The device described in this manual is the PRIMUS WaterJet, a numerical control processing center designed for cutting various materials using a high-pressure water jet, with or without abrasive powder. The manual covers models Primus 184, Primus 322, and Primus 324.
Function Description
The Primus WaterJet operates by directing a high-pressure water jet (approximately 380 Mpa, 55,000 psi) through a calibrated hole, producing a jet with a speed almost three times the speed of sound (about 810 m/s). This water jet, with or without abrasive, cuts materials through a dual action of erosion and abrasion. The water acts as a vector, and the abrasive acts as the cutting tool. Volumetric pumps, consisting of pistons sliding in cylinders, increase water pressure by using a ratio between the areas on which water and oil act (Intensification ratio).
The machine is designed to perform sectioning operations, including full thickness and partial cuts. It can also be configured with a "pendular mode" option to reduce working times for small pieces, allowing loading and unloading on one side of the table while machining occurs on the other.
Important Technical Specifications
Configurations:
The Primus line includes models 184, 322, and 324. The first two numbers indicate the work table size along the X-axis, and the last number indicates the Y-axis length.
- Primus 184: Available with a standard 3-axis head (X, Y, Z) or a 5-axis head (X, Y, Z, A, C).
- Primus 322 & 324: Available with one or two heads (3 or 5 axes each) and a pendular mode option.
Axes:
- X-axis: Along the mobile beam (moves on two shoulders).
- Y-axis: Along the fixed shoulders of the machine.
- Z-axis: Vertical movement.
- A-axis (5-axis version): Tilting axis (+60° / -60°).
- C-axis (5-axis version): Endless rotation around the Z-axis (infinite).
Axis Stroke:
- Primus 184: X: 1860mm (3-axis), 1700mm (5-axis); Y: 4000mm (3-axis), 3800mm (5-axis); Z: 250mm (3-axis), 200mm (5-axis).
- Primus 322/324: X: 3210mm; Y: 2000mm (322), 4000mm (324); Z: 250mm (3-axis), 200mm (5-axis).
Linear Speeds (m/min):
- Primus 184: X: 54, Y: 38.5, Z: 9.
- Primus 322/324: X: 45, Y: 45, Z: 15.
Workable Materials:
- Pure water jet: Foam rubber, stratified rubber, reinforced rubber, sealing materials, textile materials, footwear materials, leather, chalk, paper, corrugated cardboard, wood, thin plywood, compound materials (glass/kevlar™/carbon), plastic sheets, polystyrene, ABS, PVC, moulded circuits, foodstuffs.
- Abrasive water jet (optional): Stony materials (marble, granite, natural stones, ceramic, glazed stoneware), simple glass, laminated glass, bullet-proof glass, special glass, industrial ceramics, titanium and special alloys, steel, stainless steel, metal sheet, aluminium, copper, brass, lead, bronze, silver, gold, special thick compounds, honeycomb structures, magnetic lattens, lining, graphite, carbon fiber, gaskets, fiberglass, rock wool, thick plywood, resins.
Maximum Material Dimensions:
- Primus 184: X: 2010mm, Y: 4200mm, Z: 250mm.
- Primus 322: X: 3210mm, Y: 2000mm, Z: 250mm.
- Primus 324: X: 3210mm, Y: 4000mm, Z: 250mm.
Admissible Weight on Work Table: No more than 1000 kg/m².
Water Consumption:
- Intensifier: 3.8 l/min (22 kW, 37 kW), 4.1 l/min (45 kW), 7.8 l/min (75 kW).
- Washing pump: 18 l/min.
Electrical Characteristics: Refer to rating plate (e.g., 200-220-230V, 44/55/74A; 380-400-415V, 22/28/39A; 440-460-480V, 19/25/34A).
Pneumatic System: Supply pressure of 7 bar (-0.5 to +3 bar admissible variance). Air consumption: 500 Nl/min (Primus 184), 100 Nl/min (Primus 322/324).
Noise Level (Operator Station):
- Primus 184: 80 dB (cutting marble, 20mm thickness, 0.2m/min advance speed).
- Primus 322/324: 81 dB(A) (cutting 200x200mm sheet, 12mm thickness, double head).
- Weighted surface sound pressure level A LwA: 102 dB(A).
- Measurement uncertainty K = 4dB (A).
Installation Area Requisites:
- Temperature: +5°C to +35°C (with air conditioning, +5°C to +50°C).
- Relative humidity: 90% (without condensation).
- Altitude: 1000m (unless otherwise agreed).
- Flooring: Industrial flooring with minimum capacity 1kg/cm², unaffected by thermal/moisture variations. Loose gravel foundation (min 300mm), concrete thickness (min 200mm) with two reinforcement layers. Concrete ageing period of at least 6 months advisable.
- Lighting: Minimum 300 LUX (lx) for visual task and immediately adjacent areas.
Usage Features
Control and Interface:
The machine is controlled via a numerical control command unit (PC with monitor and keyboard) and a main control panel. A hand-held button pad (Type RM850) is also provided for manual operations and tooling, connected to the main control panel by cable.
Operating Modes:
- Start-up Mode: Resets axes and moves the head to the origin.
- Machining Mode: The working head moves to a predefined point, measures material thickness (using the thickness tracer if configured), and begins cutting. The thickness tracer compensates for planarity errors (max. 15°) to maintain optimal nozzle distance and protect components.
- Manual Mode: Allows manual movement of axes for tooling, moving the tool away from the piece, or acquiring origin positions using the laser pointer or thickness tracer. Axis transfer speed can be varied (0-125% of maximum manual speed).
- Automatic Mode: Executes specific programs for machining operations.
Safety Devices:
- Emergency Buttons: Located on the main control panel, hand-held button pad, and UHP intensifier for immediate machine stop.
- Cut-out Valve: Discharges the pneumatic system and blocks air flow for safe maintenance.
- Safety Guards: Photoelectric barriers protect operators from moving parts. In pendular mode, barriers are split to protect the working area while freeing the loading area.
- Thickness Tracer (Anti-collision): An active, multi-directional sensor that prevents collisions between the cutting head and the piece or cut residues.
Work Table:
Consists of steel blades housed in supports. Number of blades varies by configuration (glass or marble). Marble versions include metal grilles. An optional sheet/piece support system for glass cutting prevents scratching and "sanding" effects. The work table is divided into two "stations" for working areas.
Abrasive Distribution System (Optional):
An abrasive batcher on the working head ensures constant supply. An external propulsor uses compressed air to push abrasive to the batcher. If abrasive runs out, a warning message "fill the tank with abrasive" appears, and the machine pauses.
Maintenance Features
Routine Maintenance:
- Daily: Clean machine, work table (remove waste from supports and grilles), check abrasive delivery tube for wear, check abrasive distribution system for anomalies, check lubricant level in pump.
- Weekly: Check protective hood on cutting head for tears, clean dynamic dryer filter (drain condensation).
- Monthly: Clean X, Y, and Z axis guides and racks/screws, apply AGIP GR MU EP 0 lubricant. Clean suction filter of recirculation system.
- Every 6 Months: Clean machining operation basin (remove sediment with digging tools).
- Every 900-1800 Hours: Clean/replace dynamic dryer filter.
- Every 3000 Hours: Replace oil separator filter.
- Annually: Replace oil in recirculation system pump.
- Every 3 Years (or 6000 work hours): Overhaul recirculation system pump.
- When Necessary: Clean decantation basin, replace orifice and focusing nozzle (visually inspect water jet for spreading).
Special Maintenance:
- High Pressure System: Periodically check for leaks in connected tubes. If leaks persist after tightening joints, contact an Intermac-authorised technician. Components are subject to wear.
- Cutting Head: Requires interventions by specialised Intermac-authorised personnel for issues like water leakage from holes, nozzle dripping, or delays in opening/closing.
- Lubrication System: Automatic system lubricates guides, ball blocks, and Z-axis screw every 4 working hours. Requires about 0.007kg of grease per hour of effective machining. A sensor checks lubricant level and warns when low.
- Air Treatment Units: Adjusts air pressure. Dynamic dryer filter drains condensation weekly. Oil separator filter eliminates oil from compressed air.
General Maintenance Warnings:
- Machine must be OFF, electrical and pneumatic supplies disconnected and locked.
- Clean machine periodically to prevent damage and maintain warranty.
- Dispose of products (lubricants, waste) according to local and national standards.
- Water used for cutting must meet specific physical qualities (pH 7-8.5, max 1.78 mmol/l hardness, 0.71-3.57 mmol/l carbonatic hardness, 100 mg/l chlorides, 450 μS/cm electric conductivity, 350 mg/l filtered residue, 1 mg/l Cl2 dissolved chlorine, +10°C to +25°C inlet temperature).
- Never fill dynamic dryer filter cups with lubricating oil or other liquids.
- Do not touch or attempt to block water jet in case of leaks.
- Ensure all pumps are perfectly primed when switching on the machine.
Decommissioning - Demolition:
Requires qualified personnel. Involves turning off and disconnecting power, removing tools, cleaning and protecting parts from corrosion, and using appropriate methods for transport and installation if relocating. Lubricants, glass waste, batteries, and electronic cards must be disposed of according to local regulations.
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