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ITW GSE Hobart PoWerMaster 2400 Series Manual

400 hz ground power unit with 28 vdc outlet (optional)
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Manual
Hobart PoWerMaster® 2400
400 Hz Ground Power Unit
With 28 VDC outlet (optional)
Serial no.
Type
SX240
ITW GSE HOBART 11001 Us Highway 41 North Palmetto, FL 34221 U.S.A
T: (toll free in US): 800-899-1841 T (International): + 1 941-721-1000 E: technicalsupport@itwgse.us

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Summary of Contents for ITW GSE Hobart PoWerMaster 2400 Series

  • Page 1 Hobart PoWerMaster® 2400 400 Hz Ground Power Unit With 28 VDC outlet (optional) Serial no. Type SX240 ITW GSE HOBART 11001 Us Highway 41 North Palmetto, FL 34221 U.S.A T: (toll free in US): 800-899-1841 T (International): + 1 941-721-1000 E: technicalsupport@itwgse.us...
  • Page 2 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 Diagrams and drawings are subject to change without prior notice. Latest diagram versions can be found at www.itwgse.com Printed: March 2017 Document no.

  • Page 3: Table Of Contents

    Operation Manual - Hobart PoWerMaster® 2400 – 30 - 90 kVA Index INDEX Declaration of Conformity ..................6 Safety Instructions ..................... 7 General Description ....................8 Built in features / protections ..................13 Transport and Installation ..................15 Storage Before Installation.................... 15 Operational and Environmental Conditions after Commissioning .......

  • Page 4: Index

    Operation Manual - Hobart PoWerMaster® 2400 – 30 - 90 kVA Index Output Mode ......................... 53 Fan Control ........................54 Remote Stop ........................54 EF Interlock........................54 EF Interlock Ripple Level ..................... 55 7.10 EF Interlock Delay ......................55 7.11 Aircraft Connector Insertion ..................
  • Page 5 Operation Manual - Hobart PoWerMaster® 2400 – 30 - 90 kVA Index 578807 Additional Output Contactor (Diagram 478801) ............73 578808 Dry Contacts (Diagram 478801) ................... 73 578809 Door Interlock (Diagram 478801) ................74 578810 Neutral Conductor Rupture Supervision ............... 74 578814 Terminal Extension .......................

  • Page 6: Declaration Of Conformity

    Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA Declaration of Conformity 1.0 Declaration of Conformity Document no. 578.650BB Page 6 of 91...

  • Page 7: Safety Instructions

    Operation Manual - PoWerMaster® 2400 – 30 - 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 8: General Description

    Operation Manual – AXA 2400 Compact Power– 30 - 90 kVA General Description 3.0 General Description The figure below shows the basic principle of the Hobart PoWerMaster® 2400 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 9 Operation Manual – AXA 2400 Compact Power– 30 - 90 kVA General Description Capacitor Board (A5): This module includes the following functions: • Input and Output RFI filters to reduce the EMI/EMC emission into the mains and output to such a level that surrounding equipment is not disturbed.
  • Page 10 Operation Manual – AXA 2400 Compact Power– 30 - 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 11 Operation Manual – AXA 2400 Compact Power– 30 - 90 kVA General Description • Interface for individual overload protection (X20). • Neutral Voltage Supervision. • Neutral Conductor Rupture supervision. • Door Interlock (X27). • Earth Leakage Failure via (X22) and current sensor on ground wire from 400 Hz neutral. •...
  • Page 12 Operation Manual – AXA 2400 Compact Power– 30 - 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 13: Built In Features / Protections

    Operation Manual – AXA 2400 Compact Power– 30 - 90 kVA General Description Built in features / protections No Break Power Transfer: The unit is protected against misalignment during the No Break Power Transfer. Over/under voltage at input: The input voltage supervision is based on the rectified DC. The supervision ensures that the unit does not trip even in case of an abnormal low input voltage level.
  • Page 14 For change of setting please refer to Section 6.3 & 7.17 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 15: Transport And Installation

    Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA Transport and Installation 4.0 Transport and Installation Storage Before Installation To secure optimal storage conditions prior to installation, we recommend that the converter is stored inside. This protects the unit from rain and excessive humidity while it is left without power. Only equipment in seaworthy packing should be stored outside.
  • Page 16 Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA Transport and Installation Adequate lifting gear is not part of the delivery. Fig. 4.3.2 Lifting with crane (Place M10 lifting rings at the 4 corners) The Hobart PoWerMaster® 2400 horizontal version is delivered on a specially designed wooden pallet. Transport and mounting of the Hobart PoWerMaster®...

  • Page 17: Installation And Fastening Instructions

    Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA Transport and Installation Installation and fastening instructions Fig. 4.4.1 Foot Print & Spacing, Fixed Unit Fig. 4.4.2 Mounting Holes, Fixed Unit Document no. 578.650BB Page 17 of 91...
  • Page 18 Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA Transport and Installation 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 Document no.
  • Page 19 Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA Transport and Installation Center of Gravity Fig. 4.4.5 Center of Gravity Fixed units Document no. 578.650BB Page 19 of 91...
  • Page 20 Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA Transport and Installation Fig. 4.4.6 Center of Gravity Horizontal units Document no. 578.650BB Page 20 of 91...

  • Page 21: Connection Of Cables

    Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA Transport and Installation Connection of Cables Standard Remote I/O terminals (refer to section 4.9 for connection of I/O terminals) 50/60 Hz Input terminals: 3 x ¼-20 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)

  • Page 22: Mains Input

    Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA Transport and Installation Mains Input Due to personal health and safety, the Hobart PoWerMaster® 2400 unit must always be protected by grounding the PE terminal ( ). NOTE: The minimum ground wire size is #6 AWG / 16 mm². Consult local authorities to ensure this meets local requirements.

  • Page 23: 400 Hz Interlock

    Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA Transport and Installation 400 Hz Interlock The interlock safety system ensures that the output contactor stays engaged as long as the aircraft connector is inserted into the aircraft receptacle. The aircraft provides 28 VDC on the F terminal with respect to the 400 Hz neutral terminal.
  • Page 24 Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA Transport and Installation • Aircraft Connector temperature supervision (Optional - see section 11). The 3 x PTC resistors in series (one for each phase) are supplied with +24 VDC from the Hobart PoWerMaster®...

  • Page 25: Tcp/Ip On-Board Interface

    Note! Detailed information on the Modbus Communication and available parameters can found in the document 999.008, which can be obtained from ITW GSE on request. Refer to chapter 6.3 and section 7.19 & 7.20 for communication set-up Document no. 578.650BB...

  • Page 26: Technical Specifications

    Operation Manual - PoWerMaster® 2400 – 30 - 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 SAE ARP 5015 Ground equipment –...
  • Page 27 Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA Technical Specifications Output: Power 30, 45, 60 or 90 kVA, cos(ϕ) = 1 Voltage 3 x 200/115 V Power factor 0.7 lagging to 0. 95 leading Voltage regulation < 0.5 % for balanced load and 30 % unbalanced load Voltage transient recovery ∆U <...
  • Page 28 Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA Technical Specifications Miscellaneous: Physical: Dimensions Please refer to outline drawing at following pages Weight Fixed and Bridge-Mount 683 lbs. / 310 kg Mobile 1014 lbs. / 460 kg +220 lbs. / +100kg Environmental: Storage temperature 50°F to 95°F / +10 to +35°C &...
  • Page 29 Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA Technical Specifications Fixed Horizontal Mobile Fig. 5.0.1 Fixed, Bridge-Mounted and Mobile Unit Document no. 578.650BB Page 29 of 91...
  • Page 30 Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA Technical Specifications Fig. 5.0.2 Fixed, Bridge-Mounted and Mobile Unit with base Module / ARU Document no. 578.650BB Page 30 of 91...

  • Page 31: Operator's Instructions (Display/Led/Keypad Layout)

    Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA Operator’s Instructions 6.0 Operator’s Instructions (Display/LED/Keypad layout) Mains On Display ”Blue” LED Navigation Warning keypad ”Yellow” Output 1 Alarm/Failure Start/Stop ”Red” LED (Reset) Output 2 Output 1 On Start/Stop ”Green” LED (Reset) Output 2 On ”Green”...

  • Page 32: Using The Display/Keypad

    Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA Operator’s Instructions Using the Display/Keypad To enable a smooth and easy operation, the operator control panel has a simple layout. The LED display is located at the top. It is used to provide information during operation / service / maintenance. It either shows operational data, warnings or failure information in plain text combined with a time stamp and a 4 digit code which can be used in combination with the manual to show more detailed information on the reported message.

  • Page 33: Operating The Unit

    Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA Operator’s Instructions Operating the unit • 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 not is fully inserted.
  • Page 34 Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA Operator’s Instructions • After operation, the unit has to be turned 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.

  • Page 35: Basic Menu

    Save ”Black Box” / ”Power Log” records or update software * Detailed instructions on the Software Update can be found in the document 699.135 which can be obtained from ITW GSE on request. Document no. 578.650BB Page 35 of 91...

  • Page 36: Parameters - Menu Structure

    Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA Operator’s Instructions 6.3.1 Parameters – Menu structure Document no. 578.650BB Page 36 of 91...
  • Page 37 Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA Operator’s Instructions Standard I/O configuration: Inputs Outputs Function Ref. Function Ref. Function Ref. Function Ref. Start/Reset (1) X1: I1 Stop (2) X2: I10 400 Hz 1 On X1: O1 X3: O9 Running Aircraft Interlock 1...
  • Page 38 Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA Operator’s Instructions Additional I/O port status: ACR configuration: Inputs Outputs Function Ref. Function Ref. Function Ref. Function Ref. Not used X3: O12 400Hz Not used X2: I14 X4: O13 Output 1 On 400Hz X4: I15 X4: O14...
  • Page 39 Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA Operator’s Instructions PIT configuration: Inputs Outputs Function Ref. Function Ref. Function Ref. Function Ref. Not used X3: O12 Not used X2: I14 Not used X4: O13 Pit open X4: I15 Not used X4: O14 Output 1...

  • Page 40: Setup - Menu Structure

    Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA Operator’s Instructions 6.3.2 Setup – Menu structure 11:27:47 Setup Menu 01/01/2017 Output Voltage Settings: 115.0 / 200.0 V 80.0 – 135.0 V (Phase-Neutral) Note: Values above 125 cannot be stored ◄...
  • Page 41 Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA Operator’s Instructions Setup – Menu structure (continued) 11:27:47 Setup Menu 01/01/2017 Fan Control Settings: Normal Normal Boost ◄ Back Modify 11:27:47 Setup Menu 01/01/2017 11:27:47 Setup Menu 01/01/2017 Fan Control Remote Stop Settings: Remote Stop...
  • Page 42 Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA Operator’s Instructions Setup – Menu structure (continued) 11:27:47 Setup Menu 01/01/2017 GPU Enable Settings Active Bypassed Active ◄ Back Modify 11:27:47 Setup Menu 01/01/2017 11:27:47 Setup Menu 01/01/2017 GPU Enable Door Switch Settings: Door Switch...
  • Page 43 Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA Operator’s Instructions Setup – Menu structure (continued) 11:27:47 Setup Menu 01/01/2017 Settings in additional sub-menu: Real Time Clock Setup Month , Day, Year, Hour, Minute, Second ◄ Back Modify 11:27:47 Setup Menu 01/01/2017 11:27:47...
  • Page 44 Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA Operator’s Instructions Setup – Menu structure (continued) 11:27:47 Setup Menu 01/01/2017 6 Characters: <UNDEFINED> A – Z , 0 – 9 , Space - ◄ Back Modify 11:27:47 Setup Menu 01/01/2017 11:27:47 Setup Menu...

  • Page 45: Black Box - Menu Structure

    Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA Operator’s Instructions 6.3.3 Black Box – Menu structure Document no. 578.650BB Page 45 of 91...

  • Page 46: Power Log - Menu Structure

    Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA Operator’s Instructions 6.3.4 Power Log – Menu structure Power Log 001/100 Total Time: 22.0 Minutes Start Date: 01/01/2017 0 – 30 kW Start Time: 10:34 30 – 60 kW Minutes Used: 60 –...

  • Page 47: Update Software / Save Logs - Menu Structure

    Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA Operator’s Instructions 6.3.5 Update Software / Save Logs – Menu structure 10:30:00 USB MENU 01/01/2017 Update in Progress! Please Wait. Swapping Flash Blocks 10:30:00 USB MENU 01/01/2017 10:30:00 USB MENU 01/01/2017 Update in Progress! Update Display Software...
  • 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: Incompatible Software Version

    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.

  • Page 51: Default Factory Settings

    Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA Operator’s Instructions Default Factory Settings Output Voltage (V): 115.0/200.0 Compensation Type: Manual (Plug & Play if GPU supplied with cable) Output 1 Compensation (V): 0.0 (Set if the GPU are supplied with cable) Output 2 Compensation (V): Output Mode: Individual (Depending on configuration)

  • Page 52: Set-Up Lock / Output Mode / Compensation

    Operation Manual – AXA 2400 Compact – 30 - 90 kVA Service, Maintenance, Overhaul 7.0 Set-up Lock / Output Mode / Compensation Preventing changes of set-up parameters To avoid unintentional modification of the Set-up parameters, it is possible to block the access to the Set-up Mode, by means of a DIP switch situated at the Display Board A3.

  • Page 53: Manual Compensation

    Operation Manual – AXA 2400 Compact – 30 - 90 kVA Service, Maintenance, Overhaul 4. Initiate the cable identification process by pressing the ground power unit’s START button. 5. Within a few seconds, the cable parameters are identified and the ground power unit returns to Standby Mode.

  • Page 54: Fan Control

    Operation Manual – AXA 2400 Compact – 30 - 90 kVA Service, Maintenance, Overhaul Note! An aircraft requires an input voltage of 115V ±3V. The unit can only compensate for a maximum voltage drop of 14 V since the highest output voltage is limited to 129 V. When extremely long 400 Hz distribution cables are used, it might be necessary to use parallel output cables to stay within the required aircraft voltage.

  • Page 55: Ef Interlock Ripple Level

    Operation Manual – AXA 2400 Compact – 30 - 90 kVA Service, Maintenance, Overhaul Note! The value will be automatically reset to Active if the unit detects 28 volts on the "F" pin input of the I/O board. 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.

  • Page 56: Gpu Enable

    Operation Manual – AXA 2400 Compact – 30 - 90 kVA Service, Maintenance, Overhaul 7.12 GPU Enable Some airports utilize a key card reader or key lock to keep track of who is using the GPU. This feature prevents the GPU from turning on the output unless the GPU Enable signal is present. The default value is Bypassed.

  • Page 57: Earth Leakage Level

    Operation Manual – AXA 2400 Compact – 30 - 90 kVA Service, Maintenance, Overhaul 7.16 Earth Leakage Level If the output Neutral wire is connected to the chassis ground and the neutral wire breaks while there is an unbalanced aircraft load then an unsafe condition exists. This function monitors the current in the ground wire.

  • Page 58: Ethernet Configuration

    Operation Manual – AXA 2400 Compact – 30 - 90 kVA Service, Maintenance, Overhaul 7.20 Ethernet Configuration This set of submenus 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. Go into the Setup Menu and then scroll up or down to the Ethernet Configuration submenu.

  • Page 59: Costumer Id

    Operation Manual – AXA 2400 Compact – 30 - 90 kVA Service, Maintenance, Overhaul 7.24 Costumer ID This submenu allows the user to assign a name to the unit for reporting purposes when Fault or Power Log files are saved to a USB stick or drive. Go into the Setup Menu and then scroll up or down to the Costumer ID submenu.

  • Page 60: Service, Maintenance, Overhaul

    Operation Manual – AXA 2400 Compact – 30 - 90 kVA Service, Maintenance, Overhaul Service, Maintenance, Overhaul To make certain that the unit is always ready for use it must be maintained on a regular basis. Only qualified personnel should remove covers for service, maintenance or overhaul purposes. Recommended Maintenance Schedule •...

  • Page 61: Battery Back-Up & Replacement

    Operation Manual – AXA 2400 Compact – 30 - 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. are not lost during mains drop-outs. The expected life of the battery is approximately 7 years.
  • Page 62 If the blue LED on the Control Board (location can be found on the Fig. 8.1.1) 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.

  • Page 63: Trouble Shooting & Repair

    Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA Trouble Shooting & Repair 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 64: Fault Guidance

    Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA Trouble Shooting & Repair 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:...
  • Page 65 2nd. Corrective action 3rd. Corrective action 4th. Corrective action Replace Control Board A1 Verify ID Chip inserted Contact ITW GSE 300 - 301 Check input voltage Check Q4 & G1 Check wires attached to X1 (X2 /X3) Check emergency stop...
  • Page 66 Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA Trouble Shooting & Repair Continued from previous page Error code 2nd. Corrective action 3rd. Corrective action 4th. Corrective action 1501 Check fuse F5 Set fans to ”Boost” and check voltage Check dust filters Between + &...
  • Page 67 Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA Trouble Shooting & Repair Continued from previous page Error code 2nd. Corrective action 3rd. Corrective action 4th. Corrective action 7000 Check output voltage setup value Check ARU Module and wiring 7100 Check output voltage setup value Check ARU Module and wiring...

  • Page 68: Illustrated Parts List

    Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA Illustrated Parts List 10.0 Illustrated Parts List Please contact technicalsupport@itwgse.us for recommended list of spare parts, diagrams and drawings. Inverter Module A1: Control Board Q4: Circuit Breaker A2: Interface Board Q1: Input Disconnector G1: 24 VDC Supply X2: I/O Terminals...
  • Page 69 Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA Illustrated Parts List C7-C9: Output Capacitors M1 – M2: Fans T1: 12 Pulse Transformer L1: Input Choke T2: 400Hz Transformer Figure 10.0.2 Rear View Document no. 578.650BB Page 69 of 91...
  • Page 70 Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA Illustrated Parts List Inverter Module Air intake grills Q4: Circuit Breaker C7-C9: Output Capacitors M1 – M2: Fans A5: Capacitor Board T1: 12 Puls Transformer Q2: Output Contactor L1: Input Choke G1: 24 VDC Supply Q1: Input Disconnector X2: I/O Terminals...

  • Page 71: Options

    Operation Manual – AXA 2400 Compact – 30 - 90 kVA Options 11.0 Options 578803 Base module Additional base module, which extends the height /length of the ground power unit by 340 mm and the weight by 20 kg/51 lbs. (Refer to drawings section 5) 578804 Lockable Door (Fixed) As a standard, the GPU is supplied with a quarter-turn lock...

  • Page 72: 5788Xx Remote Control Boxes Available

    Operation Manual – AXA 2400 Compact – 30 - 90 kVA Options 5788xx Remote Control Boxes available 578806 1 x 400 Hz Output 578818 2 x 400 Hz Output 578819 1 x 400 Hz & 1 x 28 VDC Output 578820 1 x 400 Hz Output &...

  • Page 73: Additional Output Contactor (Diagram 478801)

    Operation Manual – AXA 2400 Compact – 30 - 90 kVA Options 578807 Additional Output Contactor (Diagram 478801) All units are equipped with one output contactor. All models are, however, prepared for an additional output contactor and I/O terminal block X2. Please refer to section 7.0 for Output Mode / Compensation possibilities.

  • Page 74: Door Interlock (Diagram 478801)

    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: Document no. 578.650BB Page 74 of 91...

  • Page 75: 578814 Terminal Extension

    Operation Manual – AXA 2400 Compact – 30 - 90 kVA Options 1) The need for an additional control wire which is likely to be the first to break. 2) The difficulties of implementing the method in existing installations if a free control wire is not present.

  • Page 76: 578817 Military Interlock (Diagram 478801)

    Operation Manual – AXA 2400 Compact – 30 - 90 kVA Options 578817 Military Interlock (Diagram 478801) For military aircraft, the interlock 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.

  • Page 77: 578829 Anti-Condensation Heater (Diagram 478801)

    Operation Manual – AXA 2400 Compact – 30 - 90 kVA Options 578829 Anti-Condensation Heater (Diagram 478801) In areas with high relative humidity, temperature drops cause formation of dew inside the enclosure of the GPU. On a long-term basis this can affect components such as relays, switchgears and printed circuit boards (PCBs).

  • Page 78: For Gpus With 28 Vdc Active Rectifier Unit

    Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA For GPUs with 28 VDC Active Rectifier Unit 12.0 For GPUs with 28 VDC Active Rectifier Unit All Hobart PoWerMaster® 2400 units from 30 kVA to 90 kVA can be equipped with a 28 VDC Active Rectifier Unit (ARU) output.
  • Page 79 Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA For GPUs with 28 VDC Active Rectifier Unit Input Contactor (Q3): The 400 Hz input power to the ARU is supplied and controlled via Q3. Power Supply (G20): 24 VDC / 10 A (Factory adjustment = 25 Volt) regulated control voltage is supplied from the Power Supply G20.

  • Page 80: Connection Of Cables

    Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA For GPUs with 28 VDC Active Rectifier Unit 12.2 Connection of Cables Standard Remote I/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 mm²...

  • Page 81: Interlock

    Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA For GPUs with 28 VDC Active Rectifier Unit 12.3 Interlock To ensure personnel health and safety, the converter is equipped with an interlock system. The system ensures that the output only stays engaged as long as the plug is inserted into the aircraft receptacle. I.e. as long as 28 VDC is present at terminal X2:F.

  • Page 82: Operator's Instruction

    Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA For GPUs with 28 VDC Active Rectifier Unit 12.4 Operator’s Instruction The 28 VDC ARU is operated by means of the Display / Keyboard Interface. Please refer to section 6.0 (Operators Instructions) and 6.1 (Using the Display/Keypad). 12.5 Operating the unit •...
  • 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 Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA For GPUs with 28 VDC Active Rectifier Unit • After operation, the unit has to be turned off before removing the aircraft plug. Press the 28 VDC Start/Stop button • The aircraft cable can now be removed 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.

  • Page 85: Additional Menu Items For Aru

    Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA For GPUs with 28 VDC Active Rectifier Unit 12.6 Additional menu items for ARU Setup – ARU additional parameters 11:27:47 Setup Menu 01/01/2017 28 V Voltage Settings: 28.0 V 19.0 – 33.0 V ◄...

  • Page 86: Aru Default Factory Settings

    Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA For GPUs with 28 VDC Active Rectifier Unit 12.7 ARU Default Factory Settings: 28 V Voltage (V): 28.0 28 V Compensation (V/600 A): 0.0 (Set if GPU is supplied with cable) 28 V Current Limit (A): 1000 /1500 (400A / 600 A) Output Mode:...

  • Page 87: Specifications

    Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA For GPUs with 28 VDC Active Rectifier Unit 13.0 Specifications Output: Voltage : 28 VDC Current : 600 A continuously Voltage regulation : < 0.5% Voltage ripple : < 2% Voltage transient recovery : Complies with ISO 6858 / MIL-704E Overload capability...

  • Page 88: Trouble Shooting & Repair

    Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA For GPUs with 28 VDC Active Rectifier Unit 14.0 Trouble Shooting & Repair Please refer to section 9.1 for Fault Guidance Additional 28 VDC ARU related failures: 6102 Cable 2 temperature too high 6302 EF signal drop out –...

  • Page 89: Aru Illustrated Parts List

    Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA For GPUs with 28 VDC Active Rectifier Unit 15.0 ARU illustrated parts list X2: I/O Terminals (28 VDC) X1: I/O Terminals Q3: Output 2 (400 Hz) G20: 24 VDC Supply ARU Module Output Terminals Figure: 15.0.1 Front View (complete unit)
  • Page 90 Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA For GPUs with 28 VDC Active Rectifier Unit A20: ARU Board PM20: Rectifier Module Output terminals (- & +) Air intake Grill Figure 15.0.2 Front View (ARU) 6 x ARU Transformer Air intake Grill Figure 15.0.3 Rear View (ARU)
  • Page 91 Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA For GPUs with 28 VDC Active Rectifier Unit Output terminals (+& -) C20: Output Capacitors ARU Module R20: Discharge Resistor Heat Sink M20: Fan 6 x ARU Transformer T20: Current Sensor Figure 15.0.4 Top View (ARU) Document no.

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