Ingersoll Typhoon HSM User manual

2018 - E
HIGH SPEED MACHINING SPINDLE TJS-HPC
OPERATION MANUAL

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CONTENT
FCC COMPLIANCE STATEMENT ...................................................................................................................... 3
SAFETY FIRST................................................................................................................................................. 4
1. GENERAL INFORMATION........................................................................................................................... 5
Statement of Conformity .................................................................................................................................5
Introduction.....................................................................................................................................................6
1.5 Main Features............................................................................................................................................7
1.5.1 Wireless Rotation Speed Display - Overview ...................................................................................7
Display Information ..................................................................................................................................8
1.5.2 Built-in and Direct Mounting System to CNC Spindle.....................................................................9
1.5.3 Shaft Locking for Tool Clamping ......................................................................................................9
1.5.4 Integrated Coolant Nozzle System...................................................................................................10
1.5.5 Tool Clamping..................................................................................................................................10
2. INSTALLATION ........................................................................................................................................... 11
2.1 Battery Installation for RPM Wireless Transmitter .....................................................................................11
2.2 Display.......................................................................................................................................................11
2.2.1 Prerequisite for Display Installation ................................................................................................11
2.2.2 Display Installation Workspace........................................................................................................11
2.2.3 Connect HSM HPC Spindle to Display ............................................................................................12
2.2.4 Display Screen ................................................................................................................................13
2.2.5 Disconnect HSM HPC Spindle from Display ....................................................................................16
2.3 The HSM HPC Spindle...............................................................................................................................17
2.3.1 Prerequisite for CNC Machine.........................................................................................................17
2.3.2 HSM HPC Spindle Installation to CNC ............................................................................................17
2.3.3 Placement of HSM HPC Spindle in Toolholder ...............................................................................18
2.3.4 Tool Prerequisites............................................................................................................................19
2.3.5 Tool Installation for HSM HPC Spindle............................................................................................19
2.3.6 Tool Clamping and Runout Check (Recommendations).................................................................20
3. MAINTENANCE.......................................................................................................................................... 21
3.1. Periodic Maintenance...............................................................................................................................21
3.2. Battery Change on RPM Transmitter.........................................................................................................21
3.3. Recommended Operating Environment ..................................................................................................21
3.4. Storage......................................................................................................................................................21
3.4.1 Pre-Storage......................................................................................................................................21
3.4.2 Storage Conditions..........................................................................................................................21
4. OPERATING THE HSM HPC SPINDLE.......................................................................................................... 22
4.1 Recalculation of Table Feed for the HSM HPC Spindle .............................................................................22
4.1.1. Existing Machining Process ............................................................................................................23
4.1.2 New Machining Process..................................................................................................................23
5. TROUBLESHOOTING.................................................................................................................................. 24
5.1 Display Messages .....................................................................................................................................24
5.2 HSM HPC Spindle Shaft Does Not Rotate or RPMS Not Corresponding To Coolant Pressure....................24
5.3 HSM HPC Spindle Unused Within the Past Month....................................................................................24
6. WARRANTY SUMMARY.............................................................................................................................. 25
7. CUSTOMER SERVICE AFTER PURCHASE..................................................................................................... 27

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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.
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.
To comply with FCC Section 1.310 for human exposure to radio frequency electromagnetic fields, implement
the following instructions: 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.

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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, supplier, owner, and all organizations responsible for the
prevention of accidents.
Ensure the Following
• 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.
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
• Risk of cuts or other serious injuries during tool change.
- Do not change the tool in a rotating or moving state.
- Always wear appropriate protective equipment (such as protective gloves, safety glasses, etc.) during the
change of cutting tools to avoid cuts caused by cutting edges.
Warning
• Always use safety glasses or protective screens to protect your eyes.
• Only install 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
• Secure 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.
SAFETY FIRST

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1. GENERAL INFORMATION
The HSM HPC Spindle meets the following standards:
European Standards (CE)
• EMC: EN 301489-1/17
• Radio: EN 300328 V 1.8.1
• Safety: EN 61010-1:2010
American Standards (UL)
• EMC: FCC Part 15 B
• Radio: FCC Part 15 C
• Safety: UL 61010-1
International Standards
• Safety: IEC 61010-1:2010
Statement of Conformity

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Introduction
The HSM HPC Spindle is a unique High Pressure Coolant (HPC),High Speed Machining (HSM) spindle.It is driven
by the CNC machine spindle’s coolant-through-flow, and can handle operating pressure up to 70 bar (7Mpa).
The HSM HPC Spindle does not require any special installation, aside from mounting onto the machine spindle.
It operates as any other standard tool holder in the tool magazine or ATC.
The HSM HPC Spindle case includes: The wireless RPM display case includes:
• Nut ER11 GHS
• Wrench ER11 SMS
• Shaft Lock Flat Key
• Allen key - Hexagonal 2.0 mm
• Battery - Lithium metal non-rechargeable, CR2 type
Actual size and types of accessories may vary due to
configuration and manufacturing process
• TSD - wireless RPM display
• AC/DC 5V power supply
For USA/Japan:
Included EU to US/Japan AC adapter plug
Fig. 1. Spindle case contents Fig. 2. Display case contents
Fig. 3. Shaft lock flat key and wrench
1. GENERAL INFORMATION

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1.5 Main Features
The HSM HPC Spindle system uses the machine’s existing coolant or cutting fluid supply as a pressurized energy
source (40 to 70 bars), rotating the spindle turbine in the range up to 50,000 RPMs.
The spindle features a compact, robust, patented design, engineered for operation with high pressure coolant
pumps. Max power output 1.5 Kw up to 50,000 RPMs*.It is ideal for finishing / semi-finishing applications using
small diameter cutting tools.
* RPMs are based on pressure coolant stability and flow rate. The obtained RPMs depend on the output efficiency which is influ-
enced by the inducted coolant pressure, fluid density and flow rate.
1.5.1 Wireless Rotation Speed Display - Overview
Fig. 5. HSM HPC Spindle wireless transmitter and
display
The HSM HPC Spindle is equipped with an integrated
wireless display system, allowing real-time monitoring
of the rotation speed during machining. The spindle
housing is fitted with a wireless transmitter that sends
RPM data to the display unit (receiver) mounted outsi-
de of the machine.
The receiver is powered by a 5V DC universal AC/DC
power adapter connected to either a 220V AC or 110V
AC power source. The transmitter is powered by a
non-rechargeable CR2 lithium battery.
1. GENERAL INFORMATION

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Display Information
• 2.4 GHz radio frequency transmission
• Direct wireless rotational speed monitoring, range up to 10m
• Externally powered receiver display
• Connection up to 127 tools. Displays information from only one operating unit
• Internal battery-powered transmitter unit
• Individual ID number for each transmitter unit
Wireless RPM display main view
Fig. 6. Wireless RPM display main view
Fig. 7. Wireless RPM display mounting options
1. GENERAL INFORMATION
DC power
socket
Attach to the machine
panel by built-in magnets
Stand
Receiver display dimensions
RPM transmitter
unit
unit ID
number
signal readout
transmitter unit
identification
number
RPM wireless
transmitter
detection side
spindle RPM LCD screen
power switch
on/off
transmitter
unit‘s battery
level
DC power
socket
function buttons

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1.5.2 Built-in and Direct Mounting System to CNC Spindle
The HSM HPC Spindle mounting adaptation options:
• ER32 collet chuck with a special tightening nut, suitable for all standard toolholders with an ER32 adaptation.
• Integral options for other adaptations are available upon request.
Fig. 8. HSM HPC Spindle with mounting adaptation options (for Illustration purposes only)
1.5.3 Shaft Locking for Tool Clamping
The shaft lock mechanism provides a simple, easy way
to change the cutting tool on the HSM HPC Spindle.For
tool mounting instructions see page 19.
Fig. 9. HSM HPC Spindle with shaft lock mechanism
1. GENERAL INFORMATION

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1.5.4 Integrated Coolant Nozzle System
Integrated coolant nozzle system provides direct jet
coolant application for fast efficient chip evacuation.
Fig. 10. Integrated coolant nozzle system
1. GENERAL INFORMATION
1.5.5 Tool Clamping
The HSM HPC Spindle is compatible with ER11 collet chuck.It is recommended to use ER 11 high-precision spring
collets.
When longer overhang is required,10 and 25mm length ER11 thermal shrink collets are available.
Fig. 11. Overhang solution types
NUT ER11 GHS
Collet ER11 SPR NUT ER11 GHS
ER11 SRK...10
Thermal collet
NUT ER11 GHS
ER11 SRK...25
Thermal collet

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2.1 Battery Installation for RPM Wireless Transmitter
Install battery into the RPM transmitter:
1. Unscrew the 4 battery case cover screws with 2 mm
hexagonal Allen key
2. Remove the case cover
3. Ensure O-ring inside the cover is seated properly,
and is intact
4. Insert the CR2 lithium battery (+/-)
5. Replace the battery case cover
6. Replace the 4 battery case cover screws securely
7. The transmitter is ready for operation
2. INSTALLATION
Fig. 12. Battery case opening
2.2 Display
HSM HPC Spindle is equipped with an integrated wireless display unit, allowing real-time monitoring of the
rotating speed during machining.
2.2.1 Prerequisite for Display Installation
Make sure that the following prerequisites are met:
1. Electrical power: 220/110V AC, standard socket.
2. Distance from HSM HPC Spindle to display unit no more than 10 m.
3. Place display unit in accessible area for unobstructed viewing.
2.2.2 Display Installation Workspace
1. Mount the display onto a metallic surface using the
magnet on the back of the display, or place on a flat
and level surface.
2. Connect the display to an AC socket.
3. Switch the display ON
Fig. 13. Switch display ON
RPM wireless
transmitter
detection side
ON

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2.2.3 Connect HSM HPC Spindle to Display
The display and the HSM HPC Spindle must be connec-
ted (paired) so they can “identify” each other. Each
transmitter unit has an individual ID number
How to connect the Spindle to the display:
1. Make sure the display is ON.
2. Press ‘CONNECT‘ on the display panel, and then sli-
de the transmitter (assembled on the spindle) across
the left side (detection side) of the display unit, as
shown in the image right.
2. INSTALLATION
Fig. 14. Several spindles (not working simultaneously)
connected to one display

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2.2.4 Display Screen
When turned on, NO SIGNAL / 0 RPM screen will ap-
pear.
2. INSTALLATION
Fig. 15. NO SIGNAL displayed
Fig. 16. Connection screens
While connecting the spindle you will see CONNEC-
TING displayed, then <device ID> CONNECTED.
Notice that the battery level of the spindle is shown.
Make sure <device ID> on connected screen corres-
ponds to ID # signed on to the RPM transmitter unit.
The main display screen shows the spindle currently
operating. The spindle ID number, rotation speed, and
battery level appear.
Fig. 17. Main display screen

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If the display detects more than one spindle working at
the same time, the message “MULTIPLE SIGNALS” is
shown (see Fig.20).
To view a list of all spindles connected to the display,
press the “List” button.
Select “List” to select the device to disconnect from the
next screen.
Note: Disconnected feature will turn OFF internal bat-
tery consumption in the transmitter unit.
2. INSTALLATION
Fig. 20. More than one device working simultaneously screen
Fig. 18. List of connected Spindles on display
Fig. 21. Disconnection list for multiple signals screen
Fig. 19. Disconnected display

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The display can be cleared from all connected spindles,
or a list of previously connected devices can be viewed.
If the connect or disconnect procedure is not successful
for any reason, an appropriate message is shown - see
page 24 for troubleshooting.
If the battery of the spindle currently in operation is
running low, the following warning is shown - see page
24 for troubleshooting.
2. INSTALLATION
Fig. 22. Disconnect all sensors screen
Fig. 23. Connection failed screen
Fig. 24. Disconnect failed screen
Fig. 25. Low battery screen

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2.2.5 Disconnect HSM HPC Spindle from Display
1. Make sure the display is ON.
2. Press ‘DISCONNECT ‘ on the display panel, then slide the transmitter (assembled on the spindle) across the left
side (detection side) of the display unit, as shown in the picture.When disconnecting the spindle you will see the
“Disconnecting” screen. “<device ID> disconnected screen” - notice that the battery level of the spindle
is shown. Make sure the <device ID> on disconnected screen corresponds to the ID # signed on to the RPM
transmitter unit.
If the spindle is not spinning fast enough, the “LOW
RPM” alert is shown.
If the spindle is spinning too fast, the “HIGH RPM”
alert is shown.
2. INSTALLATION
Fig. 26. Low RPM screen
Fig. 27. High RPM screen

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2.3 The HSM HPC Spindle
2.3.1 Prerequisite for CNC Machine
1. Coolant flow through the main CNC machine spindle.
2. Minimum coolant pressure at main machine spindle outlet: 40 bar.
3. Maximum coolant pressure at main machine spindle outlet: 70 bar.
4. Moderate flow rate of 16 - 22 L/min.
5. Use with water-based emulsion or cutting oil; viscosity up to 20 (Cp)
6. Minimum coolant filtration level: 100 µm.
7. Active mist collector.
8. With emulsion coolant, use an anti-foaming agent additive suitable for emulsion to prevent foaming.
9. With oil coolant, high pressure increases the amount of oil fumes:
• Use appropriate means of fire protection and extinguishing.
• Use anti-dissolution additive suitable for the oil.
2. INSTALLATION
2.3.2 HSM HPC Spindle Installation to CNC
When the HSM HPC Spindle is mounted on the machine, the CNC machine spindle should be stationary, except
for tool check procedure or Z-offset measurement. In these cases, machine spindle must be rotated at max. 3000
RPMs to avoid risk of breakage/injury.
To avoid CNC machine spindle rotation during the HSM HPC Spindle operation, use the correct software M-code
to lock the spindle orientation. Eg: “M19” code locks the spindle in a defined angle position.
Fig. 28. (1 + 2) HSM HPC Spindle on CNC machine

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2.3.3 Placement of HSM HPC Spindle in Toolholder
Caution: Deviation from these steps may lead to locking of the tightening nut to the HSM HPC Spindle.
The HSM HPC Spindle only operates with a toolholder that has a coolant through channel.
To secure the HSM HPC Spindle in a toolholder: See steps in Figure 29 (left to right).
2. INSTALLATION
Fig. 29. (1 - 5)
Placement of HSM HPC Spindle in toolholder
1. Use a standard toolholder with ER32 collet chuck
2. Loosen the HSM HPC Spindle tightening nut 1.5 full turns
3. Insert built-in ER32 taper shank into ER32 collet chuck until the HSM HPC Spindle tightening nut will be placed
on the toolholder
4. Fasten the HSM HPC Spindle tightening nut onto the toolholder,without turning the spindle relative to the nut
5. Fasten the HSM HPC Spindle tightening nut to clamp it together with the toolholder using an ER 32 spanner.
Use hand force only
Fig. 30. Example of toolholder
with a coolant-through hole
Fig. 31. HSM HPC Spindle holding ER32 collet chuck
2 31
4
5
Toolholder with
ER32 collet chuck
ER32
mounting nut
TJS HPC ...K-ER32 R/L

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First assemble the ER 11 collet and tool.
1. Insert nut for tightening.Align flat sides of the shaft with the positioning slot on the spindle cover.
2. Position shaft lock flat key over the nut. Black dot fits into the positioning slot underneath.
3. Slide shaft lock flat key to the left to secure it in place
4. Insert ER11 wrench into the grooves on the Nut.
5. Turn ER11 wrench clockwise to tighten.
2.3.5 Tool Installation for HSM HPC Spindle
2. INSTALLATION
1 2 3
4 5
To remove the tool:
Insert the wrench and turn counter-clockwise to loosen the nut (this may take a few turns). Slide the shaft lock flat
key to the right to unlock. Keep the shaft lock in the secure position if you wish to insert a new tool.
Fig. 34 a + b Inserting wrench
Fig. 32 Inserting nut Fig. 33 a + b Inserting shaft lock flat key
2.3.4 Tool Prerequisites
HSM HPC Spindles are used in applications with tool shank diameters up to 6 mm.

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2.3.6 Tool Clamping and Runout Check (Recommendations)
The HSM HPC Spindle is designed to perform high speed operations with small diameter cutting tools for very
accurate machining.
It is very important to properly perform the instructions related to cutting tool setup, correct clamping procedure
and tool runout.
Standard clamping tools, such as ER11 spring collets and standard clamping accessories are used on the HSM
HPC Spindle.
To get a minimum runout value use ER11 SPR...AA or AAA spring collects with an exact hole size.
According to ISO 15488, the collet runout tolerances should be checked as shown in the images below.
2. INSTALLATION
Spindle housing should
remain static!
Runout is measured by
rotating the shaft manually or
running an air supply through
the machine spindle.
Dynamic Balancing System:
• Shaft G0.4
Fig. 37.
Testing runout tolerance