CHMER WIRE CUT- EDM User manual

WIRE CUT- EDM
Operation Manual
SOFTWARE VERSION：W5F F0800
MANUAL VER：B
Copyright Reserved
CHING HUNG MACHINERY & ELECTRIC INDUSTRIAL CO., LTD.
886-4-23500333
Please Read This Manual Thoroughly Before Operation

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

INDEX
0-1
Company Profile--------------------------------------------------
0-1
0-2
Safe Instruction---------------------------------------------------
0-5
Chapter 1.
System Introduction
1-1
System Composition---------------------------------------------
1-1
1-2
Panel & Keyboard------------------------------------------------
1-2
1-3
Machine Body & Filtration Unit-------------------------------
1-16
1-4
System Boot Up and Shut Off----------------------------------
1-21
Chapter 2.
W5F Software Function
2-0
Map of W5F Software
2-1
DISP Mode--------------------------------------------------------
2-1
2-2
FILE Mode--------------------------------------------------------
2-10
2-3
AUTO Mode------------------------------------------------------
2-57
2-4
MAN Mode-------------------------------------------------------
2-85
2-5
DATA Mode-------------------------------------------------------
2-126
2-6
HELP Mode-------------------------------------------------------
2-136
Chapter 3
Application of G, M code
3-1
G Code Illustration-----------------------------------------------
3-1
3-2
Usage Description of G Code-----------------------------------
3-7
3-3
Auxiliary function (M Code)------------------------------------
3-42
3-4
G, M Code Comparison with Others---------------------------
3-47
Chapter 4
Appendix
4-1
Consumable List--------------------------------------------------
4-1
4-2
Shield Room-------------------------------------------------------
4-5
4-3
Precaution for Malfunction--------------------------------------
4-9
4-4
Setup of Remote Monitoring Software------------------------
4-11
4-5
Lower Head Disassembled and Assembled-------------------
4-15
4-6
Upper Head Disassembled and Assembled-------------------
4-18
VER: E5B-1087B
DATE: 2012.01
EDITOR: Eirene Wu

CHMER Wire-Cut EDM Operation Manual W5F
0-1 Company Profile
CHMER BRIEF EVENTS:
1.1975 ◆CHMER EDM company was founded（with registered capital
NT$200.000.-）to market the first“Transistor”EDM machine in
Taiwan.
2.1976
◆
The first hydraulic control EDM machine came out.
3.1977 ◆EDM machine with th
e functions of free adjustment of pulse on & off
was produced.
4.1979
◆
Moving to the new factory for developing southeast-Asia market.
5.1980
◆
Leading to export EDM machine made in Taiwan to Europe.
6.1981 ◆Supplying the first EDM with P.W.M. servo motor driver to the
domestic market.
7.1982 ◆Achieving two patents for the new square axes with national central
standard bureau of the republic of China.
8.1983 ◆The first EDM manufacturer obtaining“Golden dragon award”form
the government.
9.1985 ◆In April, the first multifunctional CNC EDM machine equipped with
orbit-cut was produced.
◆
In July , the first EDM machine with the finest and super finish device
of U-SPARK In Taiwan was produced.
◆
In August, Sound Best Trading Co., Ltd Established.
◆
In September, Hung Yu Trading Co., Ltd Established.
10.1986
◆
In February, Ching Yeng Machine & Electric Co., Ltd Established.
11.1987 ◆In July, the first EDM machine without backlash on x & y axes was
marketed.
◆In April, the WIRE-CUT EDM machine was completed and obtained
the excellent-product design award from CETRA of Taiwan, ROC
12.1988
◆
In August, small hole drilling EDM was completed.
◆In December, President Wang was honored with the model of
business – founding youth for the 11th term.
13.1989
◆
In March, the giant bridge type of EDM was created.
◆In April, marketing new type of CNC EDM which interfale was
available for modifying to sparking conditions during machining.
◆
In Jun, Chiao Yeng Machine Co., Ltd. Established.
◆
In Jun, Hwang Long Machinery Industrial Co., Ltd. Established.
14.1990 ◆In October, obtaining the patent for structure improvement of the
giant bridge type of EDM
（
NEW MODEL NO.58428
）
0-1

CHMER Wire-Cut EDM Operation Manual W5F
15.1991 ◆In October, the patent for improvement structure of the worktable guide
bridge type of EDM
（
NEW MODEL NO.68192
）
◆Obtaining the patent for improved structure of the Prototype of EDM
tank ascending & descending
（
NEW MODEL NO.74419
）
.
16.1992
◆
In September, capital increased up to NT$50.000.000.-
17.1993 ◆In October, moving to the new factory with air—conditioning system to
enlarge production covering digital products of high-scientific
technology.
◆
In Sep, Hang Zhou Ruipeng Machinery & electric Co., Ltd Established.
18.1994 ◆
In January, NC EDM with programmable Z axis, model CM240Z+50NZ,
& CNC EDM with PC base controller, model CM240Z+50NC, achieved
excellent product award of “IT’S VERY WELL MADE IN TAIWAN”
from CETRA in Taiwan.
◆
In March, Sound Best Automaticalization Industry Co., Ltd Established.
◆
In December, Yukon CNC Machinery Co., Ltd. Established.
19.1995 ◆In January the 1st
EDM manufacturer, in Taiwan, obtaining certificate of
quality assurance specified as ISO 9002 form the BCIO of Ministry of
Economic Affairs.
◆In March, President Wang, received Award of “GOLDEN TALENT” as
“INVENTIVE ENTERPRISER” from INDUDTRY ASSOCIATION
OF TAICHUNG, TAIWAN.
◆In November, Honored as “MODEL OF INDUSTRY” form Taichung
County Govern.
◆In December, obtained “GRAND GRAGON CENTURYAWARD OF
TAIWAN”.
20.1996 ◆In January, obtain Attestation of conformity for technical file and
non-annex IV machinery with the requirements of the machinery
directive 89/392/EEC “FROM NOTIFY BOY”
◆
AMTRI VERITAS LTD. certificate number
：
AV EC 1105
（
G
）
.
◆In February NC EDM with programmable Z axis, model
CM380Z+50NZ & CNC EDM with PC base controller, models
CM855C+75NC, CM645C+75NC achieved excellent products award of
“IT’S VERY WELL MADE IN TAIEAN” from CETRA in Taiwan
again.
◆In August, the products of wire-cut EDM, CNC EDM & NC EDM
WITH PROGRAMMABLE Z AXIS obtained
“THE INTERNATIONALGOLDEN GLOBE AWARD FOR
0-2

CHMER Wire-Cut EDM Operation Manual W5F
EXCELLENT EXPORT PRODUCT MADE IN TAIWAN”.
21.1997 ◆In Jan, CNC wire-cut EDM models CW430F, CW430W, CW530F,
Cw530W obtained award of “IT’S VERY WERY WELL MADE IN
TAIWAN”
22.1998 ◆CNC Wire-cut EDM models CW640 obtained award of “IT’S VERY
WELL MADE IN TAIWAN”.
23. 1999
◆
Obtain Rising Star Award and National Award.
24.2000
◆
Enterprises Professional Manager Award.
◆The 67th of “Top 100 up growth backbone enterprises”. Statistics by “Common
wealth” magazine.
25.2001 ◆Provide fist precision bridge CNC wire cut EDM & CNC powder
EDM.
◆The 29th of “Top 100 potential enterprises” Statistics by “Common
wealth” magazine.
26.2002 ◆
In January, “CW432S” “A53C+75N” obtained Award of “IT’S VERY
WELL MADE IN TAIWAN”
◆In February, obtained certificate of quality assurance of ISO 2000
Version.
27.2003 ◆
In January, “CM434Z+50EZ” obtained Award of “IT’S VERY WELL
MADE IN TAIWAN”
◆
Register into Emerging stock market.
◆In September, “CM323Z+50EZ+OB-head obtained”﹝Middle
Enterprise Innovation Research Award
﹞
◆In November, CHMER obtained “The Nest Innovation research
Company” award.
28.2004 ◆In January, “CW-32CF/S”wire-cut EDM models obtained of “IT’S
VERY WELL MADE IN TAIWAN” award.
◆In March, CHMER obtained ISO 14000 Quality system certified, who
is the 1
st
among EDM manufacture in Taiwan.
◆In March, Introduce the 1st linear motor high precision wire-cut EDM
in Taiwan.
29.2005 ◆In January, “P42SL” high precision wire-cut EDM model obtained of
“IT’S VERY WEEL MADE IN TAIEAN” award.
0-3

CHMER Wire-Cut EDM Operation Manual W5F
COMPANY ORGAIZATION
Taichung Headquarters
：
1.CHING HUNG MACHINERY & ELECTRIC INDUSTRIAL CO.,LTD
No.3, Jing-Ke 1st Road, Nantun District, Taichung City 408, Taiwan
TEL:[phone] FAX:[phone]
2.Taipei Branch office
HUNG YU TRADING CO.,LTD.
NO.13,Dec4.Chung Hsing Ed , San Chung City, Taiwan, R.O.C
TEL：[phone] FAX：[phone]
3.Hang Zhou Factory
HANG ZHOU RUIPENG MACHINERY & ELECTRIC CO.,LTD.
No.25,Ningdong Road Xiaoshan Economic Techinical Development Zone
TEL：[phone] FAX：[phone]
0-4

CHMER Wire-Cut EDM Operation Manual W5F
0-2 Safety Instruction
0-2-1Machine stop
When the emergency occurs, operator can stop machine by following two ways：
Emergency Stop & Main Power switch.
Emergency Stop：When pressed, except of computer power, motors, pumps
would be shut off.
Main Power：When turned off, the power of machine and Power Cabinet will
all be shut off.
No Fuse Breaker：Be sure to turn off no fuse breaker and main power before
maintenance.
0-2-2 Precaution of safe operation
A safe operation is relying on complete precautions to occasional accidence,
machine breakdown and operator negligence. Please keep these in mind and
check machine security every time before actual operation. Even though,
there are many built-in safety constructions in machine, still possible to have
potential dangers if depends on machine too much and absent the precautions in
mind.
Emergency Stop
Main Power
No Fuse Breaker
0-5

CHMER Wire-Cut EDM Operation Manual W5F
0-2-3 Operation precautions
1. If find or smell or hear any abnormal conditions, please press emergency
stop button immediately then start to locate the problem.
2. There will have fatal high voltage high current passing through on duration.
Therefore, strictly prohibit touch anywhere is above water pan during
sparking.
3. There also will have electric power on traveling wire from wire spool to wire
waste box. Prohibit to any parts wire will contact during sparking.
4. Keep away from XY axis and its metal covers for potential finger-folding
injury at jogging XY plane.
5. There always will have water on worktable & water pan. Don’t stand on it
anytime.
6. Screw well PE ground lines in power cabinet and electrical boxes (on
machine column & water tank) for avoiding electric shock.
7. When power on will start exhaustion fans. Don’t insert your fingers into fans
or its filters.
8. Don’t open power cabinet doors (front door & rear door), doors of electrical
boxes or metal covers of machine body for avoiding electric shocks.
9.When machine shut down, there still have electric power on capacitors.
Don’t touch it.
10. Don’t let water splash on power cabinet or electrical boxes for avoiding
electric shock.
11. Stop machine immediately when finding out split/broken plastic coated of
electrode cables (connect between machine body & power cabinet) and,
don’t start machine before repair
12. Don’t dismount lines with E or PE marks ground lines to keep away of
electric shock.
13.On machine duration or after machining, there will have higher temperature
on work piece. Don’t touch it directly by hands.
14.Watch out of finger cut injury or, as put on work piece with sharp edge or
put on wire spool.
15.Please must shut down main power switch before opening power cabinet
doors or electrical boxes.
16.Please check and screw well fork pins on terminal blocks before powering
on. If any loosen pin and power on, may cause unbalance power input,
motor noise, motor burning, terminal block burning.
17.Regarding the waste materials like silt, lubricating, paper filters, used wire,
ion resin and broken parts please take over with quality recycle dealer or
obey local deposition law.
18.For taking care of water splash out shall open upper / lower flushing knobs
from minimum to maximum.
0-6

CHMER Wire-Cut EDM Operation Manual W5F
19.Avoiding water splash on floor at any time, that has potential dangers people
fall down or get electric shock.
20. The light from the work-lamp could generate high heat on the items
illuminated. Please be aware and keep fusible material such as plastic
cables away from being irradiated by work-lamp.
Safe operation and place for the personnel
1. Get rid of metal chips, water or oil is onto around the machine.
2. Operator puts on safe glasses and safe shoes.
3. When move in/ move out the work piece from working table, watch out the
fall down risk.
Checking points for safe dielectric cutting
1.Ensure work piece is fixed well by proper jigs and fixture ways on working
table.
2.Wire electrode is loading and traveling well by instructions.
3. Electrode cables / ground lines
a. Are they screwed properly？
b. Cable coating in good conditions without any split？
c. Upper/ lower nozzle distances are adjusted well won’t crash to each
other
Precaution of the use of stainless steel
1.The improper way of material conservation will shorten its life span.
Stainless steel tends to erode more rapidly after in touch with other materials.
2. The rust from other material could be passed to stainless steel if not properly
stored.
Checking points before cutting
1.Dielectric level is set properly (Submerged model)？
2. Is dielectric level dropping down accidentally？
3. Is work tank locked properly (submerge type)？.
4. Is Rubber Seal of tank door damaged？
Checking points while cutting
1. Make sure no leakage of dielectric.
2. Upper/Lower flush pressure were adjusted to be coincident？
0-7

CHMER Wire-Cut EDM Operation Manual W5F
3. Is Cutting technology well setup?
4. For no-man operation, please make sure machine can achieve：
a. Smooth and reliable cutting condition?
b. Constant and stable flush pressure?
c. Dielectric level (for submerge type) remains constant？
0-8

Chapter 1.
System Introduction
■
1.1 System Composition
1-1
■
1.2 Panel & Keyboard
1-2
■
1.3 Machine Body & Filtration Unit
1-16
■
1.4 System Boot Up and Shut Off
1-21

CHMER Wire-Cut EDM Operation Manual W5F
1-1 System Composition
Wire Cut machine is consisted of three major parts：Power Cabinet, Machine Tool, and
Filtration Unit.
1. Power Cabinet
Contains majority of fuses, TFT LCD Display, Power Line, Computer and
Sparking Circuit.
2. Machine Tool
There are two types of Machine Tool: Submerged and Flushing, which differed
from each other by whether equipped with (S) a stainless tank or not (F). For
example, CW 530S, CW 530F.
3. Filtration Unit
For dielectric filtration and de-ionization.
Power Cabinet
Machine Body
Filtration Unit
Filtration Unit
1-1

CHMER Wire-Cut EDM Operation Manual W5F
1-2 Power Cabinet, Console Panel and Remote Control
1-2-1 Power Cabinet & Console Panel
Console Panel
1
6
2
3
3
4
5
Power Cabinet
9
8
10
1-2

CHMER Wire-Cut EDM Operation Manual W5F
1. Analog Voltage Meter
Display the variation of EDM voltage to control machining speed.
2. Monitor
15”(standard) TFT LCD monitor.
3. Control panel
a. Text key: for normal information and number input.
b. Hot key: control the EDM conditions. (e.g. EDM power supply, dielectric,
wire feed rate and tension)
c. Function key: system function execution.
4. Buzzer
Provide warning sound to remind the operator.
5. EMG-stop button
Under any situation, push this button will cut off power of the controller.
6. Main Power Switch
Main switch of the CNC controller.
7. Remote control
Contains basic hot key to operate the machine.
8. No Fuse Breaker
ON/OFF switch for electric current inflow and overload protection.
9. CF Card Drive/ USB Card Reader (Reserved for OPT)
Data storage interface of NC program from external computer. CF memory card or
USB for data storage.
10. CNC Power ON button
This button is for CNC controller power actuation.After switching on the main
electric power, push this button will actuate the CNC controller. Also, its power
indicator will be on at the same while.
※
Optional Functions (have to confirm controller’s version)
a. Mi
crosoft Mouse / Touch Screen
b. Memory CF Card capability
c. Installing in-house GENTEC Remote Monitoring software enables N.C. file
download /upload, watching on machining status from Client PC through
Internet
1-3

CHMER Wire-Cut EDM Operation Manual W5F
1-2-2 Introduction of text keys
1. A~Z
Input key of English alphabet
2. 0~9
Number input
3. Page up, Page down
For page exchange (NC program or column)
4. Home, End
When executing program edit or data input, move
the cursor to the left or right of the line.
5. Back
When executing program edit or data input, move the
cursor backwards and delete the original bit.
6. Space
Blank bit.
7. Enter
For data input, function execution or lines addition during program editing.
8. Ins
Switch knob of character insert or replacement when editing program.
9. Del
When executing program edit or data input, delete the character on the cursor
10.
↑
,
↓
For cursor movement or working data change when executing program edit or
data input.
11.
→
,
←
For cursor movement when executing program edit or data input.
12.+/-
Positive/negative marking of input data or increase/decrease of EDM data.
13.Esc
Cancel the input data.
1-4

CHMER Wire-Cut EDM Operation Manual W5F
1-2-3 Introduction of quick function key
Operator could apply below quick command：
1. Use ＋/－button to change the value of each item of sparking data.
2. Type S??? (ex: S045) in Data Bar is to backup current sparking data to
S-code No. 045.
3. Type E??? (ex: E045) in Data Bar is to call up existing sparking data from
S-code No. 045 for use.
4. To reset Work Coordinate., type Rin Data Bar then press ENTER.
5. To specify the value of each axis in Work Coordinate., type X??? Y???
Z??? U??? V??? in Data Bar then press ENTER . ??? is specified value.
6. To move axis incrementally, type MX??? MY??? MZ??? MU??? MV???
In Data Bar and press ENTER. Mactually means Move.
7. To move axis by specific Coordinate. System, type M#X??? M#Y???
M#Z??? M#U??? M#V??? in Data Bar and press ENTER. #(0：Machine
Coordinate. / 1：PGM / 2：G92 / 3：Work Coordinate.)
8. To move axis to reference point (G054~G959), type MG#5$X??? Y???
Z??? U??? V???.”#ranges from 0~9, and $is from 4~9.
9. To move 1/2 distance of what mentioned from 6.~8., type MX/2, MY/2,
MU/2, MV/2.
10. In Data Bar, type GO and press ENTER , machine will move to the zero
points of the coordinate system where the cursor is currently on.
11. To execute N.C program from specific line, type N??? under
MEM\F1(MEM. PATH) when RESET button is lit on.
1-5

CHMER Wire-Cut EDM Operation Manual W5F
1-2-4 Introduction of operation key
1. JOG
If this button is pressed, four kinds of table moving speed are selectable
including H (high speed), M (middle speed), ML (speed between middle and
low) and L (low speed). Under this mode, if the axis-moving key is pressed,
the table will move by setting speed. If it is released, the table will stop
moving.
Note: 1. If the JOG button is pressed twice in 1 second, it will execute AUTO
mode.
2. The value of JOG feed-rate override may adjust in the mode Help-2
>「System Double Value Parameter」, PA#36~PA#41 (We strongly
recommend user may not modify the value at will, otherwise it may
cause unexpected damage to machine tool)
2. STEP JOG
If this button is pressed, the table will move by set increment. The set
increments include H (1000µ), M (100µ), ML (10µ) and L (1µ). Under this
mode, if the axis-moving key is pressed one time, the table will move 1
increment distance. If you want 2 increments movement, press the axis-moving
key twice.
1-6

CHMER Wire-Cut EDM Operation Manual W5F
Note: 1. Additionally increases the JOG speed to be 2 steps.
Setting method: Press H or M key twice in 1 second. Flash indicator
means that setting is finished.
2. The value of STEP JOG feed-rate override may adjust in the mode
Help-2>「System Double Value Parameter」, PA#42~PA#47 (We
strongly recommend user may not modify the value at will,
otherwise it may cause unexpected damage to machine tool.)
3. H, M, ML, L
These four keys are for speed setting under JOG mode. However, they are for
moving distance setting under STEP JOG mode.
Note: 1. Additionally increases the JOG speed to be 2 steps.
Setting method: Press H or M key twice in 1 second. Flash indicator
means that setting is finished.
2. The value of STEP JOG feed-rate override may adjust in the mode
Help-2>「System Double Value Parameter」, PA#42~PA#47 (We
strongly recommend user may not modify the value at will,
otherwise it may cause unexpected damage to machine tool.)
4.
+U/+X，-U/-X，+V/+Y，-V/-Y，+Z，-Z
These are axis direction keys. Under JOG or STEP JOG mode, they could
control the moving direction of the worktable.
5. UV/XY
This is direction switch key. When the indicator is lit, it represents XY plane. On
the contrary, it becomes UV plane. (Parameter 68 bit 1)
6. VERT
Press twice quickly, then worktable will return to vertical point; it ends up
when the LED lights on.
7. S
.
PT
This key is for start point quick return. When it is pressed, the worktable will
return to start point quickly. If the indicator is lit, it represents that the present
position is the start point.
1-7

CHMER Wire-Cut EDM Operation Manual W5F
8. B
.
PT
This key is for break point quick return. When it is pressed, the worktable will
return to wire break point quickly. If the indicator is lit, it represents that the
present position is the break point.
9. RE-TRACE S
.
PT
This key is for start point tracing. When it is pressed, the worktable will return
to wire break point then return to the start point along the previous machining
path at last. (Auto wire feeding)
10.TRACER B
.
PT
This key is for break point tracing. When it is pressed, the worktable will return
to start point then return to the wire break point along the previous machining
path at last. (Auto wire feeding)
Note. 1. Those four path trace functions #7~#10 can only be executed
one at a time.
2. The data of trace path according to the last G92 coordinate in processing.
3. While reboot the machine, it restore the last path data which had been
stored.
4. Press can interrupt during the trace function is activated.
5. User can start these four functions (path trace) when EDM spark power
is activated (Water flushing, wire feed, spark, ED -POS).
6. Auto wire feed would be activate when execute those trace functions.
11. OPT STOP
This is for optional pause. When the indicator is lit, if the program is executed
to M01, the machine will pause and systems of water supply, wire feeding and
electric power are will be off. If the indicator is off, M01 will be ignored.
12. BLOCK SKIP
This is for optional block skip. When the indicator is lit, the block interval
marked by “/” will be ignored. When the information is loaded from memory
to buffer area, the skip setting will be kept. This bottom is unavailable during
processing is activated.
13. SINGLE BLOCK
This is for single block execution. When pressing this key during program
1-8