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ITW GSE 7400 Original User Manual

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Original User Manual
ITW GSE 7400 (Mark II)
90 kVA
Battery Powered
(3 or 4 Leaf Battery Packs)
400 Hz Ground Power Unit
+ 28 VDC outlet (optional)
+ Range Extender (optional)
Type:
3GWB - 90/
www.itwgse.com

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Summary of Contents for ITW GSE 7400

  • Page 1 Original User Manual ITW GSE 7400 (Mark II) 90 kVA Battery Powered (3 or 4 Leaf Battery Packs) 400 Hz Ground Power Unit + 28 VDC outlet (optional) + Range Extender (optional) Type: 3GWB - 90/ www.itwgse.com...

  • Page 2: Important Note

    IMPORTANT NOTE Only qualified personnel may carry out Service/Troubleshooting/Maintenance/Repair of the ITW GSE 7400 GPU. Refer to ITW GSE’s website https://itwgse.com/ contact ITW GSE for further information. IMPORTANT NOTE We recommend that the battery that stores the GPU settings etc.is changed after 5 years of use in order to prevent data loss (only applicable for the coin cell battery type).

  • Page 3: About This User Manual

    This manual provides information about the ITW GSE 7400 Ground Power Unit. The manual covers the range of the 7400 - 90 kVA 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 Battery Powered GPU 90 kVA Abbreviations Advanced Cable Retriever Active Rectifier Unit American Wire Gauge Building Management System Controller Area Network Diagnostic Trouble Code Dual In-Line Package Digital Signal Processor Engine Control Module Electronic Fuel Injection...

  • Page 5: Pictograms Used In Manual

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA 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 Number Part Schematic...

  • Page 6: Table Of Contents

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Contents 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 Battery Powered GPU 90 kVA Contents Technical Specifications & Warranty ................ 48 Technical specifications and information ............48 7400 Battery Warranty Conditions ..............51 Operator’s Instructions (Display / LED / Keypad Layout) ........52 Using the Display / Keypad ................
  • Page 8 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Contents 7.12 Earth Leakage Level ..................88 7.13 Earth Leakage Delay ..................88 7.14 Minimum SoC (State of Charge) to Start ............88 7.15 Max Grid Current ..................... 88 7.16...
  • Page 9 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Contents Troubleshooting & Repair ..................117 PCB Fuses & Battery Fuses ................117 Fault Guidance / Error Codes ................ 121 10.0 Illustrated Parts List ....................126 10.1 Component placement ................... 126 10.2...
  • Page 10 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Contents 12.6 Additional menu items for ARU ..............163 12.7 ARU Default Factory Settings ................ 165 12.8 28V Voltage ....................165 12.9 28V Compensation ..................165 12.10 Current Limit Step Size .................. 165 13.0...
  • Page 11 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Contents 20.0 Range Extender illustrated parts list ............... 190 20.1 Component placement ................... 190 20.2 Placement of labels - Range Extender ............195 Document No. 575.410DB Page 11 of 195...

  • Page 12: Declaration Of Conformity

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Declaration of Conformity Declaration of Conformity Document No. 575.410DB Page 12 of 195...

  • Page 13: Safety Instructions

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Safety Instructions 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 14 On-board main 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 15: General Description / Boards And Modules / Programing

    Battery Packs (B1, B2, B3, B4): The ITW GSE 7400 consists of up to four battery packs. The battery pack voltage is 400 VDC nominal, and the capacity of each pack is 40 kWh. For intercommunication and supervision of each battery, an internal BMS system monitors the batteries.
  • Page 16 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA General Description Control Voltage Charger (G10, G8 & G9, Q6): When connected to the 50/60 Hz supply, charger G10 charges batteries G8 and G9. This battery voltage is used as internal control voltage. The control voltage for the internal supply is fed through control voltage battery MCB Q6.
  • Page 17 400 Hz GPU to this input if it turns out that the turnaround time is longer than expected and the unit may run out of power. This enables the already attached ITW GSE 7400 connected to the aircraft to pass through the added 400 Hz power via the first GPU. Automatically switching off the first GPU and applying the second GPU to the output.
  • Page 18 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA General Description  Grid Current input from T4 (X14)  Connection to ARU (X15)  ARU inputs (X16)  24 VDC supply & EPO to Comm. Boards (X17) ...
  • Page 19 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA General Description AUX Board (A5): This board is an additional interface board, which contains inputs for door sensors, beacons, siren, power supplies, control voltage batteries and more. The AUX board includes the following functions: ...
  • Page 20 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA General Description Communication Boards 579558 (A12, A22, A32, A42): This board is used to interface between the control board and the battery packs / battery chargers via the CAN bus. The communication board includes the following functions: ...
  • Page 21 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA General Description Supply Module 10 A (G10): Charges internal batteries G8 & G9 when mains / utility power is connected. Power supply is from factory set to 28.3 V.
  • Page 22 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA 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 23 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA General Description ID Chip (A6): The ID chip is connected to interface board A2 (X25) and is fixed to the I/O zone plate. It contains information on the GPU configuration and stores all setup values, black box and power log records.

  • Page 24: Control Board And Display Boards (Standard & Alternative)

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA General Description Control Board and Display Boards (Standard & Alternative) The unit may be equipped with standard or alternative types of Control Boards and Display Boards. These boards can be used in any combination.
  • Page 25 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA General Description Please be aware that Control Board and Display Board can or may be occurring in any combination, this will have impact on the software that has to be loaded on the boards.

  • Page 26: Communication Boards (Standard & Alternative)

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA General Description Communication Boards (Standard & Alternative) The unit may be equipped with standard or alternative type of Communication Boards (AURIX circuit removed). All communication Boards need to be same type.

  • Page 27: Battery Guard

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA General Description Battery Guard Battery Guard (Q17): Battery Guard is inside the compartment where the AUX batteries G8 / G9 also are located. If one of the two Power Supplies (G10 / G11) is active, the Battery Guard is by-passed, as one of those (Power Supplies) then charges the batteries.

  • Page 28: Indication Beacons

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA General Description Indication Beacons Unit Operation / Charging (H1) & Warning / Low Battery (H2): Various beacons/labels may be located on top of the canopy of the unit. Siren (S5) Picture shows standard color configuration.

  • Page 29: Siren Tones / Pattern Programing

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA General Description Siren Tones / Pattern programing The tone may be altered, if other tones / pattern are preferred. Please refer to Section 11.0 for beacons colors. Please refer to Sections 6.5 and 7.14 for Minimum SoC to Start.

  • Page 30: Built-In Features / Protections

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA General Description Built-In Features / Protections No-Break Power Transfer: The unit is protected against phase angle misalignment during no-break power transfer. Over/Under DC Voltage: The DC voltage supervision monitors the battery’s DC voltage. The supervision ensures that the unit does not trip if one of the battery packs has low voltage, as the unit will automatically disconnect the battery pack.
  • Page 31 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA General Description Neutral Voltage Supervision (NVS): As standard, the unit is delivered with a jumper wire between the 400 Hz neutral and earth / ground. If the jumper wire is removed for any reason (e.g. local regulation), the unit monitors the voltage between the 400 Hz neutral and earth / ground.

  • Page 32: 50/60 Hz & 400 Hz Tow Bar Interlock

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA General Description 3.10 50/60 Hz & 400 Hz Tow Bar Interlock The unit is manufactured as standard with a 50/60 Hz & 400 Hz tow bar interlock feature that automatically lights / flashes a warning light (depending on customer’s configuration).

  • Page 33: 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 34: Preparation Before Transportation

    90 kVA Transportation and Installation Preparation before transportation Before the ITW GSE 7400 is ready for transport, the unit must be prepared. (1) MCB Q6 Fig. 4.5.1 Breaker Q6 1. Switch “OFF” the breaker Q6 by moving the operating lever down (Circle 1).

  • Page 35: Transportation

    Do not lift by crane The four tie-down rings shown in the can be used to fasten the ITW GSE 7400 during transport. The rings have been designed to be drawn in the direction of the ring, approx. 30° downwards.
  • Page 36 Transportation and Installation Please observe that a forklift with a minimum of 4000 kg capacity is required. LC (Load Centre) is 950 mm, which is half the width of the ITW GSE 7400 and equivalent to the center of gravity.
  • Page 37 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Transportation and Installation Fig. 4.6.3b Centre of Gravity / Dimensions (Paillard trailer) Document No. 575.410DB Page 37 of 195...
  • Page 38 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Transportation and Installation Steering wheel angle is more than ± 90° from neutral to allow a minimum turning radius of 2.1 m. 5.2 meters between curbs is required to turn.
  • Page 39 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Transportation and Installation Steering wheel angle is more than ± 90° from neutral to allow a minimum turning radius of 2.2 m. 5.3 meters between curbs is required to turn.
  • Page 40 The mobile unit version is equipped with a front wheel parking brake, which can be adjusted to tolerate parking on a slope of at least 7 degrees. The ITW GSE 7400 eGPU tow bar braking system is designed around the guidelines specified in the Airport Handling Manual (AHM 916 ‘Basic Requirement for Towing Vehicle Interface’).
  • Page 41 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Transportation and Installation Fig. 4.6.5b Braking areas (Paillard trailer) Darker colors indicate increased brake activation. When the tow bar is locked in the vertical ‘Parking’ position (1) the brake is fully engaged. Between position (2) and (3) the brake is not engaged and the wheels can run freely.

  • Page 42: Preparation Before Use

    Note The ITW GSE 7400 will automatically go into sleep mode if not used for 15 minutes. Front Canopy may be equipped with side locks, they will not influence the opening of the Canopy, but remember to lock those as well, when locking the two locks on front.

  • Page 43: Connection Of Cables

    90 kVA Transportation and Installation Connection of Cables Before connecting any cables to either the input or output, ensure that the ITW GSE 7400 is switched off. Switch OFF breakers (Q3 shipped in ON position) in the following sequence: 1. Switch off the “Control Voltage Battery MCB – Q6” located behind the front canopy on the left-hand side of the ITW GSE 7400.
  • Page 44 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Transportation and Installation Standard input connections 3 x M8 (3x ¼-20 by 1”) 6 Nm (53.1 in lbf) (L1, L2, L3) 50/60 Hz input terminals: 1 x M10 bolt 50 Nm (444 in lbf) (Ground/PE) Fig.

  • Page 45: Mains / Utility Input

    Transportation and Installation Mains / Utility Input 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 as below table:...

  • Page 46: 400 Hz Interlock

    The ITW GSE 7400 may be optionally equipped with a 400 Hz input, which is located on the left-hand side of the ITW GSE 7400 (see picture on page 39), if the ITW GSE 7400 is expected to run out of energy during a supply state.

  • Page 47: Tcp/Ip On-Board Interface

    Transportation and Installation 4.13 TCP/IP On-Board Interface The ITW GSE 7400 is equipped with a TCP/IP (RJ45) communication port for supervision and monitoring of the GPU by a central computer, for example. The port is located on the control board (A1).

  • Page 48: Technical Specifications And Information

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA 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 49 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Technical Specifications & Warranty Power 90 kVA (160kWh), cos() = 1, continuous (4 battery packs) 90 kVA (120kWh), cos() = 1, continuous (3 battery packs) Voltage 3 x 200/115 V Power factor 0.7 lagging to 0.95 leading...
  • Page 50 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Technical Specifications & Warranty Miscellaneous: Physical: Previous trailer: Dimensions (LxWxH) 2961 x 1860 x 1579 mm / 116.6 x 73.2 x 62.2 inches Mobile unit (3 battery packs) 2125 kg / 4.685 lbs * Mobile unit (4 battery packs) 2475 kg / 5.456 lbs *...

  • Page 51: 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 52: Operator's Instructions (Display / Led / Keypad Layout)

    90 kVA Operator’s Instructions Operator’s Instructions (Display / LED / Keypad Layout) Depending on the ITW GSE 7400 layout, the different types of operator panels are shown below: 1 x 400 Hz output 2 x 400 Hz output 1: LED Graphic Display 7: Output 1 (400 Hz) ON/OFF 8: Output 2 ON (400 Hz) “Green”...
  • Page 53 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Operator’s Instructions 1 x 400 Hz & 1 x 28 VDC output 1: LED Graphic Display 7: Output 1 (400 Hz) ON/OFF 8: Output 2 ON (28 VDC) “Green” LED 2: Navigation Keypad 3: Power ON “Blue”...

  • Page 54: Using The Display / Keypad

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA 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...

  • Page 55: Charging The Unit

    Note *See Section 6.5 & 7.15 to limit the charging current, to protect cable / pre-fuse. ITW GSE recommend to set maximum current to 5 A lower than the plug used. Grid current can as maximum be set to 100 A.

  • Page 56: Operating The Unit

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA 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 ...
  • Page 57 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Operator’s Instructions Default Display Screen, Operating OUTPUT 115.1 / 200.0 V <20 A Phase A: 115.0 V < 20 A E-F Present Phase B: 115.0 V < 20 A...

  • Page 58: Operating The Unit As 400 Hz Pass Through

    Start the additional 400 Hz Ground Power Unit and make sure it is supplying 400 Hz.  The ITW GSE 7400 automatically switches to the external 400 Hz and supplies the aircraft via the already connected cable/plug from the ITW GSE 7400. The switchover is done as an NBPT;...

  • Page 59: Basic Menu

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Operator’s Instructions Basic Menu Home Setup Black Box Save/Upload Power Log View Parameters 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 60: 6.5.1 Parameters - Menu Structure

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Operator’s Instructions 6.5.1 Parameters – Menu Structure OUTPUT Phase A: 0.0 V < 20 A Phase B: 0.0 V < 20 A Phase C: 0.0 V < 20 A Average: 0.0 V...
  • Page 61 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Operator’s Instructions Parameters – Menu Structure (Continued) Battery 1 Highlight the by using the navigation Voltage: 400 V keys. Current: 0.0 A State of Charge: 96.2 % Press to select View Parameters submenu.
  • Page 62 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Operator’s Instructions Parameters – Menu Structure (Continued) Battery 4 Voltage: 391 V Current: 0.0 A Use the to browse through the various State of Charge: 96.2 % screens. Mode:...

  • Page 63: 6.5.2 I/O Configuration

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Operator’s Instructions 6.5.2 I/O Configuration 6.5.2.1 1 x 400 Hz output Inputs Outputs Function Ref. Function Ref. Function Ref. Function Ref. Connector 1 Not Used Not Used Not Used...

  • Page 64: X 400 Hz Outputs

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Operator’s Instructions 6.5.2.2 2 x 400 Hz outputs Inputs Outputs Function Ref. Function Ref. Function Ref. Function Ref. Connector 1 Not Used Not Used Not Used X7:I1 X16:I15 X27:O1...

  • Page 65: X 400 Hz & 1 X 28 Vdc Output

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Operator’s Instructions 6.5.2.3 1 x 400 Hz & 1 x 28 VDC output Inputs Outputs Function Ref. Function Ref. Function Ref. Function Ref. Connector 1 Not Used Not Used...

  • Page 66: Range Extender Option

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Operator’s Instructions 6.5.2.4 Range Extender option Covering below combinations: 1 x 400 Hz output / 2 x 400 Hz outputs / 1 x 400 Hz & 1 x 28 VDC outputs...

  • Page 67: 6.5.3 Setup - Menu Structure

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Operator’s Instructions 6.5.3 Setup – Menu Structure 11:27:47 Setup Menu 24/09/2019 Output Voltage Settings: 115.0 / 200.0 V 80.0 – 135.0 V (Phase-Neutral) Note: Values above 125 cannot be stored...
  • Page 68 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Operator’s Instructions Setup – Menu Structure (Continued) 11:27:47 Setup Menu 24/09/2019 Settings: 400 Hz EF Interlock Active Bypassed Active Back Modify 11:27:47 Setup Menu 24/09/2019 11:27:47 Setup Menu 24/09/2019...
  • Page 69 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Operator’s Instructions Setup – Menu Structure (Continued) 11:27:47 Setup Menu 24/09/2019 Earth Leakage Level Settings: 10 A 0.0 = Disabled 0.1 – 15.0 A Back Modify 11:27:47 Setup Menu...
  • Page 70 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Operator’s Instructions Setup – Menu Structure (Continued) 11:27:47 Setup Menu 24/09/2019 Date / Time Format Settings: HH:MM:SS I DD:MM:YYYY HH:MM:SS I DD:MM:YYYY HH:MM:SS AM I MM:DD:YYYY Back Modify 11:27:47...
  • Page 71 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Operator’s Instructions Setup – Menu Structure (Continued) 11:27:47 Setup Menu 24/09/2019 28V Compensation Settings: 0.0V/600A 0 – 3.0 V Back Modify 11:27:47 Setup Menu 24/09/2019 11:27:47 Setup Menu 24/09/2019...
  • Page 72 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Operator’s Instructions Setup – Menu Structure (Continued) 11:27:47 Setup Menu 24/09/2019 Cannot reset service interval. Less than Five months from last service. Settings: Confirm Service has been performed Back...

  • Page 73: 6.5.4 Black Box - Menu Structure

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Operator’s Instructions 6.5.4 Black Box – Menu Structure 14:54:33 24/09/2019 4307 OVERLOAD: 200% < I < 300% - 10 s Alarm Data 001/100 O UTPUT VOLT Phase A: 94.2 V...
  • Page 74 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Operator’s Instructions Black Box – Menu Structure (Continued) Battery 1 Voltage: 400 V Curr en t: 0.0 A State of Charg e: 96.2 % Mode: Discharge Status Code :...

  • Page 75: 6.5.5 Power Log - Menu Structure

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Operator’s Instructions 6.5.5 Power Log – Menu Structure Power Log 001/100 Total T ime: 22.0 Minu tes 0 – 30 kW Start Date: 24/09/2018 30 – 60 kW Start Time: 10:34 60 –...

  • Page 76: 6.5.6 Update Software / Save Logs / Load Config File

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Operator’s Instructions 6.5.6 Update Software / Save Logs / Load Config File 10:30:00 USB MENU 24/09/2019 Update in Progress! Please Wait. Swappin g Flash Blocks 10:30:00 USB MENU 24/09/2019...
  • Page 77 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Operator’s Instructions Update Software / Save Logs / Load Config File (Continued) 10:30:00 USB MENU 24/09/2019 Update in Progress! Do not turn off or reset dur ing u pdate !
  • Page 78 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Operator’s Instructions Update Software / Save Logs / Load Config File (Continued) 10:30:00 USB MENU 24/09/2019 Saving log 10:30:00 USB MENU 24/09/2019 10:30:00 USB MENU 24/09/2019 Update Display Software...
  • Page 79 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Operator’s Instructions Update Software / Save Logs / Load Config File (Continued) 10:30:00 USB MENU 24/09/2019 Reading Flash Drive. Please Wait Press To Reset 10:30:00 USB MENU 24/09/2019 10:30:00...

  • Page 80: 6.5.7 Incompatible Software Version / Wrong Software

    Select 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 81 Before changing PCB Boards, consult ITW GSE. Alternatively, if you intend to proceed because you have already contacted or received the PCB Boards from ITW GSE / had PCB Boards on stock / took PCB Boards from another ITW GSE unit, use the guidelines below to update the software: 1.

  • Page 82: Default Factory Settings

    Operation Manual – ITW GSE 7400 Battery Powered GPU 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 GPU supplied with cable)

  • Page 83: Setup Lock / Output Mode / Compensation

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA 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 the icon menu by means of the set-up menu.

  • Page 84: Output Voltage

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Setup Lock / Output Mode / Compensation 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 (values above 125 V cannot be stored).

  • Page 85: Manual Compensation

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Setup Lock / Output Mode / Compensation Manual Compensation This is the traditional method of cable compensation. The output voltage is increased in proportion to the load current (voltage / 100 A). This method is used where the impact of asymmetrical cables, unbalanced loads and varying power factors may be neglected, or the auto-calibration tool isn’t...

  • Page 86: 400 Hz Ef Interlock

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Setup Lock / Output Mode / Compensation 400 Hz EF Interlock The EF interlock is a personnel and equipment safety feature that is found in all commercial aircraft. This 28 VDC signal will not be present until the SSFC closes its output contactor and provides 400 Hz power to the aircraft.

  • Page 87: Aircraft Connector Insertion

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Setup 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 88: Earth Leakage Level

    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 89: Engine Start Soc

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Setup Lock / Output Mode / Compensation 7.16 Engine Start SoC This set of submenus allows the user to adjust the Engine Start SoC, to set the % (10 to 50%) of when the Range Extender Engine should automatically start, if it’s installed.

  • Page 90: Modbus Slave Address

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Setup Lock / Output Mode / Compensation 7.20 Modbus Slave Address If the unit is part of an RS-485 Modbus RTU BMS or RMS monitoring system, it must be assigned a Modbus slave address.

  • Page 91: Current Limit Step Size

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Setup Lock / Output Mode / Compensation 7.25 Current Limit Step Size This submenu is used to set the current step size, by pressing the current increase / decrease push button on the Standby menu screen.

  • Page 92: Menu Lock

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Setup Lock / Output Mode / Compensation 7.29 Menu Lock This set of submenus allows the user to adjust the Menu Lock, either to lock or unlock to menu from pushing the center button on the keypad.

  • Page 93: Service, Maintenance, Overhaul

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Service, Maintenance, Overhaul Service, Maintenance, Overhaul To ensure 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.

  • Page 94: Unit Reports Service Interval

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Service, Maintenance, Overhaul Unit reports service interval Every 6 months (180 days) the unit reports via the display, that the service maintenance has to be done. As a minimum you have to do a quarterly maintenance inspection and fill in the table in section 8.3.4 with the Historical data for the batteries.

  • Page 95: Recommended Maintenance Schedule

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Service, Maintenance, Overhaul Recommended Maintenance Schedule 8.3.1 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 96: 8.3.2 Quarterly

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Service, Maintenance, Overhaul 8.3.2 Quarterly Maintenance Instruction for ITW GSE 7400 Quarterly This inspection does not in any way suspend local / airport rules and regulations Check aircraft connector(s).
  • Page 97 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Service, Maintenance, Overhaul Continued from previous page Check all reflectors / beacons / siren. Check reflectors for damage / function. Check beacons for damage / function. Check siren for damage / function.

  • Page 98: 8.3.3 Yearly

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Service, Maintenance, Overhaul 8.3.3 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).
  • Page 99 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Service, Maintenance, Overhaul Continued from previous page Check all reflectors / beacons / siren. Check reflectors for damage / function. Check beacons for damage / function. Check siren for damage / function.
  • Page 100 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Service, Maintenance, Overhaul Continued from previous page Grease front wheel turntable (Paillard trailer) Grease front wheel turntable (3 pcs.) / front shaft (2 pcs.) with grease. Apply grease to the oiler of the turntable / shaft, see picture below.

  • Page 101: Adjusting Braking System (Previous Trailer)

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Service, Maintenance, Overhaul Adjusting Braking System (previous trailer) Darker colors indicate increased brake activation. When the tow bar is locked in the vertical ‘Parking’ position (1) the brake is fully engaged. Between position (2) and (3) the brake is not engaged and the wheels can run freely.
  • Page 102 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Service, Maintenance, Overhaul Wire Connection at the Brake Compensator: Connect the brake wires from the wheels at each side of the brake compensator (275.415), leaving 10 mm of thread as illustrated below.
  • Page 103 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Service, Maintenance, Overhaul Brake Adjustment Bolt: Jack the 7400 eGPU up free of the ground, so the front wheels can turn freely. Tighten the adjustment bolt in a clockwise direction until the wheel will not turn.
  • Page 104 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Service, Maintenance, Overhaul Now lower the tow bar to the dropped horizontal position (4*) again and see if the brake is fully engaged and thus the eGPU braked. If not, repeat the two steps above until the unit brakes adequately in the dropped horizontal position (4*).

  • Page 105: Adjusting Braking System (Paillard Trailer)

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Service, Maintenance, Overhaul Adjusting Braking System (Paillard trailer) Darker colors indicate increased brake activation. When the tow bar is locked in the vertical ‘Parking’ position (1) the brake is fully engaged. Between position (2) and (3) the brake is not engaged and the wheels can run freely.
  • Page 106 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Service, Maintenance, Overhaul Wire Connection at the Brake Equalizer: The two brake wires from the drum brakes are mounted though the plate and connected to the outer holes at the ‘brake equalizer’ as illustrated below.
  • Page 107 The brake adjustment bolt is only needed if adjustment is no longer available in the main brake wire cable (at worn or well-used brakes). Jack the 7400 eGPU up free of the ground, so the front wheels can turn freely. Tighten the adjustment bolt in a clockwise direction until the wheel will not turn.
  • Page 108 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Service, Maintenance, Overhaul Tow bar Brake In Locked Vertical Position (1*) Raise the tow bar to locked vertical (1*) and tighten the left brake wire going under the pulley wheel.

  • Page 109: Units Produced Before November 2020

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Service, Maintenance, Overhaul Units produced before November 2020 Units produced before November 2020 and having issues/problems with the brakes, make sure to install the new Brake Compensator. Untighten the two brake wires at the tow bar.

  • Page 110: Semiannual (Half-Yearly) Battery Maintenance Log

    A USB can be used to download the parameters and then be viewed on a computer. Downloading parameters please refer to section 6.5.6 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 111 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Service, Maintenance, Overhaul 18 months Historical average Value Comments Historical Average Temperature Battery 1 °C Historical Average Temperature Battery 2 °C Historical Average Temperature Battery 3 °C Historical Average Temperature Battery 4 °C...
  • Page 112 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Service, Maintenance, Overhaul 36 months Historical average Value Comments Historical Average Temperature Battery 1 °C Historical Average Temperature Battery 2 °C Historical Average Temperature Battery 3 °C Historical Average Temperature Battery 4 °C...
  • Page 113 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Service, Maintenance, Overhaul 54 months Historical average Value Comments Historical Average Temperature Battery 1 °C Historical Average Temperature Battery 2 °C Historical Average Temperature Battery 3 °C Historical Average Temperature Battery 4 °C...

  • Page 114: Battery Backup & Replacement (Only Applicable For Coin Cell)

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Service, Maintenance, Overhaul Battery Backup & Replacement (only applicable for Coin Cell) The following section is only applicable for the coin cell battery type. Note The on-soldered battery type on the alternative Control Board 579573, does not need to be changed in the expected lifetime of the unit.
  • Page 115 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA 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 116 If the blue LED on the control board (located in Fig. 8.8.3) flashes with approximately one flash 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 reprogrammed. Document No. 575.410DB...

  • Page 117: Pcb Fuses & Battery Fuses

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Troubleshooting & Repair Troubleshooting & Repair Allow only qualified 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 118 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Troubleshooting & Repair Additional error information regarding the output voltage, overload and area covered by the error code can be derived from the error code as follows: Output Voltage:...
  • Page 119 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA 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...
  • Page 120 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Troubleshooting & Repair Fuse # Applies to Type Rated Voltage Amp Rating External charger / Bussmann (FWP) 750 V 250 A inverter input Farraz Shawmut 700 V 250 A Fig.

  • Page 121: Fault Guidance / Error Codes

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Troubleshooting & Repair Fault Guidance / Error Codes In the event 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 122 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Troubleshooting & Repair Continued from previous page Error Code Error Text on Display Help Text First Corrective Action Voltage > 32 V – 4 sec. 7000 OUTPUT VOLTAGE TOO HIGH Voltage >...
  • Page 123 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Troubleshooting & Repair Continued from previous page Error Code Second Corrective Action Third Corrective Action Fourth Corrective Action Replace control board A1 4600+code Check output filter capacitors C7–C9 Check output transformer T2...
  • Page 124 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Troubleshooting & Repair Communication Board error/warning codes All codes from 10…60,128 + code may be added 256(CAN BUS not active), 512(BMS not active) and 1024(Pack not charging) Code Watchdog Reset...
  • Page 125 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Troubleshooting & Repair Error code on Battery Guard: Short circuit detected Overload or over temperature Under voltage Over voltage Note Before replacing any PCBs or the inverter module, check the corresponding connections and wiring.

  • Page 126: Illustrated Parts List

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Illustrated Parts List 10.0 Illustrated Parts List 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 127 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Illustrated Parts List S7: Smoke Detector A42: Comm. Board A32: Comm. Board A22: Comm. Board A12: Comm. Board G10: 24 VDC Supply G11: 24 VDC Supply Q1: Input Contactor...
  • Page 128 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Illustrated Parts List Active Rectifier Unit (Optional) +/- 28 VDC output (Optional) A8 : Soft Start Board * A5: I/O Aux. Board B4: Leaf Pack 4 cable (+ & -) B3: Leaf Pack 3 cable (+ &...
  • Page 129 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Illustrated Parts List Q3: Safety Switch F41-42: Fuse (150A) F31-32: Fuse (150A) F21-22: Fuse (150A) F11-12: Fuse (150A) V41: Diode Q42: Contactor V31: Diode Q32: Contactor V21: Diode Q22: Contactor...
  • Page 130 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Illustrated Parts List S5: Siren Amber Beacon (Operating/Charging)* Blue Beacon (Warning/Low Battery)* Display USB Forklift Pockets Forklift Pockets Leaf Pack Battery no. 4 Leaf Pack Battery no. 3 Leaf Pack Battery no. 2 Leaf Pack Battery no.
  • Page 131 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Illustrated Parts List Amber Beacon (Operating/Charging)* S5: Siren Blue Beacon (Warning/Low Battery)* Display USB Forklift Pockets Forklift Pockets Leaf Pack Battery no. 4 Leaf Pack Battery no. 3 Leaf Pack Battery no. 2 Leaf Pack Battery no.
  • Page 132 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Illustrated Parts List Fig. 10.1.6a Old tow-bar / 5 bolts wheels / previous Trailer Fig. 10.1.6b Paillard tow-bar / 4 bolts wheels / Paillard Trailer Document No. 575.410DB Page 132 of 195...
  • Page 133 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Illustrated Parts List Fig. 10.1.7 Placement of Battery Guard (Compartment where AUX batteries are located) Document No. 575.410DB Page 133 of 195...
  • Page 134 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Illustrated Parts List Tie-Down Ring Tie-Down Ring Tie-Down Ring Tie-Down Ring Fig. 10.1.8a Bottom view 4 x Tie-Down rings (previous trailer) Tie-Down Ring Tie-Down Ring Tie-Down Ring Tie-Down Ring Fig.

  • Page 135: Placement Of Labels (Ce Version)

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Illustrated Parts List 10.2 Placement of labels (CE version) Fig. 10.2.1 Front View (language may vary) Document No. 575.410DB Page 135 of 195...
  • Page 136 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Illustrated Parts List 3 labels in various language placed here See section 8 (210 x 148 mm) Fig. 10.2.2 Interior View of Converter cover labels (language may vary) Document No. 575.410DB...
  • Page 137 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Illustrated Parts List Fig. 10.2.3 Interior View of Fuse cover labels (language may vary) Document No. 575.410DB Page 137 of 195...
  • Page 138 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Illustrated Parts List Placed on Electronic Zone back-plate. Behind Fuse F3). Placed horizontally to the right of the Interface Board, lower end. Placed horizontally next to each Communication Board.
  • Page 139 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Illustrated Parts List Placed next to Q11. Placed next to Q21. Placed next to Q31. Placed next to Q41. Placed bottom of Electronic Zone under Q1. Placed on Q2 and bottom of Electronic Zone and next to Q2.

  • Page 140: Placement Of Labels (Ul Version)

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Illustrated Parts List 10.3 Placement of labels (UL version) 200 mm 144 mm Fig. 10.3.1 Front View (language may vary) Document No. 575.410DB Page 140 of 195...
  • Page 141 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Illustrated Parts List 3 labels in various language placed here See section 8 (210 x 148 mm) Fig. 10.3.2 Interior View of Converter cover labels (language may vary) Document No. 575.410DB...
  • Page 142 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Illustrated Parts List Fig. 10.3.3 Interior View of Fuse cover labels (language may vary) Document No. 575.410DB Page 142 of 195...
  • Page 143 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Illustrated Parts List Placed on Electronic Zone back-plate. Behind Fuse F3). Placed horizontally to the right of the Interface Board, lower end. Placed horizontally next to each Communication Board.
  • Page 144 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Illustrated Parts List Placed next to Q11. Placed next to Q21. Placed next to Q31. Placed next to Q41. Placed bottom of Electronic Zone under Q1. Placed on Q2 and bottom of Electronic Zone and next to Q2.

  • Page 145: Options

    Active Rectifier Unit (Diagram 475810) The ITW GSE 7400 can be equipped with a 28 VDC Active Rectifier Unit (ARU). This option adds an additional 28 VDC / 600 A output. Both 400 Hz & 28 VDC can be used simultaneously. Total continuous amount of power is 45 kW (AC) + 300 A (DC).

  • Page 146: 575812 / Ap-575812 Nbpt Contactor (Diagram 475801)

    Adds a 400 Hz inlet, located in the left-hand side of the cable compartment and towards the front of the ITW GSE 7400. Protected by a lid and with an NBPT feature, which allow the ITW GSE 7400 to pass through any additional 400 Hz connected to this input in the event of unexpected long turnaround time.

  • Page 147: 575814 / Ap-575814 Yellow Beacon

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Options 575814 / AP-575814 Yellow Beacon Depending on client specification, the color of the beacons can be changed. The beacon may either be continuously lit or flashing. 575815 / AP-575815...

  • Page 148: 575818 / Ap-575818 Lockable Tow Bar Interlock (Diagram 475801)

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Options 575818 / AP-575818 Lockable Tow Bar Interlock (Diagram 475801) This option adds a magnetic lock to the tow bar. Unless the cables are in the corresponding compartments, the tow bar is mechanically locked and cannot be lowered.

  • Page 149: 575820 / Ap-575820 White Clearance Light (Diagram 475801)

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Options 575820 / AP-575820 White Clearance Light (Diagram 475801) Adding four white clearance lights, one on each corner of the unit, makes the equipment more visible on the apron and in hangars.

  • Page 150: 575822 / Ap-575822 Range Extender Add-On (Diagram 475822)

    Range Extender Add-On (Diagram 475822) The ITW GSE 7400 can be equipped with a Range Extender. This option adds a gen-set for the 7400. The gen-set module will have enough power to supply narrow-body aircraft in those relative rare cases, when the battery capacity is insufficient for a full day’s operation, e.g.

  • Page 151: 575823 / Ap-575823 Itw Gse Connect (Diagram 475801)

    For GPS location / monitoring parameters and unit status, a mobile device with integrated antenna & SIM card is installed. Historical and on the fly data can be retrieved through the ITW GSE Portal & Cloud via your account. Document 999.014 shows available addresses/parameters via MODBUS.

  • Page 152: 575824 / Ap-575824 I/O Control Terminals (Diagram 475801)

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Options 575824 / AP-575824 I/O Control Terminals (Diagram 475801) For additional Inputs / Outputs control purposes, I/O terminals can be added with the inputs & outputs shown on the schematic.

  • Page 153: 575826 / Ap-575826 Lockable Tow Bar Interlock, Paillard (Diagram 475801)

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Options 575826 / AP-575826 Lockable Tow bar Interlock, Paillard (Diagram 475801) This option adds a magnetic lock to the tow bar. Unless the cables are in the corresponding compartments, the tow bar is mechanically locked and cannot be lowered.

  • Page 154: 575827 / Ap-575827 Din Ø40 Towing Eye

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA Options 575827 / AP-575827 DIN ø40 Towing eye This option adds a DIN ø40 mm towing eye, replaces the standard towing eye (ø68/25 mm). Note This option, only to be used with the Paillard running gear.

  • Page 155: 578816 / Ap-578816 Itw Gse Service Tool

    ITW GSE Service Tool In an ITW GSE 7400 unit, Black Box / Power logs as well as real-time readings are available via the display. With the Service Tool, it is possible to download the Black Box / Power Log to a PC or laptop and furthermore it is possible to view real-time reading on the monitor.

  • Page 156: For Gpus With 28 Vdc Active Rectifier Unit

    12.0 For GPUs with 28 VDC Active Rectifier Unit All ITW GSE 7400 units from 68 kVA to 90 kVA 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 45 kW (AC) and 300 A (DC).
  • Page 157 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA For GPUs with 28 VDC Active Rectifier Unit ARU Rectifier (PM20): The output voltage is kept at 28 VDC by using thyristors, regardless of the input voltage level and the load.

  • Page 158: Connection Of Cables

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA For GPUs with 28 VDC Active Rectifier Unit 12.2 Connection of Cables 28 VDC Output terminals: 2 x 4 x ø11 (M10 bolt) 50Nm (444 in lbf) 9 x 0.4 - 4 mm² (AWG21 – 11) Remote I/O terminals: Fig.

  • Page 159: Interlock

    Operation Manual – ITW GSE 7400 Battery Powered GPU 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.

  • Page 160: Operator's Instruction

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA For GPUs with 28 VDC Active Rectifier Unit Operator’s Instruction 12.4 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).
  • Page 161 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA For GPUs with 28 VDC Active Rectifier Unit  Press the On/Off button to power up the GPU if it is not already awake.  Insert the 28 VDC aircraft cable into the aircraft. Make sure the cable is inserted until you feel a natural resistance.
  • Page 162 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA For GPUs with 28 VDC Active Rectifier Unit Default Display Screen Operation 28 V Voltage 28.0 V 115.0 V 39 A Current 600 A 400 Hz I: Power 16.8 kW...

  • Page 163: Additional Menu Items For Aru

    Operation Manual – ITW GSE 7400 Battery Powered GPU 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 –...
  • Page 164 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA For GPUs with 28 VDC Active Rectifier Unit Parameters – ARU additional parameters 28 V Voltage 28.0 V Current 600 A Power 16.8 kW Back Next/Prev Use the to browse through the various screens.

  • Page 165: Aru Default Factory Settings

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA For GPUs with 28 VDC Active Rectifier Unit 12.7 ARU Default Factory Settings 28V Voltage (V): 28.0 28V Compensation (V/600 A): 0.0 (Set if GPU is supplied with cable)

  • Page 166: Specifications

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA For GPUs with 28 VDC Active Rectifier Unit 13.0 Specifications Output: Voltage : 28 VDC Current : 600 A continuously (300 A simultaneously with 400 Hz) Voltage regulation : < 0.5% Voltage ripple : <...

  • Page 167: Troubleshooting & Repair

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA For GPUs with 28 VDC Active Rectifier Unit 14.0 Troubleshooting & Repair Please refer to section 9.1 for Fault Guidelines Additional 28 VDC ARU related failures: 6102 Cable 2 temperature too high EF signal drop out –...

  • Page 168: Aru Illustrated Parts List

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA For GPUs with 28 VDC Active Rectifier Unit 15.0 ARU illustrated parts list 15.1 Component placement Thyristors (A to L) A20: ARU Board underneath PCB Output Terminals Cables to transformers ( - &...
  • Page 169 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA For GPUs with 28 VDC Active Rectifier Unit ARU control Cable ARU Transformers C20: Capacitor R20: Resistor M20: FAN 28 VDC Output Fig. 15.1.2 Side view (X-ray ARU cover) Document No.

  • Page 170: For Gpus With Range Extender Add-On

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA For GPUs with Range Extender Add-On 16.0 For GPUs with Range Extender Add-On Note Please also refer to B&S Engine manual Please also refer to Meccalte alternator manual 16.1...

  • Page 171: Connection Of Input Cable

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA For GPUs with Range Extender Add-On Terminal Block (X10): Optional Beacons (Run & Low Fuel) can be attached to the terminals in X10. Connections to Interface Board (X27 & X28) All controls and wires to and from the engine / Generator / relays are directed to the I/O’s at the...

  • Page 172: Input Cable Recognition

    If the charging needs to be started again, push the charger push button and the charging starts. The Range Extender will keep running as long as the ITW GSE 7400 unit provides 400 Hz (28 VDC) Refer to section 19.0 for Keypad layout Refer to section 6.0 for operating the unit.

  • Page 173: Range Extender Default Factory Settings

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA For GPUs with Range Extender Add-On 16.6 Range Extender Default Factory Settings : 20 % (10 – 50%) Engine Start SoC See section 6.6 for 400 Hz default factory settings.
  • Page 174 Output current to high Short circuit at output Physical: Additional weight to standard 7400 Hz unit: 400 kg / 882 lbs Ambient: Operating ambient for the Gasoline Range Extender is -10°C to 45°C / -40 F to 113 F. Document No. 575.410DB...
  • Page 175 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA For GPUs with Range Extender Add-On Fig. 17.0.1a Outer dimension with Range Extender (Previous trailer) Document No. 575.410DB Page 175 of 195...
  • Page 176 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA For GPUs with Range Extender Add-On Fig. 17.0.1b Outer dimension with Range Extender (Paillard trailer) Document No. 575.410DB Page 176 of 195...

  • Page 177: Service, Maintenance, Overhaul

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA For GPUs with Range Extender Add-On 18.0 Service, Maintenance, Overhaul 18.1 Engine Maintenance Schedule Maintenance Instruction for Range Extender This inspection does not in any way suspend local / airport rules and regulations.

  • Page 178: Electronic Fuel Injection (Efi) System

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA For GPUs with Range Extender Add-On 18.2 Electronic Fuel Injection (EFI) System The EFI System monitors engine temperature, engine speed and battery voltage for engine starting and warm up. There are no adjustments on the system.

  • Page 179: Change Engine Oil

    18.5 Change Engine Oil Used oil is a hazardous waste product and must be disposed of properly. Do not discard with household waste. Check with your local authorities or ITW GSE service center for safe disposal/recycling facilities. Remove Oil With engine off but still warm, disconnect the spark plug wires (D, Fig. 18.5.1) and keep it away from the spark plug (E, Fig.

  • Page 180: Service Air Filter

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA For GPUs with Range Extender Add-On Remove Oil For replacement intervals, see the Maintenance Schedule. Drain the oil from the engine. See Remove Oil section. Remove the oil filter (G, Fig. 18.5.3) and dispose of properly.
  • Page 181 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA For GPUs with Range Extender Add-On Assemble the dry pre-cleaner (F, Fig. 18.6.1), if equipped, to the air filter (E). Install the filter (E, Fig. 18.6.1) and secure with retainer (D) and fastener (C).

  • Page 182: Service Fuel System

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA For GPUs with Range Extender Add-On 18.7 Service Fuel System  Keep fuel away from sparks, open flames, heat and other ignition sources.  Check fuel lines, tank cap and fittings frequently for cracks or leaks. Replace if necessary.

  • Page 183: Service Cooling System

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA For GPUs with Range Extender Add-On 18.8 Service Cooling System  This is an air-cooled engine. Dirt and debris can restrict the airflow and cause the engine to overheat, resulting in poor performance and reduced engine life.

  • Page 184: Troubleshooting & Repair

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA For GPUs with Range Extender Add-On 19.0 Troubleshooting & Repair Please also refer to section 9.1 for ITW GSE 7400 Fault Guidelines. 19.1 Range Extender Warning codes Malfunction Indicator Lamp Run No Output Voltage...

  • Page 185: Additional Engine Information

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA For GPUs with Range Extender Add-On 19.2 Additional Engine Information Additional Engine information can be retrieved from the parameter menu. 115.1 / 200.0 V <20 A E-F Pr esent...

  • Page 186: Engine Warning Codes

    Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA For GPUs with Range Extender Add-On 19.3 Engine Warning Codes The table below shows the complete list of error codes and first corrective action: Error Code Red Engine / Engine Error Code...
  • Page 187 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA For GPUs with Range Extender Add-On Document No. 575.410DB Page 187 of 195...

  • Page 188: Gasoline Fuel & Range Extender Forced Start

    ITW GSE recommends that the engine is started at least every three months, running for at least ½ hour with a load of approximate 30 kVA to burn some of the old gasoline: After the exercise, top up the tank with new gasoline until it’s full again.
  • Page 189 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA For GPUs with Range Extender Add-On Key position & functions Key position Function Description The engine is turned off Ignition Ignition signal provided and unit auto detects it Start Ignition + Start Ignition &...
  • Page 190 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA For GPUs with Range Extender Add-On 20.0 Range Extender illustrated parts list 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 191 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA For GPUs with Range Extender Add-On M10: Gasoline Engine S10: Battery Isolator Switch Fig. 20.1.2 Back Motor / Generator Zone (Door open) Exhaust pipe Air intake and filter G6: Generator...
  • Page 192 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA For GPUs with Range Extender Add-On H8: Malfunction Indicator Lamp K3: 24 VDC Starter Relay K1-K2: 24VDC relays X10: Terminal Block K4: 12 VDC relay K5: 230 VAC relay Fig.
  • Page 193 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA For GPUs with Range Extender Add-On Q10: Generator Output MCB X15: Output socket of Range Extender Fig. 20.1.5a Front view (Previous trailer) Document No. 575.410DB Page 193 of 195...
  • Page 194 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA For GPUs with Range Extender Add-On Q10: Generator Output MCB X15: Output socket of Range Extender Fig. 20.1.5b Front view (Paillard trailer) Document No. 575.410DB Page 194 of 195...
  • Page 195 Operation Manual – ITW GSE 7400 Battery Powered GPU 90 kVA For GPUs with Range Extender Add-On 20.2 Placement of labels - Range Extender 3 to be placed at muffler box (side towards front no labels) Fig. 20.2.1 Rear View (with Range Extender) Document No.

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