Hypertherm HyPrecision 15 User manual

HyPrecision15/30/50™
Waterjet Pump
Operator Manual
808240 | Revision 1 | English

HyPrecision 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.
© 2015 Hypertherm Inc.

HyPrecision15/30/50
Operator Manual
808240
Revision 1
English
Original Instructions
July 2015
Hypertherm Inc.
Hanover, NH 03755 USA
www.hypertherm.com

North America
USA and Canada
Technical service
800-643-9878 Toll-free
[e-mail]
Customer service
800-737-2978 Toll-free
Return materials
866-643-7711 Toll-free
Asia Pacific
TechnicalService-Asi[email protected]
Singapore
65 6841 2489
65 6841 2490 Fax
China
86-21-60740003
86-21- 60740393 Fax
Japan
[phone]
[phone] Fax
India
[phone]/ 2/ 3/
[phone] Mobile
[phone] Fax
Korea
[phone]
[phone] Fax
Australia and New Zealand
[phone]
[phone] Mobile
[phone] Fax
Europe, Middle East, and Africa
Technical service
00 800 4973 7843 Toll-free
[phone]
[phone] Fax
Techni[email protected]
Customer service
00 800 3324 9737 Toll-free
[phone]
00 800 4973 7329 Toll-free fax
[phone] Fax
Return materials
[phone]
[phone] Fax
South America
TechnicalService-4"@Hypertherm.com
Brazil
55 11 2409 2636
55 11 2408 0462 Fax
Argentina
[phone]
Peru
[phone]
Chile
[phone]
Venezuela
[phone]
México
52 55 5681 8109
52 55 5681 7978
52 55 5683 2127 Fax

HyPrecision15/30/50 Operator Manual 808240 5
Contents
Pump information .......................................................................................................................... 9
Warranty ................................................................................................................................. SC-11
Product stewardship ........................................................................................................... SC-13
National and local safety regulations ................................................................................................................................ SC-13
Certification test marks ....................................................................................................................................................... SC-13
Declaration of conformity ............................................................................................................................................ SC-13
Differences in national standards ...................................................................................................................................... SC-15
Higher-level systems ............................................................................................................................................................ SC-15
Environmental stewardship .............................................................................................. SC-17
Proper disposal of Hypertherm products ........................................................................................................................ SC-17
Proper handling and safe use of chemicals .................................................................................................................... SC-17
Particle emission and wastewater quality ....................................................................................................................... SC-17
Safety ...................................................................................................................................... SC-19
User qualification and training ........................................................................................................................................... SC-19
Emergency medical information and treatment ............................................................................................................. SC-20
Symbols and marks ............................................................................................................ SC-21
Information and hazard symbols ........................................................................................................................................ SC-21
Symbols and marks found on the data plate and the pump ....................................................................................... SC-22
1 Terminology .................................................................................................................................. 25
2 Product description .................................................................................................................... 29
Pump exterior .................................................................................................................................................................................. 30
Major systems ................................................................................................................................................................................. 32
Hydraulic system .................................................................................................................................................................... 32
Low-pressure water system ................................................................................................................................................ 37
High-pressure water system ............................................................................................................................................... 39
Electrical system .................................................................................................................................................................... 40
3 Options ........................................................................................................................................... 43
Voltage ..................................................................................................................................................................................... 43

6HyPrecision15/30/50 Operator Manual 808240
Contents
Air-cooled external heat exchanger ....................................................................................................................................43
Water-modulating valve ........................................................................................................................................................43
4 Operation ....................................................................................................................................... 45
Safety ................................................................................................................................................................................................45
Overview ...........................................................................................................................................................................................46
Inspect the pump before operation ............................................................................................................................................48
Turn on the pump ...........................................................................................................................................................................48
Turn on the pump locally .......................................................................................................................................................48
Turn on the pump remotely ...................................................................................................................................................49
Operate the pump ..........................................................................................................................................................................50
Operator interface ..................................................................................................................................................................50
Operate the pump remotely .................................................................................................................................................58
Stop the pump ................................................................................................................................................................................59
Emergency stop ......................................................................................................................................................................59
Routine stop during operation .............................................................................................................................................59
Routine stop at the end of the day .....................................................................................................................................59
5 Preventive maintenance ............................................................................................................ 61
Benefits of preventive maintenance ...........................................................................................................................................61
Safety ................................................................................................................................................................................................62
Tips ....................................................................................................................................................................................................63
Preventive maintenance schedule ..............................................................................................................................................64
Tools ..................................................................................................................................................................................................66
Complete list of preventive maintenance kits, parts, tools, and materials .................................................................67
Every shift .................................................................................................................................................................................68
Every 40 hours ........................................................................................................................................................................76
Every 500 hours ......................................................................................................................................................................78
Every 1,000 hours ..................................................................................................................................................................85
Every 1,500 hours ..................................................................................................................................................................92
Every 2,000 hours ..................................................................................................................................................................93
Every 3,000 hours ..................................................................................................................................................................94
Every 6,000 hours ............................................................................................................................................................... 100
Every 12,000 hours ............................................................................................................................................................. 101
Service the intensifier ................................................................................................................................................................. 102
Disassemble the intensifier ................................................................................................................................................ 104
Assemble the intensifier .....................................................................................................................................................111
Service the bleed-down valve .................................................................................................................................................. 128
Disassemble the bleed-down valve .................................................................................................................................131
Assemble the bleed-down valve ......................................................................................................................................133
Install the bleed-down valve ..............................................................................................................................................135

HyPrecision15/30/50 Operator Manual 808240 7
Contents
Start the pump after preventive maintenance .......................................................................................................................137
Preventive maintenance interval checklist ..............................................................................................................................139
Preventive maintenance records ......................................................................................................................................144
6 Parts lists .....................................................................................................................................147
7 Troubleshooting .........................................................................................................................153
Safety ..............................................................................................................................................................................................153
Tips .................................................................................................................................................................................................153
Alarm screens ...............................................................................................................................................................................154
The pump will not start ...............................................................................................................................................................154
Intensifier .......................................................................................................................................................................................155
Stroking problems ...............................................................................................................................................................155
Leaks .......................................................................................................................................................................................159
Short seal life ........................................................................................................................................................................160
Hydraulic fluid ...............................................................................................................................................................................161
Low pressure ........................................................................................................................................................................161
High temperature .................................................................................................................................................................161
Low water pressure .....................................................................................................................................................................163
From the intensifier ..............................................................................................................................................................163
To the intensifier ...................................................................................................................................................................163
Motor fault .....................................................................................................................................................................................164
8 Pump specifications .................................................................................................................165
HyPrecision 15 .............................................................................................................................................................................166
HyPrecision 30 .............................................................................................................................................................................167
HyPrecision 50 .............................................................................................................................................................................168
All models ......................................................................................................................................................................................169
Hydraulic fluid .......................................................................................................................................................................169
Operating conditions ..........................................................................................................................................................169
Cooling requirements .........................................................................................................................................................169
Utility fittings ..........................................................................................................................................................................170
Torque values ...............................................................................................................................................................................171
Fasteners ...............................................................................................................................................................................171
Fittings ....................................................................................................................................................................................173
9 Installation ...................................................................................................................................177
Safety ..............................................................................................................................................................................................177
Buyer obligations .........................................................................................................................................................................178
Seller obligations .........................................................................................................................................................................179
Requirements ................................................................................................................................................................................179

8HyPrecision15/30/50 Operator Manual 808240
Contents
Location ................................................................................................................................................................................. 179
Temperature ..........................................................................................................................................................................179
Electrical power ................................................................................................................................................................... 180
Air ............................................................................................................................................................................................ 180
Water ...................................................................................................................................................................................... 181
Receive and unpack the pump ................................................................................................................................................. 183
Install the external heat exchanger ........................................................................................................................................... 184
Make the connections for remote operation .........................................................................................................................184
Make the connections to the utility panel ............................................................................................................................... 186
Add hydraulic fluid .......................................................................................................................................................................187
Connect the electrical power ................................................................................................................................................... 188
Do the first startup ....................................................................................................................................................................... 189
Recycling and end of product life ............................................................................................................................................193

Pump information
HyPrecision15/30/50 Operator Manual 808240 9
Pump information
Model
Serial number
The serial number is on the data plate, which is found above the connection panel on the back of the pump.
System
schematic
drawing number
The system schematic drawing number is found on the data plate and inside the electrical enclosure door on
a green label.
Purchase date
Distributor
Installation date
Installed by
Notes

10 HyPrecision15/30/50 Operator Manual 808240
Pump information
Pump information

Warranty
Safety and compliance SC-11
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 regulators
(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-12 Safety and compliance
Warranty
Warranty

Product stewardship
Safety and compliance SC-13
Product stewardship
Hypertherm maintains a global Regulatory Management System to ensure 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 disposed of in accordance with national and local regulations applicable to the
installed site.
Certification test marks
Certified products are identified by one or more certification test marks from accredited testing laboratories. The
certification test marks are found on or near the data plate.
Each certification test mark means that the product and its safety-critical parts conform to the relevant 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 authorized by the accredited
testing laboratory.
Once the product has left the Hypertherm factory, the certification test marks are invalidated if any of these events occur:
The product is modified in a manner that creates a hazard or nonconformance with the applicable standards.
Safety-critical parts are replaced with unauthorized spare parts.
Assembly is unauthorized.
An accessory that uses or generates a hazardous voltage is added.
There is tampering with a safety circuit or other feature that is designed into the product as part of the certification, 
or otherwise.
A Conformité Européene (CE) mark constitutes a manufacturer’s declaration of conformity to applicable European
directives and standards. Only those versions of Hypertherm products with a CE mark found on or near the data plate
have been tested for compliance with the European Low Voltage Directive and the European Electromagnetic
Compatibility Directive.
Declaration of conformity
This Declaration of Conformity applies to these HyPrecision Waterjet Pump models based on testing of the
HyPrecision™ 50S model:
Date of first fixing of Conformité Européene (CE) mark (Declaration of Conformity issued): 15 June 2010
HyPrecision 15 HyPrecision 50S HyPrecision 100D
HyPrecision 30 HyPrecision 60S HyPrecision 150D
HyPrecision 50 HyPrecision 75S

SC-14 Safety and compliance
Product stewardship
Product stewardship
Date of this Declaration of Conformity: 17 March 2014
This Declaration of Conformity was reissued because of a change to the product model name. No changes were made
regarding safety.
Model units with a CE mark on the data plate meet the essential requirements of these European Union (EU) Directives
using the relevant section of the EU standards and other normative documents.
97/23/EC Pressure Equipment Directive (PED)
2006/42/EC Machinery Directive
2006/95/EC European Low Voltage Directive
2004/108/EC European Electromagnetic Compatibility (EMC) Directive
This declaration is not valid on units without a CE mark on the data plate.
For European customer inquiries, contact:
European Customer Service
Hypertherm Europe B.V.
Vaartveld 9 4704 SE
Roosendaal, the Netherlands
[phone]
To see the signed Declaration of Conformity in English, go to the Hypertherm web site at www.hypertherm.com.
1. Click Downloads library.
2. Select a HyPrecision product from the Product type dropdown list.
3. Click on the Regulatory folder that is shown below the search fields.
4. Click on the EU Declaration of Conformity folder.
These navigation instructions are subject to change without notice.

Safety and compliance SC-15
Product stewardship
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:
Voltages
Plug and cord ratings
Language requirements
Electromagnetic compatibility requirements
These differences in national or other 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 include, but are not limited to:
Australia
New Zealand
Countries in the European Union
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 properly for the end-use site.
Higher-level systems
When an original equipment manufacturer (OEM) or system integrator adds equipment such as cutting tables, motor
drives, motion controllers, or robots to a Hypertherm Waterjet cutting system, the combined system can be considered a
higher-level system. A higher-level system with hazardous moving parts can constitute industrial machinery or robotic
equipment, in which case the system integrator or end-use customer could be subject to more regulations and standards
than those relevant to the waterjet cutting system as 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 supply 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 also can be subject to
approval by local authorities. Seek 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 contaminants and
movement as required by the final end-use installation site. When the external interconnecting cables are subject to oil,
dust, water, or other contaminants, hard usage ratings could be required.
When external interconnecting cables are subject to continuous movement, constant flexing ratings could be required. It
is the responsibility of the end-use customer or the OEM or system integrator to ensure the cables are suitable for the
application. Since there are differences in the ratings and costs that can be required by local regulations for higher-level
systems, it is necessary to verify that external interconnecting cables are suitable for the end-use installation site.

SC-16 Safety and compliance
Product stewardship
Product stewardship

Environmental stewardship
Safety and compliance SC-17
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.
Proper handling and safe use of chemicals
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 Material Safety Data Sheets (MSDS) and
Safety Data Sheets (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, go to the Hypertherm web site
at www.hypertherm.com.
1. Click Downloads library.
2. Select Material Safety Data Sheets from the Category dropdown list.
3. Click on the Material Safety Data Sheets folder that is shown below the search fields.
4. Click on the MSDS folder.
These navigation instructions are subject to 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 will pose a physical hazard or health risk. Please 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-18 Safety and compliance
Environmental stewardship
Environmental stewardship

Safety
Safety and compliance SC-19
Safety
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
How to recognize hazardous energy sources
The correct methods for isolating and controlling energy, including lock out–tag out procedures
User qualification and training
All users must read and understand these instructions before installing, operating, or doing maintenance on 
this equipment.
Do not permit an untrained person to operate a waterjet pump. Operators must be qualified to install, operate, and
maintain this equipment. Training should include this information:
How to start and stop the pump during routine operation and in an emergency situation
The conditions and actions that can lead to injuries to people and damage to the pump
How to operate all controls
How to identify and respond to fault indicators
How to do maintenance procedures
A copy of this manual
This list is not all-inclusive.

SC-20 Safety and compliance
Safety
Safety
Emergency medical information and treatment
The use of high-pressure equipment exposes the operator and other people in the area to high-pressure water. Potential
harms include eye injuries, lacerations, infections, and amputations. Do not put ice or heat on a waterjet injury. Support
injured limbs and extremities above heart level if possible.
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.
Waterjet operators should carry a waterproof emergency medical tag or card that describes the nature of high-pressure
waterjet injuries and the recommended treatment.
Give this card to emergency responders and medical professionals. It can be copied, cut out, laminated, and folded.
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.
The person carrying this card has been
exposed to a waterjet of up
to 4,137 bar (60,000 psi) and a velocity
of 609 m/s (2,000 feet/second). The
waterjet can contain abrasive materials.
Skin can appear intact or show a minor
pinhole-sized puncture wound. The
injured area can become swollen, painful,
and pale over the next 4 to 6 hours.
Tissue becomes ischemic and necrotic
within 12 hours.
Consult a surgical specialist immediately
for decompression, removal of foreign
materials, and debridement.
Administer broad-spectrum, intravenous
antibiotics for Gram-negative and
Gram-positive organisms.
X-ray is the imaging of choice.
Acute compartment syndrome is
possible.
Leave the wound open.
Do not use solvents other than isotonic
sodium chloride solution for irrigating
the wound.
Do not use digital or local nerve blocks.
Give analgesics by mouth or injection.
MEDICAL
INFORMATION