AS-6050 Manual P/N: 12112 Rev: A
Section 10
Maintenance & Troubleshooting
10.1 Maintenance
This section outlines the scheduled and preventative maintenance required to keep the intensifier pump in good working order. The following pages contain Parts and Service contact Information, Maintenance
Guidelines, a Scheduled Maintenance Chart, and a Maintenance log.
10.1.1 Parts and Service Contact Information
Accustream Inc.
4757 Mustang Circle
Mounds View, MN 55112
Toll Free: 1-866-566-7099
Phone: 763-717-7099
Fax: 763-717-7093
Email: [email protected]
Web: www.accustream.com
10.1.2 Maintenance Guidelines
The AS-Series pumps require preventative and scheduled maintenance to remain in good working order, prevent unscheduled downtime, and extend the life of the components. To provide safe and proper maintenance, read and follow all Maintenance Guidelines in this section.
Always bleed down all HP water pressure and lockout the electrical control cabinet prior to performing any maintenance. Failure to do so can result in
severe injury.
High pressure water leaks can cause major damage to anything in its line of fire. Always repair any leaks immediately to avoid damage to equipment and/or serious personal injury.
• Carefully read all of the safety guidelines in the Safety section of this manual. Read and understand the pertinent sections to the maintenance that you are planning to perform.
• Shut off the main disconnect. When the power is shut off, the bleed down valve will open and bleed off high pressure water stored in the discharge piping. Always double check to make sure that all high pressure water has been discharged prior to servicing the pump.
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AS-6050 Manual P/N: 12112 Rev: A
• When servicing any electrical component of the pump always follow proper lockout/tag out procedures. Remember even when the main disconnect is off the lines coming to the pump are still hot unless shut off at their source.
• When servicing the cooling or cutting water assemblies, shutoff water to the pump and drain the water in the accumulator by opening the ball valve to the left of the filters.
• Use catch pans under areas where water or oil may be spill during the course of maintenance.
• Always maintain a clean work area. Inspect and clean the pump regularly to spot issues before they become costly repairs. Always make repairs immediately. Keep a maintenance record.
10.1.3 Scheduled Maintenance Chart
The following maintenance intervals are based on 4000 hour per year operation. Less hours of use will increase maintenance intervals.
Maintenance Description
Inspect all Cables and Plugs for Damage
Check Safety Circuits
Grease Motor Bearings s
A
R eq ir u ed
I
P er
S h if t
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W ee kl y o
M n th ly
3
M n o th s
6
M n o th s
Y ea y rl
I
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Inspect Fittings and Hose for Damage
Adjust Cooling Water Flow
Check Inlet Water Pressure
Inlet Water Filters
Check Pressure in Water Accumulator - Set to 40 psi
Visually Inspect for Leaks
Check Temperature of Intensifier and Bleed Down Valve
Lap LP Poppet and Check Valve Face
Replace HP Seals
Replace HP Filter at Pump Outlet
Replace Hydraulic Rod Seal
Replace Plunger Bearing
Change Oil Filter (Sooner if By-pass Occurs)
Change Oil
Check Oil Level
Check Oil Temperature
Check for Oil Leaks
A - Adjust I - Inspect R - Replace
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AS-6050 Manual P/N: 12112 Rev: A
10.1.4 Maintenance Log
Pump Model
Date
Hours
Initial
Date
Hours
Initial
Date
Hours
Initial
Date
Hours
Initial
Date
Hours
Initial
Date
Hours
Initial
Date
Hours
Initial
Date
Hours
Initial
Date
Hours
Initial
Date
Hours
Initial
Date
Hours
Initial
Date
Hours
Initial
Serial #
Problem Found and Work Performed
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AS-6050 Manual P/N: 12112 Rev: A
Maintenance Log
Pump Model
Date
Hours
Initial
Date
Hours
Initial
Date
Hours
Initial
Date
Hours
Initial
Date
Hours
Initial
Date
Hours
Initial
Date
Hours
Initial
Date
Hours
Initial
Date
Hours
Initial
Date
Hours
Initial
Date
Hours
Initial
Date
Hours
Initial
Date
Hours
Initial
Serial #
Problem Found and Work Performed
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AS-6050 Manual P/N: 12112 Rev: A
Maintenance Log
Pump Model
Date
Hours
Initial
Date
Hours
Initial
Date
Hours
Initial
Date
Hours
Initial
Date
Hours
Initial
Date
Hours
Initial
Date
Hours
Initial
Date
Hours
Initial
Date
Hours
Initial
Date
Hours
Initial
Date
Hours
Initial
Date
Hours
Initial
Date
Hours
Serial #
Problem Found and Work Performed
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AS-6050 Manual P/N: 12112 Rev: A
Maintenance Log
Pump Model
Date
Hours
Initial
Date
Hours
Initial
Date
Hours
Initial
Date
Hours
Initial
Date
Hours
Initial
Date
Hours
Initial
Date
Hours
Initial
Date
Hours
Initial
Date
Hours
Initial
Date
Hours
Initial
Date
Hours
Initial
Date
Hours
Initial
Date
Hours
Initial
Serial #
Problem Found and Work Performed
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AS-6050 Manual P/N: 12112 Rev: A
10.2 Troubleshooting
The following troubleshooting chart lists symptoms, possible causes, and recommended solutions for troubleshooting the AS-Series pumps. If you receive a fault message and have corrected the fault condition you can reset the pump by pressing the ACK/RESET button on the front control panel. This will clear the fault and allow you to re-start the pump.
1. Fault Display Error Message
Display Error Message
Hydraulic Oil Level Low
Possible Cause
The Oil Level had dropped from a leak at a fitting or from performing maintenance on the hydraulic assembly.
Corrective Action
Inspect the fittings and components of the hydraulic system for leaks. After
Identifying the cause of lost oil, add oil per instructions in the Hydraulic section of this manual.
Hydraulic Oil Temp > 130F
(55C) or Hydraulic Oil Temp >
150F (65C)
Motor Fault
Cable may be damaged or connector is unplugged.
Inlet cooling water to the pump not turned on.
Replace cable if damaged. Plug in connector if unplugged.
Turn on inlet cooling water. Read the
Low Pressure Water section of this manual.
High cooling water inlet temperature. Test the temperature of the inlet water.
If the temperature is outside of the normal range outlined in the
Specifications section of this manual you may need a water chiller.
Cooling water flow rate may not be high enough.
Check the flow rate by monitoring the cooling water out. If the flow rate is too low then adjust the water modulating valve. See the Low Pressure Water section of this manual.
Cable may be damaged or connector is unplugged.
Replace cable if damaged. Plug in connector if unplugged.
Heat exchanger could be clogged.
Fuse FU-5 in the PLC has blown. A short in the cooling or cutting water coils is the most likely cause. A less likely scenario would be a short in the motor wiring for the boost motor or main motor.
The main motor thermal overload (OL-
MAIN) may have tripped.
Repair or replace heat exchanger.
Check the cutting water coil (SOL-1) and the cooling water coil (SOL-2) for shorts. Usually you will see the plastic body deformed from heat. Check all cables for damage. Replace any faulty parts.
Reset by pushing the reset button on the thermal overload. Refer to Electric
Motors in the Electrical System section of this manual.
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AS-6050 Manual P/N: 12112 Rev: A
Display Error Message
Inlet Water Pressure Below
40PSI (2.8BAR)
Too Many Motor Starts Per
Hour
Intensifier Over Cycle (pay attention to arrow direction)
Possible Cause Corrective Action
Inlet cutting water to the pump not turned on.
Boost pump motor contactor (MS-
BOOST) may be tripped. If this is the cause you will see the knob pointing at reset.
Boost pump thermal overload (OL-
BOOST) may be tripped.
Boost pump fuses FU-9, FU-10, or FU-
11 may be blown.
The cutting water coil (SOL-1) may be shorted.
The motor has been started too many times in 15 minutes.
Several possibilities exist for the possible causes of this error. The error caused by the intensifier stroking too quickly in one or both directions.
Turn on inlet cutting water. Read the
Low Pressure Water section of this manual.
Reset by turning the knob on the motor contactor back to auto. Refer to Electric
Motors in the Electrical System section of this manual.
Reset by pushing the reset button on the thermal overload. Refer to Electric
Motors in the Electrical System section of this manual.
A blown fuse is evidence of a potentially serious problem such as a severely damaged motor, or a short in the system.
Locate and correct problem, replace fuse, and restart the pump.
Inspect the coil. Normally a short in the
SOL-1 coil or its cable would result in a blown fuse FU-5 and a fault message of
Motor Fault so this is an unlikely scenario. If the coil or wire is damaged, replace it and restart the pump.
Wait 15 minutes to let the motor armature cool down before starting again.
Note the direction of the intensifier over cycle and refer to Intensifier Cycle in the
High Pressure Water section of this manual.
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AS-6050 Manual P/N: 12112 Rev: A
2. General Pump Operation
Problem
Pump Will Not Start
Hydraulic Pump Does Not Make
Pressure or Makes Low Pressure
Possible Cause
Power disconnected
E-Stop depressed
Pump enclosure door open
Motor overload relay tripped
Line Fuses Blown or Missing
Pump Remote key switch in wrong position
Corrective Action
Reconnect power
Check Main Disconnect
Pull out all E-stop buttons
Close door and properly latch disconnect handle
Check and correct
Adjust volume stop on pump
Check and correct
Change key switch position
Defective Cut Pressure Select solenoid
Manually over-ride valve until replacement arrives
Defective Cut Pressure Control valve Replace valve
Defective hydraulic pump and/or compensator
Defective relief valve
Pierce pressure is enabled
Replace pump
Replace valve
Change pierce pressure to cut pressure at the display
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AS-6050 Manual P/N: 12112 Rev: A
3. Intensifier Operation
Problem
Intensifier Does Not Cycle
Intensifier Cycles and Oil Pressure
Okay But Not Enough Pressure at
Head
Intensifier Over Cycles or Cycles
Unevenly
Possible Cause Corrective Action
On/Off Valve for cutting head is off Turn cutting head on
Intensifier is disabled
Defective shift valve or end of travel proximity switch
Enable intensifier at display
Replace if necessary
-Disassemble and repair. Pins must move freely to bottom of bore
One of the indicator pins is hung up as shown by both proximity switch lights on at the same time
Clogged high pressure filter
Partial obstruction in HP lines
Worn Hydraulic Piston Seal
Too much demand on pump
Replace HP Element
Correct obstruction
Rebuild hydraulic center section
Reduce number or size of orifices
Various reasons See Over Cycle Section in HP Water
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AS-6050 Manual P/N: 12112 Rev: A
4. High Pressure Cylinder and Check Tube
Problem
End of HP Cylinder Drips
Cylinder End Drips And Is Hot
Check Valve Is Hot and HP Cylinder
End Drips
Check Valve is Hot and HP Cylinder
End Does not Drip
Oil Present In Dynamic End of HP
Cylinder
Bronze Back-Ups Have Short Life
Hydraulic Center Section Is Much
Hotter Than Hydraulic Oil
Possible Cause
Worn HP Seal
Check for crack at end of HP
Cylinder
Piston seal has just been replaced and needs breaking in
Corrective Action
Replace HP Seals and Hoops
Replace HP Seals and Hoops and HP
Cylinder if necessary
Check for crack in Check Valve Body Replace HP Seals and Hoops and
Check Valve Body if necessary
Replace Leaking HP Poppet and Seat
Leaking LP Poppet and Check Valve
Body face
Replace or repair
Leaky hydraulic rod seal Replace rod seal
Worn Plunger Bearing Replace Plunger Bearing
Piston seal is worn Rebuild center section
HP Seal Life Is Short Poor mating surfaces
Pump has cycled roughly
Pump over cycled
No action required
Inspect, repair and/or replace HP
Cylinder ID and Plunger
Start-up new seals carefully
Check demand on pump
Cylinder end too hot
Hoops are broken from belled out HP cylinder end
Correct problem. Refer to the High
Pressure Section of the manual
Replace HP cylinder when necessary
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AS-6050 Manual P/N: 12112 Rev: A
5. Hydraulic Oil
Problem
Oil Is Too Hot
Oil has milky appearance
Oil Life is short
Possible Cause
Worn relief valve
Inlet water is warmer
Piston seal in intensifier is worn
Heat exchanger is fouled
Hydraulic pump is worn
Oil is contaminated with water
Oil temperature too hot
Corrective Action
Replace
Adjust modulating valve
Rebuild intensifier center section
Clean out heat exchanger tubes or replace heat exchanger
Replace
Replace oil per the manual instructions. Replace rod seal
.
Reduce oil temperature
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