NAKANISHI E4000 Motor Spindles User Manual
- June 9, 2024
- NAKANISHI
Table of Contents
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
51
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.
52
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>,
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.
53
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.
54
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.
55
English
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)
56
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
57
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)
specification2
Photo Coupler : 9 Analog Connections : 1
MOS Relay : 8 Analog : 3
Photo Coupler 1 Relay Contact 2 (Safety Relay BOX)
58
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
English
59
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
60
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.
62
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.
63
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.
64
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
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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
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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.
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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
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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.
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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.
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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
84
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