DK7740A CNC EDM WIRE CUTTING MACHINE

TECHNOLOGY DOCUMENTS
SERIAL NUMBER:

SUZHOU ZHONGGU MACHINE & ELECTRONIC TECHNOLOGY CO., LTD THE PEOPLES REPUBLIC OF CHINA

TECHNOLOGY DOCUMENTS CONTENT

1. USERS MANUAL 2. PARKING LIST 3. WARRANTY CARD

Suzhou Zhonggu Machine & Electronic Technology Co.,Ltd Addr: 888 Chenyang Rd, Xiangcheng District, Suzhou, China. Tel: +86-0512-85185518 FAX: +86-0512-85185515 Website: www.zgedm.com email: webmaster@zgedm.com

MACHINE:
ZGEDM

DK7740A

CNC EDM WIRE CUTTING MACHINE

INSPECTION CERTIFICATE
WORKTABLE TRAVEL: WORKTABLE DIMENSION: SERIAL NUMBER: 500400 720460

SUZHOU ZHONGGU MACHINE & ELECTRONIC TECHNOLOGY CO., LTD THE PEOPLES REPUBLIC OF CHINA
Suzhou Zhonggu Machine & Electronic Technology Co.,Ltd Addr: 888 Chenyang Rd, Xiangcheng District, Suzhou, China. Tel: +86-0512-85185518 FAX: +86-0512-85185515 Website: www.zgedm.com email: webmaster@zgedm.com

DK7740A CNC EDM WIRE CUTTING MACHINE

THIS MACHINE HAS PASSED ALL INSPECTION ITEMS AND SALE ALLOWED

MANAGER (SIGN) INSPECTOR (SIGN)

DATE:

YEAR

MONTH

SUZHOU ZHONGGU MACHINE & ELECTRONIC TECHNOLOGY CO., LTD THE PEOPLES REPUBLIC OF CHINA
Suzhou Zhonggu Machine & Electronic Technology Co.,Ltd Addr: 888 Chenyang Rd, Xiangcheng District, Suzhou, China. Tel: +86-0512-85185518 FAX: +86-0512-85185515 Website: www.zgedm.com email: webmaster@zgedm.com

DK77 Series EDM Wire Cutting Machine

User's Manual

NOTICE
1. We provide one year warranty for machine principally. 2. Service contents: Mechanical and electrical malfunctions under normal working environment and correct operations. 3. Please pay attention during warranty: 1) Any problems caused by input voltage problem (input voltage must be 380V 20V) are not in warranty. 2) Any problems caused by nature disaster like fire, flood or thunder are not in warranty. 3) Any problems caused by operation mistakes are not in warranty. 4) Users should not add any new peripheral in the computer, change any devices in the computer or modify the operation system. Problems caused by virus are not in warranty. 5) If above cases occurs, we have to charge when provide the service. 6) The wear parts on the machine are not including in warranty. 7) (Wire cutting machines wear parts: pulleys, guide wheel, conductor block and etc.) (Drilling machines wear parts: electrode, chuck, seal rubber, guide, timing belt and etc.) We do not provide any warranty service if the customer does not take the payment on terms. 8) Please contact us with out hesitates when you face any operation questions. If you dont have proper operator, please contact us and we will provide training courses in our company. 4. We will provide service over life of the machine in charge after warranty.

Suzhou Zhonggu Machine & Electronic Technology Co.,Ltd Addr: 888 Chenyang Rd, Xiangcheng District, Suzhou, China. Tel: +86-0512-85185518 FAX: +86-0512-85185515 Website: www.zgedm.com email: webmaster@zgedm.com

INSTALLATION
Dear user, Kindly please under the instructions to install the machine properly after you open package: 1. Please check all items on the parking list. 2. Please read the manuals and technology documents carefully before you start the machine. 3. Please take off all block junctions on the machine, sweep the seal grease and lubricate all parts of machine. 4. Please adjust the level of machines work table. 5. The power supply must be 3 phase 380V 50Hz voltage. Please connect the PE terminal to protect earth for safe. Otherwise we do not take charge of any electrical shock.

Thank you very much for your cooperation!

Suzhou Zhonggu Machine & Electronic Technology Co., Ltd

Suzhou Zhonggu Machine & Electronic Technology Co.,Ltd Addr: 888 Chenyang Rd, Xiangcheng District, Suzhou, China. Tel: +86-0512-85185518 FAX: +86-0512-85185515 Website: www.zgedm.com email: webmaster@zgedm.com

II

Part 1 Machine Introduction

DK77 series CNC EDM Wire Cut is consisted with machine basement, worktable, wire drum, wire shelf, working fluid circulation system and machine electric and CNC system. The CNC controls worktable running in X, Y direction according to the post accurately. The wire runs cyclically from the wire drum to upper and lower guide rollers in high speed. Theres high frequency pulse electron discharging between wire and workpiece on machining, the discharging path generates high temperature to erode metal. The ashes of melted metal are washed out by the working fluid. Theres place to install taper device (Option) on the front of wire arms. The taper device can rotate wire in U and V direction. The machine can perform interpolation movement in X, Y and U, V axes to cut taper parts and upper/lower dual-shape parts.

1. Machine Basement
The machine basement is a completed casting, installed machine electrical parts inside and worktable, wire drum, wire arms on it. The working fluid tank is put beside it.

2. Worktable
The worktable is consisted with upper carriage, middle carriage, ball screws and guides. The worktable on carriages moves on roller guides or linear guides that driven by high precision ball screws which controlled by step motor with gear box. The producer has adjusted and tightened the ball screws in a proper way. Please do NOT disassemble them without professionals.

3. Wire System
The wire system controls molybdenum wire running cyclically along the path consisted by wire drum, upper rollers and lower rollers. The wire drum is made in a thin cylinder that insulated with drum spindle. It rotates in 11m/s linear velocity to send out the wire and runs on guides go and back to keep the wire route in the proper position. The wire drum changes running direction when touch limit switches. This circuit of limit switches is simple, high response, low noise and long life. Theres another over travel switch to stop machine running only if the limit switches are out of work. The wire shelf is consisted by column, fixed arm, mobile arm and guide rollers. The carbide conduct blocks are installed on the front of fixed and mobile arms respectively. And the guide rollers, conduct blocks are insulated against wire arms. The wires path is open, firstly, the wire go out from the wire drum to tension adjustment device on column, then go to the conduct blocks in front via upper guide roller, and pass the upper and lower muzzles, back to wire column via lower guide roller finally. The workpiece is fixed between upper and lower muzzles. Operator shall align the wire to vertical position before machining. Therere 2 valves inside the column, and the valves knobs are on the column to adjust the flux of working fluid from upper and lower muzzles. Turn the hand wheel on the top of column can move the mobile arm up and down to adjust the height between guide rollers to adapt different height of workpieces. The operator shall keep the guide rollers, conduct blocks and wire arms clean to get good machining results.

The pump on working fluid tank deliveries working fluid via valves to muzzles in the front of arms to shoot work fluid to workpiece from up and down sides at same time when machining to wash out the ashes of metal. The working fluid drops in the box gutter flume then flows back to tank. And the dirty working fluid could be filtered and settled in it. Please clean the tank in time. The working fluid is mixed by WEDM soap scream and clean water in rate 1:20.

4. Operation Notices
1. The wire is powered by electricity when machining, it may cause people be shocked if touch on it. The operator shall take essential protection wares and do NOT touch the discharging parts when machining. 2. Connected the machine tool to protection ground tightly. 3. Choose the coordinate according to workpieces or design drawings properly to calculate and generate the post. The operators shall consider the clamping method and wire diameter in advance and choose a proper start point. 4. Please check the post program carefully before machining. And if the part is complex, the operators could dry run the machine to simulate the work path to test the post. 5. The operators shall consider the worktable travels when clamping workpiece and posting program. In case of small parts and high difficulty parts, the operators must put workpiece on worktable properly to avoid over travel problem. 6. Please drill small holes in right position to through the wire before machining on molds that can not be cut from out side.

7. Check the wire tension before machining. If the wire is losing, tighten it by the tools in time. 8. Put on the protection cover on wire drum and close the door of cabinet before machining. Do NOT take off the cover to avoid wire throw off if wire broken. 9. Start the wire drum first and check if it runs well, then turn on the pump, and turn on high frequency at last to start machining. Turn off them backwards when finished.

5. Runs Machine in Good Conditions

The principle factors to influence machining precision and methods to improve machining precision: Apparently, the machine motion precision influences the working result precision directly. But the discharging gap and workpiece distortion will influence the machining precision during cutting besides the machine motion precision as well. 1. Machine precision: Even the machine tool is inspected in proper conditions by the producer before delivery, but the user shall check it again before machining precise parts and adjust it if necessary. (1). Check guide rollers: Operator shall check the guide rollers V-shape slot to see if it was worn out carefully before machining, see Fig-1. The wire is running in high speed in the V-shape slot during machining and it would cause some discharging and friction, the guide rollers V-shape would form a deeper slot underneath. It will cause the wire vibrate, make bad machining result and break the wire, please change the worn out rollers in time. And please often clean the dirt in V-shape.


Fig-1

(2). Check conduct blocks: The conduct blocks are made in carbide, please check if theres slot on it before machining. If the wire is inserted into the slot, please rotate it to change the touch position or change the blocks. (3). Check the backlash in X, Y ball screws: The backlash would change after a long time working, in case of machining high precision parts, please check it and adjust it if necessary to standard value before machining. 2. Discharging gap: The discharging gap between wire and workpiece are influenced by material, cutting speed, working fluid and etc. (1). Discharging gap changing: Because the difference from materials, heat treatments or workpiece thickness, the discharging gap is changing. The materials chemical characters, physical characters and flux of working fluid would change the gap as well. (2). Relationship of discharging gap and cutting speed (working current): The relationship between them is like a parabola, the gap is smaller when the cutting speed is faster in a specific range. But the cutting speed must slower than the eroding velocity, otherwise the wire and workpiece are short circuit and stop machining. Keep the current stable to keep erosion voltage stable and gap stable. So choose a set of proper time on

(Ton), time off (Toff) and other parameters to get a stable condition. Normally, operators choose big Ton on roughing to increase the cutting speed, and small Ton on finishing. Keep the current stable to keep the cutting speed regularity to guarantee the machining results. (3). Relationship of discharging gap and working fluid: The difference from working fluid components, the resistances, wash out abilities and dielectric abilities of fluid are different. All these factors can change the gap. So in finishing, the operator must choose a proper gap composition when posting the program. 3. Method to decrease workpiece distortion: The principle sequence for finishing steel parts on WEDM shall follow the steps: raw material, forging, anneal, rough machining, quenching, temper, grinding, EDM wire cutting, handcraft by locksmith. Therere 2 chances in this machining linkage to make big distortion and influence cutting precision. The material suffers the first distortion on rough machining, and the second distortion on temper. These distortions can not be ignored in high precision parts. For example, see Fig-2, when cutting the tempered steel square, on the wire path from A to B, the steel square could change itself as the dash line shown. As a result, the finished part is different from the design, if theres stain stress in the material, the width of the cut down square would be wider, or if theres press stress inside, the cut down square would be narrower.

Fig-2

On the right of Fig-2, we illustrate a distortion on machining part with a hole. During the machining of cutting the square hole, because of the stress inside material, the square hole would be like a tambour in dot line or a saddle in dash line. Sometime the distortion would take a more important part of role on machining precision than machine precision itself. Sometimes users can see the distortion by eyes and even the material would explode on machining. In order to avoid big distortion on materials, we analyzed molds and parts distortion factors under our knowledge in long time machining, we suggest follow below methods: (1). Choose small distortion materials as possible as you can. These materials are CRWMN, CR12M0, GCR15 and other alloy tool steel. (2). Try the best to lower the stress on forging and anneal. (3). Choose proper techniques and operation in right way on quenching and temper. Set the temperature as low as possible to lower limit and coolant equally on quenching. And set the temperature as high as possible to higher limit with enough time. Operation in this way can eliminate the stress as much as possible after heat treatment. (4). Methods on techniques:

A. Arrange the cold and heat steps properly to prepare for the heat treatment as last to decrease the stress and distortion. For high precision parts, temper the part in how temperature after cutting to stable the size. B. Do not cut the mold from outside of workpiece directly but make a hole to though the wire beside the edge of workpiece. And the cutting range should not near the workpiece edges to guarantee theres enough intensity on workpiece to against the stress inside. See Fig-3.

-18mm B

Fig-3

C. It is better to use twice cutting for upper punch molds on workpiece that grinded and tempered. The workpiece distortion is about 0.03mm, so better left 0.12-0.2mm (in the case of use 0.18mm molybdenum wire) cutting allowance per side and cut it in a higher speed. After the first cutting, the balance of stress inside the workpiece would be rebuilt to a new balance. Then cut to demand size to get a better precision. D. Machining the shape before heat treatment and left 0.6-1mm machining allowance for lower punch molds. In this case, the molds material distorted big enough during heat treatments. While the cutting allowance is quite small and would not break the stress inside

workpieces and the parts would not distort after cutting. For some low hardenability materials, this technique keep and increase the shape harden and improve the quality of mold. E. Choose the start point near workpieces gravity center and clamp it properly. When cutting to the closed point, the workpiece would distort little. F. Add some supports in proper position for big workpiece to decrease the distortion caused by the gravity of cut down part. G. For small parts and long semi-manufacture parts, therere too much factors to avoid all distortion. In this case, we suggest users adopt check and cut mixed method, measure the part during machining and modify posting program in time to get the design demands. 4. Analysis of cutting surface: The metallographic analysis and surface hardness test indicate theres a harden layer in different thickness and discrete, harder than before on the surface. The thickness of this layer is about 5-30um, hardness is about HV100 and like re-quenched. But theres another lower hardness layer about 2-4um thick attached, and maybe with some small cracks. So the 0.01mm thick on top of surface is not wearable. To increase the molds quality, when making small clearance fit molds, users shall left some allowance for grinding by hand.

6. Lubrication System
No 1 2 3 4 5 6 7 Lubricate part X axis ball screw Y axis ball screw X axis screw nut Y axis screw nut Wire drum linkage Wire drum screw nut Wire drum guides Frequency Every day Every day Every day Every day Every day Every day Every day Method Oil gun Oil gun Oil gun Oil gun Oil gun Oil gun Oil gun Oil 30# Oil 30# Oil 30# Oil 30# Oil 30# Oil 30# Oil 30# Oil

ATTENTION: 1. Change the high speed grease on the guide rollers every 2 weeks 2. Change other bearings every half year 3. Motors bearings shall be lubricated under motors manual

7. Machine Transporting and Installation

Left the machine under the wooden pallet. Open the wooden box in workshop, dont hit the box. Take off the cover of box first, and then take off the walls (or wrapped plastic bag). Take out the tool box and clean the protection grease. Then put the machine on hard ground with machine feet. Take off fixed iron parts on machine. Clean worktable to adjust horizontal level of the machine (horizontal level is 0.04/1000). Then connect all cables and check the precision of machine. Stands the machine on hard concrete ground and separate with vibration source and electrical magnetic noise.

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8. Machine Maintenance
Often clean the machine is the best way to keep the machine precision and long life, improve work efficiency. Please taking care the following matters: 1. Lubricate the machine with clean oil in time according to the manual. 2. Move all movable parts by hand to check if all in good condition before turn on the machine. 3. The machine shall work in environment temperature 5-35C, humidity 40-75, air pressure 86-110KPa. In order to get the best cutting result, keep the temperature constantly about 20C. 4. Clean the machine after working and put on grease on the easy rust parts. Clean the machine completely on time. 5. If theres any problem during machining, please stop working and contact professionals to repair it. 6. Read the operation manual carefully before operation on machine.

11

Part 2 Mechanism
1. Machine Tool Usage
EDM wire cutting machine DK-series consists of Numeric ControlHigh Frequency Power Generator and Machine Body. This machine tool is used to process metal dies patterns and mechanical parts used in electronic apparatuses, precision machines, commercial industry and military industry etc, with high precision, high stiffness and high toughness.

2. Machines Specifications
Machine Type Worktable Dimension Worktable Travels Max Machining Thickness Max Machining Taper Max Cutting Speed Best Surface Roughness Wire Diameter Wire Running Velocity Working Fluid Precision Movement Vector Power Source Power Dissipation Max Load Weight 250kg 320kg 600kg DK7732 366576 320400 400mm DK7740 410690 400500 400mm DK7750 550850 500630 500mm DK7763 7201100 630800 500mm (800mm Optional) DK7780 8201300 8001200 500mm (1200mm Optional)

0~60/100mm (Optional) 180mm2/min Ra0.8um 0.10-0.2mm 11m/s Water mixed with soap Accord to standard GB7926-87 0.001mm AC.380V.50Hz 2.2kw 1000kg 1200kg

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3. Machines Operational Part

No 1 2 3 4 Name Wire drum travel limit fork Operation Panel Valves Hand wheels of X, Y axes Function Adjust the width of wire Refer to next charpter Adjust upper/lower muzzles Move the worktable in X, Y axes

4. Operating and Adjustment

1. Preparation before working: Turn on the power switch and check the machine tool working status. Fill or change the cooling water. Check the Molybdenum wire

2. Adjust the arm: Make the Molybdenum wire is vertical against the worktable.

3. Check the worktable: Open the step motor function, the step motor will be stuck. Input some motion distance, make the axis go forward and backward, check if the gauge will back to "0" position. 4. Place and clamp the workpiece: Fix the workpiece holder on the worktable. Fix the workpiece on the holder properly. Check the position of the workpiece in the available travel area. The workpiece and holder is not touch the arm during processing. Clean the worktable.

5. Adjust the guide rollers:

13

Keep the guide rollers run fluently and stable. Attach lube on the bearing when change the rollers.

6. Operating steps: a. Turn on the computer b. Type in the post program c. Start the Molybdenum wire drum motor Don't turn on discharge. Please check the stress of the Molybdenum wire now. d. Turn on the water pump There are a line of drains on the lower arm, please keep it clean. e. Set the pulse width The pulse width influences the efficiency, accuracy and roughness. Choose a set of proper parameters is very important for processing. f. Start processing, adjust the current to stable status to avoid short circuit.

g. Process finished, turn off the high frequency power generator. Then turn off the pump and Molybdenum wire drum motor.

! Use the red emergency button when error occurs. This button can cut off the power at once.

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5. Troubleshooting
No Troubles Causes Solutions 1. stress the wire or replace the wire 2. check the table 3. adjust the parameters

Wire dent on 1. wire is loose the workpiece 2. the table is not balance surface 3. cut tract is not stable 1. wire is loose 2. V-channel on the pulleys wear out Wire shaking 3. vibration during turn direction 4. wire is bended 1. too wide in the pulley bearings Rollers run 2. trashes go into pulleys not agility 3. pulleys and bearings wear out 1. wire wears out 2. wire shaking heavy 3. lack of cooling water, the trash can't be pushed out Wire break 4. parameters are not fit the processing, cause short circuit 5. there is oxidation layer on the workpiece surface 1. low accuracy in the X, Y axis motion. 2. low vertical accuracy 3. pulleys and bearings wear Bad accuracy out 4. controller and the step motor lost the control pulse, the table not back the "0" position

1. 2. 3. 4.

stress the wire or replace the wire replace the pulleys and bearings adjust or replace the spindle replace the wire

1. adjust the pulley 2. wash the pulleys in the coal oid 3. replace the pulleys and bearings

1. 2. 3. 4. 5.

replace the wire check the cause of wire shaking adjust the flow of cooling water choose proper parameters cut the oxidation layer off the workpiece

1. check and adjust the spindles 2. check and adjust the vertical position 3. adjust or replace the pulleys and bearings 4. check and adjust the controller or replace the step motor.

15

6. Wear Parts
Part Name Conduct Block Guide roller assembled Wire drum junction Muzzle Quantity 3 2 3 2 Installed Position Upper/lower wire arms Upper/lower wire arms Connection drum and motor Upper/lower wire arms

16

Part 3 Electrical
The machine electrical equipments take the role of controlling wire drums motor running and directions, pump running, wire broken protection and other protection functions. For more details, please refer to the Electrical Schematics. Parameters set This kind of machine is upgraded from high speed wire cutting, but it is completely different from the controller. It is upgraded parameter setting to computerized from IC digital setting, upgraded wire running speed to variable from constant. These upgrades realized multiple cutting in finishing surface performance. But therere a lot of factors that influence the finishing result besides pulse parameters, discharging parameters. These factors include the molybdenum quality and diameter, working fluid type and etc. Even a settled set of parameters would performance different result because of the experiences of operators, workpiece materials and heat treatments. In this case, the operators not only shall follow the parameters table, but also have to practice during working. The principle rule of multiple cutting is cut once and trimmed twice. The high frequency pulse parameters are divided into 3 settings of BIG, MID, and SMALL. The BIG is for the first cutting, and MID is for first trimming, SMALL is for second trimming. Choose No.3, No.2 and No.1 on the computer to get the 3 type of high frequency pulse. For example, to cut a diameter 10mm and 40mm height column in multiple cutting:

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High frequency pulse No.3, 2 and 1 No.3 for rough cutting No.2 for first trimming No.1 for finishing trimming

Ton (us) 7 10 13

Toff 2 1 1

Power 7 15 15

InverterHz 2 4 6

Attention: The bigger Ton, the higher efficiency and bigger discharging gap. The smaller Ton will make machining stable but lose efficiency. The bigger current will get big cutting velocity but lower the stability and increase wires wear. The lower servo voltage, the higher efficiency but may not stable. The higher Inverter (Hz) can wash out ashes faster and make machining faster and easier.

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1. Plugs Definition
30PIN PLUG Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 4L+ 4L+ 4L+ 4L+ UY VY WY +24 04 +24V power Drum motor off (NC) Drums motor 4 axes step motors COM Label PE 24V1 Lamp power 24V2 18 19 20 21 22 23 24 25 26 27 28 29 30 12 AL2 02 13 COM 16 01 543 220 AL4 PMPM+ Drum motor onNO Wire broken protection Wire broken protection Emergency Stop Negative sample Positive sample Comment Ground Pin No. 16 17 Label 05 03 Comment Drum motor off (NC) Drum motor off led Drum change direction 1 (NO) Emergency Stop Drum motor on(NO) Drum change direction 2 (NC)

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20PIN PLUG Pin No. 1 2 3 4 5 6 7 8 9 10 XA XB XC XD XE YA Red Yellow Blue White Black Red Label PE Comment Ground Pin No. 11 12 13 14 15 16 17 18 19 20 Label YB YC YD YE UA UB UC VA VB VC V axis U axis Comment Yellow Blue White Black

4PIN PLUG Pin No. 1 2 3 4 Label W V U PE Comment Pump power phase W Pump power phase V Pump power phase U Ground Pin No. Label Comment

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Signals for controller on PCI slot (25PIN) 1 2 3 4 5 6 7 8 9 10 11 12 13 XA XB XC XD XE YA YB YC YD YE 12VPJD2 14 15 16 17 18 19 20 21 22 23 24 25 UA UB UC VA VB VC TK0 TK1 PJD1 PJD0 PMPM+

12V+ TK0, TK1, TK2 are stop condition signals. TK0, TK1 are normal open (NO); TK0, TK2 are normal closed (NC). PJD0, PJD1, PJD2 are high frequency singles. PJD0, PJD1 are normal open (NO); PJD0, PJD2 are normal closed (NC). PM-, PM+ are discharging sample.

Signals for controller on PCI slot (9PIN) 1 2 3 4 5 12VZA ZB ZC 12V+ 6 7 8 9 TK0 TK1 TK2

Attention: never short circuit 12V- with PM-, the 12V is supply by extend device. Jumper: Short the 25PINs no.13 with 9PINs No.5. Short the 25PINs No.20 with 9PINs No.9 (Stop signal). Break circuit the second machine stop line on front (change signals from NO to NC)

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15 PIN SLOT(J7) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Mitsubishi Inverter RUN C SE SD B

Tyco Inverter SYN+ RELAY SYNCOM TRIP

Comment A: frequency level B: alarm signal A: Cut off high frequency when direction changing COM B: out put relay

STF RL RM RH PC STR

FWD SP1 SP2 SP3 FM+ REV

Motor runs CW Frequency segment No.1 Frequency segment No.2 Frequency segment No.3 Motor runs CCW

Central control boards J8 Plug to 30 PIN PLUG J8 1 2 3 4 5 6 7 8 30 PIN PLUG 14 15 16 17 18 19 20 21 +24 04 05 03 12 AL2 02 13 J8 9 10 11 12 13 14 15 16 30 PIN PLUG 22 23 24 25 26 27 28 29 COM 16 01 543 220 AL4 PMPM+

Central control boards J10 1 2 3 4 5 6 High frequency KM1 Pump KM2 A1-110V A6-6V B6-0V A5-12V 7 8 9 10 11 12 B1-0V A4-12V B4-0V A2-20V B2-0V B5-0V

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VCC 13 9 R 6 220 VCC R 5 8 P-2 P-3 P-4 P-5 P-6 13 15 14 12 1 5 2 4 AA B B C C 11 10 9 6 7 U7 X0 X1 X2 X3 X4 X5 X6 X7 A B C INH VEE 4051 16 104 D4 K2 1 P-1
+

11 J1 13 25 12 24 11 23 10 22 9 21 8 20 7 19 6 18 5 17 4 16 3 15 2 14 1 X D C AA B B B A C C VCC 1/4 1/6 1/8 1us U2 DB25 K1 K1-8 K1-4 D3 R 8 K1-6 K1-16 4.7K 4.7K 1 C 9 C 8 3 4 D1 1 AC V+ B RIDGE2 C 5
+

2 3 R 100K 4

U1A

1 4

F-ON1 F-ON2

4 5

U9C

4012

10

2. High Frequency Board Schematics

C 2 220uF C 3

100K

8 U4 3 15 14 13 R 3 100K R ST C LK C INH K Q0 Q1 Q2 Q3 Q4 Q5 Q6 Q7 Q8 Q9 C O 4017 3 2 4 7 10 1 5 6 9 11 12

U8C

4011

10

4011

F-OUT

6 1 7 2 8 3 9 4 10 5
F-OUT 11 13 FF -OUT 9 K1-6 4 K1-8 J3 K1-16 16 1 1 2 3 4 5 6 7 8 9 10 R 9 U10A VCC 8 F-ON2 2 7 6 5 U10B TIP521-2 R 11 20K R 10 20K F-ON1 3 4 VCC 9 10 11 12 4012 Y1 4M Hz 470uF/25V U12 1 V IN 78L05 V OUT GND 3 D2 LED 2 VCC R 7 3K C 1 20 R 1 10M 4017 U1B 13 U5 15 14 13 R ST C LK C INH K Q0 Q1 Q2 Q3 Q4 Q5 Q6 Q7 Q8 Q9 C O 470uF/25V C 6
+

P-1

U9B

6 K1-4 8

FF -OUT

4011

P-2

U9A

4011 Q1 Q2 Q3 Q4 Q5 Q6 Q7 Q8 Q9 Q10 Q11 Q12 9 7 6 5 3 2 4 13 12 14 15 1

P-3

12

U9D

VCC

JUM P
10 11

11 1/2 1/4 1/8 1/16 1/32 1/64 1/128 1/256 C LK R ST

J2

13

4011

C ON10 F1 FUSE1 104 104

U6 1us 1/2 1/3 1/4 1/6 1/8 1/12 1/16 1/24 1/32 1/48 1/64 1/96 1/128 1/192 1/256 9 8 7 6 5 4 3 2 23 22 21 20 19 18 17 16 IN 0 IN 1 IN 2 IN 3 IN 4 IN 5 IN 6 IN 7 IN 8 IN 9 IN 10 IN 11 IN 12 IN 13 IN 14 IN 15 OUT

P-4

U8B

6 4040 U3 3 2 4 7 10 1 5 6 9 11 12 Q1 Q2 Q3 Q4 Q5 Q6 Q7 Q8 Q9 Q10 Q11 Q12 10 R 2 10K 11 C LK R ST 4040 9 7 6 5 3 2 4 13 12 14 15 1 1/3 1/6 1/12 1/24 1/48 1/96 1/192

4011

1 2 3 4 5 6 7 8 9 10

AC V-

U8A

C ON10

P-5

3 A B C D /EN 4067

10 11 14 13

A B C D

4011

P-6

12

U8D

2 4 6 8 10 1 3 5 7 9

11

13

15

4011

23

A R 1A 14 240 DIA 41 48 R 2A 2K 2 40 49 U1A U1E R 1B 12 240 DIB 41 48 4 4049 D2B 1/2W 12V R 2B 2K 4049 U1B 5 QB IR F250N 11 B B D3B B 29X Y3 D2A 1/2W 12V AA U1F 3 4049 15 QA IR F250N D3A B 29X Y3

VL

1A +C 10UF

VL

VL

1B +C 10UF

R 3 10W 3K

C 5 104

C 4 104

4 3 2 1

8 7 6 5

3. Power Board

9 J1 C C 10 9 8 7 6 5 4 3 2 1 7 4049 VCC AA B B C C 14 DD 3 U2A 4049 4049 2 U2F 15 6 C ON8 EE FF DD U1C 4049

U1D 10

R 1C 240 DIC 41 48 D2C 1/2W 12V R 2C 2K QC IR F250N

D3C B 29X Y3

VL

1C +C 10UF

E D3D R 1D 240 DID 41 48 D2D 1/2W 12V R 2D 2K QD IR F250N B 29X Y3

VL

1D +C 10UF

6 5 4 3 2 1

12 11 10 9 8 7

2 4 6 8 10 1 3 5 7 9
9 E E D? 1 2 3 4 5 6 7 8 VDD /A A /B B /C C GND 4049 -1 5 NC /F F NC /E E /D D 16 15 14 13 12 11 10 9 FF 7

E R 1E U2D 4049 U2C 4049 6 10 240 DIE 41 48 D2E 1/2W 12V R 2E 2K QE IR F250N D3E B 29X Y3

VL

1E +C 10UF

F R 1F 11 U2E 4049 U2B 4049 4 12 240 DIF 41 48 D2F 1/2W 12V R 2F 2K QF IR F250N D3F B 29X Y3

VL

1F +C 10UF

24

J8 1 2 3 4 J8_5 5 6 7 8 9 10 11 B6-0V 12 J8_13 13 14 PM15 PM+ 16

C ON16

+24V

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 +24V J5_11 J5_13 J5_14 J5_15 J5_16 J5_17 relay/c J5-6 J5_20

J5

C ON20

2 4 6 8 10 12 14 16 18 20 1 3 5 7 9 11 13 15 17 19
+24V 11 13 9 6 4 8 1 k4 16 +24V SPEAKER

11

11 rev/str

com/sd

13

13

fwd/stf

J5_7

J5-19

J5-19

+24V

J8_13

J8_5

J8-5

k1

16

J8-15

k5

16

4. Central Control Board

A6-6V J8_10

2A

F3

R 3 470 7 +C J8_13 2200uF B 6-0V

U0

J9 1 2 3 4 5 6 7 8 9 10 J5_14 A4-12V PJD J5_6 J9_8 13 J5_13 6 B 4-0V 4 KM-F C 10 16 J5_15 J10 1 2 3 4 5 6 7 8 9 10 11 12 120/0.5W B 1-0V A1-110V A5-12V 2 B 5-0V 3 AC AC D1A C ON12 KM-F KM-P A1-110V A6-6V B 6-0V A5-12V B 1-0V A4-12V B 4-0V A2-20V B 2-0V B 5-0V R 5 K2 R 4 120/0.5W F2 2A V+ VB RIDGE U1 1 V V OUT IN 2 +C GND 1000uF/50V 7824 A2-20V 2 B 2-0V 3 AC AC D1B V+ VB RIDGE 1 4 3 1 4 U2 1 V V OUT IN 1 +C GND 1000uF/50V 3 1 J5_11 8 KM-P C 9 16 8 9 J5_17 9 6 J5_16 11 J5_20 11 C ON10 syn-/se

+24

11 13 J8-5 UB 4 J1 13 25 12 24 11 23 10 22 9 21 8 20 7 19 6 18 5 17 4 16 3 15 2 14 1 1 K3 2 5 +C 7812 470uF/50V C C 6 6 R ? R ES1 2 3 +C C C AP 4 470uF /50V R 1 470 DB25 XD XE +24V D11 LED +12V D22 LED +12V PM+ VA PMGND PJD YE +24V YD TK YC +24V YB VC YA VB XE VA XD UC XC UB XB UA XA XC XB XA 1 2 3 4 5 6 7 8 9 10 J2 YE YD YC YB YA 1 2 3 4 5 6 7 8 9 10 J3 VB VC UC J4 1 2 3 4 5 6 7 8 9 10

11

13

TK

8 +C 2200uF

16 U/V

k8

11

com/sd

8 Y

16

7 1 8 2 9 3 10 4 11 5 12 6

k7

1 syn+/run9 2 10 fwd/stf 3 relay/c 11 4 sp1/rl syn-/se12 5 sp2/rm com/sd13 6 sp3/rh trip/b 14 7 fm+/pc 15 8 rev/str

6 1 7 2 8 3 9 4 10 5

DB9 DB15 J6 J7

1 6 RH 2 7 RM 3 8 RL 4 9 5

D4

13 sp2/rm

sp1/rl

16

J9_8

k6

13

sp3/rh

J8-10

25

NC C OM NO JI-5 C OM NO J1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 +24V JI-5 JI-6 JI-7 JI-8 JI-9 JI-10 JI-11 JI-12 JI-13 JI-14 JI-15 JI-16 JI-17 JI-18 JI-19 JI-20 J1-7 + SB 2 NC

NC

C OM

NO

JI-9

NC

JI-19

C OM

NO

JI-8

SB 1

NC C OM NO JI-15 C OM NO J1-16 + SB 4 NC

NC

C OM

NO

5. Buttons board

AL1 AL2

JI-13

NC

JI-8

C OM

NO

JI-15

SB 3

C ON20 C OM

NC NO J1-11 C OM NO J1-20 + SB 5 NC

NC

C OM

NO

JI-17

NC

JI-8

C OM

NO

JI-11

2 4 6 8 10 12 14 16 18 20 1 3 5 7 9 11 13 15 17 19
SB 8 + C OM

SB 6

SB 7 NC NO NC J1-6 C OM NO +24V

NC

C OM

NO

+24V

NC

C OM

NO

J1-14

26

Part 4 Operation and post program

1. Parameters list
15 1 14 2 13 3 12 4 11 6 10 8 9 12 8 16 7 24 7 1:2 6 32 6 1:3 5 48 5 1:4 31 1 7 10 6 20 4 64 4 1:5 15 2 5 25 3 96 3 1:6 7 3 4 30 2 1 0 Ton (s) Toff

128 192 256 2 1:7 3 4 3 40 1 1:8 1 5 2 50 0 1:9 0 6 1 60

Set Toff to 0 when use single trip cut function

Power Inverter (Hz)

Recommender 2 sets of parameters for widely usages. (Only for reference, adjust them according to practice jobs) Cut normal steels (Thickness less than 80mm and cut with trim) Set No. M10 M11 M12 M13 Ton 3 12 9 6 Toff 2 0 1 2 Power 31 15 15 7 Inverter 2 7 3 2

Cut normal stainless steels (Thickness less than 80mm and cut with trim) Set No. M10 M11 M12 M13 Ton 3 13 10 6 Toff 2 0 1 2 Power 31 15 15 7 Inverter 2 7 4 2

Attention: The M10 set is used for align molybdenum wire to vertical, please do NOT change this set.

27

2. Post the trim program (Cut once and trim twice)

1. Draw the parts shape, like the circular drawing in blew picture:

Drawings above process are graphic for assistant purpose

Drawings to be processed

2. Go to next step:

Press Next to go to next step

28

3. Set the total times of cutting and trimming:

Set the times of CUT. Only cut once, set it to 1; and cut 3 times, set it to 3.

4. Save the posted G code:

29

5. Go to the working screen and read out the posted program:

High frequency switch

Power on the step motor (J)

Servo sensitive

Read out the saved post

30

6. Set Parameters before Machining

1. Go to the parameter list from working screen:

Go to the parameter list

2. Choose other parameters menu:

Choose other parameters

31

3. Go to the next menu:

Get into the parameters setting

It will pop up a message to inquire you if you need to modify the parameters? Answer it NO 4. Choose the set of parameters in M13 and send it:

32

MACHINE:
ZGEDM

DK7740A

CNC EDM WIRE CUTTING MACHINE

PACKING LIST
WORKTABLE TRAVEL: WORKTABLE DIMENSION: SERIAL NUMBER: 500400 720460

SUZHOU ZHONGGU MACHINE & ELECTRONIC TECHNOLOGY CO., LTD THE PEOPLES REPUBLIC OF CHINA

DK77 SERIES EDM WIRE CUT

No.
1 2 3 4 5 6 7 8 9 10 11 12 13

PACKING LIST
ITEMS QUANTITY
1 set 4 pairs 1 set 1 set 1 set 1 set 1 set 1 set 1 set 1 book 1 sheet 1 sheet 1 sheet

1 PAGE PAGE 1

COMMENTS

Machine tool DK7740A Machine foot and foot bolt Crank for wire drum Breakwater cover for wire drum Wire tension adjuster Clamp Water muzzle Vertical guage Guide rollers installation tool Users manual Inspection certificate Packing list Warranty card

Installed on machine Only for taper device

NOTES:

PACKAGE INSPECTOR: DATE:

MACHINE:
ZGEDM

DK7740A

CNC EDM WIRE CUTTING MACHINE

WARRANTY CARD
WORKTABLE TRAVEL: WORKTABLE DIMENSION: SERIAL NUMBER: 500400 720460

Contact us: Address: No.888 Xiangcheng District, 215131, Suzhou, China Telephone: +86-0512-85185518 Email: webmaster@zgedm.com

SUZHOU ZHONGGU MACHINE & ELECTRONIC TECHNOLOGY CO., LTD THE PEOPLES REPUBLIC OF CHINA

WARRANTY TERMS
1. We provide one year warranty for every machine tool. 2. Please send the warranty card to us after start machines. We will establish users profile to provide you the warranty services. 3. When you face some problems of machines, regardless in or out of warranty, kindly please contact us and tell us detailed problems, machines information and service place to help us send technician to the machine as soon as possible. 4. All wear parts are not in warranty, e.g. pulleys, bearings, guides and bulbs. Users shall buy the wear parts but no service cost during the warranty period. 5. Please take the warranty card with you when you come to us for exchanging malfunction parts. Users shall under our instructions when change any part on the machine themselves. 6. If problems caused by users transport the machine, add new part on the machine, not care the machine properly or operate the machine not under instructions, we do not take the responsibility for service free of charge even if the machine is in warranty. 7. We sell spear parts and wear parts for our machines. When you need to buy them, please contact us and tell us what you need. We will send the parts you need after you pay them. 8. The operators shall be trained before start the machine or maintenance. If you need some train courses, please fill the TRAIN COURSES TABLE and send us with warranty card. 9. When you need update machines or some special functions, please contact our sales department. We provide maintenance and technology service over life of machines.

WARRANTY CARD OF ZGEDM (PART 1)

Serial number: CUSTOMER DEALER MACHINE DATE INVOICE DATE YY/MM/DD YY/MM/DD MACHINE MACHINE S/N INVOICE S/N Please save the part 1 in users hand

Suzhou Zhonggu Machine & Electronic Technology Co.,Ltd Addr: 888 Chenyang Rd, Xiangcheng District, Suzhou, China. Tel: +86-0512-85185518 FAX: +86-0512-85185515 Website: www.zgedm.com email: webmaster@zgedm.com

WARRANTY CARD OF ZGEDM (PART 2)

Serial number: CUSTOMER MACHINE DEALER BANK TELEPHONE MANAGE DEP. MACHINE S/N INVOICE DATE ACCOUNT FAX OPERATE DEP. ADDRESS MACHINE DATE INVOICE S/N POST NUMBER EMAIL REST DAY Please send part 2 to our company

CUSTOMER FEEDBACK SURVEY

INSTALL RESULT: TECHNICIAN: CUSTOMERS ADVICE: CUSTOMER (SIGN):
Suzhou Zhonggu Machine & Electronic Technology Co.,Ltd Addr: 888 Chenyang Rd, Xiangcheng District, Suzhou, China. Tel: +86-0512-85185518 FAX: +86-0512-85185515 Website: www.zgedm.com email: webmaster@zgedm.com

DATE:

DATE:

SERVICE RECORDS
DATE PROBLEM SERVICE EXCHANGED PART SERVICE RESULT TECHNICIAN CUSTOMER COMMENTS SIGN

Suzhou Zhonggu Machine & Electronic Technology Co.,Ltd Addr: 888 Chenyang Rd, Xiangcheng District, Suzhou, China. Tel: +86-0512-85185518 FAX: +86-0512-85185515 Website: www.zgedm.com email: webmaster@zgedm.com