PowerDredge™
Abrasive Removal System
Instruction Manual
808990 | Revision 0 | English
PowerDredge and Hypertherm are trademarks of Hypertherm Inc. and may be registered in the United States and other countries. All
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.
© 2015 Hypertherm Inc.
PowerDredge
Instruction Manual
808990
Revision 0
English
September 2015
Hypertherm Inc.
Hanover, NH 03755 USA
www.hypertherm.com
North America
USA and Canada
Technical service
800-643-9878 Toll-free
TechnicalService-Hanover@Hypertherm.com
Customer service
800-737-2978 Toll-free
Return materials
866-643-7711 Toll-free
Asia Pacific
TechnicalService-Asia@Hypertherm.com
Singapore
65 6841 2489
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China
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Japan
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India
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Korea
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Australia and New Zealand
+61 (0) 7 3103 1695
+61 (0) 4 3760 6995 Mobile
+61 (0) 7 3219 9012 Fax
Europe, Middle East, and Africa
Technical service
00 800 4973 7843 Toll-free
+31(0) 165 596900
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Customer service
00 800 3324 9737 Toll-free
+31 (0) 165 526156
00 800 4973 7329 Toll-free fax
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Return materials
+31 (0) 165 596936
+31 (0) 165 596906 Fax
South America
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Brazil
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Argentina
+54 (11) 5199-4668
Peru
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Chile
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Venezuela
+58 (212) 335-7522
México
52 55 5681 8109
52 55 5681 7978
52 55 5683 2127 Fax
ENGLISH
WARNING! Before operating any Hypertherm equipment, read the safety
instructions in your product’s manual. Failure to follow safety instructions can
result in personal injury or in damage to equipment.
Copies of the manuals may accompany the product in electronic and printed
formats. You can also obtain copies of the manuals, in all languages available
for each manual, from the “Downloads library” at www.hypertherm.com.
DEUTSCH / GERMAN
WARNUNG! Bevor Sie ein Hypertherm-Gerät in Betrieb nehmen, lesen Sie
bitte die Sicherheitsanweisungen in Ihrer Bedienungsanleitung. Das
Nichtbefolgen der Sicherheitsanweisungen kann zu Verletzungen von Personen
oder Schäden am Gerät führen.
Bedienungsanleitungen und Handbücher können dem Gerät in elektronischer
Form oder als Druckversion beiliegen. Sie können alle Handbücher und
Anleitungen in den jeweils verfügbaren Sprachen eines bestimmten
Handbuchs auch in der „Download-Bibliothek“ unter www.hypertherm.com
herunterladen.
DANSK / DANIS H
ADVARSEL! Inden Hypertherm udstyr tages i brug skal
sikkerhedsinstruktionerne i produktets manual gennemlæses. Følges
sikkerhedsvejledningen ikke kan det resultere i personskade eller beskadigelse
af udstyret.
Kopier af manualerne kan ledsage produktet i elektroniske og trykte formater.
Du kan også få kopier af manualer, på alle sprog der er til rådighed for hver
manuel, fra "Download-biblioteket" på www.hypertherm.com.
PORTUGUÊS / PORTUGUESE
ADVERTÊNCIA! Antes de operar qualquer equipamento Hypertherm, leia as
instruções de segurança no manual do seu produto. Não seguir as instruções
de segurança pode resultar em lesões corporais ou danos ao equipamento.
Cópias dos manuais podem acompanhar os produtos nos formatos eletrônico
e impresso. Também é possível obter cópias dos manuais em todos os idiomas
disponíveis para cada manual na “Biblioteca de downloads” em
www.hypertherm.com.
FRANÇAIS / FRENCH
AVERTISSEMENT! Avant d’utiliser tout équipement Hypertherm, lire les
consignes de sécurité dans le manuel de votre produit. Le non-respect des
consignes de sécurité peut engendrer des blessures physiques ou des
dommages à l’équipement.
Des copies de ces manuels peuvent accompagner le produit en format
électronique et papier. Vous pouvez également obtenir des copies de chaque
manuel dans toutes les langues disponibles à partir de la « Bibliothèque de
téléchargement » sur www.hypertherm.com.
ESPAÑOL / SPANISH
¡ADVERTENCIA! Antes de operar cualquier equipo Hypertherm, leer las
instrucciones de seguridad del manual de su producto. No cumplir las
instrucciones de seguridad podría dar lugar a lesiones personales o daño a los
equipos.
Pueden venir copias de los manuales en formato electrónico e impreso junto
con el producto. También se pueden obtener copias de los manuales, en todos
los idiomas disponibles para cada manual, de la “Biblioteca” en
www.hypertherm.com.
ITALIANO / ITALIAN
AVVERTENZA! Prima di utilizzare le attrezzature Hypertherm, leggere
le istruzioni di sicurezza nel manuale del prodotto. Il mancato rispetto delle
istruzioni sulla sicurezza può causare lesioni personali o danni all’attrezzatura.
Il prodotto può essere accompagnato da copie elettroniche e cartacee del
manuale. È anche possibile ottenere copie del manuale, in tutte le lingue
disponibili per ogni manuale, da “Archivio download” all’indirizzo
www.hypertherm.com
NEDERLANDS / DUTCH
WAARSCHUWING! Lees voordat u Hypertherm-apparatuur gebruikt
de veiligheidsinstructies in de producthandleiding en in de Veiligheids- en
nalevingshandleiding (80669C). Het niet volgen van de veiligheidsinstructies
kan resulteren in persoonlijk letsel of schade aan apparatuur.
De handleidingen kunnen in elektronische en gedrukte vorm met het product
worden meegeleverd. De handleidingen, elke handleiding beschikbaar in alle
talen, zijn ook verkrijgbaar via de “Downloadbibliotheek” op
www.hypertherm.com
.
.
日本語 / JAPANESE
警告 ! Hypertherm 機器を操作する前に、この製品説明書にある安全情報を
お読みください。安全情報に従わないと怪我や装置の損傷を招くことがあ
ります。
説明書のコピーは、電子フォーマット、または印刷物として製品に同梱さ
れています。各説明書は、 www.hypertherm.com の「ダンロードライブラ
リ」から各言語で入手できます。
简体中文 / CHINESE (SIMPLIFIED)
警告！在操作任何海宝设备之前，请阅读产品手册中的安全操作说明。若未
能遵循安全操作说明，可能会造成人员受伤或设备损坏。
随产品提供的手册可能提供电子版和印刷版两种格式。您也可从
“Downloads library” （下载资料库）中获取每本手册所有可用语言的副本，
网址为 www.hypertherm.com.
NORSK / NORWEGIAN
ADVARSEL! Før du bruker noe Hypertherm-utstyr, må du lese
sikkerhetsinstruksjonene i produktets håndbok. Unnlatelse av å følge
sikkerhetsinstruksjoner kan føre til personskade eller skade på utstyr.
Eksemplarer av håndbøkene kan medfølge produktet i elektroniske og trykte
utgaver. Du kan også få eksemplarer av håndbøkene, i alle tilgjengelige språk
for hver håndbok, fra "nedlastningsbiblioteket" på www.hypertherm.com
SVENSKA / SWEDISH
VARNING! Läs säkerhetsinstruktionerna i din produktmanual försiktigt innan
du använder din någon Hypertherm-utrustning. Underlåtenhet att följa
dessa säkerhetsinstruktionerkan resultera i personskador eller skador
på utrustningen.
Kopior av manualen kan medfölja produkten i elektronisk och tryckform.
Du hittar även kopior av manualerna i alla tillgängliga språk i
”nedladdningsbiblioteket” (Downloads library) på www.hypertherm.com
한국어 / KOREAN
경고 ! Hypertherm 장비를 사용하기 전에 제품 설명서에 나와 있는 안전
지침을 읽으십시오 . 안전 지침을 준수하지 않으면 신체 부상이나 장비
손상을 초래할 수 있습니다 .
전자 형식과 인쇄된 형식으로 설명서 사본이 제품과 함께 제공될
수 있습니다 . www.hypertherm.com
라이브러리 )' 에서도 모든 언어로 이용할 수 있는 설명서 사본을 얻을
수 있습니다 .
의 'Downloads library( 다운로드
.
.
ČESKY / CZECH
VAROVÁNÍ! Před uvedením jakéhokoliv zařízení Hypertherm do provozu
si přečtěte bezpečnostní pokyny v příručce k produktu. Nedodržování
bezpečnostních pokynů může mít za následek zranění osob nebo poškození
majetku.
Kopie příruček a manuálů mohou být součástí dodávky produktu, a to v
elektronické i tištěné formě. Kopie příruček a manuálů ve všech jazykových
verzích, v nichž byly dané příručky a manuály vytvořeny, naleznete v „Knihovně
ke stažení“ na webových stránkách www.hypertherm.com
.
TÜR KÇE / TUR KI SH
UYARI! Bir Hypertherm ekipmanını çalıştırmadan önce, ürün kullanım
kılavuzunda yer alan güvenlik talimatlarını okuyun. Güvenlik talimatlarına
uyulmaması durumunda kişisel yaralanmalar veya ekipman hasarı meydana
gelebilir.
Kılavuzların kopyaları, elektronik ve basılı formatta ürünle birlikte verilebilir.
Her biri tüm dillerde yayınlanan kılavuzların kopyalarını www.hypertherm.com
adresindeki “Downloads library” (Yüklemeler kitaplığı) başlığından da elde
edebilirsiniz.
POLSKI / POLISH
OSTRZEŻENIE! Przed rozpoczęciem obsługi jakiegokolwiek systemu firmy
Hypertherm należy się zapoznać z instrukcjami bezpieczeństwa
zamieszczonymi w podręczniku produktu. Nieprzestrzeganie instrukcji
bezpieczeństwa może skutkować obrażeniami ciała i uszkodzeniem sprzętu.
Do produktu mogą być dołączone kopie podręczników w formacie
elektronicznym i drukowanym. Kopie podręczników, w każdym udostępnionym
języku, można również znaleźć w „Bibliotece materiałów do pobrania” pod
adresem www.hypertherm.com.
PУССКИЙ / RUSSIAN
БЕРЕГИСЬ! Перед работой с любым оборудованием Hypertherm
ознакомьтесь с инструкциями по безопасности, представленными в
руководстве, которое поставляется вместе с продуктом. Невыполнение
инструкций по безопасности может привести к телесным повреждениям
или повреждению оборудования.
Копии руководств, которые поставляются вместе с продуктом, могут быть
представлены в электронном и бумажном виде. Копии руководств на всех
языках, на которые переведено то или иное руководство, можно также
загрузить из раздела «Библиотека документов» на веб-сайте
www.hypertherm.com.
SUOMI / FINNISH
VAROITUS! Ennen minkään Hypertherm-laitteen käyttöä lue tuotteen
käyttöoppaassa olevat turvallisuusohjeet. Turvallisuusohjeiden laiminlyönti
voi aiheuttaa henkilökohtaisen loukkaantumisen tai laitevahingon.
Käyttöoppaiden kopiot voivat olla tuotteen mukana elektronisessa ja
tulostetussa muodossa. Voit saada käyttöoppaiden kopiot kaikilla kielillä
”latauskirjastosta” osoitteessa www.hypertherm.com.
БЪЛГAPCКИ / BULGARIAN
ПРЕДУПРЕЖДЕНИЕ! Преди да работите с оборудване Hypertherm,
прочетете инструкциите за безопасност в ръководството на вашия
продукт. Неспазването на инструкциите за безопасност би могло да
доведе до телесно нараняване или до повреда на оборудването.
Копия на ръководствата може да придружават продукта в електронен и в
печатен формат. Можете да получите копия на ръководствата, предлагани
на всички езици, от “Downloads library” (Библиотека за теглене) на адрес
www.hypertherm.com
ROMÂNĂ / ROMANIAN
AVERTIZARE! Înainte de a utiliza un echipament Hypertherm, citiţi instrucţiunile
privind siguranţa din manualul de utilizare a produsului. Nerespectarea
instrucțiunilor de siguranță pot rezulta în vătămare personală sau în avarierea
echipamentului.
Produsul poate fi însoțit de copii ale manualului în format tipărit și electronic.
De asemenea, dumneavoastră puteți obține copii ale manualelor, în toate limbile
disponibile pentru fiecare manual, din cadrul secțiunii ”Librărie de descărcare”
aflată pe site-ul www.hypertherm.com
.
.
MAGYAR / HUNGARIAN
VIGYÁZAT! Mielőtt bármilyen Hypertherm berendezést üzemeltetne, olvassa
el a biztonsági információkat a termék kézikönyvében. A biztonági utasítások
betartásának elmulasztása személyi sérüléshez vagy a berendezés
károsodásához vezethet.
A termékhez a kézikönyv példányai elektronikus és nyomtatott formában
is mellékelve lehetnek. A kézikönyvek példányai (minden nyelven) a
www.hypertherm.com weboldalon a „Downloads library” (Letöltési könyvtár)
részben is beszerezhetők.
ΕΛΛΗΝΙΚΆ / GREEK
ΠΡΟΕΙΔΟΠΟΙΗΣΗ! Πριν θέσετε σε λειτουργία οποιονδήποτε εξοπλισμό της
Hypertherm, διαβάστε τις οδηγίες ασφαλείας στο εγχειρίδιο του προϊόντος. Η
μη τήρηση των οδηγιών ασφαλείας μπορεί να επιφέρει σωματική βλάβη ή
ζημιά στον εξοπλισμό.
Αντίγραφα των εγχειριδίων μπορεί να συνοδεύουν το προϊόν σε ηλεκτρονική
και έντυπη μορφή. Μπορείτε, επίσης, να λάβετε αντίγραφα των εγχειριδίων
σε όλες τις γλώσσες που διατίθενται για κάθε εγχειρίδιο από την ψηφιακή
βιβλιοθήκη λήψεων (Downloads library) στη διαδικτυακή τοποθεσία
www.hypertherm.com.
繁體中文 / CHINESE (TRADITIONAL)
警告！ 操作任何 Hypertherm 設備前，請閱讀產品手冊中的安全說明。不遵
守安全指示可能會導致人身傷害或設備損壞。
手冊複本可能以電子和印刷格式隨附產品提供。您也可以在
www.hypertherm.com 的 「下載資料庫」內獲取所有手冊的多語種複本。
SLOVENŠČINA / SLOVENIAN
OPOZORILO! Pred uporabo katerekoli Hyperthermove opreme preberite
varnostna navodila v priročniku vašega izdelka. Neupoštevanje navodil za
uporabo lahko povzroči telesne poškodbe ali materialno škodo.
Izdelku so lahko priloženi izvodi priročnikov v elektronski ali tiskani obliki. Izvode
priročnikov v vseh razpoložljivih jezikih si lahko prenesete tudi iz knjižnice
prenosov “Downloads library” na naslovu www.hypertherm.com
SRPSKI / SERBIAN
UPOZORENJE! Pre rukovanja bilo kojom Hyperthermovom opremom
pročitajte uputstva o bezbednosti u svom priručniku za proizvod. Oglušavanje
o praćenje uputstava o bezbednosti može da ima za posledicu ličnu povredu ili
oštećenje opreme.
Može se dogoditi da kopije priručnika prate proizvod u elektronskom
i štampanom formatu. Takođe možete da pronađete kopije priručnika, na svim
jezicima koji su dostupni za svaki od priručnika, u “Biblioteci preuzimanja”
(“Downloads library”) na www.hypertherm.com.
SLOVENSKÝ / SLOVAK
VÝSTRAHA! Pred použitím akéhokoľvek zariadenia od spoločnosti Hypertherm
si prečítajte bezpečnostné pokyny v návode na obsluhu vášho zariadenia.
V prípade nedodržania bezpečnostných pokynov môže dôjsť k ujme na zdraví
alebo poškodeniu zariadenia.
Kópia návodu, ktorá je dodávaná s produktom, môže mať elektronickú alebo
tlačenú podobu. Kópie návodov, vo všetkých dostupných jazykoch,
sú k dispozícii aj v sekcii “Downloads library” na www.hypertherm.com
.
.
Contents
Safety .......................................................................................................................................SC-11
User qualification and training .............................................................................................................................................SC-11
Self-tipping hopper safety ....................................................................................................................................................SC-12
Abrasive bag safety ................................................................................................................................................................SC-13
Emergency medical information and treatment ...............................................................................................................SC-15
Product stewardship ............................................................................................................SC-17
National and local safety regulations ..................................................................................................................................SC-17
Certification test marks .........................................................................................................................................................SC-17
Differences in national standards ........................................................................................................................................SC-18
Higher-level systems ..............................................................................................................................................................SC-18
Environmental stewardship ...............................................................................................SC-19
Proper disposal of Hypertherm products ..........................................................................................................................SC-19
Proper handling and safe use of chemicals ......................................................................................................................SC-19
Particle emission and wastewater quality .........................................................................................................................SC-19
Warranty ..................................................................................................................................SC-21
1 Specifications .............................................................................................................................. 23
Overview ......................................................................................................................................................................................... 23
Self-tipping hopper ...................................................................................................................................................................... 24
Pump ............................................................................................................................................................................................... 25
Abrasive removal bag .................................................................................................................................................................. 25
PowerDredge Instruction Manual 808990 7
Contents
2 Installation .................................................................................................................................... 27
Receive and unpack the system ............................................................................................................................................... 27
Unload the system ................................................................................................................................................................ 27
Unpack the system ............................................................................................................................................................... 28
Claims ...................................................................................................................................................................................... 28
Install the system .......................................................................................................................................................................... 28
Inside the waterjet tank ....................................................................................................................................................... 29
Outside the waterjet tank .................................................................................................................................................... 32
Install the self-tipping hopper and pump ........................................................................................................................ 33
3 Operation ...................................................................................................................................... 37
Operation guidelines .................................................................................................................................................................... 37
Start the system ............................................................................................................................................................................ 37
Stop the system ............................................................................................................................................................................ 39
4 Maintenance ................................................................................................................................ 41
Run a sweeping program ........................................................................................................................................................... 41
Replace the bag ............................................................................................................................................................................ 42
Remove the bag .................................................................................................................................................................... 42
Install the bag ........................................................................................................................................................................ 46
Empty the bag ............................................................................................................................................................................... 47
Clean the strainer weekly ............................................................................................................................................................ 48
Clean the standard strainer ................................................................................................................................................ 48
Clean the heavy-duty strainer ............................................................................................................................................ 50
Clean the self-tipping hopper annually .................................................................................................................................... 52
Pump maintenance ....................................................................................................................................................................... 53
Replace the ball valves and seats ..................................................................................................................................... 53
Replace the diaphragms ..................................................................................................................................................... 55
Remove the diaphragm assemblies .......................................................................................................................... 55
Assemble the new diaphragms ................................................................................................................................. 58
Install the diaphragm assemblies .............................................................................................................................. 59
Replace the air end kit ......................................................................................................................................................... 61
Replace the muffler plate and air valve assembly components ......................................................................... 61
Replace the air chamber components ..................................................................................................................... 63
5 Troubleshooting .......................................................................................................................... 67
Troubleshooting guide ................................................................................................................................................................. 67
Push air into the tank ................................................................................................................................................................... 69
Reverse the flow of the system ................................................................................................................................................. 70
Manually flush the system ........................................................................................................................................................... 72
8 PowerDredge Instruction Manual 808990
Contents
6 Parts ............................................................................................................................................... 73
Pump kits ........................................................................................................................................................................................ 73
Self-tipping hopper kits ............................................................................................................................................................... 73
Strainer kits .................................................................................................................................................................................... 73
Overflow kits .................................................................................................................................................................................. 74
Other kits ........................................................................................................................................................................................ 74
PowerDredge Instruction Manual 808990 9
Contents
10 PowerDredge Instruction Manual 808990
Safety
The end user is responsible for the safe operation of this equipment.
The safety precautions in this manual are general and can not anticipate every situation. Hypertherm Inc. acknowledges
that unforeseen situations due to equipment failure, site variability, insufficient maintenance, failure of control equipment,
and other events can cause equipment damage, injuries, or death. It is the user’s responsibility to identify hazards and
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, 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 the written hazard communication program and safety data sheets
How to recognize hazardous energy sources
The correct methods for isolating and controlling energy, including lock out–tag out procedures
User qualification and training
All users must read and understand these instructions before installing, operating, or doing maintenance on this
equipment.
Do not permit an untrained person to operate this equipment. Operators must be qualified to install, operate, and maintain
this equipment. Training should include this information:
How to start and stop the system during routine operation and in an emergency situation
The conditions and actions that can lead to injuries to people and damage to the system
How to operate all controls
How to identify and respond to problems
How to do maintenance procedures
A copy of this manual
This list is not all-inclusive.
Safety and Compliance SC-11
Safety
Self-tipping hopper safety
Read the instruction manual.
Stay clear of the self-tipping hopper when transporting or dumping.
WARNING!
CRUSH HAZARD
Make sure that the self-tipping hopper handle is in the locked position with safety latch engaged except when
dumping.
When you stack self-tipping hoppers, nest self-tipping hoppers correctly.
When you store self-tipping hoppers, do not stack empty self-tipping hoppers over 3 high.
When you store self-tipping hoppers, do not stack loaded self-tipping hoppers over 2 high.
Do not exceed the capacity of the forklift vehicle, self-tipping hopper, or operator.
Never use a self-tipping hopper that needs repairs.
A rod or pole can be used to assist with tripping the release from heights.
SC-12 Safety and Compliance
Abrasive bag safety
These symbols appear on the label on the abrasive bag.
Safety
WARNING!
The forks of the forklift vehicle
must be the same width as the
bag.
Do not lift more than one bag at
a time.
Do not lift the bag by bringing all
of the loops to the center.
Do not position the bag so that
you cannot see and operate the
forklift vehicle.
Do not lift the bag from the side
with only 2 loops.
Do not lift the bag by only one
loop.
Avoid sharp edges.
The forklift vehicle forks must be
dulled or protected.
Do not stand under the bag.
Do not open the bottom of the
bag while standing under the
bag.
Do not cut the bottom of the bag
while standing under the bag.
Safety and Compliance SC-13
Safety
HANDLING RECOMMENDATIONS
The forks on the forklift vehicle
must be at the same width as the
bag.
Use extensions with a crane to
lift the bag.
When you empty the bag, stay
clear of the bag.
Use all 4 loops and extensions to
lift the bag from the side.
Lift vertically with all 4 loops.
Position the bag so that you can
see when you operate the forklift
vehicle.
Avoid ultraviolet (UV) light exposure or inclement weather.
SC-14 Safety and Compliance
Safety
Emergency medical information and treatment
The use of high-pressure equipment exposes the operator and other people in the area to high-pressure water. Potential
harms include eye injuries, lacerations, infections, and amputations. Do not put ice or heat on a waterjet injury. Support
injured limbs and extremities above heart level if possible.
A high-pressure injection injury is a surgical emergency. Seek immediate medical treatment for all high-pressure waterjet
injuries. Delayed treatment can lead to 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.
Give this card to emergency responders and medical professionals. It can be copied, cut out, laminated, and folded.
MEDICAL
INFORMATION
A high-pressure injection injury is
a surgical emergency.
Seek immediate medical
treatment for all high-pressure
waterjet injuries.
Delayed treatment can lead to
serious injuries or death.
The person carrying this card has been
exposed to a waterjet of up to 4,137 bar
(60,000 psi) and a velocity of 609 m/s
(2,000 feet/second). The waterjet can
contain abrasive materials.
Skin can appear intact or show a minor
pinhole-sized puncture wound. The
injured area can become swollen,
painful, and pale over the next 4 to 6
hours. Tissue becomes ischemic and
necrotic within 12 hours.
Consult a surgical specialist immediately
for decompression, removal of foreign
materials, and debridement.
Administer broad-spectrum, intravenous
antibiotics for Gram-negative and
Gram-positive organisms.
X-ray is the imaging of choice.
Acute compartment syndrome is
possible.
Leave the wound open.
Do not use solvents other than isotonic
sodium chloride solution for irrigating
the wound.
Do not use digital or local nerve blocks.
Give analgesics by mouth or injection.
Safety and Compliance SC-15
Safety
SC-16 Safety and Compliance
Product stewardship
Hypertherm maintains a global Regulatory Management System to ensure that products comply with regulatory and
environmental requirements.
National and local safety regulations
National and local safety regulations shall take precedence over instructions supplied with the product. The product shall
be imported, installed, operated and disposed of in accordance with national and local regulations applicable to the
installed site.
Certification test marks
Certified products are identified by one or more certification test marks from accredited testing laboratories. The
certification test marks are found on or near the data plate.
Each certification test mark means that the product and its safety-critical parts conform to the relevant national safety
standards as reviewed and determined by that testing laboratory. Hypertherm puts a certification test mark on its
products only after that product is manufactured with safety-critical parts that have been authorized by the accredited
testing laboratory.
Once the product has left the Hypertherm factory, the certification test marks are invalidated if any of these events occur:
The product is modified in a manner that creates a hazard or nonconformance with the applicable standards.
Safety-critical parts are replaced with unauthorized spare parts.
Assembly is unauthorized.
An accessory that uses or generates a hazardous voltage is added.
There is tampering with a safety circuit or other feature that is designed into the product as part of the certification, or
otherwise.
A Conformité Européene (CE) mark constitutes a manufacturer’s declaration of conformity to applicable European
directives and standards. Only those versions of Hypertherm products with a CE mark found on or near the data plate
have been tested for compliance with the European Low Voltage Directive and the European Electromagnetic
Compatibility Directive.
Safety and Compliance SC-17
Product stewardship
Differences in national standards
Nations can apply different performance, safety, or other standards. National differences in standards include, but are not
limited to:
Voltages
Plug and cord ratings
Language requirements
Electromagnetic compatibility requirements
These differences in national or other standards can make it impossible or impractical for all certification test marks to be
put on the same version of a product. For example, the Canadian Standards Association (CSA) versions of Hypertherm’s
products do not comply with European electromagnetic compatibility requirements and therefore do not have a CE mark
on the data plate.
Countries that require a CE mark or have compulsory electromagnetic compatibility regulations must use CE versions of
Hypertherm products with the CE mark on the data plate. These include, but are not limited to:
Australia
New Zealand
Countries in the European Union
Russia
It is important that the product and its certification test mark be suitable for the end-use installation site. When
Hypertherm products are shipped to one country for export to a different country, the product must be configured and
certified properly for the end-use site.
Higher-level systems
When an original equipment manufacturer (OEM) or system integrator adds equipment such as cutting tables, motor
drives, motion controllers, or robots to a Hypertherm Waterjet cutting system, the combined system can be considered a
higher-level system. A higher-level system with hazardous moving parts can constitute industrial machinery or robotic
equipment, in which case the system integrator or end-use customer could be subject to more regulations and standards
than those relevant to the waterjet cutting system as manufactured by Hypertherm.
It is the responsibility of the end-use customer and the OEM or system integrator to do a risk assessment for the
higher-level system, and to supply protection against hazardous moving parts. Unless the higher-level system is certified
when the OEM or system integrator incorporates Hypertherm products into it, the installation also can be subject to
approval by local authorities. Seek advice from legal counsel and local regulatory experts if you are uncertain about
compliance.
External interconnecting cables between parts of the higher-level system must be suitable for contaminants and
movement as required by the final end-use installation site. When the external interconnecting cables are subject to oil,
dust, water, or other contaminants, hard usage ratings could be required.
When external interconnecting cables are subject to continuous movement, constant flexing ratings could be required. It
is the responsibility of the end-use customer or the OEM or system integrator to ensure the cables are suitable for the
application. Since there are differences in the ratings and costs that can be required by local regulations for higher-level
systems, it is necessary to verify that external interconnecting cables are suitable for the end-use installation site.
SC-18 Safety and Compliance
Environmental stewardship
Proper disposal of Hypertherm products
Hypertherm waterjet cutting systems, like all products with electronics, can contain materials or parts, such as printed
circuit boards, that can not be discarded with ordinary waste. It is your responsibility to dispose of Hypertherm product or
part in an environmentally suitable manner and in compliance with national and local codes.
In the United States, check all federal, state, and local laws. In the European Union (EU), check the EU directives,
national, and local laws. For more information, go to www.hypertherm.com/weee
local laws. Consult with legal or other compliance experts when applicable.
. In other countries, check national and
Proper handling and safe use of chemicals
Material safety data sheets (MSDS) and safety data sheets (SDS) are part of a hazard communication plan that supplies
detailed information about hazardous 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), to align with
the United Nations’ Globally Harmonized System of Classification and Labelling of Chemicals (GHS). The GHS is an
international system for standardizing chemical classification and labeling.
Chemical regulations in the USA, Europe, and other locations require that Material Safety Data Sheets (MSDS) and
Safety Data Sheets (SDS) be made available for chemicals that are supplied with the product and chemicals used in or
on the product. The list of chemicals is supplied by Hypertherm. To see MSDS and SDS, go to the Hypertherm web site
at www.hypertherm.com
1. Click Downloads library.
2. Select Material Safety Data Sheets from the Category dropdown list.
3. Click on the Material Safety Data Sheets folder that is shown below the search fields.
4. Click on the MSDS folder.
These navigation instructions are subject to change without notice.
.
Particle emission and wastewater quality
Hypertherm does not manufacture or supply the materials that are cut and has no knowledge whether the particles
released from 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 purchasing, installing, and operating the equipment.
Safety and Compliance SC-19
Environmental stewardship
SC-20 Safety and Compliance
Waterjet product warranty coverage
Product Parts coverage
27 months from the ship date,
HyPrecision pumps
or 24 months from the date of proven installation,
or 4,000 hours, whichever occurs first
Warranty
PowerDredge abrasive
removal system
Abrasive metering devices
On/off valve air actuators
Diamond orifices
Consumable parts are not covered by this warranty. Consumable parts include, but are not limited to, high-pressure
water seals, check valves, cylinders, bleed-down valves, low-pressure seals, high-pressure tubing, and low- and
high-pressure water filters, and abrasive collection bags.
All third-party pumps, pump accessories, hoppers, hopper accessories, dryer boxes, dryer box accessories and plumbing
accessories are covered by the respective manufacturers’ warranties and not covered by this warranty.
15 months from the ship date
or 12 months from the date of proven installation, whichever occurs first
15 months from the ship date
or 12 months from the date of proven installation, whichever occurs first
15 months from the ship date
or 12 months from the date of proven installation, whichever occurs first
600 hours of use with the use of a thimble filter
and compliance with Hypertherm’s water quality requirements
Safety and Compliance SC-21
Warranty
SC-22 Safety and Compliance
Section 1
Specifications
Overview
The PowerDredge™ abrasive removal system is designed to remove abrasive from any waterjet tank. This system reduces
tank shoveling costs and associated downtime.
A single compressed air hose connected to a pump powers the system. The pump uses suction to pull water and
abrasive into the nozzles from the bottom of the waterjet tank. Then, the water and abrasive go through a strainer and
dispersion tube. The dispersion tube removes some of the energy from the water so that the abrasive can fall into the
abrasive-collector bag in the self-tipping hopper. The bag holds the abrasive but allows water to flow into the overflow
tube and back to the waterjet tank. (See Figure 1.)
To remove used abrasive from the self-tipping hopper, remove the bag from the self-tipping hopper.
PowerDredge Instruction Manual 808990 23
1 – Specifications
1
2
3
5
6
8
9
10
11
12
7
13
4
Direction of water flow
1 Waterjet tank
2 Upright pipe with a cap
3 Nozzle
4 Gate valve
5 Air quick-disconnect
6 Standard strainer (shown) or heavy-duty strainer
7 Pump
8 Dispersion tube
9 Self-tipping hopper
10 Overflow tube
11 PVC overflow (shown) or flexible overflow
12 Regulator
13 Pump air valve
Figure 1
Self-tipping hopper
Self-tipping hopper dimensions: 1,981 mm X 1,093 mm X 1,220 mm (78 inch X 43 inch X 48 inch)
Self-tipping hopper empty weight: 420 kg (1,085 lb)
Allow space in front of the self-tipping hopper for forklift vehicle access to remove the bag from the self-tipping
hopper.
Install the self-tipping hopper so that the end of the overflow that goes into the waterjet tank is at least 76 mm
(3 inches) lower than the water height in the self-tipping hopper.
24 PowerDredge Instruction Manual 808990
Pump
Pump dimensions: 368 mm X 429 mm X 308 mm (14.5 inch X 16.9 inch X 12.1 inch)
Pump weight: 22 kg (49 lb)
The air requirement is a minimum of 2 bar at 140 slpm (30 psi at 5 scfm).
The maximum distance between the pump and the cutting table is 600 mm (2 feet).
Abrasive removal bag
Maximum capacity: 1,360.8 kg (3,000 lbs)
The bag is for one-time use only.
1 – Specifications
PowerDredge Instruction Manual 808990 25
1 – Specifications
26 PowerDredge Instruction Manual 808990
Section 2
Installation
Receive and unpack the system
Unload the system
WARNING!
A crane or forklift vehicle must be used to lift components weighing more than 25 kg (55 lb). Lifting
must be done by an operator trained in accordance with local regulations. Position slings, ropes and
other lifting gear where they cannot slip and where the load is balanced. The angle between slings
or ropes used for lifting must not exceed 60 degrees.
Lift components or assemblies above their center of gravity to prevent them from turning over.
Unload boxes, crates and pallets, or cartons with forklift vehicles or slings, depending on their size and construction.
To unload the self-tipping hopper:
Move only one self-tipping hopper at a time.
1. Insert the forklift vehicle forks into the opening in the base with forks spread as wide as possible. Make sure that the
forks do not go past the front of the base.
2. Tilt the mast of the forklift vehicle back to prevent the self-tipping hopper from falling off of the forks.
3. Lift the self-tipping hopper to the minimum practical height and move at a safe speed.
PowerDredge Instruction Manual 808990 27
2 – Installation
Unpack the system
Make sure that you received all items in good condition. Contact your original equipment manufacturer (OEM) if any
items are damaged or missing.
Boxes and parts are sometimes packed inside the self-tipping hopper.
Inspect the system for damage that may have occurred during shipment. If you find evidence of damage, see Claims.
Before you set up and operate this system, read the Safety section in the front of this manual.
Claims
Claims for damage during shipment – If your unit was damaged during shipment, you must file a claim with the
carrier.
Claims for defective or missing merchandise – If any component is missing or defective, contact your OEM
within 10 days of receipt of equipment. If you need additional assistance, call the nearest Hypertherm office listed in
the front of this manual.
Install the system
Your OEM will work with you to design the plumbing layout for your tank.
If you are retrofitting this system to a previously installed cutting table, go to Inside the waterjet tank on page 29. Your
OEM provides a detailed layout drawing, gate valves, pipes, and fittings.
If your OEM has already installed the plumbing in your tank, go to Outside the waterjet tank on page 32.
The plumbing inside the waterjet tank will look similar to this.
Your system can be different from the one shown in this manual. See the layout drawing provided with your system for
specific details.
28 PowerDredge Instruction Manual 808990
2–Installation
1
1
Inside the waterjet tank
1. If the waterjet tank is not empty, drain the tank, and remove the abrasive.
Each branch of the plumbing must have a 40-mm (1.5-inch), NPT, female coupling in the waterjet tank wall. Your layout
drawing specifies where these are located.
2. If the tank does not have a coupling, go to step a. If the coupling in the tank is too large, go to step b.
a. Install the coupling provided in the tank wall where specified in your layout drawing.
b. Use the reducers to decrease the coupling to the size specified on your layout drawing.
You must use PTFE tape on the first fitting that connects to the coupling. On the remaining
fittings inside the waterjet tank you can use PTFE tape, but it is not necessary.
3. Use a pipe wrench to tighten these connections.
It can be helpful to support the pipes with wooden
blocks when you tighten the fittings.
PowerDredge Instruction Manual 808990 29
2 – Installation
2
2
3
3
4. Start at the couplings in the tank wall, and install the plumbing according to your layout drawing.
The plumbing must be flat on the floor of the tank.
5. Make sure that the open holes in the T-fittings and
90-degree elbows point up.
6. Tighten a nozzle into each of the T-fittings.
30 PowerDredge Instruction Manual 808990
2–Installation
4
5
6
4
5
6
7
7
7. At the end of each pipe, attach a 90-degree NPT elbow , a 457-mm (18-inch) piece of pipe , and cap . Hand
tighten the cap.
Make sure that the cap can be removed. This allows the waterjet to push water into the
system if it becomes clogged.
8. Attach one of the hose clamps around each of the supports in the tank.
If you do not have supports in your tank, continue to the next step.
PowerDredge Instruction Manual 808990 31
2 – Installation
Ta nk
4
5
6
7
1
2
3
1
23456
7
Outside the waterjet tank
Use PTFE tape on all connections outside the tank.
1. For each coupling , install the reducers (if necessary), a
union , and a gate valve .
2. Install the plumbing manifold.
The plumbing manifold on the outside of the tank can
require pipes to be cut to size and then threaded.
3. Where all of the branches come together, install the air
quick-disconnect .
4. Install a gate valve .
5. Install the standard strainer (shown) or heavy-duty strainer
(not shown).
32 PowerDredge Instruction Manual 808990
2–Installation
Install the self-tipping hopper and pump
1. Put the self-tipping hopper and pump into position. Follow the specifications in Self-tipping hopper on page 24 and
Pump on page 25.
2. Put an empty abrasive bag in the self-tipping hopper.
3. Attach the carrying loops to the 4 shackles on the self-tipping hopper. This prevents the bag from falling into the
self-tipping hopper.
4. Put the dispersion tube on the self-tipping hopper over the abrasive bag.
Use 2 people to lift the dispersion tube.
5. Attach the 40-mm (1.5-inch) green inlet hose from the pump to the strainer.
a. Cut the hose to the correct length.
b. Install the barbed end of the quick connect fittings into the hose.
To make the assembly of the hoses onto the barbed end of the fittings easier, heat the
end of the hose with a heat gun and lubricate the barbed end of the fitting with
penetrating oil. Twist the fitting as you push it on.
c. Attach the hose to the barbed fitting with a hose clamp.
PowerDredge Instruction Manual 808990 33
2 – Installation
6. Attach the 40-mm (1.5-inch) green outlet hose from the pump to the dispersion tube.
a. Cut the hose to the correct length.
b. Install barbed end of the quick connect fittings into the hose.
To make the assembly of the hoses onto the barbed end of the fittings easier, heat the
end of the hose with a heat gun and lubricate the barbed end of the fitting with
penetrating oil. Twist the fitting as you push it on.
c. Attach the hose to the barbed end of the fitting with a hose clamp.
7. Connect the air supply to the pump. (See Pump on page 25 for minimum air supply requirements.)
CAUTION!
The pump must sit on the same level as the cutting table. Do not elevate it.
8. Use the following steps, if you have the PVC overflow option. If you have the flexible overflow option, go to step 9.
a. Attach the overflow assembly to the coupling outside the self-tipping hopper.
b. Make sure that the end of the overflow that goes into the waterjet tank is at least 76 mm (3 inches) lower than the
water height in the self-tipping hopper.
c. If necessary, cut the overflow to the correct length.
34 PowerDredge Instruction Manual 808990
9. Use the following steps to install the flexible overflow.
1
2
3
1
2
3
4
4
a. Attach the overflow assembly to the coupling outside the
self-tipping hopper.
b. Make sure that the quick-disconnect points down.
c. Use the quick-disconnect to attach the flexible overflow to the
overflow assembly.
d. Cut the hose to the correct length.
e. Attach the U-shaped assembly to the
other end.
f. Hang the U-shaped assembly over
the edge of the waterjet tank.
g. Make sure that all connections are
tight.
2–Installation
10. Fill the waterjet tank with water.
11 . Open the air valve on the pump to start the flow of water and abrasive
into the self-tipping hopper.
12. Fill the self-tipping hopper with water.
13. Adjust the regulator so that the gray water flows over
the opening in the overflow tube but does not fill the
overflow tube.
The pressure for each system will be different. A
good starting point is 0.83 bar (12 psi).
Make sure that water flows out of the dispersion
tube without water splashing out of the self-tipping
hopper.
If the pump is running too fast, only water will be
pumped into the hopper.
PowerDredge Instruction Manual 808990 35
2 – Installation
36 PowerDredge Instruction Manual 808990
Section 3
1
1
Operation
Operation guidelines
Do not cut with materials that float such as plastic bricks or wood. These materials can clog the system.
Operate the PowerDredge continuously while cutting. Start the system when you start cutting. Stop the system
30 minutes after the last cut or at the end of the cutting shift. The energy from the cutting process mixes the water
and abrasive in the tank. This allows the system to use suction to remove the used abrasive from the tank.
When the system operates correctly, the amount of abrasive in the bottom of a waterjet tank will be approximately
127 mm (5 inches). The system does not remove all of the abrasive from the tank but mixes any abrasive in the tank.
You can adjust the gate valves on the side of the tank for the system depending on where the cutting happens. If you
close a branch of nozzles, it adds suction to the nozzles that remain open that are connected to the same pump.
Start the system
1. Open the gate valves on the side of the waterjet tank.
2. Open the air valve on the pump to start the flow of water and abrasive through the system.
3. Adjust the regulator so that the gray water flows over
the opening in the overflow tube but does not fill the
overflow tube.
The pressure for each system will be different. A
good starting point is 0.83 bar (12 psi).
Make sure that water flows out of the dispersion
tube without water splashing out of the self-tipping
hopper.
If the pump is running too fast, only water will be
pumped into the hopper.
PowerDredge Instruction Manual 808990 37
3 – Operation
2
2
3
3
4. After the self-tipping hopper is full, the overflow tube can easily keep up with the flow into the self-tipping hopper.
5. The edge of the bag acts like a filter to keep solids in the bag.
Over time, fine particles of abrasive accumulate outside of the bag and must be removed
from the self-tipping hopper. (See Clean the self-tipping hopper annually on page 52.)
38 PowerDredge Instruction Manual 808990
Stop the system
1
1
Close the air valve on the pump.
3–Operation
PowerDredge Instruction Manual 808990 39
3 – Operation
40 PowerDredge Instruction Manual 808990
Section 4
Maintenance
Run a sweeping program
Abrasive collects in the corners and along the edges of the tank away from where the cutting happens. The best way to
control the level of abrasive in the tank is to run a sweeping program cycle during downtime or once every second day
while running the system. This program pushes abrasive away from the walls and into the center of the tank.
Make sure that there are no obstructions on the table before running the program.
Use the following guidelines to create your program:
This program must be water-only at 1,270 mm (50 inches) per minute.
The height of the cutting head must be 13 mm (0.5 inch) above the cutting surface.
If applicable, the height sensor foot must be tethered or inoperable.
The program moves the cutting head around the perimeter of the table then back and forth every 305 mm (12 inches)
along the longest side of the table.
PowerDredge Instruction Manual 808990 41
4 – Maintenance
1
1
2
2
Replace the bag
Look in the self-tipping hopper daily to see how much abrasive is in the abrasive bag. When the bag is 3/4 full, replace
the bag.
WARNING!
Turn OFF and lockout/tagout the air supply to the pump according to your company’s lockout/tagout
procedure before you do any maintenance.
The water in the self-tipping hopper and bag contains waste material. The water is not potable and
may be hazardous to your health if contact is made.
Remove the bag
1. Close the air valve on the pump.
2. Close the gate valves on the side of the waterjet tank.
42 PowerDredge Instruction Manual 808990
3. Disconnect the hose that goes into the dispersion tube from the pump.
334
5
4
5
6
7
6
7
4. Remove the dispersion tube from the top of the self-tipping hopper .
4 – Maintenance
Use 2 people to lift the dispersion tube.
5. Remove the carrying loops from the shackles and replace the shackles in the metal tabs.
PowerDredge Instruction Manual 808990 43
4 – Maintenance
6. Use the following steps to use a fork lift vehicle to lift the bag. If you have a crane, go to step 7.
WARNING!
Follow your company’s forklift vehicle and/or crane safety procedures while moving the bag.
The abrasive bag can be up to 1,360.8 kg (3,000 lbs). Use lifting equipment that can safely
lift and move the bag.
a. Set the forks on the vehicle to the same width as the self-tipping hopper.
CAUTION!
To prevent the carrying loops from tearing, the forklift vehicle forks must be dulled or protected. The
bag must be lifted vertically, using all four carrying loops.
b. With the vehicle forks parallel to and
approximately 50.8 mm (2 inches) above the
top of the self-tipping hopper, slowly move the
forklift vehicle toward the self-tipping hopper.
c. As the forks approach the first set of carrying
loops, put the forks through the respective
loops.
d. As the forks approach the second set of
carrying loops, put the loops on the forks. Make
sure that the carrying loops are not twisted.
7. Use the following steps to use a crane to lift the
bag.
a. Align the crane over the bag.
b. Use a frame or similar device to keep the carrying loops aligned vertically with the corners of the bag.
CAUTION!
To prevent the carrying loops from tearing, do not pull the carrying loops to the center.
The bag must be lifted vertically, using all four carrying loops.
c. Attach the carrying loops to the frame or similar device. Make sure that the carrying loops are not twisted.
44 PowerDredge Instruction Manual 808990
4 – Maintenance
8. Take the bag to the disposal area immediately.
WARNING!
WET FLOOR
The floor can become slippery when wet. The bag will leak water onto the floor.
9. Discard of the bag and contents. You can separate the bag from the contents, if necessary. See Empty the bag on
page 47.
WARNING!
Always follow your company and local regulations for proper disposal of the bag, abrasive, and water
that contains waste material.
PowerDredge Instruction Manual 808990 45
4 – Maintenance
1
2
3
1
2
3
4
5
4
5
6
6
Install the bag
1. Put an empty bag into self-tipping hopper.
Make sure that the bag is pushed down into the self-tipping hopper.
2. Insert the carrying loops into the shackles , and put
shackles in the metal tabs on the self-tipping hopper.
3. Put the dispersion tube on the top of the self-tipping
hopper .
Use 2 people to lift the dispersion tube.
Make sure that the bag is between the dispersion tube
and the side of the self-tipping hopper.
4. Attach the hose to the dispersion tube.
Make sure that the hose is latched.
5. Open the gate valves on the side of the waterjet tank.
6. Open the air valve on the pump to start the flow of water and abrasive through the system.
46 PowerDredge Instruction Manual 808990
Empty the bag
1. Put the bag over the abrasive disposal area.
The bag has 3 ties on the bottom.
2. Use pliers to release the 2 side ties.
4 – Maintenance
WARNING!
Keep the area near the bag clear of people and tools. The abrasive and any water in the bag will
immediately fall into the disposal area when you release the last tie.
3. Use pliers to release the middle tie.
4. Discard of the bag.
WARNING!
Do not reuse the bag. The bag is for one-time use only.
Always follow your company and local regulations for proper disposal of the bag, abrasive, and water
that contains waste material.
PowerDredge Instruction Manual 808990 47
4 – Maintenance
1
1
223
4
3
4
Clean the strainer weekly
Clean the standard strainer
1. Close the air valve on the pump.
2. Close the gate valves on the side of the waterjet tank.
3. Remove the cover from the short end of the standard strainer .
48 PowerDredge Instruction Manual 808990
4. Remove the intake filter .
5
5
5. Discard the contents.
4 – Maintenance
WARNING!
Always follow your company and local regulations for proper disposal of the bag, abrasive, and water
that contains waste material.
6. Flush the filter with water.
7. Install the clean filter into the standard strainer.
8. Tighten the cover onto the end of the standard strainer.
9. Open the gate valves on the side of the waterjet tank.
10. Open the air valve on the pump to start the flow of water and abrasive through the system.
PowerDredge Instruction Manual 808990 49
4 – Maintenance
1
1
223
4
3
4
Clean the heavy-duty strainer
1. Close the air valve on the pump.
2. Close the gate valves on the side of the waterjet tank.
3. Remove the cover from the heavy-duty strainer .
4. Remove the intake filter.
50 PowerDredge Instruction Manual 808990
4 – Maintenance
5. Discard the contents.
WARNING!
Always follow your company and local regulations for proper disposal of the bag, abrasive, and water
that contains waste material.
6. Flush the filter with water.
7. Install the clean filter into the heavy-duty strainer.
8. Tighten the cover onto the end of the heavy-duty strainer.
9. Open the gate valves on the side of the waterjet tank.
10. Open the air valve on the pump to start the flow of water and abrasive through the system.
PowerDredge Instruction Manual 808990 51
4 – Maintenance
Clean the self-tipping hopper annually
WARNING!
Follow your company’s forklift vehicle and/or crane safety procedures while moving the self-tipping
hopper.
Stay clear of the self-tipping hopper.
Always follow your company and local regulations for proper disposal of the bag, abrasive, and water
that contains waste material.
1. Remove the bag from the self-tipping hopper. (See Remove the bag on page 42.)
2. Remove the overflow from the self-tipping hopper.
3. Use a forklift vehicle to move the self-tipping hopper to the disposal area.
a. Insert the forklift vehicle forks into the opening in the base with forks spread as wide as possible. Make sure that
the forks do not go past the front of the base.
b. Tilt the mast of the forklift vehicle back to prevent the self-tipping hopper from falling off of the forks.
c. Lift the self-tipping hopper to the minimum practical height and move at a safe speed.
4. Remove the safety cable ties on the self-tipping hopper.
5. Release the handle on the self-tipping hopper.
6. Tilt the mast of the forklift vehicle slightly forward to remove the water and abrasive from the self-tipping hopper.
7. Tilt the mast of the forklift vehicle back.
8. Put the handle on the self-tipping hopper into the locked position.
9. Install new safety cable ties on the self-tipping hopper.
10. If necessary, put the self-tipping hopper on the ground and use a shovel to remove the remaining abrasive.
11 . Use a forklift vehicle to move the self-tipping hopper back into its original position.
12. Install the overflow on the self-tipping hopper. (See step 8 on page 34.)
13. Install a bag in the self-tipping hopper. (See Install the bag on page 46.)
52 PowerDredge Instruction Manual 808990
Pump maintenance
1
1
2
2
3
4
5
3
4
5
See the pump manufacturer’s manual for more detailed information on pump maintenance.
Replace the ball valves and seats
1. Close the air valve on the pump.
2. Close the gate valves on the side of the waterjet tank.
4 – Maintenance
3. Disconnect the air supply from the pump.
4. Disconnect the water hoses from the pump.
5. Remove the small clamps from the top of the pump.
6. Remove the discharge manifold .
PowerDredge Instruction Manual 808990 53
4 – Maintenance
6
7
6
7
8
9
10
11
8910
11
7. Remove the ball valve and seat from the top of each liquid chamber.
8. Remove the small clamps from the bottom of the pump.
9. Lift the pump off of the intake manifold .
10. Remove the ball valve and seat from each side.
11 . Install the new seats and ball valves in the intake
manifold.
12. Put the pump on the intake manifold.
13. Install the small clamps on the bottom of the pump.
14. Install the new seats and ball valves in the top of each
liquid chamber .
15. Put the discharge manifold on top of the pump.
16. Install the small clamps on the top of the pump.
17. Connect the water hoses to the pump.
18. Connect the air supply to the pump.
19. Open the gate valves on the side of the waterjet tank.
20. Open the air valve on the pump to start the flow of water and abrasive through the system.
54 PowerDredge Instruction Manual 808990
Replace the diaphragms
1
1
223
4
3
4
Remove the diaphragm assemblies
1. Close the air valve on the pump.
2. Close the gate valves on the side of the waterjet tank.
4 – Maintenance
3. Disconnect the air supply from the pump
4. Disconnect the water hoses from the pump.
PowerDredge Instruction Manual 808990 55
4 – Maintenance
7
6
5
5
6
7
8
8
9
9
5. Put a mark on the pump between the large clamps to
help with assembly.
6. Remove the small clamps from the top of the pump.
7. Remove the discharge manifold .
8. Set the ball valves aside.
9. Remove the small clamps from the bottom of the pump.
10. Lift the pump off of the intake manifold .
11 . Remove one of the large clamps.
12. Remove the liquid chamber .
56 PowerDredge Instruction Manual 808990
13. Use a wrench to remove the center bolt from the diaphragm assembly.
10
10
14. Remove the remaining large clamp.
15. Remove the remaining liquid chamber.
4 – Maintenance
16. Pull the diaphragm assembly with the center shaft out of the pump.
17. If you are replacing the diaphragms, continue with this procedure. If you are replacing the air end kit, go to step 1 in
Replace the air end kit on page 61.
PowerDredge Instruction Manual 808990 57
4 – Maintenance
Assemble the new diaphragms
1. Put the diaphragm assembly with the center shaft into a vise with
wood blocks and tighten the vise.
2. Use a wrench to remove the bolt from the center shaft.
3. Remove the washer.
4. Replace the diaphragm and assemble the washer and bolt.
5. Use the bolt to install the diaphragm assembly onto the center shaft.
6. Remove the diaphragm assembly from the vise.
7. For the other diaphragm assembly that does not have the shaft,
remove the washer.
8. Replace the diaphragm and assemble the washer and bolt.
58 PowerDredge Instruction Manual 808990
Install the diaphragm assemblies
1. Install the diaphragm assembly with the center shaft into the center of the pump.
2. Install the liquid chamber on the same side.
Use the mark you made in step 5 on page 56 to correctly align the liquid chamber.
4 – Maintenance
3. Install a large clamp to hold this part of the diaphragm assembly in place.
4. Install the remaining diaphragm assembly on the other side of the pump.
5. Install the liquid chamber.
Use the mark you made in step 5 on page 56 to correctly align the liquid chamber.
6. Install the large clamp.
PowerDredge Instruction Manual 808990 59
4 – Maintenance
2
1
1
233
7. Put the ball valves in place.
8. Put the pump on the intake manifold .
9. Install the small clamps on the bottom of the pump.
10. Put the ball valves in place.
11 . Put the discharge manifold on top of the pump.
12. Install the small clamps on top of the pump.
13. Connect the water hoses to the pump.
14. Connect the air supply to the pump.
15. Open the gate valves on the side of the waterjet tank.
16. Open the air valve on the pump to start the flow of water and abrasive through
the system.
60 PowerDredge Instruction Manual 808990
Replace the air end kit
1
2
3
1
2
3
4
5
4
5
Replace the muffler plate and air valve assembly components
1. Loosen the screws on the muffler plate.
2. Remove the muffler plate and air valve assembly from the
center section .
4 – Maintenance
3. Remove the muffler plate from the air valve assembly.
4. Replace the muffler plate gasket and
air valve assembly gasket .
To help position the gaskets, use a
small amount of the NLGI grade 2
white EP bearing grease.
PowerDredge Instruction Manual 808990 61
4 – Maintenance
6
6
7
8
7
8
5. On the air valve assembly, remove the end cap .
6. Replace the O-ring on the end cap.
7. Tighten one of the long screws that you removed from the muffler plate
into the top of the air valve spool .
8. Pull on the screw to remove the spool.
9. Lubricate the bore with NLGI grade 2 white EP bearing grease or
equivalent.
10. Install the new spool.
11 . Install the end cap.
12. Assemble the muffler plate and air valve assembly.
13. Install the muffler plate and air valve assembly and tighten the screws.
62 PowerDredge Instruction Manual 808990
Replace the air chamber components
1
1
2
2
1. Complete Remove the diaphragm assemblies on page 55 before you continue.
2. Use snap ring pliers to remove the snap ring on both sides of pilot spool .
3. Use 2 hex wrenches to remove the air chamber screws .
4 – Maintenance
4. Remove the pilot spool.
PowerDredge Instruction Manual 808990 63
4 – Maintenance
334
4
5
5
5. Remove one of the air chambers from the center section.
6. Remove the other air chamber from the center section.
7. Replace the shaft seal on both sides of the center section.
8. Clean the center hole of the center section.
9. Lubricate the center hole of the center section with NLGI grade 2 white EP bearing grease.
10. Replace the center block gaskets .
11 . Install both air chambers onto the center section.
12. Lubricate the new pilot spool with NLGI grade 2 white EP bearing
grease.
13. Install the new pilot spool.
14. Install the new snap rings on the pilot spool.
64 PowerDredge Instruction Manual 808990
15. Use 2 wrenches to install the air chamber screws.
16. Install the diaphragm assemblies. (See Install the diaphragm assemblies on page 59.)
4 – Maintenance
PowerDredge Instruction Manual 808990 65
4 – Maintenance
66 PowerDredge Instruction Manual 808990
Troubleshooting guide
Problem Cause Solution
Section 5
Troubleshooting
The system pumps only water into the
self-tipping hopper.
Abrasive returns to the waterjet tank. The abrasive-collector bag is full. Replace the bag. See Replace the
The pump is left on for too long after
the cutting head is turned off.
There is not enough abrasive in the
waterjet tank (less than 5 inches from
the bottom of the tank) to pump into
the self-tipping hopper.
The cutting is happening in a small
area of the waterjet tank. The mixing of
the water and abrasive is isolated to a
small area in the tank.
The pressure on the regulator on the
pump is too high.
Turn ON the pump at the start of
cutting and off 30 minutes after stop.
Run a sweeping program during
downtime or once every second day.
See Run a sweeping program on
page 41.
Adjust the gate valves on the tank to
make the flow stronger where the
cutting happens. If you close a group
of nozzles, the suction will be stronger
on the ones that remain open.
Decrease the pressure on the
regulator to approximately 0.83 bar
(12 psi). For more information, see
Start the system on page 37.
bag on page 42.
The abrasive does not sink to the
bottom of the self-tipping hopper
because the water flows too quickly.
Decrease the pressure on the
regulator to approximately 0.83 bar
(12 psi). For more information, see
Start the system on page 37.
PowerDredge Instruction Manual 808990 67
5 – Troubleshooting
Problem Cause Solution
The flow is slow. Abrasive has built up past the nozzles
and clogged the system (14 inches
maximum).
Sweeping is not happening often
enough.
Abrasive solidifies in the bottom of the
waterjet tank.
Foreign materials clog the nozzles. Do not cut with plastic bricks or other
Foreign materials clog the strainer. Clean the strainer. See Clean the
See Reverse the flow of the system
on page 70 or Push air into the tank
on page 69.
Run a sweeping program during
downtime or once every second day.
See Run a sweeping program on
page 41.
Run a sweeping program during
downtime or once every second day.
See Run a sweeping program on
page 41.
materials that can clog the nozzles.
Clear the nozzles. See Reverse the
flow of the system on page 70,
Manually flush the system on
page 72, or Push air into the tank on
page 69
strainer weekly on page 48 or Clean
the heavy-duty strainer on page 50.
Flow is slow and water comes out of
the pump muffler.
Flow is slow but the regulator
pressure is high.
Foreign materials clog the dispersion
tube.
The regulator is set too low. Increase the pressure on the regulator
The regulator is defective. Inspect the regulator. Replace it if
The air supply is not sufficient. Make sure the air supply meets the
A pump diaphragm is defective. Replace the diaphragms. See
A pump ball valve or seat is defective. Replace the ball valves and seats. See
Clear the dispersion tube. See
Manually flush the system on
page 72.
to approximately 0.83 bar (12 psi). For
more information, see Start the system
on page 37.
necessary.
minimum recommended setting. See
Pump on page 25.
Replace the diaphragms on page 55.
Replace the ball valves and seats on
page 53.
68 PowerDredge Instruction Manual 808990
Push air into the tank
1
1
Ta nk
2
3
2
3
3
Use this procedure to push air back into the waterjet tank and unclog the nozzles.
1. Close the air valve on the pump.
2. Close the gate valve immediately after the quick-disconnect.
3. Connect the air supply.
5 – Troubleshooting
4. Open the air valve on the air quick-disconnect to let air go
through the nozzles.
PowerDredge Instruction Manual 808990 69
5 – Troubleshooting
1
1
223
3
Reverse the flow of the system
Use this procedure to reverse the flow of the system to help unclog the system. This procedure cannot unclog the
dispersion tube.
1. Close the air valve on the pump.
2. Close the gate valves on the side of the waterjet tank.
3. Disconnect the hose leading into the dispersion tube from the pump.
WARNING!
WET FLOOR
The floor can become slippery when wet. The hose will leak water onto the floor.
70 PowerDredge Instruction Manual 808990
5 – Troubleshooting
4
5
4
5
4. Hang the open end over the side of the waterjet tank to let it pull clear water from the top of the tank.
5. Interchange the intake hose and discharge hose .
6. Open the gate valves on the side of the waterjet tank.
7. Open the air valve on the pump to start the flow of water and abrasive through the system.
PowerDredge Instruction Manual 808990 71
5 – Troubleshooting
1
1
Manually flush the system
Use this procedure to push water through the system with the waterjet cutting head and help unclog the system.
1. Turn OFF the water to the cutting head.
2. Remove the caps from the vertical pipes in the waterjet tank.
3. Move the waterjet cutting head over the opening.
4. Manually turn ON the water to the cutting head to flush the system.
CAUTION!
Do not let the water run longer than 5 minutes. You will cut a hole in the plumbing or floor of the
system.
5. Turn OFF the water to the cutting head.
6. Install the caps on the pipes.
72 PowerDredge Instruction Manual 808990
Pump kits
Kit number Description
16152 Pump
16139 Kit: Pump - Air end
16138 Kit: Pump - Wet end
16155 Kit: Hoses
Self-tipping hopper kits
Kit number Description
Section 6
Parts
16133 Kit: Abrasive bags (200)
16181 Abrasive bag (1)
16156 Self-tipping hopper
16153 Kit: Overflow tube inside hopper
Strainer kits
Kit number Description
16134 Standard strainer
16135 Heavy-duty strainer
PowerDredge Instruction Manual 808990 73
6 – Parts
Overflow kits
Kit number Description
16136 PVC overflow
16137 Flexible overflow
Other kits
Kit number Description
16154 Air quick-disconnect
16132 Nozzle
74 PowerDredge Instruction Manual 808990
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