Hypertherm HyPrecision 15 Operator's Manual
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Hypertherm HyPrecision 15 Operator's Manual

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HyPrecision15/30/50
™
Waterjet Pump
Operator Manual
808240 | Revision 1 | English

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  • Page 1 HyPrecision15/30/50 ™ Waterjet Pump Operator Manual 808240 | Revision 1 | English...
  • Page 2 HyPrecision 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. © 2015 Hypertherm Inc.
  • Page 3 HyPrecision15/30/50 Operator Manual 808240 Revision 1 English Original Instructions July 2015 Hypertherm Inc. Hanover, NH 03755 USA www.hypertherm.com...
  • Page 4 Europe, Middle East, and Africa USA and Canada Technical service Technical service 00 800 4973 7843 Toll-free 800-643-9878 Toll-free +31(0) 165 596900 TechnicalService-Hanover@Hypertherm.com +31(0) 165 596906 Fax Customer service TechnicalService-HyperthermEurope@Hypertherm.com 800-737-2978 Toll-free Customer service Return materials 00 800 3324 9737 Toll-free...

  • Page 5: Table Of Contents

    Differences in national standards ............................SC-15 Higher-level systems ................................SC-15 Environmental stewardship ....................SC-17 Proper disposal of Hypertherm products ........................SC-17 Proper handling and safe use of chemicals ........................SC-17 Particle emission and wastewater quality ........................SC-17 Safety ............................SC-19 User qualification and training ............................
  • Page 6 Contents Air-cooled external heat exchanger ............................43 Water-modulating valve ................................43 4 Operation ............................45 Safety ........................................45 Overview ......................................46 Inspect the pump before operation ............................48 Turn on the pump ...................................48 Turn on the pump locally ...............................48 Turn on the pump remotely ..............................49 Operate the pump ..................................50 Operator interface ..................................50 Operate the pump remotely ..............................58...
  • Page 7 High temperature .................................161 Low water pressure ..................................163 From the intensifier ................................163 To the intensifier ...................................163 Motor fault .....................................164 8 Pump specifications .........................165 HyPrecision 15 .....................................166 HyPrecision 30 .....................................167 HyPrecision 50 .....................................168 All models ......................................169 Hydraulic fluid ..................................169 Operating conditions ................................169 Cooling requirements .................................169...
  • Page 8 Contents Location ....................................179 Temperature ..................................179 Electrical power ................................... 180 Air ......................................180 Water ...................................... 181 Receive and unpack the pump ..............................183 Install the external heat exchanger ............................184 Make the connections for remote operation ......................... 184 Make the connections to the utility panel ..........................186 Add hydraulic fluid ..................................

  • Page 9: Pump Information

    Pump information Model Serial number The serial number is on the data plate, which is found above the connection panel on the back of the pump. System schematic drawing number The system schematic drawing number is found on the data plate and inside the electrical enclosure door on a green label.
  • Page 10 Pump information HyPrecision15/30/50 Operator Manual 808240...

  • Page 11: Warranty

    600 hours of use with the use of a thimble filter Diamond orifices and compliance with Hypertherm’s water quality requirements 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.
  • Page 12 Warranty SC-12 Safety and compliance...

  • Page 13: Product Stewardship

    Once the product has left the Hypertherm factory, the certification test marks are invalidated if any of these events occur: ...
  • Page 14 Vaartveld 9 4704 SE Roosendaal, the Netherlands +31(0)165 596907 To see the signed Declaration of Conformity in English, go to the Hypertherm web site at www.hypertherm.com. 1. Click Downloads library. 2. Select a HyPrecision product from the Product type dropdown list.

  • Page 15: Differences In National Standards

    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.
  • Page 16 Product stewardship SC-16 Safety and compliance...

  • Page 17: Environmental Stewardship

    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.
  • Page 18 Environmental stewardship SC-18 Safety and compliance...

  • Page 19: 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.

  • Page 20: Emergency Medical Information And Treatment

    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.

  • Page 21: Symbols And Marks

    Symbols and marks Information and hazard symbols Some symbols in this table could be relevant to other products. This symbol identifies an imminently hazardous situation, which, if not avoided, will result in death or serious injury. DANGER This symbol identifies a potentially hazardous situation, which, if not avoided, could result in death or serious injury.

  • Page 22: Symbols And Marks Found On The Data Plate And The Pump

    Symbols and marks Symbols and marks found on the data plate and the pump Some symbols or marks in this table could be relevant to other products. To reduce the risk of serious injuries or death, wear approved protection and follow safety recommendations when working with electricity.
  • Page 23 Symbols and marks Compressed air that operates the bleed-down valve AIR IN Water-cooled pump: low-pressure cooling water from the local utility or a chiller that circulates through the heat exchanger Air-cooled pump: hydraulic fluid returning from an external air cooler COOLING IN Water-cooled pump: water from the heat exchanger that goes to a drain or a chiller Air-cooled pump: hydraulic fluid that is sent to an external air cooler...
  • Page 24 Symbols and marks SC-24 Safety and compliance...

  • Page 25: Terminology

    Section 1 Terminology Some terms could be relevant to other products. attenuator A pressure vessel that maintains consistent output water pressure by compensating for pressure fluctuations caused by the intensifier stroking American Wire Gauge, a standardized wire gauge system used in North America A unit of pressure;...
  • Page 26 Water that is not pressurized by the intensifier National pipe thread taper, a common United States standard for tapered threads that are used on fittings and pipes An original equipment manufacturer of machines that include Hypertherm products that are sold directly to end users overstroke (fault) An overstroke fault occurs when the hydraulic piston travels faster in 1 or both directions than the output water flow of the waterjet pump can support.
  • Page 27 An integrator of waterjet cutting systems that include Hypertherm products that are sold directly to end users reverse osmosis A method for treating water by forcing it through a semipermeable membrane to remove impurities that can damage...
  • Page 28 Terminology HyPrecision15/30/50 Operator Manual 808240...

  • Page 29: Product Description

    Section 2 Product description This section gives a broad overview of the major parts of the pump and what they do. HyPrecision pumps use a hydraulic system to pressurize water for waterjet cutting. Four systems make up the pump: hydraulic, low-pressure water, high-pressure water, and electrical. These systems are not independent of each other.

  • Page 30: Pump Exterior

    2 – Product description Pump exterior 1 Side cover 5 Bottom deck 2 Top deck 6 Front cover 3 Electrical enclosure 7 Gauge panel 4 Operator interface 8 Operation panel Gauge panel Prefilter water pressure gauge The prefilter gauge shows the pressure before the water goes through the filters. Normal operating range is 2.8 bar to 7.5 bar or 276 kPa to 758 kPa (40 psi to 110 psi).
  • Page 31 2 – Product description To determine the approximate cutting water pressure, multiply the hydraulic pressure gauge value by 20. Hydraulic pressure Cutting water pressure 4,100 bar × 20 = 82,000 bar Example: 41 ,000 kPa × 20 = 820,000 kPa 3,000 psi ×...

  • Page 32: Major Systems

    2 – Product description Major systems Hydraulic system 1 Heat exchanger 4 Primary hydraulic pump 2 Hydraulic center section 5 Primary motor 3 Primary hydraulic manifold 6 Hydraulic fluid tank The primary motor runs the primary hydraulic pump, which draws fluid from the hydraulic fluid tank and pressurizes it. The pressurized hydraulic fluid passes through the heat exchanger and the hydraulic filter to the primary hydraulic manifold, which contains a shift valve that alternates the supply of hydraulic fluid to each side of a reciprocating piston in the intensifier.
  • Page 33 2 – Product description Hydraulic fluid tank 1 Sight gauge 4 Drain 2 Temperature and level sensor 5 Suction strainers 3 Filler-breather cap A filler-breather cap keeps the contents of the tank free of airborne contaminants and permits access to the tank for adding hydraulic fluid.
  • Page 34 2 – Product description Primary hydraulic manifold 1 Shift valve 2 Relief valve A shift valve mounted on the manifold directs the flow of pressurized hydraulic fluid to alternating sides of the piston in the intensifier. A relief valve protects the pump from too much pressure. Intensifier 1 High-pressure water 4 Low-pressure water...
  • Page 35 2 – Product description Hydraulic control manifold 1 Hydraulic control manifold 3 Hydraulic pressure gauge 2 Pierce-pressure adjustment knob Standard pumps are equipped with a hydraulic control manifold, which includes a pierce-pressure adjustment knob, a solenoid valve that changes the pierce pressure, and a solenoid valve that turns the pump pressure on and off. A hydraulic pressure gauge shows the pressure in the manifold.
  • Page 36 2 – Product description Cooling loop Compressing hydraulic fluid generates substantial heat that can damage equipment and decrease the life of the fluid. A cooling loop keeps the hydraulic fluid at its optimal temperature. The heat exchanger, gear pump, hydraulic fluid, and low-pressure cooling water or an external fan make up a cooling loop.

  • Page 37: Low-Pressure Water System

    2 – Product description Low-pressure water system The low-pressure water system includes the inlet cutting water. In water-cooled systems it also includes a cooling water loop and a heat exchanger. Inlet cutting water 1 Accumulator 4 Water filters 2 Water pressure gauges 5 Inlet cutting water 3 Low-pressure water switch Inlet cutting water (CUTTING WATER IN) from a water softener or a reverse osmosis system flows through 2 water filters...
  • Page 38 2 – Product description Cooling water (for water-cooled systems) 1 Heat exchanger 2 Ball valve When the primary motor is running, low-pressure cooling water from the local utility or a chiller (COOLING IN) circulates through the heat exchanger, drawing heat away from the hydraulic fluid. Water from the heat exchanger exits the cooling system to a drain or is recycled to a chiller (COOLING OUT).

  • Page 39: High-Pressure Water System

    2 – Product description High-pressure water system 1 Attenuator 3 Bleed-down valve 2 High-pressure ends The plungers in the intensifier compress water up to 4,137 bar or 413,685 kPa (60,000 psi). This pressurized water exits the high-pressure end through a check valve and goes to the attenuator. Attenuator The stroking of the piston generates a brief change of water pressure in the high-pressure ends, causing the water pressure to drop.

  • Page 40: Electrical System

    2 – Product description Electrical system 1 Proximity switches 5 Primary motor 2 Hydraulic control solenoid 6 Air bleed-down solenoid 3 Low-pressure water switch 7 Cutting water valve 4 Shift valve solenoids The pump uses 3-phase alternating current (AC) electricity. Some parts such as valve solenoids and sensors use 24-volt direct current (DC) electricity from a power supply in the electrical enclosure.
  • Page 41 2 – Product description Primary motor 1 Gear pump 3 Shaft access cover 2 Primary hydraulic pump 4 Primary motor The primary motor drives the primary hydraulic pump that moves hydraulic fluid through the intensifier and a gear pump that moves hydraulic fluid through the cooling loop. Electrical enclosure 1 Stack light 3 Primary breaker disconnect lever...
  • Page 42 A micro SD card inside the enclosure is used to load updates to the control software or to back up the program. Motor starter The HyPrecision 15 and 30 models have a motor starter contactor. A thermal overload relay is mounted to the bottom of the contactor.

  • Page 43: Options

    Section 3 Options HyPrecision 15, 30, and 50 pumps are available with these optional features. Voltage 50 Hz 60 Hz 460 V 400 V 208 V to 230 V Refer to the data plate or the system schematic drawing for the voltage of the pump.
  • Page 44 3 – Options HyPrecision15/30/50 Operator Manual 808240...

  • Page 45: Operation

    Section 4 Operation Safety Refer to the instruction manual. Read and understand all of the safety guidelines in this manual. A waterjet is a cutting tool. A high-pressure injection injury is a surgical emergency. Seek immediate medical treatment for all high-pressure waterjet injuries. Delayed treatment can lead to serious injuries or death. WARNING Do not operate the pump without the shaft access cover and all other safety devices correctly installed.

  • Page 46: Overview

    Keep the work area clean and free of fluid spills.  Hypertherm products are designed and manufactured with a commitment to continuous quality control and safety. Contact a Hypertherm Technical Service Associate for information about the installation, operation, maintenance, and repair of this equipment.
  • Page 47 4 – Operation Operator interface 1 Hour meter 4 Date and time 2 F1 and F2 5 Enter 3 Numeric keypad 6 Direction arrows The operator interface is a programmable controller for the pump and the intensifier. A series of screens shows equipment status and permits the operator to operate the pump and intensifier.

  • Page 48: Inspect The Pump Before Operation

    4 – Operation The primary breaker disconnect lever disconnects electricity to the pump motor and controls. Inspect the pump before operation Examine the equipment before starting the pump.  Look for leaks, deterioration, damage, or other conditions that can interfere with operation. ...

  • Page 49: Turn On The Pump Remotely

    4 – Operation 4. Check the high-pressure water, low-pressure water, and hydraulic systems for leaks. Use a piece of cardboard or other solid material to check for leaks when the pump is on. Do not use hands, cloth, paper, or towels. WARNING Do not attempt to repair a leak with pressure in the system.

  • Page 50: Operate The Pump

    When an original equipment manufacturer (OEM) or a system integrator makes a cutting system by combining Hypertherm equipment with other equipment, the end-use customer and the OEM or the system integrator are responsible for supplying protection against hazardous moving parts.
  • Page 51 4 – Operation Alarm screens When the programmable controller detects a fault condition, an alarm screen shows information about the problem and the stack light blinks. If this occurs, refer to the Troubleshooting section, which begins on page 153. HyPrecision15/30/50 Operator Manual 808240...
  • Page 52 4 – Operation Primary screen  Press F1 to turn on the pump and the intensifier.  Press F2 to turn on the pump in cooling mode.  Press 1 on the numeric keypad to go to the intensifier settings screen. Primary screen •...
  • Page 53 4 – Operation Pump running screen 1 Pump symbol 3 Intensifier stroke rate indicator 2 Pump pressure mode indicator When the pump symbol blinks, the pump is running.  Press F1 to turn off the pump.  Press F2 to put the pump in cooling mode. ...
  • Page 54 4 – Operation Adjust the pierce pressure The pierce-pressure adjustment knob is on the front of the hydraulic control manifold behind the pump’s front cover. The hydraulic gauge shows the hydraulic fluid pressure. 1 Pierce-pressure adjustment knob 2 Hydraulic pressure gauge Do this with the pump running in pierce-pressure mode.
  • Page 55 217 bar or 2,1 718 kPa (3,150 psi). This setting can be adjusted.  The differential pressure valve limits the minimum hydraulic pressure. The differential pressure valve is set at 21 bar or 2,068 kPa (300 psi). If the differential pressure valve requires adjustment, contact Hypertherm Technical Service for support. Compensating valve...
  • Page 56 4 – Operation Cooling mode screen 1 Cooling symbol 2 Intensifier enabled symbol When the cooling symbol blinks, the pump is in cooling mode.  Press F1 to turn on the pump and the intensifier.  Press F2 to turn off the pump. ...
  • Page 57 4 – Operation Intensifier settings screen  Press 1 on the numeric keypad to enable or disable the intensifier.  Press enter to adjust the overstroke percentage. Intensifier settings screen • Pump off Change the overstroke Primary screen percentage • Pump off Intensifier enabled Intensifier disabled Adjust the overstroke percentage...

  • Page 58: Operate The Pump Remotely

    4 – Operation Operate the pump remotely Refer to the remote-source manufacturer’s instructions for operating the pump from a remote source. This turns on the controls by turning on the primary control relay. The controls must be turned on before other commands can be used. If the pump is off, this turns on the primary control relay.

  • Page 59: Stop The Pump

    4 – Operation Stop the pump Emergency stop The EMERGENCY STOP pushbutton is intended for urgent disabling of the controls. It is not the preferred method of turning off the pump. Press the EMERGENCY STOP pushbutton.  The control circuit turns off, which causes the pump, primary motor, and intensifier to turn off. ...
  • Page 60 4 – Operation HyPrecision15/30/50 Operator Manual 808240...

  • Page 61: Preventive Maintenance

    Section 5 Preventive maintenance Hypertherm products are designed and manufactured with a commitment to continuous quality control and safety. Contact a Hypertherm Technical Service Associate for information about the installation, operation, maintenance, and repair of this equipment. Hypertherm Inc. recommends preventive and scheduled maintenance for HyPrecision pumps. High-quality equipment that is serviced on a schedule lasts longer than equipment that is not regularly maintained.

  • Page 62: Safety

    5 – Preventive maintenance Safety Refer to the instruction manual. Read and understand all of the safety guidelines in this manual. To reduce the risk of serious injuries or death, wear approved protection and follow safety recommendations when working with electricity. DANGER People who maintain and repair this equipment can be injured or killed if hazardous energy is not properly controlled.

  • Page 63: Tips

    5 – Preventive maintenance Follow all safety requirements and applicable safety laws and regulations. Coordinate preventive maintenance and repair activities with operations and safety staff. Examine and clean the pump regularly. Make repairs promptly. Use proper tools for maintenance procedures. Some tools are designed to make the procedure easier and to prevent damage to the pump.

  • Page 64: Preventive Maintenance Schedule

    5 – Preventive maintenance Preventive maintenance schedule These maintenance intervals are general guidelines. The top left of the operator interface screen shows the total hours the pump has been in operation. Every Every Every Every Every Every 1,000 1,500 3,000 shift hours hours...
  • Page 65 These procedures require disassembling the intensifier. Detailed instructions about disassembling and reassembling the intensifier begin on page 110.  To reduce downtime, Hypertherm recommends doing maintenance on both ends of the intensifier at the same time. Repair the check valves.

  • Page 66: Tools

    5 – Preventive maintenance Tools Some maintenance and repair procedures recommend or require special tools. This page is intended to help a user identify tools that could be unfamiliar or are known by other names. Seal housing removal tool (included in the HyPrecision standard tool kit) Open-ended wrench Open-ended crowfoot wrench Dental pick...

  • Page 67: Complete List Of Preventive Maintenance Kits, Parts, Tools, And Materials

    5 – Preventive maintenance Complete list of preventive maintenance kits, parts, tools, and materials Kits Tools Materials    12084 HyPrecision standard tool kit 13897 TDS meter 11210-30 30-micron lapping paper    15566 HyPrecision basic standard  11111 Blue Goop high-pressure ...

  • Page 68: Every Shift

    5 – Preventive maintenance Every shift Make sure that the emergency stop pushbutton works  If the pump is configured to run remotely and has a motion system (robot or cutting table), the emergency circuits from the robot or cutting table can be wired in series with the local emergency stop circuit. The EMERGENCY STOP pushbutton is available on the operation panel.
  • Page 69 5 – Preventive maintenance Examine the pump for leaks or damage Use a piece of cardboard or other solid material to find leaks when the pump is operating. Do not use hands, cloth, paper, or towels. WARNING Failure to correct the cause of a leak can result in damage to the fittings. CAUTION Repair or replace parts identified in the preventive maintenance schedule or if the parts show signs of deterioration, corrosion, or damage.
  • Page 70 5 – Preventive maintenance Check the low-pressure water pressure gauges The prefilter water pressure gauge shows the water pressure before the water goes through the filters. The postfilter water pressure gauge shows the water pressure after the water goes through the filters. 1 Prefilter water pressure gauge 2 Postfilter water pressure gauge Do this task when the pump is running.
  • Page 71 5 – Preventive maintenance Check the hydraulic fluid indicator 1 White indicator 2 Red zone  Replace the filter after every 1,500 hours of operation.  Replace the filter when the white indicator stays in the red zone while the pump is running at operating temperature. Refer to page 92 for instructions.
  • Page 72 5 – Preventive maintenance Check the hydraulic fluid level Sight gauge Do this task when the pump is running. 1. Make sure that the hydraulic fluid level is at the top mark on the sight gauge. 2. Add hydraulic fluid if necessary. Refer to page 73 for instructions. HyPrecision15/30/50 Operator Manual 808240...
  • Page 73 5 – Preventive maintenance Add hydraulic fluid The capacity of the hydraulic fluid tank is 151 L (40 gallons).  For air-cooled pumps, increase the hydraulic fluid available by at least 19 liters (5 gallons) to fill the hoses and heat exchanger.
  • Page 74 5 – Preventive maintenance Check the hydraulic fluid quality  Contact a hydraulic fluid supplier for a precise report on the hydraulic fluid quality. 1 Drain valve lever 3 Sight gauge 2 Filler-breather cap Do this task when the pump is not running. 1.
  • Page 75 5 – Preventive maintenance Examine the bleed-down valve for leaks or damage Failure to correct the cause of a leak can result in damage to the fittings. CAUTION Weep holes Do this task when the pump is running. 1. Remove the rear pump panel. 2.

  • Page 76: Every 40 Hours

    5 – Preventive maintenance Every 40 hours Measure the hydraulic fluid temperature Keep the hydraulic fluid temperature in the hydraulic fluid tank between 37.8°C (100°F) and 51.7°C (125°F). Hydraulic fluid that is too hot can deteriorate and cause the pump to fail. Hydraulic fluid that is too cool causes the pump to operate sluggishly.
  • Page 77 5 – Preventive maintenance Adjust the hydraulic fluid temperature Required tools, materials, and parts Flat-blade screwdriver (for pumps with an optional water-modulating valve) Infrared thermometer Do this task when the pump is running. Water-cooled with a heat exchanger 1. Open the valve on the cooling water line to increase the cooling water flow to the heat exchanger. Close the valve on the cooling water line to decrease the cooling water flow.

  • Page 78: Every 500 Hours

    5 – Preventive maintenance Every 500 hours Measure the pressure in the water accumulator tank 1 Accumulator tank 2 Water pressure gauges Required tools, materials, and parts Air pressure gauge (Schrader valve) Compressed air source Do this task when the pump is not running. 1.
  • Page 79 5 – Preventive maintenance 3. Remove the valve stem cap from the water accumulator. 4. Use an air pressure gauge to measure the pressure in the water accumulator. The optimum air pressure is 2 bar or 207 kPa (30 psi). To reduce the pressure, press the valve stem to release air from the accumulator.
  • Page 80 Replace the check valve after every 2,000 hours of operation. This procedure is for a moderately worn check valve. Severe wear requires replacement.  To reduce downtime, Hypertherm recommends doing preventive maintenance on both ends of the intensifier at the same time. ...
  • Page 81 5 – Preventive maintenance 3. Put the check valve or poppet face flat on the lapping paper and slide it back and forth. Apply light pressure. Rocking the part or using too much pressure can damage the part face. CAUTION 1 Low-pressure poppet 2 Check valve 4.
  • Page 82 Put the parts on a clean, dry, oil-free surface.  To reduce downtime, Hypertherm recommends doing preventive maintenance on both ends of the intensifier at the same time.  Refer to the Parts lists section, which begins on page 147, for part numbers and ordering information.
  • Page 83 Put the parts on a clean, dry, oil-free surface. Replace the high-pressure cylinder after every 3,000 hours of operation.  To reduce downtime, Hypertherm recommends doing preventive maintenance on both ends of the intensifier at the same time.  Refer to the Parts lists section, which begins on page 147, for part numbers and ordering information.
  • Page 84 5 – Preventive maintenance 5. Cut the nonstick scouring pad in half. Put 1 half of the pad in each end of the cylinder. Put 1 thumb in each end of the cylinder on top of the pad and press down. Press evenly on the pad while rolling the cylinder forward and backward. Nonstick scouring pad 6.

  • Page 85: Every 1,000 Hours

    Put the parts on a clean, dry, oil-free surface. Replace both filters at the same time. Hypertherm HyPrecision 15, 30, and 50 pumps come with 2 water filters that remove contaminants from the cutting water. ...
  • Page 86 5 – Preventive maintenance Do this task when the pump is not running. 1. Turn OFF the water to the pump. 2. Open the valve to drain the water from the system. Make sure that the water pressure gauges show 0 bar or 0 kPa (0 psi).
  • Page 87 5 – Preventive maintenance 11. Close the water valve. 12. Turn ON water to the pump. 13. Turn ON the pump in cooling mode. 14. Press the filter purge buttons until water comes out from under each button. 15. Put the pump in running mode. 16.
  • Page 88 5 – Preventive maintenance Test the low-pressure water TDS level Some TDS meters might require calibration before use. For best results, calibrate the meter at 25.0°C (77°F). Refer to the instructions supplied with the TDS meter. If multiple readings are taken, turn the meter off and on for each reading. ...
  • Page 89 5 – Preventive maintenance 4. Put the TDS meter in the water sample up to the maximum immersion level (5 cm/2 inches). Tap the meter lightly to release air bubbles.  The meter is not waterproof. Do not submerge the unit in water. 5.
  • Page 90 Put the parts on a clean, dry, oil-free surface.  To reduce downtime, Hypertherm recommends doing preventive maintenance on both ends of the intensifier at the same time.  Refer to the Parts lists section, which begins on page 147, for part numbers and ordering information.
  • Page 91 5 – Preventive maintenance Repair the bleed-down valve Failure to correct the cause of a leak can result in damage to the fittings. CAUTION Overtightening a fitting can cause it to fail. Use 2 wrenches when loosening or tightening a high-pressure connection.

  • Page 92: Every 1,500 Hours

    5 – Preventive maintenance Every 1,500 hours Replace the hydraulic filter Failure to correct the cause of a leak can result in damage to the fittings. CAUTION Follow local regulations when disposing of used fluids and filters. Put the parts on a clean, dry, oil-free surface. ...

  • Page 93: Every 2,000 Hours

    Put the parts on a clean, dry, oil-free surface. Install new high-pressure water seals when the check valve is replaced.  To reduce downtime, Hypertherm recommends doing preventive maintenance on both ends of the intensifier at the same time. ...

  • Page 94: Every 3,000 Hours

    5 – Preventive maintenance Every 3,000 hours Replace the hydraulic fluid Follow local regulations when disposing of used fluids and filters. Put the parts on a clean, dry, oil-free surface. Install a new hydraulic filter and filler-breather cap when the hydraulic fluid is replaced. ...
  • Page 95 5 – Preventive maintenance Strap wrench or adjustable pliers Hose or pipe for draining hydraulic fluid Container for used hydraulic fluid Recommended materials Clean funnel Do this task when the pump is not running. 1. Remove the drain valve plug. 2.
  • Page 96 5 – Preventive maintenance 3. Disconnect the lower ends of these hydraulic hoses to drain them. 1 Gear pump suction line 4 From the primary hydraulic manifold to the intensifier (right) 2 From the primary hydraulic manifold to the intensifier (left) 5 Case drain hose 3 Primary pump suction 6 From the primary hydraulic manifold to the hydraulic...
  • Page 97 5 – Preventive maintenance 7. Clean the inside of the tank with a lint-free towel and isopropyl alcohol. Make sure that no debris remains on  the bottom. Make sure that all towels are removed from the tank before it is filled. CAUTION Do not use soap, detergent, or solvents.
  • Page 98 Put the parts on a clean, dry, oil-free surface.  To reduce downtime, Hypertherm recommends doing preventive maintenance on both ends of the intensifier at the same time.  Refer to the Parts lists section, which begins on page 147, for part numbers and ordering information.
  • Page 99 5 – Preventive maintenance Replace the bleed-down valve body Failure to correct the cause of a leak can result in damage to the fittings. CAUTION Overtightening a fitting can cause it to fail. Use 2 wrenches when loosening or tightening a high-pressure connection.

  • Page 100: Every 6,000 Hours

    Put the parts on a clean, dry, oil-free surface.  To reduce downtime, Hypertherm recommends doing preventive maintenance on both ends of the intensifier at the same time.  Refer to the Parts lists section, which begins on page 147, for part numbers and ordering information.

  • Page 101: Every 12,000 Hours

    Put the parts on a clean, dry, oil-free surface.  To reduce downtime, Hypertherm recommends doing preventive maintenance on both ends of the intensifier at the same time.  Refer to the Parts lists section, which begins on page 147, for part numbers and ordering information.

  • Page 102: Service The Intensifier

    5 – Preventive maintenance Service the intensifier Failure to correct the cause of a leak can result in damage to the fittings. CAUTION Overtightening a fitting can cause it to fail. Use 2 wrenches when loosening or tightening a high-pressure connection.
  • Page 103 5 – Preventive maintenance 1. Turn OFF the pump. 2. Turn OFF power from the primary utility source. Use standard lock out–tag out procedures. 3. Open the valve to drain the water from the system. Make sure that the water pressure gauges show 0 bar or 0 kPa (0 psi).

  • Page 104: Disassemble The Intensifier

    5 – Preventive maintenance Disassemble the intensifier Preventive maintenance on the intensifier involves accessing various assemblies at specified intervals. Remove the output adapter and high-pressure poppet assembly After this many hours Replace these parts of operation High-pressure poppet assemblies 1,000 Output adapters 6,000 1 High-pressure poppet seat...
  • Page 105 5 – Preventive maintenance Remove the high-pressure end cap 1 Studs 3 High-pressure end cap 2 Low-pressure water fitting 4 Stud nuts Required tools, materials, and parts Clean, lint-free towel Isopropyl alcohol 13/16-inch open-ended wrench (high-pressure water fitting) 7/8-inch open-ended wrench (low-pressure water fitting) Square drive socket, 1-1/2 inch ×...
  • Page 106 5 – Preventive maintenance Remove the high-pressure cylinder assembly and check valve After this many hours Repair these parts of operation Check valves Low-pressure poppets High-pressure cylinders After this many hours Replace these parts of operation High-pressure water seals Check valves 2,000 Low-pressure poppets Low-pressure poppet baskets...
  • Page 107 5 – Preventive maintenance 2. Remove the check valve by rolling the cylinder and tapping the check valve with a rubber mallet. Tap at an angle away from the cylinder. 3. Tilt the cylinder so that the low-pressure poppet comes out. 4.
  • Page 108 5 – Preventive maintenance Remove the seal housing assembly and plunger bearing After this many hours Replace these parts of operation High-pressure seal backups O-rings Hydraulic rod seals Plunger bearings 3,000 Seal housings 6,000 Install a new plunger bearing every time the high-pressure cylinder is replaced. ...
  • Page 109 5 – Preventive maintenance 1. Slide the seal housing removal tool into the groove on the seal housing. 2. Use a hex wrench to turn the screws on the seal housing removal tool.  Alternate sides so that the tool pulls the housing straight out of the high-pressure end cap. 3.
  • Page 110 5 – Preventive maintenance Remove the indicator pin assembly After this many hours Replace these parts of operation Indicator pin spring 3,000 Indicator pin 6,000 1 Socket-head cap screws and lock washers 4 O-ring 2 Indicator pin cap 5 Indicator pin spring 3 Backup ring 6 Indicator pin Required tools, materials, and parts...

  • Page 111: Assemble The Intensifier

    5 – Preventive maintenance Assemble the intensifier Overtightening a fitting can cause it to fail. Use 2 wrenches when loosening or tightening a high-pressure connection. Using only 1 wrench can increase bending stress to the parts and cause damage or premature failure.
  • Page 112 5 – Preventive maintenance 1. Put the indicator pin into the indicator pin hole in the high-pressure end cap. Turn the pin so that the offset post goes into the aperture at the back of the hole. 2. Put the spring on the indicator pin. 3.
  • Page 113 5 – Preventive maintenance Install the seal housing assembly and plunger bearing Put the parts on a clean, dry, oil-free surface.  Refer to the Parts lists section, which begins on page 147, for part numbers and ordering information. 1 High-pressure seal backup 3 Hydraulic rod seal 2 Seal housing 4 Plunger bearing...
  • Page 114 5 – Preventive maintenance 3. Put the backup ring and the O-ring on the seal housing. The backup ring should be positioned closer to the wide end of the seal housing. The O-ring should be positioned closer to the narrow end of the seal housing. 1 Backup ring 2 O-ring 4.
  • Page 115 5 – Preventive maintenance 7. Put hydraulic fluid inside the narrow end of the seal housing. 8. Put the seal housing on the plunger with the narrow end toward the end cap. 9. Press the rod seal into the seal housing. 10.
  • Page 116 5 – Preventive maintenance Install the high-pressure water seals, high-pressure cylinder assembly, and check valve Do not put grease or lubricant on the check valve face or in the cylinder bore. These are designed for  dry contact. Put the parts on a clean, dry, oil-free surface. ...
  • Page 117 5 – Preventive maintenance 1. Put the seal installation spacer tool on a clean, dry, oil-free surface. 1 Sleeve 3 Push tool 2 Spacer tool 4 Locator tool 2. Put the high-pressure cylinder over the spacer tool so that the tool fits in the cylinder bore. HyPrecision15/30/50 Operator Manual 808240...
  • Page 118 5 – Preventive maintenance 3. Put the spacer tube into the high-pressure cylinder with the poppet facing up. Make sure that the poppet is flat. 4. Put the seal installation locator tool on top of the cylinder. HyPrecision15/30/50 Operator Manual 808240...
  • Page 119 5 – Preventive maintenance 5. Put the seal installation sleeve in the locator tool with the flat opening toward the cylinder.  The beveled opening faces up. 6. Put a small quantity of high-vacuum grease on the red O-ring. 7. Put the red O-ring into the groove on the high-pressure water seal. 8.
  • Page 120 5 – Preventive maintenance 9. Put the push tool into the insertion sleeve with the stepped end up. Press down evenly while holding the sleeve tightly against the cylinder. 10. Remove the push tool from the insertion sleeve. 11. Make sure that the seal is positioned in the cylinder correctly. HyPrecision15/30/50 Operator Manual 808240...
  • Page 121 5 – Preventive maintenance 12. Put the hoop into the insertion sleeve with the sharp edge toward the cylinder. 13. Put the push tool into the insertion sleeve with the stepped end up. Tap the push tool sleeve with a rubber mallet until the push tool contacts the sleeve.
  • Page 122 5 – Preventive maintenance 18. Put the poppet assembly into the cylinder. 19. Put the end of the check valve into the seal. Tap on the small end of the check valve with a rubber mallet until it is seated against the cylinder end. 20.
  • Page 123 5 – Preventive maintenance Install the high-pressure end cap Overtightening a fitting can cause it to fail. Use 2 wrenches when loosening or tightening a high-pressure connection. Using only 1 wrench can increase bending stress to the parts and cause damage or premature failure.
  • Page 124 5 – Preventive maintenance 4. Torque the stud nuts to 373 N ∙ m (275 lbf ∙ ft).  Tighten each nut in 45° increments using a repeating sequential cross pattern until the recommended torque is reached. 5. Connect the low-pressure water line. 6.
  • Page 125 5 – Preventive maintenance Install the output adapter and the high-pressure poppet assembly Overtightening a fitting can cause it to fail. Use 2 wrenches when loosening or tightening a high-pressure connection. Using only 1 wrench can increase bending stress to the parts and cause damage or premature failure.
  • Page 126 5 – Preventive maintenance 2. Use a cotton-tipped applicator to guide the high-pressure seat into the check valve. The wide end of the seat should face down. 3. Press the seat into the high-pressure antiseize lubricant in the check valve. The lubricant holds the seat in position. 4.
  • Page 127 5 – Preventive maintenance 7. Torque the output adapter to 41 N ∙ m to 47 N ∙ m (30 lbf ∙ ft to 35 lbf ∙ ft). 8. Put high-pressure antiseize lubricant on the high-pressure connector threads. 9. Connect the high-pressure water line. ...

  • Page 128: Service The Bleed-Down Valve

    5 – Preventive maintenance Service the bleed-down valve Failure to correct the cause of a leak can result in damage to the fittings. CAUTION Repair or replace parts identified in the preventive maintenance schedule or if the parts show signs of deterioration, corrosion, or damage.
  • Page 129 5 – Preventive maintenance 2. Open the valve to drain the water from the system. Make sure that the water pressure gauges show 0.0 bar or 0 kPa (0 psi). Water valve in open position 3. Use a cross-tip screwdriver to remove the electrical connector from the actuator housing. 4.
  • Page 130 5 – Preventive maintenance 5. Remove the gland nut connecting the water drain tubing to the bleed-down valve. 6. Remove the gland nut on the high-pressure collar at the high-pressure fitting of the valve. 7. Remove the bleed-down valve assembly from the pump. HyPrecision15/30/50 Operator Manual 808240...

  • Page 131: Disassemble The Bleed-Down Valve

    5 – Preventive maintenance Disassemble the bleed-down valve Repair the bleed-down valve after every 1,000 hours of operation. Replace the bleed-down valve body after every 3,000 hours of operation. 1 Actuator 5 Valve body 2 Needle guide 6 Seat 3 Needle 7 Flow reducer 4 High-pressure valve seal 8 Outlet adapter...
  • Page 132 5 – Preventive maintenance 5. Clean each part with a lint-free towel and isopropyl alcohol. Do not use soap, detergent, or solvents. 6. Examine all parts for deterioration, corrosion, or damage. 7. Clean and examine parts that will be replaced to identify wear patterns or damage that can signify other problems. 8.

  • Page 133: Assemble The Bleed-Down Valve

    5 – Preventive maintenance Assemble the bleed-down valve Overtightening a fitting can cause it to fail. Use 2 wrenches when loosening or tightening a high-pressure connection. Using only 1 wrench can increase bending stress to the parts and cause damage or premature failure.
  • Page 134 5 – Preventive maintenance 5. Put the needle through the needle guide and the valve seal. 1 Needle 3 Valve seal 2 Needle guide 4 O-ring  Make sure that the point of the needle faces the seal. 6. Put high-vacuum grease on the red O-ring on the valve seal. Make sure that the red O-ring on the valve seal faces away from the needle.

  • Page 135: Install The Bleed-Down Valve

    5 – Preventive maintenance Install the bleed-down valve Overtightening a fitting can cause it to fail. Use 2 wrenches when loosening or tightening a high-pressure connection. Using only 1 wrench can increase bending stress to the parts and cause damage or premature failure.
  • Page 136 5 – Preventive maintenance 3. Attach the electrical connector to the solenoid valve on the actuator housing. 4. Connect the compressed-air line to the solenoid valve. 5. Close the water valve. Water valve in closed position 6. Turn ON the water to the pump. HyPrecision15/30/50 Operator Manual 808240...

  • Page 137: Start The Pump After Preventive Maintenance

    5 – Preventive maintenance Start the pump after preventive maintenance A turning motor shaft can be dangerous. DANGER Close all doors and replace all covers, including the shaft access cover. CAUTION Failure to correct the cause of a leak can result in damage to the fittings. CAUTION Test the equipment before putting it into use.
  • Page 138 5 – Preventive maintenance 14. Check the high-pressure water, the low-pressure water, and the hydraulic systems for leaks. If a leak is found, identify the source and repair the problem. Refer to the Troubleshooting section, which begins on page 153. 15.

  • Page 139: Preventive Maintenance Interval Checklist

    5 – Preventive maintenance Preventive maintenance interval checklist Every 40 hours (page 76)  Measure the hydraulic fluid temperature. Every 500 hours (page 78)  Measure the pressure in the water accumulator tank.  Repair the check valves.  Repair the low-pressure poppets. ...
  • Page 140 5 – Preventive maintenance Every 1,500 hours (page 92)  Measure the pressure in the water accumulator tank.  Replace the hydraulic filter.  Repair the check valves.  Repair the low-pressure poppets.  Replace the high-pressure water seals, the hoops, and the high-pressure seal backups. ...
  • Page 141 5 – Preventive maintenance Every 3,000 hours (page 94)  Measure the pressure in the water accumulator tank.  Replace the water filters.  Test the low-pressure water TDS level.  Measure the hydraulic fluid temperature.  Replace the hydraulic filter. ...
  • Page 142 5 – Preventive maintenance Every 6,000 hours (page 100)  Measure the pressure in the water accumulator tank.  Replace the water filters.  Test the low-pressure water TDS level.  Measure the hydraulic fluid temperature.  Replace the hydraulic filter. ...
  • Page 143 5 – Preventive maintenance Every 12,000 hours (page 101)  Measure the pressure in the water accumulator tank.  Replace the water filters.  Test the low-pressure water TDS level.  Measure the hydraulic fluid temperature.  Replace the hydraulic filter. ...

  • Page 144: Preventive Maintenance Records

    5 – Preventive maintenance Preventive maintenance records Problem found and work done Date Hours Initials Date Hours Initials Date Hours Initials Date Hours Initials Date Hours Initials Date Hours Initials Date Hours Initials Date Hours Initials HyPrecision15/30/50 Operator Manual 808240...
  • Page 145 5 – Preventive maintenance Problem found and work done Date Hours Initials Date Hours Initials Date Hours Initials Date Hours Initials Date Hours Initials Date Hours Initials Date Hours Initials Date Hours Initials Date Hours Initials HyPrecision15/30/50 Operator Manual 808240...
  • Page 146 5 – Preventive maintenance HyPrecision15/30/50 Operator Manual 808240...

  • Page 147: Parts Lists

    Genuine Hypertherm parts are the factory-recommended replacement parts for this pump. The Hypertherm warranty might not cover damage caused by using nongenuine Hypertherm parts. To order parts, contact the original equipment manufacturer (OEM) or Hypertherm Inc. with the part numbers and quantities.
  • Page 148 6 – Parts lists Tools 12084 HyPrecision standard tool kit Part number Description 11448 AccuGoop, 4 oz. 11558 Seal installation locator tool 11811 Seal installation sleeve 11812 Seal installation push tool 12932 Seal installation spacer tool 11985 Seal housing removal tool 12019 Hex driver, 3/4 in.
  • Page 149 6 – Parts lists Preventive maintenance repair kits Quantify refers to the number of units included with each part number. 15566 HyPrecision basic standard spares kit Part number Description Quantity 15563 HyPrecision premium high-pressure seal kits 15565 HyPrecision basic poppet repair kit 11328 On/off valve and bleed-down valve repair kit 11669...
  • Page 150 6 – Parts lists Quantify refers to the number of units included with each part number. Part number Description Quantity 11014 High-pressure poppets 11126 Poppet springs 11015 High-pressure seats 14792 Low-pressure poppets 13907 Low-pressure poppet springs 15564 6-inch cotton-tipped applicators (cotton swabs) 11328 On/off valve and bleed-down valve repair kit Part number Description...
  • Page 151 6 – Parts lists Other parts Part number Description 11743 Bleed-down valve flow reducer 14141 High-performance bleed-down valve body 11523 Check valve assembly 11520 Low-pressure poppet basket 11530 Output adapter 11522 High-pressure cylinder 11609 Seal housing 11608 Plunger bearing 11521 Spacer tube 16025 Hydraulic filter, 10 micron, absolute...
  • Page 152 6 – Parts lists HyPrecision15/30/50 Operator Manual 808240...

  • Page 153: Troubleshooting

    Failure to correct the cause of a leak can cause damage to the water fittings. CAUTION  Hypertherm products are designed and manufactured with a commitment to continuous quality control and safety. Contact a Hypertherm Technical Service Associate for information about the installation, operation, maintenance, and repair of this equipment.

  • Page 154: Alarm Screens

    7 – Troubleshooting Alarm screens The programmable controller monitors activities while the pump is running. When the controller detects a problem with the system, the operator interface shows a status symbol and the stack light blinks. When operating the intensifier or primary motor is likely to damage the system, the intensifier and the primary motor turn off.

  • Page 155: Intensifier

    Make sure that there is not an obstruction in the high-pressure tubing.  The hydraulic piston seals could be worn. Contact Hypertherm Technical Service for support.  If a high-pressure cylinder is hot, disassemble it and look for flaws, deterioration, erosion marks, or cracks in the parts, including the check valve and piston seal.
  • Page 156 7 – Troubleshooting Overstroking Symbol Fault/warning Stack light Result Intensifier overstroke to the right The intensifier turns off. Intensifier overstroke to the left The pump runs in cooling mode. The display does not show a symbol for overstroking in both directions. Intensifier overstroke in both The screen will show 1 of the directions...
  • Page 157 The low-pressure water relief valve is venting water to the drain.  Call Hypertherm for help with adjusting the valve. The postfilter water-pressure gauge shows that the If the difference between the values on the pre- and pressure for the inlet cutting water is lower than 2.8 bar post-filter water-pressure gauges is higher than 0.7 bar...
  • Page 158 7 – Troubleshooting 8. If the intensifier overstrokes in one direction, check these possible causes. Possible cause Solution The high-pressure water seals are worn or damaged. Replace the high-pressure water seals. • Examine the face of the poppet and the mating face on the check valve.

  • Page 159: Leaks

    7 – Troubleshooting Leaks Make sure that the tubing, water fittings, and quick disconnects inside and outside of the pump are not leaking. Damage to the high-pressure water seals and the hoops is the most common cause of water leaking from the intensifier. Water dripping from the high-pressure cylinder shows that the seals will soon require changing.

  • Page 160: Short Seal Life

    7 – Troubleshooting Hydraulic fluid leak from Possible cause • The rod seal has failed. • The O-ring or O-ring backup on the seal housing  Dynamic seal housing weep hole has failed. Anywhere on the intensifier An O-ring has failed. A leaking high-pressure seal in the intensifier can force water past the rod seal and into the hydraulic fluid.

  • Page 161: Hydraulic Fluid

    7 – Troubleshooting Hydraulic fluid Low pressure The most common causes of low hydraulic fluid are a leak from a fitting or a hose in the hydraulic system and loss of hydraulic fluid during routine maintenance. A float switch in the hydraulic fluid tank triggers an alarm when the hydraulic fluid level is too low.
  • Page 162 • Turn the OL-FAN dial to RESET and then to AUTO. Do not adjust the setting on the thermal overload unless instructed to do so by a Hypertherm Technical Service Associate. CAUTION...

  • Page 163: Low Water Pressure

    Determine the cause of a blown fuse before replacing it. For fuse sizes and locations, refer to the technical drawings. Some spare fuses are included with the controller. All fuses can be purchased from Hypertherm or an electrical supply store.

  • Page 164: Motor Fault

    7 – Troubleshooting Motor fault Symbol Fault/warning Stack light Result The intensifier turns off. Primary motor fault The pump turns off. A primary motor fault means that there is a problem starting or running the motor. If this is suspected to be the cause of the alarm, take these actions.

  • Page 165: Pump Specifications

    Section 8 Pump specifications This section includes details about the pump, including this information:  Power and water specifications and orifice sizes for each pump model  Physical qualities such as dimensions, weight, and capacity  Recommended operating conditions  A description of the utility panel ...

  • Page 166: Hyprecision 15

    8 – Pump specifications HyPrecision 15 Dimensions and weights Width 864 mm (34 in.) Shipping weight 498 kg (1,908 lb) Length 1,778 mm (70 in.) Operating weight 947 kg (2,088 lb) Height 1,168 mm (46 in.)  The shipping weight is for the pump, pallet, and packaging. Exact weights are determined at shipment. Operating weight is for an unpackaged pump with hydraulic fluid.

  • Page 167: Hyprecision 30

    8 – Pump specifications HyPrecision 30 Dimensions and weights Width 864 mm (34 in.) Shipping weight 938 kg (2068 lb) Length 1,778 mm (70 in.) Operating weight 1,020 kg (2248 lb) Height 1,168 mm (46 in.)  The shipping weight is for the pump, pallet, and packaging. Exact weights are determined at shipment. Operating weight is for an unpackaged pump with hydraulic fluid.

  • Page 168: Hyprecision 50

    8 – Pump specifications HyPrecision 50 Dimensions and weights Width 864 mm (34 in.) Shipping weight 1,040 kg (2292 lb) Length 1,778 mm (70 in.) Operating weight 1,121 kg (2472 lb) Height 1,168 mm (46 in.)  The shipping weight is for the pump, pallet, and packaging. Exact weights are determined at shipment. Operating weight is for an unpackaged pump with hydraulic fluid.

  • Page 169: All Models

    8 – Pump specifications All models Hydraulic fluid • ISO viscosity grade (VG) 32 or 46 antiwear mineral oil Type • synthetic hydraulic fluid Tank capacity 151 L (40 gallons) Maximum temperature 54.4°C (130°F) Maximum pressure 217 bar or 21,718 kPa (3,150 psi) Hydraulic pump pressure limit set at the factory Operating conditions...

  • Page 170: Utility Fittings

    8 – Pump specifications Utility fittings Utility fittings are found on the rear of the pump. 1 AIR IN 4 CUTTING WATER OUT 2 CUTTING WATER IN 5 COOLING OUT 3 WASTEWATER OUT 6 COOLING IN This diagram describes the flow of water through the pump system. WASTEWATER To a drain Bleed-down...

  • Page 171: Torque Values

    8 – Pump specifications Torque values Fasteners When installing more than 1 fastener on a part, tighten each fastener in 45° increments using a repeating sequential cross pattern until the recommended torque is reached. Because of high forces inside the intensifier, all bolts and cap screws that fasten load-carrying parts are grade 8. Fasteners that are exposed to cyclic loading also use lock washers.
  • Page 172 8 – Pump specifications SAE J518 flange bolts Code 61 Grade 8 Code 62 Grade 8 1/16-in. dash Bolt size size N∙m lbf ∙ ft N∙m lbf ∙ ft 5/16-28 in. 3/8-16 in. 3/8-16 in. 7/16-14 in. 1/2-13 in.  These torque values are for bolts that are coated in white lithium grease antiseize bolt lubricant.

  • Page 173: Fittings

    8 – Pump specifications Fittings Do not use lubricants on low-pressure water fittings. These charts apply to all hydraulic and high-pressure water fittings. Special fittings Use a high-pressure antiseize lubricant such as Blue Goop or AccuGoop on high-pressure water fittings. Torque Wrench size N∙m...
  • Page 174 For hydraulic fittings, lubricate the O-rings with hydraulic fluid or O-ring lubricant before assembly.  Hypertherm recommends using thread sealant on all NPT hydraulic fittings. When using thread sealant on a male tapered pipe thread with a female straight or parallel pipe thread, the maximum value is 50% of the standard maximum.
  • Page 175 8 – Pump specifications Steel JIC 37° Brass JIC 37° SAE O-ring boss Minimum Maximum Minimum Maximum Minimum Maximum 1/16-in. dash size N∙m lbf ∙ ft N∙m lbf ∙ ft N∙m lbf ∙ ft N∙m lbf ∙ ft N∙m lbf ∙ ft N∙m lbf ∙...
  • Page 176 8 – Pump specifications HyPrecision15/30/50 Operator Manual 808240...

  • Page 177: Installation

    Section 9 Installation Safety Refer to the instruction manual. Read and understand all of the safety guidelines in this manual. To reduce the risk of serious injuries or death, wear approved protection and follow safety recommendations when working with electricity. DANGER A waterjet is a cutting tool.

  • Page 178: Buyer Obligations

     Make all connections to the pump.  Hypertherm does not always supply the pump with hydraulic fluid in the tank. It is the buyer's responsibility to fill the tank with hydraulic fluid. HyPrecision15/30/50 Operator Manual 808240...

  • Page 179: Seller Obligations

    9 – Installation Seller obligations If Hypertherm Inc. installs the equipment, some or all of these tasks are the responsibility of the Hypertherm technician as defined in the sales agreement.  Make sure that the buyer understands all buyer obligations.

  • Page 180: Electrical Power

    9 – Installation Electrical power To reduce the risk of serious injuries or death, wear approved protection and follow safety recommendations when working with electricity. DANGER Make sure that a line disconnect switch for incoming electrical power is installed near the pump’s power supply to serve as a supply-voltage disconnecting or isolating device.

  • Page 181: Water

    Total suspended solids (TSS) Suspended solids refers to small, solid particles that are suspended in water. Filters are used to remove these solids. Hypertherm pumps include water filters that remove TSS from the cutting water. Total dissolved solids (TDS) Dissolved solids refers to molecular, ionized, or microgranular particles in solution in water. TDS include hard elements such as iron, calcium, magnesium, and silica, which form deposits on the inside of high-pressure plumbing and can damage check valves, seals, orifices, and other consumables.
  • Page 182 Some TDS meters require calibration before use. For best results, calibrate the meter at 25.0°C (77°F). Refer to the instructions supplied with the TDS meter.  Utility and well water quality can change over time. Hypertherm recommends regular testing. Required tools, materials, and parts pH tester...

  • Page 183: Receive And Unpack The Pump

    4. Make sure that the delivery and shipping documents match the equipment that was ordered and what was received. Report shortages or damages to the OEM or to Hypertherm Waterjet within 10 days of receipt of the equipment. ...

  • Page 184: Install The External Heat Exchanger

    9 – Installation Install the external heat exchanger An external heat exchanger is an option for air-cooled pumps. Make sure that there is a minimum clearance of 91 cm (36 inches) in the front and rear of the heat exchanger to permit enough air flow for efficient cooling.
  • Page 185 9 – Installation Remote pump run indicator 6047, 24COM Output Controls on indicator 5024C Output Controls on Wire number Type of contact Operation 6027, 5024A Momentary, normally open Status 6027, 5024A Momentary, normally open Pump on Wire number Type of contact Operation 6028 Input, momentary, normally open...

  • Page 186: Make The Connections To The Utility Panel

    9 – Installation Make the connections to the utility panel Do not couple the WASTEWATER OUT and the COOLING OUT lines. Coupling these lines can cause cooling water to back up into the system, which can cause damage to the bleed-down valve and the intensifier parts.

  • Page 187: Add Hydraulic Fluid

    9 – Installation 1/4-in. NPT male Connect compressed air to this fitting to operate an air-actuated connector bleed-down valve. AIR IN 3/8-in. high-pressure Connect a high-pressure plumbing line from this fitting to the waterjet female connector cutting table. CUTTING WATER 3.

  • Page 188: Connect The Electrical Power

    9 – Installation Connect the electrical power A line disconnect switch for incoming electrical power must be installed near the pump’s power supply to serve as a supply-voltage disconnecting (isolating) device. WARNING The primary incoming electrical power must be installed by a licensed electrician and must be in compliance with all applicable codes.

  • Page 189: Do The First Startup

    9 – Installation Do the first startup Do not leave waterjet cutting equipment turned on and unattended. WARNING To prevent catastrophic damage to the pump parts, connect the hydraulic lines between the pump and the external heat exchanger before checking the motor direction on an air-cooled pump. CAUTION Use this procedure at installation and after maintenance or repairs are done on the intensifier, the high-pressure water system, or the low-pressure water system.
  • Page 190 9 – Installation 1 Gear pump 3 Shaft access cover 2 Primary hydraulic pump 4 Primary motor rotation arrow 1. Remove the shaft access cover. 2. Set the pierce pressure to its minimum by turning the control knobs all the way to the left (anticlockwise). 3.
  • Page 191 2 Motor direction arrow 8. If the pump has an optional external heat exchanger, make sure that the fan motor turns in the direction shown by the arrow. HyPrecision 15 and 30 HyPrecision 50 1 Fan direction arrow 2 Airflow direction arrow If the pump motor or the fan motor turns in the wrong direction, follow these instructions: a.
  • Page 192 3. Make sure that the hydraulic pressure is 34 bar or 3,447 kPa (500 psi) or lower. If the pressure is higher than 34.5 bar or 3,447 kPa (500 psi), contact Hypertherm Technical Service for support. 4. Remove the cutting head and the orifice.

  • Page 193: Recycling And End Of Product Life

    9 – Installation If the CNC control is not available, turn the head ON and OFF in 1-second intervals for 15 minutes. This shocks the high-pressure tubing and frees debris in the tubing.  Debris can cause damage to the on/off valve needle and seat. If this occurs, attempt to complete this procedure by removing debris from the parts rather than replacing the parts right away.
  • Page 194 9 – Installation HyPrecision15/30/50 Operator Manual 808240...

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