Omax ProtoMax Bedienungsanleitung
ProtoMAX®
Operation Guide
Lockout/Tagout
Implement standard practices and procedures to shut down equipment, isolate it
from its energy source(s), and prevent the release of potentially hazardous energy
while maintenance and servicing activities are being performed.
Equipment Grounding Requirements
•Ensure the equipment is properly grounded in accordance with national, state,
and local codes. Never remove any prong from the plug. Always plug into a
proper electrical outlet.
•To reduce the risk of electric shock, during a malfunction or breakdown,
grounding provides the electric current with a path of least resistance. The
machine is equipped with an electric cord designed with an equipment-
grounding conductor (EGC) and a grounding plug (United States, Canada and
Mexico only). You must plug the cord into a matching outlet that is properly
installed and grounded in accordance with all local codes and ordinances.
•Do not modify the plug provided—if it does not fit the outlet, have the proper
outlet installed by a qualified electrician.
•Connecting the EGC improperly can result in electric shock.
•Contact a qualified electrician or service personnel if you do not understand the
grounding instructions, or if in doubt as to whether the equipment is properly
grounded.
•Do not use extension cords with the equipment.
•If the cord is damaged or worn, immediately replace it. Contact OMAX for
replacement parts and instructions for replacement. The insulation of the EGC is
covered with a green or green with yellow-striped surface. If replacement of the
electric cord or plug is necessary, do not connect the equipment-grounding
conductor to a live terminal. Refer to the equipment-specific wiring
configuration.
•The equipment is intended to be used on a circuit with an outlet similar to the
one shown (United States, Canada and Mexico only):
Figure 205
•The grounding plug is similar to the one shown (United States, Canada and
Mexico only):
Figure 206
•Ensure that the equipment is connected to an outlet that matches the plug
configuration.
•The equipment must not be connected to any different type of electric circuit.
•No adapter is available, or should be used with this equipment.
•For countries other than United States, Canada and Mexico; OMAX does not
supply a suitably rated industrial grade plug.
•Contact a qualified electrician or service personnel for installation of a suitably
rated industrial grade plug in accordance with national, state, and local codes.
•A pin and sleeve plug, rated at least 30A, 230V, 2-pole+E (3-wire
grounding), IP44 or better, having a first-make last-break protective bonding
contact (earthing contact) in accordance to standards IEC 60309-1 and IEC60309-
2 may fulfill this requirement.
Figure 207
•You must plug the cord into a matching outlet that is properly installed and
grounded in accordance with all local codes and ordinances.
Figure 208
Explosive Atmosphere Precautions
Machining certain types of material such as titanium with a waterjet may produce
sparks. Do not operate the equipment in an explosive atmosphere. Do not allow
explosive or flammable vapors to accumulate in the area of the equipment.
Equipment Safety Features
The abrasive waterjet provides several built-in safety features:
Overpressure Protection
During operation, pump pressure is monitored to prevent an overpressure
condition. If the pump exceeds the factory set maximum pressure limit, the safety
relief valve activates and shuts down the pump unit.
Electrical Protection
The equipment controller includes short circuit, over current and thermal protection
for the pump motor.
Electrical Disconnect/Emergency Machine Off (EMO)
An electrical disconnects/emergency machine off (EMO) switch is used to remove
the main AC electrical supply from the machine. To isolate the machine from its
electrical supply, always unplug the main AC supply power cord from its electrical
supply outlet.
Safety Lid
The lid of the equipment is designed with a safety interlock to prevent waterjet
operation when the lid is open.
Safety Legend
The following safety signal-word panels and paragraph notifications may appear
throughout this and other documentation. Each provides safety-issue identification
and recommended actions to avoid the hazard. Be alert! Follow the recommended
safety actions and precautions to prevent injury or damage to the equipment.
WARNING
Indicates a hazardous situation which, if not avoided, could result in death or
serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor or
moderate injury.
NOTICE
Used to address practices not related to physical injury ─property damage only.
NOTE:
Used to provide supplementary information, emphasize a point or give a tip for easier
operation.
Required Tools
The following table contains a list of tools with the appropriate sizes needed when
operating the ProtoMAX.
Customer Provided Tools
These tools are not provided by OMAX or included with the ProtoMAX.
Icon
Tool
Size(s)
Torque wrench
15–102 in-lb (2–12 Nm)
Hex socket
4 mm
Shop towels
Allen wrench
4 mm
Open-end wrench
19 mm
Crowfoot wrench
19 mm
OMAX Provided Tools
The following table contains a list of tools provided by OMAX that are needed to
operate the ProtoMAX. Tools listed with part numbers are included with
the ProtoMAX or are available for purchase. Contact technical support for more
information.
Icon
Tool
Size(s)
Stand-off tool
(P/N 317876)
Technical Specifications
See ProtoMAX Utilities Requirements for the technical specifications.
Introduction
This guide provides information and instructions to operate the abrasive waterjet
cutting system. It explains how the pump and abrasive waterjet system work. It also
provides instructions on how to machine a part, how to start and stop the system, and
how the software (Intelli-MAX® Proto) is used to machine a part.
Abrasive Waterjet Overview
The ProtoMAX abrasive waterjet is a precision machining tool that operates under
software control using high-pressure water and garnet abrasive to cut complex parts
out of most materials including metal, plastic, glass, ceramics, stone and composites
using standard CAD drawing files.
Components
The ProtoMAX takes up little shop floor space. The cutting stage has a 12 in. (30 cm)
(X-axis) by 12 in. (30 cm) (Y-axis) cutting area with an easy material alignment system
for cutting parts. The precision drive components are protected inside sealed bellows
from water and garnet abrasive. The manual Z-axis allows cutting of materials up to 1
in. (3 cm) thick. The cutting area is fully enclosed by a see-through enclosure
supporting a safety interlock system to halt abrasive waterjet cutting when opened.
The ProtoMAX consist of the following major components:
Figure 209
1] Table assembly
[2] High-pressure pump
Table Assembly
The ProtoMAX table assembly is comprised of the cutting stage, garnet abrasive
delivery system, catcher tank, electrical control enclosure, water filter, and operator
controls.
Figure 210
[1] Garnet abrasive delivery system
[4] Electrical control enclosure
[2] Cutting stage and X, Y, and Z stage
[5] High-pressure plumbing
[3] Catcher Tank
[6] Power and water controls
Cutting Stage Lid and Side Panels
NOTICE
Do not remove the side panels under normal conditions. Damage may occur when
operating the ProtoMAX with the side panels removed. Only remove them when
required by maintenance or troubleshooting procedures.
The cutting stage lid provides safe access to view the cutting process. The lid has a
built in safety interlock switch that halts all cutting operations (pauses MAKE, stops
stage motion, and turns off the pump) when the lid is opened. Always use the Pause
button in the software to pause the system before opening the lid. This allows the
operator to safely inspect the work and adjust materials as needed. Once the lid is
closed, the cutting operation may be continued. Side panels provide protection to
the catcher tank and pump. Incoming water pressure may be monitored through the
viewing portal located on the right side panel. Panels should remain on the table
assembly during operation. Panels can be easily removed for access to the interior
components.
Figure 211
[1] Cutting stage lid
[2] Side panel (x 3)
X, Y, and Z-axis Cutting Stage
The cutting stage provides a 12 in. (30 cm) (X-axis) by 12 in. (30 cm) (Y-axis) cutting
envelope. The Z-axis allows manual up and down movements for cutting materials
up to 1 in. (3 cm) thick.
The cutting stage uses the same grid and coordinate system as in the Intelli-
MAX software. When looking down on the table, the X-axis runs left to right and the
Y-axis runs front to back. The Z-axis allows vertical movement of the cutting head.
When the ProtoMAX is homed, the nozzle is moved to the position X=0 and Y=0
coordinate at the lower left corner of the cutting envelope.
Figure 212
[1] X-axis
[2] Y-axis
[3] Z-axis
Slat Bed
The cutting stage has a removable slat bed assembly to support cutting materials.
The slat bed assembly is removed to access the cutting tank for cleaning and
maintenance. The slat bed assembly is secured to the cutting stage frame and
provides support for the part being machined.
Figure 213
[1] Mounting plate, rear
[3] Mounting plate, front
[5] Square fixture plate
[2] Slats
[4] Slat comb bracket (x 2)
[6] Slat comb (x 2)
Catcher Tank
The catcher tank stores the water from the cutting nozzle and provides a settling
tank for the spent garnet abrasive and cut away material. The catcher tank bottom is
shielded to prevent cutting through when operating the machine.
NOTICE
Do not add chemicals to the catcher tank water. Damage to the catcher tank and
other components may occur.
Figure 214
[1] Catcher tank
Tank Drain
The adjustable tank drain helps maintain optimal water level by allowing excess
water to drain from the catcher tank during cutting operations. The drain has a
flexible tube to adjust the water level as needed and allows cutting underwater. The
tank overflow allows excess water to exit through the drain port and drain hose to
prevent overfilling.
Figure 215
[1] Adjustable tank drain
[2] Tank overflow drain
[3] Tank drain hose
Material Holding System
The material holding system fixtures (secures) materials while machining a part.
Fixturing prevents the material from moving, vibrating, floating, tipping, or falling
into the tank. The abrasive jet stream is very powerful. The force exerted from the
abrasive waterjet stream into the tank can move or float the material during the
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