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]

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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 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

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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.

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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.

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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.

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Introduction
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Figure 1-2: High Pressure Water System Components
Operating System
A programmable logic controller (PLC) provides basic intensifier shift control and monitors out
of limit conditions. Operator interface is through the control panel display where operating
parameters are set and monitored.
Figure 1-3: Control Panel Main Menu

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Introduction
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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.
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.

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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
2 The surface of high pressure water and hydraulic
components becomes hot during normal operation.
Failed, or failing components, can become extremely
hot during operation.
P/N 05114970
3 Ensure that all protective guards, shields or covers are
in place on the equipment at all times. Never operate
the pump with the guards removed.
P/N 80082209

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Introduction
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Table 1-2
Warning Label Precautions
4 High pressure water and/or hydraulic pressure can
remain in the system even when the pump has been shut
off. All pressure can be safely bled from the system by
opening the high pressure cutting water valve for a few
seconds after shutting off the pump.
Pressing the emergency stop button turns the control
power to the intensifier off, stops the pump and bleeds
the high pressure water through the safety dump valve.
Depressurization of the high pressure system creates a
loud hissing sound when the dump valve opens. The
sound fades quickly as the pressure drops.
P/N 05098017
5 All personnel involved in the installation, operation
and/or service of the intensifier must carefully read,
understand and follow the procedures in this manual to
avoid creating unsafe conditions, risking damage to the
equipment, or personal injury.
P/N 20415794
Safety precautions and warnings for specific procedures are emphasized throughout this manual
as illustrated in the following examples. These precautions must be reviewed and understood by
operating and maintenance personnel prior to installing, operating or servicing the machine.
Adherence to all Warnings, Cautions and Notes is essential to safe and efficient service and
operation.
Warnings emphasize operating or service procedures, or conditions that can result
in serious personal injury or death.
Cautions emphasize operating or service procedures, or conditions that can result in
equipment damage or impairment of system operation.

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NOTE
Notes provide additional information that can expedite or improve operating or
service procedures.
Emergency Medical Treatment
An emergency medical card is included in the binder of this manual. This information should be
used to aid in the treatment of a waterjet injury. Additional cards may be obtained by contacting
KMT Waterjet Systems using the address or telephone number shown on the card.
Medical Alert
This card is to be carried by personnel working
with high pressure waterjet equipment. Obtain
medical treatment immediately for ANY high
pressure waterjet injuries.
KMT Waterjet Systems
635 West 12th Street
Baxter Springs, KS 66713
[phone]
This person has been working with water jetting
at pressures to 60,000 psi (374MPa, 4,137 bar,
3867 Kg/cm2) with a jet velocity of 3,000 fps
(914 mps). Foreign material (sand) may have
been injected with water. Unusual infections
with microaerophilic organisms occurring at
lower temperatures have been reported, such as
gram negative pathogens as are found in
sewage. Bacterial swabs and blood cultures
may therefore be helpful. This injury must be
treated as an acute surgical emergency and be
evaluated by a qualified surgeon. Circulation
may be compromised, therefore, DO NOT
APPLY HEAT TO INJURED PART. For first
aid: (1) Elevate injured part (2) Antibiotics (3)
Keep injured person NPO.
1.5 Worldwide Product Support
The KMT Waterjet Customer Service Department is available to answer your questions regarding
equipment installation and service. Technical assistance is available by phone and on-site support
is available on request.
On-site technical assistance is available during equipment installation and startup. Additionally,
technical support for service and maintenance issues and training of operators and maintenance
personnel is available. Periodic training sessions are also conducted at KMT Waterjet and
customer facilities.

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Contact the KMT Waterjet Customer Service Department for additional information.
USA Customer Service Department Europe Technical Manager
KMT Waterjet Systems
PO Box 231
635 West 12th Street
Baxter Springs, KS 66713
USA
Phone: [phone]
Fax: [phone]
Email: [e-mail]
Email: [email protected]
KMT Waterjet Systems GmbH
Wasserstrahl-Schneidetechnik
Auf der Laukert 11
D-61231 Bad Nauheim
Germany
Phone: [phone]
Fax: [phone]
Email: ord[email protected]
1.6 Spare Parts
KMT Waterjet maintains a well-stocked Spare Parts Department, staffed by trained,
knowledgeable personnel. If required, emergency shipment is available. Contact the Customer
Service Department to order spare parts, or for additional information.
1.7 Manual Organization
This manual contains operating and maintenance procedures for the complete SL-V series.
Information is organized as follows:
Section 1, Introduction, provides equipment features and options, a brief operational
overview, details regarding safety issues and contact information for product support.
Section 2, Installation, details installation requirements and procedures. Systematic
guidelines for commissioning the intensifier are also provided.
Section 3, Maintenance, highlights routine and preventive maintenance requirements.
Precautions associated with high pressure cutting equipment are also reviewed.
Section 4, Operation, explains the control functions and the display panel where operating
parameters are set and monitored.
Sections 5 through 9 are specific to each individual system. Each section contains a
detailed description of the principles of operation and the function of each system.
Routine maintenance procedures associated with the system are also included.
Section 10, Troubleshooting, is a comprehensive guide containing the information
required to diagnose problems and repair the machine.
Section 11, Specifications, contains a comprehensive list of equipment specifications; a
detailed discussion of water quality standards and treatment guidelines; as well as
horsepower requirements for various orifice sizes.
Section 12, Parts List, contains part numbers, descriptions and drawings to facilitate the
ordering of replacement parts.

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1.8 Equipment and Service Manual Questionnaire
We are interested in your impression of the KMT Waterjet System recently installed at your
location. Your comments and recommendations will aid us in our continuing goal to improve our
products, and make our technical information more useful to our customers.
At your convenience, please take a few minutes to complete the following questionnaire, and
return it to the applicable Customer Service Department listed above.

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Equipment and Service Manual Questionnaire
1. General Appearance
Was the unit received in good condition? Yes No
Comments:
Is the unit a convenient size? Yes No
2. Controls
Are the controls user friendly? Yes No
Is the unit easy to operate? Yes No
Comments:
3. Performance
Does the unit perform smoothly and meet your expectations? Yes No
Does the unit run quietly? Yes No
Comments:
4. Did the installation and startup go smoothly? Yes No
Comments:
5. What features do you consider the most significant?
Quiet operation
Appearance
Performance/Operation
Repair/Maintenance
Other
6. What areas could be improved?
Appearance
Performance
Serviceability
Other

Equipment and Service Manual Questionnaire
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7. Manual Organization
Does the Table of Contents help you find topics easily? Yes No
Comments:
Is the information well organized? Yes No
Comments:
Is the page layout suitable for the material being presented? Yes No
Comments:
8. Graphics
Are the illustrations suitable for the material being presented? Yes No
Comments:
9. Text
Does the information adequately explain how to operate and service the
equipment? Yes No
Comments:
Are there paragraphs or procedures you feel need clarification? Please identify
them by page number and add your comments. Yes No
Comments:
Is there anything you would add or delete to make the manual more useful? Yes No
Comments:
Is there any information that should receive more emphasis? Yes No
Comments:
Name Title
Company Date
Address

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8-2012/Rev 10 2-1
SECTION 2
INSTALLATION
2.1 Overview
Installation and commissioning requirements and procedures are detailed in this section. These
procedures require a thorough understanding of the individual components and systems, safety
issues, and the overall operation of the intensifier.
All personnel involved in the installation, operation and/or service of the intensifier must
carefully review this manual prior to installing and commissioning the machine.
The Technical Service Department at KMT Waterjet Systems is available to assist in the
installation and commissioning process. Service and repair training for maintenance personnel is
also available.
2.2 Installation Summary
The following summary lists the procedures required for the installation and commissioning of
the intensifier system. Details and requirements for each item are discussed in this section.
Upon receipt, the machine must be uncrated and moved into position on a level surface.
Properly sized power drops with fused disconnects must be installed.
A pneumatic drop with a manual shutoff valve and regulator for the air connection must
be installed.
Plumbing and manual shutoff valves for the inlet and outlet cooling water (oil-to-water
models), and the inlet and outlet cutting water must be installed.
Incoming source water must meet specific water quality standards, flow rates and pressure
requirements. It may be necessary to install water conditioning and/or pressure boosting
equipment to meet these water purity and pressure requirements.
Drain water plumbing must be suitably located and installed for the proper disposal of
wastewater.
High pressure tubing runs from the intensifier to the cutting station must be installed with
the appropriate mountings, support brackets and hardware.
Wiring must be installed and connected between the intensifier and the cutting station
control system.
The machine must be commissioned and tested.