Wire - Edm Operation Manual 4w426r

]；1 [IO <Wire Alignment Jig>] 5.Up Point: The height of Up Pt. the wire in which touch the jig. 6.Dn Point: The height of Down Pt. the wire in which touch the jig. 7.UV Move Angle：The angle UV tilts for calibration. Usually set it the same as the taper angle that will be cutting. 8.Sensor Angle：Display the tilt angle result after the measurement 9.Tolerance Angle: The tolerance allows the sense angle error. 10.DA, DB Dist.：Present DA/DB value. 11.DA, DB Error：Records the tolerance compared to previous DA/DB. 12.Last DA&DB：Records previous DA/DB value. 2-98

CHMER Wire-Cut EDM Operation Manual W5F

 Example for DA,DB(Y-axis direction) 1. Starting Edge search and sense the edge of L-type Jig. 2. The sense wire stay back to start point. 3. U V-axis move to the indicated UV angle and V-axis lean forward. 4. The sense wire touch the Up Pt. 。 5. Again the sense wire stay back to start point. 6. U V-axis move to the indicated UV angle and V-axis lean backward. 7. The sense wire touch the Down Pt. 8. Again the sense wire stay back to start point. 9. Finished. Illustration of DA/DB Calibration 1

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DA/DB Calibration procedures 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

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, input the actual Z height into HELP-1=> F3=> Z AXIS HEIGHT, such as “S45,” then computer will calculate the Z height automatically, and then do search home again. (5). When Search Home is done, press twice, and lower Z axis down to keep a 0.2 mm distance above the 45mm L-Block. (6) If on the screen, Z coordinate value is not approximately 45.2 mm, then repeat above step (1).~(5).

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2. Setup DA, DB. (1) Put L-Block on worktable as indicated by figure below. (2) Edge Find in–X ( please refer to Chapter 4.1. ) (3) Move the wire away from L-Block in +X for at least 15mm by key or MDI MOVE (refer to Chapter 4.6). (4) Press

（DA, DB MOVE）

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

DA DB MOVE information

(6) Set TOUCH MODE=0 (short) for L-Block. Set TOUCH MODE=1 (IO) if Alignment Jig is used. (7) Set WIRE TENSION= 4~15. (8) Set DA. DB DIR.= 2 (-X) (9) Press Press to start DA, DB MOVE. 2-101


Note: 1. Generally, Vertical point will not be exactly the same if measured at different location due to normal mechanical tolerance. Therefore, it is recommended the calibration to be performed within working area. 2. If the voltage is below 2V, the controller will alert the Alarm 2100.

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DADB Operation Flow Chart DA DB

Thread the wire thru up/lower head

Choose the usage jig：Ｌ -Type Jig or Wire Alignment Jig)，and laid the jig on work-table.

Press Function Key MAN

Press

F4: DA、DB MOVE

SETUP：DA/DB DIR.、WIRE FEED.、WIRE TENSION、TOUCH MODE、UP POINT、 DN POINT、UV MOVE ANGLE、SENSE ANGLE、TOLERANCE ANGLE Error Code (2400)

Press “START”

Check and message displaying “edge search”

NO

YES

Not staying at aligned point. Check if wire breaks

Check if short between wire and work-piece.

Action is completed and stayed at start point. Check if touch the limit during movement.

Finished

RESET LED must lit

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2-4-1-5 F5 (Edge Move) This function allows s to measure and calibrate work pieces, grooves and the inner hole center with the edge search function. Note: It is recommended to remove the water hose on the upper head and blow dry the up/low nozzles. Edge Move Screen

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2 10 3 4

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8

Function description： 1.Edge Dir：Select the direction to edge move. (0:X＋, 1:Y＋, 2:X－, 3:Y－, 4:X＋Y＋, 5:X－Y＋, 6:X－Y－, 7:X＋Y－ 2. Edge Mode：Select which type of edge move. (0:Edge); 1:Slot, 2:Center. The value in the next line is the radius of the slot or inner hole. 3. Record No.：Select the record point (PT0-PT2) to save after calibration. 4. Ref. AXIS: XY axis direction refers to the above figure. 5. Rec. PT0&PT1 ANGLE：The angle between the line of PT0, PT1 and X axis. The angle could be from -180° to +180°). Input “AR” and press ENTER to copy to AR. Set for axis rotate or input “PR” for program rotation. 6. Record Point 0: The mechanical position of Record Point 0. 7. Record Point 1: The mechanical position of Record Point 1. 8. Record Point 2: The mechanical position of Record Point 2. 9. Board .：The middle point of a linear distance 10. Cylinder .：To find the center point of a hole or cylinder. 2-104


11. Board Width：To measure the length of an object. 12.Cylinder Dia.：To measure the diameter of a hole or cylinder Illustration of various Edge Move Single Edge Search: Threading wire and move to the side of work piece

Middle point of Slot: Threading wire into work piece.

Inner Hole Center Search: Threading wire into work piece.

Procedures of various Edge Move 1. First, set Edge Move data 1~5 properly like Edge Mode, Edge Dir… 2. Press and Edge Move will start.. 3. The machine will quickly approach touch the work piece and the voltage will slightly drops due to the . 4. Then the machine will move backward and the voltage would go up to5~7V. 5. Lastly, the machine will slowly approach again and record the mechanical position in the record point.

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Edge Move Flowchart MAN

F5 Edge Move

Set Edge Move Data

Press

to start.

NO

Wire is properly threaded? YES

YES

Short circuit? NO

Edge Dir. is correct? YES Edge Mode is correct?

YES

Alarm message?

is On? YES

NO Edge Move will be completed when machine stops

YES Edge Max Dist. is correct?

Try again.

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Try again.


Board . is to find the middle point of a linear length.

Middle point



Procedure of Board . (Ex：X direction)

B

A

1. Measure the position of points A and B with Edge Mode=Edge and save

them in Record PT. 0 and PT1. 2.Cut off the brass wire. 3.Move the cursor to Board ., input ‘GO’ and press , then worktable will move to the middle point between A and B. 4. Done.. Cylind . is to find the center location of a cylinder object. B

A

Center point

C

Procedure of Cylind . 1. Measure the position of points A, B and C with the Edge Mode=Edge and save them in Record PT0, PT1 and PT2 2. Cut off the brass wire. 3. Move the cursor to Cylind ., input ‘GO’ and press , then worktable will move to the center point of the cylinder object. 4. Done. Note. A, B and C could be any three points around the cylinder. For better measuring result, please keep the three points far from each other as much as possible. 2-107


Board . Flowchart (By X-axis direction) Board .(X-Axis Direction) Set EDGE DIR 2(X-) Set EDGE MODE(EDGE) Set Rec. PT ( 1 )

Thread wire thru up/lower guide then move to side “A”

Press Function Key

Press

START

and execute the action

MAN

While the action be completed and it record at ( REC.1) column

Press F5: EDGE MOVE

Set EDGE DIR 0(X＋) Set EDGE MODE(EDGE) Set Rec. PT ( 0 ) Set EDGE Max. Dist.

Cut off the wire

Move cursor to BOARD ., then key-in‵GO′， Press

START

ENTER


While the action be completed and it record at ( REC.0 ) column

Machine move to centre point

YES

Move to another side “B” “ of work-piece

Finished

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NO

Check if touch the limit of axes.


Cylinder . Flowchart Cylinder .

Thread wire thru up/lower guide then move to

Press Function Key

Move to another side “B” “ of work-piece

Set EDGE DIR 3(Y-) Set EDGE MODE(EDGE) Set Rec. PT ( 1 )


Cut off the wire

MAN

Press F5: EDGE MOVE

Press

START


Set EDGE DIR 0(X＋) Set EDGE MODE(EDGE) Set Rec. PT ( 0 )


Move cursor to CYLIND.., then key-in‵GO′，ENTER

Machine move to centre point

Finished

Press

START

Move to another side “C” “ of work-piece


While the action be completed and it record at ( REC.0 ) column

Set EDGE DIR 2(X-) Set EDGE MODE(EDGE) Set Rec. PT ( 2 )

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2-4-1-6 F6 (MDI. Cut) This function allows s to perform simple cutting action by entering one line or a maximum of 5 lines in the NC program. F6 MDI Cut Screen

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1.Reference Coordinate: Before executing MDI CUT, to set this reference coordinate. 2.2nd Reference Coordinate: To set any coordinate as the comparison during MDI CUT is on progress. 3. MDI. Cut Block Text: The area to quickly compose 1~5 lines N.C program. Machine would stop after the lines are finished. 4.MDI. Text Input Area: There to input the text what going to execute cutting process later on. 5. SC Code：To edit erosion data that will be used in MDI Cut.

Note: Before MDI. Cut, make sure system is in idle status and to avoid Alarm 10200.

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is on


MDI. Cut Flowchart Press MAN Press F6 MDI Cut

Edit MDI. Cut Block Text

Edit SC Code Press to proceed

NO

Wire break? NO

YES

N.C. language is used correctly?

MDI. Cut starts Try again.

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2-4-1-7 F7 (Coord. Move) This function allows s to move the system to the origin of the selected coordinate system by configuring the coordinate system. Coord. Move Screen

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2

Function Description： 1.Select reference coordinate : A to select the main reference coordinate this window. 2. Select coordinate system to display. There are 8 areas in B. for s to configure coordinate system which are： 0=Mach. coordinate, 1=PGM. coordinate, 2=G92 coordinate; 3=Local coordinate; 4=Go To (display residual movement of each block). G***=free coordinate system (G54~G59; G154~G159; G254~G259; G354~G359; G454~G459; G554~G559; G654~G659; G754~G759; G854~G859; G954~G959, a total of 60 sets.) Note.1. All coordinate systems are based on the mechanical system. When you move one coordinate system, the other coordinate systems would change relatively. 2. Move cursor to one of the coordinate system and press , worktable will move to the origin of that coordinate system. Input ‘C’ +ENTER to copy Mach. Coord or ‘R’ +ENTER to reset. 3. System status must be idle before Mem Coord. 4. Mem Coord. sequence is XYUV axis first, then Z axis. 2-112

CHMER Wire-Cut EDM Operation Manual W5F Formatted

2-4-1-8 F8 (Record Move) Allow to move worktable to the position of record point. Record Move Screen

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Function Description： 1.Select reference coordinate : A to select the main reference coordinate this window. 2. Select coordinate system to display. :There are 8 areas in B. f for s to configure record points which are 0~9=Rec. PT 0-9, 10=program start point, 11=G92, and 12=Wire break location. Note: 1. All coordinate systems are based on the Mach. Coord.. When you modify any one record point, the others would change relatively. 2. Move cursor to one of the record point and press , worktable will move to the target. 3. Input ‘C’ +ENTER to copy Mach. Coord. or ‘R’ +ENTER to reset. 4. System status must be idle before Record. Move. 5. Mem Record sequence is XYUV axis first, then Z axis.

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2-4-1-9 F9 (Angle Move) This function searches 2 base points on the work piece by means of edge search to calculate the intersection angle between the line formed by these2 points and the X-axis to provide s with a reference for mold calibration, program uses and axis rotation. Note: It is recommended to remove the water hose on the upper head and blow dry the up/low nozzles. Angle Move Screen

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Function description: 1.Start Pos.: Select the direction for measurement. 0-1 X-axis ；2-3 Y-axis ；4-5 X-axis ；6-7 Y-axis 2. Wire Feed: WF for calibration. 3. Wire Tension: WT used for calibration. 4. AR Setted: Axis Rotation. 5. Move Dist.: The move distance D between any 2 measure points. 6.X-axis angle：The intersection angle between the line formed by 2 measure points and the X-axis. After measuring the angle, input ‘AR’ + ENTER to input the angle to AR Setted or‘PR’ + ENTER to input the angle to MEM. Data Setted 1. 7. Angle error: The error between the present record and the previous results. 2-114


8.Angle PT0: Records the current position of measure point 1. 9.Angle PT1: Records the current position of measure point 2. 10.Graph illustration of Angle Move. Angle Move Example current wire position D=100mm 5 4 Table

Work piece

1. Press MAN F9 (Angle Move) Set Start Pos= 5 Set Wire Feed=10 Set Wire Tension=10 Set Move Dist.=100.000Press and wire will 5, retract, move for D=100mm, touch 4 and get the angle value Then, move cursor to. X-axis Angle when worktable stops Input ‘AR’ and press ENTER Input work piece angle to AR Setted.

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2-4-1-10 F10 (Corner Move) This function is to measure two linear sides of a work-piece in order to find X,Y position of a corner. Note : It is recommended to remove the water hose on the upper head and blow dry the up/low nozzles. Corner Move Screen

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5 6 Function description: 1.Start Pos.：Select which corner (0；1；2；3) to measure. 2. Wire Feed: WF for calibration. 3. Wire Tension: WT used for calibration. 4.Wire Dia.：Input the diameter of the wire currently used, and the corner point will automatically deduct the radius of the wire. 5.Move Dist.：DX, DY are the length of worktable movement. 6.Corner Ept.：The tolerance between the present and previous results. 7.Corner Pt.： Record the position of the current corner point. Move cursor to the corner point, enter ‘GO’ and press ENTER, the copper wire will move to the corner point of the work piece. 8.Corner Pt0： Records the current position of DX. 9. Corner Pt1： Records the current position of DY.

Note.1. Before Corner, make sure system is in idle status and is on to avoid Alarm 10200. 2. If the voltage is below 2V, the controller will alert the Alarm 2100. 3. Alarm 2000 will appear if the progress is interrupted. 2-116


Corner Move Example wire current position DX 20mm

Work Piece

Table

DY 20mm

Procedures Press MAN Press and to select Screen 1 Press F0 Corner Move Set Start Pos.= 2 Set Wire Feed=10 Set Wire Tension=10  Set Wire Dia.=0.25 Set Move Dist. DX=-20.00 and DY=- 20.00 press ENTER to start the action move the cursor to Corner Pt. when action stops input ‘GO’ ENTER worktable moves to the corner.

◎The Final Result Would be as follow:

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2-4-2 MAN (Manual mode) Submenu-2

2-4-2-1 F1 (Open Move) This function allows s to solve the short circuit problem caused by poor straightness of start hole. After performing Open Move, the cutting wire would be aligned to the start hole to resolve short circuit. Note : It is recommended to remove the water hose on the upper head and blow dry the up/low nozzles. Open Move Screen

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Formatted


Function description: 1. Wire Diameter: Input the correct wire diameter what is in use. 2. Wire Feed: Input the wire feed speed during edge finding. 3. Wire Tension: Input the wire feed tension during edge finding. 4. Search Radius: The machine moves within the radius with the start point as the center and Alarm comes up if it moves out of the radius. 5. Search Mode: There are 4 search modes as selection. 0=U. L. Line：4 axis (xyuv) move by actinoid path. 1=U. Fix&L. Line：2 axis (xy) move by actinoid path. 2=U.&L.ARC：4 axis (xyuv) move by circular path. 3=U.FIX&L.ARC：2 axis (xy) move by circular path.

Mode 0 Mode 1 Mode 2 Mode 3 6. Upper Plane：The position of the upper plane of work piece. 7. Lower Plane： The position of the lower plane of work piece.

Note.1. Before Corner, make sure system is in idle status and is on to avoid Alarm 10200. 2. If the voltage is below 2V, the controller will alert the Alarm 2100. 3. Alarm 2000 will appear if the progress is interrupted.

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CHMER Wire-Cut EDM Operation Manual W5F Formatted

2-4-2-2 F2 (3PT. Center) This function allows s to use the 3-point edge search method to automatically

search the edge and calculate the center of these points. Note: It is recommended to remove the water hose on the upper head and blow dry the up/low nozzles. 3PT.Center Screen

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Function description: 1.Operator Mode：Select to find center of a hole or a cylinder. 2.Rec.0 Angle Dir.：Angle division. Normally set as 0°. 3.Rec.1 Angle Dir.：Angle division. Normally set as 45°. 4.Rec.2 Angle Dir.：Angle division. Normally set as 135°. 5.Radius：The approximate radius (must be>actual cylinder diameter) of cylinder. 6.Cylind. .：The center of cylinder formed by Record P0~PT2. 7.Center EPT.：The tolerance between the present and previous results. 8.Cylinder Dia.：Diameter of a hole or a cylinder measured. 9.Record PT0：Position record No.1. 10.Record PT1：Position record No.2. 11.Record PT2：Position record No.3.

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2-4-2-3 F3 (Board Move) This function allows s to measure the center of a board (work-piece) outer profile with the edge search function. Note: It is recommended to remove the water hose on the upper head and blow dry the up/low nozzles. Board Move Screen

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9

Function description: 1.START POS.：Select direction for calibration.. 0[X＋]，1[Y＋]，2[X－]，3[Y－] 2.Edge OP. Flag : Disable or Enable the Edging mode [The surface of a side ] 3.Wire Feed: The speed of wire feeding during edge search. 4.Wire Tension: The speed of wire tension during edge search. 5.Wire Diameter: Input the correct brass wire what is in use. (It will deduct the radius of wire into “BOARD ”) 6.Board Move (W): Estimate the width of the board. (Work-piece) 7. Board Move (D): Estimate the moving distance out of 8.Board E: According the input information to estimate the size of the board. (Work-piece) 9.Board Width：The measured width of the board. (Work-piece) 10.Board .：Record the position of the current center point. Move cursor to the center point, enter ‘GO’ and press ENTER, the brass wire 2-122


will move to the center point of the work piece. 11.Board PT0: Records the current position of DX 12. Board PT0: Records the current position of DY  Example for BOARD MOVE 1. Confirm the machine is in “IDLE” status. 2. Fix the work-piece on the work table. 3. Setup for the need information e.g. START POS.、Edge OP. Flag 、Board Move (W&D) and so on. 4. Press “START” and make sure the function is activated. (Gap Volt. Around 5~7 V in the progress) 5. While the action be completed and it record at ( BOARD PT0 ) column 6. Move to another side of the work-piece and to do edge finding. 7. While the action be completed and it record at ( BOARD PT1 ) column 8. The 3rd step edge finding on the surface of the work-piece. 9. The last move the cursor to board . column and press “GO” and “Enter” 10. Done. Note: 1. Before Corner, make sure system is in idle status and is on to avoid Alarm 10200. 2. If the voltage is below 2V, the controller will alert the Alarm 2100. 3. Alarm 2000 will appear if the progress is interrupted.

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2-4-2-4 F4 (EDGE ALIGN) This function allows s in realistic to measure the angle of a work-piece. The machine upper head (U, V axis)will move to align the angle of a work-piece (Edge-Find). Note: It is recommended to remove the water hose on the upper head and blow dry the up/low nozzles. Edge Align Screen

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Function description: 1.Align DIR.：Select direction for calibration. 0[X＋]，1[Y＋]，2[X－]，3[Y－] 2. Align UV Move: The estimate distance to reach the work-piece. 3. Z PT. (UV): The shift distance between U&V axes. 4. Align UP PT.: The height of Upper position. (On work table) 5. Align DN PT.: The height of Lower position. (On work table, usually is “0” unless there is a block to pull high) 6. OBJ. VERT. PT.: Work piece vertical point. 7. E. VERT. PT.: Vertical point error. 8. L. VERT. PT.: The angle error compared from current and the last time. 9. Align PT0: Record the aligned information of machine coordinate 0. 10.Align PT1: Record the aligned information of machine coordinate 1. 11. Align PT2: Record the aligned information of machine coordinate 2. 2-124


 Example for EDGE ALIGN 1.Confirm the machine is in “IDLE” status. 2.Fix the work-piece on the worktable. 3.Setup for the need information e.g. Align DIR., Align UV Move, Align UP PT., Align DN. PT. and so on. 4. Press “START” and make sure the function is activated. (Gap Volt. Around 5~7 V in the progress) 5. U&V axes moving and to do edge finding. 6. Move to another side and do edge finding. 7. Record the position to Align PT0, Align PT1 and Align PT2. 8. Calculate the record position and then move the cursor to Z PT. (UV) column and then press “GO” and “Enter” 9. Done. Note: 1. Before Corner, make sure system is in idle status and is on to avoid Alarm 10200. 2. If the voltage is below 2V, the controller will alert the Alarm 2100. 3. Alarm 2000 will appear if the progress is interrupted.

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2-4 MAN (Manual Mode) Operation Guide The MAN function allows s to calibrate the work piece and machine, search the origin, make simple positioning and perform cut actions. There are two sub-function menus in the MAN function; s can press buttons to switch to different sub-function menus. MAN (Manual Mode) Submenu-1 Screen 8

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1. Name of current NC program 2. Coordinate display: This controller provides 65 sets of coordinate systems for s to choose from. a. Mach. Coord: This coordinate system is formed with the origin of various axes. This system is not modifiable; and gear gap and node distance compensations are made according to this coordinate system. b. PGM: This coordinate system is formed according to the first G92 point of an NC program and cannot not modified. c. G92 Coordinate: This coordinate system is formed according to other G92 of a NC program and cannot not modified. d. Local Coord.: This coordinate system allows s to configure and check the 2-85


accuracy of processing programs. Move cursor to the coordinate setup column and modify the coordinate value according to the methods below. 1. Input X__Y__Z__U__V__ + ENTER values to setup the value of individual axis. 2. Input C + axis name + ENTER name to copy the axis value of mechanical coordinates. Input C + ENTER to reset all axis 3. Input R + axis name + ENTER to set the axis value to “0”. Input R + ENTER to reset all axis. e. Go To (Dist Go To): Show the residual movement of each block of a N.C. program. f. Work Coordinate.: W5F controller provides 60 sets work coordinate system (G54~G59, G154~159,...G954~G959) 60 sets of coordinates open for doing position moves among different molds and performing erosion on each mold. 3. AR Set: After configuring AR, the coordinate of the original X and Y axes will rotate at a certain angle according to the settings. It will be unable to do Search Home when AR is in use. a. AR: Axis rotation angle, s can directly input a value to configure the rotation angle corresponding to X axis. If the value is not ‘0’, data displayed machine status will show ‘AR’ on the top of screen to remind s that axis AR now is in use. b. V: Vertical offset distance of axis rotation. c. H: Horizontal offset distance of axis rotation. 4. Hints column: Hints column provides information of the corresponding settings of the item where the cursor is located. 5. Data input area: Based on the settings of the hints column, s can input the setup item in this area. 6. Submenu button : Switch to the other submenu 7. Function key: Allow s to select various functions. 8. N-code display column: Displays the current N-code position of a program. If there is no N-code in a program, value in this column will be N00000. 9. Mode display area: Display which mode is currently in use. 10. Axis function display: Displays axis functions currently in use: MX: X-axis Mirror; MY: Y-axis Mirror; EXY: XY Axes Mirror; PS: Program Scaling Mode; PR: Program Rotation Mode. 11. Z-Lock display area: After Z-Lock SW is turned on, this area would appear the message. 2-86


12. AR display area: After AR is turned on, this area would appear the message. 13. Other information display: This column displays the following data: (1) system elapsed time; (2) metric and British system display; (3) program version (e.g. F03.08); and (4) SC code version (e.g. 2.7). 14. Time counter: Display the current time. 15. Voltage meter: Display the voltage on processing. 16. Voltage display: Display the voltage value on the progress. 17. Feed rate: Display the speed of table movement. (e.g. a. Edge search speed b. Dry run Speed c. Feed-rate Speed) 18. Cutting data area：Display the current cutting condition. 19. Information area (1): Displays machine information like working status, message and Alarm code. 20. Information area (2): Displays the current information status such as axis limit, power-off, I/O 232 error, AWT error and other information.

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CHNER Wire-Cut EDM Operation Manual W5F

2-5 MDI (S.Code Data Mode) 2-5-1 F1 (S.Data List) S.Data List is a database which contains S.C 0~9999 (total 10,000) codes erosion technology for s to set during machining. F1: S. Data List Screen

Note. Among S.C. 0~999 are opened to edit and modify for s; S.C.1000~S.C.9999 are pre-loaded by manufacturer and are available to modify through entering .

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2-5-2 F2 (DEF. S. BASE) DEF. S. BASE is a bar-article database; it’s used to provide a fast way to choose the needed S. Code in ’s common jobs. There are the blank 2,000 codes could be filled up by s. CHMER has pre-loaded 335 codes which are called from built-in data base; and s may add and modify the database via「F3 Search Offset」. (Note: is requested.) F2: S. DEF. S. BASE

Note: 1. s can use the command such as「ALT+N」to sort data by “CUT-NUM” (Cut Numbers), or「ALT+M」to sort data by “Material”, or 「ALT+W」 to sort data by “Wire Diameter”, or「ALT+T」to sort data by “Thickness”, or 「ALT+D」to sort data by “Date” (Data Built Date) properly 2. s may pull up/ down the right window scroll to review the built data; further to press “ENTER” on the indicated data output to「F3 Search Offset」for advanced setting.

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2-5-3 F3 (Search Offset) Search Offset acts as a guideline to help s find out suitable erosion data from database by inputting the work condition such as Wire Dia., material of work-piece…etc. In addition, the erosion data and H or D offset can be saved to memory buffer of processing in the controller by turning on function. Besides, there s can save S.C. data into the bar-article database in F2 (DEF. S. BASE) & F4 (USE. S. BASE) for commonly & repeatedly jobs. F3: Search Offset Screen







Function description： 1. Work condition input a. Wire diameter: value of brass wire diameter b. Material: work piece material (0=-defined, 1=SKD-11, 2=Copper, 3=Tungsten Steel, 4=Aluminum, 5=Graphite, 6=SKD-61, 7=Titanium, 8=P20) c. Thickness: work piece thickness d. Condition: setting search condition accords to cutting method and finished products d. No. Of Cut: the number of cut required

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e. : the erosion data and S and H offset can be saved to memory buffer of processing in the controller, i.e.「AUTO-2」->F4 MEM SKIM &「FILE-3」-> F4 SIM.SKIM or enter S and H code name before running. 2. Erosion data and H offset setting area：To set S.Code data and offset in each cut separately. s can use E*** to call from DEF or S*** to save. 3. 「Bar-article」database setup: firstly choose to save data in “Default” or “” database, then to go「REG.DAT.BAS」press “Enter” to save. (F2:DEF.S.BASE or F4:USE.S.BASE ) 4. COMP.SHIFT VALUE: To match with ” ”, may modify the H offset value in memory buffer during the process.

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2-5-4 F4 (USE S. BASE) USE S.BASE is a bar-article database; it’s used to provide a fast way to choose the needed S. Code in ’s common jobs. There are total blank 2,000 codes could be filled up by s. CHMER has pre-loaded 335 codes which are called from built-in data base; and s may add and modify the database via「F3 Search Offset.」 F4: USE DEF.S.BASE Screen

Note: 1. s can use the command such as「ALT+N」to sort data by “CUT-NUM” (Cut Numbers), or「ALT+M」to sort data by “Material”， or 「ALT+W」to sort data by “Wire Diameter”, or 「ALT+T」to sort data by “Thickness”, or「ALT+D」to sort data by “Date” (Data Built Date) properly. 2. s may pull up/ down the right window scroll to review the built data; further to press “ENTER” on the indicated data output to「F3 Search Offset」for advanced setting.

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2-5-5 F6 (CORNER BASE) CORNER BASE is a bar-article database; it’s used to provide a fast way to choose the needed “Corner Setting” in ’s common jobs. There are the blank 960 codes could be filled up by s. (No. 0~959) s may add and modify the database via「F7 Modify Corner」. F6: CORNER BASE Screen

Note: 1. s can use the command such as「ALT+M」to sort data by “Material”, or 「ALT+W」to sort data by “Wire Diameter”, or「ALT+T」to sort data by “Thickness”, or「ALT+D」to sort data by “Date” (Data Built Date) properly. 2. s may pull up/ down the right window scroll to review the built data; further to press “ENTER” on the indicated data output to「F7 Modify Corner」 for advanced setting “REG.DAT.BAS” or “SET TO WORK AREA”.

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2-5-6 F7 (Modify Corner) Search Offset acts as a guideline to help s sorting a suitable “Corner” data into bar-article database；also on the go to save & find corner data for commonly & repeatedly jobs. F7: Modify Corner Screen





  

Function description: 1.Work condition input a. Wire diameter: Value of brass wire diameter. b. Material: Work piece material (0=-defined, 1=SKD-11, 2=Copper, 3=Tungsten Steel, 4=Aluminum, 5= Graphite, 6=SKD-61, 7=Titanium, 8=P20) c. Thickness: Work piece thickness d. Condition: Setting search condition accords to cutting method and finished products 2.REG. DAT. BAS.： firstly doing the corner setup at right-hand area, then to go 「REG.DAT.BAS」press “Enter” to save into the「Bar-article」database. (F6: CORNER BASE ) 2-132


3.SET TO WORK AREA: firstly doing the corner setup at right-hand area, then to go「SET TO WORK AREA」press “Enter” to copy into 「MEM-1」 -> F5: CORNER DATA. 4.WORK AREA MOD.: Opposite “SET TO WORK AREA”. After pressing “Enter”, it recall (load) the present corner data from「MEM-1」-> F5: CORNER DATA to here for further setup. 5. Corner data setting area: To refresh the setting corner data then save or output.

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2-5-7 F9 (Delete Data) Usually this function remains dark, if the screen stays at F2 DEF. S. BASE, F4 USE.S. BASE or F6 CORNER BASE then s can proceed to delete the bar-article data through this key. F9: Delete Data Screen

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2-5-8 F10 (Copy Data) Usually this function remains dark, if the screen stays at F2 DEF.S. BASE, F4 USE.S. BASE or F6 CORNER BASE then s can proceed to copy the bar-article data through this key. F10: Copy Data Screen

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2-6 HELP (Help Function) 2-6-1 F1 (System Message) This function displays the message codes what had ever showed on the screen, i.e. time, date and description of message that had recently appeared in the controller. System Message screen

Contents description Description of machine, NC program status, error message, and the occurrence time, date and what code and descriptions according to the code sequence of NC editing message.

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2-6-2 F2 (Device Info.) This sub-function displays the current status of use of every system device. Device Info screen

1.

2.

6.

3.

7.

4.

5.

8.

9.

Contents description 1. Device Name：The list of consumables parts that are monitored by controller. 2. Use Count：A counter that shows that used hours of the consumables parts to remind s . Press ‘R’ + ENTER to reset after replacement. 3. Life Count：Recommendation of replacement of consumable parts life span. (Note: Need for entry setup and input format i.e.400000=40:00:00=40 hours) 4. Reset Date：Indicates the date when the consumable parts must be replaced. 5. Red bar means the percentage of devices that has been used, and green means the remaining unused percentage.

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Note:

If the use percentage of all devices exceeds 100%, the message “Device” will be displayed in the status column on the screen of the controller to notify s; but it does not interfere to stop machine process for operation at all. 6. W.RESIST / SET：(OPTION) Only some specify models can equip this hardware. (Please consult it from the selling agency)Just send command in software to set water conductivity value instead of to go the setup on water conductivity control . 7. W.TEMP/SET: (OPTION) Only some specify models can equip this hardware. (Please consult it from the selling agency)Just send command in software to set water temperature value instead of to go the setup on water chiller control . 8. MACH. TEMP/SET: (OPTION) Only some specify models can equip this hardware. (Please consult it from the selling agency)Just send command in software to set temperature compensation value；while controller receive the value then transform into H offset to maintain the job accuracy. (Note: This function still keep going on experiment. ) 9. DEV.EXCHG.: Enable /Disable the function# 6~8.

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2-6-3 F3 (Work Set) This sub-function lists some work settings of the controller. Work Set Page 1 Screen

1.

2.

Function description 1. Flag a. Font SW.: Text language (0=English; 1=Chinese) (Note: It’s temporary to change the function text language, but system message text stay remain; if necessary then must to change the flag parameter and reboots) b. Unit SW: Length unit (0=Metric; 1=British Inch) (Note: It’s temporary to change the function text language, but system message text stay remain; if necessary then must to change the flag parameter and reboots) c. Nc. Msg. Sw: 0=Off; 1=On (Program name scan) d. En. Ex. Counter.: 0=linear; 1=arc 2-139


e. Touch Screen Enable: (OPTION) Enable / Disable the touch . It is only available while machine equipped this hardware. f. Touch PT. Mark Show Switch: Setting oiler GAP TIME or MOVE TIME. g. Oiler Integrated: 0=Off; 1=On 2. Section a. Adc Low Base: Reference value of 0V converted from ADC. (Note: shall not modify the value himself, otherwise it may cause the cutting accuracy problem since voltage has been varied, please consult from the selling agency if need) b. Adc High Base: Reference value of 100V converted from ADC. (Note: shall not modify the value himself, otherwise it may cause the cutting accuracy problem since voltage has been varied, please consult from the selling agency if need) c. Rece. WT.: Wire tension when retracting. (Note: Equal to S.C. “WT”) d. Rece. WF: Wire feed when retracting. (Note: Equal to S.C. “WF”) e. Rece. WL: Flush water pressure when wire retracting. (Note: Equal to S.C. “WL”) f. Eg. Srt. Gap: Short circuit voltage in Edge Move. Alarm message would appear once actual voltage drops below the setup value. (Note: The default value is 2, setting range from 2 to 5.) g. Eg. Spark Gap.：The lowest eroding voltage while performing Edge Move. Alarm message would appear once actual voltage drops below the setup value. (Note: The default value is 20, setting range from 10 to 70. ) h. Spark Srt. Gap.：Short circuit voltage while performing erosion. Alarm message would appear once actual voltage drops below the setup value. (Note: The default value is 10, setting range from 4 to 50. ) i. Comp. Init. Path Inc. Wt: Adjust the wire tension in AUTO=> F2 Page1 j. Color Id：Color code: Change the system background color. 0=black and white; 1=default color; 2=self-defined color. k. Lcd Coord. Id.：Coordinate system displayed on the remote control (0=Mach. Coord.; 1=program Coord.; 2=G92; 3=Local Coord. 4=Residual Coord.

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Work Set Page 2 Screen

1.

2.

3.

Function description 1. TIMER a. CRT Off Time: Screen Saver. The controller will shut off the screen if no data are entered after this value. (Note: The minimum setting is 30 sec) b. Buzzer Time: Buzzer action time (period) to remind s. c. Mem. Spark Acc.: Discharge energy acceleration time. d. Mem. Spark Delay: The delay of discharge power initiation (ED-POS) when initiates processing. e. Short Time: The short circuit judge time during program processing. f. S-code delay: The S-code action delay time. g. M code Delay Stop: Program M00 pause delay time. h. Rece. Wire Time: The delay time of wire retraction after manual threading is done. (Note: For equipped AWT m/c only) i. Low Water Filter: The delay time for action after water level sensor is triggered. j. WIRE FR. TM.: (For wire dia. 0.1mm in use) To prevent wire breaks from a sudden voltage rising at begins of processing. k.WIRE TN.TM.: (For wire dia. 0.1mm in use) To prevent wire breaks from a sudden tension rising at begins of processing. 2-141


l. RECE. WIRE DELAY: AWT race wire delay when wire breaks at sparking. m. TANK SLEEP: Input tank sleep time. 2. DIST. SET a. Z-axis height: Set the distance between the Z-axis origin and worktable. b. Edge Back Dist: The retract distance of machine after Edge Move is done. c. Edge Short Dist: The sense short distance of edge search is on progress. d. Edge Max Dist: The maximum distance of Edge Move. Controller will interrupt and gives warning signals if exceeded this distance. e. Short Dist: The retract distance once short is occurred. f. X&U Prot. Dist: X, U travel reduction (+/- direction) to avoid collision. g. Y&V Prot. Dist: X, U travel reduction (+/- direction) to avoid collision. h. Y&U Prot. Dist: Y, U travel reduction (+/- direction) to avoid collision. i. Z Protect Pt.: Protect distance accords to XY axes. j. AWT Wire Param.: Input the correct diameter of wire used. k. Z Home Prot. PT.: Z Down protection when using MEM1=>F1 function. 3. Name a. Mach. Name: Machine name b. Spark Ver.: Version of erosion database that installed in controller. c. FLOPPY Path: Path of storage device “ floppy drive”. d. HD. Path: Path of storage device “ Hard drive”. (i.e. CF Card, DOC, Hard Disk…etc) e. STORAGE 0 Path: Path of 1st USB storage device. f. STORAGE 1 Path: Path of 2nd USB storage device. g. Machine ID: Given serial number of machine. h. Power Box ID: Given serial number of Power Cabinet (Generator). i. NC. EXT. NAME: NC file format. If input「*」then all file format can be recognized in controller；If input 「TXT」or「NC」then only *.txt and *.nc files can be recognized when browsing.

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Work Set Page 3 Screen

Function description 1. System Info 1. (only available in specific machine model; as well as the functions in F2 DEVICE INFO.) a. W. Resist/ Set: Status: Setup the resistance of dielectric. b. W. Temp / Set Dac: Setup the temperature of dielectric in the work-tank. c. Mach. Temp/Set: Setup the temperature of air-conditioner installed inside the machine. d. Curr. / Target Temp: Display of current and target temperature.

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2-6-4 F4 (Net Set) This function provides s can do FTP Ethernet transmission；to and the needed files between controller and PC. (Note: The file format only *.nc or *.txt ) Net Set Screen

2.

1.

3.

Function description: 1. Machine Data a. Machine Name: Input the “ name” of Ethernet setup. b.Machine IP.: Input the main IP address. The format is : 192. 

168. 

0. 

53. 

Note: #1~#3 must set the same according to present domain address；regard to #4, may set any address from 0 to 2-144


255 that don’t conflict for each other. c. SUB.MASK.IP: Input the secondary IP address. The format is:

d.

255.

255.

255.







0. 

GATEWAY IP: Input the correct gateway IP address if must across another. domain address, The format is :

192. 

168.

0.





1. 

2. FTP DATA a. FTP SERVER : If machine controller to be Client end, and PC to be server end, then needs to require the from server to entry. b. FTP SERVER IP: As above mentioned, the client end must confirm the correct server IP address then can search on Ethernet. c. CUSTOMER NAME & : If machine controller to be Server end, and PC to be client end, then controller becomes and must provide the name & for s to entry. Cautions: Before connecting the network, s must confirm that connection between IP HUB and Ethernet Card (installed in PC) would be fine. The signal will lit on of the Ethernet card.

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Appendix ： Ethernet Setup（ETHRRNET SET） The construction of Ethernet Network is through a physical switching HUB there are the cables connected between server (’s PC) and client (CHMER controller); CHMER provide the Ethernet connector be ready on our controller (GIPC .NET board) and attach full authorized software ed. Refer the figure as follow:

Note：Repeatedly to check the work lamp LED status whether lit on mother board (controller) & switching HUB. It’s quite important ! Otherwise, the setup of local LAN becomes meaningless, before the software operation must confirm this point in advance. There, step by step we would utter the setup procedures into three parts separately: 1. Setup of PC or Laptop（server; computer） 2.Configure the content of the batch file AUTOEXEC.BAT & boots memory load file CONFIG.SYS 3. Setup of Controller software（client; controller)）

Connection Example：[Machine controller as server end, PC as client end] STEP1：(PC) Mouse cursor select 「START」  「EXECUTION」input command 「cmd」， entry to virtual DOS，input command 「ipconfig」，then can acquire the information：1. Machine IP Address 2. Sub Mask IP 3. Gateway IP address...etc. STEP2：(IPC) Press “Help” button F4: NET SET，then input machine IP address、 Sub Mask IP 、Gateway IP address and doing setup 「CUSTOMER 2-146


NAME」 &「」. STEP3： (PC) Mouse cursor select「START」「EXECUTION」input command 「cmd」, entry to virtual DOS，input command「ftp 192.168.0.xxx IP Address」 examine the connection whether success, if yes, then it appears ftp >____ message. STEP4：(PC) Mouse cursor select「START」 click「IE Explorer」and input web address「ftp 192.168.0.xxx ip 位址」  A window comes up and inquire (S NAME)、(), please input those information as required, then it will enter to a window folder, s can start to use 「copy」、「paste」 to and files. Note： even may consider client end files management software such as 「CUTEFTP」to add the files transmission efficiency.

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2-6-5 F5 (Message Text) Descriptions of the alarm message and codes. Message Text Screen

1

W5F MESSAGE, ALARM and ERROR CODE DEFINITION 4 5 6 10 20 40 60 62 64 70 80 90 100 101 102

SOFTWEAR AND HARDWEAR SERIAL NUMBER NOT MITCH U_NUMBER_NOT_MITCH SYSTEM DATAS ARE NOT MITCH LAST SHUT DOWN! CONTROL SYSTEM READY OK. CONTROL SYSTEM POWER READY OK! CONTROL SYSTEM SHUT DOWM OK SYSTEM PARAM.SET TO DEFAULT PARAM. SYSTEM DATE & TIME IS SETTED BEFORE NOW. SYSTEM DATE & TIME IS SETTED AFTER NOW. DEFAULT PARAM.SET TO SYSTEM PARAM. CONTROL SYSTEM SEND PARAM.TO AWT.MODULE OK! SYSTEM MEMORY POOL EMPTY X AXIS POSITION ERROR IN EPCIO MODULE. Y AXIS POSITION ERROR IN EPCIO MODULE. Z AXIS POSITION ERROR IN EPCIO MODULE. 2-148


103 U AXIS POSITION ERROR IN EPCIO MODULE. 104 V AXIS POSITION ERROR IN EPCIO MODULE. 200 GLOBAL VARIABLE ERROR WHEN VALUE OPERATOR 201 GLOBAL VARIABLE ERROR WHEN VALUE OPERATOR 202 SYSTEM VARIABLE ERROR WHEN VALUE OPERATOR 203 H. VARIABLE ERROR WHEN VALUE OPERATOR 204 D. VARIABLE ERROR WHEN VALUE OPERATOR 210 ACOS FUNCTION ERROR WHEN VALUE OPERATOR 211 SQET FUNCTION ERROR WHEN VALUE OPERATOR 212 VALUE CODE ERROR WHEN VALUE OPERATOR 220 RIGHT "]" MISS WHEN VALUE OPERATOR 221 LEFT "[" MISS WHEN VALUE OPERATOR 230 OPERATOR UNIT TOO MANY WHEN VALUE OPERATOR 250 VALUE CODE ERROR WHEN VALUE OPERATOR 251 DIVION IS ZERO WHEN VALUE OPERATOR 260 VALUE OUTSIDE MAX.RANGE WHEN VALUE OPERATOR 261 VALUE OUTSIDE MIN.RANGE WHEN VALUE OPERATOR 262 RULE ERROR WHEN VALUE OPERATOR (EX20.5) 1000(**)DRIVER ALARM[**=01(X),02(Y),04(Z),08(U),16(V),31(XYZUV)] 1100(**)TOUCH HARD LIMIT SWITCH[**=01(X),02(Y),04(Z),08(U),16(V),31(XYZUV)] 1150 BRAKES ACTIVE IN LINEAR MOTOR TYPE 1200(**)TOUCH SOFT LIMIT SWITCH[**=01(X),02(Y),04(Z),08(U),16(V),31(XYZUV)] 1300(**)ERROR OVERFLOW[**=01(X),02(Y),04(Z),08(U),16(V),31(XYZUV)] 1400 IO232 LINK OFF 1450 PG232 LINE OFF or OFF 1480 WATER EMPTY IN TANK 1490 OILER LUBRICATES 1492 LUBRICANT IS EMPTY IN OILER DEVICE 1500 DEVICE POWER OFF 1520 HI-POWER SOFTWEAR DEVICE 1521 HI-POWER HARDWEAR DEVICE 1530 SCODE DATA PROTECTED (OV<4&&PW=**0) 1532 CE. FUNC. PROTECTED 1540 SPARK POWER RELAY CAN'T ON BEACUSE WIRE BREAK 1541 SPARK POWER RELAY CAN'T ON BEACUSE WIRE NOT FOUND 1542 SPARK POWER RELAY CAN'T ON BEACUSE CE.FUNC. 1600 AWT. MODULE ERROR 1610 OVER LIMIT FRICT SENSOR 1620 WIRE THROUGH TIME OUT 1621 WIRE THROUGH CAN'T LOW GUILD 1622 WIRE THROUGH FAILURE 2-149


1640 1690 1695 1699 1703 1729 1730 1731 1732 1734 1735 1736 1737 1744 1746 1800 1810 1820 1830 1840 2000 2010 2021 2022 2023 2024 2040 2041 2042 2043 2044 2051 2052 2053 2054 2055 2056 2057 2058 2059 2060 2061 2062

WIRE BROKEN MESSAGE PRESS "STOP" KEY TO ABORT AWT.CMD Z AXIS MOVING,MAY BE TOUCH OBJECT PRESS "STOP" KEY TO ABORT AWT.CMD WIRE THROUGH CAN'T SENSOR UP GUILD SENSOR ERROR ENCODER ERROR HEATOR ERROR HEATOR ERROR AIR TOO WEAK(UP 5KG/CM/CM) DURING DO ANNEAL,WIRE BROKEN AWT MODULE ERROR CLIPPER POSITION SENSOR DURING DO ANNEAL,WIRE BREAK SWITCH NOT READY AC. DRIVER ALARM AT AWT. MODULE AWT.MODULE SET PARAMETER or LINK ERROR AWT.MODULE LINK OFF AWT.MODULE DRIVER ALARM AWT.MODULE AIR TOO WEAK(UP 5KG/CM/CM) WIRE EMPTY in AWT. MODULE PRESS STOP KEY WHEN TABLE MOVING. DRIVER or MOTOR ERROR WHEB TABLE MOVING. CAN’T EXEC. HOME OP. WHEN AR. ON CAN’T EXEC. HOME OP. WHEN PROT. ON CAN’T EXEC. HOME OP. WHEN MACH. LOCK ON CAN’T EXEC. HOME OP. WHEN Z MACH. PT. BELOW Z PORT. PT. ABORT RETURN VERTICAL PT. BY PRESSING STOP KEY ABORT START PT. BY PRESSING STOP KEY ABORT BREAK PT. BY PRESSING STOP KEY ABORT RE-TRACE START PT. BY PRESSING STOP KEY ABORT TRACE BREAK PT. BY PRESSING STOP KEY ABORT MEN1>F1 CMD. BY PRESSING STOP KEY ABORT MEN1>F2 CMD. BY PRESSING STOP KEY ABORT MEN1>F3 CMD. BY PRESSING STOP KEY ABORT MEN1>F4 CMD. BY PRESSING STOP KEY ABORT MEN1>F5 CMD. BY PRESSING STOP KEY ABORT MEN1>F6 CMD. BY PRESSING STOP KEY ABORT MEN1>F7 CMD. BY PRESSING STOP KEY ABORT MEN1>F8 CMD. BY PRESSING STOP KEY ABORT MEN1>F9 CMD. BY PRESSING STOP KEY ABORT MEN1>F0 CMD. BY PRESSING STOP KEY ABORT MEN2>F1 CMD. BY PRESSING STOP KEY ABORT MEN2>F2 CMD. BY PRESSING STOP KEY 2-150


2063 2064 2070 2140 2141 2142 2143 2144 2151 2152 2153 2154 2155 2156 2157 2158 2159 2160 2161 2162 2163 2164 2170 2200 2210 2300 2400 2500 2600 2610 2602 2612 2700 2740 2800 2810 2820 2900 2902 3000 4000 4010 4020

ABORT MEN2>F3 CMD. BY PRESSING STOP KEY ABORT MEN2>F4 CMD. BY PRESSING STOP KEY ABORT MEN2>F0 CMD. BY PRESSING STOP KEY RETURN VERTICAL PT. BY USING JOG CMD. RETURN START PT. BY USING JOG CMD. RETURN BREAK PT. BY USING JOG CMD. RETURN RE-TRACE START PT. BY USING JOG CMD. RETURN TRACE BREAK PT. BY USING JOG CMD. MEM1>F1 CMD. IS FINISHED MEM1>F2 CMD. IS FINISHED MEM1>F3 CMD. IS FINISHED MEM1>F4 CMD. IS FINISHED MEM1>F5 CMD. IS FINISHED MEM1>F6 CMD. IS FINISHED MEM1>F7 CMD. IS FINISHED MEM1>F8 CMD. IS FINISHED MEM1>F9 CMD. IS FINISHED MEM1>F0 CMD. IS FINISHED MEM2>F1 CMD. IS FINISHED MEM2>F2 CMD. IS FINISHED MEM2>F3 CMD. IS FINISHED MEM2>F4 CMD. IS FINISHED MEM2>F0 CMD. IS FINISHED EDGE or VERT.MOVE DIST.TOO LONG GAP VOLTAGE ERROR WHEN SEARCH EDGE PITCH PARAMETER TXT NOT FOUND NOT VERT.PT.WHEN DADB OPERATOR SEARCH HOLE OPEN RANGE OVERFLOW SETTED SPARK*OFFSET(NEW) DEFAULT DATA BASE SPARK*OFFSET(NEW) DATA BASE SPARK*OFFSET(MODIFY) DEFAULT DATA BASE SPARK*OFFSET(MODIFY) DATA BASE SPARK&OFFSET or SET FAILURE(EDIT THIS FILE) SPARK&OFFSET or SET FAILURE(ABSENT IN DATA BASE) NOT VERT.PT.WHEN ALIGN OPERATOR UP, DOWN GUIDE DISTANCE ERROR WHEN ALIGN MOVE TABLE MOVES TO OBJECT VERT. PT. CORNER DATA DATA BASE CORNER DATA (MODIFY) DATA BASE CAN'T COMPUTER OUTSIDE CENTER! OPEN FILES TOO MANY IN EDIT MODULE MEMORY ERROR IN EDIT MODULE MEMORY ERROR IN EDIT MODULE 2-151


4050 4080 4100 4110 4200 4210 4300 4400 4410 4420 4430 4450 4500 4510 4520 4600 4605 4610 4620 4630 4640 4700 4720 4721 4722 4723 4724 4725 4726 4800 4810 4850 4860 4870 4880 4890 4892 4894 4900 4910 4920 4930 5000 5010

CLOSE FILE DISABLE WHEN THIS FILE CUTTING EDIT_COPY_ERROR NC.TEXT FORMAT ERROR NC.MEMORY ERROR MOVE CURSOR OUTRANGE IN EDIT MODULE SEARCH N CODE IN EDIT MODULE SIMULATE OPERAROR PRESS ESC KEY ABORT RECEIVER or SENDER OK WHEN DNC OPERATING DNC INPUT WAIT TOO LONG TIME DNC INPUT WAIT CHAR TOO LONG TIME DNC ABORT by DNC TRANSFER TABLE ERROR CAN'T MODIFY,DELETE,SAVE FILE WHEN EDITING OPEN FILES TOO MANY WHEN EDITING OPEN FILE ERROR INSERT STRING IS NOT SETTED INSERT STRING LENGTH TOO OVERFLOW SEARCH STRING IS NOT SETTED SEARCH STRING IS NOT FOUND REPLACE STRING IS NOT SETTED REPLACE STRING IS NOT FOUND SPARK OFFSET SET SET NC DATA INTO NC.PGM. SET TAPER DATA INTO NC.PGM. SET CONRER(INNER0) DATA INTO NC.PGM. SET CONRER(INNER1) DATA INTO NC.PGM. SET CONRER(OUTER0) DATA INTO NC.PGM. SET CONRER(OUTER1) DATA INTO NC.PGM. SET AWT.WORK DATA INTO NC.PGM. EDIT BLOCK ERROR MANY WHEN EDITING EDIT BLOCK ERROR MANY WHEN EDITING PRESS STOP WHEN BROWSERING FILE NAME FILE NAME NOT EXIST WHEN EDITING NC.PGM.COUNT TOO MANY WHEN EDITING MEMORY ERROR WHEN EDITING EDIT_BROWSER_ USE_ERROR EDIT_BROWSER_USE_ID_ERROR EDIT_BROWSER_USE_ABORT NOT MITCH WHEN INPUTING TOO LONG WHEN INPUTING NOT MITCH WHEN INPUTING MODIFY PARAM.ERROR WHEN ERROR M.CODE STOP WHEN RUNNING NC.PGM. SINGLE STOP WHEN RUNNING NC.PGM. 2-152


5015 5020 5030 5040 5050 5060 5070 5080 5090 5100 5112 5115 5116

PGM. AND G92 COORD. DON’T MATCH WIRE BREAK WHEN RUNNING NC.PGM. WIRE SHORT WHEN RUNNING NC.PGM. PRESS STOP KEY FEEDHOLD WHEN RUNNING NC.PGM. SYSTEM SLEEP ACTION. PGM.START POINT NOT MITCH WHEN SKIM CUT OP. BLOCK SKIP KEY IS PRESSED WHEN RUNNING NC.PGM. EXCHANGING DEVICE SWHEN RUNNING NC.PGM. WAIT PLC MODULE INPUT SIGNAL WIRE EMPTY WHEN RUNNING NC.PGM. INTER SENDER WHEN PGM. CUT AWT. MODULE ALARM RUNNING NC. PGM. (DRIVER ALARM) AWT. MODULE ALARM RUNNING NC. PGM. (LOW AIR PRESSURE) 5117 AWT. MODULE ALARM RUNNING NC. PGM. (WIRE EMPTY) 5118 AWT. MODULE ALARM RUNNING NC. PGM. (CODE: 16111, 16211 SAME) 5119 AWT. MODULE ALARM RUNNING NC. PGM. (CODE: 16112, 16212 SAME) 5120 M20 STOP WHEN KEY M20-STOP ON 5121 M21 STOP WHEN KEY M21-STOP ON 5122 M22 STOP WHEN AWT CUT MODE =M22 MODE. 5200 CONTROLLER SYSTEM USE OVERTIME! 5210 CONTROLLER SYSTEM USE OVERTIME! 5220 CONTROLLER SYSTEM USE OVERTIME! 5230 CONTROLLER U ID. ERROR 5240 THE LIFE OF CONTROLLER WILL APPROACH OVERTIME 5250 ETS CAN’T RUN UNDER CONTROLLER 5500 TRACER PATH ERROR WHEN RUNNING NC.PGM. 5600(**) MEM JOG MOVE FINISH 5700(**) MEM JOG MOVE ABORT 5800 MEM.START CUT AT INITIAL MEM.CUT 5810 MEM.START CUT CONTIUNE AFTER MEM.CUT STOP 5850 MEM. START PT. IS OBJECT VERT. PT. 5880 EXECUTE RE. CUT FUNC. STEP BY STEP 5890 EXECUTE RE. CUT FUNC. 5900 MEM_CUT_MSG_FINISH 5920 MEM_CUT_MSG_ABORT 5980 STEP RE. CUT FINISH 6000(**) DRIVER ERROR WHEN RUNNING NC.PGM. 6100(**) TABLE TOUCH LIMIT SWITCH WHEN RUNNING NC.PGM. 6200(**) TABLE OUTRANGE SOFTWARE LIMIT AREA WHEN RUNNING NC.PGM. 6300 PLANE POINT ERROR BETWEEN MOTION AND SENDER 2-153


MODULE 6320 CUT PATH ERROR 6340 PGM. COORD. DON’T MATCH INTER. MODULE WHEN RUNNING NC. PGM. 6350 JOG CMD.MOVE ERROR IN MEM.CUT 6380 MOTION WORK DATA ERROR 6400 IO232 MODULE ERROR WHEN MEM.CUTTING 6450 RE-CUT MOTION DATA ERROR AFTER PRESSING STOP KEY 6480 NCODE NOT FOUND WHEN EXECUTE NCODE OPERATOR 6500 MEM_ERROR_AWT_THRU_MISS_OVERCOUNT 6610 AWT. FEED WIRE CMD. SET 6611 AWT. FEED WIRE CMD. SET AT WIRE-BREAK PT. 6612 AWT. FEED WIRE CMD. SET AT G92 PT. 6613 AWT. FEED WIRE CMD. SET AT M20 PT. 6614 AWT. FEED WIRE CMD. SET AT M21 PT. 6615 AWT. FEED WIRE FINISH 6620 AWT. CUT WIRE CMD.SET 6621 AWT. CUT WIRE CMD.SET AT M21 PT. 6622 AWT. CUT WIRE CMD.SET AT M22 PT. 6623 AWT. CUT WIRE CMD.SET AT M23 PT. 6624 AWT. CUT WIRE CMD.SET AT SHORT PT. 6625 AWT. CUT WIRE FINISH 6630 AWT. HANDLE WIRE CMD.SET 6635 AWT. HANDLE WIRE FINISH 8000 HOLE OPERATOR WHEN RUNNING NC.PGM. 8100 NC.FILE IS MODIFIED WHEN RE-START CUT. 8200 START NOT AT VERT.PT WHEN BEGIN CUT. 8300(?) CUT PATH OUT OFF TABLE TRAVEL(?=1(X),2(Y),4(U),5(V)). 9000 START WORK ERROR WHEN RUNNING NC.PGM. 91*? MOTION CMD. SAVE [*(0O,1LINE,2ARC),?(0O,1START,2END)] 91*?MOTION CMD. RESTORE [*(0O,1LINE,2ARC),?(0O,1START,2END)] 10100 DATA CAN'T BE MODIFIED IN THIS STATE 10200 THE FUNCTION CAN'T EXECUTE BECAUSE TABLE BUSING 10300 THE FUNCTION CAN'T EXECUTE. 10400 DATAS CAN'T BE SETTED OR MODIFYIED WHEN RUNNING NC.PGM. 10500 AXIS ROTARY CAN'T SETTED UNDER THIS STATE 10600 LIMIT ACTIVE WHEN PRESS START KEY 11200 RE. CUT DATA ERROR 12000 RANGE ERROR AT INPUTING FLAG DATA 12010 RAGNE ERROR AT INPUTING CHAR DATA 12020 RANGE ERROR AT INPUTING UNSIGNED CHAR DATA 12030 RANGE ERROR AT INPUTING INTEGER DATA 12040 RANGE ERROR AT INPUTING LONG INTEGER DATA 2-154


12050 RANGE ERROR AT INPUTING DOUBLE DATA 12080 DATA TYPE NOT MITCH WHEN INPUTING DATA 13000(***) FTP MODULE ERROR 16010 AWT_DRIVER_ERROR 16020 AWT_AIR_WEAK_ERROR 16030 AWT_WIRE_EMPTY_ERROR 16040 AWT_PARAM_NULL_ERROR 16050 AWT_WORK_STOP_KEY 16060 AWT_CUT_WIRE SENSOR ERROR 16101 AWT_THRU_OVER_TIMER_ERROR 16102 AWT_THRU_OVER_COUNT_ERROR 16103 AWT_THRU_OVER_DIST_ERROR 16104 AWT_THRU_WAIT_STOP_ERROR 16105 AWT_THRU_ANNEAL_ERROR 16106 AWT_THRU_CUT_ERROR 16107 AWT_THRU_CUT_OVER_TIME_ERROR 16108 AWT_THRU_WASTE_OVER_TIME_ERROR 16109 AWT_THRU_HEATER_ERROR 16110 AWT_THRU_CLIP_WIRE_ERROR 16111 AWT_THRU_WASTE_FORWARD_FEED_ERROR 16112 AWT_THRU_TENSION WHEEL INDEX NOT FOUND 16201 AWT_CUT_OVER_TIMER_ERROR 16202 AWT_CUT_FEED_ERROR 16203 AWT_CUT_WAIT_STOP_ERROR 16204 AWT_CUT_ANNEAL_ERROR 16205 AWT_CUT_CUT_ERROR 16206 AWT_CUT_CUT_OVER_TIME_ERROR 16207 AWT_CUT_WASTE_OVER_TIME_ERROR 16208 AWT_CUT_OVER_TIME_ERROR 16209 AWT_CUT_HEATER_ERROR 16211 AWT_CUT_WASTE_FORWARD_FEED_ERROR 16212 AWT_CUT_TENSION_WHEEL_INDEX NOT FOUND 20010(?*????) AXIS GEAR RATION OUTRANGE(0.05~20.)WHERE *:0(X),1(Y),2(Z),3(U),4(V),5(B) 30000 INTERPRETER MODULE ERROR 30010 FILE NAME ERROR IN INTERPRETER MODULE 30020 LOOP LESS IN INTERPRETER MODULE 30030 SUBROUNT FILE NAME IN INTERPRETER MODULE 30040 NC.PGM.FILE NAME ERROR IN INTERPRETER MODULE 30050 BLOCK NOT EXIST IN INTERPRETER MODULE 30060 BLOCK FORMAT ERROR IN INTERPRETER MODULE 30070 FETCH NC.TEXT ERROR IN INTERPRETER MODULE 30080 SYSEM POOL EMPTY IN INTERPRETER MODULE 30090 NC BLOCK TOO LONG CHAR IN NC. PGM. (MAX: 100CHAR) 2-155


30110 30120 30130 30150 30160 30180 30200 30210 30220 30230 30300 30310 30320 30330

N. CODE ERROR IN INTERPRETER MODULE O.CIDE ERROR IN INTERPRETER MODULE SUBROUNT DEEP LEVEL OVER 8 IN INTERPRETER MODULE COORDINAGE TRANSFER ERROR IN INTERPRETER MODULE NC. ROTARY AND AXIS ROTARY SETTED ERROR SYNC.COMMAND OVERFLOW ARC COMMAND R=0 IN INTERPRETER MODULE ARC COMMAND R VALUE ERROR IN INTERPRETER MODULE ARC I, J COMMAND ERROR IN INTERPRETER MODULE ARC K, L COMMAND ERROR IN INTERPRETER MODULE MDI. COMMAOND ERROR IN INTERPRETER MODULE GCODE ILLEGAL IN INTERPRETER MODULE G10 SETTED INSUFFICIENT DATA WORK COORD. RULE ERROR(COMP.OFF,VERT.PT,TAPER ANGLE=0). 30340 AXIS MIRROR&EX.&ROTARY&SCALE ERROR by G53 and RECORD PT MOVING 30350 NOT AT VERT. PT. ERROR BY G53 AND RECORD PT. MOVING 30360 NOT AT ZERO PT. (UV) BY WORK COORD. MOVING 30601~30609 G34 SET VALUE OUTSIDE RANGE 30610 DATAS ARE NOT FOUND BY G34 IN DATAS BASE 30651~30659 G35 SET VALUE OUTSIDE RANGE 30660 CORNER DATAS ARE NOT FOUND BY G35 IN DATAS BASE 30710 DIVIDE ZERO WHEN VARIABLE OPERATOR 30720 SQRT MINUS WHEN VARIABLE OPERATOR 30730 A ADDRESS VALUE MISS WHEN VARIABLE OPERATOR 30740 A ADDRESS VALUE MISS WHEN VARIABLE OPERATOR 30750 B ADDRESS VALUE MISS WHEN VARIABLE OPERATOR 30760 C ADDRESS VALUE MISS WHEN VARIABLE OPERATOR 30800 SKIM OPERATOR SETTED ERROR(start, end pt. not MITCH) 31000 MACRO COMMAND ERROR IN INTERPRETER MODULE 31110 DIV=0 ERROR IN INTERPRETER MODULE 31120 SQER ERROR IN INTERPRETER MODULE 31130 H.VARIALE ERROR IN INTERPRETER MODULE 31140 H.VARIABLE A ADDRESS ERROR IN INTERPRETER MODULE 31150 H.VARIABLE B ADDRESS ERROR IN INTERPRETER MODULE 31160 H.VARIABLE C ADDRESS ERROR IN INTERPRETER MODULE 31200 GLOBAL VARIABLE ERROR IN INTERPRETER MODULE 31201 GLOBAL VARIABLE ERROR IN INTERPRETER MODULE 31202 SYSTEM VARIABLE ERROR IN INTERPRETER MODULE 31203 H.VARIABLE ERROR IN INTERPRETER MODULE 31204 D.VARIABLE ERROR IN INTERPRETER MODULE 31210 ACOS FUNCTION ERROR IN INTERPRETER MODULE 31211 SQET FUNCTION ERROR IN INTERPRETER MODULE 2-156


31212 31220 31221 31230 31250 31251 31260 31261 31262 34000 34010 34100 34111 35000 35010 35020 35030 35040 36000 36010 36020 36500 36510 36520 36530 4?***

VALUE CODE ERROR IN INTERPRETER MODULE RIGHT "]" MISS IN INTERPRETER MODULE LEFT "[" MISS IN INTERPRETER MODULE OPERATOR UNIT TOO MANY IN INTERPRETER MODULE VALUE CODE ERROR IN INTERPRETER MODULE DIVION IS ZERO IN INTERPRETER MODULE VALUE OUTSIDE MAX.RANGE IN INTERPRETER MODULE VALUE OUTSIDE MIN.RANGE IN INTERPRETER MODULE RULE ERROR WHEN VALUE OPERATOR (EX: 20.5) TAPER_ERROR_ID TAPER_ERROR_START_RULE INVERT TAPER ANGLE ERROR INVERT TAPER ANGLE ERROR WHEN SKIP HANDLE CORNER ERROR ID CORNER ERROR WHEN PATH LINE-LINE CORNER ERROR WHEN PATH LINE-ARC CORNER ERROR WHEN PATH ARC-LINE CORNER ERROR WHEN PATH ARC-ARC COMP.ERROR ID COMP.ERROR START RULE COMP.ERROR END RULE COMP.ERROR OVERCUT COMP ERROR OVERCUT WHEN SKIP OVERCUT HANDLE COMP ERROR OVERCUT WHEN SKIP OVERCUT HANDLE COMP ERROR OVERCUT WHEN SKIP OVERCUT HANDLE AXIS HOME PT.ERROR(?=X1,Y2,Z3,U4,V5)(***:um)

2-157


2-6-6 F6 (Help Text) This sub-function allows s to understand the functions and meanings of all sub-functions in the main functions of the system. Help Text Screen

2-6-7 F8 (Mark Color) can change color layout of the items listed below.

2-158


 Name

Data Unit Description Range identification Program Point color identification Auxiliary Point color identification Upper Nozzle Point color identification Lower Nozzle Point color identification Record Point 0 color identification Record Point 1 color identification Record Point 2 color identification Record Point 3 color identification Record Point 4 color identification Record Point 5 color identification Record Point 6 color identification Record Point 7 color identification Record Point 8 color identification Record Point 9 color Program Cut Start identification Point color identification G92 Set Point color identification Program Interruption Point color identification M00 Point color identification M01 Point color identification M02 Point color

0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255

Description System program side position identification System program side position identification System program side position identification System program side position identification System record point 0 position identification and color. System record point 1 position identification and color. System record point 2 position identification and color. System record point 3 position identification and color. System record point 4 position identification and color. System record point 5 position identification and color. System record point 6 position identification and color. System record point 7 position identification and color. System record point 8 position identification and color. System record point 9 position identification and color. System program cut start point position identification and color. System program G92 set point position identification and color. System program interruption position identification and color. NC program M00 pause point position identification and color. NC program M01 pause point position identification and color. NC program M02 end point position identification and color. 2-159


identification color identification M21 Point color identification M22 Point color identification M23 Point color identification M30 Point color Program Over Cut identification Point color identification Program Short Circuit Point color identification Program Break Wire Point color identification Protection Point 0 color identification Protection Point 1 color Touch (Mouse) identification Point color Program Reverse identification Cone Angle Point color identification Reserved Point 4 color identification Reserved Point 5 color identification Reserved Point 6 color identification Reserved Point 7 color M20 Point

0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255 0~255

NC program M20 wire drawing point position identification and color. NC program M21 wire cutting point position identification and color. NC program M22 wire cutting point position identification and color. NC program M23 wire cutting point position identification and color. NC program M30 end point position identification and color. NC program over cut point position identification and color. NC program short circuit point position identification and color. NC program break wire point position identification and color. System protection point 0 position identification and color. System protection point 1 position identification and color. System touch (mouse) point position identification and color. NC program reverse cone angle point position identification and color. System reserved point 4 position identification and color. System reserved point 5 position identification and color. System reserved point 6 position identification and color. System reserved point 7 position identification and color.

2-160


2-6-8 F9 (Installment) This controller provides the function of installment management. The screen has 16 items of monthly payment can be respectively set with date, time to remind customer of the due date of each installment. In addition, the would be required for editing or modifying the installment data. When the installment is due, would not be able to run a N.C. program and erosion; the rest functions would keep working properly. Exit System Screen



Data and time information 1. Installment No.: Months for installment management. 2. Current date & time: Operation in Programmed Cycles 3. Terminal date & time: Due time and date. 4. This ready date & time: Time and date of system boot-up. 5. Last ready date & time: Time and date of last system boot-up.

2-161


2-6-9 F10 (Exit System) Exit System is to exit W5F software for maintenance purposes and require to be activated. Exit System Screen

`

2-162

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)

3-43

■ 3-4 G, M Code Comparison with Others

3-48


3-1 G Code Illustration G Code Description Remark Position G00 Linear Cut G01 Cut circle in +CW G02 Cut circle in +CCW G03 Pause G04 X-axis mirror Enable G05 Y-axis mirror Enable G06 Axis change Enable G08 Cancel Mirror and Axis Change G09 D offset value variation G10 NC setting G11 Taper Data setting G12 Inner Corner data setting column 1~7 G13 AWT setting G14 Inner Corner data setting column 8~17 G17 Exterior Corner data setting 1~7 G18 Exterior Corner data setting 8~17 G19 Use British Inch unit G20 Use Metric unit G21 Call up sub-program G22 * identical to M98 Back to main program G23 * identical to M99 G26, G27 NC PGM Rotation (ON/OFF) G28, G128 G228, G328 G428, G528 Jog move to Record point (0~9) G628, G728 G828, G928 G29, G129 G229, G329 Record present coordinate to Record point G429, G529 (0~9) G629, G729 G829, G929 Call up MDI=>F3 Search Offset database G34 Cancel wire offset G40 3-1


Wire offset on left side Wire offset on right side Arc Conner function setting Arc Conner function canceling Taper angle canceling Flag parameter#20, Taper angle wire diameter left Defaul(1)Negative Taper angle wire diameter right Jog move to indicate point in Mechanism coordinate Quick positioning to G54~G59 coordinate G54~G59 point Identical Corner on XY/UV plane G60 *taper cutting Non-identical Corner on XY/UV plane G61 *taper cutting Program mirror G62 NC program rotate and scaling G64 Operate edge, slot, hole G71 Variable value record to H offset column G83 Program arc corner radius setting G87 *taper cutting Program arc corner setting function setting G88 Program arc corner setting function G89 canceling Absolute coordinate commands setting G90 Incremental coordinate commands setting G91 1st Program start point G92 Manual feeding to limit feed-rate constant G94 Servo feeding (to cancel the constant feed) G95 Program axis exchange G97 G101 A=B G102 A=B+C G103 A=B-C G104 A=B*C G105 A=B/C G106 A=SQRT(B*B+C*C) G107 A=B*SIN(C) G108 A=B*COS(C) G109 A=ATAN(B/C) G110 A=SQRT(B*B-C*C) G132 Over-cut check & compensation Enable (2) G133 Over-cut check Enable (0) G41 G42 G48 G49 G50 G51 G52 G53

3-2


G134 G135 G136 G137

Invert-cut check & compensation Enable (2) Invert-cut check Enable (0) Over-cut & Invert-cut check and error message (1) Neglect both Over-cut & Invert-cut check (0)

G154~G159 G254~G259 G354~G359 G454~G459 G554~G559 Switch to any of indicate work coordinate G654~G659 G754~G759 G854~G859 G954~G959 G200 Go To A Value G201 If B=C GoTo A Value G202 If B
L M

Description Taper Cutting Sub-Program Mirror. Call up S-code Offset (compensation) Call up S-code Machining feed-rate Mentioned above 1.Length of curve (X) 2.Work-piece thickness if used with G92 Length of curve (Y) In G22: Rotation angle of sub-program In M98: Enlargement ratio of sub-program In G92: Work-piece rotate angle V-axis Arc data address in AUX plane (if used with G22, G98 as number of sub-program loop) Auxiliary Function (M code) 3-3


Code N O P

Description Sequence of program line. Ex: N1, N2…N100. File name. Ex: O0123. Used with G04 as pause time; with G22 or G98 as call up sub-program. Q Used with M98 as sub-program rotation R Corner radius S 1.Call up S-code 2.Scale rate of sub-program used with G22or G98 T Taper angle setup in G52. U U axis move command V V axis move command X 1. X axis move command. 2. Used with G04 as the length of pause time Y Y axis move command Z Z axis move command Z1=, Z5= PGM plane & AUX plane height setup TP, TN PGM plane & AUX plane height setup OV=, PW= ON=, OFF= AN=, AFF= During the process to set the detail S-code contents SV=, FR= WF=, WT= WL=, FM= The value tagged along with function code is recognized as decimal. Example: X15. X15.000 mm orX15.0000 inch Y-30.5 Y-30.500 mm orY-30.5000 inch F2.54 F2.540mm/min or F2.5400 inch G04 P1000 Pause for 1.000 second. Metric (G21) & English (G20) Conversion G21 X1. 1 mm G21 X1 0.001mm G20 X1. 1 inch G20 X1 0.0001 inch

3-4


Integer & Real Number metric input X1000Y25.2 =X1.0Y25.2 X20.Y23129 =X20.Y23.129 Sequence of program line “O” sequence of program For a multiplex program (master & sub-program) is must; “O” as the tile and 4 following numbers (0000~9999), for the program research and call up. “N” sequence of program “N” as the tile and 4 following numbers (0000~9999), for the block research and call up. “/” Ellipsis symbol The symbol “/” (ellipsis) in the block, in NC program the block will be neglected not to execute when the switch (BLOCK SKIP) on the console is enabled. “F” Feed-rate override G94 command is a manual main speed the unit is mm/min or inch/min. “S” or “E” work condition code The work conditions “S-code” data on line. [Variable] in program (Metric) 1. Data address direct input: X2000 2000μm X10. 10.mm A1.5 1.5degree A2000 2.degree 2. The definition of Variable: (Symbol “=” can be replaced by “\”) H50=30.(H50\30) 30. H52=30.*2(H52\30.*2) 60. H53=3.0-4.(H53\3.0-4.0) -1.0 3. Variable address setting: XH50 YH52 AH53

30.mm 60.mm -1.0 degree

4. Function operation: H60=100.*SIN(30.) 50. H61=ACOS(0.5) 30. H53=SQRT(100.) 10. X3.-2. 1.mm A 45./30. 1.5 degree 3-5


5. Operate Order: H101 = H111 + H112 * SIN [ H113 ]

 

  Parenthesis  Function  Multiplication (Division) ○,4 Addition (Subtraction) EA

6. Operate Order: H101 = SQRT [ [ [ H111 – H112 ] * SIN [ H113 ] + H114 ] * H115 ] ; 1st Setup P

P

2nd Setup P

P

3rd Setup P

P

Example: (1) G1X7000 + 1000 – 2000 → G1X6000 (2) G1Y – 5000 + 1000 * 3 → G1Y – 2000 (3) G1X – H50 + 2000 + H51 (if suppose H50 = 3., H51 = 2.) →G1X1. (4) G1YH60 + 3000/H61 – 500 (if suppose H60 = 5., H61 = -2.) →G1Y + 3 (5) G1X2000 * 2 * 3 →G1X12. (6) G1XHH50 (if suppose H50 = 200., H200 = 10.) →G1X10. Note: W5F controller for Mathematics Function as follows: SIN, COS, TAN, ATAN, ACOS, SQRT, ABS, FIX (behind decimal would be unconditioned delete)

3-6


3-2 Usage Description of G Code 3-2-1 G00 Quick positioning Syntax：G00X____Y_____(or U____V____); The tool is moved by pre-set speed to pointed target. The function is useful under incremental coordinate or absolute coordinate to control 1~4 axes. If the cutting mode is “OFFSET”, U,V command is effective.

3-2-2 G01 Linear Cutting Syntax ：G01X____Y____F_____; This command is for linear path cutting. If it is under fixed speed cutting mode, the tool can execute cutting function by F code speed to pointed location. The function is useful to control 1~4 axes cutting at the same time and combined with M function and S function.

3-2-3 G02, G03 Arc cutting Syntax：G02X___Y___I___J___F___; G03X___Y___I___J___F___; This command is for arc path cutting. G02 is clockwise and G03 is counterclockwise. The starting point is the present location and the end point is the location that commanded by G02 or G03. The radius of the arc is the vector from starting point to the end point.

End Point Start Point Center

3-7


G02/G03X__Y__I__J__{R__} If R is the center of the circle, +R represents the arc less than 180 degrees. On the contrary, -R represents the arc more than 180 degrees.

DEMO1.NC U

G92X0.Y0.; G91 G01Y5. G02X5.I2.5 M02 OR G92X0.Y0.; G91 G01Y5. G02X5.R2.5 M02

N1 N2 N3 N4 N5 N1 N2 N3 N4 N5

2B

DEMO2.NC N1 N2 N3 N4 N5 N1 N2 N3 N4 N5

G92X0.Y0. G91 G01Y5. G02X5.Y5.I5. M02 OR G92X0.Y0. G91 G01Y5. G02X5.Y5.R5. M02 3-8


DEMO3.NC N1 G92X0.Y0; N2 G91 N3 G01Y5. N4 G02X5.Y5.R-5. N5 M02 OR N1 G92X0.Y0; N2 G91 N3 G01Y5. N4 G02X5.Y5.J5. N5 M02

DEMO4.NC N1 G92X0.Y0.; N2 G90G00X20.Y-20.; N3 G01Y-45.F2.0; N4 X32.; N5 G02X45.Y-58.I+13.; N6 G01Y-65.; N7 G03X81.Y-65.I18.; N8 G01Y-56. N9 G02X87.Y-50.I6.; N10 G01X104. N11 G03X110.Y-44.J6.; N12 G1Y-20.; N13 X20.; N14 G00X0.Y0.; N15 M02; UV Cutting with G01, G02 and G03 Syntax：G01 X___Y___U___V___ Aux Plane (I)

UV move PGM Plane (Z)

3-9


G02 X___Y___I___J___U___V___K____L___ G03 X___Y___I___J___U___V___K____L___

(U,V)

Circle of UV plane

DEMO5.NC N1 G92X2.5Y5.;

(I,J) Note: UV moves G90 (absolute) to vertical point.

N2 G01Y5.V7.5 N3 X7.5U10.V5. N4 Y-20.U5.V-10. N5 X-20.U-10.V-5. N6 Y20.U-5.V10.; N7 X12.5U0V7.5 N8 Y-5.V0. N9 M02;

Note: UV moves G90 (absolute) to vertical point. DEMO6.NC N1 G91 N2 G92X-30.Y0. N3 G01X10.U5.; N4 G02I20.K-5.; N5 G01X-10.U-5. N6 M02

3-10


DEMO7.NC N1 TP0. N2 TN10. N3 G92X0Y0. N4 G91 N5 G41G01X-5.Y-5.:G01X-5.Y-5.H1=0.2 N6 G01Y-10.:G02Y-10.R5.*SQRT[2.] N7 G01X-10.:G02X-10.R5.*SQRT[2.] N8 G01Y10.:G02Y10.R5.*SQRT[2.] N9 G01X10.:G02X10.R5.*SQRT[2.] N10 G40G01X5.Y5.:G01X5.Y5. N11 M02 Note: UV moves G90 (absolute) to vertical point.

3-2-4 G04 Pause Syntax：G04P_____; or G04X_____; When the controller read this command, it will pause according to the time set in P or X. The range is 0.001~9999.999. Generally, it is used for peak angle machining. 3-2-5 G05, G06, G08, G09 Mirror and Axis Exchange Function Syntax: G05 ; Set X Axis Mirror G06 ; Set Y Axis Mirror G08 ; Set Axis Exchange G09 ; Cancel NC Mirror and Axis Exchange DEMO8.NC O1000.NC N1 G91G92X0Y0 N2 G09 N1 N1000 N3 M98P1000 N2 G01X8.Y12. N4 G05 N3 G01G41X5. N5 M98P1000. N4 G01Y5. N6 G09 N5 G01X8. N7 G06 N6 G02X10.I5. N8 M98P1000 N7 G01Y-10. N9 G09 N8 G01X-18. N10 G05 N9 G01Y5. N11 G06 N10 G40X-5. N12 M98P1000 N11 G00X-8.Y-12. N13 M02 N12 M99 3-11


3-2-6 G10 D offset setting Syntax: G10P__R__ DEMO-9.NC N1 G91G92X0Y0 N2 G10P2R0.2 N3 M98P3000 N4 G10P2R0.1 N5 M98P3000 N6 M02

P: D offset code number

R: Set Value

O3000.NC N1 N3000 N2 G01G42Y5.D2 N3 G01X5. N4 G01Y-10. N5 G01X-10. N6 G01Y10. N7 G01X5. N8 G40G01Y-5. N9 M99

3-2-7 G11 NC DATA Setting Syntax：G11Q__X__Y__Z__R__S__I__J__C__F__W__A__ Q：Main PGM rotation (Angle) X、Y、Z：X= X axis mirror (0: Disable 1: Enable) Y= Y axis mirror (0: Disable 1: Enable) Z= Axis change (0: Disable 1: Enable) R：The stop distance ahead of M00、M01 S：Main PGM Scaling I：Over-Cut check in NC path J：Invert-Cut check in NC path C：Corner compensation mode in NC path (0~6) F：Scaling of Corner compensation in NC path (0~5) W：Overall of NC path offset. A：Overall of NC Taper angle offset.

3-12


3-2-8 G12 Taper Data Setting Syntax：G12C__A__Z__I__； C：Taper Cut mode (0: VERT 1:TAPER 2. UV 3:PLANE A：Set Taper angle Z：Height of NC PGM Plane I：Thickness of Work-piece

3-2-9 G13, G17, G18, G19 Corner Data Setting Syntax: (INNER CORNER) G13W＿C＿X＿Y＿K＿L＿R＿； CORNER [DATE:TIME] G18T＿F＿V＿I＿J＿P＿U＿D＿B＿S＿ T：DWELL F：MAX. FEED V：INC.OV I：INC. ON J：INC. OFF P：INC. SV U：INC. FR D：INC. WT B：INC. WL S: SCODE BASE W：CTRL.SW C：CORNER DATA X：ENTER PWR.R Y：EXIT PWR.R K：ENTER DIST. L：EXIT DIST. R：RADIUS

(EXTERIOR CORNER) G17W＿C＿X＿Y＿K＿L＿R＿； CORNER [DATE:TIME] G19T＿F＿V＿I＿J＿P＿U＿D＿B＿S＿ T：DWELL F：MAX. FEED V：INC.OV I：INC. ON J：INC. OFF P：INC. SV U：INC. FR D：INC. WT B：INC. WL S: SCODE BASE W：CTRL.SW C：CORNER DATA X：ENTER PWR.R Y：EXIT PWR.R K：ENTER DIST. L：EXIT DIST. R：RADIUS

3-13


3-2-10 G14 AWT Setting Syntax：G14X__C__D__P__B__T__S__Z__Y__E__ ;AWT. DATA [DATE: TIME] X：AWT ACTION。C：CUTTER M CODE D：REPEAT THRU. CNT. P：SKIP CNT. B：W. BRK. CTRL. FLOW T：THRU CTRL. FLOW S：SHORT CTRL. FLOW Z：Z MOVE SWITCH Y：TR. BP.SPARK. SW. E：TR-BP.S.C.

3-2-11 G20/G21 English/Metric Conversions Syntax：G20 X___Y___U___V___; G21 X___Y___U___V___ G20 is for English unit (inch) and G21 for Metric (mm). If the unit is changed, the following information will be also changed: (1) Feed rate set by F code. (2) Coordinate setting command (3) Movement distance of incremental feed. (4) Some parameters (5) Use same unit in the program as possible

3-2-12 G22 Call Up Sub-Program G22L

H

L：Appoint which sub-program to run. Ex: L123 calls up O0123 as sub-program. If L not specified, controller will show error 2040 and skip G22 command. H：From which line (N10, N20, N30…) to start the sub-program. If not specified, sub-program runs from the first line (N10). Error 2050 will appear if H is specified but no sequence number (N10, N20, N30…).

3-2-13 G23 End of Sub-Program If G23 not placed in the last line of a sub-program, Alarm 2030 will appear. Note：1. Sub-Program has to be capped with letter O. Ex: O0123. 2. Sub-Program name should not be duplicated of any existing files. 3. Be aware of not to use M02 command in sub-program, which will block repeat function (P). 3-14


DEMO10.NC Main Program O1880 G92X0Y0 H2=0.4; G22L2H100. G01X20. G22L2.H100. M02

Sub-Program O0002 N100 G92X0Y0 G01G42Y5.H2 X5. Y-10. X-10. Y10. X5. G40Y-5. G23

3-15


3-2-14 Enlarge sub-program, call rotation Syntax：G22L

K

L is the N.C. file (ex.: L0001 = call up O0001.) If there is no value for L, Alarm 2040 will then appear. K is for sub-program rotation. DEMO11.NC Sub-Program O1810;SUB.PGM G92X0Y5. G01G42Y5. G01X5. G01Y-5. G02Y-15.J-7.5 G01X-10. Y20. X5. G40Y-5. G23

Main-Program O1800;(MAIN) G92X0Y0 G22L1810K-90. G01X20. G22L1810 G01X20. G22L1810Q90. M02

3-16


3-2-15 Sub-Program multiplications Syntax：G22L

S

S indicates the ratio of multiplication for the sub-program. DEMO12.NC O1820;SUB.PGM G92X0Y5. G01G42Y5. G01X5. G01Y-5. G02Y-15.J-7.5 G01X-10. Y20. X5. G40Y-5. G23

Main Program: O1821;(MAIN) G92X0Y0 G22L1820S2. M02

3-17


3-2-16 Sub-Program Mirror G22L____B____ To Mirror a Sub-Program： B : 0 → Function Disabled 1 → X Mirror 2 → YMirrow 3 → XY exchange DEMO13.NC O1830;SUB.PGM G92X0Y5. G01G42Y5. G01X5. G01Y-5. G02Y-15.J-7.5 G01X-10. Y20. X5. G40Y-5. G23

Main-Program: O1832;MAIN G22L1830 G01X50. G22L1830B1 G01X50. G22L1830B2 G01X50. G22L1830B3 M02

3-18


3-2-17 Sub-Program Rotate (K) and Repeat (P) G22L___K____P____ K：Rotate Sub-program based on G92 zero point. P：Repeat the execution of Sub-program. If P not specified, sub-program called up only once. DEMO14.NC Sub-Program O1840; G92X0Y-25. G42G01Y-5. G02X-5.Y5.J5. G01Y5. G02X10.I5. G01Y-5. G02X-5.Y-5.I-5. G40G01Y5. M00 G01X-17.768Y-7.332; M00 G23;

Main-Program O1843;MAIN(M98PQL) G22L1840K360.P8. M02

3-19


DEMO15.NC Sub-Program O1850;SUB.M98P__Q__L__ G91G02X1078Y-26J-22500 G01X47Y991 G02X16Y139I1109J-53 X57Y273I4370J-767 X159Y536I5175J-1248 X261Y647I7837J-2788 X448Y868I8839J-4007 X603Y940I11096J-6367 X1478Y-181I-2669J-26868 X350Y-1060I-11849J-4501 X218Y-952I-9339J-2635 X92Y-692I-8192J-1442 X21Y-558I-5302J-480 X-13Y-279I-4437J65 X-20Y-138I-1106J86 G01X-200Y-972 G02X1052Y-243I-4545J-22036 Note: To simply run this sub-program, add G23 G92X0Y0 in the first line.

Main-Program O1854;M98PLQ G92X0Y20. G42G01Y2.5H1=0.2 G22L1850K-360.P25 G40G01Y-2.5; M00 G92X0Y20. G40G01Y2.5 G22L1850K-360.P25 G40G01Y-2.5; M02

3-20


3-2-18

G26、G27 Main PGM rotation ON/OFF

Syntax: G26A___{X____Y____} A：Rotate angle. X,Y：X, Y axis vector distance of angle rotate. G27 Disable NC rotation. DEMO16.NC N1 G91G92X20.Y0. N2 G26A45. N3 M98P4000 N4 G27 N5 G00X15. N6 M98P4000 N7 M02 O4000.NC N1 N4000 N2 G01G42Y2. N3 G01X5. N4 G01Y-4. N5 G01X-10. N6 G01Y4. N7 G01X5. N8 G40G01Y-2. N9 M99

3-2-19 G28~G928 Jog move to Record Point (0~9) G29~G929 Record present coordinate to Record Point (0~9) Syntax: G28{P__}；

G29{P__}；

Note: 1. If doesn’t fill up P__, then the default setting is REC.0. 2. It be availed that U/V axis at vertical aligned point. 3. Do not use G92~G929 under NC program mirror.

3-21


DEMO17.NC N1 G92X20.Y0. N2 G91 N3 G29P5 N4 G00X50. N5 G00X50.Y50. N6 G00Y50. N7 G28P5

Note. 1. Compensation H setup located in AUTOF6 (MEM. H. Var.), and open to use from H001 to H999. D can be used for compensation, too; it is located in AUTOF7 (MEM. D. Oft) and open to use from D01 to D14. 2. H or D value stands for single side compensation 3. If H or D not specified in program, Controller will automatically read default D or H value as compensation. 4.Generally, compensation value equals wire radius+ 1/2 spark width but it might have to be slightly tuned up with different work conditions such as : eroding power, dielectric temperature, work-piece material. It is recommended to reference Cutting Data Manual and make necessary adjustment. About the Offset and wire diameter compensation. 1. Offset Setting For wire cut processing, there needs the wire Diameter compensation to make the wire be shifted to left or right side by a regular value to get the correct NC path in the final result. To set the value in controller by MEM > F6 H Offset or F7: D Offset. And G41/G42 command are used to do which the purpose as above mentioned. 2. Begin to set Offset in NC program 3-22


Please note G41 & G42 command must apply with G00、G01 command at beginning of lines of NC PGM; G02 & G03 must not put ahead of the lines, otherwise the error message will be generated. We utter the detail as follows: PGM NC PATH

WIRE PATH

(1) N1

G01F20.;

N2

G41(G42)D___X___Y___;

N3

X___;

N1 N2 N3

G01F20.; G41(G42)D___X___Y___; G02X___Y___J___;

(2)

3. The relationship of G41、G42 & G40. System will manage the NC path to shift the wire by G41 & G42 during processing until the G40 (offset cancellation) command be executed.

3-23


4. Offset direction change It may neglect G40 and to switch G41 to G42 command during the process. EX： N1 G01F30.; N2 G41(G42)D___; N3 : : : : : N20 G01 X___Y___F___; N21 G42(G41)X___Y___; N22 N22X__; ; ; 5. Change wire radius in the process EX : N1 G41 D01 F01 F20.; N2 X___Y___; N3 X___Y___D02; N4 X___Y___

6. Cancel Offset (G40 Command) In same one block NC program, just G01&G00 or G02 &G03, It can not be mixed to use G02 & G01 in same block, otherwise it cause a error in controller.

3-24


(1) N20

N20 G41(G42)...;

: : N31

: : N31 G01 X___F___;

N32

N32G40X___Y___;

N1 : : N15 N16

G41(G42)...; : : G02 X___Y___I___J___F___; G01 G40X___Y___;

(2)

7. Interference of NC path There might be generated an over-cut during the NC program and error will happen. The reason may cause as follows： 1. Program NC path against the offset direction. 2. The Arc radius is smaller than the wire radius. 3-25


Note : 1. D offset to set in MEM>F7: D Offset. 2. H offset to set in MEM>F6: H Offset 3. T Offset also a kind of compensation code 4. The priority if D01or H01 would be decided by flag parameter setting. 3-2-20 G34 Call up MDI=>F3 Search Offset database Syntax: G34{C__}{P__}{B__}{A__}{W__}{X__}{S__}{H__}{U__} C: Cutting numbers P: No. of cut B: 0=DEF. S. BASE; 1= S. BASE A: Work piece material W: Wire diameter X: Work piece thickness S: Spark base value H: Offset value U: Comp. Shift value Note: It is recommended to place before G92. 3-2-21 G48/G49 R-Corner Function (On/Off) Syntax： G48R G49 G48 is to set a particular radius at every t of line; G49 is to cancel. If R not appointed a value, G48 will be invalid. In addition, once R is set equal or larger than the linear movement, or no motion command (G00, G01, G02,…) coming after in next line, Alarm 5111 will appear.

3-26


DEMO18.NC G92X0Y0 G01G42Y2.H01=0.2 G01X2.G48R0.5 G01Y-4. G01X-4. G01Y4. G01X2. G49 G40G01Y-2. M00 G01G42Y2.H01=0.2 G01X2. G01Y-4. G01X-4. G01Y4. G01X2. G49 G40G01Y-2. M02

3-2-22 G50、G51、G52 Taper Cutting Taper Cutting can be appointed by either A (default) or G Code. Syntax： A0 : Cancel Taper Cutting A0___ A+ ___ A+ : Wire tilt to left at +A angle. A-___ A- : Wire tilt to right at -A angle. G50___ G51T ___ G52T ___ Specify Taper command A(+/-) or G51/G52 for proper Taper direction and angle. Be sure to put movement command (G00, G01, G02, G03) in front of Taper command to avoid program error.

3-27


 1. Regular Taper Cut (1). Line → Line

a.

b. Aux plane (I) A+ PGM plane (Z)

A+

Aux plane (I) PGM plane (Z)

Aux plane (I) A-

A-

Aux plane (I)

(2). Line → Arc a.

b. Aux plane (I)

Aux plane (I)

PGM plane (Z) Aux plane (I)

PGM plane (Z) Aux plane (I)

A+

A+

A-

A-

 2. Taper Cancel (A0 or G50) To cancel Taper command, use linear move command G01 or G00, not G02 or G03 to avoid program error. (1) Line → Line A0 A+

A-

Aux PGM Aux

(2) Arc → Line A+ A0 AAux

Aux PGM

3-28


 3. Taper direction shift (1) Line → Line

A+

AA+ Aux

APGM

Aux

(2) Line → Arc A+ AA+

A-

Aux plane (I) PGM plane (Z) Aux plane (I)

Example 1 : PGM plane (Z)

G92 X0. Y0. N0 G42 A5. X5. N1 X5. N2 X5. N3 A2. X5. .. ..

Aux plane (I)


G92 X0. Y0. N0 G42 A5. X5. N1 X5. N2 A2. → UV move to 2˚ N3 X5. N4 X5. .. ..

Aux plane (I)

3-29



G92 X0. Y0. N0 G42 A5. X5. N1 X5. N2 A2. → UV move to 2˚ N3 M00 → Pause N4 X5. .. ..

Aux plane (I)

DEMO19.NC G92X0Y0 G01G42Y2.G52 T1. G01X2. G01Y-4. G01X-4. G01Y4. G01X2. G01G40Y-2.G50 M00 G01G42Y2.G51 T1. G01X2. G01Y-4. G01X-4. G01Y4. G01X2. G01G40Y-2. G50 M02

3-30


DEMO20.NC G92X0Y0 G91 G42A2.G01Y5. G01X6. G01Y5. G01Y5. G03X-1.Y1.R1. G01X-10. G03X-1.Y-1.R1. G01Y-5. G01Y-5. G01X6. G40G50A0.Y-5. M02

DEMO21.NC (T52) G92X0Y0 G91 G42G52T2. G01Y5. G01X6. G01Y5. G01Y5. G03X-1.Y1.R1. G01X-10. G03X-1.Y-1.R1. G01Y-5. G01Y-5. G01X6. G40G50T0.Y-5. M02

3-31


DEMO22.NC G92X0Y0 G42A2.G01Y5. G01X6. G01Y5. G01Y5. A1. G03X-1.Y1.R1. G01X-10. G03X-1.Y-1.R1. A2. G01Y-5. G01Y-5. G01X6. G40A0.Y-5. M02 DEMO23.NC G92X0Y0 G91 G42A2.G01Y5. G01X6. G01Y5. G01Y5. A1.G03X-1.Y1.R1. G01X-10. G03X-1.Y-1.R1. G01Y-5. A2.G01Y-5. G01X6. G40A0.Y-5. M02

3-2-23 G53 Positioning to machine coordinate Syntax： G53X_ Y_;

3-2-24 G54~G59 Record Points Syntax：G92X0Y0 G00{G54~G59}X__Y__; 3-32


Note：G92 must be laid before G00 & Recommend to use G90. DEMO24.NC G92X0Y0 G00G54 G92X0Y0 G01G42Y2. G01X2. G01Y-4. G01X-4. G01Y4. G01X2. G01G40Y-2. M02

3-2-25 G60 (Identical R Corner on PGM, Aux plane) In Taper Cutting, use G60 to obtain identical radius corner on both XY and UV plane. Syntax:：G60R _； Note: G60 must be used with G01. DEMO25.NC G91 G92X0Y0 G01G42Y5.A1. G01X5.G60R2. G01Y-10.G60R0. G01X-10.G60R1. G01Y10. G60R0. G01X5. G01G40Y-5. M02

3-33


3-2-26 G61 (Different R-Corner on PGM and Aux plane) In Taper Cutting, use G61, R is the radius of PGM plane, and K is for Aux Plane. 1R K to obtain different R-Corner on XY and UV plane. Syntax：G61R K Note：G61 must be used with G00 or G01.

DEMO26.NC G92X0Y0 G01G42Y5.A1. G01X5.G61R2.K. G01Y-10.G61R1.5K0 G01X-10.G61R1.K1.A2. G01Y10.A1. G01X5. G01G40Y-5. M02

3-2-27 G62 (Mirror) For mirroring program route, which is also identical to Mirror SW in AUTOF2 (MEM. Data1). Syntax：G62X{0/1}Y{0/1} (XY：axis to mirror 0/1：Mirror On/ Mirror Off)

3-34


DEMO27.NC O0000; M98 H100 G00X30. G62X1 M98H100 G62X0 G00Y30. G62Y1 M98H100 G00X-30. G62X1Y1 M98H100 M02 N100 G92X0Y5. G01G42Y5. G01X5. G01Y-5. G02Y-15.J-7.5 G01X-10. Y20. X5. G40Y-5. M99 M02

3-35


3-2-28 G64 (PGM Rotate, Scaling) Syntax: G64K

S

K: Rotate S: Scale

DEMO28.NC N1 G92X0Y0 N2 G91 N3 G64K45. N4 M98P5000 N5 G64K0 N6 G00X20. N7 G64S2. N8 M98P5000 O5000.NC N1 G01G42Y5. N2 G01X5. N3 G01Y-10. N4 G01X-10. N5 G01Y10. N6 G01X5. N7 G40G01Y-5. N8 M99 N9 G01G42Y5.

3-2-29 G71 Edge Search, Slot, Hole Syntax：G71Q__P__; Q：1st start direction (0=X+, 1=Y+, 2=X-, 3=Y-, 4=X+Y+,5=X-Y+, 6=X-Y-,7=X+Y-) P：Operate mode (0=Edge 1=Slot 2= Hole) Note：It recommends to add coordinate setting.

3-2-30 G83 Save system data to H parameter variable table Syntax：G83{X__}{Y__}{Z__}{U__}{V__}{A__}{T__}; X/Y/Z/U/V：Save program coordinate to H parameter variable table. 3-36


A：Save last work time to H parameter variable table T：Save work time (start from G92) to H parameter variable table EX: G83T203; Save work time to H203 G83X300Y301Z302U303V304；Record XYZUV to H300~H304.

3-2-31 G87 (Identical R-Corner on PGM and Aux plane) To specify the same or different radius on Aux and PGM plane. Syntax：G02G87{G03}X__Y___I__J___{R__}{Q__} I J ：The radius of both Aux and PGM plane. R：The radius of PGM plane. Q：The radius of Aux plane.

Note: G87 has to be used with G02 or G03. Program Syntax G01 X___ Y___; G87 G02 {G03} X___ Y___ I___ J___ {R___ } {Q___ }; G01 X___ Y___;

Aux plane (I)

PGM. plane

3-37


DEMO29.NC O0087;TEST G87 N001 G91F3. G92X171522Y106811 G41G01X0Y4000A-5. G01X-4500Y-0 G02X-500Y500J500G87A0. G01X0Y4000A5. G02X500Y500I500G87 G01X9000Y-0 G02X500Y-500J-500G87A0. G01X0Y-4000A-5. G02X-500Y-500I-500G87 G01X-3500Y-0 M01 G01X-1000Y-0 G01X-300Y-0 M01 F100. G01X300Y-4000G40 M02

3-2-32 G88 G89 Corner Clearance G88 is to clean cut at 90° right angle; G89 is to cancel Corner Clearance. See below illustration： 1

2

2

1

3

(No Corner clearance)

(G88 Corner clearance)

3-38


DEMO30.NC O0088;G88 G92X0Y0 G01G42H1=200Y2. X2. Y-4. X-4. Y4. X2. G40G01Y-2. M00 G92X0Y0 G88G01G42H1=20 0Y2. X2. Y-4. X-4. Y4. X2. G40G01Y-2. M00 G92X0Y0 G01G40H1=200Y2. X2. Y-4. X-4. Y4. X2. G40G01Y-2. M02

3-2-33 G90/G91 (Absolute / Incremental Coordinate) Syntax：G90 X G91 X

Y Y

In G90 (Absolute Coordinate), machine moves corresponding to G92. G91(Incremental Coordinate) moves corresponding to the previous end-point. Note: To avoid accumulating tolerance, for cutting bilateral shape, G90 is recommended, and G91 for the shape of stair and arc. 3-39


DEMO31.NC O9091 G92X0Y0 G90G00X25.Y10. G01Y30. X10. G02X25.Y45.I15. G01X50. Y30. X60. G02Y10.J-10. G01X25. G00X0.Y0. G02X0Y0 G91G00X25.Y10. Y20. X-15. G02X15.Y15.I15. G01X25. Y-15. X10. G02Y-20.J-10. G01X-35. G00X-25.Y-10. M02

3-2-34 G92 Program start point Syntax：G92 X___ Y___{Z__}{I__}{K__}{S__}; Z: Program plane I: Auxiliary plane. If I is “+”, then it means it is upon PGM plane (Z) K: Program rotation angle S: Program enlargement ratio Note. If Z, I not appointed, controller would take default value in AUTOF2 (MEM. Data1)

3-40


3-2-35 G94/G95 (Constant Feed-rate) Syntax： G94F ; G95; G94：Turn on Constant Feed-rate, which is identical to FM=1. Feed-rate until is mm/Min or Inch/HR G95：Turn on Constant Feed-rate and switch to servo control

3-2-36 G97 (Axis exchanger) Syntax：G97X1：Open Axis exchange G97X0：Close Axis exchange Note: G97 is identical to XY Exchange SW. in AUTOF2 (MEM. Data1.)

3-2-37 G101~G110 (variables) 1. G101AH__B__;------->A=B Ex：G100AH100B20.------>H100=20. 2. G102AH__B__C__;------>A=B+C Ex：G102AH51BH51C1.------>H51=H51+1 3. G103AH__B__C__;------->A=B-C Ex：G103AH51B7.CH50------>H51=7-H50 4. G104AH__B__C__;----->A=B*C Ex：G104AH52BH53CH54----->H52=H53*H54 5. G105AH__B__C__;---->A=B/C Ex：G105AH55BH53C10.---->H55=H53/10. 6. G106AH__B__C__;----->A=SQRT(B*B+C*C) Ex：G106AH54BH50CH53--->H54=SQRT(H50*H50+H53*H53) 7:G107AH__B__C__--->A=B*SIN(C) Ex：G107AH58B100.CH53---->H58=100.*SIN(H53) 3-41


8. G108AH__B__C__--->A=B*COS(C) Ex：G108AH50BN54C30.----->H50=H54*COS(30.) 9. G109AH__B__C__---->A=ATAN(B/C) Ex：G109AH55BH56CH57--->H55=ATAN(H56/H57) 10. G110AH__B__C__---->A=SQRT(B*B-C*C) Ex：G110AH54BH50CH53--->H54=SQRT(H50*H50-H53*H53) 3-1-37 G132~G136 Setting over-cut or invert-cut check in NC program which is same as EDIT-3→ F5 SIM DATA→OVERCUT SW. & INVERT SW. columns. (Page 2-35) Syntax: G132;

G133;

G134;

G135

3-2-38 G136~G137 Setting both over-cut and invert-cut check in NC program. Syntax: G136; G137

3-2-38 G200~G202 (G code logic loop) Syntax： 1. G200A__：Skip to Block “A”. EX: G200A100 -> Skip to N100. 2. G201A__B__C__：If B=C then skip to Block “A”. EX: G201A200BH50CH51 -> If H50=H51then skip to N200. 3. G202A__B__C__：If B If H51
3-42


3-3 Auxiliary Function (M Code) 3-3-1 Introduction of auxiliary function The following table is M code used on the controller. M code M00 M01 M02 M04 M05 M07 M10 M11 M12 M13 M15 M17 M18 M20 M21 M22 M23 M26 M30 M37 M38 M39 M40 M41 M42

Definition Program pause Optional stop Program finish B-axis constant Feed-rate (CCW) B-axis constant Feed-rate (CW) Reset the counter of Hour Meter Block pause ON Block pause OFF Await input IO signal Send output IO signal Cutting mode select Z -Lock on Z -Lock off AWT Feed wire AWT Cut wire Cut wire Cut wire Cutting power select NC Program finish Corner control mode 1 Corner control mode 2 Corner control OFF Water filling in work tank to sink ON Water filling in work tank to sink OFF Water drain out of work tank ON

3-43

Remark

Same as M30

For AWT device For AWT device For AWT device For AWT device Same as M02


M43 M44 M45 M70 M80 M81 M82 M83 M84 M85 M90 M91 M98 M99

Water drain out of work tank OFF Await for dielectric is completely submerged ON Await for dielectric is completely submerged OFF Retrace to G92 Water flushing from upper/lower nozzle ON Water flushing from upper/lower nozzle OFF Wire feed ON Wire feed OFF EDM Power ON EDM Power ON Machine feed under Servo feed Machine feed under constant feed Call sub-program Back to main program

1. M00 Program pause When program is executed to M00, the machining will stop. Its EDM power, wire feed and cutting fluid supply will be close automatically. If you want to continue the machining, press “START” key. 2. M01 Program pause If the switch on the control is lit on, once program runs to M01, The supply of eroding power, wire feed and flush water will all stop. To resume, press “START” key

.

3. M02 Program finish If the program is executed to M02, it means that the program is finished. The machining will stop and its EDM power, wire feed and cutting fluid supply will be closed automatically.

4. M04、M05 B-axis Constant Feed-rate controls M04：B-axis constant feed-rate control setting by CCW (Must equipped with B-axis) 3-44


M05：B-axis constant feed-rate control setting by CW (Must equipped with B-axis) 5. M07 Reset total machining hour Reset machining hours. 6. M10 Single block pause (ON) The program will pause for a few seconds. The pause time is set in conical function. Pause time can also be set in AUTOF3 (MEM. Data 3) 7. M11 Single block pause (OFF) Cancel the single block pause function. 8. M12 S Await input IO signal Process stop and disable EDM power, wire feed, water until the “I8” IO port of TB8-IO has got the signal then continue to work. 9. M13 S Send output IO signal Controller sends a “0.5sec” signal to “O8” IO port of TB8-IO. 10. M15 Cutting mode setup Syntax M15P Identical to Cut Method in MEMF2 (MEM. Data 1). P is the variable of M15： M15P0：Regular cutting M15P1：Taper cutting M15P11：UV cutting 11. M17 Z axis lock：To lock up Z axis in current position. 12. M18 Z axis open：To release Z axis lock.

13. M20 M21 M22 M23 AWT command AWT command, please refer to Chapter 2 of AWT Operation Manual.

3-45


14. M26 Cutting power select Controller will change the LP setting in machining condition. 15. M30 Program Termination：Read as end of program and machining, wire feed and dielectric supply will stop. 16. M37 Corner Type 1：Select Corner Type 1 in AUTOF5 Corner Data 17. M38 Corner Type 2：Select Corner Type 2 in AUTO F5 Corner Data 18. M39 Corner Type 0：Select Corner Type 0 in AUTO F5 Corner Data 19. M40 Water In：Identical to

.

20. M41 Water In Stop: Stop to refill water. 21. M42：Same as

; open the drain gate in work tank.

22. M43：Same as

; close the drain gate in work tank.

23. M44：Hold machining until water full; identical to AUX1. 24. M45：Cancel M44; identical to AUX1. 25. M70：Retrace to G92. 26. M80：Flush water ON; identical to 27. M81：Flush water OFF; identical to 28. M82：Wire feed ON; identical to 29. M83：Wire feed OFF; identical to

.

.

.

30. M84：Open the relay of eroding power; identical to

.

31. M85：Close the relay of eroding power; identical to

.

32. M90：Machine feed under Servo control; identical to FM=0. 3-46


33. M91：Machine feed under constant speed; identical to FM=1. 34. M98：Call up sub-program. Syntax：M98 P___ L___；{G22L__P__} P：Program to load. For example, P0001 is to appoint O0001 as sub-program. Alarm 2024 would appear if P not specified. L：Times to run sub-program. If not specified, sub-program runs only once. M98 P___ H___; {G22L__H__} H：Specify which block in sub-program to start from. If not appointed, it starts from 1st block. M98 P___ L___ {K___} {Q___};{G22S__Q__} K：Enlargement ratio of sub-program. Q：Rotation angle of sub-program. Note. 1. Start/end point of sub-program must be at the same position when K & Q are used. 35. M99 Back to main program：Must be put in the last block of sub-program, or Alarm occurs.

3-47


3-4 G, M Code Comparison with Others G Code Item G00/G01/G02/G03 G04 G20/G21 G22/G23 G40/G41/G42 G48/G49 G50/G51/G52 G60/G61 G87 G88/G89 G90/G91 G92 G94/G95 G101~G110 G200~G202 Cutting Mode Setup Item M15P__ P0: Regular Cut P1: Taper Cut P11: UV Cut Taper Setup Item A__ … … A0 G51{G52}T__ … … G50T0

Description

Turn to Chapter 3-1

Used by CHMER FANUC

Used by CHMER FANUC SODICK CHMER FANUC SODICK

Plane Setup Item G92X__Y__Z{J}__I__

Used by CHMER FANUC 3-48

Used by C,F,M,S,SO (note 1) C,F,M,S,SO C,F,SO C,M (note 2) C,F,M,S,SO C,F,S C,F,SO C,F C,M C,M C,F,M,S,SO C,F,M,S,SO C,F C,M C,M


Spark Condition Setup Item S__

Used by CHMER FANUC CHMER MAKINO SODICK

E__

M Code Item M00 M01 M02 M10 M11 M15 *M20 *M21 *M22 *M23 M30 M37 M39 M80 M81 M82 M83 M84 M85 M90 M91 M98 M99

Description

Used by Pause C,F,M,S,SO Optional pause C,F,M,S,SO Program finish C,F,M,S,SO Block pause ON C Block pause OFF C Cutting mode select C,F AWT cut wire C,M,S AWT cut wire C,M,S AWT cut wire C,S AWT cut wire C,S Program finish C,F,M,S Corner control ON C Corner control OFF C Water flow in work sink ON C,M Water flow in work sink OFF C,M Wire feed ON C,M Wire feed OFF C,M EDM Power ON C,M,SO EDM Power ON C,M,SO Machine feed under Servo feed C,M Machine feed under constant feed C,M Call sub-program C,F,SO Back to main program C,F,SO

Note 1 G22L___P___H___ M98P___L___H___ G23 M99 Note 2 G41{G42}D__; G41{G42}T__; G41{G42}H__;

C,M C,F C,M C,F C,F,S C,S C,M

3-49

Remark： C = CHMER EDM CODE F = FANUC CODE M = MITSUBISHI CODE S =SEIBU CODE SO=SODICK

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


4-1 Consumables List Item

Part number

Name of part

Standards

Count

HK3

3KG(F TYPE) 6KG(S TYPE)

F016

2 Pieces

Ion exchanging resin 1.

D7D350RES

Paper filter 2.

D7DF016

Upper and Lower nozzle 3.

MW53W92B

Upper& Lower Diamond guide 4.

M140001B

H type ∅4(standa rd) ∅6 ∅8

2 Pieces

0.105, 0.11 0.205, 0.21 0.255, 0.256 (↑Standard) 0.305, 0.31

2 Pieces

(Chmer standard)

2 Pieces

Conductive plate 5.

M7A350ESPTB

4-1


Brass wire 6.

M7A530025B

Diameters： 0.1, 0.20, 0.25(stan dard) 0.3

5kg

(Chmer standard)

1set

(Chmer standard)

1 Piece

(Chmer standard)

1 Piece

(Chmer standard)

1Piece

(Chmer standard)

1 Piece

Electric cable assembly (Machine to control box) 7.

Accords to machine type

Wire tension wheel 8.

MW53A39C

Lower head bearing 9.

M7B16000H2RS

Lower head bearing 10.

M5ABEA6000

Rejection ceramic wheel (upper) 11.

MW53A17C

4-2


Rejection ceramic wheel (lower) 12.

MW53A16B

(Chmer standard)

1 Piece

(Chmer standard)

1 Piece

∅4(standard) ∅6 ∅8

1 Piece

∅4(standard) ∅6 ∅8

1 Piece

(Chmer standard)

1 Piece

The bearing of rejection ceramic wheel 13.

M7B11980R

AWT upper nozzle 14.

MW53W11D

AWT lower nozzle 15.

MAWT077C

AWT parts: Heater 16.

MAWT050E

4-3


AWT ceramic pipe of heater 17.

MAWT358B

AWT lower wire guide 18.

MW53A92C

(Chmer standard)

1 Piece

0.11 0.21 0.26 (standard) 0.31

1 Piece

Standard

1 Piece

Standard &AWT

1 Piece

AWT

1 Piece

16x1.5 23.6x1.78 26x2

3 Pieces

8x1.9 28x2 33.5x2

3 Pieces

Upper ceramic plate 19

MW64A44K

Lower ceramic plate 20

MW53W55D

AWT upper ceramic plate 21

MAWT100C

Oil seal 22

M7F2S16 M7F2S236 M7F2S26 AWT upper oil seal

23

M7F2P8 M7F2S28 M7F2S34

4-4


4-2 Shield Room The machine’s operation space must be isolated in case that the wire cutting machine causes the problems of TV or the other signal receiving of wireless equipment. And the wire-cutting machine is in shielded room. It should note the following: 1.It should be provided ground wire in the shielded room (See the following figure). Shielded room control system

Main system

2. If there is not a ground wire provided in the shielded room, it should connect the ground wire system to the ground terminal (Through-bolt) then CONNECT IT WITH THE GROUND IN THE SHORTEST DISTANCE. (See the following figure). Shielded room control

Main system

Through-b olt

4-5

system


4-2-1 Magnetic interference and its prevention method The dissemination route of magnetic interference can be divided into 4 kinds (shown in the following figure). 1. Sky emitting: To emit directly to other machines. 2. Interfered magnetic wave radiated in the sky. To emit to wires or signal wires around the machine, and then enter into the machine. 3. From power wire of the machine to entering into power wire of the other machines. 4. To be emitted by power wire of the machine to the sky, then radiate magnetic waves to the other machine.

       

T.V.

4-6


4-2-2 Prevention method from magnetic interference Wire cutting machine is to make use of the electric spark produced by electrode wire and work piece to process, therefore the plugs of welding machine or engine can also produce magnetic waves. This magnetic wave is called as interfered magnetic wave, and that a bad condition produced by this magnetic wave is referred as magnetic interference. The prevention method is as follows: ITEMS To change the place of antenna or wire cutting machine.

DESCRIPTION A,B,C,D in the following figure is the place where the antenna is located. A,C points are the places that may be easy to occur interference. Making the distance of the wire cutting machine and antenna be possible to separate, and setting antenna should be as shown as the place of B, D. B

A

C

EDM

Broadcasting station D

On the contrary, to set a new wire cutting machine’s position, as the A,C places in the following figure and the places that easy to produce interference, therefore, it is better to set in the places of B, D. points. B

C

A

Broadcasting station D

4-7


ITEMS Direction of antenna

DESCRIPTION To assure if antenna direction is proper. Antenna is with directional, the TV wave in the figure is the most strongest sensitive, and is the most weakest to feel interfered magnetic wave. TV wave

Radioactive wave

4-8


4-3 Precaution for Malfunction 4-3-1 Water leakage of high pressure pump One of the common reasons is that Paper Filter gets dirty and clogged, so there is no sufficient clean water flowing down to the tank, or the high pressure pump gets obstructed by objects dropped into water tank. Eventually, the high pressure pump keeps running with no load and sealing components gets burnt and lose its function. To prevent： 1. Replace Paper Filter once the pressure exceeds 2.0 Kg/cm2 2. Check regularly clean water level and refill when the level is low. 3. Be sure not to drop objects into water tank.

Lastly, above mentioned malfunction is not considered as “warranty,” and there will be expenses requested by agent or manufacturer for the repair.

4-3-2 Used cutting wire scattered on the ground Short circuit would happen once the used wire comes out of the bin and interrupt machining or even damage the electrical components in Power Cabinet. In addition, the noise caused by short circuit could interfere motor/driver to make incorrect cutting path and ruin the job. To avoid machine down and loss, please check and clean the used wire bin regularly. Lastly, above mentioned malfunction is not considered as “warranty,” and there will be expenses requested by agent or manufacturer for the repair.

4-9


4-3-3 Poor mechanical accuracy caused by improper room temperature The assembly and calibration of CHMER Wire Cut EDM is processed under 23℃±1℃ room temperature. To obtain best mechanical accuracy, please adjust room and dielectric temperature to 23℃±1℃. Moist air or steam could be generated and rust transmission components such as linear guide, ball-screw, servo motor. In addition, temperature rise would cause metal expansion (+11μm in length per 1℃ rise.) Lastly, above mentioned malfunction is not considered as “warranty,” and there will be expenses requested by agent or manufacturer for the repair.

4-10


4-4 Setup of Remote Monitoring Software W5F Simulator Instruction System requirement W5F simulator can be installed in laptop and family PC. *U required: Pentium 500 or higher. *DRAM:128Mbytes or higher. *Working environment: WIN98 or later. *Screen Display: 800*600 is the most optimum resolution. Procedures: 1. Create a folder C:\W5F1 and unzip the compressed file W5F.zip to this folder. This folder will now contain four separate folders FONT, NC, PARAM, W5F. 2. Copy the folder W5F to the C:\ drive. You will now have folder C:\W5F. 3. Open the C:\W5F folder and click on the icon W5F to start the simulator 4. When the first time you run the simulator, MAC error, for example, MAC error (00-13-46-6C-E8-F4) will certainly appear and lock most of the function. Please write down the code appears in the dialogue box and e-mail our agent for de-coding. After decoding, Simulator can run normally. W5F Simulator Operation ALT+F1  DIAG ALT+F2  FILE ALT+F3  MEM ALT+F4  MAN ALT+F5  DATA ALT+F6  HELP ：Left Shift ：Right Shift RESET： CTRL +

+

ENTER

+

ENTER

R

To trigger wire break：CTRL + Del ：0301  ENTER ---------------------------------------------------------4-11


Open up Main Menu of Remote Monitor：ALT + Z Close Main Menu：Esc or X on the up right corner. Zoom in Main Menu to the Tool Bar：ALT + X Exit system：ALT + Q Main Menu of Remote Monitor

1. Scan List A. Scan：Browse company Intranet to look for machine accessible. Click twice on the highlighted item and add it to Link List. B. TwinCAD：Execute CAD/CAM software (optional). C. Help：Guide lines of use. D. Exit System：Exit Simulator.

4-12


2. Link List A. Add：Put machine accessible into Link List. B. ： current N.C. file from machine to computer (C:\NC) C. ： N.C. from computer to machine (C:\NC). D. Click twice on the machine accessible to get Online, and click twice again to get Offline. 3. Phone Setting Only available in Taiwan. Please consult HiNet or link to http://www.cht.com.tw/BusinessCat.php?CatID=885 for more information. A. ： number provided by Telephone company. B. ：Pin number for message receive. C. Phone：Phone number for message receive. D. Edit：Appoint Alarm message to transmit and the text content.

E. Enable：On/Off Phone Function 4-13


Note. 1. Remote Monitoring is limited to one machine at a time. To get access to other machine, please Offline current machine before connecting to another one. 2. If there are more than one machine to Remote Monitor, please differentiate them by setting different IP address; otherwise, there might be only one machine scanned and found by Simulator.

Pick any number from 2~254 for differentiation

4-14


4-5 Lower Head Disassembled and Assembled This manual is to teach the person the proper way to disassemble and assemble the heads for cleaning or maintenance. Make sure when performing these steps to have power turned off at the control and both switches in the off position to prevent shocks from happening.

1. Start by removing the top half of the lower head.

1.

2.

2. Its 4 screws hold the plate down (Picture 1). Lift the nozzle off and use the guide remover to remove the guide (Picture 2).

3.

3. Remove the spark cables from the head. It should be 4 screws with 2 cables each screw (Picture 3).

4-15


4. Next, disconnect the hose from the side of the head. Make sure to put a zip tie on the hose to not loose the nut inside the tank (Picture 4).

4.

5. Remove the 2 screws from the back of the silver part of the head and lift up on the head to remove (Picture 5).

5.

6.

6. 4 more screws from the underside will disconnect the brass piece from the stainless piece. Then loosen the setscrew from the front to remove the carbide . Remove the pre-guide with an Allen wrench. It is located on the lower side of the stainless piece (Picture 6).

7.

8.

7. Remove the lower roller. Removing the 3 Allen screws from the right side

does this. The wheel should slide out from there (Picture 7 & 8). 8. From here, you can clean the parts removed from the head outside of the tank. Stuff left on the arm can be cleaned inside, but make sure to use a bucket or something under the head and arm to prevent cleaners from getting into the water unit. 9. Reverse the process after making sure everything is dry and free of cleaner residue. 4-16


Make sure you recheck your lower head height…here is how: 1. After assembling the head, have the 2 screws holding the upper part of the assembly to the head loose. What you will use to adjust the height is a setscrew shown (Picture 9). What this does is lift or lowers the head according to you (Picture 10).

10.

9.

2. Have a truly straight piece of steel in the tank that can reach over the head. 3. While holding the lower flush nozzle up, tighten the setscrew to lift the nozzle within 0.002 to 0.005 of you work piece. Allow for more room if you piece is not truly flat. Once head is at desired height, tighten the 2 screws and you are complete.

4-17


4-6 Upper Head Disassembled and Assembled This manual is to teach the person the proper way to disassemble and assemble the heads for cleaning or maintenance. Make sure when performing these steps to have power turned off at the control and both switches in the off position to prevent shocks from happening.

1. Start by removing the front plate and carbide . The plate is mounted on by 2 screws on the front (Picture 1). The carbide has a setscrew on the right side located in a hole to the left of the power line shaft (Picture 2).

2.

1.

2. Remove the parts off the bottom of the head. These include the flush nozzle, guide, holder for flush nozzle and spring. The nozzle comes off with the holder, which unscrews. The guide comes off with the guide remover (Picture 3).

3.

4-18


3. Remove the shaft above the upper head. Either loosing the setscrew or removing the 2 screws 4. from the holder does this. Be sure to align the put the screws in loose and put it on the upper ceramic piece, before tightening the screws (Picture 4).

tube, head

4. 5. Remove the cover over the gears. Removing the 4 Philips screws on the front of it does this (Picture 5).

5. 6. Remove the brass upper half. To do this, loosen 3 Allen screws on the top going down into the other half. They are hard to find, 2 are in front, and the other 1 is directly behind the left one. The other connections are for the heater. After removing all of those, the brass half should be able to slide out (Picture 6). After removing the 4 screws holding them together, the top half comes off, but cables will still be connected. You need to disconnect the 2 screws holding the black motor on (Picture 7) and the setscrew on the gear to allow you to move the head more. The pre-guide is something that really needs to be watched (Picture 8). It is located between the 2 halves.

6.

7.

8.

7. After cleaning, reverse the steps for reassembly.

4-19

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