Hypertherm DynaMAX 550P Operator's Manual
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Hypertherm DynaMAX 550P Operator's Manual

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DynaMAX™ 550P/560P/575P
Waterjet Pump
Operator Manual
811390 – REVISION 0
ENGLISH

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Summary of Contents for Hypertherm DynaMAX 550P

  • Page 1 DynaMAX™ 550P/560P/575P Waterjet Pump Operator Manual 811390 – REVISION 0 ENGLISH...
  • Page 2 DynaMAX, Seal Maintenance Indicator, SMI, Seal Maintenance Technology, SMT, AccuStream, 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. Environmental stewardship is one of Hypertherm’s core values. www.hypertherm.com/environment...
  • Page 3 DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390 REVISION 0 ENGLISH Original instructions January 2022 Hypertherm, Inc. Hanover, NH 03755 USA www.hypertherm.com...
  • Page 4 For training and education resources, go to the Hypertherm Cutting Institute (HCI) online at www.hypertherm.com/hci. Hypertherm products are designed and manufactured with a commitment to continuous quality control and safety. Contact a Hypertherm Technical Service Associate for information and support regarding the installation, operation, maintenance,...

  • Page 5: Table Of Contents

    National and local safety regulations.......................13 Certification test marks............................13 Differences in national standards ........................14 Higher-level systems ............................15 Environmental stewardship...................... 17 Hypertherm products: waste and recycling....................17 Particle emission and waste water quality ..................... 17 Chemical handling and usage...........................18 Safety............................19 Manuals ..................................19 User qualification and training...........................20...
  • Page 6 4 Preventive maintenance ......................65 Safety..................................66 Benefits of preventive maintenance..................... 67 Training ...............................68 Tools ................................68 Preventive maintenance schedule........................70 General ............................... 72 Examine and clean the equipment ....................... 72 Examine the pump for leaks or damage....................74 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...
  • Page 7 Prepare for storage..........................127 Record maintenance ..........................127 Inputs and outputs ..........................130 Alarm log ..............................130 Postmaintenance start procedure ..................... 131 Prepare for storage............................134 Recycling and end of product life ......................... 135 DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...
  • Page 8 Controller errors ..............................171 Input-output status..........................171 7 Specifications...........................173 All DynaMAX 5-series pumps .........................174 Environmental conditions ........................174 Hydraulic fluid ............................174 Utilities ..............................174 Compressed air ............................. 175 DynaMAX 550P..............................176 Dimensions and weights ........................176 Electrical..............................176 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...
  • Page 9 Measure the air pressure in the water accumulator tank ............. 205 Flush the pump and the high-pressure tubing ................206 Operator interface: Adjustment screens ..................... 207 Pump Adjustments..........................207 Seal Maintenance Indicator ........................ 214 DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...
  • Page 10 Contents Enter or change the time and date....................215 Intensifier Control..........................216 Pressures ..............................217 SD Card ..............................218 Remote operation.............................. 218 Storage................................218 9 Declaration of Incorporation....................219 10 Technical drawings........................221 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...

  • Page 11: Warranty

    12 months from the date of proven installation, Abrasive regulator whichever occurs first On-off valve air actuator 600 hours of operation with the use of a thimble filter Diamond orifice and compliance with Hypertherm’s water quality requirements DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...
  • Page 12  the result of the system being operated contrary to Hypertherm’s instructions or stated limits  of rated and normal use. For information about the manufacturer’s warranty, refer to the conditions of sale provided when the product was purchased.

  • Page 13: Product Stewardship

    Hypertherm puts a certification test mark on its products only after that product is manufactured with safety-critical parts that have been approved by the accredited testing laboratory. Once the product has left the Hypertherm factory, the certification test marks are invalid if one or more of these events occurs.

  • Page 14: Differences In National Standards

    Incorporation to applicable European directives and standards. Only those versions of Hypertherm products with a CE mark on or near the data plate have been tested for compliance with the applicable European directives, such as the Low Voltage Directive, the Electromagnetic Compatibility Directive, and the Machinery Directive.

  • Page 15: Higher-Level Systems

    Unless the higher-level system is certified when the OEM or system integrator incorporates Hypertherm products into it, the installation can be subject to approval by local authorities. Get advice from legal counsel and local regulatory experts if you are not sure about compliance.
  • Page 16 Product stewardship 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...

  • Page 17: Environmental Stewardship

    Particle emission and waste water quality Hypertherm does not manufacture or supply the materials that are cut and has no knowledge about the particles released from materials that are cut and if they can pose a physical danger or health risk.

  • Page 18: Chemical Handling And Usage

    Chemical regulations in the USA, Europe, and other locations require that MSDS and 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: 1. Go to www.hypertherm.com/docs.

  • Page 19: Safety

    A PDF of the manual downloads to your device. These navigation instructions can change without notice. The safety precautions in this manual are general and cannot anticipate every situation. Hypertherm, Inc. acknowledges that unforeseen situations such as equipment failure, site variability, insufficient maintenance, failure of control equipment, and other events can cause equipment damage, injuries, or death.

  • Page 20: User Qualification And Training

    How to operate all controls  How to identify and respond to a problem with the equipment  How to do maintenance procedures  A copy of the operator manual  This list is not all-inclusive. 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...

  • Page 21: Emergency Medical Information And Treatment

     X-ray is the preferred imaging method.  Acute compartment syndrome is possible.  Leave the wound open.  Do not use solvents other than isotonic sodium chloride solution for irrigating the wound. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...

  • Page 22: Safety Information For Operation, Maintenance, Repair, And Installation

    WARNING Let only approved personnel operate this machinery. WARNING Release all high-pressure water before doing work on this equipment. WARNING HOT SURFACE Do not touch. WARNING 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...
  • Page 23 Personal protective equipment is recommended. If you do not use personal protective equipment, there is a risk of injury or death. WARNING WARNING High-pressure water can cause eye injuries. Wear approved eye protection when operating or doing work near this equipment. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...
  • Page 24 Water leaking from a high-pressure fitting or the bleed-down valve can be hot. CAUTION Examine and clean the equipment regularly. Refer to the Examine and clean the equipment page 72. CAUTION Do repairs immediately. 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...

  • Page 25: Symbols And Marks

    COULD cause minor or moderate injuries or WILL cause damage to the equipment if ignored. CAUTION NOTICE identifies a condition or a situation that COULD cause damage to the equipment if ignored. This symbol identifies a mandatory action. This symbol identifies a prohibited action. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811370...
  • Page 26 Symbols and marks This symbol identifies tools or materials that are necessary or recommended for a procedure. This symbol identifies a tip or helpful information. 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...

  • Page 27: Symbols And Marks Found On The Equipment

    Connections may come loose during shipping and normal operation. Hydraulic, water, and electrical connections can come loose during shipping and normal operation. It is recommended that all connections are checked at installation and annually. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...
  • Page 28 Type of hydraulic fluid recommended Hydraulic fluid tank volume (liters) Full-load current (amperage) SCCR Short-circuit current rating Imax Primary motor maximum current draw (amperes) Primary motor power output (kilowatts) L/min Maximum outlet flow rate (liters/minute) 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...
  • Page 29 Declaration of Incorporation to applicable European directives and standards. Only those versions of Hypertherm products with a CE mark on or near the data plate have been tested for compliance with the applicable European directives, such as the Low Voltage Directive, the Electromagnetic Compatibility Directive, and the Machinery Directive.
  • Page 30 Water-cooled system: This line carries low-pressure water from the heat exchanger to a drain or to a chiller. Air-cooled system: This line carries hydraulic fluid from the system to the external heat exchanger. Prefilter water pressure Postfilter water pressure 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...

  • Page 31: Product Description

    Product description It is possible that not all of the information in this section applies to all pump models. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...

  • Page 32: Flow Of Water And Hydraulic Fluid

    3 Prefilter water gauge Low-pressure water goes to a drain. 4 Water filters 12 Drip tray 5 Postfilter water gauge 13 Seal Maintenance Indicator™ (SMI) 6 Water accumulator tank 14 Dirty water container 7 Intensifier 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...

  • Page 33: Cooling Loop

    When the primary motor is operating, cooling water goes through the heat exchanger, transferring heat away from the hydraulic fluid to the cooling water. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...
  • Page 34 When the primary motor is operating, hydraulic fluid goes through the heat exchanger, where a fan pushes ambient air through the heat exchanger. 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...

  • Page 35: Pump Exterior

    2 Postfilter water-pressure gauge The prefilter water-pressure gauge The postfilter water-pressure gauge shows the water pressure before the shows the water pressure after the water water goes through the filters. goes through the filters. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...
  • Page 36 From the drip tray, fluid flows through a clear tube to the SMI. When a drip passes an optical sensor, a blue LED illuminates, showing which of the weep holes on the intensifier is the source of the drip. 1 SMI tube 3 Drip sensor LED (blue) 2 Power LED (green) 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...
  • Page 37 The operation panel turns the control circuit in the pump on and off and controls local and remote pump operation. Dirty water container Water and hydraulic fluid captured in the drip trays goes to the dirty water container found under the electrical enclosure. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...
  • Page 38 E button. Refer to Emergency MERGENCY STOP stop on page 60. An override key is provided for access to the components on the top deck. 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...
  • Page 39 The bleed-down valve is a normally open, air-actuated dump valve. The valve releases high-pressure water from the system when the pump is turned off or when the operator changes from cut mode to pierce mode. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...

  • Page 40: Pump Interior

    3 Primary motor and maintains a consistent output water pressure. Primary motor 1 Proportional control valve 4 Hydraulic pump 2 Gear pump 5 Primary motor 3 Hydraulic manifold 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...
  • Page 41 A hydraulic relief valve sends hydraulic fluid back to the hydraulic fluid tank when the pressure is too high. Primary motor The primary motor drives the gear pump and the hydraulic pump. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...
  • Page 42 Product description Rear view 1 Hydraulic fluid tank 3 Hydraulic fluid filter 2 Boost pump 4 Water manifold 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...
  • Page 43 When the intensifier starts to stroke, the boost pump turns on. When there is no demand for cutting water, the boost pump turns off. Hydraulic fluid filter This filter removes contamination from the hydraulic fluid. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...
  • Page 44 6 Low-pressure water relief valve The transducer monitors the manifold water pressure. The relief valve prevents water in the system from being too high. When the valve opens, water goes to the drain. 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...

  • Page 45: Optional Equipment

    An electrical interlock on the top cover prevents access to the components on the top deck while the system is pressurized. The interlock is connected to the emergency-stop circuit. When the top cover is opened, the pump switches to emergency-stop mode and bleeds off all pressure. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...
  • Page 46 Optional equipment 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...

  • Page 47: Operation

    Operation Safety Read and understand all of the safety guidelines in this manual. Refer to Safety on page 19 before operating, doing maintenance on, repairing, and installing the pump. WARNING DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...

  • Page 48: Use The Controls

    Operation Use the controls Operation panel The operation panel turns the control circuit in the pump on and off and controls local and remote pump operation. key switch button OCAL REMOTE ONTROLS ON Push this button to turn the control circuit in When the key switch is in the L OCAL the pump.

  • Page 49: Operator Interface

    The intensifier is overstroking (red). Intensifier status indicator and stroke-rate bars It is normal for the intensifier to stroke faster during the start sequence and when changing from pierce pressure to cut pressure. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...
  • Page 50 Operation During normal operation, the intensifier strokes smoothly to the left and to the right at the same speed. The stroke-rate bars show the speed of the piston moving to each side of the intensifier. Refer to Overstroke on page 159 for troubleshooting information. Intensifier control ×...
  • Page 51 Select the pressure mode on page 59 system. for information about pressure modes. The intensifier animation is not related to the actual stroke rate and can be moving when the intensifier is not stroking. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...

  • Page 52: Turn On The Pump: Beginning Of Day Or Beginning Of Shift

    5. Look for leaks, deterioration, damage, or other conditions that can interfere with operation. 6. Make sure that all connections, fasteners, locking devices, hoses, and fittings are tight. 7. Make sure that all warning decals are visible and legible. Contact Hypertherm for replacement decals. 811390 Operator Manual...

  • Page 53: Check The Hydraulic Fluid Quality

    1. Look through the sight gauge to see the color of the hydraulic fluid. Good hydraulic fluid is almost transparent. 2. Remove the filler-breather cap on top of the tank. 3. Smell the hydraulic fluid. Good hydraulic fluid has almost no odor. 4. Install the filler cap. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...

  • Page 54: Turn On The Utilities

    Operation Turn on the utilities Close all doors and replace all panels and covers, including the top cover and access covers. 1. Turn the supply water to the pump. 2. Turn the compressed air source. 3. Turn the electrical main (line disconnect switch). 4.

  • Page 55: Make Sure That The Emergency Stop Operates Correctly

    Intensifier bridge and bottom deck  2. Examine the low-pressure tubes and the hoses for leaks. 3. Examine the bleed-down valve for leaks or damage. A hot bleed-down valve can suggest that there is a leak. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...

  • Page 56: Check The Low-Pressure Water Pressure Gauges

    Operation 4. Examine the weep holes in the high-pressure ends for leaks. Water leaking from a weep hole is a sign of a faulty part or a loose connection. 1 Output adapter leak 3 Dynamic seal leak 2 High-pressure seat leak 5.

  • Page 57: Check The Hydraulic Filter Gauge

    Do this task when the pump is operating. 1 Filter-breather cap 3 Drain valve 2 Sight gauge Make sure that the hydraulic fluid level is at the top mark on the sight gauge. Add hydraulic fluid, if necessary. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...

  • Page 58: Operate The Pump Remotely

    Operation Operate the pump remotely Refer to the OEM’s instructions for starting the pump and for operating the pump from a remote source. On the operation panel, turn the L key switch OCAL REMOTE REMOTE The remote indicator light is on Stop the pump Refer to the OEM’s instructions for turning the pump off.

  • Page 59: Operate The Pump Locally

    Stop the pump Use this procedure during normal operation. On the operator interface, touch the symbol. STOP The control circuit stays on.  The pump, the primary motor, and the intensifier turn off.  DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...

  • Page 60: Emergency Stop

    Operation The bleed-down valve opens to release high-pressure water from the system.  The supply-water valve closes to stop low-pressure water from entering the system.  Emergency stop The emergency stop button does not disconnect main electrical power from the machine. WARNING This is not the preferred method of turning off the pump.

  • Page 61: Redundant Intensifiers

    3 Top deck access holes Change the intensifier that is in operation Do this task when the pump is not operating. 1. Turn the primary breaker disconnect lever on the electrical enclosure door to DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...
  • Page 62 Operation 2. Turn the supply water to the pump. Make sure that the water pressure gauges show 0.0 bar (0 psi). 3. Turn the electrical main (line disconnect switch). Use standard lock out–tag out procedures. 4. Open the top cover and separately remove the front panel from the pump. 5.
  • Page 63 Troubleshooting The intensifier cannot stroke if any of these are not in the correct position: the high-pressure water valve handles  the proximity switch wires  the hydraulic valve handles  DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...
  • Page 64 Operation 811390 Operator Manual DynaMAX550P/560P/575P Waterjet Pump...

  • Page 65: Preventive Maintenance

    Use the maintenance log feature to record maintenance performed on the pump and the intensifier. Refer to Record maintenance on page 127 for instructions. It is possible that not all of the information in this section applies to all pump models. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...

  • Page 66: Safety

    WARNING Permit only approved personnel to operate, maintain, and repair this machinery. WARNING Release all high-pressure water before doing work on this equipment. WARNING 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...

  • Page 67: Benefits Of Preventive Maintenance

    135 Benefits of preventive maintenance Hypertherm recommends preventive and scheduled maintenance for all waterjet pumps. High-quality equipment that is maintained on a schedule lasts longer than equipment that is not maintained regularly. This maintenance includes adjustments, cleaning, lubrication, repairs, and replacement of parts.

  • Page 68: Training

    Special tools are recommended or necessary for some maintenance and repair procedures. This page is intended to help a user identify tools that are unfamiliar or are known by other names. Open-ended wrench Crowfoot wrench Screwdriver Standard Phillips O-ring pick 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...
  • Page 69 Preventive maintenance Seal housing removal tool Intensifier repair tools Sleeve Spacer Push tool Locator DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...

  • Page 70: Preventive Maintenance Schedule

    Check the low-pressure water pressure  gauges. Clean the Seal Maintenance Indicator tubes.  Measure the air pressure in the water accumulator tank. Low-pressure water.  Test the water quality. Replace the Seal Maintenance Indicator  tubes. 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...
  • Page 71 Disassembling the intensifier is necessary for some of these procedures (page 99). To reduce downtime, Hypertherm recommends doing preventive maintenance on both ends of the intensifier at the same time. Repair the check valves and the low-pressure poppets. Install the high-pressure hoops, the high-pressure water seals, the ...

  • Page 72: General

    Do this every work shift. 1. Check the dirty water container. Refer to local regulations regarding waste water. Environmental rules can apply to disposal. Water in the container could have oil in it. 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...
  • Page 73 Push up on the tray tab until the tray makes a click. 6. Make sure that all warning decals are visible and legible. 7. Contact Hypertherm for replacement decals. 8. Clean the operator interface, if necessary. To prevent damage to the operator interface: ...

  • Page 74: Examine The Pump For Leaks Or Damage

    Hydraulic fluid tank access cover  Hydraulic connections  Valves  Top and bottom pump decks  2. Examine the low-pressure tubes and the hoses for leaks. 3. Examine the bleed-down valve for leaks or damage. 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...
  • Page 75 The SMI monitors the rate of drops from the static seal and the dynamic seal. 5. Examine the high-pressure tubing for leaks. 6. Look for deterioration, damage, or other conditions that can interfere with operation. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...

  • Page 76: Electrical System

    Do this task when the pump is not running. 1. Examine electrical cords and cables for kinks or damage to the insulation. 2. Examine electrical plugs and other electrical connections for corrosion or damage. 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...
  • Page 77 3. Make sure that the SMI cable harness is not damaged and that the connections are not loose. 4. The cable harness connects to the junction box (shown) and to the rear of the SMI. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual...

  • Page 78: Hydraulic System

    Do this task when the pump is running at operating temperature. 1. Use a standard screwdriver to remove the pump cover. 2. Make sure that the white indicator bar is not in the red zone. 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...

  • Page 79: Check The Hydraulic Fluid Level

    The capacity of the hydraulic fluid tank is 151 L (40 gallons). Parts, tools, and materials Antiwear (AW) mineral oil or synthetic hydraulic Recommended materials fluid, ISO viscosity grade (VG) 32 or 46 Clean funnel Do this task when the pump is not running. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...

  • Page 80: Check The Hydraulic Fluid Quality

    Antiwear (AW) mineral oil or synthetic hydraulic Clean towels fluid, ISO viscosity grade (VG) 32 or 46 Torque wrench 15/16-inch crowfoot wrench or socket Do this task when the pump is not running. 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...
  • Page 81 Install a new hydraulic filter and filler-breather cap when replacing the hydraulic fluid. Do not put too much hydraulic fluid in the tank. If it is not possible to analyze a sample of the hydraulic fluid. Hypertherm recommends replacing the hydraulic fluid every 3,000 hours.
  • Page 82 5. Remove the access cover on the tank. 6. Use a strap wrench to remove the suction strainers in the tank. 1 Suction strainer, 1-1/2 inch (to the gear pump) 2 Suction strainer, 2-1/2 inch (to the hydraulic pump) 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...
  • Page 83 22. Operate the pump in pierce-pressure mode for 15 to 20 minutes. If air is in the hydraulic system, the pump can be noisy during operation. Refer to The pump makes noise during operation on page 168. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...

  • Page 84: Lubricate The Primary Motor Bearings

    Motors are lubricated with this grease at the Clean towels factory Do this task when the pump is running. 1. Remove the grease fitting cap from the motor. 2. Make sure the grease fittings are clean. 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...
  • Page 85 9. Do this procedure again on the other end of the motor. It is possible that grease does not come out of the grease outlet when the new grease is pumped in. Use only the recommended volume. CAUTION DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...

  • Page 86: Low-Pressure Water System

    The inner surfaces of the SMI tubes become dirty over time. Dirty tubes can cause a fluid monitoring sensor error. Parts, tools, and materials Replacement kit, SMI tubes, DynaMAX 550P/560P/575P Refer to the DynaMAX standard tool kit. 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...
  • Page 87 4. Rinse the tube with clean water. 5. Connect the tube to the push-to-connect fitting on top of the SMI. 6. Push the tube into the clip. 7. Do this procedure for all 4 tubes. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...

  • Page 88: Replace The Seal Maintenance Indicator Tubes

    Optimal pressure DynaMAX 550P-560P-575P 3.5 bar (50 psi) 4. Add compressed air to increase the pressure in the tank. To reduce pressure in the tank, push on the valve stem to release air. 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...

  • Page 89: Check The Low-Pressure Water Pressure Gauges

    1. Subtract the value shown on the postfilter water pressure from the value shown on the prefilter water pressure. 2. Replace the water filters if the difference between the values on the prefilter water-pressure gauge and the postfilter water-pressure gauge is lower than 0.7 bar (10 psi). DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...

  • Page 90: Air Cooler

    3. After cleaning, dry the cooler. Clean the hydraulic fluid side of the cooler Do this task when the pump is not running. 1. Disassemble the cooler to find the degree of contamination. 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...

  • Page 91: Low-Pressure Water

    5. Put a new 0.22-micron filter cartridge in the housing with the plug at the bottom and the gray rubber gasket at the top. 6. Put a new filter cartridge in the 1-micron filter canister and the 10-micron filter canister. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...
  • Page 92 14. On the operator interface, touch the symbol. 15. Make sure that the difference between the values on the prefilter water-pressure gauge and the postfilter water-pressure gauge is lower than 0.7 bar (10 psi). 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...

  • Page 93: Test The Water Quality

    3. Take a sample of the water from the supply tube. Make sure that the water is clear and odorless. 4. Connect the low-pressure water supply tube to the intensifier. 5. Make sure that the water is clear and odorless. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...
  • Page 94 The TDS measures the total concentration of dissolved substances in postfilter water. Dissolved solids cause deposits that can cause damage to check valves, seals, orifices, and other consumables. the optimal range is 0.0025% to 0.015% (25 ppm to 150 ppm). 1. Disengage the intensifier. 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...
  • Page 95 If multiple readings are taken, turn the TDS meter between readings. 8. Compare the reading using the table starting on page 93 9. Rinse the meter in clean, deionized water or filtered water after use. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...

  • Page 96: Intensifier

    Always tighten fittings to the specified torque. Do not use an adjustable wrench on high-pressure fittings. CAUTION Use clean hands when changing high-pressure parts. To reduce downtime, Hypertherm recommends doing preventive maintenance on both ends of the intensifier at the same time. 811390 Operator Manual...
  • Page 97 • Indicator pin cap 6 High-pressure hoop Indicator pin spring 7 High-pressure water seal 17 Plunger Low-pressure poppet (spring not shown) 18 Hydraulic end cap Low-pressure poppet basket 19 Proximity switch 10 Spacer tube DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...

  • Page 98: Prepare To Do Maintenance On The Intensifier

    5. Turn power from the primary utility source. Use standard lock out–tag out procedures. 6. Turn the water to the pump. 7. Make sure that the water pressure gauges show 0.0 bar (0 psi). 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...

  • Page 99: Disassemble The Intensifier

    The high-pressure poppet seat can cause cracks, erosion marks, or dents in the output adapter. If a poppet part is damaged, replace all 3 components. 1 High-pressure poppet seat 3 High-pressure poppet spring 2 High-pressure poppet 4 Output adapter DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...
  • Page 100 Square drive socket, 1-1/2 inch × 3/4 inch (included in the 1-12084 DynaMAX 5-series standard Tool kit. 1. Remove the end cap nuts. 2. Pull the high-pressure end cap off. 3. Remove the end cap gasket. 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...
  • Page 101 6. Turn the cylinder over and put it on the locating ring. 7. Prevent the spacer tube from sliding out when the cylinder is turned over. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...
  • Page 102 Parts, tools, and materials Clean towels Seal housing removal tool Isopropyl alcohol 1/8-inch hex wrench (for the seal housing removal tool) Two 10-32 stainless steel screws O-ring pick (or similar tool) (to remove the plunger bearing) 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...
  • Page 103 Remove the indicator pin assembly Replace the indicator pin springs every 3,000 hours. 1 Cap screw and lock washer 5 Indicator pin spring 2 Indicator pin cap 6 Indicator pin O-ring backup, -013 Indicator pin O-ring, -013 DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...
  • Page 104 Do not rock the part or use too much pressure. Doing so can cause damage to the part face. This procedure is for a moderately worn check valve. Replace very worn components. 1 Check valve assembly 2 Low-pressure poppet 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...
  • Page 105 Repair the high-pressure cylinders every 500 hours. Replace the high-pressure cylinders: • every 3,000 hours • if the cylinder is chipped or cracked Debris in the cylinder can cause the seals or the poppets to fail. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...

  • Page 106: Assemble The Intensifier

    Do not tighten a fitting too much. The fitting can fail. Put the parts on a clean, dry surface. Before assembling high-pressure or hydraulic parts, clean the parts to remove grease and other contamination. 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...
  • Page 107 The hydraulic center section includes the piston, the plungers, the hydraulic cylinder, the hydraulic end caps, the low-pressure seals, and the proximity switches. Preventive maintenance on these parts requires special tools. Contact a Hypertherm Technical Service Associate for information and support regarding the installation, operation, maintenance, and repair of this equipment.
  • Page 108 2. Put the spring on the indicator pin. 3. Put the O-ring backup on the indicator pin cap. 4. Put a small quantity of hydraulic fluid on the O-ring. 5. Put the O-ring on the indicator pin cap. 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...
  • Page 109 Parts, tools, and materials DynaMAX premium high-pressure seal repair kit Petroleum-based O-ring lubricant, 56 g (2 oz.) Plunger bearing Antiwear (AW) mineral oil or synthetic hydraulic fluid, ISO viscosity grade (VG) 32 or 46 Seal housing DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...
  • Page 110 O-ring backup faces the wide end of the seal housing. The O-ring fits into the concave groove on the O-ring backup. 4. Put the plunger bearing on the plunger. Push the plunger bearing into the hydraulic end cap. 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...
  • Page 111 13. Put the high-pressure seal backup on the plunger and push it against the seal housing. 14. Make sure that the bottom weep holes are aligned. 15. If the proximity switch was removed for this procedure, reinstall it. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...
  • Page 112 Check valve assembly Seal installation tools (Refer to 1-12084 Low-pressure poppet basket DynaMAX 5-series standard Tool kit). Spacer tube Rubber mallet 1. Put the seal installation spacer tool on a clean, dry surface. 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...
  • Page 113 Keep the poppet and the poppet basket clean. Grease can cause the poppet to stick. 4. Make sure that the poppet moves easily. 5. Put the low-pressure poppet basket with the low-pressure poppet into the spacer tube. 6. Put the spacer tube into the high-pressure cylinder. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...
  • Page 114 10. Put a small quantity of high-vacuum grease on the red O-ring. 11. Put the red O-ring into the groove on the high-pressure water seal. 12. Put the high-pressure water seal into the insertion sleeve with the red O-ring toward the cylinder. 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...
  • Page 115 18. Hold the sleeve tightly in the cylinder while tapping the push tool. 19. Remove the seal insertion push tool, the sleeve, and the locator. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...
  • Page 116 24. Put the cylinder and the check valve on to the plunger by pushing on the end of the check valve until the cylinder is touching the seal housing. Install the high-pressure end caps 1 Stud 3 High-pressure end cap nuts 2 Low-pressure water fitting 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...
  • Page 117 High-pressure end cap nut page 180 8. Tighten each fastener in 68 N∙m (50 lbf∙ft) increments. Use a repeating cross pattern. Refer to Special fasteners on page 180 9. Connect the low-pressure water line. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...
  • Page 118 2. Use a cotton-tipped applicator to guide the high-pressure poppet seat into the check valve. The wide end of the high-pressure poppet seat faces toward the check valve. 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...
  • Page 119 Make sure that some of the threads on the high-pressure tubing are visible at the fitting. Refer to Special fasteners on page 180. 10. Torque the high-pressure water fitting to 68 N∙m (50 lbf∙ft). Refer to High-pressure water fittings (gland nuts) on page 185 DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...

  • Page 120: Bleed-Down Valve

    Do not use soap, detergent, or solvents. 1 Air fitting 6 Bleed-down valve body 2 Actuator 7 Bleed-down valve poppet seat 3 Needle bushing 8 Air-actuated bleed-down valve flow reducer 4 Needle 9 Outlet adapter 5 High-pressure valve seal 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...

  • Page 121: Repair The Bleed-Down Valve

    (line disconnect switch). Use standard lock out-tag out procedures. 5. Disconnect the compressed air hose from the air fitting on top of the actuator. 6. Disconnect the water drain tube from the bleed-down valve. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...

  • Page 122: Install The Bleed-Down Valve

    Refer to Fittings on page 182 for torque values. 2. Connect the water drain tube to the bleed-down valve. 3. Connect the compressed air hose to the fitting on top of the actuator. 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...

  • Page 123: Start The Pump After Maintenance

    • Working on the electrical system. Refer to Start the pump on page 54 for instructions 1. Turn the electrical breaker. 2. Turn the water to the pump. 3. Monitor for leaks. 4. Turn the compressed air supply. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...
  • Page 124 The pump can not be turned on until the control circuit is on. 9. Turn the pump in cooling mode. 10. The post-maintenance start program operates. Refer to Postmaintenance start procedure page 131. 11. Monitor for leaks. 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...

  • Page 125: Operator Interface: Maintenance Screens

    Touch the current screen symbol to go back 1 screen. To use the maintenance screens, touch a symbol with a border around it. This usually opens another screen. A field with no border shows that the item is informational. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...

  • Page 126: Primary Maintenance Screen

    The unit must be in cooling mode. The cooling symbol with a hand flashes as a reminder. Start the pump after maintenance Touch this symbol to open the Start Procedure screen. Refer to page 126 for instructions. 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...

  • Page 127: Prepare For Storage

    There are 3 Intensifier Components screens. Touch an arrow symbol at the bottom of a screen to move between the screens. 4. Touch the symbol on the screen for each component that was replaced. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...
  • Page 128 6 Indicator pin spring (3,000 hours) 8 Indicator pin (6,000 hours) 10 Seal housing (6,000 hours) 9 Output adapter (6,000 hours) 11 Spacer tube (12,000 hours) After a symbol is selected, the Maintenance Reason screen opens. 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...
  • Page 129 9. Touch the applicable symbol on the screen to record the reason that the part was replaced. This information is saved as a .CSV file on the SD card. 1 Leak 3 Scheduled preventive maintenance 2 Worn or broken part DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...

  • Page 130: Inputs And Outputs

    Touch this symbol to open the screen that shows inputs and outputs for the controller. Refer to Controller errors on page 171 for detailed description. Alarm log Touch this symbol to open the Alarm Log screen. 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...

  • Page 131: Postmaintenance Start Procedure

    8. Touch the symbol on the screen to start the procedure. While to procedure continues, examine the pump for high-pressure water leaks and hydraulic fluid leaks. Monitor these areas.  Hydraulic connections  Valves  Intensifier bridge and button deck DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...
  • Page 132 Stage 4: Pressure Increasing The target pressure increases to 690 bar (10,000 psi).  Pressure Increasing flashes on the screen at 1-second  intervals. The intensifier strokes to increase the water pressure in the  system. 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...
  • Page 133 Examine the Pump flashes on the screen at 1second intervals. 1. Examine the pump for loose fittings or leaks.  2. Touch the symbol. The main motor turns off.  The primary operation screen opens.  The pump is ready for operation. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...

  • Page 134: Prepare For Storage

    On the operator interface, touch the symbol on the Prepare for Storage screen. The cutting water and the cooling water supply valves open. d. Turn the compressed air supply for at least 2 minutes to dry the system. 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...

  • Page 135: Recycling And End Of Product Life

    Make sure that dangerous substances are disposed of safely and that the correct personal protective equipment is used. The safety specifications must be in accordance with the current local regulations at all times. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...
  • Page 136 Preventive maintenance 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...

  • Page 137: Parts Lists

    Parts lists Genuine Hypertherm parts are the factory-recommended replacement parts for this pump. It is possible that the Hypertherm warranty will not cover damage caused by nongenuine Hypertherm parts. To order parts, contact the original equipment manufacturer (OEM). DynaMAX 550P/560P/575P Waterjet Pump...

  • Page 138: Tools

    These tools are shipped with the pump. The tool case contains all of the above items except: The torque wrench has a separate case.  The granite lapping block is shipped in a wooden box.  The breaker bar is shipped in a bag.  811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...

  • Page 139: Maintenance And Repair Kits

    1-11136 High-vacuum grease, 150 g (5.3 oz.) Seal backup, high pressure, bronze Hydraulic rod seal, 1 inch O-ring, check valve and seal housing, -035 O-ring, check valve, -031 O-ring backup, -035 O-ring, -011 Gasket, high-pressure end cap DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...
  • Page 140 Description Quantity High-vacuum grease, 5 g (0.2 oz) Poppet seat, bleed-down valve Valve seal, high-pressure Needle, bleed-down valve Needle guide, bleed-down valve O-ring, -011 Flow reducer insert, bleed-down valve, air actuated Dowel, wooden 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...

  • Page 141: Optional Equipment

    Optional equipment Part number Description 1-16968 Air-cooled system kit, 230V, HyPrecision P-50/P-50S 1-16957 Air-cooled system kit, 400 V/460 V, DynaMAX 550P 1-16958 Air-cooled system kit, 400 V/460 V, HyPrecision P-60/P-75S 1-17310 Electrical interlock kit, DynaMAX 550P/560P/575P 1-17293 Electrical interlock bracket, DynaMAX 550P/560P/575P...

  • Page 142: Replacement Parts

    Parts lists Replacement parts Top cover Part number Description 1-17304 Top cover, DynaMAX 550P/560P/575P Fittings Part number Description 1-13157-60-4 Collar, high pressure, 1/4 inch 1-13157-60-6 Collar, high pressure, 3/8 inch 1-13158-60-4 Gland nut, high pressure, 1/4 inch 1-13158-60-6 Gland nut, high pressure, 3/8 inch...

  • Page 143: Hydraulic System

    Service kit, gear pump, DynaMAX 550P/560P/575P 1-18042 Service kit, hydraulic pump, DynaMAX 550P 1-18043 Service kit, hydraulic pump, DynaMAX 560P/575P 1-18046 Service kit, hydraulic shaft seal, DynaMAX 550P 1-18047 Service kit, hydraulic shaft seal, DynaMAX 560P/575P 1-18050 Service kit, hydraulic O-rings, DynaMAX 550P 1-18051...

  • Page 144: Low-Pressure Water System

    Replacement kit, inlet water tubes, intensifier 1-17498 Tube, replacement, bleed-down valve 1-17487 Fittings kit, push-to-connect 1-12056 Motor, boost pump, 1/2 hp 1-12057 Boost pump kit, 100 gallons per hour, DynaMAX 550P/560P/575P 1-19168 Boost pump assembly, wet end 1-11832 Gauge, low-pressure water 1-13897 Meter, TDS 811390...

  • Page 145: High-Pressure Water System

    Support ring, split Intensifier high-pressure ends Part number Description 1-11530 Output adapter 1-11523 Check valve assembly 1-11521 Spacer tube 1-11522 Cylinder, high pressure 1-11609 Seal housing 1-11520 Poppet basket, low pressure 1-11608 Plunger bearing DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...
  • Page 146 Parts lists 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...

  • Page 147: Troubleshooting

    Obey local protocols for recycling or disposal of parts, materials, and fluids. National and local environmental rules can apply to disposal. Refer to Recycling and end of product life on page 135. Coordinate maintenance and repairs with facility and safety staff. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...

  • Page 148: General

    Troubleshooting General If the problem is not found in this section, contact a Hypertherm Technical Service Associate for information and support. Keep accurate maintenance records. Records can help with predicting and preventing maintenance problems. Use SAE (US standard) tools for most procedures.

  • Page 149: Alarms

    To acknowledge an alarm, touch the screen. The Alarm Log screen opens. Touch Ack (acknowledge) or Ack All (acknowledge all) on the screen. The beacon light stops flashing and the alarm screen closes. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...

  • Page 150: Warnings

    Warning: Right Dynamic Seal between 8 hours and 50 hours. Warning: Left Static Seal Warning: Right Static Seal Warning: Empty the Dirty Water The dirty water container is full. Empty the container. Container 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...
  • Page 151 Associate for information and support. An optical sensor is dirty. • Remove the tubes from the optical sensors. • Liberally clean the optical sensors with isopropyl alcohol. • Dry the optical with compressed air. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...

  • Page 152: Faults

    The motor is being started too Wait longer between stopping and frequently. starting the motor. The motor bearing is too hot. Lubricate the bearing. A fuse in the electrical enclosure Replace the fuse. has blown. 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...
  • Page 153 It can take e several minutes for the system to reboot. The relief valve on the pump Contact a Hypertherm Technical manifold has failed. Service Associate for information and support. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...
  • Page 154 Fault 3: Left Static Seal Fault 3: Right Static Seal A warning or a fault occurs during the start sequence The start sequence timers are adjustable. Refer to Start Procedure Timers on page 209 for information. 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...

  • Page 155: Intensifier

    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 seal replacement will soon be necessary. Numbers pointing to items in the illustration correspond with numbers in the table. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...
  • Page 156 • Make sure that the fitting is tightened correctly and to the correct torque value. The tube end is cracked or Replace the component. damaged. The output adapter has failed. 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...
  • Page 157 — Water leaks at a rate of more The high-pressure seal has failed. Replace the seal. than 30 ml/minute. Hydraulic fluid leaks at a rate The hydraulic seal has failed. of more than 30 ml/minute. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...
  • Page 158 Replace the hydraulic fluid and examine all of the parts, including the inner surfaces of the hydraulic fluid tank, the hydraulic hoses, and the seals. It could be necessary to drain and flush other areas such as the shift valve, the hydraulic manifolds, and the hydraulic pump. 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...

  • Page 159: Overstroke

    10-micron water filter. If the filter is black, the overstroke without triggering the boost pump has failed and must be replaced. low-pressure alarm for the Contact a Hypertherm Technical Service low-pressure water. Associate for information and support. • While the pump is operating, make sure that the LED on the low-pressure water drain valve solenoid is on.
  • Page 160 Is the overstroke is to the right? A poppet is sticking, worn, or damaged. • Check the low-pressure poppet on the right side of the intensifier. • Check the high-pressure poppet on the left side of the intensifier. 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...
  • Page 161 216. a red × on the intensifier symbol. The cutting head is off. Turn on the cutting head. A proximity switch or the Replace the component. Contact a Hypertherm proximity switch cord failed. Technical Service Associate for information and support.
  • Page 162 Clean or replace the component. defective. A hydraulic piston seal is worn or damaged. Contact a Hypertherm Technical Service Associate for information and support. There is a leak in the system. Identify the source of a leak and correct the problem.
  • Page 163 Replace the water filters. The boost pump has failed. If the filter is black, the boost pump has failed and must be replaced. Contact a Hypertherm Technical Service Associate for information and support. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...

  • Page 164: High-Pressure Water Seal Life Is Short

    Make sure that the supply-water flow and pressure are sufficient. Refer to the Specifications section in this manual. The proportional control valve is not operating correctly. Contact a Hypertherm Technical Service Associate for information and support. The water quality is not sufficient.

  • Page 165: Hydraulic Fluid

    The pump is in pierce-pressure Make sure that the pump is in mode. cut-pressure mode. The relief valve on the hydraulic Contact a Hypertherm Technical manifold has failed. Service Associate for information and support. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...
  • Page 166 It could be necessary to drain marks, corrosion, or cracks. and flush other areas such as If damage is found, replace the the shift valve, the hydraulic component. manifold, and the hydraulic pump. 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...

  • Page 167: Temperature

    • The pump operates in cooling mode for 3 minutes. If the temperature remains at or higher than 65°C • The operator interface shows F AULT (149°F): >65C >3 M YDRAULIC LUID INUTES • The primary motor turns off. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...

  • Page 168: The Pump Makes Noise During Operation

    2. Use a torque wrench to tighten the hose clamps to a maximum of 29 N∙m (22 lbf∙ft). If the pump is still noisy after tightening the hose clamp, contact a Hypertherm Technical Service Associate for information and support.

  • Page 169: Low-Pressure Water

    If the value on the prefilter water-pressure gauge is higher than 4.8 bar (70 psi): • In the electrical enclosure, turn the switch on the boost pump motor contactor to 0. • On the operator interface, turn boost pump monitoring. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...

  • Page 170: Seal Maintenance Indicator (Smi)

    Seal Change screen shows on the operator interface.  Touch the symbol to acknowledge that a seal was replaced.  Touch the X symbol to close the screen. The fault alarm shows on the screen after 2 hours.  811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...

  • Page 171: Controller Errors

    Q14 Remote fault light Q7 Left shift-valve solenoid Q15 Beacon light – red Q8 Right shift-valve solenoid Q16 Beacon light – green AI1 Hydraulic pressure AQ1 Not used AI2 Remote pressure control AQ2 Not used DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...
  • Page 172 Troubleshooting 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...

  • Page 173: Specifications

    US Customary units in parentheses. 1 bar (15 psi) 10 mm (3/8 inch) 115 N∙m (85 lbf∙ft) This equipment is manufactured in the US, so a metric equivalent is not always available because of inexact conversion. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...

  • Page 174: All Dynamax 5-Series Pumps

    Set at the factory Normal operation temperature 37.8°C to 43.3°C (100°F to 110°F) If it is not practical to analyze a sample of the hydraulic fluid, Hypertherm recommends replacing the hydraulic fluid every 3,000 hours. Refer to Replace the hydraulic fluid on page 81.

  • Page 175: Compressed Air

    Mineral deposits can clog the cooling fins in the heat exchanger. Softened water is necessary for most systems. Get advice from a specialist for recommendations for choosing a water treatment system. Reverse osmosis systems are available from Hypertherm. Water quality Test Optimal range 6.0 to 8.0...

  • Page 176: Dynamax 550P

    4,140 bar (60,000 psi) setpoint Pierce-pressure 1,380 bar (20,000 psi) — factory setpoint and C OOLING IN OOLING OUT Flow 11.4 L/minute (3.0 gallons/minute) — Pressure 2.8 bar (40 psi) 7.6 bar (110 psi) 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...

  • Page 177: Dynamax 560P

    4,140 bar (60,000 psi) setpoint Pierce-pressure 1,380 bar (20,000 psi) — factory setpoint and C OOLING IN OOLING OUT Flow 11.4 L/minute (3.0 gallons/minute) — Pressure 2.8 bar (40 psi) 7.6 bar (110 psi) DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...

  • Page 178: Dynamax 575P

    4,140 bar (60,000 psi) setpoint Pierce-pressure 1,380 bar (20,000 psi) — factory setpoint and C OOLING IN OOLING OUT Flow 11.4 L/minute (3.0 gallons/minute) — Pressure 2.8 bar (40 psi) 7.6 bar (110 psi) 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...

  • Page 179: Orifices

    WARNING Because of high pressure in the intensifier, all fasteners used on hydraulic and high-pressure water parts are grade 8. Lock washers are necessary for fasteners that are used for cyclic loading. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...

  • Page 180: Special Fasteners

    These torque values are for fasteners that are coated with antiseize bolt lubricant (white lithium grease). Code 61 grade 8 Code 62 grade 8 1/16-inch Bolt size (low pressure) (high pressure) dash size (inch) N∙m lbf∙ft N∙m lbf∙ft 5/16-28 3/8-16 3/8-16 7/16-14 1/2-13 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...
  • Page 181 To make a good seal, the sealing face must be parallel to the mating surface and the bolt tension must be even. 7. Use a torque wrench to tighten the bolts to the specified value. Tighten each bolt in small increments. Use a repeating cross pattern. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...

  • Page 182: Fittings

    Some torque specifications are found on the technical drawings. Hydraulic fittings Hypertherm recommends thread sealant for all NPT fittings. This table shows maximum values. The torque necessary to make a sufficient seal depends on the condition of the pipe threads and can be much lower than the maximum.
  • Page 183 Minimum Maximum 1/16-inch dash size N∙m lbf∙ft N∙m lbf∙ft SAE O-ring boss Do not use thread sealant on SAE hydraulic fittings. Lubricate O-rings with hydraulic fluid or O-ring lubricant before assembly. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...
  • Page 184 If a fitting leaks after tightening it to the maximum torque value, disassemble the parts. Repair or replace parts that show deterioration, corrosion, or damage. Use a high-pressure antiseize lubricant such as Blue Goop or PURE Goop on high-pressure water fittings. 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...
  • Page 185 2. Put the gland nut on the high-pressure tube. 3. Put the collar on the high-pressure tube. Make sure that some of the threads on the high-pressure tube are visible at the fitting. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...
  • Page 186 5. Tighten the gland nut by hand. 6. Use a torque wrench to tighten the gland nut to the specified value. Low-pressure water fittings Do not use lubricants on low-pressure water fittings. All low-pressure water connections use push-to-connect fittings. 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...

  • Page 187: Installation

    This work should be done only by an approved technician. It is the buyer's responsibility to investigate and obey all local codes. Obey all safety requirements and applicable safety laws and regulations. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...

  • Page 188: Buyer Responsibilities

    Only use tubing that is rated for this pressure. WARNING The buyer is responsible for these obligations. Cooperate with Hypertherm and the Hypertherm original equipment manufacturer (OEM)  regarding the installation of the equipment. Obey all setup and first-time start up instructions in this manual.

  • Page 189: Requirements

    This lets air movement help cool the machine and keeps space available for doing maintenance and repairs. Hypertherm recommends installing the pump on a level surface with a difference in height of no more than 8 cm (1/4 inch) between opposite ends. Install the pump on a solid, flat surface that can hold the weight of the equipment and is thick enough to resist vibration.

  • Page 190: Hydraulic Fluid

    48,000 Hydraulic fluid Hypertherm does not always ship the pump with hydraulic fluid in the tank. Domestic pumps usually ship from the factory with AW 32 hydraulic fluid. Antiwear (AW) mineral oil or synthetic hydraulic fluid, ISO viscosity grade (VG) Type 32 or 46.

  • Page 191: Utilities

    Water quality reports that show pH, silica, and hardness levels are frequently available for no charge from public utility water suppliers. Reverse osmosis systems are available from Hypertherm. The quality of the water supplied to the intensifier has a direct effect on the life of the intensifier and consumables.

  • Page 192: Receive And Unpack The Equipment

    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 193: Install The Pump

    Refer to the specific pump model in the Specifications section of this manual. Level the pump Hypertherm recommends installing this pump on a level surface with a difference in height of not more than 8 cm (1/4 inch) between opposite ends.
  • Page 194 3. Use the included hardware to mount the high-pressure tubing whip bracket on the angle plate. 4. After the high-pressure tubing is connected to the utility panel, install the high-pressure tubing clamps on the whip bracket. 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...

  • Page 195: Install The External Heat Exchanger (Optional)

    5. Put the cord and the threaded end of the cord grip connector through the wiring access hole. 6. Put the lock nut on the cord grip connector. 7. Connect the motor wires (L1, L2, and L3) to the motor starter. Connect the ground wire to the grounding lug (PE). DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...

  • Page 196: Connect The Utilities To The Pump

    The cooling loop OOLING IN COOLING OUT keeps the hydraulic fluid in the pump at its optimal temperature. The utility connections are identified by hang tags with symbols on them. 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...
  • Page 197 Keep these parts to use if the pump is stored or shipped. 2. Connect the utilities to the pump. Refer to Fittings on page 182 for torque values and information about how to correctly install water fittings. All low-pressure water connections use push-to-connect fittings. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...
  • Page 198 OUTLET on the external heat tank. exchanger. • Connect the other end to the ball valve at the heat exchanger inlet. Factory-installed fitting: -16 JIC male 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...

  • Page 199: Check The Hydraulic Fluid

    Make sure that hydraulic fluid is available during installation and for the first start. CAUTION Look at the hydraulic sight gauge to check the fluid level. Add hydraulic fluid, if necessary. Refer to Do the first start on page 200 and Add hydraulic fluid page 79. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...

  • Page 200: Connect The Electrical Power

    CAUTION This procedure could cause damage to the orifice. Do not do the first start with a diamond orifice installed. Hypertherm recommends using a ruby CAUTION orifice during the first 40 hours of operation.

  • Page 201: Do A Preoperation Inspection

    If the available air pressure is too high, install an air regulator (not included) to reduce the pressure. 3. Turn the electrical main (line disconnect switch). 4. Turn the primary breaker disconnect lever on the electrical enclosure door to DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...

  • Page 202: Make Sure That The Primary Motor Turns In The Correct Direction

    5. Make sure that the primary motor turns in the direction shown by the rotation arrow. If the pump motor turns the wrong direction a. Turn the primary breaker disconnect lever on the electrical enclosure door to 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...
  • Page 203 Then TART touch the S symbol. h. Make sure that the primary motor turns in the direction shown by the rotation arrow. 6. Install the shaft access cover. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...

  • Page 204: Make Sure That The Heat Exchanger Fan Motor Turns In The Correct Direction

    CAUTION 1. Set the pressure to 345 bar (5,000 psi). 2. On the operator interface, touch the C symbol to turn the pump. OOLING MODE 3. Let the pump operate for 2 to 3 minutes. 4. Monitor for leaks. 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...

  • Page 205: Adjust The Boost Pump Pressure

    The supply water components are rated for a maximum of 8.6 bar (125 psi). High pressure CAUTION can cause damage to the components. If the supply water is from a reverse osmosis system, contact a Hypertherm Technical Service Associate for information and support. Do this task when the pump is operating in cooling mode.

  • Page 206: Flush The Pump And The High-Pressure Tubing

    12. Increase the pressure to 4,140 bar (60,000 psi). Operate the program in a loop for 15 minutes. If the on-off valve leaks, examine the needle, the seat, the seals, and the orifice for damage. Replace parts, if necessary. The pump is ready for operation. 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...

  • Page 207: Operator Interface: Adjustment Screens

    Pump Information on page 208 Remote Configuration on page 211 Start Procedure Timers on page 209 Stop Procedure Timers on page 212 Pressure Adjustments on page 210 Pump Fault Behavior on page 213 DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...
  • Page 208 Touch the up or down arrows to select the units (bar or psi) that show on the operator interface screens. Software Part # This is the Hypertherm part number and the revision version for the software installed on the controller. Software Version This is the version of the software on the controller.
  • Page 209 The system has this much time to get to the pierce-pressure setpoint. The timer default is 5 seconds. Stage 5 If the pump is in cut-pressure mode, the system has this much time to get to the cut-pressure setpoint. The timer default is 5 seconds. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...
  • Page 210 The default is 34 bar (500 psi). The smallest increment is 10 bar (100 psi). Decrease This is how much that the target pressure decreases each time the – symbol on the primary operation screen is touched. The default is 34 bar (500 psi). 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...
  • Page 211 • the pump is controlled by Modbus TCP over Ethernet. Modbus Pressure This turns Modbus control of the pump pressure on or off. IP Address Enter a static IP address. Netmask Enter the netmask. Gateway Enter the gateway. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...
  • Page 212 The default is 180 seconds. LP Drain Valve This timer determines how long after the pump turns off the low-pressure (LP) drain valve opens and releases the low-pressure water from the system. The default is 30 seconds. 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...
  • Page 213 The system can monitor a boost pump for fault conditions. This turns monitoring on or off. Fan Fault Monitor The system can monitor a heat exchanger for fault conditions. This turns monitoring on or off. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...

  • Page 214: Seal Maintenance Indicator

    If a fault occurs and the Stop On Fault feature is not on, this timer determines how long after a fault is acknowledged that the system pauses before showing the Alarms screen again. The default is 2.0 hours. 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...

  • Page 215: Enter Or Change The Time And Date

    Date symbol and field Touch the symbol to change the date format. Options are DD-MM-YY or MM/DD/YY. Touch the field next to the symbol to open a numeric keypad. Use the keypad to change the date. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...

  • Page 216: Intensifier Control

    This shows the total hours that the intensifier has been in operation. Strokes This shows the total number of strokes on the intensifier. A stroke is counted each time a proximity switch is activated. 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...

  • Page 217: Pressures

    The setpoint is based on the pump model. DynaMAX 550P 2.0 bar (29 psi) DynaMAX 560P 1.7 bar (25 psi) DynaMAX 575P 1.5 bar (21 psi) Hydraulic This shows the hydraulic pressure in the system. Output DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...

  • Page 218: Sd Card

    If the microSD card is missing or damaged, the screen shows SD Card Not Found. Remote operation To connect the pump directly to an external control device, such as a CNC, refer to the CNC manual and contact a Hypertherm Technical Service Associate for information and support. Storage Refer to Prepare for storage on page 134 for information about storing this equipment.

  • Page 219: Declaration Of Incorporation

    4. Click on the Declaration of Incorporation for your product. A PDF of the document downloads to your device. These navigation instructions can change without notice. For information about this document, refer to Certification test marks on page 13. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...
  • Page 220 Vaartveld 9 4704 SE Roosendaal The Netherlands SIGNED: _____________________________________ ____ _ _ __ _ _ __ _ _ _ _ _ _ _ _ __ Gordon Rice Gordon Rice Executive Vice President - Waterjet 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...

  • Page 221: Technical Drawings

    The hydraulic and water system drawing is in this section. The electrical drawings are shipped in an envelope that is found inside the electrical cabinet. Hypertherm recommends printing these pages on A3-, tabloid-, or ledger-size paper. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual...
  • Page 222 Technical drawings 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump...
  • Page 223 Technical drawings DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390...
  • Page 224 We review your comments and ideas regularly and use them when planning changes. We promise to consider every suggestion. Your satisfaction is our highest priority. Send this information with your comments to Technical.Service@hypertherm.com. DynaMAX 550P/560P/575P Waterjet Pump Operator Manual 811390, revision 0  Include page numbers, if applicable.

This manual is also suitable for:

Dynamax 560pDynamax 575p

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