EWS Spinjet SJ 20-ER32 User manual

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Manual
. SpinJet

Precision meets Motion
EWS Weigele GmbH & Co. KG · Maybachstr. 1 · D-73066 Uhingen · Tel. [phone] · Fax [phone] · [e-mail] · www.ews-tools.de
Manual
. SpinJet
1General
1.1 Safety First ...................................................................................................................3
1.2 Statement of Compliance ...........................................................................................4
1.2.1 European standards (CE) ................................................................................................4
1.2.2 American standards (UL).................................................................................................4
1.2.3 International standards....................................................................................................4
1.3 Introduction..................................................................................................................4
1.4 SpinJet Contents .........................................................................................................4-5
1.5 Main Features ..............................................................................................................5
1.5.1 Wireless Rotation Speed Display.....................................................................................6-7
1.5.2 Built-in and Direct Mounting System to CNC Spindle......................................................7-8
1.5.3 Shaft Locking for Tool Clamping .....................................................................................8
1.5.4 Integrated Coolant Nozzle System ..................................................................................9
1.5.5 Tool Clamping.................................................................................................................9
2Installation
2.1 Battery installation into the RPM wireless transmitter ............................................10
2.2 Display ..........................................................................................................................10
2.2.1 Prerequisite for display installation...................................................................................10
2.2.2 Display Workplace Installation.........................................................................................10
2.2.3 Connect..........................................................................................................................11
2.2.4 Screens ..........................................................................................................................12-14
2.2.5 Disconnect .....................................................................................................................15
2.3 HSM Jet Spindle ..........................................................................................................15
2.3.1 Prerequisites for the CNC machine .................................................................................15
2.3.2 Spindle Installation onto the CNC machine .....................................................................16
2.3.3 Placement of HSM Jet Spindle in Toolholder...................................................................17-18
2.3.4 Prerequisites for Tools.....................................................................................................18
2.3.5 Tool Installation into HSM Jet Spindle..............................................................................19-20
2.3.6 Check for Run-Out upon Tool Clamping..........................................................................20-21
3Maintenance
3.1 Periodic Maintenance .................................................................................................22
3.2 Battery Change on RPM Transmitter ........................................................................22
3.3 Operation Conditions ..................................................................................................22
3.4 Storage .........................................................................................................................22
3.4.1 Pre-Storage ....................................................................................................................22
3.4.2 Condition for Storage......................................................................................................22
4Working with the HSM Jet Spindle
4.1 Recalculating of the Feed for HSM Jet Spindle........................................................23
4.1.1 Existing machining process.............................................................................................23
4.1.2 New machining process..................................................................................................23
5Troubleshooting
5.1 Display messages........................................................................................................24
5.2 The HSM Jet Spindle shaft does not rotate or RPM does not correspond
correctly to coolant pressure......................................................................................24
5.3 The HSM Jet Spindle has not been used in the last month.....................................24
6Warranty

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Manual
. SpinJet
2
FCC Compliance Statement
This device has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the
FCC Rules. These limits are designed to provide reasonable protection against harmful interference in residential
installations. This equipment generates uses and can radiate radio frequency energy and, if not installed and used in
accordance with the instructions, may cause harmful interference to radio and television reception.
However, there is no guarantee that interference will not occur in a particular installation. If this device does cause such
interference, which can be verified by turning the device off and on, the user is encouraged to eliminate the interference
by one or more of the following measures:
- Re-orient or re-locate the receiving antenna.
- Increase the distance between the device and the receiver.
- Connect the device to an outlet on a circuit different from the one that supplies power to the
receiver.
- Consult the dealer or an experienced radio/TV technician.
To comply with FCC Section 1.310 for human exposure to radio frequency
electromagnetic fields, implement the following instruction:
A distance of at least 20 cm between the equipment and all persons should be
maintained during the operation of the equipment.
!
WARNING!
Changes or modifications to this unit not expressly approved by the party responsible for
compliance could void the user‘s authority to operate the equipment.
This device complies with FCC Rules Part 15:
Operation is subject to two conditions:
1. This device may not cause harmful interference, and
2. This device must accept any interference that may be received or that may cause undesired
operation.

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1. General
1.1. Safety first
Manual
. SpinJet
3
!
!
!
!
!
!
Read the manual
Safety of the operator is a main concern. This equipment is as safe as we are able to make it.
Avoid accidents by reading the safety alerts, investing a few seconds of thought and a careful
approach to handling equipment. You, the operator, can avoid many accidents by observing
the following precautions. Review the safety instructions of the manufacturer, suppler, owner,
and all organizations responsible for the prevention of accidents.
Ensure that:
- The work area and the area around the CNC machine are free of obstacles
- The work area is properly lit
- This equipment is operated only by a responsible adult trained in this operation
- This equipment is not operated by a person under the influence of drugs or alcohol
- This equipment is not operated by a person with any illness or physical condition that
might reduce reflexes or awareness and increase exposure to risk.
- Before starting any kind of work, install all of the safety devices prescribed by the
builder of the machine or power tool are in place
- Shaving/dust suction equipment must be used at the same time as the tool
Warning: Rotating Tools, Entanglement Hazard
To avoid risks associated with the use of rotating tools it is strongly recommended to use
the utmost caution and concentration when working.
Warning: Rotating Tools, Cut or Severe Hazard
Always wear correctly sized gloves that allow the sensitivity necessary to operate the tool
correctly and give adequate protection in the event of the blade being touched during use.
Warning:
Always use safety glasses or protective screens to protect your eyes.
- Install only tools in perfect condition that are recommended for the material to be worked
and that are suitable for the type of machine used
- Do not use cracked or deformed tools
- Check that the balancing, keying and centering of rotary tools are carried out correctly
- Fix the tool correctly using the proper tightening and adjustment devices
- Remove all tightening and adjustment devices before use
- Check that the tool rotates in the correct direction
- Never exceed the limits of a piece of machinery. If its ability to do a job, or to do so
safely, is in question - DON’T TRY IT

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1.2. Statement of Compliance
The HSM Jet Spindle meets the following
standards
1.2.1 European standards (CE)
- EMC: EN 301489-1/17
- Radio: EN 300328 V 1.8.1
- Safety: EN 61010-1:2010
1.2.2 American standards (UL)
- EMC: FCC Part 15 B
- Radio: FCC Part 15 C
- Safety: UL 61010-1
1.2.3 International standards
- Safety: IEC 61010-1:2010
. SpinJet
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Manual
1.3. Introduction
The HSM Jet Spindle is a unique High Speed Machining spindle (20 krpm, 30 krpm & 40 krpm). It is driven by the CNC
machine/turret spindle coolant thru flow at minimum pressure of 20 bar. SpinJet does not require any special installation
aside from the installing it to the spindle/turret. It then operates like any other standard tool holder in the magazine.
1.4. SpinJet Contents
The wireless RPM display case includes:
1. TSD - this is wireless RPM display
2. Universal AC/5VDC power supply
* For USA/Japan: include EU to US/Japan
AC adaptor plug

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Ø 3.2
45
Machining conditions
for cutting speeds of
180 m/min in steel
Rotating speed
Diameter of cutting tool
mmmm
machine spindle
10
20
30
40
50
60
1 2 3 4 5 6
SJ 20
2.6-3.5 mm
KRPM
krpm
SJ 30
1.6-2.5 mm
SJ 40
0.2-1.5 mm
HSM Jet Spindle
type / RPM
SJ 20-ER32 20000*
RPM
30000*
RPM
40000*
RPM
50000*
RPM
60000*
RPM
50000*
RPM
40000*
RPM
30000*
RPM
40000*
RPM
SJ 30-ER32
SJ 40-ER32
Coolant pressure
20 bar 30 bar 40 bar
* approximitate RPM values - depend on pressure, flow rate
and used coolant type
. SpinJet
5
Manual
1. NUT ER11 GHS - this is a standard nut
2. WRENCH ER11 SMS - this is a standard wrench*
3. WRENCH DIA3.2x45 - this is a specialized shaft
lock tool*
4. ALLEN KEY - Hexagonal 2.0 mm
5. BATTERY - Lithium Metal non-rechargeable,
CR2 type
* Actual size and types of accessories may varydue to
configuration and manufacturing process
The HSM Jet Spindle includes:
1.5. Main Features
The HSM Jet Spindle spindles are best used when high RPMs is required for small diameter tools on limited RPM CNC
machines. The system utilizes the CNC machine tool’s existing coolant supply driven by a high pressure pump (minimum
20 bar) as an energy source to rotate a turbine up to 60.000 RPM. The HSM Jet Spindle can be supplied either as right-
hand or left-hand option.
The HSM Jet Spindle is not intended to replace the CNC machine spindle, but rather to upgrade the existing
CNC machine, providing improved performance, faster machining, better surface quality, and extended tool life.
The new spindles can be used for semi-finish and finish machining applications such as milling, drilling, and jig grinding.
HSM Jet Spindle models operating ranges:
Fig. 3: Rotation speed vs. tool diameter Fig. 4: The relation between coolant pressure
& RPM value based on HSM Jet Spindle

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RPM wireless
transmitter
RPM wireless
RPM transmitter
unit
Unit ID number
Transmitter unit
Identification number
signal readout
RPM wireless
transmitter
detection side
Spindle RPM LCD screen
Power switch
on / off
Transmitter
unit‘s battery
level
DC power
socket
function buttons
1.5.1 Wireless Rotation Speed Display general view
The HSM Jet Spindle is equipped with an integrated wireless display system, allowing real-time monitoring of
the rotating speed during machining.
This system consists of a transmitter installed on the spindle housing, and a receiver display.
The receiver is powered by a 5 VDC universal AC/DC power adaptor connected to either a 220 VAC or
a 110 VAC power source.
The transmitter is powered by an exchangeable CR2 lithium battery.
Display Information
- 2.4 GHz radio frequency transmission
- Direct wireless rotational speed monitoring up to 5 m range
- Externally powered a receiver display
- Enables reading of all HSM Jet Spindle systems being used on a specific CNC machine
This is limited to 127 tools
- Internally battery‘s powered RPM transmitter unit
- Own ID number for each RPM transmitter unit
. SpinJet
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Manual
Fig. 6: Wireless display and RPM transmitter unit main view
Fig. 5: HSM Jet Spindle wireless transmitter and display

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DC power
socket
Attach to the machine
pannel by built-in magnets
Stand
Receiver display dimensions
80
113.5
130
32
10 6
30.8
REVISIONS
ZONE REV. DESCRIPTION DATE APPROVED
01
B
A
8 7 6 4
D
C
5 1 2 3
A
B
4 3 2 1
C
F
E
D
mm
MATERIAL:
PER:
HARDNESS:
PER:
Sketched in SolidWorks v
APPROVED
CHECKED
DESIGN
WEIGHT: grams ref
OPERATION NAME
DIMENSIONS
ARE IN
SIZE
A3
DRAWN
NAME
DATE
SCALE :
2:1
SURFACE
ROUGHNESS:
PART No
REV. :
Part Name
Project
N7
COATING:
PER:
SIGNAT
SHEETS
SHEET
1 of 1
File Name & Path: / receiver_general_assy_11_2_2014.Slddrw
ORIGINALLY
APPROVED
Typhoon
TJS control panel
receiver_general_assy_11_2_2014
HRc
Unspecied tolerances
0.1; 0 30'.
Break all sharp edges R0.2 max
or 0.2x45 chamfer.
PROJECTION
STYLE
FINAL DRAWING
00
R.B
R.B
R.B.
24/09/13
24/09/13
12/02/14
12/02/14
R.B.
The information disclosed in this document is proprietary to Colibri spindles Ltd. and may not be used for manufacture or any other purpose without the written consent of Colibri spindles Ltd.
confidential
. SpinJet
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Manual
Fig. 7: Wireless RPM display mounting options
1.5.2 Built-in and Direct Mounting System to CNC Spindle
HSM Jet Spindle is available in several mounting adaptation types:
- ER32 collet chuck with a special tightening nut, suitable for all standard tool holders with an
ER32 adaptation - This is the default type.
- Integral options with various adaptations are available upon request.
40.SK4012SJ... SJ...-ER32 SJ...ZYL20 40.HSK6312SJ... 40.C612SJ...

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1.5.3 Shaft Locking for Tool Clamping
The shaft lock mechanism provides you with a simple and easy way to change the tool installed on your
HSM Jet Spindle spindle. For instructions on installing the tool into the spindle see page 21.
. SpinJet
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Manual
Fig. 9: HSM Jet Spindle with pin mechanism locked
!
Warning:
Do not hold the pin handle while tightening/loosening the shaft lock mechanism.
Failure to obey this warning might lead to a broken spindle shaft.
It is strictly prohibited to use the HSM Jet spindle if shaft lock hole’s protection plug is
damaged or missing.
60.xx12SJ... 40.xx12SJ...
Fig. 10: Integrated coolant nozzle system

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NUT ER11 GHS
Collet ER11 SPR
NUT ER11 GHS
+10 mm
+15 mm
NUT ER11 GHS
+10 mm
ER11 SRK ...25
Thermal collet
ER11 SRK ...10
Thermal Collet
. SpinJet
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Manual
1.5.4 Integrated Coolant Nozzle System
The Integrated coolant nozzle system provides 3 main advantages:
- Direct jet coolant application
- Better and faster chip evacuation
- Prevents tool thermal shock
Fig. 10: Integrated coolant nozzle system
1.5.5 Tool Clamping
The HSM Jet Spindle is compatible with ER11 collet chuck.
The assembly of rotating elements (collet, nut and tool) must be balanced to a G2.5 at 40,000 RPM.
We recommend that you use ER 11 high precision spring collets.
When longer overhang is required, 10 & 25 mm long ER11 thermal shrink collets are available.
Fig. 11: Overhang solutions types

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RPM wireless transmitter
detection side
ON
. SpinJet
10
Manual
2. Installation
2.1. Battery installation into the RPM wireless transmitter
To install the battery into the RPM transmitter:
1. Unscrew the 4 screws holding the battery case cover using a hexagonal 2 mm Allen key.
2. Remove the battery case cover.
3. Make sure the O-ring inside the cover is seated well, and intact.
4. Put in the CR2 lithium battery in correct direction
5. Return the battery case cover to its place.
6. Fasten the battery case cover with the 4 screws that were removed.
Now the transmitter is ready to work.
2.2. Display
The HSM Jet Spindle is equipped with an integrated wireless display system, allowing real-time monitoring of the
rotating speed during machining.
2.2.1 Prerequisites for display installation
Make sure that the following pre-requisites are met:
1. Electrical power: 220/110 VAC, standard socket.
2. Distance from HSM Jet Spindle to Display: no more than 5 m.
3. Available space for the display so that operator will have a close and unobstructed view of it.
2.2.2 Display Workspace Installation
1. Mount the display onto a metallic surface using the magnet on the back of the display,
or place on a flat and leveled surface.
2. Connect the display to an AC socket.
3. Switch the display ON.
Fig. 12: Battery case open

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. SpinJet
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Manual
2.2.3 Connect the HSM Jet Spindle to the display
The display and the HSM Jet Spindle must be connected (paired) so they can „identify“ each other.
Each transmitter unit has an own ID number (See Fig. 6)
To connect the HSM Jet Spindle to the display:
1. Make sure the display is ON.
2. Press ‚CONNECT‘ on the display panel, then slide the transmitter (assembled on the HSM Jet Spindle)
across the left side (detection side) of the display unit, as shown in the picture.
Note: Connecting feature is the turning ON of the internal battery consumption on the transmitter unit.
To save a battery energy and in case that SpinJet is not in use - do Disconnection procedure (see paragraph 2.2.5).
Fig. 14: Many HSM Jet Spindles (not working simultaniusly) can be connected to one display

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. SpinJet
Manual
While connecting the HSM Jet Spindle you will see the CONNECTING
displayed, then the „<device ID> CONNECTED -
notice that the battery level of SpinJet is shown.
Make sure that <device ID> on connected screen corresponds to the ID #
signed onto the RPM transmitter unit.
The main display screen shows the HSM Jet Spindle that is working now.
This shows the HSM Jet Spindle’s ID number, rotation speed, and battery
level.
You can see a list of all of the HSM Jet Spindles the display has been
connected to, by pressing the „list“ button.
Fig.16: Connection Screens
Fig.17: Main display screen
Fig.18: List of connected SpinJet Spindles display
12
2.2.4 Screens
When turned on NO SIGNAL / 0 RPM screen will appear.
Fig. 15: No signal displayed

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. SpinJet
Manual
13
Note:
Disconnecting feature is the turning OFF of the internal battery
consumption on the transmitter unit.
If the display detects more than one HSM Jet Spindle working at
any time, a ”MULTIPLE SIGNAL“ is shown (see Fig. 20).
Select „List“ to choose the device to disconnect from the next screen.
The display can be cleared from all connected HSM Jet Spindles,
or a list of previously connected devices can be viewed.
Fig. 20: Multiple signals screen
Fig. 21: Disconnection list for multiple signals screen
Fig. 22: Disconnect all sensors screen
Fig.19: Disconnection display

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. SpinJet
Manual
If the connect or disconnect processes don‘t succeed for any reason,
an appropriate message is shown - see page 26 for troubleshooting.
If the battery of the HSM Jet Spindle you are currently using is running
low - the following warning is shown - see page 26 for troubleshooting.
If the HSM Jet Spindle is not spinning fast enough, the „LOW RPM“
alert is shown.
If the HSM Jet Spindle is spinning too fast, the „HIGH RPM“
alert is shown.
Fig. 23 & 24: Connection / Disconnection failed screen
Fig. 26: Low RPM screen
Fig. 27: High RPM screen
Fig. 25: Low battery screen
14

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. SpinJet
Manual
15
2.2.5 Disconnect the HSM Jet Spindle from the display
1. Make sure the display is ON.
2. Press ‚DISCONNECT‘ on the display panel, then slide the transmitter (assembled on the HSM Jet Spindle)
across the left side (detection side) of the display unit, as shown in the picture.
While disconnecting the HSM Jet Spindle you will see the „Disconnecting“ screen. „<device ID> disconnected screen“ -
notice that the battery level of the HSM Jet Spindle is shown.
Make sure that <device ID> on disconnected screen corresponds to the ID # signed onto
the RPM transmitter unit.
2.3. HSM Jet Spindle
2.3.1 Prerequisites for the CNC Machine
1. Coolant flow through the main CNC machine spindle
2. Minimum coolant pressure, at main machine spindle outlet: 20 bar
3. Maximum coolant pressure, at main machine spindle outlet: 40 bar
4. Minimum flow rate: 12 L/min
5. Minimum coolant filtration level: 100 µm
6. An active mist collector
7. With the emulsion coolant, use an anti-foaming agent additive suitable for your emulsion to prevent foaming.
8. Use emulsion coolant with oil percentage higher than 4%
9. With oil coolant, the high pressure increases the amount of oil fumes:
a. Use appropriate means of fire protection and extinguishing.
b. Use anti-dissolution additive suitable for your oil.

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2.3.2 HSM Jet Spindle Installation onto the CNC Machine
While the HSM Jet Spindle is mounted on the machine, the CNC machine spindle should be stationary, except for tool
checking procedure or Z-offset measurement. In those cases it must not exceed 3000 RPM, or risk breaking/injury.
To avoid the CNC machine spindle rotation during the HSM Jet Spindle operation use the correct
software M-code to lock the Spindle orientation.
For example: „M19“ code locks the spindle in a defined angle position.
Before installing a HSM Jet Spindle with a filter on the machine spindle, make sure that the filter is clean.
. SpinJet
Manual
Fig. 28: SpinJet on CNC machine
16
.SpinJet
SpinJet Installation onto turret
See Manual ”Driven tools“

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X1.5
1
3


4 5
2
. SpinJet
Manual
17
2.3.3 Placement of HSM Jet Spindle in the Toolholder
Caution: Deviation from these steps might lead to locking of the tightening nut to the HSM Jet Spindle.
The HSM Jet Spindle will only work with a toolholder that has a coolant through channel.
To fix the SpinJet Spindle in a toolholder: See steps from left to right in Figure 29.
1. Use a standard tool holder with ER32 collet chuck
2. Loosen the HSM Jet Spindle tightening nut 1.5 full turns
3. Insert built-in ER32 taper shank into ER32 collet chuck until the HSM Jet Spindle tightening nut will be placed on the
toolholder
4. Fasten the HSM Jet Spindle tightening nut onto the toolholder, without turning the HSM Jet Spindle relative to the nut
5. Fasten the HSM Jet Spindle tightening nut to clamp the HSM Jet Spindle and the toolholder together with an ER 32
spanner, use hand force only
Fig. 29: Placement of HSM Jet Spindle in toolholder steps

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Werkzeughalter mit
ER32-Spannzange
ER32
Befestigungs-
mutter
SJ...-ER32
Maximum tool working diameter, Ø[mm]
HSM Jet Spindle type SJ 20 SJ 30 SJ 40
Rotational Spindle speed [Krpm]**
Coolant pressure range [bar]***
Recommended coolant
flow rate range [l/min] 12-18 12-18 12-18
Milling
Recommended Cutting tool diameter [mm] 2.0-3.5 1.0-2.5 0.2-1.5
Drilling
Recommended Cutting tool diameter [mm]
≤ 2.0 ≤ 2.0 ≤ 1.2
Grinding
Recommended Cutting tool diameter [mm]
≤ 10.0 ≤ 10.0 -
Thread milling
Recommended Cutting tool diameter [mm]
≤ M5 ≤ M5 -
Chamfering & Engraving
Recommended Cutting tool diameter [mm]
≤ 6 mm tool shank ≤ 6 mm tool shank ≤ 6 mm tool shank
Recommended cutting speed [m/min]
20* 30* 40*
20 20 20
30* 40* 50*
30 30 30
40* 50* 60*
40 40 40
for steel ≤ 200
for aluminium ≥ 200
* approximately rotational spindle speed
** 20 Krpm based on min. coolant pressure 20 bar & min. flow rate 12 l/min
*** recommended coolant pressure 30-40 bar
. SpinJet
Manual
2.3.4 Tool prerequisites
HSM Jet Spindle spindles are for applications requiring tool shank diameters of up to 6 mm.
Fig. 31: HSM Jet Spindle holding with ER32 collet chuck
18
Fig. 30: Example of a toolholder with a hole for coolant flow

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. SpinJet
Manual
Fig. 31: HSM Jet Spindle holding with ER32 collet chuck
19
2. Turn the shaft, while pushing the WRENCH DIA3.2X45 in,
toward the center of the HSM Jet Spindle, until the
WRENCH DIA3.2X45 handle reaches the HSM Jet Spindle.
3. Loosen the ER11 nut with the provided ER11 wrench,
and remove the nut.
4. Insert the tool into the collet.
5. Place the collet in the spindle.
Fig. 33: WRENCH DIA3.2X45 in the HSM Jet Spindle
Fig. 35: Collet and tool in the HSM Jet Spindle
Fig. 34: Loosening ER11 nut
!
Warning:
Do Not hold the WRENCH DIA3.2X45 (shaft lock pin) handle while tightening/loosening
the ER11 nut. Failure to obey this warning might lead to a broken spindle shaft.
2.3.5 Tool Installation into the HSM Jet Spindle
The HSM Jet Spindle can hold various tools that use an ER11 collet.
To set a tool into the HSM Jet Spindle:
1. Insert the WRENCH DIA3.2X45 in the shaft lock hole, on the side
of the spindle.
Fig. 32: Inserting the WRENCH DIA3.2X45 into the HSM Jet Spindle