ITW GSE Hobart PoWerMaster 2400 Series Manual Download Page 64

Page: 64 / 91

Operation Manual -

PoWerMaster®

2400 – 30 - 90 kVA

Trouble Shooting & Repair

Document no. 578.650BB

Page 64 of 91

9.1

Fault Guidance

In case you need to contact us for further fault guidance, please do not forget to enter the serial number
of the GPU (found at the rating plate) and the actual error code on the fault finding form that can be
downloaded from

www.itwgse.com

List below shows the complete list of error codes and first corrective action:

Error code

Error text in display

Help text

1st. Corrective action

NO ERRORS

100

LOGGING UNSUCCESSFUL

200

CONTROL BOARD FAILURE

Watchdog Timeout

Press start to reset

201

CONTROL BOARD FAILURE

CRITICAL: Memory Error

202

WRONG SOFTWARE VERSION

Install correct software version

250

UPDATE FAILED

Please retry operation

300

CONTROL VOLTAGE LOW

Control Voltage < 20V (Running)

Press start to reset

301

CONTROL VOLTAGE LOW

Control Voltage < 20V (Standby)

350

F1 OR F2 FUSE BLOWN

Replace fuse F1/F2 and press start
to reset

400

EMERGENCY STOP ACTIVATED

Release emergency stop and
press start to reset

500

CONTROL BOARD ADC0 FAILURE

600

CONTROL BOARD ADC1 FAILURE

700

CONTROL BOARD BATTERY FAILURE

750

REAL-TIME CLOCK NOT SET

Please set to current time and date

800

INPUT VOLTAGE TOO LOW

Voltage < 340V – 500ms

900

INPUT VOLTAGE TOO HIGH

Voltage > 460V – 500ms

1000

SOFTSTART ERROR

DC Voltage < 400V

1100

DC VOLTAGE TOO LOW

DC Voltage < 300V - 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

CPLD Unknown Fault

2000+code

GATE VOLTAGE ERROR

IGBT XY Ready

2000+code

GATE VOLTAGE ERROR

IGBT XY Fault

Press start to reset

3000

OUTPUT VOLTAGE TOO HIGH

Voltage > 130V - 250ms

3100

OUTPUT VOLTAGE TOO HIGH

Voltage > 140V - 15ms

3500

OUTPUT VOLTAGE TOO LOW

Voltage < 104V - 500ms

4000

OVERLOAD: 100% < I < 125% - 600 s

Phase X

4100

OVERLOAD: 125% < I < 150% - 60 s

Phase X

4200

OVERLOAD: 150% < I < 200% - 30 s

Phase X

4300

OVERLOAD: 200% < I < 300% - 10 s

Phase X

4400

OVERLOAD: I > 300% - 1 s

Phase X

4500+code

SHORT CIRCUIT AT OUTPUT

Phase X

4600+code

FILTER CURRENT TOO LOW

Phase X

4700+code

FILTER CURRENT TOO HIGH

Phase X

4800

INVERTER SOFTSTART FAILURE

5000

TRANSFORMER TEMP TOO HIGH

5100

EARTH LEAKAGE FAULT AT OUTPUT

5101

EARTH LEAKAGE FAULT AT OUTPUT

5200

NEUTRAL VOLTAGE FAULT AT OUTPUT

Table continues on next page

Summary of Contents for Hobart PoWerMaster 2400 Series

Page 1: ...lmetto FL 34221 U S A T toll free in US 800 899 1841 T International 1 941 721 1000 E technicalsupport itwgse us Manual Hobart PoWerMaster 2400 400 Hz Ground Power Unit With 28 VDC outlet optional Serial no Type SX240 it s all about connections ...

Page 2: ...ge without prior notice Latest diagram versions can be found at www itwgse com Printed March 2017 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 Refer to section 8 2 for further information ...

Page 3: ...400 Hz Interlock 23 4 9 Control Interface Remote I O Terminals 23 4 10 TCP IP On board Interface 25 5 0 Technical Specifications 26 6 0 Operator s Instructions Display LED Keypad layout 31 6 1 Using the Display Keypad 32 6 2 Operating the unit 33 6 3 Basic Menu 35 6 3 1 Parameters Menu structure 36 6 3 2 Setup Menu structure 40 6 3 3 Black Box Menu structure 45 6 3 4 Power Log Menu structure 46 6 ...

Page 4: ...7 7 19 Date Time Format 57 7 20 Ethernet Configuration 58 7 21 Modbus Slave Address 58 7 22 LED Brightness 58 7 23 Unit of Measure 58 7 24 Costumer ID 59 7 25 Battery Replaced 59 7 26 Language 59 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 68 11 0 Opti...

Page 5: ...7 Military Interlock Diagram 478801 76 578829 Anti Condensation Heater Diagram 478801 77 591100 Auto Calibration Plug 77 12 0 For GPUs with 28 VDC Active Rectifier Unit 78 12 1 General Description 78 12 2 Connection of Cables 80 12 3 Interlock 81 12 4 Operator s Instruction 82 12 5 Operating the unit 82 12 6 Additional menu items for ARU 85 12 7 ARU Default Factory Settings 86 12 8 28V Voltage 86 ...

Page 6: ...Operation Manual PoWerMaster 2400 30 90 kVA Declaration of Conformity Document no 578 650BB Page 6 of 91 1 0 Declaration of Conformity ...

Page 7: ...health and 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 air...

Page 8: ...z mains voltage is converted into a galvanic isolated 3 phase 400 Hz output voltage A functional description of each part is given in the following sections 3 1 Basic Principle Input Disconnector Q1 The Input Disconnect circuit breaker disconnects all power to the ground power unit Upon closing the switch disconnect circuit breaker the ground power unit passes through an initialization test and th...

Page 9: ...e Board Input Choke 12 pulse Transformer L1 T1 The combination of the choke the 12 pulse transformer 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 90 kVA kW and a unity power factor This means less stress on the main supply network and the distribution transformers ...

Page 10: ...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 contactor also disengages Interface Board A2 The purpose of this board is to interface between the Control Board and the rest of the ground power unit The interface module includes the following functions Int...

Page 11: ...and pre fused from the 3 phase circuit breaker Q4 Control Board A1 The Control Board is based on a micro controller and a digital signal processor DSP Together they regulate supervise and diagnose possible external and internal faults As soon as the ground power unit is connected to the mains and constantly during normal operation the Control Board runs through a self check program which checks al...

Page 12: ...ller Area Network and can be placed up to 100 m away from the unit when using the Remote Control Box Furthermore the display module includes a USB connection which can be used to download the Black Box log and the Power Log files and for update of the display software ID Chip A6 The ID Chip is connected to Interface Board A2 and is fixed to the I O zone plate It contains information on the GPU con...

Page 13: ...ngs 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 unit has a built in system to protect itself the output cables if the units output s are short circuited for some reason Internal high temperature If for some reason the internal temperature on the Inverter Module or ...

Page 14: ...lock signal To change of setting please refer to Section 6 3 7 9 Earth Leakage Supervision ELS In systems where the 400 Hz neutral is grounded and there is a break of the cable s 400 Hz neutral the ELS system monitors the residual current in the internal neutral earth connection The supervision will shut down the unit in case the residual current reaches the pre set level For change of setting ple...

Page 15: ... 0 4 2 Operational and Environmental 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...

Page 16: ...nting position while it is still placed and firmly fixed to on 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 Hobart PoWerM...

Page 17: ...nual PoWerMaster 2400 30 90 kVA Transport and Installation Document no 578 650BB Page 17 of 91 4 4 Installation and fastening instructions Fig 4 4 1 Foot Print Spacing Fixed Unit Fig 4 4 2 Mounting Holes Fixed Unit ...

Page 18: ...age 18 of 91 Fig 4 4 3 Mounting Holes Spacing Bridge Mounted Unit Fig 4 4 4 Removable gland plate Made of Aluminium Zinc alloy coated sheet steel to prevent corrosion at the cable gland holes Gland plate is situated inside the cubicle and only one is supplied if the unit is with Base Module ARU ...

Page 19: ...Operation Manual PoWerMaster 2400 30 90 kVA Transport and Installation Document no 578 650BB Page 19 of 91 Center of Gravity Fig 4 4 5 Center of Gravity Fixed units ...

Page 20: ...Operation Manual PoWerMaster 2400 30 90 kVA Transport and Installation Document no 578 650BB Page 20 of 91 Fig 4 4 6 Center of Gravity Horizontal units ...

Page 21: ...bles Standard Remote I O terminals refer to section 4 9 for connection of I O terminals 50 60 Hz Input terminals 3 x 20 by 1 M8 25mm 225in lb 25 4 Nm L1 L2 L3 1 x M10 bolt 444 in lb 50 Nm Ground PE 400 Hz Output terminals 4 x M8 A B C N 225in lb 25 4 Nm Remote I O terminals 17 x 0 4 4 mm AWG 21 11 Fig 4 5 1 Connection of Cables ...

Page 22: ... factory for recommendations on different lengths 100 load PF 1 0 Aircraft Rating 30 kW 45 kW 60 kW 90 kW Line Current 400V 480V 49 41 A 70 59 A 96 80 A 140 117 A Recommended Fuse Size 63 A 100 A 125 A 160 A Maximum Fuse Size 160 A 160 A 200 A 200 A Minimum Input Wire size 6 16 mm 4 25 mm 2 35 mm 1 50 mm Minimum Output Wire size 6 16 mm 4 25 mm 2 35 mm 2 0 70 mm Based on single wire at 30 feet con...

Page 23: ...k safety system must always be activated unless the ground power unit is undergoing service maintenance or test by 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 X14 is a 24 VDC input either by using the internal 24 VDC suppl...

Page 24: ...ut can either be supplied from the Hobart PoWerMaster 2400 as shown below or supplied from an external supply as the input Terminals X1 6 7 are insulated Acceptable input range 24 Volt 20 Indications Lamps for GPU On Interlock 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 S...

Page 25: ...Read Holding Registers 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 provid...

Page 26: ...eries characteristics of aircraft electrical supplies EMC Safety standards Please refer to the declaration of conformity chapter 1 Solid State Ground Power Unit Input Model Amps 0 8 Amps 1 0 Hertz Voltage Max Fuse Line Current Dist PF at nominal load 30SX240 38 A 49 A 45 65 400 15 32 A 41 A 45 65 480 10 160 A 12 0 97 26 A 33 A 45 65 600 15 45SX240 58 A 70 A 45 65 400 15 48 A 59 A 45 65 480 10 160 ...

Page 27: ...factor 1 414 3 Voltage modulation 1 0 Phase angle symmetry 120 1 for balanced load 120 2 for 30 unbalanced load Frequency 400 Hz 0 001 Overload 100 continuous 125 for 10 minutes 150 for 60 seconds 200 for 30 seconds 300 for 10 seconds 400 for 1 second Efficiency Overall efficiency 0 94 at 35 90 kVA load PF 0 8 0 90 at 25 kVA load PF 0 8 Stand by losses 65 W No load losses 2 2 kW Protections Input ...

Page 28: ...bs 310 kg Mobile 1014 lbs 460 kg ARU 220 lbs 100kg Environmental Storage temperature Operating temperature 50 F to 95 F 10 to 35 C 20 to 70 RH 40 F to 132 F 40 C to 56 C 40 F to 113 F 40 C to 45 C with ARU Relative humidity 10 100 non condensing Noise level 65 dB A 1m Ingress protection IP54 NEMA 3R Overall unit IP55 NEMA 4 Electronic section Miscellaneous Color RAL 7035 standard other colors on r...

Page 29: ...Operation Manual PoWerMaster 2400 30 90 kVA Technical Specifications Document no 578 650BB Page 29 of 91 Fixed Horizontal Mobile Fig 5 0 1 Fixed Bridge Mounted and Mobile Unit ...

Page 30: ...Operation Manual PoWerMaster 2400 30 90 kVA Technical Specifications Document no 578 650BB Page 30 of 91 Fig 5 0 2 Fixed Bridge Mounted and Mobile Unit with base Module ARU ...

Page 31: ...uble Output 400 Hz 28 VDC Output 400 Hz with Cable Retriever Hoist Navigation keypad Output 1 Start Stop Reset Output 2 Start Stop Reset 28 VDC Output Start Stop Reset 400Hz Output Start Stop Reset Cable Retriever Hoist Cable IN OUT Display Display Navigation keypad Mains On Blue LED Warning Yellow LED Alarm Failure Red LED Output 1 On Green LED Output 2 On Green LED 28 VDC On Green LED ...

Page 32: ...re Too 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 p...

Page 33: ...f the plug not is fully inserted Press the 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 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 displayed From the default display screen...

Page 34: ... off before removing the aircraft plug Press the Start stop button The aircraft cable can now be removed from the aircraft and placed at the cable rest position Note Please notice that the Start Stop button also functions as a Reset push button If for some reason the unit stops due to an error failure press the Start Stop Reset to reset the unit ...

Page 35: ...h the available sub menus To enter the Icon Menu press the from the default menu and hold it down for approximately 10 seconds To Select a sub menu 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 ...

Page 36: ...Operation Manual PoWerMaster 2400 30 90 kVA Operator s Instructions Document no 578 650BB Page 36 of 91 6 3 1 Parameters Menu structure ...

Page 37: ...tion 1 X1 I3 12 Cable Temp 2 X2 I12 3 Aircraft Connector Inserted 1 X1 O3 11 GPU Ready Com Error X3 O11 4 Cable Temp 1 X1 I4 13 NCR 2 X21 I13 4 GPU ready Com Error X1 O4 12 Not used X3 O12 5 NCR 1 X21 I5 14 Not used X2 I14 5 400 Hz 2 On X2 O5 13 Not used X4 O13 6 GPU Enable X1 I6 15 Not used X4 I15 6 Interlock 2 present X2 O6 14 Not used X4 O14 7 Remote EPO X14 I7 16 Not used X4 I16 7 Aircraft Con...

Page 38: ...R supply voltage present X4 O15 8 17 ACR supply voltage X4 I17 8 16 ACR OK ACR error X4 O16 9 18 ACR error X4 I18 Note please refer to schematic for further information Hoist configuration Inputs Outputs No Function Ref No Function Ref No Function Ref No Function Ref 1 10 1 9 2 11 2 10 3 12 3 11 4 13 4 12 Not used X3 O12 5 14 Not used X2 I14 5 13 400Hz Output On X4 O13 6 15 Not used X4 I15 6 14 Ai...

Page 39: ...nction Ref No Function Ref No Function Ref 1 10 1 9 2 11 2 10 3 12 3 11 4 13 4 12 Not used X3 O12 5 14 Not used X2 I14 5 13 Not used X4 O13 6 15 Pit open Output 1 X4 I15 6 14 Not used X4 O14 7 16 Pit open Output 2 X4 I16 7 15 Not used X4 O15 8 17 Not used X4 I17 8 16 Not used X4 O16 9 18 Not used X4 I18 Note please refer to schematic for further information ...

Page 40: ...meter 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 Settings 80 0 135 0 V Phase Neutral Note Values above 125 cannot be stored Settings Manual Plug Play Settings Disabled Enabled Settings...

Page 41: ...ange 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 01 01 2017 EF Interlock Active Back Modify Settings Normal Boost 11 27 47 Setup Menu 01 01...

Page 42: ...ve 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 Bypassed Active 11 27 47 Setup Menu 01 01 2017 Door Switch Active Back Modify Settings Bypassed Active 11 27 47 Setup Menu 01 01 2017 Plug Temperature Normally Closed Back Modify Settings 0 0 Disabled 0 1 50 0 V 11...

Page 43: ...ust 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 01 01 2017 LED Brightness High Back Modify Settings Low Medium High 11 27 47 Setup Menu 01 01 2017 Ethernet Configuration Back Modify Settings in additional sub menu Ethernet Mod...

Page 44: ... 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 01 01 2017 Warning Do not confirm unless the Control Board battery has been changed Confirm Battery Replaced Yes Back Modify Settings Yes No 11 27 47 Setup Menu...

Page 45: ...Operation Manual PoWerMaster 2400 30 90 kVA Operator s Instructions Document no 578 650BB Page 45 of 91 6 3 3 Black Box Menu structure ...

Page 46: ...Log 100 100 Start Date 24 12 2016 Start Time 22 17 Minutes Used 64 kWh Used 74 0 Back Next Prev Graph Total Time 22 0 Minutes 0 30 kW 30 60 kW 37 36 21 60 90 kW 6 90 kW Back Total Time 6 0 Minutes 0 30 kW 61 30 60 kW 30 21 60 90 kW 0 90 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 ...

Page 47: ...ise use the to highlight the function Update Display Software Press to select function and update firmware The firmware is now being uploaded to the display card Upload is counting from 0 to 100 and Update Complete Please Reset is displayed when the update has been completed To Reset the unit press button 10 30 00 USB MENU 01 01 2017 Update in Progress Please Wait Swapping Flash Blocks 0 10 30 00 ...

Page 48: ...Operation Manual PoWerMaster 2400 30 90 kVA Operator s Instructions Document no 578 650BB Page 48 of 91 ...

Page 49: ...Operation Manual PoWerMaster 2400 30 90 kVA Operator s Instructions Document no 578 650BB Page 49 of 91 ...

Page 50: ...tandard Software or vice versa you will be prompted Incompatible Software Version Before changing software versions consult ITW GSE or if your intension really is to continue as you already contacted received the software files from ITW GSE use below guidance to update software 1 Press simultaneous for 5 seconds software will start automatically and will be updated 2 Repeat step number 1 for updat...

Page 51: ...pen EF Interlock Bypassed Active if GPU supplied with cable 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 578809 Cable Temperature Normally Open Neutral Voltage Supervision V 42 0 Earth Leakage Level A 15 0 Earth Leakage Delay ms 1000 ...

Page 52: ...oltage range for all commercial 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 th...

Page 53: ...e used at the same time 1 Apply full load to output 1 2 Enter the Compensation Type submenu and select 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 If the unit is equipped ...

Page 54: ...l 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 7 7 Remote Stop In the United States the Remote Stop push button contacts must be Normally Clo...

Page 55: ...the new value Press the LEFT arrow button to exit the submenu and return to the submenu list 7 10 EF Interlock Delay Some of the newer aircraft take a longer time between when 400 Hz power is supplied to the aircraft and when the aircraft returns the 28 VDC EF Interlock signal This setting allows the adjustment of the amount of time the unit will wait until determining that the EF signal is not pr...

Page 56: ...Press the LEFT arrow button to exit the submenu and return to the submenu list 7 14 Plug Temperature Some aircraft cables have temperature sensors installed in the connector This sub menu allows the unit to accept Normally Opened or Normally Closed temperature sensor switches to be used Go into the Setup Menu and then scroll up or down to the Plug Temperature submenu Press the center button to ent...

Page 57: ...he 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 18 Real Time Clock Setup This set of sub menu s allows the user to adjust the internal clock to the correct l...

Page 58: ... 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 22 LED Brightness The unit status LED s have three brightness levels The default is set to medium Go into the Setup Menu and the...

Page 59: ...o the Battery Replacement 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 7 26 Language This submenu is used to change the language that all of ...

Page 60: ... Weekly Verify function of the 90 Switch if present Quarterly Check air filters Wash or change as appropriate Quarterly Check that all fans are running properly Yearly use Boost mode in Fan Control setup submenu Check rubber seals at front door rear panel Yearly Check internal bolt screw and wire connections Yearly Visual inspection of PCB s control unit gate drive Yearly Verify proper operation o...

Page 61: ...not exposed to any danger However 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...

Page 62: ...f the singe green arrow on Figure 8 2 2 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 sele...

Page 63: ...2 V 2 A F2 D24 I O Fuse ATO Blade 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 Fan Fuse ATO Blade Fuse 32 V 10 A Fig 9 0 1 Fuses F1 F5 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 to be carried ...

Page 64: ...et to current time and date 800 INPUT VOLTAGE TOO LOW Voltage 340V 500ms 900 INPUT VOLTAGE TOO HIGH Voltage 460V 500ms 1000 SOFTSTART ERROR DC Voltage 400V 1100 DC VOLTAGE TOO LOW DC Voltage 300V 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...

Page 65: ... COMPLETED OUTPUT X List below shows the complete list of error codes and next corrective actions Error code 2nd Corrective action 3rd Corrective action 4th Corrective action 0 100 200 Replace Control Board A1 201 Verify ID Chip inserted Contact ITW GSE 202 250 300 301 Check input voltage Check Q4 G1 350 Check wires attached to X1 X2 X3 400 Check emergency stop Check user EPO A2 X14 Replace Contro...

Page 66: ...ol Board A1 Replace Interface Board A2 4800 Check DC voltage Check output voltage feedback voltage Replace Control Board A1 Replace Interface Board A2 Replace Inverter Module 5000 Let the unit cool down and press start to reset Check dust filters and fans Check short circuit sensor replace sensor TH if necessary Replace Control Board A1 Replace Interface Board A2 5100 Check set up value Remove loa...

Page 67: ...A1 Replace Interface Board A2 7500 Let the unit cool down and reset Check airflow air filters fan Check temp sensor at rectifier heat sink 8000 Check ACR Supply Q6 8001 Reset ACR Check ACR VFD 8100 Check Cable Coil VFD Motor Replace Control Board A1 Replace Interface Board A2 8200 Check Cable Coil VFD Motor Replace Control Board A1 Replace Interface Board A2 8300 Check Cable Handling System Replac...

Page 68: ...Please contact technicalsupport itwgse us for recommended list of spare parts diagrams and drawings Figure 10 0 1 Front View Inverter Module A1 Control Board A2 Interface Board Cable Strain Relief Bar Q1 Input Disconnector Q4 Circuit Breaker G1 24 VDC Supply X1 I O Terminals Q2 Output 1 Q3 Output 2 optional X2 I O Terminals Option ...

Page 69: ...Manual PoWerMaster 2400 30 90 kVA Illustrated Parts List Document no 578 650BB Page 69 of 91 Figure 10 0 2 Rear View C7 C9 Output Capacitors L1 Input Choke T1 12 Pulse Transformer T2 400Hz Transformer M1 M2 Fans ...

Page 70: ...emergency stop button are situated in a separate box See Section 11 0 Options item 578xxx Remote Control Boxes M1 M2 Fans C7 C9 Output Capacitors T2 400Hz Transformer T1 12 Puls Transformer L1 Input Choke Cable Strain Relief Bar X1 I O Terminals Inverter Module Q4 Circuit Breaker A5 Capacitor Board Q2 Output Contactor G1 24 VDC Supply Q1 Input Disconnector Air intake grills X2 I O Terminals Option...

Page 71: ...awings section 5 578804 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 door The handle is locked by a profile square 6 mm cylinder according to DIN 18252 18254 depth 40 mm Each ground po...

Page 72: ...00 Hz Output 578819 1 x 400 Hz 1 x 28 VDC Output 578820 1 x 400 Hz Output controls for Retriever Hoist 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 Above picture shows the configuration with 2 x 400Hz output ...

Page 73: ...I O terminal block X2 Please refer to section 7 0 for Output Mode Compensation possibilities 578808 Dry Contacts Diagram 478801 If dry contacts are needed for additional indication to the PBB or to a BMS system this option offers 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...

Page 74: ... neutral will be detected immediately Principle wiring diagram for Neutral Conductor Rupture Supervision Unbalanced voltage at the aircraft connector due to a broken neutral would add a 400 Hz voltage to the 28 VDC interlock voltage measured at the ground power unit If the injected AC voltage exceeds approx 10 VAC the output is disconnected This type of error is recognised as an interlock failure ...

Page 75: ...d adequate to safeguard against hazards related to a broken neutral 578814 Terminal Extension If more than 2 x cables per output phase are needed 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 Bolts washers spring washer and nuts 578815 RS485 Interface Diagram 478801 All units are supplied with connections fo...

Page 76: ...k system must be switched from civilian interlock to military interlock by means of selector switch S30 behind the front door The GPU thereafter delivers 28 VDC on the E pin and this voltage is returned to the F pin by the aircraft Standard wiring diagram for military interlock Note This option requires a 400 Hz cable without the E F jumper in the connector head ...

Page 77: ...nents such as relays switchgears and printed circuit boards 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 one 30 W anti condensation heater automatically switches on and prevents condensation from arising Schematic for H...

Page 78: ... 400 Hz power rating of the unit 12 1 General Description 12 1 1 Principle of 28 VDC ARU The 28 VDC part is basically an Active Rectifier Unit and supplied from the 400 Hz part where the 28 VDC output voltage is controlled regardless of the varying 400 Hz input voltage The DC output current is calculated very precisely on the basis of the 400 Hz parameters and via the current transformer T20 locat...

Page 79: ... 28 VDC by using thyristors regardless of the input voltage level and the load ARU Board A20 The ARU Board interfaces with the processor board and the rest of the 28 VDC unit Supplied from G20 X2 Connection to ARU control input on A2 X1 Control of thyristors Measures the output voltage Interface for heatsink thermostat X5 Input for current transformer T20 X6 Resistor R20 The discharge resistor R20...

Page 80: ... O terminals refer to section 4 9 for connection of I O terminals 28 VDC Output terminals 2 x 4 x ø11 3 8 bolt M10 bolt 444 in lb 50 Nm Remote I O terminals 15 x 0 4 4 mm AWG21 11 Fig 12 2 1 Connection of Cables Note Recommended output cable dimension to the aircraft is 2 x 4 0 95 mm for continuously loads up to 400 amps and 4 x 4 0 95 mm for higher continuous loads ...

Page 81: ...andard wiring diagram For service maintenance and test purposes the interlock system can be by passed via the display setup To ensure personnel health and safety the converter automatically returns into normal mode once it receives a 28 VDC voltage at terminal F2 e g when the plug is connected to an aircraft The 28 VDC output can be operated remotely via the I O terminals related to Output 2 Pleas...

Page 82: ...elected increment step To ensure hassle free starting of the aircraft engine the current limit function is delayed 0 7 seconds Insert the aircraft cable into the aircraft Make sure the cable is inserted till you feel a natural resistance The plug may be equipped with a 90 switch split F pin In this case the unit will not function if the plug is not fully inserted Press the 28 VDC Start Stop button...

Page 83: ...Operation Manual PoWerMaster 2400 30 90 kVA For GPUs with 28 VDC Active Rectifier Unit Document no 578 650BB Page 83 of 91 ...

Page 84: ...d from the aircraft and placed at the cable rest position Note Please note that the 28 VDC Start Stop button also functions as a Reset push button If for some reason the unit stops due to an error failure press the Start Stop Reset to reset the unit once the fault number and message have been recorded and reported to maintenance Note that this will remove the fault message from the screen if it is...

Page 85: ...7 47 Setup Menu 01 01 2017 28 V Voltage 28 V Compensation Current Limit Step Size Language Back Select Parameter 11 27 47 Setup Menu 01 01 2017 28 V Voltage 28 0 V Back Modify Settings 19 0 33 0 V Settings 0 0 3 0 V Settings 50 100 200 300 A Setup ARU additional parameters 11 27 47 Setup Menu 01 01 2017 28 V Compensation 0 0V 600A Back Modify 11 27 47 Setup Menu 01 01 2017 Current Limit Step Size ...

Page 86: ...d as the load increases The allowed setting is between 0 0 and 3 0 VDC at the rated continuous load of the unit Note that the maximum output voltage of the unit is 33 VDC Enter the Setup Menu and then scroll up or down to the 28V Compensation 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 c...

Page 87: ...in the overload range 400 2400 A Setup Output voltage 19 33 V Voltage compensation 0 3 V per 600 A Current limit 200 1600 A in steps of 50 100 200 300 A 400 A version 300 2400 A in steps of 50 100 200 300 A 600 A version Steps depending on chosen value in the set up menu Protections Rectifier temperature to high Short circuit at output Over and under voltage at output in case U 20 VDC for more tha...

Page 88: ...er to section 9 1 for Fault Guidance Additional 28 VDC ARU related failures 6102 Cable 2 temperature too high 6302 EF signal drop out Output 2 6402 90 signal drop out Output 2 7000 Output voltage too high 32 V 4 sec 7100 Output voltage too high 40 V 150 ms 7200 Output voltage too low 20 V 4 sec 7300 Short circuit at 28 V output 7500 28 V rectifier temp too high ...

Page 89: ...PUs with 28 VDC Active Rectifier Unit Document no 578 650BB Page 89 of 91 15 0 ARU illustrated parts list Figure 15 0 1 Front View complete unit Q3 Output 2 X1 I O Terminals 400 Hz X2 I O Terminals 28 VDC G20 24 VDC Supply ARU Module Output Terminals ...

Page 90: ...A For GPUs with 28 VDC Active Rectifier Unit Document no 578 650BB Page 90 of 91 Figure 15 0 2 Front View ARU Figure 15 0 3 Rear View ARU A20 ARU Board 6 x ARU Transformer Air intake Grill PM20 Rectifier Module Air intake Grill Output terminals ...

Page 91: ... kVA For GPUs with 28 VDC Active Rectifier Unit Document no 578 650BB Page 91 of 91 Figure 15 0 4 Top View ARU 6 x ARU Transformer ARU Module Output terminals R20 Discharge Resistor C20 Output Capacitors M20 Fan T20 Current Sensor Heat Sink ...

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ITW GSE Hobart PoWerMaster 2400 Series, Manual

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