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ITW GSE Hobart 2400 Manual

Power coil 400 hz ground power unit & cable retriever system
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OM2250
Rev 0 - June 23 2016
Serial no.
Type
3GVF-200/260-N
T: (toll free is US): 800-899-1841
Manual
Hobart 2400 Power Coil
400 Hz Ground Power Unit
Cable Retriever System
3GWC -200/
ITW GSE HOBART
●
T (International): +1 941-721-1000
it's all about connections
&
-
●
11001 Us Highway 41 North
●
Palmetto, FL 34221
●
E: technicalsupport@itwgse.us
●
U.S.A

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  • Page 1 OM2250 Rev 0 - June 23 2016 it’s all about connections Manual Hobart 2400 Power Coil 400 Hz Ground Power Unit & Cable Retriever System Serial no. 3GWC -200/ Type 3GVF-200/260-N ● ● ● 11001 Us Highway 41 North Palmetto, FL 34221 U.S.A...
  • Page 2 OM2250 Rev 0 - June 23 2016 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. Refer to section 8.3 for further information Diagrams and drawings are subject to change without prior notice. Latest diagram versions can be found at www.itwgse.com Printed: June 2015 Document no.

  • Page 3: Table Of Contents

    OM2250 Rev 0 - June 23 2016 Operation Manual – Hobart PoWerMaster® 2400 Power Coil – 60 - 90 kVA Index INDEX Declaration of Conformity ..................5 Safety Instructions ..................... 6 General Description ....................7 Built in features / protections ..................12 Transport and Installation ..................
  • Page 4 OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA Index 7.10 GPU Enable........................47 7.11 Door Switch ........................47 7.12 Plug Temperature ......................47 7.13 Neutral Voltage Supervision ..................48 7.14...

  • Page 5: Declaration Of Conformity

    OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA Declaration of Conformity 1.0 Declaration of Conformity Document no. 577.420-B Page 5 of 70...

  • Page 6: Safety Instructions

    OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA Safety Instructions IMPORTANT SAFEGUARDS DANGER – TO REDUCE THE RISK OF FIRE OR ELECTRIC SHOCK, CAREFULLY FOLLOW THESE INSTRUCTIONS 2.0 Safety Instructions This unit is only intended to be installed, operated and maintained by competent persons having the necessary knowledge regarding delivery of external power to an aircraft.

  • Page 7: General Description

    General Description 3.0 General Description The figure below shows the basic principle of the Hobart 2400 Power Coil unit. The 50/60 Hz 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.
  • Page 8 OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA General Description Capacitor Board (A5): This module includes the following functions:  Input RFI filters to reduce the EMI/EMC emission into the mains to such a level that surrounding equipment is not disturbed.
  • Page 9 OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA General Description Output Transformer (T2): The output transformer ensures galvanic separation between input and output. It also transforms the voltages from the Inverter Module into the required aircraft voltage (3 x 200/115 V). The filter choke for the output AC-filter is an integral part of the transformer.
  • Page 10 OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA General Description  Remote I/O and Dry contacts for PBB (X4)  Protected interface for interlock signals.  Neutral Voltage Supervision.
  • Page 11 OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA General Description Display Board & Keyboard (A3 / A4): The display module serves as the interface for daily operation. The display communicates with the Control Board via a CAN bus (Controller Area Network) and can be placed up to 100 m away from the unit, when using the Remote Control Box.

  • Page 12: Built In Features / Protections

    OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA General Description Built in features / protections No Break Power Transfer: The unit is protected against misalignment during a No Break Power Transfer.
  • Page 13 For change of setting please refer to section 6.3. Note! An additional protection method offered by ITW GSE as an option is the Neutral Conductor Rupture (NCR). The supervision is based on the presence of an injected current in the neutral conductor (i.e. as long as the injected current is present, the neutral is intact).

  • Page 14: Transport And Installation

    The Hobart 2400 Power Coil is delivered on a specially designed wooden pallet. Transport and mounting of the Hobart 2400 Power Coil is carried out by lifting the unit by a fork-lift, truck or the like to the intended mounting 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.

  • Page 15: Installation And Fastening Instructions

    OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA Transport and Installation Installation and fastening instructions Fig. 4.4.1 Spacing between units and mounting holes for bracket. Document no. 577.420-B Page 15 of 70...
  • Page 16 OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA Transport and Installation Fig. 4.4.3 Cable entry via gland plate Fig. 4.4.4 Center of Gravity Document no. 577.420-B Page 16 of 70...

  • Page 17: Connection Of Cables

    OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA Transport and Installation Connection of Cables Remote I/O terminals available (refer to section 4.9 for connection of I/O terminals) 3 x ¼-20 by 1” (M8/25mm) 25.4 Nm (225 in-lb) (L1–L2–L3)

  • Page 18: Mains Input

    14.9 Nm to 21.7 Nm (132 in-lb to 192 in-lb) Output contactor: 17.6 Nm (156 in-lb) Due to the RFI filter at the input, the leakage current for the Hobart 2400 Power Coil is > 40 mA. Document no. 577.420-B Page 18 of 70...

  • Page 19: 400 Hz Output

    OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA Transport and Installation 400 Hz Output At delivery, the 400 Hz neutral is connected to the Protective Earth terminal (PE). If a floating output is required, the green/yellow jumper wire must be removed.
  • Page 20 OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA Transport and Installation o GPU Enable – Input signal (X7:3 - 4) o 400 Hz Ready / 400 Hz Error – Contact N.O. (X7: 5 - 6) / N.C. (X7: 6 - 7) o 400 Hz On / 400 Hz Off –...

  • Page 21: Tcp/Ip On-Board Interface

    OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA Transport and Installation Fig. 4.9.2 Example of wiring for external control and Lamps indication 4.10 TCP/IP On-board Interface The Hobart 2400 Power Coil is equipped with a TCP/IP (RJ45) communication port for supervision and monitoring of the Ground Power Unit (GPU) e.g.
  • Page 22 OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA Transport and Installation In the following section, the different kinds of data available are described.  The most common modes are: System in use, system in standby and system in fault.

  • Page 23: Technical Specifications

    OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA Technical Specifications 5.0 Technical Specifications Standards: ISO 6858 Aircraft ground support electrical supplies - general requirements BS 2G 219 General requirements for ground support electrical supplies for aircraft Ground equipment –...
  • Page 24 OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA Technical Specifications Overload 100 % continuous 125 % for 10 minutes 150 % for 60 seconds 200 % for 30 seconds...
  • Page 25 OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA Technical Specifications Fig. 5.0.1 Bridge Mounted Document no. 577.420-B Page 25 of 70...

  • Page 26: Operator's Instructions (Display/Led/Keypad Layout)

    OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA Operator’s Instructions Operator’s Instructions (Display/LED/Keypad layout) Mains On Display ”Blue” LED Navigation keypad equipped with 4 Warning arrows and 1 select ”Yellow”...

  • Page 27: Using The Display/Keypad

    Note! Please refer to section 6.0 for the push button layouts. Operator’s instructions (operating via aircraft plug) The Hobart 2400 Power Coil offers the possibility to operate the unit from the plug. Start 400 Hz & Reset Cable IN...
  • Page 28 OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA Operator’s Instructions  Insert the aircraft cable into the aircraft. Make sure the cable is inserted till you feel a strong resistance.
  • Page 29 OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA Operator’s Instructions Default Display Screen Operating OUTPUT Phase A: 115.0 V < 20 A 115.1 V <20 A Phase B: 115.0 V <...

  • Page 30: Basic Menu

    OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA Operator’s Instructions Basic Menu: Home Set-Up Black Box Save / Upload Power Log View Parameters The basic Icon Menu is shown above with the available sub-menus.
  • Page 31 OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA Operator’s Instructions 6.4.1 Parameters – Menu structure OUTPUT Phase A: 0.0 V < 20 A Phase B: 0.0 V < 20 A Phase C: 0.0 V...
  • Page 32 OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA Operator’s Instructions Parameters (continued) – Menu structure Input / Output Port Status Use the ▼/▲ to browse through the various screens.
  • Page 33 OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA Operator’s Instructions 6.4.2 Setup – Menu structure 11:27:47 Setup Menu 16/05/2015 Output Voltage Settings: 115.0 V 80.0 – 135.0 V ◄ Back ● Modify...
  • Page 34 OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA Operator’s Instructions Setup (continued) – Menu structure 11:27:47 Setup Menu 16/05/2015 Fan Control Settings: Normal Normal Boost ◄ Back ● Modify...
  • Page 35 OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA Operator’s Instructions Setup (continued) – Menu structure 11:27:47 Setup Menu 28/06/2013 GPU Enable Settings Active Bypassed Active ◄ Back ● Modify...
  • Page 36 OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA Operator’s Instructions Setup (continued) – Menu structure 11:27:47 Setup Menu 28/06/2013 Settings in additional sub-menu: Real Time Clock Setup Month , Day, Year, Hour, Minute, Second ◄...
  • Page 37 OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA Operator’s Instructions Setup (continued) – Menu structure 11:27:47 Setup Menu 28/06/2013 6 Characters: <UNDEFINED> A – Z , 0 – 9 , Space - ◄...
  • Page 38 OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA Operator’s Instructions 6.4.3 Black Box – Menu structure 14:54:33 06/28/2013 4307 OVERLOAD: 200% < I < 300% - 10 s ● Alarm Data...
  • Page 39 OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA Operator’s Instructions 6.4.4 Power Log – Menu structure Power Log 001/100 Total Time: 22.0 Minutes 0 – 30 kW Start Date: 06/28/2013 30 –...
  • Page 40 OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA Operator’s Instructions 6.4.5 Save/Upload – Menu structure 10:30:00 USB MENU 28/06/2013 USB Firmware Update Detected Do you wish to update? 0.0% Press ●...
  • Page 41 OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA Operator’s Instructions Save/Upload (continued) – Menu structure 10:30:00 USB MENU 28/06/2013 USB Firmware Update Detected Do you wish to update? 0.0% Press ●...
  • Page 42 OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA Operator’s Instructions Save/Upload(continued) – Menu structure 10:30:00 USB MENU 28/06/2013 Saving log 10:30:00 USB MENU 28/06/2013 10:30:00 USB MENU 28/06/2013 Update Display Software...

  • Page 43: Default Factory Settings

    OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA Operator’s Instructions Default Factory Settings: Output Voltage (V): 115.0 Compensation Type: Plug & Play Fan Control: Normal Remote Stop: Normally Open...

  • Page 44: Set-Up Lock / Output Mode / Compensation

    OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA Set-up Lock / Output Mode / Compensation Set-up Lock / Output Mode / Compensation Preventing changes of set-up parameters To avoid unintentional modification of the...

  • Page 45: Manual Compensation

    OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA Set-up Lock / Output Mode / Compensation 4. Initiate the cable identification process by pressing the ground power unit’s START button.

  • Page 46: Ef Interlock

    OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA Set-up Lock / Output Mode / Compensation EF Interlock The EF interlock is a personnel and equipment safety feature that is found in all commercial aircraft.

  • Page 47: Aircraft Connector Insertion

    OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA Set-up Lock / Output Mode / Compensation Aircraft Connector Insertion Some aircraft power cables are equipped with a micro-switch or split "F" pin in the connector. This device sends a 28 VDC signal to the unit when the connector is inserted at least 90% of the way into the aircraft power receptacle.

  • Page 48: Neutral Voltage Supervision

    OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA Set-up Lock / Output Mode / Compensation 7.13 Neutral Voltage Supervision If the output Neutral wire is not connected to the chassis ground then the unit can monitor the voltage difference between aircraft neutral and ground.

  • Page 49: Ethernet Configuration

    OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA Set-up Lock / Output Mode / Compensation 7.17 Ethernet Configuration This set of sub-menu s allows the user to enter the Ethernet IP address, Subnet Mask, Gateway address and DNS1 values for TCP/IP communications with a BMS or RMS central monitoring system.

  • Page 50: Costumer Id

    OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA Set-up Lock / Output Mode / Compensation 7.22 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.

  • Page 51: Service, Maintenance, Overhaul

    OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA Service, Maintenance, Overhaul 8.0 Service, Maintenance, Overhaul To make certain that the unit is always ready for use it must be maintained on a regular basis.
  • Page 52 OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA Service, Maintenance, Overhaul 14. Visual inspection of components and printed circuit boards i.e. – control unit / gate drives. 15. Check of the output contactor’s contact sets and coil.
  • Page 53 OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA Service, Maintenance, Overhaul # Position 11: Flexible cable harness & control cables: Depending on the accessibility of the Power Coil at the point of installation, the visual inspection of the flexible cable harness &...

  • Page 54: Cable Replacement Mode

    Service, Maintenance, Overhaul Cable Replacement Mode The Hobart 2400 Power Coil has a feature called “Cable Replacement Mode”. The feature enables the maintenance crew to bypass the limit switches and rotate the coil in low speed during inspection of the flexible power &...

  • Page 55: Battery Back-Up & Replacement

    OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA Service, Maintenance, Overhaul Battery back-up & replacement Situated on the back of the control board, is a coin type lithium battery which ensures that Firmware / Set-up data etc.
  • Page 56 OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA Service, Maintenance, Overhaul Battery holder and battery Fig. 8.2.2 Control Board (rear view) Before you remove the battery from the holder, make sure that the replacement battery is within reach, as the Control Board must not be without battery power for more than 30 seconds.

  • Page 57: Trouble Shooting & Repair

    OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA Trouble Shooting & Repair 9.0 Trouble Shooting & Repair Only have qualified personnel remove covers for troubleshooting and repair. Please be aware that the DC capacitors can remain charged to a dangerous voltage up to 5 minutes after the mains input power has been disconnected.

  • Page 58: Fault Guidance

    OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA Trouble Shooting & Repair Fault Guidance In case you need to contact us for further fault guidance, please contact technicalsupport@itwgse.us List below shows the complete list of error codes and first corrective action:...
  • Page 59 OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA Trouble Shooting & Repair Error code Error text in display Help text 1st. Corrective action 7000 OUTPUT VOLTAGE TOO HIGH Voltage > 32V - 4s OUTPUT VOLTAGE TOO HIGH Voltage >...
  • Page 60 OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA Trouble Shooting & Repair Error code 2nd. Corrective action 3rd. Corrective action 4th. Corrective action 5000 Let the unit cool down and press start to...

  • Page 61: Illustrated Parts List

    OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA Illustrated Parts List 10.0 Illustrated Parts List Please contact technicalsupport@itwgse.us for recommended list of spare parts, diagrams and drawings. PM1: Inverter Module...
  • Page 62 OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA Illustrated Parts List PM1: Inverter Module C7-C9: Output Capacitors Cable Guide Q4: Circuit Breaker Cable Drum A5: Capacitor Board Q1: Input Disconnector...
  • Page 63 OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA Illustrated Parts List C10-C12: Filter Capacitors Terminals Block (S2-S3-S4) M1-M2: Fan Tray Cable Drum M3: Motor & Gear Box 400Hz Plug Cable Strain Relief Figure 10.0.3 Right Hand Side View...
  • Page 64 OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA Illustrated Parts List PM1: Inverter Module M1-M2: Fan Tray T1: 12 Pulse Transformer L1: Input Choke T2: Output Transformer Figure 10.0.4 Right Hand Side View (X-Ray view) Document no.
  • Page 65 OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA Illustrated Parts List S2: Limit Stop Out S3: Limit Stop In * S4: Limit 4 m * Position of limit switches S3-S4 may vary depending on cable length.
  • Page 66 OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA Illustrated Parts List Air inlet grills Gland Plate Air exhaust grill Air inlet grills Gland Plate Air exhaust grill Figure 10.0.6 Document no.

  • Page 67: Options

    OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA Options 11.0 Options AP-577801 Remote Control Box The Remote Control Box is used for operation of the Hobart 2400 Power Coil especially if the 400 Hz cable is out of reach, often attached at the passenger boarding bridge.

  • Page 68: Ap-577802 Neutral Conductor Rupture Supervision

    The NCR option protects personnel as well as the aircraft in case of a broken neutral. Note! In general ITW GSE does not recommend the NCR option for the following reasons: 1) The need for an additional control wire, which is likely to be the first to break.

  • Page 69: Ap-577803 Rs485 Interface (Diagram 477800)

    OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA Options AP-577803 RS485 Interface (Diagram 477800) All units are supplied with connections for RS232. The RS485 Interface option provides a galvanic isolated RS485 connection and allow for multi-point connection.

  • Page 70: Ap-577805 Door Switch (Diagram 477800)

    OM2250 Rev 0 - June 23 2016 Operation Manual - Hobart 2400 Power Coil – 60 - 90 kVA Options AP-577805 Door Switch (Diagram 477800) The door interlock ensures that the ground power units output contactor(s) open and the unit immediately returns to standby mode if the door is opened.

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