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Tronair 11-2820-0000 Operation & Service Manual

28.5 vdc ground power unit
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OPERATION & SERVICE MANUAL
Model: 11-2820-0000
28.5 VDC Ground Power Unit
05/2024 –− Rev. 06
For Spare Parts, Operations & Service Manuals or Service Needs
Scan the QR code or visit Tronair.com/aftermarket
The Tronair Group of Companies:
Tronair | EBIS | Columbus Jack | Eagle | DAE | Malabar International
Tronair, Inc.
Phone: (419) 866-6301 | 800-426-6301
1 Air Cargo Pkwy East
Web: www.tronair.com
Swanton, OH 43558
Email: sales@tronair.com

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Summary of Contents for Tronair 11-2820-0000

  • Page 1 For Spare Parts, Operations & Service Manuals or Service Needs Scan the QR code or visit Tronair.com/aftermarket The Tronair Group of Companies: Tronair | EBIS | Columbus Jack | Eagle | DAE | Malabar International Tronair, Inc. Phone: (419) 866-6301 | 800-426-6301 1 Air Cargo Pkwy East Web: www.tronair.com...
  • Page 2 REVISION DATE TEXT AFFECTED 02/2017 Original Release 10/2017 Modified Parts Lists 09/2018 Modified Parts List 11/2022 Modified Parts List 05/2023 Modified 9.7 Engine/Alternator/Engine Mounting 05/2024 Added 1.6 Cold Weather Features, Modified 10.2 Recommended Spare Parts Lists...

  • Page 3: Table Of Contents

    Model: 11-2820-0000 28.5 VDC Ground Power Unit TABLE OF CONTENTS PAGE PRODUCT INFORMATION .............................. 1 DESCRIPTION..............................1 MODEL & SERIAL NUMBER ..........................1 MANUFACTURER .............................. 1 FUNCTION................................1 REQUIREMENTS ............................... 1 COLD WEATHER FEATURES ........................... 1 SAFETY INFORMATION ..............................1 USAGE AND SAFETY INFORMATION ......................

  • Page 4: Product Information

    FUNCTION The 11-2820-0000 Ground Power Unit (GPU), is a diesel powered unit designed to serve as a 28.5 volt DC power source for parked aircraft. It can provide 600 amps continuous for aircraft servicing, and up to 2000 amps peak for starting.

  • Page 5: Explanation Of Warning & Danger Signs

    Model: 11-2820-0000 28.5 VDC Ground Power Unit EXPLANATION OF WARNING & DANGER SIGNS WARNING! Accidental Starts! Always turn off and lock out the battery switch before servicing this GPU. Only qualified service personnel may service this equipment. Read and understand the technical manual before servicing this equipment.

  • Page 6: Safety Guidelines

    Model: 11-2820-0000 28.5 VDC Ground Power Unit SAFETY GUIDELINES • Operator must be properly trained prior to operating the GPU • Pre-operation check must be performed before each use. (Refer to operating instructions) • DC contactor must be OFF when connecting and disconnecting the cable from the aircraft •...

  • Page 7: Operation

    The user shall operate the GPU in accordance with the Operation and Service Manual. • The employer of the operator shall provide all necessary training. NUMERICAL VALUES Model ......11-2820-0000 Serial Number ....(See Nameplate on GPU) 5.2.1 Physical Weight (Dry) ....3000 lbs (1361 kg) Width ......

  • Page 8: Location & Layout Of Controls

    Model: 11-2820-0000 28.5 VDC Ground Power Unit LOCATION & LAYOUT OF CONTROLS 5.3.1 Control Panel (External) Screen Emergency Stop Menu Key Button Applies DC Power Fault Indicator Power On Warning Indicator Power On Indicator Power Off Up Key Enter Key...

  • Page 9: Control Panel Screens

    Model: 11-2820-0000 28.5 VDC Ground Power Unit 5.3.2 Control Panel Screens Power Up Main Operating DC Voltage (Actual) DC Voltage Setpoint DC Amperage (Actual) Aircraft Cable Status DC Current Limit Setting Fuel Level DC Output Contactor Status Unit Status Status Timer 04/2024 | Rev.

  • Page 10: Engine Status

    Model: 11-2820-0000 28.5 VDC Ground Power Unit 5.3.2 Control Panel Screens (continued) Engine Status Engine Speed Oil Pressure Engine Speed Target Engine Temperature Engine Alternator Voltage Engine Power Load Engine Running Hours Unit Status Status Timer Alternator Status DC Voltage Setpoint...

  • Page 11: System Information

    Model: 11-2820-0000 28.5 VDC Ground Power Unit 5.3.2 Control Panel Screens (continued) System Information 5.3.3 Control Panel Software Settings To enter the software settings, press the Menu Key Enter password 0000, press Enter Key after each 0 04/2024 | Rev. 06...
  • Page 12 Model: 11-2820-0000 28.5 VDC Ground Power Unit 5.3.3 Control Panel Software Settings (continued) Select ACFT/GPU Bypass, press Enter Key CAUTION! The DC aircraft cable interlock is enabled when the third and smallest pin on the aircraft receptacle completes the circuit in the split pin connector. Under no circumstances should the split pin be bridged in order to switch on the DC.
  • Page 13 Model: 11-2820-0000 28.5 VDC Ground Power Unit 5.3.3 Control Panel Software Settings (continued) Select Current Setpoint, press Enter Key Adjust the Current Limit (2000A should be used if no current limit is required), press Enter Key 04/2024 | Rev. 06...

  • Page 14: Controls, Engine Compartment

    Model: 11-2820-0000 28.5 VDC Ground Power Unit 5.3.4 Controls, Engine Compartment FUEL FILL Item Description Function Connects and disconnects unit Pos. 12 Volt battery cables. Must be in the ON position Battery Switch for unit to run. GPU is shipped with switch in the OFF position 04/2024 | Rev.

  • Page 15: Start Up Procedures

    Model: 11-2820-0000 28.5 VDC Ground Power Unit START UP PROCEDURES 5.4.1 Pre-Use Inspection CAUTION! A pre-use inspection must be carried out prior to each use to ensure safe operation of the GPU. Failure to carry out these procedures listed below may result in severe damage to the GPU or prevent efficient operation.

  • Page 16: Emergency Shut Down Procedure

    Model: 11-2820-0000 28.5 VDC Ground Power Unit 5.4.4 Emergency Shut Down Procedure In the event an emergency shut down is necessary, press the emergency stop switch located on the operator panel. The Emergency Stop button is for emergencies only. CAUTION! Do not use for normal shut down.

  • Page 17: Packaging And Storage

    Model: 11-2820-0000 28.5 VDC Ground Power Unit PACKAGING AND STORAGE PACKAGING REQUIREMENTS Turn battery switch to OFF position Drain fuel Ensure fuel cap is secure Securely fasten doors Wrap for paint protection Strap unit in truck or shipping container using 4 cargo straps. Hook one strap through each tie-down ring on the front NOTE: Use at least four (4) straps with a minimum 3,000 lb (136 kg) capacity each.

  • Page 18: Long Term Storage

    Model: 11-2820-0000 28.5 VDC Ground Power Unit 6.5.2 Long Term Storage Special precautions are necessary to protect the GPU from rust and corrosion. It is recommended that the unit be stored in a building that is heated during winter months. Moisture absorbing chemicals should be placed inside the unit in climates where there is excessive dampness.

  • Page 19: Trouble Shooting

    Model: 11-2820-0000 28.5 VDC Ground Power Unit TROUBLE SHOOTING FAULT POSSIBLE CAUSE SOLUTION Battery switch turned to off Check, turn to on No Power When “Power On” Loose battery terminals Check, clean and tighten terminals Switch is Pressed Power ON switch inoperative...

  • Page 20: Maintenance

    Model: 11-2820-0000 28.5 VDC Ground Power Unit MAINTENANCE As with all Ground Support Equipment it is very important to provide proper preventative maintenance and service. This will increase the service life of the diesel engine, which can be expected to operate for 30,000 hours without a major overhaul (this may vary according to local operating conditions.) The following specifies consumable service...

  • Page 21: General (Daily Checks)

    Model: 11-2820-0000 28.5 VDC Ground Power Unit MAINTENANCE (continued) Cooling System: Use 50/50 ethylene glycol and diethylene glycol mixture. Refer to section 4 of the Deutz Operation and Maintenance Manual (provided as a supplement to this manual) for anti-freeze and water quality recommendations.

  • Page 22: Short Term Preventive Maintenance Schedule

    Model: 11-2820-0000 28.5 VDC Ground Power Unit SHORT TERM PREVENTIVE MAINTENANCE SCHEDULE It is recommended to change the engine oil and filter after the first 50 hours of operation. The following table is provided as a guide to for frequent service intervals. The Doosan Operation and Maintenance Manual (provided as a supplement to this manual) provides engine service interval information for daily, 250 hour, 500 hour, 1000 hour and 2000 hour intervals.

  • Page 23: Daily Checks

    Model: 11-2820-0000 28.5 VDC Ground Power Unit DAILY CHECKS Unit ......Visually inspect outside of GPU for loose hardware, loose parts, frayed wires/cables and general appearance. Radiator ....Open radiator access door and remove radiator cap (cold only). Ensure that coolant is up to the bottom of the fill neck.

  • Page 24: Soundfoam

    Model: 11-2820-0000 28.5 VDC Ground Power Unit SOUNDFOAM NOTES: All panels to be 2” thick Panels are soundfoam M Finish is black matte film and MDK adhesive Panels drawn with adhesive side shown Item Part Number Description K-5176-A Soundproofing, Back Panel...

  • Page 25: External Components

    Model: 11-2820-0000 28.5 VDC Ground Power Unit EXTERNAL COMPONENTS Item Part Number Description Z-9167 GPU CHASSIS ASSEMBLY S-3011-01 LOUVER, BACK LEFT H-2884 DOOR, LATCH S-2411 SIDE, TRAY RT H-2915 PULL, TAB EC-1794 BOX, VERTICAL MOUNTING JUNCT EC-2709 BASE, BLACK FOR 169 LED LIGHT...
  • Page 26 Model: 11-2820-0000 28.5 VDC Ground Power Unit EXTERNAL COMPONENTS (continued) Item Part Number Description Z-9229 WELDMENT, CONTROLS PANEL S-3014 PANEL, TOP FRONT Z-9230 WELDMENT, LOUVER DOOR H-2827 HINGE, DOOR Z-6168-00 LID, RADIATOR ACCESS (P) Z-9231 WELDMENT, TOP REAR J-6341 MEMBER, REAR CROSS...

  • Page 27: Engine/Alternator/Engine Mounting

    Model: 11-2820-0000 28.5 VDC Ground Power Unit ENGINE/ALTERNATOR/ENGINE MOUNTING Item Part Number Description Z-9232 GPU CHASSIS TS-2665-01 TUBE, MOUNTING TS-2664-01 TUBE, MOUNTING Z-9233 ASSEMBLY, ENGINE/ALTERNATOR Z-9208 ASSEMBLY, SHELF Z-9217-01 WELDMENT, STARTER BATTERY TRAY EC-3149 BATTERY, 12 VOLT H-4005 TIE-DOWN, BATTERY...
  • Page 28 Model: 11-2820-0000 28.5 VDC Ground Power Unit ENGINE/ALTERNATOR/ENGINE MOUNTING (continued) Item Part Number Description H-4028 VMC ISOLATOR S-3019-01 BRACKET, ECU SUPPORT EC-2982 FUSE HOLDER, ECU Z-9243 ASSEMBLY, FUEL TANK J-6369-01 SPACER, ENGINE MOUNT S-3018-01 BRACKET, FUEL FILTER SUPPORT 04/2024 | Rev. 06...
  • Page 29 Model: 11-2820-0000 28.5 VDC Ground Power Unit ENGINE/ALTERNATOR/ENGINE MOUNTING (continued) Item Part Number Description H-4024 ENGINE EC-3093 ALTERNATOR 04/2024 | Rev. 06 Page | 26...

  • Page 30: Alternator

    Model: 11-2820-0000 28.5 VDC Ground Power Unit ALTERNATOR Item Part Number Description Bolt, Hex Head Grade 8, ⅜ - 16 x 1 Long G-1420-107010 Flatwasher, ⅜ Hardened G-1513-1070N G-1514-M100R Lockwasher, M10 G-1533-100035 Bolt, Hex Head, M10 x 35 mm 04/2024 | Rev. 06...

  • Page 31: Fuel Tank And Frame

    Model: 11-2820-0000 28.5 VDC Ground Power Unit FUEL TANK AND FRAME Item Part Number Description Z-7773-01 WELDMENT, FUEL TANK CAGE H-4196 FUEL TANK Z-7756 WELDMENT, FUEL NECK 15253 FILL CAP LESS SCREEN (GREEN) A-1279-01 ANGLE, SUPPORT N-2783-02 DRAIN, COCK N-2206-03-SS PLUG, HEX HEAD 04/2024 | Rev.

  • Page 32: Rectifier/Contactor/Battery Switch/Output Cable

    Model: 11-2820-0000 28.5 VDC Ground Power Unit RECTIFIER/CONTACTOR/BATTERY SWITCH/OUTPUT CABLE NOTE: 1 Align arrows on Item 18 (Fan) per drawing. 04/2024 | Rev. 06 Page | 29...
  • Page 33 Model: 11-2820-0000 28.5 VDC Ground Power Unit This page left blank intentionally. 04/2024 | Rev. 06 Page | 30...
  • Page 34 Model: 11-2820-0000 28.5 VDC Ground Power Unit RECTIFIER/CONTACTOR/BATTERY SWITCH/OUTPUT CABLE (continued) NOTE: 1 Align arrows on Item 21 (CT) per drawing. 04/2024 | Rev. 06 Page | 31...
  • Page 35 Model: 11-2820-0000 28.5 VDC Ground Power Unit RECTIFIER/CONTACTOR/BATTERY SWITCH/OUTPUT CABLE (continued) Item Part Number Description Z-9209-01 WELDMENT, SHELF EC-1656 BATTERY, 12 VOLT EC-2045 RECTIFIER, 28VDC 6-PHASE EC-2395 CHOKE EC-2968 TRANSFORMER, SINGLE PHASE EC-2970 VOLTAGE REGULATOR EC-2971 RELAY, 500A 12VDC J-6312-01...

  • Page 36: Sub Assembly Components

    Model: 11-2820-0000 28.5 VDC Ground Power Unit 9.10 SUB ASSEMBLY COMPONENTS Item Part Number Description Z-9178 WELDMENT, REAR AXLE Z-9179 WELDMENT, FRONT AXLE H-4000 TIRE, GPU CHASSIS H-3424 H-3200 Z-9191 WELDMENT, FRAME G-1301-02 1/8" Cotter Pin R-2096 PIN, TOWBAR J-3427...

  • Page 37: Provision Of Spares

    If warranty coverage is approved, either replacement parts will be sent or the product will have to be returned to Tronair for repairs. If the product is to be returned, a Return Material Authorization (RMA) number will be issued for reference purposes on any shipping documents.

  • Page 38: Appendices

    Model: 11-2820-0000 28.5 VDC Ground Power Unit 13.0 APPENDICES Wiring Diagram – INS-2372 APPENDIX I APPENDIX II Controller - Murphy MPC-20 Alternator Operation & Maintenance Manual – Magnaplus 361 APENDIX III APPENDIX IV Declaration of Conformity Additional Documents See Doosan for D34 Operation & Maintenance Manual 04/2024 | Rev.
  • Page 39 APPENDIX I Wiring Schematic (INS-2372)
  • Page 41 REVISIONS THIS DRAWING IS THE PROPERTY OF TRONAIR, INC. IT IS FURNISHED TO YOU FOR CONFIDENTIAL INFORMATION PURPOSES ONLY AND IS NOT TO BE DISCLOSED DESCRIPTION DWN CHK DATE TO ANYONE OR REPRODUCED OR USED FOR MANUFACTURING PURPOSES WITHOUT THE EXPRESS WRITTEN PERMISSION OF TRONAIR, INC.
  • Page 42 THIS DRAWING IS THE PROPERTY OF TRONAIR, INC. IT IS FURNISHED TO YOU FOR CONFIDENTIAL INFORMATION PURPOSES ONLY AND IS NOT TO BE DISCLOSED TO ANYONE OR REPRODUCED OR USED FOR MANUFACTURING PURPOSES WITHOUT THE EXPRESS WRITTEN PERMISSION OF TRONAIR, INC.
  • Page 43 THIS DRAWING IS THE PROPERTY OF TRONAIR, INC. IT IS FURNISHED TO YOU FOR CONFIDENTIAL INFORMATION PURPOSES ONLY AND IS NOT TO BE DISCLOSED TO ANYONE OR REPRODUCED OR USED FOR MANUFACTURING PURPOSES WITHOUT THE EXPRESS WRITTEN PERMISSION OF TRONAIR, INC.
  • Page 45 APPENDIX II Controller (Murphy MPC-20)
  • Page 93 APPENDIX III Alternator Operation and Maintenance Manual (Magnaplus 361)
  • Page 115 APPENDIX IV Declaration of Conformity...

  • Page 117: Eu Declaration Of Conformity

    Enter serial number(s) Declaration: Tronair has assessed the equipment described above against the Essential Health and Safety Requirements of one or more Directives. Based on this assessment, the equipment described above is deemed to comply with the directive(s) listed below.