Hypertherm Echion User manual

Echion™
Operator Manual
810770 – REVISION 3
ENGLISH

HyPrecision, Echion, 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.
Environmental stewardship is one of Hypertherm’s core values, and it is critical to our success and our customers’ success. We
are striving to reduce the environmental impact of everything we do. For more information:www.hypertherm.com/environment.
© 2020 Hypertherm, Inc.

Hypertherm, Inc.
Hanover, NH 03755 USA
www.hypertherm.com
Echion
Operator Manual
810770
REVISION 3
ENGLISH
Original instructions
June 2020

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)
[e-mail]
(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)
[e-mail]
(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)
[e-mail]
(Technical Service Email)
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)
[e-mail] (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)
T[email protected] (Technical Service Email)
For training and education resources, go to the Hypertherm Cutting Institute (HCI) online at www.hypertherm.com/hci.
Hypertherm products are designed and manufactured with a commitment to continuous quality control and safety. Contact
a Hypertherm Technical Service Associate for information and support regarding the installation, operation, maintenance,
and repair of this equipment.

Contents
Warranty.............................................................................................................................. SC-11
Waterjet product warranty ........................................................................................................................ SC-12
Disclaimer ..................................................................................................................................................... SC-12
Product stewardship ......................................................................................................... SC-13
National and local safety regulations...................................................................................................... SC-14
Certification test marks.............................................................................................................................. SC-14
Differences in national standards............................................................................................................ SC-15
Higher-level systems .................................................................................................................................. SC-16
Environmental stewardship.............................................................................................. SC-17
Hypertherm products: waste and recycling.......................................................................................... SC-18
Chemical handling and usage.................................................................................................................. SC-19
Particle emission and waste water quality ............................................................................................ SC-20
Safety................................................................................................................................... SC-21
Manuals ......................................................................................................................................................... SC-22
User qualification and training.................................................................................................................. SC-23
Emergency medical information and treatment.................................................................................... SC-24
Safety information for operation, maintenance, repair, and installation .......................................... SC-25

Contents
Symbols and marks ........................................................................................................... SC-29
Information and symbols............................................................................................................................ SC-30
Symbols and marks found on the equipment....................................................................................... SC-31
1 Optional equipment ................................................................................................................. 35
2 Operation.................................................................................................................................... 37
Safety..................................................................................................................................................................... 38
About the controls .............................................................................................................................................. 38
Operation panel....................................................................................................................................... 38
Operator interface................................................................................................................................... 39
Turn on the pump: beginning of day ............................................................................................................... 41
Inspect the pump .................................................................................................................................... 41
Check the hydraulic fluid....................................................................................................................... 43
Turn on the utilities .................................................................................................................................. 44
Turn on the controls................................................................................................................................ 44
Start the pump......................................................................................................................................... 45
Do the preoperation maintenance checks......................................................................................... 46
Operate the pump............................................................................................................................................... 49
Select the pressure mode..................................................................................................................... 49
Set the target water pressure .............................................................................................................. 49
Stop the pump..................................................................................................................................................... 50
Stop the pump remotely ........................................................................................................................ 50
Stop the pump locally ............................................................................................................................ 50
Emergency stop....................................................................................................................................... 51
Turn off the pump: end of day .......................................................................................................................... 52
3 Preventive maintenance .......................................................................................................... 53
Safety..................................................................................................................................................................... 54
Benefits of preventive maintenance................................................................................................................ 55
Training .................................................................................................................................................................. 55
Operator interface: Maintenance screens..................................................................................................... 56
Move the plunger..................................................................................................................................... 56
Start the pump after maintenance....................................................................................................... 57
Prepare for storage................................................................................................................................. 57
Inputs and outputs .................................................................................................................................. 58
Alarm log ................................................................................................................................................... 58

Contents
Tools ....................................................................................................................................................................... 59
Preventive maintenance schedule................................................................................................................... 60
Intensifier............................................................................................................................................................... 62
Repair the hydraulic center section .................................................................................................... 65
Repair the high-pressure cylinder, the check valve, and the low-pressure poppet ................ 66
Install the high-pressure components................................................................................................ 69
Examine the output adapter and the high-pressure poppet assembly....................................... 73
Assemble the check valve and the low-pressure poppet.............................................................. 74
Repair the bleed-down valve............................................................................................................................ 75
Clean the air cooler ............................................................................................................................................ 78
Clean the air side of the cooler............................................................................................................ 78
Clean the hydraulic fluid side of the cooler....................................................................................... 79
Replace the water filter...................................................................................................................................... 80
Test the total dissolved solids (TDS) level .................................................................................................... 81
Test the water quality.............................................................................................................................. 83
Replace the hydraulic filter element................................................................................................................ 84
Add hydraulic fluid .................................................................................................................................. 85
Replace the hydraulic fluid................................................................................................................................ 86
Lubricate the primary motor bearings............................................................................................................. 88
Start the pump after maintenance................................................................................................................... 90
Postmaintenance start procedure ....................................................................................................... 91
Prepare for storage............................................................................................................................................. 93
Recycling and end of product life ................................................................................................................... 96
4 Parts lists................................................................................................................................... 97
Tools ....................................................................................................................................................................... 98
Intensifier repair tools............................................................................................................................. 99
Maintenance and repair kits............................................................................................................................ 100
Optional equipment kits................................................................................................................................... 103
Replacement parts........................................................................................................................................... 104
Lubricants .............................................................................................................................................. 104
Electrical system.................................................................................................................................... 105
High-pressure water system.............................................................................................................. 106
Low-pressure water system............................................................................................................... 108
Hydraulic system .................................................................................................................................. 109

Contents
5 Troubleshooting....................................................................................................................... 111
Safety.................................................................................................................................................................. 112
General............................................................................................................................................................... 112
Primary operation screen................................................................................................................................ 113
Alarms................................................................................................................................................................. 114
Types of alarms ..................................................................................................................................... 114
Primary motor.................................................................................................................................................... 117
Intensifier............................................................................................................................................................ 118
Leaks....................................................................................................................................................... 118
Overstroke ............................................................................................................................................. 121
Hydraulic fluid ................................................................................................................................................... 123
Temperature........................................................................................................................................... 124
Pressure ................................................................................................................................................. 125
Level ........................................................................................................................................................ 126
Appearance ........................................................................................................................................... 127
Water .................................................................................................................................................................. 128
Low-pressure water............................................................................................................................. 128
High-pressure water............................................................................................................................ 129
Leaks....................................................................................................................................................... 131
The pump makes noise during operation ................................................................................................... 133
Controller errors ............................................................................................................................................... 134
Input/output status............................................................................................................................... 134
6 Specifications.......................................................................................................................... 135
All Echion-model pumps ................................................................................................................................ 136
Environmental conditions ................................................................................................................... 136
Hydraulic fluid ....................................................................................................................................... 136
Utilities .................................................................................................................................................... 137
Echion 15........................................................................................................................................................... 138
Dimensions and weights .................................................................................................................... 138
Electrical................................................................................................................................................. 138
Water....................................................................................................................................................... 138
Echion 30........................................................................................................................................................... 139
Dimensions and weights .................................................................................................................... 139
Electrical................................................................................................................................................. 139
Water....................................................................................................................................................... 139
Echion 50........................................................................................................................................................... 140
Dimensions and weights .................................................................................................................... 140
Electrical................................................................................................................................................. 140
Water....................................................................................................................................................... 140

Contents
Orifices ............................................................................................................................................................... 141
Stroke rate ......................................................................................................................................................... 141
Torque values .................................................................................................................................................... 142
Fasteners................................................................................................................................................ 142
Fittings .................................................................................................................................................... 144
7 Installation............................................................................................................................... 147
Safety.................................................................................................................................................................. 148
Buyer responsibilities ...................................................................................................................................... 148
Requirements.................................................................................................................................................... 149
Location.................................................................................................................................................. 149
Cooling ................................................................................................................................................... 149
Hydraulic fluid ....................................................................................................................................... 149
Utilities .................................................................................................................................................... 150
Receive and unpack the equipment ............................................................................................................ 151
Install the pump ................................................................................................................................................ 152
Install the pump-mounted plumbing kit (optional) ........................................................................ 153
Connect the utilities to the pump................................................................................................................. 156
Connect the water and the air........................................................................................................... 157
Connect the electrical power ............................................................................................................ 158
Check the hydraulic fluid................................................................................................................................ 159
Do the first start................................................................................................................................................ 159
Do a preoperation inspection............................................................................................................ 160
Turn on the utilities ............................................................................................................................... 160
Make sure that the primary motor turns in the correct direction ............................................... 161
Turn on the pump ................................................................................................................................. 162
Adjust the boost pump pressure ...................................................................................................... 162
Flush the pump and the high-pressure tubing .............................................................................. 163
Operator interface: Adjustment screens .................................................................................................... 164
Pump Adjustments............................................................................................................................... 164
Pressure ................................................................................................................................................. 169
Date / Time / Language ...................................................................................................................... 169
Intensifier Control................................................................................................................................. 170
SD Card ................................................................................................................................................. 171
8 Declaration of Conformity ......................................................................................................173

Contents
9 Touchscreen maps .................................................................................................................. 175
Primary operation screen................................................................................................................................ 177
Adjustment screens......................................................................................................................................... 181
Maintenance screens ...................................................................................................................................... 185
10 Technical drawings................................................................................................................. 189

Echion Operator Manual 810770 SC-11
Warranty
Warranty

Warranty
SC-12 810770 Operator Manual Echion
Warranty
Waterjet product warranty
Hypertherm’s warranty does not extend to defects, failures, damages, deficiencies, or errors that
are:
not reported to Hypertherm within the warranty period; or
the result of modification, abuse, misuse, noncompliance with the installation or operation
instructions, unauthorized repair, inadequate maintenance, neglect, accident, or the use of
unapproved parts; or
the result of normal wear; or
the result of the system being operated contrary to Hypertherm’s instructions or stated limits
of rated and normal use.
For information about the manufacturer’s warranty, refer to the conditions of sale provided when the
product was purchased.
Consumable parts are not included in this warranty. Consumable parts include high-pressure water
seals, check valves, cylinders, bleed-down valves, low-pressure seals, high-pressure tubing, and
filters.
All third-party motors, pumps, and plumbing accessories are warrantied by the respective
manufacturers and are not included in this warranty.
Disclaimer
All product information contained in this manual is believed to be reliable as of the date of
publication. The manual could contain technical inaccuracies or typographical errors and can be
changed or updated without notice.
Product Warranty coverage up to
Echion™ pump
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
EcoSift™ abrasive recycling system
Reverse osmosis system
Bulk abrasive pot
Abrasive regulator
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

Echion Operator Manual 810770 SC-13
Product stewardship
Product stewardship
Hypertherm maintains a global regulatory management system to make sure that products comply
with regulatory and environmental requirements.

Product stewardship
SC-14 810770 Operator Manual Echion
Product stewardship
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 the pump’s 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.
Once the product has left the Hypertherm factory, the certification test marks are invalid if one or
more of these events occurs.
The product is modified in a manner that causes danger or does not conform with the
applicable standards.
Safety-critical parts are replaced with unapproved spare parts.
Assembly is unauthorized.
An accessory that uses or generates dangerous 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, and the Machinery Directive.
If this product has a Declaration of Conformity, a copy (in English) is included. Refer to
Declaration of Conformity on page 173.

Product stewardship
Echion Operator Manual 810770 SC-15
Product stewardship
Differences in national standards
Nations can apply different performance, safety, or other standards. National differences in
standards include, but are not limited to:
voltage.
plug and cord ratings.
language requirements.
electromagnetic compatibility requirements.
Differences in national or other standards can make it impractical or impossible 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; therefore, they do not have a CE mark on the data
plate.
Countries where the CE mark in necessary or that have compulsory electromagnetic compatibility
regulations must use CE versions of Hypertherm products with the CE mark on the data plate.
These could include:
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 correctly configured and certified for the end-use installation site.

Product stewardship
SC-16 810770 Operator Manual Echion
Product stewardship
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 system is considered a higher-level system. A higher-level system with dangerous 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 dangerous 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 not sure about compliance.
External cables connecting parts of the higher-level system must be made for exposure to
contamination and movement as necessary for the end-use installation site. When the external
interconnecting cables are subject to exposure to oil, dust, water, or other contamination, hard
usage ratings could be necessary.
When external interconnecting cables are subject to continuous movement, constant flexing ratings
can be necessary. It is the responsibility of the OEM, system integrator, or end-use customer to
make sure that external connecting cables are correct for the application and obey all national, state,
and local regulations.

Echion Operator Manual 810770 SC-17
Environmental stewardship
Environmental stewardship

Environmental stewardship
SC-18 810770 Operator Manual Echion
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 products or parts 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 information, go to
www.hypertherm.com/customer-support/product-service/recycling.

Environmental stewardship
Echion Operator Manual 810770 SC-19
Environmental stewardship
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 dangerous 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 dangerous
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 M S DS and S DS:
1. Go to www.hypertherm.com/docs.
2. Look for “To view all regulatory and compliance documents, click here” below the Select your
product box.
3. Look for Safety Data Sheets. Click +.
These navigation instructions can change without notice.

Environmental stewardship
SC-20 810770 Operator Manual Echion
Environmental stewardship
Particle emission and waste water quality
Hypertherm does not manufacture or supply the materials that are cut and has no knowledge about
the particles released from materials that are cut and if they can pose a physical danger or health
risk. Get advice from your supplier or other technical advisor for guidance concerning the properties
of the material you cut with a Hypertherm product.
If you are not familiar with the current applicable government regulations and legal standards for the
installation site, get advice from a local expert before you purchase, install, and operate this
equipment.