Jet Power FILTER II Manuel utilisateur

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

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.

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