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Service and Maintenance Guide

1. 1 locii 1 Access Control Operation A 4 Initial Equipment Power A 4 Stopping the JetMachining Center to Allow Operator Access A 4 Re arming the Circuit Following an Access Violation A 4 Appendix B Rebuilding the High Pressure Swivel Go co eS ee ee ee B 1 Tools and Materials B 1 Removing the High pressure Swivel B 1 Disassembling the High pressure B 2 Replacing the Seals and O Rings 1 0 2 0 ccc ees B 4 Replacing the Bear 25 za ue 20044 Ch OIE B 6 Reassembling the High Pressure Swivel Halves B 10 Installing the High pressure Swivel B 10 cosmos 309 Ptud 4 Y aO Ce LR RD Ra RR ERR ER bene B 11 Appendix C Rebuilding the Dual On Off Valve gon RCT H c C 1 Tools and Materials Needed C 1 Removing the Dual On Off C 1 Disassembling the Dual On Off Valve C 4 Reassembling the Dual On Off C 5 Installing the Dual On Off Valve C 7 go E
2. Parts are Too Short or Flat Spots Appear When Cutting Curves Home Position for Soft Limits are 8 Problems with Machining Poor Surface Finish mos Holes Too Large and Undersized Parts Excessive Taper on Part Holes are ioari d Yu Abrasivejet Not Piercing 1 Abrasivejet Quit ACCUIICY EON 23 ane CREER E oo Rd Problems with the Nozzle and Abrasive vi T CMAK 400444B The OMAX JetMachining Center Service and Maintenance Guide Water is Forced Up the Abrasive 4 10 80160 Not Cutting Square 4 10 Abrasive Material Pours Out the Top of the Abrasive Tube 4 11 The Jet Looks Wide and 77 4 11 Abrasive Has Stopped Flowing 4 11 Water Leaking from the Nozzle 4 12 Water Leaking from the On Off 4 13 Miscellaneous 4 14 Water Spurts Out
3. 6 10 Lubrication Points for Cantilever Style X Y Carriages 6 11 Greasing the X and Y Carriages 6 11 400444B vii FL A OMAK The OMAX JetMachining Center Service and Maintenance Guide Vili Lubrication Points for the Motorized 7 1 6 12 Greasing the Z axis Bearings 6 12 Lubrication Points for the 80160 6 15 Greasing the 80160 Y axis Carriage 6 15 Greasing the 80160 X axis Rails 6 16 Rebuilding the Abrasivejet Nozzle 6 18 PC Controller Maintenance 6 18 Cleaning the OMAX Industrial Keyboard and Mouse 6 18 Cleaning the LCD Monitor Screen 6 18 Replacing the Cabinet Air 6 18 Rebooting Windows 6 19 Running the Disk Defragmenter Utility 6 19 Upgrading Your OMAX Software 6 19 Replacing the CMOS 6 20 Mamicnance LoS 6 21 Chapter 7 Pump Maintenance General BAe Od Lede Ree 7 1 COMSUMADIC Fats aha cease
4. C 5 Figure C 11 Apply Lubriplate to Seal and Stem Assemblies esses C 5 Figure C 12 Apply Lubriplate to Valve Body Borte eerie nin niet rn eene rarae C 6 Figure C 13 Insert the Stem and Seal Assemblies into the Valve C 6 Figure C 14 Applying Blue Goop and Installing the Retaining Screw C 6 Figure C 15 Insert the Stem Assembly into the Valve Body sess C 6 Figure C 16 Sliding the Valve Gland Nut and Fitting Ring onto the Valve C 6 Figure C 17 Align UHP Line with the Opening in the Fitting eene C 7 Figure C 18 Applying Blue Goop and Ensuring Three Threads Show C 7 Figure C 19 Applying Blue Goop to the Valve Body Threads essere C 7 Figure C 20 Flushing the System with Water Only at High Pressure C 8 xiv Fo 400444B T CMAK Chapter 1 Safety First This chapter identifies describes and locates each safety label attached to the OMAX equipment These labels provide information essential for safe equipment operation In addition this chapter emphasizes important safety precautions that must be observed while operating servicing and maintaining this equipment and identifies the safety devices built into this equipment While maintenance and
5. 2 4 Figure 2 10 Components of the JetMachining Center Models 60120 80160 and 80X 80X illustrated sese 2 5 Figure 2 11 The JetMachining Center PC Controller sees eene nennen nnns 2 5 Figure 2 12 Control Panel Operator Switches ise peser re eda Faire 2 6 Figure 2 13 Controller Rear Door Internal Components esses eene 2 7 Figure 2 14 Controller Cabinet Internal eene eene enne nnn nnns ness 2 8 Figure 2 15 Air Filter Location Beneath the Controller 2 8 Figure 2 16 User Components on Front Panel of Controller 2 0 Figure 2 17 PC Rear Panel Cable 2 0 Figure 2 18 X Y Carriage Components of the JetMachining Center Models 2626 2626 2652 5555 55100 55100 2 10 Figure 2 19 X Y Components of the JetMachining Center Models 60120 80160 and 80X 80X illustrated enne 2 10 Lupe 2 20 Motorized Ek ciu M tunt ossa cur aries uM vate 2 11 Figure 2 21 JetMachining Center Abrasivejet System Components 5555 illustrated 2 11 Figure 2 22 Components of OMAX Abrasivejet Nozzle Assembl
6. esses 5 5 3 0 AC Power Lees LL L2 and Lo ce 5 7 Figure 5 7 Example of Pump Fault Condition Appearing on Keypad 5 7 Figure 5 8 VFD Remote MOUSE 5 8 Peire He VDC POW Ci Sy adie 5 9 Figure 5 10 Circuit Breakers CB2 and Location cece 5 10 Figure 5 11 Keypad Ribbon Cable and 34 Pin Connector Location 5 12 Figure 5 12 24 VDC Power supply Fuse Location 5 12 Figure 6 1 Outlet Water Filter Screen at Back of 6 3 Figure 6 2 Example of Typical OMAX Servo Motor Ball Screw Timing Belt Connection 6 5 Figure 6 3 Timing Belt Locations Typical of OMAX Cantilever Tables see 6 5 Figure 6 4 Carriage End Cover Screws Removed to Access Timing 6 6 Figure 6 5 Components Involved in Adjusting the Timing Belt Tension sees 6 6 Figure 6 6 Y axis Servo Motor Ball Screw Timing Belt Connection for Bridge Tables 6 7 Figure 6 7 Timing Belt Locations for Bridge style 6 7 Figure 6 8 Remove Cover Plate to Access the
7. 2 6 PC Controller Internal 2 6 PC COMUOUCT d hd du aded ed eee rd bct nd 2 8 PC Front Pinel NER ESSE Ed Ed 2 9 DC Rear Panel 2 9 400444B The OMAX JetMachining Center Service and Maintenance Guide X Y Z axis Motion Abrasivejet Delivery Abrasive et The Abrasive High pressure ub Qm Dual Valve 2 cero yore e ig su c Chapter 3 Introduction to the OMAX Pump Description of the OMAX Pui p CombpObehlts doncc s edes FE EE RES Pump Viewed from Front and Right Side Front Pump View with Front Panel Removed Top Pump View with Lid Pump Side View with Right Panel Pump Control Panel 22292 pA Ped EE High pressure Pump On Off Switch Charge Pump On Off Emergency Stop Switch E
8. E Maintaining the Water Filtration 7 31 Changing Water Filter 7 32 Cleaning the Pump White Water Tank 7 34 rankcase OIL ausos Sue eade aco ER RUE op e Ar ease 7 35 Belt NIamtendlfee a ur que sacado aoa ee FA bowen daa 7 35 Lubricating the Electric 7 37 Replacing the Electrical Enclosure Air 7 39 Maintenance m 7 40 Chapter 8 Customer Service Contacting OMAX Customer Service 8 Orders Pats 8 Returning Pats SUERTE Sea qeu Sq 8 Returned Material 8 Parts Ordered mM ETOT 2355 xe 8 2 Un sed Pas vci cctevaceewawe pat aci Ed anie ax dra bars 8 2 Parts Shipped 8 3 400444B 400444B The OMAX JetMachining Center Service and Maintenance Guide Parts Returned for 8 3 Parts Returned for Warranty Repair or Replacement 8 3 Two Year Limited 8 4 Appendix A Access Control Circuit COMCINS qq
9. 6 20 Figure 7 1 Major Components of Wet end Pump 7 4 Figure 7 2 Highs Wetend Assembly 7 5 Figure 7 3 Nut Loosening Sequence for Removing Clamp Plate from High Pressure Assembly 7 6 er ap Plate IR 7 6 Figure 7 5 Removing Wet end lt isisccdiewsivencasvariucaneseecdicdeniadenindssieusinbtsintesesstavalvesditacsiguenieavereecs 7 6 Figure 7 6 OMAX Special Disassembly Tools scsacsnsscasianeanacannncdlennsentondasmestenesencssetseosacesterenseaeusesaaleneensaieeapacs 7 7 Figure 7 7 High Pressure Wet end Assembly Components esses eren 7 7 Figure 7 8 Removing the Cylinder and Check Valve Assembly sss 7 8 Figure 7 9 Using the Check Valve Assembly Removal Tool 7 8 Figure 7 10 Sealing Assembly Components aeos easet cc etae Pru Ets na o su 7 9 Figure 7 11 Removing the Sealing Assembly using an Arbor 7 9 Figure 7 12 Separating the Backup Support Ring Assembly from the Displacer sss 7 9 7 15 Dynamic Scal Inspection
10. ee 7 1 High pressure Wet end 7 2 Routine Maintenance E Less Frequent Maintenance qi Minor Maintenance 7 2 Major Maintenance Detall 2 2 oven pw ex E ERGO ee ES 7 3 Oven so qucm doa eodem Ae nee Geode eed 7 3 Maintaining the Wet end Pump 7 4 Removing the High pressure Wet end 7 5 Disassembling the High pressure Wet end Assembly 7 7 Inspecting the Backup Ring Assembly 7 10 Inspecting the Liquid 1 7 11 Disassembling and Inspecting the Check Valve Assembly 7 12 Reassembling the Check Valve Assembly 7 15 Replacing the High pressure Port Adapter Seals and Filter 7 18 Reassembly of the High pressure Wet end Assembly 7 21 Replacing the Water Coolant Housing Seal 7 23 Removing Plunger Assemblies 7 24 Reinstalling Plunger 7 26 Assembling the Dynamic Seal Assembly 7 26 Reassembling the
11. Access Control Circuit 400444B Appendix B Rebuilding the High pressure Swivel FN The OMAX JetMachining Center Service and Maintenance Guide 400444B Rebuilding the High Pressure Swivel Use the following procedure to disassemble and replace worn components in a high pressure swivel Contents Tools and Materials NE de ccccccccseecceeseeeeceeeeeeceeeseeseeeeeeeeeeeeeeeeeesseaeeeessaaeeeessaeeessaaseeeessaess page C1 Removing the High pressure page C1 Disassembling the High pressure page C2 Replacing ihe Seals and O RINGS dd Lived Dk usd es taU Ld hee udin page C4 Replacing the page C6 Reassembling the High Pressure Swivel Halves page C10 Installing the High pressure page C10 Figure B 1 High pressure Swivel used in OMAX JetMachining Centers Tools and Materials Needed Lubriplate grease P N 201304 e Spanner wrench P N 304512 e Soft jawed vice e Seal removal tool P N 201726 6 mm Allen wrenches e Blue Goop anti galling compound P N 200365 Arctic Grease P N 202335 e Seal Replacement Kit P N 305088
12. E rire rphR a RAPRAERTAT Li IIIJ a j ssess rrr ground cable B 227 a Figure 2 17 PC Rear Panel Cable Connections 400444B 2 9 The OMAX JetMachining Center Service and Maintenance Guide Introduction to OMAX Tables X Y Z axis Motion System The precision X Y axis motion system installed on the 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 see Figure 2 18 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 The entire bearing and drive mechanisms are surrounded and sealed in urethane bellows that prevent water and abrasive particles from entering and severely damaging critical mechanical components f Y axis carriage X axis carriage Li cutting table Figure 2 18 X Y Carriage Components of the JetMachining Center Models 2626 2626 xp 2652 5555 and 55100 55100 illustrated The 60120 80160 and 80X motion systems consist of a Y axis bridge attached to dual X axis rails rigidly mounted to the catcher tank see Figure 2 19 Y axis bridge 1 high pressure pl
13. e 7 34 Figure 7 54 Pump Crankcase Oil Drain Hose Filler Pipe sese 7 35 Figure 7 55 OMAX Pump Belt Guard Cover 7 36 Figure 7 56 OMAX Pump Belt with Belt Guard Cover 232 7 36 Figure 7 57 Location of Front and Rear Motor Grease Fittings and Pipe 7 38 Fig re 7 55 Electrical Euclosute Air Piers e a 7 39 Figure A 1 External Electrical Circuit Requirement for the A 2 Figure A 2 Access Control Enclosure Attached to Side of OMAX Controller A 2 igtur M es ACC Satr LEDS aa rr A 3 Figure B 1 High pressure Swivel used in OMAX JetMachining Centers B 1 Figure B 2 Typical High Pressure Swivel B 1 Figure B 3 Components of the High pressure Swivel B 2 Figure B 4 Clamp the Swivel Assembly in a Soft jawed B 3 Figure B 5 Use the Swivel Spanner Wrench to Unscrew the Swivel Retaining B 3 Figure B 6 Separate the Swivel Assembly into its Male and Female Halves B 3 Figure B 7 Remove the Three Swivel Assembly Screws with the 5mm Allen Wrench B 4 Figure B 8 Remove the Swivel Back up Ring from the Swivel Assembly sere B 4 Figure B 9 Use the Removal Tool
14. Condition and Possible Causes Corrective Action The Y axis is no longer exactly Square the Y axis bridge against the hard stops on the perpendicular to the X axis right controller side of the machine You should resquare home the Y axis whenever The X axis drive motor faults The Y axis bridge crashes Accuracy Errors Condition and Possible Causes Corrective Action The material being cut is improperly Always have firm anchoring in X Y and Z directions secured even if the material is heavy Never anchor directly to slats These are insecure and can easy vibrate The nozzle is inadequately secured Ensure that the nozzle is firmly attached The material being cut has internal Material stresses can cause huge part errors As the stresses part is machined these stresses can cause the material to move and stretch Temperature caused the material to The material is stored in a different temperature than expand the tank water and changes size during or after cutting The nozzle and material collided Avoid traversing over previously cut features Watch for parts or slugs that tip or float around The nozzle is worn out of round 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 Problems with the Nozzle and Abrasive System Water is Forced Up the Abrasive Tube Condition and Possible Causes Corrective Action Nozzle body is lo
15. Figure 7 13 Dynamic Seal Inspection 8 Remove the Dynamic Seal Assembly from inside the end of the Displacer Remove the Large O ring from the outside of the Dynamic Seal Separate the components of the Dynamic Seal Assembly by pushing the Dynamic Seal out of the Retainer Remove the Small O ring from inside the Retainer Figure 7 14 Dynamic Seal Assembly Components 9 Repeat steps 4 8 for the remaining two Backup Ring and Displacer Assemblies 10 Since they are not reusable discard the O rings the plastic ring seals and the plastic Dynamic Seal of the Dynamic Seal Assembly The metal Retainer is reusable Inspecting the Backup Ring Assembly 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 Tool needed for inspection e magnifying glass 400444B TMAX Pump Maintenance The OMAX JetMachining Center Service and Maintenance Guide To inspect the backup support ring assembly 1 With the magnifying glass examine the edges and interior of the metal lip in the bore of the Backup Ring Figure 7 16 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
16. Figure B 23 Fully Tighten the Bearing Lock Nut using the Swivel Spanner Wrench B 9 Figure B 24 Apply Arctic Grease to Top of Bearing Assembly esses B 9 Figure B 25 Assemble the Two Swivel Body Halves B 10 Figure B 26 Tightening the Retaining Nut with the Spanner B 10 Figure B 27 Replace the O ring with New One sncieaicdssnsavasusseansdnntosrvecenanassxecesanad urinen AEAT EEEE B 10 Figure C 1 Dual On Off Valve with the MAXJET 5 Nozzle 1 Figure C 2 Removing the Air Actuator Assembly C 2 Figure C 3 Removing the Retaining Screw from the Valve Body C 2 Figure 4 Loosening the Valve Gland Nut using Two Open End C 2 Figure C 5 Removing the Valve Gland Nut from the Nozzle Assembly C 3 Figure C 6 Components of the OMAX Dual On Off Valve ccccccccccceeeeeeeeeeeeeeeseseesnnaaaeeeeeeeeeeeeeeeees C 4 Figure C 7 Components of the Dual On Off C 4 Figure C 8 Removing the Stem Assembly from the Valve C 5 Figure C 9 Pushing the Seal Assembly from the Valve C 5 Figure C 10 Discard the On Off Seat Seal Assembly and Stem
17. on the lip Figure 7 16 Backup Ring Inspection 2 Refer to the below illustration that 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 lip damaged by plunger rubbing Figure 7 17 Example of Lip Damage to Backup Ring Note Whenever plunger rubbing has occurred the plunger assembly must be replaced along with the dynamic seal and backup support ring assembly Inspecting the Liquid Displacers Tool needed for inspection e 1 inch micrometer The small flanges on each end of the liquid displacer should be 0 8115 to 0 8125 inches 20 61 to 20 64 mm in diameter If these diameters are undersized leakage between the coolant housing and the cylinder could result 400444B Fr The OMAX JetMachining Center Service and Maintenance Guide To inspect the liquid displacers 1 WARNING Caution Note 7 12 Pump Maintenance Clean the Liquid Displacers Figure 7 18 and use the micrometer to measure the outside diameters of each Displacer end Any Displacer that measures less than 0 8115 inches 20 61 mm in diameter on either end should be replaced Inspect the displacer edges on the ends to determine if the edges are sharp free of any missing material
18. 2 Check the water level in the white water tank Figure 7 53 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 400444B 5 11 F The OMAX JetMachining Center Service and Maintenance Guide Servicing the OMAX Pump 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 5 11 Keypad Ribbon Cable and 34 Pin Connector Location on page 5 12 ribbon cable fem 34 connector Figure 5 11 Keypad Ribbon Cable and 34 Pin Connector Location 4 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 correct the problem detach the 34 pin cable from the keypad and visually inspect the female connector ensuring all pins are fully locked into the housing See Figure 5 11 Keypad Ribbon Cable and 34 Pin Connector Location on page 5 12 Caution Ifa pin is not locked into the housing gently pull it out of the connector noting what socket it fits in The pin ha
19. Pump Maintenance The OMAX JetMachining Center Service and Maintenance Guide Tools required to replace the high pressure port adapter seals and filter 14 mm Allen wrench 5 8 open end wrench Soft blow mallet Two large flat tipped screwdrivers e Small flat tipped screwdriver External snap ring pliers Torque wench capable of 100 ft lbs Lubriplate OMAX P N 201304 Anti seize compound OMAXP N 202563 Soft jawed vise port adapter body high pressure seal S filter adapter J filter assembly filter adapter 4 1 high pressure seal port adapter body Figure 7 31 Port Adapter and Filter Assembly Components 400444B Fedo The OMAX JetMachining Center Service and Maintenance Guide Pump Maintenance To replace the High pressure Port Adapter Seals and Filter 1 2 Place the Manifold body Figure 7 1 into a vise Using the 14 mm Allen wrench remove the four Socket Head Screws Figure 7 1 from both Port Adapters With the soft blow mallet strike the Port Adapter on each side until a gap opens between the Manifold and Port Adapter With two flat tipped screwdrivers pry the Port Adapter out of the Manifold Follow the same procedure to remove the second Port Adapter Caution Avoid scoring the metal components or damaging the filter 5 10 11 12 13 14 15 Remove the Filter Assembly Using the 5 8 open end wrench remove
20. e inch pound torque wrench Additional Requirements for Bearing Removal Arbor press Bearing assembly P N 202964 Bearing puller Pry bars Removing the High pressure Swivel Figure B 2 illustrates a typical high pressure swivel installation high pressure high pressure swivel assembly Jo plumbing _ swivel tube clamp _ d Screws 2 ea clamp bar screws 2 ea clamp bars clamp bar screws 2 ea Figure B 2 Typical High Pressure Swivel Installation 400444B B 1 F 9 OMAK OMAX JetMachining Center Rebuilding the High Pressure Swivel To remove a high pressure swivel 1 As necessary move the nozzle to a location providing easy access to the swivel s being serviced 2 Switch Off the AC power for both the pump and table Disconnect their main AC power breakers Attach an Out of Service tag on each breaker and observe all applicable electrical safety requirements 3 Prior to removal carefully wash off the entire high pressure swivel assembly using water and compressed air Be especially careful to remove all grit and abrasive 4 Use the 6 mm Allen wrench to remove both clamp bars 4 screws from the swivel assembly releasing the plumbing tubes Caution Be very careful while removing swivel components The high pressure support structure will become unsupported and can fall once key components are removed 5 Remove the four screws securing the swivel tube clamp
21. 13 Fault Message Variable Drive Fault 5 13 Chapter 6 Table Maintenance Maintenance Schede E 6 1 Tank Mathtendli6B s ses cn qma 6 2 Cleaning Tips 6 2 Removing Garnet Accumulation 6 2 Solids Removal System Clean Out Software 6 3 Cleaning the Filter Screen for the Tank s Water Outlet 6 3 Controlling Tank 6 3 Slat Replacement 6 4 Table Maintenance ada ac 440436045 bode EHE d Pin E dS 6 4 Maintaining the X Y Carriage 6 4 Timing Belt Inspection and 6 5 Timing Belts for Cantilever style Tables 6 5 locate Tunis E RR rA ERR ds 6 5 Inspecting and Adjusting Timing Belts 6 5 Timing Belts for Bridge style 6 7 Locating Timing Belts 6 7 Adjusting Timing Belts Y axis 6 8 Adjusting Timing Belts 80160 X axis 6 8 Lubricating the JetMachining 6 9 Grease Fittings and Couplers 6 9 Identifying Lubrication Points
22. 21 22 Start M1 Set the RPM for the main motor M1 Clear a VFD fault The pump MICROPROSSOR receives two signals from the VFD the main motor M1 torque which is representative of pump pressure and the VFD FAULT signal If for some reason the VFD faults the VFD shuts Off the main motor M1 opens relay R2 which shuts Off the charge pump and closes relay R1 which sends a VFD FAULT signal to the pump MICROPROCESSOR CONTROLLER The MICROPROCESSOR CONTROLLER then reports on the pump DISPLAY that a VFD FAULT has occurred To clear the fault the MICROPROCESSOR CONTROLLER can be commanded to clear the fault condition of the VFD by pressing the RESET button on the keypad The pump can then be restarted In addition the pump MICROPROSSOR CONTROLLER detects and reports a FAULT status of the CHARGE PUMP CONTACTOR if it should be closed but remains open It also detects and reports a FAULT status if the charge pressure is less than 50 psi when the charge motor M2 is running When connected to the OMAX Jet Machining Center COMPUTER CONTROLLER the pump MICROPROCESSOR CONTROLLER receives and interprets the PUMP ON or OFF LOW PRESSURE and NOZZLE ON or Off signals from the COMPUTER CONTROLLER Pump Specifications __ psv Width Depth Weight Type Inlet water 85 978 Sin 1678 Sin 01 5 om 7501 750 Fixed displacement Fixed displacement Fixed displacement triplex triplex triplex 1 1 4 0 I
23. 3 When the Charge Pump is turned On water from the white tank reservoir feeds the preconditioned water to the 10 blue filters in the pump cabinet Figure 7 51 Note The pre filter gauge Figure 7 51 reads the pressure of the charge pump before the filters Pressure should read higher than 75 psi and can be adjusted up to 120 psi 4 Water is pulled by the charge pump from the white tank reservoir through a 200 mesh strainer OMAX P N 200935 and pumped to the pre filter 1 micron through the 2nd final filter 45 microns and then into the pump 5 The final filter gauge reads the pressure after both filters have filtered the water Note The difference in pressure between the gauges when the pump is running at high RPM determines filter status 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 When the low pressure water system is not maintained properly the following error message can appear Charge pump pressure low This message is typically caused by the charge pump not being able to develop sufficient water pressure triggering the 50 PSI low pressure switch causing the high pressure pump to shut down and the Charge pump pressure low message to appea
24. External Wall mounted W ater Water Filters Pump Incoming W alter Figure 7 49 The Low pressure Water Filtration System A W ate r O u t wall mount water In fine filter coarse filter Figure 7 50 Incoming Water Filters Wall Mounted final filter gauge pre filter gauge air bleed buttons water out line i FOAL Patten P t i a water in from n X re filter final filter charge pump E 2 final filter safety switch shuts off relief valve relief valve adjust PSI with knurled pump at pressures knob at bottom below 50 PSI Figure 7 51 Pump Internal Water Filtration System 400444B T OMAK The OMAX JetMachining Center Service and Maintenance Guide Pump Maintenance How the low pressure water system filtration works 1 Water from your local source is piped into your building and is plumbed to two OMAX wall mounted pre filters a 20 micron course filter and a 5 micron fine filter See Figure 7 50 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 This filtered water then flows to the white reservoir tank Figure 7 53 located under the crankcase in the pump cabinet
25. Figure 7 7 of the first Cylinder until it contacts the check valve Retainer Nut inside the Cylinder check valve assembly cylinder check valve removal tool Figure 7 9 Using the Check Valve Assembly Removal Tool 3 Strike the tool firmly against a solid surface to remove the Check Valve Assembly from the Cylinder Assembly Set the Check Valve Assembly aside until later Repeat for the remaining two cylinders 4 Using the Removal installation Tool Figure 7 6 push the Sealing Assembly Displacer Retainer and Seal Assembly Short Seal Ring and Backup support Ring Assembly Figure 3 10 out of the Cylinder from the Check Valve Assembly end toward the Coolant Housing Assembly end using an Arbor press Figure 7 11 Repeat for the remaining two cylinders 7 8 400444B Fo Pump Maintenance The OMAX JetMachining Center Service and Maintenance Guide Note The long seal ring on the inlet side of the check valve assembly usually remains in the cylinder bore and can be easily removed by hand QO backup support ring assembly dynamic seal assembly OlSpiacer Figure 7 10 Sealing Assembly Components removal installation tool cylinder arbor press Figure 7 11 Removing the Sealing Assembly using an Arbor Press 5 Separate the Backup support Ring Assembly Figure 3 10 from the Displacer by placing the large end of the Removal installation Tool Figure 7 12 over
26. Never operate the OMAX pump with any of its protective guards or covers removed or rendered inoperative Removing the abrasive feed hose from the nozzle while still under pressure will blow abrasive particles into the room air getting into eyes and contaminating tools and machines 400444 F Safety First The OMAX JetMachining Center Service and Maintenance Guide Placement of Safety Labels OMAX g go JetMachining Cent g 1 nter Figure 1 2 Safety Labels 80160 400444B 1 F The OMAX JetMachining Center Service and Maintenance Guide Safety First ETH TEH Figure 1 3 Safety Labels 60120 Figure 1 4 Safety Labels SOX 1 4 400444B F Safety First The OMAX JetMachining Center Service and Maintenance Guide M ATCH YOI WATCH YOUR KEEP STAY CLEAR HANDS AND GUARDS M you can rend this sign FINGERS a covor ia missing Do NOT IN PLACE operate with cover missing HANDS FINGERS External Pump Safety Labels WATCH TOUR Internal Pump Safety Labels Figure 1 5 Safety Labels OMAX Pumps Safety Precautions Always observe the following safety precautions while operating your OMAX equipment Carefully operated the OMAX is a safe productive tool When operated carelessly serious injury can easily result 400444B Table Safety Requirements Do Be careful when handling materials in the tank Fingers can b
27. Note 400444B The OMAX JetMachining Center Service and Maintenance Guide upstream filter 1 micron E c ownstream 28 d i filter 45 micron red air bleed p I In b w ae Figure 7 52 Low pressure Water Filters with Pressure Gauges To replace the water filter cartridges a oe Se NY c 10 Position the waterjet nozzle in a safe location or remove the nozzle Turn Off the charge pump Lift the pump s cover lid and remove the front panel cover Unscrew each filter housing using the spanner wrench provided OMAX P N 200773 Remove and discard the filter elements Wash and rinse the filter housing to remove all sediment and coatings from inside the housing 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 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 After replacing the two elements turn On only the charge pump Hold down the red buttons on top of the filters next to the pressure gauges Figure 7 52 to bleed air from the filters If all the air is not purged from the filters the charge pump cannot develop sufficient pressure and the main pump unit will shut down displaying the fault message Charge Pressure
28. 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 O ring and the stem assembly 2 Slide the seal assembly onto the stem assembly shaft with the O ring facing towards the valve body Figure C 12 Ensure that the seal assembly slips over the pointed end of the stem assembly 3 Lubricate both the seal assembly O Ring and the stem assembly with Lubriplate grease seal assembly with O ring towards valve body Figure C 11 Apply Lubriplate to Seal and Stem Assemblies 400444B C 5 F OMAX JetMachining Center Rebuilding the Dual On Off Valve 4 Lightly coat the valve body bore down past the threads to the internal lip with Lubriplate grease PO Figure C 12 Apply Lubriplate to Valve Body Bore 5 Tightly grasp the stem assembly with the seal assembly installed and gently push them down into the lubricated valve body bore Figure C 13 Insert the Stem and Seal Assemblies into the Valve Body Note fthe stem assembly body resists insertion into the valve body because of the seal assembly O 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 ar
29. body stem Figure 7 25 Placing the Outlet Check Valve Retainer on the Check Valve Body Stem Ensure that the hole through the outlet check valve seat lines up with the hole in the outlet check valve body stem The outlet retainer can inadvertently be installed 180 degrees out of its required position Always ensure that the hole through the outlet check valve seat lines up with the hole in the end of the check valve body stem WARNING 6 Using the 3 32 Allen wrench tighten the two Socket Head Screws from to 5 in lbs 34 to 57 N m Holding the Allen wrench as shown in Figure 7 26 prevents over tightening the screws 400444B LAR Pump Maintenance The OMAX JetMachining Center Service and Maintenance Guide Figure 7 26 Tightening the Socket Head Screws Repeat steps 1 through 6 for the remaining Check Valve Body Assemblies Next begin assembling the inlet side of the Check Valve Body Assembly This is the side with the threaded pocket and two holes Figure 7 27 9 Install the Short Support Ring with the small notch facing down over the outside of the Check Valve Body Stem on the inlet side short support ring with notch down i ZO UNA Inlet Check Valve Body Stem t d F hd T i r 8 i gure 7 27 Installing the Short Support Ring 10 Install the Long Seal Ring over the outside of the Stem Figure 7 27 11 Next insert the Inlet
30. final filter exceeds 50 psi typically 12 psi the pressure switch 51 may be defective If the upstream gauge pre filter does not exceed approximately 70 psi the charge pump may be partially plugged or defective Verify that all air has been bled from the water filters 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 Changing Water Filter Cartridges page 7 32 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 Fault Message Charging Pump Contactor This message appears on the OMAX 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
31. motor pull Fe A xg d yp ball screw Figure 6 2 Example of Typical Servo Motor Ball Screw Timing Belt Connection Timing Belts for Cantilever style Tables Note Cantilever tables include the Models 2626 2626 xp 2652 5555 and 55100 OMAX recommends that timing belts for the Model 2626 xp not be removed or adjusted Doing so could greatly affect its cutting precision Please contact Customer Service for additional 2626 xp timing belt information Locating Timing Belt 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 6 3 X carriage timing belt location Figure 6 3 Timing Belt Locations Typical of OMAX Cantilever Tables 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 400444B uu 6 5 Fw The OMAX JetMachining Center Service and Maintenance Guide Table Maintenance 3 Verify that AC power to the OMAX JetMachining Center was properly disconnected Caution Ensure that both the 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 carri
32. nicks gouges or burrs Score marks from the cylinder bore are normal Do not attempt to smooth score marks by sanding as this makes the diameter undersized 0 8115 to 0 8125 inches f Figure 7 18 Liquid Displacer Measurements Disassembling and Inspecting the Check Valve Assembly The following explains how to inspect the check valve components in a check valve assembly and replace the valve seats It is important to inspect the seats and mating surface of the check valve body Worn or damaged seats must be replaced Inspection is best performed with the aid of a magnifying glass Water leaking past check valves can form jets that damage the check valve body Do not run the OMAX pump if the output pressure begins to drop by more than 4 6 KSI from the original RPM If the check valve seats are worn continued pump operation can damage the check valve body Replacing the check valve seats in all three cylinders at the same time is a good practice Once one check valve seat has worn to the point of replacement the others are quick to follow To reduce overall downtime replace the high pressure seals and the check valve seats whenever the wet end has been disassembled Tools needed to disassemble and inspect the Check Valve Assembly 3 32 Allen wrench Magnifying glass 5 8 crows foot 1 2 wrench Propane torch Channel lock pliers Needle nose pliers OMAX removal tools Figure 7 6 Soft jawed vise F 400
33. open end wrench Once removed scrub it clean using a mixture of mild soap and water LM outlet water filter Figure 6 1 Outlet Water Filter Screen at Back of Tank 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 water supports bacteria growth that can infect open wounds Use the bacteria 400444B 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 The JetMachining Center comes with sufficient chemicals to last approximately one year When reordering chemicals use Pace Pool Chlorinating Tablets manufactured by Olin Chemicals or an equivalent product If you switch to a different brand be sure to read any warning labels Mixing different brands of chemicals could create a hazardous situation F 9 T TAAR The OMAX JetMachining Center Service and Maintenance Guide Table Maintenance Caution Do Not add chlorine tablets when using an EBBC
34. sioce ceccscaccavsesswsseavasievsncednodicensensencsansnavashswnancnendsieancvnansadlseens 7 17 Fig te 7 27 Installing the Short Support RING 7 17 Figure 7 28 Inserting the Check Valve Ball and Check Valve Seat into the Inlet Ball Retainer 7 17 Figure 7 29 Applying Anti seize Compound to Threads and Bottom Face of Retainer Nut 7 18 Figure 7 30 Installing the Inlet Retainer NUt ee ececcceesesessnnneeeeeeeeeeeeeeeeeeeeeseeeeeeeseesaaaaaaaeeeeeeeeeeeeeeees 7 18 Figure 7 31 Port Adapter and Filter Assembly Components eese 7 19 Figure 7 32 High pressure Wet end Assembly 7 21 Figure 7 33 Installing the Liquid Displacer on the Check Valve 7 22 7 34 Reversed Displacer Example eee tentur on dtd usc qu vendues epa s Ue asus 7 22 Figure 7 35 Sliding the Cylinder over the 7 23 Figure 7 36 Coolant Housing Assembly eene eene eene eene 7 23 Figure 7 37 Removing the Coolant Housing Assemblies esses nenne 7 24 Figure 7 38 Adapter Block Pony Rod and Plunger Assembly sse 7 25 Figure 7 39 Access Cover Plate Top of
35. the sealing surface is probably eroded which requires that the fitting be disassembled and any eroded parts replaced WARNING Properly preparing and connecting ultra high pressure UHP tubing and fittings is critical in maintaining a safe and leak free high pressure system 4 2 400444B F t Servicing the OMAX Tables The OMAX JetMachining Center Service and Maintenance Guide 400444B The following components are typical in a high pressure fitting Gland iut Slotted Collet Collar Body Tube Cone 3 Threads Body Cone 60 Degree Angle Figure 4 2 Components of the Ultra High pressure Fitting Ultra High pressure UHP Tube The tubing that transports the water under high pressure Tube Cone The end of the tubing is coned at a 59 angle allowing it to seat with the 60 angle body cone Tube Thread Tube threads are left handed allowing the tubing to mate with the collar during assembly Body This is the female tubing receptacle Examples are ELL 90 fittings TEE fittings swivel fittings and or on off valve fittings Body Cone The body is coned at a 60 angle allowing it to seat with the 59 angle of the tube cone Body Thread The body threads are right handed Slotted Collet The slotted collet provides the correct spacing between the collar and the gland nut It also provides a slip capability when the gland nut is being tightened during installation Collar The collar threads a
36. 15 Use the Blunt tip Grease Needle to Lubricate the Four Z axis Bearings 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 After sliding the bearing assemblies again add grease to the four Z axis bearing assemblies Remove the top Z axis bellows clamp and drop down the bellows to expose the lead screw bearing Figure 6 16 6 14 400444B F LAR Table Maintenance The OMAX JetMachining Center Service and Maintenance Guide Figure 6 16 Motorized Z Lead Screw Bearing Location 10 Place at least two drops of 30 weight oil onto the grooved part of the lead screw bearing surface 11 Following lubrication of all five motorized Z bearings reclamp both ends of the bellows to the Z axis by raising the Z axis as high as possible making reclamping easier Tighten the clamp ensuring that it holds the bellows securely in place and verify that the bellows is not being pinched 12 Once the bellow is 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 the 80160 The ball screws and bearings on the 80160 must be greased and inspected at least once per year Greasing the 80160 Y axis Carriage 1 Move the Y axis to its mid position move the X axis to the end at the far
37. 6 18 lead screw bearing motorized Z 6 15 LED pump power supply 5 13 LEDs Access Control Circuit A 1 linear bearing fitting 6 11 liquid displacer 7 11 installing 7 21 reversed 7 22 list of figures xi lock out tag out 1 7 log maintenance 6 21 Low Pre Set 3 7 Low Pre Set 3 6 low pressure water circuit 3 8 lubrication 6 9 motorized Z 6 12 lubrication points 80160 6 15 cantilever tables 6 11 JetMachining Centers 6 10 M maintenance general 7 1 log 6 21 7 40 PC Controller 6 1 6 18 pump 7 1 table 6 1 6 4 tank 6 1 6 2 manual audience iii organization iii purpose iii supporting documentation iii message Charge Pressure Low 3 7 Index 2 Charging Pump Contactor 3 7 Dead Head 3 7 Variable Drive Fault 3 7 messages fault 3 7 normal 3 7 messages fault Charge Pressure Low 5 11 Charging Pump Contactor 5 11 Dead Head 5 13 Variable Drive Fault 5 13 motion system X Y Z axis 2 10 motor belt 7 35 motorized Z lubrication 6 12 motorized Z axis 2 11 mouse failure 4 14 mouse cleaning 6 18 N normal messages 3 7 nozzle assembly 2 12 nozzle assembly water leaks 4 12 nozzle rebuild 6 18 oil crankcase 7 35 On Off switch pump 3 5 on off valve 2 13 On off valve water leaks 4 13 operator switches 2 6 orifice size dump valve cutting 4 2 nozzle cutting 4 2 overpressure protections 1 7 override switch 2 6 overview Model 2626 2 1 Model 2626 xp 2 1 Model 2652 2 2 Model 55100 2 2 Model 60120 2 3 Model 8016
38. 8 4 for warranty information about pump consumable and wear parts General Maintenance Variable Change water filters whenever the difference in pressure between the inlet and outlet gauges is equal to or larger than 20 psi Variable Replace electrical enclosure air filters approximately once per month or more frequently if required 6 Months Lubricate the main electric motor bearings refer to Lubricating the Electric Motor page 7 37 for grease specifications Consumable Parts The table below identifies the consumable parts accessories for OMAX pumps that wear out or otherwise need replacement on a predictable basis as part of normal system operation For assistance in ordering consumable parts contact OMAX Technical Support 200 Mesh Strainer Charge Pump Tank Reservoir 200935 10 Cartridge Coarse Charge Pump Pre filter 202533 10 Cartridge Fine Charge Pump Pre filter 202532 Air Filter 11 5 x 3 5 inside pump enclosure 202736 400444B Fal F The OMAX JetMachining Center Service and Maintenance Guide Pump Maintenance High pressure Wet end Maintenance Routine Maintenance Schedule Recommended Hours Wet end Maintenance P3050 3055V P4055V Install Minor Maintenance Kit P N 302700 500 Install Major Maintenance Kit P N 302701 1000 install Minor Maintenance Kt PN 302700 1500 install Major Maintenance Kit PN 302701 1000 _ install Minor Maintenance Kt P
39. A 1 is closed when ON When OFF it indicates S2 is open Power On Off LED A green LED that s ON when the ACC is powered ON and OFF when it is powered OFF A Signal Input LED A green LED that indicates safety switch S1 see Figure A 1 is closed when ON When OFF it indicates S1 is open Access Control Operation Initial Equipment Power Up 1 2 3 4 7 8 9 Switch the Pump AC power ON Switch the Controller AC power ON Once Windows is ready launch OMAX Make When Make starts verify that the status line below the OMAX logo flashes the message Babysit Triggered Switch the Access Control Circuits AC power switch ON 1 Verify that the green ACC power On Off LED lights indicating output from the 24 VDC supply Figure A 3 Verify that both the A and B signal input LEDs are ON Figure A 3 If these LEDs are ON push the Reset button Figure A 2 Verify that the message Babysit Triggered disappears 10 The JetMachining Center is now ready for cutting Stopping the JetMachining Center to Allow Operator Access When it s necessary to enter the protected cutting area to remove and replace material 1 Raise and move the nozzle away from the cutting material allowing ample room for the material to be removed or replaced With the nozzle out of the way switch the Run Setup switch on the ACC enclosure to its SETUP position turn clockwise and verify that the amber Setup mode l
40. Assemble the outlet side of the Check Valve Assembly first 2 Apply Lubriplate to the O ring Place the Static Backup Ring then the Static Seal and then the O ring onto the outlet side of the Check Valve Body Note The outlet side of the Check Valve Body has three holes in the end of the stem Figure 7 24 The notch and chamfer on one side of the Static Backup Ring faces toward the Check Valve Body 3 Apply anti seize lubricant to the threads of the two Socket Head Screws Install the Flat Washers and the two Socket Head Screws through the Outlet Check Valve Retainer Figure 7 24 400444B fals rF F The OMAX JetMachining Center Service and Maintenance Guide Pump Maintenance outlet check valve retainer outlet check valve ball 1 E socket head screws fiat washer EU Em outlet check valve seat Figure 7 24 Inserting the Socket Head Screws 4 Place the Outlet Check Valve Ball followed by the Outlet Check Valve Seat in the Outlet Check Valve Retainer Be sure that the flat side of the Outlet Check Valve Seat faces away from the ball The Outlet Check Valve Seat should be flush or no more than 0 001 0 0254 mm above the surface of the Outlet Check Valve Retainer 5 Place the assembled Outlet Check Valve Retainer on the outlet end of the Check Valve Body Stem with the Outlet Check Valve Seat up against the end of the stem Figure 7 25 outlet check valve retainer outlet check valve
41. D nU Esa 7 10 Figure 7 14 Dynamic Seal Assembly Components 7 10 Figure 7 15 Backup Support Ring Assembly Components nennen nennen 7 11 Figure 7 16 Backup Ring Inspection 7 11 Figure 7 17 Example of Lip Damage to Backup Ring 7 11 Figure 7 18 Liquid Displacer Measurements oiccicciccccsossdaseeccnanesdasesssnecssesseavacsavseesdasaavesasseauasins 7 12 Figure 7 19 Check Valve Assembly nnne n nennen nennen nns 7 13 Figure 7 20 Removing the Retainer Nut from the Check Valve Body seen 7 13 Figure 7 21 Using a Propane Torch to Remove the Support 7 14 Figure 7 22 Inspecting the Valve Seat for Erosion eene nennen enne 7 14 Figure 7 23 Check Valve Assembly Components eicere eee aU SEXE FREE REESE 7 15 bieure 7 24 Inserts the Socket Head S CLOW isateainadccondun cacsedecescesan sasagadoadncbancedcondsabaataacassndelsanaceennanesnceontedsads 7 16 Figure 7 25 Placing the Outlet Check Valve Retainer on the Check Valve Body Stem 7 16 Fa 400444B T CMAK The OMAX JetMachining Center Service and Maintenance Guide Figure 7 26 Tightening the Socket Head Screws
42. Guide Pump Maintenance check valve j d assembly BE t Figure 7 33 Installing the Liquid Displacer on the Check Valve Assembly Caution the wrong end of the liquid displacer is installed on the check valve assembly a large gap appears between the displacer and the seal ring See Figure 7 34 The end of the displacer must make contact with the seal ring If a gap is present the displacer was installed Incorrectly Figure 7 34 Reversed Displacer Example 4 Apply a light coat of Lubriplate 201304 just inside the bore of the Cylinder and on the end of the cylinder without the large chamfer Figure 7 35 Slide the Cylinder over the Displacer Long Seal Ring and Short Support Ring until it comes in contact with the Check Valve Body 5 Verify that the end of the Cylinder without the large chamfer is against the Check Valve Body Caution The liquid displacer provides a close tolerance fit inside the bore of the cylinders however the cylinder should slide easily over the displacer if the cylinder is kept square with the displacer It may be necessary to press firmly on the cylinder to push it over the seal ring If the support ring was not removed during maintenance the cylinder may not slide over it by hand In this situation place a rag over the open end of the cylinder and tap it into place with a soft mallet 92 400444 F LAR Pump Maintenance The OMAX JetMachining Center Service and M
43. Kent Washington USA If the returned parts are not new or if OMAX receives them after the 30 day limit the OMAX Customer Service Coordinator determines their proper disposition Unused Parts To return unused parts for credit 15 Obtain RMA number Return your unused parts prepaid to OMAX Corporation within 30 days of the shipping date the part was originally shipped All parts are examined by the Customer Service Department to ensure they are unused in new condition and free of handling damage If the parts are determined to be new and are received within the 30 day limit you receive full credit for the amount charged minus the 15 restocking fee A copy of the credit memorandum will be forwarded to you for use on future orders 400444B F t Customer Service 400444B The OMAX JetMachining Center Service and Maintenance Guide Parts Shipped in Error To return parts shipped in error for credit 1 Obtain an RMA number Return your shipped in error parts prepaid to OMAX Corporation within 30 days of the shipping date when the part was initially sent All parts are examined by the Customer Service Department to ensure they are unused in new condition and free of handling damage If the parts are determined new and are received within the 30 day limit you receive full credit for the amount charged and the part originally ordered is shipped If the returned parts are not new or are received by OMAX
44. RPM is less than P3050V 750 Pump Model P3055V 850 P4055V To change the oil in the pump crankcase 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 e 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 Replace the plug at the end of the red drain hose Refill the oil through the filler pipe Replace the filler pipe cap SS 89 oe Replace the front cover filler pipe crankcase oil level dipstick Figure 7 54 Pump Crankcase Oil Drain Hose Filler Pipe Belt Maintenance The heavy duty belt connecting the OMAX 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 400444B rF PMAX The OMAX JetMachining Center Service and Maintenance Guide Pump Maintenance 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 fo
45. With extreme rubbing a rough area showing discoloration of the plunger surface develops 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 7 24 400444 Pump Maintenance The OMAX JetMachining Center Service and Maintenance Guide wrench flats plunger assembly Figure 7 38 Adapter Block Pony Rod and Plunger Assembly Tools needed to remove the plunger assemblies e 3 4 crows foot 3 8 drive e 3 8 drive breaker bar To remove the plunger assemblies 1 Remove the Coolant Housings Figure 7 37 if not already removed 2 Access to the Wrench Flats on the Plunger Assemblies is through an opening in the top of the Adapter Block Remove the metal Cover Plate Figure 7 1 on top of the adapter block and set it aside 3 Remove the Access Cover Plate on the vertical end of the Belt Guard to gain access to the pulley on the pump crankshaft Cw 7 E 5 uz ES Figure 7 39 Access Cover Plate on Top of Pump Belt Guard 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 on a 3 8 dr
46. all servo axis drives and resets any faulted drive Override Manual override is for diagnostic uses only and in not generally needed during normal operation PC Controller Internal Components WARNING A The PC 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 AC power source and verify no circuit voltage is present 2 6 400444B F 9 TAAN Introduction to OMAX Tables The OMAX JetMachining Center Service and Maintenance Guide Access to the PC controller s internal components is via the locked handle on the rear of the enclosure Components inside the controller are divided into two basic sections the electronic circuits installed inside the rear panel door Figure 2 13 and the PC and monitor units mounted inside the controller cabinet itself Figure 2 14 At the bottom of the controller is a filter Figure 2 15 for the air being circulated to cool the internal components See the Table Maintenance Chapter page 6 18 for instructions on removing and replacing this filter USB controller USB controller Eze pe f air valve assembly me E B d Ween power supply Figure 2 13 Controller Rear Door Internal Components 400444B 227 Fw The OMAX JetMachining Center Service and Maintenance Guide Introduction to OMAX Tables EEE gm 110 V
47. at High Pressure 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 Ibs 40 6 54 Newton meters 9 Following installation test nozzle operation using high pressure water only Refer to Figure C 20 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 Servicing the High pressure Plumbing System on page 4 2 For Assistance Contact OMAX Technical Support OMAX Corporation 21409 72nd Avenue S Kent WA 98032 USA Phone 800 838 0343 Phone 253 872 2300 techsupport omax com http www omax com C 8 400444B ro t Index A about this manual iii abrasive hopper 2 13 abrasive index value 4 7 abrasivejet delivery system 2 11 abrasivejet nozzle 2 12 abrasives choosing 2 13 Access Control Circuit controls A 2 operation A 4 access cover 80160 lubrication 6 16 80160 timing belt 6 8 air bleed buttons 7 31 air filter 2 8 air filter replacing PC Controller 6 18 air tank 2 14 anti bacterial chemicals 6 3 Arbor press 7 7 Arctic Grease 6 9 Artic grease 6 4 assembly check valve 7 12 coolant housing 7 24 plunger 7 24 port adapter 7 19 wet end 7 21 audio amplifier 2 8 B babysit A 4 babysit condition 4 6 babysit triggered 4 15 backup ring assembly 7 10 lip damage 7 11 bacteria growth 6 3 ball scre
48. connection until finger tight 6 Finally tighten the gland nut use two wrenches to its specified torque value see Table 4 1 1 4 tube coning and threading 60 Kpsi 25 lb ft 34 Nm 3 8 tube coning and threading 60 Kpsi 60 Ib ft 68 Nm M8 clamp bar screws 10 12 lb ft 13 6 16 3 Nm Table 4 1 Torque Values for UHP Fittings Working with High Pressure Systems To properly install and maintain fittings and tubings in high pressure systems observe the following Caution Do thread the body and tube Do observe the correct thread direction when threading the body and tube body thread right handed tube thread left handed Do thoroughly clean fitting components prior to assembly Any dirt or contamination can compromise the metal to metal seal creating a path for the water to escape Do apply Blue Goop to lubricate the gland nut threads prior to assembling the fitting This prevents the metals from galling together and ensures that the fitting can be disassembled later Applying too much Blue Goop can contaminate or foul other machine components Applying just the correct amount of Blue Goop to your high pressure components prevents the stainless steel componts from galling and avoid contamination problems Apply Blue Goop sparingly Do follow the Three Thread Rule see above Do tighten the gland nut to their proper torque specification based upon connection size Refer to Table 4 1 Fittings will leak if not s
49. encoders These models do not require use of timing belts for X axis movement Y axis f Y axis bridge L upright cover A S a vw j j iss h T Mn dT pas al 60120 80 Figure 6 7 Timing Belt Locations for Bridge style Tables 400444B 6 7 The OMAX JetMachining Center Service and Maintenance Guide Table Maintenance Caution 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 2 Switch the Main AC Power Switch for the JetMachining Center to Off Lock Out and Tag Out the Main AC Power Disconnect Switch 3 Verify that AC power to the OMAX JetMachining Center was properly disconnected Ensure that 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 5 6 T Expose the timing belt by removing all screws 10 ea holding the upright cover plate Set the upright cover plate and removed screws aside for safekeeping Adjust the timing belt following the procedures provided in Inspecting and Adjusting Timing Belts page 6 5 beginning with step 4a When complete replace the upright cover plate Ad
50. even though the CHARGE PUMP SWITCH may be On and the CHARGE PUMP CONTACTOR closed The entire 24 VDC portion of the electrical circuit is protected with the 0 5 amp FUSE immediately after the 24 VDC POWER SUPPLY The pump MICROPROCESSOR CONTROLLER and control circuit operate with 24 VDC power provided by the 24 VDC POWER SUPPLY The WATER PRESSURE SWITCH protects the OMAX pump from running without a water supply or without sufficient charge pressure It closes at charge pressures above 50 psi and provides a 24 VDC signal to the pump s MICROPROCESSOR CONTROLLER Ift a PRESSURE TRANSDUCER is installed on the OMAX pump it is powered by the 24 VDC POWER SUPPLY and the pressure signal is sent directly to the pump MICROPROCESSOR CONTROLLER If an OMAX Jet Machining Center COMPUTER CONTROLLER is connected through the COMPUTER COMMUNICATION control of the OMAX pump is via the Jet Machining Center COMPUTER CONTOLLER It controls PUMP ON and OFF It also commands the OMAX pump LOW PRESSURE mode which can be commanded only from the OMAX Jet Machining Center COMPUTER CONTROLLER The OMAX pump MICROPROCESSOR CONTROLLER handles operation of the pump It consists of a microprocessor display and keypad It is powered by the 24 VDC POWER SUPPLY FF The OMAX JetMachining Center Service and Maintenance Guide 12 Introduction to the OMAX Pump 18 The OMAX pump MICROPROCESSOR CONTROLLER provides three commands to the VFD 19 20
51. for swivels and the dual on off valve e Explains procedures for properly servicing the high pressure plumbing system Lists corrective steps to follow when the equipment fails to perform as expected Chapter 5 Servicing the OMAX Pumps e Provides procedures for disassembling assembling the pump wet end assembly for maintenance and repair e Documents general pump servicing procedures Chapter 6 Table Maintenance e dentifies and provides a recommended schedule for maintenance activities e Explains maintenance requirements for both the table components and the PC Controller e Provides forms for logging maintenance activities Chapter 7 Pump Maintenance e Identifies pump maintenance activities required based upon pump run time in hours 400444B iii F OMAX JetMachining Center Service and Maintenance Guide e Lists replacement parts and kits needed for specific maintenance objectives Chapter 8 Customer Service e Provides contact information for OMAX Customer Service Explains how to order and return purchased parts for your OMAX equipment Appendix A Access Control Circuit e Describes equipment components for the Access Control Circuit and provides operator instructions Appendix B Rebuilding the Bulkhead Swivel Contains disassembly and assembly procedures for rebuilding the OMAX bulkhead swivel Appendix C Rebuilding the High Pressure Swivel Contains disassembly and assembly procedures for rebuilding the OMAX high pressu
52. grounding and wiring methods comply with the most recent version of the NEC IEC 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 Check the fuses at the main power disconnect Check that the main power is On Check that the On Off switch on the pump unit is On and that the On Off switch on the controller is On Check that the E stop switches on the pump unit and the computer controller are reset Check that 460 VAC 10 380 or 415 VAC 10 for international is present on L1 L2 and L3 at the bottom of the DIN rail inside the pump control enclosure refer to Figure 5 6 oo m o I p L3 white wire 6 5 6 AC Power Legs LI L2 and L3 F igure 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 4 Check the FAULT condition displayed on the OMAX keypad display If
53. in this chapter is important in ensuring proper equipment performance and accuracy Typically the frequency of most maintenance activities is based upon the length of time that the equipment has been in operation however harsher than normal environmental factors can require that maintenance activities be scheduled at a frequency greater than indicated in the table below See Wash away the abrasive 6 2 Daily and as often as required to maintain a Tank accumulation from the equipment clean working environment Maintenance and work area Remove all garnet sludge and 6 2 Whenever abrasive particles begin to slugs from the tank bottom excessively accumulate on the material being machined Inspect individual slats for wear Inspect and rotate monthly Replace when Replace and rotate excessively scored and no longer stable Clean the outlet water filter 6 3 Check Check monthly Figure 6 1 Figure 6 1 Run tank on program EN needed when using the Ae neste en eg ONES Solids Removal Removal System SR SRS anti bacterial chemicals to the 6 3 Before chemicals in the floating device tank water controlling tank odor and become depleted and bacteria growth can bacteria growth thrive Check monthly Table Lubricate carriage components Yearly 3 PC Controller Maintenance Replace air filters 6 18 Every three months or sooner when necessary Clean monitor screen As As necessary for sharp view
54. 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 Circuit Breakers CB1 CB2 Tripping i Throw the circuit breaker slower 2 Check for loose wires between the 2 KVA transformer and circuit breakers Tighten any found 400444B F Servicing the OMAX Pump The OMAX JetMachining Center Service and Maintenance Guide 3 Determine if the transformer is defective by switching breakers CB1 and CB2 Off and disconnecting the red wire 1170 from transformer terminal X1 Switch circuit breaker CB1 back On If CB1 trips the transformer is shorted and must be replaced Refer to Figure 5 10 for circuit breaker locations 4 Inspect the fan motors keypad transformer DC power supply etc to
55. of Blue Goop and thread the bearing lock nut onto the swivel body by hand until tight Figure B 22 Hand Tighten the Bearing Lock Nut 12 Use the swivel spanner wrench to tighten the bearing lock nut securely Figure B 23 Fully Tighten the Bearing Lock Nut using the Swivel Spanner Wrench 13 Apply OMAX Arctic Grease P N 202335 to the top of the swivel body bearing assembly apply Arctic grease Figure B 24 Apply Arctic Grease to Top of Bearing Assembly 400444B B 9 F OMAX JetMachining Center Rebuilding the High Pressure Swivel Reassembling the High Pressure Swivel Halves 1 Place the female half of the swivel body in the soft jawed vice Figure B 25 apply Blue Goop and assemble the two swivel body halves male swivel body half female swivel body half Figure B 25 Assemble the Two Swivel Body Halves Note When clamping the assembly in the vice ensure that the two flat sides of the female swivel body are aligned flush to the jaws of the vice 2 Use the swivel spanner wrench to tighten the retaining nut Figure B 26 Tightening the Retaining Nut with the Spanner Wrench 3 Remove the large O ring Figure B 27 replacing it with a new O Ring Figure B 27 Replace the O ring with New One 4 Wipe off any excess grease from the swivel The high pressure swivel rebuild is finished Installing the High pressure Swivel Once rebuilt swivel installation is the reverse of the removal instruct
56. of Products This warranty specifically excludes coverage of any claims for the effects of corrosion erosion adverse water conditions and temperature normal wear and tear or component failures caused by i accident ii negligence misuse improper installation or abuse or iii unauthorized repair or alteration or failure to maintain the OMAX JetMachining Center that contains the affected components in accordance with the technical bulletins and specifications provided by the OMAX All labor is the responsibility and expense of the Buyer The liability of OMAX under this warranty is limited at OMAX s exclusive option solely to repair or replacement with equivalent items or refund of the purchase price upon return of the subject nonconforming Product Replacement parts may be either new or reconditioned at OMAX s option Freight charges brokerage charges duties and taxes for return of parts and for parts or components provided by OMAX under this warranty will be the responsibility of the Buyer This warranty is conditioned upon a OMAX being notified in writing by Buyer within 30 days after discovery of defects b the return of presumed defective components to OMAX within 30 days of notification transportation charges brokerage charges duties and taxes prepaid by Buyer and c OMAX s examination of such components disclosing to its satisfaction that such defects were not caused by negligence misuse improper maintenance abuse improper i
57. of the JetMachining Center Models 2626 2626 xp 2652 5555 and 55100 55100 illustrated 2 4 400444B F Introduction to OMAX Tables The OMAX JetMachining Center Service and Maintenance Guide Y axis bridge V PC controller abrasivejet nozzle catcher tank X axis rail rail i z Figure 2 10 Components of the JetMachining Center Models 60120 80160 and SOX SOX illustrated PC Controller The JetMachining Center PC Controller Figure 2 11 is identical for all OMAX models It contains a standard video monitor with a Windows based computer PC running the OMAX software responsible for starting and stopping the high pressure water pump turning the water and abrasive flow On and Off and maneuvering the abrasivejet nozzle along its precise cutting path This internal PC is easily accessed by lifting up the controller s bottom access panel Directly below the monitor is the operator s control panel used in conjunction with the keyboard to run the JetMachining Center The keyboard and mouse are designed specifically to withstand exposure to the water and abrasive particles presented in an abrasivejet environment The controller s hinged arm allows it to be positioned according to an operator s viewing requirements video monitor me _ control panel p er J p P access panel lift up to access wet 7 water resistant SEE keyboar
58. provide protection against sharp metal edges and waterborne microorganisms Dispose of cutting wastes properly and in accordance with all local and federal regulations The OMAX 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 FF The OMAX JetMachining Center Service and Maintenance Guide Safety First Because of inevitable water spills cover the floor around the operator area with a nonslip material such as a textured rubber mat or nonslip paint Use only approved work platforms Never climb on or around the equipment using makeshift devices Always use the muff on the abrasivejet nozzle It helps keep the noise level low during machining and reduces splash and spray Always use proper lifting techniques and equipment to handle heavy work materials Always remove power from the equipment when through using the JetMachining Center for the day Don t Don t operate the OMAX JetMachining Center without first being adequately trained to operate it correctly and safely Don t allow nozzle movement while handling material in the tank Stop the abrasivejet before making any adjustments Nozzle movement can exert up to 1 000 Ibs 4 4 kN of force easily crushing any hands or fingers caught between it and another object Don t stand on
59. reaches the same pressure as in the OUTLET PASSAGE the OUTLET CHECK VALVE BALL moves away from its seat allowing the water to pass into the OUTLET PASSAGE 6 When the PLUNGER slows and stops at its original top dead center position step 1 the pressure inside the CYLINDER falls and the OUTLET PASSAGE closes off This cycle then repeats 7 High pressure STATIC SEALS prevent water from leaking between the CYLINDER and the CHECK VALVE BODY between the CYLINDER and the BUSHING HOUSING and between the CHECK VALVE BODY and the OUTLET MANIFOLD A high pressure DYNAMIC SEAL prevents water from escaping around the PLUNGER To prolong the life of the DYNAMIC SEAL GUIDE BUSHINGS are used to maintain alignment of the PLUNGER through the DYNAMIC SEAL 10 The BUSHING HOUSING has a COOLING WATER INLET port and COOLING WATER OUTLET port which allow water to flow through the BUSHING HOUSING to cool the PLUNGER and lubricate the GUIDE BUSHINGS The cooling water also picks up any leakage from the DYNAMIC SEAL and recycles it back to the water tank FF The OMAX JetMachining Center Service and Maintenance Guide Introduction to the OMAX Pump Overview of Electrical Circuit The simplified diagram shown below provides an overview of the electrical components and electrical logic of the OMAX pump Customer Disconnect VFD sO VAC P et CB1 2 KVA Transformer Computer 120 VAC Controller Pow
60. right the Home position 2 At this time carefully inspect each bellows for any tears or cuts Caution If tears are noted replace the bellows immediately or repair the tear using the Bellows Repair Kit OMAX Part 302393 Running the OMAX with an opening in the bellows allows garnet and grit to enter and damage the precision mechanisms causing serious damage to the entire assembly Do not use the OMAX until torn bellows are repaired or replaced 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 6 11 Note This is also an excellent time to 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 80160 fittings and pump grease three strokes at the most into each of the five lubrication points four linear bearings and one ball screw nut 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 components Wipe excess grease f
61. see if any components have shorted or burned out Replace any burned out componenis and re test the circuit breakers Circuit Breaker CB3 Tripping Circuit breaker CB3 may trip when the charging pump is overloaded or the motor is shorted Refer to Figure 5 10 for circuit breaker locations 1 Check that the water filters are not plugged or damaged causing the charge pump to overheat Replace the filters if needed Check the charge pump water inlet in the water tank ensuring the screen is not blocked or plugged 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 fnoloose 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 Fault Message Charge Pressure Low This fault message appears on the OMAX pump s display when the water pressure at switch S1 immediately downstream of the water filters is less than 50 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 7 53 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 Check the pressure gauges before and after the water filters If the downstream gauge
62. the Abrasive Index value was and require that the abrasive index value in the Pump not changed to compensate for its lesser and Nozzle Configuration screen be adjusted OMAX cutting ability recommends garnet as the abrasive because it provides a good cutting rate with relatively low mixing Refer to Pump and Nozzle tube wear Garnet is also non hazardous and is easily Configuration in the OMAX interactive disposed Other abrasives may increase mixing tube reference OIR for a list of abrasive wear and be a disposal hazard index values to be used when cutting with Warning abrasives other than garnet 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 The standoff between the abrasivejet For best results the standoff should be no more than nozzle and the material is too great 0 050 1 3 mm The abrasive flow has stopped or has Disassemble the plugged items and blow them clean been reduced by dirt or wet abrasive and dry using an air hose The mixing tube has worn with use and is Wear occurs first at the inlet and a conical wear zone no longer capable of forming an grows toward the exit end Check the tube bore at the adequate jet two ends using a drill or gage pin When the outlet has grown by 0 005 0 13 mm the mixing tube is near the end of its use
63. the same and the starting and stopping of the waterjet takes place without delay In addition dual pressure operations such as needed for low pressure glass piercing are also possible When dual pressure operation is desired low pressure is automatically achieved by opening both the dual on off valve and the pump dump valve simultaneously 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 material and removed material particles see Figure 2 25 Excess water exits the catcher tank by traveling through a water outlet filter screen Figure 6 1 that can be raised or lowered to determine the tank s water level A series of steel slats positioned above the catcher tank form a cutting surface that supports a part as it is being machined The Model 2626 xp high precision JetMachining Center features a stainless steel tank stainless steel slats and stainless steel slats holders catcher tank Figure 2 25 JetMachining Center Catcher Tank Pressurized air is required to operate the On Off valves controlling the level of the tank water and the water and abrasive flow Tank water level is controlled using OMAX s Rapid Water Level Control Figure 2 26 rapid water level control Figure 2 26 OMAX s Rapid Water Level Control The Rapid Water Level Control requires the following performance from an auxiliary air source Pressure
64. the threads and surface between the nut and clamp plate so that the torque applied properly loads the ring seals and studs 11 To ensure that an evenly distributed load is developed on the Clamp Plate and Cylinders torque each Nut one half turn in succession using a torque wrench and following the tightening sequence specified below until a torque of 175 ft Ib 237 N m is achieved on each Nut OD OQ D Figure 7 48 Clamp Plate Torque Sequence for Clamp Plate Nuts Caution Verify that all nuts are tightened evenly in the order specified in Figure 7 48 to avoid internal component damage and to achieve an even loading of the ring seals and studs 12 Rotate the pump Crankshaft by hand until each Plunger crosses top dead center to ensure the Plungers clear the inlet retainers and no binding exists in the Wet end assembly that prevents a smooth rotation 13 Reinstall the access cover onto the belt guard Figure 7 39 14 Complete the Pump assembly by connecting the outlet high pressure tubing and low pressure inlet hoses 7 30 400444B ro 9 TAAN The OMAX JetMachining Center Service and Maintenance Guide Pump Maintenance Maintaining the Water Filtration System Proper maintenance of the four water filters in your OMAX low pressure water system directly impacts the performance of your OMAX machine Cooling Water Charge Pump Internal Water Filters High Pressure
65. three lines of the OMAX keypad screen The fourth line on the OMAX keypad display always monitors the cumulative pump hours Charge Pressure Low Charging Pump Contactor Dead Head Variable Drive Fault If the drive is shut down by a fault the message Variable Drive Fault appears on the keypad display screen and the red LED next to the reset button lights 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 Before resuming operation of the pump unit the cause of the fault must be investigated and corrected Refer to the procedures described in the Troubleshooting section of this document Overview of the Charge Pump Water Circuit 400444B The OMAX pump unit contains a manually switched charge pump and filter system that must provide at least 80 psi 50 psi on earlier pumps of inlet water pressure to the crankshaft drive high pressure pump Water pressure readings at the water filter gauges see Figure 7 51 typically range from 90 120 psi The charge pump allows the OMAX pump unit to be connected to low pressur
66. to Take Out the Swivel Seal and O ring eee B 4 Figure B 10 Insert the Swivel Seal with New O ring into the Swivel Body eere B 5 Figure B 11 Insert the Swivel Back up Ring with a New O ring Installed into the Swivel Body B 5 Figure B 12 Tighten the Three Screws to the Swivel Back up B 5 Figure B 13 Place a Deep Socket over the Swivel Body B 6 Figure B 14 Center the Socket Over the Surface of the Swivel Body B 6 Figure B 15 Use the Bearing Puller to Remove the Bearing Assembly sse B 6 Figure B 16 Use Pry Bars to Remove the Inner Race from the Swivel Body B 7 Figure B 17 Male Swivel Body Bearing B 7 Figure B 18 Pack the Bearing Assembly with Arctic Grease B 7 Figure B 19 Reinstalling the Bearing Inner dd eee depen B 8 Figure B 20 Installing the Bearing Assembly with the Arbor 2 2 2 22 B 8 Figure B 21 Replace the O ring on the Swivel B 8 Figure B 22 Hand Tighten the Bearing Lock 9 400444 Fo T The OMAX JetMachining Center Service and Maintenance Guide
67. verify tubing loose gland nut gland nut torqued at 60 lb ft 68 Nm between fitting ring and valve cracked body loose nut replace defective component tighten gland nut nut valve body cracked inlet or valve replace defective component tighten body loose nut nut between nozzle body and inlet cracked inlet or nozzle replace defective component body body leaky O ring e weep hole on nozzle body chipped jewel cracked replace defective component body leaky seal 4 12 400444B F o Servicing the OMAX Tables The OMAX JetMachining Center Service and Maintenance Guide Water Leaking from the On Off Valve Figure 4 4 Sources of Water Leaks in the On Off Valve Troubleshooting Leaks in the On Off Valve refer to Figure 4 4 Leak Leak Other Point Description Suspected Causes Recommended Action Point Leaking around the plate and not cracked inlet or valve replace defective component tighten from any weep hole body loose bolts loose bolts e weep hole UHP adapter to body leak replace defective component cracked body Cracked body or leaky replace defective component seal 400444B 4 13 F The OMAX JetMachining Center Service and Maintenance Guide Servicing the OMAX Tables Miscellaneous Problems Water Spurts Out of the Tank Condition and Possible Causes Corrective Action Contain the spray using the muff A disc cut from a 2 5 cm thick sponge makes an effective muff The part is positioned on top of
68. with transparent lid allowing operator to view provided status LEDs Reset Button Rearms JetMachining Center back to its normal operating mode allowing recovery from a triggered safety violation or setup request Setup Mode Indicator When lit indicates access control circuit is currently in the Setup mode Run Setup Switch Switches ACC operation to either the Setup or Run mode Setup allows access into the protected zone without triggering a complete shutdown of the JetMachining Center babysit During Setup a slow speed control of nozzle motion is allowed but pump and nozzle operation is not permitted Run enables operation of the JetMachining Center if both safety switches S1 S2 are closed and the Reset button was pressed following an alarm shutdown Power On Off Switch Switches AC power for the ACC enclosure OFF when in the 0 position switches AC power ON when in the 1 position Receiver Connector Provides 24VDC for external safety switches and input connections for signals from the two safety switches Figure A 1 Three status LEDs are available inside the ACC enclosure that are useful in determining various equipment functions Refer to Figure A 3 B signal input LED Sate 2o22 ie 2909 Figure A 3 ACC Status LEDs 400444B A 3 T OMAX JetMachining Center Access Control Circuit B Signal Input LED A green LED that indicates safety switch S2 Figure
69. 0 12 ft 0 076 mm 4572 mm x 2261 mm 6731 mm x 3861 mm 4050 kg 4191 mm x 2032 mm 3 66 m Specifications OMAX 80X 1 JetMachining Center Position Table Size X Y Cutting Travel Ceiling Height Accuracy Footprint Requirement 0 003 259 x 89 337 L x 152 W 44 000 Ibs 240 x 80 12 ft 0 076 mm 6579 mm x 2261 mm 8560 mm x 3861 mm 20 000 kg 6096 mm x 2032 mm 3 66 m 400444B 229 rF The OMAX JetMachining Center Service and Maintenance Guide Introduction to OMAX Tables Model 80160 JetMachining Center Designed for the precise abrasivejet machining of large parts from stock in sizes up to 6 by 12 Figure 2 8 The OMAX Model 50160 JetMachining Center Specifications Model 80160 JetMachining Center Position Table Size Weight X Y Cutting Travel Ceiling Height Accuracy empty tank Requirement 0 003 174 x 89 243 L x 134 W 10 000 Ibs table only 168 x 80 12 ft 0 08 mm 4419 mm x 2261 mm 6172 mm x 3403 mm 4536 kg 4267 mm x 2032 mm 3 66 m Description of JetMachining Center Components OMAX JetMachining Centers can be divided into four major sections e PC Controller Figure 2 11 page 2 5 e X Y axis Motion System Figure 2 18 page 2 10 Abrasivejet Delivery System Figure 2 21 page 2 11 Catcher Tank Figure 2 25 page 2 14 abrasivejet PC controller X axis carriage nozzle Y axis carriage Figure 2 9 Components
70. 0 2 4 Model 80X 2 3 P parts consumable pump 7 1 ordered in error 8 2 ordering 8 1 returned for repair 8 3 returned for warranty repair 8 3 returning 8 1 shipped in error 8 3 unused 8 2 patent numbers ii 4 T CMAK pause switch 2 6 PC 2 8 front panel 2 9 rear panel 2 9 PC Controller 2 5 2 8 air filter 2 8 internal components 2 6 replacing air filter 6 18 PC Controller maintenance 6 1 6 18 pipe wrench caution 7 5 plumbing high pressure 2 13 plunger 3 8 plunger assembly 7 24 pneumatic ports 2 7 port adapter filter 7 18 seals 7 18 power on off switch 2 6 power strip 2 8 power supply 2 7 24 VDC 5 9 precautions safety 1 5 pressurized air 2 14 propane torch 7 14 pump charge 3 2 circuit breakers 5 9 circuit breakers tripping 5 10 components 3 2 connector 34 pin 5 9 control panel 3 5 description 3 1 display screen 3 6 electrical circuit overview 3 10 high pressure 3 1 how it works 3 8 introduction 3 1 keypad 3 6 low output pressure 5 3 maintenance 7 1 no AC power 5 7 no keypad display 5 8 not starting 5 7 On Off switch 3 5 power supply LED 5 13 safety requirements 1 6 servicing 5 1 specifications 3 12 water leaks in wet end 5 5 wet end diagram 3 9 wet end servicing 7 4 wrong KSI display 5 10 pump hours 3 7 pump view 400444B front panel removed 3 3 front right side 3 2 right panel open 3 4 top lid open 3 4 pump wet end details 3 9 R rapid water level control 2 14 rear panel PC 2 9 r
71. 00 JetMachining Center Provides the precise abrasivejet machining of parts in sizes to 5 by 10 Figure 2 5 The OMAX Model 55100 JetMachining Center Specifications Model 55100 JetMachining Center Position Table Size Weight X Y Cutting Travel Ceiling Height Accuracy empty tank Requirement 0 003 126 x 65 155 94 W 8 000 Ibs table only 100 x 55 10 ft 0 08 mm 3200 mm x 1650 mm 3937 mm x 2388 mm 3629 kg 2540 mm x 1397 mm 3 05 m 2 2 400444B F Introduction to OMAX Tables The OMAX JetMachining Center Service and Maintenance Guide Model 60120 JetMachining Center Large scale precision machining for larger parts or multiple parts from large stock up to 5 x 10 1 5 m x 3 m Figure 2 6 The OMAX Model 60120 JetMachining Center Specifications OMAX 60120 JetMachining Center Position Table Size Weight X Y Cutting Travel Ceiling Height Accuracy empty tank Requirement 0 08 mm 3656 mm x 1956 mm 5715 mm x 2794 mm 2818 kg 3200 mm x 1575 mm 3 05 m Model 80X JetMachining Center Designed for large scale precision machining of larger parts or multiple parts from stock up to 6 8 x 13 4 2mx4 m Figure 2 7 The OMAX Model 80 JetMachining Center Specifications OMAX 80X JetMachining Center Position Table Size M9 ht X Y Cutting Travel Ceiling Height Accuracy m fe tank Requirement 0 003 180 x 89 265 L x 152 W 9 000 Ibs table only 165 x 8
72. 14 Refer to the OMAX JetMachining Center Operator s Guide for instructions on changing the nozzle orifice Refer to the OMAX Pump Service and Maintenance Guide for instructions on changing the dump valve orifice Maintenance of the Dual On Off Valve is required when any of the following symptoms appear Water entering the abrasive feed tube when the nozzle first fires leaky seal e Water is dripping from the mixing tube leaky valve stem e Water leaks 180 degrees from where the UHP plumbing enters the dual on off valve bad valve seal e Water drips from the UHP nipple on the dual on off valve loose fitting cracked body or fitting Rebuilding the Dual On Off Valve Maintenance procedures for the Dual On Off Valve are provided in the Appendix section located at the end of this document Refer to Appendix C Rebuilding the Dual On Off Valve servicing 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 swivels 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 Figure 4 2 is backed off allowing at least three threads to show which is necessary for proper seating Whenever a leak continues
73. 2 559252 NIAID euJ83X3 cS Em NN ___ 0 ureuno 1ubijsjeubis 2 onuoo pue 1 L L 3 indui jeubis 9 9 indui eubis jndino DAA pZ e LLI V NO ro TAE The OMAX JetMachining Center Service and Maintenance Guide 400444B Access Control Circuit This document describes technical requirements of the OMAX Access Control Circuit and explains its operation Contents o t NR EE m page A 1 ACCESS CONTO QC CATION MR EE ETE page A 4 Initial Equipment Power Up page A 4 Stopping the JetMachining Center to Allow Operator Access page A 4 Re arming the Circuit Following an Access Violation page A 4 Introduction The OMAX Access Control Circuit ACC is designed to create a designated safety zone around an OMAX JetMachining Center that protects operators from injury when using the OMAX equipment 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 lt is the customer s responsibility to install some type of fencing or other device that res
74. 35 Y gt bearing assembly F A be xo Figure B 18 Pack the Bearing Assembly with Arctic Grease 400444B B 7 Far o OMAX JetMachining Center Rebuilding the High Pressure Swivel 8 After packing the bearing assembly with Arctic grease re install the two inner races inner race Figure 19 Reinstalling the Bearing Inner Race 9 Install the bearing assembly onto the male swivel body a Place the male swivel body in the arbor press b Place the swivel retaining nut onto the male swivel body c Lightly grease the swivel body bearing mount where the bearing assembly installs d Position the bearing assembly onto the swivel body shaft Place a 1 inch 2 54 cm deep well socket on top of the bearing assembly Figure B 20 This will be used to press the bearing assembly into the swivel body Make sure the socket presses against only the inside bearing race wt rs retainer nut su Figure B 20 Installing the Bearing Assembly with the Arbor Press e Press the bearing assembly onto the swivel body using the arbor press until fully seated f Remove the swivel body from the arbor press 10 Lightly coat the O ring with Lubriplate Install the O ring onto the swivel body Caution Be careful to not scratch or damage the stem Figure B 21 Replace the O ring on the Swivel Body B 8 400444B F TMAX Rebuilding the High Pressure Swivel OMAX JetMachining Center 11 Apply a light coat
75. 444B Pump Maintenance The OMAX JetMachining Center Service and Maintenance Guide water inlet fitting s check valve body stem check valve body outlet check valve seat inlet ball retainer inlet check valve ball outlet check valve ball inlet check valve ball inlet check valve seat outlet check valve retainer long seal ring flat washer we head 9 we 622 static seal O ring O ring Figure 7 19 Check Valve Assembly Components To disassemble and inspect the check valve assembly 1 Begin disassembly of a Check Valve Assembly from the inlet Cylinder side Clamp the Check Valve Body into the soft jaws of a vise and using the 5 8 crows foot remove the Retainer Nut Figure 7 20 Figure 7 20 Removing the Retainer Nut from the Check Valve Body 2 Referring to Figure 7 19 remove the Inlet Ball Retainer the Inlet Check Valve Ball and the Check Valve Seat A pair of needle nose pliers can be helpful when removing the Inlet Ball Retainer 3 Ifthe Seal Ring did not remain in the end of the Cylinder Figure 7 1 remove it from the Check Valve Body Stem and discard it 4 Inspect the Support Ring for cracks chips or damage particularly in the area around the center where it contacts the edge of the Cylinder If no damage is found there is no need to remove it except at the recommended rebuild intervals Minor scoring marks are permitted Caution Never attempt to remove scoring marks by sandin
76. 75 120 psi 517 827 kPa Flow Rate 16 0 cfm 453 I m minimum 2 14 400444B F 9 Introduction to OMAX Tables The OMAX JetMachining Center Service and Maintenance Guide Internal air connections to the Rapid Water Level Control are identified in Figure 2 27 air supply to air supply to controller JetMachining Center air signal from controller to raise water level Figure 2 27 Rapid Water Level Control Internal Pneumatic Connections 400444B 2 43 The OMAX JetMachining Center Service and Maintenance Guide F Introduction to OMAX Tables 400444B Introduction to the OMAX Pump This section introduces the OMAX high pressure water pump unit and provides the following information Describes the OMAX pump unit e Identifies the pump components Provides an overview of the water circuit e Explains how the OMAX pump works Provides an overview of electrical circuit Lists specifications for all OMAX pump models Figure 3 1 OMAX High Pressure Water Pump Description of the OMAX Pump The OMAX variable speed high pressure pump is an electrically driven variable speed positive displacement crankshaft drive triplex pump that provides the high pressure water required by the OMAX JetMachining System to operate It incorporates several features that make it less costly to operate and maintain All water used to cool the pump is recycled for reuse when operated with an optional ch
77. 80160 X axis Timing 6 8 Figure 6 9 View of 80160 Timing Belt With Access Plate 6 9 Figure 6 10 Lubrication Points on OMAX Cantilever Style X Y Carriages 6 11 Figure 6 11 Lubrication Fittings for Cantilever Style X Y Carriages sss 6 11 cd PAP M a 6 13 Figure 6 13 Lift Bellows 10 Expose Grease POIDS ies oon IC deddcneatiaondssentendedsans 6 13 Figure 6 14 Z axis Bearing Locations Requiring Lubrication 6 14 Figure 6 15 Use the Blunt tip Grease Needle to Lubricate the Four Z axis 6 14 Figure 6 16 Motorized Z Lead Screw Bearing Location cccceeesssssncecceceeeceeeeeeeeeeeeeeeeeeeeseaaaaaeeeeeeeeeees 6 15 Figure 6 17 Remove 80160 Access Covers to Reach Rail Lubrication 1 6 16 Figure 6 18 Grease Fittings for 80160 Ball Screw Bearing Housing and Linear Bearing 6 17 Figure 6 19 Grease Fitting for Lubricating the X axis Ball Screw Bearing Housing 6 17 Figure 6 20 Grease Fitting for Lubricating the 2nd X axis Linear Bearing eeeeeesee 6 18 Figure 6 21 Typical C MOS Lithium Balle V
78. AC power strip outlet air route F Figure 2 15 Air Filter Location Beneath the Controller Cabinet PC Controller Inside the OMAX controller Figure 2 14 is a standard PC with the Windows operating system running the OMAX Make and Layout software To access the front of this PC lift up the PC access panel see Figure 2 11 for location User access typically is required when inserting media into the CD DVD drive or a flash drive memory into one of the two USB ports Figure 2 16 400444B Introduction to OMAX Tables The OMAX JetMachining Center Service and Maintenance Guide PC Front Panel The PC front panel presents the following devices to the OMAX operator Figure 2 11 CD DVD drive CD DVD drive open close button USB ports 2 ea Power On Off button Note The PC automatically powers up when the controller On Off switch Figure 2 12 is On Use of the PC front panel Power On Off switch is not required CD DVD drive ee Figure 2 16 User Components on Front Panel of Controller PC PC Rear Panel The back of the PC is accessible by opening the PC controller s rear door During normal operation there are few reasons for the user to access to the PC rear panel Cabling to the PC rear panel is as follows AC power cable from power strip Figure 2 14 Audio cable to audio amplifier Figure 2 14 USB cable to USB controller Figure 2 13 Video cable to monitor Figure 2 14
79. Body Shaft 2 Center the socket over the swivel body shaft to provide a uniform contact with the surface of the swivel body and protect the swivel body shaft deep socket over shatt and contacting swivel body Figure B 14 Center the Socket Over the Surface of the Swivel Body 3 Attach the bearing puller as illustrated below and pull the bearing assembly free from the swivel body bearing puller bearing assembly Figure B 15 Use the Bearing Puller to Remove the Bearing Assembly 4 The bearing s inner race may not pull out with the bearing If this happens two pry bars can be used to remove the inner race as follows B 6 400444B FIN Rebuilding the High Pressure Swivel OMAX JetMachining Center a Reposition the swivel body in the soft jawed vice to allow a better leverage as shown below Boon Figure B 16 Use Pry Bars to Remove the Inner Race from the Swivel Body b Slide the two pry bars under the flat surface on the swivel body just below the race Figure B 16 above Evenly and carefully pry the race free from the swivel body 5 Gather the replacement bearing components as illustrated below bearing inner race bearing lock nut Figure B 17 Male Swivel Body Bearing Components 6 Thoroughly clean grease and foreign debris from all parts being reused using an ultrasonic cleaner 7 With both inner bearing races removed pack the bearing assembly with OMAX Arctic Grease PN 2023
80. Check Valve Ball followed by the Seat into the Inlet Ball Retainer Figure 7 28 Be sure the flat side of the Seat faces away from the ball Note The inlet check valve seat normally protrudes well above the face of the ball retainer inlet ball retainer inlet check valve 2 body stem 1 i i inlet check inlet check valve seat valve ball Ma CI inlet check fg valve ball Figure 7 28 Inserting the Check Valve Ball and Check Valve Seat into the Inlet Ball Retainer Inlet ball retainer 400444B Te o The OMAX JetMachining Center Service and Maintenance Guide Pump Maintenance 12 Hold the Check Valve Body so its stem is facing down to enable insertion of the assembled Inlet Ball Retainer Figure 7 28 Note An alignment pin inside the pocket of the check valve body is designed to fit into a slot machined on the outside of the retainer Be sure to engage the alignment pin into this slot Do not turn the assembly over until the retainer is fully engaged into the slot When correctly installed the inlet ball retainer will be almost flush with the end of the check valve body stem 13 Apply anti seize compound to the threads of the Retainer Nut and to the bottom face that contacts the Inlet Ball Retainer Figure 7 29 Uy 4 A anti seize compound ME Doc D threads M j J retainer nut inlet ball retainer inle
81. Debris Loud Noise Eye and ear protection are required during operation Emergency Stop Switch E stop Pushing E Stop in immediately shuts down both the pump and display The E Stop is disengaged reset by manually pulling it back to its original position The pump cannot be restarted until E Stop is reset 400444B 1 1 Fo The OMAX JetMachining Center Service and Maintenance Guide Safety First WATCH YOUR HANDS AND FINGERS KEEP GUARDS IN PLACE Keep hands away irom jet or walk con alata Pinch points Keep hands clear STAY CLEAR if you can read this sign a cover is missing Do NOT operate with cover missing Do not disconnect abrasive hose with system pressuriz d Never operate the OMAX with any of its protective guards or covers removed or rendered inoperative Never make unauthorized alterations to the equipment or components Never operate the OMAX with any of its protective guards or covers removed or rendered inoperative Never place your hands in the vicinity of the nozzle while cutting oeek immediate medical attention in the event of a waterjet injury Injuries caused by high pressure waterjets are serious Do not delay Never step stand or walk on the support slats They are weakened with continued cutting and may collapse under your weight Never place your hands or fingers in areas where they are in danger of becoming pinched during equipment operation
82. ID 8 nno HO Index 1 ro x A The OMAX JetMachining Center Service and Maintenance Guide x 400444 The OMAX JetMachining Center Service and Maintenance Guide Figures 400444B Page Figure 1 1 Safety Labels 2626 2626Ixp 2652 5555 and 55100 sees 1 3 Fig re 1 2 Vie ME eb UP 1 3 Powe I gt abe ty Label 1 4 Figure 1 4 Safety Labels TM 1 4 Figure 1 3 Satety Labels OMAX 5 1 5 Figure 2 1 The OMAX Model 2626 JetMachining Center esses ee enne eene 2 Figure 2 2 The OMAX Model 2626lxp JetMachining Center nennen 2 Figure 2 3 The OMAX Model 2652 JetMachining eene nennen 2 2 Figure 2 4 The OMAX Model 5555 JetMachining 2 2 Figure 2 5 The OMA X Model 55100 JetMachining Center sse 2 2 Figure 2 6 The OMAX Model 60120 JetMachining 2 3 Figure 2 7 The OMAX Model 80X JetMachining Center essen 2 3 Figure 2 8 The OMAX Model 80160 JetMachining Center sse 2 4 Figure 2 9 Components of the JetMachining Center Models 2626 2626 2652 5555 55100 55100
83. Low on the keypad screen To recover from this fault press the RESET button on the keypad Start the charge pump and bleed any remaining air from the water filters 11 Turn Off the charge pump 12 Replace the front panel cover and lower the lid 13 Heinstall the nozzle FA The OMAX JetMachining Center Service and Maintenance Guide Pump Maintenance Cleaning the Pump White Water Tank Seal debris and particles will accumulate 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 three water return SE hoses from cylinders charge pump 200 mesh water inlet 1 E filler screen charge pump suction line water level float d Figure 7 53 White Water Tank To clean the water tank and charge pump suction screen 1 Ensure that power to the Charge Pump is Off Remove the pump s front panel allowing access to the Water Tank see Figure 7 53 Remove the water tank lid Shut the water supply to the Pump unit Off 2 3 4 5 Empty the tank water by powering the charge pump On 6 Once the water level is at or below the charge pump suction inlet power the charge pump Off 7 Remove the remaining tank water by mopping it up using a clean rag 8 Once tank water has been removed wipe the interior of the tank clean 9 Remove the charge pu
84. N 302700 _ Install Major Maintenance PN 302701 1800 _ Note Repeat the above sequence for the corresponding pump after every Overhaul Kit installation Less Frequent Maintenance Schedule Recommended Hours Wet end Maintenance Minor Maintenance Detail E oi 7 2 400444 F o 7 Pump Maintenance The OMAX JetMachining Center Service and Maintenance Guide Major Maintenance Detail Task Description 200904 Bal Kit 300733 302701 e Overhaul Detail Tek pm 200377 200905 202398 Ucupsea 0 0 seal E Kit Replace 301635 Ring seal seal Ring seal 3095998 302244 Back Back up ring assembly with support ring ring Back up ring assembly with support ring with support ring Seal assembly 303401 Check valve assembly internal inlet 304104 Filter assembly manifold 300727 Back up ring Displacer liquid 400444B 7 F The OMAX JetMachining Center Service and Maintenance Guide Pump Maintenance Maintaining the Wet end Pump Assembly plunger assembly 3 ea housing socket head assembly 3 ea screws 4 ea dynamic seal cylinder 3 ea SiL ACID isplacer backup ring assembly 3 check valve 3 ea 24mm nut 8 ea adapter block tie rod 8 ea port adapter 2 ea Figure 7 1 Major Compon
85. O Closed Loop System to treat your tank water Chlorine will ruin your filter system The EBBCO Closed Loop System has its own ozone generator that controls 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 New sets of galvanized steel slats can be ordered from OMAX Stainless steel slats are also available through special order stainless steel slats are standard on the 2626 xp It s also possible to cut your own slats using your JetMachining Center Each slat should be 1 8 3 mm thick and 4 10 cm tall To provide a level support surface ensure that the 4 10 cm slat dimension remains within 0 005 0 1 mm Make the length equal to the existing slat length Table Maintenance Maintaining the X Y Carriage Bellows The bellows protecting the precision bearings of the X Y carriages on your OMAX are often overlooked yet they are vital co
86. Pump Belt Guard sse 7 25 Figure 7 40 Dynamic Seal Assembly 7 26 Figure 7 41 High pressure Wet end 7 27 Figure 7 42 Coolant Housing Assembly Installation and Hose Connections 7 28 Figure 7 43 Installing the Short Ring Seal onto the Backup Support Ring 7 28 Figure 7 44 Sliding the Backup support Ring Assembly onto the Plunger 7 28 Figure 7 45 Sliding the Dynamic Seal Assembly onto the Plunger esee 7 29 Figure 7 46 Sliding the Wet end Assembly over the Plungers 7 29 Figure 7 47 Installing the Clamp 1 nennen enne nennen enne nennen nnns 7 30 Figure 7 48 Clamp Plate Torque Sequence for Clamp Plate Nuts sss 7 30 Figure 7 49 The Low pressure Water Filtration System sss nnne 7 31 Figure 7 50 Incoming Water Filters Wall Mounted eene enne nnne 7 31 Figure 7 51 Pump Internal Water Filtration System eene eene eene eene nennen nenne 7 31 Figure 7 52 Low pressure Water Filters with Pressure Gauges ccccssssssecccccecececceeeeeeeeeeeessennnnneeeeeeeees 7 33 Figure 7 59 White Water QUE
87. The OMAX JetMachining Center Service and Maintenance Guide OMAX Corporation Information 253 872 2300 x3 21409 72nd Avenue South Fax 253 872 7446 Kent WA USA 98032 Customer Service 800 298 4036 E Mail techsupport omax com Web http www omax com OMAX JetMachining Center Service and Maintenance Guide This document contains subject matter to which OMAX Corporation has proprietary rights Recipients of this document shall not duplicate use or disclose information contained herein in whole or in part for any use other than the purpose for which this manual was provided OMAX Corporation believes the information described in this manual is accurate and reliable From time to time design improvements will be made to the OMAX 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 u
88. When finished greasing slide the bellows back over the carriage components reinstall and retighten each bellows clamp Greasing the 80160 X axis Rails 1 Remove the oval access covers from both sides of the 80160 Set the 6 removed screws and cover aside for safekeeping m gt oval access cover E E 1 TR Cente Figure 6 17 Remove 80160 Access Covers to Reach Rail Lubrication Points Note nside 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 6 18 6 16 400444B ro Table Maintenance The OMAX JetMachining Center Service and Maintenance Guide bearing housing tx A ball screw ball screw nut 2 grease fitting J Figure 6 18 Grease Fittings for the 80160 Ball Screw Bearing Housing and Linear Bearing 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 Zerk grease fitting the linear bearing provides the flush style grease fitting 4 Again move the
89. X pump keypad must be pressed to clear the fault condition and e f the fault reoccurs troubleshooting the cause of the fault must be resumed If a VFD fault message occurs on the OMAX keypad display check the fault message reported on the ABB drive display panel inside the pump electrical enclosure 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 refer to the ABB User s manual If a VFD fault persists contact OMAX Customer Service 3 400444B To restart the OMAX pump the fault condition must be cleared by pressing the Reset button on the OMAX 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 FF The OMAX JetMachining Center Service and Maintenance Guide F Servicing the OMAX Pump 400444B Chapter 6 Table Maintenance This chapter covers the maintenance normally required to ensure reliable operation of your OMAX JetMachining Center For maintenance of your OMAX pump please refer to The OMAX Pump Service and Maintenance Guide P N 400407 WARNING All maintenance activities must be performed by qualified personnel Maintenance Schedule Use of the maintenance schedule and the maintenance log page 6 21 provided
90. Y carriage until the other end of the ball screw bearing housing Figure 6 18 is positioned in front of the access window with its Zerk grease fitting accessible Figure 6 20 ball screw bearing housing lubrication fitting Zerk ball screw bearing housing ball screw Figure 6 19 Grease Fitting for Lubricating the X axis Ball Screw Bearing Housing 5 Pump grease into this fitting as described earlier repeat this for the same fitting on the opposite side of the tank Note tis 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 6 20 and grease it appropriately Repeat this for the same bearings on the opposite side of the tank 400444B 6 17 Fr 4 The OMAX JetMachining Center Service and Maintenance Guide Table Maintenance Note Figure 6 20 Grease Fitting for Lubricating the 2nd X axis Linear Bearing 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 inches 64 cm per minute to distribute the grease along the rail 8 Complete the X axis lubrication process by replacing each oval access plate Rebuilding the Abrasivejet Nozzle For nozzle repair and maintenance procedures refer to The OMAX JetMachining Center Operator s Guide P N 400433 EN that is provided with your JetMachining Center This documen
91. a slat and the jet is piercing the material causing the jet to reflect upwards The abrasivejet is not piercing the See the earlier item Abrasivejet Not Piercing Material under material Machining Quality Abrasive Material Piles Up on the Work Piece Silt buildup at the tank bottom tank Remove the slats and clean out the tank 5 excessive The OMAX has an Unpleasant Odor Bacteria are growing in the tank Check the floating chlorine dispenser to ensure it still contains the bacteria killing pool chemicals supplied with the OMAX Keyboard and or Mouse Failure Condition and Possible Causes Corrective Action No mouse movement 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 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 Keyboard not responding Verify that the keyboard 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 Try rebooting the PC to see if corrects the problem Swap the keyboard with a known good keyboard to eis if s pro
92. ace 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 lubricated ball bearings The motor s ball bearings should be lubricated at intervals according to the pump s hours of service per year as follows Hours of Service Per Year Relube Interval 400444B oeasonal Idle 6 months or more 1 year beginning of season Continuous High Ambient Temp 6 months Dirty or Moist Locations High Vibrations Use these recommended high quality ball bearing lubricants Shell Dolium R and or Chevron SR1 2 Sodium Calcium Lubriko M6 Tools needed to lubricate the electric motor Grease gun screwdriver 3 16 flat tip To lubricate the motor s ball bearings 1 Disconnect the pump s AC power source Hemove the pump s front and rear panel covers Access the shaft end of the motor refer to Figures 7 55 and 7 56 a Remove the outside belt guard cover b Remove the inside shaft guard c Remove the lower portion of the belt guard Locate the grease fittings located on each of the motor ends Remove the pipe plugs located opposite the grease fittings The OMAX JetMachining Center Service and Maintenance Guide Pump Maintenance grease fitting Caution 7 38 xo 9 10 11 12 pipe plug grease fitting b i Figure 7 57 Location of Front and Rear Moto
93. afety Valve Tools and Materials Needed Blue Goop LPS lubrication 1 open end wrench 2 ea ball 2 ea P N 200904 seat P N 301583 Torque wrench capable of reading 50 75 ft lbs with 1 crows foot Use the two 1 open end liste to unscrew the safety valve from the tee fitting use 1 wrench tee fitting MI safety valve fuse 1 wrench Figure 5 3 Safety Valve Removal Remove and discard the two balls and seat Figure 5 2 Clean the plunger and safety valve body with water using air to flush the water out of the spring chamber opray some LPS lubrication into the holes and blow out with air to prevent rusting of the valve Rub Blue Goop onto both ends of the replacement seat the two replacement balls and the threads of the safety valve body Stack the parts together refer to Figure 5 2 and screw the assembled body into the tee fitting by hand 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 5 3 Tighten to 50 75 foot pounds Lower the RPM at startup for a few minutes to ensure no pressure spikes occur that will fail the valve again With the pump running at high pressure inspect the safety valve closely for any signs of water leakage 400444B F 9 TAAN Servicing the OMAX Pump The OMAX JetMachining Center Service and Maint
94. after the 30 day limit the OMAX Customer Service Coordinator determines the proper disposition If the replacement parts are needed sooner than 10 working days issue a new purchase order and clearly label it with the RMA number and a tag that reads Shipping Error If in stock the replacement part will be shipped within three working days Same day for urgent requests If the claim is approved a credit memorandum for the originally shipped parts is forwarded to you This credit can be used on future orders Parts Returned for Repair To return parts for OMAX Repair Services 1 2 Obtain an RMA number Ship the parts along with a purchase order to OMAX Corporation Repair charges are based on standard rates for labor plus the currently listed price for any replacement components required You will be notified if the repair charge exceeds 50 of the cost for a new part The OMAX Repair Department completes the repair If the parts are either not repairable not cost effective to repair or not approved for repair they are either returned to you or scrapped upon your request Parts Returned for Warranty Repair or Replacement To return parts for warranty repair or replacement 1 The Customer Service Department evaluates all parts returned to ensure that they are covered by the OMAX Corporation warranty When a part is under warranty OMAX determines if the part should be repaired or replaced When a part is not unde
95. age cover plate Remove the 6 screws from the X axis cover plate or the 3 screws from the Y axis cover plate remove these SIX screws E X axis timing belt cover plate Figure 6 4 Carriage End Cover Screws Removed to Access Timing Belt 5 Set the cover plate and all removed screws aside for safekeeping 6 Remove each timing belt and inspecting it for tears cracks missing teeth and other defects as follows a Loosen the motor plate s pivot screw Refer to Figure 6 5 b Loosen the tension adjustment screw 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 for tears cracks missing teeth and other issues indicating replacement If defects are noted replace the belt push down to loosen belt X axis timing belt Y axis timing belt Figure 6 5 Components Involved in Adjusting the Timing Belt Tension 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 on it directly beneath the tension adjustment screw c Push hard and hold a steady pressure while tightening the tension adjustment screw 6 6 400444B ro TMAX Table Maintenance T
96. aintenance Guide lin T gt chamfer end of cylinder installed away from TET heck valve bod liquid displacer check valve body i check valve body 8 Figure 7 35 Sliding the Cylinder over the Displacer 6 Repeat steps 3 through 5 for the remaining cylinders 7 Set the Wet end Assembly aside until it is time to reassemble the Pump Replacing the Water Coolant Housing Seal The low pressure seal in the coolant housing should be replaced at every rebuild of the pump Tools needed to replace the water coolant housing seal e internal snap ring pliers e small screwdriver e Lubriplate OMAX P N 201304 flat washer seal retainer iy Figure 7 36 Coolant Housing Assembly Components 400444B 7 23 F F The OMAX JetMachining Center Service and Maintenance Guide Pump Maintenance To replace the water coolant housing seal 1 Remove the Coolant Housing Assemblies Figure 7 37 by sliding them forward until they clear the end of the Plungers The Coolant Housing fits snugly to the bore in the Adapter Block Figure 7 37 and may be difficult to remove Use the two Fittings top and bottom of the Coolant Housing to rotate the assembly while removing it During removal keep it aligned with the bore coolant housing A adapter block assembly i f Mil coolant hose u RA KU X R 4 Bs push lock fittings 4 Figure 7 37 Removing the Coolant Housing Ass
97. apter M i check valve inlet hard plumbing j 2 m GINE water hoses ea late cR e port adapter hard plumbin clamp plate amp 24 mm nuts 8 6 4 Figure 7 2 High Pressure Wet end Assembly 3 Remove the three Water Hoses from the Check Valve Inlets using the 9 16 open end wrench Hold the fitting with the 1 2 open end wrench to avoid unscrewing it from the Check Valve Body 4 Using the 24 mm socket or 15 16 socket and 1 2 breaker bar remove the eight 24 mm Nuts from the Clamp Plate Figure 7 2 being careful to remove the load on the Tie Rods evenly Break loose the Nuts at the ends of the Clamp Plate first then use a crisscross pattern when breaking the remaining four Nuts loose Figure 7 3 Using the same pattern back each Nut off 1 2 turn until the load is removed from the Tie Rods 400444B 73 F The OMAX JetMachining Center Service and Maintenance Guide Pump Maintenance QD i py QURE 43 Figure 7 3 Nut Loosening Sequence for Removing Clamp Plate from High Pressure Assembly 5 Remove the clamp plate and set it aside clamp plate j Figure 7 4 Clamp Plate Removal 6 Slide the Wet end Assembly away from the Coolant Housings See Figure 7 5 Keep the assembly level and square being careful not to bind the internal Plungers All components typically stay in the Cylinders as the Wet end Assembly is re
98. ard Check for water leakage between the manifold and check valve bodies and between the cylinders and check valve bodies refer to Figure 5 5 If leaking remove and disassemble the wet end inspect and clean all parts and replace seals 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 Remove and disassemble the wet end inspect and clean all parts and replace seals 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 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 While the high pressure pump is running at high pressure in Test mode check the cylinders and the three white hoses Figure 7 53 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
99. attended the service training classes provided by OMAX as part of the original equipment purchase Supporting Documentation For a complete and up to date list of all available OMAX documents please visit the OMAX technical support Web site http www omax com support customers default asp Note Auser name and password are required to access the OMAX technical support site To set up a new user account please contact OMAX Customer Service at 800 298 4036 Organization This service and maintenance guide for the OMAX JetMachining Centers provides the following content Chapter 1 Safety First e Identifies equipment labels designed to support safe equipment operation shows their location and explains their meaning e Lists important safety do and don ts to follow that are essential in ensuring safe equipment operation e Explains the safety devices built into the OMAX equipment Chapter 2 Introduction to OMAX Tables e Identifies the available OMAX models and describes their major components e Provides basic equipment specifications Chapter 3 Introduction to OMAX Pumps e Identifies the major components of the OMAX pumps and breaks each down into their individual pieces providing names and descriptions e Provides equipment specifications e Graphs pump operating characteristics e Describes the pump control panel explaining available operator control devices Chapter 4 Servicing the OMAX Tables e Provides servicing information
100. bing garnet hopper abrasive On O valve bimba high pressure SEES t water On Off Ea 155 pui valve _ abrasivejet _ nozzle 400444B 2 11 F The OMAX JetMachining Center Service and Maintenance Guide Introduction to OMAX Tables Abrasivejet Nozzle In an abrasivejet nozzle Figure 2 22 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 composed of sapphire or diamond Figure 2 23 pneumatic input for On Off valve operation mux high pressure water On Off control valve abrasivejet nozzle 4 mo abrasive feed input line E 2 Figure 2 22 Components of an OMAX Abrasivejet Nozzle Assembly This narrow stream of water exits the jeweled orifice travelling up to 2500 feet per second 760 m s 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 high pressure water from On Off valve jeweled orifice _ abrasive feed tube from hopper abrasive and water mixing tube abrasivejet cutting stream Figure 2 23 Internal Workings o
101. blem goes away verifying that keyboard itself is at fault Software Problems Please refer to Troubleshooting in the OMAX Interactive Reference OIR for help with software issues For PC problems refer to the Dell Customer Support web site http support dell com support edocs systems Op745 en UG en solving htmzwp1296962 Blue Screen Errors Condition and Possible Causes Corrective Action Loose USB cable If the USB cable is Ensure that the USB cable is plugged in adequately unplugged while Make is running the Reboot the PC monitor will blue screen Using older version of Windows 2000 Update to Service Pack 2 or newer version of Windows 2000 400444B F 7 Servicing the OMAX Tables The OMAX JetMachining Center Service and Maintenance Guide Corrupt device driver 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 Babysit Triggered Message Note The OMAX has several switches monitoring machine operation When any of these switches are triggered the abrasive jet nozzle immediately stops operation and no longer continues machining or is able to be moved When an attempt is made to restart operation a Babysit Triggered error message appears To recover from a babysit condition first correct the cause that triggered the babysit then hold down the Override switch on the co
102. bling 7 7 removing 7 5 wet end water leaks 5 5 white water tank 3 3 7 34 Z Zerk coupler 6 9 Index 3 The OMAX JetMachining Center Service and Maintenance Guide Index 4 400444B
103. bly with O ring fitting ring valve gland nut set screw 1 Ensure that your working area for rebuilding this assembly is clean with all required tools and materials available see page D 1 for list Figure C 6 Components of the OMAX Dual On Off Valve 2 Pullthe fitting ring and valve gland nut from the valve body on off seat 1 valve gland nut Figure C 7 Components of the Dual On Off Assembly C 4 400444B F Rebuilding the Dual On Off Valve OMAX JetMachining Center 3 Use the needle nose pliers to remove i stem assembly from the valve body UHP tube fitting ring valve body stem assembly Figure C 8 Removing the Stem Assembly from the Valve Body 4 Ifthe 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 valve body Allen wrench Figure C 9 Pushing the Seal Assembly from the Valve Body ha stem assembly 5 Clean all parts not being replaced in the repair kit Discard the used on off seat seal assembly with O ring and stem assembly asse 4 T e assembly Figure C 10 Discard the On Off Seat Seal Assembly and Stem Assembly Note All items included in the Dual On Off Valve Repair Kit P N 301927 must be used Do not reuse any parts that are provided in the repair kit
104. both the controller and pump unit are in their On positions Verify that 460 VAC 10 380 or 415 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 Figure 5 6 If no power is present across these terminals see No AC Power at Pump Unit on page 5 7 Check that 460 VAC 10 380 or 415 VAC 10 International is present across the primary terminals H1 and H4 H3 for international units of the 2KVA transformer Check that 110 VAC is present at the output secondary terminals X1 and X3 or X4 of the 2KVA transformer Refer to Figure 3 6 for location 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 Check for and tighten any loose wires on the input and or output side of the 24 VDC power supply 400444B F Servicing the OMAX Pump The OMAX JetMachining Center Service and Maintenance Guide Note Note green LED ETT z Figure 5 9 24 VDC Power Supply If the power supply s green LED is not lit no 120 VAC is present as measured across terminals L and N on top of the 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
105. ce and Maintenance Guide 7 Remove the six screws securing the access covers to the frame Set the all screws and both access cover ae aside exposing the ball screws and timing belts Figure 6 9 adjustment plate timing belt b j ary Gory Gey ee Cibi E eg E 58 Figure 6 9 View of 80160 Timing Belt With Access Plate Removed 8 Adjust each timing belt following the procedures provided in Inspecting and Adjusting Timing Belts page 6 5 beginning with step 6a 9 When inspection and adjustment are complete replace access covers for both sides Lubricating the JetMachining Center Like all machines your OMAX requires regular lubrication to keep its moving parts running smoothly and to protect them from drying out To preserve the life of your system 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 grease approved by OMAX Customer Service OMAX recommends Jet Lube s Arctic Grease Anhydrous calcium 12 hydroxystearate OMAX P N 202335 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 particularly if you are simply pumping a few squirts into the Zerk fittings during your routine maintenance inspection Caution I
106. check for a leaky suction line Do not run the OMAX pump once the pressure at a given RPM for a given nozzle drops more than 2000 4000 psi Continued operation with damaged check valve seats or failed dynamic seals can result in further damage to components in the wet end and may result in higher rebuild costs 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 400444B F 0 Servicing the OMAX Pump The OMAX JetMachining Center Service and Maintenance Guide Water Leaks in the Wet end Assembly This section identifies the location of possible water leaks in the wet end assembly Figure 5 5 and suggests possible ways to correct them Figure 5 5 Sources of Water Leaks in the Wet end Assembly Troubleshooting Leaks in the Pump Wet end Assembly refer to Figure 5 5 Leak Other Point Description Suspected Cause Recommended Action Point Leak from Coolant Housing Seal Coolant Housing Seal Replace Coolant Housing Seal at failure next rebuild this is coolant water and will not affect output pressure or pump life Leak s between Cylinder Body Insufficient torque on Check torque on Clamp Plate Nuts and Coolant Housing and or Clamp Plate Nuts Apply fresh anti sei
107. ck valve pump outlet manifold me 1 Figure 3 10 The High pressure Wet end of the OMAX Pump 8 400444B F Introduction to the OMAX Pump The OMAX JetMachining Center Service and Maintenance Guide 400444B Outlet Coolant Manifold Water Inlet Seal Dynamic Guide x Seal Bushing i A Y A Pi OS VER ose CR ee VAT EN 12772 aaa s au E E E BH NW 1 a 1 1 1 E H E E WB E 8 u P BH oY BH b B b B b b B B i roc 1 E on u 1 b m nm E dm d a mw n omn p P 1 i D prr GOOD SO Inlet Check Outlet Outlet Check Valve Ball Plunger Cylinder Cooling Passage Valve Ball Check Liquid Displacer Water Outlet Valve Body Figure 3 11 Details of the Pump Wet end At the bottom of the PLUNGER stroke the CYLINDER fills with water As the PLUNGER moves back pressure inside the CYLINDER increases as the water is compressed The INLET CHECK VALVE BALL prevents the compressed water from flowing back out the WATER INLET PORT The LIQUID DISPLACER occupies dead space within the cylinder and improves volumetric efficiency 5 When pressure in the CYLINDER
108. d Off Gently wipe its surface using a lint free cloth dampened with a small amount of distilled water Distilled water shouldn t leave streaks behind after drying Replacing the Cabinet Air Filter Beneath the OMAX Controller is an air filter Figure 2 15 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 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 400444B F Table Maintenance The OMAX JetMachining Center Service and Maintenance Guide Note 400444B dusty environment check the filter at least monthly Checking it should become part of your routine maintenance program This filter is an easily obtained automobile air filter Fram CA 327 or equivalent Rebooting Windows Microsoft Windows 2000 and Windows XP are complicated operating systems They manage all memory disk reading and writing and memory operations for every program that run on your computer While Windows 2000 XP are considerably more stable than earlier versions of Windows they can still run into problems For example if a program misuses memory or has a memory leak Windows may not be able to r
109. d and mouse Figure 2 11 The JetMachining Center PC Controller Control Panel The JetMachining Center s control panel provides five function switches for JetMachining Center operation Figure 2 12 e Emergency Stop E stop e Power On Off e Reset Override e Pause 400444B pM F The OMAX JetMachining Center Service and Maintenance Guide Introduction to OMAX Tables Water Level Up Down emergency stop controller reset override water level Up switch E stop power On Off switch Down switch Figure 2 12 Control Panel Operator Switches Control Panel Operator Switches Water Level Up Down Control Raises 1 and lowers 1 the water in the catcher tank to cover uncover the material being cut 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 after an E stop Pause Pauses the motion of the abrasivejet and shuts down the abrasivejet nozzle Machin ing can be restarted without loss of machine positioning information Power On Off Turning the power switch to the On position on the front of the controller after the pump has been powered up automatically starts the computer Reset 7 Reset disables
110. d in error repair etc any additional helpful information Write the RMA number at the top of the packing list and on the shipping label and include a copy of your sales order Note Fach HMA number is different This number must appear on the shipping label and on all shipping documentation All inquiries concerning the returned parts should also refer to this number 4 Ship your returned parts prepaid to OMAX Corporation Attn Customer Service Department 21409 72nd Avenue South Kent WA 98032 USA Parts Ordered in Error Returned parts ordered by a customer in error are subject to a testing and restocking charge of 1596 of the list price Parts returned for restocking must be returned prepaid to OMAX Corporation within 30 days of the original parts order ship date To return a part ordered in error for credit 1 Obtain RMA number Return your ordered in error parts prepaid to Corporation within 30 days of the date the part was originally shipped Returned parts are examined by the Customer Service Department to ensure they are unused in new condition and free of handling damage If the parts are determined to be new and received within the 30 day limit you receive full credit for the amount charged minus the 15 restocking fee A copy of the credit memorandum will be forwarded to you for use on future orders You must issue a new purchase order for any replacement parts Parts are shipped to you FOB
111. e OMAX pump 1 For convenience rotate the pump Crankshaft until the center Plunger is at top dead center maximum extension The ends of the other two Plungers should then be even and extend out far enough for assembly of the wet end without further rotation of the crankshaft 2 Apply a light coat of extreme pressure lube or Blue Goop to the area of the Coolant Housing Assembly that engages into the Cylinder bore 3 Slide the Coolant Housing Assembly over the Plunger until it is fully engaged into the bore in the Adapter Block Figure 7 42 Note that the plunger is not rigidly held and can be moved slightly for alignment with the Coolant Housing Assembly 400444B e F F The OMAX JetMachining Center Service and Maintenance Guide Pump Maintenance coolant housing assembly e M Sun gt adapter block y supply water hose coolant housing assembly 4 returnwaterhose F5 i Figure 7 42 Coolant Housing Assembly Installation and Hose Connections 4 Trim the ends of the low pressure water supply and return hoses square and back about 4 Install them into the push lock fitting on the coolant housing assemblies Note Hoses from the low pressure supply manifold block should be connected to the upper fittings on the coolant housings The hoses connected to the lower fittings should return water to the water tank 5 Slide the Short Seal Ring onto the Backup support Ring Asse
112. e bores on the Manifold Position the Port Adapters with its flat side of the body facing away from the direction of the Cylinders Figure 7 1 Note Either Port Adapter can be installed first As the second one is being installed ensure that it engages into the filter assembly properly without being forced and causing damage Tapping the end of the port adapter lightly with a soft blow mallet may be required to seat it completely into the manifold 16 Place the Manifold assembly onto a flat surface with the Check Valve Figure 7 1 ports facing up Apply a small amount of anti seize lubricant to the threads of the four Socket Head Screws Figure 7 1 and tighten them sufficiently to hold the Port Adapters in place Secure the Manifold assembly into a vise and torque each Socket Head Screw to 100 ft lbs 135 N m 400444B F t Pump Maintenance The OMAX JetMachining Center Service and Maintenance Guide Reassembly of the High pressure Wet end Assembly Note This section provides procedures for the complete reassembly of the pump wet end It is very important that all parts are kept clean In general all the high pressure wet end parts for the OMAX pump may be cleaned by simply wiping them with a clean lint free rag and blowing them off with shop air Remember any dirt left in the pump can pass through the nozzle possibly damaging it Clean all parts and assemble the pump components in a clean environment Whenever the high pres
113. e caught between heavy parts and the sharp edges of the support slats Wear hearing protection while in the vicinity of the OMAX When cutting in air noise levels can exceed 120 dB Cut under water whenever possible When water covers both the material being cut and the nozzle tip the noise level measured in the operator s area drops to approximately 80 dB Wear approved safety goggles whenever cutting Regular glasses are not sufficient eye protection Have an eyewash station located near the OMAX 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 Treat all injuries with caution Because bacteria in the water can build up even a seemingly minor break in the skin can introduce harmful bacteria into the wound Any injury involving contact with the water should receive immediate attention Use antibacterial chemicals in the tank water an exception is with the EBBCO Closed Loop to reduce this hazard and always wear protective gloves if you have cuts or open wounds on your hands Seek immediate medical attention in the event of a waterjet injury Injuries caused by high pressure waterjets are serious Do not delay Inform the physician of the cause of the injury what type of waterjet project was being performed at the time of the accident and the source of the water When setting up material for cutting wear gloves that
114. e checked and adequate jet possibly replaced Wear occurs first at the inlet and a conical wear zone grows toward the exit end Check the tube bore at the two ends using a drill or gage pin as a gage 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 Abrasive Has Stopped Flowing Condition and Possible Causes Corrective Action The abrasive flow is stopped or has been Disassemble the plugged items and blow them clean reduced by dirt or wet abrasive and dry with an air hose Caution Do not point the air stream toward a person or toward any item you want to keep free of abrasive The standoff distance is so low that the Increase the standoff to between 0 040 1 0 mm and nozzle is plugged by the work piece 0 050 1 3 mm before it starts cutting and water is deflected to the abrasive tube The shop air pressure is insufficient to The abrasive valve requires 70 to 95 psi 5 to 7 bars open the abrasive valve shop air Material oi acm above rater beg Gub 00807 that the standoff height is at least 0 040 0 080 0 1 0 2 oi acm above the rater beg Gub 00807 above the material being cut uam Mixing Tube 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 Leaky On Off Valve Contact OMAX Technical Support for details on troubleshooting a leaky On Off valve asse
115. e exposed 6 Apply some Blue Goop onto the threads of the retaining screw and install it in the valve body using the 1 4 open end wrench 4 open end on J retaining screw Figure C 14 Applying Blue Goop and Installing the Retaining Screw 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 Goop T on off seat valve body Figure C 15 Insert the Stem Assembly into the Valve Body 8 Slide the valve gland nut and fitting ring onto the valve body refer to step 2 in the disassembly instructions fitting ring _ valve gland nut Figure C 16 Sliding the Valve Gland Nut and Fitting Ring onto the Valve Body 9 The repair of the Dual On Off Valve is complete C 6 400444B F TMAX Rebuilding the Dual On Off Valve OMAX JetMachining Center 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 x valve body correct UHP line fun d nment with F fitting ring alve body ion Figure C 17 Align the UHP Line with the Opening in the Fitting Ring 2 Insert the UHP input line into the fitting ring Ensure that the t
116. e 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 P N 203339 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 6 4 400444 F t Table Maintenance The OMAX JetMachining Center Service and Maintenance Guide 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 6 2 These belts should not wear out with ordinary use but must be checked annually as port of your routine maintenance schedule for cracks tears and proper tension _
117. e water sources that may vary over a wide range of available pressures Part of the water supplied to the OMAX pump unit functions as cooling water for the high pressure seals and plungers When a chiller is installed to cool the water source this cooling water is recycled back through the white water tank for reuse rather than going to the waste water drain FF The OMAX JetMachining Center Service and Maintenance Guide Introduction to the OMAX Pump Manual control of the charge pump allows it to be run independently at any time to purge the tank and water lines with cooler water prior to starting the main high pressure pump This increases the life of the high pressure seals Cooling Water Relief Valve Incoming Tank HC A Charge Pump Water t Dump A 2 lt gt Filters Pump eS Valve Water recycled back to Water Tank when chiller installed Drain when chiller Drain High Pressure Water Figure 3 9 The Charge Pump Low pressure Water Circuit How the OMAX High pressure Pump Works The OMAX pump works as follows 1 The PLUNGER is drawn back to the right in the figure by motion of the crank 2 This draws water in through the WATER INLET PORT past the INLET CHECK VALVE BALL and into the CYLINDER During this suction stroke the OUTLET CHECK VALVE BALL prevents high pressure water entering the CYLINDER from the OUTLET PASSAGE E cylinder input water che
118. eassembly check valve 7 15 wet end assembly 7 21 reboot PC Controller 6 1 registered trademarks ii relay banks 2 7 repair kit bellows 6 4 repair parts 8 3 replaceable pump parts 7 1 replacement slats 6 4 Reset button 3 6 reset switch 2 6 retainer nut check valve body 7 13 Return Material Authorization number 8 2 returning parts 8 1 RMA number 8 2 rule three thread 4 4 Run button 3 6 runtime hours 3 7 S safety 1 1 features 1 7 precautions 1 5 safety labels 2626 2626 xp 2652 55100 1 3 60120 1 4 80160 1 3 80X 1 4 OMAX pump 1 5 safety valve 1 7 3 3 3 4 safety valve leaking 5 4 safety valve resealing 5 1 safety valve warning 5 2 5 4 schedule table maintenance 6 1 schematic Access Control Circuit A 1 servicing high pressure plumbing 4 2 pump 5 1 wet end assembly 7 4 servo LEDs 4 15 servo motors stalled 4 6 short ring seal 7 28 silicone sealant 6 4 400444B The OMAX JetMachining Center Service and Maintenance Guide slat replacement 6 4 slats 2 14 slotted collet UHP tubing 4 3 snap ring 7 24 software updates 6 1 software garnet cleanout 6 3 software problems 4 14 software upgrading 6 19 solids removal system 6 1 specifications pump 3 12 splash shield 6 2 SHS 6 1 SHS sweep program 6 3 otop button 3 6 switch charge pump 3 5 E Stop 3 5 pump On Off 3 5 swivel 2 13 high pressure B 1 swivels 4 1 swivels rebuilding 4 1 T table maintenance 6 1 maintenance schedule 6 1 safet
119. ecover the memory Each time the program is run a little more memory is lost and eventually this memory loss begins to affect other programs 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 This is a particular temptation with Windows XP which displays the desktop up to one minute before it s actually finished loading everything 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 Alt Del to check when CPU usage has dropped to zero Running the Disk Defragmenter Utility When Windows saves a file on the hard drive it stores this file in whatever memory locations are currently available If for example a five megabyte file is saved and there are only five one megabyte spaces available this file would be broken down and stored in five different locations As time
120. emblies 2 After removing the Coolant Housing pull the Coolant Hoses out of the Push Lock Fittings by pulling back on the outer ring of the fitting to release the locking device within the Fitting while pulling on the Coolant Hose 3 Remove the Snap Ring Figure 7 36 with the set of internal snap ring pliers Use the small screwdriver to lift the Flat Washer Seal Retainer out of Housing bore Remove the Seal in the same fashion 4 Apply a small amount of Lubriplate to the lip of the new Seal and install it with the pressure lip or cup facing into the Coolant Housing followed by the Flat Washer Seal Retainer and the Snap Ring Caution The snap ring must be fully engaged in the snap ring groove If not fully engaged it can contact the plunger damaging its surface 5 Setthe Coolant Housing Assemblies aside for later pump assembly Removing Plunger Assemblies Removal and inspection of the pump plungers is necessary only if plunger rubbing of the backup ring occurred Rubbing may be expected if the dynamic seal indicates the plunger was out of alignment or if the backup ring indicates plunger rubbing Caution Damaged plungers ALWAYS cause premature dynamic seal failure Plunger damage can easily be seen with the naked eye or with a low power magnifying glass It 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
121. embling C 4 installing C 7 reassembling C 5 removing C 1 dump valve 4 1 dump valve rebuilding 4 2 dynamic seal 7 9 E e 6 4 EBBCO closed loop system 6 4 electrical circuit pump overview 3 10 electrical protection VFD 1 7 emergency stop switch 1 7 2 6 emergency stop switch E Stop 3 5 equipment safety features 1 7 E Stop switch 3 5 e stop switch 1 7 2 6 F failure grease 6 9 fault messages 3 7 figures list of xi filter cartridges water 7 32 filter screen tank water 6 3 filters wall mounted 7 31 fitting UHP 4 4 front panel PC 2 9 fuse pump 5 12 fuse pump power supply 5 9 G garnet accumulation 6 2 gland nut torque values 4 4 grease cup motorized Z 6 14 grease fittings and couplers 6 9 grease Arctic 6 9 grease Artic 6 4 grease failure 6 9 H Hi Pre Set 3 6 3 7 high pressure plumbing 2 13 4 2 high pressure seal creating 4 4 high pressure swivel 2 13 disassembling B 2 installing B 10 reassembling B 10 removing B 1 replacing seals and o rings B 4 replacing the bearing B 6 high pressure systems dos and don ts 4 4 Index 1 The OMAX JetMachining Center Service and Maintenance Guide hopper abrasive 2 13 hours runtime 3 7 inspection timing belts 6 5 J Jet Lube Arctic Grease 6 9 JetMachining Center components 2 4 K keyboard failure 4 14 keyboard cleaning 6 18 keypad 3 6 L labels 1 1 labels safety 1 1 LCD monitor 2 8 LCD monitor cleaning
122. emove the retaining screw from the valve body using the 14 open end wrench retaining screw __ open end wrench Figure C 3 Removing the Retaining Screw from the Valve Body 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 AA 1 open end fitting ring gland nut i i Figure C 4 Loosening the Valve Gland Nut using Two Open End Wrenches C 2 400444 Rebuilding the Dual On Off Valve OMAX JetMachining Center 6 Loosen the valve gland nut from the inlet body by placing a 13 16 open end wrench on the valve gland nut i 13 16 open end Figure C 5 Removing the Valve Gland Nut from the Nozzle Assembly 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 C 4 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 when carried C 3 400444B FF OMAX JetMachining Center Rebuilding the Dual On Off Valve Disassembling the Dual On Off Valve Caution The on off valve and its rebuild location must be thoroughly cleaned prior to rebuilding sea assem
123. enance Guide Troubleshooting the OMAX Pump This section provides troubleshooting procedures for the OMAX pump Most pump operations are controlled and monitored via the OMAX keypad All fault messages except those related specifically to the Variable Frequency Drive VFD appear on the OMAX 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 OMAX Keypad 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 manual must be followed Problems covered in this troubleshooting section include Low Pump Output Pressure Water Leak in the Wet end Assembly No Power at Pump Unit Pump Does Not Start No Keypad Display Pump Runs but Keypad Display Reads 0 3 KSI or O KSI Circuit Breakers CB1 CB2 Tripping Circuit Breaker CB3 Charge Pump Tripping Fault Message Charge Pressure Low Fault Message Charging Pump Contactor Fault Message Dead Head Fault Message Variable Drive Fault Following each problem is a list of possible causes If you continue to have problems with your OMAX pump after following these procedures contact OMAX Customer Service by telephone or by fax Refer to Chapter 8 Customer Service Low or Fluctuating Pump Output Pressure Cautio
124. end g on crankcase sprocket Rad AC motor sprocket i i p Figure 3 4 Pump with Rear Panel Removed 400444B 3 3 ro The OMAX JetMachining Center Service and Maintenance Guide Introduction to the OMAX Pump Top Pump View with Lid Opened hinged pump lid belt cover guard pump cylinders x3 high pressure M _ high pressure water out p P pump crankcase E i r g water pressure gauges x2 water filters x2 pressure A N dump valve transducer ia dui DOM cooling water p Ar lines x3 pump outlet i iM 4 manifold a A wet end E Cu C al input water E E p lines x3 for high ressure pum low pressure C al Ti E water supply is M manifold x3 high pressure j Figure 3 5 Top View of Pump with Lid Open Pump Side View with Right Panel Open control transformer VFD keypad and display P variable lH frequency drive power L X nn VFD distribution 288 IB terminals 7 airfilter Figure 3 6 Pump Internal Components on Right Side 3 4 400444B F Introduction to the OMAX Pump The OMAX JetMachining Center Service and Maintenance Gu
125. enter Rebuilding the High Pressure Swivel Replacing the Seals and O Rings 1 Clamp the female half of the swivel assembly into the soft jawed vice and use the 5mm Allen wrench 5mm Allen wrench remove screws Figure B 7 Remove the Three Swivel Assembly Screws with the 5mm Allen Wrench 2 Once all three screws are removed use one of the removed screws as a jacking screw to help remove the swivel backup ring and O ring seal by screwing it down into one of the threaded holes in the back up ring This will lift the backup ring for easy removal b T d B Eie f T F i removed screw aee 1 y i used as jacking VE screw T3 Figure 8 Remove the Swivel Back up Ring from the Swivel Assembly 3 Remove the swivel seal with the attached O ring using the swivel seal removal tool Figure B 9 Insert the tool into the hole in the swivel seal and catch the bottom side of the seal with the tool When caught pull the tool upwards removing the swivel seal and O ring swivel seal removal tool Figure B 9 Use the Removal Tool to Take Out the Swivel Seal and O ring 4 Clean the backup ring and female swivel body in an ultrasonic cleaner B 4 400444B F LAR Rebuilding the High Pressure Swivel OMAX JetMachining Center 5 Lubricate the new swivel seal and O ring with Lubriplate and insert them into the swivel body Figure B 10 Ensure that the O Ring end o
126. ents of the Wet end Pump Assembly 7 4 400444 F Pump Maintenance The OMAX JetMachining Center Service and Maintenance Guide Removing the High pressure Wet end Assembly The high pressure wet end assembly consists of those pump parts which are bolted to the crankcase and are directly involved in providing high pressure water Refer to Figure 7 2 When disassembling this assembly keep all parts together in related sets noting the original position of each set The following tools are necessary for removal of the wet end assembly Yo open end wrench 9 16 open end wrench 13 16 open end wrench 1 open end wrench 24 mm metric socket 2 drive or substitute 15 16 socket Yo drive breaker bar torque wrench capable of 175 ft lb 235 N m Caution Never use a pipe wrench on any OMAX equipment Do not disassemble the pump wet end unless a torque wrench capable of 175 ft Ib 235 N m is available for reassembly To remove the high pressure wet end assembly 1 Turn power to the Pump Off at the main AC disconnect Place a lock out tag on the power disconnect to alert others that maintenance is in progress 2 Disconnect the Hard Plumbing from the Port Adapter using the 13 16 and a 1 wrench See Figure 7 2 WARNING Before disconnecting the hard plumbing ensure that the pump has been shut down allowing the system to depressurize tie rods 8 ea port ad
127. er a CB2 1 Bypass Switch L Charge Contactor Fan Pump Keypad Microprocessor Controller and Display Start M1 RPM Reset Torque Pressure charge pump switch VFD Fault Fault Power Optional Water Pressure Pressure Transducer Switch Fault Pressure Computer 1 gt Pump On Communication gt Low Press Nozzle Figure 3 12 Simplified Pump Electrical Diagram Note When troubleshooting electrical or control problems with your OMAX pump the detailed electrical schematics that are provided in addition to this document should be consulted 3 10 400444B ro 7 OMAX Introduction to the OMAX Pump The OMAX JetMachining Center Service and Maintenance Guide 400444B 10 11 12 13 15 16 17 The main 460 VAC three phase power 380 or 415 VAC for international applications comes into the OMAX electrical enclosure from the CUSTOMER DISCONNECT and supplies power directly to the VFD The VFD in turn when given the command from the OMAX pump MICROPROCESSOR CONTROLLER starts and runs the main pump motor M1 The VFD is protected from line voltage surges by internal transient voltage surge suppression Two legs of the 3 phase power the 2 KVA TRANSFORMER that steps the voltage down to 120 VAC The 2 KVA TRANSFORMER and everything downstream of it is protected by the tw
128. f the Abrasivejet Nozzle 2 12 400444B ro TMAX Introduction to OMAX Tables The OMAX JetMachining Center Service and Maintenance Guide Caution 400444B The Abrasive Hopper The abrasive hopper mounts to the OMAX Y carriage and holds up to 25 pounds 11 kg of abrasive A hinged top cover prevents dirt and other shop contaminates from entering and contaminating the abrasive The abrasive rate of flow is regulated by a computer controlled pneumatic valve Bimba valve and the Bimba valve orifice located at the bottom of the hopper _ iL a a abrasive hopper Bimba control valve EM S ir control line for abrasive feed S ud BI de hose connection in Figure 2 24 Abrasive Hopper Components 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 then requires cleaning Even very small particles of dirt can 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 for your OMAX JetMachining Center 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 abra
129. f the grease used is not compatible with Arctic Grease or another brand a chemical reaction can occur that separates both grease types and impairs the lubrication qualities of both Once this happens a premature failure of a bearing or associate device is probable 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 Lubrication requires the use the correct grease and correct grease gun fitting that matches the installed grease fitting 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 only Refer to the following table for an illustration of each Grease Fitting Required Coupler Where Used Zerk nipple Standard grease gun with Zerk y linear coupler provided with OMAX bearings ball machine screws and ball screw bearing housings 400444B 6 9 rF F Ta TAAK The OMAX JetMachining Center Service and Maintenance Guide Table Maintenance Grease Fitting Required Coupler Where Used grease cup blunt tip grease needle Motorized Z linear P N 202633 bearings de Identifying Lubrication Points Use the following table to identify lubrication points for specific OMAX table models Note Jet Lube s Arctic Grease should be used
130. f the seal goes into the hole first swivel seal with new O ring Figure B 10 Insert the Swivel Seal with New O ring into the Swivel Body 6 Lubricate with Libriplate and install the new O ring onto the swivel back up ring Press the swivel backup ring into the swivel body Figure B 11 aligning the three screw holes in the swivel back up ring with those in the swivel body swivel back up ring Figure B 11 Insert the Swivel Back up Ring with a New O ring Installed into the Swivel Body 7 Insert and tighten the three screws removed earlier in step 1 to 48 7 inch pounds 5 5 Nm using the 5mm Allen wrench ensure that the screws were inserted into the three countersunk holes not the threaded holes 5mm Allen swivel back u ring screws 3 Figure B 12 Tighten the Three Screws to the Swivel Back up Ring 400444B B 5 Fr OMAX JetMachining Center Rebuilding the High Pressure Swivel Replacing the Bearing Note tis not necessary to remove the swivel bearing assembly if only the swivel seals require servicing Bearing removal is necessary only when the bearing itself must be replaced cleaned or regreased 1 Place the male half of the swivel body into the soft jawed vice and place a 9 16 or 14 mm deep well socket over the swivel body shaft and onto the swivel seal E swivel body shaft SW ve S e a Figure B 13 Place a Deep Socket over the Swivel
131. for all lubrication points except for the Motorized Z lead screw bearing Figure 6 16 which uses 30 weight oil OMAX JetMachining amp Center Models Lubrication Points Y axis 4 inear bearings igure 6 10 5555 55100 carriage 1 ball screw nut Figure 6 11 1 ball screw tail bearing X axis 4 linear bearings igure 6 10 carriage 1 ball screw nut Figure 6 11 1 ball screw tail bearing X axis ball screw SS d housing Figure 6 10 Y axis Inear igure 5 10 1 ball screw nut Figure 6 11 1 ball screw tail bearing X axis 2 igure 6 18 1 ball screw nut Figure 6 19 1 ball screw bearing housing Figure 6 20 on each side of the 80160 Y axis 4 linear bearings Figure 6 10 1 ball screw nut Figure 6 11 1 ball screw tail bearing lubrication not required FEN Y axis 4 linear bearings igure 6 10 1 ball screw nut Figure 6 11 1 ball screw tail bearing ubrication not requireo NENNEN Motorized Z axis 4 linear bearings igure 6 14 1 lead screw bronze bearing 30 weight oil Figure 6 16 6 10 400444B ro t Table Maintenance The OMAX JetMachining Center Service and Maintenance Guide Lubrication Points for Cantilever Style X Y Carriages Figure 6 10 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 X axis axis linear bearings 2 ea on opposite sides 4 total i F LI bos Mem Y axi
132. ful life for precise cutting The sapphire jewel that forms the jet is Replace the jewel and the jewel holder chipped dirty or out of tolerance The high pressure water pump is not Measure the water pressure If it is below specification delivering the pressure called for in the follow the directions in your pump manual to setup screen troubleshoot the problem Abrasivejet Quit Cutting Condition and Possible Causes Corrective Action The abrasive flow has stopped or has Disassemble the plugged items and blow them clean been reduced by dirt or wet abrasive and dry using an air hose Do not blow air into the abrasive inlet of the nozzle This this will unseat the jewel 4 9 Ns MAX The OMAX JetMachining Center Service and Maintenance Guide Servicing the OMAX Tables The mixing tube in the abrasivejet nozzle Use the software in Make to turn the water On and Off is plugged trying to dislodge the plug If this does not work you may need to disassemble the nozzle for cleaning or replacing the mixing tube The jewel orifice is plugged with foreign Remove the nozzle and flush the lines Replace the material in the water line jewel with a new one The high pressure water pump is not Measure the pressure If it is below specification follow delivering the pressure called for in the the directions in your pump service and maintenance setup screen manual to troubleshoot the problem 80160 Not Cutting Square Parts
133. g 5 Ifthe Support Ring does not pass inspection or has reached its recommended replacement time proceed to step 6 400444B Feds The OMAX JetMachining Center Service and Maintenance Guide Pump Maintenance Caution 14 6 A small amount of the Short Seal Ring may have extruded under the Short Support Ring locking it to the Check Valve Body Stem To remove the Short Support Ring from the Check Valve Body Stem use a propane torch to heat it slightly 20 30 seconds This softens the plastic between the Check Valve Body Stem and the Short Support Ring allowing it to be removed by hand using a rag or a pair of channel lock pliers Once the short support ring has been heated do not reuse it the material softens and can no longer support the ring seal compression Take care not to scratch the check valve body stem surface with pliers during this process 10 11 12 13 14 15 Figure 7 21 Using a Propane Torch to Remove the Support Ring Inspect the outer diameter of the Check Valve Body Stem for indications of erosion Inspect for erosion on the surface that was against the Inlet Check Valve Seat This may indicate leakage between the flat side of the Inlet Check Valve Seat and the Check Valve Body Stem or leakage between the Inlet Check Valve Ball and Inlet Check Valve Seat Using the magnifying glass inspect the Inlet Check Valve Ball for pitting or chipping If pits chips or frosted spots are
134. goes by the available storage spaces could even get smaller and smaller forcing Windows to use smaller and smaller storage locations Soon this original five megabyte file becomes stored in hundreds of individual locations Reassembling a file stored in this fashion takes a lot longer than it would for a file stored in a single memory location In extreme cases it may take several minutes to load a large file that has become fragmented into hundreds of separate pieces 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 To run the Windows Disk Defragmenter utility Click the Start icon Select All Programs Select Accessories Select System Tools Select Disk Defragmenter select the drive to defrag and click Defragment oS 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 This is a good utility to run overnight or while you re at lunch 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 by checking www omax com support for the latest u
135. he Backup support Ring Assemblies 9 Slide the Wet end Assembly previously set aside over the Plungers After starting to slide the Wet end Assembly into position do not pull the Wet end Assembly back or cock it as this could cause internal components to dislodge from their assembled position As the Cylinders begin to slide over the Short Seal Rings Figure 7 46 they may or may not go on all the way by hand The small gap that occurs between the end of the Cylinders and the Coolant Housings Assemblies closes when the Wet end Assembly is correctly torqued ny plunger BA CRM B Figure 7 46 Sliding the Wet end Assembly over the Plungers 10 Install the Clamp Plate and two Nuts on the Studs numbered 1 and 2 in Figure 7 47 using a generous amount of anti seize compound on both the Stud threads and the side of the Nuts that face the Clamp Plate Tighten the two Nuts evenly until they are snug An even gap of approximately 0 070 1 78 mm should remain between the end of the Cylinders and the Coolant Housing Assemblies Install the remaining Nuts hand tight again using a generous amount of anti seize on the Stud threads and Nut faces 400444B 7 29 F F The OMAX JetMachining Center Service and Maintenance Guide Pump Maintenance clamp plate _ c Y wet end i assembly Figure 7 47 Installing the Clamp Plate Caution Itis extremely important that sufficient anti seize compound be used to lubricate
136. he OMAX JetMachining Center Service and Maintenance Guide 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 properly tensioned timing belt it should deflect approximately 1 8 to 1 4 of an inch 0 30 to 0 64 cm 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 Y axis movement for the Bridge tables use the identical servo motor ball screw configuration as described previously in Timing Belts for Cantilever style Tables Bridge style tables include the 80X 60120 and 80160 See Figure 6 6 F UG ee m motor adjustment ncn uc plate NT servo motor pulley ball screw pulley 80160 Y axis timing belt Figure 6 6 Y axis Servo Motor Ball Screw Timing Belt Connection for Bridge Tables Locating Timing Belts Timing belt locations for bridge tables are identified in the figure which follows Note X axis designs for the Models 60120 and 80X use traction drives with linear
137. hreads 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 4 three threads Figure C 18 Applying Blue Goop and Ensuring Three Threads Show Tighten the UHP input line using the 13 16 and 1 open end wrenches Tightened to 50 ft lbs no greater than 75 ft los Refer to Figure C 4 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 C 19 Ane Blue Goop to the Valve Body Threads 5 Reinstall the air actuator assembly Use the 1 1 8 crows foot to torque it at 250 in lbs 28 2 Nm Refer to Figure C 2 6 Re attach the air line to the air line fitting on top of the air actuator assembly Refer to Figure C 1 400444B Cy F OMAX JetMachining Center Rebuilding the Dual On Off Valve 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 nozzle command in Make Select High pressure Water only Action FI Preview in Sereen Begin Machini Tes EN Change Paih Sup Water Water amp Abrasive Shrasive Pressure 4brasive Flow Fate high pressure High Figure C 20 Flushing the System with Water Only
138. ide Pump Control Panel The pump unit controls are located on the front of the panel at the right hand end of the pump See Figure 3 2 page 3 2 for illustration The panel has a 5 button keypad with display pump On Off Switch Manual Charge Pump Switch and an Emergency Stop Switch E Stop keypad and display Screen MAM high pressure pump On Off switch charge pump On Off switch e _ emergency stop switch Figure 3 7 Pump Control Panel The pump unit control has two modes of operation Keypad and Remote If the pump unit operates as a standalone pump control is via the keypad only If the pump unit operates with an OMAX JetMachining Center control is shared between the JetMachining Center Controller and the 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 turn 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 a remote command is received from the OMAX JetMachining Center WARNING 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
139. ides an estimated shipment date Same day shipments for system down emergencies can be accommodated if the requested part is in stock and the order received before 12 00 noon Pacific Time Returning Parts All parts returned to OMAX Corporation for any reason are handled according to the Returned Material Procedure described below Return procedures vary depending upon the reason for the return The normal process for returned parts takes approximately ten working days once the part is received All returned parts must have an RMA number and be returned within 30 days of the shipping date with proof of purchase to be considered for credit Returned Material Procedures The following procedures are used by OMAX Corporation to handle part returns OMAX issues credit for returned parts if received in their original condition or had failed under conditions covered by the OMAX warranty 400444B 8 1 F The OMAX JetMachining Center Service and Maintenance Guide Customer Service Please follow these steps when returning parts 1 Contact the Customer Service Department to obtain a Return Material Authorization number RMA Please provide the following information your company name and address your name and telephone number OMAX sales order number Original purchase order number itemized list of all parts being returned including quantity part number and description reason for return defective ordere
140. ight turns ON Figure A 2 With the Setup light ON you can now enter the protected area and break the safety switch circuits When finished leave the protected area ensure that the safety switches are again closed and verify that LEDs A and B are both ON Press the Reset switch Figure A 3 Switch the Run Setup switch to its Run position The machine is now ready to resume cutting Re arming the Circuit Following an Access Violation Whenever the safety circuit is triggered by an access violation the message Babysit Triggered appears on screen the OMAX pump shuts Off and all nozzle activity immediately ceases Note Abrasives will typically flow for a short time following a shutdown which may plug the nozzle Following a Babysit Triggered condition always inspect the abrasive line and blow out any abrasive that is present To recover from a Babysit Triggered condition following an access violation A 4 400444B F t Access Control Circuit OMAX JetMachining Center Correct the situation that triggered the shutdown switch opened etc Verify that both A and B status LEDs are lit Figure A 3 Press the blue Reset button Verify that the Babysit Triggered message disappears Re home the nozzle If a Tilt A Jet is installed auto square it D sx u The machine is again ready for cutting 400444B A 5 F OMAX JetMachining Center A 6 F
141. iller or closed loop system It contains its own charging pump and filter system allowing it to be used with a low pressure water Source The entire high pressure wet end assembly may be removed as a unit by removing only eight nuts All pump components are designed for low noise operation approximately 72 dB The OMAX pump runs with low vibration reducing wear and tear on components and surrounding connections The pump s major drive components include the variable frequency drive VFD the main electric motor the belt drive between the motor and the high pressure pump and the crankshaft drive for the high pressure pump The electronic VFD varies the electric motor speed and therefore the pump speed by varying the frequency of the motor s electric power The variable frequency drive accommodates slight variations in 400444B 3 1 F _ Q The OMAX JetMachining Center Service and Maintenance Guide Introduction to the OMAX Pump nozzle flow characteristics produces no current surge upon starting and provides high power factors and VFD motor efficiencies throughout the useful power range Pump components are mounted in a compact enclosure that occupies only 15 square feet 1 4 square meters of floor space All electrical control components and VFD are located in the electrical enclosure mounted on the right hand end of the pump unit The main electric drive motor belt drive and OMAX high pressure crankshaft drive pump assembl
142. 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 6 21 Typical CMOS Lithium Battery The role of the CMOS battery The BIOS is the program that starts a computer up and the CMOS memory is where the BIOS stores the date time and system configuration details needed to start the computer The computer s CMOS memory is always running Even when the computer is turned off a small amount of current still runs through the PC This current is responsible for maintaining the CMOS settings When the power to the OMAX is turned off at the power source the flow of current to the PC stops That s when the CMOS battery takes over the CMOS always needs a power source What happens when the CMOS battery fails If the battery fails and the computer isn t receiving power from an electrical outlet the CMOS memory quits and important BIOS settings are lost When lost the date and time settings reset to the manufacturer s date and time which is usually years from the current date and time Because the registration for the OMAX software is date and time dependant it s especially important for OMAX users to make sure the CMOS always maintains a power source Should the BIOS settings be lost and your computer loses track of the correct date and time
143. inear bearings Figures 6 10 and 6 11 For a 55100 also locate the ball screw bearing housing 400444B F The OMAX JetMachining Center Service and Maintenance Guide Table Maintenance Note t 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 Caution 6 Pump grease into the carriage fittings until 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 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 After sliding the bearing assemblies again connect the grease gun and pump grease until it begins to squeeze out from under the assembly Locate and grease the two ball screw tail bearings Figure 6 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 If tears are noted in a bellows
144. ing for As necessary for sharp viewing viewing Update OMAX Software As soon as updates are released by OMAX Reboot PC Controller Daily Run Windows Defragmenter 6 19 Monthly program Replace CMOS battery in the PC 6 19 as needed normally will last approximately 5 Controller years or more 400444B 6 1 F 7 The OMAX JetMachining Center Service and Maintenance Guide Table Maintenance Tank Maintenance Caution It s 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 s also important to keep a clean working area to minimize abrasive exposure to your machine In general you should keep the OMAX clean and wiped down by having plenty of sponges available in the machining area and regularly washing down the table surfaces When washing down the equipment hold the hose at a distance of at least 18 inches 46 cm from the washing surface to prevent possible damage to exposed seals Air may also be used to blow 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 with a sponge regularly Keep the bellows clean S
145. ions During installation it is important to torque gland nuts as follows 1 4 tube coning and threading 60 Kpsi 25 lb ft 34 Nm 3 8 tube coning and threading 60 Kpsi 60 16 68 Nm M8 clamp bar screws 10 12 Ib ft 13 6 16 3 Nm B 10 400444B ro TMAX Rebuilding the High Pressure Swivel 400444B For Assistance Contact OMAX Technical Support OMAX Corporation 21409 72nd Avenue S Kent WA 98032 USA Phone 800 838 0343 Phone 253 872 2300 techsupport omax com http www omax com OMAX JetMachining Center B 11 OMAX JetMachining Center Rebuilding the High Pressure Swivel B 12 400444B ro Appendix C Rebuilding the Dual On Off Valve FN The OMAX JetMachining Center Service and Maintenance Guide 400444B Rebuilding the Dual On Off Valve Use the following procedure to repair a faulty Dual On Off Valve Contents Tools and Materials N deGd ccccccccccssesecceceeaeeeeceeeseeaeeceeeeseeeeseeeeesseaeaeeeeeeseeeeeeeeeeeeaseeeeeeeeeaas page C 1 Removing the Dual OMON 2 ed qeseeubguc gute ducta Ud pP page C 1 Disassembling the Dual On Off Valve page C 4 Reassembling the Dual On Off Valve esses nennen nennen nnne nnnm page C 5 Installing the Dual On Off page C 7 Tools and Materials Needed Repa
146. ip of the Dynamic Seal 2 Apply a small amount of Lubriplate to the outside of the Small O ring Snap the metal Retainer over the Small O ring onto the Dynamic Seal 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 4 Place the Large O ring over the outside of the back of the Dynamic Seal 26 400444B ro t Pump Maintenance The OMAX JetMachining Center Service and Maintenance Guide Reassembling the Pump This section provides procedures for reassembling the OMAX pump WARNING After the pump is reassembled the crankcase should be turned over by hand to verify all plungers reach their full stroke without contacting the check valve retainers BE CAREFUL NOT TO CATCH ANY FINGERS BETWEEN THE DRIVE BELT AND SPROCKETS Tools needed to reassemble the pump Yo wrench 9 16 wrench 13 16 wrench 1 open end wrench 24 mm metric socket or 15 16 socket 12 drive Yo drive ratchet wrench Torque wrench capable of more than 175 ft Ibs 235 N m Extreme pressure lube OMAX P N 202496 OMAX Removal Installation Tool see Figure 7 6 coolant housing assembly short seal ring check valve assembly backup support ring assembly dynamic seal assembly retainer nut ball retainer long seal ring short support ring Figure 7 41 High pressure Wet end Assembly bu p rj To reassemble th
147. ir Kit P N 301927 Lubriplate grease P N 201304 e Blue anti galling compound P N 200365 Pliers needle nose e Open end wrenches 14 13 16 1 11 Allen Wrench mm Torque wrench capable of reading at least 50 ft 1 1 8 crows foot for torquing air los 68 Newton meters actuator Removing the Dual On Off Valve Figure C 1 below illustrates an OMAX Dual On Off Valve connected to a MAXJET 5 Nozzle __ dual on off valve assembly 4 MAXJET 5 nozzle Figure C 1 Dual On Off Valve with the MAXJET 5 Nozzle 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 2 Remove the air line from the air line fitting on top of the air actuator assembly Figure C 2 and move it out of the way 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 400444B 1 Fo oN OMAX JetMachining Center Rebuilding the Dual On Off Valve 3 Remove the air actuator assembly from the valve body using a 1 3 8 open end wrench air line fitting a ee i __ air actuator assembly 1 3 8 open end wrench mue valve body Asie itting ring ETT Figure C 2 Removing the Air Actuator Assembly 4 R
148. ive Action Pause button pressed Release Pause button Access Control Circuit triggered Refer to Re arming the Circuit Following an Access European Market only Violation page A 4 4 16 400444 Q Servicing the OMAX Pump This section describes how to rebuild the high pressure wet end of the OMAX pump It is strongly recommended that the OMAX pump be serviced at regular intervals according to the maintenance schedules documented in Chapter 7 Pump Maintenance It is important to inspect various parts for wear or damage and to replace worn or damaged parts to promote the longest life possible with each build of the high pressure pump It is also recommended that the procedures be followed in the order given each time the pump is rebuilt 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 manual must be followed Resealing the Safety Valve Note 400444B The safety valve P N 300756 in the OMAX pump functions to prevent an excessive build up of water pressure in the system plumbing high pressure plumbing safety valve Figure 5 1 OMAX Pump High pressure Safety Valve During normal operation the pump will reach pressures up to 57 KSI At this pressure the VFD slowly lowers the motor s RPM to prevent overpressuring the system If lowering the RPM does no
149. ive breaker bar with a steady pull to loosen the Plunger Assembly Avoid jamming the wrench and permanently bending the Plunger Assembly 400444B r 4 The OMAX JetMachining Center Service and Maintenance Guide Pump Maintenance Reinstalling Plunger Assemblies Tools needed to reinstall plunger assemblies e 3 4 crows foot 3 8 drive e 250 in Ibs 28 N m 3 8 drive torque wrench Anti seize lubricant OMAX P N 202563 To reinstall the pony rod and plunger assemblies 1 Ensure that the threads on the Plunger Assemblies Figure 7 38 and the face and threads of the pistons in the crankcase are clean 2 Apply the anti seize lubricant to the mounting face and threads of the Pony Rods 3 Install the Plunger Assemblies into the crankcase and hand tighten 4 Rotate the pump crankshaft so the Plunger is at bottom dead center Caution The plunger must be at bottom dead center fully retracted when being tightened to avoid bending the plunger assembly 5 Using a 3 4 crow s foot and torque wrench tighten each assembly to a torque of 225 in lb or 19 ft Ib 25 N m Assembling the Dynamic Seal Assembly The high pressure dynamic seal assembly is assembled as follows Tools needed to assemble the dynamic seal assembly Arbor press Lubriplate OMAX P N 201304 large O ring Figure 7 40 Dynamic Seal Assembly Components To assemble the dynamic seal assembly 1 Place the Small O ring on the extended l
150. justing Timing Belts 80160 X axis Note X axis designs for the Models 60120 and 80X use traction drives with linear encoders These models do not require use of timing belts for X axis movement Caution The 80160 uses the standard OMAX servo motor ball screw design for its X axis movement Figure 6 9 Two ball screws are used for X axis movement one on each side of the table Figure 6 7 1 Locate the timing belt access covers available on both sides of the 80160 frame Figure 6 8 Figure 6 8 Remove Cover Plate to Access the 80160 X axis Timing Belt 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 Qr duh dee From Make on the PC Controller move the Y axis assembly down the table until it just 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 Shutdown Make and power Off the PC Controller Switch the Main AC Power Switch for the JetMachining Center to Off Lock Out and Tag Out the Main AC Power Disconnect Switch Verify that AC power to the OMAX JetMachining Center was properly disconnected 400444B F Table Maintenance The OMAX JetMachining Center Servi
151. large flat blade screwdrivers Magnifying glass coolant housing assembly short seal ring check valve assembly backup support ring assembly dynamic seal assembly retainer nut ball retainer long seal ring short support ring Figure 7 7 High Pressure Wet end Assembly Components Note Remember to maintain all removed parts in related sets noting the original position of each set 400444B m The OMAX JetMachining Center Service and Maintenance Guide Pump Maintenance To disassemble the high pressure wet end assembly 1 Remove the Cylinders 3 ea and the Check Valve Assemblies 3 ea from the Manifold using two flat blade screwdrivers to lift the Check Valve Assembly and Cylinders out of the pressure Manifold cylinder flat blade screwdriver 2 ea check valve assembl Figure 7 8 Removing the Cylinder and Check Valve Assembly Note f the coolant housing assemblies remained fixed to the cylinders when removing the wet end assembly clamp the outside diameter of the coolant housing into the soft jaws of a vise and strike the side of the cylinder with a soft blow mallet to remove the coolant housings from the cylinders The close tolerance fit of the coolant housing into the cylinder bore extends only into the bore of the cylinder approximately 0 050 and should remove easily 2 Insert the Check Valve Removal Tool Figure 7 9 through the Backup support Ring Assembly
152. lity Thickness Click Setup in Make and choose Pump and Nozzle Settings Pump and Nozzle Configuration and verify that the following parameters are set correctly Water Pressure Orifice Diameter Mixing Tube Diameter Abrasive Flow Rate Standoff height is not set correctly 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 Jet stream is too wide Raise the nozzle approximately 4 inches 10 2 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 stream bast seam An abrasive other than garnet is Other abrasives do not typically cut as well as garnet and being used and the Abrasive require that the abrasive index value in the Pump and Nozzle Index value was not changed to Configuration screen be adjusted OMAX recommends garnet compensate for its lesser cutting as the abrasive because it provides a good cutting rate with ability relatively low mixing tube wear Garnet is also non hazardous and is easily disposed Other abrasives may increase mixing Refer to Pump and Nozzle tube wear and be a disp
153. llowing procedure Caution Never tighten the belt to remove all deflection This shortens the belt life Tools needed to service the pump belt Two 94 wrenches e 9 straight edge 10 mm socket To service the pump belt 1 Disconnect the pump s AC power source Lift the pump s cover lid and remove the pumpss front and rear panel covers 2 3 Disconnect the high pressure plumbing from the pump and remove the pump s rear cover panel 4 Remove the belt guard cover using the 10 mm socket Ji belt guard cover 10 __ screws sprocket B a i vw shaft guard _ lower guard L A Figure 7 56 OMAX Pump Belt with Belt Guard Cover Removed 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 6 Install the replacement belt ensuring the teeth mesh properly 36 400444B ro TMAX Pump Maintenance The OMAX JetMachining Center Service and Maintenance Guide Using the eye bolt outside nuts tighten the belt to the tension specification provided above 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 Repl
154. 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 Solids Removal System Clean Out Software The Solids Removal System SRS system prevents garnet from accumulating in your tank To keep your SRS running at its best it s important that twice a week you run the SRS Sweep Program that s included with your OMAX software This program stirs up residue that is at the bottom of the tank and distributes the accumulated abrasive evenly throughout Once the water has been churned up and the abrasive is circulating through the tank the SRS is able to suck out the excessive material The SRS Sweep Program is located on your PC in the OMAX Corporation gt OMAX Layout and Make Samples Useful Tools directory This drawing is written for the size of the 55100 tank so you should resize the drawing to accommodate the size of your OMAX JetMachining Center From beginning to end the sweep process takes about 15 minutes Run the program twice a week to keep your SRS working at its best Cleaning the Filter Screen for the Tank s Water Outlet Water accumulated in the catcher tank exits through a water outlet filter Figure 6 1 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
155. mbly Refer to Rebuilding the Dual On Off Valve page C 1 for repair instructions Abrasive Material Pours Out the Top of the Abrasive Tube Condition and Possible Causes Corrective Action The abrasive flow has stopped or has Disassemble the plugged items and blow them clean been reduced by dirt or wet abrasive and dry using an air hose Caution Do not point the air stream toward a person or toward any item to be kept free of abrasive Foreign material in the water line has Remove the nozzle and flush the lines Replace the plugged the jewel jewel with a new one The standoff distance is so small that the Increase the standoff to between 0 040 1 0 mm and nozzle is being plugged by the work 0 050 1 3 mm piece before it starts cutting and water is deflected to the abrasive tube 400444B 4 11 F The OMAX JetMachining Center Service and Maintenance Guide Servicing the OMAX Tables Water Leaking from the Nozzle Assembly Figure 4 3 Sources of Water Leaks in the Nozzle Assembly Troubleshooting Leaks in the Nozzle Assembly refer to Figures 4 3 above and C 6 for assembly drawing Leak Leak Other Point Description Suspected Causes Recommended Action Point eb air actuator weep hole leaky seal Verify air actuator torqued at 250 in los 28 2 Nm replace seal between air actuator and fitting leaky seal ring between fitting ring and gland nut cracked body bad UHP replace defective component
156. mbly and up against the support ring Figure 7 43 Installing the Short Ring Seal onto the Backup Support Ring Assembly 6 Slide the Backup support Ring Assemblies onto the Plungers with the black bushing inside the Backup support Rings toward the Coolant Housing Assembly Push the Backup support Ring Assembly down the Plunger until it rests against the Coolant Housing Assembly coolant housing r d assembly P a backup support ring S assembly Figure 7 44 Sliding the Backup support Ring Assembly onto the Plunger 26 400444B ro Pump Maintenance The OMAX JetMachining Center Service and Maintenance Guide 7 Slide the assembled Dynamic Seal Assembly onto the Plunger until it rests against the Backup support Ring Assembly The flat end of the Dynamic Seal Assembly must be against the Backup support Ring Assembly and the metal retainer must be on the side away from the Backup support Ring Assembly Note 7he dynamic seal assembly is an interference fit on the plunger It can be difficult to install at times You may find it helpful to use the OMAX installation and removal tool Figure 7 6 as a push tool to install the dynamic seal assembly coolant housing 4 assembly backup support ring assembly dynamic seal assembly P plunger Figure 7 45 Sliding the Dynamic Seal Assembly onto the Plunger 8 Apply a light coating of Lubriplate to the exterior surface of the outer ring on t
157. moved 4 coolant 3 housing hoses EM Oo Figure 7 5 Removing the Wet end Assembly 7 When a Coolant Housings sticks to the Wet end Assembly stop and disconnect the Hoses top and bottom from each Coolant Housing Proceed as in step 6 above Note fa coolant housing sticks to the cylinder and cannot be removed by hand disconnect the coolant hoses and allow the coolant housing to remain attached to the cylinder 8 Set the Wet end Assembly on workbench with the Manifold down and the Cylinders standing upright 7 6 ro 400444B Pump Maintenance The OMAX JetMachining Center Service and Maintenance Guide Caution f one cylinder has problems and the wet end assembly has been removed all three cylinders must be removed and rebuilt using these procedures for disassembling and reassembling the high pressure wet end If the wet end was fully assembled torque applied and then removed the ring seals are not reusable and must always be replaced Disassembling the High pressure Wet end Assembly The following OMAX disassembly tools are available to aid in the assembly and disassembly of the wet end assembly s high pressure seal components check valve removal tool P N 301578B removal installation tool P N 301644C Figure 7 6 OMAX Special Disassembly Tools Tools needed for disassembling the wet end assembly e OMAX Special Disassembly Tools Figure 7 6 Arbor Press provided by OMAX with pump Two
158. mp water inlet filter screen from the end of the suction line 10 Clean the water inlet filter screen by flushing it backwards with water and blowing it dry with shop air 11 Reinstall the cleaned filter screen and firmly tighten it in place by hand 12 Turn the water supply ON allowing the water tank to fill 13 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 see Figure 7 52 14 Power the change pump Off 15 Replace the water tank lid 16 Replace the pump s front panel 7 34 400444B F Pump Maintenance The OMAX JetMachining Center Service and Maintenance Guide Changing Crankcase Oil To avoid excessive wear and damage to the crankcase bearings it is important to change the crankcase oil according to the intervals specified in the maintenance schedule The oil must also be changed 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 holds two quarts 1 9 L of oil Note Whenever extended periods of pump operation at a motor RPM that is less than shown below are anticipated you should add one additional quart 3 total of oil to the pump crankcase Add additional quart of oil if
159. mponents 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 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 by your OMAX Customer Service technician To keep the X Y bearings in top notch condition 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 P N 302393 If the bellows become damaged beyond repair replace them you ll save a lot of time and money in the long run by protecting the precision linear bearings and ball screws 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 ball screw nut Use only Arctic Grease P N 304368 and follow the instructions provided in Lubricating the JetMachining Center page 6 9 Befor
160. n 1 2 3 400444B Never run the OMAX pump once pressure at a given RPM for a given nozzle drops more than 2000 4000 psi 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 Check the high pressure plumbing for leaks loose fittings or split tubing Verify that the water level in the white water tank Figure 7 53 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 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 Changing Water Filter Cartridges page 7 32 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 FF The OMAX JetMachining Center Service and Maintenance Guide Servicing the OMAX Pump 4 WARNING D Caution 10 BN Wa e r p re S S u re Po g au g Figure 5 4 Pressure Gauges for Water Filters 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 Never attempt to adjust the safety valve doing so creates a safety haz
161. n cannot be withdrawn from the housing without first pushing the tab against its pin If the RPM is displayed correctly but the displayed pressure is 0 3 KSI or O KSI the pump control circuit board may not be receiving the pressure signal The pressure signal for OMAX pumps comes from the pressure transducer A T appears on the OMAX 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 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 Checkthat 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 5 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
162. nstallation accident or unauthorized repair or alteration Accessories or equipment manufactured by others but furnished by OMAX shall carry the warranty conveyed by the manufacturer to OMAX which may be passed on to the Buyer The original warranty period of any component that has been repaired or replaced by OMAX shall not thereby be extended OMAX will indemnify Buyer for any damages and costs finally awarded against Buyer on the grounds that a Product but not any items manufactured by third parties infringe any valid United States patents or copyrights of any third party provided that Buyer notifies OMAX in writing of any such claim within ten days after learning thereof and that Buyer gives OMAX full control over the defense and settlement of the claim and fully cooperates with OMAX with respect thereto If any such claim is brought or appears to OMAX likely to be brought OMAX may at its option replace or modify the Products to make them non infringing or refund to Buyer upon return of the Products at issue the price paid therefor less twenty percent for each year which has passed since the date of delivery hereunder Buyer shall discontinue all use of any portion of the Products that has been replaced or modified or for which a refund has been tendered OMAX s obligations hereunder shall not apply to any claim based on i OMAX having followed Buyer s specification or requests ii the use of Products to practice a process not recommended b
163. ntroller 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 Condition and Possible Causes Corrective Action Verify that system air pressure is 70 95 psi 5 to 7 bars Fault in a servo circuit Check the fault relays on the controller back door for a light identifying which axis faulted Figure 2 13 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 e Green LED On steady or blinking at fast rate normal operation e No LEDs lit power failure e Red LED steady On blown fuse e Green LED slowly flashing servo fault e Green LED On steady servo not enabled Whenever any of the above faults are indicated contact Technical Support X axis servo card Y axis servo card X axis servo card Figure 4 5 Servo Card Locations for Y and X axis for Bridge style Tables 400444B dodo F F The OMAX JetMachining Center Service and Maintenance Guide Servicing the OMAX Tables Fis Y axis servo card Figure 4 6 Servo Card Locations for Y and X axis 2626 26261 2652 5555 55100 Servo Motors Condition and Possible Causes Correct
164. o pole circuit breaker CB1 Turning Off CB1 kills the power to the 2 KVA TRANSFORMER and all the 120 VAC and 24 VDC power in the OMAX pump The only component within the pump powered is the VFD Immediately downstream of the 2 KVA TRANSFORMER is the single pole circuit breaker CB2 Turning CB2 Off kills all 120 VAC and 24 VDC power in the OMAX pump with the exception of the VFD and the 2 KVA TRANSFORMER The electrical enclosure cooling FAN the Jet Machining Center COMPUTER CONTROLLER the charge pump motor M2 and the 24 VDC POWER SUPPLY are powered with 120 VAC from the 2 KVA TRANSFORMER Connecting the COMPUTER CONTROLLER of the OMAX Jet Machining Center externally completes the 120 VAC circuit within the OMAX pump to power the FAN the charge pump motor M2 and the 24 VDC POWER SUPPLY Without the COMPUTER CONTROLLER connected the BYPASS SWITCH must be closed to complete the 120 VAC circuit and power the FAN the charge pump motor M2 and the 24 VDC POWER SUPPLY Through the COMPUTER CONTROLLER power circuit the emergency stop switches not shown in the simplified diagram on the COMPUTER CONTROLLER and the OMAX pump are in series Pressing either emergency stop shuts down both the OMAX pump and the COMPUTER CONTROLLER Manually closing the Charge Pump On Off Switch starts the charge pump at any time Charge pump motor M2 is protected by the circuit breaker CB3 Turning Off CB3 prevents the charge pump motor M2 from starting
165. observed on the Ball surface replace it Inspect the Inlet Check Valve Seat for erosion across the Inlet Check Valve Ball and on the flat sealing surface that contacts the Check Valve Body Stem If erosion or damage is observed replace the seats ms A polished band on the seat under the ball is normal An erosion mark across the band is a leakage path Figure 7 22 Inspecting the Valve Seat for Erosion Marks Turn the Check Valve Body over and remove the Socket Head Screws using the 3 32 Allen wrench Also remove the Flat Washers and the Outlet Check Valve Retainer The socket head screws and washers should be replaced according to the maintenance schedule Perform the same inspection of the Outlet Check Valve Ball and Outlet Check Valve Seat See steps 7 11 above Carefully inspect the Check Valve Body Stem for indications of erosion on the surface contacting the Outlet Check Valve Seat This may indicate leakage between the flat side of the Outlet Check Valve Seat and the Check Valve Body Stem or leakage between the Outlet Check Valve Ball and Outlet Check Valve Seat Remove and discard the O ring and Static Seal Inspect the Static Backup Ring ensuring that the edges are sharp and square with no nicks or gouges Also see if it is cracked near the notch and replace it whenever damage Is apparent Clean the Check Valve Body Stem and the radius at its base 400444B F Pump Maintenance The OMAX JetMachining Center Se
166. of the 4 14 Abrasive Material Piles Up on the Work Piece 4 14 The OMAX has an Unpleasant 4 14 Keyboard and or Mouse 4 14 Software PrODICMS s 04224 even x Rer dd Rp 2 orae dcinde eda 4 14 Blue Screen Errors 4 14 Babysit Triggered 4 15 Chapter 5 Servicing the OMAX Pump Resealing the Safety 5 1 Troubleshooting the OMAX 5 3 Low or Fluctuating Pump Output Pressure 5 3 Water Leaks in the Wet end Assembly 5 5 No AC Power at Pump 5 7 Pump Does Not 5 7 No Keypad Display 4 ek RE E EE REP E 5 8 Pump Runs but Display Reads 0 3 KSP or 0 5 10 Circuit Breakers CBI CB2 5 10 Circuit Breaker Tripping 5 11 Fault Message Charge Pressure 5 11 Fault Message Charging Pump 5 11 Fault Message Dead 5
167. olate the equipment from its energy source s and prevent the release of potentially hazardous energy 400444B 1 7 F The OMAX JetMachining Center Service and Maintenance Guide Safety First 1 8 400444B F Chapter 2 Introduction to OMAX Tables This chapter provides an overview of the available JetMachining Center models It identifies their major parts and explains their purpose For information about operating this equipment refer to the OMAX JetMachining Center Operator s Guide P N 304952 The OMAX JetMachining Centers Overview The OMAX JetMachining Center is a precision abrasivejet machining tool operating under software control that cuts complex parts out of most materials including metal plastic glass ceramics stone and composites from standard CAD drawings Eight different Models of the OMAX JetMachining Center are currently available the Models 2626 2626 xp 2652 5555 55100 60120 80160 and 80X Model 2626 JetMachining Center Provides a smaller work envelope for the precise abrasivejet machining of small parts ae Figure 2 1 The Model 2626 JetMachining Center Specifications Model 2626 JetMachining Center Position Table Size Weight X Y Cutting Travel Ceiling Height Accuracy empty tank Requirement 0 08 mm 1168 mm x 787 mm 2946 mm x 1829 mm 1364 kg 737 mm x 660 mm 2 44 m Model 2626 xp JetMachining Center Provides ultra precision in the abrasiveje
168. osal hazard Configuration in the OMAX Warning interactive reference OIR for a list Never use silica sand as a cutting abrasive Fine silica dust of abrasive index values to be used inhaled during the cutting process can lead to silicosis a when cutting with abrasives other serious lung disease Silicosis is a type of pneumoconiosis than garnet which includes black lung disease The mixing tube has worn Wear occurs first at the inlet with a conical wear zone growing excessively and is no longer toward the exit end Measure the tube bore at the two ends capable of producing the required using a drill or gage pin When the outlet has grown by 0 005 jet stream 0 13 mm the mixing tube is near the end of its useful life for precise cutting The jewel that forms the jet is Replace the jewel and the jewel holder chipped dirty or out of tolerance The abrasive flow has stopped or Disassemble the plugged items and blow them clean and dry has been reduced by dirt or wet using an air hose abrasive The high pressure water pump is Measure the pressure and if it is below specification follow the not delivering the pressure called directions in your pump service and maintenance manual to for in the setup screen troubleshoot the problem 400444B 1 7 rF F f The OMAX JetMachining Center Service and Maintenance Guide Holes Too Large and Undersized Parts Condition and Possible Causes Corrective Action The tool off
169. ose Tighten the nozzle body The on off valve is leaking Repair the on off valve using the appropriate repair kit The mixing tube in the abrasivejet nozzle Use the software in Make to turn the water On and Off is plugged trying to dislodge the plug If not unplugged install the mixing tube on upside down and try again If not unplugged replace the mixing tube The inlet body or valve body is damaged Inspect both parts for signs of a crack Replace part whenever damage is noted The standoff distance is so small that the Increase the standoff to between 0 040 1 0 mm and nozzle is plugged by the work piece 0 050 1 3 mm before it starts cutting and water is deflected to the abrasive tube 4 10 400444 7 OMAX Servicing the OMAX Tables The OMAX JetMachining Center Service and Maintenance Guide The high pressure pump is not delivering Measure the water pressure If it is below specification the pressure called for in the setup follow the directions in your pump manual to screen troubleshoot the problem The Jet Looks Wide and Fuzzy Condition and Possible Causes and Possible Causes CoreciveAction Action 6 sapphire jewel that forms the jet is as cae the jewel and the jewel holder chipped dirty or out of tolerance The mixing tube has worn with use and is If changing the jewel does not improve the quality of no longer capable of forming an the jet then the mixing tube needs to b
170. ower source Open the door to the pump s electrical enclosure Remove the four wing nuts and the round cover plate Remove the two air filters Replace the air filters with FRAM CA326 or equivalent Replace the cover and wing nuts LU OE SF amo ok i Close the door to the electrical enclosure 400444B 7 39 ro The OMAX JetMachining Center Service and Maintenance Guide Pump Maintenance Maintenance Log 7 40 400444B Chapter 8 Customer Service This chapter explains how to reach OMAX Customer Service and provides instructions for the ordering and returning of parts Contacting OMAX Customer Service OMAX Customer Service personnel can be reached throughout the workday for technical questions or ordering parts as follows 8am 8pm EST Monday through Friday 8am 5pm EST Saturday and Sunday Voice 253 872 2300 x3 or 800 298 4036 International 01 253 872 2300 x3 Fax 253 872 7446 E mail techsupport omax com Ordering parts parts omax com Ordering Parts OMAX parts can be ordered from Customer Service either by calling 800 298 4036 international 01 253 872 2300 x3 faxing 253 872 7446 or emailing parts omax com When ordering parts please provide the following information part name part number e quantity needed date required your shipping information purchase order number Parts in stock are shipped within 3 working days from receiving the order When not in stock OMAX prov
171. pdates Software updates are always free 6 19 Fr The OMAX JetMachining Center Service and Maintenance Guide Table Maintenance Note A user name and password are required to access the OMAX technical support site To set up a user account contact OMAX Customer Service at 800 298 4036 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 Replacing the CMOS Battery 6 20 A small coin sized battery in your computer powers the PC s CMOS memory It s important to
172. perly 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 5 11 Keypad Ribbon Cable and 34 Pin Connector Location on page 5 12 11 Check if Circuit Breakers CB1 and or CB2 have tripped If either of these circuit breakers have tripped or are tripping regularly See Figure 5 10 Circuit Breakers CB1 CB2 and CB3 Location on page 5 10 FI The OMAX JetMachining Center Service and Maintenance Guide Servicing the OMAX Pump circuit breakers i pe Figure 5 10 Circuit Breake rs CB2 and CB3 Location Pump Runs but Display Reads 0 3 KSI 0 KSI ls Caution oee 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 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 pi
173. pm at 3 to 0 5 1 8 lpm at 3 to 1 3 4 9 lpm at 3 to 150 psi 20 100 Kpa 150 psi 20 100 Kpa 150 psi 20 100 Kpa Charge water tank 5 gal 18 9 Liter with 5 gal with float valve 5 gal with float valve float valve Output Pressure 50 KSI 345 MPa 55 KSI 380 MPa 55 KSI 380 MPa Electric Motor Type Marathon Motors 30 hp Marathon Motors 30 Marathon Motors 40 hp 22 kW 22 kW 30 kW 600 to 2000 600 to 2000 600 to 2000 PM Voltage 460 380 or 415 460 VAC 3 phase Voltage 460 380 or 415 International International VAC 3 phase VAC 3 phase 50 60 Hz 50 60 Hz 50 60 Hz Variable Speed Drive Type Voltage ABB ACS550 Pulse ABB ACS550 Pulse ABB ACS550 Pulse Width Modulated PWD Width Modulated PWD Width Modulated PWD variable frequency variable frequency variable frequency 380 480 3 phase 380 480 3 phase 380 480 3 phase 50 60 Hz 50 60 Hz 50 60 Hz Crankcase see Changing Crankcase Oil page 7 35 for additional oil specifications Capacity SAE 30 Non detergent SAE 30 Non detergent 30 Non detergent ISO 100 ISO 100 ISO 100 2 quarts 1 9 L 2 quarts 1 9 L 2 quarts 1 9 L 400444B F 1 MAX Chapter 4 servicing the OMAX Tables This chapter provides information for servicing a JetMachining Centers swivels dual on off valve and high pressure plumbing Troubleshooting procedures are also provided that are useful when analyzing performance is
174. pray the X Y and Z axis bellows as needed to keep them free of abrasive material accumulation If abrasive particles get inside and onto the bearings they will no longer function as precision bearings Check regularly to make sure there are no rips or tears in the bellows Inspect the bellow cuff and bellow adapters ensuring that everything is properly sealed Once bellows damaged is detected repair it immediately Refer to Maintaining the X Y Carriage Bellows page 6 4 Note OMAX supplies a repair kit for bellows rips and tears P N 302393 Caution Use a splash shield during machining You can purchase a splash shield from OMAX or construct one yourself from clear plastic A splash shield 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 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 Ensure that your garnet remains dry Always store it in a location removed and protec
175. 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 400444B F Introduction to the OMAX Pump The OMAX JetMachining Center Service and Maintenance Guide Note Note Up down Arrow Buttons Pressing the up arrow increases the pump s RPM which increases water u pressure Neither pressure nor RPM can be increased above their maximum C allowable limits Pressing the down arrow at any time decreases pump RPM and pressure down to the minimum RPM Normal Operation Messages When the pump is operating normally the OMAX keypad screen displays four lines of information Water Press T Pump output pressure in kpsi 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 OMAX JetMachining Center Controller RunTime Hour Meter accumulative number of hours the drive motor pump has run It is not re setable Fault Messages If a fault occurs the pump shuts down and one or more of the following messages will be displayed on the first
176. quipment and use only original manufacturer replacement parts Follow a periodic maintenance schedule that ensures proper equipment operation Following maintenance activities clear all tools and rags from around the OMAX pump before starting Don t Don t start the OMAX pump unless you know how to stop it Never open or perform maintenance on the OMAX pump with the main disconnect ON or unlocked or while the pump unit is operating Always follow standard lock out tag out procedures 400444B F t Safety First The OMAX JetMachining Center Service and Maintenance Guide Don t apply power to this pump while maintenance work is in progress Always lock the main power to the OMAX pump Off at its source e Don t make unauthorized alterations to the equipment or components Never perform any electrical and maintenance work on this equipment unless you have received appropriate training and are qualified to service OMAX pumps Equipment Safety Features The OMAX equipment provides several built in safety features Emergency Stop Switch E Stop Both the pump unit and PC controller are equipped with an emergency stop switch The E Stop is engaged by pushing it in Once engaged it immediately shuts down the pump unit and abrasivejet Refer to Figure 2 12 for an illustration of the E Stop switch and its location on the controller front panel Overpressure Protection During operation pump pressure is monitored to prevent an o
177. r This situation can be prevented by following these suggestions for filter maintenance e When one filter requires replacement change all four filters e Change the 20 wall filters monthly or until a specific replacement interval can be determined Increase the interval between wall filter changes until the 10 blue pump filter interval starts to fall when running at high RPM Use this as a baseline for the interval for the wall filter changes f the pressure difference between the gauges is more than 20 psi when running the pump at high RPM change the pump s 10 blue filters e Record the time between all filter changes Clean the 200 mesh strainer in the Charge Pump reservoir every 3 months or more frequently if needed Note f problems with your water supply are suspected send a sample of water from the white reservoir tank in the pump to OMAX for a water test Take the sample after running the pump for approximately 20 minutes This sample will let you know if additional water treatment may be required Changing Water Filter Cartridges The OMAX pump uses two filters for the low pressure water from the water tank Figure 7 52 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 7 32 400444 ro t Pump Maintenance
178. r Grease Fittings and Pipe Plugs Wipe the tip of each grease fitting clean and connect the grease gun Apply 2 3 full strokes from the grease gun to each grease fitting Wipe up any grease forced out the hole and replace the pipe plugs Replace the belt guard components Replace the pump s front and rear panel covers Close the pump s cover lid Run the motor for 20 minutes before opening up the panel covers and replacing the pipe plugs removed previously 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 400444 Pump Maintenance The OMAX JetMachining Center Service and Maintenance Guide Replacing the Electrical Enclosure Air Filters The two air filters located on the inside of the electrical enclosure door 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 1 air filters 2 ea 14 ea cover plate inside electrical enclosure door Figure 7 58 Electrical Enclosure Air Filters To replace the air filters Disconnect the pump s AC p
179. r Service and Maintenance Guide 3 Using a 5 16 8 mm socket unscrew the two clamps holding the bellows in place that are identified in Figure 6 12 below unscrew these two clamps Figure 6 12 Z axis Assembly Note This is an excellent time to conduct a thorough inspection of the internal components to detect and correct any bellows tears garnet contamination worn bearings pitted bearing track etc 4 Lift up the bellows to expose the grease points on the Z axis mechanism Figure 6 13 Lift Bellows to Expose Grease Points 5 There are four bearings in the Z axis housing that require lubrication using Jet Lube s Arctic Grease OMAX P N 202335 see Figure 6 14 400444B 6 13 rF F Ta TAAK The OMAX JetMachining Center Service and Maintenance Guide Table Maintenance Note tis not necessary to remove the Z axis to lubricate these bearings The figure below shows a disassembled Z axis for clarity lubricate lubricate lubricate lubricate W Figure 6 14 Z axis Bearing Locations Requiring Lubrication 6 Attach the blunt tip needle extension P N 202633 to the grease gun to lubricate each of the four bearing assemblies There is a small grease cup at the end of the bearing that this needle extension fits against Note n 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 6
180. r warranty it will either be repaired at your expense returned to you without repair or scrapped at your request When a part is urgently needed while the equipment is still under warranty OMAX suggests that you issue a new purchase order for the required part Write the RMA number on the purchase order and also note that the parts ordered are to replace parts sent in for warranty consideration If the part is in stock it is shipped within three working days If it is not in stock the part will be sent as soon as possible If the warranty claim is approved OMAX issues a credit memorandum for the parts A copy of the credit memorandum is sent to you for use on future orders FF The OMAX JetMachining Center Service and Maintenance Guide Customer Service Two Year Limited Warranty OMAX Corporation OMAX warrants its OMAX JetMachining Center and all components of its manufacture the Products to be free of defects in workmanship and material for a period of two years from the date of shipment or 4 000 operational hours whichever comes first This warranty covers all machinery and electronics equally however it does not include wear parts and consumable parts such as seals valves abrasive jet nozzles mixing tubes orifices high pressure hose or high pressure pump components Further Buyer is strongly cautioned that poor water quality and high inlet water temperature will significantly affect operational life
181. re left handed and screw onto the end of the tubing to prevent the gland nut from slipping off the tube end Weep Hole This is a designed leak point that allows fluid to escape whenever fitting pressure exceeds the maximum sealing point FF Ta TAAK The OMAX JetMachining Center Service and Maintenance Guide Servicing the OMAX Tables Creating the High Pressure Seal Maintaining the proper cone angles on the body and tube is critical in creating a high pressure seal Figure 4 2 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 Assembling a 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 Figure 4 2 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
182. re swivels Appendix D Rebuilding the Dual On Off Valve e Contains disassembly and assembly procedures for rebuilding the OMAX dual on off valve iv 400444B t The OMAX JetMachining Center Service and Maintenance Guide Contents Page PED OU UNS MANU al iii Me EPO E 11 PANG IU C iii Supporting iii OL AMM 7 AO 11 Bun V gil xi Chapter 1 Safety First spia dg E 1 1 Placement of Satety 6050423 px y qma ds 1 3 Safety 1 5 Table Safety Requirements 1 5 Pump Safety Requirements 1 6 Equipment Safety Features 1 7 Emergency Stop Switch E Stop 1 7 Overpressure 1 7 Electrical ProrecuOm 2 Dads uuo 1 7 Access Control COIFCUIL s uiae a penn dos npe d hae 1 7 Lock out Tag out 1 7 Chapter 2 Introduction
183. ream Refer to the corrective actions provided for Wide Jet Stream in Poor Surface Finish page 4 7 400444B A Quality of 1 will just barely pierce the material and usually has significant taper Both taper and 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 The standoff should be no more than 0 050 1 3 mm for best results Check that the following items are correct for the material setup in Make Machineability Thickness In setup for Make verify that Pump and Nozzle settings are correct for the following parameters Water pressure Orifice diameter Mixing tube diameter Abrasive flow rate 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 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 Wear occurs first at the inlet with a conical wear zone growing toward the e
184. replace the bellows immediately or repair the tear using the Bellows Repair Kit OMAX Part 302393 Running the OMAX with an opening in the bellows allows garnet and grit to enter and damage the precision mechanisms causing serious damage and requiring replacement of the entire assembly Do not use the OMAX until the bellows are repaired or replaced 1 Lubrication Points for the Motorized Z 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 couples with standard grease guns is included with your OMAX Greasing the Z axis Bearings 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 axis stretches the bellows and allows for a more thorough cleaning It also makes it easier to remove the bellows Caution 2 Carefully inspect the bellows for any tears or rips If tears are noted replace the bellows immediately or repair the tear using the Bellows Repair Kit OMAX Part 302393 Running the OMAX with an opening in the bellows allows garnet and grit to enter and damage the precision mechanisms causing serious damage and requiring replacement of the entire assembly Do not use the OMAX until the bellows are repaired or replaced 400444B F t Table Maintenance The OMAX JetMachining Cente
185. rom the rails when finished 8 Locate and grease the ball screw tail bearing at the end of the Y axis ball screw Figure 6 10 400444B 6 15 F TAAR The OMAX JetMachining Center Service and Maintenance Guide Table Maintenance Note t 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 Bellows on page 6 4 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 Caution If tears are noted a bellows replace the bellows immediately or repair the tear using the Bellows Repair Kit OMAX Part 302393 Running the OMAX with an opening in the bellows allows garnet and grit to enter and damage the precision mechanisms causing serious damage and requiring replacement of the entire assembly Do not use the OMAX until any torn bellows are repaired or replaced 11
186. rvice and Maintenance Guide 16 If leaking was observed between either the Check Valve Body or the Manifold and Cylinder Figure 7 1 check the radius at the base of the Check Valve Body Stems for fine cracks using the magnifying glass Note Be careful not to confuse lines of discoloration with actual cracks 17 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 18 Always discard any damaged or eroded parts and replace them with new ones 19 Repeat this procedure for the two remaining Check Valve Assemblies Reassembling the Check Valve Assembly The following procedure explains how to reassemble the Check Valve Assemblies Figure 7 23 Tools needed e 3 32 Allen wrench e 5 8 crows foot 0 124 diameter anti rotation pin drill blank 1 8 x 2 3 4 OMAX P N 202094 e 250 in Ib torque wrench 0 124 diameter anti rotation pin e Anti seize compound OMAX P N 202563 Lubriplate OMAX P N 201304 e Soft jawed vise water inlet fitting C check valve body stem check valve body bin outlet check valve seat inlet ball retainer outlet check valve ball static backup ring V inlet check valve seat outlet check valve cw flat washer short support ring socket head screw P ge Figure 7 23 Check Valve Assembly Components To reassemble the check valve assembly 1
187. s Figure C 2 and the four clamp bar SCrews 6 Remove the high pressure swivel assembly from the table and take it to a clean room environment for rebuilding Caution The swivel assembly and the rebuild location must be thoroughly cleaned prior to rebuilding Disassembling the High pressure Swivel swivel seal removal tool ur swivel body male N swivel spanner wrench O ring swivel body male bearing lock nut O ring back up ring O ring swivel seal Figure B 3 Components of the High pressure Swivel Assembly B2 400444B F Rebuilding the High Pressure Swivel OMAX JetMachining Center To disassembly the High Pressure Swivel 1 Clamp the cleaned swivel assembly in a soft jawed vice as illustrated in Figure B 4 When clamping the assembly ensure that the two flat sides of the female swivel body are aligned flush to Note the jaws of the vice 2 If present remove the top plug on the swivel assembly Figure B 4 3 Unscrew the swivel retaining nut using the swivel spanner wrench Figure B 5 by rotating it counterclockwise wrench nut Figure B 5 Use the Swivel Spanner Wrench to Unscrew the Swivel Retaining Nut 4 Separate the swivel assembly into its two halves a male and the female half swivel body male swivel body female Figure B 6 Separate the Swivel Assembly into its Male and Female Halves 400444B B 3 FF o OMAX JetMachining C
188. s 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 5 Check for a blown 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 5 12 24 VDC Power Supply Fuse Location on page 5 12 fuse 0 5 Amp Note A box of 0 5 Amp fuses is supplied with every new pump unit stored in a plastic container attached to the bottom of the enclosure 5 12 400444B ro Servicing the OMAX Pump The OMAX JetMachining Center Service and Maintenance Guide 6 Tighten any loose wires on the input and or output side of the 24 VDC power supply Note f the power supply s green LED fails to light there is 120 VAC being delivered as measured across L and N If 120 VAC is present the power supply has failed and must be replaced 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
189. s by mail at OMAX Corporation Technical Publications 21409 72nd Avenue South Kent WA USA 98032 OMAX Corporation is continually improving their equipment to bring you the best in abrasivejet machining technology For that reason your OMAX JetMachining Center may differ slightly from what is described in this document If you have any questions please feel free to contact us at 1 800 838 0343 or e mail us at techsupport omax com You can also receive technical support on line at http www omax com support user name and password required for access OMAX MAXJET 5 Intelli MAX Tilt A Jet MAXJET4 2626 xp9 and JetMachining are registered trademarks of OMAX Corporation Intelli TRACE Mis a trademark of OMAX Corporation Windows is a registered trademark of Microsoft Corporation The OMAX Machine tool apparatus and linear motion track is 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 September 2008 2008 OMAX Corporation li 400444B OMAX JetMachining Center Service and Maintenance Guide About this Manual Purpose This document provides technical information specific to the repair and maintenance of the OMAX JetMachining Center abrasive cutting tables Models 2626 2626 xp 2652 5555 55100 60120 80160 and 80X Audience This document assumes the reader has basic mechanical skills and
190. s linear bearings 2 ea on opposite sides 4 total n Y axis carriage EE X axis ball screw bearing housing 55100 and 5555 Y axis ball screw nut Figure 6 10 Lubrication Points on OMAX Cantilever Style X Y Carriages VIJL Hj ball screw bearing housin ball screw nut grease fitting grease fitting eang he and 5555 Figure 6 11 Lubrication Fittings for Cantilever Style X Y Carriages 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 bellow clamp at the end with the timing belt see Figure 6 6 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 l
191. servicing activities are being performed 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 Safety Labels Safety Wear Gloves Since bacteria in the tank water can build up even a seemingly minor break in the skin could introduce harmful bacteria into a wound Always wear protective gloves if you have cuts or open wounds on your hands When setting up material for cutting wear gloves that provide protection against sharp metal edges Electrical Hazard Indicates the presence of life threatening voltages Never access areas labeled as such without first X taking appropriate safety precautions locking out power verifying no voltage present on circuits prior to maintenance activities etc Lock Out Power Never open or conduct maintenance on the OMAX equipment with the main power disconnect ON or unlocked or while the pump unit is operating Always follow standard lockout tag out procedures Don t apply power to the equipment while maintenance work is in progress Always lock the main power to the OMAX pump Off at its source Eye Protection Always wear approved safety goggles whenever cutting Regular glasses do not provide sufficient eye protection Ear Protection Always wear hearing protection while in the vicinity of the OMAX When cutting in air noise levels can exceed 120 dB Flying
192. set is set incorrectly Tool offset is on the wrong side of the path Servicing the OMAX Tables If not enough material is being removed hole too small or part too large decrease the tool offset by half the dimensional error observed 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 Layout to order the part again You can check your tool offset using Preview to Screen in Make Excessive Taper on Part Edges Condition and Possible Causes Corrective Action The cut was made with the Quality value set too low The standoff between the abrasivejet nozzle and the material is too high The setup values entered in Make are not consistent with the actual physical values An abrasive other than garnet is being used and the Abrasive Index value was not changed to compensate for its lesser cutting ability Refer to Pump and Nozzle Configuration in the OMAX interactive reference OIR for a list of abrasive index values to be used when cutting with abrasives other than garnet The mixing tube has worn with use and can no longer form an adequate jet The sapphire jewel that forms the jet is chipped dirty or out of tolerance Wide Jet St
193. sive extrusion fit and or Damaged O ring damage e Extrusion of Static Ring Seal Leak from Weep Hole on Port Possible damage to Seal Replace Port Adapter and Seal Adapter surface of the Port Replace Tubing Adapter Possible damage to Tubing seat Warm Fitting on Check Valve e Damaged Check Valve Rebuild Wet end Assembly Inlet Seat or Ball Inspect for damaged Check Valve Note There can be a Inlet Seat or Ball replace as damaged Check needed Valve Inlet Seat Ball with no noticeable heat Warm Cylinder at Check Valve e Damaged Check Valve Rebuild Wet end Assembly end Outlet Seat or Ball Inspect for damaged Check Valve e Outlet Seat or Ball replace as needed Cylinder poe warm at Dynamic NORMAL NONE Seal end only Sudden loss of pressure and Cracked Check Valve e Rebuild Wet end Assembly Cylinder Body very warm or hot Body between the High Inspect for cracks damage in the and Low Pressure ports Check Valve Body internal cracking inspect viewing through the low pressure port may require magnification 5 6 400444B F Servicing the OMAX Pump The OMAX JetMachining Center Service and Maintenance Guide No AC Power at Pump Unit 1 Have acertified electrician verify that AC power is available at the main power disconnect by measuring the voltage between all three legs WARNING t is the customer s responsibility to ensure that all components and conductors as well as
194. sives also contains less dust When dust is present static electrical charges can build up causing the abrasive particles to clump together hindering their flow High pressure Plumbing The high pressure plumbing routes the high pressure water from the OMAX pump to the abrasivejet nozzle This system of plumbing includes the tubing high pressure fittings swivels and 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 Swivel Swivels provide the flexibility in the plumbing system that allows the cutting nozzle and associated high pressure plumbing to travel across the table surface while maintaining a watertight seal There are two types of swivels used on the OMAX JetMachining Centers bulkhead and high pressure See Figure 4 1 on page 4 1 The Model 2626 does not require swivels Dual On Off Valve The Dual On off Valve controls the water flow through the cutting nozzle and operates in conjunction with the high pressure pump s dump valve When water to the cutting nozzle is shut off the software 2 13 af TAK The OMAX JetMachining Center Service and Maintenance Guide Introduction to OMAX Tables automatically opens the dump valve routing the high pressure water through it instead This allows continual pump operation during times when the nozzle is not cutting Using this technique the water pressure always remains
195. source the pump E Stop stops only the pump and not the controller Operator Keypad and Display Screen The keypad provides five function buttons with a four line message display screen See Figure 3 8 below for illustration display screen Run button with status LED Stop button with status LED Reset button with status LED arrow button down zT arrow button OMAX Figure 3 6 Front Panel Keypad and Display Screen 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 A T appears with the water pressure information Water Pres T if a pressure transducer is connected and recognized by the pump controller card The five buttons on the OMAX Keypad function as follows v Run Button otarts the pump when pressed if operating in a standalone mode not being controlled by the OMAX JetMachining Center 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
196. stop 0 0 eens Operator Keypad and Display Kon BURHON DIOP DUMON ae re OS Mech NP DM PPP Normal Operation Fault Messages cuo o2 ge dna didus io dc RAP ous ded ws ace udi dod Overview of the Charge Pump Water Circuit Up down Arrow Buttons How OMAX High pressure Pump Overview of Electrical uiuos Gedo eked hae deemed e RU ed Pamp specications e 2500225406 etane i aoe Seer eeu Chapter 4 Servicing the OMAX Tables all Rebuilding Swivels The Dual OMO Valy sepe into es sete ts rents a ekrk Ok Rebuilding the Dual On Off Valve Servicing the High pressure Plumbing System Creating the High Pressure Assembling a UHP Working with High Pressure Troubleshooting the JetMachining Problems with Machine Motion Abrasivejet Nozzle Doesn t
197. sue that may occur during operation of your OMAX equipment When service to an OMAX abrasive waterjet nozzle is needed refer to the OMAX JetMachining Center Operator s Guide P N 304952 To service OMAX pumps refer to The OMAX Pump Service and Maintenance Guide P N 304757 WARNING All service activities must be performed by OMAX qualified personnel Swivels Swivels are a key component of the OMAX high pressure plumbing system They allow the abrasivejet nozzle to move across the table surface when cutting without allowing water to leak from the high pressure plumbing system Two different styles of swivels are used on OMAX JetMachining Centers see Figure 4 1 the bulkhead swivel and the high pressure swivel Bulkhead swivels were used on earlier OMAX table models currently they have been replaced by high pressure swivels in the scissor style plumbing and are no longer found on new machines Figure 4 1 The OMAX Bulkhead and High pressure Swivels Rebuilding Swivels Although swivels are very durable occasional servicing may be required In particular if a swivel begins to leak at a rate of more than one drop per minute its seals and O rings will require replacing by following the procedures provided in Appendix B Rebuilding the Bulkhead Swivel and Appendix B Rebuilding the High Pressure Swivel The Dual On Off Valve The Dual On Off Valve controls water flow through the cutting nozzle and operates in conjunction wi
198. sure wet end of the pump has been disassembled Prior to starting the pump always remove the nozzle assembly from the plumbing to prevent debris from damaging or plugging the orifice Run the pump for ten minutes without the nozzle to clear out any debris after reassembly e Always inspect all parts and replace the high pressure seals as a set Carefully wipe each part clean with a lint free rag and blow them out with compressed air Never tighten or loosen plumbing while under pressure Tools needed for reassembly of the high pressure wet end assembly e Soft mallet e Lubriplate OMAX P N 201304 coolant housing assembly short seal ring check valve assembly dynamic seal assembly Figure 7 32 High pressure Wet end Assembly Components p Lg T To re assemble the high pressure wet end assembly 1 Apply a light coat of Lubriplate 201304 to the interior of the holes on the pressure Manifold Figure 7 1 and to the Check Valve Body Figure 7 23 outlet side O ring and Static Seal 2 Install all three assembled Check Valve Bodies into the pressure Manifold Note Because of pins in the pressure manifold check valve bodies can be installed in only one position 3 Place the Displacer over the Inlet Check Valve Retainer Figure 7 23 until it contacts the Long Seal Ring Figure 7 32 Repeat this for all three Check Valve Assemblies 400444B 7 21 The OMAX JetMachining Center Service and Maintenance
199. t Spots Appear When Cutting Curves Condition and Possible Causes The part was not held firmly The part moved during the cutting due to nozzle drag or upwelling of enough the water beneath the part Make sure the part is securely fixtured This is the most common reason for scrap parts The is reaching its Move the work piece toward the table s center Set soft limits that hardware limits allow you to be warned before hardware limits are reached Home Position for Soft Limits are Lost Condition and Possible Causes Corrective Action The OMAX reached its hardware Move the work piece toward the center of the table Set soft limits limits that allow you to be warned before hardware limits are reached Note Auto Homing should recover all positioning for the waterjet including soft limits Wires or connections inside the Turn Off the controller power and open the back of the controller controller may have loosened cabinet Verify each connection making sure all connectors are firmly seated Close the cabinet turn the power back On and try again 4 6 400444 F 7 OMAX Servicing the OMAX Tables The OMAX JetMachining Center Service and Maintenance Guide Problems with Machining Quality Poor Surface Finish Condition and Possible Causes Corrective Action Setup values in Make are not Check that the following data is correctly entered for setup in consistent with the actual physical Make values Machineabi
200. t check valve body stem 2 anti seize compound on bottom face Figure 7 29 Applying Anti seize Compound to Threads and Bottom Face of Retainer Nut 14 Screw the Retainer Nut over the Inlet Ball Retainer and into the threaded Inlet Check Valve Body Stem Hand tighten 15 Apply a light coat of Lubriplate to the 0 124 diameter anti rotation pin and insert it through the outlet port of the Check Valve Retainer and into the Check Valve Body Clamp the outside diameter of the Check Valve Body in the soft jaws of a vise and torque the Retainer Nut to 200 in lbs 22 6 Nm using a 5 8 crows foot Figure 7 30 0 124 diameter inserted into outlet port of check valve retainer Torque wrench 4 5 8 crows foot check valve inlet check body valve body Figure 7 30 Installing the Inlet Retainer Nut 16 Remove the anti rotation pin Note This may require clamping the pin in a vise and pulling on the check valve body 17 Repeat the above assembly procedures for the remaining two Check Valve Assemblies Replacing the High pressure Port Adapter Seals and Filter The port adapter high pressure seals should be replaced at each pump rebuild or at any time excessive leakage 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 7 18 400444B ro TMAX
201. t is also available for downloading at http www omax com tech support php password required To set up a user account contact OMAX Customer Service at 800 298 4036 PC Controller Maintenance Note 6 18 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 particles or stains from an LCD screen ensure that the monitor is first turne
202. t machining of small parts 1 k T P p Figure 2 2 The OMAX Model 2626 xp JetMachining Center Specifications Model 2626 xp JetMachining Center Position Table Size Weight X Y Cutting Travel Ceiling Height Accuracy empty tank Requirement 0 001 46 x 31 116 L x 72 W 3520 Ibs table only 29 x 25 8 ft 0 025 mm 1168 mm x 787 mm 2946 mm x 1829 mm 1600 kg 737 mm x 635 mm 2 44 m 400444B 2 1 F The OMAX JetMachining Center Service and Maintenance Guide Introduction to OMAX Tables Model 2652 JetMachining Center Provides the precise abrasivejet machining of small to medium sized parts B Figure 2 3 The OMAX Model 2652 JetMachining Center Specifications Model 2652 JetMachining Center Position Table Size Weight X Y Cutting Travel Ceiling Height Accuracy empty tank Requirement 0 08 mm 1753 mm x 762 mm 8531 mm x 1702 mm 1505 kg 1321 mm x 660 mm 2 44 m Model 5555 JetMachining Center Provides the precise abrasivejet machining of small to medium sized parts Figure 2 4 The OMAX Model 5555 JetMachining Center Specifications Model 5555 JetMachining Center Position Table Size Weight X Y Cutting Travel Ceiling Height Accuracy empty tank Requirement 0 003 80 x 65 131 L x 95 W 6291 Ibs table only 55 x 55 10 ft 0 08 mm 2032 mm x 1650 mm 3327 mm x 2413 mm 2854 kg 1397 mm x 1397 mm 3 05 m Model 551
203. t prevent an overpressure condition the safety valve will activate when a pressure of 63 KSI is reached An activated valve should reseal itself OK but could begin to leak after resetting itself a number of times When leaking occurs resealing the safety valve 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 The high pressure water seal occurs between the seat and the first ball Figure 5 2 The body contains a large spring that pushes on the ball and seat creating a water seal up to 63 000 PSI 4 or 2K When leaks occur in the safety valve they will be observed at the 4 holes in the large body which normally are dry with no water inside The pump is designed to shut off when pressure reaches 60 ksi or above If the pressure rises too rapidly it may exceed 60 ksi The safety valve is designed to activate at 63 ksi 2 ksi F _ TAAN The OMAX JetMachining Center Service and Maintenance Guide Servicing the OMAX Pump WARNING Never attempt to adjust the safety valve doing so creates a safety hazard ball 2 plunger se M seat gt ball 1 Figure 5 2 Safety Valve Internal Components To Reseal the S
204. ted from the typical wet abrasivejet environment Damp garnet will lump together and not flow properly Check the Tilt A Jet bellows daily If your JetMachining Center uses the Tilt A Jet option keep its bellows clean and check them daily for rips and tears If a hole develops in one of these bellows and allows garnet in the precision bearings will suffer A rip or tear in a Tilt A Jet bellows cannot be repaired Contact your distributor or OMAX Customer Service for replacement Removing Garnet Accumulation Since garnet abrasive and metal particles are constantly accumulating in the tank a regularly scheduled removal of accumulated deposits is necessary Usually when large quantities of abrasive particles quickly settle on the material being machined it s an excellent indicator that the tank is holding too much abrasive and removal is necessary 400444B F t Table Maintenance The OMAX JetMachining Center Service and Maintenance Guide Note When removing abrasive material from the bottom of the tank it s best to completely drain water from the tank before attempting to remove the abrasive waste The drier the abrasive the easier it shovels out Using a pointed shovel is probably the most effective way of emptying the tank by hand 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
205. th a dump valve installed in the OMAX high pressure pump When water to the cutting nozzle is shut off the software automatically opens the dump valve routing the high pressure water through it instead Water routed to the dump valve is automatically cut off whenever the nozzle again resumes cutting This allows a continual pump operation during times when the nozzle is not cutting By using this dump valve in 400444B 4 1 F B CHAAX The OMAX JetMachining Center Service and Maintenance Guide Servicing the OMAX Tables conjunction with the dual on off valve water cutting pressure always remains close to the same 8 9 ksi drop and the starting and stopping of the waterjet stream takes place without delay This technique also allows dual pressure operations such as needed for low pressure glass piercing Whenever dual pressure operation is required low pressure is automatically achieved by opening both the dual on off valve and the pump s dump valve simultaneously The orifice in the pump s dump valve plays a major role in maintaining the required cutting pressure A worn or damaged orifice results in a lower than expected pressure while a partially clogged orifice results in pressures greater than desired For efficient operation of both the dual on off valve and the dump valve their orifice sizes should be paired as follows Nozzle Cutting Orifice Dump Valve Orifice 0 010 P N 302028 09 0 014 P N 302028 13 0 015 P N 302028
206. the Backup support Ring Assembly and breaking the Short Seal Ring loose from the Displacer removal installation displacer Figure 7 12 Separating the Backup Support Ring Assembly from the Displacer 6 The Backup support Ring Assembly Figure 7 15 is machined together as one assembly The outer Support Ring is pressed onto the inner Backup Ring These parts should not be separated The Short Seal Ring Figure 7 10 should be easily removed by hand Remove the Short Seal Ring from all three Backup Ring Assemblies 7 Before removing the Dynamic Seal Assembly Figure 7 10 from the displacer inspect the Dynamic Seal for extrusion Figure 7 13 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 400444B p F The OMAX JetMachining Center Service and Maintenance Guide Pump Maintenance some extrusion is normal material missing excessive extrusion E ay 4e Normal wear about 200 hours Failed seal due to plunger rubbing backup ring or possibly lack of cooling water flow
207. the Filter Adapters from each Port Adapter Remove the Snap Ring Retainer from the end of the Port Adapter stem using the snap ring pliers Slide the High pressure Seal O ring and Backup Ring off the stem of the Port Adapter Body Discard the High pressure Seal and O ring Clean the Backup Ring and Port Adapter Examine the edges of the Backup Ring to determine if the edges are square and sharp Check the Backup Ring for cracks near the notch Replace the backup ring whenever problems are apparent Install the Backup Ring onto the stem of the Port Adapter with the chamfer on the inside of the backup ring facing toward the Port Adapter Body Place a small amount of Lubriplate on the new O ring and install it on a new High pressure Seal Slide the High pressure Seal onto the stem of the Port Adapter Body such that the large diameter portion of the High pressure Seal is next to the Backup Ring Install the Snap Ring Retainer Place a small amount of Lubriplate on the O ring and install it into the O ring groove on the Filter Adapter Thread the Filter Adapter into the stem of the Port Adapter body Tighten until just snug using the 5 8 open end wrench Repeat the above rebuild procedure for the remaining Port Adapter Assembly Install the Filter Assembly on one of the Port Adapters by sliding it over the end of the Filter Adapter until the Filter Adapter rests against Filter Adapter shoulder Apply a small amount of Lubriplate into th
208. the display indicates a fault Figure 5 7 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 OMAX keypad to clear the display and re enable the pump unit Figure 5 7 Example of Pump Fault Condition Appearing on Keypad Display 5 Check if the pump keypad display is lit If it is not go to No Keypad Display 400444B 367 F 9 OMAR The OMAX JetMachining Center Service and Maintenance Guide Servicing the OMAX Pump 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 OMAX keypad or from the OMAX controller Refer to Figure 5 8 REM indicates 210 1 remote mode operation press to switch LOC REM and REM LOC modes Figure 5 8 VFD Remote REM Mode No Keypad Display The display on the OMAX Keypad is blank and or no red LED s next to the buttons are lit 1 2 3 Check that no E stop switches are engaged Check that the On Off switch on
209. the support slats They are weakened by continued cutting and cannot be expected to support your weight Don t operate the OMAX with any of its protective guards or covers removed or rendered inoperative Don t operate the OMAX in an explosive atmosphere Machining titanium and certain other materials can produce sparks Never allow explosive or flammable vapors to accumulate in the area of the OMAX Don t allow unauthorized personnel access to the machining area without proper supervision Don t switch tank chemicals for bacterial control without first reading the manufacturing warnings on the labels Mixing different kinds of chemical pellets can create a hazardous situation Don t use silica sand as a cutting abrasive Fine silica dust produced by the cutting process can lead to silicosis a serious lung disease Don t operate the machine in close proximity to other machines as water can spray or splash out of the cutting table area Pump Safety Requirements Do Operate the OMAX pump only after reading this manual and receiving instruction from qualified personnel otay in a location within easy reach of the emergency stop switch otart the pump only when all side panels are securely in place Maintain all protective guards and shutdown devices around the OMAX pump Immediately notify responsible repair personnel whenever leaks are detected in pump fittings or connections Follow the manufacturer s recommendations for servicing the e
210. the terminals inside the pump electrical enclosure even when the pump On Off switch is Off Charge Pump On Off Switch The charge pump is responsible for the pre circulation of water through the pump reservoir tank and cooling lines This flow purges 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 on the pump s front panel 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 from the PC Controller without the charge pump running the high pressure pump will not start and an error message appears on the front panel display Emergency Stop Switch E stop Pushing E Stop in immediately shuts down both the pump and display The E Stop is disengaged reset by manually pulling it back to its original position The pump cannot be restarted until E Stop is reset 400444B Jw F F The OMAX JetMachining Center Service and Maintenance Guide Introduction to the OMAX Pump Note Note If the pump is connected to an OMAX JetMachining Center pushing E Stop in at any time either the E Stop on the pump itself or the E Stop on the JetMachining Center immediately shuts down both the pump and the JetMachining Center If the computer and controls are being powered from an alternative 115 VAC
211. 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 5 12 24 VDC Power Supply Fuse Location on page 5 12 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 Checkthat 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 5 11 Keypad Ribbon Cable and 34 Pin Connector Location on page 5 12 Caution Ifa pin is not locked into the housing gently pull it out of the connector being sure to note what 400444B 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 pro
212. to Tables The OMAX JetMachining 2x gag A Pm 2 1 Model 2626 JetMachining 2 1 Specifications Model 2626 JetMachining Center 2 1 Model 2626lxp JetMachining 2 1 Specifications Model 2626Ixp JetMachining Center 2 1 Model 2652 JetMachining 2 2 Specifications Model 2652 JetMachining 22 Model 5555 JetMachining 2 2 Specifications Model 5555 JetMachining 2 2 Model 55100 JetMachining 2 2 Specifications Model 55100 JetMachining 2 2 Model 60120 JetMachining 2 3 Specifications OMAX 60120 JetMachining Center 2 3 Model 80X JetMachining 2 3 Specifications OMAX 80X JetMachining Center 2 3 Specifications OMAX 80X 1 JetMachining Center 2 3 Model 80160 JetMachining 2 4 Specifications Model 80160 JetMachining Center 2 4 Description of JetMachining Center Components 2 4 LaCie ees ee eee ee eee eee eee ee ae 2 5 Contool Panel uas outer cn irr 10599 2225 Control Panel Operator Switches
213. tricts access to the open sides of the JetMachining Center table Typical devices could be a light curtain a fixed enclosure with switches attached or a safety mat using an external relay connection Electrically 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 figure that follows illustrate the required external circuit connections for the two switch inputs 400444B A 1 F OMAX JetMachining Center Access Control Circuit 2 24VDC output lt 11 t eee 4 S Q9 iL a 2 External Circuit 9 Powerand control reult trips s 1 ae eon rol Access control circuit trips ols S Igne CUTAN whenever either of the two m Switches break contact 5 COCE Figure 1 External Electrical Circuit Requirement for the ACC The Access Control Circuit is enclosed in an electrical enclosure with a hinged lid and attached to the left side of the OMAX controller See Figure A 2 Access Control Circuit enclosure 21 Reset button receiver connector Figure A 2 Access Control Enclosure Attached to Side of OMAX Controller A 2 400444B FIN Access Control Circuit OMAX JetMachining Center Access Control Circuit Enclosure Electrical box fastened to the OMAX controller
214. ufficiently tightened Do periodically inspect the UHP tubing and fittings for leaks A hole in the tubing sprays as a fine mist Do replace damaged or leaking components in the UHP fitting Always replace and never repair damaged or leaking components Damaged components generally fail once exposed to high pressure Don t over tighten the gland nut This could obstruct the end of the tube and restrict flow 400444B F Servicing the OMAX Tables The OMAX JetMachining Center Service and Maintenance Guide e Don t apply 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 e Don t try to adjust a fitting while still under high pressure An injury and or a damaged system component could result Troubleshooting the JetMachining Center 400444B This section presents possible problems that could appear during operation of your JetMachining Center and suggests ways to resolve them If after following the suggested corrective actions a problem persists please contact OMAX Customer Service as directed in the Customer Service chapter of this guide FF The OMAX JetMachining Center Service and Maintenance Guide Servicing the OMAX Tables Problems with Machine Motion Abrasivejet Nozzle Doesn t Move Condition and Possible Causes Corrective Action The Emergency Stop button was T
215. umbin gnp p g cutting table Figure 2 19 X Y Components of the JetMachining Center Models 60120 80160 and SOX SOX illustrated 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 and 80X utilize a high precision traction drive coupled with position feedback from magnetic encoding tape In addition their X axis rails do not require lubrication and are resistant to garnet contamination 2 10 400444B Introduction to OMAX Tables The OMAX JetMachining Center Service and Maintenance Guide 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 manually operated Z axis is standard using a hand crank for position control The optional motorized Z axis is more common using a stepper motor under software control to drive a lead screw to obtain height adjustments in 0 001 0 0254 mm increments Figure 2 20 Both the manual and motorized Z axis units are completely protected against water and grit contamination using urethane bellows high pressure water On Off Figure 2 20 Motorized Z axis Abrasivejet Delivery System The abrasivejet delivery system consists of high pressure plumbing a high pressure nozzle and an abrasive feed system hopper 4 high pressure plum
216. ure 2 T1 Details of the Pomp en aeos eon E bebe aE EEEE 3 0 Figure 2 12 Samphtied Pump Electrical Diagrami 3 10 Figure 4 1 The OMAX Bulkhead and High pressure Swivels sss 4 Figure 4 2 Components of the Ultra High pressure Fitting sss eene 4 3 Figure 4 3 Sources of Water Leaks in the Nozzle Assembly sss 4 12 Figure 4 4 Sources of Water Leaks in the On Off Valve sss eene nennen nennen 4 13 Figure 4 5 Servo Card Locations for Y and X axis for Bridge style 4 15 Figure 4 6 Servo Card Locations for Y and X axis 2626 2626 2652 5555 55100 Servo Motors 4 16 FL OMAK xi The OMAX JetMachining Center Service and Maintenance Guide xii Figure 5 1 OMAX Pump High pressure Safety 1 5 1 Fieure 5 2 Safety Valve Internal C OmpOnenmts vies ccceciasinssesssvesnnnsdensadbanetteaddnnentnaaednesadtavaivevsGuendemunbhiedcaterectawenes 5 2 Foue ee OCU VAI COV o N 5 2 Figure 5 4 Pressure Gauges for Water Piers ea ENEA 5 4 Figure 5 5 Sources of Water Leaks in the Wet end Assembly
217. urn the Emergency Stop Off and then On again and reset the pressed homes and soft limits Because your soft limits may be incorrect after using the emergency D button you can disable them by entering zero for the X and Y imits A soft limit has been reached Use the jog buttons to move up and down if you have hit a soft limit only one of those directions will 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 A babysit condition was triggered Refer to Babysit Triggered Message page 4 15 Wires or connections in the Turn off the power and open the back of the electrical cabinet Test computer may have become each connection and make sure the connectors are firmly seated loose Close the cabinet turn the power back on and try again oervo motors stalled This condition could be caused by Nozzle collision Mechanical issue sticky ball screw etc 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 Machine stops running with no oevere noise or noise spike on USB cable caused the device driver messages and unable to close to lock Rebooting the PC is necessary Parts are Too Short or Fla
218. verpressure condition If the pump exceeds the factory set maximum pressure limit the control shuts down the pump unit and displays the message Dead Head of Pump In addition to the software maximum pressure limit all OMAX pumps are equipped with a factory set Safety Valve to provide a hard plumbed over pressure limit 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 charging pump motor Circuit breakers protect the internal transformer and a 0 5 Amp fuse protects the pump keypad Access Control Circuit The OMAX Access Control Circuit ACC is designed to create a designated safety zone around an OMAX JetMachining Center that protects operators from injury when using the OMAX equipment 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 Refer to Appendix A Access Control Circuit for additional information Lock out Tag out Procedure When powering down your equipment to perform required maintenance and service activities OMAX recommends that standard lock out tag out practices and procedures be implemented that is
219. w bearing housing fitting 6 11 ball screw nut fitting 6 11 bellows adapter ring 6 4 bellows maintaining 6 4 bellows repair kit 6 4 bellows tear in 6 12 belt guard cover 7 36 belt motor 7 35 Bimba valve 2 13 BIOS 6 20 Blue Goop applying too much 4 4 blue screen errors 4 14 400444B The OMAX JetMachining Center Service and Maintenance Guide blunt tip grease needle 6 10 blunt tip needle 6 14 body cone UHP tubing 4 3 body thread UHP tubing 4 3 bulkhead swivel 2 13 button Reset 3 6 Run 3 6 Stop 3 6 up down arrow 3 7 C cables PC rear panel 2 9 catch tank 2 14 caution pipe wrench use 7 5 Charge Pressure Low 3 7 charge pump 3 2 switch 3 5 water circuit 3 8 charge pump switch 3 5 Charging Pump Contactor 3 7 check valve 7 13 check valve assembly inspection 7 12 check valve assembly tool 7 8 chemicals anti bacterial 6 3 clamp plate 7 30 cleaning tips tank tank cleaning tips 6 2 cleanout software 6 3 closed loop system 6 4 CMOS battery 6 20 collar UHP tubing 4 3 consumable parts 7 1 control panel 2 5 3 5 controller 2 5 control panel 2 5 operator switches 2 6 coolant housing 7 6 coupler blunt tip 6 10 Zerk 6 9 cover belt guard 7 36 crankcase oil 7 35 customer service ordering parts 8 1 D dead head 3 7 defragmenter 6 1 dipstick 7 35 displacer liquid 7 11 display screen 3 6 drive CD DVD 2 9 FA OMAK drive variable frequency VFD 3 1 dual on off valve 2 13 4 1 disass
220. 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 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 5 7 Fault Message Dead Head This message appears on the OMAX pump s display when pump output pressure equals or exceeds 60 000 psi After determining the cause of the overpressure also check the pressure safety valve on the pump to ensure it s not damaged 1 2 3 9 Verify that the high pressure orifice and nozzle are not plugged or partially plugged Verify that the orifice in use is not too small particularly if it has just been installed If equipped with dual On Off valves check that air is being supplied to the On Off valves 70 80 Ibs of air pressure required Verify that the orifice in the dumping On Off valve is not too small or is not plugged or partially plugged Check that none of the high pressure tubing is blocked or plugged Fault Message Variable Drive Fault This message appears on the OMAX pump s display when there is a fault with the variable frequency drive VFD If a VFD fault occurs e The problem that created the fault must be corrected e The RESET button on the OMA
221. xit end Measure the tube bore at the two ends using a drill or gage 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 Replace the jewel and the jewel holder F Servicing the OMAX Tables The OMAX JetMachining Center Service and Maintenance Guide 400444B Holes are Not Round Condition and Possible Causes Corrective Action The part was not securely fixtured The part moved during the cutting because of nozzle allowing movement drag or upwelling of the water beneath the part Make sure the part is securely fixtured The jet is elliptical rather than round due Change the sapphire If the jet still remains elliptical to wear in the mixing tube or a slightly change the mixing tube imperfect sapphire orifice Refer to the corrective actions provided for Wide Jet Stream in Poor Surface Finish page 4 7 Abrasivejet Not Piercing Material Condition and Possible Causes Corrective Action The setup values entered in Make are not Check that the following items are correct for the consistent with the actual physical material setup in Make values Machineability Thickness In setup for Make verify that Pump and Nozzle settings are correct for the following parameters Water pressure Orifice diameter Mixing tube diameter Abrasive flow rate An abrasive other than garnet is being Other abrasives do not typically cut as well as garnet used and
222. y seen 2 12 Figure 2 23 Internal Workings of the Abrasivejet Nozzle nn nennen 2 12 Figure 2 24 Abrasive Hopper 2 13 Figure 2 25 Jet Machining Center Catcher feasadtdenstianedsadaamnegecnncdex 2 14 Figure 2 26 OMAX s Rapid Water Level 2 14 Figure 2 27 Rapid Water Level Control Internal Pneumatic Connections 2 15 Figure 3 1 OMAX High Pressure Water Pump 3 Figure 3 2 OMAX Variable Speed High Pressure Pump Front 3 2 Figure 3 3 Pump with Top Lid Open and Front Panel Removed sse 3 3 Pisure 3 4 Pomp with Rear Panel ISCIHOWVOG e oett 3 3 Figure 3 5 Top View of Pump with Lid 3 4 Figure 3 6 Pump Internal Components on Right Side 3 4 Piu ppt Dal bass dct Date dit EE EDD Um RUE 3 5 Figure 3 6 Front Panel Keypad and Display Screen 3 6 Figure 3 9 The Charge Pump Low pressure Water Circuit esses enne 3 8 Figure 3 10 The High pressure Wet end of the OMAX Pump 3 8 Fig
223. y OMAX or iii in conjunction with items or modifications not supplied by OMAX and the Buyer shall similarly indemnify OMAX with respect to such claims THE FOREGOING STATES OMAX S SOLE RESPONSIBILITY AND BUYER S SOLE REMEDY FOR ANY INFRINGEMENTS OF PROPRIETARY RIGHTS OMAX MAKES NO OTHER WARRANTY EXPRESS OR IMPLIED OF ANY KIND INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR USE OR THOSE ARISING FROM COURSE OF PERFORMANCE COURSE OF DEALING OR USAGE OF TRADE IN NO EVENT SHALL OMAX BE LIABLE TO BUYER OR TO ANY THIRD PARTY FOR INDIRECT SPECIAL INCIDENTAL CONSEQUENTIAL OR PUNITIVE DAMAGES INCLUDING WITHOUT LIMITATION LOSS OF USE DELAYS OR LOST PROFITS OR SAVINGS RELATED TO THE PRODUCTS THE USE ORLOSS OF USE THEREOF THE PERFORMANCE OR BREACH OF THIS AGREEMENT BY OMAX OR OTHERWISE EVEN IF OMAX IS AWARE OF THE POSSIBILITY OF SUCH DAMAGES AND EVEN IF THE EXCLUSIVE REMEDIES STATED HEREIN FAIL OF THEIR ESSENTIAL PURPOSE BUYER S RIGHTS AS STATED HEREIN ARE ITS EXCLUSIVE REMEDIES Buyer agrees that regardless of the form or action whether in contract or tort including negligence OMAX s liability for damages hereunder or otherwise with respect to the Products or their use shall not exceed the total sum paid by Buyer to OMAX for the Products causing such damages R 02 21 06 8 4 400444B F t Appendix A Access Control Circuit 1203002 yeaL yeaig SIYM OM y JO Jaya ae 0113 3112210 04300
224. y are mounted on a welded steel tray connected to a steel pump frame with anti vibration mounts The water module is mounted on a steel tray and consists of the water tank and charge pump Removable covers are provided on the front back and left end of the pump unit The pump s laminated wood top can be raised allowing easy access to the water filters and pump high pressure wet end The charging pump brings water from the water tank to the filters Cooling water is recycled back to the water tank Pump Components Pump Viewed from Front and Right Side hinged cover lid bs panel removal screws electrical disconnect t pump contro pane Se M LL nn keypad and display 1 locking door latch alr intake filter power On Off switc charge pump On Off switch Figure 3 2 OMAX Variable Speed High Pressure Pump Front View 3 2 400444 Introduction to the OMAX Pump The OMAX JetMachining Center Service and Maintenance Guide Front Pump View with Front Panel Removed mp W cover lid gt L pump crankcase water filters high pressure safety valve front panel controls pump drive AC motor white water tank AC motor power cable Figure 3 3 Pump with Top Lid Open and Front Panel Removed Rear Pump View with Rear Panel Removed e n AE X zm wet
225. y requirements 1 5 tables servicing 4 1 tag power disconnect 7 5 tank white water 3 3 7 34 tank maintenance 6 1 tank odor controlling 6 3 tank catcher 2 14 tear bellows 6 12 three thread rule 4 4 timing belt 80160 6 7 6 8 adjusting 6 5 adjusting bridge style 6 8 locating 6 5 locating 80160 6 7 timing belts 6 5 tool check valve assembly 7 8 tools dual on off valve rebuild C 1 rebuilding high pressure swivel B 1 tools special OMAX 7 7 torch propane 7 14 torque values gland nuts 4 4 trademarks ii troubleshooting JetMachining Center 4 5 FA OMAK machine motion 4 6 machining quality 4 7 miscellaneous problems 4 14 nozzle and abrasive system 4 11 OMAX pump 5 3 software problems 4 14 tube cone UHP tubing 4 3 tube thread 4 3 U U S patent numbers ii UHP fitting 4 4 UHP system 4 2 ultra high pressure UHP 4 2 up down arrow button 3 7 USB controller 2 7 USB ports 2 8 V valve seat erosion 7 14 Variable Drive Fault 3 7 VFD variable frequency drive 3 1 W warning electrical wiring codes 5 7 qualified service personnel 5 3 safety valve adjustments 5 2 5 4 warranty 8 4 water circuit overview 3 7 water coolant housing 7 23 water filter cartridges 7 32 water filters wall mounted 7 31 water filtration system 7 31 water leaks nozzle assembly 4 12 water leaks On off valve 4 13 water leaks wet end 5 5 water level control 2 6 Water Press T 3 7 weep hole 4 3 wet end assembly disassem
226. your OMAX software becomes unregistered In addition some hardware built into the motherboard may become disabled due to the BIOS default settings 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 But why wait for a warning 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 400444B F t Table Maintenance The OMAX JetMachining Center Service and Maintenance Guide Maintenance Log Run Hours Maintenance Performed Done By Date 400444B 6 21 The OMAX JetMachining Center Service and Maintenance Guide F Table Maintenance 400444B Chapter 7 Pump Maintenance The following maintenance activities and schedules are provided to aid in the development of a successful pump maintenance program Refer to Chapter 4 Servicing the OMAX Tables for detailed maintenance procedures Note The hours listed in this chapter for recommended pump maintenance scheduling are NOT warranty hours Please refer to the OMAX Two Year Limited Warranty on page
227. ze to face of between Cylinder Body and Insufficient anti seize on Clamp Plate Nuts and threads and Check Valve Body immediately Clamp Plate Nuts tighten to 175 ft Ibs after rebuild Leak between the Cylinder and Cracked Support Ring e Rebuild Wet end Assembly Coolant Housing Damage to the Support Inspect Support Rings for damage Ring that supports the Ring Seal Cracked Cylinder 400444B 5 5 F The OMAX JetMachining Center Service and Maintenance Guide Servicing the OMAX Pump Leak Other Point reor ert Suspected Cause Recommended Action Point Leak between Check Valve dM Liquid Displacer installed Rebuild Wet end Assembly and Cylinder Body immediately upside down Inspect Liquid Displacer for damage after rebuild and to ensure it is within tolerance before re installing in the Cylinder If damaged replace Leak between the Check Valve Cracked Check Valve Rebuild Wet end Assembly Body and Cylinder Body e Inspect Support Rings for damage Cracked Support Ring Inspect Check Valve Body for e Damage to Support Ring cracks and replace if cracked es Prepon the Ring damaged ea Cracked Cylinder Mania een Adapter and Leak between the Check Valve Cracked Check Valve Rebuild Wet end Assembly Body and the Manifold Body Inspect Manifold and Check Valve Cracked Manifold Body for damage cracks e Seal is loose fit to stem Inspect O rings and Seals for of the Check Valve exces

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