Flow MACH 300 User manual

MACH 300 SYSTEM MANUAL
Includes Ancillary Options
M-810 | REV. C | en | APRIL 2021

About this content
Due to continuing product improvement, the inform tion cont ined in this document is subject to ch nge
without notice. Flow Intern tion l Corpor tion sh ll not be held li ble for technic l or editori l omissions
m de herein, nor for ny incident l or consequenti l d m ge resulting from the use of this m teri l.
Registered trademarks
In the United St tes, Dyn mic W terjet®, FlowCUT®, FlowM ster®, FlowNEST®, FlowPATH®,
FlowXpert®, HyperJet®, HyPlex®, P ser®, nd XD® re registered tr dem rks of Flow Intern tion l
Corpor tion.
Windows is either registered tr dem rk or tr dem rk of Microsoft Corpor tion in the United St tes
nd/or other countries.
All other registered tr dem rks shown re the property of their registered owners.
Copyright
This content cont ins inform tion protected by copyright. No p rt of this document sh ll be reproduced
in ny m nner without prior written consent from Flow Intern tion l Corpor tion.
© 2021 Flow Intern tion l Corpor tion. All rights reserved. ORIGINAL INSTRUCTIONS.
Other notes
◦ If you see reference to the number of "p ges" included in section, it is referring to the number of
rticles in th t section. It is not physic l p ge count. Simil rly, footnotes re t the end of n
rticle, not lw ys t the end of physic l p ge.
◦ Im ges shown re for gener l reference only nd m y v ry from ctu l product.
Symbols used in content
Disc rd p rt
Keep this p rt; you will inst ll it l ter in the procedure.
© 2021 Flow Intern tion l Corp.
Retrieved from Flow KB on April 12, 2021 PST

Service and Support
We've committed ourselves to the success of our customers for over 40 years. As a result, nearly 1 out
of every 3 systems built is delivered to repeat customers. We are proud to provide the largest and most
highly trained support team, with the experience to ensure your success.
United States & Canada
23500 64th Avenue South · Kent, Washington 98032 · USA
Tel: [phone]
Central America, South America, Mexico & Caribbean
Tel: [phone] or 8882
Europe, Middle East & Africa
Gutenbergstrasse 10 · D64331 Weiterstadt · Germany
Tel: [phone]
Taiwan, China, Korea, Southeast Asia, Australia & New Zealand
Tel: [phone]
Japan
Tel: [phone]
© 2021 Flow International Corp.
Retrieved from Flow KB on April 12, 2021 PST

Safety
Important! Read carefully before use. Keep for future reference.
Safety
Pages: 13
•How we show safety messages in content
How we show safety messages in content.
•Intended use statement
Review of what the intended use is, who the intended user is for systems—including
ancillary options—and modifications.
•Emergency medical information
Vital information to be given to medical personnel in case of emergency.
•Lockout/Tagout (LOTO)
Supplemental instructions to your facility Lockout/Tagout procedures. Includes instructions
for systems and CF900 hopper.
•Personal Protective Equipment (PPE)
Recommendations for PPE.
•Electrical safety
Includes instructions for the electrician.
•Exceptional or emergency situations
What to do if you come across these exceptional or emergency situations.
•Safety during cleaning
Safety precautions to follow during cleaning.
•Safety during maintenance
Follow these safety precautions while doing maintenance.
© 2021 Flow International Corp.
Retrieved from Flow KB on April 12, 2021 PST
Safety

•Safety during operation
Safety precautions to follow during operation.
•Safety for transport
Recommendations to follow if you have to transport the machine.
•Transporting the CF900 hopper
Recommendations for how-to transport the hopper.
•Safety labels
Includes information on safety labels and diagrams.
© 2021 Flow International Corp.
Retrieved from Flow KB on April 12, 2021 PST
Safety

How we show safety messages in content
In our content, safety messages are highlighted with the safety alert symbol and a signal word, only a
signal word, or only a signal word panel. Pay attention to these safety messages—they alert you to
hazardous situations!
Safety alert symbol
This is the safety alert symbol. It is used to alert you to potential physical injury hazards. Obey all
safety messages that follow this symbol to avoid possible injury or death.
Signal words
WARNING!
WARNING indicates a hazardous situation, which if not avoided, could result in death or serious
injury.
CAUTION!
CAUTION indicates a hazardous situation, which if not avoided, could result in minor or moderate
injury.
Signal word panels
DANGER indicates a hazardous situation, which if not avoided, will result in death
or serious injury.
NOTICE indicates a non-hazardous situation, which if not avoided, could result in
property damage.
© 2021 Flow International Corp.
Retrieved from Flow KB on April 12, 2021 PST
Safety

Intended use statement
Intended use
The machine is used to cut virtually any type of material, including metal, stone, glass, and
composites, across various industrial sectors.
Additional applications may be possible, but only with appropriate adjustments to the machine,
which must be discussed with the manufacturer. A new Conformity Evaluation may be required
and additional guidelines may then apply.
Any other use of the machine is not in accordance with its intended use and therefore not
permissible.
In particular, the machine is not meant for the processing of explosive materials or materials that
release explosive emissions. The machine may not be operated in areas that are vulnerable to
explosions. In addition, the machine is not designed for food processing.
During normal operation of the machine, the operator shall maintain a minimum safe distance of
1200 mm (48 in.) from each side of the machine.
Intended use for ancillary items
• The PASER CF900 Abrasive Delivery System (ADS) is designed for the continuous transport of
abrasive to the abrasive metering system located above the cutting head.
• Spreader bars allow a simple means of cutting small repetitive parts quickly, by duplicating the
same cutting action simultaneously across multiple cutting heads.
© 2021 Flow International Corp.
Retrieved from Flow KB on April 12, 2021 PST
Safety

Intended user
System operation and maintenance should be done by Flow-trained personnel. However, other
suitably trained personnel may also operate the system and do maintenance on it.
We recommend that all service work be done by Flow Service. However, other suitably trained
personnel may do service work on the system.
Work on the electrical or control system may only be done by trained, certified electricians.
Modifications
Modifications to the system, including all machine, pump, cutting head, software, and ancillary
components, is prohibited after the manufacturer distributes the system. If the system is altered
after distribution, conformity of the machine to the EC directives and standards no longer applies
and the CE mark must be removed.
We recommend the exclusive use of original replacement parts.
© 2021 Flow International Corp.
Retrieved from Flow KB on April 12, 2021 PST
Safety

Emergency medical information
WARNING! Obtain medical treatment immediately for ANY high-pressure waterjet injuries. Even
minor injuries that are painless or inconspicuous can lead to grave health problems.
It is vital that medical personnel have information about this type of injury. We recommend that anyone
who works with high-pressure waterjet equipment carry a waterproof medical alert card. This card
should describe their work and the nature of injuries inherent in using waterjets. You should also inform
medical personnel what type of abrasive you used and the type of material you cut.
© 2021 Flow International Corp.
Retrieved from Flow KB on April 12, 2021 PST
Safety

Medical Alert card part numbers (by language)
Czech …………… A-8466CZ
English …………… A-8466
French …………… A-8466F
German …………… A-8466G
Italian …………… A-8466I
Polish …………… A-8466PL
Portuguese …………… A-8466P
Russian …………… A-8466RU
Spanish …………… A-8466S
© 2021 Flow International Corp.
Retrieved from Flow KB on April 12, 2021 PST
Safety

Lockout/Tagout (LOTO)
Only trained personnel can do Lockout/Tagout. These instructions are supplemental to your facility
Lockout/Tagout procedures. We recommend your safety personnel approve all Lockout/Tagout
instructions for anyone who works around high-pressure waterjet equipment.
To do a Lockout/Tagout, do the following:
1. Jog the cutting head to a loading or safe position.
2. Close all programs, and then press the E-stop.
3. Select Start >Shut down to turn off the machine PC.
4. Wait until the machine PC is completely shut down, and then turn off the main power to the
machine (pump and machine disconnect).
5. Lock the interface enclosure, and then put an appropriate tag on the enclosure.
(Picture shown for general reference only and may vary from your machine model.)
6. Turn off the air and water supply.
© 2021 Flow International Corp.
Retrieved from Flow KB on April 12, 2021 PST
Safety

Lockout/Tagout for the CF900 hopper
To do a Lockout/Tagout for the hopper, do the following:
• Turn off the power switch, lock it, and then put an appropriate tag on it. Turn off the air supply to
the hopper.
© 2021 Flow International Corp.
Retrieved from Flow KB on April 12, 2021 PST
Safety

Personal Protective Equipment (PPE)
Personal protective equipment (PPE) is equipment worn to minimize exposure to serious workplace
injuries and illnesses. All PPE clothing and equipment should be of safe design and construction, and
should be maintained in a clean and reliable fashion.
We recommend your safety personnel approve all PPE for anyone who works around high-pressure
waterjet equipment.
Wear a mask! Wear a dust mask to reduce particle or dust inhalation when you
fill the abrasive delivery system with abrasive.
Wear eye protection! Wear safety glasses with side shields or safety goggles to
shield your eyes from flying debris and spray, including pressurized abrasive that
may leak from the hopper silo or hose.
Wear ear protection! Wear ear protection while the machine is in operation.
Wear protective clothing! Wear protective clothing to shield your body from
flying debris and spray.
© 2021 Flow International Corp.
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Safety

Wear protective gloves! Wear protective gloves when you handle sharp catcher
tank slats or have to work around dirty water in the catcher tank. When you clean
a hopper (ADS), wear gloves to prevent abrasive particles from penetrating any
skin abrasions.
Wear protective footwear! Wear steel or composite toe footwear.
© 2021 Flow International Corp.
Retrieved from Flow KB on April 12, 2021 PST
Safety

Electrical safety
Life threatening danger due to surge! Always assume that electrical components
are live. Always turn the main switch to the system off when working on the electrical system. Post a
sign “Maintenance in Progress—Do Not Energize.” Work on the electrical or control system may only be
done by trained, certified electricians. Work must be done in accordance with respective guidelines.
Instructions for the electrician
• If it necessary to work on live components, then a second person must be available to turn the
unit current off at the main switch in case of emergency.
• The main switch must always be turned off during maintenance work and service work on the
machine. It must be secured against unintentional activation with a lock for the length of the
work.
• To protect sensitive components in the machine control, the electrician must ground themselves
before working at the control computer and the PLC control.
• Only specified safety mechanisms of equal power and inertia should be used.
• Only measuring tools in accordance with respective guidelines should be used.
• Always take great care when the electrical system is being worked on.
• Only use insulated tools when working on the electrical system.
• All replacement wires or cables must conform to the manufacturer’s specifications, including
color coding, wire numbers, and size.
© 2021 Flow International Corp.
Retrieved from Flow KB on April 12, 2021 PST
Safety

Exceptional or emergency situations
Contact with special materials
Note the safety datasheets of the manufacturer when you handle colors, solvents or special
substances. Such substances must be stored in accordance with applicable ordinances
(Operational Facility Ordinance). Note the local wastewater regulations.
Electrostatic discharges
During cutting, the high flow rate of water and abrasive could cause electrostatic charging.
Discharges could lead to the ignition of flammable substances, dust, or gases. Ground all
components so that static electricity does not form a spark.
The machine comes with the appropriate grounding cables. If the cables are defective, replace
them immediately.
Emissions
Always pay attention to the data sheets of the material being cut! Although rare, flammable gases
could develop in the water if you cut materials (such as aluminum) that lead to aggressive oxide
formation. Work in a well-ventilated area to minimize exposure to vapors that could occur.
To avoid deflagrations, lower the water level in the catcher tank until the water is under the
bottom of the material.
Explosions
Do not operate the machine in areas that are vulnerable to explosions.
If you weld, do flame cutting, or use an angle grinder in close proximity to the machine, clean the
surrounding area and remove flammable materials. Under certain conditions, material dust can
lead to deflagration or explosion.
© 2021 Flow International Corp.
Retrieved from Flow KB on April 12, 2021 PST
Safety

Fire
If you cut flammable or difficult-to-extinguish materials, pay particular attention to fire prevention/
extinguish protocols.
Familiarize yourself with the exit routes at your facility. Know how to trigger a fire alarm. Know
where fire extinguishers/blankets are located and how to use them. Know what the appropriate
extinguisher is to use for the materials you process.
In the event of a fire, keep calm. Call the fire department, and follow evacuation protocols.
© 2021 Flow International Corp.
Retrieved from Flow KB on April 12, 2021 PST
Safety

Safety during cleaning
Follow these safety precautions during cleaning:
• Do not clean any part of your machine with the high-pressure water stream.
• Only use recommended cleaners (or equivalents) to clean your machine. Follow the safety
instructions given by the manufacturer of the cleaner.
• Only use cleaners in well-ventilated areas. Avoid prolonged breathing of fumes and contact with
skin or eyes.
Keep a clean work environment
• Keep the area around the machine clean and free of obstacles.
• Keep the floor clean and dry—abrasive residue, material dust, and water make the floor
slippery. We recommend that you use grid plates or anti-slip mats to reduce the risk of slipping.
• Do not use any part of the machine as a place to store things.
© 2021 Flow International Corp.
Retrieved from Flow KB on April 12, 2021 PST
Safety

Safety during maintenance
General
• Do a Lockout/Tagout on the system—including the machine, high-pressure pump, and all
ancillary equipment—before you do any maintenance. (Electrical and pneumatic air).
• Be alert at all times when doing maintenance on the machine.
• Do not patch damaged hoses—replace them.
• High-pressure water can remain in the system for an extended time after shutting down the
water source. Always bleed-down system pressure before servicing any part of the system.
• Do not exceed specified pressure setting limits for pneumatic or hydraulic components.
Exceeding these limits may result in serious injury to personnel or damage to the equipment.
• Torque all fittings to the manufacturer’s torque specifications.
• Follow the manufacturer’s recommendations for maintaining the equipment, and use only
original manufacturer replacement parts.
• Follow the manufacturer’s system startup procedure to ensure safe operation.
• Use care when lifting equipment covers during operation.
High-pressure system safety
• Do not patch high-pressure tubing—replace it.
• Welding on high-pressure component or high-pressure tubing is forbidden.
• Do not step on or lean against high-pressure tubing. Doing so could cause leaks.
• Do not touch weep holes with your bare hands or try to stop water by plugging the holes.
• Only use high-pressure fittings, valves, and tubing that are rated for the pressure of your
equipment [4150 bar (60,000 psi) or 6000 bar (87,000 psi)], depending on your configuration].
• Do not exceed specified operating pressures for high-pressure water system components.
© 2021 Flow International Corp.
Retrieved from Flow KB on April 12, 2021 PST
Safety

Tools
• Special tools could be provided for certain work. Only use these special tools for the work
intended. Follow the procedures for using the tool(s) to avoid injury or damaged components.
• If instructions call for the use of a certain tool, only use the tool specified to avoid injury or
damage components.
© 2021 Flow International Corp.
Retrieved from Flow KB on April 12, 2021 PST
Safety