Summary of Contents for Diamond Wire Technology CS400
- Page 1 INSTRUCTION MANUAL Millennium Series Capstan Saws Models CS400, CS410, CT400, CS810 and CT800 Diamond Wire Technology 1605 S. Murray Blvd. Colorado Springs, CO 80916 (719) 570-1150 (719) 570-1176 (FAX)
- Page 2 Thank you for your purchase of this wire Saw. This manual provides important information and instructions for the assembly, installation, adjustment, operation and maintenance of your new wire Saw. By carefully following these instructions, you are assured of obtaining the best results possible with this equipment.
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Page 3: Table Of Contents
CONTENTS Introduction ___________________________________________________________________________________ 1 Mechanical Setup_______________________________________________________________________________ 1 Shipping Considerations_______________________________________________________________________ 1 Electrical and Pneumatic Connections ___________________________________________________________ 2 Drain Connection ____________________________________________________________________________ 2 Spray System (Optional) ______________________________________________________________________ 2 Wire Inspection ______________________________________________________________________________ 3 Guide Pulley Spacing _________________________________________________________________________ 3 Mounting the Part Specimen ______________________________________________________________________ 4 Operator Interface ______________________________________________________________________________ 5 Power On _____________________________________________________________________________________ 6 Manual Mode __________________________________________________________________________________ 6... -
Page 4: Introduction
Introduction The Diamond Wire Technology Millennium Capstan Saws are designed to make a series of programmed cuts in a variety of materials. Slicing saws are designed to allow you to make up to 100 cuts (50 cuts with the Dicing Option) from a single program. Furthermore, each cut can be programmed to a different width if desired. -
Page 5: Electrical And Pneumatic Connections
Electrical and Pneumatic Connections The Saw requires 115 volt 50/60 Hz, single-phase power. Plug the controller power cord into a 15 Amp grounded outlet. Connect the saw to a source of dry, lubricated air delivering at least 80psi. Connect the STEPPERS, SENSORS, and CAPSTAN cables to their corresponding connectors on the right side of the saw. -
Page 6: Wire Inspection
Item 3 - 1/4” line from factory air supply. Item 4 – 3/8” tubing for coolant return to pump suction side Item 5 - 1/4” tubing connecting supply air to pump. Once the coolant pump pallet has been connected to the saw ensure that the WIRE/RUN switch is toggled to the WIRE position. -
Page 7: Mounting The Part Specimen
pulleys. Begin with the saw in an un-wired condition. Loosen the four 5/32” cap screws on each pulley arm and move equally so that they both remain equidistant from the center. Tighten all eight screws snug but not excessively. Observe carefully, and jog the yoke if necessary to ensure that the pulleys and the bow sensor will clear the specimen and fixture during a complete cut program. -
Page 8: Operator Interface
Securely attach the part specimen to the table substrate using whatever method is appropriate for the material. Operator Interface This section describes the controller’s user interface, including each of the input switches and the LCD display. POWER rocker switch – Provides AC power to the controller and the saw. -
Page 9: Power On
Right Arrow – Accept the choice or value currently displayed and proceed to the next screen. The up and down arrow keys have three modes of operation: single step, slow repeat, and fast repeat. This behavior is in effect for jogging motion and data entry, allowing both precise and efficient control/input. -
Page 10: Jogging The Actuators
Startup Screen – Manual Mode Manual operation of the wire drive: Turn the wire Speed control on the front of the control box to the "0" setting. If the wire Speed control is set at a setting other than "0", operation of the wire drive will commence immediately once the RESET Button is pressed. - Page 11 Press the up arrow to move the yoke upward, and press the down arrow to move the yoke downward. Note the position value moves in the opposite direction. This is because downward yoke movement is considered positive since this is the direction of cut. A quick tap on either the up or down arrow key results in a single step.
- Page 12 Press the up arrow to rotate the table in the positive direction, CCW. Press the down arrow to rotate the table in the negative direction, CW. Note that while the table rotates CCW, the cutting wire “rotates” CW relative to the table surface. Therefore, when programming an automatic cut sequence, think of the cutting wire moving relative to the specimen.
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Page 13: Common Setup Actions
knurled knob. You can rotate the lead screws manually if you wish, but be aware that such a change in position is not reflected on the display. Common Setup Actions Two additional operations are accessed from the Select Action menu. Use the up and down arrows to select either and then press the right arrow key. - Page 14 diameter of the cutting wire, and the value is added to the slice thickness each time the table is indexed into position for the next cut. Note that this addition is calculated and indexed automatically. As a result, you specify the finished thickness of each cut and the kerf loss is accounted for with this parameter.
- Page 15 the next cut sequence. By default, this value is calculated to return the table to the same position it was at the start of the previous cut sequence. This assumes you will be making symmetrical cuts for each rotational cut sequence. You may enter a different value if your application requires it. Programming Tip: Even though the saw utilizes anti-backlash nuts, there is still the possibility of some backlash in the table index stage.
- Page 16 The following steps 8 & 9 are for Model CT400 and CT800 saws only 8. Use the up and down arrow keys to specify the rock angle. Select 0 if you do not wish to have any rock action. 9. Use the up and down arrow keys to specify rock speed. You have three choices: slow, medium and fast.
- Page 17 11. Use the up and down arrow keys to specify the desired wire bow. Allowed values range from 0.1 to 5.0 degrees. This is the angle made by the cutting wire, the right guide pulley, and the horizontal. The angle is directly proportional to cutting force. The optimum angle varies depending on the material to be cut and is usually determined through experience.
- Page 18 14. Use the up and down arrow keys to specify a new downward velocity of the yoke while cutting. 15. Use the up and down arrow keys to specify a percentage of the total cut depth at which the indicated velocity is in effect. If the starting percentage plus the percentage specified here equals 100%, then the cut is performed with the two specified velocities and prompting skips to Step 17.
- Page 19 19. This question is asked if any program parameters have changed. Answer “yes” if you want the operating parameters just specified to be stored in non-volatile EEPROM memory so that they are “remembered” even if power is turned off. Answer “no” if you want to perform a cut program using the parameters you just specified without overwriting those stored in EEPROM.
- Page 20 23. As the display indicates, press the RESET button to begin the cut program. The RESET button illuminates and the wire drive is operational. You can adjust the speed of the wire drive at any time. The AUX output is active if you have employed it. While cutting is in progress, the display indicates progress as follows: Every 15 seconds, the display automatically changes to one of the three following informational screens:...
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Page 21: Wiring The Saw
To stop a program currently in progress, press the left arrow key. Wiring the Saw When the wire wears out or breaks after many hours of use, it must be replaced. One possible exception is if the wire breaks off at either retaining hole. In this case you can loosen the thumbscrew, discard the small broken piece of wire, and thread the free end back through the retaining hole after pulling a small amount of slack from the capstan. -
Page 22: Removing A Broken Wire
from jumping off the pulleys. 5. Loosen the thumbscrew and gently pull the end of the wire from the retaining hole. 6. Using a hand-over-hand action, simply pull the wire from the capstan. Do not allow the wire to rake over any fixed surface, pulley shaft, or sensor that could be damaged from wire abrasion. 7. - Page 23 capstan to its home position at the front. 4. Press the RESET again to send the capstan to its rear position. This is the initial wiring position. 5. Verify that the capstan stopped in the proper position. Use the capstan alignment gage to set the capstan in the proper position. Lay the capstan gage flat on the face of the yoke plate;...
- Page 24 mark should be visible along the edge of the forward capstan guard. 10. Slip the wire end through the retaining hole from behind. It should come through the outside flange of the capstan near the thumbscrew. 11. Loosen the thumbscrew and wind the wire back around its shaft one-half a turn.
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Page 25: Adjustment And Maintenance
turn so that the wire is tangent to the capstan circumference and takes off directly toward the upper pulley. This removes as much slack as possible from the completed wiring. 24. Tighten the thumbscrew, securing the wire. 25. Turn down the air regulator to 2 or 3 psi and switch the Tensioner RUN/WIRE switch to RUN, then increase pressure just until the wire becomes taut. -
Page 26: Bow Sensor Calibration
The sensor is adjusted and calibrated at the factory, but could require adjustment and/or calibration if the sensor bracket is bent or moved, or pulley wear/replacement changes its relative position to the wire. At no time should the cutting wire be in direct contact with the sensor face. -
Page 27: Wire Tensioner
Use the up and down arrow keys to specify the cutting gap, or distance between the inside edges of the two guide pulleys. When ready, press the right arrow key to proceed. At this screen you are being asked to confirm that the wire is straight between the guide pulleys. This is also the opportunity for final preparations before motion and calibration begins in the next step. - Page 28 Table 2 – Tensioner Air Pressures Table 2 – Tensioner Air Pressures Wire Tensioner Air Pressure Wire Tension Wire Tension Diameter (lbs) 0.006” 0.150mm 10 psi 69 Kpa 2.1 lb 9.4 N 0.008” 0.200mm 15 psi 103 Kpa 3.1 lb 13.8 N 0.010”...
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Page 29: Preventative Maintenance
To replace a pulley: 1. Remove the jam nut using a 9/16” socket or wrench. 2. Use a two-legged wheel puller to pull the old pulley/bearing assembly forward and off the shaft. 3. Clean the shaft and check that it is smooth. If it has any significant scratches, carefully work them out with an abrasive pad or emery cloth. - Page 30 Apply a small amount Mobil Vactra #2 way lube (or equivalent) onto the pins of the 2- pin driver. - SPEC Reassemble in reverse. From the rear of the saw apply a small amount Mobil Vactra #2 way lube (or equivalent) to the edges of the linear rail to ensure smooth operation.
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