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PNC PC System

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2. GU LINN 801515384 93 HOLINOW 80102 YONS Issue JUNE 05 UK IV 10 6 Maintenance Inspection item Method Oil filled axis movement ball Manual pull rod auto screw etc Quantity of dielectric _ Daily Door tighten check of work tank J Dielectric level setting check Function chek Fire detect function check Function cheek Extinguisher pressure check Week Lubricant quantity and waste oil check Waste oil retrieve EE Dielectric filter check Pressure meter Monthly Transfer belt check y Air filter cotton of electric cabinet clean Visual Extinguisher contents quantity check Scales 0 Screw thread of electrode clean and Clean and lubricate lubricate Six Replacement Monthly Door tighten check of oil tank X y screw shaft clean and lubricate movement confirm Functonchek _ Cooler titer clean _ _ Q o gt D D Extinguish device precision check Extinguish device replacement Motor carbon dioxide inspection Disassemble check executed by supplier or local authorized agent Mechanical precision measuring and Measuring and revising revising Knot distance inaccuracy measuring Measuring and revising We recommend use 5 20 lubricant or equivalent oil at lubricant system The lubricator of lubricant system Use grease N
3. SPK F2 Sparking Touch for Probing Caution Sparking Probing with low JOG_FEED amp low LV code SELECT AXIS Choose Axis amp Direction F5 RUN After sparking codes axis amp direction decided press F5 to run Press START to start probing with sparking ON 1 Waiting until electrode touches the work piece sparking occurs 2 Reduce the JOG FEED 0 1 3 Jogging axes with X X Y Y keys watching the spark until the axes have moved to the wanted position 4 Press STOP to finish the sparking probing o Press A back to previous page set the new Data Applicable Software VER P D4K II 20 Issue JUNE 05 UK x F2 F3 gt AXIS T F3 Axis Centring by probing both external sides of work piece Move the electrode to the start point above work piece press F 2 PROBE then F3 A Procedure SELECT AXIS Choose Axis amp Direction 1 200 RANDOM SET Reset 0 Probing point 0 Preset 1 200 The probing data will be transferred to the corresponding pos data of pos table of the Pattern PROBING DISTANCE Probing distance B Z UP DISTANCE Z up position during probing C F5 RUN Press F5 to start probing cycle SIARI SPEED UP Press START to increase probing speed TOUCH POS PRESET NEW Preset new Axis Centre Position Data Applicable Software 4 II
4. SPEED ustment EE Clockwise Speed p Anticlockwise Speed Down FL TORQUE DLE Pic 12 D I E isinthe mid ight of Power 7 5 When machine stands still check the coordinates of all axes stay still If the coordinate value umps consistently ad ust the knobs on the PMC board to make the coordinate still See Pic 12 or Z axis ad ust the first knob Pic 12 7 6 Home search procedure efer to the operational manual for procedure gt 7 7 inishing the Home search the electrode can be fitted to the machine for Short testing Electrode Short Protection se a conductive material to touch the electrode amp workpiece When a long beep sounds and the signal of TO CH shows on the monitor the function of Electrode Short Protection is O K See Pic 13 2 fy 25 400 O CH Test finished Y 0 000 0 000 FELLE TOUCH VER Pic 13 I 14 Issue JUNE 05 UK 8 Procedures of machine abandoning When the machine needs to be eliminated and demolished certain basic rules must be observed to protect the environment and public health Please obey local safety regulation for EDM etc All machine components must be divided according to category as follows All sheathes flexible hosing and plastic or non metal components Electrical components are such as switches lamp etc Insulation materials wool lexib
5. as 20 38 71 06 1 2 200 20 40 7 74 024 06 1M Y LV HV Ton Toff GAPV ROUGHNESS TWO GAP WEAR RATIO SPEED V s 2xGAP mm 90 mm3 min iS SISI E zo gt 20 56 om 187 _ 100 2 20 2 20 2 20 2 10 20 40 7 74 02 11 194 2 is 20 40 33 76 192 gt o 20 Tas si 02 os 20 2 250 20 40 39 04 183 LV HV Ton Toff GAPV ROUGHNESS TWO GAP WEAR RATIO SPEED 55 2 20 40 39 61 025 s6 27 25 2 125 20 40 68 02 17 248 25 2 20 20 a3 032 06 21 25 2 250 20 40 90 033 04 214 III 13 Issue JUNE 05 UK Graphite Steel A A US us V 2xGAP mm 90 3 min 2 100 20 36 38i em 12 me 20 99 oss 04 251 2 n os 2 ao 40 40 LV Toff GAPV Si ROUGHNESS TWO GAP WEAR RATIO SPEED A A US us V 2xGAP mm 90 mm3 min as ao wo s sa 34 312 ras 2 ars 20 40 22 14 35 2 200 20 40 4 82 032 35 2 250 20 40 033 04 308 35 2 ao 40 41 103 04 308 2 sos s n me os os me 35 2 400 40 40
6. Applicable Software VER P D4K II 39 Issue JUNE 05 UK PNC F4 PATTERN 2F5 2 RUN x To Finish pattern editing press out of the pattern POS table display Rechecking the CAVE NR Z POS DURING MOVING ERODING START POINT WORK TYPE BLK_SET CAVE_SET Press F5 to RUN the pattern machining Press F5 Dialogue shows 1 FROM BEGINING 2 SET BLK NR CAVE NR 1 1 Press 1 ENT to spark from cavity NO 1 of pattern table 2 Press 2 ENT to select BLK NR and CAVE NR for sparking Applicable Software VER P D4K II 40 Issue JUNE 05 UK PNC F4 PATTERN 2 F5 2 RUN x Display of pattern machining 1 PNC pattern machining can be interrupted by pressing on the remote control box temporary Pressing for sparking OFF 2 During interruption Z axis can be moved up down X amp Y can be moved away for intermediate check of sparking gt 3 Press of remote control box X amp Y axes will be moved back to interrupted position firstly then Z down to resume sparking gt Applicable Software VER P D4K II 41 Issue JUNE 05 UK F4 PATTERN 2POS X Y Z ENT gt F8 AUTO CAV F1 MATRIX START POS START POS Applicable Software VER P D4K II 42 Issue JUNE 05 UK F4 PATTERN 2POS X Y Z ENT gt F8 AUTO START POS Applicable Software II 43 Issue JUNE 05 UK F4 PATTERN 2POS X 2 ENT
7. 0 000 JOG FEED HIMIHUM POS 255 255 UER P D3C 1 800 HHA H1 POS CAVE 17 288 H1H No x POS Y POS Z POS Z POS DURING MOVING 18 B BB8 8 B8B88 8 000 ERODING START POINT 1 4 _ 8 88 0 000 5 8 800 0 000 8 0808 COMT 1 STEP BLK SET CAVE SET 6 _ 8 888 _ 0 000 MARK ALL MARK ONE 5 MARK DEL SET INC DATA INC AUTO Fi FA F3 F4 F5 FH Pattern POS editing Cursor moved to POS X Y Z ENT the pattern POS table will appear F1 F8 for functions gis any NO of table editing random data or editing with any functionsF1 F8 MARK ALL Selecting whole table for POS editing MARK ONE Selecting the chosen cavity NO cursor POS for POS editing MARK INS Inserting one POS as the chosen cavity NO cursor POS before it MARK DEL Deleting the chosen cavity NO cursor POS DATA SET Entering new POS to marked data INC DATA Adding the same data to all marked original data DATA INC Adding incremental to all marked data by one The 1 marked one no change 8 AUTO CAV Fixed pattern POS editing Moving the cursor to the wanted start cavity NO Press for fixed pattern POS editing a dim Applicable Software VER P DAK II 34 Issue JUNE 05 UK PNC F4 PATTERN MODE i HORK POS H1 LABEL H
8. 800 80 20 900 960 4000 1000 1000 100 1500 1500 1500 1500 1600 1600 1600 1600 1700 1700 eo Graphite gt Steel Rough eroding Low wear ratio Ton LV about 25 Medium eroding medium wear Ton LV about 15 20 Finish eroding higher wear Ton LV about 5 10 Suggesting table between LV amp Ton for lower Graphite electrode wear ratio 0 1 2 314 5 6 o 50 70 100 120 150 125 200 200 550 550 600 600 650 650 700 700 730 700 800 800 900 900 900 900 1200 1200 1200 1200 1200 7 Gap Voltage setting for retracting control 1 Range 0 15 2 Smaller GAP then smaller sparking gap quicker not easy to remove debris Bigger GAP then bigger sparking gap slower easier to remove debris El 3 GAP data set by pressing keys to fetch data Applicable Software VER P D4K II 29 Issue JUNE 05 UK SPK EDT 8 SPD Speed of Auto Jump 1 Range 0 15 2 Smaller SPD then slower jump for bigger area of electrode and fine sparking 3 Bigger SPD then quicker jump for long electrode doing deep sparking for longer jump distance for easier debris removal 4 Matched well with UPD amp WT better efficiency achieved 5 Enter data directly or use lt keys to fetch data 9 UPD jump UP Distance 1 Range 1 2
9. SCL CN4 5 6 SK1 2 3 gt PGM CN1 2 3 Especially check for contact problem 2 Linear scale fail 3 PMC620 PCB fail 3 6 Counting accuracy and compensation Testing method 1 Checked with fine Dial Gauge amp Block Gauge 2 Compare the difference of 100mm travel with a few times of measuring to get its average 3 Enter the average data into MP120 MP125 4 Check again until satisfied 3 7 X Y Z Run Away when Power ON Possible causes 1 No position feedback from linear scale 2 No Tacho feedback TG 3 Servo Drive MDR 680 fails 4 PC Module Counting direction incorrect I O PCB 620 fail Caution when Power ON and axis runs away Press down the Emergency Stop button as soon as possible The power of servo system will be cut off Manually traverse the M C table to the safe area for further remedies IV 6 Issue JUNE 05 UK Remedies X Y Z Axis Run Away Is the Position Counting correct Mains switch ON F1 pressed gt A pressed instead of Enter Main Menu of system but DO NOT Power ON Turn the pulley of each axis by hand to check its position counting O K or not No counting or counting is not normal please refer to the last step of fault finding to diagnose the problem No Tacho TG feedback due to wiring 1 Power OFF remove PMC CN2 connector for motion control Power ON again if still run away fault could be Tacho Cable of Tac
10. Sparking touching for alignment Probing externally Workpiece midpoint Datum of one axis Probing internally Circle Centre Datum Probing Corner Datum Probing Centre point of 4 sides Manual Data Input for Axis Positioning Actual Pos Data divided by 2 Centre point data Insert One Sparking Block Delete One Sparking Block Cycle stop at block for intermediate check Save the new Sparking Code contents Multi cavity position data editing Mark whole table data for editing Mark selected POS data for editing Insert selected POS data Delete selected POS data Enter new POS data to all marked data Adding data to all marked original data Adding all marked data with incremental one by one Multi cavity position data editing with fixed pattern MATRIX Matrix pattern 2 Pattern with Inserting mid point of matrix Pattern with whole line shifted of matrix SQUARE Square pattern CIRCULAR Circular pattern LINEAR Linear pattern Sparking Codes editing Time Control setting Enable amp Timer setting Program Directory Program Delete Program Copy II 3 Issue JUNE 05 UK 3 Machine Panel F1 22 F4 Les Les Je Q 6151 55 IIS Applicable Software VER P D4K II 4 Issue JUNE 05 UK 4 Power Switch Button Main Power S
11. 20 20 40 29 8 20 40 28 012 67 2 re 2 ao 20 32 41 20 33 01 2 20 40 s 015 16 35 _6 2 100 20 40 016 12 37 MEC UNE OE 6 2 150 20 40 33 06 III 11 Issue JUNE 05 UK Graphite Steel A A US us V 2xGAP mm 90 3 min 20 20 40 39 28 78 a2 s 2 20 3 72 4 20 40 so 3 014 44 st efa 100 20 40 32 38 om 18 or INE WE BM MN M 8 2 150 20 40 33 06 58 LV HV Ton Toff GAPV ROUGHNESS TWO GAP WEAR RATIO SPEED A A US us V in 2xGAP mm 90 mm3 min mss si 20 4 39 oj 19 6 2 10 20 33 42 ois 14 2 uso 20 40 52 020 06 gt ws 2 s Tas om o4 10 2 200 20 40 36 04 62 A A US us V 2xGAP mm 90 mm3 min 2 20 33 76 2 2 20 40 2 41 21 o 112 2 150 20 40 35 54 021 06 10 EITERECHERE ETE OE 1212 200 20 40 36 III 12 Issue JUNE 05 UK Graphite Steel A A US us V 2xGAP mm 90 3 min 20 40 42 23 ns ao s2 em 12
12. gt F8 AUTO_CAV gt F5 CIRCULAR CIRCLE CENTER C F4 PATTERN POS X Y Z ENT gt F8 AUTO 6 LINEAR START POS Operating procedure 1 Editing program Depth Sparking Code AUX Function 2 Editing Pattern for multi Cavities machining with PNC 3 Pattern Program executed Applicable Software VER P D4K II 44 Issue JUNE 05 UK F5 RUN MOD 1 After electrode and work piece are aligned sparking program edited Press F5 for single cavity sparking 2 During sparking when security system finds something wrong sparking will be turned OFF automatically Only when the fault is cleared press ENT to erase the error status latch then press START to resume sparking 3 For PNC intermediate stop by pressing STOP then ESC for sparking off 4 For ZNC only need to press STOP for sparking off 9 of Remote Control Box for sparking ON amp Resume working Applicable Software VER P D4K II 45 Issue JUNE 05 UK e Single Cavity sparking can be started from any Block No F u ES NL NE n P Applicable Software VER P D4K II 46 Issue JUNE 05 UK F6 AUX SET Mode AUXiliary sparking function SETting Contents of each AUX edited by pressing set to toggle switch END MAX STAR NO IN DST SEN SET BEEP ON OFF AUTOPUMP ON OFF BACK PRO ON OFF Applicable Software VER P D4K REZ AY OB CODE OB SPEED EMD UP DST SE
13. 44 481 0 41 0 43 0 45 0 48 0 53 0 56 0 59 14 1 15 3 16 4 gt 18 gt 18 re 10 LO O O O O CO O 17 10 O LO lt A 8 00 Issue JUNE 05 UK III 9 Graphite Steel LV HV Ton Toff ROUGHNESS TWO GAP WEAR RATIO SPEED A A us us Se umRa 2xGAP mm 06 mm3 min fe s fas p wr es _ gt 10 50 26 18 45 73 2 20 50 33 20 on 24 96 20 28 23 012 14 12 A A US us V 2xGAP mm 90 mm3 min 1 20 25 182 00 56 3 1 60 20 50 33 261 012 21 20 LS 20 50 29 286 16 23 3 1 100 20 50 30 12 27 III 10 Issue JUNE 05 UK Graphite Steel A A US us V 2xGAP mm 90 mm3 min ra a io 3160 6 ME L E E Lerma x on 29 s se ow is at o9 27 LV HV Ton Toff GAPV s ROUGHNESS TWO GAP WEAR RATIO SPEED A A US us V 2xGAP mm 90 mm3 min GE EE s 40 20 40 20 346 48 3 s 2 20 40 30 32 ors 26 5 2 20 1 34 21 33 rool 20 s sr 51215 52 se 10 fa 5 2 20 40 o6 2 A A US us V 2xGAP mm 90 mm3 min 2
14. D4K II 14 Issue JUNE 05 UK 8 2 F1 MANUAL x PNC F1 MANUAL HOME F1 Homing for Reference Mark Approaching for Datum Memory 1 Z up automatically until Limit Switch be reached 2 X Y automatically until Limit Switch be reached 3 3 Axes move back to look for the Ref Mark of Encoder automatically after Ref Mark be passed over Axis stops mark before MACHINE POS disappear means Ref Mark passed already 4 WORK_POS displays the Actual position data MACHINE POS displays the Reference position to Ref Mark Applicable Software VER P D4K II 15 Issue JUNE 05 UK F1 MANUAL AXIS F2 Axis Positioning by Manual Data Input 1 Select Axis to move XorYorZ 2 Enter the new position including sign if necessary 3 Press ENT key 08 ORBIT CUT COC 280 Special Option of OBPNC or OBZNC Pressed for COC 280 Auto Centring MP SET is only done by experienced service engineer After one option complete press A key back to the Last Menu ready for the next job Applicable Software VER P D4K II 16 Issue JUNE 05 UK PNC F2 PROBE MOD Auto Probing Function 1 Calibrating the electrode and aligning the work piece before Probe Mode 2 Press the PROBE key on Operating Panel to disable Short Protection for accurate calibration amp alignment Electrode Alignment button Short Supervision Disable e
15. This function works only in PROBE Mode careful when traversing axes with this function activated in PROBE mode there is no Short protection Applicable Software VER P D4K II 17 Issue JUNE 05 UK PNC F22F1 PROBE2SURFAC SURFACE F1 Probing Edge of 3 axes for Surface Datum Description SELECT AXIS 1 200 RANDOM SET RETURN POS F5 RUN START SPEED UP TOUCH POS PRESET NEW DATA Applicable Software VER P D4K Choose Axis amp Direction Reset 0 Probing point 0 gt Preset 1 200 The probing data will be transferred to the corresponding pos data of pos table of Pattern Key in Back Position after Probing then ENT Press F5 start the probing Press START on Box to increase Probing speed Preset new position data for Touched Edge II 18 Issue JUNE 05 UK PNC F22F1 PROBE 2SURFACE 1 gt F1 Probing Edge of 3 axes for Surface Datum SURFACE Measuring Auto Probing for large Mould Work piece Do the SURFACE probing twice for each axis the average data will show on the table of each AXIS CENTER at the upper right corner of CRT Press F7 AXIS_ POS and key in this Axis amp Centre Data to move the axis to the CENTRE point by control Then you can reset its data be the new Datum Applicable Software VER P D4K II 19 Issue JUNE 05 UK PNC F22F2 25
16. avoid any impacts gt Weight 1500 Kgs X E uipments for movement ork Lift Truck with loading capacity of 1700KG above Pic 4 I 11 Issue JUNE 05 UK 6 Procedure of installation 1 Site the machine in its desired position A space of 1M must be maintained all around the machine for operator s inspection amp installation Make certain that machine is well seated avoiding any movements or unbalancing See Pic All clear space of 1M 2 Assemble amp fix with bolts all the outer shell covers to the machine 3 Place a spirit level on the work table then ad ust the bolts on the machine base to achieve perfect level See Pic 7 Pic 7 4 Place the Power Supply nit to the right side of machine body rom the Electrical box on the rear of Power Supply nit remove the remote control box key for door of Power Supply nit amp Power Supply Specification See Pic emove the cover and take above mentioned items I 12 Issue JUNE 05 UK 5 Connect all the signal cables on the machine to the Power Supply nit according drawing on the rear cover of the electrical box Linear Scale Control Cable D type Pin Motor Control cable Metal Connector SCL signal control Cable D Type 25Pin mm Electrode wire Power cable for pump motor See Pic Power input pump Power output Linear Scale Motor emote ox Electrode SCL Cable Pic Connect specified Power Supply
17. 21 Issue JUNE 05 UK x F22F4 gt CAVE CEN F4 Cavity Centring by probing the Cavity internally Manual traverse the electrode into the cavity press F4 CAVE CEN Available for square or circular cavities Procedure 1 O DATUM 1 200 RANDOM SET Reset 0 Probing point 0 Preset 1 200 The probing data will be transferred to the corresponding pos data of pos table of the Pattern 2 Press to start the auto cavity centring Press START to increase probing speed 3 Eventually stop at the Cavity centre Preset a new position data be Datum Applicable Software 4 II 22 Issue JUNE 05 UK F22F5 PROBE2CORNER Quadrant QUADRANT CHOICE 4 corner 1 2 3 4 can be selected for probing PROBING DISTANCE Entering the bigger rough range of X and Y distance Z UP DISTANCE Down Distance of Z axis for probing O DATUM 1 200 RANDOM SET Reset 0 Probing point 0 Preset 1 200 The probing data will be transferred to the corresponding pos data of pos table of Pattern F5 RUN Press F5 to start probing cycle Applicable Software VER P D4K II 23 Issue JUNE 05 UK CORNER 2 gt 5 After Corner probed automatically the display shows YCEN Preset new data or Reset 0 press to finish the probing cycle Applicable Software VER P D4K II 24 I
18. 42 o4 201 LV HV Ton Toff GAPV ROUGHNESS TWO GAP WEAR RATIO SPEED 150 20 0 30 30 on rao 2 200 20 9 032 308 rao 2 zs0 20 o6 3 4 2 40 41 107 097 06 364 gt ne os gt wo 40 a2 8 os a0 2 aso 40 40 43 oa 3 4 _ III 14 Issue JUNE 05 UK Graphite Steel A A US us V 2xGAP mm 90 mm3 min as 2 ws z 40 39 30 03 18 45 2 200 20 40 41 10 033 12 392 45 2 250 20 40 41 10 033 06 398 soo a oe 5 2 400 40 40 2 121 040 04 45 2 o as os o4 ort ras 2 soo so 40 LV HV Toff GAP V ROUGHNESS TWO WEAR RATIO SPEED A A US us V n 2xGAP mm 96 mm3 min 3 aa so n 2 aso so 40 118 06 _ faos 40 129 04 2 450 40 40 oas 04 383 LV HV Ton GAPV ROUGHNESS TWO GAP WEAR RATIO SPEED 55172 300 42 121 038 09 ss 2 60 60 45 1 04 04 308 III 15 Issue JUNE 05 UK Graphite Steel LV HV Ton Toff GAPV ROUGHNESS TWO GAP WEAR R
19. 43 All should correspond to local voltage 4 4 Please check all voltage on all transformers I O are they all O K PTF1 8553 0 200 0 55 PIF2 0 2110 18 6 0 18 214 gt 0 14 3 If Yes it s correct If No could be fuse blown or wiring missing 4 5 PCB check Check all PCB s are installed correctly with no contact problems Check all wiring plug connectors with no contact problems If necessary remove the PCB s connectors wires plugs then fit them again Make sure PCB LED display light up O K as normal 4 6 Good Luck IV 9 Issue JUNE 05 UK 21 9 3 5 1 5 Layout of electric cabinet apis 7518 51 YA PU 9 vU gt 959 z gn lad k LU LA D T D D wo 9189 29 2 2 8IgU U YOH dan rad 820190 X X Z3 VU 3 do 9 55 a 3513 d aOLINOH 90103 5975 AQ 1 TUOU c 5 JId 58 U 209 sna 2 109 29 God 299 29 8 0199 HS NIUM opis 10014 PT opis 97 opis Joed Edu Su 985 CI SAS El 9U 145 CO O 2365 43WHOJSNGUL GU LINA AJddns 93
20. 5 as 15 o0 5 gt 45 26 20 2 20 2 100 15 5 27 22 15 15 2 125 15 45 28 25 012 12 Toff GAPV ROUGHNESS TWO GAP WEAR RATIO SPEED 913121574511 os oo 24 os opeta fs om az fos 5 22 oo SS 15 4 24 16 oo 28 rots 40 15 5 25 17 58 20 5 26 22 22 24 joo 20 5 28 24 009 16 19 125 20 5 20 28 o0 10 L6 III 2 Issue JUNE 05 UK Copper Steel FE zs 5 5 LV HV Ton Toff GAPV ROUGHNESS TWO GAP WEAR RATIO SPEED A A V mRa 2xGAP mm 06 mm23 min afa profs 40 3s oor 4 2 1 2 5 24 16 41 54 2 80 10 40 2 23 012 12 12 2 1 100 10 40 2 25 013 18 2 1 125 10 40 315 014 05 14 us V mRa 2xGAP mm 06 mm3 min 120 5 0 25 18 52 6 1 40 20 255 ois 14 20 a si o1 oe 21 III 3 Issue JUNE 05 UK Copper Steel ROUGHNESS umRa 2 qu ROUGHNESS TWO GAP umRa 2xGAP mm sis 46 22 o so si 97 21 28 757211110146 117737 16 39 rs 2 125 20 40 22 39 01
21. 55 steps 2 Smaller UPD then save dry run time Bigger UPD then waste longer dry run time 3 Enter data directly or use gt gt keys to fetch data 10 WT working Time after auto Jump 1 Range 1 255 steps WT 0 means no Auto jump 2 Smaller WT then shorter working time easier for debris removal Bigger WT then longer working time harder for debris removal 3 Enter data directly or use gt keys to fetch data 11 P N discharge Polarity 1 Electrode be positive polarity polarity 2 Changing the setting by key 12 TIME TIME record of each block of sparking program Calculated by PC itself Electrode be Negative 13 ConTroL of Z LOCK ON OFF for extra external Orbit Head function 1 Orbit Head activated 0 Orbit Head OFF F3 INSert 1 block in program INS BLK DEL BLK STOP E5 Feed Hold when this block finished F4 DELete 1 block in program B lt F8 SAVE the Sparking CODE DATA to its corresponding CODE TABLE In memory it will overwrite the old CODE DATA in memory Applicable Software VER P DAK II 30 Issue JUNE 05 UK Di EDT E 328 ose cst oec After editing press A key to exit Press Y key to save new CODE data to CODE Table in memory then return to main menu Press key to not save and return to main menu Applicable Software VER P D4K II 31 Iss
22. 6 10 Fs 2 iso 20 44 oiv 2 2 1751 20 40 as oiv 04 24 HV Ton Toff GAPV ROUGHNESS TWO GAP WEAR RATIO SPEED rela 5 4 19 00 98 M re 2 20 5 zr 224 012 78 21 5 z 246 56 27 2 10 3 315 34 re 2 1 36 016 16 re 2 us z 40 1 oiv 12 36 re 2 io 2o 4o a2 42 34 2 17 20 40 45 08 06 32 4 Issue JUNE 05 UK Copper Steel ROUGHNESS TWO GAP umRa 2xGAP mm ao se s 09 22 79 101211510140 134177527170 17 6 2 ws z 40 5 54 15 53 rio 2 200 20 e 8 63 08 so 1912 250 20 27 68 02 04 48 LV HV Ton Toff GAPV ROUGHNESS TWO GAP WEAR RATIO SPEED 2 2 22 41 oiv 52 2 fiso 20 5 54 86 12 2 250 20 40 27 024 72 III 5 Issue JUNE 05 UK Copper Steel WEAR RATIO SPEED 90 mm3 min A A us us V umRa 2xGAP mm 90 mm3 min 20 2 o0 10 35 34 5 1 0 23 9 0 139 20 2 250 20 35 90 12 151 2 300 0 s 0 101 032 08 144 LV HV Ton Toff GAPV US ROUGHNESS TWO GAP WEAR RATIO SPEED A A US US V u mRa 2xGAP mm 06
23. AM ROM Card Fail gt Replaced RAM ROM Card System Initiation via F1 System self diagnosis or not Output system OK signal amp PC control ready Card PIC630 PMC620 Fail Push ON for Power ON check Panel indicating LEDs Refer to the following description Pressing ON button on Panel oystem Start Up O K IV 4 Issue JUNE 05 UK 3 3 System Supervision Indicating LED Description MAIN POWER ON Mains switch ON Mains Power O K OFF Mains Switch OFF or Mains Power not O K All the other indicating LEDs off Check Fuse Mains or PPC9540 PCB fail ON X axis over travel L S not reached OFF X axis is over travel Power ON blocked Check X Limit Switch wiring SK7 Connector Wiring amp PGM CN10 or PPC9540 PCB fail gt ON Y axis over travel L S not reached OFF Y axis is over travel Power ON blocked Check Y Limit Switch wiring SIK8 Connector Wiring amp PGM CN11 or PPC9540 PCB fail ON Z axis over travel L S not reached OFF Z axis is over travel Power ON blocked Check Z Limit Switch wiring SK9 Connector Wiring amp PGM CN12 or PPC9540 PCB fail XAXIS LIMIT Y AXIS LIMIT LIMIT EMERGENCY ON Emergency Stop button not pressed down OFF Emergency Stop button pressed down Check Buttons wiring on Panel amp Remote Box ON PC System ready for Power ON Sparking amp Servo OF
24. ATIO SPEED us us HE mRa mm3 za min Baa 036 2 40 os os 2 400 40 40 141 2 40 153 04 04 49 2 500 50 40 44 164 045 04 a31 12151 so so is irs os 600 40 18 0 50 420 III 16 Issue JUNE 05 UK IV PC Based EDM System Trouble shooting 1 Modules Name Elements Contents Function Fault Response Fault Response PC Main Board With ECOWIN EDM Display not normal firmware System hanging access between amp System initiation fail Input Output Card PIC630 Sparking Module Power ON fail System monitoring System hanging PC Module Supervision fail Position Data display and oystem initiation fail counting Power ON fail Motion Control Servo motion control System hanging Card System monitoring No position counting or counting not normal Axis Run Away PC Power Supply Above 200W Power supply of IPC System initiation fail pne m display 14 colour CRT User Friendly MMI No display or not normal System initiation fail No or wrong key in Keyboard Entry keyboard KB9610 For entry key in with PC Power ON fail POWER ON Control Over Travel not normal Security supervision Supervision not normal O Card Sparking servo output Sparking servo control PPC9540 Equivalent Sparking signal amp normal wit
25. Anocaonic PC Based EDM System Operation Manual mmm ANOT IONIC Lu UNIT 3 HOLLINGDON DEPOT STEWKLEY ROAD SOULBURY NR LEIGHTON BUZZARD BEDS LU7 ODF Tel 44 01525 270261 Fax 44 01525 270235 m Email sales anotronic com Internet http www anotronic com n PC ased EDM System Installation Information Diagram 1200 740 Issue JUNE 05 UK 2 Warning Sign Interpretation A DANGER DANGE ire potential hazard keep flames away A DANGER DANGE Do not touch the electrode during operation WA NING The minimum depth of the electrical discharge below the fluid surface shall be 50mm WA NING Health potential hazard umes must be removed by extraction e uipment Heath L The and fumes must be reos Dy A DANGER DANGE Hazardous voltage Turn off power before servicing Hazardous Voltage Tum off power before servicing 3 Issue JUNE 05 UK WA NING ire potential hazard The flashpoint of dielectric fluid must be over 70 C Only to be opened by a technician to avoid any danger Lubricant LUBRICANT I 4 Issue JUNE 05 UK 3 Warning Sign Position aN i iy LIS I 5 Issue JUNE 05 UK ront y ack I 6 Issue JUNE 05 UK 4 Machine Specification Machine Specification Nox Eee Standard Access
26. ENT Moving the cursor to No 1 Press F8 AUTO CAV for fixed pattern cycle editing Caution The cursor No is the start cav No Multi blocks of fixed pattern cycles can be edited and executed gt Applicable Software II 36 Issue JUNE 05 UK PATTERN PNC F4 PATTERN MODE 7 HORE POS H1 LABEL HR 81 POS 2 0 000 X 8 HBBHB H 0 000 Z B B888 0 000 BBA FEED HIHIHUH POS 255 1 81 ART MATRIX PATTERN2 PATTERNS SQUARE CIRCULAR LINEAR Fi FA F3 F4 F5 PATTERN 2POS X Y Z ENT gt F8 AUTO 5 pr F1 MATRIX F 2 2 F F 4 SQUARE F5 CIRCULAR F6 LINEAR Applicable Software VER P D4K II 37 Issue JUNE 05 UK PNC F4 PATTERN MODE PATTERN g Multi Blocks of AUTO CAV editin JUNE 05 UK II 38 Issue Applicable Software VER P D4K PATTERN 2POS X Y Z ENT 2F8 AUTO CAV F1 MATRIX SURF PUSH TENT 1 Following the dialogue Referring to the drawing to edit the pattern data 2 Press ENT then back to pattern table display automatically The calculated new POS data will be inserted into the table like following 44 H H HHA 4H HHH 10 H Z
27. F PC System not ready yet Power ON blocked Check 1 PCBs of PC Modules put in correct location 2 PIC PMC PCB fail 3 PC Modules fail SYSTEM Caution Power ON blocked as any one of the above green System indicating LEDs not lit up 3 4 Position Data not Counting or counting not normal when axes moving Possible causes 1 Power Supply of Linear Scale 2 Cables of Linear Scales Scales SCL SN1 2 3 SCL CN4 5 6 gt SK1 2 3 3 Intermediate Signals Cable of Scales PGM CN4 gt PMC CN1 4 Driver PCB of Scales Signals PGM942 5 PCB SCL963 or PMC 620 6 Linear Scale Path of counting signals of Linear Scales Reader head Scale cable gt Scale connector gt SCL CN1 2 3 gt SCL CN4 5 6 gt SK 1 2 3 gt PGM CN1 2 3 gt PGM CN4 gt 1 IV 5 Issue JUNE 05 UK Pin assignment of linear scales SCL CN1 2 3 for X Y Z axis SCL CN1 2 3 pin 1 2 5 SCL CN1 2 3 pin 2 A phase SCL CN1 2 3 pin 3 phase SCL CN1 2 3 pin 4 Ref signal SCL CN1 2 3 pin 5 OV SCL CN1 2 3 pin 6 3 5 Counting repeatability 1 Testing method 1 Check with Dial Gauge move to desired point Reset 0 on both Dial Gauge amp PC Position DATA 2 Move axis away then back to zero point Compare the reading between Dial Gauge amp Position DATA 2 Reason of error 1 Linear scale signal connected improperly Please check every node scale head scale cord scale socket SCL CN1 2 3
28. FF when program completed Reserved button Applicable Software VER P DAK II 8 Issue JUNE 05 UK 6 System Start up 1 Switch ON in C W direction the Main Power Switch that located on the right side of Cabinet Power for PC will be activated 2 After PC Self Diagnosis The PC Monitor will display PUSH SYSTEM 3 Press Function Key F1 to initiate the EDM PC Base Control System 4 Press the Power ON Button to enable the Power for Sparking amp Servo ON PUSH OM gt PHR ON Applicable Software VER P D4K II 9 Issue JUNE 05 UK 5 System Start up O K Applicable Software VER P D4K II 10 Issue JUNE 05 UK 7 Remote Control Box STOP START gt Y SPEED Applicable Software VER P D4K II 11 Issue JUNE 05 UK oparking ON During Sparking press oparking W resume Sparking ON STOP Sparking OFF Stop Program Run SHORT Supervision disable in Manual Mode When a Short happens between electrode and workpiece axes moving is inhibited Press STOP button and Axis button together to move out of Short status Normally STOP amp Z pressed together Sparking Off After STOP key is pressed Press ESC key to activate the Sparking Off Electrode Manual traverse Up Electrode Manual traverse Down Ele
29. M SET BEEP BACK PRO ENT_LOCK SCREEN Z LOCK Z UP or not after program END Up to Limit Switch Up to STARt position of program 2 Up DIStance to MIN POS of sparking job for slow down Range 5steps SENsitivity of retracting Range 0 255 Larger SEN SET more sensitive to retract for debris removal slower machining Smaller SEN SET less sensitive to retract for debris removal better machining Buzzer off delay ON OFF control System activates alarm buzzer after PGM END or malfunction encountered to alert operator Beeps until any key on panel be pressed Beeps for 5 second only Dielectric PUMP AUTOmatically ON with Sparking ON PUMP ON with Sparking ON PUMP NOT ON with Sparking ON BACK PROtection function activated when arcing occurs due to poor debris removal sparking is turned off to prevent electrode and work piece damage BACK PRO activated BACK PRO not activated II 47 Issue JUNE 05 UK ENT LOCK ENTry LOCKed or not during sparking ON program editing not allowed during sparking OFF program editing allowed during sparking SCREEN SCREEN protection mode ON OFF ON Activate Screen Protection mode Screen background is black OFF Screen Protection mode not activated Z LOCK Z Axis LOCK ON OFF during sparking ON Z LOCK for external Orbit Head application OFF 2 LOCK ZXYZIXY For OBCUT option Working Plane OB CODE For OBCUT option Working Code OB SPEED For OBCUT opti
30. R 81 H 0 000 7 a H HHH Y 0 000 H BBH DISTANCE 0 000 8 880 JOG FEED MINIMUM POS 255 255 VER P D3C 1 BBB 88 81 CAVE HR i 288 x POS POS zpos Z POS DURING MOVING 10 BBB ERODING START POINT 1 BBB WORK TYPEC B CONT 1 STEP 4 8 008 8 880 8 880 SET 5 888 8 880 8 088 CAUE SET 6 0 880 _ 8 888 8 088 ALL J HARK ONE I INS I MARK DEL DATA SET INC DATA DATA INC AUTO Fi FZ F3 F4 F5 F6 F8 PATTERN with AUTO fixed pattern cycle 1 Cursor moved to POS X Y Z ENT the pattern POS table appeared with cursor 2 Moving cursor to wanted 1 cavity NO of wanted pattern block Could be not the 1 cavity of POS table 3 Press AUTO CAV for fixed pattern cycle editing 4 Selecting wanted pattern cycle 5 Following the dialogue to edit the POS Distance Cavity No etc 6 Press All the new calculated POS data will be generated into the table 7 Moving the cursor to the next wanted 1 cavity No of next wanted pattern block 8 Repeating the same procedures 3 6 9 Ensuring the programmed cavities POS NR Z POS are correct press wy to finish pattern editing Press 5 to run the pattern sparking Applicable Software VER P DAK II 35 Issue JUNE 05 UK PATTERN PNC F4 PATTERN MODE F4 gt PATTERN gt POS X Y Z
31. a hoisting belt to thread through two rings on the top of power supply unit See Pic 2 Weight 150 Kgs gt E uipment for Loading Crane or Lifter with loading capacity of 200KG or above Steel Wire Pic 2 With Hooks Issue JUNE 05 UK I 9 2 ecommended Loading methods for complete Machine sing Nylon elts See Pic 3 Procedures 1 Move the tank to the end of Axis 2 See the Pic 3 Nylon belts hang on steel rings on machine body and hooked on the crane Machine must be well balanced amp stable 3 Avoid amp Protect the elts touching the surface paint of machine body 4 Lift up amp Move to correct site Caution for all the movements gt Keep the balance of machine gt Avoid Any Impact Weight 1500 Kgs E uipment for Moving Pic 3 Crane Loading capacity of 1700Kg above Steel Wire 5M 2 3 Moving method by ork Lift Truck See Pic 4 Procedures 1 Move the tank to the end of Axis 2 Adust the forks of fork lift truck to a suitable width 3 Drive the fork lift truck in the centre direction of machine body the forks must be longer than the bottom of the machine body 4 Protect the surface paint of machine body 5 Lift the machine up to the suitable height Caution for the stability amp balance of machine body Move to the installed site gt or all the moving procedures The balance of machine body must be and
32. agement ualified Standardization Management I 17 Issue JUNE 05 UK PC Based EDM System User Manual Applicable Software VER P D4K 1 Issue JUNE 05 UK 1 Cabinet Layout 1 JD 50 Applicable Software VER P D4K II 2 Issue JUNE 05 UK F1 F2 F3 Layout of Operating Screen MODE MANUAL PROBE SPK EDT PATTERN RUN AUX SET SAVE FILE EDT POS X Y Z ENT MARK ALL MARK ONE MARK INS MARK DEL DATA SET INC DATA DATA INC AUTO CAV FUNCTION HOME AXIS DATUM OB CEN MP SET SURFACE SPK TCH AXIS CEN CAVE CEN CORNER SIDE CEN AXIS POS 1 2 INS DEL BLK STOP COD SAVE Program Run Sparking Auxiliary Condition setting Saving current system data COD EDIT TIME SET PGM DIR PGM DEL PGM COPY LODE Applicable Software VER P DAK Move all Axes to Ref position Move X Y Z Axes to new position Working Data setting 1 20 sets of datum can be set ORBIT Head Auto Centring Option Machine parameter setting Should only be changed by experienced service engineer Probing 3 axes surface Datum
33. ctrode Manual traverse in X direction u Z Electrode Manual traverse in X direction CN Electrode Manual traverse in direction KA Electrode Manual traverse in Y direction Feed rate override for Manual traverse Emergency Stop Button Disable Power not including Power for PC C Ce RE c fe Applicable Software VER P DAK II 12 Issue JUNE 05 UK 2 After Start Up succeeded PC shows the above Main Menu oystem is operational for the following functions 1 Manual Traverse 1 Press one of the Axis keys Z Z X X Y Y on Remote Control Box to move Axis 2 Feed rate override the Remote Control Box shown on PC Monitor JOG FEED 3 System has SHORT security feature Axis moving inhibited when Short occurs Press the STOP button on Remote Control Box to disable the SHORT security feature with one of the Axis keys to move out of Short Be careful to press the correct Axis key when a Short has occurred 2 Preset position coordinate XorYorZ or Number ENT 3 Do the Sparking job 1 Press F5 Function key RUN or START button on Remote Control Box to Run the Last Program to Spark Ensure that the Position data is correct 2 Sparking job can be interrupted by STOP button on Remote Control Box Applicable Software VER P DAK II 13 Issue JUNE 05 UK 8 Operating Mode 8 1 Menu Applicable Software VER P
34. e and dirt Service or installation of this machine must be performed by ualified personnel only ollow procedures described in the operating manuals Turn off and lock out power at the main electrical panel before servicing This machine should be situated at least 3 Metres from other e uipment Make sure all the electrical components are securely grounded The work environment must have ade uate ambient lighting over 500 lux Keep the area moderately ventilated the area should be fitted with an extraction system The waste should be handled in accordance to the environmental safety regulations of the local authority and relevant international provisions Metal connection of external device such as filter system fume exhaust system passing through the shielding of the e uipment shall be electrically bonding to the shield in case of connection to a protruding cap this bonding is not necessary This machine may interfere with radio broadcast e uipment If you have any problems about the safe operation of the machine refer to your supervisor immediately or consult LIMITED 1 16 Issue JUNE 05 UK 11 Structure of Quality Management Documentary Management Personnel Education amp Training Testing E uipment Management ualified ualified c O O 8 D 5 U U Q A e 2 A Environmental Management Production Assembling uality Document Man
35. eel Electrode Steel 300 301 302 303 304 305 306 307 309 Applicable Software VER P DAK Reserved II 51 Issue JUNE 05 UK F8 2 FILE EDT 2 F4 TIME SE 4 TIME control enable amp SET timer In addition to Depth control we also can enable the TIME CONTROL to finish the machining 1 SET TIMER shown above programming table at right side when TIME CTL enabled 2 When the last block of program be executed program completed due to Depth reached or Set Timer runs out dependant on which one comes first 3 Then Z Up or not according to END UP of AUX SET to finish sparking program TIME SET Applicable Software VER P D4K II 52 Issue JUNE 05 UK F8 gt FILE EDT gt F5 DIR FS ProGraM DIRectory J NN roma mara NN Applicable Software VER P D4K II 53 Issue JUNE 05 UK F8 gt FILE EDT gt F6 PGM DEL F6 ProGraM DELete DELETE PGM NR key in PGM_NR Applicable Software VER P D4K II 54 Issue JUNE 05 UK F8 2 FILE EDT 2 F7 PGM COP 27 ProGraM COPY Copy from an existing source program to a new target program SOURCE PGM NR Key in Source PGM Nr then ENT TARGET PGM NR Key in Target PGM Nr then ENT Applicable Software VER P DAK II 55 Issue JUNE 05 UK III PC ased EDM System Program lable Sparking Copper Steel ROUGHNESS umRa E HE NE ia ow m aa olas 28 14 09 2
36. h PC anti arcing Gap control not stable signal processing Sparking On but Electrode up not down Poor Sparking stability oparking Codes output Easy arcing oparking oscillator Always arcing Equivalent sparking control Wrong spark decodes Anti arcing control Wrong sparking current Sparking On but electrode up not down Searing HV output O 7A No HV output P 9 5 931 LV output 0 64A LV output not normal Output Always arcing Mother board of Sparking No sparking current Module Sparking On but oignals transferring electrode up not down Power for driver no moving Spark decoding Oscillating signal PDC9348 for sparking Signals Transfer PBS938 H 12 for HV L 12 for LV S 12 for Servo OSVCC for OSCillator DC Servo Motor Driver Servo Motor no moving Drive Unit Servo driver MDR 680 DCV 36 150 Motor burned out IV 2 Issue JUNE 05 UK Resistors for each Limiting sparking current Sparking Power Servo Power Portable line control box 2 PCbasic set up 60A 120A 180 A 250A 120 75 1504 H280 5A MVCC 10A 80V 140V 1 CMOS BIOS set up Mains Switch ON press key entering CMOS BIOS set up A Disable A D Diskette B The others same as normal PC set up RPR 64 Power Resistor Resistor broken Modules sparking current lower 120 180 250 320 A than command For Low Voltage cur
37. ho or Servo Drive MDR 680 fail 2 PC Module fails 3 Path of Tacho TG of Servo Motor TG of Motor SK7 8 9 PSE TB1 XMDR CN1 2 7 3 8 Easy arcing or always arcing After Power for Sparking and Servo Sparking On not initiated yet About 120V showed on V Meter It s not normal PCB PSP931 of Sparking Module is defective After Power ON for Sparking and Servo Sparking On not initiated yet About 12V showed on V Meter O K Possible causes 1 Wrong sparking codes setting Too big of Ton or too small of Toff or GAP 2 PCB PDC9348 of Sparking Module is defective IV 7 Issue JUNE 05 UK 3 9 Executing Sparking On Electrode moves up instead of down for machining oparking On initiated no touch yet between electrode and workpiece No voltage exists on Volt Meter or smaller than 120V Electrode moves up instead of down for machining No Volts or not high enough V meter after Sparking On Wrong Sparking Codes 1 LV 0 HV 0 so no voltage out Electrode up 2 SERVO too low UPD too big WT too small Power fault 1 Volt of LV 120V Volt of DC 280V 2 After POWER ON Measuring Electrode with OV at LO PSP931 TB3 it should be 120V with OV at PSP931 TB1 7 it should be 280V 3 If not check Fuse Mains voltage and phase could be voltage too low or phase missing 4 No OSC signal PDC9348 PCB of Spa
38. le rubber strips Metals and dielectric fluid errous metals Copper ronze and brass arious In this way all materials can be eliminated correctly recycled or melted down for re use or disposed of so that they do not harm the environment 9 Operator Position AC POWER Power Filtering E D M I 15 Issue JUNE 05 UK 10 Safety Instructions 10 1 10 2 10 3 10 4 10 5 10 10 7 10 10 10 10 10 11 10 12 10 13 10 14 10 15 10 1 10 17 10 1 This machine should only be operated by properly trained persons The operator must read understand and follow all instructions and warnings Do not remove the machine signs CE marking nameplates fixed on the machine This machine should not be operated by anyone fitted with a pacemaker Always check the sparking power is off before touching the workpiece or electrode Operators should wear safety glasses safety shoes and should remove rings watches ewellery and loose fitting clothing for their own protection while operating the machine The machine should not be operated in a potential explosive surrounding Always clamp the work piece and electrode securely The safe level of dielectric fluid is a minimum of 40 mm above highest discharge to prevent fire efore starting the machine the fire sensor head should be pointed towards the sparking position and a maximum of 20cm from it Maintenance area should be kept free from obstructions greas
39. lower wear ratio used for deeper machining L Every 10 steps with same LV amp different wear ratio 12A LV with different wear ratio L gt 1st digit bigger number bigger gap lower wear ratio used for deeper machining L gt Every 5 steps with same LV with different wear ratio 15A LV with different wear ratio 20A LV with different wear ratio 25A LV with different wear ratio 30A LV with different wear ratio 35A LV with different wear ratio 40A LV with different wear ratio 45A LV with different wear ratio 50A LV with different wear ratio 55A LV with different wear ratio 60A LV with different wear ratio Reserved e Graphite Electrode Steel 1 10A LV with different wear ratio 15A LV with different wear ratio 20A LV with different wear ratio 25A LV with different wear ratio 30A LV with different wear ratio 35A LV with different wear ratio 40A LV with different wear ratio 45A LV with different wear ratio 50A LV with different wear ratio 55A LV with different wear ratio 60A LV with different wear ratio Reserved 5A LV 10A LV 20A LV 30A LV 40A LV LV 60A LV 110 114 115 119 120 124 125 129 130 134 135 139 140 144 145 149 150 154 155 159 160 164 165 199 200 209 210 214 215 219 220 224 225 229 230 234 235 239 240 244 245 249 250 254 255 259 260 264 265 299 St
40. mm3 min 25 2 250 25 e o 90 14 1 7 _ III 6 Issue JUNE 05 UK Copper Steel LV Toff GAP V ROUGHNESS TWO GAP WEAR RATIO SPEED A A us us Se umRa 2xGAP mm 06 mm3 min EIESEQEQE RE e os er so os 18 27 3512 20 t 103 036 14 272 _ 35 2 so so 121 08 263 35 2 450 40 40 42 124 258 LV HV Ton Toff GAPV ROUGHNESS TWO GAP WEAR RATIO SPEED rao 2 200 20 9 032 29 40 2 250 20 o t 96 034 2 19 1 042 35 HI 7 Issue JUNE 05 UK Copper Steel LV Toff GAPV ROUGHNESS TWO GAP WEAR RATIO SPEED A A US US V n u mRa 2xGAP mm 06 mm3 min 45 3 0 9 336 4s 2 600 23 40 44 164 049 02 32 US US V u mRa 2xGAP mm 06 mm3 min o0 2 350 22 40 43 11 8 0 39 1 3 391 2 400 19 129 09 386 A so 2 feo 21 s 02 364 LV HV Ton GAPV e ROUGHNESS TWO GAP WEAR RATIO SPEED A A US US V umRa 2xGAP mm 06 mm3 min 55 2 450 40 43 194 042 09 42 2 5 049 40 10 III 8 Issue JUNE 05 UK Copper Steel SPEED TWO GAP WEAR RATIO 2xGAP mm ROUGHNESS LV A VDI A us us V 60 2 400 40 40 43 60 2 450 40 40 44 60 2 500 40 40
41. n bigger spark quicker bigger gap but rougher omaller HV then smaller spark slower smaller gap better surface finish 3 Enter value directly or use keys to fetch data 4 Application 1 Working with LV 2 HV only with Positive Discharge for fine finish 3 only with Negative Discharge for fine finish 5 duty of Sparking cycle 1 Range 1 2000us divided into 48steps 2 Comparing with constant LV command Bigger Ton then rougher finish bigger gap lower wear ratio omaller Ton then better finish smaller gap higher wear ratio 3 Ton set by pressing keys to fetch data 6 Toff OFF duty of Sparking cycle 1 Range 1 255 us real data display 2 Comparing with constant LV amp Ton commands Smaller Toff then quicker but debris removal not easy Bigger Toff then slower but debris removal easier 3 Enter value directly or use keys to fetch data Applicable Software VER P D4K II 28 Issue JUNE 05 UK SPK EDT Caution There is a rough formula between Ton vs LV for good sparking performance Copper gt Steel Rough eroding Low wear ratio Ton LV about 30 Medium eroding medium wear Ton LV about 20 25 Finish eroding higher wear Ton LV about 10 15 Suggesting table between LV amp Ton for lower Copper electrode wear ratio 2 3 4 5 6 7 8 9 0 30 60 90 125 150 175 200 200 250 _20_ 600 650 650 700 750 750
42. ng the existing program from Memory 2 DEPTH 10 ENT 3 START or RUN Start Sparking 2 DEPTH Sparking depth command Range 999 999 oparking up be possible when Depth command higher than current WORK POS Total block Nr in program calculated by itself 4 DIRECTION Sparking direction defaulted 5 AXIS Sparking Axis all of X Y Z be available for PNC Z only for ZNC Applicable Software VER P D4K II 27 Issue JUNE 05 UK sce ERODING TABLE 1 DEPTH Depth command for each block of program All the depth commands must be logical F3 SPK_EDT 2 CODE oparking code command Sparking codes stored in buffer memory The contents can be modified when spark is off Using the key to search code or enter the code Nr directly e Please refer to the COD EDIT 3 LV Low Voltage Current command Standard range 0 64 A 1 Can be modified only when spark is off 2 Bigger LV then bigger spark quicker bigger gap but rougher omaller LV then smaller spark slower smaller gap better surface finish Caution When large LV is set the security must be paid attention to especially Flame Dielectric Level and Dielectric Temperature 3 Only when matched well with Ton amp Toff better working efficiency will be achieved 4 Enter value directly or use keys to fetch data 4 HV High Voltage Current 1 Range 0 7 2 Bigger HV the
43. o 0 00 only Each delivery of oil is amounted to 2c c Seal the grease tank and keep it clean Refill from gun only never refill from the top of reservoir The tank capacity is 650c c Average flow pressure is 100kgf cm IV 11 Issue JUNE 05 UK 102 666L p112100 30uy WYsIAdOI ZE L69L Z8E IVA 55 ay Je paajsisay GG098S9 Auedwod 9 8 8 AUedwod e si 39U493U 5 5 3 GEZOLZ SZSLO LOZOLZ SZSLO 1 202 sixes pue 8u3 speg pJezzng Kinginos peoy 15 HUN Q112 UOc20UV 20 25 foue3 nsuo e3IAJ9S 12e43002 qns pue 5 Sui up ou pews x uiuos 01 dn Sunino BdIAJVS 120J1002 qnS WGI 211M 126431002 qns IDF 12e43u02 qns WDF 9 WGI DND SapoJ329 3 pue 53 INQ Jo 5 9 eum ejnueyv uSiseq 20 25 5 1934 gt IND3 s ulype y 2 420432913 JO 9 815 X X 0062 03 dn 01 DND 9 Jenue A SeuludeW eSJeupsiq 21329 3
44. on Working Speed MATERIAL For Future Use ROTARY T For Rotary Indexer option ON Signals to amp from Rotary Indexer OFF Normal PNC Operation F7 Save Mode Save the current machining data into buffer memory before power turned off Applicable Software VER P D4K II 48 Issue JUNE 05 UK F8 FILE EDI Mode Sparking FILE EdiTing Mode COD EDIT CObDes Eroding Table Editing F4 TIME SET TIME control enable SET timer FS PGM DIR ProGraM DlRectory Fe PGM DEL ProGraM DELete FZ PGM COPY ProGraM COPY Applicable Software VER P D4K II 49 Issue JUNE 05 UK F8 2 FILE EDT gt COD EDI CODes EDITing Eroding Table Editing J ee ee eee Ld We offer an Eroding Table Data Base for your reference to choose for working You can optimize its contents or setup your own combination be a new code for your specific application We suggest you divide the codes into groups according to material amp LV for easier recall CODE range 001 499 according to material 001 199 Copper Electrode Steel 200 299 Graphite Electrode Steel 300 309 Steel Electrode Steel 310 319 Copper Electrode Tungsten 320 499 Reserved for Users Applicable Software VER P D4K II 50 Issue JUNE 05 UK Copper Electrode Steel 001 009 010 109 HV 1 9 LV L gt 1st digit bigger number bigger gap
45. on can then be pressed to continue sparking OIL TEMP Indicator for Oil Over Temperature am O Indicator for Oil Level Low CH Flame Supervision ON OFF button 1 Flame detection during sparking 2 Enabled automatically after system Start up 3 Sparking turned OFF as soon as alarm occurs 4 Alarm Indicator ON amp Buzzer indicating alarm 5 After alarm problem is cleared press ENT key to clear alarm START button can then be pressed to continue sparking O Indicator for flame Detection CH FREMONTOR Arcing Supervision ON OFF button 1 Arc detection during sparking 2 Enabled automatically after system Start up 3 Sparking turned OFF as soon as alarm occurs 4 Alarm Indicator ON amp Buzzer indicating alarm 5 After alarm problem is cleared press ENT key to clear alarm START button can then be pressed to continue sparking YN ARCING Q Indicator for Arc Detection Applicable Software VER P DAK II 7 Issue JUNE 05 UK Electrode Alignment button Short Detection Disable This function works only in PROBE Mode Be careful when traversing axes with this function be activated there will be NO Short Detection Dielectric Pump Manual ON OFF button Synchronized Flushing ON OFF button Pulsed Flushing when electrode jumps back in Auto Jump cycle Timer Better for reducing electrode wear Automatic Power Off button Sparking amp Servo Power turned O
46. ories Optional Accessories Paper ilter Auto ire Extinguisher Electrode Holder Dielectric Cooler lushing Nozzles Permanent Magnetic Table Drill Chuck system 3 Tooling Clamping Kits Tool ox Working Lamp I 7 Issue JUNE 05 UK 9 Packing Transportation Wooden case Disassembling amp Lifting 5 1 The E D M machine is packed in a standard export wooden case it must be handled carefully without dropping or tipping the machine Care must be taken during transportation 5 2 Detailed Checks on the unloaded Wooden Case Please first check the outside of the wooden case as soon as you receive it If you find any damage or have any queries notify us or our agents immediately before you unpack the wooden case Please do not place the packed machine outdoors without suitable protection to prevent accidental damage or the absorption of moisture 5 3 Wooden Case Disassembling Procedures Shown as Pic 1 Please read the following procedure and see the figure shown below 1 the upper cover first gt 2 the side covers of front amp rear machine part gt 3 emove the other two side covers gt 4 emove the locking bolts on the base of the case LF URL 25 Tools needed Nail emover Hammer Pic 1 Ad ustable Wrench Gloves I 8 Issue JUNE 05 UK 5 4 Load amp nload 1 POWE S PPL NIT Transportation recommendation power supply unit only sing
47. rent No LV or HV sparking For High Voltage current current output For Servo driver power No servo motion Manual Jog with potential key function Sparking Start Stop Security I O Supervision not normal Linear scale signals driver Position counting fault Axis run away 2 Set Up of Linear Scales for different specification Mains switch ON before system initiation press ESC key Monitor displays A gt For PNC with Scale 0 001mm type gt X1 then ENT key For PNC with Scale 0 005mm type X5 then ENT key For ZNC with Scale 0 001mm type Z1 then ENT key For ZNC with Scale 0 005mm Z5 then ENT key Mains Switch OFF and ON again it will work IV 3 Issue JUNE 05 UK 3 Fault Finding 3 1 Mains ON no Display on CRT Panel Indicating LEDs lit gt Fuse blown NO Missing or faulty Mains voltage input Power cable loosened or Phase missing CRT Fault Checked with another CRT replacement to know CRT or not PC Module Fault 1 PC Power Supply 2 Main Board 3 2 Power ON sequence Mains switch turned ON PC will be ON together PC start self diagnosing If shows KEYBOARD ERROR OR NO KEYBOARD PRESENT 1 Cable of keyboard not connected 2 Keyboard fail CMOS BIOS SET UP DISK BOOT FAILURE INSERT SYSTEM DISK AND PRESS ENTER 1 CMOS BIOS not matching y Please set up CMOS BIOS again 2 R
48. rking Module fail No Servo signal output V meter should higher than 120V SVO data on CRT greater than 125 after Sparking On and before real sparking happens If SVO data on CRT 125 then it could be 1 Sparking Wires be short 2 Feedback of Sparking Voltage missing 3 PPC9540 PCB of Sparking Module fault Wrong Servo output Volt display on V meter higher than 120V after oparking On SVO display on CRT gt 125 then it could be PMC 620 PCB of PC Module fail 4 Electrode moves up after Sparking On initiated Press to start sparking No voltage on V meter electrode moves up 4 1 Monitoring problem Please turn off monitoring then run sparking again If Sparking On O K please eliminate the monitored security problem Otherwise go to next step Preset sparking codes as follows then try again IV 8 Issue JUNE 05 UK 4 2 Please input new codes for testing PGM 106 DEPTH 1 000 P BLK 6 DINECTION AXIS Z DEPTH CODE LV GAP SPD WT TIME CTL 1 5 000 068 6 2 1175 40 2 8 4 8 00 00 00 0 If Sparking problem solved please pay attention to your sparking codes editing next time Otherwise check next step 4 3 Power supply voltage problem Please check local power supply voltage specification wiring and input are all correct Please check voltage between each line L1 L2 L3 gt L11 L22 L23 131 L32 L33 41 L42 L
49. ssue JUNE 05 UK F2 gt F6 PROBE gt SIDE_CEN 9 Manual traverse electrode to the rough centre above the work piece Press F6 SIDE CEN Procedures 1 X PROBING DISTANCE Enter the X width electrode radius 10 safety clearance 2 Y PROBING DISTANCE Enter the Y width electrode radius 10 safety clearance 3 ZUP DISTANCE Down Distance of Z axis for probing 4 O DATUM 1 200 RANDOM SET Reset 0 Probing point 0 Preset 1 200 The probing data will be transferred to the corresponding pos data of pos table of the Pattern gt RUN Press F5 to start probing cycle Press START to increase probing speed Applicable Software VER P DAK II 25 Issue JUNE 05 UK SIDE CEN PNC F22F6 PROBEDSIDE After SIDE CEN is finished display shows XCEN YCEN Preset new data or Reset 0 press to finish the probing cycle Applicable Software VER P D4K II 26 Issue JUNE 05 UK SPK EDT Sparking PGM Editing Mode SPK ED e Move the cursor to somewhere of program format to preset new data 1 Program Number 1 9999 Existing suggesting Program Nr in Buffer Memory 1001 1025 Copper Steel 1A 25A 2001 2060 Graphite Steel 60A Entering the existing program for the wanted Current Code and Depth command the program can then be run For instance from rough to fine finish 10 MM Depth Copper oteel 1 PGM 1006 ENT loadi
50. to the electrical box emove the filter tray on the left side and pour the dielectric oil into the tank gt 7 Turn on the Electrical Supply irst confirm all the cables and wires are correctly connected gt Switch on the main power on the Power Supply nit start operating 7 Operation amp Adjustment 7 1 Confirm the moving value amp direction of linear scale is correct gt Turn the main power switch on Press 1 T monitor only DO NOT press the Power On utton gt Turn the motor manually Check the moving value amp direction of the coordinates To TEER m m 25 400 Coordinate l k 10 7 2 Turn the power ON Caution be ready to press O to avoid sudden axis running gt efore press ON move the Z axis to the centre of Linear scale to prevent the sudden axis running causing machine or other e uipments damaged If sudden axis running happens check the motor TG amp the power supply of the axis is correctly connected 7 3 sing the remote control box to move Z axis check the direction of moving correct or not Check the limit sensors Z axes and emergency stop button I 13 Issue JUNE 05 UK 74 remote control box to move the axis check the speeding stability of the axis amp the overloading of motor When overloading occurs during axis moving and causes electricity turn off ad ust the SPEED knobs on the driver See Pic 11 Z axis LH
51. ue JUNE 05 UK AXIS CEN PNC F4 PATTERN MODE 8 Press PATTERN for multi cavity editing key in the sub program Number now you can set up max 20 sets of multi cavity pattern forms and be stored in memory Pressing ENT key to enter PATTERN programming menu to start editing For multi cavity sparking editing the Sparking Codes and Depth F4 to edit the multi cavity sparking position pattern and sparking types There are some fixed patterns available AUTO After pattern editing finished press back to previous page Press 5 to run the multi cavity sparking 4 4 oh N 2 Applicable Software VER P D4K II 32 Issue JUNE 05 UK PATTERN PNC PATTERN MODE 1 Follow the dialogue to edit the Pattern mode 2 The POS table of pattern Max 200 POS will be positioning amp sparking Caution When sparking Z POS in the pattern POS table is the start sparking point and the DEPTH in Sparking PGM will be the distance to spark Incremental 4 The POS table can be random editing or edited by AUTO into fixed pattern 5 gt Press for fiked pattern POS editing 6 The multi cavity sparking is available on different planes as follows Applicable Software VER P D4K II 33 Issue JUNE 05 UK PNC F4 PATTERN MODE POS H1 LABEL HR 81 0 000 7 a 8 Y 0 ji 000 H HHH DISTANCE
52. witch Isolator With this switch ON the PC be ON Power ON Button Power Enable After the PC has booted press to enable Sparking Power and Servo Power OFF Power OFF Button oparking Power amp Servo Power are turned off when the IS pressed Applicable Software VER P DAK II 5 Issue JUNE 05 UK 5 System indicator on Panel MAIN POWER C L 4 OILTEMP XAXIS LIMIT OIL LEVEL 24 S 2 YAXIS LIMIT 3 4 FRENONTOR ZAXIS 4 ARCING EMERGENCY POL 24 S SYSTEM O C ERODNG _ W YN After the Main Power Switch is turned ON system supervision starts working X AXIS LIMIT Z Axis L S not touched EMERGENCY Emergency Stop SYSTEM PC Ready Caution If any one of the above Green indicators are OFF then Power Enable will fail OIL TEMP Dielectric Temperature High OFF f ON then Sparking OFF OILLEVEL Dielectric Level Low OFF If ON then Sparking OFF Applicable Software VER P DAK II 6 Issue JUNE 05 UK Aux Function ON OFF on Pane Dielectric Level amp Temperature Supervision ON OFF 1 Securing dielectric level amp Temperature during sparking 2 Enabled automatically after system Start up 3 Sparking turned OFF as soon as alarm occurs 4 Alarm Indicator ON amp Buzzer operates indicating alarm 5 After alarm problem is cleared press ENT key to clear alarm START butt

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