Name: Omax JetMachining Center 80160
Brand: Omax
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The OMAX

JetMachining

Center

Operator’s Guide

OMAX Corporation Information: 253.872.2300

21409 72nd Avenue South Fax: 253.872.6190

Kent, WA USA 98032 Technical Support: 800.298.4036

Web: http: //www.omax.com

E-mail: omax@omax.com

About this Manual3
Purpose3
Supporting Documentation3
Organization3
Table of Contents5
Figures9
Safety First13
Safety Labels13
Placement of Safety Labels15
Figure 1-1: Safety Labels for the OMAX Models 2626, 2626|Xp, 2652, 5555, and 5510015
Figure 1-2: Safety Labels for the OMAX 8016015
Figure 1-3: Safety Labels for the OMAX 6012016
Figure 1-4: Safety Labels for the OMAX 80X16
Safety Precautions17
Figure 1-5: Safety Labels for the OMAX High-Pressure Pump17
Pump Safety Requirements18
Figure 1-6: Sound Level Map of OMAX Jetmachining Center19
Equipment Safety Features20
OMAX Jetmachining Center Safety Checklist21
Introduction23
OMAX High-Pressure Pump23
Figure 2-1: OMAX High-Pressure Water Pump23
Pump Components24
Front and Right Side Views24
Figure 2-2: OMAX Variable Speed High-Pressure Pump Front View24
Figure 2-3: Pump Control Panel Components24
Figure 2-4: Front Panel Keypad and Display Screen25
Control Panel Switches26
Figure 2-5: Pump Control Switches26
Front View with Front Panel Removed27
Figure 2-6: Pump with Top Lid Open and Front Panel Removed27
Top View28
Side View with End Panel Open28
Figure 2-7: Pump Top View with Lid Open28
Figure 2-8: Pump Internal Components on Right Side28
OMAX Jetmachining Center29
Major Components of the Jetmachining Centers29
Figure 2-9: OMAX 80160 Jetmachining Center29
PC Controller30
Figure 2-10: the Model 55100 OMAX Jetmachining® Center30
Figure 2-11: the Jetmachining Center PC Controller30
Control Panel Switches31
X-Y Table31
Figure 2-12: Control Panel Operator Switches31
Accessories for the OMAX Jetmachining Center32
Tilt-A-Jet32
Figure 2-13: the OMAX 80X Jetmachining Center32
Figure 2-14: OMAX Tilt-A-Jet32
Precision Optical Locator33
Waterjet Brick33
Figure 2-15: OMAX Precision Optical Locator33
Figure 2-16: Waterjet Brick33
Solids Removal System34
Chiller34
Figure 2-17: OMAX Solids Removal System34
Figure 2-18: OMAX Inlet Water Chiller34
Drill Head Attachment35
Closed Loop Water Recycling System35
Figure 2-19: OMAX Drill Head Attachment35
Figure 2-20: Closed Loop Water Recycling System35
Terrain Follower36
Figure 2-21: OMAX Terrain Follower Attached to a Tilt-A-Jet36
Operation37
Operating the High-Pressure Pump37
Starting the Pump37
Stopping the Pump38
Emergency Shutdown Procedures38
Setting the Pump RPM38
Pump Operating Characteristics39
OMAX Jetmachining Center Overview39
About Abrasivejet Machining39
Figure 3-1: the Abrasivejet Nozzle40
The OMAX Software41
OMAX Layout Program41
OMAX Make Program41
OMAX Interactive Reference41
Figure 3-2: the Abrasive Waterjet System41
Drawing the Part Using Layout42
Setting the Tool Path42
Making the Part42
Determining Quality42
Clamping and Positioning Materials for Cutting42
Figure 3-3: Quality Examples42
Using Tabs for Holding Small Parts43
Figure 3-4: Using Tabs Prevents Small Parts from Falling in the Tank43
Ensuring Clean and Quiet Machining44
Keep the Abrasivejet Nozzle under Water44
Place a Muff on the Abrasivejet Nozzle44
Keep Extra Sponges on Hand44
Washing Heavy Garnet Deposits from Parts44
Figure 3-5: Cutting Nozzle with a Muff Attached44
Tips for Effective Cutting45
Setting Soft Limits46
Auto Homing Your Machine46
Operating the Jetmachining Center47
Configuring Your Drawing47
Figure 3-6: Selecting Auto Home in OMAX Make47
Cutting Parts48
Setting up the Hardware48
Figure 3-7: White Water Tank Internal View48
Figure 3-8: White Water Tank Location in OMAX Pump49
Figure 3-9: Verify Correct Mixing Tube Placement50
Figure 3-10: Use the Homes Menu Option to Initiate an Auto Home50
Figure 3-11: Use Setup to Enable the Soft Limits51
Figure 3-12: Pump and Nozzle Test Options51
Figure 3-13: Example of both Good and Poor Quality Jet Streams51
Figure 3-14: Comparison of Jet Streams with Different Jewel and Mixing Tube Conditions52
Figure 3-15: Comparison Spread of Waterjets and Abrasive-Waterjets at Different Health States52
Figure 3-16: Nozzle Pressure Test Stop Button53
Figure 3-17: Bimba Valve Abrasive Feed Block54
Figure 3-18: Setup Menu for Pump and Nozzle Settings54
Figure 3-19: Settings for Pump and Nozzle54
Configuring the Make Software55
Figure 3-20: Event and Relay Timing Displayed Values55
Figure 3-21: Material Setup Example55
Cutting the Material56
Figure 3-22: Cut, Pierce, and Terrain Follower Setting Options56
Figure 3-23: Nozzle Position Functions56
Shutting down the Jetmachining Center57
Figure 3-24: Z-Axis Height57
Figure 3-25: Pump and Nozzle Test Options58
Startup Checkoff Sheet59
Shutdown Checkoff Sheet60
Maintenance61
Pump Maintenance61
General61
Main Electric Motor Lubrication61
Changing Crankcase Oil61
Routine Maintenance Schedule62
Figure 4-1: Changing the Pump's Crankcase Oil62
Less Frequent Maintenance Schedule63
Jetmachining Center Maintenance63
Rebuilding the Nozzle64
Nozzle Operation64
Identifying When to Repair and Rebuild the Nozzle64
Preparing for Nozzle Repair/Rebuild64
Removing the Nozzle Mixing Tube66
Removing the Nozzle Body from the Inlet Body66
Figure 4-2: Remove the Abrasive Hose from the Nozzle66
Figure 4-3: Removing the Nozzle Mixing Tube66
Removing the Filter Seal Assembly from the Inlet Body67
Removing the Orifice Assembly67
Figure 4-4: Removing the Nozzle Body from the Inlet Body67
Figure 4-5: Screwing the Removal Tool into the Filter Seal67
Figure 4-6: Removing the Orifice Assembly from the Nozzle Body67
Removing the Mixing Chamber Disc68
Removing the Mixing Chamber68
Figure 4-7: Removed Orifice Assembly and Mixing Chamber Disc68
Figure 4-8: Pressing the Mixing Chamber from the Nozzle Body68
Removing the Nozzle Body O-Ring69
Cleaning and Inspecting Nozzle Components69
Figure 4-9: Removing the O-Ring from the Nozzle Body69
Figure 4-10: Rinsing Parts with Clean Water69
Figure 4-11: Cleaning Parts in Ultrasonic Cleaner with White Vinegar70
Figure 4-12: the Four Primary Nozzle Assembly Components Requiring Inspection70
Figure 4-13: Good Jewel Orifice70
Figure 4-14: Chipped Orifice Assembly Jewel71
Figure 4-15: Plugged Jewel Orifice71
Figure 4-16: Worn Mixing Chamber Discs72
Figure 4-17: Worn Mixing Tubes72
Figure 4-18: Pump and Nozzle Test Options73
Figure 4-19: Installing the Mixing Tube Upside down to Dislodge a Clogged Opening73
Reassembling the Nozzle Assembly74
Nozzle Filter Seal Assembly74
Figure 4-20: Worn Mixing Chamber74
Figure 4-21: Purging the High-Pressure System of Contaminates with the Nozzle Removed74
Figure 4-22: Nozzle Filter Seal Assembly74
Mixing Chamber75
Figure 4-23: Filter Seal Assembly Inserted into Inlet Body75
Figure 4-24: Locating the Mixing Chamber Groove and Abrasive Inlet Hole for Alignment75
Figure 4-25: Using the Push Tool and Arbor Press to Insert the Mixing Chamber into the Nozzle Body75
Mixing Chamber Disc and Orifice Assembly76
Figure 4-26: Installing the O-Ring on the Nozzle Body76
Figure 4-27: Placing the Mixing Chamber Disc in the Center Bore of the Nozzle Body76
Figure 4-28: Inserting the Orifice Assembly in the Nozzle Body with the Jewel Side Facing up76
Nozzle Body77
Figure 4-29: Applying Blue Goop to the Nozzle Body Inlet Threads77
Figure 4-30: Installing the Nozzle Body Onto the Nozzle Inlet Body77
Figure 4-31: Aligning the Nozzle's Abrasive Inlet Hole77
Figure 4-32: Damage Caused by an Off-Center Orifice78
Figure 4-33: Tightening the Nozzle's Brass Retainer Nut78
Figure 4-34: Tightening the Nozzle Body to the Inlet Body78
Mixing Tube79
Figure 4-35: Inserting the Mixing Tube into the Nozzle Body79
Figure 4-36: Placing the Mixing Tube Collet and Nut Onto the Mixing Tube79
Figure 4-37: Tightening the Mixing Tube Onto the Nozzle Body79
Nozzle Tests80
Maximizing Nozzle Life80
Figure 4-38: Abrasive Damage from Not Using a Nozzle Muff81
Removing and Reinstalling the Inlet Body on a Tilt-A-Jet82
Figure 4-39: Removing the Air Hose from the Air Canister Fitting Ring82
Figure 4-40: Using a 1-1/8" Open-End Wrench to Remove the Air Canister82
Figure 4-41: Removing the Coil Nipple from the On/Off Valve Body Adapter Fitting82
Figure 4-42: Removing the 5Mm allen Screws that Secure the On/Off Valve Body83
Figure 4-43: Removing the On/Off Valve Body with Seat from the Tilting Plate83
Figure 4-44: Removing the Inlet Body from the Tilting Plate83
Removing a Stuck Inlet Body84
Figure 4-45: Installing the Body Removal Tool Post to Remove a Stuck Inlet Body84
Figure 4-46: Placing the Tube over the Tool Post and Tightening the Flange Nut84
Figure 4-47: Removing the Brass Inlet Body Retaining Nut with the Spanner Wrench84
Cleaning the Inlet Body85
Figure 4-48: Using White Vinegar to Loosen a Stuck Inlet Body85
Figure 4-49: Tightening Flange Nut to Detach the Inlet Body85
Figure 4-50: Cleaning the Inlet Body Hole with Brush and Soapy Water85
Reinstalling the Inlet Body86
Figure 4-51: Applying Blue Goop to the Inlet Body Male Threads and Bore Diameter86
Figure 4-52: Hand Tightening the Inlet Body and Aligning to Tilting Plate Hole86
Figure 4-53: Applying Blue Goop and Anti-Seize Compounds to Valve Body Components86
Figure 4-54: Correct Placement of the Valve Body Seat into the Valve Body87
Figure 4-55: Placing the On/Off Valve Body against the Cutting Head Inlet Body87
Figure 4-56: Tightening the Four Valve Body Screws and Applying Blue Goop to the Gland Nut Threads87
Removing and Reinstalling a Mini-Maxjet 5 Nozzle Assembly88
Disassembling a Minijet Nozzle88
Figure 4-57: Tightening the Coil Nipple to the On/Off Valve Body Adapter Fitting88
Figure 4-58: Installing the On/Off Valve Air Canister88
Step 2: Remove the Minijet Nozzle Body from the Inlet Body Extension89
Step 3: Remove the Inlet Body Extension from the Inlet Body89
Figure 4-59: Removing the Minijet Nozzle Body from the Inlet Body Extension89
Figure 4-60: Removing the Inlet Body Extension from the Inlet Body89
Step 4: Remove the Minijet Dummy Orifice from the Inlet Body90
Figure 4-61: Inspecting the Body Extension for Erosion Marks90
Figure 4-62: Inspecting the Dummy Orifice for Erosion Marks90
Step 9: Remove Ring Seals and O-Rings91
Reassembling the Minijet Nozzle Assembly91
Figure 4-63: Removing O-Ring and Ring Seals from the Inlet Body Extension91
Figure 4-64: Installing Ring Seals and O-Rings in the Inlet Body Extension91
Figure 4-65: Inserting the Dummy Orifice into Inlet Body Extension91
Figure 4-66: Tightening the Inlet Body Extension to the Inlet Body92
Figure 4-67: Inspecting for Properly Seated Orifice Assembly and Mixing Chamber Disc92
Figure 4-68: Hand Tightening Minijet Nozzle Body to the Inlet Body Extension92
Mini-Maxjet 5 Installation and Operation93
Installing the Mini-Maxjet 593
Operating the Mini-MAXJET 593
Figure 4-69: Tightening the Minijet Body to the Inlet Body Extension93
Figure 4-70: Setup Menu for Pump and Nozzle Settings93
Dump Orifice Maintenance94
Figure 4-71: Settings for Pump and Nozzle94
Setting the Adjustable Dump Orifice (ADO)95
Figure 4-73: Two Types of Dump Valves Used in OMAX Pumps95
Figure 4-74: Adjustable Dump Orifice Location in OMAX Pump95
Figure 4-75: the ADO Pressure Adjustment Knob96
Figure 4-76: Select the ORD File, Variable Dump Orifice Adjustment Routine96
Figure 4-77: Click the Nozzle Test Button to Set Pump Pressure97
Figure 4-78: the Test Pump and Nozzle Window97
Figure 4-79: Set the KSI for Waterpres on the Pump's LCD98
Figure 4-80: Click the Test STOP Button after Setting Your Desired Pump Pressure98
Figure 4-81: Click Start to Pressurize the Adjustable Dump Orifice98
Changing the Dump Valve Orifice Size99
Disassemble the Dump Valve and Removing the Orifice Assembly99
Figure 4-82: Dump Valve Location in Pump99
Figure 4-83: Dump Valve and Associated Components99
Figure 4-84: Loosening the Gland Nut on the Dual On/Off Valve100
Figure 4-85: Removing the Gland Nut from the Port Adapter100
Figure 4-86: Removing the Gland Nut and Tubing from the Port Adapter100
Figure 4-87: Removing the Valve Assembly from the Dump Valve Body101
Figure 4-88: Lifting the Valve Assembly from the Dump Valve Body101
Figure 4-89: Removing the Valve Seat from the Dump Valve Body101
Reassembling the Dump Valve with Replacement Orifice Assembly102
Figure 4-90: Removing the Orifice Assembly from the Dump Valve Body102
Figure 4-91: Apply Blue Goop and Place Orifice Assembly in Dump Valve Body102
Figure 4-92: Apply Blue Goop and Insert Valve Seat in Dump Valve Body102
Figure 4-93: Attaching the Dump Valve Assembly and Body102
Software Updates103
Figure 4-94: Aligning the Gland Nut Threads with the Water Inlet Hole103
Troubleshooting the OMAX Pump104
Display Screen Messages104
Normal Operation Messages104
Pump Fault Messages104
Possible Pump Faults104
Fault Message, "Charge Pressure Low104
Fault Message, "Charging Pump Contactor105
Fault Message, "Dead Head105
Fault Message "Variable Drive Fault105
Low Pump Output Pressure106
No Power at the Pump Unit106
Pump Does Not Start106
No Keypad Display107
Troubleshooting the OMAX Jetmachining Center108
Machine Motion108
Machining Quality108
Software Problems112
Nozzle and Abrasive System113
Miscellaneous114
Positioning Accuracy Overview115
Consumable Parts117
Maintenance Log119
Training Log120
Customer Support121
Contacting OMAX Customer Service121
Ordering Parts121
Returning Parts121
Returned Material Procedures121
Parts Ordered in Error122
Unused Parts122
Parts Shipped in Error123
Parts Returned for Repair123
Parts Returned for Warranty Repair or Replacement123
Two-Year Limited Warranty124
OMAX Glossary125
Index141

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Omax JetMachining Center 80160 Specifications

General

Brand	Omax
Model	JetMachining Center 80160
Category	Cutter
Language	English

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