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www.axapower.com

Manual

AXA 2300 Compact

400Hz Ground Power Unit
With 28 VDC outlet (optional)

Serial no.

Type 3GV -200/ -

AXA Power ApS • Smedebakken 31 – 33 • DK-5270 Odense N • Denmark

Telephone: + 45 63 18 60 00 • Fax: + 45 66 18 70 92 • Email: sales@axapower.com
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Diagrams and drawings are subject to change without prior notice. Latest
diagram versions can be found at www.axapower.com

Printed: February 2011

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Operation Manual - AXA 2300 Compact – 30 - 90 kVA

Index

INDEX

1.0 Declaration of Conformity ................................................ .......................................5

2.0 Safety Instructions ................................................. .................................................. .6
3.0 General Description ................................................ ...................................................7
4.0 Transport and Installation................................................ .......................................10
4.1 Storage Before Installation................................................. ............................................ 10
4.2 Operational and Environmental Conditions after Commissioning................................. 10
4.3 Transport ................................................. .................................................. .................... 10
4.4 Installation and fastening instructions................................................ ............................. eleven
4.5 Cable Inlet................................................ .................................................. ................... 12

4.6 Connection of Cables................................................. .................................................. ...13

4.7 Mains Input ................................................ .................................................. ................. 14

4.8 400Hz Output................................................. .................................................. .............. 14
4.9 400Hz Interlock................................................. .................................................. ........... 14

4.10 Control Interface (Remote I/O Terminals)................................................. ........................... fifteen

4.11 Interface via RS485 or TCP/IP ........................................... .......................................... fifteen

5.0 Technical Specifications ................................................ .......................................16

6.0 Operator's Instructions................................................ .........................................twenty
6.1 Using the display: .............................................. .................................................. ......... twenty-one

7.0 Set-up of Parameters ........................................................... ................................................22

7.1 Adjustable parameters in Set-up Mode:.............................................. ................................ 22
7.2 Lock of set-up parameters.............................................. ................................................. 2. 3
7.3 Cable compensation set-up: ........................................... .............................................. 2. 3
7.4 Manual Compensation: ................................................. .................................................. 24

8.0 Service, Maintenance, Overhaul.............................................. ................................25

8.1 Recommended Maintenance Schedule................................................. ........................... 25

8.2 Battery back-up................................................ .................................................. ............. 25

9.0 Trouble Shooting & Repair................................................ ............................................26

9.1 Fault Guidance ................................................ .................................................. ............ 26

10.0 Illustrated Parts List................................................ ..................................................30

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Index

11.0 Options................................................ .................................................. .................33

578902 Input Autotransformer (diagram 478901)................................................. ........................... 33

578903 Base module................................................... .................................................. ................. 33
578904 Lockable Door................................................... .................................................. .............. 33
578905 Cover for instrumentation ................................................ .................................................. 33
578906 Remote Control Box.............................................. .................................................. ..... 3. 4
578907 Additional Output Contactor (diagram 478901)................................................ ................. 34 578909 Door Interlock

(diagram 478901) ......................... .................................................. ...... 34 578910 Neutral Driver Rupture

Supervision...................................... .................................. 35
578911 90% Switch Interlock................................................ .................................................. ..... 36
578912 GPU Enable (key reader, bridge, cable drum etc.) ................................... ................... 36
578915 RS485 Interface.............................................. .................................................. ............ 37
578916 TCP/IP Interface ........................................... .................................................. ............ 37
578917 Military Interlock............................................... .................................................. ......... 37 578923
Display Heater.................................. .................................................. ........................ 37
578924 Control Box Heater ................................................ .................................................. ....... 37
573956 Service Tool ................................................ .................................................. ................. 38
591100 Auto Calibration Plug ................................................ .................................................. ...38

12.0 For units equipped with 28 VDC outlet................................................ ....................39

12.1 General Description................................................ .................................................. .... 39
12.2 Connection of Cables................................................. .................................................. ...39
12.3 Operator's Instruction ................................................ .................................................. .41

12.4 Setup of Parameters ................................................. .................................................. ..... 41

12.5 Specifications................................................ .................................................. ............. 42

12.6 Trouble Shooting & Repair................................................ ............................................ 43

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Operation Manual - AXA 2300 Compact – 30 - 90 kVA

Declaration of Conformity

1.0 Declaration of Conformity

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Operation Manual - AXA 2300 Compact Power – 30 - 90 kVA

Safety Instructions

2.0 Safety Instructions

This unit is only intended to be installed, operated and maintained by competent persons having the
necessary knowledge regarding delivery of external power to an aircraft. Prior to use, service and maintenance,
the competent person must be familiar with all relevant parts of this manual.

Electric Shock

To ensure personal health and safety, the electrical installation must comply with all local regulations and legislation

• Touching live electrical parts can cause fatal shocks and severe burns. • Internal parts
where the voltage exceeds 50 V are covered and/or marked with: • Keep all panels and covers
securely in place. • Have only qualified people remove
covers for maintenance or troubleshooting. • When connecting the unit to the aircraft, make sure
that the output power is off. • Frequently inspect the installation for damage and bare wiring – Repair /
replace if necessary.

Moving Parts

• Keep away from fans. • Have

only qualified people remove covers for maintenance or troubleshooting.

Hot Parts

• Do not touch hot magnetics. • Allow

a cooling period before doing maintenance.

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Operation Manual - AXA 2300 Compact Power – 30 - 90 kVA

General Description

3.0 General Description

The below figure shows the basic principle of the AXA 2300 Compact Power. The 50/60 Hz mains voltage
is converted into a galvanic isolated 3-phase, 400 Hz output voltage. A functional description of each part
is given in the following sections.

3.1 Basic Principle

Input Breaker (Q1):

The input breaker disconnects all power supply to the ground power unit. Upon engagement, the ground
power unit passes into standby mode.

RFI (Input):
Filter to reduce the 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 & 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.

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General Description

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 in- and output. It also transforms the voltages from the inverter
module into the required aircraft voltage (3 x 200/115 V). The filter choke for the output AC-filter is an 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 outlet. 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 1 second, 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 (eg RS485, 24 VDC and EPO link). • Pre-fuse for
display module (F3) • Measuring transformers
for supervision of the mains 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

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General Description

Supply Module (A5):

Beside the generation of a 24 VDC control voltage, the module includes fuses for AC-short circuit protection
(F1-F3), MOV's (varistors) for mains 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, monitor and diagnose eventual external and internal faults. As soon as the ground power unit is
connected to the mains, and constantly during normal operation, the processor module runs through a self-
check program which checks all internal functions of the ground power unit. If an internal or external error
is detected, the display shows the nature of the error. All immediate parameters related to a shut-down are
stored in the ground power unit's memory.

Display Module & Keyboard (A3/A4):

The display module serves as the interface for daily operation. Thanks to the RS485 communication, it is
possible to locate the display module up to 1 kilometer away from the ground power unit. More
information in chapter 6.

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Transport and Installation

4.0 Transport and Installation

4.1 Storage Before Installation To secure
optimal storage conditions prior to installation, it is recommended that the converter is stored inside to protect
it from rain and excessive humidity while it is left without power on.
Only equipment in seaworthy packaging can be stored outside.

4.2 Operational and Environmental Conditions after Commissioning When the converter has
been installed and commissioned, we advise that the input is always kept with input power on to provide
optimal conditions for the electronic components and to avoid humidity in the form of condensed water from
reaching vital parts.
If for some reason the converter has been without input voltage for a period, a visual inspection should be
carried out. In case that humidity is discovered on any internal parts, the parts have to dry out before input
voltage is again applied.

4.3 Transport

Fig. 4.3.1 Access for fork-lift, truck or similar

The access requires removal of 8 screws.

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Transport and Installation

Fig. 4.3.2 Transport by fork-lift truck

4.4 Installation and fastening instructions

Fig. 4.4.1 Foot Print, Fixed Unit

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Transport and Installation

Fig. 4.4.2 Foot Print, Bridge-mounted Unit

4.5 Cable Inlet

Fig. 4.5 Removable gland plate

situated inside the cubicle made of alu-zink to prevent corrosion at the cable gland holes

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Transport and Installation

4.6 Connection of Cables

Remote I/O terminals

Fig. 4.6 Connection of cables

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Transport and Installation

4.7 Mains Input

Due to personal health and safety, the AXA2300 unit must always be protected by grounding
the PE terminal ( ).

The mains input connection to the unit should be pre-fused according to section 5.0.

As a correct phase sequence is of importance for the function of the AXA2300, the ground power unit is
equipped with an automatic phase sequence detection. The detection is automatically carried out when
the mains is turned on. If the phase sequence is wrong, this is shown on the display, and correction is
made by inversing two phases.

4.8 400 Hz Output At

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

Independently of installation method, it is mandatory that local regulations and legislation are
fulfilled in order to ensure personal health and safety.

4.9 400Hz Interlock

The interlock safety system ensures that 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.

Fig. 4.9 Standard wiring diagram for civil aircraft

For service, maintenance and test purposes, the interlock system can be by-passed 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, eg when the ground power unit is connected to an aircraft.

To secure personal health and safety the interlock safety system must always be activated unless
the ground power unit is undergoing service, maintenance or testing by qualified personnel.

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Transport and Installation

4.10 Control Interface (Remote I/O Terminals)

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

• External Emergency Stop •

External Start / Stop & 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
driver rupture (Optional - see section 11)

Fig. 4.10 Example of wiring for external control via the I/O terminals

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

4.11 Interface via RS485 or TCP/IP

Please refer to section 11 for detailed information.

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Technical Specifications

5.0 Technical Specifications

Standards:
ISO 6858 Aircraft ground support supplies electrical - general requirements
BS 2G 219 General requirements for ground support electrical supplies for aircraft
SAE ARP 5015 Ground equipment – 400 Hz ground power performance requirement
MIL-704E Aircraft electric power characteristics
DFS 400 Specification for 400 Hz aircraft power supply
EN2282 Aerospace series characteristics of aircraft electrical supplies
EMC & Safety standards Please refer to the declaration of conformity, chapter 1

Solid State Ground Power Unit:

Input:
Voltage 3 x 400 V ± 15 % or according. to customers spec.
Frequency 50 / 60 Hz ± 5% 12-
Rectification pulse 30
Rating kVA 38 A 45kVA 60kVA 90kVA
Line Current ± 15% 58 A ± 15% 75 A ± 15% 112 A ± 15%
Recommended pre-fusing 50 A 100 A Line Current Distortion < 100 A 125 A
10% < 7% > 0.97 at 100 % load None, soft start Up to 20 ms < 10% < 7%
Power Factor
Inrush current
Power interruption
Output:
power 30, 45, 60 or 90 kVA, cos(ÿ) = 0.8 3 x
Voltage 200/115 V 0.7
power factor lagging to 0. 95 leading < 0.5 %
Voltage regulation for balanced load and 30 % unbalanced load
Voltage transient recovery ÿU < 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 1.414 ± 3 % < 1.0
Crest factor % (typically <
Voltage modulation 0.5 %) 120° ± 1° for balanced
Phase angle symmetry load 120° ± 2° for 30 %
unbalanced load
Frequency 400 Hz ± 0.001 % 100
Overload % Power Factor 1 for 1 hour 125 %
Power Factor ÿ 1 for 10 minutes 150 % Power
Factor ÿ 1 for 60 seconds 200 % Power Factor ÿ 1
for 30 seconds 250 % Power Factor ÿ 1 for 10
seconds 300 % Power Factor ÿ 1 for for 1 second

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Technical Specifications

Efficiency:
Overall efficiency at > 0.94 at 35-90 kVA load >
cos ÿ = 0.8 0.90 at 25 kVA load <
Standby losses 50 W <
No-load losses 2 kW
Protections:
Input over-and under voltage
Input overload
Internal voltage error
Internal high temperature
Output over-and under voltage (according to DFS 400)
Overload at output
Short circuit at output
No Break Power Transfer
Generative loads
Neutral voltage supervision

Miscellaneous:
Physical:
Dimensions Kindly refer to outline drawing at following page
Weight
Fixed and Bridge-Mount 330 kg
Mobile 500kg
Environmental:
Operating temperature -40°C to + 52°C (55° is optional)
Relative humidity 10-95 % (10-100 % optional) <
noise level 65 dB (A) at 1 m, typically 60 dB (A)
Ingress protection IP55 electronic part
Miscellaneous:
MTBF (Proven) 100,000 hours
MTTR Max. 20 minutes

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Operation Manual - AXA 2300 Compact – 30 - 90 kVA

Technical Specifications

Fig. 5.1 Fixed, Bridge-Mount and Mobile Unit

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Operation Manual - AXA 2300 Compact – 30 - 90 kVA

Technical Specifications

Fig. 5.2 Fixed and Mobile Unit with base Module

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Operator's Instructions

6.0 Operator's Instructions

Fig. 6.1 Instrumentation for unit equipped with additional 400 Hz Output

Fig. 6.2 Instrumentation for unit equipped with 28 VDC Output (optional)

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Operator's Instructions

6.1 Using the display:

There are four basic display modes:

• Default Mode: Shows the status of the ground power unit and makes it possible to browse
through different ground power unit parameters. Eg input voltage, output
voltage, load etc.

• Alarm Mode: Facilitate browsing through previous errors and thereto related parameters

• Power Log Mode Browsing through previously recorded operations.

• Setup Mode Viewing and adjusting selected parameters – See chapter 7.

Fig. 6.3 Change between the display modes Fig. 6.4 View of parameters etc.
press the horizontal arrow buttons To view parameters, logged data and setup values
related to the different display modes,
press the vertical arrow buttons.

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.

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Set-up of Parameters

7.0 Set-up of Parameters

To view or change adjustable parameters, select Setup Mode
and press the center button for 5 seconds.

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

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

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

Press the center button to confirm the adjustment.

Return to previous mode by means of the horizontal arrow buttons

7.1 Adjustable parameters in Set-up Mode:

For units equipped with 28 VDC Outlet: Refer to section 12 for set-up parameters

• OUTPUT VOLTAGE (Phase-Neutral)

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

• CABLE IDENTIFICATION (No / Yes – Plug & 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 V.

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Set-up of Parameters

7.2 Lock of set-up parameters

To avoid unintentional modification of the

Set-up parameters, it is possible to block the
access to the Set-up Mode, by means of a DIP
switch situated at the Display Module A3.

Fig. 7.1 Display Module A3

7.3 Cable compensation set-up:

Plug & Play:

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

1. Short circuit the aircraft connector by means of the Auto

Calibration Plug (p/n 591100).

2. Select compensation type to “PLUG & PLAY” via Setup Mode.

3. Change “IDENTIFY CABLE” to “YES”

4. Initiate the cable identification process by pressing the ground power unit's START button.

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

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

Please be aware that it is not possible to use the Plug & Play voltage compensation if the ground power
unit is equipped with two or more outlets!

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Set-up of Parameters

7.4 Manual Compensation:

This is the traditional (Manual) method of cable compensation, where the output voltage is increased in
proportion to the load current (Volt / 100 A). This method is usable where the influence of unsymmetrical
cables, unbalanced load and varying power factor can be neglected. Manual compensation is applicable for
ground power units equipped with two outlets.

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”.

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Service, Maintenance and Overhaul

8.0 Service, Maintenance, Overhaul

To make certain that the unit is always ready for use, it must be maintained on a regular basis.

Only have qualified people remove covers for service, maintenance or overhauls.

8.1 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 sealing 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 PCB's - 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

Especially for mobile units

• Check tires for wear and tear Yearly

• Check correct air pressure (4.3 Bar = 62 PSI) Quarterly

8.2 Battery backup

Situated on the processor board, a lithium battery ensures that set-up data etc. are not lost during mains
drop-outs. The expected life of the battery is approx. 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 8-9 years of use.

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Trouble Shooting & Repair

9.0 Trouble Shooting & Repair

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.

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 1, Table 2 and
Table 3 suggests 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.

9.1 Fault Guidance

In case that you need to contact AXA for further fault guidance, please do not forget to enter the serial
number of the GPU (can be found at the rating plate) and the actual error code on the fault finding formula
that can be downloaded from www. axapower.com (pls. refer to section After Sales Department)

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Operation Manual - AXA 2300 Compact – 30 - 90 kVA

Trouble Shooting & Repair

Error Code Apply the suggested corrective actions

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

0000-0099
NO ERROR LOGGED YET

0100-0199
1 3 24
LOGGING WAS NOT COMPLETE. SUCCESSFULLY

0150
1 2
WATCHDOG RESET OCCURED

0200-0299
14 35 2
INTERNAL DC SUPPLY VOLTAGE ERROR

0300-0399
2 1
EMERGENCY STOP ACTIVATED OR FUSE BLOWN

0400-0499
12
AC SOFTSTART ERROR

0500-0599
1 5 7 23 6 4
INVERTER ERROR

0600-0699
12
INPUT VOLT. – PHASE SEQUENCE NOT FOUND

0700-0799
145 3 2
INPUT VOLTAGE – FREQUENCY TOO HIGH

0800-0899
145 3 2
INPUT VOLTAGE – FREQUENCY TOO LOW

0900-0999
145 2 3
INPUT VOLTAGE – PHASE SEQUENCE WRONG

1000-1099
145 3 2
INPUT VOLTAGE TOO HIGH

1100-1199
145 3 2
INPUT VOLTAGE TOO LOW

1500-1599
1 5 3 4 2
DC VOLTAGE < 350V

1600-1699
1 5 3 4 2
DC VOLTAGE > 850V

1700-1799
1 7 3 6 2 Four. Five
DC CAPACITOR SHARING ERROR

2000-2099
1 5 46 2 3
INVERTER TEMPERATURE TOO HIGH

2100-2199
1 3 2 4
GATE VOLTAGE ERROR
Emergency
electrolytic
Processor

gatedrive)
Interface

Interface

Interface
Replace

Replace

Replace

Replace
(wiring /

Inverter
Inverter

Inverter

Inverter
Module

Module

Module

Module
Module

Module
(wiring)

Module

Module

Module

Module
Restart

voltage

voltage

voltage

voltage

voltage
Reset /

display
Supply
Supply

Supply

-control
device

supply
Power
Check

Check

Check

Check

Check

Check

Check

Check

Check

Check

Check

Check

Check
output

kohm)

filters/
Pover

Alarm

Alarm
Mode

Mode
VDC)

setup

VDC)
input

Stop
fuse

fuse

cap.

fans

fans
unit

F1-

F1-

DC

(24
x4.7
via

via

R1

via
A1

A2

A5

A2

A5
F2

F3
20
(>

(2
at

at

at

at

to

Table 1: Error Codes 0000 - 2199

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Operation Manual - AXA 2300 Compact – 30 - 90 kVA

Trouble Shooting & Repair

Error Code Apply the suggested corrective actions

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

3000-3099
145 23
OUTPUT OVERVOLTAGE: U > 128 V – 250 ms

3100-3199
1 3 4 2
OUTPUT OVERVOLTAGE: U > 140 V – 15 ms

3300-3399
1 5 7 24 3 6
OUTPUT OVERVOLTAGE: U > 32 V – 4 s

3400-3499
146 3 2 5
OUTPUT OVERVOLTAGE: U > 40 V – 1 s

3500-3599
1 5 7 2 346
OUTPUT UNDERVOLTAGE: U < 100 V – 300 ms

3600-3699
146 235
OUTPUT UNDERVOLTAGE: U < 90 V – 50 ms

3700-3799
146 235
OUTPUT UNDERVOLTAGE: U < 70 V – 10 ms

3900-3999
1 5 7 2 4 3 6
OUTPUT UNDERVOLTAGE: U < 20 V – 30 s

4000-4099
145 3 2
OVERLOAD: 100% < I < 125% – 600 s

4100-4199
145 3 2
OVERLOAD: 125% < I < 150% – 60 s

4200-4299
145 3 2
OVERLOAD: 150% < I < 200% – 30 s

4300-4399
145 3 2
OVERLOAD: 200% < I < 250% – 10 s

4400-4499
145 3 2
OVERLOAD: I > 250% – 1 s

4500-4599
145 3 2
SHORT CIRCUIT AT OUTPUT

4600-4699
1 5 346 2
TRANSFORMER FILTER CURRENT TOO LOW

4700-4799
1 3 2 54
TRANSFORMER FILTER CURRENT TOO HIGH

4800-4899
5 6 1 2 3. 4
TRANSFORMER TEMPERATURE TOO HIGH

4900-4999
5 7 4 1 3 6 2
28V RECTIFIER TEMPERATURE TOO HIGH
compensation

Transformer
Disconnect

capacitors
Processor

ifdefective
Interface

Interface
Interface

Interface
Interface
overload
Remove

heatsink
Replace

Replace

Replace

Replace

Replace
Inverter
Inverter
Module

Module

Module
Module
(wiring)

Module
(wiring)

Bypass

(wiring)

rectifier
Restart

voltage
Reset /

sensor
Output

control

sensor
sensor
400Hz
Check

Check

Check

Check

Check

Check

Check

Check
output

output

down,

filters/
Reset

Reset

circuit

temp.
setup

setup
cable

Short
Mod.
load/
Start

Start

TRU
TRU
then
filter

fans
cool
volt.

and
unit

unit
C7-

the
Let
C9
A1

A2

A6
A2

A6
A2
T2

at
at
in
&

Table 2: Error Codes 3000 - 4999

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Operation Manual - AXA 2300 Compact – 30 - 90 kVA

Trouble Shooting & Repair

Error Code Apply the suggested corrective actions

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

5000-5099
27 5 8 1 3 4 6
EARTH / INSULATION ERROR AT OUTPUT

5100-5199
1 4 3 5 2
NEUTRAL CONDUCTOR RUPTURE OUTPUT 1

5200-5299
143 5 2
NEUTRAL CONDUCTOR RUPTURE OUTPUT 2

5300-5399
1 5 4 6 23
OVERLOAD OUTPUT 1

5400-5499
1 5 4 6 2 3
OVERLOAD OUTPUT 2

5500-5599
5 6 1 2 3 4
ADAPTION TRANSFORMER OVERHEATED

5600-5699
1 6 5 7 3 24
NEUTRAL VOLTAGE SUPERVISION ERROR

5700-5799
1
DIP SWITCH IN WRONG POSITION

5800-5899
1 2
ERROR: CABLE IDENTIFICATION FAILED

5900-5999
CABLE SUCCESSFULLY IDENTIFIED

6000-6099
END OF TEST

XX00-XX99
12
NOT A DEFINED NUMBER
installation
Processor

insulation

presence
ifdefective
Interface
Interface

Interface
overload

switches
between
Remove
Replace

Replace

Replace

Replace
Module

Module
Module
(wiring)

(wiring)

Bypass
Restart

failures
Reset /

Sensor
Check/

sensor
control

sensor

circuit.
Check

Check

Check

Check

Check

Check

Check
(SW2)
output
down,

filters/
Reset

Reset

Reset
wiring

circuit
Relay

Relay
repair

Relay

setup

setup
value
Short
RCM

RCM
RCM

short
Mod.
Start

Start

label
CT's

then
(X5)

fans
cool

acc.
and
and

and
unit

unit

Set
the
Let
A1

A2
A2

A2

A2

for

of
at

to
in
+

Table 3: Error Codes 5000 – 6099

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Operation Manual - AXA 2300 Compact – 30 - 90 kVA

Illustrated Parts List

10.0 Illustrated Parts List

Please refer to www.axapower.com for a recommended list of spare parts (Section Product). There you
can also find diagrams and drawings of the unit. Most parts may be available via our web-shop.

Figure: 10.1: Front View

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

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Operation Manual - AXA 2300 Compact – 30 - 90 kVA

Illustrated Parts List

Figure 10.2: Rear View

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Operation Manual - AXA 2300 Compact – 30 - 90 kVA

Illustrated Parts List

Figure 10.3: Top/front View

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Operation Manual - AXA 2300 Compact – 30 - 90 kVA

Options and Diagrams

11.0 Options
This ground power unit might be equipped with one or more of the following options:

578902 Input Autotransformer (diagram 478901)

(Only valid for units with ratings of 60 kVA max.)

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

• 3 x 200 VAC (recommended pre-fuse: 315 A) • 3

x 230 VAC (recommended pre-fuse: 315 A)

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

578903 base module

Additional base module, which extends the height/length of the ground power unit by 345 mm and the
weight by 20 kg. (kindly refer to section 5)

578904 Lockable Door

As a standard, the GPU is supplied with a quarter-turn lock intended for a double
bit 5 mm pin key. One key is supplied per ground power unit.

On an optional basis, the ground power unit can be supplied with a lockable
swing handle at the front door. The handle is locked by a profile cylinder
according to DIN 18252 (depth = 40 mm). Each ground power unit is supplied
with 2 identical keys.

578905 Cover for instrumentation

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

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Operation Manual - AXA 2300 Compact – 30 - 90 kVA

Options and Diagrams

578906 Remote Control Box

The control box is used for operation of the ground power unit, if placed away from the aircraft parking
position or placed under a passenger boarding bridge.

578907 Additional 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.

578909 Door Interlock (diagram 478901)

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

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Operation Manual - AXA 2300 Compact – 30 - 90 kVA

Options and Diagrams

578910 Neutral Driver Rupture 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 instantly.

NCR Board internal wiring diagram

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.

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Operation Manual - AXA 2300 Compact – 30 - 90 kVA

Options and Diagrams

578911 90% Switch Interlock

This feature supervises that the 90% switch in the 400 Hz plug is activated. If the 90% switch is not activated, the respective

outlet cannot be engaged. The option also includes a potential free output showing whether the 90% signal is present or not.

The option is valid for ground power units with one or two outlets.

Wiring diagram for 90% Switch and GPU Enable

578912 GPU 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.

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Operation Manual - AXA 2300 Compact – 30 - 90 kVA

Options and Diagrams

578915 RS485 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.

PIN Assignment for RS485 Interface

578916 TCP/IP Interface (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

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Operation Manual - AXA 2300 Compact – 30 - 90 kVA

Options and Diagrams

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.

Aircraft Connector Aircraft Receptacle

Ground Power Unit Wire
TO TO TO

b b b
Interlock:
Civ. Mil. c c c
N N N
F F F +28VDC
AND AND AND To control

Standard wiring diagram for military interlock

573923 Display Heater

For fixed units with display on front door

573924 Control Box Heater

For bridge mounted or mobile units with remote control box.

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 soft-ware 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 adapter, 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.

591100 Auto Calibration Plug

Short circuit connection for Plug & Play set-up.

See section 7.

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Operation Manual - AXA 2300 Compact – 30 - 90 kVA

For GPUs with 28 VDC Transformer Rectifier

12.0 For units equipped with 28 VDC outlet

12.1 General Description

All AXA2300 units from 30 kVA to 90 kVA can be equipped with a 28 VDC output.

As the 28 VDC part is supplied from the 400 Hz output, simultaneous use of the 400 Hz and the
28 VDC outlets is not possible.

12.1 Principle of 28 VDC TRU

The 28 VDC part is basically a Transformer Rectifier Unit (TRU), where the output voltage is
controlled by varying the 400 Hz input voltage. The DC current is not measured directly, because it can
be calculated very precisely on the basis of the 400 Hz parameters.

The 400 Hz output contactor (Q3) and the TRU Interface board (A20) are both located inside the
400 Hz cubicle, while the remaining components shown in figure 12.1 are located in a separate base
module – Please refer to section 5 for outline drawings.

12.2 Connection of Cables

The supply cables to the aircraft are connected to the terminals labeled + and –. Recommended output
cable dimension is 2 x 120 mm².

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Operation Manual - AXA 2300 Compact – 30 - 90 kVA

For GPUs with 28 VDC Transformer Rectifier

To secure personnel's health and safety, the converter is equipped with an interlock system. The system
ensures that the output only stays engaged as long as the plug is inserted into the aircraft receptacle. Eg
as long as 28 VDC is present at terminal F2.

- - -
To airframe

+ + +
To aircraft

Jumper
busbar

F2
To control

Ground Power Unit Wire Plug Aircraft Receptacle

12.2 Standard wiring diagram, Civil aircraft

For service, maintenance and test purposes, the interlock system can be by-passed via the display setup.
To secure personnel health and safety, the converter automatically returns into normal mode once it
receives a 28 VDC voltage at terminal F2. Eg when the plug is connected to an aircraft.

The 28 VDC output can be operated remotely via the I/O terminals related to Output 2. Please refer to
section 4.8.

12.3 Top View of 28 VDC Module

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Operation Manual - AXA 2300 Compact – 30 - 90 kVA

For GPUs with 28 VDC Transformer Rectifier

12.3 Operator's Instruction

The 28 VDC is controlled by means of the Display / Keyboard Interface – Please refer to section 6.

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

12.4 Setup of Parameters

Further to the parameters that can be viewed and changed according to section 7, 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 load bank.

2. Select “DC CABLE COMPENSATION” via the Setup Mode.
3. Adjust the compensation by means of the vertical arrow buttons at the display keyboard, until the
voltage at the aircraft connector equals the no load voltage.

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Operation Manual - AXA 2300 Compact – 30 - 90 kVA

For GPUs with 28 VDC Transformer Rectifier

12.5 Specifications

Output:
Voltage : 28VDC
Current : 600 A continuously
Voltage regulation: < 0.5%
Voltage ripple: < 1%
Voltage transient recovery: Complies with ISO 6865 / MIL-704E
Overload 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).

Setup:
Output voltage : 20-32V

Voltage compensation : 0-4 V per 600 A

current limit : 600-2400 A in steps of 300 A

Protections:
Rectifier temperature to high
Short circuit at output
Over-and under voltage at output in case:
U < 20 VDC for more than 4 seconds
U > 32 VDC for more than 4 seconds
U > 40 VDC for more than 1 second

Physical:
Additional weight to 400 Hz unit: 100 kg
For dimension please refer to section 5 (eg units equipped with base module).

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Operation Manual - AXA 2300 Compact – 30 - 90 kVA

For GPUs with 28 VDC Transformer Rectifier

12.6 Trouble Shooting & 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 and wiring

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

1. Could be due to a heavy overload – Reset unit.
2. Check output voltage setup value.
3. Check TRU interface and wiring

Output Over Voltage > 32 V / 40 V – 4s / 1s (error code 3300 & 3400):

1. Could be due disconnection of a heavy overload – Reset unit.
2. Check output voltage setup value.
3. Check TRU interface and wiring

Document no. 578.010 rev.: F Page 43 of 43