X-Cite 1001P User manual

RDS - 1
Reso-notTM Damping System
XCITE
1001P FIELD TEST POWER SUPPLY

XCITE
Owner’s Manual
Xcite Systems Corporation 675 Cincinnati Batavia Pike Cincinnati, Ohio 45245
Tel: [phone] Fax: [phone] Email: [email protected] Web: www.xcitesystems.com

Preface
XCITE
Copyright 1997
Xcite Systems Corporation
This document contains proprietary information of Xcite Systems Corporation and is
tendered subject to the conditions that the information (a) be retained in confidence (b) not
be reproduced or copied in whole or in part and (c) not be used or incorporated into any
product except under an express written agreement with Xcite Systems Corporation.
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1001P Field Test Power Supply

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1. Introduction
TheXcite1001PFieldTestHydraulicPowerSupplyisdesignedtofulfillthepower
requirements for Xcite Series Controlled Force hydraulic Exciters and other
actuators that do not require an average flow of more than 1.2 GPM. This power
supply is completely portable and can be used in a wide variety of test
environments. It has been “human-engineered” for ease of operation and
maintenance. All control functions can be handled by a Xcite Master Controller,
enabling a single test operator to effectively run the entire operation.
2. Theory of Operation
2.1. Hydraulic System
A 1.2 GPM constant displacement gear pump is driven directly by a 3 HP
1800 RPM 115 VAC/ 230 VAC electric motor. At 1725 RPM the pump ports a
nominal 1.2 GPM which is directed to the pressure quick disconnects through
a 2 micron filter. A relief valve maintains a constant 3000 psi output pressure
by bleeding flow to the reservoir.
Theusermustbe aware that when morethan1.2GPMisdemanded by
theexciterhead (low frequencystokeorweak structure stiffnessathigher
frequencies),thepumppressure will drop. For maximum force capabilityfrom
thesystem,the stroke must be limitedtorangeswhichallow the pump to
maintain3000 psi pressure.
A time delayed cooling fan provides air flow across a heat exchanger which is
in the return line to cool the hydraulic fluid returning from the exciter head.
For ease of filling and draining of the reservoir before transporting the power
supply,atransferpump is used. When the ball valve is intheFILLdirection,fluid
ispumpedfromthereservoirfill hose directly into the reservoir. See Drawing
B-30220 - Item #26 Inthe EMPTYdirection,hydraulicfluidispumpedoutofthe
quickdisconnectnipplewhichis removed from the top of the reservoir forthe
emptyingoperation. (Seephotobelow.)

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2.2. Electrical Control System
TheElectricalControlSystemfor the 1001P Hydraulic Power Supply is pack-
agedintwoenclosures mounted inside the pumpcabinet. Thefirstenclosure
isaccessiblefromthe front panel of the PowerSupplybyremovingfourscrews
and is called “Electrical Control Box #1”. See Drawing B-30223
Thisenclosurecontains the fusesforthesystemdesignated as:
y107FU - 4.0Amp (Fan Motor Fuse)
y108AFU - 6.25Amp (115 Volt Operation Fuse)
y108BFU - 3.2Amp (230 Volt Operation Fuse)
Thesecondenclosure is mounted near thetopofthePower Supply and is only
accessiblebyremovingthe entire pump assembly from the cabinet. This
enclosureiscalled“Electrical Control Box #2” and containsthemotorstarter,
control relays and controltransformer. See Drawing B-30224
During operation, either 115 VAC or 230 VAC single phase power is applied to
themaincontacts of the pump motorstarter;thetimedelayrelay of the cooling
fanandtransformerT1. The voltage selector switch (107PB)selectsoperation
of the entire 1001P Hydraulic Power Supply from either 115 VAC or 230 VAC,
60Hz. Drawing B-30222 and B-30224 depictsthe voltage selector switch inthe
230 Volt position. In this position, voltage is applied to the primary coil of
transformerT-1 and is “stepped” down to115 VAC for operation of all control
relaysandthe Xcite MasterController.
Whenthevoltageselector switch107PBisswitchedtothe 115Vposition,
115 VAC power is applied directly to the control relays and the Xcite Master
Controller. ThePump Motor (MTR1) andtheFanMotor (MTR2) are
automaticallyconvertedto 115V operation by switchingthewindingsof
MTR1andMTR2 with control relays111CRand112CR respectively.
The1001PHydraulic PowerSupplyisstartedwhen the START button onthe
Xcite Master Controller is depressed. 115V control voltage is applied back
throughJ1-Dto the “Remote Emergency StopConnector”(RES);the
“EmergencyStop”button and thentothecoils of motor startercontrolrelays
115Mand116M. Inorderfor voltagetoreachthese control relays, the oillevel/
temperatureandfilterswitches must all be closed. This meansthereissufficient
oilinthereservoir, the oil temperature is lessthan150°Fandtheoilfilteris
clean. Iftheseconditionsareall met, the control relays 115M and 116Mare
energizedandMTR1 and MTR2 are started.

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PressingtheSTOPbuttononthepumpde-energizesthe control relays 115M
and116Mandthe unit shutsdown. Automaticshutdownwillalsooccurifthe oil
level,temperatureor filter switchismomentarilyopened.
3. Description
Theentirepower supply isshock-mountedina roto-molded plasticinstrumentstyle
enclosure. Interconnectionsareeasily identified bycall-outsonthepanels. A power
cord is supplied as standard equipment. See Drawing’s B-30220, 30221, 30222,
B-30223 and B-30224 at end of this section. Major Components are:
yA4-gallonoilreservoir
yMotor
yConstantdisplacementpump
yA2-micronfilter
yAir/heatexchanger
yOiltransferpump
y(2)Electricalcontrolboxes
Alongwiththesemajor components are a numberofcontrolsandconditionindicators
givingcontinuous monitoring ofsupplyconditions.
3.1. Pressure Gauge
Thisgaugeindicates the supplypressureatthe pump outlet.Withnoflow, the
gage should normaly read 3000 to 3100 psi.
3.2. Power Indicator Lamp
This lamp is illuminated at all times when the electrical power cord is
connectedto the poweroutlet.
3.3. Emergency Stop Switch and Remote Emergency Stop Connector
This is a push to stop switch that de-energizes the pump motor starter when
depressed. Thisswitchmaybeusedtohalt the pump in place of the STOP
buttononthe Xcite MasterController, ifnecessary. Itshouldbenoted thatthe
EmergencyStop Switch MUST be pulled out for the 1001P Power Supply to
operate. Ifitisdepressed(staysdepressedoncepushed),theunitwillNOT
operate.
A“RemoteEmergencyStop”connector(RES)isalsoprovidedtoallowthe user
to wire a remote SPST switch to stop the Power Supply. Amating connector
forwiringtheremote emergency stop is included.
3.4. Hydraulic Supply and Return Connectors
These are male and female quick-disconnect fittings. The female fitting goes
tothesupply line; themalefittinggoes to thereturnline.

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3.5. HPC Control Connector
Thisisa6-pinAmphenol connector used to interface the pump totheMaster
Controller.
3.6. Oil Level/ Temperature Gauge
Thisgaugeindicatesthe level of oil in the reservoir. Itismounteddirectlyto the
oilreservoir. The system should not be operatedwithlessthan3.5gallonsofoil.
3.7. Voltage Selector Switch
Thisswitchallowsthe 1001P Hydraulic Power Supplytobeusedwitheither
115 VAC or 230 VAC 60 Hz power, single phase. See 2.2. and B-30224
3.8. Fuses
Allreplaceablefusesaremounted in Electrical Box #1 on the front panelofthe
Power Supply. See 2.2. for appropriate ratings and Drawing B-30223 for
location.
3.9. Oil Level/ Temperature Switch
This switch is located inside the reservoir. It shuts down the unit if the oil
levelistoolow or if the oil temperature exceeds 140° F. Indicator lampsare
illuminatedonthefront panel of control box #1 iftheoillevelistoolow or the
HydraulicPowerSupply is over its temperaturelimit.
3.10. Filter Switch
Thefilterswitch is mountedonthefilterassembly, located attheoutputof
thepump. Ifthedifferential pressure across the filter elementexceeds35psi,
theswitchis momentarilyactivated, de-energizing the pumpmotorstarter.
Ifthisoccurs, it generally indicatesthatthefilterelement is dirty andneeds
replacement. Anindicatorlampis illuminated when the filter needsreplaced.
4. Preliminary to Operation
Several preparatory steps must be taken prior to operating the unit.
4.1. Remove the front and rear cabinet covers.
4.2. Turn the voltage selector switch to the correct position for the line voltage
being used.
4.3. Connectthe hydraulicsupplyandreturn linestothe frontpanelquick-
disconnects.

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4.4. Connectthepowercord to the power source, makingsurethatthepower
indicatorlampislit.Useblackandwhitewiresforvoltage,greenfor ground.
TheredwireisNOT used.
NOTE: TheunitshouldNEVERbeoperatedwiththehoses coiled, nor should
anythingbe set onthehoses, nor shouldtheybe driven over.
4.5. Checkthelevelofthe oil using the sight gauge on the backofthereservoir.
Theoilreservoirshouldbecompletely filled with Mobil DTE-24 or DTE-25.
Ifnecessaryfill the reservoirusingthetransferpump. See 2.1.
4.6. ConnectthePump Control Cable (fromtheMasterController) to the
connector on the front panel.
4.7. Makesurethe front andrearofthecabinet are notobstructedbyanythingthat
wouldrestricttheflow of air into and out ofthecabinet.
4.8. Pressthe PUMPSTART button on the Master Controller tostartthe pump. To
stoptheunit,pressthePUMPSTOPbutton on the Master Controllerorthe
EMERGENCY STOP buttonon the pump’s front panel.
4.9. Check the pressure gauge and verify the pump is operating at 3000 to 3200 psi.
Failuretocomply with the abovecancauseseveredamageto the servovalve,
exciterhead,andpump. Allwarrantiesareinvalidatedifdamageoccursdueto
overpressure.
4.10. Inthe eventthehydraulicpower supplywillnot start,checkforoil over
temperature, or low oil level; or if the power supply starts but will not run
continuously, the filter element is clogged and needs replacement.
5. Care and Maintenance
5.1. General
The pump requires little regularly-scheduled maintenance. However, you
shouldkeepthe unitreasonablycleanand shouldobservethefollowing precau-
tions.
5.1.1. Keepthequick-disconnect dustcoversinstalledwhenever theunit
isnotinuse.
Oils should not be mixed. If the type of oil is changed, purge the system.

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5.1.2. Alwayscleanthe quick-disconnects beforemakingany
connections.
5.1.3. Makesurethe heat exchanger fan isnotblockedduring
operation.
Theonlyperiodicmaintenance required is change the oilevery2000hoursand
changethefilterwhenever it becomes clogged. The filter unitconsistsofa
screw-offcanisterand replaceable filterelement.
5.2. Field Test Reservoir Draining/ Refilling Procedure
This is a closed-loop system. If general cleanliness methods are followed,
thefiltershouldnotrequire replacement for long periods of time. Oil should be
changedevery2000 hours of pumpoperation.
Ifthesupply is to betransportedsuchthatthe cabinet could be
tippedover,theoilshouldbe drained from the reservoir. See
drainingandfillingprocedureinSection 2.1.
5.3. Change Oil Filter
Unscrewthebottom of thecontainerandchange the cartridge.
See Drawing B-30221 - Item #13 for filter model number
6. Troubleshooting
This section lists the most common problems encountered, as well as their probable
causes. Iftheproblemcannot be readily corrected, contact yourXciteCustomerSer-
viceRepresentative.
Problem Probable Cause
Power lamp is not lit when unit is plugged in. Check power source.
Fuses blown. Low line voltage or motor
malfunction.
Unit shuts off 2-4 seconds after power is applied. Dirty filter element.
Lowhydraulicpressure(less than 3000 psi.) Excessiveflowbeyond
1.2GPM.
Defectivereliefvalve

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7. Specifications
Dimensions
Height 33.5”
Width 27.25”
Depth 36.5”
Weight 250 lbs
Cooling Air(heatexchanger w/fan)
MaximumAmbientAirTemp 100° F
PowerRequirements 115 VAC, 35Amp, 50/60 Hz, single-phase
from CircuitMains 230 VAC, 20Amp, 50/60 Hz, single-phase
OilType Mobil DTE-24 or DTE-25
(DONOTMIXOIL TYPES)
OperatingPressure 3000 psi + 5%
Pressure Control Spring operated relief valve
Pump 1.2 GPM constant displacement at 1725 rpm
Motor(FullLoad) 3 hp, single-phase; 115VAC@27Amps;
230V[email protected]Amps; 1725 rpm; 184 TC frame size
Radiated Noise Front - 72 db
(at3ft.fromcabinet) Side - 68 db
Rear - 74 db
8. Drawings
AssemblyHydraulic Power Supply B-30220
HydraulicSystemSchematic B-30221
ElectricalSchematic B-30222
ElectricalControlBox#1 B-30223
ElectricalControlBox#2 B-30224