G8TER,
Have you contacted Makino Technical Support at 1-888-625-4664 about your Wire Break issues?
It sounds like you have addressed and inspected all the usual mechanical component suspects, but have you tried the following?
Have you tried a different Spool of wire to see if your Wire Break issues continue?
While it is rare, a bad spool of wire does occur every now and again. As BajaFire noted, some wire spool issues occur as a result of a wire manufacturing process issue (bad annealing, extremely dirty, etc.), and it is common to see both wire break and wire threading issues with a bad spool. I have also seen bad spools of wire where the wire itself is contaminated, damaged, or heavily oxidized (this could be from the wire not being covered properly during transit or storage, or from being someone's Old-Stock). I have also seen issues with physical damage to a Wire Spool as a result from shipping to where the outer flanges are tweaked and compressing the wire on the spool. Another "I can't believe I missed that" thing to check is to ensure that the Wire Spool Nut is properly tightened and holding the spool in place (for obvious reasons)! And this brings me to my last suggestion that is Wire Spool related...have you checked the wire spool to see if the wire isn't wrapped underneath itself on the spool? This situation can be difficult to spot, but if the wire is somehow wrapped underneath itself, it will create extra drag and tension that will result in Wire Breaks (I share in the frustration of all Operators that have experienced this!).
What Wire Type and Spool size are you using? Hoping that you machine has the longer/wider Rollers that are included with the 16kg/35# Spool Option, as these spools are longer in length than the P5 (11lbs.) and P10 (22 lbs.) spools.
D-Shaft Tension Roller:
It appears that you have cleaned and inspected the main brake D-Shaft Roller and eliminated it as being a source issue (wire is not slipping on this roller). Have you checked and confirmed the Wire Tensions? If the Wire Tension is too high or too low, it can result in Wire Breaks.
DI-System:
Have you confirmed that your water conductivity level is within the proper range (15um/cm)? If the water Conductivity level is out of wack, your machining will be VERY unstable with many Wire Breaks, and the water will begin to pick up a "fishy" smell. There is a function on the OTHERS page that tells the machine to ignore the current Water Conductivity Level. This function [W Cond Skip], which means Water Conductivity Skip, is intended to bypass the Conductivity Alarm and allow you to override the machine so that you can complete whatever job is running on the machine when the "Replace DI-Resin" Alarm occurs. I have seen where Operators forget to turn this function OFF, which would allow the Water Conductivity to get out of balance to where it should be.
- Brian
