edm_numerical_control_220v60hz

Electric Discharging Machine
(Controllers of the BHxxASEB)
User’s Manual
Rev. 2007.12
Machine Model： Machine No.：
Controller Model： Controller No.：

Introductory Note
Thanks for purchasing this product from us. It is advisable for you to,
before you use the product, read this manual where you could get enough
knowledge to use it to your best advantage and avoid inconveniences
caused by any possible misoperation.
This manual is for the BHxxASEB pulse controllers only.
We alone and fully assume the power for the interpretation of this
manual which is subject to change without any prior notice.

Some of the Safety Signs
No smoking.
Don’t fight fire with water.
Don’t hand-touch the electrodes.
Danger! Electric shock.
Caution! (For more, please refer to

the details.)
Some of the Safety Signs
Wear protective gloves to avoid

electric shock from the electrodes.
Contents
1. Main functions and range of uses ..................……………………… …….........…. 1
2. Main technical parameters ..................................…………………………….......... 1
2.1. Main mechanic parameters ..............................…………………………….......... 1
2.2. Main controller parameters............................……………………………............ 2
2.3. Instructions on the protection functions of the system.................………...............2
3. Transferring the machine tool ................………………………………………….. 3
4. Trail operation of the machine tool.....................................……………….............. 6
4.1. The normal working conditions of the machine tool.............…............................ 6
4.2. Installing and adjusting the machine tool..............................…………….............7
5. Safety instructions and matters to be heeded.......………………............................. 8
5.1. Safety instructions................................………………………………...................8
5.2. Matters to be heeded...........…………………………….......................................10
6. The structure of the machine tool, the drive system and the lubrication system..10
6.1. The structure of the machine tool..…………………............................................10
6.1.1. The main spindle head .............……...……………………...............................10
6.1.2 The upright column and the operating platform components………………,,,..11
6.1.3. The operating liquid case and groove parts ............…………….…..................12
6.2. The drive system of the machine tool.........................……………......................13
6.3. The lubrication system of the machine tool .............................………................14
7. Maintenance of the machine tool...........................................………………..........15
8. Operation instructions of the machine tool............................…………..................16
8.1. A brief introduction to the functions of the controller…………………… ……16
8.2. The control panel .....................……………………………............….................18
8.3. Instructions on the X.Y.Z display zone ............…………………........................20
8.4. Instructions on the alarm zone ...................…………………….................. 22
8.5. Operation instructions ..................................……………………………........... 23
8.5.1. Special instructions of button..........…………………........................ 23
8.5.2. Instructions on tri-axial function keys.............…………………………......... 24
8.5.2.1. Zero-clearing tri-axial data ....................……………………………........... 24
8.5.2.2. Calculating the middle value of tri-axial data (halving)..........…………......24
8.5.2.3. Resetting tri-axial data ............……………………………......................... 25
8.5.2.4. Finding the mid-point of the work-piece............................………….......... 25
8.5.3. Instructions on setting discharging parameters ............………...................... 26
8.5.3.1. Adjusting processing current and automatically loading parameters………26
8.5.3.2. Adjusting high voltage current..............…………………........................... 26
8.5.3.3. Adjusting pulse width.....................…………………………………….........27
8.5.3.4 Adjusting pulse gap….......………………………………..............................27
8.5.3.5 Adjusting servo tracking voltage (processing voltage)......………................. 27
8.5.3.6 Adjusting parameters related to period heightening............…….................. 28
8.5.3.6.1. Explaining period heightening..........................………………….............. 28
8.5.3.6.2. Activating period heightening and adjusting processing time................... 28
8.5.3.6.3. Adjusting slow-motion distance in period heightening.....................……. 29
8.5.3.6.4. Adjusting fast-motion distance in period heightening ..........…........…..... 29
8.5.3.6.5. Adjusting second-time super-heightening ......................…………........... 30
8.5.3.7. Selecting different pulses in the discharging process ...............……............ 30
8.5.3.8. Adjusting servo tracking speed................................……………………..... 32
8.5.3.9. Activating anti-carbon deposition self-adaptable control.............................. 32
8.5.4. Instructions on Z axle target depth setting ...................………………............ 33
8.5.4.1. Setting processing segment target depth.....................………………........... 33
8.5.4.2 Multiple segments processing..................................……………………...... 33
8.5.4.2.1. Instructions on display…………………..........................................33
8.5.4.2.2. Switchover procedures between different segments................................... 34
8.5.4.2.3 Activating and completing multi-segment processing.……........................ 34
8.5.4.2.4 Exemplifying multi-segment processing……………………………...35
8.6. Instructions on other functions...................………………………….................. 37
8.7. Hand-control box buttons ..........................…………………………….............. 39
8.8. System entry procedures after password expires ...................……..................... 39
9. An introduction to deslagging and motion of oil ....................…........................... 40
9.1. Ejection deslagging ..............................................……………………………... 42
9.2. Absorption deslagging.........................................…………………………........ 44
9.3. Edge deslagging.......................................………………………………............ 45
9.4. The pressing deslagging of processing liquid ............…………......................... 48
9.5. Simultaneous oil ejection deslagging.........................…………………............. 48
9.6. The technique of deslagging ..............................…………………..................... 49
9.6.1. Deslagging pressure ........................…………………………......................... 49
9.6.2. Firedamp questions......................……………………………......................... 50
9.6.3. The use of mold backup plate....................……………………....................... 52
9.6.4. Exemplifying edge deslagging.......…………………....................................... 52
9.6.5. Lateral flow deslagging ...............................…………………………............ 55
9.6.6. Amalgamated deslagging....................………………………...........................56
10. Troubleshooting.................................………..………………………………..... 57
11. Figure of the system.....................................……………………………............. 58
12. Internal circuit diagram .............................………………………................ 59
12.1. External circuit sketch (Drawing A) ……………………………………… 59
12.2. #001，#002 Wire connection sketch (Drawing B) …………………… 60
12.3. #003，#008 Wire connection sketch (Drawing C)……….……………. 61
12.4. #004 Wire connection sketch (Drawing D)………………………………… 62
12.5. #005 Wire connection sketch (Drawing E)………………………………… 63
12.6. BH40A : #006 external connection sketch (Drawing F-40)……………… 64
12.7. BH80A BH100A: #006external connection sketch (Drawing F-80)……… 65
12.8. machine tool connection sketch (Drawing G) …………………………66
12.9. Output wire connection sketch (Drawing H) …………………………67
13. Consumable parts list ………………………………………………………...….68
The BHxxASEB controller discharge machine—— user’s manual Page 1 of 69
1. Main functions and range of uses
This machine is mainly for the processing and the reshaping of small
and medium-sized mold cavities as well as the shaping of specialized
high-strength spare parts.
It is suitable for shaping mold cavities of the spare parts in fields like
machinery, the auto industry, the aviation industry, the military industry,
the light industry, the electrical appliances and meters, daily commodities
manufacturing industries and the plastic molding industry.
2. Main technical parameters
2.1. Main mechanic parameters

Model
ZNC250 ZNC320 ZNC325 ZNC435 ZNC540
Parameters
Operating platform (mm) 280×450 300×450 350×630 450×700 500×800
820×500×2 850×560×3 900×560×3 1250×720× 1450×890×
Operating groove (mm)
80 20 80 450 500
X axle range (mm) 250 300 350 450 500
Y axle range (mm) 200 200 250 350 400
Z axle range (mm) 200 200 300(200) ①
200 200
Slider range (Dual range)
× × ×/(200) 250 250
①
(mm)
From main axle’s junction
plate to the operating 540 580 600(700) 730 800
①
platform (mm)
Electric pole carrying
30 50 50 75 100
capacity (kg)
Maximum capacity of the
200 300 500 700 1000
operating platform (kg)
Maximum configuration
1390×1480×201 1390×1480×210 1440×1460×222 1560×1600×216 1810×1500×230
dimension of the machine
0 0 5 5 0
tool (mm)
Weight of the machine tool
1000 1200 1300 1800 2000
(kg)
Please note: Those with ① are the parameters with dual range for the ZNC350 model.
2.2. Main controller parameters

Model
BH40ASEB BH80ASEB BH100ASEB
Parameters
Input voltage Three-phase 220V/60Hz Three-phase 220V/60Hz Three-phase 220V/60Hz
Power 6KW 8.7KW 10KW
Maximum machining
40A 75A 99A
current
Maximum bottom surface
Ra 0.4μm Ra 0.4μm Ra 0.4μm
finish quality
Minimum electrode loss 0.2% 0.2% 0.2%
Maximum machining
200mm3/m 500mm3/m 800mm3/m
speed
2.3. Instructions on the protection functions of the system
(1). The flame detection function
To be activated by the user. Please refer to 8.6 for more.
The system determines whether there is flame or not based on the
detection of heat quantity. An 110V AC socket is preset for automatic
extinguishers. When flame is detected, the machining process is halted
with power supply uncut off, for heat quantity miscalculation might be
caused by other heat sources like sunlight and workshop lighting.
(2). The oil temperature detection function
The liquid level of oil must be kept >10cm. When oil temperature
rises >600C, the machining process is halted with power supply uncut off.
(3). The oil level detection function
When the oil level is lower than the indicated scale on the left side
of the oil tank, the machining process is halted with power supply uncut
off. The user may manually adjust the scale to fix on the level.
(4). The open-valve power off function
Automatically activated.
When the valve of the controller is opened, the system cuts off
power automatically. As some components in the system may remain
electrically alive, it is imperative to wait, after the main power supply is
shut off, at least 5 minutes prior to an open-valve checkup.
3. Transferring the machine tool
Before the machine tool is transferred, the X and Y axels must be
fastened with fastening boards to restrict their movements. Bad bounces,
tilts and bumps must be avoided to keep the machine tool well-balanced.
When handled by a crane, the machine should be lifted from exactly the
place as indicated. The length of the lifting cables and the lifting angle
must be appropriate; the cables must be capable of the weight 4 times as
mush as that of the machine tool. Contacts between the cables and the
machine must be avoided as much as possible. The contacting areas could,

if necessary, be cushioned with soft materials so that damage to the
machine could be minimum.
In the transferring process, cables must be fastened tightly to the
wooden case of the machine; the case must not be put upside-down, on
any of its sides or tilted; any up-lifting or down-loading movement must
be slow to keep the machine upright until it’s stable on the ground.
After the machine is unloaded, please check if there is any damage,
and make sure all accessories are there as is stated in the package list
before a trial operation.
Please refer to the pictures on the next page.

Reference pictures:
4. Trail operation of the machine tool
4.1. The normal working conditions of the machine tool
Physical conditions:
The highest air temperature around shall not exceed +400C, the
lowest no less than 00C; the average air temperature around within 24
hours shall not be more than +350C.
When the highest air temperature around rises above +400C,
humidity shall then be kept within 40%; in lower temperatures, humidity
could be correspondingly higher but still no more than 80%; special
measures must be taken to deal with the occasional dewing caused by
temperature changes.
The spot to keep the machine must be below 1500m over sea level
with the air pressure between 86 to 106kPa.
Power supply:
3-phase AC220V/60Hz with voltage fluctuation ±10V allowable.
3-phase 5-wire or 3-phase 4-wire with fine ground connection
devices (Please refer to 12.6 for instructions on wire connection).
Other conditions:
The spot to keep the machine must be fireproof. No flammable or
explosive is allowed near the machine tool.

The spot to keep the machine must be fireproof. It is imperative for
rain not to wet the machine tool.
The spot to keep the machine must be dustproof and
well-ventilated.
The spot to keep the machine must be shockproof.
The spot to keep the machine must have relatively few chemically
active substances; it must be proof against oily, salty and harmful gases.
4.2. Installing and adjusting the machine tool
Machine tools are installed differently with different models. Spaces
between the machine and operating liquid groove are reserved for upper
and lower die plate operations. At the same time, it must be guaranteed
that the doors of the controller must be normally opened so that repairs
could be done. For smooth and precise operations of the machine tool, the
foundation must be built with hard concrete. After the tool is in place, the
wood block filler and fastening boards for the X and Y axles must be first
dismantled. Then the rust-resistant oil is to be removed from the surfaces
of the operating platform and guideway, followed by petrol cleaning. The
level instrument is then revolved to adjust tuning screws of the anti-shock
pad. 0.04/1000 level accuracy is expected after horizontal and vertical
adjustment.
The controller must be stably placed upright, its doors opened
before connected to power supply. The joining screws inside must be
checked to see whether they are loose or there is water. The ventilation
openings must be checked to make sure they are not jammed. The trial
operation may begin if there is nothing wrong. The operation must be
carried out by specialized personnel certified by the manufacturer of the
machine tool, as the operator must be familiar with the operations and
handle possible risks.
1. When the X and Y axles have covered their travel limits, the
distance between the edge of the machine and the wall surface must be
above 600mm to avoid any possible collision when the machine is in
operation.
2. As processing liquid is in use for operation, the floor around
the machine tool must be non-slip to avoid possible risks.
5. Safety instructions and matters to be heeded
5.1. Safety instructions
(1). Please choose specialized discharge oil of high ignition point which
must be above 750C
(2). Stop using the processing machine when the operators are not around.
The entire machining process must be attended to by specialized

personnel.
(3). Keep the processing liquid 15cm higher than the processed material.
(4). Fire control device is necessary around the machine tool. The 1211
extinguisher could be a fine choice.
(5). No operation is allowed with wet hands. Checkup is to be done 5
minutes after the main power supply is cut off so that electric shock could
be avoided.
(6). Insulating pad and non-slip pad must be ready in order so that electric
shop and slipping could be avoided.
(7). In order to avoid electric shock, please wear protective gloves and do
not touch the electric poles.
(8). Please check whether safety devices are in order before any
operation.
(9). The repairs of the machine tool must be done under the instructions
of certified specialized personnel. No unauthorized change is allowed to
be made on the machine tool.
(10). Please make sure the power wire and the ground wire are properly
connected.
(11). Everything is to be done strictly according to the manual.
(12). The controller must be kept well-ventilated.

5. 2. Matters to be heeded
(1). The emergency stop button (the power-off button) is to be used only
in times of emergency. Please use the off button under normal conditions;
otherwise errors could occur to the data protected when there is a power
failure.
(2). When the machine is restarted, research for the datum point;
otherwise the data concerning tri-axial sizes risk being altered.
(3). The AC 220V power supply socket in the socket box at the back of
the controller is only for constant power supply. No other device is
allowed to be connected here.
(4). The ventilation opening is to be checked and cleaned monthly to
make sure it isn’t jammed up with dust which may affect heat
elimination.
6. The structure of the machine tool, the drive system and the lubrication
system
6.1. The structure of the machine tool
The machine mainly consists of the main spindle head, the upright
column, the operating platform, the oil tank, the operating liquid box, the
clamping fixture and the electrical controlling parts.
i) The main spindle head
This part is driven by imported direct current electrical engine with a

proportion of 1:4 for simultaneous transmission. Connected to the main

axle by high-precision lead screws on its head, the spindle makes upward
and downward zero clearance movement to form a Z axle. On both sides
of the main axle is installed the linear guideway to ensure the precision
(0.02/300) and sensitivity of the main axle. For the ZNC450-up models,
the spindle makes double upward and downward movements generated
by dipole electric motors with a 1:4 proportion for simultaneous
movement with the lead screw. Locking devices are also installed to
ensure the effectiveness and stability of carrying out electric erosion
operations.
A 0-30 mm dial indicator is installed on the surface to indicate the
height of the cutter with the range of 0-8 mm and its stability.
ii) The upright column and the operating platform components
The high-strength cast steel upright column is used to withstand the

weight of the main spindle head and the electrodes to ensure they have
enough rigidity and stability.。
The operating platform components consist of the body section, the
carriage, the operating platform and the lead screws. The guideway
surface is made up of durable plastic material to reduce fiction. The
horizontal and vertical movement of the platform is driven by the
high-precision ball lead screws. Streaming manual input and dial
zero-setting, locking and grating positioning are also used to locate
devices. The locating precision is 0.01/300.
iii) The operating liquid case and groove parts

The operating recycling system is welded by steel and composed of
the operating liquid case and the operating liquid groove.
The liquid passes through the oil pump into the filtering device
(Class B for ZNC350-up models). After flowing through the lower part of
the overfall valve, it finds its way into the groove. The groove has a front
entrance as well as side entrance, both of which are sealed tight with soft
oil-resistant rubber ribbon. On the left side of the groove are the
liquid-level adjusting device, the liquid-temperature protection device and
the liquid-discharging device. The liquid can flow back to the case
through the liquid-level adjusting panel and the liquid-discharging panel.

a) The drive system of the machine tool
The drive mechanism sketch
Main axle screw drive
Main axle screw drive Spindle up/down screw

Spindle upward/downward screw
X Hand reel
X Screw shaft
X Screw shaft
Handle The handle causes the hand reel to spin, upon which the screw
shaft drives the operating platform to move in X/Y directions.
The servo motor causes the pulley to spin, upon which the screw
X Screw nut shaft drives the main axle to move in up/down directions.
Y Screw nut The slowing motor causes the sprocket to spin, upon which
Y Screw shaft the screw shaft drives the spindle to move upward/downward.
Y Screw shaft
Y Hand reel
b) The lubrication system of the machine tool
Machine tool lubrication sketch

Manual pump
The points in the sketch are to be lubricated twice for each shift.
4 3
Main Ascending X Level X "V" X Axle Y Level Y "V" Y Axle

spindle /descending
5 Name screw screw
guideway Guideway screw guideway Guideway screw
7 6 No.
8 Operation Manual Manual Manual Manual Manual Manual Manual Manual
Mode pump pump pump pump pump pump pump pump
Manual Manual Manual Manual Manual Manual Manual Manual
Lubricant
pump pump pump pump pump pump pump pump
7. Maintenance of the machine tool
(1). Please activate the manual oil injector before everyday use to ensure
the juncture of the Z axle properly lubricated so that its service life could
be maximized.
(2). Frequently check the junctures of the X and Y axles are properly
lubricated.
(3). Frequently wipe the machine to keep it clean so that its service life
could be maximized.
(4). Frequently check whether the processing liquid is too dirty. Replace,
if necessary, the filter screen and cleanse the filter box to improve
effectiveness and efficiency.
(5). Frequently check whether the electric fan in the power supply box is
well-ventilated.
(6). Frequently check whether the rubber in the operating groove is in a
fine condition to ensure safety.
(7). Cleanse the operating platform after machining to keep it clean and in
a well-maintained condition with proper protective treatments.

8. Operation instructions of the machine tool
As the use of the controller is a major part involved in the
operation of the machine tool, this section will be mainly elaborating on
the operation instructions of the controller.
8.1. A brief introduction to the functions of the controller
(1). Based on the fuzzy control theory, it is a high-efficiency quality

discharging processing machine.
(2). The memory-retaining capacity in the case of power failure offers a
permanent storage of discharging parameters.
(3). The tri-axle optical scale is compatible with INC/ABS coordinator
switchover. Based on the precision of the scale, the configuration of the
system can be matched with the switching, its minimum display unit
being 1μm.
(4). Homenergic discharging produces fine even processed surfaces with
minimum loss and high speed.
(5). Automatic carbon tracking and detecting. If there is the carbon
deposition tendency, the system will make automatic adjustments to
lower arc discharging rates.
(6). The Z axle offers “Fast” and “Slow” 2-level cutter deslagging choices
with high-frequency movements for deep-hole processing.
(7). The Z axle offers up to 10-segment editing choices for both one-time
rough processing and precise processing.
(8). A small, easy and light hand-control box that can be stuck to
everywhere.
(9). Positive direction positioning of the Z axle processing coordinate.

(10). Multi-pulse easy-control processing circuits for various needs.
(11). The “Intelligent Expert” system for beginners. Once a numerical value
of the current is input, the processing parameters will be automatically
loaded.
(12). Multiple risk warnings and precautions to minimize damage caused by
misoperation.
(13). Multi-module choices for the user.
Please note: ①. If there is a power supply when the main axle is in operation (e.g. in
the discharging processing status), errors may occur between the ROM data and the
actual data of the three axles. It is advisable for the user to make readjustments.
8.2. The control panel
(1). BH80A panel

(2). BH40A panel

8.3. Instructions on the X.Y.Z display zone
8.3.1. In discharging status (when light is on and light is
off)
X display zone: displaying target values (depth values)
Y display zone: displaying maximum values of the Z-axle
Z display zone: displaying authentic values of the Z-axle
8.3.2. In tri-axial displaying status (when light is off and
light is off)
X display zone: displaying the absolute and relative values of X-axle
Y display zone: displaying the absolute and relative values of Y-axle
Z display zone: displaying the absolute and relative values of Z-axle
Please note: Press for coordinates switchover. The
absolute values are on display when the light is on.

8.3.3 In system displaying status (when light is off and
light is on)
The alarming zone displays the page of the system.
Press the number buttons to select a system page whose
corresponding information is listed as below.

Page X axle information Y axle information Z axle information
0 Current date③ Current time ④ Current week ⑤
1 Overall expiry date① Monthly expiry date ② Trial expiry date
2 User level Customer level Temporary password clearing
3 006 software version 006 software SN 001 software version
4 001 software SN 003 software version 003 software SN
5 004 software version 004 software SN

Notes:
①: When“------” is on display, the master password is cleared.
②：When “Monthly expiry date” is on display, the password value is input.
③,④,⑤：User setting is allowed only when the password is cleared.
8.4. Instructions on the alarm zone
In system displaying status, the system codes are on display (see
8.3.3); in others, status codes and alarm codes are displayed, their
corresponding information listed as below.
Status codes:
Code Information
01 Positive and negative poles short-circuited
02 Positive and negative poles open-circuited
Alarm codes (Press button to disable alarm):
Code Information
10 This discharging processing is successfully completed.
11 Oil level (too low) alarming (Subject to user setting; see 12.5)
12 Oil temperature (>60Cº) alarming (Subject to user setting; see 12.5)
13 Flame alarming (subject to user setting; see 12.5)
21 VMOS breakdown on 004 board
20 FU1 fuse failure on 004 board (No detection when the current value is 0)
22 Machine overloading overtime error
26 Fast-up overshoot
27 Fast-down overshoot
28 Fast-down overshoot distance exceeds the slow-down on (the latter over-demanded).
32 006 board detection error upon startup

33 004 board initialization error
50 Sub-password expires.
52 The system clock halts.
40-43 Data storage error
53 Wrong password
51 Overall time expires (Disabled upon input of master password.
14 Motion alarming after X axle is positioned (Subject to user setting; see a.5)
15 Motion alarming after Y axle is positioned (Subject to user setting; see a.5)
8.5. Operation instructions
8.5.1. Special instructions of button
In the discharging process, processing parameters are subject to
change so that various needs could be met. This may cause instability,
and sometimes careless parameter setting may directly damage the
processing parts. To be protected against this, the system offers a special
button . The user may press it after confirming the parameters,
upon which they are then finalized. For the sake of convenience, this
system provides a led. When it is on, the user may effect the input
parameters by pressing .
The parameters which are effected only after pressing are
the absolute values of X, Y, Z axles, the relative value of Z axle,
processing depth, current, pulse width, pulse gap, servo, high voltage,
time, first-level, second-level, second-time, loss and so on.
Instructions concerning this button are omitted in the following
sections. The user may just press upon the prompt of after
setting all the necessary parameters.

8.5.2. Instructions on tri-axial function keys
8.5.2.1. Zero-clearing tri-axial data
First, switch over to the tri-axial displaying status (see 8.3.2),

①
then:
Press
…………Zero-clearing X axle③
Press
…………Zero-clearing Y axle
③
Press
…………Zero-clearing Z axle
②③
Please note:
①. Confirm the coordinate status of the data to be zero-cleared as

indicates.
②. Z axle zero-clearing procedures are also effective under processing

displaying status.
③. Press to cancel input and restore the original value.
8.5.2.2. Calculating the middle value of tri-axial data (halving)
First, switch over to relative coordinates of the tri-axial displaying
status (see 8.3.2), then:

①
The original value halved

②
Press

②
Press

②
Press
Please note:
①. With absolute coordinates, this operation equals a zero-clearing

operation.
②. Errors may occur when “halving” operation produces \decimal fraction

which is left out. The user may press to cancel the input and restore the
original value.
8.5.2.3. Resetting tri-axial data
status (see 8.3.2), then:

①
or or [Number Keys②] ③
Please note:
①. With absolute coordinates, this operation equals a zero-clearing

operation.
②. Press to switch symbols and to input decimal point.
③. Press to cancel the input and restore the original value.
8.5.2.4. Finding the mid-point of the work-piece
status (see 8.3.2), move the processing platform to have the electric poles
slight touch the end of the work-piece and zero-clear the corresponding
data on the coordinate (see 8.5.2.1); move the processing platform to the
position where this coordinate is zero positioned and this is the mid-point
of the work-piece on its corresponding axle.

8.5.3. Instructions on setting discharging parameters
8.5.3.1 Adjusting processing current and automatically loading
parameters
Press ; when the display window flashes, press number keys to
input the current value ; press to cancel, or press to

①
complete without altering other discharging parameters; or press to
finish inputting the current value while other corresponding discharging
parameters automatically loaded by the system. The valid range for the
②
setting of the BH40A model is 0-45; BH80A, 0-75; BH100A, 0-99.
Please note:
①. Affected by the processing parameters, the indicated value in actual

processing from the current meter may be different from the preset processing current.
The former should be taken as the true one.
②. They system parameters are not necessarily the optimal ones; they are for
reference only.
8.5.3.2. Adjusting high voltage current
input the high voltage current value; press to cancel, or press
or to finish input. The valid range of setting is 0-5.

8.5.3.3. Adjusting pulse width
input the pulse width value; press to cancel, or press or
to finish input. The unit being microsecond, the valid range of setting is
4-999.
8.5.3.4. Adjusting pulse gap
input the pulse gap value; press to cancel, or press or
to finish input. The unit being 10 microseconds, the valid range of setting
is 1-99.
8.5.3.5. Adjusting servo tracking voltage (processing voltage)
input the processing voltage value; press to cancel, or press
or to finish input. The valid range of setting is 1-9. The larger the
value, the higher the indicated processing voltage from the voltage meter.
8.5.3.6. Adjusting parameters related to period heightening
8.5.3.6.1. Explaining period heightening
In order to enhance the effects of post-discharging deslagging, a
2-level period heightening function is devised for this system, i.e., after a
certain period of discharging (processing), Z axle is heightened in slow
motion to the first preset position (level 1), and then in fast motion to the
second preset position (level 2), and lowered; being lowered, it is lowered
in fast motion to the second preset position (level 2) and then in slow
motion (normal discharging). In order to avoid two-time discharging, the
pulse power supply automatically shuts down when Z axle is heightened.
8.5.3.6.2 Activating period heightening and adjusting processing time
input the processing time value; press to cancel, or press or
to finish input. The valid range of setting is 0-9. The larger the
value, the longer the processing time in the process of period heightening;
if the input value is 0, then the period heightening shuts off.

8.5.3.6.3. Adjusting slow-motion distance in period heightening
input the slow-motion distance value; press to cancel, or press
or to finish input. The valid range of setting is 1-9. The
larger the value, the longer the slow-motion distance in the process of
period heightening; normally, it is set at 1 or 2. The larger the contact area
of the work-piece and the electric poles, the larger the value should be.
8.6.3.6.4. Adjusting fast-motion distance in period heightening
input the fast-motion distance value; press to cancel, or press
or to finish input. Speed choices can be made by pressing ;
when its light is on, “slow” is selected. The valid range of setting is 1-9.
The larger the value, the longer the fast-motion distance in the process of
period heightening.
8.6.3.6.5. Adjusting second-time super-heightening
Under some circumstances (such as deep hole discharging
processing), period heightening may still not be able to achieve effective
deslagging. For this, a second-time super-heightening function is devised
for the system, i.e., after several rounds (which needs setting) of period
heightening movements, a super-heightening is to be done. Its parameter
setting procedures are as follows.
input the period heightening time value; press to cancel, or press
or to finish input. The valid range of setting is 0-9; if the input
value is 0, then the super-heightening shuts off.
8.5.3.7. Selecting different pulses in the discharging process
Electrode loss, processing efficiency, surface roughness and side
discharging gap are inter-related in electric spark processing. The
adjustments of the parameters cannot bring all of them into their best state
at the very same time. For this, parameters of are devised for the
user’s convenience. Parameter setting procedures are as follows.
input the period heightening time value; press to cancel, or press

or to finish input. The valid range of setting is 2-8; the user may
select different parameters according to different needs and processing
targets.
A clarification is provided below.
Pulse
Clarification Field of application Targets for application
value
Improve efficiency at
Electric poles: iron,
the price of high loss
2，3， Demanding of efficiency, work-piece: iron; Electric
rate; the smaller the
4 undemanding of loss. poles: copper,
value, the higher the
work-piece: alloy.
speed and the loss rate.
Electric poles: copper,
Moderately demanding of
both efficiency and loss work-piece: iron;
5 Standard (yet not so much of loss), large-planed large-current
demanding of fine smooth processing.
surface finish.
Improve anti-carbon
6 deposition pulse with Ibid. Ibid.
relatively high loss rate.
Improve anti-carbon
For most discharging
7 deposition pulse without Ibid.
processing targets.
increased loss rate.
Demanding of efficiency,
loss rate and surface
In the cases of thin-sliced
finish quality. The more
printed electric poles, one
Improve anti-carbon lowered loss rate, the
electric pole processing
8 deposition pulse with better. Not so demanding
multiple molds,
lowered loss rate. of electric pole surface
demanding of loss rate
crack (fatigue crack).
and discharging stability
Applicable to small-plane
processing.
8.5.3.8. Adjusting servo tracking speed
Adjust the turn-button clockwise to quicken servo tracking speed
and counter-clockwise to slow it. At the end of the counter-clockwise
turning, Z axle remains static in the process of discharging (period
heightening and manual up and down operations unaffected). Make
adjustments according to the fluctuation of Z axle centesimal meter.
8.5.3.9. Activating anti-carbon deposition self-adaptable control
Press . The led is then on and the self-adaptable heightening
function is activated. In the activated status, the system monitors the
discharging process. If there is any bad discharging, the self-heightening
movement is automatically loaded (Its parameters are the same as period
heightening. See 8.5.3.6.3 and 8.5.3.6.4), to avoid arc-discharging .

①
Press . The led is then on and the self-adaptable pulse function
is activated. In the activated status, the system monitors the discharging
process. If there is any bad discharging, self-adjustments of pulse
parameters is automatically made. It is advisable not to activate this
function for materials (such as alloy) that are difficult to process.
Please note:
①. The system is capable of avoiding arc-discharging to a certain degree. It is

unable to rule out the possibility of arc-discharging or carbon deposition. Therefore,
despite the self-adaptable control functions, manual adjustment is always necessary.
8.5.4. Instructions on Z axle target depth setting
8.5.4.1. Setting processing segment target depth
Switch over first to the discharging displaying status (see 8.3.10;
press ; when X display zone flashes, press number keys to input
the target depth value ; press to switch symbols; press to

①②
to input decimal point; press to cancel and press to complete
input.
Please note:
①. The input target depth value must be quantified in terms of the

differentiating rate of the optical scale. Therefore, there could be an automatic
adjustment when the input is finished.
②、If the input value is 1.000，then the present segment processing ends when Z
axle value (under same coordinates circumstances) is equal to or more than 1.000, i.e.,
the input value is Z axle’s target.
8.5.4.2. Multiple segments processing
8.5.4.2.1. Instructions on display
When displays [-], displays the final processing

segment value; when displays numeric values, displays the
present segment value. Display switchover can be made in the following
way.
Press ; when the display window flashes, press for
display switchover.
8.5.4.2.2. Switchover procedures between different segments
This machine is a Z axle automatic segment processing model. Each
processing may contain up to 10 sets of processing data. The user may
select according to the actual conditions. Switchover procedures between
different segments are as follows.
Press ; when X display window flashes, press number keys to
input segment value. Press to cancel, or press or to
complete input.
8.5.4.2.3. Activating and completing multi-segment processing
Press . The led is then on and multi-segment processing is
activated. After completing the target depth of the present segment, the
system is automatically switched to the discharging parameters of the
next segment and sends off a signal sound. After completing the target
depth of the last segment, this discharging processing is then finished.
Instructions on setting the last segment value are as follows.
Switch display status to the last processing segment value
( refer to 8.5.4.2.1); press ; when the display window flashes，press
number keys to input the last segment value. Press to cancel, or
press or to complete input.

8.5.4.2.4. Exemplifying multi-segment processing
Press ; the system enters this mode when the led is on.
(1). The processing position figure
P
O
L Oil
E level
ZO (present Z axle position)
0.000
P0(1.000mm)
P1(2.000mm)
P2(3.000mm)
P3(3.500mm)
Processing
target
(2). The processing conditions
The total processing depth: 3.500mm
Processing 1.000mm with 8A current, i.e. the position of P0

(3). Operation procedures
(a). Move the electric poles to the processing position and complete
X, Y, Z axle position setting (See 8.5.2).
(b). Press and Z axle automatically lowers until electric poles
reach the work-piece, displays “01” and gives off a signal sound.
Zero-clear Z axle data (see 8.5.2.1).
(c). P0 is correspondent to segment 0 with its target depth of 1.000
and current of 8A;
P1 is correspondent to segment 1 with its target depth of 2.000
and current of 6A;
P2 is correspondent to segment 2 with its target depth of 3.000 and
current of 3A;
P3 is correspondent to segment 3 with its target depth of 3.500 and
current of 1A;
And input corresponding discharging processing parameters for
each segment (see 8.5.4.1and 8.5.3).
(d). Switch display status and input the last segment value
(see 8.5.4.2.3).
(e). Switch display status and load parameters for segment 0
(see 8.5.4.2.1and 8.5.4.2.2).
(f). Press and to start discharging processing.

8.6. Instructions on other functions
Oil temperature alarm activation button. Activated when the
led is on.
Flame alarm activation button. Activated when the led is on.
Oil level alarm activation button. Activated when the led is
on.
X and Y axle movement alarm activation button. Activated
when the led is on.
Z axle locking button.
Dual range movement alarm activation button. Activated
when the led is on.
To activate: Press till the led is on.
To deactivate: Press till the led is off.
Z axle or dual range manual upward movement button.
Z axle or dual range manual downward movement button.
Z axle manual up/downward movement button or
fast-motion period heightening low-speed selection button.

In fast-motion status, the system locking is effective,
unaltered by user operation.
Keyboard locking button.
Z axle reversed movement or processing startup button.
Automatic shutdown after discharging (power off) button.
When the led is on and the positive and negative electrodes
are short-circuited, Z axle forbids the electric poles to contact
the work-piece so that damage of either could be avoided.
Oil pump activation button. Activated when the led is on.
Discharging processing activation button.
Discharging processing deactivation button.
Mirror surface special processing activation button. Not
available for the time being.
When the led is on,the coordinate system is english; when
the led is off, it is metric.

8.7. Hand-control box buttons
corresponds with on the panel
8.8. System entry procedures after password expires
1. Method 1
(1). The user may call the agent and tell him the data in Y display zone of
the 3rd system page and in X display zone of the 4th system page and the
current date (the data in X display zone of system page 0). (Please refer to
8.3.3).
(2). The agent tells the user the password.
(3). Switch over to page 1 in the system displaying status(see 8.3.3), input
the password in the Y display zone (monthly expiry date/password), then
press to complete input.

(4). Shut the system down and restart the controller.
2. Method 2 (dependent on the software version)
(1). Call the agent or the manufacturer and tell him the data displayed in
X and Y display zones of system page 9 (the current date must be correct);
when the system detects the password locking status, the 9th page is
automatically loaded.
(2). Get the password from the agent or the manufacturer.
(3). Input the password in Z axle (system page 9).
(4). Restart the controller.

Please note: when there is the system password locking alarm, it is designed,
for convenience’s sake, that automatic switchover will be made to load system page 9.
9. An introduction to deslagging and motion of oil
Deslagging means the appropriate circulation of processing liquid
between electric poles and work-pieces. As far as the discharging process
is concerned, it is so important that only the proper deslagging could lead
to the utmost processing effect.
Recently, this machine’s servo organization has undergone a very
significant improvement, which promotes the deslagging function as well
as processing the most complex prototype with no big problems.

We analyze the changes between the slots when no deslagging
process happens.
At first, processing liquid is clean because the insulation power of
clean processing liquid is better then those that have particles. Before
the first discharge occurs there is a delaying period.
After the first discharge (figure 13-1), particles are produced. The
residue produced in the slots increases gradually, thus reducing the
insulation of processing liquid. Therefore, discharge can be extended
easily (figure 13-2).
figure 13-1 figure 13-2
However, if the concentration of the particle somewhere in the slots
becomes too high (figure 13-3), it will form the second discharge between
electric poles and carbon residue, resulting in improper discharge which
will deteriorate into electric arc damaging electric poles and molds.
The particle accumulation has to be removed by deslagging, in
other words, by the circulation of processing liquid in the slot.
figure 13-3
The coordination of deslagging, discharge pulse and current is
equally important in the discharging process, which needs to be adjusted
carefully to achieve the optimum effects for the degree of process liquid
pollution.
Different deslagging methods should be employed to solve different
problems.
9.1. Ejection deslagging (figures 13.1-1 & 13.1-2)
figure 13.1-1 figure 13.1-2

This oil ejection deslagging method is to eject processing liquid
from the work-piece through an oil ejection platform or through electric
poles.
In the first case (figure 13.1-1), the work-piece has been bored and
installed on an oil ejection platform and then connected to deslagging
equipment.
In the second case (figure 13.1-2), the middle of the electric pole is
bored and processing liquid is input through the gripping head of the
electric pole directly.
Processing the work-piece by way of the ejection deslagging method
produces some slight cone in spite of the use of equilateral electric poles.
This is because the discharged particles are pressed to the two sides of
electric poles, and the side discharge caused the cone effect. This
deslagging method is usually used for pressed molds with a slight conic
slot. Of course, pressed molds must be processed from the opposite
direction to obtain the desired cone.
When drilling deep holes by using black lead, the effect of
deslagging is excellent. The high pressure processing liquid can be led to
electric poles with the latest technological developments. The
cellularity of back lead allows enough processing liquid to deslag to the
slots through the electric poles (figure 13.1-3)

figure 13.1-3
9.2. Absorption deslagging (figures 13.2-1 & 13.2-2)
figure 13.2-1 figure 13.2-2

This method allows the processing liquid to be absorbed through
the work-piece via the bottom of the hole or through electric poles.
Compared with ejection deslagging, the conic effect could be avoided
because the absorption discharges along the
particles on the two sides of electric poles.
In so doing, true cylindrical holes
Can be produced.
Vacuum absorption cannot be too
strong. In some applied cases, absorption figure 13.2-3
can be replaced by ejection so it can exceed absorption pressure (figure
13.2-3). The absorption deslagging is comparatively faster as it goes
through electric poles instead of the work-piece.
9.3. Edge deslagging
Edge deslagging is used when one or more holes can not be drilled
on electric poles or the work-piece, e.g., the process of molds for souvenir
seals and the making of plastic film for deep, narrow slots.
When edge dislagging is adopted, air spout must be adjusted
carefully. So the processing surface of the entire electric pole can be
deslagging evenly. This technique should be coordinated with the shaking
for electric poles to improve the deslagging effect.

When the plane surface is processed (figure 13.3-1), the deslagging
direction must be consistent with the shaping entry angles. When
processing molds of souvenir seals, as its longitudinal shape is not flat, it
is necessary to use a special air spout to suit it
figure 13.3-1
When the deslagging direction is not parallel with the edge of electric
pole (figure 13.3-2) , it will cause disturbing flow and defective
deslagging as only little processing liquid enters the slots.
figure 13.3-2
On the other hand, if the deslagging direction is fine (figure 13.3-3),
most processing liquid will enter the slots.
figure 13.3-3
Edge deslagging cannot be inlet from the two edges at the same time
because the two flows will counteract with each other at the bottom of the
hole and therefore cannot be eliminated (figure 13.3-4).
figure 13.3-4
In the case of rectangular slots, the processing liquid should be
directed to the longer side of the electric pole so that it can flow into the
bottom of the hole (figure 13.3-5).
figure 13.3-5
9.4. The pressing deslagging of processing liquid
Deslagging by using the interval pumping of electric poles. When
the electric pole is lifted, the slots become wide and at the same time, the
clean processing liquid will flow in and mix with the polluted processing
liquid. When the electric pole is lowered down, residue will be eliminated
(figure 13.4-1).
figure 13.4-1
This method is especially useful for deep hole processing because it
can process without pressure-added deslagging.
9.5. Simultaneous oil ejection deslagging
With metal electric poles in use to process, it can be known whether
there is any abnormal loss in the ejection zone, which increases as the
pressure of deslagging increases (figure 13.5-1).
figure 13.5-1
To avoid this, simultaneous oil ejection is introduced, which means
processing liquid is ejected while the electric poles move upward. That
also means only when the electric poles move upward will processing
liquid deslag in the slots because of the pressure received. This period is
non-processing time (figure 13.5-2).
figure 13.5-2
9.6. The technique of deslagging
The above-introduced deslagging methods can be chosen freely by
the user. In some cases, it can be used together and examples will follow.
Though these methods could not solve all problems, it is hoped that it
could contribute to the solution of all practical problems.
9.6.1. Deslagging pressure
Deslagging pressure can be measured through the manometer
installed on the processing slots.
----- Using metal electric pole processing: no matter it is ejection or

absorption deslagging, try to minimize the pressure to lower loss.
----- Using black lead electric pole processing: it is not so important what
the degree of electric pole loss, ejection or absorption pressure is.
9.6.2 Firedamp questions
If firedamp is accumulated in the ejection container without any
precautious measures, explosion is likely to occur in the discharging
process, which will lead to dislocation.
To avoid forming explosive mixture, which means the mixture of
firedamp and air, is important. So it is better to check whether the ejection
container is filled with processing liquid before starting to process.
Besides, it is necessary to check whether processing liquid is high enough
not to let in air by pumps.
To decrease the amount of firedamp in the container, it is imperative
to connect the absorption to the highest point of the container. As is
shown in figure 13.6.2-1, when absorption occurs evenly around electric
poles, more even balance and better effect will arise.
figure 13.6.2-1
figure 13.6.2-2
When processed by inner concave electric poles (figure 13.6.2-2),
firedamp will possibly accumulate in the hollow part of the electric poles.
Therefore, holes must be drilled on the electric holes upwardly to ensure
that firedamp could be released completely by way of natural releasing or
absorption releasing.
When processing large plane surface areas with the absorption
method, it is suggested to drill conic base holes and put a drilling ball
inside. Functioning as a one-way clique, it can lead firedamp out to
decrease the effect of absorption (figure 13.6.2-3).
figure 13.6.2-3
9.6.3. The use of mold backup plate
As for the processing of cylinder interlock bore, it is appropriate to
use absorption processing, but the following precautious measure must be
taken.
1. Backup plate electric poles must be adopted to let the entire
electric pole length pass the work-piece.
2. As there is a cone after processing, which is 1/10’s cm from the
processing exit, it is necessary to insert a 1cm–thick metal board made of
the same material with the work-piece between the work-piece and the
container hole to avoid the formation of cone on the work-piece. The
work-piece itself should be 1cm thicker than originally required and the
extra thickness could be worn out after the discharge (figure 13.6.3-1).
figure 13.6.3-1
9.6.4. Exemplifying edge deslagging
(a) Make a groove between the electric pole and its supporter to
ensure that processing liquid could flow from one side of the electric hole
(figure 13.6.4-1).
(b) The use of flat air spout could eject processing liquid toward the
lower part of the gripping head on one edge of the electric pole so as to
avoid the edge motion of the electric pole (figure 13.6.4-2).
13.6.4-1 13.6.4-2
(c) Processing a thin and complex shape, like an aluminous pressing
mold, it is hard to drill holes in advance because it has been heat-treated.

An excellent device can be employed and its mechanism is as
follows (figure 13.6.4-3).
figure 13.6.4-3
----- Electric hole (C) is fixed at the lower part of container B.
---- Discharge-etching an approximately 2cm–thick aluminum chip by
using this electric pole. Starting work from two directions, and work XY
(0.5cm). To expand this hole, the aluminum chip has been reprocessed.
---- Then after the aluminum chip passes through the electric pole, and is
fixed on the back surface of the electric pole’s clamping fixture. Please
note that the slot between expanded holes and the electric pole will form
a deslagging groove which allows processing liquid to deslag only from

one side downward so as to avoid the deslagging from the opposite
direction as is shown in (figure 13.3-4).
Processing this aluminum chip takes only several minutes but the
processing time gained after molding is considerably ample.
9.6.5. Lateral flow deslagging
Drilling the deslagging hole is sometimes difficult. Unless the used
electric pole is powerful enough, this deslagging technique is very
beneficial. Without this deslagging system, some discharge processing in
the production can hardly be carried out (figure 13.6.5-1).
figure 13.6.5-1
9.6.6. Amalgamated deslagging
This means the combination of absorption and ejection deslagging
which usually processes drilling jigs and pressing molds of complex
shapes. It can eliminate all firedamp and remaining particles accumulated
on the convex surface of the work-piece and ensure a fine circulation of
processing liquid in the entire processing zone (figure 13.6.6-1).
figure 13.6.6-1
10. Troubleshooting
Malfunction Solution
When the system starts and the time value Tune the potentiometer on the panel clockwise
is 0, Z axle is motionless yet manual to adjust servo tracking speed
up/down movement still works.
No sparking when the electric pole Check the conductivity of the electric pole and
contacts the work-piece and it goes the work-pieces. It could be caused by
downward to crush itself or the insulation.
work-piece.
The main axle fails to work upon startup. Check fuse FU1 on board 003
Alarm code 35 (VMOS breakdown on Check VMOS on board 004 (Contact your local
board 004) repairs service)
Alarm code 36 (problem with fuse FU1 Check and replace fuse FU1 (0.15A) on board
(0.15A) on board 004 004
Alarm code 37 (Discharge detection Check to see whether the cable on board 004
signal error on board 004) marked with “E1” is properly connected
（
Alarm code 38 (Board 003 undetected by Check to see if the 9-pin cables and plugs from
the system) board 001 to 003 are properly connected
Alarm code 39 (Board 004 undetected by Check to see if the 9-pin cables and plugs from
the system) board 001 to 004 are properly connected
Alarm code 41 (Password expires) Contact the sales-agent
Alarm code 42 (system clock halts) It’s OK if password is cleared; otherwise
contact the sales-agent.
Z axle cannot move in both directions. Check the range button.
Oil entry control tuned maximum, yet Cleanse and replace the pleated paper filter
slow inflow.
Abnormal sounds when Z axle moves Check to see whether the tuning screw of Z axle
is in good condition, and whether the main axle
belt is loose
11. Figure of the system
Board 001 Board 006

Coordinates the servo module Brain-machine interface
and the amplifier module, providing friendly and
detects and controls Z axle handy input and output
displacement interface
Board 004 Board 003

Main amplifier module Servo module
Controls forms of pulses Controls Z axle movement
and distribution of high/low for stable discharge
voltage currents
Board 005
Minor amplifier module
Drives high/low voltage currents
according to instructions from
the main module
12. Internal circuit diagram (For reference purposes only)
12.1. External circuit sketch (Drawing A)

1 2 3 4
Three-phase AC220V/60Hz input
PE1 L3 L2 L1
SB1 32A
0.5 mm2 red
D D
KM2
L1-0
L3-0
L2-0
QF1 SLP
B/C4
BH40A: 25A
BH80A: 50A K1 B/C4,G/B1
BK2
L2-5 SB2-NO
~24V
QF5 K0-2 K0-3
QF4 L3-5 G/C1
2A K0-1 3A KM2-NO
0.5 mm2
L2-1
QF3 4A L1-4 C/D1,D/D1

C
L2-4 D/D1 C
L3-1
L1-1
L3-4 C/D1
BH40A: 2.5mm2 0.5 mm2
0.5 mm2
BH80A: 4 mm2 BK1 QF6 2A
A1-1 A1-2
F-40/D2,F-80/D2
~220V
A2 F-40/D2,F-80/D2
B/C4
~110V B2 QF7 1A
B1-1
G/C1
~160V B1-2 0.5 mm2
BH40A: 2.5mm2 LV1 E/A1 D/C1
BH80A: 4 mm2 ~65V C2
LV2 E/A1 QF8 10A
~65V LV3 D/C1
B N B
E/A1 C1-2
C1-1 1 mm2
BH40A: 6 mm 2
L3-2 L2-2 L1-2 BH80A: 10mm2

L3-2 0.5 mm2 white
AC220V fan
QF9 L2-5
KM2
BH40A: 4.2KW(7.9+6.4(A)) 2A
0.5 mm2
BH80A: 8.4KW(18.3+6.4(A)) QF2
4A AC220V socket
L1-3
B/D3
L2-3
B/D3
L3-3
B/D3
A
1 mm2 Company name A
Name External circuit sketch Date 22-Nov-2007
NO. A Revision BHxxASEB
Drawn by Revised by Checked by
1 2 3 4
12.2. #001，#002 Wire connection sketch (Drawing B)

1 2 3 4
VCC
GND
PCB
PE
#002 KM3
9 x 0.15 mm2 Shielded wire
D L1-3 L1-6 D
A/A3
L2-3 L2-6 220V/60Hz Oil pump
A/A3
M
3~
A/A3 L3-3 L3-6
red K1
(#002) A/D3
UP2
0.5 mm2 UP2 G/D1
DN2
DN2 G/C1
B2
B2 A/B4
K0-6
C K0-6 G/B1 C
9 x 0.15 mm
2
Shielded wire
PCB PMP
FRDR
FRDR
SLP
G/C1
SLP A/D3
red
#001
F1-2
F1-2 D/D4
F2
D/C4 (#004) F2 D/D4
J0
J0 G/B1
J1
J1 G/B1
VCC GND J2
J2 G/B1
J3
J3 G/B1
B B
F-40/B4,F-80/B4 (#003) (#006)
VCC
GND
0.5 mm2
F-40/B4,F-80/B4
0.5 mm2
C/A1
F-40/B4,F-80/B4
Open-door power off
9 x 0.15 mm Shielded wire

2
A Company name A
Name #001，#002 Wire connection sketch Date 22-Nov-2007
NO. B Revision BHxxASEB
1 2 3 4
12.3. #003，#008 Wire connection sketch (Drawing C)
1 2 3 4
BK3
~42V
L1-4 BB3
A/C4 ~12V
BB2
D D
L3-4 ~12V
A/C4 BB1
~24V
0.5 mm2
BA1 BA2
M1
1 mm2 G/C1 M
M2 DC Speed-testing device
G/C1
G/C1 V
G/C1 0.5 mm2
BA1 BA2 M1 M2
BB3
C C
BB2 BD2
0.5 mm2
BB1
E1
E1 E/B4 G/B1
BD1
E0-1 E/A4 G/B1
PCB VM+
VM-
VM+
VM-
E0-1
4.7K
LK1
LK2
#003
RES-
RES-
RES+
RES+
LK1 E24
B LK2 PCB E0-1 B
BC1 BC1 #008 BD2

BC2 BC2 BD1
0.5 mm2
GND
VCC
Reserved for future use

0.5 mm2
GND
F-40/B4,F-80/B4
VCC
F-40/B4,F-80/B4
A Company name A
B/A1 Name #003，#008 Wire connection sketch Date 22-Nov-2007
9 x 0.15 mm2 Shielded wire NO. C Revision BHxxASEB
1 2 3 4
12.4. #004 Wire connection sketch (Drawing D)
1 2 3 4
0.5 mm2
BK4
AB2
~12V/50W AB1
L1-4
A/C4
~12V/15W
B/B4,F-80/B1
D D
F1-1 F2
QF10
~12V/15W 1A
B/C4,F-80/B1
AC2 F1-2
L2-4
AC1
~12V/25W AA1
A/C4 E/B1
~12V/25W AA2
E/B1
K0-6
0.5 mm2 G/B1
E/B1
0.5 mm2 red
16 16-pin data cable
C 9 x 0.15 mm2 Shielded wire C

0.5 mm2
AC1
AC2
RTR
K0-6
C1-2
A/B4 C1-2 B/B1
C2
A/B4 C2
HO VCC
E/D4 HO VCC
1.5 mm2 E/B4
E/A4
E1
E0-1
E1
E0-1
PCB GND
+12
GND
+12 F-40/C4,F-80/C4
F-40/C4,F-80/C4
1 mm2
#004 F1-2
F-40/C4,F-80/C4
F2
B Lout 0.5 mm2 B
E/D4 AB1
AB2
BH40A: 10mm2
BH80A: 16mm2
AP-
E/A3
A Company name A
Name #004 Wire connection sketch Date 22-Nov-2007

BH40A: 10mm2
NO. D Revision BHxxASEB
BH80A: 16mm2
1 2 3 4
12.5. #005 Wire connection sketch (Drawing E)
1 2 3 4
1.5 mm2
E0-1
HO
D/B1
D
Lout D
D/B1
BH40A: 10mm2
BH80A: 16mm2
9R/220W
36R/70W
18R/160W
150R/200W
300R/190W
4.5R/320W
3.5R/400W
3.5R/400W
3.5R/400W
3.5R/400W
3.5R/400W
3.5R/400W
1 mm2 H2
2.5 mm2
H1 I6 I7 I8
I4 I5 I10
I1 I2 I3 I9
H3
H2
H1
I1
I2
I3
I4
I5
I6
I7
I8
I9
I10
I11
I12
I13
E0-1
C C
PCB
#005
1 mm2
D/C4
JGND
AA1
AA2
J12
16-pin data cable
B 0.5 mm2 B
AA1 E1
D/C4 C/C3,D/B1
AA2 BH40A: 10mm2
D/C4 16mm2
+
BH80A:
V
0.5 mm2 300V DC voltage meter
-
BH40A: 10mm2
BH80A: 16mm2
BH40A: 6 mm2
BH80A: 10mm2 E0-1
C/C3,D/B1
LV1 0.5 mm2 BH80A：100A Direct current meter
A/B3 BH40A：50A Direct current meter
LV2
A/B3 + - 0.5 mm2
A LV3 A Company name A
A/B3
1K/10W
AP+
KM2-NC
Name #005 Wire connection sketch Date 22-Nov-2007

AP-
100A/800V Bridge
D/A1 NO. E Revision BHxxASEB
10000UF/200V 475/400V Drawn by Revised by Checked by
1 2 3 4
12.6. BH40A : #006 external connection sketch (Drawing F-40)
1 2 3 4
Power switch
D D
L N P1
(AC) +V COM2 COM1 +5V
A1-2
A/C4
A2
A/C4
VCC
B/B1,C/A1,D/B4
0.5 mm2 GND
B/B1,C/A1,D/B4
+12
D/B4
C C
0.5 mm2
PCB #006 (BH40A)
VCC GND
+ -
SPW-2
SPW-1
PW-1
PW-2
B B
0.5 mm2
PW-2
B/A1
PW-1
KM2-NC 9 x 0.15 mm2 Shielded wire

SP1
- 0.5 mm2 SB2-NC
+ SPW-1
DC12V Buzzer SPW-2
A Company name A
Name BH40A : #006 external connection sketch Date 22-Nov-2007
NO. F-40 Revision BHxxASEB
1 2 3 4
12.7. BH80A BH100A: #006external connection sketch (Drawing F-80)
1 2 3 4
Power switch
P1
D D
L N
(AC) +V COM2 COM1 +5V
A1-2
A/C4
A2
A/C4
VCC
B/B1,C/A1,D/B4
0.5 mm GND
2
B/B1,C/A1,D/B4
+12
D/B4
C C
0.5 mm2
KM2-NC
PW-1 PW-1
PW-2
PW-2
PCB #006 (BH80A,BH100A)

F2
+ -
GND
VCC
F1-2
SPW-1
SPW-2
F2
D/D4
B B
F1-2
D/D4
B/A1
SB2-NC
0.5 mm2 SPW-1 9 x 0.15 mm2 Shielded wire
9 x 0.15 mm2 Shielded wire
SPW-2
SP1
-
+ DC12V Buzzer
0.5 mm2
A Company name A
Hand-control box
Name BH80A BH100A: #006external connection sketch Date 22-Nov-2007
NO. F-80 Revision BHxxASEB
1 2 3 4
12.8. machine tool connection sketch (Drawing G)
1 2 3 4
0.5 mm2
DN2 DN2-1 15uF/400V
D UP2 UP2-1 AC110V slowing device D
M
3~
B1-2
19-pin socket
electric extinguisher electro-magnetic valve
DN2 1 1 (Reserved for future use)
B/C4
UP2 2 2
B/C4 FRDR
B1-2 3 3 K1
A/B4
FRDR
For connection with the emergency stop button for future use
4 4
B/C4 Short-circuit K0-3 and K0-6 if it is not the option
5 5 red
VM- 6 6 VM-
C/C3
C VM+ VM+ C
7 7
C/C3 M
M1 M1
C/C3
8 8 DC servo machine
M2 9 9 M2 M2-1
C/C3 V
K0-3 red
10 10
A/C3 K0-3 M2-2
K0-6 11 11 SB3
B/C4，D/C2
J3 K0-6 J3 1 mm2
12 12
B/B4 Oil level switch
J2 13 13 J2
B/B4 Oil temperature switch
J1 14 14 J1
B/B4 Flame detection
J0 15 15 J0
B/B4
LK1 16 16 LK1
B B/B4 B
LK2 LK2 Reserved for future use
17 17
B/B4
18 18 K0-6
K1 19 19
A/D3
AC24V work-lamp
K1
0.5 mm2
A Company name A
Name machine tool connection sketch Date 22-Nov-2007
NO. G Revision BHxxASEB
1 2 3 4
12.9. Output wire connection sketch (Drawing H)
1 2 3 4
This power supply is for the translatory head only.

D
It's not for lighting or any other purposes. D
Connection wire for the machine tool

19-pin socket corresponding to Sketch G
C C
X Y Z
Leakage protection switch Power socket for Air socket

the translatory head
socket for the
Wire connection poles
hand-control box
B B
L3
A1
PE2
L2
A2
A3
B1
B2
B3
PE3
L1
PE1
Red Black
L1,L2,L3: 220V/50Hz Power input

PE1: Ground output
A1,A2,A3,PE2: Output driven by oil pump A with PE2 as the ground wire
B1,B2,B3,PE3: Output driven by oil pump B with PE3 as the ground wire
A Company name A
Name BH80A：Output wire connection sketch Date 22-Nov-2007
NO. H Revision BHxxASEB
1 2 3 4
13. Consumable parts list

No. Marker Name Model Manufacturer Certification
BH80A LC1-3210-AC24V
1 KM2 Contactor Schneider CE
BH40A LC1-1810-AC24V
2 KM3 Contactor LC1-0910-AC24V Schneider CE
3 SB1 Switch LW26-GS-32/04-2 WENZHOU CanSen CE
4 SB2 Button HB22 WENZHOU ONPOW CE
BH80A DZ47-60-C50-3P CE
5 QF1 Small-sized shirt-circuiting device CHNT
BH40A DZ47-60-C25-3P
6 QF2
Small-sized shirt-circuiting device DZ47-60-C5-3P CHNT CE
7 QF3
8 QF4 Small-sized shirt-circuiting device DZ47-60-C2-2P CHNT CE
10 QF6 Small-sized shirt-circuiting device
11 QF9 Small- Small-sized shirt-circuiting device DZ47-60-C2-1P CHNT CE
12 QF10 Small-sized shirt-circuiting device
15 P1 Power switch D-50A MEAN WELL CE
No. Marker Name Model Manufacturer Certification

Input: Three-phase 220V
Output:
1.0-110V 170W
2.0-24V 70W
JBK-3
16 BK1 3.0-160V 600W Customized CE
Isolation transformer
3.65V-65V-65V
BH40A: 2.8KW
BH80A:
7KW
JBK-3 Input: Three-phase 220V
17 BK2 Customized CE
Isolation transformer Output: 0-110V 150W
Input: Two-phase 220V
Output:
JBK-3
18 BK3 1.12V-0-12V 50W Customized CE
Isolation transformer
2.0-24V 50W
3.0-36V 170W
Input: Two-phase 220V
Output:
JBK-3 1.12V-0-12V 50W
19 BK4 Customized CE
Isolation transformer 2.0-12V 50W
3.0-12V 15W
4.0-12V 15W

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Electric Discharging Machine

(Controllers of the BHxxASEB)

Machine Model： Machine No.：

Controller Model： Controller No.：

knowledge to use it to your best advantage and avoid inconveniences

caused by any possible misoperation.

This manual is for the BHxxASEB pulse controllers only.

manual which is subject to change without any prior notice.

Don’t fight fire with water.

Don’t hand-touch the electrodes.

Danger! Electric shock.

Caution! (For more, please refer to

Wear protective gloves to avoid

1. Main functions and range of uses

and medium-sized mold cavities as well as the shaping of specialized

high-strength spare parts.

manufacturing industries and the plastic molding industry.

2. Main technical parameters

2.1. Main mechanic parameters

2.2. Main controller parameters

2.3. Instructions on the protection functions of the system

(1). The flame detection function

To be activated by the user. Please refer to 8.6 for more.

The system determines whether there is flame or not based on the

detection of heat quantity. An 110V AC socket is preset for automatic

extinguishers. When flame is detected, the machining process is halted

caused by other heat sources like sunlight and workshop lighting.

(2). The oil temperature detection function

To be activated by the user. Please refer to 8.6 for more.

(3). The oil level detection function

To be activated by the user. Please refer to 8.6 for more.

(4). The open-valve power off function

power automatically. As some components in the system may remain

electrically alive, it is imperative to wait, after the main power supply is

shut off, at least 5 minutes prior to an open-valve checkup.

3. Transferring the machine tool

Before the machine tool is transferred, the X and Y axels must be

fastened with fastening boards to restrict their movements. Bad bounces,

must be appropriate; the cables must be capable of the weight 4 times as

machine must be avoided as much as possible. The contacting areas could,

if necessary, be cushioned with soft materials so that damage to the

machine could be minimum.

In the transferring process, cables must be fastened tightly to the

any of its sides or tilted; any up-lifting or down-loading movement must

After the machine is unloaded, please check if there is any damage,

before a trial operation.

Please refer to the pictures on the next page.

4. Trail operation of the machine tool

4.1. The normal working conditions of the machine tool

hours shall not be more than +350C.

When the highest air temperature around rises above +400C,

humidity shall then be kept within 40%; in lower temperatures, humidity

could be correspondingly higher but still no more than 80%; special

measures must be taken to deal with the occasional dewing caused by

with the air pressure between 86 to 106kPa.

3-phase AC220V/60Hz with voltage fluctuation ±10V allowable.

3-phase 5-wire or 3-phase 4-wire with fine ground connection

devices (Please refer to 12.6 for instructions on wire connection).

The spot to keep the machine must be fireproof. No flammable or

explosive is allowed near the machine tool.

The spot to keep the machine must be fireproof. It is imperative for

rain not to wet the machine tool.

The spot to keep the machine must be dustproof and

The spot to keep the machine must be shockproof.