WIRE - EDM Operation Manual

WIRE CUT- EDM Operation Manual

SOFTWARE VERSIONW5F F0800

MANUAL VERB

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 machines 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.

3. Push emergent switch 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.

4. Push emergent switch 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 machines power wire (in power cabinet, water

tank, or cooling machine.). Please contact our local agency first, or CHMER headquarter for this.

5. To avoid dangerous shock, be sure to stop electricity discharging before

installing copper wire and work-piece. 6. Do not touch any part around worktable (upper/lower head, wire and

water) during machining to prevent from high voltage strike. 7. Do not modify electrical circuit.

8. Please take reference to relative chapter in this manual for daily

maintenance. 9. Please keep this manual closely with the machine.

Thank you again for purchasing CHMERs product. Please call our Service Department at 886-4-23500979 anytime for technical support and repair. It is our honor to be at your service

INDEX

0-1 Company Profile-------------------------------------------------- 0-1 0-2 Safe Instruction--------------------------------------------------- 0-5

Chapter 1. System Introduction

1-1 System Composition--------------------------------------------- 1-1 1-2 Panel & Keyboard------------------------------------------------ 1-2 1-3 Machine Body & Filtration Unit------------------------------- 1-16 1-4 System Boot Up and Shut Off---------------------------------- 1-21

Chapter 2. W5F Software Function

2-0 Map of W5F Software 2-1 DISP Mode-------------------------------------------------------- 2-1 2-2 FILE Mode-------------------------------------------------------- 2-10 2-3 AUTO Mode------------------------------------------------------ 2-57 2-4 MAN Mode------------------------------------------------------- 2-85 2-5 DATA Mode------------------------------------------------------- 2-126 2-6 HELP Mode------------------------------------------------------- 2-136

Chapter 3 Application of G, M code

3-1 G Code Illustration----------------------------------------------- 3-1 3-2 Usage Description of G Code----------------------------------- 3-7 3-3 Auxiliary function (M Code)------------------------------------ 3-42 3-4 G, M Code Comparison with Others--------------------------- 3-47

Chapter 4 Appendix

4-1 Consumable List-------------------------------------------------- 4-1 4-2 Shield Room------------------------------------------------------- 4-5 4-3 Precaution for Malfunction-------------------------------------- 4-9 4-4 Setup of Remote Monitoring Software------------------------ 4-11 4-5 Lower Head Disassembled and Assembled------------------- 4-15 4-6 Upper Head Disassembled and Assembled-------------------

4-18

VER: E5B-1087B

DATE: 2012.01 EDITOR: Eirene Wu

CHMER Wire-Cut EDM Operation Manual W5F

0-1 Company Profile CHMER BRIEF EVENTS:

1.1975 CHMER EDM company was foundedwith registered capital NT$200.000.-to market the firstTransistorEDM machine in Taiwan.

2.1976 The first hydraulic control EDM machine came out. 3.1977 EDM machine with the functions of free adjustment of pulse on & off

was produced. 4.1979 Moving to the new factory for developing southeast-Asia market. 5.1980 Leading to export EDM machine made in Taiwan to Europe. 6.1981 Supplying the first EDM with P.W.M. servo motor driver to the

domestic market. 7.1982 Achieving two patents for the new square axes with national central

standard bureau of the republic of China. 8.1983 The first EDM manufacturer obtainingGolden dragon awardform

the government. 9.1985 In April, the first multifunctional CNC EDM machine equipped with

orbit-cut was produced. In July , the first EDM machine with the finest and super finish device

of U-SPARK In Taiwan was produced. In August, Sound Best Trading Co., Ltd Established. In September, Hung Yu Trading Co., Ltd Established. 10.1986 In February, Ching Yeng Machine & Electric Co., Ltd Established. 11.1987 In July, the first EDM machine without backlash on x & y axes was

marketed. In April, the WIRE-CUT EDM machine was completed and obtained

the excellent-product design award from CETRA of Taiwan, ROC 12.1988 In August, small hole drilling EDM was completed. In December, President Wang was honored with the model of

business founding youth for the 11th term. 13.1989 In March, the giant bridge type of EDM was created. In April, marketing new type of CNC EDM which interfale was

available for modifying to sparking conditions during machining. In Jun, Chiao Yeng Machine Co., Ltd. Established. In Jun, Hwang Long Machinery Industrial Co., Ltd. Established. 14.1990 In October, obtaining the patent for structure improvement of the

giant bridge type of EDM NEW MODEL NO.58428 0-1


15.1991 In October, the patent for improvement structure of the worktable guide bridge type of EDMNEW MODEL NO.68192

Obtaining the patent for improved structure of the Prototype of EDM tank ascending & descendingNEW MODEL NO.74419.

16.1992 In September, capital increased up to NT$50.000.000.- 17.1993 In October, moving to the new factory with airconditioning system to

enlarge production covering digital products of high-scientific technology.

In Sep, Hang Zhou Ruipeng Machinery & electric Co., Ltd Established. 18.1994 In January, NC EDM with programmable Z axis, model CM240Z+50NZ,

& CNC EDM with PC base controller, model CM240Z+50NC, achieved excellent product award of ITS VERY WELL MADE IN TAIWAN from CETRA in Taiwan.

In March, Sound Best Automaticalization Industry Co., Ltd Established. In December, Yukon CNC Machinery Co., Ltd. Established. 19.1995 In January the 1st EDM manufacturer, in Taiwan, obtaining certificate of

quality assurance specified as ISO 9002 form the BCIO of Ministry of Economic Affairs.

In March, President Wang, received Award of GOLDEN TALENT as INVENTIVE ENTERPRISER from INDUDTRY ASSOCIATION OF TAICHUNG, TAIWAN.

In November, Honored as MODEL OF INDUSTRY form Taichung County Govern.

In December, obtained GRAND GRAGON CENTURY AWARD OF TAIWAN.

20.1996 In January, obtain Attestation of conformity for technical file and non-annex IV machinery with the requirements of the machinery directive 89/392/EEC FROM NOTIFY BOY

AMTRI VERITAS LTD. certificate numberAV EC 1105G. In February NC EDM with programmable Z axis, model

CM380Z+50NZ & CNC EDM with PC base controller, models CM855C+75NC, CM645C+75NC achieved excellent products award of ITS VERY WELL MADE IN TAIEAN from CETRA in Taiwan again.

In August, the products of wire-cut EDM, CNC EDM & NC EDM WITH PROGRAMMABLE Z AXIS obtained

THE INTERNATIONAL GOLDEN GLOBE AWARD FOR 0-2


EXCELLENT EXPORT PRODUCT MADE IN TAIWAN.

21.1997 In Jan, CNC wire-cut EDM models CW430F, CW430W, CW530F, Cw530W obtained award of ITS VERY WERY WELL MADE IN TAIWAN

22.1998 CNC Wire-cut EDM models CW640 obtained award of ITS VERY WELL MADE IN TAIWAN.

23. 1999 Obtain Rising Star Award and National Award. 24.2000 Enterprises Professional Manager Award. The 67th of Top 100 up growth backbone enterprises. Statistics by Common

wealth magazine.

25.2001 Provide fist precision bridge CNC wire cut EDM & CNC powder EDM.

The 29th of Top 100 potential enterprises Statistics by Common wealth magazine.

26.2002 In January, CW432S A53C+75N obtained Award of ITS VERY WELL MADE IN TAIWAN

In February, obtained certificate of quality assurance of ISO 2000 Version.

27.2003 In January, CM434Z+50EZ obtained Award of ITS VERY WELL MADE IN TAIWAN

Register into Emerging stock market. In September, CM323Z+50EZ+OB-head obtainedMiddle

Enterprise Innovation Research Award In November, CHMER obtained The Nest Innovation research

Company award. 28.2004 In January, CW-32CF/Swire-cut EDM models obtained of ITS

VERY WELL MADE IN TAIWAN award. In March, CHMER obtained ISO 14000 Quality system certified, who

is the 1st among EDM manufacture in Taiwan. In March, Introduce the 1st linear motor high precision wire-cut EDM

in Taiwan. 29.2005 In January, P42SL high precision wire-cut EDM model obtained of

ITS VERY WEEL MADE IN TAIEAN award.

0-3


COMPANY ORGAIZATION Taichung Headquarters 1.CHING HUNG MACHINERY & ELECTRIC INDUSTRIAL CO.,LTD

No.3, Jing-Ke 1st Road, Nantun District, Taichung City 408, Taiwan TEL:+886 4-23509188 FAX:+886 4-23509199

2.Taipei Branch office

HUNG YU TRADING CO.,LTD. NO.13,Dec4.Chung Hsing Ed , San Chung City, Taiwan, R.O.C TEL02-2988-8668 FAX02-2985-0850

3.Hang Zhou Factory

HANG ZHOU RUIPENG MACHINERY & ELECTRIC CO.,LTD.

No.25,Ningdong Road Xiaoshan Economic Techinical Development Zone TEL0571-8283-1032 FAX0571-8283-2034

0-4


0-2 Safety Instruction

0-2-1Machine stop

When the emergency occurs, operator can stop machine by following two ways

Emergency Stop & Main Power switch.

Emergency StopWhen pressed, except of computer power, motors, pumps

would be shut off.

Main PowerWhen turned off, the power of machine and Power Cabinet will all be shut off.

No Fuse BreakerBe sure to turn off no fuse breaker and main power before

maintenance.

0-2-2 Precaution of safe operation A safe operation is relying on complete precautions to occasional accidence, machine breakdown and operator negligence. Please keep these in mind and check machine security every time before actual operation. Even though, there are many built-in safety constructions in machine, still possible to have potential dangers if depends on machine too much and absent the precautions in mind.

Emergency Stop

Main Power

No Fuse Breaker

0-5


0-2-3 Operation precautions 1. If find or smell or hear any abnormal conditions, please press emergency

stop button immediately then start to locate the problem. 2. There will have fatal high voltage high current passing through on duration.

Therefore, strictly prohibit touch anywhere is above water pan during sparking.

3. There also will have electric power on traveling wire from wire spool to wire waste box. Prohibit to any parts wire will contact during sparking.

4. Keep away from XY axis and its metal covers for potential finger-folding injury at jogging XY plane.

5. There always will have water on worktable & water pan. Dont stand on it anytime.

6. Screw well PE ground lines in power cabinet and electrical boxes (on machine column & water tank) for avoiding electric shock.

7. When power on will start exhaustion fans. Dont insert your fingers into fans or its filters.

8. Dont open power cabinet doors (front door & rear door), doors of electrical boxes or metal covers of machine body for avoiding electric shocks.

9. When machine shut down, there still have electric power on capacitors. Dont touch it.

10. Dont let water splash on power cabinet or electrical boxes for avoiding electric shock.

11. Stop machine immediately when finding out split/broken plastic coated of electrode cables (connect between machine body & power cabinet) and, dont start machine before repair

12. Dont dismount lines with E or PE marks ground lines to keep away of electric shock.

13.On machine duration or after machining, there will have higher temperature on work piece. Dont touch it directly by hands.

14.Watch out of finger cut injury or, as put on work piece with sharp edge or put on wire spool.

15.Please must shut down main power switch before opening power cabinet doors or electrical boxes.

16. Please check and screw well fork pins on terminal blocks before powering on. If any loosen pin and power on, may cause unbalance power input, motor noise, motor burning, terminal block burning.

17. Regarding the waste materials like silt, lubricating, paper filters, used wire, ion resin and broken parts please take over with quality recycle dealer or obey local deposition law.

18. For taking care of water splash out shall open upper / lower flushing knobs from minimum to maximum.

0-6


19. Avoiding water splash on floor at any time, that has potential dangers people fall down or get electric shock.

20. The light from the work-lamp could generate high heat on the items illuminated. Please be aware and keep fusible material such as plastic cables away from being irradiated by work-lamp.

Safe operation and place for the personnel

1. Get rid of metal chips, water or oil is onto around the machine. 2. Operator puts on safe glasses and safe shoes. 3. When move in/ move out the work piece from working table, watch out the

fall down risk.

Checking points for safe dielectric cutting 1.Ensure work piece is fixed well by proper jigs and fixture ways on working

table. 2.Wire electrode is loading and traveling well by instructions. 3. Electrode cables / ground lines

a. Are they screwed properly b. Cable coating in good conditions without any split c. Upper/ lower nozzle distances are adjusted well wont crash to each

other

Precaution of the use of stainless steel

1.The improper way of material conservation will shorten its life span. Stainless steel tends to erode more rapidly after in touch with other materials.

2. The rust from other material could be passed to stainless steel if not properly stored.

Checking points before cutting

1.Dielectric level is set properly (Submerged model) 2. Is dielectric level dropping down accidentally 3. Is work tank locked properly (submerge type). 4. Is Rubber Seal of tank door damaged

Checking points while cutting

1. Make sure no leakage of dielectric. 2. Upper/Lower flush pressure were adjusted to be coincident

0-7


3. Is Cutting technology well setup? 4. For no-man operation, please make sure machine can achieve

a. Smooth and reliable cutting condition? b. Constant and stable flush pressure? c. Dielectric level (for submerge type) remains constant

0-8

Chapter 1.

System Introduction

1.1 System Composition 1-1

1.2 Panel & Keyboard 1-2

1.3 Machine Body & Filtration Unit 1-16

1.4 System Boot Up and Shut Off 1-21


1-1 System Composition

Wire Cut machine is consisted of three major partsPower Cabinet, Machine Tool, and Filtration Unit.

1. Power Cabinet Contains majority of fuses, TFT LCD Display, Power Line, Computer and Sparking Circuit.

2. Machine Tool There are two types of Machine Tool: Submerged and Flushing, which differed from each other by whether equipped with (S) a stainless tank or not (F). For example, CW 530S, CW 530F.

3. Filtration Unit

For dielectric filtration and de-ionization.

Power Cabinet

Machine Body

Filtration Unit

Filtration Unit

1-1


1-2 Power Cabinet, Console Panel and Remote Control

1-2-1 Power Cabinet & Console Panel

Console Panel

1

6

2

3

3

4

5

Power Cabinet

9

8

10

1-2


1. Analog Voltage Meter Display the variation of EDM voltage to control machining speed.

2. Monitor 15(standard) TFT LCD monitor.

3. Control panel a. Text key: for normal information and number input. b. Hot key: control the EDM conditions. (e.g. EDM power supply, dielectric,

wire feed rate and tension) c. Function key: system function execution.

4. Buzzer Provide warning sound to remind the operator.

5. EMG-stop button Under any situation, push this button will cut off power of the controller.

6. Main Power Switch Main switch of the CNC controller.

7. Remote control Contains basic hot key to operate the machine.

8. No Fuse Breaker ON/OFF switch for electric current inflow and overload protection.

9. CF Card Drive/ USB Card Reader (Reserved for OPT) Data storage interface of NC program from external computer. CF memory card or USB for data storage.

10. CNC Power ON button This button is for CNC controller power actuation. After switching on the main electric power, push this button will actuate the CNC controller. Also, its power indicator will be on at the same while.

Optional Functions (have to confirm controllers version)

a. Microsoft Mouse / Touch Screen b. Memory CF Card capability c. Installing in-house GENTEC Remote Monitoring software enables N.C. file

download /upload, watching on machining status from Client PC through Internet

1-3


1-2-2 Introduction of text keys 1. A~Z

Input key of English alphabet 2. 0~9

Number input 3. Page up, Page down

For page exchange (NC program or column) 4. Home, End

When executing program edit or data input, move the cursor to the left or right of the line.

5. Back When executing program edit or data input, move the cursor backwards and delete the original bit.

6. Space Blank bit.

7. Enter For data input, function execution or lines addition during program editing.

8. Ins Switch knob of character insert or replacement when editing program.

9. Del When executing program edit or data input, delete the character on the cursor

10. ,

For cursor movement or working data change when executing program edit or data input.

11. ,

For cursor movement when executing program edit or data input. 12. +/-

Positive/negative marking of input data or increase/decrease of EDM data. 13. Esc

Cancel the input data.

1-4


1-2-3 Introduction of quick function key

Operator could apply below quick command

1. Use / button to change the value of each item of sparking data.

2. Type S ??? (ex: S045) in Data Bar is to backup current sparking data to

S-code No. 045.

3. Type E ??? (ex: E045) in Data Bar is to call up existing sparking data from

S-code No. 045 for use.

4. To reset Work Coordinate., type R in Data Bar then press ENTER.

5. To specify the value of each axis in Work Coordinate., type X??? Y???

Z??? U??? V??? in Data Bar then press ENTER . ??? is specified value.

6. To move axis incrementally, type MX??? MY??? MZ??? MU??? MV???

In Data Bar and press ENTER. M actually means Move.

7. To move axis by specific Coordinate. System, type M#X??? M#Y???

M#Z??? M#U??? M#V??? in Data Bar and press ENTER. # (0Machine

Coordinate. / 1PGM / 2G92 / 3Work Coordinate.)

8. To move axis to reference point (G054~G959), type MG#5$X??? Y???

Z??? U??? V???.# ranges from 0~9, and $ is from 4~9.

9. To move 1/2 distance of what mentioned from 6.~8., type MX/2, MY/2,

MU/2, MV/2.

10. In Data Bar, type GO and press ENTER , machine will move to the zero

points of the coordinate system where the cursor is currently on.

11. To execute N.C program from specific line, type N??? under

MEM\F1(MEM. PATH) when RESET button is lit on.

1-5


1-2-4 Introduction of operation key

1. JOG If this button is pressed, four kinds of table moving speed are selectable including H (high speed), M (middle speed), ML (speed between middle and low) and L (low speed). Under this mode, if the axis-moving key is pressed, the table will move by setting speed. If it is released, the table will stop moving.

Note: 1. If the JOG button is pressed twice in 1 second, it will execute AUTO mode. 2. The value of JOG feed-rate override may adjust in the mode Help-2

>System Double Value Parameter, PA#36~PA#41 (We strongly

recommend user may not modify the value at will, otherwise it may cause unexpected damage to machine tool)

2. STEP JOG

If this button is pressed, the table will move by set increment. The set increments include H (1000), M (100), ML (10) and L (1). Under this mode, if the axis-moving key is pressed one time, the table will move 1 increment distance. If you want 2 increments movement, press the axis-moving key twice.

1-6


Note: 1. Additionally increases the JOG speed to be 2 steps. Setting method: Press H or M key twice in 1 second. Flash indicator means that setting is finished.

2. The value of STEP JOG feed-rate override may adjust in the mode

Help-2>System Double Value Parameter, PA#42~PA#47 (We

strongly recommend user may not modify the value at will, otherwise it may cause unexpected damage to machine tool.)

3. H, M, ML, L These four keys are for speed setting under JOG mode. However, they are for moving distance setting under STEP JOG mode.

Note: 1. Additionally increases the JOG speed to be 2 steps. Setting method: Press H or M key twice in 1 second. Flash indicator means that setting is finished.

2. The value of STEP JOG feed-rate override may adjust in the mode

Help-2>System Double Value Parameter, PA#42~PA#47 (We

strongly recommend user may not modify the value at will, otherwise it may cause unexpected damage to machine tool.)

4. +U/+X-U/-X+V/+Y-V/-Y+Z-Z

These are axis direction keys. Under JOG or STEP JOG mode, they could control the moving direction of the worktable.

5. UV/XY This is direction switch key. When the indicator is lit, it represents XY plane. On the contrary, it becomes UV plane. (Parameter 68 bit 1)

6. VERT Press twice quickly, then worktable will return to vertical point; it ends up when the LED lights on.

7. S.PT This key is for start point quick return. When it is pressed, the worktable will return to start point quickly. If the indicator is lit, it represents that the present position is the start point.

1-7


8. B.PT This key is for break point quick return. When it is pressed, the worktable will

return to wire break point quickly. If the indicator is lit, it represents that the present position is the break point.

9. RE-TRACE S.PT

This key is for start point tracing. When it is pressed, the worktable will return to wire break point then return to the start point along the previous machining path at last. (Auto wire feeding)

10. TRACER B.PT This key is for break point tracing. When it is pressed, the worktable will return to start point then return to the wire break point along the previous machining path at last. (Auto wire feeding)

Note. 1. Those four path trace functions #7~#10 can only be executed one at a time.

2. The data of trace path according to the last G92 coordinate in processing. 3. While reboot the machine, it restore the last path data which had been stored.

4. Press can interrupt during the trace function is activated. 5. User can start these four functions (path trace) when EDM spark power is activated (Water flushing, wire feed, spark, ED -POS). 6. Auto wire feed would be activate when execute those trace functions.

11. OPT STOP

This is for optional pause. When the indicator is lit, if the program is executed to M01, the machine will pause and systems of water supply, wire feeding and electric power are will be off. If the indicator is off, M01 will be ignored.

12. BLOCK SKIP This is for optional block skip. When the indicator is lit, the block interval marked by / will be ignored. When the information is loaded from memory to buffer area, the skip setting will be kept. This bottom is unavailable during processing is activated.

13. SINGLE BLOCK This is for single block execution. When pressing this key during program

1-8

CHMER Wire-Cut EDM Operation Manual W5F execution, the indicator will be lit. If the START key is pressed, program single block will be executed. After that block is finished, the machine will stop moving. If you want to continue the next block, press the START key again. Generally, it is for program path inspection.

14. DRY RUN This is for trial run without real sparking. Screen would display program path while table is moving. Be sure to turn it off after the trial run. We could use STOP key to pause it and START key to keep it moving.

Note. 1. DRY RUN speed can be adjusted by JOG on console panel (Flag#042=ON).

2. Keep pressing the button twice in 1 sec to disable/enable.

15. MACH LOCK To lock up machine table when program is running (But Machine doesnt move) and only does Absolute coordinate showing the position move.

Note: MACH LOCK is unavailable during processing is activated.

16. START Press this key to execute system function or start running a program. When the indicator is lit, it means that the machine is moving. On the contrary, the machine is in idle status.

17. STOP Press this key to interrupt system function or program execution. When the indicator is lit, it means that the machine is idle. On the contrary, the machine is in working status.

18. WATER Pump switch of flushing water coming from upper/lower nozzle.

19. WIRE

Wire feeds from the spool with 7V~8V on the wire.

20. EDM POWER Open and close the relay of erosion power.

21. ED POS Switch of erosion power signal that release the energy from Power Cabinet.

1-9


22. WIRE BREAK If there is wire break, the indicator will be lit. After the wire is re-threaded, the indicator will be off automatically.

23. SHORT If the wire touches the work-piece, or the wire is not threaded properly, it will cause short between the wire and work-piece. Then, the indicator will be on. If the problem hasnt been solved, the machine cannot work.

24. MIR / ROT / SCALE If the machining program is under function of MIRROR, ROTATION or SCALE, the indicator will be on automatically.

25. RESET

To remove the current processing from memory and initialize its working condition setup. Press the button once, then a window comes up and ask if to

reset the processif press the button twice quickly then program will be reset

automatically. Then the LED lit means initialize progress is success, user can modify the setting i.e.: offset, taper cutting data.

26. RE-START

To resume program removed by RESET or interrupted by power black out.

Note. 1. To execute RE-START, must be lit on.

1-10


Re-Start Procedures

(After program reset) (After power blackout)

27. Servo When lit on, dielectric, wire feed and eroding power will be automatically activated while executing a N.C. program.

28. Axis Exchange

29. X Mirror

30. Y Mirror Note: These three functions #28~#30 are to change the path of NC program. The LED lit means that mirror function now is activated.

Push twice rapidly

Search for last file

Push AUTO

Press twice

Push

Job resumed

Back to break point

Push AUTO

Press twice rapidly

Press twice Search for last file

Push

Job resumed

Back to break point

Search Home for 5 axis

1-11

CHMER Wire-Cut EDM Operation Manual W5F Ex

31. AWT thread wire and then stop on present location. Press START to

resume.

32. AWT cuts wire and then stop on present location. Press START to resume.

33. Wire Retract When pressing this key, if the indicator is on, the wire will be retracted automatically. When pressing it again, the function will be off.

34. Press this button the controller will hold on machining until work-piece is completely submerged.

35. AUX2 Spark calibration (align UV axis) with default S-code.

36. Drain Push the button to drain out the water in the work-tank.

37. Water-IN Push the button to start filling up work-tank.

Mirror X Mirror Y Mirror X&YMirror

Axis exchange X Y X&Y

1-12


1-2-5 Remote Control

NO NAME FUNCTION AND DESCRIPTION

1

ZLOCK(For Z-axis anti-collusion)

Z LOCK (MAN F1 SEARCH HOMEZ.LOCK.SW )

Stop Z-axis from going down further than the set point. To

lock/unlock, push the button twice rapidly.

2

JOG/ STEP JOG

Switch the mode between JOG/STEP JOGwhen LED lit

means JOG mode be activatedlit off means STEP JOG

mode is activated.

1-13


3 AUTO

Enter to processing modeAUTO

4

JOG Feed-rate

Manual JOG Feed-rate speed override.

H/M switch ML/L switch

5 EDGE CENTER

Edge MAN F5 (Edge Move)Mode 0.

CenterMAN F5 (Edge Move)Mode 2.

6 SERVO

When lit on, dielectric, wire feed and sparking power will be automatically activated while executing a N.C. program.

7 Coordinate zero return

Zero return the local coordinate value of XY or UV axes on LCD display of remote. HELP->F3 WORK PARAM -> Page 2/3 ->LCD Coord. ID = 3

8 Air Blow For AWT to expel waste wire.

9 For AWT AWT feed the wire.

AWT system feed the wire.

10 For AWT Cut wire

AWT cut off the wire.

11

Pump

Water Pump. Press this button then LED lit, water pump ON, start flushing on upper/lower head. Again press this button then water pump OFF, stop flushing.

12 Wire Feed

Wire feeds from the spool come with 7V~8V also show on Analogue/Digital voltmeter.

13 EDM POWER

Open and close the relay of erosion power.

14 ED-POS

Switch of erosion power signal that to release the spark energy from Power Cabinet.

1-14


15

SHORT

If the wire touches the work-piece, or the wire is not threaded properly, it will cause short between the wire and work-piece. Then, the indicator will be on. If the problem still, the machine cannot work. User have to clear all the possibility why short be caused.

16

Break Point Return

This key is for break point quick return. When it is pressed, the worktable will return to wire break point quickly. If the indicator is lit, it represents that the present position is the break point.

17 Wire Breaks

If there is wire break, the indicator will be lit. After the wire is re-threaded, the indicator will be off automatically.

18 Suction

Vacuum suction to assist wire threading.

19

UV / XY Axis

Switch Up

This is direction switch key. When the indicator is lit, it

represents XY plane. On the contrary, it becomes UV

plane.

20 START

Press this key to execute system function or start running a program. When the indicator is lit, it means that the machine is moving. On the contrary, the machine is in idle status.

21 STOP

Press this key to interrupt system function or program execution. When the indicator is lit, it means that the machine is idle. On the contrary, the machine is in working status.

22 DRAIN

Push the button to drain out the water in the work-tank.

23 WATER FILLING- IN

Push the button to start filling up work-tank.

1-15


1-3 Machine Body & Filtration Unit

1-3-1 Work table

Use the buttons on Remote Control or control panel to move Work-table. XY axis

move by table while UV axis by Upper Head. Use speed button for optimum federate.

1-3-2 Wire Transport System

Below illustrations indicate how to locate cutting wire for both AWT and non-AWT wire transport system.

+Y

-X

+V

-Y

+X

+U

+Z

-Z -U

-V

Wire transport of non-AWT 1-16


1-3-3 Jumbo Wire Spooler For the use of wire spooler over 7Kg, Jumbo Wire Spooler can fit up to 30Kg wire spool.

1. Connect power line to 220V. 2. Put a reel of cutting wire properly. 3. Follow the figure pasted inside and bring wire through the wire transport system. 4. Done.

Note: 1. Jumbo Wire Spooler feature requires AWT system 2. Wire Spool used must be no larger than below dimension.

Bobbin name

Flange diameter

Barrel diameter

Outer width

Flange thickness

Arbor hole diameter

D d L a H

355mm 222mm 200mm 19mm 38mm

Wire transport of AWT

1-17


WORKING

WATER LOW

UP

DOWNPRESENTVALUE

SET/SAVE

SV

PV

K

DIGITALWATER CONDUCTIVITY

VALUE

1-3-4 Control Panel of Filtration Unit

1. Digital Water Conductivity Meter

SET/SAVE VALUE: Target conductivity value PRESENT VALUE: Current conductivity value UP: value + DOWN: value - WorkingDeionization activated Water lowLevel alarm SV (SET/SAVE)New target setup PV : System stand-by

Floor layout of Jumbo Wire Spooler

1-18

CHMER Wire-Cut EDM Operation Manual W5F Operation of Digital Conductivity Meter

1. Normally, 5 seconds after machine power turned on, PV will be lit on, which

indicates the digital conductivity meter is displaying correct value and in stand-by status.

2. Next, press SV button, the screen will display previous target value, which can be readjusted by UP and DOWN button.

3. When new setup is done, press SV button to save it into memory; if not save the value, the value may as same as previous value and then return to PV mode after a few seconds.

4. Once the new target value is set higher than current one, deionization process (Working lit on) will start until new target value reached; however, if new target value is smaller than current one, water conductivity will remain the same until ion-resin completely consumed or diluted by new tap water.

4. When water level is too low, WATER LOW alarm will be lit on and blocks deionization process temporarily until alarm dissolved.

5. The latest status of Digital meter before system shut down will be memorized.

Note (1). Cleaning of probe. It is recommend clean the probe once every month to maintain the accuracy of measurement.

(2). Push PV button to exit SV mode any time. (3). To avoid de-ionization over frequently, the activation will be put off for a

default period. 2. Flush water regulation (1). Flush Knob (Up)

Adjust flush pressure. Optimum value

is 0-15kg/cm2. (2). Pressure Gauge (Up)

Indicate flush pressure when mechining.

(3). Flush Knob (Down) Adjust flush pressure. Optimum value is 0-15kg/cm2.

(4). Pressure Gauge (Down) Indicate flush pressure when mechining.

+

SKON

CL

SE

EN

O

O

P

+

SKON

CL

SE

EN

O

O

P

1-19


(5). Paper Filter pressure gauge Indicates the interior pressure of Paper Filter. Once it exceeds 2kg/cm2 , it should be replaced to maintain machining performance.

(6). Water low alarm

Indicated insufficient water inside Filtration. Fill up the tank with distilled water properly to avoid idling water pump.

3. Water level indicator Once the lever drops down to red area, please refill immediately to avoid pump dry run.

red

blue

1-20


1-4 System Boot Up and Shut Off

1. No Fuse Breaker: ON/OFF switch for electric current inflow and overload protection. However, while instantaneous over current over 50A, the switch will turn to OFF automatically. In this case, please find out and eliminate actual causes before power recovery.

2. Main powerAfter turn on No Fuse Breaker then switch on main power. 3. Emergency StopShut down motor driver, filtration pump and eroding power

once pressed. To recover the power, release Emergency stop and push Green Button.

4. Green ButtonLit on and activate motor driver, filtration pump and eroding power once pressed. (This button is only for open power; please press Emergency Stop to shut down machine.)

1-4-1 System boot up 1. Press the Emergency Stop Button. 2. Turn on the No Fuse Breaker. 3. Turn (right) on the rotary switch. 4. Controller runs BIOS and boot up. 5. Introduction page and operation screen appear.

Power Cabinet

1

2

3

4

1-21


A few seconds...

6. Release Emergency Stop. 7. Press Green Button and activate machine body (motor drive, filtration pump and

eroding power) 8. If there is no any error message appear, proceed Homing for each axis.

Introduction page

Operation screen

1-22


1-4-2 Homing Asterisk symbol * (*X,*Y,*Z,*U,*V) indicates a specific axis position is not tracked by the controller. Please do Homing and eliminate asterisk before start machining. The procedure of Homing is described as below:

NoteZ-axis home reference point equal to Z-axis height setting.

Press MAN

Press F1 Search Home

Screen shows Search Home message.

Press axis arrow keys: X+ Y+ U+

V+ Z+

Search Home finished when all * disappear.

Machine begins to move?

YES

NO

YES

Alarm Message

Terminated

Press

must be on and turn off AR and Protect Flag.

NO

YES

1-23


1-4-3 System Shut off 1. Press Emergency Stop. 2. Turn (left) on the rotary switch, and UPS (Uninterrupted Power Supply) start

beeping in the meantime controller begins data back-up. 3.Power shut off.

Note: 1. Please hold on at least for 30 seconds to recover machine power (Green Button) after Emergency Stop to prevent from possible damage on motor driver and circuit boards.

2. Do not execute file up/down load during system shut off.

1-24

Chapter 2. .

W5F Software Function

2.0 Map of W5F Software

2.1 DISP Mode 2-1

2.2 EDIT Mode 2-10

2.3 MEM Mode 2-57

2.4 MAN Mode 2-85

2.5 DATA Mode 2-126

2-6 HELP Mode 2-136


2-0 Map of W5F Software 2-1 DISP Mode

2-2 FILE Mode

F2 Flag Message

F3 Data Info

F1 Axis Message

F7 Block Message

F6 Motion Message

F5 IO Status

F4 IO History

F1 Open N.C Program

F2 Save N.C. Program

F8 Delete Line

F3 Save As Program

F5 Receive N.C.

F6 (Reserved)

F7 Undo

F9 (Reserved)

F10 N.C. Browser

F1 Sure Execute

F2 (Reserved)

F5 (Reserved)

F7 Store Browser1

F6 (Reserved)

F9 Removal Browser

F10 HD Browser

F3 (Reserved)

F4 (Reserved) F4 Close N.C. Program

F8 Store Browser0

F1 Edit N.C PGM F2 Copy N.C. PGM

F10 HD Browser

F9 Removal Browser

F8 Store Browser0

F7 Store Browser1

F3 Delete N.C. PGM F4 Send N.C. PGM F5 Protect Switch

F6 Pick N.C. PGM

Page 1/3

F8 AWT Message


2-3 AUTO Mode

2-4 MAN

F1 Set String

F6 Cancel M. Block

F5 (Reserved)

F2 Search String F3 Insert String F4 Replace String

F7 Delete M. Block

F8 Move M. Block

F9 Copy M. Block

F10 Set M. Block

F1 Move Line

F6 SIM. H. VAR.

F2 Search N. Code

F5 SIM. Data

F3 (Reserved)

F4 SIM. Skim

F7 SIM. D. OFT

F8 Spark Offset F9 Figure Color F10 SIM. Execute

F1 MEM Path F2 MEM Data 1.

F8 MEM Hole

F7 MEM D. OFT.

F3 MEM Data3

F4 MEM Data4

F5 Corner Data

F6 MEM H.VAR.

F9 Figure Color F10 Path Zoom

F1 (Reserved)

F9 Scope

F2 MEM Coord. F3 MEM Record

F8 MEM NC. PGM

F7 Cut NO. INFO,

F6 (Reserved)

F4 MEM Skim F5 (Reserved)

Page 2/3 Page 3/3

Page 1/2 Page 2/2

F10 Path Zoom


2-4 MAN Mode

2-5 MDI Mode 2-6 HELP Mode

F4 Net Set

F3 Work Set

F2 Device INFO.

F1 System Message

F5 Message Text

F6 Help Text

F1 Search Home F2 MDI Move

F10 Corner Move

F9 Angle Move

F8 Record Move

F7 Coord. Move

F3 VERT Move F4 DA, DB Move F5 Edge Move F6 MDI Cut

F1 Open Move F2 3PT Move F3 Board Move F4 Edge Align

Page 1/2 Page 2/2

F1 S. Data List

F6 Corner Base

F5 (Reserved)

F2 DEF. S. Base F3 Search Offset F4 USE S. Base

F7 Modify Corner

F8 (Reserved)

F9 Delete Datas

F10 Copy Datas F10 Exit System

F9 Installment

F7 (Reserved)

F8 Mark Color


2-1 DISP (Diagnostic Mode) Operation Guide

2-1-1 F1 (Axis Message)

This sub-function displays the internal information of all axes on the controller. The work data of axes are on the right hand side.

Note. The Diagnostic Mode provides the correct information for

maintenance personnel to handle machine errors.

Axis Message Screen

2-1


2-1-2 F2 (Flag Message) This sub-function displays the status of all flags on the console to facilitate maintenance personnel to understand the work status of the console. There are 24 pages (F000~F999) in this sub-function, press PgUp and PgDn buttons to turn pages.

Note: The Diagnostic Mode provides the correct information for

maintenance personnel to handle machine errors.

Flag Message Screen

2-2


2-1-3 F3 (Data Info.)

For Maintenance Personnel Use (displays internal data value of controller)

Data Info Screen

2-3


2-1-4 F4 (I.O. History)

For Maintenance Personnel Use (this sub-function records the time, date and status of the changes of I/O data of controller peripherals to facilitate maintenance personnel or designers to check the status of machine errors. The system provides the records of the last 1000 changes).

I/O History Screen

2-4


2-1-5 F5 (I.O. Status) For Maintenance Personnel Use (this sub-function displays the work data of all I/O interfaces on the controller, including IO232, HK232, RK232, SPC232, and ATC232 modules)

I/O Status Screen

Function Description

0: Interface error code. The value should be 0, meaning that the system works

properly. 1: Send/Receive delay time, expressed in ms. 2: Send/Receive packet frequency (the value increases if succeeded but remains

the same if disconnected). 3: The 2 bytes on the leftnumber of characters sent/received; the 2 bytes on

the rightthe total number of characters sent/received. 4~19: Data stream of characters sent/received.

2-5


2-1-6 F6 (Motion Message) For Maintenance Personnel Use (this sub-function displays the value of motion module data to reflect the machine movement status.)

Motion Message Screen

2-6


2-1-7 F7 (Block Message) This function contains latest 1000 sets NC program single block machining information.

Block Message Screen

1. Enter S+Enter: Controller may arrange in time order automatically 2. Enter D+Enter: Controller may delete the information where the cursor located 3. Enter TH=40+Enter: Controller may modify present locations working

thickness information 4. EnterR+Enter: controller may record sparking condition in 1 sec

2-7


Contents Description:

Present Single Block Information: 1. Mainly and Secondary reference coordinates

2. Average Gap Voltage and Feed-rate

3. Single block path length \ Present position

4. Block Status: First line: The ratio of Erosion power reduction

and distance variation

Second line: Status about Corner

Third line: The activated s-code data, OVPW=LP

Fourth line: The activated s-code data, ONOFFANAFF

Fifth line: The activated s-code data, SVFRWFWTWL

Block information record for latest 1000 blocks

Block Number

Start Cutting Date Finish Cutting Time

Start PT. Ang. End PT. Ang.

Path Len. Of Main PGM

Path Len. Of Aux. PGM

Average Volt.\Diff. Highest \Lowest

Breaks Short

S. Code Data Average Speed / Erosion energy ratio

Water conductivity, Efficiency of erosion, Gap Voltage, Feed-rate and S-code Data

2-8


2-1-8 F8 (AWT Message)

For Maintenance Personnel Use (This sub-function displays the movement status of machines during wire threading.)

AWT Message Screen

2-9


2-2-1 EDIT-1 Page

The function keys in File allow users to operate all NC program and file functions. There are 3 submenus in this function menu; users can select 3 submenus with Arrow Buttons.

Submenu (EDIT-1)

Submenu (EDIT-2)

Submenu (EDIT-3) 2-10


EDIT P1 Screen 1. If the name of the current NC program has been changed, an asterisk * will

appear in front of the program name. 2. Total number of files currently opened; it gets to 8 files at one time. Press TAB

key to flip the opened files and F4 to close the opened one. 3. Cursor status: To type and edit program now staying REP (replace character) Or

INS. (insert between character) While status stays REP then curse status

2

4

3

1

6

5

2-11


becomes ___ otherwise the curse status becomes for INS. 4. Cursor position L:

a/b ; C: s/t. L: a means total lines, and L: b means which line the cursor is on; C: t represents total bite and C: s means the bite position in a line.

5. Editing area. 6. In a NC program, letters are in red and numbers are in blue to prevent confusion. .

2-2-1-1 F1 (Open Program) This item allows users to load the file from the storage device to the computer for execution, modification or editing a new NC program.

1. Press F1 (Open Program) Enter in the dialog box at the center of the screen the name of the file you wish to open and the storage device (0: hard drive; 1: diskette; 2: web; 3: CF card). (Enter a new file name to create a new file. In this case, you must choose hard drive 0 as the default storage device (DOC).

2. Press F1 (Sure Execute)Open file.

G 92 X 0 Y 0

Blue

Red

2-12


2-2-1-2 F2 (Save Program) This function allows users to save an opened NC program to the storage device. When saving files, the function key will go down, and the asterisk * in front of the filename will disappear. When the function key goes up again, the saving process has been completed.

2-2-1-3 F3 (Save As)

This function allows users to save NC program in a new name or in another storage device. The process is the same as Open ProgramF3 (Save As) Enter a new filename or the new storage device F1 (Sure Execute) or ENTER

Note: If the new file name is the same as the original filename or already exists in the

new storage device, a prompt dialog box asking you to replace filename or not will appear. Select OK or Cancel and press ENTER or F1 (Sure Execute). (Select OK or Cancel with or key.)

2-13


2-2-1-4 F4 (Close Program) To close an opened NC program.

Operation: 1.Switch the screen to the NC program screen you wish to close (press

Tab key). 2. Press F4 (Close Program). 3.To close all opened NC programs, press the F4 key until the number of

opened files appearing in the information bar is 0.

2-2-1-5 F5 (Receive Program)

This function allows users to send program to the controller from an external computer via the DNC using the RS232 port. (This function will be disabled when manipulated by touch screen.)

2-2-1-6 F7 (Undo) This function can recover the erased character at the last step.

2-2-1-7 F8 (Delete Line) To delete a line in NC program.

2-14


2-2-1-8 F9 (FTP D. LOAD) Through Ethernet transportation, user can download the program from PC to controller in the LAN. User must have done the essential setup of TCP/IP between PC / IPC in advance. (If users need to use this function, please contact maintenance personnel.)

2-2-1-9 F10 (N.C. Name Browser)

As shown in the screen below: 2 9 10 11 5

1. Searched files no. in list 7. Sorting files by alphabet of title. HOTKEY (ALT+N) 2. Folder of search target 8. Sorting files by size. HOTKEY (ALT+S) 3. File List of this folder 9. Sorting files by built date HOTKEY (ALT+D) 4. Storage device space 10. Protect switch for writing only. HOTKEY ( ALT+R) 5. System Memory space 11. Browsing files by text mode. HOTKEY (ALT+T) 6. Cursor selected file 12. Browsing files by graph mode . HOTKEY (ALT+G)

4 12

1

7

8

3

6

2-15

CHMER Wire-Cut EDM Operation Manual W5F Press F0 (Browse Program Name) and it shows detailed info. of each file: Filename File size Date Time Re-write Protection Remark 2-2-1-10 F0 (Browse Program Name) There are 9 items in this function:

F1 (EDIT PROGRAM): Open and edit the selected file. F2 (COPY PROGRAM): Copy a single selected file. Operation is the same as

[EDIT/F3 (Save As)]. When copying many files, the controller will copy the selected files to the hard drive (Select with F6).

F3 (DELETE PROGRAM): Delete selected files [NB: Protected files cannot be deleted.]

F4 (SEND PROGRAM): Send selected files to an external device via the DNC.

F5 (PROTECT SWITCH): When read-only is set, an R will appear in the ST column.

F6 (PICK PROGRAM): The switch symbol will appear if selected. F7 (STORE 1 BROWSER): Reserved (path must set in HELP=> F3.) F8 (STORE 0 BROWSER): Reserved (path must set in HELP=> F3.) F9 (REMOVAL BROWSER): Load a diskette in the drive. F10 (HD. BROWSER): Programs on hard drive.

Note:

1. Pressing ESC key can interrupt the search process. Matched items will be displayed on the screen.

2. If the search is failed then it will show the different message on the screen.

3. Press spacebar to switch the status of column where the cursor stays. a. Press CTRL key and spacebar at the same time or F6 key to

select all files. b. Press CTRL, ALT and F3 keys at the same time to delete all

files in the device. c. Press the ALT+ N key to display files by name; ALT+ S key to

display files by size; ALT+ D key to display files by built date. d. Press the ALT+ R key to set file rewrite only; ALT+ T key to browsing file by text mode; ALT+ G to browsing file by

graphic mode. e. If user knew the file first tile what would like to search then can direct input such as: A or B to browse the files.

O0004 1198 2006/05/06 08:15:12 R CHMER

2-16


Enter strings for search

Enter the new string you wish to insert or replace.

4. To open an unknown file name (but knew whats the storage device) a. Press F1 OPEN NC. PGM. b. Press F10 NC. NAME BROWSER c. Selected the storage device, such as F7 STOR.1 BROWSER

or F8 STOR.0 BROWSER (any optional CF CARD reader or USB device); usually to choose F9 FLOPPY BROWSER, F10 HD. BROWSER.

d. Use Page UpPage Down keys to select the need file, then press ENTER or F1 SURE & EXECUTE to open file.

2-2-2 EDIT-2 Page

2-2-2-1 F1 (Set String)

This function allows users to edit and set the new and old strings they wish to search, replace or insert.

2-17


2-2-2-2 F2 (Search String) This function allows you to search strings down the pages from the cursor position.

Press F1 (Set String)

Press F2 (Search String)

Enter strings for search

Cursor move to the search target

2-18


2-2-2-3 F3 (Insert String) This function allows users to insert the set string in the cursor position.


Press F3 (Insert String)

ENTER

Enter string for insert

Move the curser to the position for insert.

2-19


2-2-2-4 F4 (Replace String)

This function allows users to search current strings and replace them with new ones.

Insert new string after the index of cursor.

2-20


Push F4 (Replace String) and use function keys below:

F1 (No Replace): Only search, not replace

F3 (One Replace): Replace one at a time

F5 (ALL Replace): Replace all F8 (ABORT&EXIT): Cancel Replace String.


ENTER F4 (Replace String)

Enter strings for search Enter the new string to insert or replace.

2-21


A. F1 (No Replace): Only search, not replace.

B. F3 (One Replace): Replace one at a time.

Move the cursor to string then again press F1 then cursor will move to next same string.

Move the cursor to the top character then press F3 then cursor will replace the old string once.

2-22


C. F5(All Replace): Replace all. Note: When there is neither string data specified, nor set in the program, error

message ALARM 4620 will appear after you press F2 (Search String), F3 (Insert String) or F4 (Replace String).

Replace all original string (M00) Become new instead string(M01)

2-23


2-2-2-5 F6 (Cancel M.BLOCK) To cancel highlighted lines made by F0 (Set M. Block).

Press F6 (Cancel M.BLOCK)

The selected blocks still remains.

2-24


2-2-2-6 F7 (Delete M. BLOCK) To erase the highlighted blocks.

Press F7 (Delete M.BLOCK) Note: When there is no any line to be highlighted, Edit-Error-Message will appear

when you use this function.

2-25


2-2-2-7 F8 (Move M. BLOCK) Move highlighted lines to a target location.

1. Move cursor to the line for move and press F10 (Set M BLOCK)

2. Move cursor to target location then press F8.

Move the block G01X-8.Y0. under the line of M01.

2-26


2-2-2-8 F9 (Copy M. BLOCK) Copy highlighted lines to target location.

1. Press F10 to highlight the lines then move cursor to the target location.

Select the blocks ready to make copy later.

2-27


2. Press F9 (COPY MARK) for duplication.

Move the cursor to the block ahead to make copy later.

The duplication is done. (1st time)

2-28

CHMER Wire-Cut EDM Operation Manual W5F 2-2-2-9 F10 (Set M. BLOCK):

To highlight a certain line or area for program edition.

If pressing F9 again then the Triplication is done. (2nd time copy)

Select the blocks ready to make copy later.

2-29


2-2-3 EDIT-3 Page 2-2-3-1 F1 (Move Line)

This function allows users to move the cursor to a particular line by entering the line number.

Hotkeys: Ctrl+Page UpMove cursor to the first line. Ctrl+Page DownMove cursor to the first line.

2-2-3-2 F2 (Search N Code) Allows users to search the position of the N code he wishes to check.

Procedure: F2 (Search N Code) input the number of N code

ENTERCursor moves to the line of the N code.

2-30

CHMER Wire-Cut EDM Operation Manual W5F For example: Search the NC. Program N 2

Note: N must be tagged before each block of N.C. program; otherwise, Search N code cannot be performed.

Cursor move to N002

2-31


2-2-3-3 F4 (Sim. Skin) This function allows users to execute the simulation of skim cut with a simple one cut program.

Example A: 10mm x 10mm square punch with one cut

1. Load or compose a simple 10mm x 10mm N.C. program. 2. Press F4 (Sim. Skin) 3. Enable the SKIM SPARK SWITCHSet NO. of SKIM SPARK

COUNT Set OFFSET NO.,OFFSET VAL.F10(SIM. EXECUTE)

One Cut Punch program.

One Cut Simulate PGM path.

It calls the S-code

data from database

of MDI there.

2-32


Press F1 (Step Sim.) to run simulation block by block. Press F3 (Sim. Step++)or F4 (Sim. Step--) to increase/decrease the number of step. F2 (Reset Sim.) is to restart the simulation.

F10 (PATH ZOOM) to increase/decrease the view of observe.

Offset is activate

ZOOM out to enlarge the scale of Viewer.

2-33


2-2-3-4 F5 (SIM Data) This function allows users to configure data for simulation

SIM Data Screen

Description of Function

NC Data Setup 1. PGM Rot. Angle Rotate based on the center at G92 (display mode is

configurable from Flag 14 by maintenance personnel according to customer requirements). The range of program rotation is -360 to +360.

2. Mirror & ExchangeIt allows users to use the mirror function on X and Y axes and exchange axes in a simulation.

A. X-axle mirror switch To reverse the movement of X axle in the program. 0=Off; 1=On.

B. Y-axle mirror switch To reverse the movement of Y axle in the program. 0=Off; 1=On.

C. X and Y axles exchange: To exchange the movement of X and Y axes in the program. 0=Off; 1=On.

1

3

4 5

12

13 14

6

15

2

16

9 10 12

7 8

11

17

18

19

20

21

22

2-34


NC Program X-axle Mirror Y-mirror X/Y Mirror

Axle Exchange Axle Exchange/X-axle

Mirror

Axle Exchange/Y-axle

Mirror

Axle Exchange/X/Y Mirror

3. M. Stop Dist.To set stop distance of M00 ahead M02 to material is

about to break 4. PGM Scale To enlarge the dimension of a N.C. program. 5. Over Cut SWWhen running the simulation program, the control will

alert if there is an over-cut. This item also provides the over-cut management function. 0=Disabled; 1=Check and Stop Simulation, 2=Skip Over Cut Path

6. Invert CheckTo check if any geometric intersection exists in Taper Cut path. 0=No Check; 1=Error and Abort, 2=Skip

7. Comp. Corner ModeProvides users different corner path modes from

0-6.

Geometric intersection

2-35


2-36


8. Comp. Corner RatioTo set the distance off the program path in Corner Control. The distance equals Offset (H or D) x Comp. Corner Ratio.

9. Taper Set

1. Cut Modes

0= VerticalAux plane remains vertical to PGM plane, which means

there is no UV axis movement.

1=TaperAux plane is oblique to PGM plane at a specific degree of

angle. In this case, XYUV axis would be moving simultaneously in identical path to cut cone shape.

2=UVXYUV axis would be moving simultaneously but in

different path to cut two shapes on the top and at the bottom of a workpiece.

3=PlaneSame as 2=UV used for cutting two shapes on top and at

bottom but in different way of program composition. The program of 2=UV, in which the shape on top is consisted of innumerable points and lines while 3=Plane can use G, M code to compose it to much simplified the program and enhance the accuracy.

Distance off program path

2-37


Example of 3=Plane

Cut Mode = 0 VERT , 1ANGLE, 2 UV, 3 PLANE

Program of Aux Plane ( X=U, Y=V.) joint the left program by @. Plane Program 2

Program of PGM plane

Program of Auxiliary plane

2-38

CHMER Wire-Cut EDM Operation Manual W5F A. . If set cut mode= 0 / 1 / 2 then all simulate graphic would be

the same as follows:

B. If set cut mode= 3 then the simulate graphic would be as follows (two different cutting path):

(The graphic be correctly to show as above is truly under PLANE mode!)

ONLY the graph of PGM plane be shown up !

The Upper graph shown is PGM plane.

The Bottom graph shown is AUX plane.

2-39


10. Taper angleWhen performing a taper cutting and if taper angle is not defined

in the NC program, the value of the taper angle can be set by this value also.

11. NC PGM Plane (Z)Generally, Z (PGM Plane) is the distance off work-table

in a N.C. program; usually set Z=0 if there is no spacer put beneath a work-piece.

12. Object Thick (I)I (Aux Plane) is referred to the height position of the

work-piece; its value could be + or and it is used to exchange the position of PGM and Aux plane. For example, in above Cut Mode=3, it is set Z=0 and I=30, so UV path appears on top. If we set Z=30, I=-30, then the path will be turned up-side down.

13. Upper GuideThe height of upper nozzle, which is referred as Z3 in previous

W5E system. Z3=Current Z axis height +DB.

14. Lower GuideThe height of lower nozzle to work table is identical to DA.

2-AUX. Plane

1- PGM Plane

2-40


ZBase line of taper or called Program Plane IHeight of taper.

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

Note 1: How to make Taper Cutting? Answer: There are two variables, Z and I, are related to the setup of Taper Cutting;

the figure below shows how they are correlated to

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

Example

I

Z

+I

I Z

Z

G92X0Y0 G91Z30.I-30.

G01G42Y5.H1A3. G02X5.Y5.J-5. X-10.Y0.I-5. X5.Y5.I5. M02

2-41


15. Comp. Shift ValueAdditional offset added up to N.C. program. Operator could

get quick compensation for rough or skim cut without modifying H or D in program.

16. Taper Shift ValueAdditional taper angle added up to N.C. program. Operator

could get quick compensation for rough or skim cut without modifying A in program.

17. D. Comp: D01~D14 are for compensation, same as H.

18. Skip Set /1~/14: Select which block in a N.C. program to skip. 19. N.C. Data Register

Copy N.C. Data, Taper Data, Corner Data, and AWT Data to N.C. program. Move cursor to the item and press ENTER.

EX: G11Q__X__Y__Z__RS__I__J__C__F__W__A__ ; NC. DATA[DATE]

Explain: Q: PGM rotate XYZ: Change program path. (i.e. Mirror, Axes

change ) R: Set stop distance of M00 ahead M02 S: Program Scale

I: Overcut check J: Invert cut check C:Corner type F: Extra offset for corner W:Extra offset in NC program

A: Extra offset for taper in NC program Example : 1.Load N.C. program.

2. Press F5(SIM.DATA) , and move cursor to N.C. DATA and then

to do setting one by one. 3. Move cursor to NC. DATA, then press ENTER

4.User can find the scripts (N.C. DATA) in NC program when back to preview.

2-42


ENTER

The registration in NC program is success.

1.Key-in NC DATA for registration.

2. Press ENTER

2-43

CHMER Wire-Cut EDM Operation Manual W5F 20. TAPER Data (Register) To do setting registration in NC program before processing.

EX: G12C__A__Z___I___ ; TAPER DATA [DATE] Explain:

CCUT METHOD ATAPER ANGLE ZNC. PGM.PLANE IOBJECT THICKNESS

Example: 1.Load N.C. program. 2. Press F5(SIM.DATA) , and move cursor to TAPER SET and then

do setting one by one. 3. Move cursor to TAPER DATA, then press ENTER 4.User can find the scripts (TAPER DATA) in NC program when back to preview.

ENTER

1.Key-in TAPER SET for registration.

2. Press ENTER

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The registration in NC program is success. 21. CORNER Data (Register) To do setting registration in NC program

before processing. EX1: (INNER CORNER)

G18TFVIJPUDBS G13WCXYKLR CORNER [DATE:TIME]

TDWELL FMAX. FEED VINC.OV IINC. ON JINC. OFF PINC. SV UINC. FR DINC. WT BINC. WL S: SCODE BASE WCTRL.SW CCORNER DATA XENTER PWR.R YEXIT PWR.R KENTER DIST.

LEXIT DIST. RRADIUS

EX2: (EXTERIOR CORNER) G19TFVIJPUDBS

G17WCXYKLR CORNER [DATE:TIME] TDWELL FMAX. FEED VINC.OV IINC. ON JINC. OFF PINC. SV UINC. FR DINC. WT BINC. WL S: SCODE BASE WCTRL.SW CCORNER DATA XENTER PWR.R YEXIT PWR.R KENTER DIST.

LEXIT DIST. RRADIUS

2-45


ENTER

2. Press

ENTER

2-46


The registration in NC program is success. 22. AWT Data (Register) To do setting registration in NC program before

processing. EX: G14X__C__D__P__B__T__S__Z__Y__E__ ;AWT. DATA[DATE:TIME] Explain: XAWT ACTIONCCUTTER M CODE DREPEAT THRU. CNT.

PSKIP CNT. BW. BRK. CTRL. FLOW TTHRU CTRL. FLOW SSHORT CTRL. FLOW ZZ MOVE SWITCH YTR. BP.SPARK. SW. ETR-BP.S.C.

Example :

1.Load N.C. program. 2. To go MEMmode and Press F3(MEM DATA3) , and switch back to

EDITmode and move cursor to TAPER SET and then to do setting one by one.

3. Move cursor to AWT DATA, then press ENTER 4. User can find the scripts (AWT DATA) in NC program when back to

preview.

Exterior Corner

Inner Corner

2-47


ENTER

1.Key-in

AWT

DATA

for

registration.

2. Press

ENTER

2-48


The registration in NC program is success. 2-2-3-5 F6 (SIM. H. VAR)

This function allows users to set the H parameter (000-999, totally 1000 sets) in the simulation. The first page will display the H parameter from H00-H49. Press Pg Up Pg Dn to change page.

Note. H000 is invalid; please use H001-H999. Sim. Data Screen

2-49

CHMER Wire-Cut EDM Operation Manual W5F Note: 1. Press arrow keys to move cursor to the desired column; or press PgUp

and Pg Dn keys to turn page (50 sets a page); or key in H*** to move cursor to the *** entry of data.

2. If the number is entered without a decimal point, a 0 will appear; if there Is, the figure will be displayed as 0.000.

2-2-3-6 F7 (Sim. D. Oft)

This function allows users to set the D parameter offset (000-999, totally 1000 sets) in the simulation. Change page with the same method as in F6 (SIM. H. VAR).

Note: D000 is invalid; please use H001-H999.

Sim. D. Oft Screen

Note: 1. Press arrow keys to move cursor to the desired column; or press Page Up

and Page Down keys to turn page (50 sets a page); or Key in (D***) to move cursor to the *** entry of data.

2. If the number is entered without a decimal point, a 0 will appear; if there

is, the figure will be displayed as 0.000.

2-50


2-2-3-7 F8 (Spark Offset) This function allows users to register the cutting data, offset value, to the NC.

program. F8 (Discharge Data Correction) Screen

Data Setup Description: 1. Wire diameter: Value of the diameter of brass wire. 2. Material: The material of work piece (0=user defined; 1=SDK-11;

2=copper; 3=tungsten steel; 4=aluminum; 5=graphite; 6= SKD-61; 7=titanium; 8= P20)

3. Work piece thickness 4. No. of cut : The number of cuts in the processing. 5. Registration switch: Registration location is in Help 2\F4: Other

Parameter Setup 6. Cutting data and offset value 7. Spark Base: It means S-code database. To choose the type.

a. Default: It has built-in original S-code database cant be modified. b. User: User can define his own database at will.

8. Reg. Dat. Bas. : Press Enter then it saves the S-code to database Immediately. 9. Comp. Shift. Value: After processing, if the cutting result is

dissatisfied then user can directly input the offset value to fix.

7

1

2

3

4

5

6

8

9

2-51


Procedures

Load the program and press F8 (Spark Offset)press arrow keys to move cursor to the desired column, set value and move cursor to Register, press ENTER.

Press button to switch screen to view cutting data in the NC program

2-52


2-2-3-8 F9 (Figure Color)

This function allows users to set the path display mode and colors in the simulation.

Figure Color Screen

Data Setup Description 1. Data displayed on the screen Observation view position: Set the height of observation view. Viewing angle: (0: XY plane display; 1: Isogonics display; 2: 3D

display) Vertical angle: View from the rotation angle of vertical axle in 3D

display. Horizontal angle: View from rotation angle of the horizontal axle

in 3D display. Show/hide Flag: Show and hide flag at the bottom of path.

2. Show/hide individual cuts. 3. Show/hide operation view. 4. Path color setup of cuts and operation views.

1

2

3

4

2-53


Press arrow keys to move cursor to the position for changing colors.

Press H ENTER to open the Color Chart to select color.

Press arrow keys to select the desired color from the color panel to change color.

Note: Call the program of corresponding functions before running their sub-functions.

2-54


2-2-3-9 F10 (Sim. Execute)

This function allows users to simulate the NC program. Sim. Execute Screen

Data Setup Description 1. 12 [01]: Master program of simulation; [01] represents the number

of steps in the simulation. 2. 12 B00001: Name, lines and location of simulation program. 3. Program coordinates and work piece thickness in simulation. 4. Program compensation value in simulation. 5. Program taper angle value in simulation. 6. Work coordinate area (including right upper corner and left lower

corner). 7. Work piece dimensions. 8. Total length of program path. 9. Scale 10. Color of program and auxiliary view.

1

2 3

4

6

7

8

9 10

5

2-55


Press F10 (Path Zoom)

Press+ or key to enlarge or miniaturize view when the zoom in/out window appears. Press arrow keys to move to window of the section to zoom in/out and press ENTER

Note: To enlarge the selected section, users can zoom in/out the section

repeatedly and press HOME to return to the original view.

2-56


2-3 AUTO (Program Mode) Operation Guide The function is activated after the graph simulation in EDIT mode is done. Users have confirmed the entire program paths are correctly before going to official processing. There are 2 submenus in this function menu; users can select 2 submenus with

Arrow Button.

Submenu MEM-1 Screen

Submenu MEM-2 Screen

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CHMER Wire-Cut EDM Operation Manual W5F Program Mode Operation Guide

F1 MEM. PATH

F2 MEM. DATA1

F8 MEM. HOLE

F3 MEM. DATA3

F5 CORNER DATA

F6 MEM. H. VAR.

F7 MEM. D. OFT.

MEM-1

F9 FIGUR COLOR

F10 PATH ZOOM

(Shows NC program path, master screen 1)

(Configures status data 1 before running NC program processing.)

(Setup the data about the entire corner technique for each of the NC program during processing.)

(Sets D-code correction from 000-999 in the NC program; a total of 1000 sets.)

(Sets H-variable (correction) from 000-999 in the NC program; a total of 1000 sets.)

(Sets the color of the NC program path status and path.)

(Configures status data 3 before running NC program processing.)

F4 MEN. DATA4

(Data of the last 2000 records of processing hold status in the NC program.)

MEM-1

(Configures status data 4 before running NC program

(Allows users to zoom in and zoom out the path to view part of or

the entire path of the program)

2-58


-

(Reserved, inactive)


(Shows the information of cutting number.)

(Allows users to zoom in and zoom out the path to view part of or the entire path of the program)

F1 Not Used.

F2 MEM. COORD.

F7 CUT NO. INFO

F3 MEM. RECORD.

F4 MEM. SKIN

F5 NOT USED

F6 NOT USED

MEM2

F8 MEM. NC. PGM

F9 SCOPE


(Same as MAN/F7 Coordinate System, move functions are the same)

(Records the last 100 program processing records)

(Records the status of gap voltage, servo voltage, and machine servo feeding speed in the controller during processing.)

(Same as MAN/F8 Coordinate System, move functions are the same)

(Sets mold trimming process data in processing.)

F10 PATH ZOOM

MEM-2

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Program Processing Standard Process

Start

Open N.C. file and perform Simulation.

Press AUTO

Check AUTO. Data 1 & 2, offset H or D.

modify setup when light on

Press AUTO

Press

Automatically activates water, wire and power buttons

Runs the program

(Ready for processing)

2-60


2-3-1MEM-1 2-3-1-1 F1 (Mem. Path)

This item shows the current status of the processing track to facilitate operators to observe the current status and program path of processing.

Screen of MEM Path

Content description Coordinate area: Operators can choose which coordinate system for display. Example: It used to set upper column be Mach. Coord.and lower column be Local Coord. that for the convenient to observe.

Procedures: Move the cursor (with arrow keys) to coordinate area and input any coordinate code 0~4, or G54~G99.

CUT Time: Work hours that has elapsed. EST Time: Estimated total work hour required.

Main program name: When the color in this area gray (LED RESET lit), the main program is not available to load another new program to memory buffer.

Program segment information column (If you have configured the offset correction and cone angle offset in Program Data Setup 1, the data in this column will turn red characters.)

-1

-2

2-61


Besides, controller provides new functions to review the important block information during programming. There are total 6 pages could be switched through TAB key. We list all of them as following:

PAGE 1/6 PAGE 2/6 PAGE 3/6 PAGE 4/6 PAGE 5/6 PAGE 6/6

PAGE 1/6 Processing Status of PGM: A. Executed cutting time / Estimate remaining time B. Main N.C. Program Name C. Program message:

a. Line 1: Program footnotes b. Line 2: The present position of the NC program during processing. c. Line 3: offset direction and value. d. Line 4: Actual cutting position (Z). e. Line 5: Work piece thickness (I). f. Line 6: Taper angle (A).

PAGE 2/6 Block Status and information: A. Average Gap Voltage / Feed-rate B. Block Length / Current Position of Block C. Block Status:

a. Line 1: Before entering to corner shows 1/1, Entering corner shows 0/0. b. Line 2: The current executed block, whats the angle entering/exiting the

corner. c. Line 3: Motion Status. NormalZEROLOWUPDOWN d. Line 4: The S-code that executing at this block now.

PAGE 3/6 Corner data, Status and information:

A. Corner State: Normal MoveOuter-Down Outer-Low-EnterOuter-Low-ExitingOuter-UpInner-DownInner-Low-EnterInner-Low-ExistingInner-Up

B

C

2-62


1/1means1: Spark energy Inc. & Dec. % / 1: Not enter to corner B. Corner Max. Feed: To limit the maximum feed-rate at corner. C. Corner Data: The S-code status of current corner pass. ( ) shows the corner

setting to increase & decrease value. Note: As above 3 items are bounded to the setup of F5 CORNER DATA. PAGE 4/6 Sparking information (for maintenance personnel) PAGE 5/6 AWT thread Status and information

A. AWT CMD.: Through-ing AN.CUT (J) AN.CUT (A) AWT.SPARK IDLE CLR.GUILDWIRE AT A0 WIRE AT A1 WIRE AT A2 WIRE AT A3 WIRE AT A4CLAMP WIRE TENSIONING HEAT WIRE COOL WIRE CUT WIRE CUT WIRE RECE.WIRE UNCLAMP WIRERECE. WIRE 1

B. AWT STEP: FINISH SETTING COUNTDOUBLESHORTCHAR

C. AWT TIMER: AWT executing time. D. THRU.COUNT: The counter of wire threading through times. E. SUCCESS: Based on #D, the static about success rate of threading.

PAGE 6/6 AWT command Status and diagnostic (for maintenance personnel)

-1 The color display of cut path at Program plane & Auxiliary plane. -2 The color of each symbol meaning of G codes and M codes in

the NC program. Discharge efficiency, gap voltage, cutting speed and cutting data display. NC program path diagram. NC program path length display: Upper SectionTotal Path Length; Lower

SectionRemaining Path Length

2-63


2-3-1-2 F2 (MEM. Data 1)

Mem. Data 1 Screen (page 1/6)

Note: 1. The RESET must be lit on before the preset. 2. Among MEM.DATA1 & MEM.DATA3 & MEM.DATA4, user can

switch up by PgUp & PgDn keys for total 6 pages for NC setting before processing.

PAGE NO. 1/6

Function Descriptionthe operation is same as FILE=>F5

2-64


PAGE NO. 2/6

Function Description:

MEM.FN& NCODE

1. MAIN PGM.NAME: Users can call the NC program with

this item (REST indicator must be on).

2. START N CODE: To start running an NC program

from specific block (Flag11=ON) and

controller will directly jump to the specified

block to run.

3. RE-CUT SW.: The program can automatically search the

unfinished mold hole in the previous processing.

When the automatic RE-CUT SW. is set to ON,

the controller would automatically search the

unfinished mold hole, and then move to the M20 point

of the hole, trace the last discharging position and start cutting.

Note: This function is only available in machine which have equipped AWT device, the mainly apply inmulti-cavitiesjob.

SKIP SET

Skip Set: Select M00 block in a N.C. program to skip. And please note machine function key BLOCK SKIP must be enabled. And controller will recognize the order /1M00/2M00/3M00etc automatically to enable /disable to execute M00.

PAGE NO. 3/6

Function Description

AWT DATA 1. ACTION: Set AWT on or off in N.C.

program execution. 2. CUTTER M CODE: AWT work

mode. 0=Disable cut wire M code.

The program will skip this step 2-65


when it runs to M-code cut wire. 1=M21: The program performs

threading at point M20 and cuts wire at point M21 to reduce wire (coarse cut).

The machine continues to run without action (flag parameter 10=Off: program runs without action) or directly moves (flag parameter 10=On: program directly runs to the next mode) to the next point M20 to perform threading.

2=M22: (flag parameter 10=Off: program runs without action) Program runs to point M20 to perform threading; then it runs without action to point M21 to start processing and reduces wire at point M22 (for handling waste materials). (Flag parameter 10=On: program directly runs to the next mode) Controller directly searches point M21 to perform threading and cuts wire until processing to point M22.

3=M23: The program performs threading at point M20 and reduces wire after processing to M23 (for mold trimming).

3. W. BRK. CTRL. FLOW: AWT process after wire-break occurs. 0=STOP (controller interrupts processing)

1=NEXT (controller automatically moves to next threading position)

2=M20 (controller automatically returns to this M20 point and performs threading, runs without action or performs processing to the breaking point).

3=BP (AWT performs threading at the wire break point)

4.THRU. CTRL. FLOW: AWT process when threading wire unsuccessfully. 0=STOP (controller interrupts processing)

1=NEXT (controller automatically moves to next threading position)

5.SHORT CTRL. FLOW: AWT process when short occurs (0=STOP; 1=NEXT) 6.WATER IN AT THRU: Whether controller opens water while threading. 7.THRU. WIRE WATER OFF: If threading unsuccessfully, whether leak out

water while threading again. 8.SKIP/REPEAT THRU. CNT.: The maximum skip time when threading

unsuccessfully; controller will stop machining when exceed the setting times./AWT threading tolerance.

9.Z MOVE SW.: Z axis retracts distance before going to M20 for threading.

2-66


10.TR_BP. SPARK SW.: Whether perform eroding or not while tracing back to break point.

11.TR-BP. SC.: S-Code select if use while tracing back to break point. (It connected with TR_BP. SPARK SW.)

SWITCH SET 1. S Code SW.: Sets the S-code action -Enable [1] and Disable [0]

in NC processing. 2. Sleep SW.: When it is ON, the controller will shut down peripheral power

supply from program processing is interrupted (M00,M01,M02...etc), or AWT failure or completion in one minute.

3. BP. Check. SW.: Sets the interruption point check of controller on/off after program processing interruption.

4. Dry Run G04 SW.: Sets G04 (Pause command ) on/off when the program runs without action.

5. Trace Spark

Documents

WIRE - EDM Operation Manual