Nakanishi EMA - 3020K User manual

1
EMA - 3020K
Brushless Motor Spindle
OPERATION MANUAL 001
OM-K0547E
Thank you for purchasing the Brushless Motor Spindle " EMA - 3020K ". This Brushless Motor Spindle is designed
for grinding, small diameter drilling and milling, etc. The E3000 CONTROLLER and Air Line Kit are required to
drive this Brushless Motor Spindle. Read this and all the associated component Operation Manuals carefully before
use. Always keep this Operation Manual in a place where a user can referred to for reference at any time.
■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 classied 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.
CAUTIONS FOR HANDLING AND OPERATION
1.
①This Brushless Motor Spindle is not a hand tool. It is designed to be used on CNC machines or
special purpose machines.
②Do not exceed the " Maximum Allowable Motor Rotation Speed " (Refer to " 6 - 1 Specications ").
An excess of the Maximum Allowable Motor Rotation Speed may cause damage to the inside
components and short life.
③Do not touch the cutting tool while it is running. It is very dangerous.
④Wear safety glasses, dust mask, and use a protective cover around the Brushless Motor Spindle
whenever the Brushless Motor Spindle is rotating.
⑤Never connect, disconnect or touch the Power Cord Plug or Motor Cord Plug with wet hands. This
may cause an electric shock.
⑥Never operate or handle the Brushless Motor Spindle until you have thoroughly read the Operation
Manuals and safe operation has been conrmed.
1）To prevent injuries / damages, check the Brushless Motor Spindle and cutting tool for proper
installation, before operating the Brushless Motor Spindle.
2）Before disconnecting the Brushless Motor Spindle, 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 Spindle.
⑦When installing a Brushless Motor Spindle to a xed base, make sure the xed base is grounded
in order to avoid the risk of an electric shock.
⑧When 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.
WARNING

2
⑨Do not use bent, broken, chipped, out of round or sub-standard tools, as this may cause them to
shatter or explode. Tools with fractures or a bent shank will cause injury to the operator. When
using a new tool, rotate it in a low speed and increase speed gradually for safety.
⑩Do not exceed the maximum recommended allowable tool speed. For your safety, use speeds
below the maximum allowable speed.
⑪Do not apply excessive force. This may cause tool slippage, tool damage, injury to the operator or
loss of concentricity and precision.
WARNING
①Do not drop or hit this Brushless Motor Spindle, as shock can damage to the internal components.
②Be 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.
③When cleaning a Brushless Motor Spindle, stop the Brushless Motor Spindle and remove debris
with a soft brush or a cloth. Do not blow air into the dust proof cover area (refer to section
" 6 - 2 Outside View " ) with compressed air as foreign particles or cutting debris may get into the
ball bearing.
④Always clean the tool shank before installing the tool in the spindle.
⑤When 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 insufcient tool shank gripping force.
⑥Select suitable products or tools for all applications. Do not exceed the capabilities of the
Brushless Motor Spindle or tools.
⑦Do not stop the supply cooling air for motor during operation of the machine.
Removing the air pressure from the Brushless Motor Spindle causes a loss of purging, allowing
the Brushless Motor Spindle to ingest coolant. This will cause damage to the Brushless Motor
Spindle.
⑧Carefully direct coolant spray to the tool. Do not spray directly on the Brushless Motor Spindle
body. If large amount spray directly on the Brushless Motor Spindle, it may cause excess load of
the motor rotation with loss of durability to the Brushless Motor Spindle.
⑨Stop working immediately when abnormal rotation or unusual vibration are observed. Immediately,
please check the content of section " 14. TROUBLESHOOTING ".
⑩Always check if the tool, collet, collet nut, connection hose and supply air hose for damaged
before and after operating.
⑪If the collet or collet nut show signs of wear or damage, replace them before a malfunction or
additional damage occurs.
⑫After installation, repair, initial operation, or long periods of non operation, please refer to section
" 11. BREAK-IN PROCEDURE " detailed in Table. 2. When checking the spindle, no vibration or
unusual sound should be observed during rotation.
⑬Do not disassemble, modify or attempt to repair this Brushless Motor Spindle. Additional damage
will occur to the internal components. Service must be performed by NSK NAKANISHI or an
authorized service center.
⑭When using this Brushless Motor Spindle for mass production, please consider the purchase of an
additional Brushless Motor Spindle to be used as a back-up in case of emergency.
⑮Securely connect the compressor supply connection hose and the air hose to the Air Line Kit and
the Brushless Motor Spindle to avoid accidental disconnection during use.
CAUTION

3
BASIC PACKAGE2.
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
* The collet, collet nut and air hese are attached to the spindle.
WARRANTY3.
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 manufactures defects. Please contact us or your local distributor for details.
①Defect in manufacturing.
②Any shortage of components in the package.
③Where damaged components are found when initially opening the package.
(This shall not apply if the damage was caused by the negligence of a customer.)
Brushless Motor Spindle・・1pc. Collet
ȭ3.0mm (CHK - 3.0) or ȭ3.175mm
(CHK - 3.175)・・1pc.*
(For U.S. market ȭ3.175mm
(CHK - 3.175))
Collet Nut (K - 265)・・1pc.*
Air Hose (0.3m)・・1pc.* Wrench (12 x 14)・・2pcs.
12
14
Grease Nipple・・1pc.
Grease Dispenser・・1pc. Inspection Card・・1pc.
᳨ᰝᡂ⦼⾲
Inspection Card
Operation Manual・・1set
ྲྀᢅㄝ󰩣᭩
OPERATION MANUAL

4
CONTACT US4.
For your safety and convenience when purchasing our products, we welcome your questions.
If you have any questions about operation, maintenance and repair of the product, please contact us.
Company Name
Business Hours
U.S. Toll Free No.
Telephone No.
Fax No.
Web Address
:
Industrial Div.
: 8:30am to 17:00pm (CST)
(closed Saturday, Sunday and Public Holidays)
: 800-585-4675
: 847-843-7664
: 847-843-7622
: www.nskamericacorp.com
Contact UsContact Us
For U.S. Market
Company Name
Business Hours
Telephone No.
e-mail Address
:
: 8:00am to 17:00pm
(closed Saturday, Sunday and Public Holidays)
: [phone]
: [email protected]
For Other Markets
FEATURES5.
①The Brushless Motor Spindle housing is made from precision ground, hardened, stainless steel (SUS) with an
outside diameter of ȭ30mm.
②Excellent durability and high reliability are obtained by using a high-speed brushless motor, which eliminates
the need for brush replacement and frequent maintenance.
③A quick disconnect cord is available for easy brushless motor removal.
④Various sizes of collets are available CHK 0.5mm - 6.35mm. Standard collet is CHK 3.0mm or CHK 3.175mm
(For U.S. market CHK 3.175mm).
SPECIFICATIONS AND DIMENSIONS6.
6 - 1 Specications
Model EMA - 3020K
Maximun Motor Rotation Speed 32,000min-1 (rpm)
Maximum rotating speed at the tool 21,300min-1 (rpm)
Spindle Accuracy Less than 2m
Reduction ratio 1 / 1.5
Max. Output 280W
Weight 760g
Noise Level at 1m distans Less than 70dB (A)
Temperature Humidity Atmospheric Pressure
Operation Environment 0 - 40°C MAX.75%
(No condensation)
800 - 1,060hPa
Transportation and Storage
Environment
-10 - 50°C 10 - 85% 500 - 1,060hPa

5
<Option>
Motor Cord
*Note 1
Length：3m, 4 (3.7)m, 6 (5.7)m, 8 (7.7)m
(The Air Hose (
ȭ4mm) of the same length is attached.)
Collet (CHK - □□ ) ȭ0.5 - ȭ6.0mm in 0.1mm increments and ȭ2.35mm, ȭ3.175mm,
ȭ4.76mm, ȭ6.35mm
Special arbor for metal saw
(KCH - 03)
For O.D. ȭ30mm and under
Grinding arbor (AGM - 03) For grindstone I.D. ȭ5.0mm
*Note 1：Motor Cord is sold separately.
Please select the suitable motor cord length for your application.
Do not exceed the " Maximum Allowable Motor Rotation Speed " (Refer to " 6 - 1 Specications ").
An excess of the Maximum Allowable Motor Rotation Speed may cause damage to the inside
components and short life.
WARNING
6 - 2 Outside View
88.8
113.6
141.4
(27.8)
(11)
(300)
ȭ18.5
31
58.8
(17.4
)
ȭ15.9
ȭ30
ࠉȭ30


ȭ29.9
※
※Dust Proof Cover Area
14 350
300
250
200
150
100
50
0
12
10
8
6
4
22
0 2468101214161820
21.3
Torque (cN・m)
Output (W)
Speed ( x103min-1) (rpm)
Continuous Duty Area
Output
Torque
Fig. 1
6 - 3 Torque Characteristics
Fig. 1

6
CHANGING THE TOOL7.
Do not tighten the collet without inserting a tool or dummy bur, as this will damage the collet, spindle
or collet nut, causing difculty removing the collet.
CAUTION
Please set the cutting tools to minimize the overhang amount. 13mm is the maximum amount of
overhang to maintain high accuracy and safety.
RECOMMENDATION
①Set the provided 12mm wrench on the spindle.
②Place the provided 14mm wrench on the collet nut
and turn it counterclockwise to loosen the collet
and remove the tool (The rst turn will loosen
the collet nut, but the tool will not release and
turning will become stiff. Keep turning through the
stiffness and the collet will open).
③
Clean the collet and collet nut, then insert the new
tool and tighten the collet by turning clockwise. Do
not overtighten.
Tool
12
14
Collet Nut
Spindle Shaft
Loosen
Tighten
12
14
Fig. 3
REPLACING THE COLLET8.
When installing the collet into the collet nut, be sure to fully engage the latch inside the collet nut
to the groove on the collets outer diameter area. In addition, remember that if the collet is attached
without being engaged with the latch of the collet nut, the collet cannot be removed and this may
cause damage to the collet or the spindle.
CAUTION
①Remove the tool according to the section
" 7. CHANGING THE TOOL " procedure above
and remove collet nut assembly (Fig. 4).
②The collet and collet nut are secured by a groove
in the collet and a ange in the collet nut. To
remove the collet hold the collet nut in one hand
and push diagonally down on the collet. The collet
should be released (Fig. 5).
③To install the collet, hold the collet at a slight angle,
and insert it into the collet nut (Fig. 6).
Press the collet in the collet nut by positioning the
collet in the collet nut and pressing down on at
surface (Fig. 5).
Be sure to fully engage the latch inside the
collet nut into the groove on the collet's outer
circumference area (Fig. 7).
Latch
Latch
Groove
Collet
Collet Nut
Collet Nut
DOWN
Collet
Wrench Seat
Tool
14
12
Spindle Shaft
Collet Nut
Loosen
Fig. 4 Fig. 5
Fig. 6 Fig. 7

7
・Before connecting to the Motor Cord to the Brushless Motor Spindle and CONTROLLER, verify
the Main Power Switch on 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 Cap etc. to prevent damage or contamination to the Motor Cord Plug when
not in use.
CAUTION
①Remove the Protective Cap of the Motor Cord.
Connector
Alignment Pin Alignment Hole
Connector
Motor Cord Side
Brushless Motor Spindle Side
Take Out
Protective Cap
Insert
Take Out
Push
Tighten
Brushless Motor Spindle Side Motor Cord Side
Connector Nut
② Carefully insert the alignment pin into the alignment hole and push straight into the Connector of the Motor Cord.
⑤Insert the provided air hose.
④Remove the protective air inlet Quick Disconnect
Cover.
③Tighten the Connector Nut with clockwise.
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
When installing a Brushless Motor Spindle to a xed base, make sure the xed base is grounded in
order to avoid the risk of an electric shock.
WARNING
CONNECTION OF MOTOR CORD
9.
INSTALLATION OF THE BRUSHLESS MOTOR SPINDLE
10.

8
・When installing a Brushless Motor Spindle, do not hit, drop or cause shock to the Brushless Motor
Spindle. This may cause damage to internal components and result in malfunctions.
・When mounting the Brushless Motor Spindle, be sure to secure within Clamping Area etched on
the Brushless Motor Spindle O.D. If the Brushless Motor Spindle is installed incorrectly, damage to
the internal components is possible.
・Cautions when tightening the securing bolts on to a Split Type Holder
Do not over-tighten the bolt. This will cause damage to Brushless Motor Spindle's precision.
Tighten the bolt until the Brushless Motor Spindle body can not be rotated by hand within the xture.
Extreme tightening is not necessary or recommended.
Apply working force and check that the Brushless Motor Spindle is tight before using.
CAUTION
①When mounting a Brushless Motor
Spindle, refer to the Clamping Area
etched on the Brushless Motor
Spindle (Fig. 13).
45 71.6
(Clamping Area)
CLAMPING AREA
CLAMPING AREA
Grip Ring (Sold Separately)
Spacer
Fastening Bolt
Bushing with Slit
Fastening Bolt
Bushing Split
Split Type Holder
Slit
Fastening Bolt
Fig. 13
* When installing the Brushless Motor
Spindle, it is recommended to use a
" GR - 30 Grip Ring (sold separately
(Fig. 14)) ". If the GR - 30 Grip Ring
cannot be used due to the restriction
of dimension and space, install as
shown in ②below.
Fig. 14
②When installing a Brushless Motor Spindle to the holder, recommended installation method is shown Fig 15.
Refer to " ③How to fabricate the Split Type Holder ". If this is not possible, install as shown in Fig. 16.
Fig. 15 Fig. 17Fig. 16

9
Deformation
Fastenig Bolt
Bearing
Damage of internal
Components
Side ViewFront View
Spacer
Slit
Fastening Bolt
Spacer
Fastening Bolt
Screw for Removal
Spacer
Fastening Bolt
Screw for Removal
Do not allow set screws to come directly in contact
with the Brushless Motor Spindle body as shown
in Fig. 17, as this will result in damage to the
Brushless Motor Spindle housing and internal
components.
When installing, never clamp directly over the
bearings, as this will result in bearing damage
(Refer to Fig. 18).
CAUTION
Fig. 18
③How to fabricate the Split Type Holder
(1) Rough bore the inside diameter of the Split
Type Holder.
(2) Cut a slit. (Ex. Slit 2mm) wide.
(3) Tighten the Screw for Removal and Force
Open the Slit Area.
(4) Insert a spacer (Ex. thickness = 2mm)
into the Slit Area.
(5) Loosen the Screw for Removal, and tighten
the fastening bolt with its specied torque.
(6) Finish the Split Type Holder so that the inside
diameter of the Split Type Holder is ȭ30 with
its tolerance range from
-
0.01mm to
-
0.015mm, and its roundness and cylindricity
of less than 5m.
(7) When inserting the Brushless Motor Spindle
loosen the Fastening Bolt, and tighten the
Screw for Removal, widening the Slit Area. Fig. 19
・How to conrm the correct tightening or clamping of the Brushless Motor Spindles in the holder
Measure the current value of the CONTROLLER's power cord by the clamp meter.
Fasten the holder so that the increase in the no-load current value (during rotation at the maximum
rotation speed) with the Brushless Motor Spindle fastened is 20mA (for type 120V) / 10mA (for
type 200V / 230V) or less, compared to the no-load current value (during rotation at the maximum
rotation speed) without fastening the Brushless Motor Spindle. Do not over-tighten the Fastening
Bolt. It may damage Brushless Motor Spindle's precision and shorten the life of the bearings.
・The nal responsibility for ensuring holderʼs safety for use in a given application is left to the
designer of the equipment in which NAKANISHI's Brushless Motor Spindle is installed.
NAKANISHI offers Brushless Motor Spindle with a wide variety of capabilities and specications.
Please carefully check the Brushless Motor Spindle's specications against the requirements of
your equipment and verify suitability and safety of the Holder prior to initial use.
CAUTION

10
BREAK-IN PROCEDURE11.
Steps 1 2 3 4
Rotation Speed
(min-1) (rpm)
5,000 10,000 20,000 32,000
Rotation Time (min) 15 10 10 15
Items to Check No Abnormal
Noises
The Brushless Motor Spindle housing temperature
during the break-in process should not exceed
20 degrees C (36 degrees F) above ambient
temperature. Should the Brushless Motor Spindle
exceed this limit, rest the Brushless Motor Spindle
for at least 20 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 Brushless Motor Spindle for proper installation.
The Brushless Motor
Spindle housing
temperature during
the break-in process
should not exceed
20 degrees C (36
degrees F) above
ambient temperature.
During transportation, storage or installation, the grease inside the bearings will settle. If the Brushless Motor
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
GREASE INJECTION12.
・Be sure to use our specied grease. The other type grease may cause damage to Brushless Motor
Spindle.
・
When the thread on the side of the Brushless Motor Spindle is removed, need to stop the air supply.
Failure to stop the air ow will cause grease to spray out of the grease inlet.
CAUTION
To extend the durability of the reduction gear, inject grease at every 70 - 100 hours in the manner described below.
Grease injection prevents the friction of the parts assembled inside as well as heat generation. It also prevents the
degradation of grease inside.
Periodic grease injection is an important part of routine maintenance.
12 - 1 Grease Injection
③Mount the Grease Nipple on the top of the
provided Grease Dispenser. And attach the
Grease Nipple on the topped hole removed the
thread in the step.
Injection bar
Grease DispenserGrease Nipple
Screw
Fig. 20
Fig. 21
①Turn OFF the power switch of the
CONTROLLER and stop the air supply.
②Remove the Grease Inlet Screw on the
Brushless Motor Spindle with a screw driver
(Fig. 20).

11
⑤Inject grease about 0.5mℓ.
④
Holding the Grease Dispenser, turn ON the
power switch of the CONTROLLER and start the
air supply. Set the motor rotation speed
" 0 " at the CONTROLLER to avoid the motor
rotation.
Fig. 22
Too much grease generates high heat, make
sure to only supply the volume of grease as
specied.
CAUTION
⑥Turn OFF the power switch of the CONTROLLER
and remove the Grease Nipple.
Finally tighten the screw.
Product Description Code No.
Grease
for
Reducer
（2.5mℓ） 1547
（10mℓ） 1550
（100mℓ） 1549
Table. 3 Grease
12 - 2 After Grease Injection
①After grease injection, please carry out break-in as follow. Start rotating slowly and over a short period of time,
increase speed gradually until Maximum Allowable Motor Rotation Speed (refer to section " 11. BREAKE-IN
PROCEDURE ").
②When air supply starts again, excess grease may come out at the dust proof area. Clean off the grease
completely.
* Can purchase our specied grease as standard accessories. Please purchase and use the Grease Dispenser
inject with our specied grease (Table. 3).
CAUTIONS WHEN USING GRINDSTONES AND TOOLS13.
The maximum surface speed or rpm is always specied for a grindstone. Do not exceed the maximum
speed with reference to the calculating chart below. Always follow the grindstone manufacturer's
recommendations.
3.14 x Diameter (mm) x Rotation Speed (min-1) (rpm)
Surface Speed (m / s) = 1,000 x 60
CAUTION
① The proper surface speed for general grindstones is 10 - 30m / s.
② Do not exceed 13mm of overhang for mounted grindstones as shown in Fig. 23. If the overhang must exceed
13mm, reduce the motor speed in accordance with Table. 4.
③ Dress the grindstone prior to use.
④ Do not use cutting tools with bent or broken shanks, cracks or excessive run-out.
⑤ For grinding, the maximum depth of cut should not exceed 0.01mm radially or axially. Reciprocate the tool
several times after each pass to eliminate tool pressure.
⑥ Always operate cutting tools within the allowable recommended speed of the cutting tools. Use of a cutting tool
outside of the allowable speed of the cutting tools could cause damage to the spindle and injury to the operator.

* N = Max. Operating Speed with 13mm overhang.
Overhang (mm) Max. Speed (min-1) (rpm)
20 N x 0.5
25 N x 0.3
50 N x 0.1
Table. 4 Overhang and Speed
13
Contents are subject to change without notice.
Fig. 23
TROUBLESHOOTING14.
If a problem or concern occur, please check the following items prior to consulting your dealer.
Trouble Cause Inspection / Corrective Action
Brushless Motor Spindle
does not rotate or rotate
smoothly.
The spindle ball 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.)
Overheating during
rotation.
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.
Abnormal vibration or
noise during rotation.
The tool shank is bent. Replace the tool.
Cutting debris has contaminated the
ball bearing.
Replace the ball bearings.
(Return to NAKANISHI dealer service.)
The spindle ball bearings have been
damaged.
Tool slippage. Collet or collet nut are not correctly
installed.
Check and clean the collet and collet nut.
Reinstall the collet and collet nut.
The collet and the collet nut are
worn.
Replace the collet and collet nut.
High run-out. 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.)
Contaminants inside the collet and
the collet nut or the spindle.
Clean the collet, collet nut and the inside of the
taper and spindle.
The spindle ball bearings have been
damaged.
Replace the ball bearings.
(Return to NAKANISHI dealer service.)
Refer to the E3000 CONTROLLER Operation Manual.
DISPOSAL OF THE BRUSHLESS MOTOR SPINDLE15.
When disposal of a Brushless Motor Spindle is necessary, follow the instructions from your local government
agency for proper disposal of industrial components.
2015.04.20 0002
⑦ Keep the cutting tool shank and collet clean. If contaminants are left in the collet or collet nut, excessive run-out
will cause damage to the cutting tool and or spindle.
⑧ Do not strike or disassemble the Brushless Motor Spindle.
⑨ Please set the cutting tools to minimize the overhang amount. 13mm is the maximum amount of overhang to
maintain high accuracy and safety.