Pump Return, ProtoMAX^®

Service Guide

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 1-800-298-4036 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
November 2019
© 2019 OMAX Corporation

Machine Safety Labels

These safety labels can appear on the equipment. If ignored, physical injury, death, or equipment damage may occur. Read the complete safety information in the operation, installation, or maintenance guide before the equipment is installed, operated, or maintained.

Safety Precautions

Safety instructions must be followed when the equipment is installed, operated, or maintained. If ignored, death or physical injury can result, or damage can occur to the equipment. Always follow the applicable safety precautions when work is done with this equipment.

Use the equipment ONLY for its intended function

• Read the installation manual before the equipment is set up to learn about important installation and safety information.
• Read the documentation for recommended accessories. The use of incorrect accessories can cause a risk of injury to persons or damage to equipment.
• Wear eye and hearing protection. Always wear ISO-approved impact safety glasses.
• Make sure the equipment is installed correctly before the system is started.
• Never stand on the equipment. Serious injury can occur if the machine tips or you touch the machining tool during operation.

Do not make changes

• Do not make changes to the equipment or components that are not approved.
• Changes to the equipment can cause a risk of physical injury to the operator and others and can cause damage to the equipment or other property. Changes to the equipment will void the warranty.
• Do not change, defeat, or bypass the equipment safety features.

Do not remove panels

• Do not remove the panels during operation. Only remove them when required by maintenance or to troubleshoot problems.

Check for damaged parts

• Before the equipment is used, carefully examine guards or other parts that are damaged to make sure that it operates correctly and functions as intended. Examine to make sure parts that move, move freely, are aligned correctly, are not broken, are mounted correctly, and for other conditions that can have an effect on its operation. Replace guards or other damaged parts.

Use caution, stay alert, and be 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 follow the safety precautions when the equipment is installed, operated, maintained, or serviced. Carefully operated, the abrasive waterjet is a safe tool. When operated carelessly, serious injury can result.
• Wear a face or dust mask.
• Do not reach over the machine to operate it. Keep feet on the floor and balanced at all times.
• Keep a minimum of 16 in. (40 cm) away from pressurized equipment during operation.
• Do not try to tighten the ultra high-pressure (UHP) fittings when the system is pressurized.

Keep the tools and equipment in good condition

• Keep machine and accessories clean for the best and safest performance.
• Always keep the equipment in good condition.
• Follow the maintenance instructions for equipment and accessories.
• Keep all protective guards and stop devices.

Do not operate the equipment in a dangerous environment

• Do not use the equipment in or around flammable gases or liquids.
• Do not expose the equipment to rain or use it outdoors.
• Keep the equipment in a bright work area.

Never leave the equipment unattended during operation

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

Never operate the equipment without safety guards or covers

• Do not change, bypass, or try to defeat the safety guards, covers, or switches.
• Keep the guards in position and in working order.
• Do not remove the safety cover or guard during operation.
• Know the location of the ON/OFF switch.
• Know how to disconnect the primary power supply to the equipment.
• Start and operate the machine only when all side panels are in position.

Never put your hands in the area of the nozzle during operation

• Seek immediate medical aid for all waterjet injuries. Injuries caused by high-pressure abrasive waterjets are serious. Do not wait!
• Refer to the WaterJet Technology Association (WJTA) warning card for important medical aid information.

Figure 1  

Be careful when material(s) is moved in the catcher tank

• Do not operate the equipment when material is moved into the catcher tank.
• Always stop the abrasive waterjet before adjustments are made to the material or the abrasive jet.
• Always be careful when material is moved into the catcher tank. Fingers can be caught between a heavy part and the support slats.
• Be careful around the support slats. The abrasive waterjet also cuts the support slats; the edges can become sharp and cause cuts or collapse.

Do not touch live electrical components or parts

• Always use a licensed electrician or approved person to install the primary power source to use with the machine.
• Examine the equipment power and control cables regularly for correct connection and installation. Damaged, exposed, and bare wires can cause electrocution or death!
• Make sure the equipment is correctly connected and grounded in accordance with the national, state, and local codes. Do not remove the prongs from the plug. Always plug into the correct electrical outlet.
• Never use any electrical plug adapter.
• Make sure the power switch is in the OFF position before the equipment is plugged in to stop accidental starts.
• Always disconnect the equipment from the primary power before service or maintenance work is done.

Noise Emission Precautions

Environmental factors, such as how the room or structure is built, other machines and power tools in the area, and other noise sources, can have an effect on the environment's true noise level. When installed and operated correctly, the equipment's 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 that involve contact with the catcher tank water should receive medical aid immediately. Refer to the WJTA Warning Card for important medical aid information.

An injury caused by high-pressure waterjets can be dangerous. If there is a waterjet injury:

• Get medical aid immediately. Do not wait!
• Tell the physician of the cause of the injury.
• Tell the physician about the type of abrasive waterjet work done when the accident happened and the water source.
• Give this information to 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, and 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

Do standard practices and procedures to shutdown and stop the equipment, isolate it from its energy source(s), and prevent the release of potentially dangerous energy when maintenance and service work is done.

• 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  

• 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 with standards IEC 60309-1 and IEC60309-2 can fulfill this requirement.

Figure 4  

• The cord must be plugged into a matching outlet that is correctly 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 can cause sparks. Do not operate the equipment in an explosive environment. Do not let explosive or flammable vapors collect in the area of the equipment.

Removal of Waste Materials

Discard all machining wastes correctly in accordance with all local and federal regulations. Abrasive waterjet machining causes two types of waste: the water used for machining and the solid material that collects in the catcher tank. Although the used garnet abrasive is not dangerous, the waste deposited from the cut material can require special treatment.

Sufficient Shop Ventilation

Make sure there is good airflow in the work area to dissipate gases, vapors, and fumes. The machine contains a large amount of water. The ambient temperature in the shop and of the water can have an effect on water evaporation. To decrease the effect on other equipment in the shop, make sure there is good airflow in the shop. Also, some materials, such as aluminum particles, are known to make hydrogen in water.

Equipment Safety Features

The abrasive waterjet has several built-in safety features:

Overpressure Protection

During operation, pump pressure is monitored to prevent an overpressure condition. If the pump pressure increases more than the factory-set maximum pressure limit, the safety relief valve starts and stops the pump.

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 primary AC electrical supply from the machine. To isolate the machine from its electrical supply, always unplug the primary AC supply power cord from its electrical supply outlet.

Safety Lid

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

Safety Legend

The safety signal word panels and paragraph notifications can be shown throughout this and other documentation. Each gives the safety issue identification and recommended actions to prevent the risk. Be alert! Follow the recommended safety steps, procedures, and precautions to prevent injury or damage to the equipment.

Identifies a dangerous situation that could result in death or serious injury if not avoided.

Identifies a dangerous situation that could result in minor or moderate injury if not avoided.

Identifies situations that are important but not dangerous or related to physical injury; for example, messages related to property damage.

Used to give information, emphasize a point, or tips for easier operation.

OVERVIEW

Perform the following when replacing the ProtoMAX pump.

• Unpack the new pump
• Remove the original pump
• Install the new pump
• Prepare the original pump for return
• Return the original pump

Reuse the crate and shipping materials to pack and ship the original pump.

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

Two people are recommended to move the pump. Always move the pump slowly to avoid injury.

Do not tilt the pump on the side. Tilting the pump may damage the caster brackets. Roll or lift the pump by its frame when moving to avoid damage.

Oil may leak from the oil filler port during shipment if the dip stick is not replaced with the red plug. Shipping services may refuse shipment if oil is leaking from the pump.

To prevent the pump from moving during shipment, do not position the brackets in the same place as received. Load the original pump in the opposite direction as the new pump was loaded so the lag bolts are drilled on fresh wood. No predrilling is required.

RETURN THE ORIGINAL PUMP

When the original pump is ready for shipping, notify OMAX at omax.shipping@omax.com for the next steps.

Provide the following information in the email.

• Business name and name of person reporting
• Address
• Phone number
• Email address