Hypertherm EcoSift User manual

EcoSift™
Waterjet abrasive recycling system
Operator Manual
809500 | Revision 0 | English

EcoSift, PowerDredge, and Hypertherm are trademarks of Hypertherm Inc. and may be registered in the United States and other
countries. All other trademarks are the property of their respective holders.
One of Hypertherm's long-standing core values is a focus on minimizing our impact on the environment. Doing so is critical to our, and
our customers', success. We are always striving to become better environmental stewards; it is a process we care deeply about.
© 2017 Hypertherm Inc.

EcoSift
Operator Manual
809500
Revision 0
English
Original instructions
November 2017
Hypertherm Inc.
Hanover, NH 03755 USA
www.hypertherm.com

Hypertherm Inc.
Etna Road, P.O. Box 5010
Hanover, NH 03755 USA
603-643-3441 Tel (Main Office)
603-643-5352 Fax (All Departments)
[email protected] (Main Office Email)
800-643-9878 Tel (Technical Service)
[email protected] (Technical Service Email)
800-737-2978 Tel (Customer Service)
[e-mail] (Customer Service Email)
866-643-7711 Tel (Return Materials Authorization)
877-371-2876 Fax (Return Materials Authorization)
[email protected] (RMA email)
Hypertherm México, S.A. de C.V.
Avenida Toluca No. 444, Anexo 1,
Colonia Olivar de los Padres
Delegación Álvaro Obregón
México, D.F. C.P. 01780
52 55 5681 8109 Tel
52 55 5683 2127 Fax
[e-mail] (Technical Service Email)
Hypertherm Plasmatechnik GmbH
Sophie-Scholl-Platz 5
63452 Hanau
Germany
00 800 33 24 97 37 Tel
00 800 49 73 73 29 Fax
31 (0) 165 596900 Tel (Technical Service)
00 800 4973 7843 Tel (Technical Service)
[email protected] (Technical Service Email)
Hypertherm (Singapore) Pte Ltd.
82 Genting Lane
Media Centre
Annexe Block #A01-01
Singapore 349567, Republic of Singapore
65 6841 2489 Tel
65 6841 2490 Fax
[email protected] (Marketing Email)
TechSupportAP[email protected] (Technical Service Email)
Hypertherm Japan Ltd.
Level 9, Edobori Center Building
2-1-1 Edobori, Nishi-ku
Osaka 550-0002 Japan
81 6 6225 1183 Tel
81 6 6225 1184 Fax
[e-mail] (Main Office Email)
TechSupportAP[email protected] (Technical Service Email)
Hypertherm Europe B.V.
Vaartveld 9, 4704 SE
Roosendaal, Nederland
31 165 596907 Tel
31 165 596901 Fax
31 165 596908 Tel (Marketing)
31 (0) 165 596900 Tel (Technical Service)
00 800 4973 7843 Tel (Technical Service)
[email protected]
(Technical Service Email)
Hypertherm (Shanghai) Trading Co., Ltd.
B301, 495 ShangZhong Road
Shanghai, 200231
PR China
86-21-80231122 Tel
86-21-80231120 Fax
86-21-80231128 Tel (Technical Service)
[email protected]
(Technical Service Email)
South America & Central America: Hypertherm Brasil Ltda.
Rua Bras Cubas, 231 – Jardim Maia
Guarulhos, SP – Brasil
CEP 07115-030
55 11 2409 2636 Tel
[email protected] (Technical Service Email)
Hypertherm Korea Branch
#3904. APEC-ro 17. Heaundae-gu. Busan.
Korea 48060
82 (0)51 747 0358 Tel
82 (0)51 701 0358 Fax
[email protected] (Marketing Email)
TechSupportAP[email protected]
(Technical Service Email)
Hypertherm Pty Limited
GPO Box 4836
Sydney NSW 2001, Australia
61 (0) 437 606 995 Tel
61 7 3219 9010 Fax
[email protected] (Main Office Email)
TechSupportAP[email protected]
(Technical Service Email)
Hypertherm (India) Thermal Cutting Pvt. Ltd
A-18 / B-1 Extension,
Mohan Co-Operative Industrial Estate,
Mathura Road, New Delhi 110044, India
91-11-40521201/ 2/ 3 Tel
91-11 40521204 Fax
[e-mail] (Main Office Email)
TechSupportAP[email protected]
(Technical Service Email)
1/28/16

5EcoSift Operator Manual 809500
Contents
Warranty .................................................................................................................................... SC-9
Product stewardship ............................................................................................................SC-11
Declaration of conformity ......................................................................................................................................................SC-12
Environmental stewardship ............................................................................................... SC-15
Safety ....................................................................................................................................... SC-17
This manual ..............................................................................................................................................................................SC-17
Residual risks ...........................................................................................................................................................................SC-17
User training .............................................................................................................................................................................SC-18
Lifting hazards .........................................................................................................................................................................SC-19
Damaged machinery and parts ...........................................................................................................................................SC-19
Work area .................................................................................................................................................................................SC-19
Personal protective equipment ............................................................................................................................................SC-20
Symbols and marks ............................................................................................................. SC-21
1 Terminology .................................................................................................................................. 27
2 Product description .................................................................................................................... 33
Overview ...........................................................................................................................................................................................34
EcoSift hopper ................................................................................................................................................................................36
Waste hopper ..................................................................................................................................................................................36
Waste-abrasive collection bag (optional) .........................................................................................................................37
EcoSift unit .......................................................................................................................................................................................37
Operation panel ......................................................................................................................................................................38
Diaphragm pumps ..................................................................................................................................................................39
3 Options ........................................................................................................................................... 41
Voltage ......................................................................................................................................................................................41
Waste hopper ..........................................................................................................................................................................41
4 Operation ....................................................................................................................................... 43
Safety ................................................................................................................................................................................................43
Operation panel ..............................................................................................................................................................................44
Turn ON the EcoSift ......................................................................................................................................................................47
Examine the machine before operation .............................................................................................................................47
Prepare the EcoSift ................................................................................................................................................................48
Start the EcoSift ......................................................................................................................................................................49
Turn OFF the EcoSift .....................................................................................................................................................................50
Routine stop .............................................................................................................................................................................50
Stop for maintenance, repair, or at the end of the day ..................................................................................................51

6EcoSift Operator Manual 809500
Contents
Emergency stop ......................................................................................................................................................................51
Operator interface screens ..........................................................................................................................................................52
Home screen (RUNNING PAGE) .......................................................................................................................................52
MENU screen ..........................................................................................................................................................................53
ABRASIVE RECYCLE RATE TREND screen ..................................................................................................................55
FAULTS screen .......................................................................................................................................................................56
I/O STATUS screen ...............................................................................................................................................................56
Component on/off screens ..................................................................................................................................................57
FEED PUMP screen ...............................................................................................................................................................59
TIME screen .............................................................................................................................................................................60
CONSUMABLES screens ...................................................................................................................................................61
OPTIONS screen ...................................................................................................................................................................63
SCALE WEIGHT/PROCESS TEMPERATURE screen ................................................................................................64
5 Preventive maintenance ............................................................................................................ 65
Benefits of preventive maintenance ...........................................................................................................................................65
Safety ................................................................................................................................................................................................66
Training .............................................................................................................................................................................................67
Preventive maintenance schedule ..............................................................................................................................................68
Special tools ....................................................................................................................................................................................68
Cooling time .....................................................................................................................................................................................69
Examine the EcoSift unit ...............................................................................................................................................................70
Examine the EcoSift hopper .........................................................................................................................................................70
Replace the recycled-abrasive collection bag .................................................................................................................71
Replace the hopper wear plate ...........................................................................................................................................73
Examine the waste hopper ...........................................................................................................................................................76
Replace the waste-abrasive collection bag ......................................................................................................................76
Clean the waste hopper ........................................................................................................................................................81
Examine the sprayer head .............................................................................................................................................................83
Examine the primary screen .........................................................................................................................................................84
Replace the primary screen ..................................................................................................................................................84
Replace the ball carrier screen ............................................................................................................................................88
Examine the secondary screen ....................................................................................................................................................89
Empty the secondary screen waste container .................................................................................................................89
Examine the dryer box ...................................................................................................................................................................90
Monitor the dryer box ammeter ............................................................................................................................................90
Replace a dryer box component or remove a blockage ................................................................................................91
Replace the dryer blower air filter .......................................................................................................................................93
Examine the diaphragm pumps ...................................................................................................................................................94
Repair a diaphragm pump ....................................................................................................................................................96
Start the EcoSift after maintenance ........................................................................................................................................109

EcoSift Operator Manual 809500 7
Contents
Long-term storage .......................................................................................................................................................................109
Recycling and end of product life ............................................................................................................................................110
Preventive maintenance records ..............................................................................................................................................111
6 Parts ..............................................................................................................................................113
7 Troubleshooting .........................................................................................................................117
Safety ..............................................................................................................................................................................................117
Uncontrolled shutdown ..............................................................................................................................................................118
After an uncontrolled shutdown .......................................................................................................................................118
Warnings and faults ....................................................................................................................................................................119
Remove a warning or a fault ..............................................................................................................................................120
Warning and fault descriptions ........................................................................................................................................121
Diaphragm pumps .......................................................................................................................................................................127
A diaphragm pump does not operate .............................................................................................................................127
A diaphragm pump operates slowly ................................................................................................................................128
The water flow is slow ........................................................................................................................................................130
Abrasive returns to the cutting table tank ......................................................................................................................131
8 Specifications .............................................................................................................................133
EcoSift unit ....................................................................................................................................................................................133
Safety ......................................................................................................................................................................................133
Electric power .......................................................................................................................................................................133
Environmental ratings ..........................................................................................................................................................134
Diaphragm pumps ...............................................................................................................................................................134
Hoppers .........................................................................................................................................................................................135
EcoSift hopper ......................................................................................................................................................................135
Waste hopper .......................................................................................................................................................................135
9 Installation ...................................................................................................................................137
Safety ..............................................................................................................................................................................................137
Buyer obligations .........................................................................................................................................................................138
Planning .........................................................................................................................................................................................138
Location ..................................................................................................................................................................................139
Requirements ........................................................................................................................................................................140
Receive and unpack the equipment ........................................................................................................................................142
EcoSift unit ............................................................................................................................................................................142
EcoSift hopper ......................................................................................................................................................................142
Parts ........................................................................................................................................................................................143
Waste hopper .......................................................................................................................................................................145
Install the EcoSift .........................................................................................................................................................................146
Special tools .........................................................................................................................................................................146

8EcoSift Operator Manual 809500
Contents
Install the EcoSift unit ......................................................................................................................................................... 147
Install the EcoSift hopper ................................................................................................................................................... 156
Install the waste hopper ..................................................................................................................................................... 157
Connect the hoses ..............................................................................................................................................................161
Connect the electric power ............................................................................................................................................... 162
Install the abrasive collection components .................................................................................................................... 166
Do the first startup ....................................................................................................................................................................... 168
Examine the EcoSift before operation ............................................................................................................................ 168
Prepare the EcoSift ............................................................................................................................................................. 169
Start the EcoSift ................................................................................................................................................................... 170
10 Technical drawings ...................................................................................................................173

Safety and compliance SC-9
Warranty
Warranty
Waterjet product warranty coverage
Hypertherm’s warranty does not cover any defect, failure, damages, deficiency, or error that is:
not reported to Hypertherm in the warranty period; or
due to modification, abuse, misuse, noncompliance with the installation or operation instructions,
unauthorized repair, improper maintenance, neglect, accident, or the use of unapproved parts; or
due to normal wear; or
if the system has been operated contrary to Hypertherm’s instructions or stated limits of rated and normal
use.
For full details of the manufacturer’s warranty, refer to the conditions of sale provided when the product was
purchased.
Consumable parts are not covered by this warranty. Consumable parts include screens, hoses, and abrasive
collection bags.
Third-party pumps, hoppers, dryer boxes, dryer box accessories, and plumbing accessories are covered by the
respective manufacturers' warranties and are not covered by this warranty.
Product Warranty coverage up to:
HyPrecision pump
27 months from the ship date,
or 24 months from the date of proven installation,
or 4,000 hours of operation, whichever occurs first
PowerDredge™ abrasive
removal system
15 months from the ship date,
or 12 months from the date of proven installation, whichever occurs first
EcoSift™ abrasive recycling
system
15 months from the ship date,
or 12 months from the date of proven installation, whichever occurs first
Reverse osmosis system 15 months from the ship date,
or 12 months from the date of proven installation, whichever occurs first
Bulk abrasive pot 15 months from the ship date,
or 12 months from the date of proven installation, whichever occurs first
Abrasive regulator 15 months from the ship date,
or 12 months from the date of proven installation, whichever occurs first
On/off valve air actuator 15 months from the ship date,
or 12 months from the date of proven installation, whichever occurs first
Diamond orifice 600 hours of operation with the use of a thimble filter and compliance with
Hypertherm’s water quality requirements

SC-10 Safety and compliance
Warranty
Warranty
Disclaimer
Product information contained in this manual is believed to be reliable as of the date of publication. The content in
this manual may contain technical inaccuracies or typographical errors. This manual can be changed or updated
without notice.

Safety and compliance SC-11
Product stewardship
Product stewardship
Hypertherm maintains a global regulatory management system to make sure that products comply with regulatory
and environmental requirements.
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 discarded in compliance with national and local regulations
applicable to the installation site.
Certification test marks
Certified products are identified by 1 or more certification test marks from accredited testing laboratories. The
certification test marks are on or near the data plate.
Each certification test mark means that the product and its safety-critical parts conform to the national safety
standards as reviewed and determined by that testing laboratory. Hypertherm puts a certification test mark on its
products only after that product is manufactured with safety-critical parts that have been approved by the
accredited testing laboratory.
After the product has left the Hypertherm factory, the certification test marks are invalid if any of these events
occurs:
The product is modified in a manner that creates a hazard or nonconformance with the applicable standards.
Safety-critical parts are replaced with unapproved spare parts.
Assembly is unauthorized.
An accessory that uses or generates a hazardous voltage is added.
A safety circuit or other feature that is designed into the product as part of the certification has been
tampered with.
The Conformité Européene (CE) mark affixed to a product signifies the manufacturer’s declaration of conformity
to applicable European directives and standards.
Only those versions of Hypertherm products with a CE mark on or near the data plate have been tested for
compliance with the applicable European directives, such as the Low Voltage Directive, the Electromagnetic
Compatibility Directive, the Pressure Equipment Directive, and the Machinery Directive.
To see the Declaration of Conformity in English and other languages:
1. Go to www.hypertherm.com/docs.
2. Select Waterjet Family in the Product/Product type dropdown list.
3. Select Regulatory in the Category dropdown list.
The navigation instructions can change without notice.

SC-12 Safety and compliance
Product stewardship
Product stewardship
Declaration of conformity

Safety and compliance SC-13
Product stewardship
Differences in national standards
Nations can apply different performance, safety, or other standards. Differences in national standards include, but
are not limited to:
Voltage
Plug and cord ratings
Language requirements
Electromagnetic compatibility requirements
Differences in standards can make it impossible or impractical for all certification test marks to be put on the
same version of a product. For example, the Canadian Standards Association (CSA) versions of Hypertherm’s
products do not comply with European electromagnetic compatibility requirements and therefore do not have a
CE mark on the data plate.
Countries that require a CE mark or have compulsory electromagnetic compatibility regulations must use CE
versions of Hypertherm products with the CE mark on the data plate. These may include, but are not limited to:
Countries in the European Union
Australia
New Zealand
Russia
It is important that the product and its certification test mark be suitable for the end-use installation site. When
Hypertherm products are shipped to one country for export to a different country, the product must be configured
and certified correctly for the end-use installation site.
Higher-level systems
When an original equipment manufacturer (OEM) or a system integrator adds equipment such as cutting tables,
motor drives, motion controllers, or robots to a Hypertherm waterjet cutting system, the combined system is
considered a higher-level system. A higher-level system with hazardous moving parts can constitute industrial
machinery or robotic equipment, in which case the OEM, system integrator, or end-use customer can be subject
to more regulations and standards than those applicable to the waterjet cutting system manufactured by
Hypertherm.
It is the responsibility of the end-use customer and the OEM or system integrator to do a risk assessment for the
higher-level system and to provide protection against hazardous moving parts. Unless the higher-level system is
certified when the OEM or system integrator incorporates Hypertherm products into it, the installation can be
subject to approval by local authorities. Get advice from legal counsel and local regulatory experts if you are
uncertain about compliance.
External interconnecting cables between parts of the higher-level system must be suitable for exposure to
contaminants and movement as required by the final end-use installation site. When the external interconnecting
cables are subject to exposure to oil, dust, water, or other contaminants, hard usage ratings can be required.
When external interconnecting cables are subject to continuous movement, constant flexing ratings can be
required. It is the responsibility of the OEM, system integrator, or end-use customer to make sure that external
interconnecting cables are suitable for the application and comply with all national, state, and local regulations.

SC-14 Safety and compliance
Product stewardship
Product stewardship

Safety and compliance SC-15
Environmental stewardship
Environmental stewardship
Hypertherm products: waste and recycling
Hypertherm waterjet cutting systems, like all products with electronics, can contain materials or parts, such as
printed circuit boards, that cannot be discarded with ordinary waste. It is your responsibility to discard
Hypertherm product or part in an environmentally suitable manner and in compliance with national and local
codes.
In the United States, read all national, state, and local laws. In the European Union (EU), read the EU directives,
national, and local laws. In other countries, refer to national and local laws. Consult with legal or other compliance
experts when applicable. For more information, go to
www.hypertherm.com/customer-support/product-service/recycling.
Chemical handling and usage
Material safety data sheets (MSDS) and safety data sheets (SDS) are part of a hazard communication plan that
supplies detailed information about hazardous chemicals. The information includes the chemical’s toxicity and
reactivity, first aid for exposure, approved storage and disposal, recommended protective equipment, and
spill-handling procedures.
The Occupational Safety and Health Administration (OSHA) has presented new hazardous chemical labeling
requirements as a part of its recent revision of the Hazard Communication Standard (29 CFR 1910.1200), to
align with the United Nations’ Globally Harmonized System of Classification and Labelling of Chemicals (GHS).
The GHS is an international system for standardizing chemical classification and labeling.
Chemical regulations in the USA, Europe, and other locations require that MSDS and SDS be made available for
chemicals that are supplied with the product and chemicals used in or on the product. The list of chemicals is
supplied by Hypertherm.
To see MSDS and SDS:
1. Go to www.hypertherm.com/docs.
2. Select Waterjet Family in the Product/Product type dropdown list.
3. Select Material Safety Data Sheets in the Category dropdown list.
The navigation instructions can change without notice.
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 can pose a physical hazard or health risk. Consult with your supplier or other
technical advisor for guidance concerning the properties of the material you 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-16 Safety and compliance
Environmental stewardship
Environmental stewardship

Safety and compliance SC-17
Safety
Safety
The end user is responsible for the safe operation of this system.
The safety precautions in this manual are general and cannot anticipate all situations. Hypertherm acknowledges
that unforeseen situations such as 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 to take the steps necessary to minimize risks.
This manual
Copies of the manuals may accompany the product in electronic and printed formats. To see an electronic copy
of a manual in all languages available for each manual:
1. Go to www.hypertherm.com/docs.
2. Select Waterjet Family in the Product/Product type dropdown list.
3. Select Manuals/Service Information in the Category dropdown list.
The navigation instructions can change without notice.
Residual risks
Many safety enhancements have been included in this system. Despite all precautions, some residual risks can
exist.
Some sections of this manual include safety information specific to the section. Read and
understand all of the safety guidelines in this manual.
WARNING
Before operating any Hypertherm equipment, read the safety instructions in the product's manual.
Failure to obey safety instructions can cause personal injury or damage to equipment.
Keep this manual near the system. The manual is intended to familiarize the user with the EcoSift
and its parts, safe operation, and maintenance.

SC-18 Safety and compliance
Safety
Safety
User training
Users must read and understand these instructions before installing, operating, or doing maintenance on this
system.
Do not let an untrained person operate this system. Only approved personnel can operate, maintain, and repair
the machinery. Training must include this information:
How to start and stop the system during routine operation and in an emergency situation
The conditions and actions that can lead to injuries to personnel and damage to the system
How to operate all controls
How to identify and respond to a problem with the system
How to do maintenance procedures
A copy of the operator manual
This list is not all-inclusive.
Personnel who operate or are exposed to this machinery 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
How to recognize hazardous energy sources
The correct methods for isolating and controlling energy.
Foreseeable misuse
Do not use this system in a manner not specified by Hypertherm or for a purpose for which it is not
intended. Such use may impair the protections provided by the system.
DANGER
• Personnel who maintain and repair this machinery can be seriously injured or killed if
hazardous energy is not controlled. Injuries can include burns, cuts, fractures, or
electrocution.
• Disconnect and lock out the electric power supply before opening the electrical enclosure or
doing maintenance or repair procedures.
• Isolate all sources of electric, mechanical, hydraulic, pneumatic, chemical, thermal, and other
energy with a lockable energy-isolating device that meets local and national requirements.
Refer to Safety on page 66.
DANGER
• Personnel who work on deenergized machinery can be seriously injured or killed if the
machinery is reenergized without permission.
• All personnel must respect lock-out devices. Only the person(s) who applied the devices
shall remove them.
• All personnel in an area where energy-control procedures are used must receive training
regarding the energy-control procedure and the prohibition against removing a lock-out
device.

Safety and compliance SC-19
Safety
Lifting hazards
Damaged machinery and parts
Use the emergency stop knob to stop the system immediately. Refer to Emergency stop on page 51.
Use a lock-out device according to the work site’s policy to isolate and control energy.
Make sure that all warning decals are maintained so that they are visible and can be read. Do not cover, block, or
remove any warnings, cautions, or instructional materials.
Work area
Safe operation of this system includes keeping the area around the machinery clean, dry, and organized.
Keep work areas clear of tripping hazards and loose items.
WARNING
• Lifting must be done by a trained operator.
• Obey all work site-safety requirements, the safety instructions for the lifting equipment, and the
safety information in this manual.
• Misuse of lifting equipment can cause the load to become unstable, which can cause property
damage, personal injury, or death.
WARNING
Do not operate the EcoSift when it is damaged or broken.

SC-20 Safety and compliance
Safety
Safety
Personal protective equipment
Personal protective equipment is important for keeping operators, those working in the area near the machinery,
and maintenance personnel safe. Obey your company’s safety program in all aspects of safety, to include the use
of personal protective equipment.
Other clothing
Abrasive dust and particles can cause rashes, abrasions, and other irritations. Wear long sleeves and long pants
to protect skin.
Wear approved personal protective equipment such as goggles, gloves, and respirators when
operating or working near this machinery.
Wear approved eye protection when operating or working near this machinery.
Protect eyes from particles, cut material, water, and abrasive.
Wear approved ear protection and control exposure time when operating or working near this
machinery.
Wear approved hand protection when operating or working near this machinery.
Wear work gloves to protect hands from lacerations, cuts, and abrasions.
Wear approved nonslip safety footwear when operating or working near this machinery.
Wear approved respiratory protection when operating or working near this machinery.
Wear a respirator when milling, handling abrasives, and doing other activities determined by the
local regulatory bodies and the facility health and safety committee as potential sources of
airborne dust and particles that can cause discomfort, illness, or other irritations.
Airborne hazards vary based upon the material being machined.