The provided document is an instruction manual for the NBK EPU-210 Wired Positioning Units - Modbus Compliant.
Function Description
The NBK EPU-210 Wired Positioning Unit is designed to automate the positioning mechanism of feed screws in general industrial applications. By replacing a manual feed screw operation handle with this unit, it automates the positioning of various devices and equipment. The unit allows for equipment settings and control to be performed via a PC, a PLC (Programmable Logic Controller), or directly using the unit's integrated buttons and display.
The unit features a seven-segment LED display that shows two rows of four digits. In normal mode, the upper row displays the current position, and the lower row displays the target position. An indicator LED shows the current status of the unit. Operation buttons (MODE/ESC, SET, PREV, NEXT, Plus, Minus) allow for manual rotation of the output shaft, parameter setting, and mode switching.
The EPU-210 supports Modbus RTU (RS-485) communication, enabling integration into larger control systems. It can operate in several modes:
- Normal Mode: Standby mode, waiting for commands from a higher-level host (PC or PLC) or the unit itself.
- Manual Operations Mode: Allows for setting the home position and performing manual return-to-home or jog operations.
- Target Position Operation Mode: Enables movement to a saved target position and allows the current position to be saved as a target position.
- Setting Mode: Used to change various unit parameters.
Optional accessories enhance the unit's versatility:
- Mounting Plates (EOAP-200): Facilitate mounting the unit by utilizing existing positioning pin holes from digital position indicators.
- Collars (EOCL-200): Allow the shaft hole diameter of the wired positioning unit to be adjusted to match different rotating shafts.
- High Torque Adapters (EOAT-200): Decelerate the rotating speed and amplify the torque of the wired positioning units.
- Mounting Plates for High Torque Adapters (EOTAP-200): Similar to EOAP-200 but designed for mounting the unit with a high torque adapter.
- Collars for High Torque Adapters (EOTCL-200): Allow the shaft hole diameter of the high torque adapter to be adjusted.
Important Technical Specifications
Operating Environment:
- Temperature: -5 to 50°C (23 to 122°F) (no freezing)
- Humidity: 20 to 85% RH (no condensation)
- Pollution degree rating: 3
- Elevation: No greater than 2,000 m (6,600 ft) above sea level
- Installation: Indoor environment, not exposed to direct sunlight (UV rays), free of continuous vibration, sufficient strength of installation surface, environment facilitating heat dissipation, and allowing easy inspection and cleaning. Avoid environments with water immersion, corrosive atmosphere, flammable gas, harmful gas, or near flammable materials.
Electrical Specifications (EPU-210):
- Power supply voltage: 24 VDC ±10%
- Current consumption: Standby: 30 mA, Rated: 0.6 A, Max: 1 A
- Rated output: 5 W
- Rated rotational speed: 60 ± 10 rpm
- Rated torque: 0.8 N·m (7.07 lbf·in.)
- Continuous operable time: Not exceeding one minute (allow around ten minutes for cooling after continuous use).
- Output shaft holding torque: 0.7 N·m (6.19 lbf·in.) (reference value, not guaranteed).
- Stop accuracy: ±5°
- Input: Wired communication RS-485 (Modbus RTU)
- IP code: IP65
Physical Dimensions (EPU-210, excluding power cable and protrusions):
- 45 mm x 150 mm x 45 mm (1.772 in. x 5.906 in. x 1.772 in.)
- Mass: Loose wires: 301 g (10.62 oz), Connector: 335 g (11.82 oz)
Cable End Specifications:
- EPU-210-A (Loose wires): Yellow (24V), Brown (0V), Blue (D+), White (D-), Shield (DG).
- EPU-210-B (Connector): M12 A-code 4-pin shielded male connector (Amphenol Corporation MSAS-04BMMB-SL7001). Pin 1 (24V), Pin 2 (D+), Pin 3 (0V), Pin 4 (D-), Shield (DG).
- Power Supply/Communication Cable: Oil-resistant PVC sheath, 5.4 mm (0.213 in.) outer diameter. Tin-plated annealed copper stranded wire conductor, 2P (pairs), AWG25 size. Minimum bend radius: 32.4 mm (1.276 in.). Cable length: 1 m (3.3 ft).
High Torque Adapters (EOAT-200) (Optional):
- Product No.: EOAT-200-4 (Gear ratio 4), EOAT-200-8 (Gear ratio 8)
- Rated torque: EOAT-200-4: 2.7 N·m (23.8 lbf·in.), EOAT-200-8: 5.4 N·m (47.7 lbf·in.)
- Output shaft rotation direction: Same direction as input shaft.
- Allowable output shaft load: Radial load: 190 N (42 lbf) (10 mm (0.394 in.) from mounting surface), Thrust load: 155 N (34 lbf).
- Output shaft holding torque: EOAT-200-4: 2.5 N·m (22.1 lbf·in.), EOAT-200-8: 5 N·m (44.2 lbf·in.) (reference values, not guaranteed).
- Backlash: 1° or less.
- Mass: EOAT-200-4: 359 g (12.66 oz), EOAT-200-8: 361 g (12.73 oz).
Allowable Load (Output Shaft):
- Unit alone: Radial load: 19.6 N (4.4 lbf), Thrust load: 19.6 N (4.4 lbf).
- With high torque adapter: Radial load: 190 N (42 lbf), Thrust load: 155 N (34 lbf).
Modbus RTU Communication Specifications:
- Protocol: Modbus RTU
- Interface: RS-485
- Communication method: Half-duplex communication
- Max. number of connections: 32 units
- Synchronization method: Start-Stop synchronization
- Stop bit: 1 (Fixed)
- Parity bit: Even (Fixed)
- Communication speed (kbps): 9.6 / 19.2 / 38.4 / 57.6 / 115.2
Usage Features
Installation:
The manual provides detailed instructions for installing the unit alone, with mounting plates, with collars, with high torque adapters, and with combinations of these accessories. Key steps include drilling positioning pin holes, mounting the rotating shaft, passing the shaft through the unit's output shaft, inserting positioning pins, and securing the unit with hex socket set screws. Recommended tightening torques are provided for secure installation.
Connections:
Connection examples are provided for controlling the unit alone, with a PC as the higher-level host, and with a PLC as the higher-level host. Daisy chain connections are supported for multiple units. For PC connections, a serial converter is required to convert RS-485 to serial communication. Terminating resistors (120 Ω) must be installed between communication line terminals "D+" and "D-" on the serial converter side and the last unit in a daisy chain.
Unit Settings and Control (by Unit Alone):
The unit can be configured and controlled using its integrated buttons and seven-segment display.
- Baud Rate Setting: Configurable from 9.6 to 115.2 kbps.
- Station Number Setting: Configurable from 01 to 32.
- Terminating Resistor Setting: Can be turned ON/OFF.
- Feed Screw Lead Setting: Sets the distance the workpiece moves per full rotation (00.10 to 99.99 mm).
- Movement (+) Rotation Direction Setting: Defines the output shaft rotation direction for (+) movement (CW or CCW).
- High Torque Adapter Setting: Configurable for OFF, Gear ratio 4, or Gear ratio 8, compensating for movement decrease when using adapters.
- Backlash Compensation Setting: Configurable for OFF, POS (compensation for movement from (-) to (+) direction), or NEG (compensation for movement from (+) to (-) direction). This is recommended when using high torque adapters.
- Movement Range Upper/Lower Limit Setting: Defines the operational range (Upper: 0000.0 to 3000.0 mm; Lower: 0000.0 to -3000.0 mm). If the current position exceeds these limits, the unit stops and retracts.
- In-Position Range Setting: Sets the range around the target position where the indicator LED turns green (00.0 to 50.0 mm).
- Target Position Setting: Provides 11-point memory (00 to 10) for target positions (-3000.0 to 3000.0 mm).
- Initialization: Resets all settings to factory defaults.
Manual Operations Mode:
- Jog Operation: Moves the workpiece continuously while the plus or minus button is pressed.
- Home Setting: Sets the current position as the home position.
- Return to Home Position: Moves the workpiece to the set home position.
Target Position Operation Mode:
- Target Position Movement: Calls a registered target position and moves the workpiece to that position.
- Target Position Registration: Registers the current position as a target position.
Unit Settings and Control (by PC/PLC):
For PC control, dedicated software "MOD-COM" is required. For PLC control, Modbus RTU commands are used. The manual provides detailed Modbus RTU communication settings, including message frames, function codes (03H for Read, 05H for Write to Coil, 06H for Write to Holding Register, 10H for Write to Multiple Holding Registers), and register addresses for monitoring and setting various parameters.
Maintenance Features
Safety Precautions:
The manual emphasizes reading safety precautions thoroughly. It highlights the importance of confirming equipment specifications, implementing safety circuits, ensuring proper wiring and insulation, installing external emergency stop circuits, and installing external brakes if danger exists during stoppage or failure. Prohibited actions include handling with wet hands, allowing metal fragments or water splashes, installing in vibrating locations, disassembling, repairing, modifying, operating with power on during inspection, and using with flammable gases.
Inspection Checklist (Monthly):
- Verify power supply voltage is within specified range.
- Confirm operating environment is within specification ranges.
- Check for abnormal odor or noise.
- Inspect for adhesion of dust or foreign material.
- Check for loose fastening parts (output shaft, feed screw, connectors).
- Inspect for damaged or excessively stressed cables.
- Look for scratches or deformation on the main unit.
Troubleshooting:
A comprehensive troubleshooting guide is provided for various symptoms, including:
- Indicator LED not lighting up.
- Cannot mount to equipment.
- Feed screw cannot be driven.
- Communication not possible.
- Current position not correctly displayed.
- Error reset not possible.
Each symptom includes verification steps and corresponding countermeasures, often referencing specific pages in the manual for detailed instructions.
Error Codes:
The unit's LED lights up or flashes red to indicate errors or failures. An error code is automatically displayed on the seven-segment display. Pressing and holding the MODE/ESC button for 3 seconds resets the error. The manual lists various error codes (e.g., Movement timeout error, Movement range lower/upper limit detection, Abnormal temperature detection, Overcurrent error, Low voltage detection, Out of movement range error, Read/Write failure error, EERAM data error, Memory data error) along with their descriptions and potential causes.
Unit Replacement:
Procedures for unit replacement due to malfunction are outlined, differing based on whether a PC or PLC is used as the host. It is crucial to turn off power before replacement. Settings of an existing unit cannot be exported to a replacement unit; reconfiguration is necessary. For PC replacement, saving backup data of setting files is recommended.
Warranty:
- Warranty Period: 300 hours of operation or one year after delivery, whichever comes first.
- Warranty Scope: Repairs or replacement free of charge under normal usage conditions, in accordance with the manual.
- Exclusions: Improper use, repairs, modifications, damage during transportation, usage outside specifications, natural disasters (fire, earthquake, lightning, flood), abnormal power supply voltage, exposure to water, oil, metal fragments, or other foreign materials.
The warranty covers the main unit only, not secondary damage.
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