Intermac Primus 184 User manual

Serial number
ENGLISH
Translation of the original instructions
PRIMUS
WaterJet
Primus 184, Primus 322, Primus 324
User Manual
1.2
P5802P0108

Information about the publication
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Information about the publication
This manual has been prepared for use by customers only, and contains information protected by
copyright. It must not be photocopied or reproduced in any form, either fully or in part, without the
prior written consent of the manufacturer.
Code Issue Code of previous issue
P5802P0108 1 //
Revision Description of updates
0 (07/2009) new document
1 (05/2010) 5-axis head
2 (09/2011) New sizes 322, 324 and general review

Information about the publication
4BIESSE S.p.A. © - P5802P0108.fm251111

Index
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Index
Introduction ................................................................................................................................. 9
1 Safety information
1.1 First aid and medical assistance ...................................................................................... 13
1.2 Lifting and handling .......................................................................................................... 15
1.3 Installation ........................................................................................................................ 15
1.4 Protection against overcurrents ....................................................................................... 15
1.5 Protection against indirect contacts ................................................................................. 16
1.6 Protection against fire ...................................................................................................... 16
1.7 Preparation and machining operations ............................................................................ 16
1.8 Maintenance .................................................................................................................... 17
1.9 Scrapping ......................................................................................................................... 18
1.10 Danger signs .................................................................................................................... 19
1.11 General prohibition signs ................................................................................................. 19
1.12 Obligation signs ................................................................................................................ 20
1.13 Signs fixed to the machine ............................................................................................... 20
2 Machine description
2.1 General description of the machine ................................................................................. 21
2.2 Configurations of the Primus line ..................................................................................... 22
2.3 Primus overview and main parts ...................................................................................... 24
2.4 Base and basin ................................................................................................................ 25
2.5 Beam of X and Y axes ..................................................................................................... 26
2.6 3-axis working head (X, Y, Z) ........................................................................................... 27
2.7 5-axis working head (X, Y, Z, A, C) .................................................................................. 28
2.8 Work table ........................................................................................................................ 29
2.9 Safety devices .................................................................................................................. 30
2.10 Identification of the manufacturer and the machine ......................................................... 31
3 Basic concepts
3.1 Axes ................................................................................................................................ 33
3.2 Manual movement of the axes ........................................................................................ 34
3.3 Axis transfer speed change ............................................................................................. 34
3.4 Working areas .................................................................................................................. 34
3.5 Origins .............................................................................................................................. 34

Index
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3.6 Machine operation ........................................................................................................... 35
4 Intended use and unintended use
4.1 How to use the machine .................................................................................................. 37
4.2 Characteristics and dimensions of workable materials .................................................... 38
4.3 Executable machining operations .................................................................................... 39
4.4 Personnel qualifications ................................................................................................... 40
4.5 Work area ........................................................................................................................ 40
4.6 Danger area ..................................................................................................................... 41
4.7 Residual risks .................................................................................................................. 41
5 Commands and indicator devices
5.1 Layout of the commands and indicator devices - Primus ............................................... 44
5.2 Main control panel ............................................................................................................ 45
5.3 hand-held button pad ....................................................................................................... 47
5.3.1 Using the hand-held button pad .................................................................................... 49
6 Preparing the operating section
6.1 Cutting unit ....................................................................................................................... 51
6.2 Machining parameters ..................................................................................................... 51
7 Anti-collision thickness tracer
7.1 General remarks .............................................................................................................. 53
7.2 Use ................................................................................................................................... 53
8 Using the machining water recirculation system
8.1 Lifting ............................................................................................................................... 55
8.2 Physical treatment ........................................................................................................... 55
8.3 Extraction of the suspended solids .................................................................................. 56
9 Basic use
9.1 Machine start-up .............................................................................................................. 57
9.2 Resetting the machine axes ............................................................................................. 58
9.3 Stopping the machine functions ....................................................................................... 58
9.4 Restoring normal machine functioning ............................................................................. 59
9.5 Switching the machine off ................................................................................................ 59
9.6 Using the abrasive distribution system (optional) ............................................................ 60

Index
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10 Carrying out machining operations
10.1 Warnings relating to machining operations ..................................................................... 61
10.2 Machining operation procedure ....................................................................................... 62
10.3 Origin management and selection .................................................................................. 62
10.4 Positioning and locking the piece ..................................................................................... 63
10.5 Using the machine in manual mode (axis movement) ..................................................... 64
10.6 Using the machine in automatic mode ............................................................................. 64
10.7 Starting the machining operation ..................................................................................... 64
10.8 Working cycle ................................................................................................................... 64
10.9 Machining identical pieces ............................................................................................... 65
10.10 Unloading the piece ......................................................................................................... 65
10.11 Interrupting the machining operation ................................................................................ 66
11 Routine and special maintenance
11.1 Routine maintenance ....................................................................................................... 68
11.1.1 Maintenance of the air treatment units .......................................................................... 78
11.1.2 Summary and frequency of maintenance operations .................................................... 83
11.2 Special maintenance ........................................................................................................ 85
11.2.1 Maintenance of the pump in the machining water recirculation system ........................ 85
11.2.2 Maintenance of the high pressure system .................................................................... 85
11.2.3 Maintenance of the cutting head ................................................................................... 86
12 Technical characteristics
12.1 Layout .............................................................................................................................. 88
12.2 General data ................................................................................................................... 92
12.3 General intensifier data .................................................................................................... 92
12.4 Admissible weight on the work table ................................................................................ 93
12.5 Water consumption .......................................................................................................... 93
12.6 Electrical characteristics ................................................................................................... 93
12.7 Lighting ............................................................................................................................ 93
12.8 Main machine axes - X, Y, Z ............................................................................................ 94
12.9 Noise level ........................................................................................................................ 95
13 Handling and transport
13.1 Warnings concerning machine transportation and installation ......................................... 97
13.2 Parts to be transported ..................................................................................................... 98
13.3 Unloading the machine .................................................................................................... 99
13.3.1 Responsibility for machine unloading and positioning .................................................. 99
13.3.2 Lifting safety .................................................................................................................. 99
13.3.3 Lifting the Primus ........................................................................................................ 100
13.3.4 Lifting the Primus 322/324 .......................................................................................... 101

Index
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14 Installation and assembly
14.1 Machine layout, connection points and working dimensions ......................................... 103
14.2 Installation area requisites ............................................................................................. 103
14.3 Layout of the support feet .............................................................................................. 106
14.4 Levelling of the machine ................................................................................................ 108
14.5 Safety guards .................................................................................................................. 110
14.6 Connecting the machine to the hydraulic system ........................................................... 111
14.7 Connecting the machine to the electric system .............................................................. 112
14.7.1 Connection cable ......................................................................................................... 113
14.7.2 Power levels of the Primus 184/322/324 ...................................................................... 113
14.8 Connecting the machine to the pneumatic system ......................................................... 114
14.9 Equipment supplied ........................................................................................................ 114
15 Decommissioning - demolition
16 Warranty and customer service
16.1 Warranty ......................................................................................................................... 117
16.2 Customer service ............................................................................................................ 117
17 Message list
18 Enclosures
19 Drawings and diagrams

Introduction
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Introduction
This document, together with the interface instruction manual and any attachments, provide the
information required for proper use of the machine. The procedures indicated must only be carried
out by staff with adequate training.
In order to avoid incorrect manoeuvres that might result in injury to persons it is important to read
and fully understand all the documents supplied with the machine. The manufacturer cannot be
held responsible or legally liable for any damage resulting from incorrect use of the documentation.
The description or illustration of certain devices may differ slightly from the actual ones without in
any way compromising their comprehension. Some devices indicated and described in this
manual may not be present on your machine.
This document complies with the indications in Machine Directive 2006/42/CE.
Conventions
The text sections that must not be overlooked are highlighted and preceded by the symbols
described and illustrated below.
Paragraphs marked with this symbol indicate an imminent danger, and the contents
must therefore be taken into careful account in order to prevent a serious accident.
Paragraphs marked with this symbol indicate procedures to be used and actions to
be taken to avoid any damage to goods and property.
This symbol is used to indicate points of particular importance that must not be overlooked.

Introduction
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Documents supplied with the machine
The supplied documents must be stored in a suitable place within easy access of and known to the
persons using the machine throughout the machine's working life, and must accompany the
machine if passed on to third parties.
Based on the model or configuration of the machine, some of the following might not be present.
The following is a list of the documents supplied with the machine:
User Manual. Contains information on use of the machine. Given the complexity of the
subjects dealt with, this information may be divided into a number of sections.
User interface instruction manual. Contains the information on use of the machine's user
interface. Given the complexity of the subjects dealt with, this information may be divided into
a number of sections.
Spare parts catalogue. Used to identify and order components to be replaced, following the
instructions provided. It is not necessarily translated into the language of the country to which
the machine is being sent.
Pneumatic diagrams. These describe the machine's pneumatic systems and are for the sole
use of the trained technicians authorised by the manufacturer. They are not necessarily
translated into the language of the country to which the machine is being sent.
Wiring diagrams. These describe the machine's electrical systems and are for the sole use of
the trained technicians authorised by the manufacturer. They are not necessarily translated
into the language of the country to which the machine is being sent.
CE declaration of conformity. This certifies that the machine complies with the directives
indicated. It is only issued for machines sold in EEC countries and those where Machine
Directive 2006/42/EC is applied.
Attachments. These contain additional information that completes and/or replaces the
information in the document with which they are enclosed.
Interactive digital support. Contains the main documents supplied with the machine.
Some documents might be integrated in the user interface or in the interactive digital
support.

Introduction
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CE declaration of conformity
The following are the contents of the CE Declaration of conformity:
• The name and address of the manufacturer.
• The name, model and serial number of the machine.
• The composition of the line with the data of the machines that comprise it: The
manufacturer, name, model and serial number.
(only for machine lines - Fixed systems)
• Compliance with directives 2006/42/CE - Machinery Directive, 2004/108/CE -
Electromagnetic Compatibility Directive, 2006/95/CE - Low Voltage Electrical Materials
Directive.
• The person authorised to prepare the technical folder and their address.
• EC type test data: the notified body, their address, identification number and the number of
the certificate.(only for machines in annex IV)
• The place and date of issue of the declaration.
• The signature of the authorised person.
• The name and surname of the person authorised to sign.
• The position of the person authorised to sign.
Links related to the PC use
The machine operation is guaranteed under the following conditions:
The PC must be certified by INTERMAC.
The PC must be configured according to the Operating Instructions defined by Intermac.
Hardware: it is not possible to fit any hardware on the PC that is not explicitly authorised by
Intermac.
Software: it is not possible to install ANY software on the PC that is not explicitly authorised by
Intermac. This refers to the operating system (Windows) as well as other software applications.
As regards Windows, it is not allowed to install updates or service packs that have not been
certified by Intermac. In other words, the Windows version to be installed, including the service
pack, is the one supplied on the CD together with the PC.

Introduction
12 BIESSE S.p.A. © - P701K0001.fm251111

1 Safety information
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1 Safety information
The machine must only be installed and used in industrial environments.
The machine will work safely if it is used by qualified persons in accordance with the
recommendations and instructions provided in this manual. BIESSE will not be liable for any harm
to people or damage to property caused by inexperienced and unqualified operators, or by failure
to comply with the following recommendations.
Never remove or tamper with the guards (on the machine or inside the electric
panels) in order to carry out unintended machining operations, as this will result in
serious risks for the operator. BIESSE declines all responsibility for harm to people
or damage to property resulting from incorrect use or deliberate misuse of the
machine.
In the event of an electrical or mechanical fault, do not carry out any operations or
manoeuvres on your own initiative if these are not within your area of skill and
responsibility; you could jeopardise your own safety or that of other people.
The behaviour of operators and maintenance/cleaning/control personnel etc. must comply strictly
with the accident prevention measures in force in the country where the machine is used.
1.1 First aid and medical assistance
What to do if there is an accident while using the cutting and water jet systems
Possible cases of injury and shock:
• the total or partial perforation of the skin and subcutaneous tissues, leading to a necrosis
inside the limb as a result of the damage to the tissues around the injury
• the amputation of a limb (or limb part) if the jet is excessively pressurised
• infection in the tissues, caused by the elements carried by the water
• the contusion of an organ (also internal) if the jet is not powerful enough to cause the
perforation of the skin. The skin will appear dark bluish and will be painful; the muscles
below will begin to swell and so the capillary vessels will compress and prevent the flow of
blood, triggering a necrosis. Only quick medical intervention can prevent the spread of the
gangrene.
Immediate first aid is essential in the event of an accident, followed by the quick intervention of
specialised medical personnel.

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First aid:
• apply life-saving techniques if necessary, then deal correctly with the operator's state of
shock
• treat his injuries
• if any body parts have been amputated, pick them up and keep them in a safe and
appropriate manner
After giving first aid, transfer the victim to the nearest hospital immediately. In the meantime,
it is useful (and perhaps fundamental) to telephone Accident and Emergency to inform them
of the situation, so that they will be ready when the patient arrives at the hospital.
The surgeon in particular must be well informed about what exactly has happened, the time
needed to reach the hospital, and the type of injury suffered.
With this aim, it is advisable to send a precise but brief description of the WJ (WaterJet)
technology, including the specific damage it may cause.
The damage that could be caused by the Waterjet includes three types in particular:
cuts:
• high pressure jet, powerful enough to pierce the tissues and partially or totally amputate a
limb (or part of it), but without harming the surrounding areas
• low pressure jet, causing more serious harm due to the return pressure that damages the
area around the injury itself. The contusive and/or destructive effect does not in fact involve
only the skin, but also the anatomical structures below
impact-related injury
risks of infection due to impurities: the water that filters in the skin carries substances that
are alien to the human body
The most misleading aspect is that there may be no surface injury, only a bluish contusion.
In addition, if the jet strikes near vital organs, the impact energy may be transferred to the organ
itself, damaging it. Finally, the effect of the water that filters in the tissues is a dual one: it damages
the cells directly or indirectly causing them to swell; it also diffuses - inside and in every direction -
bacteria, oils, paint, particles of abrasive or other toxic substances that may trigger allergic
reactions or react chemically (generating acid-base imbalances, pH alterations, etc.). As a result, it
is no longer possible to precisely identify the extent of the contamination.
With regards the risk of infection propagation, even a simple “jab” with a high pressure jet must not
be underestimated.
Bibliography
AAVV Acts of the “12th International Conference on WATER JETTING TECHNOLOGY“ C. GEE, 1994
AAVV Acts of the “13th International Conference on WATER JETTING TECHNOLOGY – Application and
opportunities“ Cagliari 29-31 October 1996 C. GEE, 1996
JISHA Safety Guidelines for WaterJet machining JISHA, 1992 Petrolati per Reimpianto di segmenti Riv. It. Chir.
Amadei -Abbiati Plastic Surgery, 1992

1 Safety information
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For further information, contact:
Azienda Ospedaliera Ospedale Civile di Legnano - Clinica di Chirurgia Plastica
Doctor Petrolati
Via Candiani, 2
Phone number [phone]
Associazione Italiana WaterJet
Dipartimento di Meccanica - Politecnico di Milano
Mr. M. Monno
Via Bonardi, 9 - 20133 MILAN
www.aiw.polimi.it
1.2 Lifting and handling
1. The lifting and movement of the machine (or any part of it) must be carried out by personnel
with the necessary technical expertise, and using means of appropriate capacity.
2. Do not stand in the field of action of the crane while the machine is being lifted.
3. Only use the lifting system described in this manual.
1.3 Installation
1. Operations must always be carried out by qualified personnel authorised by INTERMAC.
2. Before starting, make sure that the various parts of the machine have suffered no damage
from impact, tearing or abrasion. Damage to electrical cables or sheathing will compromise
the safety of the machine’s electrical system.
3. The installation room must be free of dark areas, irritating dazzle or dangerous stroboscopic
effects caused by the factory lighting system.
The minimum values prescribed by the industrial and craft activities Standard for general
machining operations concerning this machine is 300 LUX (lx).
1.4 Protection against overcurrents
1. The material supplied is fitted with protection devices for overcurrents, and in particular for the
internal requirements of the machine itself (against short-circuits).
2. It is the duty and responsibility of the user to guarantee protection against machine supply
overcurrents (in particular against short-circuits), suitable for the presumed short-circuit
current of his system in the machine connection point.

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1.5 Protection against indirect contacts
1. The user's system upstream from the machine must be designed, installed, and maintained in
compliance with the relevant safety regulations for “low voltage user systems”.
2. As regards the conditions/prescription of point 1), the correlative “protective earthing system”
must comply with the applicable requisites for co-ordination with the associated active
devices.
1.6 Protection against fire
1. If there is a fire in the electrical parts, use powder and gas-based extinguishing devices.
Do not direct water jets onto the machine: they may cause short-circuits. If the fire is not
extinguished immediately, pay attention to the possible dispersion of air, water, oil and heating
fluids. If the machine is exposed to flames for a long time, the pressurised tanks and pipes
may burst: be careful to avoid being struck by the fluids.
2. It is advisable to keep fire extinguishers near the machine.
To prevent the risk of fire, keep the machine clean and free of oils, solvents, rags, etc.
1.7 Preparation and machining operations
1. Before starting machining operations, the operator must be fully familiar with the position and
operation of all the machine commands and characteristics.
2. Wear protective clothing of the approved type (goggles, gloves, helmet and footwear).
3. Do not attempt to modify the safety system management programs. BIESSE declines all
responsibility for any harm to people or damage to property resulting from unauthorised
modifications of this kind.
4. The machine must be set up by one person only. Ensure that nobody else approaches the
machine during the set-up operations.
5. When entering the working area, remove the key from the “Axis disconnection” selector, to
prevent anybody from restarting the machine.
6. Never leave tools on the machine when the set-up has been completed.
7. Before starting the machining operation, check there is nobody within the dangerous machine
areas.
8. Check that nothing can impede the regular movement of the machine along the Cartesian
axes, and that all the casings, doors and protective covers are in place and securely fixed.
9. Before beginning the machining operation, check that the tooling of the machine has not been
tampered with by anybody else.
10. Do not use the machine when under the influence of medication or drinks that could reduce
the speed of your reactions.

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11. Always keep the working area clean and tidy.
12. Do not climb onto the machine when a program is being executed or the axes are moving.
1.8 Maintenance
1. Respect the frequencies indicated for maintenance interventions.
2. To ensure correct machine operation, components must always be replaced with original
spare parts.
3. Before carrying out any type of maintenance and/or cleaning operation, stop the machine and
disconnect it from the power supply using the procedures listed in this manual.
4. Interventions on pneumatic systems must only be carried out after discharging the pressure
from those systems.
5. Repairs to electrical systems must be carried out after the power supply has been
disconnected, and with the emergency button activated.
6. Wait at least 5/6 minutes before approaching the electronic equipment so as to allow the
capacitors the time to discharge any residual energy.
7. Maintenance must always be carried out by qualified personnel.
8. Every time units need to be dismantled or installed, make sure they are supported with lifting
devices appropriate for the load involved.
9. Transfer the load to suitable supports or stands immediately.
10. Never attempt to climb on or off the machine when it is moving.
11. Never use petrol, solvents or flammable fluids to clean the parts; use commercially available
type-approved detergents that are non-toxic and non-flammable.
12. When a repair or maintenance needs to be performed in areas not accessible from the
ground, use a ladder or a platform with steps complying with local and national standards.
13. Carry out all maintenance and repair works with caution, following the instructions provided in
this manual.
14. Once the maintenance interventions have been carried out, check that all the safety devices
are in good condition before restarting the machine.
15. Always use personal protection devices.
16. Use electric tools that comply with current safety regulations.
17. Before starting the machine, make sure that nobody is carrying out maintenance work on it.
18. Do not work under or near any kinematic systems that have not been appropriately supported
and locked in position.
19. Before carrying out cleaning, repairs or other work on the machine, always turn the starter
switch to the locked position.
20. Wear protective goggles with side shields.

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21. Before removing any guard, stop the machine completely and disconnect the power supply,
checking to ensure that none of the parts are still moving.
22. The machine must only be used for the purpose for which it was designed.
23. The machine must always be used in compliance with the safety regulations in force in every
country.
24. When handling the lubricants, do not smoke, eat or drink. Adhere to the regulations currently
in force with regard to the handling of oils and mineral greases.
25. Before handling the lubricants, always wear anti-spray goggles or a mask, oilproof gloves and
oilproof overalls to prevent irritation or allergy.
26. Keep the lubricants in a naturally aired room, far from heat sources (electric panels, naked
flames, etc.).
27. Avoid the direct contact of the lubricants with pure oxygen and acids.
28. All the lubricants must be eliminated via the authorised used oil collection organisations.
29. If lubricant is spilt, spread sand over the surface to absorb the product; the sand must then be
gathered up with a spatula and sent for incineration to the authorised special waste collection
organisations. Wash surfaces with solvents (chlorinated or aliphatic), taking care not to let the
vapours stagnate in the work area.
30. For people who are particularly sensitive to lubricants, an allergic reaction or oil acne is
possible, especially if the skin has previously been damaged owing to an abrasive (hand
cleaning paste or wounds) or chemical (solvents, strong alkaline detergents, etc.) attack.
Contact with the eyes can cause irritation.
31. If the lubricants are incorrectly handled, it is possible to note the effects of overexposure, such
as a slight irritation of the eyes or skin; if this should happen, move away from the exposure
source and contact a doctor.
32. If the lubricants come into contact with the skin, wash the affected part with soap and water.
33. If the lubricants come into contact with the eyes, rinse with water.
34. If a lubricant of the “oils” category is swallowed, seek medical advice immediately.
35. If a lubricant of the "greases" category is swallowed in a small quantity, call a doctor
immediately. If the quantity is more than 1/2 litre, give 1 or 2 glasses of water and call a doctor
immediately. Do not induce vomiting if the patient has fainted, and do not administer anything
else by mouth.
1.9 Scrapping
1. The operations must be carried out by qualified personnel.
2. Turn the machine off, disconnect it from the power supply, and discharge all the air from the
pneumatic system.
3. Fix all parts capable of moving by inertia or by gravity.

1 Safety information
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1.10 Danger signs
The danger signs on the machine are described and illustrated below.
1.11 General prohibition signs
EDANGER! Before carrying out any operations on the electrical system, make
sure that the power supply has been turned off.
=DANGER! Risk of crushing hands between moving mechanical parts.
DANGER! Risk of cuts from high pressure water jet
9
Do not remove the safety devices and guards. Their temporary removal is only
permitted for maintenance purposes, as long as all the necessary safety
precautions are adopted.
7
No access to the machine working areas.
8
Do not clean or lubricate moving parts.
?
Do not smoke near the machine.
...!. Do not pour polluting liquids into the drainage points.

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20 BIESSE S.p.A. © - P723K0002.fm251111
1.12 Obligation signs
1.13 Signs fixed to the machine
The signs fixed to the machine must never be removed for any reason whatsoever.
The signs must be clearly legible and not covered by any objects.
Damaged signs should be replaced (request new ones from the manufacturer).
6
Ensure that the guards and safety devices are in efficient working order.
4
Disconnect the power supply before inserting or removing the plugs.
5
The wearing of suitable work clothes is compulsory.
;
The wearing of safety shoes is compulsory.
0
The wearing of a safety helmet is compulsory.
3
The use of gloves is compulsory.
1
Ear protection is compulsory.
R The wearing of protective goggles is compulsory.