Nakanishi EM-4040 User manual

CAUTION
WARNING
EM-4020・EM- 4020A
EM-4040
・EM - 4040A
OPERATION MANUAL
Brushless Motor
Thank you for purchasing the EM-4020・EM-4020A・EM-4040・EM-4040A Brushless Motor. The <E4000
CONTROLLER>, <E4000 Series Spindle>, and <Air Line Kit > are required to drive this brushless motor. Read
these Operation Manual carefully before use. Also read <E4000 CONTROLLER>, <E4000 Series Spindle>, and
<Air Line Kit> Operation Manuals. Always keep this Operation Manual in a place where a user can referred to for
reference at any time.
1. CAUTIONS FOR HANDLING AND OPERATION
■Read these warnings and cautions carefully and only use in the manner intended.
■ These warnings and cautions are intended to avoid potential hazards that could result in personal injury to the
operator or damage to the device. These are classified as follows in accordance with the seriousness of the risk.
Class Degree of Risk
WARNING A safety hazard could result in bodily injury or damage to the device if
the safety instructions are not properly followed.
CAUTION
A hazard that could result in light or moderate bodily injury or damage
to the device if the safety instructions are not followed
①This brushless motor is not a hand tool. It is designed to be used on CNC machines or special
purpose machines.
②Do not touch the cutting tool while it is running. It is very dangerous.
③Wear safety glasses, dust mask and use a protective cover around the spindle whenever the
spindle is rotating.
④Never connect, disconnect or touch the Connector and Motor Cord Plug with wet hands. This
may cause an electric shock.
⑤Never operate or handle the brushless motor until you have thoroughly read the Operation
Manuals and safe operation has been confirmed.
1) To prevent injuries / damages, check the spindle and cutting tool for proper installation,
before operating the brushless motor.
2) Before disconnecting the brushless motor, always turn the control power off and turn the
compressed air supply to the CONTROLLER off. Then it is safe to remove the brushless
motor.
⑥When installing a brushless motor to a fixed base, make sure the fixed base is grounded in
order to avoid the risk of an electric shock.
①Do not drop or hit this brushless motor, as shock can damage to the internal components.
②Select suitable products or tools for all applications. Do not exceed the capabilities of the
spindle or tools.
③Carefully direct coolant spray to the tool. Do not spray directly on the brushless motor body.
④Stop working immediately when abnormal rotation or unusual vibration are observed.
Afterwards, please check the content of section 7 "TROUBLESHOOTING".
⑤After installation, repair, initial operation, or long periods of non operation, please carry out
break -in as follow. Start rotating slowly and over a short period of time, increase speed
gradually until allowable maximum speed.
⑥Do not disassemble, modify or attempt to repair this brushless motor. Additional damage
will occur to the internal components. Service must be performed by NSK NAKANISHI or an
authorized service center.
⑦When using this brushless motor for mass production, please purchase the another brushless
motor as a spare in case of an emergency.
2. FEATURES
① The Brushless Motor housing is made from precision ground, hardened, stainless steel (SUS) with an outside
diameter of ȭ40 mm.
②Excellent durability and high reliability are obtained by using a high-speed brushless motor, which eliminates
the need for brush replacement and frequent maintenance.
③The maximum output is 1200W.
④A quick disconnect cord is available for easy brushless motor removal.
⑤Air-cooling system with a small volume of air (100ℓ/ min) is used to prevent heat buildup and allows long
continuous operation.
OM-K0644E
3. SPECIFICATIONS AND DIMENSIONS
3 - 1 Specifications
Standard Accessories
・Wrench (36mm)・・1pc. ・Operation Manual・・1set.
3 - 2 Outside View
Fig. 1
3 - 3 Torque Characteristics
Model EM-4020 EM-4020A EM-4040 EM-4040A
Maximum Rotation Speed 20,000min-1 40,000min-1
Max. Output 1,200W
Weight 1,300g 1,800g 1,300g 1,800g
*Note1 : Motor Cord is sold separately. Please select the suitable motor cord length for your application.
<Option>
Motor Cord
*Note1
EMCD-4000- □M
(Power Line)
Cord Length : 2m, 4m, 6m, 8m
(The Air Hose ( ȭ6mm) of the same length is attached.)
EMCD-4000S- □M
(Signal Line)
Cord Length : 2m, 4m, 6m, 8m
(The Air Hose ( ȭ6mm) of the same length is attached.)
These Motor Cords <EMCD-4000-8M and EMCD-4000S-8M> are never to be usd for Angle
Type Brushless Motors <EM-4020A and EM-4040A>. 8 Meter Cords cannot be used on "A"
Type (90-Degree) Motors.
Fig. 2
①EM-4020・EM-4040 ②EM-4020A・EM-4040A
Fig. 3 Fig. 4
①EM-4020・EM-4020A ②EM-4040・EM-4040A
CAUTION
ȭ40 0
-0.01
（300）172.8
（14.4）
ȭ40 0
-0.01
（2,000）
（14.4）
195.2
0 5 10 15 20
1400
1200
1000
800
600
400
200
0
100
90
80
70
60
50
40
30
20
10
0
Continuous Duty Area
Speed (ｘ103min-1)
Output (W)
Torque (cN・m)
Output
Torque
0 5 10 15 20 25 30 35 40
1400
1200
1000
800
600
400
200
0
100
90
80
70
60
50
40
30
20
10
0
Speed (ｘ103min-1)
Output (W)
Torque (cN・m)
Continuous Duty Area
Output
Torque

5. CONNECTION OF MOTOR CORD
・Before connecting to the Motor Cord to the Motor and CONTROLLER, verify the Main Power
Switch in the CONTROLLER is turned OFF. If the Main Power Switch on the CONTROLLER is
ON while connecting the Motor Cord, damage to the CONTROLLER is possible.
・Install the protective cover (Protective Cover etc.) to prevent damage or contamination to the
Motor Cord Plug when not in use.
①Remove the Protective Cover of the Motor Cord (Motor Power Line and Motor Signal Line).
Fig. 6
②Carefully insert the Alignment Pin into the Alignment Hole and push straight into the Connector of the Motor
Cord.
Fig. 8
③Tighten the Coupling Nut with clockwise.
Fig. 9
③Insert the air hose of the Motor Cord Side to the air joint of the Motor Side.
Fig. 10
①Loosen the Fastening Screw (3 locations) of the Motor
Cord Exit Housing.
②Adjust the Motor Cord Exit Housing to the desired
position.
③Re-tighten the Fastening Screws (3 locations) of the
Motor Cord Exit Housing.
4. POSITION ADJUSTMENT OF THE MOTOR CORD EXIT HOUSING (BLUE
AREA) ON THE EM-4020A and EM-4040A
The Motor Cord Exit Housing (Blue Area) of the EM-4020A and EM-4040A can be adjusted by rotating to a desired
position.
Fig. 5
7. TROUBLESHOOTING
Make sure your hands and all interlocking parts of the spindle and motor are clean before
connecting the motor to the spindle. This is critical in preventing contaminants from entering
the motor or spindle.
Align the threads on the front end of the motor and the rear end of the spindle, then rotate the spindle clockwise. If
the drive shaft of the motor does not engage the drive dog on the spindle, it will not be possible for the spindle to
rotate. DO NOT FORCE THIS CONNECTION. Turn the spindle back a few threads, rotate the collet cap or spindle
shaft slightly by hand until the drive shaft and the drive dog are fully engages. This may take several attempts.
Use the 36mm wrench that have been provided for the final tightening of the spindle to the motor.
Fig. 11
If a problem or concern occurs, please check the following prior to consulting your dealer.
Trouble Cause inspection / Corrective Action
Motor does not
run.
Power is not supplied. ・Make sure to turn ON the Main Power Switch on
the rear of the CONTROLLER.
・Connect the power cord correctly to the AC Power
Input Terminal Block of the CONTROLLER.
Motor Cord Plug is not connected to
the Motor and CONTROLLER.
Connect the Motor Cord plug correctly to the Motor
and CONTROLLER.
Control Button (CTRL) is set to
Manual mode but trying to start with
an External Command Signal through
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 " 13 - 1 (1) Details of External Input / Output
Connector A Signal Table 2 Pin No. 14 " section of
the E4000 CONTROLLER Operation Manual. )
When using the E4000 Safety Relay
Box, Emergency Stop Signal is OFF
(Open).
Emergency Stop Signal is ON (Closed).
An Error has occurred. (Error LED is
lit.)
Check the "Resetting System after Error Codes" of
the E4000 CONTROLLER Operation Manual. 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.
Can not increase
or decrease the
speed of the
motor.
Motor Fixed Speed is set in
parameter. Turn this Parameter OFF
to allow rotational speed changes
Release parameter .
(Refer to " 15 - 4 ③Setting Fixed Motor Speed
" section of the E4000 CONTROLLER Operation
Manual.)
Can not set the
motor speed to
its maximum
allowable speed.
Either the required speed value is
higher than the maximum rotation
speed of the motor, or the upper limit
of the rotational speed has been set
in parameter .
Set the Maximum Rotation Speed to a value less
than the Motor Rotation Speed set in Parameter
.
Abnormal
vibration or noise
during rotation.
Cutting debris has contaminated the
ball bearing.
Replace the ball bearings.
(Return to NAKANISHI dealer service.)
Low air pressure. Adjust to the air pressure 0.2 – 0.35MPa.
2015.07.20 002 九
CAUTION
Motor Cord Exit Housing (Blue Area) cannot
be rotated more than 360 degrees. If forcibly
rotated, the mechanical stop inside the Exit
Housing will break and cause the base of the
cord to kink, leading to internal damage of the
cord.
Motor Cord Exit Housing
(Blue Area)
： Fastening Screw
(3 locations)
Rotating Part
Turns 360ﾟ
CAUTION
Protective CoverDetach
Motor Power Line
Fig. 7
Protective CoverDetach
Motor Signal Line
MotorCordSideMotor Side
Alignment Pin Alignment Hole
Tighten
Coupling Nut
Insert
6. CCONNECTION TO THE SPINDLE
CAUTION
Tighten
Turn
Transmission Clutch
36
36

Refer to the E4000 CONTROLLER Operation Manual.