Unitron UDC-420M Maintenance Manual

Ground power unit

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Unitron

MAINTENANCE MANUAL

GROUND POWER UNIT

MODEL: UDC-420M

PART NO: 198-15000-60T

This manual provides installation, operation, troubleshooting, and maintenance information

Unitron, LP • 10925 Miller Road • Dallas, TX 75238

Phone: +1 800-527-1279, +1 214-340-8600 • Fax: +1 214-341-2099

E-mail: service@unitronlp.com • Website: www.unitronlp.com

IMPORTANT SAFETY INFORMATION

READ AND SAVE THESE INSTRUCTIONS

QUESTIONS: 800-527-1279

WWW.UNITRONLP.COM

Revised: September 20, 2022

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Questions and answers

Abdellatif Jaber

April 2, 2025

alarm schema mismatch with code (10 EF 0000 0000 0000)

Abdellatif Jaber

April 2, 2025

red light still illuminates 0n board card (A10) (sd15).

Summary of Contents for Unitron UDC-420M

Page 1 This manual provides installation, operation, troubleshooting, and maintenance information IMPORTANT SAFETY INFORMATION READ AND SAVE THESE INSTRUCTIONS QUESTIONS: 800-527-1279 WWW.UNITRONLP.COM Unitron, LP • 10925 Miller Road • Dallas, TX 75238 Phone: +1 800-527-1279, +1 214-340-8600 • Fax: +1 214-341-2099 E-mail: service@unitronlp.com • Website: www.unitronlp.com Revised: September 20, 2022...
Page 2 Unitron, LP MAINTENANCE MANUAL MODEL UDC-420M PART NO. 198-15000-60T DESCRIPTION: Ground Power Unit THIS PAGE INTENTIONALLY LEFT BLANK...
Page 3 This manual may not be reproduced and is intended for the exclusive use of Unitron customers. The terms and conditions governing the sale of Unitron products consist solely of those set forth in the contracts between Unitron and its customers. No statement contained in this publication, including statements regarding capacity, suitability for use, or performance of products, shall be considered a warranty by Unitron for any purpose or give rise to any liability of Unitron.
Page 4 Unitron, LP MAINTENANCE MANUAL MODEL UDC-420M PART NO. 198-15000-60T DESCRIPTION: Ground Power Unit THIS PAGE INTENTIONALLY LEFT BLANK...
Page 5 Unitron, LP MAINTENANCE MANUAL MODEL UDC-420M PART NO. 198-15000-60T DESCRIPTION: Ground Power Unit TABLE OF CONTENTS The installation, troubleshooting, and maintenance chapters of this manual are not intended for the equipment operator and should only be used by qualified service personnel.
Page 6 2) Viewing Event Log ........................40 3) Managing and Reading Event Log ..................... 42 CHAPTER 4. ILLUSTRATED PARTS BREAKDOWN A. Introduction ............................43 B. Manufacturer Identification ......................43 C. Illustrated Parts Breakdown......................45 CHAPTER 5. SCHEMATIC DIAGRAMS 198-15300-60T....... Schematic, Ground Power Unit, UDC-420M, TSP-4, T-3(MT)65...
Page 7 Unitron, LP MAINTENANCE MANUAL MODEL UDC-420M PART NO. 198-15000-60T DESCRIPTION: Ground Power Unit SAFETY Important Safety Instructions SAVE THESE INSTRUCTIONS Safety information is provided throughout this manual. Read the complete material before installing, operating, or servicing this unit. Follow all instructions and safety information.
Page 8 Unitron, LP MAINTENANCE MANUAL MODEL UDC-420M PART NO. 198-15000-60T DESCRIPTION: Ground Power Unit THIS PAGE INTENTIONALLY LEFT BLANK...
Page 9 Unitron, LP MAINTENANCE MANUAL MODEL UDC-420M PART NO. 198-15000-60T DESCRIPTION: Ground Power Unit INTRODUCTION This introduction provides information regarding organization, scope, purpose, and general contents of this manual, along with the method for using this manual. A. ORGANIZATION OF THIS MANUAL This manual is organized in a logical order, separated by chapters and subsections.
Page 10 Unitron, LP MAINTENANCE MANUAL MODEL UDC-420M PART NO. 198-15000-60T DESCRIPTION: Ground Power Unit THIS PAGE INTENTIONALLY LEFT BLANK...
Page 11 Unitron, LP MAINTENANCE MANUAL MODEL UDC-420M PART NO. 198-15000-60T DESCRIPTION: Ground Power Unit CHAPTER 1 - GENERAL INFORMATION, SPECIFICATIONS, AND INSTALLATION INSTRUCTIONS This chapter provides general information, specifications, and installation procedures for the unit, along with a list of standard and optional features.
Page 12 Unitron, LP MAINTENANCE MANUAL MODEL UDC-420M PART NO. 198-15000-60T DESCRIPTION: Ground Power Unit 2) Optional Features • Dual Range Input Voltage (Field Adjustable) (Option T3 -MT) This unit is configured to accept one of two voltage range conditions. The two voltage ranges are either 208 to 240 VAC or 380 to 480 VAC.
Page 13 Unitron, LP MAINTENANCE MANUAL MODEL UDC-420M PART NO. 198-15000-60T DESCRIPTION: Ground Power Unit 5) Environmental • Acoustical Noise........<65 dBA max. at 5 feet (1.5m) (60 dBA typical) • Temperature Range ........-40°C to +55°C • Relative Humidity ........0 to 95% (non-condensing) •...
Page 14 Unitron, LP MAINTENANCE MANUAL MODEL UDC-420M PART NO. 198-15000-60T DESCRIPTION: Ground Power Unit 35.0 IN [889 MM] AIRFLOW AIRFLOW FRONT VIEW 38.0 IN [965 MM] AIR EXHAUST 38.0 IN [965 MM] LEFT SIDE VIEW Figure 1. Dimensions UDC-420M...
Page 15 DESCRIPTION: Ground Power Unit C. INSTALLATION AND HANDLING WARNING: The UDC-420M weighs a maximum weight of 311 pounds (141 kg), excluding cable. To avoid damage to the unit, keep it on the pallet and move only with a forklift to the final setup location.
Page 16 MUST BE PRESENT ON THE INPUT POWER SIDE OF THE UNIT. IMPORTANT: • Unitron, LP does not specify user-furnished wiring, connectors, circuit breakers, or disconnect switch sizes due to different conditions and codes throughout the world. All wiring must comply with National Electrical Code (NEC), or EU equivalent, and local •...
Page 17 Unitron, LP MAINTENANCE MANUAL MODEL UDC-420M PART NO. 198-15000-60T DESCRIPTION: Ground Power Unit CAUTION: PROTECT THE INSIDE OF THE UNIT FROM DAMAGE. DO NOT ALLOW METAL FILINGS OR SHAVINGS TO FALL INTO THE UNIT WHILE PUNCHING THE CONDUIT ACCESS PORT(S).
Page 18 Unitron, LP MAINTENANCE MANUAL MODEL UDC-420M PART NO. 198-15000-60T DESCRIPTION: Ground Power Unit TOP VIEW FROM REAR OF UNIT (TOP COVER REMOVED) POSITIVE BUSBAR NEGATIVE BUSBAR Figure 4. Input and Output Connection Points 5) Connecting DC Output Power Cable The unit is routinely shipped with the output power cables installed. However, if it is necessary for the user to install or replace the output power cable, the following guidance is provided.
Page 19 Unitron, LP MAINTENANCE MANUAL MODEL UDC-420M PART NO. 198-15000-60T DESCRIPTION: Ground Power Unit Verify unit power cables are not connected to a power source. Remove the top cover. Remove the cable access panel from the rear of the unit. Route the output cable through the output port to the positive busbar, and to the negative busbar.
Page 20 • Installation of a cord grip on the cable is recommended. • Unitron, LP does not specify user-furnished wiring, connectors, circuit breakers, or disconnect switch sizes due to different conditions and codes throughout the world. • The input power must be connected through an external circuit breaker or disconnect switch...
Page 21 Unitron, LP MAINTENANCE MANUAL MODEL UDC-420M PART NO. 198-15000-60T DESCRIPTION: Ground Power Unit Locate the input contactor (K1) and ground terminal (GB1) in Figure Connect the input power wires as follows, contacts accept 1/4 inch ring lugs: Cable Wire Connection Point •...
Page 22 MODEL UDC-420M PART NO. 198-15000-60T DESCRIPTION: Ground Power Unit 7) Reconfiguring Input Voltage Range This UDC-420M has been designed to operate in a Low Voltage or a High Voltage range of input voltages: • Low Voltage Range (LV208 to 240 VAC •...
Page 23 Unitron, LP MAINTENANCE MANUAL MODEL UDC-420M PART NO. 198-15000-60T DESCRIPTION: Ground Power Unit Review the strapping configuration on the plate decal: • Low Voltage Range (LV)......Connect busbars across posts 1-2 and 3-4 • High Voltage Range (HV) ......Connect busbars across posts 2-3 and 5-6 IMPORTANT: Both busbars must be in place for proper operation of unit.
Page 24 Unitron, LP MAINTENANCE MANUAL MODEL UDC-420M PART NO. 198-15000-60T DESCRIPTION: Ground Power Unit THIS PAGE INTENTIONALLY LEFT BLANK...
Page 25 Unitron, LP MAINTENANCE MANUAL MODEL UDC-420M PART NO. 198-15000-60T DESCRIPTION: Ground Power Unit CHAPTER 2 - OPERATIONS This chapter provides a description of the operator controls and indicators, along with operating instructions for the unit. DANGER - ELECTRIC SHOCK HAZARD: SAFETY INFORMATION IS PROVIDED THROUGHOUT THIS MANUAL.
Page 26 Unitron, LP MAINTENANCE MANUAL MODEL UDC-420M PART NO. 198-15000-60T DESCRIPTION: Ground Power Unit A. CONTROLS AND INDICATORS EMERGENCY OPERATOR AUDIBLE OFF SWITCH CONTROL PANEL ALARM DATA PORT DOOR INTERLOCK SWITCH Figure 10. Controls and Indicators SELECTABLE NON-SELECTABLE INPUT DC OUTPUT...
Page 27 Unitron, LP MAINTENANCE MANUAL MODEL UDC-420M PART NO. 198-15000-60T DESCRIPTION: Ground Power Unit 1) Operator Control Interface The unit is primarily operated using features of the Operator Control Panel. The Operator Control Panel comprises several controls and indicators. Refer to...
Page 28 Unitron, LP MAINTENANCE MANUAL MODEL UDC-420M PART NO. 198-15000-60T DESCRIPTION: Ground Power Unit Audible Alarm The audible alarm sounds whenever specific fault conditions are detected. Refer to Figure IMPORTANT: An Alarm should never be Silenced without also being Cleared. Data Port This unit has an external USB data port, for maintenance purposes only.
Page 29 Unitron, LP MAINTENANCE MANUAL MODEL UDC-420M PART NO. 198-15000-60T DESCRIPTION: Ground Power Unit 2) Startup DANGER - ELECTRIC SHOCK HAZARD: ENSURE EXTERNAL INPUT POWER CIRCUIT BREAKER OR DISCONNECT SWITCH IS OFF (OPEN). IMPORTANT: • Before attempting to apply power to, or to startup the unit, read completely through this chapter.
Page 30 Unitron, LP MAINTENANCE MANUAL MODEL UDC-420M PART NO. 198-15000-60T DESCRIPTION: Ground Power Unit 480V 0.0V 480V 28.0V 425A 60Hz 60Hz 67hr 24hr 67hr 24hr 07/Apr. 14:50 07/Apr. 14:50 Figure 12. Home Screen - OFF and ON 3) Normal Shutdown Use this procedure to remove power from the load and to turn OFF the unit.
Page 31 Unitron, LP MAINTENANCE MANUAL MODEL UDC-420M PART NO. 198-15000-60T DESCRIPTION: Ground Power Unit C. MONITORING OPERATION 1) Home Screen During normal operation, the control panel will display the Home Screen, 12. Select Figure selectable entities by touch. When the touch screen displays the unit screen saver, touching anywhere on the screen brings up the Home screen.
Page 32 Unitron, LP MAINTENANCE MANUAL MODEL UDC-420M PART NO. 198-15000-60T DESCRIPTION: Ground Power Unit MAIN MENU OPERATION MENUS SCREEN BRIGHTNESS MENU LANGUAGE REPAIR MENU CONTROL MENU MAX TEMPERATURE SLEEP MODE – SLEEP MODE TIME MIN / MAX DC BUS PADLOCK ON / OFF – PASSWORD...
Page 33 Unitron, LP MAINTENANCE MANUAL MODEL UDC-420M PART NO. 198-15000-60T DESCRIPTION: Ground Power Unit 3) Control Menu Functions Password Padlock The Padlock Password can be used to require a password before the unit can be used. The default password is 42.
Page 34 Unitron, LP MAINTENANCE MANUAL MODEL UDC-420M PART NO. 198-15000-60T DESCRIPTION: Ground Power Unit 4) Adjust Menu Functions The Adjust menu has the following functions for this unit. This menu is password protected with a default password of 42. Once the password is entered the Adjust menu will be accessible for 5 minutes or until power is cycled.
Page 35 Access the Event Log to retrieve recorded unit alarms and events, used for diagnostic purposes. Nameplate Date Access the Nameplate Data to retrieve unit configuration data. Service Contact Information – Unitron, LP Press the phone icon in the Repair menu title bar to display the Unitron Service contact information.
Page 36 Unitron, LP MAINTENANCE MANUAL MODEL UDC-420M PART NO. 198-15000-60T DESCRIPTION: Ground Power Unit 6) Evaluate Menu The Evaluate menu gives the current input and output operating values, used to assist in understanding unit operational status. Input These Input Power parameter readings are given: •...
Page 37 Therefore, Maintenance Training Courses are offered on an individual basis. To ensure that our customers derive maximum benefit from their unit, Unitron offers a variety of training classes tailored to specific interests and requirements. Maintenance classes can be presented at either the Unitron factory or the customer's site.
Page 38 Unitron, LP MAINTENANCE MANUAL MODEL UDC-420M PART NO. 198-15000-60T DESCRIPTION: Ground Power Unit 3) Scheduled Maintenance - Semiannual PROCEDURE Test the output voltage and frequency with certified equipment. Output should be within the range specified in the specification chart for the unit. Output should be within the range specified in the“DC Output Power Specifications and Capabilities”...
Page 39 Unitron, LP MAINTENANCE MANUAL MODEL UDC-420M PART NO. 198-15000-60T DESCRIPTION: Ground Power Unit Replace all 2 filters, 1 per side. LEFT SIDE VIEW Figure 16. Air Filter Replacement...
Page 40 Unitron, LP MAINTENANCE MANUAL MODEL UDC-420M PART NO. 198-15000-60T DESCRIPTION: Ground Power Unit C. TROUBLESHOOTING This section provides information for troubleshooting the unit. This information is provided for qualified equipment maintenance personnel only. DANGER - ELECTRIC SHOCK HAZARD: LETHAL LEVELS OF VOLTAGE ARE PRESENT WITHIN THE UNIT.
Page 41 Unitron, LP MAINTENANCE MANUAL MODEL UDC-420M PART NO. 198-15000-60T DESCRIPTION: Ground Power Unit NAVIGATIONAL ICONS FOR LOG ENTRIES RESET EVENT SELECTED EVENT ENTRY ALARM SOUND EVENT LOG MAIN FIELD (ON/OFF) DELETE EVENT ENTRIES REPORTED CODE FOR EVENT Figure 17. Event Log Screen...
Page 42 Unitron, LP MAINTENANCE MANUAL MODEL UDC-420M PART NO. 198-15000-60T DESCRIPTION: Ground Power Unit 3) Managing and Reading Event Log When an event or alarm occurs, an entry is made in the Event Log. The Event Log is accessed from the Repair menu, and viewed on the Alarm screen. For the purpose of viewing and managing the Event Log, the Alarm Silence and Alarm Clear icons may be ignored.
Page 43 Unitron, LP MAINTENANCE MANUAL MODEL UDC-420M PART NO. 198-15000-60T DESCRIPTION: Ground Power Unit CHAPTER 4 - ILLUSTRATED PARTS BREAKDOWN This chapter contains illustrated parts breakdowns for the unit, along with the manufacturer information. This information is provided for qualified equipment maintenance personnel only.
Page 44 Unitron, LP MAINTENANCE MANUAL MODEL UDC-420M PART NO. 198-15000-60T DESCRIPTION: Ground Power Unit Table 2: Manufacturers with Cage Code Numbers CAGE NO. NAME ADDRESS 27264 Molex Inc. 1500 Hancel Parkway Mooresville, IN 46158 32353 ABB Control Inc. 1206 Hatton Rd.
Page 45 CAGE code number. The following pages provide detailed illustrations of the component parts and their location within the unit. For ordering information, contact: Unitron, LP · 10925 Miller Road · Dallas, TX 75238 · 800-527-1279 · Attn: Customer Service.
Page 46 Unitron, LP MAINTENANCE MANUAL MODEL UDC-420M PART NO. 198-15000-60T DESCRIPTION: Ground Power Unit A4, X17 • FRONT VIEW (DOOR REMOVED) • FRONT VIEW (DOOR REMOVED) Figure 19. UDC-420M Ground Power Unit, Sheet 1 of 3...
Page 47 Unitron, LP MAINTENANCE MANUAL MODEL UDC-420M PART NO. 198-15000-60T DESCRIPTION: Ground Power Unit • X11D TOP VIEW (EXTERNAL PANELS REMOVED) • TOP VIEW (EXTERNAL PANELS, A1, AND A2 REMOVED) Figure 19. UDC-420M Ground Power Unit, Sheet 2 of 3...
Page 48 REAR WHEEL - LEFT REAR WHEEL - RIGHT (SWIVEL W/BRAKE) (SWIVEL W/BRAKE) REAR VIEW (PANEL REMOVED) FILTER MAT (1 PER SIDE, 2 PER UNIT) FRONT WHEELS (FIXED) LEFT SIDE VIEW Figure 19. UDC-420M Ground Power Unit, Sheet 3 of 3...
Page 49 DESCRIPTION: Ground Power Unit Figure/ CAGE Item Part Number Description Qty. Code Ref. Des. 19 – 198-15000-60T 19-0 UDC-420M, TSP-4, T-3(MT) 3BC99 198-14015-7 19-1 . IN/OUT PNL ASSY, UDC, S2, 6P, 3BC99 198-15022-4 19-2 . PWR MDL ASSY,600A,UDC,6P (P) 3BC99 198-15042-3 19-3 .
Page 50 Unitron, LP MAINTENANCE MANUAL MODEL UDC-420M PART NO. 198-15000-60T DESCRIPTION: Ground Power Unit F1, XF1 F2, XF2 F3, FX3 Z2-Z3 BUSBAR BUSBAR Figure 20. Input/Output Panel Assembly – A1...
Page 51 Unitron, LP MAINTENANCE MANUAL MODEL UDC-420M PART NO. 198-15000-60T DESCRIPTION: Ground Power Unit Figure/ CAGE Item Part Number Description Qty. Code Ref. Des. 20 – 198-14015-7 20-0 IN/OUT PNL ASSY, UDC, S2, 6P 3BC99 198-13030-1 20-1 . PWA, UFC, SYSTEM CONTROL...
Page 52 Unitron, LP MAINTENANCE MANUAL MODEL UDC-420M PART NO. 198-15000-60T DESCRIPTION: Ground Power Unit A22JP1 AIR FLOW AIR FLOW X12E X12F X12G X12H Figure 21. Power Module Assembly – A2, Sheet 1 of 3...
Page 53 Unitron, LP MAINTENANCE MANUAL MODEL UDC-420M PART NO. 198-15000-60T DESCRIPTION: Ground Power Unit C5, C6 THM1 CR2 CR1 Figure 21. Power Module Assembly – A2, Sheet 2 of 3...
Page 54 Unitron, LP MAINTENANCE MANUAL MODEL UDC-420M PART NO. 198-15000-60T DESCRIPTION: Ground Power Unit SECTION A - A SECTION B - B Figure 21. Power Module Assembly – A2, Sheet 3 of 3...
Page 55 Unitron, LP MAINTENANCE MANUAL MODEL UDC-420M PART NO. 198-15000-60T DESCRIPTION: Ground Power Unit Figure/ CAGE Item Part Number Description Qty. Code Ref. Des. 21 – 198-15022-4 21-0 POWER MODULE ASSY, 600 A, UDC, 6(P), 450A 3BC99 198-16042-2 21-1 . ASSEMBLY, IGBT, 225 A, GEN 7...
Page 56 Unitron, LP MAINTENANCE MANUAL MODEL UDC-420M PART NO. 198-15000-60T DESCRIPTION: Ground Power Unit C60, C61 R60, R61 R4 (TOP) R5 (MIDDLE) R6 (BOTTOM) Figure 22. Magnetics Assembly – A3, Sheet 1 of 3...
Page 57 Unitron, LP MAINTENANCE MANUAL MODEL UDC-420M PART NO. 198-15000-60T DESCRIPTION: Ground Power Unit CBL1-CBL4 CR1-CR6 THM2 SECTION A - A SECTION B - B Figure 22. Magnetics Assembly – A3, Sheet 2 of 3...
Page 58 Unitron, LP MAINTENANCE MANUAL MODEL UDC-420M PART NO. 198-15000-60T DESCRIPTION: Ground Power Unit SECTION C - C LEADS TO A2 DETAIL D - D SECTION D - D Figure 22. Magnetics Assembly – A3, Sheet 3 of 3...
Page 59 Unitron, LP MAINTENANCE MANUAL MODEL UDC-420M PART NO. 198-15000-60T DESCRIPTION: Ground Power Unit Figure/ CAGE Item Part Number Description Qty. Code Ref. Des. 22 – 198-15042-3 22-0 MAGNETICS ASSY, UDC, AC FANS, 6P, 3BC99 198-15043-1 22-1 . CABLE ASSY, SCHOTTKY DIODES, UDC...
Page 60 Unitron, LP MAINTENANCE MANUAL MODEL UDC-420M PART NO. 198-15000-60T DESCRIPTION: Ground Power Unit TSP-4 (HN1) (TSP-4) (SW1) JU-X16 BACK VIEW INSIDE UNIT Figure 23. Meter Panel Assembly – A4...
Page 61 Unitron, LP MAINTENANCE MANUAL MODEL UDC-420M PART NO. 198-15000-60T DESCRIPTION: Ground Power Unit Figure/ CAGE Item Part Number Description Qty. Code Ref. Des. 23 – 198-19029-9 23-0 METER PANEL ASSY, TS, 4", TEX WHT 3BC99 HG1G-4VT22TF-B 23-1 . TOUCHSCREEN,4.3,TFT-LCD,BLK BEZEL...
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Page 63 Unitron, LP MAINTENANCE MANUAL MODEL UDC-420M PART NO. 198-15000-60T DESCRIPTION: Ground Power Unit CHAPTER 5 - SCHEMATIC DIAGRAMS This chapter provides details schematic diagrams for the unit. The following schematic is provided: 198-15300-60T Schematic, Ground Power Unit, UDC-420M, TSP-4, T-3(MT)
Page 64 Unitron, LP MAINTENANCE MANUAL MODEL UDC-420M PART NO. 198-15000-60T DESCRIPTION: Ground Power Unit THIS PAGE INTENTIONALLY LEFT BLANK...

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198-15000-60t