08 Maintenance

Dubai International Airport Expansion
Contract #TD56 Passenger Loading Bridges

March 2015
8. Maintenance
Volume 5 - Jetpower PWM

Section 8 - Maintenance
Page 75
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March 2015
8.
Maintenance
Description
Page
Procedure for the Logical Diagnosis and Correction of Faults....................77
Initial Checks...................................................................................77
Wiring.....................................................................................77
Status Lights..........................................................................79
Input Power............................................................................80
DC Voltages............................................................................80
Low Voltage Power Supply Problem.................................................80
Converter Faults..............................................................................81
Main Faults.......................................................................................82
Troubleshooting Tips........................................................................86
Troubleshooting Flow Charts.....................................................................90
Parts Replacement..................................................................................103
The Card Rack................................................................................103
The Inverters.................................................................................103
IGBT Installation............................................................................104
IGBT Drive Board Installation.........................................................104
The Output Cable...........................................................................106
Replacing the Output Cable...........................................................108

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1.
Procedures for the logical diagnosis and correction of faults

A.
Initial Checks
(1)
Wiring
Following the initial installation of a Jetpower PWM
converter or the replacement of parts, it is always best
to inspect and verify that all wiring is correct and secure.
(a)
(b)

Input/Output Wiring
The incoming three phase 50 or 60 Hertz power

is normally brought into the unit through the
case and connected to a circuit breaker.
Verify that the wires are connected securely.
Verify that the output cable is connected

correctly and check for lug bolt tightness.
Control Wiring
Check the converters start/stop wiring that's

connected to TB-6 pins 1 through 6.
Check the output cables E and F safety

interlock wiring.
Insure the connector on the IV Sense board is

properly seated.
If the converter is mounted on a passenger

boarding bridge, use the bridge schematic to
check the bridge interlock wiring connected to
TB-4.
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(c)
(d)
(e)

SCR Wiring
Insure that the three wires coming from the

input circuit breakers are securely fastened to
the appropriate SCR.
Verify that the connectors on the ends of the

wires going from the SCR interface board to the
SCR are properly seated.
Transistor Drive Boards
Verify that all the 12 VAC and 9 pin D

connectors are properly seated.
Check that the transistor output wire from each

transistor terminal C2E1 is properly positioned
and that the three transistor board mounting
screws are tight.
Card Rack Connectors
On the 24 phase board insure that the cable

from P1 to inverters 1 & 2 is connected to the
top connector and that the cable from P2 to
inverters 3 & 4 is connected to the bottom
connector.
These connectors can be installed in the wrong

place and the Jetpower will operate, but the
output voltages will not be correct.
Carefully check the three (3) connectors

plugged into the BITE board.
Carefully check the two (2) connectors plugged

into the Logic board.
Carefully check the connector plugged into the

Power Supply board.
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(2)
Status Lights
When first inspecting a Jetpower PWM converter that
has been reported as having a problem, always begin by
first checking the status of the three lights on the front
of the unit.
Color Status Indication
No Faults Being Reported
Red
Of
Red
Steady
Red
Flashin
g
Yello
w
Of
Yello Steady
w
Yello Flashin
w
g
Green
Of
Green Steady
Green Flashin
g
The red light off indicates that there are no

faults being reported by the converter.
This is the normal operating condition of this
light.
System Fault
When the red light is on steady, a fault
condition has occurred.
Check the seven segment displays on the logic
board to see what the fault is.
Input Out of Phase
When the red light is flashing, either the input
(380/480 volts) is missing one or two phases,
or the input voltages are out of tolerance.
No Input Power Applied
The yellow light off indicates that the 380 or
480 input voltage is not being received by the
converter.
Input Power Applied
The yellow light will always be on steady
whenever the input circuit breaker is on and
input power is being supplied to the converter.
Aircraft Safety Circuit Bypassed
To enable a Jetpower converter to be operated
without an aircraft (no 28 volts on pin F) the
bypass switch on the logic board must be
turned on.
A flashing yellow light indicates that the bypass
switch on the logic board is turned on.
400 Hz Power Off
The green light off indicates that the converter
is not operating and 400 Hz power is not
present at the aircraft plug.
400 Hz Power to the Aircraft Plug
The green light is on steady whenever the
converter is turned on and is operating.
No 28v Received from the Aircraft
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Color Status Indication

Once 28 volts has been supplied to the
converter, its removal causes the converter to
shut off and the green light to begin flashing.

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(3)
(4).
B.
Input Power
(a)
If the red fault light is flashing, then either the

input (380/480 volts) is missing one or two phases
or the input voltages are out of tolerance.
(b)
Depress first the A IN, then the B IN and finally the

C IN push buttons on the key pad.
(c)
The input voltages should be displayed on the

digital panel meter, visible through the clear
Plexiglas window.
(d)
If the incoming voltages are not correct, use a

hand held digital voltmeter and trace back
through the converter to the incoming circuit
breaker and then on to the source of the utility
power to determine where the problem is.
DC Voltages
(a)
Check the +5 VDC and the 15 VDC by observing

the three green LED's located on the P/S board.
(b)
These LED's should be on and all at about the

same intensity.
Low Voltage Power Supply Problem

(1)
If any of the power supply LED's are not lit or are dim,
turn off the main power to the converter, unplug the
Power Supply board from the card rack (leaving the
cable plugged into the front of the board) and then turn
back on the main power to the converter.
(2)
If the three LED's are still not properly lit, replace the P/S
board.

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(3)
If the LED's are properly lit with the board unplugged,

turn off the main power to the converter and find the
source of the problem.
(a)
To do this, first place an ohm meter between

ground (pins 1,A,22 or Z) on the card racks edge
connector and the pin associated with the unlit
LED. +15v is pin 2,B. -14v is pin 21,Y. +5v is pin
3,C.
(b)
Then remove one circuit board at a time from the

card rack until the cause of the problem (usually a
short) is eliminated.
CAUTION:
BE EXTREMELY CAREFUL TO NOT

REMOVE OR INSTALL A CIRCUIT BOARD
WITH THE MAIN INPUT POWER ON.
B.
Converter Faults
A steady red light on the front of the converter indicates that a
fault signal has been returned to the logic board.
(1)
Inverter Alarms
(a)
One of the most common causes of a fault (red)

light is an inverter alarm.
(b)
A number will appear on the top numerical LED

located on the edge of the logic board which
indicates which inverter is causing the problem.

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(2)
Main Faults
The bottom LED on the Logic board displays the main faults.
The following is a detailed description of these faults:
Indicati Fault
on
1
Input Voltage to High.

This fault should only occur when the input voltage is
more than 10 % higher than the rated input voltage. For
480 volt rating this would be 528 volts, for 415 it would
be 456 volts, for 380 it would be 418 volts. Use the
voltage reading obtained on the digital meter on the unit
for checking this because this is what the fault circuitry
uses. If the voltages are all OK it is worth checking the
voltage setting on the Logic Board for an incorrect
setting. See Logic Board description for how to set the
switches. If this still does not eliminate the fault then the
Logic board could be bad. This fault is reset by first
pushing the stop button and then by removing and
reapplying the input power. This fault will also cause the
red lamp on the front panel to blink.
DC Bus Fault.
This fault is to indicate that a fault has occurred on the
DC bus Discharge system. Whenever input power is
removed the Discharge board activates and discharges
the voltage on the DC bus. Two large resistors mounted
on the Discharge bard are used to discharge this voltage.
A heat sensor is mounted on the resistors. If the resistors
get too hot the heat sensor will trip and a DC Bus fault
will occur. This fault could mean that the Discharge
board tried to discharge with power applied to the unit.
This could happen if the board failed or the cable
connected to the board is not plugged in or a wire has
come loose going to this connector. There is one green
LED on the board. This indicates that the board is
receiving 120vac to tell in to NOT discharge. When the
120vac goes away it will discharge.
Output Voltage Low.
This fault will occur when the output voltage goes below
100 volts for more than 4 seconds. Under normal
conditions this should not ever occur. The most common
occurrence is when the voltage control pot has been
turned down and the Jetpower is started. If the voltage is
not adjusted above 100 volts within 4 seconds this fault

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Indicati Fault
on
will occur. This fault is cleared by pushing the stop button.
4
Output Voltage Above 180 Volts.

This is another fault that should not ever occur. It is in the
unit to shut it down if the voltage ever got this high in
order to meet MIL-STD-704. If this fault occurs then
something is wrong with the 24 Phase board that makes it
put out too high of output voltage. This fault is cleared by
pushing the stop button.
Output Voltage High.
This fault could occur if the voltage goes above 126 volts
for to long. It is a timed fault. The higher the voltage the
faster it faults. At 2 volts above the limit the Jetpower will
run for 1 second, but at 20 volts above the limit it will run
for about .1 seconds. This is according to a curve that
MIL-STD-704 specifies. Note that some individual
specifications call for different over voltage limits so the
level that this fault occurs could vary. This fault is cleared
by pushing the stop button.
Output Overload.
This fault can occur if the Jetpower is operated in an
overload condition to long. It is timed so that the higher
the load the faster the fault will occur. The maximum load
is 200%. At about 210% the fault will occur almost
instantly. The fault can be reset by pushing the stop
button.
No 28 Volts on E & F.
This fault occurs if the 28 volt interlock system with the
aircraft is not functioning. When the Jetpower is started it
produces 400 Hz. But if after 4 seconds the 28v interlock
signal is not received on TB F from the aircraft this fault
will occur. It will also occur instantly if the 28 volt signal is
ever lost after this initial 4 second start up time. The most
likely reason this fault would occur is if the output cable is
bad or the plug was pulled from the aircraft while hot.
The fault can be cleared by pushing the stop button.
E & F Over-Voltage.
This fault occurs if greater than 60 volts is ever present
on the 28 volt aircraft interlock wires. This could occur if
the output cable has a short in it that applies one of the
output phase wires to the 28 volt wires. The fault can be
cleared by pushing the stop button.

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Indicati Fault
on
9
Input Voltage Low.

This fault should only occur when the input voltage is
lower than 15 % below the rated input voltage. For 480
volt rating this would be 408 volts, for 415 it would be
353 volts, for 380 it would be 323 volts. Use the voltage
reading obtained on the digital meter on the unit for
checking this because this is what the fault circuitry uses.
If the voltages are all OK it is worth checking the voltage
setting on the Logic Board for an incorrect setting. See
Logic Board description for how to set the switches. If this
still does not eliminate fault the Logic board could be bad.
The fault can be cleared by pushing the stop button. This
fault will also cause the red lamp on the front panel to
blink.
No Output Voltage Control.
This fault will occur if the Jetpower does not detect the
output voltage. It is to protect the aircraft in the event
something failed in the Jetpower. The Jetpower regulates
its output voltage by observing what it reads at the
output. If it reads 0 volts at the output it would try to
make the output voltage go higher until it reads the
correct voltage. It no signal was detected but the voltage
was actually there then very high voltages could be
produced on the output.
This fault could occur if the Jetpower is in Automatic
control (toggle switch on 24 Phase board) and the voltage
control pot is turned down all the way when the start
button is pushed. In this condition no voltage is detected
and a fault will occur. To stop this turn the voltage control
pot up about 1/3 of the way and then push the start
button. The Jetpower should come on and then the
voltage can be turned up before an under voltage fault
occurs.
This fault can also occur if the plug on the IV Sense board
has been removed or is not connected properly.
The fault can be cleared by pushing the stop button.
Single Output Line shorted.
This fault monitors if one of the output phases goes
above 130 volts but the other two remain low. This should
never occur but is there for protection. The fault can be

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Indicati Fault
on
d
E
Output Frequency out of Tolerance.

This fault should never occur. It detects the output
frequency and faults if the frequency is lower than 370 Hz
or greater than 430 Hz. The 400 Hz generator is crystal
locked so the frequency should never vary. But if the
crystal failed and it doubled or halved in frequency (most
likely failure) this fault would occur. This is an indication
that that 24 Phase board has failed. The fault can be
not used
Over Temperature
This fault can occur if one of the large heatsinks get too
warm. There are heatsinks on each power switching
transistor bank (or IGBT) and on the main rectifier bank.
Each heatsink has a temperature switch. They are all
wired in series. If any one the switches opens this fault
would occur. When this fault occurs the fans on the
Jetpower continue to operate but the Jetpower will not.
This allows the Jetpower to cool down. This fault could
occur if a fan failed and a moderate load was applied to
the Jetpower which would cause an over heat condition. If
the Jetpower is not warm it is possible that a connection
on one of the temperature switches has come off. The
fault can be cleared by pushing the stop button.
IGBT Alarm.
This fault occurs when a power IGBT has failed to turn on
when it was supposed to. It can occur if the transistor is
bad or when an extreme load was applied that was not
caught by the overload fault.. The top display on the
Logic board will identify which IGBT failed. Sometimes it is
obvious that a IGBT (or IGBT) has failed. Physical damage
can be seen around the IGBT where it has destroyed
itself. If no physical damage is observed then push the
stop button, remove and reapply the input power and
push the start button again. If no fault occurs it was
probably some kind of short on the output that is no
longer there. If a fault occurs again then the IGBT that is
identified on the top display is bad.
Always replace both the IGBT and the Drive board that is
mounted on top of it. After replacing a IGBT put the Logic

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Indicati Fault
on
board into test mode to test the IGBTs before operating
normally.

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D.
Troubleshooting Tips
To simplify troubleshooting, remember that the
Jetpower PWM ground power unit consists of only four
(4) basic parts.
(1)
The Silicon Controlled Rectifiers (SCR's)

(a)
This section receives the incoming volts AC and

changes it to DC.
(b)
This DC voltage is then changed to 400Hz square

waves by the inverters. The square waves are
then combined by the output transformers to form
the three output waveforms.
(c)
Therefore, if your problem is something that

afects all three of the output voltages the
same then the problem is most likely with
the rectifier section.
(d)
The rectifier is designed to provide the DC bus

voltage necessary to produce up to 140 kVA of 3
Phase 400 Hz power.
It contains three (3) high current dual SCRs which
are used as a switched rectifier to put the DC on
the bus.
This type of rectification is commonly called a six
(6) step rectifier.
NOTE:
FMC Jetway Systems does provide a twelve (12)

step rectifier as an option.
(e)
The SCR control signal that turns the SCRs on and

off is generated on the Logic board.
The Logic board knows when to turn the SCRs on
and off for proper operation.
When the start button is pushed the Logic board
sends the control signal to turn the SCRs on.

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When either the stop button is pushed or a fault

occurs the Logic board removes the control signal.
When the start switch is pushed the SCRs are
turned on and the voltage on the DC bus will ramp
up slowly until the SCRs are completely on.
A small pot located on the front of the SCR Ramp
board can be used in testing. This pot is a manual
adjustment of the DC voltage on the bus. When
turned fully counter clockwise no voltage will be
present on the bus. As the pot is turned clockwise
the voltage will increase. Normal operation is the
pot fully clockwise.
(f)
Bus Fuse.
This is a fuse that is installed in the main bus
directly above the SCRs. If a transistor has
destroyed itself or some other major fault this fuse
could be blown. If everything appears OK but no
voltage is on the output, it is worth checking this
fuse with an ohm meter.
(3)
(3)
The Inverters (IGBTs)

(a)
The inverter section consists of the 24 phase

board that sends out the inverter drive signals to
the four (4) inverters.
(b)
The inverters receive the DC voltage from the SCR

section. Through the use of large power IGBTs,
they change this DC voltage to a string of square
waves.
(c)
Each of the four (4) inverters are made up of three

sections. Each section contains a IGBT drive
board and a power IGBT.
(d)
Therefore, if your problem is afecting one

phase diferent than another phase then the
problem will most likely be with one section
of an inverter.
The Transformer Section

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(4)
(a)
The output transformers receive the pulses from

the inverter sections and combine them to form
the output waveforms.
(b)
Therefore, gross irregularities in the output

voltages will usually be caused by a problem
in the transformer section or an inverter.
(c)
When troubleshooting the transformer section

always check first for discolored or loose
connections.
(d)
Then carefully inspect the transformers input and

output wires to insure that they are not shorted to
the case or to one of the transformer lugs.
(e)
When operated with a load the transformer

primaries should all have approximately the same
current.
The Control Section

This section consists of the Logic board, the stop/start
push buttons and the IV sense board.
(a)
Logic Board
The Logic board provides the control logic that
stops and starts the converter.
This board also receives the 28 volts that comes
from the aircraft and provides the logic that
controls the operation of the three indicator lights
on the front of the converter.
Therefore, if you have a problem with the 28
volt return system or in the operation of the
start/stop controls, the problem may be with
the Logic board.
(b)
The Stop/Start Push Buttons

The stop/start push buttons can be checked using
the installation drawings and an ohm meter.

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(c)
IV Sense Board
The IV Sense board monitors the output voltages
and currents and sends samples back to the 24
Phase board and the BITE board.
Therefore, if your problem is output voltage
regulation the cause may be either the IV
Sense board or the 24 Phase board.
If the problem is with the digital panel meter the
cause may be with either the key pad assembly,
the IV Sense board, the BITE board or the meter
itself.
(5)
The Output Cable

(a)
Most problems with the output cable will be either

shorts between the conductors or open
conductors.
(b)
Always disconnect the cable from the converter

prior to ohming it out.
This will insure you do not get erroneous readings
by reading back through the output transformer
windings.
(c)

Problems occurring immediately after an output

cable installation most likely will be caused by the
output phase rotation being connected incorrectly.
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2.
Troubleshooting Flow Charts

The following pages are troubleshooting
charts for the Jetpower PWM units.
Not all faults are contained here.
Only the ones that are
considered more prevelant
The faults displayed on the lower

display on the 24 Phase board
are:
0 - No
fault
1 - Input Voltage to high
2 - DC bus fault
3 - Output voltage to low
4 - Output voltage > 180v
5 - Output voltage > 130v
6 - Output overload
7 - No 28v on EF
8 - EF overvoltage
9 - Input Voltage to low
A - Output Voltage not detected
b - Single output line shorted
C - Output frequency fault
E - Overtemperature
F - IGBT fault
This drawing and any associated information or amendments are proprietary and confidential to
Jetway Systems. The drawing and information may only be used for the specified contract under
which it is delivered and only by the purchaser. Acceptance of the drawing and information
constitutes agreement not to reproduce it in whole or in part and not to disclose it to any other
party and not to use it for any purpose beyond the limited license granted herein without prior
written consent.
Jetway Systems
a division of FMC
Description
INSTR JETPOWER PWM TROUBLSHOOTING CHARTS

MLFullm
Appd.
er
By
Date 08Feb99
Date

Code 54077
Drawing
291236
4
Rev. NC
Sheet 1 of
13
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Page 2 of 13
2912364
Jetpower PWM Troubleshooting Chart
Faults 1 and 9
Read Ain, Bin, Cin

with Panel Meter
Red Flashing Light
Yes
Is SW3
on Logic board set
correctly?
Rev NC
-15% to +10% of
rated input voltage?
Yes
No
Check input
voltage at main
circuit breaker
No
Set SW3 per

instructions
in manual
Replace
Logic Board
Check wiring to
small circuit
breaker
Check input
voltage at small
circuit breaker
Within Tolerance?
Yes
Correct input
power problem
No
Within tolerance?
No
Yes
Check voltages on LV MOV Board:

input voltage =
J3-1 to J3-2 = 18 16 14 vac
J3-1 to J3-3 = 18 16 14 vac
J3-1 to J3-4 = 18 16 14 vav
(+- 1v)
480
415
380
vac
Correct wiring
problems
No
Within tolerance?
Check for loose

wires on small
three phase
transformer
No
Yes
Check voltages on LV MOV Board:

input voltage =
J4-1 to J4-2 = 18 16 14 vac
J4-1 to J4-3 = 18 16 14 vac
J4-1 to J4-4 = 18 16 14 vac
(+- 1v)
Yes
480
Within Tolerance?
Wires OK?
415
380
Replace small
three phase
transformer
vac
No
Check connectors
on board, if ok then
replace LV MOV
board
Yes

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Yes
Faults 1 and 9
Red Flashing
Light
Page 3 of 13
2912364
Check wiring from LV MOV board

to Power Supply board:
LV MOV Brd
PWR Supply Brd
J4-1
to J1-6
J4-2
to J1-7
J4-3
to J1-8
J4-4
to J1-9
Find wiring
problem?
Rev NC
Yes
Correct wiring
problem
No
Check voltage on Mother

board connectors P2-P7
pin 17, 18, 19 to ground.
They should have similar
voltage readings as were
measured on LV MOV
board
Replace Power
Supply board
No
Voltages within
tolerance?
Check voltages
on pin 17, 18, 19
again
Voltages within
tolerance?
Yes
Finished
Yes
No
Remove all boards except Power

supply from card rack. Remeasure
voltages on P2-P7 pin 17, 18, 19.
Replace BITE
Board
Plug in Logic board with plugs on front of

board not connected.
Check voltages on pin 17, 18, 19 again.
Remove Logic board and plug in BITE

board with plugs unplugged. Check
voltages on pin 17, 18, 19 again.
Voltages within
tolerance?
Yes

Yes
No
Yes
Voltages within
tolerance?
Voltages within
tolerance?
No
No
Replace Mother
board
Replace Logic
board
Replace BITE
board
Plug boards back in and

start over
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This sheet only applies if a SCR RAMP
board is NOT installed in the card rack.
Page 4 of 13
2912364
With input power applied, push stop/reset button. Turn off main circuit breaker.
Lower the SCR side door. Look at the Bus Charge board, especial y the ceramic
Fault 2 - DC Bus
Fault
Rev NC
resistors.
Check bus fuse
Yes
Is fuse ok?
Yes
Does
Bus Charge board
look ok?
No
Change Bus
Charge board
Look at each IGBT (XSTR)

and Drive board for damage.
No
Change fuse
Do IGBTs
(XSTRs) and Boards look
ok?
No
Replace bad ones

with replacment
kits.
Yes
Put Logic Board into test mode (refer to manual for this). Toggle auto/manual switch
down. Toggle bypass switch up. Connect DC voltmeter from top to bottom bus bars
near IGBTs. Turn on input breaker.
WARNING:VOLTAGE ON DC BUS SHOULD STAY BELOW 10 VDC. IF IT DOES
NOT THEN DO NOT CONTINUE.
Push Stop/reset.
Push Start.
Are any
drive board leds
on?
No
Do all
of the Drive board LEDs
come on?
Yes
Choose a board that has an LED

on. With power stil on, remove
the 24 Phase plug from this
board and plug in a plug from a
board that the LEDs are not on.
Yes
No
Choose a no LED board. Push

stop. With power stil on, remove
the 24 Phase plug from the no
LED board and plug in a plug
from a good LED board.
Yes
Did LEDs go off?
Push start
Does
LED come on
now?
Yes
Turn off main

breaker and
Replace 24 Phase
board
No
No
Turn off main circuit breaker.

Replace Drive board

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Jetpower PWM Troubleshooting
Chart
Page 5 of 13
2912364
Fault 2 - DC Bus
Fault
Rev NC
Yes
Turn input CB off.

Put Logic board in normal
mode.
While watching LEDs on Bus

Charge board turn on the main
CB.
Do two green
LEDs come on?
Yes
Do two yellow
LEDs come on?
No
Set Logic board in

normal mode
No
Turn off main CB,

replace Logic board
Yes
Does
bus fault occur
after 20
seconds?
Replace Bus
Charge board
Yes
Go back to
beginning
No
Push stop and then

start
Operate ok?
No
Go back to
beginning
Yes
Return auto/manual and

switches
bypass to their normal
positions
Finished
Jetpower PWM
Troubleshooting Chart
The green flashing lamp indicates that the 28vdc from the aircraft
did not get back to the Jetpower.
Fault 7
Green flashing
Volume 5lamp
- Jetpower PWM
A load bank or cable test box and a dc voltmeter wil be

required to solve this problem. The aircraft can be used to
replace the load bank or test box.
Toggle the bypass switch up. When this is done the

yellow LED on the Logic board wil come on and the
Page 6 of 13
2912364
Rev NC
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Jetpower PWM
Troubleshooting Chart
Page 6 of 13
2912364
The green flashing lamp indicates that the 28vdc from the aircraft
did not get back to the Jetpower.
Fault 7
Green flashing
lamp
Rev NC
A load bank or cable test box and a dc voltmeter wil be

required to solve this problem. The aircraft can be used to
replace the load bank or test box.
Toggle the bypass switch up. When this is done the

yellow LED on the Logic board wil come on and the
yellow lamp wil blink.
Plug in the output cable to the load bank or test box. Toggle
the 28v switch on the test set to on. Start the Jetpower.
Locate the green LED on the rear of the Logic board.

This is connected to pin F of the output cable.
28v is being received by

Logic board
Yes
Is green LED on?
Toggle the bypass switch

down. Jetpower should
continue to run. If not then
replace the Logic board.
No
Measure voltage on terminal F where

output cable connects.
Check that the output

cable is wired correctly. If
it is then the cable is bad.
No
Is
voltage at least
20 vdc?
Yes
Wire 216 goes to P1-7 on Mother

board. Measure voltage on P1-7.
If an extender card is available plug it

into a spare slot on the mother board.
Measure voltage on pin 5.
Yes
Is
voltage at least
20 vdc?
Yes
Is
voltage at least
20 vdc?
No
Is
Yes
Measure voltage on
wire 216 on TB6.
voltage at least
20 vdc?
No
find bad connection
Replace the Logic

board.
No
shut unit down and unplug P1

connector and plug it in again. Try
again. If stil no change replace
Mother board.

Return auto/manual and bypass

switchs to their normal positions
Page 97
Rev 0

March 2015
Page 7 of 13
2912364
Fault A
Rev NC
No output voltage detected
Do the green LEDs on the

IGBT Drive boards come on
momentarally when the
start is pushed?
yes
Voltage Control
Pot turned down all
the way (fully
counterclockwise)
when auto/manual
switch is in auto
position.
Turn the pot to about

the middle point
before pushing the
Start button and try
again.
IV Sense Board
plug unplugged.
This could be the

connector on the
IV Sense board or
one of the wires
from the IV Sense
cable is loose
where it goes into
the Mother board.
See wiring diagram
120vac lost.
One or more 24
Phase board
cables unplugged.
Check fuse on LV
MOV board.
Check the
connectors on the
24 Phase board
and each of the
connectors on the
IGBT Drive boards.
Check that the 24

Phase board
connectors have
the correct cables
in the correct
location. The cable
from inverter
sections 1 and 2
go into the top
connector (P1).
The cable from
inverter sections 3
and 4 go into the
bottom connector
(P2).

No
Fuse ok
Fuse blown
Use AC voltmeter
to follow the
120vac from point
to point. The
120vac wires are
numbered 122 and
123. Refer to
Jetpower wiring
diagram. Start at
LV MOV board.
Replace
fuse
Page 98
Rev 0

March 2015
2912364
Page 8 of 13
Rev NC
Fault E Overtemperature
Are
any of the fans
turning?
Yes
Are all of fans

operating?
No
Check voltages on fan wires. Measure from

wire 123 to 243. Should be 120vac when
Jetpower is operating or has an E fault.
Votlages ok?
Is the
fan gril bent and
pressing into
the fan?
No
Yes
No
Are the
power connectors
connected tightly onto fan
terminals?
Yes
Replace Logic
board
Yes
No
Use wiring
diagram and
find where
voltage is
lost.
Fix fan gril

No
Yes
Fix plugs
The fan
wires goto terminal blocks.
Are wires 123, 243
tight?
No
Tighten connections
Yes
Replace fan
Has
the Jetpower been
operating with a
load?
No
Locate P8 on Mother
board. Measure
voltage on pin 4 of P8.
(wire #244)
Yes
Let fans run for 5 minutes to cool

Jetpower. Push stop/reset after
this 5 minutes.
No
Is
voltage +5vdc
(+- 1v)
No
Replace Logic board
Did E fault go away?
No
Does fault E stil

occur?
Yes
Yes
Restart Jetpower
Restart Jetpower
Replace
Mother board
Goto Page 2

Page 99
Rev 0

March 2015
Page 9 of 13
2912364
Fault E Overtemperature
Rev NC
Need to find where temperature sensor line is broken. The line

is a series loop that is grounded at one end of the line. Follow
path shown below. Fix the loose connection when found. If no
loose connections are found use ohm meter and check for an
open thermo switch. They are supposed to be normally closed.
Be sure to remove power to Jetpower before proceding.
Mother board
P8-4
Mother board
P8-5 (gnd)
244
TB3-244
244
SCR Heatsink
thermoswitch
245
TB3-245
245
Inv #1 Heatsink
thermoswitch
241
Inv #2 Heatsink
thermoswitch
240
Inv #3 Heatsink
thermoswitch
239
Inv #4 Heatsink
thermoswitch
238

Page 100
Rev 0

March 2015
Page 10 of 13
2912364
Fault F - IGBT
Rev NC
This chart is for Jetpowers

that have SCR RAMP
boards installed
Note which IGBT has

faulted on top display
Remove input power

and examine IGBT
identified by top display
Reapply input power,

push stop/reset, and
push start.
Is
physical damage
evident?
No
Replace IGBT and

Drive board.
Look carefully for
damage on nearby
IGBTs. Replace all that
show signs of damage.
Yes
Reapply input power.
IGBT fault stil

occur?
No
Could have been an

overload problem.
Operate unit.
Look at LEDs on IGBT

Drive boards. They
should all be off.
Yes
Replace IGBT
indicated on display
Remove 24 Phase
cable from drive board
where LED is on.
No
Are they all off?

Yes
Replace 24 Phase
board
Yes
Did LED go off?

No
Replace IGBT and

drive board
Turn small trim pot located

at top of SCR RAMP board
fully clockwise.
Set auto/manual switch to
manual. Unplug plug on
front of SCR RAMP board.
Turn voltage control pot
fully coounterclockwise.
Push start.
Goto page 2

Page 101
Rev 0

March 2015
Page 11 of 13

Chart
2912364
Fault F - IGBT
This chart is for Jetpowers

that have SCR RAMP
boards installed
Rev NC
No
Do all
of the Drive board LEDs
come on?
Yes
Push stop, remove

input power, plug in
SCR RAMP board
plug. Reapply input
power. Push start.
Swap 24 Phase cable

plugs from a Drive
board where no LEDs
come on to one where
the LEDs come on.
Slowly turn pot on SCR

RAMP board clockwise
untill fully clockwise.
Do LEDs
now light on the no LED
board?
Yes
Replace 24 Phase
board
Turn output voltage
control pot until there is
30-40 volts on the
output. Check all three
output voltages using
the panel meter.
No
Replace the drive

board and IGBT where
LEDs will not light
No
Check that all of the

drive boards got
attatched correctly to
the IGBTs.
Are they all within 1

volt of each other?
Yes
Turn the voltage

control pot up until
output is 100v. Let run
for 1-2 minutes.
Push stop. Toggle
auto/manual switch to
auto. Push start. Adjust
voltage to 115.
If load bank is available

apply load. If not then
repair is done.

Page 102
Rev 0

March 2015
Chart
Fault F - IGBT
Examine the IGBT that

is identifed on the top
fault display
This sheet is for use when

the Jetpower has a Bus
Charge board installed
Replace the IGBT and

drive board
Yes
Page 12 of 13
2912364
Rev NC
Is there evidence
of damage?
No
Examine other IGBTs

for evidence of
damage
Replace the IGBTs and

drive boards
Yes
Is there evidence
of damage?
No
Use ohm meter and check the

DC bus fuse (if there is one
installed). Replace if bad.
Put Logic board into test mode

(see manual) and turn on input
power.
Replace all boards and

IGBTs that have have
LEDs on
Yes
Do any drive
boards LEDs come
on?
No
Push stop and then

start button
Replace 24 Phase
Board
No
Do any drive
board LEDs come
on?
Yes

Page 103
Rev 0

March 2015
Fault F - IGBT
Page 13 of 13
This sheet is for use when

the Jetpower has a Bus
Charge board installed
2912364
Rev NC
Swap 24 Phase cables from drive

board that LEDs come on to
board that LEDs do not come on.
No
Do LEDs
now light on board
where they did not
before?
Push stop, remove

power and then put
Logic board back into
normal mode
Yes
Replace 24
Phase board
No
Do all
drive board LEDs
come on?
Apply input power and

push start
Replace drive board if

LEDs do not light

Page 104
Rev 0

March 2015
3.
Parts Replacement
The most common part necessary to replace will be a circuit board.
CAUTION:
ALWAYS REMEMBER TO TURN OFF THE MAIN

CIRCUIT BREAKER ON THE UNIT AND USE EXTRA
CARE WHEN REMOVING OR INSTALLING A CIRCUIT
BOARD.
A.
B.
The Card Rack

(1)
The circuit boards in the card rack are designed using a

common bus. This means that they can plugged into
any one of the six (6) slots in the card rack.
(2)
Each circuit board edge connector is off set so that the

board cannot be installed up-side down.
(3)
Use the plastic levers mounted on the front corners of

each board to assist in the removal of the circuit board.
The Inverters
(1)
(2)
Circuit Board Removal

(a)
To replace the inverter assembly you must first

disconnect the 9 pin D connector and the two
power supply connectors from the IGBT drive
board.
(b)
Remove the three large screws from the center of

the IGBT drive board and remove the IGBT drive
board.
Power IGBT Removal

Remove the four screws holding the power IGBT in place
and by carefully prying the + and - bus bars away, slide
the IGBT off to the side and out.

Page 105
Rev 0

March 2015
(3)
(4)
IGBT Installation
(a)
First ensure that the mounting surface on the

heatsink is clean and free of all dirt and grit.
(b)
Next wipe off the bottom of the new IGBT.
(c)
Remove the paper backing from the heat transfer

pad and place it between the IGBT and the
heatsink.
(d)
Mount the IGBT using the four corner mounting

screws. The screws must be tightened gradually
to insure the IGBT is seated properly.
(e)
Use a torque wrench and insure each screw is

torqued to 26 inch/pounds.
IGBT Drive Board Installation

(a)
First install insulator sheet on to IGBT Drive Board

then install a IGBT drive board, carefully place the
drive board assembly against the power IGBT
insuring that the small spade connectors on the
board are properly mated to the IGBT.
(b)
Insure the output cable going to summing

transformers is placed in its proper position
between the feedback board and the C2E1 (left)
terminal of the IGBT.
(c)
Screw the drive board assembly onto the power

IGBT using the three large screws. Use a torque
wrench and insure each screw is torqued to 26
inch/pounds.
(d)
To complete the installation, reconnect the power

supply connectors and the 9 pin D connector.

Page 106
Rev 0

March 2015
(5)
In some cases the power IGBT package may actually

explode and in so doing cause physical damage to other
components within the Jetpower converter.
If you suspect additional damage may have been done,
use the following procedure after replacing the IGBT.
(a)
Insure the input power to the converter is of.
(b)
Unplug connector on SCR Ramp Board.
(c)
Turn the auto/manual switch on the bottom of the

Logic board to the MANUAL (down) position.
(d)
Turn the output voltage adjust potentiometer all

the way counterclockwise.
(e)
Turn the bypass switch on the front of the logic

board to the bypass ON (up) position.
(f)
Turn the input power circuit breaker on.
(g)
Verify that all three (3) LED's on the power supply

board are on.
CAUTION:
Be extremely careful to not remove or

install a circuit board with the main
input power on.
(h)
With the input power applied, verify that none of

the green LED's on the IGBT drive boards are on.
If one or more of the green IGBT drive board
LED's are on, remove the 9 pin "D" connector
from the edge of the board and swap it with a
cable from a board who's LED is not on.
If the problem (the green LED on with no input
signal) remains with the board, replace both the
drive board and the IGBT.

Page 107
Rev 0

March 2015
If the problem follows the cable, remove the

hood (backshell) from the 9 pin "D" connector
and check for loose or broken wires.
If no problem is found with the cable, replace
the 24 phase board.
(i)
Press the start push button and verify that all the
green LED's on the IGBT drive boards are on
steady.
If one or more of the green IGBT drive board
LED's are not on, remove the 9 pin "D"
connector from the edge of the board and swap
it with a cable from a board who's LED is on.
If the problem (the green LED is not on) remains
with the board, replace both the drive board and
the IGBT.
If the problem follows the cable, remove the
hood (backshell) from the 9 pin "D" connector
and check for loose or broken wires.
If no problem is found with the cable, replace
the 24 phase board.
(j)
Depress the stop push button and turn off the

input power circuit breaker.
(k)
Plug in cable to SCR Ramp Board.
(l)
Turn the input power circuit breaker back on.
(m)
Return the auto/manual switch on the top of the

voltage control board to the auto (up) position.
(n)
Set the output voltage adjust potentiometer to

approximately it's mid range.
(o)
Depress the start push button.

Page 108
Rev 0

March 2015
(p)
Adjust the output voltage adjust potentiometer
until the
output voltage reads approximately 115
volts on the
digital panel meter.
C.
The Output Cable

(1)
Checking the Output Cable

Problems with a 400Hz output cable can be of several
types and are usually caused by the miss-use of the
cable.
(a)
Shorted Conductors
To check for a shorted output cable, first turn the
output voltage control potentiometer all the way
counter clockwise and then switch the converter
to MANUAL output voltage control using the toggle
switch located on the bottom of the 24 Phase
board. Now start the unit and bring the output
voltage up slowly while monitoring the output
current. A rapid rise in output current with no load
applied to the unit indicates a shorted output
cable.
(b)
Open Conductors
An open conductor will result in the absence of
one or more of the output phases at the aircraft
plug.
First, insure that the converter is operating
correctly by measuring all three phases at the
output terminal block in the converter.
Now measure the voltages at the end of the cable
to verify that one or more line is open.

Page 109
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March 2015
(c)
The 28v Return Lines (E & F)

If the cable head is inadvertently left lying on the
apron, it may be run over by a vehicle.
A common result is to have the E or F lines be
either broken or shorted to one the 400Hz phases
resulting in further damage to the converter.
(2)
Replacing the Output Cable

(a)
Ordering a New Cable

New cables or replacement heads may be ordered
directly from FMC Jetway Systems.
The cables come complete with an aircraft plug on
one end and 3/8 inch terminal lugs on the other
end with the individual wires marked Phase A,
Phase B, Phase C, neutral, E and F.
(b)
Installation
Insure that the connections made to the
converters output terminal block are tight and that
the correct phase rotation has been observed.

Page 110
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March 2015
This page has been left blank intentionally for future expansion and
comments.

Page 111
Rev 0

March 2015
This page has been left blank intentionally for future expansion and
comments.

Page 112
Rev 0

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Dubai International Airport Expansion

Contract #TD56 Passenger Loading Bridges

Volume 5 - Jetpower PWM

Dubai International Airport Expansion

Volume 5 - Jetpower PWM

Dubai International Airport Expansion

Procedures for the logical diagnosis and correction of faults

Volume 5 - Jetpower PWM

The incoming three phase 50 or 60 Hertz power

Verify that the wires are connected securely.

Verify that the output cable is connected

Check the converters start/stop wiring that's

Check the output cables E and F safety

Insure the connector on the IV Sense board is

If the converter is mounted on a passenger

Dubai International Airport Expansion

Volume 5 - Jetpower PWM

Insure that the three wires coming from the

Verify that the connectors on the ends of the

Transistor Drive Boards

Verify that all the 12 VAC and 9 pin D

Check that the transistor output wire from each

Card Rack Connectors

On the 24 phase board insure that the cable

These connectors can be installed in the wrong

Carefully check the three (3) connectors

Carefully check the two (2) connectors plugged

Carefully check the connector plugged into the

Dubai International Airport Expansion

The red light off indicates that there are no

Dubai International Airport Expansion

Color Status Indication

Volume 5 - Jetpower PWM

Dubai International Airport Expansion

If the red fault light is flashing, then either the

Depress first the A IN, then the B IN and finally the

The input voltages should be displayed on the

If the incoming voltages are not correct, use a

Check the +5 VDC and the 15 VDC by observing

These LED's should be on and all at about the

Low Voltage Power Supply Problem

Volume 5 - Jetpower PWM

Dubai International Airport Expansion

If the LED's are properly lit with the board unplugged,

To do this, first place an ohm meter between

Then remove one circuit board at a time from the

BE EXTREMELY CAREFUL TO NOT

One of the most common causes of a fault (red)

A number will appear on the top numerical LED

Volume 5 - Jetpower PWM

Dubai International Airport Expansion

Input Voltage to High.

Volume 5 - Jetpower PWM

Dubai International Airport Expansion

Output Voltage Above 180 Volts.

Volume 5 - Jetpower PWM

Dubai International Airport Expansion

Input Voltage Low.

Volume 5 - Jetpower PWM

Dubai International Airport Expansion

Output Frequency out of Tolerance.

Volume 5 - Jetpower PWM

Dubai International Airport Expansion

Volume 5 - Jetpower PWM