Pump Return, ProtoMAX®

Service Guide

 

 

 

 

 

 

 

 

 

 

OMAX Corporation

21409 72nd Avenue South

Kent, WA USA 98032

Information:

Technical Support:

E-Mail:

Web:

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
November 2019
© 2019 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.

WARNING Electrical Shock Hazard
This symbol indicates the presence of life-threatening voltages. Never access areas labeled as such without first taking appropriate safety precautions: locking out power, verifying no voltage is present on circuits prior to maintenance activities, etc.

WARNING Flying Debris/Loud Noise
Eye and ear protection are required during operation. Removing the abrasive feed tube from the nozzle while under pressure will blow abrasive particles into the air, getting into eyes, and could contaminate tools and machines.

WARNING Keep Fingers and Hands Away From Moving Parts!
Fingers and hands can be pinched or cut by a moving parts hazard when the table is powered. Keep hands and fingers out of the path of moving parts. Never reach into moving machinery.

WARNING Pinch Hazard
When closing the lid, keep hands clear from the edge of the tank.

WARNING Keep Hands Away From Jet
Never position 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!

WARNING Watch Hands and Fingers
Keep the motor guards in position at all times during operation. Keep hands way from belts and pulleys when doing maintenance.

Electrostatic Discharge
Attention! Observe precautions for handling electrostatic sensitive devices.

No Open Flame
Do not allow smoking near the machine. Do not operate the equipment in an explosive atmosphere. Make sure that no ignition source (such as open flame or electrostatic discharge) is nearby the equipment. Do not store flammable materials near the equipment. Do not use equipment in or around flammable gases or liquids. Do not allow explosive or flammable vapors to accumulate in the area of the equipment. Proper ventilation in the work area will assist in dissipating the accumulation of gas, vapor, and fumes. Be especially careful when cutting materials that create sparks, such as titanium—these can ignite gases in the tank.

Do Not Operate With Guard Removed
Do not operate machine with guards or panels removed.

Do Not Spray
Do not spray water on or near the machine electrical enclosure.

 

Step Hazard
Never step, stand or walk on the support slats. They are weakened with cutting and may collapse additional weight.

Read Manual First/Do Not Adjust
Never make adjustments to equipment prior to reading the manual. Special instructions may be required. Adjustments may cause injury or damage equipment.

MANDATORY ACTION Disconnect Power
To isolate the machine from its electrical supply, always unplug the main AC supply power cord from its electrical supply outlet.

Read Manual
Read the equipment operator's guide for specific operator instructions and additional safety requirements. Do not attempt to operate this machine until you have read and understand all safety precautions and operating instructions.

Wear Ear Protection
Always wear hearing protection while in the vicinity of the equipment. When cutting above water, noise levels can exceed 70 dBA.

Wear Eye Protection
Always wear approved safety glasses whenever cutting. Regular glasses do not provide sufficient eye protection! The garnet abrasive is not a chemical irritant, but if not quickly washed out, it can injure an eye just as any sand would. In addition, tank water could contain particles from the material or chemical irritants. Have an eyewash station located near the work area in the event abrasive spray splashes into your eyes.

Wear Gloves
Bacteria in the tank water can build up. A minor break in the skin can introduce harmful bacteria into a wound. Always wear protective gloves if you have cuts or open wounds on your hands. When setting up material for cutting, wear gloves that provide protection against sharp metal edges.

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 obey 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.
  • Make sure the equipment is installed properly before startup.
  • Never stand on the equipment. Serious injury could occur if the machine tips or you touch the cutting tool during operation.
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 make sure that it will operate properly and function as intended–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 obey 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 stop 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 prevent 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 bright 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 the guards in position 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 position.
Never position 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.
  • Examine the equipment power and control cables regularly for proper connection and installation. Damaged, exposed, and bare wires can cause electrocution or death!
  • Make sure 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 doing 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 done 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 done 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, 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

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 done.

Equipment Grounding Requirements
  • Make sure 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  

  • Make sure 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 hit 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.

Sufficient 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 sufficient ventilation in your shop. Additionally some materials (especially aluminum particles) in water are known to produce hydrogen in water.

When you cut aluminum, the small particles in the tank react with the water to generate hydrogen. Usually, 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 prevent the hazard. Be alert! Follow the recommended safety actions and precautions to prevent injury or damage to the equipment.

WARNING

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

CAUTION

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

NOTICE

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

NOTE

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 set up the ProtoMAX pump.

Customer Provided Tools

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

Icon Tool Size(s)

Safety gloves  

Safety glasses  
Utility knife  

Scissors  

Pry bar  

Socket wrench  

Socket 7/16 in.
Ball-end hex wrench 4 mm, 5 mm
Open-end wrench 10 mm, 17 mm

OMAX Provided Tools

These tools are included with the ProtoMAX pump.

Icon Tool Size(s)

 

 Pump crate
(P/N 209203)		  

Packing straps/clips  

REFERENCES

Documents

The following table contains documents associated with these instructions.

Part Number Title
401420 Installation, ProtoMAX
401434 Operation, ProtoMAX
401440 Maintenance, ProtoMAX

Videos

Videos associated with these instructions are located at protomax.com.

DOCUMENT SCOPE

This document contains instructions for unpacking a new ProtoMAX pump and sending the original pump back to OMAX.

OVERVIEW

Perform the following when replacing the ProtoMAX pump.

UNPACK THE NEW PUMP

Caution

The ProtoMAX pump weighs approximately 175 lbs (79 Kg). To avoid injury, clear the area of obstacles and debris before installation. Two or more people are recommended to move the ProtoMAX pump. Always move the pump slowly to prevent injury or damage.

1. Place the pump crate near the installation location.
2. Remove the plastic sheeting and shipping bands from the box and discard.

Warning

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.

Caution

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

3. Carefully remove the shipping crate top and sides, and set aside.

Figure 6  

NOTE

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

4. Remove the lag bolts securing the pump to the crate and set aside.

Figure 7  

NOTE

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

5. Remove the pump side bolts [1] and brackets [2], then set aside.

Figure 8  

Caution

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

Notice

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.

6. Unlock the pump wheels and lift the pump from the crate.

Figure 9  

7. Remove the crank case cover [1] screw, then set aside.

Figure 10  

8. Turn the pump around, loosen the front cover captive screws, then remove the front cover [1] and the crankcase cover.

Figure 11  

9. Remove the red plug [1] from the oil filler port and set aside for returning the original pump.

Figure 12  

10. Retrieve the dip stick from the wrapper taped to the wet end of the pump.
11. Insert the dip stick [1] to the oil filler port [2].

Figure 13  

12. Replace the front cover and crankcase cover.

REMOVE THE ORIGINAL PUMP

CAUTION

Prior to performing any service, ensure the air supply to the system is turned OFF and the entire pneumatic system is exhausted including any accessories. Failure to release pressure may result in injury.

1. Turn ProtoMAX OFF.
2. Disconnect all lines to the original pump. See 401440 Maintenance, ProtoMAX.
3. Remove the original pump from the machine, then set aside. See 401440 Maintenance, ProtoMAX.
4. After the new pump is installed, prepare the original pump for return. See Prepare the Original Pump for Return.
Notice

If the original pump is leaking oil, drain the oil prior to preparing for return. Shipping services may refuse shipment if oil is leaking from the pump.

INSTALL THE NEW PUMP

1. Connect the new pump to the ProtoMAX. See 401420 Installation, ProtoMAX.
2. Test the new pump and check for leaks. See 401434 Operation, ProtoMAX.

PREPARE THE ORIGINAL PUMP FOR RETURN

Caution

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

1. Remove the crank case cover [1] screw, then set aside.

Figure 14  

2. Turn the pump around, loosen the front cover [1] captive screws, then remove the front cover and the crankcase cover.

Figure 15  

3. Remove the dip stick [1] from the oil filler port [2].

Figure 16  

4. Retrieve the red plug [1] from the new pump, then screw it to the oil filler port.

Figure 17  

NOTE

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.

5. Replace the front cover and crankcase cover.
6. Mark the location of the lag bolt holes on the crate floor.
NOTE

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.

Notice

Do not lift the pump by the safety valve or wet end. Roll or lift the pump by its frame when moving to avoid damage.

Figure 18  

7. Lock the pump wheels, then load the pump to the crate.
8. Loosely install the side bolts [1] and brackets [2] to the side of the pump.

Figure 19  

9. Install the lag bolts to secure the pump to the crate.

Figure 20  

10. Tighten the side bolts [1] and brackets [2].

Figure 21  

11. Replace the crate sides.
12. Place a copy of the emailed RMA packing slip inside the crate, then replace the crate top.
13. Enclose the crate with the shipping box, then secure the box using the provided packing straps and metal buckles.
NOTE

To secure the box to the crate, loop the straps through the metal buckles, then pull to tighten.

Figure 22  

14. Write the RMA number on the box.

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

TECHNICAL SUPPORT

Refer to the ProtoMAX website for technical support contact information.