EDM WIRE CUTTING MACHINE

OPERATIONAL MANUAL

MODEL: DK77 series

(Control cabinet)

TAIZHOU HITECH NC MACHINE TOOL CO., LTD.

Safety protection of digitally controlled cabinet

I This digitally controlled desk cabinet is powered by 220V10% and 50HZ AC. The
vertical cabinet is powered by 380V10% and 50HZ AC. The power is not more than 1KW.
The power is not more than 1KW. If the voltage fluctuation is bigger, the electromagnetic
voltage regulation power can be installed.
II Single-phase and three-wire plug is used for the desk cabinet. The middle pin of the
plug (namely PE end) should be earthed. The screw on the below shell should be earthed
(with PE flag).
III The vertical cabinet should be powered by 380V10% and 50HZ three-phase and
four-wire power and 4-core jacket (1 pin is connected to N neutralized line). The pin 2, 3
and 4 respectively connect L1, L2 and L3 line. The earthing wire is connected to the
screws on the vertical cabinet shell (with PE flag).
Do not connect three phase lines to the neutral wire or PE terminal. Otherwise, it will burn
the machine and endanger the operator.
IV The vertical cabinet is equipped with the emergency stop button and the power
should be instantly cut off in case of an emergency.

We do not assume any responsibility for the physical body safety

accident caused by incorrect wiring.

Operation instruction:
This wire cutting control cabinet is a new-generation product which is developed by
us according to market requirements for the wire cutting controller and integrates
strengths of different control systems. This control cabinet is composed of computer
(including programming and control integrated software) or single-board device,
high-frequency power supply and driving power of the step motor. This cabinet uses the
analog and digital oscillation integrated circuit and power amplification circuit with the
high-power VMOS field effect tube, features simple structure, stable performance, easy
operation, high machining efficiency, intuitive and accurate selection of electric machining
parameters and high output power and is ideal for fitting of new machine tool and
rehabilitation of the old machine tool.

Chapter I High-frequency pulse power

(I) Main technical specification
1 Pulse of output matrix: pulse width: ti
pulse interval to
2 Machining voltage:

60~95V

3 Machining current:

0.3~6A

4us~60us

2~15ti

4 Power output: optional K1~K9

5 Maximum machining thickness:

400cm

6 Maximum machining efficiency: 120 (thickness of working part: 50~80cm)

7 Environmental temperature: 0~40
8 Relative humidity: 85%25
9 The elevation is lower than 1000m.

(II) Main structure and working principle of circuit

This power is composed of main oscillation circuit, pulse width adjustment circuit,
pulse interval adjustment circuit, power amplification driving circuit, high-frequency signal
sampling circuit and rectifier circuit. Its framework is shown as the following figure.
Pulse width

and

interval

Main
oscillation
circuit
Adjustment
circuit

Power
Working

part
amplification
Molybdenum
circuit
wire

Sampling circuit

Computer

Main power

The main oscillation circuit can generate the main frequency pulse via 4MHz crystal
oscillator and output 250KHz (the pulse width is 2us) and 625KHz (pulse width is 8us)
square wave pulse via the frequency division circuit. The 2us square wave is inputted to
the pulse width adjustment circuit. At this tie, the input wave form of the OR gate is
generated by the pulse width and interval adjustment circuit according to the required duty
ratio. The pulse interval is adjusted by selecting four single-knife and one-close switch.
The quantification ratio unit of the pulse adjustment is 4us. The pulse interval can be
adjusted within 1-15 times of the pulse width. After the wave form is amplified by the front
circuit, it will drive VMOS power tube and output stable and orderly machining signals.
The power amplification circuit uses 9 high-quality high-power VMOS field effect
tubes and 9 selection switches. The VMOS tube features quick on/off speed, voltage
driving and high output current, so this pulse power features simple line, stability, reliability

and easy repair. Different performances should be better than the traditional
high-frequency pulse power.
The DC power is composed of the bridge rectifier circuit, provides the power to the
main oscillation circuit, power output circuit and driving circuit of the step motor and
features simple line, stability and reliability and easy repair.

Chapter II Operation
I Operation
1 To connect the power of the control cabinet and turn on the main power switch, the fan
inside the control cabinet will rotate.
2 9 high-frequency power tube selection switches control output of the high-power VMOS
field effect tube, the number of the power tubes can be flexibly selected according to
the different cutting process requirements to get higher average machining current.
3 The pulse width is selected via 4 ship-shape switches, including 4us, 8us, 16us and
32us switch. The pulse width is calculated via addition. E.g. when 8us and 16us switch
are closed, the cutting pulse width is 32us (8+16). In a word, smaller pulse width and
lower machining energy indicate better finish of the machining working part, but the
speed is lower.
4 The pulse interval is selected via 4 ship-shape switches, including 1, 2, 4 and 8 switch.
1-15 levels are optional. The pulse width is calculated via addition. E.g. when 2 and 4
switch are closed, the pulse interval is 6 (2+4), namely the pulse interval is 6-time
pulse width. In a word, bigger pulse interval and smaller cutting current and energy
facilitate machining of the thick working parts.
After above machining, the machine tool can enter the normal machining state.
II Selection of high-frequency electric parameters
Cutting example (only for reference)
SN

Thickness
of
working part
mm

Machining
current
A

Pulse
width
us

Pulse
interval

Power
tube
(piece)

Cutting speed
2
mm

/min

20-30

1.5

12

30

30-50

2-2.5

24

3-4

50

60

2.5

36

4-5

80

80-100

2.5

48

60

150-180

2.0

40

40

25-280

2.5

48

40

Chapter III Notices

I The power jacket should have better earthing line.
II The control cabinet should be installed with the axial flow fan. You should frequently
check and clean dirty to guarantee normal operation. Otherwise the blocked ventilation
will increase the temperature and damage the power tube and component.

III If the high-frequency power processing parameters are changed in processing, it will
easily break the silk, so the parameters should be changed quickly when the
molybdenum silk canister converts the direction.
IV To reduce the high-frequency loss and improve productivity, the control cabinet should
be near to the machine tool as closely as possible.
V To stabilize cutting and make the control cabinet operate well during operation, the
stabilized power should be installed on demand.
Chapter IV Pin definition
25-core definition table of power amplifier
1

10

11

12

13

+12V

XA

XB

XC

Take -

Take
+

0V

Cut
off

UA

UB

UC

XD

XE

14

15

16

17

18

19

20

21

22

23

24

25

YA

YB

YC

Power
off

Power
off

Cut
off

VA

VB

VC

YD

YE

30-core definition table

1

10

11

12

13

14

15

12V

12V

XA

XB

XC

XD

XE

YA

YB

YC

YD

YE

Wor
king
part

Positive
for sample

Speed
variation
1

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

Spe
ed
vari
atio
n

Neg
ativ
e
for
sa
mpl
e

Mol
ybd
enu
m
wire

Hig
h
freq
uen
cy
off

Hig
h
freq
uen
cy
off

Po
wer
off
1

Po
wer
off
2

UA

UB

UC

VA

VB

VC

Speed
variation 3

Common
for speed
variation

The pin 15 of 30 cores connects the speed adjustment end M3 of the frequency converter
and the pin 16 connects the speed adjustment end M4 of the frequency converter.
The pin 29 connects the speed adjustment end M5 of the frequency converter and the pin
30 connects the public end GND of the frequency converter.
The above four pins can be used in multi-time cutting cabinet.

Definition of AB pin of power amplification board

XY axis
A1

A2

A3

A4

A5

A6

B1

B2

B3

B4

B5

B6

V+

X1

X2

X3

X4

X5

Y1

Y2

Y3

Y4

Y5

V-

B1

B2

B3

B4

B5

B6

V1

V2

V3

UV axis
A1

A2

A3

A4

V+

U1

U2

U3

A5

A6

V-

Chapter V Troubleshooting
When the system fails, you should analyze the problem, find the problem root and solve it.
1 No high-frequency output
Check high-frequency part. To press the high-frequency self-calibration button on the
front panel, when at least one power tube switch is on, the self-calibration button
should be on. If so, it indicates that the high-frequency part is normal. Otherwise, the
high-frequency party fails.
When the high-frequency part is normal, if there is no high-frequency output, generally
it indicates high-frequency failure of the switch of the computer and reversing switch of
the machine tool or disconnection of the connection line.
2 Over current
Generally the power tube breaks down or the components such as FR607 are short
circuit.
3 Out-of-step of motor
The phase lack of the phase motor will lead to operation exception of the step motor,
so this failure should be solved. When the rectifying voltage is normal, you can
determine that the phase lack is caused by the control card or power amplifier via the
following method. Connect the negative pole with the black pen of the multimeter and
connect the pole D of each Z44 with the red pen (namely heat radiator). If the
computer operates on this shaft, this tube should fluctuate in check. The fluctuation is
about 5~12V. If this circuit does not fluctuate, this circuit fails. To connect the pole G
with a red pen, the fluctuation is about 5~8V. If no fluctuation occurs, generally it is
caused by the control card failure. To measure the resistance between the pole G and
S, if the resistance is smaller, Z44 is damaged. Generally this resistance is about 20K.
4 No outage memory
Generally the battery on the control card has no power or falls off.

Power amplification principle drawing (only for reference):

220V~

12V~

QL-40A-400V

100

1N4007
20K

Vcc 1
V
IN

10000uF/25V

12V

UA

100

20K

6/50W

Z44

XY

10

LED

4.7K

UV

YE

VC

100

100

1N4007

LED

4.7K

1000uF/25V

4/50W

Z44

7812
V
OUT
GND
3

XA

3
1

1N4007

1N4007

20K

20K

4/50W

Z44

6/50W

Z44

Vcc

LED

4.7K

Vcc

LED

4.7K

FR307

82V~
1

1N4007

74V~

V+

58V~

V-

+
A
-

50V~
3

104

66V~

AC

AC

220V~

300/75W

High-frequency principle diagram (only for reference):

K1

K1

10/75W

10/75W

104

104

9
IN

Q1
IRF640

Q9
IRF640

100
1N4744

1N4744

100
10K

10K

Wiring diagram of desk cabinet (only for reference):

AC13V
K1~K8

13 0

10/75W

FR607*2

300/75W

C10

INT

50 58 66 74 82

12

C32

AC

AC

0V

16PIN

16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1

AC

V-

AC

30-19 25-1
V+

A
+

220 220

25-7

6.8K

1N4007

30-20
25-8

+
30-18

16PIN

30-13

25-20

AC13V
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1

A4

A5

A6

A7

A1

A5 B3

A6 B4

A7 B5

A12 B6

A2

A8 B1

A9 B1

A10 B1

A11 B1

A3

B2

B2

B2

B2 B13

A16 B10

A15 B9

A14 B8

A13 B7

B12 B11

B1 B1

B1 B1
16

B1 B1
8

B1 B1
4

B14 B14

32

0V

104

B2

OUT

Wiring diagram of vertical cabinet (only for reference):

K1~K8

300/75W

FR607*2

10/75W

INT

0V

16PIN

L-

16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1

30-19 25-1

AC13V

25-7

13

23

12 12 12 73 58 73 58 73 58

L+
6.8K

1N4007

U3 V3 W3

13

24

24

0 6.3

+
30-18

16PIN

30-13

OUT

25-20

220V

JT

PE

PE

0V

AC13V

104

16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1

380 380 380 0

30-20
25-8

24V1

24V2

13

HLV
73 73 73

JT U1 V1 W1

58 58 58

P4 P5 P6

U3 V3 W3

12V 12V 12V

24V1

2.5mm
N

U3

P1 P2 P3

U3

SB U2 V2 W2
1
N

2
U1

V1
3

W1
4

P1 P2 P3

U2 V2 W2

P1 P2 P3

F4 F5 F6

51

DZ47-63-D10

DZ47-63-D10

DZ47-63-D32

DZ47-63-D3

51

3TH82-62E 220VAC
KM1

3TH82-44E 24VAC
KM2

U1

JT

SB

W3

A4

A5

A6

A7

A5 B3

A6 B4

A7 B5

A12 B6

A8 B1

A9 B1

A10 B1

A11 B1

A3

A1

V-

V+

L-

100A
F4

F5

F6

P4

P5

A B

V+

Y2 30-9
Y1 30-8

30-25 U3
30-24 U2

V3 30-28

30-23 U1
V+

V2 30-29
V1 30-30

B2

B2

B2

B2 B13

A16 B10

A15 B9

A14 B8

A13 B7

B12 B11

B1 B1

B1 B1
16

B1 B1
8

B1 B1
4

B14 B14

32

VY5 30-12
Y4 30-11
Y3 30-10

30-3 X1

P6

A B
V-

30-7 X5
30-6 X4
30-5 X3
30-4 X2

B2

L+

100A

A2

24V2
HLV