Hypertherm HyPrecision Predictive P-15 User manual

HyPrecision Predictive™ Waterjet Pumps
P-15 / P-30 / P-50 / P-50S / P-60S / P-75S
Operator Manual
810120 | Revision 0 | English

HyPrecision, Seal Maintenance Indicator, SMI, Seal Maintenance Technology, SMT, AccuStream, Blue Goop, PURE Goop, 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.
© 2018 Hypertherm, Inc.

HyPrecision Predictive™ Waterjet Pumps
P-15 / P-30 / P-50 / P-50S / P-60S / P-75S
Operator Manual
810120
Revision 0
English
Original Instructions
October 2018
Hypertherm, Inc.
Hanover, NH 03755 USA

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

HyPrecision Predictive waterjet pump Operator Manual 810120 5
Contents
Pump information ........................................................................................................................ 11
Warranty .................................................................................................................................. SC-13
Waterjet product warranty ................................................................................................................................ SC-13
Disclaimer ............................................................................................................................................................. SC-14
Product stewardship ............................................................................................................ SC-15
National and local safety regulations .............................................................................................................. SC-15
Certification test marks ...................................................................................................................................... SC-15
Declaration of conformity .................................................................................................................................. SC-16
Differences in national standards .................................................................................................................... SC-17
Higher-level systems .......................................................................................................................................... SC-17
Environmental stewardship ............................................................................................... SC-19
Hypertherm products: waste and recycling .................................................................................................. SC-19
Chemical handling and usage .......................................................................................................................... SC-19
Particle emission and waste water quality .................................................................................................... SC-19
Safety ....................................................................................................................................... SC-21
User qualification and training .......................................................................................................................... SC-22
Emergency medical information and treatment ............................................................................................ SC-22
Symbols and marks .............................................................................................................SC-23
Information and symbols .................................................................................................................................... SC-23
Symbols and marks found on the equipment ............................................................................................... SC-24
Measurements ..................................................................................................................................................... SC-26
1 Terminology ................................................................................................................................. 27
2 Product description .................................................................................................................... 35
Flow of water and hydraulic fluid .............................................................................................................................36
Cooling loop ............................................................................................................................................................................ 37
Pump exterior ...............................................................................................................................................................39
Pump interior ................................................................................................................................................................46
3 Optional equipment .................................................................................................................... 51
4 Operation ....................................................................................................................................... 53
Safety .............................................................................................................................................................................54
Do a preoperation inspection ...................................................................................................................................56

6HyPrecision Predictive waterjet pump Operator Manual 810120
Contents
Turn on the utilities ......................................................................................................................................................56
Use the controls ..........................................................................................................................................................57
Operation panel ......................................................................................................................................................................57
Operator interface: Operation screens .............................................................................................................................58
Operate the pump remotely ......................................................................................................................................60
Operate the pump locally ..........................................................................................................................................61
Operate the pump ..................................................................................................................................................................65
Stop the pump .............................................................................................................................................................67
Emergency ...............................................................................................................................................................................67
Typical .......................................................................................................................................................................................67
5 Preventive maintenance ............................................................................................................ 69
Safety .............................................................................................................................................................................70
Benefits of preventive maintenance ........................................................................................................................71
Training ..........................................................................................................................................................................71
Tools ...............................................................................................................................................................................72
Preventive maintenance schedule ...........................................................................................................................73
General ..........................................................................................................................................................................76
Examine and clean the equipment ......................................................................................................................................76
Examine the pump for leaks or damage ............................................................................................................................78
Electrical system ..........................................................................................................................................................79
Make sure that the emergency stop operates correctly ................................................................................................79
Make sure that the electrical interlock operates correctly .............................................................................................79
Examine cords, plugs, and cables ......................................................................................................................................80
Hydraulic system .........................................................................................................................................................81
Check the hydraulic filter ......................................................................................................................................................81
Check the hydraulic fluid level .............................................................................................................................................82
Check the hydraulic fluid quality .........................................................................................................................................83
Lubricate the primary motor bearings ................................................................................................................................87
Low-pressure water system ......................................................................................................................................89
Examine the transport tubes .................................................................................................................................................89
Clean the Seal Maintenance Indicator tubes ...................................................................................................................89
Replace the Seal Maintenance Indicator tubes ...............................................................................................................91
Measure the air pressure in the water accumulator tank ...............................................................................................92
Check the low-pressure water pressure gauges ............................................................................................................93
Replace the water filters .......................................................................................................................................................93
Test the low-pressure water TDS level .............................................................................................................................95
High-pressure water system: Intensifier ................................................................................................................97
Prepare to do maintenance on the intensifier ..................................................................................................................98
Disassemble the intensifier ...................................................................................................................................................99

HyPrecision Predictive waterjet pump Operator Manual 810120 7
Contents
Assemble the intensifier .....................................................................................................................................................108
High-pressure water system: Bleed-down valve .............................................................................................. 122
Remove the bleed-down valve from the pump .............................................................................................................122
Disassemble the bleed-down valve .................................................................................................................................123
Assemble the bleed-down valve ......................................................................................................................................124
Install the bleed-down valve ..............................................................................................................................................125
Start the pump after maintenance ........................................................................................................................ 126
Operator interface: Maintenance screens .......................................................................................................... 127
Primary maintenance screen .............................................................................................................................................128
Postmaintenance start procedure ....................................................................................................................................132
Prepare for storage .................................................................................................................................................. 135
Recycling and end of product life ........................................................................................................................ 136
6 Parts lists .....................................................................................................................................137
Tools ............................................................................................................................................................................ 138
Maintenance kits ....................................................................................................................................................... 139
Replacement parts ................................................................................................................................................... 143
Electrical system ..................................................................................................................................................................143
Hydraulic system ..................................................................................................................................................................144
Low-pressure water system ..............................................................................................................................................145
High-pressure water system .............................................................................................................................................147
Other parts ................................................................................................................................................................ 148
7 Troubleshooting .........................................................................................................................149
Safety .......................................................................................................................................................................... 150
Normal status ............................................................................................................................................................ 152
Pump starting ........................................................................................................................................................................152
Pump on .................................................................................................................................................................................152
Alarms ......................................................................................................................................................................... 152
Warnings ...............................................................................................................................................................................153
Faults ......................................................................................................................................................................................156
Intensifier problems ................................................................................................................................................. 158
Intensifier control ..................................................................................................................................................................158
Stroking ..................................................................................................................................................................................158
High-pressure water seal life is short .............................................................................................................................162
Hydraulic fluid ........................................................................................................................................................... 162
Temperature ..........................................................................................................................................................................162
Pressure .................................................................................................................................................................................164
Level ........................................................................................................................................................................................164
Leaks .......................................................................................................................................................................................165
Water .......................................................................................................................................................................... 166

8HyPrecision Predictive waterjet pump Operator Manual 810120
Contents
Pressure .................................................................................................................................................................................166
Leaks ......................................................................................................................................................................................168
Seal Maintenance Indicator (SMI) ........................................................................................................................ 171
Operator interface ...............................................................................................................................................................172
A warning or a fault occurs during the start sequence ................................................................................... 174
The pump makes noise during operation ........................................................................................................... 174
Controller problems ................................................................................................................................................. 175
Input/output status ..............................................................................................................................................................175
8 Pump specifications .................................................................................................................177
All HyPrecision pump models ............................................................................................................................... 178
Environmental conditions ...................................................................................................................................................178
Hydraulic fluid .......................................................................................................................................................................178
Utilities ....................................................................................................................................................................................178
HyPrecision P-15 ..................................................................................................................................................... 180
HyPrecision P-30 ..................................................................................................................................................... 181
HyPrecision P-50 ..................................................................................................................................................... 182
HyPrecision P-50S .................................................................................................................................................. 183
HyPrecision P-60S .................................................................................................................................................. 184
HyPrecision P-75S .................................................................................................................................................. 185
Orifices ....................................................................................................................................................................... 186
Torque values ............................................................................................................................................................ 187
Fasteners ...............................................................................................................................................................................187
Fittings ....................................................................................................................................................................................188
9 Installation ...................................................................................................................................193
Safety .......................................................................................................................................................................... 194
Buyer responsibilities .............................................................................................................................................. 196
Requirements ............................................................................................................................................................ 197
Location .................................................................................................................................................................................197
Temperature ..........................................................................................................................................................................197
Hydraulic fluid .......................................................................................................................................................................197
Utilities ....................................................................................................................................................................................198
Receive and unpack the equipment ..................................................................................................................... 199
Install the pump ......................................................................................................................................................... 200
Install the external heat exchanger (optional) ................................................................................................................ 200
Install the external boost pump (optional) ...................................................................................................................... 202
Install the external plumbing package (optional) .......................................................................................................... 204
Make the connections to the utility panel .......................................................................................................................205
Add hydraulic fluid ...............................................................................................................................................................207

HyPrecision Predictive waterjet pump Operator Manual 810120 9
Contents
Connect the electrical power ............................................................................................................................................208
Do the first start ........................................................................................................................................................ 209
Do a preoperation inspection ............................................................................................................................................209
Turn on the utilities ..............................................................................................................................................................209
Make sure that the primary motor turns in the correct direction ...............................................................................210
Make sure that the heat exchanger fan motor turns in the correct direction .........................................................212
Turn on the pump .................................................................................................................................................................213
Adjust the external boost pump pressure ......................................................................................................................213
Measure the air pressure in the water accumulator tank ............................................................................................214
Flush the pump and the high-pressure tubing ..............................................................................................................215
Operator interface: Adjustment screens ............................................................................................................ 216
Primary adjustments screen ..............................................................................................................................................217
Remote operation ..................................................................................................................................................... 226
Storage ....................................................................................................................................................................... 226
10 Technical drawings ...................................................................................................................227

10 HyPrecision Predictive waterjet pump Operator Manual 810120
Contents

HyPrecision Predictive waterjet pump 11
Pump information
Model
Serial number
The serial number is on the data plate, which is found on the utility panel on the back of the pump.
System schematic
drawing number
The system schematic drawing number is found in the electrical enclosure door on a green label.
Purchase date
Distributor
Installation date
Installed by
Notes

12 HyPrecision Predictive waterjet pump
Pump information

Safety and compliance SC-13
Warranty
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.
Product Warranty coverage up to
HyPrecision pump 27 months from the ship date,
or 24 months from the date of proven installation,
or 4,000 hours of operation, whichever occurs first
PowerDredge™ abrasive removal
system
15 months from the ship date,
or 12 months from the date of proven installation, whichever occurs first
EcoSift™ abrasive recycling
system
15 months from the ship date,
or 12 months from the date of proven installation, whichever occurs first
Reverse osmosis system 15 months from the ship date,
or 12 months from the date of proven installation, whichever occurs first
Bulk abrasive pot 15 months from the ship date,
or 12 months from the date of proven installation, whichever occurs first
Abrasive regulator 15 months from the ship date,
or 12 months from the date of proven installation, whichever occurs first
On/off valve air actuator 15 months from the ship date,
or 12 months from the date of proven installation, whichever occurs first
Diamond orifice 600 hours of operation with the use of a thimble filter and compliance with
Hypertherm’s water quality requirements

SC-14 Safety and compliance
Warranty
Warranty
Disclaimer
All product information contained in this manual is believed to be reliable as of the date of publishing the manual.
The content is subject to change without notice. Content in the manual could contain technical inaccuracies or
typographical errors and could be changed or updated without notice.

Safety and compliance SC-15
Product stewardship
Product stewardship
Hypertherm maintains a global regulatory management system to make sure that products comply with regulatory
and environmental requirements.
National and local safety regulations
National and local safety regulations shall take precedence over instructions supplied with the product. The
product shall be imported, installed, operated, and discarded in compliance with national and local regulations
applicable to the installation site.
Certification test marks
Certified products are identified by 1 or more certification test marks from accredited testing laboratories. The
certification test marks are on or near the data plate.
Each certification test mark means that the product and its safety-critical parts conform to the national safety
standards as reviewed and determined by that testing laboratory. Hypertherm puts a certification test mark on its
products only after that product is manufactured with safety-critical parts that have been approved by the
accredited testing laboratory.
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 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.
To see the Declaration of Conformity in English and other languages:
1. Go to www.hypertherm.com/docs.
2. Select Waterjet Family in the Product/Product type dropdown list.
3. Select Regulatory in the Category dropdown list.
The navigation instructions can change without notice.

SC-16 Safety and compliance
Product stewardship
Product stewardship
Declaration of conformity

Safety and compliance SC-17
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 and therefore
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.
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.

SC-18 HyPrecision Predictive waterjet pump
Product stewardship
Product stewardship

Safety and compliance SC-19
Environmental stewardship
Environmental stewardship
Hypertherm products: waste and recycling
Hypertherm waterjet cutting systems, like all products with electronics, can contain materials or parts, such as
printed circuit boards, that can not 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.
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 MSDS and SDS:
1. Go to www.hypertherm.com/docs.
2. In the “Product/Product type” dropdown list, select Waterjet Family.
3. In the “Category” dropdown list, select Material Safety Data Sheets.
These navigation instructions can change without notice.
Particle emission and waste water quality
Hypertherm does not manufacture or supply the materials that are cut and has no knowledge whether the
particles released from materials that are cut can pose a physical danger or health risk. Get advice from with your
supplier or other technical advisor for guidance concerning the properties of the material you cut with 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, Get advice from a local expert before purchasing, installing, and operating the equipment.

SC-20 Safety and compliance
Environmental stewardship
Environmental stewardship