1128X0X0X00 Rev04 11-21

OPERATION & SERVICE MANUAL
28.5 VDC Ground Power Unit
Models:
112850S0000 112850S0100 112850S0200 112850D0200
112850D0000 112850D0100 112850D0100AV 112850D0100-A5
112860S0000 112860S0100 112860S0200 112860S0200
112860S0100-A4 112860S0100-A6
112860D0000 112860D0100 112860D0200
112860D0100-A5 112860D0200-A5
11/2021 - Rev. 04
Tronair, Inc. Phone: (419) 866-6301 | 800-426-6301

1 Air Cargo Pkwy East Web: www.tronair.com
Swanton, OH 43558 Email: [email protected]
REVISION DATE TEXT AFFECTED
01 01/2009 Original Release
02 03/2009
03 06/2013 Modified 5.2.3 Converter Commissioning and 5.3 Switching On
04 11/2021 Modified parts list
Models 112850S0000 112850S0100 112850S0200
112850D0000 112850D0100/AV 112850D0100-A5 112850D0200
112860S0000 112860S0100 112860S0100-A4 112860S0100-A6 112860S0200
112860D0000 112860D0100 112860SD100-A5 112860D0200 112860SD200-A5
TABLE OF CONTENTS
PAGE
1.0 INTRODUCTION ............................................................................................................................................................... 1

1.1 MODEL DISCTIPTIONS ..................................................................................................................................... 1
1.2 SAFETY NOTES ................................................................................................................................................. 2
2.0 TECHNICAL DATA ........................................................................................................................................................... 3
3.0 SYSTEM DESCRIPTION .................................................................................................................................................. 4
3.1 INTRODUCTION................................................................................................................................................. 4
3.2 DETAILED DESCRIPTION ................................................................................................................................. 4
3.3 PERFORMANCE UNDER UNUSUAL CONDITIONS ......................................................................................... 4
3.4 SYSTEM CONTROL ........................................................................................................................................... 5
3.5 SAFETY AND PROTECTION ............................................................................................................................. 5
3.6 CONTROL AND MONITORING .......................................................................................................................... 5
3.6.1 Power Supplies for Controls & Monitoring ........................................................................................................... 5
3.6.2 Internal System Control ....................................................................................................................................... 5
3.6.3 Converter Operation............................................................................................................................................ 5
3.7 VOLTAGE REGULATION MODE ....................................................................................................................... 5
3.7.1 General ............................................................................................................................................................... 5
3.8 CONTROL PANEL .............................................................................................................................................. 6
3.8.1 Operator Controls................................................................................................................................................ 6
3.8.2 Emergency Stop.................................................................................................................................................. 6
3.9 OVERVIEW OF 28V DC GPU COMPONENTS .................................................................................................. 6
4.0 INSTALLATION AND CONNECTIONS ............................................................................................................................ 7
4.1 GOODS INSPECTION ........................................................................................................................................ 7
4.2 HANDLING ......................................................................................................................................................... 7
4.3 PROTECTION..................................................................................................................................................... 7
4.4 STORAGE .......................................................................................................................................................... 7
4.4.1 Floor Loading Capacity ....................................................................................................................................... 7
4.4.2 Space Requirements/Dimensions ....................................................................................................................... 8
4.4.3 Altitude, Temperature & Humidity ....................................................................................................................... 8
4.5 ELECTRICAL CONNECTIONS (POWER) .......................................................................................................... 8
4.5.1 Cable Entry ......................................................................................................................................................... 8
4.5.2 Cable Sizing ........................................................................................................................................................ 9
4.5.3 Mains Fuses ........................................................................................................................................................ 9
4.5.4 Connections ........................................................................................................................................................ 9
5.0 OPERATING INSTRUCTIONS ....................................................................................................................................... 10
5.1 GENERAL ......................................................................................................................................................... 10
5.1.1 Control Panel .................................................................................................................................................... 10
5.1.2 Operator Controls.............................................................................................................................................. 10
5.2 COMMISSIONING ............................................................................................................................................ 10
5.2.1 Tools Needed .................................................................................................................................................... 10
5.2.2 Settings ............................................................................................................................................................. 11
5.2.3 Converter Commissioning ................................................................................................................................. 11
5.3 SWITCHING ON ............................................................................................................................................... 13
5.4 EMERGENCY STOP ........................................................................................................................................ 13
5.5 OUTPUT VOLTAGE DC ADJUSTMENT .......................................................................................................... 14
6.0 TROUBLE SHOOTING ................................................................................................................................................... 14
6.1 GENERAL ......................................................................................................................................................... 14
6.2 PROCEDURES IN THE EVENT OF MALFUNCTIONS .................................................................................... 15
6.3 MONITORS & FAULT INDICATION ................................................................................................................. 16
7.0 MAINTENANCE AND SERVICE .................................................................................................................................... 16
7.1 PREVENTIVE MAINTENANCE ........................................................................................................................ 16
7.1.1 General ............................................................................................................................................................. 16
7.1.2 Cleanliness ....................................................................................................................................................... 16
7.1.3 Voltage Check ................................................................................................................................................... 16
7.2 SERVICE .......................................................................................................................................................... 16
8.0 ADDITIONAL INFORMATION ........................................................................................................................................ 17
8.1 LED FUNCTIONS & ARRANGEMENTS........................................................................................................... 17
9.0 GUARANTEES/LIMITATION OF LIABILITY .................................................................................................................. 17
10.0 APPENDICES ................................................................................................................................................................. 17
11/2021 | Rev. 04
Models 112850S0000 112850S0100 112850S0200
112850D0000 112850D0100/AV 112850D0100-A5 112850D0200
112860S0000 112860S0100 112860S0100-A4 112860S0100-A6 112860S0200
112860D0000 112860D0100 112860SD100-A5 112860D0200 112860SD200-A5
This product can not be modified without the written approval of Tronair, Inc. Any modifications done without written approval
voids all warranties and releases Tronair, Inc., its suppliers, distributors, employees, or financial institutions from any liability
from consequences that may occur. Only Tronair OEM replacement parts shall be used.
1.0 INTRODUCTION
Many systems and devices in the aerospace industry,
and other fields, require a DC voltage of 28 volts. As
this cannot be supplied by the utility directly, converters
are employed which supply the necessary voltage and
eliminate supply irregularities to a limited extent.
Normally these units are used to supply smaller aircraft
with electric power. There are special reasons why
aircraft need a 28V DC voltage for internal supply. To
save costs in maintenance and operation, and also for
environmental reasons, aircraft are supplied by
external electrical power supplies when they are
parked at airport terminal stands with their engines
shut down.
This manual describes the Tronair 28V Ground Power Unit (GPU). If you follow these instructions you will be able to handle
the equipment with confidence and utilize all its facilities.
NOTE 1. Naturally an operating manual cannot cover every conceivable installation, operating, maintenance or servicing
situation. Should problems arise, or if the data in this manual is not sufficiently detailed, please contact your local
Tronair representative who will be pleased to give further assistance.
2. If the equipment is installed for use as an aircraft ground power system, please pay particular attention to Section
10, which summarizes the special features of this type of application.
1.1 MODEL DISCTIPTIONS

Output Input Input Input
Model Number Cable Frequency Voltage Cable Remarks
ft (m)
No input cable
112850D0000 Dual 50(HZ) 200-415 NA
One 20ft 4/0(AWG) & one 50ft 2/0(AWG) non-engine starting DC output cable
50ft input cable
112850D0100 Dual 50(HZ) 200-415 50 (15.2)
50ft input cable with external adjustable voltage
112850D0100AV Dual 50(HZ) 200-415 50 (15.2)
112850D0100-A5 Dual 50(HZ) 208-480 50 (15.2) 50ft input cable, two 50ft 4/0(AWG) DC output cables
100ft input cable with one 20ft 4/0(AWG)
112850D0200 Dual 50(HZ) 200-415 100 (30.5)
One 50ft 2/0(AWG) non-engine starting DC output cable
112850S0000 Single 50(HZ) 200-415 NA No input cable, one 20ft 4/0(AWG) DC output cable
112850S0100 Single 50(HZ) 200-415 50 (15.2) 50ft input cable, one 20ft 4/0(AWG) DC output cable
No input cable
112860D0000 Dual 60(HZ) 208-480 NA
50ft input cable
112860D0100 Dual 60(HZ) 208-480 50 (15.2)
112860D0100-A5 Dual 60(HZ) 208-480 50 (15.2) 50ft input cable, two 50ft 4/0(AWG) DC output cables
100ft input cable
112860D0200 Dual 60(HZ) 208-480 100 (30.5)
100ft input cable
112860D0200-A5 Dual 60(HZ) 208-480 100 (30.5)
Two 50ft 4/0(AWG) DC output cables
112860S0000 Single 60(HZ) 208-480 NA No input cable, one 20ft 4/0(AWG) DC output cable
50ft input cable with Crouse-Hinds plug installed
112860S0100-A4 Single 60(HZ) 208-480 50 (15.2)
One 20ft 4/0(AWG) DC output cable
112860S0100-A6 Single 60(HZ) 208-480 50 (15.2) 50ft input cable, one 20ft 4/0(AWG) DC output cable, AP20468 plug
112860S0200SP Single 60(HZ) 208-480 100 (30.5) 100ft input cable, one 20ft 4/0(AWG) DC output cable, special paint color
11/2021 | Rev. 04 Page | 1

Models 112850S0000 112850S0100 112850S0200
112850D0000 112850D0100/AV 112850D0100-A5 112850D0200
112860S0000 112860S0100 112860S0100-A4 112860S0100-A6 112860S0200
112860D0000 112860D0100 112860SD100-A5 112860D0200 112860SD200-A5
1.2 SAFETY NOTES

The 28V DC GPU is a piece of electrical equipment which carries voltages and currents that are hazardous to personnel. The
following advice must therefore be observed at all times:
• Installation, operation and maintenance of this equipment must be carried out according to the instructions in this manual.
• Ensure that the equipment is handled only by well-trained and authorized personnel.
• Take suitable measures to ensure that only trained operating and maintenance personnel have access to the interior of
the system; the doors should be kept locked and the keys retained by authorized persons.
• System installation, service and maintenance must be performed by trained staff.
• The relevant regulations of the local codes and standards, and other safety instructions should be observed.
• All personnel who have to work on the equipment should be familiar with first-aid procedures relating to electrical
accidents.
• Even when the equipment is switched off, a few internal parts remain “live” while they are connected to the incoming
supply.
• Work on the equipment must only take place with the unit switched off and isolated. Proper Lockout/Tagout procedures
must be followed at all times.
• Built-in capacitors can remain charged, even when the complete system is “de-energized”. They should be suitably
discharged by trained personnel before contact is made with the connections.
• Fuses must not be rewired or shorted out and rewired fuses must not be used. When replacing fuses, only the same or
lower current ratings and the same types (slow-blow, quick-acting, very quick-acting) should be used.
• The system environment should be kept as clean as possible and metallic or other electrically-conducting dust particles in
particular must be prevented from being sucked in through the air inlet.
• The warning and hazard notices inside the equipment must be observed.
Explanation of the warning symbols used in these operating instructions are as follows:
WARNING Appears alongside all instructions which must be followed exactly in order to eliminate personal injury
and corruption/destruction of data
IMPORTANT Appears alongside all instructions which must be followed in order to eliminate damage to equipment and/or
malfunctions
NOTE Indicates important information or advice, which must be followed during installation, operation, service or
maintenance.
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Models 112850S0000 112850S0100 112850S0200
112850D0000 112850D0100/AV 112850D0100-A5 112850D0200
112860S0000 112860S0100 112860S0100-A4 112860S0100-A6 112860S0200
112860D0000 112860D0100 112860SD100-A5 112860D0200 112860SD200-A5
2.0 TECHNICAL DATA

Length: 42 in (107 cm)
Width 31 in (79 cm) Single
33 in (84 cm) Dual
Height 33 in (84 cm)
Type 28V DC GPU 600A

Input Data
Input power 25 kVA
Nominal voltage 3ph 208V/60 Hz, 400V/50 Hz, 480V/60Hz ±10%
Nominal frequency 50 Hz or 60 Hz ±5%
Nominal input current at
208V 60Hz 56 A
400V 50Hz 29 A
480V 60Hz 24 A
575V 60Hz 21A
Output Data
Output power 16.8 kW
Nominal voltage 28V
Nominal current 600 A
Voltage adjustment range Nominal 20 – 31V (other values on request)
DC ripple voltage (without filter) < 1V
DC ripple voltage (with filter) < 786 mv
Voltage characteristics:
– static ±1%
– dynamic (100% load step) MIL-Std. 704, Fig. 5
Recovery time < 200 ms
Output frequency DC
Overload capability Max 2000A for up to 2sec
Option
General Data
Total efficiency > 90%
Maximum losses 4 kW
Audible noise < 70 dB(A)
Temperature range -4 − +104 F (–20 - +40°C)
Humidity max. 95%
Paint finish RAL 7032
Protection type IP54/Nema 3R
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Models 112850S0000 112850S0100 112850S0200
112850D0000 112850D0100/AV 112850D0100-A5 112850D0200
112860S0000 112860S0100 112860S0100-A4 112860S0100-A6 112860S0200
112860D0000 112860D0100 112860SD100-A5 112860D0200 112860SD200-A5
3.0 SYSTEM DESCRIPTION

3.1 INTRODUCTION
The 28V GPU is manufactured using the latest state-of-the-art technology. The design concept and the selected components
utilize the latest trends in power electronics, and represents the best solution for the different problems of Ground Power
Supplies. The 28V GPU is built with output voltage regulation and load current limiting. The following block diagram shows the
principle.
WARNING!
Even when the 28V GPU is switched off, a few internal parts still remain “live”.
The transformer converts the mains supply to a voltage suitable for supplying the load via the rectifier. The transformer is a
two winding transformer which provides galvanic isolation between the mains and the load. The rectification is achieved by
using a 6-pulse SCR. The output filter network limits the ripple at the output voltage to a low level.
An integrated control panel with push buttons and an LED’s operate the unit is located on the front door of the unit.
3.2 DETAILED DESCRIPTION

An integrated interface board contains a micro controller to control and monitor all functions of the system. Depending on the
measurement values, the input voltage of the transformer is regulated in order to obtain the correct output voltage. All
functions are digitally controlled.
The following functions are built in:

• Measurement and evaluation
• Output voltage regulation and current limiting
• System control (PLC function)
Measurement values from the input are collected via the interface board, and from the output direct to the controller board,
where they are evaluated and monitored.
Normally the overload and short circuit protection is provided by the interface board. Protection, by the input circuit breaker
CB1, takes place in case of malfunctions of the electronics.
The measurement values are also used for voltage regulation. The output voltage regulation consists of a voltage regulator
plus a current regulator, which is the main regulator. This means if a current limit has been set in the setup menu, this current
regulator will limit the output voltage to a value at which the set current is reached. If the current is less than the set maximum,
the voltage regulator will limit the output voltage to obtain the set value. In this case, the current regulator is turned off. The
output of these regulators is converted to a pulse pattern, which is transmitted to the firing board to fire the SCR modules.
The complete unit is operated via the system control. This works similar to a standard PLC. This means that particular input
events will generate particular output events.
There is a Control Panel on the front of the cabinet which contains the main disconnect switch with LED (light emitting diodes)
indications and on/off buttons. The Control Panel gives the user a comprehensive status indication of the unit. The LED’s on
the control panel show the status of each logical section of the unit, displaying green, yellow or red, and flashing or steady
state to show various normal, available, warning and abnormal states of the unit. The push buttons allow the user to switch the
DC output on and off and adjust unit settings. Output voltage and current are displayed on the control panel.
3.3 PERFORMANCE UNDER UNUSUAL CONDITIONS

Overload - The converter can deliver up to a maximum of 2000 A for 3 sec. At higher overloads the output current is limited.
Short-circuit on the load busbar - In principle, a short-circuit occurring on the output side is handled similar to an overload,
except that the output voltage is very low. The output power will be limited as described above for an overload. The rectifier
itself has short-circuit protection.
Mains fault - If the mains supply is outside permissible tolerances, it is not possible to start the system. If the converter is
running and the mains supply goes out of the permissible tolerances, the converter will switch off within 50ms.
Output fault - The converter monitors the output voltage continuously. If it exceeds the permissible tolerances the unit is
switched off.
Over-temperature - In the event of a fan failure, the system continues to run normally until the over-temperature protection
cuts in.
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Models 112850S0000 112850S0100 112850S0200
112850D0000 112850D0100/AV 112850D0100-A5 112850D0200
112860S0000 112860S0100 112860S0100-A4 112860S0100-A6 112860S0200
112860D0000 112860D0100 112860SD100-A5 112860D0200 112860SD200-A5
3.4 SYSTEM CONTROL

System control consists of one System Interface Board, a firing board, one Operator Panel.
The System Interface Board handles the master system control function. Control commands from the Control Panel CP are
transmitted to this controller, evaluated and converted into the appropriate actions. Current operating parameters (measured
values etc.) are also evaluated by the System Interface Board. The following measure values are not displayed, but are also
monitored for deviations from the specification:
• Input under & over-voltage
• Output under & over-voltage
• Output overload
• Over-temperature
3.5 SAFETY AND PROTECTION

The design philosophy for the 28V DC GPU is that it will endeavor to protect itself at all times. Self-protection is incorporated in
both the hardware and software designs. Where situations arise that could either cause damage to the converter, or endanger
the output load, the general rule is to disconnect and/or shutdown.
For safety of personnel, an Emergency Stop button is fitted local to the Control Panel on the front of the converter cubicle.
3.6 CONTROL AND MONITORING

3.6.1 Power Supplies for Controls & Monitoring
All the electronic cards within the converter receive their power via transformers.
3.6.2 Internal System Control

System Interface Board has the function of complete system control.
Control Panel consists of control and display elements for the user. Commands are analyzed by the system controller and
interpreted into actions. Measurement values for the input and output circuits are processed and displayed.
3.6.3 Converter Operation

As soon as mains incoming power is applied to the control logic the microprocessors commence operating and the internal
function becomes active. Initially their only function is a ‘watchdog operation’ checking for faults within the converter and
monitoring the incoming supply for voltage and frequency deviations. Any faults or deviations detected are reported internally
at the System Interface Board.
3.7 VOLTAGE REGULATION MODE

3.7.1 General
The unit supplies a load which requires a supply voltage with very little deviation. (Normally 28V DC +/- 1%). If a very long
cable is used between the converter and the aircraft (load), a voltage drop will be created which might be greater than the
acceptable voltage tolerance of the aircraft. If this happens, it is no longer possible for many units on the market to provide an
acceptable voltage supply to the aircraft especially under all load conditions.
To overcome this problem, two possibilities are available:

1. The cable between the converter and the load could be designed in such a way that the voltage drop will be decreased so
that the supply voltage is within tolerance range. The amount of copper wires and/or size can be increased or parallel cables
can be used. However there comes a point where the size of the copper wires required could become too heavy or costly, or if
the length of run is so long, that increasing the amount or wire size will still not be enough to keep the tolerance within the
voltage range, for all load conditions.
2. The converter must incorporate a LDC (Line Drop Compensation) system that can provide active compensation so as to
automatically compensate for the voltage drop.
With very long cable runs, parallel cables will increase the wire investment costs dramatically and if flexible aircraft cables are
also used, then parallel cabling might not be possible or practical.
To ensure that the proper voltage is delivered to the aircraft plug under all load conditions, there must be a means of
measuring the voltage at the aircraft plug, and sending those voltage signals back to the converter, so they can be analyzed
and responded to. This requires that signal wires be run between the plug and the converter unit, where again cost and
practicality must be considered.
11/2021 | Rev. 04 Page | 5

Models 112850S0000 112850S0100 112850S0200
112850D0000 112850D0100/AV 112850D0100-A5 112850D0200
112860S0000 112860S0100 112860S0100-A4 112860S0100-A6 112860S0200
112860D0000 112860D0100 112860SD100-A5 112860D0200 112860SD200-A5
3.8 CONTROL PANEL

There is a local Control Panel on the cubicle door of the converter which contains a light emitting diode (LED) indications, E-
Stop, and meters
The LED’s on the control panel are red, green and yellow. They are also bi-functional, able to display as steady state or
flashing. With combinations it is possible to display healthy state, non-operational, abnormal and fault conditions.
Green steady state .......................... Running or switched on

Yellow flashing ................................ Warning
Red flashing .................................... Hardware fault (circuit breaker, contactor, etc.)
Red steady state ............................. Abnormal condition (e.g. mains fault, overload, etc)
The Red indicating LED is for fault conditions that are recoverable, such as overload. These faults are displayed as a Steady
Red light. Faults requiring maintenance attention, such as CB open, are displayed as a Flashing Red light.
3.8.1 Operator Controls

Push buttons “ON” and “OFF” control the converter operations.
3.8.2 Emergency Stop

In an emergency, to immediately open the unit’s input and output contactors, the large red button on the Control Panel must
be pressed.
IMPORTANT Bear in mind, however, that the mains in feed is still “live”. The converter can only be isolated by using suitable
external means such as padlocking the supply breakers of the incoming distribution board.
3.9 OVERVIEW OF 28V DC GPU COMPONENTS

The modules and components of the individual sizes of the 28V DC GPU are shown in the outline drawings in this section. The
sizes and arrangement of the modules and components shown vary slightly according to the power rating and version of the
28V DC GPU sets.
Abbreviation Description of Component

MOD 1 Rectifier SCR
PCB 2 Firing board
Interface board
K-1 28V Relay
K-2 28V Relay
T2 Power supply transformer
PAN 1 Control panel
CAPS Filtering capacitors
FAN 1 Cooling Fan
R1 Load resistor
CB 1 Input circuit breaker
CB 2-6 Protective circuit-breaker control voltage
SW 5 Current limit POT
T1 Isolated 3 phase input transformer
AUX 1 Transformer auxiliary voltage
AUX 2 Transformer auxiliary voltage
CONT 1 DC output contactor
CONT 2 DC output contactor
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Models 112850S0000 112850S0100 112850S0200
112850D0000 112850D0100/AV 112850D0100-A5 112850D0200
112860S0000 112860S0100 112860S0100-A4 112860S0100-A6 112860S0200
112860D0000 112860D0100 112860SD100-A5 112860D0200 112860SD200-A5
4.0 INSTALLATION AND CONNECTIONS

4.1 GOODS INSPECTION
Before leaving the factory, the correct mechanical and electrical state of
the 28V DC GPU is checked in a final inspection. As soon as the
equipment has arrived check whether any freight damage has occurred
and if necessary, bring this to the attention of the freight operator. In no
circumstances put a damaged converter into service without consulting
your Tronair representative first.
4.2 HANDLING
The converter can be rolled into place or moved by means of a forklift or
pallet lift truck
IMPORTANT Moving by crane should only be used in exceptional

circumstances using load-spreading rails above the unit.
Please pay attention to the following handling advice:

• Equipment should only be transported in an upright position
• The equipment must not be tilted or turned over
• Always avoid sharp impacts
• Where possible, leave the equipment in its original packing when moving it, this provides the best possible protection
against damage
• When moving the equipment on raised floors, it could be necessary to use a means of load distribution in order to avoid
damage to the floor
4.3 PROTECTION
During installation and cabling it is absolutely essential that the equipment is protected from the ingress of water, concrete or
metal particles, and dust etc. Protection of the equipment is particularly important when other trades or construction is taking
place in the same vicinity. All inlets and parts of the equipment not being worked on should be covered, at the least with
heavy-duty polyethylene, and preferably with more substantial packing.
It is also important to ensure that people working overhead do not stand on the equipment or use it as a convenient platform
for other work.
On completion of any work requiring the opening of the equipment doors or panels or removal of cover plates or gland plates,
the unit should be thoroughly vacuumed out and re-packed or protected. Tronair accepts no liability for any damage to
equipment caused by physical mal-treatment or by ingress of foreign material.
4.4 STORAGE
If it is necessary to store the converter for any length of time than it should be stored in a dry, well-ventilated room that is free
of corrosive materials. Where possible, the original packing should not be removed during storage.
IMPORTANT In no circumstances must the converter be stacked, or stored outside.
4.4.1 Floor Loading Capacity

The weight of the equipment is distributed over a relatively small area; special care must therefore be taken to ensure that the
floor loading capacity is adequate. The exact value can be obtained from the Technical Data. If necessary, the supporting
surface can be reinforced by interposing a suitable steel plate. Please consult your architect or Tronair representative if you
require assistance.
11/2021 | Rev. 04 Page | 7

Models 112850S0000 112850S0100 112850S0200
112850D0000 112850D0100/AV 112850D0100-A5 112850D0200
112860S0000 112860S0100 112860S0100-A4 112860S0100-A6 112860S0200
112860D0000 112860D0100 112860SD100-A5 112860D0200 112860SD200-A5
4.4.2 Space Requirements/Dimensions

About 80 cm/32” clearance should be left in front of the unit to provide unimpeded access to the cubicle. Local or general
safety regulations, e.g. escape routes, should also be observed. In no circumstances must the air inlet (around the bottom of
the unit) and the air outlet (around the top of the unit) be covered or obstructed.
4.4.3 Altitude, Temperature & Humidity

The 28V DC GPU is designed for an installation altitude of up to 1000 meters above mean sea level, an ambient temperature
of -20 to 40 oC / -4 to +104 oF and a relative humidity of up to 95%. The optimum temperature is around 68 oF. Please ensure
that any existing air-conditioning plant meets these conditions and is also able to remove the unit's dissipated heat. Details are
shown in the Technical Data (Section 2). The cooling air must always be free of corrosive agents. You should consult your
Tronair representative if planning an installation above 1000 meters.
4.5 ELECTRICAL CONNECTIONS (POWER)

4.5.1 Cable Entry
The input and output cables are connected in the lower part of the cubicle. The cables can be brought up to the cubicle from
the rear (input cable) and the right (output cable) and led in through end panel of the cubicle. Please refer to table below for
the cable sizes, which must conform to local electrical code.
Cables must be properly gasketed with a screwed gasket fitted with a strain-relief device and sealing ring.
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Models 112850S0000 112850S0100 112850S0200
112850D0000 112850D0100/AV 112850D0100-A5 112850D0200
112860S0000 112860S0100 112860S0100-A4 112860S0100-A6 112860S0200
112860D0000 112860D0100 112860SD100-A5 112860D0200 112860SD200-A5
4.5.2 Cable Sizing

Cables should be sized in accordance with the rating of the next protective device upstream, taking into account
temperature, voltage-drop and installation method factors, as per the appropriate standard for the site. In general, Tronair
recommends that the voltage-drop for both input and output power cables should not exceed 1.5%, and that the connecting
cables should be as short as possible especially the output cable (less than 10 m/30 feet is recommended). Tronair should be
consulted if these requirements cannot be met.
When specifying the cable lengths allow for about 0.5 m/20 in. inside the cubicle. The table on the following page shows the
recommended cable types:
Equipment Type Line Rated Input Cable (If Less Than 30´)/ Output Cable
Voltage Amps Copper Size
28V DC GPU 600A 208 56 1 x NYY 4 x 10 RE/10 or #4 2 x NYY 120 or 2x 4/0 cables
230 51 1 x NYY 4 x 10 RE/10 or #4
400 29 1 x NYY 4 x 6 RE/6 or #8
480 24 1 x NYY 4 x 4 RE/4 or #8
575 20 1 x NYY 4 x 4 RE/4 or #8
4.5.3 Mains Fuses

To meet Health & Safety requirements, lockable isolating fused-switches must always be installed for the mains infeed. The
fuses should be of type GL. Likewise, it should be possible to isolate the converter output from downstream circuits by means
of an external lockable switch or circuit breaker. Please consult your Tronair representative regarding use of circuit breakers
for the mains infeed.
Equipment Type Mains Isolator CB
28V DC GPU 600A 100 A 25 A, 5A
4.5.4 Connections
Power:
• 3 phase Mains Supply + Neutral
• 2 wire 28V DC + and –
The terminal arrangement will depend on the size and configuration of the 28 VDC GPU. The following drawings show the
various configurations:
Terminal No. of Terminal Function Short Name
L1 Mains Input L1
L2 Mains Input L2
L3 Mains Input L3
N50/N60 Mains Neutral N50
+ Load Output +
Load Output -
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112860S0000 112860S0100 112860S0100-A4 112860S0100-A6 112860S0200
112860D0000 112860D0100 112860SD100-A5 112860D0200 112860SD200-A5
5.0 OPERATING INSTRUCTIONS

5.1 GENERAL
This chapter describes how the 28V DC GPU should be operated. After an introduction to the operator controls and indicators,
the steps for switching the system on and off are given. A smooth sequence of operations is only achieved if the individual
steps are carried out in the specific order.
5.1.1 Control Panel

The Control Panel on the cubicle door contains LED indicators, push buttons, main disconnect switch and E-stop switch.
Specific switching functions are initiated, operating information are displayed.
If an abnormal operating condition or fault occurs, the red “General failure” LED lights up. At the same time the LED’s on the
control panel show the current operating status and the fault is indicated on the panel.
5.1.2 Operator Controls
5.2 COMMISSIONING
WARNING!
Before initial start-up, check the following:
1. Is the equipment damaged? If yes, do not put into service without consulting your Tronair
representative
2. Is the cabling properly installed? (Mains, output, remote control, etc.,?) Correct if necessary
5.2.1 Tools Needed

The following tools will be needed in order to put the 28 VDC GPU into operation:
• Multimeter
• Allen wrench
• 7/16 wrench
• Various screwdrivers
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112860D0000 112860D0100 112860SD100-A5 112860D0200 112860SD200-A5
5.2.2 Settings
The rectifier is available in 50 Hz and 60 Hz, both units are capable of being operated at various input voltages. The 50 Hz unit
can be operated with 200V, 380V or 415V and the 60Hz unit with 208V, 240V or 480V. Before the mains supply is switched
on, the unit type has to be adjusted correctly.
Setting the various transformer taps:

The unit is equipped with two control voltage transformers (T2 and T3) and one main transformer (T1). The wires have to be
connected to the correct tap in accordance with the mains input voltage at T1 transformer. T1 transformer has terminals for 3
different input voltages. Place the wire jumpers according to the drawings below.
VOLTAGE CHANGING INSTRUCTIONS – 50 Hz
VOLTAGE CHANGING INSTRUCTIONS – 60 Hz

High Voltage: 480/240/208
5.2.3 Converter Commissioning

WARNING!
A. Commissioning must be only carried out by trained personnel since work has to be done on
component that may be “live”!
B. Power up the device only when requested to do so in the following text.
ATTENTION:
I. Commissioning tasks should be carried out if:
• the system is being put into service for the first time,
• changes have been made, or
• repairs were carried out
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112860S0000 112860S0100 112860S0100-A4 112860S0100-A6 112860S0200
112860D0000 112860D0100 112860SD100-A5 112860D0200 112860SD200-A5
5.2.3 Converter Commissioning (continued)

II. Carry out the individual steps in the correct sequence:
1. Check all T-1 transformer connections and tighten if necessary. Ensure voltage is tapped for (480, 240, 208VAC 60Hz or
415,380, 200 VAC 50Hz)
2. Ensure MAIN DISCONNECT SWITCH on the GPU is in the OFF position
3. Connect AC input power cable to the main power outlet and apply electrical power
4. Set current limiting switch on front panel to highest setting (2000 AMP)
5. Turn GPU main disconnect switch to ON
6. Ensure green main input power lamp is ON, DC voltmeter is indicating 28.5 volts, and no other fault lamps are on
NOTE: Ensure DC output power is not on and DC lamps are off.
7. For all models, connect a load bank to the DC OUTPUT CABLE 1, set load bank to 2000 Amps, and ensure load bank
switch is OFF
8. Connect a digital multi meter to the test points on the load bank
NOTE: The following test is for Single Output Cable units.
9. Push the WHITE DC ON switch. Observe GREEN DC ON lamp is ON
10. Ensure load bank is ON and cooling fans should begin spinning
11. Switch the load bank to 300 AMP; verify the voltage at the load bank is 28.0 (MIN) - 28.9 (MAX) Volts DC. Adjust R-67 on
Interface Board to obtain correct voltage output
12. Move load bank switch to AUTO; verify the voltage range at the load bank is 16.0 thru 28.9 volts DC and a minimum
1600 AMPS at full load
13. Observe Amber Warning lamp flashes if DC output volts drops below 21VDC. LET LOAD BANK COOL, push Black
DC Off switch
NOTE: The following test is for Dual Output Cable units.
14. Follow steps 1 thru 8
15. Push GREEN DC ENABLE ON switch; verify GREEN DC ENABLE lamp is ON
16. Push the WHITE DC 1 ON switch, observe GREEN DC 1 lamp is ON
18. Connect a load bank to the DC OUTPUT CABLE 2
19. Push the WHITE DC 2 ON switch, observe GREEN DC 2 lamp is ON
20. Repeat steps 13 and 17 using DC OUTPUT CABLE 2. Let load bank COOL, push Black DC 2 Off switch
21. Connect load banks to DC OUTPUT CABLES 1 and 2. (Set Load for 300 Amps Each)
22. Push the WHITE DC 1 & 2 ON switches, observe GREEN DC 1 & 2 lamps are ON
23. Observe voltage on digital multi meter, it should indicate 28(MIN) VDC with loads. Reduce loads to 0 Amps
24. Let load banks COOL, push Black DC 1 & 2 Off switches
25. Disconnect load banks
26. Turn disconnect on main power outlet to OFF
27. Final inspect the unit for missing, loose, components
28. When the unit passes all test, release unit for normal operation
NOTE: The following test is for External Voltage Adjustable units
30. Open control panel door, locate the Interface Board, insure voltage adjust switch (SW1) is in the external (EXT) position
31. Insure over-volt trip switch (SW2) is in the low (LOW) position. Close control panel door
33. Set current limiting switch on front panel to highest setting (2000 AMP)
34. Turn GPU main disconnect switch to ON
35. Ensure green main power lamp is ON, DC voltmeter is indicating 28.5 volts and no other fault lamps are on
36. Connect a load bank switch to the DC OUTPUT CABLE 1, set load bank to 2000 Amps and ensure load bank switch is
OFF
37. Connect a digital multi meter to the test points on the load bank
39. Adjust voltage control knob on control panel to 28 VDC mark
40. Push WHITE DC 1 ON switch, observe GREEN DC 1 lamp is ON
41. Ensure load bank is ON and cooling fans should be spinning
42. Switch the load bank to 300 AMP; verify the voltage at the load bank is 28.0 (min) – 28.9 (max) Volts DC. Adjust the
External Voltage control knob on the control panel to obtain correct voltage output
43. Move load bank switch to AUTO; verify the voltage range at the load bank is 16.0 thru 28.9 volts DC and a minimum 1600
Amps at full load
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112860D0000 112860D0100 112860SD100-A5 112860D0200 112860SD200-A5
5.2.3 Converter Commissioning (continued)

44. Observe amber warning lamp flashes if DC output volts drops below 21 VDC. LET LOAD BANK COOL, push black DC
OFF switch
45. Disconnect load bank
46. Turn disconnect on main power outlet to OFF
47. Final inspect the unit for missing or loose components
48. When the unit passes all tests release for normal operation
5.3 SWITCHING ON
NOTE: Before switching the set on for the first time after installation, check that the cabling has been correctly
installed.
2. Set current limiting switch on front panel to as needed
3. Turn GPU main disconnect switch to ON (RIGHT/HORIZONTAL)
4. Ensure green main input power lamp is ON, DC voltmeter is indicating 28.5 volts, and no other fault lamps are on
Note: Ensure DC output power is not on and DC lamps are off
5. For all models, connect the DC output cable (s) to the aircraft DC socket. Ensure cable plug is fully inserted into the
socket
6. Push the WHITE DC ON switch. Observe GREEN DC ON lamp is ON
7. The unit will operate normally
8. Push BLACK DC OFF switch to stop
9. Turn GPU main disconnect switch to OFF (LEFT/VERTICAL)
10. Disconnect DC cable from aircraft. Disconnect AC input power cable and stow cables on GPU
NOTE: The following steps are for Dual Output Cable units
WARNING!
Do not use DC Cable 2 for starting aircraft engines 300 amps maximum output.

13. Push the WHITE DC 1 or 2 ON switches; observe GREEN DC 1 or 2 lamps are ON. (USE BOTH CABLES IF
NEEDED)
14. Push BLACK DC OFF switches to stop
15. Push RED DC ENABLE OFF switch
17. Disconnect DC cable (s) from aircraft. Disconnect AC input power cable and stow cables on GPU
NOTE: The following test is for External Voltage Adjustable units
19. Connect the DC output cable(s) to the aircraft DC socket. Ensure cable plug is fully inserted into the socket
20. Adjust voltage control knob on control panel to 28 VDC mark
21. Push the WHITE DC 1 ON switch, observe GREEN DC 1 lamps is ON
22. The unit will operate normally
23. Push BLACK DC OFF switch to stop
24. Turn GPU main disconnect switch to OFF (left/vertical)
25. Disconnect DC cable from aircraft. Disconnect AC input power cable and stow cables on GPU
WARNING!
Even when switched off, a few components inside the set remain “live“. Only trained personnel should be
allowed to work on set.
5.4 EMERGENCY STOP

In an emergency, to immediately shut off the system, the red Emergency Stop push button on the Control Panel must be
pressed. Bear in mind, however, that the mains in feed is still “live”. It can only be isolated by using suitable external means
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5.5 OUTPUT VOLTAGE DC ADJUSTMENT

WARNING!
Dangerous voltages in side control panel door!
This adjustment procedure shall be performed by qualified personnel!
1. Open control panel door.

2. Connect AC input power cable to the main power outlet and apply electrical power.
3. Turn GPU main disconnect switch to ON (RIGHT/HORIZONTAL)
4. Ensure green main input power lamp is ON, DC voltmeter is indicating 28.5 volts, and no other fault lamps are on.
NOTE: Ensure DC output power is not on and DC lamps are off.
5. For all models, connect a load bank to the DC OUTPUT CABLE 1, set load bank to 2000 Amps, and ensure load bank
switch is OFF.
6. Connect a digital multi meter to the test points on the load bank.
NOTE: The following test is for Single Output Cable units.
7. Push the WHITE DC ON switch. Observe GREEN DC ON lamp is ON.
8. Ensure load bank is ON and cooling fans should begin spinning.
9. Switch the load bank to 300 AMP; verify the voltage at the load bank is 28.0(MIN) - 28.9(MAX) Volts DC. Adjust R-67 on
Interface Board to obtain correct voltage output.
10. Move load bank switch to AUTO; verify the voltage range at the load bank is 16.0 thru 28.9 volts DC and a minimum
1600 AMPS at full load.
11. Observe Amber Warning lamp flashes if DC output volts drops below 21VDC. LET LOAD BANK COOL, push Black
DC Off switch.
13. Disconnect DC cable from load bank. Disconnect AC input power cable and stow cables on GPU.
6.0 TROUBLE SHOOTING

6.1 GENERAL
NOTE In the event of a fault, the system fault messages should be evaluated using the chart below.
If the cause of the fault is within the converter and you cannot clear it with your own personnel, please contact your Tronair
Service representative:
TRONAIR, Inc. Telephone: (419) 866-6301 or 800-426-6301

1740 Eber Road Fax: (419) 867-0634
Holland, Ohio 43528-9794 USA E-mail: [email protected]
Website: www.tronair.com
It is very helpful for fault diagnosis if you can tell us the fault messages in the order in which they occurred.
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112860D0000 112860D0100 112860SD100-A5 112860D0200 112860SD200-A5
6.2 PROCEDURES IN THE EVENT OF MALFUNCTIONS

Follow the steps below in case of malfunctions:
Action Upon Fault Detection

(Green)
Amber Red Output
Fault Fault Sense Input DC Output SCR Firing Input
Condition Warning Fault Contact Recovery Notes
Description Location Breaker Contactor Enable Voltage
LED LED or LED
LED
Firing Board to
None Normal ON ON Enabled ON OFF OFF ON None
Interface Board
Any phase voltage Unit Unit Unit Unit
Missing Firing Board to Opened Unit Power Unit Power Is Input Breaker
missing (>5% of Power Power Is Power Power
Phase Interface Board Immediately Is Off Off Must be Cycled
rated voltage) Is Off Off Is Off Is Off
Secondary AC Unit Unit Unit Unit
Input Opened Unit Power Unit Power Is Input Breaker
Voltage >115% of Interface Board Power Power Is Power Power
Overvoltage Immediately Is Off Off Must be Cycled
max voltage range Is Off Off Is Off Is Off
Primary AC Automatic when If input voltage is
Input Under
Voltage <85% of Interface Board ON ON ON BLINK ON OFF ON condition to low unit will
Voltage
rated voltage changes brown out
Output Voltage
Opened
Output Over >103% of Max of Disabled Input Breaker
Interface Board ON After On BLINK BLINK OFF
Voltage 32.5V at unit Immediately Must be Cycled
100ms
output (> 33.5V)
Output Output <97% of Automatic when
Under Min of 24 V at unit Interface Board ON ON ON ON BLINK OFF ON condition
Voltage output (< 23.3V) changes
Opened
Output High Output Current > Disabled Input Breaker
Interface Board ON After ON ON BLINK OFF
Over Current 2100A Immediately Must be Cycled
100ms
Transformer
Transformer Any/All Core Opened
Thermal Disabled Input Breaker
Over- Temperature ON After ON ON ON OFF
Switches to Immediately Must be Cycled
Temperature > 180°C 100ms
Interface Board
SCR/Heatsink
Any/All SCR Opened
SCR Over- Thermal Disabled Input Breaker
Temperature ON After ON OFF BLINK OFF
Temperature Switches to Immediately Must be Cycled
> 82°C 100ms
Interface Board
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6.3 MONITORS & FAULT INDICATION

The following LEDs are used to define the color/flashing status of the GPU on the Control Panel:
(Green) Input (Amber) (Red) (Green) Output

Condition
Power LED Warning LED Fault LED Contactor LED
Normal Operation/Output Switch On On Off Off On
Power Off or Missing Phase or Input Overvoltage Off Off Off Off
Input Undervoltage *Blink* On Off On
Output Overvoltage On *Blink* *Blink* Off
Output Undervoltage On *Blink* Off On
Output High Overcurrent (>2100A) On On *Blink* Off
Transformer Overtemperature On On On Off
SCR Overtemperature On Off *Blink* Off
Normal Operation/Output Enable Switch Off On Off Off Off
Emergency Stop Switch Pushed In Off Off Off Off
7.0 MAINTENANCE AND SERVICE

7.1 PREVENTIVE MAINTENANCE
7.1.1 General
Because of their construction, Tronair converters require practically no maintenance. The few operations necessary should be
carried out carefully since they contribute to the trouble-free operation and increased service life of the installation.
7.1.2 Cleanliness
Always ensure that the system environment is kept as free as possible of dust, metal chips, lubricants, etc. Check at regular
intervals, that all air inlets and outlets are free of dust and are not blocked by any obstructions, sheets of papers, etc. Air inlets
(underside of the roof) should be vacuumed from time to time.
In no circumstances use compressed air since this can force dust particles into the interior and cause malfunctions.
7.1.3 Voltage Check

To ensure that the set is delivering the correct voltage we recommend that this be checked at regular intervals.
7.2 SERVICE
Prior to delivery each converter is subjected to a thorough check, which includes running at full load for a prolonged period,
and the prescribed overload test. Faults should not normally occur during proper, careful handling. Faults cannot be entirely
ruled out, however, if caused by transportation, unfavorable environmental or operating conditions, or incorrect operation.
If a fault occurs and you are unable to rectify this yourself with the aid of the fault table, please contact us at:
TRONAIR, Inc. Telephone: (419) 866-6301 or 800-426-6301

1 Air Cargo Pkwy East Fax: (419) 867-0634
Swanton, Ohio 43558 USA E-mail: [email protected]
Website: www.tronair.com
With all enquiries please state the model number and serial number of the equipment. These are located on the front panel of
the unit.
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112860D0000 112860D0100 112860SD100-A5 112860D0200 112860SD200-A5
8.0 ADDITIONAL INFORMATION

8.1 LED FUNCTIONS & ARRANGEMENTS
As described in Section 3, the system control is completely digital. System control software is comprised of measurements,
evaluation of measurements, threshold control, and a programmable logic control (PLC) known as the User Program. The
individual parts are fully integrated to operate together as a software control system. The most important function is that of the
User Program. The PLC has digital inputs and outputs which converts the information coming from the hardware into a form
recognizable by the User Program software. Each input and output is monitored by an LED, and all inputs and outputs, which
are used, are shown on the control diagrams. Checking the status of these LED’s is a quick and easy way of establishing the
operational status of the converter, and is useful during fault-finding. An illuminated LED indicates a high potential (+24V) at
the hardware digital input or output. If the LED is off, then the potential is low (0V).
9.0 GUARANTEES/LIMITATION OF LIABILITY

Tronair products are warranted to be free of manufacturing or material defects for a period of one year after shipment to the
original customer. This is solely limited to the repair or replacement of defective components. This warranty does not cover the
following items:
a) Parts required for normal maintenance
b) Parts covered by a component manufacturers warranty
c) Replacement parts have a 90-day warranty from date of shipment
If you have a problem that may require service, contact Tronair immediately. Do not attempt to repair or disassemble a product
without first contacting Tronair, any action may affect warranty coverage. When you contact Tronair be prepared to provide the
following information:
a) Product Model Number
b) Product Serial Number
c) Description of the problem
If warranty coverage is approved, either replacement parts will be sent or the product will have to be returned to Tronair for
repairs. If the product is to be returned, a Return Material Authorization (RMA) number will be issued for reference purposes
on any shipping documents. Failure to obtain a RMA in advance of returning an item will result in a service fee. A decision on
the extent of warranty coverage on returned products is reserved pending inspection at Tronair. Any shipments to Tronair must
be shipped freight prepaid. Freight costs on shipments to customers will be paid by Tronair on any warranty claims only. Any
unauthorized modification of the Tronair products or use of the Tronair products in violation of cautions and warnings in any
manual (including updates) or safety bulletins published or delivered by Tronair will immediately void any warranty, express or
implied.
The obligations of Tronair expressly stated herein are in lieu of all other warranties or conditions expressed or implied. Any
unauthorized modification of the Tronair products or use of the Tronair products in violations of cautions and
warnings in any manual (including updates) or safety bulletins published or delivered by Tronair will immediately
void any warranty, express or implied and Tronair disclaims any and all liability for injury (WITHOUT LIMITATION and
including DEATH), loss or damage arising from or relating to such misuse.
10.0 APPENDICES
APPENDIX I Wiring Diagram and Schedule – Single Output
APPEDIX II Diagram and Schedule – Dual Output
APPENDIX III Declaration of conformity
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Parts List
When ordering replacement parts/kits, please specify model, serial number and color of your unit.
Item Part Number Description Qty

1 G-1439-1050-S Nutsert, Thinwall ¼ - 20 33
2 G-1439-1070-S Nutsert, 3/8 – 16 Open End 24
3 G-1503-1070N Flatwasher, 3/8 Narrow SS 34
4 G-1502-1070R Lockwasher, 3/8 Regular SS 19
5 G-1112-107010 Bolt, 3/8 – 16 x 1.0 LG, HH SS 12
6 U-1112 Caster, Rigid 2
7 U-1085 Caster, Swivel 2
10 EC-2128 SCR Pak 1
11 Z-6943 Assy., Transformer 1
Z-6897-01 Weldment, Frame 1
12
Z-6897-SP Weldment, Frame (Special Paint) 1
13 G-1112-107020 Bolt, 3/18 - 16 2.0 LG, HH SS 4
14 13002 Shunt Resistor 1
15 G-1112-105020 Bolt, ¼ - 20 x 2, HH SS 4
16 G-1503-1050N Flatwasher, ¼ Narrow SS 4
17 G-1502-1050R Lockwasher, ¼ Regular SS 4
18 G-1112-107012 Bolt, 3/18 - 16 x 1 ¼ LG, HH SS 4
19 G-1500-1070 Nut, 3/8 – 16 HH SS 3
N/S G-1351-03-SS Rivet, 1/8 Open End SS 4
N/S G-1580 Door, Latch Receptacle 2
N/S 12048 Split Polyloom ½, 36 in 1
N/S 12085 Split Polyloom 1, 36 in 1
N/S 13092 Cradle, Mounting 10
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112860D0000 112860D0100 112860SD100-A5 112860D0200 112860SD200-A5
Parts List

1 S-2293 Door/Control panel Ref
2 H-3155 Handle, Circuit Breaker 1
LED Green (Single) 2
3 EC-2008-02
LED Green (Dual) 4
4 EC-2008 LED Amber 1
5 EC-2008-03 LED Red 1
6 14009 Voltmeter DC 1
7 14008 DC Ammeter 1
8 12031 Knob, DC 1
9 14131 Switch On/Off 1
10 14132 Switch, Emergency Stop 1
11 G-1577-19 Fastener, ¼ Turn 2
12 G-1579 Washer, Sealing ¼ Turn 2
13 G-1578 Retainer, ¼ Turn Fastener 2
14 H-3191*084.50 Tape, Neoprene Foam Seal 1
15 EC-2144-07 Potentiometer, 10K Sealed 1
16 V-1033 Label, Tronair 1
17 V-1050 Label, ISO Electrical 1
18 V-2097 Label, Warning 1
19 V-1986 Label, Read Manual 1
Flange, Latch (Single) 2
20 14142
Flange, Latch (Dual) 4
Block, Contact Green (Single) 3
21 14143
Block, Contact Green (Dual) 5
Block, Contact Red (Single) 1
22 14144
Block, Contact Red (Dual) 3
23 V-2258 Label, Panel 1
24 V-2258 Label, Serial Number CE 1
N/S EC-2165 P6 Interface Harness 1
N/S 14130 Switch, Power On/Off 1
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112860D0000 112860D0100 112860SD100-A5 112860D0200 112860SD200-A5
Parts List

1 EC-1027 Contactor, DC Output (Single) 1
3 EC-2065 Terminal Block, 4 Pole Black 1
4 EC-2083 Terminal Block, 4 Pole Lt Gray 2
5 EC-2084 Terminal Block, 4 Pole Red 1
6 EC-2065 Plate, End 4CTerminal Block 2
7 EC-2169 Circuit Breaker, 100 Amp 1
8 EC-2127 Firing Board 1
9 EC-2129 Interface Board 1
10 EC-2177 Relay, High Circuit 1
11 EC-2138 Fan Speed Controller w/Probe 1
12 EC-2141 Capacitor, Fan Motor 1
13 EC-2157 Transformer, Control 115/24 VAC, 4A 1
14 EC-2156 Transformer, 117V – 24VT 1
15 G-1112-105006 Bolt, ¼ - 20 x ¾ HH SS 4
16 G-1497-101002 SCR, 6-32 x ¼ RD HD PH SS 28
17 G-1497-102006 SCR, 8-32 x ½ RD HD PH SS 3
18 G-1497-101034 SCR, 6-32 x 3 ½ RD HD PH SS 4
19 G-1497-103104 SCR, 10-32 x ½ RD HD PH SS 6
20 G-1501-1010 Stopnut, 6-32 Elastic SS 7
22 G-1501-1050 Stopnut, ¼ - 20 Elastic SS 6
23 G-1503-1010N Flatwasher, 6 Narrow SS 8
24 G-1503-1030N Flatwasher, 10 Narrow SS 7
26 Z-6900 Assembly, Capacitors 1
27 EC-2159 Circuit Breaker, 25 Amp 1
28 12002 Circuit Breaker, 5 Amp 3
29 12034 PCB Stand Offs 14
Relay, Compact 24VDC (Single) 1
30 13064
Relay, Compact 24VDC (Dual) 2
31 13070 Anchor, Din Rail End 2
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Parts List

32 13072*008.50 Rail, Din 1
Socket, Relay 11 PIN (Single) 1
33 13074
Socket, Relay 11 PIN (Dual) 2
37 EC-2163 P2 Interface Board Harness 1
41 EC-2176 Connector, Lag 3/8 Stud 6
43 4002-6 Diode, Power 1
Diode, Plug-In Relay Socket (Single) 1
N/S EC-2085
Diode, Plug-In Relay Socket (Dual) 2
N/S EC-2158 Temp Sensor 1
The following parts are for the 112860S0100-A4 unit ONLY: (all other parts are for all units)
N/S CRHX1806-71 Plug, Input Male Installed on the input cable
N/S CRHX1806-62 Plug, Insert Loose with unit, to be installed by customer
N/S CRHX1806-91 Receptacle, Female Loose with unit, to be installed by customer
11/2021 | Rev. 04 Page | 22

Models 112850S0000 112850S0100 112850S0200
112850D0000 112850D0100/AV 112850D0100-A5 112850D0200
112860S0000 112860S0100 112860S0100-A4 112860S0100-A6 112860S0200
112860D0000 112860D0100 112860SD100-A5 112860D0200 112860SD200-A5
Parts List

1 J-4324 Buss Bar Bridge 1
2 J-4303 Buss Bar 1
3 J-4304 Buss Bar 2
4 EC-2134 Resistor 1
5 EC-2133 Capacitor 8
6 G-1112-105010 Bolt, ¼ - 20 x 1 LG, HH SS 4
8 G-1502-1050R Lockwasher, ¼ SS 4
9 G-1593-07SS Lockwasher, Internal Tooth, #10 16
10 G-1476-103103 SCR, #10-32 SOC BUT HD CAP 16
11 G-1476-103106 SCR, #10-32 SOC BUT HD CAP SS 16
12 G-1503-1030N Flatwasher, #10 SS 4
13 G-1500-1031 Nut, #10 – 32 Hex SS 2
14 H-3156 Resistor, Bracket 2
15 G-1500-1050 Nut, ¼ – 20 Hex SS 4
16 G-1500-1050 Nut, ¼ - 20 Hex SS 4
18 H-3173 Nut, Plastic Capacitor 8
N/S EC-1034-01 Terminal Ring 4
11/2021 | Rev. 04 Page | 23

APPENDIX I
Wiring Diagram and Schedule

Single Output
INSTRUCTION DOCUMENT NUMBER:
PAGE 1 OF 4 INS-1993
Model: 1128X0S0X00– Wiring Schedule (Single Output 50/60 Hertz)) DATE: 01/2011 REV: 04
NOTE: REFER TO WIRING DIAGRAM INS-2007
WIRE WIRE
LETTER SIZE/COLOR FROM TO
A 20/BLACK P-6 HARNESS CONNECTOR (PIN 5) EMERGENCY STOP SWITCH SW1 TERMINAL (3)
B 20/BLACK P-6 HARNESS CONNECTOR (PIN 6) EMERGENCY STOP SWITCH SW2 TERMINAL (1)
C 20/BLACK P-6 HARNESS CONNECTOR (PIN 18) EMERGENCY STOP SWITCH SW2 TERMINAL (2)
D 20/BLACK P-6 HARNESS CONNECTOR (PIN 17) EMERGENCY STOP SWITCH SW1 TERMINAL (4)
E 20/GREEN P-6 HARNESS CONNECTOR (PIN 7) DC POWER ON/OFF SWITCH SW3 TERMINAL (4)
F 20/GREEN P-6 HARNESS CONNECTOR (PIN 20) DC POWER ON/OFF SWITCH SW3 & SW4 TERMINALS (3)
G 20/GREEN P-6 HARNESS CONNECTOR (PIN 19) DC POWER ON/OFF SWITCH SW4 TERMINAL (4)
H 20/BLACK P-6 HARNESS CONNECTOR (PIN 1) INPUT POWER ON LAMP L1 TERMINAL (PLUS)
I 20/GREEN P-6 HARNESS CONNECTOR (PIN 13) INPUT POWER ON LAMP L1 TERMINAL (MINUS)
J 20/BLACK P-6 HARNESS CONNECTOR (PIN 2) WARNING LAMP L2 TERMINAL (PLUS)
K 20/GREEN P-6 HARNESS CONNECTOR (PIN 14) WARNING LAMP L2 TERMINAL (MINUS)
L 20/BLACK P-6 HARNESS CONNECTOR (PIN 3) FAULT LAMP L3 TERMINAL (PLUS)
M 20/GREEN P-6 HARNESS CONNECTOR (PIN 15) FAULT LAMP L3 TERMINAL (MINUS)
N 20/BLACK P-6 HARNESS CONNECTOR (PIN 9) CURRENT LIMIT POT SW5 TERMINAL (a)
O 20/GREEN P-6 HARNESS CONNECTOR (PIN 21) CURRENT LIMIT POT SW5 TERMINAL (c)
P 20/BLACK P-6 HARNESS CONNECTOR (PIN 10) CURRENT LIMIT POT SW5 TERMINAL (b)
Q 20/BLACK P-6 HARNESS CONNECTOR (PIN 24) DC CURRENT METER M1 TERMINAL (PLUS)
R 20/GREEN P-6 HARNESS CONNECTOR (PIN 12) DC CURRENT METER M1 TERMINAL (MINUS)
S 20/BLACK P-6 HARNESS CONNECTOR (PIN 8) DC VOLT METER M2 TERMINAL (PLUS)
T 20/GREEN P-6 HARNESS CONNECTOR (PIN 22) DC VOLT METER M2 TERMINAL (MINUS)
U 20/BLACK P-6 HARNESS CONNECTOR (PIN 4) DC 1 ON LAMP L4 TERMINAL (PLUS)
V 20/GREEN P-6 HARNESS CONNECTOR (PIN 16) DC 1 ON LAMP L4 TERMINAL (MINUS)
W 20/BLACK BLACK TERMINAL BLOCK (1) LATCH RELAY K1 TERMINALS (9 & 10)
X 20/BLACK P-3 HARNESS CONNECTOR (PIN 1) LATCH RELAY K1 TERMINAL (13)
Y 20/GREEN P-3 HARNESS CONNECTOR (PIN 5) LATCH RELAY K1 TERMINAL (14)
Z 20/GREEN P-3 HARNESS CONNECTOR (PIN 8) DC SHUNT (PLUS)
AA 20/GREEN P-3 HARNESS CONNECTOR (PIN 4) DC SHUNT (MINUS)
BB 20/BLACK SCR BUS BAR (PLUS) P-3 HARNESS CONNECTOR (PIN 3)
INS-1993
1128X0S0X00 WIRING SCHEDULE
WIRE WIRE
4/0 BLACK DC CONTACTOR CONT1 CONTACT
CC 20/RED P-8 HARNESS CONNECTOR (PIN 1) P-5 HARNESS CONNECTOR (PIN 1)
DD 20/RED P-8 HARNESS CONNECTOR (PIN 3) P-5 HARNESS CONNECTOR (PIN 3)
EE 20/RED P-8 HARNESS CONNECTOR (PIN 5) P-5 HARNESS CONNECTOR (PIN 5)
FF 20/RED P-9 HARNESS CONNECTOR (PIN 1) P-3 HARNESS CONNECTOR (PIN 1)
GG 20/RED P-9 HARNESS CONNECTOR (PIN 2) P-3 HARNESS CONNECTOR (PIN 2)
HH 20/BLACK P-9 HARNESS CONNECTOR (PIN 3) P-3 HARNESS CONNECTOR (PIN 3)
II 20/BLACK P-9 HARNESS CONNECTOR (PIN 4) P-3 HARNESS CONNECTOR (PIN 4)
JJ 20/BLACK P-9 HARNESS CONNECTOR (PIN 5) P-3 HARNESS CONNECTOR (PIN 5)
KK 20/GREEN P-9 HARNESS CONNECTOR (PIN 8) P-3 HARNESS CONNECTOR (PIN 8)
LL 20/BLACK P-9 HARNESS CONNECTOR (PIN 9) P-3 HARNESS CONNECTOR (PIN 9)
MM 20/BLACK P-9 HARNESS CONNECTOR (PIN 10) P-3 HARNESS CONNECTOR (PIN 10)
NN 20/GREEN P-9 HARNESS CONNECTOR (PIN 11) P-3 HARNESS CONNECTOR (PIN 11)
OO 20/BLACK P-9 HARNESS CONNECTOR (PIN 12) P-3 HARNESS CONNECTOR (PIN 12)
PP 20/BLACK SCR BUS BAR (PLUS) BLACK TERMINAL BLOCK (1)
QQ 20/BLACK LATCH RELAY K1 TERMINAL (5) DC CONTACTOR CONT1 COIL
RR 20/BLACK BLACK TERMINAL BLOCK (1) BLEED RESISTOR SOLENOID SOL1 COIL
SS 20/GREEN LT. GRAY TERMINAL BLOCK (4) DC CONTACTOR CONT1 COIL
TT 20/RED FAN CONTROLLER PC BOARD PCB3 TERMINAL (L) RED TERMINAL BLOCK (3)
UU 20/RED P-2 HARNESS CONNECTOR (PIN 6) CIRCUIT BREAKER CB4
VV 20/RED P-2 HARNESS CONNECTOR (PIN 13) TRANSFORMER T3 (RED WIRE)
WW 20/GREEN SCR BUS BAR (MINUS) LT. GRAY TERMINAL BLOCK (4)
XX 20/GREEN LT. GRAY TERMINAL BLOCK (4) BLEED RESISTOR SOLENOID SOL1 COIL
YY 16/RED CIRCUIT BREAKER CB2 GFCI OUTLET SOC1 TERMINAL (HOT) OR BLACK TERMINAL BLOCK (8)
GFCI OUTLET SOC1 LINE TERMINAL (WHITE) OR YELLOW TERMINAL
ZZ 16/WHITE TRANSFORMER T1 TERMINAL (A2)
BLOCK (10)
AB 20/RED CONTROL TRANSFORMER T2 (RED WIRE) CIRCUIT BREAKER CB5
AC 12/RED CIRCUIT BREAKER CB6 230 VOLT AC OUTLET (SOC 1)
AD 16/RED CIRCUIT BREAKER CB2 RED TERMINAL BLOCK (6)
CAPACITOR ASSEMBLY BUS BAR (PLUS)
AE 6/BLACK SCR BUS BAR (PLUS)
BLEED RESISTOR R1
CAPACITOR ASSEMBLY BUS BAR (MINUS)
AF 6/BLACK SCR BUS BAR (MINUS)
BLEED RESISTOR SOLENOID SOL1 (CONTACT)
AG 20/GREEN TRANSFORMER THERMO TERMINAL BLOCK P-2 HARNESS CONNECTOR (PIN 8)
AH 20/GREEN TRANSFORMER THERMO TERMINAL BLOCK P-2 HARNESS CONNECTOR (PIN 9)
AI 20/BLACK SHUNT-TRIP CIRCUIT BREAKER (BLACK WIRE) P-2 HARNESS CONNECTOR (PIN 5)
AJ 20/GREEN SHUNT-TRIP CIRCUIT BREAKER (BLACK WIRE) P-2 HARNESS CONNECTOR (PIN 12)
01/2011 | Rev. 04 Page | 2
INS-1993
WIRE WIRE
AK 20/RED CIRCUIT BREAKER CB5 P-2 HARNESS CONNECTOR (PIN 7)
AL 20/GREEN TRANSFORMER T3 (RED WIRE) P-2 HARNESS CONNECTOR (PIN 14)
20/RED P-2 HARNESS CONNECTOR (PIN 3)
AM TRANSFORMER T1 TERMINAL (X3)
4/0 BLACK SCR MODULE MOD1 TERMINAL SCR# 5
AN TRANSFORMER T1 TERMINAL (X2)
AO TRANSFORMER T1 TERMINAL (X1)
AP 20/BLACK TRANSFORMER T2 (BLACK WIRE) CIRCUIT BREAKER CB3
AQ 20/RED CIRCUIT BREAKER CB3 RED TERMINAL BLOCK (6)
AR 20/GREEN TRANSFORMER T3 (RED/YELLOW WIRE) P-2 HARNESS CONNECTOR (PIN 11)
AS 20/RED TRANSFORMER T3 (RED WIRE) CIRCUIT BREAKER CB4
AT 16/RED TRANSFORMER T1 TERMINAL (A1) CIRCUIT BREAKER CB2
AV NOT USED NOT USED
AW 16/WHITE TRANSFORMER T1 TERMINAL (A2) LT.GRAY TERMINAL BLOCK (5)
AX NOT USED NOT USED
AY 20/BLACK RED TERMINAL BLOCK (3) UNIT COOLING FAN FAN1 (BLACK WIRE)
AZ 20/RED REDTERMINAL BLOCK (6) FAN CONTROL PCB PCB3 TERMINAL (L)
BA 20/GREEN LT GRAY TERMINAL BLOCK (5) FAN CONTROL PCB PCB3 TERMINAL (N)
BC 20/BLUE FAN CONTROL PCB PCB3 TERMINAL (F) UNIT COOLING FAN FAN1 (BLUE WIRE)
BD 20/BROWN LT GRAY TERMINAL BLOCK (2) UNIT COOLING FAN FAN1 (BROWN WIRE)
BE NOT USED NOT USED
BF NOT USED NOT USED
BG NOT USED NOT USED
BH 6/BLACK SHUNT-TRIP CIRCUIT BREAKER (L1) TRANSFORMER T1 TERMINAL (H3)
BI 6/BLACK SHUNT-TRIP CIRCUIT BREAKER (L2) TRANSFORMER T1 TERMINAL (H2)
BJ 6/BLACK SHUNT-TRIP CIRCUIT BREAKER (L3) TRANSFORMER T1 TERMINAL (H1)
BK NOT USED NOT USED
BL NOT USED NOT USED
BM NOT USED NOT USED
BN 12/WHITE TRANSFORMER T1 TERMINAL (A4) 230 VOLT AC OUTLET (SOC 1)
BO NOT USED NOT USED
BP NOT USED NOT USED
BQ NOT USED NOT USED
BR 4/0 BLACK SCR BUS BAR (PLUS) DC CONTACTOR CONT1 MAIN CONTACT
BS NOT USED NOT USED
01/2011 | Rev. 04 Page | 3

INS-1993
WIRE WIRE
BT 6/BLACK BLEED RESISTOR R1 BLEED RESISTOR SOLENOID SOL1 MAIN CONTACT
BU 12/RED TRANSFORMER T1 TERMINAL (A3) CIRCUIT BREAKER CB6
01/2011 | Rev. 04 Page | 4

APPENDIX II
Wiring Diagram and Schedule

Dual Output
INSTRUCTION DOCUMENT NUMBER:
PAGE 1 OF 4 INS-1998
Model: 1128X0D0XXX– Wiring Schedule (Dual Output 50/60 Hertz) DATE: 01/2011 REV: 03
NOTE: REFER TO WIRING DIAGRAM INS-1992
WIRE WIRE
A 20/BLACK P-6 HARNESS CONNECTOR (PIN 5) EMERGENCY STOP SWITCH SW1 TERMINAL (3)
B 20/BLACK P-6 HARNESS CONNECTOR (PIN 6) EMERGENCY STOP SWITCH SW2 TERMINAL (1)
C 20/BLACK P-6 HARNESS CONNECTOR (PIN 18) EMERGENCY STOP SWITCH SW2 TERMINAL (2)
D 20/BLACK P-6 HARNESS CONNECTOR (PIN 17) EMERGENCY STOP SWITCH SW1 TERMINAL (4)
E 20/GREEN P-6 HARNESS CONNECTOR (PIN 7) DC ENABLE ON SWITCH SW3 TERMINAL (4)
F 20/GREEN P-6 HARNESS CONNECTOR (PIN 20) DC ENABLE ON/OFF SWITCH SW3 & SW4 TERMINALS (3)
G 20/GREEN P-6 HARNESS CONNECTOR (PIN 19) DC ENABLE OFF SWITCH SW4 TERMINAL (4)
H 20/BLACK P-6 HARNESS CONNECTOR (PIN 1) INPUT POWER ON LAMP L1 TERMINAL (PLUS)
I 20/GREEN P-6 HARNESS CONNECTOR (PIN 13) INPUT POWER ON LAMP L1 TERMINAL (MINUS)
J 20/BLACK P-6 HARNESS CONNECTOR (PIN 2) WARNING LAMP L2 TERMINAL (PLUS)
K 20/GREEN P-6 HARNESS CONNECTOR (PIN 14) WARNING LAMP L2 TERMINAL (MINUS)
L 20/BLACK P-6 HARNESS CONNECTOR (PIN 3) FAULT LAMP L3 TERMINAL (PLUS)
M 20/GREEN P-6 HARNESS CONNECTOR (PIN 15) FAULT LAMP L3 TERMINAL (MINUS)
N 20/BLACK P-6 HARNESS CONNECTOR (PIN 9) CURRENT LIMIT POT SW5 TERMINAL (a)
O 20/GREEN P-6 HARNESS CONNECTOR (PIN 21) CURRENT LIMIT POT SW5 TERMINAL (c)
P 20/BLACK P-6 HARNESS CONNECTOR (PIN 10) CURRENT LIMIT POT SW5 TERMINAL (b)
Q 20/BLACK P-6 HARNESS CONNECTOR (PIN 24) DC CURRENT METER M1 TERMINAL (PLUS)
R 20/GREEN P-6 HARNESS CONNECTOR (PIN 12) DC CURRENT METER M1 TERMINAL (MINUS)
S 20/BLACK P-6 HARNESS CONNECTOR (PIN 8) DC VOLT METER M2 TERMINAL (PLUS)
T 20/GREEN P-6 HARNESS CONNECTOR (PIN 22) DC VOLT METER M2 TERMINAL (MINUS)
U 20/BLACK P-6 HARNESS CONNECTOR (PIN 4) DC ENABLE ON LAMP L4 TERMINAL (PLUS)
V 20/GREEN P-6 HARNESS CONNECTOR (PIN 16) DC ENABLE ON LAMP L4 TERMINAL (MINUS)
W 20/BLACK BLACK TERMINAL BLOCK (1) LATCH RELAY K1 TERMINALS (9 & 10)
X 20/BLACK P-3 HARNESS CONNECTOR (PIN 1) LATCH RELAY K1 TERMINAL (13) OR BLACK TERMINAL BLOCK (7)
DC 1 POWER OFF SWITCH SW7 TERMINAL (2) OR LATCH RELAY
Y 20/GREEN P-3 HARNESS CONNECTOR (PIN 5)
DC 2 POWER OFF SWITCH SW9 TERMINAL (1) K1 TERMINAL (14)
INS-1998
1128X0D0XXX WIRING SCHEDULE
WIRE WIRE
Z 20/GREEN P-3 HARNESS CONNECTOR (PIN 8) DC SHUNT (PLUS)

AA 20/GREEN P-3 HARNESS CONNECTOR (PIN 4) DC SHUNT (MINUS)
BB 20/BLACK SCR BUS BAR (PLUS) P-3 HARNESS CONNECTOR (PIN 3)
CC 20/RED P-8 HARNESS CONNECTOR (PIN 1) P-5 HARNESS CONNECTOR (PIN 1)
DD 20/RED P-8 HARNESS CONNECTOR (PIN 3) P-5 HARNESS CONNECTOR (PIN 3)
EE 20/RED P-8 HARNESS CONNECTOR (PIN 5) P-5 HARNESS CONNECTOR (PIN 5)
FF 20/RED P-9 HARNESS CONNECTOR (PIN 1) P-3 HARNESS CONNECTOR (PIN 1)
GG 20/RED P-9 HARNESS CONNECTOR (PIN 2) P-3 HARNESS CONNECTOR (PIN 2)
HH 20/BLACK P-9 HARNESS CONNECTOR (PIN 3) P-3 HARNESS CONNECTOR (PIN 3)
II 20/BLACK P-9 HARNESS CONNECTOR (PIN 4) P-3 HARNESS CONNECTOR (PIN 4)
JJ 20/BLACK P-9 HARNESS CONNECTOR (PIN 5) P-3 HARNESS CONNECTOR (PIN 5)
KK 20/GREEN P-9 HARNESS CONNECTOR (PIN 8) P-3 HARNESS CONNECTOR (PIN 8)
LL 20/BLACK P-9 HARNESS CONNECTOR (PIN 9) P-3 HARNESS CONNECTOR (PIN 9)
MM 20/BLACK P-9 HARNESS CONNECTOR (PIN 10) P-3 HARNESS CONNECTOR (PIN 10)
NN 20/GREEN P-9 HARNESS CONNECTOR (PIN 11) P-3 HARNESS CONNECTOR (PIN 11)
OO 20/BLACK P-9 HARNESS CONNECTOR (PIN 12) P-3 HARNESS CONNECTOR (PIN 12)
PP 20/BLACK SCR BUS BAR (PLUS) BLACK TERMINAL BLOCK (1)
QQ 20/BLACK LATCH RELAY K1 TERMINAL (5) DC CONTACTOR CONT1 COIL
RR 20/BLACK BLACK TERMINAL BLOCK (1) BLEED RESISTOR SOLENOID SOL1 COIL
DC 1 CONTACTOR CONT1 COIL
SS 20/GREEN LT. GRAY TERMINAL BLOCK (4)
DC 2 CONTACTOR CONT2 COIL
TT 2/RED FAN CONTROLLER PC BOARD PCB3 TERMINAL (L) RED TERMINAL BLOCK (3)
UU 20/RED P-2 HARNESS CONNECTOR (PIN 6) CIRCUIT BREAKER CB4
VV 20/RED P-2 HARNESS CONNECTOR (PIN 13) TRANSFORMER T3 (RED WIRE)
WW 20/GREEN SCR BUS BAR (MINUS) LT. GRAY TERMINAL BLOCK (4)
XX 20/GREEN LT. GRAY TERMINAL BLOCK (4) BLEED RESISTOR SOLENOID SOL1 COIL
YY 12/RED CIRCUIT BREAKER CB2 GFCI OUTLET SOC1 TERMINAL (HOT) OR RED TERMINAL BLOCK (8)
GFCI OUTLET SOC1 LINE TERMINAL (WHITE) OR LT. GRAY TERMINAL BLOCK
ZZ 12/WHITE TRANSFORMER T1 TERMINAL (A2)
(10)
AB 20/RED CONTROL TRANSFORMER T2 (RED WIRE) CIRCUIT BREAKER CB5
AC 12/RED CIRCUIT BREAKER CB6 230 VOLT AC OUTLET (SOC1)
AD 16/RED CIRCUIT BREAKER CB2 RED TERMINAL BLOCK (6)
01/2009 | Rev. 01 Page | 2
INS-1998
WIRE WIRE
CAPACITOR ASSEMBLY BUS BAR (PLUS)

AE 6/BLACK SCR BUS BAR (PLUS)
BLEED RESISTOR R1
CAPACITOR ASSEMBLY BUS BAR (MINUS)
AF 6/BLACK SCR BUS BAR (MINUS)
BLEED RESISTOR SOLENOID SOL1 (CONTACT)
AG 20/GREEN TRANSFORMER THERMO TERMINAL BLOCK P-2 HARNESS CONNECTOR (PIN 8)
AH 20/GREEN TRANSFORMER THERMO TERMINAL BLOCK P-2 HARNESS CONNECTOR (PIN 9)
AI 20/BLACK SHUNT-TRIP CIRCUIT BREAKER (BLACK WIRE) P-2 HARNESS CONNECTOR (PIN 5)
AJ 20/GREEN SHUNT-TRIP CIRCUIT BREAKER (BLACK WIRE) P-2 HARNESS CONNECTOR (PIN 12)
AK 20/RED CIRCUIT BREAKER CB5 P-2 HARNESS CONNECTOR (PIN 7)
AL 20/WHITE TRANSFORMER T3 (RED WIRE) P-2 HARNESS CONNECTOR (PIN 14)
AM TRANSFORMER T1 TERMINAL (X3)
AN TRANSFORMER T1 TERMINAL (X2)
AO TRANSFORMER T1 TERMINAL (X1)
AP 20/BLACK TRANSFORMER T2 (BLACK WIRE) CIRCUIT BREAKER CB3
AQ 20/RED CIRCUIT BREAKER CB3 RED TERMINAL BLOCK (6)
AR 20/GREEN TRANSFORMER T3 (RED/YELLOW WIRE) P-2 HARNESS CONNECTOR (PIN 11)
AS 20/RED TRANSFORMER T3 (RED WIRE) CIRCUIT BREAKER CB4
AT 16/RED TRANSFORMER T1 TERMINAL (A1) CIRCUIT BREAKER CB2
DC 1 ON LAMP L5 TERMINAL (PLUS)
AV 20/BLACK DC CABLE 1 ON SWITCH SW6 TERMINAL (4)
LATCH RELAY 1 K1 TERMINALS (8 & 13)
AW 16/WHITE TRANSFORMER T1 TERMINAL (A2) LT.GRAY TERMINAL BLOCK (5)
DC 1 ON LAMP L5 TERMINAL (MINUS)
AX 20/GREEN DC CABLE 1 OFF SWITCH SW7 TERMINAL (1)
LATCH RELAY 1 K1 TERMINAL (14)
AY 20/BLACK RED TERMINAL BLOCK (3) UNIT COOLING FAN FAN1 (BLACK WIRE)
AZ 20/RED RED TERMINAL BLOCK (6) FAN CONTROL PCB PCB3 TERMINAL (L)
BA 20/GREEN LT.GRAY TERMINAL BLOCK (5) FAN CONTROL PCB PCB3 TERMINAL (N)
BC 20/BLUE FAN CONTROL PCB PCB3 TERMINAL (F) UNIT COOLING FAN FAN1 (BLUE WIRE)
BD 20/BROWN LT.GRAY TERMINAL BLOCK (2) UNIT COOLING FAN FAN1 (BROWN WIRE)
01/2009 | Rev. 01 Page | 3

INS-1998
WIRE WIRE
DC 2 ON LAMP L6 TERMINAL (PLUS)

BE 20/BLACK DC CABLE 2 ON SWITCH SW8 TERMINAL (3)
LATCH RELAY 2 K2 TERMINALS (8 & 13)
DC 2 ON LAMP L6 TERMINAL (MINUS)
BF 20/GREEN DC 2 POWER OFF SWITCH SW9 TERMINAL (2)
LATCH RELAY 2 K2 TERMINAL (14)
BG NOT USED NOT USED
BH 6/BLACK SHUNT-TRIP CIRCUIT BREAKER (L1) TRANSFORMER T1 TERMINAL (H3)
BI 6/BLACK SHUNT-TRIP CIRCUIT BREAKER (L2) TRANSFORMER T1 TERMINAL (H2)
BJ 6/BLACK SHUNT-TRIP CIRCUIT BREAKER (L3) TRANSFORMER T1 TERMINAL (H1)
BK LATCH RELAY 2 K2 TERMINAL (12)
DC CABLE 1 ON SWITCH SW6 TERMINAL (3)
BL 20/BLACK BLACK TERMINAL BLOCK (7)
DC CABLE 2 ON SWITCH SW8 TERMINAL (4)
BM LATCH RELAY 1 K1 TERMINAL (12)
BN 12/WHITE TRANSFORMER T1 TERMINAL (A4) 230 VOLT AC OUTLET (SOC1)
BO 20/BLACK NOT USED NOT USED
BP 20/BLACK BLACK TERMINAL BLOCK (1) LATCH RELAY 2 K2 TERMINAL (9)
BQ 20/BLACK LATCH RELAY 2 K2 TERMINAL (5) DC 2 CONTACTOR CONT2 COIL
BR 4/0 BLACK SCR BUS BAR (PLUS) DC CONTACTOR CONT1 MAIN CONTACT TERMINAL
BS 4/0 BLACK SCR BUS BAR (PLUS) DC CONTACTOR CONT2 MAIN CONTACT TERMINAL
BT 6/BLACK BLEED RESISTOR R1 BLEED RESISTOR SOLENOID SOL1 MAIN CONTACT
BU 12/RED TRANSFORMER T1 TERMINAL (A3) CIRCUIT BREAKER CB6
01/2009 | Rev. 01 Page | 4

APPENDIX III
Declaration of Conformity
DECLARATION of CONFORMITY
The design, development and manufacture is in accordance with European Community guidelines
Relevant standards complied with by the machinery:

MIL-STD-704F
UL 1012
EN 55011
EN60146 part 1-1
EN 61000-6-2
NFPA 70
Identification of person empowered to sign on behalf of the Manufacturer:
Quality Assurance Representative
Tronair, Inc. Phone: (419) 866-6301 | 800-426-6301

1 Air Cargo Pkwy East Web: www.tronair.com
Swanton, OH 43558 Email: [email protected]

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OPERATION & SERVICE MANUAL

28.5 VDC Ground Power Unit

Tronair, Inc. Phone: (419) 866-6301 | 800-426-6301

1.0 INTRODUCTION ............................................................................................................................................................... 1

1.1 MODEL DISCTIPTIONS

11/2021 | Rev. 04 Page | 1

1.2 SAFETY NOTES

11/2021 | Rev. 04 Page | 2

2.0 TECHNICAL DATA

Type 28V DC GPU 600A

11/2021 | Rev. 04 Page | 3

3.0 SYSTEM DESCRIPTION

3.2 DETAILED DESCRIPTION

The following functions are built in:

3.3 PERFORMANCE UNDER UNUSUAL CONDITIONS

11/2021 | Rev. 04 Page | 4

3.4 SYSTEM CONTROL

3.5 SAFETY AND PROTECTION

3.6 CONTROL AND MONITORING

3.6.2 Internal System Control

3.6.3 Converter Operation

3.7 VOLTAGE REGULATION MODE

To overcome this problem, two possibilities are available:

11/2021 | Rev. 04 Page | 5

3.8 CONTROL PANEL

Green steady state .......................... Running or switched on

3.8.1 Operator Controls

3.8.2 Emergency Stop

3.9 OVERVIEW OF 28V DC GPU COMPONENTS

Abbreviation Description of Component

11/2021 | Rev. 04 Page | 6

4.0 INSTALLATION AND CONNECTIONS

IMPORTANT Moving by crane should only be used in exceptional

Please pay attention to the following handling advice:

IMPORTANT In no circumstances must the converter be stacked, or stored outside.

4.4.1 Floor Loading Capacity

11/2021 | Rev. 04 Page | 7

4.4.2 Space Requirements/Dimensions

4.4.3 Altitude, Temperature & Humidity

4.5 ELECTRICAL CONNECTIONS (POWER)

11/2021 | Rev. 04 Page | 8

4.5.2 Cable Sizing

4.5.3 Mains Fuses

11/2021 | Rev. 04 Page | 9

5.0 OPERATING INSTRUCTIONS

5.1.1 Control Panel

Specific switching functions are initiated, operating information are displayed.

5.1.2 Operator Controls

5.2.1 Tools Needed

11/2021 | Rev. 04 Page | 10

Setting the various transformer taps:

VOLTAGE CHANGING INSTRUCTIONS – 50 Hz

VOLTAGE CHANGING INSTRUCTIONS – 60 Hz

5.2.3 Converter Commissioning

11/2021 | Rev. 04 Page | 11

5.2.3 Converter Commissioning (continued)

11/2021 | Rev. 04 Page | 12

5.2.3 Converter Commissioning (continued)

11. Follow steps 1 thru 5