manual · 3) moving the ygs-43z ①use forklift of pallet jack to move the machine. picture 2-1. a...

MANUAL

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YGS-43ZNC

Contents

1. Safety Label Interpretation ------------------------------------4~71) Explanation about the safety label -----------------------------------42) The Emergency Off Switch (EMO Switch)--------------------------------53) A word of caution for the machine’s installation ----------------------64) The product’s warranty and the liability---------------------------7

2. Operating and Installation Manual ----------------------------8~14

1) Specif ication of YGS-43Z -----------------------------------82) Procedure of removing the wooden box------------------93) Handling the YGS-43Z ----------------------------------------114) Leveling the YGS-43Z ------------------------------------------125) Connecting power to YGS-43Z ------------------------------14

3. Operation -------------------------------------------------------15~41

1) The sys tem operat ion ----- --- ---- -- ---- ---- --- ---- -- 152) The system application

① The function to set the operating values------------------ 18② Digital readout zero location -------------------------------- 20③ Digital readout center location -------------------------- 20④ MM/INCH conversion function ---------------------------- 21⑤ ABS/INC function Change ------------------------------------ 21⑥ Buzzer function ------------------------------------------ 22⑦ Z-Axis auto return ------------------------------------------ 22⑧ Z –Axis movement ---------------------------------------- 23⑨ W-Axis movement ---------------------------------------- 23⑩ X, Y-axis movement -------------------------------------- 24⑪ Spindle rotation ------------------------------------------- 24⑫ Auxiliary flushing pump ------------------------------------- 25⑬ High pressure pump’s operation -------------------------- 25⑭ Edge pickup --------------------------------------------------- 26⑮ Center point pickup ------------------------------------------- 30⑯ EP-DATA (LOAD) ------------------------------------------- 38⑰ EP-DATA (SAVE) ------------------------------------------- 39⑱ Spark Erosion --------------------------------------------- 40⑲ Changing EP-data ----------------------------------------- 41

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4. Maintenance ---------------------------------------------------44~74

1) Vertical calibration ---------------------------------------------442) Electrical parts -------------------------------------------------453) Water tank -----------------------------------------------------524) Replacement of Filter -------------------------------------------555) Replacement of Ion resin ---------------------------------------566) High pressure pump -------------------------------------------577) High pressure pump oil ----------------------------------------588) High pressure pump maintenance ------------------------------599) High pressure pump maintenance procedure -------------------6010) Head maintenance -------------------------------------------------6311) Linear Scale maintenance ---------------------------------------74

5. Frequently Asked Questions(FAQ) ----------------------- 75~78

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Contents

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1. Safety Label Interpretation

1) Explanation about a label safety

① Voltage warning label.

- “WARNING” Hazardous voltage. Touching the energized parts can cause burning, injury, even cause death. Please make sure to turn off the power before operating or maintaining the system.

② Please read the manual carefully before operating the machine

It is advisable for the users to read the manual carefully before operating or maintaining the machine for there are possibilities to cause injuries, fetal safety accidents and damages to the system, product and the equipment due to the user’s insufficient understanding of the system’s operation and the maintenance.

③ A label to advise the users to wear safety glasses and gloves.

- Before operating system, safety glasses and hand protection must be worn. Not wearing this safety equipments may cause serious injury or death.

Image 1-1 A warning label for the hazardous voltage.

Image 1-2. Please read and understand the manual before operating the equipment

Image 1-3. Safety glasses and gloves must be Worn for protection

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1. Safety instructions

2) Emergency Off Switch (EMO Switch)

!!! Warning!!! Please do not touch the machine(‘s surface) by using hands or other objects in the event of an emergency, although the operation will be stopped and the breaker inside of the machine’s cabinet will be powered off by operating the EMO and the interlock switches, the machine and the parts will still be energized.

-Before operating or maintaining the machine, please make sure to check the location of the EMO switch and understand how to use it.- Please be prepared for any possible safety accidents by regularly checking the EMO switch’s availability.

▶ EMO Operation Procedure

1. Press the emergency stop switch whenthere is a chance of danger to themachine or personal injuries.

2. After pressing the emergency stopswitch, the switch will look in recessedposition. This will prevent machine fromturning on

Image 1-4 . Pressing Emergency Off Switch and non-contact Magnetic Safety Switch.

Image 1-5. Resetting Emergency Off Switch

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3) A Word of Caution for installing the equipment

▶ Please do not install the machine in the following conditions:

( Risk of electrical shock, fire, and damage to the equipment① Avoid installing and using the machine near flammable gas and humid

places. There is a risk of electric shock, damage and fire② Avoid a places near flammable materials.③ Avoid dusty places for installment.④ Contact us before using this machine near extreme vibrations .

▶ Please read and understand this operators’ manual before running the machine.(There is a risk of electric shock, personnel injury and damage to equipment)

① When you maintain the section supposed to be energized and carry current, make sure that the system power is turned off.Turn the electrical power off before servicing the machine.

② Follow instructions when connecting power.③ Do not bend or pull the power cables and the electric cables forcefully. ④ Machine must be on the ground. Failure to do so may cause electric

shock.⑤ Do not operate the machine when power cables are exposed.⑥ Turn the main power off when an interruption of the power supply occur

s or overheating protection is running.⑦ There is a risk of electric shock. ⑧ Do not touch the terminal of controller for 30 seconds after powered off.. ⑨ Do not use this machine over its control limits. ⑩ Do not touch the machine with wet hands⑪ Cover must be installed around he rotating parts.⑫ If problem occurs, turn off the main power.⑬ Do not touch the work-piece, spindle module and electrode during

discharge machining (there is a risk of electric shock)⑭ Contact us and our agent before moving the machine or making any

changes to it.⑮ Before operating the machine over temperature limit (10℃~+40℃ ), you

must contact the distributor or the manufacturer before operating the machine.

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4) Product Warranty and Liability

▶ Warranty Limitations

Yougar M&T Inc.’s liability is void if damage to the product is caused by natural

disaster, alteration to product without Yougar Enterprise Inc’s consent, misuse or improper use of product.

▶ Warranty for the Products

① Yougar M&T INC. Guarantees that this product will be free from defects in materials and workmanship for a period of 1 year after delivery to a specified location.

② Warranty is restricted to the repair of machine itself and includes software upgrades.

③ This warranty does not apply to consumable parts and failure or damage caused by improper use of unauthorized service or consumable products..

▶ Warranty Exceptions

The following cases are excluded from the scope of the warranty.①Using or handling the machine in the improper condition and environment

where is not set forth by our catalog or additional details of specifications.②Damages caused by using spare purchases from other suppliers not authorized by

YOUGAR.③Damages caused by modifications or repairs not authorized by distributor or

YOUGAR.④Damages caused improper use of machine than is not outlined in this manual.⑤Damages due to the non-predictable reason by the level of science and

technology at delivery time.⑥Damage caused by natural disaster.


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2. Installation

1) The dimension and specification of YGS-43Z

YGS – 43Z

Max. Work piece Weight 500 Kg

Table Travel of X Y 400 X 300 mm

Z Axis Travel 400 mm

W Axis Travel 400 mm

Machine Dimensions 900 X 1000 X 2000

Machine Weight 600 Kg

Total power supplySingle phase 220V / 3KW,

50~60Hz

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2. Installation

2) Procedure of removing the wooden crate -1

① The packed condition ② Remove the ceiling board

③ Remove the front side board ④ Remove the back side board

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2. Installation

2) Procedure Of Removing Wooden Crate -2

⑤ Remove the fixed support. ⑥ Remove the left side board

⑦ Remove the right side board ⑧ Lift out the machine from the bottom using a fork lift.

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2. Installation

3) Moving the YGS-43Z

① Use forklift of pallet jack to move the machine.

Picture 2-1. A Pallet Jack

② The proper way to move the machine is by using a pallet jack or forklift from bottom.

!!!CAUTION!!!Using a crane to move the machine might cause damage to the machine.

③ Picture 2-3 shows the wrong procedure. Do not lift up the upper part of machine with crane.

Picture 2-3

Picture 2-2

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2. Installation

4) Adjusting the level (Left-Right Side) - 1

① Locate the machine leveling logs and have required tools at hand.

[ REQUIRED TOOLS]- 30mm open end wrench (1pc), precision level (1pc)(Refer to picture 2-4)

② Place the precision level of the “X” axis on the table as shown in the picture 2-5. Check the level of the machine

If the precision level leans to the right side, it means that the right side is higher.

③ If the machine is not leveled, adjust leveling legs located on the sides of the machine. By adjusting the leveling legs to clockwise direction, the machine will be adjusted down.

Adjust both legs on the side of machine until level.

Picture 2-5. Checking the level of machine

Picture 2-4. 30mm open end wrench (left) Precision Level (right)

Check the level of the machine

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2. Installation

4) Adjusting the level (Front-Back Side) -2

② Please check the slope of the machine by looking at the position of the water drop.

At this time, if the water drop lean to one side, it means that the side is higher than the other side.

③ By adjusting the leveling legs to clockwise direction, the machine will adjust down.

Adjust both legs on front or back of the machine until leveled.

그림 2-6 수평계를 이용하여 모습

Put the water drop and then check its position.

Picture 2-7. Checking the position of water drop.

① Place the precision level on the “Y” axis of the table as shown in picture 2-7. Check level of machine.

If machine is not level, adjust leveling legs located in the front and back of the machine.

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2. Installation

5) Connecting the electricity supply

① Separate the PG connector which is on the back side of the machine by turning counter clockwise and then insert the power cable into the inside of connector cover.

② Connect electricity supply(4㎟ * 3P) to the terminal case on the cover.

- Single phase 220V 3Kw (Ø2, 220V 3Kw)※ L1, MP = Ø2. 220V 3KwPE = Earth (Ground Connection)

③ After inserting the cable inside of the machine, connect the power cable to the terminal case.

Picture 2-9 PG connector

Picture 2-10 connection to terminal cover

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1) System operation -1

1. Switch-on the main power

2. Turn on the main powersource switch, which is on theright-down side of the machine.

3. When the re-set turns the power on to only the front of the machine.

※ Turning the machine power switch to the right side and the reset switch will run the machine.

※ If the inner temperature sensor is operated, push the re-set switch on.

4. When turning to clockwise direction, it comes out and off.

5. Turn the machine’s power on.※ If the machine power does not work, please check the number 3 and 4.

6. The machine is ready to operate.

Start

Main switch ON(NFB)

Re-set switch ON(Safety Relay)

Emergency SwitchOFF

(E/M Stop)

System Switch On(System Power)

Ready for Processing

Main Power Switch

Re-set Switch

Emergency Switch

Machine power switch

Alam

Picture 3-1

Picture 3-2

3. Operation

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3. Operation


1. To open the water tank drawer, lift the handle up and pull it outwards.

Caution> Handle can be locked

2. Name and configuration

① Water inflow nozzle ② Dirty water tank③ Water level sensor④ Clean water tank⑤ Water filter (SF 330)⑥ High pressure pump⑦ Auxiliary pump⑧ Ion pump⑨Filter pump

3. Fill clean water tank (A) and dirty water tank to 2/3 full.

Picture 3-3

Picture 3-4

Picture 3-5

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3. Operation


① Purge air from auxiliary pump.(Draw off air for 5 minutes.)

② On high pressure pump.(Please do not put an electrode into the spindle when purging air from the high pressure pump.)

③ Turn on air-draw off valve (A) to anti-clock wise direction and take out the air.(Emit the air enough for 5 mins.)

④ It is much easier to purge the air from the pump by opening and closing the valve repeatedly.

⑤ If water does not get pumped easily, prime pump by opening piston value with wrench, pour water slowly into the pump and close the piston value.

⑥ Pour water into the port of the pump.

Picture 3-6

Picture 3-7

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3. Operation

2) System application

A. Use X, Y coordinates to operate value.

B. Choose the axis direction.

C. Input coordinates value.

D. Choose a code.

E. Press “Enter” key.

F. Set value on control panel

① Value setting function

Choose Axis

Input value

Choose code +/-

Enter

Value setting function

Setting coordinates

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2) 시스템 활용

EXAMPLE: Setting “Y” axis coordinates value to -25.130.

Choose Y-axis.

Input “-25.130” value in “Y” axis key pad.

Choose (+/-) Direction. ※ You can skip this if value is a positive

number.

Press “Enter” Key

This will set “Y” axis at -25.130 on control panel.

① Value setting function

Choose axis

Choose Code +/-

Enter

Input value

Finish inputting the value

3. Operation


Input the value

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▶ Indicate X, Y-axis to ZERO”0.000”

A. Xo : X-axis coordinates ZERO “0.000”

B. Yo : Y-axis coordinates ZERO “0.000”

C. The coordinates indicates ZERO “0.000”.

▶ This function indicates ½ axis value.

A. Choose axis direction.

B. Press “1/2” key on control panel.

C. Coordinates will indicate midpoint pickup.

② Setting coordinates to Zero “0.000”.

Choose Axis Xo Yo

Coordinates ZERO

Done ZERO coordinates

1/2

1/2 partition function

Done ½ partition function

③ Midpoint pickup function

3. Operation


Choose the axis

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▶ Indicate coordinates panel after changing MM and INCH.

A. Push mm/inch key.

B. Lamp ON : inch setting Indicated by 4 place decimal (000.0000”)Indicates decimal point under 4 position

C. Lamp OFF : mm setting indicated by 3 place decimal (0000.000”)Decimal point under 3 position.

▶ This function is used to change ABS/INC position.

A. Absolution position(ABS) change to incremental (INC).

B. Push abs/inc key. Lamp ON : abs setting

position(value 1)Lamp OFF : inc setting position

(value 2)

C. ABS(absolution value) & INC (Incremental) indicated on control panel.

④ MM and INCH Control Panel Change.

⑤ ABS/INC Change Function

MM/INCH conversion

Changed

mminch

mm inch

ABS/INC

Finish

absinc

absinc

3. Operation


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▶ Buzzer sound occurs when electrode comes in contact with work piece when buzzer function is turned on. (e.g.) Bee sound.

A. Turn on Buzzer function.B. Turn off Buzzer function.

▶ When using pick up function, buzzer will sound if spindle rotation ad buzzer functions are both on.

▶ Z-axis’s movement will be stopped once it trips the limit switch.

→ Press Z Auto Up key.

▶ Z-axis’s movement will be stopped at once if you push the stop key although the Z axis is still moving.

⑥ Buzzer function

⑦ Z axis return

Buzzer

Done

STOP

Z Auto Up

Done

3. Operation


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▶ Use each key when Z-axis transfer.

A. Transfer quickly Z+ direction.

B. Transfer quickly Z- direction.

C. Transfer carefully Z+ direction.

D. Transfer carefully Z- direction.

▶ Can not move the Z and W axises at the same time.

Can not move the Z axis during the spark erosion

process.

▶ Use each key when W-axis transfer.

A. Transfer quickly W+ direction.

B. Transfer quickly W- direction.

C. Transfer carefully W+ direction

D. Transfer carefully W- direction

▶ Cannot move Z and W axis at same time.Cannot move W axis during spark erosion. process.

⑧ Z –axis transfer

⑨ Use each key when W-axis transfer.

Z Move

Z

Z

Z

Z

done

W Move

W

W

W

Done

W

3. Operation


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A. Y+ transfer: Turn Y-axis handle to clockwise direction.B. Y- transfer : Turn Y-axis handle in counter clockwise direction.C. X+ transfer : Turn Y-axis handle in counter clockwise direction.D. X- transfer : turn Y-axis handle to clockwise direction

Spindle

Done

⑪ Spindle rotation

▶ Spindle rotation – clockwise or counter clockwise.

A. Spindle rotates clockwise direction.

B. Spindle rotates counter clockwise.

C. Spindle rotates anti-clockwise direction.

D. Spindle stops.

▶ Even if spindle rotation is on, the spindle direction will change if switch is pressed.

⑩ X, Y-axis transfer

Picture 3-8

3. Operation

2) The system application

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⑫ Auxiliary(sub) pump

▶ Sub pump operates and auxiliary water comes out from side of guide.

A. Sub pump operates.

B. Sub pump operation stops.

▶ This function operates automatically during spark erosion process.

⑬ High pressure pump operation

▶ High-pressure pump operates and water comes out from electrode.

A. High pressure pump operates.

B. High pressure pump stop operation.

▶ This function operates automatically duringspark erosion process.

SUB Pump

Done

High Pressure Pump

Done

3. Operation


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⑭ Touch function( Edge Finger)

▶ This function is used to find edge of work piece with buzzer function.

A. Using X,Y-axis transfer handles, findedge of work piece <Picture 3-9>.

B. Using W key, bring machine Z axis down so the guide is 3mm-7mm from surface or work piece.

▶ If using small diameter electrodes, do not lower electrode more than 4mm past work piece surface.

C. Press buzzer key to turn on function.

D. Press spindle key to turn on spindle rotation.

E. Bring electrode below work piece by 3-7mmby pushing Z-key.

F. Bring electrode to work piece by using X-axistransfer handle.

Searching corner

Transfer X-axis

W

Z

Picture 3-9

3. Operation


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⑭ Pick up function (corner pickup-1)

▶Stop axis-transfer if Buzzer sound occurs.

A. Set X-coordinates to ZERO “0.000”.

B. Raise electrode above work piece surface by using Z+ key <Picture 3-10>.

C. Move X-axis towards work piece by ½diameter of electrode.

D. Zero X-axis on control panel.

E. This will be X-axis base point.

Picture 3-10

Xo

Z

X-axis semi-diameter transfer

Xo

X, Y-axis transfer

3. Operation


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⑭ Pick up function (corner pick up-2)

A. Using X,Y axis transfer handle, move electrode past the edge of Y axis of work piece <Picture 3-11>.

▶ Spindle rotation and buzzer functions must be on and if it off, switch on again.

▶ If W-axis height has been changed, bring the guide to 3-7mm above work piece surface.

B. Low electrode 3-7mm past the surface of the work piece using Z button on control panel. <Picture 3-12>

C. If using small diameter electrodes, do not lower electrode more than 4mm past work piece surface.

D. Using X,Y-axis transfer handle, move the electrode slowly towards work piece until buzzer sounds. Back electrode away from work piece and repeat.

E. Zero “0.000” Y axis on control panel.

Picture 3-11

Z

Picture 3-12

Y –axis transfer

Yo

3. Operation


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A. Raise electrode above work piece surface by using Z+ key. <Picture 3-11>

B. Move Y axis towards work piece by ½ diameter of electrode.

C. Zero Y axis on control panel.

D. Using X, Y axis transfer handles, move electrode to Zero (0.000) position in both axis <Picture 3-13>.

E. Corner pickup is complete.

F. When using buzzer function make sure that your work piece is clean. If work piece is dirty, this may lead to an incorrect reading.

⑭ Pick up function(corner pick up-3)

Z

Y-axis half-diameter transfer

Yo

transferX, Y-axis transfer

Done

Picture 3-13

3. Operation


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⑮ Pick up function ( Center point searching-1)

▶ Searching center point

A. Use buzzer function when searching for workpiece control.

Use X, Y axis transfer handles to locate outside of work piece <Picture 3-14>.- You can search either X or Y-axis first.- Once you start searching with one axis do

not move the other axis until search is complete.

B. Using W-axis, move the guide 3-7mm from work piece surface.

C. Turn on buzzer function on control panel

D. Turn on spindle rotation on control panel.

E. Lower the electrode 3-7mm past the surface of work piece using Z key on control panel.

Picture 3-14

Searching center point

W

Z

3. Operation


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⑮ Pick up function(Center point pick up-1)

A. When using X axis first, use the X axis transfer handle and move the electrode slowly towards work piece until buzzer sounds, Repeat pick up.

B. Zero (0.000) X axis on control panel.

C. Raise electrode above work piece by using Z-axis on control panel.

D. Using the X-axis, move the electrode to the opposite side of the work piece. Be sure that you are past the work piece.

E. Lower the electrode 3-7mm past the surface of the work piece using Z axis button on control panel.

F. Use the X axis transfer handle and slowly move electrode towards work piece until buzzer sounds. Repeat. Pick up.

X-axis transfer

Z

X-axis transfer

Z

X-axis transfer

3. Operation


Xo

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⑮ Pick up function(Center point pick up-2)

A. Press “½” key on the control panel. This will change the X-axis value by one half.

B. Raise electrode above work piece by using Z-axis button on control panel.

C. Using X axis transfer handle, move X axis to zero (0.000) on control panel.

D. Using Y-axis transfer handle, move Y axis to the out side of work piece.

E. Lower the electrode 3-7mm past the surface of the work piece using Z axis button on control panel.

F. Use the Y axis transfer handle and slowly move electrode towards work piece until buzzer sounds. Repeat pick up.

G. Zero (0.000) Y axis on control panel.

1/2

Z

X –axis transfer

Y-axis transfer③

Z

Y-axis transfer

Choose axis Yo

3. Operation


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⑮ Pick up function (Center point pick up-3)

A. Raise electrode above work piece by using Z axis on control panel.

B. Using Y axis transfer handle, move the electrode to the opposite side of the work piece. Be sure that you are past the work piece.

C. Lower the electrode 3-7mm past the surface of the work piece using Z axis button on control panel.

D. Use the Y-axis transfer handle and slowly move electrode towards work piece until buzzer sounds. Repeat pick up.

E. Choose Y-axis to ½.

F. Press “½” key on the control panel. This will change the Y axis value by one half.

G. Raise electrode above work piece by using Z axis button on control panel.

Z

Y-axis transfer④

Z

Y-axis transfer

Choose axis Y

1/2

Z

3. Operation


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⑮ Pick up function (Center point pick up-4)

A. Using Y axis transfer handle, move Y axis to zero (0.000) on control panel.

B. Center point pick up is complete

C. For square or rectangular work piece use same procedure <Picture 3-15>.

D. For interior center point pick up, use same procedure <Picture 3-16>.

Y-axis transfer

Done

Picture 3-15

Picture 3-16

3. Operation


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▶ Coordinates application : ABS/INC coordinates application sample -1

ABS/IN application

Searching basic point

absinc

Choose Axis Xo Yo

A. Example: For work piece similar to above use the following procedure.

B. Use corner pick up to locate coordinates 0,0. Be sure to subtract ½ of electrode diameter (Refer to Picture 10-13).

C. Set X, Y axis coordinates to zero (0.000) on control panel.

D. Press ABS/INC key on control panel to choose absolute or incremental.

3. Operation


Coordinates set (0.0)


By INC coordinates

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A. Using X, Y axis transfer handles, move to location (X) 43.7, (Y) 39.3.

B. Press ABS/INC button to incremental.

C. Reset X Y coordinates to zero (0.000) on control panel.

D. Start spark erosion process.

E. Using X, Y axis transfer handles, move to location (X) 18.5, (Y) 18.2.

Position transfer

absinc

Choose axis Xo Yo

processingSpark erosion

processing

Position transfer

▶ Coordinates application : ABS/INC coordinates application sample-2

3. Operation




By INC coordinates

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▶ Coordinates application : ABS/INC coordinates sample-3

3. Operation

2) System Application

A. Start spark erosion process.

B. Set X, Y axis coordinates to zero (0.000).

C. Using X, Y axis transfer handles, move to (X) 18.50, (Y) 18.2.

D. Using same procedure, finish the internal holes.

Spark erosion

Choose Axis Xo Yo

Position transfer

Spark Erosion



By ING Coordinates

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▶ Coordinates application: ABS/INC coordinates sample-4

3. Operation


A. Press ABS/INC button to absolute.

B. Using X, Y axis transfer handles, move to location (X) 10.0, (Y) 10.0.

C. Start spark erosion process.

D. Using the above procedure, finish remainder of holes.

absinc

Position transfer

Spark erosion

Done



By ING Coordinates

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▶ LOAD EP-DATA

A. Press EP-Data key.

B. Press number key.

C. Input data number.

D. Press load key.

E. To uninstall data input “55”.

▶ Example: Finding EP-Data “105”

A. Press number key.

B. Input “105” using number pad.

C. Press “Load” key.

D. EP-Data will be displayed in panel.

EP-DATA LOAD

No.

Data in-put

LOAD

Done

Example: Finding EP-Data “105”

LOAD “105”

No.

105” No. in-out “105”

LOAD

⑯ EP-DATA (LOAD)

3. Operation


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▶ SAVE(Installation)

A. Save the new “EP-DATA” that currently signed on panel whatever you have found.(Number Lange : 001~999)

B. Press number key.

C. Input data number (001~999)

D. Press “Save” key.

※ If EP-Data is installed on an existing data number, you will lose old data.

▶ Example: Install current EP-DATA “73”

A. Press number key.

B. Input “73” in number pad

C. Press “Save” key.

D. Installation is complete.

No.

Done

Example:Current EP-DATA installation

No.

Done

EP-DATA SAVE

SAVE

EP-DATA SAVE

In put No.

SAVE

⑰ SAVE EP-DATA (cutting technoloty)

3. Operation


Input the installed No.

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⑱ Spark Erosion

A. Starting Spark erosion process.

B. When the “START” key is pressed, this turns on the spindle rotation, high pressure pump and sup pump at the same time.

C. Stopping spark erosion process.Press “STOP” key. This will be stop spark erosion process along with spindle rotation, high pressure pump and sub pump.

D. During operating the high pressure ,sub-pump and spindle, if you press “STOP“ key, all operation will be suspended.

E. Setting Z-axis auto stop depth.

F. Press “Z” key.

G. In put depth value of Z-axis.

H. Press “ENTER” key to set depth.

▶ If not sure of what depth to set, input value largeenough to penetrate through work.

Example) Input value over 150% of work piece thickness.

▶ Once you spark erode the first hole, this will determine the Z axis depth you need.

▶ If Z-axis depth is correct, just move to the next hole location and press the “START” key.

START

START

STOP

Done

Z Auto Setting

Z

No. in put

Setting done

ENTER

Z

ENTER

3. Operation


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▶ On Arc sparking time(Time that arc sparking is on)A. Indicate the arc fire occurrence time. (ON TIME)B. If value is set high, the electricity pressure will be higher and the sparking processing will

be faster but the electrode consumption will be increased and processing hole will be bigger.

C. Setting range ( 01~32 )

▶ Off arc erosion time (Time that arc sparking is off)A. Indicate removal of the arc fire time. (OFF TIME)B. If value is set big, the electricity pressure will get lower and the sparking drilling will be

slower but the electricity pressure will be stable.C. Setting range( 01~ 32)

▶ IP peak electricity sizeA. Indicate electricity power in side of arc fire.B. B. If the value is set high, the electricity pressure will be higher and faster but the

consumption will be increased and the processing hole will be bigger. C. Setting range( 01~36 )

▶ Setting between Vg pole electricity pressure (Target processing electricity pressure)A. Indicate electricity pressure between electrode and work-piece.B. If the value is set high, the processing electricity pressure will be higher and if the value is

set low, the electricity pressure will get lower.C. Setting range ( 01~32)

▶ Sv Z-axis servo motor speedA. It indicates Z-axis servo motor speed on spark processing.B. If the value is smaller, speed is faster but processing electricity pressure might be unstable. C. Setting range(01 ~ 32) D. When processing dia.0.50mm, if the value is too lower, electrode will be bent.

⑲ Changing EP-data

3. Operation


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▶ Cap spark sub electricity (Capistor)A. Use out side sub electricity needs to process spark erosion.B. Setting range ( 01~32 )

▶ Hp high pressure pump pressureA. It controls high-pressure pump’s pressure. B. If the value is bigger, the pressure is higher and processing is faster but if small dia.

electrode sill be bent .C. Setting range (01~10)

⑲ Changing spark processing condition

3. Operation


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4. Maintenance

1) Vertical calibration-1

▶ Separate the electrode guide with wing nut (“C”)

① Place a ø6 rod in the position of electrode guide.

② Place the measurement equipment (Indicator) in the X-axis direction on the

table.

③ Move the X, Y axis to be located on the top of ø6 rod.

④ Check the verticality by moving the W-axis upward and downward.

⑤ In the case of Calibration for V-axis, use only bolts for V-axis

<Remark>

If you release the front side bolt and fasten the back side bolt, then the V-axis

will be turn into V+ direction.

If you fasten the front side bolt and release the back side bolt, then the V-axis

will be turn into V- direction

⑥ After finishing the calibration of V-axis, start the calibration of U-axis.

C

W

L Wrench3 mm

picture 4-1

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4. Maintenance

1) ) Vertical calibration-2

① Place the measuring equipment (Indicator) in the Y-axis direction on the table.

② Move the X, Y axis to be located on the top of ø6 rod.

③ Check the verticality by moving the W-axis upward and downward.

④ In the case of Calibration for U-axis, use only bolts for U-axis

<Remark>

If you release the left side bolt and fasten the right side bolt, then the U-axis

will be turn into U+ direction.

If you fasten the left side bolt and release the right side bolt, then the U-axis

will be turn into U- direction

① After calibration for V-axis, calibrate U-axis again.

② If you have calibrated U-axis, then you have to calibrate V-axis again.

※ In the case of Calibration for U-axis, use only the left and right side bolts.

In the case of Calibration for V-axis, use only the front and back side bolts.

W

L Wrench3 mm

picture 4-2

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4. Maintenance

2) Electric part -1

▶ Name and configuration

① Stepping motor drive

② SMPS 1 : 200W 24V (Input : 220V Output : DC24V)

③ SMPS 2 : 50W 24V, 5V ((Input : 220V Output : DC24V, 5V)

④ P.C.B. for motor control (Motion)

⑤ P.C.B. for control (EDM)

⑥ P.C.B. for discharging (FET)

⑦ Discharging transformer

⑧ Main power switch

⑨ SMPS 3

⑩ Transformer

⑪ Power supply (SSR, Relay, MC, Circuit Breakers, Safety Relay)

1

2

4

53

6

98

7

1011

picture 4-3

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4. Maintenance

2) Electric part -2- Electrical Diagram

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4. Maintenance

2) Electric part -3- Electrical Diagram (EDM & FET)

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4. Maintenance

2) Electric part -4


Discharging part

① Cooling Fan

220V 120 Φ

② SMPS 3

30W 12V (Input : 220V Output : DC12V

③ Terminals

V90, W0 discharging power input, output

④ Discharging P.C.B

It generates discharging voltages.

picture 4-4

1

2

3

4

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4. Maintenance

2) Electric part -5


Power supplying part

① Power Magnet S/W

② Circuit Breakers 1 (Discharging)

③ Circuit Breakers 2 (Power)

④ Relay (Power)

⑤ Safety Relay

⑥ Power input terminal

⑦ Ground Connection Terminal

⑧ Electrolytic Condenser

picture 4-5

1

2 3 4

5

6

7

8

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4. Maintenance

2) Electric part -6


Power supplying part

① SSR1 : Discharging power On/Off

WYLG1C25Z4 : Input DC 4~32V Output AC 240V (25A)

② SSR2 : Filter Pump On/Off


③ SSR3 : ION Pump On/Off


④ SSR4 : Sub Pump On/Off


⑤ SSR5 : Electric power On/Off


1 432 5

picture 4-6

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4. Maintenance

2) Electric part -7

① Transformer : Input : AC 220, 200V Output AC 9, 15V (350W)

① Discharging Transformer : Input : AC 220, 200V Output AC 35, 40, 45, 75,

80V (3.5Kw)

② Main power switch

picture 4-7

picture 4-8

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4. Maintenance

3) Water tank -1


① Nozzle for dirty water in flow

Dirty water flows through this nozzle.

② Dirty water tank.

Used water which inflows through nozzle stay here

③ Sensor for water height

When dirty water comes in contact with the sensor, the filter pump will

turn on.

④ Clean water tank

When the filter pump turns on, the clean water is stored in this tank.

picture 4-9

1

23

4

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4. Maintenance

3) Water tank -2


⑤ Water filter (SF 330)

This filter is used to clean the water that flows from the filter pump.

Replacement filter : 1. When filter does not work well

2. If filter is damaged.

⑥ High pressure pump

Creates water pressure through electrode.

⑦ ION pump

Used to maintain the ion value. Circulates water in clean water tank.

⑧ Auxiliary pump

⑨ Filter pump

picture 4-10

5

6

7

8

9

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4. Maintenance

3) Water tank -3- Maintenance of water tank

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4. Maintenance

4) Replacement of Filter

<Caution> When you release or fasten the coupling, you have to put on the protection gloves.

① Release the coupling(‘A’)

② As you push the “B” section in the direction of the arrow, push the valve in the direction of

“C”. Then the two parts will be separated each other

③ Release the socket on the filter by turning it in the direction of “D”

④ Replace the filter

A

B

CD

⑤ Assemble the coupling socket by turning it in the direction of clockwise.

⑥ Put the filter into the water tank

⑦ Fasten the coupling finally.

<Caution> Turn off the main power before filter replacement.

picture 4-11

picture 4-12

picture 4-13

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4. Maintenance

5) Replacement of Ion resin

<Caution>

※ After replacement, please clean the area near O ring” before fastening.

※ Take care of “O ring” not to lose it during replacement.

① Turn off the system and main power

② Release the ion resin tank by turning

it in the direction of “A:

③ Empty the used ion resin.

④ Fill in the new ion resin up to the

“MAX” line(2/3).

⑤ Fasten the ion resin tank by turning

it in the direction of “B:

※ Replacement cycle

For long time, if the ion value is

maintained or goes over 100, then

you have to replace it.

B A

MAX

<Caution>O ring

picture 4-14

picture 4-15

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4. Maintenance

6) High pressure pump


1

2

8

5

3

4

9

10

7

6

picture 4-16

No. Name No. Name

1 Pressure control valve 2 Oil inlet

3 Inlet 4 By-pass valve

5 Piston valve 6 By-pass outlet

7 High pressure outlet 8 By-pass outlet

9 Pressure gauge 10 High pressure pump motor

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4. Maintenance

7) High pressure pump oil

▶ High pressure pump oil checking and supplement method

1. Turn the oil gauge in counterclockwise direction and take it out upward.

2. Clean the oil gauge first and take it into oil inlet and take it out.

3. After checking the oil level, if the level is below the ‘low level’ line, then

supplement the oil up to proper level(Low ~ High).

4. You have to supplement the oil up to proper level(Low ~ High) of the oil

gauge, or up to 2/3 level of the checking window.

※ Caution : ① The supplement oil must be engine oil for diesel engine.

② The oil supplement must be done when machine is not operating

<NOTE> The oil level must be checked once in every 3 months. If the oil level is

low, it must be supplemented or changed.

High

Low

picture 4-17Oil gauge Oil level checking window

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4. Maintenance

8) Cleaning high pressure pump

▶ When it is required to clean the pump,

▷ In the case of the delayed replacement of filter or continuous use of damaged filter, some

small debris may flow into the pump.

① The small debris which flows into the pump may cause extreme changes of water pressure

and loud noisy.

② Water pressure suddenly goes down.

③ If this condition lasts for long time without any action, the piston in the pump will be

damaged.

<NOTE> Filter replacement and/or clean water tank cleaning will extend the life of the pump.

picture 4-18

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4. Maintenance

9) Method of Cleaning high pressure pump-1

그림 4-17그림 4-18

▶ Cleaning the high pressure pump

① Prepare for a box wrench(22mm) like the above picture.

Box Wrench22 mm

1 2 3

4 5 6

② Remove all bolts of the piston valve which are numbered from 1 through 6 on the above

picture.

picture 4-19

picture 4-20

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4. Maintenance


※ Please refer the above picture during assembly.

① Release and remove all bolts from 1 through 6.

② Pull out the piston valve which is below the bolts

using long-nose pliers.

③ If you give a little twist to the ‘A’ point of the

piston valve with flat(-) driver, it will separate easier.

<Caution>

Be careful not to loose and break parts during

separation.

④ Clean all parts of the piston valve.

⑤ Be sure to put all clean parts in correct location.

<Caution>

Pay attention to the direction of each parts during

assembly.

picture 4-21

picture 4-22

picture 4-23

A

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4. Maintenance


▶ The above picture is a fully assembled pump.

① Check the arrangement of pipe once more.

② Remove the drill chuck from the spindle.

③ Turn on the high pressure pump by clicking the “Flush” button.

④ Open the by-pass valve(‘B’) by turning it in counterclockwise direction.

※ Let the air go out for 30 ~ 40 seconds.

⑤ Close the by-pass valve(‘B’) by turning it in clockwise direction.

※ Do not use excessive force.

⑥ Check to make sure water flows out of spindle.

⑦ After all checking is completed, start again the machining.

picture 4-24

B

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4. Maintenance

10) Head module (Rubber O ring replacement) -1

a

f

b

c

de

g

h

ij

l

k

m

n

o

▶ <Name & configuration>

a. Spindle motor

b. High-pressure(carbide)

nozzle

c. Bracket for nozzle fixing

d. Bracket for nozzle fixing

e. Bolts for shaft fixing

f. Spindle gear

g. Timing belt (76XL)

h. Gear box

i. Ceramic washers (3 PCS)

O ring (P3, P7)

j. Spindle shaft

k. bearing (No. 6002)

l. Angular bearing

(No. 7002)

m. Bearing (No. 6804)

n. Spindle bearing housing

o. Bearing housing

picture 4-25

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4. Maintenance


그림 4-26

② Remove the spindle motor

( ※ Caution : Remove the connector)

3) Remove the Discharge Cable

4) Remove the high-pressure (carbide) nozzle

※ Caution : high-pressure (carbide) nozzle.

3ea

remove connector

3

4ea

① Take off the cover of head module

picture 4-27

picture 4-28

picture 4-26

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4. Maintenance

10) Head module (Replace “spanner” with “open end wrench”) -3

⑦ After releasing the bolts,

insert high pressure nozzle.

⑧ Blow the air into upper of shaft spindle.

(Slightly hand the high-pressure nozzle

part.)

Blow air inside

Spanner (22mm)

Spanner (17mm)

⑤ Loosen with an open end wrench the 17mm lower bolts and the 22mm upper bolts.

⑥ Release shaft fixing bolts .

picture 4-29

picture 4-30

picture 4-31

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4. Maintenance


Ceramic washer O ring : P3(2T)

O ring : P7(2T)

O ring P3 : inner diameter 3Ø 2T

O ring P7 : inner diameter 7Ø 2T

<reference>

Put the P3 O ring inside of P7 O ring.

< reference > A. Neuron bearing is not a replaceable

part. (It can be used again).

B. Assembly in reverse order. ※ Please do not use excessive force.

⑨ Separate the neuron bearing and O ring as shown in the picture and replace the O ring.

⑩ <Caution> When exchanging O rings

and bearings, lubricate them with

grease.

picture 4-32

picture 4-33

Bearing No. 6002

Angular bearingNo. 6002

Bearing No. 6804

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4. Maintenance

10) Head module (Spindle Bearing Replacement ) -1

② Remove the spindle motor

( ※ Caution : Remove the connector)

③ Remove the Discharge Cable

④ Remove the high-pressure (carbide) nozzle

3ea

remove connector

3

4ea

① Remove the cover on the head

module.

picture 4-35

picture 4-34

picture 4-36

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4. Maintenance


⑦ Remove the gear and timing belt together.

⑧ Release four (4ea) bolts of gear box

⑤ Loose with an open end wrench the 17mm lower bolts and the 22mm upper bolts.

⑥ Release shaft fixing bolts . (Picture 4-38 Release 4 bolts)

Remove the gear parts.

Release bolts (4ea)

⑩ Remove the cooper plate (A) with in

the left parts of spindle.

⑪ Remove the carbon brush (B).

B

Spanner (22mm)

Spanner (17mm)

A

picture 4-37

picture 4-38

picture 4-39

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4. Maintenance


⑫ Remove the bearing housing bolts (4ea)

⑬ Separate the bearing housing at the bottom of the spindle.

(picture 4-40)

⑮ Raise the spindle shaft and separate from

bearing housing. (Picture 4-42)

Upper bearing 1 required - No. 6002

Lower Angular bearing 2 required - No.

7002

* When replacing angular bearings, be

aware of bearing direction.

Remove bearing housing

Remove bolts (4ea)

bearing 6804

⑭ Replace the bearing in housingWhen changing bearing, be sure to lubricate it with grease (Picture 4-41)

picture 4-41

picture 4-40

picture 4-42

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4. Maintenance

10) Head module (Spindle Bearing Replacement ) -4- SPINDLE_ASSEMBLY diagram

picture 4-43

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4. Maintenance

10) Head module (Spindle Bearing Replacement ) -5- SPINDLE_ASSEMBLY_1

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4. Maintenance

10) Head module (Spindle Bearing Replacement ) -6- SPINDLE_ASSEMBLY_2

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4. Maintenance

10) Head module (Replacing the Spindle Bearing) -7- SPINDLE_ASSEMBLY_3

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4. Maintenance

11) Linear Scale

X-Axis Scale

Y-Axis Scale

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5. Frequently Asked Questions(FAQ)

▶ Is there any problem with your machine?

▷ (Here are frequently asked questions. Please read it through before

running the machine.)

1. If you cannot turn on the system, then•Check that main power is plugged in. (The machine must be grounded).•Check the main switch, which must be turned on.•Check the emergency stop button, which must not be pressed down.=> Try to turn the switch again to release the EM-stop button (Ref. Page 10).•Check a fuse in the electric module. (Check C/B in the electric module)

2. If you cannot boot the computer system, then•Check the status of thermal sensors and proximity sensors. •Check the main power switch.

3. If the water jet on the machine does not work or the water jet pressure is low:•Check the level of the water in the water tank.•Check the high pressure pump motor.=> In the case of normal operation of motor•Check the high pressure pump to make sure that it is clean.In the case of abnormal operation of motorCheck output voltage of CN8(1,3:+),(2,4: -) from FET PCB.

4. If the auxiliary water doesn’t flow, then•Check a fuse in the electric module. (Check C/B in the electric module)•Check the operation of SSR4.(Check the input voltage of DC 24V when SSR4 is on)•Open the nipple and blow out the impurities. If the motor is operating correctly. (Be sure to turn the main power off before opening nipple).

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5. If the spindle motor doesn’t rotate, then.•Check the machine power is turned on.•Check the timing belt in the spindle module. •Check and exchange the bearing in the case of breakage.

6. If the Z-axis does not come down,•Check the possibility of contact between electrode and work piece with each other.•Check the power status of Z-axis motor driver.

7. If you cannot control the pressure level, •See section on how to clean the high pressure pump.

8. If the electrode shakes a lot, •Check that the electrode is straight.•Check the condition of the SV valve. If the valve is high, the electrode might be bent.•Check and exchange the bearing of the spindle module.

9. If water flows out from the machine’s head,•Check and exchange the rubber o-ring.•Check and exchange the carbide jet nozzle.

10. If the W-axis does not come down,•Check that the main power is turned on.•Check the power lamp of W-axis driver•Check the soft limits•Newly detect the W-axis origin.

11. If the X or Y axis doesn’t move,•Check the main power is turn on.•Check the power lamp of X or Y-axis driver.

12. If the keyboard or mouse doesn’t work,•Check the connection of the keyboard or mouse•Reboot the computer system.

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13. If the discharging voltage is not generated,

•Check the C/B 20A in the electric module.

14. If the Z-axis goes up when you push the discharging button,

•Check the possibility of shortage in the head module or worktable.

•Check the C/B 20A in the electric module.

•Check the voltage reading.

15. If the size of the finished hole is not good,

•Check the size of the guide to make sure that it is the correct size at electrode.

•Check the status of guide(wearness).

•Check and modify the straightness of head.

16. If the electrode is bent during machining,

•Check the connection between the discharging cable and the worktable.

•Check the solidarity between the work piece and the worktable.

•Check the status of water jet from electrode.

•Check the SV value among the machining conditions

•Check the carbon-brush in the head module.

17. If the electrode travels too far after completion of drilling,

•Check to see if the Zs valve is too large.

•Check the input value for work-piece height.

18. If you cannot drill through the work piece,

•Check to see if the Zs valve is too small.

•Check the input value for work-piece height.

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19. If the clean water tank does not filter the unclean water,

• Check the status of filter and change it if necessary.

• Check and clean the hose leading to the filter.

• Check the status of inhalation tube whether it is bent or leaking

• Check and clean the checking sensor for water level.

• Check the operation status of filtering pump.

20. If the ION value does not go down,

• Check and clean the ion sensor in the clean water tank.

• Exchange the ion resin.

• Check the working status of the ion pump.

• Check and clean the ion by checking the sensor in the purifying module.

manual · 3) moving the ygs-43z ①use forklift of pallet jack to move the machine. picture 2-1. a...

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