dk7740a wire cut

DK7740A

CNC EDM WIRE CUTTING MACHINE

TECHNOLOGY DOCUMENTS

SERIAL NUMBER:

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: [email protected]

TECHNOLOGY DOCUMENTS CONTENT

1. USER’S MANUAL

2. PARKING LIST

3. WARRANTY CARD



INSPECTION CERTIFICATE

WORKTABLE TRAVEL: 500×400

WORKTABLE DIMENSION: 720×460

SERIAL NUMBER:



ZGEDM

MACHINE:

DK7740A


DK7740A CNC EDM WIRE CUTTING MACHINE

THIS MACHINE HAS PASSED ALL INSPECTION ITEMS AND SALE ALLOWED

MANAGER (SIGN)

INSPECTOR (SIGN)

DATE: YEAR MONTH



DK77 Series EDM Wire Cutting Machine

User's Manual

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: [email protected] I

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 machine’s wear parts: pulleys, guide wheel, conductor block and etc.)

(Drilling machine’s 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 don’t

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: [email protected] II

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 machine’s 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

1

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.

There’s 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.

There’s 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.

2

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. There’s 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 wire’s 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.

There’re 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.

3

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.

4

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.

5

正常已磨损

Fig-1

(2). Check conduct blocks: The conduct blocks are made in carbide, please check if

there’s 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 material’s 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

6

(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. There’re 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 there’s stain stress in the material, the width of the cut

down square would be wider, or if there’s press stress inside, the cut down square would be

narrower.

7

切割加工后钢材变形情况切割孔类工件变形情况

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:

8

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 there’s enough intensity on workpiece to against the stress inside. See

Fig-3.

坯料

凸模

穿丝孔

尺寸一般在 -18mm，若凸模轮廓尺

寸较大或凸模材料淬透性较差，则B尺寸

也要相应放大。

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 mold’s material distorted big enough during heat

treatments. While the cutting allowance is quite small and would not break the stress inside

9

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 workpiece’s 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, there’re 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 there’s 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 there’s 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.

10

6. Lubrication System

No Lubricate part Frequency Method Oil

1 X axis ball screw Every day Oil gun 30# Oil

2 Y axis ball screw Every day Oil gun 30# Oil

3 X axis screw nut Every day Oil gun 30# Oil

4 Y axis screw nut Every day Oil gun 30# Oil

5 Wire drum linkage Every day Oil gun 30# Oil

6 Wire drum screw nut Every day Oil gun 30# Oil

7 Wire drum guides Every day Oil gun 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, don’t 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.

11

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 5-35°C, humidity 40-75﹪, air

pressure 86-110KPa. In order to get the best cutting result, keep the temperature

constantly about 20°C.

4. Clean the machine after working and put on grease on the easy rust parts. Clean the

machine completely on time.

5. If there’s any problem during machining, please stop working and contact professionals

to repair it.

6. Read the operation manual carefully before operation on machine.

12

Part 2 Mechanism

1. Machine Tool Usage

EDM wire cutting machine DK-series consists of Numeric Control，High 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 DK7732 DK7740 DK7750 DK7763 DK7780

Worktable Dimension

366×576 410×690 550×850 720×1100 820×1300

Worktable Travels

320×400 400×500 500×630 630×800 800×1200

Max Machining Thickness

400mm 400mm 500mm 500mm

(800mm Optional) 500mm

(1200mm Optional)Max Machining Taper

0~60°/100mm (Optional)

Max Cutting Speed

≥180mm2/min

Best Surface Roughness

Ra≤0.8um

Wire Diameter 0.10-0.2mm

Wire Running Velocity

11m/s

Working Fluid Water mixed with soap

Precision Accord to standard GB7926-87

Movement Vector 0.001mm

Power Source AC.380V.50Hz

Power Dissipation ≤2.2kw

Max Load Weight 250kg 320kg 600kg 1000kg 1200kg

13

3. Machines Operational Part

No Name Function

1 Wire drum travel limit fork Adjust the width of wire

2 Operation Panel Refer to next charpter

3 Valves Adjust upper/lower muzzles

4 Hand wheels of X, Y axes 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:

14

- 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.

15

5. Troubleshooting

No Troubles Causes Solutions

1 Wire dent on the workpiece surface

1. wire is loose 2. the table is not balance 3. cut tract is not stable

1. stress the wire or replace the wire2. check the table 3. adjust the parameters

2 Wire shaking

1. wire is loose 2. V-channel on the pulleys

wear out 3. vibration during turn

direction 4. wire is bended

1. stress the wire or replace the wire2. replace the pulleys and bearings 3. adjust or replace the spindle 4. replace the wire

3 Rollers run not agility

1. too wide in the pulley bearings

2. trashes go into pulleys 3. pulleys and bearings wear

out

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

4 Wire break

1. wire wears out 2. wire shaking heavy 3. lack of cooling water, the

trash can't be pushed out 4. parameters are not fit the

processing, cause short circuit

5. there is oxidation layer on the workpiece surface

1. replace the wire 2. check the cause of wire shaking 3. adjust the flow of cooling water 4. choose proper parameters 5. cut the oxidation layer off the

workpiece

5 Bad accuracy

1. low accuracy in the X, Y –axis motion.

2. low vertical accuracy 3. pulleys and bearings wear

out 4. controller and the step

motor lost the control pulse, the table not back the "0" position

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.

16

6. Wear Parts

Part Name Quantity Installed Position

Conduct Block 3 Upper/lower wire arms

Guide roller assembled 2 Upper/lower wire arms

Wire drum junction 3 Connection drum and motor

Muzzle 2 Upper/lower wire arms

17

Part 3 Electrical

The machine electrical equipments take the role of controlling wire drum’s 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 there’re 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:

18

High frequency pulse No.3, 2 and 1

Ton (us) Toff Power Inverter（Hz）

No.3 for rough cutting 7 2 7 2

No.2 for first trimming 10 1 15 4

No.1 for finishing trimming 13 1 15 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 wire’s 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.

19

1. Plugs Definition

30PIN PLUG

Pin No. Label Comment Pin No. Label Comment

1 PE Ground 16 05 Drum motor off (NC)

2 24V1 17 03 Drum motor off led

3 24V2 Lamp power

18 12 Drum change direction

1 (NO)

4 19 AL2 Emergency Stop

5 20 02 Drum motor on(NO)

6 21 13 Drum change direction

2 (NC)

7 4L+ 22 COM

8 4L+ 23 16

9 4L+ 24 01 Drum motor on（NO）

10 4L+

4 axes step motors’ COM

25 543 Wire broken protection

11 UY 26 220 Wire broken protection

12 VY 27 AL4 Emergency Stop

13 WY

Drum’s motor

28 PM- Negative sample

14 +24 +24V power 29 PM+ Positive sample

15 04 Drum motor off (NC) 30

20

20PIN PLUG


1 PE Ground 11 YB Yellow

2 12 YC Blue

3 13 YD White

4 14 YE Black

5 XA Red 15 UA

6 XB Yellow 16 UB

7 XC Blue 17 UC

U axis

8 XD White 18 VA

9 XE Black 19 VB

10 YA Red 20 VC

V axis

4PIN PLUG


1 W Pump power phase W

2 V Pump power phase V

3 U Pump power phase U

4 PE Ground

21

Signals for controller on PCI slot (25PIN)

1 XA 14 UA

2 XB 15 UB

3 XC 16 UC

4 XD 17 VA

5 XE 18 VB

6 YA 19 VC

7 YB 20 TK0

8 YC 21 TK1

9 YD 22 PJD1

10 YE 23 PJD0

11 12V- 24 PM-

12 PJD2 25 PM+

13 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 12V- 6

2 ZA 7 TK0

3 ZB 8 TK1

4 ZC 9 TK2

5 12V+

Attention: never short circuit 12V- with PM-, the 12V is supply by extend device.

Jumper: Short the 25PIN’s no.13 with 9PIN’s No.5. Short the 25PIN’s No.20 with 9PIN’s No.9 (Stop signal).

Break circuit the second machine stop line on front (change signals from NO to NC)

22

15 PIN SLOT(J7) Mitsubishi Inverter

Tyco Inverter

Comment

1 RUN SYN+ A: frequency level

2

3 C RELAY B: alarm signal

4 SE SYN- A: Cut off high frequency when direction changing

5 SD COM COM

6 B TRIP B: out put relay

7

8

9

10 STF FWD Motor runs CW

11 RL SP1 Frequency segment No.1

12 RM SP2 Frequency segment No.2

13 RH SP3 Frequency segment No.3

14 PC FM+

15 STR REV Motor runs CCW

Central control board’s J8 Plug to 30 PIN PLUG

J8 30 PIN PLUG J8 30 PIN PLUG

1 14 +24 9 22 COM

2 15 04 10 23 16

3 16 05 11 24 01

4 17 03 12 25 543

5 18 12 13 26 220

6 19 AL2 14 27 AL4

7 20 02 15 28 PM-

8 21 13 16 29 PM+

Central control board’s J10

1 High frequency KM1 7 B1-0V

2 Pump KM2 8 A4-12V

3 A1-110V 9 B4-0V

4 A6-6V 10 A2-20V

5 B6-0V 11 B2-0V

6 A5-12V 12 B5-0V

23

2. High Frequency Board Schematics

1 14 2 15 3 16 4 17 5 18 6 19 7 20 8 21 9 22 10 23 11 24 12 25 13J1D

B25

OU

T1

IN 7

2IN

63

IN 5

4IN

45

IN 2

7

IN 0

9

A10

B11

D13

C14

/EN15

IN 1

8

IN 3

6

IN 8

23

IN 9

22

IN 10

21

IN 11

20

IN 12

19

IN 13

18

IN 14

17

IN 15

16

U6

4067

VC

C

Q5

1

Q1

2Q

03

Q2

4

Q6

5

Q7

6

Q3

7

Q8

9

Q4

10

Q9

11

CO12

CK IN

H13

CLK

14

RST15

U5

4017

Q12

1

Q6

2Q

53

Q7

4

Q4

5Q

36

Q2

7Q

19

CLK

10

RST11

Q9

12Q

813

Q10

14

Q11

15

U3

4040

Q12

1

Q6

2Q

53

Q7

4

Q4

5Q

36

Q2

7Q

19

CLK

10

RST11

Q9

12Q

813

Q10

14

Q11

15

U2

4040

2345

1

U1A

4012

9101112

13

U1B

4012

VC

C

Y1

4MH

z

R110MC120

R210K

1/2 1/41/81/161/321/641/1281/256

1/31/61/121/241/481/961/192

1/2

1us

1us

1/31/41/61/81/121/161/241/321/481/641/961/1281/1921/256

X4

1

X6

2

X3

X7

4

X5

5

VE

E7

C9

B10

A11

X0

13

X2

14X

115

INH

6

X3

12

U7

4051

Q5

1

Q1

2Q

03

Q2

4

Q6

5

Q7

6

Q3

7

Q8

9

Q4

10

Q9

11

CO12

CK IN

H13

CLK

14

RST15

U4

4017

R3100K

123

U8A

4011

564

U8B

4011

8910

U8C

4011

121311

U8D

4011

123

U9A

4011

564

U9B

4011

8910

U9C

4011

121311

U9D

401112345678910

J2CON

10

12345678910

J3CON

10

13119

1

16

468

K2

13119

1

16

468

K1

1

3

2V

V

GN

DIN

OU

T

U12

78L05

AC

1

V+

2

AC

3

V-

4

D1

BRID

GE

2

+

C6470uF/25V

+

C5470uF/25V

F1FUSE1

ABCD

A B C DA

ABBCC

AA

BBCC P-1

P-2

P-3

P-4

P-5

P-6

P-1

P-2

P-3

P-4

P-5

P-6

VC

C

VC

C

12

87

U10A

34

65

U10B

TIP521-2

VC

C

R1020K

R1120K

F-ON

1

F-ON

2

F-ON

1F-O

N2

R6220

C3104

+C2220uF

VC

C

R5100K

VC

C

D4

D3

R84.7K

R94.7K

C8104

C9104

K1-6

K1-6

K1-8

K1-8

K1-16

K1-16

K1-4

K1-4

F-OU

T

F-OU

TFF-O

UT

FF-OU

T

R4100K

1/41/6

1/8

R73KD

2

LED

12345

678910

JUM

P

1 23 4

5 67 8

9 10

24

3. Power Board

R1A

240

R2A2K

DIA

4148D

2A1/2W

12V

D3A

BY329X

QA

IRF250N

+C1A10U

F

1 2 3 4 5 6 7 8 9 10

J1CON

8

R310W 3K

C5104C4104

AVL

32

U1A

4049

54

U1B

4049

76

U1C

4049

910

U1D

4049

1112

U1E

4049

1415

U1F

4049

R1B

240

R2B2K

DIB

4148D

2B1/2W

12V

D3B

BY329X

QB

IRF250N

+C1B10U

F

BVL

R1C

240

R2C2K

DIC

4148D

2C1/2W

12V

D3C

BY329X

QC

IRF250N

+C1C10U

F

CVL

R1D

240

R2D2K

DID

4148D

2D1/2W

12V

D3D

BY329X

QD

IRF250N

+C1D10U

F

DVL

R1E

240

R2E2K

DIE

4148D

2E1/2W

12V

D3E

BY329X

QE

IRF250N

+C1E10U

F

EVL

R1F

240

R2F2K

DIF

4148D

2F1/2W

12V

D3F

BY329X

QF

IRF250N

+C1F10U

F

FVL

32

U2A

4049

54

U2B

4049

76

U2C

4049

910

U2D

4049

1112

U2E

4049

1415

U2F

4049

VC

C

CC

CC

BB

BB

AA

AA

DD

DD

FF

FF

EE

EE

VL

A B C D E F

1 23 4

5 67 8

9 10

1 2 3 4

5 6 7 8

1 2 3 4 5 6

7 8 9 10

11

12

VD

D1

/A2

A3

/B4

B5

/C6

C7

GN

D8

D9

/D10

E11

/E12

NC

13F

14/F

15N

C16

D?

4049-1

25

4. Central Control Board

1 14 2 15 3 16 4 17 5 18 6 19 7 20 8 21 9 22 10 23 11 24 12 25 13J1D

B25

12345678910

J3Y

12345678910

J2X

12345678910

J4

U/V

XA

XB

XC

XD

XE

YA

YB

YC

YD

YE

UB

UC

VA

VB

VC

XA

XB

XC

XD

XE

YA

YB

YC

YD

YE

UA

UB

UC

VA

VB

VC

GN

D

+12V

+24V

+24V

PM+

PM-

PJD

TK

162738495

J6 DB

9

192

103

114

125

136

147

158

J7 DB

15

1234567891011121314151617181920

J5CO

N20

12345678910111213141516

J8CO

N16

12345678910

J9CON

10123456789101112

J10

CON

12

13119

1

16

468

k113

119

1

16

468

k4

13119

1

16

468

k5

13119

1

16

468

k6

13119

1

16

468

k7

13119

1

16

468

k8

+C11000uF/50V

+C21000uF/50V

1

3

2V

V

GN

DIN

OU

T

U1

7824

1

3

2V

V

GN

DIN

OU

T

U2

7812+

C5

470uF/50V

+C3

470uF /50V

C6C6C4CAP R?RE

S1

R1470

D22

LED

D11

LED

+12V

+24V

B5-0VB2-0VA

2-20V

A5-12V

KM

-FK

M-P

A1-110V

A6-6V

B6-0V

B1-0VA

4-12VB4-0V

13119

1

16

468

K2

13119

1

16

468

K3

F22A

F32A

D4

R3470

U0

+C72200uF

+C82200uF

B6-0V

R4120/0.5W

R5120/0.5W

C9C10

B1-0V

A5-12V

B5-0V

A2-20V

B2-0V

AC

2

AC

3

V+

1

V-

4

D1A

BRID

GE

AC

2

AC

3

V+

1

V-

4

D1B

BRID

GE

J8_13

A6-6V

KM

-FK

M-P

A1-110V

A4-12V

B4-0V syn-/se

syn+/run

relay/c

syn-/se

com/sd

trip/b

fwd/stf

sp1/rl

sp2/rm

sp3/rh

fm+/pc

rev/str

sp3/rh sp2/rm

sp1/rl

fwd/stf

rev/strcom

/sd

PJD

J9_8

J8-10

J8-15J8-5

J5_13

J5_16

J5_17

J5_20

J5_15J5_11

+24VJ8_5

J5_7

J8_13

+24V SPEA

KE

R

+24V

com/sd

RH

RM

RL

+24V

J5-6

J5_11

J5_13J5_14

J5_14

J8_10

J5_6J9_8

+24V

J8_5

B6-0VJ8_13

PM-PM+

J5_15J5_16J5_17

relay/c

J5_20

TK

+24

1 23 4

5 67 8

9 1011 12

13 1415 16

17 1819 20

12

34

56

78

910

1112

1314

1516

12345

678910

123456

789101112

J5-19J5-19

J8-5

26

5. Buttons board

1234567891011121314151617181920

J1CON

20

COM

NC

NO

COM

NC

NO

+-

SB1

COM

NC

NO

COM

NC

NO

+-

SB2

COM

NC

NO

COM

NC

NO

+-

SB3

COM

NC

NO

COM

NC

NO

+-

SB4

COM

NC

NO

COM

NC

NO

+-

SB5

COM

NC

NO

COM

NC

NO

+-

SB6

COM

N

C

NO

COM

NC

NO

+-

SB7

COM

N

C

NO

COM

NC

NO

+-

SB8

JI-5JI-9

JI-19

JI-15JI-13

JI-8

JI-8

JI-15

JI-17JI-8

JI-11

+24V

JI-20JI-19 JI-18JI-17 JI-16JI-15 JI-14JI-13 JI-12JI-11 JI-10JI-9 JI-8JI-7 JI-6JI-5

J1-7

J1-16

J1-11

J1-20

J1-6+24V

+24V

J1-14

AL

1

AL

2

1 23 4

5 67 8

9 1011 12

13 1415 16

17 1819 20

27

Part 4 Operation and post program

1. Parameters list

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

1 2 3 4 6 8 12 16 24 32 48 64 96 128 192 256

Ton

(μs)

7 6 5 4 3 2 1 0 Set Toff to 0 when use single trip cut function

1:2 1:3 1:4 1:5 1:6 1:7 1:8 1:9Toff

31 15 7 3 1 0

1 2 3 4 5 6 Power

7 6 5 4 3 2 1

10 20 25 30 40 50 60

Inverter

(Hz)

Recommender 2 sets of parameters for widely usages.

(Only for reference, adjust them according to practice jobs)

① Cut normal steels (Thickness less than 80mm and cut with trim)

Set No. Ton Toff Power Inverter

M10 3 2 31 2

M11 12 0 15 7

M12 9 1 15 3

M13 6 2 7 2

② Cut normal stainless steels (Thickness less than 80mm and cut with trim)

Set No. Ton Toff Power Inverter

M10 3 2 31 2

M11 13 0 15 7

M12 10 1 15 4

M13 6 2 7 2

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

change this set.

28

2. Post the trim program

(Cut once and trim twice) 1. Draw the part’s shape, like the circular drawing in blew picture:

2. Go to next step:

Drawings above

process are graphic

for assistant purpose

Drawings to be

processed

Press Next to

go to next step

29

3. Set the total times of cutting and trimming:

4. Save the posted G code:

Set the times of

CUT. Only cut

once, set it to 1;

and cut 3 times,

set it to 3.

30

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

31

6. Set Parameters before Machining

1. Go to the parameter list from working screen:

2. Choose other parameters menu:

Go to the

parameter list

Choose other parameters

32

3. Go to the next menu:

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:

Get into the

parameters setting


PACKING LIST



SERIAL NUMBER:



ZGEDM

MACHINE:

DK7740A

1 PAGE DK77 SERIES EDM WIRE CUT PACKING LIST

PAGE 1

No. ITEMS QUANTITY COMMENTS

1 Machine tool DK7740A 1 set

2 Machine foot and foot bolt 4 pairs

3 Crank for wire drum 1 set

4 Breakwater cover for wire drum 1 set

5 Wire tension adjuster 1 set

6 Clamp 1 set Installed on machine

7 Water muzzle 1 set Only for taper device

8 Vertical guage 1 set

9 Guide rollers installation tool 1 set

10 User’s manual 1 book

11 Inspection certificate 1 sheet

12 Packing list 1 sheet

13 Warranty card 1 sheet

NOTES:

PACKAGE INSPECTOR: DATE:


WARRANTY CARD



SERIAL NUMBER:

Contact us:

Address: No.888 Xiangcheng District, 215131, Suzhou, China

Telephone: +86-0512-85185518 Email: [email protected]



ZGEDM

MACHINE:

DK7740A


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 user’s 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, machine’s 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: Please save the part 1 in users’ hand

CUSTOMER

DEALER MACHINE

MACHINE DATE YY/MM/DD MACHINE S/N

INVOICE DATE YY/MM/DD INVOICE S/N


WARRANTY CARD OF ZGEDM (PART 2) Serial number: Please send part 2 to our company

CUSTOMER ADDRESS

MACHINE MACHINE S/N MACHINE DATE

DEALER INVOICE DATE INVOICE S/N

BANK ACCOUNT POST NUMBER

TELEPHONE FAX EMAIL

MANAGE DEP. OPERATE DEP. REST DAY

CUSTOMER FEEDBACK SURVEY

INSTALL RESULT:

TECHNICIAN: DATE:

CUSTOMER’S ADVICE:

CUSTOMER (SIGN): DATE:


SERVICE RECORDS

DATE PROBLEM SERVICE EXCHANGED

PART SERVICE RESULT

TECHNICIANCUSTOMER

SIGN COMMENTS

dk7740a wire cut

Documents

axis ball

high frequency

high precision

pump power

taper device

high frequency

high speed

working fluid