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WARRANTY CERTIFICATE
Date :
period of 12 months from the date of installation but not exceeding 15 months from the
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
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
Date of Installation :
Warranty ends on :
Electronica india limited eNova OS, 1S &2S Machine & P.F. Unit Operating Manual Page i
List of Figures
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
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.
• 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.
Electronica india limited eNova OS, 1S &2S Machine & P.F. Unit Operating Manual Page 2
• 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.
Electronica india limited eNova OS, 1S &2S Machine & P.F. Unit Operating Manual Page 3
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.
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.
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.
Electronica india limited eNova OS, 1S &2S Machine & P.F. Unit Operating Manual Page 4
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.
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.
Electronica india limited eNova OS, 1S &2S Machine & P.F. Unit Operating Manual Page 5
3 Instructions for Operator Regarding Mechanical
Components.
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.
Resolution 0.0005 mm
Electronica india limited eNova OS, 1S &2S Machine & P.F. Unit Operating Manual Page 6
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.
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.
Electronica india limited eNova OS, 1S &2S Machine & P.F. Unit Operating Manual Page 7
4 Maintenance of Machine Tool
Electronica india limited eNova OS, 1S &2S Machine & P.F. Unit Operating Manual Page 8
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 ¨
Electronica india limited eNova OS, 1S &2S Machine & P.F. Unit Operating Manual Page 9
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.
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.
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.
Electronica india limited eNova OS, 1S &2S Machine & P.F. Unit Operating Manual Page 10
• 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.
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.
Electronica india limited eNova OS, 1S &2S Machine & P.F. Unit Operating Manual Page 11
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.
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.
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.
When the conductivity goes too low or too high than the set values' Conductivity control unit
following corrective measures should be taken.
EVENT ACTION
Electronica india limited eNova OS, 1S &2S Machine & P.F. Unit Operating Manual Page 12
6 Information on Wire Drive System with Automatic
Wire Threading.
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.
1 Wire Electrode --
8 Idle Pulley --
Electronica india limited eNova OS, 1S &2S Machine & P.F. Unit Operating Manual Page 13
9 Spring Bracket Bracket fixing one end of wire detecting spring.
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
Front guide block has internally revolving ring, conducting pin &
3 Front guide block
seal guide.
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
Electronica india limited eNova OS, 1S &2S Machine & P.F. Unit Operating Manual Page 14
property, it is recommended to replace with new one to
maintain high precision machining.
16 Wire approach A guide inducing injection of wire electrode into the guide block.
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.
Electronica india limited eNova OS, 1S &2S Machine & P.F. Unit Operating Manual Page 15
property, it is recommended to replace with new one to
maintain high precision machining.
14 Lower seal guide holder A holder supporting seal guide & approach.
15 Seal guide Guiding part inducing wire into lower feeding roller.
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.
Electronica india limited eNova OS, 1S &2S Machine & P.F. Unit Operating Manual Page 16
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.
3 Guide path insulator Part for insulating & supporting guide path.
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.
Electronica india limited eNova OS, 1S &2S Machine & P.F. Unit Operating Manual Page 17
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.
5 Drive pulley Connected with main roller, maneuvers lower roller by flat belt.
7 Adjustable roller. A roller keeping the tension of flat belt by elasticity of spring.
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.
Electronica india limited eNova OS, 1S &2S Machine & P.F. Unit Operating Manual Page 18
3 Cutter actuating motor Actuates wire cutting arm.
7 Wire ejection plate Ejects the waste of wire wound on the fork shaft.
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
Electronica india limited eNova OS, 1S &2S Machine & P.F. Unit Operating Manual Page 19
6.8 Trouble shooting
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.
Electronica india limited eNova OS, 1S &2S Machine & P.F. Unit Operating Manual Page 20
6.9 Items to Check Weekly.
• 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.
Electronica india limited eNova OS, 1S &2S Machine & P.F. Unit Operating Manual Page 21
Figure 1 Machine Tool Slinging Diagram for eNova OS and 1S
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Figure 2 Machine Tool Slinging Diagram for eNova 2S
Electronica india limited eNova OS, 1S &2S Machine & P.F. Unit Operating Manual Page 23
Figure 3 Transport Lock for Main Table for eNova OS & 1S
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Figure 4 Transport Lock for Main Table for eNova 2S
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Figure 5 Transport Lock for U,V and Z Axis for eNova OS,1S and 2S
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Figure 6 Floor Plan eNova OS
Electronica india limited eNova OS, 1S &2S Machine & P.F. Unit Operating Manual Page 27
Figure 7 Floor Plan eNova 1S
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Figure 8 Floor Plan eNova 2S
Electronica india limited eNova OS, 1S &2S Machine & P.F. Unit Operating Manual Page 29
Figure 9 Foundation Details for eNova OS & 1S
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Figure 10 Foundation Details for eNova 2S
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Figure 11 Upper Flushing Assembly (SAWT)
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Figure 13 Lower Flushing Assembly
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Figure 14 Wire Drive System (SAWT)
Electronica india limited eNova OS, 1S &2S Machine & P.F. Unit Operating Manual Page 34
Figure 16 Wire Drive System (AWT)
Electronica india limited eNova OS, 1S &2S Machine & P.F. Unit Operating Manual Page 35
Figure 18 Wire Guidance System (SAWT)
Electronica india limited eNova OS, 1S &2S Machine & P.F. Unit Operating Manual Page 36
Figure 19 Wire Guidance System (AWT)
Electronica india limited eNova OS, 1S &2S Machine & P.F. Unit Operating Manual Page 37
Figure 20 AWT Assembly
Electronica india limited eNova OS, 1S &2S Machine & P.F. Unit Operating Manual Page 38
Figure 21 Work Tank for eNova
Electronica india limited eNova OS, 1S &2S Machine & P.F. Unit Operating Manual Page 39
Figure 22 Seal Assembly for eNova
Electronica india limited eNova OS, 1S &2S Machine & P.F. Unit Operating Manual Page 40
Figure 23 Work-Table with Maximum size (L x W) job mounted
Electronica india limited eNova OS, 1S &2S Machine & P.F. Unit Operating Manual Page 41
Figure 25 Work-Table with Movable Bridge Mounted
Electronica india limited eNova OS, 1S &2S Machine & P.F. Unit Operating Manual Page 42
7 Paper Filtration System
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.
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.
Electronica india limited eNova OS, 1S &2S Machine & P.F. Unit Operating Manual Page 43
8 Installation of P.F. Unit
8.1 Installation of eNova OS,1S & 2S PF Unit
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.
Connect bunches to the respective positions on the generator properly, Then power ON the system
and check for the direction of rotation of pump.
pump.
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.
Electronica india limited eNova OS, 1S &2S Machine & P.F. Unit Operating Manual Page 44
9 Operation of P.F. Unit Major Parts
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).
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.
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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).
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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.
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
Electronica india limited eNova OS, 1S &2S Machine & P.F. Unit Operating Manual Page 47
Figure 27 P.F. Assembly for eNova OS
Electronica india limited eNova OS, 1S &2S Machine & P.F. Unit Operating Manual Page 48
Figure 28 P.F. Assembly for eNova 1S
Electronica india limited eNova OS, 1S &2S Machine & P.F. Unit Operating Manual Page 49
Figure 29 P.F. Assembly for eNova 2S
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Figure 30 Normal Cycles of Filtration System
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