Wazer WAZER Main Unit User Manual Download Page 1

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141 Flushing Avenue

Brooklyn, NY 11205

User Manual

Original Instructions - V5.0

WAZER Water Jet Cutter Main Unit (WAZER V1.5)

WAZER Water Jet Cutter Pump Box (Pump V1.5A/V1.5B)

Summary of Contents for WAZER Main Unit

Page 1: ... WAZER Inc 141 Flushing Avenue Brooklyn NY 11205 User Manual Original Instructions V5 0 WAZER Water Jet Cutter Main Unit WAZER V1 5 WAZER Water Jet Cutter Pump Box Pump V1 5A V1 5B ...

Page 2: ...eby declares that to the best of WAZER s knowledge products and components described in this manual do not contain the chemical substances prohibited by the EU Restriction of Hazardous Substance directive EU Directive 2011 65 EU at the time of shipment from the factory This declaration is in conformity with the applicable requirements of 6 substances restric tions in EU Directive 2011 65 EU RoHS r...

Page 3: ...dures 111 Additional Resources 126 Customer Support 126 Decommission 126 Disposal and recycling of WAZER 127 Warranty 128 Contents Introduction 1 Important Safety Information 3 Signal Words 3 Safety Symbols 4 Product Safety Label Locations 5 Peelable Labels 8 General Power Tool Safety Warning 9 WAZER Safety Precautions 11 WAZER 14 WAZER Workflow 14 WAZER Components 15 How it works 15 WAZER Systems...

Page 4: ...Manual Includes Safety WAZER is a powerful system please read understand and follow these safety guidelines to avoid damage or injury About WAZER You will learn about the operating principles of WAZER and familiarize yourself with its components It may be tempting to skip this section but understanding these concepts will be helpful every time you use WAZER Setting Up WAZER Walk through the proces...

Page 5: ... hazards These are important to the safety of WAZER users Others are there to make sure your machine or environment does not suffer any damage Be sure to familiarize yourself and all other users of the machine with these signal words Make sure to refer back to this section as needed SAFETY ALERT SYMBOL This is the safety alert symbol It is used to alert you to potential personal injury hazards Obe...

Page 6: ...nts during operation ENTANGLEMENT HAZARD Avoid contact with components in motion during operation ELECTRICAL SHOCK HAZARD Avoid contact with all exposed electronics during operation EYE PROTECTION Always wear appropriate eye protection to avoid potential injuries to your eyes Read Understand User Manual Read and understand operator s manual before using this machine Failure to follow operating ins...

Page 7: ...arns you of the suffocation danger when dealing with plastic bags Keep this bag away from children This label warns you of the operation maintenance and repair hazards of the WAZER Pump Box This label warns you of the heavy weight of the WAZER Pump box and instructs you to use the proper lifting technique when moving it This label warns you of the electric shock hazard associated with an improper ...

Page 8: ...et cutter avoid body contact with earthed or grounded surfaces such as pipes radiators ranges and refrigerators There is an increased risk of electric shock if your body is earthed or grounded Before every operation of a water jet cutter make sure that the water connections and water piping and joints are leak free Water leaks may increase the risk of electric shock Because the electronics will be...

Page 9: ...age to property Never operate a water jet cutter with broken or kinked high pressure hose lines Always ensure the positioning of the hose line is unlikely to cause people to trip or the kink loop and tensile force to be excessive during operation Never cut any unknown or toxic materials and properly dispose of waste products Always refer to the Safety Data Sheet SDS from the material manufacturer ...

Page 10: ...s it s the combination of water with running electricity that does so letting them air dry ensures that the next turn on won t destroy something Never attempt to identify the location of a leak when the machine is on Disassembly and Decommission Never discard WAZER in the trash WAZER is a tool that contains electric and electronic components proper disposal is required Never skip steps when decomm...

Page 11: ...igh pressure waterjet technology with several electro mechanical systems to bring you an all in one cutting solution The Pump Box pressurizes water that is then routed to Main Unit and expelled through a small orifice where it accelerates to a very high velocity At this point the WAZER introduces Abrasive to the Jet to create a slurry of water and abrasive This high pressure stream of abrasive slu...

Page 12: ...components and their location 2 Abrasive System This system stores the abrasive and controls its flow to the high velocity Jet 3 Enclosure This contains the water Used Abrasive and Material you are cutting within WAZER 4 Filtration This system separates tank water and used abrasive collects the used abrasive from the tank and drains water out of WAZER 5 Gantry This system controls the motion of th...

Page 13: ...WAZER MAIN UNIT INSIDE PUMP BOX BACK PUMP BOX INSIDE The WAZER SECTIO N 3 18 19 ...

Page 14: ...aneous Compatible File Types dxf svg Connectivity SD Card Noise Emission 74 3dB Noise Pressure Level 87 3dB Storage Condition 0 C 40 C 32 F 104 F for prolonged storage 0 C 70 C 32 F 160 F for 24 hours Maximum Working Pressure Flow Rate 4600psi 32MPa at 0 5 gal min 1 9L min 21 Machine System Schematics Main Unit Control System Diagram The above illustration shows the high level system schematic of ...

Page 15: ...n your WAZER These include electrical shock protection protection from contact with the high pressure water stream and correct water management to protect your environment Pump Box Electronics Layout Diagram The above illustration shows the high level system schematic of the Pump Box wiring and electro mechanical components ...

Page 16: ...three water connections Establish three Power Cable connections Anchor WAZER to the wall Most of these tasks have multiple steps It is crucially important to get the installation right or WAZER will not function properly Read carefully and don t hesitate to get in touch with WAZER support if you are still unclear after reviewing the User Manual VIDEO icon indicates that video instructions are avai...

Page 17: ...n WAZER should not be used in noisy electromagnetic environments Some appropriate environments include laboratories household workshops and most machine shops Heavy industrial environments that contain machinery or devices that induce electromagnetic interference on other adjacent devices either on the same circuit or in the general proximtiy should be avoided Water Drainage Make sure that it does...

Page 18: ...WAZER box through some environments i e tight corners narrow doors may not be possible In this case skip to WAZER Unboxing Note that you will need to take extra care not to damage WAZER when moving the machine to its final location 4 WAZER Stand Leg Accessory if included Remove the WAZER Stand Leg Accessory box 5 Abrasive if included Remove the Abrasive buckets 6 Pump Box Two person lift With one ...

Page 19: ...inside the cutting area this is from quality assurance testing 8 If you have purchased the Stand Leg Accessory switch to those instructions at this point These instructions are included in the Stand Leg Accessory box If you intend to set up WAZER on a table or desktop then continue reading here 9 By now you should have selected an appropriate location for WAZER If not review the Location Requireme...

Page 20: ... for return and decommissioning if required Verify Your Shipment s Contents In an effort to improve your WAZER experience there may be additional items that we include with your shipment It is likely they are included to aid in the setup maintenance or operation of your WAZER 1x User Manual 1x WAZER Main Unit 1x Pump Box 1x WAZER Power Cable GFCI PRCD 1x Water Filter Kit Setup Kit 1x SD Card 1x Pu...

Page 21: ...ge and two on the bottom front edge 2 Remove the gray Pump Box cover by pulling the bottom front edge forward and top edge up 3 Remove the red Oil Cap with the provided 17 mm wrench and replace it with the yellow Pump Vent Cap found in the white box in the Setup Kit Tighten the cap until it is finger tight and retain the red oil cap for later shipping 4 Replace the Pump Box cover and tighten the P...

Page 22: ...ck High Pressure Hose before installation If the High Pressure Hose outer layer has been damaged down to the outer wire layer the High Pressure Hose shall be withdrawn from use Contact WAZER for replacement Water Inlet Hose 2 Step Water Drain Hose 3 Step High Pressure Hose 1 Step Water Drain Water Hook Up Quick Connect System We have provided a Push to Connect John Guest style system for both hose...

Page 23: ... bolts sharp metal plates etc Every installation will be different but we recommend using zip ties and the provided hose routing anchors to help with tidy routing Do not cut the hose yet Here are some routing examples that may be helpful 4 Connect Water Inlet Hose to water supply Now we will make the connection to your plumbing We have provided hardware for two types of connections You will either...

Page 24: ...rew the Sink Adapter into the water supply 6 Reinstall the faucet supply into the threaded side of the Sink Adapter 7 Do NOT cut the end of the Water Inlet Hose to size yet 8 DO NOT turn on the water supply valve yet 9 Move on to Hose 2 Install the Water Drain Hose Option 2 Garden Hose Adapter These threads are often found in commercial buildings garages and workshop sink faucets In your Plumbing ...

Page 25: ...e Water Drain Hose Connection swivels for more direct routing You may choose to untwist the twist tie holding the Signal Cable and Power Transformer wire to the back of WAZER for better access to the Water Drain Hose Connection and to the High Pressure Hose Connection 2 Route the Water Drain Hose This will likely be similar to your Water Inlet Hose routing Zip tie the hose to other plumbing or use...

Page 26: ...sure Connection located on the back corner of WAZER Ensure that fitting is full seated and the collar has snapped forward Pull on the hose be certain of the connection Make sure the Pump Box is in a location that does not cause added stress to the High Pressure and Water Inlet Hoses Make sure the High Pressure Hose does not bend too sharply coming out of the back of the Pump Box If there is a shar...

Page 27: ...nto the On Off valve The remainder of the Water Inlet Hose can be cut to length to be routed between your sink adapter or Garden Hose Adapter installed at the beginning of this hose setup procedure We recommend leaving enough slack to create a small loop in the line near the connection point This allows extra slack to reposition in the future and relieves the joints to prevent leaking Attach the s...

Page 28: ...y Kit WAZER has a current draw of 2 Amp If you are in a 110VAC region and have the 110vac Pump Box V1 5A plugged into a 15 Amp Circuit you will need to run WAZER off an entirely separate circuit Make sure to plug the WAZER Power Cable into an outlet on another circuit If you are in a 110VAC region and have the 110vac Pump Box V1 5A plugged into a 20 Amp Circuit you can run WAZER and Pump Box off t...

Page 29: ...h approximately 400 lbs 180kg To ensure the safety of the WAZER and its users it is required that you anchor the machine to a wall or solid structure with the provided bracket and hardware To anchor WAZER 1 Install the Wall Mount Bracket using the provided hardware The bracket is installed on the back right side of WAZER when viewed from behind with a 4 mm Allen key 2 Move WAZER into position and ...

Page 30: ...You may notice that the Cut Bed and water level are not parallel This may occur if the machine is not level on the surface it is placed OR if the Cut Bed is not level If your machine is not level you may have water management errors in the future If your cut bed is not level it is guaranteed that you will have back flows and failed cuts in the near future We highly recommend you check how level th...

Page 31: ... Files onto the SD Card WAZER has a slot near the Control Panel that accommodates a standard sized SD Card It is important that you insert the SD Card before turning WAZER on An SD Card is provided with your Setup Kit This SD Card contains the Cut File for the Welcome Cut Place it in WAZER now Turn On WAZER There are 5 things that can prevent your WAZER from turning on The GFCI PRCDs cords must be...

Page 32: ...our first cut we suggest you perform a water level setup To do this turn the water supply on to your WAZER and simply select Setup Maintenance Maintenance Water Level Setup from your WAZER s controller menu Follow the on screen prompts to ensure that your WAZER establishes its water level If you happen to run into an error the first time through this mode do not worry just re run it one more time ...

Page 33: ...ZER may lead to poor quality and damage to your machine You must use the Abrasive suggested on the WAZER website The WAZER is calibrated to run with the 80 mesh alluvial garnet available for purchase at www wazer com To load Abrasive Pull out the Abrasive Hopper located on the left side of WAZER We recommend using a large cup to pour the Abrasive through the two screens until the Abrasive Hopper i...

Page 34: ...rst cut you do not need to worry about this step but going forward we highly suggest doing the Tank Cleaning Maintenance regularly The details of conducting this procedure is found in Section 7 Maintenance Replacing the Used Abrasive Buckets is sometimes tricky here are two techniques to help Push the Used Abrasive Buckets down into their retainers to fill with water so they do not float The metal...

Page 35: ...teners You can use any fasteners that are about 5 mm in diameter to secure your materials to the corrugated Cut Bed The coarser the thread the better hence wood and sheet metal screws are ideal Be mindful of the Nozzle profile and the screw head size you choose to minimize Nozzle crashes and losing a Cut To fasten your Material Place several Fastening Screws around the Material and screw them dire...

Page 36: ...e cutting head without us noticing Be mindful of this because if this happens you will have a jam clog and lost cut If the Nozzle Height is set too low it might crash and ruin your Cut which would require significant maintenance If the Nozzle height is set too high you may notice a small effect on your Cut Quality It is better to be slightly too high than to be too low If you lost your Nozzle Heig...

Page 37: ...ZER will have a constant vibrating buzz while cutting along with a few ticking sounds at The start and end of cut segment that come from the Pump Box The Pump Box should emit a smooth hum there should be no erratic sounds coming from the Pump Box or constant ticking WAZER will also generate noise from the Jet cutting the Material and creating turbulence in the Tank If you observe the Control Box a...

Page 38: ... happen instantaneously because WAZER must perform the correct Shutdown Once paused you can either cancel the cut or continue the cut Select the option you want and press okay to confirm your selection If you choose to cancel WAZER will immediately purge its line pressure in the form of a burst of water from the nozzle The nozzle will stay in the last position DO NOT open the Door until you hear t...

Page 39: ...ificant change in the sound of WAZER s operation If there is an Abrasive Clog press Start Stop immediately Refer to the website resources section for more information Leaks Despite WAZER being an enclosed system it is not completely sealed You will inevitably find an occasional drip or some Used Abrasive outside of the WAZER However you should monitor for any abnormal drips leaks or puddles If you...

Page 40: ...5psi are not an issue unless the pressure drops below 35psi in which case a failed cut is imminent It is important to make sure that water hungry devices or fixtures aren t used during a cut on the WAZER This failure could be the result of something as simple as turning on a faucet in an adjacent room The water draw can cause a drop to the inlet pressure which can be below the lowest allowable for...

Page 41: ...at do not expose you to the Tank water 4 Leave the Door Open After a Cut everything inside WAZER is wet We suggest leaving the Door open so the internal surfaces can dry This prevents tight areas from growing mold and allows you to brush away the Used Abrasive once it is dry It is much more difficult to clean the Used Abrasive when it is wet 5 Perform a General Inspection It is always a good idea ...

Page 42: ...nd before its next cut This will loosen the excess abrasive at the bottom of your tank and in the collection ports making the collection system more effective during cutting This will help keep WAZER clean and will prevent you from needing to scoop Used Abrasive out of the Tank by hand If you notice that WAZER is not collecting Used Abrasive as quickly as it should please perform the procedures li...

Page 43: ...erly Improperly seated buckets are incapable of collecting used abrasive effectively thus create used abrasive pile up more in the tank bottom Make sure that your abrasive buckets are always properly seated This may require you to push some of the abrasive out from under the bucket away or scoop it out 6 Short Medium and Long Term Maintenance To ensure safe and reliable operation you MUST familiar...

Page 44: ...re seat hose end into cutting head Close the On Off Valve Turn WAZER Off Empty the Used Abrasive Leave the Door Open NEVER skip any Startup or Shutdown steps Failure to complete these steps could lead to injury and damage to WAZER and your property Cutting with WAZER Checklist 1 Preparation Wear proper Personal Protective Equipment Open the On Off Valve Fill the Tank Once dry brush away used abras...

Page 45: ... different learning curves Choosing design software is a personal decision based on your needs industry and technical abilities If you are just starting out with two dimensional design we suggest starting with a simple 2D option such as LibreCAD or QCAD If you have some digital design experience you may want to use something like Inkscape It may be a good idea to reach out to others in your indust...

Page 46: ...cknowledge you have read Terms of Services and Privacy Policy by clicking the adjacent box NOTE Some users have reported trouble with registering their serial number later because of a block symbol on the Submit Serial Number button Once you have typed in your number either click outside the text box or press Enter to validate the number then the button will activate and allow you to finish regist...

Page 47: ...e settings getting changed Cut File Steps Step 1 Import File Import File Compatibilities dxf 2D file type that most engineering and design software will export The dxf library supports arcs circles ellipses lines polylines and splines All text must be converted to vector paths dxf files do not include units Wam tries to infer the correct units but if it cannot the part will default to inches svg 2...

Page 48: ...bled during multi selection Step 3 Material Selection WAZER needs to know the Cut Rate or how fast it can cut for your Material Rather than relying on the user to calculate and enter this directly for every Cut we have created a Material Library that holds all this information You can simply specify your Material and thickness from the available selections and Wam will set the correct Cut Rate Whe...

Page 49: ...aterial This will likely be sufficient for most Cuts and will seldom need to be changed However you should always review the default locations in case they will cause problems with your Design If you need to make changes select Manual Tab Placement and move the problem Tabs by left clicking and dragging them You can also add and remove Tabs by left clicking Additionally there may be use cases wher...

Page 50: ...eting Materials You can always come back and edit delete a Material you have created by clicking on the custom Material in the Material Library editing the fields desired and saving the Material Please note that editing deleting is only available for custom Materials default Materials cannot be edited Material Entry Material Type This field is the highest level organizational structure of your Mat...

Page 51: ...he Jet has Pierced the Material Lead This field refers to the distance away from the intended Cut Path where the cutting should start Even though the Jet coming out of the Nozzle is consistent the Pierce Hole will be larger than the Kerf You therefore want to Pierce away from the Cut Path and then Lead into it Additionally this is a good parameter to modify for Materials that chip easily or are no...

Page 52: ...ocedure outlined in Maintenance Misc Procedures Clearing the Filtration System Nozzle Purge This function turns on the High pressure system of WAZER This can be used to purge pressure from the High Pressure lines when the water is turned off It can also be used to observe the water stream for debugging Follow the instruction shown on UI screen Abr Flow Rate This function turns on the abrasive syst...

Page 53: ...etains water pressure at this moment this function will clear the residual pressure from High pressure lines HP Pump This function engages the pump box for a short time You may hear AC motor running in the Pump Box Jog This feature enables you to move the nozzle to any point on the Cut Bed by manually controlling the buttons on control pad 98 Cut Rate Testing The WAZER will cut a series of arcs at...

Page 54: ... removal so we suggest you acquire a waterproof container a bin or industrial garbage bag large enough to hold the Cut Bed Lift the Cut Bed out of the Tank and into the container Flip the Cut Bed upside down so the side you were just cutting on is facing away from you Remove the brackets that are attached to the bottom of the Cut Bed If this side of the Cut Bed is new simply flip the Cut Bed over ...

Page 55: ...wever some abrasive can still accumulate in the middle and edges of the Tank especially if you are only cutting in one area To collect this Used Abrasive run the Tank Cleaning Cycle from the Setup Maintenance menu of the Control Panel This procedure will help prevent any clogs in the Filtration System We also recommend running this cycle before cutting if your machine has been sitting for a long t...

Page 56: ...Open Abrasive drawer 3 Remove Abrasive Valve Plug 4 Select Setup and Maintenance 5 Select Abr Flow Rate 6 Place or hold a cup or container below the Abrasive Valve 7 Now hit okay to begin the flow of abrasive If the valve simply doesn t open consistently see Machine Procedures Pinch Valve Teardown The timer will count while the abrasive is flowing 8 After the 1 min Abrasive Flow test weigh the con...

Page 57: ...Box Oil Change The Pump Box oil needs to be changed after the first 50 hours of use and then every 300 hours after that These oil changes aren t done because of the degradation of the oil but because of the impurities that will find their way into the oil over time These impurities will result in premature wear if allowed to stay in the oil for extensive periods of time 300hours 1 If you have rece...

Page 58: ...Remove the two 4mm Allen bolts The cutting head will be completely separate from the gantry Discard the old cutting head and prepare the new head for installation Make sure not to confuse the two You may wish to tape the old head in order to mark the difference Place the new cutting head straight vertically onto the gantry block and reattach the two 4mm Allen bolts Failing to install the head stra...

Page 59: ...to Prime the Low Pressure System and then Prime the High Pressure System To Prime the Low Pressure System Fill WAZER tank as instructed Open Drain Filter Cover lightly tap Drain Filters to let trapped air escape You will see bubbles coming out Turn WAZER on Select the Setup Maintenance on the Control Panel Select Peripheral Check Remove the front bucket cover Select Low Pressure Pump LP Pump and a...

Page 60: ... Cleaning cycles until the amount of Used Abrasive collected in the Buckets is minimal or once there is no excess Used Abrasive piled up in the Tank It is important that you run a Tank Cleaning Cycle after every cut This will help keep WAZER clean and will prevent you from scooping Used Abrasive out of the Tank by hand Cleaning the Abrasive Hose End The end of the Abrasive Hose End accumulates sil...

Page 61: ...r Wearing safety glasses spray 10 15 psi of air into the opening of the pickup fitting on the inside of the Abrasive Hopper while holding the Pinch Valve Button This will clean out the hose Hold the Pinch Valve Button and peer through the bottom of the Abrasive Hopper Verify that it is dry and clear of obstruction Then insert the rubber plug back into the bottom of the Abrasive Hopper Wearing safe...

Page 62: ...ses Repeat for the other side of WAZER Replace the Front Tank Cover and press the OK Button to exit the Used Abr Collect mode If you are repeatedly having this clog within a couple minutes it is likely you have an excessive amount of Used Abrasive that has accumulated in the Tank You may need to do this procedure multiple times or remove the Cut Bed and manually clean out the bottom of the Tank In...

Page 63: ...ter 1 Canister Style 1 Remove the Water filter from the bracket DO NOT attempt to do this step while mounted to the wall 2 Place the drain hose into a sink or bucket 3 Turn the valve until water starts coming out of the drain hose You will notice that wipers will start to remove the debris caught on the filter 4 After a few turns the valve at the bottom of the Water Filter will open and this debri...

Page 64: ...efore pulling the hose out Let the water drip dry Procedure 9 Place the plastic cover over with the metal end nut Re secure with the wrench you have Sealing here is all achieved by o rings so be careful and do not over tighten 10 Use one hand to hold the brass nut and screw on the inlet hose connector 11 Replace the Pump Box Cover tighten the Thumb Screws reattach all plumbing and electrical conne...

Page 65: ... Chamber Use 11mm and 28mm wrench to unscrew Mixing chamber from Guide rod Use masking tape to cover the bottom of Guide Rod The Orifice is now exposed in the body of the Mixing Chamber you can see a tiny hole in the middle Remove the Orifice from the Mixing Chamber by whacking it against your palm Use a toothpick or metal dental pick to remove debris from the threads both inside and outside Make ...

Page 66: ...ut Bed Bolt in that corner This will lower the Cut Bed Tighten the bolt until the Nozzle Height Tool slips between the Nozzle and Cut Bed with little to no slope or resistance b If you do not collide and there is room between the Nozzle and Cut Bed loosen the Nozzle Lock Knob and use the Nozzle Height Tool to reset the height off of the Cut Bed If this is your first pass around the Cut Bed corners...

Page 67: ...ble from pump box cut it off from the Main unit discard it Open Pump box cover replace the yellow Pump Vent Cap with red Oil Cap If lost contact WAZER for assistance Put pump cover back on If you have a WAZER Stand up take the Stand Leg and Shelf off by reversing the process of installing Please refer to Stand Leg Accessory for installation process Be mindful of every safety precaution Information...

Page 68: ...rol modification of the Product The Product s software or firmware To damage occurring during transportation of the Product such claims are the sole responsibility of the shipper Use of third party abrasive does not in and of itself void this warranty However damage caused by use of third party abrasive is excluded from this warranty Conditions The Warranty is granted under the following condition...

Page 69: ...ware or the loading of files onto WAZER will void the machine s warranty The use of non WAZER released approved firmware and configuration files onto a WAZER machine The usage of any non WAZER approved CAM software to generate g code or manually modified created g code to run a WAZER Approved g code creation solutions will be updated by WAZER If there is any uncertainty please contact WAZER custom...

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