Hypertherm Abrasive Regulator II User manual

Abrasive Regulator II™
Instruction Manual
809030 | Revision 0 | English

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Abrasive Regulator II
Instruction Manual
809030
Revision 0
English
Original Instructions
October 2015
Hypertherm Inc.
Hanover, NH 03755 USA
www.hypertherm.com

Abrasive Regulator II Instruction Manual 809030 5
Contents
Warranty ................................................................................................................................... SC-7
Environmental stewardship ................................................................................................ SC-9
Proper disposal of Hypertherm products ........................................................................................................................... SC-9
Particle emission and wastewater quality .......................................................................................................................... SC-9
Safety ...................................................................................................................................... SC-11
National and local safety regulations ................................................................................................................................ SC-11
User qualification and training ........................................................................................................................................... SC-11
Symbols and marks ............................................................................................................ SC-13
1 Terminology .................................................................................................................................. 15
2 Product description .................................................................................................................... 17
3 Operation ....................................................................................................................................... 19
Safety ................................................................................................................................................................................................ 19
Inspect the regulator before operation ..................................................................................................................................... 19
Operate the regulator ................................................................................................................................................................... 19
Adjust the regulator for a new abrasive .................................................................................................................................... 21
4 Preventive maintenance ............................................................................................................ 23
Safety ................................................................................................................................................................................................ 24
Replace worn plates ..................................................................................................................................................................... 25
Recalibrate the control knob ....................................................................................................................................................... 30
5 Parts lists ....................................................................................................................................... 31
Replacement parts ........................................................................................................................................................................ 32
Other parts ...................................................................................................................................................................................... 32
Complete list of preventive maintenance parts, tools, and materials ................................................................................. 33
6 Troubleshooting ........................................................................................................................... 35
7 Installation ..................................................................................................................................... 37
Safety ................................................................................................................................................................................................ 37
Buyer obligations ........................................................................................................................................................................... 37
Requirements .................................................................................................................................................................................. 38
Attach the abrasive regulator to the cutting table .................................................................................................................. 38
Connect the abrasive regulator to the solenoid valve ........................................................................................................... 40
Connect the abrasive regulator to the abrasive pot .............................................................................................................. 41
Do the first startup ......................................................................................................................................................................... 41
Recycling and end of product life .............................................................................................................................................. 42

6Abrasive Regulator II Instruction Manual 809030
Contents

Safety and compliance SC-7
Warranty
Warranty
Waterjet product warranty coverage
Consumable parts are not covered by this warranty. Consumable parts include, but are not limited to, high-pressure
water seals, check valves, cylinders, bleed-down valves, low-pressure seals, high-pressure tubing, and low- and
high-pressure water filters.
Product Parts coverage
HyPrecision pumps
27 months from the ship date,
or 24 months from the date of proven installation,
or 4,000 hours, whichever occurs first
Bulk abrasive hoppers 15 months from the ship date
or 12 months from the date of proven installation, whichever occurs first
Abrasive metering devices 15 months from the ship date
or 12 months from the date of proven installation, whichever occurs first
On/off valve air actuators 15 months from the ship date
or 12 months from the date of proven installation, whichever occurs first
Diamond orifices 600 hours of use with the use of a thimble filter
and compliance with Hypertherm’s water quality requirements

SC-8 Safety and compliance
Warranty
Warranty

Safety and compliance SC-9
Environmental stewardship
Environmental stewardship
Proper disposal of Hypertherm products
Hypertherm waterjet cutting systems, like all products with electronics, can contain materials or parts, such as printed
circuit boards, that can not be discarded with ordinary waste. It is your responsibility to dispose of Hypertherm
product or part in an environmentally suitable manner and in compliance with national and local codes.
In the United States, check all federal, state, and local laws. In the European Union (EU), check the EU directives,
national, and local laws. For more information, go to www.hypertherm.com/weee. In other countries, check national
and local laws. Consult with legal or other compliance experts when applicable.
Particle emission and wastewater quality
Hypertherm does not manufacture or supply the materials that are cut and has no knowledge whether the particles
released from materials that are cut will pose a physical hazard or health risk. Consult with your supplier or other
technical advisor if you need guidance concerning the properties of the material you will cut using a Hypertherm
product.
If you are not fully aware of and up to date on all applicable government regulations and legal standards for the
installation site, consult a local expert before purchasing, installing, and operating the equipment.

SC-10 Safety and compliance
Environmental stewardship
Environmental stewardship

Safety and compliance SC-11
Safety
Safety
National and local safety regulations
National and local safety regulations shall take precedence over instructions supplied with the product. The product
shall be imported, installed, operated, and disposed of in accordance with national and local regulations applicable to
the installed site.
User responsibilities
The end user is responsible for the safe operation of this equipment.
The safety precautions in this manual are general and can not anticipate every situation. Hypertherm Inc.
acknowledges that unforeseen situations due to equipment failure, site variability, insufficient maintenance, failure of
control equipment, and other events can cause equipment damage, injuries, or death. It is the user’s responsibility to
identify hazards and take the steps necessary to minimize risks.
Keep these instructions near the equipment. This manual is intended to familiarize the user with the equipment and its
parts, operation, and maintenance.
All people who operate or are exposed to this equipment must know this information:
Applicable safety standards
The use, limitations, and care of personal protective equipment
The location of the written hazard communication program and safety data sheets
User qualification and training
All users must read and understand these instructions before installing, operating, or doing maintenance on this
equipment.
Operators must be qualified to install, operate, and maintain this equipment. Training should include this information:
How to start and stop the equipment during routine operation and in an emergency situation
The conditions and actions that can lead to injuries to people and damage to the equipment
How to operate all controls
How to do maintenance procedures
A copy of this manual
This list is not all-inclusive.
Specific safety messages are included in the relevant sections of this manual.

SC-12 Safety and compliance
Safety
Safety

Safety and compliance SC-13
Symbols and marks
Symbols and marks
Information and hazard symbols
Some symbols in this table could be relevant to other products.
DANGER
This symbol identifies an imminently hazardous situation, which, if not avoided, will result in
death or serious injury.
WARNING
This symbol identifies a potentially hazardous situation, which, if not avoided, could result in
death or serious injury.
CAUTION
This symbol identifies a potentially hazardous situation, which, if not avoided, could result in
minor or moderate injury, or property damage.
WARNING
A waterjet is a cutting tool. A high-pressure injection injury is a surgical emergency. Seek
immediate medical treatment for all high-pressure waterjet injuries. Delayed treatment can
lead to serious injuries or death.
High-pressure water can cause eye injuries. Wear approved eye protection when operating
or working near this equipment.
Prolonged exposure to noise can cause permanent hearing loss. Wear approved ear
protection and control exposure time when operating or working near this equipment.
High-pressure water can cause severe cuts or lacerations, abrasions, and punctures. Wear
approved hand protection when operating or working near this equipment.
Precision parts have sharp corners or edges. Wear protective gloves when handling parts.
Some materials can produce airborne contaminants or suspended particles when cut. Wear
approved respiratory protection.
Refer to the instruction manual. Read and understand all of the safety guidelines in this
manual.
This symbol identifies a mandatory action.
This symbol identifies a prohibited action.
This symbol identifies tools or materials that are required or recommended for a procedure.
This symbol identifies a note or helpful information.

SC-14 Safety and compliance
Symbols and marks
Symbols and marks

Abrasive Regulator II Instruction Manual 809030 15
Terminology
Section 1
Terminology
Some terms could be relevant to other products.
abrasive
Fine mesh particles, typically garnet, used in the waterjet cutting process
abrasive delivery pot
Where abrasive is held before it goes to the abrasive regulator
bar
A unit of pressure; 1 bar equals 100 kPa or 14.5 psi or 100,000 N∙m2
control knob
A device used to adjust the abrasive flow rate to the cutting head
fitting
A coupling, valve, or gauge that stops, regulates, or directs the flow of water in a hose or a tube
flow rate
Measured in grams per minute 1 g/min = 0.0022 lb/min, or pounds per minute 1 lb/min = 453.6 g/min
high-pressure water
Water that has been pressurized by the intensifier for cutting or piercing
hose
A flexible hollow cylinder; dimensions are based on its inside diameter (ID)
inside diameter
The diameter measurement of the inside of a cylinder
ISO
The International Organization for Standardization is an independent membership organization that develops
voluntary standards

16 Abrasive Regulator II Instruction Manual 809030
Terminology
Terminology
kPa
A kilopascal is a unit of pressure; 1 kPa equals 0.01 bar or 0.15 psi or 1,000 N∙m2
low-pressure water
Water that is not pressurized by the intensifier
NPT
National pipe thread taper, a common United States standard for tapered threads that are used on fittings and
pipes
OEM
An original equipment manufacturer of machines that include Hypertherm products that are sold directly to end
users
outside diameter
The diameter measurement of the outside of a cylinder
psi
Pound-force per square inch is a unit of pressure; 1 psi equals 0.07 bar or 7 kPa or 6,894 N∙m2
regulator
The abrasive regulator
SAE
SAE International is a professional association of engineers and technical experts that coordinates the
development of technical standards based on best practices in the aerospace, commercial vehicle, and
automotive engineering; SAE Code 61 fittings are designed for 207 bar or 20,684 kPa (3000 psi) applications;
SAE Code 62 fittings are designed for 414 bar or 41,369 kPa (6,000 psi) applications
tube
A flexible hollow cylinder; dimensions are based on its outside diameter (OD); the inside diameter depends on the
thickness of the tube
valve
A device used to control the rate of flow in a hose or a tube

Abrasive Regulator II Instruction Manual 809030 17
Product description
Section 2
Product description
HyPrecision cutting systems use an abrasive during the cutting process to maximize cutting performance and ensure
quality results. The abrasive regulator is designed to be positioned above the cutting head and to receive abrasive
from a separate abrasive pot.
The abrasive moves from the pot through a feed hose to the regulator. Abrasive collects in the acrylic tube and then it
moves through the metering aperture, which permits abrasive to go to the cutting head.
The control knob changes the flow rate of abrasive to the cutting head. The control knob is marked from 1 to 10.
The flow rate is adjustable during cutting.
6
2
3
4
5
7
8
9
1
1Vent fitting
2Air cylinder fittings
3Air cylinder
4Control knob
5Delivery tube fitting
6Feed hose barb
7Acrylic tube
8Regulator body
9Regulator base

18 Abrasive Regulator II Instruction Manual 809030
Product description
Product description

Operation
Abrasive Regulator II Instruction Manual 809030 19
Section 3
Operation
Safety
Inspect the regulator before operation
Look for air leaks, deterioration, damage, or other conditions that can interfere with operation.
Make sure that all connections and fasteners are tight, including locking devices, hoses, hose clamps, and fittings.
Make sure that all operational and instructional marks are present and legible.
Operate the regulator
The regulator is air operated. Air is typically supplied by a 4-way 2-position solenoid valve. Refer to the diagram on
page 40.
Open the regulator
When air enters the cylinder’s outer connection the gate opens to permit abrasive to flow to the cutting head. The air
leaves the regulator through the inner connection to a vent.
Close the regulator
When air enters the cylinder's inner connection the gate closes and the abrasive stops flowing. The air leaves the
regulator through the outer connection to a vent.
Refer to the instruction manual. Read and understand all of the safety guidelines in this manual.
Examine and clean the regulator regularly. Make repairs immediately.
Keep the work area clean and free of fluid spills.

20 Abrasive Regulator II Instruction Manual 809030
Operation
Operation
Adjust the flow rate
Adjust the control knob to set the flow rate in pounds.
This chart is based on 80-mesh alluvial abrasive. Flow rates can vary due to grit size.
Suggested setpoints
Control knob
setting
Pounds per
minute (lb/min)
Grams per
minute (g/min)
Control knob
setting
Pounds per
minute (lb/min)
Grams per
minute (g/min)
1/3 0 0 5-1/3 0.65 295
2/3 0.025 11 5-2/3 0.72 327
1 0.075 34 6 0.8 363
1-1/3 0.1 45 6-1/3 0.88 399
1-2/3 0.125 57 6-2/3 0.95 431
20.1568 71.05476
2-1/3 0.18 82 7-1/3 1.15 522
2-2/3 0.2 91 7-2/3 1.25 567
3 0.25 113 8 1.38 626
3-1/3 0.3 136 8-1/3 1.5 680
3-2/3 0.35 159 8-2/3 1.62 735
4 0.4 181 9 1.7 771
4-1/3 0.45 204 9-1/3 1.8 816
4-2/3 0.5 227 9-2/3 1.92 871
5 0.58 263 10 2.2 998
Orifice/nozzle .010/.030 .011/.030 .012/.030 .014/.040 .016/.040
Control knob setting 5-1/3 5-2/3 6 7-1/3 7-2/3
3
2-2/3
2-1/3