EDM and WEDM machine retrofits

Older sinker and wire EDM machines usually have solid mechanics but outdated controls, worn drives and limited programming options. Retrofitting an EDM or WEDM machine keeps it productive for years – with new functions and better machining performance – for a fraction of the price of a new machine.

We design and build EDM machines, generators, CNC controllers and their software ourselves. That is why we retrofit machines made by ZAP B.P. and machines of our own design, using components we know inside out.

Retrofit scope

EDM machine control upgrade (to the PP15ster PLC controller)

The PP15ster controller replaces the existing control system of a sinker EDM machine and greatly extends its functionality. It runs part programs based on G and M codes, which makes it possible to:

machine along any straight line in the work space, along any straight line with electrode rotation (A axis), along any arc in the XY plane (especially useful for EDM threading), and in a helical motion along the Z axis,
switch additional functions on and off by the program during machining: electrode vibration, circular orbiting and square orbiting (Z axis only),
select one of ten work coordinate systems by the program,
declare machining of n cavities in a given direction (with or without electrode wear compensation).

Further advantages of the controller:

simple and intuitive user interface,
part program storage on a microSD card,
communication with a PC via USB Device or WiFi – part program transfer and full control of all controller processes with AT commands.

PP23ster EDM generator

The PP23ster generator is a complete control module for EDM machines made by ZAP B.P. and of our own design. Besides the PP15ster controller it contains a new power block that increases machining efficiency and reduces electrode wear. It also adds functions such as changing machining parameters by the program during the process.

Ball screws and AC servo drives

We replace lead screws with ball screws – optionally together with an upgrade to AC servo drives. The result: less backlash, smoother axis motion and better positioning repeatability.

How a retrofit works

Contact and machine description – model, year, photos and the problems you want to solve,
Assessment – we decide which components are worth replacing and which only need adjustment or repair,
Quotation – scope, cost and lead time,
Installation and commissioning – fitting the new components and machining tests,
Operator training – on the new control (see EDM and WEDM operator training).

After the retrofit, the machine is still looked after by our EDM/WEDM machine service, and spare parts are available in our catalogue.

Frequently asked questions

Is it worth retrofitting an old EDM machine?

If the mechanics (frame, guideways, table) are in good condition, upgrading the control, generator and drives is usually much cheaper than buying a new EDM machine, while giving comparable programming and machining capabilities.

Which machines do you retrofit?

Mainly EDM machines made by ZAP B.P. and of our own design. For other sinker and wire EDM machines, contact us and we will check whether a retrofit is possible.

Can I buy a used machine that has already been retrofitted?

Yes – see the used EDM and WEDM machines category or ask about the current offer.

Tell us about your machine

Describe the machine (manufacturer, model, year) and what you want to achieve. We will tell you what can be done and what it will cost.

Call us: +48 507 493 844 Write to us