Jet Power FILTER II User manual

OPERATION AND
MAINTENANCE MANUAL
PN 28.04.1014
SUPERSOM IND. E COM. LTD.
GROUND POWER UNIT - GPU
OUTPUT OF 28 VDC AND 24 VDC
SPECIAL EDITION FOR AIRCRAFT
MANUFACTURER
JET POWER FILTER II - PN 28.09.1013

OPERATION AND MAINTENANCE MANUAL PN 28.04.1014 GPU JET-POWER FILTER II 2500 PN 28.09.1013
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Sumário
1 - DESCRIPTION................................................................................................................................4
1.1 - GENERAL...................................................................................................................................4
1.1.1 - PRESENTATION.................................................................................................................4
1.1.2 - TECHNICAL INFORMATION...............................................................................................5
1.2 - SPECIFICATIONS........................................................................................................................7
1.2.1 - OUTPUT CABLES AND TRANSFORMER.............................................................................7
1.2.2 - CONTROL PANEL (UPPER PANEL).....................................................................................8
1.2.3 - LOWER PANEL ............................................................................................................... 10
1.2.4 - FRONT PANEL ................................................................................................................ 11
1.2.5 - SIDES.............................................................................................................................. 11
1.2.6 - UPPER PART................................................................................................................... 12
1.2.7 - LOWER PART ................................................................................................................. 12
1.2.8 - NOTES............................................................................................................................ 12
2 - OPERATION ............................................................................................................................... 13
2.1 - GENERAL................................................................................................................................ 13
2.1.1 - SUPPLYING FOR AN AIRCRAFT IN ASSEMBLING............................................................ 13
2.1.2 - TESTING AND ADUJSTING THE SURGE PROTECTOR RELAY IN OUTPUT SOURCE SOCKET
14
2.1.3 - OPERATION AND FUNCTIONING................................................................................... 15
3 - THEORY OF OPERATION ............................................................................................................ 16
3.1 - POWER GENERATION SYSTEM .............................................................................................. 16
3.2 - OPERATION DESCRIPTION..................................................................................................... 16
4 - TROUBLESHOOTING .................................................................................................................. 17
4.1 - NOTES.................................................................................................................................... 17
4.1.1 - POSSIBLE FAULTS........................................................................................................... 17
5 - INSPECTIONS, VERIFICATIONS AND LUBRICATIONS.................................................................. 21
6 - REMOVAL AND INSTALATION ................................................................................................... 22
6.1 - REMOVAL .............................................................................................................................. 22
6.2 - INSTALLATION ....................................................................................................................... 22
7 - ADJUSTS AND TESTS.................................................................................................................. 24
7.1 - ADJUSTMENT OF THE CURRENT LIMITING ........................................................................... 24
7.2 - ADJUSTMENT OF THE TENSION LIMITING ............................................................................ 24
7.3 - ADJUSTMENT OF THE OUTPUT TENSION.............................................................................. 24
7.4 - ADJUSTMENT OF THE CURRENT LIMITING ........................................................................... 24

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7.5 - CALIBRATE THE INSTRUMENTS ............................................................................................. 25
7.6 - RIPPLE TEST ........................................................................................................................... 25
7.7 - OUTPUT TENSION TEST ......................................................................................................... 25
7.8 - ADJUSTMENT OF THE DIFFERENTIATOR CIRCUIT ................................................................. 26
8 - CLEANING AND PAINTING......................................................................................................... 26
8.1 - CLEANING.............................................................................................................................. 27
8.2 - PAINTING............................................................................................................................... 27
9 - REPAIRS ..................................................................................................................................... 28
10 - LIST OF GENERAL PARTS............................................................................................................ 29
11 - DESCRIPTION............................................................................................................................. 30
11.1 - PRESENTATION.................................................................................................................. 30
11.2 - CIRCUIT OF ELECTRONIC PROTECTION II (PN 28.01.1018)................................................ 30
11.3 - CIRCUIT OF ELECTRONIC PROTECTION III (PN 28.00.3717)............................................... 31
11.4 - POWER CIRCUIT (PRIMARY) .............................................................................................. 31
11.5 - POWER CIRCUIT (SECONDARY) ......................................................................................... 33
11.6 - DIFFERENTIATOR CIRCUIT (PN 28.01.7000) ...................................................................... 36
12 - SPECIAL TOOLS, ADAPTERS AND EQUIPMENTS ........................................................................ 36
12.1 - SPECIAL KEY TO WITHDRAWAL DIODES (PN 28.01.1191)................................................. 36
12.2 - SUPPORT TO HOIST THE EQUIPMENT (PN 28.01.1192).................................................... 36
12.3 - SOURCE OF 0-60mV FOR CALIBRATION OF THE PROTECTION CIRCUIT (PN 28.01.1193). 36
13 - GALLERY OF PHOTOS................................................................................................................. 38
13.1 - DIFFERENTIATOR CIRCUIT ................................................................................................. 38
13.2 - LINKING OF THE AJUSTMENT SWITCH OF 7 POSITIONS.................................................... 39
13.3 - KNOBS LINKING ................................................................................................................. 40
13.4 - SECONDARY CIRCUIT......................................................................................................... 40
13.5 - LINKING OF THE INPUT CABLE........................................................................................... 40
13.6 - PANEL OF INSTRUMENTS .................................................................................................. 41
13.7 - IDENTIFICATION PLATE...................................................................................................... 41
13.8 - BLOCK OF CONNECTORS OF THE DIFFERENTIATOR CIRCUIT ............................................ 42

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1 - DESCRIPTION
1.1 - GENERAL
1.1.1 - PRESENTATION
The “JET-POWER FILTER II” is a static GPU designed to provide
ground power for maintenance and startup of aircraft having 28 VDC
electrical systems.
The “JET-POWER FILTER II” changes alternating current at its input
to a continuous current of 28V (adjustable on panel) by using its trans-
former and six-phase rectification. Therefore when electric energy is
available to supply the GPU it can substitutes external batteries or/and
GPU equipped with diesel engine.
The “JET-POWER FILTER II” provides pure output tension with ex-
tremely low ripple (0.035% at 100A), even under normal load, causing
no interference with aircraft equipments.
Due to its transformer and oversized rectifier the regulation is excellent
and provides protection against short circuit, over current, overvoltage
and phase failure.
The “JET-POWER FILTER II” has been resized especially for
MANUFACTURER to be used in extreme conditions (24 hours work-
ing) providing power to mounting equipments on an aircraft during
stages of assembly and electronics testing.
It is equipped with a second output cable of 28 and 24 VDC,to substitute
aircraft´s battery, being able to reduce 09 volts on its output voltage rel-
ative to the first output by setting its selector switch on position “7”.

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1.1.2 - TECHNICAL INFORMATION
1.1.2.1 - INPUT:
220V (Brazil);
208V (USA);
Three-phase, no phase sequence.
NOTE: The neutral of “JET-POWER FILTER II” is the BLUE cable.
1.1.2.2 - 1st OUTPUT (Plug for Output Source)
It is located on the left front side, coming directly from inside the source,
providing 24 to 33 VDC, depending on how the seven position switch
(front panel) is set.
1.1.2.3 - 2nd e 3rd OUTPUT (28 and 24V to substitute aircraft´s battery)
They are two gray connectors, placed at the front center, to be used with
one cable, connected on the left to provide tension and current equal to
the first output (28 V), or connected on the right to provide 09 volts less
than the first output. When giving 33 volts it will provide 24 volts (up
to 10A, protects against overload). The cable to be connected to these
outputs is loose, with a gray connector, with length as ordered (5 or 10
m). In order to avoid accidental disconnection lock it by using the at-
tached pin.
1.1.2.4 - MAXIMUM CURRENT:
2,000A at peak (supply capacity);
600A continuous (28V output).
NOTE: The current delivered by “JET-POWER FILTER II” at the start,
or during equipment tests, depends on the turbine kind or the applied
load.
1.1.2.5 - CURRENT LIMITER

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The current can be limited to 30, 50, 100, 200, 300, 400, 500, 750,
1000, 1500 e 2000A.
NOTE: The “JET-POWER FILTER II” is equipped with an electronic
circuit adjustable up to 11 positions. It turns off the source when the
current set at knob is reached.
1.1.2.6 - MAXIMUM POWER
56kVA at peak with full load.
NOTE: The Power required from installation can be much lower if not
using maximum current.
EXAMPLE: With load up to 1200A in the output, the power necessary
will be 37kVA maximum at peak. The rated power of the network
should be above 25kVA.
1.1.2.7 - AUTOMATIC PROTECTION (for the aircraft)
It automaticallyshuts down the equipment in case ofphase failure, over-
voltage or over current (above the settled value), in order to minimize
risks to the aircraft and GPU.
1.1.2.8 - RIPPLE
0,59% at 300A (28V output);
With load from 0 to 100A, only 0.01 VAC - Ripple 0,035%.
1.1.2.9 - DIMENSIONS
111.5 cm (length) x 85 cm (width) x 88.5 cm (height).
1.1.2.10 - WEIGHT
528 Lbs.

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1.2 - SPECIFICATIONS
1.2.1 - OUTPUT CABLES AND TRANSFORMER
1.2.1.1 - INPUT CABLE (PN 28.01.1146)
The cable is quadripolar, brand “Prysmian”, model CORDPLAST, 4 x
10 mm2of gauge, 25 meters of length. It does not come with a plug (the
plug can vary according to the local utility company).
1.2.1.2 - 1st OUTPUT CABLE 28VCD, direct plug (PN 28.01.3340)
The normal output cable line is double, extra flexible, 95 mm2of gauge,
5 meters of length, equipped with anti-friction protection and output
socket; brand “SUPERSOM”(PN 28.01.1139).
1.2.1.3 - 2nd OUTPUT CABLE 28 and 24 VCD, gray connector (PN
28.01.4705 with 5 meters and PN 28.01.4710 with 10 meters)
This is a brand new model of cable, all detachable, equipped with anti-
friction. It comes with 5 or 10 meters of length (as ordered), double
gauge of 70 mm2, in one end it comes with a gray connector and in the
other end it comes with a rubber plug , 28V standard, brand
“SUPERSOM”(PN 28.01.1139). Must be used to substitute the battery,
can be attached to the 28VDC connector of high current or to the distin-
guish output connector (24 VDC).
1.2.1.4 - TRANSFORMER (208V/220V –PN 28.01.1103)
It is designed to deliver alternated current of low voltage to the
rectifier circuit;
Comes with 09 output connections (six-phase), resulting in
28VDC after rectification;
It has 27 input wires to provide a voltage adjustment at the equip-
ment input.
NOTE: It can be used in 208 or 220V by only switching cables plugged
into the fuse holder. These cables are marked according to its voltage

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(208 or 220V). They cannot be plugged together; it could cause a short
circuit. To plug in one cable the other must be removed and isolated.
The three cables must have the same voltage (208V USA or 220V Bra-
zil).
Power : 56 kVA at peak;
Maximum output current: 2,000 A;
5 seconds off peak with voltage drop of 20%.
1.2.2 - CONTROL PANEL (UPPER PANEL)
1.2.2.1 - SWITCH FOR ADJUSTMENT OF THE OUTPUT TENSION
(PN 28.01.1150)
It sets the output tension from 24 to 33VDC.
1.2.2.2 - SWITCH FOR ADJUSTMENT OF THE OUTPUT CURRENT
LIMITER (PN 28.01.1122)
Placed on the right side of the panel, it must be used to set the maximum
current allowed on the aircraft in which it is connected. The accuracy
of this setting is around 5%.
The current limit is taken by a complete disconnection of the output
current after 1 second exceeding the set value.
Never place the current limiter knob in range below that demanded by
the load necessary for maintenance or during starts to avoid cuts during
the maintenance or at the start. Please check the aircraft manual to know
about its maximum current demanded.
ATTENTION:
The setting above the maximum current range allowed by the aircraft
does not mean that the current will come to this value in normal condi-
tions, even at the start.
Under normal conditions the GPU will deliver only the current de-
manded by the aircraft.

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1.2.2.3 - SWITCH ON/OFF (Level 1 and 2) - AUTOMATIC
PROTECTION (PN 28.01.1121)
It´s function is to permit the use of the equipment in case off breakdown
at the protection circuit or release the use with voltages over 31.5 VDC.
With the switch set on position “1” it could be used normally but there
will be no automatic turning down.
1.2.2.4 - KNOB “ON” (PN 28.01.1119) AND “OFF” (PN 28.01.1120)
They turn the equipment on and off. The turning off knob can also
RESET the protection circuit.
When the equipment is shut down by the protection circuit the turning
off knob must be used to restart. Otherwise the equipment will not turn
on.
1.2.2.5 - LED INDICATOR OF EQUIPAMENT “ON”: (PN 28.01.1124)
It is placed between the knobs. When the equipment is shut down by the
protection circuit it will turn off and the protection circuit will remain
turned on to indicate what caused the shutting down.
1.2.2.6 - BURNED FUSES INDICATORS (PN 28.01.1124)
When lighted it indicates burned or loosen fuse(s). The fuses are located
inside the front cover, closed to the three-phase cable entrance. To open
the front cover, unscrew the two screws on its sides.
1.2.2.7 - INDICATORS OF AUTOMATIC SHUT DOWN (PN 28.01.1126)
The three red light indicators inform the operator the cause of shutting
down when occurs one or more of the following:
Phase failure at the input power;
Overvoltage and over current at the equipment output.
They are monitored by the “Protection Circuits II and III”.

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1.2.2.8 - INDICATORS OF PHASE PRESENCE (PN 28.01.1125)
Three Green LEDs –they light only when the GPU is turned on.
If one of them is out it indicate phase failure. Before using the GPU
verify and fix what caused the phase failure. If used with one phase out,
it will be notice a high drop of voltage, increasing the load. The output
voltage will drop to around 21V with only 50A of load causing high
current at the capacitors. These LEDs are monitored by the “Protection
Circuit III”.
1.2.2.9 - VOLTIMETER (PN 28.01.1127)
Indicates the 28V outputs voltage, where the output cables are con-
nected.
During start peak the voltage at the aircraft will be lower than indicated
on this voltmeter due to voltage drop at the output cables and the internal
aircraft cables.
1.2.2.10 - AMMETER: (PN 28.01.1128)
Indicates the current provided to the aircraft (the sum of the currents in
the two output cables).
60mV instrument, coil, 2000A scale.
1.2.3 - LOWER PANEL
1.2.3.1 - IDENTIFICATION PLATE (PN 28.02.1216)
It indicates three-phase input voltage, range of output voltage (adjusta-
ble), maximum peak current, serial number, equipment´s part number,
weight and dimensions.