2000 Series Waterjet Operating Manual

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Introduction

Overview

This manual gives an overview for the basic operation of the MachMotion Waterjet control. The screen is shown below, followed by a brief summary of the different features of the screen. The numbers shown in the screenshot refers to a brief description below the image. 

Control Startup

To open the control software, double-click on the profile icon on the desktop.

Control Screen Overview

G-code Tab

1. Toolpath
   • Regen Toolpath: refresh the displayed toolpath
   • View Top: top view of the part
   • View ISO: side view of the part
2. File
   • Recent: load a recently loaded G-code program
   • Load: load a G-code program from the computer
   • Edit: edit the G-code program currently loaded into the control
   • Close: close the G-code program that is currently loaded into the control
3. Advanced
   • Single Block: when active, the control will go line by line through the G-code program when the operator presses [Cycle Start]
   • Block Delete: when active, the control will skip the lines in the G-code program indicated by their block level
   • Part Counter: displays the number of parts that the machine has produced
   • M1 OPT Stop: when active, the control will stop at any M1 command in the G-code program and wait for the operator to press [Cycle Start]
   • Dry Run: when active, the control will ignore all mist or flood commands
   • M-S-T Lock: when active, the control will ignore all M-codes, jet commands, and tool commands
   • File Resume: allows the operator to select a line of G-code to start the program from and makes the control ready to run from that location
   • Collapse: minimizes the advanced section to only show M1 OPT Stop and File Resume
4. Status
   • Status: displays the most recent message
   • State: displays the current control state
   • Cycle Time: displays how long the G-code program has been running
   • Date: displays the current date and time of the control
5. Axis Digital Readouts
   • For each axis on the control, there is the following:
     • A DRO displaying the current position
     • A DRO displaying the distance left to travel
     • A gauge displaying the current load on the axis
     • Indication that the axis has not been homed if the axis letter is flashing
   • MDI:  opens or closes a window for G-code commands
   • Viewing Part: toggles the axis position DROs between machine coordinates and the current fixture coordinates
6. Active Modals
   • Active Offset: displays the current fixture offset
7. Tool Display
   • T: displays the current selected tool number
   • Next Tool: displays the next tool to be used by the G-code program
   • Diameter: displays the stored diameter of the current tool
   • Length: displays the stored length of the current tool
8. Feedrate Display
   • F: displays the current commanded feedrate
   • Feed OV: displays the current feedrate override percentage (0-300%)
   • Rapid OV: displays the current rapid override percentage (0-100%)
9. Jet Display
   • Pierce Delay: displays the current pierce delay while jets are turning on in seconds
   • Abrasive Rate: shows the rate of abrasive output at a percentage of ability
   • High Pressure: toggles if the jets operate in high pressure mode
   • Cut Recovery: moves machine to the closest point on the path of the loaded G-code program and asks for confirmation to start cutting from there
   • Station 1 - 4: toggles which jet stations will turn on when jets are on and which stations also use abrasive

Fixtures Tab

1. Edit
   • Edit Offsets: edit the active fixture offsets
2. Fixtures
   • Fixture Table: view and edit the fixture table for all fixtures
3. Align
   • Plate Alignment: open plate alignment wizard to rotate machine for crooked plate material
4. Fixture Offset
   • Displays the current fixture offset for each axis
5. Work Shift Offset
   • Displays the current work shift offset for each axis and allows the operator to edit them
6. G52 Offset
   • Displays the current G52 offset for each axis
7. Axis Digital Readouts
   • For each axis on the control, there is the following:
     • A DRO that displays the current position and allows to edit the current fixture offset
     • A DRO displaying the distance left to travel
     • A gauge displaying the current load on the axis
     • A button to zero the current fixture offset to the current location

Service Tab

Maintenance Tab

1. Limits
   • Soft Limits: toggles software limits on or off
   • Limit Override: toggles to allow for the machine to move off a limit switch
2. PLC
   • Reset Pocket: only used for tool changers
   • PLC Sequence
3. Enable
   • Disable: toggles if the machine is enabled or disabled
4. Settings
   • Interface Config: opens the MachMotion parameters for editing
   • Motion Controller: opens the configuration for the active motion controller
   • Screen Config: opens the configuration to change the colors and password protect aspects of the screen
   • Industrial Theme: applies standard colors to screen objects
   • Toggle Menu: opens settings for top menu bar
   • Compile Scripts: refreshes programming scripts
5. Homing
   • Home X: sends X axis to do its homing routine
   • Home Y: sends Y axis to do its homing routine
   • Home Z: sends Z axis to do its homing routine
   • Home All: all axes do their homing routine in their configured order
6. Support
   • Remote Support: starts a remote support session with the MachMotion technical support team
   • Support: opens the online MachMotion Support Library
   • Updates: checks for updates to the MachMotion control software
   • History: view the operator message history
7. User
   • Logout: logs out of the Windows username
   • Power: turns off the computer

Dashboard Tab

The dashboard is used to make the control just the way you want it! For more information, read here.

Machine I/O Tab

This tab is used for diagnostics and shows all enabled machine signals.

Homing

To home the machine, begin by pressing the [Reset] button. Then navigate to the [Service/Maintenance] tab and press [Home All]. There is an optional parameter to prompt the user to home the machine on startup.

Programmed Movement

MDI

To command a movement using the MDI feature, press the [MDI] button.

G-code

The primary method of commanding motion is using G-code files. G-code files can be hand written, generated by a wizard, or generated from CAD files using a CAM program.

Toolpath Screen

The controls to manipulate the toolpath screen are as follows:

• • Zoom – Right click with the mouse and move mouse up/down or using the scroll wheel on the mouse
  • Rotate – Left click with the mouse and rotate the part by moving the mouse
  • Pan – Press and hold [Ctrl] on the keyboard and left click with the mouse, then pan by moving the mouse (one-hand control option is to use left and right mouse click and move the mouse. No [Ctrl] press needed)

Cut Recovery

The control comes with a feature that allows the user to jog the machine to anywhere on the part and start running the G-code program from there. Operation of this feature is as follows:

1. Jog the machine close to the position to start from. Using the toolpath on the screen may help the operator get close to the path.
2. Press [Cut Recovery] in the Jet Display group. The operator will be asked to press [Cycle Start] to confirm the motion on to the path.
3. The control will evaluate if the jets should be on at this point in the file, and then ask the operator to press [Cycle Start] to confirm running the file from this point.

Jet Control

G-code Jet Commands

The jet is controlled with with M-codes M3 (On) and M5 (Off). These commands can be done in G-code or through MDI. Pierce, abrasive and High Pressure timers can all be set manually or set while calling the M3. Values set with M3 will override values set manually.  The command should look like this:  M3 P H E 

P is pierce delay, H is pressure delay and E is abrasive delay. Time will be set in seconds. Example: M3 P2 H3 will turn on the jet with a 2 second delay and pressure on for 3 seconds. E is not called in this example so it will default to the user settings instead of what is called in the G-Code. 

Manual Jet Control

To control the jet separately from G-code, use the spindle controls on the operator panel. The buttons for [FWD] and [REV] will both turn the jet on, while the [STOP] button will turn the jet off.

Jet Run Settings

The control supports up to four jets. A jet must be enabled in the parameters by mapping the appropriate outputs to control the pressure on, high pressure, and abrasive.

When commanding the jets on, the selection of which jets turn on is done on the screen. Each station can be selected individually if it should turn on and if it should use abrasive. All stations that are on will operate in high-pressure mode or not together. All stations using abrasive will use abrasive at the same rate. All stations that turn on will use the same pressure, abrasive, and pierce delays.

Configuring Jet Parameters

The MachMotion parameters can be accessed on the [Service/Maintenance] tab by pressing the [Interface Config] button.

In the [Jet/General] section, are parameters for the number of jets and the delay times to use while turning the jets on. The control supports up to four jet stations that are controlled simultaneously. The selection of which jets turn on is done on the screen.

For each jet, outputs must be mapped for turning on their pressure, abrasive, and high pressure states in the [Jet/Output] section. If the abrasive is a servo motor feed system, then the servo motor needs to be enabled in the [Jet/Abrasive] section and the appropriate axis ID assigned to it. The axis ID is the axis number that the motor is mapped to in Mach config. The axis must be an OB axis (axes 6-11).

To allow for jet height control while the machine is cutting, an axis must be mapped to the Z override axis. This axis ID must be an OB axis (axes 6-11) and must not be the same as an abrasive motor. The control must be restarted for changes to this value to take effect.

Jet On and Off Sequence

All enabled jets will turn on or off the outputs at the same time.

Jets On Diagram (M3)

Jets Off Diagram (M5)

Delay Descriptions: 

1. Jet Abrasive Line Delay (ms) “JetAbrasiveDelay”- Turns Jet and Abrasive on at the same time. Then applies the delay. Identical to “Jet Abrasive On Delay” and “Jet Pierce Delay”.

2. Jet Abrasive On Delay (sec) “JetAbrasiveOnDelay”- Turns Jet and Abrasive on at the same time. Then applies the delay. Identical to “Jet Abrasive Line Delay” and “Jet Pierce Delay”.

3. Jet Abrasive Off Delay (sec) “JetAbrasiveOffDelay”- Turns off Abrasive, applies delay, Turns off Jets. Identical to "Jet Abrasive Purge Line Delay"

4. Jet Abrasive Purge line Delay (ms) “JetAbrasivePurgeDelay”- Turns off Abrasive, applies delay, Turns off Jets. Identical to “Jet Abrasive Off Delay”.

5. Jet Pre-Off Delay (ms) “JetPreOffDelay”- Applies delay, then turns Jet off.

6. Jet Off Delay (ms) “JetOffDelay”- Turns Jet off, then applies delay.

7. Jet Pierce Delay (sec) ““JetPierceDelay”- Turns Jet on, then applies delay.

8. Jet Pressure Delay (ms) “JetPressureDelay”- Turns Jet on, then applies delay, then turns on Abrasive.

9. Jet High Pressure Delay (ms) “JetHighPressureDelay”- When “High Pressure Toggle” is high, it applies the delay, then turns on Jet and Abrasive. No yellow wait bar appears.

10. Jet Pump On Delay (ms) “JetPumpAutoOnDelay”- Turns on Pump, applies delay, flashes button until delay is over

Intensifier Control

Overview

The Mach waterjet control supports intensifier pump systems for high-pressure waterjet cutting. The intensifier control system provides automatic monitoring and safety protection for critical components including check valves, oil temperature, bleed-down systems, and water pressure. The control can manage up to two independent intensifier units with comprehensive monitoring and diagnostic capabilities.

Intensifier Safety Monitoring

The control continuously monitors the intensifier system and will automatically disable the machine or alert the operator when safety conditions are detected. All intensifier monitoring systems integrate with the Global Monitoring System (GMS) to provide real-time alerts and automatic protective actions.

Temperature Monitoring

Check Valve Temperature Alarms

• Each intensifier supports monitoring for two check valves
• When a check valve temperature alarm is triggered, the machine will immediately disable and alert the operator
• This protects the check valves from thermal damage during operation
• Action: Machine disables automatically - Check the cooling system and allow check valves to cool before resuming operation

Oil Temperature Warning

• Provides early notification when intensifier oil temperature is elevated but still within safe operating range
• Allows the operator to take corrective action before reaching critical temperature
• The machine will continue to operate but displays a warning notification
• Only monitors when the jet pump is running (pressure ramping or at full pressure)
• Action: Monitor the oil temperature - Consider reducing duty cycle or checking oil cooling system

Oil Temperature Alarm

• Triggers when oil temperature reaches critical levels
• Machine will immediately disable to prevent damage to the intensifier
• Only monitors when the jet pump is running (pressure ramping or at full pressure)
• Action: Machine disables automatically - Allow oil to cool and inspect cooling system before resuming

Bleed Down Over Temperature Alarm

• Monitors the temperature of the bleed-down valve system
• When temperature exceeds safe limits, the machine disables automatically
• Action: Machine disables automatically - Check bleed-down valve operation and cooling

Oil Level Monitoring

Oil Low Alarm

• Monitors the hydraulic oil level in the intensifier reservoir
• When oil level drops below minimum safe operating level, machine disables immediately
• Action: Machine disables automatically - Check for leaks and refill oil to proper level before resuming

Water Pressure Monitoring

Inlet Water Pressure Low Warning

• Provides early notification when inlet water pressure drops below optimal level
• Machine continues to operate but alerts the operator
• Only monitors when the jet pump is running (pressure ramping or at full pressure)
• Action: Check water supply pressure and flow - Address before pressure drops further

Inlet Water Pressure Low Alarm

• Triggers when inlet water pressure is insufficient for safe intensifier operation
• Machine will immediately disable to prevent damage
• Only monitors when the jet pump is running (pressure ramping or at full pressure)
• Action: Machine disables automatically - Verify water supply is adequate and pressure sensor is functioning

Stroke Monitoring

Stroke Over Speed Alarm

• Monitors the stroke rate of each intensifier
• Triggers when stroke rate exceeds the configured maximum safe speed
• Prevents damage from excessive cycling speed
• Machine will disable automatically when detected
• Action: Machine disables automatically - Check for pressure control issues or improper settings

Stroke Stall Alarm

• Monitors for insufficient stroke rate indicating stalled operation
• Triggers when stroke rate falls below the configured minimum
• Detects mechanical binding or insufficient pressure
• Machine will disable automatically when detected
• Action: Machine disables automatically - Inspect for mechanical issues or pressure problems

Configuring Intensifier Setting

The intensifier settings can be accessed on the [Service/Maintenance] tab by pressing the [Interface Config] button. Navigate to the Jet/Intensifier section.

Input/Output Configuration

For each intensifier unit, the following inputs and outputs must be mapped:

Intensifier 1 & 2 Shift Control:

• Shift Left Input - Confirms intensifier has shifted to left position
• Shift Left Output - Commands intensifier to shift left
• Shift Right Input - Confirms intensifier has shifted to right position
• Shift Right Output - Commands intensifier to shift right

Temperature Monitoring Inputs:

• Check Valve 1 Temperature Alarm Input - Digital input from check valve 1 temperature switch
• Check Valve 2 Temperature Alarm Input - Digital input from check valve 2 temperature switch
• Oil Temperature Warning Input - Digital input from oil temperature warning sensor
• Oil Temperature Alarm Input - Digital input from oil temperature alarm sensor
• Bleed Down Over Temperature Alarm Input - Digital input from bleed-down temperature sensor

Pressure and Level Monitoring Inputs:

• Inlet Water Pressure Low Warning Input - Digital input from water pressure warning sensor
• Inlet Water Pressure Low Alarm Input - Digital input from water pressure alarm sensor
• Oil Low Alarm Input - Digital input from oil level sensor

Control Outputs:

• Bleed Down Valve Output - Controls the bleed-down valve solenoid
• Boost Pump Output - Controls the boost pump motor
• Water Cooling Output - Controls intensifier cooling system
• Inlet Water Valve Output - Controls inlet water supply valve

Stroke Monitoring:

• Stroke Over Speed Alarm (Intensifier 1 & 2) - Maximum stroke rate threshold before triggering over-speed protection
• Stroke Stall Alarm (Intensifier 1 & 2) - Minimum stroke rate threshold before triggering stall protection

Timing Settings

Debounce Times (seconds):

These settings prevent false alarms from momentary sensor fluctuations.

• Jet Intensifier Oil Temp Warning Debounce - Time the oil temperature warning input must be active before triggering warning (default: 1.0 seconds)
• Jet Intensifier Oil Temp Alarm Debounce - Time the oil temperature alarm input must be active before triggering alarm (default: 1.0 seconds)
• Jet Intensifier Inlet Water Pressure Low Warning Debounce - Time the water pressure warning input must be active before triggering warning (default: 1.0 seconds)
• Jet Intensifier Inlet Water Pressure Low Alarm Debounce - Time the water pressure alarm input must be active before triggering alarm (default: 1.0 seconds)

Startup and Shutdown Delays:

• Jet Intensifier Inlet Water Pressure Delay - When inlet water pressure sensor is not mapped, this delay (in seconds) is applied after opening the inlet water valve to allow pressure to stabilize (default: 2.0 seconds)
• Jet Intensifier Inlet Water Pressure Wait On Input Timeout - When inlet water pressure sensor is mapped, maximum time (in seconds) to wait for good water pressure signal during startup. If timeout is exceeded, an alarm is triggered (default: 10.0 seconds)
• Jet Intensifier Water Cooling Off Delay - Time (in seconds) to keep cooling water running after intensifier shuts down to ensure proper cool-down (default: 60.0 seconds)

Operating the Intensifier

Startup Sequence

When the jet pump is commanded on (M174), the control will automatically execute the following sequence:

Pump Status: STARTING

1. Bleed Down Valve - CLOSES
   • The bleed-down valve closes to prepare the system for pressurization
2. Inlet Water Valve - OPENS
   • Inlet water valve opens to supply water to the intensifier

Pump Status: INLET WATER ON

3. Boost Pump - STARTS
   • Boost pump motor starts to pre-pressurize the water supply
4. Water Cooling - STARTS
   • Water cooling system activates to maintain proper operating temperature
5. Inlet Water Pressure Check
   • If pressure sensor is mapped: Waits for inlet water pressure good signal (timeout per configured parameter)
   • If pressure sensor is not mapped: Delays for configured time to allow pressure to stabilize
   • If pressure is not detected within timeout period, triggers "Intensifier Inlet Water Low Pressure Alarm" and machine disables

Pump Status: STARTING MOTOR

6. Pump Motor Output - ACTIVATES
   • Main pump motor output is turned on
7. Momentary On Output - PULSES (if mapped)
   • If configured, sends a momentary pulse to start the pump motor (350ms pulse)
8. Pump On Delay
   • Waits for configured pump delay time to allow motor to reach operating speed
   • Displays progress bar: "Waiting for Jet Pump Delay"
9. Pump Is On Input Check (if mapped)
   • Waits for confirmation signal that pump motor is running
   • Timeout: 60 seconds
   • Displays: "Waiting for Jet Pump to turn On"

Pump Status: MOTOR UP TO SPEED

10. Pressure Ramp Delay
    • Waits for configured ramp delay time as pressure builds
    • Displays progress bar: "Waiting for Pressure Ramp Up Time"

Pump Status: PRESSURE RAMPING DONE

11. Safety Monitoring Active
    • All temperature, pressure, and stroke monitoring systems are now active
    • Ready for cutting operations

Shutdown Sequence

When the jet pump is commanded off (M175), the control will automatically execute the following sequence:

1. Pump Motor Output - DEACTIVATES
   • Main pump motor output is turned off
2. Momentary Off Output - PULSES (if mapped)
   • If configured, sends a momentary pulse to stop the pump motor (350ms pulse)
3. Bleed Down Valve - OPENS
   • Bleed-down valve opens to safely depressurize the system
4. Boost Pump - STOPS
   • Boost pump motor is turned off
5. Inlet Water Valve - CLOSES
   • Inlet water valve closes to stop water supply

Pump Status: OFF

6. Water Cooling - CONTINUES RUNNING
   • Water cooling system remains active for the configured cool-down period
   • Default: 60 seconds after pump shutdown
   • This ensures the intensifier cools down properly before cooling water stops
7. Water Cooling - STOPS (after delay)
   • After the configured delay period elapses, cooling water is turned off
   • Cool-down timer is managed automatically by the control

Troubleshooting Intensifier Alarms

Alarm/Warning	Possible Causes	Corrective Action
Check Valve Temperature Alarm	Inadequate cooling, excessive duty cycle, failing check valve	Check cooling flow, reduce duty cycle, inspect check valve
Oil Temperature Warning/Alarm	Low oil level, insufficient cooling, excessive ambient temperature	Check oil level, verify cooling system operation, improve ventilation
Oil Low Alarm	Oil leak, insufficient initial fill	Inspect for leaks, refill to proper level
Inlet Water Pressure Warning/Alarm	Low supply pressure, clogged filter, failing pressure sensor	Check supply pressure, replace filters, test sensor
Bleed Down Over Temperature	Excessive bleed-down frequency, valve malfunction	Allow cool-down time between cycles, inspect valve operation
Stroke Over Speed Alarm	Pressure control malfunction, improper parameter settings	Check pressure regulation system, verify stroke speed settings
Stroke Stall Alarm	Mechanical binding, insufficient inlet pressure, low oil level	Inspect for obstructions, check water supply and boost pump, check oil level

Notes

• All monitoring systems only activate when the pump status indicates the pump is running (MOTOR UP TO SPEED or PRESSURE RAMPING DONE)
• The water cooling delay timer begins when the pump status changes to OFF
• Debounce times help prevent nuisance alarms from momentary sensor fluctuations
• Always verify all safety sensors are functioning properly before starting operations
• Review alarm history in Global Monitoring System diagnostics for troubleshooting patterns

Pump Pressure Control

Overview

The Mach waterjet control provides advanced pressure control for the jet pump system. The pressure control system can operate in two modes: open-loop (simple output control) or closed-loop (automatic pressure regulation with feedback). This allows the system to precisely control cutting pressure for optimal cut quality and consistent results.

Pressure Control Modes

Open-Loop Mode (Basic Pressure Control)

Open-loop mode is enabled when Jet Pump Pressure Control Enable is set to Yes and Jet Pump Pressure Control Closed Loop Enable is set to No.

In this mode, the control sends a command signal directly to the pump's pressure control output based on the operator's pressure setting. The system does not monitor actual pressure - it simply outputs a proportional control signal.

How It Works:

1. Operator sets desired pressure set on the screen or (stored in pound variable #9000)
2. When pump starts, pressure smoothly ramps up to commanded value over configured ramp time
3. Control converts commanded pressure to analog output voltage/current based on scaling settings
4. Output signal is sent to pump's pressure control input
5. When pump stops, pressure smoothly ramps down over configured ramp time

Advantages:

• Simple configuration - no pressure sensor required
• Predictable and repeatable output
• Smooth pressure transitions with configurable ramp rates

Limitations:

• No feedback - cannot compensate for pressure variations
• Requires manual calibration between commanded pressure and actual output
• Cannot detect if actual pressure deviates from commanded pressure

Closed-Loop Mode (Automatic Pressure Regulation)

Closed-loop mode is enabled when both Jet Pump Pressure Control Enable and Jet Pump Pressure Control Closed Loop Enable are set to Yes, and a pressure sensor input is mapped.

In this mode, the control continuously monitors actual pressure from a sensor and automatically adjusts the output to maintain the desired pressure. This provides precise pressure regulation even when conditions change.

How It Works:

1. Operator sets desired pressure on the screen or (stored in pound variable #9000)
2. When pump starts, pressure smoothly ramps up to commanded value over configured ramp time
3. Control continuously reads actual pressure from analog input sensor
4. PI (Proportional-Integral) controller calculates the difference between desired and actual pressure
5. Output is automatically adjusted to eliminate pressure error
   • Proportional (P) term: Provides immediate response proportional to pressure error
   • Integral (I) term: Gradually eliminates steady-state error and compensates for system drift
6. System maintains commanded pressure even if pump wear, temperature changes, or load variations occur
7. When pump stops, pressure smoothly ramps down over configured ramp time

Advantages:

• Precise pressure control regardless of external conditions
• Automatic compensation for pump wear and system variations
• Consistent cutting results over time
• Monitors actual pressure for quality assurance

Requirements:

• Analog pressure sensor must be installed and mapped
• Sensor scaling must be properly configured
• PI controller gains must be tuned for your specific pump system

Configuring Pressure Control Settings

The pressure control settings can be accessed on the [Service/Maintenance] tab by pressing the [Interface Config] button. Navigate to the Jet/Pressure Control section.

Basic Settings

Jet Pump Pressure Control Enable - Yes/No

• Master enable for pressure control functionality
• When set to Yes: Pressure control is active, output follows commanded pressure with ramping
• When set to No: Pressure control is disabled, output remains at minimum
• Must be enabled for either open-loop or closed-loop operation

Jet Pump Pressure Max - Maximum pressure (psi)

• Maximum pressure the operator can command
• Used for scaling calculations and safety limiting
• Typical value: Maximum rated pressure of your pump system

Jet Pump Pressure Min - Minimum pressure (psi)

• Minimum pressure the operator can command
• Used for scaling calculations
• Output returns to this value when pump is off or during shutdown

Analog Output Settings

Jet Pump Pressure Analog Output - I/O Signal mapping

• Analog output signal that controls the pump's pressure regulator
• Typically a 0-10V or 4-20mA signal to the pump controller
• Must be mapped to a valid analog output

Jet Pump Pressure Output Scale Min - Minimum output value

• The raw output value corresponding to minimum pressure
• For 0-10V systems: typically 0
• For 4-20mA systems: typically 4

Jet Pump Pressure Output Scale Max - Maximum output value

• The raw output value corresponding to maximum pressure
• For 0-10V systems: typically 10
• For 4-20mA systems: typically 20

Ramp Settings

Jet Pump Pressure Ramp Up Time - Ramp up time (seconds)

• Time for pressure to ramp from minimum to maximum when pump starts
• Provides smooth pressure increase to protect pump and plumbing
• Typical range: 5-20 seconds depending on pump size
• Longer ramp times = gentler startup, less mechanical stress

Jet Pump Pressure Ramp Down Time - Ramp down time (seconds)

• Time for pressure to ramp from maximum to minimum when pump stops
• Provides smooth pressure decrease to prevent water hammer
• Typical range: 5-20 seconds depending on pump size
• Longer ramp times = gentler shutdown, less shock to system

Closed-Loop Settings

Jet Pump Pressure Control Closed Loop Enable - Yes/No

• Enables automatic feedback-based pressure regulation
• Requires pressure sensor to be installed and mapped
• When set to Yes: PI controller actively maintains commanded pressure
• When set to No: Open-loop mode - output follows commanded pressure without feedback

Jet Pump Pressure Analog Input - I/O Signal mapping

• Analog input from pressure sensor (transducer)
• Typically a 0-10V or 4-20mA signal from the pressure sensor
• Must be mapped for closed-loop operation

Jet Pump Pressure Input Scale Min - Minimum input value

• The raw input value corresponding to minimum pressure reading
• For 0-10V sensors: typically 0
• For 4-20mA sensors: typically 4

Jet Pump Pressure Input Scale Max - Maximum input value

• The raw input value corresponding to maximum pressure reading
• For 0-10V sensors: typically 10
• For 4-20mA sensors: typically 20

PI Controller Tuning Settings

These settings control the behavior of the closed-loop PI (Proportional-Integral) controller. Proper tuning is essential for stable and responsive pressure control.

Jet Pump Pressure Control Gain KP - Proportional gain

• Controls the immediate response to pressure error
• Higher values = faster response but can cause oscillation
• Lower values = slower response but more stable
• Internal scaling: Displayed value is multiplied by 0.1 internally
• Typical starting value: 10-50 (actual gain 1.0-5.0)
• Tuning tip: Start low and gradually increase until system responds quickly without excessive overshoot

Jet Pump Pressure Control Gain KI - Integral gain

• Controls the accumulation of error over time to eliminate steady-state offset
• Higher values = faster elimination of steady error but can cause instability
• Lower values = slower error correction but more stable
• Internal scaling: Displayed value is multiplied by 0.1 internally
• Typical starting value: 1-10 (actual gain 0.1-1.0)
• Tuning tip: Start very low and increase only if steady-state error persists

Jet Pump Pressure Control Deadband - Deadband (psi)

• Pressure error tolerance zone where PI corrections are not applied
• Prevents unnecessary corrections for minor pressure variations
• Within deadband: Output tracks ramped setpoint with learned integral bias
• Outside deadband: Full PI control actively corrects pressure error
• Typical value: 50-200 psi depending on system and cut quality requirements
• Tuning tip: Larger deadband = more stable but less precise; smaller deadband = more precise but may oscillate

Operating Pressure Control

Setting Commanded Pressure

The operator can set the commanded cutting pressure in several ways:

• Manually adjust the pressure value on the control screen before starting a cut
• In G-code using M3 command: M3 S[pressure] - Example: M3 S50000 sets pressure to 50,000 psi
• In G-code by setting pound variable: #9000 = [pressure]

The commanded pressure is stored in pound variable #9000 and can be viewed or modified at any time.

Pressure Control Operation

When the pump starts (M174):

1. System reads commanded pressure from #9000
2. Pressure output begins at minimum value
3. Output smoothly ramps to commanded pressure over configured ramp-up time
4. If closed-loop is enabled:
   • PI controller activates once motor is up to speed
   • System continuously measures actual pressure
   • Output automatically adjusts to maintain commanded pressure
5. If open-loop:
   • Output holds at commanded value (no automatic adjustment)

During operation:

• Operator can change commanded pressure at any time
• System smoothly ramps to new pressure value
• Closed-loop mode maintains pressure even if conditions change

When the pump stops (M175):

1. Output smoothly ramps down to minimum value over configured ramp-down time
2. PI controller is reset to prepare for next cycle
3. Output returns to minimum (zero pressure)

Tuning the Closed-Loop Controller

Proper tuning of the PI controller is essential for optimal performance. Follow this step-by-step procedure:

Initial Setup

1. Verify pressure sensor is reading correctly
   • Check that sensor input scales properly (min/max values)
   • Confirm sensor readings match a calibrated gauge
2. Set conservative starting values:
   • KP = 10 (actual gain 1.0)
   • KI = 1 (actual gain 0.1)
   • Deadband = 100 psi
3. Set appropriate ramp times (10-15 seconds recommended for initial tuning)

Tuning Procedure

1. Start with Proportional Gain (KP)
   • Run pump to a moderate pressure (50% of maximum)
   • Observe how quickly pressure reaches commanded value
   • If response is too slow: Increase KP by 10
   • If pressure oscillates or overshoots: Decrease KP by 5
   • Repeat until pressure reaches setpoint quickly without excessive overshoot
2. Add Integral Gain (KI)
   • Monitor for steady-state error (pressure settles slightly above or below target)
   • If steady error exists: Gradually increase KI by 1
   • If pressure becomes unstable or slow-cycling: Decrease KI
   • Goal: Eliminate steady error while maintaining stability
3. Adjust Deadband
   • Observe pressure stability at setpoint
   • If pressure varies unnecessarily: Increase deadband
   • If pressure tolerance is too loose: Decrease deadband
   • Balance between stability and precision based on cut quality needs
4. Test at Multiple Pressures
   • Verify controller works well at low, medium, and high pressures
   • Fine-tune gains if needed for best overall performance

Troubleshooting Controller Issues

Symptom	Possible Cause	Solution
Pressure oscillates continuously	KP too high, KI too high	Reduce KP first, then reduce KI if needed
Slow response to pressure changes	KP too low	Increase KP gradually
Pressure settles above/below target	KI too low or zero	Increase KI gradually
Pressure hunts or cycles slowly	KI too high	Reduce KI
Excessive overshoot on startup	Ramp time too short, KP too high	Increase ramp time, reduce KP
Pressure varies unnecessarily	Deadband too small	Increase deadband
Pressure doesn't match commanded	Sensor scaling incorrect, output scaling incorrect	Verify input and output scale settings
No pressure control response	Closed-loop not enabled, sensor not mapped	Enable closed-loop, verify sensor mapping

Notes

• The PI controller only operates when the pump motor is up to speed (after initial startup delays)
• Gains are internally scaled by 0.1 to keep displayed values in a reasonable range
• The integral term is clamped to prevent windup and includes anti-windup protection
• Controller state resets when pump shuts down to ensure clean startup on next cycle
• For best results, tune the controller at typical operating pressures for your application
• If you change pump systems or components, re-tune the controller for optimal performance

M-Codes

M3	Jets On, Optional values:  P = Pierce Delay (sec) E = Abrasive Delay (sec) H = Pressure Delay (sec) K = Abrasive Rate (0-100%)  S = Pressure (psi) overwrites #9000
M5	Jets Off
M170	Jets Abrasive Master Enable On
M171	Jets Abrasive Master Enable Off
M172	Jets High Pressure On
M173	Jets High Pressure Off
M174	Jet Pump On   S = Pressure (psi) overwrites #9000
M175	Jet Pump Off

G-Code Parameters

1910	Wiggle Piercing Circles During Pierce Delay (1 = On, 0 = Off)
1911	Wiggle Piercing Number of Loops
1912	Wiggle Piercing Diameter
1913	Wiggle Piercing Feedrate

Pound Variables

9000	Commanded Jet Pressure (psi)

Intensifier pump

You can set values between 1 and 10 seconds for turning the intensifier on and off. In [Configure | Control | Spindle tab] use the Accel Time for turning it on, and the Decel Time for turning it off.

Appendix

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