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Abrasive Transfer System (ATS)

Abrasive Transfer System (ATS)

Operation and maintenance information for the ATS 2200 and ATS 4400.

Pages: 10

•

ATS specifications

Specs for ATS 2200 and ATS 4400.

•

Install the bulk bag

To install the ATS bulk bag, follow these steps.

•

Set up the hoses

Follow these step-by-step instructions to set up the hoses for the ATS 2200 and ATS 4400.

•

ATS startup

Make sure to follow these steps for ATS startup.

© 2021 Flow International Corp.

Retrieved from Flow KB on April 14, 2021 PST

Ancillary option: Abrasive Transfer System (ATS)

Summary of Contents for MACH 300

Page 1: ...MACH 300 SYSTEM MANUAL Includes Ancillary Options M 810 REV C en APRIL 2021...

Page 2: ...ther registered trademarks shown are the property of their registered owners Copyright This content contains information protected by copyright No part of this document shall be reproduced in any mann...

Page 3: ...erience to ensure your success United States Canada 23500 64th Avenue South Kent Washington 98032 USA Tel 1 800 526 4810 Central America South America Mexico Caribbean Tel 54 9 11 4700 8881 or 8882 Eu...

Page 4: ...ency Lockout Tagout LOTO Supplemental instructions to your facility Lockout Tagout procedures Includes instructions for systems and CF900 hopper Personal Protective Equipment PPE Recommendations for P...

Page 5: ...rt Recommendations to follow if you have to transport the machine Transporting the CF900 hopper Recommendations for how to transport the hopper Safety labels Includes information on safety labels and...

Page 6: ...sages that follow this symbol to avoid possible injury or death Signal words WARNING WARNING indicates a hazardous situation which if not avoided could result in death or serious injury CAUTION CAUTIO...

Page 7: ...e materials or materials that release explosive emissions The machine may not be operated in areas that are vulnerable to explosions In addition the machine is not designed for food processing During...

Page 8: ...r control system may only be done by trained certified electricians Modifications Modifications to the system including all machine pump cutting head software and ancillary components is prohibited af...

Page 9: ...nel have information about this type of injury We recommend that anyone who works with high pressure waterjet equipment carry a waterproof medical alert card This card should describe their work and t...

Page 10: ...language Czech A 8466CZ English A 8466 French A 8466F German A 8466G Italian A 8466I Polish A 8466PL Portuguese A 8466P Russian A 8466RU Spanish A 8466S 2021 Flow International Corp Retrieved from Fl...

Page 11: ...head to a loading or safe position 2 Close all programs and then press the E stop 3 Select Start Shut down to turn off the machine PC 4 Wait until the machine PC is completely shut down and then turn...

Page 12: ...o a Lockout Tagout for the hopper do the following Turn off the power switch lock it and then put an appropriate tag on it Turn off the air supply to the hopper 2021 Flow International Corp Retrieved...

Page 13: ...quipment Wear a mask Wear a dust mask to reduce particle or dust inhalation when you fill the abrasive delivery system with abrasive Wear eye protection Wear safety glasses with side shields or safety...

Page 14: ...to work around dirty water in the catcher tank When you clean a hopper ADS wear gloves to prevent abrasive particles from penetrating any skin abrasions Wear protective footwear Wear steel or composit...

Page 15: ...be turned off during maintenance work and service work on the machine It must be secured against unintentional activation with a lock for the length of the work To protect sensitive components in the...

Page 16: ...cables are defective replace them immediately Emissions Always pay attention to the data sheets of the material being cut Although rare flammable gases could develop in the water if you cut materials...

Page 17: ...at your facility Know how to trigger a fire alarm Know where fire extinguishers blankets are located and how to use them Know what the appropriate extinguisher is to use for the materials you process...

Page 18: ...n well ventilated areas Avoid prolonged breathing of fumes and contact with skin or eyes Keep a clean work environment Keep the area around the machine clean and free of obstacles Keep the floor clean...

Page 19: ...ns Follow the manufacturer s recommendations for maintaining the equipment and use only original manufacturer replacement parts Follow the manufacturer s system startup procedure to ensure safe operat...

Page 20: ...work intended Follow the procedures for using the tool s to avoid injury or damaged components If instructions call for the use of a certain tool only use the tool specified to avoid injury or damage...

Page 21: ...r hands in the tank when the machine is operating Plan material clamping in advance so that you don t handle material or parts while the machine is in operation Never climb on or around the equipment...

Page 22: ...ter the distance of the nozzle exit to the material smaller than 2 5 mm the noise emission is under 85 dB A However under certain circumstances the machine causes higher noise emissions At the start o...

Page 23: ...lift in accordance with local regulations Make sure that you have flaggers and spotters present while you load or unload equipment Never walk under a hanging load Secure the load so that it does not m...

Page 24: ...er a pair of lower beams on the frame accessible from all four sides WARNING Load and unload all equipment with a properly rated forklift or pallet jack in accordance with local regulations We recomme...

Page 25: ...in personal injury Prohibited Action labels convey actions that are prohibited because it could result in personal injury Hazard Alert labels warn you of hazards which could result in personal injury...

Page 26: ...ch point hazard Protective Earth Ground Risk that you could crush your body due to force from the side Risk that you could slip or fall due to wet or slick surfaces Risk that you could entangle your h...

Page 27: ...Machine safety labels Mach 300 View 1 2021 Flow International Corp Retrieved from Flow KB on April 12 2021 PST Safety...

Page 28: ...View 2 2021 Flow International Corp Retrieved from Flow KB on April 12 2021 PST Safety...

Page 29: ...View 3 2021 Flow International Corp Retrieved from Flow KB on April 12 2021 PST Safety...

Page 30: ...View 4 View 5 Z axis cover 2021 Flow International Corp Retrieved from Flow KB on April 12 2021 PST Safety...

Page 31: ...View 6 Roll around console 2021 Flow International Corp Retrieved from Flow KB on April 12 2021 PST Safety...

Page 32: ...View 7 Spreader bar Where used Mach 500 Mach 300 for machines configured with multiple cutting heads 2021 Flow International Corp Retrieved from Flow KB on April 12 2021 PST Safety...

Page 33: ...CF900 hopper safety labels Where used Ancillary option Mach 500 Mach 300 Mach 200 Mach 100 2021 Flow International Corp Retrieved from Flow KB on April 12 2021 PST Safety...

Page 34: ...Light curtain safety labels Where used Ancillary option Mach 500 Mach 300 Mach 200 2021 Flow International Corp Retrieved from Flow KB on April 12 2021 PST Safety...

Page 35: ...n The system is a no nonsense waterjet solution that is efficient and practical Combining advanced Flow waterjet technology into a small package the Mach 300 minimizes impact on shop floor space and y...

Page 36: ...erJet rated at 6500 bar 94 000 psi Software FlowCut FlowPath 2D CAD CAM package FlowXpert 3D CAD CAM package FlowNest geometric nesting module FlowCode G Code converter module Ancillary options For th...

Page 37: ...TS Final Filter System 100 lb hopper 2200 lb hopper Paser CF900 Abrasive Delivery System Continuous fill hopper Accessories Supersack stand for hopper Component ID 2021 Flow International Corp Retriev...

Page 38: ...ne only does not include the high pressure pump Ethernet connection The maximum cable length for Ethernet connection is 76 m 250 ft If a longer length of cable is required you must install a switch ne...

Page 39: ...t the weight of the machine when the catcher tank is filled with dirty water Free of expansion joints in the area that you plan to put your machine The purpose of expansion joints is to concentrate fo...

Page 40: ...pe in BSPTF If machine has UltraPierce Vacuum Assist an additional 538 L min 6 9 8 3 bar 19 scfm 100 120 psi per Z axis end effector is required Drain Capacity 8 L min 0 bar 2 gpm at 0 psi minimum per...

Page 41: ...the machine A Follow these steps to start the machine from a cold start no power Emergency stop In an emergency press the E stop button on the roll around console This article also includes how to res...

Page 42: ...tness accuracy 0 0762 mm m 0 003 in 3 ft Repeatability 0 0635 mm 0 0025 in Operating parameters Mixing tube 4 in length Standoff 2 54 mm 0 10 in Dynamic Waterjet 10 rotation Electrical Power supply 3...

Page 43: ...e disabled Flashing White Green Manual The drives are enabled and you can jog the axes manually and home the machine Flashing White Red Set up Mode The machine is in Set up Mode Solid Green Automatic...

Page 44: ...cle Emergency stop Disables the drives and stops the high pressure water stream abrasive flow and the pump Power Enables the drives Reset Resets the drives USB Port Connection point for peripherals Ke...

Page 45: ...l state drives are enabled and you can jog the axes manually You must put the machine in Manual state before you turn the key switch to ON Otherwise it will cause a machine E stop condition and you ll...

Page 46: ...r around the table that will impede movement of the axes All cover panels and doors on the machine are in place or closed The catcher tank slats are in good like new condition Inspection 2 The air and...

Page 47: ...en the connection occurs the indicator lights turn red 6 Disengage the E stop buttons on the roll around console and the pump 7 If you have light curtains press the foot switch to reset them 8 Press t...

Page 48: ...o get back to normal operation quickly 1 Make sure that the danger or issue that prompted the emergency stop is fixed or corrected 2 Disengage the E stop 3 Click OK on the message 4 In the FlowSENSE D...

Page 49: ...position 2 Exit all programs 3 Press the E stop 4 Click Start and then click Shut down to turn off the machine PC 5 Wait until the machine PC is completely shut down and then switch off the main powe...

Page 50: ...o this point and start the cut by USING CURRENT HOME POSITION message select Yes End restart or resume the part program When you end the part program the high pressure water stream and abrasive flow s...

Page 51: ...ect the error 2 Click OK on the message in FlowCUT 3 In the FlowSENSE Diagnostics dialog box click Acknowledge all and then click Close 4 Press the Reset button the indicator lights will turn white 5...

Page 52: ...t improve surface quality Increasing water pressure to increase water velocity thus abrasivejet power will improve surface finish Hard or soft materials Taper is a product of the cutting effectiveness...

Page 53: ...ing thick materials at relatively high speed the stream exit lags behind the stream entrance trailback Corners or small radii cause the lower region of the stream to deflect outward creating a less ac...

Page 54: ...Abrasive is too fine Use a coarser grade of abrasive Damaged or worn orifice Check integrity of the waterjet stream Inspect orifice replace if needed Cutting speed is lower than normal kerf is too wi...

Page 55: ...ing speed Mixing tube standoff is too great Check standoff it should be set to 0 10 in Abrasive flow rate is too low Increase abrasive flow rate Water pressure is too low Increase water pressure Rough...

Page 56: ...0 Mach 300 Cutting with a spreader bar Pages 4 Overview Adjust the cutting head spacing Cutting head vertical adjustment Selecting a cutting head 2021 Flow International Corp Retrieved from Flow KB on...

Page 57: ...d won t turn off it most likely needs an on off valve repair Cutting is slightly less accurate near the ends of the spreader bar than near the center Use the minimum practical spacing for your part it...

Page 58: ...he cutting head carriage for easy reference Note that the tubing may be slightly stiff so not all positions on the spreader are available If it resists being adjusted don t force it Allow the tubing t...

Page 59: ...m are exactly vertical Use the four screws that hold the cutting head clamp to the bracket on the back two M6 cap screws have clearance for adjusting the angle left right and two M4 set screws adjust...

Page 60: ...heads to use in FlowCut To enable cutting head s select the Head 1 left cutting head and or the Head 2 right cutting head check box To disable cutting head s clear the Head 1 and or the Head 2 check b...

Page 61: ...Waterjet Pages 5 Introduction to Dynamic Waterjet Materials and fixtures Vertical position and standoff affect parts Analyze cut parts to identify the source of an issue Other tips and recommendation...

Page 62: ...ombination of electromechanical hardware devices and software techniques Taper This illustration shows how a cut into a piece of material typically results in non vertical walls The non parallel natur...

Page 63: ...2021 Flow International Corp Retrieved from Flow KB on April 13 2021 PST Cutting with Dynamic Waterjet...

Page 64: ...is warped up Non flat material affects standoff and cutting accuracy How much error will result from non flat material is directly related to the tilt applied by FlowCut and the change from programmed...

Page 65: ...f the path and clamp material tightly Make sure that clamps or fixtures will be cleared by the wrist motors Ensure the material is held tightly in place during the cutting process Unlike Standard Wate...

Page 66: ...head This vertical positioning is critical because it affects the quality of the parts being cut View 1 Shows an exaggerated view of what happens to a part if the cutting head is not vertical Instead...

Page 67: ...ion the programmed parts will not be cut accurately Large angles on a part require setting a large standoff If a sufficient standoff is not set the mixing tube can hit the material being cut In the ex...

Page 68: ...ng head did not home in a vertical position Curved sides If the top view of a rectangular part shows curved sides with the same curve at the top and bottom of the cut then either the standoff or calib...

Page 69: ...erial In extremely thick parts it may be impossible to make perfect inside corners on the bottom of the cut without some process changes These changes may require guidance from Flow Technical Service...

Page 70: ...ormal cutting conditions we recommend that you keep the override value at 100 If you change it be aware that this will also affect features such as taper correction Go as fast as the finish Since the...

Page 71: ...with air Weekly Dynamic Waterjet height sensor calibration Weekly Dynamic Waterjet straightness adjustment Weekly Clean and inspect the bellows for rips Monthly Lubricate the bearings and linear rails...

Page 72: ...ssure tubing and gland nut collar Always lubricate threads and the area between the gland nuts and collars with Blue Lubricant If the high pressure tubing OD is Then torque the gland nut to 1 4 in 20...

Page 73: ...im in the middle of the material 3 Jog the machine to the center of the material with the arrow keys on the keyboard 4 Open a ord file in FlowCUT verify Dynamic Waterjet is turned on and then select R...

Page 74: ...not perpendicular to the part the edge quality will reflect as a poor cut To help avoid this do an adjustment weekly so that you don t inadvertently damage expensive material Tools Dial indicator Ind...

Page 75: ...Y axis until it is approximately 457 mm 18 in from the front of the table Ensure that you can reach the cutting head with the magnetic base and dial indicator 5 In FlowCut go to Jet setup On the Heig...

Page 76: ...ive If it went clockwise it is a positive value If it went counterclockwise it is a negative value 7 Under Motor B enter the value in the Bottom reading box and then select Apply the dial indicator sh...

Page 77: ...en select Apply the dial indicator should go to zero or just past it Remember to enter the minus sign if it s a negative value You don t have to enter a positive sign for a positive value 6 Select Zer...

Page 78: ...Mach 200 Mach 100 The abrasive metering valve has four main components an air isolator an abrasive on off valve an abrasive metering disk and a diverter 2021 Flow International Corp Retrieved from Flo...

Page 79: ...the valve at the correct pressure will cause the rubber stopper to fail prematurely Abrasive metering disk The metering disk controls abrasive flow to the cutting head Each disk is marked with the op...

Page 80: ...2 Twist the knurled aluminum piece on the lower half of the metering valve clockwise and then remove the piece and allow the abrasive to empty out 3 Remove any abrasive or moisture that is present on...

Page 81: ...asive metering disk do the following 1 Twist the diverter clockwise then carefully pull down to remove it from the main body 2 Remove the metering disk from the top of the diverter Clear off abrasive...

Page 82: ...36 Multi purpose Precision Lubricant or equivalent cleaner Bellows and painted surfaces Johnson Envy Instant Cleaner or equivalent Bearings and linear rails Mach 100 Shell Tonna S2 M 68 Mach 200 Mach...

Page 83: ...ubricant or equivalent cleaner To clean the linear rails do the following 1 Pull back all the bellows 2 Spray a light even layer of cleaner on the rails 3 Allow time for the cleaner to penetrate the d...

Page 84: ...lean the bellows do the following 1 Inspect the bellows for rips and tears 2 Spray a light even layer of foam cleaner on the surface of the bellows 3 Allow time for the cleaner to penetrate the dirt a...

Page 85: ...ge A 31748 1 Clean lint free cloth Sheet of plywood Grease points View User faces the front of the machine X axis bearings Bridge rear side center X axis ball nut Motor drives enclosure rear side V ax...

Page 86: ...k fitting for each ball nut If necessary jog the machine until the Zerk fittings are accessible 5 Do a Lockout Tagout LOTO for the machine 6 Lubricate each ball nut with three pumps of grease from the...

Page 87: ...stream that passes into the mixing chamber creating an area of partial vacuum The vacuum draws a metered flow of abrasive through the abrasive delivery line where it combines with the water to create...

Page 88: ...s designed to automatically align the orifice with the mixing tube It will not swage or jam into the body and no special tools are required to install it Mixing chamber The mixing chamber introduces a...

Page 89: ...e to help contain jet spray during piercing The cutting head is designed to be used with a spray shield do not operate without the spray shield in place To replace the spray shield slip it over the sl...

Page 90: ...Flow Parts for cutting head A M Blast disk 711933 1 Collet 710806 1 Mixing chamber 041138 1 Mixing chamber cap A 11080 Mixing tube DELTA NXT Premium 1000003 XX 40 Mixing tube DELTA Standard 1000001 X...

Page 91: ...ch 500 Standard or Dynamic Waterjet Mach 300 Standard or Dynamic Waterjet Mach 200 Standard Waterjet Flow Parts for water only cutting head Nozzle body 041154 1 Nozzle retainer B 1041 1 Orifice Diamon...

Page 92: ...e interval Every four hours of operation Summary Flush the mixing chamber vent with clean water to minimize residue buildup Picture shown for general reference only and may vary from your machine mode...

Page 93: ...of the following conditions Prominent off center wear at the nozzle exit tip ID Chips in the downstream end outside edge of the nozzle that originate at the outside diameter and leave less than 0 020...

Page 94: ...nd orifice or nozzle nut do the following 1 Soak the part in an ultrasonic cleaning bath for approximately 5 10 minutes and then remove the part from the ultrasonic bath and thoroughly dry with pressu...

Page 95: ...essure from the system 2 Pull firmly on the abrasive feed line to remove it from the cutting head and then open the cutting head clamp 3 Using a 1 1 8 in wrench on the mixing chamber and a 7 8 in wren...

Page 96: ...e seating surface that is in the mixing chamber is free of abrasive and debris and then drop the orifice assembly flat face down taper side up into the recess of the body 9 Apply a thin even layer of...

Page 97: ...for increasing the life of on off valve parts After replacing high pressure plumbing or other equipment on your high pressure pump flush the system directly into the catcher tank before running the h...

Page 98: ...D Mach 300 Standard Waterjet Dynamic Waterjet Maintenance and tool kits On off valve seal kit 014988 1 On off valve tool kit 019623 1 Reference Troubleshooting the on off valve Dynamic XD Install on o...

Page 99: ...ommend that you install all seal kit components at the same time to reduce maintenance time and machine downtime When working on high pressure components it is critical that you use backup wrenches Ex...

Page 100: ...pment damage 2 Turn off the supply air and then disconnect the pneumatic line and high pressure tubing from the valve 3 Open the clamp and remove the cutting head assembly including the on off valve a...

Page 101: ...seal installation tool against the tip of the poppet and then push the poppet out of the valve body The seal O ring and backup ring should also come out with the poppet If they don t push these parts...

Page 102: ...red on the length of the poppet 3 Install the poppet seal assembly pointed end first into the actuator end of the valve body Remove the seal guide tool 4 Apply a thin even layer of BLUE LUBRICANT to t...

Page 103: ...e body Install the 014 O ring into the groove to hold the poppet seat in place 6 Apply a thin even layer of BLUE LUBRICANT to the external threads of the valve body and then thread it onto the nozzle...

Page 104: ...ing head assembly on the machine a Loosely clamp the cutting head align the valve with the high pressure tubing and then connect the high pressure tubing b Tighten the clamp to secure the cutting head...

Page 105: ...to reduce maintenance time and machine downtime Water leaks past the high pressure assembly top of high pressure seal Drips every few cycles This indicates seal and backup ring wear It s OK to contin...

Page 106: ...the valve aim it into the catcher tank and then secure it 3 If installed open the manual shut off valves Turn the pump on 4 If there is a steady stream of high pressure water going into the catcher ta...

Page 107: ...ANCILLARY OPTIONS For Mach 300...

Page 108: ...s for DCF General specs including operating parameters and facility environment requirements for the DCF Best practices when using DCF Best practices when using the Dynamic Contour Follower Set up DCF...

Page 109: ...ntative maintenance schedule for DCF Reference this PM schedule for DCF Flow Parts for DCF Spares and consumables for the DCF Troubleshooting the DCF by symptom Troubleshoot the DCF based on the sympt...

Page 110: ...Component ID for DCF 2021 Flow International Corp Retrieved from Flow KB on April 14 2021 PST Ancillary option Dynamic Contour Follower...

Page 111: ...ision detector Collision detection is important it protects the cutting head and mixing tube from damage caused by fixtures or parts that may tip up during cutting The collision detector ring snaps on...

Page 112: ...Radio frequency interference minimal Operating parameters Compatibility machines with Standard Waterjet or Dynamic Waterjet Mixing tube 4 in length Standoff Standard Waterjet 1 27 5 08 mm 0 05 0 20 in...

Page 113: ...e cutting head increases Use fixtures to hold your material but make sure there s enough space between the fixtures and DCF Firmly clamp the material if you are using contour following Edge quality de...

Page 114: ...he height at the start of each cut The sensor remains active and will constantly adjust standoff against any changes in the surface level of the material being cut This is called floating or contour f...

Page 115: ...r 1 Click Option Component 2 Scroll down until you see Enable collision sensor click 1 and then click Close To disable the collision sensor 1 Click Option Component 2 Scroll down until you see Disable...

Page 116: ...hrough the blast ring during operation replace it immediately Inspect the brush foot and measure the length of the bristles Weekly Replace when approximately one third of the bristles are gone or if t...

Page 117: ...k Part 040507 1 DCF blast ring Part 714100 1 DCF blast shield assembly Part 019122 1 DCF carbide insert Part 714039 1 2021 Flow International Corp Retrieved from Flow KB on April 14 2021 PST Ancillary...

Page 118: ...n sensor assembly 4 in Part 015286 1 DCF foot assembly Part 019121 1 DCF foot brush Part 714034 1 2021 Flow International Corp Retrieved from Flow KB on April 14 2021 PST Ancillary option Dynamic Cont...

Page 119: ...CF before you return to service Abrasive spray could have worn the bellows to the point where moisture is getting inside the PCB and causing damage Replace the foot assembly The cable could have faile...

Page 120: ...em This also indicates the device is not calibrated correctly Calibrate the DCF making sure to follow all steps in the instructions Feedrate errors This indicates the device is not calibrated correctl...

Page 121: ...ludes information on what settings to choose Calibrate UltraPierce Learn how to calibrate UltraPierce Flow Parts for UltraPierce Spares and consumables for UltraPierce Rotate and replace the exhaust h...

Page 122: ...t connects the educator to the cutting head The system uses a vacuum to remove the abrasive pulled through the head by the vacuum eductor When the vacuum assist is off there is no air supplied to the...

Page 123: ...e an option 4 Under ON procedure enter the time in seconds of each dwell and then select Abrasive on first then jet on to minimize delamination 5 Under OFF procedure enter the time in seconds of each...

Page 124: ...decrease ON procedure Recommended starting point for each dwell After vacuum on 1 5 seconds and then increase as needed based on the length of the abrasive feed line After abrasive on 1 5 seconds and...

Page 125: ...ied to every file opened until you close FlowCut The next time you open FlowCut settings revert to the default To save the settings for all future FlowCut sessions select Save as default Settings are...

Page 126: ...device do the following 1 Shut down the machine 2 Disconnect the abrasive line from the abrasive inlet port 3 Assemble vacuum gauge including adapter coupling and tubing and then connect it to the op...

Page 127: ...ockwise to increase the vacuum level to 10 12 Hg Some applications may require more than 10 12 Hg This is acceptable but higher vacuum levels will shorten the life of the vacuum unit 8 Tighten the jam...

Page 128: ...maintenance kit Part 014579 1 Includes carbide liner O rings and pinch valve tubing Vacuum Assist tool kit Part 014578 1 Includes installation tool and vacuum gauge with tubing and fittings 2021 Flow...

Page 129: ...n thin or if there are any holes in it Parts Tubing hose A 18883 3 5 Tools Sharp shears or hose cutter To replace the exhaust hose do the following 1 Shut down the machine 2 Remove the exhaust hose an...

Page 130: ...re are any holes in it Parts Carbide liner 712251 2 O ring A 0275 012 Pinch valve tubing A 23920 17 Tools Needle nose pliers Shears Vacuum Assist tool kit 014578 1 Installation tool Supplies White Foo...

Page 131: ...f WHITE FOOD GRADE GREASE to the two O rings and then install them into the inside grooves of the vacuum unit 7 Insert the carbide liner short end first into the latex tubing and then slide the assemb...

Page 132: ...cutting UltraPierce is leaking this causes insufficient vacuum levels in the cutting head so that it cannot draw abrasive properly Find the leak and repair it Abrasive feed rate it too high lower the...

Page 133: ...Kink the pinch valve air line and secure it with a cable tie Insert a small two way valve in the pinch valve line for convenience Dynamic XD interference with the C motor arm or contact with the mate...

Page 134: ...correct position with respect to the cutting head and adjust the clocking if it is not in the correct position The protective cover that is below the C axis MUST be installed at all times for safety 2...

Page 135: ...error message is displayed Axes travel stops On off valve closes High pressure pump is shut off and the high pressure lines are depressurized However if the machine is in Set up Mode and the light cu...

Page 136: ...ant The remote pendant allows you to move the axes independently set user home and control the water level 2021 Flow International Corp Retrieved from Flow KB on April 14 2021 PST Ancillary option Rem...

Page 137: ...us jog in the positive direction based on the selected jog rate Control buttons Sets the position of the cutting head as User Home Moves the cutting head to the User Home position No functionality No...

Page 138: ...on control wheel Moves the selected axis at an incremental jog based on the selected jog rate To move the axis in a positive direction turn the control wheel clockwise To move the axis in a negative d...

Page 139: ...led and corresponding functionality on the keyboard is disabled To disable the pendant To disable the pendant do the following 1 Release both enabling buttons on the pendant 2 In FlowCUT select Click...

Page 140: ...200 and ATS 4400 Install the bulk bag To install the ATS bulk bag follow these steps Set up the hoses Follow these step by step instructions to set up the hoses for the ATS 2200 and ATS 4400 ATS start...

Page 141: ...for bag dewatering for the ATS Remove the bulk bag To remove the bulk bag from the ATS 2200 or ATS 4400 follow these steps Cleaning the pump During cross flow separation and dewatering operations mud...

Page 142: ...tation stopper Hydraulic hand pump double acting opens lid Hoses Dewatering hose 1 in x 6 ft with quick release brass cam lock fittings debris screen Discharge hose 1 5 in x 16 ft with quick release b...

Page 143: ...e the top of the VacBOX a Loosen the two door lock pivot bolts and then rotate both bolts off the door lock tabs b Turn the directional control valve on the hand pump clockwise and then use the hand p...

Page 144: ...tween the top of the bag cage and the rubber lid seal loss of vacuum will occur and machine performance will decrease c Spread the bag evenly across the top of the bag support frame to ensure a good s...

Page 145: ...following 1 Attach the clear suction line to the inbound side of the cross flow separator 2 Attach the clear discharge hose to the outlet manifold of the pump 2021 Flow International Corp Retrieved fr...

Page 146: ...3 Attach the hose set to the filter nozzle 2021 Flow International Corp Retrieved from Flow KB on April 14 2021 PST Ancillary option Abrasive Transfer System ATS...

Page 147: ...o not have enough water in the catcher tank to pre charge the VacBOX use a water hose to fill the machine before you begin to remove the garnet 4 Open the air valve slightly on the supply side of the...

Page 148: ...oes not need to run continuously It can be operated only as needed to prevent the accumulation of garnet in the catcher tank To begin extraction do the following 1 Move the suction nozzle assembly to...

Page 149: ...machine Settled material is pulled through the cross flow separator and deposited into the bulk bag Clean water free of settled material is returned to the catcher tank through the discharge hose To u...

Page 150: ...ator as it does in Cross flow mode This creates a vacuum outside of the bag which pulls water through the bag membrane Silt and fines are left in the bulk bag and clean water is returned to the catche...

Page 151: ...e handle to Cross flow mode for 30 seconds to start the pump and drain water from the cross flow separator into the catcher tank 3 Turn off the supply air valve 4 Bleed any remaining vacuum from the h...

Page 152: ...e is in operation remove the suction and discharge hoses from below the water level but leave them over the catcher tank to remove any excess water from the cross flow separator After several seconds...

Page 153: ...e the suction and discharge hoses from below the water level but leave them over the catcher tank to remove excess water from the cross flow separator After several seconds the discharge hose will sto...

Page 154: ...sharp edges on the lifting device to avoid cutting the straps and dropping the load Immediately transfer a fully loaded bulk bag to a pallet for safe transportation to storage disposal area If you ar...

Page 155: ...Bag Dewatering setting ATS 4400 Back Vac setting Mud build up on the bottom of the cage will interfere with operating the machine in Bag Dewatering or Back Vac mode Ensure the inside is rinsed clean...

Page 156: ...nse adapter 2 Disconnect the cross flow separator or the dewatering hose from the top of the pump 3 Connect the pump rinse adapter to the inlet of the pump and then turn on the water to the hose Make...

Page 157: ...ame The overflow water from the catcher tank flows through the weir tanks then is pumped through the filters As the water passes through the tanks the larger particles settle out Any suspended particl...

Page 158: ...by the sump pump 3 Remove the tanks from the frame and dump out the accumulated solids 4 Replace the tanks in the frame Replace the filter elements Replace the 50 micron filter elements Part A 00750...

Page 159: ...ry and filtered to 10 microns Capacity 56 6 L min 6 2 bar 2 scfm 90 psi 283 2 L min 6 2 bar 10 scfm 90 psi initial fill Interface in NPT 2021 Flow International Corp Retrieved from Flow KB on April 14...

Page 160: ...ry and filtered to 10 microns Capacity 56 6 L min 6 2 bar 2 scfm 90 psi 283 2 L min 6 2 bar 10 scfm 90 psi initial fill Interface in NPT 2021 Flow International Corp Retrieved from Flow KB on April 14...

Page 161: ...rom the warning indicator and audible signal Recommended pressure settings for CF900 pressure regulators Recommended pressure settings for CF900 pressure regulators including schematic Fill start or s...

Page 162: ...he vessel releases pressure before entering the fill cycle 2 Sieve When you fill the ADS with abrasive it goes through the sieve to its temporary storage place the silo 2021 Flow International Corp Re...

Page 163: ...ditions and sends control signals to the solenoid valves the yellow warning indicator and the audible signal 6 Vessel low abrasive switch If this switch does not sense abrasive for 20 seconds the yell...

Page 164: ...See Understand the warning indicators audible signal article 4 Display panel See Using the display panel during operation article 5 CE label 6 Panel lock The PLC and terminal strip are located behind...

Page 165: ...air and controlled by SOL351 Proximity switch PS219 inside vessel sends a signal to the PLC to indicate presence of abrasive If there is no abrasive the PLC sends a signal to release the pressure from...

Page 166: ...Electrical Supply voltage 100 240 VAC 50 60 Hz or 24VDC2 AC frequency 50 60 Hz Full load current 100 VAC 0 48 A 240 VAC 0 20 A 24 VDC 2 0 A Largest load current 2 0 A Short circuit current rating SCC...

Page 167: ...Using the display panel during operation 2021 Flow International Corp Retrieved from Flow KB on April 14 2021 PST Ancillary option PASER CF900 Abrasive Delivery System...

Page 168: ...for 10 seconds ALT No functionality DEL No functionality ESC No functionality OK Functional from the Running screen only Password Functionality disabled Stop Run A check mark show what state the unit...

Page 169: ...el Running ADS is conveying abrasive Silo Empty Silo is empty Vessel Empty Vessel is empty Replace Insert of Pinch Valve Reset P3 Displays after 6000 cycles When you see this notice it s time to repla...

Page 170: ...tern Fill the silo with abrasive you have reached the minimum level of abrasive required for operation Recover from the error in FlowCUT FlowSENSE Yellow warning indicator illuminates continuously aud...

Page 171: ...o 5 5 bar 80 psi and PR2 to 2 bar 30 psi Next adjust the pressure for PR2 since this is what pushes abrasive to the metering valve Pressure may be ok at 2 bar 30 psi but if you have to make adjustment...

Page 172: ...urized abrasive leaking from the silo Wear a dust mask or respirator to reduce particle or dust inhalation when you fill the hopper with abrasive Observe proper lifting techniques when lifting abrasiv...

Page 173: ...or startup Shut off supply air to the hopper but left the hopper powered on Apply supply air to the hopper first and then cycle power to the hopper off then on again Turned off power to the hopper but...

Page 174: ...noid valves for damage Daily Examine the solenoid valve on the pinch valve for damage Daily Examine the pressure gauges for functionality Daily Ensure the pressure difference between PR1 and PR2 is at...

Page 175: ...sert A 31850 1 Tools Adjustable wrenches 6 in 12 in Supplies Clean lint free rag Wooden blocking Notes Assistant required for this step Safety precaution The vessel could weigh up to 91 kg 200 lb when...

Page 176: ...ure 4 Disconnect all abrasive and air hoses from the vessel pinch valve and pneumatic controls 5 Disconnect the cables from the manifold pressure sensors Label the cables so that it is easier to conne...

Page 177: ...unted on the pinch valve 9 Position wooden blocking between the floor and the abrasive outlet port to support the vessel during removal 10 Remove the four M16 hex screws and then lower the vessel onto...

Page 178: ...ean the gasket with a lint free rag and then set it aside 13 Remove the M16 hex screws and nuts and then remove the pinch valve 14 Remove the gasket Clean the gasket with a lint free rag and then set...

Page 179: ...and housing Tapered surfaces should be smooth paint discoloration is okay with no grooves or pitting Replace the pinch valve flange if the tapered surfaces have damage Replace the pinch valve if need...

Page 180: ...ve seal Do not allow the pinch valve seal to twist during tensioning If the screws cannot engage the flange threads use M12 70 mm screws to seat the flanges until the stock flange bolts are engaged 7...

Page 181: ...pinch valve and then attach it to the pinch valve with four M16 screws 7 Evenly tighten the four M16 screws The gap between the vessel flange and the lower pinch valve flange must be even after all o...

Page 182: ...Bulk Transfer Empty Shutdown Fill the silo with abrasive you are out of abrasive and the ADS will remain stopped until filled P395 System Abrasive Bulk Transfer Low Warning Abrasive level is low fill...

Page 183: ...yellow warning indicator and or the audible signal is not on The bulb to the yellow warning indicator may have burned out Test the function of the indicator and then replace the bulb if needed Test t...

Page 184: ...re to PR2 but maintain at least a 3 45 bar 50 psi difference between PR1 and PR2 The PV1 pinch valve seal is defective Install a new seal Air leaks from the silo after a fill cycle and the vessel is u...

Page 185: ...ssure regulators Your air supply pressure may be too high Ensure you air supply is 6 9 8 3 bar 100 120 psi 2021 Flow International Corp Retrieved from Flow KB on April 14 2021 PST Ancillary option PAS...

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