Diamond Wire Technology CS400, Instruction Manual

Page 1: ...INSTRUCTION MANUAL Millennium Series Capstan Saws Models CS400 CS410 CT400 CS810 and CT800 Diamond Wire Technology 1605 S Murray Blvd Colorado Springs CO 80916 719 570 1150 719 570 1176 FAX ...

Page 2: ... of your new wire Saw By carefully following these instructions you are assured of obtaining the best results possible with this equipment In the event you experience difficulty with the operation of your saw or if you have special cutting problems please call us at 800 237 6792 and ask for technical assistance We are always at your disposal for consultation and service ...

Page 3: ...________________________________________________________10 Automatic Mode _______________________________________________________________________________10 Wiring the Saw________________________________________________________________________________ 18 Wire Break Detection ________________________________________________________________________ 18 Removing a Worn Wire ____________________________...

Page 4: ...meter and flexibility of diamond wire a small angle forms between the part and the pulleys as cutting proceeds It is in fact this wire bow that imparts the necessary force upon the specimen and allows cutting to occur The saws incorporate a Bow Sensor which continuously monitors wire deflection and automatically adjusts the velocity of the yoke drive to maintain a constant bow and hence a constant...

Page 5: ...s active whenever the wire drive is in operation The connector AMP 206429 1 is available from several electronic suppliers Drain Connection The base of the saw is designed to contain cutting lubricant if your application calls for it Two 3 8 push to connect fittings located on the rear of the saw should be plumbed with a drain hose to carry away excess fluids An overflow slot is cut near and above...

Page 6: ...the wire on the capstan Every wire on the capstan should rest in its own groove There should be no wire loops crossed over one another on the capstan Observe the wire on the capstan There should be no more than one or two empty grooves on the capstan below the wires entering and exiting the capstan The wire should be seated in the groove of each of the four pulleys Note that the entire strung wire...

Page 7: ...s not enough slack in the cutting wire remove the end of the wire from the capstan pull about 6 of wire from the capstan and reinsert the wire end back into the next retaining hole and secure it 6 Making sure that the wire is strung over all four pulleys loosen the wire end in its capstan retaining hole pull through any excess slack and retighten 7 Turn down the air regulator to 2 or 3psi and swit...

Page 8: ...sary setup screens Controller Box WIRE SPEED control Controls the speed of the cutting wire Typically you will turn the wire Speed control to near 20 to before motion begins This is the minimal motor drive current necessary to overcome initial stiction LCD display the 20 character by 2 line alphanumeric display provides a means of prompting the operator for necessary programming and operational in...

Page 9: ...WIRE only when wiring the saw Control Box Rear Tensioner RUN WIRE Switch Located adjacent to the air controls this switch should be in the RUN position for normal operation Set this switch to WIRE for wiring the saw or for adjusting the tensioner pulleys Power On Apply power to the saw by flipping the Power switch upwards A red section of the rocker appears When power is first applied the LCD scre...

Page 10: ...re Speed control up to a setting you desire Make note of the value indicated on the wire Speed control You will want to set the wire Speed control to this value prior to starting a cut program in Automatic mode To turn off the wire drive press the RESET button or turn the wire Speed control to 0 If you have pressed the RESET button the green button illumination will extinguish Jogging the Actuator...

Page 11: ...s turned on Each step of the stepper motor results in a movement of 0 00025 inches or 0 00635 mm if configured for metric display Press the up arrow to move the table forward in the positive direction towards the stepper motor Press the down arrow to move the table backward in the negative direction away from the stepper motor A quick tap on either the up or down arrow key results in a single step...

Page 12: ...ction Press the down arrow to move the rocker in a counter clockwise CCW direction A quick tap on either the up or down arrow key results in a single step Press and hold one of these keys and the rocker moves continuously at a slow rate of speed The jog rocker action has only one speed Position recommendation As noted above the absolute position on all axes is set to zero at power on Since zero or...

Page 13: ... This parameter affects display units only Actual program parameters are stored internally in machine units Therefore you can change the display units at any time and the stored program functions as intended in either case Calibrate Bow Sensor This function is explained under Bow Sensor Calibration in the Adjustment and Maintenance section Automatic Mode Automatic mode steps the operator through a...

Page 14: ...m are to be the same thickness 4 Use the up and down arrow keys to specify the slice thickness If variable slice thickness was selected in the previous step then you are prompted to enter a thickness for each slice in turn The following steps 5 6 are for Dicing Saws only 5 Use the up and down arrow keys to specify an angle of rotation prior to the next cut sequence If you enter a non zero value th...

Page 15: ...inate backlash within a multiple sequence program Enter an Index Table value greater than what is necessary to move the table back beyond the specimen and fixture Enter a Number Of Cuts value one greater than what you actually intend to cut If you must over index the table back more than one slice width set the Variable Width feature to yes and enter the over index distance for Slice 1 Width Enter...

Page 16: ... speed You have three choices slow medium and fast 10 Use the up and down arrow keys to select between Bow Calculated or User Specified for the Yoke Velocity Method Bow calculated You specify a target bow angle and the controller automatically adjusts yoke velocity to maintain the desired wire bow Proceed with Step 11 User specified You specify fixed velocity values to control the downward motion ...

Page 17: ... specify a percentage of the total cut depth for which the indicated velocity is in effect The control program allows you to specify from one to three different yoke velocities for a single cut Through experimentation and experience you can find a velocity profile that results in the best possible cut in terms of quality and time One possible scenario would be to start relatively fast just to brin...

Page 18: ...ore the cut is considered complete Typically the yoke moves ahead of the cut to maintain a slight bow in the wire which applies more downward force on the cutting surface resulting in a faster cut Dwell allows the wire to complete cutting at the center of the part even though the edges may have already been cut through 18 Use the up and down arrow keys to specify yes or no indicating whether you w...

Page 19: ...still considers your programmed cut depth as the end of cut indicator This allows you to resume back at the start of the current cut exactly where it was interrupted or anywhere in between 21 This is a simple reminder to set the wire Speed control to the desired speed prior to beginning 22 This screen appears if and only if the bow sensor is reading a value greater than zero If you had temporarily...

Page 20: ...lowing informational screens The first line indicates the current cut and the total number of cuts that are to be made in the program The second line shows the current depth of cut This screen indicates the total amount of time elapsed since the program began This screen indicates the average linear speed of the cutting wire calculated each time the capstan changes direction You can manually toggl...

Page 21: ...sted and calibrated even if it is not used to control the cutting velocities When there is a wire break saw motion ceases and the following message appears on the LCD screen Switch the AUTO MANUAL switch to Manual mode and the rear panel Capstan RUN WIRE switch to WIRE Wire break detection is disabled when running the saw in Wire Mode This permits running the capstan for the wiring process but it ...

Page 22: ...and over hand action pull this wire from the capstan Do not allow the wire to rake over any fixed surface pulley shaft or sensor that could be damaged from wire abrasion 3 After reaching the end of the wire loosen the thumbscrew and pull the wire free 4 Repeat this procedure with the other section of wire 5 Installing a New Wire 1 If you have not already done so move the wire tension pulleys to th...

Page 23: ...a metallic object near the face of the bow sensor to defeat wire break detection Turn power on and from Manual mode Run the capstan back and forth a couple of cycles to resynchronize Then switch to wire Mode and proceed to rewire the saw 6 Remove the thumbscrew in the supply spool spindle slip on a spool of wire and replace the thumbscrew so the spool is held firmly on the spindle If necessary adj...

Page 24: ...t the capstan rotates at a slow and steady rate wire is pulled from the supply spool and onto the capstan When the capstan reaches the far end of its counterclockwise rotation and has traveled fully forward away from the motor it stops automatically 17 Using your right hand pull a little more than one foot of excess wire from the supply spool 18 Tape the wire to the edge of the spool and cut the w...

Page 25: ...t wire mode This completes the wiring procedure At this time you should run the wire drive a few minutes in the manual mode to stretch the wire and fully prepare it for cutting Though this seems a lengthy and tedious procedure at first you will find that it proceeds rather quickly and smoothly after only one or two experiences As you develop your technique you might alter the hand and body positio...

Page 26: ...maller diameter cutting wire Bow Sensor Calibration The bow sensor is calibrated at the factory but should be recalibrated under the following conditions a Installation of a new wire of a different size b Adjustment of the guide pulleys spacing c Significant observed inaccuracy d The message WARNING Bow Not Zero appears even though the wire is not bowed e Physical repositioning of the bow sensor f...

Page 27: ...red for proper calibration Press the right arrow key to proceed Beware that up to one inch of downward motion is about to occur Ensure that nothing will interfere with this motion The yoke makes a series of six short downward jogs storing the sensor readings at each stage Then the yoke rises to its original position When calibration is complete the next typical step is to jog the wire up if necess...

Page 28: ...ring part of its rotation You observe eccentric wear as an up and down motion of the wire when viewed from the side 2 Flange wear results from misalignment between pulleys or misalignment between a pulley and the capstan The wire must always go into the pulley groove parallel to the sides of the pulley Flange wear appears as side to side flutter of the wire when viewed on edge Misalignment quickly...

Page 29: ...eventative Maintenance Daily Inspect the tensioner pulleys for wear or damage Inspect the pulleys for wear or damage Perform a general inspection of entire machine looking for missing or worn hardware replace as necessary Inspect and fill the oil reservoir as necessary CT400 CT800 only Use Dixon Lubricant 8TL016 Non Hydraulic Oil Or equivalent Weekly Turn the grease cup on the front end of the cap...

Page 30: ...apply a small amount Mobil Vactra 2 way lube or equivalent to the edges of the linear rail to ensure smooth operation When the wire is removed reduce air pressure to zero and check that the slides moves easily over their full length of travel Inspect the table rails and bearings Clean and lubricate with grease Check the winders for smooth operation ...