Operation and Maintenance Manual with

Illustrated Parts List for GPU-600

3-Phase Solid State
Transformer-Rectifiers

Series 500082-6xx
28.5 Volts, 600 Amps
OM 2244
12/15/2014 Rev A
OM-2244 / Operation and Maintenance Manual
DCS- 600/ Series 500082 / Solid State Transformer-Rectifiers

Introduction
This manual contains operation and maintenance information for “GPU-600” solid-state Transformer-
Rectifiers manufactured by ITW GSE, Troy, Ohio 45373.

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

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

The manual is divided into five chapters plus an appendix. Each chapter is divided into as many sections as
required. Each new section starts with page 1. Each page is identified by chapter, section and page number,
which are located in the lower, outside corner. When information located in another portion of the manual is
referred to, its location is identified by a chapter, section, paragraph or figure number.

For example: “(see Section 2-3, Paragraph 1.a.)” refers to information located in Chapter 2, Section 3,
Paragraph 1.a. If a chapter and section are not indicated in a reference, the referenced material is located in
the same section as the reference, for example: “(see Paragraph 1.a.).”

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

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

Contents of the manual is arranged as follows:

Chapter 1. Description/Operation

Chapter 2. Servicing/Troubleshooting

Chapter 3. Overhaul/Major Repair

Chapter 4. Illustrated Parts List

Chapter 5. Manufacturer’s Literature

Appendix A Options

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

Write: Aviation Ground Equipment Corp.

53 Hanse Avenue
Freeport, NY 11520

Call Inside U.S.A./Canada: (800)758-0044

Call From Foreign Countries: (516)546-0003

FAX inside U.S.A. (516)546-0198

E-Mail: [email protected]

[email protected]

Web Page: www.aviationgroundequip.com

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Safety Warnings and Cautions

WARNING
ELECTRIC SHOCK can KILL. Do not touch live electrical parts.
ELECTRIC ARC FLASH can injure eyes, burn skin, cause equipment damage, and
ignite combustible material. DO NOT use power cables to break load. Prevent tools
from causing short circuits.

IMPROPER PHASE CONNECTION, PARALLELING, OR USE can damage this and

attached equipment.

IMPORTANT Protect all operating personnel. Read, understand, and follow all instructions in the
Operating/Instruction Manual before installing, operating, or servicing the equipment.
Keep the manual available for future use by all operators.

1) General
Equipment that supplies electrical power can cause serious injury or death, or damage to other equipment or
property. The operator must strictly observe all safety rules and take precautionary actions. Safe practices
have been developed from past experience in the use of power source equipment. While certain practices
below apply only to electrically-powered equipment, other practices apply to engine-driven equipment, and
some practices to both.

2) Shock Prevention
Bare conductors, terminals in the output circuit, or ungrounded, electrically-live equipment can fatally shock a
person. Have a certified electrician verify that the equipment is adequately grounded and learn what terminals
and parts are electrically HOT. Avoid hot spots on machine. Use proper safety clothing, procedures, and test
equipment. The electrical resistance of the body is decreased when wet, permitting dangerous currents to
flow through it. When inspecting or servicing equipment, do not work in damp areas. Stand on a dry rubber
mat or dry wood, and use insulating gloves when dampness or sweat cannot be avoided. Keep clothing dry,
and never work alone.

a) Installation and Grounding of Electrically Powered Equipment

This equipment must be installed and maintained in accordance with the National Electrical Code,
ANSI/NFPA 70, or other applicable codes. A power disconnect switch or circuit breaker must be
located at the equipment. Check the nameplate for voltage, frequency, and phase requirements. If
only 3-phase power is available, connect any single-phase rated equipment to only two wires of the 3-
phase line. DO NOT CONNECT the equipment grounding conductor (lead) to the third live wire of the
3-phase line, as this makes the equipment frame electrically HOT, which can cause a fatal shock.

Always connect the grounding lead, if supplied in a power line cable, to the grounded switch box or
building ground. If not provided, use a separate grounding lead. Ensure that the current (amperage)
capacity of the grounding lead will be adequate for the worst fault current situation. Refer to the
National Electrical Code ANSI/NFPA 70 for details. Do not remove plug ground prongs. Use correctly
mating receptacles.

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b) Output Cables and Terminals

Inspect cables frequently for damage to the insulation and the connectors. Replace or repair cracked
or worn cables immediately. Do not overload cables. Do not touch output terminals while equipment
is energized.

3) Service and Maintenance

This equipment must be maintained in good electrical condition to avoid hazards stemming from
disrepair. Report any equipment defect or safety hazard to the supervisor and discontinue use of the
equipment until its safety has been assured. Repairs should be made by qualified personnel only. Before
inspecting or servicing this equipment, take the following precautions:

a) Please lock-out and Tag procedure, Shut off all power at the disconnecting switch or line breaker
before inspecting or servicing the equipment.

b) Lock switch OPEN (or remove line fuses) so that power cannot be turned on accidentally.

c) Disconnect power to equipment if it is out of service.

d) If troubleshooting must be done with the unit energized, have another person present who is trained
in turning off the equipment and providing or calling for first aid.

4) Fire And Explosion Prevention

Fire and explosion are caused by electrical short circuits, combustible material near this equipment, or
unsafe operating conditions. Overloaded or shorted equipment can become hot enough to cause fires by
self destruction or by causing nearby combustibles to ignite. For electrically-powered equipment, provide
primary input protection to remove short circuited or heavily overloaded equipment from the line.

5) Bodily Injury Prevention

Serious injury can result from contact with live circuit components inside this equipment. Shut DOWN this
equipment for inspection and routine maintenance. When equipment is in operation, use extreme care in
doing necessary troubleshooting and adjustment.

6) Medical and First Aid Treatment

First aid facilities and a qualified first aid person should be available for each shift for immediate treatment
of all injury victims. Electric shock victims should be checked by a physician and taken to a hospital
immediately if any abnormal signs are observed.

EMERGENCY
FIRST AID CALL EMERGENCY RESCUE SQUAD IMMEDIATEL. Seek additional assistance. Use
First Aid techniques recommended by American Red Cross until medical help arrives.

IF BREATHING IS DIFFICULT, give oxygen, if available, and have victim lie down.

FOR ELECTRICAL SHOCK, turn off power. Remove victim; if not breathing, begin
artificial respiration, preferably mouth-to-mouth. If no detectable pulse, begin external
heart massage.

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7) Equipment Precautionary Labels

Inspect all precautionary labels on the equipment monthly. Order and replace all labels that cannot be
easily read.

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Table of Contents

Chapter 1 Description/Operation Chapter-Section/Page#

Section 1 Description 1-1/1

General 1-1/1
Optional Equipment - Appendix A 1-1/1
Orientation 1-1/1
Mountings for the GPU 1-1/1
Safety Features 1-1/3
Theory of Operation 1-1/4
Detailed Description of GPU-600 Components 1-1/4

Section 2 Preparation for Use, Storage or Shipping 1-2/1

Receipt and Inspection of Equipment 1-2/1
Unpacking the Unit 1-2/1
Operating Location Selection 1-2/1
Input Cable Selection 1-2/1
Installation 1-2/2
Preparation for Storage 1-2/6
Preparation for Shipment 1-2/6

Section 3 Operation 1-3/1

General 1-3/1
Operation Preparation 1-3/1
Operation Procedure 1-3/1
Voltmeter 1-3/2
Output Current Limit 1-3/2

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Chapter 2 Servicing / Troubleshooting Chapter-Section/Page#

Section 1 Troubleshooting 2-1/1

General 2-1/1
Troubleshooting 2-1/2
Equipment for Troubleshooting 2-1/2
Voltages of Interest 2-1/3
SCR Malfunction Instructions 2-1/3
Troubleshooting Tables 2-1/5

Section 2 Calibration and Test of PC Control Board 2-2/1

General 2-2/1
Circuit Board Components 2-2/1
Test Procedure 2-2/5
Circuit Board Calibration 2-2/6

Section 3 Scheduled Maintenance 2-3/1

General 2-3/1
Maintenance Schedule 2-3/1
Inspection During Operation 2-3/2
Preparation for Internal Inspection 2-3/2
Internal Inspection 2-3/2
Lubrication 2-3/3
Inspection Records 2-3/4

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Chapter 3 Overhaul / Major Repair Chapter-Section/Page#

Unscheduled Repair 3-1/1

General 3-1/1
Service Information and Factory Repair 3-1/1
Converter Removal and Replacement 3-1/2
Component Removal and Replacement 3-1/2

Chapter 4 Illustrated Parts List Chapter-Section/Page#

Section 1 Introduction 4-1/1

General 4-1/1
Purpose 4-1/1
Arrangement 4-1/1
Explanation of Parts List 4-1/1

Numerical Index 4-1/3

Explanation of Numerical Index 4-1/3

Section 2 Manufacture's Codes 4-2/1

Explanation of Manufacture's (Vendor) Code List 4-2/1

Section 3 Illustrated Parts List 4-3/1

Explanation of Parts List Arrangement 4-3/1
Symbols and Abbreviations 4-3/1
Figure 1: Final Assembly 4-3/2
Figure 2: Internal Components – Part 1 4-3/4
Figure 3: Internal Components – Part 2 4-3/6
Figure 4: Base Assembly 4-3/8
Figure 5: Front Panel Assembly 4-3/10
Figure 6: Interior Panel Assembly 4-3/12
Figure 7: SCR Output Rectifier Assembly 4-3/14

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Chapter 5 Manufacture's Literature

Appendix A

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Chapter 1 Description/Operation
Section 1 Description
1) General
The GPU-600 Solid State Transformer-Rectifiers covered by this manual are manufactured by ITW GSE,
Troy, Ohio 45373. These Transformer Rectifiers (GPUs) are designed to provide ground power for
maintenance and startup of aircraft having 28-VDC electrical systems.
The number 500082 identifies the “model or series” of the GPU. The part number is followed by a
different dash number, which separates the basic units available. The criteria for input voltages, Amps,
and frequencies change with each dash number. Figure 1 uses the part number to identify the variations
possible covered by this manual.

Part & Dash CE Input Input Output Output

Mounting
Number Certified Voltage Frequency Voltage Current
DCS600T60208 Trailer -- 220/230/460 60 Hz. 28.5 VDC 600 A
DCS600T50380 Trailer -- 220/380 50 Hz. 28.5 VDC 600 A
DCS600T6O575 Trailer -- 230/460/575 60 Hz. 28.5 VDC 600 A
DCS600T50380CE Trailer Y 220/380 50 Hz. 28.5 VDC 600 A
DCS600S60208 Stationary -- 208/230/460 60 Hz. 28.5 VDC 600 A
DCS600S50380 Stationary -- 220/380 50 Hz. 28.5 VDC 600 A
DCS600S50380CE Stationary Y 220/380 50 Hz. 28.5 VDC 600 A
DCS600B60208 Bridge 220/230/460 60Hz 28.5 VDC 600 A
DCS600B60380 Bridge 220/380 60HZ 28.5 VDC 600 A

Figure 1 Series 500082 Transformer-Rectifier Part Number Descriptions

2) Optional Equipment - Appendix A

Chapters 1 through 5 of this Operation and Maintenance Manual identifies only the basic version of a
Series 500082 GPU. Component differences between the different machines will be listed when
necessary. A list of optional equipment, which make this manual unique to the GPU that you have
purchased, appears in Appendix A. An example of an item located Appendix A would be a cable basket
option.

3) Orientation
To avoid confusion in the location of components, the control panel is considered to be the front of the
unit. Left and right are determined by looking at the unit from the front.

4) Mounting for the GPU

As a standard, the Transformer-Rectifier GPU-600 is mounted on three wheels with a caster style front
th
wheel serving as a pivot point for easy maneuverability (i.e. 5 wheel). The GPU-600 can also be
mounted stationary as well as mounted on a boarding bridge with the optional bridge mount bracket.

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7
11

12
6

10

1
2
3

1. Mounting Base 7. Top Panel

2. Rear Wheels 8. Side Panel (Right Side Shown)
3. Front Caster 9. Cable Storage Basket [Option Only]
4. Front/Control Panel 10. Output Cable
5. Rear Panel [Not Shown] 11. Pull Handle
6. Cable Hanger 12. AC Power Receptacle

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Assembly of GPU-600 Power

ELECTRICAL DATA
MODEL 6T28-600CL 5T28-600CL 6T28-600CL
DCS600T60208 DCS600T50380 DCS600T6O575
SPECIFICATION NUMBER DCS600S60208 DCS600T50380CE DCS600B60380
DCS600B60208 DCS600S50380CE DCS600S50380
INPUT
Voltage 208 / 230 / 460 220 / 380 230 / 460 / 575
Amps 86 / 78 / 39 82 / 47 79 / 39 / 32
Frequency 60 50 60
Phase 3 3 3
Convenience Receptacle 10A / 115V / 60 Hz 10A / 220V / 50 Hz 10A / 115V / 60 Hz
For ground cable size See Section 2, Figure 1
OUTPUT
D.C. Voltage 28.5 28.5 28.5
Amps 600 600 600
Duty Cycle 100% 100% 100%
Kilowatts 17.1 17.1 17.1

PHYSICAL / DIMENSIONS
Model Length Width Width Height Weight
(overall) (case) (overall) (w/o cable basket) (overall)
Trailer 45.7 inches 24.1 inches 33 inches 35 inches 650 lbs.
(116.1 cm) (61.3 cm) (83.8 cm) (88.8 cm) (295 kg)
Stationary 35.1 inches 24.1 inches 33 inches 29.3 inches 600 lbs.
(89.2 cm) (61.3 cm) (83.8 cm) (74.5 cm) (272 kg)
Bridge 36 inches 24.1 inches 34.4 inches 59.8 inches
(91 cm) (61.3 cm) (87.3 cm) (151.9 cm)

Figure 3 Specifications and Capabilities

5) Safety Features
The GPU continuously monitors output values and automatically shuts down if a fault occurs in order to
minimize risks to the user, the aircraft, and the GPU.

See Sub-section 7, “Detailed Description of GPU-600 Components”, for details on the types and levels of
protection provided by the control system.

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6) Theory of Operation
The GPU provides regulated 28.5V DC. Power to the GPU is provided from the local utility company,
through the input contactor. The output contactor, controlled by the Output Switch, connects DC power to
the load.

The 28V DC power supply consists of a simple and reliable step-down transformer (1, Figure 5) whose
output is rectified by six silicon-controlled rectifiers (SCRs) (3, Figure 7) in a full-wave, center tapped
configuration. A filter consisting of an inductor and capacitors produces a low ripple DC voltage.

The printed circuit board (PC Board) (9, Figure 5) regulates the output voltage by controlling the SCR
turn-on. It does this via the phase control method; which uses the SCRs to select the desired portion of
the voltage that has been stepped down by the main transformer to produce the DC voltage. The PC
Board also provides current limiting, over-voltage and overload protection for loads connected to the DC
output. This output is floating (isolated from chassis ground), eliminating any grounding problems
between the load and the chassis ground.

CAUTION
Capacitor charge can injure! Allow capacitors to discharge fully and verify capacitor
discharge with voltmeter before touching the capacitor circuitry.

7) Detailed Description of GPU-600 Components

a) Front Panel Control Components (See Figure 4)

(1) Front Panel

The GPU operator controls mount directly to the front panel.

(2) Convenience Receptacle ( Figure 4 Item 2)

The convenience provides AC power from a secondary winding on the transformer. The output
voltage is 115 VAC for the 60 Hz units and 220 VAC for the 50 Hz units. The receptacle has a
weather cover and an MOV surge suppressor.

(3) Starting Current Control (Figure 4 Item 3)

The R13 starting current potentiometer can select any initial or starting current from 200 amperes
to a maximum of 2000 amperes. The GPU limits the output current by lowering the output voltage
for loads that draw more than the specified current.

(4) Receptacle Fuse (Figure 4 Item 4)

This front-panel fuse protects the convenience receptacle. It is rated at 10 amps.

(5) DC Voltmeter
The M2 output voltmeter ( Figure 4 Item 5) measures the DC output voltage across the main filter
capacitors. The scale has a 50 V DC maximum reading.

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1 3 6 5

8 10
4
9 11

2 7

1. Front Panel 7. DC Ammeter

2. Convenience Receptacle (115 VAC Shown) 8. Input Power Light (amber)

3. Starting Current Control 9. Output Contactor Light (green)

4. Receptacle Fuse 10. Input Power On-Off Switch

5. DC Voltmeter (M2) 11. Output Contactor Close-On-Off Switch

6. Overload/Overvoltage Light (red)

Figure 4 Front Panel Assembly of GPU-600

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(6) Overload/Overvoltage Light (Figure 4 Item 6)

The overload/overvoltage trip light turns on whenever one of the following system faults occur:
 The output voltage has exceeded 31.5 V DC.
 The output current has exceeded 2125 to 2200 A DC.
This light is an LED assembly.

(7) DC Ammeter (Figure 4 Item 7)

The DC ammeter has a 0 to 2000-amp scale. It actually measures the mill volt drop across the
R11 ammeter shunt that corresponds to the scale calibration. The scale range is so much more
than the rated output because the unit is capable of providing much more current for short
durations (engine starts).

(8) Input Power Light (Figure 4 Item 8) (amber)

This light is connected across the coil of the contactor, so it turns on when that contactor has
been energized.

(9) Output Contactor Light (Figure 4 Item 9) (green)

This light is connected across the coil of the output contactor, so it turns on when that contactor
has been energized.

(10) Input Power On-Off Switch (Figure 4 Item 10)

This switch turns the input contactor on and off. The control transformer T2 supplied power to the
input contactor coil through this switch and fuse F8. The input contactor connects the input power
to the power transformer primary windings through the voltage changeover board.

(11) Output Contactor Close-On-Off Switch (Figure 4 Item 11)

The S2 output contactor close-on-off switch has a spring loaded up position for the “close” mode,
a middle position for “on” mode, and a bottom position for the “off” mode. The output contactor
connects the DC output power to the output cable. To turn the output contactor on, move the
output contactor switch to the “close” position and then release it to the center “on” position. To
turn the output contactor off, move the output contactor switch to the “off” position.

(12) Emergency Stop Switch (CE certified units only – not shown)
This switch is located in the lower right corner. Press to shut off the GPU.

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b) Control Board ( Figure 5 Item 9)

The control board mounts inside the GPU, on a steel panel behind the left side panel. This circuit
board controls for the following functions:

(1) Electronic Overvoltage/Overload Protection Circuit

The control board turns off the power supply and turns on the DS2 red overload trip light on the
front panel if more than 31.5 V DC or 2125 A overload exists. To reset, correct the cause of the
condition and then turn the input switch off and back on.

(2) Electronically Controlled Current Limit

The starting current or output surge current is selected by adjusting R13 starting current control
on the front panel from the minimum 200 A DC to the maximum 2000 A DC.

CAUTION Excess starting current may cause damage to load, blow fuses or damage the power
supply. Contact the factory if you require a current limit lower than the 150 A DC
standard minimum limit.

(3) Regulated DC Output Voltages

The voltage value is continuously compared to the actual output. If adequate input voltage exists,
deviation from the desired voltage output is corrected by the change in SCR conduction time set
by the printed circuit board firing pulse output. This corrective action is done quickly because the
control is done electronically with only limited stored energy in the circuitry. Typical response time
is about 25 milliseconds.

(4) Thermal Overload Protection

Normally Closed, open on over temperature.
The control board turns off the SCR firing or gate pulses when the S5 overload thermostat (item
18 in Figure 5) opens. The power supply cannot produce any DC output until the S5 thermostat
cools enough to automatically reset (close).

c) Main Transformer ( Figure 5 Item 1)

The main power transformer is a forced air-cooled, core-type, three-phase unit that reduces the rated
input voltage or voltages to a voltage somewhat higher than the maximum rated output voltage. The
extra voltage for the output provides a reserve capability to compensate for under voltage on the input
circuit, for the higher IR voltage drop found as the transformer, cables and other components heat up
with load and ambient temperature rises.

The main transformer in the GPU supplies power for the DC output and powers the auxiliary output
receptacle and the fan. The main transformers for the 60 Hz. units have windings to provide 115 VAC
for the auxiliary power receptacle and fan motor. The main transformers for the 50 Hz. units have
windings to provide 220 VAC winding for its auxiliary power receptacle and a 110 VAC winding for the
fan motor.

The main transformer has a center tapped coil on each phase that provides six fused (F2-F7) sensing
or synchronizing voltage signals to the solid state printed circuit control board ( Figure 5 Item 9). Be
certain to follow the changeover diagram for both the main transformer and the control transformer (
Figure 5 Item 6) for the input voltage you have available.

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CAUTION Improper connections will cause damage. Contact factory if your equipment
specification information and/or voltage changeover diagram does not agree with your
rated three-phase input voltage.

9 8 10 15 13

12
17
11

5 14

20 19

3 18

2 1 7 6 16
1. Power Transformer (T1) 11. Front Panel
2. Capacitors (C15, C16, C17) 12. Voltage Changeover Board
3. 28.5 VDC Output Contactor (K2) 13. SCR Heat Sink Assembly
4. Pre-load Resistor Assembly (R2, R3, R4) 14. Fan Blade
5. Choke (L1) 15. Fan Motor (B1)
6. Control Transformer (T2) 16. Feedback Shunt (R12)
7. Interior Panel 17. Fan Turn-on Thermostat (S4)
8. Fuse Block (F2 through F7) 18. Overload Thermostat (S5)
9. Printed Circuit Board (A1) 19. Fan Fuse (F1)
10. Line Contactor (K1) 20. Ammeter Shunt (R11)
Figure 5 Internal Components of GPU-600

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22 23 24 7 8 9 10 11

2
12
1
25
3 6
4 14
5

21 26

20 15

13 19 18 17 16

1. TP1 SCR Gate Pulse from R10 Adjustment 14. R60 Overload Limit (TP20)
2. TP2 SCR Gate Pulse from R9 Adjustment 15. R109 28 V DC Output Calibration (TP13)
3. R9 Balance Adjustment Phase 2 (TP2) 16. R101 5 V Reference Volt Adjustment (TP19)
4. R10 Balance Adjustment Phase 3 (TP1) 17. R102 Voltage Slope Adjustment (TP17)
5. TP8 Balance SCR Gate Pulse Phase1 18. TP19 Reference Volt Test Point (R101)
6. R38 No Load Amp Off Set Null (TP14)* 19. TP17 Voltage Slope Test Point (R102)
7. R37 Over-voltage Trip Point 20. TP15 Common, PC Board Volts
8. TP3 PC Board Common 21. TPF SCR Gate Pulse Timer
9. TP4 +9.1 VDC Timer Voltage 22. TPE Gate Timer Output Phase 2
10. TP5 +15 V Regulated Voltage 23. TPD Gate Timer Output Phase 3
11 TP6 –15 V Regulated Voltage 24. TP13 Actual Output Volt (28.5 or 14.25)
12. TP7 +24 V Non regulated Voltage 25. TP20 Overload Limit (R60) Adjustment
13. TP14 Null at 0 A DC TP (R38)* 26. TPL Overload Trip Summing Point
* Note TP14 provides amplified load amp reading for comparison with overload limit (TP20) and starting
amperage limit (TP21) set by R13 control on front panel.

Figure 6 Solid State Printed Circuit Control Board Test Points of GPU-600

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The 1 amp, F2 through F7 fuses (8, Figure 5) are located near the control board behind the left side
panel. These fuses are accessible by removing the top panel.

d) Control Transformer ( Figure 5 Item 6)

The small control transformer located on the interior panel (7, Figure 5) provides 115 V AC to the K1
(10, Figure 5) input contactor coil, input contactor light A (12, Figure 4), and S1 (10, Figure 4) input
contactor switch via the half amp F8 contactor fuse (located on the control transformer). This
transformer does not provide the 10A, 115 VAC auxiliary power.

WARNING Electric shock can kill! Disconnect input power at the source to remove voltage to the
control transformer, input fuses and contactor.

e) Auxiliary Power Circuitry

The single-phase auxiliary power receptacle ( Figure 4 Item 5) has the same frequency as the
primary input voltage. It is protected by the F9 fuse ( Figure 4 Item 11), located on the front panel,
typically 10 Amperes. The auxiliary power circuitry is turned off whenever the primary contactor is
open or off. The auxiliary power winding is typically located on the middle leg (B phase) of the main
transformer. It provides power to the receptacle (5, Figure 4) and to the fan motor via the S4 fan turn-
on thermostat. The fan thermostat saves energy and reduces internal dust accumulation by allowing
the fan to run only when necessary to prevent overheating.

A “MOV” voltage surge suppressor, RV1 (6, Figure 4), is installed across the receptacle terminals to
reduce voltage surge problems to the load equipment and the power source.

f) Output Contactor Circuitry

Output contactor K2 ( Figure 5 Item 3) is operated by the output contactor ON-OFF switch S2 ( Figure
4 Item 11). Placing this switch momentarily in the TOP (spring-loaded) position turns the output
contactor ON, and placing it in the DOWN position turns the output contactor OFF.

The positive output lead is to be connected to the positive output terminal of the K2 contactor. The
negative output lead is to be connected to the R11 ammeter shunt. A small notch has been made in
the bottom of the right and left side panels to allow the output cable assembly to pass out either side.

The S5 normally-closed overload thermostat (18, Fig. 5) mounted on the main SCR rectifier heat sink
is designed to remove the output command signal whenever the heat sink temperature rise becomes
too high from overload, loss of cooling air flow, etc. The thermostat automatically resets on cool
down.

g) Output Filter Circuitry

The DC output voltage is smoothed (filtered) by an L-C filter made up of L1 iron core reactor (4,
Figure 5) carrying the output current to the load and the ripple current to the C15, C16, C17
capacitors (2, Figure 5) in parallel with the load terminals. The R2, R3, R4 bypass resistors (4, Figure
5) provide both a pre-load to the SCR devices and a safety discharge circuit for quickly discharging
the filter capacitors whenever the power supply is turned off.

Note: The 50 Hz. units have an additional capacitor in this circuit.

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CAUTION Capacitor charge can injure. Be sure capacitors are discharged before touching.

The CR7 flyback diode (9, Figure 7) acts to facilitate discharge of the output filter circuitry as well as
to protect the main SCR rectifier assembly from damaging reverse voltage spikes.

h) Main SCR Heat Sink Assembly (See Figure 7)

The main SCR heat sink assembly is mounted on the front of the rear panel. It surrounds the 115 V
AC cooling fan assembly for optimum cooling efficiency. The SCR heat sink consists of a formed
aluminum heat sink with 6 “hockey puck” silicon controlled rectifiers (3, Figure 7) held by 6 insulated
compression spring assemblies (2, Figure 7), held against it by 12 U-shaped aluminum heat sinks (4,
Figure 7) for the “SCR” device cooling. There are two snubber pc board assemblies for SCR gate
signal control and protection (10, Figure 7), and the associated insulators, thermostats and hardware.

The solid-state printed circuit board (9, Figure 5) provides a properly timed and sequenced turn on
signal to the silicon controlled rectifiers that must be conducted to provide the desired output.

If the output voltage is too high or if the output current is above the limit set by controls such as the
R13 starting potentiometer, the control board delays the SCR turn-on signal to allow less SCR device
conduction time for a corresponded lower output. Conversely, if the output voltage is too low, the
SCR turn-on signal is delivered earlier in the possible conduction time for each SCR; thereby,
allowing more power to be supplied because of the longer conduction time. Proper operation of the
SCR devices requires phase sequence and presence of all 6 voltage sensing signals, proper phase
sequence and presence of the output voltage to the SCR devices, and the proper magnitude and
sequence of the SCR turn-on signal to the SCR gate leads.

i) Thermostatically Controlled Fan ( Normally open closes on rise of temperature)

The 115 V AC fan motor ( Figure 5 Item 15) does not run until the SCR heat sink gets hot enough to
turn on the S4 thermostat ( Figure 7 Item 6). This feature can reduce the need for internal power
supply cleaning and the use of electricity.

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6 2 5
2 2

10 4
7 7
8

9 1
3,11

1. Rectifier Heat Sink 7. Rectifier Mounting Insulator

2. SCR Mounting Clamp 8. Feedback Shunt (Not Shown) (R12)
3. Silicon Rectifier (CR1 through CR6) 9. Positive Base Silicone Diode (CR7)
4. SCR Heat Sink 10. Surge Suppressors (A2, A3)
5. Overload Thermostat (S5) 11. Pin Spring
6. Fan Turn-on Thermostat (S4)

Figure 7 SCR Heat Sink Assembly of GPU-600

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Section 2 Preparation for Use, Storage, or Shipping

1) Receipt and Inspection of Equipment
The GPU has been thoroughly inspected and tested at the factory and prepared for shipment in
accordance with standard industrial practices for safe shipment. Upon receiving this equipment, inspect it
as follows.

a) Visually inspect the shipping crate for damage. If any damage is detected, request that the carrier
agent inspect the shipment and note the damage on the delivery receipt. This is for your protection.

b) If there is no obvious damage to the shipping crate, unpack the unit as follows:

2) Unpacking the Unit

a) Remove the crate. Take care to avoid damage to the equipment if bars, hammers, etc. are used in
unpacking. Remove all unused hardware from the unit.

b) Visually inspect the unit for evidence of external damage such as damaged sheet metal, scratches,
dents, etc. Check also for loose connections and components. If the equipment has been damaged
in transit, file a claim for damage at once. If you require assistance with a damage claim, furnish ITW
GSE with full information about the claim.

NOTE: Save the shipping container until the unit has been put into service and determined to be
operating correctly.

3) Operating Location Selection

For best operating characteristics and longest unit life, select an installation site that is not exposed to
high humidity, dust, high ambient temperature, flooding, or corrosive agents. Moisture can condense on
electrical components, causing corrosion or shorting circuits. Dirt on components helps retain this
moisture in addition to providing a conducting material.

Adequate air circulation is needed at all times in order to assure proper operation. Provide a minimum of
12 inches (305mm) of free air space at both the front and rear of the unit. Make sure that the ventilator
openings are not obstructed. The unit should not be installed on a grade greater than 10°.

4) Input Cable Selection

Figure 1 shows input cable size requirements for GPU units covered by this manual. This information is
from the U.S. National Electrical Code ANSI/NFPA 70. Install this equipment per the latest edition,
available from the National Fire Protection Association (www.nfpa.org). The customer must also furnish a
suitable means to safely disconnect power from the GPU.

The GPU has a large inrush current when it is first turned on, much like a large electric motor. Therefore,
to avoid falsely tripping the supply line circuit breaker or fuse, the circuit breaker or fuse should be the
type used with electric motors.

Any problems consult our Service Department

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COPPER LINE WIRE SIZE

LINE
RATED In Conduit In Flexible Cable
VOLTS
(*) (**)
208 86 No. 3 AWG No. 4 AWG
220 82 No. 3 AWG No. 4 AWG
230 78 No. 3 AWG No. 4 AWG
380 47 No. 6 AWG No. 8 AWG
460 39 No. 8 AWG No. 8 AWG
575 32 No. 8 AWG No. 8 AWG

* Conductor sizes listed are for 30 feet or less of each conductor in conduit and for copper conductors having
90º C insulation, such as type FEB, FEPB, RHH, and THHN as based on an ambient temperature of 50° C.
For conductors having other insulation, or for conductors longer than 30 feet, consult local electrical code for
the required conductor size.
** Conductor sizes listed are for 30 feet or less of each conductor in conduit and for copper conductors having
90º C insulation, such as type W, SC, SCE, SCT, PPE, G, and G-GC as based on an ambient temperature of
50° C. For conductors having other insulation, or for conductors longer than 30 feet, consult local electrical
code for the required conductor size.

Figure 1 Recommended Wire and Fuse Size Table

5) Installation
A ITW GSE GPU requires no additional preparation in order to supply power to an aircraft. It needs only
to have its input cable connected to an appropriate source of power and its output cable connected to an
aircraft. Proceed as follows for putting the GPU unit into service.

WARNING
The method of installation, conductor size, and over-current protection shall conform
to the requirements of the local electrical code, the national electrical code, or other
national codes, as applicable. Qualified persons shall do all installation wiring and
machine reconnection.

WARNING
Electric shock can kill! Open the disconnect switch, or breaker, and determine that no
voltage is present before removing top canopy and connecting wires between the
input service and power supply or working on the power supply.

a) Locate the Cable Entry Locations

Input and output cable entrance shall be made through the cable entrance holes provided in the GPU
cabinet.
The GPU has an 1.75” diameter entry hole for the input cable on the rear of the unit. The customer is
responsible for supplying a suitable cable clamp.
The GPU canopy has slots on the side for the output cable. A cable clamp holds the output cable to
the unit base.

Please contact the Service Department if you have any problem with this
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b) Verify the Input Voltage Configuration

The GPU may be configured for various input voltages, depending on the specific model
(specification number). The factory pre-configures each unit before shipment according to the
customer specifications for the input voltage. While the GPU is open for connecting cables, verify the
voltage configuration. Figure 2 shows the interior panel as viewed from the right side of the GPU.

Input Power Contactor

Voltage Changeover Control Transformer TR

Board

Figure 2 Input Voltage Configuration Locations

On the left is Voltage Changeover Panel, which sets the input voltage for the main transformer. On
the right is the control transformer, which has different taps for the various input voltages.

(1) Make sure the GPU is not connected to the electrical service.
(2) Remove the top cover.
(3) Locate the items pictures in Figure 2.
(4) Refer to Sheet 6 of the schematic diagram, which is located in Chapter 5 of this manual.
(5) Verify that the configuration matches the appropriate diagram on the schematic.

CAUTION
Reconnection of control transformer as well as main input connection panel must be
made when changing rated input voltage. See changeover diagram.

Changing the voltage configuration requires changes to main transformer T1 configuration on the
Changeover Board and changes to control transformer T2 by moving a yellow wire to a different tap
on the right side of the transformer. (See Figure 2)

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If it is necessary to change the configuration, follow these steps:

(1) On the T1 Changeover Board, move the jumper links as shown on the diagram for your voltage
requirement.
(2) On the right side of control transformer, move the yellow wire to the tap specified in the diagram.

c) Connect the Input Cable to the GPU

(1) Route the cable through the hole provided in the rear panel.
(2) Connect the three-phase line leads to input terminals on line contactor, which is located on the
interior panel inside the power supply cabinet.
(3) Be certain that the cable will not contact the fan or hot parts on the SCR heat sink assembly.
(4) Attach the equipment ground conductor to the stud provided adjacent to the contactor.

WARNING
To help protect against electrical shock from line voltage or static discharge, make
sure the GPU is grounded.

Figure 3 Input Contactor

NOTE: After connecting the input cables, it is recommended that ITW GSE # 904021 urethane coating
be sprayed on the connections at the contactor to protect these connections from corrosion,
fungus, and contamination. Spraying these connections will also reduce the potential for arcing
from dirt and condensation.

d) Connect the Input Cable to the Utility Service

Before connecting input cables to the power supply service, check voltage, amperage and phase
ratings of the service. Make certain that the capacity of the service is adequate for the power
requirements of the unit being connected to it. Make certain that the service used as the source of
input power is grounded. Refer and conform to your local electrical code when selecting and
installing power supply service.
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(1) Make sure electrical service is off.

(2) Connect the input power cables to the input power source.
(3) Connect the grounding conductor to a proper ground.
(4) Leave the electrical service turned off.

e) Connect the Output Cable

Wheel-mounted GPUs are generally shipped with the output cable already installed. For bridge-
mount or stationary GPUs, the customer must supply and connect the output cable. To connect the
output cable, follow these steps:
(1) Route the cable through the side panel and under the cable clamp.
(2) Connect the positive output lead to the positive output terminal of Output Contactor K2.
(3) Connect the negative output lead to Ammeter Shunt R11.
(4) Tighten the cable clamp.

Figure 4 Output Connections

f) Check GPU No-Load Operation

A no-load check should be made before the GPU is connected to an aircraft. Proceed as follows.
(1) Replace the top panel.
(2) Apply input power to the GPU from the input power source.
(3) On the front panel of the GPU, turn on the input power switch.
(4) Verify that the amber input power light turns on.
(5) Hold the output contactor switch up in the “Close” position until the green output contactor light
turns on.
(6) Release the output contactor switch to the middle “On” position.
(7) Verify that the voltmeter shows the proper voltage.
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(8) Using a handheld voltmeter, verify that voltage is present at the aircraft connector.
(9) Turn off the GPU.

The unit is now available for regular service.

6) Preparation for Storage

a) General

(1) The unit should be prepared for storage as soon as possible after being removed from service.

(2) The unit should be stored in a building which is dry and which may be heated during winter
months. The unit shall be stored on a grade no greater than 10°.

(3) Moisture absorbing chemicals are available for use where excessive dampness is a problem.
However, the unit must be completely packaged and sealed if moisture-absorbing chemicals are
to be effective.

b) Temporary Storage

When storing the unit for 30 days or less, prepare as follows:

(1) Use moisture-absorbing chemicals where excessive dampness is a problem. However, the unit
must be completely packaged and sealed if moisture-absorbing chemicals are to be effective.
Seal all openings. Use a waterproof, vapor proof material that is strong enough to resist puncture
damage.

(2) Store the unit in a building which is dry and which may be heated during winter months.

c) Long Time Storage

(1) To protect the GPU’s components, the complete unit should be packaged, using moisture proof
packaging and sealing material. Place containers of moisture-absorbing chemicals, such as silica
gel, in the unit before packaging.

(2) Store the unit in a building which is dry and which may be heated during winter months.

7) Preparation for Shipment

During long shipments, vibration, jolting, etc may loosen the GPU unit’s retaining hardware. Check this
hardware periodically during the shipment to make certain that retaining hardware is secure.

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Section 3 Operation

IMPORTANT
Before attempting to operate the converter, read this entire section to become fully
familiar with how the converter operates.

1) General
This section contains information for safe and efficient operation of the equipment. Operating instructions
are presented in step-by-step sequence of procedures to be followed in supplying 28 V DC to an aircraft
or similar load.

WARNING Electric shock and fire can kill! Read and understand all operating instructions before
attempting to operate the equipment. Operation attempts by untrained personnel can
endanger people, this equipment, and the load. Do not attempt to operate the
equipment for uses not approved by the manufacturer, or at input and output ratings
not listed in the specification table located in 1-1, Figure 3.

The repeated opening of input fuses or repeated functioning of the overload trip circuitry indicates a
misapplication, a faulty main component, or an improper connection or load. Correct the problem by
following the instructions in Chapter 2 before attempting to operate the power supply. Be certain that a
input disconnect means is readily accessible between the power input source and this DC power supply.
You may need to quickly isolate the DC power source from all power during an emergency, fire, or
equipment malfunction.

2) Normal and Bridge Preparation

a) Normal Preparation
(1) Verify input power is disconnected at source.

(2) Verify that the supply-input connections agree with the input voltage available by comparison to
the voltage changeover diagram.

(3) Connect output cable between load and the proper connection points in the DC power supply.

(4) When all covers or panels are in place, turn on the source of input power.

(5) Set R13 start level control knob (1-1, 8, Figure 4) to the output surge limit required for your load.

b) Bridge Preparation

(1) Perform steps a) – e) under Normal Preparation.

(2) Place S1 Input Contactor Switch in ON position (1-1, 10, Figure 4).

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3) Operation Procedure
a) Input Control Functions

(1) Turn on S1 input contactor switch (1-1, 10, Figure 4).

(2) Verify that only the amber input power light (1-1, 12, Figure 4) glows. If the light glows, no

problems exist requiring service.

b) Output Control Functions

(1) Hold the S2 output contactor switch (1-1, 11, Figure 4) in the up “CLOSE” position long enough
for the green output contactor light (1-1, 13, Figure 4) to glow.

(2) Release S2 switch to the middle “ON” position.

(3) Verify that M1 DC ammeter (1-1, 2, Figure 4) does not read excessive amperage.

(4) The DC power supply should continue to deliver power until the S2 switch is placed in the down
“OFF” position or one of the other control functions turn the unit “OFF”.

4) Voltmeter
a) Verify on the M2 DC voltmeter (1-1, 3, Figure 4) that the DC output voltage level is correct. If not, turn
off power supply, disconnect your load, and refer to Service, Chapter 2 for instructions.

5) Output Current Limit

a) If the DC ammeter continuously reads more than 600 A DC after start-up, immediately turn R13
current limit control (1-1, 8, Figure 4) down to continuous operation current point, normally 600 A DC.
This may prevent input fuse blowing and automatic overload trip out.

b) If R13 has no effect or if the output current cannot be decreased to about 200 A DC at the R13
minimum position, a faulty SCR device or control circuit malfunction is indicated requiring power
supply repair. Refer to Chapter 2 for service instructions.

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Chapter 2 Servicing / Troubleshooting

Section 1 Troubleshooting
1) General
The troubleshooting information provided in this section is limited to procedures for determining the cause
of faults and for restoring the GPU to operation after faults develop which shut off the unit.

Calibration, service, and repair are to be done by ITW GSE Service Department personnel, authorized
distributors of ITW GSE equipment, or trained qualified electronic technicians.

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

Write: Aviation Ground Equipment Corp.

53 Hanse Avenue
Freeport, NY 11520

Call Inside U.S.A./Canada: (800)758-0044

Call From Foreign Countries: (516)546-0003

FAX inside U.S.A. (516)546-0198

E-Mail: [email protected]

[email protected]

Web Page: www.aviationgroundequip.com

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2) Troubleshooting
a) Description

The troubleshooting chart lists information under three headings:

 Trouble, symptom, and condition
 Probable cause
 Test, check, and remedy

a) Use of the Troubleshooting Chart

The troubleshooting chart is designed to provide maintenance and repair personnel with a timesaving
guide for locating the source of trouble.

(1) Terminal points (reference applicable schematic and connection diagrams) provide easily
accessible and identifiable test points for checking circuits and electrical components.

(2) Test points are located throughout the circuitry in such a manner that input and output power may
be used for test purposes. Because of these test points and their location, a complete check of
circuitry may be completed very quickly. Therefore, “probable causes” and “remedies” are listed
in a step-by-step sequence which will insure power for testing in all instances where input or
output power may be used with proper safety practices, test equipment, and training experience.

(3) Printed circuit board output troubles should be pinpointed only to determine if the problem is a
board calibration problem or a PC board failure problem. Failure of PC board requires
replacement of the board. Field repair attempts are not recommended.

(4) Always check circuit fuses, circuit breakers and the position of switches first in troubleshooting.
The incorrect positioning of a switch may cause a condition that could be misinterpreted as a
fault.

(5) Electrical component reference designators (such as S1, K2, R10) may be used in the
troubleshooting chart (in parentheses after the item name) to help maintenance personnel identify
parts on the schematic diagrams.

3) Equipment for Troubleshooting

For basic troubleshooting, use a good quality multi-scale volt-ohmmeter (VOM). Troubleshooting erratic,
intermittent, or phase relationship problems requires a good oscilloscope with an isolated neutral
connection.

WARNING
High voltage - electric shock and fire can kill! Exercise extreme care to avoid contact
with high voltage leads and components that could cause serious shock and injury if
touched when troubleshooting or operating the equipment. Stay clear of moving
parts. Locate equipment in a safe environment. Have proper safety equipment
available. Do not attempt operation or repair without adequate training.

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4) Voltages of Interest
a) Across the secondary on all 3 phases - 66 VAC ± 10% *

b) To secondary coil center tap on all phases - 33 VAC ± 10% *

* The ± 10% refers to the possibility of input voltage being out of balance or not at the nominal value.

c) Across the 115 VAC receptacle - 115 VAC (230 VAC on 50hz units) ± 10% *

d) Between X1 and X3 on Fuse Block - 37 VAC ± 10% *

e) Test Point Values for PC board

A control board malfunction will probably result in one or more of the following symptoms:
 loss of output voltage
 inability to produce full load current
 output voltage too high or too low

Section 2-2 shows the circuit board test points and provides standard voltages at those points.

NOTE: The circuit board potentiometers are preset at the factory and should not have to be reset in
the field. If a need arises that would indicate the need for field adjustments, please contact the
factory. The only exception is R109, which adjusts the 28 V output level. If necessary, use this control
to increase the output voltage slightly to compensate for the voltage drop in a long output cable.

5) SCR Malfunction Instructions

a) SCR Failure Symptoms

SCR failure is not common. When they do fail, they generally do so either by shorting or by failing to
turn on.
 Shorted SCRs will generally result in tripping the circuit breaker at the power source. However, a
shorted fly-back diode (on the filter choke input or across the output contactor coil) may also trip
the breaker. This is a severe malfunction.
 If an SCR does not turn on, it may be because it is open or because the gate signal from the
control board is not reaching the SCR.
o If one SCR does not turn on, a very small change will occur at the output, which will be
difficult to notice. The ripple voltage at the output will increase.
o If two SCR’s do not turn on, the ripple current will increase and can cause other problems.
(consult troubleshooting procedure).

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b) Troubleshooting Shorted SCRs and Diodes

WARNING
Electric shock and fire can kill!
 Do not touch energized parts. Always turn off utility power to the unit before
touching anything inside.
 Do not leave the GPU on long enough to overheat or fail in the faulty condition.

(1) Turn off the unit and turn off the input power at the utility source.
(2) Disconnect the leads from the transformer to the heat sink assembly.
(3) Wrap each disconnected transformer lead with electrical tape. Mark each lead to identify it so it
can be reconnected to its proper location.
(4) Check the SCRs and fly-back diodes with the ohmmeter to located shorted devices.
(5) With the SCRs and fly-back diodes disconnected, apply power to the unit. Make sure that the
other components are not the cause of the tripped breaker.
(6) If no problems have been found, check for a device that only breaks down to a shorted condition
when voltage is applied by reconnecting one device at a time.
c) Troubleshooting Excessive Output Ripple
An open gate or an open SCR cannot be checked with a VOM. If an SCR is not firing, the AC ripple
current will increase across the filter capacitors, but that will not blow fuses.
Follow these steps to locate a bad SCR:
(1) Connect an oscilloscope across the unfiltered output:
 Connect the probe of an oscilloscope to the heat
sink
 Connect the isolated neutral of the oscilloscope to
the braid of the fly-back diode.
The output should appear as six evenly spaced pulses
of about the same height. If an SCR is not firing, one of
the pulses will be missing.
Note: if every third pulse is low or missing, check the
balance adjustments, R9 and R10, before attributing
the problem to faulty components.
(2) Disconnect the gate lead for one SCR from the
applicable suppressor board. If the lead disconnection
does not affect the output waveform, that is probably
the bad SCR.
(3) If that SCR was not the source of the problem,
reconnect the gate lead.
Figure 1 Gate Lead Connections
(4) Repeat for other SCRs, one at a time, until the
defective device is located.

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If no Oscilloscope is available: Remove all six service fuses next to the A1 PC board. Keep in mind during
this test only one fuse at a time will be placed in the holder with the with fuses other removed.

CAUTION

 The input power switch should be off whilst removing and installing
each fuse for this Test

Systematically put only one fuse in it’s holder at a time and turn the input power switch on and see if 28.5VDC
Is indicated on the Ground Power Unit Voltmeter. If voltage is present at the voltmeter then that particular
SCR(Diode) is good. Continue putting one Fuse at a time in it’s holder to check if the 28.5 VDC is present at
the voltmeter , do this until all six fuse holders (SCR) have been checked. If a particular fuse placed in its
holder (again no other fuses installed) does not indicate 28.5 VDC the SCR or that circuit has failed.

6) Troubleshooting Tables

Trouble, Symptom, Condition Probable Cause Test, Check, and/or Remedy

Machine Will Not Operate

1. Machine will not start a. The input power is turned OFF Turn the power ON at remote
at remote disconnect switch disconnect switch.
b. Blown fuse in remote disconnect Replace blown fuse. If fuse blows
switch frequently, determine and remedy
the cause.
c. Incorrect input power Check input power connections
connections at machine against appropriate connection
diagram in Chapter 5.
d. Incorrect power input (frequency Check that voltage and frequency
and voltage) of power input for this ground
power unit, according to the rating
on its nameplate.
e. Broken input cable Repair cable as necessary.
2. Line contactor fails to close a. Line contactor fuse F8 blown Replace fuse. Check for cause if
fuse blows frequently.
b. Mechanical obstruction on Remove obstruction.
contactor
c. Defective line contactor switch Replace line contactor switch.
d. Defective coil in line contactor Replace contactor if coil is open or
shorted.
e. Cable broken at line contactor Repair broken cable as necessary.

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3. Line contactor chatters a. Input cables too small or too Use input cables of sufficient
long capability for proper operation of
the machine. Refer to Section 1-2,
Figure 1 for proper cable size to be
used.
b. Faulty contactor coil Check coil voltage. If correct,
replace contactor.
c. Low line voltage Check line voltage. Correct
problem as necessary.

Trouble, Symptom, Condition Probable Cause Test, Check, and/or Remedy

Machine Will Not Operate, continued

4. Contactor operates and trips a. Wrong line voltage Check nameplate of machine for
power source circuit breaker or line voltage to be used. Then
blows fuses measure line voltage. If line voltage
is of improper value, correct this
condition as is necessary to
provide proper voltage input to the
machine.
b. Breaker incorrect size or type or Refer to Section 1-2, Figure 1 for
fuse input current requirements. Make
sure the breaker is appropriate for
a high inrush current – use a
breaker designed for motor starting
applications.
c. Links on voltage changeover Check appropriate voltage
board incorrectly connected changeover diagram in Chapter 5
for proper link positions. Make
correction as necessary.
d. SCR failure or shorted fly-back Refer to detail troubleshooting
diode instructions.
e. Short circuit in primary Remove short circuit.
connections

Trouble, Symptom, Condition Probable Cause Test, Check, and/or Remedy

Unit Turns Off After Starting

1. Unit delivers power but soon a. Power supply overloaded Reduce load, overload can be
shuts down (Thermal overload, carried only for a short time.
electronic overload or over- b. Duty cycle too high Do not operate continually at
voltage circuit trips) overload currents.

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c. Ambient temperature too high Operate at reduced loads when

temperature exceeds 104° F (40°
C) or improve cooling ambient.
d. Ventilation blocked Check that air intake and exhaust
openings are not obstructed.
e. Fan not operating Check fuse F1 on the fan shroud. If
it is good, disconnect the fan motor
leads and apply 115 VAC directly
to fan motor. Replace fan motor if it
fails to operate or if its bearings are
defective.
f. Shorted output Reset electronic overload.
2. Over-voltage/Overload trip a. Control circuit board failure Refer to detail troubleshooting
malfunction is in unit’s internal instructions.
circuitry. b. Loose connections in voltage Check for loose connections.
control circuit Tighten and secure as required.
c. Starting current potentiometer Replace potentiometer.
(R13) open
3. Fan not operating (also see a. Blown fuse (F1) Replace fuse.
causes and remedies under b. Fan control thermostat defective Place a jumper wire across the
“Machine will not start”) overheated thermostat. If fan then
runs, replace thermostat.
Note: A properly operating fan thermostat will turn on the fan at 100°F
and keep the fan running until 80° F is reached at heat sink.
c. Broken lead or connection to fan Repair wiring as necessary.
motor
d. Fan motor defective Disconnect fan motor leads and
apply 115 VAC directly to fan
motor. If it fails to operate, replace
it.

Trouble, Symptom, Condition Probable Cause Test, Check, and/or Remedy

Voltage on GPU Case

1. Operator gets shock when a. Case of machine not grounded Ground machine case to an earth-
machine case is touched type ground if utility ground is
already connected. Connect the
normal safety ground and recheck
if “utility” ground had not been
connected.

Output Current Varies Without Voltage Change

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1. Abnormal current fluctuation, a. Loose cable connections at Check for overheated connections
voltage nearly constant output and tighten.

GPU Will Not Turn Off

1. Contactor fails to open a. Contacts sticking in contactor Clean contacts or replace

contactor, whichever is needed.

No Voltage Output

1. Unit on, but no output voltage a. Protective circuit tripped Determine and correct cause of
trip. Then reset and restart unit.
b. Component failure in protective Find the defective component and
circuit replace it.
c. Control circuit board failure Check control board per Section 2-
2 and replace it if faulty.

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Trouble, Symptom, Condition Probable Cause Test, Check, and/or Remedy

Output Voltage Not Proper Level

1. Poor voltage regulation a. Loose connection of voltage Check connection at output

sensing lead contactor and control circuit board.
Tighten connection as necessary.
2. Output voltage too high (above a. Voltage calibration off Attempt calibration per Section 2-2. If
32 Volts) calibration isn’t possible replace PC
control board.
b. Voltage sensing lead open Repair or replace voltage-sensing
lead.
3. Unstable voltage a. Open filter capacitor Find and replace defective capacitor.
b. One or more SCRs not firing Adjust balance control or replace
properly defective SCR heat sink assembly if
oscilloscope shows faulty SCR
devices. Replace PC control boards
if oscilloscope shows no gate pulse
and the PC control board inputs and
controls are proper except for output.

Trouble, Symptom, Condition Probable Cause Test, Check, and/or Remedy

Output Contactor Fault

1. Output contactor will not close. a. Defective output switch (S2) With the unit turned off, place a
jumper between terminals 2 and 4 on
S2. Turn S1 on. If output contactor
closes, S2 is defective. Replace.
b. Defective input contactor With the unit turned off, place a
auxiliary contacts (K1) jumper between terminals NO 1 and
COM 3 on input contactor. Turn S1
on, and place S2 in Close position.
If output contactor closes, K1 is
defective. Replace.
c. Defective output voltage select With the unit turned off, place a
switch (S103) (if applicable) jumper between terminals 4 and 5 on
S103. Turn S1 on, and place S2 in
Close position. If Output contactor
closes, S103 is defective. Replace.

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d. Defective output contactor Measure voltage between + and –

(K2). terminals on K2 Coil with S1 on and
S2 held in Close position. If 28.5
VDC is present K2 is defective.
2. Output contactor will not stay a. Defective output switch (S2) With the unit turned off, place a
closed. jumper between terminals 1 and 3 on
S2. Turn S1 on, and place S2 in
Close position. If output contactor
stays closed after S2 is released, S2
is defective. Replace.
b. Defective output contactor With the unit turned off, place a
auxiliary contacts (K2) jumper between terminals NO 3 and
NO 4 on output contactor. Turn S1
on, and place S2 in Close position.
If output contactor stays closed after
S2 is released, K2 is defective.
Replace.

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Section 2 Calibration and Test of PC Control Board

IMPORTANT
Before attempting to make tests and adjustments on the GPU, READ THIS ENTIRE
SECTION to become familiar with the proper procedures.

1) General
This section describes the test points, test values, and adjustment locations for testing and adjusting the
printed circuit board that controls the GPU. The control board is mounted on a hinged panel. To access
the board for measurements and adjustments, open the panel so that the board is accessible from the
front of the GPU and you do not have to work next to hazardous voltages.
Use the Test Procedure (Part 3 of this section) to determine if the circuit board is operating properly. ITW
GSE recommends calibration of the PC board at the factory, but the calibration procedure is included in
this section (Part 4) in case field calibration is necessary. Faulty control boards should be returned to the
manufacturer for repair.

WARNING
Electric shock and arcs can kill or injure! Use caution to inspect or test the printed
circuit control board while the equipment is running. The voltages on the printed
circuit board are safe; however, removing the top panel exposes people to
dangerous voltages. When working with the circuit board, rotate the panel out to
move the board away from internal parts.

2) Circuit Board Components

This section is provided to help you locate test points and controls on the circuit board and understand
their functions. Figures 2 and 3 show the locations of test points and adjustment potentiometers for
possible field adjustment. Table 1 shows the functions of the test points and adjustments.

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Figure 2 GPU Circuit Board Components

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Figure 3 GPU Circuit Board Test Points and Controls

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Test Point Function Signal Controlled by:

TP1 SCR Gate Pulse Phase 3 R10
TP2 SCR Gate Pulse Phase 2 R9
TP3 PC Board Common
TP4 +10.0 VDC Timer Voltage
TP5 +15 V Regulated Voltage
TP6 –15 V Regulated Voltage
TP7 +24 V Unregulated Voltage
TP8 SCR Gate Pulse Phase 1
TP13 Actual Output Voltage (28.5 or 14.25) R109 (-28.5 V) or
R110 (-14 V)
TP14 Null at zero output current: provides amplified R38
load amp reading for comparison with
overload limit (TP20) and starting amperage
limit (TP21) set by R13 control on front panel.
TP15 PC Board Common
TP17 Voltage Slope Test Point R102
TP19 Reference Volt Test Point R101
TP20 Overload Limit R60
TP21 Starting Current R13 (front panel)
TPD SCR Gate Timer Output Phase 3
TPE SCR Gate Timer Output Phase 2
TPF SCR Gate Timer Output Phase 1
TPL Overload Trip Summing Point

Table 1 GPU Circuit Board Test Points and Controls

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3) Test Procedure
Follow the table steps in this section to verify that the PC board is functioning properly. If the voltage
readings to the PC board common are not within specification, attempt to correct the reading by adjusting
the applicable control. Be certain the operating conditions are exactly as stated in the table.

If the board does not adjust, check the leads, fuses (F2-F7), and connectors. If no external problems are
found, the PC control board is faulty. Replace it with a known good board.

After replacing the board, recheck the voltages. In some cases, minor adjustments may be required for
optimum calibration. If the replacement board shows the same magnitude of error and lack of adjustment
control, it is possible that the control board is not at fault. The voltages in the following table are all
referenced to pc board common, which is Test Point 3 (TP3) and Test Point 15 (TP15). Connect the
negative voltmeter lead to either of those test points.

TEST TEST TEST VOLTAGE TEST

STEP POINT CONDITION MEASUREMENT DESCRIPTION

Checks (+) voltage regulator output set

1 TP5 Open circuit: no load + 15 VDC ± 5%
by U4.
Checks (-) voltage regulator output set
2 TP6 Open circuit: no load - 15 VDC ± 5%
by U5.
Open circuit: Checks unregulated control voltage
3 TP7 + 24 VDC ± 10%
no load needed for 1 and 2

TP4 Checks gate pulse timer volts supply

4 Open circuit: no load + 10 VDC ± 10%
set by CR9

Checks gate pulse timer operation

+ 3.3 VDC + /-10%
TPD Open circuit: no load before phase balancing and
amplification
Checks gate pulse timer operation
+ 3.3 VDC ± 10%
5 TPE Open circuit: no load before phase balancing and
amplification
Checks gate pulse timer operation
+ 3.3 VDC ± 10%
TPF Open circuit: no load before phase balancing and
amplification
-8.2 VDC ± 10%
Checks gate pulse timer operation and
TP1 (measured with no load)
balance adjustment
With a 100 A load,
adjust R9 and R10
-8.2 VDC ± 10%
carefully for lowest Checks gate pulse timer operation and
6 TP2 (measured with no load)
ripple voltage balance adjustment
(typically 100 to 160
mV). -8.2 VDC ± 10%
Checks gate pulse timer operation and
TP8 (measured with no load)
balance adjustment.

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TEST TEST TEST VOLTAGE TEST

STEP POINT CONDITION MEASUREMENT DESCRIPTION

Checks for null (0) by R38 for the no

7 TP14 Open circuit: no load 0 VDC ± .01V
load current signal

Checks voltage slope calibrated with

8 TP17 --- + 1.25 ± 10%
R102
Checks reference voltage adjusted by
9 TP19 --- - 5 VDC ± 1%
R101
Checks output volts set by R109 in 28
TP13 --- - 28.5 VDC ± 1%
VDC mode
10
Checks output volts set by R110 in 14
TP13 --- - 14.3 VDC ± 1%
VDC mode

11 TP20 --- 6 ± .5 VDC Checks R60 overload current setting

TPL Standard load Near zero (0.002 V) Optional test

12
Checks overload light, DS2, and circuit
TPL Overload 12 to13 VDC functioning (Q10)

Table 2 GPU Circuit Board Tests

4) Circuit Board Calibration

Equipment Requirements

Calibration requires the following equipment:

 a load bank – able to pull 2200 amps at 28.5 volts
 two voltmeters - ± 2% accuracy
 an oscilloscope
 a 3.3 k resistor
 small test clips

Also, if your GPU is set up for bridge interlock and remote connection option, you will need to add
switches:
 Connect normally open "Start" switch between TB101-1 and TB101-2.
 Connect normally closed "Stop" switch between TB101-2 and TB101-3.

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Calibration Procedure

(1) Connect the output cable to the load bank.

(2) Connect a voltmeter to the output.

(3) Turn the power switch on. The amber “Power On” light should be on.

(4) Set the SCR gate balance

a) Connect the oscilloscope probe to the heat sink and the oscilloscope ground to the braid of the
heat sink fly-back diode (CR 7).
b) Verify output pulses for the six SCRs.
c) Balance the levels with R9 and R10.

(5) Close the output contactor. Make sure the green “Contactor Closed” light turns on.

(6) Turn the GPU off.

(7) Adjust the offset null

a) Connect another voltmeter to TP14 (positive) and TP15 (negative).
b) Turn on the GPU and close the output contactor.
c) The test point voltage should be 0.000 ± 0.005 VDC.
d) Adjust R38 (offset null adjust) for the proper reading.

(8) Adjust the voltage reference

a) Move the positive voltmeter lead to TP19.
b) The voltage should be -5.00 ± 0.010 VDC.
c) Adjust R101 (reference adjust) for the proper reading.

(9) Check the over-voltage adjustment

When an over-voltage occurs, the output contactor should open and the red “Overload” light should
turn on.
a) Turn the "Starting current" knob to the maximum setting.
b) Turn R109 (28 volt adjust) all the way counterclockwise. The output voltage will drop to around
22 volts.
c) Jumper a 3.3 k resistor across R111 (next to R109). The output voltage will increase to about
30 volts.
d) Use R109 to raise the output voltage until the over-voltage fault trips. The output voltage must be
between 31.0 and 31.8 VDC at the trip point.
e) Adjust R37 (over voltage adjust – control very touchy) for proper trip point.
f) Remove the 3.3 k jumper resistor and reset output voltage for 28.50 to 28.60 VDC.

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(10) Check the voltage slope adjustment

a) Apply a 400 amp load.
b) Connect the voltmeter positive to TP17 and negative to TP14.
c) The test point voltage should be 0.000 to 0.020 VDC.
d) Adjust R102 (voltage slope adjust) for proper reading.

(11) Check the current limit adjustment

a) Turn the starting current knob to the 2000 amp setting.
b) Apply a 2000 amp load and check to make sure the unit is not current limiting.
c) The output voltage should be 22.0 to 25.0 VDC.
d) Adjust R115 (max amp. adjust) for proper output voltage.

(12) Check overload trip point

When an overload occurs, the output contactor should open and the red “Overload” light should turn
on.
a) Increase the load at the load bank to make sure the overload turns on between 2125 and 2200
amps.
b) Adjust R60 (overload adjust) to adjust the current overload trip point.

(13) Check the starting current adjustment

a) Set starting current knob to 500 and apply a 700-amp load.
b) The output current should be 500 amps ± 25 amps.
c) If not, adjust R116 (current limit knob adjust) until output current equals 500 amps.
d) Remove the load.

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Section 3 Scheduled Maintenance

1) General
The ITW GSE GPU is designed to be as maintenance free as possible. Therefore, there are few
maintenance requirements. Field maintenance of the GPU should be performed only by qualified service
personnel, and should be limited to cleaning and inspection of the unit and its components, as well as, the
replacement of lamps and fuses. All service and repair work, including testing and calibration, should be
referred to the ITW GSE Service Department, to an authorized service shop for ITW GSE equipment, or
to qualified electronic technicians.

2) Maintenance Schedule

As Daily 1 month 3 months 6 months

required 8 hrs. 200 hrs. 600 hrs. 1200 hrs.
* EXTERIOR CABLES
Inspect equipment X
Inspect AC input cables X
Check cable connections (internal) X
* CONTROLS AND INSTRUMENTS
Check voltmeter functioning X
Check ammeter functioning X
Check fan thermostat operation X
Check indicating lights X
Check starting current limit functioning X
Check all output contactor contacts X
Check power input contactor contacts X
Check voltmeter & ammeter accuracy X
Check all wiring and connections X
Inspect and clean general (light duty) X
Inspect and clean general (severe duty) X
* FAN MOTOR
See Lubrication section below

*Suspicious performance overrides timetable

Figure 1 Inspection Schedule

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3) Inspection During Operation

a) Make sure the meters are functioning. If a meter is suspected of being inaccurate, check it against a
test instrument.
b) Verify the lights for Input Power On and Output Contactor closed are functional. Replace if necessary.
The Overload/Over Voltage light is an LED, so it will probably not fail.
c) Verify that the fan turns on after the unit has been operating for a while. If the fan turns on
immediately on a cold unit, that might indicate a shorted fan thermostat switch.
d) Check the Starting Current potentiometer. If this control has no effect on currents above its minimum
setting, that might indicate a faulty potentiometer or faulty circuit board.

4) Preparation for Internal Inspection

a) Turn off input power at the source. Make sure that power cannot be inadvertently turned back on.

WARNING
High voltage may be present inside the GPU cabinet, even when the unit is off.
Exercise extreme caution or FATAL SHOCK may result.

WARNING HIGH VOLTAGE - electric shock can kill! Be certain the input power source is turned
off before opening the cabinet. Stop operation immediately if a possible dangerous
fault is discovered. The front panel input contactor switch does not remove input
power from all components. Be sure capacitors are discharged before you touch.

b) Observe the front panel voltmeter and make sure the voltage is zero. If the voltage is not zero, the
capacitors still hold a charge, indicating a problem with the connection to the preload resistors.

c) Observe general condition of power-input cables and equipment output cables. Inspect for cuts and
abrasions in the insulation that could cause a short circuit. Visually inspect the output cable plug
connector for physical damage and evidence of overheating.
d) Remove the top cover.

5) Internal Inspection
a) Using compressed air or a soft brush, clean any dirt and debris from the interior.
b) Inspect terminal blocks for evidence of overheating due to loose electrical connections.
c) Inspect electrical and mechanical connections for tightness.
d) Remove the front panel screw that holds the circuit board panel. Swing the circuit board panel out to
the side.
e) Inspect the circuit board for evidence of overheating, such as burned components.
f) Inspect the hinge for the circuit board panel. If this hinge sticks or is difficult to operate, spray the
hinge with a silicone spray lubricant.
g) Inspect all wiring, leads, and cables. Inspect for cuts, abrasions, and signs of deterioration and
overheating. Inspect the leads for broken strands and terminals.

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h) Inspect the output contactor. If the contacts are badly burned, the contactor should be replaced as
soon as possible. Slightly pitted and burned contacts can be cleaned up with a commercial contact
cleaner and very fine-grained emery cloth or equivalent.
i) Turn the fan blade by hand to make sure that it turns freely.
j) If required, lubricate the fan (refer to the next section for the lubrication schedule).
k) When finished with inspections:
 Return the circuit board panel to its closed position and secure with the screw.
 Replace the top cover.
 Turn on power at the source and check for normal operation.

6) Lubrication
No lubrication is required, except for the fan motor. The fan motor incorporates a sleeve bearing, and
therefore requires periodic lubrication.

a) Lubrication Schedule
The following table shows the fan motor manufacturer’s recommendations for lubricating the motor.

Type of Duty Usage – Starts Usage – Hours Lubrication

Per Hour Per Day Interval (years)
Light 0 – 4 starts 0 – 8 hours Every 4 years
Moderate 5 - 10 starts 9 – 16 hours Every 3 years
Heavy Over 10 starts 17 - 24 hours Every 2 years

Fan Motor Lubrication Schedule

Figure 2

Lubricate more frequently in dirty environments (3, 2, or 1 years instead of 4, 3, or 2).

b) Oil Type
Use SAE-20 or 10W30 electric motor or automotive oil. Do not use definite purpose oils such as
those for sewing machines, cleaning, rust preventative, or cutting applications.

c) Quantity
Use 10 – 15 drops per end (approximately 1.0 cc or 1/8 teaspoon). Do not over oil.

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d) Oil Locations
The figure below shows a tube extending upward from the rear bearing. The front bearing has a
similar tube. Use these tubes to oil the bearings.

Figure 3 Fan Motor Oil Locations

7) Inspection Records
Since the fan lubrication is so infrequently, you should keep track of the lubrications using the chart below
or some similar record.

Inspection Fan Motor Oiled?

Inspection Notes
Date (circle Y or N)
Y N
Y N
Y N
Y N
Y N
Y N
Y N
Y N
Y N
Y N

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Chapter 3 Overhaul / Major Repair / Inspection

Unscheduled Repair
1) General
Repair of the GPU will consist primarily of parts replacement. Most of the components used in the GPU
cannot be disassembled and repaired, and must be replaced if faulty. Additionally, inoperative PC boards
cannot be repaired in the field, but must be replaced as a complete unit. PC boards may be returned to
the factory for replacement. Contact ITW GSE for parts and replacement instructions.

2) Service Information and Factory Repair

The ITW GSE Service Department can answer questions concerning the operation, repair, or servicing of
this GPU. When making such an inquiry, be sure to provide the model number, serial number, and
approximate date of receipt of the unit. If it is deemed necessary to return the unit to the factory for
servicing, contact the Service Department for authorization. It is rarely necessary to return a failed GPU
since the unit uses plug-in type assemblies throughout its systems. For warranty information, refer to the
warranty statement at the front of this manual or contact the ITW GSE Service Department.

When ordering parts from your ITW GSE Distributor, be sure to include all pertinent information from the
unit’s identification plate: Specification No., Model No., and unit rating.

3) GPU Removal and Replacement

If extensive repairs are to be made on the GPU, you may wish to move it to a more convenient location.

WARNING
High voltages may be present inside the cabinet, even when the unit is off. Exercise
extreme caution or FATAL SHOCK may result.
a) Turn off the input power at the source. Make sure that the power cannot be inadvertently turned back
on.
b) Remove the top cover.
c) Disconnect the three AC input leads at the terminals on the input contactor and the grounding wire at
the grounding lug.
d) Loosen the cable clamp on the rear of the GPU and remove the input cable from the clamp.
e) Disconnect the output cable from the output contactor (+) and the ammeter shunt (-).

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f) Loosen the cable clamp at the base and remove the output cable from the GPU.
g) If the unit is a bridge mount unit, also disconnect and remove the remote control cables.
h) If the unit is bridge mount or fixed mount, attach a lifting hoist or forklift to the bottom of the GPU and
remove the mounting screws or bolts that attach the GPU to its mounting.
i) Carefully remove the GPU.
j) Move the GPU to a clear working area where it can be placed on a solid supporting structure.
k) Re-install the GPU in the reverse order of removal. See Section 1-2 for additional information on
installing the GPU.

4) Component Removal and Replacement

Most of the components in the GPU are easily replaced when necessary. Chapter 1 and Chapter 4 show
the locations of the components in the GPU.

WARNING
To avoid the danger of electric shock, always make sure that the input power is turned
off at the source and cannot be inadvertently turned back on before working inside the
GPU.
a) Lights

The light bulbs are accessible from the front by unscrewing the lens.

Light Unit Bulb Type

Standard Type 120 MB (120 V, .025 A, T-2-1/2)
Input Power On
Units with CE marking Type 757 (28 V, .08 A)
Output Contactor Closed All Type 757 (28 V, .08 A)

Overload/Overvoltage No bulb – this is an LED assembly

b) Circuit Board
Chapter 4-3, Figure 2 gives the location and part number of the circuit board. To replace the circuit
board, unplug the connectors and remove the six screws.

c) Fuses
The following table provides the locations and functions of the fuses. If a fuse has blown, check the
related circuitry. Always replace the fuses with similar fuses having the same type and rating.

Fuse Protects Location Rating

F1 Fan Fan shroud 5 A, 250 V, Type ABC
F2 – F7 Circuit Board Fuse block next to circuit board 1 A, 250 V, Type AGC, Fast blow
F8 Input Contactor Control transformer 0.5 A, 250 V, Type AGC, Fast blow
F9 Receptacle Front Panel 10 A, 250 V, Type ABC

d) Thermostat Switches
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Two thermostat switches mount to the top of the heat sink assembly. Refer to Chapter 4-3, Figure 7.
The switch on the left side controls the fan. The switch on the right side shuts down the GPU when an
overload occurs.
The fan thermostat is normally open. If this switch fails in the open position, the fan will never turn on
and the unit will eventually shut off with an overload indication. If the fan thermostat fails in the closed
position, the fan will run continuously, even when the unit is cold. This switch turns on when the
temperature reaches 100° ± 8° F and turns off when the temperature falls back down to 80° ± 5° F.
The overload thermostat is normally closed. If this switch fails in the open position, the GPU will not
produce any output voltage. If this switch fails in the closed position, the GPU will not shut down if the
heat sink gets too hot. This switch opens when the temperature reaches 190° ± 5° F and closes when
the temperature falls back down to 172° ± 8° F.
Both of these switches can be tested using an ohmmeter and a heat gun. To replace a thermostat,
unplug the wires and then remove the two screws that hold it. Reconnect the wires to the new
thermostat.

e) Fly-back Diode
The fly-back diode, CR7, is located on the left side of the heat sink assembly near the base. Failure is
not common, but if fails in a shorted condition, it can cause high input current. Refer to Chapter 2-1
for troubleshooting information.
Chapter 4-3, Figure 7 gives the part number for the diode.
(1) Buff the heat sink in the area where the diode attaches to remove any oxidation.
(2) Smear a thin film of Burndy Penetrox “A” (or similar oxide-inhibiting electrical joint compound) in
the area where the diode attaches to the heat sink.
(3) When replacing the diode, torque the nut to 4.2 to 5.2 ft-lb. (5.7 to 7.05 N-m).

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f) SCR Diodes
The six SCR diodes mount to the heat sink. If an SCR fails to conduct, it can cause excessive ripple
in the output. If an SCR fails by shorting, the unit can draw excessive input current. SCR replacement
is somewhat complicated, so be sure that a failed SCR is the cause of the problem before replacing.
Refer to Chapter 2-1 for troubleshooting information.
If you plan to replace an SCR, you will need a 903878 Force Indicator Gauge. This gauge, shown in
Figure 1, measures the deflection of the flat spring on top of the SCR as the screws are tightened.
The gauge consists of two metal plates that are free to rotate about a common point where they are
fastened together.
 When this gauge is placed on a flat surface so that it makes three-point contact, the sheet metal
plates rotate so that the left edge of the rear plate aligns with the right edge of the front piece at
the calibration notch.
 When this gauge is placed on a properly-adjusted SCR spring, the left edge of the rear plate
aligns with the right edge of the front plate at the top notch (marked VE3000/VE2500).

Figure 1 Force Indicator Gauge

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Figure 2 SCR Mounting Components

Figure 3 Measuring the Spring Deflection

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Chapter 4-3, Figure 7 gives the part number for the diode.
(1) Disconnect and remove the failed SCR diode noting how the pieces are assembled. Figure 2
shows a cross section.
(2) Buff the heat sink in the area where the diode attaches to remove any oxidation.
(3) Smear a thin film of Burndy Penetrox “A” (or similar oxide-inhibiting electrical joint compound) in
the area where the diode attaches to the heat sink.
(4) Tighten the nuts evenly until they are finger tight.
(5) Tighten each screw in 1/4 turn increments using the correct size hex key.
(6) Place the Force Indicator Gauge firmly against the top spring as shown in Figure 3. Be sure both
ends and the center are in firm contact with the spring.
(7) Tighten the screws in 1/4 turn increments until the gauge shows correct alignment between the
left edge of the rear gauge plate and the right edge of the top notch (VE3000/VE2500) on the
front gauge plate.
(8) If you have tightened the screws too much, loosen both nuts and start over. Never adjust the
force by backing off the nuts. Friction will always produce a false reading.

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Chapter 4 Illustrated Parts List

Section 1 Introduction/ Numerical Index
1) General
The Illustrated Parts List identifies, describes, and illustrates main assemblies, subassemblies, and detail
parts of your ground power unit manufactured by ITW GSE Palmetto Florida.

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

3) Arrangement
Chapter 4 is arranged as follows:

Section 1 - Introduction
Section 2 - Manufacturer’s Codes
Section 3 - Illustrated Parts List

4) Explanation of Parts List

a) Contents

The parts list contains a breakdown of the equipment into assemblies, subassemblies, and detail
parts. All parts of the equipment are listed except:

(1) Standard hardware items (attaching parts) such as nuts, screws, washers, etc., which are
available commercially.

(2) Bulk items such as wire, cable, sleeving, tubing, etc., which are also commercially available.

(3) Permanently attached parts, which lose their identity by being welded, soldered, riveted, etc., to
other parts, weldments, or assemblies.

b) Parts List Form

This form is divided into six columns. Beginning at the left side of the form and proceeding to the
right, columns are identified as follows:

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(1) FIGURE-ITEM NO. Column

This column lists the figure number of the illustration applicable to a particular parts list and also
identifies each part in the list by an item number. These item numbers also appear on the
illustration. Each item number on an illustration is connected to the part to which it pertains by a
leader line. Thus the figure and item numbering system ties the parts lists to the illustrations and
vice versa. The figure and index numbers are also used in the numerical index to assist the user
in finding the illustration of a part when the part number is known.

(2) ITW GSE PART NUMBER Column

All part numbers appearing in this column are ITW GSE numbers. In all instances where the part
is a purchased item, the vendor’s identifying five-digit code and his part number will appear in the
“NOMENCLATURE” column. Vendor parts, which are modified by ITW GSE, will be identified as
such in the “NOMENCLATURE” column. In case ITW GSE does not have an identifying part
number for a purchased part, the “ITW GSE PART NUMBER” column will reflect “No Number”
and the vendor’s number will be shown in the “NOMENCLATURE” column. Parts manufactured
by ITW GSE will reflect no vendor or part number in the “NOMENCLATURE” column.

(3) NOMENCLATURE Column

The item identifying name appears in this column. The indenture method is used to indicate item
relationship. Thus, components of an assembly are listed directly below the assembly and
indented one space. Vendor codes and part numbers for purchased parts are also listed in this
column when applicable. ITW GSE modification to vendor items is also noted in this column.

(4) EFF (Effective) Column

This column is used to indicate the applicability of parts to different models of equipment. When
more than one model of equipment is covered by a parts list, there are some parts that are used
on only one model. This column is used for insertion of a code letter A, B, etc., to indicate these
parts and to identify the particular model they are used on. Since this manual covers only one
generator set specification, this column is not used in this manual.

EFF Part & Dash CE Input Input Output Output

Mounting
Code Number Certified Voltage Frequency Voltage Current
A 28.5
DCS600T60208 Trailer -- 220/230/460 60 Hz. 600 A
VDC
B 28.5
DCS600T50380 Trailer -- 220/380 50 Hz. 600 A
VDC
C 28.5
DCS600T6O575 Trailer -- 230/460/575 60 Hz. 600 A
VDC
E 28.5
DCS600T50380CE Trailer Y 220/380 50 Hz.
VDC
600 A
F 28.5
DCS600S60208 Stationary -- 208/230/460 60 Hz. 600 A
VDC
G 28.5
DCS600S50380 Stationary -- 220/380 50 Hz. 600 A
VDC
H 28.5
DCS600S50380CE Stationary Y 220/380 50 Hz. 600 A
VDC
J 28.5
DCS600B60208 Bridge -- 208/230/460 60 Hz. 600 A
VDC
K 28.5
DCS600B60380 Bridge -- 220/380 50 Hz. 600 A
VDC

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(5) UNITS PER ASSEMBLY Column

This column indicates the quantity of parts required for an assembly or subassembly in which the
part appears. This column does not necessarily reflect the total used in the complete end item.

Numerical Index
6 Explanation of Numerical Index

The purpose of this index is to assist the user in finding the illustration and description of a part when the
part number is known. Part numbers are arranged in alphanumerical sequence.

FIGURE – ITEM NO. ITW GSE PART NO. FIGURE – ITEM NO. ITW GSE PART NO.

5-4 16DA2162 2-7 287637

7-12 16DA954-012 7-6 287929-001
2-4 180065 4-7 288251
2-2 180294B 4-1 288262
3- 180358 1-3 288266
2-3 180480 1-2 288267
5-8 180914 5-1 288270
5-9 180914 2-1 288271
3- 181565 1-16 288272
2- 201015 6-1 288273
2-10 201016 7-1 288277
6-5 201673-004 5-2 288280-002
3-6 280023 1- 288281
7-9 280023 4-2 288282
1-5 282658 4-3 288283
6-13 283066-001 1- 288284
4-8 283322 4-4 288297-001
1-4 283323 1- 288298-001
6-14 286432-001 1-14 288300
1-10 286441 2-11 288303-001
5-3 286607-001 7-5 288304
3-3 286810-001 2-8 288305-002
6-4 286810-001 7- 288305-002
1-12 287460 5- 288307-003
5-12 287460 5- 288307-004
6-10 287460 5- 288307-006
1-15 287547-001 5- 288307-008

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FIGURE – ITEM NO. ITW GSE PART NO. FIGURE – ITEM NO. ITW GSE PART NO.

6- 288310-001 5-14 402670

6- 288310-002 7-10 402832-003
6- 288310-003 3- 403091-008
6- 288310-004 5-11 403189
6- 288310-005 5- 403955-017
6- 288310-006 7-7 404044-006
4- 288321-001 5- 404172-002
4- 288321-002 5- 404172-003
1-13 288322 5- 404277
2- 288322 5- 404335
4- 288349 5-15 404336
5-19 288351 2- 404915-001
4-5 288353 5-6 405072-002
1-7 288356 2-6 405129-001
1-8 288362-001 7-3 405139
1- 288362-002 7-2 405140-001
2- 288363 3-2 405278-007
5-18 288364 5-10 405365-001
5-13 288365 6-9 405548
2- 288366 5- 405734
1-17 288542 6- 406247-002
3-11 288731 6- 406247-003
3-12 288732 6-6 406392-001
6- 288733-001 6- 406392-002
1-11 288866 6- 406484
3- 350488-094 2-9 406991
3- 361052-009 2- 408352
7-11 367634A-003 2-12 408567
7-8 369641 6-12 408584
7-4 369642 2- 408585
2- 400234-003 4- 486143-002
5- 400613-003 3-7 487050-005
5- 400613-006 6-3 487898A
5-5 400641-012 3-9 488819
5-7 400642-003 3-8 489603
2- 400647-005 4- 489971
5- 400647-008 3-4 589561
6-8 400663 5-20 77A1157
5- 401532-002 3- 788732
1-6 402025-002 1-9 78B1130
6-2 402037-027 2- 83A1105
5-16 402658 6-11 83A1105
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FIGURE – ITEM NO. ITW GSE PART NO. FIGURE – ITEM NO. ITW GSE PART NO.

4-6 83B1101
2- W11166-009
6- W11166-011
3-10 W9760-066

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Section 2 Manufacturer's Codes

1) Explanation of Manufacturer’s (Vendor) Code List

The following list is a compilation of vendor codes with names and addresses for suppliers of purchased
parts listed in this publication. The codes are in accordance with the Federal Supply Codes for
Manufacturer’s Cataloging Handbook H4-1, (CAGE CODES) and are arranged in numerical order.
Vendor codes are inserted in the nomenclature column of the parts list directly following the item name
and description. If a manufacturer does not have a code, the manufacturer’s full name is listed in the
nomenclature column.

Code Vendor’s Name and Address Code Vendor’s Name and Address

D0024 SEMIKRON ELEKTRONIK GMBH 01XD4 Contact Industries Inc

Sigmundstrasse 200 25 Lex-Industrial Dr
P.O. Box 82 02 51 Mansfield OH 44903 - 8699
Nuernberg, Germany 90431
01428 Tuthill Corporation
E0615 Kraus and Naimer DBA Tuthill Controls Group
42 Miramar Avenue 2110 Summit St.
P.O. Box 15-009 New Haven, IN 46774-9524
Wellington, New Zealand
02660 Amphenol Corp.
S7023 Bossard LTD Fasteners Spectra-Strip/Itd
Steinhauserstrasse 70 40-60 Delaware Ave
Zug, Switzerland, CH-6300 SIDNEY, NY 13838 - 1395
0CYC7 Western Rubber & Supply 02768 Illinois Tool Works Inc.
7888 Marathon Dr Ste Fastex Division
Livermore, CA 94550 - 9314 195 S. Algonguin Rd.
Des Plaines, IL 60016-6197
0E8J0 Emka Inc.
1961 Fulling Mill Rd. 02929 Newark Electronics Div
Middletown, PA 17057-3125 4801 N Ravenswood Ave
Chicago, IL 60640 - 4457
0HZP9 Diesel Radiator Co.
1985 Janice Ave. 05HB5 Magnecomp Inc.
Melrose Park, IL 60160-1008 161 Eagles Nest Dr
Pickens, SC 29671-7808
0MR72 Henkel Corp
26941 Cablot Rd, Suite 124 05YB3 Acon Inc.
Laguna Hills, CA 92653-7007 22 Bristol Dr.
South Easton, MA 02375-1108
0TSE6 Infineon Technologies Industrial Power
Inc. 1AA44 Collmer Semiconductor Inc.
1050 US HWY 22 2542 Highlander Way
Lebanon, NJ 08833-4208 Carrollton, TX 75006
00779 Tyco Electronics (Amp) 1DG36 Phillips And Temro Industries Inc
2800 Fulling Mill Rd Bldg-38 E. M. Products Inc.
Middletown, PA 17057 - 3142 5380 Cottonwood Ln
Prior Lake, MN 55372

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Code Vendor’s Name and Address Code Vendor’s Name and Address

1DL99 Fleetguard Inc. 2N562 Power Transmission Sales Inc.

Div. of Cummins Engine Company 531 Washington
311 N. Park Street P.O. Box 229
Lake Mills, IA 50450 - 1299 Chagrin Falls, OH 44022-0229
1E045 Austin Hardware and Supply Co. 23803 N T N Bearing Corp of America
950 Northwest Technology Dr 191 Sheree Blvd Ste 101
Lees Summit, MO 64086 - 5692 Exton PA 19341-1265
1SPJ9 ITW GSE 24161 Gates Corporation
11001 US Hwy 41 N 900 S Broadway
Palmetto, FL 34221 Denver CO 80217-5887
1W134 Eaton Corp. 24446 General Electric Co.
TH
4201 N. 27 St 3135 Easton Tpke.
Milwaukee, WI 53216-1897 Fairfield, CT 06431
12662 Peterson Mfg Co. 25710 Deka Plastics Inc.
4200 E 135th St 914 Westfield Ave.
Grandview MO 64030-2896 Elizabeth, NJ 07208-1222
13445 Cole-Herse 27410 Harris Corp.
20 Old Colony Ave. 1025 W NASA Blvd.
Boston, MA 02127-2405 Melbourne, FL 32901
14552 Microsemi Corporation 28520 Heyco Inc.
2381 Morse Ave 1800 Industrial Way N.
Irvine, CA 92614-6233 Toms River, NJ 08755-4809
14799 Square D Company, Inc 3A054 McMaster Carr Supply Co.
Dba Schneider Electric USA, Inc. 9630 Norwalk Blvd.
9522 Winona Ave Santa Fe Springs, CA 90670-2932
Schiller Park, IL 60176-1084
3Y208 Taylor And Summerville Battery Co
16476 Maxima Technologies & Systems Llc 3485 Successful Way
1811 Rohrerstown Rd Dayton Oh 45414-4319
Lancaster, PA 17601-2321
30104 Automotive Controls Corp.
18265 Donaldson Company Inc. 1300 W. Oak St.
DBA Torit Products P.O. Box 788
1400 W. 94th St. Independence, KS 67301-0788
Minneapolis, MN 55431-2370
30430 Marathon Electric Mfg. Corp.
2B428 MJO Industries Inc. 398 Beach Rd.
DBA Hughes-Peters Burlingame, CA 94010-2004
8000 Technology Blvd.
Huber Heights, OH 45424 - 1573 311K7 Kissling Electrotec Incorporated
320 Business Pkwy, Ste A
2B664 All-Phase Electric Supply Co Greer, SC 29651
1620 W Main St
P.O. Box 149 38151 Marathon Electric Mfg. Co.
Springfield OH 45501-0149 100 E. Randolph St.
Wausau, WI 54401-2568

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Code Vendor’s Name and Address Code Vendor’s Name and Address

39TH9 Motion Industries Inc. 57347 Wall Industries Inc.

8580 Industry Park Dr. 5 Watson Brook Rd.
Piqua, OH 45356-8535 Exeter, NH 03833-4589
40121 Peterson Mfg. Co. Inc. 57733 Stewart-Warner Corporation
700 W. 143rd St. 333 Ludlow St
Plainfield, IL 60544-9733 Stamford, CT 06902-6987
44655 Heico Ohmite LLC 59656 Dean Technology Inc.
1600 GOLF RD 850 DBA CKE
ROLLING MEADOWS, IL 60008-4204 1000 Lucerne Road
Lucernemines, PA 15754-0211
46922 Crawford Electric Co
445 E 32 Mile Rd 6S553 Wes-Garde Components Group Inc
Romeo MI 48065-5270 300 Enterprise Dr
Westerville, OH 43081-8840
49234 Protectoseal Company
225 W Foster Ave 6Y440 Micron Technologies Inc.
Bensenville, IL 60106-1631 8000 S. Federal Way
Boise, ID 83716-7128
5N8K3 Alpha Devices
11963 Abbey Rd. 60038 Timken Corporation
Cleveland, OH 44133 1835 Dueber Ave Sw
Canton, OH 44706-2728
5P059 Tech Products Corp.
2215 Lyons Rd 61706 EAO Switch Corporation
Miamisburg, OH 45342-4465 98 Washington St.
Milford, CT 06460-3133
50508 Magnetic Components Inc.
9520 Ainslie St. 62292 EBM Industries Inc.
Schiller Park, IL 60176-1191 110 Hyde Rd.
P.O. Box 4009
52793 Saginaw Products Corp. Farmington, CT 06034-4009
DBA CIGNYS
68 Williamson St. 62445 Deutz Corporation
Saginaw, MI 48601-3246 3883 Steve Reynolds Blvd
Norcross Ga 30093
54646 Clampco Products Inc.
1743 Wall Road 66180 Automatic Timing and Controls
Wadsworth, OH 44281-9558 3312 Bloomingdale
Melrose Park, IL 60160-1030
55752 Parker Hannifin Corp.
DBA Racor Div. 66844 Powerex Inc.
3400 Finch Rd. 173 PAVILION LN
Modesto, CA 95354-4125 Youngwood, PA 15697-1800
56289 Sprague Electric Company 7M613 Wright F.B. Co. of Cincinnati
678 Main St 4689 Ashley Dr.
Sanford, MA, 04073-7003 Hamilton, OH 45011-9706
57330 Remke Industries Inc. 71382 Seal Master Bearings
310 Chadick Drive Sub Of Emerson Electric Co.
Wheeling, IL 60090-6039 1901 Bilter Rd.
Aurora, IL 60502-9704

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Code Vendor’s Name and Address Code Vendor’s Name and Address

71400 Cooper Bussmann Inc. 81703 Mulberry Metal Products Inc.

114 Old State Road 2199 Stanley Terrace
Ellisville, MO 63021-5942 Union , NJ 07083-4399
72619 Dialight Corporation 82866 Research Products Corp.
1501 State Rte 34 S P.O. Box 1467
Farmingdale, NJ 07727-3932 1015 E. Washington Ave.
Madison, WI 53701
74400 Hobbs Corporation
1034 East Ash Street 86797 Rogan Corp
PO Box 19424 3455 Woodhead Dr.
Springfield, IL 62794-9424 Northbrook, IL 60062-1812
74542 Hoyt Electrical Instruments 9Y826 Marsh Electronics Inc.
23 Meter ST. 1563 S. 101st St.
Concord, NH 03303-1894 Milwaukee, WI 53214-4032
74545 Hubbell Inc 91637 Vishay Dale Electronics Inc.
Wiring Device Div 1122 23RD St.
185 Plains Road Columbus, NE 68601-3647
Milford, CT 06460
91929 Honeywell International Inc.
74829 Ilsco Corp. DBA Honeywell
4730 Madison Rd. 11 W. Spring St.
Cincinnati, OH 45227-1426 Freeport, IL 61032-4316
75418 Kysor Industrial Corporation 94222 Southco Inc.
1 Madison Ave 210 N. Brinton Lake Rd.
Cadillac, Michigan 49601-9784 Concordville, PA 19331
75915 Littelfuse, Inc. 97520 Basler Electric Company
8755 W Higgins Road Ste 500 Route 143
Chicago, IL 60631 - 2701 Highland, IL 62249-1074
77342 TYCO Electronics Corporation
8010 Piedmont Triad Pkwy
Greensboro, NC 27409
78388 Woodward Controls Inc.
6250 W Howard St
Niles, Il 60714-3433
8A334 Cummins Bridgeway LLC
2297 SW Blvd Ste K
Grove City, OH 43123-1822
8T246 Whitesell RO & Associates, Inc.
7009 CORPORATE WAY
Dayton, OH 45459-4238
81483 International Rectifier Corp
233 Kansas St.
El Segundo, CA 90245

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Section 3 Illustrated Parts List

1) Explanation of Parts List Arrangement
The parts list is arranged so that the illustration will appear on a left-hand page and the applicable parts
list will appear on the opposite right-hand page. Unless the list is unusually long, the user will be able to
look at the illustration and read the parts list without turning a page.

2) Symbols and Abbreviations

The following is a list of symbols and abbreviations used in the parts list:

* - Item not illustrated

A, or AMP - Ampere
AC - Alternating current
AR - As required
DC - Direct current
Fig. - Figure
Ft-lb. - Foot-pounds
Hd. - Head
Hex - Hexagon
Hz - Hertz (cycles-per-second)
I.D. - Inside diameter
IN - Inch
KVA - Kilovolt-ampere
UF - Microfarad
Number - Number
NHA - Next higher assembly
N-m - Newton-meters
PRV - Peak reverse voltage
PSI - Pounds per square inch
Ref - Reference (the item has been listed previously)
TM - Technical Manual
T-R - Transformer-rectifier
V - Volt (when used as a prefix to a five-digit number, indicates
vendor code)

NOTE: An item which does not reflect an index number is an assembly which is not illustrated in its
assembled state, or it is similar (right-hand, left-hand, top, etc.) to an item which is illustrated.

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7 3 4

2 6

Figure 1 Final Assembly of GPU-600 Power Supply

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UNITS
FIGURE ITW GSE
NOMENCLATURE EFF PER
ITEM NO. PART NO.
ASSY.

1 Base Assembly (See Figure 4) Ref.

2 288267 Panel, Side 2
3 288266 Panel, Top 1
4 283323 Bracket, Cable Hanger 4
5 282658 Label, Warning Clearance 1
6 402025-002 Cable, Output, 28 V , 20 ft 1
[Other Lengths Available]
7 288356 Handle Assembly A-G 1
th
288284 …Handle, 5 Wheel A-G 1
th
288281 …Latch, 5 Wheel A-G 1
288298-001 …Grip, Foam A-G 2
* 8 288362-001 Cover, Protective, Changeover Board A,C,F,J,L 1
* 288362-002 Cover, Protective, Changeover Board B,E,G,H,K
* 9 78B1130 Nameplate, Identification 1
* 10 286441 Label, General 1
* 11 288866 Label, Service 1
* 12 287460 Label, Danger, High Voltage D,E,H 1
* 13 288322 Label, Fan D,E,H 1
* 14 288300 Label, Emergency Stop D,E,H 1
* 15 287547-001 Label, CE 1
* 16 288272 Support, Bridge Mount J,K,L 2
* 17 288542 Shield, Control Box 1

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Figure 2 Internal Components – Part 1

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UNITS
FIGURE ITW GSE
NOMENCLATURE EFF PER
ITEM NO. PART NO.
ASSY.
2- 1 288271 Panel, PC Board 1
2 180294B Board, PC, Control, Ay. 1
404915-001 …Spacer, Pc Board 6
3 180480 Choke Assembly 1
4 180065 Shunt, 2000 Amp, 50 mV (for ammeter) 1
5 Ref. Voltage Changeover Board (see note) Ref.
6 405129-001 Block, Fuse 1
W11166-009 …Fuse, Fast Blow, AGC 1 A, 250 V 6
83A1105 …Label, Fuse 1
7 287637 Motor, Fan 1
8 288305-002 Rectifier, Output, SCR Assembly (See Figure 7) 1
9 406991 Blade, Fan 1
10 201016 Shroud, Fan 1
288322 …Label, Warning, Fan 1
400234-003 …Tag, Instructions 2
201015 …Bracket, Mounting, Fan Shroud 2
11 288303-001 Block, Fuse 1
400647-005 …Fuse, 5 A 1
288363 …Label, Precautionary, Fan Fuse 1
* 12 408567 Relay, 24 VAC, 4PDT (shown on Figure 6) J,K,L 2
* 408352 …Socket, Relay J,K,L 2
* 408585 …Spring, Relay J,K,L 2
* 288366 …Chart, Wire, Bridge Mount Units J,K,L 2

Note: Item 5, the Voltage Changeover

Board, is part of the transformer.

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Figure 3 Internal Components – Part 2

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UNITS
FIGURE ITW GSE
NOMENCLATURE EFF PER
ITEM NO. PART NO.
ASSY.
3- 1 Panel, Front, GPU, Ay. (See Figure 5) Ref.
2 405278-007 Capacitor, ALS, 115000 MF, 40 VDC A,C,F,J, 3
(V56289, # 36DX772F200DF2A)
Capacitor, ALS, 115000 MF, 40 VDC B,E,G,H,K 4
* 350488-094 …Insulator, Mylar, .014, 2” Wide A,C,F,J, 3
* …Insulator, Mylar, .014, 2” Wide B,E,G,H,K 4
* 361052-009 …Clamp, Mounting, Capacitor A,C,F,J, 3
* 361052-009 …Clamp, Mounting, Capacitor B,E,G,H,K 4
* 788732 Cover, Capacitors, CE E,H 1
3 286810-001 Output Contactor, 28.5 VDC 1
4 589561 Transformer, Power A,F,J 1
180358 Transformer, Power B,E,G,H,K 1
181565 Transformer, Power C, 1
5 Panel, Interior Assembly (See Figure 6) Ref.
6 280023 Feedback Shunt (See Figure 7) Ref.
7 487050-005 Resistor, Pre-load, Assembly 1
8 489603 Panel, Rear 1
403091-008 …Plug, Hole, Plastic 1
* 9 488819 Cable, 2/0 (#202) 1
* 10 W9760-066 Cable, # 6 (#201) 1
* 11 288731 Cover, Contactor & Transformer E,H 1
* 12 288732 Cover, Capacitors, CE E,H 1

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1
8
7
3

4 2 6

Figure 4 Base Assembly

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UNITS
FIGURE ITW GSE
NOMENCLATURE EFF PER
ITEM NO. PART NO.
ASSY.
4- 288321-001 Base, Ay. A-E 1
288321-002 Base, Ay. F-K 1
1 288262 Base, Mounting, GPU 1
th
2 288282 Support, Caster, 5 Wheel A-E 1
th
288349 …Spacer, 5 Wheel A-E 1
3 288283 Catch, Latch A-E 1
4 288297-001 Kit, Caster A-E 1
th
5 288353 Brake, 5 Wheel A-E 1
6 83B1101 Tire, Symmetrical, Ball Bearing, 10° A-E 2
7 288251 Axle, Mounting, Wheels A-E 1
486143-002 …Spacer, Black, Pipe A-E 2
8 283322 Bracket, Output, Cable 2
489971 …Spacer, Output Cable 4

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1
4

7 8 10

9 11
14

G P U 600

Figure 5 Front panel Assembly

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UNITS
FIGURE ITW GSE
NOMENCLATURE EFF PER
ITEM NO. PART NO.
ASSY.
5- 288307-003 Panel, Front, GPU, Assembly A,C,F,J,L 1
288307-004 Panel, Front, GPU, Assembly B,G,K 1
288307-006 Panel, Front, GPU, Assembly E,H 1
288307-008 Panel, Front, GPU, Assembly 1

1 288270 Panel, Front 1

2 288280-002 Label, Controls (GPU-600) 1
3 286607-001 Potentiometer, 10k Ohm, 2 W (see note) Ref.
4 16DA2162 Knob, Rheostat (V44655, #5150) 1
5 400641-012 Ammeter, DC, 0-2000 Amps, 50 mVDC 1
6 405072-002 Diode, Light 1
405734 …Clip, Retainer, LED 1
7 400642-003 Voltmeter, DC 1
8 180914 Base, Light, Pilot 1
400613-006 …Lamp, 120 MB, 120 V, .025 A, T-2-1/2 A-C,F-G,J- 1
400613-003 …Lamp, Type 757, 28 V, .08 A E,H 1
404172-002 …Lens, Light, Pilot, Amber (V72619) 1
9 180914 Base, Light, Pilot 1
400613-003 …Lamp, Type 757, 28 V, .08 A 1
404172-003 …Lens, Light, Pilot, Green (V72619 1
#261193300)
10 405365-001 Switch, Toggle 1
11 403189 Switch, Toggle, 3 Position (V91929, #312TS) 1
* 12 287460 Label, Danger, High Voltage [Not Shown] 1
13 288365 Nameplate, ITW GSE, GPU 1
14 402670 Receptacle, 3-Wire [125 V, 15 A] A,C,F,J, 1
404277 …Cover, Receptacle (V81703, # WPDC) A,C,F,J, 1
401532-002 …Suppressor Assembly A,C,F,J, 1
15 404336 Receptacle, 3-Wire [230 V, 15 A] (V77116) B,E,G,H,K 1
404335 …Cover, Receptacle ( V81703,# WPRC) B,E,G,H,K 1
403955-017 …Suppressor Assembly B,E,G,H,K 1
16 402658 Holder, Fuse (V71400, # HKP-HH) 1
400647-008 …Fuse, 10 A, 250 V (V71400, # ABC-10) 1
17 Grounding Hardware Ref.
* 18 288364 Label, Precautionary, Recpt., Fuse 1
* 19 288351 Harness, Wire [not shown] 1
* 20 77A1157 Switch, Maintained, Push/Pull E,H 1

Notes:
 A,C,F,J are 60 Hz.
 B,E,G,H,K are 50 Hz.
 Potentiometer (item 3) is included with wire harness (item 19)

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Figure 6 Interior Panel Assembly (shown with bridge mount option)

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FIGURE ITW GSE UNITS PER

NOMENCLATURE EFF
ITEM NO. PART NO. ASSY.
6- 288310-001 Panel, Interior, Ay. A,F 1
288310-002 Panel, Interior, Ay. B,C,G 1
288310-003 Panel, Interior, Ay. J 1
288310-004 Panel, Interior, Ay. K 1
288310-005 Panel, Interior, Ay. E,H 1
288310-006 Panel, Interior, Ay. 1

1 288273 Panel, Interior 1

2 402037-027 Grommet, Rubber 2
3 487898A Bracket, Contactor 1
4 286810-001 Contactor, 28.5 VDC 1
5 201673-004 Diode Assembly (on line contactor) 1
6 406392-001 Transformer, Control A,F,J 1
406392-002 Transformer, Control B,C,G,K, 1
406247-002 Transformer, Control 1
406247-003 Transformer, Control E,H 1
406484 …Label, Fuse, 4-400-S, .5 Amp, 250 V 1
W11166-011 …Fuse, Fast Blow, AGC (V71400, #AGC/2) 1
7 Grounding Screws (1/4-20 Hardware) 3
8 400663 Contactor, Line A-C,F-G,J- 1
288733-001 Contactor, Line E,H 1
9 405548 Label, Ground 3
10 287460 Label, Danger, High Voltage 2
11 83A1105 Label, Fuse “PC Board Fuses” 1
12 408584 Transformer, Signal J,K, 1
13 283066-001 Block, Terminal, 6 Position J,K, 1
14 286432-001 Label, Bridge Interlock J,K, 1
15 Relays for bridge mount (see Figure 2) J,K, Ref

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7 2 6
2 2

11
8 8
9

10 4,5 1
3,12

Figure 7 SCR Output Rectifier Assembly of GPU-600 Power Supply

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UNITS
FIGURE ITW GSE PART
NOMENCLATURE EFF PER
ITEM NO. NO.
ASSY.
7- 288305-002 Rectifier, Output, SCR Assembly GPU-600 Ref.

1 288277 Heat Sink, Rectifier 1

2 405140-001 Clamp, Mounting 6
3 405139 Rectifier, Silicon, Cont. 6
4 369642 Heat Sink, SCR 6
5 288304 Heat Sink, SCR, Top 6
6 287929-001 Thermostat, Overload 1
7 404044-006 Thermostat, Fan Turn On 1
8 369641 Insulator, Mounting, Rectifier 2
9 280023 Shunt, 1200 A, 50 mV, Assembly 1
10 402832-003 Diode, Silicon, Positive Base 1
11 367634A-003 Suppressor, Surge, Assembly 2
12 16DA954-012 Pin, Spring 6

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Chapter 5 Manufacturer’s Literature

Diagram Number Diagram Description

288326, Rev. 0 Outline, Dimensional/Installation

288367, Rev 11 Diagram, Schematic & Connection

Contact ITW GSE if copies of these drawings are not with this manual. Refer to Appendix A for specific
information on GPU-600 Solid State Transformer-Rectifier optional equipment.

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Appendix A Options / Features

The following is a list of options/features available for the 500082, GPU-600 Solid State Transformer-Rectifier.
This chart contains the description, part number, and document number of the option/feature. There is also a
column to identify which option/feature is contained in this Appendix.

Option/Features Available

Description Part Number Document Number In This Section

Kit, Cable Tray 288360 TO-274

Plug, Locking (Fits 50 Hz. Aux.) 288582-001
Kit, Cable Interlock, GPU 400/600 290698
Kit, Cover, Dust 291594-001 TO-338

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Unusual Service Conditions

This information is a general guideline and cannot cover all possible conditions of equipment use. The
specific local environments may be dependent upon conditions beyond the manufacturer’s control. The
manufacturer should be consulted if any unusual conditions of use exist which may affect the physical
condition or operation of the equipment.

Among such conditions are:

1) Exposure to:

a) Combustible, explosive, abrasive or conducting dusts

b) Environments where the accumulation of lint or excessive dirt will interfere with normal ventilation

c) Chemical fumes, flammable, or explosive gases

d) Nuclear radiation

e) Steam, salt-laden air, or oil vapor

f) Damp or very dry locations, radiant heat, vermin infestation, or atmospheres conducive to fungus
growth

g) Abnormal shock, vibration or mechanical loading from external sources during equipment operation

h) Abnormal axial or side thrust imposed on rotating equipment shafts

i) Low and/or high ambient temperatures

j) High electromagnetic fields

2) Operation at:

a) Voltages above or below rated voltage

b) Speeds other than rated speed

c) Frequency other than rated frequency

d) Standstill with rotating equipment windings energized

e) Unbalanced voltages

f) Operation at loads greater than rated

3) Operation where low acoustical noise levels are required

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4) Operation with:

a) Improper fuel, lubricants or coolant


b) Parts or elements unauthorized by the manufacturer

c) Unauthorized modifications

5) Operation in poorly ventilated areas

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