Jet power Diesel 115/200vac User manual

INTRUCTION AND MAINTENANCE MANUAL

Nº 115.04.7706

GPU 90kVA, 115VAC, 400Hz with 28VDC

Nº 115.09. 7701

SUPERSOM INDÚSTRIA E COMÉRCIO LTDA

AV. SOUZA GUIMARÃES,47 –BAIRRO NOVA SUIÇA

30550-150 –BELO HORIZONTE –MINAS GERAIS –Brazil.

Site: www.gpu.com.br e-mail: [email protected]

PN 115.04.7706 - INSTRUCTION MANUAL OF GPU JET-POWER DIESEL 90kVA - 115VAC, 400Hz / 28VDC, 2500A - PN 115.09.7701.

GPU JET-POWER DIESEL 90kVA –115VAC, 400Hz / 28VDC, 2500A –PN 115.09.7090 1/40

SUMARY

SECTION 01 –Description..............................................................................................................03

1.1 - General ...................................................................................................................03

1.1.1 - Presentation ............................................................................................................03

1.1.2 - Technical information Module "Jet-Power 28VDC" .............................................04

1.1.2.1 - Entry .......................................................................................................................04

1.1.2.2 - Output .....................................................................................................................04

1.1.2.3 - Maximum Current ..................................................................................................04

1.1.2.4 - Maximum power ....................................................................................................05

1.1.2.5 - Ripple .....................................................................................................................05

1.1.2.6 - Rectification ...........................................................................................................05

1.1.2.7 - Filtering ..................................................................................................................05

1.1.3 - Technical Information generator group ..................................................................05

1.1.3.1 - Diesel Engine .........................................................................................................05

1.1.3.1.1 - Mark .......................................................................................................................05

1.1.3.1.2 - Model ......................................................................................................................05

1.1.3.1.3 - Other Information ...................................................................................................05

1.1.3.2 - Generator ................................................................................................................05

1.1.3.2.1 - Mark .......................................................................................................................05

1.1.3.2.2 - Model ......................................................................................................................05

1.1.3.2.3 - Other Information ...................................................................................................05

1.1.4 - Technical information assembly ............................................................................05

1.1.4.1 - Dimensions .............................................................................................................05

1.1.4.2 - Approximate Weight ..............................................................................................05

1.2 - Specifications of output cables ...............................................................................05

1.2.1 - Output 115V, 400Hz ..............................................................................................05

1.2.2 - 28VDC output ........................................................................................................06

1.3 - Panels and front parts .............................................................................................06

1.3.1 - Equipment Panel .....................................................................................................06

1.3.1.1 - Hour meter ..............................................................................................................06

1.3.1.2 - Oil pressure indicator .............................................................................................06

1.3.1.3 - Temperature indicator of water ..............................................................................06

1.3.1.4 - Fuel level indicator .................................................................................................06

1.3.1.5 - Digital ammeter 0-300A / 5A .................................................................................06

1.3.1.6 - Digital voltmeter 0-300VAC ..................................................................................07

1.3.1.7 - Digital frequency meter 0-999Hz ...........................................................................07

1.3.1.8 - Digital voltmeter 0-99VDC ....................................................................................07

1.3.1.9 - Digital ammeter 0-2500A .......................................................................................07

1.3.1.10 - Fault Indicators .......................................................................................................07

1.3.1.11 - Interrupting switch panel lighting ..........................................................................07

1.3.1.12 - Interrupting switch internal lighting .......................................................................07

1.3.1.13 - Interrupter switch of flasher circuit ........................................................................07

1.3.1.14 - Pushbutton for starting ...........................................................................................07

1.3.1.15 - Pushbutton to stop engine .......................................................................................08

1.3.1.16 - Switch to connect 115VAC output..........................................................................08

1.3.1.17 - Output voltage adjustment ......................................................................................08

1.3.1.18 - Set frequency...........................................................................................................08

1.3.1.19 - Emergency Pushbutton............................................................................................08

1.3.1.20 - Pushbutton to turn “ON” the output 28 VDC .........................................................08

1.3.1.21 - Pushbutton to turn “OFF” the output 28 VDC .......................................................09

1.3.2 - Other Information ...................................................................................................09

1.3.2.1 - Equipment operating sequence................................................................................09

PN 115.04.7706 - INSTRUCTION MANUAL OF GPU JET-POWER DIESEL 90kVA - 115VAC, 400Hz / 28VDC, 2500A - PN 115.09.7701.

GPU JET-POWER DIESEL 90kVA –115VAC, 400Hz / 28VDC, 2500A –PN 115.09.7090 2/40

1.3.2.2 - Information use a generator set ...............................................................................09

SECTION 02 - Operating Instructions............................................................................................10

2.1 - Start-up and maintenance in an aircraft ..................................................................10

SECTION 03 - Troubleshooting Solutions .....................................................................................12

3.1 - Notes........................................................................................................................12

3.2 - Possible defects ......................................................................................................12

SECTION 04 - Inspections, checks and lubrication ........................................................................16

SECTION 05 - Installation and removal..........................................................................................18

5.1 - Installation ..............................................................................................................18

5.2 - Removal...................................................................................................................18

SECTION 06 - Adjustments and testing .........................................................................................19

6.1 - Adjustments ............................................................................................................19

6.1.1 - Output voltage adjustment ......................................................................................19

6.1.2 - Diesel engine speed adjustment (frequency) ..........................................................19

6.1.3 - Measuring the digital instruments ..........................................................................19

6.1.4 - Control board adjustments.......................................................................................20

6.1.4.1 - Time setting to turn on the generator .....................................................................20

6.1.4.2 - Time setting of the final idle ..................................................................................20

6.1.4.3 - Time setting the initial idle .....................................................................................20

6.1.4.4 - Low fuel level adjustments .....................................................................................20

6.1.4.5 - Setting the automatic shutdown for lack of fuel .....................................................20

6.1.4.6 - Signal led´s..............................................................................................................20

6.1.4.7 - Jumper on the board ...............................................................................................20

6.1.5 - Diesel engine settings (see your manual) ...............................................................20

6.1.6 - Alternator settings (see your manual) ....................................................................21

6.1.7 - General Control Board ............................................................................................21

6.1.8 - EDG5500 –Electronic Digital Governor................................................................22

SECTION 07 - Cleaning and painting .............................................................................................26

7.1 - Cleaning ..................................................................................................................26

7.2 - Painting ...................................................................................................................26

SECTION 08 - Wiring diagrams .....................................................................................................27

8.1 - Interpretation of codes ............................................................................................27

8.2 - Electrical circuits and components list of the "Jet-Power Diesel" .........................27

8.2.1 - General circuit and interior......................................................................................28

8.2.2 - Drawing Parts Ratio ................................................................................................29

SECTION 09 - General Parts list ....................................................................................................31

SECTION 10 - Warranty one (1) year. ............................................................................................40

PN 115.04.7706 - INSTRUCTION MANUAL OF GPU JET-POWER DIESEL 90kVA - 115VAC, 400Hz / 28VDC, 2500A - PN 115.09.7701.

GPU JET-POWER DIESEL 90kVA –115VAC, 400Hz / 28VDC, 2500A –PN 115.09.7090 3/40

SECTION 01 - DESCRIPTION

1.1 - GENERAL

1.1.1 - PRESENTATION

The GPU "JET-POWER DIESEL 115 / 200VAC, 400Hz, three-phase, 90KVA",

consists of a generator set with a Diesel turbo engine Iveco 04 cylinder in-line. 4-stroke cycle

with direct injection, cranking a WEG generator of 90 KVA, 115/200 volt, three-phase, 400

Hz. Provides electrical power to the aircraft, constantly monitored and regulated

electronically, ensuring their maximum and minimum limits of voltage, frequency and

current, and in case of failure this protection system, the current to the aircraft stops if out of

bounds (off the contactor, if used to 115V 400Hz output). Improper adjustment of voltage or

frequency can also cause shutdown. When in use the 28VDC output does not occur

disconnection by frequency, only for voltage or current out of bounds.

Has Diesel motor directly coupled to the generator, towable set mounted on sturdy chassis

with drawbar and the steering system control with rotating 270 °, with radial industrial tires,

600 x 9. Parking brake triggered with tow bar in vertical position. 315-liter fuel tank, with

two side compartments for housing the one hand and cables on the other side 115VAC to

28VDC. Lighting and night signalingsystem with traffic lights high brightness LEDs, internal

and external and signalman Giroflex for warning low level of diesel oil. Electrostatics painting

in white. 2KG fire extinguisher with support. Five large access doors for complete ease of

access and maintenance. Panel with analogue instruments for measurements of mechanical

and digital quantities to electrical quantities. It has brushless generator, with minimal

maintenance cost. Generator control that controls and presents the development of all

functions automatically so that monitoring does not present failures by over frequency, under

frequency, over voltage, under voltage and overload. In the event of failure the system cannot

automatically fix the engine is switched off and the full display for fault and instrumentation

tells what happened. Fuel tank with large capacity (315 liters). System Diesel oil filters with

dual water separator, in drains. Automatic GPU operation which when turned off keeps the

engine running for about 3 minutes (adjustable time) at idle, for cooling of the engine and

turbo. Protection that immediately shuts down the engine in case of high engine temperature,

low oil pressure and low fuel tank, when it arrives at the end of the reservation before entering

air in the system. Panel protected against rain by tempered glass thick large, not to be cracked

over time, as with acrylics. Transformer / rectifier to 28VDC output, with cable 8 meters and

plug R65BS.

Technical assistance in Brazil by the company equipment manufacturer or authorized

companies to perform repairs and maintenance in or out of warranty.

The technical assistance in another country will be able to be made by the importer following

instructions in this manual or other sent by email, without voiding the warranty. FedEx or

DHL, only the cost of shipping, may send parts. If necessary visit from a technician will only

be charged travel expenses, no labor charge for three years.

From the 2012 model its operation is fully automated and with the simplest panel, easy to

understand, dispensing training of operators. Just turn “on”and “off”.

PN 115.04.7706 - INSTRUCTION MANUAL OF GPU JET-POWER DIESEL 90kVA - 115VAC, 400Hz / 28VDC, 2500A - PN 115.09.7701.

GPU JET-POWER DIESEL 90kVA –115VAC, 400Hz / 28VDC, 2500A –PN 115.09.7090 4/40

His commands are simple to operate and can be used by anyone working in the support area

by simply pressing a pushbutton "Start" on the console to put into operation and a "Stop" to

shutdown. The entire boot process, initial idling, gradual acceleration with little smoke, power

generation and measurement is done automatically and is ready to meet aircraft. For shutdown

also the process is automatic, keeping the engine running without load, at idle for 3 minutes.

It was designed for use on aircraft (airplanes and helicopters), and external power supply for

aircraft maintenance, operation and departure of the turbines.

The "JET-POWER 115V 400Hz 90KVA DIESEL", is composed of two units in the same

chassis:

- DIESEL GENERATOR GROUP with output of 115 / 200V, 400Hz, 90KVA.

- MÓDULO OF ELECTRIC GPU "JET POWER 28VDC" Input 115 / 200V, 400Hz and

output 28 VDC, up to 2500A (When equipped with the optional "Output 28VDC").

This equipment provides the output voltage of 115 / 200V 400Hz directly from the generator

and is the 28VDC power from the GPU, powered by the generator. If necessary service

115VAC to 28VDC and at the same time, the two outputs can operate simultaneously, and it

can also provide energy to power up to two external special GPU's with entry 115 / 200V,

400Hz and output 28VDC until 2500A. (Not to be bound normal electrical GPU's having input

220 / 380V, 60Hz).

His commands are simple to operate and can be used by anyone working in the area of support

by simply switching on and off.

It is important to follow the hours worked intervals to exchange engine oil, filter cleaning,

retightening, etc. (Every 400 hours, change the oil and filters).

The "JET-DIESEL POWER 115V, 400Hz, 90KVA", is manufactured in strict technical

standards and modern industrial technology, using components and high quality raw material

to ensure its efficiency, safety and durability.

Its structure and bodywork are designed in 3D system, cut by laser and bent on CNC machines

of high precision, with all the included drilling. Has no craft items. All can be exchanged at

any time, without need for adjustments. Your resined electronic circuit is drawn and salt

corrosion-proof, air and moisture.

1.1.2 - TECHNICAL INFORMATION MODULE "JET-POWER 28VDC".

1.1.2.1 - ENTRY: 115/200 V, three-phase, 400Hz.

1.1.2.2 - OUTPUT: 27 to 32 Volts, with external adjustment of the output voltage in the same knob

which adjusts the voltage of 115VAC, 400 Hz.

1.1.2.3 - MAXIMUM CURRENT: 2500 Amps peak for 10 seconds;

1,500 Amps peak for 30 seconds;

400 Amps, continuous.

PN 115.04.7706 - INSTRUCTION MANUAL OF GPU JET-POWER DIESEL 90kVA - 115VAC, 400Hz / 28VDC, 2500A - PN 115.09.7701.

GPU JET-POWER DIESEL 90kVA –115VAC, 400Hz / 28VDC, 2500A –PN 115.09.7090 5/40

The current module "JET-POWER 28VDC" provides the starting or in the testing equipment

mainly depends on the type of turbine, or the load applied to it.

1.1.2.4 - MAXIMUM POWER: 70 KVA, 15 KVA peak and continuous.

1.1.2.5 - RIPPLE: 0.009% 100 A;

0.09% 300 A.

1.1.2.6 - RETIFICATION: six-phase. (6 diodes).

1.1.2.7 - FILTERING: For high performance filter of 2.4 kHz.

1.1.3 - TECHNICAL INFORMATION GENERATOR GROUP

1.1.3.1 - DIESEL ENGINE:

1.1.3.1.1 - BRAND: Iveco.

1.1.3.1.2 - MODEL: NEF 45 SM2, 04-cylinder, turbocharged.

1.1.3.1.3 - OTHER-INFORMATION: CONSULT THE ENGINE MANUAL THAT CAME WITH IT.

1.1.3.2 - GENERATOR:

1.1.3.2.1 - BRAND: WEG;

1.1.3.2.2 - MODEL: Three-phase, 115 / 200V, 400Hz, rated power of 90 kVA, with overload capacity

of up to 125%, to guarantee a steady supply of energy 400Hz;

1.1.3.2.3 - OTHER-INFORMATION: CONSULT THE ALTERNATOR MANUAL THAT CAME WITH IT

1.1.4 - TECHNICAL INFORMATION ASSEMBLY

1.1.4.1 - DIMENSIONS: 340cm long x 180cm wide x 180 cm height.

1.1.4.2 - APPROXIMATE WEIGHT: 2,010 kg.

1.2 - SPECIFICATIONS OF OUTPUT CABLES.

1.2.1 - OUTPUT 115V, 400Hz, three-phase, 4-wire with Y, with neutral:

CABLE 4 x 70mm² + 4 x 2,5mm², length of 10 meters, with plug R67BS, aeronautical

standard for 115V 400Hz, PN115.01.6301.

PN 115.04.7706 - INSTRUCTION MANUAL OF GPU JET-POWER DIESEL 90kVA - 115VAC, 400Hz / 28VDC, 2500A - PN 115.09.7701.

GPU JET-POWER DIESEL 90kVA –115VAC, 400Hz / 28VDC, 2500A –PN 115.09.7090 6/40

1.2.2 - 28VDC output (When equipped with this option):

Cable with anti-friction protection, gauge 2 x 95mm2, with a length of eight (8) meters and

plug R65BS, aeronautical standard for 28VDC PN 28.00.1139.

1.3 - PANELS AND FRONT PARTS

1.3.1 - EQUIPMENT PANEL

It is placed at the back, with access through a window in the door protected by a tempered

glass on the top and open at the bottom side, which contains the following parts:

1.3.1.1 - HOUR METER INDICATOR

It indicates the hours of Diesel engine operation. The operating time display is important for

maintaining the diesel engine. Refer to the manufacturer's manual for how to do oil changes,

filters, cleaning, etc. Browse respect the limits indicated for longer service life of the engine

(oil change every 400 hours).

1.3.1.2 - OIL PRESSURE INDICATOR.

Indicates the engine oil pressure through analog instrument. If during operation of the engine

the pressure falls below the minimum limit the engine is automatically switched off and should

only be turned on after correcting the fault.

1.3.1.3 - WATER TEMPERATURE INDICATOR

It indicates the water temperature in degrees Centigrade, via analog instrument. If during

operation of the motor temperature rises up to 90% of the ceiling the engine is automatically

switched off and should only be turned on after correcting the fault.

1.3.1.4 - FUEL LEVEL INDICATOR (DIESEL)

Indicates analog instrument through the approximate level of existing diesel oil in the fuel

tank. Always refuel indicating above ¼ to avoid automatic shutdown for lack of fuel. Stay

tuned to the firing of a yellow LED high brightness, "Attention: Low fuel" and Giroflex,

signaling the low level when entering the reserve. At the end of the booking occurs automatic

shutdown for lack of fuel. 315 liter tank capacity. Use Diesel S10 forever, if possible.

1.3.1.5 - DIGITAL AMMETER 0-500A / 5A:

Indicates the current supplied to the aircraft on the outputs of 115V.

PN 115.04.7706 - INSTRUCTION MANUAL OF GPU JET-POWER DIESEL 90kVA - 115VAC, 400Hz / 28VDC, 2500A - PN 115.09.7701.

GPU JET-POWER DIESEL 90kVA –115VAC, 400Hz / 28VDC, 2500A –PN 115.09.7090 7/40

1.3.1.6 - DIGITAL VOLTMETER 0-300VAC

Indicates the voltage phase / neutral at the generator output, the existing 115V output cable.

1.3.1.7 - DIGITAL FREQUENCY 0-999Hz

It indicates the frequency of the output voltage of the generator.

1.3.1.8 - DIGITALVOLTMETER 0-99,9VDC

Indicates the output voltage, existing at 28VDC output cable.

1.3.1.9 - DIGITAL AMMETER 0-2500A

Indicates the current supplied to the aircraft in 28VDC output.

1.3.1.10 - FAULT INDICATORS.

There are nine LEDs, and the first six indicate overfrequency, underfrequency, overload,

overvoltage, undervoltage and overspeed.

The other three indicate motor quantities, and Battery Level, Low Oil Pressure and High

Engine Temperature. There is a protection that switches the engine off automatically in case

of low oil pressure, high engine temperature and fuel shortage, protecting the engine from air

intake and damage.

1.3.1.11 - SWITCH PANEL LIGHTING

It allows on and off the LED lighting panel and analog instruments source for night operation.

The lighting also serves to the inside of the panel.

1.3.1.12 - SWITCH INTERNAL LIGHTING

It allows on and off the lighting of the interior of the source, for nightly maintenance.

IMPORTANT: do not leave on for many hours without running the engine. Discharges the

battery.

1.3.1.13 - SWITCH CIRCUIT FLASHER

Lets you connect and disconnect external flashlights flasher track alert.

Note .: The parking lights are LED. Do not use incandescent lamps. The circuit flasher is

electronic and supports only the LED's current, but it is not damaged if you try to put lights,

just do not light up.

1.3.1.14 - PUSHBUTTON FOR START

PN 115.04.7706 - INSTRUCTION MANUAL OF GPU JET-POWER DIESEL 90kVA - 115VAC, 400Hz / 28VDC, 2500A - PN 115.09.7701.

GPU JET-POWER DIESEL 90kVA –115VAC, 400Hz / 28VDC, 2500A –PN 115.09.7090 8/40

When pressed connects the 12V control supply circuit, triggers the starter and after the motor

is spinning starts the automatic cycle that does everything you need for its operation. A green

LED, "Motor On", placed above this pushbutton indicates that the engine is running and

spinning (stationary does not light). When you need to connect the 12V circuit to display

instruments, etc., give a quick tap in his buttonhole, the circuit connects without cranking the

engine. When pressed resets the protection circuit and turn on the fault indicator LEDs 9,

testing them. When pressed with the engine running it does not trigger the starter.

1.3.1.15 - PUSHBUTTON TO STOP ENGINE

When pressed initiates the automatic cycle shutdown by turning off the generator and outputs

115VAC and 28VDC, if they are linked, and keeping the engine at idle for 3 minutes. A Red

LED, "Turning", placed above this pushbutton indicates (flashing) that is in automatic

shutdown process. After this time, the circuit cuts the throttle immediately stopping the

engine. Also off the circuit 12VDC, and resets the protective circuit that shuts down the engine

in case of lack of engine oil pressure or Diesel and overheating.

1.3.1.16 - SWITCH TO CONNECT 115VAC OUTPUT.

Let it always on when in normal operation. If when connecting the aircraft it does not accept

to be energized, press the lever up and leave it in the "ON" position. Above this key LED

indicates the contactor on and fueling the aircraft.

1.3.1.17 - OUTPUT VOLTAGE ADJUSTMENT.

It provides a fine adjustment of the output voltage. It must be set to 115V.

Caution: If 28VDC output is indicating 29,3V the 115VAC is correct.

1.3.1.18 - SET FREQUENCY (only with engine speed analog controller).

With the digital regulator of rotation frequency is fixed at 400Hz.

1.3.1.19 - EMERGENCY PUSHBUTTON.

Pressing this pushbutton switches off everything at once. Only power by this pushbutton if

you want to stop the engine immediately. It is recommended to leave the engine idling for a

few minutes, to cool the turbine, preventing stagnant oil inside stay at very high temperature,

charring on its axis.

1.3.1.20 - PUSHBUTTON TO TURN “ON” THE OUTPUT 28 VDC

When pressed energizes the contactor which connects the GPU 28VDC to feed the cable that

provides for 28VDC aircraft. (Lights an LED "28VDC").

PN 115.04.7706 - INSTRUCTION MANUAL OF GPU JET-POWER DIESEL 90kVA - 115VAC, 400Hz / 28VDC, 2500A - PN 115.09.7701.

GPU JET-POWER DIESEL 90kVA –115VAC, 400Hz / 28VDC, 2500A –PN 115.09.7090 9/40

1.3.1.21 - PUSHBUTTON TO TURN “OFF’THE OUTPUT 28 VDC

When pressed off the contactor that connects the GPU 28VDC to 28VDC interrupt the supply

of direct current to the aircraft.

1.3.2 - OTHER INFORMATION

1.3.2.1 - EQUIPMENT OPERATING SEQUENCE

The push buttons for the command source were placed so that facilitate operation.

To place the GPU in operation should first check the radiator water level, engine oil level and

Diesel oil level (to know Diesel oil level take a quick tap on the starting pushbutton to turn on

the circuit 12 volts, passing the instrument to indicate the tank level).

1.3.2.2 - INFORMATION USE AS GENERATOR.

This source can also be used as a mobile generator to provide electricity for special GPU's

with input 115 / 200V, 400Hz and 28VDC output.

To this end the installation of a special socket (optional) to output three-phase 115 / 200VAC,

400Hz is required.

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