m406_en Mach 3b and 4b Series

MACH 3B SERIESMACH 4B SERIESModels:M3-4020b, M3-3020b, M3-2513b, M3-7320b, M3-1313bM4-4020b, M4-3020b, M4-2513b, M4-7320b, M4-1313b

M-406 | Rev. B | January 2010

Due to continuing product improvement, the information contained in this document is subject to change withoutnotice. Flow International Corporation shall not be held liable for technical or editorial omissions made herein, nor forany incidental or consequential damage resulting from the use of this material.

This document contains information protected by copyright. No part of this document shall be reproduced in anymanner without prior written consent from Flow International Corporation.

MACH3 and MACH4 are trademarks of Flow International Corporation.

PASER® ECL Plus, Dynamic Waterjet�, WaterVeyor�, HyperJet�, HyPlex� Hybrid, FlowPATH�, and FlowCUT� areregistered trademarks of Flow International Corporation.

© 2009-2010 Flow International Corporation. All rights reserved.

2 | M-406 © Flow International Corporation

Mach 3b and Mach 4b Series SystemOperation & Service Manual

Mach 3b and Mach 4b Series System

Chapter 1. Equipment Description & Operation

System components 7

Integrated ultrahigh-pressure pump 8

FlowMaster PC-based controller 8

WaterVeyor abrasive removal system 8

End effector 8

Abrasivejet system 8

Catcher tank 8

Light curtain safety device 8

Spray containment kit 8

System Specifications 9

Machine features 9

Options 9

Installation requirements 10

Environment 10

Oil requirements 10

Water requirements 11

Water interface connections 12

Drain requirements 13

High-pressure tubing 13

Startup procedures 14

Starting the Hyperjet 94i-S or 94i-D intensifier pumpafter installation 14

Starting the 50i-S or 100i-D intensifier pumpafter installation 17

Starting the HyPlex pump after installation 20

System operation 22

Fault indicators 22

Machine startup 22

Machine shutdown 22

Running the pump 23

HyperJet 94i-S or 100i-D pump 23

50i-S or 100i-D intensifier pump 23

HyPlex Hybrid pump 23

Using dual pressure 23

Changing low-pressure or high-pressuresetting (intensifier pump) 23

Warning and shutdown sensors 23

Calibrating the pump to a gauge 23

Control panel 24

Chapter 2. Safety

Safety precautions 27

Warnings, cautions, and notes 27

Safety tips 27

Protective clothing 29

Emergency medical information 30

Chapter 3. 60K End Effectors

Standard end effector 31

Dynamic Waterjet end effector 31

Z-axis 32

Work envelope 32

Maintenance 32

DWJ wrist assembly 33

Maintenance 33

Wrist assembly exploded view 34

Mini on/off valve 35

Specifications 35

Maintenance 35

Troubleshooting the valve 36

Servicing the valve 41

High-precision cutting head 44

How it works 44

Chapter 4. 94K End Effector

Standard end effector 47

Dynamic Waterjet end effector 47

Z-axis 48

Work envelope 48

Maintenance 48

DWJ wrist assembly 49

Maintenance 49

On/off valve 50

Specifications 50

Maintenance 50

High-precision cutting head 51

How it works 51

Servicing the cutting head components 53

© Flow International Corporation M-406 | 3

Introduction



Chapter 5. X,Y Table

X,Y table maintenance 55

Inspection 56

Recommended lubricants 57

Recommended cleaners 57

Troubleshooting the X,Y table 58

Chapter 6. Engineering Drawings

Pumps 61

Plumbing 62

End effectors 63

X,Y assemblies 64

Catchers 64

Electrical 65

Kits 66

Miscellaneous service parts 66


Introduction

Introduction

The information in this manual will help you become familiar with your new Flow International (FLOW) equipment. Itwas compiled from the most current information available at the time of publication and is intended to cover themost common configurations.

Safety

All operating personnel and service technicians must read and follow the procedures in this manual to avoid creatingunsafe conditions, or risking damage to the equipment.

The comprehensive list of safety precautions in Chapter 2 must be followed to ensure safe operation of the equip-ment. These precautions must be reviewed and understood by operating and maintenance personnel before installing,operating, or servicing the equipment. The high-pressure waterjet system is a powerful cutting tool and must alwaysbe treated with respect.

Warnings, cautions, & notes

Before operating the equipment, please read, thoroughly understand, and follow all warnings, cautions, and notes thatappear in this manual. They are defined as follows:

WARNINGHighlights an operating or service procedure or condition that

can result in death or serious injury to personnel.

CAUTIONHighlights an operating or service procedure or condition thatcan lead to impaired system operation or equipment damage.

Note: Highlights an operating or service procedure or condition that is essential for efficient operation and service.

Notes



CHAPTER 1

Equipment Description & Operation

The Mach 3b and Mach 4b Series Systems are free-standing gantry shapecutting systems. This machine is electric ACservomotor-driven and microprocessor-controlled from the FlowMaster PC-based controller.


System components

The Mach 3b and Mach 4b Series System includes thefollowing components.

Integrated ultrahigh-pressure pump

There are five available pumps for the Mach 3b andMach 4b Series System, described in these manuals:

50i-S or 100i-D intensifier pump

Refer to manual M-349, 50i-S Pump or M-351, 100i-Dpump.

HyPlex Hybrid pump

Refer to manual M-397, HyPlex Hybrid Pump.

HyperJet 94i-S or HyperJet 94i-D intensifier pump

Refer to manual M-390, HyperJet 94i-S & 94i-D Pump

FlowMaster PC-based controller

• Refer to the FlowMaster CD

WaterVeyor abrasive removal system

The Waterveyor is designed to remove spent abrasiveand kerf material from the catcher tank.

• Refer to manual M-357, Waterveyor AbrasiveRemoval System

End effector

The Mach 3b and Mach 4b Series systems are availablewith several end effector options:

• Dynamic Waterjet XD end effector (DWJ-XD)

• Dynamic Waterjet end effector (DWJ)

• Non-DWJ end effector

Abrasivejet system

The abrasivejet system uses an abrasive delivery hopperand a cutting head.

The abrasive delivery hopper is available as an integratedhopper with no external controls, or a standalone unitwith external controls.

The abrasive level switch on an integrated hopper ismonitored through the software.

• Refer to the PASER manual that shipped with yoursystem.

Catcher tank

The catcher tank supports the cutting envelope surface.The levelness of the tank and the water in the tank isimportant to maintain consistent cutting quality.

Light curtain safety device

Mach 3b and Mach 4b Series systems with a DynamicWaterjet XD end effector are equipped with a light cur-tain to maintain a safety perimeter around the machine.

Spray containment kit

Mach 3b and Mach 4b Series systems with a DynamicWaterjet XD end effector are equipped with amulti-panel spray containment system to minimize sprayoutside of the cutting area.



System Specifications

Machine features

PC-based control

FlowMaster PC controller includes CAD, path ordering,machine controls and diagnostics, plus optional partnesting.

Digital servo system

X and Y axes (digital AC servos) provide high accuracyand low maintenance.

Ball screw drives

The Mach 3b and Mach 4b Series System uses high-pre-cision ball screws and ways.

Options

Vacuum assist

Helps when piercing brittle materials such as glass, com-posite, or stone.

Abrasive flow monitor

Alarm activates when abrasive flow rate exceeds high orlow limits.

X,Y,Z jog pendant

Allows the operator to adjust cutting head position re-motely from the main control console.


CHAPTER 1Equipment Description & Operation

Installation requirements

Environment

The pumps used with the Mach 3b and Mach 4b SeriesSystem are designed only for factory or shop use.

Ambient temperature 60° to 100°F (15.5° to 38°C)

Relative humidity Up to 90% @ 100°F (38°C)non-condensing

Airborne dust/contaminants

Minimal

Radio frequencyinterference

Minimal

Lighting Adequate to operate & servicethe equipment

Oil requirements

Use of recommended oils is vital to proper operationand maintenance of the system.

Intensifier pump

Use an oil that does not contain anti-wear additives; thefollowing oils are recommended, but other manufac-turer's equivalents can be used:

• Mobil DTE Medium, Shell Turbo T 46,Chevron Tur-bine Oil GST 46, Exxon Teresstic 46, or Texaco RegalR&O 46

Kinematic viscosity 50i-S/100i-D:310 SSU @ 100°F (38°C)

HyperJet 94i-S/94i-D:240 SSU @ 100°F (38°C)

System capacity 50i-S: 32 gallons (121 L)

100i-D: 34 gallons (129 L)

HyperJet 94i-S: 25 gallons (95 L)

HyperJet 94i-D:37 gallons (140 L)

Filtration 2 microns, continuous flow

Cooling Oil-to-water heat exchanger

Optimum oil tem-perature

105°F (40.5°C)

HyPlex Hybrid pump

Use an oil that does not contain anti-wear additives.Shell Rotella (or equivalent) is recommended, but othermanufacturer's equivalents can be used.

Use SAE 30 unless ambient temperature is above 90°F(32°C), then use SAE 40.

Reservoircapacity

2.5 qt (2.4 liter)

Fill reservoir until oil is visible on thedipstick.

SAE designa-tion

MS, SC, or SD



Water requirements

• The 50i-S and 100i-D intensifier pumps require twosources of water: cutting and cooling. Also requiredare three water drain lines for coolant, leakage, andbleed-down water. Leakage and bleed-down waterdrain lines may be plumbed together when necessary.The leakage drain must be separate where local regu-lations do not permit oil in drains. Specific require-ments are defined below.

• The HyperJet 94i-S and HyperJet 94i-D intensifierpumps each require one water source. Also requiredare three water drain lines: coolant drain, leakagedrain, and bleed-down water. Leakage andbleed-down water drain lines can be plumbed to-gether when necessary. The leakage drain must beseparate where local regulations do not permit oil indrains. Specific requirements are defined below.

• The HyPlex Hybrid pump requires a single source ofwater, and one drain line.

Cutting water

CAUTIONA high concentration of dissolved solids in the inlet water

(especially silicates and calcium) can reduce waterjet nozzlelife. If water quality is poor and filtration will not correct it, the

customer must add additional water treatment equipment.Contact Flow Technical Service for more information.

Flow recommends the use of a water softener topre-treat the cutting water.

Water pressure

• Water pressure to the intensifier pump must stay be-tween 20 and 100 psi (1.4 and 6.9 bar) at all times.

• Water pressure to the HyPlex pump must stay be-tween 40 and 60 psi (2.8 and 4.1 bar) at all times.

Water flow rate

Systems should be sized for 150% of your pump capac-ity, and should match your intended maximum dutycycle.

Cooling water (to heat exchanger)

For intensifier pump only

Dual heat exchangers regulate heat build-up in the hy-draulic oil. Optimum hydraulic oil temperature is 105°F(40.5°C). Tap water is routed first to a heat exchanger inthe pump case drain line, then to a heat exchanger inthe intensifier return line.

A thermostatically-controlled cooling water flow controlvalve designed for partially open operation is installed inthe line to regulate the water flow for maximum waterconservation.

Water flow must be sufficient to ensure that the hydrau-lic oil reservoir temperature is always maintained below110°F (43°C). Cooling water flow rate is typically 3 gpm(11 lpm) per 50 hp at an inlet water temperature of60°F (15°C).

Waterjet systems perform better with soft water. Waterwith low levels of minerals and acid will maximize heattransfer efficiency and heat exchanger life.



Water interface connections

Flow recommends the installation of manual on/offvalves in the high-pressure, inlet water, and cooling wa-ter lines. Locate valves as close as possible to the pumpinterface connection to make them easier to service.

Coolant water lines must be non-corrosive pipe or rub-ber hose. Rubber hose (per SAE Standard 20R1, 30R1,or equivalent) is recommended.

Cutting water lines (from the filtering system to the in-tensifier pump) must be as short as possible and must bePVC, copper, or equivalent. Do not use galvanized ironpiping—it will introduce minerals to the water, whichwill shorten orifice life.

Intensifier pump utility connections

• Connect inlet water line to FILTERED WATER IN.

• Connect LEAKAGE WATER to the appropriatedrain or bucket (can contain oil).

• Connect BLEED-DOWN WATER to the appropriatedrain.

• Connect cooling water supply line to COOLING

WATER IN.

• Connect COOLING WATER OUT to the factorydrain system.

Note: Purge the inlet water lines of debrisbefore completing the connection to the pump.

HyPlex Hybrid pump utility connections

• Connect inlet water line to inlet water solenoid valve.

• Connect ECV or PCV to the appropriate drain.

CAUTIONTo ensure that the Pac-V does not entrain catcher tank drain wa-ter and damage the Pac-V, connect the Pac-V drain line directlyto an outlet drain, suspend the line above the catcher tank, or

install a check valve in the Pac-V drain line.

• Connect inlet air to pneumatic air regulator.



Drain requirements

Intensifier pump

Cooling water drain

Cooling water leaving the intensifier pump is consideredwaste water. This water can be routed to a waste waterrecovery system, a recirculation system, or a drain—whichever is most applicable for the installation. If thewater is reused for cooling, a commercial water coolingsystem can be used.

If the cooling water outlet is routed directly to a wastewater drain, you must have a minimum drain capacity of5 gpm (19 lpm).

Bleed-down water

The bleed-down valve exhausts water through theBLEED DOWN WATER port on the bulkhead. This canbe connected to the same drain as the catcher overflow,if required.

Intensifier and HyPlex pumps

Leakage drain (oil or water)

The pump has a drip pan to collect oil or water leakagefrom the seals. Leakage is usually negligible; however,the drain line is sized to accommodate the worst case (ifthe bleed-down valve opens) of 10 gpm (38 lpm).

Do not connect the leakage water drain to the coolantwater drain line or any other pressurized drain system.

Catcher tank

Overflow from the catcher tank can be routed to anoptional 3-tier waste water recovery system, arecirculation system, or a drain.

Water from the catcher tank overflow outlet can containvariable amounts of abrasive particulate.

High-pressure tubing


High-pressure tubing certified for continuous operationat 60,000 psi (4138 bar) is used to route high-pressurewater from the intensifier to the attenuator, and from theattenuator to the rear bulkhead fitting. The same type oftubing also connects the intensifier pump to the cuttingequipment.

HyperJet 94i-S or HyperJet 94i-D intensifer pump

High-pressure tubing certified for continuous operationat 94,000 psi (6483 bar) is used to route high-pressurewater from the intensifier to the attenuator, and from theattenuator to the rear bulkhead fitting. The same type oftubing also connects the intensifier pump to the cuttingequipment.

HyPlex Hybrid pump

High-pressure tubing certified for continuous operationat 55,000 (3792 bar) is used to route high-pressure wa-ter from the HyPlex pump to the cutting equipment.

Note: Refer to manual M-127, Small High-pressure Com-ponents or M-393, Hyperpressure Small High-pressureComponents for more information on high-pressure tub-ing, components, and related service.



Startup procedures

Starting the HyperJet 94i-S or HyperJet 94i-Dintensifier pump after installation

Use this procedure after the equipment is first installed,and after an intensifier has been disassembled forservice.

Before starting the equipment:

• Be sure you know how to stop it.

• Read the manuals, get training from an experiencedoperator, and review the safety precautions.

• Follow a written check list that includes an inspectionfor needed or ongoing service, damaged or missingparts, leaks, or anything that could make the equip-ment unsafe to operate.

• Make sure doors and covers are in place.

• Call out "START-UP!"

• Stand in a place that is protected by safety devicesand within reach of an emergency stop switch.

WARNING

Do not operate the pump with uncertified parts.Explosive separation of the parts and serious

bodily injury could occur. Contact Flow or seekprofessional installation assistance.

All operators and service personnel must review the safetyprecautions in Chapter 2 of this manual and in all manuals

provided with this equipment before starting the equipment.

Cutting equipment and nozzles must be installed andworking before operating the pump. Operatingthe pump without proper line restriction will

damage high-pressure components.

Starting the pump

1. Fill the hydraulic pump with hydraulic oil via the up-per case port before starting the unit.

2. Make sure the inlet water filters are correctlyinstalled.

3 Locate the water supply hoses on the intensifier. Re-move tie-wraps and plastic caps.

4. Purge the inlet and cooling water systems of air anddebris:

a. Bypass the solenoid valve, if applicable.

b. Insert a fitting into each quick-disconnect cou-pling and connect to a temporary drain line (usethe fitting threaded into the intensifier end cap).

c. Open the external inlet and cooling water valves.

d. Purge the inlet and cooling water lines for threeminutes, then close the external water valves orpush the E-stop in.

e. Reconnect the intensifier fittings and supplyhoses.

CAUTION

Any debris left in the water supply lines can enter theintensifier and damage the high-pressure components.

Such damage IS NOT covered by your warranty.

Pumps are shipped without hydraulic oil. You must add oilto the reservoir and the hydraulic pump case before operating

the pump or you will SEVERELY damage the system.

5. Close the hydraulic oil reservoir drain valve and fillthe reservoir until oil is visible in the sight gauge. Usean oil that does not contain anti-wear additives. Thereservoir holds about 27 gal (102 L).

6. Loosen the hydraulic pump suction line flange fittingsand crack open the flange until oil leaks out. This en-sures that all air is bled from the suction line. Tightenthe flange fittings.

7. Remove all tools, rags, parts, and debris from aroundthe pump.

8. Open the external cutting and cooling inlet watervalves to the intensifier pump. Check all connectionsfor leaks.

9. Open the high-pressure water valve downstream ofthe intensifier pump and click Low Pressure on theRun Machine screen.

10. Locate the hydraulic pump and motor coupling.Open the cover so you can see the coupling andwatch motor rotation.

11. Click on the pump ON/OFF button to start thepump. Wait for the 5 second booster pump delay,then click the button a second time to stop the pumpas soon as the main electric motor starts. Make surethe motor shaft rotates in the same direction as thearrow on the hydraulic pump.

If the shaft rotates in the opposite direction, first re-verse the electric power phase to any two motorleads to change motor shaft rotation, and then loosenthe hydraulic pump suction line flange fittings andcrack open the flange until oil leaks out. This ensuresall air is bled from the suction line. Retighten theflange fittings. When rotation is correct, replace thecover.

Note: If using a motor starter, contact the motorstarter supplier or FLOW for more information.





HyperJet 94i-S intensifier pump

HyperJet 94i-D intensifier pump

12. Purge trapped air from the hydraulic system be-fore continuously operating the pump. Jog thepump by successively clicking the pump ON/OFFbutton. Wait for the 5 second booster pump delayin between clicks. Wait a few moments after eachjog until an audible change indicates that thepump is filled with oil. If the hydraulic pump failsto pick up pressure after 4 or 5 jogs, make surethe oil reservoir is full.

CAUTIONOperating the pump without oilcan damage the hydraulic pump.

13. Click the pump ON/OFF button to start the pump.The hydraulic pump should idle at low pressure.

WARNINGDo not tighten any loose or leaking connections while

the pump is operating or the line is pressurized.

14. Run the pump at low pressure for 10–15 minutes.Check for leaks.

15. Increase the high-pressure water pressure by click-ing on HIGH PRESSURE. Check continuously forleaks or other problems.

16. Operate the pump an additional 5–10 minuteswhile checking for leaks.

17. While the hydraulic system is warming up, mea-sure the oil temperature in the reservoir using asurface- contact thermocouple or a thermometer.Optimum oil temperature is 105–110°F(40–43°C); adjust the cooling water flow controlvalve on the bulkhead if necessary.

18. Click ON the pump ON/OFF button to stop thepump.

19. Check the oil level in the sight gauge and add oilas needed.

20. Close all water valves.

21. Thoroughly inspect the complete installation forany incomplete or low-quality work. Do not signoff the installation until all problems have been re-solved and all quality-control inspections havebeen completed.

Note: All personnel must carefully read this manualbefore operating or servicing the pump. Flow Techni-cal Service assistance is required when installing thesystem equipment. Refer to manual MS-2266, Cus-tomer Support and the preinstallation manual.

CAUTIONAll operators and service personnel mustreview the safety precautions in Chapter 2

before starting this equipment.

Pressure conversion table87,000 psi (6000 bar) intensifier

Hydraulic pressure Water pressure

PSI Bar PSI Bar

500

1000

1500

2000

2500

2750

34

69

103

138

172

190

15,700

31,400

47,100

62,800

78,500

87,000

1082

2165

3247

4330

5412

6000


16 © Flow International Corporation

Starting the 50i-S or 100i-Dintensifier pump after installation

Use this procedure after the equipment is first installed,and after an intensifier has been disassembled forservice.








WARNING







Start-up steps

1. Fill the hydraulic pump case with oil via the uppercase port before starting the unit.

2. Make sure the inlet water filters are correctlyinstalled.

3 Locate the water supply hoses on the intensifier. Re-move tie-wraps and plastic caps.

4. Purge the inlet and cooling water systems of air anddebris:

a. Bypass the solenoid valve, if applicable.

b. Insert a fitting into each quick-disconnect cou-pling and connect to a temporary drain line (usethe fitting threaded into the intensifier end cap).

c. Open the external inlet and cooling water valves.

d. Purge the inlet and cooling water lines for threeminutes, then close the external water valves orpush the E-stop in.

e. Reconnect the intensifier fittings and supplyhoses.

CAUTION

Any debris left in the water supply lines can enter theintensifier and damage the high-pressure components.

Such damage IS NOT covered by your warranty.

Pumps are shipped without hydraulic oil. You must add oilto the reservoir and the hydraulic pump case before operating

the pump or you will SEVERELY damage the system.

5. Close the hydraulic oil reservoir drain valve and fillthe reservoir until oil is visible in the sight gauge. Usean oil that does not contain anti-wear additives (rec-ommended oils are listed earlier in this chapter). Thereservoir holds about 27 gal (102 L).

6. Loosen the hydraulic pump suction line flange fittingsand crack open the flange until oil leaks out. This en-sures that all air is bled from the suction line. Tightenthe flange fittings.

7. Remove all tools, rags, parts, and debris from aroundthe pump.

8. Open the external cutting and cooling inlet watervalves to the intensifier pump. Check all connectionsfor leaks.

9. Open the high-pressure water valve downstream ofthe intensifier pump and click Low Pressure on theRun Machine screen.

10. Locate the hydraulic pump and motor coupling.Open the cover so you can see the coupling andwatch motor rotation.

11. Click on the pump ON/OFF button to start thepump. Wait for the 5 second booster pump delay,then click the button a second time to stop the pumpas soon as the main electric motor starts. Make surethe motor shaft rotates in the same direction as thearrow on the hydraulic pump.

If the shaft rotates in the opposite direction, first re-verse the electric power phase to any two motorleads to change motor shaft rotation, and then loosenthe hydraulic pump suction line flange fittings andcrack open the flange until oil leaks out. This ensuresall air is bled from the suction line. Retighten theflange fittings. When rotation is correct, replace thecover.

Note: If using a motor starter, contact the motorstarter supplier or FLOW for more information.





50i-S intensifier pump

100i-D intensifier pump

12. Purge trapped air from the hydraulic system beforecontinuously operating the pump. Jog the pump bysuccessively clicking the pump ON/OFF button. Waitfor the 5 second booster pump delay in betweenclicks. Wait a few moments after each jog until an au-dible change indicates that the pump is filled with oil.If the hydraulic pump fails to pick up pressure after 4or 5 jogs, make sure the oil reservoir is full.

CAUTIONOperating the pump without oilcan damage the hydraulic pump.

13. Click the pump ON/OFF button to start the pump.The hydraulic pump should idle at low pressure.

WARNINGDo not tighten any loose or leaking connections while

the pump is operating or the line is pressurized.

14. Run the pump at low pressure for 10–15 minutes.Check for leaks.

15. Increase the high-pressure water pressure by clickingon HIGH PRESSURE. Check continuously for leaks orother problems.

16. Operate the pump an additional 5–10 minutes whilechecking for leaks.

17. While the hydraulic system is warming up, measurethe oil temperature in the reservoir using a surface-contact thermocouple or a thermometer. Optimumoil temperature is 105–110°F (40–43°C); adjust thecooling water flow control valve on the bulkhead ifnecessary.

18. Click ON the pump ON/OFF button to stop thepump.

19. Check the oil level in the sight gauge and add oil asneeded.

20. Close all water valves.

21. Thoroughly inspect the complete installation for anyincomplete or low-quality work. Do not sign off theinstallation until all problems have been resolved andall quality-control inspections have been completed.

Note: All personnel must carefully read this manual be-fore operating or servicing the pump. Flow TechnicalService assistance is required when installing the systemequipment. Refer to manual MS-2266, Customer Sup-port and the preinstallation manual.

CAUTIONAll operators and service personnel mustreview the safety precautions in Chapter 2

before starting this equipment.

Pressure conversion table60,000 psi (4138 bar) intensifier

Hydraulic pressure Water pressure

PSI Bar PSI Bar

500

1000

1500

2000

2500

2750

3000

34

69

103

138

172

190

207

10,000

20,000

30,000

40,000

50,000

55,000

60,000

690

1379

2069

2759

3448

3793

4138



Starting the HyPlex Hybrid pumpafter installation

Use this procedure after the equipment is first installed,and after the pump has been disassembled for service.








WARNING







Starting the system

1. Flush debris from all water supply hoses before con-necting them to the pump.

CAUTIONDebris in the water supply line can cause extensive

damage to the high-pressure components. Suchdamage IS NOT covered by warranty.

2. Fill the pump case with one of the recommendedoils. The pump capacity is 2.5 qt (2.4 L). Fill the res-ervoir until the oil is visible on the dipstick.

CAUTIONNever operate the pump without oil—this can cause

extensive damage and is not covered by warranty.

3. Make sure water lines, air lines, and drain lines arecorrectly connected and routed.



HyPlex Hybrid pump

4. Clear all tools, parts, and rags from around the pump.Check all areas in and around the pump for foreignobjects and debris.

CAUTIONThe inlet water valve must be open before operating

the pump. Operating the pump with the inletwater valve closed will cause damage.

5. Open the inlet water valve; check all connections forleaks.

CAUTIONCutting equipment and nozzles must be installed andoperational before operating the pump. Operating the

pump without proper line restriction can cause damage.

6. Place the main electrical disconnect in the ONposition.

7. Release the E-stop button.

8. Activate the FlowCUT program and open a part pro-gram. Select Run Machine. The screen will displaythe pump on/off control. Verify that the low pressureicon is checked. Turn the pump on by clicking on thepump ON/OFF button.

CAUTIONDo not try to tighten any loose or leaking connections while

the pump is operating or while the line is pressurized.

9. If one of the maintenance kits has just been installed,click on Setup | Service record in the menu bar onthe Run machine screen. You must enter pump hoursand kit installation information or the pump will notrun.

10. Run the Temperature Input Offset Adjustmentroutine.

11. The scaling factor (0.13 for 30 & 50 hp pumps) needsto be adjusted if pump pressure calibration is re-quired. See Calibrating the pump control system inmanual M-397.

12. Open the manual relief valve on filters.

13. Turn the pump on by clicking on the pump ON/OFFbutton. When the pump reaches 55,000 psi(3792 bar), operate the pump at this pressure for5-10 minutes while checking for leaks. Correct asrequired.

14. Click on the low-pressure icon. Check all connectionsfor leaks.

15. Click on the high-pressure icon.

16. Turn the pump off, exit FlowCUT, and press theE-stop button.



System operation

The ultrahigh-pressure pump is operated from theFlowMaster PC controller. See the FlowCUT User'sGuide for more detailed information on running the ma-chine. A pump operation button on the FlowCUT RUNMACHINE screen is used for starting and stopping thepump. Select HIGH PRESSURE or LOW PRESSURE forthe dual-pressure feature.

Fault indicators

The safety light that is integrated into the buttons of thePC monitor enclosure alerts the operator of machinefaults. The light will flash during a Warning condition,and remain steady for a Shutdown condition. The oper-ator can determine the specific fault condition by view-ing messages on the FlowCUT screen.

Machine startup

To start the machine from a cold start (no power), makesure that main air and main water supplies are turnedon to the machine, then follow these steps:

1. Turn on main power disconnect located on the farright side of the electrical enclosure. If there is an ad-ditional disconnect on the wall that feeds power tothe machine, make sure this is turned on as well.

2. Turn on power to the machine PC.

3. Let the PC boot up to the basic Windows startscreen, where the FlowMaster icons are located.

4. Disengage all E-Stop switches.

5. Push the E-Stop reset button. The button will light up.

6. Push the CONTROL ON (OT Bypass) button. Thebutton will light up.

7. Start FlowCUT by double-clicking the FlowCUT icon.

8. At this point, you can load a part file (ORD file) andset the proper Jet Setup and material/thickness prop-erties, but this is not necessary.

9. Click on the Run Machine icon. The screen shouldchange to show the machine controls (Water, Abra-sive, Pump, and so on).

10. Home the Z-axis. Click on the Home Z,A,B-axis icon.

11. Home the X,Y-axes. Click on the Home X,Y-axesicon, then choose Go to Machine Home from theselection list. The machine should then move to thefront left corner of the work envelope and is ready torun at that point.

Machine shutdown

The machine should be shut down if it will not be runfor an extended period of time (e.g., overnight). To shutdown the machine normally, follow these steps:

1. Jog the machine manually so that the X and Y axesare near the HOME position (X0, Y0). This is not anecessary step, but it will make it more convenient toHOME the machine next time you start up the ma-chine.

Manually jog the Z-axis to its highest position off ofthe cutting surface.

2. Exit FlowCUT and shut down Windows.

3. Push the CONTROL ON button on the right side ofthe display monitor enclosure.

4. Engage the E-stop button on the right side of the dis-play monitor enclosure.

5. Turn off the power:

• If you need to leave the Main Power Disconnectswitch on in order to continue to supply powerto peripheral equipment (such as the AbrasiveRecycler), turn off power to the PC using theswitch on the front of the PC.

• Otherwise, turn off power to the machine usingthe Main Power Disconnect switch.



Running the pump

HyperJet 50 or HyperJet 100 intensifier pump

When the machine is in position to start a cut, click onthe ON pump button. The intensifier pump will not startimmediately; the water booster pump turns on first tocharge the system. After approximately 5 seconds, theintensifier pump will start and ramp up pressure. Thepump uses an electronic proportional control valve toautomatically ramp up high-pressure water. The digitalhigh-pressure gauge on the FlowCUT screen indicatesthe level of water pressure in the system. When the sys-tem reaches the desired operating pressure, you can be-gin cutting.

Click the OFF pump button to turn off the pump. Allsystem pressure is bled to 0 psi within one second ofshutting down the pump.


When the machine is in position to start a cut, click onthe ON pump button. The intensifier pump will not startimmediately; first the booster pump turns on to chargethe system. After approximately 5 seconds, the pumpstarts and begins ramping up to pressure. The pump usesan electronic proportional control valve to automaticallyramp up hydraulic pressure. The digital high-pressure gauge on the FlowCUT screen indicates theamount of water pressure in the system. When the sys-tem reaches the desired operating pressure (60,000 psi/4138 bar) you can begin cutting.

Click on the OFF pump button to turn off the pump. Allsystem pressure is bled to 0 psi within one second ofshutting down the pump.

HyPlex pump

When the machine is in position to start a cut, click onthe ON pump button. The HyPlex pump will not startimmediately; first the WATER ON solenoid energizes. Af-ter approximately 5 seconds, the HyPlex pump startsand begins ramping up pressure. The pump uses anelectronic proportional control valve to automaticallyramp up high-pressure water. The digital high-pressuregauge on the FlowCUT screen indicates the amount ofwater pressure in the system. When the system reachesthe desired operating pressure (55,000 psi/3792 bar) youcan begin cutting.

Click on the OFF pump button to turn off the pump. Allsystem pressure is bled to 0 psi within one second ofshutting down the pump.

Using dual pressure

Brittle materials, such as glass, stone, or composites,should be pierced at a lower operating pressure (such as20,000 psi/1379 bar). To select high or low pressure,highlight either the HIGH PRESSURE or LOW PRESSUREbox to the right of the PUMP on/off button.

• The default setting is HIGH PRESSURE, which is nor-mally set for an operating pressure of 60,000 psi(4138 bar) for an intensifier pump, and 87,000 psi(6000 bar) for a HyperJet pump.

• Selecting LOW PRESSURE will lower the pressure,normally 12,000–20,000 psi (828–1379 bar).

Use the LOW PRESSURE setting in conjunction with theFlowMaster PIERCE ALL HOLES FIRST function to pierceholes in a given program at low pressure before cutting.

Changing low-pressure or high-pressuresetting (intensifier pump)

Use the Jet Setup screen to enter a different low- orhigh-pressure setting.

Warning and shutdown sensors

The ultrahigh-pressure pump is equipped with severalshutdown and warning sensors.


Refer to manual M-349, 50i-S Pump or M-351, 100i-DPump.

• Shutdown sensors for low hydraulic oil level, high hy-draulic oil temperature, and low inlet water pressure.

• Warning sensors for high pump bleed-down tempera-ture, high check valve temperature, low inlet waterpressure, and high hydraulic oil temperature.

HyPlex Hybrid pump

Refer to manual M-354, HyPlex Hybrid Pump.

• Shutdown sensors for low inlet water pressure andhigh-pressure cylinder over-temperature.

• Warning sensors for high-pressure cylinder over-tem-perature and inlet water temperature.

Calibrating the pump to a gauge

Parameters for setting the low- and high-pressuresetpoints are located in one of the initialization files(acscard.ini) in the FlowMaster software. Refer to themanuals that came with the software for information onusing the Jet Setup screen.



Control panel

Control On (OT Bypass)

This illuminated pushbutton turns on control power tothe machine. Power is switched on to the servo motoramplifiers as well as the 24 VDC I/O controls. Theswitch also serves as a machine overtravel bypass. If theX or Y axis of the machine is jogged or run into theovertravel limits, this switch must be held in while themachine of jogged off the limit switch. The E-stop switchmust be disengaged and the E-stop reset switch must bepushed before control power can be turned on. Thepushbutton is illuminated when control power is on.

Z-axis raise/lower

Controls the position of the z-axis manually. Moves thecutting head assembly up or down depending on posi-tion of the switch.

E-stop reset

Resets an E-Stop. This illuminated pushbutton is lit whenthe machine is NOT in an E-stop state. This switch mustbe used to reset the machine control after an E-stopcondition.

Emergency stop (E-Stop)

Stops the machine in an emergency situation. All controlpower is killed, motion is stopped, and the UHP pumpis turned off. If the machine is ready to be shut down formaintenance or as part of the daily routine, this buttoncan be used to turn control power off before shuttingdown the PC.



CHAPTER 2

Safety

The comprehensive list of safety precautions in thischapter (and in the rest of the manual) must be followedto ensure safe operation of the equipment. The equip-ment must only be used, serviced, and repaired by per-sons who are familiar with the operating instructions andthe service procedures provided in this and other FLOWmanuals.

These precautions must be read and understood byeveryone operating and maintaining the equipment—before they start working with the equipment.

In addition to adhering to the safety rules in this manual,all applicable local safety agency rules (including OSHA,state, and national) must be adhered to.

Applicable plant general safety precautions must also befollowed.

The user shall practice and promote safetyat all times to avoid potential injuries and

unnecessary production shutdowns.

Safety precautions

FLOW designed your high-pressure waterjet cutting sys-tem and related equipment with safety in mind.Throughout the manual, safety precautions and warningsfor specific operations are highlighted. Safety precautionsare also posted on the equipment. The operator and ser-vice personnel shall pay particular attention to these pre-cautions at all times.

Operators of a high-pressure waterjet cutting systemmust treat the system as they would treat any high-speed cutting tool. Although the waterjet may appearharmless, it is a high-energy cutting tool capable of cut-ting many nonmetallic materials such as composites,plastics, and wood products. Misuse of this equipmentor carelessness in its application can be extremely haz-ardous to operating personnel. Always treat the waterjetcutting system with respect.

The label shown isavailable in two sizes:

• Part # 006317-13.75 x 6 in.(95 x 152 mm)

• Part #009837-11.8 x 3 in.(46 x 76 mm)

Warnings, cautions, and notes

Service procedures in the waterjet manuals includesafety warnings, cautions, and notes that must be read,understood, and adhered to. These are specific catego-ries of safety notices, and are defined as follows:

WARNINGHighlights an operating condition orservice procedure that can result in

death or serious injury.

CAUTIONHighlights an operating condition or serviceprocedure that can lead to impaired system

operation or equipment damage.

Note: Highlights an operating or service procedure orcondition that is considered essential for efficient opera-tion and service.


Safety tips

• Do not let the waterjet stream touch any part of yourbody.

• Do not point the waterjet at anyone.

• Take the system out of service during maintenance.The controls shall be locked and marked with a warn-ing sign.

• All personnel working on or around the equipmentshall pay particular attention to all warning signs andnotices posted in the plant and on the equipment.

• Protective guards, shields, and covers must be inplace on the equipment at all times.

• First aid facilities shall be provided in convenient lo-cations throughout the plant. These locations must beknown by all personnel.

• The work area around the equipment shall be cleanand free of debris. Oil spillage results in slipperyfloors and must be removed immediately.

• Any conditions that could result in injury must be re-ported to the plant supervisor without delay.

• Safety shoes, glasses, and hearing protection must beworn by all personnel working around the equip-ment. Do not wear dangling jewelry (such as rings,watches, or necklaces) when working around anyequipment that has moving parts.

Mechanical system

• Don't start the system unless you know how to stop it.

• Never maintain, service, or clean around the equip-ment while it is operating.

• Using the wrong tools can result in injury or costlydamage to the equipment.

• Never climb on or around the equipment on make-shift devices. Use only approved catwalks, ladders, orplatforms.

• Do not exceed specified pressure settings for pneu-matic or hydraulic components. Exceeding theselimits can cause serious injury to personnel or equip-ment damage.

• Shield and bundle equipment hoses and cables sothey do not obstruct the operator's freedom ofmovement.

• Be alert at all times when working around theequipment.

• Clear all tools, parts, and rags from any moving partsafter servicing the equipment.

Electrical system

• Only properly trained personnel shall perform electri-cal or electronic troubleshooting and servicing.

• Always assume that power is ON in all electrical sys-tems. Always check and lock out the main powerswitches before servicing the equipment. Post a sign,"Maintenance in Progress—Do Not Energize.

• Live electrical circuits are present in the control con-sole whenever the master disconnect is on, regardlessof whether the EMERGENCY STOP is engaged.

• Disconnect circuit breakers and lock them in the OFFposition before servicing the electrical system. If thisisn't possible, have someone stand by to prevent any-one from powering up the system.

• Be especially careful when servicing the power sys-tem in a damp environment.

• Never alter or bypass protective interlocks or devicesunless specifically instructed to do so, and only if allprecautions are followed.

• Give capacitors enough time to discharge. If this isn'tpossible, carefully discharge them manually.

• Do not use jumper wires across fuses or fuse holders.

• Make sure all tools are well insulated.

• Use only proper test apparatus; check it regularly tomake sure it works properly.

• Use caution when connecting a test probe to testpoints.

• All replacement wires shall conform to the manufac-turer's specifications, including color coding, wirenumbers, and size.

• Close the control panel doors or junction box coversafter servicing.

Waterjet cutting system

• High-pressure water can remain in the system for anextended time after shutting down the high-pressurewater source. System pressure can be relieved byopening any valve downstream of the outlet valve.

• Always bleed down the system pressure beforeservicing any part of the system.

• Do not touch weep holes with your bare hands or tryto stop water by plugging the holes.

• The waterjet stream is a knife. Do not put anything inits path that you do not intend to cut.

• Wear a face shield whenever required by the operat-ing instructions.

• Do not remove protective shields from high-pressuretubing. If shields are removed for servicing, they mustbe replaced before starting the system.



• Torque all fittings to the manufacturer's specifications.

• Stepping or leaning on high-pressure water tubingcan break connections and cause leaks.

• High-pressure fittings, valves, and tubing must be cer-tified for 60,000 psi (4138 bar) for 60K systems and87,000 psi (6000 bar) for Hyperjet systems. Do notsubstitute when making alterations or additions to thehigh- pressure water system.

• Do not alter or eliminate stress relief tubing coils.

• Follow the tubing manufacturer's recommendationsfor high-pressure tube bending radii.

• Do not exceed specified operating pressures forhigh-pressure components.

• Do not over-torque fittings or over- bend swivels.

• Follow the manufacturer's recommendations for ser-vicing the equipment, and use only original manufac-turer replacement parts.

• Follow the manufacturer's system startup procedureto ensure safe operation.

• Use care when lifting equipment covers duringoperation.

High-pressure waterjet cleaning tools

• Turn off equipment and relieve water pressure beforereplacing nozzles, tips, or bits.

• Hang a sign on the power supply control panel warn-ing that the equipment is being serviced and is notavailable for use until servicing is complete.

• Replace all protective covers and shielding on equip-ment before operation.

• Check for leakage after nozzle or tip replacementand correct immediately.

• Use only FLOW manufactured or approved waterjetnozzles, cleaning tips, and drilling or cutting bits.

Protective clothing

Workers operating hand-held, high-pressure waterjet cut-ting or cleaning equipment and those working nearbyshould wear protective clothing and safety devices as de-scribed in this section. FLOW recommends that work-site safety personnel approve all safety equipment andclothing for everyone working around waterjet cuttingequipment.

Eye protection

• At a minimum, operators mustwear safety glasses with sideshields and a visor, or goggles anda visor, to guard against spray andflying debris.

• All eye protection shall meet ap-propriate ANSI requirements forthat type of eye protection.

• Some states and countries havetheir own eye protection rules thatmust be followed.

Head protection

• Helmets must be worn at all timesby all personnel within the workarea. Helmet material must with-stand mechanical shock to 10 G in8 ms without fracturing.

Hand protection

• Operator must wear gloves at alltimes. Leather gloves arepreferred.

Hearing protection

• Operators and other personnel ex-posed to noise levels of more than90 dBa for more than 1 hour mustwear suitable ear protection. Earplugs and muffs are usually ade-quate.

Foot protection

• Operators and other personnelmust wear safety footwear withsteel toe-caps a minimum of0.02-in. (5 mm) thick. The toe capmust cover at least 30% of thefootwear length.

• The operator’s footwear must beequipped with metatarsal guardsto provide instep protection.

Body protection

• Waterproof garments only protect the operator fromspray and flying debris. They do NOT deflect directjet impact.


CHAPTER 2Safety

Emergency medical information

WARNINGNEVER point a waterjet cutting or cleaning tool at

yourself or at any person. Do not aim a waterjet toolat anything you do not intend to cut.

Anyone who incurs equipment-related injuries while op-erating high-pressure water equipment should be givenimmediate hospital attention. It is vital that medical per-sonnel have information about this type of injury. There-fore, all waterjet operating personnel should carry awaterproof emergency medical tag or card that describestheir work and the nature of injuries inherent in usingwaterjet cutting devices. The tag or card should containthe information in the sample below.

The card illustrated below can be purchased from FLOW(P/N A-8466). It is also available in French, German, Ital-ian, and Spanish. Simply order part number A-8466F, G,I, P, or S.



MEDICAL ALERT

This card is to be carried by personnel workingwith high-pressure waterjet equipment. Obtain

medical treatment immediately for ANYhigh-pressure waterjet injuries.

FLOW INTERNATIONAL CORPORATION23500 64th Avenue SouthKent, Washington 98032 USA(253) 850-3500

This person has been working with water jetting at pressures to92,000 psi (634 MPa, 6345 bar) with a jet velocity of 3900 fps(1190 mps). This should be taken into account during diagnosis.Unusual infections with microaerophilic organisms occurring atlower temperatures have been reported. These may begram-negative pathogens, such as those found in sewage. Bac-terial swabs and blood cultures may therefore be helpful. A lo-cal poison control center should be contacted for additionaltreatment information.

CHAPTER 3

60K End Effectors

Two 60K end effectors are available for the Mach 3band Mach 4b Series System: Standard and Dynamic.

Both end effectors use the PASER ECL Plus cutting head.

Standard end effector

The standard end effector uses a cutting head that ismounted perpendicular to the cutting envelope.

The standard end effector has four main components:

• Z-axis

• High-precision cutting head

• On/off valve

• Height sensor

Dynamic Waterjet� end effector

The Dynamic Waterjet (DWJ) is a wrist tilting endeffector designed for flat-stock machines. Its revolution-ary design provides a better way to correct two commondrawbacks to abrasivejet cutting—taper and inside cor-ner kickback.

Tilting the head removes the taper from one side of thecut, leaving a vertical cut on the side of the part. Tiltingthe jet tip into the direction of travel reduces drag, socutting speeds on inside corners can often be increasedwithout damaging the underside of the part.

The DWJ end effector has five main components:

• Z-axis

• Mini-wrist


• Mini on/off valve

• Height sensor

These are illustrated and described in this chapter.

Tips and guidance on using the DWJ effectively can befound in manual MS-2276, How To Be Successful WithDynamic Waterjet.


Z-axis

Work envelope

Tilting a cutting head influences the overall travel of anX,Y system. A tilting head with the DWJ kinematics usesX,Y,Z-axes travel to compensate for variation in the toolcenter point. Depending on tool length, the maximumtravel of the X- and Y-axes is decreased by about4 in. (50 mm).

The available travel of the Z-axis is influenced by tiltingthe cutting head and by mixing tube length. It is impor-tant when using the DWJ to consider what mixing tubewill be used. With DWJ on the system, the minimumtool length must be able to reach the catcher tank gridwhen the head is tilted to the maximum A- and B-axisangles.

The FlowMaster screen automatically shows the availablecutting envelope.

Maintenance

• The components used in the Z-axis are protectedfrom everyday machine operation, and should pro-vide years of reliable operation without servicing.There are no serviceable parts inside the Z-axis andthe unit must never be opened except by Flowtechnicians.

• In case of a collision with any foreign object, pleaseconsult Flow Technical Service for information onrealignment.



DWJ wrist assembly

The DWJ wrist assembly is powered by two servo-drivenactuators, which allow two more axes of movement (Aand B). The wrist assembly has a unique cutting headclamp that allows the operator to easily service the cut-ting head.

Specifications

Width . . . . . . . . . . . . . . . . . . . . . . . . . . . 321 mm

B-motor rotation . . . . . . . . . . . . . . . . . . . . . . . 10°

A-motor rotation . . . . . . . . . . . . . . . . . . . . . . . 10°

Maintenance

• The components used in the wrist are protected fromeveryday machine operation, and should provideyears of reliable operation without service. There areno serviceable parts inside the wrist assembly and theunit MUST NOT be opened except by Flow techni-cians.

• Check the A and B motors for smooth rotation. Thereshould be no rough spots or excessive friction. Checkby holding onto the cutting head and rotating in alldirections.



CHAPTER 360K End Effectors

Wrist assembly exploded view



Mini on/off valve

The mini on/off valve, designed specifically for the DWJ,is a pneumatically actuated valve that opens and closesthe high-pressure water line, thus controlling water flowto the cutting head and nozzle.

The mini-valve has three distinct features:

• Its small size allows it to mount directly above thecutting head and tilt with the cutting head.

• The low-mass actuator (0.5 lb) allows full accelerationand tilting of the cutting head.

• The design of the valve-to-nozzle body connectionallows the valve to be oriented by the operator in anyradial direction to mate easily to high-pressure tubingand other rigid components.

Specifications

Operatingwater pressure. . . . . . . . 0–60,000 psi (0–4138 bar)

Water connection . . . . . . . . UHP ¼ in. tubing port

Valve weight . . . . . . . . . . . . . . . . . 1.5 lb (0.68 kg)

Recommendedwater flow rate. . . . . . . . . 0–2 gpm (7.5 liter/min)

Shop air (dry or lubed) . . 60–100 psig (4.1–6.9 bar)

Air connection . . . . . . . . . . . . . . . . . 6 mm air line

Configuration . . . . . . . normally closed, air to open

Response time*Opening . . . . . . . . . . . . . . . . . . . . . . . 0.045 secClosing . . . . . . . . . . . . . . . . . . . . . . . . 0.100 sec

* Note that response time will vary depending on(1) length of the air line from the solenoid to the actua-tor, and (2) air pressure.

Maintenance

Recommended spares

To minimize maintenance downtime, at least one repairkit for each on/off valve should be on hand.

711484-1 On/off valve repair kit

A-2185 Blue Lubricant

A-4689 Food grade o-ring lube (white)

Tips for increasing the life ofon/off valve parts

• The on/off valve is sensitive to debris in the high-pressure water line that can damage the high-pressure seal assembly. To increase life of the seal as-sembly (As well as high-pressure orifice life), Flowrecommends adding a 5-micron high-pressure in-linewater filter assembly (012832-2) to your system.

• After replacing high-pressure plumbing or otherequipment on your high-pressure pump, flush thesystem directly into the catcher tank before runningthe high-pressure water through the on/off valve andorifice. This will help minimize debris in the high-pressure lines that could damage the valve or orifice.

• Always follow the service procedures in this manualwhen repairing the on/off valve to ensure proper as-sembly and installation of the valve.



Troubleshooting the valve

There are two main categories of failure of the minion/off valve: leaking water and improper openingand closing of the valve. Use the correspondingchart to troubleshoot the problem.

When inspecting the mini on/off valve, pay atten-tion to the utility connections and air lines—thehigh-pressure water supply could be partiallyblocked, or there could be bends, holes, or looseconnections in the air lines.

If causes other than those listed in the table arefound, please forward the information to the ser-vice department at FLOW (refer to MS-2266, Cus-tomer Service for contact information).

Importance of replacing all seal kitcomponents

Sometimes after troubleshooting, it may appear thatonly one or two parts included in the seal kit needto be replaced. However, you must replace all ofthe seal kit parts at the same time for severalreasons:

• All the components of the seal kit have similarexpected life times, so if one component fails,the others are likely to fail very soon.

• Failure of one component can cause extra stresson the other components, increasing the likeli-hood that they will fail.

• Installing the entire seal kit at one time will saveyou from having to tear down the valve multipletimes, thus reducing total machine downtime.



Troubleshooting: valve is leaking

Continuous leakage from the barb fitting

• SEE LOCATION 1 ON THE ILLUSTRATION ON THE PREVIOUS PAGE

Failed high-pressureseal

Remove and replace the high-pressure seal assembly using kit 711484-1; see Servicing themini on/off valve.

Note: If this is a new valve, return the failed high-pressure seal assembly to FLOW techni-cal service for evaluation.

A few drops leak from barb fitting at start up or when valve is cycled rapidly

• SEE LOCATION 1 ON THE ILLUSTRATION

Worn high-pressureseal

The high-pressure seal is beginning to wear out. It will start by leaking one drop every fewcycles, gradually increasing in frequency and volume of drops. The valve will continue tofunction in this state for many thousands of cycles, until the drops form a steady stream.

The high-pressure seal assembly can be replaced at the operator's discretion until the leakbecomes a steady stream (see above). At that point it MUST be replaced.

Continuous leakage from the high-pressure water inlet


Poorly aligned con-nection betweenhigh-pressuretubing and valve

Open the high-pressure tubing connection. Make sure the tubing is aligned properly withthe port in the valve. Inspect the collet gland—a minimum of three threads must be show-ing. Reassemble.

Loose connectionbetween high-pressure tubing andvalve

Tighten high-pressure fitting between valve and tubing.

Failed high-pressurevalve body

Failure of the valve body is not common, so check the high-pressure seal assembly first. Ifthe valve still leaks continuously after replacing the high-pressure seal assembly, there maybe a problem with the valve body.

Remove the valve from the machine (see Servicing the mini on/off valve). Inspect the areaof the valve body near the high-pressure water inlet for a crack or damage to the inletcone. If there is a crack, order a replacement valve body (710866-1) and seal kit(711484-1). If this is a new valve, return the failed valve to FLOW Technical Service forevaluation.

Leakage from weep hole below high-pressure water inlet while valve is open


Poor connection be-tween the nozzlebody and valvebody

1. Open the connection of the nozzle body to the valve body.

2. Inspect the location of the water body collar (710869-1) on the nozzle body. There shouldbe at least three to four threads exposed to ensure a proper seal from the nozzle body tothe valve seat.

3. If the large o-ring has extruded through the weep hole, remove and replace it(A-0275-014).

4. Attach the pneumatic control line to the valve actuator assembly and turn on the air toopen the valve.

5. Re-assemble the nozzle body to the valve body. This high-pressure connection requiresabout 70–80 ft-lb (95–110 N-m) of torque.



Leakage from nozzle tip while valve is closed and high-pressure pump is on


Debris in theseat/poppet orhigh-pressure sealarea

Remove and inspect the seat and poppet interface for debris such as metal shavings (seeServicing the mini on/off valve). Remove any debris and re-assemble the valve.

If leakage persists, inspect the high-pressure seal for damage from debris. If there is damageor continued leaking, replace the high-pressure seal kit (see Servicing the mini on/off valve).

Failed poppet/seat Remove and inspect the seat (see Servicing the mini on/off valve). If there is erosion on theedge of the seat bore or if there are radial cracks, replace the seal assembly.

Note that it is common to see a ring on the seat where the seat seals against the valve body(picture). Unless there is evidence of severe galling, which can result from not using bluelubricant (A-2185), this ring is normal and not a cause of valve failure.

Inspect the poppet tip for wear. If the poppet is worn, follow the service instructions to re-pair the valve and replace the high-pressure seal assembly.



Troubleshooting: Valve does not open

Low or no airpressure

1. Make sure the shop air supply is on, properly connected, and the pressure at the actuator is70-120 psig (4.8-8.3 bar).

2. Turn on the air and listen for leaks in the system. Check for kinks, breaks, and holes in theair line.

3. Check the lights on the solenoid box (on the bridge) to make sure the solenoid is switchingon and off when commanded.

Lack of high-pressure water

Make sure the pump is running. Check to see that all the hand valves leading to the on/offvalve are open.

Partially blockedhigh-pressure water

1. Turn off the pump and close the hand valve.

2. Disconnect the high-pressure water line from the valve, aim it into the tank, and secure it.

3. Open the hand valve and turn the high-pressure pump back on.

Watch to make sure there is a steady stream of high-pressure water shooting into the tank.If the stream is erratic, there may be a blockage in the lines.

4. Check all high-pressure in-line water filters in the system. If necessary, replace with the ap-propriate new filter element. (See manual M-127, Small High-Pressure Components.

Failed actuator Watch the top of the actuator while manually switching the air on and off with thehigh-pressure water on. If the air port on top of the actuator does not move up and down,there is a problem with the actuator.

Remove the mini-actuator from the air line, valve, and machine. Order a new actuator as-sembly (710875-1) and return the assembly to Flow Technical Service for evaluation.

FLOW TECHNICAL SERVICE ONLY:

Dissassemble the actuator. Make sure the u-cup seals are installed in the correct orientationand are free from kinks or folds. Remove and replace the actuator seals as required. Cleanall parts. If the internal springs are rusted, replace them. Lube internal parts and reassemblethe actuator. If it still is not working, replace it. Check the customer's air line to make sure itis providing dry, lubed air.

Damaged high-pressure valve seal

If the air port on top of the actuator moves up and down, but the valve still does not open(and you have already checked for little or no air pressure), there may be a problem withthe valve seal.

If the on/off valve has been operated while the barb fitting has been continuously leaking,the high-pressure seals may be melted and stuck in the valve body.

Replace the seal assembly (see Servicing the mini on/off valve).

Controllercommand

Make sure the controller is signaling the valve to open.



Troubleshooting: Valve does not close

Valve is leakingwater

Determine where the valve is leaking. Follow the tips in the first troubleshooting table,Valve is leaking, to diagnose the problem.

Air is not turning off Try manually switching the air on and off or disconnecting the air line to see if the valvewill close. There may be a problem with your software program or controller command toturn the air off.

Damaged high-pressure valve seal

If the air port on top of the actuator moves up and down, but the valve still does not open(and you have already checked for little or no air pressure), there may be a problem withthe valve seal.

If the on/off valve has been operated while the barb fitting has been continuously leaking,the high-pressure seals may be melted and stuck in the valve body.

Replace the seal assembly (see Servicing the mini on/off valve).

Actuator is not closing Remove the valve assembly from the machine and remove the actuator from the valve (seeServicing the mini on/off valve). Check the operation of the actuator without the valve orhigh-pressure water.

• The piston should move up and down, but slower than when used with high-pressure water

• If the piston does not move, there is a problem with the actuator

Return the actuator assembly to Flow for evaluation and order a new actuator assembly(710875-1).

FLOW TECHNICAL SERVICE ONLY:

Dissassemble the actuator. Make sure the U-cup seals are installed in the correct orienta-tion and are free from kinks or folds. Remove and replace the actuator seals as required.Clean all parts. If the internal springs are rusted, replace them. Lube internal parts and re-assemble the actuator. If it still is not working, replace it. Check the customer's air line tomake sure it is providing dry, lubed air.



Servicing the valve

You will need these tools and parts for any of the minion/off valve service procedures:

• 711484-1 Mini on/off valve repair kit

• A-2185 Blue Lubricant

• A-4689 Food grade o-ring lube (white)

• Set of crescent wrenches (standard size)

• Soft-jaw vise

• Work bench

Removing the valve

WARNINGShut down the system and bleed all high-pressurefrom the system. Turn off the high-pressure water

and high-pressure water pump. Close the hand valvebetween the pump and the cutting head.

1. Turn off air to the valve and disconnect the pneu-matic line.

2. Disconnect the high-pressure plumbing from thevalve body.

3. Open the DWJ clamp and remove the entire cuttinghead assembly, including the valve and actuator. Takethe assembly to a clean workbench for any repairprocedures.



Repairing the valve

4. Apply shop air (80 psi min) to the valve actuator as-sembly to open the valve.

5. Place the assembly in the soft-jaw vise; unscrew thevalve body nut from the valve body. This will separatethe mini valve and actuator from the cutting headand expose the poppet seat. Once the connection iscompletely loose, turn off the air to close the valve.

6. An o-ring helps hold the poppet seat in place. Re-move the o-ring and the poppet seat should fall outfrom the valve body. Discard the seat and o-ring.

Note: If the seat does not fall out when you tap thenozzle body, use your finger or the wooden dowel tohelp loosen the seat.

7. Unscrew the valve body from the actuator assembly.Set the actuator assembly aside.

8. Place the 316-in. wooden dowel (from the valve repair

kit) against the poppet tip and push it out from thevalve body.

The bearing, high-pressure seal, and backup ringshould come out with the poppet. If not, push thebearing, seal, and backup ring out of the valve bodyin the same direction as you pushed the poppet. Dis-card the poppet, seal, o-ring, and backup ring.

9. Clean any foreign material from the inside and out-side of the valve body.

10. Apply a thin film of white food grade o-ring lube(A-4689) to the new poppet, o-rings, seal, bearing,and backup ring (from kit 711484-1)

11. Put together the new seal assembly.

a. Slide the bearing ontothe poppet.

b. Place the small high-pressure o-ring on thehigh-pressure seal.

c. Push the seal onto thepoppet with the o-ringtoward the point of thepoppet.

d. Slide the backup ringinto place against thehigh-pressure seal.

The seal assembly should be approximatelycentered on the poppet.



12. Slide the poppet seal assembly into the actuator endof the high-pressure valve body, pointed end first.

13. Apply a small amount of Blue Lubricant (A-2185) tothe threads of the actuator. Reinstall the actuator as-sembly to the valve body.

14. Apply a small amount of Blue Lubricant to both sidesof the new poppet seat. Install the poppet seat intothe valve body. Push the o-ring into the groove tohold the poppet seat in place.

15. Apply a small amount of Blue Lubricant to the exter-nal threads of the valve body and thread it onto thenozzle body by tightening the valve body nut. Leavethis connection hand-tight for now.

16. Reinstall the cutting head and on/off valve assemblyto its original location on the machine by clampingthe cutting head in place.

Reinstalling the valve

WARNINGMake sure the high-pressure pump is OFF.

CAUTIONOpening the valve before tightening this connection reduces thepossibility of galling between the poppet and seat interface andreduces the force required as you are not working against the

high spring force of the actuator.

17. Attach the pneumatic control line to the valve actua-tor assembly and turn “ON” the air to open thevalve.

18. With the valve in the open position, align the valvewith the high-pressure tubing so that the weep tubeand high-pressure tubing point toward the front ofthe machine.

19. Tighten the connection between the nozzle body andthe valve body nut to 35–40 ft-lb (47–54 N-m).Once the connection is tight, turn off the air to closethe valve.

Note: Opening the valve before tightening this con-nection reduces the possibility of galling between thepoppet and seat interface and reduces the force re-quired as you are not working against the high springforce of the actuator.

20. Attach the high-pressure tubing to the valve. Becareful not to over-torque this connection.

21. Open the hand valve between the high-pressurewater source and the cutting head.

Turn on the high-pressure water source and slowly raisethe pressure while checking for leaks. Manually actuatethe valve a few times to make sure it is operating cor-rectly.



High-precision cutting head

The DWJ cutting head has the same purpose and func-tionality as Flow’s standard PASER ECL Plus system,however, it has been modified to provide the superiorcutting precision necessary for DWJ applications.

The cutting head assembly includes the nozzle body, ori-fice, mixing chamber, collet and nozzle nut, mixing tube,and Integrated spray shield and blast disk.

How it works

When the mini on/off valve is opened, high-pressure wa-ter flows through the orifice assembly into the mixingchamber, where it creates an area of partial vacuum.The vacuum draws a metered flow of abrasive throughthe abrasive delivery line, where it combines with thewater to create a high-energy abrasivejet cutting stream.

This stream exits the cutting head through the mixingtube at a velocity of up to 3000 ft/sec (914 m/s). Aftercutting, the residual energy of the abrasive stream (up to70% of nozzle tip energy) is contained and dissipated bya catcher.

Orifice assembly

A precision orifice mount in the top of the high-preci-sion mixing chamber secures and aligns the high-pres-sure orifice assembly. Standard PASER ECL Plus orificeassemblies are used with the DWJ.

High precision mixing chamber

The mixing chamber holds the orifice assembly and themixing tube in alignment. It also provides a place for theabrasive and water to mix. The precision-machinedshoulder serves as a stop for the mixing tube. There areno carbide pins or inserts used in the cutting head.

The mixing chamber is where the abrasive and watermix. The mixing chamber has two abrasive inlets, so onewill be cose to the metering valve when tightened. Inmost cutting configurations, only one inlet is used. Besure to cover the unused inlet with the provided plasticcap.

Collet and nozzle nut

The high-precision collet precisely centers the mixingtube in the cutting head. The conical shape is matchedto the machined conical shape of the downstream re-gion of the cutting head body. This ensures a precise ax-ial and radial registration of the mixing tube in thecutting head. An o-ring built into the nut seals the colletto the mixing tube. This creates the proper suction forthe abrasive and, in particular, for use with vacuumassist.



Mixing tube

The mixing tube focuses and accelerates the abrasivethat is entrained in the water stream. The PASER ECLPlus mixing tube is designed with a ring on the upper re-gion, which precisely registers the mixing tube in thecutting head. This ensures that the abrasivejet stream iscentered in the mixing tube.

A simple way to install the mixing tube is to hold the re-taining nut in your palm, snap in the collet, then drop inthe mixing tube and let it extend between your fingers.Screw this assembly onto the mixing chamber.

Integrated spray shield and blast disk

The blast disk protects the collet, nut and other precisioncomponents from the reverse spray of the jet whilepiercing material. The spray shield protects the operatorand the rest of the components of the DWJ wrist whilecutting.

The shield snaps into the nut and the blast disk fits intothe shield. They can be replaced individually or togetherwhen worn through. Flow recommends that you keeptwo of each on hand and replace them as soon as nec-essary. This will help prevent excessive wear of the moreexpensive precision components in the DWJ system.

Servicing the cutting head components

Refer to the manual M-359, PASER ECL Plus for orificeand mixing tube replacement procedures.



Notes



CHAPTER 4

94K End Effector

Two 94K end effectors are available for the Mach 3band Mach 4b Series System: Standard and Dynamic.

Both end effectors use the PASER ECL Plus cutting head.

Standard end effector

The standard end effector uses a cutting head that ismounted perpendicular to the cutting envelope.

The standard end effector has four main components:

• Z-axis


• On/off valve

• Height sensor

Dynamic Waterjet® End Effector

The Dynamic Waterjet (DWJ) is a wrist tilting endeffector designed for flat stock machines. Its revolution-ary design provides a better way to correct two commondrawbacks to abrasivejet cutting—taper and inside cor-ner kickback.

Slowing down the cutting speed used to be the best wayto reduce these effects. The DWJ cutting head providesa better way. Tilting the head removes the taper fromone side of the cut, leaving a vertical cut on the side ofthe part. Tilting the jet tip into the direction of travel re-duces drag, so cutting speeds on inside corners can of-ten be increased without damaging the underside of thepart.

The DWJ end effector has five main components:

• Z-axis

• Mini-wrist


• On/off valve

• Height sensor

These are illustrated and described in this chapter.

Tips and guidance on using the DWJ effectively can befound in manual MS-2276, How To Be Successful WithDynamic Waterjet.


Z-axis

Work envelope

Tilting a cutting head influences the overall travel of anX,Y system. A tilting head with thhe DWJ kinematicsuses X,Y,Z-axes travel to compensate for variation in thetool center point. Depending on maximum tool length,the maximum travel of the X- and Y-axes is decreased byabout 4 in. (50 mm).

The available travel of the Z-axis is influenced by tiltingthe cutting head and by mixing tube length. It is impor-tant when using the DWJ to consider what mixing tubewill be used. With DWJ on the system, the minimumtool length must be able to reach the catcher tank gridwhen the head is tilted to the maximum A- and B-axisangles.

The FlowMaster screen automatically shows the availablecutting envelope.

Maintenance

• The components used in the Z-axis are protectedfrom everyday machine operation, and should pro-vide years of reliable operation without servicing.There are no serviceable parts inside the Z-axis andthe unit must never be opened except by Flow tech-nicians.

• In case of a collision with any foreign object, pleaseconsult Flow Technical Service for information on re-alignment.



DWJ wrist assembly

The DWJ wrist assembly is powered by two servo-drivenactuators, which allow two more axes of movement (Aand B). The wrist assembly has a unique cutting headclamp that allows the operator to easily service the cut-ting head.

Specifications

Width . . . . . . . . . . . . . . . . . . . . . . . . . . . 321 mm

B-motor rotation . . . . . . . . . . . . . . . . . . . . . . . 10°

A-motor rotation . . . . . . . . . . . . . . . . . . . . . . . 10°

Maintenance

• The components used in the wrist are protected fromeveryday machine operation, and should provideyears of reliable operation without service. There areno serviceable parts inside the wrist assembly and theunit MUST NOT be opened except by Flow techni-cians.

• Check the A and B motors for smooth rotation. Thereshould be no rough spots or excessive friction. Checkby holding onto the cutting head and rotating in alldirections.




On/off valve

The on/off valve, designed specifically for the DWJ, is apneumatically-actuated valve that opens and closes thehigh-pressure water line, thus controlling water flow tothe cutting head and nozzle.

The on/off valve has three distinct features:

• Its size allows it to mount directly above the cuttinghead and tilt with the cutting head.

• The low-mass actuator (0.5 lb) allows full accelerationand tilting of the cutting head.

• The design of the valve-to-nozzle body connectionallows the valve to be oriented by the operator in anyradial direction to mate easily to high-pressure tubingand other rigid components.

Specifications

Operatingwater pressure. . . . . . . . 0–87,000 psi (0–6000 bar)

Water connection . . . . . 87K UHP ¼-in. tubing port

Valve weight . . . . . . . . . . . . . . . . . 1.5 lb (0.68 kg)

Recommendedwater flow rate. . . . . . . . . 0–2 gpm (7.5 liter/min)

Shop air (dry or lubed) . . 60–100 psig (4.1–6.9 bar)

Air connection . . . . . . . . . . . . . . . . . 6 mm air line

Configuration . . . . . . . normally closed, air to open

Response time*

Opening . . . . . . . . . . . . . . . . . . . . . . . 0.045 sec

Closing . . . . . . . . . . . . . . . . . . . . . . . . 0.100 sec

* Note that the response time will vary depending on(1) length of the air line from the solenoid to the actua-tor, and (2) air pressure.

Maintenance

Recommended spares

To minimize downtime and reduce the need for rush or-ders, you should have at least one repair kit for eachon/off valve.

014988 Seal kit


A-4689 Food grade o-ring lube (white)

014630-1 Plunger tool

014631-1 Guide tool

Tips for increasing the life of on/off valve parts

• After replacing high-pressure plumbing or otherequipment on your high-pressure pump, flush thesystem directly into the catcher tank before runningthe high-pressure water through the on/off valve andorifice. This will help minimize debris in the high-pressure lines that could damage the valve or orifice.

• Always follow the service procedures in this manualwhen repairing the on/off valve to ensure proper as-sembly and installation of the valve.

Servicing the on/off valve

Refer to the manual M-393, Hyperpressure SmallHigh-pressure Components for troubleshooting and ser-vice procedures.



High-precision cutting head

The DWJ cutting head has the same purpose and func-tionality as Flow’s standard PASER ECL Plus system,however, it has been modified to provide the superiorcutting precision necessary for DWJ applications.

The cutting head assembly includes the nozzle body, ori-fice, mixing chamber, collet and nozzle nut, mixing tube,spacer, and Integrated spray shield and blast disk.

How it works

When the on/off valve is opened, high-pressure waterflows through the orifice assembly into the mixing cham-ber, where it creates an area of partial vacuum. The vac-uum draws a metered flow of abrasive through theabrasive delivery line, where it combines with the waterto create a high-energy abrasivejet cutting stream.

This stream exits the cutting head through the mixingtube at a velocity of up to 3600 ft/sec (1100 m/s). Aftercutting, the residual energy of the abrasive stream (up to70% of nozzle tip energy) is contained and dissipated bya catcher.

Orifice assembly

A precision orifice mount in the top of the high-precision mixing chamber secures and aligns the high-pressure orifice assembly. Standard PASER ECL Plus ori-fice assemblies are used with the DWJ.

High precision mixing chamber

The mixing chamber holds the orifice assembly and themixing tube in alignment. It also provides a place for theabrasive and water to mix. The precision-machinedshoulder serves as a stop for the mixing tube. There areno carbide pins or inserts used in the cutting head..

The mixing chamber is where the abrasive and watermix. The mixing chamber has two abrasive inlets, so onewill be cose to the metering valve when tightened. Inmost cutting configurations, only one inlet is used. Besure to cover the unused inlet with the provided plasticcap.

Collet and nozzle nut

The high-precision collet precisely centers the mixingtube in the cutting head. The conical shape is matchedto the machined conical shape of the downstream re-gion of the cutting head body. This ensures a precise ax-ial and radial registration of the mixing tube in thecutting head. An o-ring built into the nut seals the colletto the mixing tube. This creates the proper suction forthe abrasive and, in particular, for use with vacuumassist.



Mixing tube

The mixing tube focuses and accelerates the abrasive thatis entrained in the water stream. The PASER ECL Plusmixing tube is designed with a ring on the upper region,which precisely registers the mixing tube in the cuttinghead. This ensures that the abrasivejet stream is centeredin the mixing tube.

A simple way to install the mixing tube is to hold the re-taining nut in your palm, snap in the collet, then drop inthe mixing tube and let it extend between your fingers.Screw this assembly onto the mixing chamber.

Integrated spray shield and blast disk

The blast disk protects the collet, nut and other precisioncomponents from the reverse spray of the jet while pierc-ing material. The spray shield protects the operator andthe rest of the components of the DWJ wrist whilecutting.

The shield snaps into the nut and the blast disk fits intothe shield. They can be replaced individually or togetherwhen worn through. Flow recommends that you keeptwo of each on hand and replace them as soon as neces-sary. This will help prevent excessive wear of the moreexpensive precision components in the DWJ system.



Servicing the cutting head components

Orifice

If you are experiencing loss of cutting power or degradedjet quality, check the high-pressure orifice assembly forevidence of blocking debris or damage.

During indirect inspection, check for evidence of erosion,wear, or other damage to the orifice assembly retainersurface. The orifice assembly must sit squarely against theretainer surface for correct alignment with the mixingtube.

Changing the orifice

CAUTIONWhen changing orifices or otherwise working on high-

pressure components, it is critical that you use backup wrenches.Excessive torque on the cutting head can damage

the wrist motors. Such damage will void your warranty.

The nozzle body, mixing chamber, orifice assembly,all work surfaces, and the hands of the service

technician must be clean and free from dirt andabrasive when working with the orifice assembly.

Blue Lubricant will readily collect dust, dirt,and abrasive. Any contamination of the orifice

assembly will most likely cause the nozzle to leak.

1. Turn the high-pressure pump off and bleed all pressurefrom the system.

2. Pull firmly on the abrasive feed line to remove it fromthe cutting head.

3. Open the cutting head clamp.

4. Using one wrench on the nozzle body and one on themixing chamber, loosen the connection between thetwo parts.

5. Once separated, store the nozzle body in the featureon top of the cutting head clamp. Take the mixingchamber to a workbench.

6. Tap the body upside down on a table to remove theorifice assembly. If necessary, lightly pry on the mountwith a screwdriver.

7. Apply a very thin film of Blue Lubricant at the top ofthe orifice assembly. Use a clean, lint-free applicator(such as a swab or small paintbrush).

CAUTIONThe amount of Blue Lubricant must be small enough

that it cannot flow toward the bore of the orifice.

8. Make sure the seating surface in the mixing chamber isfree of abrasive, then drop the orifice assembly intothe body, shaking the body until the assembly dropsinto the taper.

9. Apply Blue Lubricant to the pilot diameters andthreads of nozzle body. Attach cutting head body tonozzle body. Using a torque wrench with a crows footattachment, tighten to 30–35 ft-lb.

CAUTIONDo not over-tighten the cutting head—it will

damage mating surfaces, such as the nozzle body.It can also damage the orifice mount (by forcing

the mount out of round, or by flattening it.)Such damage is not covered by warranty.

10. Reattach the abrasive feed line and check for leaks.

Notes:

• If the cutting head leaks with 35 ft-lb of torque, take itapart and find out what’s wrong. Contamination of thenozzle components will most likely be the problem. Acomplete and thorough cleaning of hands and compo-nents will be required.

• Hand-tightening the nozzle body is not sufficient. Itwill result in leaks, which will ultimately damage noz-zle body components.



Mixing tube

Inspecting the mixing tube

For the best cutting accuracy, inspect the mixing tubeonce per shift or before starting a new job in order tomonitor and limit ID growth. This is very important for ef-fective and efficient use of the DWJ.

Tools required

• Pin gauges, or a dial caliper

Procedure

Remove the mixing tube from the mixing chamber body:

CAUTIONThe mixing tube is made from brittle carbide and iseasily damaged. Do not bend it, drop it, or twist it.

1. Inspect the mixing tube for obvious cracks, chips, ero-sion, and other damage.

Replace the mixing tube for any of these conditions:

• Obvious, off-center wear at the nozzle exit endID.

• Chips in the downstream end, outside edge ofthe nozzle that originate at the outside diameter,leaving less than 0.020 in. nozzle wall.

• Cracks that extend radially from the nozzle

• ID to OD or extend down the length of thenozzle.

• Chips in either end of the nozzle that originate atthe inside diameter. Do not confuse normal wear(concentric or off-center) of the upper end of themixing tube with chipping.

• The nozzle tip exit ID is worn enough to degradecutting accuracy and performance below accept-able levels:

For DWJ cutting: 0.010 inch (0.25 mm)greater than original size

For non-DWJ cutting: 0.02 inch (0.5 mm)greater than original size

• Imperfections other than changes of color orscoring in the area covered by the collet.

Notes:

• Some obvious erosion of the upper end of thetube is acceptable, as long as wear does not al-low water and abrasive to migrate between thetube OD and the body ID or result in degradedabrasivejet stream appearance or performance.

• Use nozzles that are too worn for DWJ cuttingfor parting material and other non-precision cut-ting jobs (such as parting materials), rather thanusing new, expensive nozzles for these jobs.

2. Inspection could also reveal some of the conditionslisted below. Any of these are acceptable as long asthey do not result in degraded abrasivejet streamappearance or performance.

• Discoloration or surface scoring.

• Erosion on the cone in the upper end of the mix-ing tube that does not affect the tube-to- bodymating or reduce the nozzle wall to less than0.020 in.

• Scoring or scratching of the exposed length ofthe mixing tube.

• Grooves, spirals or other erosive wear of the tubeID that does not affect the performance of theabrasivejet stream or excessively increase themixing tube exit end ID.

If inspection does not reveal any unacceptable conditions,reinstall the mixing tube.

Changing the mixing tube

No tools are necessary for this procedure.

Procedure

1. Make sure the intensifier pump is off and all pressurebled from the system.

WARNINGShut down the system and bleed all high-pressurefrom the system. Turn off the high-pressure water

and high-pressure water pump. Close the hand valvebetween the pump and the cutting head.

2. Remove the retaining nut and mixing tube together.

3. Put the end of the mixing tube on a pliant surface suchas wood or plastic. Press the retaining nut down andremove it from the mixing tube, then pull out thetube.

4. Install the collet into the retaining nut, install the newmixing tube into the collet from the collet side, theninstall the collet/mixing tube assembly into the cuttinghead.



CHAPTER 5

X,Y Table

The X,Y frame is a self-supporting welded rectangulartube construction, with adjustable feet to allow the frameto be aligned. Drives and linear units are directlymounted on the frame.

The cutting heads move in X, Y, and Z directions. TheY-direction is parallel to the base rail; the X-direction isparallel to the bridge.

The X-motion is generated by moving the bridge on thelinear units (buses) mounted in parallel. The X, Y, and Zaxes are driven via ball screws. The ball screws as well asother moving parts of the linear units are protected bybellows against humidity and soiling.

• The axes must be homed before use, and the Y,A,Baxis needs to be homed before the X,Y. Refer to theFlowMaster manual for information on homing.




Maintenance schedules

The following inspection schedules are based on a16-hour production day, 5 days a week, with the equip-ment located in a suitable environment. Changes tothese schedules may be necessary, depending on actualproduction hours and equipment environment.

The following covers only the X,Y machine. Be sure torefer to pump inspection and maintenance schedules lo-cated in other component manuals shipped with thesystem. These are listed at the beginning of this manual.

Inspection

Daily inspection

• Clean all exposed rails, ways, and cylinder rods. Lu-bricate with a light coating of aluminum complexbase grease.

• Clean all debris from machine and part holding/cut-ting fixtures.

• Check part clamp linkages, part clamps, locating pins,proximity switches, limit switches, and air/electricallines on the part holding/cutting fixture. Repair or re-place as needed.

• Make sure electrical enclosures and junction boxesare closed and secure.

• Individually activate all emergency stop devices, in-cluding E-stop buttons, floor mats, and light curtains.Check for proper operation and lock out any ma-chine that has malfunctioning emergency stopdevices.

Weekly inspection

• Lubricate all rail and way bearings.

• Clean all linear drive lead screws.

• Clean the bellows of the linear units with a soft brush.

Quarterly inspection

• Remove all debris from equipment and clean thor-oughly. Check all hoses, tubing, fittings, and electricallines. Replace any worn or chafed lines.

• Check condition of wire ways, traveling cables, andcable track. Clean and lubricate joints as necessarywith light machine oil.

• Clean all rails and ways thoroughly. Examine closelyfor any defect, damage, or excessive wear. Repair orreplace as required.

• Check the general condition of the equipment. Re-pair or replace lamps, indicating gauges, and switchesas required.


CHAPTER 5X,Y Table

Recommended lubricants

Use the following lubricants for X,Y components. Refer tothe pump manual and PASER manuals for recommendedlubricants for these components. Use only a hand oper-ated, low volume grease gun when applying lubricants.

For X,Y,Z ball nut and ball screw

• Lubriplate� L0083-035

For X,Y,Z linear bearings

• Lubriplate� L0083-035

CAUTIONFLOW does not recommend using any other typeof bearing grease. Mixing can cause the grease

to solidify, reducing bearing life up to 75%.

Recommended cleaners

For lead screws and rails

• CRC Industries, Technical Grade 3-36�. Spray on alight coat and allow to penetrate residue. Wipe cleanusing a lint-free cloth. Repeat as necessary.

For bellows cover, painted surfaces

• Johnson Envy� instant cleaner (or equivalent). Sprayfoam evenly over surface, wipe clean with cloth,sponge, or paper towel. Repeat as necessary.

Troubleshooting the X,Y table

1. Y-axis is not true

Contact FLOW Technical Service.

2. X-axis is not true

Set up a precision square, and run the X in and out. Contact FLOW Technical Service, if necessary.

3. X,Y axis locked in corner or will not jog

1. Exit all programs.

2. Turn machine power off and wait for 10 seconds.

3. Turn power back on and wait for PC boot-up to complete.

4. Push or pull X or Y or both axes out of corner or current position about 6 in.

5. Return to FlowCUT, select Run Machine, and then home the machine. Jog the axis.

If this does not fix the problem, call FLOW Technical Service.

4. Rough cuts are observed

Incorrect clearance. 1. Check the clearance between the pump/motor plate and the frame.

2. Make sure the machine frame is level and steady.

3. Make sure the catcher tank and grate are secure

4. Make sure your workpiece is secure.

5. X-axis makes a rough binding noise

X axes rails are not aligned. Move the carriage and feel or listen to where the binding occurs. Realign therails. When correctly aligned, tighten bolts.

6. No pressure display

Power off, improperlyconnected, or brown-out.

1. Check wiring.

2. Verify power is ON.

7. "......" pressure in display

Input display out of range. 1. Check unit scaling.

2. Check for electrical disturbance.

Loss of data set-ups. 1. Check data set-ups.


3. Disconnect and reconnect power.

8. Pressure display wanders

Loss of data set-ups 1. Check data set-ups.


3. Disconnect and reconnect power.



9. Jittery pressure display

Electrical noise in process orline.

1. Increase digital filtering.

2. Increase display rounding increment.

3. Re-route signal wires.

Process inherently unstable. Dampen process to eliminate oscillations.

10. "ULULUL" in pressure display

Input underload (negativeoverload).

Check input levels.

11. "OLOLOL" in pressure display.

Input overload. Check input levels.

12. Servomotor does not start

Power not connected. 1. Correct the power circuit.

2. Check fuses.

Loose connection. Tighten any loose parts.

Connector external wiringincorrect.

Refer to connection diagram and correct wiring.

Servomotor disconnected. Reconnect wiring or replace cable. Cable may be broken in cat-track.

Alarm tripped. Reset servo amplifiers.

13. Servomotor moves instantly and then stops

Encoder wiring incorrect orbroken.

Replace cable or connectors.

14. Servomotor speed unstable

Wiring connection to motordefective.

Tighten any loose terminals or connectors.

15. Servomotor overheated

Ambient temperature too high. Reduce ambient temperature to 40�C (104°F) max.

Servomotor surface dirty. Clean dust and oil from motor surface.

Overloaded. Run under no load. If looks fine, look for mechanical binding.

16. Abnormal noise

Mechanical mounting incorrect 1. Tighten mounting screws.

2. Center coupling.

3. Balance coupling.

Bearing defective. Check noise and vibration near bearing.

Call Flow Technical Service.

Machine causing vibrations. Call Flow Technical Service.


CHAPTER 5X,Y Table

Notes



CHAPTER 6

Engineering Drawings

The following drawings are provided with this manual (pump drawings are located with the pump manual). Pleasenote that drawings are provided for reference only. Drawings and part numbers can become obsolete as a part ofFlow’s ongoing product improvement. If part numbers are replaced by new numbers, Flow Customer Service willinform you when you order new parts.

Pumps

The complete pump drawing package is located in the pump manual shipped with the equipment. For 60K systems,refer to manual M-397 HyPlex Hybrid, M-349 50i-S, or M-351 100i-D. For 94K systems, refer to manual M-390HyperJet 94i-S & HyperJet 94i-D

60K pumps

See the pump manual or drawings tab on the CD-ROM.

013670-1 50i-S intensifier pump

013480-1 100i-D intensifier pump

046745-X 30/50 hp HyPlex Hybrid pump

94K pumps

See the pump manual or drawings tab on the CD-ROM.

020143-1 CE HyperJet 94i-S pump assembly(integrated)

020144-1 CE HyperJet 94i-D pump assembly(integrated)

042570 CE HyperJet 94i-S pump assembly(standalone)

042210 CE HyperJet 94i-D pump assembly(standalone)


Plumbing

60K plumbing assembly

044560-X Rev. 0160K high-pressure plumbing assembly

Part # Pump Heads # Whips

044560-1, -3, -5 30 HyPlex Hybrid or50 i-S

Single 1

044560-2, -4, -6 30 HyPlex Hybrid or50 i-S

Dual 1

044560-7, -9 50 HyPlex Single 2

044560-8, -10 50 HyPlex Dual 2

044560-11, -13, -15 100 i-D Single 2

044560-12, -14, -16 100 i-D Dual 2

94K plumbing assembly

044731-X Rev. 0194K high-pressure plumbing assembly

Part # Pump Heads # Whips

044731-1, -3, -5 HyperJet 94i-S Single 1

044731-2, -4, -6 HyperJet 94i-S Dual 1

044731-7, -9, -11 HyperJet 94i-D Single 2

044731-8, -10, -12 HyperJet 94i-D Dual 2



End effectors

60K end effectors

Dynamic Waterjet XD

045150-1 DWJ-XD wrist assembly

045160-1 DWJ-XD cutting head assembly

014660-1 Low profile on/off valve assembly

Dynamic Waterjet

043339-1 IFB DWJ cutting head assembly

046427-1 IFB DWJ wrist assembly

710870-1 On/off valve assembly

712262-1 PASER ECL cutting head assembly

Non-Dynamic Waterjet

043330-1 IFB single cutting head assembly

043331-1 Dual cutting head assembly (24 in.)



94K end effectors

Dynamic Waterjet

040150-2 IFB DWJ wrist assembly

014660-1 On/off valve assembly

020695-1 Cutting head assembly

043994-1 PASER ECL cutting head assembly

Non-Dynamic Waterjet

043332-1 IFB single cutting head assembly





CHAPTER 6Engineering Drawings



X,Y assembliesFor 60K and 94K Mach 3b and Mach 4b Series systems

Bases and bridges

XY module Base assembly Bridge assembly

044429-1 043908-1 1.25M base 044248-1 1.25M bridge

044430-1 043910-1 2.5M base 044248-1 1.25M bridge

044431-1 043912-1 3.05M base 044249-1 2M bridge

044917-1 044872-1 4M base 044249-1 2M bridge

044433-1 043916-1 7.32M base 044249-1 2M bridge

Cover options

044440-1 Metal-single (1.25M base cover package only)

044440-6 Metal-dual (1.25M base cover package only)

044440-2 Metal-single (60K 2.5M base cover package only)

044440-7 Metal-dual (60K 2.5M base cover package only)

044440-3 Metal-single (not available for 1.25M base)

044440-8 Metal-dual (not available for 1.25M base)

044440-4 Plastic-single (not available for 1.25M base)

044440-5 Plastic-dual ((not available for 1.25M base)

CatchersFor 60K and 94K Mach 3b and Mach 4b Series systems

Catcher dimensions are bridge x base-1 U.S., -2 Asia, -3 Europe

044292-X 1.3x1.3M catcher

047820-X 1.3x1.3M catcher (for DWJ-XD equipped system)

044285-X 2.5x1.3M catcher

047885-X 2.5x1.3M catcher (for DWJ-XD equipped system)

044297-X 3x2M catcher

047895-X 3x2M catcher (for DWJ-XD equipped system)

044180-X 4x2M catcher

047810-X 4x2M catcher (for DWJ-XD equipped system)

044320-X 7.3x2M catcher

Note: When ordering a new, complete catcher assembly, order one of the follow-ing part numbers. These drawings are not included on the CD.


CHAPTER 6Engineering Drawings

ElectricalThe electrical wiring diagram for your equipment can be found in the electrical enclosure.See engineering drawing for dashnumber identification

Assemblies

044052-1 Electrical assembly

044444-X 60K soft starter kit

Console modules

044393-1 Console module (25 foot cable)

044393-2 Console module (50 foot cable)

Transformers

044386-1 Transformers kit

A-01068-X Optional transformer

InstallationFor 60K and 94K Mach 3b and Mach 4b Series systems

046472-1 4020 Global IFB

047539-1 4020 Global IFB (for DWJ-XD equipped system)

046473-1 1313 Global IFB


046474-1 2513 Global IFB


046475-1 3020 Global IFB


046476-1 7320 (Single Zone) Global IFB

047971-1 7320 (Single Zone) Global IFB (for DWJ-XD equipped system)

047378-1 7320 (Double Zone) Global IFB

047972-1 7320 (Double Zone) Global IFB (for DWJ-XD equipped system)

Note: Installation drawings are intended for use by Flow Technical Services personnel only.These drawings are not included on the CD.



Kits

Consumables

60K

011767-X 50i-S & 100i-D consumable parts

042218-1 HyPlex Hybrid minor maintenance kit

042218-2 HyPlex major maintenance kit

94K

040467-1 HyperJet 94i-S consumable parts

040467-2 HyperJet 94i-D consumable parts

Spares

60K

010558-3 Spare 60K intensifier

94K

020070-1 Spare 87K intensifier

Tools

60K

012068-1 HyPlex Hybrid tool kit

007140-1 50i-S & 100 i-D tool kit

94K

040226-2 Complete 87K tool kit

Operator convenience kit

Standard/required for Mach 3b and Mach 4b Seriessystems equipped with a Dynamic Waterjet XD endeffector.

017137-1 Low profile clamp kit

017137-2 Low profile bracket clamp kit

047311-X Spray containment kit(for DWJ-XD equipped system)

A-24300-1 Material removal tool

A-21703-1 Battery-powered laser pointer

Miscellaneous service partsFor 60K and 94K systems

C-2217-1 Intensifier assembly fixture (60K only)

Bolts to a workbench; use for assembling the intensifier on aworkbench.


Anti-galling compound for all threaded high-pressureconnections.

A-4689 White Food Grade O-ring Lube

Use as a lubricant for all o-rings that come in contactwith water.

200006 Parker Super O Ring Lube

Use as a lubricant for all o-rings that come in contactwith hydraulic oil.

MS-2258 Intensifier Pump Maintenanceand Service Log

One copy is provided on the CD-ROM. Purchaseadditional copies for subsequent years.

m406_en Mach 3b and 4b Series

Documents

Transcript of m406_en Mach 3b and 4b Series