installation, and proceed as follows: 1. Mount the 14-V load contactor (12) using the three 1/4-20 X 1/2 round head SEMS screws (21). 2. Remove the hole plug from the top shroud of the rectifier assembly. This allows access to a 3/8-inch hole in the positive rectifier heat sink plate. 3. Mount the 14-V positive bus bar (17) to the positive rectifier heat sink plate, (position notch in the bus bar towards the generator) using the 3/8-16 X 1-1/4 hex-head screw (19) along with a 3/8-16 hex-nut, lock, nut, and flat washer (items 14, 15, 16). 4. Attach the other end of the bus bar (17) to the 14-V load contactor (12) using the 3/8-16 X 1 hex-head screw (13). 5. Refer to Figure 4 and install the 14-V negative bus bar (7, Fig. 4 and 18, Fig. 6) on the negative rectifier heat sink plate (6), using the two 1/4-20 X 1-3/4 hex-head screws (1). Do this such that: (a) the screws are inserted through the end of the bus bar having the unthreaded holes, and 1. Screw, hex-head,1/4-20 X 1-3/4 2. Nut, 1/4-20, locking 3. Flat washer, 1/4-inch 4. Insulating Bushing 5. Insulating Washer 6. Heat Sink 7. Negative Bus Bar Negative Bus Bar Installation Figure 4 (b) the flat washers (3), insulating washers (5), insulating bushing (4), and locking nut, (2) are placed on each screw EXACTLY as shown in the illustration. 6. Referring again to Figure 6, install one end of the cable (27) to the negative heat sink plate with a 3/8-16 X 1 hex-head screw (13) and the other end of this cable to the shunt, using a 3/8-16 X 2 screw (28), just as is shown in this illustration. 7. Place nameplate (20) on the mounting bracket of the 14-V load contactor, in the location indicated in Figure 6. Page 4 December 21/90
TO-212 / Instruction Manual Part No. 282565 / 14-V DC Option Kit e. Wiring the 14-DC Option Kit Refer to the following Hobart diagrams before wiring the 14-V DC option kit to the Jet-Ex4D generator circuitry. Diagram No. Diagram 282573 Connection, 14-V Option Schematic 282560 Schematic, Jet-Ex 4D (in Hobart Manual OM-2062, Chapter 6) 282561 Connection, Jet-Ex 4D (in Hobart Manual OM-2062, Chapter 6) Wires, cables, and hardware required for wiring the 14-V option kit are provided in the kit. Make connections according to Hobart diagram No. 282573. Make certain that all connections are tightly and securely made. f. Connecting 14-V DC Output Cables Figure 5 (which is an enlarged section of Figure 6) shows where the positive and negative output cables are to be connected. To make each of these connections, use a 3/8-16 X 1 hex-head screw along with a 3/8-16 hex-nut, lock, nut, and flat washer, and make the connections tightly and securely. Locations for 14- V DC Output Cable Connections Figure 5 December 21/90 Page 5
TO-212 / Instruction Manual Part No. 282565 / 14-V DC Option Kit g. Testing the 14-V DC Option Kit After field installation of the 14-V option kit, refer to Figure 3 and test the operation of the 14-V circuit as follows. (1) With voltage selector switch in the 28-V (right) position, the amber 28.5-V mode light should be illuminated. (2) Try to close the 14-V contactor using the 14.25-V output contactor switch. Contactor should not close. (3) With the 28-V contactor closed, place the voltage selector switch in the 14-V position. The 28-V contactor should open, the amber 28.5-V mode light should go out, and the blue 14-V mode light should be illuminated. (4) Adjust R45 on the voltage regulator for14.25-v DC output. (5) Try to close the 28-V contactor. It should not close. (6) Check the operation of the 14-V overvoltage (OV) relay by closing the 14-V contactor, and then increasing the output voltage by adjusting the voltage regulator. OV relay should trip at 18 to 20-V DC in 2 to 10 seconds, and should reset at 14.5-V to 15.5-V DC. (7) Re-adjust the voltage regulator to give 14.25-V DC output. (8) Close the 14-V contactor and apply approximately 550-A load for 10 minutes. (9) With no load, close the 14-V contactor and place the voltage selector switch in the 28-V position. The 14-V contactor should open, the blue 14-V mode light should go out. The amber 28-V mode light should be illuminated, and the output voltage should be 28.5-V. (10) Shut off generator set as per instructions in Hobart Manual OM-2062, Section 1-3. 4. Illustrated Parts List a. Manufacturers Codes 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, 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 vendor code, the full name of the manufacturer will be listed in the nomenclature column. CODE VENDOR S NAME AND ADDRESS 00779 Amp, Inc., P.O. Box 3608, Harrisburg, PA 17105 05277 Westinghouse Electric Corp., Semiconductor Div., Hill St., Youngwood, PA 15697 08108 Lamp Industries for use with industry designation and abbreviations for lamps 15605 Eaton Corporation, Cutler-Hammer Division, 4201 N. 27th Street, Milwaukee, WI 53216 23826 Furnas Electric Co., 1004 McKee St., Batavia, IL 60510 72619 Dialight Division, Amperex Electronic Corporation, 203 Harrison Place, Brooklyn, NY 11237 74559 Carlingswitch, Inc., 505 New Park Avenue, West Hartford, CT 06110 75382 Kulka Electric Co., 1040 Hoyt Avenue, Ridgefield, NJ 07657 Page 6 December 21/90
TO-212 / Instruction Manual Part No. 282565 / 14-V DC Option Kit 5. Service Information If you have any questions concerning your Hobart Ground Power Division equipment, you are invited to contact our service department by mail, telephone, or FAX. Write: Telephone: Hobart Brothers Company Airport Systems Group Ground Power Division 1177 Trade Road East Troy, Ohio 45373, U.S.A. (513) 332-5060 (Service Assistance) (513) 332-5050 (Parts Replacement) FAX: (513) 332-5121 December 21/90 Page 7
TO-212 / Instruction Manual Part No. 282565 / 14-V DC Option Kit 14-V DC Output Kit Figure 6 Page 8 December 21/90
TO-212 / Instruction Manual Part No. 282565 / 14-V DC Option Kit UNITS FIGURE HOBART AIRLINE PER ITEM NO. PART NO. PART NO. NOMENCLATURE ASSY 4-282565-1 KIT, 14-V OUTPUT, ASSY., (For Jet-Ex 4D with Fenders) A REF. 282565-2 KIT, 14-V OUTPUT, ASSY., (For Jet-Ex 4D without Fenders) B REF. 282649. PANEL, CONTROL, 14-V, OPTION, ASSY. 1 1 282650.. PANEL, CONTROL, 14-V, OPTION 1 2 HF-2518-23.. LIGHT, PILOT, BLUE 1 3 406040.. BOOT, TOGGLE SWITCH 2 4 402682.. SWITCH, TOGGLE, 3PDT 1 5 HF-2518-4.. LIGHT, PILOT, AMBER 1 6 HF-2518-8.. LIGHT, PILOT, GREEN 1 7 403189.. SWITCH, TOGGLE 1 * 8 402665-1.. HOUSING, RECEPTACLE, QUICK-DISCONNECT 4 * 9 489087.. PLUG, HARNESS, ASSY. 1 * 10 42517.. INSULATION, SLEEVING, FIBERGLAS, SIZE O 24" 11 180510. BOARD, PC, OVERVOLTAGE, 14-V 1 12 282120-2. CONTACTOR, 14-V DC, V23826, No. 42L109152 1 13 W-11097-2. SCREW, 3/8-16 X 1, HHC, ST 4 14 W-11242-10. WASHER, FLAT, 3/8 10 15 W-11254-6. WASHER, LOCK, 3/8 6 16 W-11278-5. NUT, HEX, 3/8-16 4 17 282566. BUS, POSITIVE, 14.25-V 1 18 282567. BUS, NEGATIVE, 14.25-V 1 19 W-11097-3. SCREW, 3/8-16 X 1-1/4, HHC, ST 1 20 400434. NAMEPLATE, 14-V 1 21 AW-1802. SCREW, SEMS, 1/4-20 X 1/2, ST 3 22 A-25. WASHER, INSULATING 4 23 DW-1704. BUSHING, INSULATING 2 24 W-11242-5. WASHER, FLAT, 1/4 4 25 50MS-732-0. NUT, KEPS, 1/4 A 2 50MS-732-0. NUT, KEPS, 1/4 B 4 26 402119-9. SCREW, 1/4-20 X 1-3/4, HHC, ST 2 27 W-9218-92. CABLE 1 28 W-11097-7. SCREW, 3/8-16 X 2, HHC, ST 1 * 29 84A-1075. MOUNT, RUBBER 3 * 30 W-11245-3. WASHER, FLAT, BRASS, #8 3 * 31 W-11254-2. WASHER, LOCK, STD, #8 3 * 32 W-11287-3. NUT, #8-32, SCR., MH, HEX, ST. 6 * Not Illustrated December 21/90 Page 9
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TO-212 / Instruction Manual Part No. 282565 / 14-V DC Option Kit UNITS FIGURE HOBART AIRLINE PER ITEM NO. PART NO. PART NO. NOMENCLATURE ASSY 4-282565-1 KIT, 14-V OUTPUT, ASSY. (continued) * 33 81B-1085. LABEL, 14-V 1 * 34 375426-2. SPACER, BOARD, PC 3 * 35 400828-1. TIE, WIRE, PLASTIC 15 * 36 402321-1. SCREW, 1/4-20 X 1/2, HW, SF-TAP, TT A 2. SCREW, 1/4-20 X 1/2, HW, SF-TAP, TT B 10 * 37 488640. BRACKET, OUTPUT CABLE, ASSY. B 1 * 38 402119-4. SCREW, 1/4-20 X 3/4, HHC, ST B 2 * 39 DWP-982. BRACKET, CABLE B 2 * Not Illustrated December 21/90 Page 11
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