Hypertherm DynaMAX 550P

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Preventive maintenance

136 811390 Operator Manual DynaMAX 550P/560P/575P Waterjet Pump

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Table of Contents5
Warranty11
Disclaimer11
Waterjet Product Warranty11
Product Stewardship13
National and Local Safety Regulations13
Certification Test Marks13
Differences in National Standards14
Higher-Level Systems15
Environmental Stewardship17
Hypertherm Products: Waste and Recycling17
Particle Emission and Waste Water Quality17
Chemical Handling and Usage18
Safety19
Manuals19
User Qualification and Training20
Emergency Medical Information and Treatment21
Safety Information for Operation, Maintenance, Repair, and Installation22
Symbols and Marks25
Information and Symbols25
Symbols and Marks Found on the Equipment27
Product Description31
Flow of Water and Hydraulic Fluid32
Cooling Loop33
Pump Exterior35
Pump Interior40
Optional Equipment45
Operation47
Safety47
Use the Controls48
Operation Panel48
Operator Interface49
Turn on the Pump: Beginning of Day or Beginning of Shift52
Clean and Inspect the Pump52
Check the Hydraulic Fluid Quality53
Turn on the Utilities54
Start the Pump54
Make Sure that the Emergency Stop Operates Correctly55
Examine the Pump for Leaks or Damage55
Check the Low-Pressure Water Pressure Gauges56
Check the Hydraulic Filter Gauge57
Check the Hydraulic Fluid Level57
Operate the Pump Remotely58
Stop the Pump58
Operate the Pump Locally59
Select the Pressure Mode59
Set the Target Water Pressure59
Stop the Pump59
Emergency Stop60
Turn off the Pump: End of Day or End of Shift60
Redundant Intensifiers61
Change the Intensifier that Is in Operation61
Preventive Maintenance65
Safety66
Benefits of Preventive Maintenance67
Training68
Tools68
Preventive Maintenance Schedule70
General72
Examine and Clean the Equipment72
Examine the Pump for Leaks or Damage74
Electrical System76
Make Sure that the Emergency Stop Operates Correctly76
Make Sure that the Electrical Interlock Operates Correctly76
Examine Cords, Plugs, and Cables76
Hydraulic System78
Check the Hydraulic Filter78
Check the Hydraulic Fluid Level79
Check the Hydraulic Fluid Quality80
Replace the Hydraulic Filter Element80
Lubricate the Primary Motor Bearings84
Low-Pressure Water System86
Examine the Transport Tubes86
Clean the Seal Maintenance Indicator Tubes86
Replace the Seal Maintenance Indicator Tubes88
Measure the Air Pressure in the Water Accumulator Tank88
Check the Low-Pressure Water Pressure Gauges89
Air Cooler90
Clean the Air Side of the Cooler90
Clean the Hydraulic Fluid Side of the Cooler90
Low-Pressure Water91
Replace the Water Filters91
Test the Water Quality93
Intensifier96
Prepare to Do Maintenance on the Intensifier98
Disassemble the Intensifier99
Assemble the Intensifier106
Bleed-Down Valve120
Repair the Bleed-Down Valve121
Install the Bleed-Down Valve122
Start the Pump after Maintenance123
Operator Interface: Maintenance Screens125
Primary Maintenance Screen126
Move the Plunger126
Start the Pump after Maintenance126
Prepare for Storage127
Record Maintenance127
Inputs and Outputs130
Alarm Log130
Postmaintenance Start Procedure131
Prepare for Storage134
Recycling and End of Product Life135
Parts Lists137
Tools138
Maintenance and Repair Kits139
Optional Equipment141
Replacement Parts142
Lubricants142
Electrical System142
Hydraulic System143
Low-Pressure Water System144
High-Pressure Water System145
Troubleshooting147
Safety147
General148
Normal Status148
Alarms149
Types of Alarms149
Warnings150
Faults152
Intensifier155
Leaks155
Overstroke159
High-Pressure Water Seal Life Is Short164
Hydraulic Fluid165
Temperature167
The Pump Makes Noise During Operation168
Low-Pressure Water169
Seal Maintenance Indicator (SMI)170
Alarms170
Controller Errors171
Input-Output Status171
Specifications173
All Dynamax 5-Series Pumps174
Environmental Conditions174
Hydraulic Fluid174
Utilities174
Compressed Air175
Dynamax 550P176
Dimensions and Weights176
Electrical176
Water176
Dynamax 560P177
Dimensions and Weights177
Electrical177
Water177
Dynamax 575P178
Dimensions and Weights178
Electrical178
Water178
Orifices179
Torque Values179
Fasteners179
Special Fasteners180
Fittings182
Installation187
Safety187
Buyer Responsibilities188
Requirements189
Location189
Cooling189
Hydraulic Fluid190
Compressed Air190
Utilities191
Receive and Unpack the Equipment192
Install the Pump193
Install the External Heat Exchanger (Optional)195
Connect the Utilities to the Pump196
Check the Hydraulic Fluid199
Connect the Electrical Power200
Do the First Start200
Do a Preoperation Inspection201
Turn on the Utilities201
Make Sure that the Primary Motor Turns in the Correct Direction202
Make Sure that the Heat Exchanger Fan Motor Turns in the Correct Direction204
Turn on the Pump204
Adjust the Boost Pump Pressure205
Measure the Air Pressure in the Water Accumulator Tank205
Flush the Pump and the High-Pressure Tubing206
Operator Interface: Adjustment Screens207
Pump Adjustments207
Seal Maintenance Indicator214
Enter or Change the Time and Date215
Intensifier Control216
Pressures217
SD Card218
Remote Operation218
Storage218
Declaration of Incorporation219
Technical Drawings221

Hypertherm DynaMAX 550P - Page 136

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