Section 5
Low Pressure Water System
20412955
8-2012/Rev 08
5-3
Cutting water then passes through a strainer to remove debris before the water enters the booster
pump. The booster pump increases the pressure to the relief valve setting, up to a maximum of
120 psi (8 bar) to ensure proper supply to the intensifier assembly.
Pressurized water passes through the filter assembly where debris is removed to prevent
contaminants from damaging the check valves and seals in the intensifier. The filter assembly
consists of a filter head, housing and a 10 micron absolute filter.
As the water enters the outlet manifold, the discharge pressure is monitored by a 60 psi pressure
switch. An automatic shutdown will occur if the pressure is below 60 psi (4 bar).
If the booster pump pressure exceeds 125 psi (8.6 bar) a relief valve opens allowing water to exit
through the 1/2-inch drain connection on the rear bulkhead. It is still possible to operate the
machine; however, excess water will continue to be released through the drain.
Discharge pressure is displayed on the Booster Pressure Gauge on the front of the machine. The
gauge should read approximately 120 psi (8 bar) while the machine is idling. When it strokes, the
pressure drop should be no greater than 30 psi (2 bar). The water pressure range should remain
between 90-120 psi (6-8 bar) during operation.
NOTE
While the intensifier assembly reverses direction, the boosted pressure will
fluctuate slightly above and below the normal setting.
A relief valve built into the filter assembly prevents excessive discharge pressure and typically
operates when the machine is in a deadhead condition. The booster pump is factory set to deliver
120 psi (8 bar) with an inlet pressure of 58 psi (4 bar). The pump may require adjustment to
satisfy system requirements.
A temperature switch, mounted on the inlet manifold, monitors the discharge temperature. If the
temperature exceeds 128 F (53 C), the switch activates an automatic shutdown circuit in the
PLC that stops the main motor. The temperature switch prevents booster pump overheating due
to lack of water or long deadhead conditions. To reduce overheating during a deadhead
condition, water is re-circulated through the orifice and check valve, and routed back through the
strainer to the booster pump inlet.
From the outlet manifold, cutting water is routed to the inlet check valves in the sealing heads on
each end of the intensifier. If the machine is equipped with redundant intensifiers, the cutting
water supply lines are manually connected to the active intensifier and manual hydraulic valves
are opened or closed to direct the hydraulic flow to the active intensifier. Control is switched
from one intensifier to the other from the control panel.
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