ITW GSE Hobart 2400 Compact User manual

ITW GSE HOBART ●11001 Us Highway 41 North ●Palmetto, FL 34221 ●U.S.A
T: (toll free in US): 800-899-1841 ●T (International): + 1 941-721-1000 ●E: technicalsupp[email protected]
Serial no.
Type 3GW -200/ -
it’s all about connections
Manual
Hobart 2400 Compact
120 / 140 / 180 kVA
400 Hz Ground Power Unit
OM2252
Rev 0 December 15 2016

Document no. 578.430AB Page 2 of 75
Diagrams and drawings are subject to change without prior notice.
Latest diagram versions can be found at www.itwgse.com
Printed: December 2016
IMPORTANT NOTE
We recommend that the battery that
safeguards GPU settings etc.
is changed after 5 years of use in
order not to lose data.
The unit has an internal supervision
that keeps track of time the battery
has been in service and will display a
warning when the battery needs to be
changed.
Refer to section 8.2 for further
information
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Operation Manual - Hobart 2400 Compact – 120 / 140 / 180 kVA
Index
Document no. 578.430AB Page 3 of 75
INDEX
1.0 Declaration of Conformity ........................................................................................5
2.0 Safety Instructions.....................................................................................................6
3.0 General Description ..................................................................................................7
3.1 Built-in features / protections........................................................................................ 13
4.0 Transport and Installation .......................................................................................15
4.1 Storage Before Installation............................................................................................ 15
4.2 Operational and Environmental Conditions after Commissioning............................... 15
4.3 Transport ....................................................................................................................... 15
4.4 Installation and fastening instructions........................................................................... 17
4.5 Connection of Cables .................................................................................................... 22
4.6 Utility Input................................................................................................................... 24
4.7 400 Hz Output............................................................................................................... 24
4.8 400 Hz Interlock............................................................................................................ 25
4.9 Control Interface (Remote I/O Terminals).................................................................... 25
4.10 TCP/IP On-board Interface ........................................................................................... 27
5.0 Technical Specifications .........................................................................................28
6.0 Operator’s Instructions (Display/LED/Keypad layout)..........................................32
6.1 Using the Display/Keypad: ........................................................................................... 34
6.2 Operating the unit: ........................................................................................................ 35
6.3 Basic Menu: .................................................................................................................. 37
6.4 Default Factory Settings: .............................................................................................. 51
7.0 Set-up Lock / Output Mode / Compensation ..........................................................52
7.1 Preventing changes of set-up parameters...................................................................... 52
7.2 Output Voltage.............................................................................................................. 52
7.3 Plug & Play Cable compensation.................................................................................. 52
7.4 Manual Compensation .................................................................................................. 53
7.5 Output Mode ................................................................................................................. 53
7.6 Fan Control ................................................................................................................... 54
7.7 Remote Stop.................................................................................................................. 54
7.8 EF Interlock................................................................................................................... 54
7.9 EF Interlock Ripple Level............................................................................................. 55
7.10 EF Interlock Delay........................................................................................................ 55
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Operation Manual - Hobart 2400 Compact – 120 / 140 / 180 kVA
Index
Document no. 578.430AB Page 4 of 75
7.11 Aircraft Connector Insertion ......................................................................................... 55
7.12 GPU Enable................................................................................................................... 55
7.13 Door Switch .................................................................................................................. 56
7.14 Cable Temperature........................................................................................................ 56
7.15 Neutral Voltage Supervision......................................................................................... 56
7.16 Earth Leakage Level ..................................................................................................... 56
7.17 Earth Leakage Delay..................................................................................................... 57
7.18 Real Time Clock Setup ................................................................................................. 57
7.19 Date/Time Format ......................................................................................................... 57
7.20 Ethernet Configuration.................................................................................................. 57
7.21 Modbus Slave Address.................................................................................................. 57
7.22 LED Brightness............................................................................................................. 58
7.23 Unit of Measure ............................................................................................................ 58
7.24 Costumer ID.................................................................................................................. 58
7.25 Battery Replaced ........................................................................................................... 58
7.26 Language....................................................................................................................... 58
8.0 Service, Maintenance, Overhaul .............................................................................60
8.1 Recommended Maintenance Schedule ......................................................................... 60
8.2 Battery back-up & replacement .................................................................................... 61
9.0 Trouble Shooting & Repair.....................................................................................63
9.1 Fault Guidance .............................................................................................................. 64
10.0 Illustrated Parts List ................................................................................................67
11.0 Options ....................................................................................................................70
578808 Dry Contacts (Diagram 478850)................................................................................... 70
578850 Base module (Drawing 278430) ................................................................................... 70
578852 Single Output (Diagram 478850).................................................................................. 71
578853 Door Interlock (Diagram 478850) ................................................................................ 71
578854 Anti-Condensation Heater (Diagram 478850).............................................................. 72
578855 RS485 Interface (Diagram 478850).............................................................................. 72
578856 Military Interlock (Diagram 478850) ........................................................................... 73
578857 Lockable Door (Fixed).................................................................................................. 73
578xxx Remote Control Box ..................................................................................................... 74
578814 Terminal Extension ....................................................................................................... 75
591100 Auto Calibration Plug ................................................................................................... 75
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Operation Manual - Hobart 2400 Compact – 120 / 140 / 180 kVA
Declaration of Conformity
Document no. 578.430AB Page 5 of 75
1.0 Declaration of Conformity
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Operation Manual - Hobart 2400 Compact Power – 120 / 140 / 180 kVA
Safety Instructions
Document no. 578.430AB Page 6 of 75
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.
•Have only qualified people remove covers for maintenance or troubleshooting.
Hot Parts
•Do not touch hot magnetics.
•Allow a cooling period before doing maintenance.
SAVE THESE INSTRUCTIONS!
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Operation Manual - Hobart 2400 Compact Power – 120 / 140 / 180 kVA
General Description
Document no. 578.430AB Page 7 of 75
3.0 General Description
The figure below shows the basic principle of the AXA 2400 Compact Power unit. The 50/60 Hz utility
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 Disconnect (Q1):
The Input Disconnect disconnects all power to the ground power unit. Upon closing the switch
disconnector/breaker, the power is distributed via the 2 MCB’s (Q2 / Q3) to each converter and via Q6
to the internal 24 Volt power supply (G1). The ground power unit performs an initialization test and
then goes into standby mode.
Magnetic Package (IT0040)
Interface Board (new)
Magnetic Package
Capacitor
Boards
(579532)
Power Module (578100)
Output Filter Cap. (KP7087)
315 A Disconnect
160 A MCB
160 A MCB Magnetic Package (IT0040)
Power Module (578100)
Output Filter Cap. (KP7087)
Output Cont. (K 4387)
Output Cont. (K 4387)
DP0222 20 A Supply
Display 579536
Cont. B.
579526
Sub D
Sub D
RFI Input
400 A Disconnect
225 A MCCB
225 A MCCB
40 A Supply
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Operation Manual - Hobart 2400 Compact Power – 120 / 140 / 180 kVA
General Description
Document no. 578.430AB Page 8 of 75
Capacitor Board (A5/A6):
These modules include the following functions:
•Input and Output RFI filters to reduce the EMI/EMC emission into the mains and output to such
alevel 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 contactors Q5 (PM1 / PM2).
•Magnetic Wave shaping circuit.
•Coil voltage for the output contactors, controlled via A2:QO1(X17) & QO2 (X18) on the
Interface Board.
Input Choke & 12-pulse Transformer (L1 & T1 / L2 & T3):
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 of 5% (ITHD) at 180 kVA/kW and a unity power factor at all loads. This means
less stress on the main supply network and the distribution transformers.
Inverter Modules (PM1 & PM2):
The Inverter Module includes the rectifier (V1-V6), the DC-filtering capacitors (C1-C6) and the soft
start circuit (Q5) controlled via X11 (PM1) and X12 (PM2). The 3-phase inverter portion of the module
generates a 400 Hz voltage system with a very low harmonic content and individual phase control. Two
PCBs (gate drive top & gate drive bottom located under the DC-filtering capacitors) 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 X26 (PM1) and X25 (PM2).
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Operation Manual - Hobart 2400 Compact Power – 120 / 140 / 180 kVA
General Description
Document no. 578.430AB Page 9 of 75
Output Transformer (T2/T4):
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 / C10-C12):
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 RFI-filter that reduces the high
frequency emissions from the ground power unit and from the aircraft.
Output Contactors (Q4/Q5):
The ground power unit is equipped with a 3-phase output contactor per output. The contactors are
engaged at start-up of the corresponding output and are disengaged when the corresponding 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 corresponding 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) of the 24 VDC for I/O connections
•Fuse (F3) for Display Board (A3) and Operator Keyboard (A4)
•Fuse (F4) of the 24 VDC for interface
•Fuse (F5) PWM control (X15) of fans (M1-M2)
•Fuse (F6) PWM control (X16) of fans (M3-M4)
•User EPO input (X6)
•Measuring transformers for supervision of the 400 Hz output 1 voltage (X28)
•Measuring transformers for supervision of the 400 Hz output 2 voltage (X27)
•Interface for gate drive situated at the Inverter Module (PM1) via GD1 (X10)
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General Description
Document no. 578.430AB Page 10 of 75
•Interface for gate drive situated at the Inverter Module (PM2) via GD2 (X7)
•Interface for current sensors situated at the Inverter Module (PM1) via I1 (X23)
•Interface for current sensors situated at the Inverter Module (PM2) via I1 (X22)
•Relay control of output contactors Q2 – Q3 (X16-X17)
•Soft-start control Inverter Module (PM1) via SS1 (X13)
•Soft-start control Inverter Module (PM2) via SS2 (X14)
•Control of Q5 & DC link measurement via DC1 (X26) for Inverter Module (PM1)
•Control of Q5 & DC link measurement via DC2 (X25) for Inverter Module (PM2)
•Input for temperature sensors T2 (X30)
•Input for temperature sensors T4 (X31)
•Input for Q2 / Q3 status (X29)
•I/O ports for remote control (Start, Stop etc.) output 1 (X1)
•I/O ports for remote control (Start, Stop etc.) output 2 (X2)
•Protected interface for interlock signals
•Interface for individual overload protection (X22 & X23)
•Neutral Voltage Supervision
•Door Interlock (X32)
•Earth Leakage Failure via (X24) and current sensor (T5) on ground wire from 400 Hz neutral
•Interface for RS232
•EEPROM (X19) contains the unique identity key of the unit
Supply Module (G1):
The generation of the 24 VDC/40 A (Adjusted from factory = 25 Volt) regulated control voltage is done
by the Supply Module G1. This module has a wide input range (323-576 VAC). It is supplied via the
capacitor module (A5) and pre-fused from the 3-phase circuit breaker Q6.
OM2252
Rev 0 December 15 2016