Common Problems with Waterjet Systems

Over the years, high-pressure waterjets have made great strides in terms of longevity and reliability. Nonetheless, they still require maintenance and repair from time to time. Problems can be avoided or solved by simple troubleshooting.

 

Over the years, have made great strides in terms of longevity and reliability. Nonetheless, they still require maintenance and repair from time to time. Problems can be avoided or solved by simple troubleshooting.

 

Overshoot

 

It is normal for the booster to stroke faster during start-up and when switching between low and high pressure; however, during normal operation, the booster should move smoothly to the left and to the right at the same speed. Sometimes, however, the hydraulic piston moves faster in one or both directions, or exceeds the pump's ability to support it. This is called overshoot. It triggers an alarm.

The first thing you should do is reset the alarm, whether you are overtraveling to the left, right or both directions. Next.

Turn off the cutting head.

Turn on the pump and allow pressure to build.

Turn on the waterjet cutting head.

Monitor the intensifier stroke frequency manually via the indicator on the operator interface or by monitoring the proximity switch.

Sometimes these steps will reset your system and resolve the problem if an overtravel alarm occurs by mistake. If they do not, then monitoring the supercharger stroke frequency will indicate how to proceed.

 

Cutting Head Assembly

 

If the supercharger is overstroking in both directions, some steps you can take are

 

Check your orifice. Are they worn or improperly installed? Has it failed? If so, reinstall or replace.

Check to see if the supercharger is leaking from the high pressure water seal. Are they leaking? If so, replace them.

Check for leaks from water lines, fittings, bleed valves, needles, and seats inside waterjet cutting heads. If they are leaking, repair or replace the parts.

Check the post-filter water pressure gauge. If it shows low pressure, make sure the cutting water supply is turned on.

Check the difference between the values on the pre-filter and post-filter water pressure gauges. If the difference is higher than 0.7 bar or 69 kPa, or 10 pounds per square inch, replace the inlet filter.

Check the prefilter water pressure gauge. If it shows low inlet cutting water pressure, make sure the cutting water supply is turned on, close the low pressure relief valve or ball valve, and make sure the inlet solenoid valve allows water to pass through. To check this, loosen the fitting behind the solenoid valve while the pump is running and verify that water is flowing out.

 

If the booster is overtraveling in only one direction, you should

 

Check to see if the supercharger is leaking from the high pressure water seal. If needed, replace.

Check the low pressure poppet valve corresponding to the overstroke side. If you see overstroke to the left, check the boost valve on the left side of the supercharger. If the overstroke is on the right side, check the right side poppet. Is the poppet valve stuck, worn or damaged? Check the face of the poppet valve and the mating surface on the check valve.

Both surfaces should have a mirror finish. If not, this low pressure poppet may need to be repaired or replaced. After you have done this, check again to make sure the repaired or new poppet fits in the basket without jamming. You may also need to repair or replace the check valve.

 

Check the high pressure poppet valve. An overstroke to the left means the high pressure poppet valve on the right side of the supercharger has failed. An overstroke to the right means the high pressure poppet valve on the left side of the supercharger is malfunctioning. Check for heat in the output adapter on the side of the booster opposite to the direction of the overstroke.

If the output adapter is hot, remove it from the check valve and inspect the high pressure poppet, spring and seat. If you find any cracks or discoloration, or if the poppet spring is damaged, replace the poppet, seat, and spring.

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