ITW GSE Hobart PoWerMaster 2400 Series User manual

ITW GSE HOBART
●
11001 Us Highway 41 North
●
Palmetto, FL 34221
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U.S.A
T: (toll free in US): 800-899-1841
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T (International): + 1 941-721-1000
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E: [e-mail]
Manual
Hobart PoWerMaster® 2400
400 Hz Ground Power Unit
With 28 VDC outlet (optional)
Serial no.
Type SX240
it’s all about connections

Document no. 578.650BB Page 2 of 91
Diagrams and drawings are subject to change without prior notice.
Latest diagram versions can be found at www.itwgse.com
Printed: March 2017
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.
Refer to section 8.2 for further
information

Operation Manual - Hobart PoWerMaster® 2400 – 30 - 90 kVA
Index
Document no. 578.650AB Page 3 of 91
INDEX
1.0 Declaration of Conformity ........................................................................................6
2.0 Safety Instructions.....................................................................................................7
3.0 General Description ..................................................................................................8
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 .................................................................................................... 21
4.6 Mains Input ................................................................................................................... 22
4.7 400 Hz Output............................................................................................................... 22
4.8 400 Hz Interlock............................................................................................................ 23
4.9 Control Interface (Remote I/O Terminals).................................................................... 23
4.10 TCP/IP On-board Interface ........................................................................................... 25
5.0 Technical Specifications .........................................................................................26
6.0 Operator’s Instructions (Display/LED/Keypad layout)..........................................31
6.1 Using the Display/Keypad ............................................................................................ 32
6.2 Operating the unit.......................................................................................................... 33
6.3 Basic Menu ................................................................................................................... 35
6.3.1 Parameters – Menu structure......................................................................................... 36
6.3.2 Setup – Menu structure ................................................................................................. 40
6.3.3 Black Box – Menu structure ......................................................................................... 45
6.3.4 Power Log – Menu structure......................................................................................... 46
6.3.5 Update Software / Save Logs – Menu structure ........................................................... 47
6.3.6 Incompatible Software Version .................................................................................... 50
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

Operation Manual - Hobart PoWerMaster® 2400 – 30 - 90 kVA
Index
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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
7.11 Aircraft Connector Insertion ......................................................................................... 55
7.12 GPU Enable................................................................................................................... 56
7.13 Door Switch .................................................................................................................. 56
7.14 Plug Temperature.......................................................................................................... 56
7.15 Neutral Voltage Supervision......................................................................................... 56
7.16 Earth Leakage Level ..................................................................................................... 57
7.17 Earth Leakage Delay..................................................................................................... 57
7.18 Real Time Clock Setup ................................................................................................. 57
7.19 Date/Time Format ......................................................................................................... 57
7.20 Ethernet Configuration.................................................................................................. 58
7.21 Modbus Slave Address.................................................................................................. 58
7.22 LED Brightness............................................................................................................. 58
7.23 Unit of Measure ............................................................................................................ 58
7.24 Costumer ID.................................................................................................................. 59
7.25 Battery Replaced ........................................................................................................... 59
7.26 Language....................................................................................................................... 59
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 ................................................................................................68
11.0 Options ....................................................................................................................71
578803 Base module.................................................................................................................. 71
578804 Lockable Door (Fixed).................................................................................................. 71
5788xx Remote Control Boxes available................................................................................... 72
578806 1 x 400 Hz Output......................................................................................................... 72
578818 2 x 400 Hz Output......................................................................................................... 72
578819 1 x 400 Hz & 1 x 28 VDC Output ................................................................................ 72
578820 1 x 400 Hz Output & controls for Retriever/Hoist........................................................ 72

Operation Manual - Hobart PoWerMaster® 2400 – 30 - 90 kVA
Index
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578807
Additional Output Contactor (Diagram 478801).......................................................... 73
578808 Dry Contacts (Diagram 478801)................................................................................... 73
578809 Door Interlock (Diagram 478801) ................................................................................ 74
578810 Neutral Conductor Rupture Supervision....................................................................... 74
578814 Terminal Extension ....................................................................................................... 75
578815 RS485 Interface (Diagram 478801).............................................................................. 75
578817 Military Interlock (Diagram 478801) ........................................................................... 76
578829 Anti-Condensation Heater (Diagram 478801).............................................................. 77
591100 Auto Calibration Plug ................................................................................................... 77
12.0 For GPUs with 28 VDC Active Rectifier Unit .......................................................78
12.1 General Description ...................................................................................................... 78
12.2 Connection of Cables .................................................................................................... 80
12.3 Interlock ........................................................................................................................ 81
12.4 Operator’s Instruction ................................................................................................... 82
12.5 Operating the unit.......................................................................................................... 82
12.6 Additional menu items for ARU................................................................................... 85
12.7 ARU Default Factory Settings: ..................................................................................... 86
12.8 28V Voltage .................................................................................................................. 86
12.9 28V Compensation........................................................................................................ 86
12.10 Current Limit Step Size............................................................................................... 86
13.0 Specifications ..........................................................................................................87
14.0 Trouble Shooting & Repair.....................................................................................88
15.0 ARU illustrated parts list.........................................................................................89

Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA
Declaration of Conformity
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1.0 Declaration of Conformity

Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA
Safety Instructions
Document no. 578.650BB Page 7 of 91
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!

Operation Manual – AXA 2400 Compact Power– 30 - 90 kVA
General Description
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3.0 General Description
The figure below shows the basic principle of the Hobart PoWerMaster® 2400 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/circuit breaker disconnects all power to the ground power unit. Upon closing
the switch disconnect/circuit breaker, the ground power unit passes through an initialization test and
then into standby mode.

Operation Manual – AXA 2400 Compact Power– 30 - 90 kVA
General Description
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Capacitor Board (A5):
This module includes the following functions:
•Input and Output RFI filters to reduce the EMI/EMC emission into the mains and output 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) via the breaker (Q4).
•Coil voltage for the output contactor(s), controlled via A2:Q1 on the Interface Board.
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 of 5% (ITHD) at 90 kVA/kW and a unity power factor. This means less stress on
the main supply network and the distribution transformers.
Inverter Module:
Beside the rectifier (V1-V6), the DC-filtering capacitors (C1-C6) and the soft start circuit (Q5)
controlled via 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 X19.

Operation Manual – AXA 2400 Compact Power– 30 - 90 kVA
General Description
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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):
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 or from the aircraft.
Output Contactor(s):
The ground power unit is equipped with a 3-phase output contactor per outlet. The contactor(s) 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) 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 (X10) of 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(s) Q2 – Q3 (X16-X17).
•Soft start control of Q5 (X12).
•Input for temperature sensors (X18).
•I/O ports for remote control (Start, Stop etc.), single output (X1).
•I/O ports for remote control (Start, Stop etc.), second output (X2) when installed.
•Protected interface for interlock signals.

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General Description
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•Interface for individual overload protection (X20).
•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 for the Hobart PoWerMaster® 2400
Supply Module (G1):
The generation of the 24 VDC / 10 A (Adjusted from factory to 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.

Operation Manual – AXA 2400 Compact Power– 30 - 90 kVA
General Description
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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
log and the Power Log files and for update of the display software.
ID Chip (A6):
The ID Chip is connected to Interface Board A2
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.

Operation Manual – AXA 2400 Compact Power– 30 - 90 kVA
General Description
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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 & 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”
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 outlet 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 outlets.
How to Bypass / Activate the function. Refer to Section 6.3 & 7.11
For detailed information /connection. Refer to chapter 4.9

Operation Manual – AXA 2400 Compact Power– 30 - 90 kVA
General Description
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Neutral Voltage Supervision (NVS):
As a standard, the unit is delivered with a jumper wire between the 400 Hz neutral and earth/ground. If
the jumper wire are removed for any reason (eg. Local regulation), the unit monitors the voltage
between the 400Hz neutral and earth/ground.
If this voltage exceeds 42 V (factory setting), the unit shuts down and reports “NVS FAILURE”.
To change the setting please refer to Section 6.3 &7.15
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 arcing 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.
To change of setting please refer to Section 6.3 & 7.9
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 & 7.17
Note!
An additional protection method offered by ITW GSE as an option is the Neutral Conductor Rupture
(NCR). The supervision is based on the presence of an injected current in the neutral conductor (i.e. as
long as the injected current is present, the neutral is intact). The advantage of this method is that a
broken neutral will be detected immediately.
In general ITW GSE does not recommend the NCR option for the following reasons:
1) The need for an additional control wire which is likely to be the first to break.
2) The difficulties of implementing the method in existing installations if a free control wire is not
present.
3) The standard protections built into the Hobart PoWerMaster® 2400 series are considered adequate to
safeguard against hazards related to a broken neutral.

Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA
Transport and Installation
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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
Access requires removal of 2 screws.

Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA
Transport and Installation
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Fig. 4.3.2 Lifting with crane
(Place M10 lifting rings at the 4 corners)
The Hobart PoWerMaster® 2400 horizontal version is delivered on a specially designed wooden pallet.
Transport and mounting of the Hobart PoWerMaster® 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 on 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 Hobart PoWerMaster® 2400
by means of a fork-lift truck
The Hobart PoWerMaster® 2400 must be fastened to the passenger boarding bridge with 4 x M12 bolts
of minimum rating of 8.8 steel.
Adequate lifting gear is
not part of the delivery.

Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA
Transport and Installation
Document no. 578.650BB Page 17 of 91
4.4 Installation and fastening instructions
Fig. 4.4.1 Foot Print & Spacing, Fixed Unit
Fig. 4.4.2 Mounting Holes, Fixed Unit

Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA
Transport and Installation
Document no. 578.650BB Page 18 of 91
Fig. 4.4.3 Mounting Holes & Spacing, Bridge-Mounted Unit
Fig. 4.4.4 Removable gland plate
Made of Aluminium-Zinc alloy coated sheet steel to prevent corrosion at the cable gland holes.
Gland plate is situated inside the cubicle and only one is supplied if the unit is with Base Module / ARU

Operation Manual - PoWerMaster® 2400 – 30 - 90 kVA
Transport and Installation
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Center of Gravity
Fig. 4.4.5 Center of Gravity Fixed units

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Transport and Installation
Document no. 578.650BB Page 20 of 91
Fig. 4.4.6 Center of Gravity Horizontal units