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12112 Rev A. - WARDJet.com

1. Hex x Deep Square Drive Socket 12019 x 13 5 Hex Driver 11448 High Pressure Food Grade Lubricant Copyright 2005 Accustream Inc 41 1 866 566 7099 AS 6050 Manual P N 12112 Rev A Due to the high forces inside the intensifier all bolts and cap screws that fasten the load carrying components are Grade 8 Fasteners exposed to cyclic loading use lock washers Unless otherwise noted when reassembling torque the load carrying fasteners to the values given in the Bolt Torque section of this manual Care must be taken to keep the interior parts and surfaces clean Parts should be placed on clean work surfaces and hands should be washed and kept clean while changing HP components such as HP seals Before reassembling any high pressure or hydraulic components verify that any dirt or other contaminants have been wiped clean 7 2 1 High Pressure Seal Removal Replacement of the high pressure seals and hoops is the most common service function Water dripping from either end of the HP Cylinder indicates that the seals may soon require changing One drip every few strokes means that the seals should be watched More than one drip with each stroke means that the seals in that HP cylinder should be changed at the first opportunity HOOP 11018 LOW PRESSURE BASKET 11520 SPACER TUBE 11521 GZ PLUNGER Za Pa YL a AAAA N STATIC DYNAMIC END ji END A A RA N SEAL BACKUP 11610 HIGH PRESSURE CYLINDER
2. Oil Present In Dynamic End of HP Cylinder Leaking HP Poppet and Seat Leaking LP Poppet and Check Valve Body face Leaky hydraulic rod seal Replace Replace or repair Replace rod seal Bronze Back Ups Have Short Life Worn Plunger Bearing Replace Plunger Bearing Hydraulic Center Section Is Much Hotter Than Hydraulic Oil HP Seal Life Is Short Piston seal is worn Piston seal has just been replaced and needs breaking in Poor mating surfaces Pump has cycled roughly Pump over cycled Worn bronze back up Cylinder end too hot Hoops are broken from belled out HP cylinder end Copyright 2005 Accustream Inc 1 866 566 7099 Rebuild center section No action required Inspect repair and or replace HP Cylinder ID and Plunger Start up new seals carefully Check demand on pump Replace Back up Correct problem Refer to the High Pressure Section of the manual Replace HP cylinder when necessary 81 5 Hydraulic Oil Problem AS 6050 Manual P N 12112 Rev A Possible Cause Corrective Action Oil Is Too Hot Worn relief valve Inlet water is warmer Piston seal in intensifier is worn Heat exchanger is fouled Hydraulic pump is worn Replace Adjust modulating valve Rebuild intensifier center section Clean out heat exchanger tubes or replace heat exchanger Replace Oil has milky appearance Oil is contaminated with water Replace oil per the manual
3. Possible Cause Corrective Action Intensifier Does Not Cycle On Off Valve for cutting head is off Intensifier is disabled Defective shift valve or end of travel proximity switch One of the indicator pins is hung up as shown by both proximity switch lights on at the same time Turn cutting head on Enable intensifier at display Replace if necessary Disassemble and repair Pins must move freely to bottom of bore Intensifier Cycles and Oil Pressure Okay But Not Enough Pressure at Head Intensifier Over Cycles or Cycles Unevenly 80 Clogged high pressure filter Partial obstruction in HP lines Worn Hydraulic Piston Seal Too much demand on pump Various reasons Copyright 2005 Accustream Inc 1 866 566 7099 Replace HP Element Correct obstruction Rebuild hydraulic center section Reduce number or size of orifices See Over Cycle Section in HP Water AS 6050 Manual P N 12112 Rev A 4 High Pressure Cylinder and Check Tube Problem Possible Cause Corrective Action End of HP Cylinder Drips Worn HP Seal Replace HP Seals and Hoops Cylinder End Drips And Is Hot Check for crack at end of HP Cylinder Replace HP Seals and Hoops and HP Cylinder if necessary Check Valve Is Hot and HP Cylinder End Drips Check for crack in Check Valve Body Replace HP Seals and Hoops and Check Valve Body if necessary Check Valve is Hot and HP Cylinder End Does not Drip
4. flat blade screwdriver Turn clockwise to increase the pressure or counterclockwise to decrease pressure BYPASS RELIEF VALVE INLET CHECK VALVE 36 Copyright 2005 Accustream Inc 1 866 566 7099 AS 6050 Manual P N 12112 Rev A High Inlet Water Pressure Inlet water pressure that exceeds 70 psi requires that the boost pump be turned off Open the electrical cabinet and turn the switch located on the boost pump motor contactor to OFF BOOST PUMP ON OFF KNOB AN WARNING The electrical cabinet contains high voltage Extreme care should be used when working in this area If you are unfamiliar with this area a qualified electrician should be used Inlet Cutting Water System Protection Low water pressure to the intensifier is sensed by a pressure switch located after the filters A sustained pressure of below 40 psi will result in pump shutdown This protects the system from running without enough feed pressure to the intensifiers Copyright 2005 Accustream Inc 37 1 866 566 7099 AS 6050 Manual P N 12112 Rev A 6 2 2 Inlet Cutting Water Filtration In order to maintain necessary fluid pressure for the pump and to keep the water clean for proper operation it is necessary to replace the water filters periodically ACCUMULATOR DISCHARGE VALVE Water Filter Service Replace filter elements when there is a 10 psi pressure differential between the two gages located on the pump control panel Replacement
5. instructions Replace rod seal Oil Life is short 82 Oil temperature too hot Copyright 2005 Accustream Inc 1 866 566 7099 Reduce oil temperature AS 6050 Manual P N 12112 Rev A Section 11 Drawings and Parts Lists The following Parts Lists and Drawings are in numerical order with the exception of the main assembly which is the first shown Part Number Description 12086 AS 6050 ASSEMBLY 11480 BLEED DOWN VALVE ASSEMBLY 11501 INTENSIFIER ASSEMBLY 11534 LOW PRESSURE WATER ASSEMBLY 11537 HIGH PRESSURE WATER ASSEMBLY 11563 HYDRAULIC TANK ASSEMBLY 11585 ELECTRICAL FRAME ASSEMBLY 11805 CONTROL MANIFOLD ASSEMBLY 12042 AS 6075 HYDRAULIC HOSE AND FITTING LIST 12048 AS 6075 ELECTRICAL SCHEMATIC 12049 AS 6075 ELECTRICAL ENCLOSURE ASSEMBLY 12050 AS 6050 MOTOR PUMP ASSEMBLY 12084 BASIC TOOLS KIT 12085 RECOMMENDED TOOLS KIT 12087 INTENSIFIER BASIC SPARES KIT 12088 INTENSIFIER FULL SPARES KIT 12113 AS 6050 HYDRAULIC ASSEMBLY Copyright 2005 Accustream Inc 83 1 866 566 7099
6. J WO EQ Copyright 2005 Accustream Inc 17 1 866 566 7099 18 AS 6050 Manual P N 12112 Rev A MENU enters the main menu mode of the controls See the Menu Modes section of this manual The UP ARROW toggles between Pressure Set Point 1 Cut and Pressure Set Point 2 Pierce This button is also used for scrolling up in any menu mode The DOWN ARROW toggles between Pressure Set Point 1 Cut and Pressure Set Point 2 Pierce This button is also used for scrolling down in any menu mode CLEAR ABORT exits active menu mode ENTER toggles in and out of EDIT mode while in different menus See the Menu Modes section of this manual MOTOR ON turns on the Boost Motor Main Motor Cutting Water Solenoid and Cooling Water Solenoid This button is only active while the pump is in local mode MOTOR OFF turns off the Boost Motor Main Motor Cutting Water Solenoid and Cooling Water Solenoid This button works while the pump is in local and remote modes INTEN ON turns on the Intensifier in Pierce Pressure for 5 seconds before ramping up to Cut Pressure This button is only active while the pump is in local mode INTEN OFF turns off the Intensifier and reduces hydraulic pressure which opens the bleed down valve and relieves the high pressure water This button works in local and remote modes ACK RESET resets pump faults EMERGENCY STOP shuts off Controls Motors Intensifier and bleeds down the high pressure
7. a transformer XFORMER 1 which produces the 115VAC power The 24VDC power supply DC 1 is powered by the 115VAC power The 24VDC power supply is wired to the PLC and Display Panel Refer to the electrical schematic to see locations of the fuses The following is a fuse chart for reference Copyright 2005 Accustream Inc 25 1 866 566 7099 AS 6050 Manual P N 12112 Rev A FU 1 FNQ 1 5 11701 Fuse on input leg of power to XFORMER 1 FU 2 FNQ 1 5 11701 Fuse on input leg of power to XFORMER 1 FU 3 FNQ 4 11702 Fuse on 115VAC output from XFORMER 1 FU 4 CC 2 12090 Fuse on 24VDC output from DC 1 FU 5 MDA 1 5 11703 Fuse for Outputs Y1 Y4 on PLC FU 6 MDA 1 5 11703 Fuse for Outputs Y5 Y8 on PLC FU 7 MDA 1 5 11703 Fuse for Outputs Y9 Y12 on PLC FU 8 MDA 1 5 11703 Fuse for Outputs Y13 Y16 on PLC 26 Copyright 2005 Accustream Inc 1 866 566 7099 AS 6050 Manual P N 12112 Rev A 5 2 3 Remote Operation Wiring Accustream AS Series pumps come standard with built in functionality for remote operation The pump includes two options for external control that integrators can use External Pressure Control and Remote Pump Control External Pressure Control EPC allows the user to switch from high to low pressure by closing a switch All other pump functionality remains at the pump s front control panel while in EPC mode as long as the key switch remains in the Local position Remote Pump Control RPC deactivat
8. be tightened into the Output Adapter Weep Hole 2 leakage means that the Output Adapter needs to be tightened into the Check Valve Body Check Valve Replacement and Reconditioning Use Poppet Kit 12024 which includes 1 of 11014 HP Poppet 1 of 11015 HP Seat 1 of 11126 Poppet Spring of 11526 LP Poppet 1 of 11679 031 o ring and 1 of 11679 035 o ring Also use 11448 High Pressure Lubricant a Remove the HP End Cap from the HP Cylinder as described in above section on High Pressure Seal Removal b Unscrew the Output Adapter from the Check Valve Body and remove and discard the HP Poppet Poppet Spring and the HP Seat c Inspect the low pressure poppet face of the Check Valve Body A worn face indicates that it should be lapped as described in the section below d Apply HP Lubricant to both sides of the HP Seat and place the seat in the cavity of the Check Valve Body e Install the Poppet Spring and HP Poppet into the Output Adapter and tighten the adapter into the Check Valve Body f Replace the o rings on the outside of the Check Valve Body g Replace the LP Poppet in the Poppet Basket located in the static end of the HP Cylinder Do not put lubricant here as it may prevent the LP Poppet from moving freely h Reassemble the end of the intensifier as described above in Installing New HP Seals Lapping Procedure for the Check Valve Body Face During use the CV Body face becomes worn from the action of the LP Poppet It may be inde
9. damage Wear hearing protection while the machine is operating Use respiratory equipment when necessary for personal safety Copyright 2005 Accustream Inc 1 866 566 7099 AS 6050 Manual P N 12112 Rev A e Read and understand the Operations section of this manual before operating the equipment e Ensure that all personnel not involved in operating the machine are a safe distance from the equipment while it is running Keep the work area clean and free of water or fluid spills 2 3 2 Maintenance Safety A WARNING Before starting any service or maintenance turn off electrical power and relieve all water and hydraulic pressure Proper lockout tagout procedures must always be followed prior to performing any maintenance of the unit e Read the instructions in all sections of this manual before performing any maintenance on the pump Important information is contained throughout to minimize hazards and wear on the machine e Use the proper tools required for specific procedures When special tools are called for use them They are specifically designed to make the job easier and to prevent damage to the equipment Remove all tools from the work area before starting the machine e Always test the pump after service or maintenance Follow startup procedures outlined in the Operation section of this manual 2 3 3 Electrical System Safety Always make certain that electrical current is shut off and lockout tag out procedures ha
10. must be replaced If there are no visible leaks then the likely cause is that one of the poppet and seat areas is bypassing water This is a good time to inspect both of the HP Poppets and Seats and both LP Poppets and the Check Valve Body face Replace and or recondition the damaged poppet faces Copyright 2005 Accustream Inc 53 1 866 566 7099 AS 6050 Manual P N 12112 Rev A 7 4 Pump Bleed Down Valve The Bleed Down Valve discharges high pressure water from the pump when the pump is turned off It operates as a normally open safety valve and is controlled by a hydraulic solenoid valve It is located inside behind the utility panel at the rear of the pump Use 11331 Bleed Down Valve Repair Kit which consists of one each of the following 11359 Oil Seal 11323 Seal Hoop 11322 Needle Stem 11321 HP Seal 11324 Bushing 11325 Seat 11447 Grease Packet O rings 12027 12 12027 08 11679 114 Back up Ring 11680 114 Also use the 12029 Bleed Down Valve Tool Kit installation procedure 54 a b c d e f Shut down the system Remove the hydraulic hose from the Bleed Down Valve and gland nut connection from the water drain tubing to the Bleed Down Valve Remove the gland nut from the collar at the high pressure port of the Bleed Down Valve Disconnect the actuator from the high pressure valve assembly Remove all the hydraulic fittings from the Actuator Housing Remove the adapter from the Bleed Down Valve
11. not be a message on the PLC screen The most likely cause of this fault is an unplugged cable between the PLC and the LCD display The fault may also be caused by a poor connection or a broken wire Correct the problem and make sure the display is operating normally before resuming operation of the pump Copyright 2005 Accustream Inc 33 1 866 566 7099 34 AS 6050 Manual P N 12112 Rev A This Page Intentionally Left Blank Copyright 2005 Accustream Inc 1 866 566 7099 AS 6050 Manual P N 12112 Rev A Section 6 Low Pressure Water 6 1 Low Pressure Water Overview Assembly 11534 This section describes the components and operation of the following parts of the Low Pressure Water Assembly e Inlet cutting water supply for the HP intensifier assembly e Cooling water inlet and outlet for the oil to water heat exchanger e Drain water out from the leakage pans and the Bleed Down Valve discharge There are four 3 4 NPT couplings located at the rear of the pump for making these connections 6 2 Inlet Cutting Water Supply The inlet water cutting supply includes all the plumbing components from the pump inlet connection to the inlet to the intensifier It includes the following Inlet water shutoff valve solenoid operated Boost pump with bypass relief valve Low pressure water filters Pressure switch for sensing low pressure condition Quick disconnects to the intensifier The boost pump housing and low pressure water f
12. or the ends may open or bell out so that the cylinder does not hold the seal and hoop properly If the cylinder is cracked the cylinder will be hot water may squirt with each stroke and the failure may appear to be a seal failure A belled out cylinder end will cause the premature failure of the seal and cause the hoop to break 7 2 4 Check Valve Assembly Check valve replacement and reconditioning is the second most common intensifier maintenance function The Low Pressure Check Valve allows inlet water to enter the HP cylinder and the High Pressure Poppet lets the pressurized water from the HP cylinder exit the intensifier Over time the faces of the poppet seat and check valve body may become worn Check valve repair involves replacing the HP Poppet HP Seat Poppet Spring LP Poppet and lapping the face of the Check Valve Body Check valve repair may be necessary when the HP End Cap area becomes hot to the touch or the intensifier strokes faster in one direction without seal leakage HP SEAT 11015 ORING 11679 031 POPPET SPRING HP POPPET Mie 11014 ada a i LUIS ZZ NGF LOW PRESSURE POPPET we O RING 11679 035 11530 OUTPUT ADAPTER 11526 WEEP HOLE 1 CHECK VALVE BODY WEEP HOLE 2 11523 HP ENDCAP 11529 46 Copyright 2005 Accustream Inc 1 866 566 7099 AS 6050 Manual P N 12112 Rev A Weep Hole Leakage See Previous Figure Weep Hole 1 leakage means that the inlet fitting needs to
13. same way the motor rotation arrow indicates If the motor rotates in the wrong direction swap a pair of wires at the starter panel s main disconnect not at the motor or starter contactors and then recheck the rotation After verifying motor rotation replace the safety cover on the pump mount and the side covers Copyright 2005 Accustream Inc 19 1 866 566 7099 AS 6050 Manual P N 12112 Rev A First Time Startup During installation it is possible that small pieces of debris are present in the high pressure lines A line filter is provided at the back of the pump however pieces of debris downstream of this may damage an orifice in the cutting head The orifice used for startup should be replaced after the first 5 10 hours of operation NIMPORTANT The following First Time Startup procedure should be followed after any a b c d e g h 20 service has been performed on the Intensifier High Pressure Water or Low Pressure Water assemblies Start motor by pressing the motor on button below the LCD display Make sure that the boost pressure is between 50 and 115 psi If the pump was shipped during winter the fittings were loosened and need to be inspected for leaks Verify that all leaks are corrected before proceeding to the next step Make sure the pump is set to Pressure Set Point 2 Pierce Press the UP or DOWN arrow keys to toggle between set point 1 and set point 2 Turn on the on off valve at the cuttin
14. section of the manual After correcting the situation resume normal operation of the pump 5 4 3 Shutdown II Messages Shutdown II messages indicate a severe fault that requires the motor and intensifier to be shut down The red light will flash and one of the following fault messages will be displayed on the LCD screen e HYDRAULIC OIL LEVEL LOW e MOTOR FAULT e LOSS OF FRONT CONTROL PANEL 32 Copyright 2005 Accustream Inc 1 866 566 7099 AS 6050 Manual P N 12112 Rev A Low Hydraulic Oil Level The probe in the hydraulic oil tank has a float switch When the oil level is too low the float drops and the fault monitoring circuit is opened To correct the situation find out where the oil has gone If the oil is in the catch pan at the bottom of the pump it should be fairly easy to find the leak If it is not in the bottom of the catch pan it could be leaking undetected through the heat exchanger Or it could be that the oil was spilled during pump maintenance Repair all leaks and fill the tank with the specified hydraulic oil to the top of the sight gauge Press the ACK RESET button to clear the fault and resume normal operation Motor Fault The Wye Delta motor starter in the pump electrical enclosure has a thermal overload module that senses the amount of current flowing through the main contactor If this current has been exceeded for a length of time the monitoring circuit is opened To clear this fault press the RESET button on
15. standard with built in functionality for remote operation The pump includes two options for external control that integrators can use External Pressure Control and Remote Pump Control Information on wiring connections is provided in the Electrical System section of the manual External Pressure Control EPC allows the user to switch from high to low pressure by closing a switch All other pump functionality remains at the pump s front control panel while in EPC mode as long as the key switch remains in the Local position Remote Pump Control RPC deactivates the Controls On Motor On and Intensifier on at the front panel of the pump These inputs are then solely controlled from a remote source Motor Off Intensifier Off and E Stop are active at both the front control panel and the remote source Remote Pump Control is activated by turning the key switch to the Remote setting Copyright 2005 Accustream Inc 21 1 866 566 7099 AS 6050 Manual P N 12112 Rev A 4 4 4 Menu Modes The AS Series pumps have two different menu modes accessible from the main display The first menu mode MM1 is used to disable the intensifier for troubleshooting or setup purposes The second menu mode MM2 is used to switch between local pressure control and external pressure control The following is the MM1 procedure to ENABLE or DISABLE the Intensifier for pump setup a Press MENU and screen will read INTENSIFIER ENABLE and will have a 0 in the upper r
16. the thermal overload module see the Thermal Overload Protection information earlier in this section You may have to allow time for the module to cool down before it can successfully be reset There are several reasons why this fault may be occurring The most likely cause is too large a water demand If an orifice has broken or plumbing is leaking water demand may be high enough to cause the motor to overload Reduce demand and reset thermal overload The next likely cause is that the thermal overload is on the wrong setting The correct setting should be 53 Amps Another likely cause is that the Hydraulic Pressure Relief Valve is opening at too low a pressure This situation usually but not always causes a rushing or whistling sound and the valve will become hot See the hydraulic section for setting the Hydraulic Pressure Relief Valve Set or replace the valve to fix the fault A less likely cause of this fault may be a bad hydraulic pump or a faulty motor These conditions are very rare Refer to the Motors information earlier in this section or to the Hydraulic Pump subsection of the Hydraulic Assembly section of this manual Loss of Front Control Panel The communication with the control panel is the first fault condition monitored by the PLC If the PLC senses loss of communication with the front control panel it will immediately shut down the motor and intensifier and flash the red light This is the one fault condition where there will
17. to the intensifier The water passes through three filters and an accumulator before entering the intensifier 6 2 1 Boost Pump Assembly The Boost Pump Assembly consists of the pump a bypass relief valve and a check valve It operates by taking the inlet supply water and adding pressure based on the setting of the bypass relief valve The pump has been set up to operate with inlet water pressure of 20 to 70 psi The bypass relief valve has been set to create a boost pressure of 45 psi For example an inlet pressure to the pump of 50 psi will result in a boost pressure of 95 psi The inlet water components of the pump are rated to a maximum pressure of 125 psi High inlet pressure may result in the boost pump creating excessive pressure and damaging components If either of the panel gages reads over 125 psi turn off the boost pump as explained below In the unlikely situation that the inlet pressure to the pump exceeds 125 psi a pressure reducing valve must be added before the inlet cutting water enters the pump Boost Pump Pressure Adjustment Adjustment must be made with the pump turned off It is factory set for inlet cutting water provided at normal pressures as provide by municipal water or well pumps In the case where the pump is supplied by a tank such as on a reverse osmosis system it is necessary to increase the boost pressure The boost pump pressure relief valve is adjusted by removing the valve cap and turning the screw with a
18. 050 Manual P N 12112 Rev A 5 3 Motors and Motor Starter Circuits 5 3 1 Main and Boost Motors The main motor is the backbone of the AS Series pump The motor transfers rotation through a jaw type coupling to the main pump which is through shafted to the gear pump The boost motor is a Y horsepower motor which drives the boost pump to provide adequate water pressure to the intensifier 5 3 2 Motor Starters The main motor starter is a Wye Delta type This is considered a reduced voltage class of starter When the MOTOR ON pushbutton is pressed the motor starts in a WYE configuration which reduces the initial current draw of the motor for startup The timer TD MAIN setting determines how long the pump will run in the WYE configuration before switching to DELTA which is the run condition The timer TD MAIN should be set to about 2 seconds While the motor is in the Delta configuration it can run at full current and torque When the MOTOR OFF pushbutton is pressed the contactors open and the motor turns off The intensifier cooling water solenoid cutting water solenoid and boost pump motor also turn off when the MOTOR OFF button is pushed Any time the motor is turned off the hydraulic pressure drops to zero which allows any high pressure water in the system to open the bleed down valve and exit through the drain The main circuit breaker MAIN DISC 1 provides short circuit protection and disconnect 5 3 3 Thermal Overload Protection The main
19. 11522 LP POPPET 11526 HP SEAL 11024 a Remove the high pressure tubing and inlet water quick disconnects from the appropriate end of the intensifier b Remove the four 1 nuts from the studs by using a cross pattern to gradually unload the high pressure end cap from the high pressure cylinder c Remove the HP End Cap and the Check Valve Body from the HP Cylinder d Remove the HP Cylinder from the Plunger and the LP Poppet from the static end of the HP Cylinder Note the dynamic end of the cylinder is the end towards the intensifier center and the static cylinder end is the outboard side and contains the LP poppet 42 Copyright 2005 Accustream Inc 1 866 566 7099 AS 6050 Manual P N 12112 Rev A PUSH TOOL SMALL END 11812 GUIDE SLEEVE 11811 LOCATING RING 11558 LARGE END e Place the dynamic end of the cylinder on the seal tool Locating Ring With the small end of the Push Tool use a rubber mallet to drive the bottom seal and hoop out ofthe HP cylinder Flip the cylinder over and repeat the process The seals hoops spacer tube and low pressure poppet cap should now be free of the HP cylinder a f Remove the Seal Backup from the Seal Housing in the hydraulic end cap It may be necessary to partially remove the Seal Housing See Hydraulic Seal Housing section for removal instructions g Clean and inspect all disassembled parts Ifthe bronze back up is to be reused verify that the weep hole and ID groove a
20. 55C or Hydraulic Oil Temp gt 150F 65C Inlet cooling water to the pump not turned on High cooling water inlet temperature Cooling water flow rate may not be high enough Cable may be damaged or connector is unplugged Heat exchanger could be clogged Turn on inlet cooling water Read the Low Pressure Water section of this manual Test the temperature of the inlet water If the temperature is outside of the normal range outlined in the Specifications section of this manual you may need a water chiller Check the flow rate by monitoring the cooling water out If the flow rate is too low then adjust the water modulating valve See the Low Pressure Water section of this manual Replace cable if damaged Plug in connector if unplugged Repair or replace heat exchanger Motor Fault Fuse FU 5 in the PLC has blown A short in the cooling or cutting water coils is the most likely cause A less likely scenario would be a short in the motor wiring for the boost motor or main motor The main motor thermal overload OL MAIN may have tripped Copyright 2005 Accustream Inc 1 866 566 7099 Check the cutting water coil SOL 1 and the cooling water coil SOL 2 for shorts Usually you will see the plastic body deformed from heat Check all cables for damage Replace any faulty parts Reset by pushing the reset button on the thermal overload Refer to Electric Motors in the Electrical System section of
21. 66 7099 AS 6050 Manual P N 12112 Rev A 4 4 Pump Operation After startup inspections have been completed and the machine is running no further direct action from the operator is required Periodically check warning indicators and gauges and inspect everything visually to ensure developing problems are detected before the equipment is damaged 4 4 1 Normal Operation During normal operation the pump will continue to stroke to meet the cutting water demand When the cutting nozzle is closed the pump will operate on standby hydraulic pressure remains at the set pressure and the intensifier is idle It is normal to see an increase in the pressure of the output water This is called the Dead Head Rise When the cutting nozzle is turned on the intensifier will begin to stroke again at a rate to meet the demand 4 4 2 Adjusting the Cut and Pierce Pressure The cut pressure and pierce pressure can each be adjusted using the knobs on the front of the pump To adjust Cut pressure the LCD display must read Pressure Set Point 1 Cut If the display reads set point two press either the up or down arrow key to toggle back to set point 1 To adjust the pierce pressure the LCD display must read Pressure Set Point 2 Pierce Note When in Pierce Pressure mode if the set point of the Cut pressure is lower than the set point of the Pierce pressure the pump will operate at the lower of the two 4 4 3 Remote Pump Operation Accustream AS Series pumps come
22. AS 6050 Manual P N 12112 Rev A Section 1 Introduction caisicccscscocsseracdosvavscscssescccossssscecdsteacdsvediasasdecvacicscsnssicsessavecs O 1 1 Company Overview and Contact InformMatiON oconnonnnonioncnioncnonononoconoconoconoconn cnn rnnrrnnr ran rrnn ninos 5 1 2 System Ova e ala 6 EAS A A NN OO 6 1 2 2 Pump Identification Fori sipaise i aa i an E Pa ARER TEE 6 1 3 Definition Si ee ei e E EE REEE EE E Hise Caps EE N dest 6 Section 2 SUMEN ad 2 1 Safety Mba A linia 7 2 2 COMMON OS ida ie tease isa 8 2 3 Operation and Maintenance Safety cccccsccesscssscssscseseesseeeseeeseecsecesecesecsseeseeeseeeseseseaeeeseeeeeesaes 8 Delo Operating SV A ai A lA A A a iD a 8 23 2 Maintenance Salada E AR li decai 9 2 3 3 Electrical System Safety ccc cccccssccssecssecsseceeceseceseceeeeseeeessecsaeeeseecsaecsaecsaeceseceseeeeeeeereeeeeeaes 9 2 3 4 High Pressure Water System Safety ccccccccessccssecssecsseceeceeceeceeeseeeseeeeeseeeseeeseeeeeesaesssees 10 2 35 Hydraulic System Sale ica o tl eee eee 10 2 3 6 Motor Pump Assembly Safety cc ccccccccccssecssecsseceeceecesecseeeseeceeseeeseceaeeeseecseecsaecnseenseenseees 10 2 3 7 Emergency Medical Treatment erinnere e e e i 11 Section 3 Installation 000000000000ssoosseessseossoossoessseoossosssoossseossssosseosseesssesssssss L3 3 1 Installation OVINA 13 3 11 Buyer ODIOS ii A ER E E E A O 13 3 1 2 Seller Obligations ieii nds 13 3 2 Vilit Requirements A E
23. Always repair any leaks immediately to avoid damage to equipment and or serious personal injury e Carefully read all of the safety guidelines in the Safety section of this manual Read and understand the pertinent sections to the maintenance that you are planning to perform e Shut off the main disconnect When the power is shut off the bleed down valve will open and bleed off high pressure water stored in the discharge piping Always double check to make sure that all high pressure water has been discharged prior to servicing the pump Copyright 2005 Accustream Inc 71 1 866 566 7099 AS 6050 Manual P N 12112 Rev A e When servicing any electrical component of the pump always follow proper lockout tag out procedures Remember even when the main disconnect is off the lines coming to the pump are still hot unless shut off at their source e When servicing the cooling or cutting water assemblies shutoff water to the pump and drain the water in the accumulator by opening the ball valve to the left of the filters e Use catch pans under areas where water or oil may be spill during the course of maintenance e Always maintain a clean work area Inspect and clean the pump regularly to spot issues before they become costly repairs Always make repairs immediately Keep a maintenance record 10 1 3 Scheduled Maintenance Chart The following maintenance intervals are based on 4000 hour per year operation Less hours of use will increase mai
24. Body Remove and discard the HP Seat Remove the kit components from the valve body by using the pin end of the BDV Tool Take the pin and push through the Oil Seal which pushes on the HP Stem Note Do Not Remove Oil Seal Copyright 2005 Accustream Inc 1 866 566 7099 g h j k m n 0 p q r AS 6050 Manual P N 12112 Rev A Inspect the Oil Seal for damage If it appears damaged remove with a pick and press in the replacement using a Vise or small Arbor Press Push the piston out of the actuator body through the oil port Discard the o ring and backup ring from the piston Clean all parts before new parts are inserted Actuator oo Piston ope H Backup Lubricate the o ring and backup ring with Grease from packet Install the piston assembly carefully into the actuator body until seated securely so that no damage is caused to the o ring Using HP Lubricant 11448 lubricate the Stem Seal Seal Hoop and Bushing Place the Bushing Hoop and Seal on the stepped diameter end of the BDV Tool in the order as shown below Use HP lubricant to lubricate the OD of the parts to be inserted Bleed Down Valve Body Bushing HP Seal l 0 0 000 t Seal Hoop Push the kit parts in until the Tool bottoms on the Valve Body Apply HP Lubricant to the Stem and insert the tip into the Oil Seal side Push the Stem until it goes through the Seal assembly and bottoms out Grease with HP Lubricant and install th
25. CVD piston pump is passed through the spool valve and is directed to either side of the hydraulic piston in the intensifier The intensifier reciprocates and creates high pressure water as output The hydraulic pump pressure is controlled by the Control Manifold Assembly It is connected to the pressure compensator port of the pump The control manifold has two pressure control valves for either cutting pressure or pierce pressure When the pump is turned off a solenoid valve in the manifold opens and the hydraulic pressure goes to its minimum The hydraulic oil is filtered and cooled through a separate kidney loop Oil is drawn from the hydraulic tank through a gear pump mounted to the end of the PCVD pump The oil then passes through the filter and heat exchanger before returning to the hydraulic tank Before starting any service or maintenance turn off electrical power and A WARNING relieve all water and hydraulic pressure Proper lockout tag out procedures must always be followed prior to performing any maintenance of the unit 8 2 Hydraulic Oil This section describes the quantity and type of oil required and how to change and add oil 8 2 1 Hydraulic Oil Requirements The pump requires forty gallons of ISO VG 32 mineral oil Copyright 2005 Accustream Inc 59 1 866 566 7099 AS 6050 Manual P N 12112 Rev A 8 2 2 Adding New Hydraulic Oil a Verify that the ball valve on the bottom of the hydraulic tank is closed b Unscr
26. Control Manifold consists of two solenoid valves for high or low pressure selection two pressure control knobs for setting of the high and low pressures a small accumulator and a gage for the hydraulic pressure The Control Manifold connects to the pump compensator port and has a comnection to the hydraulic tank 8 3 1 Cutting Pressure Knob and Pierce Pressure Knob pa Ni ts A PRE FILTER WATER PRESSURE POST FILTER WATER PRESSURE These two knobs are located on the front of the Control Manifold and are used to adjust the cutting and pierce pressures See the Operation Section for instructions on setting the operating pressure CUT PRESSURE SOLENOID VALVE PIERCE PRESSURE SOLENOID VALVE 62 Copyright 2005 Accustream Inc 1 866 566 7099 MANUAL OVERRIDE ACCUMULATOR AS 6050 Manual P N 12112 Rev A 8 3 2 Cut Pressure Select Solenoid Valve The Cut Pressure Select Solenoid Valve is located on the back of the Control Manifold directly behind the Cut Pressure Knob This is a normally open valve In case of loss of power it will discharge pressure from the hydraulic system and cause the bleed down valve to relieve high pressure water It has a manual override In the case where the solenoid coil fails the valve can be manually turned on until the coil is replaced Using the Cut Pressure Select Manual Override will prevent the discharge of WARNING i hydraulic and wat
27. Parts 11107 10 Micron Filter 11106 1 Micron Filter 11105 0 45 Micron Filter Recommended Tools Strap Wrench for turning filter housing Water Filter Element Replacement Procedure a Turn the pump off b Open the accumulator discharge ball valve to relieve trapped pressure c Unscrew the filter housing from head Remove element d Install new elements in the housing Screw the housing into head e Close the discharge ball valve f Turn the pump motor on to turn on the inlet valve and boost pump g Press the bleed valve located on the top of the filter housing to remove trapped air h Start the waterjet pump Verify satisfactory pressure readings 38 Copyright 2005 Accustream Inc 1 866 566 7099 AS 6050 Manual P N 12112 Rev A 6 3 Cooling Loop The cooling loop consists of an inlet solenoid valve to turn the water on when the motor is turned on and a water modulating valve to control the cooling water flow rate relative to the hydraulic oil temperature A probe in the tank senses the oil temperature The modulating valve has been factory set so that approximately 2 gpm of water is used to maintain a hydraulic temperature under 100 F Local air and water temperatures may require that the modulating valve be adjusted 6 3 1 Water Modulating Valve Adjustment The oil temperature in the hydraulic tank should not exceed 110 F The tank temperature can be seen on the temperature level gage located on the front of the hydra
28. al section for replacement timing guideline Better or lesser quality water than is normal may increase or decrease the duration between replacements FILTER HOUSING 11599 i a ra 5 gt FILTER ELEMENT ASSEMBLY 11600 HP Filter Assembly 11598 56 Copyright 2005 Accustream Inc 1 866 566 7099 AS 6050 Manual P N 12112 Rev A 7 7 High Pressure Plumbing Weep holes throughout the UHP water system relieve water seepage from leaking components Seepage from any of the holes indicates a faulty component loose connection or damaged seat Failure to correct the cause may result in damage to the mating fittings If weep hole leakage is observed the fitting may have loosened and require tightening Another cause of seepage is that the collar on the tubing needs to be threaded onto the tubing further Persistent seepage requires that the fitting or tube should be replaced GLAND COLLAR HP TUBING WEEP HOLE HP FITTING High pressure fittings should be lubricated with HP grease Use two wrenches to tighten one on the gland and one on the fitting to minimize side load Copyright 2005 Accustream Inc 57 1 866 566 7099 58 AS 6050 Manual P N 12112 Rev A This Page Intentionally Left Blank Copyright 2005 Accustream Inc 1 866 566 7099 AS 6050 Manual P N 12112 Rev A Section 8 Hydraulic 8 1 Hydraulic Overview Hydraulic pressure and flow from a pressure compensated variable displacement P
29. and cooling water e Verify the high pressure gage reads zero 4 5 2 Emergency Shutdown Procedure The pump has an EMERGENCY STOP E STOP palm button located on the Front Control Panel In the event of an emergency press the E STOP palm button This will immediately remove electrical power from the motor and controls The bleed down valve opens and the high pressure water is relieved down the drain If the pump is installed with a motion system and is configured to run remotely it is common for the emergency circuits from the robot or cutting table in series with the local E STOP circuit In the event that the pump has been shut down from a remote E STOP circuit it is necessary for the operator to first remove or reset the condition that caused the stop The pump can then be re started following the normal startup procedure listed earlier in this section Copyright 2005 Accustream Inc 23 1 866 566 7099 24 AS 6050 Manual P N 12112 Rev A This Page Intentionally Left Blank Copyright 2005 Accustream Inc 1 866 566 7099 AS 6050 Manual P N 12112 Rev A Section 5 Electrical System 5 1 Overview The AS 6050 has one 50hp main motor and a 1 2hp boost pump motor The electrical enclosure contains the main disconnect the motor starters and the control components All internal control power is derived from the 3 phase input power The electrical section of this manual discusses the following e Electrical Control Panel e M
30. anual P N 12112 Rev A Disassembly a Unscrew the eight bolts in the back of the manifold that connect it to the end caps b With the HP Cylinders removed loosen but do not remove the four 7 8 cap screws that preload the two Hydraulic End Caps together Use the 4 Hex x Y Deep Square Drive Socket and the Y x 13 5 Hex Driver c Unscrew and remove the four bolts under the Hydraulic End Caps that secure the intensifier assembly to the frame d Place the Center Section on a clean work bench and remove the four 7 8 cap screws Cover the manifold oil ports to prevent contamination e Pull the End Caps off the Hydraulic Cylinder This will take two people Plunger Replacement After extended use the plunger surface may become damaged and or scored a Push the Hydraulic Piston to the end of the Hydraulic Cylinder so that the plunger is accessible Use a rubber mallet to drive the opposite plunger end Do not remove the piston from the cylinder Special tooling is required to reload the piston into the cylinder b Use locking snap ring pliers on the Retaining Ring and remove the Plunger Retainer and Plunger c Replace the T Seal and its backups The inner diameter of the backup has a corner radius that is towards the T Seal The angle cut ends of the backup must overlap properly d Squirt a small amount of hydraulic fluid in the bottom of the piston cavity and lubricate the T Seal e Push the new plunger into the T Seal re
31. ccnnnannnnns 25 Copyright 2005 Accustream Inc 1 1 866 566 7099 AS 6050 Manual P N 12112 Rev A 52k PEC and LCD DISpla Y ti A AA ta At 25 5 22 DisCornects and FUSES rita taco sdaasserstescatclataskvestal teiseasscesSheustebutadens 25 5 2 3 Remote Operation Wiring ceceeccescceseceseceeeceeeeeeeeeeneeeseeeseecseecsaecsaecaeceaaecaecnaeceseceseenaeenes 27 5 2 4 Electrical Components Torque Chart ccccesccssscsssceesceeeceeeecseecseecaecaeceseseseenseeeeeeseeeenneeags 28 5 3 Motors and Motor Starter Circuits cccccccccscessseesseeteceseceseceseeeeeeseeeeeeeeeseeeseecseeeseecaecnseeeseenaeees 29 5 3 1 Main and Boost MOtors ccsccesssssscsssceeseeeseesseeeseeeseecsaecaeceaecaeceseceeeeseeeseseeeseeeseeeeeesaeenseeas 29 D322 RS A SIRO 29 5 3 3 Thermal Overload Protection cccccsccesscsssceesceeeceeseeeseeeseceseecseecsaecsaecsaeceseceseenseeneeeseeeeneeesgs 29 3 34 Motor SOrvaCe ii lali 30 5 4 System Fault Detecta 31 DAs Warnings Messages citado a ici 31 S42 Shutdown MESSAGE coccion caidas Coni R a td gas RR aa becines 32 5 43 Shutdown ll Messages meri As Aida 32 Section 6 Low Pressure Water cccccccccccsscccssccccssscccssccccscsccsscsccesccccescsssss JD 6 1 Low Pressure Water Overview Assembly 11534 ccccccsccsseceteceseceeeceeeceseecseeceeetecnseenseenseens 35 6 2 Inlet Cutting Water Supply cccccccccccssecsseesseessecsseceseceseceseceseeseeseeeseeeseseeeaeeeseeeseecsaecnse
32. e HP Seat into the bottom of the Bleed Down Valve body with the pointed end down The narrow end fits into the adapter When installing the adapter Torque to 35ft lbs Connect the high pressure valve assembly to the actuator body Reinstall the Bleed Down Valve in the machine by attaching the gland nut to the high pressure collar at the high pressure port of the valve Torque nut to 35 ft lbs Install the gland nut connecting the water drain tubing to the Bleed Down Valve Reattach the hydraulic hose to the oil port of the Bleed Down Valve The intensifier is ready for use Turn on and check for any leakage Copyright 2005 Accustream Inc 55 1 866 566 7099 AS 6050 Manual P N 12112 Rev A 7 5 Attenuator The Attenuator uses 9 16 male x 3 8 female inlet adapters on either end to connect to the 3 8 HP plumbing in the pump Leakage from the inlet adapter weep holes can be addressed by tightening the adapters into the Attenuator End Caps ADAPTER WEEP HOLE END CAP WEEP HOLE END STUDS AND NUTS NOT SHOWN Leakage from the End Cap Weep Hole or the gap between the End Cap and the Attenuator Body is not serviceable by the user If leakage persists from this area contact Accustream Service for further assistance 7 6 High Pressure Filter Assembly The HP Filter Assembly is normally located at the output of the pump It consists of a screen filter element that should be replaced on a regular basis See the Recommended Maintenance Interv
33. e motor and double check the HP water pressure is relieved down the drain before servicing any high pressure plumbing Plumbing supports and guides must be used for all HP tubing exiting the pump Failure to do so can introduce excessive bending stress and fatigue through vibration causing premature failure of the plumbing Always use two wrenches when tightening or loosening HP connections one for the gland nut and one for the fitting Excessive bending stress can be introduced to the plumbing causing premature failure Always use high pressure piping rated for the pressures you will be operating at This pump is capable of outputting 60 000 psi of water 2 3 5 Hydraulic System Safety A WARNING Pressurized fluid streams can penetrate skin causing severe personal injury If any fluid is ejected against the skin immediately seek medical attention Make sure all connections are properly tightened after performing service or maintenance Keep hands and body away from pinholes and nozzles which eject fluids under high pressure Never check for hydraulic leaks with your hand Use a piece of cardboard or other material Do not attempt to tighten or loosen any mechanical connection unless the machine is powered off and all system pressure has been relieved 2 3 6 Motor Pump Assembly Safety AN WARNING Beware of moving equipment Keep clothing and hands away from equipment that is operating Always verify covers and shields are in place befo
34. eal Housing on the plunger end until it goes on h Slide the Seal Housing by hand until it stops i Complete the New HP Seal installation by pushing the Housing in completely Copyright 2005 Accustream Inc 49 1 866 566 7099 AS 6050 Manual P N 12112 Rev A 7 2 6 End of Travel Sensing The Indicator Pin transfers the motion of the hydraulic piston at the end of travel for sensing by the proximity switch The Pin can be accessed by removing the Indicator Cap from the End Cap SPRING 11669 AA Aa INDICATOR PIN AA PLOT 11518 PO LE Newz Q BACKUP RING HYDRAULIC END 11680 013 CAP ORING 11679 013 The pin should move freely in and out all the way to the bottom of its travel Reassembly of the Indicator Pin Cap and Proximity Switch requires appropriate torque 7 2 7 Hydraulic Center Section The Hydraulic Center Section houses the Piston and the Plungers Service in this area is infrequent This section describes the service of this area with the HP Cylinders removed and the Center Section removed from the pump and serviced on a work bench ORING 11679 244 PLUNGER RETAINER BACKUP RING 11680 244 PLUNGER BEARING S BS SN Wi WM EN Uy ANA Y AW PISTON SEAL AIC HYDRAULIC 11673 LH HYDRAUL ENDCAP eas WEAR RING RH HYDRAULIC 11505 11674 ENDCAP 11506 50 Copyright 2005 Accustream Inc 1 866 566 7099 AS 6050 M
35. eam Inc 1 866 566 7099 73 AS 6050 Manual P N 12112 Rev A Maintenance Log Pump Model Serial Problem Found and Work Performed Date Hours Initial Date Hours Initial Date Hours Initial Date Hours Initial Date Hours Initial Date Hours Initial Date Hours Initial Date Hours Initial Date Hours Initial Date Hours Initial Date Hours Initial Date Hours Initial Date Hours Initial 74 Copyright 2005 Accustream Inc 1 866 566 7099 Maintenance Log Pump Model AS 6050 Manual P N 12112 Rev A Serial Problem Found and Work Performed Date Hours Initial Date Hours Initial Date Hours Initial Date Hours Initial Date Hours Initial Date Hours Initial Date Hours Initial Date Hours Initial Date Hours Initial Date Hours Initial Date Hours Initial Date Hours Initial Date Hours Copyright 2005 Accustream Inc 1 866 566 7099 75 AS 6050 Manual P N 12112 Rev A Maintenance Log Pump Model Serial Problem Found and Work Performed Date Hours Initia
36. eeseeeaeees 35 6 2 1 Boost Pump Assembly cccccesccssscssscseeceescesseeeseeeseecsaecsaeceseceseceaeceaeeseeeseaeseseeeseeesaecsaeesaeens 36 6 2 2 Inlet Cutting Water Filtration senere e i e a E e 38 6 3 Cooling Loopre te a bd 39 6 3 1 Water Modulating Valve Adjustment oooooonncninnnoonnoonnnonnonn nono nono nono ncon nono nononoco nn cnn carr ranrnnnnannrs 39 Section 7 High Pressure Water ococoooonocnonoononnncnnoccccnnnonocacacaconoracanccccoracacoconooo Fh 7 1 High Pressure Water OVErVISW ccccecscessceeseeseeeseecsceececsaecsaecaeceseseeeeeseceseecseecssecsaecnseceaeenaeees 41 7 2 RN 41 7 2 1 High Pressure Seal Removal aliada eae 42 7 2 2 Inst lling New HP Sealls cocina a tada 44 723 High Pressure Cilindro eae veddetogsedaevalacalevagetuasveabeateeuaesiald 46 12 4 Check Valve Assembly inicial nae ane a A aaa ae na ie 46 T23 Hydraulic Seal Housing crne ee e AAA EET dd 49 2 67 End Of Travel OSM iii aid ati EE e E i 50 7 2 7 Hydraulic Center Section cccccccesccssccssscesscessceeeeeeeeesneceseeeseeesaecsaecsaecsaeceaeceseenseeseeeeeesneeeags 50 7 3 Intensifier Cyc lint sranti rae a Goahe n a e at a aaret aaae aio aa 53 7 3 1 Intensifier Over Cycling Equally Both DirectioDS oooononncninnonncnnonnconnconnoonnoonnononocononanonaos 53 7 3 2 Intensifier Over Cycling One Direction oooooccnocnconnoonononananononncon nono nonn nooo noconono naco nncnn rra rnnnnnnars 53 7 4 Pump Bleed Down Val Vii it a ia tt A
37. er pressure at shutdown Pump pressure ramp up will be abrupt This feature should only be used as a temporary feature until a new solenoid coil is installed 8 3 3 Hydraulic Gage The hydraulic gage shows the operating pressure of the system It is also used to determine the current cutting water pressure Multiply the gage value by the intensification ratio of 19 25 to get the current water pressure For example with a gage pressure of 3000 psi the output pressure is about 57 000 psi 8 4 Oil Filter The gear pump takes oil from the hydraulic tank and directs it through the filter The filter element should be changed when the oil is changed or at the maintenance interval given in the Maintenance Section Copyright 2005 Accustream Inc 63 1 866 566 7099 AS 6050 Manual P N 12112 Rev A Filter element replacement procedure Requires 1 of 11245 Filter Element Unscrew the bottom of the filter housing from the top using the wrench flats at the bottom Discard the oil in the bottom housing and the old filter element Install the new element with the closed end down and thread the bottom housing back into the top part of the filter housing 8 5 Heat Exchanger After the oil passes through the filter it goes through the heat exchanger for cooling before it returns to the hydraulic tank The heat exchanger has been set up with the cooling water modulating valve as described in the Low Pressure Water Section of this manual Coolant fo
38. erify visually that the shaft is rotating the same way the motor rotation arrow indicates k If the motor rotates in the wrong direction swap a pair of wires at the bottom of the boost motor starter MS BOOST Perform the previous steps again to make sure the rotation has reversed 1 After verifying motor rotation replace any covers that were removed BOOST MOTOR COUPLING Main Motor Lubrication The main motor is supplied with sufficient grease to last indefinitely under normal service conditions Under severe or extreme operating conditions it may be necessary to add grease to each of the motor bearings Use a good quality moisture resistant polyurea based grease such as Chevron SRI 2 DO NOT use lithium based grease Mixing the two types of grease may result in loss of lubrication and shorter motor bearing life 30 Copyright 2005 Accustream Inc 1 866 566 7099 AS 6050 Manual P N 12112 Rev A 5 4 System Fault Detection The AS Series pumps have a series of fault conditions that are constantly monitored by the PLC If any fault condition is sensed by the control a message is displayed on the LCD screen Each fault condition is classified into one of three categories of severity Warning Shutdown I and Shutdown II The following is a list of conditions broken down by category For information on troubleshooting these conditions please refer to the maintenance and troubleshooting portion of this manual e Warning conditions a
39. es the Controls On Motor On and Intensifier On at the front panel of the pump These inputs are then solely controlled from a remote source Motor Off Intensifier Off and E Stop are active at both the front control panel and the remote source Remote Pump Control is activated by turning the key switch to the Remote setting The wire connections and a terminal block drawing are included for reference Required RPC Connections Description Wire No Voltage Type Contact Remote Controls On 7010 6015A 24VDC Momentary Normally Open Remote E Stop 6015A 6015B 24VDC Normally Closed Remote Pressure Control 24VDC 7018 24VDC Maintaining Normally Open Remote Motor On Input 24VDC 7030 24VDC Maintaining Normally Open Remote Intensifier On Input 24VDC 7031 24VDC Maintaining Normally Open Can be used with the key switch in the Local position as long as EPC mode is active EPC mode is always active when the key switch is in the Remote position Optional RPC Connections Description Wire No Voltage Type Contact Remote Controls On Indicator 6015D 24COM 24VDC Remote Mode Active Indicator 8010 115COM 115VAC Remote Pump Fault Indicator 7055 115COM 115VAC Remote Pump Run Indicator 8016 115COM 115VAC Sequence of Operation To operate in remote mode the key switch on the pump must be set to the remote setting a Momentarily activate the Remote Controls On b Activate t
40. ew the filler breather cover on top of the hydraulic tank FILLER BREATHER COVER c Fill with the appropriate oil until the oil level is visible at the top of the sight gage at the front of the hydraulic tank SIGHT GAGE d Replace the filler breather cover 60 Copyright 2005 Accustream Inc 1 866 566 7099 AS 6050 Manual P N 12112 Rev A 8 2 3 Evaluating Old Hydraulic Oil Hydraulic oil may need to be replaced after extended use or if it has been contaminated with water Oil quality can be evaluated visually by smell or measured by the oil supplier Water can be injected into the oil from the dynamic water seal in the intensifier A badly leaking dynamic water seal can squirt water past the rod seal into the oil See the High Pressure Section A milky oil appearance indicates that there is water in the oil This can damage the hydraulic pump and requires that the pump be shut down immediately all oil drained and components cleaned replacement of oil and replacement of the dynamic seal and rod seal Running the pump at too high of oil temperature will shorten the oil life Recommended oil temperature is under 110 F but not less than 70 F The pump will give a high temperature warning at 130 F and shutdown at 150 F See the Low Pressure Section for instructions on adjusting the water modulating valve New oil is almost clear and has no odor After running at excessive temperature the color will darken and its sme
41. g head Press INTEN ON and the hydraulic pressure will start to rise and the intensifier will begin to cycle Inspect all high pressure lines for leaks If any leaks are present refer to the HP Water section of this manual for instructions on correcting leaks After running in Set Point 2 for a minimum of 10 minutes change to Pressure Set Point 1 Cut by pressing the UP or DOWN arrow keys Inspect all High Pressure lines and fittings for leaks Turn the cutting head on and off several times to clear any debris in the lines Let the pump run for several minutes before shutting down again Verify that the hydraulic oil temperature stabilizes at 110F or below If the temperature is higher see the water modulating valve adjustment in the LP water section Normal Startup Procedure Verify all safety circuits are connected and operational Make sure the hydraulic reservoir is full by checking the sight gauge Add oil as necessary to bring the oil to an acceptable level Refer to the Hydraulic Oil Requirements section in this manual for instructions on adding oil Verify all utilities are connected to the pump and turned on at the plant Check for loose hoses and fittings and make sure there are no leaks present Press MOTOR ON and verify that the boost pump pressure is 50 115 psi Press INTEN ON and the pump will start generating pressure at the Set Point 2 for 5 seconds before switching to Set Point 1 Copyright 2005 Accustream Inc 1 866 5
42. he Remote Motor On and Wait 0 2 Seconds c Activate the Remote Intensifier On input and pause for 7 5 seconds to ramp up to high pressure or activate the Remote Pressure Control input for low pressure setting Copyright 2005 Accustream Inc 1 866 566 7099 21 AS 6050 Manual P N 12112 Rev A o000000 h S USE EU ES O LO LO SOSA APIS Terminal Blocks for Remote Wiring 5 2 4 Electrical Components Torque Chart When servicing the electrical enclosure and components within it is good practice to torque the components to the proper values to reduce the possibility of a component shaking loose from vibration The following is a list of recommended torque values for the electrical components ITM DESCRIPTION AS P N IN LB N m 1 TERMINAL BLOCK 11707 3 5 5 3 0 4 0 6 2 GROUND BLOCK 11709 4 4 6 2 0 5 0 7 3 65 AMP CONTACTOR 11757 45 5 4 65 AMP CONTACTOR CONTROL 11757 15 1 7 3 65 AMP THERMAL OVERLOAD LUGS 11760 45 5 6 40 AMP CONTACTOR LUGS 11758 45 5 7 40 AMP CONTACTOR CONTROL 11758 15 1 7 8 BOOST PUMP CONTACTOR LUGS 11712 15 1 7 9 BOOST PUMP CONTROL COIL 11712 10 1 2 10 MAIN CIRCUIT BREAKER 11698 250 29 11 PLC 11683 4 5 6 2 0 5 0 7 12 24VDC FUSEHOLDER 11705 4 4 6 2 0 5 0 7 13 120V FUSEHOLDER 11706 4 4 6 2 0 5 0 7 14 24VDC POWER SUPPLY 11689 4 5 6 2 0 5 0 7 28 Copyright 2005 Accustream Inc 1 866 566 7099 AS 6
43. he water pressure to 60 KPSI or 3100 psi hydraulic c Turn the cutting head on The pump is now operating at its highest power level d Loosen the lock nut and turn the volume stop clockwise until the pressure just starts to drop e Turn the control one quarter turn in the counter clockwise direction f The control is now set Retighten the lock nut on the volume stop control Copyright 2005 Accustream Inc 1 866 566 7099 AS 6050 Manual P N 12112 Rev A Section 9 Specifications The following specifications describe the requirements and capabilities ofthe AS 6050 pump 9 1 Pump Requirements Pump Power 50 Horsepower 60 hz e Voltage e Current e Main C B Rating Physical e Size e Clear Height e Shipping Weight in crate no oil Approx e Operating Weight Approx Ambient Conditions Min Storage Temperature not drained Min Operating Temperature Max Operating Temperature Max Relative Humidity Inlet Cutting Water Min Inlet Water Pressure Max Inlet Water Pressure Max Inlet Temperature Min Inlet Temperature Minimum Inlet Flow Rate Inlet Water Quality Hydraulic Cooling Water 460 VAC 10 67 5 A 90A 78 Wide x 40 Deep x 57 High 84 3400 3200 34 F 50 F 110 F 95 100 F or non condensing 20 psi 115 psi See LP Water Section 70 F 40 F 2 GPM See Following Water Quality Section e Min Inlet Water Pressure 40 psi e Max Inlet Water Pressure 115 psi See LP Water Sect
44. his procedure should be performed only after a new hydraulic pump has been installed Changing the adjustments on a tuned pump may cause adverse effects in the system a Disable the intensifier using the LCD display See the Operation Section for details b Press the MOTOR ON pushbutton and then the INTEN ON pushbutton fats PRESSURE LIMIT DIFFERENTIAL PRESSURE DO NOT ADJUST VOLUME STOP a c Turn the Cut Pressure Knob clockwise to make the Hydraulic Pressure 3200 psi THE INTENSIFIER SHOULD NOT CYCLE d If the pressure does not reach 3200 psi turn the Pressure Limit screw clockwise to increase the pressure to 3200 psi e If the pressure exceeds 3200 psi turn the Pressure Limit screw counter clockwise to reduce the pressure to 3200 psi f The differential pressure is set at the factory and does not require adjustment Copyright 2005 Accustream Inc 65 1 866 566 7099 AS 6050 Manual P N 12112 Rev A 8 7 2 Pump Volume Stop Adjustment NIMPORTANT This procedure should be performed only after a new hydraulic pump has been installed Changing the adjustments on a tuned pump may cause 66 adverse effects in the system The pump volume stop limits the flow of the hydraulic pump flow to the amount necessary to support the maximum orifice size This set up protects against the motor drawing excessive current a Install a 018 orifice in the cutting head b Start the motor and intensifier and set t
45. i uated T 54 7 5 A em O AN 56 7 6 High Pressure Filter Assembly saisissent il did 56 7 7 High Pressure Pl mbing ve aid 57 Section 8 Hydra Uli iii 8 1 Hydraulic Overview estic 59 8 2 Hydra Oli AA AAA EEEE AAA AAA te 59 8 2 1 Hydraulic Oil Requirements ccccccesccsseceseceseceeeceeeceeeeeeseeeseeeseecseecsaecsaecesecnseeseeseeeeneeesgs 59 8 2 2 Adding New Hydraulic Ol isso a il its 60 8 2 3 Evaluating Old Hydraulic Oil wo cc ccccccscceseceseceeeceeeceeeeeeseeeseecseecsaecsaeceseceseceseeneeseeeeeeeeass 61 8 2 4 Oil Replacement Procedure e ee ee cccecscessecsteceecesecesecseseseeeeeseeeseecseecsaecsaecsecesecsseeseeeseeeeseeeags 61 8 3 Control Manifold viii dent es ese aicenas ake dr 62 8 3 1 Cutting Pressure Knob and Pierce Pressure Knob cccecseesseseseeeseeeseeesecnsecnseceteeseeesseeeaes 62 8 3 2 Cut Pressure Select Solenoid Valve oo icieeccesesssesseeseceeeeseeseceaeeaeeeeceaeaesaeseeceaeseeeneeaeeneeenees 63 2 Copyright 2005 Accustream Inc 1 866 566 7099 AS 6050 Manual P N 12112 Rev A 8 3 3 Hydraulic Gage id Ad a da A eTa 63 8 4 Oil Hilti ds A id 63 8 5 Heat Exch da a nan 64 8 6 Hydraulic Td A E 64 8 7 Main Pump Setup assi nal ici 65 8 7 1 Setting the High Pressure Pump Limit 0 0 0 cecccesccessceseceeeceeeeescecseeeseecesecnseceseeseeeseeeeeeeeaes 65 8 7 2 Pump Volume Stop Adjustment cccccesccesecesecesecseeceeeeeeseeeseeeseecsaecsaecseceseceseeeeeeseeeseneeags 66 Section9 Spec
46. ifications iii ic 7 9 1 Pump Requirements a aa e a a aa N 67 9 2 Pump Capa ds 68 9 3 Orifiee COmMBIMALLONS mit iii aaa air 69 9 4 Inlet Cutting Water Requirement ccccccccsseesseceteceseceseceseeseeseeeeeceeeseceseeeseecseecaecnsecnseenaeens 69 9 5 Bolt Torque art id aga bancarias 70 Section 10 Maintenance amp Troubleshooting sesessoeossooesooeeessooesooeessosesoosesseee L OT Mamtenance a lA lio ae a lite 71 10 1 1 Parts and Service Contact Information oooocnonccccccononnnononanonononanonononanononnonnno conan no nnnananrnnnns 71 10 1 2 Maintenance Guidelines ida Laia aN 71 10 1 3 Scheduled Maintenance Chart ooooocccnnonoccconononononanonccnonnnnoconnnanonoonnonononnnonccnonnanonrnnnananronnnnos 72 10 1 4 Maintenance Loi adan 73 102 Troubleshooting ii E E E E E 77 Section 11 Drawings and Parts Lists cccssscsccccsssssssecsssscssecsscssesseessseess DS Copyright 2005 Accustream Inc 3 1 866 566 7099 AS 6050 Manual P N 12112 Rev A This Page Intentionally Left Blank Copyright 2005 Accustream Inc 1 866 566 7099 AS 6050 Manual P N 12112 Rev A Section 1 Introduction 1 1 Company Overview and Contact Information Our Mission To contribute to the waterjet community through the engineering manufacturing and sale of waterjet products that lower operating cost To strive for the greatest reliability and quality in our products to be the standard of comparison and t
47. ifier Over Cycle pay attention to arrow direction 78 Several possibilities exist for the possible causes of this error The error caused by the intensifier stroking too quickly in one or both directions Copyright 2005 Accustream Inc 1 866 566 7099 Note the direction of the intensifier over cycle and refer to Intensifier Cycle in the High Pressure Water section of this manual 2 General Pump Operation Problem AS 6050 Manual P N 12112 Rev A Possible Cause Corrective Action Pump Will Not Start Power disconnected E Stop depressed Pump enclosure door open Motor overload relay tripped Line Fuses Blown or Missing Pump Remote key switch in wrong position Reconnect power Check Main Disconnect Pull out all E stop buttons Close door and properly latch disconnect handle Check and correct Adjust volume stop on pump Check and correct Change key switch position Hydraulic Pump Does Not Make Pressure or Makes Low Pressure Defective Cut Pressure Select solenoid Defective Cut Pressure Control valve Defective hydraulic pump and or compensator Defective relief valve Pierce pressure is enabled Copyright 2005 Accustream Inc 1 866 566 7099 Manually over ride valve until replacement arrives Replace valve Replace pump Replace valve Change pierce pressure to cut pressure at the display 79 3 Intensifier Operation Problem AS 6050 Manual P N 12112 Rev A
48. igen AR E E iS 14 32V Site Preparation id ida EEES 14 3 2 2 Water Requirements narn ena a a aa aaa aa a e a net Een tds 14 3 23 Sewer Requires dios 14 3 2 4 Electrical Requirements snein pdea iee aa E Ep E a a Ea aaas 15 3 2 5 A OT 15 3 2 6 Recommended Tools viciado ride SEa aE p Toi 16 Section A 7 4 1 Operation OVerview o as 17 4 2 Front Control Paneles s n T as 17 4 3 PUMP Starp cla 19 AJA ESTIMO Startup ia A AA AAA ci a ii 19 4 3 2 Normal Startup Procedure curo catocn dai diiniita inside aliada ove 20 4 4 Pump Operation e ne aana a a a aa a a eaaa a aan a ae aa a ai 21 4 431 Normal Operation sneinen a a a a a e a A E sues 21 4 4 2 Adjusting the Cut and Pierce Pressure cccceccsssceseceseceesceeecseeceeseeeseeeseecseecsaeesaecnseenseenseens 21 44 3 Remote Pump Operation sirenen nirien irecte peaa EEn iior aan aa iai 21 AAA Ment Moodes inier e E EE E T EE E E Cabgins E E i 22 4 5 MU O EEEE EN AEA E E ts ak E EE E ES 23 4 5 1 Normal Shutdown Procedure cccccccccssecsseesseceeceseceseceeeseeeseeeeeeeseseceaeecseecsaeeaaecnseenseenaeens 23 4 5 2 Emergency Shutdown Procedure ccccccssesssessscsscesecssecesecsseceescseseseneseneeeseesstesseesaesseeees 23 Section 5 Electrical System A teacestactcconsatisseaa2O 5 1 O E EA tak oan ch ce T EE A A E T AE ee a A ae eS T 25 5 2 Electrical Control Panel oo oooooccnccnnnnanonananacinonananonononocnnonanananononononnnnnann nono ncnronnnnnna none n
49. ight hand corner The 0 signifies that you cannot edit the setting b Enter EDIT mode by pressing ENTER You will see the 0 change to a 1 c Press the DOWN arrow key to toggle between ENABLE and DISABLE d Press the ENTER key again to exit EDIT mode when you are on the desired setting Procedure to set the pump to External Pressure Control without Remote Pump Control active a Press and hold ENTER MENU to enter MM2 You should see a screen which reads Pressure Source Front Panel input Note the 0 in the upper right hand corner b Press ENTER to edit the value Note the O changed to a 1 c Press the UP or DOWN arrow keys to toggle between Front Panel Input and External EPC d When you are on the desired setting press the enter key again to exit the edit mode START ACCUSTREAM VERSION 1 02 PRESSURE SETPOINT 1 SETPOINT 2 MM1 MM2 INTENSIFIER PRESSURE SOURCE ENABLE FRONT PANEL INPUT DISABLE REMOTE RPC 22 Copyright 2005 Accustream Inc 1 866 566 7099 AS 6050 Manual P N 12112 Rev A 4 5 Shutdown 4 5 1 Normal Shutdown Procedure A WARNING Never leave water jet cutting equipment turned on and unattended N IMPORTANT After the equipment is shut down always make sure the high pressure water is relieved by turning on the cutting head a Turn the cutting equipment off b Press the Intensify Off and Motor Off pushbuttons c Pull the main disconnect handle to the off position Down d Turn off the plant cutting
50. ion e Max Inlet Temperature 70 F e Min Inlet Temperature 40 F e Normal Inlet Flow Rate 3 GPM OCopyright 2005 Accustream Inc 67 1 866 566 7099 AS 6050 Manual P N 12112 Rev A Hydraulics e Hydraulic Oil Type e Hydraulic Oil Capacity e Max Oil Temp e Min Oil Temp Pump Factory Settings e Hydraulic Pump Pressure Limit e Cut Pressure Set Point e Pierce Pressure Set Point Adjustable after start up Utility Hook Ups located at rear of pump Cooling Water In Cooling Water Out Cutting Water In Drain Water Out Cutting Water Out Warnings and Shutdowns ISO VG 32 mineral oil 40 Gallons 130 F 55 F 3200 psi 45 000 psi 20 000 psi Y NPT Female 34 NPT Female 34 NPT Female Y NPT Female 3 8 HP Female e Intensifier Over Cycle Shutdown e Inlet Cutting Water Below 30 psi Shutdown e Hydraulic Oil Level Low Shutdown e Hydraulic Oil Temperature Over 130 F Warning e Hydraulic Oil Temperature Over 150 F Shutdown e Oil filter Clogged Warning e Motor Fault Shutdown 9 2 Pump Capabilities Max Continuous Output Pressure 60 000 psi Min Output Pressure 5 000 psi Max Output Flow 1 1 gpm 68 Copyright 2005 Accustream Inc 1 866 566 7099 AS 6050 Manual P N 12112 Rev A 9 3 Orifice Combinations This pump will support at least the following combinations Qty 1 016 orifice Qty 2 011 orifice Qty 3 009 orifice Qty 4 008 orifice Qty 5 007 orifice Qty 6 006 orifice 9 4 Inlet Cutting Water Req
51. ions are removed d Lapping with the lapping film is complete when the face is flat with a near mirror finish 48 Copyright 2005 Accustream Inc 1 866 566 7099 AS 6050 Manual P N 12112 Rev A 7 2 5 Hydraulic Seal Housing Removing the Hydraulic Seal Housing provides access to the Rod Seal If oil is observed in the seal area during HP Seal replacement the Rod Seal should be replaced BACKUP RING ORING 11680 035 11679 035 K HYDRAULIC END Hi CAP SAT PLUNGER HP SEAL BACKUP 11610 AL H N PLUNGER O os ROD BEARING SEAL 11608 11090 a With the HP Cylinder removed slide the 11985 Seal Housing Removal Tool over the exposed Seal Housing diameter and into the groove b Jack the Seal Housing out using the two screws on the tool and pull the seal housing off the plunger c Remove the old seal and install a new Rod Seal in the Seal Housing Note the direction of the Rod Seal in the Housing d Inspect the condition of the HP Seal Backup and flip or replace as necessary ID corner chipping or loose fit on the plunger are cause for change e Replace the o ring and backup on the OD of the Seal Housing Position the o ring on the rod seal side of the groove and Backup on the backup side of the groove The backup is contoured on one side and this side is toward the o ring f Apply HP Lubricant to the outside of the o ring and to the ID of the rod seal g Using the palm of the hand push and rotate the S
52. ittings are stainless steel with rubber hoses connecting the low pressure water components The low pressure cutting water circuit can be used with inlet water quality as provided by water softening reverse osmosis or de ionized water Most installations with normal city water pressure will require no adjustment of the bypass relief valve See Inlet Water Requirements in the Specification section of the manual for further information Two water gages are located on the front panel of the pump to show the pressure after the boost pump and the pressure after the filters These are used to determine the pressure drop across the filters Quick disconnects are provided at the HP End Caps for ease of maintenance preventing low pressure water from spraying out when this connection is broken A manual ball valve is provided to discharge the accumulator prior to changing filters The boost pump will automatically shut off after the intensifier has not cycled after a period of time The pump automatically restarts when the intensifier shifts or the system water pressure drops below 40 psi Copyright 2005 Accustream Inc 35 1 866 566 7099 AS 6050 Manual P N 12112 Rev A Operation The cutting water enters the pump through the port at the rear inlet connection When the motor is turned on the inlet solenoid valve is energized allowing water to flow to the inlet of the boost pump The boost pump increases the inlet pressure to assure proper supply
53. l Date Hours Initial Date Hours Initial Date Hours Initial Date Hours Initial Date Hours Initial Date Hours Initial Date Hours Initial Date Hours Initial Date Hours Initial Date Hours Initial Date Hours Initial Date Hours Initial 76 Copyright 2005 Accustream Inc 1 866 566 7099 10 2 Troubleshooting AS 6050 Manual P N 12112 Rev A The following troubleshooting chart lists symptoms possible causes and recommended solutions for troubleshooting the AS Series pumps If you receive a fault message and have corrected the fault condition you can reset the pump by pressing the ACK RESET button on the front control panel This will clear the fault and allow you to re start the pump 1 Fault Display Error Message Display Error Message Possible Cause Corrective Action Hydraulic Oil Level Low The Oil Level had dropped from a leak ata fitting or from performing maintenance on the hydraulic assembly Cable may be damaged or connector is unplugged Inspect the fittings and components of the hydraulic system for leaks After Identifying the cause of lost oil add oil per instructions in the Hydraulic section of this manual Replace cable if damaged Plug in connector if unplugged Hydraulic Oil Temp gt 130F
54. l to bring the readers attention to known hazards and conditions which can be avoided Although an attempt to point out most conditions was made Accustream acknowledges that there are other unforeseen situations due to site variability improper maintenance etc that could also potentially cause equipment damage severe injury or death It is the end user s responsibility to identify these additional hazards and take necessary steps to minimize risks ndicates the presence of a hazard which can cause severe personal injury eath or substantial property damage if the warning instruction is ignored Highlights important instructions which must be followed to prevent personal njury and or equipment damage E Draws attention to items of important factual or procedural significance ailure to follow the instructions may result in equipment damage Hazardous voltage within can cause injury or death Disconnect and lock out main power before opening the cabinet E High pressure waterjet can cause eye injury Wear eye protection when perating or working near the machine Wear ear protection when operating or working near the machine to reduce the isk of hearing loss Airborne contaminants or suspended particles may exist when cutting certain materials Wear respiratory protection when these conditions are present E Copyright 2005 Accustream Inc 7 1 866 566 7099 AS 6050 Ma
55. lic pressure is reduced e Attenuator Assembly 11595 acts as an accumulator by using the compressibility of the water to dampen the output water pressure pulsation caused by the reciprocation of the intensifier e HP Filter Assembly 11598 is normally located at the pump output or at the upstream end of the whip for the cutting head Detailed instructions are provided on disassembly and reassembly of the hydraulic intensifier including HP seal maintenance A discussion of detailed inspection and repair for individual HP subassemblies is also provided HP attenuators are discussed but no disassembly procedures are included since attenuators are not serviceable by the customer High pressure water may be stored in the HP plumbing Water pressure must be discharged through the Bleed Down Valve before starting any service or maintenance Stay clear of weep holes when unscrewing HP fittings in case pressurized water is discharged Turn off electrical power and relieve all water and hydraulic pressure prior to service Proper lockout tag out procedures must always be followed prior to performing any maintenance 7 2 Intensifier In addition to normally used tools the following special tools are required e 300 foot pound torque wrench with square drive e 11557 Seal Insertion Tool Assembly Includes 1 each of 11812 Push Tool 11811 Sleeve Guide 11550 Locating Ring 11985 Seal Housing Removal Tool 12021 1 Hex x Square Drive Socket 12020
56. ll will worsen When the color is like dark honey and with a poor odor it is time to replace the oil 8 2 4 Oil Replacement Procedure Changing the oil is an opportunity to thoroughly clean the hydraulic system Requires 1 of 11960 2 Suction Strainer 1 of 11961 1 4 Suction Strainer 1 of 11245 Filter Element a Use new oil provided by your supplier b Drain the oil from the hydraulic tank using the ball valve at the bottom of the tank c Remove the right pan over the hydraulic tank d Remove the top cover of the hydraulic tank e Remove and discard the two suction strainers in the tank f Thoroughly clean the tank interior Make sure no particulates remain on the bottom g Install two new suction strainers DO NOT use Teflon tape or pipe dope h Drain the oil in the hydraulic hoses by disconnecting one end i Reinstall hoses j Replace the oil filter element See the Filter Section that follows k Close the ball valve drain and reinstall the tank top cover 1 Fill the hydraulic tank with new oil m Let the oil sit until any bubbles dissipate n Replace the right pan o Start the pump at low pressure and check for hose leaks In the case of severe contamination such as with water it is necessary to drain and clean out other areas such as the shift valve main manifold and the hydraulic pump Copyright 2005 Accustream Inc 61 1 866 566 7099 8 3 Control Manifold AS 6050 Manual P N 12112 Rev A The
57. manual to identify other possible causes Once the problem is corrected resume normal operation of the pump Hydraulic Oil Temp gt 150F 65C The probe in the hydraulic oil tank has two temperature switches One switch opens at 130F 55C and the other at 150F 65C If the higher temperature is exceeded the red light will begin to flash and the intensifier will shut down warning the operator of a potential cooling water problem The most likely cause of this condition is the cooling water is not turned on or the inlet cooling water temperature is too high The water modulating valve may also be out of adjustment Review the Low Pressure Water section of this manual to troubleshoot the cooling water After correcting the problem press the ACK RESET button on the control panel to turn off the Warning light Intensifier Over Cycle The intensifier over cycle fault is caused when the hydraulic piston travels one or both ways too quickly If the intensifier strokes seven times in one direction and each stroke is less than the set threshold the over cycle fault will be triggered If the piston is traveling to the right when the fault occurs the message will have a directional indicator to the right If the piston is traveling to the left the message will have a directional indicator to the left The arrows can be very helpful in determining which side may be the cause of the problem Refer to the Intensifier Cycling subsection of the High Pressure Water
58. motor and boost motor starters both have thermal overload protection The main motor thermal overload OL MAIN should be set to 38 amps for the AS 6050 To set this you need a Philips screw driver to turn the adjustment dial The boost pump thermal overload should be set to 1 6 Amps To reset the OL MAIN in the event that it has tripped press the reset button To reset the OL BOOST turn the dial to RESET and then back to AUTO TD MAIN ADJUSTMENT OL MAIN OL BOOST RESET ADJUSTMENT OL BOOST OL MAIN ADJUSTMENT RESET Copyright 2005 Accustream Inc 29 1 866 566 7099 AS 6050 Manual P N 12112 Rev A 5 3 4 Motor Service Boost Motor Replacement and Direction Check In rare cases the boost motor may need to be replaced If the boost motor is in need of replacement always make sure to wire the new motor following the proper wiring diagram for 460VAC 60Hz After replacing the motor it is necessary to perform a rotational direction check Take the following steps to ensure that the motor and boost pump are not damaged from improper rotation g Remove the front and rear cover from the pump h Make sure that you can see the boost motor coupling through the pump mount It may be necessary to have two people for this procedure i To jog the motor pull the EMERGENCY STOP button on the control panel and then press the CONTROLS ON button 3 With one hand on the MOTOR ON button and the other on the MOTOR OFF button quickly jog the motor V
59. n surface slide the Hydraulic End Caps into each end of the Hydraulic Cylinder Thread the four 7 8 cap screws in and lightly pull the end caps against the hydraulic cylinder until they bottom out The cap screw threads should be greased with a multi purpose lithium grease such as Lubriplate No 1552 Prior to torquing the 7 8 cap screws the center section must be secured with the manifold mounting face clamped to a flat surface Either clamp it to a flat work surface or bolt it back to the manifold first and then to the frame on the pump before applying torque Torque the 7 8 cap screws in a cross pattern to 275 foot pounds Start at 125 ft lbs and advance in 50 ft lb increments The eight bolts that connect the manifold to the hydraulic end caps must be torqued to the appropriate value as given in the Fastener Torque section of this manual Reassemble the end of the intensifier as described above in Installing New HP Seals Loosen the four bolts that secure the intensifier to the frame when reconnecting the HP tubing This allows it to float into the correct location Tighten the four frame connect bolts Copyright 2005 Accustream Inc 1 866 566 7099 7 3 AS 6050 Manual P N 12112 Rev A Intensifier Cycling Normally the intensifier cycles at the same speed in both directions smoothly Leaks or HP component failures will cause the intensifier to Over Cycle in one or both directions Severe over cycling will cause a fault conditi
60. nted from repeated poppet impact or have erosion tracks It is necessary to periodically inspect this surface and if necessary return it to a flat and near mirror finish This procedure is for a moderately worn CV Body face Severe wear will require that the face be turned in a lathe or ground on a precision surface grinder prior to lapping Repeated lapping may shorten the Check Valve Body s sealing diameter length so that it is not usable If the length is less than 385 as shown below it should be replaced H 0 385 LP POPPET SEALING FACE CHECK VALVE BODY 11523 Copyright 2005 Accustream Inc 47 1 866 566 7099 AS 6050 Manual P N 12112 Rev A The following items are required e Granite Inspection Plate at least 9 x 12 e 8 5 x 11 Sheets of 320 grit SiC abrasive paper e 11210 Lapping Film When the Sealing Face has slight indentations it is necessary to only lap with the 11210 lapping paper Deeper indentations require that it first be lapped with the SiC abrasive paper The procedure follows a Place either the abrasive paper or lapping film on the granite plate and tape with masking tape around the edges b Move the Check Valve Body on the film or paper back and forth without rocking It must remain flat After each movement rotate the CV Body approximately 45 degrees so that it is evenly finished c Lapping is complete with the abrasive paper when the face has an even appearance and any indentat
61. ntenance intervals Maintenance Description Inspect all Cables and Plugs for Damage Check Safety Circuits Grease Motor Bearings Electrical Inspect Fittings and Hose for Damage Adjust Cooling Water Flow Check Inlet Water Pressure Inlet Water Filters Check Pressure in Water Accumulator Set to 40 psi Low Pressure Visually Inspect for Leaks Check Temperature of Intensifier and Bleed Down Valve Lap LP Poppet and Check Valve Face Replace HP Seals Replace HP Filter at Pump Outlet Replace Hydraulic Rod Seal Replace Plunger Bearing Change Oil Filter Sooner if By pass Occurs Change Oil Check Oil Level Check Oil Temperature Check for Oil Leaks High Pressure Hydraulics A Adjust Inspect R Replace 72 Copyright 2005 Accustream Inc 1 866 566 7099 10 1 4 Maintenance Log Pump Model AS 6050 Manual P N 12112 Rev A Serial Problem Found and Work Performed Date Hours Initial Date Hours Initial Date Hours Initial Date Hours Initial Date Hours Initial Date Hours Initial Date Hours Initial Date Hours Initial Date Hours Initial Date Hours Initial Date Hours Initial Date Hours Initial Copyright 2005 Accustr
62. nual P N 12112 Rev A 2 2 Common Sense Most safety practices are common sense Readers are expected to know how to use common hand tools and the basic techniques of operating pressure producing equipment The manual provides information on hazards specifically related to the maintenance and operation of this equipment The safety guidelines found in this manual are general and cannot cover every possible situation Only thorough knowledge of the equipment can provide optimum safety The force of a waterjet can penetrate and cut through almost any material Always avoid contact with the stream of water Seek medical attention immediately if you have come in contact with a high pressure stream of water People untrained in the safety and operation of a waterjet machine should not be allowed near the system Always wear safety glasses when working on or near the pump Clean and inspect equipment regularly and fix any problems immediately after discovered 2 3 Operation and Maintenance Safety The operation and maintenance of this system should only be performed by trained qualified personnel 2 3 1 Operating Safety A WARNING Failure to wear proper safety gear can result in personal injury or death Safety shoes hard hat and other personal protective equipment are strongly lt i recommended Wear eye protection while the machine is operating gt A Extended exposure to loud noise can cause permanent hearing
63. o be a company recognized for honesty integrity and personal service The Company AccuStream is a waterjet supply company with a history of providing economical solutions for a broad range of customers Through the engineering manufacturing and sale of quality parts and products AccuStream has quickly earned a reputation for superior customer satisfaction AccuStream s rapid shift to the forefront of the waterjet industry can be attributed to an unyielding focus on customer success through product reliability and unparalleled service from a well trained customer and technical support staff History AccuStream s background in waterjet started in the mid 1980 s with the development application and sales of waterjet products for a major equipment manufacturer In the late 1990 s AccuStream was started with the goal of supplying quality spare parts and innovative products to help waterjet users lower their operating cost Today the company has become the leading source for industrial waterjet products Customer amp Technical Service At AccuStream your purchase is only the beginning of our commitment to help you succeed We think that what happens after the sale is just as important as what happens before Customer Service Representatives are available to take your calls Monday through Friday 7 00 AM to 5 00 PM CST If you need service after hours AccuStream is also on call 24 hours a day 7 days a week to ensure your system is up and r
64. on pump shutdown and the over cycle direction will be indicated by an arrow on the display screen If an over cycle shutdown or harsh cycling occurs it is important to observe the pump operation before attempting to fix the problem Turn the pump and intensifier on at a reduced cutting pressure of 1000 psi hydraulic pressure and gradually increase the pressure until the nature of the problem is seen Look for leaks and use the proximity switch lights to determine which direction the intensifier is over cycling 7 3 1 7 3 2 Intensifier Over Cycling Equally Both Directions This is most likely caused by a leak Check the tubing and fittings inside and outside the pump and fix any leaks Check the Bleed Down Valve If it feels hot or if water is coming out the pump drain line then the Bleed Down Valve should be rebuilt with a new kit A blown orifice at the cutting head will increase the HP water requirements The intensifier water inlet could be starved without setting off the low pressure alarm Check the quick disconnects to the intensifier Intensifier Over Cycling One Direction This indicates a problem inside the intensifier specifically the HP Cylinder or HP Check Valve area Verify that the water inlet connection is made to the intensifier Look for leaking from either end of the HP Cylinder Replace HP Seals if necessary If the HP Cylinder or Check Valve Body is hot disassemble and look for cracks If a component is cracked it
65. or Starts per Hour The motor can be damaged if it is started too frequently The threshold for this warning is set to six times in 15 minutes If this number is exceeded the yellow light will blink and the message will be displayed on the LCD screen Reset the alarm by pressing the ACK RESET button on the control panel Wait 15 minutes before starting the motor to allow time for the windings to cool Copyright 2005 Accustream Inc 31 1 866 566 7099 AS 6050 Manual P N 12112 Rev A 5 4 2 Shutdown I Messages Shutdown I fault conditions are severe enough to cause the Intensifier to shutdown but keep the motor running The red light will be flashing and one of the following messages will be displayed on the LCD screen e INLET WATER PRESSURE BELOW 40PSI 2 8BAR e HYDRAULIC OIL TEMP gt 150F 65C e INTENSIFIER OVERCYCLE Inlet Water Pressure Below 40PSI 2 8BAR There is a pressure switch that senses the water pressure after the boost pump If the water pressure falls below the set point the monitoring circuit will open and this fault will occur after ten seconds The most likely cause is failure of the water supply to the pump Make sure that the plant supply water is turned on Check the cutting water in solenoid for correct operation If the cutting water solenoid does not open when the motor is turned on replace solenoid valve Clogged water filters can also cause low inlet water pressure Read the Low Pressure Water section of the
66. otors and Motor Starter Circuits e Fault Detection 5 2 Electrical Control Panel 5 2 1 PLC and LCD Display The operator controls the intensifier pump through the LCD Display OI 1 on the front of the electrical enclosure which communicates with the programmable logic controller PLC 1 located inside the electrical enclosure The PLC monitors all fault conditions and controls the intensification process In the event that the communication is interrupted between the operator interface and the PLC the pump will be shut down and not able to restart until the interruption is corrected The PLC program is loaded and tested at AccuStream prior to pump shipment The program is stored on Flash ROM so no battery backup is needed in the PLC No service is necessary on the PLC All inputs and outputs are run to terminal blocks which should be used for wiring the remote options 5 2 2 Disconnects and Fuses The electrical cabinet has three different power levels contained inside 460VAC 115VAC and 24VDC The motors are powered by the 460VAC power The PLC LCD Display and all components wired to the input side of the PLC are 24VDC The motor starters solenoids and all other components wired to the outputs of the PLC are 1ISVAC Main power enters the cabinet and lands at the top of the main disconnect MAIN DISC 1 The 460VAC power then runs through each motor contactor circuit to the main motor and the boost motor Two legs of the 460VAC power run to
67. pecific Torques e 1 Nut on Intensifier Stud 275 foot lbs e 7 8 Cap Screw on Intensifier Center 275 foot lbs General Torques Cap Screw or Bolt Size Torque 10 45 in lb 1 4 105 in lb 5 16 18 ft lb 3 8 33 ft lb 7 16 53 ft lb 1 2 80 ft lb 70 Copyright 2005 Accustream Inc 1 866 566 7099 AS 6050 Manual P N 12112 Rev A Section 10 Maintenance Troubleshooting 10 1 Maintenance This section outlines the scheduled and preventative maintenance required to keep the intensifier pump in good working order The following pages contain Parts and Service contact Information Maintenance Guidelines a Scheduled Maintenance Chart and a Maintenance log 10 1 1 Parts and Service Contact Information Accustream Inc 4757 Mustang Circle Mounds View MN 55112 Toll Free 1 866 566 7099 Phone 763 717 7099 Fax 763 717 7093 Email Info Accustream com Web www accustream com 10 1 2 Maintenance Guidelines The AS Series pumps require preventative and scheduled maintenance to remain in good working order prevent unscheduled downtime and extend the life of the components To provide safe and proper maintenance read and follow all Maintenance Guidelines in this section Always bleed down all HP water pressure and lockout the electrical control cabinet prior to performing any maintenance Failure to do so can result in severe injury High pressure water leaks can cause major damage to anything in its line of fire
68. perly provided as outlined in the Specifications section of this manual e Follow all first time startup and setup instructions as provided in the Operations section of this manual e Train maintenance personnel on proper service and repair procedures e Follow standard system acceptance tests Copyright 2005 Accustream Inc 13 1 866 566 7099 AS 6050 Manual P N 12112 Rev A 3 2 Utility Requirements 3 2 1 Site Preparation A WARNING Certain locations may be hazardous if the atmosphere contains gas vapors or dust in explosive quantities Refer to the National Electric Code NEC OSHA requirements and local codes for detailed information about environmental criteria The facility must have adequate air water sewer drain and electrical service per specifications prior to installation of the equipment Floor material should be concrete capable of supporting the weight of the machine and thick enough to provide resistance to vibration 3 2 2 Water Requirements Cutting Water The water supplied to the intensifier is a crucial factor in precision waterjet cutting because of its direct affect on the service life of equipment components The pump s built in filtration is sufficient for removal of suspended solids Total Dissolved Solids TDS in the inlet water will have an adverse effect on check valves seals orifices and other consumables Most systems soften the water before it enters the pump Before installing the
69. place the Plunger Retainer and reinstall the Retaining Ring Piston Seal and Wear Ring Replacement The Piston uses a long life capped T Seal and Wear Rings for the longest possible life After extended use the intensifier may not be able to stroke as fast and the pump may generate heat This is a sign that the Piston Seal is bypassing oil and needs to be replaced Special tools are required to load the new seal on the piston and load the new piston seal assembly into the hydraulic cylinder Contact Accustream Service for further information regarding this procedure Plunger Bearing The Plunger Bearing may become worn and may lose its precision fit relative to the plunger The bearing should be replaced if the plunger fit is too loose A bearing ID measurement of 0015 greater than the plunger diameter is too loose The bearing is easily changed when the hydraulic end cap is off the hydraulic cylinder Copyright 2005 Accustream Inc 51 1 866 566 7099 AS 6050 Manual P N 12112 Rev A Reassembling the Center Section 52 a b c d e g h i J Verify that all surfaces are clean and free of contamination Replace the o ring and backup on the end cap Place the o ring on the side of the groove towards the piston and the backup on the side away from the piston The concave side of the backup is towards the o ring Lubricate the o ring with hydraulic oil Install the Plunger Bearings in the End Caps On a flat clea
70. r the heat exchanger may be water from a municipal water supply or be antifreeze based from a chiller or an in house cooling system If the coolant is water that originates from a well it will likely be high in total dissolved solids TDS which can lead to clogging and loss of efficiency of the heat exchanger It is recommended that if the cooling water is high in TDS specifically calcium that the water be softened prior to entering the heat exchanger If the hydraulic system is warmer than in the past it is possible that the heat exchanger is partially clogged The solution is to rod the tubes inside the heat exchanger to clear the obstruction or to install a new replacement 8 6 Hydraulic Tank The hydraulic tank has the following features Epoxy Painted interior for corrosion resistance Sight gage and thermometer for seeing the oil level and its temperature Filler breather cap keeps the contents of the tank free of airborne contamination Level sensor with temperature switches monitor the tank for low level and high temperature alarm conditions e Inlet suction strainers prevent contamination from reaching the main PCVD pump and the kidney loop pump 64 Copyright 2005 Accustream Inc 1 866 566 7099 AS 6050 Manual P N 12112 Rev A 8 7 Main Pump Setup Procedure to setup a new or existing hydraulic pump after the hydraulic pump has been installed onto the motor adapter 8 7 1 Setting the High Pressure Pump Limit NIMPORTANT T
71. re characterized by the yellow light on the light stack blinking and a message is displayed on the LCD screen e Shutdown I conditions are characterized by the red stack light blinking and the intensifier shutdown but the motor is still running A message is also displayed on the LCD screen e Shutdown II conditions are characterized by the red stack light blinking and the motor and intensifier shutdown A message is also displayed on the screen 5 4 1 Warnings Messages Warning messages are the least severe of the categories The purpose of the warning is to alert the operator of conditions that if ignored can result in a shutdown condition The following conditions can cause a Warning to occur e HYDRAULIC OIL TEMP gt 130F 55C e TOO MANY MOTOR STARTS PER HOUR Hydraulic Oil Temp gt 130F 65C The probe in the hydraulic oil tank has two temperature switches One switch opens at 130F 55C and the other at 150F 65C If the lower temperature is exceeded the yellow light will begin to flash warning the operator of a potential cooling water problem The most likely cause of this condition is the cooling water is not turned on or the inlet cooling water temperature is too high The water modulating valve may also be out of adjustment Review the Low Pressure Water section of this manual to troubleshoot the cooling water After correcting the problem press the ACK RESET button on the control panel to turn off the Warning light Too Many Mot
72. re clear See 8 2 3 for reconditioning of the HP cylinder and 8 2 4 for reconditioning of the check valves Copyright 2005 Accustream Inc 43 1 866 566 7099 7 2 2 AS 6050 Manual P N 12112 Rev A Installing New HP Seals Use 11451 Seal Kit which includes 4 of 11024 HP Seal with o ring 4 of 11018 Hoop and 1 of 11447 Grease Packet Also use 11610 Seal Back up a b c d e g h 44 Apply grease from the packet onto each o ring Place each o ring onto the HP seal while making sure that the o ring does not twist Put the Locating Ring and Seal Guide on the end of the Cylinder The large ID end ofthe Seal Guide should be up Coat the inner diameter of the Seal Guide with the packet grease Place the HP Seal and the Hoop onto the large end of the Push Tool Note in the picture below the orientation of the seal and hoop Push the Tool by hand down into the Seal Guide When the seal and hoop bottom in the taper strike the top of the Push Tool with a rubber mallet to fully load the seal and hoop Flip the cylinder over and install the Spacer Tube and Low Pressure Poppet Basket Install another seal and hoop as described above The Seal Back up can be reused once Either install a new backup or reuse the old one It may be necessary to pull the Seal Housing out slightly to access and remove the Backup See the Hydraulic Seal Housing section below Push the HP Cylinder onto the plunger Make sure the low pres
73. re starting 10 equipment Copyright 2005 Accustream Inc 1 866 566 7099 AS 6050 Manual P N 12112 Rev A 2 3 7 Emergency Medical Treatment N WARNING Always seek medical attention immediately in the event of contact with a high pressure stream of water Failure to do so can result in severe infection Waterjet equipment can cause severe injury and infection Any injury involving high pressure water or tegi jury y Injury g high p hydraulic oil no matter how small should be reported immediately and treated Always seek medical attention and inform the medical personnel the victim has been working with high pressure water up to 60 000 psi and nozzle velocities of up to 2000 feet per second Waterjet injuries have been known to cause infections with micro aerophilic organisms such as gram negative pathogens like found in sewage Bacterial swabs and blood cultures can aid in determining if any infection is present The injury should be treated as an acute surgical emergency and be evaluated by a qualified surgeon Circulation may be compromised therefore DO NOT apply heat Keep injured person awake elevate injured part and get antibiotics Copyright 2005 Accustream Inc 11 1 866 566 7099 12 AS 6050 Manual P N 12112 Rev A This Page Intentionally Left Blank Copyright 2005 Accustream Inc 1 866 566 7099 AS 6050 Manual P N 12112 Rev A Section 3 Installation 3 1 Installation Overview 3 1 1 Buyer Obligation
74. rts Lists Section 16 Copyright 2005 Accustream Inc 1 866 566 7099 AS 6050 Manual P N 12112 Rev A Section 4 Operation 4 1 Operation Overview The AS Series pumps are controlled from the front control panel The main disconnect on the electrical enclosure must be turned on in order for the pump to function This section outlines the operation of the front control panel startup procedures normal operation and menu modes 4 2 Front Control Panel The AS Series Front Control Panel consists of a LCD display 10 function buttons pierce pressure and cut pressure adjustment knobs and water and hydraulic gauges The control panel communicates with a PLC which controls all pump operations as well as monitors the system for fault conditions The controls can only be turned on if the main disconnect is turned on Review all button functions read this section completely and follow all instructions before attempting to start the pump The following is an image of the Front Control Panel and a summary of its components and functions F cuear I pi A Y JE ENTER MOTOR fvorar inten wren Y f ack orF on Pl orr on f RESET PRE FILTER POST FILTER WATER WATER PRESSURE PRESSURE CONTROLS ON go ojojojojojo TOTAL HOURS CUT PRESSURE PIERCE U A
75. s The buyer of an AS Series waterjet pump is responsible to cooperate with AccuStream and Accustream OEM personnel to facilitate installation of the machine e The pump should be uncrated and placed as close as possible to the position it will be used in e All Utilities must be provided prior to installation as outlined in the Specifications section of this manual e High pressure tubing should be installed by the buyer unless other arrangements have been made in the sales agreement e Water treatment equipment should be in place prior to the installation of the pump Water must meet the minimum requirements as outlined in the Specifications section of this manual e All connections to the pump are the responsibility of the buyer It is the buyer s responsibility to research and comply with all local codes including waste water disposal e AccuStream supplies the pump without any hydraulic oil in the tank It is the buyer s responsibility to fill the tank with the appropriate oil per instruction in the hydraulic section of this manual 3 1 2 Seller Obligations If AccuStream Inc is the installing party some or all of the following tasks will be the responsibility of the AccuStream technician at installation as defined in the sales agreement e Make sure the buyer has been informed of all buyer obligations and make sure the site has been properly prepared prior to installation e Make sure all utility connections have been pro
76. sure poppet end of the cylinder is out Press the Cylinder with the palm so that the seal and hoop do not pop out Copyright 2005 Accustream Inc 1 866 566 7099 AS 6050 Manual P N 12112 Rev A 1 Place the Low Pressure Poppet in the basket Do not apply lubricant in this area j Put high pressure lubricant in the pilot bores on either end of the HP Cylinder k With the Check Valve Body in the High Pressure End Cap push the check valve into the ID of the HP Cylinder 1 Using two 1 Nuts located diagonally lightly torque the HP End Cap so that it is bottomed onto the HP Cylinder m Torque the 1 nuts in a cross pattern to 275 foot pounds Start at 125 ft lbs and advance in 50 ft lb increments The stud threads should be greased with multi purpose lithium grease such as Lubriplate No 1552 n Reattach the high pressure plumbing o Turn the inlet water on and open a cutting head Allow the pump to cycle slowly at low pressure for a few minutes to ensure that the seals seat properly before returning to operating pressure Copyright 2005 Accustream Inc 45 1 866 566 7099 AS 6050 Manual P N 12112 Rev A 7 2 3 High Pressure Cylinder During use the inner surfaces at the ends of the HP Cylinder may become worn To clean this area roll polish the ID of the cylinder ends on a table First use 180 grit or finer abrasive paper then use Scotch Brite HP Cylinders may eventually fail due to fatigue leading to a crack
77. system have a water quality analyses performed by a local company that can provide water conditioning equipment See the Water Quality Section under Specifications for specific conditioning requirements Cooling Water The heat exchanger uses regular tap water for cooling the hydraulic fluid Hydraulic fluid temperature must be maintained below 130 F A consistent water flow of 3 gpm is required at an inlet temperature not exceeding 70 F In most cases public utility water is acceptable In situations where the water contains heavy mineral deposits the cooling fins in the heat exchanger may become clogged with buildup In these circumstances pre filtration and or softening may be necessary Depending on plant setup ambient temperature can also be a factor in cooling Where the equipment is confined to a small high temperature space additional cooling may be required 3 2 3 Sewer Requirements The pump has two outlet lines The Waste Water Out line carries any leakage water from the drip pans and rejected cut water from the bleed down valve The cooling water out line carries the water exiting the heat exchanger Do not couple the lines together Both outlets require independent lines to the sewer 14 Copyright 2005 Accustream Inc 1 866 566 7099 AS 6050 Manual P N 12112 Rev A drain to prevent cooling out water from backing up into the system The waste water outlet is gravity fed from the water pans and therefore must have sufficien
78. t drop to prevent backup into the system It is the end user s responsibility to investigate and comply with all local codes 3 2 4 Electrical Requirements When connecting power to the pump it is the buyers responsibility to investigate and comply with all local codes The power requirements are listed on the serial plate on the back of the pump as well as on the inside of the electrical enclosure door Circuit Breaker Interruptor Autom tico Disioncteur EACH OF THE THREE PHASES OF INPUT POWER ARE CONNECTED TO THESE TERMINALS 3 2 5 Location Requirements The pump must be placed in a location which allows access to all sides for service The pump should have a 36 inch minimum clearance free of all obstacles to allow room for service See the Pump Requirements Section under Specifications The pump should not be placed in any environment where the temperature is below freezing If freezing temperatures are expected before operating again drain all water lines and filter housings after work is completed for the day A WARNING Ifa water line fitting or valve may be frozen DO NOT operate the machine The system must be thawed until water flows freely through the entire water circuit Copyright 2005 Accustream Inc 15 1 866 566 7099 AS 6050 Manual P N 12112 Rev A 3 2 6 Recommended Tools Most maintenance of the pump can be accomplished using standard tools Refer to the recommended tools list in the Drawings and Pa
79. this manual 77 Display Error Message AS 6050 Manual P N 12112 Rev A Possible Cause Corrective Action Inlet Water Pressure Below 40PSI 2 8BAR Inlet cutting water to the pump not turned on Boost pump motor contactor MS BOOST may be tripped If this is the cause you will see the knob pointing at reset Boost pump thermal overload OL BOOST may be tripped Boost pump fuses FU 9 FU 10 or FU 11 may be blown The cutting water coil SOL 1 may be shorted Turn on inlet cutting water Read the Low Pressure Water section of this manual Reset by turning the knob on the motor contactor back to auto Refer to Electric Motors in the Electrical System section of this manual Reset by pushing the reset button on the thermal overload Refer to Electric Motors in the Electrical System section of this manual A blown fuse is evidence of a potentially serious problem such as a severely damaged motor or a short in the system Locate and correct problem replace fuse and restart the pump Inspect the coil Normally a short in the SOL 1 coil or its cable would result in a blown fuse FU 5 and a fault message of Motor Fault so this is an unlikely scenario If the coil or wire is damaged replace it and restart the pump Too Many Motor Starts Per Hour The motor has been started too many times in 15 minutes Wait 15 minutes to let the motor armature cool down before starting again Intens
80. ty circuits are connected and operational Make sure the hydraulic reservoir is full by checking the sight gauge Add oil as necessary to bring the oil to an acceptable level Use only Mineral Oil ISO VG 32 Refer to the Hydraulic Oil Requirements section in this manual for instructions on adding oil Verify all utilities are connected to the pump and turned on at the plant Check for loose hoses and fittings and make sure there are no leaks present Motor Direction Check NIMPORTANT The motor direction check should be performed anytime any electrical maintenance has been performed on the electrical panel motor wiring or line wiring to the pump Improper motor rotation can cause irreversible damage to the hydraulic pump and components This procedure involves exposing a rotating shaft Never place any object or CAUTION A any part of your body near the shaft while exposed Only visual inspection a b c should be used to prevent bodily injury Be prepared to press the EMERGENCY STOP pushbutton if necessary Remove the front cover from the pump and locate the motor rotation direction arrow Remove the safety cover on the pump mount to visually inspect the coupling rotation To jog the motor pull the EMERGENCY STOP button on the control panel and then press the CONTROLS ON button With one hand on the MOTOR ON button and the other on the MOTOR OFF button quickly jog the motor Verify visually that the shaft is rotating the
81. uirements The inlet water should be clear odorless free of biological materials and have a pH of 6 to 8 The water quality analysis should measure for e pH e Silica Content e Total Dissolved Solids TDS Most systems only need water softening to pre treat the inlet cutting water Poor water quality may require that the water be treated to remove the high levels of TDS One approach is to have the local water conditioning company provide deionizing tanks DI on an exchange basis Another approach for poor water is to install a reverse osmosis system RO The RO approach is best for high gallon per day users Water Treatment Guidelines Do not treat to 0 5 ppm or less Water of this high of purity is overly aggressive and will damage stainless steel components e High Quality Water TDS lt 50 ppm no treatment required e Good Quality Water 50ppm lt TDS lt 150ppm Soften only e Medium Quality Water 150ppm lt TDS lt 250ppm Soften or TDS removal e Poor Quality Water TDS gt 250ppm TDS removal Silica gt 15ppm Copyright 2005 Accustream Inc 69 1 866 566 7099 AS 6050 Manual P N 12112 Rev A 9 5 Bolt Torque This specification applies to all fasteners that are used to make hydraulic connections and high pressure connections such as hydraulic flange fittings proximity switch to end cap hydraulic manifold to end cap 1 intensifier nuts and intensifier center section cap screws Torque values are for lubricated grade 8 fasteners S
82. ulic tank High hydraulic oil temperatures can adversely affect oil life and high pressure seal life MODULATING VALVE ADJUSTMENT SCREW Adjustment Procedure If the oil temperature is over 110 F Turn the screw 1 4 turn clockwise to reduce oil temperature Wait 15 minutes and look at oil temperature Repeat procedure until oil temperature is below 110 F Copyright 2005 Accustream Inc 39 1 866 566 7099 40 AS 6050 Manual P N 12112 Rev A This Page Intentionally Left Blank Copyright 2005 Accustream Inc 1 866 566 7099 AS 6050 Manual P N 12112 Rev A Section 7 High Pressure Water 7 1 High Pressure Water Overview The high pressure HP water system takes the relatively low pressure water inlet up to 60 000 psi 4137 bar with a maximum flow rate of 1 6 gallons per min 6 1 liters per minute and a maximum orifice diameter of 0 018 0 45 mm High Pressure Assembly 11537 consists of the following major components e Intensifier Assembly 11501 uses hydraulic power to reciprocate the center hydraulic piston Connected to each side of the piston is a plunger The two plungers reciprocate in the high pressure cylinders to make the high pressure water Each side of the intensifier has one low pressure and one high pressure check valve to bring in inlet water and output high pressure water e Bleed Down Valve Assembly 11480 discharges high pressure water from the pump when the pump is turned off or when the hydrau
83. unning round the clock For more information please call Customer Service at 763 717 7099 or toll free 866 566 7099 Copyright 2005 Accustream Inc 5 1 866 566 7099 AS 6050 Manual P N 12112 Rev A 1 2 System Overview 1 2 1 Introduction This manual contains information necessary for the operation and routine maintenance of the AccuStream Model AS 6050 Intensifier Pump The manual is arranged in a loose leaf format so pages may be added or removed AccuStream Inc reserves the right to change any product specification or information herein without notice Updates and revisions will be made available for insertion into the manual 1 2 2 Pump Identification Form AccuStream SERIAL NUMBER For additional copies of this manual or other assistance contact AccuStream Inc 4757 Mustang Circle Mounds View MN 55112 763 717 7099 1 3 Definitions Low pressure water or LP water means water that is supplied to the intensifier for pressurizing High pressure water or HP water means water that is directed to the tool after being pressurized by the intensifier assembly Coolant water means water that is circulated through the heat exchanger for cooling the hydraulic fluid Pump means the AS Series intensifier pump 6 Copyright 2005 Accustream Inc 1 866 566 7099 AS 6050 Manual P N 12112 Rev A Section 2 Safety 2 1 Safety Symbols The following symbols are used throughout the manua
84. ve been followed before starting any service or maintenance procedures Make sure the safety devices are operational To panic stop the pump and bleed the high pressure the EMERGENCY STOP buttons must be pushed in The system pressure bleed down valves must be open e Open the main power circuit breaker plant supplied power before beginning the procedure Attach a safety tag warning others not to turn the power on e When replacing wiring use only the same size type and color as the original e After servicing ensure all electrical breakers are reconnected and doors and covers are closed before restarting e To check turn on power and activate the EMERGENCY STOP buttons by pushing them in to see if the power goes off Copyright 2005 Accustream Inc 9 1 866 566 7099 AS 6050 Manual P N 12112 Rev A 2 3 4 High Pressure Water System Safety N WARNING Never work on any high pressure component or loosen any high pressure fittings without first bleeding the system and assuring there is no high pressure water present Follow all instructions and safety recommendations in this manual Do not come in contact with any high pressure water HP water can penetrate any part of the human body and cause severe infection or death if not treated properly Do not try to repair a leak in a HP water fitting when the system is pressurized A leak at a sealing surface can cause a hazardous spray of water out the nearest weep hole Shut off th
85. water CONTROLS ON enables the pump controls LOCAL REMOTE KEYSWITCH switches from Local Pump Control to Remote Pump Control See the section on Remote Pump Control in this manual REMOTE ACTIVE light is lit when pump is in Remote Pump Control mode CUT PRESSURE knob adjusts Pressure Set Point 1 Cut See Adjusting the Cut and Pierce Pressure for more information PIERCE PRESSURE knob adjusts Pressure Set Point 2 Pierce See Adjusting the Cut and Pierce Pressure for more information HYDRAULIC PRESSURE gage displays the hydraulic pressure of the pump PRE FILTER WATER PRESSURE gage displays the water pressure before the filter bank See the Low Pressure Water section of this manual for more information POST FILTER WATER PRESSURE gage displays the water pressure after the filter bank See the Low Pressure Water section of this manual for more information Copyright 2005 Accustream Inc 1 866 566 7099 4 3 4 3 1 AS 6050 Manual P N 12112 Rev A Pump Startup First Time Startup The first time you start up your pump it is important that a Pre Start Inspection Motor Direction Check and an Initial Startup Procedure be performed to prevent serious damage to the pump components Make sure that all installation requirements have been met prior to performing any of the following checks Follow all safety procedures as outlined in the safety section of this manual Pre Startup Inspection a b c d Verify all safe

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