Intensifier Pump

Product Manual
Intensifier Pump
Ultra High Pressure Pump
Jet Edge • Saint Michael, Minnesota USA • http://www.jetedge.com
Publication
information
Copyright information
Revision A
Revision B
Revision C
Revision D
January 2004
December 2004
February 2005
June 2005
©2004 Jet Edge, a division of TC/American Monorail, Inc. All rights reserved.
All information within this document is proprietary to Jet Edge. You may not
copy or reproduce its contents without permission, except where specifically
noted.
Trademark
information
Jet Edge is a registered trademark of TC/American Monorail, Inc.
Mobil is a registered trademark of ExxonMobil Corporation.
Quinplex is a trademark of Lubrication Engineers Incorporated.
Contacting Jet Edge
Jet Edge
12070 43rd Street NE
Saint Michael, Minnesota 55376-8427 USA
Address your technical support questions to the Service department.
Phone:
1-763-497-8700
Fax:
1-763-497-8701
Toll Free: 1-800-538-3343 (1-800-JET EDGE)
Web Site: http://www.jetedge.com
Email:
[email protected]
Intensifier Pump
Contents
Preface 5
Conventions
6
Safety 7
Introduction 11
Component Identification 12
Functional Description 14
Low Pressure Water
15
Hydraulic Pressure
Electrical System
17
18
Ultra High Pressure Water
19
Specifications 22
Intensifier Models 24
Installation 25
Site Preparation
26
Water Requirements
26
Sewer Requirements
27
Electrical Requirements
Installation Procedure
28
29
Connecting Water Lines
30
Connecting Electrical Power
Testing Procedure
30
31
Adjusting the Water Modulating Valve
33
Operation 35
Basic Controls and Indicators 36
Advanced Controls and Indicators 38
Startup and Shutdown 40
Contents 3
Intensifier Pump
Programming the Advanced Controls
Display Screens
42
43
Setting the Hydraulic Pressure
44
Setting the Ultra High Water Pressure
Remote Control
45
46
Maintenance 47
General Maintenance Tips 48
Charging the Hydraulic Accumulators 49
Replacing the Water Filters 51
Cleaning the Inlet Water Strainer 52
Replacing the In-Line UHP Filter 53
Replacing the Hydraulic Filters 54
Changing the Hydraulic Fluid 55
Maintenance Record 56
Service 57
General Service Tips
58
Removing Water and Hydraulic Pressure
Manually Controlling the Valve
Servicing the Proximity Switch
59
60
61
Replacing the Proximity Switch
62
Replacing the Proximity Switch Actuator Seals
Adjusting the Proximity Switch
Replacing the Intensifier Seals
Servicing the Poppets 73
67
Lapping the Poppet
76
Servicing the Bleed Down Valve
77
Replacing the Needle and Seal
Replacing the Piston Seal
Servicing the Heat Exchanger
82
Troubleshooting 83
General Troubleshooting Tips
Warning Messages 85
Troubleshooting Chart 86
Selecting an Orifice Size 90
4
Contents
65
84
80
78
63
Intensifier Pump
Preface
Safety First!
Ordering parts
Improper operation and maintenance of your equipment can create hazardous
conditions that can result in death, serious injury, and equipment damage. Before
you attempt to use your Jet Edge equipment, read and understand the safety
information contained in the Safety section in this manual.
You can order Jet Edge parts by mail, phone, and fax. Address your technical
support questions to the Service department.
Phone:
1-763-497-8700
Fax:
1-763-497-8702
Toll Free: 1-800-538-3343 (1-800-JET EDGE)
When ordering parts, please supply the following information:
Note
Refer to the Parts Lists and Drawings that are included with this manual
to identify parts and obtain part numbers.
•
Part number and description If you are unable to provide a part number, Jet
Edge will require the equipment model number and serial number.
•
Company name and “bill to” address
•
Shipping address for parts
•
Purchase order number
•
Date parts are required
Within the United States and Canada, all parts ship via United Parcel Service
ground unless you specify another carrier. Shipping costs are prepaid and
rounded up the nearest US dollar.
Getting help
To enable Jet Edge to quickly help you, have the following information handy.
•
Have your equipment’s model and serial number available.
•
Have information available about your equipment’s configuration: such as
the type and version of control software being run and how you are using
your equipment.
•
Be able to describe the problem. Can you reproduce the problem? Did you
make any hardware or software changes before the problem started?
•
Be prepared to troubleshoot: Call from a telephone close to your equipment.
If you are not familiar with all aspects of your product, have someone who
is experienced with the equipment nearby to help you.
Preface
5
Intensifier Pump
Conventions
The following describes conventions used in this manual.
Hazard notices
Hazard notices alert you to hazards that you can encounter when performing a
procedure. They may also give directions on how to reduce the hazard. Hazard
notices immediately precede the task that exposes you to the hazard. Read all
hazard notices carefully and follow the directions given.
Danger notice
A danger notice indicates a hazard that will cause severe personal injury, death,
or substantial property damage if you ignore the hazard. For example:
DANGER
This junction box contains 460 V AC. Contact with 460 V AC can result in a
fatal shock.
Always shut off electrical power before opening the junction box.
Warning notice
WARNING
A warning notice indicates a hazard that can cause severe personal injury, death,
or substantial property damage if you ignore the warning. For example:
A water jet can produce a powerful ricochet when it contacts a work part, jig,
or grating. This ricochet can injure eyes and cut skin, resulting in deep
infections.
Always wear protection when operating a water jet.
Caution notice
CAUTION
A caution notice indicates a hazard that might cause minor personal injury and
minor equipment damage if you ignore the caution. For example:
A water jet and its pressure lines can reach 150°F (66°C). Touching these
parts can burn you.
Use caution when touching a water jet and its pressure lines
Note
A note provides useful additional information or highlights an easily overlooked
item. For example:
Note
Control names
Illustrations
Parts lists and
drawings
6
Preface
Flat spots that appear when cutting a circle can indicate excessive
backlash. These flat spots typically appear where there is a change in
cutting direction.
A bold font style identifies equipment controls, keyboard keys, as well as
computer screen names, menu items, and commands.
This manual uses illustrations to clarify text. Remember that these illustrations
may not exactly match your intensifier pump.
Parts lists and drawings do not have page numbers. Instead, they are arranged by
their part number and in numerical order following the product manual.
Intensifier Pump
Safety
This chapter contains general safety practices for your intensifier pump.
Following these practices will reduce the hazards involved operating and
maintaining your equipment.
It is expected that anyone who operates or services the intensifier pump read this
Safety section. Anyone who operates the equipment is responsible for adhering
to generally accepted guidelines for operating any machinery, as well as being
aware of the specific safety precautions applicable to Jet Edge equipment.
Training
Anyone who operates or maintains a intensifier pump should have had training
with the equipment. Jet Edge offers training.
At the customer’s request, Jet Edge will arrange for training classes on the
operation and maintenance of intensifier pumps. Training can occur at Jet Edge
or at the customer’s facility.
Understand your
product variables
Jet Edge products operate in unique environments that can include:
•
Additional mechanical and electrical equipment
•
Equipment modifications done to perform specific operations
•
Operator experience and specialization
•
Workpieces
To reduce the hazards in maintaining and operating your intensifier pump,
understand how these variables will affect the equipment.
Use common sense
Common sense combined with thorough knowledge of the intensifier pump’s
capabilities will reduce operation and maintenance hazards.
Exercise caution when near high pressure equipment and components.
The safety guidelines found in this manual are general, and cannot anticipate
every possible situation. Only thorough knowledge of the equipment can provide
optimum safety. If there is any uncertainty, contact Jet Edge.
Do not bypass safety
features
•
Read and understand the Operations section of this manual before operating
the equipment. Also study the manuals for other equipment and attachments
being used.
•
Ensure that all personnel not involved with the operation of the equipment
are a safe distance from the equipment while it is being used.
Do not bypass safety features such as the Emergency Stop switch. Eliminating
safety features can result in personal injury.
Safety
7
Intensifier Pump
Modifications
WARNING
Do not modify the equipment without first consulting Jet Edge. Modifications
can cause your intensifier pump to operate unpredictably, resulting in personal
injury.
Modifying or altering your equipment can produce unexpected results.
Serious personal injury can result from misuse or altering the equipment.
Never modify water jet equipment or accessories without prior written approval
from the manufacturer.
Protective gear
Wear clothing suitable for the job conditions.
A water jet can powerfully ricochet and send objects
flying at you. The ricochet from a water jet can injure
your eyes.
•
Always wear eye protection while the equipment
is operating.
•
Always secure small parts that the water jet might hit and send flying.
The equipment can produce noise levels above 85 dB
Prolonged exposure to noise levels above 85 dB can
result in hearing loss.
To reduce noise hazards:
•
Always wear hearing protection while the
equipment is operating.
•
Keep the water level in the catcher tank high enough to touch the workpiece.
Keep the water jet close to the workpiece.
Airborne particles can develop from the material of the
workpiece during operations. Prolonged exposure to air
particles can result in a loss of respiratory capacity.
To reduce respiratory hazards:
Slip hazard
•
Always wear appropriate respiratory equipment
while the equipment is operating and creating
airborne particles.
•
Provide ventilation for the work area as needed.
The floor around the catcher tank can become slippery
when wet. You could be hurt if you slip and fall.
To reduce the risk from slipping and falling:
8
Safety
•
Be aware of your footing.
•
Occasionally clean up the water and slop around the tank.
•
Stand on non-skid rubber mats.
Intensifier Pump
DANGER
Jet Edge equipment contain ultra high pressure water up to 60,000 psi
(4100 bar) that can produce a velocity of up to 2000 mph (3300 kph). When
ultra-high pressure water penetrates skin a serious infection will occur.
Seek medical attention immediately. Inform medical personnel of the following:
• That water pressure of up to 55,000 psi (3750 bar) are involved.
• That unusual infections have been reported with microbaerophilic organisms
that tolerate low temperatures.
• That these organisms might be Gram-negative pathogens such as are found in
sewage.
Bacterial swabs and blood cultures may be helpful.
Pressurized fluids
Use caution when operating the equipment. Pressurized
fluid streams can penetrate skin, causing severe
personal injury.
Note
If anyone is injured by pressurized fluid, be
sure to inform medical personnel that the injury
was caused by ultra-high pressure fluid. See
the Danger notice above.
To reduce high pressure hazards:
Clear bystanders
Locate all Emergency
Stop switches
•
Keep hands and body away from pinholes and
nozzles which eject fluids under high pressure.
Use a piece of cardboard, never your hand, when
checking for leaks.
•
Shutting off the water jet may not remove all
pressure. Opening a fitting with residual pressure present can produce a
cutting, penetrating spray that can result in infections.
•
Verify all pressure is relieved before disconnecting any line. Always bleed
off any residual pressure and make sure that all pressure gauges read zero
before starting service
•
Keep all covers closed while equipment is operating.
•
The accumulators are charged with high pressure nitrogen and should be
serviced only by a qualified service person.
•
Make sure all connections are properly tightened after performing service or
maintenance.
Ensure that all personnel not involved with the operation of the equipment are a
safe distance from the equipment while it is being used. Clear the work area of
bystanders before starting the equipment.
You should know where all Emergency Stop (also called E-Stop) switches are
located so you can quickly shut down the equipment in an emergency.
Safety
9
Intensifier Pump
Fire hazard
Components of the equipment can become hot enough
to ignite flammable solvents. Fire can burn you and
damage your equipment.
To reduce the risk from a fire hazard:
Check the work area
Electrical hazards
Beware of moving
components
•
Always always use non-flammable solvents for
cleaning (unless specifically directed).
•
Never use engine fuels to clean parts.
Check the work area around the equipment. Clear anything in the area that might
become a hazard or cause you to trip or stumble. Keep the work area clean—such
as and liquid on the floor—that might cause you to slip and fall.
High voltage is present. Contact with high voltage
could result in a severe shock.
•
Unless specifically required for a maintenance or
service procedure, always turn electrical power off
before starting any service or maintenance.
•
Open the main power circuit breaker (plantsupplied power) before beginning maintenance or
service procedure. Attach a safety tag warning
others not to turn the power on.
•
When replacing wiring, use only the same size, type, and color as the
original.
•
After servicing, ensure all electrical breakers are reconnected and doors and
covers are closed before restarting.
While the equipment is operating some components
might be moving. You must be aware of these moving
parts so you can avoid contact with them.
To reduce the risks from moving assemblies:
Review procedures
10
Safety
•
Keep clothing and hands away from equipment
that is operating.
•
Always verify covers and shields are in place before starting the machine.
•
Stay out of the path of moving assemblies.
Make a trial run through all operating procedures before operating the
equipment. Locate all controls. Know how the controls function; if you are
unclear about any control function or operation procedure, review the applicable
information until you understand it thoroughly.
Intensifier Pump
Introduction
This manual documents the Jet Edge series of intensifier pumps. Intensifier
pumps produce ultra-high water pressure (36,000 psi/2500 bar or 55,000 psi/
3800 bar) for use with cleaning and cutting tools and associated accessories.
Contents
Component Identification
Functional Description
12
14
Low Pressure Water
Hydraulic Pressure
15
17
Ultra High Pressure Water
Electrical System
Specifications
19
18
22
Intensifier Models
24
Typical Intensifier Pump (Model 55-50B Shown)
Introduction
11
Intensifier Pump
Component Identification
Attenuator
Intensifier
Filter Breather
Temperature/Level Sensor
Site Gauge and
Thermometer
Bleed-Down
Valve
Hydraulic
Fluid Tank
Accumulator
(intensifier)
Heat Exchanger
(primary)
Hydraulic
Manifold
Directional
Control Valve
Accumulator
(drain)
Hydraulic
Pump
Hydraulic
Filter
Flexible
Coupling
Heat Exchanger
(secondary)
Electric
Motor
Major Components
12
Introduction
Intensifier Pump
Major Components
Item
Description
Intensifier
The intensifier produces the ultra-high pressure water. Some models have
two intensifiers.
Filter Breather
Equalizes the hydraulic fluid tank to the atmosphere. It allows the
hydraulic fluid to expand when heated and prevents pressure buildup in
the tank.
Temperature/Level Sensor
Signals the control electronics when the hydraulic fluid level exceeds a
specific temperature. It also signals the control electronics if the hydraulic
fluid drops below a specific level in the hydraulic fluid tank.
Site Gauge and Thermometer
Displays the actual level of the hydraulic fluid in the hydraulic fluid tank.
The gauge includes a thermometer that displays the temperature of the
hydraulic fluid.
Bleed-Down Valve
Removes the water pressure when the system is shut down.
Accumulators
Absorbs hydraulic pressure pulsations caused by the hydraulic pump.
The primary accumulator maintains a constant hydraulic pressure to the
intensifier.
The secondary accumulator maintains a constant hydraulic pressure to the
hydraulic drain.
Hydraulic Manifold
Distributes the hydraulic fluid between all of the hydraulic components. It
also has a hydraulic control valve attached to control the flow of hydraulic
fluid to and from the intensifier.
Directional Control Valve
Controls the hydraulic operation of the intensifier.
Hydraulic Pump
Pressurizes the hydraulic fluid.
Flexible Coupling
Connects the hydraulic pump to the electric motor.
Electric Motor
Powers the hydraulic pump. The intensifier pump model number is based
on the power rating of the motor.
Heat Exchangers
Provides cooling for the hydraulic fluid.
The primary heat exchanger cools the hydraulic fluid exiting from the
intensifier manifold.
The secondary heat exchanger provides additional cooling as the hydraulic
fluid drains the pump case into the supply tank.
Hydraulic Filter
A full-flow filter in the hydraulic circuit removes contaminants to extend
service life of the components.
Hydraulic Fluid Tank
Contains the hydraulic fluid used by the system.
Attenuator
Assures a constant supply of evenly pressurized water to a tool and it
eliminates pulsations caused by the plunger reciprocating in the intensifier
Introduction
13
Intensifier Pump
Functional Description
The intensifier pump assembly has four subsystems:
•
Low Pressure Water
•
Hydraulic Pressure
•
Ultra High Pressure Water
•
Electrical System
Attenuator
To Tool
UHP Water
Plunger
Coupler
Piston
Coupler
Plunger
Intensifier
Low
Pressure
Water
Hydraulic
Pressure/
Return
Hydraulic
Pump
Electric Motor
Filter
Manifold
Electronic
Control
Hydraulic
Fluid Tank
Directional
Control Valve
Functional Diagram
14
Introduction
Intensifier Pump
Low Pressure Water
Tap water is used for two separate water circuits. See “Water Requirements” on
page 26 for information about the required condition of the local tap water.
Supply line solenoids
Strainer
Water filters
•
Conditioned tap water flows through a one-way check valve (poppet) and
through a strainer. The water pressure is increased with a booster pump and
filtered before it is routed to the intensifier cylinders. The water flows
through one-way check valves (poppets) on each end of the intensifier
assembly and into a compression cylinder where it is pressurized.
•
Conditioned tap water flows through a one-way check valve (poppet) and
through a water modulating valve to the two heat exchangers.
Solenoid-operated valves control water flow through the low pressure water
supply and coolant lines. When control power is on the valves open; when power
is off, the solenoids shift to close the valves. The closed valves prevent a
continual flow of water through the water lines when the equipment is not
running.
A 100-mesh strainer removes larger debris particles before the water enters the
boost pump and filtering bank. The strainer helps protect the booster pump and
alleviate the amount of foreign particles the filters would need to remove.
A bank of water filters in the incoming water supply line remove impurities
before they reach the intensifier. Two or three water filters (depending on the
intensifier pump model) provide successive filtering of the incoming water. The
incoming water is filtered by a 10 micron filter, followed by a 1 micron filter, and
finally by a 0.45 micron filter. Models with two filters include a 1 micron filter
and a 0.45 micron filter.
•
Some intensifier pump models have two water pressure gauges. One gauge
monitors the input water pressure before it is filtered and the other gauge
monitors the water pressure after the water has been filtered.
•
Some intensifier pump models have one water pressure gauge. It monitors
the water pressure after the water has been filtered.
A bleed valve on each filter head permits air to be bled from the assembly after it
has been taken apart to replace the filter element.
Booster pump
Pressure switch
A booster pump provides a steady supply of properly pressurized water to the
intensifiers. The pump increases water pressure to 80–100 psi (5.5–7 bar). If the
pressure drops too low, the intensifiers are deprived of enough water to operate
properly and may overcycle. The boost pump starts operating when the motor
circuits are energized.
A pressure switch monitors the water pressure from the booster pump to the
intensifier. Models with advanced controls have a dual pressure switch.
•
On models with advanced controls, if the water pressure drops below 60 psi
(4 bar) the switch signals the control electronics to trigger a warning.
•
On all models, if the water pressure drops below 40 psi (3 bar) the switch
signals the control electronics to trigger automatic shutdown.
Introduction
15
Intensifier Pump
Modulating valve
Coolant water to the heat exchangers maintains the hydraulic fluid temperature at
a suitable level. Within limits, the water modulating valve automatically
regulates the incoming water volume by means of an adjustable thermostatic coil.
The valve is mounted in the inlet line to the heat exchanger.
The hydraulic fluid should be kept at about 110°–120° F (43°–49° C). If the
temperature exceeds 185° F (85° C), an automatic machine shutdown is initiated.
The valve can be adjusted to use less water in situations where the fresh water
supply is critical, but doing so raises the hydraulic fluid temperature. Unless
operating conditions change drastically, the valve is not normally adjusted after
initial machine setup.
Heat exchangers
(Models A and B)
Two water-cooled heat exchangers cool the hydraulic fluid to a stable
temperature. Cooling water flows through the secondary heat exchanger, then to
the primary heat exchanger.
•
The primary heat exchanger cools the hydraulic fluid after it exits the
intensifier manifold, through a filter and before the hydraulic fluid is
returned to the tank
•
The secondary heat exchanger provides additional cooling of the hydraulic
fluid from the pump motor case drain.
Pump
Case
Drain
Hydraulic
Filter
Hydraulic
Return
Water
Supply
Heat exchanger
(Model C)
Hydraulic Fluid
Tank
Primary Heat
Exchanger
Secondary Heat
Exchanger
A water-cooled plate heat exchanger cools the hydraulic fluid to a stable
temperature. Hot hydraulic fluid returns to one side of the divided hydraulic tank.
A pump circulates the hot hydraulic fluid through the internal pates in the heat
exchanger to be returned to the cool side of the hydraulic tank. Cooling water
flows through the internal pates in the heat exchanger to cool the hydraulic fluid.
Hydraulic
Return
Hydraulic Fluid
Tank
Hot
Cool
Hydraulic
Filter
Circulation
Pump
Heat
Exchanger
Water
Supply
16
Introduction
Drain
Drain
Intensifier Pump
Hydraulic Pressure
Hydraulic fluid is contained in a tank. The hydraulic fluid level and temperature
can be checked manually with a site gauge located on the hydraulic fluid tank. A
float switch/temperature probe in the hydraulic tank also monitors the hydraulic
fluid level and temperature for the system electronics.
Hydraulic filter
•
If the hydraulic fluid temperature exceeds 150°F (65°C) the control
electronics issue a high temperature warning.
•
If the hydraulic fluid temperature exceeds 185°F (85°C) the control
electronics begin an over-temperature shut down.
A full-flow filter in the hydraulic circuit removes contaminants to 10 microns to
extend service life of the hydraulic components. The filter head contains an
electrical sensor that monitors the hydraulic fluid flow.
If the filter becomes clogged, a warning lamp on the control panel lights. The
mechanical bypass on the filter head has a pop-up indicator that also warns of a
clogged filter. When the indicator is green the bypass is not open. If the indicator
is red the bypass has opened. The visual indicator is useful as a secondary
verification if the control panel warning notice is showing.
A mechanical bypass valve opens to allow fluid to continue flowing if the
element becomes clogged, but the fluid is not properly cleaned and the hydraulic
components may be damaged. It is imperative that the filter element is replaced
frequently enough to perform properly. Do not overextend service life, or severe
damage can be caused.
Hydraulic pump
An electric motor drives a pump to transfer and pressurize hydraulic fluid from
the hydraulic fluid tank through a manifold to the intensifier. A flexible coupling
isolates vibrations between the electric motor and the hydraulic pump. The
coupling is designed to fail to protect the electric motor if the pump should seize
due to wear or hydraulic fluid contamination.
•
The basic intensifier pump controls the hydraulic pressure with a manually
controlled relief valve. A knob on the front of intensifier pump adjusts the
hydraulic pressure.
The relief valve has a second control knob (inside the machine) to adjust a
low pressure setting. The low pressure setting is normally used when the
intensifier pump is controlled remotely. Remote programming can switch
between the high and low pressure settings. The relief valve can also be
switched manually with an optional switching kit (contact Jet Edge for more
information).
•
The advanced intensifier pump controls the hydraulic pressure with a
proportional valve. A hydraulic pressure is programmed into the control
electronics. When the pump motor is turned on, the electronics control the
proportional valve to ramp the hydraulic fluid to the desired pressure.
Introduction
17
Intensifier Pump
Accumulator
If the hydraulic system has a sudden pressure drop, a nitrogen-charged
accumulator helps maintain sufficient fluid volume until the pump provides
adequate pressure. The accumulator also absorbs hydraulic pressure pulsations
caused by the reciprocating intensifier piston.
During the instant of changeover when the hydraulic piston reverses in the
intensifier, fluid from the high-pressure side can surge through the low pressure
return line. This short spike on each cycle can eventually damage the system.
Most models (except models 36-50B/100B) include a second accumulator to
alleviate the shock in the return line.
Some models (36-50B, 36-100B, 55-75B, and 55-100B) include an accumulator
on the hydraulic circuit for the manually controlled relief valve. The accumulator
helps produce a soft start when hydraulic pump is turned on and the relief valve
is not set to zero pressure. Pressurizing the accumulator takes enough time to
allow the hydraulic system to come up to pressure in a controlled fashion.
Directional control
valve
The directional control valve is mounted to the manifold. The directional control
valve connects the high pressure hydraulic fluid to one of the intensifier
hydraulic end caps and the hydraulic drain to the other intensifier hydraulic end
cap. This causes the hydraulic piston to move and pressurize the water in one of
the high pressure cylinders. When the hydraulic piston nears the end of its travel,
the proximity switch signals the electronics to command the directional control
valve to reverse. Reversing the the directional control valve also reverses the
hydraulic connections to the intensifier end caps which causes the hydraulic
piston to reverse its movement.
Electrical System
Electrical system controlling components are housed in a NEMA rated steel
enclosure. The electrical enclosure has a safety interlock to prevent the door from
being opened when the machine is operating. The electrical system includes the
control switches and protective sensing devices, an integral wye/delta open
transition motor starter/contactor, and other electronic components.
The wye/delta motor configuration provides an efficient motor startup and
running method, and it extends the life of the motor. When motor startup is
initiated the wye is activated and a preset timer changes the motor from wye to
delta (the motor is wound to permit the transition). For starting, the open
transition controller connects the motor in wye configuration, resulting in line
voltage being applied across two windings. After starting, the motor windings are
reconnected in delta configuration.
PLC
A programmable logic controller (PLC) monitors and controls all machine
functions, and automatically energizes relays to shut down the machine when
potentially damaging conditions develop.
The PLC is a self contained microcomputer programmed to control all electrical/
electronic machine operations. Timing, operation, sensing, and response circuits
are routed through the PLC.
18
Introduction
Intensifier Pump
Ultra High Pressure Water
Ultra high pressure water is produced by an intensifier and made available for use
by a variety of tools.
Intensifier operation
The primary component of an ultra-high pressure pump is the intensifier. A
hydraulically-driven piston inside the intensifier shifts from one side to the other
to pressurize the low pressure supply water into ultra-high pressure (UHP) water.
The left side of the figure shows the low pressure water input of the stroke while
the right side of the figure shows the pressurized output of the stroke.
High Pressure
Poppet Closed
Inlet Poppet
Open
Inlet Poppet
Closed
Proximity Switch
Detects Piston Position
High Pressure
Poppet Open
UHP
Water Out
Low Pressure
Water In
Piston/Plunger Movement
High Pressure
Hydraulic Fluid In
High Pressure
Cylinder
Hydraulic
Cylinder
Hydraulic
Fluid Drain
High Pressure
Cylinder
The figure shows high pressure hydraulic fluid produced by the hydraulic pump
enters the hydraulic cylinder pushing the piston to one side. As the piston moves
it pushes the hydraulic fluid on the other side of the piston out of the hydraulic
cylinder so it can drain back into the hydraulic fluid tank to be used again.
When the piston pulls the plunger out of the high pressure cylinder the following
occurs:
•
The back pressure from the UHP water closes the high pressure poppet. The
high pressure poppet prevents the UHP water from re-entering the high
pressure cylinder.
•
The pressure from the low pressure water opens the inlet poppet. Low
pressure water fills the high pressure cylinder.
Introduction
19
Intensifier Pump
When the piston pushes the plunger into the high pressure cylinder the water in
the high pressure cylinder becomes pressurized and the following occurs:
This information
pertains to the “A”
model designation only.
Proximity switches
•
The pressure in the high pressure cylinder forces inlet poppet closed and
prevents the UHP water from entering the low pressure water system.
•
The pressure in the high pressure cylinder overcomes the check spring
pressure and the UHP water back pressure in order to open the high pressure
poppet. The UHP water is output to the attenuator and made available for
any tools connected to the UHP water circuit.
Thermostatic sensors on the high pressure check tubes (the intensifier outlets)
monitor check tube temperature. If the high pressure outlet poppets start to wear,
leaking water causes the temperature of the check tube housing to increase. If the
temperature exceeds 150° F (66° C) the sensor energizes a relay that actuates the
warning system to alert the operator. In many cases high temperature warning is
combined with seepage from the weep holes, indicating worn components.
Two proximity switches mounted on the intensifier control the stroke of the
piston/plunger assembly. The proximity switches send a signal to the control
electronics to indicate the limit of the actuator stroke.
A spring keeps the limit switch actuator in contact with a ramp on the intensifier
plunger coupler assembly. As the piston moves side-to-side the limit switch
actuator rises and falls. When the actuator reaches its highest point (at the
compression end of the piston stroke) the actuator collar comes within the
detection range of the proximity switch which signals the control electronics that
the piston has reached the stroke limit.
Actuator
Collar
LED
Spring
Proximity
Switch
Limit Switch
Actuator
Plunger
Coupler
The collar is adjusted on the limit switch actuator to actuate the proximity switch
when the plunger coupler assembly reaches the full permissible limit of the
compression stroke. An LED on the proximity switch indicates the switch is
actuated.
Attenuator
20
Introduction
An attenuator located between the intensifier and the cutting tool creates back
pressure against the water surges from the intensifier and releases it in a steady
flow. This assures a constant supply of evenly pressurized water to the tool, and
eliminates pulsations caused by the plunger reciprocating in the intensifier.
Intensifier Pump
High pressure filter
A small replaceable filter rated at 0.5 micron is inside a housing in the line
between the attenuator and the tool. The filter removes fine debris from the water
to help prevent damage to the orifice.
Weep holes
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.
CAUTION
Blocked weep holes can cause ultra-high pressure water to accumulate in
areas that are not designed to contain such pressure. Blocked or obstructed
weep holes can cause equipment damage or failure.
Do not cover or plug any weep holes.
Water exiting through a weep hole often indicates worn seals. Failure to correct
the cause may result in extensive damage. For example, if water seeps from
intensifier connections the plunger seals may be worn. If they are not replaced,
water can contaminate the hydraulic fluid. Inspect lines and fittings frequently to
ensure faults are discovered as soon as possible.
Leakage collector
Small amounts of water or hydraulic fluid may seep through the seals in the
intensifier. The leakage is routed through plastic tubing to a collector block, then
out of the machine. Very small amounts of seepage are permissible, but if flow is
extensive a serious leak is indicated. Check the seals and poppets for excessive
wear to prevent critical equipment damage.
Bleed down valve
A solenoid-controlled valve drains UHP water from the line when the Motor Off
switch or Emergency Stop switch is pressed.
The bleed-down valve is a normally-open safety valve that prevents pressure
from being captured in the lines when the machine is turned off. Hydraulic
system pressure is applied to close the valve when the machine is operating. The
valve is controlled by a solenoid actuated by the system electrical controls.
The valve is installed in the UHP water output line. A tee in the line permits the
pressurized water to exit through the valve when control power is turned off.
When the hydraulic pump is running, pressure is applied to close the valve
mechanism. The closed valve directs the UHP water through the attenuator and
out to the tool. When control power is turned off hydraulic pressure is lost. The
needle valve opens and drains the UHP water from the line.
Introduction
21
Intensifier Pump
Specifications
All specifications subject to change without notice. Contact Jet Edge to verify
specifications that are critical to your applications.
General Specifications
Parameter
Specification
Environmental
Ambient temperature
50°–100° F (10°–37° C)
Relative humidity
Non condensing, maximum 95% at 100ºF (38ºC)
Low Pressure Water*
See “Water Requirements” on page 26
Input pressure
Minimum pressure 40 psi (3 bar)
Input temperature
Maximum temperature 70ºF (21ºC)
Filtration
On-board filtration to 0.45 micron
High Pressure Water
Output pressure
36,000 psi (2500 bar) continuous for the Series 36 pumps
55,000 psi (3800 bar) continuous for the Series 55 pumps
Flow Rate
See Flow Rate in the Model Specific Specifications table.
Motor
Type
Electric, Wye-delta start
Output
See Motor Output in the Model Specific Specifications table.
Hydraulic
Pump type
Axial piston, variable displacement, pressure compensated
Pressure rating
3250 psi (224 bar) maximum (Series 36)
3050 psi (210 bar) maximum (Models 55-30, 55-50, 55-75A)
3180 psi (219 bar) maximum (Models 55-75B, 55-100, 55-150)
Cooling
Flowing water jacket heat exchangers
Filtration
10 micron full flow
Fluid capacity
See Hydraulic Fluid Capacity in the Model Specific Specifications table.
Fluid type
Standard:
USDA food grade:
Circulation pump†
13 gpm (49 Lpm) at 60 Hz; 11 gpm (42 Lpm) at 50 Hz
Electrical Power
Medium grade turbine ISO
#4010 Quinplex or equivalent
Requires a voltage/frequency option kit to match local electrical requirements.
* Two water sources are needed; filtered water for the intensifier and public utility water for the heat exchanger.
† Model 55-50C only.
22
Introduction
Intensifier Pump
Model Specific Specifications
Model
Electric Motor
Power
Heat Load
(BTU/hour)
Hydraulic Fluid
Capacity
Water Output
Flow Rate
Maximum Rated
Orifice Size
36-50
50 hp (37 kw)
37,305 BTU
45 gal (170 L)
1.9 gpm (7.2 Lpm)
0.023 in (0.58 mm)
36-100
100 hp (75 kw)
80,422 BTU
45 gal (170 L)
4.0 gpm (15.1 Lpm)
0.034 in (0.86 mm)
36-200
200 hp (149 kw)
124,920 BTU
95 gal (360 L)
6.1 gpm (23.1 Lpm)
0.040 in (1.02 mm)
55-30
30 hp (22 kw)
21,298 BTU
20 gal (76 L)
0.65 gpm (2.5 Lpm)
0.012 in (0.30 mm)
55-50
50 hp (37 kw)
25,290 BTU
*
1.0 gpm (3.8 Lpm)
0.015 in (0.38 mm)
55-50R
50 hp (37 kw)
25,290 BTU
45 gal (170 L)
1.0 gpm (3.8 Lpm)
0.015 in (0.38 mm)
55-75
75 hp (56 kw)
55,057 BTU
60 gal (227 L)
1.5 gpm (5.7 Lpm)
0.018 in (0.46 mm)
55-100
100 hp (75 kw)
96,625 BTU
60 gal (227 L)
2.0 gpm (7.6 Lpm)
0.020 in (0.51 mm)
55-150
150 hp (112 kw)
124,920 BTU
75 gal (284 L)
2.9 gpm (10.9 Lpm)
0.025 in (0.64 mm)
55-200
200 hp (149 kw)
124,920 BTU
75 gal (284 L)
4.0 gpm (15.2 Lpm)
0.028 in (0.71 mm)
* 55-50A 26 gal (98 L); 55-50B 22 gal (83 L); 55-50C 32 gal (122 L)
Dimensions and Weight
Model
Length
Width
Height
Weight
36-50
80 in (2032 mm)
37 in (940 mm)
52 in (1321 mm)
3020 lb (1370 kg)
36-100
96 in (2438 mm)
37 in (940 mm)
60 in (1524 mm)
4600 lb (2087 kg)
36-200
92 in (2337 mm)
57 in (1448 mm)
61 in (1549 mm)
6200 lb (2812 kg)
55-30
64 in (1626 mm)
30 in (762 mm)
53 in (1346 mm)
2000 lb (907 kg)
55-50
71 in (1803 mm)
36 in (914 mm)
53 in (1346 mm)
2500 lb (1134 kg)
55-50R
54 in (1372 mm)
54 in (1372 mm)
55 in (1397 mm)
3650 lb (1656 kg)
55-75
86 in (2184 mm)
40 in (1116 mm)
55 in (1397 mm)
4100 lb (1968 kg)
55-100
86 in (2184 mm)
40 in (1116 mm)
55 in (1397 mm)
4600 lb (2087 kg)
55-150
86 in (2184 mm)
52 in (1321 mm)
55 in (1397 mm)
6100 lb (2767 kg)
55-200
92 in (2337 mm)
57 in (1448 mm)
61 in (1549 mm)
6200 lb (2812 kg)
Introduction
23
Intensifier Pump
Intensifier Models
Each intensifier pump model has a document called Parts Lists and Drawings
that includes the following model specific information:
Model Numbers
•
Parts lists for the major assemblies
•
Drawings for the major assemblies
•
Electrical schematic
•
Hydraulic schematic
•
Water schematic
The model numbers represent the ultra-high pressure water output (ksi) and the
power (hp) of the electric motor that drives the hydraulic pump. The Series 36
pumps output 36,000 psi (2500 bar) and the Series 55 pumps output 55,000 psi
(3800 bar). For example, a Model 55-100 outputs 55,000 psi and has a 100 hp
electric motor.
Note
The “C” designation represents a low cost version of an intensifier model.
Basic controls are used with the “C” designation. Other letter
designations can represent different electronics, these are usually
custom intensifier pumps. Some models have a “single” or “dual
designation that represents the number of intensifiers.
Each model is available in two configurations:
24
Introduction
•
Basic controls are found on models with the “B” designation. The “B”
models have a pressure control knob next to the pressure gauge.
•
Advance controls are found on models with the “A” designation. The
advanced controls provide additional functionality for the intensifier pump.
The advanced controls have a front panel digital display and an amber/red
beacon on top of the control panel.
Intensifier Pump
Installation
Read all information in this section before starting installation. Critical data on
space, electrical power, and water requirements must be considered when
selecting an installation site.
Contents
Site Preparation
26
Water Requirements
26
Cooling Guidelines
27
Sewer Requirements
27
Electrical Requirements
Installation Procedure
28
29
Connecting Water Lines
30
Connecting Electrical Power
Testing Procedure
30
31
Adjusting the Water Modulating Valve
33
Installation
25
Intensifier Pump
Site Preparation
The facility must have adequate air, water, sewer drain, and electrical service per
specification prior to installation of the equipment. Floor material must be of
concrete capable of supporting the weight of the machine, and thick enough to
provide resistance to vibration.
Ambient temperature must be within 50°–100° F (10°–37° C). Relative humidity
must be non condensing: maximum of 95% humidity at 100°F (38°C), or
additional heat exchanging may be required for hydraulic fluid cooling.
Additional cooling may also be required if the equipment is operated at
elevations higher than 1000 feet (300 meters) above sea level.
Certain locations may be hazardous if the atmosphere contains gas, vapors, or
dust in explosive concentrations. Refer to the National Electric Code (NEC),
OSHA requirements, and local codes for detailed information about
environmental criteria.
Water Requirements
The water supplied to the intensifier is a crucial factor in waterjet cutting because
of its direct influence on the service life of equipment components such as check
valves, seals, and the orifices that shape the water stream. A high concentration
of total dissolved solids (TDS) causes accelerated wear of these components.
As part of pre installation planning, have a water quality analysis performed by a
commercial company that specializes in water conditioning equipment. Water
quality available for the installation is unique for each application and geographic
location. Consult a water purification supplier to determine the most suitable
equipment for specific local conditions. The minimum information that should be
furnished is:
•
TDS
•
Silica content
•
pH value
Inlet water should be pretreated for either the removal of hardness or reduction in
total dissolved solids. Water softening is an ion exchange process that removes
scale forming minerals such as calcium. TDS reduction can be accomplished
with either deionizing (DI) or reverse osmosis (RO) equipment. DI or RO will
usually provide better component life than water softening processes.
The best pretreatment process for a specific application is based on the original
water quality and the desired service life of affected components. Water
treatment resulting in TDS content of less than 0.5 ppm is not recommended.
26
Installation
Intensifier Pump
Water treatment
guidelines
•
Low TDS (less than 100 ppm): Considered good water quality and can be
treated by softening.
•
Moderate TDS (100 to 200 ppm): Can be treated either with softening or
TDS reduction (RO or DI).
•
High TDS (greater than 200 ppm): Considered poor water quality and
should be treated with RO or DI.
•
High silica content (greater than 15 ppm): Can only be removed with dual
strong base DI.
•
Carbon filtration can remove objectionable odors. This is often a
consideration in food processing applications.
•
The treated water must have a pH value of 6 to 8, and should be filtered to
0.5 microns absolute to remove suspended particulates such as dirt, silt, and
algae.
The physical process of pressurizing the water within the intensifier cylinder
causes a rapid rise in water temperature. The temperature of the water supplied to
the intensifier assemblies should be kept as low as possible (70° F/21° C
maximum).
Excessive inlet water temperatures can cause accelerated wear and reduce
component service life, especially the high pressure seals. In installations where
initial supply water temperature is above the maximum recommended, additional
pre-cooling may be required.
Cooling Guidelines
The heat exchanger uses regular tap water for cooling the hydraulic fluid. A
consistent water flow of at least 5 U.S. gpm (19 Lpm) is required, at an inlet
temperature not exceeding 70° F/21° C.
Public utility water is usually acceptable for cooling purposes. In situations
where the water contains heavy mineral deposits, the exchanger tubes may
eventually become restricted by particle buildup. If this is a chronic problem
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. Recycling-type supplemental cooling units can also be
installed where the volume of fresh water used is a consideration.
Sewer Requirements
Two independent lines to the sewer drain are required. Leakage water and
coolant water exiting must be separate, or the collector manifold may overflow.
The drain should be as close to the machine as possible. Venting of water from
the exit ports is gravity-induced and must have sufficient drop to prevent backup.
Installation
27
Intensifier Pump
Electrical Requirements
The electric motor requires a three-phase power source. For complete
information about electrical service requirements refer to local building codes
and NEC and OSHA provisions. Electrical requirements may vary depending on
the motor type chosen.
The intensifier is ordered with a voltage/frequency option to accommodate the
local electrical power.
When connecting the source power be aware that the full load amperage (FLA)
listed on the motor does not reflect the total requirement for the entire setup. The
water filter/booster and any other accessories running off the same power source
increase the minimum necessary supply amperage.
28
Installation
Intensifier Pump
Installation Procedure
Perform the following procedure to install the intensifier pump.
1. Uncrate the intensifier pump.
Unpack the machine lift it from the pallet. Position the machine at the
desired location. Clearance must be provided around the machine to permit
access for routine maintenance and repairs and for connecting the various
lines. Allow at least 36 inches (91 cm) for removal of access panels.
2. Level the machine.
Lay a carpenter's level on a frame rail. Thread the leveling pads in or out as
required until the machine is level; check leveling at several different points.
Tighten the jam nuts against the legs to hold the pads in position.
3. Inspect the intensifier pump.
Inspect the entire machine. Verify all hardware, bolts, fittings, fasteners, and
connections are properly tightened. Parts may vibrate loose during factory
run-in tests or during shipping. Ensure all parts are securely installed.
4. Add hydraulic fluid to the tank.
Hydraulic oil used in food processing equipment must be USDA rated H1.
For non-food grade applications, use medium grade turbine fluid ISO-46 or
equivalent. To prevent system contamination, fluid must be filtered to 10
microns absolute before adding to the tank. Check the fluid level on the
level gauge on the hydraulic tank and replenish as required until
approximately 3/4 full. Do not fill completely to the top. The fluid requires
room for expansion as it warms during operation.
5. Connect the water lines to the machine. See “Connecting Water Lines” on
page 30
6. Adjust the water flow to the machine. See “Adjusting the Water Modulating
Valve” on page 33.
7. Connect the electrical power to the machine. See “Connecting Electrical
Power” on page 30.
8. Test the machine operation. See “Testing Procedure” on page 31.
Break-in period
After the first few hours of operation, check that all bolts, fasteners, fittings, etc.
are properly installed and tightened. Apply light machine oil to hinges.
Installation
29
Intensifier Pump
Connecting Water Lines
Plumbing connections are on the back of the machine. With the exception of the
ultra high pressure (UHP) water outlet, which requires an Autoclave-style gland,
all connection ports are U.S. standard NPT thread. Supply and drain lines should
be Parker 801-8 or equivalent, PVC, or stainless steel. Do not use copper,
galvanized, or iron pipe.
Flush the supply lines with fresh water before connection. Connect the hoses for
cooling water, drains, and the supply line for the intensifier to the ports on the
rear of the machine.
Water Connections
Connection
Coolent water runs through
the heat exchangers.
Filtered water is used by
the intensifier.
Type
Leakage Water Out
1/2 inch NPT
High Pressure Water Out
3/8 inch high pressure coupling
Coolant Water Out*
1/2 inch NPT
Coolant Water In*
1/2 inch NPT
Filtered Water In†
1/2 inch NPT
* Models 36-200, 55-150, and 55-200 have a 3/4 inch NPT connection.
† Models 36-200, and 55-200 have a 3/4 inch NPT connection.
UHP tubing to the tool must be stainless steel rated for 60,000 psi (4220 kg/cm2)
operating pressure. Cover the tubing with flexible sheathing to protect personnel
in case of a line break. A gauge (60–80 ksi capacity) is required in the UHP line
from the machine to the cutting equipment to monitor output water pressure.
Run the UHP water tubing to the tool location. Clamp the tubing to a nearby wall
or overhead bracing for stability. Vibration caused by water pulsations can induce
failure, especially at connection points, unless the tubing is securely supported.
Do not connect the High Pressure Water Out connections at this time. Wait until
after the low pressure water lines in the machine have been flushed. See the
“Testing Procedure” on page 31.
Connecting Electrical Power
The machine is ordered with a voltage/frequency option to accommodate the
local power.
30
Installation
•
Refer to the electrical schematic and the drawing for the inner control panel.
Connect the plant-supplied electrical leads to the primary circuit breaker
inside the control cabinet.
•
Refer to the schematics for the machine and any optional equipment or
accessories that runs from the control system and connect to this equipment.
Intensifier Pump
Testing Procedure
After installation is complete, review the instructions and inspect all connections
for proper installation. Monitor operation of the entire installation. If any faults
are noted, turn the equipment off and correct discrepancies immediately.
Note
Read the Safety and Operations sections of this manual before
performing any tests.
1. Turn plant electrical power on. Position the intensifier pump handle on the
control panel door to ON.
2. Verify the E-Stop button is in the outward position.
3. Verify the UHP line is not connected to a tool. Press the Controls On button
to open the water supply solenoids, but do not start the motor or intensifier.
Turn the plant water supply on and flush all lines for several minutes.
4. Press the Controls Off button. Turn the water supply off.
5. Check the motor rotation and prime the hydraulic pump.
A.
Check the pump casing to determine which way the pump should
rotate. Be ready to observe pump rotation. Also be prepared to start and
stop the motor at short intervals until the pump is primed.
B.
Press the Controls On and Motor On push buttons and verify the
pump rotates in the proper direction. If the pump rotates the wrong
way, turn the plant electrical supply off. Open the control cabinet and
switch any two of the electrical input connections. Retest to verify
proper pump rotation.
C.
While watching the pump hydraulic pressure gauge, start and stop the
motor at short intervals.
Note
•
If the pump is primed the gauge bounces to about 500 psi
(35-36 kg/cm2), then drops to a lower level.
•
If the pump is not primed, jog the motor on and off. The sound of
the pump alters noticeably as fluid is ingested.
•
If the pump does not prime, check the pump case level and pour
fresh filtered hydraulic fluid into the opening until it is visible.
Replace the plug and continue priming
When performing operational checks the High Pressure Water Out
(UHP) line must be connected to a tool or the intensifier cannot build up
full output pressure.
6. Connect a tool to the High Pressure Water Out connection. See “Connecting
Water Lines” on page 30.
Installation
31
Intensifier Pump
7. Check the intensifier operation.
A.
Turn the water supply on.
B.
Start the intensifier at relatively low pressure. A sudden surge of water
following air bleeding can fracture the orifice in the tool. Adjust the
hydraulic pressure to a low pressure.
C.
Press the Intensify On button.
D.
Inspect the entire installation and verify no water leakage.
E.
Turn the tool on to bleed air from the lines.
F.
When water flow is constant, continue to boost output pressure in equal
increments (increase the hydraulic pressure). Inspect for water and
hydraulic leakage at each stage, until full operating pressure is
achieved with no discrepancies noted.
8. Run the machine for 30 minutes to warm the fluid and stabilize the
hydraulic circuit.
9. Periodically check fluid temperature and verify it is kept between
110°–120° F (43°–49° C).
If necessary, see “Adjusting the Water Modulating Valve” on page 33 and
adjust the water modulating valve to regulate the temperature.
10. Press the Intensify Off button. Verify the intensifier stops cycling.
11. Press the Motor Off button. Verify the motor stops.
12. Press the E-stop button. Verify the Controls On switch light goes out.
Check the water output pressure gauge and verify zero pressure, indicating
that the bleed-down valve has opened.
13. Check the hydraulic fluid level and replenish as necessary. Allow 30
minutes downtime to permit any air bubbles that may be in the hydraulic
fluid to dissipate.
32
Installation
Intensifier Pump
Adjusting the Water Modulating Valve
Rotating the valve cap clockwise compresses
the thermostatic spring and restricts coolant
water flow. Water usage is decreased, but the
fluid temperature may rise beyond
acceptable limits. Rotating the cap
counterclockwise reduces spring pressure
and lowers fluid temperature by increasing
water flow.
Note
Increases
Water Flow
Adjust the water modulating valve after the “Testing Procedure” on page
31 has been completed.
1. Start the machine (see “Startup and Shutdown” on page 40). Allow the
machine to run until the hydraulic fluid is fully warmed.
2. Monitor the hydraulic fluid temperature; it should be kept at 110°–120° F
(43°–49° C).
3. Rotate the cap of the water modulating valve to increase or decrease the
water flow as desired.
4. Allow sufficient time for the hydraulic temperature probe to signal the
change to the valve.
5. Readjust as necessary to achieve the desired hydraulic fluid temperature.
Installation
33
Intensifier Pump
34
Installation
Intensifier Pump
Operation
This section describes the operator controls and operating procedures. The
intensifier pump controls are available in two configurations:
Contents
•
Basic controls are found on models with the “B” designation. The “B”
models have a pressure control knob next to the pressure gauge.
•
Advance controls are found on models with the “A” designation. The
advanced controls provide additional functionality for the intensifier pump.
The advanced controls have a front panel digital display and an amber/red
beacon.
Basic Controls and Indicators
36
Advanced Controls and Indicators
Startup and Shutdown
38
40
Programming the Advanced Controls
Display Screens
42
43
Setting the Hydraulic Pressure
44
Setting the Ultra High Water Pressure
45
Operation
35
Intensifier Pump
Basic Controls and Indicators
Basic controls are found on Models with the “B” designation. The controls and
indicators shown are described in the following table.
Note
Note
Models with the “C” designation have basic controls.
Different intensifier models
can have different layouts
of the controls.
Hydraulic
Pressure
Adjustment
Hydraulic
Pressure
Gauge
Intensifier Pump Basic Controls
36
Operation
Intensifier Pump
Basic Controls and Indicators
Control
Description
Controls On
Applies power to the control panel and initiates the Product Name variable
program (on the automated control panel). The Emergency Stop switch must
be pulled out before the controls can be turned on.
Reset Lamp Test
Turns the control panel indicators off. When electrical power is been turned on,
all indicators are lit to check for proper operation.
Emergency Stop
Shuts down all electrical power to the machine and removes the ultra high
water pressure. The Emergency Stop button is a latching switch. Once it is
pressed, it remains pressed in until it is pulled out to its normal position.
Motor On
Starts the hydraulic pump motor, enables the low pressure water supply, closes
the bleed down valve, and enables the Intensifier On switch.
Motor Fault
Lights when a motor fault is detected. See “Motor does not start; display on”
on page 89.
Motor Off
Stops the hydraulic pump motor, disables the intensifier operation, and
removes the water pressure.
Intensifier On
Starts the intensifier to build ultra high water pressure. Press Motor On before
using this control. The indicator flashes when an intensifier overcycle is
detected.
Low Water Pressure
Lights when the low pressure water drops below 40 psi (3 bar).
Intensifier Off
Removes power from the intensifier circuit and removes the water pressure.
Low Hydraulic Fluid
Lights when the hydraulic fluid drops below the acceptable level.
High Hydraulic Fluid Temp
Lights when the hydraulic fluid temperature exceeds 150°F (65°C).
Filter Clogged
Lights when a sensor in the hydraulic filter housing detects a pressure drop. If
the mechanical indicator on the filter cap shows red, the filter is clogged.
Local/Remote Mode
Selects Local control to use the front panel switches or Remote control to
operate the intensifier pump from a remote location.
Hour Meter
Displays the amount of time the electric motor has been running. The hour
meter aids maintenance scheduling.
Temperature and Hydraulic
Level Gauge
Shows the temperature and fluid level of the hydraulic fluid. The gauge is
located on the hydraulic tank.
(not shown)
•
The hydraulic fluid must be below 150°F/65°C; the nominal temperature
is 110°–120° F (43°–49° C).
•
The hydraulic fluid level should be at least halfway up the site glass.
Hydraulic Pressure
Adjustment
Adjusts the hydraulic pressure to the machine.
Hydraulic Pressure Gauge
Displays the hydraulic pump output pressure.
Power Disconnect Switch
Applies and removes electrical power to the intensifier pump. The switch is
located on the side of the electrical enclosure.
(not shown)
Operation
37
Intensifier Pump
Advanced Controls and Indicators
Advanced controls are found on Models with the “A” designation. The controls
and indicators shown are described in the following table.
Note
Different intensifier models
can have different layouts of
the controls.
Red
Beacon
Amber
Beacon
Intensifier Pump Advanced Controls
38
Operation
Intensifier Pump
Advanced Controls and Indicators
Control
Description
Beacon
Flashes when an fault is detected. The alarm also sounds. The beacon flashes
amber to indicate a warning. The beacon flashes red when a shutdown is
initiated. A message in the display describes the warning or shutdown, see
“Warning Messages” on page 85.
Display
Displays fault messages, component status information, and operating cues.
The display is used in conjunction with the Scroll Display and Toggle Display
switches to operate the Product Name variable control program.
Scroll Display
Steps through the display screens of the Product Name variable control
program.
Toggle Display
Makes selections in the current display screen. It also interrupts the warning
buzzer and flashing beacon.
Lock/Unlock Display
Enables and disables the display to make changes in the Product Name
variable control program settings.
Controls On
Applies power to the control panel and initiates the Product Name variable
program (on the automated control panel). The Emergency Stop switch must
be pulled out before the controls can be turned on.
Emergency Stop
Shuts down all electrical power to the machine and removes the ultra high
water pressure. The Emergency Stop button is a latching switch. Once it is
pressed, it remains pressed in until it is pulled out to its normal position.
Motor On
Starts the hydraulic pump motor, enables the low pressure water supply, closes
the bleed down valve, and enables the Intensifier On switch.
Motor Off
Stops the hydraulic pump motor, disables the intensifier operation, and
removes the water pressure.
Intensifier On
Starts the intensifier to build ultra high water pressure. Press Motor On before
using this control.
Pressure Set
Adjusts the pressure in some of the Display screens. The pressure for the
hydraulic pressure and the UHP water is set using the display.
Intensifier Off
Removes power from the intensifier circuit and removes the water pressure.
Hour Meter
Displays the amount of time the electric motor has been running. The hour
meter aids maintenance scheduling.
Alarm Horn
Sounds when a fault message is displayed.
Temperature and Hydraulic
Level Gauge
Shows the temperature and fluid level of the hydraulic fluid. The gauge is
located on the hydraulic tank.
(not shown)
•
The hydraulic fluid must be below 150°F/65°C; the nominal temperature
is 110°–120° F (43°–49° C).
•
The hydraulic fluid level should be at least halfway up the site glass.
Pump Pressure Gauge
Shows the hydraulic pump output pressure.
Power Disconnect Switch
Applies and removes electrical power to the intensifier pump. The switch is
located on the side of the electrical enclosure.
(not shown)
Operation
39
Intensifier Pump
Startup and Shutdown
Main power is controlled by the circuit breaker handle on the electrical panel
door.
Prestart inspection
Before starting the machine, perform the following inspection.
1. Check the hour meter to determine if periodic maintenance should be
performed.
2. Turn the plant water supplies on.
3. Inspect around and inside the equipment for water or hydraulic leaks. Check
for loose or damaged connections, fittings, hoses, etc. Correct any
discrepancies before starting the machine.
Note
For the Model 55-50C Intensifier Pump, open the front cover and check
the plastic bottle for fluid (from the weep holes). Empty the bottle as
needed.
4. Check the hydraulic fluid level and replenish if necessary.
5. Inspect lines, fittings, connections, etc. from the machine to the tool. Correct
any discrepancies noted.
6. Close covers and guards that were opened. Do not run the machine with
open covers.
Startup
The following procedure starts the intensifier pump and makes it ready for
normal operation.
Note
With experience you will learn what the normal operating sounds of the
machine. When the machine is turned on and it does not sound normal,
press the Emergency Stop push button.
1. Set the main power circuit breaker to On.
For models with advanced controls, when power is turned on the message
screen displays CONTROL POWER OFF. The message remains for 15
minutes unless Control Power On button is pushed.
2. Verify that the Emergency Stop button is out.
3. Press the Controls On button.
For models with basic controls, all indicators are turned on to verify their
operation. Press the Reset Indicator Test to turn the indicators off.
For models with advanced controls, wait for the control system
programming to complete the self-test.
4. Press the Motor On button. Permit the motor time to achieve operating
speed.
If the machine has been exposed to temperatures below 40°F/4°C, run the
machine at idle until the hydraulic fluid is thoroughly warmed.
40
Operation
Intensifier Pump
5. For models with basic controls, adjust the hydraulic pressure knob to set the
hydraulic pressure to the desired setting.
Maximum Hydraulic Pressure Settings
36-50, 36-100, 36-200
55-30, 55-50, 55-75A
55-75B, 55-100, 55-150
3350 psi (231 bar)
3050 psi (210 bar)
3180 psi (219 bar)
For models with advanced controls the hydraulic pressure automatically
ramps from zero pressure to the hydraulic pressure setting (see “Setting the
Hydraulic Pressure” on page 44).
6. Press the Intensify On button to start intensifier operation.
During operation
Once the machine is running, open the cover to check the water collection
assembly. Weep holes on the intensifier have hoses plumbed to the water
collection assembly. If excessive water is evident the high pressure seals should
to be replaced. Close the cover when done.
Note: The Model 55-50C
has drain lines routed to a
plastic bottle. Check the
bottle for leaking and trace
the drain line to its source.
S
D
LEFT
D
S
RIGHT
S = Static
D = Dynamic
Periodically check warning indicators and gauges and inspect everything visually
to ensure developing problems are detected before the equipment is damaged.
Shutdown
Perform the following procedure to shut the machine down in an orderly fashion.
1. Turn the tool off.
2. Press the Intensify Off and Motor Off buttons to remove power from the
machine controls.
3. Position the main circuit breaker handle to Off to remove power from the
entire machine.
4. For models with basic controls, adjust the hydraulic pressure knob to set the
hydraulic pressure to zero.
5. Turn the plant water supply off. Verify zero water pressure at the gauge.
Operation
41
Intensifier Pump
Programming the Advanced Controls
This information applies
only to intensifier models
with the “A” designation.
The advanced controls are factory set for normal operation. This section
describes how to change the program settings. The advanced controls include the
following:
•
Setting the hydraulic pressure
A maximum hydraulic pressure can be set to limit the amount of adjustment
for the hydraulic setpoint which sets the hydraulic pump output. See
“Setting the Hydraulic Pressure” on page 44.
•
Setting the ultra high pressure (UHP) water output
A maximum ultra high pressure can be set to limit the amount of adjustment
for the water pressure setpoint which sets the water pressure output. See
“Setting the Ultra High Water Pressure” on page 45.
•
Enabling the intensifier
The intensifier is normally enabled. It can be disabled for service purposes.
•
Selecting local or remote operation
The intensifier pump can be operated locally with the front panel controls or
it can be operated remotely.
•
Dual pressure operation (remote control only)
Two set points can be defined (DSET#1 and DSET#2) for a dual pressure
mode of operation. Using dual pressure operation allows the hydraulic
pressure to be turned on to a low pressure setting, then shifted to a high
pressure setting.
•
Controlling the automatic bleed down valve (remote operation only)
When operating the machine remotely the bleed down valve must be
controlled to bleed down the intensifier pressure. Enabling the bleed down
valve also enables the IDOFFSET setting. When shifting from high pressure
to low pressure the bleed down valve uses the offset value (about 2000–
3000 psi above the low pressure setting) to prevent the pressure from
dropping below the low pressure setting.
42
Operation
Intensifier Pump
Display Screens
Several screens of information and selections can be shown in the front panel
display. The following describe the display screens and the controls to use the
display.
•
Use the front panel Scroll switch to step through the screens in the display.
•
Use the front panel Toggle switch to make selections in the display screens.
•
Use the front panel Pressure switch to adjust the pressure setting.
The type of information being
displayed on the screen. Use
the Scroll switch to step through
the different screens.
The parameter to be displayed (Oil or H2O)
is set in Screen 2.
The mode (Local or Remote) is
set in Screen 10.
screen
value
The value is set with the front
panel Pressure control switch.
A maximum setpoint value is set
in Screen 4.
parameter
unit
mode
control
The control (manual, digital, or
analog) is set in Screen 11.
The unit of measurement (PSI, kPa, BAR, or MPa)
is set in Screen 3.
Display Screen Functions
Screen
Function
Description
1
Setpoint
Adjusts the pressure of the parameter displayed.
2
Mode of Operation
Selects Oil or H2O for the parameter shown in the various adjustment
screens.
3
Mode of Operation
Selects PSI, kPa, BAR, or MPa for the units of measurement shown in
the various adjustment screens.
4
Set Max
Sets a maximum pressure limit for the adjustment screens.
5
Main Intensifier
Enables or disables the intensifier. Models with two intensifiers list front
and rear intensifiers.
6
DSETPT#1
Adjusts the pressure for setpoint 1 when operating in the dual pressure
mode.
7
DSETPT#2
Adjusts the pressure for setpoint 2 when operating in the dual pressure
mode.
8
Automatic Bleed Down
Enables or disables the automatic bleed down feature (normally set to
disabled). The bleed down valve is enabled when operating in the dual
pressure mode.
9
IDOFFSET
Sets a pressure offset for the bleed down valve when operating with the
two set points.
10
Control Location
Selects Local or Remote as the location to control the intensifier pump.
11
Control Option
Selects Manual, Digital, Analog, or COM as the type of control.
Operation
43
Intensifier Pump
Setting the Hydraulic Pressure
Preform this procedure to set the maximum hydraulic pressure and set the
hydraulic pressure setpoint.
1. Turn the intensifier pump on.
A.
Set the main power circuit breaker to On. When power is turned on the
message screen displays CONTROL POWER OFF. The message
remains for 15 minutes unless Control Power On button is pushed.
B.
Verify the Emergency Stop button is out.
C.
Press the Controls On button. Wait for the control system
programming to complete self-test mode.
2. Press the Scroll switch to display first Mode of Operation screen.
3. Press the Toggle switch to select Oil.
4. Press the Scroll switch to display second Mode of Operation screen.
5. Press the Toggle switch to select the desired units of measurement.
6. Press the Scroll switch to display the Set Max screen.
7. Use the Pressure Set switch to adjust the hydraulic pressure to the
maximum pressure for the intensifier model.
Maximum Hydraulic Pressure Settings
36-50, 36-100, 36-200
55-30, 55-50, 55-75A
55-75B, 55-100, 55-150
3350 psi (231 bar)
3050 psi (210 bar)
3180 psi (219 bar)
8. Press the Scroll switch repeatedly to display the Setpoint screen.
9. Use the Pressure Set switch to adjust the hydraulic pressure to the desired
operating pressure for the intensifier.
44
Operation
Intensifier Pump
Setting the Ultra High Water Pressure
Preform this procedure to set the maximum hydraulic pressure and set the
hydraulic pressure setpoint.
1. Turn the intensifier pump on.
A.
Set the main power circuit breaker to On. When power is turned on the
message screen displays CONTROL POWER OFF. The message
remains for 15 minutes unless Control Power On button is pushed.
B.
Verify the Emergency Stop button is out.
C.
Press the Controls On button. Wait for the control system
programming to complete self-test mode.
2. Press the Scroll switch to display first Mode of Operation screen.
3. Press the Toggle switch to select H2O.
4. Press the Scroll switch to display second Mode of Operation screen.
5. Press the Toggle switch to select the desired units of measurement.
6. Press the Scroll switch to display the Set Max screen.
7. Use the Pressure Set switch to adjust the water output pressure to the
maximum pressure for the intensifier model.
•
For the Series 36 intensifier pumps set the maximum pressure to 36,000
psi (2500 bar).
•
For the Series 55 intensifier pumps set the maximum pressure to 55,000
psi (3800 bar).
8. Press the Scroll switch repeatedly to display the Setpoint screen.
9. Use the Pressure Set switch to adjust the hydraulic pressure to the desired
operating pressure for the intensifier model.
Operation
45
Intensifier Pump
Remote Control
Remote control duplicates some of the controls on the master control panel.
Remote operation requires a cable to be fabricated and properly wired to the
machine’s electrical system (refer to the electrical schematic).
Note
Contact Jet Edge for information about remote connections.
The machine is initially started with the main controls and the remote panel is
used for routine operation. The controls perform the same functions as those on
the front panel. The following describe how to enable remote operation.
•
For models with basic controls, turn the Mode switch to Remote to enable
remote operation.
•
For models with advanced controls, see “Display Screens” on page 43 to
configure the machine for the type of remote interface and enable the remote
mode.
Note
46
Operation
Under certain conditions (e.g. if the machine was shut down while in
comm or pendant mode), the motor cannot be started from local control
mode.
Intensifier Pump
Maintenance
This section describes when and how to maintain the intensifier pump. The
maintenance schedule is a guideline, revise the schedule as necessary to
accommodate local conditions.
Contents
General Maintenance Tips
48
Charging the Hydraulic Accumulators
Replacing the Water Filters
51
Cleaning the Inlet Water Strainer
52
Replacing the In-Line UHP Filter
53
Replacing the Hydraulic Filters
Changing the Hydraulic Fluid
Maintenance Record
49
54
55
56
Maintenance Schedule
What To Do
When To Do It*
How To Do It
Check the hydraulic fluid level
Every day
Check the site gauge. Add fresh filtered fluid to the
tank as necessary
Check the hoses and fittings
Every day
Inspect all hoses and fittings for proper connection
and for signs of separation or cracks. Replace
immediately if discrepancies are noted Also look for
evidence of any fluid leaks.
Clean the machine
Once a month
Use fresh flowing water or low-pressure shop air to
clean the machine. Dust, cutting debris, and
airborne grit cause wear of the moving parts and can
contaminate the hydraulic fluid.
Check the accumulator
precharge
Once a month
See “Charging the Hydraulic Accumulators” on
page 49.
Replace the water filters
Every 250 hours
See “Replacing the Water Filters” on page 51.
Clean the inlet strainer
Every 250 hours
See “Cleaning the Inlet Water Strainer” on page 52.
Replace the UHP filter
Every 250 hours
See “Replacing the In-Line UHP Filter” on page 53.
Replace the hydraulic filter
Every 250 hours
See “Replacing the Hydraulic Filters” on page 54.
Replace the breather
Every 250 hours
See “Replacing the Hydraulic Filters” on page 54.
Replace the hydraulic fluid
Every 1000 hours
See “Changing the Hydraulic Fluid” on page 55.
Check the motor bearings
Every 1000 hours
Grease the motor bearings according to the
manufacturer’s procedures.
* The interval is based on an 8 hour day, 5 day a week operation schedule. Dusty or dirty environments require more
frequent maintenance.
Maintenance
47
Intensifier Pump
General Maintenance Tips
Jet Edge intensifier pumps are designed to provide maximum performance with a
minimum of service and repair. However, due to the high pressures involved,
some components eventually wear out and must be repaired. By following basic
maintenance and inspection procedures, minor problems which can be remedied
before major faults develop.
WARNING
•
Review the section “Safety” on page 7 before performing any maintenance.
•
Whenever possible, turn the machine off before starting maintenance
procedures.
•
Keep a record of all maintenance and service performed, by elapsed time or
calendar scheduling. See the “Maintenance Record” on page 56.
•
Use only recommended lubricants. Do not add a lubricant unless it is the
same type and grade already in use. If there is any doubt, replace completely
with new lubricant.
•
Keep all lubricants in clean containers and protect from dust, water, and
other contaminants.
•
Carefully follow all prestart, startup, and operating procedures.
Never feel for high-pressure fluid leaks or overheating by placing a hand
directly on a component. High-pressure fluid leaks and hot components can
cause personal injury.
Use a piece of cardboard to check for leaks. Heat can be detected near a
component without physically touching it.
•
Hydraulic and water leaks are easily found by frequent visual inspection.
•
Heat buildup can be detected by passing the hand near the component.
Periodic Maintenance
Maintenance must be done at regular intervals. The intervals can be in operating
hours or on a calendar schedule; for example: 8 hours or every working day. Use
the interval that occurs first.
Break-In Period
After the first few hours of operation, check that all bolts, fasteners, fittings, etc.
are properly installed and tightened. Apply light machine oil to hinges.
48
Maintenance
Intensifier Pump
Charging the Hydraulic Accumulators
The nitrogen precharge in accumulators should be checked monthly to verify
sufficient pressure for the accumulator to perform its function properly. If the
pressure drops excessively the bladder cannot maintain an equalizing pressure in
the hydraulic system. The pressure should be checked before starting the
machine and after the machine has been idle for a long enough period to be
totally cooled.
Gauge
Head Assembly
Needle Valve
O-ring
Bleed Valve
Nitrogen Supply
Adapter Hose
Accumulator
Accumulator Charging Kit
Required equipment
Procedure
•
Accumulator charging kit (part number 28599)
•
O-Ring (part number 45793-011)
•
Dry industrial nitrogen (1800 psi minimum)
•
Teflon thread tape
Refer to the hydraulic schematic to determine correct precharge pressure.
1. Depending on the accumulator to be checked, select the proper gauge
The charging kit includes a 3000 psi (200 bar) high pressure gauge and a
600 psi or (40 bar) low pressure gauge. If charging more than one
accumulator, start with the higher-capacity accumulator first.
2. Verify the needle valve is turned fully counterclockwise (open) and the
bleed valve is fully clockwise (closed).
3. Using Teflon tape, install the gauge on the head assembly.
4. Remove the accumulator valve cover cap and the valve stem cap (if
installed).
Maintenance
49
Intensifier Pump
Carefully inspect the base of the valve stem where it enters the accumulator
neck. If a plastic seal ring or an O-ring is installed, remove them before
connecting the accumulator charging kit or the spring-loaded valve in the
accumulator may not open properly.
CAUTION
Over-torquing will break the valve stem.
Tighten the needle valve assembly only to 5 ft•lb (0.56 N•m).
5. Thread the needle valve assembly onto the valve stem far enough to ensure
the accumulator valve seat is open.
6. Turn the needle valve on the gauge assembly slowly clockwise. Observe the
pressure reading.
7. The gauge should indicate pressure within 40% of the precharge shown on
the hydraulic schematic; 1750 psi (120 bar) for the high pressure
accumulator and 20 psi (1.5 bar) for the low pressure accumulator.
•
If accumulator pressure is within the specified limits, turn the needle
valve fully counterclockwise to close and go to Step 12.
•
If accumulator pressure is low continue this procedure.
8. Install the adaptor hose between the gauge head assembly and the nitrogen
supply bottle.
CAUTION
The nitrogen supply tank in pressurized. A sudden pressure spike can
overload the gauge and damage the mechanism.
Open the valve on the nitrogen supply bottle very slowly.
9. Slowly open the valve on the nitrogen supply while observing the gauge
reading. When the reading is proper, turn the valve off and allow the
pressure to stabilize for three minutes.
10. Check the gauge reading. Repeat the charging procedure if necessary.
11. When pressure is within the specified limits, verify the valve on the supply
bottle is closed. Turn the needle valve fully counterclockwise.
WARNING
Sudden pressure release can cause personal injury.
Turn the bleed valve handle slowly.
12. Turn the bleed valve slowly counterclockwise to relieve any line pressure.
13. Disconnect the gauge and hose assembly.
14. Reinstall the seal ring and/or O-ring, the valve stem cap, and the cover cap
on the accumulator. Replace the O-ring with a new item if damaged.
15. Start the machine and verify proper operation.
50
Maintenance
Intensifier Pump
Replacing the Water Filters
One, two or three water filters (depending on the intensifier pump model)
provide successive filtering of the incoming water. The incoming water is filtered
by a 10 micron filter, followed by a 1 micron filter, and finally a 0.45 micron
filter. The water filters should be replaced after every 250 hours of machine
operation; more frequently should the local water condition require more
frequent replacements.
Note
•
Some intensifier pump models have one water pressure gage. It monitors the
water pressure of the filtered water. Record the water pressure when the
pump is running. If the water pressure drops to approximately 40 psi
(3 bar) replace the filters.
•
Some intensifier pump models have two water pressure gages. One gage
monitors the input water pressure and the other gage monitors the water
pressure of the filtered water. If the water pressure varies by approximately
20 psi (1.5 bar) the filters should be changed.
Note
Required equipment
Local water pressure fluctuations can affect readings. Use the following
as a guideline.
Note the location of the incoming water supply to the machine and verify
that the 10 micron filter is installed on the incoming water side of the line,
followed by the 1 micron filter, then the 0.45 micron filter.
The appropriate replacement filter elements from the following table.
Filtration
Intensifier Model
36-50, 36-100, 36-200
55-30, 55-50C
All Other Models
10µ
–
–
25621
1µ
25147*
25622
25622
0.45µ
–
25623
25623
* Model 36-50 requires one filter; Models 36-100 and 36-200 require 2 filters.
Procedure
1. Ensure the incoming water supply is turned off and verify that the water
pressure is zero.
2. Unthread and remove a filter canister. Remove and discard the filter
element.
3. Install a new filter element in the canister. Thread the canister into position
and hand tighten.
4. Repeat Step 2 and Step 3 for each filter.
5. Turn the supply water on. Press the bleed button on each filter head to expel
any air.
6. Operate the machine and check for leaks.
Maintenance
51
Intensifier Pump
Cleaning the Inlet Water Strainer
A 100-mesh inlet water strainer is in-line with the filtered water connection. Over
time the strainer collects enough debris from the supply line to become clogged.
If this happens the intensifier can overcycle, or a low inlet water pressure
warning might be indicated.
Ensure the intensifier pump is off and the filtered water source are turned off
before cleaning the inlet water strainer.
1. Place a bucket under the strainer housing to collect water when the strainer
housing is opened.
2. Press the red buttons on the water filters to remove any pressure in the low
pressure water system.
3. Remove the 3/8 inch hollow hex plug. Water will drain from the line.
4. Remove the 100-mesh strainer basket from the cavity.
5. Flush the 100-mesh strainer basket with fresh water. If necessary, remove
any debris with a soft brush.
6. Install the 100-mesh strainer basket into the cavity.
7. Install the 3/8 inch hollow hex plug.
8. Start the intensifier pump but DO NOT turn the intensifier on to pressurize
the low pressure system (see “Startup” on page 40).
9. Press the red buttons on the water filters to remove the air in the low
pressure water system.
Filtered
Water In
Hollow Hex
Plug
52
Maintenance
Strainer
Housing
Intensifier Pump
Replacing the In-Line UHP Filter
The filter in the UHP line between the attenuator and the tool should be changed
every 250 working hours, or sooner if debris starts to destroy orifices. To change
the filter, the housing must be removed from the water line.
Required equipment
Procedure
•
UHP filter element (part number 27171)
•
Precision Lube (part number 25750)
1. Disconnect the tubing from the UHP filter housing. Remove and discard the
filter element.
Note
Carefully observe which side of the filter housing is the inlet (the line from
the attenuator) and which is the outlet (the line to the tool). The inlet port
is tapered to accept the flared end of the filter element.
2. Clean the UHP filter housing. Inspect to verify all debris is removed.
3. Insert the new filter into the inlet side of the UHP filter housing (where the
line enters from the attenuator). Ensure the flared end of the filter element is
outward (toward the attenuator) when installed in the UHP filter housing.
4. Apply Precision Lube to the threads of the gland nuts and reconnect the
tubing. Tighten the gland nuts securely.
5. Start the machine at normal working pressure. Verify no seepage from the
connection points or the weep holes in the filter housing.
Note
The plumbing of the tubing and the location of the UHP filter housing
varies between models. The UHP filter housing is located between the
attenuator and the high pressure water output on all models.
Attenuator
High Pressure
Water Out
UHP Filter
Housing
Maintenance
53
Intensifier Pump
Replacing the Hydraulic Filters
The hydraulic filter and breather cap filter should be replaced every 250 hours of
machine operation.
Required equipment
•
12" or 15" Adjustable wrench
•
Drip pan
•
The appropriate replacement filter element and breather cap filter from the
following table.
Intensifier Model
Filter Element
Breather Cap
36-50
27713*
27409
36-100
27797
28565
36-200
27797
27409
55-30
27713*
28565
55-50
27713* or 103442†
28565
55-75
27797
28565
55-100
27797
28565
55-150
27797
27409
55-200
27797
27409
* Requires O-ring (part number 29859).
† Spin on filter for Model 55-50C.
Procedure
Ensure the hydraulic pressure is at zero before starting this procedure; see
“Removing Water and Hydraulic Pressure” on page 59.
Note
The Model 55-50C filter is a spin on filter (like an automotive oil filter).
1. Place a drip pan under the hydraulic filter. Use a wrench to loosen the
canister.
2. Remove and discard the filter element. Clean the inside of the canister.
3. Install a new filter element. Thread the canister on and hand tighten only.
4. Replace the filter breather cap on the top of the hydraulic fluid tank.
If the filters are being replaced along with the hydraulic fluid, return to Step
5 on page 55.
5. Operate the machine and check for leaks.
54
Maintenance
Intensifier Pump
Changing the Hydraulic Fluid
Be careful not to contaminate the new hydraulic fluid. The working area around
the system must be dry and free of any dust, dirt, debris, etc.
Required equipment
Procedure:
•
Portable pump with hoses
•
Funnel
•
Container for waste fluid
•
Filter system for filtering hydraulic fluid to SAE Class 4 (10 micron
absolute)
•
Hydraulic fluid (see the Hydraulic Fluid Capacity specification in the Model
Specific Specifications table on page 23)
Ensure the hydraulic pressure is at zero before starting this procedure; see
“Removing Water and Hydraulic Pressure” on page 59.
1. Drain the tank using a portable pump. Pump the fluid out through the filler
opening.
CAUTION
Operating the hydraulic pump without hydraulic fluid can severely damage
the pump.
Do not cycle the hydraulic pump to drain the hydraulic fluid.
2. Remove the top filler plug and the drain plug on the pump and allow to drain
as much as possible. Reinstall the plugs.
3. Clean the tank with a non-flammable and dry thoroughly. Clean or replace
the magnetic drain plugs.
4. Install a new hydraulic filter. See “Replacing the Hydraulic Filters” on
page 54.
5. Pump fresh filtered fluid into the tank until approximately 3/4 full.
Do not fill completely to the top. The fluid requires room for expansion as it
warms during operation.
6. Start and stop the motor in short intervals to prime the pump.
The sound of the pump alters noticeably as the fluid is ingested and fills the
system. The pump may chatter or cavitate because of air in the fluid. Turn
the equipment off and permit 30 minutes for air bubbles to dissipate before
continuing.
7. When the pump is primed and the system is filled, run the machine for 30
minutes to permit total warmup. Monitor fluid level on the sight gauge and
replenish as necessary. Inspect for leakage and verify proper operation.
Maintenance
55
Intensifier Pump
Maintenance Record
Hours
56
Date
Maintenance
In-Line
Filter
Hydraulic
Fluid
Hydraulic
Breather
Accumulator
Precharge
Electric
Motor
Water
Filters
Intensifier Pump
Service
This section describes service procedures that should be performed by a person
that has experience servicing Jet Edge intensifier pumps. The person servicing
the equipment must be familiar with all operating aspects of the intensifier pump
and the accessories and options used with it.
Jet Edge equipment is manufactured in compliance with U.S. Society of
American Engineers (SAE) standards. Although most dimensions can be
converted to metric equivalent, specifications that apply to thread pitches and
tool sizes must conform to the original design requirements.
Contents
General Service Tips
58
Removing Water and Hydraulic Pressure
Manually Controlling the Valve
Servicing the Proximity Switch
59
60
61
Replacing the Proximity Switch
62
Replacing the Proximity Switch Actuator Seals
Adjusting the Proximity Switch
Replacing the Intensifier Seals
Servicing the Poppets
Lapping the Poppet
63
65
67
73
76
Servicing the Bleed Down Valve
77
Replacing the Needle and Seal
Replacing the Piston Seal
80
Servicing the Heat Exchanger
82
78
Service
57
Intensifier Pump
General Service Tips
Component cleanliness is a primary factor in machine performance.
Contamination of any components in contact with the hydraulic fluid or water
can result in major equipment failure. To ensure optimal equipment performance,
clean all parts thoroughly and wrap or cover until reassembly.
•
CAUTION
Study the Safety section on page 7 before performing any repairs.
Do not attempt repairs that are not fully understood. Extensive equipment
damage can result from improper procedures.
If any doubt exists, contact the Jet Edge Service Department. See “Contacting Jet
Edge” on the back of the title page.
CAUTION
•
Read all instructions before starting any procedure. Do not attempt to
perform repairs unless the procedure is clearly understood. If in doubt,
contact the Jet Edge service department.
•
If power and/or pressure must be on while performing any work, stay at
least 18 in (460 mm) from any pressurized lines.
•
Use only recommended lubricants. Do not add a lubricant unless it is the
same type and grade already in use. If there is any doubt, replace completely
with new lubricant.
•
Keep all lubricants in clean containers and protect from dust, water, dirt, and
other contaminants.
•
Except where directed otherwise, use Precision Lube (part number 25750)
on all stainless steel threads. This compound is specially formulated to
prevent galling of stainless threads and fittings.
Intensifier pumps can generate enough heat to ignite flammable solvents.
Never use engine fuels to clean parts. Unless specifically directed, always use
non-flammable solvents for cleaning.
Special Tools
Bolts and cap screws
Special tools are required to properly repair some components. The tools are
specifically designed to prevent damage to the components and ease the task.
Any required special tools are identified in any procedure that requires them.
Ensure that any replacement bolt or cap screw is of the same SAE (or equivalent)
grade as the original.
Grade 2
58
Service
Grade 5
Grade 8
Intensifier Pump
Tubing Connections
For proper machine performance, UHP tubing gland nuts should be torqued
when connecting tubing after repairs have been performed:
Tubing Size
Wrench Size
Torque
1/4 in
5/8 in
25 lb•ft (33.9 N•m)
3/8 in
13/16 in
50 lbf•ft (67.8 N•m)
9/16 in
13/16 in
110 lb•ft (149.1 N•m)
Removing Water and Hydraulic Pressure
Some of the maintenance and service procedures require water pressure,
hydraulic pressure, or both to be removed. This section describes how to
accomplish zero pressure.
WARNING
High hydraulic pressures and ultra-high water pressure are present in an
intensifier pump. Disconnecting a pressurized hydraulic or water line will
cause personal injury.
Before disconnecting any hydraulic line or water line, verify that the hydraulic
pressure or ultra-high water pressure is relieved from the system.
Removing water
pressure
Water pressure is normally removed when the Motor Off button is pressed. The
bleed down valve automatically removes the water pressure when power is
removed.
If the bleed down valve is defective, or it is by passed, turn the system off and
turn on the water tool (cutter, cleaner, etc.) to relieve any water pressure in the
system.
Removing hydraulic
pressure
There are two ways to remove hydraulic pressure.
•
While the intensifier pump is running, adjust the hydraulic pressure to zero.
•
Locate the directional control valve (see the figure “Valve Actuating Pins”
on page 60). With the hydraulic pressure turned off, press the manual
actuating pin on one side of the valve, then press the manual actuating pin
on the other side of the valve. To be sure that hydraulic pressure has been
removed, repeat this procedure a second time.
Service
59
Intensifier Pump
Manually Controlling the Valve
Some of the service procedures require the valve to be controlled manually.
1. Press the Controls On button and press the Motor On button to build
hydraulic pressure
2. If the intensifier is on, press the Intensifier Off button.
3. Press the Motor Off button, hydraulic pressure should be maintained for the
duration of the service procedure. Leave control power on.
4. Each side of the valve has a manual actuating pin. Use a rigid tool to press
one of the actuating pins to cause the intensifier piston to move to one end of
its travel.
Note
Observe the proximity switch actuator. The end which has the higher
proximity switch actuator is the end the piston is in. The intensifier piston
extends to the opposite side from the directional valve actuating pin that
is pressed.
Proximity Switch
Actuator Collar
Actuating Pin
Actuating Pin
Directional Valve
Valve Actuating Pins
60
Service
Intensifier Pump
Servicing the Proximity Switch
Two proximity switches signal the control electronics when to reverse the
intensifier piston movement. The proximity switches define the limit of the
piston stroke.
The limit switch actuator follows a ramp of the plunger coupler. As the piston
moves side-to-side the limit switch actuator rises and falls. When the actuator
reaches its highest point the actuator collar comes within the detection range of
the proximity switch which signals the control electronics that the piston has
reached a limit.
Jam Nuts
0.025–0.30 in
(0.63–0.76 mm)
Connector
LED
Set Screws
Actuator Collar
O-rings
Proximity Switch
Actuator Cap
Backup Ring
Spring Washer
Actuator Spring
Limit Switch
Actuator
Actuator
End Cap
Piston
Plunger Coupler
Assembly
Proximity Switch Component Identification
Service
61
Intensifier Pump
Replacing the Proximity Switch
If a proximity switch fails, the intensifier stops cycling. Without a directionchanging signal, the intensifier piston strokes toward the failed switch.
Depending on where the piston stops, it is possible that neither switch will
provide a signal.
Apparent switch failure may be caused by the actuator collar being out of
adjustment or by an incorrect switch/collar gap. To test, touch the switch face
with a feeler gauge or screwdriver with the control power on. If the signal is
made and the piston shifts, the switch is good (the LED should also light). Check
the switch and collar positioning and adjust as required (see “Adjusting the
Proximity Switch” on page 65).
Required equipment
Procedure
•
Proximity switch (part number 28187 for pumps with the “A” designation;
part number 29314 for pumps with the “B” or “C” designation)
•
Set of feeler gauges
Refer to the figure “Proximity Switch Component Identification” on page 61
during the following procedure.
1. Run the pump to build hydraulic pressure.
2. Leave control power on, but turn the engine and intensifier off. Manually
actuate the pilot valve (see “Manually Controlling the Valve” on page 60) to
move the intensifier piston and extend the limit switch actuator.
3. Check the proximity switch gap and proximity actuator collar position to
verify the switch is not merely out of adjustment. See “Adjusting the
Proximity Switch” on page 65.
If the switch has failed, turn power off.
4. Disconnect the switch lead. Remove a jam nut to remove the proximity
switch. Discard the proximity switch.
5. Remove a jam nut on the new switch. Insert the switch into the bracket.
Thread the jam nut onto the switch.
6. Adjust the proximity switch to obtain a clearance of 0.025–0.030 in
(0.635–0.762 mm) between the end of the proximity switch and the actuator
collar.
7. Tighten the jam nuts to hold the switch in position.
8. Recheck the gap after the jam nuts are tightened.
9. Connect the switch lead.
10. Start the machine and check for proper operation.
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Service
Intensifier Pump
Replacing the Proximity Switch Actuator Seals
A proximity switch actuator is located in each hydraulic end cap of the
intensifier.
Actuator Cap
Actuator O-ring
Actuator Spring
Actuator Cap O-ring
Back-Up Ring
Spring Washer
Limit Switch Actuator
Hydraulic End Cap
Proximity Switch Actuator Assembly
Required equipment
•
Hooked dental pick or a pointed tool
•
Torque wrench
•
Spring (part number 25011)
•
End cap O-ring (part number 25009)
•
Actuator cap O-ring (part number 25007)
•
Actuator cap backup ring (part number 25008)
•
High pressure lubricant (part number 28339)
•
Grease, Mobil XHP 222 or equivalent
•
Precision Lube thread lubricant (part number 25750)
Service
63
Intensifier Pump
Procedure:
Refer to the figure “Proximity Switch Actuator Assembly” on page 63 during the
following procedure.
1. Run the pump to build hydraulic pressure.
2. Turn all power off. Manually actuate the pilot valve to shift the intensifier
piston and retract the limit switch actuator (see “Manually Controlling the
Valve” on page 60).
3. Unthread the actuator cap and lift the proximity switch actuator assembly
out of the hydraulic end cap.
If necessary, loosen or remove a jam nut on the proximity switch to move
the switch to provide clearance.
4. Wipe any spilled fluid away from the cavity in the hydraulic end cap. Cover
the hydraulic end cap opening while working on the proximity switch
actuator assembly to prevent debris and dirt from falling into the opening.
5. Disassemble the proximity switch actuator assembly.
A.
Loosen the side set screw and remove the actuator collar. Pull the limit
switch actuator and spring out of the actuator cap.
B.
Hold the actuator cap upright so the spring washer falls out.
C.
Use a pointed tool or dental pick to remove the actuator O-ring and
backup ring from inside the actuator cap. Verify no scraps or debris
remain inside.
D.
Remove the actuator cap O-ring from the actuator cap.
E.
Discard the spring, O-rings and the backup ring.
6. Clean the parts with solvent and dry with low pressure shop air. Inspect the
parts for physical damage and replace as necessary.
•
Inspect the bottom of the limit switch actuator carefully. It should be
uniformly rounded with no visibly worn or flat spots.
•
Check the upper part of the limit switch actuator for wear or scoring.
•
Slide the limit switch actuator through the actuator cap. Verify
movement is smooth and the aperture through the cap is not worn.
7. Reassemble the proximity switch actuator assembly.
A.
Coat the O-rings and backup ring with high pressure lubricant. Ensure
the cupped side of the backup ring faces toward the inner O-ring during
installation.
B.
Install the backup ring and actuator O-ring.
C.
Install the outer O-ring over the actuator cap threads.
8. Coat the limit switch actuator with high pressure lubricant. Install the spring
and spring washer on the limit switch actuator. Slide the assembly into the
actuator cap.
9. Apply Precision Lube to the threads of the actuator cap. Thread the
assembly into the hydraulic end cap and torque to 45 ft•lb (61 N•m).
64
Service
Intensifier Pump
10. Reinstall the actuator collar. Reinstall the proximity switch if removed.
11. Go to “Adjusting the Proximity Switch” on page 65.
12. Start the machine and test for proper operation. Inspect around the base of
the actuator cap and around the limit switch actuator and verify no hydraulic
fluid seepage.
Adjusting the Proximity Switch
The proximity switch senses the actuator collar when the collar moves near the
switch. Two adjustments affect the operation of the intensifier:
•
Adjusting the position of the proximity switch sets the switch within its
detection range of the actuator collar.
•
Adjusting the actuator collar sets the vertical position of collar when the
intensifier piston has reached the end of its stroke.
0.025–0.030 in
(0.63–0.76 mm)
Jam Nuts
Connector
LED
Height Adjustment
Actuator Collar
Set Screw
Limit Switch Actuator
Bracket
Proximity Switch
Required equipment
Adjusting the
proximity switch
•
Set of feeler gauges
•
A wrench
The proximity switch position must be set so it can detect the actuator collar.
1. Turn control power off.
2. Manually actuate the pilot valve to shift the intensifier piston and extend the
limit switch actuator (see “Manually Controlling the Valve” on page 60).
3. Loosen the jam nuts on the proximity switch body.
4. Adjust the proximity switch to obtain a clearance of 0.025 in–0.030 in
(0.635 mm–0.762 mm) between the proximity switch and the actuator
collar.
5. Tighten the jam nuts to hold the proximity switch in position.
6. Recheck the gap after the jam nuts are tightened.
7. Start the machine and verify proper operation.
Service
65
Intensifier Pump
Adjusting the actuator
collar
Adjusting the activator collar is a trial-and-error procedure to achieve the ideal
setting.
•
Setting the actuator collar so the limit switch actuator extends as far as
possible before activating the proximity switch provides maximum water
volume on each stroke.
•
Setting the actuator collar to actuate the proximity switch sooner in the
stroke reduces water output but also helps reduce wear on the intensifier
parts.
Perform the following procedure to adjust the actuator collar.
1. Turn control power on, but leave the motor and intensifier off. Manually
actuate the pilot valve to shift the intensifier piston and retract the limit
switch actuator (see “Manually Controlling the Valve” on page 60)
Note
CAUTION
Some proximity switches have a LED is located on the end of the switch.
The top end of the limit switch actuator can easily bend. Bending the limit
switch actuator will affect the operation of the proximity switch and require
the replacement of the limit switch actuator.
Be careful when loosening or tightening the side set screw in the actuator collar.
2. Loosen the side set screw in the actuator collar. Rotate the top set screw
clockwise to raise the actuator collar on the limit switch actuator until the
LED on the proximity switch lights.
3. Rotate the top set screw counterclockwise to lower the collar until the LED
turns off, then continue to lower the collar 1/2 turn of the set screw.
4. Carefully tighten the side set screw to lock the collar in position on the
proximity switch actuator.
5. Start the machine and check for proper operation. Readjust as necessary
until operation is satisfactory.
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Service
Intensifier Pump
Replacing the Intensifier Seals
The intensifier seal should be replaced when hydraulic leaks are detected around
the intensifier.
Note
Hydraulic
End Cap
Plunger
Although it is possible to replace only the seal that is leaking, it is
recommended that all seals and O-rings be replaced at the same time to
save equipment downtime later.
Tie
Rod
High Pressure
Cylinder
Backup
Tube
Hex
Nut
High Pressure
End Cap
Check
Tube
High Pressure
End Cap O-ring
Leakage Output
(also called
Weep Hole)
Sleeve
Bearing
Backup
Ring and
O-ring
Backup Disc
(also called
Mini Disc)
Backup Tube
(also called
Spacer Tube)
Rod
Seal
Cylinder
Backup Ring
End Cap
O-ring
Backup Ring
(also called Hoop)
High Pressure
Seal Assembly
Backup
Ring
Intensifier Seals
Service
67
Intensifier Pump
Required equipment
•
High pressure lubricant (part number 28339)
•
Torque wrench
•
Precision Lube thread lubricant (part number 25750)
•
The appropriate parts from the following table:
Intensifier Model
Part (quantity)
36-50, 36-100, 36-200
55-30, 55-50
55-75, 55-100, 55-150, 55-200
Backup Ring Rod Seal (2)
25006
25954
25953
Backup Ring O-ring (2)
30113
26471
26471
High Pressure Seal (4)
35013
35373
35574
High Pressure Backup Rings (4)
35014
35364
35572
End Cap O-ring (2)
not used
25947
25947
End Cap Backup Ring (2)
not used
26472
26472
45319-536
45319-5707
45319-5529
46646
46646
46646
Intensifier Seal Tool Kit
Intensifier Ring Tool
Procedure
Perform the following procedure to replace the intensifier seals.
1. Turn off electrical power and bleed all water and hydraulic pressure from
the system. See “Removing Water and Hydraulic Pressure” on page 59.
2. Disconnect lines and tubing from the end cap and check tube.
3. Disassemble the intensifier.
Hex
Nut
68
Service
High Pressure
End Cap
Tie
Rod
High Pressure
Cylinder
Plunger
Hydraulic
End Cap
A.
Remove the four end cap hex nuts. Loosen the four end cap hex nuts
alternately to relieve pressure evenly.
B.
Support the high pressure cylinder while removing the end cap; it can
fall free and damage the plunger. Use a plastic mallet to tap on the high
pressure end cap and remove it from the tie rods.
C.
Remove the high pressure cylinder and set it on the workbench. The
high pressure cylinder tends to stay in the end cap due to the o-ring.
Use a soft mallet to remove the high pressure cylinder.
Intensifier Pump
4. Place the high pressure cylinder on the
cap tool. Ensure the cylinder is centered
on the cap tool so the inside diameter of
the cylinder is not blocked.
Mandrel
Tool
5. Remove the high pressure seals, backup
rings, and backup tube from the high
pressure cylinder.
A.
B.
Insert the mandrel into the high
pressure cylinder and press down
(tap with a plastic mallet if
necessary). The backup tube pushes
the high pressure seal and backup
ring out of the cylinder.
Turn the high pressure cylinder over
and use the mandrel tool to remove
the other high pressure seal and
backup ring out of the cylinder.
High
Pressure
Cylinder
Cap
Tool
C.
Remove the backup tube from the
high pressure cylinder.
D.
Discard the high pressure seals and backup rings.
6. Clean all parts and inspect for damage. Remove high spots on both ends of
the cylinder and inside the sealing area of the bore with crocus cloth or
1000-grit emery. Clean thoroughly with solvent and wipe dry.
Note
The insertion sleeve tool can be used to help align cap tool.
7. Stand the high pressure cylinder upright.
Place the cap tool on top of the cylinder,
making sure it rests flush on the end (the
cap tool will spin on the cylinder if
properly seated).
8. The seal insertion sleeve has an inward
taper to compress the seal as it is pressed
through. Apply high pressure grease to the
inside of the insertion sleeve and slide the
insertion sleeve into the cap tool, larger
diameter upward.
9. Install new high pressure seals, new
backup rings, and the backup tube into the
high pressure cylinder.
A.
Insert a new high pressure seal into
the sleeve, O-ring inward (toward the
cylinder).
B.
Use the small end of the mandrel to
press the seal assembly through the
sleeve and into the end of the cylinder.
Mandrel
Tool
High Pressure
Seal Assembly
Insertion
Sleeve
Cap
Tool
High
Pressure
Cylinder
Service
69
Intensifier Pump
C.
Note
D.
E.
Twist and lift the mandrel while removing it from the sleeve. If it is
pulled directly out, it might pull the seal out. Remove the tools and
verify the seal is squarely seated within the cylinder bore.
The seal backup ring is tapered. Be sure to note which side of the seal
backup ring has the larger diameter.
Insert the seal backup ring into the
cylinder with the tapered side
(larger diameter) toward the seal.
Use the mandrel and a plastic mallet
to seat the backup ring. Verify it is
installed squarely and is flush with
the cylinder face.
Turn the cylinder over and install
the backup tube. Repeat the
procedure to install the second seal
and ring.
Mandrel
Tool
Backup Ring
(exaggerated)
Cap Tool
10. Inspect the backup disc.
A.
Note
Remove the backup disc and clean thoroughly with solvent and a stiff
brush. If necessary the faces may be cleaned with lapping paper to
remove sludge and dirt.
Stroking of the plunger through the disc wears away the surface until the
opening is no longer round. The resulting gap permits pressure to
extrude the seal material past the disc. Service life of the seal decreases
significantly as the gap enlarges through continued wear.
B.
Check for wear, chipping, or cracking at the inner perimeter where the
disc rests against the plunger. Check for burnished areas within the
bore, indicating wear.
C.
Inspect the surface for wear. During operation, the high pressure seal
backup ring can wear a depression into the face. Clean and run the
worn surface over the lapping plate to remove any high points.
•
If wear is more than 0.010" (.254 mm) deep, turn the disc over so
the seal backup ring rests against the other side.
•
If both sides are worn the disc must be replaced.
11. Inspect inside the hydraulic end cap. Minor fluid seepage is permissible, but
if leakage is excessive the seals on the cylinder backup ring must be
replaced.
70
Service
•
If leakage is excessive, perform Step 12.
•
If leakage is not excessive, go to Step 13.
Intensifier Pump
12. Replace the seals on the cylinder backup ring.
The Series 36 intensifier
pumps do not have holes
for the machine screws but
the backup ring can be
pulled out.
A.
To replace the seals on the cylinder backup
ring, insert 5/16 inch machine screws
through opposite holes in the ring removal
Ring Removal Tool
tool and thread into the cylinder backup
ring. Pull outward on the tool to extract the ring, being careful not to
mar the plunger.
B.
Inspect for burnished areas within the bore of the ring, indicating wear.
Visually check the clearance of the ring on the plunger. If light is
visible between the ring and plunger, install a new ring.
C.
Remove and discard the rod seal, backup ring, the backup O-ring, and
end cap O-ring.
Backup
O-ring
End Cap
O-ring
Backup
Ring
Rod
Seal
Backup
Disc
Plunger
Sleeve
Bearing
Cylinder
Backup
Ring
3/8”
Thread
5/16”
Thread
D.
Install a new backup O-ring and backup ring on the cylinder backup
ring.
E.
Insert a new rod seal (cup side out) inside the cylinder backup ring.
Note
Hydraulic fluid might drain from the cylinder when the sleeve bearing is
removed. Be prepared to collect any hydraulic fluid.
F.
Insert two 3/8 inch machine screws through opposite holes in the ring
removal tool and thread into holes in the sleeve bearing. Pull outward
on the tool to extract the sleeve bearing.
G.
Clean the sleeve bearing and inspect for scoring or burring.
Service
71
Intensifier Pump
H.
If possible, measure the bore of the backup disc, the cylinder backup
ring, and the sleeve bearing for concentricity. The diameter must not be
larger than the dimension from the following table at any point.
Model
Dimension
36-50, 36-100, 36-200
1.3756 in (34.939 mm)
55-30, 55-50
1.0033 in (25.484 mm)
55-75, 55-100, 55-150, 55-200
0.8853 in (22.486 mm)
13. Install new end cap O-rings in the hydraulic end cap and high pressure end
cap.
Note
Be sure the screw holes face outward when reinstalling the sleeve
bearing and backup ring.
14. Coat the parts with a very small amount of high pressure grease during
installation. Slide the sleeve bearing over the plunger and press into position
in the hydraulic end cap. Reinstall the backup ring and backup disc.
15. Apply a small amount of high pressure lubricant to the plunger. Press the
high pressure end cap onto the end of the cylinder. Slide the cylinder and
end cap onto the plunger and over the tie rods as a unit, making sure the
leakage outlet in the end cap points downward.
16. Ensure the cylinder slides squarely into the hydraulic end cap. Considerable
pressure is required to push the seals over the plunger.
17. Lubricate the tie rod threads with grease. Notice that the hex nuts have
markings on one side. These markings must face outward when the nuts are
installed. Thread the nuts onto the tie rods and tighten finger tight.
18. Tighten the nuts alternately in an "X" pattern to apply pressure evenly.
•
For models 55-30 and 55-50, torque to 250 lb•ft (339 N•m, advancing in
increments of 25 lb•ft (34 N•m).
•
For all other models, torque to 275 lb•ft (373 N•m), advancing in
increments of 25 lb•ft (34 N•m).
Start each adjustment increment at a different nut.
19. Reconnect all lines and fittings that were removed to permit servicing.
20. Inspect the assembly and verify that all parts are accounted for and all
connections are properly tightened.
21. Start the equipment. Verify proper operation with no water or hydraulic
leakage.
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Service
Intensifier Pump
Servicing the Poppets
This section describes how to replace the poppets and related components.
Capscrew
5–40 x 0.5
High Pressure
End Cap
Poppet
Housing
Inlet
Poppet
Check
Tube
Gland
Coupling
Poppet
Body
Hydraulic
End Cap
High Pressure
Cylinder
O-ring
Seal
Tie
Rod
High
Pressure
Seal
Back-Up
Hoop
O-ring
Seal
Water Check
Input Seat
High
Pressure
Poppet
Check
Spring
Poppet Component Identification
Required equipment
•
Torque screwdriver or Torque wrench with 3/32 inch hex bit
•
5-40 Thread tap
•
High pressure lubricant
•
Precision Lube thread lubricant (part number 25750)
•
Non-flammable solvent
•
Thread locking kit (P/N 27687)
•
The appropriate parts from the following table
Part (quantity)
Series 36
Series 55
High pressure poppets (2)
35011
35662
Inlet poppets (2)
35010
35370
Check springs (2)
25013
25648
Poppet seats (2)
25012
35367
Capscrews (4)
30119
29525
Service
73
Intensifier Pump
Procedure
Before starting the following procedure, turn off electrical power and bleed all
water and hydraulic pressure from the system. See “Removing Water and
Hydraulic Pressure” on page 59.
1. Disconnect water input from the check tube and disconnect the UHP tubing
from the poppet body.
2. Remove the four end cap hex nuts. Loosen alternately to relieve pressure
evenly.
3. Support the high pressure cylinder while removing the high pressure end
cap, it can fall free and damage the plunger. Use a plastic mallet to tap on the
end cap and remove it from the tie rods.
4. Remove the gland coupling. Press the check tube out of the end cap (tap
lightly with a plastic mallet if necessary).
5. Remove and discard the two capscrews that secure the poppet housing from
the check tube. Remove the poppet housing (use new capscrews during
reassembly).
6. Inspect the end of the check tube. If scored or corroded, lap to restore a
smooth finish, see “Lapping the Poppet” on page 76.
7. Inspect the inlet poppet. Lap or replace as necessary.
CAUTION
Residue from the thread adhesive can remain in the capscrew holes. If the
residue is not completely removed, the replacement screws will not
properly secure the poppet housing to the check tube.
Before reassembling, thoroughly clean the threads in the check tube. All previous
adhesive must be removed.
8. Chase the threads with a 5-40 tap (Model 55-260) or 8-32 tap
(Model 36-260) and rinse with lacquer thinner or tri-chlor. Dry the threads
before installing the capscrews.
9. Install the inlet poppet in the poppet housing.
A.
Position the poppet housing on the check tube, being careful to make
sure it is centered.
B.
From thread lock kit, install the applicator needle on the adhesive
container. Fill the screw holes from the bottom up until the cavity is
filled with adhesive.
C.
Using new capscrews, apply a liberal amount of activator to the screw
threads. Install the screws and torque to 22–25 lb•in (2.5–2.8 N•m).
Allow sufficient time for adhesive to cure thoroughly (8 hours
minimum).
10. Unthread the poppet body from the check tube. Remove and inspect the
check seat, high pressure poppet, and check spring. Replace or lap as
required.
11. Slide the check spring onto the stem of the high pressure poppet. Carefully
insert the high pressure poppet and check spring into the poppet body.
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Service
Intensifier Pump
12. Apply Precision Lube liberally to the
tapered surfaces of check seat (try to
keep the flat surfaces clean) and insert
into the check tube with the coned side
toward the poppet.
Check
Seat
Poppet
Check
Spring
13. Apply Precision Lube to the tapered surface of the check tube. Install the
check tube in the high pressure end cap.
14. Apply Precision Lube to the inner surface of the gland coupling. Slide the
gland coupling over the check tube, aligning the gland coupling port with
the water entry port in the check tube.
15. Slide the high pressure end cap over the tie rods and press onto the high
pressure cylinder. Verify the check tube port and gland coupling point
downward as shown on the drawing so the inlet water line can be connected
properly.
16. Lubricate the tie rod threads with high pressure grease. Notice that the hex
nuts have markings on one side. These markings must face outward when
the nuts are installed. Thread the nuts onto the tie rods and tighten finger
tight.
17. Tighten the nuts alternately in an "X" pattern to apply pressure evenly.
Torque to 275 lb•ft (339 N•m), advancing in increments of 25 lb•ft
(34 N•m). Start each adjustment increment at a different nut.
18. Apply Precision Lube to the threads of the poppet body. Thread the poppet
body into the check tube and tighten securely.
19. Reconnect the water input line to the check tube and reconnect the UHP
tubing to the poppet body.
Inspect the assembly and verify that all parts are accounted for and all
connections are properly tightened.
20. Start the equipment. Verify proper operation with no leakage.
Service
75
Intensifier Pump
Lapping the Poppet
Proper operation of the poppet assemblies in the intensifier requires clean,
smooth metal-to-metal surfaces. Slight corrosion or wear can sometimes be
removed by lapping to save replacing with new parts.
Required equipment
Procedure:
•
Lapping plate (part number 28523)
•
Lapping compound (part number 9686)
•
Lapping paper (part number 29524)
•
Nonflammable solvent
1. The faces of the check tube, the low pressure inlet poppet, and the poppet
body should be totally smooth; a mirror finish is desirable.
2. Apply compound liberally to the lapping plate. Rest the part on the plate.
While applying light downward pressure, rub the part around in small
circles, alternating with a figure-eight pattern.
Note
Use a figure 8 pattern when lapping.
3. Clean and inspect the surface frequently. If the compound becomes dry, add
a few drops of light oil or water to moisten.
4. Repeat the procedure, cleaning and inspecting frequently. When the surface
is bright, clean the surface with solvent and dry with shop air. Finish final
polishing with lapping paper. Ensure no traces of compound remain in water
channels and screw holes.
5. The mating areas of the high pressure poppet and the poppet seat must have
smooth face-to-face surfaces. Corrosion, erosion, and scoring prevent a tight
seal and permit water leakage. Extensive damage cannot be repaired;
replace the parts.
6. Apply compound liberally to the lapping plate. Rest the face of the poppet
seat on the plate. While applying light downward pressure, rub the part
around in small circles, alternating with a figure-eight pattern.
7. Clean and inspect the surface frequently. If the compound becomes dry, add
a few drops of light oil or water to moisten.
8. Repeat the procedure, cleaning and inspecting frequently. When the surface
is bright, clean with solvent and dry with shop air. A mirror finish is not
required, but the surface should not have any deep scratches or nicks.
Ensure no traces of compound remain in the water channel.
9. Repeat the procedure with the poppet. Thoroughly clean and dry all parts
before reassembling in the check tube.
76
Service
Intensifier Pump
Servicing the Bleed Down Valve
Valve failure may be caused by leaking seals, worn needle valve, blocked
hydraulic inlet, or failed solenoid coil. Replacement of individual parts depends
on degree of wear.
Weep hole
Seepage from the top weep hole in the valve body indicates leakage of the water
seal around the needle. Hydraulic fluid seepage indicates a worn seal on the
piston.
Seepage from the lower weep hole indicates the adaptor nut or water line is not
tightened. If the needle/seat assembly is faulty, water flow through the valve does
not stop completely when the valve shifts to direct the water to the tool. Wear of
any needle valve components usually requires replacement of all parts.
Whenever the valve is disassembled, inspect all items for wear and replace as
necessary.
Piston Housing
Valve Mount Ring
Valve Body
Adapter Nut
Capscrews
Diffuser
Weep Hole
Bleed Down Valve
Hydraulic orifice
An orifice is machined in the base of the hydraulic port stamped "P". A blocked
orifice prevents the valve from closing properly. Before taking the valve apart for
repairs, verify the problem is not merely a clogged port. Disconnect the hydraulic
line. Use low-pressure air or stiff fine wire to clear away any debris in the valve
block aperture. Reconnect the line and test for proper operation. Repeated
obstruction indicates contaminated hydraulic fluid. Test the fluid for purity to
prevent equipment damage.
Hydraulic Oriface ”P”
0.031 in (0.787 mm)
Service
77
Intensifier Pump
Replacing the Needle and Seal
While the following procedure removes the bleed down valve from the machine,
this may not be necessary. If clearance permits, it may be possible to unthread the
valve body from the seal backup screw without removing the entire assembly
from its mounting location in the equipment.
Solenoid
Valve
Needle
Bearing
Seal
Needle
Seat
Diffuser
Adapter
Nut
Water Drain
Connection
Cable
Connection
Required equipment
Hydraulic
Connection
•
Seal Backup
Screw
Valve
Body
Inlet Water
Connection
OmniJet repair kit (part number 104497)
The kit includes:
Needle (part number 101843)
Seat (part number 37135)
Seal assembly (part number 37136)
Needle bearing (part number 36826)
Procedure
•
Seal tool (part number 36873)
•
High pressure lubricant (part number 28339)
•
Precision Lube thread lubricant (part number 25750)
•
Nonflammable solvent
1. Remove the bleed down valve assembly.
A.
Disconnect the cable connection.
B.
Disconnect the hydraulic and water lines. When
disconnecting the water drain line, be careful not to drop the
diffuser.
C.
Unthread the four capscrews that attach the valve assembly
to the machine and remove the valve.
2. Hold the assembly upright. Unthread and remove the adaptor nut.
78
Service
Diffuser
Intensifier Pump
3. Tilt the body so the seat drops out of the cavity.
4. Unthread the valve body from the seal backup screw.
5. Insert the small end of the seal tool into the outlet end of the valve body and
press the entire needle, needle bearing and seal out of the valve body.
Inspect all parts and discard worn items.
Needle
Bearing
Seal
Needle
Seal Tool
Valve
Body
6. Clean the valve body and inspect for physical damage.
7. Insert the flat end of the needle into the large end of the seal tool. Stack the
needle bearing and seal on the needle.
8. Apply a light coat of high pressure grease to the entire needle/seal assembly.
Insert the assembly into the valve body. Press inward on the tool until the
assembly is fully seated.
9. Apply Precision Lube to the threads of the seal backup screw. Thread the
screw into the valve body and tighten securely.
10. Holding the body with the outlet end upright, drop the seat into the
bore of the valve body. Be sure the countersunk cavity faces
outward.
11. Apply Precision Lube to the threads of the adaptor nut and thread
into the valve body. Tighten securely.
Seat
12. Install the bleed down valve assembly on the machine. Connect the solenoid
lead. Connect the hydraulic and inlet water lines. Tighten fittings securely.
13. Cavitation can cause the diffuser to wear. Inspect and replace as necessary.
Apply a heavy coat of high pressure grease and insert the diffuser into the
adaptor nut outlet. Connect the water outlet line and tighten securely.
14. Start the machine. Verify the valve shifts and directs water to the tool. Turn
the machine off and verify the valve opens to vent the pressurized water.
Service
79
Intensifier Pump
Replacing the Piston Seal
Piston
Housing
Solenoid
Valve
Piston
Seal
Piston
Actuator
Capscrews Diffuser Adapter
Nut
Water Drain
Connection
Cable
Connection
Hydraulic
Connection
Seal Backup
Screw
Valve
Mount Ring
Inlet Water
Connection
Bleed Down Valve Piston Seal
Required equipment
Procedure
•
Piston seal (part number 28598)
•
High pressure lubricant (part number 28339)
•
Precision Lube thread lubricant (part number 25750)
1. Remove the bleed down valve assembly.
A.
Disconnect the cable connection.
B.
Disconnect the hydraulic and water lines. When
disconnecting the water drain line, be careful not to drop the
diffuser.
C.
Diffuser
Unthread the four capscrews that attach the valve assembly
to the machine and remove the valve.
2. Unthread and remove the four capscrews that attach the valve mount ring to
the piston housing. Separate the two assemblies.
3. Pull the piston out of the piston housing. Remove and discard the seal.
Note
Install the seal on the piston with the flat surface against the piston flange
and the open side outward. If an inner ring is installed within the seal,
remove it; it should not be used.
4. Coat the seal with high pressure grease and install it onto the piston.
Reinstall the piston in the piston housing.
5. Insert the capscrews through the valve mount ring and thread the capscrews
into the piston housing. Tighten alternately to apply pressure evenly until
fully tightened.
80
Service
Intensifier Pump
6. Install the valve assembly on the machine. Connect the solenoid cable
Connect the hydraulic and inlet water lines. Tighten fittings securely.
7. Apply a heavy coat of high pressure grease to the diffuser and insert it into
the adaptor nut. Connect the water outlet line and tighten securely.
8. Start the machine. Verify the valve shifts and directs water to the tool. Turn
the machine off and verify the valve opens to vent the pressurized water.
Service
81
Intensifier Pump
Servicing the Heat Exchanger
In some geographical locations, mineral deposits can collect within the internal
water tubes of the heat exchanger. Scale buildup restricts water passage through
the tubes. As a result not enough water flows through to efficiently cool the
hydraulic fluid as it transits the jacket. If this happens the sensing relays shut the
machine down because hydraulic overheating is detected.
Primary
Heat Exchanger
Secondary
Heat Exchanger
Model 55-50C
Heat Exchanger
Water
Connections
Hydraulic
Connections
Water
Connections
Hydraulic
Connections
Water
Connections
Hydraulic
Connections
To clean, disconnect the fittings and remove the heat exchanger from the
machine. Plug the hydraulic ports to prevent water from entering the outer jacket.
Unthread the screws that attach the end caps to the cylinder and remove the caps.
Scrub the tubes with a suitably sized stiff tubing brush. Flush with plenty of fresh
water after cleaning. Inspect the end cap gaskets and replace as necessary.
Reassemble the unit and reinstall on the machine.
For the Model 55-50C only:
Cleaning the inlet
water strainer
82
Service
The heat exchanger has a series of plates separating layers of water and hydraulic
fluid. A descaling fluid can be flushed through the heat exchanger to remove any
mineral deposits. If the deposits can not be adequately removed, the heat
exchanger must be replaced.
Some units have a 100-mesh strainer in the line that provides water to the
intensifiers. In time, the strainer collects enough debris from the supply line to
become clogged. If this happens the intensifier may overcycle, or a low inlet
pressure warning may be indicated. See “Cleaning the Inlet Water Strainer” on
page 52.
Intensifier Pump
Troubleshooting
The best aid to troubleshooting is familiarity with the machine and its operating
characteristics. Experience will prompt checking of potential problems before
extensive tear down must be done.
Contents
General Troubleshooting Tips
Automatic Shutdown
Weep Holes
84
84
84
Hydraulic Fluid
84
Warning Messages
85
Troubleshooting Chart
Selecting an Orifice Size
86
90
Erratic Cycling
• Check valve failed
• Seal leakage
Hydraulic Leakage
• O-ring failed
• Improper cap torque
Water Leakage
• Seat or cone failed
• Check tube damaged
• Improper torque on high
pressure poppet housing
Water Leakage
• Seal failed
• Cylinder failed
Hydraulic Leakage
• O-ring failed
• Improper tie rod torque
Water Leakage
• Fitting or water line
loose or damaged
• Cracked housing
Over Temperature
• High or low pressure
poppet failed
Hydraulic Leakage
• Rod seal failed
Water Leakage
• Seal failed
• Backup disc failed
• Cylinder failed
Troubleshooting the Intensifier
Troubleshooting
83
Intensifier Pump
General Troubleshooting Tips
Isolate the problem and check the easiest things to correct first. For example, an
apparent fault in the hydraulic system may possibly be solved simply by topping
up a low fluid level.
Eliminate possible causes systematically. Don't skip from place to place hoping
to correct a problem by trial and error. Analyze the fault and check the most
likely possibility first.
Keep a record of maintenance and service on the forms provided. If periodic
maintenance has been overlooked (for example, changing filters), the problem
might be corrected by a simple maintenance procedure.
If one component shows repeated failure, it may indicate a flaw in the component
itself, or previous repairs may have been done incorrectly.
Automatic Shutdown
To protect personnel and equipment, the machine has automatic shutdown
features which activate if a potential problem is not remedied. For example, if the
hydraulic fluid temperature exceeds permissible limits, the electronic controls
shut the machine down. Investigate the problem, starting with possible low fluid
level, and systematically eliminate possible causes.
Occasionally, the electronic circuits may be at fault, rather than the component
each circuit serves. Again, check the simpler things first, such as blown fuses. If
the problem is isolated to controller failure, contact the Jet Edge Service
Department for assistance.
Weep Holes
A loose connection will cause fittings to wear and eventually fail. After
tightening any connectors, check weep holes with the system running under
pressure. Water exiting through a weep hole on a component often indicates worn
seals.
Failure to correct the cause of seepage may result in further damage. For
example, if water seeps from the intensifier connectors the plunger seals may be
worn. If they are not replaced, the seals may fail completely and introduce water
into the hydraulic system.
84
Orifice Selection
Reduced output pressure may be caused by worn components in the intensifier, a
leaking water line to the tool, a leaking water line or fitting in the machine, or a
faulty bleed-down valve. Abrupt pressure loss often indicates that the orifice at
the tool is damaged or blown out. Inspect the tool first, before starting machine
repairs. If the cutting machine has multiple orifices, the combined flow rate may
exceed the intensifier output. See “Selecting an Orifice Size” on page 90 to
determine water supply requirements for an output flow rate.
Hydraulic Fluid
Check the hydraulic fluid level frequently. Leakage at connections and joints is
readily noticeable. Another aspect to check is apparent gain of fluid. This can
happen because the high-pressure seals in the intensifier are worn. Water is
forced past the seal and enters the hydraulic circuit. Another indication of water
in the fluid is a milky or foamy appearance. If water contamination is suspected,
do not operate the machine. Analyze fluid samples to determine if water is
present.
Troubleshooting
Intensifier Pump
Warning Messages
A variety of messages may be displayed on the display if a fault develops. The
fault sounds buzzer and starts flashing the beacon (amber for a warning, red for a
shutdown). Faults are indicated on three levels:
1. Stop motor and intensifier—the fault must be corrected before the
equipment can be restarted.
2. Stop intensifier only—the fault must be corrected before the equipment can
be restarted.
3. Alarms only—the machine keeps running, pressing the toggle push button
initiates a 30-minute bypass to permit correction of minor problems.
Press the Toggle push button to review the indicated fault. Continue scrolling to
display further indications in case there are multiple causes. For example, if the
hydraulic fluid quantity drops below acceptable level, the readouts may indicate
both low level and over temperature condition.
Cause
Check valve over-temperature >150°F/66°C
Response
Level
Warning
3
Warning
Shutdown
Shutdown
3
1
1
Low level Shutdown
Shutdown
1
Return filter bypass
Warning
3
Main motor overload
Shutdown
1
Boost pump overload
Warning
3
Charge pump filter clogged
Warning
3
Charge pump pressure low <250 psi/17 bar
Shutdown
1
Warning
Shutdown
3
2
Bleed-down over-temperature >150°F/66°C
Warning
3
Intensifier overcycle
Shutdown
1
PLC fault
Shutdown
1
Low PLC battery
Warning
3
Main motor anti-recycle
(motor cycled 6 times in 30 minutes)
Warning
3
Host alive
(Genius communication) No error message
Shutdown
1
Hydraulic oil over-temperature
>150°F (65°C)
>185°F (85°C)
Low Level
Low incoming water pressure
<60 psi/4 bar
<40 psi/3 bar
Troubleshooting
85
Intensifier Pump
Troubleshooting Chart
The troubleshooting chart is a general guide to solving the most common
problems; it is not intended to be comprehensive of every possible situation that
may develop.
Problem
Intensifier over temperature
displayed
Hydraulic filter excessive
pressure drop displayed
Hydraulic fluid low level
displayed
Hydraulic pump not running
properly
Cause
Leakage of high pressure water
seals
Check seal housing for water seals
for excessive heat. Replace seals as
required
Leakage around poppet/poppet
seal
Check valve body for excessive
heat. Replace poppet and seat as
required
Temp sensor failure
Check for continuity and replace as
required
Open wiring from 24 VDC to
sensor, or from sensor to input
module
Check wiring and repair as
required
Input module failure
Replace module
Filter is clogged
Replace filter
Pressure differential sensor failed
Check for continuity and replace as
required
Open wiring from 24 VDC to
sensor, or from sensor to input
module
Check wiring and repair as
required
Input module failure
Replace module
Low fluid level
Add fluid to tank
Hydraulic leak
Check all lines, connections, and
fittings and repair as required. Top
up fluid level
Level sensor failure
Check continuity and replace as
required
Input module failure
Replace module
Faulty pump
Replace pump
Contaminated fluid
Replace with fresh fluid
Output module failure
(The output modules have internal
Check for voltage (0 to 10 volts
depending on pressure setting).
Replace module if failed
fuses. If a fuse fails, an LED on the
module comes on.)
Servovalve failure
86
Troubleshooting
Remedy
Replace valve
Intensifier Pump
Problem
Hydraulic over temperature
Overcycling intensifier
Cause
Remedy
Sensor failure
Verify actual excessive
temperature. Replace sensor if
failed
Open wiring from 24 VDC to
sensor, or from sensor to input
module
Check wiring and repair as
required
Input module failure
Replace module
Cooling water temperature too
high
Check water temperature; should
not be above 70°F (21°C)
Inadequate coolant water supply
Check for leaking lines; Make sure
initial supply is adequate
Inlet water solenoid valve failure
Replace solenoid valve
Room ambient temperature above
100°F (37°C)
Provide additional cooling and/or
ventilation
Heat exchanger tubes clogged
Inspect tubes and clean as required
Water modulating valve failure
Check water flow out of heat
exchanger; replace valve if failed
Water modulating valve
improperly adjusted
Adjust valve setting
Leakage of UHP water to tool
Inspect all lines and fittings;
displayed repair leaks
Inlet poppet sticking
Remove poppet body and check
for free poppet movement. Replace
if faulty
Leaking poppet or poppet seat
Repair or replace
Check valve failed
Inspect check valve for cracks or
leakage caused by loose fittings
Inadequate inlet water supply
Check supply from booster pump.
Supply must be greater than the
water output to the tool
Water flow through orifices greater
than machine can provide
Combined flow rate through
orifices must not be more than the
pump can provide. See “” on
page 92. and calculate
requirements
Inlet strainer clogged
Clean strainer
Troubleshooting
87
Intensifier Pump
Problem
Intensifier cycling erratic: rapid
or sluggish
Intensifier does not cycle
Cannot build or maintain high
pressure
Motor does not start; no display
88
Troubleshooting
Cause
Remedy
High pressure seal leak
Replace seal
Inlet poppet not operating caused
by inadequate water supply
Check inlet supply and pressure
and verify sufficient flow
Booster pump failure
Check and repair
Hydraulic piston seal in intensifier
failed
Contact Jet Edge service
department
Proximity switch failed or out of
adjustment
Check switches; readjust or replace
Proximity switch or actuator failed
or out of adjustment
Inspect and readjust or replace
Open wiring between output
module and water inlet solenoid
valve, or between valve and neutral
side of 15 VAC
Check wiring; repair or replace as
required
Output module fuse blown
Replace fuse
Output module failure
Replace module
Hydraulic seal in intensifier
leaking
Listen for high-pitch squeal
indicating leakage. Also check
cylinder heat; excessive heat
indicates leakage. If seal is leaking
contact the Jet Edge service
department
Faulty hydraulic pump
compensator
Refer to pump manual
Leakage in high pressure poppet
Check for heat; excessive heat
indicates leaking. Repair poppet
Inlet strainer clogged
Clean strainer
Main power off or circuit breaker
tripped
Restore power
CPU card failure
Check LED lights on CPU card.
Replace battery if light is on. If
CPU light is on, replace CPU card
Any of fuses F4 - F7 open
Check blown fuse indicator;
replace as required
F8 - F11 2.0 amp power
Check fuse; replace as required
supply fuse open
Intensifier Pump
Problem
Motor does not start; display on
Cause
Remedy
Output module failure
Replace module
Fuse F12 blown
Replace fuse
Thermal overload tripped
Reset overload
Motor starter or contactors failed
Repair or replace
Motor faulty
Replace motor
Failure of lithium battery on CPU
card
Remove card and replace battery
with GE type IC693ACC301
PLC battery failure - alarm sounds
and light at PLC is on
Replace battery
Output module failure
Replace module
Fuse F12 blown
Replace fuse
Open wiring between output
module and pump
Check wiring and repair as
required
Booster pump failure
Refer to booster pump service
manual
Water seepage from attenuator
weep holes
Faulty or cracked seal
Not field repairable; Call Jet Edge
service department
Water output pressure is
appropriate but jet at tool is
weak
Clogged filter in line between
attenuator and tool
Replace filter
Memory loss; requires
reconfiguring after power off
Water booster pump does not
run
Troubleshooting
89
Intensifier Pump
Selecting an Orifice Size
The flow specifications provided are for one orifice. When a multiple-orifice
setup is used, the water flow must be multiplied by the number of orifices. For
example, a manifold using four 0.009 orifices at 25,000 psi requires a flow of
four times 0.267, or 1.068 U.S. gallons per minute. The following lists the flow
rate (US gpm) through an orifice at a given pressure.
Orifice Diameter Flow Rates (GPM)
Orifice
Diameter
(inches)
Pressure (psi) x 1000
20
25
30
35
40
45
50
55
0.003
0.027
0.030
0.033
0.035
0.038
0.040
0.042
0.044
0.004
0.047
0.053
0.058
0.062
0.067
0.071
0.075
0.078
0.005
0.074
0.082
0.090
0.098
0.104
0.111
0.117
0.122
0.006
0.106
0.119
0.130
0.141
0.150
0.159
0.168
0.176
0.007
0.145
0.162
0.177
0.191
0.204
0.217
0.229
0.240
0.008
0.189
0.211
0.231
0.250
0.267
0.283
0.299
0.313
0.009
0.239
0.267
0.293
0.316
0.338
0.359
0.378
0.396
0.010
0.295
0.330
0.361
0.390
0.417
0.443
0.467
0.489
0.011
0.357
0.399
0.437
0.472
0.505
0.536
0.565
0.592
0.012
0.425
0.475
0.520
0.562
0.601
0.637
0.672
0.705
0.013
0.499
0.558
0.611
0.660
0.705
0.748
0.789
0.827
0.014
0.578
0.647
0.708
0.765
0.818
0.868
0.915
0.959
0.015
0.664
0.742
0.813
0.878
0.939
0.996
1.050
1.101
0.016
0.755
0.845
0.925
0.999
1.068
1.133
1.194
1.253
0.017
0.853
0.954
1.045
1.128
1.206
1.279
1.348
1.414
0.018
0.956
1.069
1.171
1.265
1.352
1.434
1.512
1.586
0.019
1.065
1.191
1.305
1.409
1.507
1.598
1.684
1.767
0.020
1.180
1.320
1.446
1.562
1.669
1.771
1.866
1.957
0.021
1.301
1.455
1.594
1.722
1.840
1.952
2.058
2.158
0.022
1.428
1.597
1.749
1.889
2.020
2.142
2.258
2.369
0.023
1.561
1.745
1.912
2.065
2.208
2.342
2.468
2.589
0.024
1.700
1.900
2.082
2.249
2.404
2.550
2.688
2.819
0.025
1.844
2.062
2.259
2.440
2.608
2.767
2.916
3.059
0.026
1.995
2.230
2.443
2.639
2.821
2.992
3.154
3.308
90
Troubleshooting
Intensifier Pump
Orifice Diameter Flow Rates (GPM)
Orifice
Diameter
(inches)
Pressure (psi) x 1000
20
25
30
35
40
45
50
55
0.027
2.151
2.405
2.635
2.846
3.042
3.227
3.402
3.568
0.028
2.314
2.587
2.834
3.061
3.272
3.470
3.658
3.837
0.029
2.482
2.775
3.040
3.283
3.510
3.723
3.924
4.116
0.030
2.656
2.969
3.253
3.513
3.756
3.984
4.199
4.404
0.031
2.836
3.171
3.473
3.752
4.011
4.254
4.484
4.703
0.032
3.022
3.379
3.701
3.998
4.274
4.533
4.778
5.011
0.033
3.214
3.593
3.936
4.251
4.545
4.821
5.081
5.329
0.034
3.411
3.814
4.178
4.513
4.824
5.117
5.394
5.657
Orifice Diameter Flow Rates (L/min)
Orifice
Diameter
(inches)
Pressure (bar)
1400
1800
2200
2600
3000
3400
3800
0.003
0.101
0.115
0.127
0.138
0.148
0.158
0.167
0.004
0.180
0.204
0.226
0.245
0.264
0.281
0.297
0.005
0.281
0.319
0.353
0.383
0.412
0.438
0.464
0.006
0.405
0.459
0.508
0.552
0.593
0.631
0.668
0.007
0.551
0.625
0.691
0.752
0.807
0.859
0.909
0.008
0.720
0.817
0.903
0.982
1.054
1.123
1.187
0.009
0.912
1.034
1.143
1.242
1.334
1.421
1.502
0.010
1.125
1.276
1.411
1.534
1.648
1.754
1.854
0.011
1.362
1.544
1.707
1.856
1.994
2.122
2.244
0.012
1.621
1.838
2.032
2.209
2.372
2.526
2.670
0.013
1.902
2.157
2.384
2.592
2.784
2.964
3.134
0.014
2.206
2.501
2.765
3.006
3.229
3.438
3.634
0.015
2.532
2.871
3.174
3.451
3.707
3.946
4.172
0.016
2.881
3.267
3.612
3.926
4.218
4.490
4.747
0.017
3.253
3.688
4.077
4.433
4.761
5.069
5.359
0.018
3.647
4.135
4.571
4.969
5.338
5.683
6.008
0.019
4.063
4.607
5.093
5.537
5.948
6.332
6.694
0.020
4.502
5.105
5.643
6.135
6.590
7.016
7.417
Troubleshooting
91
Intensifier Pump
Orifice Diameter Flow Rates (L/min)
Orifice
Diameter
(inches)
Pressure (bar)
1400
1800
2200
2600
3000
3400
3800
0.021
4.963
5.628
6.222
6.764
7.266
7.735
8.177
0.022
5.447
6.177
6.829
7.423
7.974
8.489
8.974
0.023
5.954
6.751
7.463
8.114
8.715
9.278
9.809
0.024
6.483
7.351
8.127
8.834
9.490
10.103
10.680
0.025
7.034
7.976
8.818
9.586
10.297
10.962
11.589
0.026
7.608
8.627
9.537
10.368
11.137
11.857
12.535
0.027
8.205
9.303
10.285
11.181
12.010
12.786
13.517
0.028
8.824
10.005
11.061
12.025
12.917
13.751
14.537
0.029
9.465
10.733
11.865
12.899
13.856
14.750
15.594
0.030
10.129
11.485
12.698
13.804
14.828
15.785
16.688
0.031
10.816
12.264
13.558
14.739
15.833
16.855
17.819
0.032
11.525
13.068
14.447
15.706
16.871
17.960
18.987
0.033
12.256
13.897
15.364
16.703
17.942
19.100
20.193
0.034
13.010
14.752
16.309
17.730
19.045
20.275
21.435
Orifice Color Coding
92
Troubleshooting
Orifice mounts are marked with color coding to help keep inventory separated.
The mounts are colored in 0.010" stages. The larger sizes 0(.041 to 0.045) are
normally obtained by special order only and are not color-marked.
Black
0.006, 0.016, 0.026, 0.036
White
0.007, 0.017, 0.027, 0.037
Blue
0.008, 0.018, 0.028, 0.038
Yellow
0.009, 0.019, 0.029, 0.039
Green
0.010, 0.020, 0.030, 0.040
Silver
0.011, 0.021, 0.031
Gold
0.012, 0.022, 0.032
Pink
0.003, 0.013, 0.023, 0.033
Orange
0.004, 0.014, 0.024, 0.034
Red
0.005, 0.015, 0.025, 0.035