Instruction Manual Original instructions 808310 | Revision A | English Instruction Manual 808310 – Revision A 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 System ................................................................................................ 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 System ............................................................................................. 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 System ................................................................................................................ 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 & 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 Drawings & Parts Lists .................................................................................................. 71 12 Controls Manual ............................................................................................................. 73 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.