Hypertherm HyPrecision 100D Instruction Manual Download Page 71

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10.4

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Summary of Contents for HyPrecision 100D

Page 1: ...Instruction Manual 808310 Revision 0 English Original instructions ...

Page 2: ...Instruction Manual 808310 Revision 0 English March 2014 Hypertherm Inc Hanover NH 03755 USA ...

Page 3: ...3 5 2 Electrical Control Panel 23 5 3 Motors 27 5 4 System Fault Detection 29 6 Low Pressure Water 33 6 1 Low Pressure Water Overview 33 6 2 Inlet Cutting Water Supply 33 6 3 Cooling Water Loop Not all Models 36 7 High Pressure Water 37 7 1 High Pressure Water Overview 37 7 2 Intensifier 38 7 3 High Pressure Ends 38 7 4 Check Valve Assembly 41 7 5 Hydraulic Seal Housing 44 7 6 Hydraulic Center Sec...

Page 4: ...9 4 Inlet Cutting Water Requirements 60 9 5 Water Treatment Guidelines 61 9 6 Torque Specifications 62 10 Maintenance and Troubleshooting 63 10 1 Parts and Service Contact Information 63 10 2 Maintenance Guidelines 63 10 3 Troubleshooting 65 10 4 Maintenance Log 69 11 Document Revisions 71 12 Drawings and Parts Lists 73 13 Controls Manual 75 2 ...

Page 5: ... Hypertherm s background in waterjets started in the mid 1980s with the development application and sale of waterjet products for a major equipment manufacturer In the late 1990s Hypertherm was started with the goal of supplying quality spare parts and innovative products to help waterjet users lower their operating cost Today the company has become the leading source for industrial waterjet produ...

Page 6: ...t is directed to the tool after being pressurized by the intensifier assembly Coolant water Water that is circulated through the heat exchanger for cooling the hydraulic fluid Pump A HyPrecision pump ID Inside diameter RPC Remote Pump Control allows operation of the pump from a remote control source OCS Operator Control Station 4 ...

Page 7: ...d notes that must be read and understood The following symbols are used throughout the manual to bring the reader s attention to known hazards and conditions which can be avoided Although an attempt to point out most conditions was made Hypertherm acknowledges that there are other unforeseen situations due to site variability improper maintenance etc that could also potentially cause equipment dam...

Page 8: ...the equipment People who have not been trained in the safe operation of this waterjet machine should not be allowed near the system Always wear safety glasses when working on or near the pump Clean and inspect equipment regularly and fix all problems immediately The operation and maintenance of this system should only be performed by trained qualified personnel Ensure that all personnel not involv...

Page 9: ... the machine Always test the pump after service or maintenance follow startup procedures outlined in the Operation section of this manual Electrical System Safety Always make certain the electrical current is shut off and the proper lockout tag out procedures have been followed before starting any service or maintenance procedures Hazardous voltage within can cause injury or death Disconnect and l...

Page 10: ...can introduce excessive bending stress and fatigue through vibration causing premature failure of the plumbing and heighten risk of personal injury due to an unexpected rupture Always use two wrenches when tightening or loosening HP connections one for the gland nut and one for the fitting This will prevent excessive bending stress and premature failure of the plumbing Always use high pressure pip...

Page 11: ...attention is not received Always seek immediate surgical attention if you come in contact with any high pressure stream of fluid Failure to do so can result in severe infection The injury should be treated as an acute surgical emergency and be evaluated by a qualified surgeon Circulation may be compromised therefore DO NOT apply heat Keep effected person awake and elevate injured part Inform the m...

Page 12: ...ried by personnel working with high pressure waterjet equipment Obtain medical treatment immediately for ANY high pressure waterjet injuries Hypertherm Inc 309 5th Ave NW New Brighton MN 55112 1 651 294 8600 This person has been working with water jetting at pressures to 60 000 psi 4 137bar with a jet velocity of 2000fps 610 mps This should be taken into account during diagnosis Unusual infections...

Page 13: ...he Hydraulic section of this manual Seller Obligations If Hypertherm Inc is the installing party some or all of the following tasks will be the responsibility of the Hypertherm technician at installation as defined in the sales agreement Make sure the buyer has been informed of all buyer obligations and make sure the site has been properly prepared prior to installation Make sure all utility conne...

Page 14: ... water for cooling the hydraulic fluid Hydraulic fluid temperature must be maintained below 130ºF The hydraulic cooling water section of the Specifications area of this manual details the cooling water flow and temperature requirements In most cases public utility water is acceptable In situations where the water contains heavy mineral deposits the cooling fins in the heat exchanger may become clo...

Page 15: ...l copy is included inside the electrical cabinet Location Requirements The pump must be placed in a location which allows access to all sides for service The pump should have a minimum 36 in clearance surrounding the machine free of all obstacles to allow room for service See the Pump Requirements section under Specifications The pump should not be placed in any environment where the temperature i...

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Page 17: ...eshooting is necessary the card can be removed from the pump and the information transferred via a USB reader to Hypertherm technicians Program updates can also be installed by simply copying a new program onto the card and replacing it in the pump No service is necessary on the OCS All inputs and outputs run to terminal blocks which should be used for wiring the remote options Refer to the supple...

Page 18: ... 2 Pierce See Adjusting the Cut and Pierce Pressure in the Operation section for more information HYDRAULIC PRESSURE gauge Displays the hydraulic pressure of the pump Pumps with more than one hydraulic pump will have additional gauges The hydraulic pressure gauge can be useful in determining the approximate cut pressure To do so use the following formula Cut Pressure 19 25 X Hydraulic Pressure PRE...

Page 19: ...esent Motor Direction Check CAUTION This procedure involves exposing a rotating shaft Never place any object or any part of your body near the shaft while exposed Only visual inspection should be used to prevent bodily injury Be prepared to press the EMERGENCY STOP button IMPORTANT The motor direction check should be performed anytime electrical maintenance has been performed on the electrical pan...

Page 20: ...pressing the PUMP ON button on the touchscreen display Make sure that the boost pressure meets the inlet water requirements as outlined in the Specifications section of this manual 4 Check again for any leaks and loose fittings Take any corrective action and then proceed to the next step 5 Flush the pump and high pressure lines using the following procedure Flushing HP Water Lines After installati...

Page 21: ...f valve needle seat and seals as well as any damaged orifices Normal Startup Procedure 1 Verify all safety circuits are connected and operational 2 Check the sight gauge to make sure the hydraulic reservoir is full Add oil as necessary to bring the oil to an acceptable level Refer to Hydraulic Oil in the Hydraulic section of this manual for instructions on adding oil 3 Verify all utilities are con...

Page 22: ...he pump When restarting the pump slowly ramp up the cut pressure knob until you are at the desired set point Analog Pressure Control Pumps that are equipped with Analog Pressure Control operate similar to the standard pumps The set point values on the analog pressure control adjust with the OCS rather than the control knobs To adjust cut pressure the CUT PRESSURE icon must be active light blue Tou...

Page 23: ...ERGENCY STOP palm button located on the front control panel In the event of an emergency press the EMERGENCY STOP palm button This will immediately remove any electrical power from the motor and controls The bleed down valve will open and the high pressure water should be relieved down the drain If the pump is configured to run remotely and has a motion system the emergency circuits from the robot...

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Page 25: ...ve a transformer for 110VAC as required All field components i e solenoid valves sensors etc use 24VDC power Fusing is provided for the PLC outputs 24VDC power supply and the transformer if present Refer to the electrical schematic for fuse sizes and locations Some spare fuses are included with the controller All fuses can be purchased from Hypertherm or an electrical supply store Remote Operation...

Page 26: ... 6029 24VDC 24VDC PLC Input Momentary NC RPC Emergency Stop Connections Description Wire No Voltage Type Contact Remote Cooling Mode 6030 24VDC 24VDC PLC Input Momentary or Maintained NO Discrete Pressure Input 6022 6022A 24VDC PLC Input Maintained NO Controls On Indicator 5024C 24COM 24VDC PLC Output Remote Mode Active Indicator 6027 24COM 24VDC PLC Output Remote Pump Fault Indicator 7004 24COM 2...

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Page 28: ...n switch to high pressure If the pump is in cooling mode pressing the pump on will start the intensifier stroking Remote Pump Off This input turns the intensifier motor inlet water and cooling fan if present off After the pump is shut down you must choose cooling mode or pump on in order to start the pump For stand by condition in between programs it is recommended to leave the pump running Remote...

Page 29: ...50D are equipped with a Softstarter This is considered a reduced voltage class of starter When the motor is turned on through the operator interface or from a remote signal the Softstarter ramps the motor up to speed over a factory set amount of time After the starter reaches the Top of Ramp TOR it switches the load to a bypass contactor The Softstarter monitors a large variety of conditions inclu...

Page 30: ...sary to perform a rotational direction check Take the following steps to ensure that the motor and boost pump are not damaged from improper rotation 1 Remove the front and rear cover from the pump Make sure that you can see the boost motor coupling through the pump mount It may be necessary to have two people for this procedure 2 To jog the motor pull the EMERGENCY STOP button on the control panel...

Page 31: ...c Oil Temp 130ºF 55ºC The probe in the hydraulic oil tank has two temperature switches to monitor conditions One switch opens at 130ºF 55ºC and the other at 150ºF 65ºC If the lower temperature is exceeded the yellow light will begin to flash warning the operator of a potential cooling water problem In systems that are cooled with water the most likely cause of this condition is the cooling water i...

Page 32: ...inlet water pressure Read the Low Pressure Water section of the manual to identify other possible causes Once the problem is corrected press the RESET button on the alarm screen and resume normal operation of the pump Hydraulic Oil Temp 150ºF 65ºC If the temperature of the oil in the tank exceeds 150ºF 65ºC the red light will begin to flash and the intensifier will shut down warning the operator o...

Page 33: ... starter MS MAIN in the pump electrical enclosure has thermal overload protection to prevent motor damage from excessive heat Refer to Motor Starter Circuits and Thermal Overloads in the Electrical System section for important information regarding motor service and safety There are several reasons why this fault may be occurring One common reason for a motor fault message is a blown fuse correspo...

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Page 35: ...alve See the Inlet Cutting Water Requirements in the Specifications section of the manual for further information Inlet Water Valves and Connections All Hypertherm pumps have incoming water connections on a utility bulkhead Electronic solenoid valves and manual valves at the bulkhead fittings control incoming water supply The incoming water connection details are outlined in the Specifications sec...

Page 36: ... by municipal water or well pumps In cases where the pump is supplied by a tank such as on a reverse osmosis system it is necessary to increase the boost pressure The boost pump pressure relief valve is adjusted by loosening the jam nut and turning the T handled adjustment screw image at right Turn clockwise to increase the pressure or counterclockwise to decrease pressure High Inlet Water Pressur...

Page 37: ...ter elements when there is a 10 psi pressure differential between the two gauges located on the pump control panel Replacement Parts 10 Micron Filter 1 Models with Three Filter Elements AS part 11107 1 Micron Filter 2 All Models AS part 11106 0 45 Micron Filter 3 All Models AS part 11105 Recommended Tools Strap Wrench or Filter Wrench for turning filter housing Water Filter Element Replacement Pro...

Page 38: ...e oil temperature and adjusts the water flow to maintain a steady hydraulic oil temperature The modulating valve has been factory set to keep the oil temperature at approximately 115 F 45 C Local air and water temperatures may require that the modulating valve be adjusted Water Modulating Valve Adjustment The oil temperature in the hydraulic tank should be maintained at approximately 115 F High hy...

Page 39: ... pump when the pump is turned off or when the hydraulic pressure is reduced Attenuator The Attenuator Assembly acts as the accumulator and uses the compressibility of the water to dampen the output water pressure pulsation caused by the reciprocation of the intensifier HP Filter Optional The HP Filter Assembly optional is normally located at the pump output or at the upstream end of the whip for t...

Page 40: ...P seals hands should be washed and kept clean Before reassembling any high pressure or hydraulic components verify that the components have been wiped clean to remove any dirt or other contaminants 7 3 High Pressure Ends High Pressure Seal Replacement Replacing the high pressure seals and hoops is the most common service function Water dripping from either end of the HP cylinder indicates that the...

Page 41: ...tepped static end of the cylinder on the seal tool locating ring Use a rubber mallet at the small end of the push tool to drive the bottom seal and hoop out of the HP cylinder Flip the cylinder over and repeat the process The seals 4 with O rings 6 hoops 5 spacer tube 3 and low pressure poppet basket 8 should now be free of the HP cylinder 6 Remove the bronze seal backup 9 from the seal housing in...

Page 42: ... sharp edge toward the cylinder 7 Use the non stepped end of the seal insertion tool and a soft blow hammer to pound the hoop into place The hoop is seated properly when the seal insertion tool bottoms out on the seal guide 8 Apply a small amount of grease from the packet around the OD of the pilot on the check valve body 9 Carefully insert the check valve body into the end of the high pressure cy...

Page 43: ...he cylinder ends on a table First use 180 grit or finer abrasive paper then finish with a Scotch Brite pad HP cylinders may eventually fail due to fatigue leading to a crack or the ends may open or bell out so that the cylinder does not hold the seal and hoop properly If the cylinder is cracked it will be hot and water may squirt with each stroke This failure may appear to be a seal failure A bell...

Page 44: ...nd the HP seat 7 3 Inspect the low pressure poppet face of the check valve body 2 A worn face on the poppet 4 or check valve indicates that it should be lapped as described in the next section 4 Apply HP lubricant to both sides of the HP seat 7 and place the seat in the cavity of the check valve body 2 5 Install the poppet spring 6 and HP poppet 5 into the output adapter 3 and tighten the adapter ...

Page 45: ... lapping If the sealing face 1 has slight indentations only use 1500 grit paper Lapping is complete when the check valve body face is flat and has a near mirror finish Deeper indentations will need to be lapped with 600 grit SiC abrasive paper first Lapping is complete with this abrasive paper when the face has an even appearance and any indentations are removed The following items are required fo...

Page 46: ...ace as necessary Check for any inner diameter corner chipping or a loose fit on the plunger 4 Remove the old seal from the seal housing 5 Replace the O ring and backup ring on the OD of the seal housing Position the O ring on the rod seal side of the groove and backup on the backup side of the groove Note the position of the groove on the backup ring 6 Apply HP lubricant to the outside of the O ri...

Page 47: ...r the manifold oil ports to prevent contamination 5 Pull the end caps off the hydraulic cylinder This will take two people Hydraulic Center Plunger Replacement After extended use the plunger surface may become damaged and or scored 1 Push the hydraulic piston to the end of the hydraulic cylinder so that the plunger is accessible Use a rubber mallet to drive the opposite plunger end Do not remove t...

Page 48: ... on the end cap Place the O ring on the side of the groove towards the piston and the backup on the side away from the piston The concave side of the backup is towards the O ring Lubricate the O ring with hydraulic oil 3 Install the plunger bearings in the end caps 4 On a flat clean surface slide the hydraulic end caps into each end of the hydraulic cylinder 5 Thread the four 7 8 in cap screws in ...

Page 49: ...hes 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 ...

Page 50: ...Seal FL 11321 Bushing 11324 Poppet Seat 11141 Kit installation procedure 1 Shut down the system 2 Remove the hydraulic hose from the bleed down valve and gland nut connection from the water drain tubing to the bleed down valve 3 Remove the gland nut from the collar at the high pressure port of the bleed down valve 4 Disconnect the actuator from the high pressure valve assembly Remove all the hydra...

Page 51: ... The 1 liter attenuator uses 3 8 in HP fittings The 2 liter attenuator uses 9 16 in male x 3 8 in female inlet adapters on either end to connect to the 3 8 in HP plumbing Leakage from the inlet adapter or fitting weep holes can be addressed by tightening the adapters and fittings into the attenuator end caps Leakage from the end cap weep hole or the gap between the end cap and the attenuator body ...

Page 52: ...y result in damage to the mating fittings If weep hole leakage is observed the fitting may have loosened and it will need to be tightened Another cause of seepage is the collar on the tubing may need to be threaded further onto the tubing Persistent seepage may require replacing the fitting or tube Lubricate the high pressure fittings with a HP grease such as Blue Goop To minimize side load use tw...

Page 53: ... the end of the PCVD pump The oil then passes through the filter and heat exchanger before returning to the hydraulic tank WARNING Before starting any service or maintenance turn off electrical power and relieve all water and hydraulic pressure Proper lockout tag out procedures must always be followed prior to performing any maintenance of the unit 8 1 Hydraulic Oil Hydraulic Oil Requirements Plea...

Page 54: ...ater seal can squirt water past the rod seal into the oil see the High Pressure Water section The oil dynamic seal and rod seal will need to be replaced If you have water in your oil please report the incident to an authorized Hypertherm service representative to receive any additional instructions Oil Replacement Procedure While changing the oil consider thoroughly cleaning out the hydraulic syst...

Page 55: ...ing and pierce pressures See the Operation section for instructions on setting the operating pressure Cut Pressure Select Solenoid Valve The cut pressure select solenoid valve 5 is a normally open valve located on the back of the control manifold directly behind the cutting pressure knob In the event of a power loss the solenoid will discharge pressure from the hydraulic system and cause the bleed...

Page 56: ...the heat exchanger will be reduced and may require reducing the temperature set point of a chiller The oil temperature variations coming from the heat exchanger can be controlled by adjusting the flow rate of water The flow rate of the water can be adjusted by either the water modulating valve if applicable or a manual ball valve For directions on adjusting the water modulating valve please refer ...

Page 57: ...airborne contamination Level sensor with temperature switches which monitor the tank for low level and high temperature alarm conditions Inlet suction strainers to prevent contamination from reaching the main PCVD pump and the gear pump or kidney loop system 8 6 Main Pump Setup Contact Hypertherm if the main hydraulic pump needs to be replaced Detailed setup information is available upon request 5...

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Page 59: ...2 03m 45 1 15m Length 42in 1 07m 86 2 18m Height 58in 1 47m 56 1 42m Clearance Height 80in 2 03m 80in 2 03m 80in 2 03m Shipping Weight Approx in crate no oil 3200lb 1450kg 3300lb 1497kg 3400lb 1540kg 4250lb 1928kg 6250lb 2834kg Operating Weight Approx 3100lb 1406kg 3200lb 1450kg 3300lb 1497kg 3300lb 1497kg 4150lb 1882kg 6100lb 2767kg Ambient Conditions Min Storage Temp not drained 35 F 1 7 C Min O...

Page 60: ...ater Quality See Water Quality section Hydraulic Cooling Water if not air cooled Min Inlet Water Pressure 40 psi 2 76 bar Max Inlet Water Pressure See LP Water section 115 7 93 bar Max Inlet Temp 70 F 21 C Min Inlet Temp 40 F 4 4 C Normal Inlet Flow Rate 3 gpm 11 5 lpm 4 gpm 15 lpm 8 gpm 30 lpm 10 gpm 38 lpm Hydraulics Hydraulic Oil Type Castrol Hyspin 32 or Hyspin 46 Hydraulic Oil Hydraulic Oil C...

Page 61: ...al Utility Hook Ups located at rear of pump Cooling In 1 NPT Female Cooling Out 1 NPT Female Cutting Water In 3 4 NPT Female Drain Water Out 3 4 NPT Female Cutting Water Out 3 8 HP Female 9 16 HP Female Warnings and Shutdowns Intensifier HP Leak Warning Warning Intensifier Over Cycle Shutdown Inlet Cutting Water Under Pressure P 40 psi 2 8 bar Shutdown Hydraulic Oil Level Low Shutdown Hydraulic Oi...

Page 62: ... 50 60 50 60 1 Orifice 014 015 015 016 017 018 020 021 024 025 2 Orifices 010 010 011 011 012 013 014 015 017 018 3 Orifices 008 008 009 009 010 010 011 012 014 014 4 Orifices 007 007 008 008 009 009 010 010 012 013 5 Orifices 006 006 007 007 008 008 009 009 011 011 6 Orifices N A N A 006 006 007 007 008 008 010 010 9 4 Inlet Cutting Water Requirements Inlet Cutting Water Requirements and Testing ...

Page 63: ...reatment required No action Good Quality Water 50 ppm TDS 150 ppm Soften only Contact local water treatment specialist Medium Quality Water 150 ppm TDS 250 ppm Soften or TDS removal Specialist or RO system Poor Quality Water TDS 250 ppm Silica 15 ppm TDS removal RO System available through Hypertherm Do not treat to 5 ppm or less Water of this high of purity is overly aggressive and will damage st...

Page 64: ...or lubricated Grade 8 fasteners Specific Torques Intensifier Stud 1 in nut 275 ft lb 373 N m Intensified Center 7 8 in cap screw 275 ft lb 373 N m General Torques The torques below are to be applied only to those fasteners not listed above 10 45 in lb 5 1 N m 1 4 in 105 in lb 11 9 N m 5 16 in 18 ft lb 24N m 3 8 in 33 ft lb 45 N m 7 16 in 53 ft lb 72 N m 1 2 in 80 ft lb 108 N m High Pressure Fittin...

Page 65: ...age to anything in its line of fire Always repair any leaks immediately to avoid damage to equipment and or serious personal injury Carefully read all of the safety guidelines in the Safety section of this manual Read and understand the pertinent sections to the maintenance that you are planning to perform Shut off the main disconnect When the power is shut off the bleed down valve will open and b...

Page 66: ...se for damage I Adjust cooling water flow A Check inlet water pressure I Inlet water filters I R Check pressure in water accumulator set to 40 psi I High Pressure Water Visually inspect for leaks I Check temperature of intensifier and bleed down valve I Lap or replace LP poppet and check valve face R Replace HP seals R Replace HP filter at pump outlet I R Replace hydraulic rod seal I R Replace plu...

Page 67: ...oling water Read the Low Pressure Water section of this manual Water Oil Cooled Unit High cooling water inlet temperature Test the temperature of the inlet water If the temperature is outside of the normal range outlined in the Specifications section of this manual you may need a water chiller Water Oil Cooled Unit Cooling water flow rate may not be high enough Check the flow rate by monitoring th...

Page 68: ...Reset the alarm by pressing the FAULT RESET button on the control panel Wait 15 minutes to let the motor armature cool down before starting again Hydraulic pump does not make pressure or makes low pressure Defective cut pressure select solenoid Manually over ride valve until replacement arrives Defective cut pressure control valve Replace valve Defective hydraulic pump and or compensator Replace p...

Page 69: ...air Pins must move freely to bottom of bore Proximity switch has failed Indicated by both proximity lights being on at the same time Replace proximity switch Intensifier cycles and oil pressure okay but not enough pressure at head Clogged high pressure filter Replace HP element Partial obstruction in HP lines Correct obstruction Worn hydraulic piston seal Rebuild hydraulic center section Too much ...

Page 70: ...P cylinder drips Worn HP seal Replace HP seals and hoops Hydraulic center section is much hotter than hydraulic oil Piston seal is worn Rebuild center section Piston seal has just been replaced and needs breaking in No action required HP seal is short Poor mating surfaces Inspect repair and or replace HP cylinder ID and plunger Pump has cycled roughly Start up new seals carefully Pump over cycled ...

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Page 72: ... ______ Initials ________ Hours ______ Date ______ Initials ________ Hours ______ Date ______ Initials ________ Hours ______ Date ______ Initials ________ Hours ______ Date ______ Initials ________ Hours ______ Date ______ Initials ________ Hours ______ Date ______ Initials ________ Hours ______ Date ______ Initials ________ Hours ______ Date ______ Initials ________ Hours ______ Date ______ Initi...

Page 73: ...urrent revisions and the date in which they were revised updated Check with your local Hypertherm support personnel to verify that you have the latest revision Document Revision Description of change Date Approved by Rev A Initial Release 10 24 12 CJV 71 ...

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Page 75: ...12 Drawings and Parts Lists 73 ...

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