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E2530 SYSTEM
INSTRUCTIONS AND WARNING-Electric Devices
１．Cautions for handling and operation
２．Features
３．Specifications
４．Torque/Output Characteristics
５．Nomenclature
６．Diagrams
７．Input Voltage Switching
８．Changing Fuses
９．Power Cord Connection
contents
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10．Bracket Installation
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11．Motor Cord Connection
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12．Air Hose Connection
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13．Operation Procedures
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14．External Input/Output Control Signal Specifications
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15．Protect Function
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16．Break-In Procedure
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17．Trouble Shooting
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18．E2530 System Chart
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19．Setting of Operating Parameters
OM-K0495E
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Summary of Contents for Nakanishi E2530 SYSTEM
- Page 1 E2530 SYSTEM OM-K0495E contents INSTRUCTIONS AND WARNING-Electric Devices 10．Bracket Installation ９ １．Cautions for handling and operation ２ 11．Motor Cord Connection 10 ２．Features ３ 12．Air Hose Connection 10 ３．Specifications ３ 13．Operation Procedures 11 ４．Torque/Output Characteristics ４ 14．External Input/Output Control Signal Specifications 13 ５．Nomenclature ４ 15．Protect Function 17 ６．Diagrams ６ 16．Break-In Procedure 19 ７．Input Voltage Switching ７ 17．Trouble Shooting 19 ８．Changing Fuses ８ 18．E2530 System Chart 20 ９．Power Cord Connection ...
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Page 2: Important Instructions And Warning - Electric Devices
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, including the following. Read all these instructions before operating this product and save these instructions. 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 and a grounding plug. The plug must be plugged into a matching outlet that is properly installed and grounded in accordance with all local codes and ordnances. 2. Don't modify the plug provided - if it will not fit the outlet, have the proper outlet installed by a qualified electrician. 3. Improper connection of the grounding conductor can result in electric shock. The conductor with insulation having an outer surface that is green with or without yellow stripes is the grounding conductor. If repair or replacement of the electric cord or plug is necessary, do not connect the grounding conductor to a live terminal. 4. Check with a qualified electrician or service person if the grounding instructions are not completely understood, or if in doubt as to whether the tool is properly grounded. 5. Use only 3-wire extension cords that have 3-prong grounding plugs and 3-pole receptacles that accept the tool's plug. 6. Repair or replace damaged or worn cord immediately. 7. This tool is intended for use on a circuit that has an outlet that looks like the one illustrated in Sketch A in Figure (below)(115V). The tool has a grounding plug that looks like the plug illustrated in Sketch A in Figure (below). 8. For Installation in Machine Electrical Cabinet or when wiring directry to machine internal power terminal strip: 1) Prease refer to the pin diagram below for the proper wiring configuration. The plug shown is the female plug that attaches to the E2530 main power inlet. 2) Make sure you test each individual wire to verify proper circuit prior to attaching any wire to the terminal block. Do not assume wire colors are the same for all power cords. 9. Install an over current protective device of maximum 10 Amp on the E2530 main power circuit. Grounding Method Power cord connector L : Line N : Neutral E : Earth COVER OF GROUND OUTLET BOX... - Page 3 Thank you for purchasing the Ultra-Precision, High-Speed spindle system, E2530. The E2530 System was designed for use on CNC lathes, robots, NC lathes and special purpose machines. The motor, spindle and control unit are designed to work as an integrated system capable of 5,000-30,000min −1 . This system utilizes air to cool the motor and protect the spindle, please use an airline kit to ensure clean, dry, properly regulated air is supplied to the motor and spindle. The E2530 system is capable of ...
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Page 4: Control Unit
⑨ ⑩ ⑪ ⑫ ⑬ ⑭ ⑮ 2 ①The E2530 system is designed to be mounted in a CNC lathe, robot, NC lathe or special purpose machine for drilling, milling, slitting, grinding or other similar application. ②A high-speed brushless motor is used to achieve a maximum speed of 30,000min and eliminate the nuisance of brush maintenance. ③Speed control and protection functions utilize a high performance microprocessor. ④Automatic control and monitoring of spindle functions are possible. ⑤Wide speed range, 5,000-30,000min makes high precision machining possible. ⑥Compact control unit design allows easy installation in space restricted machines. Connectors and control panel are front mounted for easy access. ... - Page 5 4 E2530 Characteristics 140 ７ Output ６ 120 100 ５ Torque 80 ４ Intermittent Use Area 60 ３ Torque 40 ２ Continuous Use Area 20 １ ０ ３ −1 ※Output curve shown is Motor Speed（ｘ10 min ） intermittent use Curve 5 （ ）System ① ⑤ ⑥ ⑧ ⑨ ⑦ ② ⑩ ③ ④ ①Unit (NE236 Shown) ...
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Page 6: Control Panel
（ ）Control Panel ⑪ ⑫ ⑳ ⑲ ⑬ ⑱ ⑭ ⑰ ⑮ ⑯ ⑪Digital Speed Indicator (Speed) Control Panel or from an external source. Preset Speed, Actual Speed, Warning and Error ●MANUAL：Control Panel Codes are displayed to 2 digits. When the motor is ●AUTOqq ：External control through stopped the Preset Speed is displayed, when the the input/output connector. motor is rotating the actual speed is displayed. The ⑯Centering Mode Switch (500min ) display also displays the error codes when an error This switch activates the centering mode, which has occurred. ... -
Page 7: Control Unit Diagram
When any of the yellow or red LEDs are lit the are constantly monitored and the warning LED warning LED (Warning) ⑳ will flash, if this condition blinks when a hazardous condition has been is continued beyond the allowable interval the error detected. When a hazardous condition is detected LED (Error) ⑲ will flash and the motor/spindle will the warning LED blinks and the Digital Speed be shut down. ... - Page 8 7 ・The Control Unit is compatible with 120V-230V main supply voltage and is equipped with a switch for voltage selection. ！ ・Before connecting the control unit to the power supply, please check the main fuses and verify that they are compatible with the voltage being supplied. Please refer to the flow chart below for voltage switching procedures. Switch the main power switch on the control unit to OFF Disconnect the main power cord from the electrical outlet Input Voltage Supply 120V Input Voltage Supply 230V Fuse: T3.15A(250V) Fuse: T1.6A(250V) Order No.U195-152 Order No.U197-152 Refer to , Changing Fuses Refer to , Changing Fuses Move the Voltage Selection Switch Move the Voltage Selection Switch to the right hand position to the left hand position Concave Concave 100/115V 100/115V 200/230V 200/230V ※Switch Location Diagram ・The voltage selection switch is located on the lower, rear portion of the left side panel. ・Please use a standard screw driver to change the selector switch position. ！ ...
- Page 9 8 ！ ・ ・ ・ ・Push on the clips on the top and bottom of the fuse holder and remove the fuse holder and fuses. ・Remove the bad fuse or fuses and replace with the proper type and rating of fuse as listed below and determined by the input voltage being used. There are two different types of fuses depending on the input power source voltage. 115V Ｔ3.15Ａ(250V) U195-152 230V Ｔ1.6 Ａ(250V) U197-152 ・Replace the fuse holder containing the fuses into the fuse inlet box and make sure it snaps in place. 9 ・Insert the female plug into the main power inlet box ④ in the front of the unit. ・A screw hole is provided on the lower, right side of the control unit for attaching the tension relief. Use the provided Nylon Tension Relief to attach the power cord to the side of the control unit. ！ ...
- Page 10 10 ・Two mounting brackets are provided with the system. ・The brackets can be installed on the bottom or on the back of the control unit. ・After installing the brackets you can use the screw cutouts to mount the control unit. ①Bottom Installation ②Back Side Installation ・Attach the brackets using the six holes on ・Attach the brackets using the six holes on the back of the unit using the provided the bottom of the unit using the provided screws. screws. Bracket Bracket ！ ・ ・ ③Proper Clearance When installing 2 or more control units in the machine cabinet make sure to check that each single control unit has the proper clearance on all sides. 20㎜ 20㎜ 30㎜ 30㎜ 30㎜ 30㎜ ...
- Page 11 11 ・Align the guide pin A on the motor plug with the key way B on the motor socket on the front of the control unit. ・Screw in the coupling nut C of the motor plug to the motor socket D on the front of the control unit. Ｃ 12 ・Insert the provided φ6㎜ filtered air hose from the AL-0201 air line kit into the inlet joint ⑦ on the front of the control unit. (If you are not using the AL-0201 air line kit, make sure that the incoming air supply is dry, clean air.) ・Insert one end of the provided φ4㎜ cooling air hose into the back of the motor. ・Insert the other end of the φ 4㎜ cooling air hose into the output joint ⑧ on the front of the control unit using the provided 6㎜ to 4㎜ adaptor. ・Regulate air pressure between 0.15-0.25 MPa. ⑦ ⑧ Air Hose with filter Air Hose with filter Reducer Reducer （φ６―φ4） （φ６―φ4） Air Hose for the coolant of motor Air Hose for the coolant of motor （Outside diameterφ4㎜, length 4m） （Outside diameterφ4㎜, length 4m） ！ ・ ・ ・...
- Page 12 13 （1） Selecting control mode ・Using the control switch ( ) you can select between Manual (Front Panel Control) or Auto ⑮ in External Signal Source can be used to control Motor Start/Stop , Rotational Direction , 500min centering rotation . ⑮Control Switch ・Manual Mode-Front Panel Operation. ・Auto Mode-Control by External Signal Source. （2） Rotation Direction, 500min centering rotation, Motor Start/Stop. ①Manual Control Mode ・Set rotation direction Push the rotational direction switch ⑭ ・Select 500min centering rotation Push the 500min switch ⑯ (Never use 500min rotation for cutting, this mode is only for ...
- Page 13 ・Motor Start/Stop Input the motor start signal to Pin No. 14:START Motor rotating is ON 'Closed'(START LED will light) Motor stopped is OFF 'Open'(Start LED is Off) If the motor start signal is ON 'Closed' and the power switch is turned on or the control mode is changed from MANUAL to AUTO error code 'EA' will be displayed. This is a safety feature to prevent unintended rotation. （3） Setting Motor Speed ①Control Mode is set to MANUAL Set the speed by rotating the SPEED Knob ⑫. Clockwise increases speed, counterclockwise decreases speed. ⑫Knob −1 ・Motor Speed Range is 5,000-30,000min . If the air pressure is too low the control unit will not operate. ・The motor speed is displayed in 1,000min . 30 equals 30,000min ！ ⁄9 ・ ・ ・...
- Page 14 14 （1）Input/Output Connector A ①Outside INPUT-OUTPUT Connector Signal Detail / Input No. Pin Name Description Signal Function Output １ COM(+) 24VDC Power Source for Input +24V or 0V DC Power Source to be used for External Inputs. +24V or 0V External Control Inputs DC (*2). ２ DIR̲IN Rotation directed Input OFF(Open):FWD Controls the direction of rotation of the motor. signal ON(Closed):REV ３ − Not Used − Not Used ４ RESET Error Release Signal ...
- Page 15 ② Input/Output Signals ●Input Signal There are 4 kinds of input signals: rotation command, rotation direction, 500min speed command. These signals are +24VDc signals from an external signal source. Please use a separate power source that is capable of supplying 24VDC±10%, 20mA (5mA/circuit). Refer to Figures below for connections. PIN1(COM) connected to +24V DC PIN1(COM) connected to 0V DC COM： ＋ COM： 0Ｖ The side of unit The side of unit 24Ｖ 0Ｖ ＋ ●Output Signal There are 6 kinds of output signals: rotating , rotating direction , rotating pulse , rotating speed achieved , warning , and error . These signals are pulsed transistor activation signals. Voltage and Current Specifications Applied Voltage (Vmax)≦ 30VDC Working Current (Ip) ≦100mA (Rotational Pulse 50mA) Use an external power source for output circuits. It is recommended to use the same 24VDC power source used for input signals. Please refer to for connections. ＋24V The side of unit −COM：0V...
- Page 16 ●Motor Speed Control Signal ●Monitoring Signals Refer to Fig.21 for connections. There are 3 kinds of analog monitoring signals: Motor Current, Torque Load Monitor and Rotating Speed Monitor. Please refer to Fig. 22 for connections. The side of unit The side of unit １Ｋ Ω Ｖ Motor Current 10VDC Power Source for Monitor External Control Inputs １Ｋ Ω Torque Load Ｖ Motor Speed Control Signal Monitor １Ｋ Ω Rotating Speed Ｖ Monitor Voltage Potentiometer 5Ｋ Ω Fig.21 Fig.22 （2）Input/Output Connector B ①Outside INPUT-OUTPUT ConnectorB Signal Details Input / Pin Pin Name Description Signal Function ...
- Page 17 ②Input/Output Signals ●Output Signal（PIN No. 2-10, 5-13, 6-14） There are 3 kinds of output signals: Motor Signal Connect Detector , AUTO MODE and Unit Power Source Monitoring . These signals are pulsed transistor activation signals. Voltage and Current Specifications Applied Voltage (Vmax)≦30VDC Working Current (Ip) ≦ 100mA (Rotational Pulse 50mA) Use an external power source for output circuits. It is recommended to use a separate power from the one used for Input/Output Connector A. Please refer to for connections. ＋24V The Side of unit 0V 0V 0V （3）Input/Output Signal Connector Specifications 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) 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) ・The Plug and Cover are not provided with the system. Please purchase the specified plug and cover from local suppliers. ・Use only shielded cables to minimize RF interference and noise. Connect the shield to the plug cover. ・Different makers use different names for the cover. ！ ...
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Page 18: Warning Function
（4）Input/Output Connector A,B Pin Configuration １ 14 ２ 15 ３ 16 ４ １ 17 ９ ５ ２ 18 10 ６ ３ 19 11 ７ ４ 20 12 ８ ５ 21 13 ９ ６ 22 14 10 ７ 23 11 ８ 24 12 ConnectorＡ ConnectorＢ 15 ... - Page 19 （3） Resetting System after Error Codes There are 2 methods of releasing error codes. ・Push Error Reset Switch ⑰ RESET on the front panel. ・Switch the signal on PIN4(RESET) of Input/Output Connector A OFF(Open)-ON(Closed)- OFF(Open). Table 2 Error Code Problem Area Trouble Ｅ１ Excess Current Motor Current beyond safe limits. Ｅ２ Over voltage Motor Voltage beyond safe limits. Ｅ３ Motor Sensor Trouble with the sensor signal in the motor. Ｅ４ Control Unit Overheat Internal Temperature of the Control Unit too High. Ｅ５ Brake Circuit Trouble Trouble with the motor brake circuit. Ｅ６ Rotor Lock Motor stalled for more than 3 seconds. Inadequate air supplied for more than 4 seconds during rotation Ｅ７ Low Air Pressure or inadequate air supply when motor start commanded. Ｅ８ Torque Overload Torque limits exceeded for too long a period of time.See (4) on Page 24. Ｅ９ Trouble with Power Source Trouble with the power source inside the control unit. ...
- Page 20 Auto Mode Motor Speed Control setting, in the Reset the Auto Mode Motor Speed Control 'P2' parameters, is set to external command parameters. signal and trying to adjust speed with potentiometer or Auto Mode Motor Speed Control setting, in the 'P2' parameters is set to potentiometer and trying to adjust speed with Motor does not external command signal. reach the preset Check the front panel settings and input on 500 min Centering Rotation Mode is selected. Input/Output Connector A speed PIN No.16(500min ) and correct as necessary. Check the P3 parameter settings and Motor Fixed Speed is set in the P3 parameters. adjust as needed. Maximum Motor Speed is set in the P4 Check the P4 parameter settings and adjust as parameters. needed. Foreign Particles stuck in the collet chuck or spindle Clean the inside of the collet chuck and spindle High Run-Out Collet Nut is not properly positioned Position the collet nut properly Ball Bearings Worn Send to NAKANISHI for Repair Foreign Particles in the ball bearings. Send to NAKANISHI for Repair Abnormal Vibration Ball Bearings Worn or Noise during Operation Tool out of Balance Change the tool...
- Page 21 18 ・A wide variety of attachments are available depending on the application requirements ・Speed reducers are available to reduce spindle speed and increase torque. ・The (−) drive spindles were designed to be used with (−) drive motors and speed reducers. ！ Chuck Nut Chuck CHK-□□ Spindle NR-303 K-265 Grindstone AGM-03 Air Line Kit AL-0201 Axis for Metal Saw KCH-03 Speed Reducer ARG-01 90° Angle Spindle (1/4 Reduction) RAS-101 Control Unit NE236 Speed Reducer ARG-02 (1/16 Reduction) 90° Angle Spindle RA-100 (1/2.67 Reduction) Collet Chuck CH8-□□ Motor EM25-5000 Transmission Clutch Axis for Metal Saw KCH-02 90° Angle Spindle RA-200 (1/1.5 Reduction) The connection part The connection part Collet Chuck CHS-□□ − is concave −...
- Page 22 ⑥Air Input monitoring override The system can be configured to operate without cooling air, maximum speed is 25,000min . ！ CAUTION Once a parameters default setting has been changed the setting will be maintained even if power is disconnected. Please set the Error Output Mode, AUTO Mode Motor Speed Control, Fixed Motor Speed for Motor, and Maximum Motor Speed for Motor. ▲ Entering Parameter Setting Mode ...
- Page 23 ▲ Setting Error Output Mode ・Allows setting of the output signal on PIN No.8:ERR of Input/Output Connector A. ・When an error occurs the output can be set to ON(Closed) or OFF(Open). Procedure） 1. Push the Start Switch 2. is displayed. This indicates that when an error occurs the output will be OFF(Open). 3. Push the Start Switch 4. is displayed. This indicates that when an error occurs the output will be ON(Closed). 5. You can cycle through the choices by pushing the Start Switch. 6. Push the Reset Switch to send the settings to memory will be displayed depending on the position of the potentiometer. 7. If you desire to set other parameters turn the potentiometer to select the parameter to be set. 8. If you are finished setting parameters, turn the Power Switch off. If the Error Output Mode has been changed from the default setting, that setting will be displayed the next you enter Parameter Setting Mode. ▲Setting AUTO Mode Motor Speed Control ・Allows the setting of the manner in witch motor speed can be controlled when the system is being used in AUTO mode (External Command Signal Control). ・This parameter selects between speed control with the Motor Speed Adjustment Switch or by External Command Signal through Input/Output Connector A . Procedure）1. Push the Start Switch 2. is displayed. This indicates that speed control is by External Command Signal Control and the Motor Speed Adjustment Switch are Disabled. 3. Push the Start Switch.
- Page 24 4. is displayed. This indicates that speed control is by the Motor Speed Adjustment Switch and the External Command Signal Control for speed is Disabled. 5. You can cycle through the choices by pushing the Start Switch. 6. Push the Reset Switch to send the settings to memory will be displayed depending on the parameter being set. 7. If you desire to set other parameters push the Motor Speed Adjustment Switch to select the parameter to be set. 8. If you are finished setting parameters, turn the Power Switch off. ▲ Setting Fixed Motor Speed for Motor ・Allows the motor speed of Motor to be fixed. ・Fixes the motor speed in both MANUAL and AUTO modes. Procedure）1. Push the Start Switch 2. is displayed. This indicates that Fixed Motor Speed cannot be set. 3. Push the Start Switch. 4. is displayed. This indicates that Fixed Motor Speed can be set. 5. The Digital Speed Indicator will oscillate between on the selected motor speed and motor speed can be selected by turning the potentiometer. The speed control range is 5,000-30,000min . 6. Push the Reset Switch to send the settings to memory or 〜 will be displayed depending on the position of the potentiometer. 7. If you desire to set other parameters turn the potentiometer to select the parameter to be set. 8. If you are finished setting parameters, turn the Power Switch off. ▲ Setting Maximum Motor Speed for Motor ・Allows the setting of the maximum motor speed for Motor ・The set maximum motor speed effects both MANUAL and AUTO control Modes.
- Page 25 Procedure）1. Push the Start Switch 2. is displayed. This indicates that the Maximum Motor Speed is not set. 3. Push the Start Switch. 4. is displayed. This indicates that the Maximum Motor Speed is ready to be set. Maximum motor speed is displayed on the Digital Speed Indicator. 5. The Digital Speed Indicator will oscillate between on the selected motor speed and motor speed can be selected by turning the potentiometer. The speed control range is 5,000- 30,000min . 6. Push the Reset Switch to send the settings to memory Parameter number will be displayed depending on the position of the potentiometer. 7. If you desire to set other parameters turn the potentiometer to select the parameter to be set. 8. If you are finished setting parameters, turn the Power Switch off. ▲Setting 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 is set to the rotation direc- tion is controlled by Pin No.2 DIR̲IN, FWD. (Open), REV.(Closed) and the Start signal is control- led by Pin No.14 : START When is set to FWD. rotation is controlled by Pin No.14 : START and REV. rotation is controlled by Pin No.2 : DIR̲IN. Procedure）1. Push the Start Switch 2. is displayed. This indicates that the control mode is set to derection signal and start signal. 3. Push the Start Switch 4. is displayed. This indicates that the control mode is set to FWD. ON, REV. ON mode. 5. Push the Error Reset Switch to send the settings to memory will be displayed depending on the parameter being set. 6. If you desire to set other parameters push the Motor Speed Adjustment Switch to select the parameter to be set.
- Page 26 7. If you are finished setting parameters, turn the Power Switch off. ▲Setting Air Input monitoring override -1 ・The system can be set to operate without cooling air. Maximum speed is 25,000min when not using cooling air. Note : It is not recommended to use the system in this manner for general machining. This setting is only for light cutting and not for use with coolants. Procedure）1. Push the Start Switch 2. is displayed. This indicates that air must be supplied to operate the system. 3. Push the Start Switch 4. is displayed. The system can be cofigured to operate without cooling air, maximum speed is 25,000min . 5. Push the Error Reset Switch to send the settings to memory will be displayed depending on the parameter being set. 6. If you desire to set other parameters push the Motor Speed Adjustment Switch to select the parameter to be set. 7. If you are finished setting parameters, turn the Power Switch off. ▲Confirmation of the Parameter Settings ・Allows user to check the settings of the above parameters 〜 Procedure）1. Push the Start Switch 2. Display oscillates between and the setting for or 3. Push the Start Switch 4. Display oscillates between and the setting for or 5. Push the Start Switch 6. Display oscillates between and the setting for or setting motor speed (For example, display 30 for 30,000min ) (rpm) 7. Push the Start Switch 8. Display oscillates between and the setting for or Max. motor speed.
- Page 27 9. Push the Start Switch 10. Display oscillates between and the setting for or 11. Push the Start Switch 12. Display oscillates between and the setting for or 13. Push the Start Switch 14. Rturn to setting Parameter or push Error Reset Switch to finish. ▲ Default Parameter Settings When the system is shipped from NAKANISHI's factory all parameters 〜 are set to ▲ Control Panel Setting Resume Function On power up the system will resume all the Control Panel settings in the position they were in when the system was shut off. The following settings will be maintained: 1. Rotating Direction (FWD, REV) 2. Control Mode (AUTO, MANUAL) 3. 500min speed selection 4. Parameter Settings...
- Page 28 Contents are subject to change without notice. 2015.02.20 001...
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