Flow HYPLEX User manual

HYPLEX®PRIME PUMP
M-416 | REV.C|MAY2012

Due to continuing product improvement, the information contained in this document is subject to change without
notice. Flow International Corporation (Flow) shall not be held liable for technical or editorial omissions made herein,
nor for any incidental or consequential damage resulting from the use of this material.
This document contains information protected by copyright. No part of this document shall be reproduced in any
manner without prior written consent from Flow International Corporation.
HyPlex®, HyPlex® Hybrid, HyPlex® Prime, and Dynamic Waterjet® are registered trademarks of Flow International
Corporation.
© Copyright 2011-2012 Flow International Corporation. All rights reserved.
This document is the original, non-translated version.
2 | M-416 ©FlowInternationalCorporation
HYPLEX PRIME PUMP
Maintenance & Service Manual

© Flow International Corporation M-416 | 3
INTRODUCTION
HyPlex Prime Pump
Chapter 1. Equipment Description
Features 5
Specifications 6
Interface illustrations 7
Interface labels 10
Water requirements 11
Air requirements 12
Environment requirements 12
High-pressure tubing 12
Anti-vibration mat 13
Startup procedure 14
Temperature input offset adjustment routine 16
Calibrating the pump control system 16
Preparing the HyPlex Prime pump for
shipping or storage 17
Chapter 2. Safety
Safety precautions 19
Warnings, cautions, and notes 19
Safety tips 20
Protective clothing 21
Emergency medical information 22
Chapter 3. Maintenance & Troubleshooting
Periodic maintenance 23
General precautions 23
Inspection & maintenance schedules 25
Routine daily checks 25
Mandatory maintenance schedules 26
30 hp HyPlex Prime pump maintenance schedule 27
50 hp HyPlex Prime pump maintenance schedule 28
Troubleshooting the HyPlex Prime Premium pump
using FlowSENSE 29
FlowSENSE diagnostic codes 30
Troubleshooting the high-pressure components 32
Additional troubleshooting tips 32
Weep holes 32
Visual troubleshooting guide for
the high-pressure components 33
Troubleshooting table 34
Chapter 4. Service
Servicing the high-pressure pump 41
Service tips & notes 41
High-pressure components illustration 42
Using the pressure loading tool 43
Installing the Dynamic Seal Maintenance kit 45
Installing the Minor Maintenance kit 55
Installing the Major Maintenance kit 67
Installing the pressure control valve (PCV)
Maintenance kit 79
Changing the filter elements 83
Replacing the dynamic seal and plunger 84
Tensioning and aligning the belt drive 91
Servicing the belt 91
Servicing the crankcase 93
Chapter 5. Engineering Drawings
Drawing lists 95
Maintenance kits 97
Tools 99
Recommended spares 99

4 | M-416 ©FlowInternationalCorporation
HYPLEX PRIME
Maintenance & Service Manual
Introduction
The information in this manual will help you become familiar with your new Flow International (FLOW) equipment. It
was compiled from the most current information available at the time of publication and is intended to cover the most
common configurations. Your equipment was shipped with other documents and drawings. Refer to these drawings
when using the service procedures in this manual.
Safety
All operating personnel and service technicians must read and follow the comprehensive list of safety precautions in all
manuals provided with your equipment before installing, operating, or servicing the equipment. This will help avoid
creating unsafe conditions or equipment damage.
The high-pressure waterjet system is a powerful cutting tool and must always be treated with respect.
Warnings, cautions, and notes
Before operating the equipment, you must read, understand, and follow all warnings, cautions, and notes in this man-
ual. They are defined as follows:
WARNING
Highlights an operating or service procedure or condition that can
result in death or serious injury to personnel.
CAUTION
Highlights an operating or service procedure or condition that can
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.

CHAPTER 1
Equipment Description
The HyPlex Prime pump is a powerful, ultrahigh-pressure waterjet cutting tool designed for minimum maintenance
and reliable performance. The pump has an operating pressure of 55,000 psi (3790 bar), and a maximum generated
pressure of 60,000 psi (4140 bar).
Base features
•Triplex pump
•Totally-enclosed, fan cooled (TEFC) motor
•Manually adjustable output pressures from
1000–55,000 psi, dual-pressure control optional
•Dual filter system removes particles larger than
0.5 microns absolute
•Available in 30 or 50 hp motor, 60Hz or 50Hz
Basic package
For use with Flow X-Y tables prior to those introduced with B&R
controls.
•Motor starter is not included
Standard package
For use with B&R-controlled Flow X-Y tables.
•Motor starter is included
Plus package
For use with B&R-controlled Flow X-Y tables.
•UHP water system pressures are monitored by a
pressure transducer and displayed in FlowCUT
•Auto-calibration of UHP pressure control system
•Motor starter is included
Premium package
For use with B&R-controlled Flow X-Y tables.
•UHP water system pressures are monitored by a
pressure transducer and displayed in FlowCUT
•Auto-calibration of UHP pressure control system
•Motor starter is included
•FlowSENSE, an early warning system for critical parts
© Flow International Corporation M-416 | 5

Specifications
Contact FLOW Technical Service for further information.
Also see the system drawings in Chapter 5.
Dimensions
(with covers closed) 60 L x 40 W x 41 in. H
................................1524 L x 1016 W x 1042 mm H
(with covers open) 60 L x 40 W x 52 in. H
................................1524 L x 1016 W x 1321 mm H
Nominal crankcase RPM 50Hz 60Hz
30 hp....................................................716 709
50 hp..................................................1154 1114
Operating pressure...................55,000 psi (3790 bar)
Max. generated pressure ..........60,000 psi (4140 bar)
Filtration provided...............0.5 micron and 1 micron
Min. required inlet water flow rate
30 hp ...............................................2 gpm @ 57 psi
50 hp ...............................................3 gpm @ 65 psi
Low inlet water pressure switch threshold
........................................................................£15 psi
To ensure proper inlet water pressure, a boost pump may
be required.
Req. inlet water temperature range
.........................................55°F–70°F (12.7°C–21°C)
If plant inlet water temperature is outside of this range,
contact Flow Technical Service
Air.........................................90–120 psi (6.2-8.3 bar)
....................................dry and filtered to 10 microns
Drain............212°F (100°C) water at 0.9 gpm (30 hp)
.....................212°F (100°C) water at 1.5 gpm (50 hp)
Max. UHP orifice size
30 hp .......................................................-12 orifice
50 hp .......................................................-16 orifice
Voltage
Nominal
system
voltage **
Horsepower
(hp)
Frequency
(Hz)
Phase
200 * 50 *
200 * 60 *
208 * 60 *
230 * 50 *
240 30/50 60 3
380 * 60 *
400 30/50 50 3
480 30/50 60 3
500 * 60 *
* Not supported.
** Utilization voltage is often referenced, which will be
3-5% lower than the nominal system voltage. Where
referenced, the utilization voltage is equivalent to the
nameplate voltage of a product.
Crankcase oil
Use of Shell Morlina 100 Hydraulic Oil (ISO 100) is
recommended, but other manufacturer's equivalents
can be used.
When operating the pump in an environment with an
ambient temperature greater than 86°F (30°C), a
heavier oil is recommended to be used. Contact Flow
Technical Services for additional information.
Reservoir
capacity
2.0 qt (1.9 liter)
Maintain oil level between the high and low
level marks on the dipstick.
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HYPLEX PRIME PUMP
Maintenance & Service Manual

© Flow International Corporation M-416 | 7
CHAPTER 1
Equipment Description

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HYPLEX PRIME PUMP
Maintenance & Service Manual

© Flow International Corporation M-416 | 9
CHAPTER 1
Equipment Description

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HYPLEX PRIME PUMP
Maintenance & Service Manual
Interface labels
Inletwaterpressure(postfilter)
This gauge indicates water pressure after the inlet water has passed through
the 0.5 micron and 1.0 micron water filters.
Inlet water pressure (pre filter)
This gauge indicates water pressure before the inlet water has passed through
the 0.5 micron and 1.0 micron water filters.
High air pressure
This gauge indicates the air pressure supplied to the UHP pressure control
valve (PCV) as controlled by the regulator below the gauge.
On dual-pressure machines: this indicates the maximum air pressure setting.
Low air pressure
On dual-pressure machines, this indicates the minimum air pressure setting.
Inlet water connection
Connect inlet water at recommended specification.
Air inlet connection
Connect inlet air at recommended specifcation.
PCV to drain
Connect a drain line directly to an outlet drain at recommended specifica-
tions.
CAUTION
To ensure that the PCV does not suffer damage due to siphoned catcher tank
water, connect the PCV drain line directly to an outlet drain,
or suspend the line above the catcher tank water level.
High-pressure water outlet
Outlet port for ultrahigh-pressure (UHP) water.

© Flow International Corporation M-416 | 11
CHAPTER 1
Equipment Description
Water requirements
The HyPlex Prime pump requires a single source of
water, and one drain line.
Water quality
CAUTION
A high concentration of dissolved solids in the inlet water
(especially silicates and calcium) can reduce waterjet
nozzle life. 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 to
pre-treat the cutting water. Water quality should be
maintained to within the following limits:
•Total disolved solids: 17 ppm
•Water pH: between 6.5 and 9.5
Additional water quality requirements are specified in
the Inlet Water Quality document provided at pre-in-
stallation.
Water flow rate
Systems should be sized for 150% of your pump ca-
pacity, and should match your intended maximum
duty cycle.
Water temperature
An inlet water temperature of between 55°F and 70°F
(12.7°C and 21°C) is recommended for proper pump
performance. Premature pump component failure is
common if water temperatures are outside this range.
Inlet water chillers should be used if the inlet water
temperature is above this range.
Water interface connections
Flow recommends the installation of manual shut-off
valves in the inlet/cooling water line. Locate valves as close
as possible to the pump interface connection to make
them easier to service.
Water inlet lines must be non-corrosive pipe or rubber
hose. Rubber hose (per SAE Standard 20R1, 30R1, or
equivalent) is recommended.
Water inlet lines (from the filtering system to the pump)
must be as short as possible and must be PVC, copper, or
equivalent. Do not use galvanized iron piping or black
iron—it can introduce minerals to the water, which can
shorten component life.
•Connect inlet water line to pump bulkhead.
•Connect proper drain line to PCV bulkhead outlet.
CAUTIONS
To ensure that the PCV does not suffer damage due to
siphoned catcher tank water, connect the PCV drain line
directly to an outlet drain above the water line,
or suspend the line above the catcher tank water level.
Water exiting the PCV drain line is hot.

Air requirements
The HyPlex Prime pump requires a source of air be-
tween 90 and 120 psi (6.2 and 8.3 bar). The air must be
dry and filtered to 10 microns.
On the Basic and Standard versions of the pump, the
manual air regulator should be adjusted and set at the
point at which 55,000 psi water pressure is achieved
with the correct orifice installed and the nozzle open.
Environment requirements
Ambient temperature around the pump must be main-
tained between 45°F and 104°F (7°C and 40°C) to
ensure proper functioning of the pump.
High-pressure tubing
High-pressure tubing certified for continuous operation
at 60,000 psi (4140 bar) is used to route high-pressure
water from the HyPlex Prime pump to the cutting equip-
ment.
Note: Refer to manual M-127, Small High-pressure Com-
ponents for more information on high-pressure tubing,
components, and related service.
12 | M-416 ©FlowInternationalCorporation
HYPLEX PRIME PUMP
Maintenance & Service Manual

Anti-vibration mat
The anti-vibration mat is essential for the stability of the
HyPlex Prime pump and the reduction of pump vibra-
tion. The pump should be centered on the mat with no
part of the pump touching the floor beneath.
Place the mat flat on the floor and lower the pump onto
the center of the mat using a forklift.
A pallet jack may be also used to locate the pump, but
the mat should be slid under the pump when suspended
with the pallet jack. Pallet jacks loaded with the weight
of the pump will not roll on the anti-vibration mat.
Do not trim the mat or bolt the pump to the floor
through the mat material.
© Flow International Corporation M-416 | 13
CHAPTER 1
Equipment Description

Startup procedure
Preparing the pump for startup
Follow this procedure to make sure the pump is ready
for operation:
•Before the beginning of a shift
•After initial installation
•After installation of one of the HyPlex Prime
maintenance kits
1. Flush debris from all water supply hoses before con-
necting them to the pump.
CAUTION
Debris in the water supply line can cause
extensive damage to high-pressure components.
Such damage IS NOT covered by warranty.
2. Fill the pump case with a recommended oil (see the
list on Page 6). Fill the oil reservoir to the fill mark.
CAUTION
Never operate the pump without oil or with dirty oil—
this can cause extensive damage and
IS NOT covered by warranty.
3. Make sure water lines, air lines, and drain lines are
correctly connected and routed.
CAUTION
Cutting equipment and nozzles must be installed when
operating the pump. Operating the pump without proper
cutting nozzle will damage high-pressure components.
4. Clear tools, parts, and rags from around the pump.
Check in and around the pump for foreign objects
and debris.
5. Open any operator-supplied inlet water and air
valves; check all connections for leaks.
CAUTION
Operating the pump without an adequate supply
of inlet water will cause damage.
Do not tighten any loose or leaking connections while the
pump is operating or while the line is pressurized.
6. Make sure the belt guard is attached.
7. Place the main electrical disconnect in the ON
position.
8. Release the E-stop button(s).
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HYPLEX PRIME PUMP
Maintenance & Service Manual

Starting the Basic and Standard package
pumps
These are the steps to be performed at the initial startup
of a shift.
1. Check all connections for leaks.
2. Turn the manual air pressure regulator all the way
counter-clockwise.
3. Depress the red pressure relief buttons on both of
the inlet water filters to release any air.
4. Start FlowCUT and open a part file. Click the Run
Machine button. The screen will display the pump
on/off control.
5. Reduce the air pressure to the PCV to zero.
6. Click on the high-pressure selection in the sidebar.
7. Turn the pump on by clicking the pump ON button.
When the pump is spinning at full rpm, turn the
manual air pressure regulator clockwise until the
pressure display reads 55,000 psi of pressure.
Pressure is indicated on either the analog gauge (Ba-
sic) or on the digital display in FlowMaster (Stan-
dard). Operate the pump at this pressure for 5-10
minutes while checking for leaks. Correct as re-
quired.
CAUTION
Do not tighten any loose or leaking connections while the
pump is operating or while the line is pressurized.
The pump is now ready for use.
Starting the Plus and Premium package
pumps
These are the steps to be performed at the initial startup
of a shift.
1. Check all connections for leaks.
2. Depress the red pressure relief buttons on both of
the inlet water filters to release any air.
3. Run the HyPlex Prime pump Temperature Input Off-
set Adjustment routine on Page 16.
4. Run the Calibrating the pump control system routine
on Page 16.
5. Click on the low-pressure selection in the sidebar.
6. Turn the pump on for 5-10 minutes while checking
for leaks. Correct as required.
CAUTION
Do not tighten any loose or leaking connections while the
pump is operating or while the line is pressurized.
The pump is now ready for use.
© Flow International Corporation M-416 | 15
CHAPTER 1
Equipment Description

HyPlex Prime pump temperature input
offset adjustment routine
This routine applies to the Plus and Premium packages.
This software routine must be run each time the pump is
started at the beginning of a shift, and any time a
high-pressure pump component is replaced.
The routine reads the temperature inputs from the three
thermistors and calculates the relative value of each to
the lowest among the three. These relative values are
used in the calculation for continuous monitoring of the
cylinder temperature when the pump is running.
1. Make sure the pump is at room temperature. This is
important to get a uniform reading from each of the
thermistors.
2. Start FlowCUT, open a part file, and
go to the Run Machine screen.
3. Click on the Option Component
button in the sidebar. In the Option
Component dialog box that ap-
pears, scroll through the selections
to find the "Enable Temperature Sensor Offset Ad-
justment" option.
4. Enable the routine by clicking the numbered button.
Click Close to close the Option Component dialog
box.
5. Select low-pressure mode and click the Pump ON
button.
The pump will run at idle for about 45 seconds,
then go to low pressure. Pump pressure is indicated
in the status bar at the bottom of the FlowCUT Run
Machine screen.
6. When the pump goes to low
pressure, stop the pump, click
the Previous Screen button, then
click the Run Machine button to
make the routine adjustments ef-
fective.
Calibrating the pump control system
This applies to the Plus and Premium packages.
This software routine must be run each time the PCV
poppet is replaced, and whenever the pump output
pressure is significantly off the commanded pressure set-
ting.
The routine commands the pump to create pressure at
increasing set intervals and then adjusts the controls to
match each interval.
1. Start FlowCUT, open a part file,
and go to the Run Machine screen.
2. Position the cutting head away
from any material or tooling.
3. Click on the Option Component
button in the sidebar. In the Option
Component dialog box that appears,
scroll through the selections to find
the "Pressure Calibration" routine.
4. Enable the routine by clicking the numbered button.
Click Close to close the Option Component dialog
box.
WARNING
Waterjet nozzle will automatically open when finishing the
calibration routine. The cutting head must be positioned
away from any material or tooling.
5. Select low-pressure mode and click the Pump ON
button.
The pump will run at idle for about 45 seconds,
then go to low pressure (as specified by user settings
in Jet Setup). Pump pressure is indicated in the sta-
tus bar at the bottom of the FlowCUT Run Machine
screen.
6. When the pump goes to low
pressure, stop the pump, click
the Previous Screen button, then
click the Run Machine button to
make the routine adjustments effective.
16 | M-416 ©FlowInternationalCorporation
HYPLEX PRIME PUMP
Maintenance & Service Manual

Preparing the pump
for shipping or storage
Whenever a Flow pump is moved, put into storage,
or shipped, the following guidelines will help prevent
damage caused by movement or environmental condi-
tions. These instructions comply with transportation
regulations.
Note: U.S. Department of Transportation regulations re-
quire that crankcase oil be transported only in sealed
containers. Before shipping, remove all crankcase oil
from the reservoir.
Service steps
1. Disconnect power, turn off inlet water, and turn off
air.
2. Disconnect main motor lead terminals from the mo-
tor starter in the machine power enclosure. DO NOT
CUT LEADS. (Motor leads are terminated with eye
lugs and bolted to terminals from the motor starter
primary conductors.)
3. Disconnect the HP interface at the utilities bulk-
head.
4. Remove both filter canisters and empty out any wa-
ter.
5. Reattach the water filter canisters to the filter heads.
6. Remove the hose from the 1 micron filter outlet.
7. Apply compressed air to the 1 micron filter outlet
hose. Expelled water will be visible at the HP inter-
face connection at the utilities bulkhead. This should
expel most remaining water from the HP and LP cir-
cuits.
8. Reattach the hose to the 1 micron filter outlet.
9. Drain the water from the inlet water pressure gauge
lines at the end opposite the gauge. Reattach when
all water is expelled.
10. Drain the water from the inlet water line between
the utilities bulkhead and the inlet water shut-off so-
lenoid valve. Reattach after draining.
Plug fittings
11. Tie wrap the inlet water, drain, and air lines.
Crating
12. The pump must be shipped on a framed and rein-
forced wooden pallet designed to isolate and sup-
port its weight and load characteristics.
13. Secure the user interface console and motor starter
box so it cannot vibrate.
14. Wrap a plastic band around the horizontal circum-
ference of the pump, protecting all corners with
cardboard between the strap and the cover corner.
Wrap an additional plastic band around the top and
under the frame, also protecting corners with card-
board.
© Flow International Corporation M-416 | 17
CHAPTER 1
Equipment Description

Notes
18 | M-416 ©FlowInternationalCorporation
HYPLEX PRIME PUMP
Maintenance & Service Manual

CHAPTER 2
Safety
This chapter contains a comprehensive list of safety pre-
cautions that must be followed to ensure safe operation
of the equipment. These precautions must be read and
understood by everyone operating and maintaining the
equipment—before they start working with the equip-
ment. Note that OSHA and state safety agency rules
must be complied with in addition to those given in this
chapter and elsewhere in this manual. Applicable plant
general safety precautions must also be followed.
Safety precautions
FLOW designed your high-pressure waterjet cutting sys-
tem and related equipment with safety in mind.
Throughout the manual, safety precautions and warnings
for specific operations are highlighted. Safety precautions
are 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 system
must treat the system as they would treat any high-speed
cutting tool. Although the waterjet may appear harmless,
it is a high-energy cutting tool capable of cutting many
non-metallic materials such as composites, plastics, and
wood products. Misuse of this equipment or carelessness
in its application can be extremely hazardous to operat-
ing personnel. Always treat the waterjet cutting system
with respect.
Warnings, cautions, and notes
Service procedures in the waterjet manuals include
safety 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:
WARNING
An operating condition or service
procedure that can result in death or
serious injury to personnel.
CAUTION
Highlights an operating condition or service
procedure that can lead to impaired system
operation or equipment damage.
Note:Highlights an operating or service procedure or
condition that is considered essential for efficient opera-
tion and service.
Replacement label
•Part number 006317-1
3.75 x 6 in.
•Part number 009837-1
1.8 x 3 in.
© Flow International Corporation M-416 | 19

Safety tips
•Do not allow the waterjet stream to touch any part
of your body—it will cause serious injury. Do not
point the waterjet at anyone.
•During equipment maintenance, take the system out
of service. The controls must be properly locked and
marked with a warning sign.
•All personnel required to perform any system oper-
ating or service function must pay particular atten-
tion to all warning signs and notices posted in the
plant and on the equipment.
•All protective guards, shields, and covers must be in
place on the equipment at all times.
•First aid facilities shall be provided in convenient lo-
cations throughout the plant. These locations must
be known by all personnel.
•Always keep the work area around the equipment
clean and free of debris. Oil spillage results in slip-
pery floors and must be cleaned up immediately.
•Any unfavorable conditions that may result in inju-
ries shall be reported to the plant supervisor
immediately.
•As a general practice, it is recommended that safety
shoes, glasses, and hearing protection be worn by all
personnel working around the equipment. Do not
wear rings, watches, or necklaces when working
around any equipment 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.
•Do not use incorrect tools—it can cause injury or
costly damage to equipment.
•Never climb on or around the equipment on make-
shift devices. Use only approved catwalks, ladders,
or platforms.
•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.
•Shield and bundle equipment hoses and cables so
they do not obstruct the operator’s freedom of
movement.
•Always be alert when working around the
equipment.
•Clear all tools, parts, and rags from moving parts af-
ter servicing the equipment.
Electrical system
•Only a certified electrician shall perform electrical
and/or electronic troubleshooting and servicing of
electrical devices.
•Always assume that power is ON in all electrical sys-
tems. Always check and lock out the main power
switches before servicing the equipment. Post a sign,
“Maintenance in Progress—Do Not Energize.”
•Be aware that live electrical circuits are present in
the control console whenever the master disconnect
is on, regardless of whether the E-Stop is engaged.
•Disconnect circuit breakers and lock them in the
OFF position before servicing the electrical system. If
this isn’t possible, have someone stand by to prevent
someone from powering up the system.
•Take extra precautions when servicing the power sys-
tem in a damp environment.
•Never alter or bypass protective interlocks or devices
unless specifically instructed to do so, and only if all
precautions are followed.
•You must give capacitors sufficient time for dis-
charge. If this is not possible, discharging should be
done manually and with care.
•Do not use jumper wires across fuses, fuse holders,
or breakers.
•Make sure all tools are properly insulated for the job.
Use only proper test apparatus; check regularly to
make sure it is working correctly. Use caution when
connecting a test probe to test points.
•All replacement wires shall conform to the manufac-
turer’s specifications, including color coding, wire
numbers, and size.
•Close the control panel doors or junction box covers
after servicing.
Waterjet system
•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 touch weep holes with your bare hands or
try to stop water by plugging the holes.
•Remember that the waterjet stream is a knife. Do
not introduce anything into its path that you do not
intend to cut.
20 | M-416 ©FlowInternationalCorporation
HYPLEX PRIME PUMP
Maintenance & Service Manual