Troubleshooting waterjet intensifier overstroke

By Hypertherm
Posted on 02/02/2017 in SPARK the blog, Waterjet cutting

Though all Hypertherm Waterjet systems are designed with our Advanced Intensifier Technology, all waterjets require maintenance. One of the most common failures we see is called “intensifier overstroke." This happens when the piston in your intensifier strokes faster than the output flow of the waterjet pump can support.

You'll know if this is a problem because a picture like the one at top will show up on your screen. To figure out if you really do have an overstroke condition, first shut off the cutting head and bring the waterjet pump to full pressure then monitor the intensifier to see if any stroking occurs. If you see stroking it could be because of a:

1. Problem with the high-pressure poppet
2. Leak in the high-pressure plumbing
3. Leak in the waste water outlet bleed-down valve
4. Leak in your cutting head needle and seat

Though we've just listed four possible causes, the most likely cause is actually a fifth cause. It has to do with the low-pressure poppet which is probably sticking, worn, or damaged.

If you believe you have an overstroke condition but can’t find the problem, there is a troubleshooting chart which can help you dig deeper into this issue. Contact our Technical Service team at (651) 294-8600 or waterjet@hypertherm.com and we’ll be happy to help you do that.

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