Operating Manual for EDM Machine and Paper Filtration Unit

eNova OS/ 1S/ 2S
WIRE ELECTRIC DISCHARGE MACHINE
Operating & Maintenance Manual

for
A. Machine Tool
&
B. Paper Filtration Unit
HEAD OFFICE: FACTORY :
Poddar HMP Group. Electronica india limited.

4, Fairlie Place, 608/609,1 Saswad Road,
Kolkata – 700 001, India Taluka Purandar,
Tel: +91 33 2231 0268 Pune 412 301, India
Fax : +91 33 2243 6966 Tel. : +91 2115 305 800
www.electronicagroup.com
Electronica india limited., PUNE
WARRANTY CERTIFICATE
eNova OS/ 1S/ 2S
Date :
This warranty certificate is issued for machine tools_____________________ with its
Power supply unit Sr.No_______________________________supplied to
M/s.____________________________________________________________ for the
period of 12 months from the date of installation but not exceeding 15 months from the
date of shipment, against workmanship manufacturing defects, components and parts
only. Manufacturer / Supplier shall not be responsible for any defects, injuries to personnel
arising out of mishandling of the equipment following of procedure not prescribed in our
manual or negligence from the operating staff.
Date of Installation:
Warranty ends on:
Electronica india limited. Agent Customer (seal)

(This portion to be detached and sent back to supplier within 10 days from the date of
installation.)
WARRANTY CERTIFICATE
Date:
To,
Electronica india limited.
609, 610 A,
Pune-Pandharpur Road,
A/p Saswad Tal Purandhar Dist Pune – 412 301,
INDIA
eNova OS/ 1S / 2S SR. NO.
Date of Installation :
Warranty ends on :
Electronica india limited. Agent Customer (seal)

WARRANTY
IS VOID IF
RECOMMENDED
SPARES/
CONSUMMABLES
ARE NOT USED.
Electronica india limited

ATTENTION!
THE STANDARD ELEMENTS USED IN THIS MACHINE LIKE SEAL,
PUMP, KEYBOARD, MOUSE, MACHINE LAMP ARE OF REPUTED
MAKE. THESE ELEMENTS OFTEN GETS DAMAGED DUE TO
IMPROPER USAGE & POOR MAINTENANCE.
THE WARRANTY FOR SUCH ELEMENTS IS VOID IF THE DAMAGE IS
DUE TO IMPROPER MAINTENANCE.
Electronica india limited .

Table of Content
1 Introduction of Machine Tool ...................................................................................................1

2 Preparation, Transportation and Installation of the System .................................................2
2.1 Preparation for Installation................................................................................................................................... 2
2.2 Place of Installation.............................................................................................................................................. 2
2.3 Environmental Conditions ................................................................................................................................... 3
2.4 Installation of Machine Tool................................................................................................................................ 4
2.5 Leveling Procedure .............................................................................................................................................. 4
2.6 Safety Precautions................................................................................................................................................ 5
3 Instructions for Operator Regarding Mechanical Components. ...........................................6
3.1 Specifications of Machine Tool: .......................................................................................................................... 6
3.1.1 Travel Range............................................................................................................................................. 6
3.1.2 Work-Piece Size ........................................................................................................................................ 6
3.1.3 Feeds......................................................................................................................................................... 6
3.1.4 Wire Guide................................................................................................................................................ 6
3.1.5 Taper Cutting............................................................................................................................................ 6
3.2 Machine Coordinate System, Origin and Referencing......................................................................................... 7
3.3 Cautions for Safety .............................................................................................................................................. 7
4 Maintenance of Machine Tool ...................................................................................................8
5 Instructions for Operator Regarding Setting Up & Operation of the Machine.................10
5.1 Working Layout ................................................................................................................................................. 10
5.2 Work-piece mounting ........................................................................................................................................ 10
5.3 Setting Up and Operation................................................................................................................................... 10
5.4 Interconnections................................................................................................................................................. 11
5.5 Preparation for Machining ................................................................................................................................. 11
5.6 Flushing at Low & High Flushing ..................................................................................................................... 12
5.7 Dielectric fluid flushing parameters................................................................................................................... 12
5.8 Conductivity Correction..................................................................................................................................... 12
6 Information on Wire Drive System with Automatic Wire Threading. ...............................13
6.1 Wire Driving System ......................................................................................................................................... 13
6.2 Wire Guide, Upper Part ..................................................................................................................................... 14
6.3 Wire guide lower part ........................................................................................................................................ 15
6.4 Wire feeding system, lower part ........................................................................................................................ 16
6.5 Drive part (wire feeding part) ............................................................................................................................ 18
6.6 Automatic wire threading part. .......................................................................................................................... 18
6.7 Maintenance & Checking Items for Wire Drive System ................................................................................... 19
6.8 Trouble shooting ................................................................................................................................................ 20
6.9 Items to Check Weekly. ..................................................................................................................................... 21
7 Paper Filtration System ...........................................................................................................43
7.1 Specifications of Dielectric Unit........................................................................................................................ 43
7.2 Features:............................................................................................................................................................. 43
7.3 Packing & Unpacking ........................................................................................................................................ 43
8 Installation of P.F. Unit............................................................................................................44
8.1 Installation of eNova OS,1S & 2S PF Unit........................................................................................................ 44
8.2 Procedure for Filling Water ............................................................................................................................... 44
9 Operation of P.F. Unit Major Parts........................................................................................45
9.1 Major parts of P.F. Unit ..................................................................................................................................... 45
9.2 Functioning of P.F. Parts ................................................................................................................................... 45
10 Instructions for Operation & Maintenance ...........................................................................46
10.1 Filtration Cycle:............................................................................................................................................ 46
10.2 Filter Start-Up Water Volume: -................................................................................................................... 46
10.3 Conductivity Controls & Deionizer Pump: - ................................................................................................ 46
10.4 Chiller Functioning For Clean Water Temperature Control: - ..................................................................... 46
10.5 Do’s and Don’ts: - ........................................................................................................................................ 46
11 Maintenance of P.F. Unit .........................................................................................................47
11.1 Table indicating periodic maintenance: - ..................................................................................................... 47
11.2 Maintenance Tips ......................................................................................................................................... 47
Electronica india limited eNova OS, 1S &2S Machine & P.F. Unit Operating Manual Page i
List of Figures
Figure 1 Machine Tool Slinging Diagram for eNova OS and 1S........................................................22

Figure 2 Machine Tool Slinging Diagram for eNova 2S.....................................................................23
Figure 3 Transport Lock for Main Table for eNova OS & 1S.............................................................24
Figure 4 Transport Lock for Main Table for eNova 2S.......................................................................25
Figure 5 Transport Lock for U,V and Z Axis for eNova OS,1S and 2S..............................................26
Figure 6 Floor Plan eNova OS.............................................................................................................27
Figure 7 Floor Plan eNova 1S..............................................................................................................28
Figure 8 Floor Plan eNova 2S..............................................................................................................29
Figure 9 Foundation Details for eNova OS & 1S ................................................................................30
Figure 10 Foundation Details for eNova 2S ........................................................................................31
Figure 11 Upper Flushing Assembly (SAWT) ....................................................................................32
Figure 12 Upper Flushing Assembly (AWT) ......................................................................................32
Figure 13 Lower Flushing Assembly...................................................................................................33
Figure 14 Wire Drive System (SAWT) ...............................................................................................34
Figure 15 Wire Path (SAWT) ..............................................................................................................34
Figure 16 Wire Drive System (AWT) .................................................................................................35
Figure 17 Wire Path (AWT) ................................................................................................................35
Figure 18 Wire Guidance System (SAWT) .........................................................................................36
Figure 19 Wire Guidance System (AWT) ...........................................................................................37
Figure 20 AWT Assembly ...................................................................................................................38
Figure 21 Work Tank for eNova..........................................................................................................39
Figure 22 Seal Assembly for eNova ....................................................................................................40
Figure 23 Work-Table with Maximum size (L x W) job mounted......................................................41
Figure 24 Work-Table with Round job mounted.................................................................................41
Figure 25 Work-Table with Movable Bridge Mounted.......................................................................42
Figure 26 Work-Table with Job mounted on Movable Bridge............................................................42
Figure 27 P.F. Assembly for eNova OS ..............................................................................................48
Figure 28 P.F. Assembly for eNova 1S ...............................................................................................49
Figure 29 P.F. Assembly for eNova 2S ...............................................................................................50
Figure 30 Normal Cycles of Filtration System ....................................................................................51
Electronica india limited eNova OS, 1S &2S Machine & P.F. Unit Operating Manual Page ii
1 Introduction of Machine Tool
The ELEKTRA Wire cut electrical discharge machine comprises of Machine Tool, a power supply
unit, a Dielectric unit and a chiller unit.
The machine tool unit comprises of a main worktable (fixed type) on which the work-piece is
clamped, a moving column on X & Y axes, wire drive mechanism and auxiliary axes U & V, and
vertical axis Z are mounted on the moving column. The X and Y axes are moved in steps of 0.5
micron by means of AC servo motor. The U & V axes are parallel to X & Y axes respectively.
The traveling wire which is continuously fed from wire feed spool which moves through the work-
piece and is supported under tension between a pair of wire guides which are located at the
opposite sides of the work-piece. The lower wire guide is stationary whereas the upper wire guide
which is supported by the U-V table can be displaced transversely, along U and V axes, with
respect to the lower wire guide. The upper wire guide can also be positioned along Z axis by
moving the quill. A series of electrical pulses generated by the pulse generator unit are applied
between the work-piece and the traveling wire electrode, to cause the erosion of the work-piece
material. As the material removal or machining proceeds, the worktable carrying the work-piece is
displaced transversely by the X-Y controller and the driver along a predetermined path
programmed in the controller. The path specifications can be supplied to the controller via a
program, which is stored on USB, control panel, or directly to the controller (MDI made) When the
X-Y table is moving along the predetermined path, if the U-V table is kept stationary, a straight cut
with a predetermined pattern is formed. In order to produce taper machining, the wire electrode has
to be tilted. This is achieved by displacing the upper wire guide (along U-V axes) with respect to the
lower wire guide.
The desired taper angle is achieved by simultaneous control of the movement of X-Y axes and U-V
axes with their respective predetermined paths stored in the controller. The path information of X-Y
table and U-V table is supplied to the controller in terms of linear and circular elements via storage
media. While the machining is continued, the machine zone is continuously flushed with water
passing through the nozzles on the both sides of the work-piece. Since water is used as a dielectric
medium, it is very important that water does not ionize. Therefore to prevent the ionization of water
an ion exchange resin is used in the dielectric distribution system to maintain the conductivity of the
water constant.
The geometry of the profile and the motion of the wire electrode tool along the profile is fed to
through keyboard, in terms of various definitions of points, lines and circles as the tool path
element, in a totally menu driven, conversational mode. The wire compensation (for wire diameter
and machining over-cut) and taper angle can be specified for the total path or for each element
separately. After the profile is fed to ELCAM, all the numerical information about the path is
calculated automatically. The entered profile definition, the profile is recorded by the computer on
USB, which is then removed and put in the controller for execution of the program.
Electronica india limited eNova OS, 1S &2S Machine & P.F. Unit Operating Manual Page 1
2 Preparation, Transportation and Installation of the
System
ELEKTRA CNC WIRECUT EDM is supplied in 5 cases.

Case No. 1 – contains Machine tool
Case No. 2 – contains Power supply unit.
Case No. 3 – contains Dielectric unit, Dielectric cooling unit,
Case No. 4 – contains Dielectric cooling unit,
Case No. 5 – Loose components, accessories, spares etc.
Unload the cases carefully without tilting them. The slinging marks are given on the cases. Use
them while putting the ropes around the cases. The cases should be taken to their place of
installation on pallet trucks or forklift trucks. Care should be taken not to tilt the cases while they are
being shifted. Avoid any jerks during shifting. The capacity of the pallet trucks should be more than
2.5 tons. After opening the case, lift machine tool from the platform by using ropes. Do not allow
ropes to touch the machine anywhere while lifting. Lift the power supply unit, dielectric unit with the
help of ropes as shown in their respective manual. Open the boxes of loose items and Dielectric
cooling system and check the contents as per the packing slip inside the boxes. Check up all units
for apparent damage. If any damage is found inform Electronica india limited. - Pune, immediately. If
damages are heavy please arrange for necessary insurance formalities. It is advised to take the
photographs of the machine to have the record of damages.
2.1 Preparation for Installation
Do not transport the machine on open pipes, as this will cause heavy jerks to the machine. It should
be transported by using pallet or forklift trucks. It is recommended to lift the machine without jerks. If
the installed machine tool is to be transferred from one place to another CLAMP THE MAIN TABLE
BEFORE TRANSPORT.
2.2 Place of Installation
• The machine should be placed at a place free from dust and heat. The place should be kept
clean. The area allocated should be sufficiently large to accommodate the following items.
¾ Machine Tool with
¾ Power Supply Unit.
¾ Dielectric Unit.
¾ Dielectric Cooling Unit
• The machine must not be installed close to m/c tools that transmit vibrations thru’ foundation. If
vibration cannot be avoided, machine must be mounted on vibration absorbing elements.
• Machine Tool, Power Supply Unit , Pump Filter Unit and Voltage Stabilizer should be arranged
as shown in floor plan. Figure 6
Provide:
• Storage space for work pieces.
• Storage space for electronic storage Media - closed space protected from heat and direct
sunlight.
• Storage space for job files, manuals, record forms etc.
• Tool kit for periodic maintenance.
• Space for movement of material and the operator.
• Phase electrical connection with neutral and separate earth.
2.3 Environmental Conditions
The surroundings of the machine should be kept absolutely clean.

Ensure following conditions:
A fairly constant input supply voltage. The variation should not be more than ±1%. Use a servo
controlled voltage stabilizer to achieve this condition.
Frequent cleaning of the surrounding area.
Daily cleaning of the machine especially the work table.
A good and well directed source of light. The worktable and all control panels should be sufficiently
illuminated.
A common earth point for the machine.
Avoid following situations:

Direct sunlight on machine tool, power supply unit and pump filter unit.
Dust or fumes in the surrounding area.
Rain water directly coming on the machine.
Wetting of floor when machining is in progress.
A common point of 3 phase power supply for eNova OS and other machines like welding sets,
heavy presses etc. which draw heavy current intermittently.
Heavy vibrations near the machine.
Foundation Details (Ref. Figure 9)

The machine should be kept on a rigid foundation. Foundations confirming to the standard machine
tool requirements should prove adequate. A flat hard concrete floor at least 200 mm thick is
recommended in the area where machine is to be installed. Do not use separate concrete blocks as
foundation under the leveling pads of the machine. If the place of installation does not have
industrial flooring and if there are many machines inducing vibrations, isolated foundation flooring is
recommended.
2.4 Installation of Machine Tool
1. Installation work of machine tool is an important factor which affects accuracy of the job done,
machine tool life and maintenance. So it should be done carefully and systematically.
2. Remove the transport locks (Ref. Figure 3 and Figure 5). The machine tool is to be placed on four
leveling pads. Install these leveling pads in their places before the machine is placed.
3. The level of the floor should be sufficiently horizontal as the range of adjustment of pads is
limited. Level the machine in both x & y directions with the help of precision level (sensitivity =
0.02 mm /1 m). Keep the level on Work table. See to it that the table is be at the center while
checking the level. The reading should be within half division.
4. After leveling the machine see to it that lock-nuts are tightened so that the level is not disturbed.
5. The machine tool, the power supply unit & the Pump filter unit should be located as per the floor
plan given. Leave a distance of 500 mm between unit & wall. This will prove useful at the time of
maintenance.
6. Make all the connections of the power supply unit with the machine tool. See whether all cables
are intact.
7. Fill distilled water in P.F. unit, put filters and resin and check the connections of all the 3 phase
motor & see that all interconnecting pipes are tightened properly.
8. Check the supply from the stabilizer. Check voltage between neutral & earth, it should be less
than 1 volt. Check direction of motor rotation & valve fitting.
9. Make wire verticality with the help of verticality block, before making wire vertical dial the block
within 2 microns w. r. t. Z axis.
10. Load some job and start sparking.
2.5 Leveling Procedure
Please note that the leveling should be done by keeping the spirit level on the ground surface
provided on the base and not by keeping the spirit level on the job stand, it may create
inaccuracy in the squareness of the X and Y axis.
1. When the m/c tool is being placed on the floor ensure that the gap between the floor and m/c
base is 130 to 135 mm, it must not be less than 130 mm. Gap can be adjusted by adjusting the
leveling bolts on the m/c tool base. The gap of 130 to 135 mm is to be maintained to avoid the
obstruction of drain pipe with the PF unit and proper alignment of wire collection box.
2. After the m/c tool is placed on the floor as per the floor plan in the E & C readiness check list,
clean all the ground surfaces provided on Work table.
3. There are 4 leveling bolts on m/c base.
4. Keep all the axes at the middle position of total stroke. Take the spirit level of accuracy
0.020/meter
5. Keep the spirit level on work table in X direction and adjust the level with the help leveling bolt.
6. Keep the spirit level on work table in Y direction and adjust the level with the help leveling bolt.
7. Repeat above procedure until machine level is adjusted within 1 division.
2.6 Safety Precautions
Machine tool moving axes are clamped to prevent its vibration during transport. Remove these
clamps before machine tool operation. This is most important.
1. Do not leave open the doors of the power supply unit, CNC controller and the machine tool
control panel during operation.
2. The power supply should be turned OFF if these doors are to be kept open.
3. Do not operate the EDM unit when the floor is wet.
3 Instructions for Operator Regarding Mechanical
Components.
3.1 Specifications of Machine Tool:
Travel Range Axis eNoVA OS eNoVA 1S eNoVA 1S
X 320 mm 400 mm 600 mm

Longitudinal
U 100 mm 100 mm 120 mm
Y 220 mm 300 mm 400 mm

Lateral
V 100 mm 100 mm 120 mm
Vertical Z 260 mm 310 mm 360 mm
Work-Piece Size eNoVA OS eNoVA 1S eNoVA 2S
Max. Work-Piece Size 700 x 500 x 200 800 x 600 x 300 900 x 575 x 350
Max. Work Piece Wt. 300 Kg. 800 Kg. 1000 Kg.
3.1.3 Feeds eNoVA OS eNoVA 1S eNoVA 2S
Main Table X,Y Feed Rate 1000 mm/ min
Auxiliary U, V Feed Rate 600 mm/min
Z Feed Rate 600 mm/min
Resolution 0.0005 mm
Wire Feed Rate 0 - 15 m / min
Wire Tension 0 - 2.5 kgf
3.1.4 Wire Guide eNoVA OS eNoVA 1S eNoVA 1S
Wire Guide Type Diamond closed

0.25 STD
Wire Electrode Diameter
0.1, 0.15, 0.2, 0.3 OPT
3.1.5 Taper Cutting eNoVA OS eNoVA 1S eNoVA 1S
Without Awt ± 300/ 50 mm
With Awt ± 20/ 100 mm
3.2 Machine Coordinate System, Origin and Referencing
The coordinate systems are classified into the machine coordinate system and the work coordinate
system. The machine coordinate system is intrinsic to the machine and cannot be set arbitrarily,
while the work coordination system can be set arbitrarily.
Machine coordinate system, machine origin and reference point.
Each machine origin of X, Y, U and V axes is at negative end of the stroke of each axis.
Machine origin of Z is at positive limit.
The NC unit uses the machine coordinate system to control the machining start
Position, pitch error compensation, wire verticality etc.
3.3 Cautions for Safety
To protect the operator and the machine from hazards, observed the following items.
1. Confirm the position of the EMERGENCY STOP button before turning the power on.
2. Fully illuminate on and around the machine, and keep the surrounding in good order.
3. Keep closed the cover and the doors of the generator and dielectric fluid supply unit.
4. Never relocate or bypass the stroke limit, interlock limit switches etc.
5. Keep away from rotating rollers.
6. When coming close to the machine during machining, keep away from the wire roller, upper and
lower flushing assemblies which bear high voltage.
7. When loading / unloading the work piece avoids interference with the lower flushing nozzle to
avoid damage to the lower diamond guide and flushing assembly.
8. Make sure that the work-piece and the bridges do not interfere with the upper and lower flushing
nozzle.
9. Make sure that E-W bunch do not entangle during movement of table.
10. Do not keep work-piece, tools or any other material on the table or U/V covers which could
obstruct during movement.
11. Before moving the table (i.e. X, Y, U, V and Z axis), make sure that there is no obstruction in the
travel range before actual machining of the job.
12. Designate an operator solely responsible for machine operation.
13. Maintenance and repair must be done by authorized personnel. Make sufficient preparation
before working on the machine.
14. Do not operate the machine with protective covers removed.
15. Carryout procedure maintenance of filtration system.
4 Maintenance of Machine Tool
Table to indicate periodic maintenance.

Activity Daily Weekl Month Quart
y ly erly
1. Check for debris in the wire guides & clean with the help of
acetone & soft cloth. ¨
2. Cleaning of Work-tank & all the areas where particles ¨
accumulate.
3. Check that the lower flushing nozzle is not fouling against ¨
work table and work-piece.
4. Check the air pressure on Air Filter unit ¨
5. Check for the gap between lower nozzle & work-piece. The
gap should be maintained 0.2 mm. The gap can be
adjusted by rotating the nozzle mount until the gap is ¨
maintained & then lock it with the screw.
6. Cleaning of Wire Drive Assembly which includes Idler, feed

& pressure rollers to keep them free from dust & water. ¨
7. Worktable height is the distance between the table top &
diamond center of lower wire guide. This distance can be
checked with help of slip gauges. Guide span is the
distance between the diamond centers of both upper &
lower wire guides with Z axis position at zero. This distance
¨
can also be checked by slip gauges.
8. Check for wire verticality ¨
9. Check for the groove on the current carbide pick up. If the
groove has touched the upper or lower edge replace the
current carbide pick up or changing the position could solve
the problem. ¨
10. Check for debris or groove in the pallet hole, if the hole is
clogged then remove and clean it. If it is not possible ¨
replace the pallet.
11. Check water level in the P.F unit. ¨
Activity Daily Weekl Month Quart-
y ly erly
12. Check for the groove on wire feed & wire tension rollers. If
in case groove is observed replace the rollers. ¨
13. Check flushing nozzles, if in case the nozzles are damaged
replace them. ¨
14. Clean the groove on all the idler rollers and check the
rollers rotate smoothly. ¨
15. Check for play in wire feed Motor belt tension. ¨
16. Check for the movement of the tank bellow by moving the
table in Y direction see that no obstruction is there. By
moving the table in X direction check for the obstruction
due to seal to wire guide arm. ¨
17. Check alignment of Upper and Lower flushing assembly
and align it within 0.03 mm. If assembly is aligned then also
check the work-table height and guide span.
¨
18. Check mounting nuts of the pump & brackets for tightness. ¨
19. Check the bearing in the lower idler roller. If bearing is
found faulty replace the same. ¨
20. Clean the E/W connections & check terminals for loose
connections. ¨
21. Check for the cleanliness of flow meters, if the dirt is
accumulated in the flow meters remove the top nut, pointer ¨
etc. and clean the flow meters with acetone or diluted
hydrochloric acid by passing cloth from top to bottom.
22. Lubrication of L.M. Guides of X, Y, U, V, Z axes. ¨
23. The squareness of the wire verticality block is to be
checked with the help of dial. The squareness is to be
maintained within 0.005 mm ¨
5 Instructions for Operator Regarding Setting Up &
Operation of the Machine
5.1 Working Layout
Figure shows the layout of the worktable on which the job is to be mounted in order to perform
accurate machining of the component For mounting the job at a position other than the work table,
make use of adjustable bridge. (Optional accessory).
The maximum job size which can be accommodated on the worktable is given in the specifications.
To mount the jobs of maximum size refer to the figure which depicts the way in which it is to be
done. The distance between the two jobs stands between which the nozzle of the lower flushing
assembly moves in X direction is shown in the figure. Fixed bridge when mounted on the job stands
lies outs the limits of the nozzle travel. The distance between the wire guide center and job stand
edge is 12.5 mm as shown in the figure.
The round job clamping can be done on the machine with the help of round job holders provided in
the optional accessories. To wire cut the job up to 25 mm in diameter smaller 'L' shaped profile is to
be used and for jobs up to 50 mm in diameter the larger ' L ' shaped profile is to be used. A
reference hole of 8 mm is provided on the round job holder for making the wire vertical.
5.2 Work-piece mounting
The worktable can handle the work-piece of maximum size as mentioned in the specifications.
Heavier work-piece may affect the accuracies and load the coordinate table. (Before mounting the
job, grease the mounting surface of the worktable). The job should be clamped firmly on the job
stands and bridges to ensure proper electrical contact.
5.3 Setting Up and Operation
Place the machine tool, dielectric unit, power supply unit and chiller as per the floor plan. Keep the
chiller unit inside the room in which machine tool is accommodated. The interconnections are to be
made as per the instructions mentioned in the manual of the power supply unit.
After power on: -
• Power on led on front panel glows.
• Machine will not start in absence of any phase or over voltage / under voltage condition.
• Display may show some reading, let it be anything.
• Wire feed and wire tension is in OFF condition.
• Gap voltage meter shows nil voltage.
• Gap current meter shows nil current.
• Conductivity of dielectric fluid is shown on its meter.
5.4 Interconnections
Ensure that all wires are in good condition. Every cable has its code number. See to it that the cable
with one code number is fitted to the connector having its respective code number. Make the
connections so that there should not be any play. Tighten all connectors properly. A voltage
stabilizer is must for this machine. Check output voltage of stabilizer, for specifications of stabilizer
given in E & C readiness format.
Check the following

• Dielectric pump operation.
• Select wire feed function to vary the speed of the traveling wire.
• Jogging in X, Y axes with FR1, FR2 & FR3 speed. Also in 1 micron, 10 microns, 100 microns &
1 mm steps.
5.5 Preparation for Machining
1. Selection of wire :-
Use brass wire specified by M/s. Electronica india limited, Pune, India. It must be free from any
twists, corrosion and kinks, any of these defects may lead to wire breakage or unstable
machining.
2. Wire threading :- (Semi-Automatic)
Wire threading is to be done as per the procedure given below -
a) Mount the wire reel on its shaft so as to unwind the wire in the direction as shown in the
figure. Tighten the nut firmly in a clockwise on to the reel.
b) Wound the wire over the rollers as shown and then thread the wire through the wire guides,
over the carbide current pick up and through the pallet of the flushing assemblies.
c) The wire should pass through the groove centers of the wire guides. Confirm that the wire is
positioned at the center of the dielectric fluid flushing port in order to the wire surrounding
completely by the water column.
d) The wire must remain in contact with the nylon roller at all times so that it is insulated from
the machine tool.
e) Does not touch the wire or any part of the wire feed mechanism, during machining since all
are electrically live.
3. Wire tension and wire feed rate
The wire tension is to be adjusted according to the work-piece thickness and size of wire used.
Proper tension is set by adjusting the knob of wire tension. The wire feed is to be adjusted on the
basis of thickness of the job and energy settings.
4. Automatic Wire Threading:
The machine has optional automatic wire threading attachment (AWT).
For threading of wire with AWT the wire should be of hard type. Insertion of wire up to AWT is
manual. Hence while changing the wire spool first insertion of wire is manual. Refer to chapter no.
6 for more details on wire drive with Automatic wire threading system.
5.6 Flushing at Low & High Flushing
The interfacing of machine tool with pump filter unit is done by connecting the two hoses coming
from flow meters to the distributor block .The drain channel that is fixed to the machine tool base
emerges into the tank. By adjusting the knob of the flow meters, pressure of water coming out of the
flushing assemblies can be adjusted. For high-speed cutting, flushing at high pressure is selected.
The pressure / flow selection is also programmable.
To carry on the cutting at lower speed or while taking the second cut on the job usually low flushing
pressure is selected.
5.7 Dielectric fluid flushing parameters
Confirm that conductivity of the dielectric fluid is within the specified the specified range. Press the
flush switch on the control box. Adjust dielectric fluid flow valve by watching the flushing pressure
fluid flowing from the upper & lower flushing pressure should be approximately 12 kg / cm2.
The function of the deionizer is to reduce the conductivity of dielectric fluid through the ion exchange
reaction of resin.
5.8 Conductivity Correction
When the conductivity goes too low or too high than the set values' Conductivity control unit
following corrective measures should be taken.
EVENT ACTION
Add distilled water or change the resin in

Conductivity higher than the set higher
deionizer if the resin is tending to become
value.
inactive.
Conductivity lower than the set lower

Add tap water.
value.
6 Information on Wire Drive System with Automatic
Wire Threading.
6.1 Wire Driving System
Wire supply & control parts
1. Wire supply part consists of real shaft for mounting wire electrode & a device for preventing
from separation of wire.
2. For M/C with AWT- Reel shaft has internally the torque motor generating back tension felt
break arrangement is provided
3. For without AWT -Wire control part consists of feeding roller controlling the tension of wire & a
tension roller.
4. Looseness detecting sensor or spool empty sensor.
5. Idler roller – Guidance of wire from wide roller to pulley.
6. Felt Rod - Remove dust of wire.
7. Belt Tension Pulley – Adjust position of pulley to control tension of flat belt.
No. Name Functional description
1 Wire Electrode --
Locking wire reel on the shaft, done by turning nut in clockwise

2 Wire Reel locking Nut
direction.
3 Wide Roller Guidance of wire from wire electrode
Wire is passed through a couple og rollers without going

4 Wire Guide Roller
separation.
Including a powder brake adjusting tension applied on wire, a
DC geared motor controlling direction of revolution of feeding
5 Feeding Pulley
pulley, & a rotary encoder detecting speed of revolution of
feeding pulley.
Stirring tension pulley needs periodic cleansing because it’s
6 Flat Belt
worn out during long time use.
Tension is generated by inserting wire between tension pulley
7 Tension Pulley & flat belt. Needs periodic cleansing because the surface of
pulley becomes dirty during long time use.
8 Idle Pulley --
9 Spring Bracket Bracket fixing one end of wire detecting spring.
In operating mode of AWT, increases the probability to

10 Wire Detecting Spring accomplish AWT by feeding up & down detecting the contact
of wire on spring resulted from wire bending.
6.2 Wire Guide, Upper Part
1. There are diamond dies guide upholding wire correctly & conducting part transferring
electric power to wire.
2. Includes a jet nozzle generating water jet necessary for AWT
1 Upper guide block Upper wire guide body.
2 Seal guide -B Part for guiding wire to connect on conducting pin.
Front guide block has internally revolving ring, conducting pin &
3 Front guide block
seal guide.
4 Sleeve Guidance of seal guide holder.
A pin fixing seal guide, marks a contact of wire with conducting

5 Seal guide pin
pin in AWT mode, makes it easy to thread wire.
6 Dust cap Cap protecting invasion of impurities.
A ring to turn conducting pin easily by hands

Hands, engraved index numbers on it help operator to identify
7 Indexing ring
the rotary position avoiding duplicates of abrasive grooves
resulted from electrically discharging during long time use.
Electric power is transferred to wire through this device. Due to
its consumptive property, turn its rotary position of contacts to
8 Conducting ring
index number (1/8 revolution), or if you use up all position,
replace it with new part.
9 Jet nozzle Flushing water jet in AWT mode.
Upper wire guide A guide to support the correct position of wire has to change to
10
Diamond dies guide) the diameter of wire to be used. Because of its consumptive
property, it is recommended to replace with new one to
maintain high precision machining.
11 Upper nozzle cap A nozzle cap for water jet.
A nozzle for flushing water jet can be changeable to the shape

12 Double nozzle (Ext.)
of work piece to be machined.
A nozzle for flushing water jet can be changeable to the shape
13 Double nozzle (Int.)
of work piece to be machined.
A cylinder driving seal guide holder, in AWT mode, makes it
14 Knock cylinder easy to thread wire by maintaining the concentricity of diamond
dies guide & seal guide.
A screw supporting upper wire guide (Diamond dies guide) if
15 Guide block screw
replacement, dissembled by turning it in counter-clockwise.
16 Wire approach A guide inducing injection of wire electrode into the guide block.
17 Seal guide holder A holder supporting seal guide & approach.
A screw locking conducting pin. If you rotate or replace

Connecting pin locking
18 conducting pin, unlock by rotating screw in counter – clockwise
screw
with wrench.
6.3 Wire guide lower part
1. This part has the same structure as the upper part. There are diamond dies, conducting part &
guide approach helping draining of water jet in AWT mode.
2. The wire passed through lower guide is introduced into the lower roller under the lower guide.
1 Double nozzle (Ext.)

A nozzle for flushing water jet can be changed as per shape of
work-piece to be machined.
2 Double nozzle (Int.)
Guidance of wire introducing into lower part, & prevention from

3 Guide approach.
spreads of water jet in AWT mode.
Lower wire guide A guide to support the correct position of wire has to change to
4
Diamond dies guide) the diameter of wire to be used. Because of its consumptive
property, it is recommended to replace with new one to
maintain high precision machining.
5 Regularizing ring Regularizes water jet from lower part.
A nozzle cap for water jet. In machining, it’s recommended to

6 Upper nozzle cap
minimize a gap between work-piece & this cap.
7 Lock nut Locking nozzle cap in operation of machine
Front guide block has internally revolving to conducting pin, &

8 Front guide block
seal guide.
Electric power is transferred to wire through this device. Due to
Conducting pin (Current its consumptive property, turn its rotary position of contacts to
9
Pickup) index number (1/8 revolution), or if you use up all position,
replace it with new part.
A ring to turn conducting pin easily by hands
Hands, engraved index numbers on it help operator to identify
10 Indexing ring
the rotary position avoiding duplicates of abrasive grooves
resulted from electrically discharging during long time use.
Sleeve
11 Guidance of seal guide holder.
A pin fixing seal guide, makes a contact of wire with conducting

12 Seal guide pin
pin, in AWT mode, makes it easy to thread wire.
13 Seal guide - B Guiding part of wire part contact on conducting pin
14 Lower seal guide holder A holder supporting seal guide & approach.
15 Seal guide Guiding part inducing wire into lower feeding roller.
A cylinder driving seal guide holder, in AWT mode, makes it

16 Knock cylinder easy to thread wire by maintaining the concentricity of diamond
dies guide & seal guide.
17 Lower guide block Lower wire guide body.
6.4 Wire feeding system, lower part
1. This part is feeding wire which passes through lower wire guide block to capstan roller of wire
feeding drive located behind the main body by winding wire with capstan roller & pinch roller.
2. A flat belt driving lower roller is activated by capstan roller of wire feeding drive.
3. In AWT mode, guidance & feeding of wire is done by air jet into the wire approach pipe.
4. Pinch roller is pushed softly by the spring connected to spring locator. If the pinch roller is
pushed strongly, wire is bent to separate from guide path & wire threading fails.
Together with pinch roller, feeds wire to the caps of wire feeding
Lower roller, ceramic drive located on the backside of machine when wire arrives at
1
roller big the capstan of wire feeding drive, this part rotates slippery by
one way clutch.
2 Pinch roller Pushing lower roller by elasticity of spring.
3 Guide path insulator Part for insulating & supporting guide path.
A guide transferring the wire passed through lower wire feeding

roller to the backside of machine by transition of wire by 90°.
4 Guide path
This part is insulated to detect the signal of wire arrivals in AWT
mode.
Wire is smoothly transferred to the backside of machine by the
5 Air nozzle
air stream generating inside nozzle through wire approach pipe.
This pipe is a path of wire from lower roller to capstan roller of
6 Wire approach pipe
wire feeding driver on the backside of machine.
7 Front plate A flange of lower part of wire feeding system.
Lower housing is insulated from lower arm by this part. &

8 Insulator front
should be cleaned periodically.
9 Arm A part fixing & supporting lower wire guide part.
A bolt for adjusting the pushing force of pinch roller. In the case
10 Spring locator of separation of wire from this, loose the bolt to the reduce the
force by turning the bolt in counter clockwise direction.
Drives lower rollers together by connecting the axis of lower
11 Flat belt roller & the capstan roller of wire feeding driver on the backside
of machine.
6.5 Drive part (wire feeding part)
1. Composed of a cone to isolate air jet stream passed through wire approach pipe & wire feeding
roller to wind the wire with constant feeding rate.
2. Feeding part retrieves wire to wire collection box by pinch roller connecting to main capstan
roller & spring block.
This pipe is a path of wire from lower roller to capstan roller of

1 Wire approach pipe
wire feeding driver on the backside of machine.
Wire is winded tightly by two feeding rollers (main capstan &
Wire feeding roller (pinch
2 pinch roller). A long time use causes a dirty surface on it, so
roller)
should be cleaned regularly.
This part forces pinch roller to be pushed by main roller, with
3 Spring block
the pressure of spring
4 DC geared motor Connected with main roller with timing belt.
5 Drive pulley Connected with main roller, maneuvers lower roller by flat belt.
Revolves lower roller by connecting the axis of lower roller &

6 Flat belt.
the axis of feeding roller of wire driving part.
7 Adjustable roller. A roller keeping the tension of flat belt by elasticity of spring.
6.6 Automatic wire threading part.
1. This part is to clamp & cut wire, & to exhaust the waste to be cut.
2. This part has the function that makes the end of wire to be easy to re-guide for AWT, because
the end of wire become bent in the failure of automatic wire threading (abbr. AWT)
This part fixes one end of detecting spring. In AWT mode, it’s
possible to adjust the shape of cutting edge of wire & the time
1 Cutter dies holder
required for cutting by varying the distance from internal seal
guide to wire cutter arm.
2 Wire cutter arm This part has alternating motion to cut wire.
3 Cutter actuating motor Actuates wire cutting arm.
4 Wire clamp Clamps wire in AWT mode.
5 Fork shaft Processing the waste of wire by winding.
6 Cylinder Moves wire ejection plate in front direction.
7 Wire ejection plate Ejects the waste of wire wound on the fork shaft.
6.7 Maintenance & Checking Items for Wire Drive System
Items to check daily when starting & ending machining.
No. Item to check Contents to check
Remove wire chip & machining chip in the work fluid supplying
1 Work tank
unit.
1. Check whether there are injuries or cracks at tip of upper &
lower nozzle surface.
2 Nozzle checking
2. If work fluid leaks out, it results in breaking the wire due to
lower pressure.
1. Check the amount of wire in dust box.
3 Dust box checking 2. The dust box is usually full of wire after about 25 hours of
machining. So remove wire in case of long time machining.
It is worn away in about 25 hours in case of first cut. Check
4 Conducting pin checking. remaining time in the consumptive parts display.
It results in breaking the wire & decreasing machining speed.
Amount of work fluid Check the fluid surface level of work fluid supplying unit. If not
5
checking. enough, supply work fluid.
The dielectric value of
6 Check that the dielectric value is in the range of display.
work fluid checking.
Check that error or warning occurs under automatic wire
Automatic wire threading threading in the air.
7
checking. If error occurs or same warning occurs continuously more than
three items, check unit referring to section 4
Cutting wire operation
8 Checking whether error or warning occurs when cutting wire.
checking
6.8 Trouble shooting
Wire is broken frequently
Posi-
Cause of broken wire Management
tion
a) Cooling error due to blocking of a) Clean upper dies guide with rust remover. If
cooling hole of upper dies guide. needed remove dust in hole with needle.
1 b) Low touching pressure due to • After fixing dies guide, detect wire squareness.
wear of upper conducting pin. b) Check upper conducting pin, & then change
the position or replace it.
Detecting machining gap error due to
2 • Check the wear of upper conducting pin.
conducting pin wear.
3 Insufficient work fluid in upper nozzle. • Increase the pressure of upper fluid jet.
a) Cooling error due to blocking of

cooling hole of lower dies guide.
a) Clean lower dies guide with rust remover &
blow air to it. If needed remove dust in hole
with needle.
• After fixing dies guide detect wire squareness.
• For details refer maintenance & check data.
4
b) Check lower currant pick up & then change the
b) Lower touching pressure due to
position or replace it.
wear of lower conducting pin.
c) Check operation of actuator & clean it.
c) In case of JW60A/JW120A, lower
moving pin malfunction
6.9 Items to Check Weekly.
No. Item to check Contents to check
• Clean upper & lower wire guide block with weak acid.
• Clean lower wire guide block approach dies with weak acid.
Wire guide block
1 • After cleaning & assembly ensure proper forward &
clean.
backward motion of seal guide pin. Automatic wire
threading may fail because of it.
• Pump air in to hole. If there is not enough cooling water,
Cooling water drain
2 supply it.
hole cleaning.
• It results in breaking the wire at current pick up unit.
• Change the position at every 25 hours.
Current pick up
3 • It results in breaking the wire & decreasing machining
check.
speed.
• Clean wire winding roller. If black line is seen along the
Winding roller path of wire, clean it with rust remover.
4
cleaning. • It results in extrusion of wire in work tank.
• Clean ceramic roller big & small.
• Draw water from air unit using drain valve.
Air pressure control
5 • If the water soaks into air cylinder it results in malfunction
unit checking.
or failure.
• Restore machine origin of X, Y, Z axis.

Machine origin
6 • It may happen that true machine origin and the coordinate
restoring.
of NC or different after long time machining.
• Check whether wire is twisted or crossed so that wire does

Wire tension is too
7 not get loose.
high.
• If lower roller rotation is bad call Electronica india limited.
Figure 1 Machine Tool Slinging Diagram for eNova OS and 1S
Figure 2 Machine Tool Slinging Diagram for eNova 2S
Figure 3 Transport Lock for Main Table for eNova OS & 1S
Figure 4 Transport Lock for Main Table for eNova 2S
Figure 5 Transport Lock for U,V and Z Axis for eNova OS,1S and 2S
Figure 6 Floor Plan eNova OS
Figure 7 Floor Plan eNova 1S
Figure 8 Floor Plan eNova 2S
Figure 9 Foundation Details for eNova OS & 1S
Figure 10 Foundation Details for eNova 2S
Figure 11 Upper Flushing Assembly (SAWT)
Figure 12 Upper Flushing Assembly (AWT)
Figure 13 Lower Flushing Assembly
Figure 14 Wire Drive System (SAWT)
Figure 15 Wire Path (SAWT)
Figure 16 Wire Drive System (AWT)
Figure 17 Wire Path (AWT)
Figure 18 Wire Guidance System (SAWT)
Figure 19 Wire Guidance System (AWT)
Figure 20 AWT Assembly
Figure 21 Work Tank for eNova
Figure 22 Seal Assembly for eNova
Figure 23 Work-Table with Maximum size (L x W) job mounted
Figure 24 Work-Table with Round job mounted
Figure 25 Work-Table with Movable Bridge Mounted
Figure 26 Work-Table with Job mounted on Movable Bridge
7 Paper Filtration System
7.1 Specifications of Dielectric Unit
Sr Description Unit eNova OS eNova 1S eNova 2S
1 Dielectric fluid De-ionized water
2 PF Tank capacity Liters 700 850
3 De-ion resin capacity Liters 16

10 µm paper filters (Standard)
4 Filter cartridges microns
5 µm paper filters (Optional)
5 Ion exchange capacity LPM 70
6 Capacity of cooling unit Kcal/Hr 3000
7 Max. Dielectric pressure kg/ cm2 15

Outside dimensions
8 mm 2150x800x600 2150x1000x600 2150x1460x625
(L x W x H )
7.2 Features:
Single Storied Stainless Steel Construction.
Multi-Stage Filtration to improve filter life.
16 Stage Flushing Pressure.
Fine Filtration Up To 10 Micron Filtrate Size.
7.3 Packing & Unpacking

The eNova OS/1S PF Unit is packed in wooden box. The wooden plates are bolted to each other for
sturdiness, so that the unit can be handled easily during transport.
Please note that while unpacking the mark of ‘This Side Up’ is pointing in right direction remove all
nuts and bolts to unpack eNova OS/1S or 2S PF unit and keep all packaging material aside. Check
for damages if any please contact to Electronica india limited. Use forklift or crane for lifting and
moving eNova OS/1S/2S PF unit.
8 Installation of P.F. Unit
8.1 Installation of eNova OS,1S & 2S PF Unit
Positioning of Paper Filtration Unit eNova OS/1S/2S
Caster wheels at the bottom are provided only for adjustment at the location. Longer distance
movements are not recommended on caster wheels.
Use forklift or Crain to keep the unit near the machine. Move the 'X' & 'Y' axes of machine to axis
center position, then position eNova OS/1S/2S PF unit such that drain from machine tool work tank
will be at the center of the bottom tank.
PLEASE NOTE THAT
) Don’t hold to the tank walls for positioning of the unit.
) Sufficient care should be taken so that all critical components
don’t get damaged during movement of the unit.
Connect bunches to the respective positions on the generator properly, Then power ON the system
and check for the direction of rotation of pump.
The direction of rotation of pump is indicated by arrow on the
pump.
8.2 Procedure for Filling Water
Fill clean D. M. water in dirty water storage tank & start the filter pump till clear water tank is over
flowing into dirty water storage tank. Continue filling till dirty water storage tank is at least half full.
9 Operation of P.F. Unit Major Parts
9.1 Major parts of P.F. Unit
a. Stainless Steel Dirty Water Storage Tank & Clean Water Storage Tank.
b. Filter pump.
c. High pressure clean water pump.
d. Auxiliary pump.
e. Paper filters 10µm.
f. Interconnecting piping in flexible air-water hoses with necessary valves & fittings.
g. Pressure gauge.
h. Non conductive type level switches for clean and dirty water storage tanks.
i. Conductivity meter sensor.
j. De-ionization Blow molded vessel with mixed bed resin.
k. Temperature controller for filtered water (Chiller).
9.2 Functioning of P.F. Parts
1) Filter Pump: -
This sucks dirty water for subsequent filtration. It delivers the water to the filter.
2) Auxiliary pump: -
Sucks water from clean water tank and it delivers it to the deionizer.
3) Deionizer: -
This maintains conductivity of water. If conductivity increases beyond predetermined limit then
water circulates through Deionizer until conductivity reaches within specified limit.
4) Chiller: -
This refrigeration type chiller maintains the temperature of water.
5) Pressure Pump: -
It sucks clean water and delivers it to the upper and lower flushing nozzles for machining.
6) Pressure Gauge: -
It indicates system water pressure.
7) Float Switch: -
It gives signal if water level lowers in dirty tank & clean tank because of filter motor & pressure
motor tripping respectively.
10Instructions for Operation & Maintenance
10.1 Filtration Cycle:
(Refer Figure 30)
Dirty Water along with metal cutting dust is pumped by filter pump to paper filter box. From
that filter box, filtered clean water enters into clean tank. By pressure pump clean water
supply again to machine tool.
In clean tank, there is one more pump is provided which known as Auxiliary Pump. It supplies to
clean water to De-ion bowl and Chiller Unit.
This operation continues as the wire EDM machine starts & continues till the filter pressure rises by
2 Kg/cm2 (Choking Pressure).
10.2 Filter Start-Up Water Volume: -

A. Fill clean water in dirty water tank & start the dirty water pump till clear water tank is overflowing
in to dirty water tank. Continue filling till the dirty water tank is at least half full.
B. Fill sludge water tank till the level of overflow pipe.
10.3 Conductivity Controls & Deionizer Pump: -

The control panel is fitted with conductivity controller for the clean water & its probe is situated in
clean water tank. As the conductivity increases beyond preset valve (e.g. 10) it will automatically
switch on deionizer solenoid.
The deionizer solenoid will supply the water through blow molded resin bowl consisting of mixed
bed resin. The deionizer solenoid will stop automatically once the conductivity is brought under
control.
10.4 Chiller Functioning For Clean Water Temperature Control: -

The temperature of the clean water is to be maintained around 200C. If this temperature rises, chiller
pump installed inside the chiller starts automatically and chilled water goes back to the clean water
tank. Once the temperature is under control chiller pump and chiller stops automatically.
10.5 Do’s and Don’ts: -

DO’S DON'TS
Use crane or forklift for moving of PF unit from
one place to another.
Check for the direction of rotation the pumps. Do not try to change the phases of the wiring.
Ordinary consumables can be bought out from Do not buy critical items directly from local
local market. market.
11Maintenance of P.F. Unit
11.1 Table indicating periodic maintenance: -
a. Cleaning of tank For cleaning of tank there is no need to remove the tank from the
frame every time. Drain the water from the tank by opening the
drain caps the remaining water with sponge.
b. Changing deionizer resin Resin is changed only when the indicator shows the conductivity
of the water more than set value and it remains same or increases
further even when deionizer solenoid remains ON for longer time.
To change the resin remove the pipe connection remove the top
threw cap of the resin bowl wash it put new resin of recommended
quantity put the flange and pipe connections again.
c. Cleaning of conductivity Clean the electrodes of conductivity cell with clean clothe such that
cell
there will not be any deposition of water contents.
11.2 Maintenance Tips
A) Dielectric Unit: -
)The tank should be cleaned once in a month
)Tank should be topped up with distilled water at least once a week to ensure longer deionizer life
B) Deionizer: -
)Stop the system and disconnect the pipes connecting the dielectric fluid supply unit and the
cartridge type deionizer. The deionizer from the dielectric fluid supply unit
C) Drain the Dielectric Fluid: -

)Remove the ion exchange resin and wash the cylinder with flowing water .Assemble the parts
again and fill the cylinder with new resin .Check that particles of resin are not lodged between the
covers and base and other sealed locations so as to cause the dielectric fluid to leak
)Connect the pipes to the inlet and outer ports of deionizer.
Figure 27 P.F. Assembly for eNova OS
Figure 28 P.F. Assembly for eNova 1S
Figure 29 P.F. Assembly for eNova 2S
Figure 30 Normal Cycles of Filtration System

Operating Manual for EDM Machine and Paper Filtration Unit

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eNova OS/ 1S/ 2S

WIRE ELECTRIC DISCHARGE MACHINE

Operating & Maintenance Manual

HEAD OFFICE: FACTORY :

Poddar HMP Group. Electronica india limited.

eNova OS/ 1S/ 2S

This warranty certificate is issued for machine tools_____________________ with its

Power supply unit Sr.No_______________________________supplied to

M/s.____________________________________________________________ for the

date of shipment, against workmanship manufacturing defects, components and parts

manual or negligence from the operating staff.

Warranty ends on:

Electronica india limited. Agent Customer (seal)

eNova OS/ 1S / 2S SR. NO.

Electronica india limited. Agent Customer (seal)

Electronica india limited

THE STANDARD ELEMENTS USED IN THIS MACHINE LIKE SEAL,

PUMP, KEYBOARD, MOUSE, MACHINE LAMP ARE OF REPUTED

MAKE. THESE ELEMENTS OFTEN GETS DAMAGED DUE TO

IMPROPER USAGE & POOR MAINTENANCE.

THE WARRANTY FOR SUCH ELEMENTS IS VOID IF THE DAMAGE IS

DUE TO IMPROPER MAINTENANCE.

Electronica india limited .

1 Introduction of Machine Tool ...................................................................................................1

Figure 1 Machine Tool Slinging Diagram for eNova OS and 1S........................................................22

ELEKTRA CNC WIRECUT EDM is supplied in 5 cases.

2.1 Preparation for Installation

2.2 Place of Installation

2.3 Environmental Conditions

The surroundings of the machine should be kept absolutely clean.

Avoid following situations:

Foundation Details (Ref. Figure 9)

2.4 Installation of Machine Tool

2.5 Leveling Procedure

2.6 Safety Precautions

3.1 Specifications of Machine Tool:

Travel Range Axis eNoVA OS eNoVA 1S eNoVA 1S

X 320 mm 400 mm 600 mm

Y 220 mm 300 mm 400 mm

Vertical Z 260 mm 310 mm 360 mm

Work-Piece Size eNoVA OS eNoVA 1S eNoVA 2S

3.1.3 Feeds eNoVA OS eNoVA 1S eNoVA 2S

Main Table X,Y Feed Rate 1000 mm/ min

Auxiliary U, V Feed Rate 600 mm/min

Z Feed Rate 600 mm/min

Wire Feed Rate 0 - 15 m / min

Wire Tension 0 - 2.5 kgf

3.1.4 Wire Guide eNoVA OS eNoVA 1S eNoVA 1S

Wire Guide Type Diamond closed

3.1.5 Taper Cutting eNoVA OS eNoVA 1S eNoVA 1S

Without Awt ± 300/ 50 mm

With Awt ± 20/ 100 mm

3.3 Cautions for Safety

Table to indicate periodic maintenance.

6. Cleaning of Wire Drive Assembly which includes Idler, feed

5.2 Work-piece mounting

5.3 Setting Up and Operation

Check the following

5.5 Preparation for Machining

3. Wire tension and wire feed rate

5.6 Flushing at Low & High Flushing

5.7 Dielectric fluid flushing parameters

5.8 Conductivity Correction