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
OM2252
Rev 0 December 15 2016

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
OM2252
Rev 0 December 15 2016

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
OM2252
Rev 0 December 15 2016

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
OM2252
Rev 0 December 15 2016

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!
OM2252
Rev 0 December 15 2016

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
OM2252
Rev 0 December 15 2016

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).
OM2252
Rev 0 December 15 2016

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)
OM2252
Rev 0 December 15 2016

Operation Manual - Hobart 2400 Compact Power – 120 / 140 / 180 kVA
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

Operation Manual - Hobart 2400 Compact Power – 120 / 140 / 180 kVA
General Description
Document no. 578.430AB Page 11 of 75
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 update the software.
Display Board & Keyboard (A3 / A4):
The display module serves as the interface for daily operation.
The display communicates with the Control Board via a CAN bus
(Controller Area Network) and can be placed up to 100 m away from the
unit when using the Remote Control Box. Furthermore, the display module
includes a USB connection which can be used to download the Black Box
and the Power Log and for update of the display software.
OM2252
Rev 0 December 15 2016

Operation Manual - Hobart 2400 Compact Power – 120 / 140 / 180 kVA
General Description
Document no. 578.430AB Page 12 of 75
ID Chip (A7):
The ID Chip is connected to Interface Board A2
(X19) and is fixed to the I/O zone plate.
It contains information on the GPU configuration
and stores all set-up values, Black Box / Power
Log records.
OM2252
Rev 0 December 15 2016

Operation Manual - Hobart 2400 Compact Power – 120 / 140 / 180 kVA
General Description
Document no. 578.430AB Page 13 of 75
3.1 Built-in features / protections
No Break Power Transfer:
The unit is protected against misalignment during the No Break Power Transfer.
Over/under voltage at input:
The input voltage supervision is based on the rectified DC. The supervision ensures that the unit does
not trip even in case of an abnormal low input voltage level. This of course presupposes that the 400 Hz
output level and quality, required by the aircraft, can still be maintained. If the rectified DC level gets
too low or too high, the unit trips to protect itself.
Over/under voltage at output:
If the output voltage exceeds or is below the levels in the table below, the unit automatically shuts down
and opens the output contactor.
Output Voltage U > 130V – 250ms
Output Voltage U > 140V – 15ms
Output Voltage U < 104V – 500ms
Overload:
If the output current exceeds the overload ratings in the table below, the unit shuts down to protect itself
•125% for 600 seconds
•150% for 60 seconds
•200% for 30 seconds
•300% for 10 seconds
•400% for 1 second
Short circuit at output:
The unit has a built-in system to protect itself and the output cables, if the units output(s) are short
circuited for some reason.
Internal high temperature:
If for some reason the internal temperature on the Inverter Module or the Output Transformer rises
above the factory set temperature level, the unit shuts down, reporting either “INVERTER TEMP TOO
HIGH” or “TRANSFORMER TEMP TOO HIGH”
Control voltage error:
If the control voltage supplied from G1 is < 20 VDC, the unit shuts down and reports
“CONTROL VOLTAGE LOW”
OM2252
Rev 0 December 15 2016

Operation Manual - Hobart 2400 Compact Power – 120 / 140 / 180 kVA
General Description
Document no. 578.430AB Page 14 of 75
Aircraft Connector Insertion:
This feature verifies that the 90% switch / split “F” pin in the 400 Hz plug is activated. If not activated,
the respective output cannot be engaged. This also includes a potential free output showing whether the
Aircraft Connector is inserted or not. The feature is valid for ground power units with one or two outputs.
How to bypass/activate the function please refer to section 6.3
For detailed information/connection please refer to section 4.9
Neutral Voltage Supervision (NVS):
The unit is delivered with a jumper wire between the 400 Hz neutral and earth/ground. If the jumper
wire for any reason (eg. Local regulation) is removed, the unit monitors the voltage between the 400 Hz
neutral and earth. If this voltage exceeds 42 V (factory setting), the unit shuts down and reports “NVS
failure”. For change of setting please refer to section 6.3.
Neutral Voltage Displacement Supervision (NVD):
The combination of a grounded converter and an un-grounded aircraft might lead to an energized
aircraft chassis. The reason is the neutral voltage displacement caused by an unbalanced load. In case
the aircraft frame is or will be grounded during operation, a broken neutral might result in sparks as well
as burned ground wires. The neutral voltage displacement of the aircraft chassis is measured as an AC
voltage imposed on the EF interlock signal.
For change of setting please refer to section 6.3.
Earth Leakage Supervision (ELS)
In systems where the 400 Hz neutral is grounded and there is a break of the cable’s 400 Hz neutral, the
ELS system monitors the residual current in the internal neutral /earth connection. The supervision will
shut down the unit in case the residual current reaches the pre-set level.
For change of setting please refer to section 6.3.
OM2252
Rev 0 December 15 2016

Operation Manual - Hobart 2400 Compact Power – 120 / 140 / 180 kVA
Transport and Installation
Document no. 578.430AB Page 15 of 75
4.0 Transport and Installation
4.1 Storage Before Installation
To secure optimal storage conditions prior to installation, we recommend that the converter is stored
inside. This protects the unit from rain and excessive humidity while it is left without power.
Only equipment in seaworthy packing should be stored outside.
For storage conditions please refer to section 5.0
4.2 Operational and Environmental Conditions after
Commissioning
When the converter has been installed and commissioned, we strongly advise that the unit is always
kept with input power on. This provides optimal conditions for the electronic components and prevents
humidity in the form of condensed water from reaching vital parts. If for some reason the converter has
been without input voltage for a period of time, a visual inspection should be carried out. If
condensation on any internal parts is discovered, the parts have to be dry before the input voltage is
again applied.
4.3 Transport
Fig. 4.3.1 Access for fork-lift, truck or similar
Lifting access can be gained by removing both the front and back of plinths
OM2252
Rev 0 December 15 2016

Operation Manual - Hobart 2400 Compact Power – 120 / 140 / 180 kVA
Transport and Installation
Document no. 578.430AB Page 16 of 75
Fig. 4.3.2 Lifting with crane
(Place M10 lifting rings at the 4 corners)
The AXA 2400 horizontal version (see below) is delivered on a specially designed wooden pallet.
Transport and mounting of the AXA 2400 is carried out by lifting the unit by a fork-lift, truck or the like
to the intended mounting position while it is still placed and firmly fixed to the pallet. For safety
reasons, the passenger boarding bridge should be placed in a horizontal position at the lowest possible
height above ground before lifting is started.
We recommend that you keep the original pallet for future dismantling in connection with service and
maintenance.
Fig. 4.3.3 Transport and mounting of the AXA 2400 by means of a fork-lift truck
The AXA 2400 must be fastened to the passenger boarding bridge with 4 M12 bolts with a minimum
rating of 8.8 steel.
Adequate lifting gear is
not part of the delivery.
OM2252
Rev 0 December 15 2016

Operation Manual - Hobart 2400 Compact Power – 120 / 140 / 180 kVA
Transport and Installation
Document no. 578.430AB Page 17 of 75
4.4 Installation and fastening instructions
Fig. 4.4.1 Foot Print & Spacing (Fixed Unit)
Fig. 4.4.2 Mounting Holes (Fixed Unit)
OM2252
Rev 0 December 15 2016

Operation Manual - Hobart 2400 Compact Power – 120 / 140 / 180 kVA
Transport and Installation
Document no. 578.430AB Page 18 of 75
Fig. 4.4.3 Removable gland plates (Fixed Unit)
Made of alu-zink to prevent corrosion at the cable gland holes.
The gland plates are removed from inside the cubicle.
OM2252
Rev 0 December 15 2016

Operation Manual - Hobart 2400 Compact Power – 120 / 140 / 180 kVA
Transport and Installation
Document no. 578.430AB Page 19 of 75
Fig. 4.4.5 Mounting Holes (Bridge-Mounted Unit)
Fig. 4.4.6 Removable gland plates (Bridge-Mounted Unit)
Made of alu-zink to prevent corrosion at the cable gland holes.
The gland plates are removed from inside the cubicle.
Output gland plate Input gland plate
OM2252
Rev 0 December 15 2016

Operation Manual - Hobart 2400 Compact Power – 120 / 140 / 180 kVA
Transport and Installation
Document no. 578.430AB Page 20 of 75
Center of Gravity
Fig. 4.4.7 Center of Gravity (Fixed Unit)
OM2252
Rev 0 December 15 2016