NAKANISHI E4000 Motor Spindles User Manual

June 9, 2024
NAKANISHI

E4000 Motor Spindles

OM-K0596 006
E4000 CONTROLLER
OPERATION MANUAL
: P1 – P48 / English : P51 – P104

CONTENTS
IMPORTANT INSTRUCTIONS AND WARNING – Electric Devices P52 1. CAUTIONS FOR HANDLING AND OPERATION P53 2. BASIC PACKAGE P56 3. WARRANTY P56 4. CONTACT US P57 5. FEATURES P58 6. SPECIFICATIONS AND DIMENSIONS P58 7. SYSTEM CHART P61 8. TORQUE CHARACTERISTICS P61 9. PARTS NAMES P62
10. BRACKET AND RUBBER PAD INSTALLATION P65 11. POWER CORD CONNECTION P67 12. MOTOR CORD CONNECTION P68 13. AIR HOSE CONNECTION P69 14. CHANGING THE CONTROL PANEL P70 15. OPERATION PROCEDURES P71 16. EXTERNAL INPUT / OUTPUT CONNECTOR P73 17. PROTECT FUNCTION P85 18. SETTING OF OPERATING PARAMETERS P88 19. CONTROL PANEL SETTING RESUME FUNCTION P97 20. BREAK IN PROCEDURE P98 21. OPTIONAL DEVICES FOR CONTROLLER P98 22. MAINTENANCE P99 23. TROUBLESHOOTING P102 24. DISPOSAL OF THE CONTROLLER P104
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English

IMPORTANT INSTRUCTIONS AND WARNING – Electric Devices
WARNING! When using electric tools, basic safety precautions should always be followed to reduce the risk of fire, electrical shock and personal injury. Read all these instructions before operating this product and save these instructions.
A. GROUNDING INSTRUCTIONS 1. In the event of a malfunction or breakdown, grounding provides a path of least resistance for electric
current to reduce the risk of electric shock. This tool is equipped with an electric cord with a grounding conductor. 2. Improper connection of the grounding conductor can result in electric shock. The conductor with insulation having an outer surface that is green with yellow stripes is the grounding conductor. If repair or replacement of the electric cord is necessary, do not connect the gorunding conductor to a live terminal. 3. Check with a qualified electrician or service person if the grounding instructions are not completely understood, or if in doubt as whether the tool is properly grounded. 4. Repair or replace damaged or worn electrical cord immediately.
B. OTHER WARNING INSTRUCTIONS 1. For your own safety read instruction manual before operating this tool. 2. Replace cracked collet or collet nut immediately. 3. Do not over-tighten the collet nut. 4. Use only NAKANISHI manufactured collets and arbors for grinding and sawing applications. 5. REMOVE ADJUSTING KEYS AND WRENCHES. Always check to see that keys and adjusting wrenches are removed from tool before turning the units Main Power Switch on. 6. KEEP WORK AREA CLEAN. Cluttered areas and benches invite accidents. 7. DO NOT USE IN DANGEROUS ENVIRONMENT. Don’t use power tools in damp or wet locations, or expose them to rain. 8. Keep work area well lighted. 9. There is a risk of injury due to accidental starting. Do not use in an area where children may be present.
10. DO NOT FORCE THE TOOL. Never use a tool for an application it was not designed for. 11. USE THE CORRECT TOOL. Do not force tools or attachments to do a job for which it was not designed. 12. WEAR PROPER APPAREL. Do not wear loose clothing, gloves, neck ties, rings, bracelets, or other jewelry
that might get caught in moving parts. Nonslip footwear is recommended. Wear protective hair covering to contain long hair. 13. ALWAYS USE SAFETY GLASSES. Everyday eyeglasses only have impact resistant lenses, they are NOT safety glasses. Also use face or dust mask if cutting operation is dusty. 14. SECURE YOUR WORK. Use clamps or a vise to hold work securely at all times. 15. MAINTAIN TOOLS WITH CARE. Keep tools sharp and clean for best performance and to reduce the risk of injury. Follow instructions for changing accessories. 16. DISCONNECT TOOLS before servicing or when changing accessories, such as blades, cutters etc. 17. TO REDUCE THE RISK OF UNINTENTIONAL STARTING. Make sure Main Power Switch is in OFF position before connecting the Power Cord. 18. NEVER LEAVE TOOLS RUNNING UNATTENDED. TURN POWER OFF. Don’t leave tool until it comes to a complete stop. 19. For recommended operating speeds for various applications, please follow recommendations of the cutting tool manufacturer. 20. To protective E4000 CONTROLLER or electric wiring from a possible short circuit, place a circuit breaker (MCCB) between the power source and the AC Power Input Terminal Block of E4000 CONTROLLER. Select the circuit breaker with a 10A current capacity. 21. When use the Safety Relay Box, connect the Safety Relay Box to the E4000 CONTROLLER. By doing this, the outer box of Safety Relay Box is grounded and the system will be protected against electric shock.
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Thank you for purchasing the E4000 Ultra-Precision, High-Speed spindle system. The E4000 system was designed for use on CNC lathes and mills, robots, NC lathes and special purpose machines. This system utilizes air to cool the motor and purge the spindle. Please use an NAKANISHI Air Line Kit to ensure clean, dry, properly regulated air is supplied to the motor and spindle. The E4000 system is capable of being used with coolants and cutting lubricants. Please read this Operation Manual carefully before use. Also read <Brushless Motor>, and Operation Manuals. Always keep this Operation Manual in a place where a user can referred to for reference at any time.
1. CAUTIONS FOR HANDLING AND OPERATION
Read these warnings and cautions carefully and only use in the manner intended. These warnings and cautions are intended to avoid potential hazards that could result in personal injury to the operator or damage to the device. These are classified as follows in accordance with the seriousness of the risk.

Class
DANGER WARNING CAUTION

Degree of Risk
Existence of a hazard that could result in personal death or serious injury, if the safety precautions are not followed.
A safety hazard could result in bodily injury or damage to the device if the safety instructions are not properly followed.
A hazard that could result in light or moderate bodily injury or damage to the device if the safety instructions are not followed.

English

DANGER
NAKANISHI warns all end-users not to remove the Power Cord, Motor Cord, Protective Covers A and B or Options while the Control Power is ON, or if there is power to the main power cord. Disconnect the main power from its power source before removing the Power Cord, Motor Cord, Protective Covers A and B or Options. Not following these instructions may lead to serious injury or death due to electric shock.
Attach the Protective Covers A and B before use. Touching a power terminal connection by mistake may cause risk that leads to death or serious injury by electric shock.
Make sure the input power supply is OFF before wiring. If the incoming power supply is ON, it may cause risk that leads to death or serious injury by electric shock
Be sure to connect the ground wire to the earth ground. Insufficient grounding could cause an electric shock or malfunction.
Be sure to connect the ground wire of the Power cord to the AC Input Power Terminal Block (Earth Mark). Insufficient grounding could cause an electric shock or fire and malfunction.
WARNING
The CONTROLLER is not a hand tool. It is designed to be used on a CNC lathe or special purpose machines.
Do not touch the cutting tool while the spindle and tool are rotating. It is very dangerous. Wear safety glasses, dust mask, and use a protective cover around the spindle whenever the
spindle is rotating. Never connect, disconnect or touch the Power Cord and Motor Cord Plug with wet hands. This
may cause an electric shock. Never operate or handle the CONTROLLER and motor or spindle until you have thoroughly
read the owner’s manual for each component, and safe operation has been confirmed. 1) To prevent injuries / damages, check the CONTROLLER, motor, spindle and cutting tool for
proper installation, then operate the CONTROLLER, motor and spindle. 2) Before disconnecting the CONTROLLER, motor or spindle, always turn the control power
OFF and turn the compressed air supply to the CONTROLLER OFF. Then it is safe to remove the CONTROLLER, motor and spindle.
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WARNING
Do not use in dangerous environments. Protect the CONTROLLER from moisture and other contaminants. Failure to protect CONTROLLER can result in damage to internal components and injury to the operator.
To protective CONTROLLER or electric wiring from a possible short circuit, place a circuit breaker (MCCB) between the power source and the AC Power Input Terminal Block of the CONTROLLER. Select the circuit breaker with a 10A current capacity.
Check to ensure that the supply voltage is the same as the CONTROLLER rated voltage. When you use the E4000 Safety Relay Box, connect the E4000 Safety Relay Box to the E4000
CONTROLLER. By doing this, the outer box of E4000 Safety Relay Box is grounded and the system will be protected against electric shock. When installing a tool, tighten the collet correctly and check again the collet and collet nut before use. Do not over-tighten the collet. This may cause damage to the spindle. Do not use bent, broken, chipped, out of round or sub-standard tools as they may cause tools to shatter or explode. Tool with fractures or a bent shank will cause injury to the operator. When using a new tool, rotate it at a low speed and increase speed gradually for safety. Do not exceed the maximum recommended allowable tool speed. For your safety, use speeds below the maximum allowable speed. Do not apply excessive force. This may cause tool slippage, tool damage, injury to the operator or loss of concentricity and precision. When installing the motor and the spindle, make sure the Main Power Switch of the CONTROLLER turned OFF before installing. When installing a motor spindle to a fixed base, make sure the fixed base is grounded in order to avoid the risk of an electric shock.
CAUITION
A motor cooling and spindle purge air is required to operate the system correctly. The input air line must be connected to the air input joint on the front of the CONTROLLER. Air
pressure between 0.2 – 0.35MPa (29.0 – 50.8psi) must be supplied. The brushless motor and spindle require air for cooling and purging. Ensure that this air
supply is clean and dry. Introduction of dust, moisture and other contaminants into the CONTROLLER, motor and spindle will cause damage to the internal components. If water or oil is allowed to enter the CONTROLLER, failure of the CONTROLLER may result. Do not hit, drop or subject the motor, spindle or CONTROLLER to any type of shock. This will cause damage to internal components and result in a malfunction. Do not disassemble, modify or attempt to repair the CONTROLLER, motor or spindle as it will damage internal components. There are no user serviceable parts available. Motor will make a sudden stop when error LED lights or error output signal is generated. Check and correct the cause of the malfunction before continuing use. Failure to correct the problem will result in damage to the CONTROLLER, motor and spindle. When the warning LED on the CONTROLLER blinks, conditions exist that could result in dangerous operation. Check operating conditions and continue to use only after correcting the problem. When using CONTROLLER continuously, refer to continuous area on torque Characteristics Graph and check Load Monitor LED for a maximum output of (3 Green LEDs). Do not install the CONTROLLER next to RF noise sources, as malfunctions can occur. If smoke, noise or strange odors eminate from the CONTROLLER or motor spindle, immediately turn OFF the Main Power Switch. Do not place anything on top of the CONTROLLER. When installing the CONTROLLER, never place them in areas where vibration and shock are present or possible. This may cause a malfunction to occur. Do not place the CONTROLLER near any source of heat. The temperature inside the CONTROLLER will rise, resulting in a CONTROLLER failure.
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CAUITION
Connect the round terminal lugs of the Power Cord to the AC Power Input Terminal Block of the CONTROLLER securely firmly.
When using in a place where the power conditions are poor, take measures to enable a supplied input power within the specified voltage fluctuation.
Attach the provided Connector Cover for safety and dust proofing when not using Input / Output Connecter A, B or EMG Connector.
Do not press the switches on the Control Panel of the CONTROLLER with a sharp- pointed tool. When disposal of a CONTROLLER is necessary, follow the instructions from your local
government agency and dispose as an industrial waste. Be sure to clean the collet and collet nut, the inside of the spindle before replacing the tool. If
ground particles or metal chips stick to the inside of spindle or the collet, damage to the collet or spindle can occur due to the loss of precision. Always clean the tool shank and the machine spindle taper before installing the tool in the machine. When sizing the correct collet size to the tool shank diameter, a tolerance of +0 ~ -0.01mm is strongly recommended. A tool shank within the +0 ~ – 0.1mm range is mountable, however, this may cause poor concentricity and or insufficient tool shank gripping force. Select suitable products or tools for all applications. Do not exceed the capabilities of the spindle or tools. Carefully direct coolant spray to the tool. Do not spray directly on the motor and spindle body. Stop working immediately when abnormal rotation or unusual vibrations are observed. If vibrations occur, please check the contents of page number P102 ” 23. TROUBLESHOOTING “. Always check if the tool, collet or collet nut are damaged before and after operating. After installation, repair, initial operation, or long periods of non operation, please refer to Operation Manual of the spindle / motor spindle detailed in ” BREAK-IN PROCEDURE “. When checking the spindle, no vibration or unusual sound should be observed during rotation. Note that symbols are shown on the rear panel (for 3 parts). Be careful when handling these parts because a high voltage is input and output at them.
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2. BASIC PACKAGE
When opening the package, check if it includes all items listed in ” Table 1. Packing List Contents “. In the event of any shortage, please contact either NAKANISHI (see the ” 4. CONTACT US ” section) or your local dealer.

Table 1. Packing List Contents
E4000 CONTROLLER Main Body Power Cord (4m) 1pc. 1pc.

6mm Air Hose with Filter (2m) 1pc.

Connector Cap A 1pc.

Connector Cap B 1pc.

Connector Cap EMG 1pc.

Connector Cover A 1pc.

Connector Cover B 1pc.

Brackets 4pcs.

Rubber Pads (4pcs) 1set.

Opeeration Manual 1set
OPERATION MANUAL

WARNING / Error Code Label 1set

  • The Connector Cap A / B, Connector Cap EMG and Connector Cover A / B are attached to the CONTROLLER.
    3. WARRANTY
    We provide a limited warranty for our products. We will repair or replace the products if the cause of failure is due to the following manufacturers defects. Please contact us or your local distributor for details.
    (1) Defect in manufacturing. (2) Any shortage of components in the package. (3) Where damaged components are found when initially opening the package.
    (This shall not apply if the damage was caused by the negligence of a customer)
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4. CONTACT US
For safe use / purchase of our products, we welcome your questions. If you have any questions about operation, maintenance and repair of the product, please contact us.

Contact Us
For U.S. Market Company Name
Business Hours
U.S. Toll Free No. Telephone No. Fax No. Website For Other Markets Company Name Business Hours
Telephone No. e-mail

: Industrial Div.
: 8:00 to 17:00 (CST) (closed Saturday, Sunday and Public Holidays)
: +1 800 585 4675 : +1 847 843 7664 : +1 847 843 7622 : www.nskamericacorp.com
: : 8:00 to 17:00 (JST)
(closed Saturday, Sunday and Public Holidays) : +81 289 64 3520 : webmaster-ie @nsk-nakanishi.co.jp

English

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5. FEATURES
Although it is a compact unit with a motor / spindle diameter of 40mm, the E4000 system is capable of outputting high power with a maximum 1,200W, and high torque with a maximum 1.0Nm onto the motor shaft.
The E4000 features a high speed type with a maximum speed of 40,000min-1 (rpm) and a high torque type with a maximum speed of 20,000min-1 (rpm) depending on cutting conditions.
Speed control and protection functions are incorporated in the high performance microprocessor. A wide speed range, 1,000 – 40,000 min-1 (rpm) (20,000 min-1 (rpm)) and settable speed increment of
100min-1 (rpm) make high precision machining possible. Use of an external mechanism such as sequence control allows the E4000 series to be controlled from A CNC / PC
Control. In addition, power output can be monitored via external equipment. The CONTROLLER can be placed horizontally or vertically. It can be installed at various places by using the
attached mounting bracket. Each operation setting can be set with parameters (memory) that match each user’s preferred operating
method. Abnormality and malfunctioning status of the CONTROLLER can be checked by error code display by the
Error Detection (warning, error) of the system. An overheat detection sensor is built into the motor, and problems due to abnormal overheating of the motor is
prevented before it damage occurs. A straight type and right angle type electric and air connection is available to meet space limitations. The motor / spindle housing is made from precision ground, hardened, stainless steel (SUS) with an outside
diameter of 40mm. The motor cord is available from 2m to 8m in increments of 2m to meet machine electrical and NSK Control
distances. The control panel is removable. It can be installed on the rear of the CONTROLLER, allowing for flexibility of
operation. The Control Panel can be installed at a distance of 4m from the CONTROLLER body by using an optional E4000
Control Panel Extension Cord. In an Emergency Stop condition, the power to the motor can be securely disconnected via a relay by using
the E4000 Safety Relay Box. A safety system between the E4000 CONTROLLER and the machine can be configured by utilizing auxiliary contacts.

6. SPECIFICATIONS AND DIMENSIONS

6 – 1 Specifications of CONTROLLER

Product Name

E4000 CONTROLLER

Model

NE246

Input Voltage

AC200 – 240V, 50 / 60Hz, 1 PHASE, 3.2A

Input Voltage fluctuation

MAX. +/- 10

Output

AC48V, 0 – 0.66KHz, 3 PHASE, 7.8A

Max.Output Power Max.Torque

1,200W (Machine Shaft Output)
1.0N m : Motor/Motor Spindle of 20,000min-1(rpm) specification1 0.5N m : Motor/Motor Spindle of 40,000min-1(rpm) specification2

Over Voltage Category

Pollution Degree

Speed Range

External Control Signal

Input Signal
Output Signal

Class 2

1,000 – 20,000min-1 (rpm) : Motor/Motor Spindle of 20,000min-1(rpm) specification1
1,000 – 40,000min-1 (rpm) : Motor/Motor Spindle of 40,000min-1(rpm) specification
2

Photo Coupler : 9 Analog Connections : 1

MOS Relay : 8 Analog : 3

Photo Coupler 1 Relay Contact 2 (Safety Relay BOX)

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Protect Function

Weight

Dimensions

Temperature

Operation Environment

Humidity Atmospheric pressure

Installation Area

Transportation and Storage Environment

Temperature Humidity Atmospheric pressure

Height above Sea Level

Excess Current, Over Voltage, Motor Sensor Malfunction, CONTROLLER Overheat, Rotor Lock, Low Air Pressure, Over Load, External Control Signal Error, Incompatible Motor, Over Speed, Emergency Stop Error, Internal Memory Error, Blower Stop, Motor Power Line Disconnect, Motor Overheat 6.7kg W250mm x D290mm x H100mm 0 – 40 C MAX. 75% (No condensation)
700 – 1,060hPa
Indoor use -10 – 50 C 10 – 85%
500 – 1,060hPa
Less than 2000m

1 Motor/Motor Spindle of 20,000min-1(rpm) specification: BMS-4020, BMS-4020RA, BMS-4020-MQL (2M), BMS-4020-MQL-CHK (2M), EM-4020, EM-4020A
2 Motor/Motor Spindle of 40,000min-1(rpm) specification: BMS-4040, BMS-4040RA, BMS-4040-MQL (2M), BMS-4040-MQL-CHK (2M), BMS-4040-RGD-03M (2M), BMS-4040RA-RGD-03M (2M),EM-4040, EM-4040A

6 – 2 Compatibility
1The E4000 CONTROLLER is compatible with the following overseas safety standard.

Safety standard in North America (UL,CSA)

UL61010-1

CSA C22.2 No.61010-1

EC Directive

Low Voltage Directive

IEC / EN61010-1

EMC Directive

EMS EN61000-6-2

EMI EN61000-6-4

RoHS Directive

2011/65EU, (EU) 2015/863

United Kingdom Conformity Assessed (UKCA) marking

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6 – 3 Outside View of the CONTROLLER
CAUTION
Do not stack 2 CONTROLLERs on top of each other. This will increase the heat generated inside the CONTROLLERS, leading to a premature failure.
*Below is an outside view with the Brackets attached (Standard Accessory).

290

250

110 100

80 5

224 276 296 10
36

4.5

45

155

120

Fig. 1 Bottom Mounting
290

250

10

100 80 45 4.5

278 330 350 10
36
Fig. 2 Vertical Mounting

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7. SYSTEM CHART
E4000 CONTROLLER can be used in the following the systems (Fig. 3). 20,000min-1 (rpm) – 40,000min-1 (rpm)

Spindle NR – 4040

Brushless Motor EM- 4020 / 4040

Compressor

Quick Change Spindle NRR4040- QC

Motor Cord (Motor Power Line)

Air Line Kit AL- C1204

Air Quick Change Spindle NR4040- AQC

Brushless Motor EM – 4020A / 4040A

20,000min-1 (rpm) / 40,000min-1 (rpm)

Brushless Motor Spindle BMS – 4020 / BMS – 4040

Brushless Motor Spindle BMS – 4020RA / BMS – 4040RA 40,000min-1 (rpm)
Brushless Motor Spindle BMS-4040-RGD-03M

EMCD- 4000 -2M / 4M / 6M / 8M
Motor Cord (Motor Signal Line)

E4000

EMCD- 4000S

SAFETY RELAY BOX

-2M / 4M / 6M / 8M (Option) *1

E4000 CONTROLLER (200 – 240V)

*1 : A safety system for the machine can be configured by connecting a SAFETY RELAY BOX to the E4000 CONTROLLER.

Brushless Motor Spindle BMS-4040RA-RGD-03M
20,000min-1 (rpm) / 40,000min-1 (rpm)

Brushless Motor Spindle (Coolant through specification BMS- 4020-MQL / BMS- 4040-MQL
Brushless Motor Spindle (Coolant through specification BMS- 4020-MQL-CHK / BMS- 4040-MQL-CHK

Hight pressure coolant device or
Oil Mist supplying apparatus (Machine owned by customer)

8. TORQUE CHARACTERISTICS
(1) 40,000min-1 (rpm)

Fig. 3 (2) 20,000min-1 (rpm)

English

Torque (cNm) Output (W)
Torque (cNm) Output (W)

100

90

80

70

Output

60

50 40 Torque

30

20

10

Continuous Duty Area

0

5 10 15 20 25 30 35

Speed (×103min-1 (rpm))

1400 1200 1000 800 600 400 200 0 40

Fig. 4

100 90 Torque

80

70

Output

60

50

40

30

20

Continuous Duty Area

10

0

5

10

15

Speed (×103min-1 (rpm))

Fig. 5

1400 1200 1000 800 600 400 200 0 20
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9. PARTS NAMES
9 – 1 System

Fig. 6

Fig. 7

CONTROLLER Control Panel
Refer to P64 ” 9 – 2 Control Panel Details ” section. External Input / Output Connector A (EXT I / O – A)
External Input / Output Connector A is for automatic control and monitoring of motor / spindle system. Refer to P73 ” 16 – 1 (1) Details of External Input / Output Connector A Signals ” section. Attach the provided Connector Cover A for safety and dust proofing, when not using External Input / Output connector A. External Input / Output Connector B (EXT I / O – B) External Input / Output Connector B is for automatic monitoring of emergency conditions. P80 ” 16 – 2 (1) Details of External Input / Output Connector B Signals ” section. Attach the provided Connector Cover B for safety and dust proofing, when not using External Input / Output connector B. MOTOR – A Connector (MOTOR – A) : For Motor Power Line. Connect the Motor Cord Plug (Motor Power Line) of the motor spindle. Attach the provided Connector Cap A for safety and dust proofing, when not using MOTOR – A Connector. MOTOR – B Connector (MOTOR – B) : For Motor Sigmal Line. Connect the Motor Cord Plug (Motor Signal Line) of the motor spindle. Attach the provided Connector Cap B for safety and dust proofing, when not using MOTOR – B Connector. EMG Connector (EMG) : Emergency Stop Cord Connection to the E4000 Safety Relay Box. Connects the Emergency Stop Cord from the CONTROLLER to the E4000 Safety Relay Box (Sold separately). Attach the provided Connector Cap EMG for safety and dust proofing, when not using EMG Connector. Air Input Joint (AIR – IN) Supply clean, dry, regulated air for motor cooling. Regulate air to between 0.2 – 0.35MPa (29.0 – 50.8psi). When using the motor spindle for continuous use, supply the regulated air to CONTROLLER and set the air pressure to 0.35MPa (50.8psi). The air consumption is 100N / min when supplying air pressure of 0.35MPa (50.8psi). Refer to P69 ” 13. AIR HOSE CONNECTION ” section.
CAUTION
If the air pressure is too low the CONTROLLER will not operate.

Air Output Joint (AIR – OUT) Connect Air Hose to supply clean, dry, regulated air for motor and spindle cooling and purging. Refer to P69 ” 13. AIR HOSE CONNECTION ” section.
Main Power Switch (POWER) ON / OFF main power source. The designation ” I ” Indicates ON. The designation ” O ” Indicates OFF.

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AC Power Input Terminal Block The AC Power Input Terminal Block connects to the Power Cord terminals. Refer to P67 ” 11. POWER CORD CONNECTION ” section.
DANGER
Make sure the input power supply is OFF before wiring. If the incoming power supply is ON, it may cause risk that leads to death or serious injury by electric shock.
After connecting the Power Cord, be sure to attach the Protective Covers A and B for safety, dust proofing and electric shock prevention. If the Protective Covers A and B are not attached to the CONTROLLER, it may lead to the risk of death or serious injury by electric shock.
WARNING
Only use grounded power sources. Using a non-specified Power Cord, the risk of fire by overheating of the cord is possible.
Mis-wiring will cause damage to the CONTROLLER. Be sure to connect the ground wire to the earth ground. Insufficient grounding could cause an
electric shock or malfunction. Tighten the Terminal Screw of the AC Power Input Terminal Block securely. Loose Terminal
Screws to the AC Power Input Terminal Block will cause over-heating leading to damage and fire in the CONTROLLER.
Protective Cover A / Protective Cover B The Protective Cover A and B attach to the AC Power Input Terminal Block, for safety dust proofing and prevention of electric shock.
DANGER
Be sure to attach the Protective Covers A and B before use. Touching a power terminal connection by mistake may cause risk that leads to death or serious injury by electric shock.
CAUTION
Be sure to attach the Protective Covers A and B before use. Without the Protective Covers A and B, metal chips and other particles may stick to the AC Power Input Terminal Block causing electrical leakage and damage to the CONTROLLER.
Securing Band This band secures the Power Cord connected to the AC Power Input Terminal Block.
CAUTION
After connecting the Power cord to the AC Power Input Terminal Block, make sure the Power Cord is secured in place by using the provided Securing Band.
Plate When changing the Control Panel from front to rear, remove the Plate from the rear of the CONTROLLER, and reinstall it on the front of the CONTROLLER where the Control Panel was removed from. When changing the Control Panel, refer to P70 ” 14. CHANGING THE CONTROL PANEL ” section.
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English

9 – 2 Control Panel Details

Digital Speed Indicator

Preset Speed, Actual Speed, Warning and Error Codes are displayed in 3

digits format.

When the motor is stopped the Preset Speed is displayed, when the motor is

rotating the actual speed is displayed.

The display also displays the error codes when an error has occurred.

Load Monitor LED (LOAD)

The motor spindle load is displayed by 6 LED’s (3 Green, 2 Yellow and 1 Red).

Continuous operation is possible with up to all 3 green LED’s lit. If one of the

yellow LED’s is lit the motor spindle can only be run for a short time. Please refer to P85 ” 17. PROTECT FUNCTION ” section of this manual for allowable

duration of high load operation. When any of the yellow or red LED’s are lit

Fig. 8

the Warning LED (WARNING) will blink, if this condition is continued beyond

the allowable interval the Error LED (ERROR) will light and the motor spindle

will be shut down.

Motor Speed Adjustment Button (SPEED , ) (Manual adjustable speed control is possible. ( (UP) or (DOWN). 1 digit is 100min-1 (rpm).)

Speed Range

Motor Spindle : Motor/Motor Spindle of 20,000min-1(rpm) specification : 1,000 – 20,000min-1 Motor Spindle : Motor/Motor Spindle of 40,000min-1(rpm) specification : 1,000 – 40,000min-1

START / STOP Button (START / STOP)

Starts and stops motor rotation.

Rotation Direction Button (DIR)

Right hand rotation (FWD.) and left hand rotation (REV.) are as viewed with the cutting tool facing the operator.

With the cutting tool facing the operator right hand rotation (FWD.) will be clockwise rotation.

Control Button (CTRL)

This button will change the control mode to either MANUAL or AUTO.

MANUAL : Controlled by Control Panel.

AUTO : Controlled by External Input / Output Connector A from External Signal Source.

Centering Mode Button (500min-1 (rpm)) 500min-1 (rpm) operation for centering.

CAUTION
Never attempt to cut while rotating in Centering Mode.

Error Reset Button (RESET) This switch resets and allows restarting of the motor spindle after an error has been corrected. If not Error Signal cannot be released by pressing the Error Reset Button (RESET), a situation has occurred that must be corrected before the Error Signal can be reset. Some error codes will not allow the CONTROLLER to be reset.
Error LED (ERROR) When a serious problem with the system alarms is detected this LED illuminates. The motor may shut down and the Digital Speed Indicator will displays an Error Code.
Warning LED (WARNING) The operating and working conditions of the system are constantly monitored and the Warning LED flashes when a hazardous condition has been detected. When a hazardous condition is detected the Warning LED flashes and the Digital Speed Indicator alternates between the Warning Code and the actual or preset speed, depending on whether or not the motor / spindle is rotating or not.
Rotating LED (RUN) When the motor is rotating, this LED will illuminate.

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10. BRACKET AND RUBBER PAD INSTALLATION
10 – 1 Installation of the Brackets
CAUTION
If there is a possibility for the CONTROLLER from its mounting location, be sure to secure it with the Provided Brackets for safety.
When mounting the Bracket, do not loosen any other screws other than the Mounting Screws that are meant to install the Bracket.
Brackets are provided 4pcs. Bracket Mounting Screws are attached to the following locations of the CONTROLLER (Fig. 9).
Bottom: 8pcs. Both sides: 4pcs. each side. The Bracket can be installed on the ” (1) Bottom Mounting (Fig. 10, 11) ” and ” (2) Side Surface Mounting (Fig. 12, 13) ” of the CONTROLLER.
Mounting Screw

Mounting Screw

Mounting Screw

Mounting Screw

Mounting Screw (8pcs.) attached to the bottom of the CONTROLLER.

Mounting Screw (each 4pcs.) attached to the side of the CONTROLLER.
Fig. 9

(1) Bottom Mountng Remove the Mounting Screws (8pcs.) from bottom of the CONTROLLER (Fig. 9). Install the Brackets (4pcs.) to the bottom of CONTROLLER by using removed Mounting Screws (8pcs.) (Fig. 10). Attach the CONTROLLER (Bracket’s Slotted Area) to the machine using the mounting screws (8 pcs. not included / provided by the end-user.) (Fig. 11). *Mounting screws used to attach the CONTROLLER on the machine, not included / provided by the enduser.

English

Mounting Screw Bracket
Fig. 10

Mounting Screw 8pcs. (Not included / Provided by the end-user) Slotted Area Bracket
Fig. 11
65

(2) Side Surface Mounting Remove the Mounting Screws (4pcs.) from side of the CONTROLLER (Fig. 9). Install the Brackets (2pcs.) to the side of CONTROLLER by using removed Mounting Screws (4pcs.) (Fig. 12). Attach the CONTROLLER (Bracket’s Slotted Area) to the machine using the mounting screws (8 pcs. not included / provided by the end-user). (Fig. 13). *Mounting screws used to attach the CONTROLLER on the machine, not included / provided by the enduser. If ” Side Surface Mounting ” of the CONTROLLER is required. If the CONTROLLER is installed usind its side surface, the Control Panel can be rotated 90 -degees from the original position. To rotate, remove the 4 Control Panel Mounting Screw attached to Control Panel. Change position of the Control panel and re-install the 4 Control Panel Mounting Screws.
CAUTION
Make sure the input power supply is OFF before rotating the mounting direction of the Control Panel. If the incoming power supply is ON, electric shock or damage to the CONTROLLER may result.
Mounting Screw (4pcs.)

Mounting Screw Bracket

Mounting Screw (4pcs.) (Not included / provided by the end-user).
Bracket Slotted Area

Fig. 12

Fig. 13 Control Panel vertical position.

10 – 2 Installation of the Rubber Pad
If the CONTROLLER is installed in a vertical position, install the Rubber Pads to the CONTROLLER as shown in Fig. 14.

Rubber Pad

Fig. 14 66

11. POWER CORD CONNECTION
DANGER
NAKANISHI warns all end-users not to remove the CONTROLLER’s Protective Covers A and B while the Control Power is ON, or there is power to the main power cord. Disconnect the main power from its power source before removing the Protective Covers A and B. Not following these instructions may lead to serious injury or death due to electric shock.
After connecting the Power Cord, be sure to attach the Protective Covers A and B safety, dust proofing and electric shock prevention. If the Protective Cover A and B are not attached to the CONTROLLER, it may lead to the risk of death or serious injury by electric shock.

WARNING
Only use grounded power sources. Using a non- specified Power Cord, the risk of fire by overheating of the cord is possible.
Mis-wiring will cause damage to the CONTROLLER. Be sure to connect the ground wire to the earth ground. Insufficient grounding could cause an
electric shock or malfunction. Tighten the Terminal Screw of the AC Power Input Terminal Block securely.
Loose Terminal Screws to the AC Power Input Terminal Block will cause over- heating leading to damage and fire in the CONTROLLER.

(1) Loosen the mounting screws located on Protective Covers A , B and the Securing Band. Remove Protective

Covers A , B and the Securing Band from the rear of the CONTROLLER.

(2) The round terminal lugs are attached to the one side of the Power Cord. Remove the Terminal Screw from the

AC Power Input Terminal Block. Make sure to connect the round terminal to the AC Power Input Terminal Block

securely. (Table 2, Fig. 15) (3) After connecting the Terminal Screw to the AC

Table. 2

Power Input Terminal Block, be sure to securely tighten the Terminal Screws.

Cord Collar

AC Power Input Terminal Block connection position

(4) Re-Attach the Protective Covers A and B to the AC Power Input Terminal Block by using the original mounting screws.
(5) Secure the Power Cord using the Securing Band and Mounting Screw.

Black White Green / Yellow (For Ground)

AC INPUT

AC INPUT position

psition

English

Yellow / Green Cord (For Ground)
Black Cord White Cord
Power Cord

2 1
1 : AC Power Input Turminl Block 2 : Protective Cover B
Fig.15

Protective Cover A White Cord Green / Yellow Cord (For Ground) Black Cord
Securing Band
67

12. MOTOR CORD CONNECTION

CAUTION
Before connecting to the Motor Cord Plug (For Power Line / Signal Line), make sure the Main Power Switch is turned OFF. If the Main Power Switch is turned ON while connecting the Motor Cord Plug (For Power Line / Signal Line), damage may occur to the CONTROLLER .
Install the protective cover (Protective Cover etc.) to prevent damage or contamination to the Motor Cord Plug (For Power Line / Signal Line) when not in use.
After connecting the Motor Cord (For Power Line / Signal Line), do not make any sharp bends to the Motor Cord (For Power Line / Signal Line).

(1) Ensure the Alignment Pin of the Motor Cord Plug (Power Line) is located upward (12 o-clock). (2) Carefully insert the Alignment Pin of Motor Cord Plug (Power Line) into the Alignment Hole (MOTOR – A
Connector) of the rear of the CONTROLLER and push straight. Tighten the Fixing Ring of the Motor Cord Plug (Power Line). (Fig. 16, 18) (3) Ensure the Alignment Pin of the Motor Cord Plug (Signal line) is located upward (12 o-clock). (4) Carefully insert the Alignment Hole of Motor Cord Plug (Signal line) into the Alignment Pin (MOTOR – B Connector) of the rear of the CONTROLLER and push straight. Tighten the Fixing Ring of the Motor Cord Plug (Signal line). (Fig. 17, 18)

Motor Cord Plug (For Motor Power Line)

Motor Cord Plug (For Motor Signal Line)

Alignment Pin
Motor Cord Plug (Motor Power Line)

Fig. 16

Alignment Hole Alignment Hole
MOTOR – A Motor Cord Plug Connector (Motor Signal Line)
MOTOR – B MOTOR – A Connector Connector

Fig. 17

Alignment Pin
MOTOR – B Connector

Motor Cord Plug (Motor Signal Line) Fixing Ring
Motor Cord Plug (Motor Signal Line)

Motor Cord Plug (Motor Power Line) Fixing Ring
Motor Cord Plug (Motor Power Line)

Fig. 18

68

13. AIR HOSE CONNECTION
CAUTION
When not using NAKANISHI Air Line Kit, make sure that the incoming air supply is dry, clean and properly regulated.
(1) Insert the provided 6mm Air Hose (2m) with Filter (CONTROLLER’s standard accessories) from the Air Line Kit into the Air Input Joint on the rear of the CONTROLLER .
(2) Insert one end of the provided 6mm cooling Air Hose (Motor Cord’s standard accessories) into the back of the motor.
(3) Insert the other end of the 6mm cooling Air Hose (Motor Cord’s standard accessories) into the Air Output Joint on the rear of the CONTROLLER .
(4) Regulate air pressure between 0.2 – 0.35MPa (29.0 – 50.8psi).

Air Input Joint
6mm Air Hose (2m) with Filter
6mm cooling Air Hose (Motor Cord’s standard accessories)

Air Output Joint

Fig. 19
CAUTION
The Air input joint, is designed to accept cooling air between 0.2 – 0.35MPa (29.0 – 50.8psi). If the air pressure is too low, the CONTROLLER will not operate and an Error code will be generated. Set the air pressure 0.35MPa (50.8psi) when using the motor spindle for continuous use.
The cooling air also provides air purge protection to the motor spindle. If the Main Power Switch is turned OFF, the cooling air will continue to flow.
Do not make any sharp bends in the air hose, or pull on the hose as this can cause the hose to break, cut off the air supply or weaken the hose over time resulting in deterioration of the motor and spindle.
Never supply over regulated air pressure. There is a possibility to damage to the air detection sensor inside the CONTROLLER.
The air detect function within the CONTROLLER detects air input supply only. If the Air Out hose is damaged from the CONTROLLER, it will not be able to detect the lack of cooling and purging air to the motor spindle.

English

69

14. CHANGING THE CONTROL PANEL
WARNING
Make sure the input power supply is OFF before rotating the direction of setting Control Panel. If the incoming power supply is ON, it may cause electric shock or damage to the CONTROLLER.
The position of the Control Panel can be changed from the front to rear of the CONTROLLER.

(1) Remove the 4 screws that affix the Control Panel and pull the Control Panel gently from the CONTROLLER (Fig. 20). Remove the connector from rear of the Control Panel (Fig. 20).

Remove

Conector Pull
Control Panel Mounting Screw
Remove
Fig. 20

(2) Remove the screw from the Plate and pull the Plate from the CONTROLLER (Fig. 21).

Pull Plate

Mounting Screw

Remove

Fig. 21

(3) Connect the connector inside the CONTROLLER to the connector of the rear of the Control Panel. (Fig. 22).
(4) Re-attach the Control Panel using the 4 mounting screws (Fig. 22).

Connecting Connector

Mounting

Control Panel Mounting Screw

Fig. 22

(5) Mounting the Plate using the 4 mounting screws. (Fig. 23).

Mounting Plate Mounting Screw
Fig. 23
70

15. OPERATION PROCEDURES
15 – 1 Selecting Control Mode (MANUAL / AUTO). (Select the control button (CTRL) of the Fig. 24.)

(1) Using the CONTROL (CTRL) Button you can select between Manual (Front panel control) or Auto (External Signal Source) modes. External Signal Source can be used to control Motor Start / Stop, Rotation Direction, Motor Speed etc. from an external control source (CNC).
(2) When operating with the CONTROLLER Control Panel, push the Control Button (CTRL) of Fig. 24 and select MANUAL. The Manual LED will illuminate. When operating from an External Signal Source, push the Control Button (CTRL) of Fig .24 and select AUTO. The AUTO LED will illuminate. MANUAL Mode : Controlled by Control Panel . AUTO Mode : Controlled by Input / Output Connector A from an External Signal Source

Fig. 24

15 – 2 Setting Motor Start / Stop (START / STOP), Motor Rotating Direction (FWD / REV), Motor Speed (SPEED)

15 – 2 – 1 Manual Mode Operation

(1) Set Motor Rotating Direction (Set the Rotation Direction Button (DIR) of the Fig. 24.) Push the Rotation Direction Button (DIR). Select FWD. : Right hand rotation. Select REV. : Left hand rotation. With the cutting tool facing the operator right hand rotation (FWD.) will be clockwise rotation.
(2) Set 500 min-1 (rpm) Centering Rotation (Set the 500 min-1 Button of the Fig. 24.)
CAUTION
Never attempt to cut while rotating in Centering Mode.

When carrying out centering, press the 500 min-1 Button. The rotation speed is set to 500min-1 (rpm).
(3) Motor Start / Stop (Motor Start / Stop by pushing the Start / Stop Button (START / STOP) of the Fig. 24.) The motor spindle will start and the LED will illuminate.
Push Start / Stop Button (START / STOP) again and the motor will stop and the LED will go out.
(4) Setting Motor Speed (Set the Motor Speed Adjustment Button (SPEED , ) of the Fig. 24.) Set the speed by pushing the Motor Speed Adjustment Button (SPEED , ).
Speed Range Motor Spindle : Motor/Motor Spindle of 20,000min-1(rpm) specification : 1,000 – 20,000min-1 Motor Spindle : Motor/Motor Spindle of 40,000min-1(rpm) specification : 1,000 – 40,000min-1 The motor speed is displayed in 100 min-1 (rpm) increments. 200 equals 20,000 min-1 (rpm).

15 – 2 – 2 Auto Mode Operation
Use the External Input / Output Connector A to input control signals to the CONTROLLER. (1) Set motor Rotating Direction
Input the ” Rotating Direction Setting ” to Pin No. 2 : DIR_IN Right hand rotation is ” OFF ” (Open) (” FWD “, LED will illuminate). Left hand rotation is ” ON ” (Closed) (” REV “, LED will illuminate). With the cutting tool facing the operator right hand rotation (FWD.) will be clockwise rotation. (2) Set 500 min-1 (rpm) Centering Rotation
CAUTION
Never attempt to cut while rotating in Centering Mode.

Input the ” Rotates Motor at ‘ Centering speed ‘ to Pin No. 16 : 500 min-1 (rpm). 500 min-1 LED will illuminate. When using the Centering Mode: ” ON ” (‘ Closed ‘)

English

71

(3) Motor Start / Stop

Input the Motor Start Signal (Pin No. 14: START).

Motor rotating is ” ON ” (Close). When startup, START / STOP LED of the CONTROLLER will light and motor

will rotate.

(4) Setting the Motor Speed

Motor Speed Range is 1,000 – 40,000 min-1 (rpm). Maximum motor speed depends on motor and spindle

model.

Setting parameter

to

will allow the motor speed to be adjusted in Auto Mode using the Motor Speed

Adjustment Button (SPEED , ) of the Fig. 24.

(Refer to P94 ” 18 – 4

Setting AUTO Mode for Motor Speed Control “section.)

Speed Range

Motor Spindle : Motor/Motor Spindle of 20,000min-1(rpm) specification : 1,000 – 20,000min-1 Motor Spindle : Motor/Motor Spindle of 40,000min-1(rpm) specification : 1,000 – 40,000min-1

Rotational speed can be set by the using one of the following 3 methods. The Rotation Speed is setting to an

analog Signal before shipment.

Setting by Analog signal

Input the ” Motor Speed Control Voltage ” to Pin No. 23 : VR.

Refer to P78 ” 16 – 1 (3) Motor Speed Control Signal ” section.

Setting by Pulse Signal

(Set parameter

of the CONTROLLER. Refer to P95 ” 18 – 4

Selection of External Speed

Control Mode ” section.)

Input the ” Count Pulse Signal for Setting Motor Speed ” (Pin No. 3 : CNT_IN) and ” UP / DOWN Signal for

Setting Motor Speed ” (Pin No. 15 : UD_IN). One pulse will increase or decrease 100min-1 (rpm) of Spindle

Speed counted on the leading edge of the signal.

” UP / DOWN Signal ” for Setting Motor Speed is ” ON ” (Close) : increase speed, ” OFF ” (Open) :

decrease speed.

Set by the Speed Point Signal

(Set parameter

. (Refer to P95 ” 18 – 4

Selection of External Speed Control Mode ” section.)

Select the Speed Point

by combination of ” Speed Point Select 0 ” (Pin No. 17 : SEL0) and

” Speed Point Select 1 ” (Pin No. 5 : SEL1).

Set the Motor Rotation Speed. Select the Speed Point

by combination in Table. 3.

Table. 3 Speed Point

SEL1 (Pin No. 5) OFF (Open) OFF (Open) ON (Closed) ON (Closed)

SEL0 (Pin No. 17) OFF (Open) ON (Closed) OFF (Open) ON (Closed)

(5) Resetting System after Error Codes Releasing Error Code by The ” Error Release ” (Pin No. 4 : RESET). Switch the signal on Pin No. 4 (RESET) of External Input / Output Connector A OFF (Open) ON (Closed) OFF (Open). Error Signal will not be released until cause of the error has been removed. Refer to P86 ” 17 – 3 Resetting System after Error Codes ” section.

72

16. EXTERNAL INPUT / OUTPUT CONNECTOR
16 – 1 External Input / Output Connector A
(1) Details of External Input / Output Connector A Signals
WARNING
DO NOT connect any circuit other than SELV (DC+24V) (Safety Extra Low Voltage) to the External Input / Output Connector A of the CONTROLLER. This will cause I / O board damage in the CONTROLLER.
Do not supply over voltage or over current into the input / output circuit. Always install a LOAD (resistor) to the output circuit to eliminate the chance of damage to the CONTROLLER.

CAUTION
External Input / Output Connector A DOES NOT use Pins No. 9 and No. 22. If pin No. 9 and No. 22 are connected, the CONTROLLER will be damage.

Table. 4 Pin Code No.

Function

Input / Output

Description

1 COM_1

External Power Input source for External input

DC 0V or DC+24V

Power source to be used for External Inputs Signals. (not included / prepared by the end-user)

2 DIR_IN

Rotating

Input OFF (Open) : FWD.

Direction Setting

ON (Closed) : REV.

Controls the rotational direction of the

motor spindle.

Setting parameter , can start with

reverse rotation. (Refer to P96 ” 18 – 4

Selection of External Motor Start

Signal Control Mode ” section.)

3 CNT_IN

Count Pulse

Input

Signal for Setting

Motor Speed

OFF (Open)

ON (Closed)

One pulse will increase or decrease

100min-1 (rpm) in Spindle Speed depending

on parameter

setting. (Refer to P95

” 18 – 4

Selection of External

Speed Control Mode ” section.)

4 RESET

Error Release

Input

ON (Closed)

OFF (Open)

Error Code can be released and the system restarted by toggling this signal OFF and ON. Error will not be released until cause of the error has been removed.

5 SEL1

Speed Point Select 1

Input OFF (Open) ON (Closed)

Speed Point (

­

) can be

Selected by SEL0 and SEL1 signal

combination. P72 ” 15 – 2 – 2 (4) Set by

the Speed Point Signal Table 3 ” section.

Need to set parameter

.

(Refer to P95 ” 18 – 4

Selection of

External Speed Control Mode ” section.)

6 RUN

Rotating

Output OFF (Open) : Stop

Output shows that the motor is rotating.

ON (Closed) : Rotating

7 DIR_OUT Rotating Direction

Output OFF (Open) : FWD. ON (Closed) : REV.

Output shows the direction of the Motor is rotating.

English

73

Pin No.

Code

Function

Input / Output

Description

8 ERR

Error

Output OFF (Open) : Error ON (Closed) : Normal

Output shows that error has occurred.

Error code will be displayed on Digital

Speed Indicator . The error Code Logic

can be reversed by setting Parameter

.

The Error Code Logic can be either

Normally Open or Normally Closed

depending on the

Setting. In

addition, the error code can be output

as a patterned signal. For details, refer

to ” 18. SETTING OF OPERATING

PARAMETERS “.

9 Not used

*Note : Never use pin labeled ” NOT USED ”

10 GND

Internal GND for Motor Speed Control Voltage

Output Internal CONTROLLER This GND will be used for ” Motor Speed

GND

Control Voltage (VR) “.

Output DC+10V

11 Vcc

Internal Power Source for Motor Speed Control Voltage

Output Internal Power : DC+10V

Internal Power Source for ” Motor Speed Control Voltage (VR) “.

12 MOTOR_I Motor Current Monitor

Output 0V MOTOR_I 10V DC 0V : 0Amp DC+10V : 20Amp

Output Motor Current Monitor with Analog Monitor Voltage. 2Amp / 1V. Max. 20Amp.

13 GND

Internal GND for Analog Monitor

Output Internal CONTROLLER This GND will be used for analog monitor.

GND

(MOTOR_I, SPEED_V, and LOAD).

14 START

Rotate Command

Input OFF (Open) : Stop ON (Closed) : Start

Motor Start and Motor Stop Signal

Setting parameter , can start with

forward rotation. (Refer to P96 ” 18 – 4

Selection of External Motor Start

Signal Control Mode ” section.)

15 UD_IN
16 500min-1 (rpm)

UP / DOWN Signal for Setting Motor Speed

Input

Rotates Motor Input at ” Centering ” speed

OFF (Open) : Speed Down ON (Closed) : Speed Up

This signal is for increasing and

decreasing the desired speed by the use

of a Pulse Signal. Whether it increases or

decreases speed is determined by CNT_

IN. It is requred that parameter .

(Refer to P95 ” 18 – 4

Selection of

External Speed Control Mode ” section.)

OFF (Open) : Normal Operation ON (Closed) : 500min-1 (rpm)

Set motor rotation speed is 500 min-1 (rpm). Use the Centering Mode.

74

Pin No.

Code

Function

Input / Output

Description

17 SEL0

Speed Point Select 0

Input OFF (Open) ON (Closed)

Speed Point (

) can be

Selected using a SEL0 and SEL1 signal

combination. P72 ” 15 – 2 – 2 (4) Set by

the Speed Point Signal Table 3 ” section.

Need to set parameter . (Refer to

P95 ” 18 – 4

Selection of External

Speed Control Mode ” section.)

18 COM_2

External Power Input Source for External Output

DC 0V or DC+24V

Power source to be used for External outputs. (Not included / prepared by the end-user)

19 PULSE Rotating Pulse Output 1 pulse / rotation

Output 1 pulse / rotation 1 revolution of the motor generates one pulse. Duty 50%.

20 WARNING WARNING

Output OFF (Open) : Normal Operation ON (Closed) : Warning

Output shows that warning has occurred. Warning code will be displayed on Digital Speed Indicator . By setting Parameter , the Warning Codes can be output as either Normally Open or Normally Closed. For details, refer to ” 18. SETTING OF OPERATING PARAMETERS “.

21 COIN

Speed Achievement

Output OFF (Open) : Set speed not achieved ON (Closed) Set speed achieved

Shows that the Motor has achieved more than 90% of the set speed.

22 Not used

*Note : Never use pin labeled ” NOT USED ”

23 VR

Motor Speed Input 0V VR 10V Control Voltage

Analog Voltage (Set the Motor Rotation
Speed by 0V VR 10V) Motor/Motor Spindle of 40,000min-1(rpm)

specification

Motor Rotation

Motor Speed Control Voltage (VR)

Speed (min-1 (rpm)) =

2

X 10,000

Motor/Motor Spindle of 20,000min-1(rpm) specification

Motor Rotation

Motor Speed Control Voltage (VR)

Speed (min-1 (rpm)) =

4

X 10,000

Refer to Fig.31 regarding the relationship
between motor speed and Control Signal. * Unit of rotational speed : 1,000min-1 (rpm)

24 LOAD

Torque Load Monitor

Output 0V LOAD 10V

Shows that the torque being applied to the analog motor. 20% / V 100% (rating) / DC+5V Torque Load Monitor (%) = Torque Load Monitor Voltage X 20 Torque Load Monitor : 0 – 200% (0V LOAD 10V)

25 SPEED_V Rotating Speed Output 0V SPEED_V 10V Output the rotation speed of rotating

Analog Monitor

motor with Analog Monitor Voltage.

Voltage

10,000min-1 (rpm) / V

English

75

(2) Input / Output Diagram

COM _ 1

1

(DC+24V or DC 0V)

START

14

DIR _ IN

2

RESET

4

500min -1 (rpm)

16

Input / Output

Connector

SEL0

17

(D-Sub25)
SEL1

5

UD _ IN

15

CNT _ IN

3

11

Potentiometer

23

5K

10

EMG – INA +

1

EMG – INB –

9

Input / Output Connector (D-Sub15)

DC+10V VR GND

GND

SAFETY RELAY CONTACT
SAFETY RELAY BOX (option) use Pin No. 1, 3, 4, 9, 11, 12.

6 RUN 7 DIR _ OUT 8 ERR 20 WARNING 21 COIN

19 PULSE 18 COM _ 2
(DC 0V or DC+24V)

12 MOTOR I 24 LOAD 25 SPEED V 13

2 MT – CNA

10 5

MT – CNB AUTO +

13 6

AUTO PWON +

14 PWON –

3 SAFE – 1A 11 SAFE – 1B 4 SAFE – 2A 12 SAFE – 2B

Fig. 25

76

(3) Input / Output Signal Input Signal There are 8 different input signals : ” Rotate Command (START) “, ” Rotating Direction Setting (DIR_IN) “, ” Rotates Motor at ‘ Centering ‘ Rotation Speed (500min-1 (rpm)) “, ” Error Release (RESET) “, ” Count Pulse Signal for Setting Motor Speed (CNT_IN) “, ” UP / DOWN Signal for Setting Motor Speed (UD_IN) “, ” Speed Point Select 0 (SEL0) ” and ” Speed Point Select 1 (SEL1)” . These signals are DC+24V signals from an external signal source. Please use a separate power source that is capable of supplying DC+24V 10%, 100mA.
CAUTION
Do not use a power supply of more than DC+24V. This will cause damage to the CONTROLLERS I / O Board.

DC+24V or DC 0V
1 (COM_1)

The side of CONTROLLER

DC 0V or DC+24V
Fig. 26
Output Signal I There are 5 separate output signals: ” Rotating (RUN) “, ” Rotating Direction (DIR_OUT) “, ” Error (ERR) “, ” Warning (WARNING) ” and ” Speed Achievement (COIN) “. These signals are MOSS Relay Contact Connections. The output current can be connected to either sinking or sourcing. Voltage and Current Specifications Applied Voltage (V) DC+30V Working Current (lp) 100mA Refer to Fig. 27 for connections.
CAUTION
Never supply more that 100mA of current to the input / output circuit. It is highly recommended to add a LOAD (resistor) to the output circuit. Over Current Will Cause Damage to the CONTROLLER.

Use an external power source for output circuits. It is recommended to use the same DC+24V power source used for input signals. Please refer to Fig. 27 for connections.

DC+24V or DC 0V

The side of CONTROLLER

Load

6, 7, 8, 20, 21

18 (COM_2) DC 0V or DC+24V
Fig. 27

77

English

Output Signal Refer to Fig. 28 regarding the Output Signal of the ” Rotating Pulse (Pulse) “. The output signal can be connected for either sinking or sourcing. Voltage and Current Specifications Applied Voltage (V) DC+30V Working Current (lp) 50mA
CAUTION
Do not send excess current into the input / output circuit. Verify the working-current will is less than 50mA after connected the LOAD (resistor) of the output circuit. EXCESS CURRENT WILL CAUSE DAMAGE TO THE CONTROLLER.

The side of CONTROLLER

DC+24V or DC 0V

18 (COM_2)

19 (PULSE)

Load

Fig. 28

DC 0V or DC+24V

Motor Speed Control Signal Rotation Speed can be selected by, applying analog voltage to the ” Motor Speed Control Voltage (VR) “. Refer to Fig. 29, 30 for connections. Refer to Fig. 31 for the relationship between Motor Speed and ” Motor Speed Control Voltage (VR) “.
CAUTION
When applying the DC 0V to DC+10V, never input more than DC+10V to the CONTROLLER (Fig. 30). This will cause serious damage to the I / O Board in the CONTROLLER.

Potentiometer 5K

The side of CONTROLLER 11 DC+10V Power Source for
External Control Inputs 23 Motor Speed Control
10 DC 0V
Fig. 29

The side of CONTROLLER
23 Motor Speed Control Control Signal
10 DC 0V
Fig. 30

78

E4000 Motor Speed Control Voltage (VR) vs Motor Speed
4 (2)

Motor Speed (x10,000min-1 (rpm))

3 (1.5)

2 (1)

1 (0.5)

(0.1)

0.1

0

1 2 3 4 5 6 7 8 9 10

0.2V 0.4V

Motor Speed Control Voltage (VR)

Max.40,000min-1 (rpm)Motor Speed (min-1 (rpm)) VR0.2, 1,000 min-1

Motor

Speed

Control 2

Voltage

(VR)

×

10,000

Max.20,000min-1 (rpm)Motor Speed (min-1 (rpm)) VR0.4, 1,000 min-1

Motor

Speed

Control 4

Voltage

(VR)

×

10,000

  • Unit of rotational speed : 1,000min-1 (rpm)

Fig. 31

Analog Monitor Signals There are 3 separate monitoring signals : ” Motor Current Monitor (MOTOR_I) “, ” Torque Load Monitor (LOAD) “, and ” Rotating Speed Analog Monitor Voltage (SPEED_V) “. Please refer to Fig. 32 for connections.

The side of CONTROLLER

12 1K

Motor Current Monitor

(MOTOR_I)

24 1K

Torque Load Monitor

(LOAD)

25 1K

Rotating Speed Monitor Voltage

13

(SPEED_V)

DC 0V

Fig. 32

English

79

16 – 2 External Input / Output Connector B
(1) Details of External Input / Output Connector B Signals
WARNING
DO NOT CONNECT any circuit other than SELV (DC+24V) (Safety Extra Low Voltage) to the External Input / Output Connector B of the CONTROLLER, this will cause I / O board damage in the CONTROLLER.
Do not supply over voltage or over current into the input / output circuit. Always install a LOAD (resistor) to the output circuit to eliminate the chance of damage to the CONTROLLER.

CAUTION
External Input / Output Connector B DOES NOT use Pins No. 7, No. 8 and No. 15. If Pins No. 7, No. 8 and No. 15 are connected, the CONTROLLER will be damage.

Table. 5

Pin No.

Code

Function

Input / Output

Description

1 EMG – INA Emergency Stop A Input External Power

External Power Source input for

Source input for

Emergency Stop Signal or Emergency

Emergency Stop

Stop Signal.

Signal or Emergency Normal Operation ON (Closed),

Stop Signal OFF

Emergency OFF (Open).

(Open)

This signal is active only when connecting

the Safety Relay Box (Sold separately) to

the CONTROLLER.

2 MT – CNA Motor Connect Contact A

Output Continuity, OFF (Open), between Pin No. 2 and Pin No. 10 the motor is connected

When there is continuity, OFF, between Pin No. 2 and Pin No. 10 and the selected motor is connected, if no continuity is present, the motor is disconnected or the Motor Cord is broken.

3 SAFE – 1A Safety Relay Contact 1A

Output

Pin No. 3 and Pin No. 11 continuity ON (Closed) Safety Relay is OFF

When there is continuity between Pin No. 3 and Pin No. 11 ON (Closed) Safety Relay is OFF (System Stopped), no continuity Safety Relay is OFF (Open) Normal Operation.

4 SAFE – 2A Safety Relay Contact 2A

Output Pin No. 4 and Pin No. 12 continuity ON (Closed) Safety Relay is OFF

When there is continuity between Pin No. 4 and Pin No. 12 ON (Closed), the Safety Relay is OFF (System Stopped), no continuity Safety Relay is OFF (Open) is Normal Operation.

5 AUTO +

Control Mode AUTO Signal (+)

Output Control Mode AUTO When Control Mode AUTO is being used, Pin No. 5 and Pin No. the Pin No. 5 and Pin No. 13 are ON 13 are ON (Closed) (Closed).

6 PWON +

CONTROLLER Power Source Monitor (+)

Output ON (Closed) : Main Power Supply is connected. OFF (Open) : Main Power Supply is disconnected

If the Main Power Switch is ON, Pin No. 6 and Pin No. 14 are ON (Closed).

80

Pin No.

Code

7 Not Used

Function

8 Not Used

9 EMG – INB Emergency Stop B

10 MT – CNB Motor Connect Contact B

11 SAFE – 1B Safety Relay Contact 1B

12 SAFE – 2B Safety Relay Contact 2B

13 AUTO –

Control Mode AUTO Signal (-)

14 PWON –

CONTROLLER Power Source Monitor (-)

15 Not Used

Input / Output

Description

*Note : Never use pin labeled ” NOT USED ”

*Note : Never use pin labeled ” NOT USED ”

Input

External Power Source input for Emergency Stop Signal or Emergency Stop Signal OFF (Open)

External Power Source input for Emergency Stop Signal or Emergency Stop Signal OFF (Open). Normal Operation ON (Closed), Emergency OFF (Open). This signal is active only when connecting the Safety Relay Box (Sold separately) to the CONTROLLER.

Output Continuity, OFF (Open), between Pin No. 2 and Pin No. 10 the motor is connected

When there is continuity, OFF, between Pin No. 2 and Pin No. 10, the selected motor is connected, if no continuity the motor is disconnected or the motor cord is broken.

Output Pin No. 3 and Pin No. 11 continuity ON (Closed) Safety Relay is OFF

When there is continuity between Pin No. 3 and Pin No. 11 ON (Closed) Safety Relay is OFF (System Stopped). If there is no continuity Safety Relay is OFF (Open) Normal Operation.

Output Pin No. 4 and Pin No. 12 continuity ON (Closed) Safety Relay is OFF

When there is continuity between Pin No. 4 and Pin No. 12 ON (Closed) the Safety Relay is OFF (System Stopped). If there is no continuity, Safety Relay is OFF (Open) Normal Operation.

Output Control Mode AUTO When Control Mode AUTO is being used, Pin No. 5 and Pin No. Pin No. 5 and Pin No. 13 are ON (Closed). 13 are ON (Closed)

Output ON (Closed) : Main Power Supply is connected OFF (Open) : Main Power Supply is disconnected

If the Main Power Switch is ON, Pin No. 6 and Pin No. 14 are ON (Closed).

*Note : Never use pin labeled ” NOT USED ”

English

81

(2) Input / Output Signals Output Signal (Pin No. 2 – No. 10, No. 5 – No. 13, No. 6 – No. 14) There are 3 kinds of output signals : ” Motor Signal Connect Contact (MT – CN) “, ” Control Mode AUTO (AUTO) “, and ” CONTROLLER Power Source Monitor (PWON) “. These signals are MOSS Relay Contact Connections. The output current can be connected for either sinking or sourcing. Voltage and Current Specifications Applied Voltage (V) DC+30V Working Current (Ip) 100mA Please refer to Fig. 33 for connections. Output circuit is need power source (DC+24V) separately (not included / prepared by the end-user).
DC+24V DC+24V or DC 0V or DC 0V

The side of CONTROLLER 2 (MTCN – A)

Load

or 10 (MTCN – B)

5 (AUTO – A)

Load

13 (AUTO – B)

6 (PWON – A)

DC 0V or

DC 0V or DC+24V

14 (PWON – B) DC+24V

Fig. 33
Emergency Stop Signal Input (Pin No. 1 – No. 9) This signal is a switched DC+24V output. Please use a separate power source that is capable of applying DC+24V 10%, 50mA. Refer to Fig. 34 below for connections. Normal Operation circuit is ON (Closed). Emergency Stop circuit is OFF (Open). If the Emergency Stop Signal is OFF (Open) the Safety Relay in the SAFETY RELAY BOX is OFF, the power supply to the motor is interrupted and the motor stops.

DC+24V (or DC 0V) The side of
CONTROLLER 1
9

DC+24V (or DC 0V) The side of
CONTROLLER 1
or 9

DC 0V (or DC+24V)

DC 0V (or DC+24V)
Fig. 34

Safety Relay Signal (Pin No. 3 – No. 11, No. 4 – No. 12) When there is continuity between Pin No. 3 (SAFE – 1A) and Pin No. 11 (SAFE – 1B) or between Pin No. 4 (SAFE – 2A) and Pin No. 12 (SAFE – 2B) the motor is off. If there is no continuity between these pairs of pins then the system is operating normally. If the Emergency Stop Signal is OFF (Open) the Safety Relay will be OFF (Open) and the motor power will be interrupted and the motor will stop. If the (NO) Normally Open contacts of the Safety Relay are welded together by an over load or short circuit the (NC) Normally Closed contacts separation are maintained with more than 0.5mm spacing by the relay’s recoil mechanism.
82

The voltage / current specifications of No. 3 (SAFE – 1A) – Pin No. 11 (SAFE – 1B) and Pin No. 4 (SAFE – 2A) Pin No. 12 (SAFE – 2B).
Applied Voltage (V) DC+30V Working Current (Ip) 2A Refer to Fig. 35 for the connection diagram.
E4000 SAFETY RELAY BOX

RELAY

MOTOR – AOUTW – phase V – phase U – phase
MOTOR – AIN W’ – phase V’ – phase U’ – phase
EMG

MOTOR

W’ – phase V’ – phase U’ – phase

MOTOR – A EMG

DC+12V RELAY- ON

External Input / Output CONNECTOR B

1 9

EMG – INA EMG – INB

3 11
4 12

SAFE – 1A SAFE – 1B SAFE – 2A SAFE – 2B

E4000 CONTROLLER
Fig. 35

  • Safety Relay If an N – O contact becomes welded, all N – C contacts will maintain a minimum distance of 0.5 mm when the coil is not energized. N – O contacts (Normally – opened contacts) : Motor Power Line N – C contacts (Normally – closed contacts) : Contacts Output
  • Safety of the Machines when used the Safety Relay Contacts Output When input Emergency Stop Signal that is coupled to opening the movable guard of the Industrial Machinery, Safety Relay will operate and certainly open the Motor Power Line. Contact output ((SAFE-1A) – (SAFE – 1B), (SAFE – 2A) – (SAFE – 2B)) of the ” N – C Contacts” can be used for detecting the opening of the Motor Power Line. If ” N – O contacts ” become welded, contact outputs will certainly maintain OFF (Open) by Forced Guide Mechanism. Therefore, Safety Relay can be used as an opening signal of movable guard with locking mechanism for Industrial Machinery.
    83

English

16 – 3 External Input / Output Connector Specifications
CAUTION
To minimize RF interference and noise, please keep the length of the cables as short as possible and route them separately or as far away as possible from high voltage electrical cables.
Use only shielded cables to minimize RF interference and noise. Connect the shield to the plug cover.
Connect the shielded line to the Input / Output connector. (The shielded line is grounded.) Do not connect another shielded line to any externally powered instrument.
(1) External Input / Output Connector A Plug Part Number : XM2A – 2501 OMRON (or other similar high-quality product) Cover Part Number : XM2S – 2511 OMRON (or other similar high-quality product)
(2) External Input / Output Connector B Plug Part Number : XM2A – 1501 OMRON (or other similar high-quality product) Cover Part Number : XM2S – 1511 OMRON (or other similar high-quality product) Please prepare a Cover and Plug. The shielding should be connected to the Cover. Use the Mounting Screw ” M 2.6 “. *Fasten the Connector to the CONTROLLER using Mounting Screws (M2.6).
16 – 4 External Input / Output Connector A / B Pin configuration (Controller side)

1

2

14

3

15

4

16

5

17

6 7

18 19

8

20

9

21

10 11

22 23

12

24

13

25

1

2

9

3

10

4

11

5 6 7

12 13 14

8

15

External Input / Output Connector A

External Input / Output Connector B

Fig. 36

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17. PROTECT FUNCTION
17 – 1 WARNING DETECTION
CAUTION
When the warning LED on the CONTROLLER blinks, conditions exist that could result in dangerous operation. Check operating conditions and continue to use only after correcting the problem.

Always check the CONTROLLER, Motor Spindle and the condition of the cooling air prior to use. This will help prevent system errors that will result in non-operational conditions. (1) The WARNING LED (WARNING) will blink. (2) The Warning Code (listed in Table. 6) will be displayed on the Digital Speed Indicator . (3) Warning Signal is output to the ” WARNING ” (PIN No. 20 : WARNING) of External Input / Output Connector A.

Table. 6 Warning Code
A0 A1 A2 A3 A4
A5 A6 A7 AF

Warning Function Motor Signal Line Low Air Pressure CONTROLLER Overheat Over Load Emergency Stop Signal
Over Air Pressure Motor Overheat Motor Power Line Temporary Motor / Spindle Operation during FAN malfunction

Trouble Motor Signal Line or Connector not connected or damaged. Low Air Pressure during motor rotation. CONTROLLER Overheat. Motor Torque Load exceeding safe limits. Emergency Stop Signal ‘OFF (Open) ‘ in Emergency Stop Mode Condition. Excessive Air Pressure The inside temperature of the motor has reached the warning level. Motor Power Line or Connector not connected or damaged. The FAN has stop, but the Motor / Spindle is temporarily operational.

  • While the Warning Code ” AF ” is displayed, the buzzer will sound.

  • If FAN has been stopped due to a malfunction, the motor / spindle can run temporarily (Refer to P96 ” 18 – 4 Temporary Motor / Spindle Operation if FAN has Stopped (80 Square Type) ” section).

CAUTION

When the Warning LED blinks while the control is in Mode AUTO, be sure to confirm the Warning

Code displayed on the Digital Speed Indicator by refering to the ” Warning Code ” in Table 6.

If Parameter ”

” is set to ”

or

” and continuous operation continues during a FAN

Failure, damage to the CONTROLLER and its internal components will occur due to excessive

heat generation while the FAN is not operating. It is critical to reduce the cutting load conditions

and operating time to minimize the risk of internal damage. to the CONTROLLER.

17 – 2 Detection of Error (unsafe operating conditions)

Always check the CONTROLLER, motor, spindle and the condition of the cooling air prior to operation. This will

help prevent system errors that will result in unproper operating conditions.

When an Error Occurs, the following events may occur :

(1) Motor stops.

(2) The Error LED (ERROR) will lights.

(3) The Error Code in Table. 6 will displayed on Digital Speed Indicator.

(4) An Error signal is output to the ” ERR (PIN No. 8 : ERROR ) ” of External Input / Output Connector A.

  • Setting parameter

, will Change the Error Output Mode of the Error Signal. (Refer to P93 ” 18 – 4

Error output logic settings or error / warning code signal output selection ” section.)

English

85

17 – 3 Resetting System after Error Codes
There are 2 methods of releasing Error Code. (1) When the control is in MANUAL Mode:
Push the Error Reset Button (RESET) of the Control Panel. (2) When the control is in AUTO Mode:
Toggle the signal on Pin No. 4 (RESET) of External Input / Output Connector A OFF (Open) ON (Closed) OFF (Open).

  • When releasing Error using the Motor Start / Stop (Pin No.14 : START) is ON (Closed), OFF (Open) Motor Start / Stop before resuming operation.

Table. 7 Error Code E1 E2 E3 E4 E5 E6 E7
E8 EA
EL EH EE
EC EP Et EF1 EF2 EFP

Problem Area Excess Current Over Voltage
Motor Sensor Malfunction CONTROLLER Overheat Brake Circuit Trouble Rotor Lock
Low Air Pressure
Torque Over Load
External Control Signal Error
Incompatible Motor Over Speed Emergency Stop Error
Internal Memory Error Motor Power Line Disconnected Motor Overheat
FAN Malfunction (80 Square Type) FAN Malfunction (40 Square Type) Parameter Setting Error

Trouble Motor Current beyond safe limits. Motor Voltage beyond safe limits, or Motor Power Line has been damaged. The sensor signal has malfunctioned or Motor Cord (Signal Line) Connector is not connected. CONTROLLER Overheat.

Trouble with the Motor Brake Circuit. Motor Stalled for more than 3 seconds, or Motor Power Line has been damaged. Inadequate air pressure is supplied for more than 4 seconds during rotation or inadequate air pressure is supplied when a motor start commanded. Torque limits are exceeded for too long a period of time. (Refer to P87 ” 17 – 4 Torque Over Load “.)
When Control Mode is in AUTO, the Control Command Signal is ” ON (Closed) ” before Main Power Switch is turned ON. When Control Mode is AUTO, the ERROR command is released without stopping the Control Command Signal ” OFF (Open) “. An unrecognizable motor is connected to the CONTROLLER. Rotating Speed is beyond the motors capability. Activated when Emergency Stop Signal is ” OFF (Open) “, or when rotating, Emergency Stop occurred by Emergency Stop Signal ” OFF (Open) “. Internal Memory Problem (EEPROM). Motor Cord (Power Line) Connector is not connected.

The motors Internal Temperature has risen above an acceptable amount. FAN has Stopped (80 Square Type).

FAN has Stopped (40 Square Type).

A mistake has been made while setting Parameter

.

86

CAUTION

If when using the External Input / Output Connector A / B and External Monitoring, please check

and resolve source of the problem whenever an Error Code is displayed on the Digital Speed

Indicator.

When an error occurs due to internal damage of the CONTROLLER, the Error Signal can not be

reset. Please send the Motor spindle and CONTROLLER to a NAKANISHI dealer for repair.

Error Code ” EF1 ”

The FAN (80 Square Type) located on the rear of the Control Panel of the CONTROLLER has

malfunctioned and stopped. The Protect Function of the CONTROLLER is operating and motor /

spindle has stopped. The FAN (80 Square Type) needs to be replaced.

This FAN can be replaced by the customer (Refer to P99 ” 22. MAINTENANCE “).

If the FAN has been stopped due to a malfunction, the motor / spindle can be temporarily

operated by setting Parameter

to

or

, until the FAN (80 Square Type) has beed

replacedRefer to P96 ” 18 – 4

Temporary Motor / Spindle Operation if FAN has Stopped (80

Square Type) ” section).

Error Code ” EF2 ”

The FAN (40 Square Type) located on the control board inside of the CONTROLLER has

malfunctioned and stopped.

Immediate FAN replacement is necessary and it CANNOT be replaced by the customer. Return to

a NAKANISHI dealer for service.

17 – 4 Torque Over Load
CAUTION
If you constantly, operate the system in an overload condition, even for short periods of time, the CONTROLLER will overheat and damage to the control, motor and spindle are possible. NAKANISHI recommends only continuous duty operation (LOAD LED’s with 3 LED’s lit) : Torque Load Monitor (LOAD) Voltage should be less than DC+5V.

When the Load Monitor LED lights 4 or more LED’s (3 Green LED’s and 1 of more yellow LED’s) an over-load

condition exists.

During a motor overload period, the following will occurs:

(1) Warning LED (WARNING) will blinks.

(2) Warning Code ” A3 ” is displayed on the Digital Speed Indicator .

(3) Warning Signal is output to the Pin No.20 (Warning) of External Input / Output Connector A .

Overload operation is considered a short-term operation mode. The allowable operation time depends on the

number of lighted LED’s on the Load Monitor LED (LOAD).

(1) Load Monitor LED 4 LED’s (Green LED 3, Yellow LED 1) : 30 Seconds

(2) Load Monitor LED 5 LED’s (Green LED 3, Yellow LED 2) : 10 Seconds

(3) Load Monitor LED 6 LED’s (Green LED 3, Yellow LED 2, Red LED 1) : 5 Seconds

When the allowable time is exceeded the motor will stop and the following occurs:

(1) Error LED lights.

(2) Error Code ” E8 ” is displayed on the Digital Speed Indicator .

(3) Error Signal is output to Pin No. 8 (ERROR) of the External Input / Output Connector A .

  • Set the parameter

, can be Change the Error Output Mode of the Error Signal for an Open or Closed

state. (Refer to P93 ” 18 – 4

Error output logic settings or error / warning code signal output selection

” section.)

English

87

18. SETTING OF OPERATING PARAMETERS
18 – 1 Entering Parameter Setting Mode
CAUTION
When in the parameter mode, normal operation of starting, stopping, etc. operation is not possible.
When changing from the parameter mode to normal operation, be sure to toggle the Main Power Switch OFF and ON again.

(1) Make sure that the Main Power Switch is turned OFF.

(2) While push and holding the Error Reset Button while turning the Power Switch ON at the rear of the

CONTROLLER.

(3) Hold the Reset Button down for 3 seconds while the CONTROL is powering up.

(4) The buzzer will ‘ BEEP ‘ 3 times, then release the Reset Button and Parameter Setting Mode will start.

is

Displayed.

18 – 2 Parameter Descriptions

Parameter types, contents, and default are detail in Table 8. When checking a parameter or changing a parameter setting, refer to P93 ” 18 – 4 Setting procedures ” section.

Table. 8

Code

Types

Setting of Error Output

Mode

Error (warning) code

signal output

Setting AUTO Mode for

Motor Speed Control

Setting Fixed Motor Speed Setting Maximum Motor Speed Selection of External Speed Control Mode

Selection of External Motor Start Signal Control Mode
Setting of Motor Acceleration and Deceleration Time

Temporary Motor / Spindle Operation if FAN has Stopped (80 Square Type)
Confirmation of Parameter Setting
Error History

Contents Changes the Error Output Signal, when an error occurs from normally open to normally closed. The error (warning) code can be output as a patterned signal.

When the control is in AUTO mode, the speed control is adjustable from the CONTROLLER Panel, set the parameter

to

to adjust the speed in AUTO Mode.

When a Fixed Motor Speed is desired, set the parameter to

and set the desired locked in speed.

When a Maximum Motor Speed is desired, set the parameter

to

and set the maximum speed.

The following Rotation Speed options can be selected when

control mode is AUTO.

: Analog Signal

: Pulse Signal

: Speed Point Signal

When control mode is in AUTO, please set the parameter

to

and set the desired rotating direction of the motor.

Activate Pin No. 2 to set a reverse direction along with the start command.

If acceleration time of the Motor startup to Motor Maximum

Rotation Speed or deceleration time of from Maximum

Rotation Speed to motor stop need to be lengthened. Set

the parameter to

and set the desired acceleration /

deceleration time.

(Acceleration time and deceleration time are common.)

If the FAN has malfunctioned and stopped, the Motor / Spindle can be temporarily operated.

Contents of the parameters that are set can be confirmed.

(

.) No parameter setting is necessary.)

Error code history of the last 5 error events can be confirmed. (No parameter setting is necessary.)

Default

88

18 – 3 Contents of Parameters
CAUTION
The operating parameters can be preset depending on the application requirements. The operating parameter presets ( ” Error output logic settings or error / warning code signal output selection “, ” Setting AUTO mode for Motor Speed Control “, ” Setting Fixed Motor Speed “, ” Setting Maximum Motor Speed “, ” Selection of External Speed Control Mode “, ” Selection of External Motor Start Signal Control Mode “, ” Setting of Motor Acceleration and Deceleration Time ” and ” Temporary Motor / Spindle Operation if FAN has Stopped (80 Square Type)” ) are retained in non-volatile memory and will be maintained even if power is disconnected. Please operate only after confirming contents of parameter settings.

The following parameters can be set.

Error output logic settings or error / warning code signal output selection

External input and output connector A (terminal No.8: ERR) to select the output of the error signal.

To select the output logic of the error signal when an error occurs, select

or

.

Select

to output a patterned error / warning code signal of the error / warning signal when an error /

warning occurs.

Table. 9 Parameter

Set Contents Error Occurred : Signal is OFF (Open). Error Occurred : Signal is ON (Closed). Error / warning code signal output due to error / warning occurrence

If an error / warning occurs during selection, a signal with the error / warning code patterned as shown below is output. When an error occurs, an error signal is output to the external Input / Output Connector A (terminal No. 8: ERR). (Refer to Fig. 37.) When a warning occurs, a warning signal is output to the external Input / Output Connector A (terminal No. 20: WARNING). (Refer to Fig. 38.) The signal when no error / warning has occurred is OFF (open).

English

89

Error Code Pulse width

E1

20mSEC

E2

40mSEC

E3

60mSEC

E4

80mSEC

E5 100mSEC

E6 120mSEC

E7 140mSEC

E8 160mSEC

EA 200mSEC

EC 240mSEC

EE 280mSEC

EH 300mSEC

EL 320mSEC

EP 340mSEC

Et 360mSEC

EF1 380mSEC

EF2 400mSEC

EFP 420mSEC

20mSEC

420mSEC

Fig. 37

Warning Code Pulse width

A1

20mSEC

A2

40mSEC

A3

60mSEC

A4

80mSEC

A5 100mSEC

A6 120mSEC

A7 140mSEC

AF 160mSEC

A0 180mSEC

20mSEC 180mSEC

20mSEC
Fig. 38

20mSEC

Setting AUTO Mode for Motor Speed Control

Allows the setting of the Motor Speed while in AUTO Mode. This parameter selects between speed control with

the Motor Speed Adjustment Button (SPEED , ) of the Control Panel or by External Command Signal

through External Input / Output Connector A.

Table. 10 Parameter
90

Set Contents Set the Motor Rotation Speed by External Command Signal through External Input / Output Connector A.
Set the Motor Rotation Speed by Motor Speed Adjustment Button (SPEED , ) via the Control Panel.

Setting Fixed Motor Speed

CAUTION

If you set the rotation speed higher than the rotation speed set at according to .

, rotation speed will be set

Allows the Motor speed to be fixed. Proactively prevents inadvertent change in speed. The Fixed Motor Speed can set by Control Mode MANUAL or AUTO.

Table. 11 Parameter

Set Contents Fixed Motor Speed is not enabled. Fixed Motor Speed is enabled.

Setting Maximum Motor Speed

CAUTION

Actual motor rotation speed of the motor will be limited, based on maximum motor rotation speed of the type of motor connected.

Maximum Motor Speed can be set. Allows a safe maximum rotational speed limit depending on the application. The Maximum Motor Speed can set by Control Mode MANUAL or AUTO.

Table. 12 Parameter

Set Contents Setting of Maximum Motor Speed is not enabled. Setting of Maximum Motor Speed is enabled.

English

Selection of External Speed Control Mode

CAUTION

Actual motor rotation speed of the motor will be limited, based on maximum motor rotation speed of the type of motor connected.

When Control Mode is in AUTO, it is possible select the External Speed Control Mode from Analog Signal

, Pulse Signal , or Speed Point Signal . Speed preset in the control according to

– .

Table. 13 Parameter

Set Contents Set speed by Analog Signal. Set speed by Pulse Signal. Set speed by Speed Point Signal.

When setting by Analog Signal , use the External Input / Output Signal ” Motor Speed Control Voltage (Pin

No. 23 : VR) “.

When setting via the Pulse Signal , use the External Input / Output Signal ” Count Pulse Signal for

Setting Motor Speed (Pin No. 3 : CNT_IN) ” and External Input / Output Signal ” UP / DOWN Signal for Setting Motor Speed (Pin No. 15 : UD_IN) “. The motor speed change per pulse is 100 min-1 (rpm).

External Input / Output Signal UP / DOWN Signal for Setting Motor Speed is as follows:

OFF (Closed) : Rotation speed decreases

ON (Open) : Rotation speed increases

When setting by Speed Point Signal , select the Speed Point

by using the combination of

Speed Point Select 0 (Pin No.17 : SEL0) and Speed Point Select 1 (Pin No. 5 : SEL1).

91

Table. 14 Speed Point

SEL1 (Pin No. 5) OFF (Open) OFF (Open) ON (Closed) ON (Closed)

Can setting the different rotation speed in 4 Speed Points Speed ranges from 1,000 – 40,000min-1 (rpm) can be set.

SEL0 (Pin No. 17) OFF (Open) ON (Closed) OFF (Open) ON (Closed)
– .

Selection of External Motor Start Signal Control Mode

During Auto Control Mode the motor Start signal can either by a direction signal and a Start signal or a FWD.

Start and a REV. Start signal.

When in Auto Control Mode, the Motor Start Signal can be used for either forward or reverse direction by

commanding a Direction Signal and a Start Signal. When set, the rotation direction is controlled by ” Rotating

Direction Setting (Pin No. 2 : DIR_IN) “, FWD. (Open), Rev. (Closed) and the Start Signal is controlled by ”

Rotate Command (Pin No. 14 : START) “. When

is set to

FWD. rotation is controlled by ” Rotate

Command (Pin No. 14 : START) ” and REV. rotation is controlled by ” Rotating Direction Setting (Pin No. 2 :

DIR_IN) “.

Table. 15 Parameter

Set Contents Motor startup and rotating direction is not commanded by signal. The startup motor with FWD. rotation or the startup motor with REV. rotation.

Setting of Motor Acceleration Time and Deceleration Time

Sets the time from the Motor start-up until reaching the maximum Motor speed, and the Deceleration Time from

the maximum Motor speed to stop.

Display unit is second. Acceleration Time and Deceleration Time setting range : 2 – 60 seconds.

Acceleration Time and Deceleration Time are common. Setup Value Unit : Seconds.

Table. 16 Parameter

Set Contents Acceleration / Deceleration Time of the motor is not enabled. Acceleration / Deceleration Time of the motor is enabled.

Table. 17 Setup Value (Unit : Seconds) 2 4 8 10 12 14 16 18 20 25 30 45 60

Display 2 4 8 10 12 14 16 18 20 25 30 45 60

92

Temporary Motor / Spindle Operation if the FAN has stopped (80 Square Type)

CAUTION

Set Parameter to , after replacing the FAN (80 Square Type). When FAN (80 Square Type) is operating normally, and parameter is set to , the Error Code ” EFP ” will be displayed.

If FAN (80 Square Type) has stopped due to a malfunction, the motor / spindle can be temporarily operated by

setting parameter

to

or

, until replacment the FAN (80 Square Type) has been completed.

If FAN (40 Square Type) has been stopped by malfunction, no motor operation is possible until the FAN is replaced.

Table. 18 Parameter

Set Contents
FAN stop (80 Square Type) : Motor / Spindle operation has stopped. Error code ” EF1 ” is displayed.
FAN stop (80 Square Type) : Motor / Spindle can still be run. Error code ” EF1 ” is not displayed. Outputs an External Warning Signal (WARNING) to the CONTROLLER.
FAN stop (80 Square Type) : Motor / Spindle can still be run. Error code ” EF1 ” is not displayed. Does not Output an External Warning Signal (WARNING) to the CONTROLLER. If other Warning Codes other than ” AF ” occur, these output signals will be sent to the CONTROLLER (External Warning Signal) (WARNING).

Confirmation of Parameter Setting

This mode allows the user to check the settings of parameters

. The parameter

can not be checked.

Error History

The Error History, which records previous error codes can be confirmed by the Error Code displayed on

the digital Speed Indicator.

Records Error Codes for viewing when machines are being run unattended.

In case there is no Error History,

will be displayed on the Digital Speed Indicator.

The last Error Code recorded will be ” 1.E ” and the oldest will be ” 5.E ” The Error code is displayed on the

Digital Speed Indicator.

If Error History contains more than five errors, oldest Error History, ” 5.E * ” will be deleted.

18 – 4 Setting Procedures

Error output logic settings or error / warning code signal output selection

CAUTION
If the Error Output Mode has been changed from the default setting, the parameter setting will be displayed the next time you enter Parameter Setting Mode.

English

Procedure

1. Push the Start / Stop Button (START / STOP) .

is displayed. This indicates that when an error occurs, the output will be ‘ OFF (Open) ‘.

3. Push the Motor Speed Adjustment Button (SPEED , ).

is displayed. This indicates that when an error occurs, the output will be ‘ ON (Closed) ‘.

5. Push the Motor Speed Adjustment Button (SPEED , ).

6. cd is displayed. with this setting, when an error or warning occurs, the error code or warning

code is output as a patterned signal.

7. You can cycle through the choices by pushing the Motor Speed Adjustment Button (SPEED ,

).

8. Push the Error Reset Button (RESET). When set, will be displayed.

9. If you desire to set other parameters, push the Motor Speed Adjustment Button (SPEED ,

) to select the parameter that needs to be set. 10. When you are finished setting parameters, press the Error Reset Button (RESET) then turn the

Main Power Switch is OFF.

93

Setting AUTO Mode for Motor Speed Control

Procedure

1. Push the Start / Stop Button (START / STOP).

is displayed. This indicates that speed control by the Motor Speed Adjustment Button

(SPEED , ) is disabled. The External Command Signal Control will be operational.

3. Push the Start / Stop Button (START / STOP).

is displayed. This indicates that speed control is changeable by the Motor Speed

Adjustment Button (SPEED , ).

5. You can cycle through the choices by pushing the Start / Stop Button (START / STOP).

6. Push the Error Reset Button (RESET) to send the settings to memory,

will be displayed.

7. If you desire to set other parameters, press the Motor Speed Adjustment Button (SPEED , )

to select the parameter that needs to be set. 8. When you are finished setting parameters, press the Error Reset Button (RESET), then turn the

Main Power Switch OFF.

Setting Fixed Motor Speed

CAUTION
Actual motor rotation speed of the motor will be limited, based on maximum motor rotation speed and the type of motor connected.

Procedure

1. Push the Start / Stop Button (START / STOP).

is displayed. This indicates that Fixed Motor Rotation Speed can not be set.

3. Push the Start / Stop Button (START / STOP).

4. The setting motor rotation speed displayed on Digital Speed Indicator.

5. Push the Motor Speed Adjustment Button (SPEED , ) to set the motor rotation speed.

The Moto Rotation Speed range is 1,000 – 40,000min-1 (rpm)

6. Push the Error Reset Button (RESET) to send the settings to memory,

will be displayed.

7. If you desire to set other parameters, press the Motor Speed Adjustment Button (SPEED , )

to select the parameter that needs to be set.

8. When you are finished setting parameters, press the Error Reset Button (RESET), then turn the

Main Power Switch OFF.

Setting Maximum Motor Speed

CAUTION

Actual motor rotation speed of the motor will be limited, based on maximum motor rotation speed and the type of motor connected.

Procedure

1. Push the Start / Stop Button (START / STOP).

is displayed. This indicates that Maximum Motor Rotation Speed can not be set.

The Maximum Motor Rotation Speed is 40,000min-1 (rpm).

3. Push the Start / Stop Button (START / STOP).

4. The Maximum Motor Rotation Speed is displayed on Digital Speed Indicator.

5. Push the Motor Speed Adjustment Button (SPEED , ) to set the motor rotation speed.

The Moto Rotation Speed range is 1,000 – 40,000min-1 (rpm).

6. Push the Error Reset Button (RESET) to send the settings to memory,

will be displayed.

7. If you desire to set other parameters, press the Motor Speed Adjustment Button (SPEED , )

to select the parameter that needs to be set.

8. When you are finished setting parameters, press the Error Reset Button (RESET) , then turn

the Main Power Switch OFF.

94

Selection of External Speed Control Mode

CAUTION
Actual motor rotation speed of the motor will be limited, based on maximum motor rotation speed and the type of motor connected.

Procedure

1. Push the Start / Stop Button (START / STOP).

is displayed.

2 – 1 If wish to set rotation speed via an Analog Signal (Motor Speed Control Voltage).

(1) Push the Error Reset button (RESET) to write the setting into memory.

(2)

will be displayed.

(3) If you desire to set other parameters, press the Motor Speed Adjustment Button (SPEED

, ) to select the parameter that needs to be set.

(4) When you are finished setting parameters, press the Error Reset Button (RESET), then

turn the Main Power Switch is OFF.

2 – 2 To set rotation speed using a Pulse Signal.

(1) Push the Motor Speed Adjustment Button (SPEED , ).

displayed on Digital

Speed Indicator.

(2) Push the Error Reset Button (RESET).

(3) To send the settings to memory,

will be displayed.

(4) If you desire to set other parameters, press the Motor Speed Adjustment Button (SPEED

, ) to select the parameter that needs to be set.

(5) When you are finished setting parameters, press the Error Reset Button (RESET), then

turn the Main Power Switch is OFF.

2 – 3 To set rotation speed using the Speed Point Signal.

(1) Push the Motor Speed Adjustment Button (SPEED , ).

displayed on Digital

Speed Indicator. This indicates

to

the 4 Speed points can be set.

(2) Push the Start / Stop Button (START / STOP).

(3) Alternately displayed

and setting speed. The Speed Point

can be set.

Push the Motor Speed Adjustment Button (SPEED , ) to set the motor rotation

speed.

Push the Error Reset Button (RESET).

is displayed.

If you are continuously setting these parameters, push the Start / Stop Button (START /

STOP).

(4) Alternately displayed

and setting speed. The Speed Point

can be set.

Press the Motor Speed Adjustment Button (SPEED , ) to set the motor rotation

speed.

Push the Error Reset Button (RESET).

is displayed.

If you are continuously setting these parameters, push the Start / Stop Button (START /

STOP).

(5) Alternately displayed

and setting speed. The Speed Point

can be set.

Press the Motor Speed Adjustment Button (SPEED , ) to set the motor rotation

speed.

Push the Error Reset Button (RESET).

is displayed.

If you are continuously setting these parameters, push the Start / Stop Button (START /

STOP).

(6) Alternately displayed

and setting speed. The Speed Point

can be set.

Press the Motor Speed Adjustment Button (SPEED , ) to set the motor rotation

speed.

Push the Error Reset Button (RESET).

is displayed.

If you are continuously setting these parameters, push the Start / Stop Button (START /

STOP).

3. If you desire to set other parameters, press the Motor Speed Adjustment Button (SPEED , )

to select the parameter that needs to be set.

4. When you are finished setting parameters, press the Error Reset Button (RESET), then turn the

Main Power Switch OFF.

95

English

Selection of External Motor Start Signal Control Mode

Procedure

1. Push the Start / Stop Button (START / STOP).

is displayed. This indicates that motor startup and setting the rotation direction can not

performed simultaneously.

3. Push the Start / Stop Button (START / STOP).

is displayed. This setting is right hand rotation with motor startup by Rotation Command

(Pin No. 14 : START) or left hand rotation with motor startup by Rotating Direction (Pin No. 2 :

DIR_IN) are can be set.

5. You can cycle through the choices by pushing the Start / Stop Button (START / STOP).

6. Push the Error Reset Button (RESET) to send the settings to memory,

will be displayed.

7. If you desire to set other parameters, press the Motor Speed Adjustment Button (SPEED , )

to select the parameter that needs to be set.

8. When you are finished setting parameters, press the Error Reset Button (RESET), then turn the

Main Power Switch OFF.

Setting of Motor Acceleration Time and Deceleration Time

Procedure 1. Push the Start / Stop Button (START / STOP).

is displayed. In this setting, the Acceleration Time and Deceleration Time is 2 seconds,

which is the factory default time setting.

3. Push the Start / Stop Button (START / STOP).

4. Alternately displayed

and the Acceleration Time / Deceleration time (default 2 secons).

5. Push the Motor Speed Adjustment Button (SPEED , ) select the setting time. (The

Acceleration Time / Deceleration time.) (Unit : Seconds)

6. Push the Error Reset Button (RESET) to send the settings to memory,

will be displayed.

7. If you desire to set other parameters, press the Motor Speed Adjustment Button (SPEED , )

to select the parameter that needs to be set.

8. When you are finished setting parameters, press the Error Reset Button (RESET) , then turn

the Main Power Switch OFF.

Temporary Motor / Spindle Operation if FAN has Stopped (80 Square Type)

Procedure 1. Push the Start / Stop Button (START / STOP).

is displayed. This setting is for FAN (80 Square Type) and the motor / spindle is stopped.

3. Push the Start / Stop Button (START / STOP) again.

is displayed. This setting is for temporary motor / spindle operation when FAN (80 Square

Type) has been stopped due to the FAN failure.

An Output to the External Warning Signal (WARNING) will be sent to the CONTROLLER.

5. Push the Start / Stop Button (START / STOP).

is displayed. This setting is for temporary motor / spindle operation when FAN (80 Square

Type) has been stopped due to a FAN failure. An Output to the External Warning Signal

(WARNING) will be sent to the CONTROLLER. If other Warning Codes occur other than “AF”,

these signals will be sent to the CONTROLLER (External Warning Signal) (Warning).

7. Push the Error Reset Button (RESET).

8. If you desire to set other parameters, press the Motor Speed Adjustment Button (SPEED , )

to select the parameter that needs to be set.

9. When you are finished setting parameters, press the Error Reset Button (RESET), then turn the

Main Power Switch OFF.

96

Confirmation of Parameter Setting

Procedure

1. Push the Start / Stop Button (START / STOP).

2. The setting contents of the

(

or

) and

are displayed.

3. Push the Start / Stop Button (START / STOP).

4. The setting contents of the

(

or

) and

are displayed.

5. Push the Start / Stop Button (START / STOP).

6. The setting contents of the

(

or Setting Motor Speed) and

is displayed.

When motor rotation speed is 30,000min-1 (rpm),

is displayed.

7. Push the Start / Stop Button (START / STOP).

8. The setting contents of the

(

or Maximum Motor Speed) and

is displayed.

9. Push the Start / Stop Button (START / STOP).

10. The setting contents of the

(

or

) and

are displayed.

11. Push the Start / Stop Button (START / STOP).

12. The setting contents of the

(

or

) and

are displayed.

13. Push the Start / Stop Button (START / STOP).

14. The setting contents of the

(

or

) and

are displayed.

15. The setting contents of the

(

,

or

) and

are displayed.

16. You can cycle through the choices by pushing the Start / Stop Button (START / STOP).

17. If you desire to set other parameters, press the Motor Speed Adjustment Button (SPEED , )

to select the parameter that needs to be set.

18. When finished CHANGING parameters and wish to exit the Parameter Mode, press Error Reset

Button (RESET), the cycle the controls main power switch off, then ON.

Error History

Procedure

1. Push the Start / Stop Button (START / STOP). 2. The error history and error code ” 1.E ” are displayed. In case there is no Error History,
will be displayed on the Digital Speed Indicator. 3. Push the Motor Speed Adjustment Button (SPEED , ). 4. The error history and error code ” 2.E
” are displayed. 5. Push the Motor Speed Adjustment Button (SPEED , ). 6. The error history and error code ” 3.E ” are displayed. 7. Push the Motor Speed Adjustment Button (SPEED , ). 8. The error history and error code ” 4.E ” are displayed. 9. Push the Motor Speed Adjustment Button (SPEED , ). 10. The error history and error code ” 5.E * ” are displayed. 11. You can cycle through the choices by pushing the Motor Speed Adjustment Button (SPEED ,
). 12. To clear the error history, press and hold the Start / Stop Button (START / STOP) for 3
seconds while the error history is displayed. The buzzer beeps and the error history is cleared. 13. Push the Error Reset Button (RESET) while is displayed. 14. If you desire to set other parameters, push the Motor Speed Adjustment Button (SPEED , ).
to select the parameter that needs to be set. 15. When you are finished setting parameters, press the Error Reset Button (RESET) , then turn
the Main Power Switch is OFF.

English

19. CONTROL PANEL SETTING RESUME FUNCTION

On power up, the system will resume all the control panel settings in the state they were in when the CONTROLLER was Powered OFF.

The following settings will be maintained

(1) Motor Rotation Speed

(2) Rotation DirectionFWD., REV.

(3) Control ModeMANUAL, AUTO

(4) Parameter Settings

97

20. BREAK IN PROCEDURE
During transportation, storage or installation the grease inside the bearings will settle. If the spindle is suddenly run at high-speed, the lack of evenly distributed grease will cuse excessive heat leading to bearing damage. After installation, repair, initial operation, or long periods of non operation please follow the break-in procedure. Please refer to the ” BREAK IN PROCEDURE ” in Operation Manual of the Motor / Spindle.

21. OPTIONAL DEVICES FOR CONTROLLER
21 – 1 E4000 SAFETY RELAY BOX
When using the E4000 SAFETY RELAY BOX, connect to the E4000 CONTROLLER. (1) Features
Safety Relay If an ” N – O Contacts ” becomes welded, all ” N – C Contacts ” will maintain a minimum distance of 0.5 mm when the coil is not energized. ” N – O Contacts ” (Normally-opened contacts) : Motor Power Line ” N – C Contacts ” (Normally-closed contacts) : Contacts Output
Safety of the Machines when used the Safety Relay Contacts Output When input Emergency Stop Signal that is coupled to opening the movable guard of the Industrial Machinery, Safety Relay will operate and certainly open the Motor Power Line. Contact output ((SAFE-1A) – (SAFE – 1B), (SAFE – 2A) – (SAFE – 2B)) of the ” N – C Contacts ” can be used for detecting the opening of the Motor Power Line. If ” N – O Contacts ” become welded, contact outputs will certainly maintain OFF (Open) by Forced Guide Mechanism. Therefore, Safety Relay can be used as an opening signal of movable guard with locking mechanism for Industrial Machinery.
(2) Specifications

Table. 19 Product Name Model Weight Standard Accessories

E4000 SAFETY RELAY BOX
E4000 – SRB
850g (Main Body)
Relay Cord 1pc. Connector Cover 2pcs. Operation Manual 1set.

Emergency Stop Cord 1pc. Connector Cap 1pc.

21 – 2 E4000 Control Panel Extension Cord

(1) Features This control panel extension cord is designed so the Operation Panel can be mounted (4m) from the E4000 CONTROLLER.
(2) Specifications

Table. 20

Product Name

E4000 Control Panel Extension Cord

Model

E4000 – PEX4

Front Panel Dimensions

73mm x 73mm

Attachable Pitch

63mm x 63mm

Attachable Hole Dimensions 3.4mm

Cord Length

4m

Standard Accessories

Mounting Screw (M3) 4pcs.

Operation Manual 1set.

98

21 – 3 E4000 BOX for Control Panel

(1) Features This is a convenient stand-off used to mount the E4000 Control Panel Extension Cord to the machines control for operator convenience.
(2) Specifications

Table. 21

Product Name

E4000 BOX for Control Panel

Model

E4000 – PB

Weight

216g

Standard Accessories

Case A 1pc. Blind Plate 1pc. Mounting Screw (M4)

2pcs.

Case B 1pc. Mounting Screw (M3) 6pcs. Operation Manual 1set.

22. MAINTENANCE
22 – 1 Cooling FAN
The FANS (80 Square Type and 40 Square Type) for CONTROLLER cooling are located on the inside of the CONTROLLER. FAN (80 Square Type) : Located on rear of the Control Panel inside of the CONTROLLER.
The FAN (80 Square Type), can be replaced by the customer (Replace in accordance with ” 22 – 2 FAN (80 Square Type) Replacement Method “). FAN (40 Square Type) : Located on the control board inside of the CONTROLLER. If a malfunction of the (40 Square Type) FAN should occur, immediate repair is necessary. Return the CONTROLLER to NAKANISHI dealer service.
22 – 2 FAN (80 Square Type) Replacing Method
DANGER
NAKANISHI warns all end-users not to replace the E4000 – FAN : FAN (80 Sqare Type) while the Control Power is ON, or if there is power connected to the main power cord. Disconnect the main power from its power source and release the supplied air to the AIR IN quick disconnect before replacing the E4000 – FAN (80 Sqare Type). Not following these instructions may lead to serious injury or death due to electric shock.
WARNING
Disassembly and assembly of the CONTROLLER should be for the purpose of replacing the FAN (80 Square Type) only. Disassembly and assembly should be performed in accordance with this Instruction Manual. Do not disassemble this CONTROLLER for any other reason.
CAUTION
When disassembling the E4000 CONTROLLER, note the loss of any removed screws. Account for all screws when reassembling.

English

99

(1) Turn OFF the Main Power Switch of the CONTROLLER. Turn OFF the Power supply and Air supply to the CONTROLLER.
(2) Remove the Mounting Screws (2pcs.) from the Case (Chassis) of the CONTROLLER (Fig. 39). (3) Remove the Power Cord Round Terminal from the main power supply terminal.
Remove the Power Cord, Motor Cord, Air Hose, Protective Cover A, B and options etc. from the CONTROLLER.

Remove

Remove

Case (Chassis)

: Mounting Screws

Fig. 39

Case (Bonnet)

: Munting Screws

Fig. 40

(4) Remove the Case (Fromt Panel) from the CONTROLLER (Fig. 41). (5) Remove the FAN Cord (Fig. 42).

Remove

Front Panel

Remove
Fig. 41

Fan Leaded Connentor
Fig. 42

Front Panel

(6) Remove the FAN Mounting Screws (4pcs.) from the Case (Front Panel) of the CONTROLLER (Fig. 43). (7) Remove the FAN from the Case (Front Panel) of the CONTROLLER (Fig. 44). (8) Remove the Plate for FAN from the Case (Front Panel). Clean the Case (Front panel) and Plate with a lint-free
cloth (Fig. 44).

Front Panel

Front Panel

Remove
: Fan fixed Mounting Screws
Fig. 43 100

Remove Plate for FAN
Fig. 44

(9) Position the Plate for FAN on the Case (Front Panel) as shown in Fig. 45. (10) Mount the Replacement FAN onto the Case (Front Panel) by using FAN Mounting Screws (4pcs.) (Specified
Torque : 0.5N·m±0.1) (Fig. 46).

Front Panel Plate for FAN

Front Panel

Place

Mount

: Align the screw hole and screw hole.

: Using Fan fixed Mounting Screws

Fig. 45

Fig. 46

(11) Connect the FAN Cord Connector (Fig. 47). (12) Re-attach the Front Panel to the CONTROLLER’s Main Body (Fig. 47).

CAUTION
After inserting the FAN Cord, gently pull on the FAN Cord to make sure that the FAN Cord Connector will not come loose.

English

Connect

Mount

Front Panel
Fig. 47
(13) Secure the top of the Case (Cover) to the CONTROLLER’S main body using the Mounting Screws (2pcs.). (Fig. 48).
(14) Secure the Case (Chassis) to the CONTROLLER’S main body by using the Mounting Screws (2pcs. each). (Fig. 49).

Mount

Case (Cover)

: Munting Screws

Fig. 48

Mount

Case (Chassis)

: Mounting Screws

Fig. 49 101

22 – 3 Confirmation of FAN Operation

(1) Turn ON the Power Supply to the CONTROLLER.

(2) Turned ON the Main switch on the CONTROLLER.

(3) Make sure that the Error Code ” EF1 ” on the display of the CONTROLLER is no longer displayed.

No Error Code means that FAN is in normal operation.

  • If Error Code ” EF1 ” is displayed on the display of the CONTROLLER.

Once again, turn OFF the Main Power Switch on the CONTROLLER and the incoming Power Supply .

Check the connection of the FAN Cord by disassembling the CONTROLLER again.

Recheck the FAN Operation by re-assembling the CONTROLLER. If all functions are in Normal Operation,

continue on to a ” 22 – 4 Confirmation of Normal Operation “.

If once again Error Code ” EF ” is displayed on the display of the CONTROLLER, procede no further. As

this may cause damage to the FAN or CONTROLLER. Return the CONTROLLER and replacement FAN

to an authorized NAKANISHI Dealer Service Center.

If Error Code ” EFP ” is displayed, set Parameter

to

“.

22 – 4 Confirmation of Normal Operation
Re-supply Air the CONTROLLER. Turn the CONTROLLER’s Power Switch ON. Check for normal CONTROLLER functions.
If CONTROLLER is not operating normally, the CONTROLLER may be damaged. Return to a NAKANISHI Dealer Service Center.

23. TROUBLESHOOTING

If a problem or concern occurs, please check the following prior to consulting your dealer.

Trouble

Cause

Inspection / Corrective Active

Motor does not run.

Power is not supplied.

Make sure to turn ON the Main Power Switch on the rear of the CONTROLLER. Make sure to connect the round terminal of the Power Cord to the AC Power Input Terminal Block securely. (Refer to P67 ” 11. POWER CORD CONNECTION ” section.)

Motor Cord Plug (Power Line or

Connect the Motor Cord plug (Power Line

Signal Line) is not connected to the or Signal Line) correctly to the Motor and

motor and CONTROLLER.

CONTROLLER.

Control Button (CTRL) is set to Manual mode but trying to start with an External Command Signal through External Input / Output Connector A.

Start with the Start / Stop Button (START/ STOP), or set the Control Button (CTLR) on the Control Panel to Auto mode.

Control Button (CTRL) is set to Auto mode but trying to manually start with the Start Button (START/ STOP) on the Control Panel.

Start with an External Command Signal or set the Control Button on the Control Panel to Manual mode. ( When Start with an External Command Signal, refer to P74 ” 16 – 1 (1) Details of External Input / Output Connector A Signal Table. 4 Pin No. 14 ” )

When using the E4000 Safety Rlay Set Emergency Stop Signai to be “ON”

Box, Emergency Stop Signal is

(close).

OFF (Open).

102

Trouble Motor does not run.
Motor Speed is not displayed correctly.
Motor Speed is not displayed correctly.
Spindle does not rotate or rotate smoothly. Overheating during rotation. Abnormal vibration or noise during rotation.
Tool slippage.
High run-out.

Cause

Inspection / Corrective Active

An Error has occurred. (Error LED is lit.)

Check P86 ” 17 – 3 Resetting System after Error Codes. Refer to Table 7 “. Error will not be released until cause of the error has been removed.

Low Air Pressure

Adjust to the air pressure 0.2 – 0.35MPa (29.0 – 50.8psi).

Incorrect Motor Speed

Confirm the commanded rotation speed of connected motor and commanded rotation speed motor voltage is correct. (Refer to Operation Manual of the Motor Spindle).

Motor Fixed Speed is set in the parameter .

Release parameter . (Refer to P94 ” 18 – 4 Motor Speed ” section.)

Setting Fixed

The Maximum Motor Rotation speed not more than desired Motor Rotation Speed set by parameter
.

Setting the Maximum Motor Rotation

Speed more than Motor Rotation Speed by

parameter .

(Refer to P94 ” 18 – 4

Setting

Maximum Motor Speed ” section.)

Incorrect setting of the Motor Rotation Speed as set by parameter .

Setting the Motor Rotation Speed by selected

Motor Speed Rotation set in parameter .

If in AUTO,

is set to OFF, change

to .

The spindles bearings have been damaged.

Replace the ball bearings. (Return to NAKANISHI dealer service.)

The motor has been damaged.

Replace the motor. (Return to NAKANISHI dealer service.)

Cutting debris has contaminated the ball bearings, and the ball bearings are damaged.

Replace the ball bearings. (Return to NAKANISHI dealer service.)

Low air pressure.

Check air hose connection and air pressure.

The tool is bent.

Replace the tool.

Cutting debris has contaminated the ball bearings.

Replace the ball bearings. (Return to NAKANISHI dealer service.)

The spindle bearings has been damaged.

Collet or collet nut are not correctly Check and clean the collet and collet nut.

installed.

Reinstall the collet and collet nut.

The collet and the collet nut are worn.

Replace the collet and collet nut.

The tool is bent.

Change the tool.

Collet nut is not correctly installed. Secure the collet and the collet nut correctly.

The collet and the collet nut are worn.

Replace the collet and the collet nut.

Inside of the spindle is worn.

Replace the spindle shaft. (Return to NAKANISHI dealer service.)

English

103

Trouble High run-out.

Cause

Inspection / Corrective Active

Contaminants inside the collet and Clean the collet, collet nut and the inside of

the collet nut or the spindle.

the taper and spindle.

The spindle bearings have been damaged.

Replace the ball bearings. (Return to NAKANISHI dealer service.)

24. DISPOSAL OF THE CONTROLLER
When disposal of a CONTROLLER is necessary, follow the instructions from your local government agency for proper disposal of electrical components .

104

2021-12-02 CACC0105 005S

References

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