KTM STREAMLINE L-IV 50 Operation manual

Printed: 12/02/04 80081573.doc

STREAMLINE HIGH PRESSURE

WATERJET PUMP

OPERATION and SERVICE MANUAL

SL-IV 50

HSEC

230V

Manual No. 80082837

20417320

11-2004/Rev 0

NOTICE

This document contains subject matter in which KMT Waterjet Systems has

proprietary rights. Recipients of this document shall not duplicate, use or disclose

information contained herein, in whole or in part, for other than the purpose for

which this manual was provided.

KMT Waterjet believes the information described in this manual to be accurate and

reliable. Much care has been taken in its preparation; however, the Company cannot

accept any responsibility, financial or otherwise, for any consequences arising out of

the use of this material. The information contained herein is subject to change, and

revisions may be issued advising of such changes and/or additions.

KMT WATERJET SYSTEMS 2004

KMT Waterjet Systems

635 West 12th Street

POB 231

Baxter Springs, KS 66713-0231

Phone:

Fax: (800) 826-9274

(620) 856-5050

20417320

11-2004/Rev 0 i

TABLE OF CONTENTS

Title Page

Notice

Table of Contents

Appendix

Section Page

1Introduction......................................................................................................1-1

1.1 Overview...............................................................................................1-1

1.2 Performance Features and Options.......................................................1-1

1.3 Product Nameplate................................................................................1-2

1.4 Operational Overview...........................................................................1-2

Low Pressure Water System.................................................................1-2

Recirculation System ............................................................................1-3

Hydraulic System..................................................................................1-3

High Pressure Water System ................................................................1-3

Operating System..................................................................................1-4

1.5 Safety ....................................................................................................1-5

Lockout/Tagout Procedure....................................................................1-5

Warning Labels.....................................................................................1-6

Emergency Medical Treatment.............................................................1-8

1.6 Worldwide Product Support .................................................................1-9

1.7 Spare Parts ............................................................................................1-9

1.8 Manual Organization ............................................................................1-9

1.9 Equipment and Service Manual Questionnaire.....................................1-10

2Installation........................................................................................................2-1

2.1 Overview...............................................................................................2-1

2.2 Installation Summary............................................................................2-1

2.3 Site Requirements.................................................................................2-2

Transporting..........................................................................................2-3

2.4 Power Requirements.............................................................................2-3

2.5 Service Connections..............................................................................2-4

Cooling Water.......................................................................................2-5

Cutting Water........................................................................................2-6

Drain .....................................................................................................2-6

Plant Air................................................................................................2-6

2.6 Flow Requirements...............................................................................2-6

2.7 High Pressure Piping.............................................................................2-7

Measurements and Dimensions ............................................................2-9

Hand Coning.........................................................................................2-10

Power Coning........................................................................................2-11

Hand Threading ....................................................................................2-12

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11-2004/Rev 0 ii

Power Threading...................................................................................2-12

2.8 High Pressure Connections...................................................................2-13

Standard Connections ...........................................................................2-13

Anti-Vibration Connections..................................................................2-14

2.9 Commissioning.....................................................................................2-15

2.10 Decommissioning .................................................................................2-18

3Maintenance .....................................................................................................3-1

3.1 Overview...............................................................................................3-1

3.2 Maintenance..........................................................................................3-1

Daily Inspection....................................................................................3-1

Periodic Maintenance............................................................................3-1

High Pressure System Maintenance......................................................3-2

3.3 Maintenance Precautions ......................................................................3-3

4Operation..........................................................................................................4-1

4.1 Overview...............................................................................................4-1

4.2 Startup Sequence...................................................................................4-1

Startup after Motor Stop .......................................................................4-1

Startup after Emergency Stop...............................................................4-1

4.3 Main Menu............................................................................................4-2

4.4 Run Screen............................................................................................4-2

4.5 Run Screen Alarms...............................................................................4-3

4.6 Alarm Banners......................................................................................4-5

4.7 Alarm History .......................................................................................4-7

Changing the Date and Time ................................................................4-7

4.8 Set-Up Screen .......................................................................................4-8

4.9 Stroke Rate Screen................................................................................4-8

4.10 Hours Screen.........................................................................................4-9

4.11 Maintenance Screen..............................................................................4-10

4.12 Language Screen...................................................................................4-11

5Low Pressure Water System...........................................................................5-1

5.1 Overview...............................................................................................5-1

5.2 Cutting Water Supply Quality ..............................................................5-1

5.3 Operation...............................................................................................5-1

5.4 System Options.....................................................................................5-2

Operation with Optional Booster Pump and Water Filter ....................5-2

5.5 Service and Maintenance Procedures ...................................................5-4

Filter Assembly and Strainer Maintenance...........................................5-4

Booster Pump Adjustment....................................................................5-5

6Recirculation System .......................................................................................6-1

6.1 Overview...............................................................................................6-1

6.2 Operation...............................................................................................6-2

6.3 Service and Maintenance Procedures ...................................................6-3

Hydraulic Oil Maintenance...................................................................6-3

Oil Filter Maintenance..........................................................................6-6

Operating Temperature Adjustment .....................................................6-6

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11-2004/Rev 0 iii

7Hydraulic System.............................................................................................7-1

7.1 Overview...............................................................................................7-1

7.2 Operation...............................................................................................7-2

7.3 Service and Maintenance Procedures ...................................................7-3

Hydraulic Operating Pressure...............................................................7-4

Motor Maintenance...............................................................................7-5

Flexible Coupling Replacement............................................................7-6

Hydraulic Compensator Maintenance...................................................7-8

Hydraulic Pump or Electric Motor Replacement..................................7-11

8Electrical System..............................................................................................8-1

8.1 Overview...............................................................................................8-1

8.2 Operation...............................................................................................8-1

Sensors and Solenoids...........................................................................8-4

8.3 Service and Maintenance Procedures ...................................................8-8

Proximity Switch Maintenance.............................................................8-8

Optical Relay Maintenance...................................................................8-9

9High Pressure Water System ..........................................................................9-1

9.1 Overview...............................................................................................9-1

9.2 Operation...............................................................................................9-2

9.3 System Components..............................................................................9-4

9.4 Service and Maintenance Overview .....................................................9-5

Torque Specifications ...........................................................................9-6

Specialized Maintenance Tools ............................................................9-8

9.5 High and Low Pressure Water Piping...................................................9-9

9.6 High Pressure Cylinder Assembly........................................................9-9

High Pressure Cylinder Assembly Removal.........................................9-10

High Pressure Cylinder Assembly Installation.....................................9-12

High Pressure Cylinder Maintenance ...................................................9-13

9.7 Hard Seal End Caps ..............................................................................9-13

Hard Seal End Cap Removal ................................................................9-13

Hard Seal End Cap Installation.............................................................9-14

9.8 Sealing Head.........................................................................................9-15

High Pressure Discharge Check Valve.................................................9-15

Low Pressure Inlet Check Valve...........................................................9-17

Sealing Head Maintenance ...................................................................9-18

9.9 High Pressure Seal Assembly...............................................................9-19

9.10 Hydraulic Cartridge Seal Replacement.................................................9-21

Hydraulic Cartridge Seal.......................................................................9-22

9.11 Hydraulic Piston and Plungers..............................................................9-24

Hydraulic Piston and Plunger Removal................................................9-25

Bearing Rings and Seal Assembly........................................................9-26

Plunger Maintenance ............................................................................9-27

Hydraulic Piston and Plunger Installation ............................................9-28

9.12 Hydraulic Cylinder Maintenance..........................................................9-29

9.13 High Pressure Attenuator......................................................................9-29

9.14 High Pressure Dump Valve ..................................................................9-29

Pneumatic Control Valve......................................................................9-31

20417320

11-2004/Rev 0 iv

Pneumatic Actuator...............................................................................9-34

9.15 Weep Holes...........................................................................................9-35

10 Troubleshooting ...............................................................................................10-1

10.1 Overview...............................................................................................10-1

10.2 Troubleshooting Guide .........................................................................10-2

11 Specifications....................................................................................................11-1

11.1 Overview...............................................................................................11-1

11.2 Installation Specifications.....................................................................11-1

Environment..........................................................................................11-1

Sound Level..........................................................................................11-1

Equipment Dimensions and Weights....................................................11-2

Service Connections..............................................................................11-2

11.3 Water Specifications.............................................................................11-2

Cutting Water Supply ...........................................................................11-2

Recirculation System ............................................................................11-3

Water Quality Standards.......................................................................11-3

11.4 Electrical Specifications........................................................................11-6

Electrical System ..................................................................................11-6

Ampacity and Power Voltage Requirements........................................11-6

11.5 Hydraulic and High Pressure System Specifications............................11-6

Hydraulic System..................................................................................11-6

High Pressure Water System ................................................................11-7

Orifice Capacity....................................................................................11-7

Torque Specifications ...........................................................................11-9

12 Parts List...........................................................................................................12-1

12.1 Overview...............................................................................................12-1

12.2 Part Nomenclature ................................................................................12-2

12.3 Index .....................................................................................................12-3

APPENDIX

Exhibit

System Schematic

Electrical Schematic

Material Safety Data Sheets

SECTION 1

INTRODUCTION

Page 1-1 49831878

1SL-IV Waterjet Pump General Information

The Streamline SL-IV Waterjet Pump, maintains the level of component

reliability and ease of installation and maintenance that have made the

Streamline waterjet pumps the standard of the industry for both water and

Hydrobrasive™ applications.

The SL-IV Waterjet Pump uses low pressure water, which meets certain quality

requirements, and increases the pressure up to 4,136 bar (60,000 psi) for ultra-

high–pressure waterjet cutting, hydrobrasive cutting, cleaning, surface

preparation, etc.

This manual provides information for installation, operation, and maintenance

of the SL-IV Waterjet Pump.

Basic configurations of SL-IV intensifier pumps discussed in this manual are

listed in Table 1-1 below.

TABLE 1-1. Model Data- SL-IV Waterjet Intensifier Pumps

Motor

Horsepower

Rating

Plunger Quantity

and Diameter

(inches)

Hp Kw

Intensifier

Model HP Water

Max Oper

Pressure

(psi)

7/8

(0.875”)

[22 mm]

1-1/8

(1.125”)

[29 mm]

Frame

Dim “L”

(inches)

Redundant

Option

Available?

30 22 SL-IV 30+ 2 - 67.75 Yes

50 37 SL-IV 50+ 2 - 67.75 Yes

60 45 SL-IV 60+ 2 - 77.75 Yes

75 56 SL-IV 75+ - 2 77.75 Yes

100 75 SL-IV

100D

4 - 77.75 No

100 75 SL-IV 100S

60,000

- 2 77.75 Yes

1.1 Physical Description

The waterjet pump is equipped with one or two hydraulically operated

intensifiers, one or two liters of high pressure attenuator volume, a

motor/hydraulic pump assembly, an electric starter panel, control sensors,

solenoids and logic, control interface panel, a low pressure water booster pump,

and a low pressure water filter.

The high pressure system is conveniently mounted on a drip pan. All service

components are easily accessible from at least two sides simplifying

maintenance. The entire high pressure system can be removed from the rest of

the unit quickly for maintenance and serviceability.

SECTION 1

INTRODUCTION

Page 1-2 49831878

1.1.1 Standard Equipment

Following is an overview of the standard equipment for the SL-IV Waterjet

Pump:

•Variable displacement, pressure compensated hydraulic pump

•Water pressure booster and filtration system with 10-micron double-length

filter

•High efficiency heat exchanger in independent recirculation pump circuit

•Stand-alone unit with built-in motor starter (wye delta or across the line).

•High pressure safety dump valve

•Dual pressure compensator

•1 or 2 liters of high pressure attenuator volume

•Microprocessor control with diagnostic capability

•Water inlet shut-off valve

•Booster pump

•Integral water and oil drip pans

•Electrical remote control interface

SECTION 1

INTRODUCTION

Page 1-3 49831878

1.2 Functional Description

The SL-IV Waterjet Pump meets the automotive and industrial markets needs of

low to high volume production of water jet pumps. The maximum HP water

pressure is limited by a hydraulic relief valve that is factory certified and sealed.

No HP rupture disk is required.

HP water is produced by an intensifier consisting of two HP water cylinders

mounted to a hydraulic cylinder. Ceramic plungers (2 per intensifier) attach to

the hydraulic piston and extend into each HP cylinder. With two intensifiers

mounted on one SL-IV frame, both may operate simultaneously (dual) or one

may serve as stand-by for the other (redundant). Piston travel is sensed

electronically by proximity switches which control hydraulic flow to/from the

double-acting hydraulic piston/cylinder.

Refer to Table 1-2 for HP water performance limits for various power levels of

SL-IV waterjet pumps.

TABLE 1-2 HP WATER PERFORMANCE-

SL-IV WATERJET INTENSIFIER PUMPS

55,000 psi 60,000 psi

Horsepower Orifice Size

(inches)

Flow Rate

(gpm)

Orifice Size

(inches)

Flow Rate

(gpm)

30 0.011 0.60 0.010 0.52

50 0.014 0.98 0.013 0.88

60 0.015 1.12 0.014 1.02

75 0.017 1.44 0.016 1.33

100 0.020 2.00 0.019 1.88

The recirculation hydraulic loop for cooling and filtering oil runs continuously

whenever the motor is running.

1.2.1 Functional Features

Following is a list of SL-IV Waterjet Pump features:

•4,136 bar (60,000 psi) operating pressure

•Electronic reversing

•24 vdc safety control

•Standard high pressure water leak detection

•Standard dual pressure control facilitates hole piercing and kiss cut

applications

•Exclusive long slow stroke

•Cartridge type hydraulic seal

•Low pressure water booster pump and filtration

•Reduced cooling water requirements

•Choice of English, German, Spanish, Swedish and Italian readouts as

standard

•Meets CE requirements

SECTION 1

INTRODUCTION

Page 1-4 49831878

1.3 Worldwide Product Support

The KMT Waterjet Systems Service Department serves the customer, by

providing:

•Supervision of equipment installation, start up, and training for the number

of days specified in the quotation, and per approved project. Additional time

requested will be invoiced on a per diem basis, plus travel and normal living

expenses.

•Field Services: on-site technical support is available on request. These

services are invoiced on a per diem basis, plus travel, and normal living

expenses.

•Technical Assistance: the Service Department is available for technical

assistance by phone.

•Training: the Service Department conducts periodic training sessions at

KMT Waterjet designated training locations. On-site training is also

available.

1.3.1 Service Department

To contact the KMT Waterjet Service Department:

USA: Customer Service Manager Europe: Technical Manager

KMT Waterjet Systems KMT Waterjet Systems GmbH

P.O. Box 231 Wasserstrahl–Schneidetechnik

635 West 12th Street Auf der Laukert 11

Baxter Springs, KS 66713 D–61231 Bad Nauheim

USA Germany

Phone: (620) 856–2151 Phone: 49–(0)6032–997–117

Fax: (620) 856–5050 Fax: 49–(0)6032–997–270

Email: [email protected] Email: order.service@kmt-waterjet.com

1.3.2 Spare Parts

KMT Waterjet maintains a well stocked Spare Parts Department staffed by well

trained knowledgeable personnel. Emergency shipment is available.

Contact the Customer Service Department of KMT Waterjet.

1.3.3 Questionnaire

The following equipment and service manual questionnaire will provide

information to allow us to serve you better. Please complete them at your

convenience and return to the applicable Customer Service Department as

shown above.

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