DIAMOND WIRES TROUBLESHOOTING
Unilateral wear of the wire
| CAUSE | REMEDY |
| Not pretwisted enough | Twist at least once anti-clockwise |
| Too much tension on the wire | Reduce down feed |
| Distance too short between driving pulley and material | Increase distance |
| Pulleys are inclined, the wire is stopped from rotating by flanks of the pulley | Correct alignment of pulleys with wire or guide line |
Wire breaks at the connection
| CAUSE | REMEDY |
| Too much tension on the wire | Reduce down feed |
| Edges too sharp | Break the edges and install deflection pulleys |
| Too much wear at the connection | Increase water supply |
| Wrap radius too tight | Install deflection pulleys |
| Wrong connection technique | Check press and pressing tool |
Wire breaks behind the connection
| CAUSE | REMEDY |
| Too much tension on the wire. | Reduce down feed. |
| Wrap radius too tight. | Install pulleys. |
| Edges too sharp. | Break the edges and install pulleys. |
| Wire connection too long. | Install crimp-type repair connection. |
| Too much vibration on the traction wire. | Check wire for constant diameter and reduce down feed. |
Wire vibrates strongly
| CAUSE | REMEDY |
| Tension of the wire too low. | Increase down feed. |
| Edges too sharp. | Break the edges. |
| Different diameters on the wire, wire connections too thick. | Check wire for constant diameter, check connections. |
| Not enough deflection pulleys. | Install more deflection pulleys. |
Cut is not straight
| CAUSE | REMEDY |
| Not enough deflection pulleys | Install more deflection pulleys with guide line and spirit-level. |
| Wire tension too low | Increase down feed or tension. |
| Deflection pulleys are not fixed or correctly aligned when replaced during cutting | Pay attention to precise alignment and fixing of the deflection pulleys when replacing. |
Wire beads are pushed together
| CAUSE | REMEDY |
| Not enough water, leading to heating up. | Supply more water or install more water nozzles with direction into the cut. Do not let water spray from bottom to top. |
| Sliding of the wire on the driving pulley, leading to heating up. | Increase wire tension. |
Cutting speed too low
| CAUSE | REMEDY |
| Wire tension too low | Increase down feed. |
| Wrapping sections in the material too long | Install more deflection pulleys. |
| Wire polishes. | Reduce water supply. |
| Number of revolutions too high. | Reduce number of revolutions. |
Wire polishes
| CAUSE | REMEDY |
| Too much water supply. | Reduce water supply. |
| Wire tension too low. | Increase down feed. |
| Number of revolutions too high. | Reduce number of revolutions. |
Excessive wear of the wire
| CAUSE | REMEDY |
| Not enough water supply. | Increase water supply or install more water nozzles in the cut. |
| Number of revolutions too low. | Increase number of revolutions. |
| Rotating or running direction of the wire mixed up. | Pay attention to the direction of rotation of the wire. |