KMT Streamline SL-V Plus series User manual

MANUAL 20413130(R13)
STREAMLINE SL-V 100 PLUS
WATERJET INTENSIFIER
OPERATION AND MAINTENANCE MANUAL

20412906
8-2012/Rev 11
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]

20412906
8-2012/Rev 11 i
TABLE OF CONTENTS
Title Page
Notice
Table of Contents
Appendix
Section Page
1Introduction.......................................................................................................1-1
1.1 Overview................................................................................................1-1
1.2 Performance Features and Options........................................................1-1
1.3 Operational Overview............................................................................1-3
Low Pressure Water System..................................................................1-3
Recirculation System.............................................................................1-3
Hydraulic System...................................................................................1-3
High Pressure Water System .................................................................1-3
Operating System...................................................................................1-4
1.4 Safety .....................................................................................................1-5
Lockout/Tagout Procedure.....................................................................1-5
Warning Labels......................................................................................1-6
Emergency Medical Treatment..............................................................1-8
1.5 Worldwide Product Support ..................................................................1-8
1.6 Spare Parts .............................................................................................1-9
1.7 Manual Organization .............................................................................1-9
1.8 Equipment and Service Manual Questionnaire......................................1-10
2Installation.........................................................................................................2-1
2.1 Overview................................................................................................2-1
2.2 Installation Summary.............................................................................2-1
2.3 Site Requirements..................................................................................2-2
Transporting...........................................................................................2-3
2.4 Power Requirements..............................................................................2-4
2.5 Service Connections...............................................................................2-5
Cooling Water (Oil-to-Water Models)...................................................2-6
Cutting Water.........................................................................................2-7
Drain ......................................................................................................2-7
Plant Air.................................................................................................2-7
Contaminated Waste Drain....................................................................2-8
2.6 Flow Requirements................................................................................2-8
2.7 High Pressure Piping..............................................................................2-9
Measurements and Dimensions .............................................................2-10
Hand Coning..........................................................................................2-11

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Power Coning.........................................................................................2-12
Hand Threading .....................................................................................2-12
Power Threading....................................................................................2-13
2.8 High Pressure Connections....................................................................2-13
Standard Connections ............................................................................2-14
Anti-Vibration Connections...................................................................2-14
2.9 Commissioning......................................................................................2-15
2.10 Decommissioning ..................................................................................2-18
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 Kits ................................................................................................3-3
4Operation...........................................................................................................4-1
4.1 Overview................................................................................................4-1
4.2 Startup Sequence....................................................................................4-2
Startup after Motor Stop ........................................................................4-2
Startup after Emergency Stop................................................................4-2
4.3 Display Controls ....................................................................................4-3
4.4 Main Menu.............................................................................................4-4
4.5 Run Screens ...........................................................................................4-5
4.6 Pressure Control Screen.........................................................................4-6
4.7 Setup Screens.........................................................................................4-7
4.8 Stroke Rate Screens ...............................................................................4-8
4.9 Hours Screens ........................................................................................4-10
4.10 Run Screen Alarms................................................................................4-11
4.11 Alarm Banners.......................................................................................4-13
4.12 Alarms Screen........................................................................................4-14
Installing a New Battery ........................................................................4-16
4.13 Alarm History ........................................................................................4-16
Changing the Date and Time .................................................................4-17
4.14 Configuration Screen.............................................................................4-17
4.15 Maintenance Screen...............................................................................4-17
4.16 Language Screen....................................................................................4-18
5Low Pressure Water System............................................................................5-1
5.1 Overview................................................................................................5-1
5.2 Cutting Water Supply ............................................................................5-2
5.3 Operation................................................................................................5-2
5.4 Service and Maintenance Procedures ....................................................5-4
Filter Assembly and Strainer Maintenance............................................5-4

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Booster Pump Adjustment.....................................................................5-5
6Recirculation System ........................................................................................6-1
6.1 Overview................................................................................................6-1
6.2 Operation (Oil-to-Water Models)..........................................................6-1
6.3 Operation (Oil-to-Air Models)...............................................................6-3
6.4 Service and Maintenance Procedures ....................................................6-4
Hydraulic Oil Maintenance....................................................................6-4
Electric Motor Bump .............................................................................6-6
Oil Filter Maintenance...........................................................................6-7
Operating Temperature Adjustment (Oil-to-Water Models).................6-8
7Hydraulic System..............................................................................................7-1
7.1 Overview................................................................................................7-1
7.2 Optional System Components................................................................7-2
7.3 Operation................................................................................................7-2
7.4 Service and Maintenance Procedures ....................................................7-4
Hydraulic Operating Pressure................................................................7-4
Proportional Valve Maintenance ...........................................................7-6
Motor Maintenance................................................................................7-6
Flexible Coupling Replacement.............................................................7-7
Hydraulic Compensator Maintenance....................................................7-9
Hydraulic Pump or Electric Motor Replacement...................................7-12
Hydraulic Oil Replacement....................................................................7-16
Electric Motor Bump .............................................................................7-17
8Electrical System...............................................................................................8-1
8.1 Overview................................................................................................8-1
8.2 Optional System Components................................................................8-1
8.3 Operation................................................................................................8-2
Sensors and Solenoids............................................................................8-5
Softstarter...............................................................................................8-9
8.4 Service and Maintenance Procedures ....................................................8-10
Proximity Switch Maintenance..............................................................8-11
Optical Relay Maintenance....................................................................8-12
9High Pressure Water System...........................................................................9-1
9.1 Overview................................................................................................9-1
9.2 System Options......................................................................................9-2
9.3 Operation................................................................................................9-2
Redundant Intensifiers...........................................................................9-3
9.4 System Components...............................................................................9-5
9.5 Service and Maintenance Overview ......................................................9-6
Torque Specifications ............................................................................9-7
Specialized Maintenance Tools .............................................................9-9
9.6 High and Low Pressure Water Piping....................................................9-10

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9.7 High Pressure Cylinder Assembly.........................................................9-10
High Pressure Cylinder Assembly Removal..........................................9-11
High Pressure Cylinder Assembly Installation......................................9-12
High Pressure Cylinder Maintenance ....................................................9-13
9.8 Hard Seal End Caps...............................................................................9-14
Hard Seal End Cap Removal .................................................................9-14
Hard Seal End Cap Installation..............................................................9-15
9.9 Sealing Head..........................................................................................9-16
High Pressure Discharge Check Valve..................................................9-16
Low Pressure Inlet Check Valve............................................................9-18
Sealing Head Maintenance ....................................................................9-19
9.10 High Pressure Seal Assembly................................................................9-20
9.11 Hydraulic Cartridge Seal and Plunger Removal....................................9-22
Plunger Maintenance .............................................................................9-24
Plunger Installation................................................................................9-24
Hydraulic Cartridge Seal........................................................................9-25
9.12 Hydraulic Piston.....................................................................................9-26
Hydraulic Piston Removal.....................................................................9-27
Bearing Rings and Seal Assembly.........................................................9-28
Plunger Button Sockets, Seals and Retainer Pins..................................9-28
Internal Check Valves............................................................................9-29
Hydraulic Piston Installation..................................................................9-30
9.13 Hydraulic Cylinder Maintenance...........................................................9-31
9.14 High Pressure Attenuator.......................................................................9-31
9.15 High Pressure Dump Valve ...................................................................9-32
3-Port Pneumatic Control Dump Valve (SL-V 30, 50 and 60)..............9-32
2-Port Pneumatic Control Dump Valve (SL-V 100) .............................9-36
Pneumatic Actuator................................................................................9-40
9.16 Weep Holes............................................................................................9-41
10 Troubleshooting ................................................................................................10-1
10.1 Overview................................................................................................10-1
10.2 Troubleshooting Guide ..........................................................................10-2
10.3 Softstarter...............................................................................................10-12
11 Specifications.....................................................................................................11-1
11.1 Overview................................................................................................11-1
11.2 Installation Specifications......................................................................11-1
Environment...........................................................................................11-1
Sound Level...........................................................................................11-2
Equipment Dimensions and Weights.....................................................11-2
Service Connections...............................................................................11-2
Plant Air.................................................................................................11-3
11.3 Water Specifications..............................................................................11-3
Cutting Water Supply ............................................................................11-3
Cooling Water Supply............................................................................11-4

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Water Quality Standards........................................................................11-5
11.4 Electrical Specifications.........................................................................11-7
Electrical System ...................................................................................11-7
Ampacity and Power Voltage Requirements.........................................11-7
11.5 Hydraulic and High Pressure Water System Specifications..................11-8
Hydraulic System...................................................................................11-8
High Pressure Water System .................................................................11-8
Orifice Capacity.....................................................................................11-9
11.6 Torque Specifications ............................................................................11-11
12 Parts List............................................................................................................12-1
12.1 Overview................................................................................................12-1
12.2 Index ......................................................................................................12-2
APPENDIX
Exhibit
System Schematic
Electrical Schematic(s)
Material Safety Data Sheets

20412914
8-2012/Rev 09 1-1
SECTION 1
INTRODUCTION
1.1 Overview
The Streamline SL-V Plus series combines all the unique capabilities and advantages of waterjet
cutting systems with the reliability, ease of operation and service support that have made KMT
Waterjet Systems a leader in waterjet technology.
With 30, 50, 60 and 100 horsepower single and redundant models, the SL-V series accommodates
a wide range of applications. From small, single head requirements to high volume production
requiring multi-head systems; from intricate detailed cutting, to rapid hole drilling; from titanium
to produce, the SL-V series provides the solution.
Table 1-1
Streamline SL-V Plus Models
Model
Motor
Horsepower
Rating Maximum
Operating
Pressure Maximum Flow Rate (at full pressure)
Maximum Single
Orifice Diameter
(at fill pressure)HP Kw
SL-V 30 30 22
60,000 psi
(4,137 bar)
0.52 gpm (2.0 L/min) 0.010 inch (0.254 mm)
SL-V 50 50 37 0.90 gpm (3.4 L/min) 0.013 inch (0.330 mm)
SL-V 60 60 45 1.02 gpm (3.9 L/min) 0.014 inch (0.356 mm)
SL-V 100 100 75 1.88 gpm (7.1 L/min) 0.019 inch (0.483 mm)
1.2 Performance Features and Options
The SL-V series 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.
Continuous operation at 60,000 psi (4,137 bar) affords faster cutting speeds, resulting in
lower cost per inch.
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.
The quick release design of the ceramic plunger greatly simplifies removal and
installation.

Section 1
Introduction
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Each long, slow stroke of the plunger moves more water, while reducing seal and
component wear.
Comprehensive fault detection and troubleshooting logic monitor crucial pressure,
temperature and fluid levels.
Warning and shutdown sensors guard against potential equipment damage.
Performance options are available at the time of purchase, or as upgrades for existing equipment.
The KMT Customer Service Department can provide real time diagnostics,
troubleshooting and data analysis through a modem interface for remote monitoring of the
programmable logic controller (PLC).
Proportional pressure control allows the operator to select or vary the operating pressure
from the control display or remote console.
The current operating pressure can be viewed from the control display with an optional
pressure transducer.

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 9.
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.
The major components include the high pressure cylinder assemblies, hydraulic cylinder
assembly, hydraulic piston, attenuator and the safety dump valve.