Related Manuals for ITW GSE 7400 JetEx
Summary of Contents for ITW GSE 7400 JetEx
- Page 1 Original User Manual ITW GSE 7400 JetEx Battery Powered (Single Leaf Battery Pack) 28VDC Ground Power Unit Serial No. Type 3GWB-28/40I Document No. 543500EB Page 1 of 77...
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Page 2: Important Note
IMPORTANT NOTE Only qualified personnel may carry out Service/Troubleshooting/Maintenance/Repair of the ITW GSE 7400 JetEx GPU. Refer to ITW GSE’s website https://itwgse.com/ contact ITW GSE for further information. IMPORTANT NOTE We recommend that the control board battery that stores the GPU settings etc. -
Page 3: About This User Manual
This manual provides information about the ITW GSE 7400 JetEx Ground Power Unit. The manual covers the range of the 7400 JetEx series and options described in section 11. If you have any questions regarding this manual please contact your local agent, or contact details can be found at www.itwgse.com... -
Page 4: Abbreviations
Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU Abbreviations Abbreviations Advanced Cable Retriever Active Rectifier Unit American Wire Gauge Building Management System Controller Area Network Dual In-Line Package Digital Signal Processor Earth Leakage Supervision Electromagnetic Compatibility Electromagnetic Interference... -
Page 5: Pictograms Used In Manual
Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU Pictograms and Unit Types Pictograms used in manual General warning sign Electricity hazard Crushing of hands Hot surface Battery Electrostatic sensitive devices Overview of Types and Ratings Type Rating Capacity... -
Page 6: Table Of Contents
Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU Table of Contents Table of Contents About this User Manual ..............................3 Manufacturer and Contact Details ............................ 3 Abbreviations ..................................4 Pictograms used in Manual .............................. 5 Overview of Types and Ratings ............................5 Declaration of Conformity ............................ - Page 7 Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU Table of Contents Setup Lock / Output Mode / Compensation ......................53 Preventing Changes to Setup Parameters ....................53 28V Voltage ............................. 54 28V Compensation ..........................54 Current Limit Step Size ..........................54 28V EF Interlock ............................
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Page 8: Declaration Of Conformity
Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU Declaration of Conformity Declaration of Conformity Document No. 543500EB Page 8 of 77... -
Page 9: Important Safeguards
Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU General Description IMPORTANT SAFEGUARDS DANGER: TO REDUCE THE RISK OF FIRE OR ELECTRIC SHOCK, FOLLOW THESE INSTRUCTIONS CAREFULLY Safety Instructions This unit is only intended to be installed, operated and maintained by qualified persons having the necessary knowledge regarding delivery of external power to an aircraft. -
Page 10: General Description
General Description General Description The ITW GSE 7400 JetEx is a compact Ground Power Unit that produces 28VDC for use in powering aircraft while they are on the ground. The output is powered by an internal rechargeable 40kWh battery pack. To create the regulated 28VDC that is required for the aircraft, a DC to DC converter lowers the nominal 400VDC of the battery to the specified power rating. - Page 11 On-board battery packs that are sealed must not be opened and are maintenance free. • Only use the same type of Leaf Batteries, and only ITW GSE or service engineers appointed by ITW GSE are allowed to change the batteries.
- Page 12 Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU General Description Battery Charger MCB (Q11): The charger input is protected by the MCB. Battery Pack (B1): The battery pack has a nominal voltage of 400 VDC and a capacity of 40 kWh. For intercommunication and supervision, an internal BMS system monitors the battery.
- Page 13 Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU General Description Interface Board / VFD (A2): Interfaces between the control board and the rest of the ground power unit. The interface module / VFD includes the following functions: •...
- Page 14 Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU General Description • Fan Control (X26) • 24 VDC supply & EPO to Comm. Boards (X27) • CANBUS to Comm. Boards (X28) AUX Board (A5): An additional interface board, with inputs for door sensors, beacons, siren, power supplies, control voltage batteries and more.
- Page 15 Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU General Description Communication Board (A12): Used to interface between the control board and the battery pack/battery charger via the CAN bus. The communication board includes the following functions: • CAN bus (X1) •...
- Page 16 Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU General Description Supply Module 10 A (G10): Charges internal batteries G8 & G9 when mains/utility power is connected (factory-set to 28 V). This module has a wide input range. It is supplied directly from the input connector and pre-fused via the two-phase circuit breaker Q4.
- Page 17 Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU General Description Control Board (A1): The control board is based on a microcontroller. Regulate, supervise, and diagnose possible external and internal faults as soon as the ground power unit is connected to the mains/utility power, and constantly during normal operation.
- Page 18 Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU General Description ID Chip (A6): The ID chip is connected to interface board A2 (X14) and is fixed behind the board. It contains information on the GPU configuration and stores all setup values, black box and power log records.
- Page 19 Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU General Description is producing 28VDC or connected to the input grid. The warning/low battery beacon will flash when the Leaf Battery is below the minimum SoC to start parameter, when smoke is detected and when the EPO is activated.
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Page 20: Built-In Features And Protections
Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU General Description Built-In Features/Protections Over/Under DC Battery Voltage: The DC voltage supervision monitors the battery’s DC voltage. If the total battery DC level goes too low or too high, the unit trips to protect the battery pack and itself. -
Page 21: Transportation And Installation
These materials can be recycled and must be disposed according to the applicable laws and regulations in each country. All wood used in the packaging of the ITW GSE 7400 are in compliance with ISPM-15 and is not subjected to any chemical conservation treatment. -
Page 22: Transportation
Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU Transportation and Installation Transportation Tie Down/Strapping Lifting Point Lifting Point Fig. 4.5.1 Lifting points for Forklift, Truck, or Similar. Tie Down location DO NOT strap over top of the unit for transportation Document No. -
Page 23: Preparation Before Use
Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU Transportation and Installation Preparation before use Before the ITW GSE 7400 can be released for operation, the unit must be prepared. Open the Charger Zone side door and remove the Manual, located near the AGM batteries. -
Page 24: Connection Of Output Cable
Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU Transportation and Installation Connection of Output Cable Before connecting any cables to either the input or output, ensure that the ITW GSE 7400 is switched off. Follow the Lockout/Tagout procedure in section 8.1 before performing ANY internal connections. -
Page 25: Mains/Utility Input
Follow the Lockout/Tagout procedure in section 8.1 before performing ANY internal connections. For reasons of personal health and safety, the ITW GSE 7400 unit must always be protected by grounding the PE terminal ( ) during charging. NOTE: The minimum ground wire size is 16 mm² / #6 AWG. Consult local authorities to ensure this meets local requirements. - Page 26 Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU Transportation and Installation Regardless of installation method, local regulations and legislation must be followed to ensure personal health and safety. Fig. 4.7.2 Input (Charger) cable connections 3 x M8 (3x ¼-20 by 1”) 6 Nm (53.1 in-lb.) (L1, L2, L3)
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Page 27: 28Vdc Interlock
Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU Transportation and Installation 4.10 28VDC Interlock The interlock safety system ensures that the output contactor stays engaged for as long as the aircraft connector is inserted into the aircraft receptacle. The 7400 connector provides 28 VDC back to itself on the F terminal. - Page 28 Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU Transportation and Installation In the following section, the different kinds of data available are: • System in use, system on standby, and system fault. • The GPU provides a comprehensive range of internal and external parameter measurements and information, e.g.
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Page 29: Technical Specifications And Warranty
Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU Technical Specifications & Warranty Technical Specifications & Warranty Technical specifications and information Standards: Aircraft ground support electrical supplies – general requirements ISO 6858:2017(E) BS 2G 219 General requirements for ground support electrical supplies for aircraft Ground equipment –... -
Page 30: Technical Specifications & Warranty
Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU Technical Specifications & Warranty 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 Output Current 600A –... - Page 31 Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU Technical Specifications & Warranty Physical: Dimensions (LxWxH) 1978 x 1226 x 1201 mm / 77.9 x 48.3 x 47.3 inches Weight: 740 kg/1630 Lbs Document No. 543500EB Page 31 of 77...
- Page 32 Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU Technical Specifications & Warranty Environmental: Storage Temperature +10°C to +35°C / 50°F to 95°F & 20 to 70% RH Operating temperature -10°C to +45°C / 14°F to 113°F Relative humidity...
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Page 33: 7400 Battery Warranty Conditions
Technical Specifications & Warranty 7400 Battery Warranty Conditions The ITW GSE 7400 battery is warranted for 5 years against capacity loss below 72% of a new battery. The Lithium-ion batteries are designed to operate in avg. temperatures of 0°C (32F) to 35°C (95F). -
Page 34: Operator's Instructions (Display/Led/Keypad Layout)
Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU Operator’s Instructions Operator’s Instructions (Display/LED/Keypad Layout) 1 x 28 VDC output 7: Output ON (28VDC) “Green” LED 1: LED Graphic Display 2: Navigation Keypad 8: Output (28VDC) ON/OFF 3: Power ON “Blue” LED 9: Charger “Green”... -
Page 35: Operator's Instructions
Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU Operator’s Instructions Using the Display/Keypad To enable smooth and easy operation, the operator control panel has a simple layout. The LED display is located at the top and provides information during operation, service, and maintenance. Depending on... -
Page 36: Charging The Unit
Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU Operator’s Instructions Charging the Unit Connect the 50/60 Hz inlet plug to an appropriate mains/utility outlet. Depending on the configuration of the inlet charging cable and plug, it is possible to connect to a 32 A or less outlet*. -
Page 37: Operating The Unit
Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU Operator’s Instructions Operating the Unit • Press the On/Off button to power up the GPU if it is not already under power. • Insert the aircraft cable/plug into the aircraft. Make sure the plug is fully inserted until you feel a natural resistance. - Page 38 Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU Operator’s Instructions Default Display Screen, Operating 28.5 V 153 A 28 V 28 VDC Voltage 28.5 V Output Activated Current: 153 A Power 4.4 kW ≈ 230 Min. ◄ Back ▼/▲ Next/Prev...
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Page 39: Basic Menu
Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU Operator’s Instructions Basic Menu The basic icon menu is shown above with the available submenus. To enter the icon menu, press the ● from the default menu and hold it down for approximately 10 seconds. -
Page 40: Parameters - Menu Structure
Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU Operator’s Instructions 6.4.1 Parameters – Menu Structure 28 V Voltage 28.5 V Current: 153 A Power 4.4 kW ◄ Back ▼/▲ Next/Prev BATTERY SYSTEM Voltage: 407 V Current: 11 A State of Charge: 96.2 %... -
Page 41: Setup - Menu Structure
Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU Operator’s Instructions 6.4.2 Setup – Menu Structure 11:27:47 Setup Menu 24/09/2018 28V Voltage Settings: 28.0 19.0 – 33.0 V ◄ Back ● Modify 11:27:47 Setup Menu 24/09/2018 11:27:47 Setup Menu... - Page 42 Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU Operator’s Instructions Document No. 543500EB Page 42 of 77...
- Page 43 Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU Operator’s Instructions Setup – Menu Structure (Continued) 11:27:47 Setup Menu 24/09/2018 Settings Modbus Slave Address 1 - 247 ◄ Back ● Modify 11:27:47 Setup Menu 24/09/2018 11:27:47 Setup Menu 24/09/2018...
- Page 44 Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU Operator’s Instructions Setup – Menu Structure (Continued) 11:27:47 Setup Menu 24/09/2018 Confirm Battery Replaced Settings: ◄ Back ● Modify 11:27:47 Setup Menu 24/09/2018 11:27:47 Setup Menu 24/09/2018 Control Board Battery Replaced...
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Page 45: Black Box - Menu Structure
Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU Operator’s Instructions 6.4.3 Black Box – Menu Structure 14:54:33 24/09/2018 7400 OVERLOAD: I > 600 A – 60 s ● Alarm Data 001/100 28 V Voltage: 28.5 V Current: 153 A... -
Page 46: Power Log - Menu Structure
Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU Operator’s Instructions 6.4.4 Power Log – Menu Structure Power Log 001/100 Total Time: 22.0 Minutes 0 – 6.7 kW Start Date: 24/09/2018 6.7 – 11.4 kW Start Time: 10:34 11.4 – 17.1 kW... -
Page 47: Update Software / Save Logs / Load Config File
Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU Operator’s Instructions 6.4.5 Update Software / Save Logs – Menu structure 10:30:00 USB MENU 24/09/2018 Update in Progress! Please Wait. Swapping Flash Blocks 10:30:00 USB MENU 24/09/2018 10:30:00 USB MENU... - Page 48 Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU Operator’s Instructions Update Software/Save Logs – Menu structure (Continued) 10:30:00 USB MENU 24/09/2018 Update in Progress! Do not turn off or reset during update! 10:30:00 USB MENU 24/09/2018 10:30:00 USB MENU...
- Page 49 Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU Operator’s Instructions Update Software/Save Logs – Menu Structure (Continued) 10:30:00 USB MENU 24/09/2018 Saving log 10:30:00 USB MENU 24/09/2018 10:30:00 USB MENU 24/09/2018 Update Display Software Saving log Update Control Card Software...
- Page 50 Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU Operator’s Instructions Update Software/Save Logs/Load Config File (Continued) 10:30:00 USB MENU 24/09/2018 Reading Flash Drive. Please Wait Press ● To Reset 10:30:00 USB MENU 24/09/2018 10:30:00 USB MENU 24/09/2018 Update Display Software Configuration complete.
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Page 51: Incompatible Software Version
Software Version” will be displayed. Before changing software versions, consult ITW GSE. Alternatively, if you intend to proceed because you have already contacted or received the software files from ITW GSE, use the guidelines below to update the software: 1. Press ▼and▲ simultaneously for 5 seconds. The software will start automatically and will be updated. -
Page 52: Default Factory Settings
Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU Operator’s Instructions Default Factory Settings 28V Voltage (VDC): 28.0 28V Compensation (V): 0.0 (Set if GPU supplied with cable) Current Limit Step Size (A): 28V EF Interlock: Bypassed (active if GPU supplied with split “C” cable) -
Page 53: Setup Lock / Output Mode / Compensation
Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU Setup Lock / Output Mode / Compensation Setup Lock/Output Mode/Compensation Preventing Changes to Setup Parameters To avoid unintentional modification of the setup parameters, it is possible to block access to setup mode by means of the set-up menu. -
Page 54: Voltage
Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU Setup Lock / Output Mode / Compensation 28V Voltage This setup submenu allows the output voltage to be adjusted between 19.0 VAC and 33.0 VAC using the up and down navigation buttons. -
Page 55: Gpu Enable
This set of submenus allows the user to adjust the Maximum Grid current, depending on the current available for charging the ITW GSE 7400 GPU and the installed charger cable/plug. Enter the Setup menu, and then scroll up or down to the Max Grid Current submenu. Press the center ●... -
Page 56: Ethernet Configuration
Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU Setup Lock / Output Mode / Compensation 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. -
Page 57: Reset Service Interval
Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU Setup Lock / Output Mode / Compensation character. Press the center ● button to record the new value. Press the left arrow button to exit the submenu and return to the submenu list. -
Page 58: Service, Maintenance, Overhaul
Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU Service, Maintenance, Overhaul Service, Maintenance, Overhaul To ensure the unit is always ready for use, it must be maintained on a regular basis. Only certified personnel should remove covers for service, maintenance or overhaul purposes. -
Page 59: Recommended Maintenance Schedule
Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU Service, Maintenance, Overhaul 8.2 Recommended Maintenance Schedule 8.2.1 Daily / upon use Maintenance Instruction for ITW GSE 7400 Daily / upon use This inspection does not in any way suspend local / airport rules and regulations Visual check of aircraft connector(s). -
Page 60: Quarterly
A USB can be used to download the parameters and then be viewed on a computer. Downloading parameters please refer to section 6.4.5 Parameters downloaded can be viewed in ITW GSE Service Tool, which can be obtained from ITW GSE Web-Page or sent to you on request. -
Page 61: Yearly
Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU Service, Maintenance, Overhaul 8.2.4 Yearly Maintenance Instruction for ITW GSE 7400 Yearly This inspection does not in any way suspend local / airport rules and regulations Check aircraft connector(s). Check: Connector housing for damage / cracks and wear &... - Page 62 Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU Service, Maintenance, Overhaul Check all fans Check that Cooling fans are running properly Check rubber seals Check that all rubber seals are intact around the top panel, side doors. Check bolts / screws / wires Check internal bolts/screws and wire connections Visual inspection of PCB’s...
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Page 63: Battery Backup And Replacement
Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU Service, Maintenance, Overhaul Battery Backup & Replacement Situated on the back of the control board is a coin-type lithium battery, which ensures that firmware, setup data, etc. are not lost during grid power dropouts. The expected life of the battery is approximately 7 years. -
Page 64: How To Replace The Battery
Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU Service, Maintenance, Overhaul To ensure a high level of reliability of the backup battery, the only battery type that can be used on the control board is the Panasonic BR-2032. - Page 65 If the blue LED on the control board (located in Fig. 8.3.3) flashes approximately twice 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. Document No. 543500EB...
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Page 66: Troubleshooting And Repair
Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU Troubleshooting & Repair Troubleshooting & Repair Allow only Safety-Certified personnel to remove covers for troubleshooting and repair. Please be aware that the DC capacitors can remain charged with a dangerous voltage up to 10 minutes after the battery power has been disconnected. - Page 67 Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU Troubleshooting & Repair The following fuses are located on the Communication Board A12: Fuse # Applies to Type Rated Voltage Amp Rating Charger - Ignition ATO Blade Fuse 32 V...
- Page 68 Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU Troubleshooting & Repair The following fuses are located on the AUX Board A5: Fuse # Applies to Type Rated Voltage Amp Rating 24 V Supply ATO Blade Fuse 32 V...
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Page 69: Fault Guidance / Error Codes
Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU Troubleshooting & Repair Fault Guidance / Error Codes If you need to contact us for further fault guidelines, please do not forget to enter the serial number of the GPU (found on the rating plate) and the actual error code on the fault-finding form that can be downloaded from www.itwgse.com... - Page 70 Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU Troubleshooting & Repair Error Code Second Corrective Action Third Corrective Action Fourth Corrective Action Replace control board A1 Contact ITW GSE Contact ITW GSE Contact ITW GSE Contact ITW GSE Check input voltage at S10 Check Q4 &...
- Page 71 Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU Troubleshooting & Repair Communication Board error/warning codes All codes from 10…60 may be added 256,512 and 1024 Code Watchdog Reset Watchdog was triggered Watchdog Init Could not successfully initialize watchdog Init Comm.
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Page 72: Illustrated Parts List
Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU Illustrated Parts List Illustrated Parts List 10.0 Please refer to www.itwgse.com for a recommended list of spare parts. Diagrams and drawings of the unit can also be found on this website. - Page 73 Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU Illustrated Parts List Charger Input Receptacle (Gland) G10, G11: Power Supplies Q4, Q5: Switches A12: Communication Board F1: Fuse G8, G9: Batteries Q12: Relay Q3: Switch B1: Battery Terminals PE: Ground Terminal...
- Page 74 Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU Illustrated Parts List A3: Display Board A2: Interface Board A1: Control (Daughter) Board Output Terminals GPS TrackUnit Output Gland Plate Fig. 10.1.3 Electrical Cubicle (Controls/Output Section) Document No. 543500EB Page 74 of 77...
- Page 75 Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU Illustrated Parts List Air Filter Smoke Detector Output Filter T1: Output Transformer V1-V6: Output Rectifier M1, M2 Cooling Fans S1: Emergency Stop (Front Panel) A4: Operator Keypad (Front Panel) Fig. 10.1.4 Electrical Cubicle (Center Section) Document No.
- Page 76 Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU Illustrated Parts List Fig. 10.1.5 Bottom View Document No. 543500EB Page 76 of 77...
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Page 77: Options
Operation Manual – ITW GSE 7400 JetEx Battery Powered GPU Illustrated Parts List 11.0 Options 543510 / AP-543510 Remote Display (Diagram 443501) Changes the display to a remote version for installation farther away from the unit. There can only be one display connected to the unit at a time so the display in the electronics zone is removed and the holes sealed.
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