PRELIMINARY INFORMATION

The WEDM machines type ONA KE, are in conformity with the following Directives:

- Machinery Directive 891392 amended by the EC directives 9?/368, 93/44 and 93/68
- Low voltage EC Directive 73/23

The equivalent continuous A-weighted sound pressure level produced by the machines
type ONA KE at workstations does not exceed 70 db ( A ) .

Manufacturer: ONA ELECTROEROSION, S.A.

Poligono Eguzkitza, 7
48200 DURANGO (VIZCAYA)
SPAIN
Tfno: 34(9)4-6200800 - Fax: 34(9)-68 18548

Year of machine manufacturing: see "EC"certificate of conformity

Machine model: ONA KE

 INDEX

PAGE
--

CHAPTER 1 : GENERAL

1.1. RECEPTION
1.2. TRANSPORT
1.3. SITE PREPARATION
1.4. AXIS UNBLOCKING

CHAPTER 2: DESCRIPTION OF THE MACHINE

2.1. CHARACTERISTICS
2.2. WORKING TABLE
2.3. GUIDING AND SElTING OF THE WIRE
2.4. THE DIELECTRIC'S COMMANDS

CHAPTER 3: AUTOMATIC SELF-CLEANING MINERAL FILTER

3 1 INTRODUCTION
3 2. DESCRIPTION OF THE COMPONENTS
3.3. SYSTEM OPERATIONS
3 4. EROSION PROCESS
3.5 DEIONIZATION

CHAPTER 4: OPERATING AND PROGRAMMING THE CNC

4.1 CONTROLS

4.1 1 GENERATOR SWITCH

4.1.2 "ON" BUTTON
4.1.3 "OFF" BUTTON
4.1.4 GENERATOR PILOT LIGHT
4.1 5 EMERGENCY STOP
4.1 -6 AMMETER
4 1.7 VOLTMETER
4.1.8 LEOS
4.1 9 CONTROL PANEL

4 I .9.1 'ESC" KEY

4.1.9.2 KEYS FOR SELECTING ENVIRONMENTS
4.1.9.3KEYS FOR SELECTING TABS
4.1.9.4 KEYS FOR CONTROL OF EXECUTION
 4.1.9.5 STANDARD KEYS
4.1.9.6 KEYPAD
4.1.9.7 QUICK ACCESS MENUS KEYS

4.1.10 REMOTE CONTROL

4.1.10.1 AXIS CONTROL KEYBOARD

4.1.10.2 MODE SELECTION
4 1.7 0.3 AUXILIARY KEYS FOR DIRECT OPERATION

4.2 CONTROL

4.2.1 MEANS OF CONTROL

4.2.1.1 POINTER

4.2.2 WINDOWS
4.2.3 MODIFIABLE FIELDS
4.2 4 ENVIRONMENTS (PRINCIPAL WINDOWS)
4.2.5 SECONDARY WINDOWS
4.2.6 EDIT ENVIRONMENT
4 2.7 FILES

4.3 USE OF THE NUMERICAL CONTROL

4.3.1 INTRODUCTION

4.3.1.1. START-UP PAGE

4.3.2 PREPARATION ENVIRONMENT

4.3.2.1 "MANUAL" TAB

4.3.2.1. I USEFUL ZONE (Configuration of the useful

work zone)
4.3.2.I.2 EMDl (Execution Manual Data Input)

4 3 2.2 *'DEC/TRAVHTAB (Offsets and Traverse Points)

4.3.2.2.1 OFFSETS
4.3.2.2.2 TRAVERSE POINTS

4,3.2.3 "THREAD" TAB (Automatic Threading Adjustment)

4.3.2.4 "VERTICAL" TAB (Auto. Adjust. of Wtre Verticality)

4.3.2.4.1 SECUENCE O f OPERATIONS DURING

AUTOMATIC VERTICALITY ADJUSTMENT

4.3 3 EXECUTION ENVIRONMENT

4.3.3.1 BUTTONS IN THE GRAPHICS WINDOW

4.3.3.1.1 *COLOURSnTAB
 4.3.3.1.2 'GRAPH." LIMITS (Graphics Window Limitis) 4-44
4.3.3.1.3"ZOOM LIMITS" TA8 4-46

4.3.3.2"EXECUC."TAB (Execution)

4.3.3.2.1. EXECUTION DETAILS

4.3.3.2.1.1 "STATUS"TAB
4 3.3.2.1.2"WORK S E S I ~ N "TAB

4.3.3.3 "TECH." TAB (Technology tables)

4.3.3.4 "PROFILESnTAB
4.3.3.5'TAPER" TAB

4.3.4 EDITING ENVlRONMENT

1 4.3.4.1 "STRATEGIES"MENU

4.3.4.1.1 GENERATE "STRATEGIES" 4-64

1 4.3.4.1.2 GENERATE "USER'S STRATEGIES" 4-68

4.4 CUT TYPES

Bb
4.4.1 INTRODUCTION
4.4.2 VERTICAL CUT
4.4.3 TAPERED CUTTING

4 4 3.1 CONTROL OF THE DISTANCES PP, OZ

4.4.3.2 CANCELLATION OF TAPERED CU-TTING

4.4 4 XYUV CUT

0 4.5. PROGRAMMING

B 4.5.1 LOADING FILES 4-87

4.5.2 LlNEARlCl RCULAR INTERPOLATION 4-88
4.5.3 TRAVERSE 4-89
9 4.5.4 SETTING OF COOROENATES 4-90
4.5.5 COORDINATE SYSTEM (ABSOLUTE I INCREMENTAL
D METRIC J INCHES)
4.5.6 OFFSET
4-91
4-92
4.5.7 COMPENSATION ON THE LEFT I ON THE RIGHT 1
6 CANCEL
4.5.8 SETTING THE COMPENSATION NUMBER
4-93
4-96

a 4.5 9 TAPER CUT ON THE LEFT ION THE RtGHT I

CANCEL
4 5.10 TAPER CUJTING WITH CONSTANT RADlUS, WITH CONSTAN
4-98

B ANGLE, AND WITH SHARP ANGLE

4.5.11 SETTING THE TAPER CUTTING ANGLE
4-99
4- 100
4.5.12. TECHNOLOGIES
 4.5.12.1 MODE PROGRAMMING (WORKPIECEIWIRE TORQUE) 4-1 01
4.5.12.2 IDlVlDUAL GENERATOR PARAMETERS 4-1 01
4.5.12.3 START GENERATOR SETTINGS 4-1 02

4.5.13 TRANSFORMATION OF COORDlNATES 4-103

4.5.13.1 ROTATION ORIGIN

4.5.13.2 SCALE
4.5.13.3ROTATION
4.5.13.4 AXlS REVERSE (MIRROR FUNCTION)
4.5.13.5 CHANGE OF AXES

4.5.14 GEOMETRY OF CORNERS 4-110

4.5.14.1 ACTIVATION IDEACTIVATION OF

ROUNDING OFF 4-1 10
4.5.14.2 ACTIVATION I DEACTIVATION OF CHAMFERS 4-1 12

4.5.1 5 PROGRAM INSTRUCTIONS 4-113

4.5.15.1 START I END OF PROGRAM

4 5.15.2 EXECUTION OF AN EXTERNAL PROGRAM
4.5.15.3 LABELS
4 5.14.4 SUBROUTlNES
4.5.15.5 JUMPS IN EXECUTION
4.5.15.6 LOOPS
4.5.15.7 WRiTING TEXT IN THE WORKPIECE HISTORY
4.5.15.8 USE OF OPTIONAL BLOCKS
4 5.15.9 COMMENTS
4.5 15.10 COUNTERS

4.5.16 PREPARATION

4.5.16.1 ADJUSTMENT OF WlRE VERTICALITY

4.5.16.2 WIRE CUT
4.5.16.3 AUTOMATIC WlRE THREADING
4.5.16.4 INNER CENTERING
4,5.16.5 WORKPIECE MIDPOINT
4.5.16.6 WORKPIECE CONTACT (EDGING)
4.5.16.7 AUTOMATIC RETURN TO INITIAL POINT
4.5 16.8 MEMORIZATION OF CURRENT POSITION

4.5.17 SUNDRY

4.5.17.1 SE-TTING: CONTACT TOLERANCE I ANGLE

INCREMENT 4-1 19
4.5.17.2 ACTIVATE I DEACTIVATE OUTPUTS 4-1 19
4.5.17.3 PAUSES 4-1 19

4 . 5 17.4 VECTORS 4-120

4.5.18 EXAMPLES
4.5.19 SUMMARY OF PROGRAMMING INSTRUCTIONS
4.5.20 I S 0 LANGUAGE
CHAPTER 5: SECURITY

5. j . INSTRUCTIONS FOR A SAFE TRANSPORT OF THE MACHINE

5.2. WARNING SIGNALS

5.2.1. DANGER OF SLIPPERY FLOOR NEAR THE MACHINE

5.2,2. DANGER OF ELECTROCUTION IN AREAS WlTH HIGH
VOLTAGE

5.2.3. IT IS OBLIGATORY TO USE GLOVES HANDING DIELECTRIC

OR ANY ELEMENT IN CONTACT WlTH IT

5.2.4. IT IS OBLIGATORY TO WASH THE HANDS AFTER HAVING

BEEN IN CONTACT WlTH DIELECTRIC

5.3. SECURITY DEVICES INCORPORATED IN THE MACHINE

g . EMERGENCY PUSH-BUTTON
5.3.
5.3.2. TANK DOOR MICRO
5.3.3. WIRE GUARD MICRO
5.3.4. TANK MAXIMUM-LEVEL FLOAT
5.3.5. PRESOSTAT (ONLY IN ARICUT SERIES "R")
5.3.6. GENERATOR'S AIR FILTER

5.4. CORRECT USE OF THE MACHINE

CHAPTER 6: AN OVERVtEW OF THE WORK

6 I . SITUATING THE WORKPIECE IN THE MACHINE

6.2 GRAPHICS CHECK

6.2.1. NOMINALCHECK
6.2.2. COMPENSATlON CHECK
6.2 3 TAPERED CUTTING CHECK

6.3. CENTERING
6.4. DRY-RUN PROGRAM CHECK
6.5. ENTERING THE EROSION CONDITIONS

6.5.1. OFFSET

ANEX 1: CONECCTION OF ONA MACHINES TO THE MAINS (general power)

t ALARMS and MESSAGES
ANNEX tl: L ~ sof
1.3 SITE PREPARATION

Surface: A certain minimum space, varying with the model, will be required for the machine,
generator, and filter. (See figures 1-4, and q-5).

Height: Clearance above the machine should be 0.5 m. (See figure 1-5).

Weight: This also must be taken into account in preparing the site. Installation total weight.

ONA KE 1000: Installation total weight is 15.000 kg. (Machine weight is 13.000 kg. Generator
weight 400 kg. Filter weight (empty), with refrigeration unit, is 1600 kg).

Power supply: See ANNEX I.

Ground connection: individual. Resistance: 10 ohm maximum.

Water supply: A running water tap is compulsory for the dielectric module. Use water with a ph
between 5 and 8 (the same as the normal water used for human consumption).

A i r supply: To ensure a correct functioning of the machine, it is compulsory to have a dry-air

connection ( W g ) nearby, with key, pressure gauge and water filter..

Requirements of the air supply installation:

- Total maximum flow of air consumption in liters per minute = 170 LN Imin. (10 m3 Nlh).
- Nominal pressure = 6 bar.

Environment: The machine site should be clean, ventilated, of uniform temperature, and
protected from other units that produce dust and moisture, such as grinders, lathes, and milling
machines.

Vibrations: The Machine-Tool should be sitting on antivibration pads.

To work at good conditions the working table should be leveled at 0.02 rnm with the help of
leveling pads.
 1.4 AXIS UN8LOCKING
3 For the machine shipment, the X, Y, U and V axes are blocked with some pieces of red colour
that it is necessary to remove them.
13 Before the machine start up, VERlPl that the X, Y, U and V axes are UNBLOCKED. There is a
serious danger of damage. See in the figure 1-1 the location of the blocking pieces in the axes.
3
 CHAPTER 2

3. DESCRIPTION OF THE MACHINE

a
2.1 CHARACTERISTICS

3
2.1 .ITECHNICAL DATA
a
MODEL ONA A€ 300 ONA KE 450 ONA KE 600 ONA KE 1000
X - Y axes stroke (mm): 400 x 300 700 x 500 800 x 600 1500 x 1000
Z axis stroke (mm): 250 400 500 600
U - V axes stroke (mm): 80 x 80 140 x 140 500 x 500 500 x,500
~ a x i m u mworkpiece size 8 0 0 x 7 0 0 ~ 1 2 0 0 x 9 5 0 ~ 1 3 0 0 x 9 8 0 ~ 194Oxi55Ox
(X, Y, 2 ) (mm): 2 50 400 500 600
Max. workprece weight (kg): 1000 5000 5000 10000
Taper cutting angle ?8.5i01 250 mm +go 1 400 rnm _+30°/500 mm ~20°1600mm
(400 mm1500 mm1600 mm) ( 2 )
Maximum taper cutting angle: 430" 1 50 mm t-30' 1 95 mm ?3O0 1 500 -
+30° 1400
mm 1 rnm
Wire diameter {mm): 0 , l - 0,33
Wire spool: DIN 400 - DIN125 - DIN160
DIN 200 - DtN 355
W ~ r eguide: Closed, high-precision diamond guides
Position resolution (X, Y, U, V) 0,001
(rnm):
Position resolution (mm): 0,OO 1

a The machine frame (base, intermediate bodies and superior body) is constructed of cast iron and
stab~iized.

2.1.3 CARRIAGES "X-Y" "U-V" and "2" HEAD

a The movement of "X-Y" carriages and " U - V and Z head is guided by high
-
quality ball screws.
-

a Transmission from the correspondent D.C. motors, is by gear box

2.2 WORKING TABLE

This is the area where the erosion is produced and it is constructed of stainless steel, because the
machine works with deionized water.

It is provided with an internal system of workpiece holding fixture to which Mecatools accessories,
3R, Hirschmann, etc, can be adapted, if wanted.

figure 2-1 - Working table

2.3 GUIDING AND SETTING Of THE WIRE
The wire must be set as it is shwon in the "wire kinematics and automatic threading system
performance and maintenance manual"

2.4 THE DIELECTRIC'S COMMANDS

The dielectric's commands are placed on the right side of the working tank.

By means of commands 31 and 32, the water jet which flows out through the upper and lower
nozzles is controlled. The respective pressures are indicated in gauges 33 and 34.

By means of command 35 the water jet which flows out through the auxiliary jet (36)is controlled.

figure 2-2
 CHAPTER 3

AUTOMATIC SELF-CLEANING FILTER FOR WIRE CUTTING

MACHINES

3.1 INTRODUCTION

NAME

Automatic self-cleaning filter for wire cutting machines.

CHARACTERISTICS

Attention required by the operator is minimal.

It is not necessary that the machine be stopped during automatic self-locking cycles. This means
shorter operating times.

Filter elements need not be replaced, so that maintenance costs are considerably reduced.

Volume of water: ONA KE 1000: 4.800 litres.

3.1.1 FILLING THE FILTER

The filter should in all cases be filled with deionized water. If the water used is from the public
supply, there is equipment in the resin bottle for it to pass through. However, use of the resin bottle
in filling does not mean a saving in resins. Rather it should be used only to minimize the length of
time that must be waited until conductivity has reached the level set by the machine.

Water in the public supply has in most cases been treated with oxidants such as chlorine, which
not only raise the ion content but also promote oxidation. There are alternatives, such as rainwater
(after sampling to assess conductivity) and the water from condensation in air-conditioning
systems.
3.2. DESCRIPTION OF THE COMPONENTS

This section describes the diferents elements which make up the complete Filtering unit.

A' Ftush levei sensors Conductiv~tysensor

0: Filter level sensor Dielectric pump
1: Filter carboy Coaling and deionization pump
2: Dirty tank F~lterpump
3: Clean tank Auxiliary pump
4: Settling tank Pump for filling work tank
5: Resin bottle Flaw and deionrzation servovalve
6: Electrical cabinet and controls Intake for cooling unit (optional)
7: Sludge basket Pump to transfef liquid to the upper dirty tank
8: Prefilter
9. SettTing tank drainage valve
3.2.1 FILTER CARBOY

This unit contains a filter element to trap the dirt collected by the liquid during the work process, so
that clean liquid emerges. The pressure gauge and blowoff valve are in the cover.

The blowoff valve should be opened only when it is necessary to retease air from inside the unit.
This necessity arises only when the unit is filled for the first time, or when for maintenance
purposes ~thas been emptied.

In no circumstances should this valve be left open, since filter operation would be impaired.

3.2.2 DIRTY LIQUID TANK

This is the tank that receives dirty liquid from the work area.

3.2.3 CLEAN LIQUID TANK

This is the tank that receives clean liquid from the filter, and from which clean liquid will be sent to
the work area.

3.2.4 SETTLING TANK

This is the tank that receives the liquid carrying dirt that has accumulated in the filter vessel while
this latter is being cleaned. In a settling process, the dirt separates from the liquid. This dirt is
referred to as sludge.

3.2.5 RESIN BOTTLE

This bottle contains a mixed bed of resins, consisting of 50-60% strong cationic resins and 50-40%
strong anionic resins. Their function is to adjust the conduct~vitylevel of the water as programmed.
The height of the bed during filling should not exceed 600 mrn.

3.2.6 SELECTOR VALVE CONTROL

This is the electronic control governing operation of the selector valve

3.2.7 SELECTOR VALVE

Powered by a motor, and in accordance with the automatism desired, this valve interconnects
tanks to sult the operation (filtering, flushing, etc.). The body houses the pressure switch and the
nylon tube connect~ngwith the venturi that takes the water from the sludge tank.
3.2.8 PREFILTER

This small cartridge filter serves to protect the machine components against any objects that the
dean liquid tank may accidentally contain.

3.2.9 SETTLING TANK DRAINAGE VALVE

This valve is activated when the pressure switch detects resistance to the flow of fluid through the
filter vessel. Hence before the filter is flushed it is necessary to empty the settling tank.

3.2.1 0 CONDUCTIVITY SENSOR

This sensor conveys the ionic content of the water to the conductivity card.

3.2.1 1 DIELECTRIC PUMP

This is the pump that sends clean liquid to the work tank nozzles.

3.2.1 2 COOLING AND DEIONIZATION PUMP

When the conductivity level is greater than programmed, this unit pumps liquid through the
servovalve 16 to the resin carboy 5. When the programmed level has been reached, the
servovalve closes the circuit so that the water cannot go through the resin carboy. Owing to its
twofold function, this pump works constantly, sending water to the cooler via a second circuit.

3.2.1 3 FILTRATION PUMP

This is the unit that pumps liquid from the dirty tank to the filtering vessel. So that it may function
properly, ensure that it does not suck in large or fibrous particles, such as metal fragments, papers,
or rags.

3.2.14 AUXILIARY PUMP

This unit pumps liquid to the table's locking system.

3.2.15 FILLING PUMP

This is the pump that fills the work tank when the machine is in immersion mode.
3.2.16 DElONlZATlON SERVOVALVE AND FLOW VALVE

These two components are intimately related. While the first connects the deionization circuit, the
second regulates the flow in this same circuit. The cooling systems differ one from another in
respect to Rows and pressure head loss.

The method by which resin flow is regulated is as follows: When the cooler, exchanger, etc. have
been installed, adjust the shut-off valve so that the outlet flow from the resin bottle is between 15
and 20 litres per minute.

3.2.17 SERVOVALVE FOR ARM COOLING

The function of this valve is to cool the lower arm of the machine.

3.2.78 SLUDGE-REMOVAL VALVE

The funciton of this valve is to remove the sludge accumulated in the settling tank.

3.2.1 9 VENTURI FOR SLUDGE DEHYDRATION

Activated by the filter pump and from the selector valve, a hydraulic circuit is inserted consisting of
a venturi, which extracts liquid from sludge dehydration and returns it to the system.

3.2.20 SLUDGE BAG AND TANK

Here the sludge produced by the machine as it operates is contained and dehydrated. In the bag
there should always be a free volume of 30 litres, equal to one complete discharge of the sludge
volume.

3.2.21 VESSEL AND PERISTALTIC PUMP FOR THE ADDITION OF EKOADD

The purpose of this revolutionary system, patented by ONA, is to prevent the dissolution and help
the precipitation of the metal particles.lts function, which is fully automatic, consists in adding the
just right amount of EKOAOD when it is needed.

Figure 3-2
To Keep in good condition, ensure that there is enough liquid in the vesse.lf there is not, the water
will get dirty owing to the presence of ferric iron oxides."

This system contributes greatly to descaling tubes and nozzles. The saving in resins means that
they last at least 50% longer.

Skin contact should be avoided, since this product is approximately 10% acid.

To keep the nozzles and other components of the work table perfectly clean, moisten this product
with a paint brush, rinse with water, and dry.

The amount applied should be according to the metal that is going to be machined.

Steels, aluminium, and copper require the application of EKOADD, while graphite, tungsten
carbine, and titanium do not.

LEVEL SENSORS

A. SETTLING TANK LEVEL SENSORS

These sensors govern automatic filter flushing, as well as the various volumes involved.

We now look at the purpose of each of these levels.

Ad: This level terminates filter flushing in the rinsing operation, and initiates rotation of the selector
valve at the filtration position.

A2: This level terminates the flushing phase and positions the selector valve for rinsing,

A3: This level terminates settling tank drain-off by de-energizing the drainage valve (See 9, Figure
3-11, It then positions the selector valve for the flushing phase.

B. FILTER LEVEL SENSOR

This sensor activates an alarm if it is no longer in contact with water, in which case the amount of
water is not sufficient. The LED on the cover of the filter panel lights up and the machine stops. To
rectify this problem, fill the water filter up to81 and press the RESET button (9, Figure 3-4) on the
same cover. Also, reset the alarm on the generator alarm page.

8 2 . Indicates the fevel to which water must be added to the system, i.e. up to B1, so that there is
no risk the alarm will be activated.

The B1 and B2 readings are valid only when the settling tank and the clean-liquid tank are
full of water and when the work tank has been completely drained.
 I. ON-OFF filtration pump switch

baN
OFF
This control should always be ON, since it is used only for
maintenance.

2. Filtration pump pilot tight

On or off according to whether the pump is operating. The pump
starts or stops automatically when the filter is in flushing phase.
Alternatively the switch next to the pilot light can be employed, but this
option should be exercised only when maintenance work is being
carried out by specialist personnel. The normat position of the switch
is ON.

3. Pilot light for settling tank drainage

Indicates that the drainage valve of the settling tank has been opened
(9, Figure 3-I), either by the action of the pressure switch on the
selector valve or by the pressing of TEST (6, Figure 3-4).

4. Settling tank pilot light

Goes on to indicate that the settiing tank is being filled in a flushing or

rinsing operation.

5. Sludge extraction mode switch

If this switch is ON when the settling tank has been drained, the
flushing cycle wit1 not start. The tank will remain waiting for the
extracion of more sludge (See 3.3.3 regarding Sludge Drainage).

The system is reset when this switch is at OFF.

6. Pilot light to indicate end of settling tank drainage

Indicates that the system is waiting for sludge removal.

The procedure is clearly shown in the chapter dealing with sludge

drainage.

7. Test button (Manual flushing)

Used to in~tiateflushing manually, and to flush the settling tank.

The usefulness of this button is explained in the chapter dealing w ~ t h

sludge removal.
 8. Pilot Light Alarm to indicate that there is insufficient water in
the filter (See 3.2.22, section B)

9. Filter reset button (See 3.2.22,

section B)

3.3. SYSTEM OPERATIONS

3.3.1. FILTER FLUSHING (MANUAL)

All filter flushing operations are automated, but the user has the option of flushing manually.
(Normally flushing is initiated by a pressure switch, i.e. when the pressure in the filter exceeds a set
value.)

You may wish to flush for checking purposes, or to remove sludge (3.3.31,without waiting for the
pressure switch to operate. In this case press the TEST button on the filter panel (Fig. 3-4)
Drainage will begin, and subsequently the filter will be flushed.

NOTE: Before flushing manually, wait at least two hours following the most recent flushing, the aim
being to ensure that the sludge will have had time to settle at the bottle of the tank. At that stage it
will not return to the system.

3.3.2. AUTOMATIC FILTER FLUSH

The filter accumulates particles, which progressively impede the passage of the fluid. The function
of the pressure switch is to gauge this resistance. When it reaches a preset level, it doses a circuit
to activate filter flushing. The operations, along with the mechanisms involved, are as follows:

Switch act~vatesat pressure of 0.55 Kg.

Settling tank drainage valve opens.
Level A 3 IS detected (see level A sensors, Figure 3-3) in the settling tank.
Filter pump stops, selector valve rotates to flushing pos~tion.
Fitter pump starts, with flushing up to level A 2 (see level A sensors, Figure 3-3),
Filter pump stops. selector valve rotates to rinse position.
Fitter pump starts and rinsing follows up to level A 1 (see level sensor A,
Fig. 3-3)
Filter pump stops, selector valve rotates to filter position.
Filter pump operates until flushing is complete.
3.3.3 REMOVAL OF SLUDGE FROM SLUDGE TANK

When the machine is operating at maximum power, it is necessary every fifty hours to remove
sludge from the settling tank, since otherwise it will return to the system and give rise to serious
filter problems. We now look at the steps to be followed.

1: Set the Sludge Extraction Switch at ON (see 5, Fig. 3-4). It is advisable to do this 2.5 hours
before sludge is removed.

2: If after two hours the settling tank is not draining (see 3, Fig. 3-4), or if drainage has ended (see
6 , Fig. 3-4), press the TEST button (see 7, Fig. 3-4) and hold it down until the pilot light 3 (Fig. 3-4)
lights.

In either case it will be necessary to wait until the pilot light 6 goes on, indicating that settling tank
drainage is complete (Fig. 3-4), before removing the sludge.

3: When it goes on,the pilot light 6 (Fig. 3-4) indicates that the settling tank has been drained and
that sludge can be removed. Open the cock 18 (Fig. 3-1) so that the sludge in the settling tank is
shifted to the sludge tank.

When all sludge is gone from the settling tank, close the cock 18 and shift the sludge removal
switch (5, Fig. 3-4) back to the OFF position. The filter pump will stop and the system will flush,
starting at phase 4a of Section 3.3.2 (automatic filter flushing).

(The 2.5 hour wait is necessary since if TEST is pressed immediately following an automatic flush,
the particles from earlier flushes will not have settled and will return to the system.)

El SETTLING TANK
4-&$'

Minimum level when

settling tank is being
Maximum
drained prior to
sludge level
flushing or sludge
extraction

Figure 3-5
3.4 EROSION PROCESS

The erosion process is NOT interrupted in the course of these operations, whether manual or
automatic, since there is sufficient reserve in the clean tank to compensate for cessation of the
filtering pump.

3.5 DEIONIZATION

3.5.1 Introduction

Owing to the particular arrangement of the atoms composing it, a molecule of water is highly
solvent. Hence when the water cycle starts, i.e. when the water vapour condenses in the
atmosphere, the substances contained begin to dissolve, mostly via pollution, in the atmosphere.

Water in the soit dissolves more substances. Finally it is potabitized with oxidants such as chlorine,
which not only increases conductivity but also, in virtue of its oxidizing capacity, hampers erosion.

Most of these substances dissolved in the water are what make it a conductor. Water in its
pure state is not conductive.

Thus one may see how important it is to fill the filter with water and later to fill it again, and to do so
with deionized water, 1.e. water that does not contain dissolved substances or at most contains
them only in very small quantities.

Whatever the precautions, however, the particles eroded from materials being machined dissolve
in water {with the exception of a few such as graphite, which does not contribute to conductivity in
the water) It is thus necessary to adjust the deionization level, using ionic exchange resins.

Note that if positive ions (cations) predominate, the water will be acjd (pH less than 7). If anions
predominate, it will be basic (pH greater than 7).

The ideal pH for erosion is neutrai, i . ~ 7. . The mixed resin bed will hefp to bring about this
neutrality, and at the same time will lower conductivity.

3.5.2 Functioning

During erosion, the water ionizes in such manner that it becomes progressively more conductive.

Depending on this level of conduct~vity,a deionization circuit will automaticalty open or close

When the machine starts, the reading on the sensor10 (Fig. 3-1) is the conductivity level. If this is
greater than programmed, the hydraulic circuit opens. The water then passes through the resin
bottle. The circuit operates as follows:

The pump f 2 (Ftg. 3-1) sends the water from the clean tank to the valvel6. From there it goes to
the resin pump, where it is dionized by ionic exchange. It then goes to the clean tank. When the
preset conductivity level has been reached, the valve 16 closes so that water cannot cont~nueto
flow through the circuit.
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4.1 .IGENERATOR SWITCH (29)

This is a safety device. Set the control at POSJTION 2 to disconnect the generator before opening
the rear door.

1 POSITION I POSITION 2

Figure 4-2

4. f .2 "ON" BUTTON (24)

Use this button to supply power to the equipment. It remains illuminated as long as power is
supplied, indicating that any operation can be initiated.

4.1.3 "OFF" BUTTON (25)

Use this button to cut the power supply to the equipment.

4.1.4 GENERATOR PILOT LIGHT (30)

Indicates whether the generator is ON or OFF.

4.1.5 EMERGENCY STOP ( 2 3 )

Disconnects the equipment.

4.1.6 AMMETER

lndicates the average working current in the

wire.

4.1 -7 VOLTMETER

lndicates average current between wire and

workpiece.

4.1.8 LEDs

lndicates generator ON.

l ndicates short circuit, contact between wire

and workpiece.

lndicates low voltage and machine eroding.

4.f .9 CONTROL PANEL

I 2

( Figure 4-3

5 7

I. ESC key (4.7 -9.1).

2. Keys for selection of environments (4.1 -9.2).
3. Keys for selection of tabs (4.1.9.3).
4. Keys for execution control (4.1-9.4).
5. Standard keys (4.1-9.5).
6. Keypad (4.1.9.6).
7. Keys for activating the quick-access menu (4.1-9.7).

4.1.9.1 "ESC" KEY

You can use this key to:

- Close w~ndowsthat are open on screen.

- Cancel changes made in a modrfiable field (see 4.2.3)

4.1.9.2 KEYS FOR SELECTING ENVIRONMENTS

On the upper part of the keyboard there are four function keys (Fl-F4)for quick access to the
various (principal) CNC environments. In section 4.3.1 of the introduction to operation of the
numerical control, the various environments are defined into which CNC operation may be divided.
 4.1-9.3 KEYS FOR SELECTING TABS

Tabs

QPERACIONES
ILLUMINATION

Figure 4-4

The function keys F5 to F8 are for quick access to tabs. Tabs are fields such that when one is
selected a window is opened with new content on the CNC screen. . .

4.1.9.4 KEYS FOR CONTROL OF EXECUTION

Effects a return block by block, via the profile programmed, as far as the initial
n
t until the
p o ~ nor l.3key is pressed

Stops the execution of the program.

Starts or resumes execution of the program selected.

Cancels execution of the program.

4.1-9.5 STANDARD KEYS

) The letter keys. punctuation keys. and space bar are used in the same manner as those on a
typewriter
4.1.9.6 KEYPAD

The keypad, which includes arrows for cursor movement and edit key, is on the right of the control

LOM
panel. When NUM LOCK is active, numbers are written. Otherwise the keys are used to
move the cursor or to edit.

The key must be inactive if the following keys are to function:

aHOME
Sends the cursor to the start of the line.

- Sends the cursor to the end of the line.

Sends the cursor to the previous page.

Sends the cursor to the following page.

- Deletes the character immediately to the right of the cursor.

No assigned function.
4.1 -9.7 QUICK ACCESS MENUS KEYS

There are two keys with the ONA anagram . Each of them calls up a menu that allows
quick access to the most commonly used functions (Figure 4-51,

1 Change the operation mode

-
2 Load a file into the control
-3 Reset Alarms
E
4 Maintenance

Figure 4-5
4.1.1 0. REMOTE CONTROL

Mode selection
(4.7.10.2)

Flushing water flow

(ON/ OFF) L

Q u ~ return
k to indial
point

Threading jet ON Axis control keyboard

(4.7.10.1)

Posit~onsthe wire on the -

verlical 11nememorized

Wre movement /
Semiaulomabc threading

Return by route
memorized

Halts execution of ,A

program
Figure 4-6

You can use remote control to carry out preliminary operations, such as searching for zeros,
centering, and contacts. Note that prior to these operations, OPER. MANUAL must first be sefected
on the operations menu (Figure 4-7).

Figure 4-7

You can also use remote control tc adjust dielectric pressure, lo adjust the threading jet,
semiautomatrc threading. Mode may be manual or automatic.
4.1 .'I0.1 AXIS CONTROL KEYBOARD

Here one finds the keys for controlling movements on the X+, X-, Y+, Y-, U+, U-, V+, and V- axes,
which are for manual operations.

4.1-10.2 MODE SELECTION

-=
The active LED indicates which mode has been selected.

released

Use the keys

JOG. When you press an axis key, movement continues until the key is

and
100% of table speed.
to select displacement speed. You can select between 6% and

Note: several axes can effect the movements simultaneously. This operation is valid for the X,
Y, U,V, or Z axis.

-=
Use the keys
(STEP BY STEP)- When you press an axis control key, the movement
carried out will be over the distance selected.

and to select a distance between 0.001 mrn and 70 mm. Movement

-=
will be at the speed indicated in the JOG mode.

ZERO SEARCH. To initiate machine zero search, press the axis control
keys and hold down for Isecond.

m-+ 0
1

X
t t
Initial Machine
point zero

Note: Zero search can be carried out on several axes at once.

4-9
axis direction in which you want centering to be effected.

- Wait for the end of the operation with positioning at the center of the traverse.

Note: In the case of circular centering you have to carry out the operation on two axes in the
circular plane. You can do this on t h e X, Y, U, or V axis. If you press the Z axis, JOG mode is
adopted.

-= WORKPIECE CONTACT.

- Press the axis direction corresponding to the direction in which you wish to effect workpiece
contact.

Note: Thls operat~onis valid for the X, Y, U, or V axis. If you press the Z axis, the machine
switches over to the JOG mode.
 Operation Opeation

I
(1) (2'
PIECE

WIRE

, I *
F h a l polnt

- Firsf specify WORKPIECE CONTACT at points 1 and 2.

- Press the axis on which the table is to move to reach the midpoint of the workpiece

Note: This operation is valid for the X, Y , U, or V axis. If you press the Z axis, the machine
switches over to the JOG mode.

-= Key without any function.

4.1.10.3. AUXlLlARY KEYS FOR DIRECT OPERATION

SHIFT
- With the LED off, the functions under the yellow background (lower part of
the key) are performed. With the LED on, the functions carried out are those under the
orange background (upper part of the key).

iq *

m
+ #

Activates or deactivates flushwater flow to the erosion area. When ON it

enables, and when OFF it prevents, the emission of water via both cutting nozzles.

- I2 G
Quick return to initiat point. The initial point is automatically memorized

when program execution is started by means of the key . A new initial point is
specified each time programmed threading is carried out.

El Turns on the threading jet to guide the wire down to the lower guide.

- Positions the wire on the vertical line memorized. Indicates that wire is in
vertical position. (See 4.3.2.4,"Automatic Adjustment of Wire Verticality").

1 -f ;,
1
If the wire has been threaded, this sets it in motion. Otherwise it realizes
various automatisms so that thread~ngcan be semiautomatic.

To have the wire threaded semiautomatically, select

in by means of the upper gujde and carry out the threading.
El and Feed the wire

.
pq Return by memorized route.

RETURN
7 WNAL
I POINT
WORKPlECE
IHlllAL
WlNT
r----
L-----J

Ratum'm rngvgrnmnl

The MEMORIZANDO box is in the manual tab in the preparation environment (4.2.2.1). If
we effect manual movements while it is activated, or while a program is being executed, up

to one hundred movements on any axis are memorized. Press the key to have
these movements carried out in the opposite direction.

If while a program is being executed you press STOP, when you press this key
1-q
a return is made to the program origin via the route traversed. If before pressing the key you
effect manual movements, then when the key is pressed the manual movements are
retraced. When it is pressed again, in automatic mode, return is made to the origin via the
profile traversed.

iq halts execution of the program.

4.2 CONTROL

4.2.1 MEANS OF CONTROL

You can control the equipment via the keyboard (section 4.1.9), the remote control (4.1.I
O), or the
pointer (4.2.1 .1).

4.2.1 -1 POINTER

The position of the pointer is indicated by a cursor, which moves on the screen. Usually the cursor
is an arrow, but it may be a clock, a cross, or a vertical line.

When you press the left button on a modifiable field, that field becomes active and allows data to
be entered. The other two buttons, as well as the left one in some cases, have specific functions
depending on the position of the pointer. These will be explained in each case. The wheel on the
central button has no function.

4.2.2 WINDOWS

The graphics system uses windows. Its operation is very similar to that of other windows systems,
but there are certain differences in the interests of greater simplicity.

In the windows there may be one or more modifiable fields. We look at their use in the next
section.

4.2.3 MODIFIABLE FIELDS

A field is modifiable when it is active. Its colour then changes (with the text in white against a blue
background}, or a frame appears around it (as happens, for example, with the buttons).

To activate a field, place the pointer on it and press the left button on the mouse. Alternatively,
activate one f~eldand then another until you arrive at the field you wish to modify. The fields are
ordered so as to simply this procedure.

You can move to the active field by using the TAB key, the capitals key(+), or the arrow keys on
the keypad. The TAB key will take you to the next field. If you press the capitals key(+) and TAB
simultaneously, you activate the previous field. The upward-arrow key also activates the following
field, while the down key activates the previous, except in those fields in which these keys have
some other funct~on.
The modifiable fields are:

Values. The field is a single value in which the number is directly written. To validate the new
value, press the return key (8).

In the case of an ONIOFF field, activate by pressing "1" and deactivate by pressing "0". The
space bar can be used to move from either mode to the other.

If you are changing the value but wish to retrieve the initial value, press the ESC key. So that
the new value entered will be accepted, press the return key. If the active field is changed while
the key has not been pressed, the initial value is retrieved.

With some fields re resenting coordinates, you can enter the value of the current coordinate by

pressing the key . If you wish to do this all the machine zeros must be already located.

Figure 4-8

In the example in Figure 4.8, the upper value has been activated and can be modified.

Tables. A number is entered just as if it were a value. You can move around the table using
the direction arrows. To exit from the table, use the TAB key or the pointer.

Some ceils representing coordinates allow you to enter the current coordinate by pressing the

key n. All the machine zeros must first have been located.

POWER I 10
TIME OFF
VOLTAGE
SERVO
D IELEC.
WIRE TENS.
WIRE FEED 8
FINISH OFF
INVERS I OFF
CORNER CORR. I 1
FEEDRATE 1 240.0
Figure 4-9

In f~gure4-9 w e see a table with an active cell. You can use direction keys to activate the
previous or subsequent cell.
Fold-out menus: These allow various field options. Press the right button or the space bar
when the field is active in order to see a menu displayed with the options available (Figure. 4-
10). Select by pressing on the pointer, or alternatively by using the up and down keys and then
pressing the return key.

Figure 4-70

If the fold-out menu is active you can select with the direction keys and without unfolding the
menu.

Check fields: These are fields that indicate whether the option is selected. If you press
with the pointer on the field or with the space bar when the field is active, selected
4
changes to not selected, and viceversa.

Figure 4- 11

Figure 4-7 1 shows the two current types of check field. The first is independent, i.e. it indicates
whether memorization is being carried out. The second is exclusive, so that if you selec!
machine tken trabajo is excluded, and viceversa.

Buttons. To press a button, use the pointer, or, with the button active, press the return key or
the space bar. In many cases a button on the control panel has a picture symbolizing the
corresponding action. If you forget the function of a particular button, situate the pointer on it
and a line of explanatory text will appear (Figure 4-12).

3 +Ie~ralmI~l
-4
Wr
iogr
a r
q
Figure 4-12

4-16
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4.2.4 ENVIRONMENTS (PRINCIPAL WINDOWS) 1
The principal windows occupy the entire screen and have the one structure. There are three
environments, one for preparation, one for execution, and one for editing.

In the following picture of the execution environment we see the principal fields of the
environments. The other two environments have the same elements, except that the edit I
environment has no tabs.

menu bar tabs

/ /
'

-1/
'FWCU1 1 Tech I Profile \ Tapor P

INTL X-54 159 Y - 2 7 4

INTC* X-41.2 19 Y-4D.956 CX13.989 CY0.339
INTL 7-56 4 7 1

lNTL X - 70 143 Y- 12.451

INTL X- B5.578 Y Z 978
I M L X-63.S98 Y 4 957
IPJTC X - l 00 91 6 YPZ274
1NTC X-108.853 '428 21 2
INTC X - 9 1 0: YJ4 (144 rl
Hlstory or the piece

....----.-.
C---=..-......-.-....
I..

18/05/2001 06 54 Id Execut~onstart
08 59 13 Erecul~onslopa~a

PROGR.

-Teth

ON^ key
2 Figure 4-f4

function keys'
/" time

Menu bar: Each bar field displays a corresponding menu. Thus, as one may observe in Figure 4-
14, in "Archives" a menu is displayed with the options corresponding to the files.

To have a menu displayed, press with the pointer in the field desired, press the Alt key and
subsequently the direction keys, or press Alt and simultaneously the letter underlined on the menu
menu, press Alt + P).
bar (e.g. to display the "_Preparation1'

Windows with other functions can be accessed via a menu field. Some of these windows appear
without your having to look through menus, i.e. there are keys for direct access. Windows of this
type are thus indicated on the corresponding menu to the right. Figure 4-14 illustrates how you can
go to the highlighted line on the menu, or directly press Ctrl+C on the keyboard without consulting
any menu.
Tabs: You can use tabs to control every aspect of an environment. There are tabs in the execution
and preparation environments To change to a particular tab, press with the pointer on its name or
press one of the function keys F5-F8. Alternatively you can use Ctrl*Tab, even when there is a
window open.

Having selected a tab, use the Tab key to activate its fields. When the tab has been activated, you
can, if you wish, change it by means of the direction keys.

ONA key: If you press the ONA key or the buffon at the lower leR corner, the ONA menu appears
(Figure 4-15). It facilitates quicker access to the most commonly used functions. The ONA key can
be pressed whether work is being done in an environment or in a window.
1 X I v
I Change the operatjon mode

;qj I F1 Exec
I

Figure 4-15

Function keys: These allow you to change the environment, to change the tab, or to consult the
alarm window. In the edit window, in which there are no tabs, you can use the keys F5 a n d F8 to
execute certain editor functions.

Access them directly with the pointer, or with the function keys.

If there is an alarm that has not been reset, the alarm button (F4) lights up in red, as shown in
Figure 4.16.
4 -- ,
'"1. d F5 Ma
d -

Figure 4- 16

Time: Shows current time. If you double-click on the time, the system window will be d~splayed.
One of the options will be to change the control date and time.
4.2.5 SECONDARY WINDOWS

You can use menus, direct access keys, or buttons in the various environments to call up
secondary windows. These you can use to perform operations or to display data that need not be
so quickly accessible as the data appearing in the tabs. In the edit environment, they are used for
assisted programming.

Title

ONA menu

1I
. .....*.....+.....+...
tolours --nange
-
XMIN
Y MIN
!..._

fly1
I I ~ " - I~
r a-...._.....L
~ ...... ph
the operation rno
2 Load a file into the control

1 XMAX
1 YMAX

r AUTOSCALATE
F LINES BETWEEN PLANES

Figure 4- I 7

buttons

Title: The window's name indicates its use. The title can be used to change the window position,
so that data can be seen that have been occluded by it. To move it, press the left button on the
mouse, move the window to the new position, and release the button.

If you press the right button on the pointer when it is on the title, the window will disappear so that
you can see the complete environment window. When you release the button, the secondary
window w~ilreappear.

Buttons: Ail windows have an OK button. Many of them also have a cancel (cancelar) button. The
OK button closes the window and performs the corresponding operations. The cancel button also
closes the window, but it does not execute any operation. For example, if you are working with the
editor and you press the OK button, a program line will be written, but the cancel button will close
the window wh~leat the same time nothing is written.

You can close a window quickly with F1 (equivalent to OK) or with Esc (equivalent to Cancelar).
These are very useful, espec~allyif you are working with the editor.
ONA menu: In a secondary window you can use the right button on the mouse to call up the ONA
menu, as shown in Figure 4-17. This is the same menu as the one that appears if you press the
ONA key.

Flle raved

Figure 4- 78
Some windows, e.g. the one shown in Figure 4-18, remain open only a few seconds. They usually
notify the user of something, e.g. that a file has been correctly copied, that an EMDl instruction has
finalized, etc. They also have the OK button, so that they can be closed sooner than they would do
automatically.

Remember that the pointer must be within the window if the window is to be active and to be used
to initiate operations. Otherwise the control will not respond to the keyboard, except for the start-
up, stop, cancel, and backup keys used in execution. To activate the window, position the pointer
within it. If you wish you can press Esc, which will place the pointer at the centre.
4.2.6 EDIT ENVIRONMENT

This is shown in Figure 4-19. It has certain functions different from the other two. The quick-access
keys are different, and, since it has no tabs, F5 and F8 execute edit functions.

graphic representation window program functions menu

I
.. - - - - - -
- " .. -.
-. -. ...

Ella Tables EdlhoR Functions ,'

program
listing

editing
errars

/
function keys
Figure 4- 19

editor functions

If you press the right button on the mouse while using the ed~torfield, the programming function
menu will be displayed (see preceding frgure).

To select a text from the keyboard, place the cursor at the start of the text in questrion, depress the
capitals key and hold it down, and use the direction keys to move the cursor to the end of that
same text. Alternatively, using the pointer, press the left button at the start of the text, hold it down,
and move the pointer to the end.

If you wish to copy, cut, and paste a text in the editor, one way is by using the edit functions. First
select the text (with the pointer or with the keyboard). Then, in the editing menu, select cutting or
copying. Alternatively you can use the direct-access keys.
w
The drfference between copying and cutting is that in the second case the text in question is
deleted.Inbothcasssitissavedinthememolysothatlateritcanbepastedatanyotherpoint,as
many times as necessary.

i) If you have selected a text and you press the return key, a blank line is entered in front of the text
but the text is not erased. On the other hand, if you press a letter key, the letter is printed and the

a text is erased.

If you wish to copy a text, simply select the text with the pointer and move the pointer to where you
want the copy. Then press the middle button on the pointer.
i)

The CNC is structured in mes. There are various directories for saving the files corresponding to
programs, technology tables, offsets, traverse points, wire compensations, and histories. The first
five file types are used by the machine in its operations, while the history files are created
a automatically while programs are being executed (4.2.3.2).

A file can reside in the control memory or on diskette, or it can be part of the control. Hence files
are not modifiable. To indicate where it is physically located, a text is added at the start of a file. If
the file is on diskette, "A:" is added. If i t is part of the control, "ONA:" is added. If it is in the control
memory, nothing is added.
a
-
File names may be written in upper or lower case. Similarly they may be displayed in either
manner, but when a file is called it is immaterial whether capitals or small letters be used. For
example, a file rnight be called "demo" or "Demo", and its name might be displayed in upper case
or lower, but to call it from a program you can enter "DEMO", "demo", or "Demo".

The file name may not contain more than 24 characters. In any case it advisable to use the 8.3
format, i.e with eight characters, a point, and three additional characters, since there may be
problems in reading a longer name.
0
You can copy, delete, open (edit), or load files in the control. When you load a file in the control,
that file becomes the current file. i.e. the one that the control is going to use. For example, if you
i) load an offset RIe, then, when a program is executed that deploys an offset, it takes the offset from
that file. The files can be displayed (edited) without being loaded in the control.
B -
When you are going to carry out an operation on a file, the window shown in Figure 4-20 appears,
requesting the necessary data. (If you are going to copy files, the window is slightly different, as
9 shown in Figure 4-21 .)
 current files

I \.
Figure 4-20

explanatory comment file name free space

The title indicates the operation that is going to be carried out with the files.

Above on the left are the directories, i.e. the current file types, with the exception of the histories.
In the CNC, each file type is stored in an independent directory. Directories are not similarly
distinguished one from another on the diskette. Hence the first step is to select the directory
containing the files with which you are going to operate.

Under the directories you see the names of the loaded files in the CNC. While loaded, these fijes
cannot be deleted or overwritten. Their names are shown simply as an aid.

To the right are the current files for that directory. Their storage location is indicated
(nonrnodifiable memory V ,memory @ or diskette H),
along with name, volume in bytes, and
date of mos! recent modification).

On the lower left is an explanatory comment about the file, which is only for nonmodifiable
technology files.

On the right is the free space in the CNC memory. There all the user's files are kept, not only the
programs. In t h ~ sfield we see the total space free and the percentage of memory that IS still
available for use

At the bottom is the name of the file to be opened, deleted, etc., and the medium it occupies.
 If you press the accept button or the key F1 while files are being copied or deleted, the window will
not close. The operation is carried out, and you have the option to copy or delete more material. If
you press the accept button or F1 with the file name left blank, the window will close.

To indicate which document to delete, open, or load, select a file and then press the acceptance
button. Or alternatively, double-click on a file name.

You can use the button @ 210 access a file-loading window from numerous other windows.
The file-copying window is slightly different:

Name Sire Date

Techliology
, Offset 47

I Wire Cutnp, cuchara.prg 831 1110512001 1 3 5 9 00

1 H I S ~ D ~ ~ cucharilla.pry 838 1R/05/2001 08:12:00

I I 201 2K (98%) free @

\
\-
'- source file
des t i m i o n file
Figure 4-21

diskeite dump to memory -

memory dump to diskette
/

'i
?Ti Ac ept

/
C cel ,

Note that the upper part of the window is identical to the part dealing with deletion, control loading,
and file opening Below there are two fields in which to write file names, The upper of these is for
the name of the source file, the lower for the name of the destination file.
 3
If you select a file with the pointer, the name of both files is automatically supplied, along with the
source file support. It is thus easy to make several copies in succession, from one support to
another, since the support to which the copies will be directed is indicated. Subsequently you can
select one by one those files that you wish to copy, each time pressing the accept button (Aceptar)
or the F1 key. As in the case of the deletion window, the accept button does not close the window
unless the space for the name of the source file is empty.

If you wish you can change the name of the destination file. After selecting the source file, activate
the destination file field and make the change (Figure 4-21).

Figure 4-22

d
Using the two buttons on the right (Figure 4.22), you can dump the diskette contents into memory
or viceversa. When memory is dumped onto a diskette (right button), all the files in the directory
selected are copied. In other words if the offset files are being displayed, all the offset files in the
memory are copied to the diskette. If you are dumping diskettecontenis (left button), they go to the
directory selected.

Remember that when you are dumping from a diskette to a directory, all files on the diskette are
copied, and possibly some of them are not of the type rightly belonging in the directory in question.

If one of the files for copying is already in the destination directory, the control will query whether
you wish to forego copying, to overwrite that particular file in the destination directory, or to
overwrite all the files in the destination directory.

To delete a file, from any window the key or the key can be pressed.
4.3 USE OF THE NUMERICAL CONTROL

4.3.1 INTRODUCTION

CNC procedure is based on three large environments: the Editing environment, the Preparation
environment, and the Execution environment.

The Preparation environment embraces the operations under which the machine or workpiece
is prepared, i.e. specification of coordinates, offsets, traverses, EMOl funet~ons,etc.

The Execution environment is that in which the operations are specified via which it is
intended to execute a program: execution modes (normal, dry run, dry run up to the point),
cutting types (vertical, taper, etc.), technology selection, etc.

The editing environment embraces the generation, modification. and graphic representation of
programs. Programs may be edited in assisted mode or directly via the ASCII editor of the CNC.

4.3.9.9. START-UP PAGE

When the generator is turned on, the start-up page is displayed on the monitor.

% .
1

Figure 4-23
4.3.2. PREPARATION ENVIRONMENT

Ella Ezecubon peparallon fMOl Mlscslanous

I - T ? r--
LManval 1 DeclTrav 1 Thread 1 V~Rlcal 1
I
ILLUMINATION

Ill
r MEMORIZING
r GENERATOR
CONTACT TOL
r WIRE FEEDING

I
F b
A

Wok
A" <

4' -
won area 1 DOWN
;;d,- , >A?
rl Machine r *i i'

131 px
-4
FOUND ZEROES
FY FU SY FZ 1( TRAV 1 WCU 1 AWF ( VERT ( INR 11

I
I FS Manual I F6 O N 7 m ( F l Thread 1 FO V e r U i I
Figure 4-24

This environment comprises two zones:

The left zone of the screen, on which the following are displayed:
- [I]The work coordinates or machine coordinates.

- [2] Specification of work zeros.

Once you have set the axes in the zero work position you wish to specify, you can use
these three buttons to reset the coordinates. The first button resets the axes XYUVZ, the
second the axes XY, and the third the Z axis. Alternatively you can reset these by writing
d~recltyinto the coordinates.

- [3] Locating of machine zeros.

The search for machine zeros is carried out from the remote confrol (see section
4.1.10.2)
- [4j Automatic and manual modes.
If you choose automatic mode, you have the same freedom of operation except that the
CNC will not allow you to order movements from the remote control. If you choose manual
mode, the CNC will not allow you to execute EM01 instructions or programs.

- [5] Adviceline.
In this area of the screen, helpful aids are offered by the CNC to the operator, as well as
warnings, error notices, etc.
 This screen zone is permanent. Other windows do not appear within it.

The right zone of the screen, which comprises four tabs:

tabs

Figure 4-25

- Manual.
- D e f l r a v . [OffseVtraverse]
- Tread. [Threading]
- Vertical.

The selection of any tab will result in the appearance of a new window in the t h e right zone.
 4.3.2.1 "MANUAL" TAB

G.......G
t ..........z... I DBCl Trav 1 Thread I v ~ n c s lI I
y OPERATIONS
, ILLUMINATION

TANK

r GENERATOR
CONTACT TOL
I r WIREFEEDING

WATER PRESSURE UP 0
.0
Section 4.3.2.1 .I work area 1 DOWN V

Section 4.3.2.1.2

'
-kTRAV WCUT AWF VERT INTL

FS Manual ( F6 Olrrrrav I F7 Thread I F 0 Vertical I 1 1427

Figure 4-26

OPERATIONS carrled out from this tab:

- Work tank LIGHTING YI

- WORK TANK: Filling I Emptying
NOTE. On ONA Series "UE" models, these buttons are always deactivated.

- DOOR: Raisellower work tank door.

NOTE: These buttons have been activated only on those ONA "KE" models with a door that
operates vertically (optional).

- MEMORIZING: If this field has been activated, the CNC memorizes the manual traverse
effected by the operator in order subsequently to recover the initial position by executing a
RETURN 8 Y MEMORIZED ROUTE (see keyboard section 4.1.9.4 1 remote control (RETR)
4.1.10.3).

- GENERATOR: Indicates whether the erosion generator is active.

- CONTACT TOLERANCE: Specify the tolerance within which contacts will be made between
wire and workpiece. If the average of these contacts is between the values chosen, the
tolerance is correct. Otherwise the contact process will continue until the contact is
accomplished within the tolerance limits required. The range of TOLERANCE values is 0.000-
0.999mm.
WIRE FEEDING: Automatic uncoiling of 700 rnm of wire. This function can be used during a

m
,

STOP. With the threading jet and the wire motor operating, you can carry
out a semiautomatic wire threading.

WATER PRESSURE: UP I DOWN: Water pressure selection of the flushing water jets in
,

kglcm2.
4.3.2.1.1 USEFUL ZONE (Configuration of the useful work zone)
The "useful zone" key elicits the following window:

r" ACTIVATED

I ,F,;------v
# Z MAX
1

The USEFUL ZONE defines the work space permitted. You can select:
- Activated I Deactivated .

- Interior space: A useful-inferior-zone check is made. If work moves outside this zone, a zone
alarm results.
_ Exterior space; A useful-exterior-zone check is made. If the inner zone is accessed, a zone
alarm results.

The USEFUL ZONE is defined by means of COORDlNATE 1 and COORDINATE 2, so that a

three-dimensional work space is defined.

The space is defined by the coordinates POINT 1 ( X I , Y 1 , 21) and POINT 2 (X2, Y2, 22). You can

enter these coordinates via the key m, or alternatively you can write them directly

The zone alarm is reseted deactivating the useful zone and realizing an alarm reset.

With a zone alarm, the program stops and machine movements are locked until the alarm ceases.
4.3.2.1.2 EMDl - (Execution Manual Dab Input)

By pressing the button

EM01 ...
1 you can access all functions programmable in EMDI.
The operations you can select in EMDl are the same as the Programming operations referred to in
4.5. They are memorized, and you can select them with the cursor or with the pointer.

TRAV ~4 " . ..,.,.., -.

......."
dl.
They are not represented graphically, nor are there velocity graphs for the operations perFormed in
EMDI.

The most usual functions in EMDI, used in preparation, are grouped in five buttons for quick
access:

TRAV WCUT 1 AWF 1 VERT 1 IML II

- TRAV.: Traverse function (4.5.3).
- WCUT.: Wire-cutting cycle (4.5.16).
- AWF.: Automatic threading cycle (4.5.16).
- VERT.: Wire verticality adjustment cycle (4.5.16)
- INTL.: Linear interpolation function (4.5.2).
4.3.2.2 "DECiTRAV" TAB (Offsets and Traverse Points)
',

OFFSETS
Load table
default.ofs

OFFSETNUM. 1X
'f
U
1
I
34.000
19,000
V I 60.000

TRAVERSE POINTS I

TRAV.NUM. 7 5 X

G Machine coord.
Work coord.
90.0013

t
I 1 ~7 Thread 1 FB ~ ~ d i I~F ]
. . , -
*
; FS-"Manual
I

'q
FB Offmrav i l
---- - - .
,.

Figure 4-27

- I 1 By pressing this bullon you can rave the modified table.

By pressing this button you can load an offset file.

You can load OFFSETS and TRAVERSE POINTS:

- D~rectlyvia the key , taking the current position of the coordinate selected.
- Directly on the table by means of the pointer or keyboard.

- By means of the key

 'apj lasjjo ue alalap
JO 'Ado3 'uado laleal3 ue3 noh L ~ ! Y u!M nuau e ssame 01 'MOPU!M ayl 40 Ual do1 aq] le ',,al!J,,
pla!y aql u! ssaJd 'way1 ]!pa ue:, pue 'alqei e u! slas#o tie 01 ssame paJ!paney noA MOPUIM e U O J ~
4.3.2.2.2 TRAVERSE POINTS

On the TRAVERSE POINTS TABLE you can choose whether the coordinates loaded will be
treated as MACHINE COORDINATES, relative to the absolute zero, or as WORK
COORDINATES, relative to the WORK COORDINATES origin selected at the moment of
execution.

You can access the following window via the offsetbutton "edit tablen:

r T
File
-
( defaulttrv

ON

GO TO NUM. ON Mach cwrds OFF Work coords

/".."....,,.ck-...~
de&u# f#
I............,....
----."---."- - ---- p--- -
"

Figure 4-29

From a window you have direct access to all traverse points in a table, and can edit them. Press in
the field "Eile".at the top left of the window, to access a menu in which you can create, open, copy,
or delete an offset file.

NOTE:

- A change does not take effect until the table is saved

- If a table is modified and you wish to open another, the CNC allows you to save the changes.

- If the modified f~leis being used by t h e file being executed, it cannot be saved with the same
name. The CNC w ~ lallow
l it to be saved with another name.
4.3.2.3 "THREAD" TAB (Automatic Threading Adjustment)

Manual I Dec / Trav ...--*.-.

I Velucal I
-THR. ADJUST
U -36.000

0 e r c o ~ u0.25
t (900)

Brass. Uncoated. (9130 N/mm*. 12 rnlohm.mm=)

MAIN P t .
Z ZERO
THR, NR.

WCUT EMDl A W F EMDl

pz-
"-

Figure 4-30

Before considering how the threading jet is adjusted, we take at look at this tab.

"THR. ADJUST." zone: The U, V, and Z coordinates are entered so that for each threading
height the CNC will calculate the corrections necessary on the U and V axes to centre the
threading jet with the lower guide.
 N 0 TE: Normally this adjustment will not be necessary, and it will be sufficient, using the
screws, to mod;@ the threading jet angle (see section 3.5 of the manual on operation and
maintenance of the automatic thread and wire movement). The threading jet should be
centred on the lower guide in the position "wire verficality". The U and V position should
be modified with respecf to verficality only if centring cannot be achieved with the screws.

Correction is effected as follows:

- Put the Z axis at a height such that the distance between the lower guide and the upper
b about 300 mm.

- Turn on the threading jet with dielectric setfng from 25 to 31.

- Moving the U and V axes in manual mode, check that the threading jet is centred wtth
the lower guide.

- Use the key to memadie the current U, V, end Z value,^. ( I i t js not necessafy
to move the U and V axes with respect to verticality, the coordinates will be memorized
in verticality position.)

"Zm": This is the absolute value to which the Z axis wilt rise to avoid obstacles when
returning to initial threading position in the event of breakage during cutting. It can be
131
memorized with the u key.

"WIRE TYPE": The type of wire that is going to be used will be selected from those shown on
the table. When selection has been made, a description of the type will be displayed.

Selection is made by trademark. If a wire is used that is not shown on the table, one whose
description is close to that of the wire used can be selected, although the best solution in this
case is to consult ONA.

"MAIN PL.": Main Plane. Indicates the distance from the center of inclination of the lower
guide to the lower surface of the workpiece (also described as "reference plane"). The value
displayed on the screen is the same as that shown on the tabs for tapered cutting and
automatic adjustment of wire verticality (4.3.3.5and 4.3.2.4 of the Instruction Manual). If this
value is modified on any one page, it will be updated accordingly on the others.

"2 Zero": Indicates the distance from the lower surface of the workpiece up to the origin of
the Z axis. The value displayed on the screen is the same as that shown on the tabs for
tapered cutting and automatic adjustment of wire verticality (4.3.3.5 and 4.3.2.4 of the
Instruction Manual). If this value is modified on any one page, it will be updated accordingly
on the others.

"THR NR.": (Number of threadings.) The machine records the number of automatic
threadings carried out .

NOTE; All coordinales shown on lhjs page are (absolute) MACHlNE COORDINATES wtth respect
to the machine zero.
4.3.2.4 "VERTICAL" t of Wire Verticality)

--.
Manual ] Dac l Trav I Thread kedicij ]
I

VERT EMDl I

VERT, TOL. o.010

Figure 4-31

This is the absolute (machine) coordinate of the Z axis, up to which the Z axis moves, as optimum
upper point for the automatic calculation of verticality. (In the case of t h e ONA KE 350, KE 450,KE
500 and KE 1000 models this value is 200.)

This is the absolute (machine) coordinate of the Z axis, to which the Z axis moves, as optimum
lower point for the automatic calculation of verticality. (In the case of theONA KE 350, KE 450, KE
500 and KE 1000 models this value is -360.)
ZA:

Indicates the distance from the lower surface of the workpiece (workpiece support of principal
plane) as far as the verticality ring.

PP:
Principal Plane. Indicates the distance from the lower guide to the tower surface of the workpiece.
The value shown on the screen is the same as appears on the taper cutting page (section 4.3.3.5).
If this value is modified on either page, it will be updated accordingly on the other.

Indicates the distance from the reference point to the Z axis origin. The value shown on the screen
is the same as appears on the taper cutting page (section 4.3.3.5). If this value is modified on either
page, it will be updated accordingly on the other.

UN
These are the verticality coordinates with respect to the absolute zeros of the U and V axes. They
are specified while wire verticality is being automatically adjusted.

VERT. TOL
In the field VERTICALITY TOLERANCE the range is indicated within which the points 21 and 22
are going to be centerd. If t h e X-U and Y-V coordinates at Z1 and 22 are within the range selected,
the verticality cycle concludes Otherwise the interior centering at 21 and 2 2 continues.
4.3.2.4.1 SEQUENCE OF OPERATIONS DURING AUTOMATIC VERTICALITY
ADJUSTMENT

Prior to attaching the verticality ring, make sure the fixed strips for supporting the workpiece are
clean, so that the supporting surface is smooth and horizontal.

1. The first operation automatically performed when the VERT order (Automatic Verticality
Adjustment) is executed in EMDl is interior centering at the center of the verticality ring, on
the X-Y and U-V axes, at the current Z coordinate. (See Tab Manual, section 4.3.2.1 .)

2. The Z axis descends to the specified coordinate Z t . At this point an interior centering is
performed on the X-Y and U-V axes.

3. The Z axis ascends to the specified coordinate 22. At this point an interior centering is
carried out on the X-Y and U-V axes. If the X-U and Y-V coordinates at the two points Z2
and Z1 are within the range selected in the VERT. TOL. (vertical tolerance) window, the Z
axis wilt position itself on the point at which the VERT order (automatic verticality
adjustment) has been initiated.

NOTE: The VERT order can be carried out on/y in EMDl mode, and from a program.
4.3.3 EXECUTION ENVIRONMENT

.
-
-

-
Flla
- -
PmoaraUon bculion EMDI Ml~celanous

fh@ left zone on the screen, which displays:

E l ] The graphics window.

[2] Automatic and manual modes.
.
beut

oerella

SCALE D 1

FEEDRATE
ACT.
LEFT TIME
I Tech 1 Profile 1 T a p ~ r1

f
1 1 NORMAL

I M L X-70,149 Y-12451
lNTL X-85.578 YZ.978
INTL X - 63.598 Y4.957
INTL X - 100.91 5 YZZ.274
INTL X- 106.853 YZ8.212
INTL X-91

*ff-*.**.*-l.ll.
.OZ Y44.044
Hlstory of the plece
File, onagrama.prg
l P

1
=..=.=.==f*=*=

18#5/ZODl 08 54.1 4 Executlon st&

OB,59:13 Executlon stopped
08~59:21Cancelled Execut~on
=.

If you choose automatic mode, you have the same freedom of operation except that the
CNC will not allow you to order movements from the remote control. If you choose manual
mode, the CNC will not allow you to execute EMDI instructions or programs.

[3] Advice line.

PROGR.

In this area of the screen, helpful aids are offered by the CNC to the operator, as well as
warnings, error notices, etc.

[4] Work coordinates, machine coordinates, and initial point coordinates.

From this screen, if no program is being executed, you can modify the work coordinates
onagramaprg

1740.0
4
I

This screen zone is permanent. No other windows appear within it.

.
By means of the execution menu, or by pressing Ctrl + 2 , you can a window that will perform a
coordinate zoom
 The right zone of the execution environment screen displays four tabs:

tabs

Figure 4-33

- "Execut." tab (section 4.3.3.2)

_ "Tech."tab (section 4.3.3.3)
.. "Profile" tab (section 4.3.3.4)
- "Taper" tab (section 4.3.3.5)

When you choose one of these tabs, a new environment appears in the right-hand area of the
screen.
4.3.3.1 BUlTONS IN THE GRAPHICS WINDOW

-Ed Zooms on the zone selected. To select the zone, mark two points on a diagonal with the

pointer, pressing the right-hand button on the device. Then press

:
and later @I,
If you wish to magnify the area more, select another two points on the diagonal, using

the right-hand button on the pointer, then again press

By pressing the button you can elicit the parameters window within the graphics
window. It has three tabs: colors tab, graphics limits tab, and zoom limits tab.

4.3.3.1 .l COLOURS TAB

\

/ I UNION I POSITION

I
I--. Figure 4-34

This window is for assigning colors to be used on the graphics screen, as per:

- xy MOV.: Color used for representing movements in the X-Y plane in Normal or Dry-Run
execution

- uv MOV.: Color used for representing movements in the U-V plane in Normal or Dry-Run
execution.

- xy SIM.: Color used for graphics in the XY plane

 'JayJew uo!a!sod 40 10103 :NOIISOd -
'saueld ~n pus AX aql uaa/v\laq sau!(6u!pauuoa JOJ pasn ~ o r o 3 :NOINn -
'aueld An ayl u! s q y d e ~ 6do4 pasn ~0103 :'WIS 'An -
4.3.3.1.2 "GRAPH. LIMITS" (Graphics Window Limits)

colourr "mu-
..-*-
Firaqh"-limits!
"&
I
X MIN
Y MIN 1'i
1 XMAX
I

/ F AUTOSCALATE
II
F LINES BETWEEN PLANES
r GRID

- X MIN / Y MIN I X MAX I y MAX: In these fields, limits are specified for the graphics window So
that they may take effect, AUTOSCALATE must be deactivated.

If the AUTOSCALATE box is active, then each time a graphics representation is carried out the
max. and min. coordinates will be modified accordingly.

- LINES BETWEEN PLANES: if the box has been activated, this connects the lines between
drawing planes.

- GRID: creates a grid in the graphics area.

4.3.3.2 "EXECUC" TAB (Execution)

Execut 1 Tech ] Profile ] taper 1 I

Name of the
principal
program Name of the
subprogram.
Execution In 4.5.15, see
"execution in
modes
field an external
program ".
COOR X - 5 . 6 Y-2.74 UO VO
SCALE 0.1

'NTL X - 54.1 59 V-27.4

INTC+ X-41 21 9 Y-4C.956 EX1 3 989 CVQ.399
INTL Y-58.471
INTC- X - 6 5 37 Y-8.123 CX1.049 CV31 47
INTC* X-65 61 1 Y-7.913 C X - 0 ' 2 8 CY0.096
- rl
p i p i e c e
I

.
08:01:12 Incorrect position of the spool

,:
,
'
,

,
:
., > ,

;>, A",y
,
-
,
3
- 3
:!?
'
,
>,

;>,
'P"
,
?<:
,;:.:.
"%

, ,
.
, "
: ,
,>
",

., "
. -.,.
,>.
.
,
,

,
2%'
,,,.
.,*;J
I;
,,

FEEDRATE
ACT. 1-0.00 PRoGR.r-
LEFT TIME 1 --
FS Exeeut ( F6 Tech 1 F7 Profiles 1 F8 Taper 1: 8:35 1
Figure 4-37

Ed~tingof princrpal program.

- CMC Load program.

. 1 Graphically represents the program loaded.

- -1 Graphically represents the

J 141 program loaded, block by block
- r
-
: I Autoscales the program loaded, making as much use as possible of the display area. If
this entails a change in the graphics limits, the previous diagram is erased. Autoscaling is
necessary for the calculation of time remaining.

1 119) Erases the drawing in the display area.

-34 Start or continuation of the program selected

- /el Start or continuation offhe program selected, block by block.

Block-by-btock return via the profile programmed as far as the initial point or until the key

is pressed.

STOP. Halts program execution.

Cancels program execution.

EXECUTION MODES FIELD:

- NORMAL: The program is executed in normal cutting conditions.

- DRY-RUN: The program is executed with movement of axes, but with the generator off.
- DRY POINT: The program is executed with movement of axes, but with the generator off, and
only up to the point at which it was previously halted. The previous execution had to be
canceled, or the machine was turned off in the middle.
It is necessary to go the initial point just before the program is executed in this mode. When the
point has been found, the program has to halt When it is started again, it will resume in the
mode seiected before DRY POINT.

Workpiece history. While a program is being executed, incidents that occur during erosion are
recorded:
_ Date and time program started.
- File loading: technology, compensations, etc.
- Executions halted, executions restarted.
- Length of profile eroded.
- Mean velocity.
- Time taken to execute the program.
- State indicators (4.5.15).

The CNC always and automatically creates the workpiece history. If the AUTOMATIC HISTORY
SAVING is act~vated, , each program executed is saved in a sequence of ftles in the order
"histaryO", "history 1",. . ."historygM.At this latter point the sequence reverts to "historyO", "history I",
etc.

If you wish to save a particular history, you can do so via the icon ( BI (save), and the file will be
saved under another name.

CUTTING FEEDRATE:

LEFT TIME

- ACT.: Actual velocity of execution in mmlmin.

- PROG.: Programmed velocity in mmlmin.
- LEFT TIME: In the case of VERTICAL CUT, an estimiate is made of the time remaining until
execution is completed. So that this estimate can be performed, first an autoscaling has
*%*
to be carried out, and the first estimate has to be shown on the basis of 5% of the profile
realized
4.3.3.2.1 EXECUTlON DETAILS

By pressing
I you can access the following window:
D"'E
program
I Machine in dry run
-

'parameters
/
FILES IN EX€CUTION

I TECH
OFFSET 1
ONA:s-sE?5ktec
defaultofs
PO

P3
-,

1
0
0
COMP defaultcmp
I
P4 (0
SCALE I 1,000-
ABSOLUTE I l NCREMENTAL
I

ROTATE D.OC0
AX IS CHANGE I XY
AXIS SENSE X 1 DIRECT
v rIRECT

Figure 4-38

4.3.3.2.1.1 "STATUS" TAB

In this windcw the following is displayed:

- MACHINE STATE: Dry-run mode, Normal, Executing, etc.

- The FILES IN EXECUTION: Technologies, Offsets, Traverses, and Compensations

- State of the program MODIFICA~ORS: - SCALE.

- ABSOLUTE I INCREMENTAL.
- ROTATION.
- AXES CHANGE.
- AXES SENSE: X I Y.
- PROGRAM PARAMETERS: To display and modify COUNTERS used in the execution of
programs. PO-P9 can assume values from 0 to 100 (See "counters" in 4.5.15.10).
4.3.3.2.1.2 "WORK SESSION" TAB

/
!work _se~sion,
:....I....,.............. ...._...., &status I
FLUSHING T

I iS FLOCULANT I
?i DWELL MODE
r AUTO PW-OFF
I r AUTO PW-OFF IF ALARMS I
I r MANUAL RESTART I
F AUTOPOWER ON
JUMP (THR,)
r RECOVERY
v
I R EROSION PROTECTION
I
I F AUTOSAVE THE HISTORY FILE

I E-MAIL. RECEIVER sputnik@movistar4com

I --
- ,- - ----- -
-
a "
--- A- --- --- -
Figure 4-39

This window displays the following:

- CUTTING MODE: lmmersion or flushing cutting (Only on machine with immersion cutting
technology).

- DWELL MODE: You can choose whether UNLIMITED PROGRAM DWELLS be executed

- AUTO pw-OFF: You can choose whether the machine stops when the program has been
firlalized.

- AUTO pw-OFFIF ALARMS: In the case of night work, if you select this option then, if the box is
activated, any machine alarm, e.g. "wire breakage". "no wire", or "no water", will result In
automatic switch-off. This function operates only if AUTO PW-OFF is aIso activated.
- MANUAL RESTART: You can restart the machine foltowing a stop for any of the following
reasons:

- There is no current because the option AUTOPOWER ON has not been

selected.
- The emergency button has been pressed.
- The OFF button has been pressed.
- The door of the electrical cabinet has been opened.
- The program has been canceled.

This operation is very useful if you wish to restart following an accidental stop, an undesired
cancellation, etc. You can resume the previous situation and continue the work that was being
done.

In any of these situations, without any movement or change in the program that was being
executed, you can activate t h e MANUAL RESTART box and resume execution. Execution is then
carried out to the point at which the motors stop (in the manner-ofan automatic restart). When the
position has been reached, execution of the program halts. The screen displays the message
END OF POINT RECOVERY. You can then choose whether to continue with the execution.

- AUTOPOWER ON: When power has been restored following a failure, the machine
automatically resumes operation at the point where it stopped. Only if the machine was executing
a program IS cutting contined as before.

Naturally AUTOPOWER ON is subject to certain limitations:

Only what is programmed can be resumed, i.e. manual changes to execution parameters,
outputs, etc. are not recovered. Nor are executions in EMDI.

With an automatic restart, the program is again executed without your intewention. The motors do
not turn while the part of the program preceding the power failure is being executed, but all other
operations (outputs, transformations, etc.) are realized. The coordinates, even though the motors
are stopped, are updated, as are the diagrams. Once the point has been reached at which power
failure occurred, the motors reconnect and execution continues normally. The former situation
has now been fully regained.

- JUMP (THR.): Only on machines with automatic threading. Used in combination with the
rethreading function. You can introduce a number from "0" to "999". "0" indicates that the function
IS deactivated, wh~leany other number indicates how many times the jump,function can be carried
out. If, when a multicavity is being machined with this function activated, wire breakage occurs
and threading or rethreading fails, the profile is completed in dry run as far as the next cavity
("jump" from the current workpiece)
- RECOVERY - Rethreading: Only on machines with automatic threading.
By threading is meant the cycle that is carried out when the function "automatic threading" (AWF)
is programmed or the machine is automatically carrying out a threading. This function usually
undertakes 2, 3, or 4 times to thread, depending on the wire type. When the set number of
attempts has been used up the machine stops.

By rethreading is meant the cycle following wire breakage during a program's execution, until the
the machine begins to cut again.

If, with this option activated, wire breaks while a program is being executed, the wire break point
is recovered so that cutting can continue. To this end, following a sequence of wire preparations a
return is made to the initial point so that the wire can be threaded. The profile is again traced that
has already been machined in dry run (without the generator on) as far as the break point. The
generator is then turned on and cutting is resumed. If the wire moves outside the neighborhood of
the break point without breaking, rethreading is considered to have been completed. Otherwise
the operation is again attempted.

This rethreading operation is carried out the number of times programmed (see section 4.3.5
Maintenance), 10 times by default. If rethreading is not accomplished within the attempts. and the
box JUMP (THR.) has the value 0 , then the machine halts. If the box is activated with a number
higher than 0,then a jump occurs.

- EROSION PROTECTION: This activates and deactivates The Expert Erosion System. The
Expert Erosion System makes an effective controt of the cuttings process, modifying automatically
the programmed parameters of the power supply, ensuring optimum machine performance at
each stage. The Expert Erosion System is of special importance cutting complex pieces, as
staggered pieces, pieces with wide angles of taper cut, etc.

- INDICATION OF STOPPED EXECUTION. Only with machines that have an external alarm. If the
machine stops (at the end of execution, for a programmed stop, etc.), the external alarm will be
activated if it has been set to operate.

- AUTOSAVE THE HISTORY FILE: If this option has been activated, history will automatically be
saved when a program has been executed.

- SEND E-MAIL: This activates and deactivates the transmission of e-mails to the e-mail address
specified in the field "E-mail receiver".

- E-MAIL RECEIVER: Electronic mail address to be specified by the user, where the messages,
that the machine transmits in the normal course of work, will be sent. This way, the user will be
able to receive these messages via PC or even mobile phone. For the correct configuration of the
communication protocol users can contact with the Technical Service of ONA (onasat@ona-
elect roerosjon.corn)
4.3.3.3 "TECH." T A 8 Technology Tables)

I
\ 1.

Execut .,.,.Te!:
.... .
J 1 Profile ] Taper I Pausas ] Loading of
I CNC

selected
THICKNESS
CRITERION 5 - ROUGH 1 / 3 d

-
POWER 9
TIME OFF
VOLTAGE 120
SERVO
generator D IELEC.
parameters +WIRE TENS. 1 12
WIRE FEED .- A1 8
FINISH OFF
INVERS - OFF
CORNER CORR,
- --- 0
FEEDRATE 240.0

II COMPENSATION 4 m a )
PROG, CONDUCTIV, 14
ACTUAL CONDUCTIV, 11.6
ACTUAL FEEDRATE
T % PROTECTION Reset I7
F5 EX, cu T 6 T e c h m T1F8~ T
ap
e7 I
Figure 4-40

The first field ~ndrcatesthe technology selected so that it can be worked with. If you leave the
pointer on this field, there appears an explanation of the type of wire and workpiece to which the
technology loaded corresponds, providing it is a technology supplied by ONA.

The generator parameters appear in black when they coincide with the technology values. If a
parameter is modified in the technology, this field is displayed in red.

- COMPENSATION. Offset in the program being exectued. This field automatically shows the
compensation for the technology used. If a call is made from the program to a compensation file
and to a particular value, the latter is updated in this box.

- PROG. CONDUCTIV, (Programmed conductivity): Displays the default parameter. In the case of
machines with cutting technology, this parameter is 10 pSlcm.

- ACTUAL CONDUCTIV. (Acf~alconductivity). Actual conductivity measured

 You can use the button to edit the compensation tables. These tables are saved as files.
Each of them can hold up to twenty values.

I default.cmp
VALUE VALUE

NOTE: The loading of compensation files should be assigned at the start of the program, but the
compensation number should be selected after the technology. Otherwise compensation will be
updated in the compensation cell.

- ACTUAL FEEDRATE. Actual rate of execution in mmlmin.

- % PROTECTION: This activatesldeactivates modifications made to technology parameters when

wire breakage occurs. It functions independently of whether "Protection of Erosion" has been
activated (see 4 3.3.2.1.2).

RESET: Cancels current protection.

You can use the button to elicit the following window:

 -File Edltron '

( ONA:s_stZSIt.tec THICKNESS
ROUG. FINISH 1 FINlSH 2 FINISH 3 ,

POWER
TIME OFF
VOLTAGE" A

SERVO
DIELEC.
WIRE TENS.
WIRE F E E D
FINISH
JNVERS
CORNER CORR.
FZaFFr OFF
W---EF

OFFSET R. 1 0,165 1 ---- ] ---- ] ----

FEEDRATE 8 . ____ I T
OFFSET R + l F rr
FEEDRATE R+1 F 1 Z40.0 5.0 I ---- I ----
OFFSET R+zF 0.145 r 0.140
FEEDRATE R+ZF
OFFSET Rt3F
FXDRATE 8+3F
1 0.205 1
5.9 -1
0.150
6.0
1
SO 1
0.145 1 ----
;1:9. '

CURRENT
AVER. VOLT.
AVER. FEED
VDI

Figure 4-41

In this window you have a full view of the technology sejected and the option of changing figures. If
the technology file is being used, the CNC will ask whether the table is to be saved under another
name.

Technologies bearing the ONA name cannot be modified, but they can be copied onto the drsc for
the creation of user technologies.

You can use the editing menu to specify new warkpiece thicknesses, copy generator parameters,
and create, copy, or delete technology files. You can specify a new thickness on the basis of
current generator parameters, enabling their box, on the basis of the technolagy corresponding to
the thickness indicated in the technology selected in the corresponding field.
4.3.3.4 "PROFILES" TAB

I Execut ) Tech proflpj

1 1
*...!
Taper Paurar 1 I
FEEDRATE

I ACT
MOD1F(%)
0.00 PROGR,
1- 100

With this

I
'
button is
deleted the

WATER PRESSURE UP 0
.0 feedrate
representation
ACTUAL P A U : ) - DOWN 0
.0

PARTIAL MACHINE
----- 1 186:47 )
LEFTTIME - I- -- 1

I I

F5 Execut ( F6 Tech 1 F7 Profiles 1 F0 Taper 1 1 11;I5

Figure 4-42

- ACTUAL FEEDRATE: Graphifc representation of the actual velocity as function of the time
selected.

- PROGR: Programmed velocity.

- MQDIF%: The velocity rnodrfier as percentage of the velocity programmed.
- WATER PRESSURE ( U PI DOWN): Pressure selection in kg/crn2of the flushing water jets.
When you press the icon d the following is displayed:

Y MIN
Y MAX

LENGTH OF THE HlST 1 min

Here you can select:

- y MAX I y MIN. Maximum and minimum on the velocity scale.

- LENGTH OF THE HIST. Here you can specify the length of time over which velocity will be
indicated.

- DRAW AREA. If active, this fills in the area under the representation of velocity as function of
time

- TIME
PROGR. -]
OO:OO

'
v

PARTIAL EXEC. A
PARTIAL MACHINE
- - 1-
. -, ,

-
LEFTTIME i
- -- 1

- PROGR. Time elapsed since execution of the program began.

- PARTIAL. EXEC. Partial machine time. You can assign whatever value you wish to this variable,
which will update incrementally with respect to the value specified.
- P A R C ~ A LMACHINE. Partial execution time. You can assign whatever value you wish to this
variable, which will update incrementally when the generator is on.
- LEFT TIME. In the case of VERTICAL CUT, an estimiate is made of the time remaining until

execution is completed. So that this estimate can be performed, first an autoscalrng Q

- ,,,
to be carried out, and the first estimate has to be shown on the basis of 5% of the profile
realized

These times are shown in hours and minutes.

4.3.3.5 "TAPER" TAB

.............-.
I
E X ~ C U Tech
~ ] Profile i.......
x I..p ......
e r, ]
I

DRAWING P.

-
F5 Execut
.
I F6 Tech I F7 Piofiles I A

~8 Taper
,
I 1 - --1
.-
9.1 1
. .
Figure 4-43

CUT. You can select from three cutting types to execute the program loaded in the CNC:
VERTICAL, XY UV, TAPER (see section 4.3. CUTTING TYPES).

DRAWING p. Distance from the P.PPAL. to which the represntation of the cutting programmed is
I
+ <y,,

going to be produced. Press on Draw to elicit the graphic representation This is

especially useful with tapered workpieces or for working on them in XYUV, since it allows you to
perform cuts at different levels, at which you can check that the profile is correctly programmed.

The values assumed by I1z ZERO", "THICKNESSw, "PROGRAM p." and L4MAlNPL." are
explained in the tapered cutting section, 4.4.3.
4.3.4. EDITING ENVIRONMENT

In this environment you can carry out operations relating to the generation, modification, and
display of programs.

A given program can be edited while another is being executed.

Display of the program opened

Graphics win dow \

Menu bar \
i
1 -.
Ella Tables EdPon Euncllnns ""tegles .--- -" - .-.--- -
4------- - -- - --

\
PROGNAME onagtama
i' Dema Prog ' f

COOR X - 5 6 Y - ? 74 UU VO
SCALE 0.1

INTL X-54,159 Y-27.4

INTC* X-41.219 V-do 956 CX13.989 CY0.399
1HTL Y-58471
INTC- X-65.37 V - 0 123 CX1.049 CY31 4 7
I N K + X - 6 5 6 1 1 L - 7 9 1 3 CX-0.128 CYO096
INTL X - 7 0 1 4 3 Y-12.451
INTL X - 0 5 5 7 0 Y2.978
INTL X- 83 598 '7'4.957
INTL X-100.9t6 V 2 2 274
INTL X- 106.853 '476 21 Z
INTL X- 91 .OZ Y44 M*
INTL X - 1 0 2 2 7 T
INTL Y 3 9 032
INTL X - 1 1 5 63 Y 5 f . 4 4
INTL X- 80 6dS
lNTL X-75.697 V47 493
INTL X- 93 1 9 '130
INTL X- 70 149 Y6 96
1Nll X-47 1GB Y 3 0

G l a p h ~ zrepresentation Ok

1A . 1 rr prep 1 I'
/
Work coordinates

Advice line
,/
/ Program name

Zone for advice and recommendafion in the editing environment

Graphics window

A program is graphically represented in terms of compensations, rounding off, chamfers, etc.

The workpiece that will be executed is thus faithfully represented.

A vertical cut, tapered cut, or XYUV cut can be represented independently of the mode in which a
program is being executed.

To zoom, press twice with the right-hand button of the pointer: one press on the first point or end of
the diagonal with which the window zone is going to be marked that you wish to enlarge, and

another press on the other point or end of the diagonal. To display the zoom, press and the
graphics button F7.

On the MENU BAR there are four menus:

- ~ i [ menu.
e (see section 4.2.7)

Here you have the following options:

- open:Edit the program selected in the program editor.

- ~ : a new program. Asks for name, description, files to be used, etc.
N ~ Creates
- save:Saves, in the memory, the program that is being edited with the current name.
- save as: Saves, in the memory, the program that is being edited and asks for a new name.
close: Closes the program that is being edited.
- copy: Opens a window for making file copies.
- Delete: Opens a window for the deletion of files.

- Tables menu.

File Tables Edition Eunctrons Strategies

I
, . - -- ... .
A

IPROGNAM
onagrama
/" Demo Prog "/

COOR X-5.6 Y-2.74 UO VO

aire Radlus Comp. SCALE 0.1

Figure 4-45
I
- Technology: From the e,diting environment, accesses the technology tables.
offsets: From the editing environment, accesses the offset tables.
- ~ r a v e r s ePoints; From the editing environment, accesses the traverse tables.
- Wire Radius Camp.: From the editing environment, accesses the wire radius
compensation tables.
- Edition menu.
--

I PZGL ibn Dncnons strategies

-
.

I I
L
(PRCGNAME
r
onagrama
Damc Prog ' I

COOR X-5.6 Y-2.74 UO VO

SCALE 0.1

INTL X-54 159 Y - 2 7 4

INTC+ X-41.219 V-40.956 CX13.989 CYU 399
Llne edltlon mode IML Y-50.471
INTC- X-65.37 Y-6.123 CX1.049 CY31.47
INTC+ X-65.611 V-7.913 CX-0.128 CV0.096

Figure 4-46
lNTL X- 70.1 49 Y-12.451
INTL X- 65.578 Y2.978
d
I
- cut: Eliminates the selected document text and stores it in the memory.
- copy: Copies the text selected and stores it in the memory.
- paste: Inserts the memory content at the cursor point.
- ~ i n d :Searches for a sequence of characters equal to that specified in the window
displayed. Example:

Enter t h e tex? to search far

- G* to the line: Situates the cursor at the line number specified in the window displayed
Example,

Go to line
1

+ Check syntax (F5): If you select "Check syntax" or press F5 'yntu; the programmed1,
funct~onsin the program opened will be checked for correctness Calls to external programs
are not checked.
- ~ i n editor
e (F6): If you place the cursor on the line you wish to edit and select "Editor de
lineas" (line editor), or if you press IFSEditline
the ed~tingwindow for that instruction.
1, the graphics window will be replaced by

-.
-File Tables Editlon Eunctlons wtegles

y Sense -
I' Demo Frog '/

- X Y Plane COOR X-5.8 Y-2 I4 UO VII

SCALE 0.1
x r-41219
INTL X-5d 159 V-27.4
v
cx r 13989 . .

CV i 0 399
IYTC- X-65 37 Y - 8 123 C X 1 0 4 5 CY31 4 7
INTC+ X-65.811 Y-7 913 CX-0.123 CVO 096
INTL X-70.149 Y - 1 2 4 5 1
Fssdrale I --
INTL X-85 578 Y 7 978

: :1
Wire cornp number INTC X-83 598 Y4 1 5 7
INTL X-100.916 Y22 274
Wlre angle lNTL X-106 853 YZB 212
Rounalng radlus IWL %-91 02 Y44 044
INTL X - 1 0 2 271
INTt V39 082
INTL X - I t 5 5 3 Y S f 4 4
INTL X-BD Ed5
INTL X-75.637 '447.493
fNTL X-93.19 '930
lNTl X - 7 0 149 Y6.36
I JNTC X-47 108 Y 3 0
IFormat of the lnstrucnans OK
Gtaph~crepresentatran Ok

. F4 Alarms ;:1 j F6 S y n l a / ~6 qn lins F7 R~pr.5 IFB

Graph paIF1
.

Figure 4-47

If the instruction is simple, e.g. as in the case of "absolute", "incremental", or "selection de

cornpensacion", a window will appear with a listing of keywords.

More complex functions, e.g. linear and circular interpolations, technology selection, and file
loading, have their own windows.
 -

i- _--- ---- -- _.
Tables Ed~tlon Euncflons Skategles
, "-..--p--.-.""- .- - -ern* .-- _--- *_-- _ AX.-. -
PROSNAME onagrarna
Llsting of the nernonlcs r Demo ~ r o 'gI
COOR X-5.6 Y-2.74 UO VO
B ~ r a ~ r a ther scale n k

I!
SERVO < n r Program b e value o f me sewo
INTL X-54,159 V - 27.4
SHARP ANGL Sat sharp angle taper cumng INTC+ X-41 21 9 Y-40 956 CX13.989 CVD.339
Programmed stop
TAPER <n> Set taper angle
-
INTL Y 56.471
INTC- X - 65.37 Y-8.123 CX1.049 CY3f .47
TAPER LEFT Set taper cut to the lell INTC+ X-65.611 Y - 7 91 3 CX-3 126 CY0.096
TAPER OFF Cancel taper cut INTL X-70.149 V-12 d51
TAPER RIGHlSet taper cut to the right INTL X-85 576 Y2.978
TECH Selection of the generator setlings INTL X- 63.598 Y4.957
INTL X-100.916 YZ2.274
TOFF en> Program tlrne-off
I N l l X-106.853 Y28.212
TRAV Traverse
INTL X-31.02 Y44.044
USE{ Use ~ptlonalblocks INTL X-lUb27t
VCCTOR Vector INTL Y33.082
\/=a7 W i r m uadi~nlih, INTL X-115.63 YSZ.44
JNJL X-80 645
INTL X - 75.697 Y4 7.493
INTL X - 93.1 9 Y30
INTC X-70 149 Y6.96
1 INTL X-47.108 V3O
Fornat of the insiructlons: OK
Graph~creprerenlallon-Ok

Figure 4-48 I
- Graphics representation (F7): Displays the program being edited in the graphics display
area (F7).

- ~ r a p h i c sparameters (Fa), which IS equivalent to pressing the button (see section

4.3.3.5.).

- Functions Menu

Programming functions are grouped in seven blocks.

-FII?
I
Tables Edilion . Eunctions
$Irategies
Basic b
PROGNAME onagrama
Lislblg of the nem< TechnoJogy b /' Demo Prag ' I

I I I
Coord. transform. P

JNTL X - 54 1 5 3 Y - 27 4
5H.GE'f' AF.ICL Set sharf Preparat~on
INTC* X-41 .Z19 Y-40.9;
STr2F INTL Y - 5 8 . 4 7 1
TAPER cn> Set taper INTC- X- 65 37 Y - 8 123

Figure 4-49

4-63
4.3.4.1 "STRATEGIES" MENU

"Strategies" is a programming system that on the basis of a brief questionnaire enables the user to
produce any workpiece with ease. The geometry that he defines is incorporated into the final
program. The strategies system inputs the most suitable technology, the offsettings, and the
various other options offered for the user's consultation.

4.3.4.1 .IGENERATE "STRATEGIES"

When "Generate strategies" has been selected on the "Strategies" menu, the following window
appears on the screen:

Ir CHARACTERISTICS
THICKNESS

I( WIRE W P E
Cu. Coating: CuZnSO (520 N/rnm=. 1% elong.)

r CRITERION 1
!
, , , ,,,,,,,,,
FEEDRATE A
-
.
.
.-
.
-
.

I
? " -
1
-- - -s-,AA-- .. . .
r

PRECISION
2

.
r 3
1,
r 1 2
. - - -... A ,- , . .- " A A "
i

<
, -
ROUGHNESS - I,
!
f r 1 r 2
I -- -- -A- - , I

I
I OL I Cancel 1
I ,.Il-~~--A ,

- CHARACTERISTICS: Selection of workpiece material, workpiece thickness, and wire type

- CRITERION. Select your priotiries in the CRITERION area. For example, if you wish to make a
workpiece in the shortest time possible, the first criterion will be to select "1"' for VELOCITY, "2"
for PRECISION, and "3" for ROUGHNESS. If, on the other hand, you wish to produce a
workpiece exhibiting maximum precision and minimum ROUGHNESS, set PRECISION at "l",
ROUGHNESS at "2",and VELOCITY at "3".

When the data entered in the characteristics and criterion window have been confirmed, the
following window is displayed:

' \

PRECISION

I
r Z i~l~E,&?lJ

r GOOD
r VE8Y GOOD

ROUGHNESS

1 I
r VDI

r
> 27

27>VDI>24

r 23>VD1>20

Precision and roughness levels are selected in this window. It displays the various options in
accordance with the characteristics and criterion specified in the preceding window.

When this window has been confirmed, the analysis window is displayed.
 - DATA SELECTION
THICKNESS 20.000
Steel
MATERIAL (St)
CLEARANCE o.100
BercoCut special 0.30mm
1
'
WIRE TYPE
TAPER. ANG. MAX.
CuZn37. Uncoated. (900 Wmmn. 1% elong.)
i -TR ,- !+PI

r GEOMETRY
PRECISION I STANDARD
FEEOEATE 6.15 I N' REP I 1
ROUGHNESS 29
ROUNE. Mil\l. RAD. I 0.175

Generate I Cancel 11

The analysis window is divided into severai zones:

- [I] Here you see the data selected in the characteristics window. In the event that the technology
sefected does not include the thickness you have indicated, the CNC wilt choose the
thickness closest to it.

- 121 On the basis of the data that you selected in the earlier windows, the following data wijl be
displayed in this zone:

- TECHNOLOGY: technology card that will be used in generating the program.

- CRITERION: cutting mode to be employed (roughing, roughing + 1 rerun, roughing plus 2
reruns, roughing + 3 reruns).
Note: If you wish to modify the CRITERION, there is no problem in doing so on this screen,
with PRECISION, average VELOCITY, ROUGHNESS, and recommended MINIMUM
ROUNDING RADIUS being recalculated.
- PRECISION: Precision to be achieved with the technology and criterion selected.
- FEEDRATE: Estimated mean velocity with which the work will be done, taking into account
the roughing and reruns that will be carried out.
- ROUGHNESS: Final roughness of the workpiece to be produced.
- (ROUND MINI. RAD.) MINIMUM ROUNDING RADIUS: Minimum rounding radius
recommended. This is the rad~usrecommended to ensure that overcutting does not occur on
the inner edges of the workpiece.

- 131
- CLEARANCE Offsetting (mm) to be adjusted in the program.
- TAPERED CUTTING ANGLE: Indicate the maximum wire inclination on the profile to be eroded
(see 3.5)
- TRIM-CUT: Should the criterion entail one or more trim cuts, indicate whether the trim-cut is to
be carried out in the channel or on a free face of the workpiece.
Note: If you select the option FREE, following roughing, a programmed stop w ~ loccur
l so that
you can remove the piece left over.
141 GEOMETRY:
- FILE: Selection of the file that contains the workpiece profile.
- No. REP.: Number of repetititions that will be carried out from the card.
- FILE REP.: Selection of the offset file that will be used for the various repetitions of the figure to
be cut.

When data are complete, press the Generate button.

"" -
E~le Tables Edition Fynetlons Sfraiegy
-
.

p." ah.... "*"*-"WM" .....P. h=.-w-w=.m..~""~"aP~.-~.~"~"",

'* Cunng strategy

'" Steel Brass 0.30
"" Criterron Z Feedrate 3 Precision 1 Roughriess
'* Thbckness 70
" Clearance: D 1
I
" Taper angle m a 0
"'Prec~s~on STANDARD
** Roughness 29
" Feedrate 6.1 5
' " Round. Mln Rad. 0.175
X.I.lllrn"X3E ....I.... x"m"".*- .-..
~..llll""*.~*~**~"x"a..

"'Load technology Rla

LOAD TECH ONA sl33lt tec
" Clearence activat~un

CLEARANCE 0.1
'"Rough Feedrate 6 . 1 5 Roughness 29
TECH THICK 20 CRlT @
" Load Geomstry
l PROGRAM seomoZ

The program generated should be kept in a file, which in turn should be entered in the execution
environment as principal program (see 4.3.3.2).
4.3.4.1.2 GENERATE "USER'S STRATEGIES"

When you setect the option "Generate user's strategies" on the "Strategies" menu, the following
window is displayed:

- DATA SELECTION I
THICKNESS
I
MATERIAL Steel (St)
CLEARANCE
W l RE TYPE BercoCut speclal0.30 mm
TAPER. ANG. MAX. I
CuZndi. Uncoated. (900 N/mm=, 1 % elong.)
-

TECHNOLOGY USR:st2Slt.tec 4
CRITERION ROUG. v
- GEOMETRY I
PREC I SI OP4 r STANDARD FILE g !
)ge~maq
I
1
I
FEEDRATE
RCrUGHNESS
ROUND. MIN. RAD. 0.175
NQREP
FICH. REP 71
;

1
Generate I Cancel I]
--" - ." -.* ..
- " - -

USER'S STRATEGIES are carried out on the basis of a technology created by the user himself.

On this menu select THICKNESS, the User's TECHNOLOGY card to be used, and the
CRITERION according to which the cut is going to be carried out. The rest of the options that
appear are the same as those described in 4.3.4.1.1.
When you select the option "Generate", a new window is displayed showing the program
generated.
 .

I Eile Tables
-- Edition Fynctlmk Smgy
". . ,I ........
"".,m"." .................w.........u." ..........
" cumng strategy
" Stael r Brass 0.30
" Criterion 2 Feedrate 3 Precision 1 Roughnass
" mlckness 20

" Clearance: 0.7

I
" Taper angla m a x O
" Preclslon STANDARD

" Roughnass 29

'* Feedrate 6.1 5

' =.
"'
Round. Mln. Rad. 0.1 75

Load tscnnology rile

L O A D TECH USR:st25lt.t=
*' Ctearenca activation
CLEARANCE 0 1
'"Rough Feedrate 6.1 S Roughness 29
TECH THICK 20 CRlT 0
" Load Geometry
PROGRAM geom0Z
END
4.3.5. MISCELLANOUS
- - -.

""-----
I
~ c u (t ~ s c h Profile F!PR~ 1
CUT ]I-

. (i- Work
-1.874 8
. :. I I I
0 on0 I
r c .r Draw
I % r Machine
-
,a, 1

Figure 4-50

The pages that appear on this menu are principally those relating to configuration and
maintenance
 - Configuration:

, ".. . . . _ -- .... -..-" "".+""" " ----

: Elle Exsc;lflon Ereparaon EMDI ~lscelanous
' ,
Manual I Dec / Trav 1 mread rl'-] I
-
I

+ I

!
~~~wvortion ( Conngur~ion (
. . .,"-.., .. ., - - --
Ok
. 11- 0.010

--

F5 Manual 1 F5 Omrav / F7 Thread I F8 V e I c a l I 1--

14 34

Figure 4-57

- LANGUAGE' Selection of the language in which the CNC texts appear. When the language is
being changed, the CNC closes active environments and opens others in the new language.
Execution is not aborted.

- MEAS. ~ y s(Metric
. I Inches): lnd~catesthe metric system or inch system selected by the user
to REPRESENT the CNC coordinates. Reference is to the representat~ononly, not to the
programming, which will be selected via the metric or inch blocks (See section 4.5.5). The
CNC will close the active environments and will open others represented in the new
measurement system selected. Execution is not aborted.

- C. STATIC ERROR: This is an internal parameter, already configured when the unit leaves the
factory. 1t should not be altered.

- NEW VERSION: In !he event that it is necessary to load a new CNC version, you can update
the present version by pressing this button.

The rest of the parameters indicate the machine, filter, and control conftgurat~ons.They leave the
plant configured and should not be altered.
ADDING ANOf HER LANGUAGE f 0 THE CNC

You can quite simply and quickly extend the list of those Janguages in which CNC texts are displayed.
Procedure is as follows:

- From the list, select the language from which you wish to translate into the new language.

LANGUAGE
MEAS. SYSTEM
C. STATIC ERROR

-
2
- SLUD. REM, CNTR,

- Press the icon ( ~f)1. The following window will appear on the screen:

1
Save the current language into a dirlefle or copy the languages fmm the disketle?

Save language J copy languages I F-Cin] ..+.....

........-...............*............T..
,...................................................
I
II
- Select the option "Save language". The current language file will be copied onb the diskette. You
can now edit this file with a text editor (which may be the actual CNC editor), replacing each word
on display w ~ t hthe corresponding word in the new language. To stay within the field, be careful not
to exceed the maximum number of characters allowed per word.

The file you have edited should be given a new name. To do so, change the three letters making
up the name of the file. These are the same as the first three letters of the first line of the text file.
For example, if the file from which you have translated is in English (in which case its name is
"text-eng.txtU),the three first letters of the first line of the file are "eng" (for "English"). If you have
translated into Polish, the first three letters of the first line of the file will have to be replaced by the
abbreviated form of the name of the new language, i.e. "pol". Thus the new file name will be "text-
pd.txtM.
- In order to load into the CNC the new translated file, the diskette with the file must be introduced
into the disk unit of the CNC, later press the
the screen.
1 1
icon C, and the following window will appear on

I
1
i
A Save t h current
~ language into a aisketle or copy the languages from Me diskette?

You must select the option "Copy languages" and the new language will appear in the list of
languages of the CNC.
- Maintenance:

- OPERATIONS -- FILTER - COMSUMABUS

-
r DIELEC. PW. SELF CLEANNING TIMING
P W TENS S.CLEAN T. CNTR, SPOOL TYPE
r WIRE P'N. S. CLEAN PaCNTR. REST. LENGTH
r AIR S. CLEAN. MAX. LIM r-= P.WHEEL LlFE
r THREADING JET SLUD. REM, CNTR. P RESINS LIFE
r WlRE CUT F FILTER PW. GUIDES LlFE
r LOWER JET
r WlRE DRAGGIN1
F DE-IONIZ. PW. 1 CURRENT P.LIFE 1203.31
I
r ROLLERS ?-
MANUAL FLOCU. I MAX. RECOV. TRIALS 10
r M. AGITAOOR THREAD DIEL.
RAMPA 1
7
100 TMP. AGITAD. 1 300

! - --
1
I 0.000 ACTUAL FEEDRATE
/
I
I /
P.UTOMATIC OP.

z 0.000
% PROTECTlOhi Reset 17
F 5 Enerut I FB Tech / F7 Proflls. I F8 Taper
1
Figure 4-52

OPERATIONS: In this area you can switich various of the machine elements on or off. While a
program is being executed, this area remains deactivated.

CONSUMABLES: In this area data are supplied regarding wire, consumables, guides, contacts,
resins, and blades.

Basically these are hourly timers that on reaching zero produce an ALARM to advise teh user
that preventive maintenance should be carried out.

FILTER: apart

- WlRE SPOOL TYPE. The length of wire on a coil will correspond to spool type selected:

- REST. LENGTH. Length in meters of wire remaining on the spool. When there is no longer
any remarnlng, the alarm FALTA DE HlLQ occurs.

- POLYURETHANE WHEELS LIFE. Time in hours remaining until maintenance work should
be carried out on the polyurethane wire-pulling wheels.

SELF CLEANNING TIMING. If you enter " 0 , backwashing will be automatic. If you enter
"30",for example, it will occur every thirty minutes.
 - S.CLEAN T. CNTR. Overall number of bachwashes carried out.
- S. CLEAN P. CNTR. The partial number of backwashes since sludge was last removed.

- S. CLEAN MAX. LIM. This is a specification of the maximum number of bachwash

operations for sludge extraction. If the Partial Backwash Counter exceeds this figure, an
alarm occurs to indicate that sludge should be removed.

- SLUD. REM. CNTR. The number of occasions on which sludge has been'removed from the
filter.

- -
RESINS LIFE TIME REMAINlNG UNTIL CHANGE OF IONIZATION RESINS. Given in
hours. At zero an alarm occurs to indicate that resins should be changed. Change them and
reset the counter.

- GUIDES LIFE. Hours remaining until guides should be maintained.

- CURRENT P. LIFE. Hours remaining until wire connection points should be maintained

- NUM. OF CUTS (ONA UElRE models only): Number of cuts remaining until threader blades
should be replaced (in the case of machines with an automatic threader).

In each of these cases an AWRM occurs at zero to advise that preventive maintenance is
due.

MAX. RECOV. TRIALS: By MAX. RECOR. TRIALS is meant the cycle following wire breakage
during a program's execution, until the machine begins to cut again. This indicates the maximum
number of wire breaks allowed with a given workpiece before the CNC activates an alarm. The
default number is 10.

THREAD. DIEL.: Water pressure of the threading water jet

4.4. CUT TYPES

4.4.1 INTRODUCTION

With the most complex type of cut (XYUV), you can program interpolations in two planes parallel
to those containing the wire guides: the PRINCIPAL PLANE (X-Y) and the AUXILIARY PLANE (U-
V).
The X-Y coordinates indicated in the interpolations relate to the principal plane, the U-V
coordinates to the auxiliary plane.

Upper guide plane

U-V or auxiliary plane

+---- A
-N
-/- X-Y or principal plane

7 Figure 4-53
Lower guide plane
4.4.2 VERTICAL CUT

In the case of VERTICAL cutting the U and V axes do not move. If the program executed contains
interpolation on four axes, only the X-Y part of those interpolations is taken into account. Hence
only instructions relative to the X and Y axes should be programmed.

If TAPER LEFTnAPER RIGHT functions are programmed. and you have selected vertical cutting
mode, the resulting workpiece will have no conicity. Similarly, the parameters for the heights of the
planes involved in TAPERED or XYUV cutting have no effect on VERTICAL cutting.

Figure 4-54
4.4.3 TAPERED CUTTING

In the case of TAPERED cutting the wire is inclined from the vertical so that conicity will be
imparted to the workpiece. It is necessary first of all to specify the thickness of the workpiece and
the height with respect to the principal plane of aprogrammedplane (see Figure 4-55), where the
wire originally inclines on the programmed path, while at the same time the TAPERED option is

',A
selected on the cutting menu.

/ mrnrned
TAPER LEFT plane

Programmed path
Compensated path

Figure 4-55 Figure 4-56

If you wish you can program tapered cutting and compensations simultaneously. In this case the
wire inclines on the compensated path at the height of the programmed plane (Fig. 4-56).

In the case of TAPERED cutting, the U and V axes are not directly programmed. Via the functions
TAPER OFF, TAPER LEFT, and TAPER RIGHT, the tapered cut is canceled or activated (on the
left or on the right). TAPER <n> sets the angle of inclination in each linear or circular interpolation.
An angle is considered positive when it produces an inclination in the direction programmed
(TAPER LEFT or TAPER RIGHT). Thus for example, a negative angle in a right tapered cut results
in an inclination to the left (Fig. 4-55).

Regarding the selection of these functions, see section 4 5.9.

NOTE:
- Tapered cutting is not possible in EMDI.
_ Wire inclination becomes effective in the first interpolation block according to the instruction
TAPER LEFT or TAPER RIGHT.
 With TAPERED cutting the following parameters have to be specified:

EXBCU~ I ~ e c hI Profile Fiq 1

I

DRAWING P.
I

Draw I

F5 Exscut 1 F6 Tech I i?~ r o f i l e a 1 b l ! 1

F8 ~ a p e r
Figure 4-57

- THICKNESS: Workpiece thickness

- CENTER OF INCLINATION OF THE WIRE. Place inside the guide in which the wire inclines or
fits. It is the narrowest part of the guide, its " throat ".

- PROGRAM P,: Principal Plane. Distance from the center of inclination of the lower guide to the
lower surface of the piece

- Z ZERO: Distance from the lower surface of the piece to the Z axis origin.

- MAIN PL.: Programmed plane, i.e. distance of the workpiece LIFE from the reference plane

These parameters cannot be altered while a program is being executed.

4.4.3.1 CALCULATION OF THE DISTANCES PP, 02.

Thicknes

- Reference plane (table)

lower guide
Figure 4-58

- PP: (principal plane): distance from the center of inclination of the lower guide up to the reference
plane or lower surface of the workpiece (if the workpiece is not lifted, it coincides with the rest
surface of the working table).
- 02:Z zero, distance from the plane of reference to the Z axis origin.
NOTE: They are important in that they facilitate verticality, threading, and machining cycles with
tapered workpieces.

IMPORTANT NOTE: If, in the upper or lower machine head, a change, adjustment, or repair is
made to a part involved in wire guidance, the following are recommended:
- Measure the principal and OZ planes.
- Adjust verticality.
Measurement of distances

Distances read on the control will be taken in absolute value. Previously to the measurement, the
pieces indicated in the figure 4-58a must be removed from the lower und upper heads.

Measure the P P distance with gages

lo) or with a depth micrometer. The distance " B " from
the center of inclination of the lower guide up to its surface of measurement must be taken
into consideration (see figure 4-58a).
2') Send the Z axis to the origin.
3') Lower the Z axis until the distance between guides conforms to a gage (of length e.g. 30
mm).
4O) Note the machine Z coordinate.
5O) OZ= machine Z (positive) + gage (30mm) + A + B - PP
6
'
) Enter the calculated PP and OZ in the control.

'remove these pieces

remove these pieces

Surface of measurement

"B" distance:
0.10. 0.45 mm 0 guides: 2.45 rnrn
0.20, 0.25, 0.30 rnm 0 guldes: 2.45 rnm

Distances centers of inclination-surfaces of measurement of the guides

figure 4-58a
DISTANCES CENTERS OF INCLINATION-SURFACES OF MEASUREMENT OF THE GUIDES

UNLF. UPPER GUIDE Oo-30°K O.lmm 0.75 mm

UNIF. LOWER GUIDE O0-30°K O.10mm 2.45 mm
UNIF. UPPER GUIDE 0"-3U°K 0.75mm 0 75 mm
UNIF. LOWER GUIDE 0"-30°K0.15mm 2.45 mm
UNIF. UPPER GUIDE 0'-30°K 0.20mm 0.95mm
UNIF. LOWER GUIDE 0'-30°K 0.20mm 2.45 mm
UNIF. UPPER GUiDE 0'-30°K 0.25rnm 0.95m m
UNIF. LOWER GUlDE 0"-30°K 0.25mm 2.45 mm
UNIF. UPPER GUIDE OD-30°K 0.30mm 0 95 rnm
UNIF. LOWER GUIDE 0°-30°K 0.30mm 2.45 mm

4.4.3.2 CUTTING ANGLES GREATER THAN 1 2 O WITH THE ONA SERIES "KEN MODELS

Unified guides can be used with angles up to 30°,but from l Z O onward it is necessary to change the
cutting nozzles and the threading noule.

Description of elements Code

Threading nozzle 1,5 mm E57000117
Fixed cutting nozzle
Moving cutting nozzle CJ 0.4 mm
Retractile nozzle spring

NOTA: With the Moving cutting nozzle0 0.7 mm €83000083 the greater cutting angle
is t 2" instead of 8 O .

FROM 12' TO 30"

Descripfion of elements Code

Threading nozzle 2,8 mm E5700017 8
Upper and lower cutting nozzle (big cone) €83000070

IMPORTANT: If cutting angle is greater than 7 O , it is advisable to use soft wires with
high elongation coefficient (between 20 and 30%).
CUTTING ANGLES UP TO 12°WlTH THE ONA SERIES "KE" MODELS - NECESSARY PIECES

UPPER HEAD:
CUTTING ANGLE
UP TO 120

€83000007 FIXED CUlTlNG N O U L

€57000097 RETRACTILE NOZZLE SPRING 00033 UPPER GUIDE UNIF. OL3O0K 0 10 mm
69200035 UPPER GUlDE UNIF. OD-3PK0 15 mm
E57000117 THRE4DING NOZZL 69200037 UPPER GUIDE UhllF. OD-30% 0.20 mm
0 t .5 MM. 69200039 UPPER GUIDE UNlF. DK3O0K 0.25 mm
69200041 UPPER GUlDE UNIF. 0°-30°K 0.30 mm
€830000084 0 4 MOVING CUlTING NOUL
8' MAXIMUM WlTH 04
1 2 O MAXIMUM WlTH D7
D4 IS F 4 mm (NOULE E830000M)
07 IS k37 mm (NOULE E83000083)
figure 4-586

1.2' MAXIMUM CUlTING ANGLE WlTH

/A DISTANCE OF 7.5 rnm OR
SMALLER. THE GREATER IS THE
DISTANCE THE SMALLER IS THE
CUTTfNG ANGLE.
E830000084 04 MOVlNG CUTTINGNOZZLE
MEAN POSITION FOR ADAPTING
€57000097 RETRACTILE NOZZLE SPRlN IT
FIXED NOZZLEH
TO THE E
WORKPIECE. (IT IS THAT WHICH
E8300007 FIXED CUTTING N O Z L LIMITS THE ANGLE.).

LOWER HEAD:
CUTTING ANGLE
UP TO t 2 O

NOTE IF INSTEAD OF THE NOZZLES

E8300084 ( 0 4 MOVING CU?TlNG
NOZZLE) ARE USED THE €83000083
( 0 7 MOVING CUTTING NOULE) THE
MAXIMUM CUlTING ANGLE IS 12'
INSTEAD OF ' 8
\
E69200034 UNIF. LOWER GUlDE O0-30°K 0 10 rnm
E69200036 UNIF. LOWER GUlDE P+30eK 0.15 rnm
E692110a38 UNIF. LOWER GUIDE 0°-30°K 0.20 mrn
€64200040 UNIF. LOWER GUIDE 0°-30°K 0 2 5 mm
€69200042 UNIF LOWER GUIDE O0-30°K 0 30 m m

figure 4-58c
 CUTTING ANGLES GREATER THAN IZOWITHTHE ONA SERIES "KE" MODELS -
NECESSARY PIECES

UPPER HEAD:

E69200033 UPPER GUIDE UNIF. O%3ObK

E57000118 THREADING NOZZLE
0 2,8 MM.
E83000070 CUTTING NOZZLE 30'
€69200035 UPPER GUIDE UNIF. 0'-3O0K
E69200037 UPPER GUIDE UNIF. 0'-30°K
E69200039 UPPER GUIDE UNIF. 0'-30°K
E69200041 UPPER GUIDE UNIF. 0'-30°K
,MAXIMUM CUTTING ANGLE

figure 4-58d

E83WOQ70 CUTTING NOZZLE 3OV

\ p30m/

.R HEAD:

NOTE:
THE SAME GUIDES ARE USED FROM OD
I \
TO 30Q, BUT FROM 12" ONWAR THE E69200034 UNIF. LOWER GUIDE OD-30°K 0.10 m m
CUTTING NOZZLES AND THE THREADING E69200036 UFIIF. LOWER GUIDE 0"-30% 0.15 m m
NOZZLE (UPPER HEAD) MUST BE E69200038 UMF. LOWER GUlOE 0'-30°K 0.20 mm
CHANGED BY THE ONES SHOWN IN THIS E69200040 LINIF. LOWER GUIDE On-30°K 0 25 mm
DRAWING. E69200042 UMIF. LOWER GUIDE 0"-30°K 30 mm

figure 4-58e
4.4.3.2 CANCELLATION OF TAPERED CUTTING

The wire returns to the vertical position (tapered cut canceled) in the following cases:

- Directly in response to a TAPER OFF.

- In response to the following instructions:
end of progam (END)
* traverse (TRAV)
workpiece contact (EDGE)
* midpoint (MIDDLE)
inner centering (INNER CENTER)
" because four blocks have been encountered followed by nun-interpolation. In this case
the tapered cutting is only temporarily canceled, i.e. until the next interpolation
instruction.

NOTE:
The block in which return is made to the vertical position is that preceding TAPER OFF

- The first and last interpolation blocks of a tapered cutting program have to be linear (Fig. 4-
59).

- If various cutting angles are programmed, a change of sign in every case is the same as
changing the cutting type (right or left).

- If the cutting angles are negative in two sections, everything proceeds just as though they
were positive and the cutting type were changed.

Initial or final block

(tangential entry)

Figure 4-59
4.4.4 XYUV CUT

In XYUV cutting mode you can program interpolations in two planes parallel to those containing the
guides: the principal plane (or XY plane) and the auxiliary plane (or UV plane). The X-Y
coordinates indicated in the interpolations refer to the principal plane and the U-V coordinates to
the auxiliary plane.

/ U-V auxilialy plans

il-V auxiliarv. plane

. II I I /
I I
X-Y principal plane I I X-Y principal plane

ga

Figure 4-62 Figure 4-63

The programmed U-V coordinates of the final point of the movement in each interpolation are
incremental w ~ t hrespect to the X-Y coordinates of the final point of the movement in that plane.
The centers of the U-V circles are relative to the centers of the circles in X-Y. Thus in Fig. 4-63
point (d) is programmed relative to point (a), point (e) relative to point (b), and the center (f) relative
to the center ( c ) .

NOTE: The center of a circular interpolation in the auxiliary plane (U-V) is incremental with respect
to the center of interpolation in the principal plane (X-Y). The center of a circular interpolation in the
principal plane is incremental with respect to the initial point of the interpolation.
4.5 PROGRAMMING

The present aim is to provide the operator with a guide to the programmable functions. Some of
them are less often used than others, but necessary for certain machining jobs. In this manual it is
sought to deal with all programming problems likely to arise. If a problem arises that is not dealt
with here, the advisable course is to call to our Technical Assistance Service.

One can program the CNC by directly writing instructions in the editor, or via the menus, some of
which display windows that ask for the necessary data in order to complete a given instruction.
When they are entered directly, instructions may from time to time be erroneous, for which reason
it is recommended that every program be checked before it is executed.

The programming language works through ONA mnemonics. The names of the instructions are
based on the description of the operation to be performd (e.g. linear interpolation is INTL, the
specification of offset is OFFSET). This language also recognizes IS0 standard instructions,
although programming through menus does not write them. At the end of the present section the
IS0 instructions allowed are defined.

Programming instructions are dealt with in the order of the menus, since the functions are grouped
logically within them. Before proceeding through the menus, the instructions are described for
loading files into the machine.

Some of the instructions are accompanied by example programs, which serve to make the order
clear. At the end of the section there are further examples, illustrating many of the functions.

If you wish to program several motions in succession or equal interpolations, you can indicate the
type of motion in the first block and in subsequent blocks indicate only the axes. For example, the
two lines follawing perform two linear interpolations:
INTL X I 0
YIO

The explanation for each instructron is preceded by its syntax, in which the following convention is
adhered to:
<n>: Replaces with a number.
worn,: Replaces with a name (normally the name of a file or label)
<ON/OFF>: Replaces with ON or OFF. Can also be a 1 or a 0.

Examples:
OFFSETcn> -> OFFSET 5
LOAD OFFSET worn> -> LOAD OFFSET decal.ofs
INVERS <ONIOFF> -> INVERS ON
Editing Functions

As mentioned above, the functions are grouped in a logical manner in the menus. We now look at
how the menus and submenus are structured.

Basics
Linear interpolation
Circular interpolation
Traverse
Setting coordinates
Coordinate programming system (Absolute / Incremental IMetric I Inches)
Setting offset
Compensations (on the left Ion the right / Cancel I Setting)
Taper cutting (on the left / on the right / Cancel ISetting)
Programmed stop

Technology
Selection mode
Generator parameters
Start generator settings

a Transformation of coordinates
Rotat~onorigin
Scale
Rotation
Axis reverse (X I Y I XY)
Axis reverse annulation (X / Y I XY)
Axes XYZ
Axes Y X Z

Corner geometry
Start rounding off
Annul rounding off
Activatechamfer
Annul chamfer

Program
Write in the log (Status ITime)
Execute external program
Loop start
Endofbop
Program lump
Counters
Use of optional blocks
Subroutine return
Label
Program start
End of program
Insert comment
Preparation
Wire (Adjust verticality I Wire cut IAutomatic threading)
Inner centering (X / Y I U / V)
Workpiece midpoint (X IY I U I V)
Workpiece contact (X+ IY+ I U+ I V* I X- I Y- / U- I V-)
Return to origin
Maintain current position

Sundry
Settings
Exits
Dwells
Vector
4.5.A LOADING FILES

Syntax: LOAD TECH morn>

LOAD TRAV worn>
LOAD OFFSET enom>
LOAD COMP <nom>

These instructions load respectively into the control a technology file, a traverse points file, an
offset file, O F a wire radius compensation file.

If the file for loading is on a diskette, the format of the name is A:<norn>. If it is in the machine's
memory, it has nothing in front of the name. If it is a nonmodifiable file, its format is ONA:cnom>.
4.5.2 LlNEARlClRCULAR INTERPOLATION

Syntax: INTL X ~ n Y<n>

r U<n> V<n> FEED<n> COMP<n> TAPER<n> ROUND<n> CHAF<n>
INTC- Xcn> Y<n> CX<n> CYcn> U<n> Vcn> CU<n> CV<n> FEED<n>COMP<n>
TAPERcn> ROUND<n> CHAF<n>
I N T O X<n> Y<n> CXcn> CY<n>U<n> Vcn> CUcn> CV<n> FEED<n> COMP<n>
TAPER<n> ROUND<n> CHAFcnr

Performs a linear (INTL), clockwise circular (INTC-), or anticlockwise circular (INTC+) interpolation
up to the point whose coordinate is specified.

The interpolation performs a synchronized movement of the programmed axes between the initial
point and the final point, following a linear or circular path.

When specifying the final point of the interpolation (linear or circular), one should bear in mind that
its U and V coordinates are relative to the position defined by the coordinates X and Y of the point.

When specifying the center of the circular interpolatjon, the operator should remember that its U
and V coordinates are relative to the position defined by its X and Y coordinates, which in turn are
relative to the initial point XY of the interpolation.

The coordinates of the U and V axes, as well as the values of the centers U and V, are zero if they
are not programmed in the instruction (verticality).

In the case both of linear and of circular interpolations, speed, wire compensation, wire inclination
rn degrees, rounding-off radius, and chamfer length may be specified.

In the following examples there are two figures created. In the first, all interpolations are vertical,
while in the second interpolations are made on the XYUV axes (wire inclined). Note the difference
between the clockwise and anticlockwise circular interpolations. Note also how the UV coordinates
are relative to the verticality position of the wire.

TRAV Y40
INTL Y20
I N T O X5 Y 15 CX5 CYO
INTL X15 Y15
INTC- X20 Y20 CX5 CYO
INTL X20 Y40
INTL XO Y40

TRAV X-5 YO
INTL XO
INTL Y-10
INTL U5
INTC- X I 0 CX5 UO CU2.5
INTC+ Y10 CY10 V-10 CV-5
INTC- XO CX-5 VO CU5
INTL YO
INTL X-5
END
4.5.3 TRAVERSE

Syntax: TRAV X c n Y<n>

~ U<n> V<n> Z<n>
TRAV P<n>

Performs a quick displacement between the initial and final points without synchronism in the
movements of the programmed axes. The final point of the traverse can be indicated by its
coordinates or by its index in the traverse points file being used (see 4.3.2.2.2).The user can
change the traverse points file and load another one by means of the instruction LOAD
TRAV enom>.

The coordinates of the U and V axes are zero if they are not programmed in the instruction
(verticality).
4.5.4 SETTlNG OF COORDINATES

Y<n> Ucnz V<n> Z<n> THICK<n>PRGP<n>

Syntax: COOR X ~ n z

Establishes a new work coordinates origin, for which purpose the position XYUVZ of the
current point is indicated. In addition, it is possible to program the workpiece thickness and
the life plan (4.4.3).

I I

Setting the coordinates X-5 Y-5

This function is used in the examples at the end. Note especially examples 3 , 4, 6, and 12
(section 4.5.18).
4.5.5 COORDINATE SYSTEM (ABSOLUTE I INCREMENTAL I METRIC I
INCHES)

Syntax: ABS
INCR
METR
INCH

ABS and INCR establish the coordinate system: absolute (ABS) or incremental (INCR). The
setting will depend on whether the coordinates refer to the work zero or to the previous point,
respectively.

Note that absolutelincrementat selection is modal: the selection currently in effect remains
until another absolutelincremental instruction is programmed. The default value when the
CNC is initiated is absolute.

The units on the coordinates may be metric (METR) or inches (INCH)

Once the units have been selected, the CNC interprets program magnitudes accordingly.
However, display of magnitudes is metric or in inches depending on the selection made in
the Measuring System, in the configuration window. If a program does not have any
METRIINCH instruction, the coordinate system adopted is that indicated in the configuration
window
4.5.6 OFFSET

Syntax: OFFSET cn>

OFFSET <n> changes the origin of the work coordinates to that of the coordinates saved
before in an offset, referring to the machine's absolute zero. It does this by taking the
machine coordinates of the input number in the current offset file (4.3.2.2.1). You can replace
the offset file by means of the instruction LOAD OFFSET <nom>.

Offset 1 (X-20, Y- 10, UO, VO)

Offset 2 (X-30, Y-30, UO,VO)

See use of offsets ~nExample 5.

4.5.7 COMPENSATION ON THE LEFT I ON THE RIGHT I CANCEL

Syntax: COMP LEFT

COMP RIGHT
COMP OFF

These instructions are for programming compensation on the left (COMP LEFT), for
programming it on the right (COMP RIGHT), or for cancelling it (COMP OFF).

When compensation is programmed, the wire center follows a path separate from that of the
path programmed, with a distance equal to the wire radius compensation plus the gap
(between wire and workpiece). In this way the workpiece is directly given its final contour.

In the absence of an instruction to the contrary, a program will start with the offset cancelled
and wire radius offset 0 .

Compensation becomes effective with the first interpolation block following the setting of
compensation on the left (COMP LEFT) or on the right (COMP RIGHT).

One canels OFFSET:

directly by programming COMP OFF.
with one of the following instructions:
setting coordinates (COOR) and offset (OFFSET).
end of program (END).
traverse ( T R A Y .
workpiece contact (EDGE).
workpiece midpoint (MIDDLE).
inner centering (INNER CENTER).
because there are four blocks not followed by interpolation. In this case offset is
cancelled only temporarily, i.e. until the next time interpolation is instructed.

The block In which offset is cancelled is that preceding COMP OFF (direct or forced).

It should be borne in mind that if the first or last interpolation block is circular, while
compensation is active, the result is a compensation error and execution is cancelled.

If in a given program there are several offset radii programmed, then changing the sign in all
cases is the same as changing the type of offset (right to left or viceversa).

For any ~ntersection,the convention is this: if the radii of both sections are negative,
everything proceeds as if they were positive and the type of offset were changed.

In addition, the operator can change the amount of compensation by incorporating into the
interpolation the wire compensation desired (parameter COMP <n> in the interpoiation
instruction). Compensation takes effect on the completion of that same order. (During
interpo!ation it shifts over gradually from one compensation value to the other.)

See example in the following section

 'Y3019 JseI aqt
6uole JasMo 40 pua :Iuaurala leu13
'anlen lasuo pue u6!s 6u!6uleq3
4.5.8 SETTING THE COMPENSATION NUMBER

Syntax: COMP <n=

COMP crp> activates the wire radius compensation that is under the corresponding number
in the wire compensation file loaded, applying it to the correction of the profile programmed
(4.3.3.3). The operator can use the LOAD COMP cnom> instruction to change the
compensation file.

It should be remembered that mode programming (TECH function, 4.5.12) also changes the
compensation value. If it is desired to use a compensation file value, the instruction COMP
cn> should go behind the mode setting.

If it is desired to specify a (user's)compensation value and load a particular technology, the

procedure is first to load the technology file and the compensation file. The call is then made
to the technology file, and subsequently to the compensation file.

The following example illustrates how compensation is used. While the program is being
executed, the compensation selected changes, so that the path moves away more or less
from the geometry programmed (the outer square). The compensation values for this
example are

- compensation 1 = 0.2
- compensation 2 = 0.4
- compensation 3 = 1.O

ABS
COOR X I 0 Y5
COMP RIGHT
COMP 1
INTL X I 0 YO
XO YO
xo Y20
COMP 2
X20 Y20
COMP3
X20 YO
X10 YO
X I 0 Y5
COMP OFF
END
In the fdlowing example the use of the compensation is seen along with the
instruction clearence. The program is equal to the one of the previous example, with
the difference that includes the instruction "clearence 1". (see paragraphe 4.5.17.1).
The trajectory that is executed is the indicated by means of arrows.

ABS
COOR XI0 Y5
COMP RIGHT
CLEARANCE 1
COMP 1
INTL X I 0 YO
XO YO
xo Y20
COMP 2
X20 Y20
COMP3
X20 YO
X I 0 YO
X I 0 Y5
COMP OFF
END
4.5.9 TAPER CUT ON THE LEFT I ON THE RIGHT I CANCEL

Syntax: COMP en>

TAPER RIGHT
TAPER OFF

The operator can use this instruction to define taper cutting: taper to the left (TAPER LEFT), to the
right (TAPER RIGHT), or cancelled (TAPER OFF). The procedure is to set the angle of inclination
by means of the instruction TAPER en> or specify it at the end of the interpolation instruction.

Wire inclination becomes effective with the first interpolation block after taper cutting on the left or
on the right has been set.

Taper cutting is cancelled:

directly with TAPER OFF. The block in which it returns to the vertical position is that preceding
TAPER OFF
with one of the following instructions:
end of program (END).
traverse (TRAV).
workpiece contact (EDGE).
center piece (MIDDLE).
Inner centering (INNERCENTER).
because there are four blocks not followed by interpolation. In this case taper cutting is
cancelled only temporarily, i.e. until the next time interpolation is instructed.

The first and ftnal interpolation blocks of a taper cutting program have to be linear

If a program has one or more cutting angles programmed, changing the sign of each is the same
as changing from cutting on the right to cutting on the left, or viceversa.

For any intersection, the agreement is followed according to which if the cutting angles of both
sections are negative then everything happens as if they were positive and the cutting type were
changed

Taper cutting is illustrated in Examples 11 and 12 (4.5.18).

For a further explanation see 4.3.3.5 and 4.4.3.

4.5.10 TAPER CUfTlNG WlTH CONSTANT RADIUS, WITH CONSTANT ANGLE, AND
WlTH SHARP ANGLE

Syntax: CONST RAD

CONST ANGLE
SHARP ANGLE

These define the behavior of the taper cut in the insertions: constant radius (CONST RAD),
constant angle (CONST ANGLE), or sharp angle (SHARP ANGLE). The constant-radius and
constant-angle modes are known also as isoradius and isocone. The SHARP ANGLE taper cutting
mode is the default mode.

Constant-radius taper cutting is defined in linear-linear intersections with the rounding-off radius
programmed in tangential linear-circular-linear intersections. For further information regarding taper
cutting, see 4.4.3.

ISOCONE SHARP ANGLE ISORADlUS

See Example 12 (4.5.18)

4.5.1 1 SETTING THE TAPER CUTTING ANGLE

Syntax: TAPER cn>

TAPER <n> sets the taper cutting angle in degrees. This angle is not taken into account until taper
cutting is activated and an interpolation is carried out. If taper cutting has already been defined, this
instruction overrides the earlier setting.

Taper cutting is illustrated in Examples 11 and 12 (4.5.18).

4.5.1 2.1 MODE PROGRAMMING (WORKPIECEMIIRE TORQUE)

Syntax: TECH THICK <n> CRlT en>

TECH <n> en>
Both syntaxes are correct.

This instruction programs the generator (all parameters) according to thickness and other criteria
indicated, taken from the technology file. The user can replace the technology file by means of the
instruction LOAD TECH < n o w .

The thickness referred to here is that of the workpiece, and the criterion indicates which run is
going to be made (roughing, first finish in one roughing and two finishes, etc.)

Examples 2 and 3 (4.5.18) illustrate the use of this function in the case of one roughing and one or
more finishes.

4.5.1 2.2 INDIVIDUAL GENERATOR PARAMETERS

Syntax: POWER <n>

TOFF <n>
VOLT cnr
SERVO en>
WlRE TEN cn>
WlRE FEED en>
INVERS cONIOFF>
FINISH cONIOFF>
CORNER CORR cn>
DIELECTRIC <n>
FEED <n>

These program the individual generator parameters:

Power (POWER) Inversion (INVERS)

Off-time(J0FF) Finishing (FINISH)

- Voltage (VOLT)
Servo (SERVO)
Wiretension(W1RETEhr)
Corner corrections (CORNER CORR)
Dielectric (DIELECTRIC)
Feed rate (FEED)
Wire feed rate (WIRE FEED)

For more information regarding a parameter, see section 2 of the technology manual

These functions should be used only exceptionally. Normally it will be more advisable to use the
function TECH, which changes all parameters simultaneously

The TECH instruction allows the user to program all parameters at the one time By means of
LOAD TECH <nom> h e can load a different technology file.
4.5.12.3 START GENERATOR SETTINGS

Syntax: INICUT

lNlCUT eliminates the risk of a wire cut when a cut is executed outside a workpiece. The CNC
controls the generator settings until the wire is inside the workpiece and the risk of wire-cutting has
disappeared. It is at this point that the generator settings programmed by the user come into play,

This instruction should be given after the technology has been established, since lNlCUT uses
parameters belonging to that technology.

This function is used in Examples 2 , 3, and 11 (4.5.18).

4.5.13 TRANSFORMATION OF COORDINATES

4.5.1 3.4 ROTATION ORIGIN

Syntax: ROT ORIGIN X<n> Yen> U<n> Vcn>

This function is used in transformations of rotation, symmetry, and scaling types, in which a new
coordinate system is defined with respect to which these transformations will be carried out.

ROT ORIGIN assigns the program coordinate origin, specified with respect to the work coordinates
origin. To have the program and work reference systems coincide, the operator need only perform
a ROT ORIGIN XO YO.

This function is used in the examples in the following sections. In Example 11 (4.5.18) it is used
along with the rotation function.

4.5.1 3.2 SCALE

Syntax: SCALE cn>

SCALE <r> performs a coordinate scaling (starting on the line where it is specified) with a certain
scale factor. The scale simultaneously affects movements on the X and Y axes, i.e. there is only
one scale factor for the two axes.

By default, the scale factor is K = l . Lower values will reduce the figure, white larger values will
magnify it

The scale becomes effective from the block where it is specified.

If the user w~shesto carry out the scaling from a point other than the programmed coordinate
origrn, he should use the ROT ORIGIN function to set the scale center.

Note that when there are several transformations programmed simultaneously, they are executed
In the order scaling, rotation, axis inversion, and axis change.

Scaling is illustrated in the fallowing examples. In each case there are two figures. The first (with
the number 1) is the original scating, while the second is the same but with the USE1 function
elimrnated (4.5.18.8), i.e. without scaling. Note how the change of rotation origin (ROT ORIGIN)
affects scal~ng.
USE1
/SCALE 3
INTL X10
Y10
X20
YO
xo
END

USE1
INTL X I 0
/ROT ORIGIN X I 0 YO
/SCALE 3
INTL Y10
X20
YO
X10
/SCALE 1
XO
END

USE1
COOR X I 5 Y5
/ROT ORIGIN X I 5 Y5
/SCALE 1.SO
INTL YO
X 10
Y10
X20
Y0
XI5
Y5
END
4.5.13.3 ROTATION

Syntax: ROTATE <n>

ROTATE cn> is a rotation of coordinates, in degrees,to the angle specified,

Rotation becomes effective from the block specified. The rotation center is the programmed
coordinates origin.

If the operator wants the centre of rotation to be at some point other than the program's default
origin (X=O, Y=O), he can use the function ROT ORIGIN to establish the new center.

Negative angles result in clockwise rotation. Positive angles result in anticlockwise rotation.

If the functions ANGLE (4.5.17.1) and ROTATE are used together, the angle of rotation is that
specified in the function ROTATE plus the angle increment specified. See Examples 7 and 8
(4.5.18).

Note that when there are several transformations programmed simultaneously, they are executed
in the order scaling, rotation, axis inversion, and axis change.

Scaling is illustrated in the following examples. In each case there are two figures. The first (with
the number 1) is the original scaling, while the second is the same but with the USE/ function
eliminated (4.5.18.8), i.e. without scaling. Note how the change of rotation origin (ROT ORIGIN)
affects scaling.

USE1
IROTATE 45
lNTL X10
X20
Y4
XI4
Y8
XI0
YO
XO
END
USEl
INTL X I 0
/ROT ORIGIN X I 0 YO
/ROTATE 45
INTL X20
Y4
X 14
Y8
X I0
Y0
END

USEl
COOR X15 Y2
/ROT ORIGIN X I 5 Y2
/ROTATE 45
INTL YO
X10
Y8
XI4
Y4
X20
YO
XI5
Y2
END

4.5.1 3.4 AXIS REVERSE (MIRROR FUNCTION)

Syntax: MIRROR ON X
MIRROR ON Y
MIRROR ON XY
MIRROR OFF X
MIRROR OFF Y
MIRROR OFF XY

MIRROR ON ~nvertsthe axis selected, or both axes if XY has been indicated. When this function is
employed, distances on the axis or axes are measured in the other direction (x' = -x, y' = -y).
MIRROR OFF cancels the invers~on.

The mirror image is always applied with respect to the programmed coordinates origin. The
operator can change this by using the ROT ORIGIN function. This way the mirror image is applied
with respect to the new point defined.

Note that when there are several transformations programmed simultaneously, they are executed
in the order scaling, rotation, axis inverdon, and axis change.
The following examples show figures with axis inversions. In the first the same iigure is displayed
four times, first without inversion, then with inversion of the X axis, then with inversion of the Y axis,
and finally with both axes inverted. In each of the remaining two examples, there are two figures.
The first (with the number 1) is the original inverted. The second is the same figure with the USE1
function (4.5.188) eliminated, i.e. the same figure without inversion. Note how the change in
rotation origin (ROT ORIGIN) affects the inversion. (The functions GOSUB and RTS are explained
in 4.5.15.4.)

GOSUB cuadrado
MIRROR ON X
GOSUB cuadrado
MIRROR OFF X
MIRROR ON Y
GOSUB cuadrado
MIRROR OFF XY
MiRROR ON XY
GOSUB cuadrado
END
cuadrado:
INTL X I 0 Y10
X20
Y20
X10
Y10
xo YO
RTS

USE/
lNTL X I 0 Y10
/ROT ORIGIN X I 0 Y10
/MIRROR ON X
INTL X18
Y 14
XI4
Y20
XI0
Y 10
MIRROR OFF X
INTL XO YO
END
USE1
COOR X I 5 Y2
/ROT ORIGIN X I 5 Y2
/MIRROR ON X
INTL YO
X I0
Y8
X14
Y4
X20 Y 2
YO
X I5
Y2
MIRROR OFF X
END

4.5.13.5 CHANGE OF AXES

Syntax: AXlS XYZ

AXIS YXZ

AXlS YXZ effects an axis change as if the change had been made physically, i.e. references to X
in the program are now references to Y, and viceversa.

AXlS XYZ cancels this change

When change of axes is applied at some point other than the initial, change is with respect to the
bisector passing through the origin of the programmed coordinates, point specified by the function
ROT ORIGIN.

Note that when there are several transformations programmed simultaneously, they are executed
in the order scaling, rotation, axis inversion, and axis change.

The following example shows a figure with change of axes. In the first drawing the figure is with
axes changed, while in the second the USE1function has been eliminated (4.5.18.8),i.e. axes
have not been changed. Note how the change of rotation origin (ROT ORIGIN) affects the change.
There are two cases:

R>O: Circular block tangential to the two blocks that define the intersection

-1 <RcO: Circular block with corner recessing function for interior corners.
In this case R represents a compensation fraction.
4.5.14.2 ACTIVATION AND DEACTIVATION OF CHAMFERS

Syntax: CHAF <n>

CHAF OFF

CHAF <n> spec~fiesand initiates chamfering on the corners. The length of the chamfer is that
entered.

The chamfer is a linear truncation block inserted into the intersections of the profile programmed
via this instruction. The length of the chamfer is the distance, with respect to the intersection, to
which the chamfer will be inserted.

CHAF OFF deactivates chamfering.

Setting chamfer length

programmed profile programmed profile

L = Chamfer length
4.5.1 5 PROGRAM INSTRUCTIONS

4.5.1 5.1 STARTlEND OF PROGRAM

Syntax: PROGNAME warn>

END

PROGNAME indicates the start of a program, which should be in the first line of the file. It is used
only to assist the user, and its use is not essential.

END indicates the end of the program. If during execution the control has this instruction, execution
will end, even if following the block there are other instructions. Thus it serves to end the program
at a point without the necessity of erasing, or of inserting into a comment (with a "I*" in front of
those lines and a "*I" behind) the instructions that follow.

Although it is not always essential that END be inserted, insertion is good practice in the interests
of program structure.

4.5.75.2 EXECUTION OF AN EXTERNAL PROGRAM

Syntax PROGRAM cnorn>

PROGRAM worn> executes a given program from another one. When the other program has
been fully executed, execution continues on the line following that at which it the other is called.

The operator can use this instruction to divide programs up in a logical manner, leaving one
program for the description of the workpiece geometry and calling it from any other into which the
technology, offsets, etc. have been loaded.

Examples 2 and 3 (4.5.18) tllustrate the difference between the functions PROGRAM and GOSUB.

4.5.15.3 LABELS

k program. In general, labels are used for jumps (GOTO) or calls to

A label marks a point in t
subroutines (GOSUB).

If in the program labels are defined that later are not referred to via a GOT0 or GOSUB, when the
program is checked it advises the operator that there are unused labels. It does not block their
execution.
4.5.1 5.4 SUBROUT1NES

Syntax: GOSUB enom>

RTS

A subroutine is a part of the program that can be called via the instruction GOSUB, and which is
executed as far as the instruction RTS. Following execution of this last block, execution of the
program continues in the block subsequent to GOSUB.

Within a program, a subroutine opens with a label and closes with RTS. The name given to
GOSUB is that of the label.

A subroutine can be called from various points in the program.

For practical purposes one could say that the call to a subroutine is like the execution of an
externai program, but within the same file. It should be borne in mind that to return to the normal
execution of the program, the procedure to be followed in the case of a subroutine is different from
that in the case of an external program. In the first case return is subsequent to the execution of an
RTS, while in the second case the program has to reach its end or the instruction END has to be
read.

Examples 2 and 3 (4.5.18) illustrate the difference between the functions PROGRAM and GOSUB.

4.5.1 5.5 JUMPS IN EXECUTION

Syntax: G O T 0 worn>
GOT0 worn> IF Pen> <camp> <n>
GOSUB enom>
GOSUB enom> IF Pen> <cornp> cn> (<cornp>being '-', '>', '=')
'c',

Jumps in execution (branches) may be conditional or unconditional. Unconditional branches

(GOT0 worn>, GOSUB worn>) are always executed. GOT0 causes the program to continue its
normal execution from the specified label onward, while GOSUB is a call to a subroutine, return
from which is vra an RTS.

In the case of a conditional jump, the jump to a label or subroutine will not occur unless some
particular value is related in a specified way to the value on a counter. There are four possibilities:
P<n> c> < I ] > The jump is made only if the count is different from the value given.
,

P<n> < : The jump is made only if the count is less than the value given.
Pen> > en> : The jump is made only if the count is greater than the value given.
Pen> = en> : The jump is made only if the count is equal to the value given.

Examples 2 and 3 (4.5.18) illustrate the difference between the functions PROGRAM and GOSUB.
4.5.15.6 LOOPS

Syntax: REP cna

REP P<n>
ENDREP

Loops are program lines that are repeated several times in succession

REP <n> and REP Pen> mark the start of a loop, while ENDREP marks its end. The lines
repeated are those between REP and ENDREP.

To indicate how many times a loop is to be repeated, the operator can program the number directly
(REP cn>) or use a counter to which that value has been given (REP P<n>). With the use of loops
the programming of a repetitive figure, for example, is very simple.

In the following example the one figure appears four times. If the "4" in the second line is replaced
by another number, the figure is repeated the number of times thus indicated. If that line is
replaced by REP PO, then the figure can be repeated as many times as desired. The operator
need only change the value counter value PO.

l NCR
REP 4
GOSUB perfil
TRAV X25
ENDREP
END

perfil:
INTL Y7.5
X7 5
Y-15
X-I 5
Y15
X7.5
Y-7.5
RTS

Examples 7 and 8 illustrate the use of loops in generating gears

4.5.1 5.7 WRITING TEXT IN THE WO-RKPIECE HISTORY

Syntax PRINT TlME

PRINT STATUS

When one or more of these instructions are carried out, the program enters into the workpiece
history the time taken up to the moment of execution (PRINT TIME) or the current state (PRINT
STATUS), i.e the execution time, as well as the profile traversed and the average speed.

These instructions do not modify the program at all, but they may be useful when calculations are
being made.
4.5.1 5.8 USE OF OPTIONAL BLOCKS

Syntax: USE1
NOUSEI

Within a program the operator can make a block optional by putting "I" in front of it. An optional
block is one that to begin with is not going to be executed. However, if the program first reads the
mnemonic "USE/", it will indeed be executed.

The mnemonic NOUSEl ensures that optional blocks will not be executed.

Note that an optional block is not a comment (a block preceded by ""*"). An optional block is
subject to syntax check, but a comment is not.

With optionai blocks it is very easy to revise a program. The user has only to insert a "I" in front of
any line he may wish to be left unexecuted, and aftelwards add the block USE1to have it executed.

4.5.1 5.9 COMMENTS

Syntax: I* (. . . ) " I
** ( . , . )

A comment is used to add an explanation, note, etc. to a program. Text occurring within "I*" and
"*I" constitutes a comment, while so also does any line preceded by "**".

4.5.1 5.1 0 COUNTERS

Syntax. P<n> = en>

Pen> <n>
P<n> = Pen> + <n>
pen> = Pen> - <n>

Counters can be used in loops or to enable the user to control the program (add to it or reduce it
each time a certain line is used)

P<n i> = <n2> / P<n7> <n2> assign to the counter P<nl> a value n2. >. For example, the result of
P1 = 2 is that the counter 1 has the value 2.
P<nl> = P<n.l> + <nZ> increases the count Pen1> by n2 units. Note that both of the Pcnl> must
have the same value for <nl>. For example, P1 = P1 + 2 increases the count 1 by 2 units.
P<n 7 > = P<n - <n2> decreases the count Pcnl> by n2 units. Note that both of the P<nl> must
have the same value for <nl>. For example, P I = P1 - 2 decreases the count 1 by 2 units.

The count can be displayed and modified during the execution, from the execution detail window
(4 3.3.2.1).

A counter is cycl~c.If it is increasing, after 100 it returns to 0. If it is decreasing, after 0 it returns to

100.
4.5.16 PREPARATION

4.5.1 6.1 ADJUSTMENT OF WlRE VERTICALITY

Syntax: VERT

VERT initiates the automatic cycle for adjusting verticality.

4.5.16.2 WlRE CUT

Syntax: WlRE CUT

WlRE CUT initiates the automatic cycle for cutting wire.

4.5.1 6.3 AUTOMATIC WlRE THREADING

Syntax: AWF

AWF initiates the automatic wire-threading cycle.

4.5.1 6.4 INNER CENTERING

Syntax: INNER CENTER <X/YIUIV>

INNER CENTER makes workpiece contact at two points inside the cavity and is positioned
automatically on the midpoint. The operation is on the axis selected, i.e. X, Y, U, or V.

4.5.16.5 WORKPIECE MIDPOINT

Syntax: MIDDLE eXIYIUN>

is at the midpoint of the two last workpiece contacts on the axis selected.
MIDDLE. Pos~t~oning

4.5.1 6.6 WORKPIECE CONTACT (EDGING)

Syntax: EDGE cXIYIUIV>

EDGE makes contact with the workpiece In the direction specified ('+' or on the axis selected.
I-'}

Workpiece contact tolerance is selected via the instruction CONTACT TOL (4.5.17.1)
4.5.16.7 AUTOMATIC RETURN TO INITIAL POINT

Syntax: ORIGIN RET

ORIGIN RET. Movement is performed in reverse direction up to the initial point of the program
executed. By initial point is meant either the start of the program, a setting of positions, or any
order that implies a traverse.

This function is limited in two ways:

Number of blocks in return (500 blocks).
Return is only through programming blocks to the initial point.

ORIGIN RET indicates another block. When it has been executed the program-will continue.

4.5.1 6.8 MEMORIZATION OF CURRENT POSITION

Syntax: MEMOTRAVWORKcn>snorn>
MEMO TRAV MACH <n> morn>
MEMO OFFSET <n> enom>

The three instructions store the current position.

MEMO TRAV WORK saves the current position in work coordinates in the traverse points file.
MEMO TRAV MACH saves the current position in machine coordinates in the traverse points file.
MEMO OFFSET stores the current position in machine coordinates in the offset file.

The current pos~tionis saved at the number <n> of the file indicated (enom>) or of the current
offset or traverse points file if none is indicated. The operator can use the instruction LOAD TRAV
worn> yand LOAD OFFSET enom> to load a different file.
4.5.17 SUNDRY

4.5.A7.1 SETTING: CONTACT TOLERANCE I ANGLE INCREMENT1COMPENSATION

MODIFICATION

Syntax: CONTACT TOL en>

ANGLE <n>
CLEARENCE <n>

CONTACT TOL: Establishes the value within which the contacts between wire and piece are to be
carried out.

ANGLE: This sets the angle increment in repetitive operations in which different angles are
required, as for example in the gear execution. Hence it is used with the ROTATION function. The
+
angle increment ranges between k O.OO1° and 360".

A positive angle increment results in anticlockwise rotation. A negative one results in clockwise
rotation.

CLEARENCE: It is a value that is added ar it is reduced directly (according to the sign) to the value
of the compensation of the selected technology. Programmed in millimeters (see paragraphe 4.5.8)

4.5.17.2 ACTIVATE I DEACTIVATE OUTPUTS

Syntax: OUT <n> <ON/OFF>

OUT ON activates, and OUT OFF deactivates, the output whose number is selected.

4.5.17.3 PAUSES

Syntax: PAUSE <n>

PAUSE IN<n> <ONIOFF>
STOP

PAUSE: This facilitates a dwell specified in hundredths of a second.

PAUSE IN: Instructs the machine to wait until the input specified is ON or OfF, as the case may
be.

S T O P Effects a programmed stop (unlimited dwell}. The machine remains stopped until the
operator uses the start key to resume execution. In the execution detail window (in the stop mode
field) it is specified whether program STOPS are to be executed.
4.5.17.4 VECTORS

Syntax: VECTOR Len> A<n> FEED<n> COMP<n> TAPER<n> ROUNDcn2 CHAFcnr

VECTOR -=n> en> FEEDcnr COMP<n> TAPER<n> ROUNDcn> CHAFcn>

Both syntaxes are acceptable

Performs an interpolation of the XY plane in polar coordinates. For interpolation it is necessary to

indicate the length (L) and angle (A) in degrees.

In addition to defining the vector, one may specify the speed, wire compensation, wire inclination in
degrees, rounding off radius, and chamfer length.

The fallowing example shows a figure with angles, radii, and segment lengths indicated.

INCR
VECTOR 11 5 A20
INTL X30
INTC- Y-10 CY-5
INTL X-30
VECTOR Lt 5 A200
END
 .Bu!pea~j s ~ yuo s w w 6 o ~ d
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~ ~ o y sauo -lalel a y l q301q hq y301q paqu~sapade pua ~aldwlsaAe
$sly a y l 'uo!pas 6u!o6a~ojayl u! paq!nsap suo!pun) ay) 40 h e w a$eJjsnll!salduexa S u ~ ~ o l al oy ~l
Example 2 (Proqram with call to external prosrams)

1. PROGNAME example2 9. PROGRAM examplel

2. **Cut + trim cutting of example1 10. PRINT TIME
3. 11.
4, LOAD TECH 0NA:s-st25lt.tec 12. "'Finish
5. 13. TECH THICK 80 CRIT 9
6. "Roughing 14. PROGRAM example1
7 . TECH THICK 80 CRIT 8 15. PRINT TIME
8. INICUT 16. END
Line 1: Gives the name of the program. In general it will be same as the name of the file, but it
could be anything.

Lines 2 to 4 : Comment, beginning with 'I*' and ending with '*I'

Line 5: Blank.

Line 6: Setting of coordinates X=2, Y=O, U=O, V=O, 2-0.

Line 7: Automatic threading prior to cutting.

Line 8: Specifies compensation on the right.

Lines 9-27: Defines the geometry. Note that lines 9-13, 15-21, and 23-27 are all linear
interpolations, so that it is necessary only to write INTL in the case of the first interpolation. In the
subsequent cases, the movement continues to be considered a linear interpolation, until the type of
movement is changed (to circular interpolation, in this case). Also, note that in line 9 rounding off
of corners is indicated (with radius 0.25), and this continues throughout the instructions.

Line 28: Automatic wire cutting.

Line 29: Quick traverse to program origin (specified in line 6). In this way the control is finally
positioned on the same point as that on which it began.

Line 30: End of program.

The program is saved with the name "examplel", since it will be used in the following example.
Examole 1 (Geometry of a workpiece)

1. PROGNAME example1
2, l**r***********t**ff********************
3. "* Example1- Basic geometry
4, **RR*r***R***R*CbbffX***)t***Mff*** I
5. 20.X-15
6 , COOR X2 YO UO VO ZO 21. Y25
7. A W f 22. INTC- Y 15 CY-5
8. COMP RIGHT 23.INTL Y5
9. 1NTL Y 10 ROUND 0.25 24. X-5
10. X5 25. Y10
11. Y5 26.X-2
12. X f 5 27.Y9
13. Y15 28.WIRE CUT
14. INTC- Y25 CY5 29.TRAV X2 YO
15. INTL Y35 30.END

This example defines only one geometry, which will be used in Example 2. That's why no file is
loaded- it leaves the program to call to the geometry the indication of technology, compensation,
etc. Moreover, the figure has a neck so that a cut and one or more re-runs can be carried out.
When the workp~ecein Exampie 2 has been cut, a program has to be executed that will cut this
neck
Line 1: Program name.

Lines 2, 6 y 12: Comments. These are lines with '**I at the beginning.

Lines 3, 5, and 11: Left blank,

Line 4: Loads a technology table. This is a table that cannot be modified (for which reason "ONA"
appears at the front).

Line 7:Selects roughing mode and a finish (D+lA), with a thickness of 80.

Line 8: Sets the initial mode to prevent the wire from breaking as it enters the workpiece.

Line 9: Calls the program in Example Ito cut the geometry therein described.

Line 10: In the log it records the time taken for roughing.

Line 13: Programs the generator with the parameters for carrying out the finish.

Line 14: Calls the program in Example 1 to cut the geometry therein described.

Line 15; Records in the log the time taken to finish the workpiece.

Line 16: End of program.

Example 6 (Program with loops)

1. PROGNAME example6 12. ABS

2. ** Cuts the cutting edge of a saw 13.X-1
3. 14. Y1
4. COOR XO YO UO VO ZO 15. X-0.2
5. I N T L Y I 16. YO
6. X I 17. END
7. INCR 18.
8. REP 15 19. tooth:
9. GOSU8 tooth 20. INTL Y2
10. ENDREP 21. X4 Y - l
11. INTL Y4 22. RTS

In this example a loop appears. Beginning in line 8 and ending in line 10, it indicates that the
subroutine representing a tooth is performed fifteen times. Note also the use of the instructions
INCR and ABS in lines 7 and 12.
Example 7 matwheel, in absolute coordinates)

1. PROGNAME gearwheel1 12. ROTATE 0

2. ** Geamheel using absolute movement 13. INTL XO YO
and rotating around {O,D) 14. END
3. 15.
4. COOR XO YO 16. tooth:
5. COMP RIGHT 17, lNTL X1.308 Y19.957
6. ANGLE -15 18. X I ,504Y22.951
7. INTL XO Y20 19.X4.487 Y22.558
8. REP 24 20. X3.908 Y19.616
9. ROTATE0 21. X5.176 Y19.319
10. GOSUB tooth 22. RTS
11. ENDREP

The gearwheel created in this example has twenty-four teeth. The program shows the use of the
angle increment function (ANGLE) for repetitive operations (see section 4.5.17.1). Using this
function and the rotation function (ROTATE O), to create a gearwheel one need define only one
tooth.

Each gearwheel :s defined in the tooth subroutine:

INTL X1.308 Y19.957

X I ,504Y22.951
X4.487 Y22.558
X3.908 Y19 616
X5.176 Y19 319
Example 8 IGearwheet, in incremental coordinates)

1 PROGNAME gearwheel2 12. ABS

2. ** Gearwheel using incremental 13, INTL XO YO
movement and rotating around (0,O) 14. END
3. 15.
4. COORXO YO 16. tooth:
5. COMP RIGHT 17. ABS
6 . INTL X-2.633 Y 20 18. INTL XO
7. ANGLE -1 5 19. INCR
8. REP 24 20.l NTL Y2.633
9. ROTATE0 21. X2.633
10. GOSUB tooth 22.Y-2.633
11. ENDREP 23. RTS

Here the gearwheel created is similar to that created with the previous program, but incremental
coordinates and rotations are used.

Each gear is def~nedin the tooth subroutine:

ABS
INTL XO
INCR
INTL Y2.633
X2 633
Y-2 633
Example 9 [Corner roundinq off with four axes)

I. PROGNAME rounding off 8. INTC+ X-20 CX-20 U15 CUO

2. * * XYUV with rounding off 9 , INTLX-25 U10
3. COOR XO YO UO VO ZO 10. Y-15 U10 V5
4. INTL Y-15 V5 ROUND2 11. INTL XO V5
5 . X25 U-10V5 12. XO YO
6, YO U-10 13. END
7. X20 U-15

Note how in this program the rounding-off radius is maintained on the intersections, even though
the figure in the XY plane is different from that in the UV plane.
Example 10 (Rounding off of nesative radius)

1. PROGNAME radio-neg 9. YO
2. ** Rounding off of negative radius 10. X-I0
3. COOR X-5 YO UO VO ZO 11. Y-10
4. COMPO 12. XO
5. COMP LEFT 13. YO
6. lNTL XO ROUND-0.5 14. X-5
7. Y10 15. END
8. X-20

This program makes use of negative rounding-off radii. The outer figure (without rounding offj is
cut ~fthe ROUND field is eliminated in line 6. Negative rounding off extends to the edge of the
workpiece without rounding off since it is given a value of -0.5 (see section 4.5.14.1).

In this example compensation of the wire 0 has radius 1 , simply so that one can observe the effect
of negative rounding off.
1. PROGNAME example1 1 12. CONST ANGLE
2. ** taper with isocones 13. ROUND 1
3. 14. INICUT
4. 15. INTL X25 TAPER 10
5, LOAD TECH ONA:al25lt.tec 16. Y-8
6. TECH THICK 40 CRIT 0 17. X41
7. COORXO Y 5 UOVOZOTHlCK40 18. Y8
8. ROT ORlGl N XO Y5 19. X25
9. ROTATE -90 20. Y5
10. COMP LEFT 21. X7
11. TAPER RIGHT 22. END

In this example conic functions are used. The taper mode defined inclines the wire to the right
(TAPER RIGHT), the tapered cutting is of constant radius (CONST ANGLE),and the cutting angle
is 10° (defined in Iine 14). In line 6 we see that the thickness of the workpiece is 40 mm.

Corners are rounded off with a radius of 1 (line 12), and the figure is rotated (lines 7, 8). Note that
the origin of rotation is the same as that in the program.
Example 12 (Taper types)

I . PROGNAME tapers 19. INTL X-2 TAPER 3

2. ** Types of taper cutting 20,/ROUND 2
3. COORX-25 YO UOVOZOTHlCK35 21. INTL Y10
4. SHARP ANGLE 22. X-20
5. GOSUBgeo 23, INTL Y-10 TAPER 6
6. USE1 24. X I 0 Y-10
7 COOR X5 YO UO VO ZO 25. INTL X I 0 TAPER 3
8. CONST ANGLE 26 Y10
9. GOSUBgeo 27. X3
10. COOR X- t 0 Y-30 UO VO ZO 28. TRAV Y2
11. CONST RAD 29.ABS
12. GOSUB geo 30. RTS
13. END 31. Y8
14. 32. X2
15. geo: 33.TRAV Y 2
16. INCR 34. ABS
17. COMP LEFT 35.RTS
18. TAPER RIGHT

This program shows the three types of taper cutting. With the one geometry, defined in the
subroutine geo, the same cut has been performed three times, but with different types of taper

Note that iine 20 is an optional block. Hence the first time it is read, with a sharp-angle taper, it is
not executed, since USE1 has yet to be performed. On later readings the rounding off is indeed
carried out.

Note also that the coordinates in lines 3, 7, and 10 are set only so that the graphic representation
may correcly show the drawings.
The three cuts are numbered in their order of execution: the first is at a sharp angle, the second is rn
isocono, and the third is isoradio.

The wire inclination may be seen to vary It starts at 3 O , increases to 6 O , and ends back at.'3
a
4.5.20 IS0 LANGUAGE

As mentioned above, the standard I S 0 instructions are also allowed in the mnemonic language.
The following are the instructions permitted. The IS0 mnemonic is shown in the first column, while
in the second column we see the equivalent in ONA mnemonics, and in the last we see the
function fields. (If the I S 0 and ONA fields are different, the I S 0 fields are indicated first, then the
ONA fields in italics.)

TRAV
GOO -
- X<n> Y<n> U<n> V<n> Zen>
GOO TRAV Pen>
GO1 INTL X<n> Y<n> U<n> V<n> F<n> D<n> Ten> E<n> Cen>

X<n> Y<n> Ucn> V<n>FEED<n> COMP<n> TAPER<n>

ROUND<n> CHAF<n>
GO2 INTC- Xcn, Yen> I<n> Jcnw U<n> V<n> Ken> L<n> Fen> D<n>
T<n> E<n> C<n>

X<n> Y<nz CX<n> CY<n> U<n> V<n> CU<n> CVcn>

FEED<#> COMP<n> TAPER<n> ROUNDcn, CHAF<n>
GO3 INTC+ X<n> Y<n> l<n> J<n> U<n> Vcn> Ken> L<n> Fen> D<n>
Ten> E<n> C<nz

X<n> Y<n> CX<n> CY<n> U<n> Vcn> CU<n> CV<n>

-FEED<n> COMP<n> TAPER<n> ROUND<n> CHAFcn>
GO4 PAUSE

<n>
G40 COMP OFF
G41 COMPLEFT
G42 COMP RIGHT
G70 INCH
G71 METR
G90 ABS
G91 INCR
G92 COOR X<n> Y<n> U<n> V<n> H<n> Qcn>

Xxn> Y<n> U<n> V-=n=- TH/CK<n> PRGP<n>

MOO STOP
M02 END
 CHAPTER 5

SECURITY

5.1 INSTRUCTIONS FOR A SAFE TRANSPORT OF THE MACHINE

Instructions for a safe transpod and lay-out of the machine are described in chapter 1.

5.2 WARNING SIGNALS

Due to the impossibility of avoiding all the dangers, in spite of all the preventive measures
that have been installed in the machine, several warning signals have been placed on the
machine. These signals inform about t h e dangers that exist in the machine and the correct
way of working with the machine.

The warning signals are as follows:

5.2.1 Danger of slippery floor near the

machine.

Reason: there might be dielectric dropped on the floor.

5.2.2 . Danger of electrocution in areas with high voltage

Reason: high voltage in the following places:

- Inside the generator.

- In the electrode.
- In the machine.

Some of these notices bear the text: Caution: Before removing

this cover, disconnect the machine's power supply and wait
seventy seconds. Be aware that there are residual voltages,
representing a certain danger. that take some time to disappear.
 5.2.3 It is obligatory to use gloves handling
dielectric or any element in contact with it

Reason: Direct contact with dielectric may cause problems

in the skin (allergies, infections, etc.).

5.2.4 It is obligatory to wash the hands

after having been in contact with
dielectric

Reason: Direct contact with dielectric may cause problems

in the skin (allergies, infections, etc.)

5.3 SECURITY DEVICES tNCORPORATED IN THE MACHINE

5.3.t Emergency push-button.

5.3.1 .IFunction:

Should a dangerous situation arise, the emergency button can be pressed in order to stop the
nachine. In normal circumstances it should not be used instead of the STOP button.

5.3.1.2 Maintenance

Frequency: weekly.

- Function: W~ththe machine operating, press the emergency button and check that the machine
joes indeed stop.
5.3.2 Tank door micro

5.3.2.1 Function:

If the tank door opens, this micro prevent the dielectric from leaving for the tank and stop the erosion
process. Dangerous voltages in the work zone dissipate. If they are activated during normal erosion
w o k , the message TANK DOOR OPEN appears on the CNC screen.

5.3.2.2 Maintenance

- Frequency: Weekly.
- Mode: During erosion and with the tank empty, open and close the door. Check that:
I- The alarm message TANK DOOR OPEN is displayed on screen.
2- Dielectric ceases to leave for the tank
3- Erosion ceases. The pointers on the voltmeter and ammeter fall to zero.

5.3.3 Wire guard micro.

5.3.3.1 Function:

If the wire guard opens, the wire stops moving and erosion ceases. Dangerous voltages in the work
zone dissipate. If it is activated in the course of normal erosion work, the alarm WIRE GUARD is
displayed on the CNC screen.

5.3.3.2 Maintenance

- Frequency: weekly,
- Mode: While erosion is in process, open and close the wire guard and check that:
I- The alarm message WIRE GUARD is displayed on screen.
2- Erosion ceases. The pointers on the voltmeter and ammeter fall to zero.
3- Wire motion ceases.
5.3.4 Tank maximum-level float

5.3.4.1 Function:

To prevent overflow of dielectric from the work tank.

When it is activated, it prevents dielectric from leaving the tank and stops the erosion process.
Dangerous voltages in the work zone dissipate. The alarm message FLOAT is displayed on screen.

This alarm message disappears when the tank is being emptied and one presses the RESET key on
the AtARM page of the CNC.

It is advisable to check over the drainage servovalve, as well as the drainage channels, so that new
overflows cannot occur.

5.3.4.2 Maintenance

- Periodicity: monthly
- Mode: Activate the lower and upper jets. If the machine is a submerged one, set the tank at fill.
Work the float with a finger and check that:
1- The FLOAT alarm is displayed on screen.
2- The tank ceases to fill and begins to empty.
3- The lower and upper dielectric jets cease.
4- Erosion ceases. The pointers on the voltmeter and ammeter fall to zero.

5.3.5 Presostat

5.3.5.1 Function:

It detects a drop of the pressure under 6 kglcm2 at the entrance of the air.
Activation of this device wiP deactivate the power and the erosion, and will generate the 'low
pressure" alarm on the CNC's screen. To reset this alarm eliminate the reason that caused it, and
press the "reset" key on the CNC's "ALARM" page.

5.3.5.2 Maintenance

- Periodicity: monthly.
- Mode: disconnect the air input and check that the 'tow pressure" alarm is activated on the CNC's
screen.
5.3.6. Generator's air filter

5.3.6.1 Function:

Avoids the entrance of dust through the generator's ventilation grids.

5.3.6.2 Maintenance

- Periodicity: monthly
- Mode: Check if the filter is able to allow air through. othewise clean it. To clean it, take it out and
clean it with water and detergent. Dry it carefully and impregnate it using the VlSCOSlNA spray
included, always on the outside.

The upper grid must be cleaned by a soft jet of compressed air from the inner part of the generator.

Resume of security devices maintenance

Device Periodicity
Emergency push-button WEEKLY
Tank door micro WEEKLY
y
Generator air filters
WEEKLY
MONTHLY
Tank maximum level float MONTHLY
Presostat MONTHLY

figure 5-7
5.4 CORRECT USE OF THE MACHINE

Due to the impossibility of avoiding all the dangers, in spite of all the preventive measures that have
been installed in the machine, normal works with the machine must be carried out following the
next instructions:

1 - All the secunty devices described in paragraph 5.3 must be respected and their maintenance
must be carried out correctly as it is explained in this chapter.

2 - Surface around the machine must be cleaned frequently to avoid accidental slides

3 - Gloves must be obligatory used, handling dielectric or any element in contact with it. The hands
must be cleaned after having had contact with dielectric.

4 - Attend the advises given by warning signals on the machine.

5 - Residues (sludge) produced during the erosion work must be eliminated according with the in
force rule in the country of destination of the machine.

6 - Follow the maintenance guide of the machine.

 CHAPTER 6

AN OVERVIEW OF THE WORK

Here we look briefly at the operations involved in machining a workpiece. For further detail see the
technology manual.

These operations can be listed as follows:

SITUATING THE WORKPIECE IN THE MACHINE

Parallelism with respect to the coordinate axes

Planarity with respect to the table.

GRAPHICS PROGRAM CHECK

Nominal program check.

Check of the program with wire compensation.
Check of the program with tapered cutting, in simulation and in actual execution
(different planes).
* CENTERING

Locating absolute zeros.

Locating the surface of a face.
Locating the center of a hole.
Locating the center of a channel.
* DRY-RUN PROGRAM CHECK

Entering the actual wire compensation values.

Entering the actual workpiece coordinates for taper cutting.
Dry-run execution of the workpiece.
Checking that it does not touch a flange or reach the limit switch
* ENTERING THE EROSION CONDITIONS
* THE FINEHE0 WORKPIECE
6.1 SITUATING THE WORKPIECE IN THE MACHINE

Where the workpiece is to be situated will depend of the type of profile to be machined. Using a dial
indicator, check the planarity of the workpiece with respect to the table, as well as the parallelism of
one or two reference faces.

Check also that nozzles will not collide. Safety zones can be defined.

6.2 GRAPHICS CHECK

6.2.1 NOMINAL CHECK

Having entered the program, check its operation via the graphics option under the execution tab
(section 4.3.3). You may carry out an autoscaling first in order to ensure that the profile diagram is in
accordance with the machining you wish to do.

6.2.2 COMPENSATION CHECK

Check that compensation (left or right) does not trigger an alarm, which it will if the value is too high in
relation to a small movement.

6.2.3 TAPERED CUTTING CHECK

If the workpiece is to be subjected to tapered cutting, check the movement of the upper and lower
guides. You can do this through graphics, in which case you select the TAPER options under the
taper tab (see section 4.3.3.5). The graphics representation will appear under the execution tab (see
section 4.3.3.2). The upper and lower profiles will be displayed as programmed, with their inclination
and in relation to the thickness and the programmed plane.

So that tapered cutting can go ahead, the values of the principal plane and the Z zero have to be
entered. See sections 4.3.2.4("automatic verticality adjustment") and 4.4.3 ("tapered cutting").

6.3 CENTERING
Depending on the positioning of the profiles in relation to the reference points, automatic centering will
provide the initial points for machining.

Where the EDGING operation is concerned, take the radius of the wire into account so that its center
can be correctly situated on the surface to be machined.
6.4 DRY-RUN PROGRAM CHECK

The purpose of this check is to ensure that in the course of execution there will be no limit switch
alarm, that the water heads will not collide with an attaching flange, and that the power cables do not
interfere with erosion. Under the execution tab, replace the NORMAL menu by the DRY-RUN menu.

When you press "cycle start" ( ), execution will start without the generator's being turned on.
Only the movements programmed will be carried out on the workpiece.

6.5 ENTERING THE EROSION CONDITIONS

Under the technology tab ( 4 . 3 . 3 3 ,there are three basic parameters for erosion:

a.- Type of technology file to be used

b.- Thickness
c.- Criterion

When erosion is begun from outside the workpiece, it is advisable to use the function INICUT so that
the machine will change cutting conditions while entering the workpiece. When optimum conditions
have been recovered, the technology selected can be reestablished. See section 4.5.12.3 in the
programming manual.

6.5.1 OFFSET

WIRE

profile

I
-A- A - ( I
I UFFSET = --
 ANNEX l

CONNECTION OF ONA UE 1 RE 1 KE
MACHINES
TO THE MAINS (general power)
O B a d reading of the careenage door:
[tindicates a bad function of the micro for the careenage door cover. Check if
the door is well closed and the sensor we11 adjusted. Try a couple of times reset the
alarm. If it is not ok still, call to the service department. They are the micros "548"
and "S-19"

" Bad reading of the cutting box cover:

It indicates a bad function of the micro which detects the cutting box cover. To
rest follow the indication of the the service department

" Bad reading of the door micro:

I t indicates a bad function of the micro for the tank door ( l i l t ) . Check if the
door is well closed and the sensor well adjusted. Try a couple of times reset the
alarm. I f i t is not ok still, call to the service depnrftnent

" Bad reading of the machine front panel cover:

11indicates a bad function of the micro for the front panel cover. Check if the
door i s well closed and the sensor well adjusted. Try a couple of tin~esreset the
alarm. I f it is not ok still. call to fltt! service dep~rtrnetztFor Aricut machine is the
sensor 3 4 8 " and for Arion "525".

" Block execution end:

Iloir~ga execution block in block. after finishing the block the CNC gives this
IV~I-11n i ng

" Broken wire:

I!' during thc process of cutting thc wire is broken and the RE-THREADING;
uption is disablcd the alarm will appear. This alarm can hc rcsetsd inmodiaicl y to
ca~lt workiug i r thc wire is rrady again.
i1111c

It1 cast that the wire is not hroken but thc alarm appears:
ON.4 "UE" and "RE" models:
a ) Vcrify the cinematic of the wire. The movement of the wire must be
soft and without jumping la cinzn~atica,se njucve de forma suave y
sin snltos ni tirones.
b) Verify the belt of the dinanlo whcih could be broken or out of the
good position (See paragraphe 1.1.4 of the "Description and
Preventive Maintenance Manual").
C) If both are ok, call to the service department.

ONA "a" and "KE" models:

a ) Check the status of the input 13 of the board A1 4. Call to the service
department.
" Cancelled: Comoensation Error:
The CNC has found a geometrical problem or aritmeticai problem for the
programed offset value. Possible causes:

The first or last interpolation are not linems.

The offset value is bigger that the distance of'the interpolation.

" Cancelled execucution :

When the execution of a program is cancelled manually by the button "//", the
CNC gives a warning showing this message.

" Cancelled: Invalid instruction:

This message appear when there is a poblem when the program is going to be
executed. There are four possibies causes:

The program is syntaxisly incorrect. Check it

To prolect the generator, they are some combination of p m r ~ ~ e t e r
powerlvoitage which are not accepted.
The user table is emptied
The inpiit or output of the user's inpudoutpul board is out of thc rangc

" Cancelled: Untinished return:

-1'0 rcturn a file (by SPR, for example) if there are more blocks than the
n ~ a x i r n u twhich
~ are permited (500) the alarm will appcar. T h i s alarm is rcseted
byscl r ahcr moving some axis.

O Careenage door open:

0111y In ONA "AE" and "KE"models. 'Phis alarrrl indicatcs that thc carecnrrgc
back dnor or the bobine door arc opentd

'1'11~ ~ilicroswhich control this alarm are the1 "548" and thc 3 4 9 " . If the alarm
ciun no hr: reset, call to t l ~ service
r flrpnrfmntt.
 Change cutter blades:
In the consumibles page there is a counter to control the theorical life of the
cutters blades. When this values reach to zero the alarm will appear. To reset the
alarm only is neccesary to write down a value different to zero. We recomend to put
this value to 1000 cutters and after this time check it. . It is not neccesary to change
them after this time. The status of the blades should be checked

To change the parameter go to MISCELANOUS+ MAINTENANCE 3

CONSUMIBLES and here the CNT CUTTERS .

Change resins:
In the consumibles page there is a counter to control the theorical life of the
resins. When this values reach to zero the alarm will appear. To reset the alarm only
is neccesary to write down a value different to zero. We recomend to put this value
lo 300 hours and after this time check it. It js not neccesary to change them after this
time. The status of the resjsn should be checked. The resins only should be change
when the alarm " lack of conductivity conditions" appears. Check also this alarm.

'1'0 change the parameter go to MISCELANOUS+ MATNTENANCE +

CONSUMIBLES and here the TMP RESINS.

O Chopper error:
Thc CNC checks the status of the cutter continuosly. It checks if the cutler
blades are cutting. There are two posibilities:

The wire is going outside without cutting the wire through the outside
cone of the chopper. The problem seems to be that the chopper i s not
well adjusted. The operation of adjusting is not dificult and can do it. In
case of some question cal4 to flrr service department
The wire i s not goiong outside through the outside cone of the cutter. The
problem seems to be that the chopper is blocked due to some wire inside.
The input 15 of inputtoutput board A12 will he activated all the time.
Top solve the problem, the chopper must be dismounted (dismount the
set of choppcra and secondary tractor) and remove all the wire which is
inside. If the porblen~ appears several times, call to tire servirc~
d~parf~nenf.

11' [his alarm appear during a execution of a program also the "WIRE
GIiNI.Rr'\L ALARM" also will appcar.
" Collision:
The alarm will appear when there is a collision.

Anticollision system: There is a electrical and mechanical protection. When

there is a collision the mechanical protection will disconnect the transmission
between the motor and ballscrew. On the other hand after producing the
disconection betqeen the motor and ballscrew the metalic pletin will close the
electrical circuit and will give a signal to the CNC. The CNC recives this signal
and gives the alarm stopping all the motors.

In the ONA "UE" and ''RE'' models the system is installed in the axis X,Y and
2.
In the ONA " A E and "KEmodels the system is installed in all the axis.

To reset the alarm, the starnsmission between the motor and ballscrew must be
connected again. After making it the electrical circuit will open again due to the
rnetalic pletin wi l i be separated. To disconnect the transmission is neccesary to
turn the ballscrew % unclockwise more or less..

- ONA "UE" and "RE" modeis:

To access to the ballscrews:
X axis: On the rigth part of the body of the machine (between generator
and machine) there is a hole and the ballscew will be there.
Y axis: At the back of the machine there is a hole and the ballscrew will
be there.
Z axis: The top cover which protect the Z axis motor must be removed
and the ballscrew will be there.
- ON.4 "AE" and "KE" models:
'I'he access to the ballscrew is through the anticolIision system and never
directly turning the baliscrew. The 4 key allen must be used. There is a hole
upper the motor where the key will be introduced and turn 1/4 unclockwise

So~nctimethere is a alarm but there isn not collision. It could be due to reasons:
a) The small metalic pletirl is not adjusted well and close the circuit when there
i s not collision. See the figure. The separation must be aproximately I m m
bctween the pletin (blue colour) and the gear (green colour)

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 If during a execution of a program or during the execution of a operation in
automataci there is a alarm, it will provocate the stop of the operation. The CNC will
indicate "emergency stop" and also the alarm which produces this stop.

" Error:Disk full:

The disk of 3'" or the "hard" disk of the machine are full.

O Execution restart:
The CNC gives this message after starting a program which has been stopped
before.

" Execution start:

The CNC gives this message after starting a program.

a Execution stopped:
W l ~ e nthe execution of a program is slopped manually by the button "STOP",
r l ~ cCNC gives a warnning showing this message.
o File could not open:
[f the program which want to execute is an inexiting or inacccesible file.

Float:
To avoid that the water goes out of the work tank The sensor whcih control is
the "S 18". In the sumerged machine this sensor is located in the right upper part of
the work tank. In the apsortion machine is on the rigth lower part of the work tank.
To reset the alarm is just to decreade the level of water. In case that this alarm
appears when the level of water is less than the float. verify:
Check the input 12 of the A13 board if it is On and Off' when you activate the
float with your hand. If it is not working
CaIl to the service department.
O Incorrect file format:
For example, when a table of point of traverse or files of technologies or some
decalages want to be opened this warning will appear. It is the same if a decalage
table wants to be opened as a file with technology format or with program format

" Inmersion of the head:

This alarm advise us if the head is under water. It is to avoid that the head is
underwater when the head is moved down with the two floats activated.

ONA "L'E" and "RE" models; The sensor is "S2 1". It is the sensor
which is at the top of the three sensors. The signal which control it is the
input S of the inputJoutput A12. The signal can be checked by the
acticatioddesactivat ion of the float (upldown).
ONA ".4E and "KE" models: The sensor is "S 1 9". The signal which
"

co~~trolit is the input 6 of the input/output A1 2 . The signal can be checked

by the actication/desactivation of the float (upldown).

If the alarm can not be rzseted call fo rke service depart~tunt

 Lack of conductivitv conditions:
When the value of the conductivity of the water is bigger than the program
value, the CNC will give us an alarm and the CNC will be not permit to execute a
new program. The resins must be changed and wait until the conductivity decrease
to the program value. If this value doesn't decrease after some time, call to the
sewice departmelt t.
Anyway there are some steps which can be checked by the user before callling:

The flow from the output of the resin's bottle which goes to the clean
tank should be 1SIiters/mjnute. If it is less, verify
a) To compare with the input. If the flow in the input is bigger, clean the
filter on the "stick" which is inside of the bottle and chek also the
filter which is on the cover.
b ) If the flow of wster is similar in the input and output clean the
eletrovalvule "Y24" .
If the flow is cero and the pump is working, clean the eiectrovctlvule
"Y24".

I f during the execution of a program the actual value of the conductivity is

bigger than the program value the CNC will give us a warning changing to yellow
coloirr the icone for alarms. The machine will permit us to finish the job but it will
not permit start a new one if the conductivity has not decreased the value and the
icone for the alarm will became red colour.

" Lack of machine conditions:

When the generator is activated i f the CNC detects a problem in the filter,
diclcctric, desionitation, wire speed or tension or another thing which can provocatc
the desactivation of them. So in those cases there is not conditions for cutting and
the C'NC gives the alarm

Normally this alarm comes with the alarm which causes the problem. So the
sttps to vcrify the problem will bc different

If i t is ]lot possible to detect the problem call to t11rservice dcprttttent.

" Lack of water:

Indicatc a low level o r water on the dirty tank and thc alarm will appcar. In thc
pnncl control urhici~is on the filtcr the rcd led will be On.

111 ilc>rnial conditiotls the clran tank and dccanting tank are fulled and thc dirty
tank nlusl have water at least touching the sensor of minimun. If the water doesn't
r t x h t c ~the minimun Icvel the alarm will appear. I f the alarm appear is ncccesary tu
 add water. To add water the clean and decanting tank must be emptied. The
maximun level is shown in the bottle of the filter (canister). So add until the
maximun level. After adding to reset the alarm in the CNC, first of all push the
Rrset pushbutton which is in the electrical box of the filter unit and when the led is
not red the alarm can be reseted in the CNC.

The sensor which controls the level is the "S36", it ia a stick inside of the dirty
tank. The input which activates this alarm is the input 3 of the board A14(ANEX
A). If after adding the water the alarm can not be reset. call to fire service
department.

" Lack of wire conditions:

Similar to the last one "lack of machine conditions". The CNC detects some
problem which provocates the dzsactivation of wire speed or tension
If it is not possible to detect the problem cull to the service department.

O Low air pressure:

When the pressure switch "S 16" detects that the pressure of the air is less than 6
bars. the CNC will give this alarm. Verify the air installation of the factory,
compressor and so on.

11' thc pressure is 6 bars but there is the alarm, the pressure switch should be
w r i f y an also the input I4 of the input/output A13
t:ol- that call to tlte service depnrtment.

U'itli this alarm some operntions are not allowed, for example the movemen ot'
thc axis and so on .
o Machine front panel cover:
The machine front panel cover is to avoid that the user access to the cinematic of
the wire (rdlerd on the front pane1)when the machine is working. The microswitch
to control it is the 3 4 8 " in ONA " U E and " R E models and ' 3 2 5 " in ONA ' * A E
and "KE"models. If the door is open the alarm appears and the generator is Off
(not cutting). After closing the door is posible to reset the alarm. If it is not posible
call to the service depadment.

" Motors termics:

If some termic which are for the filter pumps have jumped the alarm will
appear. The termics are FI ,F2,F3 and F4. To reset the alarm the terrnic must be
reseted by the hand and then reset the alarm in the CNC.

If the alarm appears often, there is a electrical problem on the pumps or on the
power supply circuit in this case call to the service department

If the alarm appears but the terrnirs are ok check the input 10 of the A14
board( ANEX A). call to the service depurtment .
 0ut of startine position:
If there is a STOP during the execution of a program and then there is a
muvemet of some axis,the comander RETR must be executed to recuperate the start
position
If the RETR option is not executed the program can not run and the warning
"OUT OF STARTING POSITION" will appear
Alarms in relation:
Points overflow in retrace.

" Overtravel:
When the axis arrive to final of the travel the overtravel sensor is activated and
stop inmediately the movement of the axis. The control will give us the alann
"OVERTRAVEL". After reseting move the axis in the other direction.
 Point recovering position:
If during a execution of a program, the program is cancelled, there is a power
failure (with the autopower on desactivated) or the the power is shut off, there is a
posibility to continue working from the point which was the problem. To do it,

Activate the option "MANUAL RESTART" in EXECUTION +

DETAILS.
Execute the program selection the option "DRY R U N TO THE POINT".
The CNC will execute the program, without any movement of the axis,
until the line of the program which has stoped. This can be displayed
In this moment when the CNC recuperat the last line, it will show the
warnnig "END OF THE RECOVERING POINT".

" Position deflection error :

The position deflection error is the difference between the actual and theorical
position where should be, during the movement of the axis. This error can be
checked on the screen going to MISCELANOUS +
ONA 3 DIAGNOSTICS.
During the movement of the axis, the CNC wiil control the position where must go
the axis and the machine must "follow" this signal. In this moment is when appears
the deflection position error which works among some limits which are different
depending on the spped (aproximately 0.6mm in 60% of the maximun speed or
O.Ot)Imm cutting speed). ALWAYS this error must go back to the 0 value (or
prictically 0 3 0.001mm for example).

Wlier~the machine can not recuperate [he error and put it to O or keep it arnong
sonw limits, the CNC will give us an alarm "POSITION DEFLECTION ERROR
(X.Y.1J.V 0 Z)".

'I't~enumber of posibilities which generates this alarm are a lot and most of the
cascs thc technical service is neccesary.

l3u1 there are some posibilitics which the user can solve the problem. Normally i t
i s duc t o tl~efuse which is broken

- l30ARDS WITH FUSES WHICH CAN RE BROKEN:

Servo~notorsboard for tllc axis X.Y,U,V,Z. (A2 1 ,A22,A23,A24 and A25
are tlle names of the boards respcctivaly).
Mother of the servo-motors which ~ h r namc
: is A20.
Power suply for the motors which thc namc is 1159.

- I'IIOCEDUKE TO VERIFY:
l'jrst of all i t is neccesary to check if the error is for all asis or only one of
tl~cm.The first step is to move the axis onc by one ~ucheck in which there is
an alarm.
 A ) PROBLEM IN ONE AXIS ONLY (ANEX A)
Verify the fuse of the servo-motor board.
Verify permission signal in the A14 board:
X AXIS- OUTPUT NUMBER 18
Y AXIS - OUTPUT NUMBER 19
U AXIS- OUTPUT NUMBER 20
V AXIS- OUTPUT NUMBER 2 1
Z AXIS- OUTPUT NUMBER 22

If those steps are OK, call service department.

A) PROBLEM IN ALL AXIS AT THE SAME TIME(ANEX B):
Verify fuses on the mother of the servo-motors board. Fuses F1 and F2 in
A20 board.
Verify fuses on the power supply board for the motors. Fuses F1 and F2
A59 board.
If the fuses are ok, clrll service rlrpartment.

" Power fail:

If there is power failure from the factory the machine will not have power and
the alarm wilt appear.

O Progammed stop:
This is the warnning which the CNC gives when there is a STOP (MOO). The
option must be activated in EJECUTION +
DETAILS
O Secondsw roller blocked:
The secondary roller doesn't push the wire because it is stopped. The problem
could be due to some wire in the rollers, the rollers dirty or bad mechanical
adjustment
Verify if there is some wire on the rollers or they are some dirty particules which
block the tractor
Verify some mechanical part (tube probably) touch the rollers, stopping them. It
could be due to dismounting and mounting the secondary set. Maybe some piece
has been put it incorrectly

O Short-circuit return:
If the wire is in short-circuit with the piece during the execution of a program
the CNC will detect and it will move back the wire to avoid the short-circuit.

If the wire move back more than 2mm and the wire is still in short-circuit the
CNC will give the alarm "short-circuit return". The value of 2mm can be changed
by the operator from the CNC. Going to MXSCELANOUS +
CONFIGURACION
3 LIM.SHORT CIRCUIT.

If the alarm appear several times is better to inform to the service department
because could be a problem

This aIarm could appear due to:

- The conductivity of the water is high. The alarm will appear more in high
lhickness of the pieces
- Current pick up in bad conditions
- Cables of the table in bad conditions
- Using a bad technology. The chanel is not enough
- Caracterictics of the piece can provocate that the chanel will close again
- Electrical problem
- 'I'he led of the short-circuit (middle one) On after turning on the machine

Anyway it will bctter to inform to the scrvicc departrncnt..

" Sludge remotion:

111 tllc consun~ibles pagc thcre i s a countcr to control the number of autoclcaniug
u f tlic liltcr. LVhrn this valucs rcachs to thc m a s i m u r ~value [he alarnm will appear.
When thr: operation of clcaning the sludge tank is donc thc interruptor of the sludgc
tank will hc ON and the counter start again fro111 zero and teh alarm can be resetcd.
 ~fthisalarm appear is because the decanting tank has been not cleaned at least
during 50 autocleaning and it could be dangerous for the filter system due to all the
sludges can go to the mineral through the fjl ter pump.

To change the parameter go to MISCELANOUS+ MAINTENANCE +

CONSUMIBLES and here the LIMIT MAXIMUN CLEANING.

* Stop by recovery failure:

If after finishing the trend the nachine can not do the autothreading and if the
number of jumps is different to zero, the machine will go to the next poitn to do
the autothreading. If the threading is not possible, the machine will tray again as
time as the selection of jumps

This alarm is not standard and the problem seems to be that the threading
system should be adjust it. It would be good to call to the service departmenf
Alarms in relation:
Broken wire.
Stop by threading failure.
Stop by recovery failure

Stop by thread failure:

I f this alarm appear call to the service department . The CNC has detected that
some part of the all threading system has not been activated.

Stop by threading failure:

During a execution of a program if there is a broken wire and the option of RE-
'THREAD is activated in the EXECUTION + DETAILS, the machine will try to
thread again as time as it is indicated in the MISCELANOUS 3 MAINTENANCE
.3 RE--SPIREA. The recornendate value is 3. After 3 times if the machine doesn't get
thc autothreading and in the EXECUTION + DETAILS the option of JUMP is zero
,thc mnchine will give the alarrrl "stop by threading failure".

/\ln~+msin relation:
Broken wire.
Stopbythreadingfailurc.
Stop by recovery failure.
" Stop due to verticaIitv failure:
It indicates that some of the parameters which are in the verticality page are
wrong. The CNC before starting check those parameters, to know if they are "logics"
or not. For example. if the Maim PIain value is 1OQrnm,the CNC will recognice like
not valid. Another example, is if the 21 and 2 2 have positive value, the CNC also
will give us this alarm.

O Syntax error:
The CNC doesn't recognize a instruction of the program. Normally the line
which is not OK is shown in the display. The CNC doesn't let safe the program
while the mistake is there.
O
W i r e does not arrive to the secondary roller:
The CNC controls the time which needs the wire to arrive to the secondary roller
from the moment which wire touches the pipe. There is a maximun time and if after
this time the CNC doesn't receive a signal from the rollers which are running
slowler than before the alarm ivlll appear

The problem could be due to wire in the pipe and also a eIectrical problem. If
after checking the mechanical part of the lower head, pipe and secondary tractor the
problem is not solved call to flze service depnrtmettt.

" Wire does not touch the pipe:

This alarm detects situations of failure of the threading due to the wire doesn't
arrive co the secondary rollers.

The alarm appear if the wire doesn't touch the pipe after some time (fixed by the
softnware) pulling the wire from the upper head the

To reset the alarm the movement of the wire must be verified and also the status
upper and lower head in order to find the problem with the stuck of the wire
I f it is not possible to detect the problem cnfl to the service depnrfment.

Working tank door open:

Orlly models with abatible door. If during the process of openinglclosing, the
ill
door is not doing correctly the function, the control will give us an alarm. Before
rzseting the alarm the home position of the door must he ok. To do it go to
MISCELANOUS + CONFIGURATION. Inside of this menu the opcion is
"ORIGING WORKING TANK".

IF aftcr executing the door doesn't move or the alarm can not be reseted, cnll to
tht. S L ' P Y ~ C Cdep~rlmelf
t.

O Worn current P,:

I n t t ~ consumjbles
t page therc is a counter lo control the thcarical life of LIIC
currcnt pick ups. When this values reach to zero ttic alarm ivill appear. To rcsct thc
alarm o11ly is necccsary to write down a value diffcrcnt to zcro. We rcconlend to put
this value to 300 hours and aficr this titrlc check it. . 11 is not neccesary to changc
thcni aficr this time. Thc status of the current pick up should be chccked
O Zero not found:
If i n automatic operation of CNC where must r-rlemorize a machine coordinate if the axis
which want to be saved the zero of the machine is not found, the CNC will give us an
alarm. A example is when a decalage position wants to be saved, the machine doesnt let
if the zero are not found. It will be neccesary to find the zero of the axis and it is
recornandated to find also the rest of axis.
ANNEX Il-A. Inputs - outputs boards in the machines ONA AE, KE, RE and UE

(GREEN LEDS)

NOTE: The red leds are inputs and the green leds are outputs.
 To change the parameter go to MISCELANOLIS -3 MAINTENANCE
CONSUMIBLES and here the TMP CURRENT PICK UPS.

" Worn guides:

In the consurnibles page there is a counter to control the theoricai life of the
guides. When this values reach to zero the alarm will appear. To reset the alarm only
is neccesary to write down a value different to zero. This life time depends on a lot
of thing as the wire which is used, kind of cutting and so on but we recomend to put
this value to 2000 hours and after this time check it.

To change the parameter go to MISCELANOUS3 MAINTENANCE +

CONSUMIBLES and here the TMP. GUIDES.

" Worn P wheels:

111 the consumibIes page there is a counter to control the theoricat life of the
polyuretane rollers. When this values reach to zero the alarm will appear. To reset
the alarm on1y is neccesary to write down a value different to zero. We recomend to
put this value to 1500 hours and after this time check it. . It is not neccesary to
change them after this time. The status of the rollers should be checked

To change the parameter go to hlISCELANOUS+ MAINTENANCE +

CONSUM I BLES and here the TMP P ROLLERS.