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ACE4400 60 – 90 kVA Tier 4 Type: OM2247 AXA Power, Hobart, Houchin, Military and J&B has become ITW GSE. As simply ITW GSE, we still offer the same premium products and service. SAME PEOPLE - SAME PRODUCTS - SAME COMPANY...
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Operation Manual - ITW GSE 4400 Tier 4 IMPORTANT NOTICE We recommend that the battery that safeguards GPU settings etc. is changed after 5 years of use in order not to lose data. Diagrams and drawings are subject to change without prior notice.
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This manual, including all information contained therein, is exclusive and confidential property of ITW GSE. This manual is not to be copied, reproduced, or delivered or disclosed to others, in whole or in part, except with express written permission of ITW GSE.
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Operation Manual – ITW GSE 4400 Tier 4 Safety Warnings and Cautions. WARNING ELECTRIC SHOCK can KILL. Do not touch live electrical parts. ELECTRIC ARC FLASH can injure eyes, burn skin, cause equipment damage, and ignite combustible material. DO NOT use power cables to break load. Prevent tools from causing short circuits.
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Operation Manual – ITW GSE 4400 Tier 4 3) Service and Maintenance This equipment must be maintained in good electrical condition to avoid hazards stemming from disrepair. Report any equipment defect or safety hazard to the supervisor and discontinue use of the equipment until its safety has been assured.
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Operation Manual – ITW GSE 4400 Tier 4 7) Medical and First Aid Treatment. First aid facilities and a qualified first aid person should be available for each shift for immediate treatment of all injury victims. Electric shock victims should be checked by a physician and taken to a hospital immediately if any abnormal signs are observed.
Description 1) General The basic generator sets covered in this manual, manufactured by ITW GSE, are rated at 60kVA and 90kVA and are designed to produce and deliver 115/200-volt, 400 Hz, 3-phase AC power to a parked aircraft or other load. Some generator models with the Active Rectified Unit (ARU) option also provide 28.5 volts DC for aircraft having those requirements.
Operation Manual - ITW GSE 4400 Tier 4 3) Component Locations For purpose of orientation when designating RIGHT and LEFT throughout this manual, the radiator is considered to be at the FRONT of the unit and the generator is at the REAR. RIGHT and LEFT are determined by standing at the REAR facing the machine.
Operation Manual - ITW GSE 4400 Tier 4 4) Specifications a) Standards These units have been designed to be in compliance with the following standards: US EPA Tier 4/CARB Tier 4 EU Stage IV US MIL-STD-704F, SAE ARP5015 b) Physical Specifications Length 112.1 in.
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Operation Manual - ITW GSE 4400 Tier 4 d) AC Protective System Specifications Condition Trip Point Time Delay Over Voltage 130 volts 250 milliseconds 140 volts 15 milliseconds Under Voltage Any voltage below 104 volts 500 milliseconds Over Frequency 380 Hz to 420 Hz...
Operation Manual - ITW GSE 4400 Tier 4 g) Engine Specifications Manufacturer and Model Cummins Engine Company / QSB4.5 Type 4 cylinder, 4 cycle diesel, electronic controlled Bore and Stroke 4.21 in. x 4.88 in. (107 mm x 124 mm)
Operation Manual - ITW GSE 4400 Tier 4 e) Exhaust System The generator set is equipped with an Airless Selective Catalytic Reduction (SCR) system. The SCR system is used to decrease the mono-nitrogen oxides (NOx) emissions from the engines exhaust pipe. The system is composed of several main components: 1.
Operation Manual - ITW GSE 4400 Tier 4 7) Engine and Generator The engine and generator comprise the principal components of the generator set. They are mounted on a galvanized, welded steel frame chassis. The following figures show the locations of all major components and sub-assemblies.
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Operation Manual - ITW GSE 4400 Tier 4 c) Factory Installed Components and Protective Systems This generator set is assembled with the following components and protective systems: 1) Shutdown/Reset Systems Emergency Shutdown The emergency shutdown switch is to provide instant manual shut off of the generator set by disconnecting power to the ECM through the control box.
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Operation Manual - ITW GSE 4400 Tier 4 d) Warnings/Faults The control system reacts appropriately to different detected issues. These types can be generalized between warnings and faults. Warnings are given when the system is able to function but requires servicing/user interaction.
Operation Manual - ITW GSE 4400 Tier 4 8) Power Module Assembly The Power Module Assembly is mounted on the ARU table located to the rear of the machine over the generator. The panel assembly provides a means of connecting and disconnecting the generator output to and from the aircraft.
Operation Manual - ITW GSE 4400 Tier 4 9) Operator Controls The control box is a protected enclosure on the right front panel of the GPU with a modern graphical display and easy to understand controls. The display allows the user to easily have access to all critical operational information as well as providing textual descriptions of all warnings and failures.
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Operation Manual - ITW GSE 4400 Tier 4 b) Operator Controls – Operator Panel 1. LED Graphical Display 5. Alert/Failure "Red" LED 2. Navigation Keypad 6. Output ON "Green" LEDs 3. Power ON "Blue" LED 7. Output ON/OFF (Reset) 4. Warning "Amber" LED 8.
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Operation Manual - ITW GSE 4400 Tier 4 NOTE! – The screens shown in this manual reflect the current software version at the time of publication. The screens on your unit might differ slightly based on the software version running on your unit. Any changes will be described in a Service Bulletin which should be placed in the back of this manual.
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Operation Manual - ITW GSE 4400 Tier 4 OM2247 Rev B Page 26 of 125...
Operation Manual - ITW GSE 4400 Tier 4 10) Cold Weather Starting System (BH1) The intake air heater, located on the intake manifold, is used for starting the engine at very cold temperatures and reduces the white smoke associated with a cold start. The intake air heater (or grid heater) is energized or de-energized from a power relay controlled by the ECM.
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Operation Manual ITW GSE 4400 Tier 4 Section 2 Preparation for Use, Storage, or Shipping 1) Preparation for use after receipt of unit a) Inspection/Check Inspect unit thoroughly prior to operation. 1) Remove blocking, banding, ties, and other securing material.
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Operation Manual ITW GSE 4400 Tier 4 10) Check engine lubricating oil level. The oil gauge rod has “H” high-level and “L” low-level marks to indicate operating lubrication oil supply. Oil level should be kept as near the high mark as possible, without going over. See Figure 1-2-1 for capacity.
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Operation Manual ITW GSE 4400 Tier 4 b) Installing Three-Phase AC Output Cables Figure 1-2-3 Figure 1-2-4 Figure 1-2-5 The generator set may be shipped without aircraft cables. Output cables connect to the load contactors, which are located at rear of unit. (See Figure 1-2-3) The conductor size recommended for AC output cables is 2/0 AWG.
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Operation Manual ITW GSE 4400 Tier 4 c) Installing DC Output Cable (optional) 1) Remove canopy. (While not necessary, it greatly simplifies the process.) 2) For normal aircraft service, use cable assembly JB2840-30 (which meets Mil-C-7974D Assembly Specification) with 30 feet of AWG 4/0 cables having a positive and negative connection.
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Operation Manual ITW GSE 4400 Tier 4 b) Temporary Storage (30 days or less) 1) Lubricate unit completely in accordance with instructions in Chapter 2-2. This will include changing engine oil, and all filter elements. 2) Start engine and operate a minimum of two minutes so all internal engine components are coated with new oil.
Operation Manual – ITW GSE 4400 Tier 4 Section 3 Operation 1) General This section contains information and instructions for safe and efficient operation of the equipment. Operating instructions are presented in systematic sequence of procedures to be followed in supplying 400-Hz or 28.5 VDC power.
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Operation Manual – ITW GSE 4400 Tier 4 1. LED Graphical Display 5. Alert/Failure "Red" LED 2. Navigation Keypad 6. Output ON "Green" LEDs 3. Power ON "Blue" LED 7. Output ON/OFF (Reset) * 4. Warning "Amber" LED 8. Power ON & Engine Start/Stop (Reset) * * All output and engine buttons are multitasking buttons dependent on the status of the unit.
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Operation Manual – ITW GSE 4400 Tier 4 d) Power Delivery After the engine has started and the display has changed to the output status default screen, any output ON/OFF buttons can be pressed. If the unit is already at rated speed, the contactor will immediately close.
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Operation Manual – ITW GSE 4400 Tier 4 Discontinue Power Delivery with Unit Shutdown 1) Normal conditions Push the Output ON/OFF pushbutton next to the lit green LED indicator to open the output load contactor. The indicator light next to the button will go OFF, indicating the load contactor has opened and power is no longer being delivered to the aircraft.
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Operation Manual – ITW GSE 4400 Tier 4 Battery Disconnect Switch If the unit is not going to be used for a long period of time, open the battery disconnect switch to remove 24 VDC power to the control board and Cummins ECM controller. DO NOT open the battery disconnect switch while the engine is running or within two minutes after the engine has shut down.
Operation Manual – ITW GSE 4400 Tier 4 4) Icon Menu The Icon Menu is accessed from the default screen. Press the center navigation button ● while in the default menu and hold it down for approximately 5 seconds. (If the Icon menu doesn’t appear after 5 seconds, see paragraph 4.23 below to unlock access to the Icon menu.)
Operation Manual – ITW GSE 4400 Tier 4 a) View Parameters Menu The View Parameters Menu is accessed from the Icon screen. Press the center navigation button ● while in default menu and hold down for approximately 5 seconds. The Icon menu is displayed, press the right navigation button to highlight the icon.
Operation Manual – ITW GSE 4400 Tier 4 Setup Menu The Setup Menu is accessed from the Icon screen. Press the center navigation button ● while in the default menu and hold down for approximately 5 seconds. The Icon menu is displayed, press the right navigation button to highlight the Setup icon.
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Operation Manual – ITW GSE 4400 Tier 4 11:27:47 Setup Menu 28/06/2013 Settings in additional sub-menu: Real Time Clock Setup Month , Day, Year, Hour, Minute, Second Refer to Section 3 – 4.13 ◄ Back ● Modify 11:27:47 Setup Menu...
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Operation Manual – ITW GSE 4400 Tier 4 11:27:47 Setup Menu 28/06/2013 Settings: Tier IV Regeneration Enabled Enabled Disabled Do it now Refer to Section 3 – 4.25 ◄ Back ● Modify 11:27:47 Setup Menu 28/06/2013 Settings: Language English, French, German, English Italian, Polish, Portuguese, etc.
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Operation Manual – ITW GSE 4400 Tier 4 1) Output Voltage This Setup submenu allows the output voltage to be adjusted between 80.0 VAC and 135 VAC using the UP and DOWN navigation buttons. (Please note that the acceptable voltage range for all commercial aircraft is 115V ±3V.
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Operation Manual – ITW GSE 4400 Tier 4 c) Go into the Setup Menu and then scroll up or down to the EF Interlock submenu. Press the center ● button to enter the submenu, and then press the ● button again to allow the value to be changed.
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Operation Manual – ITW GSE 4400 Tier 4 ● button to record the new value. Press the LEFT arrow button to exit the submenu and return to the submenu list. 10) Cable Temperature a) Some aircraft cables have temperature sensors installed in the connector body and/or replaceable nose.
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Operation Manual – ITW GSE 4400 Tier 4 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.
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Operation Manual – ITW GSE 4400 Tier 4 Enter the Setup Menu and then scroll up or down to the Current Limit Step Size submenu. Press the center ● button to enter the submenu, and then press the ● button again to allow the value to be changed.
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Operation Manual – ITW GSE 4400 Tier 4 powered on or the output contactor(s) are opened (the unit is in Standby Mode). If this message is ignored for 6 months, the controls will be locked out and the below failure message will be displayed.
Operation Manual – ITW GSE 4400 Tier 4 Power Log The Power Log Menu is accessed from the Icon screen. Press the center navigation button ● while in the default menu and hold it down for approximately 5 seconds. The Icon menu is displayed, press the right navigation button to highlight the Power Log icon.
Operation Manual – ITW GSE 4400 Tier 4 Update/Save Log Menu The Update/Save Log Menu is accessed from the Icon screen. Press the center navigation button ● while in the default menu and hold it down for approximately 5 seconds. The Icon menu is displayed, press the right navigation button then the down button to highlight the Update/Save Log icon.
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Operation Manual – ITW GSE 4400 Tier 4 Update/Save Log (continued) – Menu structure 10:30:00 USB MENU 28/06/2013 USB Firmware Update Detected Do you wish to update? 0.0% Press ● to update firmware 10:30:00 USB MENU 28/06/2013 10:30:00 USB MENU...
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Operation Manual – ITW GSE 4400 Tier 4 Chapter 2 Service and Troubleshooting Section 1 Maintenance Inspection/Check 1) General To make certain the generator set is always ready for operation, it must be inspected and maintained regularly and systematically so that defects may be discovered and corrected before they result in serious damage to components, or failure of the equipment.
Operation Manual – ITW GSE 4400 Tier 4 3) Inspection/Checks a) General 1) See Chapter 2-2 for detailed maintenance procedures. 2) See Chapter 2-3 for adjustment and test procedures. b) “AR” Checks and Operations (As Required) 1) Engine a) Change Air Cleaner Replace the air filter when the “Air Filter Clogged”...
Operation Manual – ITW GSE 4400 Tier 4 d) “A” Checks and Operations (10 Hours or Daily). 1) Engine. a) Check DEF tank level Check DEF tank level gauge and add enough DEF to bring the tank back to full.
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Operation Manual – ITW GSE 4400 Tier 4 Water Drain Valve Figure 2-1-2 Fuel Lubricity Drain e) Check Coolant Level Check coolant level daily or at each fuel fill interval. Investigate for cause of any coolant loss. WARNING Cooling system is pressurized. To avoid personal injury, DO NOT remove radiator cap when engine is hot.
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Operation Manual – ITW GSE 4400 Tier 4 Electrical System (24 VDC) a) Check All Lights. Check all indicating lights to be sure they operate when they should. If any light fails to operate, check the indicator and insure proper power is being given. If power is present and the light does not activate, replace the light fixture.
Operation Manual – ITW GSE 4400 Tier 4 d) Check and record oil pressure. After each oil change, check and record oil pressure at operating speed after oil has warmed to approximately 140º F. Record oil pressure under identical conditions at each oil change interval.
Operation Manual – ITW GSE 4400 Tier 4 3) Electrical (400 Hz System). a) Protective Monitoring Circuits. Check operation of all protective monitoring circuits to make certain they will function if a fault occurs in the output circuit. Procedures for testing these circuits are contained in the Adjustment/Test section of this manual.
Operation Manual – ITW GSE 4400 Tier 4 h) “E” Checks and Operations (2000 Hours or 2 Years) 1) Engine. a) Steam Clean Engine. There are several reasons why the engine exterior should be kept clean. Dirt on the outside will enter fuel and oil filter cases and rocker housings when covers are removed, unless dirt is removed first.
Operation Manual – ITW GSE 4400 Tier 4 Section 2 Maintenance Procedures 1) General A suggested maintenance schedule is provided in Section 1 of this Servicing Chapter. Each step of the schedule is also covered in general in Section 1. This Section covers maintenance in more detail, where necessary.
Operation Manual – ITW GSE 4400 Tier 4 2) Lubrication a) General Proper lubrication is one of the most important steps in good maintenance procedure. Proper lubrication means the use of correct lubricants and adherence to a proper time schedule.
Operation Manual – ITW GSE 4400 Tier 4 d) Changing engine oil Change the oil once after the first 50 - 150 hours of use and then every 500 hours of engine operation thereafter. The generator set is equipped with an hour meter to record actual engine operating time.
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Operation Manual – ITW GSE 4400 Tier 4 Change oil as follows: 1) Provide an open container for catching the old oil below the oil drain plug. Container capacity must be greater than 30 quarts (28.4 liters). 2) The oil drain tube can be found by the muffler at the front of the unit.
Operation Manual – ITW GSE 4400 Tier 4 e) Engine Accessories Lubrication 1) Alternator Most alternators contain sealed bearings and require no periodic lubrication, however, check to make certain there are no lubrication points on your particular alternator. 2) Starter...
Operation Manual – ITW GSE 4400 Tier 4 3) Servicing the Air Cleaner A definite time schedule for cleaning or changing the air cleaner cannot be determined because of varying operating conditions. Pull the yellow tab out (about 1 inch) then rotate the hub counter- clockwise about one inch and pull it off of the housing to access the air cleaner filter.
Operation Manual – ITW GSE 4400 Tier 4 c) Disposal Normal trash pick-up should be acceptable. NEVER burn the air filter for disposal. 4) Engine Fuel a) How to select Fuel—Quality The quality of fuel oil used in the diesel engine is a major factor in engine performance and life.
Operation Manual – ITW GSE 4400 Tier 4 5) Engine Fuel System The fuel system consists of five primary components: fuel tank, lubricity filter, primary fuel filter, fuel lift pump, and the fuel return line. The following are maintenance procedures for each of these items.
Operation Manual – ITW GSE 4400 Tier 4 2) To change the lubricity filter: CAUTION When installing new element, do not over tighten it; mechanical tools may distort or crack filter head. a) Place a pan underneath the fuel filter to catch spilled fuel.
Operation Manual – ITW GSE 4400 Tier 4 1) To change the fuel filter: a) Shut off fuel valve. b) Place a pan underneath the fuel filter to catch spilled fuel. c) Undo fuel filter with commercial tool and spin off.
Operation Manual – ITW GSE 4400 Tier 4 g) Draining the Fuel Tank 1) The fuel tank should be drained and cleaned out annually, when the various fuel filters start to become excessively fouled and before storing the unit for long periods of time.
Operation Manual – ITW GSE 4400 Tier 4 6) Engine Cooling System a) General Cooling system service requires more than maintaining the proper coolant level in the radiator and protecting the system against freezing. Water should be clean and free of any corrosive chemicals such as chloride, sulfate, and acids.
Operation Manual – ITW GSE 4400 Tier 4 CAUTION Never use soluble oil in the cooling system. 1) General. A permanent type antifreeze is recommended for use in the cooling system. CAUTION 1. DO NOT use methanol or alcohol as antifreeze.
Operation Manual – ITW GSE 4400 Tier 4 Cleaning the Radiator Core Blow out accumulated dirt from the radiator core air passages, using water. Bent or clogged radiator fins often cause engine overheating. When straightening bent fins, be careful not to damage the tubes or to break the bond between fins and tubes.
Operation Manual – ITW GSE 4400 Tier 4 7) Engine Drive Belt a) General The engine cooling fan, alternator, and water pumps are driven by one serpentine belt, which must be replaced if worn or damaged. b) Preparation for Belt Check and Adjustment All driven assemblies must be securely mounted in operating position before checking belt tension.
Operation Manual – ITW GSE 4400 Tier 4 9) Replacing the Control Board Battery Before removing the Control Board and to avoid any static discharge to the Control Board during the replacement of the battery, please take ESD (Electro Static Discharge) precautions.
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If the blue LED on the Control Board (location can be found on the Fig. 8.2.3) flashes with approximate 2 flashes per second and the display reports “Communication Error”, the firmware on the Control Board has been erased. The Control Board must be sent to ITW GSE to be reloaded.
Operation Manual – ITW GSE 4400 Tier 4 Section 3 Adjustment/Test 1) General These adjustments and test procedures are applicable to testing and adjusting the generator set after major repair, major parts replacements, or overhaul. IMPORTANT To perform most of the following tests, a load bank with an EF interlock circuit is required.
Operation Manual – ITW GSE 4400 Tier 4 g) Re-checking the entire unit after testing: 1) Start the engine. With the engine running at normal rated speed, check the entire unit for vibration and for any parts that may have become loosened during the above checks.
Operation Manual – ITW GSE 4400 Tier 4 b) Basic Engine Adjustments Adjustment procedures applicable to the diesel engine are included in the engine manufacturer’s operation manual, which is referenced in Chapter 5. Refer to the engine operation manual for detailed information on the following engine adjustments.
Operation Manual – ITW GSE 4400 Tier 4 Interface Board Figure 2-3-2: Generator Connections 5) Diode Test Test values for diodes are not given here because they could be misleading. Test values may vary even between diodes of the same part number, rating, and manufacturer. General instructions for testing diodes are as follows: a) Disconnect exciter windings from diode lead(s).
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Operation Manual – ITW GSE 4400 Tier 4 b) Operational Test Procedure 1) Power Delivery a) Press “28 VDC” pushbutton to close the DC output contactor. The green “DC OUTPUT” LED will glow indicating that DC power is being delivered to the load bank.
Operation Manual – ITW GSE 4400 Tier 4 Section 4 Troubleshooting Procedures 1) General The Troubleshooting Chart located in this section covers the common faults and malfunctions that can be found during operation or maintenance of this equipment. The chart may not list all faults and malfunctions that can occur.
Operation Manual – ITW GSE 4400 Tier 4 5) Check Connections and Leads ALWAYS check connections and leads to a component suspected of being faulty. Generally, it is assumed that connections and wiring have been checked first and that power has not been lost as a result of defective wiring or connections.
Operation Manual – ITW GSE 4400 Tier 4 b) Faults Faults result when any of the fault limits are exceeded, an internal problem, or under certain conditions where an injury to personnel or damage to an aircraft or the GPU could occur. Faults are also stored in the Black Box memory as event records.
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Operation Manual – ITW GSE 4400 Tier 4 10.0 Troubleshooting Chart Error 1st Corrective 2nd Corrective 3rd Corrective 4th Corrective Error Text in display Description Code Action Action Action Action For faults in this section: Disconnect from Aircraft (if connected). Do not stop engine (if running). Do not let engine start (if not running).
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Operation Manual – ITW GSE 4400 Tier 4 Error 1st Corrective 2nd Corrective 3rd Corrective 4th Corrective Error Text in display Description Code Action Action Action Action Current was Remove overload OVERLOAD: 125% < between 125% Press Output Replace Control...
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Operation Manual – ITW GSE 4400 Tier 4 Error 1st Corrective 2nd Corrective 3rd Corrective 4th Corrective Error Text in display Description Code Action Action Action Action 90% Signal Is output cable 90% SIGNAL DROP Press ARU Check / correct...
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Operation Manual – ITW GSE 4400 Tier 4 Error 1st Corrective 2nd Corrective 3rd Corrective 4th Corrective Error Text in display Description Code Action Action Action Action For faults in this section: Disconnect from aircraft. Shut down engine after cooldown.
Operation Manual – ITW GSE 4400 Tier 4 Engine Controls Trouble, Symptom, Probable Cause Test, Check, and/or Remedy Condition Make sure the Emergency Stop switch is pulled out 1. The engine will not a. Emergency Stop start, and the and switch has been pressed.
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Operation Manual – ITW GSE 4400 Tier 4 Engine Controls (continued) Trouble, Probable Cause Test, Check, and/or Remedy Symptom, Condition 3. Engine will not a. Low battery output Check the battery and recharge or replace start. Cranking b. Loose starting circuit Check all connections and cables.
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Operation Manual – ITW GSE 4400 Tier 4 Engine Controls (continued) Trouble, Symptom, Probable Cause Test, Check, and/or Remedy Condition 8. Engine either goes a. Low fuel was detected or the Add No. 2 diesel fuel. from rated speed to PC1 board could be Replace PC1 Interface board.
Operation Manual – ITW GSE 4400 Tier 4 Generator Excitation Circuits Trouble, Symptom, Probable Cause Test, Check, and/or Remedy Condition 1. No (or low) a. Defective generator or In the Setup Menu, go to the Diagnostic Mode generator output excitation circuit.
Operation Manual – ITW GSE 4400 Tier 4 Generator Trouble, Symptom, Probable Cause Test, Check, and/or Remedy Condition 1. No (or low) voltage output a. Shorted diode in exciter Check diodes in accordance with Chapter rectifier (CR2). 2-3 Section 4 and 5. If diodes are good, proceed to step b.
Operation Manual – ITW GSE 4400 Tier 4 Protective Circuit NOTE: Protective monitoring is not completely functional until the load contactor is CLOSED. Since it is not advisable to vary voltages for test purposes while delivering power to an aircraft, the GPU should be connected to a load bank for trouble shooting protective circuits.
Diagram, Schematic & Connection Contact ITW GSE if copies of these drawings or manuals are not delivered with the unit (unless otherwise noted above). Refer to Appendix B for specific information on the ITW GSE 4400, 400 Hz. Generator Set, optional equipment.
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Appendix A Active Rectifier Unit (ARU) All ITW GSE 4400 units can be equipped with a 28 VDC Active Rectifier Unit (ARU) output. Both 400 Hz & 28 VDC outputs can be used simultaneously. The total continuous amount of power from the unit is calculated as the sum of 400 Hz and 28 VDC output and cannot exceed the total 400 Hz power rating of the unit.
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Operation Manual – ITW GSE 4400 Tier 4 ARU Transformers (T20): The ARU transformers steps down the 3 phased 400 Hz voltage (3 x 200 Vac) to an appropriate level for obtaining 28 VDC at the output. ARU Rectifier (PM20): The output voltage is kept at 28 VDC by using thyristors, regardless of the input voltage level and the load.
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Operation Manual – ITW GSE 4400 Tier 4 Safety Interlock To ensure personnel health and safety, the converter is equipped with an interlock system. * The system ensures that the output only stays engaged while the plug is inserted into the aircraft receptacle. (28 VDC must be present at terminal strip TB3 lug 5.)
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Operation Manual – ITW GSE 4400 Tier 4 Press “Left arrow” to decrease current Press “Right arrow” to increase limit. current limit. Insert the aircraft cable into the aircraft. Make sure the cable is inserted till you feel a natural resistance.
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Operation Manual – ITW GSE 4400 Tier 4 Default Display Screen Standby OUTPUT Phase A: 0.0 V < 20 A 12:55.21 07-07-2014 Phase B: 0.0 V < 20 A 400 Hz I: Phase C: 0.0 V < 20 A Ready For Use Average: 0.0 V...
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Operation Manual – ITW GSE 4400 Tier 4 Additional menu items for ARU OM2247 Rev B Page 111 of 125...
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Operation Manual – ITW GSE 4400 Tier 4 Setup – ARU additional parameters 11:27:47 Setup Menu 28/06/2013 28 V Voltage Settings: 28.0 V 19.0 – 33.0 V ◄ Back ● Modify 11:27:47 Setup Menu 28/06/2013 11:27:47 Setup Menu 28/06/2013 28 V Voltage...
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Operation Manual – ITW GSE 4400 Tier 4 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 ●...
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Operation Manual – ITW GSE 4400 Tier 4 A20: ARU Board PM20: Rectifier Output terminals (- & +) Figure A13-1 Front View (ARU) 6 x ARU Transformer Figure A13-2 Rear View (ARU) OM2247 Rev B Page 114 of 125...
Operation Manual – ITW GSE 4400 Tier 4 Appendix B Options The following is a list of options available for the ITW GSE 4400, 400 Hz. Generator Set. This chart contains the description and part number of the option. The description of each option follows on the pages below.
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Operation Manual – ITW GSE 4400 Tier 4 This option adds the selected color beacon light to the top of the front canopy. These beacons are delivered with a flashing light. If a steady light is desired, the jumper in the bottom of the light should be cut.
Operation Manual – ITW GSE 4400 Tier 4 Appendix C Operating in Unusual Service Conditions This information is a general guideline and cannot cover all possible conditions of equipment use. The specific local environments may be dependent upon conditions beyond the manufacturer’s control. The manufacturer should be consulted if any unusual conditions of use exist which may affect the physical condition or operation of the equipment or safety to surrounding personnel.
Appendix D Initial Software Installation Procedure Introduction: The ITW GSE 4400 GPU contains two circuit boards that may need to be programmed if they are replaced. (The Control Board (P/N AP-579526) and the Display Board (P/N AP-579536). This document instructs you how to perform this task. Make sure to program the boards with the correct software number and revision.
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Operation Manual – ITW GSE 4400 Tier 4 RRRPossible issues that may be encountered during this procedure: Error 201 ”CRITICAL”: Memory Error. Call Technician”. This is caused by the Control Board being unable to read the GPU configuration from the EEprom Board (P/N 579.533).
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Operation Manual – ITW GSE 4400 Tier 4 4. Set File system to FAT32 and make sure that Quick Format is NOT clicked. Press start. (The USB should function without issue after the format is complete. This may take several minutes to complete on larger drives.
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This formula can be downloaded from www.itwgse.com Forward to Sender: ITW GSE 4400 Information Americas: ITW GSE Americas Company: Model: + 1 941 721 1092 Fax: Serial No.: support@itwgse.us Phone: Error Code: International: ITW GSE ApS Date: ...
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