Hypertherm HyPrecision 100D, HyPrecision 150D Instruction Manual
Instruction Manual
Original instructions
808310 | Revision 0 | English
Instruction Manual
808310 – Revision 0
English
March 2014
Hypertherm Inc.
Hanover, NH 03755 USA
1 Introduction ........................................................................................................................... 3
1.1 Company Overview and Contact Information ................................................................................. 3
1.2 System Overview ............................................................................................................................. 3
1.3 Definitions ....................................................................................................................................... 4
2 Safety....................................................................................................................................... 5
2.1 General Safety .................................................................................................................................. 5
2.2 Safety Symbols ................................................................................................................................ 5
2.3 Operation and Maintenance Safety .................................................................................................. 6
2.4 Emergency Medical Treatment ........................................................................................................ 9
3 Installation ............................................................................................................................ 11
3.1 Installation Overview ..................................................................................................................... 11
3.2 Utility Requirements ...................................................................................................................... 11
4 Operation .............................................................................................................................. 15
4.1 Operation Overview ....................................................................................................................... 15
4.2 Front Control Panel ........................................................................................................................ 15
4.3 Pump Startup .................................................................................................................................. 17
4.4 Pump Operation ............................................................................................................................. 19
5 Electrical System .................................................................................................................. 23
5.1 Electrical System Overview ........................................................................................................... 23
5.2 Electrical Control Panel ................................................................................................................. 23
5.3 Motors ............................................................................................................................................ 27
5.4 System Fault Detection .................................................................................................................. 29
6 Low-Pressure Water ............................................................................................................ 33
6.1 Low-Pressure Water Overview ...................................................................................................... 33
6.2 Inlet Cutting Water Supply ............................................................................................................ 33
6.3 Cooling Water Loop (Not all Models) ........................................................................................... 36
7 High-Pressure Water ........................................................................................................... 37
7.1 High-Pressure Water Overview ..................................................................................................... 37
7.2 Intensifier ....................................................................................................................................... 38
7.3 High-Pressure Ends ........................................................................................................................ 38
7.4 Check Valve Assembly .................................................................................................................. 41
7.5 Hydraulic Seal Housing ................................................................................................................. 44
7.6 Hydraulic Center Section ............................................................................................................... 45
7.7 Intensifier Cycling ......................................................................................................................... 47
7.8 Pump Bleed-Down Valve .............................................................................................................. 48
7.9 Attenuator ...................................................................................................................................... 49
7.10 High-Pressure Filter Assembly (Optional) ................................................................................ 49
7.11 High-Pressure Plumbing Weep Holes ....................................................................................... 50
8 Hydraulic .............................................................................................................................. 51
8.1 Hydraulic Oil ................................................................................................................................. 51
8.2 Control Manifold ........................................................................................................................... 53
8.3 Oil Filter ......................................................................................................................................... 54
8.4 Heat Exchanger .............................................................................................................................. 54
1
8.5 Hydraulic Tank .............................................................................................................................. 55
8.6 Main Pump Setup ........................................................................................................................... 55
9 Specifications ........................................................................................................................ 57
9.1 Pump Requirements ....................................................................................................................... 57
9.2 Pump Capabilities .......................................................................................................................... 60
9.3 Orifice Combinations ..................................................................................................................... 60
9.4 Inlet Cutting Water Requirements ................................................................................................. 60
9.5 Water Treatment Guidelines: ......................................................................................................... 61
9.6 Torque Specifications .................................................................................................................... 62
10 Maintenance and Troubleshooting ................................................................................ 63
10.1 Parts and Service Contact Information ...................................................................................... 63
10.2 Maintenance Guidelines ............................................................................................................ 63
10.3 Troubleshooting ......................................................................................................................... 65
10.4 Maintenance Log ....................................................................................................................... 69
11 Document Revisions ........................................................................................................ 71
12 Drawings and Parts Lists ............................................................................................... 73
13 Controls Manual ............................................................................................................. 75
2
1 Introduction
1.1 Company Overview and Contact Information
Our Mission
To contribute to the waterjet community through the engineering, manufacturing, and sale of high
quality waterjet products that lower the operating cost as an alternative to costly laser and plasma
cutting.
We take pride in being a company that is recognized for its honesty, integrity, and personal service.
We strive for the greatest reliability and quality in our products and technical support.
The Company
Hypertherm is a waterjet supply company with a history of providing economical solutions for a broad
range of customers through the engineering, manufacturing, and sale of quality products and parts.
Hypertherm's rapid shift to the forefront of the waterjet industry can be attributed to our product
reliability and an unyielding focus on customer feedback and support. Hypertherm has quickly earned a
reputation for superior customer satisfaction and unparalleled service from a well-trained customer and
technical support staff.
History
Hypertherm's background in waterjets started in the mid-1980s with the development, application, and
sale of waterjet products for a major equipment manufacturer. In the late 1990s Hypertherm was started
with the goal of supplying quality spare parts and innovative products to help waterjet users lower their
operating cost. Today, the company has become the leading source for industrial waterjet products.
Customer & Technical Servic e
At Hypertherm, your purchase is only the beginning of our commitment to help you succeed. We
believe that what happens after the sale is just as important as what happens before.
Customer Service Representatives are avai lab le to tak e your calls Monday throu g h Friday 8:00 AM to
5:00 PM CST. If you need service after-hours Hypertherm is also on-call 24 hours a day, 7 days a week
to ensure your system is up and running around the clock.
For more information, please call Customer Service toll-free at 800-991-4225.
1.2 System Overview
Introduction
Pump Identification Form
Hypertherm SERIAL NUMBER ____________________________________________
For additional copies of this manual and/or other assistance, please contact:
Hypertherm, Inc.
309 5th Ave NW
New Brighton, MN 55112
+1 800-991-4225
3
1.3 Definitions
LP water: Low-pressure water that is supplied to the intensifier for pressurizing.
HP water: High-pressure water that is directed to the tool after being pressurized by the intensifier
assembly.
Coolant water: Water that is circulated through the heat exchanger for cooling the hydraulic fluid.
Pump: A HyPrecision pump.
ID: Inside diameter.
RPC: Remote Pump Control allows operation of the pump from a remote control source.
OCS: Operator Control Station.
4
2 Safety
2.1 General Safety
This section describes the hazards specifically related to the operation and maintenance of HyPrecision
100D/150D Intensifier Pumps. These precautions must be reviewed and understood by operating and
maintenance personnel before installing, operating or servicing the equipment.
The comprehensive list of safety precautions listed in this manual must be followed to ensure safe
operation of the equipment. The safety guidelines found in this manual are general and cannot cover
every possible situation; only thorough knowledge of the equipment can provide optimum safety.
Readers are expected to know how to use common hand tools safely, as well as the basic techniques for
safe operation of pressure-producing equipment.
Always remember that the waterjet stream is a cutting tool! The force of a waterjet
can penetrate and cut through almost any material.
WARNING
ervice procedures in this manual will include safety warnings, cautions, and notes that must be read
S
and understood.
The following symbols are used throughout the manual to bring the reader's attention to known hazards
and conditions, which can be avoided. Although an attempt to point out most conditions was made,
Hypertherm acknowledges tha t there are other unforeseen situations due to site variability, improper
maintenance, etc. that could also potentially cause equipment damage, severe injury, or death. It is the
end user’s responsibility to identify these additional hazards and take necessary steps to minimize risks.
2.2 Safety Symbols
Warnings, cautions, and notes
Always avoid contact with the stream of water. Abrasive waterjets expel a mixtur e
of water and abrasive that, if contact is made with skin, may be injected into the
skin leading to a serious infection. Seek immediate surgical attention if you
WARNING
WARNING
CAUTION
encounter any high-pressure stream of fluid.
Indicates the presence of a hazard, which can cause severe personal injury,
death, and/or substantial property damage if the warning instructio n is ignored.
Highlights important instructions, which must be followed to prevent personal
injury and/or equipment damage.
5
IMPORTANT
Hazardous voltage within can cause injury or death. Disconnect and lock out main
Draws attention to items of important factual or procedural significance. Failure to
follow the instructions may result in equipment damage.
power before opening the cabinet.
High-pressure waterjet can cause eye injury. Wear eye protection when operating
or working near the machine.
Wear ear protection when operating or working near the machine to reduce the
risk of hearing loss.
Airborne contaminants or suspended particles may exist when cutting certain
materials. Wear respiratory protection when these conditions are present.
2.3 Operation and Maintenance Safety
Read and understand the Operation section of this manual before operating the equipment. People who
have not been trained in the safe operation of this waterjet machine should not be allowed near the
system.
• Always wear safety glasses when working on or near the pum
• Clean and inspect equipment regularly and fix all problems immediately.
• The operation and maintenance of this system should only be performed by trained, qualified
personnel.
• Ensure that all personnel not involved in operating the machine are a safe distance from the
equipment.
• Keep the work area clean and free of water or fluid spills.
Operating Safety
Failure to wear proper safety gear can result in personal injury or death. Safety shoes, hardhat, hearing
protection, and other personal protective equipment are strongly recommended.
High-pressure waterjet can cause eye injury. Wear eye protection when operating
or working near the machine.
p.
Wear ear protection when operating or working near the machine to reduce the
risk of hearing loss.
6
Airborne contaminants or suspended particles may exist when cutting certain
ause injury or death. Disconnect and lock out main
materials. Wear respiratory protection when these conditions are present.
Maintenance Safety
• Read the instructions in all sections of this manual before performing any maintenance on the
pump. Important information is contained throughout this manual to minimize hazards and wear
t
he machine.
Before starting any ser vice or maintenance, turn off electrical power and relieve
all water and hydraulic pressure. Proper lockout/tag-out procedures must always
be followed prior to performing any maintenance of the unit.
WARNING
• Use the proper too ls requ ir e d for speci fic pro cedu res. When special tools are called for, make sure
t
o use them because they are specifically designed to make the job easier and prevent damage to th
e
quipment
• R
emove all tools from the work area before starting the machine.
.
• Always test the pump after service or maintenance: follow startup procedures outlined in the
Operation section of this manual.
Electrical System Safety
on
e
• Always make certain the electrical current is shut off a nd the proper lock o ut/t ag-out procedures
have been followed before starting any service or maintenance procedures.
Hazardous voltage within can c
power before opening the cabinet.
• Make sure that all safety devices are operational.
• To panic-stop the pump and bleed the high pressure, push in the EMERGENCY STOP button.
• Open the main power circuit breaker (plant-supplied power) before beginning the procedure. Attach
a safety tag warning others not to turn the power o
• W
hen replacing wiring, use only the same size, type, and color as the original
fter servicing, ensure all electrical breakers are reconnected and doors and covers are closed
• A
n.
.
before restarting.
• To check emergency system: turn on power and push the EMERGENCY STOP button(s). Chec
he system to make sure it has been shut down properly.
t
k
7
High-Pressure Water System Safety
Never work on any high-pressure component or loosen any high-pressure fittings without first bleeding
the system to ensure that there is no high-pressure water present. Follow all instructions and safety
recommendations in this manual.
Always avoid contact with the stream of water. Seek immediate surgical attention
if you are exposed to any high-pressure stream of fluid.
WARNING
• Avoid contact with the high-pressure water. HP water can penetrate any part of the human body and
cau
se severe infection or death if not treated properly. Seek immediate surgical attention if y
c
ome in contact with any high pressure stream of fluid.
• Do not try to repair a leak on any HP water fitting when the system is pressurized. A leak at
seal
ing surface can cause a hazardous spray of water. Shut off the motor and verify the HP water
pressure is relieved down the drain before servicing any high-pressure plumbing.
• Plumbing supports and guides must be used for all HP tubing exiting the pump. Failure to do so ca
introduce excessive bending stress and fatigue through vibration causing premature failure of the
plumbing, and heighten risk of personal injury due to an unexpected rupture.
• Always use two wrenches when tightening or loosening HP connections: one for the gland nut and
for the fitting. This will prevent excessive bending stress and premature failure of th
one
pl
umbing.
• Always use high-pressure piping rated for the type of system you are operating. This pump is
capable of outputting 60,000 psi of water.
ou
a
e
n
Hydraulic System Safety
Pressurized fluid streams can penetrate skin, causing severe personal injury or
death. If any fluid is ejected against the skin, seek immediate surgical attention.
WARNING
• Make sure all connections are properly tightened after performing service or maintenance.
• Keep hands and body away from pinholes and nozzles, which eject fluids under high pressure
ever check for hydraulic leaks with your hand: use a piece of cardboard or other material.
• N
• Do not expose skin to a pressurized leak.
• Wear appropriate protective equipment including heavy gloves and safety glasses.
• Do not attempt to tighten or loosen any mechanical connection unless the machine is powered off
and all system pressure has been relieved.
.
8
Motor/Pump Assembly Safety
Beware of moving equipment. Keep clothing and hands away from equipment that
is operating. Always verify covers and shields are in place before starting
equipment.
WARNING
2.4 Emergency Medical Treatment
Waterjet equipment can cause severe injury and infection. Anytime a person comes in contact with a
high pressure stream of fluid, it must be reported immediately and treated. It may look as though
nothing happened, but a serious infection and possible amputation may result if immediate surgical
attention is not received.
Always seek immediate surgical attention if you come in contact with any high pressure stream of fluid.
Failure to do so can result in severe infection.
The injury should be treated as an acute surgical emergency and be evaluated by a qualified surgeon.
Circulation may be compromised therefore DO NOT apply heat. K eep effec ted pe rson awak e and
elevate injured part.
Inform the medical personnel that the victim has been working with a high-pressure mixture of water
and abrasives at up to 60,000 psi and a nozzle velocity of up to 2,000 feet per second. Waterjet injuries
have been known to cause infections with micro-Europhilic organisms such as gram-negative pathogens
like those found in sewage.
9
Emergency me dic al in f ormation
MEDICAL ALERT
Anyone who receives equipment related injuries while operating high-pressure water equipment
should be given immediate hospital attention. It is vital that waterjet operators carry a waterproof
emergency medical tag or card that describes their work and the nature of injuries inherent in using
waterjet cutting devices.
This card provides general purpose information to aid in relaying information to medical or emergency
personnel.
This card is to be carried by personnel working
with high-pressure waterjet equipm ent . Obtain
medical treatment immediately for ANY highpressure waterjet injuries.
Hypertherm Inc.
309 5th Ave NW
New Brighton, MN 55112
+1 651-294-8600
This person has been working with water jetting at pressures to
60,000- psi (4,137bar) with a jet velocity of 2000fps (610 mps).
This should be taken into account during diagnosis. Unusual
infections with microaerophilic organisms occu r ring at lower
temperatures have been reported. These may be gram-negative
pathogens, such as those found in sewage. Bacterial swabs and
blood cultures may therefore be helpful. A local poison control
center should be contacted for additional treatment information.
10
3 Installation
3.1 Installation Overview
Buyer Obligations
The buyer of a HyPrecision 100D/150D waterjet pump is responsible to cooperate with Hypertherm and
Hypertherm OEM personnel to facilitate installation of the machine.
• The pump should be uncrated and placed as close as possible to the position where it will be used.
• All utilities must be provided prior to installation as o utl in ed in th e Specifications section of this
manual.
• The buyer should install high-pressure tubing unless other arrangements have been made in th
sal
es agreement.
• Water treatment equipment should be in place prior to the installation of the pump. Water must
meet the minimum requirements as outlined in the Specifications section of this manual.
• All connections to the pump are the responsibility of the buyer. It is the buyer's responsibility to
esearch and comply with all local codes including wastewater disposal.
r
Hypertherm may or may not supply the pump without any hydraulic oil in the tank. It may be the
buyer's responsibility to fill the tank with the appropriate oil per instructions in the Hydraulic section of
this manual.
Seller Obligations
e
• If Hypertherm, Inc. is the installing party, some or all of the following tasks will be the
responsibility of the Hypertherm techn ician at ins talla ti on as defined in the sal es ag reement.
• Make sure the buyer has been informed of all buyer obligations and make sure the site has been
properly prepared prior to installation.
• Make sure all utility connections have been properly provided as outlined in the Specifications
section of this manual.
• Follow all first time startup and setup instructions as provided in the Operations section of thi
m
anual.
• Train maintenance personnel on proper service and repair procedures.
• Follow sta nda rd sy stem acceptan ce tes ts.
3.2 Utility Requirements
Site Preparation
Certain locations may be hazardous if the atmosphere contains gas, vapors, or
dust in explosive quantities. Refer to the National Electric Code (NEC), IEC, OSHA
requirements, and local codes for detailed information about environmental
WARNING
The facility must have adequate air, water, sewer drain, and electrical service per the Specifications
section prior to installation of the equipment.
Floor material should be concrete capable of supporting the weight of the machine, and thick enough to
provide resistance to vibration.
criteria.
s
11
Water Requirements
flow prevention valve be supplied to separate
Local codes may require that a backthe pump from the building potable water. Consult local codes for the required
type and necessity of a valve.
IMPORTANT
Cutting Water
The water supplied to the intensifier is a crucial factor in precision waterjet cutting because of its direct
effect on the service life of equipment components. The pump's built-in filtration is sufficient for
removal of suspended solids. Total Dissolved Solids (TDS) in the inlet water will have an adverse effect
on check valves, seals, orifices, and other consumables. Most systems require that the water be softened
at a minimum before it enters the pump.
Before installing the system have a water quality analysis performed by a local company that can
provide water-conditioning equipment. See the Inlet Cutting Water Requirements section under
Specifications for specific conditioning requirements.
Cooling Water (if supplied with a Water/Oil Heat Exchanger)
The heat exchanger uses regular tap water for cooling the hydraulic fluid. Hydraulic fluid temperature
must be maintained below 130ºF. The hydraulic cooling water section of the Specifications area of
this manual details the cooling water flow and temperature requirements.
In most cases public-utility water is acceptable. In situations where the water contains heavy mineral
deposits, the cooling fins in the heat exchanger may become clogged with buildup. In these
circumstances pre-filtration and/or softening may be necessary. Depending on plant setup, ambient
temperature can also be a factor in cooling. Where the equipment is confined to a small hightemperature space, additional cooling may be required.
Sewer Requirements
The pump has two outlet lines. The WASTE WATER OUT line carries any rejected cut water from the
bleed-down valve. The COOLING OUT line carries the water exiting the heat exchanger in water
cooling units. DO NOT couple lines.
Both outlets require independent lines to the sewer drain to prevent exiting cooling water from backing
up into the system. The wastewater outlet plumbing must be lower than the outlet connection on the
pump. This will prevent potentially dirty water from backing into the bleed down valve causing closure
problems.
12
Electrical Requirements
WARNING
When connecting power to the pump it is the buyer's responsibility to investigate
and comply with all local codes. The power requirements are listed on the serial
plate on the back of the pump as well as on the inside of the electrical enclosure
CAUTION
door.
Three phase power connection
Each of the three phases of input power are connected t o the three (3) terminals at
the top of the motor switch (right). Additionally a ground leg must be attached to
the grounding lug inside the electrical cabinet.
Pumps equipped for certain foreign power may have slightly different connection
requirements. Always refer to the electrical schematic for the machine to verify
proper connection.
Schematics are supplied in the Drawing s and Part s Lists section of the manual and
an additional copy is included inside the electrical cabinet.
Location Requirements
• The pump must be placed in a location, which allows access to all sides for service.
• The pump should have a minimum 36 in. clearance surrounding the machine, free of all obstacles,
to allow room for service. See the Pump Requirements section under Specifications
• The pump should not be placed in any environment where the temperature is below freezing. If
freezing temperatures are expected before operating again, drain all water lines and filter housings
after work is completed for the day.
.
If a water line, fitting, or valve may be frozen, DO NOT operate the machine. The
system must be thawed until water flows freely through the entire water circuit.
Recommended Tools
Most maintenance of the pump can be accomplished using standard tools. Re fe r to the recomm ended
tools list in the Drawings and Parts Lists section. Contact Hypertherm to purchase replacement
specialty tools for intensifier and bleed-down valve servicing.
13
14
4 Operation
4.1 Operation Overview
This section outlines the operation of the Front Control Panel, as well as startup procedures, and normal
operation. The HyPrecision 100D/150D pumps are controlled from the front control panel.
The main disconnect on the electrical enclosure must be turned on in order for the pump to function.
4.2 Front Control Panel
The HyPrecision 100D/150D pumps are controlled via an Operator Control Station (OCS) attached to
the outside of the Electrical enclosure. The OCS monitors all fault conditions and controls the
intensification process. Certain pump models referred to as OEM may not have a control panel. In this
case, refer to the manual for the equipment that is controlling the pump.
The OCS is equipped with digital inputs and outputs for monitoring all pump and environmental
conditions as well as controlling the functions of the pump.
Other features include intensif ier enabl e/d isa ble, intensifier-overstroke threshold setup, and alarm
logging.
Log files are stored on a removable MicroSD card. When troubleshooting is necessary, the card can be
removed from the pump and the information transferred via a USB reader to Hypertherm technicians.
Program updates can also be installed by simply copying a new program onto the card and replacing it
in the pump.
No service is necessary on the OCS. All inputs and outputs run to terminal blocks, which should be used
for wiring the remote options. Refer to the supplemental control manual, for additional details about
control operation and features.
Standard Control P anel
Base model pumps have the standard control panel. The standard control panel
has an OCS panel, hydraulic gauge, cut pressure adjustment knob, and pierce
pressure adjustment knob. In addition, there are water gauges indicating the pre
and post filter water pressure.
The following image shows the standard control panel (all HyPrecision
100D/150D models).
CONTROLS ON: Enables the pump controls.
LOCAL/REMOTE KEYSWITCH: Switches from local pump control to
remote pump control. See Remot e Pump Operation under the Operation
section in this manual.
EMERGENCY STOP: Shuts off controls, motors, and intensifiers, and bleeds
down the high-pressure water.
REMOTE ACTIVE light: Lit when pump is in remote pump control mode or
remote pressure control mode.
15
Depending on the type of pump model(s) you have the layout of the gauge panel will vary.
The PIERCE PRESSURE and CUT PRESSURE adjustment knobs, located on the gauge panel, are
manually operated.
Units with the optional analog pressure control will not have the CUT PRESSURE and PIERCE
PRESSURE control knobs, which are replaced with a high precision electrical control valve.
CUT PRESSURE knob (if applicable): Adjusts Pressure Set Point 1 (Cut). See Adjusting the Cut and
Pierce Pressure in the Operation section for more information.
PIERCE PRESSURE knob (if applicable): Adjusts Pressure Set Point 2 (Pierce). See Adjusting the
Cut and Pierce Pressure in the Operation section for more information.
HYDRAULIC PRESSURE gauge: Displays the hydraulic pressure of the pump. Pumps with more
than one hydraulic pump will have additional gauges. The hydraulic pressure gauge can be useful in
determining the approximate cut pressure. To do so, use the following formula:
Cut Pressure = 19.25 X Hydraulic Pressure
PRE-FILTER WATER PRESSURE gauge: Displays the water pressure before the filter bank. See
the Low-Pressure Water section of this manual for more information.
Normal operating range: 40-110PSI
POST-FILTER WATER PRESSURE gauge: Displays the water pressure after the filter bank. See the
Low-Pressure Water section of this manual for more information.
Normal operating range: 40-110PSI
50S 60S 75S
16
4.3 Pump Startup
Initial or Post-Maintenance Startup
The first time you start up your pump it is important that the Pre-Startup Inspection, Motor Direction
Check, and First Tim e Sta rt up procedures (below) be performed to prevent serious damage to the pump
components. Make sure that all installation requirements have been met prior to performing any of the
following checks. Follow all safety procedures as outlined in the Safety section of this manual.
It is common to identify leaks in the high-pressure water, low-pressure water, and possibly hydraulic
circuits while performing these procedures. Always stop the procedure and correct the leaks before
continuing.
Pre-Startup Inspection
1. Verify all safety circuits are connected and operational.
2. Check the sight gauge to make sure the hydraulic reservoir is full. Add oil as necessary to bring
the oil to an acceptable level. Refer to Hydraulic Oil in the Hydraulic section in this manual for
instructions on adding oil.
3. Verify all utilities are connected to the pump and turned on at the plant.
4. Check for loose hoses and fittings and make sure there are no leaks present.
Motor Direction Check
This procedure involves exposing a rotating shaft. Never place any object or any
part of your body near the shaft while exposed. Only visual inspection should be
used to prevent bodily injury. Be prepared to press the EMERGENCY STOP
CAUTION
IMPORTANT
button.
The motor direction check should be performed anytime electrical maintenance
has been performed on the electrical panel, motor wiring, or line wiring to the
pump. Improper motor rotation can cause irreversible damage to the hydraulic
pump and components.
1. Open or remove the front cover from the pump and locate the motor rotation arrow.
2. Remove the safety cover on the pump mount and visually inspect the coupling rotation.
3. To jog the motor, pull the EMERGENCY STOP button on the control panel, and then press the
CONTROLS ON button.
4. Press
(COOLING MODE) and then press ( PU MP OFF) to jog the motor. Verify
visually that the shaft is rotating the same way the motor rotation arrow indicates.
If the motor rotates in the wrong direction, swap two of the wires at the starter panel's MAIN
DISCONNECT, not at the motor or starter contactors, and then recheck the rotation. After verifying
motor rotation, replace the safety cover on the pump mount and the side covers. Also, see Motors in the
Electrical System section for additional information.
17
First Time Startup
The following first time startup procedure should be followed after any service has
been performed on the intensifier,
assemblies.
high-pressure water, or low-pressure water
IMPORTANT
1. Make sure the cut pressure and pierce pressure adjustment knobs are backed out all the way. If
the pump has analog pressure control make sure the pressure setting is 10ksi or less.
The pump may have been shipped with loose fittings, filters, and components
depending on winterization requirements, where the pump is shipped to, and
other environmental factors. Make sure that all of the water fittings and loose
components are tightened before proceeding to the next step.
2. Prime the flow of the cutting water:
a. Disable the Intensifier.
b. Open the cutting head.
c. Turn the source water on.
d. Let sit for 2-3 minutes
epress the red button on the top of each of the filter housings to bleed air from the canisters.
e. D
f. Close the cutting head.
.
3. Start the pump by pressing the
t
hat the boost pressure meets the inlet water requirements as outlined in the Specifications
(PUMP ON) button on the touchscreen display. Make sure
section of this manual.
4. Check again for any leaks and loose fittings. Take any corrective action and then proceed to the
next step.
5. Flush the pump and high-pressure lines using the following procedure.
Flushing HP Water Lines
After installation of a new pump and high-pressure lines, it is common for small pieces of metal and
debris to be present in the high-pressure lines.
NEVER perform the initial startup with a diamond orifice in place. The likelihood of
damaging the orifice during the initial startup is very high!
IMPORTANT
It is important to flush the system to prevent damage to orifices, on/off valve
parts, and other parts of the HP system.
The following procedure describes one method to “flush out” the HP lines. If you purchased your
Hypertherm pump through an OEM, they may have their own procedure that they recommend. During
this procedure, damage may occur to the on/off valve sealing parts and orifices. Make sure to have spare
kits and orifices available before starting the procedure.
18
This flushing procedure should be followed after any replacement or service to the high-pressure lines
and fittings have been performed on the pump.
1. Make sure the pierce pressure control knob is backed out all the way, and the pump pressure is set
to 10ksi or less. See Adjusting the Pump Pressure in the Operation section for more
information.
2. Remove the cutting head and orifice leaving just the on/off valve body and adapter.
3. Set the pump pressure to 20ksi (approximately 1000 psi hydraulic) using the pump compensator
S
ee Adjusting the Pump Pressure in the Operation section for more information.
4. If possible, use your CNC control to make a program that will turn on and off the valve in onesecond increments and run the program in a loop for 15 minutes. This will shock the HP tubing
and free any debris present in the lines.
Any debris that breaks can cause damage to your on/off valve needle and seat. If
this happens, try to complete this procedure by removing all debris from the
components rather than replacing the parts right away.
5. Replace the sapphire orifice in the cutting head with one that is appropriately sized for your
pump.
6. Set the pump pressure to 40ksi (approximately 2000 psi hydraulic) and repeat the program
(above) for another 15 minutes.
7. Turn the pressure up to 60ksi (3000 hydraulic) and repeat the program again for 15 minutes.
8. If necessary, replace the on/off valve needle, seat, and seals as well as any damaged orifices.
.
Normal Startup Procedure
1. Verify all safety circuits are connected and operational.
2. Check the sight gauge to make sure the hydraulic reservoir is full. Add oil as necessary to bring
the oil to an acceptable level. Refer to Hydraulic Oil in the Hydraulic section of this manual
for instructions on adding oil.
3. Verify all utilities are connected to the pump and turned on at the plant.
4. Check for loose hoses and fittings and make sure there are no leaks present.
5. Press
start generating pressure at the Pressure Set Point 2 (Pierce) for five seconds before switching to
Pressure Set Point 1 (Cut).
Refer to the Pump Operation section for instructions on setting the pressure set points.
(PUMP ON) and verify that the boost pump pressure is 50-115 psi. The pump will
4.4 Pump Operation
After startup inspections have been completed and the machine is running, no further direct action from
the operator is required. Periodically check warning indicators and gauges and inspect everything
visually to ensure developing problems are detected before the equipment is damaged.
Normal Operation
During normal operation, the pump will continue to stroke to meet the cutting water demand. When the
cutting nozzle is closed, the pump will operate on standby; hydraulic pressure remains at the set
pressure and the intensifier is idle. It is normal to see an increase in the pressure of the output water.
This is called the "Dead Head Rise." When the cutting nozzle is turned on the intensifier will begin to
stroke again at a rate to meet the demand.
19
Adjusting the Cut and Pierce Pressure
The cut pressure and pierce pressure can be adjusted using the knobs on the front of the pump. To adjust
the cut and pierce settings for pumps equipped with Analog Pressure Control, refer to the following
section. To adjust the cut and pierce pressure, the pump must be running.
To adjust cut pressure, the CUT PRESSURE icon
activate the cut pressure. To increase cut pressure, turn the cut pressure knob clockwise. To decrease cut
pressure, turn the knob counterclockwise.
To adjust the pierce pressure, the PIERCE PRESSURE icon
the icon to activate the pierce pressure. To increase pierce pressure, turn the pierce pressure knob
clockwise. To decrease pierce pressure, turn the knob counterclockwise.
If the set point of the cut pressure is lower than the set point of the pierce
pressure in the PIERCE mode, the pump will operate at the lower cut pressure.
Tip: To extend the life of your high-pressure seals and other high pressure components, turn the cut
pressure all the way down by backing out the cut pressure knob before shutting off the pump. When
restarting the pump, slowly ramp up the cut pressure knob until you are at the desired set point.
must be active (light blue). Touch the icon to
must be active (light blue). Touch
Analog Pressure Control
Pumps that are equipped with Analog Pressure Control operate similar to the standard pumps. The set
point values on the analog pressure control adjust with the OCS rather than the control knobs.
To adjust cut pressure, the CUT PRESSURE icon
Touch the icon to activate the cut pressure. To increase cut pressure, push
To decrease cut pressure, push
on the display.
must be active (light blue).
on the display.
To adjust the pierce pressure, the PIERCE PRESSURE icon
the icon to activate the pierce pressure. To increase pierce pressure, push
pierce pressure, push
on the display.
must be active (light blue). Touch
on the display. To decrease
Remote Pump Operation
Hypertherm HyPrecision 100D/150D Intensifier Pumps come standard with built-in functionality for
remote operation. Information on wiring connections is provided in Electrical Co ntrol Pane l in the
Electrical System section of the manual.
Remote Pump Control (RPC) deactivates the CONTROLS ON, PUMP ON, and COOLING ON at
the front panel of the pump. These inputs are then solely controlled from a remote source.
PUMP OFF and EMERGENCY STOP are active at both the front control panel and the remote
source. RPC is activated by turning the key switch to the REMOTE setting.
20
Normal Shutdown Procedure
Never leave waterjet cutting equipment turned on and unattended.
After the equipment is shut down, always make sure the high-pressure water is
relieved by turning on the cutting head.
CAUTION
1. Turn the cutting equipment OFF.
2. Press the
(PUMP OFF) on the pump control screen.
3. Pull or rotate the main disconnect handle on the panel door to the OFF position (down).
4. Turn OFF the plant cutting and cooling water connections to the pump.
5. Verify the high-pressure water gauge reads zero (if present) or turn on the cutting head to release
any remaining water pressure.
Emergency Shutdown Procedure
The pump has an EMERGENCY STOP palm button located on the front control panel. In the event of
an emergency, press the EMERGENCY STOP palm button. This will immediately remove any
electrical power from the motor and controls. The bleed-down valve will open and the high-pressure
water should be relieved down the drain.
If the pump is configured to run remotely and has a motion system, the emergency circuits from the
robot or cutting table may be in series with the local emergency stop circuit.
In the event that the pump has been shut down from a remote emergency stop circuit, the operator will
need to remove or reset that condition first. The pump can be re-started following the normal startup
procedure listed earlier in this section. A normally closed dry contact is provided at the back of the
EMERGENCY STOP button for remote equipment shutdown.
21
22
Loading...