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TLD GPU-406 Information And Operating Instructions

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GPU - 406
GPU - 409
CHAPTER 1
General Information
and Operating Instructions
Creation: 01.31 - 2014

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Summary of Contents for TLD GPU-406

  • Page 1 GPU - 406 GPU - 409 CHAPTER 1 General Information and Operating Instructions Creation: 01.31 - 2014...

  • Page 2: Table Of Contents

    Contents Contents Contents INFORMATION ................... 1-1-1 1. Unit Description ..........................1-1-1 A. GPU-406 and GPU-409 ......................1-1-1 2. Major Component Description ....................... 1-1-7 A. Engine ............................1-1-7 B. Generator System ........................1-1-8 3. Electrical Box Assembly ....................... 1-1-10 A. Relay Panel Assembly ......................1-1-11 B.

  • Page 3: Information

    The ground power units feature a brushless-revolving-field generator, rubber-torsion-axle-mounted chassis of rugged galvanized steel construction with fifth-wheel steering, powder-coated sheet metal panels, and fiberglass housings. TLD GPU’s can be equipped to meet Tier 3 (Stage IIIA) or Tier 4 Final (Stage IV) emissions standards.

  • Page 4: Gpu-406 And Gpu-409

    GPU - 406 GPU - 409 1...Air filter 2...Exhaust silencer 3...Charge air cooler 4...Engine 5... Radiator 6...Generator GPU-406 AND GPU 409 CUMMINS TIER 3 ENGINE CONFIGURATION FIGURE 1 Creation: 01.31 - 2014 1-1-2...
  • Page 5 GPU - 406 GPU - 409 1...Air filter 2...Charge air cooler 3...Engine 4... Radiator 5...Generator 6…Diesel Oxidation Catalyst GPU-406 AND GPU 409 CUMMINS TIER 4 INTERIM ENGINE CONFIGURATION FIGURE 2 Creation: 01.31 - 2014 1-1-3...
  • Page 6 GPU - 406 GPU - 409 GPU-406 AND GPU 409 CUMMINS TIER 4 FINAL ENGINE CONFIGURATION FIGURE 3 1…Air filter 2…Charge air cooler 3…Engine 4…Radiator 5…Generator 6…DOC (Diesel Oxidation Catalyst) 7…DRT (Decomposition Reactor Tube) 8…SCR (Selective Catalytic Reducer Creation: 01.31 - 2014...
  • Page 7 GPU - 406 GPU - 409 1...Fuel Overflow Vent 2...Fuel Tanks 3...Fuel Fill GPU-406 AND GPU 409 FUEL SYSTEM FIGURE 4 Creation: 01.31 - 2014 1-1-5...
  • Page 8 3…SIM card (inside the telematics module) TLD Link TLD Link allows for remote monitoring of the units’ status in the field using the TLD Link portal from TLD’s main homepage via phone, tablet, or personal computer. TLD Link consists of 3 main components 1.

  • Page 9: Major Component Description

    GPU - 406 GPU - 409 Major Component Description For the purposes of orientation and to familiarize operators and maintenance personnel with the location of components, the radiator is considered to be at the front of the unit. The generator and controls are at the rear.

  • Page 10: Generator System

    GPU - 409 Generator System The generator system is a simple system which contains few components. The unit utilizes a TLD brand generator. The other major assembly of the generator system is the electrical box assembly, which contains the generator control module, instrument panel controls, and a relay panel.
  • Page 11 GPU - 406 GPU - 409 1…Louvered panel 13...Shim Plates 2…Screen Cover 14...Drive Plates 3...Exciter Stator 15...Ring 4...End Bell 16...Ring 5…Main Stator 17...Screen Cover 6...Cover Plate 18...Key 7…Bridge Rectifier 19...Key 8…Exciter Rotor 20...Transition Segment 9…Bearing 22...Cover Plate, Exciter 10…Main Rotor 23...Screw 11...Cooling Fan 24...Cover, End Bell...

  • Page 12: Electrical Box Assembly

    GPU - 406 GPU - 409 3. Electrical Box Assembly The electrical box assembly is located at the extreme rear of the unit and houses the instrument panel and the relay panel. FIGURE 6 1…Electrical Box 2…View Screen 3…Select Buttons 4…Control Knob 5…Emergency Stop (E-Stop) 6…Electrical Panel...

  • Page 13: Relay Panel Assembly

    GPU - 406 GPU - 409 A. Relay Panel Assembly The relay panel assembly is mounted inside the electrical box on the back wall. The relay panel provides mounting facilities for engine and generator control and protection relays, 3 current transformers, and output load contactor(s).

  • Page 14: Relay Panel Components

    The function of the contactors is to allow, or not allow, 400 Hz output power from the generator to the aircraft. The contactor states, open or closed, is controlled by the 24 VDC contactor coil. GPU-406 and GPU-409 have (1) contactor as standard and a 2nd is included with the optional 2nd 400 Hz output.
  • Page 15 GPU - 406 GPU - 409 running relay. Its function is to provide a 24V signal when the engine is running above 600 RPM. This signal is used to power an analog engine hourmeter. (9) Key Switch Power Relay – K10 K10 is the key switch power relay.

  • Page 16: Generator Control Module

    GPU - 406 GPU - 409 Generator Control Module The generator control module is mounted inside the door of the GPU’s electrical box. Its display is read without opening up the electrical box. GENERATOR CONTROL MODULE FIGURE 9 The Generator Control Module (GCM) is the brain of the GPU-400. It is a fully-automatic voltage regulator that not only provides voltage and frequency regulation, but also generator fault protection and generator power output display.
  • Page 17 GPU - 406 GPU - 409 Over-frequency: AC Output is over 420 Hz for 5 seconds Under-frequency: AC Output is under 380 Hz for 7 seconds Over voltage: AC Output is over 130 volts for 2 seconds Under voltage: AC Output is under 100 volts in 7 seconds Overload: Output is over 125% of rated capacity for 5 minutes The voltage regulator displays and latches the fault if any of the above should occur.

  • Page 18: Instrument Panel

    GPU - 406 GPU - 409 Instrument Panel The GPU’s instrument panel is located at the rear extreme of the unit. It provides the operator with controls and displays for generator and engine functioning. INSTRUMENT PANEL FIGURE 10 1…Blue Button 2…Red Button 3…Yellow Button 4…Green Button...
  • Page 19 GPU - 406 GPU - 409 The instrument panel contains the following buttons and switches: (1) Blue Button The four colored pushbuttons are the main method to control the GPU. The function of the button changes, depending on the GPU’s current operating condition. The current function of each button is always displayed on the screen directly above the button.
  • Page 20 GPU - 406 GPU - 409 (3) Yellow Button The yellow button is used to control the #2 400 Hz output. The blinking airliner icon means the output is available for use. Press and release the yellow button to activate the #2 400 Hz Output. (The solid airliner icon means the output is being used.
  • Page 21 GPU - 406 GPU - 409 (5) Dial with Pushbutton The dial with a built-in push button is used for making on-screen selections and GPU servicing. When the 28VDC output is active, the push button of the dial toggles between adjusting the DC output current limit and scrolling the engine information display.
  • Page 22 GPU - 406 GPU - 409 Check Engine Engine Hours Engine Oil Pressure Engine RPM Water in Fuel Diesel Exhaust Fluid Level – Tier 4 Final Only Exhaust System Cleaning (E.S.C) in Progress – Tier 4 Final Only High Exhaust Temperature – Tier 4 Final Only Creation: 01.31 - 2014 1-1-20...
  • Page 23 GPU - 406 GPU - 409 (7) Emergency Stop The large red button located on the control panel provides a means to stop the engine and disable power delivery when catastrophic failure and damage to either the GPU or aircraft is imminent. It is not meant to be used to shut the engine off in routine GPU operation.

  • Page 24: Contactors

    GPU - 406 GPU - 409 the efficiency of the emissions reduction system. Exhaust temperature will increase as a part of the cleaning process, and the “HIGH” Exhaust Temperature icon will appear. The “E.S.C.” icon will replace the water temperature icon to show that exhaust system cleaning is taking place. The GPU operator will only receive this notification if the engine is idling at the time of the exhaust system cleaning.
  • Page 25 GPU - 406 GPU - 409 Page Intentionally Left Blank Creation: 01.31 - 2014 1-1-23...

  • Page 27: Operation

    The level gauge should be at or near full. CAUTION: BEFORE FUELING WITH ANY TYPE OF JET FUEL, CONTACT TLD. DAMAGE TO THE FUEL INJECTION SYSTEM COULD RESULT. NEVER USE JET FUEL WITH A TIER 4 ENGINE. ONLY ULTRA LOW (<15PPM) SULPHUR DIESEL CAN BE USED WITH...
  • Page 28 GPU - 406 GPU - 409 NOTE: For antifreeze protection, use a solution of 50% long life antifreeze (ethylene glycol) and 50% distilled water. (c) Engine Lubricating Oil The oil level should be at the full mark on the dipstick. See the engine manufacturer’s manual (Chapter 5) for oil recommendations.
  • Page 29 GPU - 406 GPU - 409 NOTE: The AC aircraft cable assembly recommended shall consist of four single conductor #2/0 cables with two #12 control leads connected to an AN3430 plug. The #2/0 cables must be equipped with terminals having a 3/8 Inch diameter mounting hole.
  • Page 30 GPU - 406 GPU - 409 2. Unit Operation WARNING: IMPROPER OPERATION CAN KILL! READ AND UNDERSTAND ALL OF THE OPERATING INSTRUCTIONS BEFORE ATTEMPTING TO OPERATE THE UNIT. This section contains information and instructions for the safe and efficient operation of the unit. A.
  • Page 31 GPU - 406 GPU - 409 D. Delivering Power to the Aircraft WARNING: REMOVE THE AC PLUG FROM THE AIRCRAFT WHEN USING THE DC OUTPUT TO START AN AIRCRAFT. HAVING BOTH PLUGGED IN MAY RESULT IN BURNING THE GROUND WIRE AND GCM BECAUSE OF OVERCURRENT IN THE GROUND WIRE. (1) Connect the power cable to the external power receptacle on the aircraft.
  • Page 32 The Tier 4 Final engine equipped on a TLD ground power unit has an exhaust system fitted with a diesel oxidation catalyst (DOC) which reduces emitted hydrocarbons and carbon monoxide. The exhaust system also contains a selective catalytic reducer (SCR) which, when used with DEF, reduces emitted NO Creation: 01.31 - 2014...
  • Page 33 GPU - 406 GPU - 409 TLD ground power units have been designed to reduce overall maintenance, but some steps are required to be taken for the continued reliability of the Tier 4 Final engine and to prevent unexpected interruption in power delivery to aircraft.
  • Page 34 GPU - 406 GPU - 409 Page Intentionally Left Blank Creation: 01.31 - 2014 1-2-8...

  • Page 35: Specifications And Capabilities

    1. GPU-400 SERIES RATED LENGTH P.F. WIDTH HEIGHT AMPS TOWBAR UP MODEL With beacon 64" 112" 68" 1630 mm GPU-406 2845 mm 1728 mm W/O beacon 59” 1502 mm With beacon 64" 112" 68" 1630 mm GPU-409 2845 mm 1728 mm W/O beacon 59”...
  • Page 36 GPU - 406 GPU - 409 Generator Specifications The generator used in the ground power unit is rated at 115/200 Volts nominal, 400 Hz, and 125% of rated power for 5 minutes. It is 3-phase, 4-wire wye connected, and with a grounded neutral. It is a brushless, self-cooling, single-bearing generator directly coupled to the engine.
  • Page 37 GPU - 406 GPU - 409 Rear Towing The GPU is not designed for towing from the rear and should only be done in the event of an emergency if it is equipped from the factory with a tow hook and a reinforced rear bumper. Towing without the proper bumper reinforcements will cause damage and premature failure of the structure.
  • Page 38 GPU - 406 GPU - 409 Page Intentionally Left Blank Creation: 01.31 - 2014 1-3-4...

  • Page 39: Shipping

    GPU - 406 GPU - 409 Shipping 1. Shipping the Unit CAUTION: DO NOT SHIP THE UNIT BY RAIL. DAMAGE MAY OCCUR DUE TO HIGH AND UNPREDICTABLE ACCELERATION WHEN SHIPPING BY RAIL AND THE FACTORY SUGGESTS THAT OTHER MODES OF TRANSPORTATION BE USED. CAUTION: DO NOT USE CHAINS OR STRAPS OVER FUEL LINES, ELECTRICAL WIRES, OR COMPONENTS.
  • Page 40 GPU - 406 GPU - 409 Page Intentionally Left Blank Creation: 01.31 - 2014 1-4-2...

  • Page 41: Storage

    GPU - 406 GPU - 409 Storage 1. Storing the Unit When storing the unit in cold ambient temperatures, be sure that the proper antifreeze percentage is present in the engine cooling system. When storing the unit for extended periods of time, perform the following steps: (1) Drain the cooling system completely from the engine and radiator.
  • Page 42 GPU - 406 GPU - 409 Page Intentionally Left Blank Creation: 01.31 - 2014 1-5-2...

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Gpu-409

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