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7 . CHANGING THE TOOL
CAUTION
Do not tighten the collet chuck without inserting a tool or dummy bur, as this will damage the
collet chuck, spindle or chuck nut, causing dif culty removing the collet chuck.
RECOMMENDATION
Please set the cutting tools to minimize the overhang amount. 13mm is the maximum amount of
overhang to maintain high accuracy and safety.
① Set the provided 12mm wrench on the spindle.
② Place the provided 14mm wrench on the chuck
Chuck Nut
nut and turn it counterclockwise to loosen the
collet chuck and remove the tool. (The rst turn will
loosen the chuck nut, but the tool will not release
and turning will become stiff. Keep turning through
the stiffness and the collet chuck will open.)
③ Clean the collet chuck and chuck nut, then insert
the new tool and tighten the collet chuck by turning
clockwise. Do not overtighten.
8 . REPLACING THE COLLET CHUCK
CAUTION
When installing the collet chuck into the chuck nut, be sure to fully engage the latch inside the
chuck nut to the groove on the collet chucks outer diameter area. In addition, remember that if the
collet chuck is attached without being engaged with the latch of the chuck nut, the collet chuck
cannot be removed and this may cause damage to the collet chuck or the spindle.
① Remove the tool according to the section
" 7. CHANGING THE TOOL" procedure
above and remove chuck nut assembly.
Chuck Nut
(Fig. 16)
② The collet chuck and chuck nut are
secured by a groove in the collet chuck
and a ange in the chuck nut. To remove
the collet chuck hold the chuck nut in one
hand and push diagonally down on the
collet chuck. The collet chuck should be
released (Fig. 17).
③ To install the collet chuck, hold the collet
Fig. 16
chuck at a slight angle, and insert it into
the chuck nut (Fig. 18).
Groove
Latch
Press the collet chuck in the chuck nut by
positioning the collet chuck in the chuck
nut and pressing down on at surface.
(Fig. 17)
Chuck Nut
Be sure to fully engage the latch inside
the chuck nut into the groove on the collet
Fig. 18
chucks outer circumference area (Fig. 19).
9 . INSTALLATION INTO THE MACHINE
DANGER
Do not rotate the machining center's main spindle
with the HES Brushless Motor Spindle installed.
Rotating the machining center's main spindle with
the HES Brushless Motor Spindle installed
can cause the motor cord to become tangled and
pull the control unit off it is mounting. This may
Air Cap
cause lead to a big accident.
WARNING
Whenever installing a Brushless Motor Spindle to a
Quick Release
Ring
xed base, ensure that the xed base is grounded
in order to avoid risk of an electric shock.
① Insert and Clamp the HES Brushless Motor Spindle to the
main spindle of the machining center.
② Remove the Electric Connector Cap from the HES
Brushless Motor Spindlee by turning counterclockwise
(Fig. 20).
③ Remove the Air Cap from the HES Brushless Motor
Spindle's Air Joint (Fig. 20).
④ Install the
4mm air hose on the HES Brushless Motor
Spindle's Air Joint (Fig. 21).
⑤ Detach the plug cap for motor cord and install the motor
cord to the HES Brushless Motor Spindle's plug. Please
make sure to align the pin on the plug and the groove on
the motor cord connector. Turn the motor cord connector
clockwise to tighten (Fig. 21, 22).
Insert
⑥ Fixture the Emergency Connector in the machine. Route
the motor cord and air hose and hold them securely with
enough slack to allow for quill travel. The Emergency
Connector should be positioned horizontally and the air
hose should not have any severe bends. Make sure air
can pass freely through the air hose. If the motor cord and
air hose are not held properly, the emergency connectors
may not separate properly in an emergency (Fig. 23).
CAUTION
・
When not using the HES Brushless Motor Spindle
please replace the Electric Connector Cap and air
cap to protect the connectors from contaminants
with HES Brushless Motor Spindle body. And reset
the plug cap for motor cord to motor cord.
・
Check that the Motor Cord Connector, Air Hose
and Emergency Connector have been tightened
properly before operation.
・
DO NOT separate the emergency connector
manually.
It is not a quick disconnect connector. Emergency
System: If the machine's main spindle is rotated
by mistake, the Emergency Connector on the
motor cord will separate. If the hanger for the
Emergency Connector is too loose the Emergency
Connector can slip out of position during high
speed rotation and cause the Emergency System
to malfunction.
Please check the integrity of the Emergency
Connector and suspension prior to use.
CAUTION
・
If the Emergency Connector is separated, check
the motor cord and air hose for damage, Ieaks,
rips, torn insulation or any other damage before
reconnecting the Emergency Connector. If the
Air Emergency Connector is separated, you
may reconnect using a small dab of Super Glue
to reattach it. Check air system for leaks and if
everything checks ok you can proceed with use.
If problems exist in either the Air Emergency
Connector or the Motor Cord Emergency
Tool
Connector please send the unit to NAKANISHI
Loosen
for service. Do not disconnect the Air Emergency
connector expect in an emergency.
⑦ Installation of the provided lock bar
Screw the lock bar into the tapped hole on the spindle
Spindle Shaft
Tighten
housing as shown in Fig. 24
CAUTION
Fig. 15
The lock bar is not intended to stop the main
spindle from rotating ; it is only intended to be
used as a precautionary measure. If it is not
needed, it does not need to be installed.
10 . CONNECTING TO THE CONTROLLER
① Connect the Motor Cord and Air Hose as shown in Fig. 25.
② An Air Line Kit such as NAKANISHl'S (AL- C1204) must be used. The CONTROLLER and the HES Brushless
Motor Spindle must be supplied with clean, dry air regulated to between 0.25MPa - 0.3MPa Connect the output
Tool
of the Air Line Kit to the CONTROLLER's Air In connector. If you are not using NAKANISHl'S Air Line Kit, you
must use a regulator and air lter or dryer to supply clean, dry, regulated air to the CONTROLLER and the HES
Brushless Motor Spindle.
Water contamination in the air will cause damage to the Brushless motor and spindle.
Wrench Seat
Loosen
※ For details of the operation and connections of the CONTROLLER and Air Line Kit please refer to their
Collet Chuck
respective Operation Manuals.
③ Do not attempt to start the HES Brushless Motor Spindle until you have completed and double checked all the
DOWN
procedures described in this Operation Manual. Absolutely DO NOT ROTATE the MACHINE'S MAIN SPINDLE
Spindle Shaft
after installing the HES Brushless Motor Spindle.
Chuck Nut
Fig. 17
Connection
Hose
Latch
Collet Chuck
To Air Compressor
Primary Joint
Connector for
Air Hose
Fig. 19
11 . THE HES BRUSHLESS MOTOR SPINDLE CENTERING ALIGNMENT
CAUTION
Electric Connector
Cap
It is important to align the HES centerline to the machining center's centerline prior to using the
HES Brushless Motor Spindle. The HES Brushless Motor Spindle and taper housing are precision
machined to the exacting tolerances of the applicable standard for each taper. However, since no
Push
tolerance is +0, - 0 it could be dif cult to initially achieve perfect centerline alignment just by hand
Pull
Loosen
loading the spindle. Please follow the steps below to ensure proper centerline alignment.
Ait Joint
① To nd the main spindle's center, mount
a tool in a highprecision end mill holder
and machine the pattern described
below and measure the center. Or use
a 1/4" collet chuck (Option) and mount
an edge nder in the collet chuck to
determine the true centerline of the HES
Brushless Motor Spindle.
Fig. 20
Motor Cord
Alignment Hole
Tighten
Motor Cord Connector
Air Joint
Alignment Pin
② To adjust the HES centerline, mount
the HES Brushless Motor Spindle in the
Plug
machining center's quill and use a dial
gauge on a test pin. Loosen the six bolts
Spindle Housing
that hold the taper housing together,
slightly and tap out the X-Y eccentricity.
Rotate the machining center's spindle by
Fig. 21
Fig. 22
hand to Main Spindle verify concentricity.
(Fig. 28)
Bolt
Emergency Air Joint
Emergency Connector
Fig. 23
Block
(Not Provided)
Lock Bar
(Accessories)
Fig. 24
Motor Cord
Air Hose
CONTROLLER
LOAD
SPEED
RUN
×
1000min
-1
DOWN
UP
WARNING
ERROR
AUTO
FWD
RESET
GEAR
CTRL
DIR
START
STOP
MANUAL
REV
Secondary Joint
NE260
E3200 SERIES CONTROL UNIT
6 One - Touch Joint
A
MOTOR
EXT I/O
AIR
IN
OUT
B
SERIAL I/F
Fig. 25
Main Spindle
Spindle Taper
HES
Tooling Holder
Mill an X-Y cross pattern in
Mount the HES Brushless Motor
a scrap piece and measure
Spindle in the quill and mill the same
the X-Y intersection.
cross pattern with a smaller diameter
tool inside the previously milled
pattern. Measure the difference in the
X-Y intersections.
Fig. 26
Fig. 27
Main Spindle
Mounting Bolt
(6pcs.)
Dial Gauge
Fig. 28
12 . 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 grease will be ejected from the bearings, causing excessive heat that will cause bearing
damage. After installation, repair, initial operation, or long periods of non operation, please follow the break-in
procedure detailed in Table 2.
Table 2.
Steps
1
2
3
Rotation Speed (min
-1
) (rpm)
12,000
24,000
32,000
Rotation Time (min)
15
10
10
No Abnormal
The spindle housing temperature during the break-in process should
Noises.
not exceed 20 degrees C (36 degrees F) above ambient temperature.
Should the spindle exceed this limit, rest the spindle for at least 20
Items to Check
minutes and re-start the break in procedure from the beginning. If
the housing temperature rises again and exceeds 20 degrees C (36
degrees F) above ambient temperature, check the spindle and motor
for proper installation.
13 . TROUBLESHOOTING
If a problem or concern occur, please check the following items prior to consulting your dealer.
< CONTROLLER or Motor >
Trouble
Cause
・ Make sure to turn ON the Main Power Switch on
Motor does not run.
Power is not supplied.
the front (rear) of the CONTROLLER.
・ Insert the power cord plug correctly into the Main
Power Inlet with Power Supply Fuses of the
CONTROLLER.
・Check if a fuse is blown.
Motor Cord Plug is not connected to
Connect the Motor Cord plug correctly to the Motor
the Motor, CONTROLLER.
and CONTROLLER.
Control Button (CTRL) is set to
Start with the Start / Stop Button (START/STOP),
Manual mode but trying to start
or set the Control Button (CTLR) on the Control
with an External Command Signal
Panel to Auto mode.
through Input / Output Connector A.
Control Button (CTRL) is set to Auto
Start with an External Command Signal or set the
mode but trying to manually start
Control Button on the Control Panel to Manual
with the Start Button (START/STOP)
mode.
on the Control Panel.
Emergency Stop Signal on External
Check the setting of parameter
Input / Output Connector B is OFF
(Open).
An Error has occurred.
Check and correct the source of the Error Code.
(Error LED is lit.)
Low air pressure.
Adjust to the air pressure 0.25 ~ 0.3MPa.
Can not set the
Motor Fixed Speed is set in
Release parameter
increase or decrease
parameter. Turn this Parameter OFF
of the Motor Rotation
to allow rotational speed changes.
Speed.
Can not set the
Either the required speed value is
Set the Maximum Rotation Speed to a value less
motor speed to its
higher than the maximum rotation
than the Motor Rotation Speed set in Parameter
maximum allowable
speed of the motor, or the upper
.
speed.
limit of the rotational speed has
been set in parameter
.
Air Input Monitoring Override is set
Check the setting of parameter
in the
parameterto ON and the
motor's maximum speed has been
limited to 30,000 min
-1
(rpm).
A blinking dot appears
Gear Ratio is set to a value other
Check the setting of Gear Ratio.
on Digital Speed
than "1.0 ".
Indicator. Cannot set
the desired rotation
speed.
Refer to the E3000 CONTROLLER Operation Manual.
< Spindle >
Trouble
Cause
Spindle does not
The spindles ball bearings have
Replace the ball bearings.
rotate or rotate
been damaged.
(Return to NAKANISHI dealer service.)
smoothly.
The motor has been damaged.
Replace the motor.
(Return to NAKANISHI dealer service.)
Overheating during
Cutting debris has contaminated the
Replace the ball bearings.
rotation.
ball bearings, and the ball bearings
(Return to NAKANISHI dealer service.)
are damaged.
Abnormal vibration or
The tool shank is bent.
Replace the tool.
noise during rotation.
Cutting debris has contaminated the
Replace the ball bearings.
ball bearing.
(Return to NAKANISHI dealer service.)
The spindles ball bearings have
been damaged.
Tool slippage.
Collet chuck or chuck nut are not
Check and clean the collet chuck and chuck nut.
correctly installed.
Reinstall the collet chuck and chuck nut.
The collet chuck and the chuck nut
Replace the collet chuck and chuck nut.
are worn.
High run-out.
The tool is bent.
Change the tool.
Chuck nut is not correctly installed.
Secure the collet chuck and the chuck nut correctly.
The collet chuck and the chuck nut
Replace the collet chuck and the chuck nut.
are worn.
Inside of the spindle is worn.
Replace the spindle shaft.
(Return to NAKANISHI dealer service.)
Contaminants inside the collet
Clean the collet chuck, chuck nut and the inside
chuck and the chuck nut or the
of the taper and spindle.
spindle.
The spindle ball bearings has been
Replace the ball bearings.
damaged.
(Return to NAKANISHI dealer service.)
14 . DISPOSAL OF THE BRUSHLESS MOTOR SPINDLE
When disposal of a Brushless Motor Spindle is necessary, follow the instructions from your local government
agency for proper disposal of industrial components.
Contents are subject to change without notice.
4
5
40,000
50,000
10
10
Inspection / Corrective Action
.
.
.
Inspection / Corrective Action
2014.09.20 002
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