Over time the focus shifted from sinker EDM to wire EDM and the sinker mode was never really touched by me for a long time now. Until lately. And of course it did not survive all the changes made for the wire mode.

The core issue is that sinker runs higher currents and also has a larger electrode surface. Even without actually sparking the conductivity of the water can draw high currents in the on time of the pulse. No matter of there is an ignition or not. And this gets worse the deeper the electrode sinks into the material.

The logic was not prepared for this situation and at some point the axis will just stop moving. And to make things worse the code did not adjust to the increasing current while getting deeper into the metal and this would require manual adjustments over time while cutting.

So pretty useless. I removed half of the sensor loop and switched to single discharge analytics now. A discharge that generates a spark has a very high peak current compared to discharges into the conductive water.

It was possible to distinguish sparks from no spark discharges and this gives much easier control over the process. Some confusing parameters are gone and there should be no need for manual adjustments while cutting. Even if the average empty discharge current increases the code is aware that those aren't sparks.

A new firmware should be available within a month.