allfi 906110 User manual

Operating and maintenance instruction
Cutting Head basic 1.1
(4150 bar / 60,000 psi)
Operating and maintenance instruction
ALL I AG - Riedenmatt 1 – CH-6370 Stans
Tel.: [phone] - ax: [phone]
E-Mail: [e-mail] - http://www.allfi.com
November 2022

General
Version 1.0 2 / 24
Cutting Head Type IV & V 2.0 (4150 bar / 60,000 psi) November 14, 2022
Scope of application
The present operating and maintenance instruction is valid for:
Basic 1.1 (4150 bar / 60,000 psi)
 906110



General
Version 1.0 3 / 24
Cutting Head Type IV & V 2.0 (4150 bar / 60,000 psi) November 14, 2022
Table of contents
1 General .......................................................................................................................................4
1.1 Information on use of the operation and maintenance instruction ......................................4
1.2 Scope of delivery .................................................................................................................4
1.3 Warranty claim ....................................................................................................................4
1.4 Disclaimer............................................................................................................................4
2 Security .......................................................................................................................................5
2.1 Declaration of symbols ........................................................................................................5
2.2 General arning notes ........................................................................................................5
2.3 Intended use .......................................................................................................................6
2.4 Inadmissible usage ..............................................................................................................7
2.5 Residual risks .......................................................................................................................7
2.6 Safety installations ..............................................................................................................8
2.7 Personal protection equipment ...........................................................................................8
2.8 Qualification of the staff ......................................................................................................9
3 Structure and function ................................................................................................................9
3.1 Structure .............................................................................................................................9
3.2 Function ............................................................................................................................ 10
3.3 Accessories ........................................................................................................................ 10
4 General technical data .............................................................................................................. 11
5 Installation and commissioning ................................................................................................. 12
5.1 Fix cutting head to the machine ......................................................................................... 13
5.2 Flush cutting head ............................................................................................................. 14
5.3 Cutting head function check .............................................................................................. 15
6 Deinstallation ............................................................................................................................ 16
7 Maintenance, Service and Repair .............................................................................................. 16
7.1 Regular maintenance ......................................................................................................... 17
7.2 Replace Orifice .................................................................................................................. 17
7.3 Replace collimation tube ................................................................................................... 18
7.4 Reversing (turning) the valve seat ...................................................................................... 19
7.5 Replace seal kit and valve seat ........................................................................................... 20
7.6 Adjust the stroke of the pneumatic cylinder ...................................................................... 22
8 Faults and Troubleshooting ....................................................................................................... 23
8.1 Leakage of the cutting head: .............................................................................................. 23
8.2 Further troubleshooting .................................................................................................... 24
9 Recycling ................................................................................................................................... 24
Appendix A – Technical drawing and parts list (shipped with the product)

General
Version 1.0 4 / 24
Cutting Head Type IV & V 2.0 (4150 bar / 60,000 psi) November 14, 2022
1 General
1.1 Information on use of the operation and maintenance instruction
This operation and maintenance instruction is a key part of the product. The information in this manual
is mandatory and must be read and understood by all the persons before operating with the cutting
head type IV 2.0. The manual must be stored in distance as well as always accessible to the persons,
working with the cutting head type IV 2.0.
Should you have any questions regarding the content of the manual, please contact the manufacturer
directly.
ALL I AG - Riedenmatt 1 – CH-6370 Stans
Tel.: [phone] - ax: [phone]
E-Mail: [e-mail] - http://www.allfi.com
1.2 Scope of delivery
The individual parts contained in the shipment can be gathered from the set list in the appendix A
(technical drawing and part list). Upon receipt, the shipment has to be checked of integrity. Possible
detected defectives must be reported immediately to the manufacturer.
1.3 Warranty claim
The ALL I AG grants warranty for the shipped parts as followed:
 Material and manufacturer faults of 12 months from date of delivery or
 Defects within the first 2000 hours of operation
ollowing spare parts are excluded from the warranty:
 Seal Kit (consist of Valve needle, HP-seal 2.0, spring & Pressure plate 2.0)
 Valve Seat
 Orifice
 Collimation Tube
 O-Ring
 Valve Case
1.4 Disclaimer
ALL I AG refuses any claims of liability (material damages, physical injury, as well as disruption of
operation), that are a result of disregarding this operating and maintenance instruction.
or example, the damage as a consequence of:
 Inadmissible application of the cutting head
 Defective maintenance
 The disregard of operation instructions
 Chemical and electrolytical influences
 Use of parts, spare parts or accessory from a third-party manufacturer
 Arbitrary modifications
 Not or insufficiently trained staff
The disregard of all these instructions happens on exclusive risk and exclusive responsibility of the
client. The ALL I AG is not liable for any production downtimes.

Security
Version 1.0 5 / 24
Cutting Head Type IV & V 2.0 (4150 bar / 60,000 psi) November 14, 2022
2 Security
2.1 Declaration of symbols
This operating and maintenance instruction manual contains important notes and symbols, which are
to be considered and followed. These include:
DA GER
Danger emphasizes operating and service procedures that if not avoided,
may lead to death or serious personal injuries.
WAR I G
Warnings emphasize operating or service procedures, or conditions that
can result in serious personal injury or death.
CAUTIO
Cautions emphasize operating or service procedures, or conditions that
can result in equipment damage or impairment of system operation. If not
avoided, light or medium body injuries could be the consequence.
NOTE
otes provide additional information that can expedite or improve operat-
ing or service procedures.
Danger symbol without key word: Additional notes
2.2 General warning notes
Using of the cutting head, the following warnings are to be considered.
The specified warnings are not only restricted to the operation with the maximal
permissible operating pressure of 4150 bar / 60,000 psi. They are also valid on
work with reduced operation pressures!

Security
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Cutting Head Type IV & V 2.0 (4150 bar / 60,000 psi) November 14, 2022
DA GER
Danger of cutting of extremities on contact with waterjet
The contact with the high kinetic energy performing waterjet can have the con-
sequence of cutting of extremities or lead to other injuries.
Therefore:
 Operate the machine only, when nobody stands in the danger zone of the
waterjet.
 Never touch the waterjet, not even with personal protective equipment.
 Always sufficient safety distance during operation of the cutting head.
 Never guide the cutting head by hand during operation.
Any injuries in connection with the waterjet, alarm the emergency doctor imme-
diately.
CAUTIO
Danger of breathing difficulties and irritation of the skin and eyes by re-
leased solid particles or dust.
During machining of certain material, solid particles and dust may float in the
air, which could cause breathing difficulties and irritations to the skin and eyes.
Therefore:
 Ensure the proper ventilation of the room surrounding the machinery.
 Ensure to wear the personal protective equipment (protection glasses,
breathing mask, gloves, …)
Additionally, the rules and regulations of the working place are to be followed to
prevent injuries!
2.3 Intended use
The intended use consists in:
 operate the cutting head with air pressure
 switch the cutting head on and off to cut different material
 the fixed installation (no hand guidance) of the cutting head on the machine
 if provisions against flying fragments or a leaking liquid with high pressure are made
 if water is used exclusively as working fluid
 if the technical limit values are respected

Security
Version 1.0 7 / 24
Cutting Head Type IV & V 2.0 (4150 bar / 60,000 psi) November 14, 2022
2.4 Inadmissible usage
Inadmissible usage of the cutting head includes:
 The usage of all other fluids other than water
 The addition of other substances to the water
 Closure of the pressure relief holes
 Manually guide the cutting head by hand
 Excessive application of the cutting head e.g. large fluctuations in pressure
 Exceeding permitted limits
 Operating the valve with demounted or disabled technical protection
 Use the cutting head as a security valve
The following uses are also considered inadmissible if suitable technical protective measures are not
taken to protect the operator, other groups of persons, the machine components themselves or the
environment:
 The cutting of materials that release harmful, aggressive or explosive substances in the form
of dust, microparticles or gas.
Likewise, all other uses of the cutting head deviating from the intended use are not permitted. All ques-
tions should be addressed directly to the manufacturer.
ALL I AG - Riedenmatt 1 – CH-6370 Stans
Tel.: [phone] - ax: [phone]
E-Mail: [e-mail] - http://www.allfi.com
2.5 Residual risks
The manufacturer and/or operator of the machine where the cutting head is built in, has taken every
precautionary measure possible to reduce residual risks, as far as possible reasonably practicably.
Operation
phase
Damage Danger Reason (possible)
measures
Operation Physical
injuries
Liquids leaking under
high pressure (e.g. at
pressure relief holes)
Ignoring the torque ollow the torque
Damaged sealing
surfaces Regular supervi-
sion
Busted/Cracked
connections and
high-pressure com-
ponents as a result
of defects
Protective wall as a
technical protective
measure
lying fragments
Ignoring the torque ollow the torque
Damaged sealing
surfaces Regular supervi-
sion
Busted/Cracked
connections and
high-pressure com-
ponents as a result
of defects
Protective wall as a
technical protective
measure
Uncontrolled water jet Spring fracture Scheduled service
(chapter 7)

Security
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Cutting Head Type IV & V 2.0 (4150 bar / 60,000 psi) November 14, 2022
Operation
Physical
injuries
High kinetic energy of
water jet
Intrusion of extremi-
ties in working area
of water jet
Technical protec-
tive measures or
inherently reliable
construction of the
machine
High kinetic energy of
residual water jet
Cutting of material
Use correctly di-
mensioned water
jet absorber
Particles of raw material
and splash water
Wear protection
glasses and per-
sonal protection
equipment
Splash-water pro-
tection for technical
protective measure
Hearing
damage
Rapidly discharging of
fluid
Wear ear protector
Use correctly di-
mensioned water
jet absorber
2.6 Safety installations
The manufacturer or the operator of the full machine, which the cutting head is built in, has ensured
the following safety arrangements:
 Protection against intrusion of extremities in working area of water jet
 Safety devices to prevent flying fragments or liquids leaking under high pressure
 Emergency stoppage to immediately shut down the operating machine
 Active: Manually triggered by operator
 Passive: Automatically triggered by:
o o Penetration of limbs into the working area of the water jet
o o ailure of high pressure components or gross operating faults
o o Collision of the cutting head with fixed parts
Danger for the operator will arise if safety protections are not functionally, not
followed or evaded anytime. The operator has to ensure the functionality of the
safety protections anytime.
2.7 Personal protection equipment
The operator must offer his staff following protection equipment while he’s working:
Ear protector against:
 Noise emissions
Wear protection glasses against:
 luids and dust particles
 lying fragments

Structure and function
Version 1.0 9 / 24
Cutting Head Type IV & V 2.0 (4150 bar / 60,000 psi) November 14, 2022
Hand guards against:
 Sharp edges of components
 Intrusion of micro particles into the skin
Inhalation protection against:
 Dust particles, micro particles and spray mist
2.8 Qualification of the staff
The cutting head may only be operated and maintained by certified, trained staff.
3 Structure and function
3.1 Structure
Legend
1 Pneumatic Cylinder Type V 2.0
2 Seal Kit
2.1. Valve needle
2.2. Supporting ring
2.3. HP-Seal
3 Supporting Disc basic 1.1
4 Valve Case
5 Valve Seat
6 O-Ring
7 Coupling Ring
8 Orifice Cap
9 Collimation Tube
10 Collar 1/4"
11 Gland Nut 1/4"
12 Orifice

Structure and function
Version 1.0 10 / 24
Cutting Head Type IV & V 2.0 (4150 bar / 60,000 psi) November 14, 2022
3.2 Function
The cutting head opens and closes with a pneumatic piston actuator. The pneumatic pressure in the
cylinder lifts the piston against the cylinder springs. The valve needle lifts simultaneous with the piston
from the valve seat and opens the water channel. After the compressed air has been released the
springs in the cylinder closes the water channel of the cutting head. The compressed air is controlled
on and off by a compressed air valve (not included in delivery). The maximal permissible operating
water pressure see chapter 4.
3.3 Accessories
Article: ace Spanner DX Paste P-Paste
Article no: 040006 051055 051065
unction: Adjust of the stroke Greasing screw connections
and metallic contact areas for
standard applications
Greasing screw connec-
tions and metallic contact
areas for food safe
All accessories for metric cutting heads are included in case set 882101
All accessories for imperial cutting heads are included in case set 882101-I
Article: Torque wrench Open end fitting Mounting tool for
O-ring
Ejector mandrel
Article no: 000468 A 15 – 000493
A 17 – 000339
A 5/8" – 000521
A 22 – 000272
A 24 – 000280
040011 900070
unction: Tightens screws
with a specific
torque
O-ring assembly and
disassembly
Replace Seal Kit
and Valve Seat

General technical data
Version 1.0 11 / 24
Cutting Head Type IV & V 2.0 (4150 bar / 60,000 psi) November 14, 2022
4 General technical data
Pneumatic pressure: 6 - 7 bar / 87 psi – 102 psi
Minimum working pressure: 800 bar (11,500 psi) @ 7 bar (102 psi) air pressure
1500 bar (21,500 psi) @ 6 bar (87 psi) air pressure
Maximal working pressure: 4150 bar / 60,000 psi
Maximal working temperature: 50 °C
Maximum transport and storage temperature: 60 °C
Reaction time: up to 4 switching cycles per seconds
Weight: ca. 1.2 kg
Noise emission: 70 – 120dB (a), depends on size of orifice and con-
struction of water jet absorber
Requested water quality:
Water parameter Unit Value
Electrical Conductivity µS / cm 100 – 450
PH-value - 7.0 - 8.5
Total hardness °dH 2.0 - 10.0
Carbonate hardness
(acid capacity pH 4.3)
°dH 2.0 - 10.0
Degree of alkalinity pH 8.2 mmol / l 0 - 0.25
Chloride mg / l ≤ 50
Iron mg / l ≤ 0.2
Manganese mg / l ≤ 0.05
Copper mg / l ≤ 2.0
Silicate mg / l ≤ 5.0
( iltrate-) solid content mg / l ≤ 350
Technical data as dimensions can be found in the technical drawing in appendix A.

Installation and commissioning
Version 1.0 12 / 24
Cutting Head Type IV & V 2.0 (4150 bar / 60,000 psi) November 14, 2022
General installation tip:
 Use of a pneumatic oiler is forbidden.
 Compressed air filter with water separator must be installed.
 Compressed air filter and pneumatic valve must have a minimum nominal flow
rate of 5 m
3
/h.
 Absolute cleanliness of the pipes is important before connection.
 A high-pressure filter in front of the cutting head is recommended to extend the
service life. (e.g. ALL I HP- ilter 931335)
 ollow the steps below for installation.
 Before startup and after inspection or maintenance, check the water tightness of
the cutting head.
5 Installation and commissioning
WAR I G
Risk of injury: It is forbidden to close the pressure relief holes.
By closing the pressure relief holes, the cutting head or parts of it may explode.
Therefore: Never close or cover any pressure relief hole.
Positions of the pressure relief holes:

Installation and commissioning
Version 1.0 13 / 24
Cutting Head Type IV & V 2.0 (4150 bar / 60,000 psi) November 14, 2022
NOTE
Material damage as a result of pitting
Not or insufficient greased threads or contact areas can pit.
Therefore:
Always grease threads and metallic contact areas. Check appendix A for addi-
tional information.
NOTE
Material damage or leakage as a result of fouling
ouling components, especially at threads, can lead to leakages and damage.
Therefore:
Pay attention to the cleanliness of the components while maintaining.
NOTE
Material damage as a result of leakages
Constant leakage may damage the product.
Therefore:
Immediately eliminate leakages (see chapter 8 „ aults and Troubleshooting”).
5.1 Fix cutting head to the machine
The cutting head can be installed in the machine in two different ways. urther fastening options must
be discussed with the manufacturer.
During installation, ensure that none of the pressure relief holes are closed!
1. Unscrew gland nut from
coupling ring.
2. Remove collar from gland
nut.

Installation and commissioning
Version 1.0 14 / 24
Cutting Head Type IV & V 2.0 (4150 bar / 60,000 psi) November 14, 2022
3. Slide the gland nut over the
HP tube.
4. Screw the collar on the HP
tube (left-handed thread).
There must be 1 or 2 convo-
lutions visible between the
conus and the pressure ring.
ix coupling ring on mounting
plate
(Exemplary drawing)
Mount cutting head with
three M5 screws on machine.
ix on collimation tube
(Exemplary drawing)
Clamp cutting head on colli-
mation tube to the machine.
5. Mount cutting head on the
machine.
1. Connect the HP tube with
the cutting head
torque see appendix A.
2. Plug in compressed air
connection by snapping in.
5.2 Flush cutting head
To prevent particles carried with the water from clogging the nozzle or damaging the cutting head,
flush the cutting head:
 When newly installed.
 When servicing or replacing high pressure components upstream of the cutting head.
Procedure:
1. Remove orifice cap (see chapter 7.2)
2. Pressurize pneumatic cylinder with compressed air (6-7 bar), to open cutting head.
6
7

Installation and commissioning
Version 1.0 15 / 24
Cutting Head Type IV & V 2.0 (4150 bar / 60,000 psi) November 14, 2022
3. lush cutting head (p ≤ 500 bar / 7,250 psi) for 5 to 10 seconds with clean water.
4. Screw on orifice cap with inserted orifice on the collimation tube (see chapter 7.2)
NOTE
Possible damage as a result of direct transfer of the torque to the HP seal-
ing
The HP sealing will be damaged (pitting on sealing surface) if tight or loosen the
orifice cap without holding the collimation tube.
Therefore:
C ounterhold collimation tube if tight or loosen orifice cap.
5.3 Cutting head function check
DA GER
Danger of cutting of extremities on contact with waterjet
The contact with the high kinetic energy performing waterjet can have the con-
sequence of cutting of extremities or lead to other injuries.
Therefore:
 Operate the machine only, when nobody stands in the danger zone of the
waterjet.
 Never touch the waterjet, even with personal protective equipment.
 Always sufficient safety distance during operation of the cutting head.
 Never guide the cutting head by hand during operation.
ix cutting head on the machine and operate the cutting head with operating pressure (water pressure
= operating pressure) 5-10 times. Check following points:
 The cutting head opens and closes faultless
 The cutting head operates promptly (no time lag)
 Quality of the waterjet
 Cutting head tightness
If all checked points above are ok, the cutting head will be ready for operation. Please see chapter 8
( aults and Troubleshooting) for fault diagnostics.

Deinstallation
Version 1.0 16 / 24
Cutting Head Type IV & V 2.0 (4150 bar / 60,000 psi) November 14, 2022
6 Deinstallation
Before uninstalling the cutting head, release pressure from the HP tubes and protect
against unexpected re-pressurizing.
7 Maintenance, Service and Repair
Before uninstalling the cutting head, release pressure from
the HP tube and protect against unexpected re-pressurizing.
It’s not necessarily to unmount the cutting head from the machine. Usually the maintenance is easier if
the HP tube is removed and the cutting head is unmounted from the machine.
All maintenance, service and repair work not written in this document has to be executed by the manu-
facturer. Especially service at the cylinder.
NOTE
Material damage or leakage as a result of fouling
Dirty components, especially considering the threads, may lead to leakages and
damage of the cutting head.
Therefore:
Ensure a proper cleaning of the components.
1. Remove pneumatic hose.
2. Remove HP tube.
3. Remove cutting head from the machine
2
1

Maintenance, Service and Repair
Version 1.0 17 / 24
Cutting Head Type IV & V 2.0 (4150 bar / 60,000 psi) November 14, 2022
NOTE
Possible damage as a result of direct transfer of the torque to the HP-tube
Loosening or tightening the cap (pos. 11 on page 11) without holding the colli-
mation tube can lead to damages on the HP tube connections
Loosening or tightening the collimation tube (pos. 9 on page 11) without holding
the valve case can lead to damages on the HP tube connections
Therefore:
Hold collimation tube when loosening or tightening the cap (pos. 11 on page 11)
with an open-end wrench.
Hold valve case when loosing or tightening the collimation tube (pos. 9 on page
11) with an open-end wrench.
NOTE
Property damage as a result of pitting
Threads that are not greased or insufficiently greased may pit.
Therefore:
Always grease threads and metallic contact areas. Check appendix A for additional
information.
7.1 Regular maintenance
What
By whom
When
Replace disc springs and O-rings in
pneumatic cylinder
Service ALL I AG All 2,000 operation hours / 1
million. Cycles of operation
Check stroke Operator All 500 operation hours /
100,000 Cycles of operation
Check tightness Operator Continuous
Check water jet quality Operator Continuous
Check rubber cap for any damage Operator Continuous
7.2 Replace Orifice
1
1. Make sure the cutting head is closed
2. Remove cap from collimation tube
Attention! Counterhold collimation tube.
3. Remove orifice from cap.
4. Clean cap and sealing surface of colli-
mation tube.

Maintenance, Service and Repair
Version 1.0 18 / 24
Cutting Head Type IV & V 2.0 (4150 bar / 60,000 psi) November 14, 2022
2
1. Insert orifice according illustration.
Type of orifice check appendix A
3
1. Screw cap on the collimation tube and
tighten the cap with a torque wrench
(moment of force according appendix A)
Attention! Counterhold collimation tube
2. Mount cutting head on the machine.
3. Cutting head function check (chapter
5.3).
7.3 Replace collimation tube
1
1. Make sure the cutting head is
closed
2. Remove cap with orifice from colli-
mation tube.
Attention! Counterhold collimation
tube.
2
1. Pressurize pneumatic cylinder with
compressed air (6-7 bar). The cut-
ting head is now open and the
valve seat will not be damaged.
2. Unscrew collimation tube from
valve case. Attention! Counterhold
on valve case A 24.
3. Grease thread of new collimation
tube (see appendix A)
4. Screw and tighten the new collima-
tion tube with a torque wrench
(torque see appendix A).
Attention! Counterhold on valve
case A 24.
5. Depressurize pneumatic cylinder
3
1. Screw cap with inserted orifice on
the collimation tube (chapter 7.2).
2. Cutting head function check (chap-
ter 5.3).
2
4

Maintenance, Service and Repair
Version 1.0 19 / 24
Cutting Head Type IV & V 2.0 (4150 bar / 60,000 psi) November 14, 2022
7.4 Reversing (turning) the valve seat
1
1. Removing the cutting head from
the machine is recommended, es-
pecially if the cutting head is at-
tached to the collimation tube
(Chapter 6)
2. Connect pneumatic line to pneu-
matic cylinder and pressurize with
compressed air (6-7 bar) The cut-
ting head is now open and the
valve seat will not be damaged.
3. Screw the collimation tube out of
the valve case. Attention! Coun-
terhold the valve case SW 24
2
1. Remove the O-ring from valve
case with help of tool 040011
2. Remove the valve seat from the
valve case. Note the orientation of
groove of the valve seat (top or
bottom).
3
When groove was on top:
Valve seat can be reinstalled with
groove at the bottom.
When groove was on bottom:
Now that both seats are worn out,
valve seat must be replaced with new
one and installed with groove on top.
It is recommended to change the seal
kit as well. (See chapter 7.5)
4
1. Insert O-ring into valve case using
assembly tool 040011
2. Screw collimation tube into valve
case and tighten (torque see ap-
pendix A). Attention! Counterhold
on valve case A 24.
3. Depressurize pneumatic cylinder
and r emove pneumatic line
4. ix cutting head to the machine.
(Chapter 5.1)
5. Cutting head function check (chap-
ter 5.3).
Groove
on top
Groove on
bottom

Maintenance, Service and Repair
Version 1.0 20 / 24
Cutting Head Type IV & V 2.0 (4150 bar / 60,000 psi) November 14, 2022
7.5 Replace seal kit and valve seat
1
1. To Replace seal kit and valve seat
it is mandatory to remove the cut-
ting head from the machine.
(Chapter 6)
2. Connect pneumatic line to pneu-
matic cylinder and pressurize with
compressed air (6-7bar) The cut-
ting head is now open and the
valve seat will not be damaged
3. Unscrew the collimation tube from
the valve case. Counterhold on
valve case A 24.
4. Depressurize pneumatic cylinder
and r emove pneumatic line.
2
1. Remove the O-ring from valve
case with help of tool 040011.
2. Remove the valve seat from the
valve case. Note the orientation of
the valve seat for step 7.
3
1. Clamp pneumatic cylinder at the
width across flats in a bench vise.
Attention! Do not over tighten,
this would deform the cylinder.
Use protective jaws.
2. Unscrew valve case at the A 24.
4
1. Sit valve case on a solid surface
according illustration (needle point
face up).
2. Press the seal kit with the ejector
mandrel 900070 out of the valve
case.
3. Dispose/recycle the old seal kit.
3
Groove on
bottom
Groove on
top