Echion™

Operator Manual

810770 – REVISION 3
ENGLISH
HyPrecision, Echion, and Hypertherm are trademarks of Hypertherm, Inc. and may be registered in the United States and other
countries. All other trademarks are the property of their respective holders.

Environmental stewardship is one of Hypertherm’s core values, and it is critical to our success and our customers’ success. We
are striving to reduce the environmental impact of everything we do. For more information: www.hypertherm.com/environment.

© 2020 Hypertherm, Inc.

 Echion

Operator Manual

810770
REVISION 3

ENGLISH
Original instructions

June 2020

Hypertherm, Inc.
Hanover, NH 03755 USA
www.hypertherm.com
Hypertherm, Inc. Hypertherm Europe B.V.
Etna Road, P.O. Box 5010 Vaartveld 9, 4704 SE
Hanover, NH 03755 USA Roosendaal, Nederland
603-643-3441 Tel (Main Office) 31 165 596907 Tel
603-643-5352 Fax (All Departments) 31 165 596901 Fax
[email protected] (Main Office Email) 31 165 596908 Tel (Marketing)
800-643-9878 Tel (Technical Service) 31 (0) 165 596900 Tel (Technical Service)
[email protected] (Technical Service Email)
00 800 4973 7843 Tel (Technical Service)
800-737-2978 Tel (Customer Service) [email protected]
[email protected] (Customer Service Email)
(Technical Service Email)
866-643-7711 Tel (Return Materials Authorization)
877-371-2876 Fax (Return Materials Authorization) Hypertherm (Shanghai) Trading Co., Ltd.
[email protected] (RMA email) B301, 495 ShangZhong Road
Shanghai, 200231
Hypertherm México, S.A. de C.V. PR China
Avenida Toluca No. 444, Anexo 1, 86-21-80231122 Tel
Colonia Olivar de los Padres 86-21-80231120 Fax
Delegación Álvaro Obregón 86-21-80231128 Tel (Technical Service)
México, D.F. C.P. 01780 [email protected]
52 55 5681 8109 Tel (Technical Service Email)
52 55 5683 2127 Fax
[email protected] (Technical Service Email) South America & Central America: Hypertherm Brasil Ltda.
Rua Bras Cubas, 231 – Jardim Maia
Hypertherm Plasmatechnik GmbH Guarulhos, SP – Brasil
Sophie-Scholl-Platz 5 CEP 07115-030
63452 Hanau 55 11 2409 2636 Tel
Germany [email protected] (Technical Service Email)
00 800 33 24 97 37 Tel
00 800 49 73 73 29 Fax Hypertherm Korea Branch
31 (0) 165 596900 Tel (Technical Service) #3904. APEC-ro 17. Heaundae-gu. Busan.
00 800 4973 7843 Tel (Technical Service) Korea 48060
[email protected] (Technical Service Email) 82 (0)51 747 0358 Tel
82 (0)51 701 0358 Fax
Hypertherm (Singapore) Pte Ltd. [email protected] (Marketing Email)
82 Genting Lane [email protected]
Media Centre (Technical Service Email)
Annexe Block #A01-01
Singapore 349567, Republic of Singapore Hypertherm Pty Limited
65 6841 2489 Tel GPO Box 4836
65 6841 2490 Fax Sydney NSW 2001, Australia
[email protected] (Marketing Email)
61 (0) 437 606 995 Tel
[email protected] (Technical Service Email) 61 7 3219 9010 Fax
[email protected] (Main Office Email)
Hypertherm Japan Ltd. [email protected]
Level 9, Edobori Center Building (Technical Service Email)
2-1-1 Edobori, Nishi-ku
Osaka 550-0002 Japan Hypertherm (India) Thermal Cutting Pvt. Ltd
81 6 6225 1183 Tel A-18 / B-1 Extension,
81 6 6225 1184 Fax Mohan Co-Operative Industrial Estate,
[email protected] (Main Office Email)
Mathura Road, New Delhi 110044, India
[email protected] (Technical Service Email) 91-11-40521201/ 2/ 3 Tel
91-11 40521204 Fax
[email protected] (Main Office Email)
[email protected]
(Technical Service Email)

For training and education resources, go to the Hypertherm Cutting Institute (HCI) online at www.hypertherm.com/hci.

Hypertherm products are designed and manufactured with a commitment to continuous quality control and safety. Contact
a Hypertherm Technical Service Associate for information and support regarding the installation, operation, maintenance,
and repair of this equipment.
 Contents

Warranty.............................................................................................................................. SC-11
Waterjet product warranty ........................................................................................................................ SC-12
Disclaimer ..................................................................................................................................................... SC-12

Product stewardship ......................................................................................................... SC-13

National and local safety regulations...................................................................................................... SC-14
Certification test marks.............................................................................................................................. SC-14
Differences in national standards ............................................................................................................ SC-15
Higher-level systems .................................................................................................................................. SC-16

Environmental stewardship.............................................................................................. SC-17

Hypertherm products: waste and recycling.......................................................................................... SC-18
Chemical handling and usage.................................................................................................................. SC-19
Particle emission and waste water quality ............................................................................................ SC-20

Safety................................................................................................................................... SC-21
Manuals ......................................................................................................................................................... SC-22
User qualification and training.................................................................................................................. SC-23
Emergency medical information and treatment.................................................................................... SC-24
Safety information for operation, maintenance, repair, and installation .......................................... SC-25
 Contents

Symbols and marks ........................................................................................................... SC-29

Information and symbols............................................................................................................................ SC-30
Symbols and marks found on the equipment ....................................................................................... SC-31

1 Optional equipment ................................................................................................................. 35

2 Operation.................................................................................................................................... 37
Safety..................................................................................................................................................................... 38
About the controls .............................................................................................................................................. 38
Operation panel....................................................................................................................................... 38
Operator interface................................................................................................................................... 39
Turn on the pump: beginning of day ............................................................................................................... 41
Inspect the pump .................................................................................................................................... 41
Check the hydraulic fluid ....................................................................................................................... 43
Turn on the utilities .................................................................................................................................. 44
Turn on the controls ................................................................................................................................ 44
Start the pump ......................................................................................................................................... 45
Do the preoperation maintenance checks......................................................................................... 46
Operate the pump............................................................................................................................................... 49
Select the pressure mode..................................................................................................................... 49
Set the target water pressure .............................................................................................................. 49
Stop the pump ..................................................................................................................................................... 50
Stop the pump remotely ........................................................................................................................ 50
Stop the pump locally ............................................................................................................................ 50
Emergency stop....................................................................................................................................... 51
Turn off the pump: end of day .......................................................................................................................... 52

3 Preventive maintenance .......................................................................................................... 53

Safety..................................................................................................................................................................... 54
Benefits of preventive maintenance................................................................................................................ 55
Training .................................................................................................................................................................. 55
Operator interface: Maintenance screens..................................................................................................... 56
Move the plunger..................................................................................................................................... 56
Start the pump after maintenance....................................................................................................... 57
Prepare for storage................................................................................................................................. 57
Inputs and outputs .................................................................................................................................. 58
Alarm log ................................................................................................................................................... 58
 Contents

Tools ....................................................................................................................................................................... 59
Preventive maintenance schedule................................................................................................................... 60
Intensifier............................................................................................................................................................... 62
Repair the hydraulic center section .................................................................................................... 65
Repair the high-pressure cylinder, the check valve, and the low-pressure poppet ................ 66
Install the high-pressure components ................................................................................................ 69
Examine the output adapter and the high-pressure poppet assembly....................................... 73
Assemble the check valve and the low-pressure poppet .............................................................. 74
Repair the bleed-down valve............................................................................................................................ 75
Clean the air cooler ............................................................................................................................................ 78
Clean the air side of the cooler............................................................................................................ 78
Clean the hydraulic fluid side of the cooler....................................................................................... 79
Replace the water filter...................................................................................................................................... 80
Test the total dissolved solids (TDS) level .................................................................................................... 81
Test the water quality.............................................................................................................................. 83
Replace the hydraulic filter element................................................................................................................ 84
Add hydraulic fluid .................................................................................................................................. 85
Replace the hydraulic fluid................................................................................................................................ 86
Lubricate the primary motor bearings............................................................................................................. 88
Start the pump after maintenance................................................................................................................... 90
Postmaintenance start procedure ....................................................................................................... 91
Prepare for storage............................................................................................................................................. 93
Recycling and end of product life ................................................................................................................... 96

4 Parts lists................................................................................................................................... 97
Tools ....................................................................................................................................................................... 98
Intensifier repair tools ............................................................................................................................. 99
Maintenance and repair kits............................................................................................................................ 100
Optional equipment kits................................................................................................................................... 103
Replacement parts........................................................................................................................................... 104
Lubricants .............................................................................................................................................. 104
Electrical system.................................................................................................................................... 105
High-pressure water system.............................................................................................................. 106
Low-pressure water system............................................................................................................... 108
Hydraulic system .................................................................................................................................. 109
 Contents

5 Troubleshooting....................................................................................................................... 111
Safety.................................................................................................................................................................. 112
General............................................................................................................................................................... 112
Primary operation screen................................................................................................................................ 113
Alarms ................................................................................................................................................................. 114
Types of alarms ..................................................................................................................................... 114
Primary motor .................................................................................................................................................... 117
Intensifier............................................................................................................................................................ 118
Leaks ....................................................................................................................................................... 118
Overstroke ............................................................................................................................................. 121
Hydraulic fluid ................................................................................................................................................... 123
Temperature........................................................................................................................................... 124
Pressure ................................................................................................................................................. 125
Level ........................................................................................................................................................ 126
Appearance ........................................................................................................................................... 127
Water .................................................................................................................................................................. 128
Low-pressure water............................................................................................................................. 128
High-pressure water............................................................................................................................ 129
Leaks ....................................................................................................................................................... 131
The pump makes noise during operation ................................................................................................... 133
Controller errors ............................................................................................................................................... 134
Input/output status............................................................................................................................... 134

6 Specifications.......................................................................................................................... 135
All Echion-model pumps ................................................................................................................................ 136
Environmental conditions ................................................................................................................... 136
Hydraulic fluid ....................................................................................................................................... 136
Utilities .................................................................................................................................................... 137
Echion 15........................................................................................................................................................... 138
Dimensions and weights .................................................................................................................... 138
Electrical................................................................................................................................................. 138
Water....................................................................................................................................................... 138
Echion 30........................................................................................................................................................... 139
Dimensions and weights .................................................................................................................... 139
Electrical................................................................................................................................................. 139
Water....................................................................................................................................................... 139
Echion 50........................................................................................................................................................... 140
Dimensions and weights .................................................................................................................... 140
Electrical................................................................................................................................................. 140
Water....................................................................................................................................................... 140
 Contents

Orifices ............................................................................................................................................................... 141

Stroke rate ......................................................................................................................................................... 141
Torque values .................................................................................................................................................... 142
Fasteners................................................................................................................................................ 142
Fittings .................................................................................................................................................... 144

7 Installation ............................................................................................................................... 147

Safety.................................................................................................................................................................. 148
Buyer responsibilities ...................................................................................................................................... 148
Requirements .................................................................................................................................................... 149
Location.................................................................................................................................................. 149
Cooling ................................................................................................................................................... 149
Hydraulic fluid ....................................................................................................................................... 149
Utilities .................................................................................................................................................... 150
Receive and unpack the equipment ............................................................................................................ 151
Install the pump ................................................................................................................................................ 152
Install the pump-mounted plumbing kit (optional) ........................................................................ 153
Connect the utilities to the pump ................................................................................................................. 156
Connect the water and the air........................................................................................................... 157
Connect the electrical power ............................................................................................................ 158
Check the hydraulic fluid ................................................................................................................................ 159
Do the first start................................................................................................................................................ 159
Do a preoperation inspection ............................................................................................................ 160
Turn on the utilities ............................................................................................................................... 160
Make sure that the primary motor turns in the correct direction ............................................... 161
Turn on the pump ................................................................................................................................. 162
Adjust the boost pump pressure ...................................................................................................... 162
Flush the pump and the high-pressure tubing .............................................................................. 163
Operator interface: Adjustment screens .................................................................................................... 164
Pump Adjustments............................................................................................................................... 164
Pressure ................................................................................................................................................. 169
Date / Time / Language ...................................................................................................................... 169
Intensifier Control................................................................................................................................. 170
SD Card ................................................................................................................................................. 171

8 Declaration of Conformity ......................................................................................................173

 Contents

9 Touchscreen maps .................................................................................................................. 175

Primary operation screen................................................................................................................................ 177
Adjustment screens......................................................................................................................................... 181
Maintenance screens ...................................................................................................................................... 185

10 Technical drawings................................................................................................................. 189

 Warranty
Warranty

Echion Operator Manual 810770 SC-11

 Warranty

Waterjet product warranty

Warranty

Product Warranty coverage up to

27 months from the ship date,
Echion™ pump
or 24 months from the date of proven installation,
HyPrecision™ pump
or 4,000 hours of operation, whichever occurs first
PowerDredge™ abrasive removal system
EcoSift™ abrasive recycling system
15 months from the ship date,
Reverse osmosis system
or 12 months from the date of proven installation,
Bulk abrasive pot
whichever occurs first
Abrasive regulator
On/off valve air actuator
600 hours of operation with the use of a thimble filter
Diamond orifice and compliance with Hypertherm’s water quality
requirements

Hypertherm’s warranty does not extend to defects, failures, damages, deficiencies, or errors that
are:
 not reported to Hypertherm within the warranty period; or
 the result of modification, abuse, misuse, noncompliance with the installation or operation
instructions, unauthorized repair, inadequate maintenance, neglect, accident, or the use of
unapproved parts; or
 the result of normal wear; or
 the result of the system being operated contrary to Hypertherm’s instructions or stated limits
of rated and normal use.

For information about the manufacturer’s warranty, refer to the conditions of sale provided when the
product was purchased.

Consumable parts are not included in this warranty. Consumable parts include high-pressure water
seals, check valves, cylinders, bleed-down valves, low-pressure seals, high-pressure tubing, and
filters.

All third-party motors, pumps, and plumbing accessories are warrantied by the respective
manufacturers and are not included in this warranty.

Disclaimer

All product information contained in this manual is believed to be reliable as of the date of
publication. The manual could contain technical inaccuracies or typographical errors and can be
changed or updated without notice.

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 Product stewardship
Product stewardship

Hypertherm maintains a global regulatory management system to make sure that products comply
with regulatory and environmental requirements.

Echion Operator Manual 810770 SC-13

 Product stewardship

National and local safety regulations

Product stewardship

National and local safety regulations shall take precedence over instructions supplied with the
product. The product shall be imported, installed, operated, and discarded in compliance with
national and local regulations applicable to the installation site.

Certification test marks

Certified products are identified by 1 or more certification test marks from accredited testing
laboratories.
The certification test marks are on the pump’s data plate.

Each certification test mark means that the product and its safety-critical parts conform to the
national safety standards as reviewed and determined by that testing laboratory.
Hypertherm puts a certification test mark on its products only after that product is manufactured
with safety-critical parts that have been approved by the accredited testing laboratory.

Once the product has left the Hypertherm factory, the certification test marks are invalid if one or
more of these events occurs.
 The product is modified in a manner that causes danger or does not conform with the
applicable standards.
 Safety-critical parts are replaced with unapproved spare parts.
 Assembly is unauthorized.
 An accessory that uses or generates dangerous voltage is added.
 A safety circuit or other feature that is designed into the product as part of the certification
has been tampered with.

The Conformité Européene (CE) mark affixed to a product signifies the manufacturer’s declaration
of conformity to applicable European directives and standards.
Only those versions of Hypertherm products with a CE mark on or near the data plate have been
tested for compliance with the applicable European directives, such as the Low Voltage Directive,
the Electromagnetic Compatibility Directive, and the Machinery Directive.

If this product has a Declaration of Conformity, a copy (in English) is included. Refer to
Declaration of Conformity on page 173.

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 Product stewardship

Differences in national standards

Product stewardship
Nations can apply different performance, safety, or other standards. National differences in
standards include, but are not limited to:
 voltage.
 plug and cord ratings.
 language requirements.
 electromagnetic compatibility requirements.

Differences in national or other standards can make it impractical or impossible for all certification
test marks to be put on the same version of a product. For example, the Canadian Standards
Association (CSA) versions of Hypertherm’s products do not comply with European
electromagnetic compatibility requirements; therefore, they do not have a CE mark on the data
plate.

Countries where the CE mark in necessary or that have compulsory electromagnetic compatibility
regulations must use CE versions of Hypertherm products with the CE mark on the data plate.

These could include:

 countries in the European Union.
 Australia.
 New Zealand.
 Russia.

It is important that the product and its certification test mark be suitable for the end-use installation
site. When Hypertherm products are shipped to one country for export to a different country, the
product must be correctly configured and certified for the end-use installation site.

Echion Operator Manual 810770 SC-15

 Product stewardship

Higher-level systems
Product stewardship

When an original equipment manufacturer (OEM) or a system integrator adds equipment such as
cutting tables, motor drives, motion controllers, or robots to a Hypertherm waterjet cutting system,
the system is considered a higher-level system. A higher-level system with dangerous moving parts
can constitute industrial machinery or robotic equipment, in which case the OEM, system integrator,
or end-use customer can be subject to more regulations and standards than those applicable to the
waterjet cutting system manufactured by Hypertherm.

It is the responsibility of the end-use customer and the OEM or system integrator to do a risk
assessment for the higher-level system and to provide protection against dangerous moving parts.

Unless the higher-level system is certified when the OEM or system integrator incorporates
Hypertherm products into it, the installation can be subject to approval by local authorities. Get
advice from legal counsel and local regulatory experts if you are not sure about compliance.

External cables connecting parts of the higher-level system must be made for exposure to
contamination and movement as necessary for the end-use installation site. When the external
interconnecting cables are subject to exposure to oil, dust, water, or other contamination, hard
usage ratings could be necessary.

When external interconnecting cables are subject to continuous movement, constant flexing ratings
can be necessary. It is the responsibility of the OEM, system integrator, or end-use customer to
make sure that external connecting cables are correct for the application and obey all national, state,
and local regulations.

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 Environmental stewardship
Environmental stewardship

Echion Operator Manual 810770 SC-17

 Environmental stewardship
Environmental stewardship

Hypertherm products: waste and recycling

Hypertherm waterjet cutting systems, like all products with electronics, can contain materials or
parts, such as printed circuit boards, that cannot be discarded with ordinary waste. It is your
responsibility to discard Hypertherm products or parts in an environmentally suitable manner and in
compliance with national and local codes.

In the United States, read all national, state, and local laws. In the European Union (EU), read the EU
directives, national, and local laws. In other countries, refer to national and local laws. Consult with
legal or other compliance experts, when applicable. For information, go to
www.hypertherm.com/customer-support/product-service/recycling.

SC-18 810770 Operator Manual Echion

 Environmental stewardship

Environmental stewardship
Chemical handling and usage

Material safety data sheets (MSDS) and safety data sheets (SDS) are part of a hazard
communication plan that supplies detailed information about dangerous chemicals. The information
includes the chemical’s toxicity and reactivity, first aid for exposure, approved storage and disposal,
recommended protective equipment, and spill-handling procedures.

The Occupational Safety and Health Administration (OSHA) has presented new dangerous
chemical labeling requirements as a part of its recent revision of the Hazard Communication
Standard (29 CFR 1910.1200), to align with the United Nations’ Globally Harmonized System of
Classification and Labelling of Chemicals (GHS). The GHS is an international system for
standardizing chemical classification and labeling.

Chemical regulations in the USA, Europe, and other locations require that MSDS and SDS be
made available for chemicals that are supplied with the product and chemicals used in or on the
product. The list of chemicals is supplied by Hypertherm.

To see MSDS and SDS:

1. Go to www.hypertherm.com/docs.

2. Look for “To view all regulatory and compliance documents, click here” below the Select your
product box.

3. Look for Safety Data Sheets. Click +.

These navigation instructions can change without notice.

Echion Operator Manual 810770 SC-19

 Environmental stewardship
Environmental stewardship

Particle emission and waste water quality

Hypertherm does not manufacture or supply the materials that are cut and has no knowledge about
the particles released from materials that are cut and if they can pose a physical danger or health
risk. Get advice from your supplier or other technical advisor for guidance concerning the properties
of the material you cut with a Hypertherm product.

If you are not familiar with the current applicable government regulations and legal standards for the
installation site, get advice from a local expert before you purchase, install, and operate this
equipment.

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 Safety
Safety

The end user is responsible for the safe operation of this equipment.

WARNING Before operating Hypertherm equipment, read the safety instructions in your product's
manual.

Echion Operator Manual 810770 SC-21

 Safety

Manuals
Safety

Copies of Hypertherm manuals can accompany the product in electronic and printed formats.
Copies of the manuals are online, in all languages available for each manual.

1. Go to www.hypertherm.com/docs.

2. Under Select your product, choose Waterjet Family in the dropdown list.

3. Go to the Operator and instruction manuals section and click +.

4. Click on the manual for your product. You may have to click on SHOW ALL at the bottom of the
section.
A PDF of the manual downloads to your device.

These navigation instructions can change without notice.

The safety precautions in this manual are general and cannot anticipate every situation. Hypertherm,
Inc. acknowledges that unforeseen situations such as equipment failure, site variability, insufficient
maintenance, failure of control equipment, and other events can cause equipment damage, injuries,
or death. It is the user’s responsibility to identify dangers and to take the steps necessary to
minimize risks.

Keep these instructions near the equipment. This manual is intended to familiarize the user with the
equipment and its parts, safe operation, and maintenance.

All personnel who operate or have access to this equipment must know this information:
 applicable safety standards.
 the use, limitations, and maintenance of personal protective equipment.
 the location of the written hazard communication program and safety data sheets.
 how to recognize dangerous energy sources.
 the correct methods for isolating and controlling energy, to include lock out–tag out
procedures.

SC-22 810770 Operator Manual Echion

 Safety

User qualification and training

Safety
All users must read and understand these instructions before installing, operating, or doing
maintenance on this equipment.

Do not let an untrained person operate this equipment. Operators must be approved to operate and
maintain this equipment.

Training should include:

 how to start and stop the equipment during operation and in an emergency situation.
 conditions and procedures that can lead to injuries to personnel and damage to the
equipment.
 how to operate all controls.
 how to identify and respond to a problem with the equipment.
 how to do maintenance procedures.
 a copy of the operator manual.

This list is not all-inclusive.

Echion Operator Manual 810770 SC-23

 Safety

Emergency medical information and treatment

Safety

WARNING A waterjet is a cutting tool.

Keep away from high-pressure streams and leaks. Pressurized fluid can cause injuries.
Delayed treatment can cause injuries or death.

WARNING Do not put ice or heat on a waterjet injury.

If possible, use a support to keep injured body parts above heart level.

High-pressure equipment puts the operator and other personnel at risk of contact with
high-pressure water. Possible injuries include eye damage, lacerations, infections, and amputations.

Waterjet operators should have a waterproof emergency medical tag or card that describes the
recommended treatment for high-pressure water injuries. Show the tag or card to emergency
responders and medical professionals.

This wallet-size card can be copied, laminated, and folded.

injuries. The person with this card has been exposed to a waterjet
high-pressure waterjet of up to 4,140 bar (60,000 psi) and a velocity
immediately for all of 609 m/s (2,000 feet/second). Abrasive waterjets can
eject water and abrasive materials that can be injected into
Get medical treatment
body tissues, leading to a dangerous infection.
emergency.
injury is a surgical  Skin can appear to be not damaged or show a small
A high-pressure injection pinhole-sized puncture wound.
 The injured area can become swollen, painful, and pale
INFORMATION over the next 4 to 6 hours.
MEDICAL  Tissue becomes ischemic and necrotic within 12 hours.

 Do not use digital or local nerve blocks.  Consult a surgical specialist immediately for
 Give analgesics by mouth or injection. decompression, removal of foreign materials, and
debridement.
 Give broad-spectrum, intravenous antibiotics for
Gram-negative and Gram-positive organisms.
 X-ray is the preferred imaging method.
 Acute compartment syndrome is possible.
 Leave the wound open.
 Do not use solvents other than isotonic sodium chloride
solution for irrigating the wound.

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 Safety

Safety information for operation, maintenance, repair, and installation

Safety
Before opening the electrical enclosure or doing maintenance or repairs on this equipment, turn
DANGER OFF the electrical power and release water pressure and hydraulic pressure from the system.
Use standard lock out-tag out procedures.
Isolate all sources of electrical, mechanical, hydraulic, pneumatic, chemical, thermal, or other
energy with a lockable energy-isolating device that satisfies national and local requirements.

WARNING Make sure that all connections, fasteners, locking devices, hoses, and fittings are tight before
operation.

WARNING Make sure that the shaft access cover and all other safety devices are correctly installed before
operating this machine.

WARNING Do not stand in line with high-pressure fittings when operating this equipment.
If a high-pressure fitting fails, it can cause a stream of water or hydraulic fluid to eject from the
system with force.

WARNING Do not leave waterjet cutting equipment unattended while it is operating.

WARNING During operation, keep a restricted-access area clear that is larger than the maximum movement
range of the cutting equipment’s moving parts.

WARNING Let only approved personnel operate this machinery.

WARNING Release all high-pressure water before doing work on this equipment.

WARNING Do not touch a hot surface.

Water leaking from a high-pressure fitting or the bleed-down valve can be hot.

Obey all safety requirements and applicable safety laws and regulations.
WARNING Obey national and local codes regarding installation, repairs, and maintenance of the electrical
and plumbing systems.
All work that requires opening the electrical enclosure or removing covers or panels from this
equipment must be done only by an approved technician.
It is your responsibility to investigate and obey all local codes.

Echion Operator Manual 810770 SC-25

 Safety

WARNING A person who works on deenergized machinery can be injured or killed if the machinery is
energized without permission.
Safety

All personnel in an area where energy-control procedures are used must receive training for
energy-control procedures.

DANGEROUS VOLTAGE/RISK OF SHOCK

WARNING Doing work on this equipment while it is energized is dangerous.
Personnel who maintain and repair this equipment can be injured or killed if dangerous energy is
not controlled.
Injuries can include burns, cuts, fractures, or electrocution.

Before removing a lock-out device:

 obey the employer’s energy-control procedure.
WARNING
 examine machines and parts to make sure that they are operational.
 make sure that all personnel are safely away from machines.
After removing energy-isolation devices, make sure that all personnel in the area know that the
devices are removed and that the machine is being energized.

WARNING To reduce the risk of injuries or death, wear approved protection and obey safety
recommendations when doing work with electricity.

WARNING When work must be done in a small space or an area with limited access, the access must not
be blocked by ventilation ducts, hoses, pipes, or other equipment.

WARNING Do not block or remove warnings, cautions, or instructions.

WARNING Personal protective equipment is recommended.

If you do not use personal protective equipment, there is a risk of injury or death.

WARNING High-pressure water can cause eye injuries.

Wear approved eye protection when operating or doing work near this equipment.

WARNING This waterjet equipment could make more noise than is permitted by national or local codes.
When this intensifier is operating, the noise level is 75 dB(A) to 85 dB(A).
Water flow rate, pipe layout, and the acoustical characteristics of the building have an effect on
noise level.
Long periods of exposure to noise can cause permanent hearing loss.
Wear approved ear protection and control exposure time when operating or doing work near this
equipment.

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 Safety

WARNING High-pressure water can cause cuts, abrasions, and punctures.

Precision parts can have sharp corners or edges.

Safety
Wear approved hand protection when operating or doing work near this equipment and when
touching parts.

WARNING Some materials can cause airborne contamination or particles when cut.
Wear approved respiratory protection when operating or doing work near this equipment.

CAUTION Examine and clean the equipment regularly.

Refer to the Preventive maintenance schedule on page 60.
Do repairs immediately.

Echion Operator Manual 810770 SC-27

 Safety
Safety

SC-28 810770 Operator Manual Echion

 Symbols and marks
Symbols and marks

Echion Operator Manual 810770 SC-29

 Symbols and marks

Information and symbols

Symbols and marks

Some symbols in this table could apply to other products.

DANGER DANGER identifies an imminently dangerous condition or a situation that WILL cause
serious injuries or death if ignored.

WARNING WARNING identifies a dangerous condition or a situation that COULD cause injuries or
death if ignored.

CAUTION CAUTION, when used with the yellow warning sign, identifies a dangerous condition or a
situation that COULD cause minor or moderate injuries or WILL cause damage to the
equipment if ignored.

NOTICE identifies a condition or a situation that COULD cause damage to the

NOTICE
equipment if ignored.

This symbol identifies a mandatory action.

This symbol identifies a prohibited action.

This symbol identifies tools or materials that are necessary or recommended for a
procedure.

This symbol identifies information that could cause the user to fail at the task if ignored.

This symbol identifies a tip or helpful information.

SC-30 810770 Operator Manual Echion

 Symbols and marks

Symbols and marks found on the equipment

Symbols and marks

Some symbols or marks in this table could apply to other Hypertherm products.

DANGER DANGER identifies an imminently dangerous condition or a situation that WILL cause
serious injuries or death if ignored.

DANGER ARC FLASH AND SHOCK HAZARD

Follow all requirements in NFPA 70E for safe work practices and for Personal Protective
Equipment.

WARNING WARNING identifies a dangerous condition or a situation that COULD cause injuries or
death if ignored.

WARNING HAZARDOUS VOLTAGE

Disconnect power before servicing.

WARNING
WARNING
This product can expose you to chemicals including lead and lead compounds, which are
known to the State of California to cause cancer and birth defects or other reproductive
harm.
For more information go to www.p65warnings.ca.gov.
WARNING Hydraulic, water, and electrical connections can come loose during shipping and normal
operation.
It is recommended that all connections are checked at installation and annually.

CAUTION CAUTION, when used with the yellow warning sign, identifies a dangerous condition or a
situation that COULD cause minor or moderate injuries or WILL cause damage to the
equipment if ignored.

CAUTION Do not touch a hot surface.

Read and fully understand operator’s manual before using this machine.
Failure to follow operating instructions could result in death or serious injury.

Correct direction of motor rotation (motor rotation arrow)

S/N Serial number

V Volts

Echion Operator Manual 810770 SC-31

 Symbols and marks

Φ
Symbols and marks

Number of phases in a power system

HZ Frequency (hertz)

Type of hydraulic fluid recommended

Hydraulic fluid tank volume (liters)

FLA Full-load current (amperage)

SCCR Short-circuit current rating

IMAX Primary motor maximum current draw (amperes)

KW Primary motor power output (kilowatts)

L/MIN Maximum outlet flow rate (liters/minute)

BAR Maximum outlet water pressure (bar)

KG Weight (kilograms)

P/N Electrical enclosure part number

The Conformité Européene (CE) mark affixed to a product signifies the manufacturer’s
declaration of conformity to applicable European directives and standards.
Only those versions of Hypertherm products with a CE mark on or near the data plate
have been tested for compliance with the applicable European directives, such as the
Low Voltage Directive, the Electromagnetic Compatibility Directive, and the Machinery
Directive.

Use caution when operating this equipment.

Refer to the instruction manual. Read and understand all of the safety guidelines in this
manual.

Identifies the terminal of a protective earth (ground) electrode or a terminal intended to

connect to an external conductor for protection against electric shock during a fault
condition

Controls

Remote key switch off

The key switch is in the Local position.

Remote key switch on

The key switch is in the Remote position.

SC-32 810770 Operator Manual Echion

 Symbols and marks

COMPRESSED AIR

Symbols and marks

The bleed-down valve uses compressed air to operate.

CUTTING WATER IN
This line carries low-pressure water from a water softener, a reverse osmosis system, a
well, or a public utility to the pump.
CUTTING WATER OUT
This tubing carries high-pressure water from the intensifier to the cutting table.

WASTE WATER OUT

This hose carries water from the bleed-down valve to a drain.

COOLING IN
This line carries low-pressure water from the local utility or a chiller to the pump’s cooling
loop.
COOLING OUT
This line carries low-pressure water from the heat exchanger to the chiller or to the drain.

Start the pump symbol

Stop the pump symbol

Echion Operator Manual 810770 SC-33

 Symbols and marks
Symbols and marks

SC-34 810770 Operator Manual Echion

 Optional equipment
Optional equipment

Boost pump
The pump will not operate satisfactorily if the supply water pressure is too low for the pump to get to
stable pressure. A boost pump increases the water pressure to a value higher than the minimum
requirement.

Modbus TCP/IP communication

All Hypertherm waterjet pumps can use Ethernet to communicate with a CNC.

Utility connection panel kit

The utility connections for the Echion pump are inside the pump, at the point of use. With this kit,
utility connections are made on the outside of the pump.

Metric conversion kit

This kit includes adapter fittings for use in countries where metric connections are standard.

Pump-mounted high-pressure plumbing kit

This kit includes a bracket and a high-pressure tube to connect a high-pressure line directly to the
pump.
For part numbers, refer to Optional equipment kits on page 103.

Echion Operator Manual 810770 35

 1 Optional equipment
Optional equipment

36 810770 Operator Manual Echion

 Operation

Operation
This section assumes that the user is familiar with the Safety, Preventive maintenance,
Troubleshooting, and Specifications sections of this manual.

Images in this manual are for reference purposes. It is possible that your product configuration is
not shown accurately.

It is possible that not all of the information in this section applies to all pump models.

Echion Operator Manual 810770 37

 2 Operation

Safety

WARNING Read and understand all of the safety guidelines in this manual.
Refer to Safety on page 21 before operating, doing maintenance on, repairing, and installing
your pump.

About the controls

Operation

Operation panel

1 3

2 4

1 Controls button 3 EMERGENCY STOP button

Push this button to turn ON the control circuit in Push this button to turn off the control circuit.
the pump. The button lights when the control Refer to Emergency stop on page 51.
circuit is on. 4 Remote indicator light
2 Local/Remote key switch When the key switch is in the Remote position, this
When the key switch is in the Local indicator light is on.
position, use the operator interface to
operate the pump.
When the key switch is in the Remote
position, use the remote source, such as a
computer numerical control (CNC)
operator console, to controls the pump.

 Most functions on the operator interface are not

available when the key switch is in the Remote
position.

38 810770 Operator Manual Echion

 Operation 2
Operator interface

Refer to Touchscreen maps on page 175 to see all of the screens available on the controller.

Primary operation screen

These elements are on most screens.
2 3 4

Operation
1 5

1 Hour meter 4 Operator interface: Maintenance screens tab

This shows the total hours the pump motor has • Move the plunger to one end of the
been in operation. intensifier.
2 Primary operation screen tab • Prepare the pump for storage.
• Turn the pump on or off. • See the alarm log.
• Select the pressure mode (cut or pierce). • See the inputs-outputs from the controller.
• Set or change the water pressure. Refer to Operator interface: Maintenance
• Monitor the status of the intensifier. screens on page 56.

3 Operator interface: Adjustment screens tab 5 Date and time

• See information about your system. Refer to Date / Time / Language on page 169.
• Change some display options, such as
pressure units (bar or psi) or language.
• Change timer durations.
• Turn features such as Modbus mode on or
off.
Refer to Operator interface: Adjustment screens
on page 164.

Echion Operator Manual 810770 39

 2 Operation

12
7
11

8
Operation

9 10

6 Stop 10 Cut-pressure mode (on)

Touch this symbol to stop the pump. Touch this symbol to put the pump in
7 Start cut-pressure mode.
Touch this symbol to start the pump. Cut-pressure mode is active in this
8 LED light on/off image.
Touch this symbol to turn the red LED lights ON Refer to Select the pressure mode on page 49
or OFF. for information about pressure modes.
9 Pierce-pressure mode (off) 11 Target water pressure
Touch this symbol to put the pump in 12 Output water pressure
pierce-pressure mode.
This shows the actual water pressure when the
pump is operating.
This is the target water pressure set by the user.
Refer to Set the target water pressure on
page 49.

Intensifier status indicator and stroke-rate bars

The stroke-rate bars show the speed of the piston moving to each side of the intensifier.

1
2
3

1 Intensifier status indicator 2 Intensifier stroke rate to the left

Enabled (green) 3 Intensifier stroke rate to the right
Not enabled (red) The stroke rate is within the permitted
range (green).
The stroke rate is at the limit of the
permitted range (yellow).
The intensifier is overstroking (red).

Refer to Primary operation screen on page 113 for more information.

40 810770 Operator Manual Echion

 Operation 2
Turn on the pump: beginning of day

Follow this procedure when starting the pump for the first time each day or at the beginning of each
work shift. Daily preventive maintenance tasks are included in these instructions.

Inspect the pump

Unless otherwise recommended, install the top cover and the front panel before operating the
pump.

Operation
1. Remove the top cover.

a. Use a standard screwdriver to turn the bolt 1 on each end counterclockwise 1/4 turn.
b. Lift the cover off of the alignment pins 2 .

2. Remove the front panel.

2
2

Push down on the horizontal surface on top of the panel 1 to release the retainers tabs from the
frame 2 .

Echion Operator Manual 810770 41

 2 Operation

3. Clean all debris, water, and hydraulic fluid off of the hydraulic fluid tank 1 , the intensifier
bridge  2 , and the bottom deck 4 .

2
Operation

3 4

4. Empty the dirty water container 3 , if necessary.

Refer to local regulations regarding waste water. Environmental rules can apply to
disposal.

5. Clean the operator interface, if necessary.

To prevent damage to the operator interface:

 do not use cleaners that contain alcohol, ammonia, acetone, phosphates, or
ethylene glycol.
 do not push hard on the touchscreen.
 do not use paper towels, abrasive cloth, or dirty rags.
 do not put liquid directly onto the touchscreen.

 Gently wipe the touchscreen and keys with a clean microfiber cloth.
 Use a cleaner made for touchscreens or use a 1:1 solution of distilled water and white
vinegar.

6. Examine electrical cords and cables for kinks or damage to the insulation. Examine electrical
plugs and other electrical connections for corrosion or damage.

7. Look for leaks, deterioration, damage, or other conditions that can interfere with operation.

8. Make sure that all connections, fasteners, locking devices, hoses, and fittings are tight.

9. Make sure that all warning decals are visible and legible.
Contact Hypertherm for replacement decals.

42 810770 Operator Manual Echion

 Operation 2
Check the hydraulic fluid

Replace the hydraulic fluid:

• every 3,000 hours.
• if it is dark or milky in color.
• if it has a strong odor.
• if a test laboratory finds the quality is unsatisfactory.
Refer to Replace the hydraulic fluid on page 86.

Operation
Heat and other conditions cause hydraulic fluid to degrade. Degraded hydraulic fluid can
CAUTION cause damage to hydraulic components.
Collect a sample of hydraulic fluid from the hydraulic fluid tank and send it to a test
laboratory for analysis.
Refer to Hydraulic fluid on page 136 for recommended limits.

Contact a hydraulic fluid supplier for a precise report about your hydraulic fluid quality.

Do this task when the pump is not operating.

1. Look through the sight gauge to see the color of the hydraulic fluid. Good hydraulic fluid is
almost transparent.

2. Remove the filler cap.

3. Smell the hydraulic fluid. Good hydraulic fluid has almost no odor.

4. Install the filler cap.

Echion Operator Manual 810770 43

 2 Operation

Turn on the utilities

1. Turn ON the water to the pump.

2. Turn ON the compressed air source.

3. Turn ON the electrical main (line disconnect switch).

4. Turn the primary breaker disconnect lever on the electrical enclosure door to ON.
Operation

Turn on the controls

Turn on the controls remotely

Refer to the OEM’s instructions for starting the pump and for operating the pump from a
remote source.

1. Make sure that the EMERGENCY STOP 1 is not engaged. If the button is pushed in, turn the
button clockwise until it releases.

2. Make sure that the key switch 2 is set to Local .

3. Push the Controls button 3 .

4. Turn the key switch 2 to Remote . The remote indicator light is on 4 .

44 810770 Operator Manual Echion

 Operation 2
Turn on the controls locally

3 1

1. Make sure that the EMERGENCY STOP 1 is not engaged. If the button is pushed in, turn the

Operation
button clockwise until it releases.

2. Make sure that the key switch 2 is set to Local .

3. Push the Controls button 3 .

Start the pump

Use the Postmaintenance start procedure on page 91 if maintenance or repairs have been done
CAUTION on:
• the high-pressure water system.
• intensifier components.
• the primary motor.

1. On the operator interface, touch the symbol.

 The controller starts the pump.
 A progress bar 1 shows below the intensifier on the screen.
The normal start sequence is fully automated. Refer to Primary operation screen on page 177 for
a description of the sequence.
Monitor for leaks.

2. When the start sequence is complete, complete the Daily preventive maintenance tasks. Refer
to the Preventive maintenance schedule on page 60.

Echion Operator Manual 810770 45

 2 Operation

Do the preoperation maintenance checks

Examine the pump for leaks or damage

Do this task when the pump is operating and the system is pressurized.

1. Look for hydraulic fluid leaks. Monitor these areas.

 Hydraulic connections
 Valves
Operation

 Intensifier bridge and bottom deck

2. Examine the low-pressure tubes and the hoses for leaks.

3. Examine the bleed-down valve for leaks or damage.

A hot bleed-down valve can suggest that there is a leak.

4. Examine the weep holes in the high-pressure ends for leaks. Water leaking from a weep hole is
a sign of a faulty part or a loose connection.

1 2 3

1 Output adapter leak 3 Dynamic seal leak

2 High-pressure seat leak

5. Examine the high-pressure tubing for leaks.

6. Look for deterioration, damage, or other problems.

46 810770 Operator Manual Echion

 Operation 2
Check the hydraulic fluid level

Do this task when the pump is operating.

Make sure that the hydraulic fluid level is at the top mark on the sight gauge.

Operation
Add hydraulic fluid, if necessary. Refer to Add hydraulic fluid on page 85 for instructions.

Check the hydraulic filter gauge

Replace the hydraulic filter element:

• every 1,500 hours.
• when the needle on the gauge stays in the red zone while the pump is operating.
Refer to Replace the hydraulic filter element on page 84.

Do this task when the pump is operating at a stable temperature.

Make sure that the needle on the hydraulic gauge is not in the red zone.

Echion Operator Manual 810770 47

 2 Operation

Check the low-pressure water pressure gauges

Replace the water filter:

• every 1,000 hours.
• if the difference between the values is more than 0.7 bar (70 kPa / 10 psi).
Refer to Replace the water filter on page 80.

The prefilter water-pressure gauge shows the water pressure before the water goes through the
filter. The postfilter water-pressure gauge shows the water pressure after the water goes through
the filter.
Operation

The usual range is 2.8 bar to 7.6 bar (280 kPa to 760 kPa / 40 psi to 110 psi).

1 2

1 Postfilter water-pressure gauge 2 Prefilter water-pressure gauge

Do this task when the pump is operating.

Subtract the value shown on the postfilter water pressure from the value shown on the prefilter
water pressure.

If the difference between the values is more than 0.7 bar (70 kPa / 10 psi), replace the water filter.

Make sure that the emergency stop operates correctly

Do this task when the pump is operating.

On the operation panel, push the EMERGENCY STOP button. Refer to Emergency stop on
page 51.

48 810770 Operator Manual Echion

 Operation 2
Operate the pump

Operation
2 3
1 Target water pressure 3 Cut-pressure mode (on)
Touch this to set the target water pressure. Touch this symbol to put the pump in cut-pressure
2 Pierce-pressure mode (off) mode.
Touch this symbol to put the pump in 4 Output water pressure
pierce-pressure mode. This shows the actual water pressure when the
pump is operating.

Select the pressure mode

Cut-pressure mode 3 is used for most cutting jobs.

Pierce-pressure mode (low-pressure mode) 2 is applicable for:

 making a hole in the material to be cut.
 decreasing the risk of cracking when cutting brittle materials, such as glass or ceramic.
 preventing composite materials like carbon fiber from delaminating.
Pierce pressure is typically less than or equal to 1,380 bar (138,000 kPa / 20,000 psi).

Set the target water pressure

There are 2 ways to change the target water pressure on the operator interface.
 Touch the symbol or the symbol to change the target water pressure in preset
increments.

 To change the increments, refer to Pressure Adjustments on page 167.

 Touch the target water pressure button 1 to open a numeric keypad. Type the number and
then touch Enter.

Echion Operator Manual 810770 49

 2 Operation

Stop the pump

Stop the pump remotely

You can stop the pump from the operator interface while using remote controls. On the
operator interface, touch the symbol to stop the pump.
Refer to Stop the pump on page 50.

Refer to Emergency stop on page 51 for information about the EMERGENCY STOP button.
Operation

Refer to the OEM’s instructions for turning the pump off.

Stop the pump locally

Use this procedure during normal operation.

On the operator interface, touch the symbol.

 The pump, the primary motor, and the intensifier turn off.
 The bleed-down valve opens to release high-pressure water from the system.
 The supply-water valve closes to stop low-pressure water from entering the system.
 No output water pressure shows.
 The control circuit stays on.

50 810770 Operator Manual Echion

 Operation 2
Emergency stop
WARNING The EMERGENCY STOP button does not disconnect main electrical power from the
machine.

Use the emergency stop to stop the controls immediately to prevent injury or to reduce the risk of
injury to personnel, machinery, or work in progress. This is not the preferred method of turning
off the pump.

On the operation panel, push the EMERGENCY STOP button.

Operation
 The control circuit turns off, which turns off the pump, the primary motor, and the intensifier.
 Remote controls that are wired to the pump controller turn off.
 The bleed-down valve opens to release high-pressure water from the system.
 The supply-water valve closes to stop low-pressure water from entering the system.

The EMERGENCY STOP button must be reset before the equipment can be turned on.
Turn the button clockwise until it releases.

Echion Operator Manual 810770 51

 2 Operation

Turn off the pump: end of day

Do this procedure at the end of the day.

1. On the operator interface, touch the symbol to stop the pump.

2. Turn the primary breaker disconnect lever on the electrical enclosure door to OFF.
Operation

3. Turn OFF the utility water to the pump. Make sure that the water pressure gauges
show 0.0 bar (0 kPa / 0 psi).

4. Turn OFF the compressed air source.

5. Turn OFF the electrical main (line disconnect switch). Use standard lock out–tag out procedures.

6. Remove the top cover and the front panel.

7. Clean all debris, water, and hydraulic fluid off of the hydraulic fluid tank 1 , the intensifier
bridge  2 , and the bottom deck 4 .
1

3 4

8. Empty the dirty water container 3 , if necessary.

Refer to local regulations regarding waste water. Environmental rules can apply to
disposal.

52 810770 Operator Manual Echion

 Preventive maintenance

Preventive maintenance
This section assumes that the user is familiar with the Safety, Operation, Troubleshooting, and
Specifications sections of this manual.

Images in this manual are for reference purposes. It is possible that your product configuration is
not shown accurately.

It is possible that not all of the information in this section applies to all pump models.

Echion Operator Manual 810770 53

 3 Preventive maintenance

Safety

WARNING Read and understand all of the safety guidelines in this manual.
Refer to Safety on page 21 before operating, doing maintenance on, repairing, and installing
your pump.

CAUTION Do not tighten a fitting too much. The fitting can fail.

CAUTION Hydraulic, water, and electrical connections can become loose during shipping and normal
Preventive maintenance

operation. Examine all connections at installation and during regular maintenance.

CAUTION When replacing wiring, use only the same size, type, and color as the original wiring.

CAUTION Before assembling high-pressure or hydraulic parts, clean the parts to remove grease and other
contamination.

Clean and examine parts that will be replaced to identify wear patterns or damage that can show
other problems.

Clean each part with a towel and isopropyl alcohol. Examine all parts for deterioration, corrosion,
or damage.
Do not use soap, detergent, or solvents.

Keep the work area clean and dry. Clean fluid spills immediately.
Use a pan or a tray below areas where water or hydraulic fluid can spill during maintenance or
repair procedures.

Obey local protocols for recycling or disposal of parts, materials, and fluids.
National and local environmental rules can apply to disposal.
Refer to Recycling and end of product life on page 96.

Keep accurate maintenance records. Records can help with predicting and preventing
maintenance problems.

Keep spare parts and repair kits available.

54 810770 Operator Manual Echion

 Preventive maintenance 3
Benefits of preventive maintenance

Hypertherm recommends preventive and scheduled maintenance for Echion pumps. High-quality
equipment that is maintained on a schedule lasts longer than equipment that is not maintained
regularly. This maintenance includes adjustments, cleaning, lubrication, repairs, and replacement of
parts.
 Improves reliability
 Finds possible problems before they cause unplanned downtime and become expensive
repairs
 Extends the life of equipment and decreases the frequency of replacement
 Contributes positively to reputation and profits

Preventive maintenance
 Gives traceability through records

Training

The employer must provide training for maintenance procedures. Retrain personnel when:
 there is a change in job assignment, machinery, or procedures that can present a new
danger.
 energy-control procedures change.
 there is reason to believe there is a deficiency in a person’s knowledge of the energy-control
procedure.

Echion Operator Manual 810770 55

 3 Preventive maintenance

Operator interface: Maintenance screens

Refer to Touchscreen maps on page 177 to see all of the screens available on the controller.

On the operator interface, touch the maintenance tab to open the primary maintenance screen.
Preventive maintenance

1 4

2 5

1 Move the plunger 4 Inputs and outputs

2 Start the pump after maintenance 5 Alarm log
3 Prepare for storage

Move the plunger

Touch this symbol to open the Move the Plunger screen.

Instructions for moving the plunger begin on page 61.

56 810770 Operator Manual Echion

 Preventive maintenance 3
Start the pump after maintenance

Touch this symbol to open the Start Procedure screen.

Preventive maintenance
Refer to Postmaintenance start procedure on page 91 for more information.

Prepare for storage

Touch this symbol to open the Prepare for Storage screen.

Refer to Prepare for storage on page 93 for more information.

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 3 Preventive maintenance

Inputs and outputs

The inputs and outputs screen is useful for troubleshooting. Touch this symbol to open a screen that
shows inputs and outputs for the controller.
Preventive maintenance

Refer to Input/output status on page 134 for more information.

Alarm log

The alarm log is useful for troubleshooting. Touch this symbol to open the Alarm Log screen.

Refer to Alarms on page 114 for more information.

58 810770 Operator Manual Echion

 Preventive maintenance 3
Tools

Use the correct tools for maintenance procedures. Some tools are designed to make the
procedure easier and to prevent damage to the equipment.

Personnel who maintain and repair this equipment must know how to use standard hand tools.

Use SAE (US standard) tools for most procedures.

Special tools are recommended or necessary for some maintenance and repair procedures.

Preventive maintenance
Open-ended wrench

Crowfoot wrench

Screwdriver

Standard

Phillips

O-ring pick

Snap ring pliers

Intensifier repair tools

1 Seal installation tool
1 2 Seal removal tool
3 Cylinder locator tool

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 3 Preventive maintenance

Preventive maintenance schedule

These maintenance intervals are recommended guidelines. Find the procedures on the page
numbers listed in the Hours columns.

Interval

12,000
1,500
1,000

3,000

6,000
Daily

500
Before starting the pump
page
 Clean and inspect the pump. 39
page
 Check the hydraulic fluid.
Preventive maintenance

41

After starting the pump

page
 Examine the pump for leaks or damage. 44

page
 Check the hydraulic fluid level. 45

page
 Check the hydraulic filter gauge. 45

page
 Check the low-pressure water pressure gauges. 46
page
 Make sure that the emergency stop operates correctly. 46

Intensifier
 Repair the high-pressure cylinders, the check valves, page
and the low-pressure poppets. 66

page
 Replace the high-pressure seal cartridges. 69

Intensifier
page
 Replace the high-pressure poppet assemblies. 69
page
 Replace the low-pressure poppets and seats. 74

Low-pressure water system

page
 Clean the air cooler. 78

Bleed-down valve
page
 Repair the bleed-down valve. 75

Low-pressure water system

page
 Replace the water filter. 80

page
 Test the low-pressure water TDS level. 81

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 Preventive maintenance 3
Interval

12,000
1,500
1,000

3,000

6,000
Daily

500
Hydraulic system
page
 Replace the hydraulic filter element. 84

Intensifier
page
 Flip the high-pressure cylinder. 66

Intensifier
 Replace the high-pressure cylinders and the check valve page
assemblies. 66

Preventive maintenance
Bleed-down valve
page
 Replace the bleed-down valve body. 75

Hydraulic system
page
 Replace the hydraulic fluid. 86

Intensifier
page
 Replace the output adapters. 73

page
 Replace the seal housing assemblies. 62

Motor
page
 Lubricate the primary motor bearings. 88

Intensifier
page
 Replace the spacer tubes. 62

page
 Repair the hydraulic center section. 65

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 3 Preventive maintenance

Intensifier

Every 500 hours Every 3,000 hours

• Repair the check valves and the low-pressure • Replace the high-pressure cylinders.
poppets. • Replace the check valve assemblies.
• Repair the high-pressure cylinders.
Every 6,000 hours
• Replace the high-pressure seal cartridges.
• Replace the output adapters.
Every 1,000 hours • Replace the seal housing assemblies.
• Replace the high-pressure poppet assemblies.
Every 12,000 hours
• Replace the low-pressure poppets and seats.
• Replace the spacer tubes.
Every 1,500 hours • Repair the hydraulic center section.
Preventive maintenance

• Flip the high-pressure cylinders.

CAUTION To prevent causing damage or premature failure, use 2 wrenches when loosening or tightening
a high-pressure connection.
Always tighten fittings to the specified torque.

CAUTION Do not use an adjustable wrench on high-pressure fittings.

Use clean hands when changing high-pressure parts.

To reduce downtime, Hypertherm recommends doing preventive maintenance on both ends of

the intensifier at the same time.

7
6

5
4
2
1 3

1 Output adapter and high-pressure poppet 4 High-pressure cylinder

assembly 5 Seal housing assembly
2 Check valve assembly 6 Plunger
3 Spacer tube 7 Hydraulic center section

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 Preventive maintenance 3

Parts, tools, and materials

Intensifier repair tools 2 standard screwdrivers
1-18770 Echion high-pressure seal repair kit Large snap-ring pliers
1-18771 Echion high-pressure poppet repair kit Small snap-ring pliers
1-18849 Echion low-pressure poppet repair kit Isopropyl alcohol
1-18768 Standard tool kit Antiwear (AW) mineral oil or synthetic hydraulic
13/16-inch open-ended wrench or socket fluid, ISO viscosity grade (VG) 32 or 46

1-inch open-ended wrench Clean towels

1-1/16-inch open-ended wrench Nonstick scouring pad

1-inch socket Masking tape

Preventive maintenance
Torque wrench
Rubber mallet Recommended materials

2 O-ring picks (or similar tool) Bench vise

 Refer to Intensifier high-pressure ends on page 107 for individual replacement parts.

Do this task when the pump is not operating.

1. On the operator interface, touch the maintenance symbol to open the primary maintenance
screen.

2. Touch this symbol to open the Move the Plunger screen.

3. Touch the motor symbol to start the motor.

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 3 Preventive maintenance

4. Touch a symbol to move the intensifier plunger to the end you will be working on.

5. On the operator interface, touch the symbol to stop the pump.

6. Turn the primary breaker disconnect lever on the electrical enclosure door to OFF.
Preventive maintenance

7. Turn OFF the utility water to the pump. Make sure that the water pressure gauges
show 0.0 bar (0 kPa / 0 psi).

8. Turn OFF the compressed air source.

9. Turn OFF the electrical main (line disconnect switch). Use standard lock out–tag out procedures.

10. Use a 13/16-inch open-ended wrench to disconnect the high-pressure tubing from the
intensifier.

11. Remove the bleed-down valve. Refer to step 5 though step 10 on page 76.

12. Push the button on the quick-disconnect fitting to remove the low-pressure water line from the
intensifier.

It is possible that some water will spray from the connection when this tubing is
disconnected.

13. Use the breaker bar and the 1-1/2-inch 12-point socket to remove the endcap nuts. Use a
repeating cross pattern.

14. Remove the end cap.

 Hydraulic fluid and water will leak during this procedure. Put towels on the intensifier
bridge under the work area.

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 Preventive maintenance 3
15. Pull out the check valve.

16. Pull the high-pressure cylinder off of the plunger.

 Make sure that the spacer tube does not fall out. Dropping the spacer tube can cause
damage to it.

17. Put the cylinder locator tool and the seal installation tool together.

18. Put the tool on the seal housing and turn it clockwise so that the threads engage. Pull the seal

Preventive maintenance
housing assembly off of the plunger.

 A small amount of hydraulic fluid could leak from the hydraulic cylinder. This is normal.

Repair the hydraulic center section

Repair the hydraulic center section every 12,000 hours.

The hydraulic center section includes the piston, the hydraulic cylinder, the hydraulic end caps, the
low-pressure seals, the plungers, the T-seals, and the proximity switches.

Preventive maintenance on these parts requires special tools. Contact a Hypertherm Technical
Service Associate for information and support regarding the installation, operation, maintenance,
and repair of this equipment.

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 3 Preventive maintenance

Repair the high-pressure cylinder, the check valve, and the low-pressure poppet
 Repair the high-pressure cylinders every 500 hours.
 Repair the check valves and the low-pressure poppets every 500 hours.
 Replace the high-pressure seal cartridges every 500 hours.
 Replace the low-pressure poppets and seats every 1,000 hours.
 Replace the high-pressure cylinders every 3,000 hours or if the cylinder is chipped or cracked.
 Replace the check valve assemblies every 3,000 hours.

CAUTION Debris in the cylinder can cause the seals or the poppets to fail.
Preventive maintenance

This procedure is for a moderately worn check valve. Replace very worn components.

1. Disassemble and examine the cylinder and the check valve.

3
1 5

7
6
2 4
1 Check valve body 5 Low-pressure poppet screw
2 Low-pressure poppet 6 Spacer tube
3 Check valve wear ring 7 High-pressure cylinder
4 Poppet retainer 8 High-pressure seal cartridge

2. Disassemble the cylinder locator tool and the seal installation tool.

3. Put the high-pressure cylinder on the seal locator tool. Make sure that the spacer tube is inside
the cylinder.

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 Preventive maintenance 3
4. Put the end of the push tool against the spacer tube inside the cylinder.

5. Tap on the end of the push tool with a rubber mallet to push the bottom seal and the hoop out of

Preventive maintenance
the high-pressure cylinder.

6. Take the spacer tube out of the cylinder.

7. Disassemble all of the parts.

8. Examine the cylinder. If the area around the bore is marked or pitted or has rough edges or
burrs, remove the defects with a nonstick scouring pad.

9. Cut a nonstick pad in half. Put half of the pad in the end of the cylinder. Put 1 thumb in each end
of the cylinder and push down evenly on the pad while rolling the cylinder back and forth.

Nonstick scouring pad

10. Clean the inner surfaces of the cylinder with a towel and isopropyl alcohol.

11. Use a 1/8-inch hex wrench to remove the low-pressure poppet screw from the check valve.

12. Tape a sheet of lapping paper on a granite lapping block. Make sure that the paper is smooth
and flat.

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 3 Preventive maintenance

13. Put the check valve face or the low-pressure poppet face flat on the lapping paper and move it
back and forth. Use light pressure. Do this procedure until the face is smooth and flat and has a
mirrorlike finish.

CAUTION Do not rock the parts or use too much pressure. Doing so can cause damage to the
part faces.

CAUTION Keep the low-pressure poppet and the poppet retainer clean. Grease can cause the
poppet to stick.

Do not put grease or lubricant on the check valve face or in the cylinder bore. These
components are designed for dry contact.
Preventive maintenance

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Install the high-pressure components

Replace the seal housing assemblies every 6,000 hours.

CAUTION Water can enter the hydraulic system if the weep holes in the dynamic seal backup or the seal
housing are blocked. Make sure that there is no debris in the weep holes.

1 1 3 5

Preventive maintenance
6
4
2

1 Seal housing 4 Energized spring seal

2 O-ring backup 5 Rod seal spacer
3 O-ring 6 Snap ring

1. Use small snap-ring pliers to remove the snap ring from the seal housing.

2. Remove the rod seal spacer.

3. Use an O-ring pick to remove the energized seal spring.

4. Remove the O-ring and the O-ring backup from the seal housing.

5. Clean all surfaces. Examine the seal housing and the high-pressure seal backup. Make sure that
the inner grooves are clean.
Make sure that the weep hole is clear. If necessary, use compressed air to blow debris out.

6. Put high-vacuum grease on the backup ring and the seal housing O-ring.

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 3 Preventive maintenance

7. Put the seal housing O-ring backup and the seal housing O-ring on the seal housing.
The seal housing O-ring backup 1 has a flat side and a concave side. Make sure the flat side of
the O-ring backup faces the wide end of the seal housing. The O-ring 2 fits into the concave
groove on the O-ring backup.

1
2

8. Put the new components in the seal housing, as shown.

Preventive maintenance

9. Use snap-ring pliers to insert the snap ring. Make sure that the snap ring is seated correctly in
the groove.

10. Put the cylinder locator tool and the seal installation tool together.

11. Put the tool on the seal housing and turn it clockwise so that the threads engage.

12. Put the seal housing on the plunger with the narrow end of the seal housing toward the center
of the intensifier.

13. Turn the seal housing so that the weep hole faces down.

14. Push the seal housing tightly against the hydraulic end cap. You should feel it click.

15. Remove the tool from the seal housing.

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 Preventive maintenance 3
16. Put the cartridge in the seal installation tool.

17. Hold the seal installation tool with both hands and push the cartridge and the tool onto the

Preventive maintenance
plunger in a smooth motion. Push until the cartridge is touching the seal housing.

18. Remove the seal installation tool, leaving the cartridge on the plunger.

 Part of the cartridge stays inside the seal installation tool. This is by design.

19. Make sure that the cartridge parts are tight and none of the components are hanging down on
the plunger.

20. Put the spacer tube on the plunger.

21. Find the end of the high-pressure cylinder that was repaired with the nonabrasive pad. Put the
high-pressure cylinder over the spacer tube with that end facing the center of the intensifier.
Push the cylinder as far as possible.

 Turn the high-pressure cylinder around at 1,500 hours to promote even wear.

22. Put the check valve in the end of the high-pressure cylinder. Make sure that the weep hole faces
down toward the ground.

23. Put the high-pressure end cap over the check valve and onto the studs. Push the endcap until it
is tight against the check valve. Make sure that the low-pressure water connection points
toward the attenuator.

24. Use a clean rubber mallet to tap the exposed part of the check valve until the cylinder is fully
seated in the end of the hydraulic end cap.

25. Lubricate the stud threads with antiseize bolt lubricant (white lithium grease).

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 3 Preventive maintenance

26. Put the nuts on the studs by hand. Use a torque wrench to tighten the high-pressure end cap
nuts to 68 N ∙ m (50 lbf ∙ ft). Use a repeating cross pattern.

Tighten the nuts to 375 N ∙ m (275 lbf ∙ ft). Do this in 68 N ∙ m (50 lbf ∙ ft) increments.
Preventive maintenance

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 Preventive maintenance 3
Examine the output adapter and the high-pressure poppet assembly
 Replace the high-pressure poppet assemblies every 1,000 hours.
 Replace the output adapters every 6,000 hours.

CAUTION The high-pressure poppet seat can cause cracks, erosion marks, or dents in the output adapter.

If a poppet part is damaged, replace all 3 components.

Preventive maintenance
1
2
3
4
1 High-pressure poppet seat 3 High-pressure poppet spring
2 High-pressure poppet 4 Output adapter

Use a cotton-tipped applicator to guide the high-pressure poppet seat out of the check valve.

Tap the output adapter gently on a wooden or other soft surface to eject the poppet from the output
adapter.

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 3 Preventive maintenance

Assemble the check valve and the low-pressure poppet

1. Use a cotton-tipped applicator to put high-pressure antiseize lubricant in the recess in the
bottom of the check valve.

2. Use a cotton-tipped applicator to guide the high-pressure poppet seat into the check valve. The
wide end of the poppet seat faces toward the check valve.

3. Push the high-pressure poppet seat into the high-pressure antiseize lubricant in the check valve.

4. Put high-pressure antiseize lubricant on the threads of the output adapter.

5. Put the high-pressure poppet spring and the high-pressure poppet in the output adapter.

6. Put the output adapter in the check valve and tighten it by hand. Use a torque wrench to tighten
Preventive maintenance

the output adapter to 115 N ∙ m (85 lbf ∙ ft).

Tightening the output adapter with the high-pressure poppet in an incorrect position
can cause damage.
When the output adapter is correctly installed, the gap between the wide part of the
output adapter and the check valve is 2.5 mm (3/32 inch) and no threads are visible.

CAUTION

If the gap is too large or if threads are visible, make sure that the poppet parts have
not moved.

7. Torque the high-pressure water fitting to 68 N ∙ m (50 lbf ∙ ft).

8. Repeat this procedure on the other end of the intensifier.

9. Connect the high-pressure tubing.

CAUTION Make sure that some of the threads on the high-pressure tubing are visible at the
fitting. Refer to High-pressure water fittings on page 144.

10. Connect the low-pressure water lines.

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 Preventive maintenance 3
Repair the bleed-down valve

Repair the bleed-down valve:

 every 1,000 hours.
 if water leaks from the Waste water out connection or from the weep holes while the pump is operating.
Replace the bleed-down valve body every 3,000 hours.

7
8

Preventive maintenance
9 10

11
1

3 4
5
2 6

1 Air fitting 7 Bleed-down valve seat

2 Actuator 8 Flow reducer
3 Needle guide 9 Outlet adapter
4 Needle 10 Tee fitting
5 High-pressure valve seal 11 Plug
6 Bleed-down valve body

Parts, tools, and materials

1-17434 Bleed-down valve repair kit 1-1/8-inch open-ended wrench
1-18311 Bleed-down valve body 13/16-inch crowfoot wrench
3/4-inch open-ended wrench Torque wrench
5/8-inch open-ended wrench Clean towels
13/16-inch open-ended wrench Isopropyl alcohol
1-inch open-ended wrench

Do this task when the pump is not operating.

1. Turn the primary breaker disconnect lever on the electrical enclosure door to OFF.

2. Turn OFF the utility water to the pump. Make sure that the water pressure gauges
show 0.0 bar (0 kPa / 0 psi).

3. Turn OFF the compressed air source.

4. Turn OFF the electrical main (line disconnect switch). Use standard lock out–tag out procedures.

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 3 Preventive maintenance

5. Remove the top cover and the front panel. Refer to Inspect the pump on page 39 for
instructions.

6. Disconnect the compressed air hose from the air fitting on top of the actuator.
Preventive maintenance

7. Disconnect the water drain tube from the bleed-down valve.

8. Use 13/16-inch open-ended wrench to loosen the high-pressure fittings attached to the
bleed-down valve body.

9. If the pump-mounted plumbing kit is installed on this machine, loosen the high-pressure fitting
near the bleed-down valve.

10. Remove the bleed-down valve assembly from the pump.

11. Remove the outlet adapter from the valve body.

12. Remove the seat and the flow reducer from the outlet adapter.

13. Remove the actuator from the valve body.

14. Push a dowel through the bottom of the valve body to remove the seal, the needle guide, and
the needle.

15. Put high-pressure antiseize lubricant on the seat.

16. Put the flow reducer into the outlet adapter.

17. Put the seat into the outlet adapter.

18. Install the outlet adapter in the bleed-down valve body. Use a torque wrench to tighten the
adapter to 95 N∙m (70 lbf∙ft).

19. Put the needle through the needle guide and the valve seal. Make sure that the point of the
needle faces the seal.

20. Put high-vacuum grease on the red O-ring on the valve seal. Make sure that the red O-ring on
the valve seal faces away from the needle.

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 Preventive maintenance 3
21. Put the needle-and-seal assembly into the valve body until the needle guide is even with the top
of the bore.

22. Install the actuator on the valve body. Tighten the actuator by hand.

23. Use a torque wrench to tighten the high-pressure fittings on the valve body. Refer to
High-pressure water fittings on page 144.

24. Connect the water drain tube to the bleed-down valve.

25. Connect the compressed air hose to the fitting on top of the actuator.

26. Turn ON the utility water to the pump.

27. Turn ON the compressed air source.

Preventive maintenance
28. Turn ON the electrical main (line disconnect switch).

29. Turn the primary breaker disconnect lever on the electrical enclosure door to ON.

30. Make sure that the EMERGENCY STOP is not engaged. If the button is pushed in, turn the
button clockwise until it releases.

31. Make sure that the key switch is set to Local .

32. Push the Controls button.

33. On the operator interface, touch the symbol to start the pump.

34. Monitor for leaks.

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 3 Preventive maintenance

Clean the air cooler

Do this task:
 every 1,000 hours.
 if you receive a Fault 1: Hydraulic Fluid >65C alarm.

CAUTION Detergent can give better cleaning results. Think about the environment when selecting and
using cleaning chemicals.
Detergent must be compatible with aluminum.

CAUTION
Preventive maintenance

Protect the motor and all electronics during the cleaning procedure.

Parts, tools, and materials

Compressed air source Recommended materials
Pressurized-water source or a steam cleaner Aluminum-compatible detergent
Operation or equivalent oil Ethylene perchlorate detergent
Oil carbon detergent

Do this task when the pump is off.

Remove the top cover and the front panel. Refer to Inspect the pump on page 39 for instructions.

Clean the air side of the cooler

CAUTION To prevent damage, the stream of water or air must be parallel to the fin.
Point the water stream against the air direction.

CAUTION Detergent can give better cleaning results. Think about the environment when selecting and
using cleaning chemicals.
Detergent must be compatible with aluminum.

1. Refer to the label on the cooler to find the cooler’s air direction.

2. Clean oil and grease off of the cooler with compressed air, pressurized water, or a steam
cleaner. Direct the cleaning stream against the cooler’s air direction.

3. After cleaning, dry the cooler.

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 Preventive maintenance 3
Clean the hydraulic fluid side of the cooler
1. Disassemble the blast oil cooler to find the degree of contamination.
If contamination is moderate, connect the oil side to a closed cleaning system with a pump and
a filter.

 Ethylene perchlorate detergent can be used. Pump the detergent through the blast oil
cooler for 10 minutes.

If contamination is very bad, use an oil carbon detergent. Rinse cleaned surfaces for 30 minutes.

2. Use compressed air to remove remaining detergent.

3. Rinse the blast oil cooler with operation or equivalent oil.

Preventive maintenance

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 3 Preventive maintenance

Replace the water filter

Do this task:
 every 1,000 hours.
 if the difference between the values on the prefilter water-pressure gauge and the postfilter water-pressure
gauge is more than 0.7 bar (70 kPa / 10 psi).
Preventive maintenance

Parts, tools, and materials

Filter cartridge, water, 1.0 micron, 10-inch Recommended materials
Filter wrench (included in the standard tool kit) Bucket or pail

Do this task when the pump is off.

1. Turn OFF the water to the pump.

2. Remove the top cover and the front panel. Refer to Inspect the pump on page 39 for
instructions.

3. Use the filter wrench to loosen the filter canister.

4. Remove the used filter cartridge from the filter canister. Discard the used filter.

 There is an O-ring in the top of the canister.

5. Pour all of the water and debris out of the canister. Rinse or wipe out the canister, if necessary.

6. Put a new filter cartridge in the canister. The filter does not have a designated top or bottom.

7. Use the filter wrench to install the filter canister.

8. Turn ON the water to the pump.

9. Turn ON the pump.

10. On the operator interface, touch the symbol start the pump.

11. Make sure that the difference between the values on the prefilter water-pressure gauge and the
postfilter water-pressure gauge is less than 0.7 bar (70 kPa / 10 psi).

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 Preventive maintenance 3
Test the total dissolved solids (TDS) level

Do this task every 1,000 hours.

CAUTION The meter is not waterproof. Do not submerge the meter in water.

Some TDS meters must be calibrated before use. For best results, calibrate the meter
at 25°C (77°F). Refer to the instructions supplied with the TDS meter.

Preventive maintenance
Refer to Test the water quality on page 83.

A total dissolved solids (TDS) test measures the total concentration of dissolved substances in
postfilter water. Dissolved solids cause deposits that can cause damage to check valves, seals,
orifices, and other consumables.

Parts, tools, and materials

1-13897 TDS meter Recommended materials
Container for a water sample Bucket or pail
Clean, deionized water or filtered water

Do this task when the pump is off.

1. Push the button on a quick-disconnect fitting to remove a low-pressure water line from the
intensifier.

2. Disable the intensifier.

a. On the operator interface, touch the adjustments symbol to open the primary adjustments
screen.

b. Touch this symbol to open the Intensifier Control screen.

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 3 Preventive maintenance

c. Touch the Intensifier On box.

Refer to Intensifier Control on page 170.

3. Set the target water pressure to 345 bar (5,000 psi). Refer to Set the target water pressure on
page 47 for instructions.
Preventive maintenance

4. Turn ON the pump.

5. Take a sample of the water from a low-pressure water line after the water filter. Make sure that
the water is clear and odorless.

6. Put the TDS meter in the water sample up to the maximum immersion level (5 cm/2 inches). Tap
the meter gently to release air bubbles.

 Wait approximately 20 seconds for the reading to become stable.

 If multiple readings are taken, turn OFF the TDS meter between readings.

7. Compare the reading to the table.

Unsatisfactory Optimal Satisfactory Unsatisfactory
Lower than 0.005% 0.005% to 0.015% 0.015% to 0.022% Higher than 0.022%
(50 ppm) (50 ppm to 150 ppm) (150 ppm to 220 ppm) (220 ppm)
A reverse osmosis
Use nonmetallic or Use a reverse osmosis
— system can be used to
stainless-steel fittings system to remove TDS
remove TDS

CAUTION A TDS level that is lower than 0.005% (50 ppm) can harm waterjet parts and
requires the use of nonmetallic or stainless steel fittings.
A TDS value of lower than 0.0005% (5 ppm) can damage stainless steel parts.

Treat water with a TDS level that is higher than 0.015% (150 ppm) with reverse
osmosis.

8. Rinse the meter in clean, deionized water or filtered water after use.

9. Connect the low-pressure water line.

10. Go to the Intensifier Control screen and enable the intensifier.

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 Preventive maintenance 3
Test the water quality

Parts, tools, and materials

TDS meter pH tester
Container for a water sample Silica test kit
Clean, deionized water or filtered water Water hardness (calcium carbonate) test kit

Do this task when the pump is not operating.

1. Take a sample from the Waste water out 1 hose. If you cannot access the hose, take a sample
from the boost pump 2 or from the hose going to the inlet water solenoid 3 (for pumps without
a boost pump).

Preventive maintenance
3

2. Make sure that the water is clear and odorless.

3. Test the pH. The optimal pH measurement is between 6.0 and 8.0.

4. Test the silica (SiO2) content. The silica content must be lower than 0.0015% (15 parts per
million [ppm]).

5. Test the water hardness. The result must be equal to or lower

than 0.006% (60 ppm / 3.5 grains per gallon).

6. Test the total dissolved solids (TDS) concentration. The optimal range is 0.005%
to 0.015% (50 ppm to 150 ppm). Refer to Test the total dissolved solids (TDS) level on
page 81.

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 3 Preventive maintenance

Replace the hydraulic filter element

Do this task:
 every 1,500 hours.
 when the needle on the hydraulic gauge is in the red zone while the pump is at stable temperature.

1
Preventive maintenance

1 Filter head 2 Sight gauge

Parts, tools, and materials

Hydraulic filter element Recommended materials
Antiwear (AW) mineral oil or synthetic hydraulic Clean funnel
fluid, ISO viscosity grade (VG) 32 or 46 Clean towels
Torque wrench
15/16-inch crowfoot wrench or socket

Do this task when the pump is not operating.

1. Remove the top cover and the front panel. Refer to Inspect the pump on page 39.

2. Remove the used filter element from the filter head.

 Use a 15/16-inch crowfoot wrench or a socket if the filter element is too tight to
remove by hand.

3. Put clean hydraulic fluid on the gasket of the new filter element.

4. Twist the filter element into the filter head.

5. Use a torque wrench to tighten the filter to a value between 13.5 N ∙ m (10 lbf ∙ ft)
and 16 N ∙ m (12 lbf ∙ ft).

6. Turn ON the pump in pierce-pressure mode.

7. Look at the sight gauge to check the hydraulic fluid level. Add hydraulic fluid, if necessary.

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 Preventive maintenance 3
Add hydraulic fluid

Do not put too much hydraulic fluid in the tank.

The capacity of the hydraulic fluid tank is 120 L (32 gallons).

Parts, tools, and materials

Antiwear (AW) mineral oil or synthetic hydraulic Recommended materials
fluid, ISO viscosity grade (VG) 32 or 46 Clean funnel

Do this task when the pump is not operating.

Preventive maintenance
1. Remove the top cover and the front panel. Refer to Inspect the pump on page 39 for
instructions.

2. Remove the filler cap.

3. Fill the tank with hydraulic fluid until the fluid is at the top mark on the sight gauge.

4. Install the filler cap.

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 3 Preventive maintenance

Replace the hydraulic fluid

Do this task:
 every 3,000 hours.
 if the hydraulic fluid is dark or milky in color or has a strong odor.
 if a test laboratory finds the quality is unsatisfactory.
Refer to Check the hydraulic fluid on page 41.

Do not put too much hydraulic fluid in the tank.

Preventive maintenance

1
2

1 Filler cap 3 Sight gauge

2 Filter head

Parts, tools, and materials

1-18772 Hydraulic fluid replacement kit Recommended materials
Antiwear (AW) mineral oil or synthetic hydraulic Clean funnel
fluid, ISO viscosity grade (VG) 32 or 46 Container for used hydraulic fluid
Clean towels Isopropyl alcohol
Siphon or siphon pump
Torque wrench
15/16-inch crowfoot wrench or socket

Do this task when the pump is not operating.

1. Remove the top cover and the front panel. Refer to Inspect the pump on page 39 for
instructions.

2. Remove the filler cap or the filter head.

3. Use a siphon or a siphon pump to remove the hydraulic fluid from the tank.

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 Preventive maintenance 3
4. Disconnect the lower ends of the hydraulic hoses that enter the top of the tank.

5. Remove the filter element and install a new element. Refer to Replace the hydraulic filter
element on page 84 for instructions.

6. Disassemble the hydraulic tank cover.

a. Disconnect the temperature/level sensor cable.
b. Disconnect the hydraulic hose from the filter.
c. Remove the 2 hoses that pass through the cover.
d. Use a 7/16-inch open-ended wrench to remove the bolts and washers (10 each) from the
tank cover.

7. Clean the inner surfaces of the tank with clean towels. Make sure that no debris is left in the

Preventive maintenance
bottom of the tank.

CAUTION Remove all towels from the tank before putting hydraulic fluid in it.

CAUTION Do not use soap, detergent, or solvents. Isopropyl alcohol can be used to clean the
tank.

8. Assemble the hydraulic tank cover.

a. Install the tank cover bolts and washers (10 each).
b. Install the 2 hoses that pass through the cover.
c. Connect the hydraulic hose from the filter
d. Connect the temperature/level sensor cable.

9. Fill the tank with hydraulic fluid until the fluid is at the top mark on the sight gauge.

10. Install a new filler cap.

11. Discard the used parts.

12. Turn ON the pump in pierce-pressure mode.

13. Monitor for leaks.

14. Add hydraulic fluid, if necessary. Refer to Add hydraulic fluid on page 85.

15. Operate the pump in pierce-pressure mode for 15 to 20 minutes.

 If air is in the hydraulic system, the pump can be noisy during operation. Refer to The
pump makes noise during operation on page 133.

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 3 Preventive maintenance

Lubricate the primary motor bearings

Do this task every 3,000 hours.

CAUTION Correct lubrication is important for motor performance.

Use the correct types and amounts of grease and oil.

CAUTION The bearing can overheat if too much or not enough grease is used to lubricate the bearing
Preventive maintenance

Most handheld pump grease guns have an output of 1.25 grams of grease per pump. Check
with the manufacturer of your grease gun.

Parts, tools, and materials

Low-pressure handheld grease gun Recommended materials
NLGI grade 2 bearing grease Mobil Polyrex™ EM
Clean towels

Do this task when the pump is operating.

1. Remove the top cover and the front panel. Refer to Inspect the pump on page 39 for
instructions.

2. Remove the grease fitting cap.

3. Remove the plastic plug on the bottom side of the motor.

4. Clean the grease fitting with a towel, if necessary.

5. Attach a grease gun coupler to the grease fitting.

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 Preventive maintenance 3
6. Use a grease gun to put the specified quantity of grease in the motor.
Echion 15 Echion 30 Echion 50

13 grams 18 grams 21 grams

7. Replace the grease cap.

CAUTION Use only the recommended volume of grease.

8. Do this procedure again on the other end of the motor.

Preventive maintenance
9. Use the postmaintenance start procedure after working on the primary motor. Refer to
Postmaintenance start procedure on page 91.

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 3 Preventive maintenance

Start the pump after maintenance

CAUTION A turning motor shaft can be dangerous. Close all doors and replace all covers, including
access covers.

CAUTION Do not try to repair a leak with pressure in the system.

CAUTION Remove all tools, towels, and rags from the work area before starting the equipment.
Preventive maintenance

CAUTION Make sure that all fittings are tight after doing maintenance on or repairs to this equipment.

Start the pump normally if maintenance done on the

Use the Postmaintenance start procedure on page 91
pump was limited to: if maintenance or repairs have been done on:
• replacing the water filter.
• the high-pressure water system.
• replacing the hydraulic filter element.
• intensifier components.
• replacing the hydraulic fluid.
• the primary motor.
• repairing or replacing the bleed-down valve.
• working on the electrical system.
Refer to Start the pump on page 43 for instructions.

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Postmaintenance start procedure
A smooth start after maintenance can give the high-pressure seal longer life.

 Touch the symbol to stop the procedure and to turn OFF the pump.

Use this program to increase the water pressure gradually. The procedure takes
approximately 6 minutes. Refer to Touchscreen maps on page 177 for details about the program.

1. Turn ON the utility water to the pump.

2. Turn ON the compressed air source.

3. Turn ON the electrical main (line disconnect switch).

Preventive maintenance
4. Turn the primary breaker disconnect lever on the electrical enclosure door to ON.

5. Make sure that the EMERGENCY STOP is not engaged. If the button is pushed in, turn the
button clockwise until it releases.

6. Make sure that the key switch is set to Local .

7. Push the Controls button.

8. On the operator interface, touch the maintenance symbol to open the primary maintenance
screen.

9. Touch this symbol to open the Start Procedure screen.

10. Touch the symbol on the screen to start the procedure.

While the procedure continues, examine the pump for high-pressure water leaks and
hydraulic fluid leaks. Monitor these areas.
 Hydraulic connections
 Valves
 Intensifier bridge and bottom deck

11. When Turn On the Cutting Head flashes on the screen:

a. Move the cutting head to a safe location on the table.
b. Turn ON the cutting head.
c. Touch the symbol to continue.

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 3 Preventive maintenance

12. When Turn Off the Cutting Head flashes on the screen:
a. Turn OFF the cutting head.
b. Touch the symbol to continue.

13. When Examine the Pump flashes on the screen:

a. Examine the pump for loose fittings or leaks.
b. Examine the attenuator connections for leaks.
Preventive maintenance

c. Touch the symbol to continue.

 The main motor turns off.
 The primary operation screen opens.

14. Install the top cover and the front panel.

The pump is ready for operation.

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 Preventive maintenance 3
Prepare for storage

WARNING High-pressure water can cause eye injuries. Wear approved eye protection when operating or
doing work near this equipment.
Do not stand over components such as tubes or valves while drying the system.

All low-pressure water connections use push-to-connect fittings.

Use this procedure to prepare the system for storage. Clearing the water lines prevents freezing,
which can cause damage to the pump.

Preventive maintenance
5

2
6

Cutting water in Water-cooled system

7 Boost pump 5 Cooling in
4 Inlet water solenoid (for systems 6 Cooling out
without a boost pump)
3 Waste water out
2 Compressed air
1 Cutting water out

Refer to Connect the water and the air on page 157 for information about the connections.

Parts, tools, and materials

1/8-inch male to 1/2-inch male adapter Water-cooled system
(compressed air to cutting water in)
1-inch open-ended wrench
1/8-inch male to 1-inch male adapter
1-3/16-inch open-ended wrench
(compressed air to cooling in)
7/16-inch open-ended wrench
1-1/16-inch open-ended wrench
Filter wrench (included in the standard tool kit)

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 3 Preventive maintenance

Do this task when the pump is not operating.

1. Remove the water filter from the filter canister. Refer to Replace the water filter on page 80.

2. Pour the water out of the filter canister.

3. Install the water filter canister without the filter.

4. Disconnect the compressed air from the pump. Connect the compressed air hose to the
Cutting water in connection.

 The compressed air hose connection is 1/8-inch NPT male. The Cutting water in
connection is 1/2-inch NPT female. An adapter (not included) is necessary.

5. Use a 1-1/16-inch open-ended wrench to disconnect the Waste water out hose from the
Preventive maintenance

pump.

6. On the operator interface, touch the maintenance symbol to open the primary maintenance
screen.

7. Touch this symbol to open the Prepare for Storage screen.

8. Touch the symbol on the screen to start the procedure.

The supply water valve opens.

9. Turn ON the compressed air for a minimum of 5 minutes to dry the system.

10. Turn OFF the compressed air.

11. Touch the symbol to continue.

The water valve closes.

12. Disconnect the compressed air hose from the Cutting water in connection.

13. Make sure that the water filter canister is empty. Water can collect in the canister when the
system is cleared.

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 Preventive maintenance 3
14. Install the water filter canister with the filter.

15. Do this procedure for a water-cooled system.

Air-cooled systems do not require fluid removal.

a. Use a 1-inch open-ended wrench to connect the compressed air hose to the Cooling in
connection.

 The Cooling in connection is 1/2-inch NPT female. An adapter (not included) is

necessary.

b. Use a 1-3/16-inch open-ended wrench to disconnect the Cooling out line from the pump.

Preventive maintenance
c. Disconnect the compressed air hose from the Cooling in connection.
d. Do step 8 through step 12 again.

16. Install the original caps and the plugs for the utility connections.

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 3 Preventive maintenance

Recycling and end of product life

At the end of the life of the product or its parts, recycle or discard materials and parts. Use an
environmentally satisfactory method and in accordance with local regulations. If the product
contains substances that could cause damage to the environment, remove and dispose of them in
accordance with current local regulations. This includes liquids such as hydraulic fluid.

Make sure that dangerous substances are disposed of safely and that the correct personal
protective equipment is used. The safety specifications must be in accordance with the current local
regulations at all times.
Preventive maintenance

96 810770 Operator Manual Echion

 Parts lists

Parts lists
Genuine Hypertherm parts are the factory-recommended replacement parts for this pump. It is
possible that the Hypertherm warranty will not cover damage caused by nongenuine Hypertherm
parts.

To order parts, contact the original equipment manufacturer (OEM).

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 4 Parts lists

Tools

1-18768 Standard tool kit

1
6
5
4 12
2 3

11

10
7 9
8
Parts lists

Part number Description Quantity

1 1-12091 Torque wrench, 3/4-inch drive, 80 N∙m to 400 N∙m (60 lbf∙ft 1
to 300 lbf∙ft)
2 1-17490 Breaker bar, 40-inch 1
3 1-18038 White lithium grease, 44.3 ml (1.5 fluid oz) 1
4 1-13537 PURE Goop halocarbon-based antiseize lubricant, 28 g (1 oz) 1
5 1-11111 Blue Goop oil-based antiseize lubricant, 57 g (2 oz) 1
6 1-11136 High-vacuum grease, 150 g (5.3 oz) 1
7 1-13972 Water filter wrench 1
8 1-18851 Square drive adapter, 3/4-inch female to 1/2-inch male 1
9 1-18852 Hex-bit socket, 1/2-inch square drive, 3/8-inch 1
10 1-12021 12-point socket, 3/4-inch square drive, 1-1/2-inch 1
11 1-13281 Granite lapping block 1
12 1-11210-12 Lapping paper, 12 micron, 1 sheet 10

The tool case contains all of the above items except:

 The torque wrench has a separate case.
 The granite lapping block is shipped in a wooden box.
 The breaker bar is shipped in a bag.

98 810770 Operator Manual Echion

 Parts lists 4
Intensifier repair tools

1
3

Part number Description Quantity

1 1-18416 Seal installation tool 1
2 1-18803 Seal removal tool 1
3 1-18848 Cylinder locator tool 1

These tools are shipped with the pump.

Parts lists

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 4 Parts lists

Maintenance and repair kits

1-18769 Echion standard spare parts kit

Part number Description Quantity
1-18770 Repair kit, high-pressure seal, Echion 2
1-18771 Repair kit, high-pressure poppet, Echion 1
1-18849 Repair kit, low-pressure poppet, Echion 1
1-17434 Repair kit, bleed-down valve 1
1-18772 Replacement kit, hydraulic fluid 1
1-11106 Filter cartridge, water, 1.0 micron, 10-inch 1

1-18770 Echion high-pressure seal repair kit

Parts lists

4
1

3 5

Description Quantity
1 Spring, energized seal, 7/8-inch 2
2 O-ring backup, seal housing, -122 2
3 O-ring, seal housing, -122 2
4 Seal cartridge, high-pressure 2
5 Poppet screw, low-pressure 2

Each high-pressure seal cartridge includes:

1 2 3 4

1 High-pressure seal O-ring, greased, -119 3 High-pressure hoop

2 High-pressure seal 4 High-pressure seal backup, bronze

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 Parts lists 4
1-18771 Echion high-pressure poppet repair kit

3
1
4

Description Quantity
1 Cotton-tipped applicator 2
2 Poppet, high-pressure 2
3 Poppet spring, high-pressure 2
4 Poppet seat, high-pressure 2

Parts lists
1-18849 Echion low-pressure poppet repair kit

2
4

Description Quantity
1 Wear ring, check valve 2
2 O-ring, check valve, -120 2
3 Poppet screw, low-pressure 2
4 Poppet, low-pressure 2

Echion Operator Manual 810770 101

 4 Parts lists

1-17434 Bleed-down valve repair kit

3 4 5 6
7

Description Quantity
1 High-vacuum grease, 150 g (5.3 oz) 1
2 Poppet seat, high-pressure 1
3 Valve seal, high-pressure 1
4 Needle, bleed-down valve 1
5 Needle guide, bleed-down valve 1
Parts lists

6 O-ring, -011 1
7 Flow reducer insert, bleed-down valve 1
8 Wooden dowel 1

1-18772 Hydraulic fluid replacement kit

Description Quantity
1 Filter element, hydraulic, 5-micron 1
2 Filler cap 1

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 Parts lists 4
Optional equipment kits

Part number Description

Boost pump kit
1-18603
100 gallons per hour, 208 V / 230 V
Boost pump kit
1-18576
100 gallons per hour, 400 V / 460 V
1-18551 Modbus TCP/IP communication kit
1-18552 Utility connection panel kit
1-18553 Metric conversion kit
1-18695 Pump-mounted plumbing kit

Parts lists

Echion Operator Manual 810770 103

 4 Parts lists

Replacement parts

Item numbers in orange are not shown in the illustration. The number shows the relative location
of the part in or on the machine.
Colors (blue, green, pink, and yellow) are used in the illustrations to show where one
component ends and another begins. The colors are used for contrast and do not mean
anything specific.

1-18938 Top-cover hardware replacement kit

Description Quantity
Snap-in handle 2
Latch receptacle 2
Latch stud 2
Latch retainer 2
Latch spring 2
Parts lists

Lubricants
Part number Description
1-11111 Blue Goop oil-based antiseize lubricant, 57 g (2 oz)
1-13537 PURE Goop halocarbon-based antiseize lubricant, 28 g (1 oz)
1-11136 High-vacuum grease, 150 g (5.3 oz)
1-18038 White lithium grease, 44.3 ml (1.5 fluid oz)

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 Parts lists 4
Electrical system
2

Parts lists
Part number Description
1 1-15005 PLC, Horner XL4 (requires program 1-18855)
2 1-18755 Proximity switch
— 1-17355 Memory card, SDHC MicroSD, 32GB (not shown)

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 4 Parts lists

High-pressure water system

17
2 1 18 16
15 14
3 11 12
19 13
10

8 9

5
4
6

Part number Description

1 1-18314 Echion intensifier
2 1-14687 Sheathing end cover, high-pressure tubing, 3/8-inch
3 1-18445 Tube, high-pressure, intensifier left
Parts lists

4 1-12982 Inlet adapter, 3/8-inch male × 3/8-inch female

5 1-12280 Attenuator assembly, 1 liter
6 1-WJN6600375 Tube nipple, high-pressure, attenuator-to-tee
7 1-18694 Tube, high-pressure, L-shaped
8 1-13158-60-6 Gland nut, high-pressure, 3/8-inch
9 1-13157-60-6 Collar, high-pressure, 3/8-inch (not shown)
10 1-13160-60-4F6F Reducing coupling, high-pressure, 3/8-inch female × 1/4-inch female
11 1-13158-60-4 Gland nut, high-pressure, 1/4-inch
12 1-13157-60-4 Collar, high-pressure, 1/4-inch (not shown)
13 1-WJN6600725 Tube nipple, bleed-down valve-to-tee
14 1-13949 Air solenoid, bleed-down valve
15 1-18310 Bleed-down valve assembly, air-actuated
16 1-18311 Bleed-down valve body
17 1-17130 Plug, stainless steel NPT, 1/2-inch (not shown)
18 1-WJN6600500 Tube nipple, high-pressure, intensifier right
19 1-18784 Replacement kit, bleed-down valve air tube, 1/4-inch
— 1-12580 Protective sheathing, 3/8-inch (not shown)

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 Parts lists 4
Intensifier high-pressure ends
8
5
4
3
2
1

6 7

Part number Description

1 1-18381 Output adapter
2 1-18631 Check valve assembly
3 1-18395 Spacer tube
4 1-18386 Cylinder, high-pressure

Parts lists
5 1-18384 Seal housing assembly
6 1-11468 Spacer, rod seal
7 1-12370 Snap ring, rod seal
8 1-18935 Stud assembly

The check valve assembly includes:

1 2 3 4 5 6

1 Low-pressure poppet screw 4 Low-pressure poppet

2 Low-pressure poppet retainer 5 Check valve body
3 Check valve guide ring 6 Check valve O-ring, -120

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 4 Parts lists

Low-pressure water system

1

3 9
2
4
8
5

Part number Description Quantity

1 1-11832 Gauge, low-pressure water 1
Parts lists

2 1-18782 Replacement kit, intensifier inlet water tube 1

3 1-11679-237 O-ring, low-pressure, filter canister (not shown) 1
4 1-18318 Canister assembly, water filter 1
5 1-18417 Switch, low-pressure water 1
6 1-18577 Dirty water container 1
7 1-18783 Replacement kit, fluid management tube 2
8 1-12614 Solenoid valve, inlet water 1
9 1-18931 Boost pump wet end assembly 1
— 1-13897 Meter, TDS (not shown) 1

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 Parts lists 4
Hydraulic system
4

2
5
1
6

Parts lists
Part number Description
1 1-11733 Assembly, shift valve, 24 VDC
2 1-17348 Transducer, hydraulic
3 1-17347 Valve and coil, proportional cartridge
4 1-17349 Relief valve, hydraulic high-pressure, preset
5 1-12617 Switch, temperature and fluid level
6 1-18898 Gauge, hydraulic filter

Echion Operator Manual 810770 109

 4 Parts lists
Parts lists

110 810770 Operator Manual Echion

 Troubleshooting

This section assumes that the user is familiar with the Safety, Operation, Preventive
maintenance, and Specifications sections of this manual.

Troubleshooting
Images in this manual are for reference purposes. It is possible that your product configuration is
not shown accurately.

It is possible that not all of the information in this section applies to all pump models.

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 5 Troubleshooting

Safety

WARNING Read and understand all of the safety guidelines in this manual.
Refer to Safety on page 21 before operating, doing maintenance on, repairing, and installing
your pump.

Keep the work area clean and dry.

Clean fluid spills immediately.
Use a pan or a tray below areas where water or hydraulic fluid can spill during maintenance or
repair procedures.

Obey local protocols for recycling or disposal of parts, materials, and fluids.
National and local environmental rules can apply to disposal.
Refer to Recycling and end of product life on page 96.

Coordinate maintenance and repairs with facility and safety staff.

General
Troubleshooting

If the problem is not found in this section, contact a Hypertherm Technical Service Associate for
information and support.

Keep accurate maintenance records.

Records can help with predicting and preventing maintenance problems.

Use SAE (US standard) tools for most procedures.

112 810770 Operator Manual Echion

 Troubleshooting 5
Primary operation screen

Intensifier stroke-rate bars and status indicator

1
2
3

1 Intensifier status indicator 2 Intensifier stroke rate to the left

Enabled (green) 3 Intensifier stroke rate to the right
Not enabled (red) The stroke rate is within the permitted
range (green).
The stroke rate is at the limit of the
permitted range (yellow).
The intensifier is overstroking (red).

During normal operation, the intensifier strokes smoothly to the left and to the right at the same

Troubleshooting
speed.

 It is normal for the intensifier to stroke faster during the start sequence and when
changing from pierce pressure to cut pressure.

The stroke-rate bars show the speed of the piston and the plunger moving to each side of the
intensifier (if you are facing the front of the pump.)

The height of the bars in relation to each other show if the piston is stroking evenly from side to side
or if one side is stroking faster than the other (overstroking). This information is useful during
troubleshooting. Uneven bars can mean that poppet maintenance required.

If a bar is red, then an overstroke has caused an alarm condition on that side.

Echion Operator Manual 810770 113

 5 Troubleshooting

Alarms

The controller monitors the pump while the pump is operating. When the controller senses a
problem that is likely to cause damage to the equipment, the operator interface shows the Alarms
screen.

To acknowledge an alarm, touch the screen. The Alarm Log screen opens.
Troubleshooting

Touch Ack (acknowledge) or Ack All (acknowledge all) on the screen.

The alarm screen closes.

Types of alarms
The intensifier is... The primary motor is... Cause of alarm
The controller senses a
Warning Enabled On condition that can cause a
problem or a failure.
The controller senses a
Fault 1 Off Off condition that will cause a
problem or a failure.
The controller senses a
Fault 2 Off Off
failure condition.

114 810770 Operator Manual Echion

 Troubleshooting 5
Warnings
Alarm Cause Solution
Warning: Battery Error The controller battery is not Contact a Hypertherm Technical
operating correctly. Service Associate for information
and support.
Warning: Boost Motor The boost motor or the fan motor Reset the relay.
did not start because the thermal • Find the thermal overload relay
Warning: Fan Motor
overload relay has tripped. on the motor starter.
• Turn the knob clockwise to the
ON position (I).
• Release the knob. It snaps
counterclockwise to the OFF
position (O).
• Turn the knob clockwise to the
ON position (I) again.

Troubleshooting
On Tripped Off
Warning: Start Procedure An error occurred during stage 3 of • Make sure that the cutting head
Hydraulics the start sequence. is off.
• The cutting head is on. • Repair or replace the
• The bleed-down valve is bleed-down valve.
leaking. • Make sure that the compressed
• The bleed-down valve is not air supply is on.
receiving air. • Adjust the timer on the
• The Hydraulics timer setting is Start-procedure Timers screen.
too short. Refer to Start Procedure
Timers on page 166
Warning: Start Procedure Ramp An error occurred during stage 4 of
to Pierce Pressure the start sequence.
Warning: Start Procedure Ramp An error occurred during stage 5 of
to Cut Pressure the start sequence.
Warning: Too Many Motor Starts Starting and stopping the motor Wait longer between stopping and
in 15 Minutes rapidly can cause damage to the starting the motor.
motor.

Echion Operator Manual 810770 115

 5 Troubleshooting

Faults
Fault conditions cause the pump to turn off.

Alarm Cause Solution

Fault 1: Hydraulic Fluid >65C The system is not cooling Refer to Temperature on page 124.
The hydraulic fluid temperature is sufficiently.
higher than 65ºC (149ºF).
Fault 1: Intensifier Overstroke to A poppet (high-pressure or Check the low-pressure poppet on
Left low-pressure) is stuck or is leaking. the same side as the overstroke.
Fault 1: Intensifier Overstroke to Check the high-pressure poppet on
Right the opposite end from the
An overstroke fault occurs when the overstroke.
hydraulic piston travels faster than Refer to Overstroke on page 121.
the pump can sustain.
Fault 1: Low Inlet Water Pressure The supply-water pressure is lower Increase the supply pressure.
than 2.8 bar (280 kPa / 40 psi).
Pressure is lost because of a leak. Identify the source of a leak and
correct the problem.
The supply water is off. Turn ON the supply water.
Fault 2: Hydraulic Fluid 45C The temperature sensor in the Replace the sensor.
Sensor hydraulic fluid tank has failed.
Fault 2: Hydraulic Fluid Level is A hydraulic fitting or a hydraulic Fix the leak.
Troubleshooting

Low hose is leaking. Refer to Hydraulic fluid on

The float switch in the hydraulic page 123.
fluid tank monitors the fluid level.
The sensor is faulty. If the tank is full, replace the sensor.
A poppet (high-pressure or Check the low-pressure poppet.
low-pressure) is stuck or leaking.
Fault 2: Input to Primary Motor The controller did not receive a Contact a Hypertherm Technical
Not Received signal from the starter when the Service Associate for information
pump was turned on. and support.
Fault 2: Water Pressure Control The pump did not get to the target Replace the component.
Error water pressure within the expected
time.
• The hydraulic pressure
transducer on the pump
manifold has failed.
• The proportional valve has
failed.
• The proportional valve coil has
failed.
• The hydraulic pump has failed.
The orifice has failed. Check the condition of the orifice.
Replace it, if necessary.
A component inside the hydraulic Contact a Hypertherm Technical
center section has failed. Service Associate for information
and support.

116 810770 Operator Manual Echion

 Troubleshooting 5
Alarm Cause Solution
Fault 2: Primary Motor The thermal overload relay has Reset the relay.
The primary motor did not start. tripped. Refer to Warning: Boost Motor on
page 115.

The relay can take several

minutes to cool before
resetting.

The motor is too hot. Refer to Primary motor on

page 117.
The soft starter sensed a fault. 1. Turn the primary breaker
disconnect lever on the
electrical enclosure door to
OFF.

The pump is not energized.

2. Turn the primary breaker

disconnect lever on the
electrical enclosure door to
ON.

The pump is energized.

It can take several minutes

Troubleshooting
for the system to reboot.

A fuse in the electrical enclosure Replace the blown fuse.

has blown.

Primary motor

Problem Cause Solution

The motor is too hot. The motor is not cooling sufficiently. Clean the air inlet.
Clean the outlet and the cooling fins.
Reduce the ambient air temperature,
if possible.
The motor is being started too Wait longer between stopping and
frequently. starting the motor.
The motor bearing is too hot. Lubricate the bearing.
Refer to Lubricate the primary motor
bearings on page 88.

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 5 Troubleshooting

Intensifier

Leaks
CAUTION If a high-pressure poppet part is damaged, replace the assembly (high-pressure poppet,
spring, and seat).

Fluid leaking from a weep hole is a sign of a defective part or a loose connection.

1
3
Troubleshooting

7
6
5
2
4

Numbers pointing to items in the illustration correspond with numbers in the table.

118 810770 Operator Manual Echion

 Troubleshooting 5
Symptom Cause Solution
1 The fitting or the output adapter The high-pressure poppet is • Disassemble the parts and
is hot leaking. look for flaws, deterioration,
erosion marks, or cracks.
• Make sure that the mating
surfaces are smooth and
clean.
• If damage is found, replace
the component.
2 Water leaks from the weep hole A high-pressure tubing • Examine the connection.
connection is loose or damaged. • Make sure that the fitting is
tightened correctly and to the
correct torque value.
Refer to High-pressure water
fittings on page 144.
The output adapter has failed. Replace the component.
3 Hot water is leaking. The output adapter is loose. Make sure that the adapter is
tightened to the correct torque
value.
Refer to High-pressure water
fittings on page 144.
The high-pressure seat has failed. • Disassemble the parts and
look for flaws, deterioration,

Troubleshooting
erosion marks, or cracks.
• Make sure that the mating
surfaces are smooth and
clean.
• If damage is found, replace
the component.
The face of the check valve is Replace the check valve.
cracked.
Cold water is leaking. The O-ring on the check valve Replace the O-ring.
body has failed.
4 Cold water leaks from the weep A fitting connection is bad. Make sure that the fitting is
hole. tightened to the correct torque
value.
Refer to High-pressure water
fittings on page 144.
The fitting is warm or the The low-pressure poppet is Repair or replace the poppet.
low-pressure water line is leaking.
The check valve is cracked.
pulsing.
Replace the check valve.

Echion Operator Manual 810770 119

 5 Troubleshooting

Symptom Cause Solution

5 Hydraulic fluid is leaking from The hydraulic end cap bolts are Make sure that the end cap bolts
between a high-pressure end not tightened. are tightened to the correct torque
cap and a high-pressure value.
cylinder. Refer to Fittings on page 144.
An O-ring has failed. Examine and replace the O-ring.
A high-pressure seal is damaged • Disassemble the parts and
or has failed. look for flaws, deterioration,
erosion marks, or cracks.
• Make sure that the mating
surfaces are smooth and
clean.
• If damage is found, replace
the component.
6 Hydraulic fluid is leaking. The O-ring on the proximity switch Replace the O-ring or the sensor.
has failed.
7 Water leaks at a rate of more The high-pressure seal has failed. Replace the seal.
than 30 ml/minute.
Hydraulic fluid leaks at a rate of The hydraulic seal has failed. Replace the seal.
more than 30 ml/minute.
8 Water is leaking. The high-pressure cylinder has Replace the cylinder.
failed.
Troubleshooting

The check valve body has failed. Replace the check valve body.

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 Troubleshooting 5
Overstroke

Alarm
If an overstroke alarm shows on the operator interface:

1. Turn OFF the cutting head.

2. Acknowledge the alarm.

3. Turn the pump on in cut-pressure mode. The intensifier begins stroking.

4. Turn on the cutting head.

5. Monitor the intensifier stroke rate indicator on the operator interface.

If 1 side of the intensifier is stroking too fast, is there a leak from a weep hole on the intensifier?
Yes Inspect the high-pressure seal.
Check valve weep hole Check the output adapter torque.
Check the high-pressure fitting torque.
High-pressure endcap and high-pressure Check the torque.
cylinder
The check valve or the high-pressure cylinder is
cracked

Troubleshooting
Inspect the check valve O-ring.
No Is the output temperature hot?
Yes Inspect the high-pressure poppet.
Inspect the low-pressure poppet.
• Examine the low-pressure poppet and the
check valve body.
• Make sure that the mating surfaces are
clean and smooth with a mirrorlike finish.
No • Repair or replace the low-pressure poppet.
• Repair or replace the poppet retainer.
• Make sure that the low-pressure poppet
fits in the poppet retainer without sticking.
Shake the assembly and listen for the
poppet moving inside.
If the overstroke is to the left A poppet is sticking, worn, or damaged.
• Check the low-pressure poppet on the left
side of the intensifier.
• Check the high-pressure poppet on the
right side of the intensifier.
If the overstroke is to the right A poppet is sticking, worn, or damaged.
• Check the low-pressure poppet on the
right side of the intensifier.
• Check the high-pressure poppet on the left
side of the intensifier.

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 5 Troubleshooting

If both sides of the intensifier are stroking too fast, is a leak visible?
Yes The high-pressure tubing or a fitting is leaking. Identify the source of a leak and correct the
problem.
A high-pressure water seal is worn or • Disassemble the intensifier.
damaged. • Examine the parts. Look for flaws,
deterioration, erosion marks, corrosion, or
cracks.
• Make sure that the mating surfaces are
smooth and clean.
• If damage is found, replace the component.
The bleed-down valve is leaking or has failed. Repair or replace the bleed-down valve.
The needle and the seat in the cutting head are • Examine the parts. Look for flaws,
leaking. deterioration, erosion marks, corrosion, or
The on/off valve has failed. cracks.
The cutting head has failed. • Make sure that the mating surfaces are
smooth and clean.
• If damage is found, replace the component.
No The orifice is worn, has failed, or is incorrectly Replace the orifice.
installed.
A worn or damaged orifice can increase the
demand for high-pressure water from the
intensifier.
Troubleshooting

The orifice is the wrong size.

Is the bleed-down valve hot?

Yes The bleed-down valve has failed. Repair or replace the bleed-down valve.
The bleed-down valve is not getting air. • Make sure that the compressed air source
is on.
• Make sure that the compressed air hose is
not damaged.
• Make sure that the compressed air hose is
connected correctly.
No The postfilter water-pressure gauge shows that Replace the water filter if the difference
the low-pressure water is lower between the values on the prefilter
than 2.8 bar (280 kPa / 40 psi). water-pressure gauge and the postfilter
water-pressure gauge is lower
than 0.7 bar (70 kPa / 10 psi).
The prefilter water-pressure gauge shows that • Make sure that the water to the pump is on.
the low-pressure water is lower • Make sure that the low-pressure water line
than 2.8 bar (280 kPa / 40 psi). is connected to the intensifier.
Low water pressure can cause an • If the pump has a boost pump, examine the
overstroke without triggering the water filter. If the filter is black, the boost
low-pressure alarm for the low-pressure pump has failed and must be replaced.
water. Contact a Hypertherm Technical Service
Associate for information and support.

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 Troubleshooting 5
Hydraulic fluid

Problem Cause Solution

The intensifier does not stroke. Intensifier control is off. Turn intensifier control on.
When intensifier control is off, the Refer to Intensifier Control on
primary screen shows a red × on the page 170.
intensifier symbol.

The cutting head is off. Turn on the cutting head.

A proximity switch has failed. Replace the switch. Contact a
Hypertherm Technical Service
Associate for information and
support.
High-pressure water seal life is A component is damaged or has • Do preventive maintenance
short. failed. according to the recommended

Troubleshooting
schedule. Refer to Preventive
maintenance schedule on
page 60.
• Examine the high-pressure
cylinder, the plunger, and the
high-pressure water seal.
• Look for flaws, deterioration,
erosion marks, corrosion, or
cracks.
• Make sure that the mating
surfaces are smooth and clean.
If damage is found, replace the
component.
The supply-water flow or pressure is Make sure that the supply-water flow
too low. and pressure are sufficient.
Refer to Specifications on page 135.
The proportional control valve is not Contact a Hypertherm Technical
operating correctly. Service Associate for information and
support.
The water quality is not sufficient. Make sure that the water quality is
within satisfactory range.
Refer to Test the water quality on
page 83.

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 5 Troubleshooting

Temperature
Hydraulic fluid that is too cool is thick, which can cause increased friction and insufficient
lubrication.

Hydraulic fluid that is too hot is thin, which can accelerate wear on the parts, increase the formation
of sludge, degrade the fluid, and decrease its lubrication and protective qualities.

A sensor monitors the hydraulic fluid temperature in the tank. Increased temperature can mean that
there is a problem with the cooling system.

 High altitude and ambient air temperatures can have an effect on the temperature of
hydraulic fluid.

The hydraulic pump has failed.

Contact a Hypertherm Technical Service Associate.

A relief valve has failed.

Contact a Hypertherm Technical Service Associate.

There is a problem in the hydraulic center section of the intensifier.

Contact a Hypertherm Technical Service Associate.
Troubleshooting

The cooling water supply or the chiller is turned off.

Turn ON the water supply or the chiller.

Water-cooled system

The cooling water is not turned on.

Turn ON the cooling water.

The cooling water is too warm.

Water that is too warm is not good for cooling and can shorten high-pressure seal life.
If the cooling water or the supply-water temperature is higher than 24°C (75°F), cool the water
before use.
Make sure that the heat exchanger fins are not dirty or clogged. Flush the heat exchanger.

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 Troubleshooting 5
Air-cooled system

Do not adjust the setting on the thermal overload relay unless instructed to do so by a
Hypertherm Technical Service Associate.

The ambient air temperature is too high.

Ambient air temperature can affect cooling. If a pump that is installed in a small space or in a
high-temperature location, consider adding a chiller to the system for supplemental cooling.

The fan is not generating enough airflow.

Make sure that the fan motor breaker is not tripped.
Clean the air cooler. Refer to Clean the air cooler on page 78.

The thermal overload relay turned off the fan motor.

Reset the relay. Refer to Warning: Boost Motor on page 115.

The sensor is not sensing the correct temperature.

Plug in the sensor.

Troubleshooting
Replace the cord.

The temperature sensor is faulty or damaged.

Replace the sensor.

Pressure

The hydraulic fluid pressure is too low.

The cut pressure is not set correctly.

Make sure that the cut pressure is set correctly.

The pump is in pierce-pressure mode.

Make sure that the pump is in cut-pressure mode.

The relief valve on the hydraulic manifold has failed.

Contact a Hypertherm Technical Service Associate for information and support.

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 5 Troubleshooting

Level
A float switch in the hydraulic fluid tank causes an alarm when the hydraulic fluid level is too low.

The hydraulic fluid level is too low.

Make sure that the hydraulic fluid level is at the top mark on the sight gauge.

A hydraulic fitting or a hydraulic hose is leaking.

Fix the leak.
Tighten the fitting to the correct torque value.
Replace the hose.
Replace the O-ring.

Hydraulic fluid was lost during maintenance.

Add hydraulic fluid. Refer to Add hydraulic fluid on page 85.

Hydraulic fluid leaks from the intensifier.

An O-ring or an energized seal spring has failed.

Troubleshooting

Disassemble the intensifier.

Disassemble the parts and look for flaws, deterioration, erosion marks, or cracks.
Make sure that the mating surfaces are smooth and clean.
If damage is found, replace the component.

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 Troubleshooting 5
Appearance

The hydraulic fluid in the tank has a milky appearance.

A leaking high-pressure seal in the intensifier can push water past the energized seal spring
energized seal spring and into the hydraulic fluid. Contaminated hydraulic fluid can cause
damage to the hydraulic pump.

Water has leaked into the heat exchanger.

Water-cooled system: The heat exchanger has failed.

1. Replace the hydraulic fluid. Refer to Replace the hydraulic fluid on page 86.

 It could be necessary to drain and flush other areas such as the shift valve, the
hydraulic manifold, and the hydraulic pump.

2. Examine the parts, including the inner surfaces of the hydraulic fluid tank, the hydraulic hoses,
and the seals. Look for flaws, deterioration, erosion marks, corrosion, or cracks.
If damage is found, replace the component.

Troubleshooting

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 5 Troubleshooting

Water

Low-pressure water

The supply-water pressure is too low.

A pressure switch before the water filter senses the supply-water pressure. If the value on the
prefilter water-pressure gauge is lower than 2.8 bar (280 kPa / 40 psi), the water pressure to the
intensifier is too low. This causes a fault.

The supply-water pressure or flow is not sufficient.

Make sure that the supply water meets requirements found in Specifications on page 135.

The supply-water pressure is too high.

If the value on the prefilter water-pressure gauge is higher than 7.6 bar (760 kPa / 110 psi), the
water pressure is too high.

The boost pump is not needed.

The low-pressure water parts are rated for a maximum pressure of 8.6 bar (860 kPa / 125 psi).
Troubleshooting

In environments with high supply-water pressure, the boost pump can increase the water
pressure to higher than the maximum. This can cause damage to the water filter and other parts.
If the value on the prefilter water–pressure gauge is higher than 4.8 bar (480 kPa / 70 psi):
 In the electrical enclosure, turn the switch on the boost pump motor contactor to 0.
 On the operator interface, turn OFF boost pump monitoring. Refer to Pump Fault
Behavior on page 168.

The boost pump bypass relief valve is not adjusted correctly.

Refer to Adjust the boost pump pressure on page 162 for instructions for adjusting the valve.

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 Troubleshooting 5
High-pressure water

The pump cannot get to the target water pressure.

The orifice is defective.

Replace the orifice.

There is a leak.
If the intensifier strokes when it is in cut-pressure mode with the cutting head turned off, check
the on/off valve at the cutting head, the bleed-down valve, and the high-pressure tubing for
leaks.
Refer to Leaks on page 118.

A check valve is damaged.

Disassemble the parts and look for flaws, deterioration, erosion marks, or cracks.
Make sure that the mating surfaces are smooth and clean with a mirrorlike finish.
If damage is found, replace the component.

The pump is in pierce-pressure mode or is set incorrectly.

Troubleshooting
Put the pump in cut-pressure mode.
Make sure that the cut pressure is set correctly.

The supply water is not turned on.

Turn on the supply water.

A water filter is clogged.

Replace the water filter.

The boost pump has failed.

Examine the water filter. If the filter is black, the boost pump has failed and must be replaced.
Contact a Hypertherm Technical Service Associate for information and support.

A poppet is sticking, worn, or damaged.

Disassemble the parts and look for flaws, deterioration, erosion marks, or cracks.
Make sure that the mating surfaces are smooth and clean with a mirrorlike finish.
If damage is found, replace the component.

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 5 Troubleshooting

Pressure at the cutting head is too low.

The thimble filter on the on/off valve is clogged.

Clean or replace the thimble filter.

There is a blockage in the high-pressure tubing or at the orifice.

Remove the blockage from the high-pressure tubing.
Clean or replace the orifice.

The high-pressure poppet has failed.

CAUTION If a high-pressure poppet part is damaged, replace the full assembly (high-pressure
poppet, spring, and seat).

If an output adapter feels hot:

Disassemble the parts and look for flaws, deterioration, erosion marks, or cracks.
Make sure that the mating surfaces are smooth and clean.
If damage is found, replace the component.
Troubleshooting

A component in the high-pressure end has failed.

Replace the high-pressure seal.
If a high-pressure cylinder feels hot:
Disassemble the parts and look for flaws, deterioration, erosion marks, or cracks.
Make sure that the mating surfaces are smooth and clean.
If damage is found, replace the component.

 If the high-pressure seal is removed from the plunger when you disassemble the
intensifier, replace the seal.

The orifice is not the correct size or too many are being used at the same time.
Make sure that the number of orifices and their sizes are sufficient for the pump’s output.

An orifice has failed.

Replace the orifice.

The bleed-down valve has failed.

If the bleed-down valve feels hot or if water comes out of the drain hose, repair or replace the
bleed-down valve.

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 Troubleshooting 5
Leaks

Water leaks from the intensifier.

Refer to Leaks on page 118.

Water leaks through the intensifier drain tubes.

A high-pressure water seal is damaged.

A damaged high-pressure water seal is the most common cause of water leaking from the
intensifier.
Replace the high-pressure seal.
If a high-pressure cylinder feels hot:
Disassemble the parts and look for flaws, deterioration, erosion marks, or cracks.
Make sure that the mating surfaces are smooth and clean.
If damage is found, replace the component.

 If the high-pressure seal is removed from the plunger when you disassemble the
intensifier, replace the seal.

Troubleshooting
A fitting is leaking.

A low-pressure water line is not seated fully in the fitting.

Make sure that the low-pressure water line is pushed all the way into the fitting.
Make sure that the O-ring is not damaged or missing. Replace, if necessary.

The collar on a high-pressure water fitting is not correctly installed.

Refer to High-pressure water fittings on page 144.

A fitting on the high-pressure tubing is not tight enough.

Tighten the fitting to the maximum torque value.
Disassemble the parts and look for flaws, deterioration, erosion marks, or cracks.
Make sure that the mating surfaces are smooth and clean.
If damage is found, replace the component.

A tubing end is cracked or damaged.

Replace the tubing.

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 5 Troubleshooting

The end cap nuts are not correctly tightened.

Loosen all of the end cap nuts and then torque them to 373 N∙m (275 lbf∙ft) in 68 N∙m (50 lbf∙ft)
increments. Use a repeating cross pattern.

Water leaks onto the floor or into the pump frame

The dirty water container is full.

Empty the container.

The dirty water container is misaligned.

Move the container.
Troubleshooting

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 Troubleshooting 5
The pump makes noise during operation

The pump can make unusual noise during operation if air is in the hydraulic system.

1. Use a 10-mm socket or an open-ended wrench to tighten the hose clamp on the suction hose
that goes from the hydraulic fluid tank to the hydraulic pump.

2. Torque the hose clamp to a maximum of 16 N∙m (12 lbf∙ft).

Troubleshooting
If the pump continues to make noise after the hose clamp is tightened, contact a Hypertherm
Technical Service Associate for information and support.

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 5 Troubleshooting

Controller errors

Input/output status
This screen shows the status of inputs to and outputs from the controller.

Status: = enabled = not enabled

This table describes the assigned inputs and outputs. These can be helpful for troubleshooting.

I1 Not used l13 Not used

l2 Not used l14 Not used
I3 Hydraulic fluid temperature is higher l15 Controls on
than 65°C (149°F) I16 Remote mode on
Troubleshooting

I4 Hydraulic fluid temperature is higher l17 Remote pump on

than 45°C (113°F)
l18 Remote pump off
l5 Low inlet pressure switch
l19 Not used
l6 Front intensifier left proximity switch
l20 Remote pierce-pressure on
l7 Front intensifier right proximity switch
l21 Primary motor fault
l8 Not used
l22 Primary motor on
l9 Not used
l23 Boost pump on
l10 Not used
I24 Heat exchanger fan on
l11 Not used
l12 Not used

Q1 Low-pressure on Q9 Not used

Q2 Proportional control output Q10 Not used
Q3 Not used Q11 Not used
Q4 Pump on Q12 Primary motor on
Q5 Fan motor on Q13 Boost pump motor on
Q6 Enable bleed-down valve Q14 Remote fault light
Q7 Front-left shift-valve solenoid Q15 Left frame light (red)
Q8 Front-right shift-valve solenoid Q16 Right frame light (red)

AI1 Hydraulic pressure AQ1 Not used

AI2 Remote pressure control AQ2 Not used

134 810770 Operator Manual Echion

 Specifications

When applicable, measurements are presented in metric units, followed by International System
of Units (SI) units and US Customary units in parentheses.

1 bar (100 kPa / 15 psi) 10 mm (3/8 inch) 115 N ∙ m (85 lbf ∙ ft)

This equipment is manufactured in the US, so a metric equivalent is not always available
because of inexact conversion.

Specifications

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 6 Specifications

All Echion-model pumps

Environmental conditions

Glycol can be added to the cooling circuit to prevent freezing, but glycol is less efficient for
cooling than water.
Hypertherm recommends using a solution of not more than 25% glycol in chillers for this
system.

Ambient air temperature 4°C to 35°C (40°F to 95°F)

Relative humidity
95%
Noncondensing
Storage temperature
2°C to 55°C (35°F to 131°F)
Water not drained

Hydraulic fluid

Domestic pumps ship from the factory with AW 32 hydraulic fluid.

Type Antiwear (AW) mineral oil or synthetic hydraulic fluid, ISO viscosity
grade (VG) 32 or 46
Hydraulic fluid tank capacity 120 L (32 gallons)
Specifications

Maximum pressure
217 bar (21,700 kPa / 3,150 psi)
Set at the factory
Operation temperature 46°C to 54°C (115°F to 130°F)

A laboratory analysis of hydraulic fluid can tell you if replacement is recommended.

The maximum contamination from particulates that is permitted is 19/17/14 when tested according
to ISO 4406. The maximum recommended contamination from water is 300 ppm when tested
according to ASTM D6304c-04. If it is not practical to analyze a sample of your hydraulic fluid,
Hypertherm recommends replacing it every 3,000 hours.

Refer to Replace the hydraulic fluid on page 86.

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 Specifications 6
Utilities

Electrical power
The motor size determines the full load amperes, the overload settings, and the wire sizes. Refer to
your pump model (beginning on page 138 in this section) or to the electrical drawings.

 The electrical drawings are shipped in an envelope that is found inside the electrical
cabinet.

The pump uses 3-phase alternating current (AC) electricity. Some parts, such as valve solenoids
and sensors, use 24-volt direct current (VDC) electricity from a power supply in the electrical
enclosure.

Supply water

Do not use deionized water unless the system has stainless steel water fittings.
Deionized water can cause the plumbing parts to fail.

Softened water is necessary for most systems. Get advice from a specialist for recommendations
for choosing a water treatment system. Reverse osmosis systems are available from Hypertherm.

If the cooling water or the supply water temperature is higher than 24°C (75°F), cool the water
before use. Water that is too warm can shorten high-pressure seal life.

Cooling

Specifications
Heat removal
Refrigeration tons requirement
Pump model kW (minimum)
(minimum tons)
(minimum Btu/hour)
Echion 15 3 0.85 10,000
Echion 30 6 1.70 20,000
Echion 50 9 2.70 32,000

Compressed air
Minimum Maximum
Pressure 4.8 bar (70 psi) 5.5 bar (80 psi)

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 6 Specifications

Echion 15

Dimensions and weights

Length 135 cm (53 in.) Shipping weight 850 kg (1,850 lb)
Width 109 cm (43 in.) Operating weight 775 kg (1,700 lb)
Height 101 cm (40 in.)

The shipping weight is for the pump, the pallet, and the packaging. Exact weights are measured at
shipment. Operating weight is for an unpackaged pump with hydraulic fluid.

Electrical
11.2 kW, 15hp 50 Hz 60 Hz
Voltage 400 V 208 V to 230 V 460 V
Full-load current 23 A 45 A to 41 A 21 A
Primary circuit breaker rating 30 A 60 A 30 A

Water
Minimum Maximum
Cutting water in
Specifications

Flow 3.8 L/minute (1.0 gallon/minute) —

Pressure 2.8 bar (280 kPa / 40 psi) 7.6 bar (760 kPa / 110 psi)
Cutting water out
Flow — 1.1 L/minute (0.3 gallon/minute)
Pressure 345 bar (34,500 kPa / 5,000 psi) 4,140 bar (414,000 kPa / 60,000 psi)
Cut-pressure
— 4,140 bar (414,000 kPa / 60,000 psi)
factory setpoint
Pierce-pressure
1,380 bar (138,000 kPa / 20,000 psi) —
factory setpoint
Cooling in and Cooling out
Flow 11.4 L/minute (3 gallons/minute) —
Pressure 2.8 bar (280 kPa / 40 psi) 7.6 bar (760 kPa / 110 psi)

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 Specifications 6
Echion 30

Dimensions and weights

Length 135 cm (53 in.) Shipping weight 900 kg (2,000 lb)
Width 109 cm (43 in.) Operating weight 825 kg (1,850 lb)
Height 101 cm (40 in.)

The shipping weight is for the pump, the pallet, and the packaging. Exact weights are measured at
shipment. Operating weight is for an unpackaged pump with hydraulic fluid.

Electrical
22.4 kW, 30 hp 50 Hz 60 Hz
Voltage 400 V 208 V to 230 V 460 V
Full-load current 44 A 82 A to 76 A 38 A
Primary circuit breaker rating 60 A 100 A 60 A

Water
Minimum Maximum
Cutting water in

Specifications
Flow 4.5 L/minute (1.2 gallons/minute) —
Pressure 2.8 bar (280 kPa / 40 psi) 7.6 bar (760 kPa / 110 psi)
Cutting water out
Flow — 2.3 L/minute (0.6 gallon/minute)
Pressure 345 bar (34,500 kPa / 5,000 psi) 4,140 bar (414,000 kPa / 60,000 psi)
Cut-pressure
— 4,140 bar (414,000 kPa / 60,000 psi)
factory setpoint
Pierce-pressure
1,380 bar (138,000 kPa / 20,000 psi) —
factory setpoint
Cooling in and Cooling out
Flow 11.4 L/minute (3 gallons/minute) —
Pressure 2.8 bar (280 kPa / 40 psi) 7.6 bar (760 kPa / 110 psi)

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 6 Specifications

Echion 50

Dimensions and weights

Length 135 cm (53 in.) Shipping weight 1,000 kg (2,200 lb)
Width 109 cm (43 in.) Operating weight 925 kg (2,050 lb)
Height 101 cm (40 in.)

The shipping weight is for the pump, the pallet, and the packaging. Exact weights are measured at
shipment. Operating weight is for an unpackaged pump with hydraulic fluid.

Electrical
37.3 kW, 50 hp 50 Hz 60 Hz
Voltage 400 V 208 V to 230 V 460 V
Full-load current 74 A 136 A to 124 A 62 A
Primary circuit breaker rating 100 A 200 A 100 A

Water
Minimum Maximum
Cutting water in
Specifications

Flow 7.6 L/minute (2 gallon/minute) —

Pressure 2.8 bar (280 kPa / 40 psi) 7.6 bar (760 kPa / 110 psi)
Cutting water out
Flow — 3.8 L/minute (1 gallon/minute)
Pressure 345 bar (34,500 kPa / 5,000 psi) 4,140 bar (414,000 kPa / 60,000 psi)
Cut-pressure
— 4,140 bar (414,000 kPa / 60,000 psi)
factory setpoint
Pierce-pressure
1,380 bar (138,000 kPa / 20,000 psi) —
factory setpoint
Cooling in and Cooling out
Flow 11.4 L/minute (3 gallons/minute) —
Pressure 2.8 bar (280 kPa / 40 psi) 7.6 bar (760 kPa / 110 psi)

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 Specifications 6
Orifices

US Customary (inches)

Number of orifices Echion 15 Echion 30 Echion50

1 0.007 0.011 0.014
2 0.005 0.007 0.010
3 0.004 0.006 0.008
4 — 0.005 0.007
5 — 0.004 0.006
6 — — 0.005

Stroke rate

The maximum intensifier stroke rate is calculated using the motor wattage and the size of the
hydraulic pump.

Maximum
Echion pump model
strokes/minute
Echion 15 40 Default overstroke percentage = 5%
Echion 30 79 Maximum overstroke percentage = 20%
Echion 50 107

Specifications

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 6 Specifications

Torque values

Fasteners
WARNING Do not use more torque than the values specified in these tables for load-carrying fasteners.

End cap fasteners

These torque values are for bolts that are coated with antiseize bolt lubricant (white lithium grease).
Torque value
Wrench size
N∙m lbf∙ft
High-pressure end cap nut 373 275 1-1/2-inch socket
Hydraulic end cap screw 88 65 3/8-inch hex

Tighten each end cap nut in 68 N•m (50 lbf•ft) increments. Use a repeating cross
pattern.
Specifications

SAE J518 flange bolts

These torque values are for bolts that are coated in antiseize bolt lubricant (white lithium grease).
Code 61 grade 8 (low pressure) Code 62 grade 8 (high pressure)
1/16-inch dash size Bolt size Bolt size
N∙m lbf∙ft N∙m lbf∙ft
(inch) (inch)
-08 5/16-18 24 18 5/16-18 24 18
-12 3/8-16 43 32 3/8-16 43 32
-16 3/8-16 43 32 7/16-14 70 52
-20 7/16-14 70 52 1/2-13 108 80
-24 1/2-13 108 80 5/8-11 217 160

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 Specifications 6
Install a flange

Parts, tools, and materials

Hydraulic fluid
Antiseize bolt lubricant (white lithium grease)
Open-ended wrench (refer to Wrench size in the table on page 142)
Torque wrench

1. Examine the parts. Look for flaws, deterioration, erosion marks, corrosion, or cracks. Make sure
that the mating surfaces are smooth and clean.
If damage is found, replace the component.

2. Put the O-ring in the flange groove.

Lubricate the O-ring with hydraulic fluid before installing it.

3. Put the flange halves together.

To make a good seal, the sealing face must be parallel to the mating surface and the
bolt tension must be even. Align the flange face with the mating surface.

4. Lubricate the bolt threads with antiseize bolt lubricant.

5. Put the lock washers on the bolts.

6. Install the bolts. Specifications

7. Tighten the bolts by hand.

8. Use a torque wrench to tighten the bolts to the specified value.

Tighten each bolt in small increments. Use a repeating cross pattern.

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 6 Specifications

Fittings
WARNING Do not tighten a fitting too much. The fitting can fail.

High-pressure water fittings

WARNING High-pressure water fittings are designed to make a tight seal. If a fitting is installed
incorrectly, it can fail.

CAUTION To prevent causing damage or premature failure, use 2 wrenches when loosening or
tightening a high-pressure connection.
Always tighten fittings to the specified torque.

CAUTION Do not use an adjustable wrench on high-pressure fittings.

Use a high-pressure antiseize lubricant such as Blue Goop or PURE Goop on

high-pressure water fittings.

Use only enough torque to make a sufficient seal.

Torque values can vary depending on thread condition. A sufficient seal can be made at
values much lower than the maximum values shown in the table.
Specifications

If a fitting leaks after tightening it to the maximum torque value, disassemble the parts.
Repair or replace parts that show deterioration, corrosion, or damage.

Torque value
Wrench size
N∙m lbf∙ft
Output adapter 102 75 1 inch
High-pressure water fitting (gland nut)
1/4 inch 34 25 5/8 inch
3/8 inch 68 50 13/16 inch
9/16 inch 150 110 1-3/16 inch

This table shows maximum values. The torque necessary to make a sufficient seal depends
on the condition of the tube threads and can be much lower than the maximum.

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 Specifications 6
Install a gland nut

Parts, tools, and materials

Open-ended wrench (refer to the Torque value table on page 144)

Torque wrench
High-pressure antiseize lubricant such as Blue Goop or PURE Goop

1. Put high-pressure antiseize lubricant on the gland nut threads, the threads inside the collar, and
on the cone and the threads on the high-pressure tube.

2
3

1 High-pressure tube 2 Gland nut

3 Collar

2. Put the gland nut on the high-pressure tube.

3. Put the collar on the high-pressure tube. Specifications

Make sure that some of the threads on the high-pressure tubing are visible at the fitting.

Incorrectly installed collar: The collar interferes with the seal surface.

Correctly installed collar: The seal surface is showing.

4. Push the high-pressure tube fully into the fitting.

5. Tighten the gland nut by hand.

6. Use a torque wrench to tighten the gland nut to the specified value.

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 6 Specifications

Low-pressure water fittings

Do not use lubricants on low-pressure water fittings.

All low-pressure water connections use push-to-connect fittings.

Specifications

146 810770 Operator Manual Echion

 Installation

This section assumes that the user is familiar with the Safety, Operation, Preventive
maintenance, Troubleshooting, and Specifications sections of this manual.

Images in this manual are for reference purposes. It is possible that your product configuration is
not shown accurately.

It is possible that not all of the information in this section applies to all pump models.

Installation

Echion Operator Manual 810770 147

 7 Installation

Safety

WARNING Read and understand all of the safety guidelines in this manual.
Refer to Safety on page 21 before operating, doing maintenance on, repairing, and installing your
pump.

Buyer responsibilities

WARNING This pump can supply water pressure of up to 4,140 bar (414,000 kPa / 60,000 psi).

Only use tubing that is rated for this pressure.

WARNING Use supports for plumbing to prevent damage to plumbing from bending stress and fatigue from
vibration.

The buyer is responsible for these obligations.

 Cooperate with Hypertherm and the Hypertherm original equipment manufacturer (OEM)
regarding the installation of the equipment.
 Obey all setup and first-time start up instructions in this manual.
 Research and obey all local codes, including requirements for waste water disposal.
 Install high-pressure tubing.
 Install water-treatment equipment before the pump is installed.
 Make sure that all utilities are available during installation.
Installation

 The site must have sufficient electrical power, air, water, and drain access.
 Make all connections to the pump.
 Fill the hydraulic fluid tank.
 Perform user qualification and training. Refer to User qualification and training on page 23.

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 Installation 7
Requirements

Location
WARNING Some locations can be dangerous if the atmosphere contains explosive gas, vapors, or dust.
Refer to requirements from the National Electric Code (NEC), the International Electrotechnical
Commission (IEC), the Occupational Safety and Health Administration (OSHA), and other
national and local codes for information about environmental criteria.

Make sure that there is a minimum clearance of 91 cm (36 inches) on all sides of the equipment.
This lets air movement help cool the machine and keeps space available for doing maintenance
and repairs.

Do not install this equipment in an area where the temperature is below freezing. Freezing can
cause damage to the pump.

Install the pump on a solid, flat surface that can hold the weight of the equipment and is thick
enough to resist vibration.

Make sure that there is sufficient space for auxiliary equipment such as a water softener, a reverse
osmosis system, or a chiller.

High altitude or ambient conditions can have an effect on the temperature of hydraulic fluid. Fluid
that is too cool is thick, which causes increased friction and poor lubrication. Fluid that is too hot is
thin, which can accelerate wear on the parts, increase the formation of sludge, degrade the fluid,
and decrease its lubrication and protective qualities.

Refer to Environmental conditions on page 136 for air temperature and humidity specifications.

Cooling
If this pump is installed in a small space or in a high-temperature location, consider adding a
Installation

chiller to the system for supplemental cooling. Use the Cooling table on page 149 to calculate
the cooling load.

If the cooling water or the supply water temperature is higher than 24°C (75°F), cool the water
before use. Water that is too warm can shorten high-pressure seal life.

Hydraulic fluid
Hypertherm does not ship all pumps with hydraulic fluid in the tank.

Refer to Hydraulic fluid on page 136 for specifications.

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 7 Installation

Utilities
Refer to Utilities on page 137 for system specifications.

Electrical power
WARNING A line disconnect switch for incoming electrical power must be installed near the power
supply.
This is a supply-voltage disconnecting device or an energy-isolating device.

CAUTION The primary feed circuit breaker or fuse must be the correct size to control inrush and
steady-state current.
Use a motor-start circuit breaker or an equivalent if time-delay high-inrush fuses are not
permitted by national or local codes.

Compressed air
The bleed-down valve uses compressed air to operate.

Supply water

Local codes can require a backflow prevention valve to separate the pump from the facility’s
potable water.

Water quality
The quality of the water supplied to the intensifier has a direct effect on the life of the intensifier
and consumables.
Bad water quality increases operating costs by causing unnecessary wear on pump parts and
Installation

shortening maintenance intervals.

Before installing this equipment, test the supply water.

 Water quality reports that show pH, silica, and hardness levels are frequently available
for no charge from public utility water suppliers.

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Receive and unpack the equipment

WARNING Lifting must be done by a trained operator.

Obey all work site safety requirements, the safety instructions for the lifting equipment, and the
safety information in this manual.

For easy reference, write your pump information on the Pump information page at the back of this
manual.

Boxes and parts are frequently packed in the pump, or in crates, boxes, and packaging.
Look for accessories and spare parts before discarding the packaging.

1. Examine containers, crates, and pallets for damage.

2. Remove the equipment from the shipping crates and pallets.

3. Examine the equipment to make sure that it was not damaged during shipping. If the equipment
is damaged, a claim must be filed with the carrier.

4. Make sure that the delivery and shipping documents match the equipment that was ordered and
what was received. Report shortages or damages to the OEM or to Hypertherm Waterjet
within 10 days of receipt of the equipment.

5. Make sure that these items are included with the pump.
 Dirty water container
 Intensifier repair tools, refer to page 99
 These items are shipped inside the electrical enclosure:
 key for the Local/Remote key switch
 MicroSD card adapter
 electrical drawings
Installation

 Optional items
 1-18768 Standard tool kit, refer to page 98
 1-18769 Echion standard spare parts kit, refer to page 100
 Optional equipment kits, refer to page 103

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 7 Installation

Install the pump

CAUTION Hydraulic, water, and electrical connections can become loose during shipping and normal
operation. Examine all connections at installation and during regular maintenance.

To connect the pump directly to an external control device, such as a CNC, refer to the CNC
manual and contact your OEM or a Hypertherm Technical Service Associate for information and
support.

These instructions are for a typical installation. It could be necessary to install the components in a
different order.

Install the pump in a location that agrees with the requirements and recommendations for this
equipment. Refer to Specifications, which begins on page 135.

 Hypertherm recommends installing the Echion pump on a level surface with a

difference in height of no more than 8 cm (1/4 inch) between opposite ends.
Installation

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 Installation 7
Install the pump-mounted plumbing kit (optional)
Refer to Fittings on page 144 for torque values and information about how to correctly install
high-pressure water fittings.

The plumbing kit makes installing high-pressure tubing from the pump to the cutting table easier.

 The reducing adapter for this kit changes the 3/8-inch high-pressure connection
to 1/4 inch.
4

1 Tubing bracket 3 Reducing adapter, 3/8-inch to 1/4-inch

2 L-shaped tubing 4 Clamp

Parts, tools, and materials

1-18695 Pump-mounted plumbing kit

Installation

Two 1/16-inch open-ended wrenches

5/8-inch open-ended wrench
1-1/16-inch open-ended wrench
13/16-inch open-ended wrench
5/8-inch crowfoot wrench
13/16-inch crowfoot wrench
Torque wrench
High-pressure antiseize lubricant such as Blue Goop or PURE Goop

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 7 Installation

1. Find the mounting holes for the plumbing kit on the right side of the pump.

2. Use two 7/16-inch open-ended wrenches and hardware from the kit to install the tubing
bracket on the pump frame.

3. Use a 1-1/16-inch open-ended wrench to hold the high-pressure tee on the attenuator. Use
a 13/16-inch open-ended wrench to install the long end of the L-shaped tubing into the fitting.
Installation

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 Installation 7
4. Use a 13/16-inch open-ended wrench to install the reducing adapter on the short end of
the L-shaped tubing. Use a torque wrench to tighten the fitting to 68 N∙m (50 lbf∙ft).

5. Use a 5/8-inch open-ended wrench to install your 1/4-inch high-pressure tubing from the
cutting head into the top of the reducing adapter. Use a torque wrench to tighten the fitting
to 34 N∙m (25 lbf∙ft).

6. Use two 7/16-inch open-ended wrenches and hardware from the kit to attach the tubing to the
tubing bracket with the clamps.

Installation

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 7 Installation

Connect the utilities to the pump

CAUTION Compressed air is an energy source that can eject with force.
Be careful when connecting to and disconnecting from this energy source.

CAUTION WATER-COOLED SYSTEM

Do not connect the Waste water out hose and the Cooling out line together.
Connecting these hoses can cause cooling water to back up into the system, which can cause
damage to the bleed-down valve and intensifier parts.
CAUTION To prevent dirty water from entering the bleed-down valve, install the Waste water out hose so
that it is below the bleed-down valve.

Refer to Fittings on page 144 for torque values and information about how to correctly install
high-pressure water fittings.

The utility connections are identified with hang tags. The tags have symbols on them that
correspond with the table on page 157.

Parts, tools, and materials

9/16-inch open-ended wrench 1/8-inch NPT male fitting

13/16-inch open-ended wrench 3/8-inch high-pressure male fitting
1-1/16-inch open-ended wrench Two 1/2-inch NPT male fittings
Torque wrench
High-pressure antiseize lubricant such as Blue Goop or PURE Goop

Water-cooled system
Installation

1-inch open-ended wrench Two 1/2-inch NPT male fittings

1-3/16-inch open-ended wrench

1. Remove the top cover and the front panel. Refer to Inspect the pump on page 41 for
instructions.

2. Remove the caps from the fittings and the plugs from the utility connections.

Keep the caps and the plugs to use if the pump is stored or shipped.

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Connect the water and the air
5

2
6

1 8

Name of connection and symbol (on the tag)

 Factory-installed connection  Fitting required (not included)

Cutting water out Connect 1 end of the high-pressure tubing to the

cutting head.
This tubing carries high-pressure water from the Put the other end of the tubing through the hose
intensifier to the cutting table. access hole 1 on the side of the pump.
Connect the tubing to the high-pressure tee
inside the pump frame.
 3/8-inch high-pressure female  3/8-inch high-pressure male
Put the other utility hoses and lines into the pump through the larger cutout 8 .

Cutting water in Connect 1 end of this line to the supply water.

Connect the other end to the inlet-water
This line carries low-pressure water from a water solenoid  4 or to the boost pump 7 , if equipped.
softener, a reverse osmosis system, a well, or a
public utility to the pump.
 All low-pressure water connections use
push-to-connect fittings.
Installation

 1/2-inch NPT female  1/2-inch NPT male

Waste water out Connect 1 end of this hose to the drain.

Connect the other end to the brass tee 3 on the
This hose carries water from the bleed-down bleed-down valve assembly.
valve to a drain.
 To make maintenance of the bleed-down valve
easier, make this connection easy to remove.
 1/2-inch NPT female  1/2-inch NPT male

Compressed air Connect a compressed air hose to the solenoid

valve  2 mounted to the frame near the
The bleed-down valve uses compressed air to bleed-down valve.
operate.
 1/8-inch NPT female  1/8-inch NPT male

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 7 Installation

Water-cooled system
Cooling in Connect 1 end of this line to the supply water or to
the chiller.
This line carries low-pressure water from the local Connect the other end to the ball valve at the heat
utility or a chiller to the pump’s cooling loop. exchanger inlet 5 .
 1/2-inch NPT female  1/2-inch NPT male

Cooling out Connect 1 end of this line to the to the chiller or to

the drain.
This line carries low-pressure water from the heat Connect the other end to the heat exchanger
exchanger to the chiller or to the drain. outlet  6 .
 1/2-inch NPT female  1/2-inch NPT male

Connect the electrical power

CAUTION This waterjet pump can leak up to 160 mA.
To reduce the effects of a high leakage current, connect the pump to a dedicated supply
transformer that has separate windings.

Use electrical parts that are certified by national or local electrical codes.

Hydraulic, water, and electrical connections can become loose during shipping and normal
operation.
Examine all connections at installation and during regular maintenance.

1. Attach a ground leg to the grounding lug in the electrical enclosure.

Use this table to find the minimum cross-sectional area of the external copper ground leg.
If the cross-sectional area (S mm2) of the
copper phase conductors supplying the The minimum cross-sectional area (Sp mm2) is
equipment is
Installation

equal to or higher than 16 equal to S

higher than 16 and lower than or equal to 35 16
higher than 35 S/2

2. Connect electrical power to the primary circuit breaker. The breaker is labeled on the technical
drawing and in the electrical enclosure as CB-1.

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 Installation 7
Check the hydraulic fluid

CAUTION Make sure that hydraulic fluid is available during installation and for the first start.

Look at the sight gauge to check the hydraulic fluid level. Add hydraulic fluid, if necessary. Refer to
Add hydraulic fluid on page 85 for instructions.

Do the first start

CAUTION If a water line, a fitting, or a valve could be frozen, do not operate the pump. Thaw the equipment
until water moves easily through the system.
Examine the parts for damage. Replace parts, if necessary.

CAUTION This procedure could cause damage to the orifice.

Do not do the first start with a diamond orifice installed. Hypertherm recommends using a ruby
orifice during the first 40 hours of operation.
Installation

Use this procedure:

 at installation.
 when putting the equipment into operation after storage or shipping.
 after maintenance or repairs are done on the intensifier, the high-pressure water system, or
the low-pressure water system.

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 7 Installation

Do a preoperation inspection
WARNING Make sure that all connections, fasteners, locking devices, hoses, and fittings are tight.

 Look for leaks, deterioration, damage, or other conditions that can interfere with operation.
 Look at the sight gauge on the hydraulic fluid tank. Add hydraulic fluid, if necessary.
 Make sure that all warning decals are visible and legible.

Turn on the utilities

CAUTION A leak can cause damage to the water fittings.
Monitor for leaks during this procedure.
Identify the source of a leak and correct the problem.

1. Turn ON the utility water to the pump.

2. Turn ON the compressed air source. Set the air pressure between 4.8 bar and 5.5 bar (70 psi
and 80 psi).

Air pressure that is too low can prevent the bleed-down valve from closing and can
CAUTION cause the intensifier to overstroke.
Air pressure that is too high can cause damage to the needle and the seat in the
bleed-down valve. If the available air pressure is too high, install an air regulator (not
included) to reduce the pressure.

3. Turn ON the electrical main (line disconnect switch).

Installation

4. Turn the primary breaker disconnect lever on the electrical enclosure door to ON.

5. Make sure that the EMERGENCY STOP is not engaged. If the button is pushed in, turn the
button clockwise until it releases.

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 Installation 7
Make sure that the primary motor turns in the correct direction
WARNING It is necessary to have access to a turning shaft for this procedure.
Do not put an object or a body part near the shaft while the access cover is off.

CAUTION Make sure that the primary motor turns in the correct direction before starting the pump.
If the motor turns in the opposite direction, the impeller could turn and loosen.
This can cause damage to the hydraulic pump.

1. Make sure that the key switch is set to Local .

2. Remove the shaft access cover.

3. Push the Controls button to turn on the control circuit in the pump.

4. Touch the symbol to turn ON the pump momentarily. Make sure that the primary motor turns
in the direction shown by the rotation arrow.

5. Touch the symbol to turn OFF the pump.

If the pump motor turned in the wrong direction:
a. Turn the primary breaker disconnect lever on the electrical enclosure door to OFF.
b. Turn OFF the electrical main (line disconnect switch). Use standard lock out–tag out
procedures.
c. Inside the electrical enclosure, interchange 2 cables on the top of the primary circuit
breaker.

Installation

d. Turn ON the electrical main (line disconnect switch).

e. Turn the primary breaker disconnect lever on the electrical enclosure door to ON.
f. Do step 3 through step 4 again. Make sure that the primary motor turns in the direction
shown by the rotation arrow.

6. Install the shaft access cover.

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 7 Installation

Turn on the pump

CAUTION A leak can cause damage to the water fittings.
Identify the source of a leak and correct the problem.

1. Set the pressure to 345 bar (5,000 psi).

2. On the operator interface, touch the symbol to start the pump.

3. Let the pump operate for 2 to 3 minutes.

4. Monitor for leaks.

Adjust the boost pump pressure

CAUTION Do not set the boost pump pressure higher than 7.6 bar (760 kPa / 110 psi). The components
are rated for a maximum of 8.6 bar (860 kPa / 125 psi).
Pressure that is too high can cause damage to the components.

If the supply water is from a reverse osmosis system, contact a Hypertherm Technical Service
Associate for information and support.

1. Make sure that the value on the prefilter water-pressure gauge is between 6.9 bar
and 7.6 bar (690 kPa and 760 kPa / 100 psi and 110 psi).

1 2
Installation

1 Postfilter water-pressure gauge 2 Prefilter water-pressure gauge

If the pressure is not in range:

a. Pull the boost pump adjustment knob out.

b. Turn the knob clockwise to increase the pressure. Turn the knob counterclockwise to
decrease the pressure.
c. Push the knob in to lock it.

2. Close all doors and replace all panels and covers, including the top cover.

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 Installation 7
Flush the pump and the high-pressure tubing
CAUTION This procedure can cause damage to the on/off valve needle and the seat and to the orifice.
Keep spare parts and orifices available.

If this pump was purchased through an OEM, the OEM could recommend a different procedure
to flush out the high-pressure tubing.

It is common for small pieces of metal and debris to be present in newly installed high-pressure
tubing. Flush the system to prevent damage to orifices, on/off valve parts, and other components of
the high-pressure system.

1. Remove the cutting head and the orifice.

2. Make sure that the on/off valve is closed.

3. Turn ON the pump.

4. Set the pressure to 345 bar (5,000 psi).

5. On the operator interface, touch the symbol to start the pump.

6. Make a program that turns the valve ON and OFF in 1-second increments. Operate the program
in a loop for 15 minutes.
If a program is not available, turn the cutting head ON and OFF in 1-second intervals
for 15 minutes. This loosens debris in the high-pressure tubing.

7. Turn OFF the pump.

8. Install a ruby orifice in the cutting head. For orifice sizes, refer to Orifices on page 141.

9. Turn ON the pump.

Installation

10. On the operator interface, touch the symbol to start the pump.

11. Increase the pressure to 2,760 bar (40,000 psi). Operate the program in a loop for 15 minutes.

12. Increase the pressure to 4,140 bar (60,000 psi). Operate the program in a loop for 15 minutes.
If the on/off valve leaks, examine the needle, the seat, the seals, and the orifice for damage.
Replace parts, if necessary.

The pump is ready for normal operation.

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 7 Installation

Operator interface: Adjustment screens

Not all screens are used when installing the pump.

Touch the current screen symbol to go back 1 screen.

Refer to Touchscreen maps on page 175 to see all of the screens available on the controller.

The adjustment screens on the operator interface let the user change the system configuration.

On the operator interface, touch the adjustments tab to open the primary adjustments screen.

Pump Adjustments Intensifier Control

Pressure SD Card
Date / Time / Language

Pump Adjustments
Installation

Pump Information Remote Configuration

Start Procedure Timers Stop Procedure Timers
Pressure Adjustments Pump Fault Behavior

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 Installation 7
Pump Information
>

Model Number This is the model number of the pump.

Voltage This is the line voltage of the pump
Frequency This is the line voltage frequency of the pump.
Cooling Type This the type of heat exchanger the pump uses (water or air).
Pressure Units • Touch this field to open a numeric keypad.
• Touch the up or down arrows to select the units (bar or psi) that show on the
operator interface screens.
Software Part # This is the Hypertherm part number and the revision version for the software
installed on the controller.
Software Version This is the version of the software on the controller.

Installation

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 7 Installation

Start Procedure Timers

>

All time is in seconds. Refer to page 179 for information about the start procedure.

Ramp Time This is the time that the system takes to increase the high-pressure water pressure
from 0 to the target water pressure.
Increase the value to slow the process.
The timer default is between 3  seconds and 8 seconds, based on the pump
model.
Intensifier The system goes to the next stage when the time between intensifier strokes is
longer than this value.
The timer default is 1.5 seconds.
Inlet Water Stage 1
After the system gets to the target water pressure, the Inlet Water timer starts.
The timer default is 5 seconds.
Bleed Valve Stage 2
The intensifier strokes and has this much time to push air that is in the system out
through the open bleed-down valve.
The timer default is 5 seconds.
Hydraulics Stage 3
After the bleed-down valve closes, the system has this much time to get to the
Installation

minimum hydraulic pressure.

The timer default is 5 seconds.
The hydraulic pressure setpoint default is 17 bar (250 psi).
Refer to Hydraulic fluid on page 136 in the Specifications section.
Pierce Stage 4
The system has this much time to get to the pierce-pressure setpoint.
The timer default is 5 seconds.
Refer to the Water table for your pump model in the Specifications section.
Cut Stage 5
If the pump is in cut-pressure mode, the system has this much time to get to the
cut-pressure setpoint.
The timer default is 5 seconds.
Refer to the Water table for your pump model in the Specifications section.

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 Installation 7
Pressure Adjustments
>

Maximum This is the maximum pressure that the system can be adjusted to.
The default is 4,140 bar (60,000 psi).
Increments
Increase This is how much the target water pressure increases each time you touch the 
symbol on the primary operation screen.
The default is 34 bar (500 psi). The smallest increment is 10 bar (100 psi).
Decrease This is how much that the target water pressure decreases each time you touch
the  symbol on the primary operation screen.
The default is 34 bar (500 psi).

Remote Configuration
>

Installation

Analog Pressure This turns the remote analog pressure input on or off.
Modbus Mode This turns Modbus mode on or off.
When this mode is on, the pump is controlled by Modbus TCP over Ethernet.
Modbus Pressure This turns Modbus control of the pump pressure on or off.
IP Address Enter a static IP address.
Netmask Enter the netmask.
Gateway Enter the gateway.

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 7 Installation

Stop Procedure Timers

>

The pump is idle when the intensifier stops stroking.

Stop After Idle When this feature is on, the pump turns off after the idle duration timer expires.
Idle Duration This timer determines how long the pump is idle before it turns off.
The default is 10 minutes.
Stop Boost Pump This timer determines how long the pump is idle before the boost pump turns off.
The default is 180 seconds.

Pump Fault Behavior

>
Installation

Boost Fault Monitor The system can monitor a boost pump for fault conditions. This turns monitoring on
or off.
Fan Fault Monitor The system can monitor a heat exchanger for fault conditions. This turns monitoring
on or off.

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 Installation 7
Pressure

Hydraulic
Actual This shows the hydraulic pressure in the system.

Date / Time / Language

Change the time, and language that shows on the operator interface.

Date symbol and field

Touch this symbol to change the date format. Options are DD-MM-YY
Installation

or MM/DD/YY.
Touch the field next to the symbol to open a numeric keypad. Use the keypad to
adjust the date.
Time symbol and field
Touch this symbol to change the time format. Options are a 12-hour clock or
a 24-hour clock.
Touch the field next to the symbol to open a numeric keypad. Use the keypad to
adjust the time.
Language field
Touch the field next to this symbol to open a numeric keypad. Use the keypad to
change the language.

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 7 Installation

Intensifier Control

Intensifier On This enables and disables the intensifier.

When intensifier control is off:
• the Intensifier On box is gray.
• the primary screen shows a red × on the intensifier symbol.

Percent Overstroke percent is the increased stroke rate that is permitted before an overstroke
fault condition occurs. The maximum intensifier stroke rate is calculated using the
motor wattage and the size of the hydraulic pump. Refer to Stroke rate on page 141.
The rate can be adjusted to compensate for variations in plumbing configurations and
flow rates.

1. Touch this field to open a numeric keypad.

2. Use the keypad to enter the maximum overstroke percentage permitted

Installation

before a fault occurs.

The default is 5%. The maximum is 20%.

3. Touch Enter.
Total Hours This shows the total hours that the intensifier has been in operation.
Strokes This shows the total number of strokes on the intensifier.
A stroke is counted each time a proximity switch is activated.

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 Installation 7
SD Card

The microSD card stores the current program, the alarm log files, and the maintenance log.

Touch the microSD card symbol to see the contents of the card.

If the microSD card is missing or damaged, the screen shows SD Card Not Found.

Installation

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 7 Installation
Installation

172 810770 Operator Manual Echion

 Declaration of Conformity

To see the Declaration of Conformity in English and other languages:

1. Go to www.hypertherm.com/docs.

2. Under Select your product, choose Waterjet Family in the dropdown list.

3. Go to the Regulatory information section and click the +.

4. Click on the Declaration of Conformity for your product.

 You might have to click on SHOW ALL at the bottom of the section.

A PDF of the document downloads to your device.

These navigation instructions can change without notice.

Declaration of Conformity

For information about this document, refer to Certification test marks on page 14.

Echion Operator Manual 810770 173

 8 Declaration of Conformity

Hypertherm Waterjet
305 2nd St NW STE 115
New Brighton, MN 55112 USA
www.hypertherm.com
Declaration of Conformity

174 810770 Operator Manual Echion

 Touchscreen maps

In this section
These pages can help you navigate through all of the screens that are on the operator interface.

Touchscreen maps

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 9 Touchscreen maps
Touchscreen maps

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 Touchscreen maps 9
Primary operation screen

Refer to Operator interface on page 39 for more information about these screens.

Pierce-pressure mode Cut-pressure mode The intensifier is disabled. Modbus mode is enabled.
Refer to Intensifier Control on page 170. Refer to Remote Configuration on
page 167.

Push the Controls button Refer to Alarms on page 114.

on the operator panel to turn on the pump.

Touch the Start symbol to

turn on the pump.

Go to page 179.

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9 Touchscreen maps

178 810770 Operator Manual Echion

 Touchscreen maps 9

The start procedure

timers are adjustable.
Refer to Start Procedure
Timers on page 166 for
instructions.

Stage 1 Stage 2 Stage 3 Stage 4 Stage 5 The pump is at operating

pressure and is
The supply water pressure Air is removed from the system. The system fills with water. The pressure increases to the The pressure increases to the ready to use.
increases. pierce-pressure setpoint. cut-pressure setpoint.

• The primary motor starts. • The intensifier begins • The bleed-down valve • Water pressure in the • If the pump is in
• The hydraulic pump stroking. closes. system increases to the cut-pressure mode, water
operates at minimum • The Bleed Valve timer • Pressure in the system pierce-pressure setpoint. pressure in the system
pressure until stage 4. starts. increases to the hydraulic • The Pierce timer starts. increases to the
pressure setpoint. cut-pressure setpoint.
• After the system gets to The timer default is 5 The timer default is 5
the target water pressure, seconds. • The Hydraulics timer starts. seconds. • The Cut timer starts.
the Inlet Water timer starts. The timer default is 5 If the pump is in The timer default is 5
The timer default is 5 seconds. pierce-pressure mode, seconds.
seconds. the start procedure is The start procedure
complete. is complete.

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9 Touchscreen maps

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 Touchscreen maps 9
Adjustment screens

Refer to Operator interface: Adjustment screens on page 164 for more information about
these screens.

Refer to Intensifier Control on page 170.

Refer to Pressure on page 169. Primary Adjustments screen Refer to SD Card on page 171. SD Card Not Found

Refer to Date / Time / Language on SD Card Files

page 169.

Go to page 183.

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 Touchscreen maps 9

Refer to Pump Information on page 165. Refer to Remote Configuration on

page 167.

Refer to Start Procedure Timers on Refer to Stop Procedure Timers on

Pump Adjustments screen
page 166. page 168.

Refer to Pressure Adjustments on Refer to Pump Fault Behavior on page 168.

page 167.

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 Touchscreen maps 9
Maintenance screens

Refer to Intensifier on page 62 for more information about these screens.

Refer to Move the plunger on page 56. Refer to Inputs and outputs on page 58.

Postmaintenance Start Procedure Alarm Log

Refer to Start the pump after maintenance Primary Maintenance screen Refer to Leaks on page 118.
on page 90.

Refer to Prepare for storage on page 93.

Go to page 187.

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 Touchscreen maps 9

Stage 1 Stage 2 Stage 3 Stage 4 Stage 5 Stage 6 Stage 7

Countdown is Starting Pump Starting Pressure is Increasing Turn On the Cutting Head Pressure is Increasing Turn Off the Cutting Head Examine the Pump
The supply water pressure Air is removed from the The system fills with water. The system waits for you to The pressure increases. The system waits for you to The system waits for you to
increases. system. turn on the cutting head. turn off the cutting head. examine the pump.

• The primary motor starts. • The intensifier begins • The bleed-down valve 1. Move the cutting head to The water pressure increases 1. Turn OFF the cutting 1. Examine the pump for
• If the system has a boost stroking. closes. a safe location on the in 690 bar (10,000 psi) head. loose fittings or leaks.
pump, it turns on. • The bleed-down valve is • Water pressure in the table. increments until the pump is
2. Touch the symbol to 2. Examine the attenuator
open. system increases at 4,140 bar (60,000 psi).
• The hydraulic pump 2. Turn ON the cutting head. continue. connections for leaks.
operates at minimum to 690 bar (10,000 psi).
pressure. 3. Touch the symbol to 3. Touch the symbol to
continue. continue.
• The supply water
pressure increases until The main motor turns off.
the it gets to the target The primary operation
water pressure. screen opens.
The minimum setpoint
is 2.76 bar (40 psi).
The start procedure is
Touch the symbol to stop the procedure and turn off the pump. complete.

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188 810770 Operator Manual Echion

 Technical drawings

In this section
1-18947 Hydraulic and water system drawing

The electrical drawings are shipped in an envelope that is found inside the electrical cabinet.

Technical drawings

Echion Operator Manual 810770 189

 10 Technical drawings
Technical drawings

190 810770 Operator Manual Echion

 Technical drawings 10

SCHEM:ECHION HYD & WTR

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10 Technical drawings

192 810770 Operator Manual Echion

Your pump information

Model

Serial number
The serial number is on the data plate, which is found on the back of the pump.

Electrical drawing number

The electrical drawing number is found inside the electrical enclosure door on a green label.

Purchase date

Distributor

Installation date

Installed by

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