GPU Hitzinger MM Operator

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Operator
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1. GENERAL DESCRIPTION AND OPERATING INSTRUCTION
1.2 OPERATION
1.2.1 TOWING
The height of the towing coupling has to be between 400 mm and 600 mm.
The maximum towing speed is stated on the rating plate resp. on the drawbar. Usually the
speed is 30 km/h. At bad floor conditions the speed has to be reduced accordingly.
The brake is designed only as a parking brake. There is no function of the brake during
towing.
The weight of the towing tractor has to be adapted to the weight of the GPU in accordance to
the local regulations.
The GPU is designed for airside towing operation only. It is not licensed for public traffic areas.
Before towing the GPU check that all flaps are closed and fully locked.
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The output cables have to be stowed properly without any overhang in the cable storage.
The end of cables including the aircraft plug has to be stowed in the socket storage.
Monitoring of the plug in the storage is possible (option) and can be combined with an anti-
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theft device.
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1.2.2 PARKING
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 The GPU must be positioned on firm, level ground.
 Check that the parking brake is activated properly.
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 Warmed-up exhaust air must stream off freely and may not be sucked in again
 Check location of exhaust outlet
Carbon monoxide created by the engine can kill and cause health
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WARNING problems. Never locate engine exhausts near intake ducts of air
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conditioners. Temperature can be up to 400°C - danger of serious burning

and inflammation of combustible material.
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 The maintenance flaps have to be closed during normal operation.

WARNING
When maintenance flaps are opened, rotating and hot parts are
accessible!
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1.2.3 PRE-START CHECKS

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1.2.3.1 Check before first put into operation

 Check screws on wheels
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1.2.3.2 Each day when starting first, carry out the daily maintenance checks:
 Check oil level in engine.
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 Check oil level in the oil level controller reservoir (option).

 Check coolant level.
 Check fuel level in the tank and replenish as necessary.
CAUTION
The fuel tank should never be allowed to run dry, otherwise air will be
drawn into the fuel system, affecting the running of the unit.
WARNING
Care must be taken to avoid breathe in toxical fumes.
Keep enough distance during replenishing.
 Check gel batteries for pollution and clean them if necessary.
D POWER1 Edition 01 - Page 11 / 40

1.2.4 CONNECTING TO AIRCRAFT

Pull out the output cables of the boxes only as far as needed.
Check that output-cables are not placed near exhaust outlet.
Check the cables and the aircraft plugs for visible damages. Defective equipment may not be
used.
Remove excessive pollution (snow, ice, water, dirt) before handling.
Push in the aircraft plugs completely and secure against pulling off by tightening the additional
fixing belts.
1.2.4.1 Protection system modified overcurrent protection (TN):

According DFS400 the protection system of the GPU is designed as modified overcurrent
protection (TN). The star point of the current source (alternator) has good connection to
chassis and ground. Additional grounding connections have to be performed according the
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local regulations. (A grounding/earthing cable with clamp (25mm²) is scope of supply).
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NOTE !
It is not possible to switch on the 400Hz outputs continuously without fully
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connected aircraft plug. (Prevented by the E-F contact on 400Hz plug).
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WARNING ! Switch on of the Bypass-switch is only allowed for servicing works.
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Because during handling of the cables the existence of dangerous voltage
on the 400Hz aircraft plug may be possible!
In case of activated 400Hz by-pass switch (message "BY-PASS ON") and
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alternator voltage available the outputs can be switched on at any time
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(protection on plugs bridged).
This condition is not allowed for normal air side operation!

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1.2.4.2 Protection system modified protective insulation (IT) (option):

According DFS400 the protection system of the GPU is designed as modified protective
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insulation (IT). The star point of the current source (alternator) is insulated from chassis
(ground) (Insulation-test voltage 4kV, 50Hz for 1 minute).
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NOTE !
It is not possible to switch on the 400Hz outputs continuously without fully
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connected aircraft plug. (Prevented by the E-F contact on 400Hz plug).

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WARNING ! Switch on of the Bypass-switch is only allowed for servicing works.

Because during handling of the cables the existence of dangerous voltage
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on the 400Hz aircraft plug may be possible!

In case of activated 400Hz by-pass switch (message "BY-PASS ON") and
alternator voltage available the outputs can be switched on at any time
(protection on plugs bridged).
This condition is not allowed for normal air side operation!

1.2.5 OPERATION ELEMENTS FOR AIR SIDE OPERATION

NOTE !
This chapter describes only the operation elements necessary for the basic
air side operation.
1.2.5.1 Battery main switch 24VDC
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Battery main swith 24VDC
Switching on and off of 24VDC supply.
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1.2.5.2 Operation panel
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1 Button "Power"
Switching on and off of GPU control voltage.
2 Touch panel
3 Button "Emergency stop"

Shut down the GPU in emergency. Reset by pulling red button head.

1.2.5.3 Additional operation panel (Option)

(situated on the right side in front of flap (viewed in direction of travel))
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1 Button "Power"
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Switching on and off of GPU control voltage.
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2 Touch panel
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3 Button "Emergency stop"

Shut down the GPU in emergency. Reset by pulling red button head.
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NOTE !
All commands in connection with the operation panel listed below can be
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performed on the operation panel as well as on the additional operation

panel (Option). Both panels have implemented the same software and
screens.
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1.2.5.4 Display-Menu „HOME“
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1 Display of operation / failure messages

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2 Button "Motor Start/Stop"

Start / Stop of GPU (Diesel engine)
Green LED flashing light during start.
Green LED continuous light in case of GPU ready (in operation).
Red LED flashing light in case of a warning failure.
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Red LED continuous light in case of a shut down failure.

3 Button "Options" (Option)
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Change to Display-Menu „Options“

4 Button "Autom. Motor Stop" (Option)
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Switching on and off of automatic shut down of engine after 20 Minutes without load.
Green LED continuous light in case of automatic shut down of engine is activ.
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5 Button "400Hz 1 on/off"

Switching on and off of 400Hz output 1.
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Green LED continuous light in case of 400Hz output 1 is switched on.

Orange LED flashing light in case of 400Hz output 1 not accepted.
Red LED continuous light in case of shut down failure of 400Hz output 1 (thermal overcurrent
...).
6 Button "50Hz on/off" (Option)
Switching on and off of 50Hz sockets.
Green LED continuous light in case of 50Hz output is switched on.
Red LED continuous light in case of shut down failure of 50Hz output.
7 Button "400Hz 2 on/off" (Option)
Switching on and off of 400Hz output 2.
Green LED continuous light in case of 400Hz output 2 is switched on.
Orange LED flashing light in case of 400Hz output 2 not accepted.
Red LED continuous light in case of shut down failure of 400Hz output 2 (thermal overcurrent
...).
8 Button "Current Limit" (Option)
Change to Display-Menu „28VDC current limitation”.

9 Button "28VDC on/off" (Option)

Switching on and off of 28VDC output.
Green LED continuous light in case of 28VDC output is switched on.
Orange LED flashing light in case of 28VDC output not accepted.
Red LED continuous light in case of shut down failure of 28VDC output
(thermal overcurrent, short circuit, overvoltage, undervoltage ...).
10 Button "RESET"
Push button to reset a failure after the responsible error has been eliminated.
11 Display "Service necessary"
Message „Service necessary“ displayed as a pictogram.
12 Display "Charging generator failure"
Fault "Charging generator failure" displayed as a pictogram.
13 Display "Oil pressure too low"
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Fault „Oil pressure too low“ displayed as a pictogram.
14 Display "Coolant temperature too high"
Fault „Coolant temperature too high“ displayed as a pictogram.
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15 Button "Measurement"
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Change to Display-Menu „Measurement”.
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16 Display of working hours
Display of engine working hours.
17 Button "Messages"
Change to Display-Menu „Messages“.
18 Display "Preheating in operation"
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Message „Preheating in operation“ displayed as a pictogram.
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19 Display "Fuel shortage"

Message „Fuel shortage“ displayed as a pictogram.
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20 Display "Diesel particle filter (DPF) loading/pollution" (Option)

Message „Diesel particle filter (DPF) loading/pollution“ displayed as a pictogram.
orange (slow flashing): Warning – 100% loading
orange (fast flashing): Warning – 114% loading
orange (permanently active): Regeneration (burner) active
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1.2.5.5 Display-Menu „28VDC current limitation“ (Option)

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Button to limit the output current at 28VDC output.

Maximum 2500A - selectable values: 850A / 1000A / 1275A / 1500A / 2000A / 2500A.

1.2.5.6 Display-Menu „Options“
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1 Signalling "Failure message available"

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By pushing on this signal, the screen changes to Display-Menu „Messages“.

2 Button "Parking lights on/off" (Option)
Switching on and off of parking lights (separate button for front and rear).
Green LED continuous light in case of light is switched on.
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3 Button "Spotlight on/off" (Option)

Switching on and off of spotlight.
Green LED continuous light in case of spotlight is switched on.
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4 Button "Revolving Light on/off" (Option)

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Switching on and off of rotating light.

Green LED continuous light in case of rotating light is switched on.
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5 Spare – not used

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6 Button "HOME"
Change to Display-Menu „HOME“
7 Button "Reset Horn“ (Option)
Reset of fuel shortage horn.
8 Button "Prevention DPF-Reg.“ (Option)
Switching on and off of prevention DPF-Regeneration..
At active prevention the burner is blocked and no increased exhaust gas temperatures will arise.
From a particle filter loading of more than 114% or at motor stop the button is automatically
reset.
Green LED is on if prevention is active.

1.2.5.7 Display-Menu „Messages“
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1 Button "Moving forward through messages“
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2 Button "Moving backward through messages“

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3 Button "RESET"
Push button to reset a failure after the responsible error has been eliminated.
4 Button "HOME"
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5 Button "Data Recorder"
Change to Display-Menu „Data Recorder“
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1.2.5.8 Display-Menu „Data Recorder“
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1 Button "Moving forward through Data Recorder“
2 Button "Moving backward through Data Recorder“

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3 Button "HOME"
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4 Button "Messages"
Change to Display-Menu „Messages“.
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5 Button "Saving"
By pressing the button, the content of the data recorder will be saved as a text file on a
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connected USB stick (the USB stick must be formatted in the FAT file format).
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1.2.5.9 Display-Menu „Measurement“
1.2.5.9.1 Display-Menu „Measurement 400Hz“
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1 Display 400Hz voltage measurement

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2 Display 400Hz current measurement

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3 Display 400Hz power measurement

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4 Display frequency
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5 Display power factor

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6 Display daily consumption (Option)
7 Display total consumption (Option)
8 Button "HOME"
9 Button "28 VDC"
Change to Display-Menu „Measurement 28VDC“
10 Button "DIESEL"
Change to Display-Menu „Measurement Diesel“
11 Button "TEST"
Change to Display-Menu „TEST“ (Password protected!)

1.2.5.9.2 Display-Menu „Measurement 28VDC“
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1 Display 28VDC voltage measurement
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2 Display 28VDC current measurement

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3 Button "HOME"
4 Button "400Hz"
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Change to Display-Menu „Measurement 400Hz“

5 Button "DIESEL"
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8 Button "TEST"
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1.2.5.9.3 Display-Menu „Measurement DIESEL“
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1 Display "Battery voltage"

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2 Display "Oil pressure"
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3 Display "Coolant temperature"

4 Display "Load"
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5 Display "Fuel consumption"

6 Display "Speed"
7 Display "Diesel particle filter (DPF) loading" (Option)
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8 Display "Motor working hours"

9 Display "Service interval"
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10 Display "Motor working hours since last service"

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11 Display "Working hours until next service"

12 Button "RESET"
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Reset of service working hours

(Mot.SWh. and Serv. in)
NOTE ! After carried out motor
(Password protected!) service the service hours
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have to be resetted!
13 Display "Content of fuel tank"
14 Display daily fuel consumption (Option)
15 Display total fuel consumption (Option)
16 Button "HOME"
17 Button "400Hz"
18 Button "28 VDC"
19 Button "TEST"

1.2.5.10 Display-Menu with 2 x 28VDC outputs (Option)
1.2.5.10.1 Display-Menu „Home“
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1 Button "Current Limit" (Option)
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In case of 2 x 28VDC outputs deactivated - no function in this menu.
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2 Button "28VDC" (Option)

Change to Display-Menu „Outputs 28VDC“
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1.2.5.10.2 Display-Menu „Outputs 28VDC“
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8 Button "HOME"
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1 Button "28VDC output 1 on/off" (Option)
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Switching on and off of 28VDC output 1.

Green LED continuous light in case of 28VDC output 1 is switched on.
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Orange LED flashing light in case of 28VDC output 1 not accepted.

Red LED continuous light in case of shut down failure of 28VDC output 1.
2 Button "Current Limit output 1" (Option)
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Maximum 1275A - selectable values: 850A / 1000A / 1275A

3 Button "28VDC output 2 on/off" (Option)
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Switching on and off of 28VDC output 2.

Green LED continuous light in case of 28VDC output 2 is switched on.
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Orange LED flashing light in case of 28VDC output 2 not accepted.

Red LED continuous light in case of a shut down failure of 28VDC output 2.
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4 Button "Current Limit output 2" (Option)
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Maximum 1275A - selectable values: 850A / 1000A / 1275A.

5 Button "28VDC output 1+2 on/off" (Option)
Switching on and off of 28VDC output 1+2.
Green LED continuous light in case of 28VDC output 1+2 is switched on.
Orange LED flashing light in case of 28VDC output 1+2 not accepted.
Red LED continuous light in case of shut down failure of 28VDC output 1+2.
6 Button "Current Limit output 1+2" (Option)
Maximum 2500A - selectable values: 850A / 1000A / 1275A / 1500A / 2000A / 2500A.
7 Button "Operation Mode output 1+2" (Option)
Switch for selection of output 1+2. When activated, buttons for output 1 and output 2 are
deactivated.
9 Button „Measurement 28VDC“

1.2.5.10.3 Display-Menu „Measurement 28VDC“
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1 Display 28VDC voltage measurement output 1

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2 Display 28VDC current measurement output 1

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3 Display 28VDC voltage measurement output 2
4 Display 28VDC current measurement output 2

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5 Button "Outputs 28VDC"

Change to Display-Menu „Outputs 28VDC“
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6 Button "HOME"
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7 Button "400Hz"
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8 Button "DIESEL"
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11 Button "TEST"

1.2.6 START
WARNING!
Don’t start the GPU if the message "Bypass on" is displayed on touch
panel.
Action Reaction Display LED on button

Switch on battery main- GPU 24VDC main-
switch on. supply is switched on.
Push button The control voltage is Push button motor start LED has continuous
"Power". switched on. The control light (green) when the
and display boot (appr. control voltage is
40s). Messages on applied.
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touch panel are shown
acc. program-status of
GPU.
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Push button LED "Oilniveau" (option)
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"Motor start/stop". in the menu “TEST”
must briefly illuminate.
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At low temperatures (ca. Preglowing in operation Green LED´s on button
5C and below) the are blinking during run
preglowing unit must
operate.
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Engine must start. Automatic motor start
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Engine must run up. Motor run up (15 sec.)

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After reaching nominal Unit in Operation (Standby) Green LED´s on button

values (about 15 sec.) are lighting after run up
the GPU is ready for is finished.
supply.
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1.2.7 SWITCHING ON / OFF OF CONSUMER OUTPUTS
NOTE ! FOR GPU´S WITH 28VDC SIMULTANEOUS.

It is possible to switch on 400Hz outputs and 28VDC (option) together.
(400Hz AND/OR 28VDC).
Only plugged in outputs stay switched on!
NOTE ! FOR GPU´S WITH 28VDC NOT SIMULTANEOUS.

It is not possible to switch on 400Hz outputs and 28VDC (option) together.
(400Hz OR 28VDC).
Only plugged in outputs stay switched on!
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1.2.7.1 Switching on / off of 200V/400Hz consumer outputs
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Push button 400Hz output 1 is Unit in Operation (Output on) Green LED´s on button
"400Hz 1 on/off" for switched on. are lighting.
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switching on output.
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Push button 400Hz output 1 is Unit in Operation (Standby) Green LED´s on button
"400Hz 1 on/off" for switched off. are dark.
switching off output.
Push button 400Hz output 2 is

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Unit in Operation (Output on) Green LED´s on button
"400Hz 2 on/off" (option) switched on. are lighting.
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for switching on output.
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Push button 400Hz output 2 is Unit in Operation (Standby) Green LED´s on button
"400Hz 2 on/off" (option) switched off. are dark.
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for switching off output.
1.2.7.2 Switching on / off of 28VDC consumer output (option)

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Select 28VDC current limit 28VDC current limit will be Unit in Operation (Standby) On button “28VDC
by using button “28VDC adjusted current limit” the value of
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current limit” the 28VDC current limit

is displayed
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Push button Output 28VDC is switched Unit in Operation (Output on) Green LED´s on button
"28VDC on/off" for on. are lighting.
switching on output.
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Push button Output 28VDC is switched Unit in Operation (Standby) Green LED´s on button
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"28VDC on/off" for off. are dark.

switching off the output.

1.2.8 STOP
Push button All outputs will be Push button motor start Button "Motor start/stop"
"Motor start/stop". switched off. The Diesel will be greyed out.
engine stops immediately.
Push button The control voltage is Touch panel will be switched Green LED's on button
"Power". switched off. There is no off. are dark as soon as the
more current consumption control voltage is
needed from the starter switched off.
battery.
Switch off battery-main The control unit of the
switch. GPU can not be switched
on and so the GPU can
not be started.
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1.2.9 SPECIAL FUNCTIONS
1.2.9.1 Oil-niveau regulation (option)
1.2.9.1.1 Signals
 After starting engine the signal lamp on the oilmaster test button (in the “TEST” Menu)
illuminates up for a few seconds. Now the oil-refill-system is ready.
 If the signal light starts flashing after starting Diesel engine, the storage reservoir of the
oilmaster is almost empty.
WARNING!
REFILL oil in the storage reservoir AS SOON AS POSSIBLE!
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 If the signal light illumintes constantly after starting the engine or after a pump cycle then:
 The storage reservoir is empty
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WARNING!
Check the oil level in the engine and REFILL oil in the storage
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reservoir immediately!
 The ambient temperature has fallen below -25C and the system will not perform a
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filling cycle. Check the oil level in the engine manually.
 A functional problem with the oilmaster has occurred.
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The error signal given by the "Oil level test lamp" can be reset by push button (in the “TEST”
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Menu) on service-panel once.
Always check the engine oil level manually when the lamp is indicating a problem.
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WARNING!
The signal disappears (the light goes off) – not the malfunction – if you
reset the oil-level regulation.
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1.2.9.1.2 Pump cycle test

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WARNING! Use this test carefully. Each time you execute this test oil will be added
to the engine (0,5 liter), probably without this being necessary.
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Increased execution of this test can result in over-filling of the diesel

engine with lubricating oil.
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 Fill the storage reservoir with engine oil.

 Check all oil pipes and connections for leakage.
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 Start the diesel engine.

 Push the "Oilmaster test button" (in the “TEST” Menu) for at least 5 seconds. The unit
should now run one complete filling cycle. When during a filling cycle the ignition is
switched off the unit will stop and only start again after ignition is switched back on.
1.2.9.1.3 Determining the oil level in the sump (oil sump)

 Start the diesel engine.
 Press the "Oilmaster test button" (in the “TEST” Menu) three times within five seconds.
 Three slow flashes (2,5sec. each) -> the oil level sensor reports that the oil level is ok.
 Three fast flashes (1sec. each) -> the oil level sensor reports too low oil level in the sump.

1.2.9.2 Outputs turned off by plane

In case of a failure the GPU-outputs also can be switched off by the aircraft (caused by
voltage - monitoring in the aircraft). The message "Output X 400Hz not accepted" or "Output X
28VDC not accepted" (option) is shown on the display.
For reset of failure “Output X not accepted” switch "On" or "Off" the corresponding output.
1.2.9.3 Shut down of engine after 20 minutes

(without supply or low current (I<<))
If after starting up the engine none of the GPU outputs will be activated within a period of 20
minutes, the GPU shuts down the engine automatically. The message "Automatic Motor Stop"
is shown on the display.
For reset switch "On" or "Off" the corresponding output.
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If during GPU operation the 400Hz alternator-current or the 28VDC current (option) decreases
below minimum the message "Automatic Motor Stop (I<<)" is shown on the display.
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After a time of 20 minutes showing the message " Automatic Motor Stop (I<<)" all outputs are
switched off and the GPU shuts down the Diesel-engine automatically. The message
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"Automatic Motor Stop" is shown on the display.
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For reset switch "On" or "Off" the corresponding output.
1.2.9.4 Turn off control-unit after 20 minutes

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If the Diesel-engine has not been started within a period of longer than 20 minutes, the
control-unit shuts down the GPU automatically. (Control-unit will be turned off for saving
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battery power.)
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If a shut down error has occurred, the control-unit Hitzinger-ACON will not be switched off after
a period of 20 minutes without starting the engine. (Failure remains present until reset of
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failure).
1.2.9.5 Illumination (option)

At Diesel-engine standstill the illumination (parking lights, spot light, revolving light …) can be
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switched on and off via buttons in the display-menu "Options" (option).

When the Diesel-engine starts the illumination will be switched on and when the engine stops
it will be switched off by the control-unit automatically.
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1.2.9.6 50Hz supply (option)

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After run up of Diesel-engine and permanent light of the green LED "Motor start/stop" the
optional 50Hz output (230V or 400/230V) can be activated via button “50Hz”.
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The voltage is available at the output sockets below the switch-panel.

By shut down of the diesel engine or in case of a shut down failure, the 50Hz output is
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switched off automatically.
1.2.9.7 J1939 interface (option)

Interface for communication between Diesel engine speed-governor and Hitzinger-ACON.
All warnings and failure messages from the speed governor can be detected by the Hitzinger-
ACON and are shown on the display. In the display-menu “Measurement” the values for
engine speed, temperature, oilpressure, battery voltage, fuel consumption a.s.o. also can be
read out on the display. Shut down of engine in case of critical Diesel engine failures.
1.2.9.8 115V/400Hz supply (option)

After run up of Diesel-engine and permanent light of the green LED "Motor start/stop" (8) the
optional 400Hz output (115V or 200/115V) is activated automatically (output contactor). The
voltage is available at the output sockets below the switch-panel. In case of a shut down
failure, the output is switched off automatically.

1.2.9.9 Drive away warning (option)

If output cables are not stored correctly in the cable tray (plugs not properly stored in the plug-
trays) and the GPU is towed away the drive away warning gives an acoustic and optical alarm.
When the control-unit is switched on this function is always available. After switch off of
control-unit this function remains active for 4 hours.
If the control unit is switched on, the warning can be acknowledged by correctly storing of
cables and plugs or by pressing button “RESET” in the Display-Menu “Messages” on the
touch-panel.
If the control unit is switched off, the warning signal can only be acknowledged by storing
cables and plugs correctly in the cable tray.
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1.2.10 OPERATION MESSAGES

Message Cause
Press button "Motor Start" Switching on the GPU by pressing button "Motor Start".
Pre-heating in operation Preglowing is active (after pushing button "Motor start’’ in case of low
temperatures).
Motor start-up Engine starts (electrical starter in operation).
Motor run-up (15 sec.) Engine is running up to its nominal speed. (about 15sec.)
Plant in operation (standby) GPU in operation, without active output.
Plant in operation (output active) GPU in operation and one or more outputs active.
Automatic engine stop (I<<) Message is shown in case of alternator current is below 7A or 28VDC output
is below 30A and one ore more outputs are switched on.
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Automatic engine stop After 20 minutes of GPU supply with a alternator current < 7A or 28VDC
output is below 30A the GPU shuts down the engine automatically.
!! Test run voltage 400Hz !! Test of 400Hz voltage range
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!! Test run voltage 28Vdc !! Test of 28VDC voltage range
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!! Test run 400Hz + 28Vdc !! Test of 400Hz and 28VDC voltage range
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!! Test run speed test !! Test of Diesel engine speed.
!! Test run Ignition on !! EMR speed regulator released for programming (only for service if necessary)
Bypass 400Hz 1 on 400Hz Bypass - Output 1 is switched on - only allowed for servicing!
Bypass 400Hz 2 on
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EF safety loop in position ON bridged!
400Hz Bypass - Output 2 is switched on - only allowed for servicing!
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Bypass 400Hz 1+2 on 400Hz Bypass – Output 1 & 2 is switched on - only allowed for servicing!
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400Hz output 1 not accepted Aircraft has turned off 400Hz output 1, caused by internal voltage monitoring
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in the plane or disconnection of plug during supply.

400Hz output 2 not accepted Aircraft has turned off 400Hz output 2, caused by internal voltage monitoring
28VDC output 1 not accepted Aircraft has turned off 28VDC output 1, caused by internal voltage monitoring
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28VDC output 2 not accepted Aircraft has turned off 28VDC output 2, caused by internal voltage monitoring
ty
Emergency stop pushed! "Emergency stop button" has been pushed.

er
Warning Fault A warning fault occurred, for details check menu "Messages".
Shutdown fault A shutdown fault occurred, for details check menu "Messages".
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1.2.11 FAILURE MESSAGES

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In case of a shut down failure all outputs will be turned off immediately.
The GPU is shut down and the kind of failure is shown on the display.
In case of a warning failure the GPU will not be shut down.

The kind of failure is shown on the display.
The failure has to be eliminated. For reset of failure-messages push button "Reset" in the
Display-Menu “Messages”.
For reset of failure “Output X not accepted” switch "On" or "Off" the corresponding output.

1.2.11.1 Common control + auxiliaries failures

Message Type Cause
Emergency Stop pushed Shut down "Emergency stop button" on GPU-panel front-side has been
pushed. Voltage supply for emergency stop has been cut out
or broken wire.
Service required Warning Pre-adjusted number of working hours for service and
maintenance has been reached.
Plug not stored correct Warning Plugs are not stored in right place before moving the GPU.
(option)
50Hz frequency failure Warning, Frequency failure of the 50 Hz supply (option)
50Hz off
50Hz converter failure Warning, Converter failure of the 50 Hz supply (option)
50Hz off
es
50Hz contactor failure Warning, Contactor failure of the 50 Hz supply (option)
50Hz off
50Hz transformer Warning, Transformer overtemperature of the 50 Hz supply (option)
n
overtemperature 50Hz off
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50Hz line safety switch tripped Warning, Message is shown in case of mini CB for 50Hz socket(s) has
50Hz off been tripped or switched off. (option)
Ai
CAN-Modul 400Hz Measurement Shut down Failure of the respective CAN module
error (shut down) -113A1
CAN-Modul 400Hz Tableau error Shut down Failure of the respective CAN module
(shut down) -121A1
CAN-Modul 400Hz Control error
(shut down) -121A2
Shut down
an
Failure of the respective CAN module
ic
CAN-Modul Diesel Control error Shut down Failure of the respective CAN module
(shut down) -123A1
er
CAN-Modul Diesel J1939 error Shut down Failure of the respective CAN module
(shut down) -151A1
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CAN-Modul Drive-Away-Warning Shut down Failure of the respective CAN module (Option)
CAN-Modul Remote Control error Shut down Failure of the respective CAN module (Option)
(shut down) -125A1
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CAN-Modul MIL Control error Shut down Failure of the respective CAN module (Option)
(shut down) -125A2
CAN-Modul TGPU Control IN Shut down Failure of the respective CAN module (Option)
ty

CAN-Modul TGPU Contorl OUT Shut down Failure of the respective CAN module (Option)
er

CAN-Modul 400Hz PWM error - Warning Failure of the respective CAN module, continued operation
140A1 without the respective option is possible
op
CAN-Modul Analog IN error - Warning Failure of the respective CAN module, continued operation
141A1 without the respective option is possible
Pr
CAN-Modul 28VDC Master 1 Warning Failure of the respective CAN module, continued operation
error -122A1 without the respective option is possible
CAN-Modul 28VDC Master 2 Warning Failure of the respective CAN module, continued operation
CAN-Modul External signalisation Warning Failure of the respective CAN module, continued operation
CAN-Modul 50Hz error -124A2 Warning Failure of the respective CAN module, continued operation
without the respective option is possible

1.2.11.2 Diesel engine + genset failure

Message Type Cause
Diesel Error (Shut Down) Shut down Failure on EMR regulator, actuator, sensors, pick-up etc. on
Diesel-engine.
Diesel Error (warning) Warning Failure on EMR regulator, actuator, sensors, pick-up etc. on
Diesel-engine.
Oil pressure error (Shut Down) Shut down Oilpressure in engine is too low, oilpressure switch defective
or oil-shortage.
Coolant water temperature high Shut down Engine load too high, cooling device defective or cooling
(Shut Down) obstructed or sensor for cooling water temperature defective.
Coolant water level (Shut Down) Shut down Cooling water level in the cooler has fallen below control level.
Overspeed (Shut Down) Shut down Speed regulation defective.
Fuel temperature error (Shut Shut down Fuel temperature too high
es
down)
Fuel pressure error (Shut down) Shut down Fuel pressure too high
Turbo boost pressure (Shut Shut down Turbo boost pressure outside the permissible range
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down)
rli
Charge air temperature error Shut down Charge air temperature error outside the permissible range
(Shut down)
Ai
Ambient pressure error (Shut Shut down Ambient pressure error outside the permissible range
down)
Battery error (Warning) Warning Battery voltage is too low
Start failure (Shut down) Shut down an
Engine cranks normally but does not start.
(3 unsuccessful start-trials)
ic
Charging alternator failure Warning Operation without battery-charging.
Particulate filter - loading > 125% Shut down Loading value of Particle filter is higher than 125%, the
er
- power reduction! (shut down) regeneration was not successful.

Fuel Shortage Shut down Fuel level is below the critical level.
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Shut down only in conjunction with the DPF-System,

otherwise a Deutz technician is required for venting of the
system.
Fuel Shortage Warning Fuel Shortage has fallen below control level.
Fuel Shortage Warning Warning Fuel Shortage has fallen below control level.
of
Oil-refill failure Warning Low oillevel in Diesel engine or oil refill reservoir; oil refill unit
faulty or temperature below -25°C. (option)
Inlet air filter dirty (warning) Warning Airfilter dirty (underpressure)
ty
Sensor failure - oil pressure Warning Oil pressure switch faulty or lack of oil
er
Oil Pressure Error (warning) Warning Engine oil pressure is too low
Sensor failure - coolant water Warning Coolant temperature sensor fault
temperature
op
Coolant Water Temperature high Warning Coolant temperature in the cooler of the diesel engine is too
(warning) high
Pr
Sensor failure - coolant water Warning Coolant water level sensor fault
level
Coolant water level (warning) Warning Cooling water level in the cooler has fallen below control level.
Sensor failure - speed Warning Speed sensor fault
Overspeed (warning) Warning Engine speed is too high
Sensor failure - air inlet Warning Air inlet temperature sensor fault
temperature
Air inlet temperature (warning) Warning Air inlet temperature too high
Air inlet temperature too high Warning Air inlet temperature too high
Sensor failure - fuel temperature Warning Fuel temperature sensor fault
Fuel temperature (warning) Warning Fuel temperature too high
Sensor failure - fuel pressure Warning Fuel pressure sensor fault
fuel pressure (warning) Warning Fuel pressure too high
Sensor failure - turbo boost Warning Turbo boost pressure sensor fault
pressure
Turbo boost pressure (warning) Warning Turbo boost pressure too high

Message Type Cause

Sensor failure - charge air Warning Charge air temperature sensor fault
temperature
Charge air temperature (warning) Warning Charge air temperature too high
Sensor failure - ambient pressure Warning Ambient pressure sensor fault
Ambient pressure (warning) Warning Ambient pressure outside the permissible range
Sensor failure - ambient Warning Ambient temperature sensor fault
temperature
Ambient temperature (warning) Warning Ambient temperature too high
Feedback rack position failure Warning Rack position failure
(warning)
Throttle position undefined Warning Throttle position undefined
(warning)
Water in fuel (warning) Warning Water in fuel
es
Sensor failure - Water in fuel Warning Water in fuel sensor fault
Oil level low (warning) Warning Engine oil level is too low
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Sensor failure - Oil level low Warning Oil level sensor fault
Oil temperature high (warning) Warning Oil temperature too high
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Sensor failure - oil temperature Warning Oil temperature sensor fault
Ai
Crankcase pressure (warning) Warning Crankcase pressure is too high
Sensor failure - crankcase Warning Crankcase pressure sensor fault
pressure
Sensor failure - camshaft position
Sensor failure - flywheel position
and speed
Warning
Warning
an
Camshaft position sensor fault
Flywheel position and speed sensor fault
ic
Piston cooling pressure (warning) Warning Piston cooling pressure outside the permissible range
Sensor failure - piston cooling Warning Piston cooling pressure sensor fault
er
pressure
Starter relais (warning) Warning Start relay fault
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Sensor failure - flue gas Warning Exhaust temperature sensor fault

temperature
Flue gas temperature (warning) Warning Exhaust temperature outside the permissible range
Flue gas temperature too high Warning Exhaust temperature is too high
of
(warning)
Sensor failure - Flue gas valve Warning Flue gas valve sensor fault
Sensor failure inlet air filter Warning Inlet air filter monitoring sensor fault
ty
monitoring
Engage inlet air filter dirty Warning Dirty air filter contact active
er
(warning)
Flue gas differential pressure Warning Particle filter laden, differential pressure too high
op
(warning)
Sensor failure - flue gas Warning Differential pressure sensor fault
differential pressure
Pr
Flue gas temperature upstream Warning Upstream flue gas temperature too high
(warning)
Flue gas temperature Warning Downstream flue gas temperature too high
downstream (warning)
Particulate filter - loading > 100% Warning Loading value of Particle filter is higher than 100%, the
- Regneration required (Warning) Regenration is starting automatically.
Particulate filter - loading > 114% Warning Loading value of Particle filter is higher than 114%, the
- Regneration required (Warning) Regenration is starting automatically.
J1939 Communication error Warning CAN-Bus Error of ECU

1.2.11.3 400Hz alternator failures

Message Type Cause
Temperature warning Phase L1 Warning, all Alternator overtemperature (detected by PT100 sensor in the
outputs off alternator windings Phase 1)
Alternator overtemperature PTC Warning, all Alternator overtemperature (detected by thermistors in the
shut down (option) outputs off alternator windings) (Option)
Alternator overtemperature phase Shut down Alternator overtemperature (detected by PT100 sensor in the
L1 shut down alternator windings Phase 1)
es
n
Temperature sensor error Phase Warning, all Temperature sensor (PT100) L1 short circuit
rli
L1 below min limit outputs off
Ai
Temperature sensor error Phase
L1 maximum exceeded
Temperature sensor error Phase
Warning, all
outputs off
Warning, all
an
Temperature sensor (PT100) L1 sensor failure
Temperature sensor (PT100) L2 sensor failure

ic
L2 maximum exceeded outputs off
Temperature sensor error Phase Warning, all Temperature sensor (PT100) L3 sensor failure
er
L3 maximum exceeded outputs off

Alternator undervoltage (<70V) Shut down Undervoltage (U<70V) detected by the internal voltage-
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monitoring in the ACON (delay 0,3sec.)

Alternator undervoltage (<104V) Shut down Undervoltage (U<104V) detected by the internal voltage-
monitoring in the ACON (delay 2 sec.)
Alternator overvoltage (>124V) Shut down Overvoltage (U>124V) detected by the internal voltage-
monitoring in the ACON (delay 0,5 sec.)
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Alternator overvoltage (>150V) Shut down Overvoltage (U>150V) detected by the internal voltage-
monitoring in the ACON (delay 0,3sec.)
ty
Alternator underfrequency Shut down Underfrequency (F<345Hz) detected by the internal

(<345Hz) frequency-monitoring in ACON (delay 0,5 sec.)
er
Alternator underfrequency Shut down Underfrequency (F<380Hz) detected by the internal

(<380Hz) frequency-monitoring in the ACON (delay 4 sec.)
Alternator overfrequency Shut down Overfrequency (F>420Hz) detected by the internal frequency-
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(>420Hz) monitoring in the ACON (delay 4 sec.)

Alternator overfrequency Shut down Overfrequency (F>435Hz) detected by the internal frequency-
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(>435Hz) monitoring in ACON (delay 0,5sec.)

Alternator overcurrent L1 (110%) Shut down Overcurrent L1 (I = In x 1.1) detected by ACON
(delay 1hour)
(delay 1hour)
(delay 1hour)
(delay 5 min.)
(delay 5 min.)
(delay 5 min.)
(delay 5 sec.)
(delay 5 sec.)

Message Type Cause

(delay 5 sec.)
400Hz output 1 overcurrent Warning, Overcurrent detected by a thermistor-relay in the switchboard.
400Hz 1 OFF
400Hz output 2 overcurrent Warning, Overcurrent detected by a thermistor-relay in the switchboard.
400Hz 2 OFF (option)
400Hz output 1 not accepted Warning, Aircraft has turned off 400Hz output 1. (caused by internal
400Hz 1 OFF voltage monitoring in the plane or disconnection of plug during
supply)
400Hz output 2 not accepted Warning, Aircraft has turned off 400Hz output 2. (caused by internal
400Hz 2 OFF voltage monitoring in the plane or disconnection of plug during
supply) (option)
n es
rli
Ai
an
ic
er
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of
ty
er
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1.2.11.4 28VDC (option) failures

Message Type Cause
28VDC communication error Warning, Communication Error CAN-Bus
28VDC OFF
28VDC contactor not closed - Warning, Mini CB for 28VDC Stack supply tripped or switched off
fuse failure 28VDC OFF
28VDC undervoltage output 1 Warning, Undervoltage detected by the voltage supervision of the
28VDC OFF 28VDC Stack (measured at the aircraft plug)
28VDC undervoltage output 2 Warning, Undervoltage detected by the voltage supervision of the
(Option) 28VDC OFF 28VDC Stack (measured at the aircraft plug) (option)
28VDC overvoltage output 1 Warning, Overvoltage detected by the voltage supervision of the 28VDC
es
28VDC OFF Stack (measured at the aircraft plug)
28VDC overvoltage output 2 Warning, Overvoltage detected by the voltage supervision of the 28VDC
(Option) 28VDC OFF Stack (measured at the aircraft plug) (option)
n
rli
28VDC output 1 not accepted Warnung, Aircraft has turned off 28VDC output 1. (caused by internal
28VDC AUS voltage monitoring in the plane or disconnection of plug during
supply)
Ai
28VDC output 2 not accepted Warnung, Aircraft has turned off 28VDC output 2. (caused by internal
(Option) 28VDC AUS voltage monitoring in the plane or disconnection of plug during
supply)
28VDC overtemperature module
01
Warning,
28VDC OFF
an
Overtemperature detected by evaluation electronics on Stack
Module 1
ic
28VDC overtemperature module Warning, Overtemperature detected by evaluation electronics on Stack
02 28VDC OFF Module 2
er

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of

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28VDC cable broken group 01 Warning, Output cable 1 broken
er
28VDC OFF
28VDC cable broken group 01 Warning, Output cable 2 broken (Option)
op
28VDC OFF
Pr

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conditioners. Temperature can be up to 400°C - danger of serious burning

 The maintenance flaps have to be closed during normal operation.

1.2.3 PRE-START CHECKS

1.2.3.1 Check before first put into operation

 Check oil level in the oil level controller reservoir (option).

 Check gel batteries for pollution and clean them if necessary.

D POWER1 Edition 01 - Page 11 / 40

1.2.4 CONNECTING TO AIRCRAFT

1.2.4.1 Protection system modified overcurrent protection (TN):

(protection on plugs bridged).

This condition is not allowed for normal air side operation!

1.2.4.2 Protection system modified protective insulation (IT) (option):

connected aircraft plug. (Prevented by the E-F contact on 400Hz plug).

WARNING ! Switch on of the Bypass-switch is only allowed for servicing works.

on the 400Hz aircraft plug may be possible!

This condition is not allowed for normal air side operation!

D POWER1 Edition 01 - Page 12 / 40

1.2.5 OPERATION ELEMENTS FOR AIR SIDE OPERATION

1.2.5.1 Battery main switch 24VDC

3 Button "Emergency stop"

D POWER1 Edition 01 - Page 13 / 40

1.2.5.3 Additional operation panel (Option)

3 Button "Emergency stop"

performed on the operation panel as well as on the additional operation

D POWER1 Edition 01 - Page 14 / 40

1.2.5.4 Display-Menu „HOME“

1 Display of operation / failure messages

2 Button "Motor Start/Stop"

Red LED continuous light in case of a shut down failure.

Change to Display-Menu „Options“

5 Button "400Hz 1 on/off"

Green LED continuous light in case of 400Hz output 1 is switched on.

D POWER1 Edition 01 - Page 15 / 40

9 Button "28VDC on/off" (Option)

19 Display "Fuel shortage"

20 Display "Diesel particle filter (DPF) loading/pollution" (Option)

1.2.5.5 Display-Menu „28VDC current limitation“ (Option)

Button to limit the output current at 28VDC output.

D POWER1 Edition 01 - Page 16 / 40

1.2.5.6 Display-Menu „Options“

1 Signalling "Failure message available"

By pushing on this signal, the screen changes to Display-Menu „Messages“.

3 Button "Spotlight on/off" (Option)

4 Button "Revolving Light on/off" (Option)

Switching on and off of rotating light.

5 Spare – not used

D POWER1 Edition 01 - Page 17 / 40

1.2.5.7 Display-Menu „Messages“

2 Button "Moving backward through messages“

Change to Display-Menu „HOME“

D POWER1 Edition 01 - Page 18 / 40

1.2.5.8 Display-Menu „Data Recorder“

1 Button "Moving forward through Data Recorder“

2 Button "Moving backward through Data Recorder“

D POWER1 Edition 01 - Page 19 / 40

1.2.5.9 Display-Menu „Measurement“

1.2.5.9.1 Display-Menu „Measurement 400Hz“

1 Display 400Hz voltage measurement

2 Display 400Hz current measurement

3 Display 400Hz power measurement

5 Display power factor

6 Display daily consumption (Option)

7 Display total consumption (Option)