DK77 WEDM

OPERATION MANUAL

Suzhou Baoma Numerical Control Equipment Co., LTD

The People’s Republic of China
 Attention items
Thank you very much for purchasing our WEDM.
Before using the machine, please make sure to read the operation manual. Also keep
the safety items in mind.

: Wrong operation can cause to danger!

: Equipement or wire that is possible to make operator get a electric shock!

: Do not touch molybdenum wire when it running, which can hurt your
hands!

: AC power supply, be careful to get a electric shock! Do not

opern it without professional!

Machine attention symbols:

The attention symbol is put on the

up and down component, which
used on big tapper WEDM, the Z
axis driven by motor.
The attention symbol is put on the up
and down component, which used on
small tapper WEDM, the Z axis driven
by hand.

The attention symbol is put on the up

and down component, which used on
small tapper WEDM, the Z axis driven
by motor.

The attention symbol is put on

waterproof polymethy cover on working
table.
Attentions about operation:
 Make sure that the power supply is same as nameplate on the control cabinet.
 Make sure to cut off general power supply, then connect the input wire in control
cabinet to avoid to shock.
 Make sure to setup a non fusible circuit breaker (NFB) to prevent fire.
 Make sure the ground wire connect with ground to prevent from shocking.
 Do not make wire without professional.
 Installation the machine body first then make wire.
 Do not operate machine with wet hands. Even the machine is stop, please don’t open
the cabinet door.
 Do not touch the molybdenum wire and working table at same time.
 Do not touch the molybdenum wire when it’s running.
 Do not take away the waterproof cover on wire-winding drum, when it’s working.
 Any checking should be carried on after power supply switch off five minutes.
 maintenance and repair machine on expert’s instructions. Do not rebuild it.

Working condition:
<1> Climate condition
The temperature should be 2020±5℃; The relative humidity should be 40% to 80%;
The aire pressure should be 86 to 106 kPa.
<2> Power source condition
The fluctuant range of AC power net should be +10% to –10%.
<3> Other condition
It should be set dust proofing, no hard vibration or impact, no chemical pollution.

Disposal of machining waste:

<1> Working liquid
It should be collected in a center, pour into cement-pool then make it air-dry. The deposit
should be managed as industry rubbish.
<2> Molybdenum wire
Recycle it.

Please read the operation manual clearly, also check goods with the packing
list!
 CONTENTS

1. Machine functions and applications ……………………………………… 1

2. Technical specifications …………………………………………………… 1

3. Machine structure ……………………………………………………….… 2

4. Driving system ……………………………………………………………… 3

5. Controller ……………………………………………..……………………. 4

6. The pulse power supply ……………………………………………………. 15

7. Transportation……………………………………………………………… 17

8. Installation ………………………………………………………………..… 18

9. Adjustment …………………………………………………………………. 20

10. Operation ……………………………………………………………….…. 22

11. About the usage of wire guider………………………………………….…. 26

12. Usual problem and solution ……………………………………………… 28

13. Maintenance ………………………………………………………………… 32

14. Consumable component catalogue ………………………………………… 33

15. About mchining parameters choosing …………………………………… 34

Appendix:

The list of gears, screws, nuts, bearings and motors and lubrication…....…… 40

The principle figures about machine and electric, lubricating points..……….. 46

About the groundwork configuration see to interleaf pls.

1. Machine functions and applications
Under the control of the CNC, the machine that depended on the electrode wire and
high frequency supply cuts the workpiece according to the preparative scheduled track.
The machine is designed by CAE. The structure is reasonable and the performance is
predominant. Its rigidity is good, cutting force is low, movement is smooth, and
manipulation is safe and reliable.
The machine is fit for machining the metal molds of high precision, high hardness,
high tenacity and complex-shape parts, especially stamping molds, die molds, plastic
molds, roll gear tools and up-down differ-shape parts. The machine is a new
production of WEDM. It is applied widely in the fields of machine industry, vehicle
industry, aviation industry, home appliance, war industry, electron industry etc. And
now it is a very important machine tool in manufacture fields.

2. Technical specifications

1. Working table travel mm ×

2. Working table dimension mm ×
3. Max. Machining thickness mm
4. Max. Taper angle (Thickness<100mm)
5. Mo. Wire diameter mm φ0.15~φ0.2
6. Max. Productivity ( Material: Cr12, Quench,40mm) >100mm2/min
7. The best surface rough μm
(Material: Cr12, Quench,40mm;
once cutting& productivity=30 mm2/min) Ra≤2.5
(Material: Cr12, Quench,40mm;
several times cutting& productivity=40 mm2/min) Ra≤1.2
8. Machining precise ( Material: Cr12, Quench, φ12×40mm)
• Roundness (Below Dk7780 ≤0.015; Above Dk77100 ≤0.03)
• Taper (6°WEDM ≤0.04; 30°, 60°WEDM ≤0.10)
9. Working table movement vector mm
10. Working table repeat position precision mm
11. Working table position precision
Portrait mm
Transverse mm
12. Max. Workpiece weight Kg
13. Power Kw 2
14. Machine figure mm × ×
15. Machine weight Kg
16. Power supply 3N-380V/50HZ
17. Machine noise Db ≤80dB

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3. Machine structure
The machine is composed of the mechanism component, electric controller and
coolant system.
The mechanism component is consisted of machine body, working table, wire guide
frame, taper cutting mechanism, wire traveling unit, working tank, fixture, water-
repellent cover and coolant system etc. The linear roller guide ways and the super
high precious ball screws are applied in the machine type below DK7750 (also
including DK7750). One the other hand, the linear ball guide ways and the super high
precious ball screws are applied in the machine type above DK7763.
The span of the wire guide frame is adjustable to different type machine and the guide
wheels are designed to double-support structure.
① The machine body
The material of the cast is HT250, which makes the machine body has high load
intensity and the ability to resist distortion. The vibration-resisted stow-irons are used
in the connection of the machine body and groundwork. The installation and
adjustment are convenience. The up saddle and the middle saddle are set on the top of
the machine body, which are driven by X and Y ball screws.
② The wire traveling unit and the wire guide frame
The to-and-fro rotation of the wire-winding drum drives the electrode wire
reciprocating running. At the same time, the guide wheels and the wire let wheels
keep the movement of the electrode wire smoothly. The top and bottom electrified
blocks are used for electrifying, but if needed we also can use wire-winding drum to
realize electrifying.
③ The taper cutting mechanism
It’s driven by two step motors to realize U and V movement, which can make the
machine accomplish 4 axis (X, Y, U, V) motion together. And according to the taper
cutting mechanism, the machine can execute taper machining.
④ The working table
There, the fixtures are fixed on the working table with T-shape slots i.e. the up saddle.
⑤ The coolant system
The coolant system is composed of water tank, the working fluid, the flux valves, the
pipe unit and the fine filter unit which can make the working fluid used recently. The
working fluid is very important to the machining, that is to say, it can affect the
stability of machining and the surface quality of the machining workpiece. So you
should change the working fluid after a period, when it’s dirty and ropy. When the
pressure meter value is above 0.2Mpa, it suggest you should change the filter core.
⑥ The fixture and the spare part
• About the fixture:
The pane fixtures are only for below type DK7750 WEDM and the shape
fixtures are used on the others type WEDM.
• About the spare part:
There is assembly and disassembly components, wire tighten components,
bearing disassembly tools and the rotating handle in the spare part box.

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4. Driving system
The driving system is consisted by the working table driving system, the wire
traveling system and the taper driving system.
① The working table driving system (See to figure 4-1)
X direction:
The control system sends out a movement pulse → The step motor Q → The
gears mate 23/24 → The ball screw 13 → The nut 14 drives the saddle to move.
Y direction:
The control system sends out a movement pulse → The step motor P → The
gears mate 11/12 → The ball screw 16 → The nut 15 drives the saddle to move.

② The wire traveling system (See to figure 4-2)

Motor M → The coupling → Rotation of the wire winding drum → The gear
mate 17/18 → The gear mate 19/20 → The screw22 → The nut 21 drives the
saddle of the wire winding drum to move to-and-fro.
③ The taper driving system (See to figure 4-3)
U direction:
The control system sends out a movement pulse → The step motor E → The
gear mate 10/9 → The screw 5 → The nut 4 drives the U saddle to move.
V direction:
The control system sends out a movement pulse → The step motor B → The
gear mate 6/8 → The screw 7 → The nut 3 drives the V saddle to move.
④ The up-arm driving system
Manual or Motor driving → The worm → The worm wheels mate → The screw
→ driving the up-arm move up and down to change the span.

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5. Controller

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5
 The controller figure
(Pls. refer to the actual controller if technology update)

The machine electric, the NC system and the pulse supply are integrated an
integer in the controller box. All the function can be realized by Auto Cut
program and control system. Details about the function, operation and usage of
Auto Cut, please read the operation manual of “Auto Cut program and control
system”.
5.1 About XKG-2008 control system.
The electrical discharge machining happened between the electrode (which normally
is Molybdenum wire or Tungsten and Molybdenum alloy wire) and the workpiece by
using of the high frequency impulse power supply and the high peak current to bring
high heat and high energy to erode the workpiece.

BMW-2008 Wire cut EDM controller is a new and predominant controller, which
Develop Designed and Researched by our company. All the function and performance
is as good as XKG-2005 and the intelligentize and the convenience have been
improved remarkably, which is leader in this line.

The transducer control wire cutting directly in XKG-2005 WEDM Control system to
realize balance and stability for the changing direction of wire-winding drum, also
reduce the problem of control unit to improve the performance of WEDM.
All the function and operation can be realized in the software, which reduce the
possibility of the hardware broken and easy to be repaired. The program and control
system for BMW-2008 is Auto Cut can be run in any edition of Windows XP. The
installation, maintenance and usage is very easy and convenient. AutoCAD, CAXA
can be used directly in this system, realized the Integration CAD/CAM. This control
system support the multi-card control in one computer and multi-machine can be
controlled by one computer.

BMW-2008component

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There are some circuit elements in WEDM software interface card. For example, the
X,Y,U,V axis step motor interface circuit , high frequency pulse output control circuit,
high frequency sampling input circuit, auto-pause on machining over output circuit
and parameters chosen circuit.

X, Y, U, V Step motor drive board

The driving circuit of X, Y, U, V motor are disposed of the dictates that come from
“WEDM circuit board” control card to display the message in LED and to drive the
motors to run.
It adopted a new energy saving control method. Comparing with traditional method,
the utilization rate has been improved dramatically and the broken rate has been
reduced. Besides, the direction change for the wire-winding drum, the speed control
for the transducer, Turn on/off the wire-winding drum, Center finding, Alarm for
failure .

High Frequency Board

High Frequency board used for amplifying the pulse high frequency signal,which
comes out from Connection control Card. Besides, the High Frequency Board can
protect the wire-winding drum.

Power board

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The power board is used for supplying the power for cutting and control the relay for
pump, low/high voltage, and high frequency.

Power supply board is used for supplying the voltage DC12V.

About the failure prompt

When wire broken is happened during machining, Auto Cut system can switch off the
wire traveling motor, the water pump and the high-frequency power supply; and then
send a warning alarm. At this time, there is a failure prompt flashing on the VGA
display, only because the controller system can’t receive the sampling message and
retreat it as a short circuit happening. On the other hand, you should solve the
corresponding problem at once. When machining is over, the controller can also
switch off the wire traveling motor, the water pump and the high-frequency power
supply and wait the next dictate.

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5.2 About the control panel

A—Emergency stop button B—Voltage meter C—Current meter

D—Touch button E—Power on button F—Digital display G--Display

5.3 About the electrical controller operation

<1> About power supply

The electrical cabinet is connected with 3-Phase AC 380V/50HZ (can be changed
as customer’s request) power supply. The PE must has good connection and
ground contacting.

Open the front door of electrical cabinet, push switch QF located on controller
right side to top position to make it electrifying.

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Close front and back doors of controller. (“Switch off while open doors” safe
switches are used here.)

Turn the red emergency stop button “SB” on clockwise to make sure that it’s on
start position

Turn switch VK on cabinet on clockwise to position 1.

Press the power on button “ON”, the indicate light will be turned on, the Relay
will be on, the Display will be on and enter the Windows XP.

Double click the Auto Cut icon and enter the control panel of wire cut EDM.

The step to turn off the controller: first, EXIT the Auto Cut system. Second,
exit the Windows XP; finally, Press the “OFF” button on the controller
panel.

If you don’t use the machine for a long period, please let the power off;
but if you don’t use it for a short time, you also can make switch VF to position
“0”!

<2> Wire-running system

There are two ways to control the wire-winding drum : one is controlled by
Auto Cut system, the other is control by the button on the electric controller
panel.

There are four levels for the wire-winding speed. It can be set on the
parameters setting of Auto Cut. From “0” to “3”, the speed from “high” to
“lower”. “0” always be used for once cutting and first cutting of the multi-
cutting. Other always be used for Multi-cutting.

Transducer control the wire running speed to make it running smoothly and in a
good condition. When wire broken protection component and stroke protection
switch SQ3 acting, the wire-running switch is no function and buzzer alarm. At
this moment, you should eliminate above mention problems to make it work.
<3> About machine electric
Comparing with the traditional electric Controller, we used modern and more
workable design. All the function can be realized in the control software, which
reducing the broken rate of the hardware. It is easy to maintenance. Besides,
simplify the operation to make it easy to learn well.
The function of control the wire-winding drum, pump, High frequency, High-
lower voltage, center finding can be controlled by the button on the operation
panel on the control system. Except the emergency stop, the wire-winding
drum can be controlled normally. The pump and the high frequency button only
can be turned on when the wire-winding drum is running.
Follow reason will cause the emergency stop:
(1) The emergency button on the right-top of the panel is on.
(2) The Moly wire is broken
(3) The stroke protection switch SQ3 was stroked
(4) The limit for the X,Y saddle is pressed.

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 Attention please: when winding, please set “2” or “3” shift
speed
About setup parameters on the transducer, please refer to

accessory sheet 1
Warnings:
1. The parameters of the transducer are setup by manufacturers or
professional technicians. Do not change it; otherwise the machine may be out
of work.
2. If you change the parameters of the transducer or disassembly it and make
the machine or the transducer out of work, we will not be responsible of
repair it for free.

6. The pulse power supply

6.1 generation
BMW-2008 pulse power is high-efficient electrical discharge unit, which
is designed by us recently. Pulse signal origin from computer high frequency,
with high steady, high resisting disturbance feature. Pulse power tube drive
adopts push-pull type which improves pulse power turn on and off speed.
High-power CMOS tubes, which are used by parallel connection make it can
output strong current to improve machining efficiency. There is a outputting of
grouping-pulse wave in “XKG-2008” system, which is suitable for machining
the parts of low thickness and high surface roughness.

The following is the main technical and technologic guidelines in “XKG-2008”

system.

The voltage of power supply: 3-AC 380V 50Hz

The peak voltage of pulse: ≤DC105V

The pulse parameters: See to item 1 and item 2.

The surface rough μm
(Material: Cr12, Quench,40mm;
once cutting& productivity=30 mm2/min) Ra≤2.5
(Material: Cr12, Quench,40mm;
several times cutting& productivity=40 mm2/min) Ra≤1.2

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The best machining efficiency: ≥100mm2/min (Material: Cr12, Thickness:
40mm~50mm)

The Max. Machining thickness: 500mm

The Max. Machining current: 6A
6.2 Principle
“XKG-2005” system is composed of the DC monodies unit, the front large unit, the
power large unit and the sampling unit. (See to figure 6-1)

Figure 6-1
The front large unit is consisted of integrate circuits (MC4049) to make sure that
CMOS driving tubes work on a good condition.

6.3 About parameters choosing on multi-times machining

Low-speed WEDM cutting principle which is multi-times and different energy
discharging cutting is used in XKG-2005 control cabinet to get good workpiece
surface rough.
Dimension calculation method about multi-times cutting.
For example:
A 12mm square workpiece which need thrice cutting;
Material:Cr12; Height:40mm; Mo. Wire: Φ0.18mm.
You can setup the machining parameters according to the following items:
Clearance compensation value: 0.09mm;
First offset value:0.07;
Twice offset value:0.02;
Thrice offset value:0mm.
After machining, check the dimensions. If it is 0.02 lower than 12mm, please set
the clearance compensation value again which should be (0.09+0.02/2)=0.10mm.
On the other hand, if the dimensions is 0.02 higher than 12mm, please set the
clearance compensation value: (0.09-0.02/2)=0.08mm.
The cutting parameters are different from different material, different thickness
and different Mo. Diameter. Operator should get the best parameter from actual
work.

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Note: Normally, the last cutting offset should be 0mm!

6.4 About multi-times machining

Because the Mo. Wire electrode should be discharging repeat, the wire must be
waste with more cutting, which make the wire thinner and thinner. It must cause
to decrease the machining precision. For Φ0.18mm wire, the max. cutting area is
about 20000 mm2. It’s a suggestion that you should measure the diameter of wire
before machining and you should tighten the wire after cutting guiding path. If
find the wire diameter waste so much, please change it!
You also should care about the following points:

Check the wire vibration when wire running not cutting. (refer to chapter 12)

Check whether the wire cut into the electrified block or not.

Check the working fluid.

Run your cutting program on software simulation to check your programmer.

It’s better to keep more supporting to decrease material deforming.
Some phenomenon on workpiece cutting surface after machining.

Trace on surface. It’s a hint that wire maybe vibrate, material maybe deform,
parameter setup for offset value maybe not correct.

Black spots happen on two side on cutting area. It’s a hint that the working
fluid is not good for work.

After cutting, please clean it with oxalic acid then rinse it. Dry it with white
cloth and coat it with antirust.

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7. Transportation
Before transportation, to be sure to loose the bolts that connect screw nut to the saddle
and the fixing parts that connect the top saddle and the middle saddle, the middle
saddle and the machine body.
During transportation, to avoid some unstable factor, such as bump badly, incline etc.
when crane transporting the unpacked machine; make sure the hook and the steel wire
is reliable.
When transporting machine wood box, soft steel wire should be used to firm the box
and there are some attentions:

No inversion, side and incline too much.

Packing firmly when transportation.

When crane transportation the box, make sure the steel wire hook the box
firmly and hang on the hook of the crane (See to figure 19 <a>, 19 <b>).
When slinging or letting down, you cannot incline it and bump box bottom
or side, jerk, surge and shake.
After the box is freighted to the aim place, take off the bolts of the cover and
disassembly it first. Before installation, don’t disassembly the baseboards at once, you
should inspect whether the machine is scathing or not first and check all the
accessories according to the packing list and register the checking result.

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8. Installation
About configuring the groundwork, please refer to the following figures and sheets.

The groundwork is suit to all the types on the following table:

Type Width a(mm) Length b(mm)

DK7732 940 1516
DK7740 1070 1676
DK7750 1100 1960
DK7763 1400 2040
DK7770 1570 2085
DK7780 1630 2205

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This workground figure is suit for DK77100 WEDM. (Refer to the following table.)

Type Width a(mm) Length b(mm)

DK77100 2660 3375
DK77100C 3660 3375

Before installation, please use clean silk cloth dipping kerosene to clean the resisted-
rust oil layer, especially, on the ball screws, guide ways, the guide wheels etc and
some important parts. And make sure there is not dirty. After do this, please smear
machine oil (HT-30) to avoid rust and lubricate all moving parts.
When installation, please install working table and machine body first.
The machine installation orient should be up against nature light and there are no hard
vibration, strong power, magnetic field and noise around it. Otherwise it may
influence the machine normal working. If the circumstance is not sound, you can
adopt vibrate resisted groundwork to isolate vibration source and you must apart the
firm board when rotate the handle.
After the machine is fixed in the groundwork, inspect it by using of tow horizontal
meters, which is put on the portrait of the working table and the value of portrait and
transverse must be less than 0.04/1000 then adjust the parallelism and
perpendicularity of the hang arms to the working table.
The machining belongs to precious machine; which is in good working condition
about the temperature of 20±5℃. Don’t put it beside with a heavy machine together
and avoid vibration source.

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9. Adjustment
Before running the machine, the machine must be fixed firmly and lubricate is
plentiful, the connection of bolts and nuts is firm. There are not barriers around the
machine and you must clean the ball screws and guide ways. To make sure that the
electric wire and the ground wire are connected reliably then there is no oil leaking.
10.1 About the span adjustment
You should set up the equal span according to the machining thickness of the
workpiece. We suggest that the perfect distance between nozzle 2 or nozzle 3 and the
workpiece is 5mm to 10mm. You can use angle rule or the molybdenum wire
adjustment gauge to adjust the molybdenum wire in a vertical position. Before you
adjust the perpendicular, you should loose the fixing screw on the taper saddle and
then rotate the knob of the step motor. After adjustment, please tighten the fixing
screw on the taper saddle.

! Attention: Before adjusting, please loose the locking screws between the
up-down arm and the column.

About operating and adjusting big taper mechanism please see to figure 9-1.
It is composed of the linear bearing 1, the connected shaft 2, the driven shaft 3 and the
lengthened shaft 4 (See to the figure 9-2). The locking screws connect the driven shaft
and the connected shaft. The shafts moving relatively to the linear bearing
accomplish the swing motion. The moving precision of the linear bearing and the
shafts is so high that the big taper mechanism can work steadily and the precision can
be kept for a long period.
Before the operation and adjustment, please read the following items:
1) When using the driven shaft and the connected shaft to compound to work,
adjust the central distance of the guide wheels within the range of 141mm to
296mm.
2) When using the driven shaft 1, connected shaft and lengthened shaft 4
( L=159mm) to compound to work, adjust the central distance of the guide
wheels within the range of 280mm to 435mm.
3) When using the driven shaft 2, connected shaft and lengthened shaft 4
( L=298mm) to compound to work, adjust the central distance of the guide
wheels within the range of 435mm to 578mm.
During machining, the shaft should be higher to the top of the linear bearing about
50mm to keep the enough moving distance of the linear bearing.
About adjustment the central distance of the guide wheels, please refer to the
following steps:
1) The central distance of the guide wheels ≤ 280mm;

Loose the locking screws between the up-down arm and the column.

Loose the locking screws of the connected shaft and take out the shafts.

Rotate the up-down screw to drive the up-down arm to a new and proper
position. (If motor drives the up-down screw, please push the up or the
down button to realize the operations.)

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Assembly the shaft to the linear bearing and the driven shaft, and keep
the shaft should be higher to the top of the linear bearing about 50mm.

Fix the locking screws between the connected shaft and the driven shaft.
2) The central distance of the guide wheels ＞ 280mm

Loosen the locking screws between the up-down arm and the column.

Loosen locking screws connecting between the upper and lower bracket
and connected shaft at the connected shaft device.

Rotate the up-down screw to drive the up-down arm to a new and proper
position. (If motor drives the up-down screw, please push the up or the
down button to realize the operations.)
Attention: Before do this, please loose the locking screws between the
up-down arm and the column.

Choose the proper compound of the connected shaft and driven shaft
according to the expected length. And assembly the shaft to the linear
bearing and the driven shaft, and keep the shaft should be higher to the
top of the linear bearing about 50mm.

Attentions: When the up-down arm is driven from the top position to the
bottom position, to be sure to disassembly the connected shaft.

Warnings:
About the span adjustment, please read the instructions carefully.
Otherwise we will not be answer for it.

10.2 The guide wheels adjustment (refer to figure 9-3)

Adjust screw 7 and nut 6 to eliminate the axial clearance of the guide wheels. When
adjustment, you should make sure that the guide wheels rotate smoothly and there is
not axial clearance. When change the guide wheels, please lubricate the guide wheels
and the bearings.
10.3 About the clearance on the working table
When assembly the machine, we have been adjust the clearance to a reasonable range.
So customers should not adjust it again.

10. Operation
Be familiar with the machine components and the use of controller before running the
machine. The following is the adjustment methods:
11.1 Turn on the power supply and run the machine without any load. To observe
whether it runs normally or not. The normal items include:

The controller must work well more than 10 minutes.

The machine component work well.

The pulse power supply and the machine electric work well.

The action of all stroke switches is sensitive.

The pipe system of the working liquid system is smooth and the pressure is
normal.

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11.2 Injecting lubricate according to the machine lubricate rules.
11.3 Add or change the working liquid every 10 to 15 days.
11.4 Fixing the workpiece.

Verify the perpendicularity between the electrode wire and the working table then
to fix the fixture on the working table.

Clean the surface of fixture and workpiece then make sure that the conduct
electricity is reliable.

When fixing the workpiece, you should find out the datum plane to make sure
that the workpiece is parallel to X or Y direction of the working table by using of
the centesimal meter according to the drawing. The position of the workpiece
should be fit for the cutting range and the workpiece and the fixture should not
touch any parts of the wire traveling unit.
11.5 Coiling the electrode wire.

The wire running speed setup
Transducer is adopted in the wire traveling system of the machine. Please
choose wire-running speed to “2” or “3” on coiling wire. When cutting,
normally we choose the speed to “1”.

The tension setup
The manual coiling wire is applied, so you should adjust the tension according to
practice.

Before startup the machine, please adjust the stroke rams to both side .
Coil the electrode wire around the protruding axis of coiling wire part, firm the
button, make it passing the wire let wheel to wire winding drum and pin it by a
bolt. At this time, rotate the wire-winding drum to terminal position. Coil it
several circle and push down wire-running ON/OFF button to make the indicator
lightt turn on, and then run the wire traveling motor to coil the other terminal.
When finished, stop the wire traveling motor and cut off the end of the electrode
wire. Hang the wire tip on the wire let wheel, the wire-keeping bar, the
electrified block, the wire guide wheel, etc. then return it to the wire winding
drum, pin it and coil it reverse direction for several circles.

Tightening wire
The electrode wire may loosen only because of elasticity fatigue. After a long
time working, so you need tighten wire again by manual. Notice that the force
for tightening wire should be even. .

Coiling wire
The wire traveling route of the 0°and 6°taper: (See to figure 10-1)
The wire winding drum → The wire let wheel → The up wire guiding stick →
The electrified block → The up guide wheel → The down guide wheel → The
electrified block → The down wire guiding stick → The wire broken protection
stick → The wire winding drum.
The wire traveling route of the 30°and 60°taper: (See to figure 10-2)

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The wire winding drum → The wire broken protection stick →The up wire let
wheel → The down wire let wheel →The down guide wheel → The up guide
wheel The up wire let wheel → The down wire let wheel → The wire winding
drum.
Adjust the stroke rams again to keep the distance to two sides is about 5 to
10mm. You should take care that the turning direction of coil and the direction
of the wire traveling saddle to prevent overrun.

Wire running control panel

Attention: Taking off the handle when the wire traveling, which can
avoid dangers. The wire traveling stroke limit is adopted by a
method of the screw and the nut separated. The tail of the screw is
smooth, so when overrunning, the motor is in racing condition. Pushing
the wire traveling saddle and rotate the wire winding drum to make the
screw mate the nut to resume work.

20
11.6 Operation steps

Turn on the power supply.

Input the machining program.

Adjust the span of the wire guide frame according to the workpiece
thickness.

Fix the fixture.

Coil the electrode wire. (When finished, tighten the wire once to twice and
the force should be even.)

Choose the equal wire traveling speed. (It is determined by the workpiece
thickness and you cannot change the wire traveling speed when machining.)

Turn on the wire traveling motor.

Turn on the water pump and adjust the flux. (Before turning on the water
pump, you should close the adjustable valve. After running the water pump,
open the valve gradually to make sure that the electrode wire is embodied
by the water column.)

Turn on the high-frequency power supply and choose the electrical
parameters. (User can choose the electrical parameters according to the
cutting efficiency or surface roughness. When cutting in, please draw the
clearance of the pulse and after cutting in, adjust it to meet machining
request.)

Run the program. When cutting in, adjust the knob of the adjustable resistor
to make the hand of the current meter stably. (The current meter shaking
gently is allowable.)

When machining is over, turn off the pulse power supply first and then the
water pump and the wire traveling motor. To check whether the X, Y
coordinate arrive at the end-point or not and take off the workpiece from the
workpiece and rinse it to check it.

Attentions: There is a red emergency stop button on the controller

panel. Push down the button when emergency to stop the machine.

11.7 Taper machining

Loosen the firm bolts of U, V saddle.

Adjust the span then the perpendicularity of the electrode wire.

Measure the central distance (H2) between the up guide wheel and down
guide wheel and the distance (H1) between the down guide wheel and
fixture, then the workpiece thickness (H). (See to the following figure)
Input the value of H, H1, H2 and r into the program system to generate
automatically the machining program. (Detail, please refer to “Program
system user guide”.

21
 Workpiece

The clearance adjustment of the screw mate on the taper cutting mechanism.
(See to the following figure)
Open the top and bottom cover of the taper cutting mechanism and loose or
tighten the screw mate by a spanner to make the screw mate rotate flexibly
and no clearance in axial direction.

Clearance adjustment of the screw mate

Attention: As new machine, clearance adjustment of screw mate

have been finished in our company. So you need not adjust it by youself.

22
11. About the usage of wire guider
11.1 Scope
The wire guiders are standard parts for equipping with XKG-2005 WEDM. You can
find the functions of wire guider on the following items:

It’s a guider to guiding wire to mannish wire-running vibration, so it can
improve the workpiece cutting surface rough.

It can realize ≤1.5° taper cutting on 100mm height workpiece.
11.2 Structure
About the structure of wire guider, please refer to the following figure 11-1.

1. Wire guider house 2. Wire guider 3. Wire guiding block

4. Cover 5. M4x15 Blot 6. M4x30 Blot 7. Hinder
11.3 Requirement and installation
The wire guiders have been correctly assembled and adjusted before sale out.
Customer can use it directly. If you disassembly it, please follow the following steps
to set it up.

Take off water spraying part.

Check the position of up and down guide wheels to make sure two guide wheels
in one plane and center to center through the middle line of wire guider house.

Coil wire and tighten wire, calibrate wire perpendicularity (Both X and Y axes).
After adjusting, do not move the guide wheels.

Assembly wire guider on wire guider house. Refer to wire guider structure figure.

Make wire through the wire guider from up guide wheel to down guide wheel.
When wire go through the wire guider, please make the wire front as
straight as possible.

23

Tighten wire then check the wire perpendicularity. If needed, please adjust the
position of wire guider a little bit. You can loose 2 pcs M4x15 blots and adjust
the wire guider then fix the two blots.

Check parallelism of wire guider bottom surface with micrometer. It should be ≤
0.01mm.

Connect water pipes.

11.4 Some important items about wire guider

After adjusting wire guider component, it should be no changing on whole
machining. Otherwise it will affect on normal cutting work, especially on taper
cutting. Sometimes, when making taper cutting, operator adjust U,V servo axes to
keep wire and workpiece perpendicular. That’s forbidden! If you find wire is not
perpendicular with workpiece, you should adjust workpiece not the wire!

If you want get high surface rough and making multi-times cutting, it’s better to
use wire guider component. If making normal cutting, you can use normal way
which is guide wheel working with spraying part. The spraying part belongs to
spare parts.

If assemble wire guider component, it will affect on taper cutting. So you

only can make ±1.5° cutting with wire guider component. If you want to
make ± 3.0° cutting, please disassemble wire guider component and using
spraying part!

24
12. Usual problem and solution
12.1 Black screen
a. Check the EMS memory card;
b. Check the display card;
c. Check the fan of CPU;
d. Check the slot of CPU;
e. Check the fan of UPS;
f. Check the input voltage;
g. Check the power supply;
12.2 Wire broken and agglomeration
a. When machining, the molybdenum wire touch the workpiece and then the
wire broken. At the same time, there is forceful arc between the molybdenum
wire and the workpiece. So you should check the IRFP250 power tube
b. When machining, the saddle of wire winding drum can’t change the moving
direction immediately to make the wire broken. So you should check whether
the bolts on the travel ram are firm, whether the position-limited switch is
good and whether the close contact can be reset.
c. When machining, the molybdenum wire broken suddenly. Please check the
jumping range of the let wire wheel and the guide wire wheels.
d. When machining, the molybdenum wire let-running is abnormal. So you
should check if there is clearance on wire drum portrait or broken happened on
the bearings of wire drum.
e. Check if there is small contacting resistor between electrified block, wire
running drum, wire letting wheel and machine body. If happened, clean it.
f. Working liquid problem, so you should change it.
g. The quality of molybdenum wire is not good.
12.3 No voltage
a. Check if the IRFP250 CMOS power tube on BM2005-1 PCB is broken ;
b. Check whether there is a voltage on bridge of the high frequency circuit;
c. Check whether the resistances of the high frequency circuit is good;
d. Check whether the software controlling high frequency ON of HF interface
card is good or not;
e. Check whether the +12v indicator lights is lighting or not;
12.4 Normal wave but no motion feed
a. The circuitry of the high frequency sampling is not good;
b. There are some failures on the software interface card;
12.5 No enough moment output or no rotation for step motor.
a. DC24v working good?
b. The connector plug of the step motor is loose;
c. Whether there’s phase loss in drive circuit.
d. There are some failures on the software interface card;
e. Mechanism failures, such as gears or the axis of the motor are locked.
12.6 The wire traveling motor failure

25
 a. When machining, no changing motion direction. So you should check the
travel position-limited switch and the middle relay;
b. Can’t startup the wire traveling motor and buzzer alarm

Check whether the wire is broken or not

Check whether the stroke switch is pressed or not.

Check whether the scram switch is pressed or not.

Check whether X or Y limit switch is pressed or not.
c. Noise happened on the wire-winding drum. So you should check whether
there are plentiful lubricant on the bearings, the screw and the nut.
d. Check if there are some blocks between screw and nut, or gears?
12.7 Usual problem about machining
a. The low surface quality of the machining part.

Check the machining parameters;

Check molybdenum wire quivering;

Check the tension of molybdenum wire;

Check the working fluid;

Check whether the guide wheel and the wire let wheel is normal;

Check the transducer setup.
b. When machining big thickness workpiece, that short circuit, unstable
machining current and voltage is normal.

So you can check the machining parameters;

Adjust the transducer to make machining current stably;

The wire is too tighten;

Spraying water is normal or no?

The material is easy to deform or not?

The wire waste too much.
c. The low machining precision of machining part.

Check the missing step of the step motor;

Check the jumping range of the guide wheel and the wire let wheel;

Check the quivering of the molybdenum wire;

Check the clearance of the saddle driving and the deforming of the
workpiece.

12.8 Mechanism problem

a. The perpendicular error of the saddle. So you should adjust the V shape guide
way of the up saddle;
b. Noise on the wire-winding drum. So you should change the bearing of the
wire traveling unit;
c. Noise on changing motion direction of the wire-winding drum. So you should
change the bonds or the elastic block on the wire traveling driving system;
d. Clearance on the wire-winding drum. So you should check the screw, the nut
and the bearings and then eliminate clearance or change bearings.
12.9 Stripe on the machining surface of the workpiece

26
 a. The electrode wire is loose or quivering. So you should tighten the wire again
or change the guide wheel and the wire let wheel;
b. The machining following is not unstable. So you should adjust the high
frequency parameters and the following speed again;
c. Unqualified material about the workpiece. So you should change the
workpiece.
12.10 Wire quivering
a. The electrode wire is loose. So you should tighten the wire again;
b. The precision of the bearing and the guide wheel is reducing for a long period
running. So you should change the guide wheel and the bearing.
c. The impact and jumping range are enlarging for a long period running. So you
should adjust the wire-winding drum.
12.11 Jumping and inflexible motion about the guide wheel
a. The axial clearance of the guide wheel is increasing. So you should adjust the
clearance of the guide wheel;
b. The side jumping of the guide wheel is increasing. So you should change it not
adjust it;
c. The working liquid permeates through the bearings. So you should rinse it
with the gasoline or change it;
d. The precision of the bearings and the guide wheel falls for a long period
running. So you should change it.
12.12 Wire broken
a. The electrode wire is aging and fragile. So you should change the qualified
electrode wire;
b. The electrode wire is too tight and quivering hardly. So you should change the
electrode wire or the guide wheels;
c. No enough working liquid to drain the iron-scraps. So you should adjust the
flux or change working liquid;
d. Incorrect choice about the high frequency parameters to the workpiece
thickness. So you should setup the equal parameters;
e. The clearance is increasing when the wire winding drum changes motion
direction. So you should adjust it again;
f. The travel position limit switches are fall to make the saddle of the wire
traveling overrun. So you should check it and change or adjust it;
g. Oxidation skin on the surface of the workpiece. So you should get rid of the
oxidation skin;

27
13. Maintenance
Before running the machine, you must be familiar with the lubricating system and
lubricating rules (See to figure 13-1 and 13-2) to ensure the machine performance and
usage life.
There are oil cups and oil holes to the lubricate points and the lubricating method is
manual timely. (About the lubricating rules and attentions, please refer to the
appendix table 1.)
Keep clean to the machine and oil the lubricating point if the machine has stop for 8
hours. The electrified wheels and the wire-let wheels of the taper cutting mechanism
unit should be rinsed frequently. After rinsing, the dirty oil can’t be flow into the
backwater slot of the working table.
The guide wheels and bearings must be replaced in general after 3 to 4 months using.
If the working liquid system is jammed, dredge immediately. Otherwise the liquid
will permeate through machine, which can destroy the electric components.
The machine is equipped with wire protecting unit. Do away with the waste electrode
wire once wire broken. Isolate the machine from outside vibration and strong
magnetic field and keep clear in the workshop. When the power supply is ±10%
higher than rated voltage, the controller should be connected with steady voltage
power supply or adjustable voltage device (3N-280V3KW).
On the condition that the machine runs two shifts every day and operated as the rule,
its precision can keep for two years. The time that the machine needs heavy repairing
is not less than 8 years.

28
14.Consumable component catalogue

Code Item Quantity Position Remarks

The wire 4 bearings (D25) for 1 set
3201 The guide wheels 2
traveling unit of guide wheels
2 for little
taper or no
The wire letting taper
The wire 2 bearings (624) for 1 set
3202 wheels for single WEDM
traveling unit of guide wheels
support 4 for big
taper
WEDM
The wire letting
The wire 4 bearings (624) for 1 set
3203 wheels for double 1
traveling unit of guide wheels
support
The electrified The wire
3204 2
blocks traveling unit
Wire broken
5×15 red gem
3205 1 protection
bar
unit
2.5×20 red gem Wire support
3206 2
bar unit
The wire
3207 The elastic block 1
traveling unit
The guide It’s different from different
3208 The flush boards 1
wheel house taper WEDM

Attention: The model of the consumable components will be change from the
technical updating.

15. About machining parameters choosing

Different machining parameters lead to different machining result. There are also a lot
of factors influence on the machining quality. For example, different requirements of
precision and surface rough, different molybdenum wire, different working liquid,
different operator, different workpiece material, different material heat treatment,
different cutting servo speed, etc.
The following mentioned only for reference. You must choose or use it according to
actual machining conditions.
Power supply:3 phase AC380V/50HZ
Material: Cr12, Thickness:10mm, Working liquid: water-based working solution,
Molybdenum wire: φ0.18mm
Parameters for once cutting:
Group Speed
Groupi Power- Process Limited
Pulse Pulse for of wire Electricit efficie
Item ng amplifi ing Tracking speed for
width spacing pulse travelin y
spacing er tube voltage processing
width g ncy

29
 1

Material: Cr12, Thickness:20mm, Working liquid: water-based working solution ,

Molybdenum wire: φ0.18mm
Parameters for once cutting:
Group Speed
Groupi Power- Process
Pulse Pulse for of wire Limited speed Electri efficie
Item width spacing pulse
ng amplifi
travelin
ing Tracking
for processing city
spacing er tube voltage
width g ncy
30
1
40
2
60
3
80
4

30
Material: Cr12, Thickness:40mm, Working liquid: Water-based working solution,
Molybdenum wire: φ0.18mm
Parameters for once cutting:
Group Speed
Groupi Power- Process Elec
Pulse Pulse for of wire Limited speed efficie
Item width spacing pulse
ng amplifi
travelin
ing Tracking
for processing
trici
spacing er tube voltage ty
width g ncy
30
1
40
2
60
3
80
4
100
5

Material: Cr12, Thickness: 60mm, Working liquid: water-based working solution,

Molybdenum wire: φ0.18mm
Parameters for once cutting:
Group Speed
Groupi Power- Process
Pulse Pulse for of wire Limited speed Electri efficie
Item width spacing pulse
ng amplifi
travelin
ing Tracking
for processing city
spacing er tube voltage
width g ncy
40
1
60
2
80
3

Material: Cr12, Thickness: 100mm, Working liquid: Water-based working solution,

Molybdenum wire: φ0.18mm
Parameters for once cutting:
Group Speed
Groupi Power- Process
Pulse Pulse for of wire Limited speed Electri efficie
Item width spacing pulse
ng amplifi
travelin
ing Tracking
for processing city
spacing er tube voltage
width g ncy
30
1
50
2
70
3

31
Material: Cr12, Thickness: 10mm, Working liquid: water-based working solution,
Molybdenum wire: φ0.18mm
Parameters for thrice cutting:
Group Proces
Allo Groupin Power- Elec
Pulse Pulse for Speed of wire sing Limited speed efficien
Item wanc
width spacing pulse
g amplifie
traveling
Tracking
for processing trici
e spacing r tube voltag
width ty
e cy

Material: Cr12, Thickness: 20mm, Working liquid: water-based working solution,

Molybdenum wire: φ0.18mm
Parameters for thrice cutting:
Power
Group Group Proces
Allo Pulse - Speed of
Pulse for ing sing Limited speed Electri effic
Item wan spacin amplif wire Tracking
ce width pulse spacin voltag for processing city
g ier traveling
width g e ncy
tube

Material: Cr12, Thickness: 40mm, Working liquid: water-based working solution,

Molybdenum wire: φ0.18mm
Parameters for thrice cutting:
Puls Group Group Proces
Allo Power- Speed of Limited
Pulse e for ing sing Electri efficie
Item wanc amplifier wire Tracking speed for
e width spac pulse spacin voltag city
tube traveling processing
ing width g e ncy

32
Material: Cr12, Thickness:60mm, Working liquid: working-based working solution,
Molybdenum wire: φ0.18mm
Parameters for thrice cutting:
Puls Group Group Proces
Allo Power- Speed of Limited
Pulse e for ing sing Electri efficie
Item wanc amplifier wire Tracking speed for
e width spac pulse spacin voltag city
tube traveling processing
ing width g e ncy

Material: Cr12, Thickness: 100mm, Working liquid: water-based working solution,

Molybdenum wire: φ 0.18mm
Parameters for thrice cutting:
Puls Group Group Proces
Allo Power- Speed of Limited
Pulse e for ing sing Electri efficie
Item wanc amplifier wire Tracking speed for
e width spac pulse spacin voltag city
tube traveling processing
ing width g e ncy

Material: 45 steel, Thickness: 20mm, Working liquid: water-based working solution,

Molybdenum wire: φ0.18mm
Parameters for once cutting:
Puls Group Group Proces
Allo Power- Speed of Limited
Pulse e for ing sing Electri efficie
Item wanc amplifier wire Tracking speed for
e width spac pulse spacin voltag city
tube traveling processing
ing width g e ncy

Material: 45 steel, Thickness: 40mm, Working liquid: water-based working solution,

Molybdenum wire: φ0.18mm
Parameters for once cutting:

33
 Puls Group Group Proces
Allo Power- Speed of Limited
Pulse e for ing sing Electri efficie
Item wanc amplifier wire Tracking speed for
e width spac pulse spacin voltag city
tube traveling processing
ing width g e ncy

Material: Brass, Thickness: 20mm, Working liquid: water-based working solution,

Molybdenum wire: φ0.18mm
Parameters for once cutting:
Puls Group Group Proces
Allo Power- Speed of Limited
Pulse e for ing sing Electri efficie
Item wanc amplifier wire Tracking speed for
e width spac pulse spacin voltag city
tube traveling processing
ing width g e ncy

Material: Brass, Thickness: 40mm, Working liquid: water-based working solution,

Molybdenum wire: φ0.18mm
Parameters for once cutting:
Puls Group Group Proces
Allo Power- Speed of Limited
Pulse e for ing sing Electri efficie
Item wanc amplifier wire Tracking speed for
e width spac pulse spacin voltag city
tube traveling processing
ing width g e ncy

Material: Aluminum, Thickness: 20mm, Working liquid: water-based working

solution, Molybdenum wire: φ0.18mm
Parameters for once cutting:
Puls Group Group Speed of Proces
Allo Power- Limited
Pulse e for ing wire sing Electri efficie
Item wanc amplifier Tracking speed for
e width spac pulse spacin travellin voltag city
tube processing
ing width g g e ncy

34
 1

Material: Aluminum Thickness：40mm Working liquid: water-based working

solution, Molybdenum wire：φ0.18mm
Parameter for once cutting:
Puls Group Group Proces
Allo Power- Speed of Limited
Pulse e for ing sing Electri efficie
Item wanc amplifier wire Tracking speed for
e width spac pulse spacin voltag city
tube traveling processing
ing width g e ncy

Material：Cr12 Thickness：40mm Working liquid: water-based working

solution, Molybdenum：φ0.16mm
Parameter for once cutting
Puls Group Group Proces
Power- Speed of Limited
Pulse e for ing sing Electri efficie
Item amplifier wire Tracking speed for
width spac pulse spacin voltag city
tube traveling processing
ing width g e ncy

Material：Cr12 Thickness：40mm Working liquid: water-based working

solution, Molybdenum: φ0.20mm
Parameter for once cutting:
Puls Group Group Speed of Proces
Power- Limited
Pulse e for ing wire sing Electri efficie
Item amplifier Tracking speed for
width spac pulse spacin travellin voltag city
tube processing
ing width g g e ncy

Appendix:

The lubrication list

Table A: Lubrication
No. Lubricating points Lubricating methods Lubricating period
1 The trapezium screw of wire Oil storage slot Once a half year

35
 traveling unit lubricating
The saddles, guide ways of the Oil gun injection Once a shift
2
wire traveling unit
3 The gears to wire traveling unit Oil gun injection Once a shift
The ball screws of X, Y ZG-2 lubricating grease Once three months
4, 5
GB491
6, 7 The guide ways of X, Y Oil gun injection Once a week
The gears to X, Y ZG-2 lubricating grease Once a half year
8, 9
GB491
The screws of U, V ZG-2 lubricating grease Once a week
10
GB491
The gears to U, V ZG-2 lubricating grease Once a half year
11
GB491
The up-and-down screw and Oil gun injection Once a week
12
worm wheel
13 The up-and-down guide way Oil gun injection Once a week
When lubricating the points of 2, 6, 7, 12, 13, you should open the
Attentions
protecting cover first. (See to figure 13-1 and13-2)

Table B: The list of gears, screws and nuts

No. Item Parameters Material Heat treat Q. Position Remarks
The wire
1 Screw Tr20×3 45 1 traveling General
frame
M=1.5 z=28, α The wire
Worm
2 wheel
=20°7-d Tr20 ZQSn6-6-5 1 traveling General
×3 JB179 frame
The taper
cutting C, D
M10 SQn6.5-0.1 2
mechanis series
m
3 Nut
The taper
cutting E, F, G, H
M18×1-4h SQn6.5-0.1 2
mechanis series
m
The taper
cutting C, D
M10 45 2
mechanis series
m
Assistant
4 nut
The taper
cutting E, F, G, H
M28×1-4h 45 2
mechanis series
m
No. Item Parameters Material Heat treat Q. Position Remarks
The taper
cutting C, D
M10 40Cr C30 1
mechanis series
m
5 Screw
The taper
cutting E, F, G, H
M18×1-4h 40Cr C30 1
mechanis series
m

36
 The taper
M=0.4 z=24, α Solution
cutting C, D
=20°6-d 40Cr heat 1
mechanis series
GB2363 treatment
m
6 Gear
The taper
M=0.5 z=24, α Solution
cutting E, F, G, H
=20°6-d 40Cr heat 1
mechanis series
GB2363 treatment
m
The taper
cutting C, D
M10 40Cr C30 1
mechanis series
m
7 Screw
The taper
cutting E, F, G, H
M18×1-4h 40Cr C30 1
mechanis series
m
The taper
M=0.4 z=50, α Solution
cutting C, D
=20°6-d 45 heat 1
mechanis series
GB2363 treatment
m
8 Gear
The taper
M=0.5 z=100, α Solution
cutting E, F, G, H
=20°6-d 45 heat 1
mechanis series
GB2363 treatment
m
The taper
M=0.4 z=50, α Solution
cutting C, D
=20°6-d 45 heat 1
mechanis series
GB2363 treatment
m
9 Gear
The taper
M=0.5 z=100, α Solution
cutting E, F, G, H
=20°6-d 45 heat 1
mechanis series
GB2363 treatment
m
The taper
M=0.4 z=24, α
cutting C, D
=20°6-d 40Cr C30 1
mechanis series
10 Gear GB2363 m
The taper
M=0.5 z=24, α
cutting E, F, G, H
=20°6-d 40Cr C30 1
Gear mechanis series
10 GB2363 m
M=0.6 z=24, α Solution The
11 Gear =20°6-e 40Cr heat 1 working General
GB2363 treatment table
M=0.6 z=112, α Solution The work
12 Gear =20°6-e 40Cr heat- 1 table General
GB2363 treatment
The
Ball FFZD4004-P3-
13 screw 875×725
GCr15 C58-62 1 working General
table
No. Item Parameters Material Heat treat Q. Position Remarks
The
14 Ball nut GQ4004 GCr15 C58-62 2 working General
table
The
15 Ball nut GQ4004 GCr15 C58-62 2 working General
table
The
Ball FFZD4004-P3-
16 screw 1045×895
GCr15 C58-62 1 working General
table

37
 m=1 z=34, α Solution The wire
Little
17 Gear A =20°7-f 40Cr heat 1 traveling General
GB2363 treatment unit
m=1 z=117, α The wire
Big Gear
18 B =20°7-f Bakelite 1 traveling General
GB2363 unit
m=1 z=34, α Solution The wire
Little
19 Gear B =20°7-f 40Cr heat 1 traveling General
GB2363 treatment unit
m=1 z=117, α The wire
Big Gear
20 A =20°7-f Bakelite 1 traveling General
GB2363 unit
Nut The wire
21 compone Tr22×3-8 QSn6.5-0.1 1 traveling General
nts unit
The wire
22 Screw Tr22×3-8 45 T365 1 traveling General
unit
m=0.6 z=24, α Solution The
23 Gear =20°7-f 40Cr heat 1 working General
GB2363 treatment table
m=0.6 z=112, Solution The
24 Gear α=20°7-f 40Cr heat 1 working General
GB2363 treatment table
m=1.5 z=1, α The wire
25 Worm =20°7-f 45 HRC28 1 traveling General
GB2363 frame

Attentions: The length of the ball screw is different from different model
machine.
Table C: The length of the ball screw to different model machine
Model L1 L2 L3 L4

DK7732 565 430 645 510

DK7740 645 510 745 610

DK7750 745 610 875 740

DK7763 875 725 1045 895

DK7770 955 820 1325 1190

DK7780 1135 1000 1325 1190

DK77100 1362 1184 1587 1409

38
Table D: The list of bearings and motors
No. Item Model Specification Rank Q. Position Remarks
Cone ball 51203 Worm
A 15×35×12 D 1 General
bearing GB/T301 wheel
Front and hind
45BC340 1 C、D series
axis The taper
B Step motor
saddle E、F、G、
55BC340 1
H series
618/8
Single row 8×16×4 D 2 C、D series
GB276 The taper
C angular ball
7003C saddle E、F、G、
bearing 17×35×10 D 4
GB276 H series
618/8 The taper
8×16×4 D 2 C、D series
Single row GB276 screw
D angular ball Front
6002-2Z E、F、G、
bearing 15×32×9 D 2 bearing
GB276 H series
house
Front and hind
45BC340 1 C、D series
axis The taper
E Step motor
saddle E、F、G、
55BC340 1
H series
Single row Hind
6203
F angular ball 17×40×12 C 1 bearing General
GB276
bearing house
Single row Front
7005AC
G angular ball 25×47×12 C 2 bearing General
GB292
bearing house
Single row Front
7005AC
H angular ball 25×47×12 C 2 bearing General
GB292
bearing house
Single row 619/4
4×11×4 D 4 General
angular ball GB276 The guide
I
bearing 624 wheels
4×13×5 D 4 General
GB276
Single row Wire
6004
K angular ball- 20×42×12 D 2 traveling General
GB276
bearing unit
Single row Wire
7203
L angular ball- 17×40×12 E 2 traveling General
GB/T292
bearing r unit
Wire
AC motor YSD712
M 1 traveling General
4/8 B5
unit
Single row Wire
6004
N angular ball- 20×42×12 D 2 traveling General
GB276
bearing unit
619/4 Wire let
Single row 4×11×4 D 2 General
GB276 wheel
O angular ball-
624 The guide
bearing 4×13×5 D 2 General
GB276 wheel
90BC510 Working
P Step motor 1 General
0A table
90BC510 Working
Q Step motor 1 General
0A table
Single row Hind
6203
R angular ball- 17×40×12 C 1 bearing General
GB276
bearing house

39
Table D: The transducer introduction (Emerson)
1> Press [PRG] key to enter programmer system, which will display the current
function code (Such as: F000).
2> Press [UP] or [DOWN] key to change the function code that you want.
3> Press [FUNC/DATA] key to enter the corresponding parameter value.
4> Press “movement” key to change current cursor position.
5> Press [UP] or [DOWN] key to change parameters that you need.
6> Press [FUNC/DATA] key to save the parameters that you choose.
7> Press [PRG] key to exit programmer condition.
If you need more information about operate Emerson transducer, please refer to
Emerson TD900 manual book.

The parameter table about transducer setup( do not change it!):

Sequence Code Setup value Sequence Code Setup value
01 F000 0 11 F029 150
02 F002 1 12 F030 0.6
03 F012 0.4 13 F031 30
04 F013 0.6 14 F058 36
05 F019 0 15 F059 25
06 F024 0.1 16 F060 10
07 F027 2 17 F071 1
08 F028 5 18 F088 0

Attention: You must setup F088 first , switch off power supply then setup
parameters in order!

40
Appendix:

24 23 P 11 12 F

13

14
Q
G

15
16

Figure 4-1 The driving system of working table

21 22 M N

O I

L 20 19 18 17 K

Figure 4-2 The driving system of wire running unit

41
C 8 6 B

5 D 9 10
4
3

7
3
4

Figure 4-3 The driving system of taper unit

Figure 9-1 The taper adjustment

42
Figure 9-2 Wire frame connector and it’s adjustable range

Figure 9-3 Adjustment about the guide wheel

43
 Figure 10-1 The wire traveling path about 0° and 6° WEDM

Figure 10-2 The wire traveling path about 30° and 60° WEDM

44
Figure 13-1 The lubrication points about 0° and 6° WEDM

45
Figure 13-2 The lubrication points about 30° and 60° WE

46
Component Distribution Diagram of Controller

47
Control Panel Circuit Connect Diagram of Front Door

48
Circuit Connect Diagram of Front Door

49
Circuit Connect Diagram of Back Door

50
Interior Circuit Connect Diagram

51
Power Supply

52
The Stepping Drive of X, Y, U ,V

53
Key button Theory Diagram

54
Suzhou Baoma Numerical Control Equipment Co., LTD
Address：No. 289, Baiyangwan Street, Suzhou City of Jiangsu Province
PRC：215008
Tel：＋86 0512-65355296
Fax：＋86 0512-65354093
Service hot line：＋86 0512-65355293, ＋86 0512 65355291-8012
Website: Http://www.suzhoubaoma.com
E-mail: service@suzhoubaoma.com (Service department)
sale@suzhoubaoma.com (Sale department)

55