ITW GSE Hobart 2400 Compact User manual

ITW GSE HOBART ●11001 Us Highway 41 North ●Palmetto, FL 34221 ●U.S.A
T: (toll free is US): 800-899-1841 ●T (International): [phone] ●E: [e-mail]
Manual
Hobart 2400 Power Coil
400 Hz Ground Power Unit
&
Cable Retriever System
Serial no.
Type 3GWC -200/ -
3GVF-200/260-N
it’s all about connections
OM2250
Rev 0 - June 23 2016

Document no. 577.420-B Page 2 of 70
Diagrams and drawings are subject to change without prior notice.
Latest diagram versions can be found at www.itwgse.com
Printed: June 2015
IMPORTANT NOTICE
We recommend that the battery that
safeguards GPU settings etc.
is changed after 5 years of use in
order not to lose data.
Refer to section 8.3 for further
information
OM2250
Rev 0 - June 23 2016

Operation Manual –Hobart PoWerMaster® 2400 Power Coil –60 - 90 kVA
Index
Document no. 577.420-B Page 3 of 70
INDEX
1.0 Declaration of Conformity........................................................................................5
2.0 Safety Instructions.....................................................................................................6
3.0 General Description ..................................................................................................7
3.1 Built in features / protections........................................................................................ 12
4.0 Transport and Installation .......................................................................................14
4.1 Storage Before Installation............................................................................................ 14
4.2 Operational and Environmental Conditions after Commissioning............................... 14
4.3 Transport....................................................................................................................... 14
4.4 Installation and fastening instructions........................................................................... 15
4.5 Connection of Cables.................................................................................................... 17
4.6 Mains Input ................................................................................................................... 18
4.7 400 Hz Output............................................................................................................... 19
4.8 400 Hz Interlock............................................................................................................ 19
4.9 User Remote I/O Terminals.......................................................................................... 19
4.10 TCP/IP On-board Interface........................................................................................... 21
5.0 Technical Specifications .........................................................................................23
6.0 Operator’s Instructions (Display/LED/Keypad layout)..........................................26
6.1 Using the Display/Keypad:........................................................................................... 27
6.2 Operator’s instructions (operating via aircraft plug)..................................................... 27
6.3 Operating the unit: ........................................................................................................ 27
6.4 Basic Menu: .................................................................................................................. 30
6.5 Default Factory Settings: .............................................................................................. 43
7.0 Set-up Lock / Output Mode / Compensation..........................................................44
7.1 Preventing changes of set-up parameters...................................................................... 44
7.2 Output Voltage:............................................................................................................. 44
7.3 Plug & Play Cable compensation: ................................................................................ 44
7.4 Manual Compensation: ................................................................................................. 45
7.5 Fan Control ................................................................................................................... 45
7.6 EF Interlock................................................................................................................... 46
7.7 EF Interlock Ripple Level............................................................................................. 46
7.8 EF Interlock Delay........................................................................................................ 46
7.9 Aircraft Connector Insertion......................................................................................... 47
OM2250
Rev 0 - June 23 2016

Operation Manual - Hobart 2400 Power Coil –60 - 90 kVA
Index
Document no. 577.420-B Page 4 of 70
7.10 GPU Enable................................................................................................................... 47
7.11 Door Switch .................................................................................................................. 47
7.12 Plug Temperature.......................................................................................................... 47
7.13 Neutral Voltage Supervision......................................................................................... 48
7.14 Earth Leakage Level ..................................................................................................... 48
7.15 Earth Leakage Delay..................................................................................................... 48
7.16 Real Time Clock Setup................................................................................................. 48
7.17 Ethernet Configuration.................................................................................................. 49
7.18 Modbus Slave Address.................................................................................................. 49
7.19 LED Brightness............................................................................................................. 49
7.20 Date/Time Format......................................................................................................... 49
7.21 Unit of Measure ............................................................................................................ 49
7.22 Costumer ID.................................................................................................................. 50
7.23 Cable Replacement Mode............................................................................................. 50
7.24 Language....................................................................................................................... 50
8.0 Service, Maintenance, Overhaul.............................................................................51
8.1 Recommended Maintenance Schedule ......................................................................... 51
8.2 Cable Replacement Mode............................................................................................. 54
8.3 Battery back-up & replacement .................................................................................... 55
9.0 Trouble Shooting & Repair.....................................................................................57
9.1 Fault Guidance.............................................................................................................. 58
10.0 Illustrated Parts List ................................................................................................61
11.0 Options....................................................................................................................67
AP-577801 Remote Control Box ................................................................................................. 67
AP-577802 Neutral Conductor Rupture Supervision.................................................................. 68
AP-577803 RS485 Interface (Diagram 477800)......................................................................... 69
AP-577804 Anti-Condensation Heater (Diagram 478800)......................................................... 69
AP-577805 Door Switch (Diagram 477800)............................................................................... 70
AP-591100 Auto Calibration Plug.............................................................................................. 70
OM2250
Rev 0 - June 23 2016

Operation Manual - Hobart 2400 Power Coil –60 - 90 kVA
Declaration of Conformity
Document no. 577.420-B Page 5 of 70
1.0 Declaration of Conformity
OM2250
Rev 0 - June 23 2016

Operation Manual - Hobart 2400 Power Coil –60 - 90 kVA
Safety Instructions
Document no. 577.420-B Page 6 of 70
IMPORTANT SAFEGUARDS
DANGER –TO REDUCE THE RISK OF FIRE OR
ELECTRIC SHOCK, CAREFULLY FOLLOW THESE
INSTRUCTIONS
2.0 Safety Instructions
This unit is only intended to be installed, operated and maintained by competent persons
having the necessary knowledge regarding delivery of external power to an aircraft.
Prior to use, service and maintenance, the competent person must, be familiar with all
relevant parts of this manual.
Electric Shock
To ensure personal health and safety, the electrical installation must fulfil all local regulations and
legislation
Touching live electrical parts can cause fatal shocks and severe burns.
Internal parts where the voltage exceeds 50 V are covered and / or marked with:
Keep all panels and covers securely in place.
Have only qualified people remove covers for maintenance or troubleshooting.
When connecting the unit to the aircraft, make sure that the output power is off.
Frequently inspect the installation for damage and bare wiring –Repair / replace if necessary.
Moving Parts
Keep away from fans, cable drum, cable rollers and cable guides.
Keep panels, covers and guards closed and securely in place.
Have only qualified people remove guards or covers for maintenance or troubleshooting
and if possible only when the mains input dis-connector Q1 is open.
To prevent accidental coiling during service, make sure the mains input dis-connector is open.
Keep hands, hair, loose clothing and tools away from moving parts.
Hot Parts
Do not touch hot magnetics.
Allow a cooling period before doing maintenance.
SAVE THESE INSTRUCTIONS!
OM2250
Rev 0 - June 23 2016

Operation Manual - Hobart 2400 Power Coil –60 - 90 kVA
General Description
Document no. 577.420-B Page 7 of 70
3.0 General Description
The figure below shows the basic principle of the Hobart 2400 Power Coil unit. The 50/60 Hz mains
voltage is converted into a galvanic isolated 3-phase, 400 Hz output voltage. A functional description of
each part is given in the following sections.
3.1 Basic Principle
Input Disconnector (Q1):
The Input Disconnect, disconnects all power to the ground power unit. Upon closing the
disconnect/breaker, the ground power unit passes through an initialization test and then into standby
mode.
OM2250
Rev 0 - June 23 2016

Operation Manual - Hobart 2400 Power Coil –60 - 90 kVA
General Description
Document no. 577.420-B Page 8 of 70
Capacitor Board (A5):
This module includes the following functions:
Input RFI filters to reduce the EMI/EMC emission into the mains to such a level that
surrounding equipment is not disturbed. In addition, the two filters prevent voltage transients
from reaching vital parts in the ground power unit.
Resistors in combination with the soft start contactor (Q5).
Magnetic Wave shaping circuit.
Link from the main supply phases L1-L2-L3 to the Supply Module (G1) and VFD via the
breaker (Q4).
Input Choke & 12-pulse Transformer (L1 / T1):
The combination of the choke, the 12-pulse transformer, the magnetic wave shaping circuit and the
rectifier situated at the inverter module, ensures an almost sinusoidal line current with a Total Current
Harmonic Distortion (ITHD) of 5% at 90 kVA/kW and a unity power factor at all loads. This means
less stress on the main supply network and the distribution transformers.
Inverter Module (PM1):
Beside the rectifier (V1-V6), the DC-filtering capacitors (C1-C6) and the soft start circuit (Q5)
controlled via connector X12, the module consists of a 3-phase inverter which generates a 400 Hz
voltage system with a very low harmonic content and individual phase control. Two PCBs (gate drive
top & gate drive bottom) are used to interface between the control unit and the IGBTs. Voltage
supervision of the DC-filtering capacitors is likewise performed at the gate drives via connector X19.
OM2250
Rev 0 - June 23 2016

Operation Manual - Hobart 2400 Power Coil –60 - 90 kVA
General Description
Document no. 577.420-B Page 9 of 70
Output Transformer (T2):
The output transformer ensures galvanic separation between input and output. It also transforms the
voltages from the Inverter Module into the required aircraft voltage (3 x 200/115 V). The filter choke
for the output AC-filter is an integral part of the transformer.
AC Filter Capacitors (C7-C9) / Output RFI (A7):
The harmonic content of the inverter voltage is further reduced by means of the AC Filter, resulting in a
total voltage distortion of less than 2%. In addition to the filter choke (integrated into the transformer)
and the AC capacitors, the ground power unit is equipped with an output RFI-filter that reduces the high
frequency emissions from the ground power unit or from the aircraft.
Output Contactor:
The ground power unit is equipped with a 3-phase output contactor per outlet. The contactor is engaged
at start-up of the corresponding output, and it is disengaged, when the stop button is activated or a
system error occurs. If the interlock voltage, provided by the aircraft, is not returned to the ground
power unit within the delay settings (refer to chapter 6.3), the contactor also disengages.
Interface Board (A2):
The purpose of this board is to interface between the Control Board and the rest of the ground power
unit. The interface module includes the following functions:
Interface to the Display Board (CAN Bus, 24 VDC and EPO (External Emergency Stop))
Fuse (F1 & F2) provides the 24 VDC for I/O connections
Fuse (F3) for Display Board (A3) and Operator Keyboard (A4)
Fuse (F4) provides the 24 VDC for interface
Fuse (F5) PWM control (X10) of the fans (M1-M2) situated above the magnetics
User EPO input (X14)
Measuring transformers for supervision of the 400 Hz output voltage (X26)
Interface for gate drives situated at the Inverter Module (X13)
Interface for current sensors situated at the Inverter Module (X23)
Relay control of output contactor Q2 (X16)
Soft start control of Q5 (X12)
Input for temperature sensors (X18)
Plug control Start, Stop etc.(X1)
Cable drum limit switch inputs (X2)
VFD control (X3)
OM2250
Rev 0 - June 23 2016

Operation Manual - Hobart 2400 Power Coil –60 - 90 kVA
General Description
Document no. 577.420-B Page 10 of 70
Remote I/O and Dry contacts for PBB (X4)
Protected interface for interlock signals.
Neutral Voltage Supervision.
Neutral Conductor Rupture supervision.
Door Interlock (X27).
Earth Leakage Failure via (X22) and current sensor on ground wire from 400 Hz neutral.
Interface for RS232.
EEPROM (X34) contains the unique identity key of the unit.
Supply Module (G1):
The generation of the 24 VDC / 10 A (Adjusted from factory = 25 Volt) regulated control voltage is
done by the Supply Module G1. This module has a wide input range (340-575 VAC). It is supplied via
the capacitor module and pre-fused from the 3-phase circuit breaker Q4.
Control Board (A1):
The Control Board is based on a micro-controller and a digital signal processor (DSP). Together they
regulate, supervise and diagnose possible external and internal faults. As soon as the ground power unit
is connected to the mains, and constantly during normal operation, the Control Board runs through a
self-check program which checks all internal
functions of the ground power unit. If an internal or
external error is detected, the display shows the nature
of the error. All immediate parameters related to a
shut-down are stored in the ground power unit’s
memory. The Control Board has an on-board Ethernet
RJ45 connector, which can be used to communicate
with the BMS (Building Management System) and
USB host Type A connection to retrieve data from the
converter or to up-date the software.
OM2250
Rev 0 - June 23 2016