Wire - Edm Quick Start

WIRE - EDM
QUICK START

SOFTWAREW5F
MANUAL VERA
DATE2006.07

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 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.
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 machines 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 CHMERs 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 MOVEfind corner position--------------------------------
37
4.9 MEM ZOOMMEMF10---------------------------------------------
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

VERE5B-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.

3. A few seconds later after boot procedure

EDM
X Y , ., Z
+
&
--
+
\
=
1
4
7
0 .
)
*
2
5 $
@
%
8
3#
^
6
/
( 9
A
P
U
K
F
M
R
H
W
Q
V
L
G
S
{ [
N
I
B C D
T
] }
O
J
E

Main power
Rotary switch
Operation screen
- 1 -

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

Release Emergency-stop
Green Button
- 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 (SEARCH HOME)

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.

1.3.2 VERTICAL ALIGNMENT
Use Alignment J ig to find out vertical points after parts replacement such as
upper/lower Head, Diamond Guide or Ceramic Plates. Before executing Vertical
Alignment, the Alignment J ig has to be well located on work-table and connect its
-V +Z
-X -Y -U
NotePlease turn off AR function before SEARCH
HOME to avoid Alarm 10500.
- 7 -
signal cable to VER I/O port. Then follow steps listed below

1.Press twice quickly if its LED not lit on.
2. Press VERT. MOVE

2. Align either XU or YV at one time
Select direction2 (-X) or 1 (+Y), press to begin.
3. When vertical points are found (repeat accuracy within 5), 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.
Alignment J ig
VER I/O port
DA,DB Switch
Vertical position (U,V)
- 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 J ig, L-Block can be used for manually aligning
the axis with spark appears on wire:

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 2(-X)

L-Block
- 9 -

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 for0.2wire; set WT=12 for
0.25 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 (VERT MOVE)
and VERT. PT. will appear on screen.

- 10 -

9. Input the coordinate value and press to save.

10. Repeat 3~9 for XU axis alignment.

TipTo 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.

(2) Edge Find inX ( 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 infoUV MOVE ANGLE=3.000, UP POINT=45.000,
DN POINT=0.000TOLERANCE ANGLE=0.0050
L-Block
Cutting wire
- 13 -

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

DA DB MOVE info
- 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) HD BROWSER. Move
cursor with to select a file.

2.1.4. File Loading
Method 1
(1) Press

(2) Press (OPEN PGM)
- 17 -

(3) Input specified filename then press .

Method 2
(1) Press

- 18 -
(2) Press (NC.NAME BROWSER) Use cursor to select a file and
then press .

2.1.5 Graph Simulation
(1) Press

(2) Load a file by either (OPEN PGM) or (NC NAME BROWSER)

- 19 -

(3) Press twice (SIM DATA) (SIMU H. VAR.)
for relative setup 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 (DELETE NC. PGM)

- 20 -

Method 2: To delete multiple files
(1) Press


(3) Use to move the bar to specific file and press (PICK NC. PGM).
will tag along with selected file.

- 21 -

(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 .


(3) Press (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 twice (SIM DATA) (SIM H.
VAR.) SIM EXECUTE

4. Delete the job file O1018.

(2) Use to highlight O1018 (DELETE PGM.)

- 24 -
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 SETTEDto activate Corner Control and AWT function.

(3).Press (MEM H.VAR) to input offset value.

Corner Control items AWT items
27
3.4 Call up cutting technology
Before machining, press MEM PATH input S-code numberex
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 to start

cutting.
28
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. Press (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).
NoteTurn off AR(Angle Rotation) before executing BOARD CP.

1/2 1/2
- 34 -
4.6. MDI. MOVE
1. Press

2. Press MDI. MOVE enter value in MDI. VALUE or use C to
clear. Next, press to confirm and to start table moving.

NoteCoordinate referred above is MACH. COORD.
Speed of table moving
Modes of table moving
0XYZUV by incremental
1XYZUV by coordinate
2XYUV by incremental / Z by coordinate
3XYUV by coordinate / Z by incremental
- 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 and J og table to reference point 1.

(2). Press (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). J og 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). J og 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.
(NotePlease turn off AR before executing this function.)
4.8. CORNER MOVEfind 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 ZOOMMEMF10
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:
EndZoomed from working field
PgUpScale x 2
PgUnScale x 1/2
InsDisplay graph of last completed job.
DelZoomed from current position of cutting wire.
/Enlarge/Minimize frame size. ENTERConfirm.
HOMERecover 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:

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

(Note Please use weak discharging energy.)
wire
work piece
Short circuit
JOG
Voltage meter
- 39 -
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/cm
2
and WL=7, water pressure is
about 15kgw/ cm
2
. Keep pressure difference between upper/lower head less
than
1 kgw/cm
2
.

(2) Check if Water Cooler is working normally? Water temperature too high?
(3). Use weaker discharging energy. (Increase OFF and AFF)
Water Knob
- 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.
TipWhen it is difficult to rethread at wire-break location, move up Z axis up
and thread through to lower guide by hand when wire threading is done,
press 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 (After repair or maintenance finished)
Turn power ON 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 Turn off Rotary Switch and main
power After power recovers Turn on Main Power, Rotary
Switch and release Emergency Stop Press the Green Button Snip
and remove the wire
(Now table moving to last position
interrupted by black out) (Turn off Dry Run)
Thread wire Call up S-Code
- 42 -

Method 2. Press the Emergency Stop button Turn off Rotary Switch and main
power After power recovers Turn on Main Power, Rotary
Switch and release Emergency Stop Press the Green Button
Snip and remove the wire (back
to wire-break location) (press twice quickly)
Thread wire call up S-Code

6. QHow 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

Example A.

+I
I
Z
Z
A is taper degree. When A is +, cutting wire
moves rightward; when , it moves leftward
ZBase line of taper or called Program Plane
IHeight of taper.

G92X0Y0
G91Z30.I-30.
G01G42Y5.H1A3.
G02X5.Y5.J -5.
X-10.Y0.I-5.
X5.Y5.I5.
M02
Z=30 mm
30 mm
I=30 mm
I=30 mm
Z=30 mm
30 mm
- 44 -
G92X0Y0
G91Z0.I30.
G01G42Y5.H1A-3.
G02X5.Y5.J -5.
X-10.Y0.I-5.
X5.Y5.I5.
M02
Example B .

Example C .

G92X0Y0
G91Z27.I-27.
G01G42Y5.H1A3.
G02X5.Y5.J -5.
X-10.Y0.I-5.
X5.Y5.I5.
M02
Z=27.0
30mm
I=27.0

3mm
Z=0
I=30
30 mm
Z=0
I=30
30 mm
- 45 -
G92X0Y0
G91Z3.I27.
G01G42Y5.H1A-3.
G02X5.Y5.J -5.
X-10.Y0.I-5.
X5.Y5.I5.
M02

Example D.

8. QHow 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

Example A. Work-piece height=30.0 mm, 10 mm10 mm square at bottom /
8.0mm circle at top.

Z=3
I=27
27 mm
Z
I
ZBase line of UV Cutting
IHeight of work-piece.
Z=0
I=30
8 mm
10 mm
30 mm
- 46 -
Example B. Work-piece height=30.0 mm, 10 mm10 mm square at top / 8.0mm
circle at bottom.

Example C. Same dimension as Example A, but with a spacer (H1) put under the
work-piece.

8 mm
I=30 +H1
Z=0 +H1
30 mm
SPACER

H1
Z=30
I=30
10 mm
8 mm
30 mm
Z=0
I=30
8 mm
10 mm
30 mm
- 47 -
CHAPTER 6. SAMPLE PROGRAM
6.1 Straight Cutting

PGM 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 G40G01X3.500Y0.000A0 Offset cancelled and cut 3.5. mm in +X.
N0011 M02

End
NoteN (serial number) / H1 (offset amount) / S1545 (S-code 1545)
10
10 5
25
- 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 -

(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. EXECUTEand begin the plotting.

Screen of OPEN NC
PGM.
Screen of OPEN NC
PGM.
- 50 -
(7). Press (SET DATA) for relative setup.
(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, 10mm
2
at 2 Taper

NO. CONTENT PROGRAM NAME
N0001 G92X0Y0

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
10 5 10
25 10
- 52 -
(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.)
(7). Press (SET DATA) for relative setup.
(8). Press (MEM SETTED) to turn on CTRL. SW. and select
CORNER TYPE.
- 53 -
6.3 UV Cutting
UV cutting a Dia. 8mm circle on top and 10 mm
2
square at bottom. T=25 mm.

NO. CONTENT PROGRAM NAME
N0001 G92X0Y0 Define start point as X=0, Y=0
N0002 G91 Use G91 coordinate system
(Incremental)
N0003 G41G01X-3.492Y0.000U-1.030V0.055H1S1545 G41offset 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 YU+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 XU+V cutting
N0010 G01X-0.786Y0.000U-0.902V1.257
N0011 G01X-0.786Y0.000U-0.526V1.108
N0012 G01X-0.786Y0.000U0.180V1.032
N0013 G01X-0.786Y0.000U0.536V1.108
N0014 G01X-0.786Y0.000U0.912V1.257

10
10
10 25
8
- 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 +Y+U+V cutting
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 +Y+UV cutting
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 +X+UV cutting
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 +XUV cutting
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 YUV cutting
N0036 G01X0.000Y-1.067U-1.448V-0.027
N0037 M00 Halt
N0038 G01X0.000Y-0.400U-1.254V0.022 YU+V cutting
N0039 G01X0.000Y-0.400U-1.118V0.047
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 Halt
N0044 G40G01X3.492Y0.500U0V0 G40offset cancelled. +X+Y cutting and move
to U=0 Y=0.
N0045 M02 End
- 55 -
(1). 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 (SIM H. VER.)
(7). Press (SETTED DATA) for relative setup.
CORNER TYPE.
- 56 -
6.4. AWT Application with Sub-Program

NoteN (serial number) / H1 (offset amount) / S1545 (S-code 1545)
M21
M20
M21
M20
CONTENT DESCRIPTION
N0001 O0020; Program name

N0002 G92X0.Y0.

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.

N00013 G41G01Y-5.0H1S1545 G41Offset leftward. Cut in Y=5mm.
N00014 G01X5.0 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 G40offset cancelled. Table move +Y=5mm.
N0022 M99

Sub-program end.

-57-
(1). Press .
(4). Press (OPEN NC PGM.) to call a program,
O0304, for example, 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 (SIM H. VER)
(6) Press SIM. EXECUTEand begin the plotting.
(7). Press (SETTED DATA) for relative setup.
CORNER TYPE.
-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 Action Note
1 Machine Body Per day Dirty or wet
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.
2 LED on panel Per day Out of order replace
3 Wire Alignment Per day Not well aligned
Do
alignment

4 Drain pipe Per day Clogged clean
Avoid any objects
(waste) dropped
into tank
5 Oil Injector Per day
Machine stops
overnight
Do oil
injection
Recharge oil when
low
6 Lower Arm Per day Dirty or rusty Clean
Poor cleanness
Will worse machine
accuracy.
7 Waste wire box Per day Over 70% full Clean
8 Filtration level Per day Water level too low
Must at
least 1/2
full
Motor will dry run if
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
clogged
Clean with
solvent.
Avoid solvent flow
into de-ionized
water
12 Lower Head per day
Debris stuck & cause
short
Clean or
replace

- - 59

13
Machine Dry Run
(5 axis full stroke)
Per
week
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
Cableetc.
3 Inject grease another 812 times
in Dry Run process while
jogging forward each axis.
4.Inject grease another 812 times
while J ogging backward each
axis.
5.Lately, J og each axis by full
stroke for at least 5 times.

14 Wire suction device
Per
month
No suction or clogged clean
15 Cabinet Filter
Per
month
Dirty or dusty clean
16 Power Cabinet
Per
month
Dusty
Clean with
vacuum

17 Z axis linear guide
Per
month
Squeaking & not
smooth
Greasing
18 U axis linear guide 3 month
Squeaking & not
smooth
Greasing
19 V axis linear guide 3 month
Squeaking & not
smooth
Greasing
20 X axis linear guide 3 month
Squeaking & not
smooth
Greasing
21 Y axis linear guide 3 month
Squeaking & not
smooth
Greasing
22 Water flow valve 3 month Clogged or dirty
Take of &
clean
M6,M7 magnet valve
23 Conductivity probe 1 month Dirty Clean
24 Water Tank 3 month Debris accumulation Clean
- - 60

25 Z axis Ball screw 6 month
Squeaking & not
smooth
Greasing
26 U axis Ball screw 6 month
Squeaking & not
smooth
Greasing
27 V axis Ball screw 6 month
Squeaking & not
smooth
Greasing
28 X axis Ball screw 6 month
Squeaking & not
smooth
Greasing
29 Y axis Ball screw 6 month
Squeaking & not
smooth
Greasing
30
Upper/Lower
Nozzle
per day
Water column not
concentrate
Replace
31 Lower Head per day
Debris stuck & cause
short
Clean or
replace

32 Bellow per day
Water leak from
Bellow
Replace
33
Water Conductivity
Meter
per day
Conductivity does not
increase
Replace
resin
After 4 hours
deionization.
34 Wire Leading wheel per day Not running smoothly
Clean or
replace

35 Paper Filter per day
Filter pressure over
21.4psi (1.5/
2
)
Replace
filter
Replace a pair at
a time. Must be
disposed legally.
36
Upper/Lower
Energizer
3-5 day Rusty or worn
Clean with
solvent&
change
contact
place.
Avoid solvent flow
into de-ionized
water
37 Upper Ground Wire
Per
week
Ground wire worn
Strap
or replace
Screwed on Work
Table & Power
Cabinet.
38 Lower Ground Wire
Per
week
Ground wire worn
Strap
or replace

39 Upper/Lower Guide
Per
week
Worn, cooling hole
clogged
Clean
or replace

40 Floppy Driver
Per
month
Dusty, disk unreadable
Use disk
clean kit

- - 61

41 Brush of motor 3 month Worn Replace
42 Upper Power Cable Per year Worn Replace
Between WHP &
Upper Head.
43
Lower Power
Cable
Per year Worn Replace Grounding
44 Chiller Freon Per year Poor cooling
Recharge
freon

- - 62

Wire - Edm Quick Start

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