ProtoMAX® Operation Guide OMAX Corporation 21409 72nd Avenue South Kent, WA USA 98032 Information: Technical Support: E-Mail: Web: info@protomax.com 1-818-647-1994 support@protomax.com www.protomax.com This document contains subject matter to which OMAX® Corporation has proprietary rights. Recipients of this document shall not duplicate, use, or disclose information contained herein, in whole or in part, for any use other than the purpose for which this manual was provided. OMAX Corporation believes the information described in this manual is accurate and reliable. From time to time, design improvements will be made to the OMAX equipment. Photographs, text, and sketches within the body of this manual may not exactly represent your equipment. In general, this manual contains the most up-to-date information available.

• Garnet Organ User Guide

However, OMAX Corporation cannot accept any responsibility, financial or otherwise, for any consequences arising out of the use of this material. The information contained herein is subject to change, and revisions may be issued to advise of such changes or additions. OMAX strives to continually improve user documentation. If you have any questions or concerns about the content of this user’s guide, please e-mail us at techwriting@omax.com, or contact us by mail at: OMAX Corporation Technical Publications 21409 72nd Avenue South Kent, WA, USA 98032 OMAX Corporation is continually improving their equipment to bring you the best in abrasive waterjet machining technology. For that reason, your abrasive waterjet may differ slightly from what is described in this document. If you have any questions, please feel free to contact us at 1-818-647-1994 or e-mail us at info@protomax.com.

You can also receive technical support on-line at: Web: Original Instructions in English October 2018 © 2018 OMAX Corporation Important Safety Information SAFETY IS YOUR RESPONSIBILITY. For your own safety, read this guide thoroughly and carefully before installing, operating, maintaining, or troubleshooting the equipment. Save these instructions. This guide contains important safety information for the equipment. Careful observance of the safety information will help prevent physical injury, damage to the equipment, and extend the equipment life.

Equipment safety features, safety glasses, hearing protection, and more can reduce potential injury. Exercise caution when installing, operating, and maintaining the equipment.

Safety guards and features will not guarantee your safety if you are careless, inattentive, or use poor judgment. If it feels dangerous, do not try it. YOU ARE RESPONSIBLE FOR YOUR SAFETY IN YOUR SHOP.

Machine Safety Labels The following safety labels may appear on the equipment. If ignored, physical injury, death, or equipment damage may occur. Read the complete safety information provided in the operation, installation or maintenance guide before installing, operating, or maintaining the equipment. Read Manual First!/Do Not Adjust Never make adjustments to equipment prior to reading the manual. Special instructions may be required. Safety Precautions Safety instructions must be followed when installing, operating, or maintaining the equipment. If ignored, death or physical injury may result, or damage may occur to the equipment.

Always observe applicable safety precautions when working with this equipment. Use the equipment ONLY for its intended purpose. Read the installation manual before setting up the equipment to learn about important installation and safety information. Read the documentation for recommended accessories. The use of improper accessories may cause risk of injury to persons or damage to equipment. Wear eye and ear protection.

Always wear ISO-approved impact safety glasses. Ensure the equipment is installed properly before startup. Never stand on the equipment. Serious injury could occur if the machine tips or if you come in contact with the cutting tool.

Do not make modifications. Never make unauthorized modifications or alterations to the equipment or components. Modification to the equipment may pose risk of physical injury to the operator and/or others and may cause damage to the equipment or other property.

Modifications to the equipment will invalidate the warranty. Do not modify, defeat, or bypass any equipment safety features. Do not remove panels.

Do not remove panels under normal conditions. Only remove them when required by maintenance or troubleshooting procedures. Check for damaged parts.

Before further use of the equipment, a guard or other part that is damaged should be carefully checked to determine that it will operate properly and perform its intended function–check for alignment of moving parts, binding of moving parts, breakage of parts, mounting, and any other conditions that may affect its operation. A guard or other part that is damaged should be properly replaced. Exercise caution, stay alert and attentive.

Do not install, operate, or service the equipment while under the influence of alcohol or drugs. Read the warning labels on prescription and over the counter drugs. If in doubt, do not install or operate the machine. Do not install, operate, or service the equipment when you are tired. Always observe the safety precautions while installing, operating, or servicing the equipment. Carefully operated, the abrasive waterjet is a safe tool.

When operated carelessly, serious injury can result. Wear a face or dust mask. Do not overreach to operate the machine.

Maintain proper footing and balance at all times. Keep a minimum of 16 in. (40 cm) away from pressurized equipment during operation. Do not try to tighten ultra-high pressure (UHP) fittings while the system is under pressure. Maintain tools and equipment with care.

Keep machine and accessories clean for best and safest performance. Always maintain the equipment in top condition. Follow the maintenance instructions for equipment and accessories. Maintain all protective guards and shutdown devices. Keep the equipment and surrounding area clean and free from clutter. Remove any installation, operation, or maintenance tools from the equipment before operating.

Keep the work area clean and clutter free to avoid accidents. Keep the equipment clean for optimal performance.

Do not operate equipment in a dangerous environment. Do not use equipment in or around flammable gases or liquids.

Do not expose equipment to rain, or use outdoors. Keep the equipment in a well-lit work area. Never leave equipment unattended while operating.

Always stop and turn off the equipment before leaving. Keep visitors at a safe distance from the work area. Keep children away from the equipment work area. Do not allow children to play around or operate the equipment or any of its components. Never operate equipment without safety guards or covers. Do not modify, bypass, defeat, or render safety guards, covers, or switches inoperable. Keep guards in place and in working order.

Never remove any safety cover or guard while the equipment is running. Know the location of the ON/OFF switch. Know how to disconnect the main power supply to the equipment. Start and operate the machine only when all side panels are securely in place.

Never place your hands in the vicinity of the nozzle while cutting. Seek immediate medical attention in the event of a waterjet injury. Injuries caused by high-pressure abrasive waterjets are serious. Do not delay!. See your WaterJet Technology Association (WJTA) warning card for important medical alert information. Figure 254 Figure 255 Use care when handling material in the tank. Never operate the equipment while handling material in the tank.

Always stop the abrasive waterjet before making any adjustments to the material or the abrasive jet. Always be careful when handling material in the tank. Fingers can be caught between a heavy part and the support slats.

Use caution around the support slats. Support slats are also cut by the abrasive waterjet; the edges can become very sharp and cause cuts, or collapse. Do not touch live electrical components or parts. Always use a licensed electrician or qualified individual for installing the main power source for use of the machine.

Inspect the equipment power and control cables regularly for proper connection and installation. Damaged, exposed, and bare wires can cause electrocution or death!. Ensure the equipment is properly connected and grounded in accordance with national, state, and local codes.

Never remove any prong from the plug. Always plug into a proper electrical outlet.

Never use any electrical plug adapter. Reduce the risk of unintentional starting by ensuring the power switch is in OFF position before plugging in the equipment. Always disconnect the equipment from the main power before performing service or maintenance. Noise Emission Precautions Environmental factors, such as room or building construction, machines or power tools, and other noise sources affect the environment's true noise level.

When installed and operated properly, the equipment A-weighted emission sound pressure level, LpA, is less than 75 dBA (LpA. NOTE Used to provide supplementary information, emphasize a point or give a tip for easier operation. Required Tools The following table contains a list of tools with the appropriate sizes needed when operating the ProtoMAX.

Customer Provided Tools These tools are not provided by OMAX or included with the ProtoMAX. Icon Tool Size(s) Torque wrench 15–102 in-lb (2–12 Nm) Hex socket 4 mm Shop towels Allen wrench 4 mm Open-end wrench 19 mm Crowfoot wrench 19 mm OMAX Provided Tools The following table contains a list of tools provided by OMAX that are needed to operate the ProtoMAX. Tools listed with part numbers are included with the ProtoMAX or are available for purchase. Contact for more information. Icon Tool Size(s) Stand-off tool ( P/N 317876) Technical Specifications See for the technical specifications. Introduction This guide provides information and instructions to operate the abrasive waterjet cutting system. 2012 toyota tacoma warranty.

It explains how the pump and abrasive waterjet system work. It also provides instructions on how to machine a part, how to start and stop the system, and how the software ( Intelli-MAX® Proto) is used to machine a part. Abrasive Waterjet Overview The ProtoMAX abrasive waterjet is a precision machining tool that operates under software control using high-pressure water and garnet abrasive to cut complex parts out of most materials including metal, plastic, glass, ceramics, stone and composites using standard CAD drawing files. Components The ProtoMAX takes up little shop floor space.

The cutting stage has a 12 in. (30 cm) (X-axis) by 12 in. (30 cm) (Y-axis) cutting area with an easy material alignment system for cutting parts. The precision drive components are protected inside sealed bellows from water and garnet abrasive.

The manual Z-axis allows cutting of materials up to 1 in. (3 cm) thick. The cutting area is fully enclosed by a see-through enclosure supporting a safety interlock system to halt abrasive waterjet cutting when opened. The ProtoMAX consist of the following major components: Figure 260 1 Table assembly 2 High-pressure pump Table Assembly The ProtoMAX table assembly is comprised of the cutting stage, garnet abrasive delivery system, catcher tank, electrical control enclosure, water filter, and operator controls. Figure 261 1 Garnet abrasive delivery system 4 Electrical control enclosure 7 Side panels 2 Cutting stage and X, Y, and Z stage 5 High-pressure plumbing 8 Cutting stage lid 3 Catcher Tank 6 Power and water controls Cutting Stage Lid and Side Panels.

Notice Do not remove the side panels under normal conditions. Damage may occur when operating the ProtoMAX with the side panels removed. Only remove them when required by maintenance or troubleshooting procedures. The cutting stage lid provides safe access to view the cutting process. The lid has a built in safety interlock switch that halts all cutting operations (pauses MAKE, stops stage motion, and turns off the pump) when the lid is opened. Always use the Pause button in the software to pause the system before opening the lid. This allows the operator to safely inspect the work and adjust materials as needed.

Once the lid is closed, the cutting operation may be continued. Side panels provide protection to the catcher tank and pump. Incoming water pressure may be monitored through the viewing portal located on the right side panel.

Panels should remain on the table assembly during operation. Panels can be easily removed for access to the interior components.

Figure 262 1 Cutting stage lid 2 Side panel (x 3) X, Y, and Z-axis Cutting Stage The cutting stage provides a 12 in. (30 cm) (X-axis) by 12 in. (30 cm) (Y-axis) cutting envelope.

The Z-axis allows manual up and down movements for cutting materials up to 1 in. (3 cm) thick. The cutting stage uses the same grid and coordinate system as in the Intelli-MAX software. When looking down on the table, the X-axis runs left to right and the Y-axis runs front to back. The Z-axis allows vertical movement of the cutting head. When the ProtoMAX is homed, the nozzle is moved to the position X=0 and Y=0 coordinate at the lower left corner of the cutting envelope. Figure 263 1 X-axis 2 Y-axis 3 Z-axis Slat Bed The cutting stage has a removable slat bed assembly to support cutting materials.

The slat bed assembly is removed to access the cutting tank for cleaning and maintenance. The slat bed assembly is secured to the cutting stage frame and provides support for the part being machined. Figure 264 1 Mounting plate, rear 3 Mounting plate, front 5 Square fixture plate 2 Slats 4 Slat comb bracket (x 2) 6 Slat comb (x 2) Catcher Tank The catcher tank stores the water from the cutting nozzle and provides a settling tank for the spent garnet abrasive and cut away material. The catcher tank bottom is shielded to prevent cutting through when operating the machine. Notice Do not add chemicals to the catcher tank water. Damage to the catcher tank and other components may occur. Figure 265 1 Catcher tank Tank Drain The adjustable tank drain helps maintain optimal water level by allowing excess water to drain from the catcher tank during cutting operations.

The drain has a flexible tube to adjust the water level as needed and allows cutting underwater. The tank overflow allows excess water to exit through the drain port and drain hose to prevent overfilling. Figure 266 1 Adjustable tank drain 2 Tank overflow drain 3 Tank drain hose 4 Tank drain port Material Holding System The material holding system fixtures (secures) materials while machining a part. Fixturing prevents the material from moving, vibrating, floating, tipping, or falling into the tank.

The abrasive jet stream is very powerful. The force exerted from the abrasive waterjet stream into the tank can move or float the material during the cutting process. If the material moves during machining, the part will not be precise and may be ruined. Note See the help files for best practices tips on fixturing materials. Figure 267 1 Holding arm, short 3 Holding post 3 Holding arm, long 4 T-nut Power Switch AC power is controlled by a power switch located on the electrical control enclosure.

All ProtoMAX system power is removed when OFF. Figure 268 1 Power ON position 2 Power selector 3 Power OFF position Garnet Abrasive Delivery System The garnet abrasive delivery system consists of the high-pressure nozzle, garnet abrasive feed system (hopper and feed tube), and high-pressure plumbing. The garnet abrasive hopper lid keeps the garnet abrasive from being contaminated with debris or getting wet. The garnet abrasive screen helps to filter small pieces of debris when filling the hopper that may clog the feed tube or nozzle.

When machining a part, the garnet abrasive flows from the hopper to the abrasive waterjet nozzle through the garnet abrasive feed tube. Notice The garnet abrasive material in the hopper must be kept clean and dry. If moisture enters the hopper, the garnet abrasive material will clump and clog the feed tube, which will require cleaning. Even very small particles of dirt will clog the mixing tube. Always store the garnet abrasive material in a covered, dry location protected from metal chips and other debris. Figure 269 1 Hopper lid 3 Abrasive feed tube. 5 Hopper splash guard 7 Garnet abrasive hopper assembly 2 Garnet abrasive screen 4 Abrasive feed block 6 Hopper support plate 8 Bulk abrasive port.

tube routing is for illustration purposes only. Note Always use garnet abrasive purchased from OMAX.

This high-quality abrasive is more consistent in particle size and contain less dust. Inconsistency in particle size makes it difficult to maintain quality when cutting and increases the likelihood of the mixing tube becoming clogged. When dust is present, static electrical charges can build up, causing the garnet abrasive particles to clump together, hindering the garnet abrasive flow. Abrasive Waterjet Nozzle The abrasive waterjet nozzle contains a 0.030 in.

(0.762 mm) replaceable mixing tube, 0.008 in. (0.2032 mm) replaceable (drop-in) orifice assembly, and nozzle body. High-pressure water is forced through the orifice and enters into a larger mixing chamber, drawing the garnet abrasive from the abrasive feed tube. The water and garnet abrasive is mixed into a high-speed slurry, and then moves into the mixing tube to form the abrasive waterjet stream. The abrasive waterjet stream exits the mixing tube through the bottom of the nozzle to strike and remove the material being machined.

Figure 270 1 Nozzle inlet body assembly 4 Garnet abrasive inlet 7 Mixing tube retainer 10 Nozzle body weep hole 2 Inlet body weep hole 5 Nozzle body assembly 8 Mixing chamber 11 Inlet body O-ring 3 Nozzle filter 6 Mixing tube 9 Orifice assembly High-pressure Pump The high-pressure pump provides approximately 30,000 pounds per square inch (psi) of cutting pressure for the ProtoMAX. Output high-pressure from the pump is automatically controlled by a variable frequency drive (VFD).

The software helps prevent damage to the pump by halting operation when there is inadequate incoming water pressure, excess water temperature, or overpressure events. Figure 271 1 Crankcase 6 High-pressure water transducer 11 Electrical motor 2 High pressure wet-end 7 High-pressure water OUT connection 12 Pump frame 3 Safety valve 8 Cooling line OUT connection 13 Crankcase cover 4 Cooling line IN connection 9 High-pressure nipple support bracket 5 Water IN connection 10 Electrical connection Water Filter The water filter removes debris from incoming water that can clog and damage the high-pressure components. The water filter is mounted on the side of the table assembly. The outlet water pressure is monitored by the pressure gauge mounted on the water filter. Notice Do not operate the ProtoMAX without the incoming water supply filter.

Operating the ProtoMAX without the water supply filter will introduce debris into the system and may damage the pump and high-pressure system. Figure 272 1 Water manifold 4 Water control solenoid 7 Water temperature transducer 2 Air release button 5 Water pressure switch 8 Water connection (incoming) 3 Water pressure gauge 6 Water filter assembly Laptop The ProtoMAX laptop is pre-installed with Intelli-MAX software and is connected to the ProtoMAX by a USB cable. Figure 273 Intelli-MAX® Proto Software Intelli-MAX software by OMAX is easy-to-use and maximizes the functionality of the ProtoMAX Abrasive Waterjet. LAYOUT is computer aided design (CAD) software that creates tool paths for the ProtoMAX abrasive waterjet system.

LAYOUT includes all the basic commands expected in a CAD package, as well as tools specific to abrasive waterjet machining. The LAYOUT help system provides information needed to operate LAYOUT's functions. MAKE software controls the ProtoMAX abrasive waterjet system by sending precise motor control commands to move the nozzle along a part's cutting path, while controlling the high-pressure water. The MAKE help system provides information needed to operate the software's cutting functions. See the system for more information on LAYOUT and MAKE. Accessories Optional accessories for the ProtoMAX can be found at www.protomax.com. Make a Part Overview Intelli-MAX LAYOUT and MAKE are the software tools used in making a part.

Following the below listed steps provides the process for successfully making a part. See for detailed information on making a part. Import or create a drawing file (DXF file). The first step in making a part is to obtain or create a drawing file.

LAYOUT software provides tools to create and edit new and existing drawing files (.dxf) for machining. Drawing files may also be imported from other CAD programs. Assign machining qualities (edge finish). The next step is to assign machining qualities (edge finish) to the drawing entities (lines, arcs, etc.) that tell the nozzle how fast or slow to move to obtain the desired edge finish. Clean the drawing. Next, the drawing should be cleaned to remove duplicate entities, extra dots, gaps, and other garbage entities that are hard to find in the drawing.

A clean drawing eliminates machining confusion by defining only one continuous path for the machine to follow. Add path elements to the drawing. After cleaning, path elements need to be drawn.

Path elements tell the machine where to cut, where to travel without cutting (traverse), when to pierce the material (lead in) and the exit points (lead out). Create the machine tool path file (ORD/OMX). The last step in LAYOUT is to convert the drawing file to a machine tool path file (ORD/OMX) that tells the machine how to cut the part.

Start up the machine. After the drawing file is prepared and converted to a machine tool path file, the next step is to start the machine per the. Open and configure the ORD/OMX file. The tool path file is opened and the material setup data is entered so the machine knows the path to cut and the material type and thickness.

Load and secure the material. The material is then placed and secured to the cutting stage. Fixturing the material to prevent any movement in the X, Y, or Z directions is critical in making good parts. Position the nozzle Attach the splash guard to the nozzle assembly with the cup up. Set the nozzle stand-off at the highest point of the material surface, then move the nozzle to the start of the machine tool path. Prepare for machining. Conduct a dry run to ensure the part fits on the material and the nozzle clears any obstacle.

Any problems found during the dry run can be corrected before machining the part. Machine the part. Flip the splash guard cup down. Adjust the drain, then add water to raise it above the material surface (if applicable), then begin machining. When finished remove and inspect the part. Operate the ProtoMAX See the system for additional information on using LAYOUT and MAKE software. Startup Checklist The following checklist is a quick reference to ensure equipment startup tasks are completed in the required sequence.

Detailed instructions are located in. Caution Use care when opening or closing the lid to avoid injury. Keep hand, fingers, or body part away from the side of the table when closing the lid. Never let the lid free-fall. Figure 278 b.

Remove the abrasive feed tube from the nozzle and place it over the top of the Y-axis 1. Figure 279 c.

Verify the mixing tube is properly seated and secured in the nozzle body. Figure 280 d. Place the nozzle splash guard 1 on the mixing tube 2 with the cup folded up. Figure 281 e. Position the nozzle in the center of the tank, between two slats using the X, Y Jog buttons or keyboard arrow keys. Figure 282 f.

Garnet Organ User Guide

Lower the nozzle to within 1 in. Of the surface of the water.

Notice Always hold the nozzle when loosening the hand knob. Do not let the nozzle fall and strike the cutting deck slats or material to avoid damage to the nozzle and/or nozzle components. Close the lid. Click Test 1.

Figure 283 i. In Test Operations, select Test Cutting Head (Pump, Jet, and Abrasive), and click Next. Figure 284 j. Click Start Test.

Figure 285 k. Click Close when the test is complete. Fill the hopper with garnet abrasive. Remove the hopper lid. Figure 286 b. Pour the garnet abrasive through the garnet abrasive screen into the hopper.

Caution Bacteria in the tank water can build up. A minor break in the skin can introduce harmful bacteria into a wound. Always wear protective gloves if you have cuts or open wounds on your hands. When setting up material for cutting, wear gloves that provide protection against sharp metal edges. Figure 289 d. Open MAKE and use the X, Y Jog buttons 1 or keyboard arrow keys to position the nozzle between two slats.

Figure 290 e. Lower the nozzle to within 1 in. (3 cm) of the surface of the water, if needed. Caution Use care when opening or closing the lid to avoid injury. Keep hand, fingers, or body part away from the side of the table when closing the lid. Never let the lid free-fall.

Lift the lid and push the support arm towards the back. Figure 300 b. Lower the lid to the catcher tank. Perform a dry run. A) Open and configure (set the material type and thickness) for the machine tool path for the part.

Figure 301 b) Click Go home 1 to move the nozzle to the Path Start Home position, if needed. Figure 302 c) Click Begin Machining to display the Path Control dialog box. Figure 303 d) Right-click the Start button to display a list of dry run options.

Figure 304 e) Click Dry Run at 1/4 rapid traverse speed. Figure 305 f) At any time, click Pause if potential problems are seen during the dry run process to stop nozzle movement. Figure 306 g) When the dry run is finished, click the Close button to close the Path Control dialog. Figure 307 19. Click Go Home in the Path Start dialog box to move the nozzle to the path start point.

Fold down splash guard cup. Adjust the tank drain 1 and fill the tank with water above the material (if possible).

Note Cut parts under water when possible. Cutting under water lowers the noise level and reduces the mist and splash created by the water and abrasive. Cutting under water also helps the garnet bins collect cutting debris instead allowing the debris to settle in the tank, which makes tank cleaning easier.

Close the lid. Cut the part. Click Begin Machining 1. Figure 309 b. Figure 310 24. Check the cutting water pressure and compare to the recorded incoming water pressure. If the cutting water pressure is 25 psi or lower, the water filter should be changed (see 401440-EN Maintenance, ProtoMAX).

Adjust the tool offset 1 if needed, see Figure 311 Shutdown Checklist The following checklist is a quick reference to ensure equipment shutdown tasks are completed in the required sequence. Detailed instructions are located in. Position the nozzle for shutdown Remove the abrasive feed tube from the nozzle Run test nozzle to clear the nozzle Close MAKE Turn OFF the laptop Turn OFF the ProtoMAX Clean the machine Turn OFF the water supply Turn OFF the breaker power switch, if needed Shutdown the ProtoMAX 1.

Conduct a nozzle flush. Open the lid. Caution Use care when opening or closing the lid to avoid injury. Keep hand, fingers, or body part away from the side of the table when closing the lid. Never let the lid free-fall.

Open MAKE and use the X, Y jog buttons 1 or keyboard arrow keys to position the nozzle in the center of the tank between two slats. Figure 314 e. Click Test 1. Figure 315 f. In Test Operations, select Test Cutting Head (Pump, Jet, and Abrasive), and click Next.

Figure 316 g. Click Start Test. Figure 317 h. Figure 318 i.

Verify there is no moisture or debris in the abrasive feed tube. Insert the garnet abrasive tube into the nozzle. Figure 319 k. Close the MAKE software.

Turn OFF the laptop. Clean the machine with a clean, damp cloth. Note See the and for additional information on cutting the fixturing square. A fixturing square 1 establishes an X and Y reference to a known point in the cutting deck. The square provides a stable base for securing parts for cutting, and assists in maximizing material use when cutting. It can be used to precisely locate features on existing parts, or as a convenient surface to secure material against when cutting. Figure 321 A square fixture is made by clamping material along the X-front frame in the machine cutting deck, and then using the machine to cut an 'L' shape into it.

Since the machine cuts the 'L,' we know it to be true and square to the machine's X- and Y-axes. Recover from a Nozzle Clog There are multiple scenarios resulting from a clog in the nozzle. The fix depends on how far water has traveled back up the abrasive feed tube and whether the water entered the abrasive hopper or not. In all scenarios, correct the condition that caused the nozzle to clog, such as wet garnet, a blocked orifice, a blocked mixing tube, or other before continuing operation. Remove the garnet abrasive feed tube from the nozzle assembly 2 and the garnet abrasive feed block 1. Figure 322 2. Use clean, dry air to completely clear the clog from the abrasive feed tube.

If the water entered the abrasive feed block: 3. Remove the hopper splash guard. Figure 323 4. Remove the hopper ground strap 1. Figure 324 5. Remove the abrasive feed block 2 and insert the red plug 1 to prevent garnet from pouring out from the bottom of the hopper assembly. Figure 325 6.

Use clean, dry air to completely blow out all debris, clumps, or clogs from the abrasive feed block. If the water entered the hopper assembly: 7. Loosen the knob 1 and remove the hopper assembly from the hopper support plate.

Figure 326 8. Completely empty and wipe out the hopper. Note Make sure the hopper container is completely dry prior to filling with dry garnet abrasive. Do not reuse garnet abrasive. The hopper screen may not sufficiently remove moist clumps from the wet abrasive.

Garnet that has been exposed to moisture will clump and cannot be reused. Garnet that has been exposed to moisture will result in additional clogging.

Raise the Z-axis. Remove the nozzle splash guard and mixing tube 1 from the nozzle body. Figure 327 11. Inspect the mixing tube to see if light is visible through the bore.

If light is visible: 12. Re-install the mixing tube 1 into the nozzle body. Figure 328 If light is not visible: 13.

Turn the mixing tube 1 upside down and insert it back into the nozzle body and tighten it. Figure 329 14. Position the nozzle towards the center of the tank (off the material) between two slats. Lower the Z-axis to approximately 1 in. (3 cm) above the water surface.

Close the lid. Caution Use care when opening or closing the lid to avoid injury. Keep hand, fingers, or body part away from the side of the table when closing the lid.

Never let the lid free-fall. Open the Test dialog box and run a nozzle test to clear the mixing tube. Remove the mixing tube 1. Figure 330 19.

Remove the nozzle body assembly from the nozzle inlet body. Figure 331 20. Remove the orifice assembly 1 and inspect the chamber bore 2. Figure 332 21.

Clean the orifice assembly and the nozzle body (including the air vent hole) thoroughly prior to reassembly. Note Use care when applying lubricants around high-pressure water routes. Lubricants can enter the high-pressure water system and clog the orifice and/or mixing tube. Figure 333 3.

Wipe the excess Blue Goop from the end of the inlet body 1. Figure 334 4. Apply a light coat of Blue Goop to the first and second nozzle body threads 1, then spread the lubricant evenly around the nozzle body threads.

Figure 335 5. Wipe the excess Blue Goop from the end of the nozzle body 1. Figure 336 Once the nozzle is completely clean. Notice Always orient the orifice assembly so the brass 1 is visible from the top of the nozzle body. Inserting the orifice assembly in nozzle body in the incorrect orientation 2 may cause damage to the orifice assembly. Figure 337 6.

Insert the orifice assembly 1 into the nozzle body and adjust the orifice to ensure the it is seated correctly in the chamber bore 2. Figure 338 7. Re-install the nozzle assembly on the nozzle inlet body. Figure 339 8. Raise Z-axis and move the cutting head over the material. Insert and the mixing tube. Close the Path Control window.

Re-install the hopper and its components ( abrasive feed block, feed tube, ground strap, and hopper splash guard. Caution Use care when opening or closing the lid to avoid injury. Keep hand, fingers, or body part away from the side of the table when closing the lid.

Never let the lid free-fall. To continue cutting the part, using MAKE: 17. Click Go Home in the Path Start Home dialogue.

Figure 340 18. Right-click Begin Machining. Figure 341 19.

Click Go to Spot on Path. Figure 342 20. Move the cursor over the spot on the tool path slightly before the clog occurred and left click. Click OK on Machine will now traverse into position dialog box. Figure 343 22. Click Continue to start cutting. Figure 344 If nozzle clogging continues, it may be necessary to replace the abrasive feed tube, the mixing tube, nozzle orifice, and/or nozzle filter as one or more of these components may be causing the problem.

Reset the Pump The reset pump test runs a 30 second sequence to reset the pump. This test should be done before operating the ProtoMAX for the first time, after changing the nozzle orifice, repairing or replacing the pump, repairing any high pressure plumbing leaks, or when required by a fault or alert message. Move the nozzle between two slats.

In Test Operations, select Reset Pump, and click Next. Click Start Test and check the high-pressure plumbing for leaks (the dialog box closes when the test is complete). Technical Support Refer to the ProtoMAX website for technical support contact information.

Warranty Contact Customer Support or go to the ProtoMAX website.