( ISO 9001 : 2008 Company )

TECHNICAL SPECIFICATION
FOR TOWABLE TRAILER MOUNTED 400 PPM AIR START UNIT

1. GENERAL

• MAK ASU 400 is designed and manufactured for pneumatically starting the
main engines of aircraft of wide-bodied aircraft including B777 with GE 90 115B
engine. The unit delivers oil free and dry compressed air at 38-42 PSIG with a
maximum flow rate of 90 to 400 pounds per min.
• ALSO THE UNIT’S OUTPUT IS SUITABLE AS BLEED AIR FOR
GROUND AIR-CONDITIONING OF THE AIRCRAFT, USING THE ON-
BOARD ENVIRONMENTAL CONTROL SYSTEM. TOWARDS THIS,
THE SYSTEM IS DESIGNED TO DELIVER AIR AT 28-30 PSIG.
• All systems used in the construction of the unit are simple and effective in use,
easy to maintain. The unit is so designed to withstand any harsh working
environment normally encountered in airport operation.
• In structural and mechanical design integrity, the unit will have a minimum
overall life of twenty years or 20,000 hours while meeting all current safety
requirements.
2. UNIT DESCRIPTION

This unit comprises of a diesel engine driving an oil free screw compressor, coupled
to rear end of the engine.

The entire unit is covered by a processed acoustic enclosure to provide protection

against environmental hazards and to maintain low noise levels. Accessories of the
engine and compressor are suitably positioned in the base frame, to ensure easy access
to the service points. Stowage space for output air hose assembly is also incorporated
suitably at the outside of the enclosure. Doors are provided at appropriate locations
for easy operation, inspection and maintenance of the unit.

3. ENGINE

• The Power Unit is a CUMMINS / Equivalent Engine capable of developing power

sufficient to run the compressor to deliver 400 PPM air. Its cooling and lubrication
systems can be easily accessed for topping-up and level checks. The cooling
system also incorporates the reserve coolant facility, for automatic topping up.

• The engine model has been selected to have sufficient reserve power over the
requirement to drive the compressor at its rated rpm.

• Annunciations are provided for the following parameters

- Low lube oil pressure

- High coolant temperature

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- Low fuel tank level

• Micro-controller based protective circuits are provided for High coolant

temperature and low lube oil pressure.

• Diesel tanks of appropriate capacity permit continuous utilization of the unit in

AC pack mode through 2 hours. Two in number x 12V low maintenance, heavy-
duty batteries provide the electrical impulse for quick starting through electric
starter.

4. PNEUMATIC SYSTEM

The air supply is provided by a screw type, positive displacement GHH RAND make /
MAK make Compressor. At its rated drive shaft rpm, the compressor operates at a
higher rotary screw speed with a maximum capacity to deliver 90 to 400 PPM of oil
free, dry compressed air.

The control panel is fitted with annunciations for the following -

- Low oil pressure
- High oil temperature
- High discharge temperature

5. ELECTRICAL SYSTEM

• The electrical system is 24V negative earth.

• Charging alternator is offered as standard for battery charging.

• The batteries are easily accessed for routine maintenance and are positively
restrained in their mountings.

• A resettable emergency stop button is fitted in an easily accessible and identifiable

position in the control panel for emergency operations of the pneumatic system.

6. AIR DELIVERY HOSES

Three 50 ft. (15.2 mtrs.) delivery hoses with silicone rubber lining and scuffer jackets
are provided. Units with increased length of delivery hoses can be provided as
options.

7. CONTROL

The heart of this system is a micro-controller card, which registers output of various
signal cards from the electrical system on different parameters, and shut down the
engine when the functional parameters exceed set values.

The system has the following additional features:

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• Ensures engine running at idle speed during no load.

• Ensures electronic protection and regulation of pneumatic system against high

pressure. In the event of high pressure due to output load shut-off, this system
regulates the pressure by bringing down the engine speed, actuating the relief
valve and the pressure-maintaining valve.

• Ensures minimum operation requirement of the safety valve, thereby ensuring

accurate functioning/long life of the safety valve

8. SIZE AND DIMENSIONS

Length : < 6300 mm (tow bar folded)

Width : 2200 mm (for transportation) and 2750 while in operation
Height : 2400 mm (excluding silencers)
Weight : < 9000 kgs (dry) approx.

9. ENVIRONMENTAL CONSIDERATIONS

• All construction joints are accomplished through approved techniques.

• The design, construction and materials used are committed to with stand heavy-
duty operations within the tarmac area.

• All exposed components are protected from normal environmental impact.

10. SAFETY ASPECTS

• Basic safety requirements for Aircraft Ground Support Equipment listed in IATA-
AHM-913 are incorporated in the unit.

11. OPERATIONS AND MAINTENANCE

• The unit is capable of being operated by personnel possessing no special skills,

but having a short period of operational training.

• Periodic Maintenance can be accomplished using standard tools and easily

replaceable spares.

• Safety systems are designed in such a manner that they can be activated before
any damage can be caused to the operator or the unit.

• The routine daily maintenance is easily accomplished, as access to all areas

requiring daily inspection/maintenance, is through a single door. Similarly, all
drain points have been so routed to permit access to all draining points through a
single aperture.

12. SPECIAL FEATURES:

• User friendly.

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• Monitoring, control and operation through GUI Touch screen panel

• Electronic governor for speed control.
• Flexible coupling to eliminate mis-alignment.
• Special design for sound attenuation.
• Compact size, minimum weight and maneuverability through appropriate
configuration of speed rated engine and compressor on a specially designed chassis.

• Unit layout designed for easy access to all servicing points.

13. CONTROL PANEL FEATURES:

• The ASU is equipped with Graphical User Interface Touch Screen Display for
Metering, Control and Protection.

• Touch Screen Facility for users to explore the system easily and Better readability of
output

• Facilitated with Password protected Field Programmable option.

• Wide Operating Temperature of -30° C to 75° C (Optional)

• ASU is selectable in the following modes

• Jet Start Mode
• A/C Pack Mode.
• User Interactive Reset Option for Warnings and Alarms.

• Parameters view in both Analog and Digital Format.

• Inbuilt Maintenance chart, Fault Log Chart Features, and Troubleshooting Guide.

• Self test facility to monitor the serviceability of the control system.

• Advanced 32 bit Microcontroller system capable to operate @ 60 MHz Clock

Frequency.

• Inbuilt Hardware Protection for Control System

• Controller Circuit Designed and Developed for wide operating voltage range of 7 to
42V

• Designed with EMI/EMC Considerations.

• In Built Data Logging Features for Flash Device and SD Card in *.csv format which
shall be open in MS Excel.

• Decoding Logged Data to system through Serial Communication.

• Customer Preferable Remote Diagnosis & Monitoring Feature for best support on
service and maintenance.

• Decoding Logged Data to Cloud Network through Remote Diagnosis and Monitoring
Feature. (Optional)

• Tracking of ASU with Latitude, Longitude, Speed and with all the necessary

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parameters. (Optional)

• Trip limits can be programmed through GUI touch screen display

14. FINISH

The unit will be finish painted in standard white gloss, after the application of primer
and undercoat. Additional coats of heavy duty, weather resistant undercoating shall be
applied to all parts and accessories, subject to rust or corrosive action. Final color
scheme will be as per customer’s choice.

15. DOCUMENTATION

The operation, maintenance and trouble shooting manual with illustrated parts
catalogue in English language will be supplied.

TECHNICAL SPECIFICATIONS

Performance Specifications for Pneumatic Power

Quality of Air : Oil free

Flow rate : 90 to 400 PPM at suction pressure 14.7 psia and

suction temperature of 25°C.

Discharge pressure : 56 psia

Discharge temperature: 200 deg. C working.

AC PACK (when used with onboard ECS)

Flow rate : 90 to 400 PPM at suction pressure 14.7 psia and

suction temperature of 25°C.

Discharge pressure : 45 psia

Capacity

OAT : -20 degrees C to +50 degrees C

Altitude : Up to 3,000 ft

Operates in any weather conditions including rain, snow, hail, fog, wind, sand, &
dust.
Engine

Make : MTU DETROIT / Cummins / Equivalent

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Compressor

Make : GHH–RAND, Germany (CD72S) / MAK / Equivalent

Coupling System

Flange : SAE 0 /1
Coupling : Flexible

Regulation (Microcontroller based)

VARIABLE FLOW AND A CONSTANT PRESSURE OF 3.80 BAR A (56

PSIA) ARE ACHIEVED BY CONTROL OF ENGINE SPEED AND THE
OUTPUT AIR THROUGH A FLOW CONTROL VALVE. THIS MAKES THE
ASU VERSATILE AND UNIVERSAL IN ITS APPLICATION TO BE ABLE
TO START ALL WIDE BODY AIRCRAFT REQUIRING 90 TO 400 PPM
FOR STARTING.

Delivery Hoses

Hose with Coupling : 50 ft (L) x 3 Nos.,

Mode Setting

Air Start Air Conditioning

Output flow 90 to 400 PPM 400 PPM

Output pressure 56 PSIA 45 PSIA

Safety Valve 75 PSIA 75 PSIA

Note : The specification and scope of supply will be as specified and agreed in this offer.
However we keep improving our design constantly. So the layout is subject to change and if you
prefer we could send one after receipt of order for your approval prior to manufacture.