2000 Series Waterjet Setup Manual

Standard Setup

Jet Setup

Configure the number of jets you need and your default delays. 

You may try setting the Jet Abrasive Purge Line Delay at 1250 ms which allows the abrasive to stop flowing just before the water turns off. Also set the Jet Off Delay to 250 ms which gives us a slight pause after the water turns off and before it starts moving to the next cut.

IO Setup

Virtually every waterjet will need some of following signals. Map each of the ones you need to the correct output. 

Name	Function	Configuration
Jet Abrasive Output(s)	Turns on and off abrasive for the corresponding jet.	Map it to the correct output signal in Mach.
Jet High Pressure Output(s)	Turns on and off high pressure for the corresponding jet. Also called things like UHP On/On valve.	Map it to the correct output signal in Mach.
Jet Pressure Output(s)	Turns on and off the actual jet. Often called Water On or Jet On.	Map it to the correct output signal in Mach.
Jet Pump Output	This turns on the actual intensifier pump. If using a PLC this should trigger the PLC to start the intensifier. Often called Intensifier.	Map it to the correct output signal in Mach.

For example, Jet Pressure Output #1 here is set to Jet On/Off Solenoid. 

Some waterjets may have some of these more advanced IO. This is more for when the intensifier is controlled inside the MachMotion PLC. 

The main sequence to power on the intensifier is as follows:

1. Turn on water (Filtered water shutoff valve). This allows water to go to the intensifier. 
2. Turn off the Bleeddown Valve to prepare the intensifier to run. 
3. Turn on Boost / Water Inlet Motor. This brings the incoming water up to a low PSI (like 50PSI)
4. Wait until INLET WATER PRESSURE SHUTDOWN is active so we know the water pressure is above the base PSI. Often 3-5 seconds to build pressure.  
5. Turn on the intensifier. Turn on Cooling Water Shutoff valve to keep the water cold. 

To turn off the intensifier, the following sequence is used:

1. Turn off Intensifier and Cooling Water Shutoff. 
2. Turn on Bleeddown Valve to let the pressure out of the lines. 
3. Turn off the boost motor and the water. 

Outputs

Name	Function	Configuration
HP Bleed Down Valve	When the pump turns off this valve must open to let the pressure out of the line.	By default should be wired to the PLC.
Cooling Water Shutoff Valve	This function keeps the pump cool. Should always be on when the pump is on.	By default should be wired to the PLC.
Filtered Water Shutoff Valve	Allows water to go to the intensifier. It must be on before the intensifier is turned on or it could blow it up.	By default should be wired to the PLC.
INTENSIFIER LEFT SHIFT SOLENOID	Moves the hydraulic cylinder to the left.	Must be wired to the PLC and programmed in the PLC.
INTENSIFIER Right SHIFT SOLENOID	Moves the hydraulic cylinder to the right.	Must be wired to the PLC and programmed in the PLC.
Boost Pump / Water Inlet Motor	A boost pump is used to pressurize the water pressure being fed to the intensifier. It must be on and up to pressure before turning on the intensifier.	By default should be wired to the PLC.

Inputs

Name	Function	Configuration
Garnet Empty	Tells the operator when to refill the garnet	Setup in GMS.
INTENSIFIER LEFT CHECK VALVE OVERTEMP		Setup in GMS.
INTENSIFIER RIGHT CHECK VALVE OVERTEMP		Setup in GMS.
INTENSIFIER LEFT SHIFT SENSOR		Must be wired to the PLC and programmed in the PLC.
INTENSIFIER RIGHT SHIFT SENSOR		Must be wired to the PLC and programmed in the PLC.
INLET WATER PRESSURE WARNING		Setup in GMS.
INLET WATER PRESSURE SHUTDOWN	This input measures the water pressure at the intensifier after the water inlet motor or pump is on. It must be up to pressure before the intensifier can turn on.	Setup in GMS. AND must be wired to the PLC to prevent the Intensifier from turning on until this input is off.
HP BLEEDDOWN OVERTEMP WARNING		Setup in GMS.
HYDRAULIC OIL OVERTEMP WARNING		Setup in GMS.
HYDRAULIC OIL OVERTEMP SHUTDOWN		Setup in GMS.
HYDRAULIC OIL LEVEL SHUTDOWN		Setup in GMS.

For example, a HYDRAULIC OIL OVERTEMP WARNING GMS would be setup as follows:

Some waterjets have a servo controlled Abrasive. For that use these settings:

Analog Inputs and Outputs

You may have analog inputs and outputs used for setting pressure or garnet speed. Often you put them on the main screen of the waterjet. Configure them according to the device you are using (Siemens PLC Setup, or Rapidpath Beckhoff Setup). 

PLC Setup

If the intensifier is controlled by the MachMotion PLC, then you need to program the PLC.

Before programming the PLC, make sure to test all the machine IO in Mach. That allows you to easily confirm the IO is working. 

Then program the PLC with our default PLC program for waterjets. It is located under development SVN: C:\Mach4_Development\PLCs\PLC-Program-Generic-Waterjet-Intensifier-Pump-Control_V15 . 

Now you need to remove the outputs in Mach so only the PLC can write to them. Open the Modbus window and delete the outputs that can only be controlled by the PLC: 

For example, remove intensifier left solenoid and right solenoid that are mapped to Q0.0 and Q0.1 by clicking on output and then selecting Remove a Modbus Function button. 

Update the PLC tags inside the PLC according to the schematic you have. 

Some waterjets may need some slight modifications. You can make them here. 

You may also have to invert the input proxies for the intensifier. You can do that by changing the inputs to NC as shown here by double clicking on the contact and selecting the NC option in the drop down. 

You may also have to invert the Inlet Water Pressure Shutdown. 

Testing PLC Intensifier

You can monitor the PLC and make sure that the intensifier is cycling back and forth. 

You can also create a trace. Select add New Trace. 

Setup a trace like this by adding the intensifier strokes and proxies:

Then select the record button. 

Here is an example of a system not working correctly. Notice the inputs don't trigger on and off. 

Here is another example of it not working correctly:

 

Pump Not Working

Try running water through the jet. You should be able to get water by doing the following:

• Activate Filter Water Shutoff Valve.
• Activate Boost Pump. 
  
• Activate Jet On.