Wedm - c09 Maint Alarms List

CHAPTER 9 MAINTENANCE AND ALARM LIST
9-1 Maintenance and Inspection Items
9-2 Maintenance and Inspection Method
9-3 Maintenance and Inspection of Dielectric Fluid Reservoir
9-4 Maintenance and Inspection of the Dielectric Fluid
Temperature Control Unit
9-5 Automatic Threader (AT Unit) Maintenance and Inspection
Methods
9-6 Maintenance of the Wire Guide Block
9-7 Updating the System
9-8 List of Alarms
9-9 List of Consumables
9-10 Reference Information on Wire Electrodes

CONTENTS
I. Precautions for Maintenance and Inspection ...................................................................................... I

II. Measures for Faults and Abnormalities ............................................................................................... II
III. Prohibition of Modifications .................................................................................................................. II
9-1 Maintenance and Inspection Items ....................................................................................................... 9-1
9-2 Maintenance and Inspection Method.................................................................................................... 9-2

9-2-1 Daily Inspection and Before-Operation Inspection.......................................................................... 9-2
(1) Confirmation of wire route ............................................................................................................... 9-2
(2) Inspection of lower ceramic plate (Insulation board) ..................................................................... 9-2
(3) Inspection of nozzles....................................................................................................................... 9-3
(4) Confirmation of dielectric fluid ......................................................................................................... 9-3
(5) Confirmation of dielectric fluid specific resistivity ............................................................................ 9-4
(6) Cleaning of working tank ................................................................................................................. 9-5
(7) Confirmation of machining position ................................................................................................. 9-5
(8) Inspection of wire collection section................................................................................................ 9-6
(9) Oiling ............................................................................................................................................... 9-7
(10) Inspection of filter regulator ............................................................................................................. 9-8
(11) Inspection of oil filter........................................................................................................................ 9-10
9-2-2 Weekly Inspection ........................................................................................................................... 9-11
(1) Maintenance and inspection of lower roller section ........................................................................ 9-11
9-2-3 Monthly Inspection .......................................................................................................................... 9-11
(1) Inspection of wire-alignment device (Option) ................................................................................ 9-11
(2) Inspection of lower nozzle clearance .............................................................................................. 9-11
(3) Cleaning of fluid level sensor ........................................................................................................ 9-12
(4) Cleaning of working tank seal ......................................................................................................... 9-12
(5) Oiling of Z and UV axes .................................................................................................................. 9-13
9-2-4 6-month Inspection.......................................................................................................................... 9-17
(1) Inspection of floppy disk device ...................................................................................................... 9-17
(2) Cleaning the float switch in the work tank ....................................................................................... 9-17
9-2-5 Miscellaneous.................................................................................................................................. 9-18
(1) Display screen................................................................................................................................. 9-18
(2) Uninterruptive Power Supply (UPS) .............................................................................................. 9-18
(3) Replacing the backup battery.......................................................................................................... 9-18
(4) Hard disk (HDD) ............................................................................................................................ 9-18
(5) Replacing the servo amplifier backup battery ................................................................................. 9-18
9-3 Maintenance and Inspection of Dielectric Fluid Reservoir................................................................. 9-19

9-3-1 Dielectric Fluid Reservoir Maintenance and Inspection Items ........................................................ 9-19
(1) Replenishment of dielectric fluid ..................................................................................................... 9-20
(2) Inspection of dielectric fluid filter ..................................................................................................... 9-20
(3) Inspection of the supply pump ........................................................................................................ 9-20
(4) Cleaning of specific resistivity sensor ............................................................................................. 9-21
(5) Replacement of water purifier (ion exchange resin) ...................................................................... 9-21
(6) Cleaning the dirty fluid tank (dielectric fluid reservoir)..................................................................... 9-23
(7) Operation and maintenance of piping unit solenoid valve .............................................................. 9-24
(8) Operation and maintenance of piping unit cylinder valve (CE mark specifications) ....................... 9-30
(9) Maintenance and operation of injection nozzle solenoid valve ....................................................... 9-34
(10) Cleaning the float switch ................................................................................................................. 9-40
(11) Supply of lubricating oil to pump ..................................................................................................... 9-41
9-4 Maintenance and Inspection of the Dielectric Fluid Temperature Control Unit ............................... 9-42
9-4-1 Cleaning the air filter ....................................................................................................................... 9-43
9-4-2 Cleaning the unit cooler................................................................................................................... 9-43
9-4-3 Cleaning the condenser .................................................................................................................. 9-43
9-4-4 Error codes and remedies ............................................................................................................... 9-46
9-5 Automatic Threader (AT Unit) Maintenance and Inspection Methods............................................... 9-48
9-5-1 Maintenance and Inspection Items ................................................................................................. 9-48
(1) Maintenance and inspection table................................................................................................... 9-58
(2) Other precautions............................................................................................................................ 9-50
(3) AT Maintenance Guidance Screen.................................................................................................. 9-50
9-5-2 Maintenance and Inspection Methods ............................................................................................ 9-51
(1) Wire Feed System........................................................................................................................... 9-51
(1)-1 Wire breakage detection sensor ............................................................................................... 9-51
(1)-2 Main tension roller..................................................................................................................... 9-52
(1)-3 Retry sensor and pick arm ........................................................................................................ 9-54
(1)-4 Auxiliary die ............................................................................................................................... 9-55
(2) AT Unit............................................................................................................................................. 9-56
(2)-1 Wire pressing roller ................................................................................................................... 9-56
(2)-2 Guide pipe ................................................................................................................................. 9-57
(2)-3 Wire chip guide.......................................................................................................................... 9-60
(2)-4 Cutter contact ............................................................................................................................ 9-61
(2)-5 Wire chip take-up roller ............................................................................................................. 9-63
(3) Power Feeder.................................................................................................................................. 9-64
(3)-1 Upper power feed terminal........................................................................................................ 9-64
(3)-2 Lower power feeder .................................................................................................................. 9-67
(4) Upper Wire Guide............................................................................................................................ 9-70
(4)-1 Upper diamond die.................................................................................................................... 9-70
(4)-2 Jet nozzle ................................................................................................................................ 9-71
(5) Lower Wire Guide............................................................................................................................ 9-73
(5)-1 Lower guide roller...................................................................................................................... 9-73
(5)-2 Maintenance of guide D ............................................................................................................ 9-74
(5)-3 Aspirator sensor ........................................................................................................................ 9-75
(5)-4 Lower diamond die.................................................................................................................... 9-76
(6) Wire Collection Unit......................................................................................................................... 9-77
(6)-1 Wire collection unit .................................................................................................................... 9-77
(7) Wire Chip Collection Unit ................................................................................................................ 9-82
(7)-1 Wire chip collection box ............................................................................................................ 9-82
(7)-2 Wire chip collection hose .......................................................................................................... 9-83
9-5-3 Troubleshooting ................................................................................................................................ 9-84
9-6 Maintenance of the Wire Guide Block .................................................................................................. 9-86

9-6-1 Outline ............................................................................................................................................. 9-86
9-6-2 Cleaning cycle ................................................................................................................................. 9-89
9-6-3 How to clean.................................................................................................................................... 9-90
9-7 Updating the System .............................................................................................................................. 9-93

9-7-1 Updating the System ....................................................................................................................... 9-93
9-7-2 Restoration When System Does Not Start up Correctly ................................................................. 9-97
9-8 List of Alarms .......................................................................................................................................... 9-100

9-8-1 Operation Alarms............................................................................................................................. 9-100
9-8-2 Alarms Concerning Sequencer ....................................................................................................... 9-104
9-8-3 Operation Alarms............................................................................................................................. 9-110
9-8-4 Stop Alarms ..................................................................................................................................... 9-112
9-8-5 Servo Alarms ................................................................................................................................... 9-122
9-8-6 MCP Alarms..................................................................................................................................... 9-133
9-8-7 Other Servo Alarms ......................................................................................................................... 9-135
9-8-8 Program Alarms............................................................................................................................... 9-136
9-8-9 System Alarms ................................................................................................................................ 9-144
9-8-10 System Warning .............................................................................................................................. 9-145
9-9 List of Consumables............................................................................................................................... 9-146
9-10 Reference Information on Wire Electrodes ........................................................................................ 9-150

Caution
CAUTION
I. Precautions for Maintenance and Inspection
Perform maintenance and inspection according to the Instruction Manual so as to maintain the safety and
functions of the machine. The power must be turned OFF before starting maintenance and inspection as a
principle. Lock the main power switch when the power has been turned OFF. If the maintenance must be
done with the power ON, confirm that the machining voltage is not being applied, that the machine is not in
automatic operation, and that there are no other risks. Put up a sign such as "INSPECTION IN
PROGRESS" so that a third party will not inadvertently operate the machine during maintenance or
inspection.
1) Maintenance and inspection methods

Perform maintenance and inspection periodically of the required positions according to the Instruction
Manual. Make sure that the following items are well understood before starting the maintenance and
inspection.
2) Limits to maintenance and inspection workers

To prevent risks due to insufficient knowledge or mistaken operation of the system, only specialist
workers who understand the correct maintenance and inspection methods may perform the
maintenance and inspection. Other workers should not be allowed to touch the system.
3) Scope of maintenance and inspection

The scope of maintenance and inspection is limited to that described in the Instruction Manual or
designated by the Mitsubishi Electric Service Engineer. There are high voltage sections and
precision mechanisms in the cover and cabinet, and inadvertent handling of these may lead to electric
shocks, faults or deterioration in performance.
4) Consumable parts
Use genuine Mitsubishi parts for the replacement of consumable parts, etc. Use of parts other than
the genuine parts may lead to risks, faults, trouble and accuracy faults. Mitsubishi will not bear
responsibility for trouble, faults and accidents, etc., caused by use of non-genuine parts.
5) Treatment of waste
The dielectric fluid, dielectric fluid filter, ion exchange resin and wire electrodes, etc., are industrial
waste.
Follow the laws and ordinances of the respective country and region when disposing of these matters.
(Refer to "Waste Fluid Treatment" in "Machine Outline" for details on industrial waste.)
6) Precautions for cleaning

Make sure that dielectric fluid does not enter the internal parts of the system when cleaning using
dielectric fluid.
When using a cleaning solution, make sure it matches the purpose. Make sure that organic solvent
does not get on the resin parts. The resin parts could crack, etc., if organic solvent gets on them.
I
Caution
7) Others
Even when the NF (no-fuse breaker) is turned OFF, there may be parts that are still charged. Thus,
when replacing the fuse, etc., contact the Mitsubishi Electric Service Engineer first.
II. Measures for Faults and Abnormalities
1) Prohibition of use during Faults and Abnormalities

Immediately stop operation when a fault or abnormality is sensed. Turn the power OFF if necessary.
Always turn the main power OFF if there is any abnormal odor or smoke.
Continuing use with faults or abnormalities is extremely dangerous and may cause fatal damage to the
system or periphery.
Note that during a fault, the equipment may overheat or catch on fire.
2) Measures for faults

Immediately notify the Mitsubishi Electric Service Engineer of the fault or abnormality details, and
follow the given instructions.
III. Prohibition of Modifications

• The user must never modify this system.
• Parts other than the consumable parts and other replacement parts indicated in the Instruction Manual
must not be removed from the system.
II
9. MAINTENANCE AND ALARM LIST 9-1 Maintenance and Inspection Items
9-1 Maintenance and Inspection Items

Class Section Reference No. Item Page
9-2-1 (1) Confirmation of wire route 9-2
9-2-1 (2) Inspection of lower ceramic plate 9-2
9-2-1 (3) Inspection of nozzles 9-3
9-2-1 (4) Confirmation of dielectric fluid 9-3
9-2-1 (5) Confirmation of dielectric fluid specific resistivity 9-4
2.General 9-2-1 (6) Cleaning of working tank 9-5
9-2-1 (7) Confirmation of machining position 9-5
9-2-1 (8) Inspection of wire collection section 9-6
Daily 9-2-1 (9) Oiling 9-7
inspection,
before 9-2-1 (10) Inspection of the filter regulator 9-8
operation 9-2-1 (11) Inspection of the oil filter 9-10
inspection
9-3-1 (1) Replenishment of dielectric fluid 9-20
3. Dielectric fluid reservoir 9-3-1 (2) Inspection of filter pressure 9-20
9-3-1 (3) Inspection of the supply pump 9-20
9-5-2 (1)-3 Inspection of the pick arm 9-54
Inspection of the wire chip guide and collection
9-5-2 (2)-3 9-60
hose
5. Automatic threader 9-5-2 (4)-2 Inspection of the jet water flow 9-71
9-5-2 (7)-1 Inspection of the wire chip collection box 9-82
9-6-3 (2) (3) Cleaning the wire guide block surface 9-91
2. General 9-2-2 (1) Lower roller section 9-11
9-5-2 (3) Power feeder 9-66
Weekly 3. Dielectric fluid reservoir 9-5-2 (4)-1 Upper diamond die 9-72
inspection
9-5-2 (5)-4 Lower diamond die 9-78
Cleaning of the wire guide block (nozzle base and
5. Automatic threader 9-5-3 (2) (3) 9-86
cylinder shaft)
9-2-3 (1) Inspection of wire-alignment device 9-11
9-2-3 (2) Inspection of the lower nozzle clearance 9-11
2. General 9-2-3 (3) Cleaning of fluid level sensor 9-12
9-2-3 (4) Cleaning of working tank seal 9-12
9-2-3 (5) Oiling of Z and UV axes 9-13
3. Dielectric fluid reservoir 9-3-1 (4) Cleaning of specific resistivity sensor 9-21
9-5-2 (1)-1 Wire breakage detection sensor 9-51
9-5-2 (1)-4 Auxiliary die 9-55
Monthly
inspection 9-5-2 (1)-3 Retry sensor 9-54
9-5-2 (2)-1 Wire pressing roller 9-56
9-5-2 (2)-2 Guide pipe 9-57
5. Automatic threader 9-5-2 (2)-4 Cutter contact 9-61
9-5-2 (2)-5 Wire chip take-up roller 9-63
9-5-2 (5)-1 Lower guide roller 9-73
9-5-2 (5)-2 Guide D 9-74
9-5-2 (5)-3 Aspirator sensor 9-75
9-5-2 (6)-1 Collection roller 9-77
9-2-4 (1) Inspection of floppy disk device 9-17
2. General
9-2-4 (2) Cleaning of float switch 9-17
9-3-1 (11) Replacement of water purifier 9-41
3. Dielectric fluid reservoir
6-month 9-2-4 (2) Cleaning of float switch 9-17
inspection 4. Dielectric fluid temper- 9-4-1 Cleaning the air filter 9-43
ature control unit 9-4-3 Cleaning the condenser 9-43
9-5-2 (1)-2 Main tension roller 9-52
5. Automatic wire feeder
9-5-2 (6)-1 Collection roller 9-77
9-3-1 (5) Replacement of the ion exchange resin 9-21
Others 3. Dielectric fluid reservoir
9-3-1 (6) Cleaning of dielectric fluid reservoir 9-23
9−1
9. MAINTENANCE AND ALARM LIST 9-2 Maintenance and Inspection Method
9-2 Maintenance and Inspection Method

The methods of inspecting the dielectric fluid reservoir are explained in "Maintenance and Inspection of Dielectric
Fluid Reservoir".
9-2-1 Daily Inspection and Before-Operation Inspection

(1) Confirmation of wire route
Mount a new bobbin or a suitable bobbin with sufficient electrode wire, and after threading the wire through
the wire route, run the wire.
Check whether the traveling condition of the wire is normal while changing the set position of the wire tension
notch in the manual mode.
Also check whether the wire is smoothly collected into the wire collection box, and whether any abnormality
such as chattering, vibration, unusual sound, etc. of the traveling wire is detected.
Refer to "BASIC OPERATION, How to Thread the Wire" for details on threading the wire.
(2) Inspection of lower ceramic plate (Insulation board)

Check whether the lower ceramic plate are cracked, and wipe off dirt.
Lower guide block Ceramic plate

(insulation board)
Lower guide roller block
Fig. 2.1 Lower block
Machining powder easily accumulates in the lower guide block (refer to MAINTENANCE AND ALARM LIST,
Automatic Threader (AT Unit). If machining powder accumulates on the ceramic insulation boards set there,
electric currents may leak and the machining performance may deteriorate. Remove machining powder from
the insulation board surface once every 3 or 4 days by using a brush.
Also clean the rear side of the wire guide lower section and the lower block carefully and sufficiently.
9−2
(3) Inspection of nozzles

Check whether the upper nozzle and lower nozzle are cracked.
Especially check that the end of the nozzle is not cracked or deformed.
Upper nozzle Lower nozzle
Fig. 2.2 Nozzle
Take care to chipping.
Upper nozzle Lower nozzle
* If there is any damage, such as chipping on the nozzle, various problems could occur including a
drop in machining speed due to unstable dielectric fluid supply, a drop in workpiece accuracy, and
easier breakage of wires.
(4) Confirmation of dielectric fluid

The dielectric fluid is ejected from the upper and lower nozzles. The flow rate can be adjusted with the
dielectric ON/OFF, machining condition FB notch changeover and machining condition LQ notch changeover,
etc.
* Fill the dielectric fluid up to the upper nozzle or lower the LQ notch setting to prevent the fluid from
splattering during the check.
1) Dielectric fluid ON/OFF

Press the dielectric fluid ON/OFF changeover button, and confirm that the dielectric fluid is discharged from
the upper and lower nozzles.
2) FB notch changeover
Change the upper/lower flow rate balance (FB), and confirm that the upper/lower nozzle flow rate changes.
The following effect can be achieved by changing the FB notch setting.

NM : Standard
U : Upper flow rate restriction ............. The upper nozzle's flow rate decreases.
L Lower flow rate restriction ............. The lower nozzle's flow rate decreases.
9−3
3) LQ notch changeover
The flow rate will increase as flow rate notch (LQ) setting is increased.
A guide to the dielectric fluid flow is shown in Table 2.1.
Table 2.1 Guide to flow rate corresponding to notch setting when upper
and lower nozzles are opened
Flow rate notch
1 2 3 4 5 6 7 8
(LQ)
Flow rate guide
0.0 0.4±0.3 1±0.5 1.4±0.5 1.8±0.5 2.6±0.5 3.4±1 4.4±1
(l/min)
Flow rate notch
9 10 11 12 13 14 15
(LQ)
Flow rate guide
5±1 5.8±1 7.5±1 9.4±1 10 or more 10 or more 10 or more
(l/min)
NOTE) The above flow rates apply when the working tank is filled with dielectric fluid, the FB notch is set to NM, no
obstacles such as workpieces are placed before the upper/lower nozzle dielectric fluid outlet, and the
upper/lower nozzles are separated.
If the flow rate differs greatly from the above table, remove the control panel cover on the back of the tank,
and check the inverter's ALARM lamp. If the ALARM lamp is lit, the inverter could be faulty. If the inverter is
not faulty, the flow sensor may be faulty or clogged.
In this case, replace the part. Contact the Mitsubishi Service Dept. for replacement parts.
(5) Confirmation of dielectric fluid specific resistivity
1) Indication of specific resistivity error

During machining, confirm that the current value displayed at the top of the screen is as set. The background
of the current display section is "green" when the current is as set. "Yellow" indicates that the specific
resistivity is high, so add some tap water. If "red", the specific resistivity is low, and the message "Specific
Resistivity Error" will appear at the screen's message display area.
2) Start interlock
If machining is started while the above "LR ERR" message is displayed, the "U702: LR OUT OF CNTL" alarm
will occur, and starting will be inhibited. Replace the ion exchange resin in the water purifier. (Refer to
"Replacement of water purifier (ion exchange resin)" in “MAINTENANCE AND ALARM LIST” for details on
replacing the ion exchange resin.)
z Water Purifier (Ion Exchange Resin)

The water purifier removes ion from water to purify it, and in turn increases the electrical resistivity to improve
the insulation.
This resin can purify a maximum of several hundred liters of ordinary city water, and then is no longer
effective because of saturation.
The life of the resin will be shortened remarkably when machining special materials such as tungsten
carbide. If the resin is saturated and the water purification capacities drop, the specific resistivity will not
reach the setting, and the background color of the current value displayed on the top of the screen will
change to "red". In this case, remove the water purifier (cartridge) and replace with a new resin.
The life of the ion exchange resin may be shortened remarkably if the levels of carbon dioxide increase in
the room due to the use of a kerosene heater, etc. Always ventilate the room well.
9−4
(6) Cleaning of working tank

Clean the working tank if sludge is accumulated in the bottom. Using the gun nozzle for the water is handy.
(Refer to the "Basic Operation Section" for details on operating the gun nozzle.)
Confirm the operation of the automatic fluid level setting float switch with the following steps.
1. Press , and confirm that the dielectric fluid rises to the upper wire guide and stops.
2. Raise the Z axis approx. 100mm, and press again. If the fluid level rises, the operation is normal.
If the operation is abnormal, clean the fluid level sensor on the back of the automatic wire feeder, and then
confirm the operation again. (Refer to "Weekly Inspection, Cleaning of fluid level sensor, Maintenance and
Inspection Method” in MAINTENANCE AND ALARM LIST for details.)
(7) Confirmation of machining position

Remove the cut wire scraps, and check whether abnormalities such as scratches on the table surface,
scratches of the feeders, cracking trouble of the nozzles, etc. are detected or not. Also check the dies, and
remove foreign matters from the lower arm section (in order to prevent biting trouble).
* Mount the workpiece as shown in the Fig. 2.3. When moving the table, be careful not to bump the upper
part of the wire guide against the clamp metal.
Never touch the wire and the wire guide section during the machining. Remember to wear insulating shoes or
other suitable protection during machining work.
Clamp metal Upper nozzle
Table
Lower nozzle
Fig. 2.3
NOTE The clearance between the workpiece and upper nozzle and lower nozzle is extremely small. If the
workpiece parallelism is poor or the flatness of the upper and lower surfaces of the workpiece is
poor due to protrusions, etc., consider a different workpiece setting method, such as distancing the
nozzle. By this, prevent the nozzle and workpiece from interfering.
9−5
(8) Inspection of wire collection section

1) Is the wire curl appropriate?
2) Does the wire slip at the max. wire tension notch setting being used?
3) Are the roller surfaces dirty?
4) If there is a 0.05mm or more dent on the roller surface, reverse the roller, change the spacer position, or
replace the roller.
When reversing, install the gears on the opposite surface of the rollers.
(Use a fingernail to confirm that there are no snags, or check visually.)
* Refer to section 9-5 for details on replacing the roller.
5) Check the lower collection flow rate.
Before starting work, confirm that the wire collection roller operation and lower collection flow rate are correct.
1) Checking method
• Press the [AF WIRE COLLECT] on the manual operation box.
• The lower collection fluid will flow.
• Check that the lower collection flow rate is appropriate. (Refer to Fig. 2.4)
• Press the on the operation panel.
The lower collection fluid will stop.
• Turn ON on the operation panel. If both the upper and lower collection rollers rotate, the operation
is correct.
2) Measures for abnormalities

• If the lower collection flow rate is found to be low such as shown in Fig. 2.4, the following measures must
be taken.
1. Check that the lower roller section aspirator is not clogged with foreign matter.
(Refer to “Automatic Threader (AT Unit) Maintenance and Inspection Methods, Lower wire guide,
Cleaning the aspirator.)
Abnormal (Low flow rate) Normal
Fig. 2.4 Checking the lower collection flow rate
9−6
(9) Oiling
The BA Series is provided with an automatic lubrication unit as a standard. The mechanism automatically
lubricates each guide of the XY axes at 2-hour intervals. After oiling, the waste oil is discharged to the oil pan
found at the machine cover's left side. Confirm that the oil pan is installed at the specified position, and when
replenishing the oil, remove the oil in the oil pan to prevent it from overflowing. Make sure not to accumulate
more oil than necessary in the oil pan.
The level of lubricating oil in the automatic lubrication unit is detected with a float, and can also be confirmed
visually. Replenish the lubricating oil before the "Lubricating Oil Low" alarm occurs.
NOTE The machine could be seriously damaged if dirt or oil enters during oiling. Replenish with new
lubricant that contains no impurities.
The recommended lubricants are as follows.

Oil maker Lubricant
Mobil Mobil DTE26
Idemitsu Super hydro 68A
Shell Terrace oil 68
Nisseki Mitsubishi Super mulpas 68
Automatic lubrication unit

(left side of machine unit)
Oil pan
(rear side of machine unit)
Remove the oil pan box

from the rear side of the
machine unit.
Fig. 2.5 Automatic lubrication unit and oil pan (left side of machine)
(For BA8)
9−7
(10) Inspection of filter regulator

The filter regulator is designed to remove dust, moisture, etc. in the air.
Maintenance of filter regulator is conducted as described below.
1. Discharge the drainage before it reaches the baffle 14 .

• This system has a built-in automatic discharge unit, so when a set amount of drainage accumulates, it is
automatically discharged. This model also has a built-in manual discharge unit, which can be used as a
manual drain. When the cock 17 is turned counterclockwise, the drainage will be manually discharged.
Manually discharge the drainage if it is not automatically discharged or when dirt, etc., is accumulated at
the bottom of the metal ball 16 .
The applicable pressure range for the automatic discharge unit is 0.1 to 1.0MPa.
• Manually discharge the drainage. Use of tools may damage it.
2. Use a neutral detergent to clean the element 13 . Blast moisture with compressed air after cleaning.
3. Also clean the metal ball 16 with neutral detergent. Use of any other detergent is strictly prohibited.
4. When the pressure cannot be adjusted as desired or the pressure drop is imminent, clean and disassemble
each part, and check for any damage, etc.
5. When air leaks from the knob 1 or cover 19 , etc., clean the diaphragm assembly 4 , and O-ring 15 and
check for any damage, etc.
6. Refer to Fig. 2.7 for disassembly. (Stop the air supply to the filter regulator before disassembling.)
9−8
⑧
⑤
⑪ ⑨ ⑩
⑱
⑫
⑮
⑯
Fig. 2.7 Filter regulator
NOTE Drain the filter regulator, and at the same time drain the air source of the compressor, etc.
9−9
(11) Inspection of oil filter

The oil filter is installed to remove oil in the air, and smooth operation is not possible if the filter is clogged.
1. Discharge the drainage before it reaches the element 2 .
• This system has a built-in automatic discharge unit, so when a set amount of drainage accumulates, it is
automatically discharged. This model also has a built-in manual discharge unit, which can be used as a
manual drain. When the cock 5 is turned counterclockwise, the drainage will be manually discharged.
Manually discharge the drainage if it not automatically discharged, or when dirt, etc., is accumulated at the
bottom of the metal bowl 4 .
The applicable pressure range for the automatic discharge unit is 0.1 to 1.0MPa.
• Manually discharge the drainage. Use of tools may damage it. 2. Use a neutral detergent to clean the
case.
2. Use a neutral detergent to clean the metal bowl 4 .
3. Replace the element 2 once every two years or before the pressure drops to 0.1MPa.
Fig. 2.8 Oil filter
9 − 10
9-2-2 Weekly Inspection
(1) Maintenance and inspection of lower roller section

Refer to 9-5-2 (5)-1.
9-2-3 Monthly Inspection
(1) Inspection of wire-alignment device (Option)

1) Check whether the surface that contacts the wire is scratched.
(If there are any scratches, avoid the scratch section when using.)
2) If the surface that contacts the wire is scratched and can no longer be used, regrind the surface.
The squareness must be 0.005/50mm or less.
Alignment is possible by using the workpiece if the wire-alignment device cannot be used.
(Refer to Setup, Wire alignment/Taper specifications in NC Operation Display Screen.)
∗) Note that the wire can be polished at your nearest Mitsubishi Electric Service Center.
(2) Inspection of lower nozzle clearance

If the clearance between the table's upper surface and the lower nozzle is 0.1mm or more, the machining
performance will be adversely affected (machining speed will drop, etc.) so repairs will be required.
Measuring the clearance between the lower nozzle

Fix the dial gauge onto the mounting panel at the side of the AT unit with the fixing magnets, and set the dial
gauge so that it reads 0 at the table surface. Move the UV axes, and measure the height of the lower
nozzle's upper surface into which a spring is inserted.
If the workpiece setting jig is positioned below the top face of the table, the lower nozzle can be pushed
down and held to the lower position so that the moving table does not interfere with the workpiece setting
jig.
Mounting plate
(for fixing magnets)
Lower nozzle
Place a spring inside,
and press upward.
Fig. 2.9
9 – 11
(3) Cleaning of fluid level sensor

Clean the sensor located at the rear of the automatic wire feeder using a brush or waste, etc.
(Refer to Fig. 2.10)
Fig. 2.10 Fluid level sensor
NOTE Clean so that the contamination on the surface of the three electrodes is removed.
(4) Cleaning of working tank seal

1) Discharge the dielectric fluid from the working tank.
2) Move the X axis to the right end.
3) Remove the sludge adhered on the seal plate shown in the shaded section below with a nylon brush or
paint brush, etc., while spraying water with the spare hose.
Right side of
Left side of
seal plate
seal plate
Fig. 2.11
4) Move the X axis to the left end.

5) In the same manner as step 3), wipe off any sludge adhered on the seal plate.
9 – 12
(5) Oiling of Z and UV axes

Oil the Z and UV axes once a month.
Oil with the following procedure.
1) Z axis
• Ball screw, guide
1. Move the Z axis to the position where the Z axis base grease nipple is visible.
2. Inject grease with the grease gun. (Two positions on top and bottom.)
(Note) Refer to the following table for the grease types, etc.
Z axis
base
Grease
T/C cover
nipple
(top)
T/C cover
(bottom)
Fig. 2.12
Alvania Grease No. 2 (SHOWA SHELL SEKIYU K.K) or

Recommended grease
equivalent product
No. of pumping 1 time/grease nipple
9 – 13
2) UV axes
1. Move the Y axis to the forward stroke end so that the work can be carried out easily.
2. Remove the feeder wire suspension pipe attached to the T/C cover (bottom) and T/C cover (top).
(Photo 2)
B D
E C
Photo 1 Front view of T/C unit
Feeder wire suspension pipe
T/C cover (bottom)

Four M4 screws on left/right
Photo 2 A (Bottom of T/C unit)
NOTE In Photos 3 to 6, the parts other than the T/C cover (bottom) have been removed to show the
positions of the ball screws and guide. During the actual work, remove only the T/C cover (bottom),
and apply the grease.
9 – 14
3. Move the +U axis to the stroke end, wipe off all the old grease, and then apply new grease onto the entire
exposed ball screw with a finger.
Move the -V axis to the stroke end, wipe off all the old grease, and then apply new grease onto the entire
exposed ball screw with a finger.
Front
Photo 3 Details B (front view of U axis ball screw)
Photo 4 Details C, view from right side (right side of V axis ball screw)
9 – 15
4. Move the +U axis to the stroke end, wipe off all the old grease, and then apply new grease onto the
exposed guide section (front and back sides).
Move the -U axis to the stroke end, wipe off all the old grease, and then apply new grease onto the
exposed guide section (front and back sides).
Move the +V axis to the stroke end, wipe off all the old grease, and then apply new grease onto the
exposed guide section (right and left sides).
Move the -V axis to the stroke end, wipe off all the old grease, and then apply new grease onto the
exposed guide section (right and left sides).
Front
Photo 5 Details D (front of U axis guide)
Front
Photo 6 Details E, view from left side (left side of V axis guide)
5. Return the T/C cover (bottom) and feeder wire suspension pipe to the original positions.
After mounting the T/C cover (bottom), always attach the feeder wire suspension spring to the feeder wire
suspension pipe.
9 – 16
9-2-4 6-month Inspection
(1) Inspection of floppy disk device

When used in an ordinary environment, the floppy disk drive requires no maintenance in particular, but if read
errors frequently occur or when using in an unclean environment, periodically clean the head. The head
cleaning method is stated below.
When cleaning, use a commercially available dry type head cleaning floppy disk.
NOTE Please do not use the wet type head cleaning floppy disk. It causes the breakdown.
Cleaning method
• Insert the cleaning disk as in ordinary disk insertion.
• Refer to the instructions provided with the cleaning disk for details on the cleaning methods.
(2) Cleaning the float switch in the work tank

<Cleaning the float switch in the work tank>
A float switch for detecting the fluid level and for preventing the AT unit from submersion is installed in the
work tank. If the float switch is contaminated with sludge, it may not operate properly. Thus, clean the float
switch about once every six months.
Cleaning the float switch

There is no need to disassemble the float switch. Using a brush, etc., lightly wipe off the sludge around the
shaft. If strong impact is applied, the electrical contact in the shaft could be damaged.
The float (black) has an orientation. When installing the float, make sure that the "OPEN" indication comes to
the top. (Note that only for the FA30, the "CLOSE" indication comes to the top.)
AT unit
Refer to Chapter 9,
section 2.3.4
Fluid level sensor
Float switch
Right view of AT unit Float switch section
9 – 17
9-2-5 Miscellaneous
(1) Display screen

The life of the LCD backlight is approx. 20,000 hours.
When the backlight is consumed, the brightness of the screen will start to drop. Replace the backlight in this
case.
(2) Uninterruptive Power Supply (UPS)

The uninterruptive power supply contains a battery. The life of the battery will vary according to the ambient
temperature, but as a guide, the life is approx. 3 years at an ambient temperature of 25°C.
When the battery is consumed, the message "UPS BATTERY LOW" alarm will appear on the screen.
Replace the battery in this case.
(3) Replacing the backup battery

A lithium battery is mounted in the control unit to save the data. The life of the lithium battery is approx. 6
years, but should be replaced every 5 years.
(4) Hard disk (HDD)

The life of the hard disk is approx. 5 years. Replacing the hard disk after 4 years is recommended to prevent
trouble.
(5) Replacing the servo amplifier backup battery

This system's axis drive system uses an absolute position detection system, so a lithium battery is mounted in
the servo amplifier. The lithium battery can back up data for approx. 12,000 hours.
The battery must be replaced when it is spent and the battery low voltage warning "S52 Servo Warning 9F"
appears on the screen. If approx. 100 hours pass after the warning appears, the servo alarm "S01 Servo
Alarm 25" will occur, and it will not be possible to turn READY ON. At the same time, the absolute position
detection data will be lost. Replace the battery as soon as the warning occurs.
When "S52 Servo Warning 9F" occurs, do not turn the breaker on the power supply panel OFF as the
absolute position could be lost.
• Contact the Mitsubishi Electric Engineer for replacement of the above parts.
9 – 18
9. MAINTENANCE AND ALARM LIST 9-3 Maintenance and Inspection of Dielectric Fluid Reservoir
9-3 Maintenance and Inspection of Dielectric Fluid Reservoir

9-3-1 Dielectric Fluid Reservoir Maintenance and Inspection Items
Item Maintenance and inspection details
Before Replenishment of dielectric fluid Check that there is sufficient dielectric fluid 9-3-1 (1)
operation Inspection of dielectric fluid filter Check that the filter pressure is 0.2MPa or less 9-3-1 (2)
inspection Inspection of supply pump Check for abnormal sounds and leaks 9-3-1 (3)
1-month Inspection of specific resistivity
Clean the specific resistivity sensor 9-3-1 (4)
inspection sensor
6-month
Cleaning the float switch Clean the float switch 9-3-1 (10)
inspection
Replacement of water purifier Replace the ion exchange resin 9-3-1 (5)
Cleaning of dielectric fluid reservoir Clean the waste fluid tank 9-3-1 (6)
Others 9-3-1 (7)
Operation and maintenance of
Clean the solenoid valve 9-3-1 (8)
solenoid valve
9-3-1 (9)
Waste fluid tank

Dielectric fluid filter float switch
Supply pump
Solenoid valve
Specific resistivity
sensor
Clean fluid tank

float switch
BA8 Dielectric fluid reservoir
9 – 19
(1) Replenishment of dielectric fluid

If the fluid level in the dielectric fluid reservoir is low, the working tank may not be filled with enough fluid to
reach the workpiece height.
Checking the dielectric fluid reservoir fluid level

1) Turn ON, and drain all dielectric fluid from the working tank.
2) After draining the fluid, wait one to two minutes for the fluid level to stabilize.
3) Look at the fluid gauge in the tank. The state is normal if the upper plate of the tank is within the white
section of the fluid gauge.
If the white section is lower than the top of the fixing plate, the fluid level is insufficient, so supply fluid.
NOTE
Top of fixing plate If the tank is replenished
with water while there is
fluid in the working tank,
Tank's top plate
the fluid could overflow
from the tank when the
power is turned OFF.
Fluid level in tank
× Insufficient ○ Normal × Excessive

volume volume
(2) Inspection of dielectric fluid filter

1) If the pressure gauge indicates 0.2MPa or more, replace the filter. Note that this applies only when the
genuine Mitsubishi dielectric fluid filter is used.
2) If the pressure is 0.2MPa or less and the clean water tank is dirty, the filter may be torn so check it.
(Refer to Dielectric Fluid Reservoir Operation, Replacing filter element in System for the filter
replacement method.)
3) Replace the upper and lower filters at the same time. The filters could rupture if a clogged filter and
normal filter are used together.
NOTE The guideline for the filter pressure is for when machining ferrous material. The filter life could drop
remarkably when machining aluminum.
(3) Inspection of the supply pump
1) Check that there is no metallic sound, or abnormal vibration.
The pump used with the Mitsubishi wire-cut EDM has a carbide mechanical seal to lengthen the life.
In rare cases, this may cause a metallic sliding sound to be generated from the mechanical seal when the
pump is rotating. This will not affect the pump performance, but can be prevented by lubricating as
indicated below. Lubricate when the pump has been stopped for approx. one week, or every six months.
The transverse pump is the target for these measures.
Refer to section 9-3-1 (12) for details on supplying lubricating oil to the pump.
2) Check that there is no fluid leaking from the pump flange section.
NOTE Observe the following matters to prevent the supply pump from running dry during installation and during
initial operation after the machine has been stopped for a long time.
1) Set the dielectric fluid level to LQ = 14 notch or more.
2) Bleed the air.
3) Drop silicon oil onto the pump’s mechanical seal.
9 – 20
(4) Cleaning of specific resistivity sensor

Sludge will adhere on the specific resistivity sensor's electrode over a long period of use, preventing a correct
measurement display. Remove the specific resistivity sensor once a month, and remove any sludge on the
electrode.
Replace the filter if it has burst.
To clean the sensor, scrub the electrode section with a nylon brush, and remove any adhered sludge. The
sensor can also be washed with a weak acid solution, and then rinsed well.
Always turn the power OFF before cleaning.
Fig. 3.1 Specific resistivity sensor
(5) Replacement of water purifier (ion exchange resin)

The water purifier removes ion from water to purify it, and increases the electric resistivity for higher
insulation.
The resin (10l capacity) can purify several hundred liters of ordinary city water. However, the life of the resin
will differ according to the set specific resistivity value.
When machining special materials such as tungsten carbide, etc., the life will be considerably shorter.
If the resin is saturated and the water purification performance drops, the specific resistivity will not enter the
setting range, and the background color of the current value display at the top of the screen will stay lit in
"red".
NOTE
1) If the specific resistivity is low when the is ON, the background color of the current value display at the
top of the screen may stay lit in "red".
2) The life of the ion exchange resin will differ according to the amount of ion in the dielectric fluid, so always
use clean filtered water with low levels of salt, magnesium and calcium, etc.
3) The life of the ion exchange resin may be shortened remarkably if the levels of carbon dioxide increase in
the room due to the use of a kerosene heater, etc. Always ventilate the room well.
4) Drain the water when replacing the ion exchange resin or if freezing is anticipated.
9 – 21
<<For H-10 type (cream-colored container)>>

(1) Draining the water
A "Syphon" is used with the following procedure to drain the water.
1) Remove the end of the outlet hose, and guide it to the waste water tank. Make sure that the end of the
hose is lower than the cartridge.
2) Turn ON the water so that the hose is filled.
3) Stop the water, and remove the inlet hose from the cap immediately.
4) The water will be drained from the outlet hose due to the "syphoning" effect. It will take approx. 3 to 5
minutes for the water to be drained.
5) If the water does not drain properly, repeat the above procedure.
(2) Replacement procedures

1) Stop the unit.
2) Remove the fixing band.
3) Disconnect the hose on the cartridge outlet/inlet. (Refer to Fig. 3.4 A → B → C )
4) Remove the cartridge from the top of the tank.
5) Turn the cartridge cap counterclockwise and remove.
6) Pull out the collector pipe in the H-10 type cartridge. (Refer to Fig. 3.2.)
7) Turn the cartridge upside down, and wash off the resin with water.
8) Fill the ion exchange resin (MB-4). (Refer to Fig. 3.3.)
9) After filling, gradually fill the cartridge with water until it is almost full.
10) Insert the collector pipe in the middle of the cap, and then screw the cap onto the cartridge.
11) Install the cartridge on the set position onto the tank.
12) Connect the hose to the cartridge outlet/inlet. (Refer to Fig. 3.4 C → B → A )
13) Install the fixing band.
Hose
Cap
H-10 type resin

cartridge
Locked state
Locked pin
Cap
Unlocked state
Pipe in center of cap Lever
Collector pipe
Cartridge
State with hose
removed
Fig. 3.2 Fig. 3.3

Fig. 3.4
(3) Precautions for handling H-10 type

1) The resin tube in this water purifier is made of plastic, and must be used at room temperature.
Do not place it near sources of heat, as the body could deform.
2) The container could be damaged if directly contacted against concrete walls, etc.
3) If the resin tube is dirty, wipe it off with a neutral detergent. Do not use volatile fluids such as thinner.
4) Do not dry or freeze the ion exchange resin as the resin will break easily.
9 – 22
(6) Cleaning the dirty fluid tank (dielectric fluid reservoir)

Using the hose enclosed with the machine or a brush with a long handle, clean out the dirty fluid tank from the
opening on the top. Always turn the machine power OFF before starting cleaning.
Drain section of BA8 dielectric fluid reservoir

(Side view of dielectric fluid reservoir)
9 – 23
(7) Operation and maintenance of piping unit solenoid valve

1) Explanation of operation
1. AP11-15A ~ 25A
• AP11-15A ~ 25A-O B C
Opening operation Closing operation
⑧
①
A
⑨ A
③
⑩
④
B B
⑤ ⑪
②
⑥
⑦
⑫
• AP11-15A ~ 25A-D E F
A A
②
③ ⑨
④ ⑩
B
⑤
⑪ B
⑥
⑦ ⑫
IN OUT
When the coil is conducted, the main valve When conductivity to the coil is stopped, the
chamber B pressure passes through the seat plunger drops due to the spring force and closes
orifice A , and flows to the OUT side. At this seat A . The IN side pressure is replenished to the
moment, the seat chamber B pressure becomes main valve chamber B , making the pressure the
lower than the pressure at the IN side. With this same. Thus, the main valve closes due to the
difference in pressure, the main valve rises and the pressure in the main valve and the spring force, and
fluid flows from the IN to OUT side. the fluid stops.
9 – 24
• Main component material

Part Part
Part name Material Part name Material
No. No.
1 Plunger Stainless steel Core
8 Stainless steel
2 Bleed orifice Brass or stainless steel assembly
3 Spring Stainless steel NBR, fluoro-rubber,
9 Valve seat
Tetrafluoroethylene resin tetrafluoroethylene resin
4 Rider ring NBR, fluoro-rubber,
(C4A, F3A and F4A only) 10 O-ring
tetrafluoroethylene resin
5 Piston ring Tetrafluoroethylene resin
6 Stuffing Bronze or stainless steel 11 Body Bronze or stainless steel
Main valve NBR, fluoro-rubber,
7 Brass or stainless steel 12 Gasket
assembly tetrafluoroethylene resin
2. AP12-15A ~ 25A
• AP12-15A ~ 25A-O B C
③ ⑨
A A
⑩
④
⑤ B B
⑫
⑥
⑦ ⑪
9 – 25
• AP12-15A ~ 25A-D E F
⑧
②
A A
③
⑨
④
⑤ ⑩
B B
⑥ ⑪
⑦ ⑫
IN OUT
Opening operation
When the conductivity to the coil is stopped, the seat A opens, and the pressure in the main valve passes
through the seat orifice and flows to the OUT side. At this moment, the seat chamber B pressure becomes
lower than the supply pressure at the IN side, and a difference is generated in the IN side and OUT side
pressures. With this difference, the main valve rises and the fluid flows from the IN to OUT side.
Closing operation
When the coil is conducted, the plunger 1 is attracted to the fixed iron core 8 by that closing seat A . The
supply pressure from the IN side is replenished to the main valve chamber B , making the pressure the
same. Thus, the main valve closes due to the pressure in the main valve and the spring 3 force, and the fluid
stops.
• Main component material

Part Part
Part name Material Part name Material
No. No.
1 Plunger Stainless steel 8 Core assembly Stainless steel
2 Bleed orifice Brass or stainless steel NBR, fluoro-rubber,
9 Valve seat
3 Spring Stainless steel tetrafluoroethylene resin
Tetrafluoroethylene resin NBR, fluoro-rubber,
4 Rider ring 10 O-ring
(C4A, F3A and F4A only) tetrafluoroethylene resin
5 Piston ring Tetrafluoroethylene resin 11 Body Bronze or stainless steel
6 Stuffing Bronze or stainless steel NBR, fluoro-rubber,
12 Gasket
Main valve tetrafluoroethylene resin
7 Brass or stainless steel
assembly
9 – 26
2) Maintenance and inspection

1. Periodic inspection
1) Periodically inspect the solenoid valves once or twice a year to ensure that they can be used in the
optimum state.
2) Details of inspection
(a) Check whether any dirt or foreign matter, etc., has built up or whether any highly viscous matter has
adhered in the valve.
If there is any abnormality, disassemble and clean the valve.
(b) Check the actuator section's plunger valve seat and main valve assembly seat for damage or
abnormal wear.
If there is any abnormality, replace the part.
2. Disassembly, assembly and inspection

• Disassembly
1) Always turn OFF the power and discharge the fluid and pressure before starting disassembly work.
2) When removing coil 4
When nut 1 is loosened, the spacer A 2 (spacer A 2ａ and spacer 2ｂ for AP12), nameplate 3 , coil 4 ,
bonnet base 5 and wave washer 7 will come off.
3) When removing plunger assembly 10
When the core assembly 8 is removed using the spanner catch section, the spring 9 , plunger
assembly 10 and O-ring 11 will come off. At this time, holding the pipe section of the core assembly 8
and removing the assembly is prohibited. The valve seat for the plunger assembly 10 cannot be
removed.
4) When removing the main valve assembly 20
(a) When the four bolts 18 are removed, the stuffing 12 will come off and then the spring 19 and main
valve assembly 20 can be removed.
(b) The rider ring 21 (mounted only for steam) and piston ring 22 mounted on the main valve assembly 20
can be removed by opening the slit by hand. The inner tension ring 23 can be removed using a sharp
object such as wire.
Take care not to deform the rider ring 21 , piston ring 22 or inner tension ring 23 at this time.
(c) The valve seat mounted on the main valve assembly 20 can be removed when the hexagon bolt and
nut are removed.
5) Clean each part with a neutral detergent or kerosene, etc. Do not use organic solvent as the rubber parts
could expand.
9 – 27
■ Exploded view
AP11-15A ~ 25A AP12-15A ~ 25A
①
①
②
2a
2b
③
③
④
④
⑤
⑥
⑤
⑥
⑦
⑦
⑧
⑧
⑨
⑩
⑩
⑨
⑪
⑪
⑫
⑫
(Only D.E.F.)
(Only D.E.F.)
⑮ ⑯ ⑰ ⑱
⑬ ⑭
⑮ ⑯ ⑰ ⑱
⑬ ⑭
(Only D.E.F.)
(Only D.E.F.)
⑲
⑲
⑳
⑳
21 Rider ring Inner ten- Piston
sion ring ring Rider ring Inner ten- Piston
21
sion ring ring
Piston ring
Piston ring
22 23
22 23
Inner tension 24
ring Inner tension 24
ring
25
25
27
27
26
26
Bleed orifice
(Only O.B.C.) (Only O.B.C.)
9 – 28
• Assembly
1) When reassembling the valves, use the disassembly procedure in reverse and do not forget to assemble
any parts.
2) Cautions for installing valve seat for main valve assembly 20
Tighten the valve seat bolts securely with a tightening torque higher than the values given below.
Type Tightening torque
11
AP 12 -15A 40 kg-cm or more
11
11
3) When assembling the stuffing 12 onto the body 27 , take care to the IN and OUT orientation.
Evenly tighten the tightening bolts 18 .
• Inspection
Turn ON and check for water leaks from the solenoid valve.
3) Troubleshooting
Fault phenomenon Cause Measures

• Foreign matter, etc., is clogged in the
• Disassemble and clean
seat orifice at the pilot section.
The fluid does not • Disassemble and clean
plunger, inhibiting movement.
flow
main valve assembly, inhibiting • Disassemble and clean
movement.
• Foreign matter is clogged in the bleed
orifice.
The fluid does not plunger, inhibiting movement.
stop • The valve seat of the plunger is
• Replace the plunger
damaged.
• The valve seat of the main valve
• Replace the valve seat
assembly is damaged.
4) Consumable parts
Consumable parts : The plunger assembly and main valve assembly are available as kits.
Plunger assembly kit ........... 9 , 10 , 11
Main valve assembly kit ...... 19 , 20 , 21 , 22 , 23 , 24 , 25
9 – 29
(8) Operation and maintenance of piping unit cylinder valve (CE mark specifications)
Normal closed (NC) type
X port
When air is pressurized onto the X port, the When the air at the X port is exhausted, the
piston assembly 2 and main valve unit 3 rise, piston assembly 2 and main valve unit 3 lower
causing the seat to open and the fluid to flow. due to the force of spring 1 , causing the seat to
close and the fluid to flow.

1. Periodic inspection
A) Periodically inspect the valves once or twice a year to ensure that they can be used in the optimum state.
B) Details of inspection
(b) Check the main valve unit and body seat section for abnormal wear or scratches.
(c) If operation defects such as internal leaking or external leaking are occurring, the following parts may
be damaged or worn. Replace them if an abnormality is found.
Part name No. in exploded view

Main valve unit 16
PSD packing 9
O-ring 12 14 17 21
MY packing 15
Plunger 26
Coil assembly 24 ( 34 37 )
9 – 30
2. Disassembly, assembly and inspection

• Disassembly
A) Always turn OFF the power and discharge the pilot air and fluid pressure before starting disassembly
work.
B) Disassembly of solenoid actuator section
When the Philips type pan head screws 23 are removed, the coil 24 can be removed and the other parts
can be removed. The parts are small, so take care not to lose the manual pushup pin, plunger spring, etc.,
when disassembling the parts.
C) When removing main valve unit
When the four hexagon socket head bolts 1 are removed, the unit can be separated into the body 22
and other parts (cylinder cover 7 , etc.).
Securely hold the spanner catch on the piston assembly with the spanner, etc., and loosen and remove
the nut 20 .
After this, the main valve unit 16 can be removed.
D) When removing piston assembly (NO, double acting type)
After removing the main valve unit in step (3), remove the adaptor 13 and then the piston assembly 10
can be removed.
NOTE Removing the NC type piston assembly from the cylinder cover can be dangerous as the reaction of
the spring is strong. Either use a jig to prevent the assembly from springing out or consult with
Mitsubishi.
• Assembly
A) When reassembling the valves, use the disassembly procedure in reverse and do not forget to assemble
any parts.
B) Apply grease onto the cylinder sliding surface and packing before assembling the piston assembly into
the cylinder cover.
NOTE Use of lithium soap grease is recommended for the grease.
C) When assembling the main valve unit, take care to the position and orientation of the seat spacer 18 .
D) When replacing the packing in the adaptor, take care to the position and orientation of the O-ring 14 and
MY packing 15 .
E) The gasket 32 has an orientation. Confirm the shape of the gasket and the shape of the slit when
assembling the gasket into the NC body 33 .
F) When assembling the solenoid actuator into the cylinder cover, face the manual section (green) of the
NO body toward the X port of the cylinder cover. In this case, the coil can face either direction.
• Inspection
A) Apply the fluid pressure and check for internal leaks and external leaks at the valve unit.
B) Next, apply the pilot pressure and confirm that the valve opens and closes normally.
9 – 31
■ Exploded view
① Hexagon socket head bolt

23 Spring washer
assembly cross-
④ Spring washer assembly cross- recessed pan
recessed pan head screw head screw
⑤ Cap
24 Coil assembly
② Spring
washer ⑥ O-ring 25 Plunger spring
26 Plunger
③ Installation
plate
27 O-ring
28 Manual
push up pin
29 NO body assembly
⑦ Cylinder cover
30 Valve unit assembly
31 Spring
⑧−1 Spring 32 Gasket
33 NC body
⑧−2 Spring
32 Gasket
⑨ PSD packing
⑩ Piston assembly
34
Coil assembly
⑪ C-type snap ring (DIN coil)
⑫ O-ring DIN terminal box

⑬ Adaptor 35
⑭ O-ring
⑮ MY packing 36 Installation screw
⑱Seat
For 20 to 50A
spacer ⑯ Main valve

⑰ O-ring unit For 15A
⑰ O-ring
⑯ Main valve DIN terminal box type
unit ⑱ Seat spacer 37
⑲ Spring washer Coil assembly
⑳ Nut (conduit coil)
21 O-ring 38 Lock nut
MY packing orientation
39 T-type terminal box

22 Body
T-type terminal box type
1. The drawing shows the NC type.

For the NO type, the spring ⑧ is assembled under the piston
assembly. The multiple type does not have a spring.
9 – 32
3. Troubleshooting
The valve does not operate.
NO YES
Is the power ON? Turn the power ON. The valve operated. Complete.
YES NO
NO Match the coil voltage YES

Is the voltage correct? The valve operated. Complete.
and power voltage.
YES NO
Does the pilot solenoid NO Replace the pilot YES

The valve operated. Complete.
valve operate? solenoid valve.
YES NO
Is the pilot pressure within NO Set the pressure within YES

the specified value? the specified value.
YES NO
Is the fluid pressure within NO Set the pressure within YES

the specified value? the specified value.
YES NO
Existence of foreign matter during disassembly ① → clean

Existence of abnormal part during disassembly ② → replace
YES
NO
Contact Mitsubishi Service Center or
your dealer.
The valve does not recover.
NO YES
Is the power OFF? Turn the power OFF. The valve recovered. Complete.
YES NO
Does the pilot solenoid NO Replace the pilot YES

The valve recovered. Complete.
valve operate? solenoid valve.
YES NO
Existence of foreign matter during disassembly ① → clean

Existence of abnormal part during disassembly ② → replace
YES
The valve recovered. Complete.
NO
Contact Mitsubishi Service Center or
your dealer.
9 – 33
(9) Maintenance and operation of injection nozzle solenoid valve

• 2-port valve (open type during conductivity)
①
④
⑤
Seat ⑥
Orifice ⑦
⑧ ⑨
⑩
Port A
(OUT) ⑪
⑫
Port C
(IN)
When the coil 1 is conducted, the plunger When the conductivity to coil 1 is stopped, the
assembly 3 is attracted to the core plunger assembly 3 is separated from the
assembly 2 and the seat opens. The fluid core assembly 2 by the force of the spring 5 ,
flows from IN to OUT. and is returned to the original position. The
seat closes. The fluid that was flowing from IN
to OUT is shut off.
Main component material

Part No. Part name Material
1 Coil Class B mold coil
2 Core assembly SUS, brass, copper (silver when body is SUS)
3 Plunger assembly SUS, NBR
4 O-ring NBR
5 Spring SUS
6 Body Brass, (SUS)
7 O-ring NBR
8 O-ring NBR
9 Connector Brass (SUS when body is SUS)
10 O-ring NBR
11 Sub-plate Brass (SUS when body is SUS)
12 Connecting plate SPC
Options are shown in parentheses.
9 – 34

Periodic inspection
1. Periodically inspect the solenoid valves once or twice a year to ensure that they can be used in the
optimum state.
2. Details of inspection
(b) Check the plunger assembly valve seat for abnormal wear or scratches.
3. The following kits are available for the consumable parts.
No. in exploded view

Kit name Configuration parts
GFWB
Clip 4
Coil 6
Coil kit (Including terminal box when
terminal box is provided.)
Wave washer 7
Core assembly kit Core assembly 8
Spring (outer spring) 9
Plunger assembly
Plunger assembly 10
kit
O-ring 11
9 – 35
3) Disassembly, assembly and inspection

• Disassembly
A) Always turn OFF the power and discharge the fluid and pressure before starting disassembly work. (If the
assembly is disassembled while the power is ON, the coil 3 will be damaged.)
B) Refer to the exploded view when disassembling the unit.
a) For the GFWB (2-port valve), if the clip 1 is removed, 2 , 3 and 4 will come off in order.
For the GFWG (3-port valve), if the socket 1 is removed, 2 , 3 , 4 , 5 , 6 and 7 will come off in
order.
b) When the core assembly 5 is removed, 6 , 7 and 8 will come off in order. When removing the
core assembly 5 , hold the lock nut section of the core assembly while the body 10 is fixed, and
remove it. For the GFWG (3-port valve), remove the socket 1 first, and then hold the lock nut
section of the core assembly 5 and remove it. Never hold the pipe section of the core assembly.
c) When the Philips type pan head screw 9 is loosened, the body 10 , O-ring 12 and O-ring 13 will
come off.
d) When removing the actuator ( 1 to 8 , 10 to 13 ) in the assembled state, rotate the coil 3 approx.
30°, and then loosen the Philips type pan head screw 9 .
<Removal of the clip>

Insert a flat-head screwdriver between the core assembly and clip handle, and turn in the direction of the
arrow. The clip will come off.
C) When washing each part, use a low-polluting washing solution such as a neutral detergent, methylene
chloride or freon 141. Note that the rubber parts could expand, so always replace them.
9 – 36
• Assembly
A) When reassembling the unit, use the disassembly procedure in reverse and do not forget to assembly
any parts.
B) To prevent biting of the spring (outer spring) 9 , temporarily tighten the core assembly 8 until it contacts
the O-ring 11 , and then tighten with the torque values listed below.
Tightening torque
Core assembly 8 Philips type pan head screw 9
12 to 18 N⋅m 0.3 to 0.46 N⋅m
<Assembly of clip>
Place a flat-head screwdriver onto the clip handle as shown below, and press in the direction of the
arrows.
• Inspection
Turn ON and check for water leaks from the solenoid valve.
9 – 37
■ Exploded view
① Clip
② Nameplate
③ Coil
④ Wave washer
⑤ Core assembly
Lock nut
⑥ Spring (outer spring)
⑦ Plunger assembly
⑧ O-ring
Valve seat ⑨ Philips type pan head screw
⑩ Body
⑪ Spring pin
⑫ O-ring
⑬ O-ring ⑭ Masking plate
⑮ O-ring
⑯ Sub-plate
⑰ Installation plate
⑱ Philips type pan head screw
9 – 38
4) Troubleshooting
• For 2-port valve (open type during conductivity)
Fault
Cause Measures
phenomenon
• The power is not ON. • Check the power supply.
• Correct the pressure to within the
• The IN side pressure is not within the
specified pressure range.
specified pressure range.
The fluid does • Change to an adequate model.
not flow • Foreign matter, etc., is clogged in the
orifice.
plunger assembly, inhibiting movement.
• The power is not turned OFF. • Check the power supply.
• The fluid flow direction and solenoid valve
• Correct the installation direction.
installation direction do not match.
The fluid does • Foreign matter is caught in the seat. • Disassemble and clean
not stop • Foreign matter, etc., is clogged in the
plunger assembly, inhibiting movement.
• The valve seat of the plunger assembly is
• Replace the plunger assembly.
damaged.
9 – 39
(10) Cleaning the float switch
<Cleaning the float switch in the dielectric fluid reservoir>

Two float switches are provided in the dielectric fluid reservoir to prevent trouble from dry operation of the
pump.
If the float switch is contaminated with sludge, it may not operate properly. Thus, clean the float switch about
once every six months.
Cleaning methods
Remove the screw fixing the float switch installation stay.
Pull the stay out of the dielectric fluid tank's top plate.
The corner of the stay can cause injury so take special care.
There is no need to disassemble the float switch. Using a brush, etc., lightly wipe off the sludge around the shaft.
If strong impact is applied, the electrical contact in the shaft could be damaged.
The float (black) has an orientation. When installing the float, make sure that the "OPEN" indication comes to
the top.
Move the float lightly by hand. Cleaning is completed if the float does not snag, etc.
Insert the stay into the dielectric fluid tank, and install the stay fixing screw.
Fixing screw
Stay
Float switch
9 – 40
(11) Supply of lubricating oil to pump

The pump used with the Mitsubishi wire-cut EDM has a carbide mechanical seal to lengthen the life.
In rare cases, this may cause a metallic sliding sound to be generated from the mechanical seal when the
pump is rotating. This will not affect the pump performance, but can be prevented by lubricating as indicated
below. Lubricate when the pump has been stopped for approx. one week, or every six months. The
transverse pump is the target for these measures.
1) Preparation for work

Always turn the power supply NF OFF.
If the NF is left ON, the pump could rotate during the work, and could lead to accidents such as entanglement
of hands.
2) Remove the coupling guard.

The coupling guard is installed with a socket bolt.
Use a 2.5mm hexagon wrench to remove the screw, and then
remove the coupling guard.
Take care not to misplace the removed screw.
3) Supply the lubricating oil.

While turning the coupling with a hand, supply several drops of lubricating oil so that it runs along the pump
shaft and enters the pump.
Use silicon-based oil for the lubricating oil.
Example) Maker: Shinetsu Chemical Co., Ltd. KF-96.30CS
Motor
Coupling Motor stool
Pump shaft
Mechanical seal
→Detail drawing
Detail drawing (state of dripping lubricating oil)
4) Install the coupling guard.

Install the coupling guard following the procedure given in step 2 in reverse.
5) Trial operation of pump

Rotate the pump and confirm that there is no abnormality.
If the coupling guard installation screw is loose, the coupling guard could vibrate and cause an abnormal
noise.
9 – 41
9. MAINTENANCE AND ALARM LIST 9-4 Maintenance and Inspection of the Dielectric Fluid
9-4 Maintenance and Inspection of the Dielectric Fluid Temperature

Control Unit
For safety purposes, always turn the main power OFF before starting
WARNING maintenance or inspection.
Inspection
Item Details
interval
Must be no abnormal vibration or noise.
General Ambient temperature (during operation) 10 to 35°C Daily
Power voltage Single-phase 200/200 to 220VAC ± 10% 50/60Hz
Remove any adhered dust with compressed air or a brush.
Air filter Daily
(Clean the filter once a week.)
Condenser fins Remove any adhered dust with compressed air or a brush. Periodically
Check that there are no fluid leaks, and that there is no abnormal
vibration or noise at the pipes.
When draining the fluid from the machine system, or when stopping
operation with the fluid drained, always drain the fluid accumulated in
Cooler Daily
the cooler from the cooler water outlet.
If fluid is left accumulated in the cooler, it could freeze or sludge, etc.,
could adhere on the inner side of the cooler. This can inhibit proper
functions.
Check that no dust, etc., has adhered to the control PCB.
Once a
Electric unit Check that the terminal block screws are tightened, and clean with
year
compressed air.
The large capacity electrolytic capacitor will deteriorate in approx. five
Electrolytic years, although this will differ according to the working conditions. Once every
capacitor When five years have elapsed after introduction, request for five years
inspection and replacement of the electrolytic capacitor.
9 – 42
9-4-1 Cleaning the air filter
• If the air filter installed on the front of the condenser is clogged, cooling will be disabled, the unit could fail and
alarms could occur. Check and clean the air filter once a week.
• Replace the air filter once every three to six months.
Note that the air filter replacement cycle will differ greatly according to the installation environment.
• Always mount the air filter when operating the machine.
(1) Remove the filter by pulling it forward and out.
Do not touch the condenser when the filter is removed.

CAUTION Failure to observe this could lead to injuries.
(2) Clean off any dirt from the filter with a vacuum cleaner or by washing with water.
• If the filter is heavily contaminated, clean it in lukewarm water in which a neutral detergent has been
dissolved.
• Do not wash the filter with hot water (approx. 50°C or more). The filter could deform.
(3) After rinsing the filter with water, dry it thoroughly in the shade.
• Do not dry the filter in direct sunlight or with a direct flame.
(4) Install the filter at the original position. (Follow the removal procedures in reverse.)
9-4-2 Cleaning the unit cooler
Wipe off the temperature control unit with a soft cloth.

Do not use substances that could damage the product such as gasoline, benzene, thinner, abrasive powder,
detergent or insecticide.
9-4-3 Cleaning the condenser
Purpose
The unit cooler's condenser may become clogged when dust or oil mist in the area adheres to it.
Clogging of the condenser can lead to faults in the unit cooler, so periodically clean the condenser (once every
six months). The procedures for cleaning the condenser are explained in the following section.
9 – 43
Procedures
<NOTES>
• Stop operation and turn power switch OFF before starting this procedure.
WARNING A fan is rotating at a high speed during operation. There is a risk of injury.
• Do not touch the condenser fins. There is a risk of injury.
CAUTION • Note that dust, etc., will scatter when cleaning.
• Carefully handle the sheet metal parts. There is a risk of injury.
(1) Disassembling the unit

1) When removing the top panel
1. Remove the blow-off port guard.
(Four screws) 5. While tilting the motor legs, remove from
2. Remove the fan. (One nut) the blow-off port.
Fan nut
Four screws
3. Remove the four motor leg screws. 6. Place the motor leg (with motor) on the
top panel.
Four screws
Motor leg
Top panel
* Use a short (approx. 8cm) screwdriver.

4. Face the condenser on the motor leg side
upward, and tilt the unit.
9 – 44
2) When not removing the top panel

1. Remove the service panel. (Eight screws) 4. Remove the four motor leg screws.
Top panel
Eight screws
Service
panel
Motor leg
Four screws
2. Remove the top panel. (Seven screws) 5. Place the motor leg (with motor) on the
electrical part box.
Filter fixing clamp Electrical part box
* The filter fixing clamp is tightened together.

Take care not to lose it.
3. Remove the fan. (One nut)
Fan nut
(2) Cleaning the condenser

7. Blow any dirt off the condenser with compressed air.
8. Clean the condenser with a commercially-available air-conditioner cleaner, etc. If the condenser is
heavily contaminated with oil and is difficult to clean, use an oil-removing detergent. At this time, the
dirtied cleaner will drop down to the bottom of the unit cooler, so wipe it off with a rag, etc.
9. Blow off any cleaner remaining on the condenser or unit cooler with compressed air.
(3) Assembling and checking the unit

10. Install the fan and panel, etc., following the disassembly procedures in reverse.
11. Turn the dielectric fluid ON, start the unit cooler, and confirm that there is no abnormal noise, etc.
9 – 45
9-4-4 Error codes and remedies
Error codes
When a protection function activates, the unit will stop operation, and an error code shown in the following
table will appear at the display.
Work procedures when error codes is displayed

• For E1 to E6
(1) Press the RESET switch on the display section. (Cancel the error)
(2) Once the recovery conditions are established, operation will start in approx. 30 seconds after the code is
displayed.
(3) If E1 to E6 apepars again after operation resumes, carry out the "remedy" given in the table.
(4) If the error recurs after carrying out the "remedy", contact your nearest Mitsubishi branch, sales office or
RKE Co., Ltd.
• For C3, C6 and C7

(1) Watch the state for a short time. (If the error is reset, the operation will automatically resume.)
(2) If the error code does not disappear or if it appears frequently, carry out the "remedy" given in the table.
(4) If the error recurs after carrying out the "remedy", contact your nearest Mitsubishi branch, sales office or
RKE Co., Ltd.
* If an error code does not appear but the unit does not start or does not stop, contact your nearest Mitsubishi
branch, sales office or RKE Co., Ltd.
9 – 46
Error Details (meaning of error Recovery

Remedy Recovery conditions
code display) method
Discharge pressure error • If there is any object obstructing the Discharge pressure Reset switch
Discharge pressure intake/exhaust, remove it. (63H) ≤ 3.1 ± 0.15MPa
(63H) ≥ 4.1 ± 0.1MPa • When using in an installation environment Condenser temperature
Condenser pressure with high intake temperature, set to an (TH11) < 70°C
(TH1) ≥ 70°C appropriate temperature.
E1 Discharge temperature error (Use of this unit within an ambient Discharge temperature
Discharge temperature temperature of 15 to 30°C is recommended.) (TH) < 116°C)
(TH) ≥ 116°C • If the air filter is dirty or contaminated with
foreign matter, clean or replace the filter.
• If the condenser fin is dirty or contaminated
with foreign matter, clean with compressed
air or a brush.
Inverter error Contact your nearest Mitsubishi branch, sales 30 seconds after code is Reset switch
E2
office or RKE Co., Ltd. displayed.
Thermistor error Contact your nearest Mitsubishi branch, sales Release open or short-circuit Reset switch
Thermistor open/short-circuit office or RKE Co., Ltd. set
TH2 : Water outlet (Repair broken wire or
temperature detection connection disconnection)
TH4 : Freezing prevention
E3
temperature detection
TH11 : Condenser
temperature detection
TH12 : Overcooling detection
Pressure switch (63H) open
Thermistor error Contact your nearest Mitsubishi branch, sales Release open or short-circuit Reset switch
• PCB temperature thermistor office or RKE Co., Ltd. set
E4
• Fin temperature thermistor (Repair broken wire or
connection disconnection)
Heating degree error Contact your nearest Mitsubishi branch, sales Heating degree Reset switch
E5 Heating degree office or RKE Co., Ltd. (TH – TH11) ≤ 80°C
(TH – TH11) > 80°C
Cooling performance insufficient • If there is any object obstructing the 30 seconds after code is Reset switch
Temperature difference intake/exhaust, remove it. displayed.
(TH2-TH1) ≥ 9°C for three • When using in an installation environment
consecutive hours with high intake temperature, set to an
appropriate temperature.
(Use of this unit within an ambient
temperature of 15 to 30°C is recommended.)
• If the air filter is dirty or contaminated with
E6 foreign matter, clean or replace the filter.
• If the condenser fin is dirty or contaminated
with foreign matter, clean with compressed
air or a brush.
• If the heat load to be cooled by this
temperature control unit is large, set the
heating amount to the correct value. (Refer to
the capacity curve diagram in section 2.3
Specifications for this unit's cooling capacity.)
Fluid freezing prevention • If the intake temperature is low, set to the Water outlet temperature (TH2) Automatic
Water outlet temperature (TH2) correct temperature. ≥ 7°C, and
< 4°C, or (Use of this unit within an ambient Freezing prevention
C3
Freezing prevention temperature temperature of 15 to 30°C is recommended.) temperature (TH4) ≥ 7°C for
(TH4) < 4°C for one consecutive one consecutive minute
minute
Heating degree error Contact your nearest Mitsubishi branch, sales 30 seconds after code is Automatic
C6 Heating degree (TH-TH11) < office or RKE Co., Ltd. displayed.
0°C for 20 consecutive seconds
Communication error Contact your nearest Mitsubishi branch, sales Reset internal communication Automatic
C7
office or RKE Co., Ltd. error
9 – 47
9. MAINTENANCE AND ALARM LIST 9-5 Automatic Threader (AT Unit) Maintenance
and Inspection Methods
9-5 Automatic Threader (AT Unit) Maintenance and Inspection Methods

9-5-1 Maintenance and Inspection Items
The maintenance and inspections to be carried out periodically to ensure that the automatic wire feeder and entire
system operate smoothly are shown in Table 5.1. The names of each part are shown in Fig. 5.1 and Fig. 5.2. Refer
to the pages indicated with the Reference No. for details on each item.
(1) Maintenance and inspection table
Table 5.1 Automatic Wire Feeder Maintenance and Inspection Items
Reference
Class Items Page
No.
Daily and preparatory 9-5-2 (1)-3 Inspection of the pick arm 9-54
inspections
9-5-2 (2)-3 Inspection of the wire chip guide and collection hose 9-60
9-5-2 (4)-2 Inspection of the jet water flow 9-71
9-5-2 (7)-1 Inspection of the wire chip collection box 9-82
9-6-3 (2) (3) Cleaning of wire guide block (front) 9-91
Weekly inspection 9-5-2 (3)-1 Maintenance and inspection of the power feeder 9-64
9-5-2 (4)-1 Maintenance and inspection of the upper diamond die 9-70
9-5-2 (5)-4 Maintenance and inspection of the lower diamond die 9-76
9-6-3 (2) (3) Cleaning of wire guide block (nozzle base, cylinder shaft) 9-91
Monthly inspection 9-5-2 (1)-1 Cleaning of the wire breakage detection sensor 9-51
9-5-2 (1)-4 Cleaning of the auxiliary die 9-55
9-5-2 (1)-3 Cleaning of the retry detection sensor 9-54
9-5-2 (2)-1 Inspection of the wire pressing roller 9-56
9-5-2 (2)-2 Inspection of the guide pipe 9-57
9-5-2 (2)-4 Inspection of the cutter contact 9-61
9-5-2 (2)-5 Inspection of the cutting roller 9-65
9-5-2 (5)-1 Inspection of the lower guide roller 9-73
9-5-2 (5)-2 Cleaning of guide D 9-74
9-5-2 (5)-3 Cleaning of the aspirator sensor 9-75
9-5-2 (6)-1 Inspection of the collection roller 9-77
6-month inspection 9-5-2 (1)-2 Inspection of the main tension roller 9-52
9-5-2 (6)-1 Inspection of the collection roller bearings 9-77
9 – 48
1-1 Wire breakage 1-2 Main tension roller

detection limit
1-4 Auxiliary die A
1-3 Retry sensor
4-1 Guide U
AT unit
3-2 Lower power feeder
5-2 Guide D
5-4 Lower diamond die guide 5-3 Aspirator sensor
5-1 Lower guide roller
Fig. 5.1 General drawing of BA8 wire travel system
1-4 Auxiliary die B
2-1 Wire pressing roller
2-2 Guide pipe unit
2-4 Cutter contact
2-3 Wire chip guide
2-5 Cutting roller
3-1 Upper power feeder

4-3 Jet nozzle
4-2 Upper diamond die guide
Fig. 5.2 AT unit
9 – 49
(2) Other precautions

1) Wire electrode
The wire electrode greatly affects the automatic insertion operation. Use the Mitsubishi-designated or
recommended wire electrode.
*1. Always use a non-paraffin type wire electrode. If a paraffin type wire electrode is used, the wire electrode
could slip at the main tension roller. This could prevent the designated tension from being applied on the
wire electrode during machining.
*2. Use a wire having characteristics following the references given in Fig. 5.3. If a wire that does not satisfy
the reference value is used, the automatic connection range could drop and the machine could stop.
1. Naturally hang an L0 = 1000mm wire.
2. Curl rate (longitudinal direction) L0–L1 : 2% or less

L0
L0=1000mm
3. Curl rate (horizontal direction) L2 : 5% or less

L1
L0
Within 4. Wave : Within 3 peaks
3 peaks
Wire electrode
L2
Fig. 5.3 Wire characteristics
2) Measures to prevent damage of wire guide section

• When carrying out multiple setup machining, such as sequential feed type machining, always provide an
uncut section in the NC program so that the cut material do not drop.
• Always check the "E.S.P.E.R>CHECK/ESTIMATE"screen before machining, and make sure that
"Automatic Insertion (M20)" and "Automatic Cut (M21)" are commanded correctly.
3) If the start hole diameter is ø1.5mm or less, or if the jet water flow interferes at the side of the start hole, the
success rate of the automatic insertion with the retrace function will drop. Thus, in the above ceases, lower
the machining condition settings, and avoid wire breakage when possible.
Start hole limits (Apply to ø0.5mm to ø1.5mm)

• Start hole roundness Within 0.1mm
• Start hole surface roughness Within 50µmRmax
(3) AT Maintenance Guidance Screen

The AT unit's maintenance sections and maintenance procedures can be confirmed on the AT Maintenance
Guidance screen. Refer to the explanation on the AT Maintenance Guidance screen in "NC Operation and
Display Screen Section".
9 – 50
9-5-2 Maintenance and Inspection Methods

(1) Wire Feed System
(1)-1 Wire breakage detection limit
Wire breakage detection limit
Pulley (1)
Wire retainer
Fig. 5.4
The wire breakage detection limit is a limit switch which detects whether the wire has broken during wire travel.
Inspection Method
The lower side of the wire breakage detection limit should be touching the wire during wire feed (when threaded).
The pick arm's wire will deform easily, so handle it carefully.
9 – 51
(1)-2 Main tension roller

Pulley (2) Main tension roller
MT pinch roller A
MT pinch roller B
Fig. 5.5
Inspection Method
The wire tension will fluctuate if there are scratches on the surface of the main tension roller or MT pinch rollers
A/B, or if the groove has deepened due to wear.
To prevent the tension from fluctuating from the deep scratches, the MT pinch roller should be used according to
each wire diameter (for ø0.1 wire, for ø0.2 wire).
1) If the roller is dirtied → Wipe the surface with thinner.
2) If there is a groove on the roller → Replace when the depth is 0.2mm or more.
3) If the main tension roller slips → Replace the roller. Refer to the Replacement Methods.
Replacement Methods
1) Turn over or change the position of the main tension roller and MT pinch roller A,B.
Four areas of the main tension roller can be used. When the surface currently being used is worn, turn over
or change the position of the roller as follows to use the unused surface:
Area ○
1 : Original position.
↓
Area ○
2 : When the area 1 is worn, turn over the main tension roller and MT pinch roller A,B to use the
area 2.
↓
Area ○
3 : Change the position of the main tension roller,MT pinch roller A,B and the spacer1,spacer2 to
use the area 3.
↓
Area ○
4 : Turn over the main tension roller and MT pinch roller A,B again to use the area 4.
Refer to Fig 5.7a and 5.7b
9 – 52
Key Shaft of main tension roller
Main tension roller

MT pinch roller A
Spacer 2
Spacer 1
Fig. 5.6
①
② ① ④③
④
③
Spacer 1
② Spacer 1
① ②
Fig.5.6a Fig.5.6b
2) If the four areas have been already used, replace the roller with the new one.
3) After installation, confirm that the main tension roller is flush with the MT pinch roller A and B. (Refer to Fig 5.7c)
Correct Wrong Wrong
Fig.5.6c
NOTE When cleaning the surface of the MT pinch rollers A or B due to the adherence of foreign matter,
use thinner instead of water or alcohol.
Do not use the machine if the main tension roller is not flush with the MT pinch roller A and B. The
wire might slip off the rollers, which causes machine downtime.
9 – 53
(1)-3 Retry sensor and pick arm
LED
Retry sensor Pick arm
Fig. 5.7
The retry sensor detects that the wire has deflected due to catching or jamming in the path while the feed motor is
feeding the wire. The pick arm reverse runs the feed motor during quick retry of the insertion to prevent the wire
from vibrating the when deflection returns.
Inspection Method
1) Check whether the surface of the retry sensor is dirty. If dirty, clean with the following method.
2) The pick arm passes the wire through the wire ring section when threading the wire. In the correct state, the
pick arm should lightly contact the wire during wire feed (when there is no deflection, and the wire is straight).
The wire is hardened, but take care when handling as it can easily deform.
Cleaning Method
If the surface of the retry sensor is dirty, an accurate detection will not be possible, so clean the surface. Directly
wipe the surface with a dry cloth, or clean with alcohol.
NOTE When cleaning, do not use organic solvents such as thinner.
9 – 54
(1)-4 Auxiliary die

<Auxiliary die A (feed panel)>
Inspection Method
1) Check whether the wire can be easily passed
through the pipe and auxiliary die A without
jamming.
2) If the wire jams, or if the wire cannot be passed
through, clean the pipe and auxiliary die A with the Pipe
following method.
Cleaning Method
1) Loosen the set screw at the side of the pipe, and
Auxiliary die A
remove the pipe.
2) Using a hexagon wrench, remove the auxiliary die A
from the auxiliary die bracket.
Auxiliary die A holder
3) Clean the inside of the pipe with an air gun, etc.
4) Clean the auxiliary die A with an ultrasonic cleaning Fig. 5.8
device.
5) Using a hexagon wrench, fix the die onto the auxiliary die bracket.
6) Install the pipe at the original position, and fix with the set screw.
7) Thread the wire, and travel the wire in the wire feed state. Confirm that the wire does not interfere with the
inner wall of the pipe.
<Auxiliary die B (AT unit)>

Inspection Method Auxiliary die B
1) Check whether the wire can be easily passed through

without jamming. Auxiliary die B block
Set screw
2) If the wire jams, or if the wire cannot be passed through,
clean the auxiliary die B with the following method.
Cleaning Method
1) Using a hexagon wrench, remove the auxiliary die B from
the auxiliary die bracket.
2) Clean the auxiliary die B with an ultrasonic cleaning device. Fig. 5.9
3) Using a hexagon wrench, fix the die at the original position on the auxiliary die bracket.
NOTE The inner diameter of the auxiliary die A is ø1mm, and is ø0.5mm for the auxiliary die B. Take care
not to mistake these.
9 – 55
(2) AT Unit
(2)-1 Wire pressing roller
Wire pressing roller
Wire pressing pinch roller
Fig. 5.10
The wire pressing roller is configured of the wire pressing roller on the fixed side and the wire pressing pinch roller
on the pressing side (fixed on the cylinder). These rotate while pressing the wire during wire feed. These rollers
have the following two functions.
1) The wire is sandwiched and energized during the wire straightening process.
2) Returning of the wire is prevented by the one-way clutch provided on each roller.
These rollers close and sandwich the wire only while the wire is running and during wire straightening process.
Inspection Method
If the wire surface is contaminated by foreign matter from the wire, or if grooves have formed due to wear causing
slipping, an energizing fault could occur. Check whether the roller surface is dirty.
Cleaning Method
Clean the surface of the wire pressing roller and wire pressing pinch roller with a cotton swab, etc., soaked with a
weak acidic detergent (KC12). If grooves have formed on the roller, replace the roller.
9 – 56
(2)-2 Guide pipe

The guide pipe lowers when inserting the wire, and feeds the wire to the upper guide block with air transfer
force without applying excessive force on the wire. If the guide section is dirty, the elevation operation could
be faulty. If dirt, etc., is present in the nozzle or the inner surface of the guide pipe, the wire will not be
transferred, and the connection rate could drop or the connection could be inhibited. The self-cleaning
function to automatically clean the nozzle section with air will activate every five hours of machining or every
20 insertions to prevent the nozzle from clogging. (Refer to AWF function list in NC Operation Display
Screen.)
Inspection Method
1) Check whether the LM guide or cylinder surface is dirty.
2) Pass the wire electrode through from the top of the guide pipe, and check whether the nozzle section is
clogged.
Compressed coil spring

M3×5 Hexagon socket bolt
Spring retainer (1)
Spring retainer (2)
Cylinder
Hold plate
LM guide
Nozzle
Pin Mounted guide pipe unit
O-ring (C00507A)
Slider head
Fig. 5.12
O-ring (C00509A)
Guide pipe
Hold plate
Fig. 5.11 Exploded view of guide pipe unit
9 – 57
Cleaning Method
1. Using the self-cleaning function manually
If the nozzle is not very dirty, remove the wire from the guide pipe, and press the STATUS "SELF CLEANING"
button to clean the nozzle.
* Don’t operate the self cleaning function while connecting the wire.
* This step is more effective if carried out periodically before the nozzle is completely clogged.
2. Disassembled cleaning method

The guide pipe section that guides the wire is configured of the slider head that slides and moves with the
cylinder and LM guide, and the aspirator nozzle with projected end to generate suction force. These are
sealed and fixed with an O-ring, pressing plate and bolt. Clean the inside of the guide pipe with the following
procedures.
1) Press the switch status "PIPE LOWER" on the NC unit, and lower the guide pipe unit.
2) Loosen the four hexagon socket bolts on the top of the slider head, and remove the retainer plate.
3) Remove the nozzle. Catch a fine pin, etc., into the hole on the top of the nozzle and pull the nozzle
upward and off so that the nozzle is not damaged.
4) Clean the inside of the guide pipe and aspirator nozzle with a cleaning agent such as GP Cleaner.
5) After cleaning, install the nozzle and retainer plate following the steps above in reverse, and fix by
tightening the four hexagon socket bolts.
6) Press the switch status "PIPE LOWER", and confirm that air does not leak from between the retainer
plate and slider head. There is no problem even if a slight amount of air leaks from the top of the nozzle.
Normally, the guide pipe does not need to be removed. However, if necessary, use the following procedures
to remove and install the guide pipe.
1) Loosen the four M3 bolts, and remove the guide pipe with the slider head.
2) Loosen the four socket bolts on the bottom of the slider head, and remove the retainer plate.
3) Remove the guide pipe.
4) After cleaning, install each part onto the slider head following the above procedure in reverse.
5) Install the LM guide onto the slider head with the following procedure.
(1) Insert the slider head into the air cylinder pin.
(2) Lift the movable block of the LM guide, and temporarily fix to the slider head with the M3 bolt.
(3) Press the slider head down with a hand, and adjust the inclination so that the center of the guide pipe
comes to the center of the hole on guide U at the top of the upper guide block. Then, tighten the M3
bolt.
(4) Carry out the switch status Guide Pipe Up/Down several times, and confirm that there is no
interference with the guide U.
3. Greasing the guide section

If the LM guide movement is poor due to contamination, etc., wipe off the rail surface of the LM guide and the
air cylinder with a dry cloth, and then grease the guide section.
NOTE
* Carefully clean off any adhered dirt, etc., with an ultrasonic cleaning device, etc.
* Take care not to bump the end of the guide pipe.
* The self-cleaning function is carried out just before the insertion operation. Thus, if the intervals of the
insertion operation are long, or if there is no M20 command in the program, this function may not be
activated. In this case, periodically carry out self-cleaning manually with the above method, or shorten
the self-cleaning machining time interval on the "MAINTENANCE" → "AWF FUNCTION LIST" screen
referring to Fig. 5.13.
* Make sure not to damage the O-ring when installing it.
9 – 58
Decrease the
setting from the
default time of 5
hours.
Fig. 5.13 MAINTENANCE → AWF FUNCTION LIST screen
9 – 59
(2)-3 Wire chip guide
Cylinder rod
Wire chip guide
Fig. 5.14
The wire chip guide guides the unthreaded wire to the wire chip collection duct. The unthreaded wire refers to the
wire for which the connection failed midway (fully retry), or the wire remaining in the upper wire guide when the
wire breaks. When the wire is cut by the energizer, the wire chip guide moves backward and connects with the
wire chip collection duct port protruding from the back. The wire is fed to the duct when the cutter roller runs in
reverse and is collected into the wire chip collection box with suction.
Inspection Methods
If wire chips are left in the wire chip guide, or if the inside of the guide is dirty, the wire chips will not be guided
properly. Check whether there are wire chips inside, or whether the inside is dirty.
Cleaning Method
1) If wire chips are inside the guide, remove the wire chips.
2) If the inside of the wire chip guide is dirty, clean it with a cleaning agent such as GP cleaner.
NOTE Use GP cleaner (fatty acid based organic solvent) to clean the wire chip guide. Never use other
organic solvents (toluene-based, xylene-based, or ketone-based), as these can cause damage.
9 – 60
(2)-4 Cutter contact
Cutter contact
pressing pad
Fig. 5.15
The cutting energizer is used to apply a voltage on the wire, and cut the wire with the heat generated by the current
that flows between the upper and lower energizers. Correct energizing will not be possible when water or dirt is
adhered on the surface, and the machine could be stopped with the "Cutting Error". The opposing cutting
energizer presser is used to press the wire so that the wire is correctly energized. If the cutting energizer presser
does not move out when cutting, the wire may not be cut.
Inspection Method
1) Check whether there is any water or dirt on the surface.
2) Move the cutting energizer and presser by hand to confirm that they move without catching and that the
installation state is not loose.
Cleaning Method
1) Wipe the surface off with a dry cloth or a cotton swab soaked with thinner.
2) If the contamination cannot be removed, or if the surface is worn, shift the position of the energizer.
(1) Using a spanner, remove the energizer section from the aluminum installation base.
(2) Contact a flat-tip screwdriver at the slit on the back of the energizer, and loosen the nut on the front.
Rotate and shift the energizer so that the position changes.
(3) Tighten the nut to fix the position, and return to the installation base.
(4) While pressing the energizer section against the installation base, slide it several times to confirm that
the movement is smooth. Then, fix with the spanner.
3) The cutting energizer presser is made of alumina ceramics. Wipe off the surface of the cutting energizer
presser with a dry cloth or a cotton swab soaked with alcohol.
9 – 61
Cutter contact block
Contact
Cylinder
Fig. 5.16
NOTE
1) If the movement of the energizer or cutting energizer presser is poor, apply grease on the base side key.
2) Apply Locktite, etc., in the screw section when reassembling to prevent loosening.
9 – 62
(2)-5 Wire chip take-up roller
Cutting pinch roller
Cutting roller
Cylinder
Fig. 5.17
The cutting roller has a function to sandwich and grip the wire when cutting the wire, and to take up the wire chips
to the wire chip guide. The right side, looking from the front, is the side driven by the motor, and the left side is the
pinch roller side. If the surface is dirty, the gripping force could drop, and the wire may not be pressed.
Inspection Method
Check whether copper chips, etc., have adhered to the roller surface.
Cleaning Method
1) Wipe the surface with a cloth soaked with thinner, etc.
2) If the surface of the roller is extremely dirty, clean the surface of the cutting roller or cutting pinch roller with a
cotton swab, etc., soaked with a weak acidic detergent (KC12).
* After using KC-12, rinse the acid off well with water.
3) Check that the cylinder movement does not catch. (Refer to the section "Checking the AT unit's drive cylinder
operation".)
NOTE If the movement of the cutting pinch roller's cylinder is poor, apply grease on the key.
9 – 63
(3) Power Feeder

The power feed terminal feeds power to the wire electrode. This terminal will wear due to electrical discharge
when machining is carried out for a long time.
If the wire breaks frequently between the electrodes during machining, remove and inspect the power feed
terminal with the following procedure.
(3)-1 Upper power feed terminal

Inspection Method
1. Removing the upper power feed terminal
1) Loosen the power feed terminal set screw.
2) Push out one side of the power feed terminal with a rod wrench, and pull the power feed terminal out from
the other side.
3) If the groove formed on the power feed terminal is deep (guide: approx. 0.5 to 1.0mm), refer to the
following "Positioning the upper power feed terminal", and shift the position to a new unworn position.
Push with rod wrench

Power feed terminal
set screw
Pull out power feed terminal
Fig. 5.18
2. Positioning the upper power feed terminal

Any position on the upper power feed terminal can be designated as the wire travel position, by using the
power feed terminal positioning jig. (Fig. 5-19(a))
1) Loosen the set screw for the lower spacer on the power feed terminal positioning jig, and remove the
lower spacer. (Fig. 5-19 (b))
2) Place the power feed terminal on the guide on the positioning block. Slide the power feed terminal along
the guide section until the terminal end contacts the A surface of the positioning shaft. (Fig. 5-19 (c))
3) In the state of step 2), move the positioning shaft so that the new surface of the power feed terminal
comes to the right end of the positioning block (power feed terminal usage position), and then fix with the
positioning block's set screws.
4) Insert the power feed terminal into the power feed terminal insertion port on the upper wire guide block.
With the end of the positioning shaft contacted against the power feed terminal, push in the power feed
terminal until the B surface of the positioning block contacts the right end of the upper wire guide block.
The position of the right end of the positioning block in step 3 will then be the wire travel position.
(X dimensions are the same.) (Fig. 5-19 (d))
9 – 64
Positioning block Set screws

Ball plunger
Positioning shaft
Lower spacer
(a) Power feed terminal positioning jig
B surface Guide section A surface
(b) Rear view of (a) (after lower spacer is removed)
Usage position (wire travel position)

A surface
Power feeder
Positioning block Positioning shaft
B surface
Right end of
positioning block
Ⅹ
(c) Determining the power feed terminal usage position (randomly set)
Wire travel position

Upper wire guide block
Positioning shaft
Positioning block
Power feed
terminal
(d) Inserting the power feed terminal
Fig. 5.19
9 – 65
3. Installing the upper power feed terminal

After changing the usage position of the power feed terminal, securely tighten the power feed terminal set
screws.
If machining is started without sufficiently tightening the set screws, the power feed to the wire will be
insufficient, and the machining speed and machining accuracy could drop.
NOTE 1) The power feed terminal can be used at a 1.5mm pitch, so a total of 24 positions on one side can
be used.
After using each side at 24 positions, replace with a new power feed terminal.
2) Wear of the power feed terminal will differ according to the usage state and machining speed.
If the machining speed drops or if the wire breaks frequently, the power feed terminal may have
reached its life.
9 – 66
(3)-2 Lower power feeder
Inspection Method
1. Removing the lower power feed terminal
1) Loosen the power feed terminal set screw on the back of the lower wire guide.
2) Push out one side of the power feed terminal with a rod wrench, and pull the power feed terminal out from
the other side.
3) If the depth of the groove formed on the power feed terminal is deep (guide: approx. 0.5 to 1.0mm), refer
to the following "Positioning the lower power feed terminal", and shift the position to a new unworn
position.
Push with rod wrench
Pull out power feed terminal
Lower wire guide Power feed terminal set screw
Fig. 5.20
2. Positioning the lower power feed terminal

Any position on the lower power feed terminal can be designated as the wire travel position, by using the
power feed terminal positioning jig. (Fig. 5-21 (a))
1) Attach the lower spacer for the power feed terminal positioning jig. (Fig. 5-21 (b))
2) Place the power feed terminal on the guide on the positioning block. Slide the power feed terminal along
the guide section until the terminal end contacts the A surface of the positioning shaft. (Fig. 5-21 (c))
3) In the state of step 2), move the positioning shaft so that the new surface of the power feed terminal
comes to the right end of the positioning block (power feed terminal usage position), and then fix with the
positioning block's set screws.
4) Insert the power feed terminal into the power feed terminal insertion port on the lower wire guide block.
With the end of the positioning shaft contacted against the power feed terminal, push in the power feed
terminal until the B surface of the positioning block contacts the right end of the upper wire guide block.
The position of the right end of the positioning block in step 3 will then be the wire travel position.
(Y dimensions are the same.) (Fig. 5-21 (d))
9 – 67
Positioning block Set screws

Ball plunger
Positioning shaft
Lower spacer
(a) Power feed terminal positioning jig
Guide section C surface

B surface
(b) Rear view of (a)
Power feed terminal usage position (wire travel position)

C surface
Power feed terminal
Lower spacer
Positioning block
Positioning shaft
B surface
Right end of
Y positioning block
(c) Determining the power feed terminal usage position (randomly set)
Wire travel position
Positioning shaft
Lower spacer
Positioning block
Power feed
terminal
Lower wire
guide block
Y
(d) Inserting the power feed terminal
Fig. 5.21
9 – 68
3. Installing the lower power feed terminal

After changing the usage position of the power feed terminal, securely tighten the power feed terminal set
screws.
If machining is started without sufficiently tightening the set screws, the power feed to the wire will be
insufficient, and the machining speed and machining accuracy could drop.
NOTE 1) The power feed terminal can be used at a 1.5mm pitch, so a total of 24 positions on one side can
be used.
After using each side at 24 positions, replace with a new power feed terminal.
2) Wear of the power feed terminal will differ according to the usage state and machining speed.
If the machining speed drops or if the wire breaks frequently, the power feed terminal may have
reached its life.
9 – 69
(4) Upper Wire Guide

(4)-1 Upper diamond die
Upper diamond die Rectifying ring hole
Pin gauge
Upper nozzle
Position of horizontal hole

Clean the hole with a pin gauge or wire, etc.
Fig. 5.22 Upper diamond die replacement method Fig. 5.23 Clean the horizontal hole of the
upper diamond die
Inspection Method
If the upper diamond die is dirty or if the hole for cooling is clogged, the automatic connection rate could drop, or
the wire could break during machining. If the No. of upper diamond die retries on the AT Maintenance Guidance
screen increases, clean the diamond die with the following procedures.
Cleaning Method
1) Remove the upper nozzle. (The upper nozzle is screwed in.)
2) Remove the diamond die using the die replacement jig.
3) Submerge the diamond die in an acidic cleaning agent, and clean with an ultrasonic cleaner or nylon brush.
(Recommended product: Nippon Mecha-Chemical Co., Ltd. KC-12 2 to 3% water-diluted solution.)
4) After cleaning, wash sufficiently with running water, and then dry it with an air gun.
NOTE The side hole at the tip is for the cooling water. If this hole is clogged with sludge, etc., the wire could
break. During maintenance, always confirm that this hole is not clogged.
9 – 70
(4)-2 Jet nozzle

Inspection Methods
Check whether the jet water flow is correct.
If the jet water flow is faulty, as shown in Fig. 5.24, the following measures must be taken.
Fig. 5.24
Cleaning Method
1) Check that the pressure set for the jet water flow is correct. The optimum jet fluid pressure will differ according
to the start hole diameter, but normally is 0.4MPa.
Check the jet fluid pressure and adjust to the correct pressure.
2) Check whether there is any foreign matter in the wire guide's upper block. If the inside of the block is heavily
dirtied, clean it.
3) Clean the hole of the rectifying ring for the upper diamond die with a nylon brush, etc.
4) If the jet nozzle is heavily dirtied, clean it. If foreign matter has entered or adhered into the jet nozzle or
opening, remove it with a cotton swab or wooden toothpick.
5) Apply a small amount of grease onto the jet nozzle's O-ring. Replace the O-ring if it is damaged.
O-ring
Jet nozzle
Spring
Opening part
O-ring
Toothpick
Fig. 5.25 Replacement method Fig. 5.26

of jet nozzle
9 – 71
Precautions for handling the jet nozzle

1) Jet nozzle
The nozzle is manufactured of ceramics at a high accuracy.
If impact is applied on the inside or outside of the nozzle, or if a strong concentrated force is applied, the
nozzle could chip. Take special care when handling the nozzle.
2) Precautions for handling

(a) Storing the nozzle
Wrap the nozzle in cushioning material, and make sure that it does not contact other parts or other
nozzles.
(Avoid storing the nozzle in a tool box or with other parts.)
Nozzle
Shock
absorbing sheet
Jet nozzle
(b) Do not apply impact on the nozzle.

Do not throw or drop the nozzle.
Avoid handling the nozzle with tools, and use hands when possible.
(c) Precautions for dielectric fluid

If foreign matter (cutting chips, etc.) enters the dielectric fluid, the nozzle will wear easily. Accurately
service the dielectric fluid filter (refer to section 3.1.2), and make sure that foreign matter does not enter
the clean fluid tank of the dielectric fluid reservoir.
9 – 72
(5) Lower Wire Guide

(5)-1 Lower guide roller
Pin
Lower guide roller unit
Aspirator sensor
Bearing
Rectification Bearing Knurled screw
ring (Left screw)
Lower guide roller

Coller
Fig. 5.27
The "lower guide roller" functions to smoothly feed the machined wire from the lower arm through the back of the
machine and collect it in the collection pipe.
Inspection Method
If machining sludge or dirt, etc., enters, causing the rotation of the lower guide roller bearings to drop, the wire
tension will increase above the adjustment value and cause the wire break. In this case, clean or replace the lower
guide roller bearings with the following method.
Cleaning Method
1) Rotate the shaft (knob of knurled screw) in the clockwise direction (left-handed screw), loosen and remove
the shaft. (IF the shaft cannot be loosened by hand, loosen by using a hexagon wrench at the cap bolt at the
center of the shaft.
2) The bearings, collar, roller and bearings are fit in order into the shaft. These will come off easily, so take care
not to lose them.
3) With all parts assembled, freely rotate the lower guide roller by hand, and confirm that the roller rotates
properly. If there is any catching, clean with a cleaning device, and then check again. If the state does not
change, replace the bearings.
4) If the groove where the roller contacts the wire is deep, replace the roller.
5) Check that there are no wire chips or contamination in the block housing. Clean if any is found.
6) Install all parts following the removal procedure in reverse. Fix the shaft by rotating it in the counterclockwise
direction(left-handed screw).
NOTE
* Note that the shaft (knob of knurled screw) is a left-handed screw.
* Always insert the collar between the left and right bearings. If the collar is not installed at the specified
position, the wire could break and the machining accuracy could drop.
9 – 73
(5)-2 Maintenance of guide D
Guide D (front)
Guide D (back)
Fig. 5.28
Guide D functions to press the wire against the power feed terminal between the terminal and the lower diamond
die. The wire chips will increase when machining is carried out for a long time or at a high speed. Cleaning fluid is
constantly injected from the left inner side of the guide and discharges the wire chips from the cutout on the front
cover.
Inspection Method
If the No. of retries for "Guide D" on the AT Maintenance Guidance screen increases, pass a wire through the
lower diamond die, and check whether there is clogging or catching. If there is clogging or catching, clean guide D
with the following procedure.
Cleaning Method
1) Remove the three M6 socket bolts fixing the guide D, and remove the guide D from the lower guide roller
block as shown in Fig. 5-27. (The guide D is fastened with two positioning pins, so it may be difficult to remove.
In this case, set a wrench on the socket bolts between the positioning pins, and tighten in the clockwise
direction. The guide D will lift up, and can be removed easily.)
2) Loosen the three M4 bolts fixing the guide D, and remove guide D.
3) Clean the removed guide D in the same manner as the diamond die, using ultrasonic cleaner or nylon brush
after soaking it in an acidic agent(KC-12).
4) Assemble the parts following step 1) to 2) in reverse. Note that guide D is fixed while positioning the back side
to the lower guide block.
NOTE When fixing guide D, securely press and fix as this section determines the power feed terminal
shearing amount.
9 – 74
(5)-3 Aspirator sensor
Aspirator sensor
Guide D
Fig. 5.29
The aspirator sensor is located between the guide D and lower guide roller. When the wire is inserted, it is
detected that the wire has accurately passed through the lower diamond die.
Inspection Method
If the No. of retries for "Aspirator Sensor" increases on the AT Maintenance Guidance screen, or if the lower
collection water is not discharged, the aspirator sensor may be clogged with sludge. Clean the aspirator sensor
with the following procedures.
Cleaning Method
1) Remove the three M6 socket bolts fixing the guide D, and remove the guide D from the lower guide roller
block as shown in Fig. 5-27. (The guide D is fastened with two positioning pins, so it may be difficult to remove.
In this case, set a wrench on the socket bolts between the positioning pins, and tighten in the clockwise
direction. The guide D will lift up, and can be removed easily.)
2) Remove the four pan-head screws installing the aspirator sensor. (The sensor can be removed easily in the
same manner as guide D by screwing in the set screws.)
Take care not to lose the O-ring.
3) Clean the inner surface of the removed aspirator sensor with a cotton swab soaked in an acidic cleaning
agent (KC-12). If heavily dirtied, lightly polish with sandpaper, etc.
4) If sludge, etc., is adhered on the taper section of the aspirator sensor installation surface of the lower guide
block, the lower collection performance will drop.
Remove any sludge, etc., if found.
5) In respect to the aspirator sensor, remove any sludge, etc., found on the taper surface.
6) Check whether the hole on the side of the rectifying ring is clogged, and clean it if clogged.
7) Set the O-ring on the aspirator, and assemble the sensor following steps 1) and 2) in reverse. Assemble the
sensor following steps 1) to 2) in reverse.
NOTE When installing the aspirator sensor, return so that the set screws do not project from the bottom of
the sensor, Then, install the sensor, and fix with the pan head screws. Lightly tighten the set screws
at the fixed position, and then install the guide D.
The guide D could deform if the set screws are projecting.
9 – 75
(5)-4 Lower diamond die
Lower nozzle
Nozzle presser
Lower diamond die

Pin gauge
Spring
Position of the horizontal hole.

Clean the hole with a pin gauge
or wire, etc.
Fig. 5.30 Fig. 5.31
Inspection Method
If the diamond die is clogged with sludge or dirt, etc., the wire could break during machining, or the insertion may
need to be retried. Clean or replace the diamond die with the following procedures.
A hose is connected to the left side of the guide to constantly supply dielectric fluid to the left side of the power feed
die. This constantly cools the power feed die, and cleans to prevent contamination caused by sludge. If the fluid is
not discharged properly, check the hose and solenoid valve, etc.
Cleaning Method
Cleaning the lower diamond die
1) Remove the lower nozzle, nozzle presser and spring.
2) Remove the diamond die using the die replacement jig.
3) Submerge the lower diamond die in an acidic cleaning agent (refer to section 5.4.4-2 Upper diamond die),
and clean with an ultrasonic cleaner or nylon brush. After cleaning, wash sufficiently with running water, and
then dry it with an air gun.
* Note that submerging the diamond die in the acid for a long time could cause the diamond sections to fall
off.
4) Assemble following steps 1) to 2) in reverse.
NOTE
1) When installing the nozzle presser, make sure the stamp faces forward.
2) The side hole at the tip is for the cooling water. If this hole is clogged with sludge, etc., the wire could break.
During maintenance, always confirm that this hole is not clogged.
3) Always use the diamond replacement jig when tightening the diamond die.
9 – 76
(6) Wire Collection Unit

(6)-1 Wire collection unit
Pressing force changeover regulator
Cylinder
Housing
Pinch roller
Capstan roller Pipe end
The wire collection roller is configured of the capstan roller on the fixed side and the pinch roller on the
pressing side. When the wire is fed, the wire is sandwiches and pressed by the rollers which rotate. Tension
is applied on the wire between the main tension rollers and wound up.
Inspection methods
1) If the roller surface is contaminated with wire scraps or is worn and has grooves, the set tension will not
be applied, and the collection wire could easily curl.
• If the roller is contaminated, clean the surface.
• If the roller is damaged, reverse the roller, change the spacer position, or replace the roller.
2) Is the curled state correct? (Use the following guide to judge whether the curled state is correct.)
When not rotating : Within three crests having 30mm width or less per 1m.
During 1st cut : The wire must make a 200mm diameter or more circle when fit into the wire
collection box, and must not build up abnormally. (for ø0.2BS wire)
* Rollers should be used according to wire diameter to prevent the wire from slipping because of
the wire scratches on the roller surface.
<Replacing the rollers>

1) Remove the splash-proof cover (acrylic cover)
from the wire collection section.
Remove the pinch roller
2) Turn the roller pressing force changeover

regulator to the 0MPa position.
3) Using an M4 hexagon wrench, remove the M4

socket bolt on the pinch roller section, lift up the
housing, and remove the pinch roller off the shaft.
There is a collar in the pinch roller. Remove it so Remove the M4 bolts
that it does not get lost. *1 (3 bolts)
9 – 77
4) Remove the three M4 socket bolts, and remove

the capstan roller.
There is a collar in the capstan roller. Remove it Remove the M4 bolts
so that it does not get lost. (3 bolts)
5) The collection roller's wire travel position can be

changed with the following two methods. By
using these two methods in combination, the Remove the capstan roller
same roller can be used four times. *2
1. Reversing the roller front and back

Reverse the pinch roller and capstan rollers so that the front side
comes to the back.
2. Shifting the collar position

Before setting the rollers, attach the collar previously removed onto
the end of the pinch roller and capstan roller shafts.
Attach the rollers in the same direction as the previous direction.
Collar
Attach the collar
6) If the four positions on the roller surface have

already been used, replace it with a new one.
Attach the collar to

the back of the key part
7) Following the removal procedure in reverse, fix the

pinch roller and capstan roller respectively with the
M4 socket bolts.
There is a resin spacer between the gear and roller,
so take care when inserting the screw.
A metal spacer must be attached at each shaft's
bolt mounting section.
8) Install the splash-proof cover (acrylic cover).

Attach a metal spacer
9 – 78
NOTE
1) The roller can be replaced without removing the pipe end or shifting its position, so leave the pipe end intact.
2) The wire travel position can be shifted to (1) to (4) on the collection roller.
(2)
(4)
(3)
(1)
Collection roller wire travel position
Roller Roller Shaft

Shaft
Bolt Bolt
Collar
Collar (1) (3) (4)
(2)
(1) Use normally. (Collar is on outside of roller.) (3) Attach collar to inner side of roller and use.
(2) Reverse roller's front and back, and use. (4) Reverse roller's front and back, and use.
Procedures for using four times
9 – 79
*3 Change the position or replace the upper and lower pinch rollers and capstan rollers at the same time. The
wire could curl more if only one roller is replaced.
*4 The rear side vertical sectional view of the housing and pinch roller and the disassembled parts are shown
below.
Housing
Bearing
Gear
Resin spacer Collar
Pinch roller shaft

Metal spacer
Rear side vertical sectional view of housing and pinch roller section
Housing Collar Mounting screw
Pinch roller shaft Gear + Resin spacer + Metal spacer

Capstan roller + Bearing
Disassembled housing and pinch roller section
9 – 80
<Removing the housing>

The housing must be removed when servicing the collection unit. Use the following procedures to remove the
housing.
1) Remove the splash-proof cover (acrylic cover)

from the wire collection section.
M4 bolts (3 bolts)
2) Turn the roller pressing force changeover
regulator to the 0MPa position.
3) Remove the three M4 socket bolts.

Remove the hook and stopper plate.
Stopper
Hook
4) Remove the M4 socket bolt fixing the housing, Remove the housing
and lift the housing up and off.
5) This completes the removal work.
Housing fixing bolt
6) To mount the housing again, following the removal procedures in reverse, and fix it with the M4 bolts.
7) When attaching the stopper plate, always press the stopper plate against the upper side and fix with the
M4 bolt. Lift the housing up to the stopper and fix the hook plate with the M4 screw.
* If the movable distance of the capstan roller is insufficient, an insertion fault could occur.
8) Install the splash-proof cover (acrylic cover).
9 – 81
(7) Wire Chip Collection Unit

(7)-1 Wire chip collection box
The wire chip collection box is a device used to suck in and collect the wire chips fed into the wire chip
collection hose after cutting. This device is driven by a motor and generates a suction force in the same
manner as a vacuum cleaner.
Intake
Door
Collection box
Fig. 5.32
Inspection Method
If too many wire chips accumulate, a sufficient suction force will not be generated. When the No. of collection
times set on the AT Maintenance Guidance screen has passed, always remove the wire chips from the collection
box.
Cleaning Method
1) Confirm that the "Cutting" operation is not being executed, and open the door for the cutting chip collection
box on the back of the machine.
2) Pull out the acrylic collection box, and remove the wire chips.
3) Check that there are no wire chips caught in the hose or at the opening of the wire chip collection box.
4) If any wire chips are caught in the wire chip collection hose, remove them from the hose. (Refer to the
following section on the wire collection hose.)
5) Finally, close the door.
NOTE
1) The motor has a fuse. If the motor does not operate, remove the column bar, and replace the fuse located at
the right of the device.
2) Note that the suction force will not be generated unless the door is completely closed.
9 – 82
(7)-2 Wire chip collection hose

The wire chip collection hose guides the cut wires from the wire chip collection duct to the collection box. If
long pieces of wire chips get caught inside, the wires will remain in the wire chip collection duct or wire chip
guide, and operation will stop.
Wire chip collection
切カス回収ダクト
duct
A Wire chip
collection hose
Wire chip
collection duct
Wire chip
切カスワイヤガイド
guide
Wire chip
collection box エアガン
Air gun
Fig. 5.33 Fig. 5.34
Inspection methods
Visually check whether any wire chips are caught in the wire chip collection hose, and remove any with the
following procedures.
Removing the wire chips

When relatively short wire chips are caught
1) Highlight "GUIDE TILT" on the SWITCH STATUS screen in red, and tilt the cutting chip wire guide.e
2) Insert an air gun into the wire chip wire inlet on the front of the machine as shown in Fig. 5.33.
3) Press "WIRE CHIP VACUUM" on the SWITCH STATUS screen, and generate a vacuum.
4) Turn the air on to blow out the wire chips from the hose into the collection box. (Take care so that the wire
chips do not get into eyes.)
5) Repeat steps 3) and 4).
When long wire chips are caught

1) If wire chips are caught, insert a hand from the notch on the column cover (Fig. 3.32 Section A), and pull
the hose out of the wire chip collection box, and then remove the wire chips.
2) Return the hose to near the wire chip collection box installation opening.
NOTE
* Do not remove the collection hose from the wire chip collection duct on the rear of the AT unit. Failure to
observe this could lead to duct damage.
9 – 83
9-5-3 Troubleshooting
If a fault or other abnormality occurs with this unit or the entire system, both the manual and automatic operation
will stop. The alarm lamp on the control unit will turn ON to indicate the details of the abnormality. This section
describes the causes of automatic wire feeder faults which can be remedied by the user.
If a fault other than that explained in this section occurs, or if repairs are not possible following this section, contact
the Mitsubishi Service Center.
Alarm T219 WIRE INST ERR, U722 WIRE INST ERR

State The wire cannot be inserted.
Cause 1 The number of retries exceeded the set number of times.
(Causes include clogging of the DD or guide U, ball at the tip of the cut wire, turbulent jet
flow, deviation of lower hole pitch, etc.)
Remedies (1) Clean the DD.
(2) Clean the guide U.
(3) Clean the cutting energizer.
(4) Clean the cutter roller.
(5) Clean the jet nozzle.
(6) When carrying out pitch machining, change the AWF function skip to "Valid", and
change the number of set times.
Cause 2 During insertion (M20), the wire is not fed out.
Remedies (1) Check that the wire path is correct.
(2) Check whether the wire has come off the pulley in the wire path.
Alarm U715 WIRE CUT ERROR

State (1) When executing cutting (M21), the wire could not be cut. (When the wire end is near
the cutting energizer)
(2) When executing cutting (M21), the wire end was curled up.
Cause 1 The cutting current is insufficient.
Remedies (1) Clean the energizer.
(2) Check the operation of the cutting energizer. If the movement is heavy, grease the
keyway at the installation section.
(3) Check the operation of the presser pad. If the movement is heavy, grease the
Cause 2 An appropriate cutting tension is not applied.
Remedies (1) Clean the MT roller.
Cause 3 The wire is not fed, and the wire cannot be caught between the cutter rollers during full
retry cutting.
Remedies (1) Pass the wire through the auxiliary dies A and B. If there is a load, clean.
(2) Pass the wire through the guide pipe nozzle. If there is a load, clean.
(3) Check the end of the guide pipe. If deformed, replace the pipe.
(4) Clean the main tension roller.
9 – 84
Alarm U830 CUT WIRE REMAINING

State When collecting the wire chips, there is remnant wire between the wire chip duct and
upper guide block.
(The error will occur and operation will stop if wire is remaining at the cutting section
even after the maximum wind up time is exceeded.)
Cause 1 The wire chips are caught in the wire chip guide or duct.
Remedies (1) Check the inside of the wire collection duct, and remove any remnant wire. Check
the curling rate of the wire being used. If the curling rate exceeds the reference,
replace the wire.
(2) Clean the wire collection duct and hose.
(3) Remove the remnant wire from the collection hose.
Cause 2 Sufficient suction force is not generated.
Remedies (1) Completely close the door to the wire collection box.
(2) Check that the blower fan is rotating.
If the fan is not rotating, check the fan fuse. If blown, replace the fuse. (Fuse: 7A)
Cause 3 The wire cannot be wound up with the cutter roller.
Remedies (1) Clean the cutter roller.
(2) Check that the cutter motor is rotating.
(3) Clean the cutting energizer.
Check the operation of the cutting energizer. If the movement is heavy, grease the
Check the operation of the presser pad. If the movement is heavy, grease the
(4) If the wire chip guide is tilted toward the back, check that the spring on the back of
the wire chip guide is not interfering with the cast parts of the AT unit.
Alarm U708 NO WIRE

State (1) The wire breakage detection sensor detected a wire breakage for 5 seconds or
more during insertion
(2) The retry detection sensor detected a wire slack for 30 seconds or more during
insertion
Cause 1 There is no wire left in the wire bobbin, or the remaining amount is low.
Remedies Replace the wire bobbin.
Cause 2 The wire breakage detection sensor is making an incorrect detection.
Remedies Clean the surface of the wire breakage detection sensor.
Cause 3 The operation of the wire breakage detection pulley is heavy.
Remedies Clean and grease the installation surface of the arm fixing the wire breakage detection
pulley.
Cause 4 The wire is not passed through the pick arm.
Remedies Correctly thread the wire.
Cause 5 The retry detection sensor is making an incorrect detection. The wire surface is oxidized
or the surface is not glossy.
Remedies (1) Clean the detection surface of the retry detection sensor.
(2) Replace with a new wire.
9 – 85
9. MAINTENANCE AND ALARM LIST 9-6 Maintenance of the Wire Guide Block
9-6 Maintenance of the Wire Guide Block

9-6-1 Outline
(1) Necessity of the cleaning

With the wire electric discharge machines, the wire guide block is the important part for machining
performance and accuracy.
Debris is generated by operations, making the fluid in the working tank dirty. Since the wire guide block is put
in this fluid, dirt is gradually adhered to it. Excess dirt on the wire guide block could cause the machining
performance and accuracy to drop, or the guide block to break due to abnormal electrical discharge.
To maintain the machinability as an electrical processing machine, a periodic cleaning is required.
Upper wire guide block
Lower wire guide block
Upper wire guide block Lower wire guide block
Severe adhesion to the wire guide block may cause erosion (rust) on the surface and inside of the
block, or may affect machining performance, machining accuracy, and the AT INSERT functions as
a result of the abnormal discharge generated between the power feeder and the wire guide block
due to power feed failure.
Use of a torn or non-designated filter allows the dirty fluid to circulate, resulting in acceleration of the
sludge accumulation on the guide block. To maintain fine operation of the machine, always use
the designated fluid filter and replace it when torn. (Refer to “List of consumables” in the
chapter 9-9)
(2) Outline of the cleaning

Clean the following sections of the upper and lower wire guide blocks.
9 − 86
1) Surface of the wire guide block (upper/lower)

Clean the surface of the wire guide block to prevent severe dirt adhesion.
Upper wire guide block Lower wire guide block
2) Power feed terminal installation section (upper/lower)

Inject water (water gun) or air (air gun), etc., into the power feed terminal insertion port to clean so that wire
and power feed terminal cutting chips do not build up in the power feed terminal installation section.
Power feed terminal
insertion port
3) Cylinder shaft (upper)

Following the steps below, clean the cylinder shaft, apply grease and move the cylinder several times to
confirm that the movement is smooth. (Use Multemp PS2 or equivalent product for the grease.)
(1) Remove the cylinder (two M3 screws) and cylinder base (two M4 screws) mounted on the die bracket.
(2) Apply a thin coat of grease on the cylinder shaft.
(3) Follow steps (1) and (2) in reverse to mount the cylinder and cylinder base.
Cylinder
Cylinder base
Cylinder shaft
If the axis rotation remains un-smooth after cleaning and applying the grease, contact the
service center.
9 − 87
(3) Confirmation after cleaning
1) Mount the power feed terminal correctly to the wire guide block.
Upper wire guide Lower wire guide

(Installation of the power feed terminal) (Installation of the power feed terminal)
The power feed terminal is the very important part in WEDM.

Always use the designated one and replace if torn. (Refer to “List of consumables” in the
chapter 9-9)
Use of non-designated power feed terminals could cause the machining performance to drop due
to a difference in dimensions and materials.
2) Always tighten the set screw and confirm that the power feed terminal is fixed.
Tighten the set screw
Upper wire guide Lower wire guide

(Tightening the set screw) (Tightening the set screw)
9 − 88
9-6-2 Cleaning cycle
(1) Surface of the wire guide block

Clean the surface after every machining.
(2) Nozzle base

Clean the nozzle base when changing the power feed terminal usage position.
(3) Cylinder shaft

Clean the parts when using a new surface of the power feeder.
If the dirt adhesion is too stubborn to remove, please contact the service center.
During this cleaning process, if abnormality is found in the parts, please contact the service center.
Do not use the commercial cleaning spray because it might damage the resinous part of the AT
unit.
After cleaning, close the lid and fasten the setscrew firmly. Failure to do so will cause power
feed failure, leading to abnormal discharge between the power feeder and wire guide block.
As a result, it might affect machining performance, machining accuracy, and the AT INSERT
function.
9 − 89
9-6-3 How to clean
(1) Item required

• Nylon brush
It is generally used for cleaning.
Nylon brush
• Brass brush
It is used for the severely dirty area.
Brass brush
Brushes are not included in the machine. Please purchase one for cleaning.
Never use a steel wire brush since it may damage the parts.
9 − 90
(2) Upper wire guide block
1) Surface of the wire guide block

• Remove the dirt with a nylon brush, pouring a proper amount of the dielectric fluid on the guide block
surface. Use the water gun if available since the use of it will ease this process.
• Use a brass brush for severe dirt.
Cleaning the wire guide block surface
2) Upper power feed terminal installation section

• Inject water (water gun) or air (air gun), etc., into the power feed terminal insertion port and remove any wire
or power feed terminal cutting chips.
Cleaning the upper power feed terminal installation section
3) Power feed terminal

Remove the power feed terminal from the machine, submerge in an acidic cleaning agent, etc., and clean
with an ultrasonic cleaner or nylon brush. After cleaning, wash sufficiently with running water, and then dry it
with an air gun.
Pay attention so that AT unit does not get wet with the fluid. A large amount of the fluid may
drawn the unit and cause it to break.
Do not use the commercial cleaning spray because it might damage the resinous part used in
the AT unit.
9 − 91
(3) Lower wire guide block
1) Surface of the wire guide block

• Remove the dirt with a nylon brush, pouring a proper amount of the dielectric fluid on the guide block
surface. Use the cleaning gun nozzle if available since the use of it will ease this process.
• Use a brass brush for severe dirt.
Cleaning the wire guide block surface
2) Lower power feed terminal installation section

• Inject water (water gun) or air (air gun), etc., into the power feed terminal insertion port and remove any wire
or power feed terminal cutting chips.
Cleaning the lower power feed terminal installation section
3) Power feed terminal

Remove the power feed terminal from the machine, submerge in an alkaline cleaning agent, etc., and clean
with an ultrasonic cleaner or nylon brush. After cleaning, wash sufficiently with running water, and then dry it
with an air gun.
Pay attention so that AT unit does not get wet with the fluid. A large amount of the fluid may
drawn the unit and cause it to break.
Do not use the commercial cleaning spray because it might damage the resinous part used in
the AT unit.
9 − 92
9. MAINTENANCE AND ALARM LIST 9-7 Updating the System
9-7 Updating the System

9-7-1 Updating the System
Update the system with the following procedures.
NOTE
1) The system update process cannot be interrupted or stopped.
Do not turn the power OFF during the system update process.
2) If the power turns OFF due to a power failure during the system update, and the system does not start up
correctly, refer to the section "9-7-2 Restoration When System Does Not Start up Correctly" and remedy.
3) Before updating, record the "MAINT TIMERS" and "SWITCH SCREEN 2" screens data, etc., and confirm
that the FLD contains the pitch error data.
Select the submenu "SYSTEM UPDATE" on the MAINTENANCE screen.
Turn the , and wait for the LED to turn OFF.
When the LED turns OFF, turn the again.
SYSTEM UPDATE
screen (A)
Insert the first floppy disk, and select the submenu "UPDATE".
Continued on next page
9 – 93
Continued from previous page
Were all required floppy disks inserted? Yes
No
The updated version (No. written

on the floppy disk) will appear, so
this will differ according to the
system.
Insert the next FLD, and press on the operation panel, or select [OK] using the slide pad.
When this dialog appears, press on the operation panel, or select [OK] using the slide pad.
The SYSTEM UPDATE screen (A) will appear.
Eject the floppy disk, turn , and wait for the LED to turn OFF.
If a servo alarm or MCP alarm occurs, turn the no-fuse breaker OFF and ON.
Turn the power ON.
Select "MAINTENANCE>ADMIN INFO>VERSION",

and confirm that the updated version is displayed at "MAIN SYSTEM".
9 – 94
Insert the FLD (Label name: PITCH ERROR & BACK LASH) enclosed with the machine into the FLD
drive, and select the overlap window "PROGRAM>I/O".
Input the data in the following file order.
6. F. INI (This may not be registered depending on the model or machine.)
5. ZC. INI (This may not be registered depending on the model or machine.)
4. CUTPRM. INI (01CUTPRM. INI, 015CUTPRM. INI, 015ANLPRM. INI may not be registered
depending on the model or machine.)
3. VGSET. INI (VGSET1. INI to VGSET3. INI may not be registered depending on the model or
machine.)
2. B. INI (This may not be registered depending on the machine.)
1. P.P
6. Inputting F. INI (Input items 3 to 5 above

in the same manner.)
Set as shown on the left and select the menu
"I/O START". F. INI will be input.
Note that this may not be registered depending
on the model or machine.
3. Inputting VGSET. INI

Set as shown on the left, and select the menu
"I/O START". VGSET. INI will be input.
2. Inputting B. INI
"I/O START". B. INI will be input.
Note that this may not be registered depending
on the machine.
1. Inputting P.P
"I/O START". P. P will be input.
This completes the upgrading of the system.
9 – 95
NOTE
1) If "EXECUTE ZERO POINT RETURN XYZUV" (see following screen) appears on the screen
immediately after loading the system or immediately after a servo alarm, carry out zero point return right
away.
Before starting zero point return, remove any items which could obstruct the axis movement.
The axis can be moved with JOG movement even while "EXECUTE ZERO POINT RETURN XYZUV" is
displayed, but the nozzle could interfere with the table, so do not move near the stroke end.
9 – 96
9-7-2 Restoration When System Does Not Start up Correctly

These procedures are used to restore the system if the system does not start up correct because the power was
turned OFF during the system update process, etc.
If the system does not start up correctly, turn the power OFF and carry out the following procedure.
NOTE
1) If the power OFF switch does not function, contact the Mitsubishi Service Center.
2) The operation panel switches will not function. Use the slide pad.
Turn the power ON.

The system startup screen will appear, but after a short time, the screen will darken, and then will
change to green.
The screen will darken again, and the message「To Execute "EDM SYSTEM RESCUE", Push the
Button. (Not "L" Key)」will appear for approx. 2 seconds.
Press the button on the operation panel during this time. The "EDM SYSTEM RESCUE" screen
will appear.
will appear.
The system is restored to the original HD version,

so the displayed version will differ according to
the system.
Select "Restore" using the slide pad.
9 – 97
A confirmation dialog will appear, so select "Yes" using the slide pad.
Restoration of the system will start. When completed, a dialog indicating the completion will appear.
Using the slide pad, select "OK".
To update the system again, select "Re-Setup", and to use with the original version,
select "NcStart" with the slide pad.
The system is restored to the original HD version,

so the displayed version will differ according to
the system.
To update the system again, select this.

The SYSTEM UPDATE screen will appear, so
follow the system update procedures and
update the system.
To use the original version,

select this. Normally, this is not
selected.
This completes the restoration of the system.
9 – 98
NOTE
1) If "EXECUTE ZERO POINT RETURN XYZUV" (see following screen) appears on the screen
immediately after loading the system or immediately after a servo alarm, carry out zero point return right
away.
Before starting zero point return, remove any items which could obstruct the axis movement.
The axis can be moved with JOG movement even while "EXECUTE ZERO POINT RETURN XYZUV" is
displayed, but the nozzle could interfere with the table, so do not move near the stroke end.
9 – 99
9. MAINTENANCE AND ALARM LIST 9-8 List of Alarms
9-8 List of Alarms

9-8-1 Operation Alarms
(1) General CRT Operations
Error
Message & Details Remedies Remarks
No.
E01 SETTING ERROR • Set the correct data once again.
The set data is improper.
E02 DATA OVER • Set the data within the correct range once
The set data is beyond the set range. again.
E13 NB NOT FOUND
The block of the designated sequence No.
or block No. does not exist in the designated
program.
E14 PROG NOT FOUND
The designated program does not exist in
the memory.
E18 PARITY V • Create a paper tape without any parity V
A parity V error was detected at the data error again.
input time. • Or set the parity V invalid through the
communication parameter screen.
E20 OVER RUN ERR • Check the set NC I/O device parameter or
The control method by the DC code and the setting on the I/O device side, and if
others for I/O operation are incorrect. improper, set them again.
It’s being used by another program • Carry out the intended operation again
Erase, search, parameter or other data after completion of the program running or
changes, etc. of the machining program was by interrupting (or resetting) the program
tried during the operation. execution.
E100 NOT MANUAL MOD • Turn ON the manual mode, and then
The manual mode was not on when the restart the manual positioning.
manual positioning was started.
E114 DATA NOT READY • Set the incomplete items on the
The setting data on the "E.S.P.E.R > AUTO "E.S.P.E.R > AUTO PG2" screen.
PG2" screen is incomplete.
E310 WireUnavailabl • Input the wire diameter and material again
The wire diameter or material input is or check whether the machining
incorrect, or machining conditions for the conditions have been input.
corresponding wire diameter or material are
not found.
E311 WorkUnavailabl • Input the workpiece material again or
The workpiece material input is incorrect, or check whether the machining conditions
machining conditions for the corresponding have been input.
workpiece material are not found.
E312 Thickness over • Input the thickness again or check
The thickness input is incorrect, or whether the machining conditions have
machining conditions for the corresponding been input.
thickness are not found.
E320 Cut.proc. Err • Input a possible number of cuts again.
The number of cuts set in the machining
process exceed the upper limit of the
number of cuts that can be realized.
9 – 100
Error
No.
E321 Add.Cut Err • Set within the number of cuts first
The machining start designation set with machined.
additional cut exceeds the number of cuts
first machined.
E322 FewCuts (Plus1) • Plus one cutting is possible only for
Plus one machining was set for machining machining of the 3rd cut and following.
up to the 2nd cut. Either cancel the plus one cut setting or
change the designated surface
roughness, and set the number of cuts to
3rd cut or more.
E340 There exists no E-pack for PM, land • Review the combination, and then search
process or special machining which is for the machining conditions.
applicable to such combination of wire
and workpiece.
E341 E-pack may not be installed or incorrect. • Check that the machining conditions are
correctly input.
(2) Editing related
Error
No.
READ ONLY • Turn READ ONLY OFF before editing.
READ ONLY was set to ON for the
machining program that was to be edited,
and thus editing was not possible.
It's being used by another program. • When machining, wait for the machining
The machining program that was to be to end or cancel the machining. If
edited is being used in the machining or the checking, wait for the check to end or
program check, and thus editing was not cancel the check. Then, edit the program.
possible.
It's locked now • Turn OFF the EDIT LOCK of the target
Setting, erasing, the LNO or changing etc., program in the program list, and then
was attempted to a program that is locked. execute again.
9 – 101
(3) Graphic related

Error
No.
Checking
The NC program is being read for checking.
Check End
The NC Program has been read to the end.
Check Aborted • Read again if necessary.
The check has been canceled with key
operations during reading.
Program Error • Correct the NC Program, and then read
The reading ended because of a NC again.
program error.
Too Large Program • Shorten the NC program, and then read
The NC program exceeded the maximum again.
length (approx. 50000 blocks) which can be
checked.
Alarm • The alarm message will appear in the
The redrawing stopped because of an NC screen, so take the same remedies as for
program error. machining.
Re-Drawing
The path is being redrawn following the
execution order.
Re-Draw End
The redrawing ended at the program end or
with an alarm.
M0, M1 Stop
The redrawing stopped at M0 or M1.
Single Stop
The redrawing stopped with a single block
stop.
Re-Draw Aborted • The path can be redrawn from the head
The redrawing was canceled with the by pressing the keys.
key.
Stroke End
The stroke range was exceeded during the
check.
Viewport Changing • This status can be exited by pressing the
The viewpoint can be changed with the key.
arrow keys.
TOO LARGE SIZE (InvalidOpe) • The figure scale is too large, and the
TOO LARGE SIZE (ZeroDiv) figure cannot be checked. Review the
TOO LARGE SIZE (Overflow) scale.
TOO LARGE SIZE (Underflow)
TOO LARGE SIZE (Exception)
No E-pack for PM • Input the machining conditions FLD data
The machining conditions were searched I/O, and then search for the machining
for without the PM E-Pack. conditions.
NO[S] DATA • Register the estimated speed [S] of the
The estimate speed [S] for the machining machining conditions infometer.
conditions infometer has not been
registered.
No F cmnd • Input an F command.
There is no F command so the estimated
time cannot be calculated.
9 – 102
Error
No.
No E-pack • Register the commanded E-pack.
The commanded E-Pack was not found so
the estimated time cannot be calculated.
E Cmmand in AUTO2nd • When using "PM SKIM CUT" with the
When "PM SKIM CUT" is used with the E.S.P.E.R, an E command does not need
E.S.P.E.R, and an E command (machining to be issued in the shape program.
condition command) is found in the shape Delete the E command from the shape
program, this will appear on the Machining program.
Estimate screen after the check is carried
out on the "PROG. CHECK/EST TIME"
page.
9 – 103
9-8-2 Alarms Concerning Sequencer

Error
No.
U700 WRONG PWR SUP • Call the service engineer in charge. Do not turn
A faulty power supply was detected. machining
ON. Other
sections could
be damaged.
U702 LR OUT OF CNTL • Contact the Mitsubishi Electric Engineer.
A faulty specific resistivity was detected.
U704 FLUID OFF • Make sure to supply the dielectric fluid
The machining was started without before starting the machining.
supplying the dielectric fluid.
U705 WIRE FEED OFF • Make sure to set the wire and supply the
The machining was started without setting dielectric fluid before starting the
the wire. machining.
U706 AWF NOT HOME • Set the AWF to the home position before
The AWF was not in the home position at starting the program.
program startup.
U707 NOT MANUAL MODE • Enter the manual mode and then
A manual mode command was executed re-execute.
when not in the manual mode.
U708 NO WIRE • Replace the wire bobbin before restarting
A wire absence was detected during the the operation. Also check if the limit
execution of M21. position is normal.
U709 MACHING LOCK • Execute in the machining OFF state.
Positioning, etc., was executed when
machining was ON.
U711 AUX TB CONTACT • Remove obstacle which caused the This may not
Contact with the auxiliary table was contact trouble from the working tank. be provided
detected. depending on
the model.
U712 COVER OPEN • Close the safety cover before starting
Machining was started while the safety machining.
cover was open.
U715 WIRE CUT ERROR • Refer to chapter 5.3 Troubleshooting and
The wire cannot be cut within the specified remedy.
time. (AT) • Check the diameter and the material of
the wire in use. In case the wire cannot be
cut, even if the diameter and the material
are normal, call the service engineer in
charge.
U716 A.W.F. ABNORMAL • Refer to the "Section 3" and check the
Faulty AWF operation. unit.
U718 WRONG CUT ARM • Contact the Mitsubishi Electric Engineer.
The wire retainer does not return to the
original position even when the set time
elapses.
U719 NOT IN POS. • Return the cutter arm to the home
The AWF cutter arm is not at the home position.
position.
9 – 104
Error
No.
U722 WIRE INST ERR • Clean the dies.
The wire could not be inserted. Take necessary measures by referring to
the troubleshooting procedure stated in
the Maintenance and Inspection section
(of the automatic wire feeder) in the
Instruction Manual.
U723 UV NOT ORIGIN • Return the U and V axes to the origin.
The U and V axes are not at the origin. (The UV origin has not been set yet, or the
U and V axes moved.)
U726 A.W.F. AIR DOWN • Check the air pressure.
An air pressure drop was detected.
U728 WATER COLL. ERR • Check if there is anything that obstructs
The water collection box operation is the opening and closing of the collection
abnormal. cover, and remove if found.
• Check that the air pressure is 400kPa or
more.
U730 T/C IN FLUID • Adjust the upper limit of the dielectric fluid
The water level in the work tank has so that the taper unit is not submerged.
reached the taper unit.
U736 ASR NOT HOME • Set ASR to the home position, and then
The ASR deviated from the home position restart the operation.
during the axis movement after the
operation start.
U737 ASR MANU MODE • Set ASR in the AUTO mode.
The ASR was in the manual mode when
M52 was commanded.
U738 ASR ABNORMAL • Discharge the scraps by hand, and then
The handle caused contact trouble, or restart the operation.
scraps were not removed.
U740 TCH SNSR NOT H • Set the touch sensor to the home position
The touch sensor deviated from the home in the manual mode, and then restart the
position during the axis movement after the operation.
operation start.
U741 TCH SNSR MODE • Clear the touch sensor mode.
The machining was tried while the touch
sensor mode was ON.
U742 WRONG TCH SNSR • Check the air source, and then call the
The touch sensor operation does not start service engineer in charge.
even when the specified time elapses.
U743 TCH SNSR CONT • Move the probe in the reverse direction by
The probe caused contact trouble during the using the corresponding JOG.
axis movement in the touch sensor mode.
U746 AWC NOT HOME • Set the AWC to the home position and
The AWC is not at the home position when then start.
the program is started.
U747 AWC MANU MODE • Set the AWC to the AUTO mode.
The AWC is not in the AUTO mode when
the AWC operation is commanded.
U748 AWC ABNORMAL • Refer to the AWC Instruction Manual, and
The AWC control unit detected an error. cancel the AWC control unit error.
9 – 105
Error
No.
U750 ZP-RTN NOT FIN • Execute X, Y, Z axis zero point return
If X, Y, Z axis zero point return has not been before executing AWC operation.
completed when AWC operation is
commanded.
U756 APC NOT HOME • Set the APC to the home position and
The APC is not at the home position when then start.
the program is started.
U757 APC MANU MODE • Set the APC to the AUTO mode.
The APC is not in the AUTO mode when the
APC operation is commanded.
U758 APC ABNORMAL • Refer to the APC Instruction Manual, and
An APC operation error was detected, or the cancel the APC control unit error.
APC was stopped during operation.
U766 LOW AIR PRESS • Check the air pressure.
The air pressure dropped continuously • Check the compressor's power supply.
during the specified time.
U794 CLEAN SIDE LOW • Check the quantity of dielectric fluid in the
The fluid level in the clean fluid tank has dielectric fluid reservoir, and replenish if
dropped. low.
• The filtering flow rate is low. Check the
filter pressure gauge, the filter hose for
bends, the pump intake port for clogs and
the filter drain valve for a loose
connection.
U795 DIRTY SIDE LOW • Check the quantity of dielectric fluid in the
The fluid level in the waste fluid tank has dielectric fluid reservoir, and replenish if
dropped. low.
U796 OVER RUN • The unit switch that detects the stroke end
The axis moved beyond the hardware may be broken, so contact the Mitsubishi
stroke end. Electric Engineer.
U814 WIRE PROCESSING UNIT • Remove the tangled wire.
This occurs if the wire has become • Check whether the cutter unit is worn,
entangled in the wire processing unit or if and replace if worn.
the motor has locked. • Check that the wire processing unit
connector [WCM] is connected.
U822 DOOR POS.ERR • Lower the working tank door to the lower
The clamp switch was pressed before the limit, and then press the clamp switch
working tank door was raised to the upper again.
limit.
U823 DOOR CLAMP ERR • Check whether the door clamp limit switch
The door was not clamped within the is broken.
specified time. • If the power was turned OFF and ON in
The clamp was released suddenly for some the clamped state, the clamp may be
reason. released. In this case, lower the working
tank door to the lower limit, and then press
the clamp switch again.
U824 WaterRemaining • There may be dielectric fluid higher than
Unclamping of the door was executed while the table. Discharge the fluid and then
there was still dielectric fluid in the working unclamp the door.
tank.
9 – 106
Error
No.
U825 DoorUnclampERR • Check whether the door clamp limit switch
The door was not unclamped within the is broken.
specified time. • For the FA20 class, lower the working
tank door to the lower limit and then press
the clamp switch again.
U827 SET PARAMETER • Input the pitch error compensation
READY ON was attempted before the pitch amount and backlash compensation
error compensation amount and backlash amount, turn the power OFF and ON, and
compensation amount were input. then turn READY ON.
U828 REMOTE I/O NOT JOIN • Contact the Mitsubishi Electric Engineer.
A fault has occurred in the remote I/O.
• The cable is disconnected.
• The remote I/O is faulty.
U830 CUT WIRE REMAINING • Remove the wires from the cut wire duct.
Scraps of cut wire could not be collected • Refer to chapter 5.3 Troubleshooting and
into the wire collection box, and are remedy.
remaining in the cut wire duct.
U831 OIL PUMP ERR • Contact the Service Center. (Turn the
The NF turned OFF because the lubrication lubrication pump’s NF ON.)
pump was overloaded.
U832 Dielectric fluid reservoir controller • Contact the Service Center.
abnormal
A tank control error was detected.
U833 Feed pump halt • Contact the Service Center. (Reset the
An overcurrent (error) was detected in the thermal relay for the supply pump’s motor
supply pump’s motor. in the tank control box.)
U834 Filter pump halt • Contact the Service Center. (Reset the
An overcurrent (error) was detected in the thermal relay for the filter pump’s motor in
filter pump’s motor. the tank control box.)
U835 Fill pump halt • Contact the Service Center. (Reset the
An overcurrent (error) was detected in the thermal relay for the filling pump’s motor
filling pump’s motor. in the tank control box.)
U836 Ionizer pump halt • Contact the Service Center. (Reset the
An overcurrent (error) was detected in the thermal relay for the water purifier pump’s
water purifier pump’s motor. motor in the tank control box.)
U837 Z axis coolant pump halt • Contact the Service Center. (Reset the This may not
An overcurrent (error) was detected in the Z thermal relay for the Z axis cooling be provided
axis cooling pump’s motor. pump’s motor in the tank control box.) depending on
the model.
U838 Circulate pump halt • Contact the Service Center. (Reset the This may not
An overcurrent (error) was detected in the thermal relay for the circulation pump’s be provided
circulation pump’s motor. motor in the tank control box.) depending on
the model.
U839 Fan cooler halt • Contact the Service Center. (Reset the This may not
An overcurrent (error) was detected in the thermal relay for the fan cooler motor in be provided
fan cooler motor. the tank control box.) depending on
the model or
option
settings.
9 – 107
Error
No.
U840 Unit cooler abnormal • Contact the Service Center. (Reset the This may not
An error was detected in the unit cooler. unit cooler (at the top of the dielectric fluid be provided
tank).) depending on
the model.
U841 Solenoid abnormal 1 • Contact the Service Center. (Replace the
An overcurrent (error) was detected in the fuse (F1) in the tank control.)
solenoid valves (block 1) for the tank
control.
control.
control.
U844 Sub unit abnormal • Contact the Service Center.
An error was detected in the SUB unit in the • Do not turn machining ON.
power supply panel. Other sections could be damaged.
U849 DC unit abnormal 1 • Contact the Service Center.
An erroneous rise in the temperature of the
electronic parts in the DC unit was detected.
U850 DC unit abnormal 2 • Contact the Service Center.
An erroneous rise in the temperature of the
electronic parts in the DC unit was detected.
U852 Generator coolant fan halt • Contact the Service Center.
An overcurrent (error) was detected in the • Do not turn machining ON.
cooling fan in the power supply panel. Other sections could be damaged.
U853 Generator temperature increasing • Contact the Service Center.
An erroneous rise of the temperature in the
power supply panel was detected.
U854 OUTSIDE WIRE DIAMETER RANGE (WIRE • Remove the wire processing unit when
PROCESSING UNIT) using ø0.15 or less wire. (The wire
This occurs when a wire diameter ø0.15 or processing unit is compatible only with
less is selected while the wire processing ø0.2 or more wire diameters.)
unit is mounted. • When using a ø0.2 or more wire,
designate the diameter of the wire being
used.
U855 WIRE PROCESSING UNIT MOTOR STOP • Turn the cutter motor switch ON.
This occurs if the cutter motor switch is OFF • Turn the cutter motor breaker ON.
or if the cutter motor breaker is OFF.
U861 MAIN UNIT F3 POWER ERROR • Contact the Service Center.
This occurs if an overcurrent (error) of the • Do not turn machining ON.
main unit in the power supply panel is Other sections could be damaged.
detected.
U862 MAIN UNIT CONTROL POWER ERROR • Contact the Service Center.
This occurs if the control power for the main • Do not turn machining ON.
unit in the power supply panel is detected. Other sections could be damaged.
U863 MAIN UNIT 1 TEMPERATURE ERROR • Contact the Service Center.
This occurs if an abnormal rise in the • Do not turn machining ON.
temperature for the electrical parts in main Other sections could be damaged.
unit 1 is detected.
9 – 108
Error
No.
U864 MAIN UNIT 2 TEMPERATURE ERROR • Contact the Service Center.
This occurs if an abnormal rise in the • Do not turn machining ON.
temperature for the electrical parts in main Other sections could be damaged.
unit 2 is detected.
U865 AVR INPUT ERROR • Contact the Service Center.
This occurs if an abnormality is detected in • Do not turn machining ON.
the AVR input voltage in the power supply Other sections could be damaged.
panel.
U866 A POWER SUPPLY ERROR • Contact the Service Center.
power supply A of the AVR in the power Other sections could be damaged.
supply panel.
U867 B POWER SUPPLY ERROR • Contact the Service Center.
power supply B of the AVR in the power Other sections could be damaged.
supply panel.
U868 C POWER SUPPLY ERROR • Contact the Service Center.
power supply C of the AVR in the power Other sections could be damaged.
supply panel.
U869 PAM PROTECTOR OFF • Turn the breaker ON.
This occurs if the PAM circuit breaker is • If the breaker cannot be turned ON,
OFF or if an overcurrent (error) is detected contact the Service Center.
in the PAM circuit.
U870 CLEAN FLUID TEMPERATURE DROP A warning or alarm could occur when
This occurs if the clean fluid temperature machining multiple holes or during
cannot be controlled because of a low clean repetitive machining in a short time (when
fluid level. machining cycle time is 10 minutes or less).
To maintain the machining accuracy, the
dielectric fluid temperature is strictly
controlled when using the twin unit cooler
specifications.
When using the above machining modes,
make sure that the clean fluid level is
sufficient before starting machining.
If a warning or alarm occurs, carry out
temperature run-in operation for more than
an hour, and extend the machining cycle
(use the dwell function).
9 – 109
9-8-3 Operation Alarms

Error
No.
M01 NEAR POINT DOG LENGTH • Contact the Service Center.
INSUFFICIENT
Zero point return could not be completed
properly because an error was found.
M02 Z PHASE PASSING INCOMPLETE • Contact the Service Center.
Zero point return could not be completed
properly because an error was found.
M04 INTERLOCK AXIS • The interlock function is valid, so release it
Some axis was interlocked because the and then start operation.
interlock function became valid (input signal • Confirm the sequence of the machines.
OFF state). • Check whether the interlock signal wire is
broken.
M06 H/W STROKE END • Move the machine by manual operation
Some axis came to a stroke end. because the stroke end limit switch is
The stroke end function was validated (the working (to cause a stroke end).
input signal turned ON), and an axis • Confirm that the stroke end signal wire is
reached the stroke end. broken.
• Confirm that the limit switch is working
normally and is not damaged.
M07 S/W STROKE END • Move the machine by manual operation
The function of the stored stroke limit I or II because the machine is in the stroke end
took effect. state.
• Confirm parameter details if not at axis
end.
M09 WRONG 0-PNT NO. • Execute dog type zero point return.
2nd to 4th zero point return was executed for
an axis that has not completed zero point
return.
M163 AXIS-S OVER • Set the axis magnification again.
The speed when axis magnification was
applied exceeded the axis parameter
speed.
M605 EXP-AWF ERROR • Turn OFF either the cut-off mode or the
The extended AWF mode selection is uncut mode because both of them have
incorrect. been selected.
• The uncut amount is not set, so set it.
• Turn ON the manual wire retrace when
the A.W.F. unit is not installed.
M618 STILL CONTACT • Check the workpiece surface for rust, dirt
The contact cannot be canceled even when or burrs, etc.
returned 10µm from the contact detection • Check whether the hole is too small.
position during positioning.
M619 IN CONTACT • Clear the contact state, and then restart
The wire is already in contact with the the positioning operation.
workpiece before the start of positioning.
M624 AWF NOT HOME • Start the operation after returning the
The operation start was tried when the AWF AWF to the home position.
was not in the home position.
9 – 110
Error
No.
M625 WIRE BROKEN • Turn ON the pretension switch.
A wire breakage was detected at the time of • Check whether the limit switch is in
positioning. position or not.
• Check whether the wire electrode is
broken or not.
M626 NOZZLE CNT STP • Check whether the Z movement
The nozzle contacted the workpiece when command in the NC program is incorrect.
the nozzle contact stop function was • Check whether there is a conductive
selected and machining was OFF, or the matter between the upper nozzle and
nozzle and workpiece contacted when the workpiece.
collision detection function was selected. • Set the Z axis position again.
M627 OUT OF MARGIN • Clean the surface of the workpiece, and
The error of the results after repeating then position again.
positioning several times exceeds the
tolerable range.
M628 pisy timeout • When using a program with many small
The pre-reading of the corner position did blocks, it will take time to pre-read the
not end within a set time while using the corner position. Thus, the corner expert
corner expert function. function cannot be used. Turn the corner
expert switch OFF.
M629 ANGLE RANGE OVER • Set the angle within the correct range.
An angle exceeding the tolerable angle was
set.
M641 MEASURING NOW • Turn OFF the dimension measurement
The positioning mode was selected with the switch, or wait for dimension
manual operation box while the dimension measurement to end before selecting the
measurement switch was ON. positioning mode.
M657 EXCESSIVE ABSOLUTE POSITION • The zero point return incomplete state
ERROR will be entered, so carry out zero point
The difference of the absolute position when return again.
the power failed and was recovered
exceeds 4mm.
M666 ZERO POINT RETURN INCOMPLETE • Carry out zero point return before starting
Automatic operation was started before automatic operation.
zero point return was completed.
9 – 111
9-8-4 Stop Alarms

T01 CAN’T CYCLE ST The automatic operation start from the NC stop state was impossible.
Error
No.
T101 AX IN MOTION • Start the operation once again after all
The automatic operation start is impossible axis movement stop.
because an axis is moving.
T102 READY OFF • Check the cause of the error, and take
The automatic operation start is impossible necessary measures according to the
alarm contents.
because the NC is not in the state.
T103 RESET ON • Resetting. Wait and then start automatic

The automatic operation start is impossible operation.
due to reset signal input.
• Check whether the switch is
working normally.
T104 STP SGNL ON • The switch has been pushed.
The switch on the machine • Confirm that the feed hold signal wire is
operation panel is on (valid.) not broken.
T105 H/W STROKE END • In case the stroke end is detected at the
The automatic operation start is impossible axis end, move the axis by manual
because some axis has reached the stroke operation.
end. • Confirm that the stroke end signal wire is
not broken.
• Check whether the stroke end limit switch
is damaged or not.
T106 S/W STROKE END • Move the concerned axis by manual
The automatic operation start is impossible operation.
because some axis has reached the S/W • Unless the stroke end was detected at the
stroke limit. shaft end, check the parameter contents.
T114 SEARCHED E-CONDITION NOT FOUND • Search for the machining conditions on
When [MACHINING MODE "PM ROUGH the E.S.P.E.R screen before starting.
CUT"] or [MACHINING MODE "PM SKIM
CUT"] is selected on the E.S.P.E.R screen,
machining was started in the machining
conditions search incomplete state.
9 – 112
T02, T06, T07, T08 The automatic operation under execution stopped due to some condition.
AUTO OPERATION STOP
Error
No.
T201 H/W STROKE END • Move the axis from the stroke end limit
An axis reached the stroke end. switch position by manual operation.
• Change the workpiece setting position
and the machining program.
T202 S/W STROKE END • Move the axis by manual operation.
A stored stroke limit was detected. • Change the workpiece setting position
and the machining program.
T203 RSET SGNL ON • Execute the automatic operation from the
The reset signal was input. machining program start point since the
position of program execution has
returned to the program head.
T204 STP SGNL ON • It is possible to restart the automatic
The "FEED HOLD" switch has been turned operation by the "CYCLE START" switch.
ON.
T205 OP MODE SHFT • Change the operation mode to automatic,
The operation mode was changed to the and then restart.
manual mode during automatic operation.
T209 AWF MANU. MODE • Change the mode from MANUAL to
The A.W.F has been put into the MANUAL AUTO, and restart the operation.
mode by M20 or M21. • Insert and cut the wire by hand, then
restart the operation.
T210 WIRE BREAKAGE • Set the wire again, and restart the
The wire broke during the machining. machining.
• Turn ON the pretension switch.
T211 30 SEC CONTACT • Clear the short-circuit, and restart the
A short-circuit state continued for 30 machining.
seconds during the machining. • Check for cut workpiece dropping, wire
setting error, scrap overflowing from the
wire collection box, etc.
T212 NEXT BLK MISS • Check whether the tape has slipped off.
The next block cannot be read.
T213 WORKING OFF
• Turn ON , and , and then
The button was pressed during
restart.
machining.
T215 SEQUENCE ERROR • Select the main menu "MAINTENANCE",
An error occurred in the A.W.F, ASR, etc. and confirm the sequence error with the
submenu "ADMIN INFOR>STATUS".
Follow the remedy methods given for that
error.
T217 NC ALARM • Remove the cause of the error and restart
An error occurred in the A.W.F, ASR, etc. the operation.
T219 WIRE INST ERR • Readjust the dies, etc., and restart the
A wire insertion error occurred during the operation.
execution of M20. • Take necessary measures by referring to
the troubleshooting procedure stated in
Maintenance and Inspection of the
automatic wire feeder.
9 – 113
Error
No.
T220 IN CONTACT • Clear the contact state, and restart the
The wire is already in contact with the automatic positioning.
workpiece before the start automatic
positioning.
T221 STILL CONTACT • Check the surface condition (rust, stains,
The contact state is not cleared even if the burrs, etc.) of the workpiece.
wire electrode is moved back by 10µm from • Confirm that the wire insertion hole is not
the point where contact was detected at the too small.
positioning time.
T222 INTER LOCK • Fix wire breakage and restart the
A wire breakage was detected during the positioning.
positioning time.
T224 MODE IN USE • Clear the other mode.
The positioning was tried while some other
mode was ON.
T227 ASR NOT HOME • Return the ASR to the home position and
The ASR deviated from the home position restart the operation.
while the axes were moving.
T228 TCH SNSR NOT H • Return the touch sensor to the home
The touch sensor deviated from the home position and restart the operation.
position during the start operation.
T229 TCH SNSR CONT. • Clear the contact state by using the
The operation stopped due to contact concerned JOG key and restart the
trouble of the probe while the touch sensor operation.
was ON.
T230 AUTO RTN FIN • Continue the next operation.
The auto return was finished.
T231 AWF MAN MODE • Never change the mode from AUTO to
The mode changed from AUTO to MANUAL MANUAL when the A.W.F is in operation.
during an A.W.F mode operation.
T232 F CMD NOTHING • Input the speed command FA through the
No speed command was input. screen or by the NC program.
T233 AX-SCALE OVER • Set the axis scale factor again.
The speed exceeded the speed value
designated by the axis parameter when the
axis scale factor was ON.
T234 Z-AXIS NOT RET • To automatic return the Z axis, do not
Automatic return of the X, Y, U, V and B axis change "AUTO RETURN" or
was completed, but automatic return of the AutoRtn.Separate. Then restart.
Z axis is not completed. • To continue the program from that
position without automatic return of the Z
axis, turn OFF "AUTO RETURN" or
AutoRtn.Separate. Then restart.
T236 RETRY STOP • Insert the wire manually, and then press
Movement to the M20 positioning of the
the button.
figure to be remachined in the remachining
mode was reached.
T237 A.W.F. SKIP • Wire insertion is difficult due to an
A uncut skip occurred. improper start hole or the wire broke
during machining. Complete the
machining of the all other figures, correct
the trouble, and then remachine.
9 – 114
Error
No.
T245 OPERATION ERR • Select the main menu "MAINTENANCE",
An operation error (M–) occurred, and the and confirm the operation error with the
machine stopped. submenu "ADMIN INFOR>STATUS".
error.
T246 PROGRAM ERR • Select the main menu "MAINTENANCE",
A program error (P–) occurred, and the and confirm the program error with the
machine stopped. submenu "ADMIN INFOR>STATUS".
error.
T249 G48 W/O 0-RTN • Execute dog type zero point return.
A G48 command was issued to an axis that
has not completed zero point return.
T252 READY FOR RE–
• Press the button to remachine.
Movement to the start position has been
completed in the remachining mode.
T253 READY FOR APC
• Press the button to remachine.
Movement to the M53 position has been
completed in the remachining mode.
T254 NO M20 • Use a program that has an M20 command
There is no M20 command in the program for each measurement figure, when
so dimension measurement cannot be executing dimension measurement
executed. (automatic, semiautomatic modes).
• Perform dimension measurement without
using a program (use manual
measurement.)
T255 MEASRNG DONE • Dimension measurement using the
There were 26 or more M20 commands in program can be executed only to the 25th
the program, but dimension measurement M20 command.
was completed to the 25th M20 command. • Measure the remaining figures with the
dimension measurement (manual
measurement mode).
T259 START MEASURE • Move to the measurement start point with
• The measurement of one figure was JOG key, and then press the button.
completed with manual measurement.
• Movement to the M20 position has been
completed during semiautomatic
measurement.
T262 RESTART READY • Confirm the position, and then press the
Movement to the last M20 position or the
button to restart the program.
program start position has been completed.
T270 RETURN ERROR • Wire breakage return cannot be executed
Wire breakage return cannot be executed with reverse path return.
with reverse path return. Turn OFF the REVERSE PATH RET.
Switch on the AWF screen, and then
restart. Normal wire breakage return will
be executed.
T271 NO PM E-PACK • Register the E-Pack exclusive for PM.
The E-Pack exclusive for PM is not
registered when machining with PM.
9 – 115
Error
No.
T272 pisy discord • Refer to the explanation on the
A deviation was detected in the pre-read [CORNER MASTER II] switch in section
corner position and actual corner position 4.2.2 List of various switches in Chapter 5
when using the [CORNER MASTER II] NC Operation Display Screen, and check
function. whether an operation that is subject to
function limits was carried out. When the
alarm on the left occurs and restart is
executed, the following program will be
executed up to the next M20 without
using the [CORNER MASTER II] .
T273 NO WIRE • Replace the wire bobbin and the start.
A wire absence was detected when M21 Check for deviation of the limit.
was executed.
T274 LOW AIR PRESS • Check the air pressure.
The air pressure dropped continuously • Check the compressor's power supply.
during the specified time.
T275 INTERLOCK AXIS • The interlock function is valid, so cancel
The interlock function is valid (the input the interlock before starting.
signal is OFF), and an axis entered the • Check the sequence for the machines.
interlock state. • Check the interlock signal wire for
disconnection.
T605 EXP-AWF ERROR • Cutoff and uncut are simultaneously
The expanded A.W.F. mode selection is selected, so turn one OFF.
incorrect. • The uncut amount is not set, so set it.
• If the A.W.F. unit is not provided, turn
manual wire breakage recovery ON.
T626 NOZZLE CONTACT STOP • Check whether the Z axis movement
The nozzle contacted the workpiece when command in the NC program is incorrect.
the nozzle contact function was selected • Check whether there is any conductive
and machining was OFF. foreign matter between the upper nozzle
and workpiece.
• Set the Z axis position again.
T628 PRE-READ ERROR • In a program with many small blocks, it
When using the corner expert function, may take too long to pre-read the corner
pre-reading of the corner position did not position. Thus, the corner expert function
end within a set time. cannot be used and must be turned OFF.
T702 LR OUT OF CNTL • Contact the Service Center.
A specific resistivity error was detected.
T704 FLUID OFF • Always fill the dielectric fluid before
Machining was attempted before filling the starting machining.
dielectric fluid.
T705 WIRE FEED OFF • Insert the wire and fill the dielectric fluid
Machining was attempted before inserting before starting machining.
the wire.
T706 AWF NOT HOME • Set the AWF at the set position before
The AWF was not at the set position when starting.
the program was started.
T707 NOT MANUAL MODE • Enter the manual mode and carry out the
A manual mode command was executed operation again.
when the system was not in the manual
mode.
9 – 116
Error
No.
T709 MACHING LOCK • Turn machining OFF before positioning.
Positioning was attempted when machining
was ON.
T711 AUX TB CONTACT • There is an obstacle in the work tank.
The auxiliary table contact was detected. Remove it.
T712 COVER OPEN • Close the safety cover before starting
Machining was attempted with the safety machining.
cover opened.
T715 WIRE CUT ERROR • Check the wire diameter and material. If
The wire could not be cut even after the these are correct and the alarm recurs,
designated time elapsed. (AF) contact the Service Center.
T716 A.W.F ABNORMAL • Refer to the Instruction Manual
There is an error in the AWF operation. [Maintenance] and check the unit.
T718 WRONG CUT ARM • Contact the Service Center.
The wire retainer did not return to the
original position even after the set time
elapsed.
T719 NOT IN POS. • Return the cutter arm to the set position.
The AWF unit's cutter arm is not at the set
position.
T723 UV NOT ORIGN • Return the UV axis to the zero point. (The
The UV axis is not at the zero point. UV zero point is not set, or UV has
moved.)
T728 WATER COLL. ERR • Check for matters obstructing the
Abnormal operation of the water collection opening/closing operation around the
box was detected. collection cover, and remove if found.
• Check that the air pressure is 400kPa or
more.
T730 T/C IN FLUID • Check the upper limit of the dielectric fluid,
The work tank water level has reached the and adjust so that the taper unit is not
taper unit. submerged.
T737 ASR MANU MODE • Set the ASR to the automatic mode.
ASR was set to manual movement when
M52 was commanded.
T738 ASR ABNORMAL • Remove the scrap manually, and then
The scrap could not be removed when the restart.
handle contacted it.
T741 TCH SNSR MODE • Cancel the touch sensor mode.
Machining was started in the touch sensor
mode.
T742 WRONG TCH SNSR • Check the air source, and then contact the
The touch sensor did not move even after Service Center.
the designated time elapsed.
T743 TCH SNSR CONT • Move in the reverse direction with jogging.
The axis contacted the probe when moving
in the touch sensor mode.
T746 AWC NOT HOME • Set the AWC at the set position before
The AWC was not at the set position when starting.
9 – 117
Error
No.
T747 AWC MANU MODE • Set the AWC in the automatic mode.
The AWC was not in the automatic mode
when AWC operation was commanded.
T748 AWC ABNORMAL • Refer to the AWC Instruction Manual and
The AWC control unit detected and error. cancel the AWC control unit error.
T750 ZP-RTN NOT FIN • Return the X, Y and Z axes to the zero
The X, Y and Z axes have not been returned point before starting AWC operation.
to the zero point before AWC operation was
commanded.
T756 APC NOT HOME • Set the APC at the set position before
The APC was not at the set position when starting.
T757 APC MANU MODE • Set the APC in the automatic mode.
The APC was not in the automatic mode
when APC was commanded.
T758 APC ABNORMAL • Refer to the APC Instruction Manual and
An error was detected in the APC operation, cancel the APC control unit error.
or the APC was stopped during APC
operation.
T794 CLEAN SIDE LOW • Check the level of the dielectric fluid in the
The fluid level in the cleaning fluid tank has dielectric fluid reservoir, and replenish if
dropped. necessary.
• The filter flow rate is insufficient. Check
the filter pressure gauge, and check the
filter hose for bending or the pump intake
port for clogging. Also check that the filter
drain valve is securely tightened.
T795 DIRTY SIDE LOW • Check the level of the dielectric fluid in the
The fluid level in the waste fluid tank has dielectric fluid reservoir, and replenish if
dropped. necessary.
T814 WIRE PROCESSING UNIT • Remove the tangled wire.
This occurs if the wire has become • Check whether the cutter unit is worn, and
entangled in the wire processing unit or if replace if worn.
the motor has locked. • Check that the wire processing unit
connector [WCM] is connected.
T822 DOOR POS. ERR • Lower the work tank door to the lower
The clamp switch was pressed before the limit, and then press the clamp switch
work tank door was raised to the upper limit. again.
T823 DOOR CLAMP ERR • Check whether the door clamp limit switch
The door was not clamped within the is broken.
specified time, or the clamp was suddenly • If the power is turned OFF and ON in the
dislocated for some reason. clamped state, the clamp may dislocate.
In this case, lower the work tank door to
the lower end, and then press the clamp
switch again.
T824 WaterRemaining • There may be dielectric fluid above the
Unclamping of the door was attempted table. Discharge the fluid, and then
while there was dielectric fluid in the work unclamp.
tank.
9 – 118
Error
No.
T825 DoorUnclampERR • Check whether the door clamp limit switch
The door was not unclamped within the is broken.
specified time. • When using the FX20, lower the work tank
door to the lower end, and then press the
unclamp switch again.
T828 REMOTE I/O NOT JOIN • Contact the Service Center.
A fault occurred during the remote I/O.
• The cable is dislocated.
• The remote I/O is faulty.
T830 CUT WIRE REMAINING • Remove the wires from the cut wire duct.
Scraps of cut wire could not be collected • Refer to chapter 5.3 Troubleshooting and
into the wire collection box, and are remedy.
remaining in the cut wire duct.
T832 Dielectric fluid reservoir controller • Contact the Service Center.
abnormal
A tank control error was detected.
T833 Feed pump halt • Contact the Service Center. (Reset the
An overcurrent (error) was detected in the thermal relay for the supply pump's motor
supply pump's motor. in the tank control box.)
T834 Filter pump halt • Contact the Service Center. (Reset the
An overcurrent (error) was detected in the thermal relay for the filter pump's motor in
filter pump's motor. the tank control box.)
T835 Fill pump halt • Contact the Service Center. (Reset the
An overcurrent (error) was detected in the thermal relay for the filling pump's motor in
filling pump's motor. the tank control box.)
T836 Ionizer pump halt • Contact the Service Center. (Reset the
An overcurrent (error) was detected in the thermal relay for the water purifier pump's
water purifier pump's motor. motor in the tank control box.)
T837 Z axis coolant pump halt • Contact the Service Center. (Reset the This may not
An overcurrent (error) was detected in the Z thermal relay for the Z axis cooling pump's be provided
axis cooling pump's motor. motor in the tank control box.) depending on
the model.
T838 Circulate pump halt • Contact the Service Center. (Reset the This may not
An overcurrent (error) was detected in the thermal relay for the circulation pump's be provided
circulation pump's motor. motor in the tank control box.) depending on
the model.
T839 Fan cooler halt • Contact the Service Center. (Reset the This may not
An overcurrent (error) was detected in the thermal relay for the fan cooler motor in be provided
fan cooler motor. the tank control box.) depending on
the model or
option
settings.
T840 Unit cooler abnormal • Contact the Service Center. (Reset the This may not
An error was detected in the unit cooler. unit cooler (at the top of the dielectric fluid be provided
tank).) depending on
the model.
T841 Solenoid abnormal 1 • Contact the Service Center. (Replace the
control.
9 – 119
Error
No.
control.
control.
T854 OUTSIDE WIRE DIAMETER RANGE • Remove the wire processing unit when
(WIRE PROCESSING UNIT) using ø0.15 or less wire. (The wire
This occurs when a wire diameter ø0.15 or processing unit is compatible only with
less is selected while the wire processing ø0.2 or more wire diameters.)
unit is mounted. • When using a ø0.2 or more wire,
designate the diameter of the wire being
used.
T855 WIRE PROCESSING UNIT MOTOR STOP • Turn the cutter motor switch ON.
This occurs if the cutter motor switch is OFF • Turn the cutter motor breaker ON.
or if the cutter motor breaker is OFF.
T858 UNIT COOLER PUMP STOP • Notify the state to the Service Center.
This occurs if an overcurrent (error) is (Reset the thermal relay for the unit
detected in the unit cooler's pump motor. cooler's pump in the tank control box.)
T859 FRONT COVER [UPPER] CLOSED; DOOR • Open the front cover.
RISE DISABLED
This occurs if the working tank door is raised
while the front cover (upper) is closed.
T860 WIRE CHIP COLLECTION BOX OPEN • Close the wire chip collection box door.
This occurs if the wire chip collection box is
open.
T869 PAM PROTECTOR OFF • Turn the breaker ON.
This occurs if the PAM circuit breaker is • If the breaker cannot be turned ON,
OFF or if an overcurrent (error) is detected contact the Service Center.
in the PAM circuit.
T870 CLEAN FLUID TEMPERATURE DROP A warning or alarm could occur when
This occurs if the clean fluid temperature machining multiple holes or during
cannot be controlled because of a low clean repetitive machining in a short time (when
fluid level. machining cycle time is 10 minutes or less).
To maintain the machining accuracy, the
dielectric fluid temperature is strictly
controlled when using the twin unit cooler
specifications.
When using the above machining modes,
make sure that the clean fluid level is
sufficient before starting machining.
If a warning or alarm occurs, carry out
temperature run-in operation for more than
an hour, and extend the machining cycle
(use the dwell function).
9 – 120
T03 BLOCK STOP The program stopped after executing one block in the program during the
automatic operation.
Error
No.
T301 SINGLE BLOCK STOP • If necessary, turn the single block switch
The single block switch is ON. OFF.
T302 MACRO BLOCK STOP • It is possible to restart.
The macro variable H3006 is used in the
program, and the block before it was
executed.
T305 M0, M1 STOP • It is possible to restart.
M0 or M1 was executed.
T04 COLLATING STOP A collating stop occurred during the automatic operation.
Error
No.
T401 CHECKUP STOP • It is possible to restart the automatic
A collating stop occurred. operation by turning ON the start switch.
9 – 121
9-8-5 Servo Alarms

Warning details for servo system errors including the drive amplifier, motor, encoder, etc.
S01 SERVO ALARM: PR After removing the cause of the alarm, the alarm can be reset by
(The address of the axis which caused an carrying out the reset method shown below.
error is displayed)
• Alarm display on servo amplifier
The QA Series servo amplifier is installed on the left side of the machine bed looking from the front.
Refer to it when a S01 Servo alarm PR occurs.
Resetting method : PR ······ After removing alarm cause, turn the power OFF and ON.
AR ······ After removing alarm cause, turn the power OFF and no-fuse breaker OFF, and
then start
up again.
• : Item carried out by User.
: Item carried out by Manufacturer.
Error Reset
Name Details Investigation method Remedy
No. method
10 Undervoltage The PN bus wire voltage is 200V or • Check the input voltage. • Input 3-phase 200V.
less. 1) Is a single-phase 200V or 100V • Contact the service center.
input?
2) Is there an open phase?
Check the contactor operation, check Replace the contactor.
the conductivity.
Check the output from the amplifier. PR
1) Is connector (CN3) disconnected? Connect correctly.
2) Is the cable broken? Replace the cable.
Check the contactor drive relay Replace the relay.
operation, check the conductivity
faulty.
Check the power capacity. Review the power supply.
11 Axis selection The axis setting rotary switch was Confirm the rotary switch setting. • Contact the service center.
error set illegal in the 2-axes integrated Correctly set.
drive unit. AR
(Set a No. that is the axis No.
minus 1.)
12 Memory error The memory IC (SRAM or Always repeated. • Contact the service center.
FLROM) check sum was illegal. Replace the drive unit.
Check for abnormalities in the unit’s Take measures according to
peripheral environment. the cause.
Ex. AR
High temperature :
confirm cooling fan.
Grounding not enforced :
add grounding measures.
13 Software Software operation sequence error Confirm the repeatability. • Contact the service center.
processing or operation timing error • Check the grounding state and • Improve the ambient
error PR
ambient temperature. environment.
Replace the amplifier.
16 Pole position The differential input of the U, V, or Check the servo parameter (SV25) • Contact the service center.
detection error W phase of the pole position setting correctly. Correctly set.
detection signal of the OHE type Correctly connect.
detector were both "H" or "L". The detector connector (unit side and PR
detector side) is disconnected.
The detector cable connection is Replace the detector cable.
faulty.
17 A/D converter The A/D converter conversion Check the repeatability. • Contact the service center.
error value is incorrect.
• Check the grounding state and • Improve the ambient PR
Replace the amplifier.
18 Detector, initial Initial communication with the Check the connector connection. • Contact the service center.
communication detector was not possible. Check the cable connection. Connect correctly.
error
Replace with the cable for another Replace the detector cable.
axis and check the repeatability. PR
Exchange the detector and amplifier Replace the parts on the side
connection with that for another axis that caused the alarm.
and check the repeatability.
(Pinpoint the cause)
9 – 122
Error Reset
No. method
1A Serial detector The initial communication with the Check the connector connection. • Contact the service center.
communication serial pulse encoder installed on Check the cable connection. Connect correctly.
error (SUB) the ball screw end was not Replace with the cable for another Replace the detector cable.
possible. axis and check the repeatability.
1B CPU error An error was detected in the data Exchange the detector and amplifier Replace the parts on the side
(SUB) stored in the EEROM of the serial connection with that for another axis that caused the alarm.
pulse encoder installed on the ball and check the repeatability.
screw end. (Pinpoint the cause)
(Alarm output by the detector.)
1C LED error Deterioration of the LEDs in the
(SUB) serial pulse encoder installed on
the ball screw end was detected.
(Alarm output by the detector.) PR
1D Data error An error was detected in the per
(SUB) rotation position data of the serial
pulse encoder installed on the ball
screw end.
1E Serial detector The thermal protector built in the
thermal error detector operated in the serial
(SUB) pulse encoder installed on the ball
screw end.
1F Communicatio Communication with the detector in
n error (SUB) the serial pulse encoder installed
on the ball screw end was cut off.
20 No signal The differential input of the A, B or Check the servo parameter (SV25) • Contact the service center.
detected 1 Z phase signal from the motor end setting correctly. Correctly set.
installation detector were both "H"
The detector connector (unit side and Correctly connect.
or "L".
detector side) is disconnected.
(Software detection in B Series.)
The detector cable connection is Replace the detector cable. PR
faulty.
21 No signal The differential input of the A, B or Check for abnormalities in the unit’s • Contact the service center.
detected 2 Z phase signal from the machine peripheral environment. Take measures according to
end installation detector were both (Ex. Ambient temperature, noise, the cause.
"H" or "L". grounding) Ex.
(Software detection in B Series.) PR
High temperature :
22 LSI error LSI operation error Check the repeatability. • Contact the service center.
Replace the amplifier. AR
Check the grounding state and Improve the ambient
24 Ground fault A motor cable ground fault was Check the motor cable and • Contact the service center.
detected. connection. Replace the cable.
Correct the connection.
PR
Check the conductivity between Replace the motor.
Detected only at the ON cables.
instant.
25 Absolute The absolute position in the Check the battery voltage with a • Contact the service center.
position data detector was lost. tester. Replace the battery.
lost (Occurs at 3V or less)
Open the panel at the top of the Connect correctly. AR
amplifier and check, and check the
battery connection.
Check the conductivity with a tester. Replace the cable.
9 – 123
Error Reset
No. method
26 Not used axis A power module error occurred in Check for abnormalities in the unit’s • Contact the service center.
error the axis that is not being controlled peripheral environment. Replace the drive unit or take
set as "F" by the axis setting rotary (Ex. Ambient temperature, noise, measures according to the
switch in the 2-axes integrated grounding) cause.
drive unit.
Ex. PR
High temperature :
27 Absolute An error was detected in the CPU The detector connector (unit side and • Contact the service center.
position of the absolute position linear detector side) is disconnected. Correctly connect.
detection scale scale.
CPU error (Alarm output by the detector.) The detector cable connection is Replace the detector cable.
faulty.
PR
Check for abnormalities in the unit’s Replace the detector (liner
peripheral environment. scale) or take measures
according to the cause.
Ex.
High temperature :
28 Absolute The scale moved at more than The absolute position linear scale • Contact the service center.
position 45mm/sec during initialization with specifications are not provided. Set the SV025 : MTYP
overspeed the absolute position linear scale. parameter correctly.
(Alarm output from the linear
scale.) The machine operated during an Check the motor mechanical
alarm. brakes and machine system.
Perform investigation item 3.
29 Absolute A hardware error was detected in Open the panel at the top of the Connect correctly.
position the absolute position detection amplifier and check the battery
detection circuit circuit of the absolute position connection.
error linear scale.
(Alarm output from the linear Check the conductivity with a tester. Replace the cable.
scale.) PR
Check for abnormalities in the unit’s Replace the detector (linear
peripheral environment. scale) or take measures
according to the cause.
Ex.
High temperature :
2A Relative A hardware error was detected in • Check the ambient environment. • Contact the service center.
position the relative position detection Check the repeatability. • Review the ambient
detection circuit circuit of the absolute position
environment.
error linear scale.
(Alarm output from the linear Replace the detector.
scale.)
2B Detector, CPU Detector internal circuit error PR
error
2C Detector, LED The LED in the detector has
error deteriorated.
2D Detector, data Detector position data error.
error
9 – 124
Error Reset
No. method
2F Detector, Communication with the detector The alarm 18 occurs when the power • Contact the service center.
communication was cut off or there was an error in is turned ON. Connect correctly.
error the received data.
Check the connector connection. Replace the detector cable.
The alarm 18 occurs when the power Replace the parts on the side
is turned ON. that caused the alarm.
Exchange the detector and amplifier PR
connection with that for another axis
Is the cable shielded?
Review the cable wiring and
Is the cable wired with the same route shield.
as the motor power line?
30 Over-regenerat Overheating of the regenerative Check the regeneration capacity. • Contact the service center.
ion resistor was detected. Change the regenerative
resistor.
Check the parameter (SV036). Set correctly.
PR
Review the power supply.
Occurs at OFF.
Check the power voltage with a

tester.
31 Overspeed The motor speed exceeded the Check the machine specifications. • Contact the service center.
tolerable value. Set correctly.
Check SV001 (PC1), SV002 (PC2), Set correctly.
SV018 (PIT), SV025 (MTYP).
Is the speed loop gain too low? Adjust the gain. PR
Is the current limit value too low? Adjust the limit value.
Does the alarm occur when the Replace the detector.
power is turned ON?
Change with another axis and check
the repeatability.
32 Power module The power module overcurrent This should happen simultaneously • Contact the service center.
overcurrent protection function activated. Replace the cable.
with ON.
Check the motor cable and Correct the connection. PR

connection.
Check the conductivity between the Replace the motor.
cables.
33 Overvoltage The PN bus wire voltage exceeded • Check the power voltage with a • Contact the service center.
400V. tester. Review the power supply.
Occurs when the power is turned ON.
Check the resistance value of the Replace the regenerative
regenerative resistor. resistor.
PR
Check the connector at the bottom of Connect correctly.
the amplifier.
Check the parameter (SV036). Set correctly.
1000 is set when using the option
option resistor.
34 NC There was an error in the Check the conductivity with a tester. • Contact the service center.
communi-catio communication data from the CNC. Replace the cable.
n, CRC error
Are the communication pair cables
connected in reverse? PR
Check the grounding state. Correctly ground.
Change the connection with that for Replace the amplifier.
another amplifier and find the cause. Replace the NC unit.
35 NC The movement command data Is this a sub-micron system? • Contact the service center.
communi-catio sent from the CNC was excessive. Is the axis a rotary axis? PR
n, data error
9 – 125
Error Reset
No. method
36 NC The communication from the CNC Check the connector (CN1A, CN1B). • Contact the service center.
communi-catio was cut off. (Including the other axes) Correctly connect.
n, transmission PR
error
38 NC There was an error in the Are the communication pair cables • Contact the service center.
communi-catio communication data from the CNC. connected in reverse? Replace the cable.
n, protocol
error 1 PR
another amplifier and find the cause. Replace the CNC unit.
39 NC There was an error in the Check the conductivity with a tester. • Contact the service center.
communi-catio communication data from the CNC. Replace the cable.
n, protocol
Are the communication pair cables
error 2
connected in reverse? PR
another amplifier and find the cause. Replace the CNC unit.
3A Overcurrent The motor drive current is Is VGN1 higher than the standard • Contact the service center.
excessive. value in respect to the load inertia? Lower VGN1.
Is vibration occurring?
Check the current loop gain. Set the standard value.
Is the current FB exceeding the Lower FC.
current command during
acceleration/ deceleration?
The U, V, W phase connection is Connect correctly.
incorrect.
The line is connected to the motor of
another axis.
The detector cable is connected to Connect correctly.
another axis. PR
Check the repeatability. Replace the amplifier.
Replace the detector.
3B Power module Overheating of the IMP used for The heat radiating environment is • Contact the service center.
overheat the servo drive's main circuit was abnormal. Replace the fan or consider
detected. ventilating or cooling
measures for the panel.
Investigate the installation Correctly ground.
environment. Take noise measures for the
Is the grounding correct? device on the left.
Are there any noise generating
equipment in the surrounding area?
3C Regenerative An error was detected in the Check the connector at the bottom of • Contact the service center.
circuit error regenerative transistor or resistor. the amplifier. Connect correctly.
Check the resistance value of the Replace the regenerative AR
regenerative resistor. resistor.
Is the regenerative resistor burned? Replace the amplifier.
42 Feedback error ① A skip of the detector feedback Open the panel at the top of the • Contact the service center.
1 signal pulse occurred in the amplifier and check the battery Correctly connect.
OHE type or OHA type connection.
detector used in the Check the conductivity with a tester. Replace the cable.
semi-closed loop system and Exchange the detector and amplifier Replace the parts on the side
ball screw end closed loop connection with that for another axis that caused the alarm. PR
system. and check the repeatability.
② A skip of the detector feedback (Pinpoint the cause)
signal pulse in the low-speed
serial type absolute position
linear scale.
43 Feedback error A deviation occurred in the Check the repeatability. • Contact the service center.
2 feedback amount from the motor Replace the detector.
end detector and machine end PR
Check the ambient environment. Check the ambient
detector in the closed loop system.
environment.
9 – 126
Error Reset
No. method
60 Instantaneous The 24VDC voltage connected to Is 24VDC applied on the CN22 • Contact the service center.
stop the CN22 connector has dropped. connector? Increase the power voltage.
Is the CR unit LED lit? Replace the unit.
Check the problems in the
grounding wiring and noise,
etc. AR
The wiring and power voltage is an Replace the power supply
error and wiring.
Wiring contact defect, etc. Replace the wiring or
increase the power supply
capacity.
61 Power module This is detected a overcurrent in Occurs each time servo turns ON • Contact the service center.
overcurrent the power module in the power after turning 200VAC ON. Replace the unit.
supply.
The total of all motors’ loads exceeds Lower motor load and
power supply rated capacity. operation frequency.
Rated power supply capacity is not Increase the power supply
secured. capacity.
PR
Measure the voltage between R-S, Improve the power phase
S-T, T-R with a tester. balance.
environment. Perform the noise measures
Is the grounding correct? for the device.
Is there any noise generating
63 Auxiliary The auxiliary regeneration Dirt on the regenerative resistance • Contact the service center.
regeneration transistor in the power supply is unit on the unit rear. Take measures so that cutting
error continuously ON. oil or dust does not get on the
fins on the unit rear. PR
Confirm the conductivity of the Replace the unit.
terminal block (P, N, R, S, T) and the
resistor surface.
65 Rush relay The rush resistance short circuit Investigate the repeatability and • Contact the service center.
error relay in the power supply does not occur each time. Replace the unit.
turn ON.
environment. Perform the noise measures PR
Is the grounding correct? for the device.
Is there any noise generating
67 Open phase One phase of input 3ø200VAC is The voltage of each input phase is • Contact the service center.
not connected. incorrect PR
• Supply the correct power.
68 Watch dog The power supply software Investigate the repeatability and • Contact the service center.
process did not end within the occur each time AR
• Replace the unit.
designated time.
69 Ground fault Motor ground fault. The insulation between the UVW • Contact the service center.
terminals of all motors and the
• Motor defect or cable ground
grounding is 100kΩ or less. fault.
Replace motor and cable.
PR
Is motor or cable covered with oil? • Take measures so that oil
does not come in contact.
Clean the motor’s cannon
connector and inside the
terminal box.
6A Contactor melt The externally connected contactor An error did not occur on the driver • Contact the service center.
side (power module error, etc.) PR
is ON even during OFF. • Replace contactor.
6B Rush relay melt The rush resistance short circuit Investigate the installation • Contact the service center.
relay in the power supply is ON. environment.
• Correctly ground. PR
An error occurred on the drive side • Replace the unit.
(power module error did not occur.)
9 – 127
Error Reset
No. method
6C Main circuit Charging to the main circuit is not The CHARGE lamp remains lit when • Contact the service center.
error normal. an error occur. PR
• Replace the unit.
6D Parameter The power supply unit (CR) Confirm the parameters of the drive • Contact the service center.
error capacity and the regenerative unit connected to the power supply Set the correct value.
resistance type (rtyp) set in the unit. PR
parameter PTYP are not set to an Servo : SV036 (PTYP)
adequate combination.
6E Memory error Error in the memory circuit in the • Investigate the installation • Contact the service center.
power supply. environment. Replace the unit.
Is the grounding correct?
• Is there any noise generating Correctly ground. AR
Investigate the repeatability and
occur each time.
6F A/D converter Error in the A/D converter in the 7-segment LED display of the power • Contact the service center.
error/ power power supply, or the driver supply is F. A/D converter error.
supply error detected an error in the power
Perform same remedies as
supply.
for alarm 6E memory error.
Replace the unit.
AR
The rotary switch setting is not 0.1. Correctly set the rotary switch.
Check the driver communication Replace the cable.
cable wiring.
Try replacing the driver Replace the unit.
communication cable.
71 Instantaneous The externally installed contactor is Is the externally installed contactor • Contact the service center.
stop/ external OFF. The power supply operates
emergency An instantaneous stop exceeding OFF due to , etc.?
normally. Review the PR
stop 25ms occurred. machine sequence.
Is the RST wiring correct? Repair the wiring.
73 Over-regenerat The regenerative resistor’s load Confirm that the external • Contact the service center.
ion exceeded the tolerable value. regenerative resistance type set in Set to the correct setting, and
the parameter (PTYP) of the drive confirm again. PR
unit connected to the power supply
unit is correct.
74 Regenerative The external regenerative The unit is hot. • Contact the service center.
resistance resistance thermal relay has Perform heat measures for
overheat functioned. the regenerative resistor.
1) Install in a well-ventilated PR
place.
2) Cool with a fan, etc.
The wire of the CN22 (B) connector Replace with correct wiring.
pins 1 and 2 are cut.
75 Overvoltage The voltage between PN exceeded • Investigate the installation • Contact the service center.
410V. environment. Increase the power supply
Is the grounding correct? capacity.
• Is there any noise generating PR
Is rated power supply capacity Correctly ground.
secured? Perform the noise measures
for the device on the left.
76 External The rotary switch setting and Confirm the rotary switch setting and Set the rotary switch to 0 or 1.
emergency parameter (PTYP) setting do not the parameter (PTYP) of the drive Or set the parameter (PTYP) AR
stop setting match. unit connected to the power supply correctly.
error unit.
77 Power module Overheating of the power module • Investigate the installation • Contact the service center.
overheat (IPM) in the power supply was environment. Replace the fan.
detected. Is the grounding correct?
• Is there any noise generating devices AR
in the surrounding area?
Investigate the heat radiating Correctly ground.
environment. Take noise measures for the
device.
9 – 128
Error Reset
No. method
7F Power reboot The control mode (standard Turn the power ON again.
alarm amplifier mode or high-gain mode)
recognized by the EEPROM and
the mode set in the parameters
differ.
82 Power supply A wire breakage or incorrect Check if the connector for the • Contact the service center.
no signal connection of the cable connected communication cable is Correctly connect.
with the power supply was disconnected.
detected. Check the cable breakage. Replace the communication
cable. PR
(Pinpoint the cause.)
88 Watch dog The servo amplifier software Check the repeatability. • Contact the service center.
process was not executed within Replace the amplifier. AR
the designated time.
Check the grounding state. Ground correctly.
S02 INIT PARAM ERR The parameter transferred from the NC to the AMP at the NC power
input time is abnormal.
Error Reset
No. method
37 Initial The servo parameter setting is Check the setting range of the • Contact the service center.
parameter incorrect. parameter having the error No.
error
SV025: A non-entered motor type
was selected.
SV027: 1mc 1 and 2 were set.
SV036: A non-entered resistor type
was selected. PR
Check parameters SV001, SV002
and SV018.
Check the parameter SV017.
Check parameters SV057 and
SV058.
Check the parameter SV027 bit 15.
S03 SERVO ALARM: NR This alarm is displayed when an abnormal state of the servo system is
detected. It is possible to clear this alarm by the "NC reset" key input
after removal of the cause of the alarm.
Error Reset
No. method
46 Motor overheat Overheating of the motor was Check the ambient temperature. • Contact the service center.
detected. Improve the ambient
environment.
Has the overload alarm (50) cut off Review the operation pattern. —
the amplifier power and caused a
forced reset?
Is the load too large?
4F Instantaneous The power was cut off for 50msec • Is the weather OK? • Contact the service center.
stop or more. (Has lightning occurred?) • Connect correctly.
Is the connector or connection • Improve the power supply.
disconnected. —
When using overseas, there are
cases when the power supply is poor.
Check the connection. • Connect correctly.
9 – 129
Error Reset
No. method
50 Overload 1 An excessive load was applied for Review the motor capacity selection. • Contact the service center.
longer than the set time. Change the motor or amplifier
capacity.
Check the brake operation. Repair the faulty section.
1) Check the brake relay.
2) Check the connector connection.
Check the load current on the NC Replace the faulty section in —
servo monitor and find the machine the machine.
load.
Is the ball screw bent?
Is there interference with the Do not use positioning pins.
positioning pin?
Are SV021 and SV022 set to the Set the standard values.
standard values?
51 Overload 2 An excessive load was applied for Visually check whether there was a • Contact the service center.
longer than the set time. collision with the machine.
• Check the cause of the
collision.
Is there interference with the Do not use positioning pins.
positioning pin?
Check the motor power line (U, V, Connect correctly.
W). —
1) Is the U, V, W phase order
correct?
2) The power line is not connected.
3) Is the cable connected to the
motor for another axis?
Change with another axis and check Replace the detector.
the repeatability.
52 Excessive error The actual motor position and Is the motor speed fluctuating? • Contact the service center.
1 model position difference was Adjust the gain.
excessive at servo ON.
Is the acceleration/deceleration time Adjust the parameters.
constant too short?
The current limit value is too low and
a sufficient torque is not output.
The motor brakes cannot be Repair the brake circuit.
released?
Check the SV023 (SV053) setting Adjust the parameters. —
value.
Check the motor power line (U, V, Connect correctly.
W).
1) Is the U, V, W phase order
correct?
2) Is the cable connected to the
motor for another axis?
Change with another axis and check • Replace the detector.
the repeatability.
Check the connection. • Connect correctly.
Excessive error The actual motor position and Check the SV026 setting value. • Contact the service center.
53 2 model position difference was Check the NC parameters. Set correctly. —
excessive at servo OFF.
Excessive error The motor current did not flow Check the connection of the motor • Contact the service center.
54 3 when the excessive error 1 alarm power line (U, V, W phases). Connect correctly. —
was detected.
58 Collision A collision detection type 1 error Check the parameters. • Contact the service center.
detection 0 was detected during the G0 modal Set correctly.
(rapid traverse).
—
59 Collision A collision detection type 1 error
detection 1 was detected during the G1 modal
(cutting feed.)
5A Collision A collision detection type 2 error The alarm occurs even if the • Contact the service center.
detection 2 was detected. detection level is raised. —
Replace the unit.
9 – 130
Error Reset
No. method
5F Contactor The contact point of the external Check the contactor conductivity. • Contact the service center.
fusing contactor fused. Replace the contactor.
SV017 (SPEC). bit 3 should be set to Set the parameter.
1. —
(The setting is made only for the axis
that is actually controlling the
contactor.)
Check the relay and control cable. Repair the defective section.
S51 The parameters warning is displayed.

(The address of the axis to have caused a
warning is displayed.)
Error Reset
No. method
E4 Parameter A parameter exceeding the setting Check the parameter setting • Contact the service center.
error warning range was set. The illegal conditions. Set correctly.
parameter is ignored, and the —
value used before the illegal
parameter was set is held.
S52 The servo warning is displayed.

(The address of the axis to have caused a
warning is displayed.)
Error Reset
No. method
90 Low speed The initial communication with the Check the parameter. • Contact the service center.
serial initial low speed serial type absolute Set correctly. PR
communication position linear scale was not
error possible.
91 Detector The absolute position serial data Open the panel on top of the amplifier • Contact the service center.
communication was not correctly sent from the and check the battery connection. Connect correctly.
error OHA type detector and low-speed
serial type absolute position linear —
scale.
Check the state of the axis when the Repair the faulty section.
NC power was turned ON.
92 Detector serial There was an error in the format of
format error the serial data from the OHA type
—
detector and low-speed serial type
absolute position linear scale.
93 Initial absolute The position data fluctuated when
position creating the initial absolute PR
fluctuation position.
96 MP scale In the MP scale absolute position
feedback error detection system, an excessive
deviation in the motor end —
installation detector and MP scale
feedback amount was detected.
97 MP scale offset In the MP scale absolute position
error detection system, an error was
detected in the offset data read PR
when the NC power was turned
ON.
9E Detector There was an error in the data of Check the repeatability. • Contact the service center.
multi-rotation the multi-rotation counter in the Replace the detector. —
counter error detector.
9 – 131
Error Reset
No. method
9F Battery voltage The battery voltage dropped. The battery life is approx. 5 years. • Contact the service center.
drop (This will change according to the Replace the battery.
usage state.)
—
Open the panel at the top of the Connect correctly.
amplifier and check.
E0 Over-regenerat The regeneration level reached Check the regeneration capacity. • Contact the service center.
ion warning 80% or more. Check the parameter (SV036). Change the regenerative
resistor.
E1 Overload The load level reached 80% or —
warning more. Occurs at OFF. Set correctly.
Check the power voltage with a Review the power supply.
tester.
E3 Absolute A deviation was detected in the Check whether a battery error • Contact the service center.
position absolute position data and occurred recently. Replace the detector. —
counter incremental position data.
warning
E9 Instantaneous The power was cut off for 25msec S03 SERVO ALARM • Contact the service center.
stop warning or more but 50msec or less. Refer to Error No. 4F. —
Connect correctly.
EA External The external emergency stop • Contact the service center.
emergency signal was input. Turn OFF the external —
stop input emergency stop switch.
EB Over-regenerat 80% of the over-regeneration Confirm that the external • Contact the service center.
ion alarm level was reached. regenerative resistance type set in Set to correct setting, and
the parameter (PTYP) of the drive confirm again. —
unit connected to the power supply
unit is correct.
9 – 132
9-8-6 MCP Alarms

An abnormal state was detected in the drive amplifier or other interface section.
(The message shown in bold characters is displayed.)
• : Item carried out by User.
: Item carried out by Manufacturer.
Y01 MEMORY ALARM Check the RAM and ROM since the memory is abnormal.
Error No. Message & Details Remedies
0001 1 UNIT ABNML • Contact the service center.
Replace the HR113 card.
0002 2 PORT RAM ABNORMAL • Contact the service center.
0004 ROM ABNORMAL • Contact the service center.
The data transfer between the MCP and the amplifier is abnormal after
Y02 SYSTEM ALARM
the NC power input.
0001 CRC ERROR • Contact the service center.
Check the mounting condition of the amplifier.
Confirm the insertion of the connector and the
amplifier power source.
0002 RECEPTION TIMMING ERROR • Contact the service center.
0004 NO. OF RECEPTION FLAME ERROR • Contact the service center.
0008 DATA ID ERROR • Contact the service center.
0010 NO. OF CONTROL AXIS ERROR • Contact the service center.
Y03 AMP UNEQUIPPED • Contact the service center.

Check the mounting condition of the amplifier.
Confirm the cable connection.
Check whether the connection cable is broken.
Confirm the insertion of the connector.
Check whether the power has been input to the amplifier.
Check whether the axis No. switch of the amplifier is correct.
Y04 2 PORT MEMORY PARITY • Contact the service center.
Y05 IINIT PARAM ERR The parameter necessary at the NC power input time is abnormal.
0001 INPUT UNIT SETTING ABNORMAL • Contact the service center.
The internal setting is incorrect.
0002 SET VALUE OF RNG (MOVE UNIT) OR PC2 • Contact the service center.
(GEAR RATIO 2) ILLEGAL Confirm the set parameters.
Check the machine parameters "PC2" and "RNG"
displayed on the servo parameter screen.
0003 RNG (MOVE UNIT) OR PC2 (GEAR RATIO • Contact the service center.
2) NOT SET YET Confirm the set parameters.
Check the machine parameters "PC2" and "RNG"
0004 PIT (BALL SCREW PITCH) OR PC1 (GEAR • Contact the service center.
RATIO 1) NOT SET YET Confirm the set parameters.
Check the machine parameters "PC1" and "PIT"
9 – 133
An alarm occurred when the control axis was valid due to an abnormal
Y51 PARAM. ABNORMAL
parameter.
LINEAR ACCELERATION AND • Contact the service center.
DECELERATION RAPID FEED TIME Confirm the machine parameter "G0tL" displayed
CONSTANT ABNORMAL on the axis specification parameter screen.
0001
The time constant has not been set, or the
set value of the time constant is not within
the specified range.
LINEAR ACCELERATION AND • Contact the service center.
DECELERATION MACHINING FEED TIME Confirm the machine parameter "G1tL" displayed
CONSTANT ABNORMAL on the axis specification parameter screen.
0002
The time constant has not been set, or the
PRIMARY DELAY RAPID FEED TIME • Contact the service center.
CONSTANT ABNORMAL Confirm the machine parameter "G0t1" displayed
0003 The time constant has not been set, or the on the axis specification parameter screen.
PRIMARY DELAY MACHINING FEED TIME • Contact the service center.
CONSTANT ABNORMAL Confirm the machine parameter "G1t1" displayed
0004 The time constant has not been set, or the on the axis specification parameter screen.
9 – 134
9-8-7 Other Servo Alarms

Z AXIS CONTACT • Move the Z axis in the contact clearing direction.
S402 The Z axis is in contact with the workpiece,
worktable, etc.
IH XY MAX LMT • Change the program because the movable range of
S403 The IH in use went beyond the movable the XY table is narrower when the IH is in use.
range of the XY table.
9 – 135
9-8-8 Program Alarms

(The message shown in bold characters is displayed.)
A program alarm occurs during the automatic operation, it appears as a program error mainly in case the
machining program includes some programming error or in case the created program does not meet the NC
specifications.
Error
No.
P10 EXCS AXIS NO. • Divide the commands in the block with the
The number of axis addresses error into two groups.
commanded in the same block is larger
than the specified number.
P30 PARITY H • Check the paper tape in use.
The number of punched holes for one • Check the tape punch and the tape
character in the EIA code paper tape was reader.
even, or the number of punched holes for
one character in the ISO code paper tape
was odd.
P31 PARITY V • Make the number of characters in one
The number of punched characters in one block on the paper tape even.
block on the paper tape was odd.
(In case the parity V selector switch is ON.)
P32 ADDRESS ERROR • Check the program address and correct it.
An address other than specified was set. • Confirm the specification.
P33 FORMAT ERROR • Check the program again.
The command format in the program is
illegal.
P34 G-CODE ERROR • Confirm the G code address in the
A G code other than specified was program, and correct it.
commanded.
P35 CMD-VALUE OVER • Check the program again.
The command value of each address went
beyond the setting range.
P36 PROGRAM END ERR • M02 and M30 are not set at the program
"EOR" was read when the tape and the end.
memory were ON. • "M99" or "G23" is not set at the
sub-program end.
P37 L OR N IS 0 • Set a number within the range of 1 to
Zero was set as the program No. and the 99999999 as the program No.
sequence No. • Set a number within the range of 1 to
99999 as the sequence No.
P39 G-CODE UNMATCH • Never write illegal G code whose
A combination of G codes, whose combination is prohibited in the same
simultaneous designation is prohibited, block.
exists in the same block.
P51 OFFSET MODE • Correct the program so that the
The inch command and the millimeter inch/millimeter changeover is not
command were set in the G41 and G42 executed during the diameter correction.
modal.
P60 OVER CMP. LENG. • Check whether the commanded axis
The commanded moving distance is too address is beyond the designated range.
large.
9 – 136
Error
No.
P70 ARC ERROR • Check the program start point and end
The set arc start point, arc end point, and point and numeric value of the address for
arc center are incorrect. arc center designation.
• Check the sign (plus or minus) of the set
address value.
P71 ARC CENTER • Check the numeric value of each address
The arc machining time set by R and the in the program.
arc center cannot be decided.
P151 G.2, 3 CMP ERR • Set the linear machining command (G01)
Some correction command (G40,G41, or or the rapid feed command (G00) in the
G42) was input while the arc mode (G02 or compensation command block or the
G03) was ON. cancel block. (To put the modal into
"linear interpolation")
P152 L.S.P. NOTHING • Check the program again.
The intersecting point of one block skip, in
the interference block being processed
during execution of the tool diameter
correction (G41 or G42), cannot be
decided.
P153 LF ERROR • Check the program again.
An interference error occurred during the
tool diameter correction (G41 or G42).
P170 NO CORR. NO. • Add the offset number command to the
The correction No. (H○○) was not offset command block. Confirm the
designated at the input time of the offset number of combinations of the correction
command (G41, G42, or G43), or the Nos., and correct the command so that
number of the set correction Nos. the number of correction Nos. does not
exceeded the specified quantity. exceed the allowable number of
combinations.
P222 G36 ANGLE ERR • Check the program again.
The angle space set by G36 was 0.
P230 NESTING OVER • Confirm the allowable number of
The number of sequential calls of one sub-program calls, and correct the
sub-program from another exceeded 30. program so that the number of
subprogram calls does not exceed 30.
P231 NO N-NUMBER • Set the sequence No. in a suitable block.
No sequence number was found at the
time of access to a sub-program or return
from a sub-program, or the sequence No.
designated by the GOTO command has
not been set.
P232 NO PROGRAM NO. • Register the subprogram, or, correct the
The program No. of the accessed subprogram No. called by the main
sub-program has not been set. program.
P241 NO VARI NUMBER • Correct the program variable No. within
The commanded variable No. is larger the specified range.
than the specified variable No.
P242 EQL.SYM.MSSG. • Set the " = " for the variable definition in
The " = " was not designated at the time of the program.
variable definition.
9 – 137
Error
No.
P244 VAR.DEFF.OVER • Decrease the number of variable
The number of defined variables in one definition commands in one block to 10 or
block exceeded 10. less.
P251 MULT.F.ROT • Confirm the program.
Another figure rotation command was
input during execution of one figure
rotation command.
P253 R-DIFF. OVER • Correct the program so that the radius
The set finishing radius deviated by 6µ or error is within the specified value.
more and also by R/1024 mm or more from
the reference radius while figure rotation
was in progress.
P272 NC/MACRO ILL. • Check the program again, and set the NC
The NC statement and the macro statement in a block different from that of
statement coexist in the same block. the macro statement.
P273 MACRO OVERCALL • Check the program again, and correct the
The multiple macro calls exceeded the program so that the number of macro calls
allowable degree. does not exceed the specified number.
P275 MACRO ARG. EX. • Review the program so that the No. of
The number of argument combinations in sets match.
the macro call argument type II is too large.
P276 CALL CANCEL • Check the program again.
The G67 command was input when the • Set the G66 command before the G67
G66 command modal was not ON. command input because the G67
command is a cancel command.
P277 MACRO ALM MESG • This alarm is created by the user, so use
An alarm command was issued to H3000 the appropriate measures.
by the user.
P280 EXC.[ , ] • Check the program again.
The number of [ ] pairs in one block Correct the program so that the number of
exceeded 5. "[" and "]" pairs does not exceed 5.
P281 [,] ILLEGAL • Check the program again, and correct the
The number of set in one block differs from program so that the respective "[" and "]"
that of "[" and "]" set in the same block. are paired.
P282 CALC. IMPOSS. • Check the program again, and correct the
The arithmetic expression is incorrect. arithmetic expression.
P283 DIVIDE BY ZERO • Check the program again, and correct the
The denominator of the division is zero. arithmetic expression so that the
denominator of the division does not
become zero.
P290 IF SNT. ERROR • Check the program again.
The IF [<qualification>] GOTO statement
is incorrect.
P291 WHILE SNT. ERR • Check the program again.
The WHILE [<qualification>] DO ~END
statement is incorrect.
9 – 138
Error
No.
P292 SETVN SNT. ERR • Check the program again.
The variable name setting SETVN • Reduce the number of characters
statement is incorrect. constituting the variable name of the
SETVN statement to 7 or less.
P293 DO-END EXCESS • Check the program again, and correct the
The number (multiplexing degree) of for program so that the number of the
DO and END in the WHILE multiplexing degree in the DO ~ END
[<qualification>] DO ~ END statement statements does not exceed 27.
exceeded 27.
P294 DO-END MMC. • Check the program again, and correct the
~
The DO END is not expressed as a pair. program so that the respective DO ~ END
is paired.
P295 WHILE/GOTO TPE • Select the memory operation since a
The WHILE or GOTO statement was program including the WHILE or GOTO
detected in the tape during the tape statement cannot be executed in the tape
operation. operation.
P296 NO ARR (MACRO) • Check the program again.
The address indispensable to the user
macro has not been set.
P297 ADR-A ERR • Check the program again.
The address A is not set by a variable in
the user macro.
P298 NO MEMORY (MAC) • Check the program again.
G200 to G203 commands for the user
macro were used in the tape operation,
MFD operation, or BTR operation.
P300 VAR NAME ERROR • Correct the program so that the variable
The variable name has not been correctly name is correct.
designated. Check the variable name of the program,
and if wrong, change it to the correct name.
P301 VAR NAME DUPLI • Correct the program so that the variable
Overlapping variable names were names never overlap.
detected.
P312 G109 B, C 0 • Check the address B and the address C in
The address B and the address C set by the G109 block again.
G109 in the user macro are zero.
P314 CHR. NUM. OVER • Reduce the number of characters in one
The number of characters in one block block to 248 or less.
exceeded 248.
P315 1ST CHR. ERR • Correct the program.
A numeric character or a symbol was set in
the first character position of the block.
P316 G54-59 (ARC) • Correct the program so that the workpiece
The workpiece coordinate system was coordinate system never changes when
changed at the arc modal time. the arc modal is ON.
P317 G54-59 (F.ROT) • Correct the program so that the workpiece
The workpiece coordinate system was coordinate system never changes while
changed while the figure rotation was in the figure rotation is in progress.
progress.
9 – 139
Error
No.
P318 RETURN F.ROT • Correct the program so that zero return
A return command (G27 to G30, G47, command (G27 to G30, G47, G48, or
G48, or G60) was input during execution of G60) is input while the graphic rotation is
the graphic rotation. in progress.
P319 G92 (F.ROT) • Do not input the G92 command while the
The G92 command was input during sub-program is in progress.
execution of the figure rotation.
P320 G53 (F.ROT) • Do not input the G53 command while the
The G53 command was input during sub-program is in progress.
execution of the figure rotation.
P351 SCALE ARC • Turn ON the scale factor to both the
The scale factor of either the horizontal horizontal axis and the vertical axis of the
axis or the vertical axis of the arc was arc, or keep both axes free from the scale
turned on. factor.
P370 G14 P ERR. • Keep the value of P within the range of
The P No. is beyond the specified range. 0 ≤P≤ 10.
P371 PORT# ERR. • Check the program again.
The external port No. is beyond the
specified range.
P382 CONER NO MOVE • Set the G01 command in the block next to
The move command has not been set in the corner R/C command.
the block next to the corner R/C.
P383 CONER SHORT • Make the corner R/C smaller than the
The moving distance is shorter than set by move distance because the moving
the corner R/C command. distance is shorter than the corner R/C.
P384 CORNER SHORT • Make the corner R/C smaller than the
The moving distance in the next block set move distance because the moving
by the corner R/C command is smaller distance in the next block is shorter than
than the corner R/C. the corner R/C.
P385 G0 IN CONR • Check the program again.
The corner R/C was commanded when the
G00 modal was ON.
P392 LES AGL (GEOMT) • Correct the geometric angle.
The angle difference between one
geometric straight line and another is
within 1°.
P393 INC ERR (GEOMT) • Set the geometric second block by the
The geometric second block has been set absolute value.
by the increment value.
P394 NO GO1 (GEOMT) • Execute the G01 command.
No straight line command has been set in
the geometric second block.
P395 NO ADRS (GEOMT) • Check the program again.
The geometric format is incorrect.
P396 PL CHG. (GEOMT) • Change the plane before execution of the
The plane change was commanded during geometric command.
the geometric command execution.
9 – 140
Error
No.
P400 RETURN ERR • The No. of blocks between the M20s must
The No. of blocks between M20 and next be less than 1000 when using the
M20 exceeded 1000 during the graphic "REVERSE PATH RET".
check.
P430 AXIS NOT RET. • Return the concerned axis to the origin by
Some move other than return to origin was manual operation.
commanded to an axis whose return to
origin has not been executed.
P434 COLLATION ERR • Check the program again.
Some axis did not return to the origin when
the zero verification (G27) was executed.
P435 G27/M ERROR • Set the M single command in a block
The M single command has been different from that of the G27 command
concurrently set in the G27 command because the M single command cannot
block. be set in the G27 command block.
P436 G47/M ERROR • Set the M single command in a block
The M single command has been different from that of the G47 command
concurrently set in the G47 command because the M single command cannot
block. be set in the G47 command block.
P460 TAPE I/O ERROR • Clean the photo-sensor block of the tape
An error occurred in the tape reader, or an reader, and then read the tape again.
error occurred in the printer at the macro
print time.
P461 FILE I/O ERROR • Replace the diskette, and retry the file
The files of the machining program cannot read.
be read.
P462 COMPUTER LINK • Reset the operation.
A communication error occurred during the
BTR operation.
P463 BTR I/O ERR. • Check the cables.
The data cannot be read during BTR run. • Check the communication parameters of
the transmission equipment.
P500 NO MOVE CMD. • Correct the program so that three or more
No move program extending over three move blocks exist within the 30 advanced
blocks was found within 30 advanced reading blocks.
reading blocks during the offset mode.
P501 PRE-READ ERR. • Check the program again.
The advanced reading buffer for move
blocks became FULL during the offset
mode.
P502 PRE-READ ERR. • Decrease the number of non-move blocks
The advanced reading buffer for non-move among the move blocks.
blocks became FULL during the offset
mode.
P503 INTERFERENCE • Check the program again.
The interference check function • Turn ON the interference check function,
encountered an uncertain factor, or the and execute the machining again.
prevention of excessive cut became
activated.
Interference was detected in the
"interference error check" mode.
9 – 141
Error
No.
Interference to defy ready clearance
occurred.
P506 RQ. G87 UV ERR • Check the program again.
The designation of G87 or RQ caused the
UV to stick in the preceding or subsequent
straight line block.
P507 READ BUFFER OVER • Reset.
The read buffer for the MFD, TAPE or BTR
operation program was exceeded.
P550 MFD IN USE • Wait until MFD operation by another
The MFD is busy with execution of some function is completed.
other function.
P551 MFD ERR. • Confirm the insertion of the floppy.
The floppy has not been inserted. (Or the • Confirm the write protect state of the
MFD is out of order.) floppy.
• Check whether the MFD is damaged or
not.
P990 PREPRO ABNORML • Contact the Mitsubishi Electric Engineer.
The software operation is abnormal.
P1070 E-PACK ERR. • Store the E-Pack.
The E-pack has not been stored, or an E • Use the E No. designated in the
No. not designated in the specification was specification.
commanded.
P1072 POS. ERR. • Confirm the specification.
The commanded valid axis is not set by the
G29 command or the G30 command.
P1074 APP COMPEN • Change the approach compensation
The approach compensation length length.
exceeds the movement amount of one
block.
P1080 RQ G87 ERR1 • When setting G87 and the RQ designate
The pattern of straight line-arc-straight line the pattern of straight line-arc-straight line
block has not been set in the G87 and the block.
RQ.
P1081 IJ ERROR • Do not designate the IJ in the straight line
IJ has been designated in the preceding block by G87 or RQ.
straight line block by G87 and RQ, or IJ • Do not designate IJ in the UV setting block.
has been designated in the UV setting
block.
P1082 RQ G87 ERR2 • Set the same tool offset in both the arc
The tool offset in the arc set for the G80 and the subsequent straight line block.
mode by G87 RQ command is different
from the tool offset in the subsequent
straight line block.
P1083 UV CIR. ERR. • Set the straight line mode in the UV
The mode of the UV setting block is not the setting block.
straight line mode.
9 – 142
Error
No.
P1084 G88 CIR. ERR. • Set the tool offset and taper offset in the
The tool offset and taper offset of the arc in arc to the same values as of those in
the G88 mode are different from those of another.
another. (Helical insertion)
P1086 OFSET M0SEARC • Use the M0 search function in the offset
The M0 search function was used in the cancel state.
offset mode.
P1088 TAPER • Make the taper offset value smaller than
The taper stroke end exceeded 32mm. 32mm.
P1091 CP, BL POP ERR • Make the number of G22 commands
The number of G22 (sub-program call) equal to that of G23 commands.
commands differs from that of G23
(sub-return) commands.
P1094 Z-OPT. ERR. • Do not command the Z axis move through
The Z axis option has not been adopted. the NC program.
P1095 IH-OPT ERR. • Do not use any command concerned with
The initial hole option has not been the initial hole option device.
adopted.
P1096 M70 UV EXIST • Keep the UV command invalid in the initial
The UV command was input in the initial hole mode.
hole mode.
P1097 M82 IN IH-MOD • Keep the "wire feed ON" command (M82)
The "wire feed ON" command was input in invalid in the initial hole mode.
the initial hole mode.
P1098 NON H/W OPT • Confirm the specification of the H/W
The M code was commanded to a function option.
not supported by the H/W option.
P1099 CM MODE SELECTION ERROR • Review the P command in the program.
Appears when the P command range for
the M110 or M111 command is incorrect.
9 – 143
9-8-9 System Alarms

Error
No.
Z01 WATCH DOG 1 • Contact the Mitsubishi Electric Engineer.
This error occurs in case a process to be
finished by the NC system (software) does
not end within the set time.
Z02 SYSTEM ERROR • Contact the Mitsubishi Electric Engineer.
The NC system (software) was destroyed.
Z03 MEMORY PARITY • Replace the card containing the
This error occurs in case some instruction destroyed instruction or data with a new
or data was found destroyed during the card.
operation by the NC system (software).
Z04 MEMORY PROTECT • Contact the Mitsubishi Electric Engineer.
Writing of data into a write protected
memory was attempted.
Z05 DIVIDE BY ZERO • Check the parameter machining data.
Illegal data requiring a division by zero
exists in the parameter machining data or
other.
Z06 CAN'T LOAD MFD • Replace the floppy or the floppy disk unit
The floppy storing the system S/W cannot (including the card).
be read due to destruction or the IOP
floppy disk unit is out of order.
Z07 CRC ERROR • Load the backup copy of the floppy again.
The data on the system S/W was • Contact the Mitsubishi Electric Engineer.
destroyed.
Z08 FILE AREA ERR • Contact the Mitsubishi Electric Engineer.
The system is abnormal.
Z09 REMOTE I/O ERR • Replace the cable.
This error occurs if any of the following • Replace the remote I/O unit.
trouble is detected in the system • Input the power source to the remote I/O
employing a remote I/O unit. unit.
• Some wire of the cable is broken.
• Data sending error
• Data input error
• Remote I/O trouble
• Power failure of remote I/O unit
Z10 BACKUP BATTERY ABNORMAL • Contact the Mitsubishi Electric Engineer.
The battery for saving data in the NC is The battery may need to be replaced.
spent, and the data cannot be backed up.
9 – 144
9-8-10 System Warning

Error
No.
Z50 UNEXPECTED-INT • Contact the Mitsubishi Electric Engineer.
An illegal interrupt occurred due to an
external factor such as noise.
Z51 FROM ERROR • Contact the Mitsubishi Electric Engineer.
The FROM operation is abnormal.
Z52 BACKUP BATTERY LOW • Report the state to the Mitsubishi Electric
A drop in the voltage of the battery used to Engineer. The battery may need to be
save the NC internal data was detected. replaced.
If this occurs during machining, replace the
battery after completing that machining.
Z53 UPS AC FAIL
During a power failure, it can be
determined whether the power was turned
OFF due to the power failure or due to the
power OFF switch being turned OFF.
Z54 UPS BATTERY LOW • Charge the battery. (Leave the NC power
The battery mounted in the UPS used for ON for a short while.)
holding the NC power during a power If this does not solve the problem, report
failure is spent. the state to the Mitsubishi Electric
Engineer. The battery may need to be
replaced.
• If this occurs during machining, replace the
battery after completing that machining.
9 – 145
9. MAINTENANCE AND ALARM LIST 9-9 List of Consumables
9-9 List of Consumables

Standard Replacement
Part name Specification, model Remarks
specification timing guide
Power feeder X088D493H01 48 places
(Upper and lower) 2 Mounted
or 1 year
Diamond die ø0.1 X056C412G55
Type-P (Upper)
ø0.15 X053C834G52
ø0.2 X055C538G54
1 (For ø0.2) Mounted 0.5 to 1 year
ø0.25 X055C538G55
ø0.3 X055C538G56
For angle master ø0.2 X059D986G51
Wire guide unit

Diamond die ø0.1 X052B243G63
Type-P (Lower) ø0.15 X052B243G64
ø0.2 X052B507G54
ø0.25 X052B507G55 1 (For ø0.2) Mounted 0.5 to 1 year
ø0.3 X052B507G56
Guide (U) Inner diameter ø0.4 X055C631G52 Mounted
(For replacement, 1 to 1.5
1
please contact the years
Service Center)
Guide (D) Inner diameter ø0.8 X055C630G54 1 to 1.5
1 Mounted
years
Power feed terminal Guides (U)
Upper diamond die Lower diamond die Guide (D)
9 – 146
Filter DIA FILPER TYPE 8M (S642D854P21) 2-piece set 300hr (4-pc
Dielectric fluid reservoir
specifications)
120hr (2-pc
specifications)
(Coupler) S642D854P14 2 Mounted
(reusable)
Ion exchange resin MB4 (10l) 1 Mounted 100 hr
(Organo) Container: H-10 (Resin spent
type)
* The above replacement timing is reference for finish machining typical steel material.
The timing may differ according to the machining details and working environment.
Filter
Ion exchange resin (export specifications)

<Resin spent type>
9 – 147
Spare parts list

Upper nozzle ø4 X056C836H01 Mounted
1 (ø4) 2 years
ø7 X056C836H03 Accessory
Lower nozzle ø4 X054D881H07 Mounted
1 (ø4) 2 years
ø7 X059D083H02 Accessory
Jet nozzle ø0.3 X054D826H09
Wire guide unit
ø0.5 X054D826H06
ø0.75 X054D826H07
1 (Hole diam.
ø1.0 X054D826H08 Mounted 2 years
ø1.5)
ø1.5 X058D054H02
ø2.0 X058D054H13
ø2.5 X054D826H12
O-ring For upper CO 0534A 1 Mounted
2 years
CO 0612A 2 Mounted
For upper and lower CO 0520A 2 Mounted 2 years
Jet nozzle
C00520A C00534A
(between nozzle mounting base (between upper nozzle and
and upper block) nozzle mounting base)
C00612A
(mounted on jet nozzle)
Upper nozzle
C00520A
(under guide D
rectifying ring)
Lower nozzle
9 – 148
Main tension roller S684D893P59 1 Mounted (usable 4 times) 2 years
Brush X088D274G51 1 Mounted 2 years
MT pinch roller A, B X058D912G51 2 Mounted (usable 4 times) 1 to 2 years
Feed system
Auxiliary die A X088D339G51 1 Mounted 1 year

Auxiliary die B X059D084G51 1 Mounted 1 year
Collection roller (capstan) X055C663G51 1 Mounted (usable 4 times) 1 year
Collection roller (pinch roller) X055C662G51 1 Mounted (usable 4 times) 1 year
Collection roller bearing 6902-H-20T1X P840K002P36
2 Mounted 1 year
ZZ1*, NS7S1
Lower roller bearings F608-H-VV P840F000P69 2 Mounted 1 year
Auxiliary die B
Auxiliary die A
Main tension roller

(ceramic)
Collection roller Collection roller Collection roller bearing

(capstan) (pinch roller) (pinch roller)
Lower roller bearing MT pinch roller A (right side) (ø50)

(pinch roller) B (lower side) (ø50)
Ceramic MT pinch roller (ø60)
9 – 149
9. MAINTENANCE AND ALARM LIST 9-10 Reference Information on Wire Electrodes
9-10 Reference Information on Wire Electrodes

Always use the following applicable wire electrodes
Mounting of wire processing unit

Part name
Automatic wire feeder (option)

: Can be used in mounted state
Type Maker : Usable U: Should be used in unmounted
×: Unusable state
×: Unusable
FBHM-V Furukawa Electric Co.,
Ltd.
Brass wire
SBS-HN Sumiden Fine Conductors

HBZ-U (N) Hitachi Densen Co.,
Ltd.
OB-PN Oki Electric Cable Corp.
MEGACUT-typeD BERKENHOFF GmbH × U
High-speed machining wire
HIE Hitachi Densen Co.,

× U
Ltd.
HIF Hitachi Densen Co.,
U
Ltd.
MOSWIRE Oki Electric Cable Corp.
U
BERKENHOFF GmbH
MOS4000 Oki Electric Cable Corp.
U
BERKENHOFF GmbH
SZS Sumiden Fine Conductors U
NOTE
1. The following problems could occur if non-recommended wires are used.
1) The machining speed could drop
2) The wire could break easily
3) The workpiece accuracy could drop
4) The automatic connection insertion rate could drop
5) The wire could get entangled in the wire collection section
2. The high-speed machining wire does not curl as neatly as the brass wire, so the wire insertion ability
could drop. The ceramic pinch roller B (option) should be used when using the high-speed wire to
improve the wire insertion ability.
3. If high-speed machining wire is used with a machine having a wire processing unit (option), the wire
may not curl neatly after passing through the collection rollers, and may not enter the cutter inlet. This
can cause an error with the wire processing unit. In this case, the wire processing unit must be
unmounted.
When using the machine with wire processing unit, the wire processing unit should be unmounted
before using the high-speed machining wire.
4. Always use non-paraffin type brass wire.
9 – 150
Brass Wire (FBHM-V Wire)

Specification : Wire diameter tolerance : ±1µm
Tensile strength : 980 to 1180N/mm2
Wire Type and Winding Length (km)
Wire dia. Bobbin size (winding weight)

Item Name
(mm) P-3R (1.6kg)
ø0.1 FBHM-10V 24.5
ø0.15 FBHM-15V 10.9
Packing (bobbin/box) 6
ø20
ø130
ø80
Bobbin dimensions (mm)
10 90 10
Maker : Furukawa Electric Co., Ltd.
Brass Wire (SS-HN Wire)

0
Specification : Wire diameter tolerance : −2
µm

Item Name
(mm) P-3 (1.6kg) P-3 (3kg)
ø0.1 SS-10HN 24.5 45.9
ø0.15 SS-15HN 10.9 20.4
Packing (bobbin/box) 6 6
ø20
ø20
ø130
ø130
ø80
ø80

10 90 10 10 90 10
Maker : Sumiden Fine Conductors
9 – 151
Brass Wire (OB-PN Wire)

Tensile strength : 980N/mm2 or more

Item Name
(mm) P-3 (1.6kg) P-3 (3kg)
ø0.1 OB-10PN 24.5 45.9
ø0.15 OB-15PN 10.9 20.4
Packing (bobbin/box) 6 6
ø20
ø20
ø130
ø130
ø80
ø80
10 90 10 10 90 10
Maker : Oki Electric Cable Corp.
9 – 152
Brass Wire (FBHM-V Wire)


Item Name
(mm) P-3R (3kg) P-5R (5kg) P-10R (10kg) P-15 (20kg)
ø0.2 FBHM-20V 11.4 19.0 38.0 76.0
ø0.25 FBHM-25V 7.3 12.2 24.4 48.6
ø0.3 FBHM-30V 5.1 8.4 16.8 33.8
Packing (bobbin/box) 6 4 2 1
ø34
ø25
ø20
ø20
ø250
ø200
ø130
ø110
ø160
ø90
ø80
ø90
10 90 10 12 90 12 15 110 15 12 110 12
Maker: Furukawa Electric Co., Ltd.
Brass Wire (SBS-HN Wire)

Specification : Wire diameter tolerance : 0 µm
−2

Item Name
(mm) P-3 (3kg) P-5 (5kg) P-10 (10kg) P-20 (20kg) DIN160 (5kg)
ø0.2 SBS-20HN 11.5 19.1 38.0 76.0 30.6
ø0.25 SBS-25HN 7.3 12.2 24.4 48.8 19.6
ø0.3 SBS-30HN 5.1 8.5 17.0 34.0 13.6
Packing (bobbin/box) 6 4 2 1 2
ø20
ø34
ø20
ø25
ø22
ø130
ø250
ø160
ø200
ø110
ø160
ø100
ø80
ø90
ø90

10 90 10 12 90 12 12 110 12 15 110 15 16 128 16
Maker: Sumiden Fine Conductors
9 – 153
Brass Wire (HBZ-U(N) Wire)


Item Name
(mm) P-3RT (3kg) P-5RT (5kg) P-15L (20kg)
ø0.2 HBZ-U(N)20 11.4 19.0 76
ø0.25 HBZ-U(N)25 7.2 12.0 49
ø0.3 HBZ-U(N)30 5.1 8.4 34
Packing (bobbin/box) 6 4 1
ø34
ø20
ø20
ø250
ø130
ø110
ø160
ø80
ø90
10 80 10 12 90 12 15 110 15
Brass Wire (OB-PN Wire)


(mm) Item Name K-125 K-160
P-3R (3kg) P-5R (5kg) P-10 (10kg) P-15 (20kg)
(3.8kg) (6.0kg)
ø0.2 OB-20PN 11.5 19.1 38.2 76.4 14.5 22.9
ø0.25 OB-25PN 7.3 12.2 24.4 48.8 9.3 14.7
ø0.3 OB-30PN 5.1 8.5 17.0 34.0 6.5 10.2
Packing (bobbin/box) 6 4 1 1 4 4
ø25
ø20
ø20
ø34
ø16
ø22
ø200
ø130
ø160
ø250
ø110
ø125
ø160
ø100
ø90
ø80
ø90
ø80

10 12 90 12 12 110 12 15 110 15 12.5 100 12.5 16 128 16
90 10
Maker: Oki Electric Cable Corp.
9 – 154
High Speed Machining Wire (MEGACUT-type D Wire)

0
Specification : Wire diameter tolerance :−2 µm

Item Name
(mm) P-3R (3kg) P-5R (5kg) P-10 (10kg) P-15 (20kg)
ø0.2 MEGACUT20D 11.0 18.3 36.7 73.5
ø0.25 MEGACUT25D 7.0 11.7 23.4 46.8
ø0.3 MEGACUT30D 4.9 8.1 16.2 32.4
ø25
ø20
ø20
ø34
ø130
ø200
ø160
ø250
ø110
ø80
ø90
ø90
10 90 10 12 90 12 12 110 12 15 110 15
Maker : BERKENHOFF GmbH

Importer : Oberon Co., Ltd.
High Speed Machining Wire (HIS Wire)


Item Name
(mm) P-3R (3kg) P-5R (5kg) P-15 (20kg)
ø0.2 HIS20 11.4 19.0 76.0
ø0.25 HIS25 7.2 12.0 48.8
ø0.3 HIS30 5.1 8.4 34.0
ø20
ø20
ø34
ø130
ø160
ø110
ø250
ø80
ø90
10 90 10 12 90 12 15 110 15
Maker : Hitachi Densen Co., Ltd.
9 – 155
High Speed Machining Wire (MOSWIRE)

0
Specification : Wire diameter tolerance : −2 µm

Item Name
(mm) P-5R (5kg) P-10 (10kg) P-15 (20kg) K160 (6.0kg)
ø0.2 OS-20S 19.1 38.2 76.4 22.9
ø0.25 OS-25S 12.2 24.4 48.8 14.7
ø0.3 OS-30S 8.5 17.0 34.0 10.2
ø20
ø20
ø34
ø22
ø160
ø200
ø250
ø110
ø160
ø100
ø90
ø90
12 90 12 12 110 12 15 110 15 16 128 16
Maker : Oki Electric Cable Corp.

BERKENHOFF GmbH
High Speed Machining Wire (HIR Wire)


Item Name
(mm) P-3R (3kg) P-5R (5kg) P-15 (20kg)
ø0.2 HIR20 11.4 19.0 76.0
ø0.25 HIR25 7.2 12.0 48.8
ø0.3 HIR30 5.1 8.4 34.0
ø20
ø20
ø34
ø130
ø160
ø250
ø110
ø80
ø90
10 90 10 12 90 12 15 110 15
Maker : Hitachi Densen Co., Ltd.
9 – 156
High Speed Machining Wire (SZS Wire)

Specification : Wire diameter tolerance : 0 µm
−2

Item Name
(mm) P-3 (3kg) P-5 (5kg) P-10 (10kg) P-20 (20kg) DIN160 (8kg)
ø0.2 SZS-20H 11.5 19.1 38.0 76.0 30.6
ø0.25 SZS-25H 7.3 12.2 24.4 48.8 19.6
ø0.3 SZS-30H 5.1 8.5 17.0 34.0 13.6
Packing (bobbin/box) 6 4 2 1 2
ø20
ø34
ø20
ø25
ø22
ø130
ø250
ø160
ø200
ø160
ø110
ø100
ø80
ø90
ø90
10 90 10 12 90 12 12 110 12 15 110 15 16 128 16
Maker : Sumiden Fine Conductors
High Speed Machining Wire (MOS4000 Wire)
Specification : Tensile strength : 730N/mm2 or more

Item Name
(mm) P-5R (5kg) P-10 (10kg) P-15 (20kg) P-160 (6.0kg)
ø0.2 OS-20S 19.1 38.2 76.4 22.9
ø0.25 OS-25S 12.2 24.4 48.8 14.7
ø0.3 OS-30S 8.5 17.0 34.0 10.2
ø22
ø20
ø25
ø34
ø160
ø100
ø160
ø250
ø200
ø110
ø90
ø90

12 90 12 12 110 12 15 110 15 16 128 16
Maker: Oki Electric Cable Corp.

BERKENHOFF GmbH
9 – 157

Wedm - c09 Maint Alarms List

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CHAPTER 9 MAINTENANCE AND ALARM LIST

9-1 Maintenance and Inspection Items

9-2 Maintenance and Inspection Method

9-3 Maintenance and Inspection of Dielectric Fluid Reservoir

9-4 Maintenance and Inspection of the Dielectric Fluid

Temperature Control Unit

9-5 Automatic Threader (AT Unit) Maintenance and Inspection

9-6 Maintenance of the Wire Guide Block

9-7 Updating the System

9-8 List of Alarms

9-9 List of Consumables

9-10 Reference Information on Wire Electrodes

I. Precautions for Maintenance and Inspection ...................................................................................... I

9-1 Maintenance and Inspection Items ....................................................................................................... 9-1

9-2 Maintenance and Inspection Method.................................................................................................... 9-2

9-3 Maintenance and Inspection of Dielectric Fluid Reservoir................................................................. 9-19

9-6 Maintenance of the Wire Guide Block .................................................................................................. 9-86

9-7 Updating the System .............................................................................................................................. 9-93

9-8 List of Alarms .......................................................................................................................................... 9-100

9-9 List of Consumables............................................................................................................................... 9-146

9-10 Reference Information on Wire Electrodes ........................................................................................ 9-150

1) Maintenance and inspection methods

2) Limits to maintenance and inspection workers

3) Scope of maintenance and inspection

6) Precautions for cleaning

II. Measures for Faults and Abnormalities

1) Prohibition of use during Faults and Abnormalities

2) Measures for faults

III. Prohibition of Modifications

9-1 Maintenance and Inspection Items

9-2 Maintenance and Inspection Method

9-2-1 Daily Inspection and Before-Operation Inspection

(2) Inspection of lower ceramic plate (Insulation board)

Lower guide block Ceramic plate

Lower guide roller block

Fig. 2.1 Lower block

(3) Inspection of nozzles

Upper nozzle Lower nozzle

Fig. 2.2 Nozzle

Take care to chipping.

Upper nozzle Lower nozzle

(4) Confirmation of dielectric fluid

1) Dielectric fluid ON/OFF

The following effect can be achieved by changing the FB notch setting.

(5) Confirmation of dielectric fluid specific resistivity

1) Indication of specific resistivity error

z Water Purifier (Ion Exchange Resin)

(6) Cleaning of working tank

(7) Confirmation of machining position

Clamp metal Upper nozzle

(8) Inspection of wire collection section

2) Measures for abnormalities

Abnormal (Low flow rate) Normal

Fig. 2.4 Checking the lower collection flow rate

The recommended lubricants are as follows.

Automatic lubrication unit

Remove the oil pan box

(10) Inspection of filter regulator

1. Discharge the drainage before it reaches the baffle 14 .

Fig. 2.7 Filter regulator