OMAX Corporation 21409 72nd Avenue South Kent, WA USA 98032

Information: Technical Support: E-Mail: Web:

info@protomax.com 1-818-647-1994 support@protomax.com www.protomax.com

This document contains subject matter to which OMAX® Corporation has proprietary rights. Recipients of this document shall not duplicate, use, or disclose information contained herein, in whole or in part, for any use other than the purpose for which this manual was provided.

OMAX Corporation believes the information described in this manual is accurate and reliable. From time to time, design improvements will be made to the OMAX equipment. Photographs, text, and sketches within the body of this manual may not exactly represent your equipment. In general, this manual contains the most up-to-date information available. However, OMAX Corporation cannot accept any responsibility, financial or otherwise, for any consequences arising out of the use of this material. The information contained herein is subject to change, and revisions may be issued to advise of such changes or additions. OMAX strives to continually improve user documentation. If you have any questions or concerns about the content of this user’s guide, please e-mail us at tech_writing@omax.com, or contact us by mail at:

 

OMAX Corporation

Technical Publications

21409 72nd Avenue South

Kent, WA, USA 98032

 

OMAX Corporation is continually improving their equipment to bring you the best in abrasive waterjet machining technology. For that reason, your abrasive waterjet may differ slightly from what is described in this document. If you have any questions, please feel free to contact us at 1-818-647-1994 or e-mail us at info@protomax.com. You can also receive technical support on-line at: Web: http://www.protomax.com.

 

Original Instructions in English
October 2018
© 2018 OMAX Corporation

Important Safety Information

SAFETY IS YOUR RESPONSIBILITY.

For your own safety, read this guide thoroughly and carefully before installing, operating, maintaining, or troubleshooting the equipment.

Save these instructions.

This guide contains important safety information for the equipment. Careful observance of the safety information will help prevent physical injury, damage to the equipment, and extend the equipment life.

Equipment safety features, safety glasses, hearing protection, and more can reduce potential injury. Exercise caution when installing, operating, and maintaining the equipment. Safety guards and features will not guarantee your safety if you are careless, inattentive, or use poor judgment. If it feels dangerous, do not try it.

YOU ARE RESPONSIBLE FOR YOUR SAFETY IN YOUR SHOP.

Machine Safety Labels

The following safety labels may appear on the equipment. If ignored, physical injury, death, or equipment damage may occur. Read the complete safety information provided in the operation, installation or maintenance guide before installing, operating, or maintaining the equipment.

Safety Precautions

Safety instructions must be followed when installing, operating, or maintaining the equipment. If ignored, death or physical injury may result, or damage may occur to the equipment. Always observe applicable safety precautions when working with this equipment.

Use the equipment ONLY for its intended purpose.

• Read the installation manual before setting up the equipment to learn about important installation and safety information.
• Read the documentation for recommended accessories. The use of improper accessories may cause risk of injury to persons or damage to equipment.
• Wear eye and ear protection. Always wear ISO-approved impact safety glasses.
• Ensure the equipment is installed properly before startup.
• Never stand on the equipment. Serious injury could occur if the machine tips or if you come in contact with the cutting tool.

Do not make modifications

• Never make unauthorized modifications or alterations to the equipment or components.
• Modification to the equipment may pose risk of physical injury to the operator and/or others and may cause damage to the equipment or other property. Modifications to the equipment will invalidate the warranty.
• Do not modify, defeat, or bypass any equipment safety features.

Do not remove panels

• Do not remove panels under normal conditions. Only remove them when required by maintenance or troubleshooting procedures.

Check for damaged parts

• Before further use of the equipment, a guard or other part that is damaged should be carefully checked to determine that it will operate properly and perform its intended function–check for alignment of moving parts, binding of moving parts, breakage of parts, mounting, and any other conditions that may affect its operation. A guard or other part that is damaged should be properly replaced.

Exercise caution, stay alert and attentive

• Do not install, operate, or service the equipment while under the influence of alcohol or drugs. Read the warning labels on prescription and over the counter drugs. If in doubt, do not install or operate the machine.
• Do not install, operate, or service the equipment when you are tired.
• Always observe the safety precautions while installing, operating, or servicing the equipment. Carefully operated, the abrasive waterjet is a safe tool. When operated carelessly, serious injury can result.
• Wear a face or dust mask.
• Do not overreach to operate the machine. Maintain proper footing and balance at all times.
• Keep a minimum of 16 in. (40 cm) away from pressurized equipment during operation.
• Do not try to tighten ultra-high pressure (UHP) fittings while the system is under pressure.

Maintain tools and equipment with care

• Keep machine and accessories clean for best and safest performance.
• Always maintain the equipment in top condition.
• Follow the maintenance instructions for equipment and accessories.
• Maintain all protective guards and shutdown devices.

Keep the equipment and surrounding area clean and free from clutter

• Remove any installation, operation, or maintenance tools from the equipment before operating.
• Keep the work area clean and clutter free to avoid accidents.
• Keep the equipment clean for optimal performance.

Do not operate equipment in a dangerous environment

• Do not use equipment in or around flammable gases or liquids.
• Do not expose equipment to rain, or use outdoors.
• Keep the equipment in a well-lit work area.

Never leave equipment unattended while operating

• Always stop and turn off the equipment before leaving.
• Keep visitors at a safe distance from the work area.
• Keep children away from the equipment work area.
• Do not allow children to play around or operate the equipment or any of its components.

Never operate equipment without safety guards or covers.

• Do not modify, bypass, defeat, or render safety guards, covers, or switches inoperable.
• Keep guards in place and in working order.
• Never remove any safety cover or guard while the equipment is running.
• Know the location of the ON/OFF switch.
• Know how to disconnect the main power supply to the equipment.
• Start and operate the machine only when all side panels are securely in place.

Never place your hands in the vicinity of the nozzle while cutting

• Seek immediate medical attention in the event of a waterjet injury. Injuries caused by high-pressure abrasive waterjets are serious. Do not delay!
• See your WaterJet Technology Association (WJTA) warning card for important medical alert information.

Figure 1  

Use care when handling material in the tank

• Never operate the equipment while handling material in the tank.
• Always stop the abrasive waterjet before making any adjustments to the material or the abrasive jet.
• Always be careful when handling material in the tank. Fingers can be caught between a heavy part and the support slats.
• Use caution around the support slats. Support slats are also cut by the abrasive waterjet; the edges can become very sharp and cause cuts, or collapse.

Do not touch live electrical components or parts

• Always use a licensed electrician or qualified individual for installing the main power source for use of the machine.
• Inspect the equipment power and control cables regularly for proper connection and installation. Damaged, exposed, and bare wires can cause electrocution or death!
• Ensure the equipment is properly connected and grounded in accordance with national, state, and local codes. Never remove any prong from the plug. Always plug into a proper electrical outlet.
• Never use any electrical plug adapter.
• Reduce the risk of unintentional starting by ensuring the power switch is in OFF position before plugging in the equipment.
• Always disconnect the equipment from the main power before performing service or maintenance.

Noise Emission Precautions

Environmental factors, such as room or building construction, machines or power tools, and other noise sources affect the environment's true noise level. When installed and operated properly, the equipment A-weighted emission sound pressure level, LpA , is less than 75 dBA (LpA < 75 dBA). Therefore, OMAX recommends that the operator wear hearing protection during equipment operation.

Treat All Injuries with Caution

Injuries involving contact with the water should receive immediate attention. See the WJTA Warning Card for important medical alert information.

Seek immediate medical attention in the event of an abrasive waterjet injury. Inform the physician of the cause of the injury, what type of waterjet project was being performed at the time of the accident, and the source of the water.

Because of the stagnant water within the tank, even a seemingly minor break in the skin can introduce harmful bacteria into the wound. Any injury involving contact with the water should be attended to immediately.

Unusual infections with aerophilic microorganisms occurring at lower temperatures have been reported. These may be gram-negative pathogens, such as those found in sewage. Bacterial swabs and blood cultures may therefore be helpful in assisting a physician's diagnosis.

An injury caused by high-pressure waterjets can be serious. In the event of any waterjet injury:

• Seek medical attention immediately. Do not delay!
• Inform the doctor of the cause of the injury.
• Tell the physician what type of waterjet project was being performed at the time of the accident and the source of the water.
• Communicate the following information to the medical personnel:
  This patient may be suffering from a waterjet injury. Evaluation and management should parallel that of a gunshot injury. The external manifestations of the injury cannot be used to predict the extent of internal damage. Initial management should include stabilization and a thorough neurovascular examination. X-rays can be used to assess subcutaneous air and foreign bodies distant from the site of injury. Injuries to the extremities can involve extensive nerve, muscle, vessel damage, as well as cause a distal compartment syndrome. Injuries to the torso can involve internal organ damage. Surgical consultation should be obtained. Aggressive irrigation and debridement is recommended. Surgical decompression and exploration may also be necessary. Angiographic studies are recommended pre-operatively if arterial injury is suspected. Bandages with a hygroscopic solution (MgSO4) and hyperbaric oxygen treatment have been used as adjunctive therapy to decrease pain, edema, and subcutaneous emphysema. Unusual infections with uncommon organisms in immunocompetent patients have been seen; the source of the water is important in deciding on initial, empiric antibiotic treatment, and broad-spectrum intravenous antibiotics should be administered. Cultures should be obtained.

Lockout/Tagout

Implement standard practices and procedures to shut down equipment, isolate it from its energy source(s), and prevent the release of potentially hazardous energy while maintenance and servicing activities are being performed.

Equipment Grounding Requirements

• Ensure the equipment is properly grounded in accordance with national, state, and local codes. Never remove any prong from the plug. Always plug into a proper electrical outlet.
• To reduce the risk of electric shock, during a malfunction or breakdown, grounding provides the electric current with a path of least resistance. The machine is equipped with an electric cord designed with an equipment-grounding conductor (EGC) and a grounding plug (United States, Canada and Mexico only). You must plug the cord into a matching outlet that is properly installed and grounded in accordance with all local codes and ordinances.
• Do not modify the plug provided—if it does not fit the outlet, have the proper outlet installed by a qualified electrician.
• Connecting the EGC improperly can result in electric shock.
• Contact a qualified electrician or service personnel if you do not understand the grounding instructions, or if in doubt as to whether the equipment is properly grounded.
• Do not use extension cords with the equipment.
• If the cord is damaged or worn, immediately replace it. Contact OMAX for replacement parts and instructions for replacement. The insulation of the EGC is covered with a green or green with yellow-striped surface. If replacement of the electric cord or plug is necessary, do not connect the equipment-grounding conductor to a live terminal. Refer to the equipment-specific wiring configuration.

• The equipment is intended to be used on a circuit with an outlet similar to the one shown (United States, Canada and Mexico only):

Figure 2  

• The grounding plug is similar to the one shown (United States, Canada and Mexico only):

Figure 3  

• Ensure that the equipment is connected to an outlet that matches the plug configuration.
• The equipment must not be connected to any different type of electric circuit.
• No adapter is available, or should be used with this equipment.
• For countries other than United States, Canada and Mexico; OMAX does not supply a suitably rated industrial grade plug.
• Contact a qualified electrician or service personnel for installation of a suitably rated industrial grade plug in accordance with national, state, and local codes.
• A pin and sleeve plug, rated at least 30A, 230V, 2-pole+E (3-wire grounding), IP44 or better, having a first-make last-break protective bonding contact (earthing contact) in accordance to standards IEC 60309-1 and IEC60309-2 may fulfill this requirement.

Figure 4  

• You must plug the cord into a matching outlet that is properly installed and grounded in accordance with all local codes and ordinances.

Figure 5  

Explosive Atmosphere Precautions

Machining certain types of material such as titanium with a waterjet may produce sparks. Do not operate the equipment in an explosive atmosphere. Do not allow explosive or flammable vapors to accumulate in the area of the equipment.

Disposing of Waste Materials

Dispose of cutting wastes properly and in accordance with all local and federal regulations. The abrasive waterjet produces two types of waste: the water used for cutting and the solid material that accumulates in the catcher tank. Although the garnet abrasive itself is inert, the waste deposited from the material being cut may require special handling.

In abrasive waterjet cutting, garnet particles are accelerated with high-pressure water to strike the material creating a residue of abrasive grit and eroded particles from the cut material. Eventually, this residual sludge settles to the catcher tank bottom and accumulates until it must be removed for disposal. Depending upon the material makeup of this sludge, different disposal constraints will be imposed by the various local and federal regulations. For example, when cutting toxic materials, such as lead or radioactive metals, appropriate measures for the safe disposal of this type of contaminated water and sludge must be rigidly followed. Always consult with your local utilities company about sewage or water treatment requirements and proper sludge disposal procedures.

Adequate Shop Ventilation

Proper ventilation in your work area will assist in dissipating the accumulation of gas, vapor, and fumes. Your machine contains water that will evaporate depending on the ambient temperature in your shop and the temperature of the water in the tank itself. In order to reduce impact on other equipment in your shop, you should maintain adequate ventilation in your shop. Additionally some materials (especially aluminum particles) in water are known to produce hydrogen in water.

When you cut aluminum, the fine particles in the tank react with the water to generate hydrogen. Normally, hydrogen bubbles to the surface and escapes into the shop in harmless, low concentrations.

Take care that no ignition source (such as open flame or electrostatic discharge) is nearby the equipment.

Watch for hydrogen bubbles when machining aluminum. If you cut a lot of aluminum, you will create aluminum powder from the removed material. This powder will accumulate at the bottom of the tank along with your garnet. The aluminum then reacts with the water, releasing Hydrogen gas in the process. If you cut a lot of aluminum on a regular basis, then this is something to take into consideration.

Do not allow smoking near the machine. Take care that no ignition source (such as open flame or electrostatic discharge) is nearby the equipment. Do not store flammable materials near the equipment. Be especially careful when cutting materials that create sparks, such as titanium—these can ignite gases in the tank.

Equipment Safety Features

The abrasive waterjet provides several built-in safety features:

Overpressure Protection

During operation, pump pressure is monitored to prevent an overpressure condition. If the pump exceeds the factory set maximum pressure limit, the safety relief valve activates and shuts down the pump unit.

Electrical Protection

The equipment controller includes short circuit, overcurrent, and thermal protection for the pump motor.

Electrical Disconnect/Emergency Machine Off (EMO)

An electrical disconnect/emergency machine off (EMO) switch is used to remove the main AC electrical supply from the machine. To isolate the machine from its electrical supply, always unplug the main AC supply power cord from its electrical supply outlet.

Safety Lid

The lid of the equipment is designed with a safety interlock to prevent waterjet operation when the lid is open.

Safety Legend

The following safety signal word panels and paragraph notifications may appear throughout this and other documentation. Each provides safety issue identification and recommended actions to avoid the hazard. Be alert! Follow the recommended safety actions and precautions to prevent injury or damage to the equipment.

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

Used to address practices not related to physical injury—property damage only.

Used to provide supplementary information, emphasize a point or give a tip for easier operation.

Required Tools

The following table contains a list of tools with the appropriate sizes needed to setup the ProtoMAX.

Customer Provided Tools

These tools are not provided by OMAX or included with the ProtoMAX.

Icon	Tool	Size(s)
	Safety gloves
	Safety glasses
	Utility knife
	Scissors
	Pry bar
	Socket wrench
	Socket	7/16 in.
	Ball-end hex wrench	5 mm, 4 mm
	Open-end wrench	10 mm, 13/16 in., 3/4 in. (2)
	Snips
	Torque wrench	15–102 in-lb (2–12 N·m)
	Crowfoot wrench	5/8 in., 19 mm
	Screw driver (flat tip)
	Flashlight
	Hex socket	4 mm

 

OMAX Provided Tools

The following table contains a list of tools provided by OMAX needed to setup the ProtoMAX. These tools are included with the ProtoMAX.

Icon	Tool	Size(s)
	Lifting straps
	Dielectric compound, electrical
	Stand-off tool

 

Installation Requirements

Two people are required to lift and/or move the ProtoMAX. The table is top heavy and may tilt or shift during movement. Always lift or move the table slowly to avoid injury.

See the ProtoMAX Utilities Requirements document for the equipment footprint and other technical requirements before installing the system or contact us at support@protomax.com.

What is Included

Figure 6  

[1] Table assembly	[7] Seal removal tool (not used)	[13] Garnet abrasive (55 lb)
[2] High-pressure plumbing assembly	[8] Nozzle assembly	[14] High-pressure pump
[3] Water filter wrench (not used)	[9] Nozzle splash guard	[15] Laptop with Intell-MAX® Proto installed
[4] Stand-off tool	[10] Material holding kit	[16] Garnet hopper assembly
[5] Nozzle filters (x 3)	[11] Incoming water hose	[17] Document packet (not shown)
[6] Hose clamp	[12] Lifting straps

Unpack the ProtoMAX

The crated ProtoMAX weighs approximately 600 lbs (272 Kg). To avoid injury, clear the area of obstacles and debris before installation. Two or more people are required to move the ProtoMAX. Always move the ProtoMAX slowly to prevent injury or damage.

1.

Place the pallet near the installation location, ensuring the front of the pallet is facing away from any wall or obstruction(s). See ProtoMAX Utilities Requirements for placement and location information.

2.

Remove the plastic sheeting and shipping bands from the box and discard.

SUFFOCATION RISK! Plastic sheeting can be dangerous. Thin plastic film may cling to the nose and mouth preventing breathing. Keep the plastic bag away from babies, small children, and pets.

Plastic sheeting may be slippery. Once the plastic sheeting is removed from the ProtoMAX, remove it from the area to avoid slip, trip, and/or fall injuries.

3.

Carefully remove the shipping crate top and sides.

4.

Remove the plastic sheeting from the ProtoMAX and discard.

5.

Remove and read the document package.

6.

Remove box [1] from the pallet.

Figure 7  

7.

Remove all items from box 1.

8.

Connect power to the laptop, start the laptop, and open 401420A-EN Installation, ProtoMAX from TechDocs located in the ProtoMAX Knowledgebase for the remaining installation instructions for the ProtoMAX.

Figure 8  

9.

Remove the garnet abrasive [1] from the pallet, and set aside.

Figure 9  

The garnet abrasive container is very heavy. Use proper lifting techniques to avoid back and other possible injuries.

10.

Carefully remove the side panel kit [1] and set aside.

Figure 10  

11.

Sweep the floor to ensure it is free of debris and clean the area where the ProtoMAX will be placed.

12.

Remove the lag bolts securing the pump to the pallet and discard.

Figure 11  

The pump may be moved for easier access to the side bolts.

13.

Remove the pump side bolts and bracket and discard.

Figure 12  

Two people are required to move the pump. Always move the pump slowly to avoid injury. Do not lift the pump by the safety valve or wet-end; move the pump by the frame [1] to avoid damage.

Figure 13

Do not tip the pump on the side. Tilting the pump may damage the caster brackets. Always move the pump by rolling it or lifting it by the frame to avoid damage.

14.

Unlock the pump wheels and move the pump by the frame [1] from the pallet, and set aside (Figure 13).

Ensure the safety valve has cleared the machine frame and other components before lifting or moving off the pallet.

15.

Cut the straps securing the table assembly to the pallet and discard.

Figure 14  

Two or more people are required to move the table or pump. Do not lift or drag the table by the lower support legs. The table is top and rear heavy and may tilt or shift during movement. Always move the table slowly to avoid injury.

Figure 15  

16.

Position the table for movement:

a.

Unlock the wheels.

b.

Turn the table counter-clockwise and move the table towards the left, off the shipping blocks.

Use care when moving the table to avoid damaging the ProtoMAX power cord. The power cord may be pinched between the shipping block and the support bracket when rotating and/or moving the ProtoMAX. Pinching the power cord may damage the electrical cables inside the cord.

Figure 16  

c.

Remove the shipping blocks from the pallet.

17.

Move the table from the pallet:

Do not let the ProtoMAX fall to the floor. Dropping or jarring the ProtoMAX will damage the machine and internal components. When using lifting straps for movement, use the opposite (free) hand to support and guide the ProtoMAX.

a.

Lift the table front and slowly move it forward until the ProtoMAX is midway off the pallet edge, then gently lower the legs to the ground.

Figure 17  

b.

Lift the table rear and move the ProtoMAX off the pallet, then gently lower the table to the floor.

Figure 18  

18.

Roll the ProtoMAX to the installation location and lock the wheels.

Align the wheels under the bracket before locking. Protruding wheels may cause tripping or falling hazards. To avoid injury and/or damage, lock all ProtoMAX wheels. The lock stops the wheel from rotating and rolling, which prevents the ProtoMAX from moving during operation.

a.

Place a shipping block next to the frame leg.

b.

Slightly lift the frame leg with a pry bar and rotate the wheel under the bracket.

Figure 19  

c.

Lower the frame leg, lock the wheel, then remove the shipping block.

d.

Repeat steps 18.a.–18.c. for each frame leg.

Set Up the ProtoMAX

 

Ensure the equipment is properly grounded in accordance with national, state, and local codes. Never remove any prong from the plug. Always plug into the proper electrical outlet. See the ProtoMAX Utilities Requirements document and Safety section for important grounding information. Improper connection can result in a risk of electrical shock. If the electrical outlet is NOT properly grounded, or if in doubt as to whether the tool is properly grounded, contact a qualified electrician or service personnel.

 

This section provides the instruction to setup up the ProtoMAX and make it ready for operation. See the ProtoMAX Utilities Requirements document for important information.

 

Place and Connect the Pump

DO NOT cut the black cable ties! Black cable ties secure components to the table and should remain in place. ONLY cut the orange cable ties. Orange cable ties are used to protect and secure components during shipment.

1.

Roll the pump under the table and lock one of the pump wheels [1].

Leave a 1–2 in. space [2] between the back of the pump and the control cabinet.

Figure 20

2.

Carefully remove the packing materials and connect the cooling line OUT to the push-to-connect OUT connection [1] on the pump. The cooling OUT line and connection have yellow cable ties attached.

Connecting points are capped to prevent debris from entering into the lines. Remove the protective cap before making connections.

Figure 21  

3.

Carefully remove the packing materials and connect the cooling line [1] from the IN connection on the pump to the push-to-connect fitting at the solenoid. The cooling IN lines and connections have red cable ties attached.

Figure 22  

4.

Carefully remove the packing materials and connect the supply water hose from the pump wet-end [2] to the 90 degree fitting [1] and tighten.

Do not use Teflon tape or pipe sealant on the water connections. Teflon thread or sealant particles may enter into the high-pressure plumbing system and damage the pump and/or nozzle.

Figure 23  

5.

Carefully remove the packing materials from the transducer cable [2] , apply a light coat of dielectric compound to the transducer cable, then connect the transducer cable to the transducer [1].

Figure 24  

Pump Style One

 

Figure 25

Pump Style Two

6.

Carefully remove the packing materials, apply a light coat of dielectric compound to the pump power cord connector [1], then push the cord in and turn to connect to the pump power connector [2].

Figure 26

To prevent cross-threading the plug and connector, line up the notches [3] on the cable plug and power connector. Push the plug until it seats in the connector, then rotate the shell counter-clockwise until the threads engage, then turn the shell clockwise to tighten.

Connect the High-Pressure Plumbing

1.

Verify the u-shape high-pressure nipple, gland nut, slotted collar, and collar are assembled and aligned.

High-pressure nipples have left-hand threads, therefore when connecting components, turn clockwise to loosen and counter-clockwise tighten. Cross threading high-pressure connections may cause leaks and/or water damage from the leak(s).

Nipples contain small caps to protect the threading and keep debris from entering the high-pressure plumbing during shipment. The caps must be removed before assembling the high-pressure plumbing fittings. Do not use pliers to remove the black caps or cut the black caps from the nipple. Pliers and knives will damage the nipple threads causing leaks and/or water damage.

When preparing the ProtoMAX high-pressure tubing, it is extremely important to follow instructions. Some high-pressure tubing and fittings are pre-assembled. Fittings may need readjustment during installation to ensure proper seals and eliminate potential leaks. Use the provided stand-off tool to ensure the fittings are properly seated and sealed.

a.

Rotate the nipple cap clockwise to remove it from the gland nut and verify there is no debris in the high-pressure tube.

Figure 27  

b.

Verify the collar [1] is installed in the correct position using the stand-off tool [2]; adjust the collar to the correct depth if needed.

Figure 28  

2.

Remove the bracket cap [1].

Figure 29  

3.

Loosen the bracket.

Figure 30  

4.

Position the pump so the high-pressure plumbing is aligned vertically and horizontally, and the rear of the pump is 1–2 in. from the control cabinet.

Figure 31

5.

Attach the assembled u-shape nipple to the pump high-pressure outlet OUT connection [1] and hand-tighten.

Figure 32  

6.

Verify the gland nut is set approximately to the depth of the nozzle stand-off tool.

Figure 33  

7.

Adjust the position of the bracket [1], then tighten the bracket.

Figure 34  

8.

Lock the pump wheels [1].

Figure 35  

9.

Torque the pump connection.

The jaws of the crowfoot must maintain a 90-degree angle to the horizontal axis of the torque-wrench handle throughout the torquing rotation. Other angles of orientation will alter the set torque.

Figure 36  

Figure 37  

10.

Attach the bracket cap [1] and tighten.

Ensure the flexible conduit is not trapped under the bracket.

Figure 38  

11.

Verify the torque seals [1, 2] are not cracked or missing on all pre-assembled high-pressure connections and nozzle inlet body connection.

Personal injury and/or damage may occur if high-pressure torque seals are cracked or missing. Contact Technical Support before operating the ProtoMAX if any high-pressure plumbing seal is cracked or missing.

Figure 39

 

Remove the Cutting Deck Shipping Materials

DO NOT cut the black cable ties! Black cable ties secure components to the table and should remain in place. ONLY cut the orange cable ties. Orange cable ties are used to protect and secure components during shipment.

1.

Lift the lid and lock it into the upright position.

Use care when opening or closing the lid to avoid injury. Never let the lid free-fall. Keep hand, fingers, or body parts away from the side of the table when closing the lid.

Figure 40  

2.

Cut the orange cable ties securing the packaged abrasive garnet hopper assembly stored beneath the lid. Lift the package from the tank and set it aside for later.

3.

Loosen the thumb screws and remove the right garnet bin, then remove the desiccant packets from the tank.

Figure 41  

4.

Remove the drain hose and incoming water hose, and armor plate protective packaging from the tank and set aside.

If needed, loosen the cutting deck bolts, lift the cutting deck, then re-tighten the bolts.

Figure 42  

5.

Reinstall the garnet bin.

6.

Remove the remaining packing materials from the slats and bellow protector.

Do not discard the Z-axis shipping support assembly. The shipping support must be installed to prevent damage to the Z-axis bridge anytime the ProtoMAX is moved.

7.

Loosen the t-nut and bolt [1], align the t-nut with the frame slot and lift the support bracket assembly [3] from the frame (Figure 43).

 

Lightly tap the bolt to loosen t-nut from the frame, if needed.

8.

Loosen the hand knob [2] and remove the support bracket [3].

Hold the inlet body when loosening the hand knob. Do not let the inlet body fall and strike the cutting deck slats. Damage to the inlet body may occur, which may cause leaks.

Figure 43

9.

Tighten the hand knob [2] (Figure 43).

10.

Loosen the screws [1], remove the rear support bracket, then tighten the screws.

Figure 44  

Connect the Drain Hose

1.

Remove the drain hose from its storage in the ProtoMAX tank.

2.

Insert the drain hose through the hole [1] at the rear of the enclosure.

Figure 45  

3.

Slide the hose completely onto the barbed hose fitting [1].

Figure 46  

4.

Position the hose clamp around at least two barbs on the fitting, then tighten the hose clamp until the clampends are from 0 to 1/16 in. (0 to 1.5875 mm) apart.

Figure 47  

5.

Connect the incoming water line to the manifold IN connection [1] and secure with the hose clamp.

Figure 48

Install the Garnet Abrasive Hopper

The garnet abrasive assembly was originally stored under the tank and removed and set aside in a previous step. See Remove the Cutting Deck Shipping Materials.

1.

Locate the garnet abrasive hopper assembly and carefully remove the packing materials.

2.

Adjust the cutting deck light to access the hopper mounting location [1].

Figure 49  

3.

Cut the orange cable tie securing the grounding cable.

4.

Attach the hopper assembly [1] to the exterior of the roll bar with the supplied hardware [2].

 

Ensure the ground connection located inside the roll bar is attached to the inward hopper mounting bolt [2]. Order on bolt is washer, grounding cable, then lock washer.

DO NOT cut the black cable ties! Black cable ties secure components to the table and should remain in place. ONLY cut the orange cable ties. Orange cable ties are used to protect and secure components during shipment.

Figure 50  

5.

Insert the hopper assembly in its mounting bracket [1].

Figure 51  

6.

Insert the abrasive feed tube through the roll bar [2], then insert the feed tube into the abrasive feed block [1].

Verify the abrasive feed tube is not kinked or twisted.

Figure 52  

7.

Attach the hopper splash guard [1] to the hopper bottom, ensuring the washer is on the bottom of the hopper splash guard, then tighten the thumb screw [2].

Figure 53  

8.

Remove the shipping materials from the abrasive screen and place the garnet abrasive screen in the hopper.

Figure 54  

9.

Fill the hopper with garnet abrasive.

 

Only use garnet abrasive purchased from OMAX.

a.

Pour the garnet abrasive through the garnet abrasive screen into the hopper.

 

Gently tap the hopper side to evenly settle the garnet abrasive in the hopper.

Figure 55

b.

Place the hopper lid on the top of the hopper and secure the latching device.

Figure 56  

10.

Close the machine lid.

a.

Lift the lid and push support arm towards the back.

Use care when opening or closing the lid to avoid injury. Never let the lid free-fall. Keep hand, fingers, or body parts away from the side of the table when closing the lid.

Figure 57  

b.

Lower the lid to the catcher tank.

 

Power ON the ProtoMAX

Ensure the equipment is properly grounded in accordance with national, state, and local codes. Never remove any prong from the plug. Always plug into the proper electrical outlet. See the ProtoMAX Utilities Requirements document and Safety section for important grounding information. Improper connection can result in a risk of electrical shock. If the electrical outlet is NOT properly grounded, or if in doubt as to whether the tool is properly grounded, contact a qualified electrician or service personnel.

1.

Remove the cable tie securing the power cable to the frame.

2.

Route the cable and connector under the bottom-rear support bracket.

3.

Remove the packing materials from the cable connector.

4.

Plug the power cord into the main power outlet.

For countries other than United States, Canada and Mexico, OMAX does not supply a suitably rated industrial grade plug.

Contact a qualified electrician or service personnel for installation of a suitably rated industrial grade plug in accordance with national, state, and local codes. A pin and sleeve plug, rated at least 30A, 230V, 2-pole+E (3-wire grounding), IP44 or better, having a first-make last-break protective bonding contact (earthing contact) in accordance to standards IEC 60309-1 and IEC60309-2 may fulfill this requirement. You must plug the cord into a matching outlet that is properly installed and grounded in accordance with all local codes and ordinances.

Figure 58  

5.

Connect the laptop power cord into the laptop and to a 110 volt outlet, if needed.

 

For other voltages, the laptop power supply is rated 100-240V, 50/60HZ.

Figure 59

6.

Power ON the laptop.

Allow the laptop to completely boot before connecting the USB cable.

7.

Remove the USB cable from the top of the Control Box and remove the packaging.

8.

Route the USB cable [1] through the bottom back of the machine.

Figure 60  

9.

Connect the USB cable to the laptop.

Figure 61  

10.

Turn the power switch ON [1] and verify the cutting deck light is on.

Figure 62  

11.

Open MAKE and observe the color of the numbers in Nozzle Position pane [1].

• Bright green - the ProtoMAX and laptop are communicating
• Dull green - the ProtoMAX and laptop are not communicating
• Yellow - the laptop is not connected to the ProtoMAX

Figure 63  

12.

Remove any tools and/or obstacles from the cutting deck.

13.

Home the machine.

a.

Read the Warning and click OK.

b.

Click the Machine needs to be homed icon.

Figure 64  

c.

Read the Warning and click OK.

Flush the High-Pressure Plumbing

Flushing the system ensures there is no debris in the high-pressure plumbing that can clog the nozzle during operation.

Plugs or caps on the ProtoMAX system indicates required connections. To avoid injury and/or damage, verify all water and high-pressure connections are made before continuing. Contact OMAX Technical Support if needed.

1.

Open and secure the lid.

Use care when opening or closing the lid to avoid injury. Never let the lid free-fall. Keep hand, fingers, or body parts away from the side of the table when closing the lid.

Figure 65  

2.

Unscrew the protective cap from the inlet body and verify the nozzle filter [1] is not installed; remove the nozzle filter if installed and discard.

Figure 66  

3.

Loosen the Z-axis [1] and lower it to the lowest position.

Hold the inlet body when loosening the hand knob. Do not let the inlet body fall and strike the cutting deck slats. Damage to the inlet body may occur, which may cause leaks.

Figure 67

Verify the abrasive feed tube is not connected to the nozzle.

Figure 68  

4.

Close the lid.

Use care when opening or closing the lid to avoid injury. Never let the lid free-fall. Keep hand, fingers, or body parts away from the side of the table when closing the lid.

5.

Connect the other end of the incoming water line to the water source (connection to the water source is customer supplied).

Do not pinch or trap any wires in the opening. Pinching or trapping may damage the wrapped cable, causing communication errors or inaccurate water temperature readings.

6.

Open the main water source.

7.

Push the button [1] on the water filter to release the air.

 

Place a rag over the top of the water filter to prevent water from spraying.

Figure 69  

8.

Check for leaks at the incoming water [1] , filter out [2], solenoid [3], solenoid to pump [4], cooling line to pump [5], cooling line IN [6], and pump incoming water [7] connections.

Figure 70  

9.

In MAKE, use the X, Y Jog buttons [1] or the keyboard arrow keys to position the nozzle between two slats in the center of the cutting deck.

Figure 71  

10.

Click Test [1].

Figure 72  

11.

In the Test Operations dialog box, select Flush plumbing, click Next.

Figure 73  

Verify the abrasive feed tube is not connected to the nozzle.

Figure 74  

12.

Click Start Flush.

The flush test will run for 30 minutes. The pump will cycle on and off during the test operation, but water will still flow. The test automatically stops after 30 minutes.

Keep a minimum of 16 in. (40 cm) away from pressurized equipment during operation. Do not try to tighten ultra-high-pressure (UHP) fittings while the system is under pressure. Do not touch or rub suspected high-pressure plumbing leaks. Rubbing or touching suspected high-pressure leaks may result in injury. If a leak is found, shutdown the system, then fix the leak before continuing. Never attempt to fix a leak while the ProtoMAX is running.

13.

Check the high-pressure plumbing for leaks at the nozzle [1], high-pressure fittings [2], pump connection [3] and safety release valve [4] during the test operation.

Figure 75

• If a leak is found, shut down the system and torque the connection using the information in the following table.

The jaws of the crowfoot must maintain a 90-degree angle to the horizontal axis of the torque-wrench handle throughout the torquing rotation. Other angles of orientation will alter the set torque.

Figure 76  

Figure 77

Tools and Torque Specification	Location
	Pump [1]
	Nozzle [2]
	High-pressure fitting [3]

14.

Click Close when the flush is complete.

15.

Fill the tank with water up to the top of the slats and check for leaks at the tank front [1], tank rear [2], and tank drains [3].

Figure 78

Install the Nozzle

Do not install the nozzle before performing the initial system flush.

1.

Open and secure the lid.

Use care when opening or closing the lid to avoid injury. Never let the lid free-fall. Keep hand, fingers, or body parts away from the side of the table when closing the lid.

Figure 79  

2.

Place a piece of cardboard or other material on top of the slats to keep small parts from falling into the tank.

3.

Raise the Z-axis plate.

Hold the inlet body when loosening the hand knob. Do not let the inlet body fall and strike the cutting deck slats. Damage to the inlet body may occur, which may cause leaks.

4.

Install the nozzle filter [1] into the inlet body.

Figure 80  

5.

Carefully remove the protective cap from the nozzle assembly.

Always orient the orifice assembly so the brass [1] is visible from the top of the nozzle body. Inserting the orifice assembly in nozzle body in the incorrect orientation [2] may cause damage to the orifice assembly.

Figure 81  

6.

Insert the orifice assembly [1] into the nozzle body and adjust the orifice to ensure the it is seated correctly in the chamber bore [2].

Figure 82  

Do not use a brush or cotton swab or foam-tipped applicator to apply lubricants because they may leave fibers and clog the nozzle.

7.

Apply a light coat of Blue Goop to the second and third threads [1] of the inlet body, then spread the lubricant evenly around the inlet body threads.

Use care when applying lubricants around high-pressure water routes. Lubricants can enter the high-pressure water system and clog the orifice and/or mixing tube.

Figure 83  

8.

Wipe the excess Blue Goop from the end of the inlet body [1].

Figure 84  

9.

Apply a light coat of blue goop to the first and second nozzle body threads [1], then spread the lubricant evenly around the nozzle body threads.

Figure 85  

10.

Wipe the excess Blue Goop from the end of the nozzle body [1].

Figure 86  

11.

Attach the nozzle [3] to the inlet body [1].

Figure 87  

Remove the thumb screw [1] and mixing tube [2] from the nozzle body if necessary to fit the torque wrench prior to tightening. Hold onto the mixing tube [2] so that it does not drop out of the nozzle body when the thumb screw [1] is removed.

Figure 88  

12.

Verify the mixing tube is properly seated into the nozzle body and the thumb screw is tightened.

Figure 89  

13.

Place the nozzle splash guard onto the mixing tube, then fold the splash guard cup.

Figure 90  

14.

Close the lid.

Use care when opening or closing the lid to avoid injury. Never let the lid free-fall. Keep hand, fingers, or body parts away from the side of the table when closing the lid.

Test the ProtoMAX

Before operating the ProtoMAX verify the PC, electrical, and water connections are secure.

Ensure the equipment is properly grounded in accordance with national, state, and local codes. Never remove any prong from the plug. Always plug into the proper electrical outlet. See the ProtoMAX Utilities Requirements document and Safety section for important grounding information. Improper connection can result in a risk of electrical shock. If the electrical outlet is NOT properly grounded, or if in doubt as to whether the tool is properly grounded, contact a qualified electrician or service personnel.

Verify the abrasive feed tube is not connected to the nozzle.

Figure 91  

1.

Run the Reset Pump test operation.

The reset pump test runs a 30 second sequence to reset the pump. This test should be done before operating the ProtoMAX for the first time, after changing the nozzle orifice, repairing or replacing the pump, repairing any high pressure plumbing leaks, or when required by a fault or alert message.

a.

Open MAKE.

b.

Move the nozzle between two slats.

c.

Click Test.

d.

In Test Operations, select Reset Pump, and click Next.

e.

Click Start Test and check the high-pressure plumbing for leaks (the dialog box closes when the test is complete).

2.

Verify the lid safety switch operation.

The cutting stage lid has a built-in safety interlock to halt all cutting operations (pauses MAKE, stops stage motion, and turns off the pump) when the lid is opened.

a.

In Test Operations, select Test Cutting Head (Pump, Jet, and Abrasive), and click Next.

b.

Click Start Test.

c.

Open the lid to verify the test stops (the pump turns off, MAKE pauses, and stage motion stops).

d.

Close the lid.

e.

Verify the X-axis and Y-axis moves.

3.

Test the nozzle without abrasive.

a.

Open and secure the lid.

Use care when opening or closing the lid to avoid injury. Never let the lid free-fall. Keep hand, fingers, or body parts away from the side of the table when closing the lid.

Figure 92  

Verify the abrasive feed tube is not connected to the nozzle.

Figure 93  

b.

Position the nozzle in the center of the tank, between two slats.

Figure 94  

c.

Close the lid.

Use care when opening or closing the lid to avoid injury. Never let the lid free-fall. Keep hand, fingers, or body parts away from the side of the table when closing the lid.

d.

Click Test [1].

Figure 95  

e.

In Test Operations, select Test Cutting Head (Pump, Jet, and Abrasive), and click Next.

Figure 96  

f.

Click Start Test.

Figure 97  

g.

Click Close when the test is complete.

4.

Test the nozzle with abrasive.

a.

Insert the abrasive feed tube into the garnet abrasive inlet [1].

Figure 98  

b.

Click Test [1].

Figure 99  

c.

In Test Operations, select Test Cutting Head (Pump, Jet, and Abrasive), and click Next.

Figure 100  

d.

Click Start Test.

Figure 101  

e.

Observe the garnet abrasive tube [1] to verify abrasive is flowing.

Figure 102  

f.

Click Close when the test is complete.

The nozzle test automatically stops and closes the Test in progress ... window after 60 seconds.

Install the Material Holding Kit

The material holding kit is an optional ProtoMAX accessory that helps stabilize materials on the cutting stage.

1.

Loosen the t-nut all the way, but do not remove it from the part holding post.

2.

Align the part holding post assembly with the channel.

Figure 103  

3.

Set the part holding assembly in the channel and begin tightening, the t-nut [1] rotates perpendicular to the channel, then tighten to secure.

Figure 104  

4.

Place the material clamp [1] on the part holding post [2] and press down to secure.

Figure 105

5.

Lift up on the back of the arm [1] or rotate the arm sideways and lift to remove (Figure 105).

Install the Bottom Support Bracket and Side Panels

1.

The bottom frame support bracket is in a package located behind the middle frame support bracket. To remove it, grasp it on the left side and carefully lift it diagonally from the frame.

 

Always lift the bracket diagonally from the left end. The bracket cannot be removed by lifting straight up.

2.

Remove all packing materials from the bottom frame support bracket.

3.

Install the bottom frame support bracket [1] using the provided hardware.

Figure 106  

4.

Install the side panels:

a.

Slide one end of the panel into the support leg slot.

Support the bottom of the panel while inserting the edges into the frame support.

b.

Press the other side of the panel down into the opposite support leg slot.

Figure 107  

c.

Press on the center of the panel to secure it to the table frame.

d.

Repeat steps 1–3 for each panel.

The ProtoMAX installation is complete and ready for operation. Refer to the document, 401434 Operation, ProtoMAX.

Cut the Fixturing Square

See the fixturing-square instructions and video for additional information on cutting the fixturing square.

A fixturing square [1] establishes an X and Y reference to a known point in the cutting deck (Figure 108). The square provides a stable base for securing parts for cutting, and assists in maximizing material use when cutting. It can be used to precisely locate features on existing parts, or as a convenient surface to secure material against when cutting.

Figure 108

A square fixture is made by clamping material along the X-front frame in the machine cutting deck, and then using the machine to cut an "L" shape into it. Since the machine cuts the "L," we know it to be true and square to the machine's X- and Y-axes.

Technical Support

Refer to the protomax.com for technical support contact information.

Warranty

Contact Customer Support or go to the ProtoMAX website.