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Hypertherm EcoSift, Operator'S Manual

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Hypertherm EcoSift Operator'S Manual Download Page 99

Preventi

ve maintenance

Preventive maintenance

EcoSift

Operator Manual

809500

99

8.

Use a 1/2-inch wrench or socket to remove both liquid chambers from the center section.

9.

Use two 3/4-inch wrenches or sockets to remove the diaphragm assembly from the center section.

10.

Remove 1 outer piston and diaphragm from the center section.

2

1

1

Center section

2

Liquid chamber

1

2

1

2

1

Outer piston

2

Diaphragm

Summary of Contents for EcoSift

Page 1: ...EcoSift Waterjet abrasive recycling system Operator Manual 809500 Revision 0 English ...

Page 2: ...other trademarks are the property of their respective holders One of Hypertherm s long standing core values is a focus on minimizing our impact on the environment Doing so is critical to our and our customers success We are always striving to become better environmental stewards it is a process we care deeply about 2017 Hypertherm Inc ...

Page 3: ...EcoSift Operator Manual 809500 Revision 0 English Original instructions November 2017 Hypertherm Inc Hanover NH 03755 USA www hypertherm com ...

Page 4: ...apan 81 6 6225 1183 Tel 81 6 6225 1184 Fax HTJapan info hypertherm com Main Office Email TechSupportAPAC hypertherm com Technical Service Email Hypertherm Europe B V Vaartveld 9 4704 SE Roosendaal Nederland 31 165 596907 Tel 31 165 596901 Fax 31 165 596908 Tel Marketing 31 0 165 596900 Tel Technical Service 00 800 4973 7843 Tel Technical Service technicalservice emea hypertherm com Technical Servi...

Page 5: ... equipment SC 20 Symbols and marks SC 21 1 Terminology 27 2 Product description 33 Overview 34 EcoSift hopper 36 Waste hopper 36 Waste abrasive collection bag optional 37 EcoSift unit 37 Operation panel 38 Diaphragm pumps 39 3 Options 41 Voltage 41 Waste hopper 41 4 Operation 43 Safety 43 Operation panel 44 Turn ON the EcoSift 47 Examine the machine before operation 47 Prepare the EcoSift 48 Start...

Page 6: ...ling time 69 Examine the EcoSift unit 70 Examine the EcoSift hopper 70 Replace the recycled abrasive collection bag 71 Replace the hopper wear plate 73 Examine the waste hopper 76 Replace the waste abrasive collection bag 76 Clean the waste hopper 81 Examine the sprayer head 83 Examine the primary screen 84 Replace the primary screen 84 Replace the ball carrier screen 88 Examine the secondary scre...

Page 7: ...127 A diaphragm pump does not operate 127 A diaphragm pump operates slowly 128 The water flow is slow 130 Abrasive returns to the cutting table tank 131 8 Specifications 133 EcoSift unit 133 Safety 133 Electric power 133 Environmental ratings 134 Diaphragm pumps 134 Hoppers 135 EcoSift hopper 135 Waste hopper 135 9 Installation 137 Safety 137 Buyer obligations 138 Planning 138 Location 139 Require...

Page 8: ...EcoSift hopper 156 Install the waste hopper 157 Connect the hoses 161 Connect the electric power 162 Install the abrasive collection components 166 Do the first startup 168 Examine the EcoSift before operation 168 Prepare the EcoSift 169 Start the EcoSift 170 10 Technical drawings 173 ...

Page 9: ...ties and are not covered by this warranty Product Warranty coverage up to HyPrecision pump 27 months from the ship date or 24 months from the date of proven installation or 4 000 hours of operation whichever occurs first PowerDredge abrasive removal system 15 months from the ship date or 12 months from the date of proven installation whichever occurs first EcoSift abrasive recycling system 15 mont...

Page 10: ...sclaimer Product information contained in this manual is believed to be reliable as of the date of publication The content in this manual may contain technical inaccuracies or typographical errors This manual can be changed or updated without notice ...

Page 11: ...sting laboratory After the product has left the Hypertherm factory the certification test marks are invalid if any of these events occurs The product is modified in a manner that creates a hazard or nonconformance with the applicable standards Safety critical parts are replaced with unapproved spare parts Assembly is unauthorized An accessory that uses or generates a hazardous voltage is added A s...

Page 12: ...SC 12 Safety and compliance Product stewardship Product stewardship Declaration of conformity ...

Page 13: ... drives motion controllers or robots to a Hypertherm waterjet cutting system the combined system is considered a higher level system A higher level system with hazardous moving parts can constitute industrial machinery or robotic equipment in which case the OEM system integrator or end use customer can be subject to more regulations and standards than those applicable to the waterjet cutting syste...

Page 14: ...SC 14 Safety and compliance Product stewardship Product stewardship ...

Page 15: ...as presented new hazardous chemical labeling requirements 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 locatio...

Page 16: ...SC 16 Safety and compliance Environmental stewardship Environmental stewardship ...

Page 17: ...ages available for each manual 1 Go to www hypertherm com docs 2 Select Waterjet Family in the Product Product type dropdown list 3 Select Manuals Service Information in the Category dropdown list The navigation instructions can change without notice Residual risks Many safety enhancements have been included in this system Despite all precautions some residual risks can exist Some sections of this...

Page 18: ...orrect methods for isolating and controlling energy Foreseeable misuse Do not use this system in a manner not specified by Hypertherm or for a purpose for which it is not intended Such use may impair the protections provided by the system DANGER Personnel who maintain and repair this machinery can be seriously injured or killed if hazardous energy is not controlled Injuries can include burns cuts ...

Page 19: ...y warnings cautions or instructional materials Work area Safe operation of this system includes keeping the area around the machinery clean dry and organized Keep work areas clear of tripping hazards and loose items WARNING Lifting must be done by a trained operator Obey all work site safety requirements the safety instructions for the lifting equipment and the safety information in this manual Mi...

Page 20: ...g or working near this machinery Protect eyes from particles cut material water and abrasive Wear approved ear protection and control exposure time when operating or working near this machinery Wear approved hand protection when operating or working near this machinery Wear work gloves to protect hands from lacerations cuts and abrasions Wear approved nonslip safety footwear when operating or work...

Page 21: ...ssure injection injury is a surgical emergency Get immediate medical treatment for all high pressure waterjet injuries Delayed treatment can cause serious injuries or death WARNING Sharp edges and shear points can cause serious injury Keep hands away WARNING Rotation To repair or maintain the motor disconnect the power source from the motor and any accessory devices and let the motor to come to a ...

Page 22: ...he floor Refer to the manual Read and understand all of the safety guidelines in this manual Wear approved eye protection when operating or working near this machinery Protect eyes from particles cut material water and abrasive Wear approved ear protection and control exposure time when operating or working near this machinery Wear approved hand protection when operating or working near this machi...

Page 23: ... conductor for protection against electrical shock in the case of a fault AIR FLOW The arrow indicates the direction of airflow SHIPPING BRACKETS REMOVE BEFORE OPERATION REPLACE BEFORE SHIPPING This symbol identifies tools or materials that are required or recommended for a procedure This symbol identifies a note or helpful information ...

Page 24: ...flow rate liters minute MPa Maximum outlet water pressure megapascals Kg Weight of the system kilograms DWG System technical drawing schematic number The Conformité Européene CE mark affixed to a product signifies the manufacturer s declaration 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...

Page 25: ...is manual Crush hazard Stay clear of the hopper while transporting or dumping WARNING This symbol identifies a potentially hazardous situation which if not prevented can cause serious injuries or death The forks on the forklift must be at the same width as the bag Do not lift the bag from the side with only 2 loops Do not lift more than 1 bag at a time Do not put the bag on the forks so that you c...

Page 26: ... the bag Avoid sharp edges HANDLING RECOMMENDATIONS HANDLING RECOMMENDATIONS Use extensions with a crane to lift the bag The forks on the forklift must be at the same width as the bag Lift vertically with all 4 loops Put the bag on the forks so that you can see when you operate the forklift Use all 4 loops and extensions to lift the bag from the side Avoid ultraviolet UV light exposure or inclemen...

Page 27: ...uter numerical control CNC controls the motion of a machine tool dB A A weighted decibels dB A is an expression of the relative loudness of sounds in air as perceived by the human ear energy isolating device A mechanical device that physically prevents the transmission or release of energy to include a manually operated electric circuit breaker a disconnect switch a manually operated switch by whi...

Page 28: ...s used to hold liquids hose A flexible hollow cylinder Dimensions are based on the inside diameter ID ID Inner diameter the diameter of the inside of a hose a tube or a pipe impact wrench An air electric or hydraulic powered tool that delivers high torque to turn a socket also called an impact gun air wrench air gun or rattle gun ISO The International Organization for Standardization ISO an indepe...

Page 29: ...inute a European measurement of the flow rate of a gas at a certain volume and temperature refer to SLPM N m2 Newtons per square meter N m2 is a unit of pressure 1 N m2 equals 0 00001 bar or 0 001 kPa or 0 00015 psi Nm3 Normal cubic meter the flow rate of a gas at a certain volume and temperature noncondensing humidity Water can cause damage to instruments and electronic components Equipment opera...

Page 30: ...ronmental ratings on page 134 RTV Room temperature vulcanization silicone rubber is mixed with a curing agent to form a compound that is temperature and thermal resistant SAE SAE Society of Automotive Engineers International a professional association that coordinates the development of technical standards based on best practices in the aerospace commercial vehicle and automotive engineering SAE C...

Page 31: ...Terminology Terminology EcoSift Operator Manual 809500 31 VAC Volts of alternating current valve A device used to control the rate of flow in a pipe or a tube VDC Volts of direct current ...

Page 32: ...Terminology Terminology 32 EcoSift Operator Manual 809500 ...

Page 33: ...sed for rinsing the abrasive and the abrasive particles that are too small or too large to use for cutting go into waste containers WARNING Do not use the EcoSift to recycle abrasive that has been used to cut plastics wood hazardous material or heat sensitive material with a melting point or flammability of less than 176 7 C 350 F The EcoSift can only recycle garnet and aluminum oxide abrasive The...

Page 34: ...3 Water from the top of the cutting table 4 Feed pump 5 Agitation pump 6 EcoSift hopper 7 Waste water to the cutting table 8 Abrasive pump 9 Distribution head 10 Primary screen 11 Dryer box 12 Secondary screen 13 Recycled abrasive collection bag 14 Waste container 15 Hot air and abrasive particles 16 Waste water and abrasive particles 17 Dust collector 18 Waste hopper Abrasive Water Waste water Ho...

Page 35: ... recycle to the top of the dryer box 11 The dryer box contains heating elements and a blower to remove moisture from the abrasive The clean abrasive moves from the dryer box to the secondary screen 12 which vibrates to isolate the good abrasive from debris and abrasive particles that are too large to be reused The debris and large particles fall into a waste container 14 Clean dry abrasive passes ...

Page 36: ...ottom of the hopper A dispersion tube is only used on the EcoSift hopper if the EcoSift is installed with an existing PowerDredge system Waste hopper Refer to item 18 on page 34 Water and abrasive flow from the EcoSift to a waste tube that empties into the waste hopper Water returns to the cutting table through the overflow tube The waste hopper tilts easily for cleaning 1 2 3 1 Overflow tube 2 Di...

Page 37: ...ack of the unit are removable When a side panel is removed the primary screen and the dryer box are visible The secondary screen and the waste container are visible without removing a panel The diaphragm pumps are located on the back of the unit WARNING Work that requires opening the electrical enclosure or removing covers or panels from the EcoSift unit must be done only by an approved technician...

Page 38: ...peration panel Controls for the EcoSift are on the outside of the electrical enclosure Refer to Operation on page 43 for detailed descriptions of the controls 1 2 3 5 4 1 Scale display 2 Operator interface 3 Electrical disconnect knob 4 Dryer box ammeter 5 Emergency stop knob ...

Page 39: ...tom of the EcoSift hopper and moves it to the top of the EcoSift unit The mixture goes through the distribution head and onto the primary screen Feed pump The feed pump controls the mixing of water and abrasive in the EcoSift hopper The pump pulls water from the top of the cutting table into the bottom of the hopper Agitation pump The agitation pump pulls water from the top of the cutting table in...

Page 40: ...Product description Product description 40 EcoSift Operator Manual 809500 ...

Page 41: ...Dredge abrasive removal system is not in use order a waste hopper and an overflow assembly Refer to page 114 Waste hopper overflow The standard waste hopper overflow configuration uses a rigid PVC tube to move water from the waste hopper to the cutting table This option is recommended when the hopper is installed 3 meters 10 feet or less from the cutting table tank The flexible overflow option is ...

Page 42: ...Options Options 42 EcoSift Operator Manual 809500 ...

Page 43: ...ds of hazardous chemical products Testing or monitoring can be necessary to meet national or local air quality regulations Wear approved personal protective equipment such as goggles gloves and respirators when operating or working near this machinery Refer to Personal protective equipment on page SC 20 Exposure to abrasive dust can irritate the upper respiratory system Eyes Abrasive can cause eye...

Page 44: ...w the system status and let the operator start and stop the unit It also shows failure information lets the operator to test various components notifies the operator that the recycled abrasive collection bag is full and monitors the time a consumable part has been in use For details about all of the screens refer to the Operator interface screens on page 52 Fault indicator beacon The beacon comes ...

Page 45: ... Isolate all sources of electric mechanical hydraulic pneumatic chemical thermal and other energy with a lockable energy isolating device that meets local and national requirements Refer to Safety on page 66 DANGER Personnel who work on deenergized machinery can be seriously injured or killed if the machinery is reenergized without permission All personnel must respect lock out devices Only the pe...

Page 46: ...al enclosure or to reset the primary breaker O OFF This disconnects electric power to the EcoSift unit The electrical panel is energized TRIP This indicates that the breaker is open I ON This connects electric power to the EcoSift unit PUSH Push this to open the electrical enclosure door The knob must be in the O OFF position RELEASE The RELEASE screw is not used Do not use the emergency stop knob...

Page 47: ...machinery Refer to Training on page 67 for more information WARNING Do not operate this machinery without the access covers and all other safety devices installed Do not remove guards while the unit is operating WARNING Wear approved personal protective equipment such as goggles gloves and respirators when operating or working near this machinery Refer to Personal protective equipment on page SC 2...

Page 48: ... 3 Make sure that the feed pump the agitation pump and the abrasive pump valves are open The valves are on the EcoSift hopper near the hose connections 4 Make sure that the air agitation valve on the EcoSift hopper is open It is not necessary to open the valve completely Too much air causes the water to churn which prevents the abrasive from collecting in the bottom of the hopper 3 5 1 6 4 2 1 Eco...

Page 49: ...d the feed pump start operating the status changes from READY to RUNNING a mixture of water and abrasive falls onto the primary screen 4 Make sure that the abrasive pump pressure is set to 1 9 bar 27 psi 5 Make sure that there is sufficient abrasive on the primary screen If there is too much abrasive on the primary screen lower the abrasive pump pressure until the quantity of abrasive on the prima...

Page 50: ...er supply before opening the electrical enclosure or doing maintenance or repair procedures Isolate all sources of electric mechanical hydraulic pneumatic chemical thermal and other energy with a lockable energy isolating device that meets local and national requirements Refer to Safety on page 66 DANGER Personnel who work on deenergized machinery can be seriously injured or killed if the machiner...

Page 51: ... valves are on the EcoSift Hopper near the hose connections 6 Turn OFF the electric power supply 7 Use a lock out device according to the work site s policy to isolate and control energy Emergency stop The EcoSift does an uncontrolled shutdown when the emergency stop knob is pushed Refer to Uncontrolled shutdown on page 118 Turn OFF the pump valves when stopping the EcoSift for longer than 1 day A...

Page 52: ...unds per hour to the recycled abrasive collection bag 3 Information only This shows the temperature of the heating elements inside the dryer box The optimal temperature is between 137 8 C 280 F and 160 0 C 320 F 4 STATUS Information only This shows the status of the EcoSift Refer to STATUS on page 52 5 MENU opens the MENU screen Refer to MENU screen on page 53 6 GRAPH opens the GRAPH screen Refer ...

Page 53: ...CONSUMABLES This opens 1 of the CONSUMABLES screens Refer to CONSUMABLES screens on page 61 HEATING ELEMENTS This opens the HEATING ELEMENTS screen Refer to Component on off screens on page 57 PRIMARY SHAKER This opens the PRIMARY SHAKER screen Refer to Component on off screens on page 57 DRYER BLOWER This opens the DRYER BLOWER screen Refer to Component on off screens on page 57 FEED PUMP This op...

Page 54: ...f screens on page 57 FAULT LIGHT This opens the FAULT LIGHT screen Refer to Component on off screens on page 57 ALARM HORN This opens the ALARM HORN screen Refer to Component on off screens on page 57 OPTIONS This opens the OPTIONS screen Refer to OPTIONS screen on page 63 I O STATUS This opens the I O STATUS screen Refer to I O STATUS screen on page 56 TIMERS This opens the TIME screen Refer to T...

Page 55: ...e graph shows the rate of abrasive in kilograms or US pounds per hour that is delivered to the recycled abrasive collection bag Information only The green line on the graph shows the recycle rate averaged over 5 minutes Information only The red line on the graph shows the feed pump output number 4500 to 7500 divided by 100 This is used for troubleshooting or maintenance After turning ON the manual...

Page 56: ... which starts on page 119 I O STATUS screen The input and output information on this screen is typically useful to a certified technician Information only The specified controller input or output is on MAIN opens the home screen RUNNING PAGE Refer to Home screen RUNNING PAGE on page 52 MENU opens the MENU screen Refer to MENU screen on page 53 ...

Page 57: ...TPUT ON The indicator is green when the component is on MAIN opens the home screen RUNNING PAGE Refer to Home screen RUNNING PAGE on page 52 MENU opens the MENU screen Refer to MENU screen on page 53 HEATING ELEMENTS screen PRIMARY SHAKER screen DRYER BLOWER screen FEED PUMP screen DUST COLLECTOR BLOWER screen AGITATION PUMP screen Refer to page 59 for more information ABRASIVE PUMP screen ...

Page 58: ...r Manual 809500 RINSE WATER screen FAULT LIGHT screen ALARM HORN screen For testing This turns the water from the sprayer head ON or OFF For testing This turns the fault indicator beacon ON or OFF For testing This turns the alarm ON or OFF ...

Page 59: ...e of the feed output number The value range is 4500 to 7500 Temperature TEMPERATURE Information only This shows the temperature of the heating elements inside the dryer box OUTPUT ON Information only The indicator is green when the component is on Touch this to turn the component ON or OFF MAIN opens the home screen RUNNING PAGE Refer to Home screen RUNNING PAGE on page 52 MENU opens the MENU scre...

Page 60: ...L TIME CLOCK Information only This shows the time in 24 hour format 2 System Run Time SYSTEM RUN TIME Information only This shows how long in hours and minutes that the machine has been operating 3 MAIN opens the home screen RUNNING PAGE Refer to Home screen RUNNING PAGE on page 52 1 2 3 ...

Page 61: ... Primary Screen Life screen Hopper Wear Plate Life screen 1 Use these to toggle between the PRIMARY SCREEN LIFE screen and the HOPPER WEAR PLATE LIFE screen 2 Primary Screen Life Hours Minutes or Hopper Wear Plate Life Hours Minutes PRIMARY SCREEN LIFE or HOPPER WEAR PLATE LIFE Information only This shows the time in hours and minutes that the component has been in operation 5 3 1 4 2 5 3 1 4 2 ...

Page 62: ...PLACE THE COMPONENT TOUCH RESET AFTER REPLACING THE COMPONENT TOUCH RESET AFTER REPLACING THE COMPONENT 4 Screen Life h SCREEN LIFE and WEAR PLATE LIFE Information only A bar shows a visual representation of the component s operation time in hours h Enter the maximum time setpoint on the OPTIONS screen Refer to page 63 Wear Plate Life h 5 MAIN opens the home screen RUNNING PAGE Refer to Home scree...

Page 63: ...tpoint in hours The maximum setting for the primary screen is 600 hours The maximum setting for the wear plate is 2 000 hours 3 4 MAXIMUM WEIGHT Touch this to open a numeric keypad Enter the maximum weight for the recycled abrasive collection bag The maximum weight that the bag can hold is 454 kg 1 000 lb 5 MAIN opens the home screen RUNNING PAGE Refer to Home screen RUNNING PAGE on page 52 6 MENU...

Page 64: ... off Temp TEMP Information only This shows the temperature of the heating elements inside the dryer box Weight WEIGHT Information only This shows the weight of the recycled abrasive in the collection bag Information only The blue line on the graph shows the weight of the recycled abrasive in the collection bag Information only The green line on the graph shows the rate of abrasive in kilograms or ...

Page 65: ... not maintained regularly Maintenance includes but is not limited to adjustments cleaning lubrication repairs and replacement of parts Benefits of preventive maintenance Improves reliability Identifies potential problems before they cause unplanned downtime and become expensive repairs Extends the life of the system and decreases the frequency of replacement Contributes positively to reputation an...

Page 66: ...UTION Do not touch hot surfaces ABRASIVE DUST CAN CAUSE RESPIRATORY EYE AND SKIN IRRITATION Get medical treatment if necessary Abrasive cutting and recycling causes small particles of airborne dust Refer to the SDS for the abrasive used and material being cut in your facility for information about the hazards of hazardous chemical products Testing or monitoring can be necessary to meet national or...

Page 67: ...ep accurate maintenance records Good records can help with predicting and preventing maintenance problems Refer to Preventive maintenance records on page 111 Keep the work area clean and free of fluid spills Use buckets or other containers in areas where water can spill during maintenance or repair procedures Personnel who maintain and repair this machinery must know how to use standard hand tools...

Page 68: ...eekly Annually Examine the EcoSift unit page 70 Examine the diaphragm pumps page 94 Repair a diaphragm pump page 96 Examine the EcoSift hopper page 70 Replace the recycled abrasive collection bag page 71 Replace the hopper wear plate page 91 Examine the waste hopper page 76 Replace the waste abrasive collection bag page 71 Clean the waste hopper page 81 Put the balls on the screen page 88 Examine ...

Page 69: ...status is READY 2 Touch MENU to open the MENU screen 3 Touch DRYER BLOWER to highlight the selection Touch the enter symbol The DRYER BLOWER screen opens 4 Touch I to turn ON the dryer blower The OUTPUT ON indicator is green when the component is on Touch MAIN to open the home screen RUNNING PAGE CAUTION Do not touch hot surfaces CAUTION The heating elements can take up to 24 hours to cool Make su...

Page 70: ...ycled abrasive collection bag if necessary Refer to Replace the recycled abrasive collection bag on page 71 Examine the EcoSift hopper Do this task when the EcoSift is operating 1 Examine the hopper for leaks deterioration or damage 2 Examine the pipes the hoses the fittings and the connections for leaks deterioration or damage Identify the source of a leak and correct the problem 3 Make sure that...

Page 71: ...cale 5 Put a recycled abrasive collection bag on top of the pallet 6 Put the neck of the bag through the bag support 7 Fold the top of the bag over the support WARNING Lifting must be done by a trained operator Obey all work site safety requirements the safety instructions for the lifting equipment and the safety information in this manual Misuse of lifting equipment can cause the load to become u...

Page 72: ...nual 809500 8 Close the clamp to hold the bag on the support 9 Put a rubber strap through the bag loops on each corner 10 Make sure that the scale display shows 0 0 Touch ZERO to set the scale to 0 0 Touch UNITS to toggle between metric units and US customary units 1 2 ...

Page 73: ... energy with a lockable energy isolating device that meets local and national requirements Release all water pressure from the pumps before starting maintenance or repairs Bleed down and lock out compressed air sources Compressed air systems do not always depressurize when other power is disconnected Refer to page 66 for more information WARNING Compressed air is an energy source that can discharg...

Page 74: ...r 5 Empty the EcoSift hopper Use an assistant to help tip the hopper on its side Use a shovel to remove the abrasive 6 Lift the nozzle assembly to get access to the wear plate CAUTION A shovel can cause damage to the hose and other parts in the bottom of the hopper CAUTION Do not put the side of the hopper with the overflow drain on the ground This can cause damage to the hardware 3 1 2 4 1 Agitat...

Page 75: ...tant to help put the dispersion tube assembly on the hopper The elbow fitting points toward the ground 11 Connect the discharge hose to the dispersion tube 12 Make sure that all connections and fasteners are tight including locking devices latches bolts hoses and fittings 13 Examine the pipes the hoses the fittings and the connections for leaks deterioration or damage Identify the source of a leak...

Page 76: ...ied in the preventive maintenance schedule or if the parts are defective deteriorated corroded or damaged WARNING Lifting must be done by a trained operator Obey all work site safety requirements the safety instructions for the lifting equipment and the safety information in this manual Misuse of lifting equipment can cause the load to become unstable which can cause property damage personal injur...

Page 77: ...te abrasive collection bag on page 78 or Use a crane to remove the waste abrasive collection bag on page 79 4 Empty the waste abrasive collection bag Refer to Empty the waste abrasive collection bag on page 80 5 Put a new waste abrasive collection bag in the hopper 6 Attach the carrying loops to the lifting tabs on the hopper with the shackles Make sure that the bag is pushed down into the hopper ...

Page 78: ...nstructions for the lifting equipment and the safety information in this manual Misuse of lifting equipment can cause the load to become unstable which can cause property damage personal injury or death WARNING Slippery surface The abrasive collection bag can spill water onto the floor The floor can be slippery when wet CAUTION The forklift forks must be dulled or protected to prevent tearing the ...

Page 79: ...n in this manual Misuse of lifting equipment can cause the load to become unstable which can cause property damage personal injury or death WARNING Slippery surface The abrasive collection bag can spill water onto the floor The floor can be slippery when wet The maximum weight that the waste abrasive collection bag can hold is 1 000 kg 2 205 pounds Use lifting equipment that can lift and move the ...

Page 80: ...or Obey all work site safety requirements the safety instructions for the lifting equipment and the safety information in this manual Misuse of lifting equipment can cause the load to become unstable which can cause property damage personal injury or death WARNING Do not stand below the abrasive collection bag The maximum weight that the waste abrasive collection bag can hold is 1 000 kg 2 205 pou...

Page 81: ...d release the hopper tilt latch It could be necessary to tilt the forks forward or backward to decrease tension on the hopper tilt latch before the latch releases WARNING Slippery surface The floor can be slippery when wet WARNING Lifting must be done by a trained operator Obey all work site safety requirements the safety instructions for the lifting equipment and the safety information in this ma...

Page 82: ...sition Make sure that the tilt latch is engaged 10 Connect the overflow tube to the coupling on the inside of the hopper 11 Connect the end of the overflow tube with the elbow to the coupling on the outside of the hopper 12 Make sure that all connections and fasteners are tight including locking devices latches bolts hoses and fittings 13 Examine the pipes the hoses the fittings and the connection...

Page 83: ...ulators behind the gauge panel on the back of the EcoSift unit 2 Test the water hardness Mineral buildup from hard water can block the nozzle 3 Clean the nozzle a Turn OFF the machine b Remove the nozzle c Use needle nose pliers to remove the small piece of metal from inside the nozzle d Use compressed air to blow debris out of the nozzle e Put the small piece of metal into the nozzle f Install th...

Page 84: ...ep spare parts available so that they are ready when required To order parts refer to the Parts section which begins on page 113 Do this task when the EcoSift is not operating WARNING Work that requires opening the electrical enclosure or removing covers or panels from the machine unit must be done only by an approved technician CAUTION Do not touch hot surfaces Do not spray water inside the dryer...

Page 85: ...ad to the side 3 Use a nut driver to remove a side panel from the EcoSift unit 4 Loosen the nut on the clamp ring 5 To open the clamp ring push in the lock and pull the clamp lever It could be necessary to loosen the nut on the other side of the clamp ring 6 Remove the overflow tube 7 Lift the top of the assembly that contains the primary screen 8 Turn the top of the assembly over to get access to...

Page 86: ... to Replace the ball carrier screen on page 88 12 Put petroleum jelly on the rubber gasket on the bottom of the new primary screen 13 Replace the primary screen The rubber gasket is on the bottom side of the screen 14 Put the top assembly on the screen 15 Fill the gap between the primary screen and the metal wall above it with a bead of silicone The silicone bead directs the abrasive into the drye...

Page 87: ...perator Manual 809500 87 16 Close the clamp ring Make sure that the primary screen and the frame are centered 17 Tighten the hex nuts on the frame 18 Install the overflow tube 19 Install the side cover 20 Move the sprayer head over the screen and tighten it ...

Page 88: ...EcoSift is not operating 1 Remove the balls from the carrier screen 2 Remove the screen clamp 3 Replace the ball carrier screen 4 Install the screen clamp 5 Put the balls on the screen WARNING Work that requires opening the electrical enclosure or removing covers or panels from the machine unit must be done only by an approved technician CAUTION The heating elements can take up to 24 hours to cool...

Page 89: ...ear or damage Replace the screen if necessary Empty the secondary screen waste container Do this task when the EcoSift is not operating 1 Remove the waste container from the bracket 2 Discard the contents of the container 3 Install the waste container CAUTION Do not touch hot surfaces CAUTION Do not touch hot surfaces Obey local regulations when discarding parts materials abrasive and wastewater R...

Page 90: ...f the machine is working correctly the current on each leg L1 L2 and L3 is no more than 2 amperes more or less than the others Do this task when the EcoSift is operating 1 Turn ON the dryer blower and the heating elements 2 Touch SEL to see the reading for each leg If the difference between readings is more than 2 amperes a heating element has failed Refer to Replace a dryer box component or remov...

Page 91: ...rs or panels from the machine unit must be done only by an approved technician WARNING Installation maintenance and repairs to the electrical and plumbing systems must meet national and local electrical and plumbing codes This work must be done only by an approved technician CAUTION Do not touch hot surfaces CAUTION The heating elements can take up to 24 hours to cool Refer to Cooling time on page...

Page 92: ...er sources 7 Turn ON the dryer blower 8 Pour 45 kg 100 pounds of abrasive into the top of the dryer box Make sure that the added abrasive covers the tops of the elements This prevents a blockage in the blower nozzles WARNING Rewiring the heating element involves 3 phase wiring This work must be done only by an approved technician Refer to the wiring diagram in Preventive maintenance on page 65 ...

Page 93: ...e cover 5 Hand tighten the wing nut on the dryer blower filter 6 Install the right side cover WARNING Work that requires opening the electrical enclosure or removing covers or panels from the machine unit must be done only by an approved technician WARNING Installation maintenance and repairs to the electrical and plumbing systems must meet national and local electrical and plumbing codes This wor...

Page 94: ...tion or damage Examine the pipes the hoses the fittings and the connections for leaks deterioration or damage Identify the source of a leak and correct the problem 2 Close the agitation valve on the EcoSift hopper CAUTION Do not touch hot surfaces Repair or replace parts identified in the preventive maintenance schedule or if the parts are defective deteriorated corroded or damaged 3 1 2 4 1 Abras...

Page 95: ...r goes into the hopper 4 Turn ON the agitation pump Water flows into the hopper 5 Turn OFF the agitation pump 6 Connect the agitation pump hose to the hopper 7 Open the agitation valve on the EcoSift hopper 8 Do these steps again for the feed pump and then for the abrasive pump 9 Make sure that all connections and fasteners are tight including locking devices latches bolts hoses and fittings ...

Page 96: ... sources Compressed air systems do not always depressurize when other power is disconnected Refer to page 66 for more information WARNING Compressed air is an energy source that can discharge with force Use care when connecting and disconnecting this energy source Obey local regulations when discarding parts materials abrasive and wastewater Refer to Recycling and end of product life on page 110 R...

Page 97: ...er from the pump 2 Turn the pump upside down to drain the liquid from it 3 Use a marking pen to make a line on each liquid chamber and the center section This will help to align the parts during reassembly 1 2 3 5 4 6 1 Discharge manifold 2 Liquid chamber 3 Inlet manifold 4 Center section 5 Muffler 6 Air valve assembly ...

Page 98: ... inch wrench or socket to remove the discharge manifold from the liquid chambers 5 Remove the check valve balls the seats and the seat O rings 6 Use a 1 2 inch wrench or socket to remove the inlet manifold from the liquid chambers 7 Remove the check valve balls the seats and the seat O rings ...

Page 99: ...ench or socket to remove both liquid chambers from the center section 9 Use two 3 4 inch wrenches or sockets to remove the diaphragm assembly from the center section 10 Remove 1 outer piston and diaphragm from the center section 2 1 1 Center section 2 Liquid chamber 1 2 1 2 1 Outer piston 2 Diaphragm ...

Page 100: ...ove the other diaphragm assembly from the shaft a Put the shaft in a vise with nonmarring jaws Make sure that the shaft is not nicked scratched or gouged b Use an impact wrench and a 3 4 inch socket to remove the diaphragm assembly from the shaft 13 Use a 3 16 inch hex key wrench to loosen the bolts that hold the air valve assembly on the center section ...

Page 101: ...air valve body 15 Remove the air valve end cap from the air valve body 16 Remove the gaskets from the muffler plate and the air valve body 17 Put an air valve bolt into the air valve spool to help pull the spool out of the air valve body 18 Remove the air valve bolt from the air valve spool 19 Remove the O ring from the air valve body end cap ...

Page 102: ... that hold the pilot spool in the center section 21 Remove the pilot spool from the center section 22 Use an O ring pick to remove the 2 shaft seals from shaft hole in the center section 23 Discard the shaft seals the snap rings the muffler plate gasket the air valve gasket the air valve spool the end cap O ring and the pilot spool ...

Page 103: ...kidney shape Squeeze the jaws to hold the seal in this shape while it is installed in the shaft hole 4 The shaft seal can have a bump from being deformed for installation Push on the bump until it is equally smooth all the way around the groove 5 Lubricate the pilot spool with NLGI grade 2 white EP bearing grease Lubricate stainless steel bolts with antiseize bolt lubricant white lithium grease to...

Page 104: ...r section 8 Use two 3 4 inch wrenches to assemble the center section Lubricate the shaft with NLGI grade 2 white EP bearing grease To tighten the outer pistons turn them in opposite directions at the same time Torque the outer pistons and the diaphragms to 3 40 N m 30 lbf in 1 1 3 3 2 4 2 5 1 Outer piston 2 Diaphragm 3 Inner piston 4 Center section 5 Shaft ...

Page 105: ...emble the air valve 11 Lubricate the valve spool and the end cap O ring with NLGI grade 2 white EP bearing grease Align the pins on the air valve to the alignment holes in the center section to make sure that the air valve is installed correctly CAUTION Prevent damage to the seals when handling the air valve spool Do not remove the seals 1 2 3 4 1 Air valve body 2 Valve spool 3 End cap O ring 4 En...

Page 106: ...e muffler plate to the alignment hole in the air valve body to make sure that the air valve is installed correctly 14 Use a 3 16 inch hex key wrench to attach the muffler plate and the air valve body to the center section 15 Torque the air valve bolts to 3 05 N m 27 lbf in 16 Use a 1 2 inch wrench or socket to attach the liquid chambers to the center section Lubricate stainless steel bolts with an...

Page 107: ...ce the O rings the check valve seat and the check valve ball in the lower liquid chambers 19 Use a 1 2 inch wrench or socket to attach the inlet manifold to the liquid chambers Lubricate stainless steel bolts with antiseize bolt lubricant white lithium grease to prevent seizing Torque the bolts to 8 47 N m 75 lbf in 1 5 2 3 4 1 Check valve ball 2 Check valve seat 3 Valve seat O ring 4 Manifold O r...

Page 108: ...t to attach the inlet manifold to the liquid chambers Lubricate stainless steel bolts with antiseize bolt lubricant white lithium grease to prevent seizing Torque the bolts to 8 47 N m 75 lbf in 22 Install the muffler on the muffler plate 23 Connect the inlet hose the discharge hose and the compressed air hose 1 5 2 3 4 1 Check valve ball 2 Manifold O ring 3 Check valve seat 4 Valve seat O ring 5 ...

Page 109: ...it is operating WARNING Wear approved personal protective equipment such as goggles gloves and respirators when operating or working near this machinery Refer to Personal protective equipment on page SC 20 CAUTION If a water line a fitting a hose or a valve might be frozen do not operate the system Thaw the system until water moves freely through the entire water circuit Remove all tools and mater...

Page 110: ...roduct or its parts recycle or discard materials and parts using an environmentally satisfactory method and in accordance with your company policy and local regulations If the product contains substances that are harmful to the environment remove and discard the product safely in accordance with national and local hazardous material handling regulations This includes liquids such as hydraulic flui...

Page 111: ...EcoSift Operator Manual 809500 111 Preventive maintenance records Problem and work done Date Hours Initials Date Hours Initials Date Hours Initials Date Hours Initials Date Hours Initials Date Hours Initials Date Hours Initials Date Hours Initials ...

Page 112: ...ive maintenance 112 EcoSift Operator Manual 809500 Problem and work done Date Hours Initials Date Hours Initials Date Hours Initials Date Hours Initials Date Hours Initials Date Hours Initials Date Hours Initials Date Hours Initials ...

Page 113: ... this system The Hypertherm warranty might not cover damage caused by using nongenuine Hypertherm parts To order parts contact the original equipment manufacturer OEM or Hypertherm with the part numbers and quantities Hypertherm Waterjet 305 2nd Ave NW Suite 115 New Brighton MN 55112 USA 1 866 566 7099 1 651 294 8620 fax ...

Page 114: ...ncluded with the assembly 1 16136 PVC overflow assembly 1 16137 Flexible overflow assembly Description Quantity Waste hopper 1 Hopper overflow tube 1 Screw pin anchor shackle 4 1 2 ton 5 8 inch 4 Waste abrasive collection bag 2 Description Quantity PVC overflow elbow assembly 1 PVC overflow tube with coupling 152 4 cm 60 inch length 2 Description Quantity PVC overflow elbow assembly U shaped 1 Fle...

Page 115: ... replacement kit Description Quantity Check valve ball 4 Diaphragm 2 Manifold O ring 2 359 0 139 4 Valve seat O ring 1 734 0 139 4 Description Quantity Grease air system 2 67 g 0 09 oz 1 Gasket muffler plate 1 Gasket air valve 1 Pilot sleeve assembly 1 Closed air valve spool assembly 1 Reducer bushing 1 2 inch to 1 4 inch 1 Retaining snap ring 2 O ring 0 103 1 362 1 Glyd ring O ring 0 749 0 133 2 ...

Page 116: ...AC 2 500 W 5 1 16483 Narrow heating element 400 VAC 2 500 W 4 1 16489 Narrow heating element 480 VAC 2 500 W 4 1 16495 Type J thermocouple with probe 1 1 16490 Type J thermocouple with compression fitting 1 1 16474 Blower air filter 1 1 16493 Spray nozzle dust collector 1 1 16451 Feed and agitation hose assembly 2 1 16452 Abrasive hose assembly 1 1 16463 Abrasive pump to distribution head hose ass...

Page 117: ...m the pumps before starting maintenance or repairs Bleed down and lock out compressed air sources Compressed air systems do not always depressurize when other power is disconnected Refer to page 66 for more information WARNING Compressed air is an energy source that can discharge with force Use care when connecting and disconnecting this energy source WARNING Work that requires opening the electri...

Page 118: ...er 2 Wait 2 minutes 3 Turn ON the heating elements to add heat to the system 4 Wait 1 minute 5 Turn ON the primary shaker 6 Wait 3 minutes The abrasive is shaken off of the primary screen 7 Turn OFF the primary shaker the elements and the dryer blower 8 Start the system normally 9 When the temperature is 160 0 C 320 F make sure that the abrasive pump pressure gauge needle changes A steady needle i...

Page 119: ...ut warnings and faults in the STATUS area Warning and fault statuses shown on this screen are 1 If the home screen RUNNING PAGE shows a warning or fault status touch MENU The MENU screen opens EMERGENCY STOP LOW ABRASIVE LOW TEMPERATURE FAULTED HIGH TEMPERATURE 1 2 3 4 5 1 Highlight bar 2 Arrow up Scrolls up in the list 3 Arrow down Scrolls down in the list 4 Escape Returns to the home screen RUNN...

Page 120: ...to show a list of active warnings and faults Touch ALARM HISTORY to see the previous 11 warnings and faults This screen is for information only 3 Correct the problem Refer to the Warning and fault descriptions section which begins on page 121 4 If the EcoSift turned off turn ON the unit Remove a warning or a fault Touch CLEAR FAULTS to remove the warning or the fault ...

Page 121: ...f normally It could be necessary to clean out the wet abrasive before starting the machine Refer to Uncontrolled shutdown on page 118 Do not use the emergency stop knob to turn OFF the EcoSift in nonemergency situations The system does not do a normal shutdown and wet abrasive is left on the primary screen and in the abrasive pump and hoses which can cause a blockage Cause Solution The primary scr...

Page 122: ...oo much current The overload relay opened the circuit breaker Push the RESET button on the overload relay inside the electrical enclosure The overload setting is incorrect Contact a Hypertherm Technical Service Associate Refer to Hypertherm contact information on page 4 The overload relay failed The motor failed Cause Solution The dust collector motor is using too much current The overload relay o...

Page 123: ...BLOWER screen opens 7 Touch O to turn ON the dryer blower The OUTPUT ON indicator is green when the component is on SHUTDOWN TEMP This fault occurs when the temperature in the dryer box is less than 115 6 C 240 F The EcoSift does not turn off normally It could be necessary to clean out the wet abrasive before starting the machine Refer to Uncontrolled shutdown on page 118 If the abrasive in the dr...

Page 124: ...system compensates by sending more water and less abrasive to the primary screen This causes the temperature in the dryer box to increase Cause Solution The sensor is not plugged in Plug in the sensor The sensor is not receiving sufficient power Make sure that the sensor display lamp is on This shows that the sensor is receiving 24 VDC The cable is damaged Replace the cable The sensor failed Repla...

Page 125: ...BLOWER PRESS The EcoSift does not turn off normally It could be necessary to clean out the wet abrasive before starting the machine Refer to Uncontrolled shutdown on page 118 This fault occurs when the air pressure from the dryer blower in the dryer box is too low Cause Solution The primary screen is blocked Remove blockages from the primary screen There is too much wet abrasive in the dryer box T...

Page 126: ...lement temperature is more than 160 0 C 320 F The system turns off the elements to cool The system turns on the elements when they are at a safe operating temperature CRITICAL HIGH TEMP The EcoSift does not turn off normally It could be necessary to clean out the wet abrasive before starting the machine Refer to Uncontrolled shutdown on page 118 This fault occurs when the heating element temperatu...

Page 127: ...ssed air supply is off Makes sure the compressor is plugged in and the power switch is on The pressure in the compressed air tank is low Operate the compressor to increase the pressure Refer to the compressor manual for more troubleshooting instructions There is a blockage in the pump Disassemble the pump and look for blockages in the air passages or debris that prevents the pump parts from moving...

Page 128: ...feed pump operates too slowly the system compensates by sending less water and more abrasive to the primary screen If the condition is not changed a fault occurs and the EcoSift turns off Refer to RECYCLE RATE on page 124 The pressure in the compressed air tank is low Operate the compressor to increase the pressure Refer to the compressor manual for more troubleshooting instructions A check valve ...

Page 129: ... Disconnect the hose from its connections and clean out the inside of the hose with utility water or do the following 1 Disconnect the hose from the hopper 2 Turn ON the affected pump 3 Open the ball valve to send water through the hose Use an assistant to direct the water from the hose into a container such as a bucket ...

Page 130: ...crease the pressure Refer to the compressor manual for more troubleshooting instructions A pump diaphragm is damaged or has failed Water can be seen coming from the muffler when this occurs Replace the diaphragms Refer to Repair a diaphragm pump on page 96 The compressed air pressure is set too low Turn the regulator knob to increase the pressure to approximately 0 8 bar 12 psi A check valve ball ...

Page 131: ...e hopper This is only applicable when the EcoSift is installed with an existing PowerDredge system Turn the regulator knob to decrease the pressure to approximately 0 8 bar 12 psi The waste abrasive collection bag is full When the waste abrasive collection bag is 75 full replace the bag Refer to Replace the waste abrasive collection bag on page 76 If a collection bag is not being used the waste ho...

Page 132: ...Troubleshooting Troubleshooting 132 EcoSift Operator Manual 809500 ...

Page 133: ...ent VAC electricity Some parts such as valve solenoids and sensors use 24 volt direct current VDC electricity from a power supply in the electrical enclosure Width 203 cm 80 in Height 251 cm 99 in Length 198 cm 78 in Shipping weight empty 1 134 kg 2 500 pounds Pollution degree System 4 Electrical panel 3 Overvoltage category III 50 Hz 60 Hz 400 VAC 480 VAC 3 phase at 40 FLA 3 phase at 34 FLA Recom...

Page 134: ...oise Data in the All Subcategories dropdown list The navigation instructions can change without notice Diaphragm pumps Do not install this system in an environment where the temperature is freezing Ambient temperature 0 0 C to 40 0 C 32 F to 104 F Altitude above mean sea level up to 2 000 m 6 562 feet Operation temperature 5 0 C to 40 0 C 41 F to 104 F Transportation and storage temperature 25 0 C...

Page 135: ...r company s lifting safety procedures while moving this machinery Use straps chains or a crane rated for the weight of the system Do not stack hoppers EcoSift hopper Width 105 cm 41 5 in Height 133 cm 52 5 in Length 121 cm 47 5 in Shipping weight empty 272 kg 600 pounds Waste hopper Width 130 cm 51 in Height 140 cm 55 in Length 142 cm 56 in Shipping weight empty 340 kg 750 pounds Width 89 cm 35 in...

Page 136: ...Specifications Specifications 136 EcoSift Operator Manual 809500 ...

Page 137: ... burns cuts fractures or electrocution Disconnect and lock out the electric power supply before opening the electrical enclosure or doing maintenance or repair procedures Isolate all sources of electric mechanical hydraulic pneumatic chemical thermal and other energy with a lockable energy isolating device that meets local and national requirements Refer to Safety on page 66 DANGER Personnel who w...

Page 138: ...the site is prepared The installation site must have sufficient electric power air water and drain access Make all connections to the system Train all users Refer to User training on page SC 18 for more information Planning The EcoSift can be installed with an existing PowerDredge abrasive removal system or with an alternative waste hopper The diagram shows PowerDredge system components in blue 6 ...

Page 139: ...iency Waste hopper Install the waste hopper on the left side of the EcoSift unit below the dust collector and the waste water tube WARNING Some locations can be hazardous if the atmosphere contains gas vapors or dust in explosive quantities Refer to requirements from NFPA 70 National Electrical Code NEC the International Electrotechnical Commission IEC and the Occupational Safety and Health Admini...

Page 140: ...4 F Altitude above mean sea level up to 2 000 m 6 562 feet Operation temperature 5 0 C to 40 0 C 41 F to 104 F Transportation and storage temperature 25 0 C to 55 0 C 13 F to 131 F Relative humidity noncondensing 50 at 40 0 C 104 F 90 at 20 0 C 68 F WARNING Make sure that a line switch for disconnecting incoming electric power is installed near the power supply to serve as a supply voltage disconn...

Page 141: ...4 in Total flow rate 15 9 L min 4 2 gal min WARNING Isolate all sources of electric mechanical hydraulic pneumatic chemical thermal and other energy with a lockable energy isolating device that meets local and national requirements Bleed down and lock out compressed air sources Compressed air systems do not always depressurize when other power is disconnected Refer to page 66 for more information ...

Page 142: ... documents agree with the system that was ordered and what was received Report shortages or damages to the OEM or to Hypertherm Waterjet no more than 10 days after receipt of the system EcoSift unit Technical drawings for the system are found inside the electrical enclosure EcoSift hopper The hopper arrives with all of the internal plumbing and external connections installed WARNING Lifting must b...

Page 143: ...the EcoSift shipping crate and the EcoSift hopper Make sure that no parts are missing Distribution head assembly Leveling foot 2 Overflow tube Overflow hose assembly Agitation and feed hose 25 mm 1 inch OD 2 Agitation and feed inlet hose 25 mm 1 inch OD 2 Abrasive hose 19 mm 3 4 inch OD Rubber strap 4 ...

Page 144: ... 144 EcoSift Operator Manual 809500 Assorted hardware Heat shield Waste tube assembly Dust collector assembly Plastic pallet Scale Recycled abrasive collection bag 2 Waste container Primary screen spare Hopper wear plate spare ...

Page 145: ...aste hopper for the EcoSift If a PowerDredge abrasive removal system is not part of the system purchase a waste hopper and an overflow assembly Boxes and parts are packed inside the hopper Make sure that no parts are missing PVC overflow option Flexible overflow option Waste hopper Overflow tube Hopper overflow tube 2 Hopper overflow elbow assembly Overflow hose assembly ...

Page 146: ...pers in a different order Special tools Some procedures recommend or require special tools This page is intended to help a user identify tools and parts that are unfamiliar or are known by other names Nut driver Hacksaw Open ended wrench Snap ring pliers Box end wrench O ring pick Adjustable wrench Silicone dispenser caulk gun Pipe wrench Hammer drill Hose clamp Electrician s fish tape draw tape ...

Page 147: ... 60 96 cm 24 inches Full set of standard open ended wrenches sockets nut drivers and screwdrivers Electrician s fish tape draw tape Measuring tape 14 mm open ended wrench Ladder Full set of metric hex key wrenches PTFE tape or thread sealant 2 adjustable wrenches Epoxy Pliers or knife 2 sections of threaded rod no larger than 19 mm 3 4 inch in diameter Saw Hammer drill Nuts to fit the threaded rod...

Page 148: ...e left and right side panels from the EcoSift unit 2 Use a 14 mm open ended wrench to remove the shipping brackets between the upper and lower drums of the primary shaker The brackets protect the shaker during shipping and are not necessary for operation Keep the brackets for moving or storing the unit 2 1 1 Left side panel 2 Right side panel ...

Page 149: ... socket head cap screws M8 1 2 20 mm into the threaded holes in the EcoSift frame 2 Put the smaller hose in the push to connect fitting on the bottom inlet of the distribution head assembly This is the fresh water hose 3 Put a hose clamp over the larger hose Connect this hose to the top inlet of the distribution head assembly This is the abrasive hose Tighten the hose clamp with a flat tip screwdr...

Page 150: ...rge chute 2 Install 4 socket head cap screws M8 1 25 25 mm through the mounting plate and into the EcoSift frame 3 Put the flexible tube over the bottom of the primary shaker discharge chute Install 2 hose clamps to hold the flexible tube in position 1 2 4 3 5 1 Flexible tube 2 Hose clamp 3 Mounting plate 4 Screw slots 5 Waste water tube 1 2 1 Primary shaker discharge chute 2 Waste tube assembly ...

Page 151: ...n assistant to put the dust collector frame and motor assembly on the EcoSift frame The frame hooks over an L shaped bracket on the EcoSift 3 Install 4 socket head cap screws M6 1 00 10 mm through the mounting plate and into the EcoSift frame 4 Connect the ground wire on top of the EcoSift frame to the top of the dust collector assembly with a bolt and a hex nut 1 2 4 3 1 Frame and motor assembly ...

Page 152: ...lar below the dust collector frame The dust collector collar the vent hose and the rubber sleeve are all 1 assembly 6 Install 6 socket head cap screws M6 1 00 10mm through the collar and into the threaded holes in the dust collector frame 7 Attach the vent hose to the vent intake flap on top of the EcoSift unit ...

Page 153: ...at shield The screws go into the threaded holes in the dust collector frame 3 Put the flexible conduit along the bottom of the heat shield and install a socket head cap screw M6 1 00 10 mm through the middle hole on the top of the heat shield The screw goes into the threaded hole in the dust collector frame 4 Open the junction box on the bottom of the dust collector motor 1 2 3 4 1 Heat shield 2 C...

Page 154: ...perator Manual 809500 5 Put the wires from the flexible conduit into the junction box and tighten the connector on the conduit 6 Connect the wires Refer to the wiring diagram in Technical drawings on page 173 7 Install the junction box cover ...

Page 155: ...rs of the EcoSift unit There are 2 nuts on each foot The lower nut sets the height The upper nut tightens against the lower nut to keep the nuts from moving 2 Use a hammer drill to make holes in the floor on each side of the unit The holes must align with the holes in the lagging tabs on the EcoSift frame 3 Use a length of threaded rod nuts and epoxy to lag the frame to the floor Let the epoxy cur...

Page 156: ...justable wrench to adjust each of the 4 leveling feet Install the EcoSift hopper Put the EcoSift hopper in position with the hose connections facing the pumps on the back of the EcoSift unit CAUTION Prevent damage to the primary screen Make sure that the unit is level in all directions front to back and side to side ...

Page 157: ...to the waste outlet elbow Turn the end of the elbow so that water and abrasive will flow into the bag No glue or cement is required for this connection When correctly installed the rubber sleeve of the dust collector is lower than the water hose in the waste hopper 3 Put an empty waste abrasive collection bag in the hopper This is optional Attach the carrying loops to the lifting tabs on the hoppe...

Page 158: ... a hose onto the barbed end of a fitting easier heat the end of the hose with a heat gun and lubricate the barbed end of the fitting with penetrating oil Twist the fitting while pushing it on If the waste hopper is not part of a PowerDredge system Install the overflow There are 2 overflow options PVC overflow 1 Connect the hopper overflow tube to the coupling on the inside of the hopper Elbow Do n...

Page 159: ... water from the hopper returns to the cutting table tank Add a 4 inch NPT elbow to the end of the tube to point the water flow in a direction to decrease splashing 5 Make sure that all connections are tight Flexible overflow 1 Connect the hopper overflow tube to the coupling on the inside of the hopper 2 Connect the U shaped overflow elbow assembly to the overflow hose assembly Make sure that the ...

Page 160: ...Sift Operator Manual 809500 3 Connect the overflow hose assembly to the coupling on the outside of the hopper 4 Hang the hopper overflow elbow assembly over the edge of the cutting table tank 5 Make sure that all connections are tight ...

Page 161: ...ring operation 4 Connect the agitation pump and feed pump water inlet hoses to the lower connections on the pumps 5 Connect the other end of the agitation and feed pump inlet hoses in the waterjet cutting table below the water line 6 Connect a clean water supply hose to the water inlet 7 Connect a compressed air hose to the air inlet 8 Connect the drain hose from the waste hopper to the waterjet t...

Page 162: ...plumbing codes This work must be done only by an approved technician WARNING To decrease the risk of serious injuries or death wear approved protection and obey safety recommendations when working with electricity WARNING Working on this system while it is energized can cause a potentially dangerous situation which if not prevented can cause serious injuries or death Use a lock out program when pe...

Page 163: ...vers or panels from the EcoSift unit must be done only by an approved technician WARNING Installation maintenance and repairs to the electrical and plumbing systems must meet national and local electrical and plumbing codes This work must be done only by an approved technician WARNING To decrease the risk of serious injuries or death wear approved protection and obey safety recommendations when wo...

Page 164: ...hat the shaft and the counterweight disk spin It can be helpful to have 1 person operate the panel while another person watches the rotation of the shaft and the counterweight disk 6 On the home screen RUNNING PAGE touch O to turn OFF the EcoSift 7 Turn the electrical disconnect knob to O OFF 8 If the shaft and the counterweight disk turn counterclockwise when seen from above the motor is wired co...

Page 165: ...lockwise when seen from above the motor is not wired correctly 9 Turn OFF the electric power supply 10 Use a lock out device according to the work site s policy to isolate and control energy 11 Inside the electrical enclosure exchange 2 of the electric cables on the terminals 12 Test the motor rotation again ...

Page 166: ...g harness for the scale through a conduit below the electrical enclosure Pull the harness from the back of the EcoSift unit toward the front 4 Plug the circular connector on the wiring harness into the socket on the bottom of the electrical panel Twist the connector to lock it 5 Put a recycled abrasive collection bag on top of the pallet 6 Put the neck of the bag through the bag support 7 Fold the...

Page 167: ...to tighten the hose clamp to hold the bag on the support 9 Put a rubber strap through the bag loops on each corner 10 Put the waste container in the bracket next to the bag support Adjust the bracket so that the bucket captures large particles coming from the secondary screen chute ...

Page 168: ...alled Do not remove guards while the unit is operating WARNING Wear approved personal protective equipment such as goggles gloves and respirators when operating or working near this machinery Refer to Personal protective equipment on page SC 20 CAUTION If a water line a fitting a hose or a valve might be frozen do not operate the system Thaw the system until water moves freely through the entire w...

Page 169: ...en The valves are on the EcoSift hopper near the hose connections 3 Make sure that the air agitation valve on the EcoSift hopper is open It is not necessary to open the valve completely Too much air causes the water to churn which prevents the abrasive from collecting in the bottom of the hopper CAUTION Do not turn ON the EcoSift without abrasive in the dryer box The EcoSift can only recycle garne...

Page 170: ...ust collector turns on 2 When the temperature is 115 6 C 240 F the shaker the agitation pump and the feed pump start operating 3 Make sure that the agitation pump pressure is set between 1 4 bar and 1 7 bar 20 psi and 25 psi 4 When the temperature is 160 0 C 320 F the abrasive pump and the feed pump start operating the status changes to RUNNING a mixture of water and abrasive falls onto the primar...

Page 171: ...ive on the primary screen If there is too much abrasive on the primary screen lower the abrasive pump pressure until the quantity of abrasive on the primary screen is sufficient Long term storage To store the EcoSift refer to Long term storage on page 109 Sufficient quantity of abrasive Too much abrasive ...

Page 172: ...Installation Installation 172 EcoSift Operator Manual 809500 ...

Page 173: ... Technical drawings Technical drawings In this section Wiring diagrams 400 VAC 480 VAC Air diagrams Water diagrams If you are printing this manual from a PDF Hypertherm recommends printing the diagrams on A3 tabloid or ledger size paper ...

Page 174: ...Technical drawings Technical drawings 174 EcoSift Operator Manual 809500 ...

Page 175: ...N IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF WARDJET IS PROHIBITED MOUNTED TO ELEC CABINET JB1 CUSTOMER SUPPLIED 400VAC 3 PHASE 50 Hz 40 0FLA PE VOLTAGE INTERCONNECT WIRE 380 NONE H2 H6 120 X4 X5 X2 X3 X2 X5 ALL DRAWING COMPONENTS SHOWN SIZED FOR 400V MAINS MOUNTED NEAR HEATER BOX MOUNTED ON PRIMARY SHAKER ...

Page 176: ...IN THIS DRAWING IS THE SOLE PROPERTY OF WARDJET ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF WARDJET IS PROHIBITED MOUNTED TO HEATER BOX MOUNTED IN SIDE OF HEATER BOX MOUNTED IN HEATING ELEMENT BRACKET MOUNTED ON REGULATOR PLATE ...

Page 177: ...RIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF WARDJET ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF WARDJET IS PROHIBITED STACK LIGHT ...

Page 178: ...JET ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF WARDJET IS PROHIBITED Gain Bias Limit Heater Open Alarm Z3 Z2 Z1 Signal 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11 10 9 8 7 L3 L2 L1 L3 L2 L1 L3 L2 L1 L3 L2 L1 L3 L2 L1 L3 L2 L1 A2 24 22 21 A1 COIL 14 NO 12 NC 11 COM PE U V W ...

Page 179: ...HE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF WARDJET ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF WARDJET IS PROHIBITED Length of lock bar 5 125 SC1 SCALE CONTROLLER PLC1 XL4 OCS CAB1 ...

Page 180: ...ETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF WARDJET ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF WARDJET IS PROHIBITED 1T1 1T2 1T3 JB1 ...

Page 181: ... OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF WARDJET IS PROHIBITED MOUNTED TO ELEC CABINET JB1 CUSTOMER SUPPLIED 480VAC 3 PHASE 60 Hz 34 2FLA PE VOLTAGE INTERCONNECT WIRE 480 460 440 H3 H4 H2 H5 120 115 110 X4 X5 X2 X3 X2 X5 ALL DRAWING COMPONENTS SHOWN SIZED FOR 480V MAINS MOUNTED NEAR HEATER BOX MOUNTED ON PRIMARY SHAKER ...

Page 182: ...IN THIS DRAWING IS THE SOLE PROPERTY OF WARDJET ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF WARDJET IS PROHIBITED MOUNTED TO HEATER BOX MOUNTED IN SIDE OF HEATER BOX MOUNTED IN HEATING ELEMENT BRACKET MOUNTED ON REGULATOR PLATE ...

Page 183: ...RIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF WARDJET ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF WARDJET IS PROHIBITED STACK LIGHT ...

Page 184: ...T ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF WARDJET IS PROHIBITED Gain Bias Limit Heater Open Alarm Z3 Z2 Z1 Signal 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11 10 9 8 7 L3 L2 L1 L3 L2 L1 L3 L2 L1 L3 L2 L1 L3 L2 L1 L3 L2 L1 A2 24 22 21 A1 COIL 14 NO 12 NC 11 COM PE L1 L2 L3 ...

Page 185: ...HE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF WARDJET ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF WARDJET IS PROHIBITED Length of lock bar 5 125 SC1 SCALE CONTROLLER PLC1 XL4 OCS CAB1 ...

Page 186: ...ETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF WARDJET ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF WARDJET IS PROHIBITED 1T1 1T2 1T3 JB1 ...

Page 187: ...E A P ECOSIFT AERATOR E B AIR INPUT ABRASIVE PUMP FEED PUMP AGITATION PUMP 3 8 NYLON TUBING 1 4 NYLON TUBING COM W X A D A D CONTROL PANEL 3 8 NYLON TUBING 3 8 NYLON TUBING 3 8 NYLON TUBING ...

Page 188: ...O RESERVOIR ABRASIVE DISTRIBUTION HEAD 5X SPRAY NOZZLES DUST COLLECTOR 9X SPRAY NOZZLES WATER IN ECOSIFT HOPPER MANIFOLD BLOCK MANIFOLD BLOCK WATER RESERVOIR WATER RESERVOIR ABRASIVE PUMP AGITATION PUMP FEED PUMP ...

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