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To all new OMAX Customers,

For your system to run without any problems, it is crucial to follow these procedures:

1. Check your salt level in the brine tank on a regular basis. Do not allow salt to go
below water level in brine tank.
It will hold a maximum of 300 pounds.

2. The following items need to be replaced on a monthly basis:

a. 20" 5 micron pre-filter
b. 20" Carbon pre-filter

3. The reject water flow should always be ON while unit is running. In order for
water to flow through reverse osmosis membranes properly it is important that
reject water is constantly flushed from system. NEVER turn off reject flow
meter.

Note: The above-mentioned filters can be purchased directly through South Coast Water.

Filters are priced as follows:

1. PF520 - 20" 5 micron pre-filter at $9.75 each

2. CARF20 - 20" carbon pre-filter at $19.75 each

Applicable shipping and handling charges may apply. Minimum order is 6 of each
filter. Please call 714-648-2488 or fax your orders to 714-648-2493.

Congratulations on your new OMAX / South Coast Water RO unit. We appreciate

your continued business with us.

Thanking you,
The South Coast Water Team Revised 4/9/2011

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 CONTENTS

REVERSE OSMOSIS

EQUPMENT SPECIFICATIONS

INTRODUCTION TO REVERSE OSMOSIS

REVERSE OSMOSIS SYSTEM

PURIFIED WATER STORAGE AND DISTRIBUTION

INSTALLATION INSTRUCTION

COMPONENTS

START UP INSTRUCTIONS

WIRING DIAGRAM

RESISTIVITY MONITOR

LITTLE ROCK CONTROLLER

PSI SWITCH

STORAGE TANK

FLOWMETERS

FLUID 0 TECH PUMP

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9
 RO SYSTEM SPECIFICATIONS

FRAME: 1.25" WELDED BOX STEEL SAND BLASTED AND

POWERED COATED.

PUMP AND MOTOR: FLUID 0 TECH PUMP COUPLED TO 1 HORSE

POWER TEFC MOTOR.

PREFILTER: 20" POLYPRO HOUSING WITH 20" 5 MICRON

FILTER. 20" POLYPRO HOUSING WITH 20"
BLOCK CARBON

R.O. MEMBRANES: 2-4X40 THIN FILM TYPE MEMBRANES HOUSED

IN SINGLE ELEMENT HOUSINGS.

INLET SOLENOID VALVE: IPV 3/4' 110 VOLT SOLENOID/DIAPHRAGM

TYPE.

FLOWMETERS: PANEL MOUNTED PRODUCT AND WASTE FLOW

METER EQUIPPED WITH THROTTLE VALVE.

PRESSURE GAUGES: 1- 0-160 PSI LIQUID FILLED BOTTOM MOUNT

STAINLESS STEEL.
1- 0-160 PSI LIQUID FILLED PANEL MOUNT
STAINLESS STEEL

LOW PRESSURE CUT OFF

SWITCH: FACTORY SET AT 10 PSI.

WASTE FLOW CONTROL: BLUE AND WHITE PANEL MOUNT FLOW

CONTROL WITH VALVE.

PLUMBING: INLET SIDE LOW PRESSURE: 1/2" PUSH LOK

TUBING AND FITTINGS
PRODUCT WATER: 1/2” POLYPRO TUBING
WASTE:3/8" POLYPRO TUBING

ELECTRICAL CONNECTIONS: CORD AND PLUG

CONNECTIONS: INLET 3/4" NPT

PRODUCT 1/2" MALE
WASTE 1/2" MALE

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 RO SYSTEM SPECIFICATIONS

OPERATING PRESSURE: 90 PSI

ELECTRICAL SWITCHES: TOGGLE AND PUSH BUTTON WITH PILOT

LIGHTS

INDICATOR LIGHTS: LED

MOTOR CONTROL: SINGLE CONTROL RELAY FOR R.O. PUMP

ELECTRICAL: 110 SINGLE PHASE (R.O. PUMP)llO-VOLT

CONTROL CIRCUIT
 REVERSE OSMOSIS SYTEM:

UNIT CAPACITY: 2500GPD@77°F

MEMBRANES:

MODEL: 4X40 THIN FILM

MEMBRANE TYPE: TF
OPERATING PRESSURE; 125 PSI
MAXIMUM FEED TEMP: 95®F
RECOMMENDED pH: 6 TO 12
GALLONS PER CARTRIDGE
AT77°F: 2200
AVERAGE REJECTION: 96%

MEMBRANE VESSELS:

NUMBER OF VESSELS: 2
MODEL: 4X40 PVC
VESSEL RATING: 240 PSI
VESSEL CONSTRUCTION: PVC
MAXIMUM TEMPERATURE: 130°F

BOOSTER PUMP:

FLUID 0 TECH MODEL: 2507

FLOW RATE: 5GPM
WORKING PRESSURE: 120 PSI
MATERIAL: BRASS
MOTOR HORSE POWER: IHP

FRAME:

CONSTRUCTION: STEEL 48
DIMENSIONS: 26"HX48"WX12D
SURFACE COVERING: POWDER COAT

INSTRUMENTATION PANEL:

FLOWMETER: 2
PRESSURE GAUGES: 2
REJECT CONTROL VALVE: 1

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 WATER SOFTENER MODEL SCW 56001-5

GRAINS REMOVED: 40,000 PER CUBIC FOOT

FLOW RATE: lOGPM
RESIN: 1.5 CUBIC FEET TOTAL
PIPE SIZE: 3/4
RESIN TANKS' DIMENTIONS: 10"X54"
BRINE TANK DIMENSIONS: 18"X30"
VALVE: FLECKENSTEIN

PREFILTER:

TYPE: SPUN POLY

MICRON RATING: 5
HOUSING; POLY
LENGTH 20

CARBON FILTER:

TYPE: CARBON BLOCK

HOUSING: POLY
LENGTH: 20

PRESSURE GAUGES:

PRESSURE: 0-160
NUMBER: 2
MATERIAL: STAINLESS STEEL
LIQUID FILLED: YES

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 COMPONENT IDENTIFICATION

1. HIGH PRESSURE GAUGE

0 - 160-PSI liquid filled panel mount gauge. Located top center of panel, this gauge
measures the water pressure in PSI that is applied across the membrane.

The pressure to this gauge is adjusted in two ways:

First: By turning the reject control valve clockwise the pressure will
increase; counter clockwise will decrease pressure. CAUTION: Do
not close this valve completely while in use.

Second: By adjusting the bypass valve located at acorn nut on pump head.

Note: Proper recovery must be set according to application.

2. REJECT FLOW METER

Located top left of panel; this meter is calibrated in gallons per minute. Its purpose
is to measure the amount of reject water so the proper ratio of reject/product water
recovery can be set.

3. PRODUCT FLOW METER

Located top right of panel, its purpose is to measure the amount of product water in
gallons per minute.

4. REVERSE OSMOSIS MODULES

Located on bottom of frame. The reverse osmosis module and how it operates is
explained in the front of this manual.

5. REJECT CONTROL VALVE

This valve is located on left side of panel on the reject valve. Its purpose is to meter
or restrict the flow of reject water existing in the module,thus creating the
necessary pressure inside the module so that the raw water must be forced through
the membrane,thus the effect of reverse osmosis. CAUTION; This control valve
should NEVER be closed completely while in use.
Adjusting this valve to attain the proper reject/product water ratio is accomplished
by turning the control knob located on the body of valve. Turning clockwise will
increase the pressure setting within the module and reduce the amount of reject
water. CAUTION: Do not exceed the maximum PSI setting recommended: 120 PSI.

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Turning counter-clockwise will reduce the pressure in the module and increase the
reject water flow. If a desired pressure/reject/product ratio cannot be attained by
this valve, lower the pressure at the internal bypass valve [located at the acorn nut
on the head of the pump) by using a flathead screw driver and turning
counterclockwise, then reattempt to adjust the pressure via the reject flow meter
valve.

6. PRESSURE PUMP

Located on platform offrame,this pump is responsible for creating the necessary

high pressure needed for efficient reverse osmosis operation. Pressure is adjusted
using the reject control valve and the internal bypass valve.

CAUTION: Do not run pump dry - no not exceed the recommended pump output
pressure(120 PSl)

7. INLET SOLENOID VALVE - OUTPUT

This valve is located on the side of the pre-filter attached to the front of the frame.
Its purpose is to shut off the feed supply of water when the unit is in the non
operating mode. This valve is a normally closed valve. If electrical current should
be shut off, this valve would close, thus stopping the feed water.

8. PRE-FILTER AND GAUGES

Attached to the frame, this filter will have a varied use depending upon need.
Consult Pre-Treatment Section for the type filter in your system.

Note: Under no conditions should the inside core of the pre-filter cartridge
become dirty.

9. WATER QUALITY MONITOR

Located in lower right corner of control box,the monitor measures the quality of the
product water by electrical conductance. The electrical scale on this meter is read in
PPM's (parts per million).

10. ON-OFF SWITCH

Located on bottom right corner of control box. This switch controls the electrical
supply to RO unit. There is a second on off switch located on the membrane panel.

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11. POWER ON
Located at the bottom of control box. This panel indicates when the RO unit is in the
“Run" Mode.

12. MAGNETIC MOTOR CONTRACTOR

Located inside of control box. 1 horsepower rated motor contractor to accept the in
rush current needed to start the high-pressure pump motor.

13. LEVEL CONTROL RELAY

Located inside of control box. Its purpose is to automatically start and stop the RO
unit by a signal from the product water storage tank sensor.

14. TIME DELAY

Located inside of control box. Time delay is 10 seconds. Its purpose is threefold:

First - when on-off switch is turned on "on" the time delay starts and opens the feed
solenoid valve to allow all of the air to be expelled before the high-pressure pump
comes on.

Second - in the event of momentary surge or low-pressure condition,the RO unit

would not cycle (turn on-off rapidly).

Third - If a true low feed condition should exist, the time delay will allow the
existing pressure in the system to bleed off and allow low-pressure switch to
activate before RO unit cycles.

15. LOW PRESSURE SWITCH

Located on the inlet of pressure pump. This switch is fed from the feed water before
going into the high-pressure pump. Should the feed water drop below 10 PSI, the
contacts in this switch would open and through the time delay shut down the RO
unit. Should feed water pressure return, the RO unit will automatically re-start.
CAUTION: Do not Bypass This Switch.

16. LOW PRESSURE INDICATOR

Located on control box. This will indicate when the RO unit is in low feed water
condition.

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INSTRUCTION TO REVERSE OSMOSIS

1. HOW REVERSE OSMOSIS WORKS

Reverse Osmosis is the process in which water is forced by pressure through a semi-
permeable membrane. Water passes through the membrane while the dissolved
and particulate materials are left behind. When pressure is applied to the
concentrated solution, water is forced through the membrane from the
concentrated side to the dilute side. See Fig. 1:

2. FACTORS AFFECTING THE OPERATION AND THE USEFUL LIFE OF REVERSE

OSMOSIS MEMBRANE
There are five main factors that affect reverse osmosis membrane:

A. Pressure
B. Hydrolysis
C. Bacteria
D. Temperature
E. Surface Coating or Fouling

A. Pressure: excessive pressure tends to deform or

compact the membrane. The compaction causes the
membrane to become less porous, thus decreasing the
amount of product water.

B. Hydrolysis: is the effect of chemicals in the feed water

on the membrane. In general, this happens when the
water temperature is high and the pH is below 2.5 and
above 7. For optimum life of the membrane,the pH
should be between 5 and 6.

C. Bacteria: if allowed to grow on the membrane, will

digest the top layer of the membrane and reduce the
ability of the membrane to reject salt.

D. Temperatures: above 95°F are generally avoided

because of problems in the membrane support
structures and the accelerated compaction and
hydrolysis rates. Membrane production rates will go
up with higher temperatures and down with lower
temperatures.

E, Fouling or Surface coating: is one of the most

common problems with reverse osmosis. It is the salts

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 (calcium carbonate, etc.) that precipitate on the
membrane. These salts plug the pores and channels,
reducing the water production rate.

3. MEMBRANE TYPES

There are two basic types of reverse osmosis membrane configurations:

F. Spiral Wound:
G. Hollow Fiber:

4. TYPICAL MEMBRANE REJECTIONS (AVERAGE)

Note: Spiral wound and hollow fiber membranes may differ slightly in percent
rejection but overall they are very similar in rejection capability. The major
difference is the fact that cellulose acetate membranes must have a low concentrate
of chlorine in the feed water and the polyamide membrane cannot see any chlorine.

5. SOME COMMON TERMS AND DEFINITIONS RELATED TO REVERSE OSMISIS

A. Feed water: the raw water introduced into the R.O. modules

B. Product water: the pure water produced by the R.O. membranes

C. Reject water: the wastewater that will not pass through the membrane and
is directed to drain

D, Membrane: commonly referred to as the R.O. membrane without the

pressure vessel

E. Module: referred to as the complete membrane in the pressure vessel

F. G.P.D. (Gallons per day): this is the standard at which R.O. systems are sized.
Example: a 1000 G.P.D. R.O. system will produce 1000 gallons per day of
pure water in 24-hour periods. Systems are generally sized for the maximum
amount of water used in the heaviest 24-hour period

G. P.P.M.(parts per million): the method by which the quality of the R.O.
product water is measured

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H. Percent Recovery: the amount of water that is recovered by the R.O.
membranes. Example: ifyou introduce 100 gallons offeed-water into the
membrane and you produce 60 gallons of product water and 40 gallons of
reject water,this is known as 60% recovery

1. Percent Rejection: the amount of salts or chemicals rejected by the R.O.

membrane

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 EFFECT OF TEMPERATURE ON REVERSE OSMOSIS

In the system it is also important to consider incoming water temperature. The

units are rated for product flow at 77°F [25°C]. The product flow reduces with
lower temperature according to this curve.

REVERSE OSMOSIS WATER TREATMENT

The application of reverse osmosis to the solution of problems in water treatment

requires an understanding of the basic mechanisms involved in the process,the
limitations of reverse osmosis and the pretreatment requirements.

THE MEMBRANE

Reverse osmosis utilizes the unique properties of a semi-permeable membrane to

allow fluid to pass while restricting the flow of dissolved ionic material. With
pressure applied to impure water on one side ofsuch membrane material, pure
water will pass through,leaving most of the impurities behind. The rejection of the
dissolved ionic material is a function of both molecular weight and ionic charge. For
example, we can expect a nominal 90% rejection of sodium chloride, which means
that the product water passing through the membrane will have a concentration of
salt approximately one-tenth that of the feed water. The rejection of calcium
carbonate (hardness) will be near 95%,while most metallic salts will be rejected at
a rate of98% to 99%.

The rejection of non-ionic or organic material is primarily by mechanical filtration.

Most substances with a molecular weight of over 100 will be completely rejected by
an intact reverse osmosis membrane. Low molecular weight organics, such as
formaldehyde or phenol, can pass freely though an R.O. membrane,as can most
dissolved gasses. Oil, suspended solids and particulate matter are mechanically
filtered, as are viruses, bacteria, pyrogens, and larger organic molecules.

To carry the rejected material away from the membrane surface,the feed side of the
R.O. membrane is continually flushed with an excess flow, usually two to five times
the product flow. This avoids clogging of the membrane surface and reduces the
tendency toward scale formation.

THE REVERSE OSMOSIS SYSTEM

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The reverse osmosis system is composed oftwo major parts; the high-pressure
pump(120 psi max.) and the membranes. The initial purified water production
rate is measured at this pressure.

The system is carefully designed to make certain that minimum flow rates within
the membranes are maintained. This factor is important to the efficient operation of
the membrane. The reason for this is as follows: as pure water passes through the
membrane under pressure, it leaves behind, at the membrane surface, a very high
percentage of the dissolved substances originally present in the supply water. This
“boundary layer" becomes more and more concentrated through the system. The
membrane tends to reject a constant percentage of“what it sees". For example, if
the water in contact with the membrane is 500 parts per million, then the purified
water going through the membrane at the point will be about 25 parts per million
(5%). At a different location in the membranes,the water in contact with the
membrane may be concentrated to 1,000 parts per million, at that point the product
water going through the membrane will be about 50 parts per million (5%),and so
on. By maintaining sufficient feed flow movement around the membrane,this
concentrated boundary layer is kept at a minimum,and purified water quality is the
highest possible. The other benefit of proper flow rates is that suspended matter
tends to be carried out of the system more effectively.

For these reasons,the design flow rates should not be changed except in the “safe'
direction. The “safe" direction in general is increasing the concentrate flow out of
the system (but NOT to exceed the values specified for the particular membranes
used).

It should be noted,as discussed previously,that the less we concentrate the supply

water in the reverse osmosis system; the better is the product water quality. In
other words,the lower the water recovery at which we operate, the better the
product water quality. For some applications, the economic benefits of better
product water quality far outweigh the extra cost of rejected water. An example of
this is where reverse osmosis water is to be deionized afterwards subsequently.

It appears that there are longer-term benefits to be gained by operating at lower

percent water recovery, particularly in reducing maintenance to the systems, and
minimizing precipitation problems, which may arise due to operator error.

It is important to realize that the purified water from a reverse osmosis system is
delivered to essentially atmospheric pressure, usually to a vented storage tank. In
general,the reverse osmosis system cannot be operated by opening and closing a
valve in the product water line (unless special pressure relief is provided). The
reason for this is that the high pressure in the system drives the water across the
membrane,and no flow of water would be possible if the pressure on both sides of
the membrane were the same. If for some reason the product water line is closed

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while the system is operating, the pressure would build up. Of course, if the purified
waterside of the system were strong enough,the pressure would end up the same as
the pump pressure, but at that point no water would flow across the membrane! In
real life, the plastic tubing on the product waterside normally would not tolerate
such high pressure.

The membranes are capable of taking 175 psi of"forward" pressure, i.e., from the
direction of the supply waterside to the purified waterside. However,they CANNOT
tolerate "back" pressure, i.e., in the direction from the purified waterside to the
supply waterside. The maximum backpressure should be no more than 3 or 4 feet
head of water. In order to prevent damage to membranes from this source, a CHECK
VALVE is placed in the purified water line, so that when the system shuts down,
backpressure is effectively sealed off. This safety device should NEVER be bypassed.

When a reverse osmosis system is shut down,and the supply water is in a "resting"
state over the membranes [i.e. almost no pressure across the membranes)the
purified water which bleeds through tends to have about the same mineral content
as the supply water. As a result, the first water sample obtained after start-up is
higher in mineral content, until the system is flushed out in a few seconds.

PURIFIED WATER STORAGE AND DELIVERY SYSTEM

As previously discussed,the R.O. purified water is almost always delivered to a

storage tank. Normally,such a storage tank is sized to provide sufficient water to
cope with the number of hours of continuous use, e.g., 8 hours, 16 hours etc. In an
exactly balanced system, the reverse osmosis system would be running
continuously; and it is capable of continuous duty. However,in practice, demand
fluctuates, and the storage tank is usually provided with a HIGH LEVEL switch that
turns off the reverse osmosis system when the tank is full. At this point, the reverse
osmosis system is still producing some water by virtue of the supply water pressure,
unless a solenoid valve is used to cut off the supply.

The purified water in the storage tank is distributed to the use points by means of a
moderate pressure, high capacity centrifugal pump. This pump can be provided
with a demand pressure switch, which turns on the pump when it senses a drop in
pressure. Alternatively, it can be operated continuously, with a pressure relief
system to recirculate water back to the tank, when there is no demand. Such
distribution systems give satisfactory service, because it avoids the detrimental,
repetitive on-off condition for the pump motor. The pumps, however, must NEVER
be allowed to run dry, since this will rapidly deteriorate the shaft seal. To prevent
this, the storage tank is fitted with a LOW LEVEL switch, which shuts down the
distribution pump if the water level in the tank gets dangerously low.

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 PRE-START CHECK LIST

1. PREFILTER CARTRIDGE IN PLACE

2. INLET BALL VALVE OPEN

3. MINIMUM INLET PRESSURE 40 PSI

4. CONTROL SWITCH TO “OFF^

5. SYSTEM IS PLUGGED INTO 110V/60H OUTLET

6. LEVEL CONTROL PROPERLY CONNECTED

7. REJECT AND PRODUCT TUBES CONNECTED TO DRAIN AND STORAGE TANK

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 START-UP

1. DO NOT START SYSTEM UNTIL PRE-START CHECK LIST IS COMPLETED

2. TURN CONTROL SWITCH TO "ON

(TIME DELAY WILL OPEN INLET SOLENOID VALVE AND ALLOW AIR TO
BE EXPELLED FOR 10 SECONDS)

3. AFTER 10 SECOND DELAY,PUMP WILL START. GREEN LIGHT WILL

COME ON.

4. IMMEDIATELY MONITOR HIGH-PRESSURE GAUGE TO INSURE THAT

SYSTEM DOES NOT EXCEED 120 PSl!!!

5. CHECK GAUGES

A) PRODUCT FLOW METER (1.5) IS AT PROPER

RATE
B) REJECT FLOW METER (1.5) IS AT PROPER
RATE
C) HIGH-PRESSURE GAUGE IS AT PROPER PSI
(100-120)

6. SYSTEM SHOULD NOW BE RUNNING PROPERLY.

7. PRODUCT WATER PPM SHOULD TAKE ABOUT 20 MINUTES TO REACH

OPTIMUM QUALITY.

8. TO CHECK LOW-PRESSURE SWITCH,TURN OFF INLET BALL VALVE,

LOW-PRESSURE SWITCH WILL ACTIVATE AT 12-15 PSI. AFTER
PRESSURE BLEEDS,THE LOW FEED PRESSURE LIGHT(RED) WILL
ILLUMINATE.

9. CHECK LEVEL CONTROLS TO INSURE THAT UNIT STARTS AND STOPS.

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 TROUBLESHOOTING

SYMPTOM PROBABLE CAUSE SOLUTION

RO unitwill No electrical power to Check power

Not start control circuit

Storage tank level full Drain some water

out oftank

On-Off switch Check or replace

Coil in magnetic motor Contact factory

Starter burned out

Low feed pressure Check low pressure

Pump motor Check or replace

Level Control relay Contact factory

Low Feed pressure Feed water valve Check

Turned off

Feed solenoid valve Check or replace

Defective

Pre-filters clogged Check or replace

Inlet water Check

Restriction

Low pressure switch Check or replace

Defective

Inlet water pressure Check

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*

ISOMETRIC.VIEW o.oDota.oeo

1
Z2S0i:0.DM

■miE! WATER TANK. LEVEL SWITCH HOLE LOCATlO^

PROPRlCTAHY INFDRUATIQH 'DRAWING BY: MATERIAL / SPEanCATION

S. VEENHUIZEN
n«5 (MMttt B INC PROPOmr
or OMM CORPOtUTHN MO NOT DATE: S/26/05
TO ee cootED OR nmoouecD REVISED BY;
wmouT THE mrrEN qmseht SHEET 1 on .CHANCE NO.
or cuw coftroMDON. OATt DWC NO.

The above picture shows the location as to where the fl oat switch is to be located.
The switch threads should go through the tank with the o-ring on it then the half
coupling tightened down from the inside of the tank. Disregard the above hole
size and make the diameter 1.65 inches.

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 GENERAL INSTALLATION INFORMATTON

Please review the following items thoroughly to ensure an efficient and safe
installation of the water treatment system. The included page shows a typical
installation line drawing of the South Coast Water treatment system.

Operating Conditions-A minimum operating water pressure of 45 psi is required for

the RO system to operate properly. Water temperature is not to exceed 95°F. Do not
subject the system to freezing conditions.

Space Requirements-Allow adequate space for the water treatment system and
associated piping a minimum of 43" on each side of the RO. This required for
membrane removal.

Inlet Piping-Inlet plumbing should be adequately supported to avoid excessive load

on the softener valve, the plumbing size should be a minimum of 3/4".

Soft Water Feed-A 3/4" hose is connected to the inlet solenoid valve of the RO. The
hose is to be connected to the outlet barbed fitting on the back of the water softener.

Product Line Piping-A 3/8" blue polyester tube with a 1/2” threaded fitting is
provided for the connection of the product water line to the OMAX charge tank. The
other end is to be pushed into a T with a John Guest fitting on the back of the RO
system.

Drain Line Piping-A 1/2" clear vinyl tube from the softener and 3/8" red polyester
tube from the RO are provided to connect to your drain. The following general drain
line piping guidelines should be observed.

> 3/4" or larger piping

> Should not exceed 20 feet
> Should not be elevated higher than the system
> No restrictions and no shut-off valves should be installed in the drain line.
> Minimal number of elbows and fittings should be installed in drain line.

Electrical-110 VAC 60 Hz 30 amp power is required for the operation of the

softener, control panel and motor of the system. A control wire is also provided for
the high level switch that you will mount into the side of the storage tank (see
above). Connection is made easy by slipping the electrical connectors on the end of
the wire to the two plugs on the high level switch.

RO Service-The system needs little maintenance to keep it running properly. As a

general rule we suggest you change the 5-micron and carbon pre-filter once a

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 f
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^ month. You can purchase these from South Coast Water. It is very important to keep
I

i salt in the brine tank; regular rock salt, which you can purchase at any hardware
store, will work fine.

If you have any questions regarding maintenance please feel free to call (714)648-
2488 and one of our technicians will be glad to assist.
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*
Contents
Page

Chapter 1
Safety First
Safety Labels 1 -1
Safety Precautions 1 -3
Table Safety Requirements 1-3
Lock-out/Tag-out Procedure 1-3
Disposing of Waste Materials 1 -3
Adequate Shop Ventilation 1 -3
Equipment Safety Features 1-3
Emergency Stop Switch (E-Stop) 1 -3
Overpressure Protection 1 -3
Electrical Protection 1 -4
Electrical Disconnect 1 -4
Access Control Circuit 1 -4
Safety Checklist 1 -5

Chapter 2
The OMAX JetMachining Center
JetMachlning Center Components 2-1
PC-based Controller 2-2
Operator Control Panel 2-3
Control Panel Switches 2-3
Internal PC-based Controller Components 2-4
Windows® PC 2-5
PC Rear Panel 2-5
X- Y- Z-axis Motion System 2-5
Abrasivejet Delivery System 2-7
Abrasivejet Nozzle 2-8
The Abrasive Hopper 2-9
High-pressure Plumbing 2-9
Swivels 2-9
The Dual ON/OFF Valve 2-10
The Adjustable Dump Orifice 2-10
Catcher Tank 2-11
Rapid Water Level Control 2-11
EnduroMAX® Direct Drive Pump Overview 2-13
Pump Front View with Side Panel Removed 2-14
Pump Rear Vieww/ith Side Panel Removed 2-14
Pump Top View with Lid Opened 2-15
Pump Side View with Right Panel Opened 2-16
EnduroMAX Operator Controls 2-16
High-pressure Pump ON/OFF Svfltch 2-17
Charge Pump ON/OFF Switch 2-17
Emergency Stop Switch (E-stop) 2-17
Operator Keypad and Display Screen 2-17
Display Screen 2-18
Run Button 2-18
Stop Button 2-18
Reset Button 2 - 18
Up/down Arrow Buttons 2-18
Temperature Control 2-18
Disconnect Switch for Main AC Power Source 2-19

Chapter 3
Operating the OMAX JetMachining Center
About Abrasivejet Machining 3-1
The OMAX Intelli-MAX® Software 3-2
Intelli-MAX Make Program 3-2
OMAX Interactive Reference 3-2
Operating the High-pressure Pump 3-3
Pump Operating Characteristics 3-3
Start the Pump 3-3

400433H-EN III
k.
OMAX
 Set the Pump RPM 3-4
Set the Adjustable Dump Orifice (ADO) 3-4
Removing a Stuck Tapered Pin 3-8
Stopping the Pump 3-8
Emergency Shutdown Procedures 3-8
Operating the JetMachining Center 3-8
Configure Your Drawing 3-8
Determine a Cutting Quality 3-9
Clamp and Position Your Materials for Cutting 3-9
Use Tabs for Holding Small Parts 3-9
Set Machine Limits 3-10
Cut Your Parts 3-10
Start the Pump and Controller 3-10
Configure the Make Software 3 -18
Cut the Material 3 -19
Shutting Down the JetMachining Center 3-20
Ensuring Clean and Quiet Machining 3-21
Keep the Abrasivejet Nozzle Under Water 3-21
Place a Splash Guard on the Abrasivejet Nozzle 3-21
Washing Heavy Garnet Deposits from Parts 3-22
Startup Check List 3-22
Shutdown Check List 3-24

Chapter 4
Pump and Table Maintenance
Maintenance Schedules 4-1
OMAX Maintenance Overview 4-1
Maintaining the EnduroMAX Pump 4-4
Consumable Pump Parts 4-4
Parts Required for Wet End Maintenance 4-5
Tools and Other Items Required for Pump Maintenance 4-5
Remove the High-pressure Wet End Components 4-6
Inspecting the Backup Ring Assembly and Dynamic Seals 4-10
Rebuilding the Coolant Housing 4-12
Inspect the Check Valve Assembly 4-13
Rebuild the Check Valve Assembly 4-15
Rebuild the Dynamic Seals 4-17
Removing Plunger Assemblies 4-18
Reinstalling Plunger Assemblies 4-19
Reassemble the Wet End Assembly 4-20
Replacing a Tie Rod Stud 4 - 24
Replacing the Crankshaft Pony Rod Seals 4-25
Replacing the High-pressure Port Adapter Seals and Filter 4-26
Maintenance of the Water Filtration System 4-29
Changing Water Filter Cartridges 4-30
Cleaning the Pump’s tA/hite Water Tank 4-31
Flushing the Machine After Maintenance 4-32
Changing Crankcase Oil 4-33
Servicing the Pump Motor Belt 4-34
Lubricating the Electric Motor 4-35
Replacing the Electrical Enclosure Air Filter 4-36
Rebuilding the Safety Valve 4-37
Maintaining the OMAX Table 4-39
Tools Required for Table and Pump Maintenance 4-39
Maintenance Log 4-41
Maintaining the High-pressure Plumbing System 4-42
Creating a High-Pressure Seal 4-42
Using Blue Goop® Thread Lubricant 4-42
Assembling the UHP Fitting 4-43
Three Thread Rule 4-43
Tank Maintenance 4-43
Cleaning Tips 4-43
Removing Garnet Accumulation 4-44
Cleaning the Filter Screen for the Tank’s Water Outlet 4-44
Controlling Tank Odor 4-44
Slat Replacement 4-45
Maintaining the X-Y Carriage 4-45
Timing Belt Inspection and Tensioning 4-45
Timing Belts for Cantilever Tables 4-46
Locating the Timing Belts 4-46

IV 400433H-EN
V
OMAX
 Inspecting and Adjusting Timing Belts 4-46
Timing Belts for Bridge-style Tables with Ball Screws 4-48
Locating the Timing Belts 4-48
Adjusting Timing Belts: Y-axis 4-48
Adjusting Timing Belts: 80160 X-axis 4-49
Lubricating the JetMachining Center 4-50
Grease Fittings and Couplers 4-50
Identifying Lubrication Points 4-51
Lubrication Points for Cantilever Style X, Y Carriages 4-52
Greasing the X and Y Carriages 4-52
Lubrication Points for the Motorized 2-Axis 4-53
Greasing the Z-axis Bearings 4-53
Lubrication Points for Bridge Style X, Y Carriages 4-56
Lubricating 80160 X-axis Rails 4-57
Lubricating X-axis Rails for the 120X and larger Bridge Tables 4-59
Maintaining the MAXJET© 5i Integrated Nozzle 4-60
Introduction 4-60
Nozzle Removal 4-61
Nozzle Cleaning 4-61
Nozzle Installation 4-61
Removing the Filter Seal Assembly from the Inlet Body 4-62
Nozzle Filter Seal Assembly 4-62
Install the Nozzle Filter Seal Assembly 4-63 ,
Removing the Nozzle Body 0-Ring 4-63
Cleaning and Inspecting Nozzle Components 4-63
Cleaning 4-63
Mixing Tube 4-65
Maximizing Nozzle Life 4-66
Mini-MAXJET 5 Installation and Operation 4-68
Installing the Mini-MAXJET 5 4-68
Operating the Mini-MAXJET 5 4-68
Rebuilding the Dual ON/OFF Valve 4-69
Removing the Dual ON/OFF Valve 4-69
Disassembling the Dual ON/OFF Valve 4-72
Reassembling the Dual ON/OFF Valve 4-73
Installing the Dual ON/OFF Valve 4-75
PC-based Controller Maintenance 4-76
Cleaning the OMAX Industrial Keyboard and Mouse 4-76
Cleaning the LCD Monitor Screen 4-76
Replacing the Cabinet Air Filter 4-77
Replacing the CMOS Battery 4-77
Clues to a CMOS battery failure 4-77
Rebooting Windows 4-77
Running the Disk Defragmenter Utility 4-77
Upgrading Your OMAX Software 4-78

Chapter 5
Troubleshooting the OMAX Table
Troubleshooting the OMAX JetMachining Center 5-1
Problems 5-1
Abrasivejet Nozzle Doesn’t Move 5-1
Parts are Too Short, or Flat Spots Appear When Cutting Curves 5-1
Home Position or Soft Limits are Lost 5-1
Poor Surface Finish 5-1
Holes Too Large and Undersized Parts 5-2
Excessive Taper on Part Edges 5-2
Holes are Not Round 5-2
Abrasivejet Not Piercing Material 5-2
Abrasivejet Quit Cutting 5-2
80160 Not Cutting Square Parts 5-2
Accuracy Errors 5-2
Water is Forced Up the Abrasive Tube 5-2
The Jet Looks Wide and Fuzzy 5-3
No Abrasive Flow 5-3
No Abrasive Flowing from the Abrasive Tube 5-3
Water Comes Out the Top of the Abrasive Feed Tube 5-3
Water Spurts Out of the Tank 5-3
Abrasive Piles Up on the Work Piece 5-3
The Table Has an Unpleasant Odor 5-3
Keyboard or Mouse Fail to Work 5-3

400433H-EN V

OMAX
 Blue Screen Errors 5-3
'Babysit Triggered" Message 5-3
Solutions 5-4
Correcting Water Leaks in the Nozzle Assembly 5-8
Correcting Water Leaks in the TAJ ON/OFF Valve 5-9

Chapter 6
Troubleshooting the EnduroMAX Pump
Keypad Display Messages 6-1
Normal Operation Messages 6-1
Pump Fault Messages 6-1
Fault Message -“Charge Pressure Low” 6-2
Fault Message -“Charging Pump Contactor" 6-2
Fault Message -“Dead Head” 6-4
Fault Message -“Variable Drive Fault" 6-4
General Pump Problems 6-4
Low or Fluctuating Pump Output Pressure 6-5
No AC Power at Pump Unit 6-6
Pump Does Not Start 6-6
No Keypad Display 6-7
Pump Runs but Display Reads "0.3 KSI", or “0 KSr 6-9
Fuses F1/F2 Blowing 6-10
Circuit Breaker CB1 Tripping 6-10
Correcting Water Leaks in the Wet-end Assembly 6-11
Correcting Water Leaks in the ADO Assembly 6-13
Troubleshooting ADO Assembly Leaks 6-14

400433H-EN
V/
V
OMAX
 Chapter 1
Safety First
This chapter describes safety labels that may appear on your OMAX equipment. If ignored, physical injury
death, or equipment damage may occur. Read the safety instructions before you use your waterjet.

Safety Labels

Machine Safety

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 gioves that provide protection against sharp metal
edges.

Read this Manual

Do not attempt to operate this machine until you have read and understand all safety precautions
and operating instructions.

Eye Protection
rr^ Aiways wear approved safety goggles whenever cutting. Regular glasses do not provide sufficient
eye protection! Have an eyewash station located near the work area in the event abrasive spray
splashes into your eyes. 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 chemicals irritants.

Ear Protection
Always wear hearing protection while in the vicinity of the waterjet. When cutting in air, noise levels
can exceed 120 dB.

Flying Debris/Loud Noise

Eye and ear protection are required during operation.

Watch Your Hands and Fingers

Never place your hands or fingers in areas where they are in danger of being pinched or crushed
during equipment operation.

400423H-EN 1 -}

[t]
OMAX
 step Hazard
Never step, stand or walk on the support slats. They are weakened with cutting and may
collapse under your weight.

/iVWARNING Never operate the equipment with protective guards or covers removed or
STAY CLEAR! rendered inoperative.
If you can read this sign,
a cover Is missing. Do NOT
operate with cover missing.

/l^WARNING
Never place your hands in the vicinity of the nozzle while cutting.
Keep hands away
from fet.
Seek immediate medical attention in the event of a waterjet injury. Injuries
caused by high-pressure waterjets are serious. Do not delay!

45»WABNtNG
Removing the abrasive feed hose from the nozzle while under pressure will blow abrasive
particles into the air, getting into eyes and could contaminate tools and machines.

Do not
disconnact
abraslva hose
with system
pressurized.

ZLCAUTION
Ensure that system is locked-out prior to servicing the On/Off Valve. Do not
ACTUATOR attempt to turn ON the pump unless the On/Off valve is installed and torqued
TORQUE VALUE: to the required settings. Read the user’s guide prior to servicing this device.
21 ft-lb (28.5 N-m)

Electrical Safety
Electrical Hazard
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.

Lock Out Power

Never do maintenance on the waterjet equipment with the main AC power disconnect ON,
unlocked, or while the pump is operating. Always follow standard lockout/tag-out procedures, and
JlLi lock out the main pump power at its source.

1-2 400433H-EN

OMAX
 Safety Precautions
Always observe the following safety precautions while operating or servicing your equipment. Carefully
operated, the waterjet is a safe tool. When operated carelessly, serious injury can result. Never make
unauthorized alterations to the equipment or components.

Table Safety Requirements

Injuries involving contact with the water should receive immediate attention. Use antibapterial chemicals
in the tank water to reduce this hazard.
Seek immediate medical attention in the event of a waterjet injury. Inform the physician of the cause of
the injury, what type of wateijet project was being performed at the time of the accident, and the source
of the water.

Lock-out/Tag-out Procedure
WARNING! OMAX recommends the implementation of 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.

Disposing of Waste Materials

Dispose of cutting wastes properly and in accordance with all local and federal regulations. The
abrasivejet 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 abrasivejet cutting, garnet particles are accelerated with high-pressure water to strike the material
creating a residue of abrasive grit and eroded particles from the work-piece. 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

Machining certain types of material such as titanium with a waterjet will produce sparks. Therefore, do
not operate your waterjet in an explosive atmosphere or allow explosive or flammable gasses to
accumulate in the work area. Proper ventilation in your job shop will assist in dissipating the
accumulation of gas, vapor, and fumes. When you cut aluminum, the fine particles in the tank react with
the water to generate hydrogen gases. Normally, hydrogen bubbles to the surface and escapes'into the
shop in harmless, low concentrations. Take care that an ignition source (e.g., open flame, electrostatic
discharge) is not nearby when operating any feature on your abrasivejet system.

Equipment Safety Features

The abrasivejet provides several built-in safety features.

Emergency Stop Switch (E-Stop)

The pump and table controller are equipped with emergency stop switches. The E-Stop is engaged by
pushing it in. Once engaged, it immediately shuts down the pump unit and abrasivejet.

Overpressure Protection
During operation, pump pressure is monitored to prevent an overpressure condition. If the pump
exceeds the factory set maximum pressure limit, the control shuts down the pump unit. In addition to the
400433H-EN 1-3

OMAX
 software maximum pressure limit, all pumps are equipped with a factory set “Safety Valve” to provide a
hard-plumbed, over-pressure relief valve.

Electrical Protection
The variable frequency drive(VFD) provides electrical protection as well as speed control for the pump’s
main drive motor. The DIN rail-mounted contactor and circuit breaker provide short circuit protection to
the charge pump motor. Circuit breakers protect the internal transformer. A 0.5 Amp fuse protects the
pump keypad.

Electrical Disconnect
Electrical disconnect that cuts off and isolates the equipment from its main electrical supply is provided
as standard equipment on all machines sold in countries where installation of this electrical disconnect is
mandatory. This disconnect is provided as an optional accessory in other countries where installation of
this device is not a requirement.

Access Control Circuit

The Access Control Circuit(ACC), if applicable, is designed to create a designated safety zone around
the waterjet that protects operators from injury during use. The access control circuitry continually
monitors the closure status of two external switch contacts. The breaking of contact with either switch
immediately trips the safety circuit, disabling the cutting process until the cause of the violation is
corrected and the access control circuit reset.

1-4 4Q0433H-EN

[t]
OMAX
 Safety Checklist
Safety Checklist Topics
Safety Labels
Wear Gloves
Electrical Hazard; Danger - 480 Volts
Lock Out Power
Eye Protection - Approved Safety goggles/Eyewash Station
Ear Protection
Flying Debris/Loud Noise
Danger - Watch your Hands and Fingers
Warning - Keep hands away from jet
Warning - Worn slats
Warning - Pinch points
Safety Precautions
Material handling: do not allow nozzle movement while handling material in the tank
Cutting underwater
Treat injuries with caution; WJTA Warning Card - medical attention for any waterjet injury
Special handling of hazardous materials
Prevent slipping due to water spills
Use adequate ventilation. Do not operate In an explosive atmosphere or near an ignition source.
Use only approved work platforms
Use the splash guard (muff) to reduce splash, spray, and noise level
Use proper lifting equipment
Remove power from equipment when not in use
Operate equipment after reading equipment manuals and receiving qualified instruction
Be able to quickly access the emergency stop switch
Start pump only when all guards are in place
Maintain protective guards and shutdown devices on/around pump
Immediately notify repair personnel if leaks are found in pump fittings or connections
Follow manufacturer’s recommendations for servicing and use only original manufacturer replacement parts
Follow periodic maintenance schedule that ensures proper equipment operation
Following maintenance activities, clear all tools and rags from around the equipment before starting. Be
aware of trip hazards (cords/cables, etc.).
Do not start equipment unless you know how to stop it
Never open or do maintenance on the equipment with the main disconnect ON or while the pump is
operating. Always follow lockout/tag-out procedures
Do not make unauthorized alterations to the equipment or components
Keep a minimum of 16"(40 cm) between you and high-pressure components.
Do not use silica sand as a cutting abrasive. Silica dust produced by the cutting process can lead to silicosis,
a serious lung disease.
Do not operate the machine in close proximity to other machines; water can spray or splash out of the
cutting table area.
Equ pment Safety Features
Emergency (E-Stop) Switches
Overpressure Protection safety valve and software shutdown
Electrical Protection
Electrical Disconnect
VFD / DIN rail mounted contactor and circuit breaker (short circuit protection to the charge pump motor)/
Circuit breakers protect internal transformer/ 0.5 Amp fuse protects pump keypad

Date

1
Students Name Signature

1
By signing this document. I acknowledge receipt and review of this Safety Checklist and understand items contained within. This document will
be kept on file at OMAX in the Customer records.

08302013

400433H-EN 1-5

[t]
OMAX
1-6 400433H-EN

OMAX
i

I
 Chapter 2
The OMAX JetMachining Center
The OMAX JetMachining Center is a precision abrasivejet machining tool operating under software control
and able to cut complex parts out of most materials including metal, plastic, glass, ceramics, stone and
composites using standard CAD drawing files.

JetMachining Center Components

OMAX JetMachining Centers can be divided into these major sections (Figures 2-1 and 2-2)
● PC-based controller
● X- Y- and Z-axis motion system
● Abrasivejet delivery system
● Catcher tank
● High-pressure pump (see Chapter 3: Introduction to the EnduroMAX Pump)

® /
i
®

i
Figure 2-1

0 PC-based controller (D abrasivejet nozzle

0 X-axis carriage © Motorized Z-axis
0 Y-axis carriage Catcher tank
0 garnet hopper
0 abrasive feed tube

400433H-EN 2-}

OMAX
 Figure 2-2

0 PC-based controller 0 catcher tank

0 motorized Z-axis 0 X-axis rail
0 Y-axis bridge 0 abrasiveJet nozzle

PC-based Controller
The JetMachining Center PC-based controller contains a standard video monitor with a Windows-based
computer(PC) running the OMAX software Layout and Make. The operator control panel is directly
below the monitor along with the keyboard and mouse. .

®
®

Figure 2-3

0 water-resistand keyboard and mouse 0 video monitor

0 PC access panel 0 PC-based controller cabinet
0 operator control panel © hinged arm

2-2 400433H-EN

OMAX
 Operator Control Panel
The JetMachining Center front panel provides five function switches for JetMachining Center operation:

@ ®
Figure 2-4

Emergency stop switch (E-Stop) 0 pause switch

controller power ON/OFF switch 0 water level up/down switch
reset/override switch

Control Pane! Switches

Emergency Stop
Immediately shuts down the high-pressure water pump and stops all abrasivejet
operations. The emergency stop (E-stop) should be used only for real emergencies.
When pressed, the OMAX not only stops cutting but also loses important machine
positioning data.

Caution: The abrasive feed line must always be cleaned out following an E-stop!

Power ON/OFF
I Turning the power switch to the ON(|)position on the front of the controller after the
o pump has been powered up, automatically starts the computer.
Reset
Disables all servo axis drives and resets any faulted drive.

Servo Motor Override

j||| A manual override for diagnostic uses only and not required for normal operation.

Pause
Halts motion of the abrasivejet and shuts down operation of the abrasivejet nozzle.
Machining can be restarted without loss of machine positioning information.

Water Level Up/Down Control

Raises (t) and lowers (.1) the water in the catcher tank to cover/uncover the material
being cut.

400433H-EN 2-3

K
OMAX
 Internal PC-based Controller Components
WARNING! The PC-based controller’s electrical cabinet contains potentially lethal voltages. Prior to
doing any service or maintenance activities inside this electrical enclosure, always turn OFF
and lockout the OMAX A C power source and verify no circuit voltage is present.

Access to the PC-based controller’s Internal components Is via the locked handle on the rear of the
enclosure.

0 9-axis controller board 0 air valve assembly

Figure 2-6
0 relay board 0 outlet air tube
0 LCD monitor 0 pneumatic hoses
0 front panel switches 0 power supply
0 PC

2-4 400433H-EN

OMAX
 Windows® PC

Inside the OMAX PC-based controller (Figure 2-6) is a standard PC with the Windows operating system
running the Intelli-MAX® Make and Layout software.

Note: The PC automatically powers up when the controller ON/OFF switch (Figure 2-4) is ON. Use of the PC
front panel Power ON/OFF switch is not required.

I
I
0«4X'
I
I
@

Figure 2-7

0 CD/DVD drive 0 USB ports

0 Power ON/OFF 0 Drive open/close button

PC Rear Panel
The back of the PC is accessible by opening the PC-based controller’s rear door.
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urn f■l■M ■■■ ‘ A
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.
rmm ®J *m»00
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Figure 2-8
0 video cable 0 AC Power
0 USB cables; mouse, keyboard 0 ground cable
USB controller
0 audio cable

X- Y- Z-axis Motion System

Cantilever Style Waterjet
The precision X- Y-axis motion system installed on OMAX models 2626, 2626|xp, 2652, 5555, and 55100
consists of a bridge X-axis and a cantilever Y-axis rigidly mounted to the cutting table. Both X and Y
carriages ride on rigidly mounted linear rolling bearings. The carriages are moved by preloaded ball screws
driven by steel reinforced timing belts from brushless digital servo motors that provide position feedback.
Each step command to a servo amplifier moves the carriage approximately 0.0005" (0.013 mm).

400433H-EN 2-5

[t]
OMAX
 0 Z-axis 0 cutting tabie
0 X-axis carriage 0 Y-axis carriage

Bridge Style Waterjet

The 60120, 80160 and SOX motion systems consist of a Y-axis bridge attached to dual X-axis rails rigidly
mounted to the catcher tank. The Y beam connects to the carriage that moves along the X-axis rail. X-axis
movement for the 80160 is driven using the typical OMAX ball screw configuration. X-axis movement for the
60120, SOX. 120X and 160X utilizes a high-precision linear drive coupled with position feedback from
magnetic encoding tape. In addition, the X-axis rails do not require lubrication and are resistant to garnet
contamination.

Figure 2-JO

0 Y-axis bridge 0 Z-axis

0 high-pressure plumbing 0 X-axis rail
0 cutting table

Motorized Z-axis
The OMAX Z-axis motion system is responsible for nozzle movement in the up/down direction. The design of
the Z-axis is practically identical for all OMAX tables. A motorized Z-axis comes standard and uses a
synchronous motor under software control to drive a lead screw that allows height adjustments in 0.001"
(0.0254 mm)increments. The Motorized Z-axis unit is completely protected against water and grit
contamination using urethane bellows.

2-6 400433H-EN

OMAX
 ©

I:

Figure 2-11

0 hand crank 0 nozzle

0 high-pressure plumbing 0 bellows
0 high-pressure water ON/OFF valve

Abrasivejet Delivery System

The abrasivejet delivery system consists of the high-pressure plumbing and swivels, a high-pressure nozzle,
and an abrasive feed system (hopper).

Figure 2-12
0 swivel 0 abrasive control valve
0 swivel 0 abrasivejet nozzle
0 high-pressure scissor plumbing 0 high-pressure water ON/OFF valve
0 garnet hopper

400433H-EN 2-7

[t]
OMAX
 Abrasivejet Nozzle
In an abrasivejet nozzle, when the high-pressure water is allowed to pass by the ON/OFF control valve,
it is forced through a small hole in a jeweled orifice typically made of sapphire or diamond.

Figure 2-13

0 abrasivejet nozzle 0 high-pressure water ON/OFF control valve

0 water input from high-pressure pump 0 abrasive feed input line from garnet hopper
0 air input for ON/OFF valve operation
This narrow stream of water exits the jeweled orifice and as it moves into a larger chamber, the high-velocity
stream of water draws in the abrasive from the abrasive feed tube. This stream of water with the acquired
abrasive then moves into a mixing tube where the water and abrasive combine to form the abrasivejet
stream which exits the mixing tube at the bottom of the nozzle to strike the material being machined.

®
®

© abrasivejet cutting stream 0 abrasive feed tube connection

(D jeweled orifice 0 abrasive and water mixing tube
high-pressure water from ON/OFF valve

2-8 400433H-EN

OMAX
 The Abrasive Hopper
The abrasive hopper mounts to the OMAX Y-carriage and holds up to 25 pounds (11 kg) of abrasive. A
hinged lid prevents dirt and other shop contaminates from mixing with the abrasive. The abrasive rate of
flow is regulated by a computer-controlled pneumatic valve and orifice located at the bottom of the
hopper.

Figure 2-15
© hinged lid 0 air control line for abrasive control valve
© abrasive hopper 0 abrasive feed hose connection
© abrasive control valve

Caution: The abrasive material in the hopper must be kept clean and dry. If moisture enters the hopper,
the abrasive material will clump and clog the feed tube which will require cleaning. Even very
small particles of dirt will clog the mixing tube. Always store your abrasive material in a
covered, dry location protected from metal chips and other machining debris.

When choosing abrasives, always pick a high-quality abrasive. High-quality abrasives are much more
consistent in abrasive particle size. Inconsistency in particle sizes makes it difficult to maintain quality
and precision when cutting and also increases the likelihood of your mixing tube becoming plugged.
High-quality abrasives also contain less dust. When dust is present, static electrical charges can build
up, causing the abrasive particles to clump together, hindering good flow,

High-pressure Plumbing
The high-pressure plumbing routes the water from the OMAX pump to the abrasivejet nozzle. This
system of plumbing includes the tubing, high-pressure fittings, swivels, and nozzle ON/OFF valve.
Properly prepared and connected, ultra high-pressure(UHP)tubing and fittings are critical in maintaining
a safe and leak-free, high-pressure system.

Swivels
Swivels are a key component in the OMAX high-pressure plumbing system. They allow the abrasivejet
nozzle to move across the table surface when cutting and prevent water from leaking from the high-
pressure plumbing system. Different styles of swivels have been used on OMAX JetMachining Centers:
the bulkhead swivel, high-pressure swivel, and Dual Port Swivels. Bulkhead swivels were used on
earlier OMAX table models with whip-style plumbing; high-pressure swivels using the scissor-style
plumbing have been replaced by dual port swivels and are no longer found on the latest machines. The
Model 2626 does not use swivels.

400433H-EN 2-9

OMAX
 I

®
Figure 2-16

0 bulkhead swivel 0 dual port swivel

0 high-pressure swivel

The Dual ON/OFF Valve

The Dual ON/OFF Valve controls water flow through the cutting nozzle and operates in conjunction with
the Adjustable Dump Orifice installed in the OMAX EnduroMAX pump.

Figure 2-17

0 dual ON/OFF valve 0 cutting nozzel

The Adjustable Dump Orifice

When the nozzle is no longer cutting and the high-pressure water shuts OFF,the Dual ON/OFF Valve at
the nozzle closes and automatically re-routes this water through the pump's Adjustable Dump Orifice
(ADO) until the nozzle is again turned on to resume cutting. The ADO dump valve then closes. This
action allows a continual pump operation during times when the nozzle is not cutting and assures that
the water pressure always remains the same, allowing the starting and stopping of the waterjet stream to
take place without delay. This technique also enables dual pressure operations, as required for low-
pressure glass piercing, for example, by opening both the dual ON/OFF valve and the dump valve
simultaneously.

r ^

a
®
Figure 2-18

0 dump valve assembly 0 KSI adjustment knob

0 ADO assembly

2-70 400433H-EN

OMAX
 Catcher Tank
The JetMachining Center’s large catcher tank stores the water from the cutting nozzle and provides a
settling tank for the spent abrasive and cut away material. Excess water exits the catcher tank by
traveling through a water outlet filter screen that can be raised or lowered to determine the tank’s
maximum water level.
A series of steel stats positioned above the catcher tank form the cutting surface support the part being
machined. The Model 2626|xp high-precision JetMachining Center features a stainless steel tank,
stainless steel slats, and stainless steel slats holders.

0 catcher tank 0 slats

0 cutting table

Rapid Water Level Control

Pressurized air is required to operate the valves that raise and lower the tank water level and turns On
and OFF the nozzle water and abrasive flow. Tank water level is controlled using the OMAX Rapid
Water Level Control.

Figure 2-20

0 rapid water level control

The Rapid Water Level Control requires an auxiliary air source. For air source requirements, refer to the
OMAX Utility Requirements document.

400433H-EN 2-n

OMAX
 Internal air connections to the Rapid Water Level Control are as identified below:

€|^

Figure 2-21
0 air signal from controller to raise water level 0 air supply to controller
0 air supply to air spray nozzle 0 auxiliary air supply input
0 air supply to JetMachining Center

2-12 400433H-EN

[t]
OMAX
 EnduroMAX® Direct Drive Pump Overview
The EnduroMAX Direct Drive Pump is an eiectricaily driven, variable speed, positive displacement,
crankshaft driven, triplex pump that provides up to 60,000 PSI of high-pressure water.

Figure 2-22

0 removable front panel pump control keypad and display

0 panel latch
0 hinged top cover
0 main AC power disconnect
0 temperature control display
power On/Off button
© charge pump On/Off switch
emergency stop switch
Variable Frequency Drive (VFD) enclosure
air intake filter

400433H-EN 2-13

OMAX
 Pump Front View with Side Panel Removed

Figure 2-23

0 pump AC motor (7) variable frequency drive enclosure

0 dump valve
0 high-pressure wet end
0 pump crankcase
0 water filters (2 ea.)
0 adjustable dump orifice (ADO)
0 front panel controls
0 air filter
0 white water tank (charge pump reservoir)
0 bag water filter assembly
® AC power cable for motor

Pump Rear View with Side Panel Removed

Figure 2-24

0 charge pump 0 VFD enclosure air exit

0 white water tank with temperature control circuit 0 pump wet end
0 Variable Frequency Drive (VFD) enclosure 0 pump drive AC motor
0 motor belt guard
2-14 400433H-EN

OMJVX
 Pump Top View with Lid Opened

Figure 2-25

inlet water lines belt cover guard

high-pressure outlet line (2 ea.) pump crankcase
seal coolant water lines out(3 ea.) @ water pressure gauges (2 ea.)
seal coolant water lines in (3 ea.) (g) water filters {2 ea.)
pump cylinders (3 ea.) adjustable dump orifice(ADO)
pressure transducer dump valve
0 high-pressure outlet manifold high-pressure safety valve

400433H-EN 2-15

OMAX
 Pump Side View with Right Panel Opened

Figure 2-26
0 input air fan
0 power distribution terminals
0 pump display circuit board
0 air exhaust vent
0 VFD keypad and display
0 Variable frequency drive (VFD)
0 pump grounding strap

EnduroMAX Operator Controls

Operator controls are located on the front panel at the right-hand side, providing a 5-button keypad with
LCD display, pump ON/OFF Switch, Manual Charge Pump Switch, and an Emergency Stop Switch (E-
Stop):

keypad ana luu aispiay

pump disconnect
switch

temperature display corurol panel uiN/ui-t-

switch
charge pump ON/OFF
switch
emergency srop swucn
(E-stop)

larr'filter

2-16 400433H-EN

[t]
OMAX
 The EnduroMAX provides two modes of operation: keypad and remote. Operating as a standalone
pump, control is via the keypad only. Operating with the MicroMAX JetMachining Center, control is
shared between the MicroMAX table controller and the pump’s keypad.

High-pressure Pump ON/OFF Switch

The pump ON/OFF switch controls power to the keypad and display. When switched OFF, the keypad is
disabled, the display goes blank, and the pump immediately stops. When switched ON (turned
clockwise), the keypad and display both become enabled; the pump is also enabled but starts only when
either the Run button is pressed if the pump is in a standalone mode, or when a remote command is
received from the MicroMAX JetMachining Center.

WARNINGI The pump ON/OFF switch will not remain in the ON position unless power to the pump unit is
received from the AC main power disconnect. Whenever power at the main disconnect is ON,
there is always live AC power on the DIN rail and at the terminals inside the pump electrical
enclosure even when the pump ON/OFF switch is OFF.

Charge Pump ON/OFF Switch

The charge pump circulates water through the pump’s reservoir tank and cooling lines. This flow flushes
warm water from the reservoir tank and the pump cooling lines before the high-pressure pump starts.
Cooler water increases the life of the high-pressure pump seals.
The charge pump ON/OFF switch controls power only to the charge pump; however, the charge pump
must be ON for the high-pressure pump to start. If an attempt is made to start the high-pressure pump
without the charge pump running, the high-pressure pump will not start and the error message."Charge
Pressure Low”, appears on the front panel display.

Emergency Stop Switch (E-stop)

Pushing the E-Stop switch in immediately shuts down the pump. The E-Stop is disengaged (reset) by
manually pulling it back to its original position. The pump cannot be restarted until the E-Stop switch is
reset.

Note: If the pump is connected to the MicroMAX JetMachining Center, pushing E-Stop (either the E-Stop on the
EnduroMAX pump, or the E-Stop at the MicroMAX table control) immediately shuts down both the pump
and the MicroMAX.

Operator Keypad and Display Screen

The pump keypad provides five function buttons and a four-line message display screen.

display screen

Run button with status LED

O Stop button with status LED

O Reset button with status LED

up
arrow button

o
down
arrow bXTtton

Figure 2-28

400433H-EN 2-17

OMAX
 Display Screen
When the pump is operating normally, these four lines of text appear:
Water Pres XX. X KSI - pump output pressure in KSI
High Preset xxxx RPM - preset drive motor high RPM
Low Preset xxxx RPM - preset drive motor low RPM
RunTime XXX HRS - accumulative number of pump run hours

Note: A “T" appears with the water pressure information (“Water Pres T)if a pressure transducer is connected
and recognized by the pump controller card.

Water Press T
Pump output pressure in KSI - the "T” appears when the value displayed is from the pressure
transducer
Hi Pre Set
Preset drive motor high RPM
Low Pre Set
Preset drive motor low RPM when low pressure mode is invoked by the MicroMAX JetMachining
Center Controller,
RunTime
Hour Meter, accumulative number of hours the drive motor/pump has run. It is not resettable.
If a fault occurs, the pump shuts down and a fault message indicating the type of fault appears on the
first three lines of the keypad display.
The five buttons on the keypad function as follows;
Run Button
Starts the pump when pressed if operating in a standalone mode. When
started, the motor RPM (pump pressure) will return to the last value of Hi Pre-
Set. The red status LED to the right of this button is lit when the pump is in the
"run” mode.
Stop Button
Immediately stops pump operation whenever pressed if in standalone keypad
or remote mode. When held down for 3 seconds, displays the pump's
operational mode, the rated pressure, and software version. The red status
LED to the right of this button is lit while the pump is stopped.
Reset Button
Clears a pump fault condition. Pressing either the up or down arrow while also
pressing the Reset button, sets the Low Pre-Set pump motor RPM (low
pressure). The red status LED to the right of this button is lit whenever the
pump is in a fault condition. A reset is required for recovery.
Up/down Arrow Buttons
Pressing the up arrow increases the pump's RPM which increases water
pressure. Neither pressure nor RPM can be increased above their maximum

<5 allowable limits. Pressing the down arrow at any time decreases pump RPM
and pressure down to the minimum RPM.

Temperature Control
The Temperature Control unit monitors the charge pump water temperature. When water temperature
remains below 70“ F (21“ C), water that is normally discharged from the relief valve to a waste water
drain is instead recirculated back into the charge pump's white water tank. When water temperature
rises above 70® F (21® C), a valve opens allowing this higher temperature water to be discharged down
the waste water drain, preventing it from being recirculated back into the charge pump water and
potentially damaging the high-pressure seals.

2-18 400433H-EN

OMAX
 Disconnect Switch for Main AC Power Source
This ON/OFF switch controis the AC input power source for pump operation. When OFF, all AC power to
the EnduroMAX pump is disconnected and aii pump operations stop; when ON, main AC power to the
pump is restored allowing pump operation. This switch also has provisions for attaching a padiock to
prevent switch movement during pump maintenance or other activities.

WARNING! Always follow standard lockout/tagout procedures while doing pump maintenance.

400433H-EN 2-19

OMAX
 V
■ - I- 'ii
■J

'5k.i

O
*»*■

>9'

r> i_-

2-20 400433H-EN
I;
[t]
OMAX

L ■> ■' f,
 Chapter 3
Operating the OMAX JetMachining Center
This chapter provides information and instructions supporting operation of the OMAX JetMachining Center. It
explains how the pump and abrasivejet system work and provides instructions on starting and stopping the
system and doing an emergency shut-down. It also discusses the JetMachining software, explains important
tasks to be performed in configuring the machine priorto cutting, lists tips for effective use of your equipment,
and outlines the steps involved in the cutting process from equipment power-up to power-down.

About Abrasivejet Machining

An abrasivejet uses water that is pressurized to more than 40,000 pounds per square inch (psi)(2760 bar).
This high-pressure water enters at the top of the cutting nozzle and is forced through an orifice assembly
containing a round jewel with a small hole in it (Figure 3-1). Forcing the water through the hole in the jewel
accelerates the stream of water up to 2500 feet per second (760 m/s). This fast moving stream moves into a
larger chamber, where the speed of the water creates a suction that draws in the flow of abrasive. The
abrasive is stored in a hopper on the moving head of the X-Y table. An air-controlled abrasive valve releases
a stream of abrasive into a feed tube where it flows to the nozzle. This stream then moves into the mixing
tube. The mixing tube has a small hole through the center that serves to contain the water and abrasive as
they mix to form an abrasivejet. The water and abrasive are combined into a high-speed slurry at the bottom
of the mixing tube. This slurry becomes the cutting tool as the tube focuses the jet stream at high velocity out
of the bottom of the tube and onto the material being machined.

high-pressure water

orifice assembiy/jewei

. abrasive feed tube

mixing tube

Figure 3-1

400433H-EN 3-1

OMAX
 high-pressure
water feed

: abrasive hopper

h
: abrasive feed tube
abrasivejet
cutting nozzle

Figure 3-2

The OMAX Intelli-MAX® Software

OMAX Intelli-MAX software is used to create part drawings(OMAX Layout) and to cut the part(OMAX
Make). The OMAX software completely controls the operation of the JetMachining Center.
In addition to OMAX Layout and Make, many other useful utilities are supplied with your OMAX Intelli-MAX
software.
Intelli-MAX Layout Program
The Intelli-MAX CAD module called Layout creates parts for cutting. This drawing software includes a
full range of drawing and editing tools. DXF files from other CAD programs can be imported into Layout.
The end result of Layout will be the creation of an OMAX Routed Data file (ORD), which also contains
the machine cutting instructions.

Intelli-MAX Make Program

The Intelli-MAX Make software prepares the Layout drawing for the cutting process. It calculates the
speed of the abrasivejet for optimum results and controls all machining operations. Make can calculate
how much time and abrasive material will be required to machine the part, and allows you to review the
exact path of the abrasivejet. even when not connected to the OMAX JetMachining Center.

OMAX Interactive Reference

The OMAX Interactive Reference(OIR) is an extensive set of Help files that document all the features of
Layout and Make. The OIR provides a wealth of information—not only about the commands in the
software, but also practical, real-world tips on how to effectively use your OMAX.
There are several ways to access the OIR:
1. Click the Help button when using a command.
Many Layout and Make commands provide a Help button that starts the OIR and opens the page
describing that command.
2. Press the F1 key while In either Layout or Make.
3. Double-click the desktop OIR icon (OMAX Interactive Reference).
4. Click HELP in the Layout or Make main menu.

3-2 400433H-EN

OMAX
 Operating the High-pressure Pump
WARNING! When operating this equipment, always observe the safety precautions listed in Chapter 1 of
this document Failure to do so can result in bodily injury or death.

When attached to an OMAX JetMachining Center, control is shared between the JetMachining Center
Controller and the pump keypad. The JetMachining Center turns the high-pressure pump ON to begin a cut
and turns it OFF between cuttings.
Before starting the pump unit:
1. Check the pump’s maintenance log and other records for any ongoing service activities. Verify that no
"Out of Service” tags are posted on the pump’s main electrical disconnect or on its ON/OFF switch. If
service is scheduled and necessary, have it completed before resuming pump operation.

WARNING! Before powering the pump for operation, verify that equipment service is not in progress.

2. Visually inspect the pump components for damaged parts, leaks, and other conditions that could
prevent safe and proper operation. Ensure that the area around the pump is clear of tools and other
objects that could block immediate access to controls functions, hindering safety.
3. Verify that the oil level in the pump crankcase is sufficient for operation (three quarts required).
4. Ensure that all pump side panels and enclosures are in place and properly secured.
5. Familiarize yourself with the location and function of the controls identified previously in Figures 3-7
and 3-5.

Pump Operating Characteristics

● The electric motor should always be operated at or above the minimum RPM to ensure sufficient
lubrication of the pump crank within the crankcase. The pump control will not permit sustained operation
below the minimum RPM.
● The maximum design output pressure is limited to 60,000 psi. The pump control does not allow sustained
operation above these limits.
● Low Preset is the factory set value of motor RPM for low-pressure operation and can be changed at
anytime by the user. When operating with the OMAX JetMachining Center, this is the operating pressure
for piercing and etching and is activated from the JetMachining controller.
● Hi Preset is the factory set motor RPM value for high-pressure operation and also can be changed at
anytime by the user until the maximum allowed output pressure of the pump is reached. The Hi PreSet
value can be adjusted up to, but not above, the Operating Point output pressure value, or a maximum of
2000 RPM. Hi Preset is the motor RPM value that the pump normally returns to when started. When
operated with the JetMachining Center, it is the high-pressure mode.
● Operating Point is the motor RPM corresponding to maximum performance and maximum horsepower
available.

start the Pump

WARNING! Prior to starting the pump, verify that everyone is clear of the high-pressure cutting nozzle.

1. Place the electrical Disconnect for source power in its ON position.

2. Turn the source air supply valve ON.
3. Turn the source water supply valve ON.
4. Turn the pump’s front panel red Disconnect Switch ON.
5. Press the pump’s front panel green Power Switch ON.

400433H-EN 3-3

[t]
OMAX
 6. Turn the charge pump switch to its ON position.
Caution: The ideal inlet water temperature for pump operation is between 45° F(T C)and 60° F(16°C).
As the inlet water temperature rises above 70°F(21° C), the pump dynamic seal life begins to
deteriorate. Cylinder temperature will begin to rise immediately following a shutdown with the
charge pump OFF. Excessive temperatures could easily be reached during a prolonged
shutdown. As a precaution following an extended shutdown such as during a lunch break,
always run the charge pump for as long as it takes to lower water temperature in the white
water tank to that of the inlet water temperature prior to cutting.

7. Verify that the PC-based controller starts and stops the pump as required for operation.
Caution; Always test the pump at low pressure water only prior to running the pump at high pressure.

8. Once the pump starts, verify that the red LED next to the Run button on the keypad is lit (see
Figure 3-7), and the RPM reading on the display achieves the “Hi PreSet” value.

Set the Pump RPM

The pump RPM determines cutting pressure. Use the keypad’s arrow buttons to adjust it up or down
while the pump is either running or not running. Generally, both the high and low-operating pressures are
preset with the pump operating in a test mode.
1. To increase the high-pressure value, press the keypad’s up arrow.
The “Hi PreSet” RPM value will increase. If the pump is running when this arrow button is pressed,
the pressure shown on the keypad display also increases. When the pump is running and the “Hi
PreSet” RPM results in an output pressure greater than the maximum allowed, the RPM value
decreases to conform to the maximum allowable pressure. The display screen will then repeatedly
flash the message “@MAX”.
2. To decrease the high-pressure value, press the keypad’s down arrow.
The “Hi PreSet” RPM value decreases. If the pump is running when this arrow button is pressed,
the pressure shown on the keypad display also decreases.
3. The pump control has a "Low PreSet” RPM mode for low-pressure operations with the OMAX
JetMachining Center. This is useful for piercing brittle materials or etching and scribing materials at
reduced pressure.
4. The “Low PreSet” RPM value is set by pressing and holding the keypad’s Reset button while also
pressing either the up or down arrow button. Attempts to set the RPM lower than 700 RPM
causes the display to repeatedly flash the message “@MIN”. The low RPM mode can be activated
oniy by a signal from the JetMachining Center controller.

Set the Adjustable Dump Orifice(ADO)

The Dual ON/OFF Valve controls water flow through the cutting nozzle (Figure 3-3) and operates in
conjunction with the adjustable dump orifice (Figure 3-4) installed in the OMAX high-pressure pump.

3-4 400433H-EN

OMAX
 Matching nozzle pressure with the pressure of the adjustable dump orifice is important in preventing
damage to ultra high-pressure components.
The cutting head pressures observed when the machine is actually cutting should be 1-2 KSI above the
dump orifice pressure. Dump orifice pressures are observed when the machine is traversing towards the
next cut. For example, a cutting head pressure observed at 50 KSI should see traverse pressures of
about 48-49 KSI.

KSI adjustment

Figure 3-4

To equalize the ADO pressure with the nozzle cutting pressure;

1. Power up both the pump and PC-based controller.
2. Open the pump’s top lid to access the knob on the ADO.
3. To ensure the valve stem is correctly positioned once the pump starts, screw the wing nut towards the
knob until the spring makes initial contact with both the wing nut and knob (Figure 3-5).
4. Screw the knob into the ADO body until the wing nut makes contact with the ADO body.
5. Hold the knob, preventing it from turning, and screw the wing nut back towards the knob, leaving
approximately a 1/4th inch (6.25 cm) gap between the ADO body and wing nut. This gap provides the
necessary adjustment room for the knob. If not enough gap is available, the wing nut will contact the
ADO body too soon, preventing the knob from being adjusted any further. If this happens, simply
unscrew the wing nut away from the ADO body to allow more adjustment travel.

Caution: The Adjustable Dump Orifice was not designed to dose completely as a "needle valve" would.
NEVER screw the adjustment knob all the way in clockwise and force the tapered stem into the
tapered seat Doing so mayJam the stem into the seat, requiring that the ADO be disassembled
to unJam the stem.

If the tapered stem is accidentally forced too far and becomes stuck, follow the instructions
provided on page 3-8, Removing a Stuck Tapered Pin.
screw knob in
contact is made with

1 pressure
adjustment knob
V*

wing nut &

Figure 3-5

400433H-EN 3-5

OMAX
 Caution: The safety valve may fire due to excessive pressure if the pump runs with the nozzle shut OFF
and the ADO valve completely closed.

pressure adjustment knob

CW = valve closed
CCW = valve open

Figure 3-6

6. Launch the OMAX Make software and position the nozzle to accommodate a high pressure, water-
only nozzle test.
7. In Make, click the Test button to view the Test Pump and Nozzle window options;
● St*a ●
Soft Limits Disabled Test Pump and Nozxle
Rtady to begin machining.
Warning:
Aeion Sorpe of these DiKia’JDr* w< medcleiy ii:tivstethe
cvttrg he*4. Sesu't Ihstthe nsijIcB panting n ssafe
vd desred drecion Consdtr h«t tirn]rla rrsiensi
Chartae Path SetuDl Previtw to SereenI fleotn Maehaiaia L> Test Saw cen csjse censideftMe splosh end Ihst Trng si or
engircaiibedonge'aostaccfsonncIsretpiviTKfit h
~6tabalier sddlnn. do nol l>e the no22ie foi e;(tertCed amoiints ol
Ine win 1 appse the water level, as dcngso anouiAly
Katesielt lluainusi (RB 27.0) acde the Podam of the tank
Kachineatoilley: J15.3 1)
Ihls^caeas: O.SO^S^nehes
-Selad lh« last to run
C AbrasvsOnV
nozzle Test button C Pump OtUyCOtinpValre open)
ff ^Vatar Ony(Purr ■ ac^aj
C Water and Ahrash«(Pump ● sctfre)
-PwB Fresiura.
i (7 High
: r Low

● -r3
Curalion of test:
|93 ^seionda

StailTeai

I
Figure 3-7

8. In Test Pump and Nozzle, select Water Only(Pump is active) and either Low or High depending on
your desired cutting pressure.

Caution: Always test the pump at low pressure water only prior to running the pump at high pressure.

WARNING! The cutting head is about to turn ON. For safety, ensure that the nozzle is positioned
correctly and everyone is clear of the cutting area.

9. Click the Start Test button to start the pump and fire the nozzle.
10, On the pump control panel, use the UP and DOWN arrow keys to set your desired cutting pressure
while the nozzle test is active:
IJaterPres 52 KSI= pressure
Hi9h Preset 1039 RPfl value I
Low Prebet 622 RPM
Runline O.05 HRS

Figure 3-8

3-6 400433H-EN

OMAX
 11. When the desired water cutting pressure is set, click STOP to halt the test and remove nozzle
pressure;
TesUn progress...

P AUomelicalfcp >l«o aflet 60 i«cond(<l

: 02 : 96
■ STOP
1
Figure 3-9

12. Again, click the Test button (Figure 3-7) and this time select Pump Only(Dump Valve open) and
either Low or High depending on your previous selection (step 8).
-SefctI l»»t 19 run:
C Ah»$ivt Only
^imp Only CDgmoVehftoptnj
r' WtltrOnlyCPuniplisebv*)
r wtler and Abrasive(Pump « aciive)
rftinv ►ass»«.
(● High
r Low

Durthen oflest
n-
|e0 ^seconds

¥
^gjTeei

Figure 3-10

13. Click the Start Test button to activate the pump.

14. At the ADO, turn the Pressure Adjustment Knob (Figure 3-11) until the pressure indicated on the
pump’s control panel LCD (Figure 3-8) is 1 -2 KSI lower than the KSI set previously in Step #10 above.

Note: A 3/16" (4.8 cm) Allen wrench inserted Into the end of the knob will assist in fine tuning the ADO pressure
adjustment.

Figure 3-11

Note: The ADO pressure must never be allowed to exceed nozzle pressure. Also, ADO pressure should not be
more than 2 KSI below nozzle pressure.

WARNING! Never continue unscrewing the adjustment knob until it’s able to detach itself from the ADO
body while the water is under pressure.

15. Once the correct pressure is set, hold the knob in place to prevent it from rotating, then tighten the
wing nut to lock the knob in position.
16. Click the Stop button (Figure 3-9) to halt the test.

400433H-EN 3-7

OMAX
 17. Replace all removed pump panels and close the pump lid.
18. Adjustment of the ADO pressure is complete.

Note: The ADO pressure requires readjusting anytime a different sized orifice is installed in the nozzle, or a
defective or worn Jewel is replaced. Verify pressure during machine startup daily.

Removing a Stuck Tapered Pin

In the event that a tapered pin becomes stuck in the tapered seat, follow these removal instructions:
1. Shut the pump down by locking out all air, power and water sources.
2. Bleed off the residual air pressure from the system by allowing the On/Off valve on the nozzle to
open and ensure there is no stored energy (pressurized water) in the high pressure lines.
3. Remove the On/Off valve from the ADO to expose the seat of the ADO valve.
4. Rotate the yellow knob on the ADO counterclockwise to back out the adjustment screw. Be sure to
back the screw out enough to allow for the dislodging of the tapered pin.
5. Insert a pin (0.049" to 0.055" in diameter) into the opening of the seat and using a small hammer,
tap loose the tapered pin from the seat.
6. Reassembly the On/Off valve onto the ADO.

Stopping the Pump

1. Press the keypad’s Stop button.
2. If the pump is connected to an OMAX JetMachining Center, the PC-based controller automatically
starts and stops the pump as required during operation.

Note: The pump may be stopped at any time by pressing the emergency stop switch, either on the pump or on
the JetMachining Center controller.

3. When the pump stops, verify that the red LED next to the keypad’s Stop button is lit (see Figure
3-7).
4. Turn the charge pump switch to its OFF position.
5. Turn the pump ON/OFF switch to its OFF position.
6. Turn OFF the pump’s Disconnect Switch when installed.

Emergency Shutdown Procedures

Pushing the emergency stop switch immediately shuts down both the pump and the JetMachining
Center. The emergency stop switch is reset by manually pulling it back to its original position. The pump
cannot be restarted until the emergency stop switch is reset.

Operating the JetMachining Center

Note: The following guidelines for operating the JetMachining Center assume that the OMAX operator has
received the factory training provided as part of the original equipment purchase and installation.

Configure Your Drawing

1. Import your part file (.dxf) into Layout, the OMAX drawing tool.
2. Use the Clean command to clean up the drawing file by removing any unnecessary dots, closing any
gaps, and removing any duplicate entities.
3. Define the quality of the cut needed for each part entity (see Determine a Cutting Quality on page 3-9):

● Quality 1 is the lowest quality cut and the fastest.

3-8 400433H-EN

[t]
OMAX
 ● Quality 5 is the highest quality cut and the slowest.
4. Add nozzle lead Ins and lead outs to the cutting path.

» Lead ins are typically drawn longer; lead outs are drawn shorter.
● The side of the entity where you placed your lead in/outs determines whether the nozzle cuts on the
left or right side of the entity.
● The nozzle travels in the direction of the least sharp turn (the widest angle) on the lead in.
● Always verify your lead in and lead out configurations in Layout.
● Use a 90“ lead in and lead out on square corners.
● Use a narrow angle on the lead in/lead out to minimize witness marks or blemishes.
5. Save the completed version of your ,dxf file.
6. Use the Layout Path Special Tool to specify the machine path.

● Configure the path either manually or automatically.

● Render as a Solid to verify the outcome.
● Run problem detection and correct any found.
7. Save your final path drawing. Layout automatically saves it as an OMAX ORD file.

Determine a Cutting Quality

Each entity in a drawing is assigned a quality value (1-5) which controls how quickly the abrasivejet
nozzle moves when it cuts the piece. The slower the abrasivejet nozzle moves, the higher the quality of
a cut. At the highest quality (5), the abrasivejet nozzle moves the slowest. Quality also takes into
account the material being cut. When working with a softer material such as polypropylene, for example,
a quality of 5 moves the abrasivejet nozzle much faster than a quality of 5 would while working with
steel. Quality is always relative to the machineability of the material.

Clamp and Position Your Materials for Cutting

Large clamping forces are not ordinarily needed to secure material to the cutting table, but the material must
not be allowed to move as it is being machined. One of the primary causes for out-of-tolerance parts is
allowing the material to move while being cut.

WARNING! Always be careful when handling material in the OMAX tank. During normai usage, the
abrasivejet cuts into the support slats and their edges can become extremeiy sharp. A void
situations where your fingers can become pinched between the cutting material and a
support slat. Wear protective gloves!

A small downward force (about one pound or 4 newtons) is exerted on the material from the abrasivejet
stream; however, a much larger upward force is exerted from all the air forced down with the abrasivejet
stream. Once released, this air pushes upwards against the material.
The best way to secure material is to clamp it against the frame or tank. Never clamp material to the slats
themselves. Slats can sway back and forth slightly, moving the material with them. Use the slats only for
vertical support. The larger the surface area of the material being cut, the more securely it must be clamped
since the upward force from the jet stream’s captured air will have more material to push upon.

Note: The size of the high-pressure water pump also affects the clamping required. If the pump power is
doubled, the amount offorce exerted on the material will also double.

WARNING! Always use the proper lifting equipment when handling heavy materials.

Use Tabs for Holding Small Parts

When cutting small parts, design them using small holding tabs (Figure 3-12) that prevent the part from
detaching and slipping past the slats and down into the tank.

400433H-E^’ 3-9

[t]
OMAX
 Note: Using Waterjet Brick for holding small parts is an effective alternative to designing tabs.

Set Machine Limits

In the OMAX,there are two types of limits that restrict the area of nozzle movement on a table’s cutting
surface: absolute limits (hard) designed into the machine's hardware and user-defined soft limits.
Absolute Limits define the maximum cutting area that is available on a particular table. These are
mechanical limits that are set using physical stops installed on the ends of the ball screw threads or
linear drive rails for both the X and Y-axis (Y=0, X=0 points). Although the cutting head can be
commanded to reach these absolute limits, this seldom is done since this frequently is where the cutting
head would crash into the side of the table and cause serious equipment damage, especially if the crash
is done at full speed.
Soft Limits are software defined to prevent the cutting head from reaching the table’s absolute limits or
to avoid hitting other fixtures placed within the cutting area. These limits can be set to create a smaller
working area within the available maximum cutting area. When a soft limit is reached, a controlled stop is
immediately initiated that prevents further cutting head movement. Whenever a nozzle movement is
commanded that will exceed a defined soft limit, a window pops up warning the operator that set limits
will be exceeded. When using the keyboard to move the cutting head manually and a soft limit is
reached, the software immediately halts head movement using a controlled slowdown and stop that
prevents the nozzle from exceeding a user-defined soft limit.

Cut Your Parts

WARNINGI Safe operation of this equipment requires that you have read and can practice all the safety
"dos" and "don’ts" presented in ‘‘Chapter 1: Safety First"

Start the Pump and Controller

Caution; Before powering up this equipment, ensure that you and other operators have access to the
required protection devices(safety glasses, ear plugs, and rubber gloves).

1. Place the electrical Disconnect supplying source power in its ON position.

2. Turn the source air supply valve ON.
3. Turn the source water supply valve ON.
4. Turn the pump's front panel red Disconnect Switch ON.
5. Press the pump’s front panel green Power Switch ON.
6. Turn the charge pump switch to its ON position.

3-10 400433H-EN

OMAX
 7. Check the white water tank inside the pump (Figures 3-13 and 3-14) to verify the water level is
between one-half and three-fourths full.

8. Turn the pump control panel switch ON. View the pump’s LCD screen to verify pump operation.
9. At the white water tank, lift the drain cap (see below) and verify cooling water flows from all three
hoses equally.

return water lift drain cap from

white water tank
hoses(3 ea.)

>

Figure 3-13

WARNING! Always run the charge pump for as long as it takes following initial power up and when the
pump has been inactive for 30 minutes or more. This allows cool water to circulate and cool
off the dynamic seal area of the pump, ensuring that pump seals are cooled down prior to
high-pressure operation.

i
%

v/hitev/ater
I Idigital temperature
display
tank

A
Figure 3-14

10. After running the charge pump, view the front panel digital temperature display that monitors the
white water tank. This temperature must always remain below 70° F (21 ° C).

Caution; If your inlet water is above 60° F(16° C), you may experience a shorter life from your pump
seals. If the temperature Is above 70° F(21° C), a chiller will be required. It is important to
understand if the metal in the pump cylinders ever exceeds 80° F(27° C), the first 5 minutes of
running could destroy a possible 100 hours ofseal life. Continue doing this for 5 days in a row,
and the pump will need a rebuild.

11. Power up the JetMachining Center by switching the PC controller’s power ON. Verify that the
Windows operating system boots up without issues.
12. When applicable, also power ON any attached OMAX accessories (solids removal system, bulk
feed hopper, chiller, etc.).
13. Verify the nozzle being used matches the size required for the part being cut. Change it to the
correct size when required.

Caution: Changing the nozzle orifice size also requires resetting of the adjustable dump orifice(ADO)in
the high-pressure water line of the OMAX pump. Correctly matching the nozzle pressure with

400433H-EN 3-11

OMAX
 that in the ADO minimizes water pressure difference in the high-pressure plumbing during
nozzle OFF and ON conditions, thus reducing pressure spikes and premature plumbing
failures. See page 3-4 for ADO adjustment procedures.

14. Ensure that your mixing tube has been installed properly using the nozzle/mixing tube gauge as
illustrated below in Figure 3-15:

nozzle guard
:s shoulder
o
N3
i
Mini
MAXJET5
gauge
mixing
tube tip

mixing ^ //
tube tip .

^ .
Nozzle/Mixing Tube Gauge
(P/N 306730)

Measuring the MAXJET S Measuring the Mini MAXJET 5

Figure 3-15

● Verify that the gauge touches both the mixing tube tip and the nozzle guard shoulder,
● Verify that no gap exists at either location.

Note: If a gap greafer than 0.010" is seen at either location, it is recommended that you disassemble the nozzle,
clean all the components, re-assemble the nozzle, ensure that the mixing tube is pushed in all the way, and
recheck for correct mixing tube placement using the nozzle/mixing tube gauge.

15. Pour the desired abrasive size(mesh) into your nozzle hopper. Ensure that the amount added will
be sufficient to finish cutting the part.
16. Check the tank’s water level. Make sure that the material being cut can be covered and also
uncovered with tank water. Add or drain tank water as needed.
17. In Windows, click the OMAX Make icon to launch the cutting software.
18. Auto Home the machine to ensure that the machine's zero (absolute home) position is set (Figure
3-16).

Caution: Prior to auto homing the machine, ensure that the Z-axis height is high enough to prevent
nozzle movement from striking the table sides. Also ensure that the nozzle is within 1 foot(30.5
cm) of the home position.

Note; Auto Homing is the process of locating a table’s Absolute Home. All homes are related to Absolute Home
and is the only home position that can be lost. Resetting Absolute Home resets all other homes to their
correct positions. To ensure positioning accuracy, Absolute Home must always be re-zeroed before
another home is created. It is important that Auto Home be run to re-zero Absolute Home at the
beginning of each work day and whenever you shut down for maintenance or reboot the PC-based
controller. Absolute Home is usually in the front corner of your machine. For the 80160, Absolute Home is
in the rear, far corner of the machine.

3-J2 400433H-EN

OMAX
 a. To auto home your OMAX, move the cutting head to about 10" for each axis from the Home
corner.
b. In Make, click Homes/Advanced/Auto Home...
SB>e
File Tools Setup Homes View History Register Software Help
EdK, Create, or Choose Home to Di$;May.,.

Auto Square Tit (Re<albrate)..■

Qiickty Square Tit...

Advanced Auto Home...

Hekj on Homes... Re-Zero Absolute Horr<e...

Figure 3-16

c. When the warning message appears, if appropriate, click OK.

Note: The machine will now move In the X-axis direction until it gently contacts the X-axis hard stop. It then
moves in the Y-axis direction until it gently contacts the Y-axis hard stop.

d. When prompted to re-zero Absolute Home, select Yes. Your OMAX should now be accurately
aligned and ready for use.
19. Verify that the soft limits are enabled (Setup/Advanced/Soft Limits - see Figure 3-17):
File Tools j Homer Vtew Hrtory Help
Configure Di^y 6 Units,,.
Toom’Preferences...
>>b Quotes tiCosbr^...

Pump end Nozzle settings...

Event and Kdey Tnlng.,.
Cutting Model Optimizations...
Motion Preferences...
Error Mapping...
Transfer/Bachjp Settings

I Advanced Soft Unto ^ Setbycomerandsw...

“ Set by two comers...
AdvarKed / Admiristrator Sett*...
t Enable soft Unto ]

Figure 3-17

20. Position the nozzle between two table slats at 1 (2.54 cm) to 1.5" (3.81 cm) above the water
surface.

WARNING! Always use ear protection when operating the abrasivejet nozzle above water.

21. Test nozzle operation at Low Pressure:

a. Click the Test button to display the Test Pump and Nozzle options:
- Select V>e lest to run
Abrasnre Only
C Pump Only (OumpVahre open)
f* Wslar Only (Pump b active)
Water and Abrssrve (Pump is actrre)
f-Pump Pressure —
r" Hgh

Duration oftest: jfg seconds

¥
KertTjj^

Figure 3-18
I

b. Select Water Only (Pump is active) and Low, then click Start Test (Figure 3-18).

400433H-EN 3-13

OMAX
 c. When the jet stream begins, remove the abrasive feed tube from the abrasive feed block on
the abrasive control valve (Figure 3-23) and block air flow through the feed tube by holding a
finger against the tube opening. Then, examine the quality of the jet stream as illustrated
below:

good quality

Figure 3-19

Note: Always block the abrasive feed tube prior to visually inspecting the jet quality. Air from this tube interferes
with the jet stream, making inspection difficult.

d. Refer to Figure 3-20 to compare the effect that a damaged orifice and worn mixing tube have
on the quality of a nozzle’s jet stream.
Good Orifice Chipped Orifice Badly Chipped
Good Mixing Good Mixing Tubi Orifice; Worn
Tube Mixing Tube
Good Orifice Slighiiy Chipped Badly Chipped

- ● t IS r A

Water Only

Figure 3-20

3-14 400433H-EN

OMAX
 e. Refer to Figure 3-21 to see how the shape of a jet stream's shape indicates the quality of its
cutting performance.
— Oeod I
— Margkiall I J
— I — 0««<1
— Mar^tMl
— Bid T

CM
CM
0

/ .
AWJ ■ MAXJET 5 Worz/e Water-only Nozzle

Figure 3-2]

f. During the jet stream test, adjust the pump RPM to develop the desired low pressure, then
write down the pump RPM and KSI values from the pump LCD display screen for the low-
pressure test,
g. If still running, click Stop to end the low-pressure pump test;
Test in prof^ress... i
17 |l w\MinuUlil

: 10 : 65

■ STOP "]

Figure 3-22

22. Test nozzle operation at high-pressure:

Caution; Do not operate the abrasive waterjet for more than several seconds when the nozzle is above
the water surface at a distance greater than 1.5"(3.81 cm). Air entrapment in the water
increases with nozzle height, eventually allowing thejet stream to strike the tank bottom with
sufficient force to cut a hole through the bottom. This applies to using "Test Nozzle" and
cutting thick materials at a high quality setting. Always make sure that cutting is done either
under water or with the water level immediately below the work piece.

a. If necessary, click the Test button to again display the nozzle test options (refer back to Figure
3-18).
b. Select Water Only(Pump is active) and High, then click Start Test(see Figure 3-18 for
options).
c. When the jet stream begins, pinch the abrasive feed tube until blocked to examine the quality
of the jet stream, verifying that it’s straight and narrow as illustrated in Figure 3-19.

400433H-EN 3-15

[t]
OMAX
 Note: Always plug the end of the abrasive feed tube prior to visually inspecting the jet quality. Air from the tube
interferes with the jet stream, making inspection difficult.

d. During the jet stream test, adjust the pump RPM to achieve the desired high pressure then
write down the pump RPM and KSI values from the pump LCD screen for the high-pressure
test.
e. During this test, also check the charge pressure at full flow. The difference between the two
pressure gauge readings must not exceed 20 PSI. If more than this, the water filters most
likely require changing,
f. Click Stop to end the high-pressure pump test (Figure 3-22).
23. Test nozzle operation using Water and Abrasive;
a. If necessary, click the Test button to display the nozzle test options (Figure 3-18).
b. Select High, then click Water and Abrasive to begin the test(see Figure 3-18).
c. Verify an increase in the sound level and stream diameter from the abrasive flow,
d. Click Stop to end the Water and Abrasive Test (Figure 3-22).
24. Measure the abrasive flow rate:

Note: The abrasive flowrate should be measured each week (or sooner, whenever there are operational or
environmental changes). Ensure the nozzle mixing tube, orifice, and flow rate for the abrasive size are
correctly matched to the size of the pump motor being used:

Nozzle Abrasive Flow Rate

Pump Motor Nozzle Mixing
Size Orifice Tube 80 Mesh
20 Hp 0.011"(0.279 0.030" 0.50 Ibs/minute
mm) (0.76 mm) (.23 kg)
30 Hp 0.014"(0.356 0.030" 0.75 ibs/minute
mm) (0.76 mm) (-34 kg)
Dual 30 Hp 0.020" 0.042" 1.8 Ibs/minute
(0.508 mm) (1.07 mm) (.82kg)
40 Hp 0.015" 0.042" 1.00 Ibs/minute
(0.38 mm) (1.07 mm) (.45 kg)
Dual 40 Hp 0.022" 0.042" 1.8 Ibs/minute
(0.559 mm) (1.07 mm) (.82 kg)

Caution: Changing the nozzle orifice size a/so requires adjustment of the adjustable dump orifice(ADO)
to reduce pressure spikes which lead to premature plumbing failures.

a. Remove the abrasive feed block from the abrasive control valve cylinder (Figure 3-23) by
pulling it straight back.
^pneumatic [abrasive feed block'
Bcontrol line
^rasive feed
block abrasive feed
abrasive leei
■ ^
Iblock removed
tube *. 2

V ’

'abrasive control
\'''
Ivalve cylinder
f h
^ IjS^TIT ^ V I
Abrasive control valve components Abrasive control valve with abrasive feed block removed

Figure 3-23

3-J6 400423H-EN

OMAX
 b. Place a container directly below the abrasive control valve to catch the abrasive released
during the measurement flow,
c. Click the Test button to display the nozzle test options (Figure 3-18),
d. Click Abrasive to begin the abrasive flow.

Note: By default, the abrasive flow automatically stops after one minute.
e. With an accurate scale, weigh the abrasive collected in the container during the one minute
flow and record the abrasive weight in pounds. Do not include the weight of the container!
f. Replace the abrasive feed block by pressing it back into the abrasive control valve.
25. Verify “Pump Nozzle Settings” in Setup match your actual measured values.
Caution: It is critical that the software settings match your actual MEASURED values for the pump
pressures and abrasive flow rate. Also, it is criticai that the nozzie setup exactly match the
nozzle installed on your machine. If not properly matched, poor cutting and frustration results.

a. Click Setup in Make and select Pump and Nozzle Settings...;

File Took Setup) Home; View History Regi
Configure [>i$i^4y & Units...
"Zoem”Preferences...
}ob Quotes(iCosting...

It PwpandNozzlesettings..,
Event end Reley Timing,,.
Cutting Model Optimizations...
Motion Preferences...

Figure 3-24

b. Correct any values being displayed that differ from those recorded when testing your OMAX
machine.
Pierme el Pump in High Piessue Mode: [50000 PSI

PieMue el Pimp h Low Pieuue Mode: [20000 PSI

Jewel(o(rice]Diemelet: [0.014 in^t

Meting Tube Diameter |0.03 inchet

Abretive Flow Rate: |l LbArin

AbresiveSize [ot Mesh(US Slendetd)

Abrasive Index 1 (Use 1.0 for garnet)

Figure 3-25

c. Click OK to save any changes made.

400433H-EN 3-17

[f]
OMAX
 26, From Setup, click Event & Relay Timing. Make sure that the values displayed are correct for your
machine and cutting situations. Click OK to save any changes made.
OMAX Machin« Setup

Pur^ & Nozzle CorJigutelion EvertlRela/Tnwig jcuHingModelOptimaaliontj Hobon| EnoiMapeinol

■TWng Setup lof Sped* Tumibora: (Note: Al iri* «e in "Seconds’!
HiAPieMM LbwF"^**
Cut:
0^ efta nozzle Uti belote Native turns cn
Addtiond delay to dow jet to stabize before pcoceedng: |0.5 [05
Irnelodeatabasivehoninozzlewhenlnthedcutfrig: jO.5 |05

Etch:
Delay afie> nozzle fites beloe abtasive him on: |02 (OT
Addkional delay to alow jet to slabize befote pioceedng to start: |03 [03

Timeioiinnozzleafte(elchldcleatabasiv«fto(nnozzle: [05 [05

Sctrbe:
Delay altetnonlefiies befote moving |oT
Watei Only;
Delayaneinozzlerietbeforsniowvg [i

Tiavetse: Seconds to wal aflet shutdown beloie Itavetse; I

Other:
Pump warm up delay belote list move: [^
High ptessue to Low piessue delay: ^
Low pressure to High ptessuie delay:
^ Restore Timing to Cefaukt

✓ OK ? £, OMAX

Figure 3-26

Note: For determining values for Event and Relay Timing, it is best to start with the default values and then adjust
these values to match your own requirements.

21. From Setup, click Cutting Model Optimizations and verify that those selections match your
cutting requirements. Click OK to save any changes made.

Configure the Make Software

1. Select the drawing for your part;
a. Click the Change Path Setup button (or use File/Open (Change Path Setup)from the menu
bar) and follow the path to where your drawing’s file is stored,
b. When located, clicking the ORD file name opens that drawing in the adjacent preview screen.
2. From the same window previously opened by clicking Change Path Setup (step 1 a above), enter
your Material Setup values and turn ON/OFF applicable accessories:
'Erdttycut M«leri«l Sptif)hvtr
Mateiiat MacMrvubSy
r
Thieknesr fnm

Tod Offset I 3429 mm

Rdaliorv: fo degtMt

Sul»; X
r EnablsTA

T«»aOlls'.' d-.-gieti

Figure 3-27

3-18 400433H-EN

[t]
OMAX
 3. If required, also configure the Cut Settings and Pierce/Terrain Follower Settings:
CutSeOingt ■ ■
r CJ u*^ Low Prelaw

Eldi Speed in/fni P lo/r pressure

ScdbeSpeed I'’-' tn/ro») 17 :n.v pressure

erOrt'Speed fioO In'r,--': r !ure

Pierce/TenewFelowwSeni'igi
I UtejeMopierce LiterMilopierce|
r* Lite Low Piestue
r VeiyeiiUleMelentl
I~ UteTerrenPoleweiletetarrdirkeintantjend^

Wlg^lopctct: ^roer'XT to erteUe IrtefrflERCE)

Figure 3-28

Cut the Material

1. Move the nozzle to an out-of-way area on the table that allows ample working room for the
material to be placed and secured to the table.
2, Lower the tank water level to just below the table slats.
3. Place the material to be cut on the slats and use adequate fixturing to keep the material flat and
stable during cutting.
4. Position the nozzle to begin the cut and set the Path Start Home:
a. Place the nozzle above the material being cut, ensuring efficient use of the available materia!
and where it will not overshoot the material during the cut.
b. Once the nozzle is correctly positioned, click Zero as the Distance from Path Start (Figure 3-
29).
NcntoPettton
DUance horn 'User Home":
000^
2.9158 1.6565 R
Gc h0tn»
Di>laneefccBi'FalhSl»r;
000*
2ta
0.0000 0.0000 Ge horne

4-f ^ if t ^ t M_
vtqor I UavaX I JooLafllJM Bchtl jMllBNMDwnJ Uo\’>yI LcC»!«

Figure 3-29

5. Set your nozzle standoff above the material between 0.040" and 0.080"(0.060" required for the
Tilt-A-Jet, 0.80" required forthe A-Jet) and zero the 2-axis;
a. Press 1 to move the nozzle down quickly; press 7 to move it up quickly.
b. Press PageDown to move the nozzle down in 0.1 inch (.254 cm)increments; PageUp to
move it up.
c. Adjust the correct nozzle height above the material by placing a gauge between the nozzle tip
and the material being cut and adjusting the Z-axis up or down appropriately.
d. When properly adjusted, click View/Show Z Coordinates to display the Z Height Coordinates
pop-up window:

Iri 0.0000

Figure 3-30

e. On the Z Height display (Figure 3-30). click the 00 button to set the Z coordinates at zero.
6. Conduct a dry run to verify your cutting path:
a. Click the Begin Machining button to display the OMAX Path Control window,
b. Right-click the Start button to display the options window.

400433H-EN 3-J9

OMAX
 c. Click Dry run at full (Rapid transverse)speed...(or another speed of your choice)to initiate
the dry run.
d. Verify the nozzle travels over the material to be cut as expected,
e. if necessary, correct your Path Start Home position and try another dry run.
7. Raise the nozzle using the Z Height adjustment and attach the nozzle splash guard.
8, Lower the nozzle to its zero Z-axis coordinates (click the arrow on the right side of the Z Height
pop-up display).
9. Raise the water level in the tank above the cutting material.
10. Begin cutting by clicking Begin Machining/Begln.

Caution: Always remain near the JetMachining Center during the cutting process, in the event of a
serious problem, use the Emergency Stop switch to immediately halt operations.

11. Once machining stops, raise the nozzle, lower the water lever, rinse the abrasive debris from the
cut material, and remove the cut part(s) from the machine.

Shutting Down the JetMachining Center

1. Position the nozzle between two table slats at 1 (.254 cm)to 1.5"(3.81 cm)above the water
surface.
2. Allow the pump to run for 20 seconds to clean and clear all abrasives from the nozzle;

Caution: Do not operate the abrasive waterjet for more than several seconds when the nozzle is above
the water surface at a distance greater than 1.5"(3.81 cm). Air entrapment in the water
increases with nozzle height, eventually allowing thejet stream to strike the tank at full force
and possibly cut a hole through the tank bottom.

a. Click the Test button to display the Test Pump and Nozzle test options:
Ut/Test Pump and Nozzle

Warning:
Some ofthete operation* wlinneditleV tctivite V>e
cuUng head Be lure that the nozzle is pointng In a safe
anddesroddrecboA. Consioertnatfirnpntamaterial
can cause considerable spiash, and that atari
angle can be dangerous to personnel or equcment in
additcn, do not fre the nozzle for esrtended amounts of
time win I abova the water levet, as doing so can Qulddy
erode the bottom of the tank

Select the test to run: -

C Abrashre Only
r Ajfflp Only (Dump Valve open)
hVater Only(Pump Is actwelj
C WatKsnd Abrasive <^mp I* active)
-Pump Pressure:
(● Moh
r Low

r3
Oureton of test; jjj ^ seconds

Start Teal

X CIOS* (5) ? Help [

Figure 3-31

b. Select Water Only (Pump is active) and High pump pressure, then click Start Test to begin
the jet stream,
c. After at least 20 seconds click STOP to halt the jet stream.

3-20 400433H-EN

uT]
OMAX
 3. Lower the tank water to its lowest level.
4. Move the nozzle to a table area where it will be out of the way during cleanup.
5. Wipe down the machine table and surrounding area, cleaning up any splashed water and abrasive
material.
6. Remove any debris floating in the water.
7. Complete any shop-specific clean-up procedures.
8. Remove any discs or USB memory devices that may still be in the PC-based controller.
9. Close OMAX Make and all other software applications running on the OMAX PC-based controller.
10. Click the Windows Start button and select Shut Down.
11. Verify that the computer has powered down (indicator lights OFF and a blank screen).

12. If applicable, depressurize the Bulk Feed Hopper.

13. Turn the charge pump OFF.
14. Switch the water supply valve OFF.
15. Power the PC-based controller OFF.

16. Switch the air supply valve OFF

Caution: NEVER turn the PC-based controller power OFF without first shutting down the PC using the
proper Windows shut down procedures(Start/shutdown). Always wait for the PC to completely
shut down before powering OFF the PC-based controlier. Failure to do a shutdown properly
can corrupt Windows with the ioss of critical files.

17. Turn the pump power switch OFF.

18. Turn OFF the pump’s Disconnect Switch when installed.
19. Turn the air supply valve OFF.
20. Disconnect the breaker box that provides main power to the OMAX equipment.

Ensuring Clean and Quiet Machining

There are a number of techniques that promote clean and quiet machining with the OMAX.

Keep the Abrasivejet Nozzle Under Water

Machining under water is significantly quieter than machining with the nozzle above water. There is also
less spray from the abrasivejet when under water. Keep the abrasivejet nozzle under Y*" to 2"(6 mm to
51 mm)of water during machining.

Note: Raising the abrasivejet nozzle above the water once machining is finished, prevents the water and
abrasive mix from being drawn into the mixing tube and plugging it.

When working with a highly buoyant material such as wood or paper products, it may not be possible to
keep the abrasivejet nozzle underwater. In this situation, always wear hearing protection and be
prepared for the additional over-spray during machining.

Place a Splash Guard on the Abrasivejet Nozzle

The OMAX is shipped with a splash guard (Figure 3-32) that fits over the abrasivejet nozzle. This splash
guard serves several purposes. It keeps the noise level low during machining, reduces splashing and
spraying, and protects the Z-axis and cutting head components. Always place a splash guard on the
abrasivejet nozzle when machining.

400433H-EN 3-21

OMAX
 Figure 3-32 Cutting Nozzle with a Splash Guard Attached

Washing Heavy Garnet Deposits from Parts

Garnet is deposited on the surface of a part during machining. This is most noticeable when working with
thick materials. When too much spent abrasive has accumulated, the abrasivejet nozzle will need to
plow through it. causing the material to shift and reduce the accuracy of the cut.
If too much garnet accumulates on a part while machining, wash away the deposits with a hose while the
OMAX makes the cut.

Startup Check List

Use the following check list to ensure that all equipment startup tasks are completed and in the required
sequence. For more detailed startup instructions, refer to Cut Your Parts, page 3-10.

WARNING! Safety First- Always wear safety glasses, ear protection, and hand protection when
operating your OMAX JetMachining Center.

1. □ Main disconnect for AC source ON.

2. □ Air source valve OPENED.
3. n Water source valve OPENED. Verify white tank water level.
4. n Turn the pump’s front panel red Disconnect Switch ON.
5, n Press the pump’s front panel green Power Switch ON. Verify that pump LED screen becomes
active
6. n Charge Pump POWERED ON.
7. n Lift the drain cap from the top of the white water tank.
8. □ Verify cooling flow from the 3 white tank hoses.
9. □ Allow the water to run for 15 minutes prior to operating pump at high pressure or until water
reaches appropriate temperature. Replace drain cap.
10. □ PC-based controller POWERED ON.
11. □ Verify there is adequate air flow coming out of both the pump and PC Controller cabinet air vent
outlets.
12. n Bulk feed hopper PRESSURIZED (if applicable).
13. □ Completely lower the tank water level and then raise it again to slat level to purge the air
dome.
14. □ OMAX Make STARTED.
15. n Table AUTO HOMED to ensure that absolute home position is correct.
16. □ Verity that soft limits are ENABLED.
17. □ Verify nozzle orifice and mixing tube SIZE.

3-22 400433H-EN

OMAX
 18. □ Nozzle POSITIONED between slats, 1" to 1.5" (2.54 - 3.8 cm) maximum above the water level.
19. O Nozzle low-pressure water test STARTED. Click "Test”, "Low”, and "Water”.
20. □ Straight and narrow jet stream VERIFIED while restricting air flow to the abrasive feed tube.
21. □ RPM and Pressure ADJUSTED and RECORDED from the pump LCD screen.
22. O Nozzle low-pressure test STOPPED.
23. □ Nozzle high-pressure test STARTED. Click “Test”, “High”, and "Water”.
24. O Straight and narrow Jet stream VERIFIED while pinching the abrasive feed tube.
25. 0 RPM and Pressure ADJUSTED and RECORDED from the pump LCD screen.
26. □ Pump filter pressure VERIFIED.
27. O Inspect high pressure system (tubing, fittings, swivels, pump) for leaks.
28. □ Nozzle high-pressure test STOPPED.
29. □ Adjustable Dump Orifice pressure adjusted (see page 3-4) within 1-2 KSI lower than nozzle
pressure.
30. □ Water and Abrasive test STARTED. Click “Test”, "High”, and “Water & Abrasive".
31. □ increased sound level and stream diameter CONFIRMED.
32. O Verify abrasive size and type.
33.0 Abrasive flow rate MEASURED.
34. O Verify level of abrasive in hopper.
35. □ Setup, Pump and Nozzle settings VERIFIED correct.
36. 0 High- and low-pressure values SET to match pump settings above.
37. 0 Cf
Event & Relay Timing” settings VERIFIED for application.
38. □ Cutting Model Optimization settings are VERIFIED for application.
39. O Cut kerf check part and ADJUST offset as needed.
You are now ready to begin machining.

400433H-EN 3-23

[t]
OMAX
 Shutdown Check List
Use the following check list to ensure that all equipment shutdown tasks are completed and in the required
sequence. For more detailed shutdown instructions, refer to Shutting Down the JetMachining Center, page
3-19.

WARNING! Safety First- Always wear safety glasses, ear protection, and hand protection when
operating your OMAX JetMachining Center.

1. □ Nozzle POSITIONED between slats, 1 to 1.5" (2.54 - 3.8 cm) maximum above the water level.
2. □ Nozzle high-pressure test STARTED. Click "Test", "High”, and "Water".
3. n Pump RUN for 20 seconds to clean and clear all abrasives, then test stopped.
4. n Water LOWERED to lowest level.
5. □ Nozzle POSITIONED at desired location for shut down.
6. □ USB/other media REMOVED from PC.
7. □ OMAX Make CLOSED.
8. □ Windows “Shut Down” CLICKED.
9. □ PC shutdown VERIFIED (no PC lights: black monitor screen).
10. n PC-based controller POWERED OFF.
11.0 Bulk feed hopper DEPRESSURIZED (if applicable).
12. n Charge pump POWERED OFF.
13. □ Other accessories POWER OFF (if applicable)
14. □ Pump disconnect switch POWERED OFF.
15. n Water supply valve CLOSED.
16. □ Air supply valve CLOSED.
17. □ Main breaker box POWERED OFF.
18.0 Clean the machine.
Your OMAX equipment is now properly shutdown.

3-24 400433H-EN

OMAX
 Chapter 4
Pump and Table Maintenance
This section shows how to properly maintain operation of your EnduroMAX pump and OMAX JetMachining
Center. Always service at regular maintenance intervals. It is important to continually inspect pump and table
parts for wear or damage and to immediately replace them as required.

WARNING! All electrical and maintenance work described in this chapter shouid be undertaken only by
qualified service personnel. Always follow the safety instructions presented in the first
chapter of this manual.

Maintenance Schedules
The following maintenance activities and schedules are provided to aid in the development of a successful
pump and JetMachining system maintenance program.

OMAX Maintenance Overview

Task Frequency
Pump Power-end Maintenance EnduroMAX Pump
Change crankcase oil, check belt tension After first 50 hours of operation
Change crankcase oil, check belt tension Every 300 hours after first oil change
Lubricate main electric motor bearings 6 months for continuous high ambient temp., dirty or moist
locations: high vibrations
Seasonally (each year) if idle 6 months or more
Annually if continuous operation
Every 3 years if 5,000 hours per year
Replace electrical-enclosure air filters Approximately once per month, or more frequently if
required based on shop conditions
Inspect and adjust tension or replace belt Periodically inspect, adjust tension, and replace as needed
Water filtration EnduroMAX Pumps
Vacuum and clean White Reservoir Tank Once a month or more frequently if dirt or debris is present.
and mesh screen in the pump Remove the mesh screen to clean it.
Clean Bag Filter on top of white water Once per year or as needed.
tank.
Change water filters Whenever the difference in pressure between the inlet and
outlet filter gauges is equal to, or larger than 20 psi.
Change Wall 20" Pre-filter (3 micron Monthly or as needed until an interval can be established
coarse)
Change Wall 20" Pre-filter (1 micron fine) Monthly or as needed until an interval can be established
Change the last chance nozzle filter Weekly (or more frequently as needed)

Wet-end Maintenance EnduroMAX Pumps

400433H-EN 4-1

OMAX
 Pump Rebuild
* If you run the pump at 55KSI the
interval on these pumps increases to
1,000 hours between rebuilds.
Replace Plunger Assemblies
Replace Cylinders
Replace Check Valve Bodies
Replace Manifolds, Port Adapters, End
Caps
Other Pump Maintenance
Rebuild Dump Valve
Lubricate Pump Dump ON/OFF Valve Air
Actuator Assembly 0-ring
Rebuild Safety Valve
Rebuild Adjustable Dump Orifice
assembly
High-pressure Plumbing System
Rebuild or replace swivel
Rebuild On/Off Valve
High-pressure lines and fittings
Lubricate Nozzle ON/OFF Valve Air
Actuator Assembly O-Ring.
Rotate the nozzle mixing tube 90
degrees.
PC Controller
4-2
3060
Rebuild every 1,000 hrs, alternate Minor/Major rebuild kits
4060
Rebuild every 800* hrs, alternate Minor/Major rebuild kits
5060
Rebuild every 500* hrs, alternate Minor/Major rebuild kits
3060-3,000* hrs
4060-2,400* hrs
5060-2,000* hrs
*Or if plungers are “rubbed” or damaged
3060-2,000* hrs
4060-1,600* hrs
5060-1,000* hrs
*Or if cylinders are damaged or leaking
3060 - 3,000* hrs
4060-2,400* hrs
5060-2,000* hrs
*Or if check valve bodies are damaged or leaking
3060-4,000* hrs
4060 - 3,200* hrs
5060-3,000* hrs
*Or if components are damaged or leaking
EnduroMAX Pumps
When leaking occurs (drips from the DUMP valve
discharge hose indicate a DUMP valve On/Off valve stem
to seat failure); an immediate deadhead is a clogged
DUMP valve orifice. Rebuild the DUMP VALVE and
replace the orifice.
Inspect 0-ring on a weekly basis (or other frequency
determined based on number of ON/OFF cycles). Replace
the 0-rings as needed based on wear. Lubricate the 0-
rings with Lubriplate.
When leaking occurs
When cold water leaking occurs at the adjustable orifice
(dump valve) when the nozzle is running
Rebuild if any leaks; replace if leaking continues after
rebuild or if damaged.
Water entering the abrasive feed tube when the nozzle first
fires (leaky seal)
Water is dripping from the mixing tube (leaky valve stem)
Water leaks 180 degrees from where the UHP plumbing
enters the dual on/off valve (bad valve seal)
Water drips from the UHP nipple on the dual on/off valve
(loose fitting, cracked body or fitting)
Replace if damaged or if continued leaking occurs. Do not
try to repair!
Inspect 0-ring on a weekly basis (or other frequency
determined based on number of ON/OFF cycles). Replace
the O-rings as needed based on wear. Lubricate the O-
rings with Lubriplate.
After every 8 hours of cutting.
400433H-EN
OMAX
 Clean Keyboard and Mouse As needed
Replace air filter Every 3 months or more frequently as needed based on
shop conditions
Clean monitor screen As necessary for sharp viewing
Reboot PC Controller Daily
Run Windows Defragmenter program Monthly
Update OMAX Software When updates are released by OMAX
Replace CMOS battery in the PC As needed (normally will last approximately 5 years or
Controller more)
Tank

Wash away abrasive accumulation from
equipment working area
Remove all garnet, sludge, and slugs
from the tank bottom
Inspect individual slats
Clean the outlet water filter
Run tank cleaning program
Add anti-bacterial chemicals to the
tank water (controls tank odor and
bacteria growth)
Table
Lubricate carriage components
Lubricate X/Y-axis components (if
applicable)
Lubricate the Motorized Z-axis
Inspect the timing belts (if applicable)
Rotate/replace Nozzle Mixing Tube
Clean Nozzle orifice (or the entire nozzle
body if using the MAXJETSi)
Abrasive tubing (hopper to nozzle)
Rebuild the abrasivejet nozzle*
Daily and as often as required to maintain a clean working
environment
Whenever abrasive particles begin to excessively
accumulate on the material being machined
Rotate monthly or more frequently if needed. Replace
when excessively scored and no longer stable.
Check monthly or more frequently if needed
As needed when using the OMAX Solids Removal System
(SRS)
Add anti-bacterial chemicals if needed to control tank odor.
Do not***add to the tank if using a Closed Loop
System.
Yearly
Yearly
Yearly
Yearly - replace as needed
Rotate 90 degrees (one quarter turn) every 8 hours of
cutting to even wear. Replace as needed.
Clean the jewel/nozzle orifice assembly once a week
minimum to prevent mineral buildup in the jewel assembly.
Inspect weekly, replace as needed
As required to maintain cutting quality.

*lf using the MAXJETSi Integrated

Diamond Nozzle, replace the whole
nozzle body - do not rebuildi

Note: The hours listed in this chapter for recommended pump maintenance scheduling are NOT warranty
hours. Piease refer to the OMAX Two Year Limited Warranty provided on the OMAX website for
warranty information

Note: Repeat the time durations shown for your particular pump after every Rebuild Kit installation.

In the event of a premature failure, individual cylinders can be rebuilt independently; after which, run hours
can be recorded and cylinders rebuilt independently according to recommended rebuild schedules.

400433H-EN 4-3

OMAX
 Maintaining the EnduroMAX Pump
Consumable Pump Parts
The table below identifies the consumable parts/accessories for EnduroMAX pumps that wear out on a
predictable basis as part of norma! system operation. For assistance in ordering consumable parts, contact
OMAX Technical Support.

Part Description P/N

200 Mesh Strainer, Charge Pump Tank, Reservoir 203690
1 micron, Charge Pump Pre-filter Cartridge 202533
.45 micron, Charge Pump Final-filter Cartridge 202532
Air Filter 203739

Iscrew M1~2

.cover plate

Iscrew 1/2^

Iwasher, 5/8’

Isaew

Iconnector 1/4'

screw 6/8

fitting 90
degree
r
|

Figure 4-1

4-4 400433H-EN

[t]
OMAX
 [pressure manifold| Imanifold nipplel

lend cap|
Iliquid displacerl Icheck valve]
dynamic icylifider
Icoolant housingj seal
Ibackup ring]
[plunger assembly I
/3
[bracket, RTTl-t #
T

■^bracket7LH7|

i
[screw M8[

\
L-
I tie rod nut

Parts Required for Wet End Maintenance

EnduroMAX Minor Rebuild Kit, P/N 308308
Description Part# Qtv
0-ring 200377 2 EA
Bail 200904 6 EA
Snap Ring 200913 3 EA
Seal 202398 3 EA
Extreme Pressure Lube 202496 1 EA
Seat, Check Valve 300640 6EA
Seal Retainer Sleeve 300745 3EA
Seal and Retainer Assembly 302948 3 EA
Filter Assembly Manifold 304104 1 EA
Check Valve Retainer 308104 6EA
EnduroMAX Major Rebuild Kit, P/N 308281
Description Part# Qtv
Kit. Minor Rebuild 308308 1 EA
Assy, Backup Ring 308107 3 EA

Tools and Other Items Required for Pump Maintenance

Refer to Tools Required for Table and Pump Maintenance on page 4-39 for a list or required
EnduroMAX maintenance items.

400433H-EN 4-5

OMAX
 Remove the High-pressure Wet End Components
The following procedures explain how to remove the wet end components (Figure 4-3)for maintenance
and rebuilding.
-'^inlet coolant
I lines (Sea.) ^ '
port adapter
hard plumbing port adapter
hard piumbing

high-pressure
manifoid
check valve iniet
water hoses (3 ea.)

end cap check valve

(3 ea.)

high-pressure
manifold nipple
lines

Figure 4-3

1. Turn Pump power OFF at the main AC disconnect, and shut down the water and air supplies. Bleed all
air from the system by opening the air hose. Place a “lockout tag” on the power disconnect to alert
others that maintenance is in progress.
2. Open the pump lid and remove both the front and side covers.

3. Remove the Inlet coolant line from the push-to-lock fitting on the top of the coolant housing for each
cylinder being rebuilt (Figure 4-4). Remove it by pushing down the colored outer ring of the fitting and
then while held down, pulling the hose up.

inlet coolant f:
lines (Sea.)

4-6 400433H-EN

OMAX
 4. With a 13/16" open-end wrench, loosen the high-pressure manifold nipple lines attached to the
cylinder end caps and pressure manifold for each cylinder being rebuilt (Figure 4-5). Once loosened
they can be removed by hand and set aside.

Ipressure manifold nippple manifold

line (3 ea.)

end cap
(3 ea.)

Figure 4-5

5. Using a 9/16" open-end wrench, remove the water supply lines from the check valve bodies for each
cylinder being rebuilt (Figure 4-6): '

|watersupply|
[line (3ea.)

lend cap

9/16" open-
end wrench

Figure 4-6

6. Using a felt-tipped pen or other marking device, mark each cylinder component as #1, #2, and #3 for
easy identification when reassembling.

Note: It is preferable that cylinder components not be interchanged during rebuild, but this is not a requirement.

7. Remove the four Ml6 tie rod nuts from each cylinder being rebuilt using a 15/16" or 24mm socket
(Figure 4-7).
Caution: When removing the tie rod nuts, loosen each nut 1/16 fo 1/8th of a turn until the load is
removed from the tie rods and the nuts can be turned by hand. Always loosen each nut by
repeating the pattern illustrated below: 1,2,3,4 then 5,6,7,8, then keep repeating until loosened.

400433H-EN 4-7

[t]
OMAX
 Hil^jbtie rolfnTi^
(4 ea.)

14mm socket

Figure 4-7

8. When all four tie rod nuts are removed for each cylinder being repaired, set them aside.

9. Slide the end cap(s) off the tie rod studs (Figure 4-8) and piace it on a clean work surface.

Figure 4-8

Caution; The tie rod studs help maintain cyiinder alignment during the assembly process. Cylinder
components must be held square during the rebuild process.

10. Slide the check valve(s) body out from between the tie rod studs by holding it square to prevent any
binding between them:

check valve body

●od stud

Figure 4-9

11. Slide the cylinder out from between the tie rod studs until it ciears the tie rod threads:

4-8 400433H-EN

OMAX
 rod threads

Figure 4-10

Caution: The liquid displacer may slide out with the cylinder since it is ioose in the cylinder bore. Take
care not to drop the displacer while removing the cylinder. To remove the displacer from the
cylinder bore, tip the cylinder on its end after it clears the tie rod studs.

12. Typically, the dynamic seal remains in the cylinder after removal. Push it out of the cylinder bore
using the liquid displacer.

Note: Occasionally, the dynamic seal assembly remains on the plunger and can be removed by hand or simply
removed along with the backup ring and coolant housing.

Caution: If leakage occurred between the cylinder and check valve body or between the cylinder and
backup ring (leak appears at coolant housing but metal-to-metal leak is between cylinder and
backup ring), replacing both components is mandatory to repair the metal-to-metai seal.

13, Remove the bottom outlet coolant line{s) from the coolant housing by depressing the colored ring on
its push-to-lock fitting and pulling back on the coolant hose.
14. Holding both the coolant housing's inlet and outlet fittings, slide the coolant housing, backup ring
and dynamic seal (if still in place) together off the plunger:

1 .●,1,

Iplunger
Ipnnlfli housingl
-Vs-'i
iA

Figure 4-11

15. Remove the backup ring from the coolant housing by threading the two provided M4 screws into the
holes in the backup ring and pulling up on the screws:

400433H-EN 4-9

OMAX
 D nng from
[coolant housin ycoolanUiousing
Figure 4-12

Note: Clearance between the backup ring and coolant housing is small requiring that the backup ring remain
square for its removal. If not, push it back in and attempt to slide it out again.

Caution: Never use force or some type of press to remove the backup ring from the coolant housing.

16. With a clean rag, clean the Blue Goop from the end caps, cylinders, and check valve bodies. Clean
the high-pressure grease from inside of the cooling housing and outside of the backup ring. If
necessary, the rag may be dipped in a solvent or acetone to aid cleaning.

Caution; Do not allow solvent to get on the backup ring bushing or the coolant housing u-cup seal.

Inspecting the Backup Ring Assembly and Dynamic Seals

if uneven dynamic seal extrusion or a dynamic seal failure occurred, the backup ring should be
examined in detail to determine if plunger rubbing has occurred and if the associated plunger assembly
needs to be replaced.
To inspect the backup ring assembly;
1. Using magnification, inspect the edges and interior of the metal lip in the bore of the backup ring
(Figure 4-13) adjacent to where the dynamic seal was positioned, especially if uneven or
excessive extrusion of the dynamic seal was observed. The exterior edge of the short lip should be
sharp and square with no nicks or gouges. There should be no evidence of rubbing on the lip.

Inspect lip for

plunger rubbing

4-10 400433H-EN

OMAX
 2. Figure 4-14 shows both an undamaged and a severely damaged backup ring. The short lip should
appear to be uniform in width all the way around. Any area where the width appears to be wider, or
darker, or where the machining marks are scraped away, indicates where the lip has been rubbed
by the plunger.
t
undamaged lip lip undamaged [,
of backup ring ^
lip damaged by
I
plunger rubbing —
I
P
__L
Figure 4-14

Note: Whenever plunger rubbing has occurred, the plunger assembly must be replaced along with the dynamic
seal and backup ring assembly.

To inspect the backup ring assembly:

Before removing the Dynamic Seal Assembly, inspect the Dynamic Seal for extrusion (Figure 4-15).
Extrusion of seal material around the edges of the bore in the dynamic seal is to be expected. Uneven,
excessive extrusion and/or missing material from one side across the face of the Dynamic Seal indicates
a failed seal with possible plunger damage caused by the plunger rubbing on the bore of the backup
ring. If uneven or excessive material is extruded or missing, then a close inspection of the Backup-
support Ring Assembly should be made for signs of rubbing.

some extrusion Is
normal material missing
excessive extrusion

r/ I i:. ●fr'

i
Normal wear - about 200 hours Failed seal due to plunger rubbing backup
ring, or possibly lack of cooling water flow
Figure 4-15:

400433H-EN 4-11

[t]
OM&X
 Rebuilding the Coolant Housing
plug

push in fitting

coolant housing body

u-cup
seal retainer
snap nng

Figure 4-16

1. Remove the snap ring using a snap ring pliers.:

pliers

Figure 4-17

2. Remove and discard the internal components from the coolant housing body:

[snap ring] seal retainer u-cup seal

Figure 4-18

4-12 400433H-EN
t
i
OMAX
 3. Locate the replacement components identified in Figure 4-18 in your rebuild kit. Lubricate the u-
cup seal with a thin coating of Lubriplate;
k.
Lubriplate

●●
A)
/

Figure 4-19

4. Insert the u-cup seal into the coolant housing body with the flat side of the seal facing up:

u-cup seal
flat side up'

Figure 4-20

5. Inset the seal retainer into the coolant housing body on top of the u-cup seal:

seal retained

Figure 4-21

6. Replace the snap ring using the snap ring pliers:

Qsnap ring
fi
I

i
Figure 4-22

Caution: Visually inspect the snap ring to ensure that it is fully engaged into its groove.

Inspect the Check Valve Assembly

Check valve seats are replaced at every rebuild, but it is also important to inspect the seats and mating
surface of the check valve body to determine if further inspection of other components is required. Water
leaking past check valves can form jets that damage the check valve body. Inspection is best performed
with magnification.

Caution: Do not run the EnduroMAX pump if the output pressure begins to drop by more than 2-4 KSI
from the original RPM. If the check valve seats are worn, continued pump operation can
damage the check valve body.

3k

400433H-EF 4-13

OMAX
 brass fitting, 1/8‘

D
[check valve body]
outlet side

Iseat
9
retainer
[retainer nut

Inlet side
(has pin)

Figure 4-23

Disassemble and inspect the check valve assembly;

1. Begin disassembly of the check valve assembly (Figure 4-23) from the inlet (cylinder) side. Clamp
the check valve body into a soft-jawed vise and, using the 5/8" crows foot, remove the retainer nut
(Figure 4-24).

valve body

Figure 4-24

2. Remove the ball retainer, the ball, and the check valve seat. A pair of needle nose pliers can be
helpful when removing the ball retainer:

needle nose pliers

.[ball retainer

Figu)

4-14 400433H-EN

OMAX
 3, Reverse the check valve assembly in the vise and remove the identical components from the
outlet side. Place all components on a clean work surface for cleaning and inspection.
4. Inspect for erosion on the surface that was against both check valve seats. This may indicate
leakage between the flat side of the check valve seat and the check valve body, or leakage
between the check valve ball and check valve seat.
5. Clean the check valve body stem and the radius at its base.
6. If leaking was observed between either the check valve body or the end cap and cylinder, the
check valve and adjacent components will need to be replaced.
7. If a pressure loss occurred without any external leakage, but the high-pressure cylinder runs very
hot, the check valve body is cracked internally, requiring replacement.

Note: Always discard any damaged or eroded parts and replace with new ones.

8. Repeat the above disassembly procedure for all other check valve assemblies being rebuilt.

Rebuild the Check Valve Assembly

1. Ensure that all replacement parts are available in your rebuild kit;
check valve bodvl

[retainer nUT
retainer
[g
/
/'
‘i
:● H ^

©
, A

Figure 4-26

2. Assemble the outlet side of the check valve assembly first. See Figure 4-23 to identify outlet
side (no pin on outlet side).
3. Insert the check valve ball into the retainer opening followed by the check valve seat (tapered
side of seat next to ball):

I_-
I Insert ball I
.- retainer
[ball Iseat
A\ etainerwith ball
md seat installed

y
w ..
Figure 4-27

4. Hold the check valve body upside down to prevent the ball and seat from falling out and insert
the retainer with ball and seat into the check valve body steam.

Note: Once the flats on the retainer and on the body stem inside line up, the retainer will drop into place.

400433H-EN 4-15

[t]
OMAX
 Icheck valve flat I
Iretainerflat m

N
With the check valve body
held upside down, align the
flats and insert the retainer
into the check valve body

Figure 4-28

5. Apply a light coating of anti-seize compound to the threads of the retainer nut and to the bottom
face that contacts the inlet ball retainer:

bottom face

Figure 4-29

6. Screw the retainer nut over the inlet ball retainer and into the threaded Inlet check valve body
stem. Hand tighten:

Figure 4-30

7. Clamp the outside diameter of the check valve body in the soft-jaws of a vise, refer to the torque
table below, and torque the inlet retainer nut to 180 in lbs (20.3 Nm) using a 5/8” crows foot:
j

‘ 15/8"crows foot

●● check valve body

A
soft-jawed vise [p)

Figure 4-3}

4-16 400433H-EN

OMAX
 Check valve retainer nut torque
values:
inlet retainer nut 180 in. lbs (20.3 Nm)
outlet retainer nut 230 in. lbs (26 Nm)
8. Flip the check valve assembly over in the vise and rebuild the opposite outlet side by following
the exact instructions except for setting the retainer nut torque value. Torque the'retainer nut for
the outlet side at 230 in. lbs (20.3 Nm).
9. Repeat the above rebuild procedures for all other check valve assemblies being rebuilt.

Rebuild the Dynamic Seals

|largeO-ring
dynamic seal

I retainer
small 0-ring

Figure 4-32

1. Apply a small amount of Lubriplate to the small 0-ring.

|small 0-ringf

Figure 4-32

2. Place the small 0-rlng on the extended lip of the dynamic seal.

Idynamic seal

Figure 4-34

3. Insert the dynamic seal with small 0-ring into the metal retainer and snap into place.

Note: The retainer must be held square and may require some force to snap into place. An arbor press may be
used to lightly press the retainer onto the dynamic seal.

Caution: Ensure that all press surfaces are cleaned ofcontaminates before coming into contact with the
dynamic seals.

400433H-EN 4-17

OMAX
 dynamic seal
with 0-ring

dynamic seal
pressed into retainer

Figure 4-35

4. Apply a coating of Lubriplate onto the large O-rIng and place it over the outside of the back of the
dynamic seal.

dynamic seal
pressed Into 0-ring
retainer

Figure 4-36

Removing Plunger Assemblies

Removal and inspection of plungers is necessary only if plunger rubbing of the backup ring occurred.
Rubbing may be expected if the dynamic seal shows a heavily uneven wear pattern, or if the backup ring
indicates plunger rubbing.

Caution: Damaged plungers ALWAYS cause premature dynamic seal failure.

Plunger damage cannot always be seen with the naked eye and needs to be examined carefully with
magnification. Damage is usually caused by the plunger rubbing on the backup ring or by foreign
material in the pump. Whenever a plunger rubs the backup ring, metal adheres to the plunger surface.
With extreme rubbing, a rough area showing discoloration of the plunger surface develops. Refer to the
section, Inspecting the Backup Ring Assembly and Dynamic Seals located on page 4-10.

Note: Once plunger rubbing has occurred, the plunger assembly must be replaced along with the dynamic seal
and backup ring. If material is missing from the plunger surface, the plunger assembly, backup ring and
coolant housing seal must also be replaced along with the dynamic seal.

4-18 400433H-EN

OMAX
 pony rod

\
adapter block

wrench flats

[plunger assembly]

Figure 4-37

1. Remove the cylinder assembly, if not already removed.

2. Remove the two screws(5mm Allen wrench) holding the access cover plate on the side of the
belt guard to gain access to the pulley on the pump crankshaft.

access cover
plate

Figure 4-38

3. Use a 10mm box end wrench to remove the screws from the belt access plate.
4. Use the belt pulley to rotate the pump crankshaft by hand until the plunger being removed is
positioned at bottom dead-center (fully retracted). Only two of the plunger assemblies are
accessible at a time.
5. Use the 3/4" crows foot with a 3/8" drive breaker bar to apply a steady pull and loosen the plunger
assembly.

Caution: Avoidjamming the wrench and permanently bending the Plunger Assembiy.

Reinstalling Plunger Assemblies

1. Ensure that the threads on the plunger assemblies and the face and threads of the pistons in the
crankcase are clean.
2. Apply antl-selze lubricant to the mounting face and threads of the plungers.
3. Install plunger assemblies into the crankcase and hand tighten.
4. Rotate the pump crankshaft so the plunger is at bottom dead-center.
400433H-EN 4-19

OMAX
 Caution: The plunger must be at bottom dead-center(fully retracted) when being tightened to avoid
bending the plunger assembly.

5. Using the 3/4" crow’s foot and torque wrench, tighten each assembiy to a torque of 225 in-ib, or
19ft.-lb (25 N-m).

Reassemble the Wet End Assembly

1. Appiy a small amount of extreme pressure lubricant to the outside diameter of the new backup ring.

apply extreme
pressure lubricant
tside
[backup ring

I
ixnttMWfsswr
■ ^

Figure 4-39

2. Insert the backup ring into the coolant housing.

backup rin^

B-.Jcoolant housinc

Figure 4-40

3. Install the coolant return line into the push-to-lock fitting at the bottom of the coolant housing until it
locks in place.
.4?.. ■

[coolant housing

push-to-lock fitting

saJ.^coolant return linef

|

. Figure 4-41

4. Slide the coolant housing with the backup ring installed into place over the plunger.
Caution: Keep the coolant housing square while inserting it between the tie rod studs until it rests
against the adapter block.

4-20 400433H-EN

OMAX
 ant housing I
IfP^
Mil
3[adapter bloci^
e;
Figure 4~42

5. Install the rebuilt dynamic seal over the plunger with the metal retainer facing away from the face of
the backup ring.

[backup ring

- |q]^al retaif^pill
[plunger

f
Figure 4-43

6. Use a cotton applicator and apply a thin coating of Blue Goop® to the metal sealing surfaces on both
ends of the cylinder and end'cap.

Blue Goop'
r/

Figure 4-44

7. Install the cylinder(s) sliding it in from the end of the tie rods until it contacts the backup ring/coolant
housing assembly (Figure 4-45).

Caution: The correct end of the cylinder must match up with the Check Valve. A pin in the check valve
prevents the cylinder from being installed Incorrectly. When installed wrong, the pin stops the

400mH-EN ^^■21
[t]
OMAX
 cylinder from making contact with the check valve. The arrow on the cylinder must point to the
check valve to achieve correct alignment.

[cylinder]

[check valve~[
check valve pin

CHECK VALVE 1orientation arrow

pointing to check valve

THIS END II

backup ring/
coolant housing

Figure 4-46

8. Insert the liquid displacer(s) into the cylinder(s).

Figure 4-41

9. With the small stem end of the check valve body facing the cylinder, insert the check valve
assemblies between the tie rods and slide them into place until resting against the cylinder.

4-22 400433H-EN

[r]
OMAX
 mm
check valve

[check valve

Figure 4-48

10. Slide the end cap over the tie rods until it rests against the check valve assembly.

cylinder

Figure 4-49

11. Install flat washers over the tie rods and apply a generous coat of anti-seize lubricant to the tie rod
threads and bottom face of the tie rod nuts and washer.

-seize lubricant “ y

.V

Iwasher
bottom face of nut
and washer |tie rod threads

Figure 4-50

12. Thread the tie rod nuts onto the tie rods until they just touch the washer.

^tie rod nut

tie rod

Figure 4-51

Caution: Do not attempt to tighten the tie rod nuts until all are in place.

400433H-EN 4-23

OMAX
 13. After all of the tie rod nuts are Installed, set the torque wrench at 40 ft lbs (54.2 Nm)and tighten each
nut one degree marker (Figure 4-52) at a time using the pattern shown below until torque value (40 ft
lbs) is achieved.

Caution; Always tighten the tie rod nuts by following the pattern illustrated below: 1,2,3,4 then 5,6,7,8,
then keep repeating until 40 lbs of torque Is achieved. Use of this pattern ensures that the
mating surfaces between the components remain parallel during the tightening/loosening
process, ensuring a good metal-to-metal seal. This same procedure applies to both loosening
and tightening the tie rod nuts.

degree maTRs

Figure 4-52

14. Using the tightening pattern illustrated above, continue to tighten in 15 lbs increments (55, 70. 85,100,
115) until 130 ft lbs (176 Nm) is achieved then increase to 150 ft lbs (203 Nm)followed by completing
with 175 ft lbs (237 Nm).
15. Repeat the above procedures for additional cylinders being rebuilt.
16. install high-pressure manifold nipple lines and press the coolant inlet water lines back into the
check valve push-to-lock fittings.

Replacing a Tie Rod Stud

Note: Replacing an EnduroMAX tie rod is typically only necessary in situations where it becomes damaged due
to cross threading or becoming bent.

Caution: Tie rod studs are installed into the adapter block using Loctite® 21V^ High Strength Red
Threadlocker. Never use pliers, vice grips, or a pipe wrench on the stud diameter to remove it.
This will introduce a fatigue point that eventually leads to stud failure. Always use double tie
rod nuts to remove a stud.

4-24 400433H-EN

[t]
OMAX
 To remove a tie rod stud from the adapter block: f

1. Use double tie rod nuts locked against each other to remove the stud using a 15/16"(24mm)open
end wrench.

Note: Remove the stud using the inside nut only. Use ofthe outside nut could loosen the two locked nuts instead.
tighten both nuts ^VIEEHnHnB
against each other
to remove the stud

Istud
Inside nut
(reversed from
outside nut)
V.

Figure 4-53

Note: You should always attempt to remove a stud without using heat, but for difficult studs, It may be necessary
to break down the Loctite by first applying heat with a propane torch to the adapter block near the stud for
at least 40 seconds and then retrying. If it still cannot be removed, reapply heat for an additional 30
seconds before trying to loosen it again. Repeat this process until the Loctite releases the stud.

^ ● Jadapter
block

Figure 4-54

2. When installing new tie rod studs, clean the threads with a wire brush and solvent.
3. Flush the threads with a Loctite solvent (or non-residual solvent such as acetone), blow the threads
TM
clean using air, and then spray the threads with Loctite 7471 Primer T™.
4. Apply Loctite 271 to the tie rod threads and screw them into the adapter block. Immediately torque to
30 ft lbs (use two nuts locked against each other for installation).

Replacing the Crankshaft Pony Rod Seals

The cup seals used in the Myers® crankcase prevent the crankcase oil from leaking past the plunger
rods during pump operation. Cup seal replacement Is not normally required during a typical wet
end rebuild: however when it is necessary due to excessive oil leaking, it should be scheduled to be
done in conjunction with a routine wet end rebuild.
Refer to the OMAX document “Replacing the Myers Cup Seals”, P/N 400397, for detailed instructions.

400433H-EN 4-25

OMAX
 Replacing the High-pressure Port Adapter Seals and Filter
The port adapter 0-ring seals (see Figure 4-55) should be replaced at each pump rebuild, or any time
leaking occurs between the manifold and port adapters. The pump in-line filter provides additional protection
for the orifice assembly in the nozzle and dump valve. This filter should be replaced at every pump rebuild.

^port adapter body

Figure 4-55

1. Ensure the system is powered down and there no longer is any water pressure in the high-pressure
plumbing.
2. Disconnect the high-pressure lines (13/16" open-end wrench)from both port adapters (Figure 4-56).

5 ,port adapter

IBport adapter
Idisconnect high-
[pressure line

Figure 4-56

3. Remove the two screws securing the manifold to the mounting bracket at each end (Figure 4-57).

I mounting screw]

Figure 4-57

4. Place the manifold body into a soft-jawed vise.

4-26 400433H-EN

OMAX
 5. Use a 14mm Allen wrench and breaker bar to remove the four port adapter screws and washers
(screws are torqued at 175 ft lbs/237 Nm)from each port adapter. Remove all screws with washers.
port adapter screw
(x4) with washer

Figure 4-58

6. Remove both port adapters from the pressure manifold body followed by the filter.

■
ring
ipresi
t
I-
jport adapter manifold filter adaptCl

Figure 4-59

7, Remove the manifold body from the vice.

8. Place the port adapter in the soft-jaws vice.
9. Using a 5/8" open end wrench, remove the manifold filter adapter.
10. Clean and inspect parts for damage and replace as needed.
11. Apply a light sheen of Blue Goop to the manifold filter adapter threads.
12. Install the manifold filter adapter into the port adapter.
13, Using a 5/8" crow's foot, torque to 144 in lbs or 12 ft lbs (16.3 Nm).
14. Apply a light coating of Lubriplate to the 0-ring.
15, Replace both 0-rlngs and clean any residual Blue Goop from the metal sealing surface.

r
[port adapter

I
0-ring|

Figure 4-60

16. Remove the port adapter from the vice.

17. Place the pressure manifold in the soft-jaws vice.
18, Clean the inside diameter of the pressure manifold using a lint-free rag then blow it out with air.

400433H-EM 4-27

OMAX
 19. Apply a light coat of Blue Goop using a cotton applicator to the metal sealing surface of the pressure
manifold for both port adapters.

ssure manifold

[Blue

20. Install a new filter onto a port adapter:

[port adapTeF

Figure 4-62

21. Insert the port adapter with the filter attached into the pressure manifold.
22. Insert the second port adapter into the other end of the pressure manifold, ensuring that it mates up
with the filter.

23. Apply a coat of anti-seize lubricant to the threads of the port adapter screws and both faces of the
washer. Install the screws into the port adapter and thread them into place to secure both port
adapters to the pressure manifold.
. anti-seize to
^ threads

anti-seize to
washer

Figure 4-63

24. Using a torque wrench, tighten each port adapter screw using the crisscross pattern illustrated in
Figure 4-64 below. Repeat this pattern four times using each of the incremental values listed below
until the required full torque (#4) is achieved:
Torque #1 Torque #2 Torque #3 Torque #4
40 ft/lbs 75 ft/lbs 125 ft/lbs 175 ft/lbs
54 Nm 102 Nm 169 Nm 237 Nm

4-28 400433H-EN

OMAX
 |port adapter|

[torque wrench[

^ Figure 4-64

25. Remove the pressure manifold from the vise and secure it to its mounting bracket using the two
screws previously removed (Figure 4-57).
26. Reconnect the high-pressure lines to the port adapters (Figure 4-56).

Maintenance of the Water Filtration System

Proper maintenance of the water filters in your EnduroMAX low-pressure water system directly impacts the
performance of your OMAX JetMachining Center®,
cooling water

incoming <^bag filter relief

water ^ valve high-pressure
Water Tank water

recycled water ^ charge

mam
pump water
filters pump ADO
4-
temp control
valve
waste nozzle
waste drain
drain
Figure 4-65

pre-filter gauge
final filter gauge

water in from
charge pump [water out line

safety switch shuts OFF pump

at pressures below 100 PSI

Figure 4-66

400433H-EN 4-29

OMAX
 How the low pressure water system filtration works:
1. Source water comes into the white reservoir tank (Figure 4-69) in the pump cabinet.

Note: Additional systems such as a Reverse Osmosis, a water softener, or an EBBCO closed loop system may
be installed at this point for additional water treatment when needed.

2. When the Charge Pump is turned ON, water from the white tank reservoir feeds the preconditioned
water to the 10" metal fiiters (Figure 4-66).

Note: The pre-filter gauge (Figure 4-66) reads the pressure of the charge pump before the filters (pressure
should be set at 160-170 psi with the high-pressure pump not running).

3. The charge pump pulls water from the white tank reservoir through a 200 mesh strainer and pumps it
to the pre-fiiter, through the 2nd finai filter, and then into the pump.
4. The final filter gauge reads the pressure after both filters have filtered the water.

Note: When the pressure difference between the gauges is more than 20 psi with the pump running at high RPM,
the filters are becoming clogged and should be replaced. Always change both filters. When filters are new,
the difference in pressure between the two gauges is close to zero.

Preventing problems in the low-pressure water system:

The “Charge pump pressure low” message is typically caused by the charge pump not being able to develop
sufficient water pressure, triggering the 100 psi low pressure switch, causing the high-pressure pump to shut
down.
To prevented this, follow these suggestions for filter maintenance:
● When-one filter requires replacement, change all filters.
● If the pressure difference between the gauges is more than 20 psi when running the pump at high
^i^PM,change the pump filters.
● Tilean the 200 mesh strainer in the Charge Pump reservoir every 3 months or more frequently if
needed.

Changing Water Filter Cartridges

The EnduroMAX pump uses two filters for the low-pressure water from the water tank (Figure 4-67).
Pressure gauges mounted on top of these water filters monitor the water pressure both before and after
the two filters. When the pressure differences between these two gauges becomes greater than 20 psi
(140 kPa), the filter cartridges need replacing.
/

,\K:M
[filter removal tool downstream filter
upstream filter p
1 micron

r r.

Figure 4-67

To replace the water filter cartridges;

1. Turn OFF the charge pump.
2. Lift the pump’s cover lid and remove the front panel cover.

4-30 400433H-EN

OMJUC
 3. Unscrew each filter housing, using the removal tool provided {P/N 203727-A):

Figure 4-68

Note: Refer back to Figure 4-67 for an example of the filter removal tool inserted in the water filter housing.
A. Remove and discard the filter elements.
5. Wash and rinse the filter housing to remove all sediment and coatings from inside the housing.
6. Rub a thin coating of oil (Lubriplate or equivalent) on the ends of the coarser 1 micron filter
element. Install it upstream. Reinstall the upstream filter housing.
7, Rub a thin coating of oil (Lubriplate or equivalent) on the ends of the finer .45 micron filter element.
Install it downstream. Reinstall the downstream filter housing.
8. After replacing the two elements, turn ON only the charge pump.
9. Turn OFF the charge pump.
10. Replace the front panel cover and lower the lid.

Cleaning the Pump’s White Water Tank

All types of debris accumulates over time in the small, white water tank in the pump unit. The tank and
charge pump suction screen should be cleaned at every pump rebuild, or more frequently when necessary.

filter screen
input water line

charge pump
suction line
charge pump

water level float m

bypass valve e»
dump line

Figure 4-69

1. Ensure power to the charge pump is OFF,

2. Remove the pump’s front panel allowing access to the white water tank (Figure 4-69).

400433H-EN 4-31

OMAX
 3. Lift the drain cap from the iid of the white water tank.

«»= lift drain cap from

return water white water tank
hoses(3 ea.) ‘

4. Remove the bag fiiter from the tank lid.

5. Clean the bag filter by thoroughly rinsing it using clean water.

6. Remove the water tank lid.
7. Shut the water supply to the pump unit OFF.
8. Empty the tank water by powering the charge pump ON.
9. Once the water level is at or below the charge pump suction inlet, power the charge pump OFF.
10. Remove the remaining tank water by mopping it up using a clean rag.
11. Once tank water has been removed, wipe the interior of the tank clean.
12. Remove the charge pump water inlet filter screen from the end of the suction line.
13. Clean the water inlet filter screen by flushing it backwards with water and blowing it dry with shop air.
14. Reinstall the cleaned filter screen and firmly tighten it in place by hand.
15. Replace the water tank lid.
16. Install the cleaned bag filter and replace the drain cap.
17. Turn the water supply ON, allowing the water tank to fill.
18. Power ON the charge pump and bleed any air from the two filters by holding down the red buttons on
top of the filters to bleed air from the filters (Figure 4-67).
19. Power the change pump OFF.
20. Replace the pump’s front panel.

Flushing the Machine After Maintenance

The high-pressure plumbing system should always be flushed following maintenance of any of its
components.
1. Remove both the nozzle assembly and final filter from the Z-axis.
2. Position the Z-axis about 4-5 inches from the table slats.

4-32 400433H-EN

OMAX
 Note: To minimize splashing, you could position it over Jetbrick or place a piece of cardboard or rags over the
slats beneath the Z-axis.

3. Open Make.
4. In the main menu, select File/Open.
5. Right-click in the white space to open your permanent bookmarks.
6. Left-click OMAX Sample files (for all users).
7. Select Machlne_Diagnostic_Files.
8. Scroll down the list, select CycleTest_NoAbraslve_100_Cycles.ord, and click OK.
9. Click Begin Machining then click Start.
10. Inspect the system for leaks and repair any found.
11. Replace the final filter and nozzle components.
12. Conduct a water only, low-pressure and high-pressure test, again inspecting for leaks and repairing
any found.

Changing Crankcase Oil

To avoid excessive wear and damage to crankcase bearings, change the crankcase oil according to the
intervals specified in the maintenance schedule or anytime it becomes contaminated with water or other
debris.
Always use SAE 30(ISO 100) non-detergent motor oil. Use of other types of oil may shorten pump life. If the
temperature in the pump’s physical environment exceeds 90° F (32° C), use SAE 40(ISO 150) non
detergent motor oil. The crankcase requires three quarts (2.8 L) of oil.
1. Disconnect the pump’s AC power source.
2. Lift the pump’s cover lid and remove the front panel cover.
3. Place a drain pan at the end of the red oil drain hose to catch the oil when the plug is removed
from the fitting.
4. Allow the oil to drain.
5. To force out remaining oil, apply a small amount of shop air to the hole in the oil filler tube with the
filler cap still in place. !
6. Replace the plug at the end of the red drain hose.
7. Refill the oil through the filler pipe.
8. Replace the filler pipe cap.
9. Replace the front cover.

Tii

[crankcase
|
!l
5
*. *

i“'
1
[filler pipe]

oil level
dipstick

^ loll drain hose

V i^piug
kV

Figure 4-70

mmU-EF 4-33

OMAX
 Servicing the Pump Motor Belt
The heavy-duty belt connecting the EnduroMAX pump with the electric motor occasionally requires re
tensioning or replacement. Periodically inspect the belt, looking for cracks, frays, or other wear spots. If
you see cracks, frays, or damaged/missing teeth, replace the belt immediately.
The belt should deflect 1/4" - 5/8"(6.5 -16 mm)when pushed with a force of approximately 34 - 37
pounds(15-17 Kg) midway between the pulleys. If the belt deflects more or less than 1/4" - 5/8"(6.5 -16
mm)when pushed, adjust the belt tension using the following procedure.
Caution; Never tighten the belt to remove all deflection. This shortens the belt life.

1. Disconnect the pump’s AC power source,

2. Lift the pump’s cover lid and remove the pump’s front and rear panel covers.
3, Disconnect the high-pres§ure plumbing from the pump and remove the pump’s rear cover panel.
4. Remove the belt guard cover using the 10 mm socket:

10 mm ,
screws %
j
belt access
cover plate
belt guard
cover

Figure 4-71

crankshaft
sprocket j

guard

p Imotor sprock^

?l lower guard

1
Figure 4-72

5. Loosen the pump crankcase mounting bolts. Loosen nuts on the two eye-bolts located at rear of
crankcase. If the belt is being replaced, loosen it until to increase the slack, allowing it to be
removed from the sprockets.

4-34 400433H-EN

OMAX
 6. Install the replacement belt, ensuring the teeth mesh properly.
7. Using the eye-bolt outside nuts, tighten the belt to the tension specification provided above.
8. Tighten the securing nuts until snug, then check the pulley alignment with a straightedge,
adjusting it as needed.
9. Tighten the security nuts.
10. Fully tighten all crankcase mounting bolts.
11. Reconnect all the high-pressure plumbing to the pump.
12. Replace the belt guard cover.
13. Replace the pump’s front and rear covers.
14. Close the cover lid.

Lubricating the Electric Motor

The pump’s main electric motor comes with pre-lubrlcated ball bearings. The motor’s ball bearings
should be lubricated at intervals according to the pump’s hours of service per year as noted in the OMAX
Maintenance Overview Table (page 4-1).

Use these recommended high-quality ball bearing lubricants:

Consistency Type Typical Lubrication
Medium Polyurea Shell Dolium R and/or Chevron SRI 2
Sodium-Calcium Lubriko M6

To lubricate the motor’s bali bearings;

1. Disconnect the pump’s AC power source.
2. Remove the pump's front and rear panel covers.
3. Access the shaft-end of the motor (refer to Figures 4-71 and 4-72):
a. Remove the outside belt guard cover,
b. Remove the inside shaft guard,
c. Remove the lower portion of the belt guard.
4. Locate the grease fittings located on each of the motor ends.
5. Remove the pipe plug located opposite the grease fitting:

A
motor rear
tJ,-' /
I

Figure 4-73

6. Wipe the tip of each grease fitting clean and connect the grease gun.
400433H-EN 4-35

OMAX
 7. Apply 2-3 full strokes from the grease gun to each grease fitting.
8, Wipe up any grease forced out the hole and replace the pipe plugs.
9. Replace the belt guard components.
10. Replace the pump’s front and rear panel covers.
11. Close the pump’s cover lid.
12. Run the motor for 20 minutes.

Caution: Keep the lubricant clean. Always lubricate at motor standstill. Always remove and replace the
pipe plugs at motor standstill. Never mix petroleum lubricants and silicone lubricants In motor
bearings.

Replacing the Electrical Enclosure Air Filter

The air filter located on the inside of the electrical enclosure should be replaced every month, or more
often, depending upon environmental conditions. In excessively dirty or dusty environments, it may be
necessary to replace the air filters weekly.

Caution: Failure to maintain clean air filters can result in overheating of the electrical enclosure,
resulting In an over-temperature shutdown of the variable frequency drive (VFD).

n-. z-

air filter access cover air filter

air filter cover
(opened)

Figure 4-74

1. Locate the filter access cover at the bottom of the pump front panel (Figure 4-74).
2. Pull out and down at the top of the filter cover and remove the existing filter.
3. Insert the replacement filter back Into the filter cover, ensuring proper air flow direction.
4. Push the access cover back into position on front panel.

4-36 400433H-EN

[t]
ONUkX
 Rebuilding the Safety Valve
The safety valve in the EnduroMAX pump functions to prevent an excessive build up of water pressure in the
system plumbing.

[safety valvej

high-pressure
plumbing

Figure 4-75

During normal operation, the pump can reach pressures up to 62 KSI. At this pressure, the VFD slowly
lowers the motor’s RPM to prevent overpressuring the system, if lowering the RPM does not prevent an
overpressure condition, the safety valve will activate when a pressure of 68KSI is reached. An activated
valve should reseal itself, but could begin to leak after resetting itself a number of times. When leaking
occurs, rebuilding the safety valve using a new ball and seat is required.
When the safety valve activates, there probably is another issue going on with your machine. It may simply
be a deadhead during either a cut or traverse - indicating a plugged orifice in the cutting head or the dump
valve. Harder issues to identify are pressure spikes created at the moment of shift between the cut and a
traverse.

Note: The pump is designed to shut off when pressure reaches 63 KSI or above. If the pressure rises too rapidly,
it may exceed 63 KSI. The safety valve is designed to activate at 68 KSI(± 2 KSI).

WARNING! Never attempt to adjust the safety valve, doing so creates a safety hazard!

[weep holes (x4)|

I body I

|plunger[

sea
[Blue Goop|
lextreme pressure lube|
|Blue Goopj

Figure 4-76

400433H-EN 4-37

OMAX
 1. Use two 1" open end wrenches to unscrew the safety valve from the tee fitting.

use r wrench

ijsafety valv^

^use^wrench[

Figure 4-77

2. Remove and discard the two ceramic balls and seat (Figure 4-76).
3. Clean the plunger and safety valve body with water, using air to flush the water out of the spring
chamber.
4. Spray some IPS lubrication into the holes and blow out with air to prevent rusting of the valve.
5. Apply a light film of Blue Goop onto both ends of the replacement seat and the threads of the safety
valve body.
6. Apply a thin coating of extreme pressure lubrication (P/N 202496) on the two ceramic balls.
7. Stack the parts together (refer to Figure 4-76) and screw the assembled body into the tee fitting by
hand.
8. When screwed in as far as possible by hand, torque the body to the tee fitting using the 1" open end
wrench on the tee fitting and the 1" crows foot and torque wrench on the Safety Valve (refer to Figure
4-77). Tighten to 50 - 75 foot pounds.
9. Lower the RPM at startup for a few minutes to ensure no pressure spikes occur that will fail the valve
again.
10. With the pump running at high pressure, inspect the safety valve closely for any signs of water
leakage. Correct all leakage problems before continuing.

4-38 400433H-EN

[t]
OMAX
 Maintaining the OMAX Table
This section documents the maintenance normally required to ensure reliable operation of your OMAX
JetMachining Center.

WARNING! All maintenance activities must be performed by qualified personnel.

Tools Required for Table and Pump Maintenance

The following table lists tools used in maintaining pump and table components.
Nozzle Dual ON/OFF EnduroMAX
Tools Required OMAX Table
Assembly Valve Pump
Open End Wrenches
V4n X
y^' X
IT
TW X
WTBn X
T^TTB" X X X
1"(Qty2) X X X X
X X
X X
mEn X
TDrnrri X
Crow's Foot Wrenches
T X
TT7Bn X
IT
S75 X
3/4"(3/8" drive) X
Sockets
15/16"(24mm) 1/2" drive X
5/16"(8mm) X
10mm X
14mm Allen head socket X
Breaker Bar
3/8" drive X
Torque Wrenches
250in-lb (28.2 N-m) X X
100ft-lb (136 N-m) X X
175ft-lb (237 N-m) X
Allen Wrenches
37TBn X
5mm X
Pliers
Needle Nose X X
Snap Ring X
Lubricants, etc.
Anti-seize P/N 202563(see Caution X
below)*
Lubriplate P/N 201304 X X X X
Extreme Pressure Lube (EPL) X
P/N 202496
Blue Goop anti-galling compound X X X X
P/N 302692
Loctite 271 X
Arctic Grease X
Loctite 7471 Primer T X

400433H-EN 4-39

[t]
OMAX
 Nozzle Dual ON/OFF EnduroMAX OMAX Table
Tools Required Assembly Valve Pump
Grease, Jet-Lube lemp Guard X
Synthetic MolyDisulfide (P/N
309325)
Motor Oil SAE 30(ISO 100) or SAE X
40(ISO 150) applicable SAE/ISO Oil
Electric Motor Ball Bearing Lubricant X
Blunt tip grease needle (P/N"202633) X
OMAX Special Tools
Filter Seal Assembly Removal lool X
Spanner wrench (supplied with TAJ) X
Water Filter Removal Tool X
P/N 203727-A
Inspection Tools
Magnifying glass (or microscope) X X
Other
Soft-jawed Vise X
Grease Gun X X
Propane lorch X
Ultrasonic Cleaner X
Applicable OMAX drawings X X
Standoff Gauge .040”, .060’', .080' X X
Nozzle/Mixing Tube Gauge (optional) X X
P/N 306730
M4 screw (2 ea.) P/N 201198) X
Screwdrivers, flat, standard X

* Caution: Only use the recommended Anti-Seize compound, P/N 202563. Some anti-seize
compounds contain larger metallic particles that could cause damage to pump components.

4-40 400433H-EN

OMAX
 Maintenance Log
Run Hours Maintenance Performed Done By Date

400433H-EN 4-41

[t]
OMAX
 Maintaining the High-pressure Plumbing System
The high-pressure plumbing routes the water from the high-pressure pump to the abrasivejet nozzle.
This system requires periodic inspection for leaks, etc. Inspection should include the tubing, all the high-
pressure fittings, the swiveis, and the Dual ON/OFF valve. When fitting leaks occur, power OFF the
pump, release any remaining high pressure, and re-torque the leaky fitting. If the leak persists, verify that
the collar is backed off, allowing at least three threads to show which is necessary for proper seating.
Whenever a leak continues, the sealing surface is probably eroded which requires that the fitting be
disassembled and any eroded parts replaced.

WARNINGl Properly preparing and connecting ultra high-pressure(UHP) tubing and fittings is critical in
maintaining a safe and leak-free high-pressure system.

Do not adjust any high-pressure system components while still underpressure. Bodily injury
or damage to system components may occur.

Creating a High-Pressure Seal

Maintaining the proper cone angles on the body and tube is critical in creating a high-pressure seal. This
seal is created when the angled (59*) metal edges of the tube cone seats press against the metal edges
inside the body cone which has a slightly larger angle (60*). This slight difference in angles between the
body and tube cones creates a tight, metal-to-metal seal between both components.

Using Blue Goop® Thread Lubricant

All stainless steel high-pressure fittings require the application of a quality thread lubricant such as Blue
Goop.

Note: Blue Goop functions as a lubricant; it is not a thread sealer.

This lubricant prevents the stainless steel components from galling and seizing. Using excessive
amounts of Blue Goop lubricant introduces unnecessary machine problems such as the contamination
and fouling of machine components. To avoid this, OMAX recommends applying Blue Goop using the
following procedure:
1. Prior to applying Blue Goop, knead the tube contents to work the oil throughout the goop since the
oil and solids tend to separate.
2. Use an acid brush to apply the Blue Goop onto each component that requires lubrication.
3. Apply the Blue Goop at the start of the male threads. When threading on the female component,
the Blue Goop becomes evenly distributed.
4. Refer to Figure 4-78 for an example of the correct amount of Blue Goop to apply.

Caution: A small amount of Blue Goop goes a long way. Use it sparingly!

iimuiiii.

too much Blue Goop correct amount of Blue Goop

Figure 4-78

4-42 400433H-EN

OMAX
 Assembling the UHP Fitting
Caution: Always use two wrenches when torquing UHP Fittings!

1. After the tubing and body have been properly coned and threaded, slip the gland nut onto the
tubing.
2. Screw the collar onto the threaded end of tubing, observing the following Three Thread Rule:

Three Thread Rule

Always allow three screw threads to be exposed either on the end of the tubing or between the collar
and coned end of the tubing. This allows the tube to fully seat inside the coned body and create the
required seal.
3. Apply a small amount of Blue Goop to the gland nut threads.
4. Insert the tubing into the body cone.
5. Screw the gland nut into the connection until finger-tight.
6. Finally, tighten the gland nut(use two wrenches) to its specified torque value (see Table 4-1).

Description Torque Value

1/4" tube, coning and threading, 60 KSI 25 Ib-ft, 34 N*m
3/8" tube, coning and threading, 60 KSI 60 Ib-ft, 68 N*m
M8 clamp bar screws 10-12 Ib-ft, 13.6-16.3 N-m
Table 4-1

Note; Do not over-tighten the gland nut. This could obstruct the end of the tube and restrict flow.
Do not apply a thread-sealer such as Loctite or Teflon tape to UHP fittings. The metal-to-metal contact
between the coned tubing angle and the body cone angle creates the high-pressure seal, not the fitting
threads.

WARNING! Do not try to adjust a fitting while still under high pressure. An injury and/or a damaged
system component could result

Tank Maintenance
It is good practice to wash all abrasive particles and grit from exposed JetMachining Center surfaces at
the end of each shift or work day. A clean machine lasts longer and requires less maintenance. The
OMAX is designed to prevent abrasive from contaminating bearings and other critical parts, but it is also
important to keep a clean working area to minimize abrasive exposure to your machine.

Caution: When washing down the equipment, hold the hose at a distance of at ieast 18"(46 cm)from the
washing surface to prevent possibie damage to exposed seals. Air may aiso be used to biow
away grit if the same distance is maintained.

Cleaning Tips
Keep water away from the controller
Never spray water directly at the controller cabinet, keyboard, or mouse. Wipe down the outside of
the controller regularly.
Use a splash shield during machining
A splash shield (available from OMAX)allows you to view the machining process and at the same
time keeps the spray inside the tank, which is important in maintaining a clean working area.

400433H-EN 4-43

K
OMAX
 Keep material surfaces clean while machining. When cutting thick materials, abrasive particles build
up on top of the material. Make sure that you wash off this accumulation. Otherwise, large
accumulations of abrasive tend to pile up on the cutting path which can affect machining accuracy.
Clean garnet flows better
Even small particles of paper allowed to mix in with your abrasive material can clog the nozzle,
costing downtime and possibly a ruined part. It’s much easier to start with clean abrasive and keep it
that way.

Caution: Ensure that your garnet remains dry. Always store it in a location removed and protected from
the typical wet, abrasivejet environment. Damp garnet will lump together and not flow properly.

Removing Garnet Accumulation

Since garnet abrasive and metal particles are constantly accumulating in the tank, a regularly scheduled
removal of accumulated deposits is necessary.
When removing abrasive material from the bottom of the tank, it is best to completely drain water from
the tank before attempting to remove the abrasive waste. The drier the abrasive, the easier it is to
remove

Note: The OMAX Solids Removal System (SRS)is an effective alternative to manually cleaning the tank.
Contact your OMAX sales representative for details.

Used garnet abrasive by itself is not toxic and may be taken to a dump site or disposed of normally.
However, if any hazardous materials were cut, the abrasive waste becomes subject to a number of
environmental regulations. Contact your local resources for proper disposal methods.

Cleaning the Filter Screen for the Tank’s Water Outlet

Water accumulated in the catcher tank exits through a water outlet filter (Figure 4-79). This filter should
be periodically inspection to determine if cleaning the screen is required. This filter screen may be
removed for cleaning using a 1.5" open end wrench. Once removed, scrub it clean using a mixture of
mild soap and water.

.\ outlet water lilt^

Controlling Tank Odor

Like any untreated open water in a storage container, the catcher tank can become a home for bacteria
growth, creating an offensive odor and infection source for any open wounds. To control bacteria, the
JetMachining Center uses anti-bacterial chemicals such as those used in swimming pools or hot tubs
that reside in a plastic floating device inside the tank.

WARNING! Untreated tank watersupports bacteria growth that can infect open wounds. Use the bacteria
control materials provided with the OMAX odor control kit and keep tank water away from
any open wounds by wearing appropriate gloves for protection.

Periodically check the chemical content inside the floating device. Refer to the instructions
included with the anti-bacterial chemicals. Be sure to read any warning labels. Mixing
different brands of chemicals could create a hazardous situation.

4-44 400433H-EN

OMAX
 Caution: DO NOT add chlorine tablets when using an BBBCO Closed Loop System to treat your tank
water. Chlorine will ruin your filter system. The EBBCO Closed Loop System has a method to
control bacteria growth.

Slat Replacement
In time, table slats can become scored with deep abrasivejet cuts and will be unable to provide the
stability and support required for precision cutting. Slats should be inspected for wear at least once a
month. Those weakened and worn should always be replaced.

Note: The working life of a slat can be greatly improved by periodically rotating them to different table locations.

When replacing a defective slat, also inspect the slat holder for excessive wear. When worn too much,
they no longer prevent slats from rocking back and forth which can interfere with cutting precision. Worn
slat holders should also be replaced.

Maintaining the X-Y Carriage

The bellows protecting the precision bearings of the X-Y carriages on your OMAX are vital components
of your machine. By shielding the X-Y bearings, the bellows make possible smooth and precise
movements of the cutting nozzle. If the bellows or their seals are damaged, operation of the bearings
and ball screws can be compromised by the presence of grit, water, and other contaminants. Even the
smallest tear in the bellows can cause major component damage. The resulting problems can go
beyond imprecise cuts: they can even shut down your shop while critical parts of your OMAX are
replaced or repaired.
Regularly inspect the bellows for tears and cracks. Keep the bellows clean and supple using a
conditioner such as Armor All® and repair any holes or tears by using the OMAX Bellows Repair Kit. If
the bellows become damaged beyond repair, replace them. In addition to inspecting the exterior
condition of the bellows, remove the bellow cuffs from the bellow adapters and look inside.

Caution: Always clean the outside of the bellows before looking inside to avoid the introduction of grit
and dirt into the bearings or ball screws.

With the bellows open, wipe down and lubricate the rails, bearings, and bail screw nut. Use only Arctic
Grease and follow the instructions provided in Lubricating the JetMachining Center, page 4-50.

Before resealing the bellow cuffs to the bellow adapters, check the condition of the adapter rings. If you
find the factory-installed foam backing degraded or see evidence of water intrusion, carefully and
completely remove the foam using a razor blade. Before closing and resealing the bellows, apply a
generous, continuous bead of silicone sealant to the rim of any bellow adapter surfaces where the foam
was removed. Put the bellow adapters back on, secured in place with the fastening hardware. Wipe off
any excess sealant, leaving behind smooth surfaces for the bellow cuffs to seal against. Use a flashlight
to make sure the bellow adapters have sealed against their mating component faces, then reattach the
bellows. The silicone sealant will perform as well as the original foam backing material.
By regularly cleaning, conditioning, and repairing the bellows on your OMAX. the precision bearings in
your X-Y assemblies can stay dry, clean, and problem-free.

Timing Belt Inspection and Tensioning

Steel-reinforced timing belts are used by JetMachining Center to transmit power from the servo control
motors to the ball screws for nozzle movement(Figure 4-80). These belts should not wear out with

400433H-EN 4-45

OMAX
 ordinary use, but must be checked annually as part of your routine maintenance schedule for cracks
tears, and proper tension.

servo motor motor plate

pully

timing belt

ball screw
pully

Timing Belts for Cantilever Tables

Note: OMAX recommends that timing beits for the Model 2626\xp not be removed or adjusted. Doing so could
greatly affect its cutting precision. Please contact Customer Service for additionai 2626\xp timing belt
information.

Locating the Timing Belts

Timing belts connecting the servo motor with the carriage movement ball screws are found at one
end of the X and Y-carriages as identified in Figure 4-81:

X-carriage
timing belt Y-carriage"
location timing belt
location

Inspecting and Adjusting Timing Belts

1. Switch the Main AC Power Switch for the JetMachining Center to OFF.
2. Lock-Out and Tag-Out the Main AC Power Disconnect Switch.
3. Verify that AC power to the OMAX JetMachining Center was properly disconnected.

4~46 400433H-EX

OMAX
 Caution: Ensure both X and Y-carriage end covers and the adjacent bellows areas are scrubbed clean
using soap and water followed by completely drying with towels. Abrasive grit cannot be
allowed to enter the carriage mechanisms once the timing belt cover plate is removed.

4. Expose the timing belt by removing the carriage cover plate. Remove the 6 scre\ws from the X-axis
cover plate or the 3 screws from the Y-axis cover plate:
1
I remove
Vr these

remove
1 1 SIX
screws
these three
screws
r.
4
X-axis timing belt
Y-axis timing belt cover cover plate
plate

Figure 4-82

5. Set the cover plate and all removed screws aside for safekeeping.
6. Remove each timing belt and inspect for tears, cracks, missing teeth, and other defects as follows:
a. Loosen the motor plate's pivot screw. Refer to Figure 4-83.
b. Loosen the tension adjustment screw.
c. To release belt tension, push the motor plate down from directly above the adjustment screw.
d. Once tension is released, the belt should lift easily from the pulleys.
e. Inspect the timing belt.If defects are noted, replace the belt.

motor
motor
plate r plate push down to
push downTo loosen belt
adjustment! . loosen belt
screw --S

pivot a./ pivof adjustment

screw screw screw
/
timing iming
belt belt

balTscrew
ball screw pulley
A V
pulley

Y-axis timing belt X-axis timing belt

Figure 4-83

7. Re-install and re-tension the timing belt as follows:

a. Slip the timing belt over both the upper and lower pulleys,
b. With both the pivot and adjustment screws loosened, push up on the motor plate with your
thumb placed directly beneath the tension adjustment screw,
c. Push hard and hold a steady pressure while tightening the tension adjustment screw.

Caution: Do not use anything except your thumb to push on the motor plate while tightening. Belts that
are over-tightened become noisy during operation. When pressing in on a properiy tensioned
timing belt, it should deflect approximately 1/8 to 1/4 of an inch (0.30 to 0.64 cm).

400433H-EN 4-47

OMAX
 d. Once the motor plate is securely held in place with the adjustment screw, release thumb
pressure and also tighten the pivot screw. Finish by tightening both motor plate screws
securely,
e. Replace the carriage cover plates and screws.

Caution: When re-installing the X-axis motor cover, ensure that the electrical cables do not come into
contact with the drive belt Eventually, the constant contact with the moving belt could sever
the cable.

Timing Belts for Bridge-style Tables with Ball Screws

Y-axis movement for the bridge tables use the identical servo motor/ball screw configuration as
described previously in Timing Belts for Cantilever Tables. Bridge-style tables include the SOX, 60120,
and 80160. See Figure 4-84:

motor adjustment plate [

[servo motor pulley [,

[timing beTT)

I ball screw pulley

80160 Y-axis timing belt

Figure 4-84

Locating the Timing Belts

Timing belt locations for bridge tables are identified in the figure which follows:

Note: X-axis designs for the Models 60120 and larger use drives with linear encoders. These models do not
require use of timing belts for X-axis movement

[Y-axis timing belt

|
I ^ Y-axis bridge
upright cover plate
timing belt]
_,.[ X-axis rail

80160
[X-axis timing belt 60120, 80X.120X

Figure 4-85

Adjusting Timing Belts: Y-axIs

Timing belt removal and adjustment for bridge tables is identical to the procedures previously provided
for cantilever table systems.
1. Switch the Main AC Power Switch for the JetMachining Center to OFF,
2. Lock-Out and Tag-Out the Main AC Power Disconnect Switch.

4-48 400433H-EN

[t]
OMAX
k ●
 .f
●●

3. Verify that AC power to the OMAX JetMachining Center was properly disconnecleci.
Caution: Ensure the upright cover plate and surrounding housing are scrubbed clean using soap
and water followed by completely drying with towels. Abrasive grit cannot be allowed to enter
the carriage mechanisms once the upright cover plate is removed.
4. Expose the timing belt by removing all screws(10 ea.) holding the upright cover plate.
5. Set the upright cover plate and removed screws aside for safekeeping.
6. Adjust the timing belt following the procedures provided in Inspecting and Ad;u... ^ ●- Beits,
page 4-46, beginning with step 7a.
7. When complete, replace the upright cover plate.

Adjusting Timing Belts: 80160 X-axis

The 80160 uses the standard OMAX servo motor/ball screw design for its X-axis movement (Figure 4-
87). Two ball screws are used for X-axis movement, one on each side of the table (Figure 4-85).
1. Locate the timing belt access covers available on both sides of the R0160 frame (Figure 4-86):

Figure 4-86
j

Caution: Ensure that the access cover plates and surrounding frame are scrubbed clean using soap and
water followed by completely drying with towels. Abrasive grit cannot be allowed to enter the
protected ball screw area once the access cover plates are detached.
2. From Make on the PC-based controller, move the Y-axis assembly down the table until it just
O’
reaches the front of the access cover plates. This will position the servo/ball screw assembly
alongside the access cover plate, allowing timing belt maintenance when the cover plate is
removed.
3. Shutdown Make and power OFF the PC-based controller
4. Switch the Main AC Power Switch for the JetMachining Center to OFF.
5. Lock-Out and Tag-Out the Main AC Power Disconnect Switch.
6. Verify that AC power to the OMAX JetMachining Center was properly disconnected.

400433H-EN 4-49

OMAX
 t .
●●

7. Remove the six screws securing the access covers to the frame. Set the all screws and both
access cover places aside, exposing the ball screws and timing belts {Figure 4-87):
motor motor
adjustment adjustment
plate plate

timing belt Ij .T

jadjustment screw
[pivot screw*
'■in

timing belt
&,

Figure 4-87

8. Adjust each timing belt following the procedures provided in Inspecting and Adjusting Timing.^
Belts, page 4-46, beginning with step #6a. A

9. When inspection and adjustment are complete, replace access covers for both sides.

Lubricating the JetMachining Center V '

The OMAX requires regular lubrication to keep moving parts running smoothly and to protect them from
drying out. Be sure to lubricate ball screws, ball nuts, linear rails, and the bearings on an annual, basis.
When lubricating, it is extremely important to use Jet-Lube’s Arctic Grease (Anhydrous, calcium ^ 2-
hydroxystearate) as specified by OMAX due to its superior lubrication qualities and excellent
performance over a wide temperature range. While there are many.excellent greases commercially
available, you cannot be sure that they will be compatible.
Caution: If the grease used is not compatible with Arctic Grease (or another brand), a chemical reaction
can occur that separate^both grease types and impairs the lubrication quaiities of both. Once
this happens, a premature failure of a bearing or associate device isprobabie. if you have been
mixing greases on your ball screws/nuts, X and Y-axis rail bearings, etc., even if you have not
had any issues, we highly recommend that you fully purge the mixture of greases with 100%
Arctic Grease.

Grease Fittings and Couplers

Two different types of grease fittings are current in use on OMAX tables: a standard zerk fitting, and a
grease cup fitting (on Motorized Z-Axis and Tilt-A-Jets only).
Grease Fitting Required Coupler Where Used
zei iippie. Standard grease gun with zerk X, y linear
Ci ■ coupler (provided with OMAX bearings, ball
machine) screws, and ball
screw bearing
housings

blunt-tip grease needle Motorized Z and

(P/N 202633) Tilt-A-Jet linear
bearings

4-50 400433H-EN

OMAX
 ■t

Identifying Lubrication Points

Use the following table to identify lubrication points for specific OMAX table models:

Caution; r/?e Jet-Lube® Arctic Grease, P/N 202335, should be used for all lubrication points except for
the Motorized Z iead screw (Figure 4-95) which uses Jet-Lube Temp Guard Synthetic
MolyDisulfide grease.

Note: Jet-Lube 550 grease, previously used to grease the Motorized-!, Tilt-A-Jet, and A-Jet Z-axis lead screws,
is being replaced by P/N 309325 Jet-Lube Temp-Guard'''^'’ Synthetic Moly grease, effective immediately.
Customers who operate in extreme conditions will benefit from the fully synthetic Jet-Lube TempGuard
grease. Begin using the 309325 Synthetic Moly grease at your next scheduled lubrication, or earlier if
instructed by Technical Support. The Synthetic Moly grease is compatible with Jet-Lube 550. For best
results, clean off excess Jet-Lube 550 grease before applying the new Synthetic Moly grease.

OMAX JetMachining® Lubrication Points

Center Models Locations
^'‘26, 2626|xp, 2652, Y-axIs 4 linear bearings figure
5555. 55100 carriage 1 ball screw nut Figure 4-89
1 ball screw tail bearing
X-axis 4 linear bearings Figure
carriage 1 ball screw nut Figure 4-89
1 ball screw tail bearing
x-axis 1 ball screw bearing housing Figure
carnage (55100 and 5555) Figure 4-89
mm Y-axIs 4 linear Deanngs Figure
1 ball screw nut Figure 4-89
1 ball screw tail bearing
X-axis z linear Deanngs Figure 4-97
1 ball screw nut Figure 4-98
1 ball screw bearing housing Figure 4-99
(on each side of the 80160)
60120 Y-axis 4 linear Deanngs Figure
1 ball screw nut Figure 4-89
^all screw tail bearing
X-axis lubrication not required
Y-axis 4 linear bearings Figure
1 ball screw nut Figure 4-89
1 ball screw tail bearing
X-axis lubrication not required
Y-axis zerk fittings on back of Z-axis housing Figure 4-1'DD'
160X X-axis lubrication not required
l^/iotonzed 2-axis X-axis 4 linear bearings Figure 4-92
1 lead screw (Synthetic MolyDisulfide Figure 4-95
Grease)

4Q0433H-EN
4-51

OMAX
 Lubrication Points for Cantilever Style X, Y Carriages
Figure below identifies lubrication points for the OMAX models 2626, 2626|xp. 2652, 5555, and 55100.
All grease fittings on the carriages are zerk style.
X-axis
carriage
I X-axis linear bearings
(2 ea, on opposite sides - 4 total)

Y-axis linear bearings

(2 ea. on opposite sides - 4 total)

Y-axis
, - carriage
X-axis ball
screw nut

X-axis ball screw

bearing housing
(55100 and 5555) tj screw nut

L1UUUU5U5U7U1U

ball screw nut grease fitting linear bearing grease fitting ball screw bearing housing grease
fitting (55100 and 5355)

Figure 4-89

Greasing the X and Y Carriages

1. Move both the X and Y-carriages to their mid-positions.
2. Using soap and water, clean the bellows on both carriages to remove all abrasive particles and
other contaminates. Dry the cleaned bellows with a towel.
Caution; To prevent abrasive from falling Inside the carriages and damaging the bearings, never remove
the bellows before they are cleaned thoroughly. Even the smallest amount of abrasive
contamination can severely reduce the life of lubricated carriage components.

3. Loosen the bellows clamp at the end with the timing belt (see Figure 4-84), leaving the bellows
attached on the opposite end.
4. Pull the loosened end of the bellows back, exposing the carriage, bearings, and ball screw.
Note; This is an excellent time to conduct a thorough inspection of the internal carriage components to detect
and correct any bellows tears, garnet contamination, worn bearings, pitted bearing track, etc.

5. Locate the grease fittings on the ball screw and the linear bearings (Figures 4-88 and 4-89). For
a 55100, also locate the ball screw bearing housing.

4-52
400433H-EN
[t]
OMAX
 Note: It may be necessary to loosen the bellows clamps at both ends of the carriage to access these tail
bearings. The ball screw tail bearings do not provide grease fittings. These needle bearings are easily
lubricated by forcing grease with your finger into the end of the bearing until grease squeezes out the
opposite end.

6. Pump grease into the carriage fittings untii grease begins to squeeze out (at most, requires three
strokes with the grease gun). The,grease will emerge at some location away from the area of the
grease fitting.
7. Slide the bearing assemblies back and forth on the rail at least ten times to distribute the grease
adequately on all components. Wipe excess grease from the rails when finished.
8. After sliding the bearing assemblies, again connect the grease gun and pump grease until it
begins to squeeze out from under the assembly.
9.
Locate and grease the two baji screw tail bearings (Figure 4-88).
10. Replace the bellows after ?Tarefully inspecting them for tears or cuts. Before tightening the bellows
clamps, ensure that the bellows fully cover the internal carriage components and are not being
pinched. Moving the nozzle to compress a stretched bellows will make clamping easier.

Lubrication Points for the Motorized 2-Axis

Once a year, the four bearings in the Z-axis require greasing. You do not need to remove the Z-axis to
grease these bearings. A fitting extension (blunt tipped grease needle) that cqjjples with standard
grease guns is included with your OMAX.
y
Greasing the Z-axts Bearings
1. Both raise and lower the Z-axis while carefully cleaning
the bellows using soap and water to
remove all loose garnet and grit.
-
Note: Raising and lowering the Z-ax/s stretches the bellows and allows for a more thorough cleaning. It also
makes it easier to remove the bellows.

2. Carefully inspect the bellows for any tears or rips.

3. Using a 5/16"(8 mm)socket, unscrew the two clamps holding the bellows in place that are
identified in Figure 4-90 below;

if bellowsi

\
o
1/ unscrew these
two clamps
.a

●| bellowsi

Figure 4-90

Note:
Conduct a thorough inspection of the internal components to detect and correct any bellows tears, gkrnet
contamination, worn bearings, pitted bearing track, etc.

4. Lift up the bellows to expose the grease points on the Z-axis mechanism.

Vi
400433H-EN -f-
, 4-53

OMAX
 lubrication using Jet-Lube’s Arctic
5. There are four bearings in the Z-axis housing that require
Grease.
the Z-axis to iubricate these bearings. The figure below shows a
Note; It is not necessary to remove
disassembled Z-axis for ciarity.
rai
.1,

9
9
'Q.
I lead screv7

% lubricate
lubricate

lubricate

lubricate ©
J\ Z-axis tu5e1

[I W
Figure 4-92

against.

400433H-EN

4-54
f.
IT
OMAX
 f
wr T
.> V '●■i
, \
■ ^

«●*-.

I ff'i'

1^:,

■ ■it
. "\

. «●

.V
i-:

Ik'.."
- ^^■

<i

● ●●'*>’J-l'^

♦. Jf

2
t
 Note: In the following figure, the bellows adapter plate has been removed for picture clarity. It is not necessary to
remove this part to lubricate the Z-axis bearings.

Figure 4-93

Note: Using a flashlight makes it easier to locate each bearing and grease cup.

7. Once greased, slide the bearing assemblies up and down the rail at least ten times to distribute
the grease adequately on all components.
8. After sliding the bearing assemblies, again add grease to the four Z-axis bearing assemblies.
9. On the upper bellows, remove the bottom Z-axis bellows clamp and lift up the bellows to expose
the lead screw bearing (Figure 4-94):

iiflii
lead screw U

lead screw
upper bearing
bellows

bellows
clamp
inm

Figure

400455H-EN 4 - 55

OMAX
 10. Place a light coating of Synthetic MolyDisulfide grease on the lead screw (Figure 4-95).

h'
»; lead screw
threads
I <j
t

'■ n

fl

Figure 4-95

Note: Ensure that you work the grease deep into the thread grooves.

11. Following lubrication, reclamp the bellows to the Z-axis by raising the Z-axis as high as possible,
making reclamping easier. Tighten the clamps, ensuring that the bellows are held securely In place
and verifying that the bellows are not being pinched.
12. Once the bellows are clamped in place, run the Z-axis all the way up and down a few times to
distribute the lubrication all along the screw and rails.

Lubrication Points for Bridge Style X, Y Carriages

Bridge style JetMachining Centers include the OMAX models 80160, 60120, BOX, 120X, and 160X. Ball
screw drives are used for both the 80160 X and Y carriages, but are used only for the Y carriage on the
60120 and 80X machines. The ball screws and bearings must be greased and inspected at least once
per year.
Intelll-TRAX linear drives are use on the X carriages for both the 60120 and SOX machines and do not
require lubrication (refer to Identifying Lubrication Points on page 4-51). The 120X and larger use
linear drives for both X and Y carriages. The X carriage for the 120X does not require lubrication, but its
Y carriage must be periodically lubricated (see Lubricating X-axis Rails for the 120X and larger Bridge
Tables on page 4-59 for instructions).

4-56 400433H-EN

r X
OMAX
%
 Lubricating the Y-axis Carriages for the 80160,60120 and SOX (SOX and smaller bridge machines)

Note: Refer to Lubricating X-axis Rails for the 120X and larger Bridge Tables on page 4-59 for instructions on
lubricating the 120X Y-axis carriage.

1. Move the Y-axis to its mid-position; move the X-axis to its Home position.
2. At this time, carefully inspect each bellows for any tears or cuts.
3. Clean the bellows with soap and water. Dry the bellows with a towel.

Caution: To prevent grit from getting inside and damaging critical components, never open the bellows
until they are thoroughly cleaned and dried.

4. Loosen the bellows clamp on the Y-axIs carriage. Leave the bellows attached on the other end.
5. Pull the loosened bellows back, exposing the four linear bearings and the ball screw nut (refer to
Figure 4-89).

Note: Conduct a thorough inspection of the internal components to detect and correct any bellows tears, garnet
contamination, worn bearings, pitted bearing track, etc.
6. Attach the grease gun to the zerk fittings and pump grease (three strokes at the most) into each
lubrication point (four linear bearings, two ball screw nuts, two bearing housings) until they fill and
the grease just begins to emerge.
7. Slide the bearing assemblies back and forth on the rail a few times to distribute the grease
adequately on all corhponents. Wipe excess grease from the rails when finished.
8. Locate and grease the ball screw tail bearing at the end of the Y-axis ball screw (Figure 4-88).

Note: It may be necessary to also loosen the bellows clamps at both ends of the carriage to access these tail
bearings. The ball screw tail bearing does not provide a grease fitting. These needle bearings are easily
lubricated by forcing grease with your finger into the end of the bearing until grease squeezes out the
opposite end.
9. Inspect the bellows adapter ring for any signs of water intrusion inside the bellows. If leakage is
detected, refer to Maintaining the X-Y Carriage on page 4-45 for repair instructions.
10. Replace the bellows after carefully inspecting them for tears or cuts. Before tightening the bellows
clamps, ensure that the bellows fully cover the internal carriage components and are not being
pinched. Moving the nozzle to compress a stretched bellows will make clamping easier.
11. When finished greasing, slide the bellows back over the carriage components, reinstall and
retighten each bellows clamp.

Lubricating 80160 X-axis Rails

Note: The X-axis linear drives for the 60120, SOX, and larger machines do not require lubrication.

400433H-EN 4-57

OMAX
 1. Remove the oval access covers from both sides of the 80160. Set the 6 removed screws and
cover aside for safekeeping.

oval access
cover

Figure 4-96

Note: inside the rail covers and on each side of the tank are two linear bearing grease fittings, one ball nut
grease fitting, and one ball nut bearing box grease fitting. To access these fittings, it is necessary to move
the Y-axis until each fitting is positioned in front of the oval access hole.

2. Position the Y-axis until the ball screw net appears inside the oval access hole (Figure 4-97);

ball screw bearing

housing [ball screw

ball screw nut

grease fitting

NOTICE linear bearing

Avoid mochinery damage. grease fitting
Only we OAAAX Grease
port number 202335
■■V I .a

Figure 4-97

3. Pump grease into each fitting until grease begins to emerge from each bearing (at most three
strokes with the grease gun). Repeat this for the same bearings on the opposite side of the tank.

Note: The ball screw nut provides a zerk grease fitting; the linear bearing provides the flush style grease fitting.

4. Again, move the Y-carriage until the other end of the ball screw bearing housing (Figure 4-97) is
positioned in front of the access window with its zerk grease fitting accessible (Figure 4-99).

4-58 400433H-EN

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OMAX
 ball screw bearing housing
lubrication fitting (zerk)

,|ball screw baling housing ]

V-.

[ball screw]

Figure 4-98

5. Pump grease into this fitting as described earlier; repeat this for the same fitting on the opposite
side of the tank.

Note: It is normal to see large amounts of grease on the outside of the ball screw bearing housing.

6. Locate the second linear bearing for the X-axis rail (Figure 4-99) and grease it appropriately.
Repeat this for the same bearings on the opposite side of the tank.

Avoid IT
Onlyu
port
,-y

Figure 4-99

7. After applying the grease to all the 80160 X-axis grease fittings, move theY-carriage along the
80160 rail for the full length of the machine at about 25"(64 cm)per minute to distribute the grease
along the rail
8. Complete the X-axis lubrication process by replacing each oval access plate.

Lubricating X-axis Rails for the 120X and larger Bridge Tables
Note: It is not necessary to remove the bellows to lubricate the 120X Y-axis carriage. Easily accessible zerk
fittings are available for Y-axis lubrication.

1. Position the nozzle to allow easy access to the back side of the Z-axis.
2. Locate and remove the access cover to the Y-axis grease fittings (Figure 4-100).

400433H-EN 4-59

OMAX
 NOTCE
9
NOTICE

access cover remove grease miing

access cover zerk fittings for
lubricating the 120X
M
Figure 4-100
Y-axis carriage

3. Use a clean rag to wipe off each zerk fitting, removing any old grease, dirt, garnet, etc.
4. Attach the grease gun containing OMAX specified grease and inject up to 4 pumps of grease in
each fitting.
5. Move the nozzle all the way across and back the entire Y carriage range ten times to distribute the
grease adequately.
6. Lubricate each zerk fitting a second time.
7. Wipe off any excess grease from the fittings and reinstall the access cover.

Maintaining the MAXJET® 5i Integrated Nozzle

Note: The following nozzle instructions do not apply to the MAXJET5 nozzle Assembly. See the OMAX Support
site for a copy of those procedures.

Introduction
The MAXJET 5i Nozzle Assembly is guaranteed for 500 hours (prorated for use) if installed, operated,
and maintained with proper procedures. The diamond orifice and carbide disc are intentionally fixed
inside the nozzle body to ensure internal component alignment. The permanent component alignment
produces an accurate jet stream whenever you cut.

Caution: The MAXJET 5i Nozzle Assembly contains an integrated nozzle body(Figure 4-101). The
components in the integrated nozzle body(shown in the exploded diagram) are factory-
assembled and should not be taken apart. Doing so will void the component warranty.

Once the integrated nozzle body reaches or exceeds 500 operating hours and the performance
degrades, replace the whole nozzle body, if you suspect premature nozzle degradation, contact OMAX
or MAXIEM Technical Support for assistance.

4-60 400433H-EX

K
OMAX
 MAXJET 5i I
nozzle body

Mixing

Mixing Tube Collet

Mixing Tube

Figure 4-101

Nozzle Removal
To remove the MAXJET 5i Nozzle Assembly, follow these steps:
1. Place a sheet of cardboard under the nozzle assembly on the machine to prevent any components
from falling into the tank.

Caution: Never remove the nozzle body without first removing the Mixing Tube, as it may put a large
upward force on the parts and affect orifice retainment/alignment

2. Remove the Mixing Tube Nut, Collet, 0-ring (if applicable), and Mixing Tube from the nozzle assembly
while the nozzle is still installed on the machine.
3. Remove the integrated nozzie assembly from the machine.
4. Clean the nozzle inlet body.
5. Replace the nozzle Filter Seal Assembly.

Nozzle Cleaning
The MAXJET 5i Nozzle Assembly should be cleaned once a week. To clean the integrated nozzle body
follow these steps;
1. Submerge the integrated 5i nozzle body into an ultrasonic cleaner filled with white vinegar.
2. Run the ultrasonic cleaner for 3-5 minutes or until the jewel orifice is clean.
3. Rinse the nozzle body with clean water prior to reinstalling.

Nozzle Installation
Remove any existing nozzle assembly from the machine (if applicable) then install the MAXJET 5i Nozzle
Assembly to the nozzle inlet body by following these steps:
1. Put a small amount(a light sheen) of Blue Goop on the threads of the nozzle inlet body and on the
threads of the MAXJET 5i Nozzle Assembly.

Caution: Do not over tighten as this wii! damage the alignment of the orifice assembly inside the nozzie
body. The plastic Ring Seal on the Nozzle Filter Seal Assembly, in the inlet body, accomplishes
the sealing without excessive tightening.

400433H-EN 4-61

OMAX
 2, Carefully screw the MAXJET 51 Nozzle Assembly onto the inlet body and hand tighten until snug (not
to exceed 25 ft-lb; 33.5 N.m)
3. Insert the Mixing Tube so it sits firmly against the mixing chamber inside the nozzie body.

Caution: Never install and tighten the Mixing Tube, Mixing Tube Nut, and CoUet on the nozzle body
unless the nozzle body is installed on the inlet body. Doing so can put upward force on the
integrated nozzle components moving them out of alignment.

4. Hold the Mixing Tube firmly in place and then attach the Collet, 0-ring, and Mixing Tube Nut.
5. While holding the mixing tube in place, tighten the nut to a snug fit with an 11/16" open-end wrench.
To counteract any torque, place a 1" open-end wrench on the hex of the nozzle body while the nut
is being tightened. Tighten up to 25 ft-lb (33.5 N.m). Do not exceed!

1" open-end

nozzle body

13/16" open-end J. collet and nut

mixing tube

Figure 4-102

If you have a leak, ensure all components are clean and free from dirt and abrasive, and then replace the
Ring Seal and 0-ring (apply a light film of Lubriplate to the 0-ring and Ring Seal). Over tightening will
damage the sealing surface.

Removing the Filter Seal Assembly from the Inlet Body

Nozzle Filter Seal Assembly

The nozzle filter is a consumable item that should be discarded and replaced each time you replace the
orifice or disassemble the nozzle for maintenance. See Figure 4-104 for a filter example.
1. Screw the filter seal assembly removal tool up into the filter seal assembly.

filter seal assembly !-●

filter seal assembly

removal tool

Figure 4-103

2. Pull the removal tool straight down to remove the filter seal assembly from the inlet body.
3. Unscrew the removed filter seal assembly from the removal tool and discard it. The filter seal
assembly is a consumable item and will be replaced.

4-62 400433H-EN

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 Install the Nozzle Filter Seal Assembly
1. Apply a light coating of Lubriplate to the filter’s o-ring.

Figure 4-104

2. Slide the lubricated o-ring onto the filter.

3. Push the filter with o-ring installed up into the Inlet body.

filter installed In
'Inlet body

Figure 4-105

Note: The nozzle filter seal assembly will be properly seated when the nozzle body is tightened.

Caution: The nozzle body uses a soft filter, not a high-pressure metal-to-metal seal. Do not over tighten!
The ring seal and O-ring make the seal, not the torque of the body. Over tightening will not fix a
leak and most likely creates additional repair issues. If you have a leak, inspect the sealing
surfaces and replace the seal.

Removing the Nozzle Body 0-Ring

O-rings should be removed for inspection and replaced when necessary.
1. Remove the o-rIng from the nozzle body.

nozzle body

o-nng

Figure 4-106

2. This o-ring is a consumable item and should be replaced when necessary.

Cleaning and Inspecting Nozzle Components

Cleaning
Cleaning nozzle assembly components and maintaining cleanliness is critical. Any contamination, such
as particles of garnet, metal chips, or small pieces of paper can negatively impact cutting.

400433H-EN 4-63

[t]
OMAX
 1. Make sure your work space is kept clean and free of contamination and your hands are clean prior
to handling clean nozzle components. In general, you should wash all parts using a non-abrasive,
mild soap with water, or use an ultrasonic cleaner.

Note: A small ultrasonic cleaner containing white vinegar is useful in cleaning nozzle parts and is recommended
for removing material buildup in the orifice orjewel assembly.

2. Ensure that dirt and grit are removed from all nozzle parts.
3. Rinse each part using clean water and carefully blow dry.

Figure 4-107

Caution: Use of any damaged or defective nozzle component will negatively impact performance of your
OMAX abrasivejet.

Orifice or Jewel Assembly

The MAXJET 5i body contains a diamond that requires cleaning and replacing if damaged. The hole in
the jewel is very small, approximately 0.014"(0.36 mm)in diameter for the MAXJET 5i orifice assembly
and 0.010"(0.254 mm)in a Mini MAXJET 5i assembly. Water travelling through the orifice is accelerated
to extremely high speeds. The jewel may have mineral buildup that is difficult to see with the naked eye.
The jewel can also be plugged, worn, or misaligned.
In Figure 4-108, note that in example A the edges are clean and sharp and the center hole is completely
round. No damage appears in the area around the hole, and no deposits are plugging the hole as seen
in example B.
r●
A

f^ ●

1 \
\ fv.' V

●V

Figure 4-108

Variables including elevated water temperature and pH, plus the presence of scaling ions such as
calcium, magnesium, or silicon. Ions can cause scale to build up in and around the internal diameter of

4-64 400433H-EN

OMAX
 the orifice. Mineral deposits, or scale, in the internal diameter of the orifice can form a hollow cone
surrounding the small hole in the center of the jewel. Eventually, this buildup results in poor jet quality.

Figure 4-109

If in-line filters are not used, particles that are too large to pass through the orifice will plug or damage it,
causing the pump to fault. A fine particle filter, called the "last chance filter,” is installed just before the
orifice to prevent particles upstream in the high-pressure system from entering the orifice.
If a jewel is damaged, misaligned, or not producing a well-formed jet, the life of the nozzle assembly and
the mixing tube will be dramatically reduced.

Mixing Tube
Although the mixing tube (Figure 4-101) is made from an extremely hard material, over time, the flow of
high-pressure water and abrasive will wear away the inside of the mixing tube. This results in a gradual,
irregular widening of the internal diameter of the mixing tube, causing a less accurate stream of abrasive
and water. Figure 4-110 provides some examples of worn mixing tubes. A cross section of these mixing
tubes reveals the irregular wear of their internal diameter.

Figure 4-110

The mixing tube is also very brittle and easily broken if dropped or struck hard. The key to a long mixing
tube life is maintaining a healthy orifice or jewel. Damage to mixing tubes caused by misaligned jets or a
damaged jewel is not apparent when looking through the bore of the mixing tube. The size of the kerf
and cutting performance are the best indicators of mixing tube wear. The kerf is the width of the cut
made by the abrasivejet. It can range from 0.015"(0.38 mm)to 0.060"(1.52 mm), depending on the
nozzle, the thickness of the material being cut, and the amount of wear on the mixing tube.
A clogged mixing tube is most frequently caused by using contaminated abrasive. Because the opening
in the mixing tube can be as small as 0.030"(0.76 mm)on a MAXJET 5i and 0.021"(0.53 mm)on a
Minijet, even a small particle of dirt can clog it. Other potential causes of clogging include contaminated
or wet abrasive. Metal chips from other shop operations and paper from the abrasive bag are two
common sources of contamination. Clean the mixing tube and inspect its inlet and outlet ends to see if it
needs to be replaced.
If the mixing tube is clogged, try to dislodge the blockage as follows;

400433H-EN 4-65

OMAX
 1. From the OMAX Make software, dick the Test button to display the Test Pump and Nozzle
options:
'iT^Test Pump and Nozzle
Warning:
Some of Uieie operateos wl Irmedelely ec1:va:e the
cutwgheaO. eeaore that the rtozzte 'a oomng naaale
anOOeantOOiedon. ConsOei(let ring hlo naterial
can cejMconMeielHespinh and Inal frugal an
angl:canbedan}eraj3l9F«ncnnelo'eijuipnerd ti
aOOlon do ret fire the nozze ferexterded amounSsf
tire Vpin labcpethe water level, ai CergM canqjPCUy
node die Mdsm of the lark.

Salad Ihelealo run

C ABraava Only
1“ Pvmp On^ <Ounp VaVe open)
(● ^Aatar Ony (Pwnp a
vrater and Abrasrre (^mp b adive}
-Punp Preaaate
(S High
C tow

\~3
Otaaton of teal MBonde

Strtlet

Xo=*«iSi I

Figure 4-111

2. Select High for Pump Pressure, check Water only (pump Is active), then click Start Test to
begin the jet stream.
3. Try turning the water only test ON and OFF a number of times in an attempt to dislodge the clog.
4. If that does not work, shut down the machine by following all required power shutdown and safety
procedures.
5. Remove the mixing tube from the abrasivejet nozzle, turn it upside down, and tighten it in the
nozzle body.
6. Start up the JetMachInIng Center.
7. Again, click the Start Test button and repeat the Water only test to try and dislodge the clogged
material.

mixing tube
upside down

« .
I

Figure 4-112

Maximizing Nozzle Life

There are a number of simple things you can do to maximize the life of your nozzle components;
● Don't change the Mixing Tube simply because the jet stream looks wide.
● Cut test parts and do kerf checks on a regular basis to see when cutting performance begins to
degrade.
● If the surface quality and accuracy are as expected, continue using the Nozzle Assembly.

4-66 400433H-EN

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OMAX
 ● If the quality of the cut part is not as expected, prompt correction of the problem minimizes
complications.
● Take advantage of features in the OMAX Make software that allow the using of different offset
values and mixing tube diameters to adjust for Mixing Tube wear.
● Maintain part tolerances and extend Mixing Tube life by entering the correct offset value in Make.

All nozzle components are negatively affected by contamination, dirt, or other materials present in high-
pressure systems. In general, cleanliness is a key controllable factor in extending the life of nozzle
components. Some simple but effective ways to maintain cleanliness include:
♦ Keep your work area clean.
● Store spare nozzle components and other parts in sealed, clean containers or bags until ready for
use.
● Thoroughly clean all parts and high-pressure fittings prior to assembly or reassembly.
● Use an ultrasonic cleaner with white vinegar to remove mineral build-up in the orifice assembly.
● Prevent garnet contamination:
- Don't store garnet in open bags or buckets - store in closed containers.
- Use a sharp blade to open abrasive bags.
- Always keep the top of the abrasive hopper covered to prevent water from entering.
Some best practices pertaining to parts and components will also lead to extended nozzle life:
● Do not use damaged parts. Visually inspect parts and all orifices prior to use.
● Always use pump manifold and last chance nozzle filters. Inspect and replace them on a regular
basis.
● Depending on your application, and if speed and longer life are the primary concern, use a 0.042"
mixing tube instead of the standard 0.030" mixing tube. Be aware that parts will have slightly more
taper and a wider kerf,
● Use only high-quality abrasive as it contains less dust and a more uniform particle size.
● Use a Terrain Follower to help protect the mixing tube from damage during cutting.
To reduce nozzle maintenance downtime:
● Have a spare nozzle body built and ready to replace on the machine when needed.
● Have new consumable parts on hand and replace them when rebuilding the nozzle. Once the nozzle
is installed and running, determine which parts can be reused as spares in the future.

Some machine practices that will also extend the life of the nozzle and its components:
● Use a nozzle splash guard and. whenever possible, cut underwater to reduce splash-back. The
splash-back contains water, garnet, and eroded material from the tank. Figure 4-113 provides an
example of the damage caused to a Tilt-A-Jet assembly when the machine cut without a splash
guard. This is preventable damage that will affect your warranty.

Figure 4-113

400423H-EN 4-67

[t]
OMAX
 ● After servicing the pump, nozzle, or replacing a piece of hard-plumbing, always flush the system by
performing a “water only” test for several minutes with both the orifice and last chance filter removed.
● Rotate the Mixing Tube 90° following every eight hours of cutting. This distributes wear more evenly
around the internal diameter of the Mixing Tube if the orifice is chipped or misaligned.

Mini-MAXJET 5 Installation and Operation

Installing the Mini-MAXJET 5
1, Remove the existing MAXJET 5i nozzle body, orifice, and mixing tube. Leave the Inlet body in
place.
2. Install the Mini-MAXJET 5i assembly onto the inlet body.
3. Pull the abrasive valve (refer to Figure 3-23)from the bottom of the cylindrical abrasive hopper.
4. Replace the existing abrasive orifice with the one provided with the Mini-MAXJET 5.
5. Reinstall the abrasive valve.
6, Readjust the Adjustable Dump Orifice to match operating characteristics of the Mini-MAXJET 5i
assembly. Refer to Set the Adjustable Dump Orifice (ADO), page 3-4.

Operating the Mini-MAXJET 5

Caution: To avoid deadheading the pump,lower its RPM to minimum before turning ON the nozzle jet.
When operating the pump at iower RPMs,see Changing Crankcase Oil on page 4-33 for
additional oil requirements. If you’re not using a variable RPM pump, contact OMAX Technical
Support.

Note: OMAX recommends using a 120-150 mesh garnet with the Mini-MAXJET 5i nozzle. To avoid plugging the
nozzle, never use 80 mesh or coarser garnet.

1. Calibrate the actual abrasive flow rate (refer to Measure the abrasive flow rate:, page 3-16).
2. Click Setup in Make and select Pump and Nozzle Settings:

Configure Display & Unfts.,,

■Zoom* Preferences...
)ob Quotes Gi Costing...

Purrp and Nozzle settings...

Event end Relay Timing...

Figure 4-114

3. Correct any values being displayed that differ from those recorded when testing your OMAX machine.
Change the “Abrasive Flow Rate” to the value you determined above (if calibration is not done, enter
0.3). Set the “Jewel (orifice) Diameter" to 0.010", the “Mixing Tube Diameter” to 0.021", and the “High
Pressure” to the value set for your pump;
FTessure al Nozzle in High Piessue Mode: [50000 PSI

Ptenuie al Nozzle in Low Piessure Mode: [20000 PSI

Jewel{ofiTice)Oiameter |0^0 inches

MbdngTubeDiameler; joOZl inches

Abcasive Flow Rale: [o3 LIVrrin

Abiastve Size: |12C| Mesh (US Standaid]

Abcasive IrtdeK [l (Use 1.0 for garnel)

Figure 4-115

4-68 400433H-EN

OMAX
 4. Click OK to save your changes.
5. The tool offset for the Mini-MAXJET 5 nozzle should be determined after some test cuts are
completed. The value of 0.012" may be used for the initial setup.

Rebuilding the Dual ON/OFF Valve

Maintenance of the Dual ON/OFF Valve is required when any of the following symptoms appear;
● Water enters the abrasive feed tube when the nozzle first fires (leaky seal).
● Water drips from the mixing tube (leaky valve stem).
● Water leaks 180° from where the UHP plumbing enters the dual ON/OFF valve (bad valve seal).
● Water drips from the UHP nipple on the dual ON/OFF valve (loose fitting, cracked body or fitting).

Removing the Dual ON/OFF Valve

WARNING!
Ensure that system is locked-out prior to service of On/Off Valve. Do not
attempt to turn ON the pump unless On/Off valves are installed and torqued to
the required settings.

21 ft-lb (28.5 N-m)

Figure 4-116 below illustrates an OMAX Dual ON/OFF Valve connected to a MAXJET 5i Nozzle:
air line fitting

air actuator assembly

dual ON/OFF valve assembly

-IMAXJET 5 nozzle

Figure 4-116

To remove the Dual ON/OFF Valve assembly:

1. Switch OFF the AC power for both the pump and table. Disconnect their main AC power breaker.
Attach an "Out of Service” tag on this breaker and observe all applicable electrical safety
procedures.

WARNING! Before removing the air line, you must first power OFF the pump! Once the air line
controlling the ON/OFF valve Is removed, the nozzle becomes active. Bleed pressurized air
from the system by releasing air from the air nozzle.

2. Remove the air line from the air line fitting on top of the air actuator assembly (Figure 4-117)
and move it out of the way.
3. Remove the air actuator assembly from the valve body using a 1-1/8" open end wrench.

400433H-EN 4-69

OMAX
 air line fitting

air actuator assembly

OMAX
1 1/8" open end
wrench
fitting ring
scs-*
valve body
(beneath
fitting ring)

fr
Figure 4-117

4. Remove the retaining screw from the valve body using the Va" open end wrench.

retaining
. screw
Va' open end
wrench

Figure 4-118

5. If possible, leave the UHP tube tightened in the fitting ring until the valve gland nut is loosened.
After that, remove the UHP tubing from the fitting ring.

Caution: Always use two wrenches when removing a gland nut!

|r open end [

[fitting ring~| v.

[gland nut

Figure 4-119

4-70 400433H-EN

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OMAX
 6. Loosen the valve gland nut from the inlet body by placing a 1-1/2" open end wrench on the
valve gland nut.
7/
r-
|1-1/2” open end
|inlet body

Ivalve gland

Figure 4-120

7. Rotate the ON/OFF valve assembly away from the high pressure nipple and remove the valve
gland nut.
8. Remove the gland nut from the fitting ring (Figure 4-119) and carry the Dual ON/OFF Valve
Assembly to a clean work area for rebuilding.
Caution: The ON/OFF seat is not secured in the valve body at this point and may fall out.

*-v

400433H-EN 4-71

OMAX
 Disassembling the Dual ON/OFF Valve
Caution: The ON/OFF valve and its rebuild location must be thoroughly cleaned prior to rebuilding.

air actuator
assembly

retaining
screw

seat
A
assembly
with 0-ring

|air line fitting [

[valve gland nut |

[stem assembly j

ON/OFF
seat
screw
[acorn nut ~| I - I “,
●o;
I

[valve body~|

Figure 4-121

1. Ensure that your working area for rebuilding this assembly is clean with all required tools and
materials available (see page 4-39 for list).
2. Pull the fitting ring and valve gland nut from the valve body.
|0-ring ^fitting ring

|ON/OFFsear|,tj ^.-[stem assembly

[valve body
[valve gland nut

Figure 4-122

4-72 400432H-EN

OMAX
 3. Use the needle nose pliers to remove the stem assembly from the valve body.
-lUHPtube ]
=:|Ming ring I
valve body
I^em assembly
seal assembly - 4
[needle nose pliers

Figure 4-123

A. If the seal assembly remains in the valve body, use the end of an Allen wrench (or other long tool
approximately 3mm in diameter) to push the seal assembly out of the valve body.

[valve bod^,J
[Allen wrench [stem assem^y [
f
Figure 4-124

5. Clean all parts not being replaced in the repair kit. Discard the used ON/OFF seat, seal assembly
with o-rlng and stem assembly.
stem assembly \
l^/OFFseat|

«
[seal assembly
|

Figure 4-125

Note: All items included in the Dual ON/OFF Valve Repair Kit must be used. Do not reuse any parts that are
provided in the repair kit. Reusing these parts will decrease the life of your rebuilt ON/OFF valve assembly.

6. Carefully inspect the valve body for cracks and other defects. Cracked and damaged parts must
always be replaced.

Reassembling the Dual ON/OFF Valve

1. From the ON/OFF valve repair kit, locate the ON/OFF seat, the seal assembly with 0-ring, and the
stem assembly.
2. Slide the seal assembly onto the stem assembly shaft with the 0-ring facing towards the valve
body (Figure 4-127). Ensure that the s^l assembly slips over the pointed end of the stem assembly.
3. Lubricate both the seal assembly 0-Ring and the stem assembly with Lubriplate grease;

seal assembly with 0-ring

towards valve body

|0-ring
| [stem assembly

Figure 4-126

400433H-EN 4-73

OMAX
 4. Lightly coat the valve body bore down past the threads to the internal lip with Lubriplate grease:
Lubriplate

[valve body

Figure 4-127

5. Tightly grasp the stem assembly with the seal assembly installed and gently push them down Into the
lubricated valve body bore:
[valve bo^
assemblies
[stem and seal

% fc:

Figure 4-128

Note: If the stem assembly body resists insertion into the valve body because of the seal assembly 0-ring, push
the stem assembly body in using the end of an Allen wrench (or equivalent long tool) until the internal
threads of the valve body are exposed.

6. Apply some Blue Goop onto the threads of the retaining screw and install it in the valve body using
the %" open end wrench.

[valve body
f %" open end on
y ,/lretainlna screw
/
retaining screw

Figure 4-129

7. Apply Blue Goop to each end of the ON/OFF seat where it will contact the valve body and also
where it will contact the bulkhead adapter. Insert it into the valve body (or place it in the inlet body).

[Blue Qoo^

ON/OFF seat

Figure 4-130

8. Slide the valve gland nut and fitting ring onto the valve body (refer to step #2 in the disassembly
instructions).
^fitting rin^

'|valve body|
[valve gland nut X*.

Figure 4-131

9. The repair of the Dual ON/OFF Valve is complete.

4-74 400433H-EN

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 Installing the Dual ON/OFF Valve
1. Verify that the ON/OFF seat remains in the valve body. Hand tighten the valve gland nut onto the
nozzle inlet after rotating the valve body so that the UHP line is in alignment with the opening in the
fitting ring:

|valve body

correct UHP line

alignment with [fitting ring"

|valve gland nut |-

Figure 4-132

2. insert the UHP input line into the fitting ring. Ensure that the threads on the high-pressure line have
been applied with anti-galling compound (Blue Goop) and that three threads are showing (see Three
Thread Rule, page 4-43).
|Blue Goop"
V.'
|three threads
IL A ^

Figure 4-133

3. Tighten the UHP input line using the 13/16" and 1" open end wrenches. Tightened to 50 ft-lb (no
greater than 75 ft-!b). Refer to Figure 4-119.

Note: When tightening the gland nut, ensure that the ON/OFF valve remains square to the UHP line to eliminate
stress on the UHP line.

4. Apply a small amount of anti-galling compound (Blue Goop)to the threads of the valve body.

valve body
^ [threads

Figure 4-134

5. Reinstall the air actuator assembly. Use the 1-1/8" crows foot and torque to 21 ft-lb (28.5 N-m). Refer
to Figure 4-117.
6. Re-attach the air line to the air line fitting on top of the air actuator assembly. Refer to Figure
4-116.

400433H-EN 4-75

OMAX
 7. Prior to use, remove the nozzle body (1" open end wrench)and jewel. Flush the system for at least
5 minutes using the Test button in Make. Select High pump pressure, Water Only, and click
Start Test.
Aclio*)

ChanoBWSdiolPreview to Scfaenl Be^iMacW Test Saw

|Test

Ct^Test Pump and Home

Warning:
Stirne of these o?eriticr« wl inneeiateiy actvatethe
cuRing heod. Ce sjre hat the nozat: is i»<itirg in a safe
and desred ilieclon Csnsidef tnat trngiMotnetenal
can cause consceraMesp'ash,ato that liingal an
anglecanbeda'tgefoustopersor.r.etsreoiiicrTienl In
addaion, danelhielhe nozzle lorextemled iteuntsol
tiT« want above the water layel asdoagsocanqjcU/
rrcde the bottsm of die ant

SelaetlvalarMrun
C Ah'satra Ci>V
r PuTeOfJy tDunpVairt open)
jwater only | —● (● ^at«fOvV(P>riplaKfwet
r Wa»ra’>d.iibiaswe(P«mp»»ar»»)
r ftarp Pressure. '

jhigh pressure | p Mlgh

; r Low

3
Ouralian Of teal aeuvla

[ S’»t Teel

Figure 4-135

8. After five minutes of flushing, re-install the nozzle body and jewel. Torque the Dual ON/OFF Assembly
to the nozzle body at 30 - 40 ft-lb (40.6 - 54 N-m).
9. Following installation, test nozzle operation using high-pressure water only. Refer to Figure 4-135.

Note: During a high pressure condition, check for visible leaking from the weep holes. If water leaking is present,
the sealing is not complete between UHP fittings. Refer to Maintaining the High-pressure Plumbing
System on page 4-42.

PC-based Controller Maintenance

Cleaning the OMAX Industrial Keyboard and Mouse
The OMAX keyboard and mouse are industrial components designed specifically to withstand exposure
to the water and abrasive particles presented in an abrasivejet environment.
The OMAX mouse is water-resistant, but not water-proof. To prevent water from getting inside the LED
lens, don’t operate the mouse on a wet surface. If the mouse does get wet, spray it with a soft blast of air
to help dry it out. if you get dirt on the bottom LED lens, use a clean Q-Tip to remove it.
The surface of the OMAX keyboard may be cleaned by brushing off the abrasive or wiping it clean using
a soft rag lightly dipped in mild soap and water. When cleaning, always unplug the keyboard first and, if
cleaning with water, prevent the water from entering the disconnected keyboard connector. Wipe the
keyboard dry using a dry cloth, or allow it to dry in room air. When finished, be sure to reconnect the
keyboard cable.

Cleaning the LCD Monitor Screen

Do not use a glass cleaner (Windex®, ammonia based, etc.) to clean an LCD monitor screen. It can
damage the screen surface. The screen should be wiped off using a lint-free cloth. To remove any

4-76 400433H-EN

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 particles or stains from an LCD screen, ensure that the monitor is first turned OFF. Gently wipe its
surface using a lint-free cloth dampened with a small amount of distilled water.

Replacing the Cabinet Air Fiiter

Beneath the OMAX PC-based controller is an air filter on the intake fan that prevents the controller
cabinet from overheating. This filter blocks room dust and dirt from entering the computer along with the
cooling air. Once this filter becomes plugged, air flow into the controller is restricted, causing the
computer and associated PC-based controller components to overheat. Under normal shop conditions,
you should clean or change this air filter every three months. If your OMAX is operating in an excessively
dusty environment, check the filter at least monthly. Checking it should become part of your routine
maintenance program.

Replacing the CMOS Battery

A small, coin-sized battery in your computer powers the PC’s CMOS memory. It’s important to include
changing this battery in your long-term maintenance schedule. If your battery fails and your CMOS
memory stops running, the computer will reset its BIOS settings to their default values. Fortunately,
CMOS batteries typically can last for 5-10 years.

Figure 4-136

Clues to a CMOS battery failure

According to Dell Support, the Windows XP Pro computers informs you with a text warning when
CMOS battery power is low; this message displays during the initial boot sequence. This warning
should provide enough time to replace the battery. If the battery is dead, all is not lost. The computer
typically continues to boot from the hard drive installed in the computer, Keep your hardware and
software interface intact. Change the battery at least once every three years. Before you change the
battery, please contact OMAX Customer Service for specific details.

Rebooting Windows
Microsoft Windows is a complicated operating systems. It manages ail memory, disk reading and writing,
and memory operations for every program that run on your computer.
The following guidelines will help minimize operating system problems:
● Reboot Windows at least once a day
Even if everything seems to be fine, reboot Windows at least once per day. if any memory problems
have crept in, this will clear them.
* If a program crashes, always restart Windows
If any program behaves weirdly, or crashes, restart Windows. This clears out memory and makes
sure that you start “fresh.” Once Windows becomes “confused,” it rarely fixes itself, and usually
causes more problems.
● Wait for Windows to finish booting
Windows takes awhile to boot, and it may be tempting to get started before it's finished loading. Wait
until all disk activity is done before you launch any programs. You can also monitor activity in
Windows XP using Task Manager (press Ctrl+Ait+Del) to check when CPU usage has dropped to
zero.

Running the Disk Defragmenter Utiiity

When Windows saves a file on the hard drive, it stores this file in whatever memory locations are
currently available. A disk defragmenter utility goes through the entire hard drive, combining all the file
fragments into a single location which greatly speeds up the file assembly process.

400433H-EN 4-77

OMAX
 To run the Windows Disk Defragmenter utility:
1. Click the Start icon.
2. Select All Programs.
3. Select Accessories.
4. Select System Tools.
5. Select Disk Defragmenter.
6. Select the drive to defrag and click Defragment.

Note: Depending on how badly fragmented your hard drive is, it can take anywhere from ten minutes to a few
hours to finish. Do not run other programs while it is working -just leave it alone until finished.

Upgrading Your OMAX Software

The OMAX Technology Guarantee entitles you, as the original owner, to free OMAX software upgrades
for the life of your machine. You may acquire as many software seats as needed for off-line
programming. Always keep your OMAX software up-to-date. Software updates are always free and
available from the OMAX Customer Support Web site at www.omax.com/support. To gain access, you
need a user name and password, which you can obtain by contacting OMAX Technical Support.
New versions of the software are typically posted once or twice a year and will automatically overwrite
your existing version when installed.

Caution: You should not uninstall the current version of your OMAX software before successfully
installing its replacement You may lose valuable history and settings files, causing your
OMAX machine to make substandard parts. Simply run the installation program for the new
software to install it

Caution: Before upgrading your OMAX software:

● Do not uninstall your existing OMAX software!If you do, you may lose important machine
and material settings as well as history files.
● Always reboot Windows before installing software updates. This ensures that existing
software copies are not running and Windows is properly initialized.
● After rebooting Windows, do not run other programs prior to installing your OMAX software
update. Other programs could conflict with the software installer.
● Do not change the suggested installation settings. In particular, you should use the
suggested installation location unless you have a good reason not to. if you don’t use the
default settings, future upgrades must be installed to the same non-standard directory to
work correctly.
● If you are upgrading a computer connected to an OMAX, be sure to shut down the computer
and turn if OFF after the installation is completed(you will be reminded to do this by the
install program). Otherwise, the software may not correctly control the OMAX.

7.

4-78 400433H-EN

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 Chapter 5
Troubleshooting the OMAX Table
This chapter provides information for servicing the JetMachining Center. Troubleshooting procedures are
provided that are useful when analyzing performance issue that may occur during operation of your OMAX
equipment.

WARNING! All service activities must be performed by OMAX qualified personnel.

Troubleshooting the OMAX JetMachining Center

The following lists most problems encountered with OMAX operation, Possibie causes for each probiem are
provided with the most iikeiy causes listed first. If you continue having a probiem with your OMAX after
foiiowing these procedures, contact OMAX Customer Service,

Problems
Refer to Solutions on page 5-4 to match a Corrective Action number listed below with the steps suggested to
correct specific problems.
Condition and Possible Causes Corrective
Actions
Abrasivejet Nozzle Doesn’t Move
The Emergency Stop button was pressed. 1
A soft limit has been reached. 2
A babysit condition was triggered. 3
Wires or connections in the computer may have become loose. 4
Servo motors stalled. 5
Machine stops running with no messages and unable to close Make. 6
Parts are Too Short, or Flat Spots Appear When Cutting Curves
The part was not held firmly enough. 7
The OMAX is reaching its hardware limits. 8
Home Position or Soft Limits are Lost
The OMAX reached its hardware limits. 8
Wires or connections inside the controller may have loosened. 4
Poor Surface Finish
Setup values in Make are not consistent with the actual physical values. 9
Standoff height is not set correctly. 10
Jet stream is too wide. 11
An abrasive other than garnet is being used and the "Abrasive index” value was not changed to 12
compensate for its lesser cutting ability.
The mixing tube has worn excessively and is no longer capable of producing the required jet stream. 13
The jewel that forms the jet is chipped, dirty, or out-of-tolerance. 14
The abrasive flow has stopped or has been reduced by dirt or wet abrasive. 15

400433H-EN 5-7

OMAX
The high-pressure water pump is not delivering the pressure called for in the setup screen. 16
Holes Too Large and Undersized Parts
The tool offset is set incorrectly 17
Tool offset is on the wrong side of the path. 18
Excessive Taper on Part Edges
The cut was made with the quality value set too low. 19
The standoff between the abrasivejet nozzle and the material is excessive. 20
Setup values in Make are not consistent with the actual physical requirements. 9
An abrasive other than garnet is being used and the “Abrasive Index” value was not changed to 12
compensate for its lesser cutting ability
The mixing tube is worn and unable to form a perfect jet stream. 13
The jewel that forms the jet is chipped, dirty or out of tolerance. 14
Holes are Not Round
The cutting material is not securely fixtured. 7
The jet is elliptical rather than round due to wear in the mixing tube or a slightly imperfect orifice. 14

Abrasivejet Not Piercing Material

Setup values entered in Make are not consistent with the actual physical requirements. 9
An abrasive other than the recommended garnet is being used. 12
The standoff between the abrasivejet nozzle and the material being cut is too high. 20
The abrasive flow is stopped or has been reduced by the presence of dirt or wet abrasive. 15
The mixing tube has worn excessively and is unable to form a perfect jet. 13
The jewel that forms the jet is chipped, dirty or out of tolerance. 14
The pump is not delivering the pressure specified in the setup screen. 16
Abrasivejet Quit Cutting
The abrasive flow is stopped or has been reduced by the presence of dirt or wet abrasive. 15
The mixing tube in the abrasivejet nozzle is plugged. 21
The jewel orifice is plugged with foreign material. 22
The pump is not delivering the pressure specified. 16
The nozzle abrasive hose is worn out and is collapsing or leaking 15
80160 Not Cutting Square Parts
The Y-axis is no longer exactly perpendicular to the X-axis. 23
Accuracy Errors
The material being cut is improperly secured. 24
The nozzle is inadequately secured. 25
The material being cut has internal stresses. 26
Temperature caused the material to expand. 27
The nozzle and material collided. 28
The nozzle is worn out-of-round. 29
Water is Forced Up the Abrasive Tube

5-2 400433H-EN

OMAX
 Nozzle body is loose. 25

The ON/OFF valve Is leaking. 34

The mixing tube in the abrasivejet nozzle is plugged. 21

The inlet body or valve body is damaged. 30

The standoff distance is so small that the nozzle is plugged by the work piece before it starts cutting 20
and water is deflected to the abrasive tube.
The high-pressure pump is not delivering the pressure called for in the setup screen. 16

The Jet Looks Wide and Fuzzy

The jewel that forms the jet is chipped, dirty or out of tolerance. 14
The mixing tube is worn and unable to form a perfect jet stream 13
No Abrasive Flow
The abrasive flow is stopped or has been reduced by the presence of dirt or wet abrasive. 15
The standoff distance is so narrow that the nozzle is plugged by the work piece before it starts
20
cutting and water is forced up the abrasive tube.
The shop air pressure is insufficient to open the abrasive valve. 31

No Abrasive Flowing from the Abrasive Tube

The abrasive flow is stopped or has been reduced by the presence of dirt or wet abrasive. 15
The standoff distance is so low that the nozzle is plugged by the work piece before it starts cutting 20
and water is deflected to the abrasive tube
The shop air pressure is insufficient to open the abrasive valve 31
Warped Material 26
Clogged Mixing Tube 33
Leaky ON/OFF Valve 34

Water Comes Out the Top of the Abrasive Feed Tube

The abrasive flow is stopped or has been reduced by the presence of dirt or wet abrasive. 15
The standoff distance is so low that the nozzle is plugged by the work piece before it starts cutting 32
and water is deflected to the abrasive tube
Foreign material in the water line has plugged the jewel. 22

Water Spurts Out of the Tank

The part is positioned on top of a slat, causing the jet stream to reflect upwards. 35

Abrasive Piles Up on the Work Piece

The accumulation of abrasive silt at the bottom of the tank is excessive. 36

The Table Has an Unpleasant Odor

Excessive bacteria growth in the tank. 37

Keyboard or Mouse Fail to Work

No mouse movement. 38
Keyboard not responding. 39
Blue Screen Errors
Loose USB cable. If the USB cable is unplugged while Make is running, the monitor will blue-screen. 40
Corrupt device driver 41
(I
Babysit Triggered” Message

400433H-EN 5-3

OMAX
Low air pressure 31,3
Fault in a servo circuit 42, 3
Pause button pressed 43,3

Access Control Circuit triggered. 44, 3

(European Market only)

Solutions
Refer to Problems page 5-1 for a list of problems encountered.

Corrective
Action Description
Turn the Emergency Stop OFF and then ON again and reset the homes and soft iimits. Because your
1 soft limits may be incorrect after using the emergency stop button, you can disable them by entering
zero for the X and Y- limits
Use the jog buttons to move up and down (if you have hit a soft limit, only one of those directions will
2 be blocked). Auto homing should recover the soft limits, if the soft limits are lost, refer to the help
menu in Make for instructions on setting new limits.
Note: You may want to reset your soft limits if they are too small.
The OMAX has several switches monitoring machine operation. When any of these switches are
triggered, the abrasivejet nozzle immediately stops operation and no longer continues machining or is
able Jo be moved. When an attempt is made to restart operation, a “Babysit Triggered" error message
3 appears. To recover from a babysit condition, first, correct the cause that triggered the babysit, then
hold down the Override switch on the controller front panel.
Caution: Ensure that you know what triggered the condition before attempting a babysit override.
Continuing to operate the OMAX by overriding these switches may damage the OMAX. if you are
unable to determine what triggered a babysit condition, contact OMAX Customer Support.
4 Turn OFF the power and open the back of the electrical cabinet. Test each connection and make sure
the connectors are firmly seated. Close the cabinet, turn the power back ON and try again.
This condition could be caused by:
● Nozzle collision
● Mechanical issue (sticky ball screw, etc.)
5 ● Incorrect servo tuning
● Incorrect speed, acceleration, or jerk setting
Cycle power to the machine.
Return the nozzle to Path Start Home. If Path Start Home is lost, auto homing should recover Path
Start Home.

6 Severe noise or noise spike on USB cable caused the device driver to lock. Rebooting the PC is
necessary.
7 The part moved during the cutting due to nozzle drag or upwelling of the water beneath the part. Make
sure the part is securely fixtured. This is the most common reason for scrap parts.
Move the work piece toward the table’s center. Set soft limits that allow you to be warned before
8 hardware limits are reached.
Note: Auto Homing should recover all positioning for the waterjet, including soft limits.
Check that the following data is correctly entered for setup in Make:
♦ Machineability—thickness
Click Setup in Make and choose Pump and Nozzle Settings/Pump and Nozzle Configuration and
verify that the following parameters are set correctly:
9
● Water pressure
● Orifice diameter
● Mixing tube diameter
● Abrasive flow rate

10 Click Setup in Make and choose Pump and Nozzle Settings/Motion and verify the standoff is set at a
height of 0.040 - 0.080" (0.1 - 0.2 cm).

5-4 400433H-EN

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 Raise the nozzle approximately 1.5"(3.8 cm)and initiate a high pressure, water-only test. Ensure that
the jet stream is narrow and sharp. If the jet stream is wide, replace the orifice jewel assembly, the last
chance filter, and inspect the mixing tube. If the mixing tube’s outlet hole shows elliptical wear, or the
diameter has grown approximately 0.005"(0.127 mm), it is recommended that the mixing tube also be
replaced.
11

good jet stream bad jet stream

Other abrasives do not typically cut as well as garnet and require that the abrasive index value in the
Pump and Nozzle Configuration screen be adjusted. OMAX recommends garnet as the abrasive
because it provides a good cutting rate with relatively low mixing tube wear. Garnet is also non-
hazardous and is easily disposed. Other abrasives may increase mixing tube wear and be a disposal
12 hazard.
Warning!
Never use silica sand as a cutting abrasive. Fine silica dust inhaled during the cutting process
can lead to silicosis, a serious lung disease. Silicosis is a type of pneumoconiosis, which
includes black lung disease.
If changing the jewel does not improve the quality of the jet, then the mixing tube needs to be checked
13 and possibly replaced. Wear occurs first at the inlet with a conical wear zone growing toward the exit
end. Measure the tube bore at the two ends using a drill or gauge pin. When the outlet has grown by
0.005"(0.13 mm), the mixing tube is near the end of its useful life for precise cutting.
14 Replace the jewel and the jewel holder.

15 Disassemble the plugged items and blow them clean and dry using an air hose. Replace the abrasive
hose in the nozzle when showing signs of collapsing or leaking due to excessive wear.
16 Measure the pressure and if it is below specification, follow the directions in your pump service and
maintenance manual to troubleshoot the problem.
If not enough material is being removed (hole too small or part too large), decrease the tool offset by
half the dimensional error observed.
17 If too much material is being removed, increase the offset by half the dimensional error. By measuring
parts as they are finished, you can monitor the wear of the mixing tube and periodically reset the tool
offset to achieve more precise parts.
Switch the lead in and lead out and then use the Generate Tool Path command from Layoutio order
18 the part again.
You can check your tool offset using Preview to Screen in Make.
A Quality of 1 will just barely pierce the material and usually has significant taper. Both taper and
19 surface finish should improve as the Quality number is raised (takes longer to cut the part).
Remember that different Qualities can be set to cut different portions of the same part.
20 The standoff should be between 0.040"(1.0 mm)and 0.050"(1.3 mm)for best results on a motorlzed-
z, .060" for the Tilt-A-Jet and .080" for the A-Jet.
21 Use the software in Make to turn the water ON and OFF trying to dislodge the plug. If this does not
work, you may need to disassemble the nozzle for cleaning, or replacing the mixing tube.
22 Remove the nozzle and flush the lines. Replace the jewel with a new one.
Square the Y-axis bridge against the hard stops on the right controller side of the machine. You should
23 resquare (home)the Y-axis whenever:
● The X-axis drive motor faults.
● The Y-axis bridge crashes.
24 Always have firm anchoring in X,Y, and Z directions, even if the material is heavy. Never anchor
directly to slats. These are insecure and can easy vibrate.
25 Ensure that the nozzle is firmly attached.

26 Material stresses can cause huge part errors. As the part is machined, these stresses can cause the
material to move and stretch.
27 The material is stored in a different temperature than the tank water and changes size during or after
cutting.

400433H-EN 5-5

OMAX
 28 Avoid traversing over previously cut features.
Watch for parts or slugs that tip or float around.
29 Uneven wear on the nozzle can result in a square box being cut as a rectangle, or similar errors of up
to approximately 0.010"(0.0254 cm).
30 Inspect both parts for signs of a crack. Replace part whenever damage is noted.
31 The abrasive valve requires 70 to 95 psi (5 to 7 bars) shop air.

32 Verify that the standoff height is at least 0.040" - 0.080"(0.1 - 0.2 cm)above the material being cut
(use the specified stand-off for the A-Jet and Tilt-A-Jet).
33 Use the high pressure water test to dislodge the clog. If this does not work, remove the mixing tube
and clean it in an ultrasonic cleaner.

34 Contact OMAX Technical Support for details on troubleshooting a leaky ON/OFF valve assembly.
Refer to Rebuilding the Dual ON/OFF Valve, page 4-69, for repair instructions.
35 Contain the spray using the splash guard. A disc cut from a 2"(5 cm)thick sponge makes an effective
splash guard.
36 Remove the slats and clean out the tank.

37 Check the floating chlorine dispenser to ensure it still contains the bacteria-killing pool chemicals
supplied with the OMAX.
Verify that the mouse cable has not worked itself loose and is fully plugged into the USB port at the
rear of the PC. Also, unplug the cable and inspect the USB connector for bent or damaged pins. Verify
38 that the optical sensor on the bottom of the mouse is not blocked with dirt buildup.
Try rebooting the PC to see if this corrects the problem.
Swap the mouse with a known good mouse to see if the problem goes away, verifying that mouse
itself is at fault.
Verify that the keyboard cable has networked itself loose and is fully plugged into the USB port at the
39 rear of the PC. Also, unplug the cable and inspect the USB connector for bent or damaged pins. Try
rebooting the PC to see if corrects the problem. Swap the keyboard with a known good keyboard to
see if the problem goes away, verifying that keyboard itself is at fault.
40 Ensure that the USB cable is plugged in adequately. Reboot the PC.

41 Simply re-installing OMAX software can fix this. Be sure to fully power down the controller, wait 10 or
more seconds, then turn it back ON for all driver related changes to refresh.
Check the fault LEDs on the controller back door to identify which axis faulted.
Check the faulted servo card’s LED status indicators. Refer to figures that follow for card locations.

LED indicators for both Teknic and Teknic Eclipse Servo Drives:
42 ● Green LED ON steady or blinking at fast rate - normal operation
● No LEDs lit - power failure
● Red LED steady ON - blown fuse
● Green LED slowly flashing - servo fault
● Green LED ON steady - servo not enabled
Whenever any of the above faults are indicated, contact Technical Support.
43 Release Pause button.

44 Re-arm the Access Control Circuit.

5-6 400433H-EN

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OMAX
 X-axis servo
card
Y-axis servo card

X-axis servo card

Figure 5-1: Servo Card Locationsfor Y and X-axisfor Bridge-style Table

X-axis servo
card

‘.V
!:V
(1
.N%WrtV*W.wj. J.U Jiiu, I

Y-axis servo
card

e-U

Figure 5-2: Sei-vo Card Locationsfor X and Y-axis 2626, 2626\xp, 2652, 5555, 55100 Sei-vo Motors

400433H-EN 5-7

OMAX
 Correcting Water Leaks in the Nozzle Assembly
,f

Figure 5-3: Sources of Water Leaks in the Nozzle Assembly

Troubleshooting Leaks in the Nozzle Assembly;

(refer to Figures 5-3 above)

Leak Leak/Other Point Description Suspected Causes Recommended Action

Point

o air actuator weep hole leaky seal Verify air actuator torqued at 21 ft-lb
(28.5 N-m); replace seal

e between air actuator and fitting

ring
leaky seal replace seal

e between fitting ring and gland nut cracked body, bad UHP
tubing, loose gland nut
replace defective component; verify
gland nut torqued at 60 ft-lb (68 N-m)

o between fitting ring and valve

gland nut
cracked body; loose nut replace defective component; tighten
nut

e valve body cracked inlet or valve

body; loose nut
replace defective component; tighten
nut

between nozzle body and inlet cracked inlet or nozzle replace defective component
© body body; leaky 0-ring

e weep hole on nozzle body chipped jewel, cracked

body, leaky seal
replace defective component

5-8 400433H-EN

OMAX
 Correcting Water Leaks in the TAJ ON/OFF Valve

Figure 5-4: Sources of Water Leaks in the ON/OFF Valve

Troubleshooting Leaks in the Tilt-A-Jet ON/OFF Valve:

(refer to Figure 5-4)

Leak Leak/Other Point Description Suspected Causes Recommended Action

Point

o Leaking around the plate and not

from any weep hole
cracked inlet or valve
body: loose bolts
replace defective component; tighten
loose bolts

0 weep hole UHP adapter to body leak;

cracked body
replace defective component

0 weep hole Cracked body or leaky

seal
replace defective component

o weep hole leaky UHP seal replace leaky seal

400433H-EN 5-9

OMAX
 ♦
r.

S'
k
r>

t
I

f'
r 5-10 400433H-EN
I. /I' ■
[?]
OMAX
 Chapter 6
Troubleshooting the EnduroMAX Pump
This section provides troubieshooting procedures for the EnduroMAX pump. Most pump operations are
controiied and monitored via the front panel keypad display. If you are unable to determine and correct a
pump problem by foliowing these procedures, contact OMAX Customer Service for assistance.

WARNING! All electrical and maintenance work described in this chapter should be undertaken only by
qualified service personnel. The safety instructions presented in the first chapter of this
Following each problem is a list of possible causes. If you continue to have problems with
your EnduroMAX pump after following these procedures, contact OMAX Customer Service
by telephone, or by fax.

Keypad Display Messages

Normal Operation Messages
When the pump is operating normally, the keypad displays these four lines of text:
Water Pres XX.X KSI pump output pressure in Ksi
High Preset xxxx RPM preset drive motor high RPM
Low Preset xxxx RPM preset drive motor low RPM
RunTime XXX HRS accumulative number of pump run hours

Pump Fault Messages

All fault messages, except those related specifically to the Variable Frequency Drive (VFD), appear on
the keypad display. The VFD provides power, protection, and speed control for the pump motor. If the
VFD itself faults for whatever reason, the message “Variable Drive Fault” appears on the display. When
a fault condition during pump operation occurs, the pump shuts down with one or more of the following
messages appearing in the first three lines of the keypad display.

Note: The fourth line on the keypad display always monitors the cumulative pump hours. The number of these
hours is not editable.

Charge Pressure Low

Water pressure immediately downstream of the water filters is less than 100 psi.
charging Pump Contactor
The charge pump contactor did not close or opened for some reason. It generally occurs along with
the message “Charge Pressure Low.”
Dead Head
Reported when pump output pressure equals or exceeds 63,000 psi.
Variable Drive Fault
There is an issue with the Variable Frequency Drive.

Ch. Pup^p Coniacior

Char9e Pressure Low

RunTine 391.29 HRS

Figure 6-1: Example ofPump Fault Condition Appearing on Keypad Display

400433H-EN 6-1

OMAX
 ● Before the pump can be restarted, the fault condition must be cleared from the pump control by
pressing the RESET button. The LED next to the RESET button goes out and the LED next to the
STOP button lights.
● Once the fault condition has been reset, the pump is again enabled and may be restarted.
● If all conditions triggering the fault have not been corrected, the uncorrected fault(s) reoccurs, the
pump again shuts down, and a fault message reappears on the display.

jj
Fault Message - “Charge Pressure Low
This fault message appears on the pump’s display when the water pressure at switch (S1) immediately
downstream of the water filters is less than 100 psi.
1. Verify that the charge pump’s ON/OFF switch is in the ON position.
2. Check the water level in the white water tank (Figure 4-69)for an adequate water supply. Verify that
the water source is turned ON, and the inlet screen to the charge pump in the white water tank is not
blocked.
3. Check the pressure gauges before and after the water filters. If the downstream gauge (final filter)
exceeds 100 psi (typically 150 psi), the pressure switch (SI) may be defective. If the upstream gauge
(pre-filter) does not exceed approximately 120 psi, the charge pump and/or bypass valve may be
partially plugged or defective.
4. Verify that all air has been bled from the water filters.
5. Check that the water filters are not plugged or damaged. If the pressure difference between the two
pressure gauges is more than 20 psi, replace the filter cartridges. See Maintenance of the Water
Filtration System, page 4-29.
6. Verify that the water pressure switch is operating properly. This switch must be closed for the pump to
operate. Operation of the switch may be checked by using a voltmeter to see if the switch closes when
the pump is running and sufficient pressure is indicated on the downstream pressure gauge on the
filters. If the switch is closed, the voltage on the DIN rail between wires 2181 (brown) and 2440(white)
should show 0 VDC, or very little voltage. If the switch does not close, the voltage should be about 24
VDC. Inspect the wire connections on the switch, ensuring the plug connector has not come loose. If
the switch appears to be faulty, contact OMAX Customer Service.

55
Fault Message - “Charging Pump Contactor
This message appears on the pump's display when the charge pump contactor (C1) did not close as
expected. It generally appears along with the message "Charge Pressure Low.”
1. Verify that the charge pump manual ON/OFF switch is in its ON position.
2. Check the water level in the white water tank (Figure 4-69) for an adequate water supply. Verify that
the water source is turned ON, and the inlet to the charge pump in the water tank is not blocked.
3. Check that the ribbon cable between the display and keypad is not loose and/or defective. Ensure that
the connector is fitted tightly onto the keypad and display. If red LEDs are lit on the keypad, and the
connector is tightly fitted against the keypad and display, the ribbon cable may be bad. Before
replacing the ribbon cable, first inspect the 34-pin cable on the keypad. See Figure 6-2, Keypad
Ribbon Cable and 34-Pin Connector Location on page 6-3.

6-2 400433H-EN

OMAX
 Figure 6-2: Keypad Ribbon Cable and 24-Pin Connector Location

4. Check that the 34-pin connector cable is not loose and/or defective. Ensure that the connector is fitted
tightiy onto the keypad by disengaging and then re-engaging the connector; it shouid feel snug. If that
does not correct the problem, detach the 34-pin cabie from the keypad and visuaiiy inspect the femaie
connector, ensuring aii pins are fuliy locked into the housing. See Figure 6-2, Keypad Ribbon Cabie
and 34-Pin Connector Location on page 6-3.
Caution; If a pin is not locked Into the housing, gently pull it out of the connector, noting what socket it
fits in. The pin has a iocking tab that shouid be bent outward so when correctly inserted into
the housing, the tab “iocks” into place. The locking tab should always face outward from the
housing. When correctly installed, the pin cannot be withdrawn from the housing without first
pushing the tab against its pin.
5. Check for a biown fuse (or no fuse) in the fuse holder on the DIN rail located directly below the 24 VDC
power supply. When there is power from the 24 VDC power supply, the fuse holder’s red LED lights to
indicate a blown fuse. When blown, use an equivalent 0.5 Amp replacement. See Figure 6-3, 24 VDC
Power Supply Fuse Location on page 6-3.

fuse - 0.5 Amp

Figure 6-3: 24 VDC Power Supply Fuse Location

Note: A box of0.5 Amp fuses is supplied with every new pump unit, stored in a plastic container attached to the
bottom of the enclosure.

6. Tighten any loose wires on the input and/or output side of the 24 VDC power supply.
Note: If the power supply's green LED fails to light, there is no 120 VAC being delivered, as measured across L
and N. If 120 VAC is present, the power supply has failed and must be replaced.

400433H-EN 6-3

[t]
OMAX
 7. Check that a wire has not come loose on the contactor. Using a voltmeter, check for 120 VAC between
wires 2130 and 1201 at terminals 1L1 and 3L2. Verify that these wires are tight and making good
metal-to-metal contact at terminals 1L1 and 2T1. Follow these wires all the way to the charging pump.
Check wires 2131 and 1201 between the contactor and the charge pump motor. Strip and/or tighten
any wire that may be a problem.
8. Verify that 460 VAC ±10%(380 VAC ±10% International) is present across terminals L1, L2, and L3,
located at the bottom of the DIN rail inside the electrical enclosure of the pump. If power is not present
across these terminals, refer to "No AC Power at Pump Unit", page 6-6.
))
Fault Message -“Dead Head
This message appears on the pump’s display when pump output pressure equals or exceeds 63,000 psi.
After determining the cause of the overpressure, also check the pressure safety valve on the pump to ensure
it’s not damaged.
1. Verify that the high-pressure orifice and nozzle are not plugged, or partially plugged.
2. Verify that the orifice in use is not too small, particularly if it has just been installed.
3. If equipped with dual ON/OFF valves, check that air is being supplied to the ON/OFF valves (70 - 80
lbs. of air pressure required).
4. Verify that the orifice in the "dumping” ON/OFF valve is not too small, or is not plugged, or partially
plugged.
5. Check that none of the high-pressure tubing is blocked or plugged.

Fault Message - “Variable Drive Fauit

This message appears on the pump’s display when there is a fault with the variable frequency drive (VFD). If
a VFD fault occurs:
● The problem that created the fault must be corrected;
● The RESET button on the pump keypad must be pressed to clear the fault condition;
● If the fault reoccurs, troubleshooting the cause of the fault must be resumed.
1. If a VFD fault message occurs on the keypad display, check the fault message reported on the ABB
drive display panel inside the pump electrical enclosure.
2. When a VFD fault stops the drive, the fault code number and fault description are displayed on the
VFD display panel located inside the pump electrical enclosure.

Note: For faults not listed, referto the ABB User's manual. If a VFD fault persists, contact OMAX Customer
Service.

3. To restart the pump, the fault condition must be “cleared” by pressing the Reset button on the keypad.
The display returns to the display present prior to the fault trip, if the condition that caused the VFD
fault was not corrected, the VFD continues to fault, preventing operation of the pump unit.

General Pump Problems

Problems covered in this section include:
* Low or Fluctuating Pump Output Pressure
● No AC Power at Pump Unit
● Pump Does Not Start
● No Keypad Display
● Pump Runs but Display Reads “0.3 KSI”. or "0 KSI
● Fuses F1/F2 Blowing
● Circuit Breaker CB1 Tripping

6-4 400433H-EN

[t]
OMAX
 Low or Fluctuating Pump Output Pressure
Caution: Never run the EnduroMAX pump once pressure at a given RPM for a given nozzle drops more
than 2-4 ksi. Continued operation with damaged check valve seats or failed dynamic seals can
further damage components in the pump’s wet-end, resulting in higher rebuild costs.

1. Check the high-pressure plumbing for leaks, loose fittings, or split tubing.
2. Verify that the water level in the white water tank (Figure 4-69) is sufficient, that the water source is
turned ON, and the inlet filter to the charge pump in the white water tank is not blocked.
3. Check the pressure gauges on top of the water filters. Reduced output pump pressure can result from
clogged filters. If the pressure difference between water filter pressure gauge readings is more than 20
psi, replace the filter cartridges (see Maintenance of the Water Filtration System, page 4-29). If both
gauges on top of the water filters show lower than normal pressure, clean the screen on the end of the
charge pump suction inlet inside the pump water tank.

Figure 6-4: Pressure Gaugesfor Water Filters

4. Check the pressure safety valve for leakage. If the valve leaks more than 1 drop per minute, rebuild or
replace the safety valve as soon as possible.

WARNING! Never attempt to adjust the safety valve, doing so creates a safety hazard!

5. Check for water leakage between the manifold and check valve bodies, and between the cylinders and
check valve bodies (refer to Figure 6-9). If leaking, remove and disassemble the wet-end, inspect and
clean all parts. Replace both components when leakage occurs between them.
6. Check the temperature of the high-pressure cylinders. If a cylinder is hot and no external leaks or
excessive flow back to the water tank is observed, the check valve body on that cylinder may have a
crack between the inlet and outlet passages. Rebuild the cylinder assembly by replacing the check
valve body.
7. If the abrasive jet orifice is damaged or chipped, it may pass the full flow of the high-pressure pump
without developing its rated pressure. Check by replacing with a new orifice.
8. Check the output pressure gauge (if so equipped) to determine if it registers low pressure, but the
machine still cuts quality parts with the software set at high pressure. If this is the case, the gauge may
be inaccurate or defective.
9. While the high-pressure pump is running at high pressure in Test mode, check the cylinders and the
three white hoses (Figure 4-69) that run into the white water tank for heat. Also, check if the hoses are
expelling hot and/or pulsing water. This indicates worn high-pressure seals (dynamic) that must be
replaced by rebuilding the pump wet-end. If a hose has no water flow, check for a plugged orifice in the
pump outlet manifold. When air bubbles are observed in the returning water, check for a leaky suction
line.

Caution; Do not run the EnduroMAX pump once the pressure at a given RPM for a given nozzle drops
more than 2-4 ksi. Continued operation with damaged check valve seats or failed dynamic

400433H-EN 6-5

OMAX
 seals can result in further damage to components in the weUend and may result in higher
rebuild costs.

10. If there is low pressure with high vibration, a plunger may be loose or broken. Immediately, power OFF
the pump. Turn the pump by hand to locate the bad plunger. If a plunger is broken or scored, contact
OMAX for a replacement plunger assembly. Replace all the high-pressure seals before reassembling
the pump.

No AC Power at Pump Unit

1. Have a certified electrician verify that AC power is available at the main power disconnect by
measuring the voltage between all three legs.

WARNING! It is the customer’s responsibility to ensure that all components and conductors, as well as
grounding and wiring methods, comply with the most recent version of the NEC,lEC or JIC,
whichever is applicable, as well as all regional and local codes and standards. Wiring must
be performed by a certified electrician and conform to national, state, and local
requirements.

2. Check the fuses at the main power disconnect.

3. Check that the main power is ON,
4. Check that the ON/OFF switch on the pump unit is ON and that the ON/OFF switch on the controller is
ON.
5. Check that the E-stop switches on the pump unit and the computer controller are reset.
6. Check that 460 VAC ±10%(380 or 415 VAC ±10% for international) is present on LI, L2, and L3 at the
bottom of the pump control enclosure (refer to Figure 6-5).

Figure 6-5: AC Input Power Legs - LI, L2, andL3.

Note; Power between the three legs L1, L2, and L3 can vary by up to 6% from the average of all three. A
variation that exceeds more than 6% causes a phase unbalance VFD fault.

Pump Does Not Start

1. Check that the main power is ON.
2. Check that the ON/OFF switch on the pump unit is ON.
3. Check that the E-stop switches are reset. The E-stop on the pump shuts down both the pump and X-Y
table (if connected). Likewise, the E-stop on the Controller shuts down both the X-Y table and the
pump. To reset either E-stop switch, simply pull it out.

6-6 400433H-EN

OMAX
) 1
 ) )

4 3 2 I
i i

A A

T T T
4 3 2
 4. Check the “FAULT” condition displayed on the keypad display. If the display indicates a fault(Figure 6-
1), refer to the section of this document dealing with the specific fault. More than one fault may be
reported. Usually, the fault that shut down the pump is the first reported and appears on the line of the
display closest to the pump hours. After correcting the conditions that created the fault(s), press the
reset button on the keypad to clear the display and re-enable the pump unit.
5. Check if the pump keypad display is lit. If it is not, go to "No Keypad Display.”
6, Check the display on the VFD keypad inside the electrical enclosure. It should display the condition
"REM” in the upper left corner of the display. If the VFD does not show “REM”, press the LOC/REM
button on the VFD display panel to put the drive into remote control mode(REM). In local mode(LOC)
the drive does not respond to commands from the keypad, or from the controller. Refer to Figure 6-6.

Aim
'1
‘REM t-
"REM" indicates remote rpn
mode operation .0 A
25. "C
rmct]
I

press to switch LOC/REM

and REM/LOC modes

T© TSTOP

Figure 6-6: VFD Remote (REM)Mode

No Keypad Display
The display on the EnduroMAX keypad is blank and/or no red LED’s next to the buttons are lit.
1. Check that no E-stop switches are engaged.
2. Check that the ON/OFF switch on both the controller and pump unit are in their ON positions.
3. Verify that 460 VAC ±10% (380 or 415 VAC ±10% International) is present across terminals LI, L2,
and L3 located at the bottom of the DIN Rail inside the electrical enclosure of the pump (Figure 6-5). If
no power is present across these terminals, see “No AC Power at Pump Unit” on page 6-6.
4. Check that 460 VAC ±10% (380 or 415 VAC ±10% International) is present across the primary
terminals HI and H4(H3 for international units) of the 2KVA transformer.
5. Check that 110 VAC is present at the output, secondary terminals XI and X3 or X4 of the 2KVA
transformer. Refer to Figure 3-5 for location.
6. Check that the 24 VDC power supply located on the DIN rail inside the pump electrical enclosure is
producing 24 VDC by checking DC voltage between L+ and ground on the right hand side.
7. Check for and tighten any loose wires on the input and/or output side of the 24 VDC power supply.

400433H-EN 6-7

OMAX
 green LED

Figure 6-7: 24 VDC Power Supply

Note: If the power supply’s green LED is not lit, no 120 VAC is present as measured across terminals L and N on
top ohhe 24 VDC power supply. If 120 VAC is present, the power supply has failed and must be replaced.

8. Check for a blown fuse or no fuse in the fuse holder on the DIN rail located below the 24 VDC power
supply. If there is power from the 24 VDC power supply and the fuse holder’s red LED is lit, a blown
fuse is indicated. See Figure 6-3, 24 VDC Power Supply Fuse Location on page 6-3.

Note: A box of 0.5 Amp replacement fuses is supplied with every new pump unit and is stored in a plastic
container attached to the bottom of the enclosure.

9. Check that the 34-pin connector cable is not loose and/or defective. Ensure that the connector is fitted
tightly onto the keypad by disengaging and then re-engaging the connector, it should feel snug. If that
does not solve the problem detach the 34-pin cable from the keypad and visually inspect the female
connector to make sure all of the female pins are fully locked into the housing. See Figure 6-2, Keypad
Ribbon Cable and 34-Pin Connector Location on page 6-3.

Caution: If a pin is not locked into the housing gently pull it out of the connector being sure to note what
socket it fits in. The pin has a locking tab that should be bent outward such that when correctly
inserted into the housing the tab "locks"into place. The locking tab should always be outward
facing from the housing in order to "lock"it in place. When correctly installed the pin cannot
be withdrawn from the housing without first pushing the tab in tight against its pin.

10. Verify that the ribbon cable between the display and keypad is not loose. Ensure that the connector is
fitted tightly onto the keypad and display. Ensure that the connector is properly fitted onto the correct
pins. If red LEDs are lit on the keypad, and the connector is tightly fitted against the keypad and
display, the ribbon cable may be bad. Before replacing the ribbon cable, also check the 34-pin
connector on the keypad. See Figure 6-2, Keypad Ribbon Cable and 34-Pin Connector Location on
page 6-3.
11. Check if Fuses F1 and/or F2 have blown. If either of these fuses have blown or are blowing regularly.
See Figure 6-8 for Location of F1, F2, and CB1 on page 6-9.

6-8 400433H-EN

OMAX
 circuit breakers

Figure 6-8: Location ofFI, F2, and CBl

99
Pump Runs but Display Reads “0.3 KSI”, or “0 KSI
1. See if the 34-pin connector cable is loose and/or defective. Ensure that the connector is fitted tightly
onto the keypad. If this does not solve the problem, detach the 34-pin cable from the keypad and
visually Inspect the female connector to ensure all of the female pins are fully locked into the housing.

Caution: If a pin is not locked into the housing, gently pull It out of the connector, noting what socket it
fits in. The pin has a locking tab that should be bent outward so when correctly inserted into
the housing, the tab "locks" into place. The locking tab should always face outward from the
housing. When correctly installed, the pin cannot be withdrawn from the housing without first
pushing the tab against its pin.

2. If the RPM is displayed correctly, but the displayed pressure is "0.3 KSI” or “0 KSI”, the pump control
circuit board may not be receiving the pressure signal.
3. The pressure signal for EnduroMAX pumps comes from the pressure transducer. A “T" appears on the
display for the pressure reading if the transducer is connected and recognized by the pump control
card. If the “T” is present but the pressure readout does not respond, the transducer may have failed,
requiring replacement.
4. The transducer Is a 4-20 ma transducer excited with 24 VDC from the 24 volt power supply located
within the pump enclosure. Check the transducer itself, the connection to the transducer, a bulkhead
connection through the back of the enclosure, a connection on the DIN rail inside the electrical
enclosure, and the 34-pin connection on the pump control card.
a. Check that the transducer cable is connected securely to the bulkhead connector on the back of
the pump electrical enclosure.
b. Check that the connector on the end of the transducer is securely attached to the transducer.
c. Loosen the screw holding the transducer connector and remove the connector from the end of the
transducer. Refer to Figure 3-4 for pressure transducer location.
d. With a DC voltmeter, verify that the 24 VDC exciting voltage Is present between terminal 1 and the
ground terminal in the connector. If 24 VDC is not present, check and tighten all of the 2181 and
2182 terminals on the DIN rail of the enclosure. Check again for 24 VDC between terminals 1 and
ground. Verify that the wires inside the enclosure are inserted correctly into the bulkhead
connector through the back of the enclosure. There should be 24 VDC between the dark blue wire,
2181, on pin 2 at the bulkhead connector and any ground. The white/blue wire, 2182, should have
continuity with any ground and should be connected on pin 4 of the bulkhead connector.
e. Check that the signal lead, wire 3030, is connected correctly on pin 2 of the bulkhead connector
inside the enclosure.
f. Check and tighten the wire in terminals 3030 on both sides of the DIN rail.
g. Check the 34-pin connector to verify the pressure transducer signal appears on pin 26.

400433H-EN 6-9

[t]
OMAX
 Fuses F1/F2 Blowing
1. Check for loose wires between the 2 KVA transformer and circuit breakers. Tighten any found.
2. Determine if the transformer is defective by removing F1 and F2 and disconnecting the red wire, #
1170, from transformer terminal XI. Replace FI with a good fuse. If FI blows, the transformer is
shorted and must be replaced. Refer to Figure 6-8 for fuse locations.
3. Inspect the fan motors, keypad, transformer, DC power supply, etc., to see if any components have
shorted or burned out. Replace any burned out components and re-test the fuses.

Circuit Breaker CB1 Tripping

Circuit breaker CB1 may trip when the charging pump is overloaded or the motor is shorted. Refer to Figure
6-8 for circuit breaker location.
1. Check that the water filters are not plugged or damaged, causing the charge pump to overheat.
Replace the filters if needed.
2. Check the charge pump water inlet in the water tank, ensuring the screen is not blocked or plugged.
3. Verify the charging pump is not jammed with foreign material, causing the motor to lock up. Remove
the inlet and outlet water hoses on the charging pump to see if the circuit breaker continues to trip.
4. If no loose wires are found, the expected voltages are present on all terminals, and the circuit breaker
continues to trip, the charge pump motor may need replacing.

6-10 400433H-EN

OMAX
 Correcting Water Leaks in the Wet-end Assembly
This section identifies the location of possible water leaks in the wet-end assembly (Figure 6-9) and
suggests possible ways to correct them.

Figure 6-9: Sources of Water Leaks in the Wet-end Assembly

Troubleshooting Leaks in the Pump Wet-end Assembly:

(refer to Figure 6-9)

Leak Leak/Other Point Description Suspected Cause Recommended Action

Point

Leak from Coolant Housing Seal ● Coolant Housing Seal failure ● Replace Coolant Housing Seal at next
O rebuild (this is coolant water and will not
affect output pressure or pump life)
Leak(s) between Cylinder Body ● Insufficient torque on End Cap ● Check torque on End Cap Nuts
and Coolant Housing (immediately Nuts ● Apply fresh anti-seize to face of Clamp
after rebuild) ● Insufficient anti-seize on End Plate Nuts and threads and tighten to
Cap Nuts 175 ft. lbs. by following procedures on
e page 4-14.
Leak between the Cylinder and ● Cracked Backup Ring across ● Rebuild Wet-end Assembly
Coolant Housing metal sealing surface ● Replace cylinder and backup ring
● Damage to top metal sealing
surface
● Cracked Cylinder

40043BH-EN 6-II

[t]
OMAX
 Leak Leak/Other Point Description Suspected Cause
Point
Leak between Check Valve Body
and Cylinder Body (immediately
after rebuild)
e Cap Nuts
Leak between the Check Valve
Body and Cylinder
Leak between the Check Valve
O Body and the End Cap
Leak from Weep Hole on Port
Adapter
e Leak between Port Adapter and
Manifold
Warm high-pressure tubing
© Note: There can be a damaged
Sudden loss of pressure and
Cylinder Body very warm or hot.
e Pressure ports
Oil leaking from seal in adapter
© block and begins to accumulate
beneath the Myers crankcase.
6-12
● Insufficient torque on End Cap
Nuts
● Insufficient anti-seize on End
● Cracked Check Valve Body
● Cracked Cylinder
● Cracked Check Valve Body
● Cracked End Cap
● Possible damage to tubing
seat or tubing
● Possible damage to metal-to-
metal seal
● Cracked Manifold
● Damaged Check Valve Inlet
and/or Seat or Ball
Check Valve Inlet Seat/
Ball with no noticeable
heat.
● Cracked Check Valve Body
between the High and Low
● Pony rod seal failure
OMAX
Recommended Action
● Check torque on End Cap Nuts
● Apply fresh anti-seize to face of Clamp
Plate Nuts and threads and tighten to
175 ft. lbs. by following procedures on
page 4-14.
● Rebuild Wet-end Assembly
● Replace Check Valve Body and
Cylinder
● Rebuild Wet-end Assembly
● Replace both Check Valve Body and
End Cap
● Replace Tubing
● Replace Port Adapter
● Replace Port Adapter and Manifold
● Rebuild Wet-end Assembly
● Inspect for damaged Check Valve Inlet
Seat or Ball/ replace as needed
● Rebuild Wet-end Assembly
● Inspect for cracks/damage in the Check
Valve Body (internal cracking - inspect
viewing through the low pressure port-
may require magnification)
● Replace Check Valve Body
● Replace pony rod seals following
instructions provided in OMAX
document “Replacing the Myers Cup
Seals”, P/N 400397.
400433H-EN
 Correcting Water Leaks in the ADO Assembly

On\Off Valve seat

Figure 6-10: Sources of Water Leaks in the ADO Assembly

Troubleshooting Leaks in the ADO Assembly

Leak Leak/Other Point Description Suspected Causes Recommended Action
Point

air actuator weep hole ● leaky seal ● Verify air actuator torqued at 21 ft-
o ♦ cracked body Ib (28.5 N-m); replace seal
♦ check valve body for cracks

e leak between air actuator and

fitting ring
■ leaky seal
● cracked body
● replace seal
● check valve body for cracks
leak between fitting ring and ● cracked body replace defective component; verify
e gland nut ● bad UHP tubing gland nut torqued at 60 ft-lb (68 N*m)
● loose gland nut

o leak from weep hole between

collar and nut
● cracked body; loose nut
● failed seat or seal
replace defective component; tighten
nut

leak from weep hole located damaged metal-to-metal

e beneath the 0-ring. seal between the ADO and
on/off seats
repair with repair kit for On/Off valve
first, or ADO kit if still leaks

© if leaks between gland nut and

ADO body, a low pressure leak
normal wear leakage low pressure leaks fixed during
regular scheduled maintenance.

e leak at ADO wing nut normal wear leakage rebuild with ADO kit

Note: Diagram shows both ADO and On/Off valve. Troubleshoot each component separately.

400433H-EN 6-13

[t]
OMAX
 Troubleshooting ADO Assembly Leaks
If you see leaks at the weep hole between collar and nut (item 4 on page 6-13 or at item 5 on page 6-13),
troubleshoot with these tests.
1. In OMAX Make, click Test, and then click Pump Only (Dump valve open),
2. If the leak occurs at item 4 or 5:
a. the ON\OFF valve seat is defective, or
b. the ON\OFF valve body is cracked.
3. In OMAX Make, click Test, and then click Water Only (Pump is active).
4. If the leak occurs at item 4 or 5:
a. the leak is between the ON\OFF valve seat and the ADO seat
b. repair with the ON\OFF valve repair kit first, or the ADO repair kit.

6-14 400433H-EN

OMAX
 > > >
EMERGENCY
STOP
FAN
3

BLACK 11180 i2B RED ®[1180]@

(E-STOP)
®[1180]@

®[1180]@ #1180 BLK

24V DC POWER
POWER ®[1180]® |- 1^1180 BLK SUPPLY \
CABLE 203772 o
®[1060]® - ;^^1060 WHT ●#2180 BLUE ?
D- +® >oo
PIN 1 f28 RED oJ ®[1060]@ _
(E-STOP) -® 1 ■#2060 WHT/BLU^
2 1 l>118P BLACK ^LD
PIN 2 g\ BLACK O- ®[1060]@ f®
(AC-UNE)
(AC-LINE)
A 3 l>1060 WHITE
PIN 3 jlN WHTC O-
(AC-NEUTRAL) ®[1060]® - §]060 WHT a®
/
(AC-NEUIFWkL)
6 5 CNRAEL
O-
PIN * H GREEN
- j^iGRN/Y-
(GROUND) is: b-
_l X
POWER CD g:
SWITCH
O o
CO CD
O
DC

nil'
=tfc

00 O000000
®[3180]@

36V DC POWER #3180 BLUE ®[3180]@

SUPPLY
203641 ®[3180]®
/ \
®[2060](2)

®[2060]®

®[2060]®

#2060 WHT/BLU

TITLE: SCHEMATIC, ELECTRICAL

COMPUTER CONTROLLER, 9-AXIS
NOTES: DRAWING BY: MATERIAL / SPECIFICATION
PROPRIETARY INFORMATION
EWA KURCZYCH
THIS DRAWING IS THE PROPERTY DATE: 08/27/09
1) ALL WIRE 18AWG MTW UNLESS OTHERWISE SPECIFIED OF OMAX CORPORATION AND NOT
2) TEXT OR SYMBOL FOLLOWING # IS A WIRE MARKER. TO BE COPIED OR REPRODUCED REVISED BY: SHEET 1 OF 4 CHANGE NO.
WITHOUT THE WRITTEN CONSENT WILL BREWER
OF OMAX CORPORATION.
DATE; 1/11/13 DWG NO. 40061 1 El
 > > >

307918
CIRCUIT BOARD ASSEMBLY
n
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J18 \ < ~n
RESET o o > C/)
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+24
[^002
P o
„ K:iOm
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N)0? o\:u
GND #20 BLUE 18AWG OJ —I o hoOO
C/) m
OUERRIDE o c/) [□
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INPUT #2 BLUE 18AWG -

GND #2 BLUE 18AWG -
AIR o
+24 #2^S0 RED 18AWG \
INPUT #2400 BLK 18AWG “0
7D CO

GND ^^m §>

#2060 BLU 18AWG
XI
O
PAUSE O
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CD ^ ^
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GND #23 BLUE 18AWG
TERRAIN o + 24
\
INPUT o X
3 T > o
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GND pzo
^ -f 1
o OJ O —I
<^
5 X-Zi
> —I
o> I z ^>—I
o o OCOT)
N30^ X m >
LnJ —I o ujOz:
C/) 4 TO 2

NOTES:

1) TEXT OR SYMBOL FOLLOWING # IS A WIRE MARKER TITLE: SCHEMATIC, ELECTRICAL,

2) RESET LIGHT OFF WHEN RESET SWITCH IS SELECTED COMPUTER CONTROLLER, 9-AXIS
3) OVERRIDE LIGHT OFF WHEN OVERRIDE SWITCH IS SELECTED PROPRIETARY INFORMATION
DRAWING BY: MATERIAL / SPECIFICATION
4) AIR LIGHT ON WHEN AIR IS NOT PRESENT EWA KURCZYCH
THIS DRAWING IS THE PROPERTY
5) PAUSE LIGHTS OFF WHEN PAUSE SWITCH IS PUSHED DATE: 08/27/09
OF OWAX CORPORATION AND NOT
TO BE COPIED OR REPRODUCED REVISED BY: SHEET 2 OF 4 CHANGE NO.
WITHOUT THE WRITTEN CONSENT WILL BREWER
OF OMAX CORPORATION.
DATE: 1/11/1 3 DWG NO. 40061 1 E2
 > > >

307918 J12
CIRCUIT BOARD ASSEMBLY^ +24 BLUE 22AWG
POWER FOR ALL RELAYS
+24_JMP BLUE 22AWG

+24_JMP BLUE 22AWG PUMP #1

POWER FOR PUMP-A RELAYS COMMUNICATION
J12_+24 BLUE 22AWG 306693
RELAY 0 PIN 9
OUTPUT #7
PUMP-A
PUMP ON GROUND
RELAY 1 PIN 8
OUTPUT #6
PUMP-A
LOU P PIN 3
GROUND #2060
RELAY 2 OUTPUT #2700 RED —
PUMP-A USB-RS485
JET ON GROUND #2060 BLACK ADAPTER
RELAY 3 309820
OUTPUT #2800 RED — ORG
PUMP-A #4000 ® [4000]®
ABR ON GROUND #2060 BLACK #4100 ® [4100]® YEL
J14

^+24_JMP BLUE 22AWG 1

AIR VALVE
J14_+24 BLUE 22AWG ASSEMBLY
308697
RELAY OUTPUT POWER FOR PUMP-B RELAYS
PUMP-B
PUMP ON
I
GROUND D
RELAY
PUMP-B
OUTPUT
JET ON
O
LOU P GROUND ®l
<S) ABRASIVE
RELAY OUTPUT
PUMP-8
JET ON GROUND ED®
RELAY OUTPUT
PUMP-B
ABR ON GROUND PLUG INTO
PC

TITLE: SCHEMATIC, ELECTRICAL

COMPUTER CONTROLLER, 9-AXlS
NOTES: DRAWING BY: MATERIAL / SPECIFICATION
PROPRIETARY INFORMATION
EWA KURCZYCH
THIS DRAWING IS THE PROPERTY
1) TEXT OR SYMBOL FOLLOWING # IS A WIRE MARKER DATE: 08/27/09
or OMAX CORPORATION AND NOT
TO BE COPIED OR REPRODUCED REVISED BY: SHEET 3 OF 4 CHANGE NO.
WITHOUT THE WRIHEN CONSENT WILL BREWER
OF OMAX CORPORATION.
DATE: 1/11/13 DWG NO. 40061 1 E3
> > >
\
~u
:>
“D O
O

O
/

\ o
o
BLUE 18AWG z,
“D <
>
WHT/BLU 18AWG O "0
mo
n
/ 713

307918
CIRCUIT BOARD ASSEMBLY
J17
4- + I I

TITLE: SCHEMATIC, ELECTRICAL

COMPUTER CONTROLLER, 9-AXIS
DRAWING BY: MATERIAL / SPECIFICATION
PROPRIETARY INFORMATION
EWA KURCZYCH
THIS DRAWING IS THE PROPERTY
DATE: 08/27/09
or OMAX CORPORATION AND NOT
TO BE COPIED OR REPRODUCED REVISED BY: SHEET 4 OF 4 CHANGE NO.
WITHOUT THE WRITTEN CONSENT WILL BREWER
OF OMAX CORPORATION.
DATE:i/n/l3 DWG NO. 40061 1 E4
 > > >

WATER WATER
SUPPLY SUPPLY

I WATER I I WATER I
CONOmONING CONDITIONING
KIT KiT CHIUER
SYSTEM
I
I
I
I
CHILLER I souos I SOUDS
i IRON SYSTEM
I
REMOVAL
SYSTEM
IRON t! CALCITE
RLTER REMOVAL
REDUCER SYSTEM
I REDUCER I I
I

I
OMAX OR
i
I
I
I
I

OMAX OR
£ i
I REVERSE I I OMAX i REVERSE I CLOSED OMAX
SOFTENER I w ACID EnduroMAX SOFTENER I . EnduroMAX
OSMOSIS —►— MACHINE OSMOSIS r LOOP -► MACHINE
SYSTEM j MACHINE SYSTEM j ^ MACHINE
SYSTEM I !| NEUTRAUZER| PUMP TABLE I SYSTEM I SYSTEM TABLE
PUMP

T T I I T I
I I I I
I
I I
I t I
I
▼
I
I
TI SETTUNG
I A
I
'
I
L
I
I
I I
WEIR iI L J I
I
I
I SYSTEM
I I

DRAIN
I SETTLING
L WBR
SYSTEM

WATER CIRCUIT BLOCK DIAGRAM WATER CIRCUIT BLOCK DIAGRAM

STANDARD SYSTEM CLOSED LOOP SYSTEM

TITLE; SCHEMATIC, WATER, OMAX MACHINE SYSTEM

DRAWING BY; MATERIAL / SPECIFICATION

PROPRIETARY INFORMATION
SYSTEM COMPONENT LEGEND E.KURCZYCH
THIS DRAWING IS THE PROPERTY
I I STANDARD COMPONENT OF OMAX CORPORATION AND NOT DATE; 5/6/03
TO BE COPIED OR REPRODUCED REVISED BY; SHEET1 OF 5
E ~ H OPTIONAL COMPONENT CHANGE NO. .
WITHOUT THE WRITTEN CONSENT EWA KURCZYCH
OF OMAX CORPORATION.
DATE: 4/5/13 DWG NO. 303397L1
 ) > >

PUMP ASSEMBLY TABLE ASSEMBLY

WATB^
SUPPLY I
2— I

3= >
TEMPERATURE I
CONTROL
VALVE NOZZLE -► SOUDS
WATER REMOVAL
iONDITIONINi
KIT
)( SYSTEM
MAIN I

1 PUMP BYPASS
VALVE
I
!I
I
I

DRAIN

K I I 4 , - 'i » T I
IRON DUMP 1 1 I
REDUCER
)(
VfiVJE I 1 )( u_ J I I

I
iI I

tI I I
I
I
I
I
L I

I REVERSE I k jr
SOFTENER ACID X-
■ OSMOSIS - I—» ■v
f SETTLING I
SYSTEM
1 SYSTEM I iNEUTRAUZERj" I I I I WEIR
I I > I I SYSTEM I
I I

o
i._j

I I

CHARGE I
DRAIN PUMP WITH I
RESERVOIR REUEF VALVE
DRAIN

DRAIN

WATER CIRCUIT SCHEMATIC

STANDARD SYSTEM

TITLE: SCHEMATIC, WATER. OMAX MACHINE SYSTEM

PROPRIETARY INFORMATION DRAWING BY: MATERIAL / SPECIFICATION

E.KURCZYCH
THIS DRAWING IS THE PROPERTY
OF OMAX CORPORATION AND NOT
DATE: 5/6/03
TO BE COPIED OR REPRODUCED REVISED BY: SHEET 2 OF 5 CHANGE NO..
WITHOUT THE WRITTEN CONSENT EWA KURCZYCH
OF OMAX CORPORATION.
DATE: 4-/5/13 DWG NO. 303397L2
 > > >

>
PUMP ASSEMBLY TABLE ASSEMBLY

WATER
SUPPLY
2- I

% >
I
WATER I NOZZLE > J SOUDS
REMOVAL
:ONDmONINi
KIT
)[ ■*
■1 SYSTEM
MAIN
PUMP BYPASS i
VALVE !

I
IRON I DUMP
VALVE
I
)( I
I
REDUCER
I )( I 1
I
I
1
I
~1 L !
SOFTENER
REVERSE
OSMOSIS
ACID I I
i SETTLING
SYSTEM
SYSTEM ]NEUTRAUZERj' I I I CHILLER WEIR
I -► SYSTEM
I I T
I SYSTEM
U_ J

DRAIN
I
0 CHARGE
PUMP WITH
REUEF VALVE
RESERVOIR DRAIN

WATER CIRCUIT SCHEMATIC

CHILLER ONLY

TITLE; SCHEMATIC, WATER, OMAX MACHINE SYSTEM

PROPRIETARY INFORMATION DRAWING BY: MATERIAL / SPECIFICATION

E.KURCZYCH
THIS DRAWING IS THE PROPERTY
OF OMAX CORPORATION AND NOT
DATE: 5/6/03
TO 8E COPIED OR REPRODUCED REVISED BY: SHEET 3 OF 5 CHANGE NO, .
WITHOUT THE WRITTEN CONSENT EWA KURCZYCH
OF OMAX CORPORATION.
DATE: 4/5/13 DWG NO.303397L3
 ) > >
PUMP ASSEMBLY TABLE ASSEMBLY

WATER
SUPPLY

2-
>

I WATER I NOZZLE ●> J SOLIDS I

I REMOVAL I
tONOmONIN(3 )(
KIT ■] SYSTEM I
MAIN
PUMP BYPASS
VALVE
I I

IRON CALCITE DUMP

L._J
REDUCER RLTER
)(
VALVE }(
! I I—
I I
I

T
I
L

I REVERSE I II CLOSED L
SORENER
>—! OSMOSIS I—IX]- LOOP
SYSTEM r '1
I SYSTEM I SYSTEM I I I t CHILLER
I I
I *—r T
( SYSTEM
I I

I I SETTLING
I WEIR
tI <$> CHARGE SYSTEM
I PUMP WITH
I RELIEF VALVE
I RESERVOIR
I
I
H -

r
u
r

MACHINE TABLE
AIR SIGNAL

WATER CIRCUIT SCHEMATIC

CLOSED LOOP SYSTEM

TITLE: SCHEMATIC, WATER. OMAX MACHINE SYSTEM

PROPRIETARY INFORMATION DRAWING BY: MATERIAL / SPECIFICATION

E.KURCZYCH
THIS DRAWING IS THE PROPERTY
OF OMAX CORPORATION AND NOT
DATE: 5/6/03
TO BE COPIED OR REPRODUCED REVISED BY: SHEET 4 OF 5 CHANGE NO. .
WITHOUT THE WRITTEN CONSENT EWA KURCZYCH
OF OMAX CORPORATION.
DATE: 4/5/13 DWG NO. 303397L4
 > > )
SCHEMATIC SYMBOL LEGEND
I
I

VALVE, PNEUMATIC CONTROL FLOAT VALVE

VALVE. PRESSURE REGULATOR. VARIABLE HAND VALVE

T
U —-J

VALVE. PRESSURE RELIEF, FIXED, VENTED CHECK VALVE

VALVE. PRESSURE RELIEF, VARIABLE, EXTERNAL DRAIN PRESSURE GAUGE

T
I 1 I
I

HEAT EXCHANGER TEMPERATURE CONTROL VALVE

PUMP. FIXED DISPLACEMENT -A PNEUMATIC OPERATED VALVE

PUMP, VARIABLE DISPLACEMENT

ORIFICE
I
I

PRESSURE SWITCH
I
1
1
C PRESSURE TRANSDUCER

FILTER

TITLE: SCHEMATIC. WATER. OMAX MACHINE SYSTEM

FILTER WITH BLEED PORT
DRAWING BY: MATERIAL / SPECIFICATION
PROPRIETARY INFORMATION
E. KURCZYCH
THIS DRAWING IS THE PROPERTY
OF OMAX CORPORATION AND NOT DATE:5/6/03
TO BE COPIED OR REPRODUCED REVISED BY: SHEETS OF5 CHANGE NO..
WITHOUT THE WRIHEN CONSENT EWA KURCZYCH
OF OMAX CORPORATION.
DATE: 4/5/13 DWG NO. 305397L5
 ) ) )

rn
o
Plug
5
E< 9
U
6 10
LU
rn o
AIR IN tiil WATER >o
120 PSI (827 kPa) WAX
44
✓\ /s
AIR
EXHAUST
LEVEL
CONTROL
I D
O
a
£
0
V

TO AIR GUN

TO BULK '
ABRASIVE FEED HOPPER I
(OPTIONAL) I

MACHINE AIR DOME

CONTROLLER

AIR CIRCUIT DIAGRAM 2626 & 2626XP

TITLE: SCHEMATIC. AIR. OMAX MACHINE

DRAWING BY: MATERIAL / SPECIFICATION

PROPRIETARY INFORMATION
EWA KURCZYCH
THIS DRAWING IS THE PROPERTY
OF OMAX CORPORATION AND NOT
DATE:5/6/03
TO BE COPIED OR REPRODUCED REVISED BY: SHEET 1 OF 3 CHANGE NO..
WITHOUT THE WRinEN CONSENT K. HAY
OF OMAX CORPORATION.
DATE:6/22/11 DWG N0.303398H1
 ) ) )

X Plug
5 9
U
lLi 6
lLi 10

ra o
WATER >a
AIR IN titj LEVEL
120 PSI (827 kPo) MAX
44 CONTROL
5
o E
a
N
O

/\ /s “Lv
TO AIR GUN EDUCTOR

TO BULK 1
ABRASIVE PEED HOPPER I
(OPTIONAL) I

AIR
EXHAUST

CONTROLLER

MACHINE AIR DOME

AIR CIRCUIT DIAGRAM FOR MACHINES OTHER THAN 2626/2626XP

TITLE: SCHEMATIC. AIR. OMAX MACHINE

DRAWING BY: MATERIAL / SPECIFICATION

PROPRIETARY INFORMATION
EWA KURCZYCH
THIS DRAWING IS THE PROPERTY
OF OMAX CORPORATION AND NOT
DATE:5/6/05
TO BE COPIED OR REPRODUCED REVISED BY: SHEET 2 OF 3 CHANGE NO..
WITHOUT THE WRIHEN CONSENT K. HAY
OF OMAX CORPORATION.
DATE:6/22/11 DWG NO. 303398H2
> > >

(5)
rn
AIR IN
<1>
GARNET

TO 25 LBS HOPPER

BULK ABRASIVE FEED HOPPER

(OPTIONAL)

TITLE: SCHEMATIC, AIR. OMAX MACHINE

DRAWING BY: MATERIAL / SPECIFICATION

PROPRIETARY INFORMATION
EWA KURCZYCH
THIS DRAWING IS THE PROPERTY
OF OMAX CORPORATION AND NOT DATE:3/03/06
TO BE COPIED OR REPRODUCED REVISED BY: SHEET 3 OF 3 CHANGE NO..
WITHOUT THE WRITTEN CONSENT K. HAY
OF OMAX CORPORATION.
DATE:6/22/11 DWG NO.303398H3
 ) Jj SWtTCHCS f*OW RUCK .}
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SOUftCC INPUT
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CONCUCIOttS o>cr —fcvL PIP SWrrCH SCTTIMCS (60KSI OM.Y)

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(2XS2) (?3MJ [mo]

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USED UStO

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TAftI ROKR
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NOTES:
1) ALL HOOK UP WIRE SHALL BE RATED AT 600V MINIMUM, TA0CC Is

UL LISTED. 14AWG, MINIMUM UNLESS OTHERWISE STATED VOLTAGE FUa LOAD OMAX OPTIONAL TVAWV0RU4R CCNNICTIOH
AMPCRACC DISCONNECT PAWART SCdPAOr
seovAc S1A J03174-5 VQLIACt
2) MARK ALL WIRES AND TERMINALS WITH NET LABLES
ccvMtcT Mcewvae kpk% C0*MCCT

WHERE NET NAME IS NOTED INSIDE BRACKET, 40OVAC 47A 30^174.4 MO

TlUEt SCHEUATTC. aEC., 30 HP OUAX PUUP
EXAMPLE : MARK WIRE NOTES AS [1254] WITH 1254
A
ORAWINC 9T. PMTERIAL / SPECIFICATION
A
KCVIN HAY SEC eow
3) WIRE SHOWN AS -c A T>«S OAHfMC »A0«ATY
DATE: 2/03/TO
#14 GREEN WITH YELLOW STRIPE coimtmATKH
10 0C COflCO OA ACMCCUCSO REVISCD 6Y: Size
SCALE:, SHcn 1 or 1 c
W1H0UT THC VlATTlM COCtNT WI.L efiCWCft
COAfODATtCH
DATE: 3/26/T 3 owe NO. 400577J
 jT :>
1*]
●V.
1
Access Control Circuit
User’s Guide

'●
Is*-. ■ ● *

^1

S'

:d>matl07i:253-872-2300 x3
9*^ 2-140^‘7^clii^yenue;S6Mth 253-872-7446
● -^ept, WA1JSA980» ■'*' %
Customer Service:800-298-4036
,-?r ^ ^ 1. - ,*« . ■ E-Mail: techsupport@omax.com
> # Web:http;//www.omax.com

K-i

OMAX
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 JetMachining Center. 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 their user documentation. If you have any questions or concerns about
the content of this service and maintenance guide, we want to hear from you. Please e-mail us at
tech_writing@omax.com or contact us at;

OMAX Corporation
Technical Publications
21409 72nd Avenue South
Kent, WA, USA 98032
1-800-838-0343
techsupport@omax.com
http://www.omax.com/support(User name and password required for access.)

OMAX Corporation is continually improving their equipment to bring you the best in abrasivejet machining
technology. For that reason, your OMAX JetMachining Center may differ slightly from what is described in
this document.

OMAX®, MAXJET®5, Intelli-MAX®, Tilt-A-Jet®, MAXJET4®, 26261xp®, and JetMachining® are registered
trademarks of OMAX Corporation.
MAXlEM™is a trademark of OMAX Corporation.
lntelli-TRACE™is a trademark of OMAX Corporation.
Windows® is a registered trademark of Microsoft Corporation

The OMAX Machine tool apparatus and linear motion track are covered by U.S. patent number 5,472,367.
The OMAX motion control with precompilation is covered by U.S. patent number 5,508,596.
Other patents pending.

Original instructions in English

September 2013
© 2013 OMAX Corporation

400631D-EN

OMAX
 Access Control Circuit User’s Guide

Overview
This document describes technical requirements for the Access Control Circuit and explains its operation for
both OMAX and MAXIEM waterjets.

Safety
The following safety instructions must be followed when operating your waterjet. If ignored, physical injury or
death, or damage to the equipment may occur. Always observe applicable safety precautions when using
this equipment.

A Electrical Safety

WARNINGI Electrical Hazard

A 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
present on circuits prior to maintenance activities, etc.

r Lock out power

Never do maintenance on your OMAX equipment with the main AC disconnect ON,
L.
unlocked, or while the pump is in operation. Always follow standard lockout/tag-out
procedures.

Machine Safety

MANDATORY ACTION! Read the operator manual

Refer to your OMAX JetMachining® Center User’s Guide, P/N 400433, or MAXIEM Waterjets
User’s Guide, P/N 400588 for additional safety requirements.

40063ID-EN I

[t]
OMAX
 Introduction
The Access Control Circuit(ACC)is designed to create a designated safety zone around your waterjet to
protect operators from injury while using this equipment. The control circuitry monitors status of two
switch contacts. Breaking contact trips the safety circuit, disabling the cutting process until the cause of
the vioiation is corrected and the access control circuit is reset.
It is the customer’s responsibility to install fencing or other device that restricts access to the open sides
of the cutting table. Typical devices could be a light curtain, a fixed enclosure with switches, or a safety
mat using an external relay connection.
The Access Control Circuit requires inputs from two normally-closed switching devices that break
contact whenever access to the protected cutting area is attempted. Switches S1 and S2 in the
schematic below illustrate the required external circuit connections;

2 c r=i
‘A’signaMnput
3[ SI
4 c *B^$ignal input
S2
5 C I External Circuit
7 C I
o Power and control
Access control circuit trips
^ signaU.light curtain, whenever either of the two
6 L t/l only
m switches break contact
9 t Q

Figure 1

Access Control Hardware

The ACC is in an electrical enclosure with a hinged, see-through lid.
The MAXIEM ACC is held by magnets to any steel surface within a 10-foot range of the attached cables.
The OMAX ACC is attached to the table controller.

40063ID-EN 2

OMAX
 Attached to the controller allows the ACC to be located outside of the protected area and close to the
keyboard, monitor and mouse..

Blue Reset Button A'.

4
'1
0 iGreen Ar med Indicator
I Yellow Setup

■
I Mode Indicator

y/ R un Setup
'* * ●
t
!? tuh/Setup Switch

Power ON/OFF Switch

Figure 2

Setup mode allows operator access into the protected zone without triggering a complete shutdown of the
waterjet. During Setup, a slow speed control of nozzle motion is allowed, but pump and nozzle operations
are disabled. With Setup mode activated, the operator may enter the safety zone to load material, remove
parts, etc.
Run mode enables operation if both safety switches are closed and the Reset button was pressed following
an alarm shutdown.

Components Description

Access Control Circuit enclosure Electrical box with transparent

hinged-lid for viewing the LEDs.

Green Armed indicator When lit, the protected zone is

armed. Not lit indicates not armed.

Blue Reset button Arm the protected zone after a

Yellow Setup mode indicator
Run/Setup switch
Power On/Off switch
Receiver connector
Transmitter connector
violation.
When lit, indicates access control
circuit is in the Setup mode.
Switches ACC operation mode;
Run (turn counter-clockwise)
Setup (turn clockwise)
Switches AC power:
0 is OFF
1 is ON
Provides 24 VDC for external safety
switches and receives On/Off status
inputs from the two safety switches.
(Figure 1).
Provides 24 VDC at .5 amps to
support a low power external light
curtain transmitter station.
Contact OMAX Tech Support for
technical details.

m65W-EN 3

OMAX
 LED indicators inside the ACC enclosure are used to determine equipment functions.

T/

B” signal input LED

-J, I

A signal Input LED

Transmitter <
Connector
n

1
I

Figure 3

LED LED ON LED OFF

A S1 closed S1 open
\
S2 closed S2 open
armed not armed

K2 armed not armed

armed not armed

K4 armed not armed

Access Control Operation

MAXIEM Initial Equipment Power-up
1. Turn the main power breaker to ON for the MAXIEM equipment.
2. Turn the air supply valve ON.
3. Turn the water supply valve ON.
4. Turn the charge pump ON.

40063ID-EN 4

OMAX
 5. Power ON the MAXIEM controller disconnect switch.

Figure 4

6. Press the green Power ON switch on the controller pendant.

Emergency stop f ' Pc 0

©
Figure 5

7. Turn the Rotary Disconnect on the pump electrical cabinet to ON, and then push the green power
button to power the high-pressure pump ON (ensure it is in REMOTE mode).
8. On the ACC enclosure, place the Run/Setup switch in the Setup position (turn clockwise to the
right). Switch the ACC power to ON (“I”).
9. Verify that the yellow Setup indicator light is ON. You may now enter the safety zone.
10. When finished working inside the safety zone, exit and then press the blue Reset button and verify
that the green Armed light is ON.

Note: If the green Armed light fails to come ON, check the safety enclosure fora violation of the safety zone.
When the A and B LEDs are lit in the ACC enclosure, pressing the blue Reset button arms the system. At
this point, the yellow Setup mode indicator and green Armed indicators will be ON.

11. Place the Run/Setup switch in the Run position (turn counter-clockwise to the right).
12. Follow the Startup Checklist in your MAXIEM Users Guide to complete the startup procedure.
After you have completed the Startup checklist, if a “Babysit Triggered" message does not appear in Make,
the waterjet is ready for cutting.

OMAX Initial Equipment Power-up

1. Turn the main power breaker for the OMAX equipment to ON.
2. Turn the air supply valve ON.
3. Turn the water supply valve ON.
4. Switch the Pump AC power ON.

400631D-EN 5

lT]
OMAX
 5. Switch the Controller AC power ON.
6. Once Windows has completed startup, open Make.
7. When Make starts, verify that the status line below the OMAX logo flashes the message “Babysit
Triggered.”
8. On the ACC enclosure, switch the AC power ON (“1 ’’).
9. Verify that the green ACC power ON/OFF LED lights up, indicating output from the 24 VDC
supply.
10. Verify that both the A and B signal input LEDs are ON.
11. If these LEDs are ON, push the Reset button.
12, Verify the message “Babysit Triggered” disappears.
13, The JetMachining Center is now ready for cutting.

Allowing Operator Access

When necessary to enter the protected cutting area to remove or replace material:
1. Switch the Run/Setup switch on the ACC enclosure to Setup (turn clockwise) and verify that the
yellow Setup mode indicator turns ON.
2. Raise the nozzle and move the it away from the cutting material, allowing ample room for the
material to be removed or replaced.
3. With the yellow Setup light ON, you can now enter the protected area.
4. When finished, leave the protected area, ensure that the safety switches are again closed, and
verify that LEDs A and B are both ON.
5. Press the blue Reset button.
6. Switch the Run/Setup switch to Run. The yellow indicator is OFF.
7. The machine is now ready to resume cutting.

Rearming After an Access Violation

When the safety circuit is triggered by an access violation, the message “Babysit Triggered” appears on
the screen, the green Armed indicator goes OFF, the pump is disabled, and all nozzle activity
immediately ceases.
Abrasives will typically flow for a short time following a shutdown. This may plug the nozzle; following a
"Babysit Triggered” condition, always inspect the abrasive line and blow out all abrasive.

Caution: Whenever an access violation is triggered, ali nozzle positioning information is iost; this
requires that you re-home the machine and reset the soft iimits.

To recover from a “Babysit Triggered" condition following an access violation;

1. Correct the situation that triggered the access violation (switch opened, etc.).
2. Verify that both A and B status LEDs are lit.
3. Press the blue Reset button and verify that the green Armed indicator turns ON.

Note; If the Armed indicator fails to light, typically the cause is the safety violation has yet to be corrected. Again
verify that LEDs A and B are both lit.

4. Push the green Power ON switch to power up the drive motors.

5. Verify the “Babysit Triggered” message does not appear on the Make screen.
6, Re-home the machine.
7. Return to Path Interrupted Home.

40063ID-EN 6

OMAX
 8. The machine is again ready to resume cutting.

Customer Service
Refer to the OMAX website at www.omax.com for customer service information.

Original Instructions in English

September 2013
© 2013 OMAX Corporation

400631D-EN 7

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OMAX
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301501 - Integrated On/Off Valve Assembly

ITEM QTY PART NUMBER

1 1 301801 - Actuotor Assembly
2 1 302668 - Stem Assembly
3 1 301478 - On/Off Seat
4 1 300669 — Fitting Ring 5
5 1 301476 Valve Gland Nut
6 1 301477 - Valve Body
7 1 201649 - 0-Ring
8 1 301023 — Retaining Screw
9 1 201935 Set Screw
10 1 201936 Acorn Nut
11 1 302094 - Seal Assembly

OMAX
I

TITLE: INTEGRATED ON/OFF VALVE

DRAWING BY: MATERIAL / SPECIFICATION
PROPRIETARY INFORMATION

THIS DRAWING B THE PROPERTY DATE: 4/27/11

Reference Document Only OF OMAX CORPORATION AND NOT REVISED BY:
TO 8£ COPIED OR REPRODUCED
SHEET 1 OF 1 REVISION: H
This information could WITHOUT THE WRinEN CONSENT
change without notice. OF OMAX CORPORATION.
DATE: , DWG § 400137
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