Flow HYPLEX Manual

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HYPLEX

PRIME PUMP

M-416 | REV. C | MAY 2012

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Page 1 HYPLEX PRIME PUMP ® M-416 | REV. C | MAY 2012...
Page 2 Due to continuing product improvement, the information contained in this document is subject to change without notice. Flow International Corporation (Flow) shall not be held liable for technical or editorial omissions made herein, nor for any incidental or consequential damage resulting from the use of this material.
Page 3: Table Of Contents
General precautions 23 Inspection & maintenance schedules 25 Routine daily checks 25 Mandatory maintenance schedules 26 30 hp HyPlex Prime pump maintenance schedule 27 50 hp HyPlex Prime pump maintenance schedule 28 Troubleshooting the HyPlex Prime Premium pump using FlowSENSE...
Page 4 Maintenance & Service Manual Introduction The information in this manual will help you become familiar with your new Flow International (FLOW) equipment. It was compiled from the most current information available at the time of publication and is intended to cover the most common configurations.
Page 5: Chapter 1. Equipment Description
CHAPTER 1 Equipment Description The HyPlex Prime pump is a powerful, ultrahigh-pressure waterjet cutting tool designed for minimum maintenance and reliable performance. The pump has an operating pressure of 55,000 psi (3790 bar), and a maximum generated pressure of 60,000 psi (4140 bar).
Page 6: Specifications
When operating the pump in an environment with an ambient temperature greater than 86°F (30°C), a Air.........90–120 psi (6.2-8.3 bar) heavier oil is recommended to be used. Contact Flow ........dry and filtered to 10 microns Technical Services for additional information.
Page 10: Interface Labels
HYPLEX PRIME PUMP Maintenance & Service Manual Interface labels Inlet water pressure (post filter) This gauge indicates water pressure after the inlet water has passed through the 0.5 micron and 1.0 micron water filters. Inlet water pressure (pre filter) This gauge indicates water pressure before the inlet water has passed through the 0.5 micron and 1.0 micron water filters.
Page 11: Water Requirements
CHAPTER 1 Equipment Description Water requirements Water interface connections The HyPlex Prime pump requires a single source of water, and one drain line. Flow recommends the installation of manual shut-off valves in the inlet/cooling water line. Locate valves as close...
Page 12: Air Requirements
Maintenance & Service Manual Air requirements High-pressure tubing The HyPlex Prime pump requires a source of air be- High-pressure tubing certified for continuous operation tween 90 and 120 psi (6.2 and 8.3 bar). The air must be at 60,000 psi (4140 bar) is used to route high-pressure dry and filtered to 10 microns.
Page 13: Anti-Vibration Mat
Anti-vibration mat The anti-vibration mat is essential for the stability of the HyPlex Prime pump and the reduction of pump vibra- tion. The pump should be centered on the mat with no part of the pump touching the floor beneath.
Page 14: Startup Procedure
Before the beginning of a shift • After initial installation • After installation of one of the HyPlex Prime • maintenance kits 1. Flush debris from all water supply hoses before con- necting them to the pump. CAUTION Debris in the water supply line can cause extensive damage to high-pressure components.
Page 15 3. Depress the red pressure relief buttons on both of 3. Run the HyPlex Prime pump Temperature Input Off- the inlet water filters to release any air. set Adjustment routine on Page 16.
Page 16: Temperature Input Offset Adjustment Routine
HYPLEX PRIME PUMP Maintenance & Service Manual HyPlex Prime pump temperature input Calibrating the pump control system offset adjustment routine This applies to the Plus and Premium packages. This routine applies to the Plus and Premium packages. This software routine must be run each time the PCV...
Page 17 CHAPTER 1 Equipment Description Preparing the pump for shipping or storage Whenever a Flow pump is moved, put into storage, Crating or shipped, the following guidelines will help prevent 12. The pump must be shipped on a framed and rein-...
Page 19: Chapter 2. Safety
Safety precautions CAUTION Highlights an operating condition or service FLOW designed your high-pressure waterjet cutting sys- procedure that can lead to impaired system tem and related equipment with safety in mind. operation or equipment damage. Throughout the manual, safety precautions and warnings for specific operations are highlighted.
Page 20: Safety Tips
HYPLEX PRIME PUMP Maintenance & Service Manual Safety tips Clear all tools, parts, and rags from moving parts af- • ter servicing the equipment. Do not allow the waterjet stream to touch any part • of your body—it will cause serious injury. Do not Electrical system point the waterjet at anyone.
Page 21: Protective Clothing
Body protection described in this chapter. FLOW recommends that work-site safety personnel ap- Waterproof garments only protect the • prove all safety equipment and clothing for everyone operator from spray and flying debris.
Page 22: Emergency Medical Information
The card illustrated below can be purchased from Flow International (A-8466). The tag or card should contain the following standard information: 22 | M-416 ©...
Page 23: Chapter 3. Maintenance & Troubleshooting
When connecting the volt meter to terminals for • parts failure. FLOW recommends that you keep detailed measurement, use a range higher than the expected service records to help you prepare a maintenance voltage.
Page 24 HYPLEX PRIME PUMP Maintenance & Service Manual Torque specifications Use cleaning solvents only in well-ventilated areas. • Avoid prolonged breathing fumes and contact with Refer to the following table when specific torque re- skin or eyes. quirements are not listed in a service procedure.
Page 25: Inspection & Maintenance Schedules
It also includes replacing worn parts that have reached the end of their service life. In addition, the HyPlex Prime pump has four mandatory maintenance kits that are installed at fixed intervals. These are described in Chapter 4.
Page 26: Mandatory Maintenance Schedules
At fixed intervals for the life of the pump, you must per- form a mandatory maintenance kit installation. For all HyPlex Prime pumps (except the standalone ver- sion), the Service information feature in FlowCUT is fac- tory-set to remind the operator 10 hours before the next required maintenance hour mark (these are listed below).
Page 27: Hp Hyplex Prime Pump Maintenance Schedule
CHAPTER 3 Maintenance & Troubleshooting M-416 | 27 © Flow International Corporation...
Page 28: Hp Hyplex Prime Pump Maintenance Schedule
HYPLEX PRIME PUMP Maintenance & Service Manual 28 | M-416 © Flow International Corporation...
Page 29: Troubleshooting The Hyplex Prime Premium Pump Using Flowsense
Troubleshooting the HyPlex Prime Premium pump using FlowSENSE FlowSENSE is only available for the Premium package. HyPlex Prime Premium pumps are continuously monitored by FlowSENSE, a diagnostic program that monitors a num- ber of system conditions, some of which are specific to pump conditions.
Page 30: Flowsense Diagnostic Codes
FlowSENSE is only available for the Premium package. The tables below list all shutdown and warning codes for the HyPlex Prime that may appear on the system display (or console display if a standalone pump). Likely causes and possible solutions to those causes are included after each code description.
Page 31 27258 Crankcase overtemp warning Low oil level Add oil to crankcase. Problems in crankshaft/rotating group Contact Flow Technical Service. Inspect the cable assembly (A-26009-1) at the multi-port box. Replace if Faulty cable coming from the multi-port box necessary. 27251 Overpressure warning Debris in PCV poppet seat Remove PCV and clean poppet/seat to remove debris.
Page 32: Troubleshooting The High-Pressure Components
HYPLEX PRIME PUMP Maintenance & Service Manual Troubleshooting the high-pressure Weep holes components Weep holes provide an outlet for high-pressure water in case of seal problems, and thus can help you identify You may experience conditions that are explained in the problems with the pump.
Page 34: Troubleshooting Table
HYPLEX PRIME PUMP Maintenance & Service Manual Troubleshooting table Refer to the illustrated HyPlex Prime troubleshooting guide. If you have questions about anything on the troubleshoot- ing table, contact Flow Technical Service. My pump is leaking oil. Note: Some degree of oil leakage is normal. If oil leakage appears to be excessive: Seals are worn and require replacement.
Page 35 CHAPTER 3 Maintenance & Troubleshooting Check water source (flow rate and pres- My pump does not Insufficient water pressure or volume from • sure; filtration system) produce the pressure operator supply. requested from Check hoses and fittings for leaks/kinks •...
Page 36 (see Interface illustrations for part numbers). Missing 3-phase power leg. Call a certified electrician. Incorrect version of computer code (specifi- Call Flow Technical Service for correct revision cally FlowMaster). number and install correct version. Worn PCV poppet and seat. Install PCV maintenance kit (see section In- stalling the pressure control valve maintenance kit).
Page 37 Check for loose wiring. Call a certified • electrician. Tripped circuit breaker in control box. Call Flow Technical Service. My pump starts but immediately shuts down. Ensure proper oil level Crankcase oil temperature too high (can be •...
Page 38 5 micron inlet water pre-filter. Improper inlet water plumbing material (use Call Flow Technical Service. of iron or galvanized steel). Use of alternate filter vendor (non-Flow). Flow recommends purchasing components from Flow International Corporation to ensure part quality and safety.
Page 39 Install Major Maintenance Kit. Incorrect seal installation (seal reversed). Cooling ports clogged; insufficient cooling wa- Clean cooling ports, inspect water filters and ter flow in subplate adapter and seal carrier. operator-supplied water pressure. M-416 | 39 © Flow International Corporation...
Page 41: Chapter 4. Service
• leave a residue, such as Citra-safe® or isopropyl al- lubricants recommended by FLOW. All threaded cohol. FLOW recommends that you set up a dedi- high-pressure connections require an even coating of cated solvent tank for these critical parts. Blue Lubricant (A-2185).
Page 42: High-Pressure Components Illustration
HYPLEX PRIME PUMP Maintenance & Service Manual High-pressure components 42 | M-416 © Flow International Corporation...
Page 43: Using The Pressure Loading Tool
The pressure loading tool is used to accurately load and 3. Use a 19 mm (3/4 in.) socket and ratchet to rotate the unload the tie rods on the HyPlex Prime pump. Follow tool plunger clockwise until a value of 1500 bar these instructions to prevent damage to the tie rods, gauge pressure is reached.
Page 44 HYPLEX PRIME PUMP Maintenance & Service Manual Loading the tie rods 1. Rotate the threaded pressure loading tool plunger 3. Run the primary nuts of the pump down by hand counter-clockwise until it stops to ensure it is fully re- until firmly seated against the end caps.
Page 45: Installing The Dynamic Seal Maintenance Kit
CHAPTER 4 Service Installing the Dynamic Seal Maintenance kit Use this procedure when installing the Dynamic Seal Maintenance kit on your HyPlex Prime pump. Tools Service notes Pressure loading tool assembly, 049512-1 All parts of the kit should be installed at the same •...
Page 46 8. Place the check valve body in the provided rebuild clamp. Note: Do not cover the holes on the outer circum- ference of the check valve body to prevent metal from being introduced into the opening. 46 | M-397 © Flow International Corporation...
Page 47 13. Lap the inlet check valve poppet in same method. 14. Thoroughly clean the check valve body openings and inlet poppet to remove particles from the lapping process. M-416 | 47 © Flow International Corporation...
Page 48 HYPLEX PRIME PUMP Maintenance & Service Manual Installation and reassembly Assemble the check valve Assemble the end cap 1. Insert the new outlet poppet into the new outlet poppet guide. Note: Install poppet into the outlet poppet guide as shown, with the radiused back of the outlet poppet going in first.
Page 49 The subplate adapter/seal carrier interface must be clean and free of debris. 4. Slide the dynamic seal carrier onto the plungers until seated against the register of the subplate adapter. M-397 | 49 © Flow International Corporation...
Page 50 HYPLEX PRIME PUMP Maintenance & Service Manual Install the high-pressure cylinder Assemble the inlet poppet 1. Lubricate the o-ring with o-ring lube and place it in 1. Place the inlet poppet spring over the shouldered the groove of the high-pressure cylinder.
Page 51 4. Insert the filler tube, spring end first, into the high-pressure cylinder, making sure to engage the spring into the dynamic seal. Repeat for the remaining filler tubes. M-416 | 51 © Flow International Corporation...
Page 52 HYPLEX PRIME PUMP Maintenance & Service Manual Install the end cap 4. Apply anti-seize compound to both sides of the CAUTION It is important to install the end cap in one fluid motion to- washers and to the tie rod threads.
Page 53 4. Repeat Steps 1-3 for the remaining high-pressure tubes. 5. Insert one end of the tube into the high-pressure port on the manifold and loosely thread the glands in place. Repeat for the other two high-pressure tubes. M-416 | 53 © Flow International Corporation...
Page 54 Recommended oils are listed in Chapter 1. Return the pump to service Follow the startup procedure on Page 14 before return- ing the HyPlex Prime pump to service. 54 | M-416 © Flow International Corporation...
Page 55: Installing The Minor Maintenance Kit
Read the entire procedure before beginning service, • paying particular attention to safety instructions. CAUTION Failure to follow these step-by step instructions could cause premature parts failure and/or damage to the equipment. M-397 | 55 © Flow International Corporation...
Page 56 HYPLEX PRIME PUMP Maintenance & Service Manual Disassembly For each of the three high-pressure cylinders 1. Push in the E-stop. 4. Remove the end cap, high-pressure cylinder, inlet WARNING poppet, springs, filler tube, and sleeve. Discard the Place the main electrical disconnect OFF and bleed down inlet poppet and spring.
Page 57 11. Loosen the outlet cage. 12. Remove the outlet poppet and guide, outlet poppet spring, and outlet poppet seat. Discard the poppet, seat, guide, and spring. M-416 | 57 © Flow International Corporation...
Page 58 HYPLEX PRIME PUMP Maintenance & Service Manual Lap inlet face of check valve body Installation and reassembly 13. Use the glass lapping plate from the tool kit and Assemble the check valve 320 grit lapping paper from the repair kit. Lightly 1.
Page 59 Repeat Steps 1-5 for the remaining subplate adapters 2. Rotate the pulley to fully extend the next plunger to be checked. Repeat steps for the remaining plungers. When finished, wipe off dirt and grease from all three plungers. M-416 | 59 © Flow International Corporation...
Page 60 HYPLEX PRIME PUMP Maintenance & Service Manual Assemble and install the dynamic seal carrier 1. Inspect the dynamic seal carrier for cleanliness. Make sure the guide bearing of the seal carrier is flush with the face of the carrier and is in good con- dition (the presence of cracked or loose pieces is reason for replacement).
Page 61 Position the cylinders with weep holes facing downward. Note: A small amount of force will be needed to seat the cylinder against the seal carrier. Repeat for the remaining high-pressure cylinders. M-416 | 61 © Flow International Corporation...
Page 62 HYPLEX PRIME PUMP Maintenance & Service Manual Assemble the filler tube assembly 1. Place the dynamic seal compression spring into the tapered end of the filler tube. 2. Insert the inlet poppet assembly into the filler tube, spring end first.
Page 63 9. Remove the manifold assembly from the vise. then reinstall the nuts. 7. Use the pressure loading tool to load the tie rods (see Loading the tie rods on Page 44). M-416 | 63 © Flow International Corporation...
Page 64 HYPLEX PRIME PUMP Maintenance & Service Manual Install the manifold assembly 6. Loosely thread the other end of each of the three tubes into the end cap ports. 1. Apply a thin coat of Blue Lubricant to each of the threads on the 3/8 in.
Page 65 Recommended oils are listed in Chapter 1. Return the pump to service Follow the startup procedure on Page 14 before return- ing the HyPlex Prime pump to service. M-416 | 65 © Flow International Corporation...
Page 67: Installing The Major Maintenance Kit
Installing the Major Maintenance kit Use this procedure when installing the Major Maintenance kit on your HyPlex Prime pump. This service is performed at every required maintenance interval for the life of the equipment. The complete service schedule for the major maintenance kit (and the minor maintenance kit) is described on Page 26.
Page 68 HYPLEX PRIME PUMP Maintenance & Service Manual Disassembly For each of the three high-pressure cylinders 1. Push in the E-stop. 4. Remove the end cap, high-pressure cylinder, inlet WARNING poppet, springs, filler tube, and sleeve. Place the main electrical disconnect OFF and bleed down all high-pressure lines.
Page 69 12. Remove the outlet poppet and guide, outlet poppet spring, and outlet poppet seat from the outlet cage. Retain the cage. Discard the outlet poppet and guide, outlet poppet spring, outlet poppet seat, and check valve body. M-416 | 69 © Flow International Corporation...
Page 70 HYPLEX PRIME PUMP Maintenance & Service Manual Installation and reassembly Assemble the check valve 1. Insert the new outlet poppet into the new outlet poppet guide. Note: Install poppet into the outlet poppet guide as shown, with the radiused back of the outlet poppet going in first.
Page 71 Repeat Steps 1–5 for the remaining subplate adapters. 2. Rotate the pulley to fully extend the next plunger to be checked. Repeat steps for the remaining plungers. When finished, wipe off dirt and grease from all plungers. M-416 | 71 © Flow International Corporation...
Page 72 HYPLEX PRIME PUMP Maintenance & Service Manual Assemble and install the dynamic seal carrier 1. Inspect the dynamic seal carrier for cleanliness. Make sure the guide bearing of the seal carrier is flush with the face of the carrier and is in good con- dition (the presence of cracked or loose pieces is reason for replacement).
Page 73 Position the cylinders with weep holes facing down- ward. Note: A small amount of force will be needed to seat the cylinder against the seal carrier. Repeat for the remaining high-pressure cylinders. M-416 | 73 © Flow International Corporation...
Page 74 HYPLEX PRIME PUMP Maintenance & Service Manual Assemble the filler tube assembly 1. Place the dynamic seal compression spring into the tapered end of the filler tube. 2. Insert the inlet poppet assembly into the filler tube, spring end first.
Page 75 Tighten to 190 ft-lb (258 N-m). then reinstall the nuts. 9. Remove the manifold assembly from the vise.. 7. Use the pressure loading tool to load the tie rods (see Loading the tie rods on page 44). M-416 | 75 © Flow International Corporation...
Page 76 HYPLEX PRIME PUMP Maintenance & Service Manual Install the manifold assembly 6. Loosely thread the other end of each of the three tubes into the end cap ports. 1. Apply a thin coat of Blue Lubricant to each of the threads on the 3/8 in.
Page 77 Recommended oils are listed in Chapter 1. Return the pump to service Follow the startup procedure on Page 14 before return- ing the HyPlex Prime pump to service. M-416 | 77 © Flow International Corporation...
Page 79: Installing The Pressure Control Valve (Pcv) Maintenance Kit
Service Installing the pressure control valve (PCV) maintenance kit Use this procedure when installing the HyPlex Prime pressure control valve maintenance kit. The complete service schedule for the PCV is located on Page 26. Every other time you install a Major Maintenance kit, you should also install the PCV Maintenance kit. The poppet, seat, and static seal described in this procedure are included in the Major Maintenance kit.
Page 80 HYPLEX PRIME PUMP Maintenance & Service Manual Disassembly The poppet, seat, seal ring, bearing, plunger, piston seal, 8. Push the bearing from the bore of the PCV body us- plunger seal, and o-rings are replaced in this procedure. ing the bearing removal/installation tool (011172-1).
Page 81 12. Reconnect the air supply and drain lines. Follow the startup procedure on Page 14 before return- ing the HyPlex Prime pump to service. 6. With the air cylinder in a soft jaw vise, slide the body over the plunger and thread into the mounting block until the PCV body is firmly seated.
Page 83: Changing The Filter Elements
Note: This inspection can provide early warning of a change in inlet water quality. Filter life and inlet wa- ter quality are directly related. 6. Clean the canisters and install new filter cartridges. M-416 | 83 © Flow International Corporation...
Page 84: Replacing The Dynamic Seal And Plunger
50 hp pump that fails at 150 hours since last grate dynamic seal repair with the preventive mainte- service), FLOW recommends replacing all components nance described in this manual. FLOW suggests the to prevent unexpected down time. following strategy.
Page 85 Using the plunger nut poppet, springs, filler tube, and sleeve. tool, remove and retain the plunger nut and spring. Slide the plunger assembly from the crosshead bore and discard. M-416 | 85 © Flow International Corporation...
Page 86 HYPLEX PRIME PUMP Maintenance & Service Manual Installation and reassembly Assemble and install the dynamic seal carrier 1. With the crosshead in its fully extended position, ap- ply anti-seize to the nut, and place spring into the 1. Inspect the dynamic seal carrier for cleanliness.
Page 87 Position the cylinders with weep holes facing downward. Note: A small amount of force may be needed to seat the cylinder against the seal carrier. Repeat for the remaining high-pressure cylinders. M-416 | 87 © Flow International Corporation...
Page 88 6. Remove the temporarily installed hex nuts. Apply anti-seize to both sides of the washers and threads, then reinstall the nuts. 7. Use the pressure loading tool to load the tie rods (see Loading the tie rods on Page 44). M-397 | 88 © Flow International Corporation...
Page 89 4. Repeat Steps 1–3 for the remaining two high-pres- sure tubes. 5. Insert one end of the tube into the high-pressure port on the manifold and loosely thread the glands in place. Repeat for the other two high-pressure tubes. M-416 | 89 © Flow International Corporation...
Page 90 Recommended oils are listed in Chapter 1. Return the pump to service Follow the start-up procedure on Page 14 before return- ing the HyPlex Prime pump to service. M-397 | 90 © Flow International Corporation...
Page 91: Tensioning And Aligning The Belt Drive
Do not use subsititute hardware. 4. Install the four new belts. • Note: It is important to replace all four belts at the same time to maintain consistent performance of the drive system. M-416 | 91 © Flow International Corporation...
Page 92 HYPLEX PRIME PUMP Maintenance & Service Manual When the tension is correct: 5. Turn the nut on the tension bar CW until there is tension on the belts. 8. Use a 3/4 in. socket to torque the three flanged nuts 6.
Page 93: Servicing The Crankcase
Servicing the crankcase Replacing the piston rod seal assembly The only service required for the HyPlex Prime crank- case is to maintain adequate levels of clean oil and to re- The piston rod seal assembly contains three oil seals in- place worn piston rod seal assemblies.
Page 95: Chapter 5. Engineering Drawings
The following drawings are provided with this manual. Please note that drawings are provided for reference only . Drawings and part numbers can become obsolete as a part of Flow's ongoing product improvement. If part numbers are replaced by new numbers, Flow Customer Service will inform you when you order new parts.
Page 96 HYPLEX PRIME PUMP Maintenance & Service Manual Electrical Elementary electrical drawings are located in the system manual. Control package 049886-X No control package 30 hp Standard 460V 60Hz, 380V 50Hz 30 hp Plus, Premium 460V 60Hz, 380V 50Hz 30 hp Standard 230V 60Hz...
Page 97: Maintenance Kits
A-0265-062 Internal snap ring 049656-DWG HP assembly drawing 30 1 A-0275-029 HP o-ring A-20386-1 Anti-seize lubricant 31 1 SB-0258 Minor maintenance bulle- SB-0261 Dynamic seal maintenance bulletin 34 1 042145-2 PCV poppet/seat assembly M-416 | 97 © Flow International Corporation...
Page 98 HYPLEX PRIME PUMP Maintenance & Service Manual 050624-2 Rev. A Major maintenance 30/50 hp pump Part # Description 011051-1 Dynamic seal A-00621-33 Rod seal 011042-1 Inlet poppet 011040-1 Outlet poppet guide 011039-1 Outlet poppet 011041-1 Outlet poppet seat A-0275-025 O-ring...
Page 99: Tools
CHAPTER 5 Engineering Drawings Tools Recommended spares These parts are not contained in a spares kit, but FLOW recom- mends that you keep them on hand. 012068-3 Rev. K Tool kit Water filters Part # Description A-25216-1 0.5 micron filter...

Flow HYPLEX Manual

Chapter 1. Equipment Description

Chapter 2. Safety

Chapter 3. Maintenance & Troubleshooting

Chapter 4. Service

Chapter 5. Engineering Drawings

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Troubleshooting

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