hobart 2300 400 hz ground power unit 30 - 90 kva with 28 ... · telephone 800-345-3851 or...

OM-2218REV B 061513REV B CH 1 091513

Operation and Maintenance Manual with

Illustrated Parts List

Hobart 2300 400 Hz Ground Power Unit

30 - 90 kVAWith 28 VDC outlet (optional)

Hobart Ground SystemsPalmetto, FL 34221

U.S.A.www.HobartSystems.com

OM-2218 / Operation and Maintenance ManualHobart 2300® / Series 500036 - 500039/500066 - 500069 Solid State Converter

June 15, 2013 CE Declaration of Conformity Page i


June 15, 2013 CE Declaration of Conformity Page iii

AUTHORIZATION TO MARK

Applicant: Manufacturer:

Address: Address:

Country: Country:Contact: Contact:Phone: Phone:FAX: FAX:Email: Email:

Standard(s):

Product:

Models:

for William T. Starr, Certification Manager

(941) 721-1158

Authorized by:3176982

(941) 721-1158941-721-1081

Robert Lawter

[email protected]

ITW Military11001 US Highway 41 NorthPalmetto, FL. 34221

11001 US Highway 41 NorthPalmetto, FL. 34221

USA

ITW Military

941-721-1081

Power Supply

This document supersedes all previous Authorizations to Mark for the noted Report Number.

UL 1012, 8th Edition, Power Units Other than Class 2, November 9, 2010 with revisions through January 19, 2012.

This Authorization to Mark is for the exclusive use of Intertek's Client and is provided pursuant to the Certification agreement between Intertek and its Client. Intertek's responsibility and liability are limited to the terms and conditions of the agreement. Intertek assumes no liability to any party, other than to the Client in accordance with the agreement, for any loss, expense or damage occasioned by the use of this Authorization to Mark. Only the Client is authorized to permit copying or distribution of this Authorization to Mark and then only in its entirety. Use of Intertek’s Certification mark is restricted to the conditions laid out in the agreement and in this Authorization to Mark. Any further use of the Intertek name for the sale or advertisement of the tested material, product or service must first be approved in writing by Intertek. Initial Factory Assessments and Follow up Services are for the purpose of assuring appropriate usage of the Certification mark in accordance with the agreement, they are not for the purposes of production quality control and do not relieve the Client of their obligations in this respect.

Intertek Testing Services NA Inc.165 Main Street, Cortland, NY 13045

Telephone 800-345-3851 or 607-753-6711 Fax 607-756-6699

AXA2300

Control Number:

Cortland, NYReport Issuing Office:Party Authorized To Apply Mark: Same as Manufacturer

[email protected]

Robert LawterUSA

This authorizes the application of the Certification Mark(s) shown below to the models described in the Product(s)Covered section when made in accordance with the conditions set forth in the Certification Agreement and ListingReport. This authorization also applies to multiple listee model(s) identified on the correlation page of the ListingReport.

This document is the property of Intertek Testing Services and is not transferable. The certification mark(s) may beapplied only at the location of the Party Authorized To Apply Mark.

WarrantyHOBART GROUND SYSTEMS

PALMETTO, FL 34221

Data Sheet 165 Index: 990223 Replaces: 980601

June 15, 2013 Warranty Page v

WARNING: AT ALL TIMES, SAFETY MUST BE CONSIDERED AN IMPORTANT FACTOR IN THE INSTALLATION, SERVICING AND OPERATION OF THE PRODUCT, AND SKILLED, TECHNICALLY QUALIFIED PERSONNEL SHOULD ALWAYS BE EMPLOYED FOR SUCH TASKS.

1. Hobart Brothers Company (hereinafter called HOBART) warrants that each new and unused Hobart Ground Systems Equipment, (hereinafter called the PRODUCT) is of good workmanship and is free from mechanical defects, provided that (1) the PRODUCT is installed and operated in accordance with the printed instructions of HOBART, (2) the PRODUCT is used under the normal operating conditions for which it is designed, (3) the PRODUCT is not subjected to misuse, negligence or accident, and (4) the PRODUCT receives proper care, lubrication, protection, and maintenance under the supervision of trained personnel.

2. This warranty expires 15 months after shipment by HOBART to the first user, or 12 months after installation, whichever first occurs.

3. This warranty does not apply to: primary and secondary switch contacts, cable connectors, carbon brushes, fuses, bulbs, and filters unless found to be defective prior to use.

4. Hobart DOES NOT WARRANT THE FOLLOWING COMPONENTS: Engines, engine components; such as: starters, alternators, regulators, governors, etc., and cable retrieving devices. Many of the foregoing components are warranted directly by the manufacturer to the first user and serviced by a worldwide network of distributors and others authorized to handle claims for component manufacturers. A first user's claim should be presented directly to such an authorized component service outlet. In the event any component manufacturer has warranted its component to HOBART and will not deal directly with a first user then HOBART will cooperate with the first user in the presentation of a claim to such manufacturer. Under NO circumstances does HOBART assume any liability for any warranty claim against or warranty work done by or in behalf of any manufacturer of the foregoing components.

5. This warranty is extended by HOBART only to the purchaser of new PRODUCTS from HOBART or one of its authorized distributors. The PRODUCTS purchased under this warranty are intended for use exclusively by the buyer and his employees and by no other persons and, therefore, there shall be no third party beneficiary to this warranty.

6. A claim of defects in any PRODUCT covered by this warranty is subject to HOBART factory inspection and judgment. HOBART'S liability is limited to repair of any defects found by HOBART to exist, or at HOBART'S option the replacement of the defective product, F.O.B. factory, after the defective product has been returned by the purchaser at its expense to HOBART'S shipping place. Replacement and exchange parts will be warranted for the remainder of the original Warranty, or for a period of ninety (90) days, whichever is greater.

7. UNDER NO CIRCUMSTANCES whatsoever shall HOBART and its authorized distributors be liable for any special or consequential damages, whether based on lost goodwill, lost resale profits, work stoppage impairment of other goods or otherwise, and whether arising out of breach of any express or implied warranty, breach of contract, negligence or otherwise, except only in the case of personal injury as may be required by applicable law.

8. Continued use of the PRODUCT(S) after discovery of a defect VOIDS ALL WARRANTIES.

9. Except as authorized in writing, this warranty does not cover any equipment that has been altered by any party other than HOBART.

10. THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HERE OF. HOBART MAKES NO WARRANTIES, EXPRESSED OR IMPLIED, OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

11. HOBART neither assumes nor authorizes any person to assume for HOBART any liability in connection with the PRODUCTS sold, and there are no oral agreements or warranties collateral to or affecting this written Warranty. This warranty and all undertakings of HOBART thereunder shall be governed by the laws of the State of Ohio, United States of America.

OM-2218 / Operation and Maintenance ManualHobart 2300® / Series Series 500036 - 500039/500066 - 500069 Solid State Converter

September 15, 2013 Revisions Page vii

Record of Change

Rev Release Date By Description

A 05/30/2013 pwd/cal Original

B 06/15/2013 cal Added CSE data; Added Safety Warnings and Cautions

B CH1 09/15/2013 cal Updated Spare Parts list. Updated contact information.

OM-2218 / Operation and Maintenance ManualHobart 2300® / Series 500036, 500037, 500038, 500039/

Solid State Converter

Revisions June 15, 2013 Page viii

This page intentionally left blank.


June 15, 2013 Chapter 1-1 Page - ix

1) SAFETY WARNINGS AND CAUTIONS

IMPORTANT SAFETY INSTRUCTIONS – SAVE THESE INSTRUCTIONS!

WARNING

THIS UNIT IS ONLY INTENDED TO BE INSTALLED, OPERATED AND MAINTAINED BY COMPETENT PERSONS HAVING THE NEC-ESSARY KNOWLEDGE REGARDING DELIVERY OF EXTERNAL POWER TO AN AIRCRAFT. PRIOR TO USE, SERVICE AND MAIN-TENANCE, THE COMPETENT PERSON MUST, BE FAMILIAR WITH ALL RELEVANT PARTS OF THIS MANUAL.

WARNING

ELECTRIC SHOCK WARNINGS

• To ensure personal health and safety, the electrical installation must fulfil all local regulations and legisla-tion

• Touching live electrical parts can cause fatal shocks and severe burns.

• Internal parts where the voltage exceeds 50 V are cov-ered and / or marked with an Electric Shock Warning icon. (See left.)

• Keep all panels and covers securely in place.

• Have only qualified people remove covers for mainte-nance 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.

WARNING

MOVING PARTS WARNINGS

• Keep away from fans.

• Have only qualified people remove covers for maintenance or troubleshooting.


June 15, 2013 Chapter 1-1 Page - x

WARNING

HOT PARTS WARNINGS

• Do not touch hot magnetics.

• Allow a cooling period before doing maintenance.


June 15, 2013 Table of Contents Page xi

TABLE OF CONTENTS

Chap. No. Title Page No.

Safety Warnings and Cautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ixIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii

1 DESCRIPTION/OPERATIONSection-1Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1-1

General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1-1Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1-3

Section-2 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-1Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-1Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-1Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-3Protections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-3Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-4Life, etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-4

Section-3 Preparation, Adjustment, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-1Storage Before Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-1Operational and Environmental Conditions after Commissioning . . . . . . . . . . . . . . . . . . 1-3-1Mounting of Bottom Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-1Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-2Installation and Fastening Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-3Cable Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-4Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-5Utility Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-6400 Hz Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-6400 Hz Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-6Control Interface (Remote I/O Terminals) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-7Interface via RS485 of TCP/IP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-8

Section-4 Instruction for Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-1Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-1Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-1Initial Adjustments and Control Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-3Pre-operation Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-3Start-up Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-3Setup Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-4Using the Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-5Adjustable Parameters in Setup Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-6Lock setup Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-6Cable Compensation setup (Plug and Play). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-7Manual CABLE Compensation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-8Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-8


Table of Contents June 15, 2013 Page xii

TABLE OF CONTENTS (Continued)

Chap. No. Title Page No.

2 TROUBLESHOOTING AND REPAIRSection-1 Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-1

Fault Guidance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-23 OVERHAUL / MAJOR REPAIR

Section-1 Overhaul / Major Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-1General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-1Service Information and Factory Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-1Test Equipment and Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-1Recommended Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-2Battery back-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-2

4 PARTSSection-1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-1Purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-1Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-1

Section-2 Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2-1Section-3 Illustrated Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3-1

5 MANUFACTURER LITERATUREAPPENDIX A - OPTIONSAPPENDIX B - 28 VDC OPTION

Operator Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1-1Setup of Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1-1Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1-1


June 15, 2013 List of Figures Page xiii

LIST OF FIGURES

Fig. No. Title Chap/Sec/Page

Figure - 1-1-1. Basic Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1-3Figure - 1-2-1. Fixed, Bridge-Mount and Mobile Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-5Figure - 1-2-2. Fixed and Mobile Unit with Base Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-6Figure - 1-3-1. Access for forklift (requires removal of 8 screws) . . . . . . . . . . . . . . . . . . . . . . . . 1-3-2Figure - 1-3-2. Transport by forklift truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-2Figure - 1-3-3. Foot Print, Fixed Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-3Figure - 1-3-4. Foot Print, Bridge-mounted Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-3Figure - 1-3-5. Removable gland plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-4Figure - 1-3-6. Connection of Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-5Figure - 1-3-7. Standard wiring diagram for civil aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-6Figure - 1-3-8. Example of wiring for external control via the I/O terminals . . . . . . . . . . . . . . . . 1-3-7Figure 1-4-1. Instrumentation for unit equipped with additional 400 Hz Output . . . . . . . . . . . . 1-4-1Figure 1-4-2. Navigation Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-4Figure 1-4-3. Change between the display modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-5Figure 1-4-4. View of parameters etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-5Figure 1-4-5. Display Module A3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-6Figure 1-4-6. Auto-Calibration Plug to Aircraft Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-7Figure 1-4-7. The Start Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-7Figure 4-3-1. Hobart 2300 Vertical - Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3-1Figure 4-3-2. Hobart 2300 Rear View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3-2Figure 4-3-3. Top/front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3-3Figure 4-3-4. Hobart 2300 Trailer Mounted GPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3-4Figure A-1. Remote Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1-3Figure A-2. Output Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1-4Figure A-3. NCR Board and Internal wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1-4Figure A-4. Wiring diagram for Neutral Conductor Rupture Supervision . . . . . . . . . . . . . . . A-1-5Figure A-5. Wiring diagram for Plug Insertion Interlock and GPU Enable . . . . . . . . . . . . . . A-1-6Figure A-6. PIN Assignment for RS485 Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1-7Figure A-7. TCP/IP or Ethernet Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1-8Figure A-8. Standard Wiring Diagram for Military Interlock . . . . . . . . . . . . . . . . . . . . . . . . . A-1-8Figure A-9. Service Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1-9

xiv

OM-2218 / Operation and Maintenance ManualHobart 2300® / Series 500036 - 500039/500066 - 500069




June 15, 2013 List of Tables Page xv

LIST OF TABLES

Table No. Title Chap/Sec/Page

Table 1-1-1. Converters Part Number Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1-2Table 1-2-1. Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-1Table 1-4-1. Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-2Table 1-4-2. Pre-operational Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-3Table 1-4-3. Start-Up Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-4Table 1-4-4. Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-9Table 2-1-1. Error Codes 0000 - 2199 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-3Table 2-1-2. Error Codes 3000 - 4999 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-4Table 2-1-3. Error Codes 5000 - XX00-XX99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-5Table 3-1-1. Special Tools and Test Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-2Table 4-2-1. Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2-1Table 4-2-2. Spare Parts Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2-2Table 5-1-1. Manufacturer Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-1Table A-1-1. Available Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1-1

xvi




June 15, 2013 Chapter 1-1 Page - xvii

1) INTRODUCTION

This manual contains operation and maintenance information for a 400 Hz Solid State Converter (SSFC) distributed by Hobart Ground Systems, Palmetto, Florida 34221.

This manual, including all information contained therein, is exclusive and confidential property of Hobart Ground Systems. This manual is not to be copied, reproduced, or delivered or disclosed to others, in whole or in part, except with express written permission of Hobart Ground Systems.

This manual is not intended to be a textbook on electricity or electronics. Its primary purpose is to provide information and instructions to experienced operators, electricians, and mechanics that have never operated this equipment. It is the intent of this manual to guide and assist operators and maintenance personnel in the proper use and care of the equipment.

Read the instructions before starting the unit. Use of the manual shall not be put off until trouble or a need for help develops. Learn to use the manual and to locate information contained in it. Its style and arrangement are very similar to commercial aircraft manuals.

The manual is divided into five chapters plus appendices. Each chapter is divided into as many sections as required. Each new section starts with page 1. Each page is identified by chapter, section and page number, which are located in the lower, outside corner.

When information located in another portion of the manual is referred to, a chapter, section, and paragraph or figure number identify its location. For example: “see Section 2-3, Paragraph 1.a.” refers to information located in Chapter 2, Section 3, Paragraph 1.a. If a chapter and section are not indicated in a reference, the referenced material is located in the same section as the reference, for example: “see Paragraph 1.a..”

The appendices are in the last sections. They contains a list of available options that may be purchased or have been purchased with that unit. Items on the list with check marks next to them have been added to the standard unit per the customer’s order. Literature for each option follows. The appendices help control the information in the manual making it unique to the unit purchased.

In addition to operation and maintenance instructions, the manual contains an illustrated parts list in Chapter 4 and a collection of manufacturer literature and supplemental information in Chapter 5.

Contents of the manual are arranged as follows:

Chapter 1 - Description/OperationChapter 2 - Servicing/TroubleshootingChapter 3 - Overhaul/Major RepairChapter 4 - Illustrated Parts ListChapter 5 - Manufacturer LiteratureAppendix A - OptionsAppendix B - Options 28 VDC Option


June 15, 2013 Chapter 1-1 Page - xviii

2 Contacting Customer Service

If you have any questions concerning your Hobart Ground Systems equipment, immediately contact our Service Department by mail, telephone, FAX, or E-Mail.

Write: Hobart Ground Systems

Service Department11001 US Highway 41, NorthPalmetto, FL 34221U.S.A.

Call Inside U.S.A.

(800) 422-4166 (Parts)(877) 874-5322 (Service)

Call From Foreign Countries

+1 (941) 721-1000 (Parts)+1 (941) 721-1000 (Service)

FAX Inside U.S.A.

(941) 723-3160 (Parts)(877) 874-5321 (Service)

FAX From Foreign Countries:

+1 (941) 721-1091 (Service)

Service E-Mail: [email protected]

Spare Parts E-Mail: [email protected]

Web Page: www.hobartsystems.com

mailto:[email protected]

http://www.hobartsystems.com



June 15, 2013 Chapter 1-1 Page 1

CHAPTER 1 - Description/Operation

Section 1 - Description

1) GENERAL

This manual covers the Hobart 2300 Solid State Frequency Converter, herein referred to as SSFC, which is distributed by Hobart Ground Systems, Palmetto, Florida 34221. The converter is designed to provide ground power for equipment requiring 200 V, 400 Hz, three-phase AC power.

The number 500036, 500037, 500038, or 500039 identifies the model or series of the converter. The part number is followed by a dash number, which separates the basic units available. The criteria for input voltages, amps, and frequency changes with each dash number. Table 1-1-1 uses the part number to identify the possible variations covered by this manual.



Chapter 1-1 June 15, 2013 Page 2

Table 1-1-1. Converters Part Number Descriptions

Part and Dash Number Ratings Input Output Option

500036-001 (fixed) 30 kVA 460 VAC, 50/60 Hz 400 Hz N/A

500036-002 (bridge mounted) 30 kVA 460 VAC, 50/60 Hz 400 Hz N/A

500036-003 (mobile) 30 kVA 460 VAC, 50/60 Hz 400 Hz N/A










500066-001 (fixed) 30 kVA 460 VAC, 50/60 Hz 400 Hz 28 VDC

500066-002 (horizontal) 30 kVA 460 VAC, 50/60 Hz 400 Hz 28 VDC

500066-003 (mobile) 30 kVA 460 VAC, 50/60 Hz 400 Hz 28 VDC










CE Rated Only



500039-503 (trailer mounted) 90 kVA 400 VAC, 50/60 Hz 400 Hz N/A

CSA Rated Only

500036-601 (fixed) 30 kVA 600 VAC, 60 Hz 400 Hz N/A

500036-602 (horizontal) 30 kVA 600 VAC, 60 Hz 400 Hz N/A









2) DESCRIPTION

Figure 1-1-1 shows the basic principle of the SSFC. 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 provided in the following sections.

Figure - 1-1-1. Basic Principle

Input Disconnect (Q1)

The input disconnect removes all power to the ground power unit. On closing, the ground power unit starts up and enters standby mode.

RFI (Input)

Filter to reduce the EMC emission into the mains to such a level that surrounding equipment is not disturbed. In addition, the filter prevents voltage transients from reaching vital parts in the ground power unit.

Input Choke and 12-pulse Transformer (L1 / T1)

The combination of the choke, the 12-pulse transformer and the rectifier situated at the inverter module, ensures an almost sinusoidal line current and a power factor ~ 1. This means less stress on the main supply network and distribution transformers.




Inverter Module

Beside the rectifier and the DC-filtering capacitors, 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 drives) are used to interface between the control unit and the thyristors/IGBTs. Voltage supervision of the DC-filtering capacitors is likewise performed at the gate drives.



Output Transformer (T2)

The output transformer secures galvanic separation between input and output. It also transforms the voltages from the inverter module into the required aircraft voltage (3 x 115/200 VAC). The filter choke for the output AC-filter is an integrated 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%. Complementing the filter choke (integrated in the transformer) and the AC capacitors, the ground power unit is equipped with an RFI-filter that reduces the high frequency emission from the ground power unit.

Output Contactor(s)

The ground power unit is equipped with one output contactor per cable. The contactor is engaged at start-up of the corresponding output, and it is disengaged, when the stop button is applied. If the interlock voltage, provided by the aircraft, is not returned to the ground power unit within 3 seconds, the contactor disengages.

Interface Module (A2)

The purpose of this module is to interface between the processor module and the rest of the ground power unit. The interface module includes the following functions:

• Interface to the display module (e.g., RS485, 24 VDC and EPO link).

• Pre-fuse for display module (F3).

• Measuring transformers for supervision of the utility power voltage.

• Measuring transformers for supervision of the 400 Hz output voltage.

• Interface for gate drives situated at the inverter module.

• Interface for current sensors situated at the inverter module.

• Relay control of fans situated at the inverter module.

• Relay control of output contactor(s).

• Input for temperature sensors.

• Pre-fuse of the 24 VDC for control purposes (F1-F2).

• I/O ports for remote control (Start, Stop etc.).

• Protected interface for interlock signals.

• Interface for individual overload protection.

• Neutral voltage supervision.

• Neutral conductor rupture supervision.

• Interface for RS232.




Supply Module (A5)

Beside the generation of a 24 VDC control voltage, the module includes fuses for AC-short circuit protection (F1-F3), MOVs (varistors) for facility power transient protection and a 10 A fuse (F4) for DC overload protection.

Processor Module (A1)

The processor module is based on a micro-controller and a digital signal processor (DSP). Together they regulate, supervise and diagnose eventual external and internal faults. As soon as the ground power unit is connected to the facility power, and constantly during normal operation, the processor module runs through a self-check program that 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 shutdown are stored in the ground power unit’s memory.

Display Module and Keyboard (A3 / A4)

The display module serves as the interface for daily operation. RS485 communication allows the display module to be positioned up to 1 kilometer (0.62 miles) away from the ground power unit.




Section 2 - Technical Specifications

1) STANDARDS

DFS 400 Specification for 400 Hz aircraft power supply.

ISO 6858 Aircraft ground support electrical supplies- General requirements

BS 2G 219 General requirements for ground support electrical supplies for aircraft

MIL-STD-704F Aircraft electric power characteristics.

EN 50091-1 General and safety requirements

EN 61000-6-4 Electromagnetic compatibility, Generic emission standard

EN 61000-6-2 Electromagnetic compatibility, Generic immunity standard

SAE ARP 5015 Ground equipment – 400 Hz ground power performance requirement

EN2282 Aerospace series characteristics of aircraft electrical supplies

2) ELECTRICAL SPECIFICATIONS

a. Input

Voltage: 3 x 460V ± 15% (208/230; 400 and 600 VAC available).

Frequency: 50 / 60 Hz ± 5%

Rectification: 12-pulse

Table 1-2-1. Electrical Specifications

Power Factor: > 0.97 at 100% load

Inrush current: None, soft start

Power interruption: Up to 20 ms

Rating 30kVA 45kVA 60kVA 90kVA

Line Current 33 A ± 15% 50 A ± 15% 65 A ± 15% 98 A ± 15%

Recommended pre-fusing 50 A 100 A 100 A 125 A

Line Current Distortion 13% A <10% <7% <7%




b. Output

Power: 30, 45, 60 or 90 kVA, P.F. = 0.8

Voltage: 3 x 115/200 V.

Power factor: 0.7 lagging to 0.95 leading.

Voltage regulation: < 0.5% for balanced load and 30% unbalanced load

Voltage transient recovery: ΔU < 8% and recovery time < 10 ms at 100% load change

Total harmonic content: < 2% at linear load (typically < 1.5%)

< 2% at non-linear load according to ISO 1540

Crest factor: 1.414 ± 3%

Voltage modulation: < 1.0% (typically< 0.5%)

Phase angle symmetry: 120° ± 1° for balanced load 120° ± 2° for 30% unbalanced load

Frequency: 400 Hz ± 0.001%

Overload at 1.0 power factor 100% for 60 minutes

Overload at 0.8 power factor 125% for 10 minutes

150% for 60 seconds

200% for 30 seconds

250% for 10 seconds

300% for 1 second

Overall efficiency: > 0.94 at 35-90 kVA load

Stand-by losses: < 50 W

No-load losses: < 2 kW



3) SETUP

Output voltage: 100-128 V

Voltage compensation: 0-9V (individual for each outlet)

Delay to stand-by: 0-15 min.

Time: Year, month, day, hour, minute and seconds

Interlock: Bypass on/off

Fan: Temperature controlled or Always on

Serial Protocol: 3964R or JBUS

Serial Port: RS232 or RS422/485

JBUS slave address: 1-247

Error log / Power log: Reset

Timer (hour counter): Reset

4) PROTECTIONS

No Break Power Transfer

Input over and under voltage

Input overload

Internal high temperature

Internal voltage error

Output over and under voltage (according to DFS 400)

Overload at output

Short circuit at output

5) PHYSICAL

Weight Fixed model: 728 lbs (330 kg)

Bridge-mounted model: 728 lbs (330 kg)

Mobile model: 1102 lbs (500 kg)

For dimensions, refer to layout drawings enclosed under Chapter 5.




6) ENVIRONMENTAL

Operating temperature: -40 °F to +125.6 °F (-40 °C to +52 °C)

Relative humidity: 10-95% non-condensing

Noise level: < 65 dB (A) at 1m, typically 60 dB(A)

Standard protection: IP55 NEMA-3R (Electronic part)

7) LIFE, ETC.

Operational life: Min 25 years

Mean time between failures (MTBF):

Converter: Min 25,000 hours

Ventilation system: Min. 100,000 hours

Mean time to repair (MTTR): Max. 20 min



Figure - 1-2-1. Fixed, Bridge-Mount and Mobile Unit




Figure - 1-2-2. Fixed and Mobile Unit with Base Module




Section 3 - Preparation, Adjustment, and Maintenance

1) STORAGE BEFORE INSTALLATION

To secure optimal storage conditions prior to installation, it is recommended that the converter be stored inside to protect it from rain and excessive humidity while it is left without power on.

Only equipment in seaworthy packing can be stored outside.

2) OPERATIONAL AND ENVIRONMENTAL CONDITIONS AFTER COMMISSIONING

When the converter has been installed and commissioned, we recommend the input always be kept with input power ON to provide optimal conditions for the electronic components and to avoid humidity in the form of condensation from reaching vital parts.

If for some reason the converter has been without input voltage for a long period, a visual inspection should be carried out. In case that condensation is discovered on any internal parts, the parts have to dry out before input voltage is again applied.

3) MOUNTING OF BOTTOM FILTER

Due to transport safety, models may be delivered without the filters mounted to facilitate the means of the accompanying mounting devices. The filters should be installed before powering up the converter.

WARNING

FOR FIRE SAFETY REASONS, THE UNIT IS NOT TO BE INSTALLED ON A COMBUSTIBLE SURFACE.



4) TRANSPORT

Figure - 1-3-1. Access for forklift (requires removal of 8 screws)

Figure - 1-3-2. Transport by forklift truck



5) INSTALLATION AND FASTENING INSTRUCTIONS

Figure - 1-3-3. Foot Print, Fixed Unit

Figure - 1-3-4. Foot Print, Bridge-mounted Unit



6) CABLE INLET

Figure - 1-3-5. Removable gland plate



7) CABLE CONNECTIONS

Remote I/O terminals

Figure - 1-3-6. Connection of Cables



8) UTILITY POWER

The correct phase sequence is ABC. The SSFC ground power unit is equipped with automatic phase sequence detection. The detection is automatically carried out when the utility power is turned on. If the phase sequence is incorrect, an error message will display. Correction is made by reversing two phases.

9) 400 HZ OUTPUT

At delivery, the 400 Hz neutral is connected to the ground (PE) terminal. If a floating output is required, the yellow/green connection wire must be removed.

10) 400 HZ INTERLOCK

The interlock safety system ensures the output contactor stays engaged as long as the aircraft connector is inserted into the aircraft receptacle. The aircraft provides 28 VDC on the F terminal with respect to the 400 Hz neutral terminal.

Figure - 1-3-7. Standard wiring diagram for civil aircraft

For service, maintenance and test purposes, the interlock system can be bypassed via the display setup. To ensure personal health and safety, the ground power unit automatically returns to its initial interlock mode once it receives 28 VDC at the F terminal, e.g., when the ground power unit is connected to an aircraft.

WARNING

DUE TO PERSONAL HEALTH AND SAFETY, THE SSFC UNIT MUST ALWAYS BE PROTECTED BY GROUNDING THE

GROUND/PE TERMINAL ( ).

WARNING

INDEPENDENT OF THE INSTALLATION METHOD, IT IS MANDA-TORY THAT LOCAL REGULATIONS AND LEGISLATION ARE FUL-FILLED IN ORDER TO ENSURE PERSONAL HEALTH AND SAFETY.



11) CONTROL INTERFACE (REMOTE I/O TERMINALS)

Via the remote I/O terminals it is possible to interface to:

• External Emergency Stop

• External Start / Stop and Indication.

• Equipment requiring potential free input signals

• 90% Switch in aircraft connector (Optional - see section 11)

• Key reader, bridge, cable drum etc. via GPU enable (Optional - see section 11)

• Neutral conductor rupture (Optional - see section 11)

Figure - 1-3-8. Example of wiring for external control via the I/O terminals

WARNING

TO SECURE PERSONAL HEALTH AND SAFETY THE INTERLOCK SAFETY SYSTEM MUST ALWAYS BE ACTIVATED UNLESS THE GROUND POWER UNIT IS UNDERGOING SERVICE, MAINTE-NANCE OR TEST BY QUALIFIED PERSONNEL.



Please refer to the diagrams at the back of this manual for a complete overview of the I/O terminals provided.

12) INTERFACE VIA RS485 OF TCP/IP

Refer to Appendix A for detailed information.




Section 4 - Instruction for Use

1) INTRODUCTION

This chapter contains detailed operating instructions and procedures for the SSFC. These instructions and procedures are supplemented by illustrations for operator identification and understanding.

2) CONTROLS AND INDICATORS

Figure 1-4-1 depicts the SSFC front panel instrumentation options. Table 1-4-1 lists controls and indicators on the front panel. Some variation may occur based on field application requirements.

Figure 1-4-1. Instrumentation for unit equipped with additional 400 Hz Output

OM-2218 / Operation and Maintenance ManualHobart 2300® / Series 500036, 500037, 500038, 500039 /



Table 1-4-1. Controls and Indicators

Item Number

Name Description

1 Status This LED indicates the status of the unit. A green light indicates the unit is ready for use. A red light indicates the unit is in Fault mode, and the Display (11) shows the error code and a descrip-tion.

2 Reset This button resets any faults on the unit. If the Reset button is pressed when the Status light is green, nothing occurs. If the Reset button is pressed when the Status light is red, the unit attempts to reset. If the failure was momentary, the fault is cleared and the Status returns to green. If the failure remains, the Status stays red.

3 Indications for Output 1 400 Hz green light when output is activated. Interlock yellow when interlock is present.

4 Indications for Output 2

400 Hz or 28 VDC green light when the output is activated. Inter-lock yellow when interlock is present.

5 Current Textual label only. Used in conjunction with the Adjustment Arrows (7).

6 Limit DC Textual label only. Used in conjunction with the Adjustment Arrows (7).

7 Adjustment Arrows Use these arrows to adjust the current (28 VDC only)

8 Start/Stop Output 2 (28 VDC, Optional)

Use these buttons to start and stop Output 2 or 28 VDC. (Optional)

9 Start/Stop Output 1

Use these buttons to start and stop Output 1.

10 Display Navigation

Use the UP, DOWN, LEFT, and RIGHT arrows to navigate the Display screen.

11 Display The Display screen shows the status of the SSFC and the avail-able parameters.



3) INITIAL ADJUSTMENTS AND CONTROL SETTINGS

There are no initial adjustments and control settings to perform prior to applying power to the remote operator control station. All adjustments and control settings are factory preset.

4) PRE-OPERATION PROCEDURES

Pre-operational procedures listed in Table 1-4-2 ensure the module is properly configured prior to start-up. Some variation may occur, based on field applications.

5) START-UP OPERATION

Facility power (460 VAC, 60 Hz) can be applied to the SSFC from the external/remote power source via the input power cable. Prior to powering up or applying power to the SSFC, the pre-operational procedures should be performed. All controls and indicators are within easy acc.ess when the operator is ready to power-up the SSFC. The Start-up procedures can be found in Table 1-4-3

WARNING

NEVER ATTEMPT TO CONNECT OR DISCONNECT THE AIR-CRAFT CONNECTOR (OUTPUT) DURING SSFC OPERATION. FAILURE TO COMPLY MAY RESULT IN SERIOUS INJURY TO PERSONNEL OR DAMAGE TO THE EQUIPMENT.

Table 1-4-2. Pre-operational Procedures

Step Procedure Indication

1 Ensure the following:

a. EMERGENCY STOP pushbutton is pulled out.

b. If the remote control panel box is used, ensure the EMERGENCY STOP pushbutton is pulled out.

2 Verify the external power source circuit breaker is set to OFF.

3 Ensure the input power cable/lead is connected to the SSFC.

WARNING

BEFORE POWERING UP THE SSFC, ENSURE THE EMERGENCY STOP BUTTON AND, IF APPLICABLE, REMOTE CONTROL PANEL BOX EMERGENCY STOP BUTTON ARE NOT ENGAGED.




6) SETUP PARAMETERS

To view or change adjustable parameters, follow the directions below.

a. Select Setup Mode and hold down the center button for 5 to 7 seconds.

b. Browse through setup parameters by means of the vertical arrow buttons.

c. Press the center button to select the parameter to be adjusted.

d. Adjust the selected parameter by means of the vertical arrow buttons.

e. Press the center button to confirm the adjustment.

f. Return to previous mode by means of the horizontal arrow buttons.

g. Whenever an error is detected, a snap shot of all the measured parameters is taken. To view the “snap shot parameters”, select the specific error in Alarm Mode and press the center button.

Figure 1-4-2. Navigation Buttons

NOTEBEFORE PERFORMING THE START-UP PROCEDURES, ENSURE THE PRE-OPERATIONAL PROCEDURES HAVE BEEN COM-PLETED.

Table 1-4-3. Start-Up Procedures


1 Set facility/external power source circuit breaker to the ON (energized) position.

The following occurs:

a. Display screen illuminates.

b. No indicators illuminate.

c. The unit begins self diagnostics.

d. Once the self diagnostics have been completed, the Display screen illuminates and the LED turns green.



7) USING THE DISPLAY

The Display Message Screen, depicted in Figure 1-4-3 and Figure 1-4-4, shows the status of the SSFC, and the Navigation Display Switch Button makes it possible to browse through the converter parameters; e.g., input voltage, output voltage, load, etc. The four basic display modes are as follows:

• Default Mode: Display Message Screen is blank, until the GPU is powered up. When the unit is powered on, the Display Message Screen reads: GPU, READY FOR USE.

• Alarm Log Mode: Pressing the right arrow button once should place the display in the Alarm Log Mode. This will enable browsing through previous errors and related parameters.

• Power Log Mode: Pressing either right or left arrow buttons twice will place the display in Power Log Mode. This will enable browsing through previously recorded operations.

• Setup Mode: Pressing the left arrow key once (from powered-on/default mode) enables viewing and adjusting selected parameters (accomplished via the up and down arrow keys). See paragraph 4-7.2.

Figure 1-4-3. Change between the display modes

To change between display Modes, press the horizontal arrow buttons.

Figure 1-4-4. View of parameters etc.

To view parameters within a Mode, press the vertical arrow buttons.




8) ADJUSTABLE PARAMETERS IN SETUP MODE

For units equipped with 28 VDC Outlet: Refer to Appendix B - 28 VDC Option for setup parameters

• OUTPUT VOLTAGE (Phase-Neutral)

• COMPENSATION TYPE (Manual or Plug and Play – See next page)

• CABLE IDENTIFICATION (No / Yes – Plug and Play compensation)

• CABLE COMPENSATION (Output 1 and Output 2, if present – Manual compensation)

• REAL TIME CLOCK (Year, month, day, etc.)

• INTERLOCK BY-PASS (On / Off)

• SERIAL PROTOCOL (1=3964R and 2=JBUS)

• JBUS SLAVE ADDRESS (provided JBUS is selected)

• FAN CONSTANTLY ON (On / Off)

• LANGUAGE

• NEUTRAL VOLTAGE SUPERVISION If the voltage level between the 400 Hz neutral and ground exceeds the preset level for more than 1 second, the output is disengaged. The neutral voltage supervision can be bypassed by setting the trip level to 0 VAC.

9) LOCK SETUP PARAMETERS

To avoid unintentional modification of the Setup parameters, it is possible to block the access to the Setup Mode, by means of a DIP switch situated at the Display Module A3.

Figure 1-4-5. Display Module A3



10) CABLE COMPENSATION SETUP (PLUG AND PLAY)

The unique Plug and Play compensation system automatically identifies all relevant cable parameters needed to keep the voltage at the aircraft connector constant, at all aircraft loads.

a. Install the Auto-Calibration Plug onto the end of the aircraft cable.

Figure 1-4-6. Auto-Calibration Plug to Aircraft Cable

b. Select compensation type to “PLUG and PLAY” via Setup Mode.

c. Change “IDENTIFY CABLE” to “YES”.

d. Initiate the cable identification process by pressing the ground power unit’s START button.

Figure 1-4-7. The Start Button

e. Within a few seconds, the cable parameters are identified and the ground power unit returns to Default Mode.

f. Remove the Auto Calibration Plug and the ground power unit is ready for use.

CAUTION

IT IS NOT POSSIBLE TO USE THE PLUG AND PLAY VOLT-AGE COMPENSATION IF THE GROUND POWER UNIT IS EQUIPPED WITH TWO OR MORE OUTLETS. FAILURE TO COMPLY MAY CAUSE EQUIPMENT DAMAGE.




11) MANUAL CABLE COMPENSATION

This is the traditional (Manual) method of cable compensation, where the output voltage is increased in proportion to the load current (1 Volt / 100 A). This method can be used when banded cable(s) are used or the voltage changes caused by unbalanced loads or varying power factor loads can be ignored.

1. Apply nominal load at the aircraft connector.

2. Select compensation type to “MANUAL” via Setup Mode.

3. Select “CABLE COMP. OUTPUT 1”.

4. Adjust the compensation by means of the vertical arrow buttons until the voltage at the aircraft connectors equals the no load value.

If the ground power unit is equipped with a second outlet, the same procedure is applied for “OUTPUT 2”.

12) NORMAL OPERATION

e. The operation of the SSFC is carred out via the switches located on the front panel. Table 1-4-4 lists the option of using a remote control panel box during normal operation.

CAUTION

THE E/F INTERLOCK CIRCUIT IS DESIGNED TO FUNC-TION BY RECEIVING +28VDC FROM THE AIRCRAFT ON THE OUTPUT CABLE F-PIN. IF THE AIRCRAFT DOES NOT PROVIDE +28 VDC, THE OUTPUT CONTACTOR WILL BE INOPERABLE UNLESS THE INTERLOCK BYPASS SWITCH IS ACTIVATED.

CAUTION

BEFORE PERFORMING NORMAL OPERATION, ENSURE THE PRE-OPERATIONAL PROCEDURES AND START-UP PROCEDURES HAVE BEEN PERFORMED.



Table 1-4-4. Normal Operation


1 Set Input Disconnect circuit breaker switch to the ON position.

The following occurs:

• INPUT POWER indicator illuminates.

• Fans start running.

• DISPLAY indicators illuminate momentarily.

• Status green indicator, lower stays illuminated. Note: If there is a fault/error, Status indicator, upper illuminates red. Then proceed to CHAPTER 2 - Troubleshooting and Repair.

2 Press the Start button. The following occurs:

• The Display shows the Output 1 and Output 2 messages.

• Inverter indicator illuminates.

3 If the operator desires to view/display the status or parameters, at the Display, press the Display Naviga-tion pushbuttons to set the desired setting or mode of operation.



CHAPTER 2 - Troubleshooting and Repair

Section 1 - Troubleshooting and Repair

Usually the display text provides sufficient information to get the ground power unit into operation again. In case the display is blank, please check fuse F1, F2 and F4 at the Supply Module A5 and fuse F3 at the Interface Module A2.

If the displayed text does not provide sufficient information to solve the problem, Table 2-1-1 and Table 2-1-2 suggest prioritized corrective actions to be carried out for each error code.

Additional error-information regarding the input voltage, output voltage, transformer filter current, overload and short circuit can be derived from the error code according to the following directions:

Error Code XX01 refers to output phase A (or input phase L1) Error Code XX02 refers to output phase B (or input phase L2) Error Code XX03 refers to output phase A and B (or input phase L1 and L2)Error Code XX04 refers to output phase C (or input phase L3) Error Code XX05 refers to output phase A and C (or input phase L1 and L3)Error Code XX06 refers to output phase B and C (or input phase L2 and L3)Error Code XX07 refers to all output phases (or all input phases)

Examples: Error Code 1001 refers to a too high input voltage at phase L1. Error Code 4007 refers to overload at all 3 output phases.

WARNING

DISCONNECT SUPPLY BEFORE CHANGING ANY FUSE. FOR CONTINUED PROTECTION AGAINST RISK OF FIRE, REPLACE ONLY WITH SAME TYPE AND RATING FUSE.

WARNING

ONLY HAVE QUALIFIED PEOPLE REMOVE COVERS FOR TROUBLESHOOTING AND REPAIR. PLEASE BE AWARE THAT THE DC CAPACITORS CAN REMAIN CHARGED TO A DANGEROUS VOLTAGE UP TO 5 MINUTES AFTER THE MAINS INPUT HAS BEEN DISCONNECTED.







2) FAULT GUIDANCE

In the event that you need to contact Hobart Ground Systems for further fault guidance, please have the serial number of the GPU (can be found at the rating plate) and the actual error code of the fault available.

If you have any questions concerning your Hobart Ground Systems equipment, immediately contact our Service Department by mail, telephone, FAX, or E-Mail. See Contacting Customer Service on page xviii of this manual for contact information.



Table 2-1-1. Error Codes 0000 - 2199

0000-0099NO ERROR LOGGED YET

10100-0199LOGGING WAS NOT COMPLET. SUCCESFULLY 3

0150WATCHDOG RESET OCCURED

0200-0299INTERNAL DC SUPPLY VOLTAGE ERROR

0300-0399EMERGENCY STOP ACTIVATED OR FUSE BLOWN

0400-0499AC SOFTSTART ERROR

0900-0999INPUT VOLTAGE – PHASE SEQUENCY WRONG

1000-1099INPUT VOLTAGE TOO HIGH

0500-0599INVERTER ERROR

0600-0699INPUT VOLT. – PHASE SEQUENCY NOT FOUND

0800-0899INPUT VOLTAGE – FREQUENCY TOO LOW

1100-1199INPUT VOLTAGE TOO LOW

1500-1599DC VOLTAGE < 350 V

1600-1699DC VOLTAGE > 850 V

1700-1799DC CAPACITOR SHARING ERROR

2000-2099INVERTER TEMPERATURE TOO HIGH

2100-2199GATE VOLTAGE ERROR

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CORRECTIVE ACTIONS:Apply the suggested corrective actions

in the prioritized order: 1, 2, 3 ...

NOTE:

Before replacing any components pleasecheck the associated wiring.

42

1 2

1 4 53 2

2

1 2

1 5 7 3 62 4

1 2

23

1 4 5 23

1 4 5 32

1 4 5 23

1 4 5 23

1 5 3 4 2

1 5 3 4 2

1 7 3 6 542

1 5 4 6 2

1 3 2 4

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Table 2-1-2. Error Codes 3000 - 4999

3000-3099OUTPUT OVERVOLTAGE: U > 128 V – 250 ms

13100-3199OUTPUT OVERVOLTAGE: U > 140 V – 15 ms 3

3300-3399OUTPUT OVERVOLTAGE: U > 32 V – 4 s

3400-3499OUTPUT OVERVOLTAGE: U > 40 V – 1 s

3600-3699OUTPUT UNDERVOLTAGE: U < 90 V – 50 ms

3700-3799OUTPUT UNDERVOLTAGE: U < 70 V – 10 ms

4300-4399OVERLOAD: 200 % < I < 250 % – 10 s

4400-4499OVERLOAD: I > 250 % – 1 s

3900-3999OUTPUT UNDERVOLTAGE: U < 20 V – 30 s

4000-4099OVERLOAD: 100 % < I < 125 % – 600 s

4200-4299OVERLOAD: 150 % < I < 200 % – 30 s

4500-4599SHORT CIRCUIT AT OUTPUT

4600-4699TRANSFORMER FILTER CURRENT TOO LOW

4700-4799TRANSFORMER FILTER CURRENT TOO HIGH

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Error Codes: 3000 - 4999

NOTE:Before replacing any componentsplease check the associated wiring.

1 4 5 32

4 2

1 5 7 42 3

1 4 6 3 2

1 4 6 2 53

1 4 6 2 53

1 5 7 42 3

1 4 5 3 2

2

1 4 5 3 2

1 4 5 3 2

1 4 5 3 2

1 4 5 3 2

1 5 3 6 24

1 3 2 45

4100-4199OVERLOAD: 125 % < I < 150 % – 60 s 1 4 5 3

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4800-4899TRANSFORMER TEMPERATURE TOO HIGH

13500-3599OUTPUT UNDERVOLTAGE: U < 100 V – 300 ms 5

5 6 1 432

7 32 64

4900-499928 V RECTIFIER TEMPERATURE TOO HIGH 5 7 1 34 6 2



Table 2-1-3. Error Codes 5000 - XX00-XX99

5000-5099EARTH / INSULATION ERROR AT OUTPUT

15100-5199NEUTRAL CONDUCTOR RUPTURE OUTPUT 1 4

5200-5299NEUTRAL CONDUCTOR RUPTURE OUTPUT 2

5300-5399OVERLOAD OUTPUT 1

5500-5599ADAPTION TRANSFORMER OVERHEATED

5600-5699NEUTRAL VOLTAGE SUPERVISION ERROR

XX00-XX99NOT A DEFINED NUMBER

5700-5799DIP SWITCH IN WRONG POSITION

5800-5899ERROR: CABLE IDENTIFICATION FAILED

6000-6099END OF TEST

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Error Codes: 5000 – XX00-XX99

NOTE:Before replacing any componentsplease check the associated wiring.

2 7 5 18 4 63

3 5 2

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1 5 4 6 32

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15400-5499OVERLOAD OUTPUT 2 5 4 6 32



CHAPTER 3 - Overhaul / Major Repair

Section 1 - Overhaul / Major Repair

1) GENERAL

Repair of the converter consist primarily of part replacement. Most of the components used in the converter cannot be disassembled and repaired, and must be replaced if faulty. Additionally, inoperative PC boards cannot be repaired in the field and must be replaced as a complete unit. PC boards may be returned to the factory for replacement. Contact Hobart Ground Systems for part and replacement instructions.

2) SERVICE INFORMATION AND FACTORY REPAIR

Questions concerning the operation, repair, and/or servicing of this converter should be directed to the Service Department of Hobart Ground Systems. When making such an inquiry, be sure to provide the Service Department with the model number, serial number, and approximate date of receipt of the unit. If it is deemed necessary to return the unit to the factory for servicing, contact the Customer Service Department for authorization. It is rarely necessary to return a failed converter since the unit uses modular components and plug-in type assemblies throughout the converter. For warranty information, refer to the warranty statement at the front of this manual or contact the Hobart Service Department.

When ordering parts from your Hobart Ground Systems Distributor, be sure to include all pertinent information from the unit’s identification plate: Specification No., Model No., and unit rating. If you have any questions concerning your Hobart Ground Systems equipment, immediately contact our Service Department by mail, telephone, Email or FAX. See Contacting Customer Service on page xviii of this manual for Customer Service contact information.

3) TEST EQUIPMENT AND SPECIAL TOOLS

Table 3-1-1 lists the test equipment and special tools required for performing maintenance and testing of the facility power converter. Equivalent tools and test equipment can be used.

CAUTION

TO MAKE CERTAIN THAT THE UNIT IS ALWAYS READY FOR USE, IT MUST BE MAINTAINED ON A REGULAR BASIS. ONLY HAVE QUALIFIED PEOPLE REMOVE COV-ERS FOR SERVICE, MAINTENANCE OR OVERHAULS.










Table 3-1-1. Special Tools and Test Equipment.

4) RECOMMENDED MAINTENANCE SCHEDULE

• Check Aircraft connector. Quarterly

• Check Output cable for damaged insulation. Quarterly

• Verify function of 90% Switch, if present. Quarterly

• Check Air-filters - Wash or change as appropriate. Quarterly

• Check that all fans are running properly (constantly on via display). Yearly

• Check rubber gasket at front door, rear panel and top cover. Yearly

• Check internal bolt/screw and wire connections. Yearly

• Check vibration dampers (via rear panel). Yearly

• Visual inspection of PCBs - control unit / gate drive. Yearly

• Control of the output contactors' contact sets and coil. Yearly

• Control of output voltage at aircraft connector (with and without load). Yearly

Mobile units

• Check tires for wear and tear. Yearly

• Check correct air pressure (4,3 Bar = 62 PSI). Quarterly

5) BATTERY BACK-UP

Situated on the processor board, a lithium battery ensures that Setup data etc. are not lost during utility power drop-outs. The expected life of the battery is approximately 10 years. However, a low battery voltage does not affect the internal safety system of the GPU that monitors the output voltage, among others. Thus aircraft connected to the GPU are not exposed to any danger. To avoid loss of data we recommend to change the battery after 8 to 9 years of use.

Nomenclature Part Number Manufacturer Application

Set-Tool DIS12 Concrete FastenersUsed to insert drop-in anchor

into concrete

Tensiometer TZ5224 ITW Military GSEMeasure exertion force of

cable pin

DVM Digital Volt meter 77-2 Fluke Corporation Measure voltage or current

during troubleshooting

Soldering Gun Kit WESD51 (2UV18) Weller/K5836Used to solder wire to compo-

nent

Load Bank L-72, L-80, L-100, or L-120 CannonUsed to test output load condi-

tion



CHAPTER 4 - Parts

Section 1 - Introduction

1) GENERAL

The Illustrated Parts List identifies, describes, and illustrates main assemblies, subassemblies, and detail parts of the SSFC, manufactured by ITW GSE Group, Hobart Ground Systems.

2) PURPOSE

The purpose of this list is to provide parts identification and descriptive information to maintenance and provisioning personnel for use in provisioning, requisitioning, purchasing, storing, and issuing of spare parts.

3) ARRANGEMENT

Chapter 4 is arranged as follows:

Section 1 - Introduction

Section 2 - Recommended Spare Parts

Section 3 - Illustrated Parts List

Section 4 - Numerical Parts List



Chapter 4-2 September 15, 2013 Page 1

CHAPTER 4 - Parts

Section 2 - Recommended Spare Parts

1) List of Recommended Spare Parts

The following list is a compilation of Recommended Spare Parts.

Table 4-2-1. Recommended Spare Parts

Part Number Description CodeNumber of Units

1-34-8 9-15

AP-278020 Vertical Display insert C 1 1 1

AP-278026 Gasket for glad plate C 1 1 2

AP-532302 Operator Galvanized mounting frame C 1 1 1

AP-534206 Remote Control Box w/display C 1 1 2

AP-556705 400 Hz output transformer C 1 1 2

AP-556706 12-pulse mains transformer C 1 1 1

AP-564706 Mains AC-choke 650 uH, 116A (90kVA) C 1 1 1

AP-564707 Mains AC-choke 1300uH, 58A (45kVA) C 1 1 1

AP-578001 Power Module CE only C 1 1 1

AP-578001R Repaired Power Module w/ core return C 1 1 1

AP-578003 Power Module UL only C 1 2 3

AP-578003R Repaired Power Module w/ core return C 1 1 1

AP-578909 Door Interlock Switch BC 1 2 3

AP-578930 Base Module cabinet (13.7" high) C 1 1 1

AP-579410 Processor Board BC 1 2 3

AP-579425 Output RFI Board BC 1 2 3

AP-579500 Power Supply Module C 1 2 3

AP-579501 Interface Module BC 1 2 3

AP-579502 Display Module (SN required) C 1 2 3

AP-579504 Input RFI Board BC 1 2 3

AP-578K003 Keyboard Membrane Module C 1 2 3

AP-AE7041 Lithium Battery (replace every 5 - 7 yrs C 1 2 3

AP-AF0246 Input Disconnect Switch C 1 2 3

AP-AF0249 Disconnect Switch Handle C 1 2 3

AP-AF0257 Disconnect Switch Handle Support C 1 2 3

AP-AF0258 Shaft for Disconnect Switch C 1 2 3

AP-AF0403 Emergency Stop PB BC 1 2 3

AP-AM0060 Intake (top) Air Filter (Vertical units) ABC 3 6 9

AP-AM0061 Intake (top) Air Filter (Horizontal units) ABC 3 6 9

AP-AM0063 Output (base) Air Filter ABC 3 6 9

AP-AM0131 Air Filter (horizontal units) ABC 3 6 9

AP-DV3009 Operator Membrane Keyboard (SN req) BC 1 2 3




Table 4-2-2. Spare Parts Code

AP-IT0027 Current Sensor 300A, 1:2000 BC 1 2 3

AP-KO4082 30/45 kVA Output Contactor BC 1 1 2

AP-KO4253 60/90 kVA Output Contactor BC 1 1 2

AP-KP0488 Capacitor 0.47uF 500VAC BC 3 6 9

AP-KP7041 Capacitor 100uF 250VAC BC 9 18 27

AP-RC0006 Surge Suppressor BC 3 6 9

AP-SI0040 Fuse, 4A fast 250V ABC 5 5 10

AP-SI0106 Fuse/Fuse, 6.3A, 500V 6.3 x 32 ABC 5 5 10

AP-SI2066 ATO Fuse 10A (F) ABC 5 5 10

AP-SI2075 ATO Fuse 5A (F) ABC 5 5 10

AP-VN0013 Fan BC 1 2 3

28VDC Option items

AP-556707 Transformer 3x200/2x27 V, 170A C 1 1 1

AP-564690 Choke for filter C 1 1 1

AP-579506 TRU Interface C 1 1 1

AP-EL3305 Electrolytic capacitor 22mF 40V 20% BC 3 6 9

AP-HG0304 Diode, Pos, 275A, 300 PRV BC 1 2 3

AP-MO0410 Resistor 22 Ohm, 100 W, 5% BC 1 2 3

AP-TR7010 Thermostat 110 ± 3 °C NC BC 1 2 3

Code:

A Running Spares - Necessary For Unit Operation

B Maintenance Spares - Necessary For Unit Operation

* With General Maintenance

C Depot Spares - Necessary For Unit Operation

* Plus Some Overhaul Capabilities



CHAPTER 4 - Illustrated Parts List

Section 3 -Illustrated Parts List

Figure 4-3-1. Hobart 2300 Vertical - Front View



In mobile and bridge mounted units, the display module and the emergency stop button are situated in a separate box.

Figure 4-3-2. Hobart 2300 Rear View



Figure 4-3-3. Top/front View



Figure 4-3-4. Hobart 2300 Trailer Mounted GPU



CHAPTER 5 - Manufacturer Literature

Table 5-1-1. Manufacturer Literature

Contact Hobart Ground Systems if any of the above documentation is not within this manual (unless otherwise noted above).

Diagram Number Diagram Description

292059 Rev. 1 400 Hz Ground Power Unit Main Circuit and Instrumentation

292060 Rev. 1 400 Hz Ground Power Unit with 28VDC Tru Main Circuit and Instrumentation

292061 Rev. 1 400 Hz Ground Power Unit Options Diagram

292062 Rev. 1 400 Hz Ground Power Door Interlock


June 15, 2013 Appendix A Page 1

APPENDIX A - OptionsThis ground power unit might be equipped with one or more of the following options.

Table A-1-1. Available Options

Option/Features Available

Description Part Number

Input Auto Transformer 208VAC 30 and 45 US - 60 CE only AP-578933

Input Auto Transformer 600VAC 30 - 90 kVA AP-578932

Additional Base Module RAL9003 AP-578930

Cover for Instrumentation 30-90 kVA Fixed 578906 Remote Control Box. Incl. 30 m. control cable and EPO

AP-578905

Additional Output Contactor 60 - 90 kVA AP-578907

Additional Output Contactor 30 - 45 kVA AP-578908

Door Interlock Fixed only AP-578909

Neutral Conductor Rupture Supervision Per Output AP-578910

Plug inserted Interlock AP-578911

Terminal extension for 2 pcs. of 7 core cable AP-578914

RS485 Interface AP-578915

Modbus TCP Interface AP-578916

Military Interlock AP-57891

Display Heater AP-578923

Control Box Heater AP-578924

Diagnostic Service Tool Software AP-578925

Auto Caliazsration Plug 60-90 kVA AP-591100



Appendix A June 15, 2013 Page 2

AP 578902 Input Auto Transformer (diagram 478901) (Only valid for units without the 28 VDC option.

AP Transformer, which enables connection of the ground power unit to the following mains voltages:

• 3 x 208 VAC (recommended pre-fuse: 315 A)

• 3 x 600 VAC (recommended pre-fuse: 150 A)

The transformer is placed in a base module (refer to section 5)

AP 578903 Base module

The base module is standard on all fixed units. An additional base module can be added, as needed. An additional base module extends the height /length of the ground power unit by 13.7” (345 mm) and the weight by 44 lbs (20 kg). Refer to section 5.

AP 578905 Cover for instrumentation

A protective cover in front of the operator’s panel.



AP 578906 Remote Control Box

The control box is used for remote operation of the ground power unit.

Figure A-1. Remote Control Box




AP 578907Additional Output Contactor (diagram 478901)

AXA 2300 compact ground power units are as a standard equipped with one output contactor. All models are, however, prepared for an additional output contactor.

Figure A-2. Output Contactor

AP 578909Door Interlock (diagram 478901)

Interlock, which ensures that the ground power unit passes into stand-by mode if the door is opened.

AP 578910Neutral Conductor Rupture (NCR) Supervision

A broken neutral conductor in the 400 Hz cable combined with an unbalanced aircraft load could lead to a destructive phase-neutral voltage in the aircraft and to hazardous voltages between the aircraft chassis and the ground level. The NCR option secures that a broken neutral will be detected instantaneously.

Figure A-3. NCR Board and Internal wiring diagram



Figure A-4. Wiring diagram for Neutral Conductor Rupture Supervision

Unbalanced voltage at the aircraft connector due to a broken neutral would add a 400 Hz voltage to the 28 VDC interlock voltage measured at the ground power unit. If the injected AC voltage exceeds approx. 20 VAC the output is disconnected. This type of error is recognized as an interlock failure by the ground power unit. Since the disconnection is a reaction against a heavy unbalanced voltage at the aircraft connector, it means that this type of supervision does not protect sensitive equipment in the aircraft. The NCR option protects personnel as well as the aircraft in case of a broken neutral.




AP 578911 Plug Insertion Switch Interlock

This feature supervises that the aircraft plug is completely inserted into the aircraft power connector. This feature requires the use of a special J&B single jacket cable. If the plug is not fully inserted, the respective outlet cannot be engaged. The option also includes a potential free output showing whether the insertion signal is present or not. The option is valid for ground power units with one or two outlets.

Figure A-5. Wiring diagram for Plug Insertion Interlock and GPU Enable

AP 578912GPU Enable (key reader, bridge, cable drum etc.)

An option which can be used as interlock for instance for key/car reader, boarding bridge, cable drum, pit flooded etc. The option requires a constant closing function of the external signal providers. If the circuit is broken, the ground power unit stops. See wiring diagram above.



AP 578916RS485 Interface (diagram 478001)

As standard, ground power units are supplied with connections for RS232. The RS485 Interface option will provide a galvanic isolated RS485 connection and allow for multi-point connection.

Figure A-6. PIN Assignment for RS485 Interface




AP 578916TCP/IP (diagram 478001)

TCP/IP or Ethernet Interface is today a widely used interfacing port. With this option it is possible to interface with the ground power unit with MODBUS/JBUS RTU protocol via TPC/IP data port. A Netbiter ® Modbus Gateway module is used to interface between RS232 and TCP/IP. Ethernet Baud rate: 10/100 Mbit/s

Figure A-7. TCP/IP or Ethernet Interface

AP 578917 Military Interlock

For military aircraft, the interlock system must be switched from civilian interlock to military interlock by means of selector switch (S30) behind the front door. The GPU hereafter delivers 28 VDC on the E pin and this voltage is returned to the F pin by the aircraft.

The E terminals are prefused with 2 A per outlet.

Figure A-8. Standard Wiring Diagram for Military Interlock

A

BC

N

FE

A

BC

N

FE

+ 28 VDCTo control

Aircraft ReceptacleAircraft ConnectorGround Power Unit Cable

A

BC

N

F

E

Interlock:Civ. Mil.



AP 573923 Display

For fixed units with display on front door

AP 573924 Control Box Heater

For bridge mounted or mobile units with remote control box. AP 573956 Service Tool

AP 573956 Service Tool

In a standard ground power unit, error and power logs as well as real time readings are available via the display located on the unit. With the service tool, it is possible to download the error and power logs to a PC or laptop and further one can view the real time readings on the monitor.

The tool includes software and hardware lock for installation on a PC or laptop (PC/Laptop is not included). Further, it includes a data cable and a serial to USB adaptor, enabling connection to the USB port on a PC / Laptop. The data cable from the PC is connected to terminal X26 at the Interface Module A2.

Figure A-9. Service Tool

AP 591100Auto Calibration Plug

Short circuit connection for Plug and Play Setup.


June 15, 2013 Appendix B Page - 1

APPENDIX B - 28 VDC OptionThe 28 VDC Option applies to the 50006-69 Series only.

1) OPERATOR INSTRUCTIONS

The 28 VDC is controlled by means of the Display/Keyboard Interface. Refer to Chapter 1, Section 4 for instructions on using the Display.

To adapt the converter to different types of aircraft, it is possible to set a maximum DC current level in steps of 300 Amp. (e.g., 600, 900, 1200, 1500, 1800, 2100, and 2400 Amp). To do so, use the arrow push buttons at the bottom of the keyboard. To ensure hassle-free starting of the aircraft engine, the current limit function is delayed 0.7 seconds.

2) SETUP OF PARAMETERS

It is possible to adjust the output voltage and the cable compensation of converters equipped with 28 VDC output. To adjust the cable compensation:

1. Apply nominal load by means of a DC load bank.

2. Select “DC CABLE COMPENSATION” via the Setup Mode.

3. Adjust the compensation by means of the vertical arrow buttons.

4. on the display keyboard. Use the Current, Limit DC up and down arrows to set the no load voltage equal to the voltage at the aircraft connector.

5. Press the Center Dot on the display to accept the change.

3) SPECIFICATIONS

Output:

Voltage : 28 VDCCurrent : 600 A continuously Voltage regulation : < 0.5% Voltage ripple : < 1% Voltage transient recovery : Complies with ISO 6865 / MIL-704EOverload capability : 1200 A for 30 seconds (minimum)

1800 A for 10 seconds (minimum) 2100 A for 5 seconds (minimum) 2400 A for 2 seconds (minimum)

To protect the aircraft, the output voltage is decreased by 1 V per 300 A in the overload range (600-2400 A).



Appendix B June 15, 2013 Page 2

Setup:

Output voltage : 20-32 VVoltage compensation : 0-4 V per 600 A Current limit : 600-2400 A in steps of 300 A

Protections:

Rectifier temperature too highShort circuit at outputOver and under voltage at output in case:

U < 20 VDC for more than 4 secondsU > 32 VDC for more than 4 secondsU > 40 VDC for more than 1 second

Physical:

Additional weight to 400 Hz unit: 220 lbs (100 kg)For dimensions, refer to Chapter 1, Section 2 (e.g., units equipped with base module).

Troubleshooting and Repair:

Rectifier temperature too high (error code 4900):

1. Let the unit cool down and Reset.

2. Check airflow /air-filter/fans.

3. Check temperature sensor at rectifier heat sink.

4. Check TRU interface.

5. (A20) and wiring.

Output Under Voltage < 20 V – 4sec. (error code 3900):

1. Could be due to a heavy overload – Reset unit.

2. Check output voltage setup value.




June 15, 2013 Appendix B Page - 3

Output Over Voltage > 32 V / 40 V – 4sec. / 1sec. (error code 3300 and 3400):

1. Could be due to disconnection of a heavy overload – Reset unit.

2. Check output voltage setup value.





Appendix B June 15, 2013 Page 4

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