OPERATING & MAINTENANCE MANUAL OF MACHINE TOOL

D: 02 : 221 : 05 : 02

ELECTRONICA, PUNE WARRANTY CERTIFICATE

ELEKTRA ULTRACUT f-2 Date:

This warranty certificate is issued for Machine tool. Sr. No._________________________ with its power supply unit Sr. No._________________________ M/s. __________________________ For the period of 12 months from the date of installation but not exceeding

15 months from the date of shipment, against manufacturing defects,

Components and parts only. Manufacture / 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 :

For ELECTRONICA 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 44, MUKUNDNAGAR, PUNE - 411037. ELEKTRA ULTRACUT f-2 SR NO. : DATE OF INSTALLATION : WARRANTY ENDS ON :

____________________________________________________ For ELECTRONICA Agent Customer Seal

ATTENTION!

THE STANDARD ELEMENTS USED IN THIS MACHINE LIKE GRUNDFOS PUMP, FLOPPY DISK DRIVE ARE OF REPUTED MAKE. OFTEN THESE ELEMENTS GET DAMAGED DUE TO IMPROPER USAGE & POOR MAINTENANCE. THE WARRANTY FOR SUCH ELEMENTS IS VOID IF THE DAMAGE IS DUE TO IMPROPER MAINTENANCE.

Electronica Machine Tools Ltd.

WARRANTY IS VOID IF

RECOMMENDED SPARES/

CONSUMABLES ARE NOT USED.

Electronica Machine Tools Ltd.

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INDEX

CHAPTER DESCRIPTION PAGE NO.

1) INTRODUCTION 8

2) PREPARATION TRANSPORTATION, & INSTALLATION OF THE SYSTEM 11

3) INSTRUCTIONS FOR OPERATOR REGARDING MECHANICAL COMPONENTS 18

4) MAINTENANCE 22

5) INSTRUCTIONS FOR OPERATOR REGARDING SETTING UP & OPERATION OF THE MACHINE 25

6) MORE INFORMATION ON WIRE DRIVE SYSTEM WITH AUTOMATIC WIRE THREADING. 30

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LIST OF FIGURES

Note : All figures at the end of this manual.

FIG. NO DESCRIPTION

1. FLOOR PLAN

2. FOUNDATION DETAILS

3. EARTHING SCHEME.

4. MACHINE TOOL SLINGING DIAGRAM

5. TRANSPORT LOCK X, Y

6. TRANSPORT LOCK U, V, Z

7. UPPER FLUSHING ASSEMBLY (SAWT)

8. LOWER FLUSHING ASSEMBLY (SAWT)

9. UPPER FLUSHING ASSEMBLY (AWT)

10. LOWER FLUSHING ASSEMBLY (AWT)

11. LOWER HOUSING ASSEMBLY

12. WIRE GUIDE SYSTEM

13. WIRE DRIVE SYSTEM (SAWT)

14. AWT ASSEMBLY.

15. JOB CLAMPING

16. WORK TABLE LAYOUT.

17. WORK TABLE LAYOUT -1.

18. WORK TABLE LAYOUT -2.

19. WORK TABLE LAYOUT -3.

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CHAPTER 1

INTRODUCTION The ELEKTRA Wire cut electrical discharge machine comprises of

Machine Tool, a power supply Unit (ELPULS), and a Dielectric unit and a

chiller unit. The machine tool unit comprises of a main worktable (fixed

type) on which the workpiece is clamped, a moving column on X & Y

axes, wire drive mechanism and auxiliary axes U & V & Z are mounted

on the moving column. The X and Y axes are moved in steps of 1

micrometer by means of D.C. servo motor. The U& V axes which parallel

to X & Y axes respectively are driven by the same motors which drives

the table. The traveling wire which is continuously fed from wire feed

spool which moves through the workpiece and is supported under

tension between a pair of wire guides which are located at the opposite

sides of the workpiece. 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 workpiece and the traveling wire electrode, to

cause the erosion of the workpiece material. As the material removal or

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machining proceeds, the worktable carrying the workpiece 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 floppy disk or

directly 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 floppy disks. While the machining is continued, the

machine zone is continuously flushed with water passing through the

nozzles on the both sides of the workpiece. 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 resign is

used in the dielectric distribution system to maintain the conductivity of

the water constant. The part programming system comprising of an

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ASCII keyboard, CRT with a fine resolution graphics features, double

sided double density floppy disk drive. The geometry of the profile and

the motion of the wire electrode tool along the profile is fed to the part

programming system 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 gradient can be specified for the

total path or for each element separately. After the profile is fed to the

computer, all the numerical information about the path is calculated

automatically and it's printout can be generated if required. The entered

profile definition, the profile is recorded by the computer on the floppy

disk which is then removed and put in the controller for execution of the

program.

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CHAPTER 2

PREPARATION, TRANSPORTATION AND

INSTALLATION OF THE SYSTEM

ELEKTRA CNC WIRECUT EDM is supplied in 3 cases.

Case No. 1 contains Machine tool

Case No. 2 contains Power supply unit. Case No.3 contains Dielectric unit, Dielectric cooling unit, 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 3 tons. After opening the case, lift machine tool

from the platform by using nylon ropes. Do not allow ropes to touch the

machine anywhere while lifting. Lift the power supply unit, dielectric unit

with the help of nylon 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 the four

units for apparent damage. If any damage is found inform Electronica -

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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.

PREPARATION FOR INSTALLATION

Do not transport the machine on open pieces, 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 SLIDES BEFORE TRANSPORTATION. PLACE OF INSTALLATION.

The machine should be placed in an air conditioned room so that it will be free from dust and heat. The place should be kept clean. The area allocated should be sufficiently large to accommodate the following items,

Machine tool, Power supply unit, and Pump filter unit and chiller should be arranged as shown in floor plan (Ref. Fig. 4). Storage space for workpiece preferably a separate cupboard.

Storage space for electronic cassettes closed space protected from heat & direct sunlight.

Storage space for job files, manuals, record forms etc.

Tool kit for periodic maintenance.

Space for movement of material and the operator.

3 phase electrical connection with neutral & separate earth.

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ENVIRONMENTAL CONDITIONS The surroundings of the machine should be kept absolutely clean. Ensure following conditions

Constant room temperature of 20+/- 1 c using an air conditioner.

fairly constant input supply voltage . The variation should not be more than 1%. Use a servo controlled voltage stabilizer to achieve this condition.

Frequently cleaning the surrounding area.

A good and well directed source of light. The worktable and all control panels should be sufficiently illuminated.

AVOID FOLLOWING SITUATIONS

Direct sunlight on machine tool, power supply unit and dielectric unit.

Dust or fumes in the surrounding area.

Rain water directly coming on the machine.

Wetting of floor when machining is in progress. Relative humidity more than 70%.

A common point of 3 phase power supply for WIRE CUT EDM and other machines like welding sets, heavy presses etc. which draw heavy current intermittently.

Heavy vibrations near the machine.

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FOUNDATION DETAILS (Ref. Fig.5) 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. 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. Fig. 2, 3). The machine tool is to be

placed on five 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) .See to it that all the axes 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. All the 3 units viz. 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 generator with the machine tool. See

whether all cables are intact.

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7. Make all the connections of the generator with the machine tool. 8. 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.

9. 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.

10.Make wire verticality with the help of verticality block, before making

wire vertical dial the block within 2 microns w. r. t. Z axis. 11.Load some job and start sparking. LEVELING PROCEDURE 1) When the m/c tool is being placed on the floor ensure that the gap between the floor and m/c base is 110 mm to 115 mm, it must not be less than 110 mm. Gap can be adjusted by adjusting the leveling bolts on the m/c tool base. The gap of 100 to 115 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 and C readiness check list, clean all the ground surfaces provided on the m/c base. 3) There are 8 leveling bolts on m/c base. Lift the bolts no. 2, 4, 5 and 7 and ensure that the bolts no. 1, 3, 6 and 8 are touching the floor. 4) Keep all the axes at the middle position of total stroke. Take the spirit level of accuracy 0.020/meter. Keep the spirit level on surface marked A in diagonal direction as shown in fig and note the results. Keep the spirit level on surface marked B, note the result. Depending on the results of above checks, adjust the leveling bolts no. 1 and 3 such that the level of m/c is within 4-5 divisions. Place the spirit level on the surface marked C and D and ensure

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that the level of the m/c is within 4-5 divisions. If not, adjust the bolts no. 6 and 8. Place the spirit level on the surface marked A in vertical and horizontal direction and level the m/c within 3 divisions by adjusting the bolts no.6 and 3 respectively. Similarly place the spirit level on the surface marked B, C and D and level the m/c within 3 division of the spirit level by adjusting the leveling bolts 5) After leveling the m/c, adjust the leveling bolts no.2, 4, 5 and 7 such that the leveling pads touch the floor and then tighten all the leveling bolts and lock them by nut on the bolt. After this check once again the level of the m/c is not disturbed and is within 3 divisions of the spirit level. 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.

LEVELING BOLT

GROUND SURFACE

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SAFETY PRECAUTIONS

Machine tool table is clamped to prevent its vibration during transport. Remove these clamps before machine tool operation. This is most important. (Ref. Fig. 2, 3). 1. Not leave do doors open of the power supply unit, NC controller and

machine tool control panel during operation. 2. The power supply should be turned OFF if these doors are to be

opened. 3. Do not operate the machine when the floor is wet.

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SPECIFICATIONS OF VOLTAGE STABILIZER (3 PHASE)

1. ULTRACUT F2 : 15 KVA, @ 415 V line to line .

2. Input voltage : 310 V to 467 V line to line.

i. e . 180 -- 270 V / phase.

3. Output voltage : 415 V line to line

i. e . 240 V phase to neutral.

4. Output voltage regulation : 1% / phase of output voltage. 5. Voltage correction rate : 35 V / sec.

6. Terminations : 5 way socket on rear door (20 A) 7. Overload protection : With SIEMENS contactor & 3 phase

: thermal overload relay .

8. Other protections : Single phasing presetter, over - voltage

tripping.

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CHAPTER 3

INSTRUCTIONS FOR OPERATOR REGARDING MECHANICAL

COMPONENTS .

1. SPECIFICATIONS :

1.1. TRAVEL RANGE

TRAVEL RANGE AXIS ULTRACUT F 2

X 600 mm LONGITUDINAL

U 40 Y 400 mm

LATERAL V 40

VERTICAL Z 325 mm

1.2. WORK PIECE SIZE

WORK PIECE SIZE ULTRACUT F 2

TABLE SIZE 860 X 580mm

Max. WORK PIECE SIZE 1150 X 810 X 300 mm

Max. WORK PIECE Wt. 1000 Kg.

1.3. FEED

Main table feed rate 900 mm/ min

Resolution 0.0005 mm

Wire feed rate 0 - 15 m / min

Wire tension 2.5 kgf

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1.4. WIRE GUIDE

WIRE GUIDE TYPE Diamond closed

Wire electrode diameter

0.1, 0.25 STD 0.15 , 0.2 , 0.3 OPT

1.5. TAPER CUTTING ANGLE

1.5 TAPER CUTTING Max. Taper Angle 15 / 100 mm

2.0 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, V axes are at either end of the stroke of

each axis. The NC unit uses the machine coordinate system to control

the machining start position, pitch error compensation, wire verticality

etc.

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3.0 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, NC unit, control

panel 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, avoid interference with the

lower flushing nozzle to avoid damage to the lower diamond guide and

flushing assembly.

8) Make sure that the workpiece and the bridges do not interfere with the

upper and lower flushing nozzle.

9) Do not keep workpiece, tools or any other material on the table or U/V

covers which could obstruct during movement.

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10) Before moving the table (X & Y axes) or U or V axis, make sure that

there is no obstruction in the travel range before actual machining of the

job.

11) Designate an operator solely responsible for machine operation.

12) Maintenance and repair must be done by authorised personnel.

Make sufficient preparation before working on the machine.

13) Do not operate the machine with protective covers removed.

14) Carryout periodic maintenance of filtration system.

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CHAPTER 4

MAINTENANCE

Table to indicate periodic maintenance.

Activity Daily Weekly Monthly Quarterly

1. Check for debris in the wire guides & clean with the help of acetone & soft cloth.

2. Cleaning of Worktank & all the areas where particles accumulate.

3. Check for the gap between lower nozzle & workpiece. 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.

4. Cleaning of Wire Drive Assembly which includes Idler, feed & pressure rollers to keep them free from dust & water.

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5. 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. The distance of diamond center from wire guide face is 3.75.

Activity Daily Weekly Monthly Quarterly 6. Check for wire verticality 7. 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.

8. Clean debris on ceramic roller big and ceramic roller small.

9. 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.

10. Check for the groove on wire feed & wire tension rollers. If in case groove is observed replace the rollers.

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11. Check flushing nozzles, if in case the nozzles are damaged replace them.

12. Clean the groove on all the idler rollers and check the rollers rotate smoothly.

13. Check for play in gears & belt tension.

14. 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.

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Activity Daily Weekly Monthly Quarterly 15. Check for the play in lower

flushing assembly mounting. If any play is observed tight the two mounting screws on the insulator. Every time the screws are tightened flushing assembly is to be trued with the help of dial gauge.

16. Lubrication of Ballscrews.

17. Check the bearing in the lower idler roller. If bearing is found faulty replace the same.

18. Clean the E/W connections & check terminals for loose connections.

19. 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.

20. Lubrication of L.M. Guides of X, Y, U, V & Z axes. Use CENTOFLEXLDS 18 Special for lubrication.

21. 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

22. Water in the P.F unit. 23.Clean solenoid valve diaphragm. 24. Mounting nuts of the pump &

brackets.

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LUBRICATION SYSTEM

A manual centralized lubrication system is provided on the machine for lubrication of X, Y, U, V and Z axis Ballscrews and LM Guide shoes.

Operate the lever of hand pump 2-3 times Carry out the lubrication once in a month Schematic diagram : Refer figure no. 4.1 (page no. 24-B ) Part list : Refer page no.24-C

TECHNICAL DATA : Lubrication pump : Hand grease pump Cenlub make H-600-6 Capacity of lubrication pump : 1 Kg. Liquid grease : NLGI grade 00/000 ( Fuchs make Renolit LZR 000 or by ITW make OMEGA-77. Used under Licence by Magna Industrial Co. Ltd. ) NOTE : Refilling of the liquid grease is to be done periodically, if the level of the liquid grease goes down. Ensure that the liquid grease is pure and doesnt contain any contamination.

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FIG

. NO

. 4.1

PART LIST

S.N ITEMCODE DESCRIPTION QTY.

1 74150401027 HAND GREASE PUMP CENLUB MAKE H-

600-6

1

2 53110200000 SUPER FLEXIBLE NYLON TUBE 6 OD X 4 ID

10 M.

3 74343100009 5 WAY JUNCTION 5

4 53110230028 4MM TUBE NYLON CENLUB MAKE 20M

5 55200020000 METERING CARTRIDGES D1-0.16CC (CENLUB)

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6 74343100011 M6X0.75 BANJO ASSLY. FOR DIA 4MM TUBE

20

7 55200500001 0001IAL BANJO M6X DIA 4 5

8 55200060000 PLUG M10 X 1 8

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CHAPTER 5 INSTRUCTIONS FOR OPERATOR REGARDING SETTING UP

AND OPERATION THE MACHINE

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 job of maximum size refers 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 15 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.

Workpiece mounting

The worktable can handle the workpiece of maximum size as mentioned

in the specifications. Heavier workpiece 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

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the job stands and bridges to ensure proper electrical contact.

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 are in OFF condition. Gap voltage meter shows Nil voltage. Gap current meter shows nil current. Conductivity of dielectric fluid is shown on it's meter.

INTERCONNECTIONS

Seven cables are required for 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 stabiliser is must for this

machine. Check output voltage of stabiliser, for specifications of stabiliser

Chapter 2.

CHECK THE FOLLOWING

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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.

Check deioniser by pressing the switch, Meter reading will decrease towards zero. It may not reach up to zero.

PREPARATION FOR MACHINING

1. Selection of wire :-

Use brass wire specified by M/s. Electronica, 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 :- (MANUAL)

Wire threading is to be done as per the procedure given below -

a) Mount the wire reel on its shaft so as to unspool 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) Do not touch the wire or any part of the wire feed mechanism,

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during machining since all are electrically live.

3. Wire tension and wire feed rate

The wire tension is to be adjusted according to the workpiece 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.

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

pipe that is fixed to the tank emerges into the tank of filtration unit

between the cutout of 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 already usually low flushing pressure is selected.

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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 / cm . The function of the deioniser is to reduce the conductivity of dielectric fluid

through the ion exchange reaction of resin.

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

Conductivity higher than the set higher value.

Add distilled water or change the resin in deionizer if the resin is tending to become inactive.

Conductivity lower than the set lower value.

Add tap water.

CHAPTER 6

MORE INFORMATION ON WIRE DRIVE SYSTEM WITH AUTOMATIC WIRE THREADING.

1.1WIRE DRIVING SYSTEM Wire supply & control parts 1. Wire supply part consists of real shaft for mounting wire electrode & a

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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.

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No. Name Functional description

1 Wire Electrode --

2 Wire Reel locking Nut Locking wire reel on the shaft, done by turning nut in clockwise direction.

3 Wide Roller Guidance of wire from wire electrode

4 Wire Guide Roller Wire is passed through a couple og roller without going separation.

5 Feeding Pulley

Including a power brake adjusting tension applied on wire, a DC geared motor controlling direction of revolution of feeding pulley, & a rotary encoder detecting speed of revolution of feeding pulley.

6 Flat Belt Stirring tension pulley, needs periodic cleansing because its worn out during long time use.

7 Tension Pulley

Tension is generated by inserting wire between 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.

10 Wire Detecting Spring

In operating mode of AWT, increases the probability to accomplish AWT by feeding up & down detecting the contact of wire on spring resulted from wire bending.

1.2 Wire Guide, Upper Part

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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

NO. Name Functional description

1 Upper guide block Upper wire guide body.

2 Seal guide -B Part for guiding wire to connect on conducting pin.

3 Front guide block Front guide block has internally revolving ring, conducting pin & seal guide.

4 Sleeve Guidance of seal guide holder.

5 Seal guide pin A pin fixing seal guide, marks a contact of wire with conducting pin in AWT mode, makes it easy to thread wire.

6 Dust cap Cap protecting invasion of impurities.

7 Indexing ring

A ring to turn conducting pin easily by hands, engraved index numbers on it help operator to identify the rotary position avoiding duplicates of abrasive grooves resulted from electrically discharging during long time use.

8 Conducting ring

Electric power is transferred to wire through this device. Due to its consumptive property, turn its rotary position of contacts to 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.

24-C

10 Upper wire guide Diamond dies guide)

A guide to support the correct position of wire has to change to 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.

12 Double nozzle (Ext.) A nozzle for flushing water jet, can be changeable to the shape of work piece to be machined.

13 Double nozzle (Int.) A nozzle for flushing water jet, can be changeable to the shape of work piece to be machined.

14 Knock cylinder

A cylinder driving seal guide holder, in AWT mode, makes it easy to thread wire by maintaining the concentricity of diamond dies guide & seal guide.

15 Guide block screw

A screw supporting upper wire guide (Diamond dies guide ) if 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.

18 Connecting pin locking screw

A screw locking conducting pin. If you rotate or replace conducting pin, unlock by rotating screw in counter clockwise with wrench.

1.3 Wire guide lower part

24-C

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.

NO. Name Functional description

1 Double nozzle (Ext.)

2 Double nozzle (Int.)

A nozzle for flushing water jet can be changed as per shape of workpiece to be machined.

3 Guide approach. Guidance of wire introducing into lower part, & prevention from spreads of water jet in AWT mode.

4 Lower wire guide Diamond dies guide)

A guide to support the correct position of wire, has to change to 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.

6 Upper nozzle cap A nozzle cap for water jet. In machining, its recommended to minimize a gap between workpiece & this cap.

7 Lock nut Locking nozzle cap in operation of machine

8 Front guide block Front guide block has internally revolving to conducting pin,& seal guide.

9 Conducting pin (Current Pickup)

Electric power is transferred to wire through this device. Due to its consumptive property, turn its rotary position of contacts to index number (1/8 revolution), or if you use up all position, replace it with new part.

24-C

10 Indexing ring

A ring to turn conducting pin easily by hands Hands, engraved index numbers on it help operator to identify the rotary position avoiding duplicates of abrasive grooves resulted from electrically discharging during long time use.

11 Sleeve Guidance of seal guide holder.

12 Seal guide pin A pin fixing seal guide, makes a contact of wire with conducting 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.

16 Knock cylinder

A cylinder driving seal guide holder, in AWT mode, makes it easy to thread wire by maintaining the concentricity of diamond dies guide & seal guide.

17 Lower guide block Lower wire guide body.

24-C

1.4 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.

NO. Name Functional description

1 Lower roller ,ceramic roller big

Together with pinch roller, feeds wire to the caps of wire feeding drive located on the backside of machine when wire arrives at the capstan of wire feeding drive, this part rotates slipperily by one way clutch.

2 Pinch roller Pushing lower roller by elasticity of spring.

3 Guide path insulator Part for insulating & supporting guide path.

4 Guide path

A guide transferring the wire passed through lower wire feeding roller to the backside of machine by transition of wire by 90.This part is insulated to detect the signal of wire arrivals in AWT mode.

5 Air nozzle

Wire is smoothly transferred to the backside of machine by the air stream generating inside nozzle through wire approach pipe.

6 Wire approach pipe This pipe is a path of wire from lower roller to capstan roller of wire feeding driver on the backside of machine.

7 Front plate A flange of lower part of wire feeding system.

24-C

8 Insulator front Lower housing is insulated from lower arm by this part. & should be cleaned periodically.

9 Arm A part fixing & supporting lower wire guide part.

10 Spring locator

A bolt for adjusting the pushing force of pinch roller. In the case of separation of wire from this, loose the bolt to the reduce the force by turning the bolt in counter clockwise direction.

11 Flat belt

Drives lower rollers together by connecting the axis of lower roller & the capstan roller of wire feeding driver on the backside of machine.

1.5 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.

24-C

NO. Name Functional description

1 Wire approach pipe This pipe is a path of wire from lower roller to capstan roller of wire feeding driver on the backside of machine.

2 Wire feeding roller (pinch roller)

Wire is winded tightly by two feeding rollers (main capstan & pinch roller). A long time use causes a dirty surface on it, so should be cleaned regularly.

3 Spring block This part forces pinch roller to be pushed by main roller, with 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.

6 Flat belt. Revolves lower roller by connecting the axis of lower roller & the axis of feeding roller of wire driving part.

7 Adjustable roller. A roller keeping the tension of flat belt by elasticity of spring. 1.6 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

24-C

automatic wire threading (abbr. AWT)

NO. Name Functional description

1 Cutter dies holder

This part fixes one end of detecting spring. In AWT mode, its possible to adjust the shape of cutting edge of wire & the time 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.

MAINTENANCE & CHECKING ITEMS FOR WIRE DRIVE SYSTEM Items to check daily when starting & ending machining.

24-C

No. Item to check Contents to check Details

1 Lower arm & seal plate cleaning (when ending machining

Upper & lower guide block.

2 Work tank Remove wire chip & machining chip in the work fluid supplying unit.

3 Nozzle checking

1. Check whether there are injuries or cracks at tip of upper & lower nozzle surface. 2. If work fluid leaks out, it results in breaking the wire due to lower pressure.

4 Dust box checking

1. Check the amount of wire in dust box. 2. The dust box is usually full of wire after

about 25 hours of machining. So remove wire in case of long time machining.

5

Conducting pin checking.

It is worn away in about 25 hours in case of first cut. Check remaining time in the consumptive parts display. It results in breaking the wire & decreasing machining speed.

6 Amount of work fluid checking.

Check the fluid surface level of work fluid supplying unit. If not enough, supply work fluid.

7 The dielectric value of work fluid checking.

Check that the dielectric value is in the range of display.

8 Automatic wire threading checking.

Check that error or warning occurs under automatic wire threading in the air. If error occurs or same warning occurs continuously more than three items, check unit referring to section 4

9 Cutting wire operation checking Checking whether error or warning occurs when cutting wire.

24-C

Trouble shooting Wire is broken frequently Position Cause of broken wire Management

1

1. Cooling error due to blocking of cooling hole of upper dies guide.

2. Low touching pressure due to wear of upper conducting pin.

1. Clean upper dies guide with rust remover. If needed remove dust in hole with needle.

After fixing dies guide, detect wire squareness.

2. Check upper conducting pin, & then change the position or replace it.

2 1. Detecting machining gap error due to conducting pin wear.

Check the wear of upper conducting pin.

3 1. Insufficient work fluid in upper nozzle. Increase the pressure of upper

fluid jet.

4

1. Cooling error due to blocking of cooling hole of lower dies guide.

2. Lower touching pressure due to wear of lower conducting pin.

3. In case of JW60A/JW120A,lower moving pin malfunction

1. 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.

2. Check lower currant pick up & then change the position or replace it.

For details refer maintenance & check data.

3. Check operation of actuator & clean it.

For details refer maintenance & check data.

24-C

ITEMS TO CHECK WEEKLY.

No. Item to check Contents to check Details

1 Wire guide block clean.

Clean upper & lower wire guide block with weak acid.

Clean lower wire guide block approach dies with weak acid.

After cleaning & assembly ensure proper forward & backward motion of seal guide pin .Automatic wire threading may fail because of it.

2 Cooling water drain hole cleaning.

Pump air in to hole. If there is not enough cooling water, supply it.

It results in breaking the wire at current pick up unit.

3 Current pick up check.

Change the position at every 25 hours. It results in breaking the wire &

decreasing machining speed.

4 Winding roller cleaning.

Clean wire winding roller. If black line is seen along the path of wire, clean it with rust remover.

It results in extrusion of wire in work tank.

Clean ceramic roller big & small.

5 Air pressure control unit checking.

Draw water from air unit using drain valve.

If the water soaks into air cylinder it results in malfunction or failure.

6 Machine origin restoring.

Restore machine origin of X, Y, Z axis. It may happen that true machine origin

and the coordinate of NC or different after long time machining.

24-C

7 Wire tension is too high.

Check whether wire is twisted or crossed so that wire does not get loose.

If lower roller rotation is bad call Electronica.

TROUBLE SHOOTING STOP DUE TO BACK DATA ZERO

THE ERROR IS NOT RECOVERED AFTER TRACK BACK CHECK THE FOLLOWING

IS START HOLE SMALL CURVED OR DEVIATED SO THAT WIRE & WORK ARE TOUCHED?

MOVE WIRE WITH JOB UNDER SPARK. IF VOLTAGE IS NOT ZERO. RESTORE THE WIRE TO ORIGINAL POSITION AND RERUN NC

IS THERE WIRE CHIP IN START HOLE?

ARE WIRE AND WORK TOUCHED BECAUSE START HOLE IS TOO SMALL & JET PRESSURE IS TOO STRONG?

TURN ON SPARK & LOWER JET PRESSURE IF SPARK IS NOT OPERATIVE LOWER WT. IF SPARK STARTS INCREASE WT & JET PRESSURE TO ORIGINAL

DOES WIRE EXTRUDE IN WORK TANK

NO

NO CUT WIRE AND RECONNECT IT AND THEN RERUN NC.

YES

NO

NO

YES

YES

REMOVE WIRE CHIP & RERUN NC

YES

24-C

NO YES

DOES THE WIRE TOUCH MACHINE IN WIRE COLLECTION BOX OR WINDING ROLLERS?

YESPUT WIRE IN WIRE COLLECTION BOX & RERUN NC. IF NEEDED CUT WIRE & RECONNECT IT & THEN RERUN NC.

THE MACHINE IS NORMAL. RESTORE WIRE TO START HOLE & RECONNECT IT & CHECK ABOVE THINGS UNDER SPARK

WHEN SPARK STARTS AFTER CUTTING WIRE & RECONNECTING IT OUT SIDE OF WORK, IS THE VOLTAGE ZERO?

YES

CALL A/S CENTER OF JINYOUNG

24-C

24-C

ELEKTRA

FLOOR PLAN

PUMP FILTER

HT.= 1300

MACHINE TOOL

HT.= 2300

GEN.

HT.= 2000

WIRE COLLECTION

BOX

WIRE FEED

ASSLY

1205 1700

3680

1200

250

100

ULT

RA

CU

T F

2

165

950

600

650

WT.

400

0 K

g

D:0

2:22

1:07

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RAT

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10

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460

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420

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300

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DIT

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TEM

P. T

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20

1

C

*

4600

4200

1950

*

X = 1800 FOR DL35

X = 1575 FOR DL25

ALL

DIM

EN

SIO

NS

AR

E IN

MM

.

1000

700

1900

FIG.NO.: 1

24-C

75(T

YP.

)10

0 (T

YP.

)

180

600

475

85 930

1435

115

1100

75X75X20 MS PLATE 6 NO,S

INSTRUCTION:-THE FOUNDATION BLOCK TO BE

CASTED ON THE RABBLE

G.L.

MACHINE BASE

ELEK

TRA

FOU

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ATI

ON

DET

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SU

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FIG

. NO

.: -2

24-C

ELEK

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FIG

. NO

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24-C

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FIG

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.: -4

24-C

NOTE : ALL DIMENSIONS ARE IN MM

TRANSPORT LOCK X

TRANSPORT LOCK Y

ELEK

TRA

TRA

NSP

OR

T LO

CK

X &

YU

LTR

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f-2

FIG

. NO

.: -5

24-C

TRANSPORT LOCK-V

2 NO,S

TRANSPORT LOCK-U

4 NO,S

TRANSPORT LOCK Z

ELEK

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f-2

FIG

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24-C

10

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213

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7301

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3 412

1XX

6 875

1 4111 111

4120

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SR.NO.

ITEM CODE

11

QTY.

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24-C

ULT

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11 11

QTY

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9XX

4121

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8XX

4121

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6XX

4121

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4121

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1 111 1141

2104

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ASS

EMB

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AW

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8

24-C

ELEKTRA

SR.NO.

ITEM CODE

DESCRIPTION

14121241012X

GUIDE BLOCK

24121241024X

GUIDE HOLDER

34121241033X

JOINT

44121241044X

GUIDE BLOCK SCREW

54121241053X

JET NOZZLE

64121241063X

NOZZLE CAP

74121241074X

RING

84121241084X

PIN HOLDER

94121241094X

SLEEVE

104121241114X

RING

114121241123X

GUIDE BLOCK

124121241134X

RING

134121241144X

NOZZLE UPPER

144121241154X

NOZZLE UPPER

154121241164X

SEAL GUIDE HOLDER

164121241174X

UPPER WIRE

174121241184X

GUIDE

184121241194X

APPROACH UPPER

194121241214X

CARBIDE CURRENT PICKUP

ULTRACUT f-2

1

2 34 1413 7651016

11917

818 15

1219

UPPER FLUSHING ASSEMBLY

(AWT)

FIG.NO.:-9

24-C

ELEKTRA

SR.NO.

ITEM CODE

DESCRIPTION

14121241084x

PIN HOLDER

24121241094x

SLEEVE

34121241134x

RING

44121242174x

LOWER FLUSH. NOZZLE

54121242184x

NOZZLE CAP

64121241184X

GUIDE

74121241214x

CARBIDE CURRENT PICKUP

84121242013x

GUIDE BLOCK (L.F.)

94121242034x

LOCK NUT

104121242044x

SEAL GUIDE HOLDER

114121242054x

GUIDE BLOCK (LOWER)

124121242064x

JOINT

134121242074x

RING

144121242083x

LOWER WIRE GUIDE

154121242094x

WIRE GUIDE

164121242114x

GUIDE APPROCH

174121242124x

WIRE GUIDE

18GRUB

ULTRACUT f-2

12

3 7

45

6

89 10

11

121314

15

16 17

18

LOWER FLUSHING ASSEMBLY

(AWT)

FIG.NO.:-10

24-C

SR

.NO

.IT

EM

CO

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SC

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FIG

. NO

.: -1

1

24-C

SR.NO.

ITEM CODE

DESCRIPTION

14121241001X

UPPER ASSLY.

24121242001X

LOWER ASSLY.

34121944001X

ARM ASSLY.

44121031001X

WIRE FEED ASSLY.

54121230001X

WIRE DRIV

E ASSLY.

64121243001X

AWT ASSLY.

1 2 3

5

6

4

ELEK

TRA

WIR

E G

UID

E SY

STEM

ULT

RA

CU

T f-

2

FIG

. NO

.: -1

2

24-C

S.NO.

ITEM CODE

DESCRIPTION

14120730503X

BELT ROLLER COMP.

24120739003X

WIDE ROLLER ASSLY.

34121231003X

CLUCH ROLLER ASSLY.

44121232003X

SPOOL ASSLY.

54121233003X

IDLER ROLLER ASSLY.

64121234003X

W AXIS ROLLER

ASSLY.

7WIRE SPOOL

84121034003X

WIRE TENSION ASSLY.

16

8

5

7

4

32

WIR

E D

RIV

E SY

STEM

(SA

WT)

ELEK

TRA

ULT

RA

CU

T f-

2

FIG

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.: -1

3

24-C

X X

SR

NO

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RIP

TIO

NQ

TY

141

2124

1194

03

241

2124

2094

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341

2124

3013

01

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2124

3024

01

541

2124

3034

01

641

2124

3044

01

741

2124

3054

01

841

2124

3064

01

941

2124

3073

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1041

2124

3084

03

1141

2124

3094

01

1241

2124

3114

01

1341

2124

3124

01

1441

2124

3132

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1541

2124

3143

01

1641

2124

3154

01

1741

2124

3164

04

1841

2124

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01

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2124

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2124

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2124

3214

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2241

2124

3403

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2341

2124

3603

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2441

2124

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2550

3000

0001

62

2672

0600

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31

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1401

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CAS

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WIR

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JEC

T PL

ATE

WIR

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UID

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0.6M

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WT

MO

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TIN

GA

WT

MO

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T P

LATE

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ULA

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SU

LATO

R B

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HU

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UPP

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RLA

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AIR

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RAD

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BRG

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UPP

ERW

IRE

GU

IDE

DE

SC

RIP

TIO

N

4 6

7

8

9

11

15

18

19

21

23

SECTION X-X

1

2

3 5

10

12 1

3

14

16

17

20

22

24

25

26

ELEK

TRA

AW

T A

SSEM

BLY

ULT

RA

CU

T f-

2

FIG

. NO

.: -1

4

24-C

WORK PIECE

ULTRACUT f-2JOB CLAMPINGELEKTRA

CLAMP WITH SCREWS

CLAMPING OF JOB

FIG. NO.: -15

24-C

JOB

WORK TABLE WITH MAXIMUM SIZE MOUNTED

ELEK

TRA

WO

RK

TAB

LE L

AY

OU

TU

LTR

AC

UTf

-2

FIG

. NO

.: -1

6

24-C

FIG. NO.: -17ULTRACUT f-2WORKTABLE LAYOUT-1ELEKTRA

JOB SUPPORT

BRIDGE MOUNTEDWORKTABLE WITH FIXED AND MOVABLE

ALL DIMENSIONS ARE IN mm

24-C

SPRINTCUT f-1WORKTABLE LAYOUT-2ELEKTRA

WORKTABLE WITH MAXIMUM SIZE JOB MOUNTED

ALL DIMENSIONS ARE IN mm

FIG. NO.: -18

24-C

JOB SUPPORT

ULTRACUT f - 2WORKTABLE LAYOUT-3

WORKTABLE WITH SMALL JOB MOUNTED

ELEKTRA

ALL DIMENSIONS ARE IN mm

FIG NO.19

ULTRACUT F2 OPERATING & MAINT.MANUALINDEXINTRODUCTIONPREPARATION, TRANSPORTATION & INSTALLATIONMECH.COMPONENTSMAINTENANCESETTING UP & OPERATION OF THE SYSTEMWIRE DRIVE SYSTEM WITH AWT