Wire - Edm Quick Start

WIRE - EDM QUICK START SOFTWARE：W5F MANUAL VER：A DATE：2006.07

Copyright Reserved CHING HUNG MACHINERY & ELECTRIC INDUSTRIAL CO., LTD.

 886-4-23500333 Please Read This Manual Thoroughly Before Operation

Please Read This Manual Thoroughly Before Operation Thank you for buying our product, and for the chances of being able to offer you our high quality wire EDM series machinery and also the best after-sale services. In order to maintain machine’s peak performance and extend its life span as long as possible, we sincerely suggest all the operators carefully read this manual for first time operation. Also, for your safety, please read the following “must-known” precautions: 1. Wire EDM operators should have received relative training from our local agency, or directly from CHMER headquarter. 2. CHMER wire EDM can only applied to the machining of several kinds of metal work-piece, such as steel, aluminum, tungsten steel, copper and graphite. Push emergent-stop before executing any one of following tasks: (1). Cleaning or sorting waste wire. (2) Replacing resin or paper filter. (3) Filling up water tank. (4) Opening power cabinet. 3. Push emergency-stop and turn off rotary switch immediately when any one of the following situations occurs. (1) Hearing of funny noise, or any abnormality occurs during machining. (2) Unloading any machine’s power wire (in power cabinet, water tank, or cooling machine.). Please contact our local agency first, or CHMER headquarter for this. 4. To avoid dangerous shock, be sure to stop electricity discharging before installing copper wire and work-piece. 5. Do not touch any part around worktable (upper/lower head, wire and water) during machining to prevent from high voltage strike. 6. Do not modify electrical circuit. 7. Please take reference to relative chapter in this manual for daily maintenance. 8. Please keep this manual closely with the machine. Thank you again for purchasing CHMER’s product. Please call our Service Department at 886-4-23500333 anytime for technical support and repair. It is our honor to be at your service. 9. Caution： After every system reboot, SEARCH HOME must be performed before starting operation. (Please refer to chapter 1 of Quick Start Manual)

CHMER WIRE EDM QUICK START

INDEX CHAPTER 1. START UP OF OPERATION-------------------------------------------- 1 1.1 Booting Up Procedures------------------------------------------------------ 1 1.2 BASIC ACCESSORIES---------------------------------------------------- 3 1.3 PRE-MACHINING SETUP------------------------------------------------ 7 CHAPTER 2. ---------------------------------------------------------------------------------- 15 2.1 FILE MANAGEMENT & GRAPH SIMULATION-------------------- 15 CHAPTER 3. SETUP FOR CUTTING--------------------------------------------------- 25 3.1 Set Z axis height-------------------------------------------------------------- 25 3.2 Call up a job file for simulation-------------------------------------------- 26 3.3 MEM DATA Set-------------------------------------------------------------- 26 3.4 Call up cutting technology---------------------------------------------------

28

3.5 Reset Local Coordinate------------------------------------------------------

28

CHAPTER 4. WIRE POSITIONING FUNCTIONS---------------------------------- 29 4.1 Edge Find---------------------------------------------------------------------- 29 4.2 Find Slot Center-------------------------------------------------------------- 30 4.3 Find Hole Center------------------------------------------------------------- 31 4.4 Angle Rotation (AR)--------------------------------------------------------- 32 4.5 Find Board Center (BOARD CP.)------------------------------------------ 32 4.6 MDI. MOVE------------------------------------------------------------------ 35 4.7 CYLIND C.P (Find Cylinder Center)------------------------------------- 36 4.8 CORNER MOVE（find corner position）-------------------------------- 37 4.9 MEM ZOOM（MEMF10）--------------------------------------------- 38 CHAPTER 5. F.A.Q. & TROUBLE SHOOT-------------------------------------------- 39


CHAPTER 6. SAMPLE PROGRAM----------------------------------------------------- 48 6.1 Straight Cutting--------------------------------------------------------------- 48 6.2 Taper Cutting----------------------------------------------------------------- 52 6.3 UV Cutting-------------------------------------------------------------------- 54 6.4 AWT Application with Sub-Program-------------------------------------- 57 CHAPTER 7. MAINTENANCE INSTRUCTION------------------------------------- 59

VER：E5B-1086A


CHAPTER 1. START UP OF OPERATION 1.1 Booting Up Procedures 1. Turn on the main power. 2.Turn (right) on the rotary switch.

EDM

A

B

H

I

M

N

Q

R

S

U

V

W

[

X

Y

Z

,

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Rotary switch Main power

3. A few seconds later after boot procedure

Operation screen

-1-


4. Release Emergency-stop button 5. Press green button (to stand by)

Green Button Release Emergency-stop

-2-


1.2 BASIC ACCESSORIES 1. Diamond Guide (1). Normal Diamond Guide (upper & lower exchangeable)

(2). AWT Diamond Guide (upper & lower non-exchangeable)

uppe

lowe

-3-


2. Nozzle (1). AWT Nozzle (upper)

(2) AWT Nozzle (lower)

-4-


(3). Normal Nozzle (upper & lower exchangeable)

3.Energizing Plate (for both AWT and non-AWT)

-5-


4. Lead cutting wire through threading system (follow arrows)

non-AWT

non-AWT

AWT model

-6-


1.3 PRE-MACHINING SETUP 1.3.1 SEARCH HOME 1. Press

2. Press -V

(SEARCH HOME)

-X

-Y

-U

+Z

3. The star mark, “ * ”, beside an axis name (*X,*Y,*Z,*U,*V) would disappear after machine point is found. If not, move that one axis with direction key and do Home Search again.

Note：Please turn off AR function before SEARCH HOME to avoid Alarm 10500.

1.3.2 VERTICAL ALIGNMENT Use Alignment Jig to find out vertical points after parts replacement such as upper/lower Head, Diamond Guide or Ceramic Plates. Before executing Vertical Alignment, the Alignment Jig has to be well located on work-table and connect its -7-


signal cable to VER I/O port. Then follow steps listed below：

Alignment Jig 1.Press 2. Press

VER I/O port

twice quickly if its LED not lit on. （VERT. MOVE）

DA,DB Switch

Vertical position (U,V)

2. Align either XU or YV at one time Select direction【2 (-X) or 1 (+Y)】, press

to begin.

3. When vertical points are found (repeat accuracy within 5μ), alignment process will stop, and the text of UV will change to color gray from red. 4. Press

to reset 5 axes local coordinate value. -8-


Note. Before executing Vertical Alignment： (1) Turn off DA/DB Switch (DA DB OP. SW=OFF). Important!! (2) Well dry upper head. Any water drip left will worsen alignment accuracy. (3) To keep aligning the same axis, select the same direction in 2ND STEP. Except for using Alignment Jig, L-Block can be used for manually aligning the axis with spark appears on wire: L-Block

1. Locate L-Block on Work-table and well align it with indicator. 2. Turn (right) off two water knobs to block flush water from upper and lower head.

3. Do EDGE in –X direction： Press

（EDGE MOVE）

-9-

2(-X)


4. Press

to reset 5 axes local coordinate value.

5. Set PW=A01.The other S-code items are the same (ON:1,OFF:15,AN:1,AFF:15, SV:50, FR:10,WF:5,WT:10,WL:0,F:0). (Set WT=10 forΦ0.2wire; set WT=12 for

Φ0.25 wire). 6. Press 7. Move Y and V axis with ML or L speed until spark appears evenly on wire. Then, move table back and forth in Y direction. 8. If the spark appears evenly while table moving, write down axis V machine coordinate value and input them into VERT. PT. Press and VERT. PT. will appear on screen.

- 10 -

(VERT MOVE)


9. Input the coordinate value and press

to save.

10. Repeat 3~9 for XU axis alignment. Tip：To copy machine coordinate to VERT. PT., move Green Bar to VERT. PT., press C and

- 11 -


1.3.3 SET UP TAPER DATA: DA/DB Need to re-setup DA/DB after parts replacement such as upper/lower Head, Diamond Guide or Ceramic Plates. Please follow steps listed below：

1.Set up Z axis height (1). Put a L-Block (45mm) on the worktable. (2). Press

a to set Z HEIGHT=250.0. Next, do Z axis

search home. (3). Lower down Z axis slowly to just slightly touch the surface of L-Block. Keep 0.2mm gap away from upper nozzle. (4). Now, write down current machine coordinate value of Z axis (assume H1=46.0) (5). Use the equation below to get the tolerance value Z1： Z1=（H2-H1）+Z0 Z1=（45.00-46.00）+250= ─1+250=249.00 (6) Input new Z1 in Z HEIGHT and do search home again.

- 12 -


(8). When Home Search is done, press twice, and lower Z axis down to keep a 0.2 mm distance above the 45mm L-Block. (9). If on the screen, Z coordinate value is not approximately 45.2 mm, then repeat above step (1).~(8).

2. Setup DA, DB. (1) Put L-Block on Work-Table as indicated by figure below.

L-Block

Cutting wire

(2) Edge Find in–X ( please refer to Chapter 4.1, page 32. )

(3) Move the wire away from L-Block in +X for at least 15mm by key panel or MDI MOVE (refer to Chapter 4.6). (4) Press

（DA, DB MOVE）

(5) Input DA, DB MOVE info：UV MOVE ANGLE=3.000, UP POINT=45.000, DN POINT=0.000，TOLERANCE ANGLE=0.0050

- 13 -


DA DB MOVE info

(6) Set TOUCH MODE=0 (short) for L-Block. Set TOUCH MODE=1 (IO) if Alignment Jig is used. (7) Set WIRE TENSION= 4~15. (8) Set DA. DB DIR.= 2 (-X) (9) Press

to start DA, DB MOVE.

- 14 -


2.1. FILE MANAGEMENT & GRAPH SIMULATION 2.1.1. Browse a floppy disk 1. Press

2. Press

(NC.NAME BROWSER)

3. Press

(FLOPPY BROWSER)

2.1.2 Copy file from floppy to DOC (Disk On Chip) 1. Press

- 15 -


2. Press

(NC.NAME BROWSER)

3. Press

(FLOPPY BROWSER)

4. Move cursor with

to select a file and press

(COPY NC. PGM)

Dialogue box shows current file name, which could be modified. To specify a new file name, for example O0301, then press - 16 -

.


“FILE NAME EXIST! OVERWRITE?” appear when the file name has existed in hard disk. Select “OK” to overwrite, or select “CANCLE” and use another file name.

2.1.3. Browse DOC 1. Press

2. Press

(NC.NAME BROWSER)

cursor with

to select a file.

2.1.4. File Loading Method 1： (1) Press

(2) Press

(OPEN PGM)

- 17 -

（HD BROWSER）. Move


(3) Input specified filename then press

Method 2： (1) Press

- 18 -

.


(2) Press

(NC.NAME BROWSER)

then press

Use cursor

to select a file and

.

2.1.5 Graph Simulation (1) Press

(2) Load a file by either

(OPEN PGM) or

- 19 -

(NC NAME BROWSER)


(3) Press

twice

for relative setup

(SIM DATA)

(SIMU H. VAR.)

（SIM. EXECUTE）.

2.1.6. Delete file in DOC Method 1: Delete a single file (1) Press

(2) Press

(NC.NAME BROWSER)

(3) Use

to move the bar to select file and press

- 20 -

(DELETE NC. PGM)


Method 2: To delete multiple files (1) Press

(2) Press

(3) Use

(NC.NAME BROWSER)

to move the bar to specific file and press

► will tag along with selected file.

- 21 -

(PICK NC. PGM).


(4) Press

(DELETE NC. PGM.) to delete all selected files.

2.1.7 Practice Below step 1~4 is the normal procedure for file upload and graph simulation. 1. Copy a job file (ex:O1018) to DOC. 2. Upload O01018 from DOC. 3. Execute Graph Simulation with O01018 4. Delete the job file O0001.

- 22 -


Please try going through A~D by the functions that have been introduced or used following instructions for reference： 1. Copy a job file (ex:O1018) from floppy to DOC. (1) Insert a 1.44” floppy into disk driver and press

(2) Press

(3) Press

.

(NC.NAME BROWSER)

(FLOPPY BROWSER) then use

to highlight O1018

( COPY NC. PGM) and appear the dialogue box

.

PGM NAME is the original file name. If you need to change the name, just input a new file name in the blank and press

- 23 -


2. Upload O1018 from DOC

(1) Press

(OPEN PGM)

O1018

（SURE EXECUTE） 3. Execute Graph Simulation with O1018 (1) Press VAR.)

twice

(SIM DATA)

（SIM EXECUTE）

4. Delete the job file O1018.

(1) Press

(2) Use

(NC.NAME BROWSER)

to highlight O1018

(DELETE PGM.)

- 24 -

(SIM H.


CHAPTER 3. SETUP FOR CUTTING 3.1 Set Z axis height First of all, lower down the upper nozzle to keep 0.2mm distance (use thickness gage) between the upper nozzle and work piece. Use Z-Lock (

)

(Z lock switch 0=OFF, 1=ON) when height set-up of Z axis is done.

When Z LOCK SW. is ON, Z coordinate would be changed to color red and Z axis cannot go down anymore. Note: Press Z LOCK button on the Remote Control twice rapidly can also free up Z LOCK.

－ 25 －


3.2 Call up a job file for simulation (1) Load a job file. Please refer to Chapter 2. FILE MANAGEMENT. (2). Press

3.3 MEM DATA Set (1). Press

（MEM DATD1） to initialize conditions like taper, Offset (D),

X&Y Mirror, Axis Exchange, Scale ratio, Thickness, Axis Rotation and Overcut.

－ 26 －


(2). Press

（MEM SETTED）to activate Corner Control and AWT function.

Corner Control items

(3).Press

AWT items

(MEM H.VAR) to input offset value.

－ 27 －


3.4 Call up cutting technology Before machining, press

（MEM PATH）

input S-code number（ex：

E1545 or 1545）

(If S-code has been specified in N.C program, this step can be skipped)

3.5. Reset Local Coordinate Press

to reset Local Coordinate

cutting.

－ 28 －

to start


CHAPTER 4. WIRE POSITIONING FUNCTIONS 4.1 Edge Find 1. Press

(EDGE MOVE) To specify a direction in EDGE

DIR, for example 0(X+),

and then press to start Edge Find.

See the direction graph on screen (0=X+, 1=Y+, 2=X-, 3=Y-…) to specify correct direction. 0=EDGE 1=SLOT 2=CENTER

- 29 -


4.2 Find Slot Center 1. Press

(EDGE MOVE)  set 1(SLOT) in EDGE MODE

and choose direction in EDGE DIR to decide either left or eight side to begin with. Next, press

to start.

0=EDGE 1=SLOT 2=CENTER

- 30 -


4.3. Find Hole Center 1. Press

(EDGE MOVE)  set 2 (CENTER) in EDGE

MODE

0=EDGE 1=SLOT 2=CENTER

- 31 -


4.4. Angle Rotation (AR) 1. Press

(ANGLE MOVE) then set start position in

START POS.

to start. When measurement is

done, angle value will come up in AXIS ANGLE. Then, move green bar to it, and input “AR” to copy angle value to AR SET or by inputting “PR” to PGM.ROT.ANG (Program Rotation Angle).

Then, input “AR” and press ENTER to copy AXIS ANGLE to AR SET.

- 32 -


Input PR and press ENTER to copy AXIS ANGLE to PGM.ROT.ANG (Program Rotation Angle).

- 33 -


4.5. Find Board Center (BOARD CP.) 1/2

1. Press

1/2

(EDGE MOVE) To choose direction in EDGE DIR to start. When table moving stops, copy machine

Coordinate to RECORD PT.0 by moving the green bar to RECORD PT.0 and input “C” and press

.

2. Move the wire to the other side and repeat (1) to get RECORD PT.1 3. Move the green bar to BOARD CP, input “GO” and press

; table will

move to the middle of the length (RECORD PT.0 ＆ RECORD PT.1). Note：Turn off AR(Angle Rotation) before executing BOARD CP.

- 34 -


4.6. MDI. MOVE 1. Press

2. Press

（MDI. MOVE）

clear. Next, press

enter value in MDI. VALUE or use “C” to

to confirm and

to start table moving.

Speed of table moving

Modes of table moving 0：XYZUV by incremental 1：XYZUV by coordinate 2：XYUV by incremental / Z by coordinate 3：XYUV by coordinate / Z by incremental Note：”Coordinate” referred above is MACH. COORD.

- 35 -


4.7. CYLIND C.P (Find Cylinder Center) This function is to find the center of a cylindrical object by locating three reference points 1, 2 and 3 as shown in below figure. Three reference points could be anywhere around the cylinder as long as there is enough distance among them. Steps are：

(1). Press

(2). Press

and Jog table to reference point 1.

(EDGE MOVE)

choose direction X+ in EDGE DIR

when table stops, copy MACH Coordinate of reference point 1 to RECORD PT.0 by moving the green bar to RECORD PT.0 then press button C

. - 36 -


(3). Jog table to reference point 2.

choose direction Y- in EDGE DIR

when table stops, copy MACH Coordinate to RECORD PT-1 of reference point 2. (4). Jog table to reference point3.

choose direction X- in EDGE DIR

when table stops, copy MACH Coordinate to RECORD PT.2 (5). Move the green bar to CYLIND C.P., input “GO,” and press

then

Work-table will automatically move to the center of the cylinder. (Note：Please turn off AR before executing this function.)

4.8. CORNER MOVE（find corner position） (1). Press

(CORNER MOVE)

(2). Select one START POS. (0~3) Setup move distance DX and DY. (3). Press

, then work table will move to the corner

after measurement.

- 37 -


4.9. MEM ZOOM（MEMF10） MEM ZOOM is to enlarge or minimize a specific part of program route so that operators can closely check for any possible error. Function keys applied for Zoom are listed below:  End：Zoomed from working field  PgUp：Scale x 2  PgUn：Scale x 1/2  Ins：Display graph of last completed job.  Del：Zoomed from current position of cutting wire.  ＋/－：Enlarge/Minimize frame size. ENTER：Confirm.  HOME：Recover origianl scale.

- 38 -


CHAPTER 5. F.A.Q. & TROUBLE SHOOT 1. Q: Why the message “Short when auto cutting” appear when start machining? A: In fact, short could be caused by many reasons. However, in most cases, if start hole is not going straight down, the brass wire would be more likely touch the work piece somewhere in the start hole, as the following graph shows: wire Short circuit work piece

Solution： Press

and, now, on the screen, the voltage meter is supposed to

show1V~7V. If not, move worktable with speed M or ML When voltage shows, press and wait for voltage to comes up. When the voltage stops coming up, press

JOG

(Note： Please use weak discharging energy.) - 39 -

Voltage meter


In addition, other possibilities that causes short could be： (1). Waste wire is getting out of collection box and touches metal part or ground. (2).Too high feed rate, but too weak cutting energy. In this case, either reduce feed rate or to increase discharging energy (reduce OFF and AFF, or even increase ON and AN) can resolve the problem. 2. Q: What should I do when wire breakage happens often? A: Here are some suggestions for wire breakage: (1) . First, To check if water Knob is fully opened (turn left to open)? When WL=6, water pressure is about 12kgw/cm2 and WL=7, water pressure is about 15kgw/ cm2. Keep pressure difference between upper/lower head less than 1 kgw/cm2.

Water Knob

(2) Check if Water Cooler is working normally? Water temperature too high? (3). Use weaker discharging energy. (Increase OFF and AFF)

- 40 -


(4) Check the waste wire collection box. See if the wire is out of the box? (5) Clean wire guide and its cooling holes. (6) Are upper/lower Flush Nozzles damaged? If yes, replace them. (7) Clean Power Contact (Energizer plate) and change contact position. Tip：When it is difficult to rethread at wire-break location, move up Z axis up and thread through to lower guide by hand press

when wire threading is done,

to return to wire-break location

to resume.

(Note: To avoid wire-break, use weak energy at initial 0.3mm as approach) 3. Q: How can I know what an ALARM message means? A: There is an ALARM message lists in the computer that records all the ALARM message and what it means. Check out the list by pressing (SYSTEM MESSAGE). Ex: 10400 means “Data setup NOT alloed during machining

- 41 -


4. Q: “If I need to stop the cutting and turn off the power for some reasons like repair or maintenance, would it be possible to RESUME the unfinished job later?” A: Yes. Please follow the instruction to resume the previous job: Press

Turn OFF power

Turn power ON

(After repair or maintenance finished)

Press

(Home Search) (press twice quickly)

Thread wire

Call up S-Code (refer to Chapter 3.4, page 31.) 5. Q: Will data be erased when power black out happens during machining? A: When the power source is suddenly cut off, the UPS (Uninterrupted Power Supply) located inside Power Cabinet will store all information before computer is shut down. Follow these steps to resume a job if power black out happens： Method 1. Press the Emergency Stop button power

After power recovers

Switch and release Emergency Stop

Turn off Rotary Switch and main Turn on Main Power, Rotary Press the Green Button

and remove the wire (Now table moving to last position (Turn off Dry Run)

interrupted by black out) Thread wire

Call up S-Code

- 42 -

Snip


Method 2. Press the Emergency Stop button power

After power recovers

Switch and release Emergency Stop

Turn off Rotary Switch and main Turn on Main Power, Rotary Press the Green Button

Snip and remove the wire

(back

to wire-break location) Thread wire

(press twice quickly)

call up S-Code

6. Q：How do I make Taper Cutting? (Refer N.C. program to Chapter 6.2) A: There are two variables, Z and I, are related to the setup of Taper Cutting; the figure below shows how they are correlated to：

I

Z

- 43 -


Z (PROGRAM PLANE) is the base line of taper, and I (THICKNESS) is the height of taper, which could be set as “+” or “—” and will create different taper shape. See figure below： +I

Z

Z

–I

Example A. G92X0Y0 G91Z30.I-30.

Z：Base line of taper or called “Program Plane” I：Height of taper.

G01G42Y5.H1A3. G02X5.Y5.J-5. X-10.Y0.I-5.

A is taper degree. When A is “+,” cutting wire moves rightward; when “–,“ it moves leftward

X5.Y5.I5. M02

Z=30 mm

30 mm I=–30 mm

Z=30 mm 30 mm I=–30 mm

- 44 -


Example B . G92X0Y0 G91Z27.I-27.

3mm

G01G42Y5.H1A3. G02X5.Y5.J-5.

Z=27.0 30mm I=–27.0

X-10.Y0.I-5. X5.Y5.I5. M02

Example C . G92X0Y0

I=30

G91Z0.I30. G01G42Y5.H1A-3. 30 mm G02X5.Y5.J-5.

Z=0

X-10.Y0.I-5. X5.Y5.I5. M02 I=30 30 mm Z=0

- 45 -


Example D. I=27

G92X0Y0 27 mm

G91Z3.I27.

Z=3

G01G42Y5.H1A-3. G02X5.Y5.J-5. X-10.Y0.I-5. X5.Y5.I5. M02

8. Q：How do I setup for UV Cutting？(Refer N.C. program to Chapter 6.3) A: There are two variables, Z and I, are related to the setup of UV Cutting. The figure below shows how they are correlated to： I Z：Base line of UV Cutting I：Height of work-piece. Z

Example A. Work-piece height=30.0 mm, 10 mm×10 mm square at bottom / 8 mm

8.0mm circle at top. I=30 30 mm Z=0

10 mm

- 46 -


Example B. Work-piece height=30.0 mm, 10 mm×10 mm square at top / 8.0mm circle at bottom. 10 mm

Z=30

30 mm

I=–30 8 mm

Example C. Same dimension as Example A, but with a spacer (H1) put under the work-piece. 8 mm I=30 + H1 30 mm

H1

SPACER

Z=0 + H1

8 mm

I=30 30 mm Z=0

10 mm

- 47 -


CHAPTER 6. SAMPLE PROGRAM 6.1 Straight Cutting 10 25 10

PGM

5

CONTENT

DESCRIPTION

O0001;

Program name

N0001

G92X0.Y0.

Define start point as X=0, Y=0

N0002

G91

Use G91 coordinate system (Incremental)

N0003

G41G01X-3.500Y0.000H1S1545

Offset and cut 3. mm in ﹣X.

N0004

G01X0.000Y-5.000

Cut 5. mm in ﹣Y.

N0005

G01X-10.000Y0.000

Cut 10. mm in ﹣X.

N0006

G01X0.000Y10.000

Cut 10. mm in +Y.

N0007

G01X10.000Y0.000

Cut 10. mm in +X.

N0008

G01X0.000Y-5.000

Cut 5. mm in ﹣Y.

N0009

M00

Halt

N0010 N0011

G40G01X3.500Y0.000A0 M02

Offset cancelled and cut 3.5. mm in +X. End

Note：N (serial number) / H1 (offset amount) / S1545 (S-code 1545)

- 48 -


Operation Procedures：（1）.Press

(2). Lower down the upper nozzle and keep a distance of 0.2mm between upper nozzle and work piece. For this, using thickness gage or one piece of 0.2mm brass wire is recommended. (3). Press

(HOME SEARCH) and set 1 (ON) in Z.LOCK SW.Z to

fixate Z axis position. (4). Press

(OPEN NC PGM.) to call a program, O0304,

for example, then press

(SURE EXECUTE) to load it

out.

- 49 -


Screen of OPEN NC PGM.

(5). Press

(SIM DATA) to turn off MIRROW SW and

set VERT in CUT METHOD and D COMP or

H Parameter for

offset in SIM H. VER. (6). Press

（SIM. EXECUTE）and begin the plotting.

Screen of OPEN NC PGM.

- 50 -


(SET DATA) for relative setup.

(7). Press (8). Press

(MEM SET) to turn on CTRL. SW. and select CORNER

TYPE.

(9). Zero local coordinate: (10). Press

(MEM. PATH)

to start cutting.

Screen of MEM. PATH

- 51 -


6.2 Taper Cutting T=25. mm, 10mm2 at 2° Taper

10

25

10

NO.

5

10

CONTENT

PROGRAM NAME

N0001

G92X0Y0


N0002

G91


N0003

G41G01X-3.500Y0.000A2.H1S1545 Offset, cut 3.5 mm in ﹣X at 2° taper.

N0004

G01X0.000Y-5.000

Cut 5. mm in ﹣Y.

N0005

G01X-10.000Y0.000

Cut 10. mm in ﹣X.

N0006

G01X0.000Y10.000

Cut 10. mm in +Y.

N0007

G01X10.000Y0.000

Cut 10. mm in +X.

N0008

G01X0.000Y-5.000

Cut 5. mm in ﹣Y.

N0009

M00

Halt

N0010

G40G01X3.500Y0.000A0

Offset cancelled and cut 3.5. mm in +X. 3.5mm

N0011

M02

End

- 52 -


Operation Procedures： (1). Press

.





for example, then press

(SURE EXECUTE) to

load it out. (5). Press

(SIM DATA) to turn off MIRROW SW. and set

ANGLE in CUT METHOD and D COMP or H Parameter for offset in (SIM H.VER.) (6). Press



(SET DATA) for relative setup. (MEM SETTED) to turn on CTRL. SW. and select

CORNER TYPE. (9). Zero local coordinate: (10). Press

(MEM. PATH) - 53 -

to start cutting.


6.3 UV Cutting UV cutting a Dia. 8mm circle on top and 10 mm2 square at bottom. T=25 mm. 8

10

25

10

10 NO.

CONTENT

PROGRAM NAME

N0001 G92X0Y0


N0002 G91

Use G91 coordinate system (Incremental) N0003 G41G01X-3.492Y0.000U-1.030V0.055H1S1545 G41：offset leftward. Cut in –X =3.492mm, –U=1.03mm, +V=0.055 mm. N0004 G01X0.000Y-0.687U-1.064V0.358

Cut in –Y =0.687mm, –U=1.064mm, +V=0.358mm.

N0005 G01X0.000Y-0.687U-1.157V0.670

–Y–U+V cutting… ：

N0006 G01X0.000Y-0.687U-1.307V1.002 N0007 G01X0.000Y-0.687U-1.510V1.361

：

N0008 G01X0.000Y-0.687U-1.761V1.755

：

N0009 G01X-0.786Y0.000U-1.310V1.475 N0010 G01X-0.786Y0.000U-0.902V1.257 N0011

G01X-0.786Y0.000U-0.526V1.108

–X–U+V cutting… ：：

N0012 G01X-0.786Y0.000U0.180V1.032

：

N0013 G01X-0.786Y0.000U0.536V1.108

：

N0014 G01X-0.786Y0.000U0.912V1.257

：

- 54 -


NO.

CONTENT

DESCRIPTION

N0015

G01X-0.786Y0.000U1.321V1.475

–X+U+V cutting…

N0016

G01X-0.786Y0.000U1.773V1.755

N0017

G01X0.000Y0.786U1.493V1.304

N0018

G01X0.000Y0.786U1.275V0.895

N0019

G01X0.000Y0.786U1.126V0.519

：

N0020

G01X0.000Y0.786U1.050V0.163

：

N0021

G01X0.000Y0.786U1.050V-0.186

N0022

G01X0.000Y0.786U1.126V-0.543

N0023

G01X0.000Y0.786U1.275V-0.919

：

N0024

G01X0.000Y0.786U1.493V-1.327

：

N0025

G01X0.000Y0.786U1.773V-1.779

：

N0026

G01X0.786Y0.000U1.322V-1.499

N0027

G01X0.786Y0.000U0.913V-1.281

N0028

G01X0.786Y0.000U0.537V-1.132

：

N0029

G01X0.786Y0.000U0.181V-1.057

：

N0030

G01X0.786Y0.000U-0.168V-1.056

：

N0031

G01X0.786Y0.000U-0.525V-1.132

：

N0032

G01X0.786Y0.000U-0.901V-1.281

N0033

G01X0.786Y0.000U-1.309V-1.499

N0034

G01X0.786Y0.000U-1.761V-1.779

N0035

G01X0.000Y-1.067U-1.596V-0.896

N0036

G01X0.000Y-1.067U-1.448V-0.027

–Y–U–V cutting… ：

N0037

M00

Halt

N0038

G01X0.000Y-0.400U-1.254V0.022

N0039

G01X0.000Y-0.400U-1.118V0.047

–Y–U+V cutting… ：

N0040

G01X0.000Y-0.400U-1.044V0.054

：

N0041

G01X0.000Y-0.400U-1.033V0.055

：

N0042

G01X0.000Y-0.400U-1.085V0.059

：

N0043

M00

N0044

G40G01X3.492Y0.500U0V0

： +Y+U+V cutting… ：

+Y+U–V cutting… ：

+X+U–V cutting… ：

+X–U–V cutting… ：：

Halt G40：offset cancelled. +X+Y cutting and move to U=0 Y=0.

N0045

M02

End

- 55 -


Operation Procedures： (1). Press (2). Lower down the upper nozzle and keep a distance of 0.2mm between upper nozzle and work piece. For this, using thickness gage or one piece of 0.2mm brass wire is recommended. (3). Press




for example, and then press

(SURE EXECUTE) to load it out.

(5). Press twice

(SIM DATA) to turn off MIRROW SW

and set VERT in CUT METHOD and D COMP or H Parameter for offset in (6). Press

(SIM H. VER.)


(7). Press

(SETTED DATA) for relative setup.

(8). Press

(MEM SETTED) to turn on CTRL. SW. and select


(MEM. PATH)

to start cutting. - 56 -


6.4. AWT Application with Sub-Program M20

M20

M21

M21

CONTENT

DESCRIPTION

N0001

O0020;

Program name

N0002

G92X0.Y0.


N0003

G91


N0004

M20

Thread Wire

N0005

M98P0021L1

Call up and run sub-program O0021 1 cycle

N0006

G00X20.0

Table move +X=20.0mm

N0007

M20

Thread Wire

N0008

M98P0021L1

Call up and run sub-program O0021 1 cycle

N0009

M02

End

N00010

O0021;

Program nam

N00011

G92X0.Y0.


N00012

G91


N00013 N00014

G41G01Y-5.0H1S1545 G01X5.0

G41：Offset leftward. Cut in –Y=5mm. Cut in +X=5mm

N00015

G01Y10.0

Cut in +Y=10mm.

N00016

G01X-10.0

Cut in –X=10mm.

N00017

G01Y-10.0

Cut in –Y=10mm

N00018

G01X5.0

Cut in +X=5mm.

N0019

M21

Clip wire

N0020

M00

Halt

N0021

G40G00Y5.0A0

G40：offset cancelled. Table move +Y=5mm.

N0022

M99

Sub-program end.

Note：N (serial number) / H1 (offset amount) / S1545 (S-code 1545) -57-


Operation Procedures： (1). Press

.




(OPEN NC PGM.) to call a program,

O0304, for example, then press (5). Press

(SURE EXECUTE) to load it out.

twice

(SIM. DATA) to turn off MIRROW

SW and set VERT in CUT METHOD and D COMP or H Parameter for offset in (6) Press



(SIM H. VER)

(SETTED DATA) for relative setup. (MEM SETTED) to turn on CTRL. SW. and select


(MEM. PATH)

to start cutting.

-58-


CHAPTER 7. MAINTENANCE INSTRUCTION In order to machine running at peak performance, reduce the chance of failure and extend its life span, it is necessary to execute maintenance regularly. Below is Maintenance Item Sheet, which has listed maintenance items and provided basic information for how to do the check-up. Please be sure to follow the instruction. No.

Item

Period

Check Point

1

Machine Body

Per day

Dirty or wet

2

LED on panel

Per day

Out of order

3

Wire Alignment

Per day

Not well aligned

Action

Note

Clean & dry

Do not use compressed air to dry the water splashed on machine to avoid possible leak rusting ball screw, linear guide and worsen machine accuracy.

replace Do alignment Avoid any objects clean (waste) dropped into tank Do oil Recharge oil when injection low Poor cleanness Clean Will worse machine accuracy. Clean Must at Motor will dry run if least 1/2 water level too low. full

4

Drain pipe

Per day

Clogged

5

Oil Injector

Per day

Machine stops overnight

6

Lower Arm

Per day

Dirty or rusty

7

Waste wire box

Per day

Over 70% full

8

Filtration level

Per day

Water level too low

9

Rear filter of Power Cabinet

Per week

Dusty

Clean

10

Filter of Water Chiller

Per week

dusty

clean

11

Upper Head

Per month

12

Lower Head

per day

Avoid solvent flow Clean with clogged into de-ionized solvent. water Debris stuck & cause Clean or short replace

-59-


No.

Item

24

Water Tank

Period

Check Point Action Note 1.To keep ball-screw, Liner Guide well-lubricated and not to rust, 6 times dry run per week is mandatory. 2.Be sure in advance dry run will not be interfered by objects like work-piece, Bellow, Power Cable…etc. Machine Dry Run Per 13 (5 axis full stroke) week 3 Inject grease another 8～12 times in Dry Run process while jogging forward each axis. 4.Inject grease another 8～12 times while Jogging backward each axis. 5.Lately, Jog each axis by full stroke for at least 5 times. Per 14 Wire suction device No suction or clogged clean month Per 15 Cabinet Filter Dirty or dusty clean month Per Clean with 16 Power Cabinet Dusty month vacuum Per Squeaking & not 17 Z axis linear guide Greasing month smooth Squeaking & not 18 U axis linear guide 3 month Greasing smooth Squeaking & not 19 V axis linear guide 3 month Greasing smooth Squeaking & not 20 X axis linear guide 3 month Greasing smooth Squeaking & not 21 Y axis linear guide 3 month Greasing smooth Take of & 22 Water flow valve 3 month Clogged or dirty M6,M7 magnet valve clean 23 Conductivity probe 1 month Dirty Clean 3 month Debris accumulation -60-

Clean


No.

Item

Period

25 Z axis Ball screw

6 month

26 U axis Ball screw

6 month

27 V axis Ball screw

6 month

28 X axis Ball screw

6 month

29 Y axis Ball screw

6 month

30

Upper/Lower Nozzle

per day

31

Lower Head

per day

32

Bellow

per day

Action

35

36

Paper Filter

Upper/Lower Energizer

Greasing Greasing Greasing Greasing Replace Clean or replace Replace

37 Upper Ground Wire 38 Lower Ground Wire 39 Upper/Lower Guide 40

Floppy Driver

Filter pressure over Replace per day 21.4psi (1.5 ㎏/㎝ 2) filter

3-5 day

Rusty or worn

Per week

Ground wire worn

Per week Per week

Ground wire worn Worn, cooling hole clogged

After 4 hours deionization.

Replace a pair at a time. Must be disposed legally.

Clean with solvent& Avoid solvent flow change into de-ionized contact water place. Screwed on Work Strap Table & Power or replace Cabinet. Strap or replace Clean or replace

Use disk Per Dusty, disk unreadable clean kit month -61-

Note

Greasing

Replace resin Clean or 34 Wire Leading wheel per day Not running smoothly replace 33

Water Conductivity per day Meter

Check Point Squeaking & not smooth Squeaking & not smooth Squeaking & not smooth Squeaking & not smooth Squeaking & not smooth Water column not concentrate Debris stuck & cause short Water leak from Bellow Conductivity does not increase


No. Item 41 Brush of motor 42 43

Period 3 month

44 Chiller Freon

Action Replace

Note

Worn

Replace

Between WHP & Upper Head.

Per year

Worn

Replace

Grounding

Per year

Poor cooling

Upper Power Cable Per year Lower Power Cable

Check Point Worn

-62-

Recharge freon

Wire - Edm Quick Start

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