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Preventive maintenance

810770 Operator

Manual

Echion

Pr
ev
entive main

tenance

Clean the air cooler

Parts, tools, and materials

Do this task when the pump is off.

Remove the top cover and the front panel. Refer to

Inspect the pump

on page 39 for instructions.

Clean the air side of the cooler

Refer to the label on the cooler to find the cooler’s air direction.

Clean oil and grease off of the cooler with compressed air, pressurized water, or a steam
cleaner. Direct the cleaning stream against the cooler’s air direction.

After cleaning, dry the cooler.

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 about the environment when selecting and
using cleaning chemicals.

Detergent

must

be compatible with aluminum.

CAUTION

Protect the motor and all electronics during the cleaning procedure.

Compressed air source

Pressurized-water source or a steam cleaner

Operation or equivalent oil

Recommended materials

Aluminum-compatible detergent

Ethylene perchlorate detergent

Oil carbon detergent

CAUTION

To prevent damage, the stream of water or air must be parallel to the fin.

Point the water stream against the air direction.

CAUTION

Detergent can give better cleaning results. Think about the environment when selecting and
using cleaning chemicals.

Detergent

must

be compatible with aluminum.

Summary of Contents for Echion

Page 1: ...Echion Operator Manual 810770 REVISION 3 ENGLISH ...

Page 2: ... All other trademarks are the property of their respective holders Environmental stewardship is one of Hypertherm s core values and it is critical to our success and our customers success We are striving to reduce the environmental impact of everything we do For more information www hypertherm com environment 2020 Hypertherm Inc ...

Page 3: ...Hypertherm Inc Hanover NH 03755 USA www hypertherm com Echion Operator Manual 810770 REVISION 3 ENGLISH Original instructions June 2020 ...

Page 4: ...rm com Main Office Email 800 643 9878 Tel Technical Service technical service hypertherm com Technical Service Email 800 737 2978 Tel Customer Service customer service hypertherm com Customer Service Email 866 643 7711 Tel Return Materials Authorization 877 371 2876 Fax Return Materials Authorization return materials hypertherm com RMA email Hypertherm México S A de C V Avenida Toluca No 444 Anexo...

Page 5: ...nal standards SC 15 Higher level systems SC 16 Environmental stewardship SC 17 Hypertherm products waste and recycling SC 18 Chemical handling and usage SC 19 Particle emission and waste water quality SC 20 Safety SC 21 Manuals SC 22 User qualification and training SC 23 Emergency medical information and treatment SC 24 Safety information for operation maintenance repair and installation SC 25 ...

Page 6: ... 44 Turn on the controls 44 Start the pump 45 Do the preoperation maintenance checks 46 Operate the pump 49 Select the pressure mode 49 Set the target water pressure 49 Stop the pump 50 Stop the pump remotely 50 Stop the pump locally 50 Emergency stop 51 Turn off the pump end of day 52 3 Preventive maintenance 53 Safety 54 Benefits of preventive maintenance 55 Training 55 Operator interface Mainte...

Page 7: ...ydraulic fluid side of the cooler 79 Replace the water filter 80 Test the total dissolved solids TDS level 81 Test the water quality 83 Replace the hydraulic filter element 84 Add hydraulic fluid 85 Replace the hydraulic fluid 86 Lubricate the primary motor bearings 88 Start the pump after maintenance 90 Postmaintenance start procedure 91 Prepare for storage 93 Recycling and end of product life 96...

Page 8: ...28 Low pressure water 128 High pressure water 129 Leaks 131 The pump makes noise during operation 133 Controller errors 134 Input output status 134 6 Specifications 135 All Echion model pumps 136 Environmental conditions 136 Hydraulic fluid 136 Utilities 137 Echion 15 138 Dimensions and weights 138 Electrical 138 Water 138 Echion 30 139 Dimensions and weights 139 Electrical 139 Water 139 Echion 50...

Page 9: ...ilities to the pump 156 Connect the water and the air 157 Connect the electrical power 158 Check the hydraulic fluid 159 Do the first start 159 Do a preoperation inspection 160 Turn on the utilities 160 Make sure that the primary motor turns in the correct direction 161 Turn on the pump 162 Adjust the boost pump pressure 162 Flush the pump and the high pressure tubing 163 Operator interface Adjust...

Page 10: ...Contents 9 Touchscreen maps 175 Primary operation screen 177 Adjustment screens 181 Maintenance screens 185 10 Technical drawings 189 ...

Page 11: ...Echion Operator Manual 810770 SC 11 Warranty Warranty ...

Page 12: ...s bleed down valves low pressure seals high pressure tubing and filters All third party motors pumps and plumbing accessories are warrantied by the respective manufacturers and are not included in this warranty Disclaimer All product information contained in this manual is believed to be reliable as of the date of publication The manual could contain technical inaccuracies or typographical errors ...

Page 13: ...Operator Manual 810770 SC 13 Product stewardship Product stewardship Hypertherm maintains a global regulatory management system to make sure that products comply with regulatory and environmental requirements ...

Page 14: ... by the accredited testing laboratory Once the product has left the Hypertherm factory the certification test marks are invalid if one or more of these events occurs The product is modified in a manner that causes danger or does not conform with the applicable standards Safety critical parts are replaced with unapproved spare parts Assembly is unauthorized An accessory that uses or generates dange...

Page 15: ... Association CSA versions of Hypertherm s products do not comply with European electromagnetic compatibility requirements therefore they do not have a CE mark on the data plate Countries where the CE mark in necessary or that have compulsory electromagnetic compatibility regulations must use CE versions of Hypertherm products with the CE mark on the data plate These could include countries in the ...

Page 16: ...m 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 can be subject to approval by local authorities Get advice from legal counsel and local regulatory experts if you are not sure about compliance External cables connecting parts of the higher level system m...

Page 17: ...Echion Operator Manual 810770 SC 17 Environmental stewardship Environmental stewardship ...

Page 18: ...dinary waste It is your responsibility to discard Hypertherm products or parts in an environmentally suitable manner and in compliance with national and local codes In the United States read all national state and local laws In the European Union EU read the EU directives national and local laws In other countries refer to national and local laws Consult with legal or other compliance experts when...

Page 19: ...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 Labelling of Chemicals GHS The GHS is an international system for standardizing chemical classification and labeling Chemical regulations in the USA Europe and other locations require that MSDS and SDS be made available for chemica...

Page 20: ...eleased from materials that are cut and if they can pose a physical danger or health risk Get advice from your supplier or other technical advisor for guidance concerning the properties of the material you cut with a Hypertherm product If you are not familiar with the current applicable government regulations and legal standards for the installation site get advice from a local expert before you p...

Page 21: ...perator Manual 810770 SC 21 Safety Safety The end user is responsible for the safe operation of this equipment WARNING Before operating Hypertherm equipment read the safety instructions in your product s manual ...

Page 22: ...ions such as equipment failure site variability insufficient maintenance failure of control equipment and other events can cause equipment damage injuries or death It is the user s responsibility to identify dangers and to take the steps necessary to minimize risks Keep these instructions near the equipment This manual is intended to familiarize the user with the equipment and its parts safe opera...

Page 23: ...pment Operators must be approved to operate and maintain this equipment Training should include how to start and stop the equipment during operation and in an emergency situation conditions and procedures that can lead to injuries to personnel and damage to the equipment how to operate all controls how to identify and respond to a problem with the equipment how to do maintenance procedures a copy ...

Page 24: ... high pressure injection injury is a surgical emergency Get medical treatment immediately for all high pressure waterjet injuries The person with this card has been exposed to a waterjet of up to 4 140 bar 60 000 psi and a velocity of 609 m s 2 000 feet second Abrasive waterjets can eject water and abrasive materials that can be injected into body tissues leading to a dangerous infection Skin can ...

Page 25: ...when operating this equipment If a high pressure fitting fails it can cause a stream of water or hydraulic fluid to eject from the system with force WARNING Do not leave waterjet cutting equipment unattended while it is operating WARNING During operation keep a restricted access area clear that is larger than the maximum movement range of the cutting equipment s moving parts WARNING Let only appro...

Page 26: ... machine is being energized WARNING To reduce the risk of injuries or death wear approved protection and obey safety recommendations when doing work with electricity WARNING When work must be done in a small space or an area with limited access the access must not be blocked by ventilation ducts hoses pipes or other equipment WARNING Do not block or remove warnings cautions or instructions WARNING...

Page 27: ...hand protection when operating or doing work near this equipment and when touching parts WARNING Some materials can cause airborne contamination or particles when cut Wear approved respiratory protection when operating or doing work near this equipment CAUTION Examine and clean the equipment regularly Refer to the Preventive maintenance schedule on page 60 Do repairs immediately ...

Page 28: ...Safety SC 28 810770 Operator Manual Echion Safety ...

Page 29: ...Echion Operator Manual 810770 SC 29 Symbols and marks Symbols and marks ...

Page 30: ...N when used with the yellow warning sign identifies a dangerous condition or a situation that COULD cause minor or moderate injuries or WILL cause damage to the equipment if ignored NOTICE NOTICE identifies a condition or a situation that COULD cause damage to the equipment if ignored This symbol identifies a mandatory action This symbol identifies a prohibited action This symbol identifies tools ...

Page 31: ...ose you to chemicals including lead and lead compounds which are known to the State of California to cause cancer and birth defects or other reproductive harm For more information go to www p65warnings ca gov WARNING Hydraulic water and electrical connections can come loose during shipping and normal operation It is recommended that all connections are checked at installation and annually CAUTION ...

Page 32: ...tion of conformity to applicable European directives and standards Only those versions of Hypertherm products with a CE mark on or near the data plate have been tested for compliance with the applicable European directives such as the Low Voltage Directive the Electromagnetic Compatibility Directive and the Machinery Directive Use caution when operating this equipment Refer to the instruction manu...

Page 33: ...ic utility to the pump CUTTING WATER OUT This tubing carries high pressure water from the intensifier to the cutting table WASTE WATER OUT This hose carries water from the bleed down valve to a drain COOLING IN This line carries low pressure water from the local utility or a chiller to the pump s cooling loop COOLING OUT This line carries low pressure water from the heat exchanger to the chiller o...

Page 34: ...Symbols and marks SC 34 810770 Operator Manual Echion Symbols and marks ...

Page 35: ... can use Ethernet to communicate with a CNC Utility connection panel kit The utility connections for the Echion pump are inside the pump at the point of use With this kit utility connections are made on the outside of the pump Metric conversion kit This kit includes adapter fittings for use in countries where metric connections are standard Pump mounted high pressure plumbing kit This kit includes...

Page 36: ...Optional equipment 1 36 810770 Operator Manual Echion Optional equipment ...

Page 37: ...h the Safety Preventive maintenance Troubleshooting and Specifications sections of this manual Images in this manual are for reference purposes It is possible that your product configuration is not shown accurately It is possible that not all of the information in this section applies to all pump models ...

Page 38: ... circuit is on 2 Local Remote key switch When the key switch is in the Local position use the operator interface to operate the pump When the key switch is in the Remote position use the remote source such as a computer numerical control CNC operator console to controls the pump Most functions on the operator interface are not available when the key switch is in the Remote position 3 EMERGENCY STO...

Page 39: ...water pressure Monitor the status of the intensifier 3 Operator interface Adjustment screens tab See information about your system Change some display options such as pressure units bar or psi or language Change timer durations Turn features such as Modbus mode on or off Refer to Operator interface Adjustment screens on page 164 4 Operator interface Maintenance screens tab Move the plunger to one ...

Page 40: ...e mode 10 Cut pressure mode on Touch this symbol to put the pump in cut pressure mode Cut pressure mode is active in this image Refer to Select the pressure mode on page 49 for information about pressure modes 11 Target water pressure 12 Output water pressure This shows the actual water pressure when the pump is operating This is the target water pressure set by the user Refer to Set the target wa...

Page 41: ... included in these instructions Inspect the pump 1 Remove the top cover a Use a standard screwdriver to turn the bolt on each end counterclockwise 1 4 turn b Lift the cover off of the alignment pins 2 Remove the front panel Push down on the horizontal surface on top of the panel to release the retainers tabs from the frame Unless otherwise recommended install the top cover and the front panel befo...

Page 42: ...al plugs and other electrical connections for corrosion or damage 7 Look for leaks deterioration damage or other conditions that can interfere with operation 8 Make sure that all connections fasteners locking devices hoses and fittings are tight 9 Make sure that all warning decals are visible and legible Contact Hypertherm for replacement decals 1 2 4 1 2 4 3 Refer to local regulations regarding w...

Page 43: ...fluid 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 86 CAUTION Heat and other conditions cause hydraulic fluid to degrade Degraded hydraulic fluid can cause damage to hydraulic components Collect a sample of hydraulic fluid from the hydraulic fluid tank and send it to a...

Page 44: ...ctrical enclosure door to ON Turn on the controls Turn on the controls remotely 1 Make sure that the EMERGENCY STOP is not engaged If the button is pushed in turn the button clockwise until it releases 2 Make sure that the key switch is set to Local 3 Push the Controls button 4 Turn the key switch to Remote The remote indicator light is on Refer to the OEM s instructions for starting the pump and ...

Page 45: ...ller starts the pump A progress bar shows below the intensifier on the screen The normal start sequence is fully automated Refer to Primary operation screen on page 177 for a description of the sequence Monitor for leaks 2 When the start sequence is complete complete the Daily preventive maintenance tasks Refer to the Preventive maintenance schedule on page 60 3 2 1 1 2 3 CAUTION Use the Postmaint...

Page 46: ...bridge and bottom deck 2 Examine the low pressure tubes and the hoses for leaks 3 Examine the bleed down valve for leaks or damage 4 Examine the weep holes in the high pressure ends for leaks Water leaking from a weep hole is a sign of a faulty part or a loose connection 5 Examine the high pressure tubing for leaks 6 Look for deterioration damage or other problems A hot bleed down valve can sugges...

Page 47: ...f necessary Refer to Add hydraulic fluid on page 85 for instructions Check the hydraulic filter gauge Do this task when the pump is operating at a stable temperature Make sure that the needle on the hydraulic gauge is not in the red zone Replace the hydraulic filter element every 1 500 hours when the needle on the gauge stays in the red zone while the pump is operating Refer to Replace the hydraul...

Page 48: ...ubtract the value shown on the postfilter water pressure from the value shown on the prefilter water pressure If the difference between the values is more than 0 7 bar 70 kPa 10 psi replace the water filter Make sure that the emergency stop operates correctly Do this task when the pump is operating On the operation panel push the EMERGENCY STOP button Refer to Emergency stop on page 51 Replace the...

Page 49: ... target water pressure There are 2 ways to change the target water pressure on the operator interface Touch the symbol or the symbol to change the target water pressure in preset increments To change the increments refer to Pressure Adjustments on page 167 Touch the target water pressure button to open a numeric keypad Type the number and then touch Enter 4 1 2 3 1 Target water pressure Touch this...

Page 50: ... intensifier turn off The bleed down valve opens to release high pressure water from the system The supply water valve closes to stop low pressure water from entering the system No output water pressure shows The control circuit stays on You can stop the pump from the operator interface while using remote controls On the operator interface touch the symbol to stop the pump Refer to Stop the pump o...

Page 51: ...on The control circuit turns off which turns off the pump the primary motor and the intensifier Remote controls that are wired to the pump controller turn off The bleed down valve opens to release high pressure water from the system The supply water valve closes to stop low pressure water from entering the system WARNING The EMERGENCY STOP button does not disconnect main electrical power from the ...

Page 52: ...show 0 0 bar 0 kPa 0 psi 4 Turn OFF the compressed air source 5 Turn OFF the electrical main line disconnect switch Use standard lock out tag out procedures 6 Remove the top cover and the front panel 7 Clean all debris water and hydraulic fluid off of the hydraulic fluid tank the intensifier bridge and the bottom deck 8 Empty the dirty water container if necessary Do this procedure at the end of t...

Page 53: ...user is familiar with the Safety Operation Troubleshooting and Specifications sections of this manual Images in this manual are for reference purposes It is possible that your product configuration is not shown accurately It is possible that not all of the information in this section applies to all pump models ...

Page 54: ...aulic parts clean the parts to remove grease and other contamination Clean and examine parts that will be replaced to identify wear patterns 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 Keep the work area clean and dry Clean fluid spills immediately Use a pan o...

Page 55: ... parts Improves reliability Finds possible problems before they cause unplanned downtime and become expensive repairs Extends the life of equipment and decreases the frequency of replacement Contributes positively to reputation and profits Gives traceability through records Training The employer must provide training for maintenance procedures Retrain personnel when there is a change in job assign...

Page 56: ...to open the primary maintenance screen Move the plunger Touch this symbol to open the Move the Plunger screen Instructions for moving the plunger begin on page 61 Refer to Touchscreen maps on page 177 to see all of the screens available on the controller 2 4 1 5 3 1 Move the plunger 2 Start the pump after maintenance 3 Prepare for storage 4 Inputs and outputs 5 Alarm log ...

Page 57: ...he pump after maintenance Touch this symbol to open the Start Procedure screen Refer to Postmaintenance start procedure on page 91 for more information Prepare for storage Touch this symbol to open the Prepare for Storage screen Refer to Prepare for storage on page 93 for more information ...

Page 58: ...en is useful for troubleshooting Touch this symbol to open a screen that shows inputs and outputs for the controller Refer to Input output status on page 134 for more information Alarm log The alarm log is useful for troubleshooting Touch this symbol to open the Alarm Log screen Refer to Alarms on page 114 for more information ...

Page 59: ...s Some tools are designed to make the procedure easier and to prevent damage to the equipment Personnel who maintain and repair this equipment must know how to use standard hand tools Use SAE US standard tools for most procedures Open ended wrench Crowfoot wrench Screwdriver Standard Phillips O ring pick Snap ring pliers Intensifier repair tools 1 Seal installation tool 2 Seal removal tool 3 Cylin...

Page 60: ...ydraulic fluid level page 45 Check the hydraulic filter gauge page 45 Check the low pressure water pressure gauges page 46 Make sure that the emergency stop operates correctly page 46 Intensifier Repair the high pressure cylinders the check valves and the low pressure poppets page 66 Replace the high pressure seal cartridges page 69 Intensifier Replace the high pressure poppet assemblies page 69 R...

Page 61: ...nders and the check valve assemblies page 66 Bleed down valve Replace the bleed down valve body page 75 Hydraulic system Replace the hydraulic fluid page 86 Intensifier Replace the output adapters page 73 Replace the seal housing assemblies page 62 Motor Lubricate the primary motor bearings page 88 Intensifier Replace the spacer tubes page 62 Repair the hydraulic center section page 65 Interval Da...

Page 62: ... adapters Replace the seal housing assemblies Every 12 000 hours Replace the spacer tubes Repair the hydraulic center section CAUTION To prevent causing damage or premature failure use 2 wrenches when loosening or tightening a high pressure connection Always tighten fittings to the specified torque CAUTION Do not use an adjustable wrench on high pressure fittings Use clean hands when changing high...

Page 63: ...t the motor Intensifier repair tools 1 18770 Echion high pressure seal repair kit 1 18771 Echion high pressure poppet repair kit 1 18849 Echion low pressure poppet repair kit 1 18768 Standard tool kit 13 16 inch open ended wrench or socket 1 inch open ended wrench 1 1 16 inch open ended wrench 1 inch socket Torque wrench Rubber mallet 2 O ring picks or similar tool 2 standard screwdrivers Large sn...

Page 64: ...ne disconnect switch Use standard lock out tag out procedures 10 Use a 13 16 inch open ended wrench to disconnect the high pressure tubing from the intensifier 11 Remove the bleed down valve Refer to step 5 though step 10 on page 76 12 Push the button on the quick disconnect fitting to remove the low pressure water line from the intensifier 13 Use the breaker bar and the 1 1 2 inch 12 point socket...

Page 65: ...ge Pull the seal housing assembly off of the plunger A small amount of hydraulic fluid could leak from the hydraulic cylinder This is normal Repair the hydraulic center section The hydraulic center section includes the piston the hydraulic cylinder the hydraulic end caps the low pressure seals the plungers the T seals and the proximity switches Preventive maintenance on these parts requires specia...

Page 66: ...valves and the low pressure poppets every 500 hours Replace the high pressure seal cartridges every 500 hours Replace the low pressure poppets and seats every 1 000 hours Replace the high pressure cylinders every 3 000 hours or if the cylinder is chipped or cracked Replace the check valve assemblies every 3 000 hours CAUTION Debris in the cylinder can cause the seals or the poppets to fail This pr...

Page 67: ...ound the bore is marked or pitted or has rough edges or burrs remove the defects with a nonstick scouring pad 9 Cut a nonstick pad in half Put half of the pad in the end of the cylinder Put 1 thumb in each end of the cylinder and push down evenly on the pad while rolling the cylinder back and forth 10 Clean the inner surfaces of the cylinder with a towel and isopropyl alcohol 11 Use a 1 8 inch hex...

Page 68: ...ure Do this procedure until the face is smooth and flat and has a mirrorlike finish CAUTION Do not rock the parts or use too much pressure Doing so can cause damage to the part faces CAUTION Keep the low pressure poppet and the poppet retainer clean Grease can cause the poppet to stick Do not put grease or lubricant on the check valve face or in the cylinder bore These components are designed for ...

Page 69: ... housing and the high pressure seal backup Make sure that the inner grooves are clean Make sure that the weep hole is clear If necessary use compressed air to blow debris out 6 Put high vacuum grease on the backup ring and the seal housing O ring Replace the seal housing assemblies every 6 000 hours CAUTION Water can enter the hydraulic system if the weep holes in the dynamic seal backup or the se...

Page 70: ... the seal housing as shown 9 Use snap ring pliers to insert the snap ring Make sure that the snap ring is seated correctly in the groove 10 Put the cylinder locator tool and the seal installation tool together 11 Put the tool on the seal housing and turn it clockwise so that the threads engage 12 Put the seal housing on the plunger with the narrow end of the seal housing toward the center of the i...

Page 71: ...igh pressure cylinder that was repaired with the nonabrasive pad Put the high pressure cylinder over the spacer tube with that end facing the center of the intensifier Push the cylinder as far as possible Turn the high pressure cylinder around at 1 500 hours to promote even wear 22 Put the check valve in the end of the high pressure cylinder Make sure that the weep hole faces down toward the groun...

Page 72: ...hion Preventive maintenance 26 Put the nuts on the studs by hand Use a torque wrench to tighten the high pressure end cap nuts to 68 N m 50 lbf ft Use a repeating cross pattern Tighten the nuts to 375 N m 275 lbf ft Do this in 68 N m 50 lbf ft increments ...

Page 73: ...apter gently on a wooden or other soft surface to eject the poppet from the output adapter Replace the high pressure poppet assemblies every 1 000 hours Replace the output adapters every 6 000 hours CAUTION The high pressure poppet seat can cause cracks erosion marks or dents in the output adapter If a poppet part is damaged replace all 3 components 1 2 3 4 1 High pressure poppet seat 2 High press...

Page 74: ...ut adapter 6 Put the output adapter in the check valve and tighten it by hand Use a torque wrench to tighten the output adapter to 115 N m 85 lbf ft 7 Torque the high pressure water fitting to 68 N m 50 lbf ft 8 Repeat this procedure on the other end of the intensifier 9 Connect the high pressure tubing 10 Connect the low pressure water lines CAUTION Tightening the output adapter with the high pre...

Page 75: ...t procedures Repair the bleed down valve every 1 000 hours if water leaks from the Waste water out connection or from the weep holes while the pump is operating Replace the bleed down valve body every 3 000 hours 1 2 3 5 6 7 8 9 10 4 11 1 Air fitting 2 Actuator 3 Needle guide 4 Needle 5 High pressure valve seal 6 Bleed down valve body 7 Bleed down valve seat 8 Flow reducer 9 Outlet adapter 10 Tee ...

Page 76: ...y from the pump 11 Remove the outlet adapter from the valve body 12 Remove the seat and the flow reducer from the outlet adapter 13 Remove the actuator from the valve body 14 Push a dowel through the bottom of the valve body to remove the seal the needle guide and the needle 15 Put high pressure antiseize lubricant on the seat 16 Put the flow reducer into the outlet adapter 17 Put the seat into th...

Page 77: ...ter drain tube to the bleed down valve 25 Connect the compressed air hose to the fitting on top of the actuator 26 Turn ON the utility water to the pump 27 Turn ON the compressed air source 28 Turn ON the electrical main line disconnect switch 29 Turn the primary breaker disconnect lever on the electrical enclosure door to ON 30 Make sure that the EMERGENCY STOP is not engaged If the button is pus...

Page 78: ...f you receive a Fault 1 Hydraulic Fluid 65C alarm CAUTION Detergent can give better cleaning results Think about the environment when selecting and using cleaning chemicals Detergent must be compatible with aluminum CAUTION Protect the motor and all electronics during the cleaning procedure Compressed air source Pressurized water source or a steam cleaner Operation or equivalent oil Recommended ma...

Page 79: ...ination is moderate connect the oil side to a closed cleaning system with a pump and a filter Ethylene perchlorate detergent can be used Pump the detergent through the blast oil cooler for 10 minutes If contamination is very bad use an oil carbon detergent Rinse cleaned surfaces for 30 minutes 2 Use compressed air to remove remaining detergent 3 Rinse the blast oil cooler with operation or equival...

Page 80: ...canister if necessary 6 Put a new filter cartridge in the canister The filter does not have a designated top or bottom 7 Use the filter wrench to install the filter canister 8 Turn ON the water to the pump 9 Turn ON the pump 10 On the operator interface touch the symbol start the pump 11 Make sure that the difference between the values on the prefilter water pressure gauge and the postfilter water...

Page 81: ...he button on a quick disconnect fitting to remove a low pressure water line from the intensifier 2 Disable the intensifier a On the operator interface touch the adjustments symbol to open the primary adjustments screen b Touch this symbol to open the Intensifier Control screen Do this task every 1 000 hours CAUTION The meter is not waterproof Do not submerge the meter in water Some TDS meters must...

Page 82: ...urn OFF the TDS meter between readings 7 Compare the reading to the table 8 Rinse the meter in clean deionized water or filtered water after use 9 Connect the low pressure water line 10 Go to the Intensifier Control screen and enable the intensifier Unsatisfactory Optimal Satisfactory Unsatisfactory Lower than 0 005 50 ppm 0 005 to 0 015 50 ppm to 150 ppm 0 015 to 0 022 150 ppm to 220 ppm Higher t...

Page 83: ...d odorless 3 Test the pH The optimal pH measurement is between 6 0 and 8 0 4 Test the silica SiO2 content The silica content must be lower than 0 0015 15 parts per million ppm 5 Test the water hardness The result must be equal to or lower than 0 006 60 ppm 3 5 grains per gallon 6 Test the total dissolved solids TDS concentration The optimal range is 0 005 to 0 015 50 ppm to 150 ppm Refer to Test t...

Page 84: ... filter element 4 Twist the filter element into the filter head 5 Use a torque wrench to tighten the filter to a value between 13 5 N m 10 lbf ft and 16 N m 12 lbf ft 6 Turn ON the pump in pierce pressure mode 7 Look at the sight gauge to check the hydraulic fluid level Add hydraulic fluid if necessary Do this task every 1 500 hours when the needle on the hydraulic gauge is in the red zone while t...

Page 85: ... not operating 1 Remove the top cover and the front panel Refer to Inspect the pump on page 39 for instructions 2 Remove the filler cap 3 Fill the tank with hydraulic fluid until the fluid is at the top mark on the sight gauge 4 Install the filler cap Do not put too much hydraulic fluid in the tank Antiwear AW mineral oil or synthetic hydraulic fluid ISO viscosity grade VG 32 or 46 Recommended mat...

Page 86: ...Do this task every 3 000 hours if the hydraulic fluid is dark or milky in color or has a strong odor if a test laboratory finds the quality is unsatisfactory Refer to Check the hydraulic fluid on page 41 Do not put too much hydraulic fluid in the tank 3 2 1 1 Filler cap 2 Filter head 3 Sight gauge 1 18772 Hydraulic fluid replacement kit Antiwear AW mineral oil or synthetic hydraulic fluid ISO visc...

Page 87: ...ank 8 Assemble the hydraulic tank cover a Install the tank cover bolts and washers 10 each b Install the 2 hoses that pass through the cover c Connect the hydraulic hose from the filter d Connect the temperature level sensor cable 9 Fill the tank with hydraulic fluid until the fluid is at the top mark on the sight gauge 10 Install a new filler cap 11 Discard the used parts 12 Turn ON the pump in p...

Page 88: ...the grease fitting with a towel if necessary 5 Attach a grease gun coupler to the grease fitting Do this task every 3 000 hours CAUTION Correct lubrication is important for motor performance Use the correct types and amounts of grease and oil CAUTION The bearing can overheat if too much or not enough grease is used to lubricate the bearing Most handheld pump grease guns have an output of 1 25 gram...

Page 89: ...rease in the motor 7 Replace the grease cap 8 Do this procedure again on the other end of the motor 9 Use the postmaintenance start procedure after working on the primary motor Refer to Postmaintenance start procedure on page 91 Echion 15 Echion 30 Echion 50 13 grams 18 grams 21 grams CAUTION Use only the recommended volume of grease ...

Page 90: ...uipment CAUTION Make sure that all fittings are tight after doing maintenance on or repairs to this equipment Start the pump normally if maintenance done on the pump was limited to replacing the water filter replacing the hydraulic filter element replacing the hydraulic fluid repairing or replacing the bleed down valve working on the electrical system Refer to Start the pump on page 43 for instruc...

Page 91: ...on the electrical enclosure door to ON 5 Make sure that the EMERGENCY STOP is not engaged If the button is pushed in turn the button clockwise until it releases 6 Make sure that the key switch is set to Local 7 Push the Controls button 8 On the operator interface touch the maintenance symbol to open the primary maintenance screen 9 Touch this symbol to open the Start Procedure screen 10 Touch the ...

Page 92: ... cutting head b Touch the symbol to continue 13 When Examine the Pump flashes on the screen a Examine the pump for loose fittings or leaks b Examine the attenuator connections for leaks c Touch the symbol to continue The main motor turns off The primary operation screen opens 14 Install the top cover and the front panel The pump is ready for operation ...

Page 93: ...ipment Do not stand over components such as tubes or valves while drying the system All low pressure water connections use push to connect fittings 4 3 2 1 6 5 7 Cutting water in Boost pump Inlet water solenoid for systems without a boost pump Waste water out Compressed air Cutting water out 7 4 3 2 1 Water cooled system Cooling in Cooling out 5 6 1 8 inch male to 1 2 inch male adapter compressed ...

Page 94: ...nch NPT female An adapter not included is necessary 5 Use a 1 1 16 inch open ended wrench to disconnect the Waste water out hose from the pump 6 On the operator interface touch the maintenance symbol to open the primary maintenance screen 7 Touch this symbol to open the Prepare for Storage screen 8 Touch the symbol on the screen to start the procedure The supply water valve opens 9 Turn ON the com...

Page 95: ...ssed air hose to the Cooling in connection The Cooling in connection is 1 2 inch NPT female An adapter not included is necessary b Use a 1 3 16 inch open ended wrench to disconnect the Cooling out line from the pump c Disconnect the compressed air hose from the Cooling in connection d Do step 8 through step 12 again 16 Install the original caps and the plugs for the utility connections Air cooled ...

Page 96: ...and in accordance with local regulations If the product contains substances that could cause damage to the environment remove and dispose of them in accordance with current local regulations This includes liquids such as hydraulic fluid Make sure that dangerous substances are disposed of safely and that the correct personal protective equipment is used The safety specifications must be in accordan...

Page 97: ...sts 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 To order parts contact the original equipment manufacturer OEM ...

Page 98: ...2 1 17490 Breaker bar 40 inch 1 3 1 18038 White lithium grease 44 3 ml 1 5 fluid oz 1 4 1 13537 PURE Goop halocarbon based antiseize lubricant 28 g 1 oz 1 5 1 11111 Blue Goop oil based antiseize lubricant 57 g 2 oz 1 6 1 11136 High vacuum grease 150 g 5 3 oz 1 7 1 13972 Water filter wrench 1 8 1 18851 Square drive adapter 3 4 inch female to 1 2 inch male 1 9 1 18852 Hex bit socket 1 2 inch square ...

Page 99: ... Manual 810770 99 Parts lists Intensifier repair tools These tools are shipped with the pump Part number Description Quantity 1 1 18416 Seal installation tool 1 2 1 18803 Seal removal tool 1 3 1 18848 Cylinder locator tool 1 3 1 2 ...

Page 100: ...pressure poppet Echion 1 1 18849 Repair kit low pressure poppet Echion 1 1 17434 Repair kit bleed down valve 1 1 18772 Replacement kit hydraulic fluid 1 1 11106 Filter cartridge water 1 0 micron 10 inch 1 Description Quantity 1 Spring energized seal 7 8 inch 2 2 O ring backup seal housing 122 2 3 O ring seal housing 122 2 4 Seal cartridge high pressure 2 5 Poppet screw low pressure 2 2 3 4 1 5 1 H...

Page 101: ...chion low pressure poppet repair kit Description Quantity 1 Cotton tipped applicator 2 2 Poppet high pressure 2 3 Poppet spring high pressure 2 4 Poppet seat high pressure 2 Description Quantity 1 Wear ring check valve 2 2 O ring check valve 120 2 3 Poppet screw low pressure 2 4 Poppet low pressure 2 2 3 4 1 3 4 2 1 ...

Page 102: ...cription Quantity 1 High vacuum grease 150 g 5 3 oz 1 2 Poppet seat high pressure 1 3 Valve seal high pressure 1 4 Needle bleed down valve 1 5 Needle guide bleed down valve 1 6 O ring 011 1 7 Flow reducer insert bleed down valve 1 8 Wooden dowel 1 Description Quantity 1 Filter element hydraulic 5 micron 1 2 Filler cap 1 6 7 2 1 3 8 4 5 2 1 ...

Page 103: ...kits Part number Description 1 18603 Boost pump kit 100 gallons per hour 208 V 230 V 1 18576 Boost pump kit 100 gallons per hour 400 V 460 V 1 18551 Modbus TCP IP communication kit 1 18552 Utility connection panel kit 1 18553 Metric conversion kit 1 18695 Pump mounted plumbing kit ...

Page 104: ...llow are used in the illustrations to show where one component ends and another begins The colors are used for contrast and do not mean anything specific Description Quantity Snap in handle 2 Latch receptacle 2 Latch stud 2 Latch retainer 2 Latch spring 2 Part number Description 1 11111 Blue Goop oil based antiseize lubricant 57 g 2 oz 1 13537 PURE Goop halocarbon based antiseize lubricant 28 g 1 ...

Page 105: ...Echion Operator Manual 810770 105 Parts lists Electrical system Part number Description 1 1 15005 PLC Horner XL4 requires program 1 18855 2 1 18755 Proximity switch 1 17355 Memory card SDHC MicroSD 32GB not shown 2 1 ...

Page 106: ... 13157 60 6 Collar high pressure 3 8 inch not shown 10 1 13160 60 4F6F Reducing coupling high pressure 3 8 inch female 1 4 inch female 11 1 13158 60 4 Gland nut high pressure 1 4 inch 12 1 13157 60 4 Collar high pressure 1 4 inch not shown 13 1 WJN6600725 Tube nipple bleed down valve to tee 14 1 13949 Air solenoid bleed down valve 15 1 18310 Bleed down valve assembly air actuated 16 1 18311 Bleed ...

Page 107: ... 2 1 18631 Check valve assembly 3 1 18395 Spacer tube 4 1 18386 Cylinder high pressure 5 1 18384 Seal housing assembly 6 1 11468 Spacer rod seal 7 1 12370 Snap ring rod seal 8 1 18935 Stud assembly 2 4 6 8 3 7 1 5 1 Low pressure poppet screw 4 Low pressure poppet 2 Low pressure poppet retainer 5 Check valve body 3 Check valve guide ring 6 Check valve O ring 120 1 2 3 4 5 6 ...

Page 108: ...intensifier inlet water tube 1 3 1 11679 237 O ring low pressure filter canister not shown 1 4 1 18318 Canister assembly water filter 1 5 1 18417 Switch low pressure water 1 6 1 18577 Dirty water container 1 7 1 18783 Replacement kit fluid management tube 2 8 1 12614 Solenoid valve inlet water 1 9 1 18931 Boost pump wet end assembly 1 1 13897 Meter TDS not shown 1 1 4 8 6 2 5 7 9 3 ...

Page 109: ...t number Description 1 1 11733 Assembly shift valve 24 VDC 2 1 17348 Transducer hydraulic 3 1 17347 Valve and coil proportional cartridge 4 1 17349 Relief valve hydraulic high pressure preset 5 1 12617 Switch temperature and fluid level 6 1 18898 Gauge hydraulic filter 5 6 2 1 3 4 ...

Page 110: ...Parts lists 4 110 810770 Operator Manual Echion Parts lists ...

Page 111: ...miliar with the Safety Operation Preventive maintenance and Specifications sections of this manual Images in this manual are for reference purposes It is possible that your product configuration is not shown accurately It is possible that not all of the information in this section applies to all pump models ...

Page 112: ...id can spill during maintenance or repair procedures Obey local protocols for recycling or disposal of parts materials and fluids National and local environmental rules can apply to disposal Refer to Recycling and end of product life on page 96 Coordinate maintenance and repairs with facility and safety staff If the problem is not found in this section contact a Hypertherm Technical Service Associ...

Page 113: ... if you are facing the front of the pump The height of the bars in relation to each other show if the piston is stroking evenly from side to side or if one side is stroking faster than the other overstroking This information is useful during troubleshooting Uneven bars can mean that poppet maintenance required If a bar is red then an overstroke has caused an alarm condition on that side 3 2 1 1 In...

Page 114: ...en To acknowledge an alarm touch the screen The Alarm Log screen opens Touch Ack acknowledge or Ack All acknowledge all on the screen The alarm screen closes Types of alarms The intensifier is The primary motor is Cause of alarm Warning Enabled On The controller senses a condition that can cause a problem or a failure Fault 1 Off Off The controller senses a condition that will cause a problem or a...

Page 115: ...ff Warning Start Procedure Hydraulics An error occurred during stage 3 of the start sequence The cutting head is on The bleed down valve is leaking The bleed down valve is not receiving air The Hydraulics timer setting is too short Make sure that the cutting head is off Repair or replace the bleed down valve Make sure that the compressed air supply is on Adjust the timer on the Start procedure Tim...

Page 116: ... Fluid 45C Sensor The temperature sensor in the hydraulic fluid tank has failed Replace the sensor Fault 2 Hydraulic Fluid Level is Low The float switch in the hydraulic fluid tank monitors the fluid level A hydraulic fitting or a hydraulic hose is leaking Fix the leak Refer to Hydraulic fluid on page 123 The sensor is faulty If the tank is full replace the sensor A poppet high pressure or low pre...

Page 117: ...FF The pump is not energized 2 Turn the primary breaker disconnect lever on the electrical enclosure door to ON The pump is energized It can take several minutes for the system to reboot A fuse in the electrical enclosure has blown Replace the blown fuse Problem Cause Solution The motor is too hot The motor is not cooling sufficiently Clean the air inlet Clean the outlet and the cooling ﬁns Reduce...

Page 118: ...umbers pointing to items in the illustration correspond with numbers in the table CAUTION If a high pressure poppet part is damaged replace the assembly high pressure poppet spring and seat Fluid leaking from a weep hole is a sign of a defective part or a loose connection 7 2 6 1 4 3 5 8 ...

Page 119: ...he output adapter is loose Make sure that the adapter is tightened to the correct torque value Refer to High pressure water fittings on page 144 The high pressure seat has failed 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 component The face of the check valve is cracked Replac...

Page 120: ...ts 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 component 6 Hydraulic fluid is leaking The O ring on the proximity switch has failed Replace the O ring or the sensor 7 Water leaks at a rate of more than 30 ml minute The high pressure seal has failed Replace the seal Hydraulic fluid leaks at a rate of...

Page 121: ...racked Inspect the check valve O ring No Is the output temperature hot Yes Inspect the high pressure poppet No Inspect the low pressure poppet Examine the low pressure poppet and the check valve body Make sure that the mating surfaces are clean and smooth with a mirrorlike finish Repair or replace the low pressure poppet Repair or replace the poppet retainer Make sure that the low pressure poppet ...

Page 122: ...the demand for high pressure water from the intensifier Replace the orifice The orifice is the wrong size Yes The bleed down valve has failed Repair or replace the bleed down valve The bleed down valve is not getting air Make sure that the compressed air source is on Make sure that the compressed air hose is not damaged Make sure that the compressed air hose is connected correctly No The postfilte...

Page 123: ...Do preventive maintenance according to the recommended schedule Refer to Preventive maintenance schedule on page 60 Examine the high pressure cylinder the plunger and the high pressure water seal Look for flaws deterioration erosion marks corrosion or cracks Make sure that the mating surfaces are smooth and clean If damage is found replace the component The supply water flow or pressure is too low...

Page 124: ...perature of hydraulic fluid The hydraulic pump has failed Contact a Hypertherm Technical Service Associate A relief valve has failed Contact a Hypertherm Technical Service Associate There is a problem in the hydraulic center section of the intensifier Contact a Hypertherm Technical Service Associate The cooling water supply or the chiller is turned off Turn ON the water supply or the chiller Water...

Page 125: ... off the fan motor Reset the relay Refer to Warning Boost Motor on page 115 The sensor is not sensing the correct temperature Plug in the sensor Replace the cord The temperature sensor is faulty or damaged Replace the sensor Pressure The hydraulic fluid pressure is too low The cut pressure is not set correctly Make sure that the cut pressure is set correctly The pump is in pierce pressure mode Mak...

Page 126: ...draulic hose is leaking Fix the leak Tighten the fitting to the correct torque value Replace the hose Replace the O ring Hydraulic fluid was lost during maintenance Add hydraulic fluid Refer to Add hydraulic fluid on page 85 Hydraulic fluid leaks from the intensifier An O ring or an energized seal spring has failed Disassemble the intensifier Disassemble the parts and look for flaws deterioration ...

Page 127: ...o the hydraulic pump Water has leaked into the heat exchanger Water cooled system The heat exchanger has failed 1 Replace the hydraulic fluid Refer to Replace the hydraulic fluid on page 86 It could be necessary to drain and flush other areas such as the shift valve the hydraulic manifold and the hydraulic pump 2 Examine the parts including the inner surfaces of the hydraulic fluid tank the hydrau...

Page 128: ...is higher than 7 6 bar 760 kPa 110 psi the water pressure is too high The boost pump is not needed The low pressure water parts are rated for a maximum pressure of 8 6 bar 860 kPa 125 psi In environments with high supply water pressure the boost pump can increase the water pressure to higher than the maximum This can cause damage to the water filter and other parts If the value on the prefilter wa...

Page 129: ...ooth and clean with a mirrorlike finish If damage is found replace the component The pump is in pierce pressure mode or is set incorrectly Put the pump in cut pressure mode Make sure that the cut pressure is set correctly The supply water is not turned on Turn on the supply water A water filter is clogged Replace the water filter The boost pump has failed Examine the water filter If the filter is ...

Page 130: ...led Replace the high pressure seal If a high pressure cylinder feels hot 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 component If the high pressure seal is removed from the plunger when you disassemble the intensifier replace the seal The orifice is not the correct size or too ...

Page 131: ...re seal is removed from the plunger when you disassemble the intensifier replace the seal A fitting is leaking A low pressure water line is not seated fully in the fitting Make sure that the low pressure water line is pushed all the way into the fitting Make sure that the O ring is not damaged or missing Replace if necessary The collar on a high pressure water fitting is not correctly installed Re...

Page 132: ...ightened Loosen all of the end cap nuts and then torque them to 373 N m 275 lbf ft in 68 N m 50 lbf ft increments Use a repeating cross pattern Water leaks onto the floor or into the pump frame The dirty water container is full Empty the container The dirty water container is misaligned Move the container ...

Page 133: ...hydraulic system 1 Use a 10 mm socket or an open ended wrench to tighten the hose clamp on the suction hose that goes from the hydraulic fluid tank to the hydraulic pump 2 Torque the hose clamp to a maximum of 16 N m 12 lbf ft If the pump continues to make noise after the hose clamp is tightened contact a Hypertherm Technical Service Associate for information and support ...

Page 134: ...ght proximity switch l8 Not used l9 Not used l10 Not used l11 Not used l12 Not used l13 Not used l14 Not used l15 Controls on I16 Remote mode on l17 Remote pump on l18 Remote pump off l19 Not used l20 Remote pierce pressure on l21 Primary motor fault l22 Primary motor on l23 Boost pump on I24 Heat exchanger fan on Q1 Low pressure on Q2 Proportional control output Q3 Not used Q4 Pump on Q5 Fan moto...

Page 135: ...s are presented in metric units followed by International System of Units SI units and US Customary units in parentheses 1 bar 100 kPa 15 psi 10 mm 3 8 inch 115 N m 85 lbf ft This equipment is manufactured in the US so a metric equivalent is not always available because of inexact conversion ...

Page 136: ...3 000 hours Refer to Replace the hydraulic fluid on page 86 Glycol can be added to the cooling circuit to prevent freezing but glycol is less efficient for cooling than water Hypertherm recommends using a solution of not more than 25 glycol in chillers for this system Ambient air temperature 4 C to 35 C 40 F to 95 F Relative humidity Noncondensing 95 Storage temperature Water not drained 2 C to 55...

Page 137: ...al enclosure Supply water Softened water is necessary for most systems Get advice from a specialist for recommendations for choosing a water treatment system Reverse osmosis systems are available from Hypertherm If the cooling water or the supply water temperature is higher than 24 C 75 F cool the water before use Water that is too warm can shorten high pressure seal life Cooling Compressed air Do...

Page 138: ...z 60 Hz Voltage 400 V 208 V to 230 V 460 V Full load current 23 A 45 A to 41 A 21 A Primary circuit breaker rating 30 A 60 A 30 A Minimum Maximum Cutting water in Flow 3 8 L minute 1 0 gallon minute Pressure 2 8 bar 280 kPa 40 psi 7 6 bar 760 kPa 110 psi Cutting water out Flow 1 1 L minute 0 3 gallon minute Pressure 345 bar 34 500 kPa 5 000 psi 4 140 bar 414 000 kPa 60 000 psi Cut pressure factory...

Page 139: ... 60 Hz Voltage 400 V 208 V to 230 V 460 V Full load current 44 A 82 A to 76 A 38 A Primary circuit breaker rating 60 A 100 A 60 A Minimum Maximum Cutting water in Flow 4 5 L minute 1 2 gallons minute Pressure 2 8 bar 280 kPa 40 psi 7 6 bar 760 kPa 110 psi Cutting water out Flow 2 3 L minute 0 6 gallon minute Pressure 345 bar 34 500 kPa 5 000 psi 4 140 bar 414 000 kPa 60 000 psi Cut pressure factor...

Page 140: ...Hz 60 Hz Voltage 400 V 208 V to 230 V 460 V Full load current 74 A 136 A to 124 A 62 A Primary circuit breaker rating 100 A 200 A 100 A Minimum Maximum Cutting water in Flow 7 6 L minute 2 gallon minute Pressure 2 8 bar 280 kPa 40 psi 7 6 bar 760 kPa 110 psi Cutting water out Flow 3 8 L minute 1 gallon minute Pressure 345 bar 34 500 kPa 5 000 psi 4 140 bar 414 000 kPa 60 000 psi Cut pressure facto...

Page 141: ...ated using the motor wattage and the size of the hydraulic pump Number of orifices Echion 15 Echion 30 Echion50 1 0 007 0 011 0 014 2 0 005 0 007 0 010 3 0 004 0 006 0 008 4 0 005 0 007 5 0 004 0 006 6 0 005 Echion pump model Maximum strokes minute Echion 15 40 Default overstroke percentage 5 Echion 30 79 Maximum overstroke percentage 20 Echion 50 107 ...

Page 142: ... the values specified in these tables for load carrying fasteners Torque value Wrench size N m lbf ft High pressure end cap nut 373 275 1 1 2 inch socket Hydraulic end cap screw 88 65 3 8 inch hex Tighten each end cap nut in 68 N m 50 lbf ft increments Use a repeating cross pattern 1 16 inch dash size Code 61 grade 8 low pressure Code 62 grade 8 high pressure Bolt size inch N m lbf ft Bolt size in...

Page 143: ...t the lock washers on the bolts 6 Install the bolts 7 Tighten the bolts by hand 8 Use a torque wrench to tighten the bolts to the specified value Parts tools and materials Hydraulic fluid Antiseize bolt lubricant white lithium grease Open ended wrench refer to Wrench size in the table on page 142 Torque wrench Lubricate the O ring with hydraulic fluid before installing it To make a good seal the s...

Page 144: ...ant such as Blue Goop or PURE Goop on high pressure water fittings Use only enough torque to make a sufficient seal Torque values can vary depending on thread condition A sufficient seal can be made at values much lower than the maximum values shown in the table If a fitting leaks after tightening it to the maximum torque value disassemble the parts Repair or replace parts that show deterioration ...

Page 145: ...reads on the high pressure tubing are visible at the fitting Incorrectly installed collar The collar interferes with the seal surface Correctly installed collar The seal 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 specified value Parts tools and materials Open ended wrench refer to the...

Page 146: ...ifications 6 146 810770 Operator Manual Echion Specifications Low pressure water fittings All low pressure water connections use push to connect fittings Do not use lubricants on low pressure water fittings ...

Page 147: ... the Safety Operation Preventive maintenance Troubleshooting and Specifications sections of this manual Images in this manual are for reference purposes It is possible that your product configuration is not shown accurately It is possible that not all of the information in this section applies to all pump models ...

Page 148: ...ake sure 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 user qualification and training Refer to User qualification and training on page 23 WARNING Read and understand all of the safety guidelines in this manual Refer to Safety on page 21 before ope...

Page 149: ...water before use Water that is too warm can shorten high pressure seal life Hydraulic fluid Refer to Hydraulic fluid on page 136 for specifications WARNING Some locations can be dangerous if the atmosphere contains explosive gas vapors or dust Refer to requirements from the National Electric Code NEC the International Electrotechnical Commission IEC the Occupational Safety and Health Administratio...

Page 150: ... that show pH silica and hardness levels are frequently available for no charge from public utility water suppliers Refer to Utilities on page 137 for system specifications WARNING A line disconnect switch for incoming electrical power must be installed near the power supply This is a supply voltage disconnecting device or an energy isolating device CAUTION The primary feed circuit breaker or fuse...

Page 151: ...ded with the pump Dirty water container Intensifier repair tools refer to page 99 These items are shipped inside the electrical enclosure key for the Local Remote key switch MicroSD card adapter electrical drawings Optional items 1 18768 Standard tool kit refer to page 98 1 18769 Echion standard spare parts kit refer to page 100 Optional equipment kits refer to page 103 WARNING Lifting must be don...

Page 152: ...no more than 8 cm 1 4 inch between opposite ends CAUTION Hydraulic water and electrical connections can become loose during shipping and normal operation Examine all connections at installation and during regular maintenance To connect the pump directly to an external control device such as a CNC refer to the CNC manual and contact your OEM or a Hypertherm Technical Service Associate for informati...

Page 153: ...ings on page 144 for torque values and information about how to correctly install high pressure water fittings Parts tools and materials 1 18695 Pump mounted plumbing kit Two 1 16 inch open ended wrenches 5 8 inch open ended wrench 1 1 16 inch open ended wrench 13 16 inch open ended wrench 5 8 inch crowfoot wrench 13 16 inch crowfoot wrench Torque wrench High pressure antiseize lubricant such as B...

Page 154: ...ght side of the pump 2 Use two 7 16 inch open ended wrenches and hardware from the kit to install the tubing bracket on the pump frame 3 Use a 1 1 16 inch open ended wrench to hold the high pressure tee on the attenuator Use a 13 16 inch open ended wrench to install the long end of the L shaped tubing into the fitting ...

Page 155: ...que wrench to tighten the fitting to 68 N m 50 lbf ft 5 Use a 5 8 inch open ended wrench to install your 1 4 inch high pressure tubing from the cutting head into the top of the reducing adapter Use a torque wrench to tighten the fitting to 34 N m 25 lbf ft 6 Use two 7 16 inch open ended wrenches and hardware from the kit to attach the tubing to the tubing bracket with the clamps ...

Page 156: ...these hoses can cause cooling water to back up into the system which can cause damage to the bleed down valve and intensifier parts CAUTION To prevent dirty water from entering the bleed down valve install the Waste water out hose so that it is below the bleed down valve Refer to Fittings on page 144 for torque values and information about how to correctly install high pressure water fittings Part...

Page 157: ...w 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 end to the inlet water solenoid or to the boost pump if equipped All low pressure water connections use push to connect fittings 1 2 inch NPT female 1 2 inch NPT male Waste water out This hose carries water from the bleed down valve...

Page 158: ...t This line carries low pressure water from the heat exchanger to the chiller or to the drain Connect 1 end of this line to the to the chiller or to the drain Connect the other end to the heat exchanger outlet 1 2 inch NPT female 1 2 inch NPT male CAUTION This waterjet pump can leak up to 160 mA To reduce the effects of a high leakage current connect the pump to a dedicated supply transformer that...

Page 159: ...are done on the intensifier the high pressure water system or the low pressure water system CAUTION Make sure that hydraulic fluid is available during installation and for the first start CAUTION If a water line a fitting or a valve could be frozen do not operate the pump Thaw the equipment until water moves easily through the system Examine the parts for damage Replace parts if necessary CAUTION ...

Page 160: ...ary breaker disconnect lever on the electrical enclosure door to ON 5 Make sure that the EMERGENCY STOP is not engaged If the button is pushed in turn the button clockwise until it releases WARNING Make sure that all connections fasteners locking devices hoses and fittings are tight CAUTION A leak can cause damage to the water fittings Monitor for leaks during this procedure Identify the source of...

Page 161: ...disconnect switch Use standard lock out tag out procedures c Inside the electrical enclosure interchange 2 cables on the top of the primary circuit breaker d Turn ON the electrical main line disconnect switch e Turn the primary breaker disconnect lever on the electrical enclosure door to ON f Do step 3 through step 4 again Make sure that the primary motor turns in the direction shown by the rotati...

Page 162: ...kwise to increase the pressure Turn the knob counterclockwise to decrease the pressure c Push the knob in to lock it 2 Close all doors and replace all panels and covers including the top cover CAUTION A leak can cause damage to the water fittings Identify the source of a leak and correct the problem CAUTION Do not set the boost pump pressure higher than 7 6 bar 760 kPa 110 psi The components are r...

Page 163: ... ON and OFF in 1 second intervals for 15 minutes This loosens debris in the high pressure tubing 7 Turn OFF the pump 8 Install a ruby orifice in the cutting head For orifice sizes refer to Orifices on page 141 9 Turn ON the pump 10 On the operator interface touch the symbol to start the pump 11 Increase the pressure to 2 760 bar 40 000 psi Operate the program in a loop for 15 minutes 12 Increase t...

Page 164: ... to open the primary adjustments screen Pump Adjustments Not all screens are used when installing the pump Touch the current screen symbol to go back 1 screen Refer to Touchscreen maps on page 175 to see all of the screens available on the controller Pump Adjustments Intensifier Control Pressure SD Card Date Time Language Pump Information Remote Configuration Start Procedure Timers Stop Procedure ...

Page 165: ... pump Cooling Type This the type of heat exchanger the pump uses water or air Pressure Units Touch this field to open a numeric keypad Touch the up or down arrows to select the units bar or psi that show on the operator interface screens Software Part This is the Hypertherm part number and the revision version for the software installed on the controller Software Version This is the version of the...

Page 166: ...ult is 5 seconds Bleed Valve Stage 2 The intensifier strokes and has this much time to push air that is in the system out through the open bleed down valve The timer default is 5 seconds Hydraulics Stage 3 After the bleed down valve closes the system has this much time to get to the minimum hydraulic pressure The timer default is 5 seconds The hydraulic pressure setpoint default is 17 bar 250 psi ...

Page 167: ...34 bar 500 psi The smallest increment is 10 bar 100 psi Decrease This is how much that the target water pressure decreases each time you touch the symbol on the primary operation screen The default is 34 bar 500 psi Analog Pressure This turns the remote analog pressure input on or off Modbus Mode This turns Modbus mode on or off When this mode is on the pump is controlled by Modbus TCP over Ethern...

Page 168: ...es Idle Duration This timer determines how long the pump is idle before it turns off The default is 10 minutes Stop Boost Pump This timer determines how long the pump is idle before the boost pump turns off The default is 180 seconds Boost Fault Monitor The system can monitor a boost pump for fault conditions This turns monitoring on or off Fan Fault Monitor The system can monitor a heat exchanger...

Page 169: ...ange the date format Options are DD MM YY or MM DD YY Touch the field next to the symbol to open a numeric keypad Use the keypad to adjust the date Time symbol and field Touch this 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 adjust the time Language field Touch the field next to this s...

Page 170: ...oke rate is calculated using the motor wattage and the size of the hydraulic pump Refer to Stroke rate on page 141 The rate can be adjusted to compensate for variations in plumbing configurations and flow rates 1 Touch this field to open a numeric keypad 2 Use the keypad to enter the maximum overstroke percentage permitted before a fault occurs The default is 5 The maximum is 20 3 Touch Enter Tota...

Page 171: ...1 Installation SD Card The microSD card stores the current program the alarm log files and the maintenance log Touch the microSD card symbol to see the contents of the card If the microSD card is missing or damaged the screen shows SD Card Not Found ...

Page 172: ...Installation 7 172 810770 Operator Manual Echion Installation ...

Page 173: ...uct choose Waterjet Family in the dropdown list 3 Go to the Regulatory information section and click the 4 Click on the Declaration of Conformity for your product You might have to click on SHOW ALL at the bottom of the section A PDF of the document downloads to your device These navigation instructions can change without notice For information about this document refer to Certification test marks...

Page 174: ...Declaration of Conformity 8 174 810770 Operator Manual Echion Declaration of Conformity Hypertherm Waterjet 305 2nd St NW STE 115 New Brighton MN 55112 USA www hypertherm com ...

Page 175: ...Echion Operator Manual 810770 175 Touchscreen maps Touchscreen maps In this section These pages can help you navigate through all of the screens that are on the operator interface ...

Page 176: ...Touchscreen maps 9 176 810770 Operator Manual Echion Touchscreen maps ...

Page 177: ...ut these screens Pierce pressure mode Cut pressure mode The intensifier is disabled Refer to Intensifier Control on page 170 Modbus mode is enabled Refer to Remote Configuration on page 167 Push the Controls button on the operator panel to turn on the pump Refer to Alarms on page 114 Touch the Start symbol to turn on the pump Go to page 179 ...

Page 178: ...Touchscreen maps 9 178 810770 Operator Manual Echion ...

Page 179: ...fter the system gets to the target water pressure the Inlet Water timer starts The timer default is 5 seconds The intensifier begins stroking The Bleed Valve timer starts The timer default is 5 seconds The bleed down valve closes Pressure in the system increases to the hydraulic pressure setpoint The Hydraulics timer starts The timer default is 5 seconds Water pressure in the system increases to t...

Page 180: ...Touchscreen maps 9 180 810770 Operator Manual Echion ...

Page 181: ...terface Adjustment screens on page 164 for more information about these screens Refer to Intensifier Control on page 170 Refer to Pressure on page 169 Primary Adjustments screen Refer to SD Card on page 171 SD Card Not Found Refer to Date Time Language on page 169 SD Card Files Go to page 183 ...

Page 182: ...Touchscreen maps 9 182 810770 Operator Manual Echion ...

Page 183: ...Pump Information on page 165 Refer to Remote Configuration on page 167 Refer to Start Procedure Timers on page 166 Pump Adjustments screen Refer to Stop Procedure Timers on page 168 Refer to Pressure Adjustments on page 167 Refer to Pump Fault Behavior on page 168 ...

Page 184: ...Touchscreen maps 9 184 810770 Operator Manual Echion ...

Page 185: ...e information about these screens Refer to Move the plunger on page 56 Refer to Inputs and outputs on page 58 Postmaintenance Start Procedure Refer to Start the pump after maintenance on page 90 Primary Maintenance screen Alarm Log Refer to Leaks on page 118 Refer to Prepare for storage on page 93 Go to page 187 ...

Page 186: ...Touchscreen maps 9 186 810770 Operator Manual Echion ...

Page 187: ... pressure The supply water pressure increases until the it gets to the target water pressure The minimum setpoint is 2 76 bar 40 psi The intensifier begins stroking The bleed down valve is open The bleed down valve closes Water pressure in the system increases to 690 bar 10 000 psi 1 Move the cutting head to a safe location on the table 2 Turn ON the cutting head 3 Touch the symbol to continue The...

Page 188: ...Touchscreen maps 9 188 810770 Operator Manual Echion ...

Page 189: ...tor Manual 810770 189 Technical drawings Technical drawings In this section 1 18947 Hydraulic and water system drawing The electrical drawings are shipped in an envelope that is found inside the electrical cabinet ...

Page 190: ...Technical drawings 10 190 810770 Operator Manual Echion Technical drawings ...

Page 191: ...Technical drawings 10 Echion Operator Manual 810770 191 SCHEM ECHION HYD WTR ...

Page 192: ...Technical drawings 10 192 810770 Operator Manual Echion ...

Page 193: ... appreciate hearing from you and receiving your feedback We review your comments and ideas regularly and use them when planning changes We promise to consider every suggestion Your satisfaction is our highest priority Recommend changes for the next update to this manual Send this information with your comments to Technical Service hypertherm com Echion Operator Manual 810770 Revision 3 Include pag...

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