FW-005

Jul. 2008
Topics:

1． FW P01.02 UPGRADE
2． RETROFIT OF UVZ AXES DRIVER
3． ALIGN THE WIRE GUIDE
4． CHANGES OF CPU BOARD
5． WIRE DRUM COVER SWITCH
6． FIKUS SOFTWARE UPDATE
7． MODIFY GUIDE PULLEY ASSEMBLY
8． DIC-206 WIRE-DIELECTRIC

1． FW P01.02 Upgrade

From May 2008, the software of FWP machine was updated to version 01.02 in production.
Introduced from:
FW 1P 006-001
FW 2P 006-001
FW 3P 001-003

Points modified in this his version:

a. During the HALT status (M00, pause and wire breakage) of erosion, the axes (wire) can
be moved away from the current point by jog to do the wire-threading or observation, and
then back to the pause point to continue the cutting. In previous version, only one cycle of
this movement can be implemented, and from this new version, there is no limit anymore.
b. Correct bug: axes cannot back to the pause point if power failure occurred when axes
moved away from the Pause Point;
c. Switch off the erosion current during the delay of NC segment switching to avoid stripe.
d. Improvement: the wire speed settings changed to winding speed (low speed)
automatically if the wire breakage occurred.
e. New trim technology C825 introduced，and the wire speed of C821~824 optimized.

Retrofit policy:
It is recommended to update all the FWP machines in market to FWP 01.02.

2． Retrofit of UVZ axes driver

For FW machine with Z axis NC control, it is found in July 2008 that the UVZ axes driver board (p/n:
380506444) has risk of short circuit--- there is no insulated plate between radiator and PCB board,
just a layer of insulated paint. Air humidity and dust may cause the short circuit of power supply,
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Jul. 2008
and then burn the power supply fuse.
In order to fix the problem, 4 insulated plates have been mounted under the radiator on new
produced machine. Refer to pictures below:

Cut from Middle

Retrofit policy:
It is recommended to update all machines related; the insulation plate is free of charge for
the machines under warranty and out of warranty.
Machine concerned:
FW 3 All
FW 2P 001-001 to 007-005
FW 3P 001-001/001-002/001-003

Upgrade procedure:
Please order the insulation plate for all the related machines ((p/n: 333505233, two pieces per
machine), and update them during the customer visit (note: the case is not so urgent, but must be
done on each machine).

In case of UVZ board broken or the customer is very sensitive, you can substitute the board
directly. BAC can provide this board free of charge just when the machine is under warranty.

3． Align the wire guide

For the FWP produced before, the assembling procedure was not so strictly defined at beginning
--- the position of wire guides and wire guide wheels are not well aligned during assembling. So
the wire guide will be wore out after several months running (refer to picture below). And now, the
new assembling tool and nozzle plate have been introduced in production
line to avoid this kind of problem.

Retrofit policy:
It is now recommended that to adjust the wire guide position for all
FWP machines related machines, and also teach the customers to do it
in future.
Machine concerned:
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FW 1P 001-001 to 004-006
FW 2P 001-001 to 004-007
FW 3P 001-001 to 001-003

For the adjusting theory, please refer to the sketch map showing below:

Note: the red parts are to be aligned at each step.

Adjusting procedure:

1. Align the upper wire guide and lower wire guide wheel.

Remove lower wire guide or nozzle

plate, locate Z axis at 150mm height;
align the lower guide wheel and
upper wire guide, then set UV
coordinate to zero.

2. Align the lower wire guide with lower wire guide wheel.
Fix the nozzle plate and wire guide holder (without wire guide) to the lower arm, then locate the
wire at the center of the hole by eyeballing or ruler (tolerance< 0.2mm), finally tighten lower nozzle
plate.

Note: For machines produced before, the dimension of nozzle plate isn’t suitable for the
adjustment; you should enlarge fixation holes by grinding or substitute with a new one. The P/N of
new nozzle plate is 333.012.208.
Refer to former and new plate below:
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Jul. 2008

3. Align the upper wire guide wheel with upper wire guide.
Fix lower wire guide, and remove upper wire guide from its holder. Thread wire, and adjust the
upper guide wheel seat to let the wire locate at the center of the wire guide holder hole, then fix the
upper wire guide wheel seat.

4. Wire alignment
Please fix upper wire guide, and align wire again by alignment device. The different of UV
coordinate should be less than±0.20mm. Finally, please set U and V to zero.

4． Changes of CPU board

The default CPU board of FW P machine is ECB-641. But for the supply shortage reason in April
and May, there are about 27 units of CPU board AR-B1479 temporarily used in FW P product.
Machine concerned:
FW1P from 004-004 to 005-010
FW2P from 004-005 to 005-004
FW3P no relevant

For communication protocol reason, one RS232 - RS485 converter was applied on the 2nd serial
port of AR-B1479 board, to control the frequency transducer (inverter) of wire-drum motor. The
converter and cables are included in the package of AR-B1419 board, and no individual part
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Jul. 2008
number. The CPU main-board AR-B1419 (left) is compatible with ECB-641 (right). In case of
replacement, you should dismantle CPU board AR-1479, RS232 - RS485 converter and relative
cables.

AR-1479 ECB-641
Additionally, network function of this AR-1479 board isn’t compatible with system software, the
LAN port may not work properly in most of the case, so AR-1479 board is cancelled and no more
used on FW P machine. In case of customer needs and machine under warranty, you can
substitute this board free of change with a new ECB-641 CPU board. The part number is:
ECB-641 PN: 362505651

5． Wire drum cover switch

According to market requirement, we changed wire-drum protection switch to 3 positions---close,

open, unlocked (manual).
Introduced from:
FW 1P 007-002
FW 2P 007-003
FW 3P 001-007

Refer to the two kinds of switch hereunder:

Two state switch（p/n: 343502696） Tri-state switch (p/n: 343508397)

Thus, operator can draw out switch bar manually to disable the switch, and then starts the wire
drum motor without cover during wire winding. But for safety reason, operator must reset this
switch during normal situation.

Retrofit policy:
For the machine under warranty, sales company can order one Tri-state switch free of charge for
each machine if customer requests to do.
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Jul. 2008
6． Fikus software update

From July 2008, Fikus software was updated to Fikus visual CAM Ver13.6.30.

Some new functions added in this version:

a. DXF import/export funciton.
b. Technology point editing function: G36/G37 code can be inserted at a certain segment.
c. RS232 communication function.
d. Refreshed Chinese, English, Portuguese and Spanish manual.
e. Correct M00 position error and also semicolon missing problem.
f. Optimize gear program edit, reduce quantity of curve segment.

For former Fikus version, please update it according to customers’ requirement. If needed, please
contact Custcare Beijing to get relevant update installation files.

By the way, there are two kinds of software package (including the hardcopy of training manual).
Refer to the photos below:
a. Fikus 2D(English) software (pn: 372508369)

Installation
Guide (E)

Training Installation
manual (E) CD (E)

Dongle

The CD contains installation program, license code and Chinese, English, Portuguese e-manual.

b. Fikus 2D(Chinese) software (pn: 372508463)

Installation
Guide (C)

Training Installation
manual (C) CD (C)

Dongle

The CD contains installation program, license code and Chinese, English, Portuguese e-manual.

For the former FW P machines that shipped without training manual, we will send you the
hardcopy of training manual recently.

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7． Modify guide wheel assembly

For market requirement and design improvement, the structure of guide wheel assembly was
modified again.

Machine concerned
FW and FWP machine

Please refer to the drawings below:

387009208 387015111 387017373

Compare with former guide wheel assembly (middle one, p/n: 387015111), one bearing (p/n:
321004104) was canceled from the new guide wheel assembly (right one, p/n: 387017373), and
two sleeves (p/n: 333015109) were substituted by a new sleeve (p/n: 333003935).

387009208 Guide wheel assy. (cancelled from ME120） Guide wheel pn: 335000972
387015111 Guide wheel assy. (cancelled from ME283） Guide wheel pn: 335015107
387017373 Guide wheel assy. (compatible with both） Guide wheel pn: 335015107

The guide wheel assemblies are compatible with each other completely, please order the new
guide wheel assembly or relevant guide wheel and bearing according to customers’ need!

8． DIC-206 wire-dielectric

Just now, the default dielectric of FWP machine is DIC-206(10Kg/bucket, p/n: 371450525).

DIC-206 is water reducible concentrate of energy-saving and waste less-emission properties. Its
erosion resultant is removable by deposition or filter, and there is no dirt stuck on cutting surface.
Oral Acute Toxicity Test result is "non-observed toxicity”.

In addition, to reduce the spume caused during dielectric cycle, each bucket supplied with a bottle
of defoamer. Refer to pictures below:

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Defoamer

Front

User Instruction is under the label in back side.

Instruction

Back
Suggested dilution ratios：
To dilute one part of DIC-206 with 5.5 parts of water and make the solution uniform, then using
refractometer checking the dielectric concentration. Keep this concentration, and check every time
when more water or DIC-206 filled. (The concentration will be increased after several days if no
more water filled because the boiling point of DIC-206 is higher than water).

Instruction:
1. Shaking the bucket before pouring out the liquid.
2. The dielectric must be filtered for keeping better machining effect and longer life time.
3. It is necessary to check the dielectric concentration every shift, and make up some water or
DIC-206 to maintain the dielectric concentration at a suitable level(16.7%~19%), so as to keep
the refractometer reading in the range of 11.0~12.5
4. When using DIC-206 instead of emulsion coolant, the whole circulating system, after draining
off the used emulsion, should be cleaned out throughout, and the erosion energy can be
increased.
5. If there are some oxidation products leaving on the machined surface of workpieces after
operating with DIC-206, wiping by alcohol or using grit blasting can renew the metallic color.
6. Rust protection of workpieces and other ferrous metal parts must be done every week: using
1:5 dielectric coating on the surfaces to be protected with brush.

Special notes:
1. It is normal that the dielectric will become darker after several days, but it
is no effect on the performance if the dielectric well filtered.
2. Don't use high salt water. The best effect is using DI water.
3. It is possible to appear electrochemical etching might occur on the
aluminum wire-drum if the surfaces of aluminum wire drum have not been hardened.

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4. Do not take internally.DIC-206 can be harmful if swallowed, although rat oral acute toxicity text
result is non-observed toxicity. It is not known to be a skin irritant, but it will cause eye irritation.
In case of contact with the eyes, flush immediately with plenty of water for at least 15 minutes
and get medical attention. Inhalation of high concentration of mists may produce mucous
membrane irritation, therefore, an adequate ventilation is recommended. DIC-206 should not
pose a hazard to health when handled appropriately during industry use.

Storage and Handling:

Please store it in indoor condition above 5℃. DIC-206 is easily handling under ordinary
commercial conditions.

Typical properties：
Concentrate (Q/CY DSR 004-2006)
Item Technical parameter Test method
Appearance Light yellow liquid
Concentrate
pH 8.2～8.6 GB/T 6144/5.5
Working fluid (20% in DI water)
Appearance Translucent liquid
Rusting test Flat cast surface 24h
GB/T 6144/5.9
35±2 ℃ Stacked cast iron cylinders 4h
Cast iron 48h
Corrosion test
Copper 24h GB/T 6144/5.8
55±2 ℃
Aluminum LY12 48h
Foam test Foam height 5 min < 2 ml GB/T 6144/5.6
pH 8.2～8.5 GB/T 6144/5.5

Defoamer liquid:
For plenty of foam often appears in using this dielectric, we need to put several drops of defoamer
liquid where foam appears and water outlet of worktank. The addition of silicone defoamer may
create operation problems on the downstream processes, such as plating, painting because of
"fish eyes" forming in the finishing surface.

Remarks:
As the DIC-206 is just for Chinese market before, the label and instructions accompanied with the
bucket are all in Chinese during this period. Just now, we have asked supplier to add English
instructions for the export machines, and also the related information will be put in the User
Manual in future.

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