Operating Manual

For
Pulse Generator : ELPULS 55 Series

Product : eNova Series

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
 Table of Contents
1 Operations ....................................................................................................................... 1
2 Manual Operation Modes .............................................................................................. 4
2.1 Main mode: (Alt + F1) .................................................................................................................. 4
2.2 Job-Set Mode (Alt + F4) ............................................................................................................... 5
2.2.1 EF Mode (F1)................................................................................................................... 6
2.2.2 CF Mode (F2)................................................................................................................... 6
2.2.3 3PTCF Mode (F3) ............................................................................................................ 6
2.2.4 AlignEF Mode (F4) .......................................................................................................... 7
2.2.5 AlignCF Mode (F5) .......................................................................................................... 7
2.2.6 AWV Mode (F6) ............................................................................................................... 8
2.2.7 EFVolt (F7) ...................................................................................................................... 8
2.2.8 SLimit (Soft Limit) (F9) .................................................................................................... 8
2.3 Dry Spk mode: (Alt + F5) ............................................................................................................. 8
2.4 Coord Mode ( Alt + F6 ) ............................................................................................................... 9
3 Automatic Operation Modes........................................................................................ 10
3.1 Set M/c Mode (Alt + F7)............................................................................................................. 10
3.2 Run Mode (Alt + F8)................................................................................................................... 10
3.3 Status Mode (Alt + F9)................................................................................................................ 11
3.4 Setup mode (Alt+F10)................................................................................................................. 12
4 Programming Instructions........................................................................................... 14
4.1 Motion Program for A CNC Machine......................................................................................... 14
4.2 Structure of a NC Program.......................................................................................................... 14
5 List of messages ............................................................................................................. 19
5.1 Simulator's Messages. ................................................................................................................. 19
5.2 Controller's General Messages .................................................................................................... 19
5.3 M/c Referencing messages:......................................................................................................... 25
5.4 Submerge Messages: ................................................................................................................... 26
5.5 Large Program Downloading Messages:..................................................................................... 26
5.6 Messages related to password during password setting: ............................................................. 26
5.7 Messages related to password at the time of initialization: ......................................................... 27
5.8 Messages related to user password:............................................................................................. 27
5.9 AWT operation Messages: .......................................................................................................... 27
5.10 Rotary axis Messages: ................................................................................................................. 29
5.11 Software Installation Messages: .................................................................................................. 29
6 Short Keys...................................................................................................................... 30
7 Terminologies used in Simulation ............................................................................... 31
8 Installation Procedure of eNovaCNC.......................................................................... 32
8.1 Before starting installation .......................................................................................................... 32
8.2 Installing First Time on System .................................................................................................. 33
8.3 Install from CD-ROM ................................................................................................................. 33
8.4 Install from System ..................................................................................................................... 33
8.5 Installation Procedure.................................................................................................................. 33
8.6 Installation Steps ......................................................................................................................... 34
9 How to get and send Machine ID and Machine number........................................... 37
9.1 Get Machine ID from Command Prompt.................................................................................... 37
9.2 Machine ID from eNovaCNC application................................................................................... 39
9.3 How to Set Password to eNovaCNC ........................................................................................... 41

Note: This Manual provides guidance in brief for the operations of eNovaCNC. It should be
used in conjunction with eNovaCNC On-line or Off-line Help.

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 1 Operations

This chapter introduces you to the controller of ELEKTRA Wire EDM machine. You can
interact with the machine either through the Machine Control Panel or through keyboard &
mouse attached with the controller. The machine will interact with you with the help of the
display. The display is situated at the top of the interface panel. It shows the status of all
the operations taking place on the Machine tool.

It Contains topics such as

1. Getting Started

2. Screen Layout

The entire screen is divided into following areas.

A. Menu & Toolbar Many operations can be performed using them.

B. Profile Display Area Profile display is the area where user can get the
profile of currently downloaded program to controller
C. Coordinates Displays Actual and Go to coordinates as well as Voltage
and current during execution of the program.
D. Status Display Area Displays status parameters, position & flags.
E. Block display Display executing block while running the program
F. Message & alarm Here controller will display the messages, warnings and
errors
G. Function key panel To perform function on CNC operations
H. Status Bar Display Status bar is the bottommost area of the screen to display
status information of the program and Machine.

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 Figure 1-1 Main Screen Layout

The function key Panel is divided into two parts. The function keys displayed in first row
are used for selecting main modes like Manual, Job-Set, Run, Status, Setting etc. After
selecting main mode corresponding submenus are displayed in second row.

The main mode functions or sub menu functions can be selected directly by clicking
mouse button or using touch screen, if available.
The same can be also selected using keyboard. The main modes can be selected using
combination of ALT key + corresponding function key. E.g. to select Run mode press ALT
+ F8 and to select setting mode press ALT + F10 and so on.
The submenu can be selected by pressing the corresponding function key directly.

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The following are main modes.

Symbol Meaning Description

Main (Alt+F1) To do main functions like toggling of Wire Feed, Wire Tension,
Flushing etc, as well as auto cutting and auto threading of the
wire (Applicable for AWT machines)
Job-Set To carry out preparatory functions of job setting like Edge
(Alt+F4) Find, Center Find, Job Align etc.
Dry Spark To set the wire vertical in X and Y direction using auxiliary
(Alt+F5) axis U & V.
WCS (Alt+F6) To set co-ordinate systems for the job.
M/c Para To set machining parameters during sparking
(Alt+F7)
Run (Alt+F8) To execute the program in sparking or dry run and to set
various functions for the same.
Status To display status of the machine like co-ordinates, velocity,
(Alt+F9) Input/ Output status, G & M code status etc.
Setting To set machine related parameters, flags, pitch error
(Alt+F10) compensation, backlash compensation etc.
Motor Reset To reset all motors of the machine in the event of motor trip.
(Alt+F12) (Note : This menu do not have any submenu.)

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 2 Manual Operation Modes

<Manual> operation modes are the first available modes after loading the application.
<Manual> operations give you the functions required to perform machine commands of
jogging, machine referencing, switching ON/OFF conditions, etc. Following modes come
under manual operations:

¾ 2-1 Main mode

¾ 2-2 JobSet mode
¾ 2-3 DrySpk mode
¾ 2-4 Coord mode

2.1 Main mode: (Alt + F1)

Main mode includes function key set as follows
Function Key Set:

Symbol Meaning Description

Buzzer (F1) This key is used to toggle [Buzzer] flag ON/OFF.
Contact (F2) This key is used to toggle [Contact] option ON/OFF.
Cut (F3) This key is used to cut the wire. (Only for AWT Machines)
Thread (F4) This key is used to thread the wire. (Only for AWT Machines)
S-AWT (F5) This key is used to thread the wire manually through work-piece
and lower wire sense position
AWT (F6) This key is used to enable/disable the Auto Wire Threading
operation.
FillTnk (F7) This key is used to fill the tank with coolant.
DrnTnk (F8) This key is used to remove the coolant from tank.
Flush (F9) This key is used to switch the flushing system ON/OFF.
WFWT (F10) This key is used to switch the Wire feed and Wire tension
ON/OFF.
Halt (F11) This key halts the current operation.

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 In Main mode, Jog Mode dialog is displayed as shown below.

From this dialog user can do the Jogging, Machine referencing, Jog Zero & Prejog
operations.
2.2 Job-Set Mode (Alt + F4)
Work-piece used in manufacturing has to be referred either from an edge or from center of
a hole. Function of <JobSet> mode is to find the edge of the work-piece or the center of
the hole. <EFCF> stands for EDGE FIND and CENTER FIND Operation Before
machining; one also needs to make the Wire exactly vertical. Auto Wire Verticality facility
(abbreviated as [AWV]) is also provided in the same mode. This mode also provides
Work-piece Rotation angle calculation mode. (As AlignEF, AlignCF)

Common Functions for Job Set mode.

Symbol Meaning Description
Set (F8) To set the coordinates of current WCS to any value.
Zero (F9) To set the coordinates of current WCS to zero.
Prmtr (F10) This key pops up a dialog that lets you to set the edge find
Mode (Fast / Slow).
Halt (F11) To stop the selected operation.
Prev (F12) This key is used to switch to the Job-Set mode key set.

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2.2.1 EF Mode (F1)

This function is used to find and set edge reference for the Work-piece
EF Function Key Set:

Symbol Meaning Description

EF (F1) To find Edge along the path in the direction of selected angle.
Corner To find Corner along with the width of selected edge and set
Find(F2) the coordinates of current WCS to any value.
Slot Find (F3) To find slot along with the edge.
Set Half (F7) This function key is used for HALF FUNCTION. This key is
used to make axis coordinates half of their current value.

2.2.2 CF Mode (F2)

This function is used to find and set center reference for the Work-piece
CF Function Key Set:

Symbol Meaning Description

CF (F1) To find center along the direction and angle selected in
Center Find Angle selection dialog.
Ext CF(F2) To Find external center along with the job width.
Slot Find (F3) To find slot along with the edge.

2.2.3 3PTCF Mode (F3)

This function is used to find and set center of round work-piece by checking 3 points
on the circumference.
3 Pt. Center Find Function Key Set:

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Symbol Meaning Description
EF1 (F1) To find Edge-1 along path in the direction of selected angle.
EF2 (F2) To find Edge-2 along path in the direction of selected angle.
EF3 (F3) To find Edge-3 along path in the direction of selected angle.
GoCntr (F4) Jog to the calculated center find position.

Align Mode

This mode is used to calculate and set work piece rotation angle. After aligning the job,
the CNC rotates the coordinate system as per align angle. The subsequent actions of
machine movement, sparking, job setting takes place according to set angle.
You can align the job (and hence coordinate system) using edge reference or center of
two holes. When using edge reference for job aligning, you can also use dial gauge.

2.2.4 AlignEF Mode (F4)

AlignEF Function Key Set:

Symbol Meaning Description

Point1 (F1) To find Edge-1 along the path in the direction of selected angle.
Point2 (F2) To find Edge-2 along the path in the direction of selected angle.
Auto Align To find two points at specified distance and set the align angle.
(F3)
ALIGN (F4) To make the Align ON / OFF.
DIAL (F6) Use to find the Align angle by using Dial without doing edge find
operation.

2.2.5 AlignCF Mode (F5)

AlignCF Function Key Set:

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Symbol Meaning Description
CF1 (F1) To find Center-1 along path in the direction of selected angle.
CF2 (F2) To find Center-2 along path in the direction of selected angle.
ALIGN (F4) To make the Align ON / OFF.

2.2.6 AWV Mode (F6)

A dialog has been displayed for AWV mode, which contains mode selection for following
three operations
¾ AWV Mode: To make the wire vertical
¾ AWV-Jig: To make the wire vertical
¾ Guide Span and Worktable Height Calculation: To calculate the Guide span &
Worktable height.

2.2.7 EFVolt (F7)

EFVOLT key is used to select high or low voltage for spark during JobSet &
Dryspark Operation.

2.2.8 SLimit (Soft Limit) (F9)

SLIMIT is used to set software over travel limits for X & Y axis.

2.3 Dry Spk mode: (Alt + F5)

This mode is used for making the wire vertical with the help of verticality block so that
during cutting the sparking will be uniform along the work-piece height. If required you can
also make wire parallel to work-piece surface.
Dry spark mode includes function key set as follows

Symbol Meaning Description

X+ (F1) To find edge on X axis in positive direction.
X- (F2) To find edge on X axis in negative direction.
Y+ (F3) To find edge on Y axis in positive direction.
Y- (F4) To find edge on Y axis in negative direction.
U+ (F5) To move U axis in positive direction.

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 U- (F6) To move U axis in negative direction.
V+ (F7) To move V axis in positive direction.
V- (F8) To move V axis in negative direction.
Prmtr (F9) This key pops up a dialog that lets you to set the WF, WT &
Jstep parameters
EFVolt (F10) EFVOLT key is used to select high or low voltage for spark
during Job-Set & Dryspark Operation.
Halt (F11) To stop the Dry spark operation.

2.4 Coord Mode ( Alt + F6 )

This mode is used for setting co-ordinates for the work-piece.
Coord mode includes function key set as follows

Symbol Meaning Description

G54 (F1) To select First Work Co-ordinate System.
G55 (F2) To select Second Work Co-ordinate System.
G56 (F3) To select Third Work Co-ordinate System.
G57 (F4) To select Fourth Work Co-ordinate System.
G58 (F5) To select Fifth Work Co-ordinate System.
G59 (F6) To select Sixth Work Co-ordinate System.
SET (F8) To set the coordinates of current position to any value for
selected WCS.
ZERO (F9) To set the coordinates of current position as Zero position for
selected WCS.
Halt (F11) To Halt operation.

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 3 Automatic Operation Modes

3.1 Set M/c Mode (Alt + F7)

Set M/c mode includes following options as follows
¾ TON Pulse ON time setting
¾ TOFF Pulse OFF time setting
¾ IP Fine Pulse & Power Pulse setting
¾ VP To set Pulse peak voltage
¾ WP To set Submerge mode & Dielectric pressure
¾ WF To set Wire Feed Rate
¾ WT To set Wire tension
¾ SV To set Spark gap reference voltage
¾ SF To set Servo Feed Rate
¾ CC% To set Corner control
¾ CS % To set cutting speed override
¾ CDwell To set Corner dwell
¾ SC To set the Conductivity value

3.2 Run Mode (Alt + F8).

Run mode is used to check the loaded profile by Dry run facility and to cut the profile.
Run mode includes two-function key set as follows
Function Key Set 1:

Symbol Meaning Description

Start (F1) To start the cutting or Dry run of the programmed job.
Dry (F2) To switch the Dry run facility ON/OFF.
Step (F3) To switch the STEP Mode ON/OFF.
Hold (F4) To hold all the axes those are moving in Sparking mode.

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 MidStart (F5) To switch the Mid-start mode ON/OFF
PreSpk (F6) To switch the Pre Spark mode ON/OFF.
MDI (F7) To execute single line program.
Abort (F8) To stop the sparking & execution of program.
Noman (F9) To switch on Noman level.
Go to Start Move to the start point of cavity.
Point (F10) :
Halt (F11) To halt running program.
Next (F12) To go to function key set 2

Function Key Set 2:

Symbol Meaning Description

Skip / (F1) To switch the Skip facility ON/OFF.
OStop (F2) To switch the program stop functionality ON/OFF at M01.
F% (F3) To override the Dry run feed in terms of percentage.
Set (F4) To set the origin of active WCS.
Zero (F5) To set the selected WCS to ZERO.
Timerst (F6) To reset the timer, that counts the machining time.
Align (F7) To switch Align Mode ON/OFF
Halt (F11) To halt running program.
Prev (F12) To go to function key set 1

3.3 Status Mode (Alt + F9)

This mode displays the current status that includes various flags, G and M codes that are
active while the program is running. Status mode includes function key set as follows
Function Key Set:

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Symbol Meaning Description
GMCODE This screen displays all the G and M codes. Currently active
(F1) or executing codes are highlighted and all others are
displayed in normal intensity. This helps user to note the
status of various codes at a glance.
FLAGS (F2) The flag status screen displays ON/OFF state & values of
various controls, functions & parameters
IOSTAT (F3) The Input and Output line status is displayed port-wise in this
screen. This is used mainly for the diagnostic and
troubleshooting purpose.
DIAG (F4) DIAG screen describes the current position in terms of
ABSOLUTE MACHINE coordinates. It displays origin of
currently active WCS. It also displays the actual, commanded
and “GOTO” coordinates of all axes. In addition it shows
following error and Velocities of X, Y, U, V, Z and W axes.
Maintain (F5) Maintain screen displays routine maintenance required for
P.F.Unit.
CONSUM (F6) Consumables screen shows Total & Remaining life of
consumable components of the M/c.

3.4 Setup mode (Alt+F10)

The Setup mode allows you to set various machine related parameters.
Setup mode includes function key set as follows

Symbol Meaning Description

USER (F1) This key allows User to set/ Modify the machine related
parameters and flags.
Fact. (F2) This key allows Service Engineer to set the machine related
parameters and flags

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 U-Pass (F4) Used to set the user password for Editor, User Setup, User
Technology and Machine Condition.
If password is applied for editor then to save the program you
have to enter the password.
If password is applied for any of the remaining operating modes
then to edit and save the parameters of that mode you have to
enter the password otherwise no changes can be applicable.
PERR (F5) This is the table provided for setting the values, which can be
used for Pitch Error compensation.
Pass. (F6) To set the password. (Refer chapter “Machine ID generation
procedure” while setting password)
Default (F7) Load the default parameter given from Factory. After pressing
this key all user parameter gets overwrite.

Factory setup contains the parameters, which are set in Factory. User is not allowed to
change these parameters.
User Setup and factory setup contains following key set:

Symbol Meaning Description

MOTOR (F1) Motor setup values are factory set, and they should not be
changed unless there is a change in hardware or any other
major modifications. User is not supposed to change these
values.
MCH (F2) This mode is to set the values concerned with machine tool.
FLAGS (F3) This mode is used to set the Flag in machine.
AWT (F4) This mode is used to AWT related parameters.

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 4 Programming Instructions

This chapter explains the CODES (or COMMANDS) used in creating the NC Program with
their applications and examples. It explains all the necessary terms and definitions that
are frequently used in connection with a NC program.
4.1 Motion Program for A CNC Machine
Computerized Numerical Control (abbreviated as CNC) machine understands a group of
commands, which are called motion codes or simply G-Codes and M-Codes. The
sequence of these commands in a particular syntax is called NC PROGRAM. This NC
PROGRAM changes with the size and shape of a Part to be cut. Hence it is also called
PART PROGRAM. The codes and commands of the NC PROGRAM are converted into
machine movements and/or settings inside the controller, which in turn produces the
component according to the NC PROGRAM. As the major function of this NC Program is
to maneuver the machine table movements it is also called MOTION PROGRAM. In this
manual the terms NC PROGRAM, PART PROGRAM and MOTION PROGRAM are used
interchangeably. This Manual explains all the G, M and E codes used in ELPULS-50
controller Mastering these codes and formats will help you to exploit the power of the
machine to the fullest extent.
4.2 Structure of a NC Program
Any NC Program is divided into number of Blocks. A BLOCK is further divided into number
of Words. A WORD is an ADDRESS (an ALPHABET from A to Z) followed by an
EXPRESSION or a VALUE (positive or negative) associated with it. A WORD can be
classified as CODE (or COMMAND) and PARAMETER. Any WORD with ADDRESS 'G' or
'M' or 'E' is treated specially as CODE. All other Words are treated as Parameters and are
used along with the Codes. Codes with similar functions are associated to form a GROUP.
A block cannot have two Codes from a same GROUP. In such a condition Group Clash
occurs and Error is generated. Some codes are STAND ALONE type of codes. Any Block
can contain one and only one Stand Alone code in it.
Two characters are treated very specially by the controller. They are '/' and ‘;'. Block
beginning with '/'will be skipped by the controller if the SKIP block feature is turned ON.
Any Text after ';' in a Block is always ignored by the controller, so that you can write your
own notes, comments after this. Part of a NC Program is shown below as an Example:
Program for cutting Die plate

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; Program for Die Plate
G54 ; Select Coordinate system no 1
G71; mm Mode
G9; Mirror Off
G27; Rotation Off
G75; Complex Profile Off
G40; Wire Compensation Off
G50; Taper Cutting Off
G90 ; Absolute Programming
D1=0.165; Store wire compensation in D1
G0 X0 Y0; Rapid Traverse
M0; Machine Stop
G1 Y5; Linear interpolation
G42 D1; Apply Wire Compensation on Right side of the path
G1 X5; Linear interpolation
G1 Y-5; Linear interpolation
G1 X-5; Linear interpolation
G1 Y5; Linear interpolation
G1 X0; Linear interpolation
G1 Y0; Linear interpolation
M2; Program End

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Table 4.1: List of valid addresses.

Address Used in G& M Range Remarks

A G51,G52 0-359.999 Taper Angle
G26 0-359.999 Rotation angle
B G74 Positive Height where Bottom Profile is defined.
D G41,G42 0-99 Wire comp. Offset value
E E Codes 1-99999999 Machining Conditions, E Code
G G Codes 0-103 Preparatory Code
I, J G2,G3 +99999.9999 Offset of center point from current position
L M98 1-99 Subroutine Loop count
M M Code 0-99 Machine Codes
P M98 1-999 Subroutine Program number
P G102,G103 +99999.9999 Offset of center point from current position.
Q G102,G103 +99999.9999 Offset of center point from current position.
R G48,G1,G2,G3 0.005-99999.9 MODALCorner radius rounding
0.005-99999.9 Corner radius for rounding at the end of
the block
T G4 0-99 Dwell in seconds
G74 Positive Height where Top profile is defined.
U, V G0, G100, G101, +99999.9999 Coordinates of the end point to be
G102,G103 reached.
G54 to G59 +99999.9999 Change the WCS Origin so that current
point has specified co-ordinates.
W G51,G52 Positive Programmed height
X, Y G0, G1, G2, G3 +99999.9999 Coordinates of the end point to be
reached.
G26 +99999.9999 Coordinates of the point about which to
rotate
G54 to G59 +99999.9999 Change the WCS Origin so that current
point has specified co-ordinates.
Z G51, G52, G74 Positive Z Height

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Table 4.2: List of G Codes, Short Summary

Gcode Parameters Effect, stand alone Group Application

0 XYUVZ Modal, Not Stand Alone A Rapid Traverse
1 XYR Modal, Not Stand Alone Linear interpolation
2 XYIJR Modal, Not Stand Alone CW circular interpolation
3 XYIJR Modal, Not Stand Alone CCW circular interpolation
4 T NonModal, Not Stand Alone Dwell Time in Seconds
5 NONE Modal, Stand Alone B X Mirror
6 NONE Modal, Stand Alone Y Mirror
8 NONE Modal, Stand Alone X-Y Exchange
9 NONE Modal, Stand Alone Cancel all Mirror or
Exchanges
95 NONE Modal, Stand Alone Simultaneous X-Y Mirror
96 NONE Modal, Stand Alone Cancel all Mirror and
Exchanges
22 NONE Modal, Stand Alone O Stored stroke Limits ON.
23 NONE Modal, Stand Alone Stored stroke Limits OFF.
26 XYA Modal, Not Stand Alone D Pattern rotation ON
27 NONE Modal, Stand Alone Pattern rotation OFF
40 NONE Modal, Stand Alone F W.D. Comp. OFF
41 D Modal, Not Stand Alone W.D. Comp. LEFT
42 D Modal, Not Stand Alone W.D. Comp. RIGHT
46 NONE Modal , Stand Alone P CRK Enable
47 NONE Modal , Stand Alone CRK Disable
48 R Modal, Stand Alone G Const. Corner radius ON
49 NONE Modal, Stand Alone Const. Corner radius Off
50 NONE Modal, Stand Alone H Taper cutting mode OFF
51 AWZ Modal, Not Stand Alone Taper cutting LEFT
52 AWZ Modal, Not Stand Alone Taper cutting RIGHT
54 NONE Modal, Stand Alone I Activate WCS No. 1
55 NONE Modal, Stand Alone Activate WCS No. 2
56 NONE Modal, Stand Alone Activate WCS No. 3

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Gcode Parameters Effect, stand alone Group Application
57 NONE Modal, Stand Alone Activate WCS No. 4
58 NONE Modal, Stand Alone Activate WCS No. 5
59 NONE Modal, Stand Alone Activate WCS No. 6
70 NONE Modal, Stand Alone J Dimensions in mm
71 NONE Modal, Stand Alone Dimensions in Inch
74 BTZ Modal, Not Stand Alone K Complex machining ON
75 NONE Modal, Stand Alone Complex machining OFF
90 NONE Modal, Stand Alone L Absolute Programming
91 NONE Modal, Stand Alone Incremental
programming
100 UV Modal, Not Stand Alone N Rapid traverse for UV
101 UV Modal, Not Stand Alone Complex Linear interpolation for
Cutting
UV table
Mode
102 UVPQ Modal, Not Stand Alone CW Circular interpolation
for UV table
103 UVPQ Modal, Not Stand Alone CCW Circular
interpolation for UV table

Table 4.3: List of M Codes, short summary

MCode Parameters Application

0 None Program stop

1 None Optional stop
2 None Program end
6 None Index the Rotary Table
20 None Cut the Wire
21 None Thread the wire
98 P,L Call subprogram
99 None End sub-program

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 5 List of messages

5.1 Simulator's Messages.

¾ McCond Table Not Found.
The specified machining condition given by E code does not exist. It has to be set,
saved and then can be used.
¾ Const R in arc-invalid.
¾ Code not allowed in MDI.
¾ Error in Z / W / B / T.
¾ Error Start Corner Rad.
¾ Error End Corner Radius.
¾ Error (CT xxxx).
¾ Corner Rad. too small.
¾ Complex Not Intersect.
¾ Addnl. Block Insert Fail.
¾ Error!!!
This error displays in following cases.
1. If stroke limit error occurs.
2. If Guide Span + Z height is less than or equal to worktable height for complex &
taper programs.
¾ Lxxx : CRK distorted original profile
Where Lxxx specifies the line number in which the error has occurred.

5.2 Controller's General Messages

¾ Controller SYSTEM Software Checksum Failed.
¾ Switch off the Machine and Download System again using key 2/3.
¾ Controller PROM 1.15E version required. Switch off machine, Change PROM Chip.
Download System again Using 2/3
¾ Controller not Found !
Controller hardware problem, Contact EMTL.
¾ Communication Link Failure (mode latter)..
Internal system communication error.
¾ Controller Software version old.
¾ Controller FIRMWARE checksum failed. Contact ELECTRONICA

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 ¾ Missing GLib and/or MLib at PMAC.
¾ Terminating CNC...
¾ Pitch error table MISSING, press key to Download....
¾ 1000 Sparking hours! It's Time for Preventive maintenance.
This is a warning that 1000 sparking hours completed.
Time for preventive maintenance.
1. Cleaning of filter housed in panel cooler.
2. Check that all Fans’ are working.
3. All fuses, connectors are tight enough.
4. Clean head of floppy disk drive by head cleaning diskette.
5. Greasing of all L-M guides.
¾ Can't do. Program is running.
¾ CRK has distorted original profile, Press key.
This message appears when selected Program is downloaded to the controller in
which, because of application of Radius correction (CRK) factor profile distortion is
occurred.
¾ Reading Downloaded Program ...
After power up the previously downloaded NC program is being read in the
controller's memory
¾ Wire Break...Press any Key.
Wire break encountered at the M/c tool. Acknowledge the same with a key press at
the controller keyboard.
¾ Servo overload, RESET Drive.
Servo Drive Fault has encountered cannot continue unless the RESET operation is
done.
¾ “ … … Positive/ Negative Software Limit Reached.”
Axis name and direction will be displayed with the message. E.g. “X Axis Positive
Software Limit Reached” The axis has crossed the Software Stroke Limit set in the
SETUP mode; Software stroke limits can be disabled giving G23 code from MDI
¾ Program aborted and rewound..
Running program halted, spark off, and program rewound so program will start from
the beginning.
¾ Program Halted.
Program stopped and can be continued from the same position.

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 ¾ Program Hold.
System is in hold condition; the operation can be continued with “Start” key
¾ Step Mode - Program Halted..
Program halted in single step mode, can be continued with “Start” key
¾ Electrode Work-piece Short! Press Key.
EW short detected when contact sensing enabled.
¾ Running..
Currently loaded program is running at the machine
¾ Program End..
Program end has encountered and Program is automatically rewound and actions like
spark off, flushing off, wire feed/tension off, table movements stop are taken. “Start” key
restarts the operation from beginning of program.
¾ “ … …. Axis Positive / Negative Travel Limit Reached.
Axis name and direction will be displayed with the message. E.g. “X Axis Positive
Travel Limit Reached” Axis travel limit is reached, move the axis in opposite
direction to get out of this.
¾ DWELL in Progress......
The system is in dwell status for specified time
¾ Downloading program, Please wait!!!
Selected program is downloading to the controller, please wait
¾ No Program Downloaded! Press Key.
“Start” key is pressed without downloading the NC program; no start operation can
be done.
¾ Running program is going to be KILLED.
¾ Please download running program again.
Due to some changes made in the machine parameters the downloaded program
becomes invalid and it is being erased from the system.
¾ AL723SYS.PMC File Not Found..
¾ AL723FLX.PMC File Not Found..
Very important system software file is corrupted, install software and then operation
should be continued.
¾ Unable to open pitch error file.
Pitch error compensation file corrupted.
¾ Can not PreSpark.

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 Prespark is allowed only after program halt due to M0.
¾ PreSpark Mode can NOT be turned OFF.
Once machine is forced in prespark mode by user, prespark cannot be turned off.
The only way to turn prespark off is to abort program.
¾ Restoring conditions
This message indicates 'E' code execution is over.
¾ Power Disturbance ...Program Hold.
It is an indication of a power supply fluctuation. Machine momentarily waits and
resumes if normal power conditions are restored.
¾ Program Buffer Full...Press Key
Controller is out of memory because program is too large.
¾ PMACRSET.DAT File NOT Found..
¾ PMACIFLX.DAT File NOT Found..
Very important system file is corrupted.
¾ PROGRAM NUMBER LOST...
¾ PROGRAM ABSENT, (Err595)...
Program number internally stored is lost or misreported. Re-cycle power supply and
recheck, if the condition persists, report EMTL.
¾ WARNING : Negative radius
The taper cut in the circular block is causing XY table and UV table to move in
opposite direction. This is due to higher taper angle. You may use constant radius
to solve this problem if it is allowed in the application.
¾ MCP Not Found
If MCP card or MCP is not present or faulty.
¾ WCS Origin inconsistent, Press key...
If stored data of WCS is corrupted.
¾ Table NOT In-Pos. Set/Zero failed.
If table is moving & operator tries to set co-ordinates. It is not allowed.
¾ Program will be aborted, if exists.
¾ Servo Trip, RESET Drive...
Due to over speed, servo trips, reset it.
¾ Prejog all axes before START, Press key.
If operator halts a program & moves the table from its programmed path and
presses “Start” key.

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 ¾ Z Axis Position incorrect, Press Key.
In case of tapered and complex profiles, if difference between Z axis position and Z
axis GOTO position is greater than Z tolerance specified in SETUP.
¾ Resetting NOMAN mode...
On selecting NOMAN mode if a program is running and wire breaks or limit is
sensed, key sense for 3 minutes, if within these three minutes operator press a key
NOMAN mode gets reset.
¾ NOMAN active, Press key to continue..
It is an indication of activated NOMAN mode & after 3 minutes M/C will be turned
OFF.
¾ Enable pitch error table?
This indicates the operator that the pitch error table is disabled. It also asks whether
it should be enabled. It should normally be enabled. It can be enabled or disabled
from the SETUP.
¾ Exprn evaluation error.
The entered expression is not proper or is evaluated to a wrong value that is not
allowed.
¾ Run Time Error, Halt! Press Key.
Program is halted due to some runtime error.
¾ Please wait, Confirming program absence
¾ Save pitch error table?
¾ Download pitch error table?
¾ Start M/C Ref ?
¾ PERR downloading FAILED, press key.
¾ Downloading pitch error compensation.
¾ Battery voltage low!!!!
¾ Filter life over , change it and reset life in status
¾ Resin life over, change it and reset life in status
¾ Wire guides life over , change it and reset life in status
¾ E-W Short, Operation Aborted ! Press Key.
¾ Safety Cover Open, press key.
¾ Program Halt, Wire Brake in Outlet, Press Key.
¾ Program halt by Flush Off, Press Key.
¾ Program Halted due to Gap Short.

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 ¾ NIR Temp. High.
¾ Filter Pressure Crossed Limit, Replace It.
¾ Entering deadlock.
¾ Power recovered.
¾ Bringing axes in closed loop.
¾ All PLCs enabled.
¾ Bringing all axes in closed loop.
¾ All axes are in closed loop.
¾ Start command issued.
¾ Do M/cRef for Axes.
¾ Is Wire Normally vertical?
¾ Axes at PreSpark target position?
¾ Kill program?
¾ Abort Current Run Program?
¾ Reset time?
¾ Program not downloaded.
¾ Switching OFF Machine.
¾ Current pickup life over, change it and reset life in status
¾ Installation completed successfully!!!
¾ Power fail position not saved.
¾ Initializing System Transformation..Wait
¾ WCS Origin inconsistent.
¾ Machine Stop.
¾ Clear previous 3pt center find settings?
¾ Set calculated WCS angle?
¾ Angle Calculation Error! Aln Pt1 & Aln Pt2 angles are different.
¾ Edge find failed, clean work-piece, press key.
¾ Clear Previous Settings?
¾ Unrecoverable Communication Link Failure Shutting Down Windows & Switch OFF
UPS Manually, Press Key!!
This message is displayed when there is any problem while communicating with the
controller.
¾ Shut Down Command Issued to Windows.
Shutdown command was issued to windows by CNC.

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 ¾ Previous Shut Down was Improper, Please check UPS backup!!
During initialization this message indicates that previous shutdown process was not
completed successfully. (Probably due to UPS problem).
¾ Previous Shut Down was Clean!!
During initialization this message indicates that there was no problem during
previous shutdown.
¾ Controlled Exit from application to Desktop!!
This message indicates that user did the controlled manual exit from the
eNovaCNC application to desktop.
¾ Previous closer of eNovaCNC was a controlled exit to Desktop!!
Previous closer of eNovaCNC was controlled manual exit from the eNovaCNC
application by user to desktop.
¾ GS&WHT changed in AWV.
Tells that Guide Span & Work Table Height were changed during AWV operation.
¾ Problem in reading Guide Span & work Table Ht Setup, Check & verify setup.
Indicates problem in Setup.cnc file. Can not read Guide Span & Work Table Height
from Setup.cnc file. Here recheck all setup parameters in setup mode and save
setup before loading or running any program.
¾ Default setup has been loaded by user!!
Indicates that user has loaded default parameter given from Factory using Default
key provided in Setup mode.
¾ Setup loaded from Load Backup option by user!!
Indicates that user has loaded the setup using the Load Backup option provided in
Parameter menu.
5.3 M/c Referencing messages:
1. Message “Do M/c Ref for ... ... Axes, Press Key” as specific axis related
message, e.g. “Do M/c Ref for X, Y, Z Press key...” depending on which axes
require referencing.
2. Message “...axis M/c Ref Fail, set Limit-ABS dist, Press key...” as specific axis
related message, e.g. “X axis M/c Ref Fail, set Limit-ABS dist...”.
Check the distance between ABS point and limit. If this distance is not within
specified range then call service engineer to set the ABS.
3. M/c Referencing in progress...
Selected axis Homing/ Referencing is in progress

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 5.4 Submerge Messages:
¾ Tank door open, Prog halt, Press key.
¾ Backwash / Clean filter / PF unit fault, Prog halt, Press key.
¾ Tank door open, Fill disabled.
¾ Work tank water level low.
¾ Quill level high.
¾ Water level low not reached.
¾ PF unit fault, Prog halt, Press key.
¾ Filter pressure high, Prog halt, Press key.
¾ Float switch fault, Prog halt, Press key.
¾ MCP WFWT/ Flush Off Program halt, Press Key.

5.5 Large Program Downloading Messages:

¾ Loading program, please wait…
While downloading program to controller.
¾ Prog aborted due to previous load failure.
While loading program, if power failure occurs, & loading is not completed.
¾ Program downloading aborted.
Program downloading canceled by user.
¾ Reading program, please wait…
While downloading program to controller.
¾ Prespark disabled due to large cavity program
Prespark will be disabled for single large cavity in program, which occupies PROG
memory more than 60KB approximately
¾ Aborting load, Memory insufficient at Block No. XXXXX .
.If size of program in from “G0 to G0 for Non AWT“or “M21 to M21 for
AWT” is greater than controller memory then program will not be downloaded. If
program contains single G0 or single M21 & program size is grater than controller
memory then program will not be downloaded.
XXXXX – stands for cavity no.
5.6 Messages related to password during password setting:
¾ Password successfully set.
This message indicates password is set successfully.
¾ Invalid password

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 This message is displayed whenever there is mismatch in Machine ID of machine &
that of password.
¾ Invalid password, Mismatch in expiry dates.
This message occurs due to the mismatch in password expiry date and CNC expiry
date.
¾ Invalid password, Mismatch in dates.
This message occurs due to the mismatch in password generation date and current
date of machine.
¾ Same Password already present.

5.7 Messages related to password at the time of initialization:

¾ Unable to run eNovaCNC application, Contact Service Engineer.
This message occurs due to the mismatch in machine date.
¾ Password expired, Contact Service Engineer
The validity period for Password expired, Contact service engineer to get the new
password or to activate the machine.

5.8 Messages related to user password:

¾ The password was not correctly confirmed. Please ensure that password and
confirmation match exactly.
This message appears when password entered in password text box does not
match with password re-entered in confirmation text box.
¾ Setting file can is missing.
This message appears, if file related to user password setting is missing.
¾ Setting file can not open.
This message appears, if file related to user password setting is corrupted.
¾ Password file is missing or corrupted.
This message appears, if file related to user password is missing or corrupted.

5.9 AWT operation Messages:

¾ Clamp miss Error
This message is displayed if the wire clamp fails to hold the wire properly before
cutting the wire.
¾ Failed to cut the wire.

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 If cutter failed to cut the wire, this message gets displayed
¾ Cutting over.
Indicates the wire cutting operation is over.
¾ Retracing sparking path.
After threading the wire through wire-guides and work-piece after wire break
condition, wire traces the path up to the position where wire had broken. During this
operation this message is displayed.
¾ Failed to thread up to upper guide.
Wire failed to reach up to upper wire guide within specified time (First insertion
time) due to some obstacle.
¾ Failed to thread up to lower sense.
Wire failed to reach up to lower assembly within specified time (Third insertion time)
due to some obstacle.
¾ Failed to thread up to work-piece.
Wire failed to reach up to work-piece within specified time due to some obstacle.
¾ Wire blocked in outlet.
Wire stuck in between lower assembly and bin sense.
¾ Threading Successful.
Wire threading completed successfully.
¾ Moving to jet vertical.
Z axis is moving towards the jet so that Z-axis will be vertically aligned above the
jet.
¾ Wire spool empty, prog halt, press key.
This message is displayed if the wire bobbin becomes empty.
¾ Lower Sense, Wire blocked in outlet.
There is wire in the lower assembly.
¾ Wire stuck in outlet OR Water conductivity high.
Wire is blocked in the lower assembly or water conductivity is increased.
¾ Wire idling in progress.
After cutting the wire, the wire remained between lower assembly and bin sense is
being pulled out of assembly.
¾ Wire Blocked at Cutter, Program Halted! Press Key.
Wire is blocked in spring or near Cutter.
¾ Program Halt, Threading Retries Over, Press Key.

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 As Threading Reties are over & as Handling retry over is not selected from AWT
Setup Program is halted.
5.10 Rotary axis Messages:
¾ Rotary table program not rewound.
This message is displayed if referencing (Home Zero Position) of rotary axis is not
done.
¾ Rotary table indexing error.
This message is displayed if there is any error while indexing rotary axis.
5.11 Software Installation Messages:
¾ Failed to Load EcodeDLL Install DotNetFramework!!
This message indicates that DotNetFramework is not installed on the machine &
need to install it.
¾ Install DotNet Framework from eNovaCNC CD using Install Option!!
This message indicates that DotNetFramework is not installed on the machine &
you can install it from eNovaCNC CD using Install option provided in Help menu.
¾ Insert eNovaCNC CD containing DotNet Framework Setup and Press OK or Press
Cancel to Exit!!
While installing the DotNet Framework from the install option provided in help
menu, this message is provided to ensure that CD is inserted in the CD-ROM.
¾ Inserted CD doesn't contain DotNet Framework please insert proper CD & Install
using Install Menu!!
Indicates that DotNet Framework Setup is absent in CD.
¾ System Downloaded by 2(F2)!!
System downloaded to controller using the key (2) during initialization.
¾ System Downloaded by 3(F3)!!
System downloaded to controller using the key (3) during initialization.

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 6 Short Keys

The list of keyboard commands available in eNovaCNC is as follows –

Mode Selection Short Keys Menu Selection Short Keys

Command Short key Command Short key
Main Mode Alt + F1 File Menu Alt + F
Jog Mode Alt + F2 View Menu Alt + V
M/c Reference Mode Alt + F3 Parameter Menu Alt + M
Job-Set Mode Alt + F4 Serial Menu Alt + S
DrySpark Mode Alt + F5 Install Menu Alt + I
Co-ord Mode Alt + F6 Help Menu Alt + H
Set Machine Mode Alt + F7 Open Ctrl + O
Run Mode Alt + F8
Status Mode Alt + F9
Setup Mode Alt + F10
Motor Reset Alt + F12

Graphics short Keys Mid Start Function Short Keys

XY layer Alt + X Previous Block Up Arrow
UV layer Alt + U Next Block Down Arrow
Top layer Alt + T Go to Start Block Ctrl + PgUp
Prog-Height layer Alt + P Go to End Block Ctrl + PgDn
Draw-Height layer Alt + D Previous G0 Block PgUp
Wire-path layer Alt + W Next G0 Block PgDn
Redraw Alt + R Mark Start Block Ctrl+S
Full Graphics Alt + G Mark End Block Ctrl+E
Pan Alt + N Find Text Ctrl+F
3D profile view Alt + 3 Clear Settings Ctrl+L
AutoPan Alt + A OK Ctrl+Y
Cancel Ctrl+N

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 7 Terminologies used in Simulation

XY layer:
It is the layer drawn at XY guide level.
UV layer:
It is the layer drawn at UV guide level.
Top layer:
It is the layer drawn at the height of work-piece from worktable height.
ProgHeight layer:
It is the height at which profile is programmed.
DrawHeight layer:
Height at which user wishes to view the profile. It is user settable parameter.
Wirepath layer:
It is the connecting lines between XY and UV layers.
Guide Span:
Distance between Upper and Lower wire guides when Z position is 0.
Work-Table Height:
Distance between top surface of worktable & lower (XY) guide.

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 8 Installation Procedure of eNovaCNC
8.1 Before starting installation
There are different methods and conditions to install eNovaCNC software. You can
install software using CD/ DVD, USB or from the PC drive. If you are installing
through CD/DVD or USB then ensure that the installation software is stored in
eNovaInst directory and this directory is at root directory of CD/DVD or USB.
If you are re-installing the software or upgrading the software then it is necessary to
backup machine related parameters and setup. To backup this, select
Parameter - > Backup -> Save option.

The following window will popup. Select the options for backup from this window.

This will be helpful in case you want to restore the parameters.

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 8.2 Installing First Time on System
Following steps to be followed to install eNovaCNC Software first time on your
system from CD-Rom/ USB
- Insert CD/ USB into corresponding drive
- Explore the contents of CD/ USB and select folder eNovaInst.
- Double click on “Setup.exe” file
- Follow the instructions displayed by application.

8.3 Install from CD-ROM

Following steps to be followed to install eNovaCNC from CD-Rom
- Insert CD into CD drive
- Select “Install from CD” option from Install menu
- Follow the instructions displayed by application.

8.4 Install from System

Following steps to be followed to install a eNovaCNC from System
- Select “Install from PC” option from Install menu
- Follow the instructions displayed by application.
8.5 Installation Procedure
After using any method from above three, the installer will copy the required files on
C drive and the windows will restart automatically.
After restarting, the installer will ask to select Machine Model, Motor and Drive
model, Feedback system & Language. Select the appropriate option. In case the
selection is not correct, then it can be corrected before selecting OK button. Once
the selection is confirmed, the installer will download related files into controller.
After successful downloading of files into controller, the installer will ask to copy the
technology files. Copy these files using proper folder. The technology files can be
found on CD supplied with the machine. If the CD drive is not present then the
technology files can be transferred on USB and the same USB can be used.

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 8.6 Installation Steps

1. From list of machine models select the current machine model. After selecting the
Machine Model, the selection dialog looks like

2. From list of drives select the appropriate drive. After selecting the Motor model, the
selection dialog looks like

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4. From list of feedback select the appropriate option. After selecting feedback, the
selection dialog looks like

4. From list of languages select the language in which software to be installed. After
selecting the language, the selection dialog looks like

5. After selecting language option, press OK button. If selection is correct then at last

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setup shows following message.

6. Now the installer will download related files into controller. After successful downloading
of files into controller, the installer will inform to copy the technology files by displaying
following windows.

7. To copy the technology files, use Parameter -> Backup -> Restore option and select
Technology option from the given options. Navigate to the system to proper folder which
contains technology. The system will copy technology files from the specified path.

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 9 How to get and send Machine ID and Machine number

¾ Method 1:

9.1 Get Machine ID from Command Prompt

During Initialization of eNovaCNC application Press F4 (Function Key),

So that application closes and brings Desktop.
Now go to the command prompt using “command” as shown in Figure 9-1.

Figure 9-1 Selection of Command Prompt

DOS command prompt is displayed as shown in Figure 9-2

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 Figure 9-2 Command Prompt Screenshot

Now Type command “C:\>ipconfig/all” in command prompt as shown in Figure 9-3

Encircled in yellow.
Note: If physical address is not displayed then check the network configuration.
After executing above command following Information is displayed on screen as
Shown in Figure 9-3
Look for “Physical Address” encircled in Blue and note down the number (Address)
Displayed in front of it encircled in Red e.g. 00-10-CC-CD-D8-8A
Send this Address with the Machine No.

Figure 9-3 Reading Machine ID

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Method 2:
9.2 Machine ID from eNovaCNC application

Step1: Install eNovaCNC V 1.00 s/w or higher ver in the machine.

Step2: How to send Machine ID
1. Press Password key in SETUP mode, Password dialog will be displayed
2. Send “Machine ID” displayed on the Password Dialog
Machine ID: 00-10-CC-CD-D8-8A
Note: First check that the Machine ID is displayed on the screen. If Machine ID is not
displayed then check the network configuration.

3. OR Send Password Site ID file generated from Backup option.

(Parameter-> Backup -> SAVE -> Password file.)

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 Select drive to store generated Site ID file.
Name of Generated (site ID) file is “IMID-xx-xx-xx-xx-xx-xx.dat” IMID followed by
Machine ID No e.g IMID-00-10-CC-CD-D8-8A.dat

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 9.3 How to Set Password to eNovaCNC
After sending the site ID file or Machine ID, password or password file for that Machine ID will be
provided. Load this file from Password dialog using “Load From File” button (by specifying path of
the file) or enter the key / Password in “New password:” box & press set password button.
Name of Password file is “OMID-xx-xx-xx-xx-xx-xx.dat” IMID followed by Machine ID
e.g OMID-00-10-CC-CD-D8-8A.dat

SiteID and Password File description:

Generated (Site ID) file is “IMID-xx-xx-xx-xx-xx-xx.dat” :
Password file is “OMID-xx-xx-xx-xx-xx-xx.dat” :
Example:
For Machine ID: 00-10-CC-CD-D8-8A
Files will be
Generated (site ID) file is: “IMID-00-10-CC-CD-D8-8A.dat”
Password file is: “OMID-00-10-CC-CD-D8-8A.dat”

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