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Hypertherm DynaMAX 550P, Operator'S Manual

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Hypertherm DynaMAX 550P Operator'S Manual Download Page 153

Troubleshooting

6

DynaMAX 550P/560P/575P Waterjet Pump

Operator Manual

811390

153

Fault 2: Primary Motor

The primary motor did not start.

The soft starter sensed a fault.

• Turn the primary breaker 

disconnect ever on the 
electrical enclosure door to 

OFF

.

• Turn the primary breaker 

disconnect ever on the 
electrical enclosure door to 

ON

.

It can take e several 
minutes for the system to 
reboot.

The relief valve on the pump 
manifold has failed.

Contact a Hypertherm Technical 
Service Associate for information 
and support.

Alarm

Cause

Solution

Summary of Contents for DynaMAX 550P

Page 1: ...DynaMAX 550P 560P 575P Waterjet Pump Operator Manual 811390 REVISION 0 ENGLISH...

Page 2: ...m are trademarks of Hypertherm Inc and may be registered in the United States and other countries All other trademarks are the property of their respective holders Environmental stewardship is one of...

Page 3: ...Hypertherm Inc Hanover NH 03755 USA www hypertherm com DynaMAX 550P 560P 575P Waterjet Pump Operator Manual 811390 REVISION 0 ENGLISH Original instructions January 2022...

Page 4: ...00 800 4973 7843 Tel Technical Service technicalservice emeia hypertherm com Technical Service Hypertherm Shanghai Trading Co Ltd B301 495 ShangZhong Road Shanghai 200231 PR China 86 21 80231122 Tel...

Page 5: ...mental stewardship 17 Hypertherm products waste and recycling 17 Particle emission and waste water quality 17 Chemical handling and usage 18 Safety 19 Manuals 19 User qualification and training 20 Eme...

Page 6: ...mp for leaks or damage 55 Check the low pressure water pressure gauges 56 Check the hydraulic filter gauge 57 Check the hydraulic fluid level 57 Operate the pump remotely 58 Stop the pump 58 Operate t...

Page 7: ...sure in the water accumulator tank 88 Check the low pressure water pressure gauges 89 Air cooler 90 Clean the air side of the cooler 90 Clean the hydraulic fluid side of the cooler 90 Low pressure wat...

Page 8: ...ormal status 148 Alarms 149 Types of alarms 149 Warnings 150 Faults 152 Intensifier 155 Leaks 155 Overstroke 159 High pressure water seal life is short 164 Hydraulic fluid 165 Temperature 167 The pump...

Page 9: ...e equipment 192 Install the pump 193 Install the external heat exchanger optional 195 Connect the utilities to the pump 196 Check the hydraulic fluid 199 Connect the electrical power 200 Do the first...

Page 10: ...Manual DynaMAX 550P 560P 575P Waterjet Pump Enter or change the time and date 215 Intensifier Control 216 Pressures 217 SD Card 218 Remote operation 218 Storage 218 9 Declaration of Incorporation 219...

Page 11: ...ctual equipment configuration could be different from the examples Waterjet product warranty Product Warranty coverage up to Waterjet pump 27 months from the ship date or 24 months from the date of pr...

Page 12: ...parts or the result of normal wear or the result of the system being operated contrary to Hypertherm s instructions or stated limits of rated and normal use For information about the manufacturer s w...

Page 13: ...ore certification test marks from accredited testing laboratories The certification test marks are on the pump s data plate Each certification test mark means that the product and its safety critical...

Page 14: ...age requirements Electromagnetic compatibility requirements Differences in national or other standards can make it impractical or impossible for all certification test marks to be put on the same vers...

Page 15: ...stem and to provide protection against dangerous moving parts Unless the higher level system is certified when the OEM or system integrator incorporates Hypertherm products into it the installation ca...

Page 16: ...Product stewardship 16 811390 Operator Manual DynaMAX 550P 560P 575P Waterjet Pump...

Page 17: ...other countries refer to national and local laws Consult with legal or other compliance experts when applicable For information go to www hypertherm com customer support product service recycling Par...

Page 18: ...as a part of its recent revision of the Hazard Communication Standard 29 CFR 1910 1200 to align with the United Nations Globally Harmonized System of Classification and Labeling of Chemicals GHS The G...

Page 19: ...n the manual for your product You may have to click on SHOW ALL at the bottom of the section A PDF of the manual downloads to your device The safety precautions in this manual are general and cannot a...

Page 20: ...t methods for isolating and controlling energy to include lock out tag out procedures User qualification and training All users must read and understand these instructions before installing operating...

Page 21: ...ion WARNING Do not put ice or heat on a waterjet injury If possible use a support to keep injured body parts above heart level MEDICAL INFORMATION A high pressure injection injury is a surgical emerge...

Page 22: ...t all connections fasteners locking devices hoses and fittings are tight before operation WARNING Make sure that the shaft access cover and all other safety devices are correctly installed before oper...

Page 23: ...lled if dangerous energy is not controlled Injuries can include burns cuts fractures or electrocution WARNING Before removing a lock out device Obey the employer s energy control procedure Examine mac...

Page 24: ...characteristics of the building have an effect on noise level WARNING High pressure water can cause cuts abrasions and punctures Precision parts can have sharp corners or edges Wear approved hand pro...

Page 25: ...NING WARNING identifies a dangerous condition or a situation that COULD cause injuries or death if ignored CAUTION CAUTION when used with the yellow warning sign identifies a dangerous condition or a...

Page 26: ...marks 26 811390 Operator Manual DynaMAX 550P 560P 575P Waterjet Pump This symbol identifies tools or materials that are necessary or recommended for a procedure This symbol identifies a tip or helpful...

Page 27: ...sert any object into fan cover air inlet or outlet windows before or during running 3 Ground and protect per national electric code and local codes WARNING WARNING Risk of explosion Do not operate thi...

Page 28: ...delines in this manual WARNING Read and fully understand the operations and maintenance manuals before servicing this machine Failure to follow the correct procedures could result in serious injury Co...

Page 29: ...l Identifies the terminal of a protective earth ground electrode or a terminal intended to connect to an external conductor for protection against electric shock during a fault condition Control circu...

Page 30: ...Pump COOLING OUT Water cooled system This line carries low pressure water from the heat exchanger to a drain or to a chiller Air cooled system This line carries hydraulic fluid from the system to the...

Page 31: ...DynaMAX 550P 560P 575P Waterjet Pump Operator Manual 811390 31 Product description It is possible that not all of the information in this section applies to all pump models...

Page 32: ...from a water softener a reverse osmosis system a well or a public utility goes into the pump 2 Boost pump Increases water pressure 3 Prefilter water gauge 4 Water filters 5 Postfilter water gauge 6 Wa...

Page 33: ...e Cooling loop for a water cooled system internal heat exchanger When the primary motor is operating cooling water goes through the heat exchanger transferring heat away from the hydraulic fluid to th...

Page 34: ...r where a fan pushes ambient air through the heat exchanger 1 2 3 4 5 1 Hydraulic fluid tank Hydraulic fluid goes from the tank to the gear pump 2 Gear pump From the gear pump hydraulic fluid goes to...

Page 35: ...iver Gauge panel 5 4 3 2 1 6 7 1 Front panel 2 Gauge panel 3 Seal Maintenance Indicator SMI 4 Electrical enclosure 5 Operator interface 6 Operation panel 7 Dirty water container 1 2 1 Prefilter water...

Page 36: ...ifier seal begins wearing out water and hydraulic fluid leak from the weep holes in the high pressure ends A drip tray which is attached to the bottom of each side of the intensifier collects fluid le...

Page 37: ...ry breaker disconnect lever Operator interface On the operator interface a series of screens shows equipment status and lets the operator control the pump and the intensifier Operation panel The opera...

Page 38: ...deck Top cover A hinged top cover protects components on the top deck from dirt and debris Open the lock with a standard screwdriver Electrical interlock optional The electrical interlock is part of t...

Page 39: ...nter section of the intensifier causes a brief change of water pressure The attenuator compensates for high pressure water fluctuations and maintains a consistent output pressure The 2 liter attenuato...

Page 40: ...ater chamber with a pressurized air bladder It evens out low pressure water flow to the intensifier and maintains a consistent output water pressure 2 Water filters Water filters remove impurities fro...

Page 41: ...f the fluid The gear pump is part of the cooling loop It moves hydraulic fluid from the hydraulic fluid tank to the heat exchanger The hydraulic fluid passes through a hydraulic filter and then goes t...

Page 42: ...Product description 1 42 811390 Operator Manual DynaMAX 550P 560P 575P Waterjet Pump Rear view 3 2 1 4 1 Hydraulic fluid tank 2 Boost pump 3 Hydraulic fluid filter 4 Water manifold...

Page 43: ...ic fluid filter This filter removes contamination from the hydraulic fluid 2 1 3 4 1 Filler breather cap The filler breather cap keeps airborne contamination out of the tank and prevents pressure from...

Page 44: ...ng into the system 3 Low pressure transducer The transducer monitors the manifold water pressure 4 Bleed down valve solenoid This solenoid opens and closes the bleed down valve 5 Low water pressure wa...

Page 45: ...e temperature sensor in the hydraulic fluid tank turns on an external heat exchanger Electrical interlock An electrical interlock on the top cover prevents access to the components on the top deck whi...

Page 46: ...Optional equipment 2 46 811390 Operator Manual DynaMAX 550P 560P 575P Waterjet Pump...

Page 47: ...terjet Pump Operator Manual 811390 47 Operation Safety WARNING Read and understand all of the safety guidelines in this manual Refer to Safety on page 19 before operating doing maintenance on repairin...

Page 48: ...ol CNC operator console to control the pump Most of the functions on the operator interface are not available Refer to Operate the pump remotely on page 58 2 CONTROLS ON button Push this button to tur...

Page 49: ...rations Turn features such as Modbus mode on or off Refer to Operator interface Adjustment screens on page 207 6 Maintenance screens tab Move the plunger to one end of the intensifier Prepare the pump...

Page 50: ...ed The stroke rate bars show the speed of the piston moving to each side of the intensifier Refer to Overstroke on page 159 for troubleshooting information Intensifier control When intensifier control...

Page 51: ...ease plus the water pressure 3 Intensifier graphic The intensifier graphic is animated when the pump is on and the intensifier is engaged 4 Output water pressure This shows the actual water pressure i...

Page 52: ...cables for kinks or damage to the insulation Examine electrical plugs and other electrical connections for corrosion or damage 5 Look for leaks deterioration damage or other conditions that can interf...

Page 53: ...luid every 3 000 hours if it is dark or milky in color if it has a strong odor if a test laboratory finds the quality is unsatisfactory Refer to Replace the hydraulic fluid on page 81 CAUTION Heat and...

Page 54: ...the intensifier A gear pump moves hydraulic fluid through the cooling loop 1 On the operation panel a Make sure that the EMERGENCY STOP button is not engaged If the button is pushed in turn the button...

Page 55: ...on Refer to Emergency stop on page 60 Examine the pump for leaks or damage Do this task when the pump is operating and the system is pressurized 1 Look for hydraulic fluid leaks Monitor these areas Hy...

Page 56: ...e water pressure before the water goes through the filter The postfilter water pressure gauge shows the water pressure after the water goes through the filter The usual range is 2 8 bar to 7 6 bar 40...

Page 57: ...tor on the hydraulic gauge is not in the red zone Check the hydraulic fluid level Do this task when the pump is operating Make sure that the hydraulic fluid level is at the top mark on the sight gauge...

Page 58: ...remotely On the operation panel turn the LOCAL REMOTE key switch to REMOTE The remote indicator light is on Stop the pump Refer to the OEM s instructions for turning the pump off Refer to the OEM s i...

Page 59: ...re 2 ways to change the target water pressure on the operator interface Touch the minus symbol or the plus symbol next to the target water pressure to change the target water pressure in preset increm...

Page 60: ...pressure water from entering the system Turn off the pump end of day or end of shift 1 On the operator interface touch the STOP symbol 2 Turn the primary breaker disconnect lever on the electrical en...

Page 61: ...operation Do this task when the pump is not operating 1 Turn the primary breaker disconnect lever on the electrical enclosure door to OFF Refer to local regulations regarding waste water Environmental...

Page 62: ...e to open the valve between the attenuator and the intensifier that will be operated 6 Close the valve between the attenuator and the intensifier that will not be operated 7 Remove the proximity switc...

Page 63: ...Troubleshooting The intensifier cannot stroke if any of these are not in the correct position the high pressure water valve handles the proximity switch wires the hydraulic valve handles 1 2 1 Left p...

Page 64: ...Operation 3 64 811390 Operator Manual DynaMAX550P 560P 575P Waterjet Pump...

Page 65: ...this manual are for reference purposes It is possible that your product is not shown accurately This section assumes that the user is familiar with the Safety Operation and Specifications of this manu...

Page 66: ...ent turn OFF the electrical power and release water pressure and hydraulic pressure from the system Use standard lock out tag out procedures Isolate all sources of electrical mechanical hydraulic pneu...

Page 67: ...quipment WARNING Do not operate the pump without the shaft access cover and all other safety devices correctly installed WARNING Make sure that all connections fasteners locking devices hoses and fitt...

Page 68: ...ledge of the energy control procedure Tools Special tools are recommended or necessary for some maintenance and repair procedures This page is intended to help a user identify tools that are unfamilia...

Page 69: ...Preventive maintenance 4 DynaMAX 550P 560P 575P Waterjet Pump Operator Manual 811390 69 Seal housing removal tool Intensifier repair tools 1 Sleeve 3 Spacer 2 Push tool 4 Locator 1 2 3 4...

Page 70: ...the pump for leaks or damage Electrical system refer to page 76 Make sure that the emergency stop operates correctly Make sure that the electrical interlock operates correctly Examine cords plugs and...

Page 71: ...d the check valves Replace the hydraulic rod seals Repair the high pressure cylinders Replace the bleed down valve poppet assemblies Replace the low pressure poppets and the poppet springs Replace the...

Page 72: ...ittings When replacing wiring use only the same size type and color as the original wiring Coordinate maintenance and repairs with facility and safety staff Keep the work area clean and dry Clean flui...

Page 73: ...egible 7 Contact Hypertherm for replacement decals 8 Clean the operator interface if necessary Gently wipe the touchscreen and keys with a clean microfiber cloth Use a cleaner made for touchscreens or...

Page 74: ...icator SMI tubes for leaks and debris To clean the tubes Refer to Clean the Seal Maintenance Indicator tubes on page 86 Examine the pump for leaks or damage Do this task when the pump is running and t...

Page 75: ...m a weep hole is a sign of a faulty part or a loose connection The SMI monitors the rate of drops from the static seal and the dynamic seal 5 Examine the high pressure tubing for leaks 6 Look for dete...

Page 76: ...he electrical interlock is optional on all models with top covers Do this task when the pump is running 1 Open the top cover 2 The result is the same as described for when the EMERGENCY STOP button is...

Page 77: ...X 550P 560P 575P Waterjet Pump Operator Manual 811390 77 3 Make sure that the SMI cable harness is not damaged and that the connections are not loose 4 The cable harness connects to the junction box s...

Page 78: ...re 1 Use a standard screwdriver to remove the pump cover 2 Make sure that the white indicator bar is not in the red zone Do this every work shift Replace the hydraulic filter Every 1 500 hours When th...

Page 79: ...t the top mark on the sight gauge Add hydraulic fluid if necessary Add hydraulic fluid The capacity of the hydraulic fluid tank is 151 L 40 gallons Parts tools and materials Do this task when the pump...

Page 80: ...uid has almost no odor Replace the hydraulic filter element Parts tools and materials Do this task when the pump is not running Do this every work shift Replace the hydraulic fluid If it is dark or mi...

Page 81: ...7 Check the hydraulic fluid level Add hydraulic fluid if necessary Refer to page 79 for instructions Replace the hydraulic fluid Do this every 3 000 hours Install a new hydraulic filter and filler br...

Page 82: ...ove the access cover on the tank 6 Use a strap wrench to remove the suction strainers in the tank Hydraulic fluid replacement kit 1 12084 DynaMAX 5 series standard Tool kit Antiwear AW mineral oil or...

Page 83: ...r to Hydraulic fluid tank access cover on page 180 15 Remove the used filler breather cap 16 Fill the tank with hydraulic fluid until the fluid is at the top mark on the sight gauge 17 Install a new f...

Page 84: ...amounts of grease and oil CAUTION the bearing can overheat if too much or not enough grease is used to lubricate the bearing Use the postmaintenance start procedure after working on the primary motor...

Page 85: ...Clean grease from the outside of the grease outlet and replace the relief plug 9 Do this procedure again on the other end of the motor DynaMAX 550P DynaMAX 560P DynaMAX 575P 30 grams 40 grams 40 gram...

Page 86: ...The inner surfaces of the SMI tubes become dirty over time Dirty tubes can cause a fluid monitoring sensor error Parts tools and materials Do this every 500 hours and when the high pressure seals are...

Page 87: ...tube from the push to connect fitting on top of the SMI by pushing up on the collar of the fitting while pulling down on the tube 3 Use the tube cleaning brush to clean the inner surfaces of the tube...

Page 88: ...n the water accumulator tank Parts tools and materials Do this task when the pump is off 1 Make sure that the water pressure gauges show 0 0 bar 0 psi 2 Remove the valve stem cap from the water accumu...

Page 89: ...ng range is 2 8 bar to 7 6 bar 40 psi to 110 psi Do this task when the pump is running 1 Subtract the value shown on the postfilter water pressure from the value shown on the prefilter water pressure...

Page 90: ...Disassemble the cooler to find the degree of contamination Do this task every 1 000 hours if you receive a Fault 1 Hydraulic Fluid 65C alarm CAUTION Detergent can give better cleaning results Think a...

Page 91: ...ench to loosen each of the filter canisters 3 Make sure that the filter canisters are empty 4 Remove the used filter cartridges from the filter canisters 5 Put a new 0 22 micron filter cartridge in th...

Page 92: ...h to tighten each of the filter canisters 10 Close the water valve 11 Turn ON the water to the pump 12 Turn ON the pump in cooling mode 13 Push the water filter purge buttons until water comes out fro...

Page 93: ...clear and odorless 4 Connect the low pressure water supply tube to the intensifier 5 Make sure that the water is clear and odorless Do this every 1 000 hours A TDS level that is lower than 0 0025 25 p...

Page 94: ...measures the total concentration of dissolved substances in postfilter water Dissolved solids cause deposits that can cause damage to check valves seals orifices and other consumables the optimal ran...

Page 95: ...er filter 5 Take a sample of water from the tube 6 Connect the low pressure water supply tube 7 Put the TDS meter in the water sample up to the maximum immersion level 5 cm 2 inches Tap the meter gent...

Page 96: ...lace the high pressure cylinders Replace the check valve assemblies Every 6 000 hours Replace the output adapters Replace the seal housing assemblies Every 6 000 hours Replace the spacer tubes Repair...

Page 97: ...poppet assembly High pressure poppet seat High pressure poppet 5 Check valve assembly 6 High pressure hoop 7 High pressure water seal 8 Low pressure poppet spring not shown 9 Low pressure poppet bask...

Page 98: ...ity source Use standard lock out tag out procedures 6 Turn OFF the water to the pump 7 Make sure that the water pressure gauges show 0 0 bar 0 psi WARNING Use 2 wrenches when loosening or tightening a...

Page 99: ...terns or damage that can show other problems Clean each part with a towel and isopropyl alcohol Examine all parts for deterioration corrosion or damage Do not use soap detergent or solvents Put the pa...

Page 100: ...tly on a wooden or other soft surface to eject the poppet from the output adapter Remove the high pressure end cap Parts tools and materials 1 Remove the end cap nuts 2 Pull the high pressure end cap...

Page 101: ...Put the stepped end of the push tool against the seal and tap on the end of the push tool with a rubber mallet to push the bottom seal and the hoop out of the high pressure cylinder 6 Turn the cylinde...

Page 102: ...al housing assembly Parts tools and materials Replace the plunger bearings every 3 000 hours when replacing the high pressure cylinder Replace the seal housing assemblies every 6 000 hours Remove the...

Page 103: ...al backup and the O ring from the seal housing 5 Install the 10 32 stainless steel screws in the threaded holes in the plunger bearing Use the screws to pull the plunger bearing out of the hydraulic e...

Page 104: ...indicator pin cap 4 Remove the spring from the indicator pin 5 Remove the indicator pin from the indicator pin hole in the hydraulic end cap Repair the check valves and the low pressure poppets This p...

Page 105: ...turn the flat face of the part 45 4 Do this procedure again until the face is smooth and flat and has an almost mirrored finish Repair the high pressure cylinders 12 micron lapping paper included in t...

Page 106: ...back and forth 5 Cut 2 pieces of lapping paper each approximately 3 cm 1 1 4 inches wide by 8 cm 3 1 4 inches long 6 Put the lapping paper into the ends of the cylinder with the abrasive side touching...

Page 107: ...these parts requires special tools Contact a Hypertherm Technical Service Associate for information and support regarding the installation operation maintenance and repair of this equipment Examine pa...

Page 108: ...ator pin cap 4 Put a small quantity of hydraulic fluid on the O ring 5 Put the O ring on the indicator pin cap Replace the indicator pin springs every 3 000 hours 1 3 4 5 6 2 1 Cap screws and lock was...

Page 109: ...unger bearings every 3 000 hours when replacing the high pressure cylinder Replace the seal housing assemblies every 6 000 hours CAUTION Water can enter the hydraulic system if the weep holes in the d...

Page 110: ...g backup and the seal housing O ring on the seal housing Put the O ring on the side nearer the narrow end of the seal housing 4 Put the plunger bearing on the plunger Push the plunger bearing into the...

Page 111: ...ith the narrow end toward the hydraulic end cap 9 Push the rod seal into the seal housing 10 Turn the seal housing so that the weep hole faces down 11 Push the seal housing tightly against the plunger...

Page 112: ...ressure water seals every 500 hours Replace the check valves every 2 000 hours Replace the high pressure cylinders every 3 000 hours if the cylinder is chipped or cracked Install a new plunger bearing...

Page 113: ...ol fits in the cylinder bore 3 Put the low pressure poppet into the low pressure poppet basket 4 Make sure that the poppet moves easily 5 Put the low pressure poppet basket with the low pressure poppe...

Page 114: ...the seal installation sleeve in the locator tool with the flat opening toward the cylinder 9 The beveled opening faces up 10 Put a small quantity of high vacuum grease on the red O ring 11 Put the re...

Page 115: ...the insertion sleeve 15 Make sure that the seal is installed in the cylinder correctly 16 Put the hoop into the insertion sleeve with the sharp edge toward the cylinder 17 Put the push tool into the...

Page 116: ...with a rubber mallet until it is touching the cylinder end 22 Turn the cylinder over so that the check valve is on the bottom Put 1 hand under the bore at the bottom of the cylinder to catch the spac...

Page 117: ...gh pressure end cap 7 Torque the end cap nuts to 375 N m 275 lbf ft Refer to High pressure end cap nut on page 180 8 Tighten each fastener in 68 N m 50 lbf ft increments Use a repeating cross pattern...

Page 118: ...icator to guide the high pressure poppet seat into the check valve The wide end of the high pressure poppet seat faces toward the check valve Repair the high pressure poppet assemblies every 1 000 hou...

Page 119: ...gh pressure antiseize lubricant on the high pressure connector threads 9 Connect the high pressure tubing 10 Torque the high pressure water fitting to 68 N m 50 lbf ft Refer to High pressure water fit...

Page 120: ...entify the source of a leak and correct the problem Refer to Leaks on page 155 A leak can cause damage to the water fittings Put the parts on a clean dry surface Examine parts that are being replaced...

Page 121: ...ed air source 4 Turn OFF the electrical main line disconnect switch Use standard lock out tag out procedures 5 Disconnect the compressed air hose from the air fitting on top of the actuator 6 Disconne...

Page 122: ...Refer to Steel JIC 37 on page 183 5 Put the needle through the needle guide and the valve seal Make sure that the point of the needle faces the seal 6 Put high vacuum grease on the red O ring on the...

Page 123: ...an be dangerous Close all doors and replace all covers including access covers WARNING Do not try to repair a leak with pressure in the system WARNING Remove all tools towels and rags from the work ar...

Page 124: ...pump is energized 8 Make sure that the LOCAL REMOTE key switch on the operation panel is set to LOCAL Refer to Operation panel on page 48 for information a Push the CONTROLS ON button to turn on the...

Page 125: ...nterface let the user log and track all maintenance performed on the pump and the intensifier To use the maintenance screens touch a symbol with a border around it This usually opens another screen A...

Page 126: ...pump after maintenance 3 Prepare for storage 4 Record maintenance 5 Inputs and outputs 6 Alarm log Move the plunger Touch this symbol to open the Move the Plunger screen Touch a symbol to shift the in...

Page 127: ...ction screen 2 To open the Intensifier Maintenance screen touch the repair symbol on the top To open the Pump Components screen touch the repair symbol on the bottom Go to step 7 on page 129 3 Touch t...

Page 128: ...seal repair kit 500 hours 2 Check valve assembly 1 500 hours 3 1 12084 DynaMAX 5 series standard Tool kit 1 000 hours 4 Low pressure poppet basket 1 500 hours 5 6 7 5 High pressure cylinder 3 000 hou...

Page 129: ...for the part that was replaced After a symbol is selected the Maintenance Reason screen opens 9 Touch the applicable symbol on the screen to record the reason that the part was replaced This informat...

Page 130: ...AX 550P 560P 575P Waterjet Pump Inputs and outputs Touch this symbol to open the screen that shows inputs and outputs for the controller Refer to Controller errors on page 171 for detailed description...

Page 131: ...Turn ON the primary breaker disconnect lever on the electrical enclosure door to ON 5 On the operator panel a Make sure the emergency stop button is not engaged If the button is pushed in turn the bu...

Page 132: ...The setpoint is based on the pump model Stage 2 Remove air from the system The intensifier starts stroking Pump Starting flashes on the screen at 1 second intervals The intensifier pushes water throu...

Page 133: ...ter pressure in the system The target pressure increases to 1 380 bar 20 000 psi The target pressure increases to 2 070 bar 30 000 psi The target pressure increases to 2 760 bar 40 000 psi The target...

Page 134: ...r supply 9 Disconnect the compressed air supply hose from the CUTTING WATER IN connection 10 Water can collect in the filter canisters when the system is cleared Make sure that the filter canisters ar...

Page 135: ...of the product or its parts recycle or discard materials and parts Use an environmentally satisfactory method and in accordance with local regulations If the product contains substances that could ca...

Page 136: ...Preventive maintenance 4 136 811390 Operator Manual DynaMAX 550P 560P 575P Waterjet Pump...

Page 137: ...Parts lists Genuine Hypertherm parts are the factory recommended replacement parts for this pump It is possible that the Hypertherm warranty will not cover damage caused by nongenuine Hypertherm parts...

Page 138: ...13537 PURE Goop halocarbon based antiseize lubricant 28 g 1 oz 1 1 11111 Blue Goop oil based antiseize lubricant 57 g 2 oz 1 1 13969 O ring lubricant petroleum based 113 g 4 oz 1 1 13972 Wrench water...

Page 139: ...cartridge 0 22 micron 10 inch 1 1 11106 Water filter cartridge 1 0 micron 10 inch 1 1 11107 Water filter cartridge 10 micron 10 inch 1 1 16025 Filter hydraulic 1 1 15564 Cotton tipped applicator 2 1 1...

Page 140: ...re 2 Poppet spring high pressure 2 Poppet seat bleed down valve 2 Poppet low pressure 2 Cotton tipped applicator 2 Description Quantity 1 High vacuum grease 5 g 0 2 oz 1 2 Poppet seat bleed down valve...

Page 141: ...tank cover 1 Filter hydraulic 2 Part number Description 1 16968 Air cooled system kit 230V HyPrecision P 50 P 50S 1 16957 Air cooled system kit 400 V 460 V DynaMAX 550P 1 16958 Air cooled system kit...

Page 142: ...gh pressure 1 4 inch 1 13158 60 6 Gland nut high pressure 3 8 inch 1 13495 Antivibration fitting assembly high pressure 1 4 inch 1 14266 Antivibration fitting assembly high pressure 3 8 inch Part numb...

Page 143: ...witch temperature and fluid level 1 11964 Return diffuser 2 inch 1 16435 O ring kit shift valve 1 18054 Service kit gear pump DynaMAX 550P 560P 575P 1 18042 Service kit hydraulic pump DynaMAX 550P 1 1...

Page 144: ...y 1 17359 Relief valve water manifold 1 17493 Replacement kit water manifold tubes 1 11835 Tank water accumulator 1 17385 Container dirty water 1 17076 Seal Maintenance Indicator SMI assembly 1 16329...

Page 145: ...nch 1 13162 60 6F9M Inlet adapter 9 16 inch male 3 8 inch female 1 12280 Attenuator assembly 1 liter 1 11595 Attenuator assembly 2 liter 1 17340 Bleed down valve assembly air actuated 1 14141 Bleed do...

Page 146: ...Parts lists 5 146 811390 Operator Manual DynaMAX 550P 560P 575P Waterjet Pump...

Page 147: ...g the pump Keep the work area clean and dry Clean fluid spills immediately Use a pan or a tray below areas where water or hydraulic fluid can spill during maintenance or repair procedures Obey local p...

Page 148: ...m Technical Service Associate for information and support Keep accurate maintenance records Records can help with predicting and preventing maintenance problems Use SAE US standard tools for most proc...

Page 149: ...en opens Touch Ack acknowledge or Ack All acknowledge all on the screen The beacon light stops flashing and the alarm screen closes Beacon light Intensifier Primary motor Cause of alarm Warning Amber...

Page 150: ...otor Wait longer between stopping and starting the motor Warning Start Procedure Hydraulics Warning Start Procedure Ramp to Pierce Pressure Warning Start Procedure Ramp to Cut Pressure An error occurr...

Page 151: ...m Technical Service Associate for information and support Warning Fluid Monitoring Sensor Error A tube is dirty Clean the tubes Refer to Clean the Seal Maintenance Indicator tubes on page 86 Replace t...

Page 152: ...rom the overstroke Refer to Overstroke on page 159 Fault 1 Low Inlet Water Pressure The water pressure at the manifold is lower than the minimum setting The supply water pressure is lower than 2 8 bar...

Page 153: ...lt Turn the primary breaker disconnect ever on the electrical enclosure door to OFF Turn the primary breaker disconnect ever on the electrical enclosure door to ON It can take e several minutes for th...

Page 154: ...has failed The relief valve on the pump manifold has failed The hydraulic compensator on the pump has failed Contact a Hypertherm Technical Service Associate for information and support Fault 2 Hydra...

Page 155: ...damage to the water fittings If a fitting leaks after tightening it to the maximum torque value disassemble the parts Repair or replace parts that show deterioration corrosion or damage Blocked weep...

Page 156: ...ressure poppet is leaking Disassemble the parts and look for flaws deterioration erosion marks or cracks Make sure that the mating surfaces are smooth and clean If damage is found replace the componen...

Page 157: ...he high pressure seal has failed The fitting is warm or the low pressure water line is pulsing The low pressure poppet is leaking Repair or replace the poppet The check valve is cracked Replace the ch...

Page 158: ...ough Tighten the fitting to the maximum torque value Disassemble the parts and look for flaws deterioration erosion marks or cracks Make sure that the mating surfaces are smooth and clean If damage is...

Page 159: ...essure gauge shows that the low pressure water is lower than 2 8 bar 40 psi Make sure that the water to the pump is on Make sure that the low pressure water line is connected to the intensifier If the...

Page 160: ...eplace the poppet retainer Make sure that the low pressure poppet fits in the poppet retainer without sticking Shake the assembly and listen for the poppet moving inside Is the overstroke is to the le...

Page 161: ...r cracks Make sure that the mating surfaces are smooth and clean If damage is found replace the component No The orifice is worn has failed or is incorrectly installed A worn or damaged orifice can in...

Page 162: ...nt the monitoring circuit opens and causes a fault Cause Solution There is a blockage in the high pressure tubing or at the orifice Remove the blockage from the high pressure tubing Clean or replace t...

Page 163: ...k for flaws deterioration erosion marks or cracks Make sure that the mating surfaces are smooth and clean with a mirror like finish If damage is found replace the component The bleed down valve has fa...

Page 164: ...ing surfaces are smooth and clean If damage is found repair or replace the component The supply water flow or pressure is too low Make sure that the supply water flow and pressure are sufficient Refer...

Page 165: ...0 The sensor is not sensing the correct temperature The cord for the hydraulic fluid temperature level sensor is unplugged or damaged Plug in the sensor Replace the cord The temperature sensor is faul...

Page 166: ...through the heat exchanger Contact a Hypertherm Technical Service Associate for information and support The hydraulic fluid in the tank has a milky appearance A leaking high pressure seal in the inten...

Page 167: ...erature of hydraulic fluid When the hydraulic fluid temperature is 55 C 131 F At 45 C 113 F a switch closes to start the cooling fan The operator interface shows WARNING HYDRAULIC FLUID 55C The beacon...

Page 168: ...alarm Water cooled system The cooling water supply or the chiller is turned off Turn ON the water supply or the chiller The cooling water is too warm If the cooling water or the supply water temperatu...

Page 169: ...n Turn ON the supply water A water filter is clogged Replace the water filters The relief valve on the pump manifold has failed Contact a Hypertherm Technical Service Associate for information and sup...

Page 170: ...and the beacon light flashes After the alarm is acknowledged a box on the intensifier symbol shows where the leaking seal is A yellow box with a 1 in it means that it is a warning A red box with a 2...

Page 171: ...switch l8 Not used l9 SMI address 0 l10 SMI address 1 l11 SMI operating out l12 SMI fault l13 Not used l14 Not used l15 Controls on I16 Remote mode on l17 Remote pump on l18 Remote pump off l19 Remot...

Page 172: ...Troubleshooting 6 172 811390 Operator Manual DynaMAX 550P 560P 575P Waterjet Pump...

Page 173: ...e measurements are given in metric units or International System of Units SI units followed by US Customary units in parentheses 1 bar 15 psi 10 mm 3 8 inch 115 N m 85 lbf ft This equipment is manufac...

Page 174: ...ating current AC electricity Some components such as valve solenoids and sensors use 24 volt direct current VDC electricity from a power supply in the electrical enclosure Ambient air temperature 4 C...

Page 175: ...are available from Hypertherm Water quality Refer to Test the water quality on page 93 Water temperature If the cooling water or the supply water temperature is higher than 24 C 75 F cool the water be...

Page 176: ...lb Height 155 cm 61 in 37 kW 50 hp 50 Hz 60 Hz Voltage 400 V 208 V to 230 V 460 V Full load current 73 8 A 138 2 A to 125 8 A 62 9 A Primary circuit breaker rating 80 0 A 150 0 A 80 0 A Minimum Maxim...

Page 177: ...ght 1 450 kg 3 200 lb Height 155 cm 61 in 45 kW 60 hp 50 Hz 60 Hz Voltage 400 V 460 V Full load current 90 7 A 74 4 A Primary circuit breaker rating 100 0 A 100 0 A Minimum Maximum CUTTING WATER IN Fl...

Page 178: ...eight 1 500 kg 3 300 lb Height 155 cm 61 in 56 kW 75 hp 50 Hz 60 Hz Voltage 400 V 460 V Full load current 110 3 89 6 A Primary circuit breaker rating 125 A 100 0 A Minimum Maximum CUTTING WATER IN Flo...

Page 179: ...0 014 0 016 0 017 2 0 010 0 011 0 012 3 0 008 0 009 0 010 4 0 007 0 008 0 009 5 0 006 0 007 0 008 6 0 005 0 006 0 007 Use only enough torque to make a sufficient seal Torque values can vary depending...

Page 180: ...sifier cap screw 373 275 7 8 inch High pressure end cap nut 373 275 1 1 2 inch socket Tighten each end cap nut in 68 N m 50 lbf ft increments Use a repeating cross pattern Lubricate O rings with hydra...

Page 181: ...flange halves together 4 Lubricate the bolt threads with antiseize bolt lubricant 5 Put the lock washers on the bolts 6 Install the bolts Tighten the bolts by hand 7 Use a torque wrench to tighten the...

Page 182: ...gs Hypertherm recommends thread sealant for all NPT fittings This table shows maximum values The torque necessary to make a sufficient seal depends on the condition of the pipe threads and can be much...

Page 183: ...to make a sufficient seal depends on the condition of the pipe threads and can be much lower than the maximum 1 16 inch dash size Minimum Maximum N m lbf ft N m lbf ft 04 14 10 15 11 06 23 17 26 19 0...

Page 184: ...vent causing damage or premature failure use 2 wrenches when loosening or tightening a high pressure connection Do not use an adjustable wrench on high pressure fittings Use only enough torque to make...

Page 185: ...he gland nut on the high pressure tube 3 Put the collar on the high pressure tube N m lbf ft Wrench size Output adapter 115 85 1 inch High pressure water fittings gland nuts 1 4 inch 34 25 5 8 inch 3...

Page 186: ...Correctly installed collar The sealing surface is showing 4 Push the high pressure tube fully into the fitting 5 Tighten the gland nut by hand 6 Use a torque wrench to tighten the gland nut to the spe...

Page 187: ...arts can have sharp corners or edges Wear approved hand protection when operating or doing work near this equipment and when touching parts Some materials can cause airborne contamination or particles...

Page 188: ...that all utilities are available during installation The site must have sufficient electrical power air water and drain access Make all connections to the pump Fill the hydraulic fluid tank Perform u...

Page 189: ...HA and other national and local codes for information about environmental criteria Do not install this equipment in an area where the temperature is below freezing Freezing can cause damage to the pum...

Page 190: ...the bleed down valve If the available air pressure is too high install an air regulator not included to reduce the pressure DynaMAX pump model kW minimum Refrigeration tons minimum tons Heat removal r...

Page 191: ...ctions Softened water is necessary for most systems Get advice from a water specialist for recommendations for choosing a water treatment system WARNING A line disconnect switch for incoming electrica...

Page 192: ...these items are included with the pump Dirty water container Intensifier repair tools These items are usually shipped inside the electrical enclosure Key for the LOCAL REMOTE key switch Key for the e...

Page 193: ...p the leveling foot from moving CAUTION Hydraulic water and electrical connections can become loose during shipping and normal operation Examine all connections at installation and during regular main...

Page 194: ...ng holes for the plumbing kit on the rear of the pump 2 Install the angle plate on the pump frame 3 Use the included hardware to mount the high pressure tubing whip bracket on the angle plate 4 After...

Page 195: ...le plug 4 Put the cord grip connector on the cord 5 Put the cord and the threaded end of the cord grip connector through the wiring access hole 6 Put the lock nut on the cord grip connector 7 Connect...

Page 196: ...he external heat exchanger before starting the motor the hydraulic hoses can be damaged CAUTION To prevent dirty water from entering the bleed down valve install the WASTE WATER OUT hose so that it is...

Page 197: ...ed 5 8 inch open ended wrench 13 16 inch open ended wrench 1 1 2 inch open ended wrench Torque wrench High pressure antiseize lubricant such as Blue Goop or PURE Goop 3 8 inch high pressure male fitti...

Page 198: ...ING WATER IN This line carries low pressure water from a water softener a reverse osmosis system a well or a public utility to the pump Connect 1 end of this line to the supply water Connect the other...

Page 199: ...hiller or to the drain Connect 1 end of this line to the chiller or to the drain Connect the other end to the fitting on the pump s utility panel Factory installed fitting 1 inch NPT female Air cooled...

Page 200: ...e pump to a dedicated supply transformer that has separate windings Use electrical parts that are certified by national or local electrical codes If the cross sectional area S mm2 of the copper phase...

Page 201: ...urn ON the electrical main line disconnect switch 4 Turn the primary breaker disconnect lever on the electrical enclosure door to ON CAUTION Make sure that all connections fasteners locking devices ho...

Page 202: ...tarily Then touch the STOP symbol 5 Make sure that the primary motor turns in the direction shown by the rotation arrow If the pump motor turns the wrong direction a Turn the primary breaker disconnec...

Page 203: ...nnect switch e Turn the primary breaker disconnect lever on the electrical enclosure door to ON f On the operation panel push the CONTROLS ON button to turn ON the control circuit in the pump g On the...

Page 204: ...the fan motor turns in the wrong direction a Disconnect the electrical power to the pump b In the electrical enclosure interchange 2 wires on the bottom of the motor starter Turn on the pump 1 Set th...

Page 205: ...egulator knob on the water manifold Turn it clockwise to increase the pressure or counterclockwise to decrease pressure Measure the air pressure in the water accumulator tank Refer to Low pressure wat...

Page 206: ...p 8 Install a ruby orifice in the cutting head 9 Turn ON the pump 10 On the operator interface touch the START symbol 11 Increase the pressure to 2 760 bar 40 000 psi Operate the program in a loop for...

Page 207: ...rimary adjustments screen Pump Adjustments Not all screens are used when installing the pump Pump Adjustments on page 207 Intensifier Control on page 216 Seal Maintenance Indicator on page 214 Pressur...

Page 208: ...changer the pump uses Water A standard pump has an internal water cooling system Air An air cooled pump has an external heat exchanger Pressure Units Touch this field to open a numeric keypad Touch th...

Page 209: ...r Stage 1 After the system gets to the minimum water manifold pressure the inlet water timer starts The timer default is 5 seconds Bleed Valve Stage 2 This is the time it takes for the intensifier to...

Page 210: ...s 4 140 bar 60 000 psi Increments Increase This is how much that the target pressure increases each time the symbol on the primary operation screen is touched The default is 34 bar 500 psi The smalles...

Page 211: ...re input on or off Modbus Mode This turns Modbus mode on or off When this mode is on a Modbus symbol shows on the primary operation screen the pump is controlled by Modbus TCP over Ethernet Modbus Pre...

Page 212: ...oes into cooling mode after the idle duration timer expires Idle Duration This timer determines how long the pump is idle before it turns off or goes into cooling mode The default is 10 minutes Stop B...

Page 213: ...ure on or off Reminder Time This timer determines how long the pump operates before the reminder is displayed The default is 200 hours Boost Fault Monitor The system can monitor a boost pump for fault...

Page 214: ...the pump operates for 30 minutes after a fault is sensed and then turns off Warning The Seal Maintenance Indicator senses leaks from the intensifier This value determines the number of units that cau...

Page 215: ...l and field Touch the symbol to change the time format Options are a 12 hour clock or a 24 hour clock Touch the field next to the symbol to open a numeric keypad Use the keypad to change the time Date...

Page 216: ...d stroke rate that is permitted before an overstroke fault condition occurs The maximum intensifier stroke rate is calculated using the motor wattage and the size of the hydraulic pump The rate can be...

Page 217: ...ssure coming out of the water manifold Minimum Touch this field to open a keypad Enter the minimum pressure permitted before a fault occurs The setpoint is based on the pump model DynaMAX 550P 2 0 bar...

Page 218: ...oSD card stores the current program the alarm log files and the maintenance log If the microSD card is missing or damaged the screen shows SD Card Not Found Remote operation To connect the pump direct...

Page 219: ...m com docs 2 Under Select your product choose Waterjet Family in the dropdown list 3 Go to the Regulatory information section and click the 4 Click on the Declaration of Incorporation for your product...

Page 220: ...2100 2010 EN 60204 1 2018 EN1829 1 2010 EN 61000 6 2 2005 AC 2005 EN 61000 6 4 2007 A1 2011 The technical documentation is compiled in accordance with Annex VII Part B of Directive 2006 42 EC In respo...

Page 221: ...90 221 Technical drawings The hydraulic and water system drawing is in this section The electrical drawings are shipped in an envelope that is found inside the electrical cabinet Hypertherm recommends...

Page 222: ...Technical drawings 10 222 811390 Operator Manual DynaMAX 550P 560P 575P Waterjet Pump...

Page 223: ...Technical drawings 10 DynaMAX 550P 560P 575P Waterjet Pump Operator Manual 811390 223...

Page 224: ...priority Send this information with your comments to Technical Service hypertherm com DynaMAX 550P 560P 575P Waterjet Pump Operator Manual 811390 revision 0 Include page numbers if applicable Tell us...

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