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Hypertherm HyPrecision 50S, Operator'S Manual

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Hypertherm HyPrecision 50S Operator'S Manual Download Page 111

HyPrecision 50S/60S/75S

Operator Manual

808690

111

5 – Preventive maintenance

Preventive main

tenance

Assemble the intensifier

Refer to the 

Intensifier parts

 section on page 127 for part numbers. Refer to page 149 for ordering 

information.

Repair the hydraulic center section

The hydraulic center section includes the pistons, the plungers, the hydraulic cylinder, the hydraulic end caps, the 
low-pressure seals, and the proximity switches.

Preventive maintenance on these parts requires special tools. Contact a Hypertherm Technical Service Associate 
for information and support regarding the installation, operation, maintenance, and repair of this equipment.

CAUTION

Overtightening a fitting can cause it to fail. Use 2 wrenches when loosening or tightening a 
high-pressure connection. Using only 1 wrench can increase bending stress to the parts and cause 
damage or premature failure.

Review the 

Safety

 section, which begins on page 70.

Examine parts that are being replaced to identify wear patterns or damage that can indicate other 
problems

Put the parts on a clean, dry, oil-free surface.

Use clean hands when changing high-pressure parts such as high-pressure water seals.

Service

Interval

Repair the hydraulic center section

After every 12,000 hours of operation

Summary of Contents for HyPrecision 50S

Page 1: ...HyPrecision 50S 60S 75S Waterjet Pump Operator Manual 808690 Revision 2 English ...

Page 2: ...l 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 2016 Hypertherm Inc ...

Page 3: ...HyPrecision 50S 60S 75S Operator Manual 808690 Revision 2 English Original Instructions August 2016 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: ...Symbols and marks found on the data plate and the equipment SC 22 1 Terminology 25 2 Product description 29 Pump exterior 30 Major systems 33 Electrical system 33 Hydraulic system 35 Low pressure water system 39 High pressure water system 40 3 Options 41 4 Operation 43 Safety 43 Overview 45 Inspect the equipment before operation 47 Turn on the pump 47 Operate the pump 49 Operate the pump remotely ...

Page 6: ...ler breather cap and the suction strainers 84 Low pressure water system 88 Check the low pressure water pressure gauges 88 Measure the air pressure in the water accumulator tank 89 Replace the water filters 91 Test the low pressure water TDS level 94 High pressure water system Intensifier 96 Prepare to service the intensifier 97 Disassemble the intensifier 100 Repair the check valves and the low p...

Page 7: ...ll not start 158 Intensifier 159 Stroking problems 159 Leaks 163 Short seal life 165 Hydraulic fluid 166 Low pressure 166 High temperature 166 Water pressure 168 No water pressure or low water pressure 168 Water pressure is too high 170 Motor fault 171 Noisy operation 171 8 Pump specifications 173 All models 174 Hydraulic fluid 174 Operating conditions 174 Cooling requirements 174 HyPrecision 50S ...

Page 8: ...ter 188 Receive and unpack the equipment 190 Make the connections for remote operation 191 Install the external air cooler 193 Make the connections to the utility panel fittings 194 Add hydraulic fluid 196 Connect the electrical power 196 Do the first startup 197 Do a preoperation inspection 197 Turn on the utilities 198 Change the system configuration on the operator interface 198 Start the pump ...

Page 9: ...erial number is on the data plate which is found above the connection panel on the back of the pump System schematic drawing number The system schematic drawing number is inside the electrical enclosure door on a green label and on the data plate Purchase date Distributor Installation date Installed by Notes ...

Page 10: ...10 HyPrecision 50S 60S 75S Operator Manual 808690 Pump information ...

Page 11: ...m the ship date or 12 months from the date of proven installation whichever occurs first EcoSift abrasive recycling system 15 months from the ship date or 12 months from the date of proven installation whichever occurs first Bulk abrasive pots 15 months from the ship date or 12 months from the date of proven installation whichever occurs first Abrasive regulators 15 months from the ship date or 12...

Page 12: ...SC 12 Safety and compliance Warranty Warranty ...

Page 13: ...ng laboratory Hypertherm puts a certification test mark on its products only after that product is manufactured with safety critical parts that have been approved by the accredited testing laboratory Once 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...

Page 14: ...he EU standards and other normative documents 97 23 EC Pressure Equipment Directive 2006 42 EC Machinery Directive 2006 95 EC Low Voltage Directive 2004 108 EC Electromagnetic Compatibility Directive This declaration is not valid on units without a CE mark on the data plate For European customer inquiries contact European Customer Service Hypertherm Europe B V Vaartveld 9 4704 SE Roosendaal Nederl...

Page 15: ...s cutting tables motor 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 ...

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

Page 17: ...zardous chemicals The information includes the chemical s toxicity and reactivity first aid for exposure approved storage and disposal recommended protective equipment and spill handling procedures The Occupational Safety and Health Administration OSHA has presented new hazardous chemical labeling requirements as a part of its recent revision of the Hazard Communication Standard 29 CFR 1910 1200 t...

Page 18: ...rom materials that are cut will pose a physical hazard or health risk Please consult with your supplier or other technical advisor if you need guidance concerning the properties of the material you will cut using a Hypertherm product If you are not fully aware of and up to date on all applicable government regulations and legal standards for the installation site consult a local expert before purc...

Page 19: ...azards and to take the steps necessary to minimize risks Keep these instructions near the equipment This manual is intended to familiarize the user with the equipment and its parts safe operation and maintenance All people who operate or are exposed to this equipment must know this information Applicable safety standards The use limitations and care of personal protective equipment The location of...

Page 20: ...ries Delayed treatment can cause serious injuries or death Waterjet operators should carry a waterproof emergency medical tag or card that describes the nature of high pressure waterjet injuries and the recommended treatment Show the tag or card to emergency responders and medical professionals This card can be copied cut out laminated and folded A high pressure injection injury is a surgical emer...

Page 21: ...commendations when working with electricity WARNING This symbol identifies a potentially hazardous situation which if not avoided can cause serious injuries or death WARNING WARNING A waterjet is a cutting tool A high pressure injection injury is a surgical emergency Seek immediate medical treatment for all high pressure waterjet injuries Delayed treatment can cause serious injuries or death WARNI...

Page 22: ...or suspended particles when cut Wear approved respiratory protection Refer to the instruction manual Read and understand all of the safety guidelines in this manual This symbol identifies a mandatory action This symbol identifies a prohibited action This symbol identifies tools or materials that are required or recommended for a procedure This symbol identifies a note or helpful information Correc...

Page 23: ...nst electric shock in case of a fault AIR IN Compressed air that operates the bleed down valve COOLING IN Water cooled system Low pressure supply water or water from a chiller that goes to a heat exchanger Air cooled system Hydraulic fluid that is returning from an external air cooler COOLING OUT Water cooled system Low pressure water from the heat exchanger that goes to a drain or returns to a ch...

Page 24: ...SC 24 Safety and compliance Symbols and marks Symbols and marks ...

Page 25: ...ystem Low pressure supply water or water from a chiller that goes to a heat exchanger Air cooled system Hydraulic fluid that is returning from an external air cooler cooling mode The pump runs with the intensifier disabled Hydraulic fluid circulates through the pump at minimum pressure the cutting water solenoid is open and the boost pump is on COOLING OUT Water cooled system Low pressure water fr...

Page 26: ...s the transmission or release of energy including but not limited to the following a manually operated electrical circuit breaker a disconnect switch a manually operated switch by which the conductors of a circuit can be disconnected from all ungrounded supply conductors a line valve and any similar device used to block or isolate energy Push buttons like the EMERGENCY STOP button selector switche...

Page 27: ...ical restraint of a lock low pressure water CUTTING WATER IN Low pressure water from a water softener a reverse osmosis system a well or a public utility that is between the utility panel and the intensifier refer to prefilter water and postfilter water NPT National pipe thread taper NPT a common United States standard for tapered threads that are used on fittings and pipes OEM An original equipme...

Page 28: ...al at the output end of the high pressure cylinder This seal does not touch the plunger refer to dynamic seal supply water Water going to the pump from a water softener a reverse osmosis system a well or a public utility that is typically delivered to a location through a system of pumps and pipes system integrator An integrator of waterjet cutting systems that are sold directly to end users tubin...

Page 29: ...urize water for waterjet cutting Four systems make up the pump hydraulic low pressure water high pressure water and electrical These systems are not independent of each other Color is used throughout the manual to identify the different systems In the Preventive maintenance section which begins on page 69 color is used to highlight referenced parts ...

Page 30: ...ter pressure after the water goes through the filters The usual operating range is 2 76 bar to 7 58 bar or 275 79 kPa to 758 42 kPa 40 psi to 110 psi Hydraulic pressure gauge This gauge shows the hydraulic pressure in the pump Cut pressure control knob This knob changes the water pressure from the intensifier for cutting To calculate the approximate water pressure multiply the hydraulic pressure g...

Page 31: ...exchanger Air cooled system This is hydraulic fluid that is returning from an external air cooler CUTTING WATER IN This low pressure water goes into the pump from a water softener a reverse osmosis system a well or a public utility COOLING OUT Water cooled system This is low pressure water from a heat exchanger that goes to a drain or returns to a chiller Air cooled system This is hydraulic fluid ...

Page 32: ...from a water softener a reverse osmosis system a well or a public utility Water that has been pressurized by the intensifier for piercing or cutting Water cooled system COOLING OUT Cooling loop COOLING IN Low pressure supply water or water from a chiller that goes to a heat exchanger Low pressure water from a heat exchanger that goes to a drain or returns to a chiller Air cooled system COOLING OUT...

Page 33: ...es the piston to the end of the hydraulic center section the piston pushes against a spring loaded indicator pin A signal from the proximity sensor above the indicator pin causes the shift valve in the primary hydraulic manifold to change the direction of the intensifier Primary motor The primary motor drives the primary hydraulic pump that moves hydraulic fluid through the intensifier A gear pump...

Page 34: ... operate the pump and the intensifier The primary screen shows information about warnings and faults The primary breaker disconnect lever disconnects electricity to the pump motor and controls The operation panel turns the control circuit inside the pump on and off and controls local and remote pump operation Motor starter HyPrecision 50S 60S and 75S pumps use a soft starter to gradually increase ...

Page 35: ...aulic fluid tank through the primary hydraulic manifold The cooling loop keeps the hydraulic fluid at its optimum temperature A gear pump moves hydraulic fluid from the hydraulic fluid tank and sends it through a heat exchanger where heat transfers through fins to cooling water or to an optional fan The hydraulic fluid passes through a hydraulic filter and then returns to the hydraulic fluid tank ...

Page 36: ...h at each end of the hydraulic center section signals the shift valve Ceramic plungers connected to each side of the piston extend into the left and right high pressure ends Hydraulic fluid pushes the piston to 1 side while low pressure supply water fills the empty cylinder The plunger on the opposite side of the cylinder compresses the water for piercing or cutting 1 2 1 Shift valve 2 Relief valv...

Page 37: ...re control knob This knob changes the water pressure from the intensifier for piercing Pressure enable solenoid This solenoid turns the pump pressure on and off Cut pressure solenoid This solenoid puts the pump in pierce pressure mode when it is on and cut pressure mode when it is off Hydraulic accumulator This equalizes hydraulic fluid pressure for the hydraulic gauge Bleed down valve solenoid Th...

Page 38: ...ressure supply water or water from a chiller circulates through a heat exchanger Water from the heat exchanger goes to a drain or returns to the chiller A water modulating valve is standard in systems without a chiller This valve adjusts the flow rate of water based on the temperature of the hydraulic fluid External air cooler optional The gear pump directs hydraulic fluid to an external air coole...

Page 39: ...R OUT Boost pump Because supply water is usually at a low pressure a boost pump is used to increase the water pressure to 7 85 bar or 758 42 kPa 110 psi A sustained pressure of less than 2 76 bar or 275 79 kPa 40 psi causes the pump to turn off The boost pump assembly includes a pump a 1 way check valve and a bypass relief valve that affect the water pressure coming from the boost pump The operato...

Page 40: ...ssurized water exits the high pressure end through a check valve and goes to the attenuator Attenuator The piston stroking causes a brief change of water pressure in the high pressure ends The attenuator compensates for pressure fluctuations and maintains a consistent output water pressure Pumps with a 2 liter attenuator have an attenuator guard which is supplied for safety Bleed down valve The bl...

Page 41: ...n air cooled system the temperature sensor in the hydraulic fluid tank turns on an external air cooled fan Proportional control valve The proportional control valve electronically varies back pressure to the pump compensator The pump runs at maximum hydraulic pressure when the valve is completely closed Redundant intensifier A second intensifier reduces downtime by permitting the operator to use o...

Page 42: ...42 HyPrecision 50S 60S 75S Operator Manual 808690 3 Options Options ...

Page 43: ...ries Delayed treatment can cause serious injuries or death WARNING Do not operate the pump without the shaft access cover and all other safety devices correctly installed Do not remove guards while the pump is operating WARNING Do not operate this equipment without the guard installed WARNING Risk of explosion WARNING Personal protective equipment is recommended Failure to wear personal protective...

Page 44: ...vels When this pump is running the noise level is 75 dB A to 80 dB A Noise level is related to factors such as water flow rate pipe layout and the acoustical characteristics of the building Prolonged exposure to noise can cause permanent hearing loss Wear approved ear protection and control exposure time when operating or working near this equipment High pressure water can cause severe cuts or lac...

Page 45: ...s occurred Operator interface The operator interface is a controller for the pump and the intensifier A series of screens shows equipment status and permits the operator to operate the pump and the intensifier The operator interface is the standard controller for this pump Some original equipment manufacturers OEMs or system integrators might change the controller In these cases refer to the docum...

Page 46: ...e pump The REMOTE ACTIVE indicator light is on Most of the functions on the operator interface are disabled The pump off symbol is functional The EMERGENCY STOP button turns off the control circuit inside the pump When the EMERGENCY STOP button is pushed The control circuit turns off which turns off the pump the primary motor and the intensifier The bleed down valve opens and discharges water from...

Page 47: ...Y STOP button was pushed reset the button on the operation panel by turning it in the direction of the arrows clockwise until it pops out Turn on the pump The primary motor drives a primary hydraulic pump that moves hydraulic fluid through the intensifier and a gear pump that moves hydraulic fluid through the cooling loop In this section pump on means that the primary motor is running and the pump...

Page 48: ...key switch is set to LOCAL 2 Push the CONTROLS ON button 3 Turn the key switch to REMOTE 4 Refer to the OEM s instructions for turning the pump on WARNING Do not attempt to repair a leak with pressure in the system WARNING Use a piece of cardboard or other solid material to check for leaks when the pump is on Do not use hands cloth paper or towels WARNING Do not leave waterjet cutting equipment tu...

Page 49: ...rger than the maximum movement range of the cutting equipment s moving parts Where there is a risk of a collision do not permit people or equipment near the cutting equipment s moving parts Prevent accidental contact with the touchscreen or joystick on the computer numerical control CNC machine Accidental contact can cause unexpected operation Do not do maintenance repair or clean the machinery wh...

Page 50: ...ary motor and to enable the intensifier Pressure in the system increases until it reaches the setpoint When the pump is on the primary screen shows a stroking intensifier Primary screen Pump off Pump on Cooling mode on Motor off Intensifier disabled Motor on Intensifier enabled Hydraulic pump enabled Motor on Intensifier disabled Hydraulic pump enabled Pierce pressure mode Cut pressure mode 1 2 3 ...

Page 51: ...p without a proportional control valve use the pierce pressure control knob and the cut pressure control knob to adjust pressures manually Turn the knobs clockwise to increase pressure Turn the knobs anticlockwise to decrease pressure If the cut pressure mode setpoint is less than the pierce pressure mode setpoint the pump operates at the lower pressure When turning off the pump turn the cut press...

Page 52: ...minimum pressure is 551 58 bar 8 000 psi Intensifier and pump status indicator The examples in this section are for a pump with a redundant intensifier If the pump has 1 intensifier only 1 indicator is shown on the screen Intensifier and pump status indicators show the status of each pump and intensifier Green shows enabled status Red shows disabled status 1 2 3 4 1 Decrease pressure symbol 2 Pres...

Page 53: ...ws that the intensifier stroke rate is within the allowable range A yellow bar shows that the stroke rate is at the limit of the allowable range A red bar shows that the intensifier is overstroking For troubleshooting refer to the Stroking problems section which begins on page 159 Touch the status indicator to open the intensifier settings screen ...

Page 54: ...en Settings screen Intensifier settings Date and time settings Micro SD card System settings Model configuration Pressure adjustment Pierce pressure mode Cut pressure mode 1 2 3 4 1 Intensifier settings screen 2 Date and time settings screen 3 Pump settings screen 4 Micro SD card screen ...

Page 55: ...t on the screen Green shows enabled status Red shows disabled status Change the overstroke Do this task when the pump is running in cooling mode or is turned off 1 Touch the overstroke field to open a numeric keypad 2 Use the numeric keypad to change the overstroke percentage 3 Touch Enter to accept the change Do not set the value higher than 20 1 2 3 1 Enable or disable the intensifier 2 Enable o...

Page 56: ... time field to open a numeric keypad 2 Use the left and right arrows to highlight the hours minutes or seconds 3 Use the up and down arrows to increase or decrease the number 4 Touch Enter to accept the change 5 Use the same procedure to change the date Touch the date field to change the way the date is shown Options are day month year or month day year ...

Page 57: ... enabled the pump turns off after a specified time Idle Time without the intensifier stroking Idle Cooling When enabled the pump goes into cooling mode after a specified time Idle Time without the intensifier stroking Idle Time minutes Set the number of minutes for Idle Shutdown and Idle Cooling Analog Pressure Input Enable this when a remote 0 V to 10 V input is used to control the proportional v...

Page 58: ... be operated This is only applicable for pumps with a proportional control valve Inc Interval 1 sec Set the time between steps during ramping up when adjusting the pressure manually on the operator interface This is only applicable for pumps with a proportional control valve Dec Interval 1 sec Set the time between steps during ramping down when adjusting the pressure manually on the operator inter...

Page 59: ...Dec Amount PSI Set the increment for decreasing pressure The default value is 500 psi Init Jump Inc Dec Set the initial jump amount for increasing or decreasing pressure The default value is 500 psi Real Ramp Setpoint Set how quickly the pump ramps up to the specified pressure The higher the value the faster the pump ramps up The default value is 10 seconds ...

Page 60: ...usted on the primary screen refer to page 52 for more information The adjusted pressure is saved in the controller settings To adjust either pressure touch the applicable field on the operator interface and enter a value Modbus Mode When enabled the pump is controlled by Modbus TCP over Ethernet This is disabled for most applications Web Remote Enable Not used IP Address This information is requir...

Page 61: ... stores the current program and the alarm logging files Use this screen to see the contents of the micro SD card If the screen shows Removable Media in red the micro SD card is missing or damaged For more information about the micro SD card contact a Hypertherm Technical Service Associate for assistance ...

Page 62: ...pplicable symbol to move the intensifier to the left or to the right Doing maintenance on a high pressure end is much easier when the plunger is moved to that end Pumps without a redundant intensifier do not have the option to move the rear intensifier Maintenance log Touch the applicable area on the image of the pump Select the area where maintenance was performed Select each item and the reason ...

Page 63: ...o the maintenance log and is saved as a CSV file on the SD card Alarm log The alarm log shows recent alarms and when they occurred This can be helpful for troubleshooting 1 2 3 4 5 6 1 Part is leaking 2 Part is worn 3 Return to the maintenance options screen 4 General preventive maintenance 5 Part is cracked 6 Other reason ...

Page 64: ...than 65 C I4 Hydraulic fluid temperature is higher than 45 C l5 Supply water pressure is 40 psi or higher l6 Front intensifier left proximity switch l7 Front intensifier right proximity switch l8 Rear intensifier left proximity switch l9 Not used l10 Not used l11 Not used l12 Not used l13 Rear intensifier right proximity switch l14 Not used l15 Control on I16 Remote mode active l17 Remote pump on ...

Page 65: ...lem and the stack light blinks If this occurs refer to the Alarm screens section which begins on page 158 Q1 Enable pump pressure Q2 Not used Q3 Low pressure Q4 Pump run Q5 Fan motor on Q6 Enable bleed down valve Q7 Front left shift valve solenoid Q8 Front left shift valve solenoid Q9 Rear left shift valve solenoid Q10 Rear right shift valve solenoid Q11 Reset remote Q12 Primary motor on Q13 Boost...

Page 66: ...ump is off this enables the fan motor starter and turns on the primary motor the boost pump and the low pressure water When the motor is at operating speed the intensifier strokes in pierce pressure mode for a time that is set at the operator interface When the timer expires the intensifier strokes in cut pressure mode If the pressure control is set to pierce pressure mode the pump starts and stay...

Page 67: ...Turn OFF the cutting head 2 Touch the symbol on the operator interface to turn OFF the pump The bleed down valve opens and discharges water from the system Turn off the pump at the end of the day 1 Turn OFF the cutting head 2 Touch the symbol on the operator interface to turn OFF the pump The bleed down valve opens and discharges water from the system 3 Turn the cut pressure control knob anticlock...

Page 68: ...68 HyPrecision 50S 60S 75S Operator Manual 808690 4 Operation Operation ...

Page 69: ...s preventive and scheduled maintenance for HyPrecision pumps High quality equipment that is serviced on a schedule lasts longer than equipment that is not maintained regularly This maintenance includes but is not limited to adjustments cleaning lubrication repairs and replacement of parts Benefits of preventive maintenance Improves reliability Finds potential problems before they cause unplanned d...

Page 70: ...pressure streams and leaks Pressurized fluid can cause severe injuries Abrasive waterjets eject a mixture of water and abrasive materials that can be injected into body tissues leading to a serious infection Get immediate surgical attention after contact with high pressure stream of fluid WARNING Personal protective equipment is recommended Failure to wear personal protective equipment can cause i...

Page 71: ... for recycling or disposal of parts and materials Refer to Recycling and end of product life on page 146 Some materials produce airborne contaminants or suspended particles when cut Wear approved respiratory protection Do not operate the pump without the shaft access cover and all other safety devices in position Do not remove guards while the pump is running Follow all safety requirements and app...

Page 72: ...ment for leaks or damage page 75 Electrical system page 76 Make sure that the emergency stop button works page 76 Examine cords and plugs for deterioration or damage page 76 Hydraulic system page 77 Check the hydraulic fluid indicator page 77 Check the hydraulic fluid level page 78 Check the hydraulic fluid quality page 80 Measure the hydraulic fluid temperature page 81 Replace the hydraulic filte...

Page 73: ...al backups page 114 Replace the hydraulic rod seals page 114 Replace the seal housing O rings page 114 Replace the seal housing O ring backups page 114 Replace the high pressure hoops page 117 Replace the high pressure water seals page 117 Replace the check valve O rings page 117 Replace the low pressure poppets page 117 Replace the high pressure poppet assemblies page 124 Replace the check valves...

Page 74: ...needed for preventive maintenance on this equipment High pressure water system Bleed down valve page 129 Examine the bleed down valve for leaks or damage page 129 Repair the bleed down valve page 130 Replace the bleed down valve body page 140 Open ended wrench Crowfoot wrench Dental pick Seal housing removal tool included in the 12084 HyPrecision standard tool kit Seal installation tools included ...

Page 75: ... 4 Examine the weep holes and leak points at both of the high pressure ends for leaks Water seeping from a weep hole is a sign of a faulty part a loose connection or a damaged connection Identify the source of a leak and correct the problem Refer to Leaks on page 163 WARNING Do not touch a hot surface Fittings can get hot especially when they are not tightened properly CAUTION Failure to correct t...

Page 76: ...es water from the system The CONTROLS ON button indicator light turns off Examine cords and plugs for deterioration or damage Do this task when the pump is not running 1 Examine electrical cords for kinks or damage to the insulation 2 Examine electrical plugs and other electrical connectors for corrosion or damage Service Interval Make sure that the emergency stop button works Examine cords and pl...

Page 77: ...ting temperature Replace the filter after every 1 500 hours of operation or when the white indicator bar stays in the red zone while the pump is running at operating temperature Refer to page 83 for instructions Service Interval Check the hydraulic fluid indicator Before every work shift Replace the hydraulic filter page 83 After every 1 500 hours of operation 1 2 1 White indicator bar 2 Red zone ...

Page 78: ...ic fluid level Before every work shift DANGER People who maintain and repair this equipment can be injured or killed if hazardous energy is not properly controlled Injuries can include burns cuts fractures or electrocution Turn off electrical power and relieve all water and hydraulic pressure from the pump before starting maintenance or repairs Disconnect and lock out or tag out the electrical mai...

Page 79: ...s task when the pump is not running 1 Make sure that the drain valve is closed 2 Remove the filler breather cap on top of the tank 3 Fill the tank with hydraulic fluid until the fluid is at the top mark on the sight gauge 4 Install the original filler breather cap Do not overfill the hydraulic fluid tank ...

Page 80: ... cuts fractures or electrocution Turn off electrical power and relieve all water and hydraulic pressure from the pump before starting maintenance or repairs Disconnect and lock out or tag out the electrical main before opening the electrical enclosure or doing maintenance or repair procedures Refer to page 97 for additional information DANGER People who work on deenergized machinery can be serious...

Page 81: ... a large flat surface on the tank The optimum operating temperature for hydraulic fluid in this system is 40 6 C 105 F to 46 1 C 115 F If the temperature is outside of this range adjust the hydraulic fluid temperature Refer to page 82 for instructions CAUTION Keep the hydraulic fluid temperature in the hydraulic fluid tank between 37 8 C 100 F and 51 7 C 125 F Hydraulic fluid that is too hot can d...

Page 82: ...the chiller Close the valve on the cooling water line to decrease the cooling water flow 2 Wait approximately 5 minutes to let the hydraulic fluid temperature stabilize 3 Check the temperature 4 Repeat this procedure until the temperature is in range Water cooled system with a water modulating valve 1 Turn the screw on the top of the water modulating valve 1 2 turn to the left anticlockwise to inc...

Page 83: ...s energy is not properly controlled Injuries can include burns cuts fractures or electrocution Turn off electrical power and relieve all water and hydraulic pressure from the pump before starting maintenance or repairs Disconnect and lock out or tag out the electrical main before opening the electrical enclosure or doing maintenance or repair procedures Refer to page 97 for additional information ...

Page 84: ... the water fittings Follow local regulations when disposing of used fluids and filters Install a new hydraulic filter and filler breather cap when replacing the hydraulic fluid Service Interval Replace the hydraulic filter After every 1 500 hours of operation Replace the hydraulic fluid and the suction strainers After every 3 000 hours of operation 1 2 3 5 4 1 Filler breather cap 2 Sight gauge 3 A...

Page 85: ...ench or socket drain valve plug Standard 3 4 inch crowfoot wrench or socket access cover Torque wrench Strap wrench or adjustable pliers Hose or pipe for draining hydraulic fluid Container for used hydraulic fluid Recommended materials Clean funnel Do this task when the pump is not running 1 Remove the drain valve plug 2 Open the drain valve lever on the bottom of the hydraulic fluid tank Use a ho...

Page 86: ... hoses Refer to the Torque values section which begins on page 181 10 Close the drain valve 11 Install the drain valve plug 12 Replace the access cover on the tank Torque the nut to 27 N m 20 lbf ft 13 Remove the used filler breather cap 14 Fill the tank with hydraulic fluid Make sure that the hydraulic fluid level is at the top mark on the sight gauge 15 Install the new filler breather cap 16 Dis...

Page 87: ...c fluid Fill the tank until the fluid is at the top mark on the sight gauge Repeat this process as needed 19 Run the pump in pierce pressure mode for 15 to 20 minutes If air enters the hydraulic system the pump becomes noisy during operation Refer to Noisy operation on page 171 WARNING Do not attempt to repair a leak with pressure in the system WARNING Use a piece of cardboard or other solid mater...

Page 88: ...si Do this task when the pump is running Subtract the value shown on the postfilter water pressure from the value shown on the prefilter water pressure Replace the filters if the difference between the values on the pre and the postfilter water pressure gauges is higher than 0 69 bar or 68 95 kPa 10 psi Service Interval Check the low pressure water pressure gauges Before every work shift Replace t...

Page 89: ...pump 2 Open the water valve to drain the water from the system Make sure that the water pressure gauges show 0 0 bar or 0 kPa 0 psi 3 Remove the valve stem cap from the water accumulator tank 4 Use an air pressure gauge to measure the pressure in the tank The optimum air pressure is 2 07 bar or 206 84 kPa 30 psi Service Interval Measure the air pressure in the water accumulator tank After every 50...

Page 90: ... air to increase the pressure in the tank To reduce pressure in the tank push on the valve stem to release air 6 Repeat this procedure until the pressure is 2 07 bar or 206 84 kPa 30 psi 7 Install the original valve stem cap 8 Close the water valve 9 Turn ON the water to the pump Water valve in the closed position ...

Page 91: ... tool kit Recommended materials Bucket or pail Do this task when the pump is not running 1 Turn OFF the water to the pump 2 Open the water valve to drain the water from the system Make sure that the water pressure gauges show 0 0 bar or 0 kPa 0 psi 3 Use a filter wrench to loosen each of the filter housings CAUTION Failure to correct the cause of a leak can cause damage to the water fittings Repla...

Page 92: ...artridge in the 1 micron filter housing and the 10 micron filter housing The 1 micron and the 10 micron filters do not have a designated top or bottom 8 Install the filters and the housings with the 10 micron water filter nearest to the water valve 9 Discard the used parts 10 Use a filter wrench to tighten each of the filter housings 11 Close the water valve 12 Turn ON the water to the pump 13 Tur...

Page 93: ... mode 16 Make sure that the difference between the values on the pre and the postfilter water pressure gauges is less than 0 69 bar or 68 95 kPa 10 psi 17 Monitor for leaks Identify the source of a leak and correct the problem Refer to Leaks on page 163 WARNING Do not attempt to repair a leak with pressure in the system WARNING Use a piece of cardboard or other solid material to check for leaks wh...

Page 94: ...Clean deionized water or filtered water Do this task when the pump is running in cooling mode 1 Open the water valve to drain the water from the system Make sure that the water pressure gauges show 0 0 bar or 0 kPa 0 psi 2 Let the water run for 30 seconds 3 Take a sample from the wastewater outlet If the wastewater outlet is not accessible take a sample of the supply water going into the pump Serv...

Page 95: ...rsion level 5 cm 2 inches Tap the meter gently to release air bubbles 5 Wait approximately 20 seconds for the reading to become stable 6 Compare the reading to the TDS table on page 189 in the Installation section of this manual 7 Rinse the meter in clean deionized water or filtered water after use The meter is not waterproof Do not submerge the unit in water ...

Page 96: ...ntive maintenance on both ends of the intensifier at the same time 1 2 4 5 8 10 12 11 15 3 16 5 6 6 7 9 13 14 1 High pressure end cap and stud nuts 2 Output adapter 3 High pressure poppet assembly 4 Check valve assembly 5 High pressure hoops 6 High pressure water seals 7 Low pressure poppet 8 Low pressure poppet basket 9 Spacer tube 10 High pressure cylinder 11 High pressure seal backup 12 Seal ho...

Page 97: ...n startup or release of stored energy This energy can be from electrical hydraulic fluid or water sources Before doing a service or maintenance the following steps must be done in sequence 1 Turn off the machine 2 Disconnect or isolate the machine from the energy source s Refer to the specific provisions of the employer s energy control procedure 3 Apply the lock out and tag out devices to the ene...

Page 98: ... when the plunger is moved to that end Pumps without a redundant intensifier do not have the option to move the rear intensifier 4 Turn OFF the pump 5 Turn OFF power from the primary utility source Use standard lock out tag out procedures Refer to page 97 for more information 6 Turn OFF the water to the pump The pump must be in cooling mode to use this feature 4 5 3 1 2 1 Move the front intensifie...

Page 99: ...water from the system Make sure that the water pressure gauges show 0 0 bar or 0 kPa 0 psi 8 Disconnect the high pressure water line from the intensifier 9 Disconnect the hose from the low pressure water fitting on the high pressure end cap 2 3 1 1 Water valve in the open position 2 Prefilter water pressure 3 Postfilter water pressure ...

Page 100: ...de the high pressure poppet seat out of the check valve Tap the output adapter gently on a wooden or other soft surface to eject the poppet from the output adapter 3 Clean each part with a lint free towel and isopropyl alcohol Examine all parts for deterioration corrosion or damage Repair or replace parts identified in the preventive maintenance schedule or if the parts show deterioration corrosio...

Page 101: ... towels Isopropyl alcohol Square drive socket 1 1 2 inch 3 4 inch included in the 12084 HyPrecision standard tool kit 1 Remove the stud nuts 2 Pull the high pressure end cap off 3 Clean each part with a lint free towel and isopropyl alcohol Examine all parts for deterioration corrosion or damage Do not use soap detergent or solvents 1 2 3 1 Studs 2 Stud nuts 3 High pressure end cap ...

Page 102: ...epair the high pressure cylinders page 109 Replace the check valve O rings Replace the high pressure hoops Replace the high pressure water seals Replace the low pressure poppets After every 1 000 hours of operation Replace the check valves After every 2 000 hours of operation Replace the low pressure poppet baskets Replace the high pressure cylinders After every 3 000 hours of operation or if the ...

Page 103: ...d tap on the end of the push tool with a rubber mallet to push the bottom seal and the hoop out of the high pressure cylinder 6 Turn the cylinder over and put it on the locating ring Prevent the spacer tube from sliding out when the cylinder is turned over 7 Put the nonstepped end of the push tool against the spacer tube and tap on the end of the push tool with a rubber mallet to push the seal and...

Page 104: ...ch hex wrench seal housing removal tool Two 8 32 2 inch or longer socket head cap screws plunger bearing Recommended materials Dental pick or similar tool Service Interval Replace the high pressure seal backups After every 500 hours of operation Replace the hydraulic rod seals Replace the seal housing O rings Replace the seal housing O ring backups Replace the plunger bearings After every 3 000 ho...

Page 105: ...nger If the rod seal does not come out of the hydraulic end cap with the seal housing use a dental pick or a similar tool to pry it out Be careful to not scratch the plunger 4 Remove the high pressure seal backup and the O ring from the seal housing 5 Install 2 socket head cap screws in the threaded holes in the plunger bearing Use the screws to pull the plunger bearing out of the hydraulic end ca...

Page 106: ...eing replaced remove them from the indicator pin cap 4 Remove the spring from the indicator pin 5 Remove the indicator pin from the indicator pin hole in the hydraulic end cap 6 Clean each part with a lint free towel and isopropyl alcohol Examine all parts for deterioration corrosion or damage Service Interval Replace the indicator pin spring After every 3 000 hours of operation Replace the indica...

Page 107: ... included in the 12084 HyPrecision standard tool kit Clean lint free towels Isopropyl alcohol Masking tape 1 Tape a sheet of lapping paper on a granite surface block Make sure that the paper is smooth and flat For best results start with the 12 micron lapping paper and finish with the 15 micron lapping paper 2 Put the check valve or poppet face flat on the lapping paper and slide it back and forth...

Page 108: ...Preventive maintenance 3 After each stroke rotate the flat face of the part 45 degrees 4 Repeat this procedure until the face is smooth and flat and has a nearly mirrored finish 5 Clean each part with a lint free towel and isopropyl alcohol Do not use soap detergent or solvents ...

Page 109: ...oth and then with a nonstick scouring pad 3 Examine the edges of the cylinder bore If the bore has rough edges or burrs rub the defects with an emery cloth 4 Cut the nonstick scouring pad in half Put half of the pad in each end of the cylinder Put 1 thumb in each end of the cylinder on top of the pad and push down Push evenly on the pad while rolling the cylinder forward and backward 5 Fold or cut...

Page 110: ...into the ends of the cylinder with the abrasive side touching the cylinder 7 Repeat the rolling procedure with the lapping paper 8 Clean the inside of the cylinder with a lint free towel and isopropyl alcohol CAUTION Debris left in the cylinder can cause the seals or the poppets to fail Do not use soap detergent or solvents ...

Page 111: ...ervice Associate for information and support regarding the installation operation maintenance and repair of this equipment CAUTION Overtightening a fitting can cause it to fail Use 2 wrenches when loosening or tightening a high pressure connection Using only 1 wrench can increase bending stress to the parts and cause damage or premature failure Review the Safety section which begins on page 70 Exa...

Page 112: ...bit socket 1 Put the indicator pin into the indicator pin hole in the hydraulic end cap Turn the pin so that the offset post goes into the aperture at the back of the hole 2 Put the spring on the indicator pin 3 Put the O ring backup on the indicator pin cap 4 Put a small quantity of hydraulic fluid on the O ring 5 Put the O ring on the indicator pin cap Service Interval Replace the indicator pin ...

Page 113: ... Preventive maintenance Preventive maintenance 6 Put the indicator pin cap into the hydraulic end cap 7 Put antiseize bolt lubricant white lithium grease on the cap screws 8 Put the lock washers on the cap screws Torque the cap screws to 10 N m 8 lbf ft ...

Page 114: ... system if the weep holes in the dynamic seal backup or the seal housing are blocked Make sure that the weep holes are free of debris while doing maintenance on the intensifier Service Interval Replace the high pressure seal backups After every 500 hours of operation Replace the hydraulic rod seals Replace the seal housing O rings Replace the seal housing O ring backups Replace the plunger bearing...

Page 115: ... the narrow end of the seal housing The seal housing O ring backup has a flat side and a concave side Make sure the flat side of the O ring backup faces the wide end of the seal housing The O ring fits into the concave groove on the O ring backup 4 Put the plunger bearing on the plunger and push it into the hydraulic end cap 5 Put a small quantity of clean hydraulic fluid on the inside and the out...

Page 116: ...rod seal into the seal housing 10 Turn the seal housing so that the weep hole faces down 11 Push the seal housing tightly against the plunger bearing 12 Turn the high pressure seal backup so that 1 weep hole is in line with the seal housing weep hole 13 Put the high pressure seal backup on the plunger and push it against the seal housing 14 Make sure that the bottom weep holes are aligned 15 If th...

Page 117: ...500 hours of operation Repair the high pressure cylinders page 109 Replace the check valve O rings Replace the high pressure hoops Replace the high pressure water seals Replace the low pressure poppets After every 1 000 hours of operation Replace the check valves After every 2 000 hours of operation Replace the low pressure poppet baskets Replace the high pressure cylinders After every 3 000 hours...

Page 118: ...tube 11522 High pressure cylinder High pressure antiseize lubricant such as Blue Goop or AccuGoop Seal installation tools refer to Tools on page 74 Rubber mallet 1 Put the seal installation spacer tool on a clean dry oil free surface 2 Put the high pressure cylinder over the spacer tool so that the tool fits in the cylinder bore 3 Put the low pressure poppet into the low pressure poppet basket Mak...

Page 119: ...5 Put the spacer tube into the high pressure cylinder 6 Put the seal installation locator tool on top of the cylinder 7 Put the seal installation sleeve in the locator tool with the flat opening toward the cylinder The beveled opening faces up 8 Put a small quantity of high vacuum grease on the red O ring Keep the poppet and the poppet basket clean Grease can cause the poppet to stick ...

Page 120: ...eal 10 Put the high pressure water seal into the insertion sleeve with the red O ring toward the cylinder 11 Put the push tool into the insertion sleeve with the stepped end up Apply even pressure while holding the sleeve tightly against the cylinder 12 Remove the push tool from the insertion sleeve 13 Make sure that the seal is installed in the cylinder correctly ...

Page 121: ...inder If the edges are not even with the surface of the cylinder put the nonstepped end of the push tool on the hoop and tap the push tool with a rubber mallet 18 Put the end of the check valve into the seal Tap on the small end of the check valve with a rubber mallet until it is touching the cylinder end 19 Turn the cylinder over so the check valve is on the bottom Put 1 hand under the bore at th...

Page 122: ...ch 12091 Torque wrench 3 4 inch drive 60 lbf ft to 300 lbf ft included in the 12084 HyPrecision standard tool kit Square drive socket 1 1 2 inch 3 4 inch included in the 12084 HyPrecision standard tool kit CAUTION Overtightening a fitting can cause it to fail Use 2 wrenches when loosening or tightening a high pressure connection Using only 1 wrench can increase bending stress to the parts and caus...

Page 123: ...t lubricant white lithium grease on the stud threads 3 Hand tighten the nuts on the studs Put the smooth side of the nut toward the high pressure end cap 4 Torque the stud nuts to 373 N m 275 lbf ft Tighten each nut in 68 N m 50 lbf ft increments using a repeating cross pattern until the recommended torque is reached 5 Connect the low pressure water line 6 Torque the low pressure water fitting to ...

Page 124: ...cuGoop 1 inch crowfoot wrench or socket 13 16 inch open ended wrench or socket Torque wrench CAUTION Overtightening a fitting can cause it to fail Use 2 wrenches when loosening or tightening a high pressure connection Using only 1 wrench can increase bending stress to the parts and cause damage or premature failure Service Interval Replace the high pressure poppet assemblies After every 1 000 hour...

Page 125: ... antiseize lubricant in the check valve 5 Put high pressure antiseize lubricant on the threads of the output adapter 6 Put the high pressure poppet spring and the high pressure poppet in the output adapter 7 Put the output adapter in the check valve and tighten it by hand 8 Torque the output adapter to 41 N m to 47 N m 30 lbf ft to 35 lbf ft CAUTION Tightening the output adapter with the poppet in...

Page 126: ...aintenance 9 Put high pressure antiseize lubricant on the high pressure connector threads 10 Connect the high pressure water line Make sure that a few of the threads on the high pressure tubing are visible 11 Torque the high pressure water fitting to 41 N m to 47 N m 30 lbf ft to 35 lbf ft ...

Page 127: ...c filter 1 11105 Water filter cartridge 0 45 micron 10 inch 1 11106 Water filter cartridge 1 0 micron 10 inch 1 11107 Water filter cartridge 10 micron 10 inch 1 15564 6 inch cotton tipped applicator 2 Part number Description Quantity 11610 High pressure seal backup bronze 2 11090 Hydraulic rod seal 1 inch 2 11680 035 Seal housing O ring backup 035 2 11679 035 Seal housing O ring 035 2 11018 High p...

Page 128: ...reventive maintenance Other parts Part number Description 11210 30 Lapping paper 30 micron 11518 Indicator pin 11609 Seal housing 11608 Plunger bearing 11520 Low pressure poppet basket 11523 Check valve assembly 11521 Spacer tube 11522 High pressure cylinder 11530 Output adapter ...

Page 129: ...y the source of a leak and correct the problem Refer to Leaks on page 163 CAUTION Failure to correct the cause of a leak can cause damage to the water fittings Service Interval Examine the bleed down valve for leaks or damage Every work shift WARNING Do not attempt to repair a leak with pressure in the system WARNING Use a piece of cardboard or other solid material to check for leaks when the pump...

Page 130: ...the bleed down valve After every 1 000 hours of operation or if water leaks from the wastewater outlet or from the weep holes while the pump is running 1 7 6 9 8 11 15 14 12 10 4 3 13 2 5 1 O ring boss adapter 2 SAE O ring 3 Hydraulic piston 4 Piston O ring 5 Piston O ring backup 6 Actuator housing 7 Seal backup screw 8 Needle 9 Needle bushing 10 Seal hoop 11 High pressure seal 12 Valve body 13 Hi...

Page 131: ...drain the water from the system Make sure that the water pressure gauges show 0 0 bar or 0 kPa 0 psi 3 Use 2 wrenches to remove the hydraulic hose from the hydraulic hose fitting 4 Use 2 wrenches to remove the high pressure water fitting from the valve body 5 Use 2 wrenches to remove the output adapter from the 3 8 inch gland nut 1 3 4 2 1 Hydraulic hose 2 Hydraulic hose fitting 3 High pressure wa...

Page 132: ...gh pressure antiseize lubricant such as Blue Goop or AccuGoop Clean lint free towels Isopropyl alcohol Do this task when the pump is not running 1 Use 2 wrenches to remove the O ring boss adapter from the actuator housing 2 Replace the SAE O ring on the O ring boss adapter Put O ring lubricant on the O ring The SAE O ring and the piston O ring look almost the same The SAE O ring is thinner than th...

Page 133: ...necessary 7 Put O ring lubricant on the new piston O ring backup Roll the backup into the short end of the hydraulic piston The piston O ring backup has a flat side and a concave side Make sure the flat side of the piston O ring backup faces the short end of the hydraulic piston 8 Put O ring lubricant on the piston O ring and roll it over the long end of the hydraulic piston The piston O ring fits...

Page 134: ...ntive maintenance 9 Put the hydraulic piston in the actuator housing 10 Push the hydraulic piston into position with a wooden dowel 11 Use 2 wrenches to remove the outlet adapter from the valve body 12 Remove the high pressure poppet seat and the flow reducer from the outlet adapter ...

Page 135: ... the seal backup screw from the valve body 14 Use a wooden dowel to push the parts through the valve body 15 Clean each part with a lint free towel and isopropyl alcohol Examine all parts for deterioration corrosion or damage 16 Discard the used parts 17 Put high vacuum grease on the new needle Do not use soap detergent or solvents ...

Page 136: ... backup screw 19 Put the needle bushing on the needle The chamfered end of the needle bushing goes toward the seal backup screw 20 Put the seal hoop on the high pressure seal The tapered edge is toward the high pressure seal 21 Put the high pressure seal assembly on the needle The hoop goes toward the needle bushing 22 Put high vacuum grease on the outside of the needle assembly Chamfered end Tape...

Page 137: ...e Preventive maintenance 23 Put the needle assembly in the valve body 24 Push on the seal backup screw until it stops 25 Remove the seal backup screw Put high pressure antiseize lubricant on the threads 26 Use a socket wrench to tighten the seal backup screw in the valve body ...

Page 138: ...in the outlet adapter 28 Put high pressure antiseize lubricant on the outside threads and in the poppet seat cavity 29 Put the poppet seat in the seat cavity of the outlet adapter 30 Put high pressure antiseize lubricant on the surface of the poppet seat 31 Turn the outlet adapter into the valve body until it is hand tight ...

Page 139: ...or housing into the valve body until it is hand tight 33 Use 2 wrenches to tighten the outlet adapter and the actuator housing into the valve body 34 Use 2 wrenches to tighten the O ring boss adapter in the actuator housing 35 Install the bleed down valve Refer to Install the bleed down valve which begins on page 140 ...

Page 140: ...ssure antiseize lubricant such as Blue Goop or AccuGoop CAUTION Failure to correct the cause of a leak can cause damage to the water fittings Service Interval Repair the bleed down valve page 130 After every 1 000 hours of operation or if water leaks from the wastewater outlet or from the weep holes while the pump is running Replace the bleed down valve body After every 3 000 hours of operation 1 ...

Page 141: ... outlet adapter into the 3 8 inch gland nut 3 Put high pressure antiseize lubricant on the outside threads of the high pressure water fitting 4 Use 2 wrenches to tighten the high pressure water fitting in the valve body 5 Replace the hydraulic fitting SAE O ring on the hydraulic hose fitting Put O ring lubricant on the O ring 6 Use 2 wrenches to tighten the hydraulic hose fitting in the O ring bos...

Page 142: ...section which begins on page 181 9 Close the water valve 10 Turn ON the water to the pump Monitor for leaks Identify the source of a leak and correct the problem Refer to Leaks on page 163 Water valve in the closed position WARNING Do not attempt to repair a leak with pressure in the system WARNING Use a piece of cardboard or other solid material to check for leaks when the pump is on Do not use h...

Page 143: ...1 11679 114 Piston O ring 114 1 11680 114 Piston O ring backup 114 1 12942 Needle 1 11324 Needle bushing 1 11323 Seal hoop 1 11321 High pressure seal 1 11141 High pressure poppet seat 1 11743 Flow reducer 1 16123 Wooden dowel 1 11447 High vacuum grease 5 oz 1 Part number Description 11796 O ring boss adapter 11778 Hydraulic piston 11779 Actuator housing 12945 Seal backup screw 12943 Bleed down val...

Page 144: ... specific provisions of the employer s energy control procedure Inspect machines and parts to make sure that they are operationally intact and that nonessential items are removed from the area Make sure that everyone is safely away from machines After removing the lock out or tag out devices but before reenergizing the machine the make sure that all workers in the area of the equipment know that t...

Page 145: ...nsifier to stroke for a few minutes to make sure that the seals are installed properly 12 Turn OFF the cutting head Monitor for leaks Identify the source of a leak and correct the problem Refer to Leaks on page 163 13 Increase the pump pressure to the desired pierce pressure mode setpoint 14 Touch the cut pressure mode symbol The intensifier strokes until the pump reaches the cut pressure setting ...

Page 146: ...ntally satisfactory method and in accordance with local regulations If the product contains substances that are harmful to the environment remove and dispose of them in accordance with current local regulations This includes liquids such as hydraulic fluid Make sure that hazardous substances are disposed of safely and that the correct personal protective equipment is used The safety specifications...

Page 147: ...ntive maintenance Preventive maintenance Preventive maintenance records Problem found 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 148: ... Preventive maintenance Preventive maintenance Problem found 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 Date Hours Initials ...

Page 149: ...lacement parts for this pump The Hypertherm warranty might not cover damage caused by using nongenuine Hypertherm parts To order parts contact the original equipment manufacturer OEM or Hypertherm Inc 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 150: ...ion sleeve 11812 Seal installation push tool 12932 Seal installation spacer tool 11985 Seal housing removal tool 12019 Hex driver 3 4 inch 13 1 2 inch 12020 Deep square drive socket 3 4 inch 3 4 inch 12021 Square drive socket 1 1 2 inch 3 4 inch 12091 Torque wrench 3 4 inch drive 60 lbf ft to 300 lbf ft 13972 Filter wrench 13281 Granite lapping block 22 86 cm 30 48 cm 5 08 cm 9 inch 12 inch 2 inch...

Page 151: ...ator pin O ring backup 013 2 15564 6 inch cotton tipped applicator 2 11105 Water filter cartridge 0 45 micron 10 inch 1 11106 Water filter cartridge 1 0 micron 10 inch 1 11107 Water filter cartridge 10 micron 10 inch 1 16025 Hydraulic filter 1 Part number Description Quantity 11018 High pressure hoop 1 inch 4 11024 High pressure water seal 1 inch 4 11447 High vacuum grease 5 oz 1 11610 High pressu...

Page 152: ...tity 11141 High pressure poppet seat 1 12942 Needle 1 11321 High pressure seal 1 11323 Seal hoop 1 11324 Needle bushing 1 12880 908 Hydraulic fitting SAE O ring 1 12880 912 Hydraulic fitting SAE O ring 1 11679 114 Piston O ring 114 1 11680 114 Piston O ring backup 114 1 11743 Flow reducer 1 16123 Wooden dowel 1 11447 High vacuum grease 5 oz 1 ...

Page 153: ...ressure collar 3 8 inch 13158 60 4 High pressure gland nut 1 4 inch 13158 60 6 High pressure gland nut 3 8 inch Electrical system Part number Description 11670 Proximity switch 11518 Indicator pin 11519 Indicator pin cap 11798 Split support ring Hydraulic system Part number Description 16025 Hydraulic filter 12438 Suction strainer 1 1 2 inch 11960 Suction strainer 2 1 2 inch 14629 Filler breather ...

Page 154: ...pressure water system Part number Description 12280 Attenuator assembly 1 liter 11595 Attenuator assembly 2 liter 12943 High performance bleed down valve body 13384 Low pressure seal kit 12579 Protective sheathing 1 4 inch 12580 Protective sheathing 3 8 inch 14688 Sheathing end cover 1 4 inch high pressure tubing 14687 Sheathing end cover 3 8 inch high pressure tubing Intensifier high pressure end...

Page 155: ... Parts lists Parts lists Intensifier hydraulic center section 11508 Piston 11673 Piston seal 11674 Wear ring 11593 Plunger retainer 11675 T seal plunger coupler 11672 Nut grade 8 1 inch 14 11310 Retaining ring 11502 Hydraulic cylinder 11554 Nut threaded ...

Page 156: ...let Full set of standard crowfoot wrenches or sockets Two 8 32 2 inch or longer socket head cap screws 1 8 inch hex wrench Infrared or other type of external reading thermometer 5 32 inch hex wrench or hex bit socket Air pressure gauge Schrader valve Adjustable wrench Compressed air source Torque wrench Dental pick or similar tool recommended Strap wrench or adjustable pliers Materials 11210 30 30...

Page 157: ...h pressure parts with clean hands Before reassembling high pressure or hydraulic parts clean the parts to remove dirt and other contaminants Refer to the instruction manual Read and understand all of the safety guidelines in this manual DANGER Dangerous voltage To reduce the risk of serious injuries or death wear approved protection and follow safety recommendations when working with electricity W...

Page 158: ...ill showing after the alarm condition is corrected touch FAULT RESET on the screen This clears the fault and permits the pump to be restarted Not all pump functions are monitored by the controller The alarm log shows recent alarms and when they occurred This can be helpful for troubleshooting The pump will not start If the pump does not start or does not increase pressure check these possible caus...

Page 159: ...e broken or an indicator pin might be stuck Inspect all parts to find the cause of the fault Examine the cord ends on the proximity switches for damage Make sure that the indicator pins and springs are not damaged The intensifier strokes to 1 side and then stalls on the same side Take these actions Exchange the proximity switches with each other but not the wires Replace the proximity switches Exa...

Page 160: ...ration erosion marks or cracks in the parts including the check valve and piston seal The intensifier is overstroking The intensifier usually strokes smoothly to the left and to the right at the same speed An overstroke fault occurs when the hydraulic piston travels faster in 1 or both directions than the waterjet pump can support The intensifier usually strokes faster during startup and when chan...

Page 161: ...ve Replace the needle and the seat The low pressure water relief valve is venting water to the drain Remove the 3 8 inch tubing from the valve at the outlet fitting and monitor for leaks Contact a Hypertherm Technical Service Associate for assistance The postfilter water pressure gauge shows that the low pressure water is at less than 2 76 bar or 275 79 kPa 40 psi If the difference between the val...

Page 162: ...he check valve Make sure that the faces are smooth and flat and have a nearly mirrored finish Repair or replace the poppet Make sure that the low pressure poppet fits in the basket without sticking Repair or replace the check valve A high pressure poppet is sticking worn or damaged Overstroking to the left means that there is a failure of the high pressure poppet on the right side of the intensifi...

Page 163: ... with each stroke means that the seals in that high pressure cylinder should be changed at the first opportunity Weep holes throughout the high pressure water system let water escape from leaking parts A leak can mean that there is a faulty part a loose fitting or a damaged seat Water can enter the hydraulic system if the weep holes in the dynamic seal backup or the seal housing are blocked Make s...

Page 164: ...necessary to drain and flush out other areas such as the shift valve the hydraulic manifolds and the hydraulic pump Water leak from Possible cause Output adapter weep hole A fitting on the high pressure water tubing is not tight enough The tubing end is cracked or damaged The output adapter has failed High pressure seat weep hole The output adapter is loose The high pressure poppet seat has failed...

Page 165: ...e cylinder and plunger Make sure that the water quality is within satisfactory ranges Refer to the Water quality section which begins on page 188 Examine the ends of the high pressure cylinder for cracks Replace the high pressure water seals and hoops Check the air pressure in the water accumulator tank Refer to page 89 for instructions Replace the high pressure cylinder If the high pressure seal ...

Page 166: ... C 131 F and 1 switch opens at 65 0 C 149 F The optimum operating temperature for hydraulic fluid in this system is 40 6 C 105 F to 46 1 C 115 F If the temperature is outside of this range adjust the hydraulic fluid temperature Refer to page 82 for instructions High altitude and high ambient temperatures can affect the temperature of hydraulic fluid Fluid that is too cool is thick and causes incre...

Page 167: ...erload or the fan motor starter unless instructed to do so by a Hypertherm Technical Service Associate The ambient temperature is too high Consider supplemental cooling The fan is not generating enough airflow Make sure that the fan motor breaker is not tripped The air cooler fins are dirty or clogged The thermal overload device on the fan motor starter inside the electrical enclosure turned off t...

Page 168: ...n the setpoint the monitoring circuit opens and causes a fault A pressure switch after the water filters senses the water pressure to the intensifier A sustained pressure of less than 2 76 bar or 275 79 kPa 40 psi causes the pump to turn off This protects the equipment from running without enough pressure to the intensifier Check the water flow While the pump is running loosen a brass fitting afte...

Page 169: ...nticlockwise to 0 2 Turn the knob clockwise to the on position Pressure is lost because of a leak Identify the source of a leak and correct the problem Refer to Leaks on page 163 If the intensifier strokes when it is in cut pressure mode with the cutting head turned off check the bleed down valve and the high pressure tubing for leaks A low pressure poppet is sticking worn or damaged Examine the f...

Page 170: ... valve before the filter assembly reduces the risk of damage This relief valve is set to 8 27 bar 827 37 kPa 120 psi at the factory and should not be adjusted Possible cause Solution The boost pump is not needed If the value on the prefilter water pressure gauge is higher than 4 83 bar or 482 63 kPa 70 psi turn OFF the boost pump 1 In the electrical cabinet turn the switch on the boost pump motor ...

Page 171: ...g Examine the electrical enclosure for loose or damaged wiring Noisy operation If air enters the hydraulic system the pump becomes noisy during operation Use a 13 mm socket or wrench to tighten both hose clamps on the suction hose that goes from the hydraulic fluid tank to the bottom of the primary hydraulic pump The manufacturer recommends tightening the hose clamps to a maximum of 30 N m 22 lbf ...

Page 172: ...172 HyPrecision 50S 60S 75S Operator Manual 808690 7 Troubleshooting Troubleshooting ...

Page 173: ...specifications This section includes details about the pump including this information Power and water specifications and orifice sizes for each pump model Physical qualities such as dimensions weight and capacity Recommended operating conditions Information about fasteners and fittings ...

Page 174: ... reduces the efficiency of the heat exchanger Type Antiwear AW mineral oil or synthetic hydraulic fluid ISO viscosity grade VG 32 or 46 Tank capacity 151 L 40 gallons Maximum temperature 54 4 C 130 F Maximum pressure Hydraulic pump pressure limit set at the factory 217 18 bar or 21 718 kPa 3 150 psi Minimum Maximum Relative humidity 95 Storage temperature Water not drained 1 7 C 35 F Ambient opera...

Page 175: ...26 0 A 62 0 A Primary circuit breaker rating 80 0 A 150 0 A 80 0 A 50 Hz 60 Hz CUTTING WATER IN Minimum Maximum Flow 7 6 L minute 2 gallons minute Pressure 2 76 bar or 275 79 kPa 40 psi 7 93 bar or 792 90 kPa 115 psi CUTTING WATER OUT Flow 3 8 L minute 1 gallon minute 4 1 L minute 1 07 gallons minute Pressure 551 58 bar or 55 158 kPa 8 000 psi 4 136 85 bar or 413 685 kPa 60 000 psi Continuous pres...

Page 176: ...S Operator Manual 808690 8 Pump specifications Pump specifications This model supports these orifice sizes Number of orifices 1 0 35 mm 014 in 4 0 18 mm 007 in 2 0 25 mm 010 in 5 0 15 mm 006 in 3 0 20 mm 008 in 6 0 13 mm 005 in ...

Page 177: ...ent 89 0 A 71 1 A Primary circuit breaker rating 100 0 A 100 0 A CUTTING WATER IN Minimum Maximum Flow 9 5 L minute 2 5 gallons minute Pressure 2 76 bar or 275 79 kPa 40 psi 7 93 bar or 792 90 kPa 115 psi CUTTING WATER OUT Flow 4 9 L minute 1 3 gallons minute Pressure 551 58 bar or 55 158 kPa 8 000 psi 4 136 85 bar or 413 685 kPa 60 000 psi Continuous pressure 4 136 85 bar or 413 685 kPa 60 000 ps...

Page 178: ...S Operator Manual 808690 8 Pump specifications Pump specifications This model supports these orifice sizes Number of orifices 1 0 41 mm 016 in 4 0 20 mm 008 in 2 0 28 mm 011 in 5 0 18 mm 007 in 3 0 23 mm 009 in 6 0 15 mm 006 in ...

Page 179: ...ry circuit breaker rating 125 0 A 100 0 A 50 Hz 60 Hz CUTTING WATER IN Minimum Maximum Flow 11 4 L minute 3 gallons minute Pressure 2 76 bar or 275 79 kPa 40 psi 7 93 bar or 792 90 kPa 115 psi CUTTING WATER OUT Flow 5 7 L minute 1 49 gallons minute 6 1 L minute 1 60 gallons minute Pressure 551 58 bar or 55 158 kPa 8 000 psi 4 136 85 bar or 413 685 kPa 60 000 psi Continuous pressure 4 136 85 bar or...

Page 180: ...S Operator Manual 808690 8 Pump specifications Pump specifications This model supports these orifice sizes Number of orifices 1 0 43 mm 017 in 4 0 23 mm 009 in 2 0 30 mm 012 in 5 0 20 mm 008 in 3 0 25 mm 010 in 6 0 18 mm 007 in ...

Page 181: ...rs used on hydraulic and high pressure water parts Special fasteners These torque values are for bolts that are coated in antiseize bolt lubricant white lithium grease SAE J518 flange bolts These torque values are for bolts that are coated in antiseize bolt lubricant white lithium grease Lubricate the O rings with hydraulic fluid or O ring lubricant before assembly To make a good seal the sealing ...

Page 182: ...igh pressure water fittings Special fittings Use these values when no other torque value is identified Other torque specifications are included on the technical drawings Do not use lubricants on low pressure water fittings Wrench size Torque N m lbf ft Output adapter 1 inch 41 to 47 30 to 35 High pressure water fittings gland nuts 1 4 inch 5 8 inch 20 to 34 15 to 25 3 8 inch 13 16 inch 47 to 61 35...

Page 183: ...ttings Lubricate the O rings with hydraulic fluid or O ring lubricant before assembly NPT Size Standard maximum torque Maximum torque value when using thread sealant 75 of standard maximum Maximum torque value when using a male tapered pipe thread with a female straight or parallel pipe thread 50 of standard maximum N m lbf ft N m lbf ft N m lbf ft 1 4 inch 34 25 26 19 18 13 3 8 inch 47 35 35 26 2...

Page 184: ... ft N m lbf ft N m lbf ft N m lbf ft N m lbf ft N m lbf ft 04 14 10 15 11 7 5 8 6 14 10 16 12 06 23 17 26 19 16 12 20 15 24 18 27 20 08 46 34 52 38 27 20 33 24 43 32 47 35 10 68 50 76 56 46 34 54 40 62 46 68 50 12 95 70 106 78 72 53 81 60 88 65 95 70 16 127 94 141 104 100 74 111 82 125 92 136 100 20 168 124 187 138 102 75 113 83 169 125 190 140 24 212 156 235 173 107 79 118 87 203 150 224 165 Lubr...

Page 185: ...fety guidelines in this manual DANGER Dangerous voltage To reduce the risk of serious injuries or death wear approved protection and follow safety recommendations when working with electricity WARNING A waterjet is a cutting tool A high pressure injection injury is a surgical emergency Seek immediate medical treatment for all high pressure waterjet injuries Delayed treatment can cause serious inju...

Page 186: ...the pump Perform user qualification and training Refer to User qualification and training on page 20 for more information Seller obligations If Hypertherm Inc installs the equipment some or all of these tasks are the responsibility of the Hypertherm technician as defined in the sales agreement Make sure that the buyer understands all buyer obligations Make sure that the site is prepared for instal...

Page 187: ...es Refer to requirements from the National Electric Code NEC the International Electrotechnical Commission IEC and the Occupational Safety and Health Administration OSHA as well as local codes for detailed information about environmental criteria CAUTION When work must be done in confined spaces with limited access the access must not be blocked by ventilation ducts hoses pipes or other equipment ...

Page 188: ...ch as iron calcium magnesium and silica which form deposits on the inside of high pressure plumbing and can damage check valves seals orifices and other consumables Most systems require softened water Consult a specialist for recommendations for choosing a water treatment system Reverse osmosis systems are available from Hypertherm Test the water quality Public utility water and well water quality...

Page 189: ...tion The ideal range is 0 005 to 0 015 50 ppm to 150 ppm A TDS level that is less than 0 005 50 ppm can harm waterjet parts and requires the use of nonmetallic or stainless steel fittings Treat water with a TDS level that is more than 0 015 150 ppm with reverse osmosis or consider using deionized water CAUTION A TDS value of less than 0 0005 5 ppm can damage stainless steel parts 0 002 0 004 0 006...

Page 190: ...key for the LOCAL REMOTE key switch This is usually shipped inside the electrical enclosure A copy of the system schematic drawing This is usually shipped inside the electrical enclosure 3 Inspect the equipment to make sure that it was not damaged during shipping If the equipment is damaged a claim must be filed with the carrier 4 Make sure that the delivery and shipping documents match the equipm...

Page 191: ...dry contacts on the emergency stop at the remote control source If the pump is set up to run remotely and has a motion system robot or cutting table the emergency circuits from the robot or cutting table can be in series with the local emergency stop circuit Remote controls on If the pump is off this turns on the primary control relay Wire number Type of contact Operation 5024A Normally closed Sta...

Page 192: ... pressure mode Remote cooling on This input turns on the fan motor and the cooling water or the cooling fan logic and turns off the intensifier Wire number Type of contact Operation 6028 Input momentary normally open Status 6028 Input momentary normally open Emergency stop 5024A 5024B A jumper is installed between these terminals at the factory Normally closed Wire number Type of contact Operation...

Page 193: ...the top and bottom ports on the air cooler 3 Connect the 4 conductor cable from the air cooler motor to the panel in the electrical enclosure The full load amperes overload settings and wire sizes are different depending on the motor size For more information refer to the system schematic drawing 4 Push the cable through the cord grip connector in the electrical enclosure 5 Connect the cable to th...

Page 194: ...IC female connectors for an air cooled system Two 1 inch NPT male connectors for a water cooled system CAUTION Do not couple the WASTEWATER OUT and the COOLING OUT lines Coupling these lines can cause cooling water to back up into the system which can cause damage to the bleed down valve and the intensifier parts CAUTION Air cooled systems must be connected to the external air cooler before starti...

Page 195: ...lic utility water has a high mineral content prefiltering or softening might be necessary to prevent deposits from clogging the plates or tubes in the heat exchanger Refer to the Water quality section which begins on page 188 Air cooled system 16 JIC female connector Connect this hose to the top fitting on the external air cooler This hose carries hydraulic fluid Air cooled systems are shipped wit...

Page 196: ... Use this table to find the minimum cross sectional area of the external copper ground leg HyPrecision pumps can leak up to 160 mA To reduce the effects of a high leakage current connect the pump to a dedicated supply transformer that has separate windings WARNING A line disconnect switch for incoming electrical power must be installed near the power supply to serve as a supply voltage disconnecti...

Page 197: ...ge the hydraulic hoses the hydraulic filter or the air cooler CAUTION If a water line fitting or valve might be frozen do not operate the pump Thaw the equipment until water moves freely through the entire water circuit High pressure water can cause eye injuries Wear approved eye protection when operating or working near this equipment This waterjet equipment might exceed national and local codes ...

Page 198: ...osure door is set to ON 4 Turn ON the electrical power Change the system configuration on the operator interface A password protected system configuration menu permits the operator to change the language and to change between psi and bar on the operator interface Contact a Hypertherm Technical Service Associate for assistance WARNING Do not attempt to repair a leak with pressure in the system WARN...

Page 199: ... pump The REMOTE ACTIVE indicator light is off The operator interface is the primary point of control 4 Push the CONTROLS ON button to turn ON the control circuit inside the pump The pump can not be turned on until the control circuit is on 5 Turn OFF the cutting head 6 Turn ON the pump in cooling mode WARNING This procedure involves exposing a rotating shaft Do not put an object or a body part ne...

Page 200: ...k and correct the problem Refer to Leaks on page 163 11 Push the filter purge buttons until water comes out from under each button CAUTION Make sure that the primary motor rotates in the correct direction before starting the pump The pump shaft must turn in the direction shown by the motor rotation arrow decal Reverse rotation of the pump can unscrew the impeller and cause permanent damage to the ...

Page 201: ...the low pressure water is supplied from a tank such as water from a reverse osmosis system it is frequently necessary to increase the pressure The boost pump operates with a supply water pressure of 2 76 bar to 4 8 bar or 275 8 kPa to 482 63 kPa 40 psi to 70 psi increasing the water pressure to 7 85 bar or 758 kPa 110 psi Do this task when the pump is not running 1 Open the water valve to drain th...

Page 202: ... the program in a loop for 15 minutes If the CNC control is not available turn the head ON and OFF in 1 second intervals for 15 minutes This shocks the high pressure tubing and frees debris in the tubing Debris can cause damage to the on off valve needle and the seat If this occurs attempt to complete this procedure by removing debris from the parts rather than replacing the parts right away 8 Inc...

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