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WIRE CUT- EDM Operation Manual SOFTWARE VERSION：W5F F0800 MANUAL VER：B

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

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

Please Read This Manual Thoroughly Before Operation Thank you for buying our product, and for the chances of being able to offer you our high quality wire EDM series machinery and also the best after-sale services. In order to maintain machine’s peak performance and extend its life span as long as possible, we sincerely suggest all the operators carefully read this manual for first time operation. Also, for your safety, please read the following “mustknown” precautions: 1.Wire EDM operators should have received relative training from our local agency, or directly from CHMER headquarter. 2. CHMER wire EDM can only applied to the machining of several kinds of metal work-piece, such as steel, aluminum, tungsten steel, copper and graphite. 3. Push emergent switch before executing any one of following tasks: (1). Cleaning or sorting waste wire. (2) Replacing resin or paper filter. (3) Filling up water tank. (4) Opening power cabinet. 4. Push emergent switch and turn off rotary switch immediately when any one of the following situations occurs. (1) Hearing of funny noise, or any abnormality occurs during machining. (2) Unloading any machine’s power wire (in power cabinet, water tank, or cooling machine.). Please contact our local agency first, or CHMER headquarter for this. 5. To avoid dangerous shock, be sure to stop electricity discharging before installing copper wire and work-piece. 6. Do not touch any part around worktable (upper/lower head, wire and water) during machining to prevent from high voltage strike. 7. Do not modify electrical circuit. 8. Please take reference to relative chapter in this manual for daily maintenance. 9. Please keep this manual closely with the machine. Thank you again for purchasing CHMER’s product. Please call our Service Department at 886-4-23500979 anytime for technical support and repair. It is our honor to be at your service…

INDEX 0-1 Company Profile-------------------------------------------------- 0-1 0-2 Safe Instruction--------------------------------------------------- 0-5 Chapter 1. 1-1 1-2 1-3 1-4

System Introduction System Composition--------------------------------------------Panel & Keyboard-----------------------------------------------Machine Body & Filtration Unit------------------------------System Boot Up and Shut Off----------------------------------

1-1 1-2 1-16 1-21

Chapter 2. 2-0 2-1 2-2 2-3 2-4 2-5 2-6

W5F Software Function Map of W5F Software DISP Mode-------------------------------------------------------FILE Mode-------------------------------------------------------AUTO Mode-----------------------------------------------------MAN Mode------------------------------------------------------DATA Mode------------------------------------------------------HELP Mode-------------------------------------------------------

2-1 2-10 2-57 2-85 2-126 2-136

Chapter 3 3-1 3-2 3-3 3-4

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

Chapter 4 4-1 4-2 4-3 4-4 4-5 4-6

Appendix Consumable List-------------------------------------------------- 4-1 Shield Room------------------------------------------------------- 4-5 Precaution for Malfunction-------------------------------------- 4-9 Setup of Remote Monitoring Software------------------------ 4-11 Lower Head Disassembled and Assembled------------------- 4-15 Upper Head Disassembled and Assembled------------------- 4-18

VER: E5B-1087B DATE: 2012.01 EDITOR: Eirene Wu

CHMER Wire-Cut EDM Operation Manual W5F

0-1 Company Profile CHMER BRIEF EVENTS: 1.1975

2.1976 3.1977 4.1979 5.1980 6.1981 7.1982 8.1983 9.1985

10.1986 11.1987

12.1988

13.1989

14.1990

◆CHMER EDM company was founded（with registered capital NT$200.000.-）to market the first“Transistor”EDM machine in Taiwan. ◆The first hydraulic control EDM machine came out. ◆EDM machine with the functions of free adjustment of pulse on & off was produced. ◆Moving to the new factory for developing southeast-Asia market. ◆Leading to export EDM machine made in Taiwan to Europe. ◆Supplying the first EDM with P.W.M. servo motor driver to the domestic market. ◆Achieving two patents for the new square axes with national central standard bureau of the republic of China. ◆The first EDM manufacturer obtaining“Golden dragon award”form the government. ◆In April, the first multifunctional CNC EDM machine equipped with orbit-cut was produced. ◆In July , the first EDM machine with the finest and super finish device of U-SPARK In Taiwan was produced. ◆In August, Sound Best Trading Co., Ltd Established. ◆In September, Hung Yu Trading Co., Ltd Established. ◆In February, Ching Yeng Machine & Electric Co., Ltd Established. ◆In July, the first EDM machine without backlash on x & y axes was marketed. ◆In April, the WIRE-CUT EDM machine was completed and obtained the excellent-product design award from CETRA of Taiwan, ROC ◆In August, small hole drilling EDM was completed. ◆In December, President Wang was honored with the model of business – founding youth for the 11th term. ◆In March, the giant bridge type of EDM was created. ◆In April, marketing new type of CNC EDM which interfale was available for modifying to sparking conditions during machining. ◆In Jun, Chiao Yeng Machine Co., Ltd. Established. ◆In Jun, Hwang Long Machinery Industrial Co., Ltd. Established. ◆ In October, obtaining the patent for structure improvement of the giant bridge type of EDM （NEW MODEL NO.58428） 0-1

CHMER Wire-Cut EDM Operation Manual W5F

15.1991

16.1992 17.1993

18.1994

19.1995

20.1996

◆In October, the patent for improvement structure of the worktable guide bridge type of EDM（NEW MODEL NO.68192） ◆Obtaining the patent for improved structure of the Prototype of EDM tank ascending & descending（NEW MODEL NO.74419）. ◆In September, capital increased up to NT$50.000.000.◆In October, moving to the new factory with air—conditioning system to enlarge production covering digital products of high-scientific technology. ◆In Sep, Hang Zhou Ruipeng Machinery & electric Co., Ltd Established. ◆In January, NC EDM with programmable Z axis, model CM240Z+50NZ, & CNC EDM with PC base controller, model CM240Z+50NC, achieved excellent product award of “IT’S VERY WELL MADE IN TAIWAN” from CETRA in Taiwan. ◆In March, Sound Best Automaticalization Industry Co., Ltd Established. ◆In December, Yukon CNC Machinery Co., Ltd. Established. ◆In January the 1st EDM manufacturer, in Taiwan, obtaining certificate of quality assurance specified as ISO 9002 form the BCIO of Ministry of Economic Affairs. ◆In March, President Wang, received Award of “GOLDEN TALENT” as “INVENTIVE ENTERPRISER” from INDUDTRY ASSOCIATION OF TAICHUNG, TAIWAN. ◆In November, Honored as “MODEL OF INDUSTRY” form Taichung County Govern. ◆In December, obtained “GRAND GRAGON CENTURY AWARD OF TAIWAN”. ◆In January, obtain Attestation of conformity for technical file and non-annex IV machinery with the requirements of the machinery directive 89/392/EEC “FROM NOTIFY BOY” ◆AMTRI VERITAS LTD. certificate number：AV EC 1105（G）. ◆In February NC EDM with programmable Z axis, model CM380Z+50NZ & CNC EDM with PC base controller, models CM855C+75NC, CM645C+75NC achieved excellent products award of “IT’S VERY WELL MADE IN TAIEAN” from CETRA in Taiwan again. ◆In August, the products of wire-cut EDM, CNC EDM & NC EDM WITH PROGRAMMABLE Z AXIS obtained “THE INTERNATIONAL GOLDEN GLOBE AWARD FOR 0-2

CHMER Wire-Cut EDM Operation Manual W5F

EXCELLENT EXPORT PRODUCT MADE IN TAIWAN”. 21.1997

22.1998 23. 1999 24.2000

◆In Jan, CNC wire-cut EDM models CW430F, CW430W, CW530F, Cw530W obtained award of “IT’S VERY WERY WELL MADE IN TAIWAN” ◆CNC Wire-cut EDM models CW640 obtained award of “IT’S VERY WELL MADE IN TAIWAN”. ◆Obtain Rising Star Award and National Award. ◆Enterprises Professional Manager Award. ◆The 67th of “Top 100 up growth backbone enterprises”. Statistics by “Common wealth” magazine.

25.2001

26.2002

27.2003

28.2004

29.2005

◆Provide fist precision bridge CNC wire cut EDM & CNC powder EDM. ◆The 29th of “Top 100 potential enterprises” Statistics by “Common wealth” magazine. ◆In January, “CW432S” “A53C+75N” obtained Award of “IT’S VERY WELL MADE IN TAIWAN” ◆In February, obtained certificate of quality assurance of ISO 2000 Version. ◆In January, “CM434Z+50EZ” obtained Award of “IT’S VERY WELL MADE IN TAIWAN” ◆Register into Emerging stock market. ◆In September, “CM323Z+50EZ+OB-head obtained”﹝Middle Enterprise Innovation Research Award﹞ ◆In November, CHMER obtained “The Nest Innovation research Company” award. ◆In January, “CW-32CF/S”wire-cut EDM models obtained of “IT’S VERY WELL MADE IN TAIWAN” award. ◆In March, CHMER obtained ISO 14000 Quality system certified, who is the 1st among EDM manufacture in Taiwan. ◆In March, Introduce the 1st linear motor high precision wire-cut EDM in Taiwan. ◆In January, “P42SL” high precision wire-cut EDM model obtained of “IT’S VERY WEEL MADE IN TAIEAN” award.

0-3

CHMER Wire-Cut EDM Operation Manual W5F

COMPANY ORGAIZATION Taichung Headquarters： 1.CHING HUNG MACHINERY & ELECTRIC INDUSTRIAL CO.,LTD No.3, Jing-Ke 1st Road, Nantun District, Taichung City 408, Taiwan TEL:+886 4-23509188 FAX:+886 4-23509199 2.Taipei Branch office HUNG YU TRADING CO.,LTD. NO.13,Dec4.Chung Hsing Ed , San Chung City, Taiwan, R.O.C TEL：02-2988-8668 FAX：02-2985-0850 3.Hang Zhou Factory HANG ZHOU RUIPENG MACHINERY & ELECTRIC CO.,LTD. No.25,Ningdong Road Xiaoshan Economic Techinical Development Zone

TEL：0571-8283-1032 FAX：0571-8283-2034

0-4

CHMER Wire-Cut EDM Operation Manual W5F

0-2 Safety Instruction 0-2-1Machine stop When the emergency occurs, operator can stop machine by following two ways： Emergency Stop & Main Power switch.

No Fuse Breaker

Emergency Stop

Main Power

Emergency Stop：When pressed, except of computer power, motors, pumps would be shut off. Main Power：When turned off, the power of machine and Power Cabinet will all be shut off. No Fuse Breaker：Be sure to turn off no fuse breaker and main power before maintenance.

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

0-5

CHMER Wire-Cut EDM Operation Manual W5F

0-2-3 Operation precautions 1. If find or smell or hear any abnormal conditions, please press emergency stop button immediately then start to locate the problem. 2. There will have fatal high voltage high current passing through on duration. Therefore, strictly prohibit touch anywhere is above water pan during sparking. 3. There also will have electric power on traveling wire from wire spool to wire waste box. Prohibit to any parts wire will contact during sparking. 4. Keep away from XY axis and its metal covers for potential finger-folding injury at jogging XY plane. 5. There always will have water on worktable & water pan. Don’t stand on it anytime. 6. Screw well PE ground lines in power cabinet and electrical boxes (on machine column & water tank) for avoiding electric shock. 7. When power on will start exhaustion fans. Don’t insert your fingers into fans or its filters. 8. Don’t open power cabinet doors (front door & rear door), doors of electrical boxes or metal covers of machine body for avoiding electric shocks. 9. When machine shut down, there still have electric power on capacitors. Don’t touch it. 10. Don’t let water splash on power cabinet or electrical boxes for avoiding electric shock. 11. Stop machine immediately when finding out split/broken plastic coated of electrode cables (connect between machine body & power cabinet) and, don’t start machine before repair 12. Don’t dismount lines with E or PE marks ground lines to keep away of electric shock. 13.On machine duration or after machining, there will have higher temperature on work piece. Don’t touch it directly by hands. 14.Watch out of finger cut injury or, as put on work piece with sharp edge or put on wire spool. 15.Please must shut down main power switch before opening power cabinet doors or electrical boxes. 16.Please check and screw well fork pins on terminal blocks before powering on. If any loosen pin and power on, may cause unbalance power input, motor noise, motor burning, terminal block burning. 17.Regarding the waste materials like silt, lubricating, paper filters, used wire, ion resin and broken parts please take over with quality recycle dealer or obey local deposition law. 18.For taking care of water splash out shall open upper / lower flushing knobs from minimum to maximum. 0-6

CHMER Wire-Cut EDM Operation Manual W5F

19.Avoiding water splash on floor at any time, that has potential dangers people fall down or get electric shock. 20. The light from the work-lamp could generate high heat on the items illuminated. Please be aware and keep fusible material such as plastic cables away from being irradiated by work-lamp. Safe operation and place for the personnel 1. Get rid of metal chips, water or oil is onto around the machine. 2. Operator puts on safe glasses and safe shoes. 3. When move in/ move out the work piece from working table, watch out the fall down risk. Checking points for safe dielectric cutting 1.Ensure work piece is fixed well by proper jigs and fixture ways on working table. 2.Wire electrode is loading and traveling well by instructions. 3. Electrode cables / ground lines a. Are they screwed properly？ b. Cable coating in good conditions without any split？ c. Upper/ lower nozzle distances are adjusted well won’t crash to each other Precaution of the use of stainless steel 1.The improper way of material conservation will shorten its life span. Stainless steel tends to erode more rapidly after in touch with other materials. 2. The rust from other material could be passed to stainless steel if not properly stored. Checking points before cutting 1.Dielectric level is set properly (Submerged model)？ 2. Is dielectric level dropping down accidentally？ 3. Is work tank locked properly (submerge type)？. 4. Is Rubber Seal of tank door damaged？ Checking points while cutting 1. Make sure no leakage of dielectric. 2. Upper/Lower flush pressure were adjusted to be coincident？ 0-7

CHMER Wire-Cut EDM Operation Manual W5F

3. Is Cutting technology well setup? 4. For no-man operation, please make sure machine can achieve： a. Smooth and reliable cutting condition? b. Constant and stable flush pressure? c. Dielectric level (for submerge type) remains constant？

0-8

Chapter 1.

System Introduction

■ 1.1 System Composition

1-1

■ 1.2 Panel & Keyboard

1-2

■ 1.3 Machine Body & Filtration Unit

1-16

■ 1.4 System Boot Up and Shut Off

1-21

CHMER Wire-Cut EDM Operation Manual W5F

1-1 System Composition

Filtration Unit

Machine Body Power Cabinet

Filtration Unit Wire Cut machine is consisted of three major parts：Power Cabinet, Machine Tool, and Filtration Unit. 1. Power Cabinet Contains majority of fuses, TFT LCD Display, Power Line, Computer and Sparking Circuit. 2. Machine Tool There are two types of Machine Tool: Submerged and Flushing, which differed from each other by whether equipped with (S) a stainless tank or not (F). For example, CW 530S, CW 530F.

3. Filtration Unit For dielectric filtration and de-ionization.

1-1

CHMER Wire-Cut EDM Operation Manual W5F

1-2 Power Cabinet, Console Panel and Remote Control 1-2-1 Power Cabinet & Console Panel

3 2

4

6 3 1

Console Panel

5

8

9 10

Power Cabinet

1-2

CHMER Wire-Cut EDM Operation Manual W5F

1. Analog Voltage Meter Display the variation of EDM voltage to control machining speed. 2. Monitor 15”(standard) TFT LCD monitor. 3. Control panel a. Text key: for normal information and number input. b. Hot key: control the EDM conditions. (e.g. EDM power supply, dielectric, wire feed rate and tension) c. Function key: system function execution. 4. Buzzer Provide warning sound to remind the operator. 5. EMG-stop button Under any situation, push this button will cut off power of the controller. 6. Main Power Switch Main switch of the CNC controller. 7. Remote control Contains basic hot key to operate the machine. 8. No Fuse Breaker ON/OFF switch for electric current inflow and overload protection. 9. CF Card Drive/ USB Card Reader (Reserved for OPT) Data storage interface of NC program from external computer. CF memory card or USB for data storage. 10. CNC Power ON button This button is for CNC controller power actuation. After switching on the main electric power, push this button will actuate the CNC controller. Also, its power indicator will be on at the same while. ※Optional Functions (have to confirm controller’s version) a. Microsoft Mouse / Touch Screen b. Memory CF Card capability c. Installing in-house GENTEC Remote Monitoring software enables N.C. file download /upload, watching on machining status from Client PC through Internet

1-3

CHMER Wire-Cut EDM Operation Manual W5F

1-2-2 Introduction of text keys 1. A~Z Input key of English alphabet 2. 0~9 Number input 3. Page up, Page down For page exchange (NC program or column) 4. Home, End When executing program edit or data input, move the cursor to the left or right of the line. 5. Back When executing program edit or data input, move the cursor backwards and delete the original bit. 6. Space Blank bit. 7. Enter For data input, function execution or lines addition during program editing. 8. Ins Switch knob of character insert or replacement when editing program. 9. Del When executing program edit or data input, delete the character on the cursor 10.↑,↓ For cursor movement or working data change when executing program edit or data input. 11.→,← For cursor movement when executing program edit or data input. 12.+/Positive/negative marking of input data or increase/decrease of EDM data. 13.Esc Cancel the input data.

1-4

CHMER Wire-Cut EDM Operation Manual W5F

1-2-3 Introduction of quick function key Operator could apply below quick command： 1. Use ＋/－ button to change the value of each item of sparking data. 2. Type S ??? (ex: S045) in Data Bar is to backup current sparking data to S-code No. 045. 3. Type E ??? (ex: E045) in Data Bar is to call up existing sparking data from S-code No. 045 for use. 4. To reset Work Coordinate., type R in Data Bar then press ENTER. 5. To specify the value of each axis in Work Coordinate., type X??? Y??? Z??? U??? V??? in Data Bar then press ENTER . ??? is specified value. 6. To move axis incrementally, type MX??? MY??? MZ??? MU??? MV??? In Data Bar and press ENTER. M actually means Move. 7. To move axis by specific Coordinate. System, type M#X??? M#Y??? M#Z??? M#U??? M#V??? in Data Bar and press ENTER. # (0：Machine Coordinate. / 1：PGM / 2：G92 / 3：Work Coordinate.) 8. To move axis to reference point (G054~G959), type MG#5$X??? Y??? Z??? U??? V???.”# ranges from 0~9, and $ is from 4~9. 9. To move 1/2 distance of what mentioned from 6.~8., type MX/2, MY/2, MU/2, MV/2. 10. In Data Bar, type GO and press ENTER , machine will move to the zero points of the coordinate system where the cursor is currently on. 11. To execute N.C program from specific line, type N??? under MEM\F1(MEM. PATH) when RESET button is lit on.

1-5

CHMER Wire-Cut EDM Operation Manual W5F

1-2-4 Introduction of operation key

1.

JOG If this button is pressed, four kinds of table moving speed are selectable including H (high speed), M (middle speed), ML (speed between middle and low) and L (low speed). Under this mode, if the axis-moving key is pressed, the table will move by setting speed. If it is released, the table will stop moving. Note: 1. If the JOG button is pressed twice in 1 second, it will execute AUTO mode. 2. The value of JOG feed-rate override may adjust in the mode Help-2 >「System Double Value Parameter」, PA#36~PA#41 (We strongly recommend user may not modify the value at will, otherwise it may cause unexpected damage to machine tool)

2.

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

1-6

CHMER Wire-Cut EDM Operation Manual W5F

Note: 1. Additionally increases the JOG speed to be 2 steps. Setting method: Press H or M key twice in 1 second. Flash indicator means that setting is finished. 2. The value of STEP JOG feed-rate override may adjust in the mode Help-2>「System Double Value Parameter」, PA#42~PA#47 (We strongly recommend user may not modify the value at will, otherwise it may cause unexpected damage to machine tool.)

3.

H, M, ML, L These four keys are for speed setting under JOG mode. However, they are for moving distance setting under STEP JOG mode. Note: 1. Additionally increases the JOG speed to be 2 steps. Setting method: Press H or M key twice in 1 second. Flash indicator means that setting is finished. 2. The value of STEP JOG feed-rate override may adjust in the mode Help-2>「System Double Value Parameter」, PA#42~PA#47 (We strongly recommend user may not modify the value at will, otherwise it may cause unexpected damage to machine tool.)

4.

+U/+X，-U/-X，+V/+Y，-V/-Y，+Z，-Z These are axis direction keys. Under JOG or STEP JOG mode, they could control the moving direction of the worktable.

5.

UV/XY

This is direction switch key. When the indicator is lit, it represents XY plane. On the contrary, it becomes UV plane. (Parameter 68 bit 1) 6.

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

7.

S.PT This key is for start point quick return. When it is pressed, the worktable will return to start point quickly. If the indicator is lit, it represents that the present position is the start point. 1-7

CHMER Wire-Cut EDM Operation Manual W5F

8.

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

9.

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

TRACER B.PT 10. This key is for break point tracing. When it is pressed, the worktable will return to start point then return to the wire break point along the previous machining path at last. (Auto wire feeding) Note. 1. Those four path trace functions #7~#10 can only be executed one at a time. 2. The data of trace path according to the last G92 coordinate in processing. 3. While reboot the machine, it restore the last path data which had been stored. 4. Press

can interrupt during the trace function is activated.

5. User can start these four functions (path trace) when EDM spark power is activated (Water flushing, wire feed, spark, ED -POS). 6. Auto wire feed would be activate when execute those trace functions. 11.

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

12.

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

13.

SINGLE BLOCK This is for single block execution. When pressing this key during program 1-8

CHMER Wire-Cut EDM Operation Manual W5F

execution, the indicator will be lit. If the START key is pressed, program single block will be executed. After that block is finished, the machine will stop moving. If you want to continue the next block, press the START key again. Generally, it is for program path inspection. 14.

15.

DRY RUN This is for trial run without real sparking. Screen would display program path while table is moving. Be sure to turn it off after the trial run. We could use STOP key to pause it and START key to keep it moving. Note. 1. DRY RUN speed can be adjusted by JOG on console panel (Flag#042=ON). 2. Keep pressing the button twice in 1 sec to disable/enable. MACH LOCK To lock up machine table when program is running (But Machine doesn’t move) and only does Absolute coordinate showing the position move. Note: MACH LOCK is unavailable during processing is activated.

16.

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

17.

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

18.

19.

WATER Pump switch of flushing water coming from upper/lower nozzle. WIRE Wire feeds from the spool with 7V~8V on the wire.

20.

EDM POWER Open and close the relay of erosion power.

21.

ED POS Switch of erosion power signal that release the energy from Power Cabinet. 1-9

CHMER Wire-Cut EDM Operation Manual W5F

22.

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

23.

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

24.

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

25.

RESET To remove the current processing from memory and initialize its working condition setup. Press the button once, then a window comes up and ask if to reset the process，if press the button twice quickly then program will be reset automatically. Then the LED lit means initialize progress is success, user can modify the setting i.e.: offset, taper cutting data.

26.

RE-START To resume program removed by RESET or interrupted by power black out. Note. 1. To execute RE-START,

1-10

must be lit on.

CHMER Wire-Cut EDM Operation Manual W5F

Re-Start Procedures (After program reset)

(After power blackout)

Back to break point

Search Home for 5 axis

Push AUTO

Back to break point

Push AUTO Push

twice rapidly

Press

Press

twice

twice rapidly

Search for last file Press

twice

Search for last file

Push

Job resumed Push Job resumed

27.

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

28.

Axis Exchange

29.

X Mirror

30.

Y Mirror

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

1-11

CHMER Wire-Cut EDM Operation Manual W5F

Ex： Mirror

X Mirror

Y Mirror

X&YMirror

Axis exchange

X

Y

X&Y

31.

AWT thread wire and then stop on present location. Press “START” to resume.

32.

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

33.

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

34.

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

35.

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

36.

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

37.

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

1-12

CHMER Wire-Cut EDM Operation Manual W5F

1-2-5 Remote Control

NO

NAME

FUNCTION AND DESCRIPTION Z LOCK (MAN→ F1 SEARCH HOME→Z.LOCK.SW )

1

Stop Z-axis from going down further than the set point. To ZLOCK(For Z-axis lock/unlock, push the button twice rapidly. anti-collusion) Switch the mode between JOG/STEP JOG，when LED lit

2

JOG/ STEP JOG

means JOG mode be activated，lit off means STEP JOG mode is activated.

1-13

CHMER Wire-Cut EDM Operation Manual W5F

Enter to processing mode「AUTO」

3 AUTO

Manual JOG Feed-rate speed override. 4 H/M switch

ML/L switch

JOG Feed-rate Edge： MAN  F5 (Edge Move)Mode 0. 5 EDGE CENTER Center：MAN F5 (Edge Move)Mode 2. When lit on, dielectric, wire feed and sparking power will 6 be automatically activated while executing a N.C. SERVO program. Zero return the local coordinate value of XY or UV axes on LCD display of remote. 7 Coordinate zero HELP->F3 WORK PARAM -> Page 2/3 ->LCD Coord. return ID = 3 For AWT to expel waste wire. 8 Air Blow AWT system feed the wire. For AWT 9 AWT feed the wire. AWT cut off the wire. For AWT 10 Cut wire Water Pump. Press this button then LED lit, water pump

11 Pump

12 Wire Feed

ON, start flushing on upper/lower head. Again press this button then water pump OFF, stop flushing. Wire feeds from the spool come with 7V~8V also show on Analogue/Digital voltmeter. Open and close the relay of erosion power.

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

14 ED-POS

1-14

CHMER Wire-Cut EDM Operation Manual W5F

If the wire touches the work-piece, or the wire is not 15

SHORT

threaded properly, it will cause short between the wire and work-piece. Then, the indicator will be on. If the problem still, the machine cannot work. User have to clear all the possibility why short be caused. This key is for break point quick return. When it is

16 Break Point Return

pressed, the worktable will return to wire break point quickly. If the indicator is lit, it represents that the present position is the break point. If there is wire break, the indicator will be lit. After the wire is re-threaded, the indicator will be off automatically.

17 Wire Breaks

Vacuum suction to assist wire threading. 18 Suction This is direction switch key. When the indicator is lit, it 19 UV / XY Axis Switch Up 20

21

START

STOP

represents XY plane. On the contrary, it becomes UV plane. Press this key to execute system function or start running a program. When the indicator is lit, it means that the machine is moving. On the contrary, the machine is in idle status. Press this key to interrupt system function or program execution. When the indicator is lit, it means that the machine is idle. On the contrary, the machine is in working status. Push the button to drain out the water in the work-tank.

22 DRAIN Push the button to start filling up work-tank. 23

WATER FILLINGIN

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CHMER Wire-Cut EDM Operation Manual W5F

1-3 Machine Body & Filtration Unit 1-3-1 Work table +Z +U +V -Z

-U +X

-V

+Y

-X

-Y

Use the buttons on Remote Control or control panel to move Work-table. XY axis move by table while UV axis by Upper Head. Use speed button： for optimum federate.

1-3-2 Wire Transport System Below illustrations indicate how to locate cutting wire for both AWT and non-AWT wire transport system.

Wire transport of non-AWT

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CHMER Wire-Cut EDM Operation Manual W5F

Wire transport of AWT

1-3-3 Jumbo Wire Spooler For the use of wire spooler over 7Kg, Jumbo Wire Spooler can fit up to 30Kg wire spool. 1. Connect power line to 220V. 2. Put a reel of cutting wire properly. 3. Follow the figure pasted inside and bring wire through the wire transport system. 4. Done. Note: 1. Jumbo Wire Spooler feature requires AWT system 2. Wire Spool used must be no larger than below dimension.

Bobbin

Flange

Barrel

Outer

Flange

Arbor hole

name

diameter

diameter

width

thickness

diameter

D

d

L

a

H

355mm

222mm

200mm

19mm

38mm

1-17

CHMER Wire-Cut EDM Operation Manual W5F

Floor layout of Jumbo Wire Spooler

1-3-4 Control Panel of Filtration Unit 1. Digital Water Conductivity Meter WORKING

K WATER LOW

SV

DIGITAL

WATER CONDUCTIVITY SET/ SAVE

UP

VALUE

PV PRESENT VALUE

DOWN

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

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CHMER Wire-Cut EDM Operation Manual W5F

Operation of Digital Conductivity Meter 1. Normally, 5 seconds after machine power turned on, PV will be lit on, which indicates the digital conductivity meter is displaying correct value and in stand-by status. 2. Next, press SV button, the screen will display previous target value, which can be readjusted by UP and DOWN button. 3. When new setup is done, press SV button to save it into memory; if not save the value, the value may as same as previous value and then return to PV mode after a few seconds. 4. Once the new target value is set higher than current one, deionization process (Working lit on) will start until new target value reached; however, if new target value is smaller than current one, water conductivity will remain the same until ion-resin completely consumed or diluted by new tap water. 4. When water level is too low, WATER LOW alarm will be lit on and blocks deionization process temporarily until alarm dissolved. 5. The latest status of Digital meter before system shut down will be memorized. Note (1). Cleaning of probe. It is recommend clean the probe once every month to maintain the accuracy of measurement. (2). Push PV button to exit SV mode any time. (3). To avoid de-ionization over frequently, the activation will be put off for a default period. 2. Flush water regulation (1). Flush Knob (Up) Adjust flush pressure. Optimum value

+

2

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

PE N

C LOS

O

SKON

E

Indicate flush pressure when mechining. (3). Flush Knob (Down) Adjust flush pressure. Optimum +

value is 0-15kg/cm2. (4). Pressure Gauge (Down)

E

1-19

PE N

C LOS

mechining.

O

SKON

Indicate flush pressure when

CHMER Wire-Cut EDM Operation Manual W5F

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

(6). Water low alarm Indicated insufficient water inside Filtration. Fill up the tank with distilled water properly to avoid idling water pump.

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

浮筒水位檢 測器

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CHMER Wire-Cut EDM Operation Manual W5F

1-4 System Boot Up and Shut Off 1

4

3

2 Power Cabinet

1. No Fuse Breaker: ON/OFF switch for electric current inflow and overload protection. However, while instantaneous over current over 50A, the switch will turn to OFF automatically. In this case, please find out and eliminate actual causes before power recovery. 2. Main power：After turn on No Fuse Breaker then switch on main power. 3. Emergency Stop：Shut down motor driver, filtration pump and eroding power once pressed. To recover the power, release Emergency stop and push Green Button. 4. Green Button：Lit on and activate motor driver, filtration pump and eroding power once pressed. (This button is only for open power; please press Emergency Stop to shut down machine.)

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

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CHMER Wire-Cut EDM Operation Manual W5F

Introduction page

A few seconds...

Operation screen

6. Release Emergency Stop. 7. Press Green Button and activate machine body (motor drive, filtration pump and eroding power) 8. If there is no any error message appear, proceed Homing for each axis.

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CHMER Wire-Cut EDM Operation Manual W5F

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

Press F1 Search Home

Screen shows Search Home message.

Press

Terminated YES

Press axis arrow keys: X+ Y+ U+ V+ Z+ must be on and turn off AR and Protect Flag.

Machine begins to move?

NO

YES

NO

Alarm Message

YES

Search Home finished when all “*” disappear.

Note：Z-axis home reference point equal to Z-axis height setting.

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CHMER Wire-Cut EDM Operation Manual W5F

1-4-3 System Shut off 1. Press Emergency Stop. 2. Turn (left) on the rotary switch, and UPS (Uninterrupted Power Supply) start beeping in the meantime controller begins data back-up. 3.Power shut off. Note: 1. Please hold on at least for 30 seconds to recover machine power (Green Button) after Emergency Stop to prevent from possible damage on motor driver and circuit boards. 2. Do not execute file up/down load during system shut off.

1-24

Chapter 2.

.

W5F Software Function

■ 2.0 Map of W5F Software ■ 2.1 DISP Mode

2-1

■ 2.2 EDIT Mode

2-10

■ 2.3 MEM Mode

2-57

■ 2.4 MAN Mode

2-85

■ 2.5 DATA Mode

2-126

■ 2-6 HELP Mode

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CHMER Wire-Cut EDM Operation Manual W5F

2-0 Map of W5F Software 2-1 DISP Mode F1 Axis Message F2 Flag Message F3 Data Info F4 IO History F5 IO Status F6 Motion Message F7 Block Message F8 AWT Message

2-2 FILE Mode Page 1/3 F1 Sure Execute

F1 Open N.C Program F2 Save N.C. Program F3 Save –As Program

F1 Edit N.C PGM

F2 (Reserved)

F2 Copy N.C. PGM

F3 (Reserved)

F3 Delete N.C. PGM F4 Close N.C. Program F5 Receive N.C.

F4 Send N.C. PGM

F4 (Reserved) F5 (Reserved)

F5 Protect Switch F6 (Reserved)

F6 (Reserved)

F6 Pick N.C. PGM

F7 Undo

F7 Store Browser1

F8 Delete Line

F8 Store Browser0

F7 Store Browser1

F9 (Reserved) F10 N.C. Browser

F8 Store Browser0

F9 Removal Browser

F9 Removal Browser

F10 HD Browser

F10 HD Browser

CHMER Wire-Cut EDM Operation Manual W5F

Page 2/3

Page 3/3

F1 Set String

F1 Move Line

F2 Search String

F2 Search N. Code

F3 Insert String

F3 (Reserved)

F4 Replace String

F4 SIM. Skim

F5 (Reserved)

F5 SIM. Data

F6 Cancel M. Block

F6 SIM. H. VAR.

F7 Delete M. Block

F7 SIM. D. OFT

F8 Move M. Block

F8 Spark Offset

F9 Copy M. Block

F9 Figure Color

F10 Set M. Block

F10 SIM. Execute

2-3 AUTO Mode Page 1/2

Page 2/2

F1 MEM Path

F1 (Reserved)

F2 MEM Data 1.

F2 MEM Coord.

F3 MEM Data3

F3 MEM Record

F4 MEM Data4

F4 MEM Skim

F5 Corner Data

F5 (Reserved)

F6 MEM H.VAR.

F6 (Reserved)

F7 MEM D. OFT.

F7 Cut NO. INFO,

F8 MEM Hole

F8 MEM NC. PGM

F9 Figure 2-4 MAN Color

F9 Scope

F10 Path Zoom

F10 Path Zoom

CHMER Wire-Cut EDM Operation Manual W5F

2-4 MAN Mode Page 1/2

Page 2/2

F1 Search Home

F1 Open Move

F2 MDI Move

F2 3PT Move

F3 VERT Move

F3 Board Move

F4 DA, DB Move

F4 Edge Align

F5 Edge Move F6 MDI Cut F7 Coord. Move F8 Record Move F9 Angle Move F10 Corner Move

2-5 MDI Mode

2-6 HELP Mode

F1 S. Data List

F1 System Message

F2 DEF. S. Base

F2 Device INFO.

F3 Search Offset

F3 Work Set

F4 USE S. Base

F4 Net Set

F5 (Reserved)

F5 Message Text

F6 Corner Base

F6 Help Text

F7 Modify Corner

F7 (Reserved)

F8 (Reserved)

F8 Mark Color

F9 Delete Datas

F9 Installment

F10 Copy Datas

F10 Exit System

CHMER Wire-Cut EDM Operation Manual W5F

2-1 DISP (Diagnostic Mode) Operation Guide 2-1-1 F1 (Axis Message) This sub-function displays the internal information of all axes on the controller. The work data of axes are on the right hand side. Note. The Diagnostic Mode provides the correct information for maintenance personnel to handle machine errors. Axis Message Screen

2-1

CHMER Wire-Cut EDM Operation Manual W5F

2-1-2 F2 (Flag Message) This sub-function displays the status of all flags on the console to facilitate maintenance personnel to understand the work status of the console. There are 24 pages (F000~F999) in this sub-function, press PgUp and PgDn buttons to turn pages. Note: The Diagnostic Mode provides the correct information for maintenance personnel to handle machine errors. Flag Message Screen

2-2

CHMER Wire-Cut EDM Operation Manual W5F

2-1-3 F3 (Data Info.) For Maintenance Personnel Use (displays internal data value of controller) Data Info Screen

2-3

CHMER Wire-Cut EDM Operation Manual W5F

2-1-4 F4 (I.O. History) For Maintenance Personnel Use (this sub-function records the time, date and status of the changes of I/O data of controller peripherals to facilitate maintenance personnel or designers to check the status of machine errors. The system provides the records of the last 1000 changes). I/O History Screen

2-4

CHMER Wire-Cut EDM Operation Manual W5F

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

 Function Description 0: Interface error code. The value should be “0”, meaning that the system works properly. 1: Send/Receive delay time, expressed in ms. 2: Send/Receive packet frequency (the value increases if succeeded but remains the same if disconnected). 3: The 2 bytes on the left—number of characters sent/received; the 2 bytes on the right—the total number of characters sent/received. 4~19: Data stream of characters sent/received.

2-5

CHMER Wire-Cut EDM Operation Manual W5F

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

2-6

CHMER Wire-Cut EDM Operation Manual W5F

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







1. Enter S+Enter: Controller may arrange in time order automatically 2. Enter D+Enter: Controller may delete the information where the cursor located 3. Enter TH=40+Enter: Controller may modify present location’s working thickness information 4. EnterR+Enter: controller may record sparking condition in 1 sec

2-7

CHMER Wire-Cut EDM Operation Manual W5F

Contents Description:

 Present Single Block Information: 1. Mainly and Secondary reference coordinates 2. Average Gap Voltage and Feed-rate 3. Single block path length \ Present position 4. Block Status: First line: The ratio of Erosion power reduction and distance variation Second line: Status about Corner Third line: The activated s-code data, OV、PW=LP Fourth line: The activated s-code data, ON、OFF、AN、AFF Fifth line: The activated s-code data, SV、FR、WF、WT、WL

 Block information record for latest 1000 blocks

Start Cutting Date Start PT. Ang. Block Finish Cutting Time End PT. Ang. Number

Path Len. Of Main PGM Path Len. Of Aux. PGM

S. Code Data

Average Volt.\Diff. Highest \Lowest

Breaks Short

Average Speed / Erosion energy ratio

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

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CHMER Wire-Cut EDM Operation Manual W5F

2-1-8 F8 (AWT Message) For Maintenance Personnel Use (This sub-function displays the movement status of machines during wire threading.) AWT Message Screen

2-9

CHMER Wire-Cut EDM Operation Manual W5F

2-2-1 EDIT-1 Page The function keys in File allow users to operate all NC program and file functions. There are 3 submenus in this function menu; users can select 3 submenus with Arrow Buttons. Submenu (EDIT-1)

Submenu (EDIT-2)

Submenu (EDIT-3) 2-10

CHMER Wire-Cut EDM Operation Manual W5F

EDIT P1 Screen 2 4

1 3 6

5

1. If the name of the current NC program has been changed, an asterisk “*” will appear in front of the program name. 2. Total number of files currently opened; it gets to 8 files at one time. Press TAB key to flip the opened files and F4 to close the opened one. 3. Cursor status: To type and edit program now staying “REP” (replace character) Or INS. (insert between character) While status stays “REP” then curse status 2-11

CHMER Wire-Cut EDM Operation Manual W5F

becomes ___ ；otherwise the curse status becomes ■ for “INS”. 4. Cursor position L: a/b ; C: s/t. L: a means total lines, and L: b means which line the cursor is on; C: t represents total bite and C: s means the bite position in a line. 5. Editing area. 6. In a NC program, letters are in red and numbers are in blue to prevent confusion. Blue

. G 92

X0

Y0 Red

2-2-1-1 F1 (Open Program) This item allows users to load the file from the storage device to the computer for execution, modification or editing a new NC program. 1. Press F1 (Open Program) Enter in the dialog box at the center of the screen the name of the file you wish to open and the storage device (0: hard drive; 1: diskette; 2: web; 3: CF card). (Enter a new file name to create a new file. In this case, you must choose hard drive “0” as the default storage device (DOC). 2. Press F1 (Sure Execute)Open file.

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CHMER Wire-Cut EDM Operation Manual W5F

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

2-2-1-3 F3 (Save As) This function allows users to save NC program in a new name or in another storage device. The process is the same as Open Program：F3 (Save As) Enter a new filename or the new storage device F1 (Sure Execute) or ENTER Note: If the new file name is the same as the original filename or already exists in the new storage device, a prompt dialog box asking you to replace filename or not will appear. Select OK or Cancel and press ENTER or F1 (Sure Execute). (Select OK or Cancel with  or  key.)

2-13

CHMER Wire-Cut EDM Operation Manual W5F

2-2-1-4 F4 (Close Program) To close an opened NC program. Operation: 1.Switch the screen to the NC program screen you wish to close (press Tab key). 2. Press F4 (Close Program). 3.To close all opened NC programs, press the F4 key until the number of opened files appearing in the information bar is “0.”

2-2-1-5 F5 (Receive Program) This function allows users to send program to the controller from an external computer via the DNC using the RS232 port. (This function will be disabled when manipulated by touch screen.) 2-2-1-6 F7 (Undo) This function can recover the erased character at the last step. 2-2-1-7 F8 (Delete Line) To delete a line in NC program.

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CHMER Wire-Cut EDM Operation Manual W5F

2-2-1-8 F9 (FTP D. LOAD) Through Ethernet transportation, user can download the program from PC to controller in the LAN. User must have done the essential setup of TCP/IP between PC / IPC in advance. (If users need to use this function, please contact maintenance personnel.) 2-2-1-9 F10 (N.C. Name Browser) As shown in the screen below: 2

9

10

11

5

1

4

7

12

8

3

6

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

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CHMER Wire-Cut EDM Operation Manual W5F

Press F0 (Browse Program Name) and it shows detailed info. of each file: O0004

1198

Filename File size

2006/05/06

08:15:12

R

Time

Re-write Protection

Date

CHMER

Remark

2-2-1-10 F0 (Browse Program Name) There are 9 items in this function: F1 (EDIT PROGRAM): Open and edit the selected file. F2 (COPY PROGRAM): Copy a single selected file. Operation is the same as [EDIT/F3 (Save As)]. When copying many files, the controller will copy the selected files to the hard drive (Select with F6). F3 (DELETE PROGRAM): Delete selected files [NB: Protected files cannot be deleted.] F4 (SEND PROGRAM): Send selected files to an external device via the DNC. F5 (PROTECT SWITCH): When read-only is set, an “R” will appear in the ST column. F6 (PICK PROGRAM): The switch symbol will appear if selected. F7 (STORE 1 BROWSER): Reserved (path must set in HELP=> F3.) F8 (STORE 0 BROWSER): Reserved (path must set in HELP=> F3.) F9 (REMOVAL BROWSER): Load a diskette in the drive. F10 (HD. BROWSER): Programs on hard drive. Note: 1. Pressing ESC key can interrupt the search process. Matched items will be displayed on the screen. 2. If the search is failed then it will show the different message on the screen. 3. Press spacebar to switch the status of column where the cursor stays. a. Press CTRL key and spacebar at the same time or F6 key to select all files. b. Press CTRL, ALT and F3 keys at the same time to delete all files in the device. c. Press the ALT+ N key to display files by name; ALT+ S key to display files by size; ALT+ D key to display files by built date. d. Press the ALT+ R key to set file ”rewrite only”; ALT+ T key to browsing file by text mode; ALT+ G to browsing file by graphic mode. e. If user knew the file first tile what would like to search then can direct input such as: “A” or “B” to browse the files. 2-16

CHMER Wire-Cut EDM Operation Manual W5F

4. To open an unknown file name (but knew what’s the storage device) a. Press F1 OPEN NC. PGM. b. Press F10 NC. NAME BROWSER c. Selected the storage device, such as F7 STOR.1 BROWSER or F8 STOR.0 BROWSER (any optional CF CARD reader or USB device); usually to choose F9 FLOPPY BROWSER, F10 HD. BROWSER. d. Use ↑、↓、Page Up、Page Down keys to select the need file, then press ENTER or F1 SURE & EXECUTE to open file.

2-2-2 EDIT-2 Page

2-2-2-1 F1 (Set String) This function allows users to edit and set the new and old strings they wish to search, replace or insert. Enter strings for search Enter the new string you wish to insert or replace.

2-17

CHMER Wire-Cut EDM Operation Manual W5F

2-2-2-2 F2 (Search String) This function allows you to search strings down the pages from the cursor position. Press F1 (Set String)

Enter strings for search

Press F2 (Search String)

Cursor move to the search target

2-18

CHMER Wire-Cut EDM Operation Manual W5F

2-2-2-3 F3 (Insert String) This function allows users to insert the set string in the cursor position. Press F1 (Set String)

Enter string for insert

ENTER

Move the curser to the position for insert.

Press F3 (Insert String) 2-19

CHMER Wire-Cut EDM Operation Manual W5F

Insert

new string after the index of cursor.

2-2-2-4 F4 (Replace String) This function allows users to search current strings and replace them with new ones.

2-20

CHMER Wire-Cut EDM Operation Manual W5F

Push F4 (Replace String) and use function keys below: F1 (No Replace): Only search, not replace F3 (One Replace): Replace one at a time F5 (ALL Replace): Replace all F8 (ABORT&EXIT): Cancel Replace String. Press F1 (Set String)

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

ENTER F4 (Replace String)

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CHMER Wire-Cut EDM Operation Manual W5F

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

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

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

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

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CHMER Wire-Cut EDM Operation Manual W5F

C. F5(All Replace): Replace all.

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

Note: When there is neither string data specified, nor set in the program, error message ALARM 4620 will appear after you press F2 (Search String), F3 (Insert String) or F4 (Replace String).

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CHMER Wire-Cut EDM Operation Manual W5F

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

Press F6 (Cancel M.BLOCK)

The selected blocks still remains.

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CHMER Wire-Cut EDM Operation Manual W5F

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

Press F7 (Delete M.BLOCK)

Note: When there is no any line to be highlighted, Edit-Error-Message will appear when you use this function.

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CHMER Wire-Cut EDM Operation Manual W5F

2-2-2-7 F8 (Move M. BLOCK) Move highlighted lines to a target location. 1. Move cursor to the line for move and press F10 (Set M BLOCK)

2. Move cursor to target location then press F8.

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

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CHMER Wire-Cut EDM Operation Manual W5F

2-2-2-8 F9 (Copy M. BLOCK) Copy highlighted lines to target location. 1. Press F10 to highlight the lines then move cursor to the target location.

Select the blocks ready to make copy later.

2-27

CHMER Wire-Cut EDM Operation Manual W5F

Move the cursor ↑、↓to the block ahead to make copy later.

2. Press F9 (COPY MARK) for duplication.

The duplication is done. (1st time)

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CHMER Wire-Cut EDM Operation Manual W5F

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

2-2-2-9 F10 (Set M. BLOCK): To highlight a certain line or area for program edition.

Select the blocks ready to make copy later.

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CHMER Wire-Cut EDM Operation Manual W5F

2-2-3 EDIT-3 Page

2-2-3-1 F1 (Move Line) This function allows users to move the cursor to a particular line by entering the line number. Hotkeys: Ctrl+Page UpMove cursor to the first line. Ctrl+Page DownMove cursor to the first line. 2-2-3-2 F2 (Search N Code) Allows users to search the position of the N code he wishes to check. Procedure: F2 (Search N Code) input the number of N code  ENTERCursor moves to the line of the N code.

2-30

CHMER Wire-Cut EDM Operation Manual W5F

For example: Search the NC. Program “N 2”

Cursor move to N002

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

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CHMER Wire-Cut EDM Operation Manual W5F

2-2-3-3 F4 (Sim. Skin) This function allows users to execute the simulation of skim cut with a simple one cut program. Example A: 10mm x 10mm square punch with one cut

One Cut Simulate PGM path.

One Cut Punch program.

1. Load or compose a simple 10mm x 10mm N.C. program. 2. Press F4 (Sim. Skin) 3. Enable the「SKIM SPARK SWITCH」→Set NO. of「SKIM SPARK COUNT」→ Set 「OFFSET NO.」,「OFFSET VAL.」→F10(SIM. EXECUTE) It calls the S-code data from database of MDI there.

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CHMER Wire-Cut EDM Operation Manual W5F

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

Offset is activate

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

ZOOM out to enlarge the scale of Viewer.

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CHMER Wire-Cut EDM Operation Manual W5F

2-2-3-4 F5 (SIM Data) This function allows users to configure data for simulation SIM Data Screen 9

10 11

12 13 14

1

19

2

20

3 21

4 5 6

22

7 8

12

15

16

17

18

Description of Function： NC Data Setup 1. PGM Rot. Angle： Rotate based on the center at G92 (display mode is configurable from Flag 14 by maintenance personnel according to customer requirements). The range of program rotation is -360° to +360°. 2. Mirror & Exchange：It allows users to use the mirror function on X and Y axes and exchange axes in a simulation. A. X-axle mirror switch： To reverse the movement of X axle in the program. “0”=Off; “1”=On. B. Y-axle mirror switch： To reverse the movement of Y axle in the program. “0”=Off; “1”=On. C. X and Y axles exchange: To exchange the movement of X and Y axes in the program. “0”=Off; “1”=On. 2-34

CHMER Wire-Cut EDM Operation Manual W5F

NC Program

X-axle Mirror

Y-mirror

X/Y Mirror

Axle Exchange

Axle Exchange/X-axle Mirror

Axle Exchange/Y-axle Mirror

Axle Exchange/X/Y Mirror

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

about to break 4. PGM Scale： To enlarge the dimension of a N.C. program. 5. Over Cut SW：When running the simulation program, the control will alert if there is an over-cut. This item also provides the over-cut management function. 0=Disabled; 1=Check and Stop Simulation, 2=Skip Over Cut Path 6. Invert Check：To check if any geometric intersection exists in Taper Cut path. 0=No Check; 1=Error and Abort, 2=Skip Geometric intersection

7. Comp. Corner Mode：Provides users different corner path modes from 0-6.

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CHMER Wire-Cut EDM Operation Manual W5F

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CHMER Wire-Cut EDM Operation Manual W5F

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

9. Taper Set 1. Cut Modes： 0= Vertical：Aux plane remains vertical to PGM plane, which means there is no UV axis movement. 1=Taper：Aux plane is oblique to PGM plane at a specific degree of angle. In this case, XYUV axis would be moving simultaneously in identical path to cut cone shape. 2=UV：XYUV axis would be moving simultaneously but in different path to cut two shapes on the top and at the bottom of a workpiece. 3=Plane：Same as 2=UV used for cutting two shapes on top and at bottom but in different way of program composition. The program of 2=UV, in which the shape on top is consisted of innumerable points and lines while 3=Plane can use G, M code to compose it to much simplified the program and enhance the accuracy.

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CHMER Wire-Cut EDM Operation Manual W5F

Example of 3=Plane

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

Program of PGM plane

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

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CHMER Wire-Cut EDM Operation Manual W5F

A. . If set cut mode= 0 / 1 / 2 then all simulate graphic would be the same as follows:

ONLY the graph of PGM plane be shown up !

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

The Upper graph shown is PGM plane.

The Bottom graph shown is AUX plane.

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

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CHMER Wire-Cut EDM Operation Manual W5F

10. Taper angle：When performing a taper cutting and if taper angle is not defined in the NC program, the value of the taper angle can be set by this value also. 11. NC PGM Plane (Z)：Generally, Z (PGM Plane) is the distance off work-table in a N.C. program; usually set Z=0 if there is no spacer put beneath a work-piece. 12. Object Thick (I)：I (Aux Plane) is referred to the height position of the work-piece; its value could be + or – and it is used to exchange the position of PGM and Aux plane. For example, in above Cut Mode=3, it is set Z=0 and I=30, so UV path appears on top. If we set Z=30, I=-30, then the path will be turned up-side down.

2-AUX. Plane

1- PGM Plane

13. Upper Guide：The height of upper nozzle, which is referred as Z3 in previous W5E system. Z3=Current Z axis height +DB. 14. Lower Guide：The height of lower nozzle to work table is identical to DA.

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CHMER Wire-Cut EDM Operation Manual W5F

Note 1: How to make Taper Cutting? Answer: There are two variables, Z and I, are related to the setup of Taper Cutting; the figure below shows how they are correlated to：

I

Z

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

Z

Z

–I

Example G92X0Y0 G91Z30.I-30.

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

G01G42Y5.H1A

3. G02X5.Y5.J-5. X-10.Y0.I-5.

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

X5.Y5.I5. M02

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CHMER Wire-Cut EDM Operation Manual W5F

15. Comp. Shift Value：Additional offset added up to N.C. program. Operator could get quick compensation for rough or skim cut without modifying H or D in program. 16. Taper Shift Value：Additional taper angle added up to N.C. program. Operator could get quick compensation for rough or skim cut without modifying A in program. 17. D. Comp: D01~D14 are for compensation, same as H. 18. Skip Set /1~/14: Select which block in a N.C. program to skip. 19. N.C. Data Register Copy N.C. Data, Taper Data, Corner Data, and AWT Data to N.C. program. Move cursor to the item and press ENTER. EX: G11Q__X__Y__Z__R＿S__I__J__C__F__W__A__ ; NC. DATA[DATE] Explain: Q: PGM rotate X、Y、Z: Change program path. (i.e. Mirror, Axes change ) R: Set stop distance of M00 ahead M02 S: Program Scale I: Overcut check J: Invert cut check C:Corner type F: Extra offset for corner W:Extra offset in NC program A: Extra offset for taper in NC program Example : 1.Load N.C. program. 2. Press F5(SIM.DATA) , and move cursor ↑←↓→ to N.C. DATA and then to do setting one by one. 3. Move cursor to NC. DATA, then press ENTER 4.User can find the scripts (N.C. DATA) in NC program when back to preview.

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2. Press “ENTER ”

1.Key-in NC DATA for registratio n.

ENTER

The registration in NC program is success.

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20. TAPER Data (Register) ：To do setting registration in NC program before processing. EX: G12C__A__Z___I___ ; TAPER DATA [DATE] Explain: C：CUT METHOD A：TAPER ANGLE Z：NC. PGM.PLANE I：OBJECT THICKNESS Example: 1.Load N.C. program. 2. Press F5(SIM.DATA) , and move cursor ↑←↓→ to TAPER SET and then do setting one by one. 3. Move cursor to TAPER DATA, then press ENTER 4.User can find the scripts (TAPER DATA) in NC program when back to preview.

2. Press “ENTER” 1.Key-in TAPER SET for registratio n.

ENTER

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The registration in NC program is success. 21. CORNER Data (Register) ：To do setting registration in NC program before processing. EX1: (INNER CORNER) G18T＿F＿V＿I＿J＿P＿U＿D＿B＿S＿ G13W＿C＿X＿Y＿K＿L＿R＿ ； CORNER [DATE:TIME] 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 EX2: (EXTERIOR CORNER) G19T＿F＿V＿I＿J＿P＿U＿D＿B＿S＿ G17W＿C＿X＿Y＿K＿L＿R＿ ； CORNER [DATE:TIME] 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

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CHMER Wire-Cut EDM Operation Manual W5F

2. Press “ENTER ”

ENTER

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CHMER Wire-Cut EDM Operation Manual W5F

Exterior Corner Inner Corner

The registration in NC program is success. 22. AWT Data (Register) ：To do setting registration in NC program before processing. EX: G14X__C__D__P__B__T__S__Z__Y__E__ ;AWT. DATA[DATE:TIME] Explain: 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.

Example : 1.Load N.C. program. 2. To go 「MEM」mode and Press F3(MEM DATA3) , and switch back to 「EDIT」mode and move cursor ↑←↓→ to TAPER SET and then to do setting one by one. 3. Move cursor to AWT DATA, then press ENTER 4. User can find the scripts (AWT DATA) in NC program when back to preview.

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CHMER Wire-Cut EDM Operation Manual W5F

1.Key-in AWT DATA for registration.

2. Press “ENTER ”

ENTER

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CHMER Wire-Cut EDM Operation Manual W5F

The registration in NC program is success. 2-2-3-5 F6 (SIM. H. VAR) This function allows users to set the H parameter (000-999, totally 1000 sets) in the simulation. The first page will display the H parameter from H00-H49. Press Pg Up Pg Dn to change page. Note. H000 is invalid; please use H001-H999. Sim. Data Screen

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Note: 1. Press arrow keys to move cursor to the desired column; or press PgUp and Pg Dn keys to turn page (50 sets a page); or key in H*** to move cursor to the *** entry of data. 2. If the number is entered without a decimal point, a “0” will appear; if there Is, the figure will be displayed as “0.000”. 2-2-3-6 F7 (Sim. D. Oft) This function allows users to set the D parameter offset (000-999, totally 1000 sets) in the simulation. Change page with the same method as in F6 (SIM. H. VAR). Note: D000 is invalid; please use H001-H999. Sim. D. Oft Screen

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

and Page Down keys to turn page (50 sets a page); or Key in (D***) to move cursor to the *** entry of data. 2. If the number is entered without a decimal point, a “0” will appear; if there is, the figure will be displayed as “0.000”.

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

7

8

9 1 2 3 4 5 6

Data Setup Description: 1. Wire diameter: Value of the diameter of brass wire. 2. Material: The material of work piece (0=user defined; 1=SDK-11; 2=copper; 3=tungsten steel; 4=aluminum; 5=graphite; 6= SKD-61; 7=titanium; 8= P20) 3. Work piece thickness 4. No. of cut : The number of cuts in the processing. 5. Registration switch: Registration location is in Help 2\F4: Other Parameter Setup 6. Cutting data and offset value 7. Spark Base: It means S-code database. To choose the type. a. Default: It has built-in original S-code database can’t be modified. b. User: User can define his own database at will. 8. Reg. Dat. Bas. : Press “Enter” then it saves the S-code to database Immediately. 9. Comp. Shift. Value: After processing, if the cutting result is dissatisfied then user can directly input the offset value to fix.

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

Press NC program

button to switch screen to view cutting data in the

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2-2-3-8 F9 (Figure Color) This function allows users to set the path display mode and colors in the simulation. Figure Color Screen

3 1

4 2

Data Setup Description 1. Data displayed on the screen  Observation view position: Set the height of observation view.  Viewing angle: (0: XY plane display; 1: Isogonics display; 2: 3D display)  Vertical angle: View from the rotation angle of vertical axle in 3D display.  Horizontal angle: View from rotation angle of the horizontal axle in 3D display.  Show/hide Flag: Show and hide flag at the bottom of path. 2. Show/hide individual cuts. 3. Show/hide operation view. 4. Path color setup of cuts and operation views.

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

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

Press arrow keys to select the desired color from the color panel to change color. Note: Call the program of corresponding functions before running their sub-functions. 2-54

CHMER Wire-Cut EDM Operation Manual W5F

2-2-3-9 F10 (Sim. Execute) This function allows users to simulate the NC program. Sim. Execute Screen 1 2 3 4 5 6 7 8 9 10

Data Setup Description 1. 12 [01]: Master program of simulation; [01] represents the number of steps in the simulation. 2. 12 B00001: Name, lines and location of simulation program. 3. Program coordinates and work piece thickness in simulation. 4. Program compensation value in simulation. 5. Program taper angle value in simulation. 6. Work coordinate area (including right upper corner and left lower corner). 7. Work piece dimensions. 8. Total length of program path. 9. Scale 10.Color of program and auxiliary view.

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Press F10 (Path Zoom)

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

Note: To enlarge the selected section, users can zoom in/out the section repeatedly and press HOME to return to the original view. 2-56

CHMER Wire-Cut EDM Operation Manual W5F

2-3 AUTO (Program Mode) Operation Guide The function is activated after the graph simulation in EDIT mode is done. Users have confirmed the entire program paths are correctly before going to official processing. There are 2 submenus in this function menu; users can select 2 submenus with Arrow Button. Submenu MEM-1 Screen

Submenu MEM-2 Screen

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Program Mode Operation Guide MEM-1

F1 MEM. PATH

(Shows NC program path, master screen 1)

F2 MEM. DATA1

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

F3 MEM. DATA3

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

F4 MEN. DATA4

F5 CORNER DATA

(Configures status data 4 before running NC program

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

F6 MEM. H. VAR.

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

F7 MEM. D. OFT.

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

F8 MEM. HOLE

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

F9 FIGUR COLOR

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

F10 PATH ZOOM

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

MEM-1

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CHMER Wire-Cut EDM Operation Manual W5F

MEM2

三 -

F1 Not Used.

(Reserved, inactive)

F2 MEM. COORD.

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

F3 MEM. RECORD.

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

F4 MEM. SKIN

(Sets mold trimming process data in processing.)

F5 NOT USED

(Reserved, inactive)

F6 NOT USED

(Reserved, inactive)

F7 CUT NO. INFO

(Shows the information of cutting number.)

F8 MEM. NC. PGM

(Records the last 100 program processing records)

F9 SCOPE

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

F10 PATH ZOOM

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

MEM-2

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Program Processing Standard Process Start

Open N.C. file and perform Simulation.

Press AUTO modify setup when light on

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

Press AUTO

(Ready for processing)

Press

Automatically activates water, wire and power buttons

Runs the program

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2-3-1MEM-1 2-3-1-1 F1 (Mem. Path) This item shows the current status of the processing track to facilitate operators to observe the current status and program path of processing. Screen of MEM Path







 

-1

-2





Content description  Coordinate area: Operators can choose which coordinate system for display. Example: It used to set upper column be “Mach. Coord.”；and lower column be “Local Coord.” that for the convenient to observe. Procedures: Move the cursor (with arrow keys←↑→↓) to coordinate area and input any coordinate code 0~4, or G54~G99.  CUT Time: Work hours that has elapsed. EST Time: Estimated total work hour required.  Main program name: When the color in this area gray (LED “RESET” lit), the main program is not available to load another new program to memory buffer.  Program segment information column (If you have configured the offset correction and cone angle offset in Program Data Setup 1, the data in this column will turn red characters.) 2-61

CHMER Wire-Cut EDM Operation Manual W5F

Besides, controller provides new functions to review the important block information during programming. There are total 6 pages could be switched through TAB key. We list all of them as following: PAGE 1/6

PAGE 2/6

PAGE 3/6

PAGE 4/6

PAGE 5/6

PAGE 6/6

B

C

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

a. b. c. d. e. f.

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

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

a. Line 1: Before entering to corner shows 1/1, Entering corner shows 0/0. b. Line 2: The current executed block, what’s the angle entering/exiting the corner. c. Line 3: Motion Status. Normal∥ZERO∥LOW∥UP∥DOWN d. Line 4: The S-code that executing at this block now. PAGE 3/6 Corner data, Status and information: A. Corner State: Normal Move∥Outer-Down ∥Outer-Low-Enter∥

Outer-Low-Exiting∥Outer-Up∥Inner-Down∥Inner-Low-Enter∥ Inner-Low-Existing∥Inner-Up 2-62

CHMER Wire-Cut EDM Operation Manual W5F

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

) shows the corner

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

A. AWT CMD.: Through-ing∥ AN.CUT (J) ∥AN.CUT (A) ∥AWT.SPARK ∥IDLE ∥CLR.GUILD∥WIRE AT A0 ∥WIRE AT A1 ∥WIRE AT A2 ∥WIRE AT A3 ∥WIRE AT A4∥CLAMP WIRE ∥TENSIONING ∥ HEAT WIRE ∥COOL WIRE ∥CUT WIRE ∥CUT WIRE ∥ RECE.WIRE ∥UNCLAMP WIRE∥RECE. WIRE 1 B. AWT STEP: FINISH ∥SETTING ∥COUNT∥DOUBLE∥SHORT∥ CHAR C. AWT TIMER: AWT executing time. D. THRU.COUNT: The counter of wire threading through times. E. SUCCESS: Based on #D, the static about success rate of threading. PAGE 6/6 AWT command Status and diagnostic (for maintenance personnel)：

-1 The color display of cut path at Program plane & Auxiliary plane. -2 The color of each symbol meaning of G codes and M codes in the NC program.  Discharge efficiency, gap voltage, cutting speed and cutting data display.  NC program path diagram. NC program path length display: Upper SectionTotal Path Length; Lower SectionRemaining Path Length

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2-3-1-2 F2 (MEM. Data 1) Mem. Data 1 Screen (page 1/6)

Note: 1. The RESET must be lit on before the preset. 2. Among MEM.DATA1 & MEM.DATA3 & MEM.DATA4, user can switch up by PgUp & PgDn keys for total 6 pages for NC setting before processing. 【＊PAGE NO. 1/6】 Function Description：the operation is same as FILE=>F5

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CHMER Wire-Cut EDM Operation Manual W5F

【＊PAGE NO. 2/6】 Function Description: ①MEM.FN& NCODE

1. MAIN PGM.NAME: Users can call the NC program with this item (REST indicator must be on). 2. START N CODE: To start running an NC program from specific block (Flag11=ON) and controller will directly jump to the specified block to run. 3. RE-CUT SW.: The program can automatically search the unfinished mold hole in the previous processing. When the automatic RE-CUT SW. is set to ON, the controller would automatically search the unfinished mold hole, and then move to the M20 point of the hole, trace the last discharging position and start cutting. Note: This function is only available in machine which have equipped ”AWT” device, the mainly apply in 「multi-cavities」job. ②SKIP SET

Skip Set: Select M00” block in a N.C. program to skip. And please note machine function key “BLOCK SKIP” must be enabled. And controller will recognize the order /1M00、/2M00、/3M00…etc automatically to enable /disable to execute “M00.” 【＊PAGE NO. 3/6】 Function Description： ①AWT DATA

1. ACTION: Set AWT on or off in N.C. program execution. 2. CUTTER M CODE: AWT work mode. 0=Disable cut wire M code. The program will skip this step 2-65

CHMER Wire-Cut EDM Operation Manual W5F

when it runs to M-code cut wire. 1=M21: The program performs threading at point M20 and cuts wire at point M21 to reduce wire (coarse cut). The machine continues to run without action (flag parameter 10=Off: program runs without action) or directly moves (flag parameter 10=On: program directly runs to the next mode) to the next point M20 to perform threading. 2=M22: (flag parameter 10=Off: program runs without action) Program runs to point M20 to perform threading; then it runs without action to point M21 to start processing and reduces wire at point M22 (for handling waste materials). (Flag parameter 10=On: program directly runs to the next mode) Controller directly searches point M21 to perform threading and cuts wire until processing to point M22. 3=M23: The program performs threading at point M20 and reduces wire after processing to M23 (for mold trimming). 3. W. BRK. CTRL. FLOW: AWT process after wire-break occurs. 0=STOP (controller interrupts processing) 1=NEXT (controller automatically moves to next threading position) 2=M20 (controller automatically returns to this M20 point and performs threading, runs without action or performs processing to the breaking point). 3=BP (AWT performs threading at the wire break point) 4.THRU. CTRL. FLOW: AWT process when threading wire unsuccessfully. 0=STOP (controller interrupts processing) 1=NEXT (controller automatically moves to next threading position) 5.SHORT CTRL. FLOW: AWT process when short occurs (0=STOP; 1=NEXT) 6.WATER IN AT THRU: Whether controller opens water while threading. 7.THRU. WIRE WATER OFF: If threading unsuccessfully, whether leak out water while threading again. 8.SKIP/REPEAT THRU. CNT.: The maximum skip time when threading unsuccessfully; controller will stop machining when exceed the setting times./AWT threading tolerance. 9.Z MOVE SW.: Z axis retracts distance before going to M20 for threading. 2-66

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10.TR_BP. SPARK SW.: Whether perform eroding or not while tracing back to break point. 11.TR-BP. SC.: S-Code select if use while tracing back to break point. (It connected with TR_BP. SPARK SW.) ②SWITCH SET

1. S Code SW.: Sets the S-code action -Enable [1] and Disable [0] in NC processing. 2. Sleep SW.: When it is ON, the controller will shut down peripheral power supply from program processing is interrupted (M00,M01,M02...etc), or AWT failure or completion in one minute. 3. BP. Check. SW.: Sets the interruption point check of controller on/off after program processing interruption. 4. Dry Run G04 SW.: Sets G04 (Pause command ) on/off when the program runs without action. 5. Trace Spark PT.SW.: If Sets Enable [1] then it automatically to inspire water flushing , wire feeding and EDM power for processing when the program dry run along the path until contacting a work-piece. If sets Disable [0] then machine spark energy will delay be activated until dry run is finished. (On wire break point) 6. G92 Open PT.SW.: 0= Disable. 1= Enable, When the start point (G92) meet short, user can’t inspire the water flushing, wire feeding and EDM power for processing. (Note: Sometimes it caused by a bad starting hole and the hole was tilted) Then this function may give the help to do actions similar to edge-finding inside the hole, to get the central spot that without short. The detail setup please set as under function 「Search Mode」。 7. Search Mode: There are 4 search modes as selection for Open Move (MAN-2F1). 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.

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Mode 0

Mode 1

Mode 2

Mode 3

8. CUT CTRL.SW.: The switch of Enable / Disable the cutting break Distance control. Note: The setup of distance please set the next “OTHER”, that「CUT SET DIST.」 ③ OTHER

1. Z Inc.Dist: When the program processing is interrupted, press Z+ to lift machine head to this distance. 2. G92 Skin Dist: Sets the run-up distance in program processing that the power of spark energy at beginning will be reduced to 50 % then rise to 100% before the indicated distance is reached. ;then while the sparking wire meet the profile (work-piece), it start to change the spark energy “OV “ based on the setting of「Enter Add. OV」. EX: Suppose the run-up (approach) distance of G92 set as 5.000 mm ，then at beginning in 5 mm it started from G92 , the spark energy be deducted to 50 %，then energy be increased to 100% gradually. While the wire is about to touch profile, the spark energy ‘OV’ would be changed. (if OV=5 =95V, Enter Add. OV = -2 ,then it becomes 85V) (Please the figure as follows) 5.0mm 50%

G92

100%

approach

OV- 2

3. Enter Add. OV: Increases or decrease the value of OV between the run-up line or ridding line. (It connected with setup of G92 Skin. Dist.) 4. AWT WIRE. PARAM: According the used wire diameter and select correct AWT parameter. 5. AWT WIRE TYPE: Sets wire type. 2-68

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6. CUT SET DIST.: To set distance where the material is about to break down; controller will automatically to reduce the power of spark energy. Note: 「CUT CTRL.SW.」must be \ enabled. 【＊PAGE NO.4/6】 ①WIRE BREAK AD. SET

1. WIRE BREAK SWITCH: Switch data ON/OFF 2. WIRE BREAK COUNT: Wire breaking tolerance value to start WIRE BREAK AD. SET 3. INC. OFF&AFF: Increase OFF&AFF value 4. INC. SV: Increase SV value 5. WIRE BREAK DIST: Input distance at energy power control LEAD CTRL. SET

1. LEAD CTRL. FUNC. FLAG: Switch ON/OFF 2. EN. EX. CONTOUR: Enter & exit contour path (0=linear, 1=arc) 3. ENTER PT. ADD OV: Increase OV value when enter Enter PT. 4. COMP. I. PATH MODE/ SC. 5. COMP. I. PATH RATIO 【＊PAGE NO.5/6】

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CHMER Wire-Cut EDM Operation Manual W5F

① CORNER DATA : We discuss「Inner Corner」,「Exterior Corner」separately.

1. Ctrl-SW: Open / Close corner control (0=Off, 1=On.) 2. Corner Type: Corner control method 0~5, total 6 types. (Now mode 1、3 、 4、5 are reserved). The rest mode 0& 1, we would introduce the difference as under: a. Type 0：Power of spark energy control. (increase or decrease) ex: Suppose the S.CODE ：ON =5, OFF=9, AN=3, AFF=9 if set the「PWR.R」 =0.5，then means the power would be reduced 50%, for instead, the S.CODE would has changed to ON =2, OFF=18, AN=1; AFF=18. b. Type 2：Max. Feed-rate override control. (increase or decrease) ex: Suppose the S.CODE ：ON =5, OFF=9, AN=3, AFF=9 ; now current speed is 100mm2/min and if set the「MAX.FEED」 =75，then means the federate speed would be reduced 25%, for instead, the all S.CODE would has changed and driven by controller. (Majority to change OFF、AFF、 SV、FR) Note: For skim cut,「CUT NO. vs. Max. Feed」is also be activated while the type 2 is set. 3. Enter Pwr. R. ： Reduction percentage of original eroding energy when approaching the corner (Enter Dist.) The range set from 0.2~1.0. 「1.0」means no any deduction of the spark energy. 「0.8」means for corner control 20% spark energy would be reduced accordingly. (ON、OFF、AN、AFF) Ex: If ON =6, OFF= 9, AN=4, AFF=9 ; if set the「Enter PWR.R」 =0.8， then means the power would be reduced 20%, for instead, the S.CODE would has changed to ON =4, OFF=11, AN=3; AFF=11. 4. Exit Pwr R.：Similar to point#3 mentioned, the different is to the exiting power energy reduction after the corner is passed. 5. Enter Dist.：Approach distance of Corner Control. Set unit from 0.01~20mm. 6. Exit Dist.：Exit distance of Corner Control Set unit from 0.01~20mm. 7. Radius：Set what Corner radius to activate Corner Control. For example, if Radius=0.5, Corner Control would be activated for all the R≦0.5mm arc path in N.C. program.. 2-70

CHMER Wire-Cut EDM Operation Manual W5F

8. Dwell：Pause time after Enter Dist. It is recommended to use Dwell for clean cut on inner angle. Set unit is from 0 ~30 sec. 9. Max Feed：Limit the maximum cutting speed of Corner Control (mm2 / min) Set unit is from 10~2000mm2. 10. Inc. OV (-4~4)：OV increase in Corner Control. 11. Inc. ON (-4~0)：ON decrease in Corner Control. 12. Inc. OFF (0~40)：OFF increase in Corner Control. 13. Inc. SV (-40~40): SV increase in Corner Control. Note: There SV is no active for exterior corner during 1 or 2 skims cut ; However, SV setting is always be effected to inner corner even during 1 or 2 skims cut. 14. Inc. FR (-40~40): FR decrease in Corner Control. 15. Inc. WT (0~4): WT increase in Corner Control. 16. Inc. WL (-4~0): WL increase in Corner Control. 17. Scode Base(0~999): To use a set S-code as basement for changing. (Reserved) 18. REG. DAT. BAS: A register to save the present corner data to corner database. 19. CALL: Accroding input conditions and recall the corner data from database. a.Wire Dia. Dia 0.1 mm ~0.3mm b.Material: 0 =Default, 1= SKD-11, 2 =COPPER, 3=WC, 4=AL, 5= GRAPHITE, 6=SKD-61, 7=TITANIUM, 8= P20 c. Thickness: Input job thickness. The set unit is from 0.001~500. 20. CUT NO. vs. Max. Feed: The power [Methematics] to change the Max. Feed-rate override control for skims cut. (No. 2~ 6) Ex: If F=2.0mm/min, 1 skim = 1.5 and therefore the corner feed-rate is 3.0mm/min. (1cut speed X 1 skim cut value)

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【＊PAGE NO.6/6】

Function Description： ①SKIM CUT PROCESS DATA : This function allows users to execute the processing of skim cut with a simple one cut program.

SKIM CUT PROCESS DATA Screen





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Function Description:  Skim Spark Switch: Enable / Disable the skim cut Skim Spark Count: Numbers of skim cut Search Result: When press ”ENTER”，it recall the S-code & offset value from “MDI” F3 SEARCH OFFSET to there.  Skim cut Setup: The offset code be marked as Q（ i.e. : 101Q、102Q、103Q、 104Q…etc）、offset value and s-code setting. Note: 1. Offset value and S-Code could be modified and save to database. 2. Users must noted the program start point G92 and end point G40 shall not at same position, otherwise it will be interpreted as error # 30800. 2-3-1-3 F3 (MEM. DATA 3) (Page 3/6) Function Description：Same as N.C. setting Page No. 3/6. 2-3-1-4 F4 (MEM. DATA 4) (Page 4/6) Function Description：Same as N.C. setting Page No. 4/6. 2-3-1-5 F5 Corner Data (Page 5/6) Function Description：Same as N.C. setting Page No.5/6. 2-3-1-6 F6 MEM. H. VAR. Function Description: Set H-variable in NC program (From 000-999, total 1000 sets).

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Note: 1. Use arrow key to move cursor or Pg Up and Pg Dn to flip the page. 2.When the value contains no decimal point, a “0” will display in front of the value; if the value contains a decimal point, value will be displayed as “0.000”. Ex.: 200=0.200; and 0.200=0.200. 2-3-1-7 F7 MEM D. OFT. Function Description：Sets D-code correction in NC program (From 000-999, a total of 1000 sets).

Note: 1.Use arrow key to move cursor or Pg Up and Pg Dn to flip the page. 2.When the value contains no decimal point, a “0” will display in front of the value; if the value contains a decimal point, value will be displayed as “0.000”. Ex.:200=0.200; and 0.200=0.200. 2-3-1-8 F8 MEM. HOLE Function Description：Records the last 2000 sets of processing hole information in the controller to allow users check the threading status of holes, including manual threading status.

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A B

C

A. 1.Two coordinate systems. 2.Cut time: Upper sectionTotal time of discharge processing Lower sectionEstimated remaining time to completion. 3.Name of master program of program processing: Users can call new progressing program by entering the program name here. 4.Program segment information： Line 1: Footnotes of master program in program processing. Line 2: NC program position in program processing. Line 3: Correction direction and value. Line 4: Cutter position. Line 5: Work piece thickness Line 6: Angle of cone angle. 2-75

CHMER Wire-Cut EDM Operation Manual W5F

B. The cut start/end points AWT work time, program position, work results and position of all holes in the program. Operators can use this function with MEM1\F2 for re-processing. (Work status of all mold holes in the program (max. 4000 holes)). C. Discharge efficiency, gap voltage, machine speed and online discharge data Note: 1. If data are displayed in green color, it means threading takes place at point M20 and wire is successfully cut at point M21 in this hole. 2. If data are displayed in red color, it means cut processing failed in this hole. 3. If data are displayed in gray color, it means this hole does not exist in the program. 2-3-1-9 F9 FIGURE COLOR This sub-function allows users to set the color of path display mode and color in program processing

A.

B

A. Figure Graph 1. View Heigh: Sets height of observation side. 2. View Mode: (0: XY 2D view display; 1: isogonics view display; 2: 3D view display) 2-76

CHMER Wire-Cut EDM Operation Manual W5F

3. V. Angle: In 3D display, the view is displayed according to the angle of vertical rotation. 4. H. Angle: In 3D display, the view is displayed according to the angle of horizontal rotation. 5. Mark SW.: Shows/hides the ID under the path map. 6. NC. Show Line SW.: How many blocks to show on the path map. B. Figure Set 1. Show/hide cuts. 2. Show/hide operation view. 3. Set color for cuts and operation paths. 4. Procedures: Press arrow keys↑←↓→ to select color from the color panel.

Press ENTER to pick the color. Note: You must call out the master program before you can use the sub-functions of this program.

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2-3-1-10 F10 PATH ZOOM This function works only in AUTO/F1 (Mem Path) and allows users to zoom in and zoom out the path to view part of or the entire path of the program: Contents: 1. Press HOME key to resume to the original size. 2. Press End key to view path from the machine position. 3. Press Page Up key to enlarge view by two times from the current machine position. 4. Press Page Down key to reduce view by two times from the current machine position. 5. Press Ins key to display path with current machine as the center. 6.Press + and – key to control view frame; press Enter to let controller enlarge part of the path automatically.

2-3-2 AUTO-2 2-3-2-1 F2 (MEM. COORD.) This function allows users to move the system to the origin of the selected coordinate system by configuring the coordinate system. Mem. Coord. Screen

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B

CHMER Wire-Cut EDM Operation Manual W5F

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 users 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.

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2-3-2-2 F3 (MEM. RECORD) Allow user to move worktable to the position of record point. Mem Record Screen

A

B

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 users 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. Input ‘C’ +ENTER to copy Mach. Coord. or ‘R’ +ENTER to reset. 3. System status must be idle before Record. Move. 4. Mem Record sequence is XYUV axis first, then Z axis.

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2-3-2-3 F4 MEM. SKIM This function allows users to simulate multi-cut mold trimming processing with simple one-cut N.C. program. Function Description：Same as N.C. setting Page No. 6/6. 2-3-2-4 F8 MEM. NC. PGM This sub-function provides the last 100 program processing records to facilitate enquiries. Mem. NC.PGM Screen

A

B

C

Function Description： A. 1.Two coordinate systems. 2. Cut time: Upper sectionTotal time of discharge processing Lower sectionEstimated remaining time to completion. 3. Name of master program of program processing: Users can call new progressing program by entering the program name here. 2-81

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4.Program segment information： Line 1: Footnotes of master program in program processing. Line 2: NC program position in program processing. Line 3: Direction and value corrections. Line 4: Cutter position. Line 5: Work piece thickness Line 6: Angle of cone angle. B. 1. Sequential number/total processing time. 2. Name of master program 3. Program position when interrupted; e.g. NC.POS: O040618/16, it means Line 16 of NC program O040618 is interrupted. 4. Program length/cut length at termination. 5. Program start time. 6. Program interruption completed time. 7. Mechanical position of program start. 8. Mechanical position of program interruption. C. 1. Discharge efficiency, gap voltage, machine move speed and online discharge data. Note: 1. When the program is interrupted, the program will be displayed in red. If the program is completed, the program will be displayed in blue 2. When users switch to this screen from the controller while the function is running, they can select the processing programs with the arrow keys and then press the start button on the panel. The machine will automatically move to the interrupted position of the program waiting for the users to press the start button to continue processing. 3. The machine will automatically move to the operation flowchart of the interrupted position.

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START

Select the desired processing programs with the arrow keys.

Press Start button on the panel

NO

YES Machine moves to the interruption position

Press Start button on the panel

YES New programs continue with the processing

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NO

CHMER Wire-Cut EDM Operation Manual W5F

2-3-2-5 F9 (SCOPE) Display the monitoring information of the status of eroding power and Machine feeding speed. SCOPE Screen

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2-4-1-1 F1 (Search Home) This function allows users to set a base point for axe movements to facilitate controller calculation. It is recommended that users should run this function once every time turning on the controller or when an asterisk “*” appears in front of the axis coordinate display in order to prevent driver error. Note: Search Home is disabled when the Axis Rotation (AR) or Protect Flag functions are activated. Please disable these functions before running Search Home.

An asterisk “*” appears in front of the axis coordinate display before running Search home.

The asterisk “*” in front of the axis coordinate display disappears after running Search home.

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Search Home procedures: 1. Switch to MAN mode and press page.

&

buttons to switch to above

2. Press (START). 3. Press Z＋, X─, Y─, U＋, V＋ axes. The Z-axis would rise and then begin to move XY axes to left corner of worktable, UV axes move toward the upper right. 4. The asterisk “*” in front of the axis coordinate would disappear.

1

5

2 3 4

1. Z-Lock SW.：Z axis travel protection when set ON. 2. Protect Flag：When it is enabled (On), the machine will move only within the limited area., and in the meantime, Search home is disabled. 3. L. Down PT.：Set the limited XY area for Protect Flag. The XYsetup is based on

mechanical coordinate system. 4. R. Top PT.： Sets axis rotation angle. (See Chapter 2.4). 5. Location displays of record points.

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Search Home Flowchart: Press MAN

Press F1 Search Home

Screen shows Search Home message.

Press

Terminated YES

Press axis arrow keys: X+ Y+ U+ V+ Z+ must be on and turn off AR and Protect Flag.

Machine begins to move?

YES

NO

Alarm Message

YES

Search Home finished when all “*” disappear.

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NO

CHMER Wire-Cut EDM Operation Manual W5F

2-4-1-2 F2 (MDI. Move) This function provides a quick way for table movement of single or multiple axis. To perform MDI Move, system must be in idle status. If operators want to perform MDI Cut, press









.

MDI Move Screen

1

2

3 4 5

6

Function description: 1.Reference Coordinate: Before executing MDI Move, to set this reference coordinate for further setup in MOVE MODE. nd 2. 2 Reference Coordinate: To set any coordinate as the comparison during MDI Move is on progress. 3.AR-SET: Angle rotary, same as we have mentioned in CH2-4-1-1. . 4.MDI Value: Input the value of moving distance. 5.Move Speed: The jogging speed for MDI move, maximum do not exceed 80/min. 6.Move Mode: Choose which coordinate system to use. 0=XYZUV=I: All axes move by incremental 1=XYZUV=A: All axes move by Absolute coordinate. 2=XYUV=I ./ Z=A : XYUV axes move by incremental and Z axis move by Absolute 2-91

CHMER Wire-Cut EDM Operation Manual W5F

3=XYUV=A ./ Z=I : XYUV axes move by Absolute and Z axis move by incremental Note: Make sure system is in idle status to avoid Alarm 10500. MDI. Move Flowchart Press MAN button

Press F2 (MDI. Move)

Input Value

NO

NO

Alarm or man-made interruption?

NO

YES

Function completed?

YES Function Completed

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CHMER Wire-Cut EDM Operation Manual W5F

2-4-1-3 F3 (VERT. Move) VERT. Move is to align XY and UV axis with Vertical Alignment Jig. For a better calibrate result. Further can to do DA、DB measurement through the jig. Note: It is recommended to remove the water hose on the upper head and blow dry the up/low nozzles. F3 (VERT.MOVE) Screen

1

2

11 12

3 4

13 14

5

15

6

7

8

9

10

Function description: 1.Reference Coordinate: Before executing MDI Move, to set this reference coordinate for further setup in MOVE MODE. nd 2.2 Reference Coordinate: To set any coordinate as the comparison during MDI Move is on progress. st 3.Vert Dir. (1 step): Choose direction to calibrate first, 0[X＋]，1[Y＋]，2[X－]，3[Y－]. nd 4.Vert Dir. (2 step): Choose direction to calibrate after 1st step, 0[X＋]，1[Y＋]，2[X－]，3[Y－] 5.Wire Feed: WF used for calibration. 6.Wire Tension: WT used for calibration. 2-93

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7.Tolerance Dist: Maximum tolerance of calibrate. (Usually to set 5u as the standard, for a precise job then consider to set 3u. However, please note if the tolerance is set too small it will take too long time for it.) 8.Vert Pt: Records current vertical point. 9.Vert Pt. Err.: Records the tolerance compared to previous vertical point. 10.Last Ver, Pt.: Records previous vertical point. 11.DA, DB Op. Sw.: To perform DA and DB calibrate. 12.DA, DB Dir.: DA, DB calibration direction 0[X＋], 1[Y＋], 2[X－], 3[Y －] 13.Touch Mode: 0 [Short=L-Block tool>]; 1 [IO=Vertical Alignment Jig]. 14.Up Point: Upper contact point. 15.Dn Point: Lower contact point. Vertical alignment procedures: Use Alignment Jig to find out vertical points after parts replacement such as upper/lower Head, Diamond Guide or Ceramic Plates. Before executing Vertical Alignment, the Alignment Jig has to be well located on work-table and connect its signal cable to VER I/O port. Then follow steps listed below：

1.Press 2. Press

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

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DA,DB Switch

Vertical position (U,V)

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

to begin.

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

to reset 5 axes local coordinate value.

Note: Before executing Vertical Alignment： (1) Turn off DA/DB Switch (DA DB OP. SW=OFF). Important! (2) Well dry upper head. Any water drip left will worsen alignment accuracy. (3) To keep aligning the same axis, select the same direction in 2ND STEP.

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Except for using Alignment Jig, L-Block can be used for manually aligning the axis with spark appears on wire: 1. Locate L-Block on worktable and well align it with indicator. 2. Dismantle the water pipe. 3. Do EDGE in – X direction: Press

4. Press

（EDGE MOVE）

2(-X)

to reset 5 axes local coordinate value.

5. Set PW=A01. The other S-code items are the same (ON:1,OFF:15,AN:1,AFF:15, SV:50, FR:10,WF:5,WT:10,WL:0,F:0). (Set WT=10 forΦ0.2wire; set WT=12 for Φ0.25 wire).

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

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9. Input the coordinate value and press

to save.

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

.

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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2-4-1-4 F4 (DA, DB Move) DA, DB , Move is to measure the distance of lower guide to worktable (DA) and upper guide to the nozzle (DB). Note: It is recommended to remove the water hose on the upper head and blow dry the up/low nozzles. DA, DB Move Screen

10

1 2

11

3 4

12

5

6 7

8

9

Function description: 1.DA, DB Dir.：Select direction for calibration. 0[X＋]，1[Y＋]，2[X－]，3[Y－] 2.Wire Feed: The speed of wire feeding during edge search. 3.Wire Tension: The speed of wire tension during edge search. 4.Touch Mode: 0 [SHORT]；1 [IO ] 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

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 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

2

3

4

5

6

7

8

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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 panel or MDI MOVE (refer to Chapter 4.6). (4) Press

（DA, DB MOVE）

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

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

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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 users 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

1

9

2 10 3 4

11

5

12

6 7

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 CP.：The middle point of a linear distance 10. Cylinder CP.：To find the center point of a hole or cylinder. 2-104

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

Middle point



Procedure of Board CP. (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 CP., input ‘GO’ and press , then worktable will move to the middle point between A and B. 4. Done.. Cylind CP. is to find the center location of a cylinder object. B

A

Center point

C

Procedure of Cylind CP. 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 CP., 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

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Board CP. Flowchart (By X-axis direction) Board CP.(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 CP., then key-in‵GO′， Press

START

ENTER

and execute the action

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.

CHMER Wire-Cut EDM Operation Manual W5F

Cylinder CP. Flowchart Cylinder CP.

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 )

While the action be completed and it record at ( REC.2) column

Cut off the wire

MAN

Press F5: EDGE MOVE

Press

START

and execute the action

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

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

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

Machine move to centre point

Finished

Press

START

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

and execute the action

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 users to perform simple cutting action by entering one line or a maximum of 5 lines in the NC program. F6 MDI Cut Screen

2

1

5

3

4

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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CHMER Wire-Cut EDM Operation Manual W5F

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 users to move the system to the origin of the selected coordinate system by configuring the coordinate system. Coord. Move Screen

1

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 users 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

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

1

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. f for users 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 users 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

10

1 2 3 4

5

6

7

8

9

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

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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 contact 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

10

1 2 3

7

8

4

9

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

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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 users 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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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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2-4-2-2 F2 (3PT. Center) This function allows users 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

1

9

2 3 4

10

11 5

6

7

8

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. CP.：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 users 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

1

10

2 11 3 4

12

5

67 8

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 CP”) 6.Board Move (W): Estimate the width of the board. (Work-piece) 7. Board Move (D): Estimate the moving distance out of 8.Board ECP: 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 CP.：Record the position of the current center point. Move cursor to the center point, enter ‘GO’ and press ENTER, the brass wire 2-122

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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 CP. 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 users 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

1

9

2 3

10

4 5

11

6

7

8

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

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 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 users 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; users can press buttons to switch to different sub-function menus. MAN (Manual Mode) Submenu-1 Screen 8

9

10

11

12

13

14

1 15 2

16 17 18

3 19

4 5

20

6 7

1. Name of current NC program 2. Coordinate display: This controller provides 65 sets of coordinate systems for users 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 users to configure and check the 2-85

CHMER Wire-Cut EDM Operation Manual W5F

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, users 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 users 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, users can input the setup item in this area. 6. Submenu button : Switch to the other submenu 7. Function key: Allow users 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

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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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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 users to set during machining. F1: S. Data List Screen

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

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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 user’s common jobs. There are the blank 2,000 codes could be filled up by users. CHMER has pre-loaded 335 codes which are called from built-in data base; and users may add and modify the database via「F3 Search Offset」. (Note: Password is requested.) F2: S. DEF. S. BASE

Note: 1. Users 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. Users 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 register advanced setting.

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2-5-3 F3 (Search Offset) Search Offset acts as a guideline to help users 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 Register function. Besides, there users 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=user-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. Register: 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. Users can use E*** to call from DEF or S*** to save. 3. 「Bar-article」database setup: User firstly choose to save data in “Default” or “User” 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 ” Register”, user 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 user’s common jobs. There are total blank 2,000 codes could be filled up by users. CHMER has pre-loaded 335 codes which are called from built-in data base; and users may add and modify the database via「F3 Search Offset.」 F4: USE DEF.S.BASE Screen

Note: 1. Users 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. Users 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 register 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 user’s common jobs. There are the blank 960 codes could be filled up by users. (No. 0~959) Users may add and modify the database via「F7 Modify Corner」. F6: CORNER BASE Screen

Note: 1. Users 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. Users 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 register 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 users 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=user-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.：User 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

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3.SET TO WORK AREA: User 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 users 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 users 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 users . Press ‘R’ + ENTER to reset after replacement. 3. Life Count：Recommendation of replacement of consumable parts life span. (Note: Need password 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 users; 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 panel. 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 panel. 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

CHMER Wire-Cut EDM Operation Manual W5F

e. Touch Screen Enable: (OPTION) Enable / Disable the touch panel. 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: User 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: User 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 users. 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

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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 support file format. If user input「*」then all file format can be recognized in controller；If user 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 users can do FTP Ethernet transmission；to download and upload the needed files between controller and PC. (Note: The support file format only *.nc or *.txt ) Net Set Screen

2.

1.

3.

Function description: 1. Machine Data a. Machine Name: Input the “user 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, user may set any address from 0 to 2-144

CHMER Wire-Cut EDM Operation Manual W5F

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 PASSWORD: If machine controller to be Client end, and PC to be server end, then user needs to require the password from server to entry. b. FTP SERVER IP: As above mentioned, the client end user must confirm the correct server IP address then can search on Ethernet. c. CUSTOMER NAME & PASSWORD: If machine controller to be Server end, and PC to be client end, then controller becomes administrator and must provide the user name & password for users to entry. Cautions: Before connecting the network, users 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 (User’s PC) and client (CHMER controller); CHMER provide the Ethernet connector be ready on our controller (GIPC .NET board) and attach full authorized software supported. 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; user 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 user 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

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NAME」 &「PASSWORD」. 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 (USERS NAME)、(PASSWORD), please input those information as required, then it will enter to a window folder, users can start to use 「copy」、「paste」 to download and upload files. Note：User 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 CPU_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

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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 FEEDBACK 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 (OVF3 Search Offset database G34 Cancel wire offset G40 3-1

CHMER Wire-Cut EDM Operation Manual W5F

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

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CHMER Wire-Cut EDM Operation Manual W5F

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 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

CHMER Wire-Cut EDM Operation Manual W5F

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.

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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.

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(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

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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=USER 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 joint 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.

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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.

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 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

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 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)

Example 2 : PGM plane (Z)

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

Aux plane (I)

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Example 3 : PGM plane (Z)

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

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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

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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

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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

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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)

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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

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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

CHMER Wire-Cut EDM Operation Manual W5F

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

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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)

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CHMER Wire-Cut EDM Operation Manual W5F

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

CHMER Wire-Cut EDM Operation Manual W5F

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)

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CHMER Wire-Cut EDM Operation Manual W5F

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

CHMER Wire-Cut EDM Operation Manual W5F

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