ITW GSE Hobart 2400 Compact Manual Download

Page: 4 / 77

Operation Manual - Hobart 2400 Compact – 120 / 140 / 180 kVA

Index

Document no. 578.430AB

Page 4 of 75

7.11

Aircraft Connector Insertion ......................................................................................... 55

7.12

GPU Enable................................................................................................................... 55

7.13

Door Switch .................................................................................................................. 56

7.14

Cable Temperature ........................................................................................................ 56

7.15

Neutral Voltage Supervision ......................................................................................... 56

7.16

Earth Leakage Level ..................................................................................................... 56

7.17

Earth Leakage Delay ..................................................................................................... 57

7.18

Real Time Clock Setup ................................................................................................. 57

7.19

Date/Time Format ......................................................................................................... 57

7.20

Ethernet Configuration .................................................................................................. 57

7.21

Modbus Slave Address.................................................................................................. 57

7.22

LED Brightness ............................................................................................................. 58

7.23

Unit of Measure ............................................................................................................ 58

7.24

Costumer ID .................................................................................................................. 58

7.25

Battery Replaced ........................................................................................................... 58

7.26

Language ....................................................................................................................... 58

8.0

Service, Maintenance, Overhaul ............................................................................. 60

8.1

Recommended Maintenance Schedule ......................................................................... 60

8.2

Battery back-up & replacement .................................................................................... 61

9.0

Trouble Shooting & Repair ..................................................................................... 63

9.1

Fault Guidance .............................................................................................................. 64

10.0

Illustrated Parts List ................................................................................................ 67

11.0

Options .................................................................................................................... 70

578808

Dry Contacts (Diagram 478850) ................................................................................... 70

578850

Base module (Drawing 278430) ................................................................................... 70

578852

Single Output (Diagram 478850) .................................................................................. 71

578853

Door Interlock (Diagram 478850) ................................................................................ 71

578854

Anti-Condensation Heater (Diagram 478850) .............................................................. 72

578855

RS485 Interface (Diagram 478850) .............................................................................. 72

578856

Military Interlock (Diagram 478850) ........................................................................... 73

578857

Lockable Door (Fixed) .................................................................................................. 73

578xxx

Remote Control Box ..................................................................................................... 74

578814

Terminal Extension ....................................................................................................... 75

591100

Auto Calibration Plug ................................................................................................... 75

OM2252

Rev 0 December 15 2016

Summary of Contents for Hobart 2400 Compact

Page 1: ...L 34221 U S A T toll free in US 800 899 1841 T International 1 941 721 1000 E technicalsupport itwgse us Serial no Type 3GW 200 it s all about connections Manual Hobart 2400 Compact 120 140 180 kVA 400 Hz Ground Power Unit OM2252 Rev 0 December 15 2016 ...

Page 2: ...2016 IMPORTANT NOTE We recommend that the battery that safeguards GPU settings etc is changed after 5 years of use in order not to lose data The unit has an internal supervision that keeps track of time the battery has been in service and will display a warning when the battery needs to be changed Refer to section 8 2 for further information OM2252 Rev 0 December 15 2016 ...

Page 3: ... 24 4 7 400 Hz Output 24 4 8 400 Hz Interlock 25 4 9 Control Interface Remote I O Terminals 25 4 10 TCP IP On board Interface 27 5 0 Technical Specifications 28 6 0 Operator s Instructions Display LED Keypad layout 32 6 1 Using the Display Keypad 34 6 2 Operating the unit 35 6 3 Basic Menu 37 6 4 Default Factory Settings 51 7 0 Set up Lock Output Mode Compensation 52 7 1 Preventing changes of set ...

Page 4: ...ry Replaced 58 7 26 Language 58 8 0 Service Maintenance Overhaul 60 8 1 Recommended Maintenance Schedule 60 8 2 Battery back up replacement 61 9 0 Trouble Shooting Repair 63 9 1 Fault Guidance 64 10 0 Illustrated Parts List 67 11 0 Options 70 578808 Dry Contacts Diagram 478850 70 578850 Base module Drawing 278430 70 578852 Single Output Diagram 478850 71 578853 Door Interlock Diagram 478850 71 578...

Page 5: ...Operation Manual Hobart 2400 Compact 120 140 180 kVA Declaration of Conformity Document no 578 430AB Page 5 of 75 1 0 Declaration of Conformity OM2252 Rev 0 December 15 2016 ...

Page 6: ...nd safety the electrical installation must fulfil all local regulations and legislation Touching live electrical parts can cause fatal shocks and severe burns Internal parts where the voltage exceeds 50 V are covered and or marked with Keep all panels and covers securely in place Have only qualified people remove covers for maintenance or troubleshooting When connecting the unit to the aircraft ma...

Page 7: ... power unit Upon closing the switch disconnector breaker the power is distributed via the 2 MCB s Q2 Q3 to each converter and via Q6 to the internal 24 Volt power supply G1 The ground power unit performs an initialization test and then goes into standby mode Magnetic Package IT0040 Interface Board new Magnetic Package Capacitor Boards 579532 Power Module 578100 Output Filter Cap KP7087 315 A Disco...

Page 8: ...ormer the magnetic wave shaping circuit and the rectifier situated at the inverter module ensures an almost sinusoidal line current with a Total Current Harmonic Distortion of 5 ITHD at 180 kVA kW and a unity power factor at all loads This means less stress on the main supply network and the distribution transformers Inverter Modules PM1 PM2 The Inverter Module includes the rectifier V1 V6 the DC ...

Page 9: ...ntactor per output The contactors are engaged at start up of the corresponding output and are disengaged when the corresponding stop button is activated or a system error occurs If the interlock voltage provided by the aircraft is not returned to the ground power unit within the delay settings refer to chapter 6 3 the corresponding contactor also disengages Interface Board A2 The purpose of this b...

Page 10: ...PM2 Input for temperature sensors T2 X30 Input for temperature sensors T4 X31 Input for Q2 Q3 status X29 I O ports for remote control Start Stop etc output 1 X1 I O ports for remote control Start Stop etc output 2 X2 Protected interface for interlock signals Interface for individual overload protection X22 X23 Neutral Voltage Supervision Door Interlock X32 Earth Leakage Failure via X24 and current...

Page 11: ...ure of the error All immediate parameters related to a shut down are stored in the ground power unit s memory The Control Board has an on board Ethernet RJ45 connector which can be used to communicate with the BMS Building Management System and USB host Type A connection to retrieve data from the converter or to update the software Display Board Keyboard A3 A4 The display module serves as the inte...

Page 12: ...ption Document no 578 430AB Page 12 of 75 ID Chip A7 The ID Chip is connected to Interface Board A2 X19 and is fixed to the I O zone plate It contains information on the GPU configuration and stores all set up values Black Box Power Log records OM2252 Rev 0 December 15 2016 ...

Page 13: ... table below the unit automatically shuts down and opens the output contactor Output Voltage U 130V 250ms Output Voltage U 140V 15ms Output Voltage U 104V 500ms Overload If the output current exceeds the overload ratings in the table below the unit shuts down to protect itself 125 for 600 seconds 150 for 60 seconds 200 for 30 seconds 300 for 10 seconds 400 for 1 second Short circuit at output The ...

Page 14: ...ceeds 42 V factory setting the unit shuts down and reports NVS failure For change of setting please refer to section 6 3 Neutral Voltage Displacement Supervision NVD The combination of a grounded converter and an un grounded aircraft might lead to an energized aircraft chassis The reason is the neutral voltage displacement caused by an unbalanced load In case the aircraft frame is or will be groun...

Page 15: ...onmental Conditions after Commissioning When the converter has been installed and commissioned we strongly advise that the unit is always kept with input power on This provides optimal conditions for the electronic components and prevents humidity in the form of condensed water from reaching vital parts If for some reason the converter has been without input voltage for a period of time a visual i...

Page 16: ...ing position while it is still placed and firmly fixed to the pallet For safety reasons the passenger boarding bridge should be placed in a horizontal position at the lowest possible height above ground before lifting is started We recommend that you keep the original pallet for future dismantling in connection with service and maintenance Fig 4 3 3 Transport and mounting of the AXA 2400 by means ...

Page 17: ...t Power 120 140 180 kVA Transport and Installation Document no 578 430AB Page 17 of 75 4 4 Installation and fastening instructions Fig 4 4 1 Foot Print Spacing Fixed Unit Fig 4 4 2 Mounting Holes Fixed Unit OM2252 Rev 0 December 15 2016 ...

Page 18: ...kVA Transport and Installation Document no 578 430AB Page 18 of 75 Fig 4 4 3 Removable gland plates Fixed Unit Made of alu zink to prevent corrosion at the cable gland holes The gland plates are removed from inside the cubicle OM2252 Rev 0 December 15 2016 ...

Page 19: ...8 430AB Page 19 of 75 Fig 4 4 5 Mounting Holes Bridge Mounted Unit Fig 4 4 6 Removable gland plates Bridge Mounted Unit Made of alu zink to prevent corrosion at the cable gland holes The gland plates are removed from inside the cubicle Output gland plate Input gland plate OM2252 Rev 0 December 15 2016 ...

Page 20: ...ration Manual Hobart 2400 Compact Power 120 140 180 kVA Transport and Installation Document no 578 430AB Page 20 of 75 Center of Gravity Fig 4 4 7 Center of Gravity Fixed Unit OM2252 Rev 0 December 15 2016 ...

Page 21: ...Operation Manual Hobart 2400 Compact Power 120 140 180 kVA Transport and Installation Document no 578 430AB Page 21 of 75 Fig 4 4 8 Center of Gravity Horizontal Unit OM2252 Rev 0 December 15 2016 ...

Page 22: ...port and Installation Document no 578 430AB Page 22 of 75 4 5 Connection of Cables 50 60 Hz Input terminals 3 x M10 25mm 30 44 Nm 266 390 lb in L1 L2 L3 1 x M10 bolt 50 Nm 444 lb in Ground PE Fig 4 5 1 Connection of Primary Power Cable OM2252 Rev 0 December 15 2016 ...

Page 23: ...ge 23 of 75 X1 X2 Remote I O terminals Please refer to section 4 9 for connection of I O terminals 400 Hz Output terminals 2 x 3 x M8 A1 B1 C1 A2 B2 C2 1 x M8 N1 N2 25 4 Nm 225in lb Remote I O terminals 2 x 17 x 0 4 4 mm AWG 21 11 Fig 4 5 2 Connection of Output Power Signal Cables OM2252 Rev 0 December 15 2016 ...

Page 24: ...400 A 400 A 100 load PF 1 0 Aircraft Rating 120 kVA 140 kVA 180 kVA Line Current 400V 480V 190 160 A 220 185 A 285 240 A Recommended Fuse Size 250 A 315 A 355 A Maximum Fuse Size 400 A 400 A 400 A Tightening torques Input disconnect 30 Nm to 44 Nm 266 lb in to 390 lb in Output contactor 17 6 Nm 156 lb in Due to the RFI filter at the input the leakage current for the AXA 2400 is 40 mA 4 7 400 Hz Ou...

Page 25: ...y qualified personnel 4 9 Control Interface Remote I O Terminals Using the Remote I O terminals situated behind the front door to the left it is possible to interface to External Emergency Stop EPO The external EPO input A2 X6 is a 24 VDC input either by using the internal 24 VDC supply or an external 24 VDC voltage The SW1 EPO JUMPER right hand side of the A2 Module close to X7 X10 is then remove...

Page 26: ...terlock Present Aircraft Connector inserted signal present GPU Ready Common Error Fig 4 9 1 Example of wiring for external control via the I O terminal From the factory the jumper SW3 is set to position IO which connects the internal minus to the common reference If the 24 is wanted as reference the jumper is moved to IO Note Terminal block X2 is identical to terminal block X1 except for the GPU e...

Page 27: ... 04 0x04 Read Input Registers 06 0x06 Write Single Register 16 0x10 Write Multiple Registers In the following section the different kinds of data available are System in use system in standby and system in fault The GPU provides a comprehensive range of internal and external parameter measurements and information e g voltages currents temperatures time date etc The GPU provides two kinds of logs T...

Page 28: ...Hz 5 Hz Rectification 12 pulse Rating 120 kVA 140 kVA 180 kVA Line Current PF 0 8 150 A 125 A 175 A 150 A 230 A 195 A Line Current PF 1 190 A 160 A 220 A 185 A 285 A 240 A Maximum Fuse size 400 A 400 A 400 A Line Current Distortion 9 7 5 Power Factor nom load 0 99 0 99 1 Inrush current None Interruption ride through 20 ms Output Power 120 140 180 kVA cos ϕ 1 Voltage 3 x 200 115 V Power factor 0 7 ...

Page 29: ...vision Broken Neutral supervision Miscellaneous Physical Dimensions Please refer to the outline drawing on the following pages Weight Fixed 645 kg 1422 pounds Fixed Module 30 kg 66 pounds Bridge Mount 650 kg 1433 pounds Bridge Mount Module 35 kg 77 pounds Mobile Pending Mobile Module Pending Environmental Storage temperature Operating temperature 10 to 35 C 50 F to 95 F 20 to 70 RH 40 C to 56 C 40...

Page 30: ...Operation Manual Hobart 2400 Compact 120 140 180 kVA Technical Specifications Document no 578 430AB Page 30 of 75 Fixed Horizontal Fig 5 0 1 Fixed and Bridge Mounted OM2252 Rev 0 December 15 2016 ...

Page 31: ...Operation Manual Hobart 2400 Compact 120 140 180 kVA Technical Specifications Document no 578 430AB Page 31 of 75 Fig 5 0 2 Fixed and Bridge Mounted with Base Module OM2252 Rev 0 December 15 2016 ...

Page 32: ...32 of 75 6 0 Operator s Instructions Display LED Keypad layout Fig 6 0 1 400 Hz Standard layout Navigation keypad Output 1 Start Stop Reset Output 2 Start Stop Reset Display Mains On Blue LED Warning Yellow LED Alarm Failure Red LED Output 1 On Green LED Output 2 On Green LED OM2252 Rev 0 December 15 2016 ...

Page 33: ...Page 33 of 75 Fig 6 0 2 400 Hz layout with cable system Navigation keypad Output 1 Start Stop Reset Output 2 Start Stop Reset Display Mains On Blue LED Warning Yellow LED Alarm Failure Red LED Output 1 On Green LED Output 2 On Green LED Cable 2 In Out Cable 1 In Out LED OM2252 Rev 0 December 15 2016 ...

Page 34: ...oo High Neutral Conductor Rupture Output 1 Neutral Conductor Rupture Output 2 EF Signal Drop Out Output 1 EF Signal Drop Out Output 2 Aircraft Connector not inserted Output 1 Aircraft Connector not inserted Output 2 The unit will report an error if only one output is active and a failure signal present otherwise it will issue a warning about any of the above issues Fig 6 1 1 Display Operator panel...

Page 35: ... will not function if the plug not is fully inserted Press the corresponding Start Stop button The unit is now in operation and ready to supply the aircraft with power This is also indicated via the green LED located close to the Start Stop button s If the unit shuts off and is no longer supplying power to the aircraft this is reported in clear text in the display Also a corrective action is displ...

Page 36: ... the Start Stop Reset to reset the unit Default Display Screen Operating OUTPUT I U I Phase A 115 0 V 20 A Phase B 115 0 V 20 A Phase C 115 0 V 20 A Average 115 0 V 20 A Back Next Prev POWER P S Phase A 1 kW 1 kVA Phase B 1 kW 1 kVA Phase C 1 kW 1 kVA Sum 3 kW 3 kVA Back Next Prev Use the to browse through the various screens Use to leave the sub menu and return to Default Screen Note Parameters m...

Page 37: ...simply use the navigation keys to highlight the icon and then press the to enter the sub menu To leave the Icon Menu highlight the Home icon and press Icon explanation Back to Default screen Viewing actual converter parameters Set up menu for changing converter parameters Black Box with last 100 failures errors Power Log with last 100 operations Save Black Box Power Log records or update software ...

Page 38: ...t I 0 V 0 V Output II 0 V 0 V Inv I Temp 40 C 40 C Inv II Temp 40 C 40 C Highlight the by using the navigation keys Press to select View parameters sub menu Use the to browse through the various screens Use to leave the sub menu and return to basic Icon Menu Note Parameters may vary depending on the mode of the unit Standby operating load profile etc OUTPUT II U I Phase A 0 0 V 20 A Phase B 0 0 V ...

Page 39: ...ay vary depending on the mode of the unit Standby operating etc SYSTEM Control Voltage 25 2 V NVS Level 2 V ELS Level 3 A Hour Meter 04 49 36 Consumption 438 kWh INPUT Voltage 407 V Current 0 A UNIT INFORMATION Display FW 078105 Control FW 078105 Unit Serial 91794 1 1 Unit Rating 180 kVA MAC C8 02 58 00 00 00 Back Next Prev Input Output Port Status 1 2 3 4 5 6 7 8 I 9 10 11 12 13 14 15 16 N 17 18 ...

Page 40: ... X1 I4 16 Not used X4 I16 4 GPU ready Com Error X1 O4 12 Not used X3 O12 5 Not used X1 I5 17 Not used X4 I17 5 400 Hz 2 On X2 O5 13 Not used X4 O13 6 GPU Enable X1 I6 18 Not used X4 I18 6 Interlock 2 present X2 O6 14 Not used X4 O14 7 Remote EPO X6 I7 19 MCB1 trip X29 I19 7 Aircraft Connector Inserted 2 X2 O7 15 Not used X4 O15 8 Door Interlock X32 I8 20 MCB2 trip X29 I20 8 GPU Ready Com Error X2 ...

Page 41: ...ill now be highlighted in green Use the to adjust parameter Press to save changes Use to leave the sub menu and return to basic Icon Menu Note Availability of parameters may vary depending on the mode of the unit Standby operating load profile etc Settings 80 0 135 0 V Settings Manual Plug Play Settings Disabled Enabled Settings 0 0 5 0 V Settings 0 0 5 0 V Settings Individual Simultaneous 6 3 2 S...

Page 42: ...t to change Press to Modify parameter Parameter will now be highlighted in green Use the to adjust parameter Press to save changes Use to leave the sub menu and return to basic Icon Menu Note Availability of parameters may vary depending on the mode of the unit Standby operating load profile etc 11 27 47 Setup Menu 26 08 2016 EF Interlock Active Back Modify Settings Normal Boost 11 27 47 Setup Men...

Page 43: ...Use to leave the sub menu and return to basic Icon Menu Note Availability of parameters may vary depending on the mode of the unit Standby operating load profile etc Settings Bypassed Active 11 27 47 Setup Menu 26 08 2016 Door Switch Active Back Modify Settings Bypassed Active 11 27 47 Setup Menu 26 08 2016 Cable Temperature Normally Closed Back Modify Settings 0 0 Disabled 0 1 50 0 V 11 27 47 Set...

Page 44: ...ter Press to save changes Use to leave the sub menu and return to basic Icon Menu Note Availability of parameters may vary depending on the mode of the unit Standby operating load profile etc 11 27 47 Setup Menu 26 08 2016 LED Brightness High Back Modify Settings Low Medium High 11 27 47 Setup Menu 26 08 2016 Ethernet Configuration Back Modify Settings in additional sub menu Ethernet Mode IP Addre...

Page 45: ... to Modify parameter Parameter will now be highlighted in green Use the to adjust parameter Note can be used when entering Costumer ID Press to save changes Use to leave the sub menu and return to basic Icon Menu Note Availability of parameters may vary depending on the mode of the unit Standby operating load profile etc 11 27 47 Setup Menu 26 08 2016 Warning Do not confirm unless the Control Boar...

Page 46: ...ave the sub menu Use to leave the sub menu and return to basic Icon Menu Note The Black Box contains 100 recordings When the limit is reached the oldest failure is deleted OUTPUT I VOLT AMP Phase A 94 2 V 525 A Phase B 93 2 V 527 A Phase C 93 2 V 526 A Average 93 3 V 526 A Back Next Prev 6 3 3 Black Box Menu structure OUTPUT II VOLT AMP Phase A 0 0 V 0 A Phase B 0 0 V 0 A Phase C 0 0 V 0 A Average...

Page 47: ...17 Minutes Used 64 kWh Used 74 0 Back Next Prev Graph Total Time 22 0 Minutes 0 60 kW 60 120 kW 37 36 21 120 180 kW 6 180 kW Back Total Time 6 0 Minutes 0 60 kW 61 60 120 kW 30 21 120 180 kW 0 180 kW Back Highlight the by using the navigation keys Press to select Power Log sub menu Use the to highlight the Power Log you want to view Press to select View Log The Power Log parameters are then displa...

Page 48: ...Operation Manual Hobart 2400 Compact 120 140 180 kVA Operator s Instructions Document no 578 430AB Page 48 of 75 OM2252 Rev 0 December 15 2016 ...

Page 49: ...Operation Manual Hobart 2400 Compact 120 140 180 kVA Operator s Instructions Document no 578 430AB Page 49 of 75 OM2252 Rev 0 December 15 2016 ...

Page 50: ...ressing to select Save logs please remember to insert a USB stick into the USB port on the display loacted on back of the front door Press to select function The logs are now saved to the USB stick Saving log is counting from 0 to 100 and Done is displayed when the saving has been completed The logs are saved as one CSV File and can be viewed with the ITW GSE Service Tool Note The USB stick can be...

Page 51: ... shipped built in the America s EF Interlock Bypassed Active if GPU supplied with cables EF Interlock Ripple Level V 20 0 EF Interlock Delay sec 3 5 Aircraft Connector detection Disabled Enabled if supplied with cable 90 Switch split F pin GPU Enable Bypassed Door Switch Bypassed Active with option 578853 Plug Temperature Normally Open Neutral Voltage Supervision V 42 0 Earth Leakage Level A 15 0 ...

Page 52: ...mercial aircraft is 115V 3V This range is even tighter for some aircraft Enter the Setup Menu and then scroll up or down to the Output Voltage submenu Press the center button to enter the submenu and then press the button again to allow the value to be changed Press the up or down arrow buttons to change the selection Press the center button to record the new value Press the LEFT arrow button to e...

Page 53: ... MANUAL 3 Enter the OUTPUT 1 COMPENSATION submenu Press the center button to allow the value to be adjusted 4 Adjust the compensation using the vertical arrow buttons until the voltage at the aircraft connector equals the no load value Press the button to accept this value As the unit is equipped with a second output repeat the above steps for OUTPUT 2 7 5 Output Mode The unit is typically deliver...

Page 54: ...er button to enter the submenu and then press the button again to allow the value to be changed Press the up or down arrow buttons to change the selection Press the center button to record the new value Press the LEFT arrow button to exit the submenu and return to the submenu list 7 8 EF Interlock The EF interlock is a personnel and equipment safety feature that is found in all commercial aircraft...

Page 55: ...nu Press the center button to enter the submenu and then press the button again to allow the value to be changed Press the up or down arrow buttons to change the selection Press the center button to record the new value Press the LEFT arrow button to exit the submenu and return to the submenu list 7 11 Aircraft Connector Insertion Some aircraft power cables are equipped with a micro switch or spli...

Page 56: ...is ground then the unit can monitor the voltage difference between aircraft neutral and ground If the voltage is greater than the set value typically 42 volts an unsafe condition exists and the unit will shut off the output power The default value is 42 volts and the function is disabled if the value is set 0 0 volts and applies for both cables Go into the Setup Menu and then scroll up or down to ...

Page 57: ...displayed on all of the screens and reports can be adjusted using this submenu The selection is a 24 hour clock and DD MM YYYY date format or a 12 hour clock with the MM DD YYYY date format Go into the Setup Menu and then scroll up or down to the Date Time Format submenu Press the center button to enter the submenu and then press the button again to allow the value to be changed Press the up or do...

Page 58: ...to be changed Press the up or down arrow buttons to change the selection Press the center button to record the new value Press the LEFT arrow button to exit the submenu and return to the submenu list 7 24 Costumer ID This submenu allows the user to assign a name to the unit for reporting purposes when Fault or Power Log files are saved to a USB stick or drive Go into the Setup Menu and then scroll...

Page 59: ...glish Go into the Setup Menu and then scroll up or down to the Language submenu Press the center button to enter the submenu and then press the button again to allow the value to be changed Press the up or down arrow buttons to change the selection Press the center button to record the new value Press the LEFT arrow button to exit the submenu and return to the submenu list OM2252 Rev 0 December 15...

Page 60: ...ion Weekly Verify function of the Aircraft Connector Insertion if present Quarterly Check air filters Wash or change as appropriate Quarterly Check that all fans are running properly Yearly Check rubber seals at front door rear door Yearly Check internal bolt screw and wire connections Yearly Visual inspection of PCB s control unit gate drive Yearly Verify proper operation of the output contactors...

Page 61: ...ot exposed to any danger To avoid loss of data and Control Board lock up we recommend changing the battery after 5 years of use To ensure high reliability of the back up battery the only type of battery that can be used on the Control Board is the Panasonic BR 2032 How to change the battery Before removing the Control Board and to avoid any static discharge to the Control Board during the replacem...

Page 62: ...en arrow Mount the control board on the interface board again by gently pressing the PCB to its rest on the Interface Board Make sure that all 4 corners are fully pressed towards the Interface Board Switch on the unit via the input switch Q1 and close the door The unit now passes through the initialization test and goes into standby mode Enter the setup menu and select menu item Battery Replaced t...

Page 63: ...de Fuse 32 V 2 A F3 D8 Display Fuse ATO Blade Fuse 32 V 2 A F4 D2 Interface Fuse ATO Blade Fuse 32 V 5 A F5 D4 Fans 1 Fuse ATO Blade Fuse 32 V 10 A F6 D5 Fans 2 Fuse ATO Blade Fuse 32 V 10 A Fig 9 0 1 Fuses F1 F6 and LED indication A2 Interface Board If the displayed text does not provide sufficient information to solve the problem Table 1 Table 2 and Table 3 section 9 1 suggest corrective actions...

Page 64: ...30ms 1200 DC VOLTAGE TOO HIGH 1201 DC VOLTAGE TOO HIGH DC Voltage 800V 30 s 1202 DC VOLTAGE TOO HIGH DC Voltage 850V 2 5ms 1300 DC CAPACITOR SHARING ERROR DC Voltage 850V 1400 DC RIPPLE TOO HIGH DC Ripple 20V 3 minutes 1450 DC RIPPLE TOO HIGH DC Ripple 10V 5s 1501 INVERTER TEMP TOO HIGH IGBT 1 Temperature 110 C 1502 INVERTER TEMP TOO HIGH IGBT 2 Temperature 110 C 2000 GATE VOLTAGE ERROR 3000 OUTPU...

Page 65: ...lace Control Board A1 Replace Interface Board A2 1501 Check fuse F5 Set fans to Boost and check voltage Between and PWM at fan terminals 10 V Check dust filters Replace Control Board A1 Replace Interface Board A2 1502 Check fuse F5 Set fans to Boost and check voltage Between and PWM at fan terminals 10 V Check dust filters Replace Control Board A1 Replace Interface Board A2 2000 Replace Control Bo...

Page 66: ...put Capacitors 5200 Check set up value Remove load and check output cabling for insulation failure Replace Control Board A1 Replace Interface Board A2 5300 Reset MCB Replace Control Board A1 Replace Interface Board A2 6001 Check set up value Remove load and check output 1 plug cabling Replace Control Board A1 Replace Interface Board A2 6002 Check set up value Remove load and check output 2 plug ca...

Page 67: ... and drawings of the unit at this website Figure 10 0 1 Front View Note In mobile and bridge mounted units the display module and the emergency stop button are situated in a separate box A1 Control Board A2 Interface Board X1 I O Terminals Q4 Output 1 Q5 Output 2 A2 Display A3 Keypad X2 I O Terminals Heater Optional Cable Strain Relief Bar PM2 Inverter Module 2 A5 Capacitor Board located behind pl...

Page 68: ... 578 430AB Page 68 of 75 Figure 10 0 2 Rear View Cable Strain Relief Bar Q1 Input Disconnector G1 24 VDC Supply Q6 Circuit Breaker Heater Optional Q2 MCB Inverter 1 Q3 MCB Inverter 2 PM1 Inverter Module 1 A6 Capacitor Board located behind plate OM2252 Rev 0 December 15 2016 ...

Page 69: ...sformer L1 Input Choke T1 12 Puls Transformer Cable Relief Bar X1 X2 I O Terminals PM2 Inverter Module Q6 Circuit Breaker Q4 Q5 Output Contactors G1 24 VDC Supply Q1 Input Disconnector Q2 Q3 Input MCB C10 C12 Output Capacitors PM1 Inverter Module Air intake T4 400Hz Transformer Cable Relief Bar L2 Input Choke T3 12 Puls Transformer M3 M4 Fans OM2252 Rev 0 December 15 2016 ...

Page 70: ...the following dry contact relays Q9 400 Hz On N O Q10 Bridge Interlock N O Bridge Interlock N C Q11 400 Hz Ready N O Error N C Q11 400 Hz Ready N O Error N C Q12 Not Used N O Not Used N C Note Contacts Vmax 50 V AC DC and Imax 2 A 578850 Base module Drawing 278430 Additional base module which extends the height length of the ground power unit by 340 mm 13 4 and the weight by 30 kg 66 lbs Refer to ...

Page 71: ...actors close simultaneously One push button Start Stop at operator s panel Note If the Single Output option GPU is linked up with Remote Control Box please remember to order option 578806 Remote Control Box single output 578853 Door Interlock Diagram 478850 The door interlock ensures that the ground power unit s output contactors open and the unit immediately returns to standby mode if one of the ...

Page 72: ...ds PCBs Dew formation can however be avoided by installation of heating elements in the GPU During operation the waste heat from the circuits prevents dew from arising In stand by mode where the internal losses are insignificant two 30 W anti condensation heaters automatically switch on and prevent condensation from arising 578855 RS485 Interface Diagram 478850 All units are supplied with connecti...

Page 73: ...ndard wiring diagram for military interlock Note This option requires a 400 Hz cable without the E F jumper in the connector head 578857 Lockable Door Fixed As a standard the GPU is supplied with a quarter turn lock intended for a double bit 5 mm pin key One key is supplied per ground power unit On an optional basis the ground power unit can be supplied with a lockable swing handle at the front an...

Page 74: ... x 400 Hz Outputs 578858 2 x 400 Hz Outputs controls for Retriever Hoist 2 x 400 Hz Outputs Retriever or Hoist 2 x 400 Hz Outputs The control box is used for operation of the ground power unit when the GPU is located away from the aircraft parking position placed under or on the side of a passenger boarding bridge or on a trailer OM2252 Rev 0 December 15 2016 ...

Page 75: ...ded for instance 2 ǁ 7 x 35 mm the terminal extension allows connection of up to 4 x cables per phase The kit consists of 4 x extension bars A1 B1 C1 A2 B2 C2 1 x extension bar N1 N2 Bolts washers spring washer and nuts Note 2 x 578814 are ordered to cover both outputs 591100 Auto Calibration Plug Required for Plug Play set up See section 7 OM2252 Rev 0 December 15 2016 ...

Page 76: ...0 180 kVA 478 105 13 06 16 1 2 Main Circuit and Instrumentation RA A3 RA Scale Rev Page Type Drawn Drg no Approved Revised Title 400 Hz Ground Power Unit 2400 Series 120 180 kVA 478 105 13 06 16 1 2 Main Circuit and Instrumentation RA A3 RA Scale Rev Page Type Drawn Drg no Approved Revised Title 400 Hz Ground Power Unit 2400 Series 120 180 kVA 478 105 13 06 16 1 2 Main Circuit and Instrumentation ...

Page 77: ...oved Revised Title 400 Hz Ground Power Unit 2400 Series 120 180 kVA 478 105 13 06 16 2 2 Main Circuit and Instrumentation RA A3 RA Scale Rev Page Type Drawn Drg no Approved Revised Title 400 Hz Ground Power Unit 2400 Series 120 180 kVA 478 105 13 06 16 2 2 Main Circuit and Instrumentation RA A3 RA PWM 4 Q6 8 8 F 3 12 10 7 2 2 S1 9 6 4 M1 1 2 X6 1 2 X5 DISPLAY BOARD X3 CAN X2 X1 X4 IF USB A3 L2 L3 ...

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