CNC-Step flowJET 2015 User manual

02/06/2020 02/06/20202020-06-02
Operating Instructions
flowJET
Rev. 05/2020 (Subject to changes)
2015 / 2515 / 3015
https://www.cnc-step.com

Operating Instructions
flowJET Waterjet cutting machine
CNC-STEP GmbH & Co.KG ▪Siemensstrasse 13-15
▪47608 Geldern ▪ Germany
Page 2
Support: +49 (0)2831/91021-50
02/06/2020
flowJET
Short description
The flowJET machine type is based on a low-warpage steel construction.
The linear movement of the sled is carried out via racks, driven by powerful stepper motors. The
machine is therefore designed for 3D travel and high speeds. The portal sits on a pool of water with
an integrated air chamber to lower and raise the water level.
These operating instructions describe the installation, commissioning and maintenance of the CNC
water jet cutting system.

Operating Instructions
flowJET Waterjet cutting machine
CNC-STEP GmbH & Co.KG ▪Siemensstrasse 13-15
▪47608 Geldern ▪ Germany
Page 3
Support: +49 (0)2831/91021-50
02/06/2020
Contents
1GENERAL.....................................................................................................................7
1.1 Information about this Manual...............................................................................................7
1.2 Explanation of Symbols...........................................................................................................7
SAFETY INSTRUCTIONS...................................................................................................7
1.3 Limitation of Liability..............................................................................................................9
1.4 Copyright Protection..............................................................................................................10
2SAFETY ......................................................................................................................11
2.1 Appropriate Use .....................................................................................................................11
2.2 Basic Dangers..........................................................................................................................12
2.2.1 Danger in Electrical Systems...........................................................................................13
2.2.2 Danger of Mechanical Parts.............................................................................................14
2.2.3 Danger due to High or Low Temperatures ......................................................................18
2.2.4 Danger of Fire..................................................................................................................18
2.2.5 Danger of Radiation.........................................................................................................19
2.2.6 Danger from Chemical Compounds ................................................................................20
2.2.7 General Dangers in the Workplace..................................................................................21
2.3 Responsibility of the Operator..............................................................................................22
2.4 Staff Requirements.................................................................................................................24
2.4.1 Qualifications...................................................................................................................24
2.4.2 Training............................................................................................................................25
2.5 Personal Protection Equipment............................................................................................26
2.6 Safety Systems ........................................................................................................................28
2.6.1 Description of the Installed Safety Devices.....................................................................28
2.6.2 Safety Devices to be fitted by the Operator.....................................................................31
2.6.3 Device for releasing pressure in Lines and valves...........................................................32
2.7 Securing against Accidental Starting ...................................................................................33
2.8 Behaviour in case of Fire or Accident ..................................................................................34
MEASURES IN CASE OF ACCIDENT OR FIRE..............................................................34
2.9 Environmental Protection .....................................................................................................34
2.10 Labels and Signs.............................................................................................................36

Operating Instructions
flowJET Waterjet cutting machine
CNC-STEP GmbH & Co.KG ▪Siemensstrasse 13-15
▪47608 Geldern ▪ Germany
Page 4
Support: +49 (0)2831/91021-50
02/06/2020
2.10.1 Advisory Signs.................................................................................................................36
2.10.2 Prohibition Signs..............................................................................................................36
2.10.3 Warning Signs..................................................................................................................38
2.10.4 Fire Protection Signs........................................................................................................39
2.10.5 Rescue Signs....................................................................................................................40
3TECHNICAL SPECIFICATIONS.................................................................................41
3.1 General Specifications............................................................................................................41
3.2 Power Supply..........................................................................................................................43
3.3 Power Usage............................................................................................................................44
3.4 Operating Requirements .......................................................................................................44
3.5 Lubricants...............................................................................................................................45
3.6 Emissions.................................................................................................................................45
3.7 Name Plate ..............................................................................................................................45
4ASSEMBLY AND COMMISSIONING.........................................................................46
4.1 Overview .................................................................................................................................46
4.2 Short Description....................................................................................................................47
4.3 Description of Sub-Assemblies..............................................................................................49
4.3.1 Y-Axis with Slide ............................................................................................................49
4.3.2 Z-Axis with Slide.............................................................................................................50
4.3.3 X-Axis with Slide ............................................................................................................50
4.3.4 Operating Software..........................................................................................................51
4.3.5 Controller.........................................................................................................................51
4.3.6 Accessory Holder......................................................Fehler! Textmarke nicht definiert.
4.4 User Controls..........................................................................................................................53
4.5 Connections.............................................................................................................................54
4.6 Working and Danger Areas ..................................................................................................55
5TRANSPORTATION, PACKAGING AND STORAGE................................................56
5.1 Safety Instructions for Transportation................................................................................56
OFF BALANCE CENTRE OF GRAVITY ..........................................................................57
FALLING HAZARD BY LOAD OFF BALANCE OR CENTRE OF GRAVITY ..................57
5.2 Transport Inspection..............................................................................................................58

Operating Instructions
flowJET Waterjet cutting machine
CNC-STEP GmbH & Co.KG ▪Siemensstrasse 13-15
▪47608 Geldern ▪ Germany
Page 5
Support: +49 (0)2831/91021-50
02/06/2020
5.3 Packaging................................................................................................................................58
CAUTION!...................................................... FEHLER! TEXTMARKE NICHT DEFINIERT.
ENVIRONMENTAL DAMAGE CAUSED BY INAPPROPRIATE DISPOSAL!..................59
5.4 Icons on the Packaging ..........................................................................................................59
5.5 Transportation........................................................................................................................60
5.6 Storage.....................................................................................................................................62
6INSTALLATION AND COMMISSIONING...................................................................63
6.1 Safety Information for Installation and Commissioning....................................................63
6.2 Preparation.............................................................................................................................65
6.2.1 Placing Machine...............................................................................................................65
6.2.2 Adjusting Tabletop....................................................Fehler! Textmarke nicht definiert.
6.3 Installation ..............................................................................................................................68
6.3.1 Connecting the Computer................................................................................................71
6.3.2 Connecting the Stepper Motors .......................................................................................71
6.3.3 Installing Accessories ......................................................................................................72
6.4 Connecting to Power Supply.................................................................................................73
6.5 Commissioning .......................................................................................................................74
7OPERATION...............................................................................................................75
7.1 Safety Instruction for Operation ..........................................................................................75
7.2 Important Steps before Operation........................................................................................75
7.3 Switching-On Procedure........................................................................................................76
7.4 Important Steps during Operation.......................................................................................77
7.4.1 Clamping of Work Pieces or Materials............................................................................77
7.4.2 Operating of the Machine ................................................................................................77
7.4.3 Tool Changes ............................................................Fehler! Textmarke nicht definiert.
7.5 Switching-Off Machine..........................................................................................................85
7.6 Important Steps after Operation..........................................................................................86
7.7 Emergency Stop......................................................................................................................87
8MAINTENANCE..........................................................................................................88
8.1 Safety during Maintenance ...................................................................................................88
8.2 Spare Parts..............................................................................................................................90

Operating Instructions
flowJET Waterjet cutting machine
CNC-STEP GmbH & Co.KG ▪Siemensstrasse 13-15
▪47608 Geldern ▪ Germany
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Support: +49 (0)2831/91021-50
02/06/2020
8.3 Maintenance Schedule ...........................................................................................................91
8.4 Maintenance Procedures .......................................................................................................92
8.4.1 Cleaning Machine............................................................................................................92
8.4.2 Protection Cover Inspection or Replacement ..................................................................93
8.4.3 Machine Lubrication........................................................................................................95
8.5 Steps to be taken after Maintenance Procedure................................................................100
9TROUBLE SHOOTING.............................................................................................101
9.1 Safety during Trouble Shooting..........................................................................................101
9.2 Table of Faults......................................................................................................................103
9.3 Fault Repair..........................................................................................................................105
9.3.1 Releasing the Emergency Stop Switch..........................................................................105
9.3.2 Changing the Electrical Fuse .........................................................................................106
9.4 Start-up after Fault Repair .................................................................................................109
10 DISASSEMBLING AND DISPOSAL......................................................................110
10.1 Safety during Disassembling and Disposal................................................................110
10.2 Disassembling...............................................................................................................111
10.3 Waste Disposal .............................................................................................................111
CAUTION!.......................................................................................................................111
ENVIRONMENTAL DAMAGE CAUSED BY INCORRECT DISPOSAL!........................111
11 APPENDIX.............................................................................................................112
11.1 Accessories....................................................................................................................112
12 CUSTOMER SERVICE ...................................................................................113
12.1 Remote maintenance....................................................................................................114

Operating Instructions
flowJET Waterjet cutting machine
CNC-STEP GmbH & Co.KG ▪Siemensstrasse 13-15
▪47608 Geldern ▪ Germany
Page 7
Support: +49 (0)2831/91021-50
02/06/2020
1General
1.1 Information about this Manual
This manual enables you to handle this machine safely and effi-
ciently.
This guide is part of the machine and must be kept close to the
machine accessible to the staff at any time. Before starting any
work, the operator needs to have read and understood this manual.
Basic condition for a safe operation of the machine is the compli-
ance with all safety rules and instructions given in this manual.
In addition, the local accident prevention regulations and general
safety rules must be applied during the operation of the machine.
Illustrations or graphical representations in this manual serve the
fundamental understanding and may differ from the actual con-
struction of the machine.
In addition to these instructions, the instructions in the annexure
of the assembled components, apply accordingly.
1.2 Explanation of Symbols
Safety instructions
Safety instructions in this guide are marked by symbols. The
safety instructions are initiated by key words, which show the de-
gree of the danger.
Safety precautions must be observed strictly, and cautious action
must be taken to avoid any accidents as well as damages to per-
sons or property/objects.
DANGER!
Indicates an imminently dangerous situation which
may cause serious injury or death if ignored.

Operating Instructions
flowJET Waterjet cutting machine
CNC-STEP GmbH & Co.KG ▪Siemensstrasse 13-15
▪47608 Geldern ▪ Germany
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Support: +49 (0)2831/91021-50
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WARNING!
Indicates a potentially dangerous situation which
could lead to serious injury or death if ignored.
CAUTION!
Indicates a potentially dangerous situation which
could lead to minor or mild injury or damage to
property if ignored
ATTENTION!
The symbols or a combination of symbols highlight
potential dangers that can result in injury to persons
or damage to property if ignored.
Important safety symbols
To draw attention to special dangers the following symbols are
used in the safety instructions:
DANGER!
A combination of this symbol and warning indicate
danger of potential electrocution which could result
in personal injury or death if ignored
Hints and Recommendations
NOTE! - highlights useful tips and
recommendations as well as information for an
efficient and trouble-free operation.
.

Operating Instructions
flowJET Waterjet cutting machine
CNC-STEP GmbH & Co.KG ▪Siemensstrasse 13-15
▪47608 Geldern ▪ Germany
Page 9
Support: +49 (0)2831/91021-50
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Other symbols and icons
The below mentioned symbols are used to indicate further infor-
mation relating to the correct use of the machine:
Symbol
Description
Step by step instructions
Results by specific actions
Reference to appendix or other parts of
the manual
List without a specific order
1.3 Limitation of Liability
All information and instructions in this manual have been made
under consideration of the applicable standards and regulations,
the state of technology as well as our long-standing knowledge
and experience.
The manufacturer assumes no liability for damages due to:
Failure to comply with the instructions in this manual
Non-specified use
Operations by unqualified staff
Unauthorized alterations or modifications
Technical changes
Use of unauthorized spare parts
For special designs, additional ordering options or due to some
late technical modifications, the actual delivery may not neces-
sarily correspond to the presented explanations and descriptions.
General terms and conditions as well as the delivery terms of the
manufacturer as agreed on the delivery contract and all legal pro-
visions valid at the time of the contract fulfilment, will apply. We
reserve the right to implement technical changes and amendments
to the manual and machines as part of the improvement program
of the performance and further development of the platforms.

Operating Instructions
flowJET Waterjet cutting machine
CNC-STEP GmbH & Co.KG ▪Siemensstrasse 13-15
▪47608 Geldern ▪ Germany
Page 10
Support: +49 (0)2831/91021-50
02/06/2020
1.4 Copyright Protection
This manual is copyrighted and designed exclusively for internal
purposes.
Release of the manual to third parties, reproductions of any type
or form, extracts or parts thereof and communication of the con-
tents are not permitted without the written permission of the man-
ufacturer except for internal purposes. Any breach of this obliga-
tion shall result in liability for damages. The right to any further
claims remains reserved.

Operating Instructions
flowJET Waterjet cutting machine
CNC-STEP GmbH & Co.KG ▪Siemensstrasse 13-15
▪47608 Geldern ▪ Germany
Page 11
Support: +49 (0)2831/91021-50
02/06/2020
2Safety
This section provides an overview of all-important safety aspects
for maximum protection of the staff as well as a safe and trouble-
free operation.
Failure to follow the operating procedures and safety instructions
listed in this manual may lead to significant dangers.
maximum
2.1 Intended Use
The CNC water jet cutting system is used exclusively for cut-
ting materials of all kinds, such as plastics, wood, non-ferrous
metals (aluminium, brass, etc.), glass and ceramics with high
water pressure up to 3800bar. For various materials, an abra-
sive unit must also be used. Only purified water, but no salt-
free water, may be used for cutting. The machine has its own
control system.
Intended use also includes the adherence to all information in this
manual as well as the instructions pertaining to the components.
Any use exceeding or differing from the appropriate use is con-
sidered misuse and can lead to dangerous situations.
WARNING!
Danger resulting from misuse!
Misuse of the machine can lead to dangerous
situations!
- Use of the machine outside of the given
specifications
- Disabling or removal of any safety switches
- Modification or changing of the machine
resulting in changes to the working area or
operational parameters.
- Operation of the machine with contaminated
water

Operating Instructions
flowJET Waterjet cutting machine
CNC-STEP GmbH & Co.KG ▪Siemensstrasse 13-15
▪47608 Geldern ▪ Germany
Page 12
Support: +49 (0)2831/91021-50
02/06/2020
- Operation of the machine with other liquids
- Cutting of materials that react to water
- Operation of the machine with a technical fault.
- Operating the machine in an explosive
environment.
Any claims resulting from misuse or incorrect handling of the
machine will not be entertained.
2.2 Basic Dangers
In the following section remaining risks are listed which have
been identified based on a risk assessment.
The safety instructions and warnings given in the other chapters
of this manual must be observed to reduce health risks and to
avoid dangerous situations.

Operating Instructions
flowJET Waterjet cutting machine
CNC-STEP GmbH & Co.KG ▪Siemensstrasse 13-15
▪47608 Geldern ▪ Germany
Page 13
Support: +49 (0)2831/91021-50
02/06/2020
2.2.1 D a ng er in E le c tr i ca l S y stems
Electricity
DANGER!
Risk of death by electrocution!
Contact with live electrical parts present an
imminent danger to a person’s health. Damaged
insulation or components can cause fatal
electrocution if touched by a person.
-Only qualified electricians can work on the
electrical systems.
-In case of damage to the insulation, disconnect
the power supply immediately and arrange for
repairs.
- During all work on the electrical systems,
disconnect from the mains and verify that the
disconnected parts are free of voltage. These five
rules apply:
- Disconnect from main supply
- Secure against accidental reactivating.
- Check for current.
- Check earthing and short circuit.
- Shield or disconnect any neighbouring
machines.
- Do not bridge or disable fuses. When changing
fuses observe correct amperage
-Protect live parts from moisture. Moisture can
lead to short circuiting.

Operating Instructions
flowJET Waterjet cutting machine
CNC-STEP GmbH & Co.KG ▪Siemensstrasse 13-15
▪47608 Geldern ▪ Germany
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Support: +49 (0)2831/91021-50
02/06/2020
Stored electrical charge
DANGER!
Risk of death by electrocution from stored
energy!
Electrical charge may be stored in electrical
components which could result in electrocution
causing injury or death.
- Before commencing work, turn of the power and
wait for 10 min before continuing, to allow the
capacitors time to discharge the stored current.
2.2.2 D a ng er of M e cha ni c al P arts
High pressure Waterjet
WARNING!
Risk of injury from high pressure water jet!
The high-pressure water jet can lead to severe
personal injury or property damage.
- Before starting work, make sure that all covers,
and safety devices are installed and working
properly.
- Do not reach into the beam during operation.
- Before replacing the cutting nozzles or other
wear parts, always pull the mains plug of the
high-pressure pump and switch off the machine
and secure it against being switched on again. Be
sure to release pressure in the line using a manual
valve before starting work.

Operating Instructions
flowJET Waterjet cutting machine
CNC-STEP GmbH & Co.KG ▪Siemensstrasse 13-15
▪47608 Geldern ▪ Germany
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Support: +49 (0)2831/91021-50
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Moving Axis
WARNING!
Risk of injury by moving axis!
Collisions between persons and machine (Y-Axis,
moving parts, Rotational axis, Tools) may lead to
serious injuries.
- Keep clear of moving parts and their end-stops
- Never reach between the machine and rails
- Only perform maintenance on linear guides when
machine is switched off
- Always wear protective clothing in the work
area.
Toothed Rack
WARNING!
Risk of injury by moving rack and pinion gear
While operating clothing, hair or body parts could
get caught in the rack and pinion leading to serious
injury.
- Never reach over toothed rack when machine is
switched on.
- Maintenance may only be performed while the
machine is turned off.
- Always wear protective clothing in the working
area.

Operating Instructions
flowJET Waterjet cutting machine
CNC-STEP GmbH & Co.KG ▪Siemensstrasse 13-15
▪47608 Geldern ▪ Germany
Page 16
Support: +49 (0)2831/91021-50
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Material dropping
WARNING!
Risk of injury by falling materials!
While operating off cut debris, materials or tools
may be ejected from the work area causing serious
injury to face or eyes
- Always wear face and eye protection, gloves, and
safety shoes
- In the event of an injury, contact the medical
personnel
Uncontrolled restart
WARNING!
Uncontrolled restart can cause serious personal
injury or death!
The machine could move unexpectedly or change
direction unexpectedly resulting in injury
- Keep body parts away from the machine working
area
- Secure work area against accidental access.

Operating Instructions
flowJET Waterjet cutting machine
CNC-STEP GmbH & Co.KG ▪Siemensstrasse 13-15
▪47608 Geldern ▪ Germany
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Support: +49 (0)2831/91021-50
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High pressure
Warning!
Risk of injury due to high pressure in the
Management!
After operation, the lines and valves for
conducting and regulating the water jet are still
under high pressure. Work on the lines and
valves can only be conducted in a pressure less
state. Before any kind of maintenance of the lines
and valves release the pressure via the hand
valve. If an abrasive conveyor is installed, there
will be pressure in the line to the abrasive
dispenser. The Conveyor is to be switched off
when working on the machine thereby releasing
the pressure.
Tools
Caution!
Risk of injury due to negligent handling of tools!
Negligent handling of the tools can cause bruises or
cut injuries.
- Tools are to be handled carefully and according to
their intended standards.
-Take weight into account when transporting tools.
-Wear protective gloves and safety shoes.
Sharp edges and corners
CAUTION!
Danger of injury from edges and corners!
Sharp edges and corners can cause skin-abrasions
and cuts.
- be cautious when working near sharp edges or
corners
- If necessary, wear protective gloves.

Operating Instructions
flowJET Waterjet cutting machine
CNC-STEP GmbH & Co.KG ▪Siemensstrasse 13-15
▪47608 Geldern ▪ Germany
Page 18
Support: +49 (0)2831/91021-50
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2.2.3 D a ng er d u e t o Hig h o r L ow Temp er atures
Hot Surfaces
CAUTION!
Danger of injury from hot surfaces!
Tools, workpieces, and chippings may heat up to
high temperatures. Contact with these surfaces
could result in severe burns to the skin
- When operating the tools or workpieces always
wear heat resistant clothing and gloves.
- Before starting work ensure that all surfaces
have reached ambient room temperature.
2.2.4 D a ng er of Fi re
Highly flammable materials
WARNING!
Danger of fire through flammable materials!
- Do not smoke near the working or danger area
and avoid open flames or other potential fire
risks.
- Always have a fire extinguisher near the machine
- In case of fire, stop working and evacuate the
area. Activate the fire alarm.

Operating Instructions
flowJET Waterjet cutting machine
CNC-STEP GmbH & Co.KG ▪Siemensstrasse 13-15
▪47608 Geldern ▪ Germany
Page 19
Support: +49 (0)2831/91021-50
02/06/2020
2.2.5 D a ng er of R a di atio n
Magnetic field radiation
DANGER!
Danger from magnetic field radiation!
Magnetic fields pose a danger to persons and
property
- Persons with Pacemakers should not work on or
approach the machine. The Pacemaker may be
affected.
- Persons with metal implants should not work on
or approach the machine. The implants may heat
up or be pulled towards the machine.
- Do not wear any jewellery like rings, necklaces,
watches etc. when operating the machine.
- Do not place any electronic equipment near the
magnetic fields as these may be damaged
- Do not place any data storage devices or credit
cards, etc. near the magnetic fields as these may
be wiped out.

Operating Instructions
flowJET Waterjet cutting machine
CNC-STEP GmbH & Co.KG ▪Siemensstrasse 13-15
▪47608 Geldern ▪ Germany
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Support: +49 (0)2831/91021-50
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2.2.6 D a ng er fro m Che mi c a l C o mpo unds
Cutting water
Fig.: 1
WARNING!
Danger from exposure to Cutting water!
Exposure of the skin to the cutting water
can result in irritation or chemical burning.
-Wear protective clothing and chemical-resistant
protective gloves when handling contaminated
water.
-Avoid direct skin contact. Remove skin
impurities immediately, especially before breaks
and after finishing work.
-Only eat and drink in the designated break room.
(Fig.:1)
CAUTION!
Health risk from exposure to Cutting water!
Contact with cutting water can be detrimental to
health.
- Avoid skin contact.
- Remove cutting water from the skin immediately.
- Do not inhale vapours.