Hypertherm HyPrecision 100D, Instruction Manual

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7.7 Intensifier Cycling
Under normal operating conditions, the intensifier is designed to cycle smoothly in both directions at the
same speed.
Leaks or HP component failures will cause the intensifier to overstroke in one or both directions.
Severe overstroking can cause a fault condition and/or a pump shutdown. An arrow on the display
screen will indicate the direction of overstroke. If an overstroke shutdown or harsh cycling occurs, it is
important to observe the pump operation before attempting to fix the problem.
•
Turn on the pump and intensifier at a reduced cutting pressure of 1,000-psi hydraulic pressure.
•
Gradually increase the pressure until the nature of the problem is present.
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Use the proximity switch lights to determine which direction the intensifier is over cycling while
looking for any leaks.
End of Travel Sensing
When the hydraulic piston reaches the end of travel on either side of the cylinder it will push against an
indicator pin . The proximity switch above the pin will sense the larger diameter of the pin as it passes
under the switch. This pin should move freely in and out to the bottom of its travel. To gain access to
the indicator pin remove the indicator cap from the end cap.
Use the specified torque when reassembling the indicator pin cap and proximity
switch.
Intensifier Overstroking Equally in Both Directions
Overstroking equally in both directions is most likely caused by a leak. Check the tubing and fittings
inside and outside the pump and fix any leaks. Check the bleed-down valve. If the valve feels hot or if
water is coming out the pump drain line then the bleed-down valve should be rebuilt with a new kit.
A blown orifice at the cutting head will also increase the HP water requirements.
The intensifier water inlet could be starved without setting off the low-pressure alarm. Check the quick
disconnects to the intensifier to be sure all fittings are tight and no water is leaking.
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