Hypertherm HyPrecision 50S User manual

HyPrecision 50S/60S/75S™
Waterjet Pump
Operator Manual
808690 | Revision 2 | English

HyPrecision, AccuStream, 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.
© 2016 Hypertherm Inc.

HyPrecision 50S/60S/75S
Operator Manual
808690
Revision 2
English
Original Instructions
August 2016
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
Soporte.T[email protected] (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
HT[email protected] (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

HyPrecision 50S/60S/75S Operator Manual 808690 5
Contents
Pump information .......................................................................................................................... 9
Warranty .................................................................................................................................. SC-11
Product stewardship ............................................................................................................SC-13
Environmental stewardship ............................................................................................... SC-17
Safety ....................................................................................................................................... SC-19
User qualification and training .............................................................................................................................................SC-20
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 equipment ................................................................................SC-22
1 Terminology .................................................................................................................................. 25
2 Product description .................................................................................................................... 29
Pump exterior .................................................................................................................................................................................. 30
Major systems ................................................................................................................................................................................. 33
Electrical system .................................................................................................................................................................... 33
Hydraulic system .................................................................................................................................................................... 35
Low-pressure water system ................................................................................................................................................ 39
High-pressure water system ............................................................................................................................................... 40
3 Options ........................................................................................................................................... 41
4 Operation ....................................................................................................................................... 43
Safety ................................................................................................................................................................................................ 43
Overview .......................................................................................................................................................................................... 45
Inspect the equipment before operation .................................................................................................................................. 47
Turn on the pump .......................................................................................................................................................................... 47
Operate the pump ......................................................................................................................................................................... 49
Operate the pump remotely ................................................................................................................................................ 66
Stop the pump ................................................................................................................................................................................ 67
Emergency stop ..................................................................................................................................................................... 67
Routine stop during operation ............................................................................................................................................ 67
Turn off the pump at the end of the day ........................................................................................................................... 67

6HyPrecision 50S/60S/75S Operator Manual 808690
Contents
5 Preventive maintenance ............................................................................................................ 69
Benefits of preventive maintenance ...........................................................................................................................................69
Safety ................................................................................................................................................................................................70
Preventive maintenance schedule ..............................................................................................................................................72
Tools ..................................................................................................................................................................................................74
General .............................................................................................................................................................................................75
Examine the equipment for leaks or damage ...................................................................................................................75
Electrical system .............................................................................................................................................................................76
Make sure that the emergency stop button works ..........................................................................................................76
Examine cords and plugs for deterioration or damage ..................................................................................................76
Hydraulic system .............................................................................................................................................................................77
Check the hydraulic fluid indicator .....................................................................................................................................77
Check the hydraulic fluid level .............................................................................................................................................78
Check the hydraulic fluid quality .........................................................................................................................................80
Measure the hydraulic fluid temperature ...........................................................................................................................81
Replace the hydraulic filter ...................................................................................................................................................83
Replace the hydraulic fluid, the hydraulic filter, the filler-breather cap, and the suction strainers .......................84
Low-pressure water system .........................................................................................................................................................88
Check the low-pressure water pressure gauges ............................................................................................................88
Measure the air pressure in the water accumulator tank ...............................................................................................89
Replace the water filters .......................................................................................................................................................91
Test the low-pressure water TDS level .............................................................................................................................94
High-pressure water system: Intensifier ....................................................................................................................................96
Prepare to service the intensifier .........................................................................................................................................97
Disassemble the intensifier ................................................................................................................................................100
Repair the check valves and the low-pressure poppets ............................................................................................ 107
Repair the high-pressure cylinders .................................................................................................................................. 109
Assemble the intensifier ..................................................................................................................................................... 111
Intensifier parts ..................................................................................................................................................................... 127
High-pressure water system: Bleed-down valve ................................................................................................................. 129
Examine the bleed-down valve for leaks or damage ...................................................................................................129
Repair the bleed-down valve ............................................................................................................................................ 130
Install the bleed-down valve .............................................................................................................................................. 140
Bleed-down valve parts ...................................................................................................................................................... 143
Start the pump after preventive maintenance ....................................................................................................................... 144
Recycling and end of product life ............................................................................................................................................ 146
Preventive maintenance records .............................................................................................................................................. 147

HyPrecision 50S/60S/75S Operator Manual 808690 7
Contents
6 Parts lists .....................................................................................................................................149
Tools ...............................................................................................................................................................................................150
Preventive maintenance repair kits ..........................................................................................................................................151
Other parts ....................................................................................................................................................................................153
Complete list of preventive maintenance kits, parts, tools, and materials ......................................................................156
7 Troubleshooting .........................................................................................................................157
Safety ..............................................................................................................................................................................................157
Tips .................................................................................................................................................................................................157
Alarm screens ...............................................................................................................................................................................158
The pump will not start ...............................................................................................................................................................158
Intensifier .......................................................................................................................................................................................159
Stroking problems ...............................................................................................................................................................159
Leaks .......................................................................................................................................................................................163
Short seal life ........................................................................................................................................................................165
Hydraulic fluid ...............................................................................................................................................................................166
Low pressure ........................................................................................................................................................................166
High temperature .................................................................................................................................................................166
Water pressure ............................................................................................................................................................................168
No water pressure or low water pressure ......................................................................................................................168
Water pressure is too high ................................................................................................................................................170
Motor fault .....................................................................................................................................................................................171
Noisy operation ............................................................................................................................................................................171
8 Pump specifications .................................................................................................................173
All models ......................................................................................................................................................................................174
Hydraulic fluid .......................................................................................................................................................................174
Operating conditions ..........................................................................................................................................................174
Cooling requirements .........................................................................................................................................................174
HyPrecision 50S ..........................................................................................................................................................................175
HyPrecision 60S ..........................................................................................................................................................................177
HyPrecision 75S ..........................................................................................................................................................................179
Torque values ...............................................................................................................................................................................181
Fasteners ...............................................................................................................................................................................181
Fittings ....................................................................................................................................................................................182

8HyPrecision 50S/60S/75S Operator Manual 808690
Contents
9 Installation ...................................................................................................................................185
Safety ............................................................................................................................................................................................. 185
Buyer obligations .........................................................................................................................................................................186
Seller obligations ......................................................................................................................................................................... 186
Requirements ...............................................................................................................................................................................187
Location ................................................................................................................................................................................. 187
Temperature .......................................................................................................................................................................... 187
Electrical power ................................................................................................................................................................... 187
Water ...................................................................................................................................................................................... 188
Receive and unpack the equipment ........................................................................................................................................ 190
Make the connections for remote operation ......................................................................................................................... 191
Install the external air cooler ...................................................................................................................................................... 193
Make the connections to the utility panel fittings ................................................................................................................. 194
Add hydraulic fluid ....................................................................................................................................................................... 196
Connect the electrical power ...................................................................................................................................................196
Do the first startup ....................................................................................................................................................................... 197
Do a preoperation inspection ........................................................................................................................................... 197
Turn on the utilities ..............................................................................................................................................................198
Change the system configuration on the operator interface ..................................................................................... 198
Start the pump ...................................................................................................................................................................... 199

HyPrecision 50S/60S/75S Operator Manual 808690 9
Pump information
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 inside the electrical enclosure door on a green label and on
the data plate.
Purchase date
Distributor
Installation date
Installed by
Notes

10 HyPrecision 50S/60S/75S Operator Manual 808690
Pump information

Safety and compliance SC-11
Warranty
Warranty
Waterjet product warranty coverage
Consumable parts are not covered by this warranty. Consumable parts include, but are not limited to
high-pressure water seals, check valves, cylinders, bleed-down valves, low-pressure seals, high-pressure tubing,
and filters.
Product Warranty coverage up to:
HyPrecision pumps
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
Bulk abrasive pots 15 months from the ship date
or 12 months from the date of proven installation, whichever occurs first
Abrasive regulators 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 operation with the use of a thimble filter and compliance with
Hypertherm’s water quality requirements

SC-12 Safety and compliance
Warranty
Warranty

Safety and compliance SC-13
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 disposed of 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 found 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.
Once 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.
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.

SC-14 Safety and compliance
Product stewardship
Product stewardship
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
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 applicable section of the EU standards and other normative documents.
97/23/EC Pressure Equipment Directive
2006/42/EC Machinery Directive
2006/95/EC Low Voltage Directive
2004/108/EC Electromagnetic Compatibility 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, Nederland
31 165 596907
To see the signed Declaration of Conformity in English:
1. Go to www.hypertherm.com.
2. Search for documents library.
3. Select Waterjet Family from the All dropdown list under Product/Product type.
4. Select Regulatory from the All Categories dropdown list.
These navigation instructions can change without notice.
HyPrecision 15 HyPrecision 50S HyPrecision 100D
HyPrecision 30 HyPrecision 60S HyPrecision 150D
HyPrecision 50 HyPrecision 75S

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 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 properly 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. 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 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 federal, state, and local regulations.

SC-16 Safety and compliance
Product stewardship
Product stewardship

Safety and compliance SC-17
Environmental stewardship
Environmental stewardship
Proper disposal of Hypertherm products
Hypertherm waterjet cutting equipment, 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. In other countries, check 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.
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. This list of chemicals is supplied by Hypertherm.
To see MSDS and SDS:
1. Go to www.hypertherm.com.
2. Search for documents library.
3. Select Waterjet Family from the All dropdown list under Product/Product type.
4. Select Material Safety Data Sheets from the All Categories dropdown list.
These navigation instructions can change without notice.

SC-18 Safety and compliance
Environmental stewardship
Environmental stewardship
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.

Safety and compliance SC-19
Safety
Safety
The end user is responsible for the safe operation of this equipment.
Copies of the manuals may accompany the product in electronic and printed formats. You can also see copies of
the manuals online, in all languages available for each manual.
1. Go to www.hypertherm.com.
2. Search for documents library.
3. Select Waterjet Family from the All dropdown list under Product/Product type.
4. Select Manuals/Service Information from the All Categories dropdown list. It is optional to select a
manual type from the All subcategories dropdown list.
These navigation instructions can change without notice.
The safety precautions in this manual are general and can not anticipate every situation. Hypertherm Inc.
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.
Keep these instructions near the equipment. This manual is intended to familiarize the user with the equipment
and its parts, safe 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
WARNING
Before operating any Hypertherm equipment, read the safety instructions in your product's manual
Failure to follow safety instructions can result in personal injury or in damage to equipment.
DANGER
A person who works on deenergized machinery can be seriously injured or killed if the
machinery is reenergized without permission.
All workers must respect lock out–tag out devices.
All workers 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 or a
tag-out device.

SC-20 Safety and compliance
Safety
Safety
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 this equipment. Operators must be qualified to operate and
maintain this equipment. Training should include this information:
How to start and stop the equipment during routine operation and in an emergency situation
The conditions and actions that can lead to injuries to people and damage to the equipment
How to operate all controls
How to identify and respond to a problem with the equipment
How to do maintenance procedures
A copy of the operator manual
This list is not all-inclusive.
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 cause 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. Show the tag or card to emergency responders
and medical professionals.
This card 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 cause 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