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I have a Mitsubishi wire edm ( FA 20s advance control ) having issues with the ceramic piece in the lower guide D, clogging up with what appears to be shavings from the brass wire, not allowing threading. I use the same wire on two FA 10 wire edm's with no trouble. Any suggestions on what would cause this ?
change your flushing settings. or check you have enough pressure to push the chips out.
Have you checked your carbides to make sure that they are not "shaving" your wire? If you change wire diameter from a larger to a smaller diameter it could also be scraping off small pieces of brass, or you could have a deep groove possibly?
Check whether there is any flaws on the Electrode Pin (Power Feed Contact), also if you been cutting large tapers, make sure you not exceeding recommended taper angle for your lower wire guides and inspect for any damage especially for tiny rust particles that jam up and bond to the diamond guides.