SPM e-Zcut
WIRE CUT EDM

유지 보수 매뉴얼

Maintenance Manual Book

REV. 4.0 (ez-CON VER 3.0)
SEOUL PRECISION MACHINE CO., Ltd

MAINTENANCE MANUAL
SEOUL PRECISION MACHINE CO., Ltd


Ⅰ. Machine’s composition, installation place and preparation items …………………..5
1. Composition of machine ……………………………………………………………………………….………..5
2. Installation place and preparation items …………………………………………………………………..6
2-1 Installation Place ………………………………………………………………………………………………………………......6
2-2 Grounding ……………………….…………………………………………………………………………………………………….6
2-3 Shieldroom …………………………………………………………………………………………………………………………....7
2-4 Precaution on Selecting an electric Leakage Breaker ............................................................................7
2-5 Waste Disposal ……………………………………….....................................................................................................7
2-6 About High Frequency Distortion ……………………………………………………………………………................7

Ⅱ. Inspection items for maintenance and repair …………………………………………..…..8
1. Daily Inspection……………………………………………………………….……………..…………………..…..8
1-1 Check The Wire Path

……………………………………………………………………………………………….………….9

1-2 The Upper and Lower Insulation Plate(Ceramic)…………………………………………………………………...9

1-3 The Nozzle and The Power Feed Contact ………………….……………………………………..………………..10
1-4 The Fluid

………………………………………………………………………………………………………………….……….12

1-5 Check The Specific Resistance of fluid …………………………..……………………………………………..…….16
1-6 Check The Workpiece ……………………………………………………………………...…………………………….…….17
1-7 Check The Wire Collection Box …………………………………………………………………………………..……….17
1-8 Check The Air Pressure ………………………………………………………………………………………………….…….18
2. Weekly Inspection…………………………………………………………………………………………..…….. 18
2-1 Check The Lower roller ……………………………………………………………………………………………..…………18
2-2 Check and clean The Work Tank …………………………………………………………..…………………….……….19
2-3 Check the Wire Alignment device ………………………………………………………………………………...……..19
2-4 Check The Wire Tension ……………………………………………………………………………………………………….19
3. Monthly Inspection………………………………………………………..……………………………..…………21
3-1 Clean The Flowmeter ……………………………………………………………………………………………….….………..21
3-2 Replace Oil Filter ……………………………………………………………….………………………………………..….……..21
3-3 The Refueling of X,Y,U,V & Z axes ……………………………………………………………………………………….21
3-4 Check The Wire Collection part …………………………………………………………………………………..……….22
4. Yearly Inspection……….……………………………………………………………………………………...…....25
4-1 Measure The Precision of the Machine ……………………………..…………………………………………..…….25
4-2 Measure The Pitch Error……………………………………………………………………………….…………………..……25

Ⅲ. CNC and Relay part ……….………………………………………………………………….…….27
1. The Structure of CNC (Computer Numerical Control) and Electric Device …………..………..27
1-1 The Structure of SYSTEM…………………….…………………………………………………………………..……………..27
2. The CNC Unit ………………………………………………………………………………………………..……….28
1



2-1 Adjust Servo Offset

……………………………………………………………………………………………….…………29

2-2 DSP Program Upgrade & Dip Switch……………………………………………………………………………..…….30
2-3 Analog Gain Setting …………………………………………………………………………………………………….……….31
2-3-1 IP_High Gap Voltage ……………………………………………………………………………………………………..31
2-3-2 Control Method of Specific Resistance ………………………………………………………………………...31
2-4 Check the H/W IO Screen..……………………………………………..…………………………………………………….32
3. Power Supply Unit …………………………………………………………………………………………………33
3-1 eZ-NFB’s Overview and the Connection Diagram ……………………………………………………………….33
3-2 eZ-SERVO AC-1 Unit…………………………………………………………………………………………………..………….35
3-2-1 Overview………………………………………………………………………………………………………………………….35
3-2-2 The Connection Diagram and the Check Point……………………………………………………………..35
3-3 eZ-AC-1 Unit

………………………………………………………………………………………………………………………36

3-3-1 Overview

……………………………………………………………………………………………………………………..36

3-3-2 The Connection Diagram and the Check Point

…………………………………………………………37

3-4 eZ-AUTO-1 Unit ……………………………………………………………………………………………………………………42
3-4-1 Overview

…………………………………………………………………………………………………………..…………42


3-4-2 The Connection Diagram and the Check Point …………………………………………………...………42
3-5 eZ-AMP-1 Unit ………………………………………………………………………………………………………………..……45
3-5-1 Overview

……………………………………………………………………………………………………..………………45

3-5-2 The Connection Diagram and the Check Point

…………………………………………………………45

3-6 eZ-AUX Unit ………………………………………………………………………………………………………………………….48
3-6-1 Overview ………………………………………………………………………………………………………………………..48
3-6-2 The Connection Diagram and the Check Point ……………………………………………………………48
3-7 eZ-SMARTIO Unit ……………………………………………………………….……………………………………….………..49
3-7-1 Overview

………………………………………………………………………………………………………..……..49

3-7-2 The Connection Diagram and the Check Point

…………………………………………………..50

3-8 eZ-MOTIO Unit ………………………………………………………………………………………………………….………….52
3-8-1 Overview…………………………………………………………………………………………………………………..52
3-8-2 The Connection Diagram and the Check Point…………………………………………….………..53
3-9 eZ-PWR ……………………………………………………………………………………………………………………..…..………56
3-9-1 Overview…………………………………………………………………………………………………………………..56
3-9-2 The Connection Diagram and the Check Point……………………………………………….……..56
4. Discharge Switching Part…………………………………………………………………………………………57

4-1 Overview ……………………………………………………………………………………………………………………………….57
4-2 SMARTOUT-AUX Unit (Supporting Output Switching part)………………………………………..……….58
4-2-1 Overview…………………………………………………………………………………………………………………………58
4-2-2 The Connection Diagram and the Check Point…………………………………………….………………58
4-3 SMARTOUT-MAIN Unit (Main Power Output Switching part)………………………………….………….59
4-3-1 Overview………………………………………………………………………………………………………….……………...59
2


4-3-2 The Connection Diagram and the Check Point….………………………………………………………..59
5. Resistance Block.……………………………………………………………………………………………….…..60
6. Auxiliary Power Supply for

Switching.…………………….……………………………………….…..61

Ⅳ. Maintenance and repair of Auto wire feeder(AWF)………………………………….......62
1. The structure of Auto wire feeder …………………………………………………………………………62
2. Operation summary

…………………………………………………………………………………….………62

3. The introduction of AWF window

……………………………………………….…………….…..………63

4. Checking items before operation of Auto wire feeder ……………………………….……………65
5. Other precaution

…………………………………………………………………………………………………65


Ⅴ. Maintenance and Repair of the Fluid Unit ………………………………………………...69
1. Structure

……………………………………………………………………………………………..……………...69

2. Repair and Check of the Fluid Unit
2-1 Check The Control Panel
2-2 Supply the Fluid
2-3 The Fluid Filter

………………………………………………..………………………71

……………………………………………………………………………………………………71

…………………………………………………………………………………………………………………74
……………………………………………………………………………………………………………………74

2-4 The Pumps …………………………………………………………………………………………………………………………….75
2-5 The Specific Resistance Sensor …………………………………………………………………………………………….75
2-6 Ion Resin and Ion Resin Tank
2-7 Check each pumps

…………………………………………………………………….……………………….75

………………………………………………………………………………………….………………….76

2-8. The Fluid Supply Unit

……………………………………………………………………………..…………………………76


3. Repair and check of Fluid temperature control unit(Cooler)

……………………………..……...76

Ⅵ. Alarm schedule & Other ………………………………………………………………………….74
1. Auto door system
2. Ac Servo Motor

………………………………………………………………………………..………………79

………………….………………………………………………………………..………………81

3. LS Inverter …………………………………………………………………………………………………………….86

VII. Troubleshooting and answer ……………………..……………………………………..……....94
1. Power Switch Turned OFF instantly when Pressing Power ON S/W …………….……….………94
2. Power-On not working

………………………………………………………………………….……..……….94

3. READY-On Not working

…………………………………………………………………………………..……94

4. Power Off in Machining

………………………………………………………………………………………..94

5. Sudden Voltage Surge between DC150V and DC215V with a ‘Pop’ Sound in Machining
…………………………………………………………………………………………………………..………..………94

6. Normal Speed in Machining Low thickness Workpiece and Slowdown in Machining High
thickness Workpiece…………….…………………………………………………………………...…..……….95

3


7. When the wire could break in case the machining conditions are changed on machining
…………………………………………………………………………………………………………………………….95
8. Fluid flow rate drops over 1/2 momentarily during the 2nd Cut.………………..…..…………….96
9. Contact occurred when Wire on key is pressed after wire feeding.…………………..………….96
10. Not Changed Ion’s Level on Monitor.………………………………………………………..…….………96
11. Abnormal High, Medium and Low Speed of X, Y, U & V in Manual Mode and Table
Vibration.……………………………………………………………………………………………………...…………..97
12. In case that there is serious tolerance of workpiece straightness after machining………97
13. Not Stable feeding Speed of Wire in Machining..…………………………………….…....………...97
14. X, Y Measurement Deviation after Machining PUNCH shape..…………….…………….………98

VIII. Deal Drawings…………………………………………………………………………...……………99
1. The Deal Drawing of Upper Guide block……………………………………………………..…………...99
2. The Deal Drawing of Lower Guide block..……………………………………………………………….100
3. The Deal Drawing of Wire Collection Unit……………………………………………………….………101
4. The Deal Drawing of Wire Cutting Unit..………………………………………………………..……….102
5. The Flow Map of the Fluid….………………………………………………………………………….……...103

Annex. 1)….……………………………………………………………………………………...………….104

4


Ⅰ. Machine’ composition, installation place and preparation items

1. Composition of machine
Main unit of Flushing or Submerged machine

Fluid unit for Submerged machine, Cooler

Down transformer & AVR

Fluid unit for Flushing machine, Cooler

Cooler

The compositions of wire cut discharge machine are as shown above.
3 phases 220V 15KVA input voltage should be supplied and Down transformer or AVR is
required if machine main unit, fluid unit, cooling unit cannot use input 220 V.
5


2. Installation place and preparation items
2-1 Installation place
Wire cut discharge machine should be set up at the place where is satisfied with conditions as
shown below.
- Temperature changes greatly affect machining accuracy. The optimum temperature is 20℃
and the optimum humidity is 55%. Keep the room at a constant temperature, 20℃, at all
times to ensure high accuracy machining.(365days, 24hours)
- Many operators only pay attention to the temperature of the fluid(20℃). However, even
when the machine is correctly operated, if the machine has been installed in improper
environment, high-precision machining cannot be performed. In particular, keep the
temperature around the machine appropriate. Set the temperature of the fluid according to
the room temperature. It will reduce the deformation of the machine unit and the workpiece
and increase accuracy of the product.

- Please avoid the air emitted from supporting equipment or sunlight from the machine.
- Abrasion powders from grinding affects the machine’s driving parts, such as the slide wire
and ball screw. Therefore, please avoid them and select relatively less dusty place.
- The wire cutting discharger is to process with discharging. Therefore it generates high heat
by itself. Particularly, the cooling unit releases high heat when it cools down the fluid. You
need to be aware of above when you install supporting equipment, such as an air
conditioner.
- Especially in Korea, the temperature change greatly in winter and the parts of the machine
may expand differently, which heavily affects the machining accuracy. It is recommended to
keep a constant room temperature even when the machine is not in operation
Ex) If the temperature of the room sink to 8.5℃ from 25℃ in winter, 100mm metal may be
deformed about 0.016mm. Larger the size of the metal, more increase the deformation of
the metal by changes of the room temperature. As the room temperature affects heavily the
machining accuracy, keep maintain the proper room temperature. mm level’s accuracy will
not be obtained without managing a proper temperature.
- For reference, metal’s temperature change is very slow than air. Therefore, in principle,
generally it needs to be measured in the room in 48 hours for accurate machining.

2-2 Grounding
The machine must be grounded to protect noise from the outside, electromagnetic
interference and electric leakage. The class C grounding(with a grounding resistance of 10Ω of
less) in accordance with electricity facilities standard is recommended for the wire cut
discharge machine
- The class C grounding (separation) is recommended. (Exclusive grounding for each wire cut
discharge machine)
- Use the 14㎟ wire for grounding.
6


PE ○

PE
○

R ○
S ○
T
○

2-3 Shielded room
Shielded room is required if discharge noise may cause interference to TV set and other
communication facilities.

2-4 Precaution when choose earth leakage circuit breaker.
An electric leakage current of Wire Cut Discharge machine has filter inserted into Input power
to prevent malfunction by outside noise of Control unit. About 30~40mA flow through this
filter by being grounded one side. Malfunction could be happened in case of a high sensitivity
earth leakage circuit breaker. Therefore setting middle sensitivity Breaker of it (sensitivity flow
100mA-200mA) is recommended for Wire Cut Discharge machine.

2-5 Waste treatment
Fluid, Fluid filter, ion exchange resin, scrapped wire are industrial wastes. Please treat these
wastes according to your country and region’s laws or regulations.

2-6 About the Distortion of High Frequency
If there is high frequency in the Power unit, it could affect to machine’s operation even though
voltage is not converted. In this case, do not use machine near the devices caused high
frequency or need other counterplans such as Line Filter.

7



Ⅱ. Inspection items for maintenance and repair
Inspection table of machine
Section

Daily inspection

No.

Check Point

1

Wire Path

2

The Upper and Lower Insulation Plate(Ceramic)

3

The Nozzle and The Power Feed Contact

4

The Fluid and Water-Jet stream

5

The Specific Resistant’s Figure of Fluid


6

The Work-piece

7

The Wire Collection Box

8

The Temperature of the Cooler

9

The Air Pressure

10 The Condition of Sub Output Cable

Weekly inspection

Monthly inspection

1

The Lower Wire guide Roller of Low Block

2

The Work Tank


3

Vertical Alignment Device

4

The Wire Tension

1

The Surface of Main Tension Roller

2

The Ion Sensor Bar

3

Filter of Fluid Cooler

4

The Arm bellows cover and Fixing Bracket

5

The Door Gasket of Work Tank

6


The Upper and Lower guide’s horizontality Level

7

Check wire collection part

8

Oil-feeding on Guide Rail of X,Y Tables and Ball Screw

9

Grease-feeding on Guide Rail of U,V Saddle and Ball Screw

10 Grease-feeding on Guide Rail of Z Axis and Ball Screw

Yearly inspection

1

The Precision of the Machine

2

The Pitch Error

8



1. Daily Inspection
1-1 Check the Wire Path
Install new wire bobbin or bobbin which has enough remains wire and feed wire after making
strained it.

Also, change wire tension notch into manual mode within the using limits and

check whether there is a problem or not.
Check that wire, which is in wire collection box, is collected perfectly. Also check whether the
wire is rolled on Wire Cutting machine or not. Connect wire and check whether the wire is cut
easily or not after traveling it. Check that there are twist of wire, vibration and strange sound.

Auto wire feeder

Upper wire guide Block

Wire cutting device

Wire collection device Water collection device

Lower wire guide Block

9


1-2 Check Upper and Lower Insulation Plate (Ceramic)
Upper and Lower Ceramic Plate are intended as insulator and protector by being broken the
Ceramic if they take excessive impact while machine is operating. Check whether the Ceramic
Insulation Plate is broken or not every day because it could be a cause of problem with
machine’s precision.

The capacity of processing could be decreased because processing powder is stockpiled
around Lower wire guide or Lower block or Ceramic Insulation Plate. Clean the Ceramic
Insulation Plate and remove the processing powder with brush and rust remover once 3~4
days.

Upper Ceramic

Lower Ceramic

1-3 Check Nozzle and Power Feed Contact
1) Nozzle
1-1) Upper and lower nozzles are parts that supply efficient fluid to work tank.
1-2) Carefully check the mouth of nozzle whether there are dirt or not. If there are dirt, replace
it to new one because it could be a cause interference of efficient when the water is
injected. (Serious disconnection)

Lower Nozzle

Upper Nozzle

10


2) Power Feed Contact
Abrasion of Power Feed Contact caused poor processing and lower processing speed. Check
the Power Feed Contact if processing is unstable. Move the Power Feed Contact often to
maintain normal processing speed according to processing conditions.
(1) Methods for changing location of Upper Power Feed Contact
1-1) Remove air pressure of Upper Power Feed Contact’s moving cylinder.
- Remove the air pressure by pressing SW 3 “ON” key or operating “Pipe” key of

Remote on AWF window to easy the moving of Power Feed Contact.
1-2) Check the current location of Power Feed Contact with location of a Power Feed
Contact’s transferring screw.
1-3) Fix Power Feed Contact where you want by turning the Power Feed Contact’s
transferring screw.
◎ The screw is “M5” and the pitch of it is “0.8mm”. Use it by turning about 2 rounds.

(2) Methods for disassembly and cleaning of Upper Power Feed Contact
Lock nut

Power Feeder

Power Feed C.
Transferring screw

L Wrench

Fixed Cylinder

2-1) Remove air pressure of Upper Power Feed Contact’s moving cylinder and disassembly the
transferring screw of Power Feed Contact.
2-2) Separate the Power Feed Contact by pushing it from the left with tools such as L wrench.
2-3) Clean the Power Feed Contact with rust remover.
- Remove the wire stains and scraps stuck on Power Feed Contact and wash it.
- After washing with rust remover, fully wash it in water.
- Grind it with “oilstone”, if surface is rough.
(3) Methods for changing location and disassembly of Lower Power Feed Contact
3-1) Disassemble the fixing screw of Power Feed Contact slightly.
3-2) Check the current location of Power Feed Contact with location of a Power Feed Contact’s
adjustment screw.

3-3) Fix the transferring screw of Power Feed Contact at the position where you want by
11


turning it and tighten the Fixing screw.
- The screw is M5 and the pitch of it is 0.8mm. Use it by turning about 2 rounds.
3-4) Separating method
- Disassemble the Fixing screw slightly and push the Power Feed Contact with tools such
as L wrench.
3-5) Clean Lower guide block after separating the Power Feed Contact.
Transferring screw of

Power Feed Con.

Power Feed Con.

Fixing screw of
Power Feed Con.

L Wrench
1-4 Check the Fluid
1) Check the quantity of fluid of Fluid tank
Check whether a quantity of fluid check bar, which is
Insufficuent

attached on quantity of fluid, is located at proper

Proper

position or not.

Also check the flow of Fluid tank. If the Fluid is

Oversupplie
d

1)

insufficient, fill up with it to the proper level.
<Precaution when you fill up with Fluid>
Fill up with fluid after stop machining. If you try to fill up
with

it during the machining, do it

a little bit

insufficiently from the proper level. Because the level will go up, when the machining is stopped.
2) Flowmeter and Solenoid valve could be polluted and broken if clean water and dirty water
are mixed, because there is too much water in a Fluid tank.

2) Check the Fluid supply and condition of operating
2-1) High Fluid
(1) Press the Fluid「HIGH」button or Adjust LQ level to be 8 - 63 grade with switches
「▲」「▼」.
(2) Press「Fluid」switch.
(3) In midair where there is no workpiece, Check whether the Upper and Lower Flowmeters
indicate over10L/min or not when the all of Flowmeter’s valves are opened.
2-2) Low Fluid
(1) Press the Fluid「LOW」button or adjust LQ level to be 2~7 grade with switches「▲」「▼」.
(2) Press「Fluid」switch.

12


(3) In midair where there is no workpiece, Check whether water flows normally or not by
adjustment the valves of Low Flowmeter in condition, which the all of them are opened.
3) Check the conditions that water supply for Lower wire feeding and operation
3-1) Turn on the Wire Feeding S/W and check that water for lower feeding flows with highpressure from Lower block to the back of Wire Collecting part.
3-2) Check that high-pressure water gushed out as far as Venturi Block, which is connected with
a Water recovery unit.
3-3) Insert a wire manually to the bottom of Lower Guide Block and check that the wire is
pulled by high-pressure water.
->Check method: It is normal if the wire is inserted into the Wire cutting unit when it is
released.
4) Check the operating condition of Water Jet
4-1)) Press Water Jet On S/W in the condition that the Lower Feeding S/W is turned on and
check whether water gushed out from the Upper water nozzle or not.
4-2) The strength of water flow is adjusted by control the flowing water Control valve of Water
jet, which is located in Water pipe assembly, to proper strength.
4-3) Check the flow of Water Jet maintains a straight line without spreading out it. If not, test
the Water Jet Nozzle and Packing.

When a column of
It spreads

When the water

out from

pressure is too


the inlet

weak or strong.

The water

water get out from the

flow forms a

middle of Lower

straight line

Nozzle.
of Nozzle.

Normal

Replace
Z-nozzle

Adjust

the

pressure of
Water Jet

Check the

Nozzle and
parallel degree

13


Water Jet Nozzle
O-ring

5) Follow-up methods
5-1) Check whether the main pump located in Fluid unit is operated or not.
5-2) Check whether the Solenoid valves are operated or not if water doesn’t out even
though the pump is operated normally.
5-3) Checking methods for Solenoid valves
A. It means that the Solenoid valves operates normally if you can hear the sound such as
a snap from it when you press ON/OFF switches for wire feeding.
B. If water is not coming out even though the Solenoid valve operates normally, replace a
Diaphragm located in the Solenoid valve. Because it doesn’t work by its a breakage.
(Refer the below drawing)
5-4) Precaution when use the Solenoid valves
A. If a Fluid filter is used in plugged condition, it could be a cause of breakage because
the Fluid included sludge flows into a valve.
B. If there is noise from the valve, clean it according to the above order.
C. If the noise isn’t prevented with cleaning the valve, contact us because it is needed to
replace parts.
D. Clean the each part with a detergent or kerosene, etc. Do not use lubricant goods
because it could be damages to parts made of rubber.

14



Solenoid valve

<

Water pipe Ass’y >

Diaphragm

<Replace Diaphragm of Solenoid valve>

3) Adjustment methods for the flow of Fluid
The flow of Fluid could be adjusted by control LQ level in processing condition.
The level of Fluid pump could be operated from 1 level to 63 level and it could be adjusted
according to workpiece.
(1) In the cases of Flow「HIGH」
15


1-1) Adjust LQ level with「▲」「▼」 switches between 5level ~ 7level.
-

It is usually processed on 60Hz. If you want to process with a thin plate or to do
operation needed high precision, lower the level and process it.

1-2) Press the「Fluid」switch.
1-3) Adjust the amount of squirting water from Upper and Lower nozzle according to a
Flowmeter.
1-4) If all of the valves are opened in the air where there is no workpiece, the Upper and
Lower nozzles are indicated over 10L/min.

1-5) The methods to obtain stable machining speed in usual processing are that open the
valve of Flowmeter and make the Upper/Lower nozzles to close to workpiece. Also adjust
the position of the Upper/Lower nozzles to be 6~8 L/min. (Lower the Z-axis to adjust
Upper nozzle and turn the nozzle cap to adjust Lower nozzle.)
(2)

In the cases of Flow「LOW」

2-1) Adjust LQ level with「▲」「▼」 switches between 1 level ~ 4level.
-It is usually processed on 7Hz. Lower the level if you need to process.
*1level: Fluid does not come out. (It is used for spark discharge.)
2-2) Press the「Fluid」switch.
Adjust the flow in the valve of Fluid「LOW」. (Adjust each Upper and Lower valves.)
It is usually used for over second machining. and adjust the flow of water with each valves.
In machining Die type
.

Adjust the Upper nozzle to be largest quantity of fluid to prevent its scattering due to
crashing into workpiece.

.

It is important to adjust the level of Lower nozzle to prevent splash when the fluid struck
a workpiece. If the fluid of Upper nozzle is insufficient, wire is cut many times while
machine is being discharged even though the fluid surrounds the wire.

1-5 Check the specific resistance of Fluid
1) Specific resistance
The specific resistance of fluid is important when the machine is being discharged. Pay
attention to the value of specific resistance if you need to do precision machining and

maintain fixed Offset. (Wire semi diameter + Discharge Gap)
<Reference>
Wire and workpiece should be discharged. But some energy discharges the discharging
sludge and Ion in Fluid and the discharge gap is getting bigger because if the value of
specific resistance increases, the Ion density in Fluid is getting thicker. It causes unstable
discharge but if the value of specific resistance is about 120 and the material of workpiece is
Steel, machining speed could improve. If it is over second machining, you would hardly get
the required machining size because the discharge gap has pretty big deviation.

16


2) Indicate the error of specific resistance value (This function is not offered now.)
Input the specific resistance values that you want to maintain. It is a function to indicate
error signal if the specific resistance value passes over it. (It operates normally if the value of
specific resistance is lowered by replacement the Ion exchange resin.)

1-6 Check the Workpiece
Check whether it is controlled after wire cutting, there is a problem on table or Sub output
line related with Output, the nozzle and diamond die are normal or not. Especially check
that the Clamp or Lower Arm is not bumped while the Work is moving.
*Caution
Adjust the gap of Upper nozzle and Work to be 0.1~0.3 mm, Lower nozzle and Work to be
0.2~0.3 mm. If the plane figure of Work or its upper and lower surface is bad, consider
about it.

0.2~0.3 mm
Workpiece

0.2~0.3 mm


1-7 Check the Wire Chip Collection Box
Fluid attached on wire or Lower recovered water during the automatic filling up, could
make stagnant water in Wire recovery box even though it recovers machining wire. The
Wire collection box is waterproof but it needs to check regularly and take out the water
from it.
Also check the capacity of wire collection is enough before starting machining.
(If there are many scrapped wires in recovery box, according to wire full sensor’s
recognizes and then machine’s no working. Please remove them. Otherwise Scrapped wire
cutting unit could break because too many scrapped wires are piled.)

17


1-8. Check the Air Pressure
An Air regulator adjusts air pressure and separate moisture from air.
(An air regulator is located in the left lower side of the machine)
1) This machine uses 5kg/㎠ of air pressure. Hold the handle cap of Regulator up and turn
it to adjust the air pressure.
2) In Manual : Water will come out if the lever in lower part of Regulator is pushed to side.
In automatic: If the hose in lower part of regulator, water will come our automatically,
when water’s full.
Pressure control cap

Pressure
control
cap

Drain lever


Drain hose
<Manual>

<Auto>

2. Weekly inspection
2-1 Cleaning The Lower Roller
① Disassemble the Lower roller and check the rotation of it is good. Rotate it first with you
hand and replace the Bearing if the condition of rotation is not good.
② Check whether there is a wire scrap in Lower block housing or it is getting dirty or not.
③ After assembly, please check the roller turns softly. If there is a load on machine, it
should be disassembled to solve the problem.
* Lower roller inside Guide plays an important role for wire threading well.
The rotation condition of Roller can be checked through Acryl cover on right side. Clean
it sometimes to check the roller well. Bearings are equipped on the both of Roller
housing. Replace them if there is a problem on rotation of roller.
④ The influences on machining when Lower roller doesn’t turn well.
A. The case that lower roller turns, but not smoothly.
- Wire disconnection happens frequently if there is a line on machining surface.
B. The case that lower roller doesn’t turn.
- It is possible that the Roller doesn’t turn due to wire piece or dirt between Housing
of Lower block and Roller.
- If wire disconnection happens frequently during the machining, it could happen near
Wire Pinch roller.
⑤ Follow as below order.
A. Loosen the right side cover fixing screw of Lower block to disassemble cover.
B. Check that bearing turn smoothly with finger or pin.
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* If turn is not smoothly, check there are wire piece or foreign element on housing.
C. Turn screw in left side of block to separate Lower roller.
Clean the disassembled parts and assemble it if it turns well.
D. If it’s turning is not smoothly due to bearing, it should be replaced.
According to roller size, replace the stainless bearing with F698DD.
Lower roller Assy

Bearing
F698DD (SUS)

2-2 Check and clean Work Tank
Clean the Work Tank by cleaning nozzle, if sludge is accumulated in the bottom.
Press Rapid Fill S/W and clean the Fluid level sensor during water is filled up. Check that
each fluid level sensor is operated normally.
1) Check the operating condition of each Fluid level Sensor
1-1) WATER LOW Fluid level Sensor
Water jet is used when wire is feeding automatically due to wire disconnection during
the Taper machining (return to start hole and feed wire) or M20 code is operating. The
water in Work tank is discharged as far as WATER LOW level sensor and wire is fed.
Operate the level sensor manually and check the lamp of WATER LOW on AWF
window(F9) is turned on if a Float is in the under part or turned off if it is in the upper
part.
1-2) WATER FULL, WATER OVER Fluid level Sensor
If water is filled up with Rapid Fill S/W, water level operates WATER FULL level sensor
and water supply is stopped. If the WATER OVER level sensor operates due to
supplement of fluid, the water is discharged and the water level stops it by operation
the WATER FULL sensor. It is the method to maintain the water level during machining.

- The gap of WATER FULL and WATER OVER is about 5~10mm and coordinate the
position of sensor bracket to adjust the machining water level.


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1step door Water-over Sensor

Fluid level sensor
(Full/Over)

Water-low Sensor

2-3. Check the Wire Alignment Device
① Check the condition of wire contact surface.
② Avoid cracked part.
③ Regrind if it doesn’t have using phase due to many flaws.
Case The Wire Alignment Device cannot be used(below Angle/Height 0.003/50mm), the
wire alignment could be made by spark making microscopic discharge with Work or
side of Device. At this time, do not connect Device cable because it could be a cause of
Controller breakage.

2-4. Check The Wire Tension
The measurement of WT (Wire Tension) and PT (Pre-Tension) is shown as below.
① Wire ON with a wire 0.25 after setting 11 notch of WT and 14 notch of PT.
② Measure with a TENSION METER
③ It is different according to a load of wire coiled around the bobbin.(5 Kg wire standard)
- Wire Tension (WT 11 notch) : 1400g
- Pre-Tension (PT 14 notch) : 250g

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3. Monthly inspection
3-1. Clean the Flow Meter
Open the Upper cover and clean it with a swab.
If it has been used for a long time, a scale or position of a weight has difficulty to read it
due to adhered sludge inside of the Flow meter. In this case, take out the upper cap of it
and clean inside with a swab.
① Take out the upper cap and put little bit of KC12A(Rust remover) into it.
② Let it as it is for a few minutes and close it.
③ Open the valve and turn on Fluid S/W to clean inside of the Flow meter.

3-2. Replace oil filter
The filter of Auto lubricant inject, which is equipped on main unit
could be blocked by oil remains. If it is, replace it because it interrupts
oil lubrication.

3-3 Check the refueling of X-Y-U-V-Z axes
An auto oil injection device is adhered on X-Y axes and a semi auto grease injection
device is adhered on U-V-Z axes. Check whether the Auto refueling device is supplied oil
everyday or not.
It is important to check whether the oil is injected to refueling parts (such as Ball screw,
LM guide) of machine or not.
Keep an eye for an oil supply hose because it cannot refuel oil if it is coming loose.
① Auto oil injection device: Set to supply oill over 45 seconds during 30 hours.
Lubrication oil: ISO VG68 Turbine oil and Slide way oil (Advice: Bactra NO2)
② Grease pump: Move a lever frontwards and backwards once two months and over 12
times to supply the Grease to all of parts.(Using Grease: Soap type of Lithium series
(JIS1))

Auto oil injection device


Oil Filter

Semi auto Grease
injection device

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3-4 Check the Wire Collection part
1) Check the cutting condition of scrapped wire

① Check the cutting condition of wire
- Check there are parts, which pushed
and broken on the wire cutting part.

② The parallel degree of Cutting bite
affects the life span of machine. Therefore
check it with your eye and adjust it, if it
doesn’t.

③ If the wire is not cut well, adjust the
gap of bite with a gap control bolt.
According to cutting Bite are 2pcs, to turn
4 mm T lench

and to do an interval regulation

④ If the wire is not cut well due to abrasion on the using surface of Cutting bite, turn it to
use another surface.

⑤ The Cutting bite is and expendable supply. Therefore replace it if there are abrasions on all
of 8 surfaces.
⑥ Fasten the Cutting bite appropriately. If it is fastened too strongly, you can get a difficulty
when you disassemble it.
⑦ Refer the attached disassembly drawing of Wire cutting unit to Detail disassembly drawing.

2) Check Pinch roller
① Check that scrapped wire or dirt is attached
on the outside of Roller.
② Will have to regulate the location of the
roller rightly to wire diameter.
③ Clean the surface of Wire collection roller
with swab soaked in Thinner.
④ If the tension is unstable due to slim on
wire roller, raise the pressure capacity of roller by
fastening a roller push bolt.
⑤ If the surface of roller is getting smooth
because it has been used for a long time, use it
after re-grind. (Horizontal line grind)
⑥ Check the Bearing used on axis regularly
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because it could broken. If there is a problem on it, replace it to new one.
(Doubt if you can feel something when you turn it.)
⑦ Refer the attached disassembly drawing of Wire recovery unit to Detail disassembly
drawing.

3) Check that wire slip is occurred on 16 notch of Wire Tension (WT).
The wire is stopped, because wire slip is detached by Wire Cutting if it is occurred on roller.

Therefore if the wire slip is occurred due to serious roller abrasion, replace it.

4) Check the water collection unit
① Check that water leaks during the Wire feeding or machining at the end part. If it is,
connect hose from Venturi block to Fluid tank as shorten as possible to make water flows
well.
② Check that the wire is caught in Water collection unit during the Wire feeding. If it is,
disassemble it and clean the 3 nozzles, located in it.
-Remove the all of dirties, coated inside of Nozzle taper. It could be a cause wire catching.

<Water recovery unit for column moving>

<Water recovery unit for table moving>

5) Check the condition of sub-feeding
Check the Lower feeding S/W and check the wire travels well to Collection roller when it is
inserted into the bottom of Lower guide and set it free. If it is not, inspect it according to
below items.
① The wire is caught during passing through the Lower guide.
->Disassemble the Sub guide located at the bottom of Lower guide. Put the wire in
entrance of it and replace it if the wire is caught.
② The wire is caught at the Groove of Lower block.
->Disassemble the Lower roller after disassembly Light acrylic cover of Lower block. Bend
a thin wire to be 90˚ and check that there us a sunken area in the Wire reference
groove with it. If the sunken area is shallow, bend at the end of diamond round file to
be 90˚. Scratch with it according to the Wire reference groove to make that wire is not
caught.
If you cannot prove this problem with above method because the sunken area is deep,
due to long using, replace the Lower block.
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Lower sub guide

Wire reference
Groove

③ The wire is caught at the Water recovery unit.
->After disassembly the Recovery unit, remove the scrapped wire if it is inserted at the end
part of recovery pipe. Disassemble 3 nozzles in Recovery unit and remove a scale. Put the
wire at the end of taper, remove splinter if there is it or replace to new one if it is serious.
->If the wire is caught at the line of Wire feeding unit, check it as soon as possible. If the
wire is not connected well, it can affect productivity.

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