KMT STREAMLINE S50 User manual

MANUAL 20479050(R04)
STREAMLINE S50
WATERJET INTENSIFIER
OPERATION AND MAINTENANCE MANUAL

20479315
2-2012/Rev 03
NOTICE
This document contains subject matter in which KMT Waterjet Systems has
proprietary rights. Recipients of this document shall not duplicate, use or disclose
information contained herein, in whole or in part, for other than the purpose for
which this manual was provided.
KMT Waterjet believes the information described in this manual to be accurate and
reliable. Much care has been taken in its preparation; however, the Company cannot
accept any responsibility, financial or otherwise, for any consequences arising out of
the use of this material. The information contained herein is subject to change, and
revisions may be issued advising of such changes and/or additions.
KMT WATERJET SYSTEMS 2012
KMT Waterjet Systems
635 West 12th Street
PO 231
Baxter Springs, KS 66713-0231
Phone:
Fax: [phone] [phone]

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TABLE OF CONTENTS
Title Page
Notice
Table of Contents
Appendix
Section Page
1Introduction.......................................................................................................1-1
1.1 Overview................................................................................................1-1
1.2 Performance Features.............................................................................1-1
1.3 Operational Overview............................................................................1-2
Low Pressure Water System..................................................................1-2
Recirculation System.............................................................................1-2
Hydraulic System...................................................................................1-2
High Pressure Water System .................................................................1-2
1.4 Safety .....................................................................................................1-3
Lockout/Tagout Procedure.....................................................................1-4
Warning Labels......................................................................................1-4
Emergency Medical Treatment..............................................................1-6
1.5 Worldwide Product Support ..................................................................1-7
1.6 Spare Parts .............................................................................................1-7
1.7 Manual Organization .............................................................................1-7
1.8 Equipment and Service Manual Questionnaire......................................1-8
Terms and Conditions of Sale
Terms and Conditions, Part Sales
Terms LD-146, Domestic Service Supervisor
Terms LD-147, International Service Supervisor
2Installation.........................................................................................................2-1
2.1 Overview................................................................................................2-1
2.2 Installation Summary.............................................................................2-1
2.3 Site Requirements..................................................................................2-2
Transporting...........................................................................................2-2
2.4 Power Requirements..............................................................................2-3
2.5 Service Connections...............................................................................2-4
Cooling Water (Oil-to-Water Models)...................................................2-5
Cutting Water.........................................................................................2-5
Drain ......................................................................................................2-6
Plant Air.................................................................................................2-6
Contaminated Waste Drain....................................................................2-6
2.6 Flow Requirements................................................................................2-7

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2.7 High Pressure Piping..............................................................................2-7
Measurements and Dimensions .............................................................2-8
Hand Coning..........................................................................................2-9
Power Coning.........................................................................................2-10
Hand Threading .....................................................................................2-11
Power Threading....................................................................................2-11
2.8 High Pressure Connections....................................................................2-12
Standard Connections ............................................................................2-12
Anti-Vibration Connections...................................................................2-13
2.9 Commissioning......................................................................................2-14
2.10 Decommissioning ..................................................................................2-16
3Maintenance ......................................................................................................3-1
3.1 Overview................................................................................................3-1
3.2 Maintenance...........................................................................................3-1
Daily Inspection.....................................................................................3-1
Periodic Maintenance.............................................................................3-1
High Pressure System Maintenance.......................................................3-2
3.3 Maintenance Precautions.......................................................................3-3
3.4 Tool Kit..................................................................................................3-3
4Low Pressure Water System............................................................................4-1
4.1 Overview................................................................................................4-1
4.2 Cutting Water Supply Quality ...............................................................4-1
4.3 Operation................................................................................................4-1
4.4 Service and Maintenance Procedures ....................................................4-2
Filter Assembly and Strainer Maintenance............................................4-3
Booster Pump Adjustment.....................................................................4-4
5Recirculation System ........................................................................................5-1
5.1 Overview................................................................................................5-1
5.2 Operation (Oil-to-Water Models)..........................................................5-1
5.3 Operation (Oil-to-Air Models)...............................................................5-2
5.4 Service and Maintenance Procedures ....................................................5-3
Hydraulic Oil Maintenance....................................................................5-3
Electric Motor Bump .............................................................................5-6
Oil Filter Maintenance...........................................................................5-6
Operating Temperature Adjustment (Oil-to-Water Models).................5-7
6Hydraulic System..............................................................................................6-1
6.1 Overview................................................................................................6-1
6.2 Operation................................................................................................6-1
6.3 Service and Maintenance Procedures ....................................................6-2
Hydraulic Operating Pressure................................................................6-3
Motor Maintenance................................................................................6-4
Hydraulic Compensator Maintenance....................................................6-4

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7Electrical System...............................................................................................7-1
7.1 Overview................................................................................................7-1
7.2 Sensors and Solenoids............................................................................7-1
7.3 Service and Maintenance Procedures ....................................................7-5
Proximity Switch Maintenance..............................................................7-5
8High Pressure Water System...........................................................................8-1
8.1 Overview................................................................................................8-1
8.2 Operation................................................................................................8-1
8.3 System Components...............................................................................8-3
8.4 Service and Maintenance Overview ......................................................8-4
Torque Specifications ............................................................................8-5
Specialized Maintenance Tools .............................................................8-7
8.5 High and Low Pressure Water Piping....................................................8-8
8.6 High Pressure Cylinder Assembly.........................................................8-8
High Pressure Cylinder Assembly Removal..........................................8-9
High Pressure Cylinder Assembly Installation......................................8-10
High Pressure Cylinder Maintenance ....................................................8-11
8.7 Hard Seal End Caps...............................................................................8-11
Hard Seal End Cap Removal .................................................................8-11
Hard Seal End Cap Installation..............................................................8-12
8.8 Sealing Head..........................................................................................8-13
High Pressure Discharge Check Valve..................................................8-13
Low Pressure Inlet Check Valve............................................................8-15
Sealing Head Maintenance ....................................................................8-16
8.9 High Pressure Seal Assembly................................................................8-16
8.10 Hydraulic Cartridge Seal and Plunger Removal....................................8-18
Plunger Maintenance .............................................................................8-21
Plunger Installation................................................................................8-21
Hydraulic Cartridge Seal Installation.....................................................8-21
8.11 Hydraulic Piston.....................................................................................8-23
Hydraulic Piston Removal.....................................................................8-23
Bearing Rings and Seal Assembly.........................................................8-25
Plunger Button Sockets, Seals and Retainer Pins..................................8-25
Internal Check Valves............................................................................8-26
Hydraulic Piston Installation..................................................................8-26
8.12 Hydraulic Cylinder Maintenance...........................................................8-28
8.13 High Pressure Attenuator.......................................................................8-28
8.14 High Pressure Dump Valve ...................................................................8-29
Pneumatic Control Valve.......................................................................8-29
Pneumatic Actuator................................................................................8-33
8.15 Weep Holes............................................................................................8-34

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9Troubleshooting ................................................................................................9-1
9.1 Overview................................................................................................9-1
9.2 Troubleshooting Guide ..........................................................................9-2
10 Specifications.....................................................................................................10-1
10.1 Overview................................................................................................10-1
10.2 Installation Specifications......................................................................10-1
Environment...........................................................................................10-1
Equipment Dimensions and Weights.....................................................10-1
Service Connections...............................................................................10-2
Plant Air.................................................................................................10-2
10.3 Water Specifications..............................................................................10-2
Cutting Water Supply ............................................................................10-2
Recirculation System.............................................................................10-3
Water Quality Standards........................................................................10-4
10.4 Electrical Specifications.........................................................................10-6
Electrical System ...................................................................................10-6
Ampacity and Power Voltage Requirements.........................................10-6
10.5 Hydraulic and High Pressure System Specifications.............................10-6
Hydraulic System...................................................................................10-6
High Pressure Water System .................................................................10-6
Orifice Capacity.....................................................................................10-8
Torque Specifications ............................................................................10-8
11 Parts List............................................................................................................11-1
11.1 Overview................................................................................................11-1
11.2 Index ......................................................................................................11-2
APPENDIX
Exhibit
System Schematic
Electrical Schematic(s)
Material Safety Data Sheets

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SECTION 1
INTRODUCTION
1.1 Overview
The Streamline S50, specifically designed for integration into a waterjet cutting system, combines
all the unique capabilities and advantages of waterjet cutting with the reliability, ease of operation
and service support that have made KMT Waterjet Systems a leader in waterjet technology.
Available with an oil-to-water or an oil-to-air heat exchanger, the S50 does not include a control
panel or enclosure and will not run as a stand-alone unit. An electrical interface allows the
system builder to supply all power, control and logic interface to the intensifier from the motion
control panel. The entire cutting system can be operated and controlled from one location.
Table 1-1
Streamline S50
Motor
Horsepower
Rating Operating
Frequency Maximum Deadhead Pressure Maximum Flow Rate (at full pressure)
Maximum Single
Orifice Diameter
(at fill pressure)
HP Kw
50 37 50Hz 55,000 psi (3,792 bar)* 0.95 gpm (3.6 L/min) 0.014 inch (0.36 mm)
60Hz 60,000 psi (4,137 bar) 0.86 gpm (3.3 L/min) 0.013 inch (0.33 mm)
* To operate at 60,000 psi (4,137 bar) maximum deadhead and 50 Hz operating frequency, a second high
pressure attenuator must be added (Kit P/N 20479544).
1.2 Performance Features
The S50 is designed with the same convenience and ease of access for maintenance and service
you have come to expect from KMT Waterjet. The hydraulic cylinder head simply bolts to the
hydraulic cylinder; each high pressure assembly can be removed and serviced independently, and
the hydraulic seal cartridge can be quickly replaced as a single unit.
The robust performance and standard features are the result of aggressive development and
decades of experience.
Deadhead at 60,000 psi (4,137 bar).
The innovative hard seal end cap provides a metal-to-metal seal against the sealing head,
totally, eliminating the potential for leaks.
While dramatically increasing seal life, the unique design of the patented HyperLifeTM
seal conforms to the cylinder bore as it expands under pressure, creating an absolute seal.
Each long, slow stroke of the plunger moves more water, while reducing seal and
component wear.

Section 1
Introduction
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1.3 Operational Overview
The following provides a brief overview of the function and primary components associated with
the individual systems. A detailed discussion of each system is provided in Sections 4 through 8.
Low Pressure Water System
The low pressure water system supplies the cutting water flow to the intensifier. Major system
components include the water filter assembly and the booster pump.
Figure 1-1: System Components
Recirculation System
The recirculation system is a cooling and filtration system that provides properly conditioned oil
to the main hydraulic system. Major system components include the recirculation pump, heat
exchanger, oil filter assembly and the hydraulic oil reservoir.
Hydraulic System
The hydraulic system supplies the intensifier with the hydraulic oil required to produce high
pressure water. Major system components include the electric motor, hydraulic pump and a 4-
way directional control valve mounted on the hydraulic manifold.
High Pressure Water System
The high pressure water system is the heart of the waterjet system. Water is pressurized and
continuously delivered to the cutting head. As water passes through a tiny hole in the orifice,
water pressure is converted to water velocity capable of cutting most any material.

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Introduction
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The major components include the high pressure cylinder assemblies, hydraulic cylinder
assembly, hydraulic piston, attenuator and the safety dump valve.
Figure 1-2: High Pressure Water System Components
1.4 Safety
The high pressure waterjet cutting system is a high energy cutting tool capable of cutting many
dense or strong materials. Do not touch or be exposed to high pressure water. High pressure
water will penetrate all parts of the human body. The liquid stream and the material ejected by
the extreme pressure can result in severe injury.
All personnel operating, servicing or working near the waterjet cutting equipment shall adhere to
the following safety precautions, as well as the applicable plant safety precautions.
Only KMT factory trained, qualified personnel shall service and maintain the
equipment.
The operator shall practice and promote safety at all times to avoid potential
injury and unnecessary downtime.
The work area around the equipment shall be clean and free of debris and oil
spills.
All protective guards, shields or covers shall be in place on the equipment at
all times.

Safety glasses and ear protection shall be worn when operating or
working near the equipment.

Section 1
Introduction
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Lockout/Tagout Procedure
This lockout/tagout procedure is designed to protect all employees from injuries caused by the
unexpected energizing or startup of the machine, or the release of stored energy during service
and maintenance.
This is accomplished with energy isolating devices that prevent the transmission or release of
energy. An energy source is any source of electrical, mechanical, hydraulic, pneumatic,
chemical, thermal, or other energy source that could cause injury to personnel.
A lockout device utilizes a lock and key to hold an energy isolating device in the safe position
and prevents the machine from being energized. A tagout device is a prominent warning device
that can be securely attached to the machine warning personnel not to operate the energy isolating
device. This procedure requires the combination of a lockout device and a tagout device.
The lockout/tagout procedure applies to any employee who operates and/or performs service or
maintenance on the machine. Before any maintenance or repairs are performed, the machine
shall be isolated, and rendered inoperative as follows.
1. Shut down the machine by pressing the stop button, and open the high pressure cutting
water valve to bleed the water and hydraulic pressure from the system.
2. Disconnect, lockout and tag the main, customer supplied, power source.
3. Lockout and tag the circuit breaker/disconnect on the electrical enclosure door.
4. Close, lockout and tag the manual shutoff valves for all service connections: cutting water
in, cooling water in and out, and air.
Warning Labels
Warning labels are posted on the machine to indicate potential hazards. The operator and service
personnel shall pay particular attention to these warning labels. Table 1-2 describes the necessary
precautions and provides the part number required to order replacement labels.
Table 1-2
Warning Label Precautions
1 The electrical enclosure and motor junction box can
present an electrical shock hazard. Always disconnect
and lockout the main power before opening the
enclosure.
Always disconnect and lockout the main power and the
circuit breaker/disconnect on the electrical enclosure
door before performing any type of maintenance.
P/N 05114962