Flow HYPLEX Bedienungsanleitung
HYPLEX®PRIME PUMP
M-416 | REV.C|MAY2012
Due to continuing product improvement, the information contained in this document is subject to change without
notice. Flow International Corporation (Flow) shall not be held liable for technical or editorial omissions made herein,
nor for any incidental or consequential damage resulting from the use of this material.
This document contains information protected by copyright. No part of this document shall be reproduced in any
manner without prior written consent from Flow International Corporation.
HyPlex®, HyPlex® Hybrid, HyPlex® Prime, and Dynamic Waterjet® are registered trademarks of Flow International
Corporation.
© Copyright 2011-2012 Flow International Corporation. All rights reserved.
This document is the original, non-translated version.
2 | M-416 ©FlowInternationalCorporation
HYPLEX PRIME PUMP
Maintenance & Service Manual
© Flow International Corporation M-416 | 3
INTRODUCTION
HyPlex Prime Pump
Chapter 1. Equipment Description
Features 5
Specifications 6
Interface illustrations 7
Interface labels 10
Water requirements 11
Air requirements 12
Environment requirements 12
High-pressure tubing 12
Anti-vibration mat 13
Startup procedure 14
Temperature input offset adjustment routine 16
Calibrating the pump control system 16
Preparing the HyPlex Prime pump for
shipping or storage 17
Chapter 2. Safety
Safety precautions 19
Warnings, cautions, and notes 19
Safety tips 20
Protective clothing 21
Emergency medical information 22
Chapter 3. Maintenance & Troubleshooting
Periodic maintenance 23
General precautions 23
Inspection & maintenance schedules 25
Routine daily checks 25
Mandatory maintenance schedules 26
30 hp HyPlex Prime pump maintenance schedule 27
50 hp HyPlex Prime pump maintenance schedule 28
Troubleshooting the HyPlex Prime Premium pump
using FlowSENSE 29
FlowSENSE diagnostic codes 30
Troubleshooting the high-pressure components 32
Additional troubleshooting tips 32
Weep holes 32
Visual troubleshooting guide for
the high-pressure components 33
Troubleshooting table 34
Chapter 4. Service
Servicing the high-pressure pump 41
Service tips & notes 41
High-pressure components illustration 42
Using the pressure loading tool 43
Installing the Dynamic Seal Maintenance kit 45
Installing the Minor Maintenance kit 55
Installing the Major Maintenance kit 67
Installing the pressure control valve (PCV)
Maintenance kit 79
Changing the filter elements 83
Replacing the dynamic seal and plunger 84
Tensioning and aligning the belt drive 91
Servicing the belt 91
Servicing the crankcase 93
Chapter 5. Engineering Drawings
Drawing lists 95
Maintenance kits 97
Tools 99
Recommended spares 99
4 | M-416 ©FlowInternationalCorporation
HYPLEX PRIME
Maintenance & Service Manual
Introduction
The information in this manual will help you become familiar with your new Flow International (FLOW) equipment. It
was compiled from the most current information available at the time of publication and is intended to cover the most
common configurations. Your equipment was shipped with other documents and drawings. Refer to these drawings
when using the service procedures in this manual.
Safety
All operating personnel and service technicians must read and follow the comprehensive list of safety precautions in all
manuals provided with your equipment before installing, operating, or servicing the equipment. This will help avoid
creating unsafe conditions or equipment damage.
The high-pressure waterjet system is a powerful cutting tool and must always be treated with respect.
Warnings, cautions, and notes
Before operating the equipment, you must read, understand, and follow all warnings, cautions, and notes in this man-
ual. They are defined as follows:
WARNING
Highlights an operating or service procedure or condition that can
result in death or serious injury to personnel.
CAUTION
Highlights an operating or service procedure or condition that can
lead to impaired system operation or equipment damage.
Note: Highlights an operating or service procedure or condition that is essential for efficient operation and service.
CHAPTER 1
Equipment Description
The HyPlex Prime pump is a powerful, ultrahigh-pressure waterjet cutting tool designed for minimum maintenance
and reliable performance. The pump has an operating pressure of 55,000 psi (3790 bar), and a maximum generated
pressure of 60,000 psi (4140 bar).
Base features
•Triplex pump
•Totally-enclosed, fan cooled (TEFC) motor
•Manually adjustable output pressures from
1000–55,000 psi, dual-pressure control optional
•Dual filter system removes particles larger than
0.5 microns absolute
•Available in 30 or 50 hp motor, 60Hz or 50Hz
Basic package
For use with Flow X-Y tables prior to those introduced with B&R
controls.
•Motor starter is not included
Standard package
For use with B&R-controlled Flow X-Y tables.
•Motor starter is included
Plus package
For use with B&R-controlled Flow X-Y tables.
•UHP water system pressures are monitored by a
pressure transducer and displayed in FlowCUT
•Auto-calibration of UHP pressure control system
•Motor starter is included
Premium package
For use with B&R-controlled Flow X-Y tables.
•UHP water system pressures are monitored by a
pressure transducer and displayed in FlowCUT
•Auto-calibration of UHP pressure control system
•Motor starter is included
•FlowSENSE, an early warning system for critical parts
© Flow International Corporation M-416 | 5
Specifications
Contact FLOW Technical Service for further information.
Also see the system drawings in Chapter 5.
Dimensions
(with covers closed) 60 L x 40 W x 41 in. H
................................1524 L x 1016 W x 1042 mm H
(with covers open) 60 L x 40 W x 52 in. H
................................1524 L x 1016 W x 1321 mm H
Nominal crankcase RPM 50Hz 60Hz
30 hp....................................................716 709
50 hp..................................................1154 1114
Operating pressure...................55,000 psi (3790 bar)
Max. generated pressure ..........60,000 psi (4140 bar)
Filtration provided...............0.5 micron and 1 micron
Min. required inlet water flow rate
30 hp ...............................................2 gpm @ 57 psi
50 hp ...............................................3 gpm @ 65 psi
Low inlet water pressure switch threshold
........................................................................£15 psi
To ensure proper inlet water pressure, a boost pump may
be required.
Req. inlet water temperature range
.........................................55°F–70°F (12.7°C–21°C)
If plant inlet water temperature is outside of this range,
contact Flow Technical Service
Air.........................................90–120 psi (6.2-8.3 bar)
....................................dry and filtered to 10 microns
Drain............212°F (100°C) water at 0.9 gpm (30 hp)
.....................212°F (100°C) water at 1.5 gpm (50 hp)
Max. UHP orifice size
30 hp .......................................................-12 orifice
50 hp .......................................................-16 orifice
Voltage
Nominal
system
voltage **
Horsepower
(hp)
Frequency
(Hz)
Phase
200 * 50 *
200 * 60 *
208 * 60 *
230 * 50 *
240 30/50 60 3
380 * 60 *
400 30/50 50 3
480 30/50 60 3
500 * 60 *
* Not supported.
** Utilization voltage is often referenced, which will be
3-5% lower than the nominal system voltage. Where
referenced, the utilization voltage is equivalent to the
nameplate voltage of a product.
Crankcase oil
Use of Shell Morlina 100 Hydraulic Oil (ISO 100) is
recommended, but other manufacturer's equivalents
can be used.
When operating the pump in an environment with an
ambient temperature greater than 86°F (30°C), a
heavier oil is recommended to be used. Contact Flow
Technical Services for additional information.
Reservoir
capacity
2.0 qt (1.9 liter)
Maintain oil level between the high and low
level marks on the dipstick.
6 | M-416 ©FlowInternationalCorporation
HYPLEX PRIME PUMP
Maintenance & Service Manual
© Flow International Corporation M-416 | 7
CHAPTER 1
Equipment Description
8 | M-416 ©FlowInternationalCorporation
HYPLEX PRIME PUMP
Maintenance & Service Manual
© Flow International Corporation M-416 | 9
CHAPTER 1
Equipment Description
10 | M-416 ©FlowInternationalCorporation
HYPLEX PRIME PUMP
Maintenance & Service Manual
Interface labels
Inletwaterpressure(postfilter)
This gauge indicates water pressure after the inlet water has passed through
the 0.5 micron and 1.0 micron water filters.
Inlet water pressure (pre filter)
This gauge indicates water pressure before the inlet water has passed through
the 0.5 micron and 1.0 micron water filters.
High air pressure
This gauge indicates the air pressure supplied to the UHP pressure control
valve (PCV) as controlled by the regulator below the gauge.
On dual-pressure machines: this indicates the maximum air pressure setting.
Low air pressure
On dual-pressure machines, this indicates the minimum air pressure setting.
Inlet water connection
Connect inlet water at recommended specification.
Air inlet connection
Connect inlet air at recommended specifcation.
PCV to drain
Connect a drain line directly to an outlet drain at recommended specifica-
tions.
CAUTION
To ensure that the PCV does not suffer damage due to siphoned catcher tank
water, connect the PCV drain line directly to an outlet drain,
or suspend the line above the catcher tank water level.
High-pressure water outlet
Outlet port for ultrahigh-pressure (UHP) water.
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