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Summary of Contents for Flow MACH 500
- Page 1 MACH 500 PRE-INSTALL GUIDE JULY 2017...
- Page 2 Disclaimer Due to continuing product improvement, the information contained in this document is subject to change without notice. Flow International Corporation 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.
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Page 3: Table Of Contents
Ethernet connection ..........................14 Foundation ..............................15 Weights ..............................16 Plumbing ..............................17 Mach 500 machine ..........................17 HyPlex Prime pump ..........................17 UltraJet 60i-S & 60i-D pump ........................ 18 HyperJet 94i-S & 94i-D pump ......................19 PASER CF900 Abrasive Delivery System (ADS) ................20 Final Filter system .......................... - Page 4 Uncrate the roll-around control ....................... 33 Install utilities ..............................34 Electrical ..............................34 Plumbing ..............................34 Mach 500 ..............................35 HyPlex Prime pump ..........................36 UltraJet 60i-S or 60i-D pump ....................... 37 HyperJet 94i-S or 94i-D pump ......................38 PASER CF900 Abrasive Delivery System ..................39 Final Filter system ..........................
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Page 5: Test Your Inlet Water Quality
The water softener system must have the capacity to handle 1.5 times the maximum flow rate of the pump. Both the exiting flow rate [liters (gallons) per minute] and the flow rate of liters (gallons) per duty cycle should be considered. -
Page 6: Plumbing
Required primary water flow rate is determined by pump and orifice size. Cooling water Recommended cooling water flow rate is 11 L/min (3 gpm) per 50 hp (motor) at 15.5°C (60°F) inlet water temperature. This flow rate will increase as inlet water temperature increases. -
Page 7: Water Quality By Pump Type
Water quality by pump type Direct drive pumps General properties Temperature — 5°–21°C (41°–70°F) Clarity — clear Color — colorless Odor — none present Electrical conductivity — 100–400 µS/cm — 7–8.5 Total Dissolved Solids (TDS) — 70–280 mg/l Anions Chloride 0–100 mg/l Silica 0–8 mg/l... - Page 8 4150 bar (60K) intensifier pumps General properties Temperature — Clarity — clear Color — colorless Odor — none present Electrical conductivity — 100–550 µS/cm — 7–8.5 Total Dissolved Solids (TDS) — 70–380 mg/l Anions Chloride 0–150 mg/l Silica 0–15 mg/l Sulfate 0–50 mg/l Carbonate...
- Page 9 6500 bar (94K) intensifier pumps General properties Temperature — Clarity — clear Color — colorless Odor — none present Electrical conductivity — 100–400 µS/cm — 7–8.5 Total Dissolved Solids (TDS) — 70–280 mg/l Anions Chloride 0–100 mg/l Silica 0–8 mg/l Sulfate 0–25 mg/l Carbonate...
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Page 10: Water Properties
Water properties General properties Clarity Turbidity indicates the existence of very fine particles. Small particles can destroy orifices. Primary water should be clear. Color Color can derive from dissolved iron or from organic compounds. Primary water should be colorless. Odor Chlorine, organic solvent, and sulfur compounds can generate noticeable smell. - Page 11 Carbonate m-Alkalinity* Acid neutralizing capacity of water. Foaming and carryover of solids, causes embrittlement of steel, can produce CO , a source of corrosion. *Bicarbonate (HCO ), Carbonate (CO ), and Hydrate (OH) expressed as CaCO Hardness Sum of all hardness constituents in water. Typically expressed as their equivalent concentration of calcium carbonate primarily due to calcium and magnesium in solution, but may include small amounts of metal.
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Page 12: Schedule Training
Schedule training How do I sign up for training? Call 812.590.4922 or email techtraining@flowcorp.com at least four weeks before your preferred training dates to check availability and sign up. Can I attend training before my system is installed? Yes. In fact, we highly recommend it! What does training cover? Students who come to our training center are given the opportunity to work on dedicated training equipment while learning to solve real-life application scenarios. -
Page 13: Facility Requirements
Facility requirements Clearances Local codes and regulations will determine the actual distance that is required for clearances. Obstructions include lights, sprinkler heads, or HVAC. Recommended clearance each side 1000 mm (39 in.) Minimum vertical clearance 3810 mm (150 in.) unobstructed Electrical Pump Amperage... -
Page 14: Environment
Environment Ambient temperature 15.5°–38°C (60°–100°F) Recommended temperature 3 C (68 5 F) Relative humidity up to 90% @ 38°C (100°F), non- condensing Airborne dust/contaminants minimal Radio frequency interference minimal Lighting adequate to operate and service the machine If large temperature changes occur within an undefined period, length variances exceeding specified tolerances could occur over the entire work envelope. -
Page 15: Foundation
Foundation Everything starts with a great foundation and your waterjet is no exception! If you do not have an adequate foundation, the accuracy of your machine is affected. Your foundation must be: Free of expansion joints in the area that you plan to put your machine. (The purpose of expansion joints is to concentrate foundation movement and imperfections to these specific areas.) Structurally reinforced and undivided to ensure even settling, should any settling... -
Page 16: Weights
Weights Weights shown are for a single bridge machine whose catcher tank is filled with water. Mild steel Stainless steel Model Clean water dirty water dirty water 2020 12,091 kg 30,258 kg 26,362 kg (26,655 lb) (66,707 lb) (58,118 lb) 2030 15,982 kg 42,245 kg... -
Page 17: Plumbing
Plumbing Mach 500 Supply ..................dry and filtered to 10 microns Capacity per Z-axis end effector ............ 538 L/min @ 6.9–8.3 bar ......................(19 scfm @ 100–120 psi) Interface type ......................¾ in. BSPTF Drain Capacity per cutting head ............. 8 L/min @ 0 bar minimum ...................... -
Page 18: Ultrajet 60I-S & 60I-D Pump
UltraJet 60i-S & 60i-D pump Drains BLEED DOWN WATER Capacity ..................4 L/min (1 gpm) intermittent Interface type ....................... ½ in. NPTF OIL WATER LEAKAGE Capacity ..................4 L/min (1 gpm) intermittent Interface type ....................... ½ in. NPTF COOLING WATER OUT 50 hp capacity .................... -
Page 19: Hyperjet 94I-S & 94I-D Pump
HyperJet 94i-S & 94i-D pump Drains BLEED DOWN WATER Capacity ..................4 L/min (1 gpm) intermittent Interface type ....................... ½ in. NPTF OIL WATER LEAKAGE Capacity ..................4 L/min (1 gpm) intermittent Interface type ....................... ½ in. NPTF COOLING WATER OUT 50 hp capacity .................... -
Page 20: Paser Cf900 Abrasive Delivery System (Ads)
PASER CF900 Abrasive Delivery System (ADS) Supply ..................dry and filtered to 10 microns Air pressure/volume ................. 6.9–8.3 bar @ 566 L/min ......................(100–120 psi @ 20 scfm) Air line size ......................Interface type ......................... ¾ in. NPT Final Filter system Drain Capacity ...................... -
Page 21: Install Flowxpert Software
Install FlowXpert software If your purchase includes FlowXpert, please follow the instructions below to get your software. Please contact your Project Manager if the computer you want to download the software to is not able to connect to the internet. Request your entitlement email Before you request your entitlement email, please have your sales order number available to reference. - Page 22 3. Click Downloads. 4. In the Download column, select the software you want to install, and then click the .exe file to begin the download. 5. Click Logout. 6. Right-click the .exe file, click Run as admin, and then follow the prompts in the InstallShield wizard.
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Page 23: Customer-Supplied Items
Customer-supplied items During installation, please provide the following items: Clean, 5-gallon bucket (Used when FSE bleeds down abrasive lines) Forklift Ladder [ 2 m (7 ft) ] Hoses, fittings, and clamps for your plumbing connections Hydraulic oil WD-40® multi-use product (12 oz) Clean, lint-free rags Forklift requirements Item... -
Page 24: Review Your Payment Schedule
Review your payment schedule Every contract with us is unique. You’ll want to make sure to follow your payment schedule to avoid delays in shipping and installation. If you have any questions or concerns about your payment schedule, please contact your Project Manager or Credit Manager. Version 071517 Page 24 of 39... -
Page 25: Schedule Personnel
Schedule personnel During installation, the following personnel must be available: Who? Day 1 Day 2 Day 3 Day 4 Day 5 Forklift or crane operator to — — — place equipment. Support personnel to assist with installation as required. Electrician to attend kick-off —... -
Page 26: Schedule Your Installation
Schedule your installation Schedule your installation at least three weeks before your desired installation date. Make sure the date you select coincides with the completion of your pre-installation tasks. We recommend that you allow at least one week (from the date of your final equipment delivery) to complete these tasks. -
Page 27: Plan Your Layout
Plan your layout We’ll provide you with pre-install drawings that show the dimensions and space requirements for your system. Electrical and plumbing requirements are also included on the drawings. Plan your layout based on the drawings. Contact your Project Manager immediately if you: Did not get your pre-install drawings. -
Page 28: Unload Your Equipment
Inspect for damage When your equipment arrives, inspect it for damage. Report any shipping damage to Flow and to the carrier immediately. Record all shipping damage on the carrier’s Bill of Lading so you that you are eligible for a carrier claim. -
Page 29: Remove Crating & Packaging
Remove crating & packaging Remove the crate panels with pry bars, hammers, and a drill. Uncrate your equipment indoors! Equipment exposed to outdoor elements could get damaged. Dispose of all crating and packaging in accordance with local regulations. WARNING! Put equipment in position with a properly rated forklift accordance with local regulations. -
Page 30: Uncrate And Put The Ads In Position
Uncrate and put the ADS in position 1. Uncrate the ADS, and then remove all packaging. 2. Put the ADS in the position shown on the pre-install drawing. Uncrate ancillary items and put in position If you have ancillary items that will be located to the rear of the machine, uncrate these items and put them in position. -
Page 31: Uncrate The Base
Uncrate the base 1. Remove the blue plastic from the top of the crate, and then remove the top panel. 2. Remove the front and rear panels. 3. Remove the side panels. STOP! Do not remove any more panels or packaging from this crate until instructed to do so by our FSE during installation. -
Page 32: Uncrate The Bridge
Uncrate the bridge 1. Remove the blue plastic from the top of the crate, and then remove the top panel. 2. Remove the side panels. 3. Remove the front and rear panels. STOP! Do not remove any more panels or packaging from this crate until instructed to do so by our FSE during installation. -
Page 33: Uncrate The Roll-Around Control
Uncrate the roll-around control 1. Remove the blue plastic from the top of the crate, and then remove the top panel. 2. Remove the side panels. 3. Remove the front and rear panels. STOP! Do not remove any more panels or packaging from this crate until instructed to do so by our FSE during installation. -
Page 34: Install Utilities
Install utilities Electrical Have a qualified electrician install electrical power for your system in accordance with National Electric Code (NEC) standards or local regulations, whichever takes precedence. Provide all of the materials for your connections including electrical wires, conduits, and clamps. Identify and suppress all sources of unusually high electrical noise. -
Page 35: Mach 500
Mach 500 Connect inlet air at the recommended specifications. Connect a drain line directly to an outlet drain at the recommended specifications. Version 071517 Page 35 of 39... -
Page 36: Hyplex Prime Pump
HyPlex Prime pump Connect inlet air at recommended specifications. Connect the inlet water line at recommended specifications. Connect a drain line directly to an outlet drain at recommended specifications. Version 071517 Page 36 of 39... -
Page 37: Ultrajet 60I-S Or 60I-D Pump
UltraJet 60i-S or 60i-D pump Connect two inlet water lines at the recommended specifications. Connect three drain lines at the recommended specifications. Version 071517 Page 37 of 39... -
Page 38: Hyperjet 94I-S Or 94I-D Pump
HyperJet 94i-S or 94i-D pump Connect two inlet water lines at the recommended specifications. Connect three drain lines at the recommended specifications. Version 071517 Page 38 of 39... -
Page 39: Paser Cf900 Abrasive Delivery System
PASER CF900 Abrasive Delivery System Connect inlet air at recommended specifications. Final Filter system Connect a drain line directly to an outlet drain at recommended specification. Version 071517 Page 39 of 39...
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