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1. NOTES 7 15 4 a7 i FIGURE 2 1 Computerized Vertical Honing Machine 1 of 2 6 SECTION 2 GENERAL DESCRIPTION GENERAL Consult this section when preparing Machine for operation MAJOR COMPONENTS For location of major components on your machine see Figures 2 1 1 Adjustable oil spout 2 Oil Shut Off Valve Allows manual regulation of honing fluid flow 3 Drive Tube Imparts stroking and rotational motion from drive arm to honing tool Houses feed rod 4 Stroke Length Lock Knob 5 Stroke Length Indicator 6 Stroke Length Adjustment Hand Wheel Allows for adjustment of stroke length without opening any covers 7 Optional CE Version cover 8 Operator Station Houses all electronic hardware and software for hone control It is also main operator interface with machine 9 Work Area Doors 10 Gage Hangers One at each end of tank Integral with base 11 Traverse Hand Wheel Moves carriage drive arm and control station 12 13 Enclosure cooling vents Stainless steel door guard 15 Reservoir Latch One on each side Roll Out Reservoir Pulls out like a drawer for easy cleaning 17 Lift Handle Lifts honing tool from work piece 18 Bleed Valve 19 Cover 20 Dual Filter Canisters Hold all Sunnen filter ca
2. 25 FIGURE 4 1 Lubrication SECTION 4 ROUTINE MAINTENANCE GENERAL The following procedures and suggested maintenance periods are given as guides only and are not to be construed as absolute or invariable Local conditions must always be considered Each machine must be maintained individually according to its particular requirements CLEANING If using Honing Oil Monthly wipe exterior of machine with a clean dry cloth then clean exterior with warm water and a mild detergent or mild industrial solvent Rinse thoroughly with clean hot water and wipe dry If using Water Based Coolant Daily wipe ALL surfaces that have been in contact with coolant with a clean dry cloth Clean exterior of machine with hot water and a mild detergent Wipe all surfaces dry LUBRICATION Hand lubricate various components called out in Figure 4 1 according to intervals noted in Table 4 1 FILTER ELEMENT NOTE TIGHTEN HEX BOLT UNTIL CLAMP HALVES MEET THEN TIGHTEN T HANDLE Fein M FIGURE 4 2 Filter Element TABLE 4 1 Lubrication COOLANT LINES CHECK Monthly inspect coolant lines and fittings for leaks severe dents or kinks Tighten any loose fittings and replace damaged parts as required COOLANT LEVEL CHECK Weekly check level of coolant in reservoir and add coolant as required by pouring coolant into reservoir through spl
3. Installing Mandrel Adapter 8 Mandrel following is a setup guide using mandrel adapter 1 Using an adjustable wrench turn feed rod in Mandrel Adapter counterclockwise until wedge hook in adapter nose is fully extended 2 Slide drive tube end of Mandrel Adapter into CYCLE 2 STAGE FEED RATE 1 0 0050 IN MIN FEED RATE 2 0 0025 IN MIN SPINDLE SPEED 1 250 RPM SPINDLE SPEED 2 250 RPM STROKE SPEED 1 60 SPM STROKE SPEED 2 60 SPM SPARK OUT TIME 0 SEC DISPLAY BORE PROFILE SETUP A CLEAR CYCLE COUNT NO SERIAL PORT TRANSFERS AUTO DWELL OFF CROSSHATCH ANGLE 12 1 DEG LANGUAGE ENGLISH FIGURE 3 5 Setup Screen 19 MAX NE DIAMETER STONE BORE drive tube of machine and tighten set screw into HEAD RANGE LENGTH OVERSTROKE LENGTH one of holes see Figure 3 6 mm in mm in mm in mm in drel ad bw hand ili 2400 71 76 2030 76 301 13 5 3561140 3 Rotate mandrel adapter by hand until its set Cv 3000 76 102 3 0 4 0 89 3 5 15 6 863114 3 screw points toward you CV 3300 84 127 3 3 5 0 89 3 5 15 6 363 14 3 4 Insert stones into mandrel CV 4000 102 203 4 0 8 0 152 6 0 25 1 0 406 16 0 5 Pull back on mandrel wedge using V notch CK 2000 51 76 2 0 3 0 76 3 0 13 5 356 14 0 chuck wrench CK 2600 66 86 2 6 3 5 89 3 5 15 6 363 14 3 i CK 3000 76 127 3 0 5 0 89 3 5 15 6 363 14 3 CK 4000 102 20
4. The following precautions should be observed to ensure maximum safety while working on or around your Machine CAUTION Use ONLY replacement parts supplied by Sunnen to ensure parts meet machine s specifications 1 Wear proper Safety Items such as safety glasses and other personal safety equipment as necessary or required 2 DO NOT wear loose fitting clothes or jewelry while working on or around Machine 3 Keep area around Machine free of paper oil water and other debris at all times 4 Keep Machine and area cleaned of excessive lubricant and lubricant spills 5 Keep Machine clear of tools and other foreign objects 6 Keep Tools clean and in their proper storage compartments to maintain them in proper working condition and to prolong tool life 7 Inspect Tools before using Check for cracks burrs or bent parts that might effect operation 8 DO NOT force Tools when operating Tools will do a better and safer job when operated at rate for which they were designed 9 Turn OFF electrical power when performing service on your machine which does not require power 10 Disconnect Machine from main power supply before any work is performed inside of Electrical Control Enclosure FIGURE 3 1 Elevating Crank 11 Ensure all Guards are in place and are in proper working order 12 Use proper lifting procedures when loading and unloading Machine 13 Keep all non essential persons clear of
5. cycle Range of speeds is 40 to 100 strokes per minute in increments of 10 strokes per minute NOTE This option is only visible when 2 STAGE cycle is selected 5 FEED RATE This option allows operator to enter rate at which stones will expand during honing NOTE TO CV 616 OPERATORS Feed rate is same as setting selector cover for feed rate 6 FEED RATE 2 This feed rate is used only when 2 stage feed cycle is selected This is feed rate that will start after Feed Rate 1 is completed location where this feed rate is started is selected in run screen NOTE This option is only visible when 2 STAGE cycle is selected 7 SPINDLE TORQUE PRELOAD 1 STP This is percentage of spindle s full load that machine waits to see before machine stops rapid advancing tool and starts to use programmed feed rate NOTE TO CV 616 OPERATORS STP is equivalent to how fast or hard operator feeds hand wheel out during operation 8 RETRACT AMOUNT This is distance that tool will retract at end of a cycle This will be distance that stones will travel after they have passed point where stones first came in contact with bore NOTE TO CV 616 OPERATORS Retract amount 1s equivalent to rotating hand wheel to right 9 FEEDUP FOR FEED RATE 1 This option allows operator to set a position in cycle where feed rate spindle speed and stroke speed will change to a second set of speeds Percentage that is entered is percentage of
6. key supplied with machine Door s to enclosure is equipped with Key Lock Safety Latches WARNING Residual Voltage exists for 2 3 minutes after Master ON OFF Switch is turned OFF Before working inside Enclosure wait for all fans to stop running to allow drives to discharge 3 Turn Master ON OFF Switch to OFF position and open Doors see Figure 1 4 Doors WILL NOT open unless Master ON OFF Switch is in OFF position WARNING You must use hole provided Drilling any new holes in electrical enclosure may void machine warranty FIGURE 1 6 Coolant Reservoir FIGURE 1 7 Quick Disconnect SINNEN Te E ea ra MER FIGURE 1 8 Operator Controls 4 If not provided Remove hole plug from entrance hole in enclosure and install an approved oil tight fitting 5 Insert Electrical Supply Cord through Oil Tight Fitting and route to Electrical Disconnect Block 6 Strip 250 mm 10 in off cable s outer jacket 7 Strip 6 mm 1 4 in of insulation off each wire 8 Connect Green Wire GRN to ground terminal PE 9 Connect other three 3 wires to electrical disconnect block 10 Route and secure cord inside of enclosure Tighten oil tight fitting NOTE If supply voltage matches voltage stated on electrical specification plate skip to step 14 If supply voltage does not match voltage stated on electrical specification plate but is withi
7. 1 pump Monthly E Connecting Rod Thrust Faces SAE 20 oil Coat Crank Faces Daily F Bevel Gears SML 100 Coating on Teeth 6 Months NOTE SML 100 is Sunnen Part Number for 1 tube of Mobil SHC 32 27 8 Clean canisters as required 9 Remove new elements from protective bags and insert into canisters A slight twisting action will aid in sliding filter down over post in center 10 Replace Covers centering carefully on rubber gaskets to assure no leakage Then replace Clamps and tighten Hex Bolt in Clamp Halves until halves meet then tighten T Handle Bleed Coolant System 11 Release E Stop button by turning red knob as arrow indicates See Figure 4 8 on page 28 CAUTION Machine will not operate unless both of following conditions are met 12 Raise doors and lower lift handle to honing position 13 Direct oil spout into reservoir and turn on oil shut off valve 14 Push WHITE power ON OFF button 15 Display will light up with CK 21 Logo and prompt you to clear above error conditions It will ask you to hit GREEN cycle start button to initialize stroker machine will then cycle stroking motor to find its Top Dead Center position When it has completed this exercise setup screen will be displayed 16 Push Down arrow on numeric keypad until word COOLANT is highlighted To right of word COOLANT it will say AUTO Push right arrow key to change word AUTO to ON At this point coolant pump will begin t
8. Port Transfer Screen SERIAL PORT TRANSFER SCREEN This screen allows operator to backup saved setups to a PC restore setups from a PC and allow new firmware to be loaded if upgrades to software are available see Figure 2 7 In order to use any of features on this screen operator will need to have 9 pin serial cable that was shipped with machine This cable must be plugged into a serial port on back of a PC and other end must be plugged into connector labeled P1 on left side of board All of PC software that is described below will is provided on software disk supplied with machine For all of these options recommended baud rate is 9600 Machine can transfer as fast as 57600 but 9600 is recommended Speed that is selected is PC dependent All PCs are capable to run at 9600 AUTO DWELL SETUP SCREEN AUTO DWELL TYPE 2 STAGE THRESHOLD FEED RATE 1 DWELL THRESHOLD 60 FEED RATE 2 DWELL THRESHOLD 30 STROKES BETWEEN AUTO DWELL FOR FEED RATE 1 5 STROKES BETWEEN AUTO DWELL FOR FEED RATE 2 5 SETUP SCREEN FIGURE 2 8 Auto Dwell Setup Screen To backup saved setups select BACKUP SETUPS option using up and down arrow keys Once BACKUP SETUPS is highlighted press either left or right arrow Then go over to PC and from a DOS prompt type following command BACKUP filename COM x baudrate Where filename is name of file that will store saved setups COM x is COM port that PC will use for communi
9. Sizeloc is ON and feed up amount cannot be adjusted In order for Sizeloc to work properly operator will need to enter amount of stone wear that is being experienced This value can be adjusted from cycle to cycle Once stone wear has been entered and 24 operator has run first part and obtained correct size operator would only need to put tool into next bore and press cycle start Machine will determine amount of stock which will need to be removed during cycle in order to match size of first part Stone wear will automatically be taken into consideration when machine determines final position NOTE If amount of stone wear is very small it is easier to compensate for size differences by using bore adjustment feature instead of stone wear compensator This option is on screen only when size lock is turned ON 14 If tool is starting to loose size over a few bores this can be compensated for through a bore adjustment A bore adjustment will add or subtract an amount of stock removal from final position A bore adjustment can be done between cycles Notes for operators of GHTS hone head 1 You must run one single stage cycle with each set of stones before you can run a full two stage cycle This is because machine needs to learn a point where is needs to retract to in order to start set of stones In order to select which set of stones you are using you will need to go to 2 STAGE OPTIONS selection on run screen Thi
10. Wipe oil from around air vents POLY V BELT TENSION Adjust Poly V Belt tension wide belt as follows see Figure 4 4 1 Loosen two screws that attach bearing housing to drive arm 2 Loosen locknut on belt tension adjuster on top side of drive arm 3 Turn adjustment screw until belt is deflected 7 16 in at mid span on either side It requires approximately 8 lbs of force to deflect belt 4 Tighten fasteners loosened in steps 1 amp 2 STROKER BELT TENSION Adjust Stroker Belt tension as follows see Figure 4 5 1 Remove two attachment screws from Belt Cover on left side of machine Remove one rubber stop 2 Loosen two screws holding tensioner 3 With a large pry bar force tensioner into belt 4 When all slack has been removed from belt tighten two Tensioner Screws 5 Replace Belt Guard ROCKER ARM ADJUSTMENT Adjust Rocker Arm as follows see Figure 4 6 1 Loosen Locknut 2 Tighten Socket Head Capscrew until total amount of movement is about 6 mm 1 4 in 3 Tighten Locknut 4 Repeat for other side FAN FILTER Monthly clean fan and exhaust filters on electrical enclosure as follows see Figure 4 7 NOTE Filter elements may need to be cleaned more often depending on shop environment and your use of machine 1 Remove fan and exhaust covers on front of enclosure covers pop off FILTER ELEMENT 2 Remove filter elements 3 Clean filter elements as follows e Using
11. account bore length stone length and over stroke amount Make sure that all numbers are entered correctly Once all values are entered operator would then set stroke length to calculated value This screen also displayed crosshatch angle that in center of part using spindle and stroke speeds that have been set in speeds and dimensions screen If a 2 STAGE cycle is selected only second spindle and second stroke speeds will affect crosshatch angle 12 SAVE SCREEN STROKE LENGTH 000 2 0 IN SETUP NUMBER 1 52 NAME on 9 10 USE UP DOWN ARROWS TO SELECT SETUP PRESS F1 TO LOAD SELECTED SETUP PRESS F2 TO SAVE SELECTED SETUP PRESS F3 TO DELETE SELECTED SETUP PRESS ANY OTHER KEY TO GO BACK TO THE SETUP SCREEN FIGURE 2 5 Save Setups Screen STROKE LENGTH CALCULATOR ENTER THE CYLINDER LENGTH 4 000 IN PRESS F1 TO EDIT CYLINDER LENGTH RECOMMEDED TOOL GHSS 3410 HOLDER GHG14C233 349 ALTERNATE TOOL GHSS 3410 ENTER THE BORE DIAMETER 4 000 IN HOLDER GHG14C233 348 SUGGESTED SETTINGS STROKE LENGTH 2 0 IN SPINDLE SPEED 190 RPM STROKE SPEED 80 SPM ENTER THE STONE LENGTH 3 000 IN OVER STROKE AMOUNT 0 5000 IN CROSSHATCH ANGLE 21 2 DEG SETUP SCREEN FIGURE 2 6 Stroke Length Calculator Screen SERIAL PORT TRANSFER SCREEN BAUD RATE 9600 BACKUP SETUPS RESTORE SETUPS LOAD FIRMWARE INTO MEMORY LOAD BOOT LOADER INTO MEMORY SETUP SCREEN FIGURE 2 7 Serial
12. air pressure to blow dirt from filter element If filter element is excessively dirty clean using soap and water wring out and blow dry CAUTION Filter element MUST be dry before reinstall to ensure excess moisture does not get into enclosure 4 Replace filter elements and replace covers FIGURE 4 7 Electrical Enclosure LOW PRESSURE RELIEF VALVE FILTER 10 PSI MAX CANISTERS HIGH PRESSURE RELIEF VALVE CLEAN OIL CLEAN OIL u DUMP PIPE BJ S INTAKE STRAINER ASSEMBLY DIRTY OIL NL FIGURE 4 8 Coolant Flow Diagram 30 SECTION 5 TROUBLESHOOTING GENERAL This section contains Frequently Asked Questions Refer to it when problems occur with machine FREQUENTLY ASKED QUESTIONS Q It seems as if stroker changes speeds during cycle Why is this A stroker drive on CK 21 is programmed to optimize reversal points in stroke It is also attempting to maintain a constant crosshatch To accomplish these to things computer continually updates speed of stroker Q filters on my CK 21 do not seem to last as long Why A CK 21 removes much more stock in a given time than other honing machines Check filter life in parts per filter and performance of filters should be about same Q tool got locked up in bore How do I clear faults safely A More than likely you are showing a STROKER FAULT computer saw an unacceptable load going to stroker
13. allows operator to run a sized type cycle with two different feed rates two different spindle speeds and two different stroke speeds during same cycle 2 FEED RATE 1 This option allows operator to enter a specified feed rate for first part of cycle It remains for a preset percentage of total cycle s stock removal 3 FEED RATE 2 This is ending feed rate It is only active when 2 Stage 1s selected 4 For faster stock removal or rougher finish use a faster feed rate 5 For greater stone life or smoother finish choose a slower feed rate 6 Be sure that appropriate tool family has been chosen in TOOL area of Setup Menu 7 Be sure that a full stream of Sunnen Honing Fluid is in full contact with bore OPERATION There are several methods for operating CK 21 depending on your application First Method The first method of using this machine is very similar to that used on CV 616 allowing operator to enter amount of stock that needs to be removed If Stone Wear Compensation feature is not used operator will have to manually calculate how much stone wear will occur and add that amount to amount of stock that needs to be removed The operator presses Fl and enters this amount into system as Feed up Amount If Stone Wear Compensation feature is used operator will enter amount of stone wear that occurs for 0 01 mm 0 001 in of stock removal This number can be found by using SWC calculator After one cycle
14. begin to run Immediately toggle to OFF DO NOT run pump dry observer will note pump rotation If rotation is in direction of indicating arrow pump can be toggled back to ON and run If rotation is incorrect turn OFF main power coming into machine Then reverse two leads on main power cable Restart pump to verity rotation 9 Open manual control valve to wide open position and allow pump to purge air from honing fluid filtering system 10 As oil fills filter canisters air will escape through air vents When oil appears in air vents close vents NOTE Coolant should flow from oil spout Control amount of oil by regulating oil shut off valve 11 Turn OFF power 12 Wipe oil from around air vents FIGURE 1 9 Pump Rotation OVERARM SAFETY GUARD Install Overarm Safety Guard as follows 1 Unpack Overarm Safety Guard and hardware and check contents against packing list before discarding any packaging materials 2 Use hoist to lift guard into position and align hole in guard bracket with threaded holes in machine 3 Secure guard to machine using bolts and lock washers provided Tighten bolts 4 Attach left and right Guard Extensions using bolts provided Tighten bolts 5 Attach left and right Carriage Extensions using bolts and washers provided Tighten bolts NOTE Use washers provided as spacers between Carriage Extensions and Carriage NOTES
15. cycle is using feed rate 1 machine will not automatically dwell because auto dwell index is 40 and feed rate 1 threshold is set at 60 If honing cycle is using feed rate 2 machine will automatically dwell because auto dwell index is 40 and feed rate 2 threshold is set to 30 auto dwell index will change during honing cycle During first few cycles with auto dwell on watch trend of Auto Dwell Index If operator feels that machine should be dwell more operator should decrease dwell threshold If operator feels that machine is dwelling too much operator should increase dwell threshold RUN SCREEN OPTIONS Run Screen will have different options depending on cycle type that was selected see Figure 2 10 for all options with Sizeloc off 1 SIZED cycle type FEEDUP AMOUNT This option allows operator to enter amount of material that needs to be removed Range of values is 0 0001 to 0 2500 in for English measuring system and 0 0025 6 350 mm for metric measuring system operator can edit value in between cycles In order to edit value you need to hit F I button It will position cursor on current value Value can be entered using numeric keypad feedup amount can be adjusted while machine is running NOTE TO CV 616 OPERATORS feedup amount is same as when operator holds feed wheel and advances feed dial 2 TIMED cycle type CYCLE LENGTH This option allows operator to enter amount of time that they want machine to hone Range of
16. motor so it shut down machine order of clearing faults is VERY important for your safety Follow this procedure EXACTLY 1 DO NOT try to raise handle at this time 2 Clear faults indicated on RUN Screen 3 Toggle to SETUP screen 4 Use UP DOWN Arrow to JOG 5 Use LEFT RIGHT Arrow until field reads TOOL 6 Retract tool When tool is loose in bore there is no more stored energy in system You may now lift tool from bore Q There seems to be a metallic whine coming from front of drive arm What is this A spindle drive in your CK 21 utilizes a Planetary Differential to in part drive spindle and feed rod This transmission uses straight cut spur gears to insure longevity and durability noise you are hearing is normal for this type of gear Q What does Bore display really show me A bore display is meant to be REPRESENTATIVE of shape of hole This is generally a very accurate depiction Some very long mandrels will fool display but these cases are rare magnitude of taper or barrel shape will differ with stone type and grit hardness For example a 003 taper using metal bonds will be more dramatic than EHU 525 You will get a better idea what to expect from different stone sets as you use your CK 21 more but do not try to MEASURE with this display Can I run water based coolant in CK 21 A Yes coolant system components are all compatible with Sunnen Water Based Honing Fluids To minimize effe
17. on lower step see Figure 3 16 3 RPM range here is 90 240 4 Check that pulley step on idler assembly is correct 5 Close and lock left rear belt cover TABLE 3 3 Equivalent Feed Rates in min FEED TOOLING 41 SPM RATE cv P28 R28 Y YY P20 1 0 0015 0 0005 0 0015 0 0010 0 0005 2 0 0030 0 0015 0 0030 0 0025 0 0010 3 0 0040 0 0020 0 0045 0 0035 0 0020 4 0 0055 0 0030 0 0060 0 0045 0 0025 5 0 0070 0 0035 0 0075 0 0060 0 0030 6 0 0085 0 0045 0 0090 0 0070 0 0035 7 0 0100 0 0050 0 0105 0 0085 0 0040 8 0 0115 0 0060 0 0120 0 0095 0 0050 9 0 0130 0 0065 0 0140 0 0105 0 0055 FEED TOOLING 57 SPM RATE cv P28 R28 Y YY P20 1 0 0020 0 0010 0 0020 0 0015 0 0010 2 0 0040 0 0020 0 0040 0 0035 0 0015 3 0 0060 0 0030 0 0065 0 0050 0 0025 4 0 0080 0 0040 0 0085 0 0065 0 0035 5 0 0100 0 0050 0 0105 0 0085 0 0040 6 0 0120 0 0060 0 0125 0 0100 0 0050 7 0 0140 0 0070 0 0150 0 0115 0 0060 8 0 0160 0 0080 0 0170 0 0135 0 0065 9 0 0180 0 0090 0 0190 0 0150 0 0075 FEED TOOLING 80 SPM RATE cv P28 R28 YIYY P20 1 0 0025 0 0015 0 0030 0 0025 0 0010 2 0 0055 0 0030 0 0060 0 0045 0 0025 3 0 0085 0 0045 0 0090 0 0070 0 0035 4 0 0110 0 0055 0 0120 0 0095 0 0045 5 0 0140 0 0070 0 0150 0 0115 0 0060 6 0 0165 0 0085 0 0180 0 0140
18. operator to run a sized type cycle with two feed rates two spindle speeds and two stroke speeds Note that when using GHTS tool a different cycle type can be used for each set of stones 6 TOOL This option allows operator to select type of tool that will be used 13 options are as follows GHSS Y Y Y R28 P20 P28 CK CV ANR MPS H BAL20 AK20 ANR FL6X MPS FL6X and possibly GHTS The correct tool family needs to be selected in order for feed system to operate properly NOTE TO CV 616 OPERATORS This is equivalent to setting index plate to indicate honing tool that is being used 7 SPEEDS AND DIMENSIONS This option allows operator to go Speeds and Dimensions screen It is there that operator can adjust items such as spindle and stroke speeds This screen is described in a later section 8 AUTO DWELL This option allows operator to automatically dwell at tight spot in bore during honing This option can be turned on or off There are a few parameters that can be modified to improvement performance of auto dwell feature Highlighting AUTO DWELL option for proper stage and pressing F I can enter Auto Dwell Setup Screen When using GHTS tool this feature can be enabled or disabled for each set of stones independently The parameters for each set of set of stones can be set independently Auto Dwell Setup Screen will be explained later in this manual 9 COOLANT This option allows operator to select how coolant moto
19. set of holes above numeral 2 in hone body so guide and stone are also in line Automotive Applications ONLY 1 Position Riser blocks for in line or V block e If engine block s main bearing centerline is in line with pan rails position riser so that it is in a vertical position see Figure 3 12 large notch in center will provide clearance for main bearing housings If pan rails are below centerline position risers so they are in a flat configuration e If main bearing centerline is above pan rails turn riser blocks 90 degrees to flat position so that pan rails sit on flat part of risers see Figure 3 13 NOTE To clamp engine block in place there must be at least 2 main caps in place Block distortion will be kept to a minimum if all caps are in place and tightened to proper specification 2 Place clamp bar through main bearing bores 3 Move carriage to extreme right and raise arm 4 Make sure that pan rails are clean and free of any gasket material 5 Slide riser blocks to approximate position near ends of engine block with proper orientation for that type block 6 Place engine on riser blocks 7 Slide clamps to slots in ends of clamp bar It may be necessary to shift position of engine block so that both clamps will slide into slots at ends of clamp bar 8 With both clamps in position tighten clamp nuts evenly first by hand and then with clamp crank provided in fixturing package 9 If en
20. to run first part and hone it to correct size Once this first part is sized properly operator would then turn Sizeloc ON On run screen FEEDUP AMOUNT message will be erased from screen to remind operator that Sizeloc is on and that he cannot adjust feedup amount see Figure 2 12 In order for Sizeloc to operate properly operator may need to enter amount of stone wear that he is experiencing This value can be adjusted from cycle to cycle Once stone wear has been entered and operator has run first part and obtained proper size operator would only need to put tool into next hole and press cycle start Machine will determine amount of stock that will need to be removed during cycle in order to match size of first part Stone wear will be taken into consideration when determining final position If any of following items need to be modified while Sizeloc is on system will turn size lock off Cycle Type any Feed Rate any Spindle Speed any Stroker Speed Spindle Torque Preload Tool Coolant Spark Out Time reason that size lock is turned off is that any of above listed items can affect final size Size lock will need to be set again after first cycle NOTES SECTION 3 SETUP amp OPERATION GENERAL This section gives a step by step overview of setup amp operation procedures for this machine SAFETY PRECAUTIONS
21. to a controlled stop during honing or stroker initialization cycle Emergency stop button Shuts OFF all power to machine and causes an immediate stop in motion of machine regardless of where machine is in it s cycle Switch is used to make stroker dwell while machine is honing NOTE On Run screen there are 5 marks in middle of screen that represent five locations bore Using up down ARROW keys you can move this marker to place where you would like to dwell When you press dwell button stroker will dwell in location that you selected with arrow keys for 2 seconds For continuous dwell hold Dwell Button in for desired length of time SAFETY SYMBOLS For a description of safety symbols used on this machine refer to Table 2 2 SCREENS Operator Interface and Control Station Screen options are as follows SETUP SCREEN SAVE SETUPS COOLANT AUTO NOTE Starting in this section and continuing throughout remainder of manual references may be made to a two stage hone head GHTS These features can be enabled as an option Please contact your Sunnen representative for more information SETUP SCREEN OPTIONS This screen will allow operator to enter Setup options see Figure 2 3 Below is a list of items STROKE LENGTH CALCULATOR JOG STROKER UNITS IN CYCLE STAGE 1 SIZE TOOL GHSS SPEED AND DIMENSIONS AUTO DWELL STAGE 1 OFF PRESS F3 TO GO TO THE RUN SCREEN SPARK OUT TIME
22. 0 296875 7 5406 669291 17 0000 011811 0 3000 312500 7 9375 671875 17 0656 015625 0 3969 314961 8 0000 687500 17 4625 015748 0 4000 328125 8 3344 703125 17 8594 019685 0 5000 343750 8 7313 708661 18 0000 023622 0 6000 354331 9 0000 718750 18 2563 027559 0 7000 359375 9 1281 134375 18 6531 031250 0 7938 375000 9 5250 748031 19 0000 031496 0 8000 390625 9 9219 750000 19 0500 035433 0 9000 393701 10 0000 765625 19 4469 039370 1 0000 406250 10 3188 781250 19 8438 046875 1 1906 421875 10 7156 787402 20 0000 062500 1 5875 433071 11 0000 796875 20 2406 078125 1 9844 437500 11 1125 812500 20 6375 078740 2 0000 453125 11 5094 826772 21 0000 093750 2 3813 468750 11 9063 828125 21 0344 109375 2 7781 472441 12 0000 843750 21 4313 118110 3 0000 484375 12 3031 859375 21 8281 125000 3 1750 500000 12 7000 866142 22 0000 140625 3 5719 511811 13 0000 875000 22 2250 156250 3 9688 515625 13 0969 890625 22 6219 157480 4 0000 531250 13 4938 905512 23 0000 171875 4 3656 546875 13 8906 906250 23 0188 187500 4 7625 551181 14 0000 921875 23 4156 196850
23. 0 International Division Fax 314 781 6128 http www sunnen com e mail sunnen sunnen com MULTIPLY MILLIMETERS mm x METERS m x 1 062500 26 9880 BY 0 03937 3 281 TO GET INCHES in FEET ft SUNNEN PRODUCTS LIMITED No 1 Centro Maxted Road Hemel Hempstead Herts HP2 7EF ENGLAND Phone 44 1442 393939 Fax 44 1442 39 12 12 SUNNEN AG Fabrikstrasse 1 8586 Ennetaach Erlen Switzerland Phone 41 71 649 33 33 Fax 41 71 649 34 34 SHANGHAI SUNNEN MECHANICAL CO LTD 889 Kang Qiao East Road PuDong Shanghai 201319 P R China Phone 86 21 5 813 3322 SUNNEN ITALIA S R L Viale Stelvio 12 15 20021 Ospiate di Bollate MI Italy Phone 39 02 383 4171 Fax 39 02 383 417 50 Fax 86 21 5 813 2299 COPYRIGHT SUNNEN PRODUCTS COMPANY 2004 ALL RIGHTS RESERVED
24. 0 0070 7 0 0195 0 0100 0 0210 0 0165 0 0080 8 0 0220 0 0115 0 0240 0 0185 0 0095 9 0 0250 0 0130 0 0270 0 0210 0 0105 RUN SCREEN COUNT 0 SPINDLE LOAD TIME 30 PRESS F1 TO EDIT FEEDUP AMOUNT 0 20 40 60 80 100 FEEDUP AMOUNT 0 0039 IN STATUS STOPPED FEED POSN IN 0 0 0019 0 0039 4 DWELLS 0 DWELL TYPE COUNTER JOG TOOL SIZELOC OFF SETUP A FEEDUP FOR FEED RATE 1 50 SWC 0 000000 IN SWC SCREEN SETUP SCREEN FIGURE 3 17 Run Screen 6 Go to SETUP SCREEN on operator interface and highlight SPINDLE SPEED This is speed at which spindle will rotate during cycle Overall range of machine is 90 550 but you can only set speed according to position of idler One range is 90 240 RPM other is 250 550 RPM 7 Use DOWN ARROW to select STROKER SPEED on Operator Interface Range here is 40 100 Strokes per Minute SPM CAUTION Stroke rates of over 70 SPM are not recommended on stroke lengths over 160 mm 6 1 4 in Select Feed Rate For equivalent CV 616 feed rates refer to Table 3 3 1 Use UP DOWN Arrow to highlight Cycle type This option allows operator to select one of three types of cycles The first cycle type is SIZED This allows operator to enter amount of material that needs to be removed This value is entered on RUN screen The second cycle type is TIMED This allows operator to run for a specified time i e Plateau Honing 23 The last type is 2 STAGE This
25. 3 4 0 8 0 152 6 0 25 1 0 406 16 0 SETUP SCREEN SAVE SETUPS SPINDLE TORQUE PRELOAD 20 STROKE LENGTH CALCULATION TOOL GHC JOG STROKER COOLANT AUTO UNITS IN RETRACT AMOUNT 0 020 IN GUARD REMOVED FOR CLARITY FIGURE 3 6 Install Mandrel Adapter 6 If required place concentric sleeve on mandrel If runout is excessive during honing replace sleeve with eccentric sleeve If runout remains excessive turn sleeve around 7 Insert mandrel into adapter For all Y series mandrels and P series mandrels under 66 mm 2 6 in stones should be 90 to right of set screw For all P mandrels over 66 mm 2 6 in stones should be 90 to left of set screw 8 Push mandrel up into Adapter until it bottoms rotate it 1 4 turn to right and push up until it bottoms again 9 Tighten Set Screw securely with chuck wrench Installing Hone Head Install CV CK or GHC Series Hone Head by sliding Hone Head Drive Tube into Machine Drive Tube align Locating Screw in Hone Head Drive Tube with one of holes Machine Drive Tube then tighten screw see Figure 3 7 NOTE Locating Screw can be screwed into hole in lower part of Drive Tube when index lines are in line Replacing Stones To replace stones in CV CK Series Hone Head proceed as follows 1 Slide Movable Stop to OUT position Insert Stone Assembly with worn out stone into fixture and pull lever toward you until stone is free from ma
26. 452 17 8 NA NA 5 Stone 5 420 116 4 25 1 0 452 178 NA NA These Maximum Bore Lengths can be honed but it may be impossible to withdraw the mandrel without first lowering the workpiece or removing the tool from the workpiece TABLE 3 2 CV CK Series Hone Heads CK 21 TOOLING Refer to Sunnen Industrial or Automotive Honing Supplies Catalog for all your honing needs CAUTION Use of tooling other than Sunnen tooling will render all of features of computerized honing system useless due to fact that machine and all its parameters are calibrated to Sunnen Tooling only For bores with diameters smaller than 60 mm 2 4 in or bores over 280 mm 11 in long with diameters smaller than 66 mm 2 6 in use Sunnen CV 1010 Mandrel Adapter and an appropriate Sunnen mandrel see Figure 3 4 and Tables 3 1 amp 3 2 For larger diameter bores use Sunnen CV CK or GHSS Series Hone Heads NOTE On SETUP screen there is a TOOL option This option allows operator to select type of tool that will be used 10 options are as follows CK CV P28 P20 R28 Y YY GHC MPS AK 20 BL20 and MPS FL6X correct tool family needs to be selected in order for feed system to operate properly see Figure 3 5 SETUP When using CV Mandrel Adapter and Mandrel proceed with following step Installing CV Mandrel Adapter amp Mandrel When using CV CK Hone Head proceed to Installing Hone Head
27. 5 0000 562500 14 2875 937500 23 8125 203125 218750 5 1594 5 5563 578125 590551 14 6844 15 0000 944882 953125 24 0000 24 2094 234375 5 9531 593750 15 0813 968750 24 6063 236220 6 0000 609375 15 4781 984252 25 0000 250000 17 64 265625 6 3500 625000 629921 15 8750 16 0000 984375 1 000000 25 0031 25 4000 sd hu 275591 FORMULAS MULTIPLY INCHES in FEET ft 640625 16 2719 TO GET MILLIMETERS mm METERS m SUNNEN AND THE SUNNEN LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY Sunnen reserves the right to change or revise specifications and product design in connection with any feature of our products contained herein Such changes do not entitle the buyer to corresponding changes improvements additions or replacements for equipment supplies or accessories previously sold Information contained herein is considered to be accurate based on available information at the time of printing Should any discrepancy of information arise Sunnen recommends that user verify discrepancy with Sunnen before proceeding PRINTED IN U S A 0410 all SUNNEN SUNNEN PRODUCTS COMPANY 7910 Manchester Ave St Louis MO 63143 U S A Phone 314 781 2100 Fax 314 781 2268 U S A Toll Free Sales and Service Automotive 1 800 772 2878 Industrial 1 800 325 367
28. 90 x 812 mm 57 x 35 x 32 in Workpiece Weight Max 680 Kg 1500 Ibs Spindle Drive 3 0 kW 4 hp Range LO 90 240 RPM HI 170 550 RPM Stroker Drive 0 55 kW 3 4 hp Rate 40 100 spm Strokes Per Minute Length 19 05 305 0 mm 75 12 in Feed System Operating Torque 7 4 Nm 10 ft Ib max Rate 0 75 mm min 0 030 in min max Honing Fluid System Coolant Pump 18 9 LPM 5 GPM Pump Pressure 0 310 Mpa 45 psi max Coolant Capacity 246 liters 63 5 gal max Electrical Requirement See nameplate Pneumatic Requirement 0 552 Mpa 80 psi Compressed air Floor Weight 1360 Kg 3000 Ibs Dry weight Floor Space Approx 2200 x 2180 x 2225 mm 87 x 86 x 88 in Stroke length diameter range and workpiece weight are contingent on machine configuration workpiece and application INTRODUCTION This Instruction Manual provides information required to install operate and maintain Sunnen CK 21 Computerized Vertical Honing Machine When ordering parts for or requesting information about your Machine include Model Number and Serial Number printed on Nameplate In this book the symbol indicates steps or information that are only for the CE version of this machine The CE version is constructed to meet the highest level of safety standards as required by the European Machinery Directive Required for the European market this CE version is available for any customer The regular version of this machine is qui
29. DER INTO MEMORY At this point go to PC and type following command BL This will give you a description of options available with this program To start the download type following command BL comx baudrate Where comx is communication port being used baudrate is speed of transfer NOTE Default setting for comx parameter is COM I and default baud rate is 9600 If these parameters are acceptable you do not have to enter parameters on command line To download new firmware into machine select LOAD FIRMWARE INTO MEMORY option Pressing either left or right arrow will display message LOADING NEW FIRMWARE At this point go to PC and type following command FL This will give you a description of options available with this program To start download type following command FL comx baudrate Where comx is communication port being used baudrate is speed of transfer NOTE Default setting for comx parameter is COM I and default baud rate is 9600 If these parameters are acceptable you do not have to enter parameters on command line If PC program is waiting and message Approximate download time xx seconds is last message on screen you will have to turn off CK 21 at main disconnect and restart download This may happen if baud rate of PC is not same as baud rate of CK 2 1 You will need to wait for PC to time out before starting download again AUTO DWELL SETUP SCREEN This screen allows operator to
30. Disconnect to be sure that it is coupled into reservoir in back of machine see Figure 1 7 7 Fill machine base reservoir with 210 liters 55 gal of Sunnen coolant Dump coolant into front of machine WARNING Check all guards and ensure they are in place and locked before operating machine OPERATIONAL CHECK 1 Partially open Air Vents on Filter Canisters 2 Turn main disconnect on main electrical panel to on position 3 Release E Stop button by turning red knob as arrow indicates CAUTION Machine will not operate unless both of following conditions are met 4 Raise doors and lower lift handle to honing position 5 Direct oil spout into reservoir and open oil shut off valve on front of machine 6 Push WHITE power ON OFF button see Figure 1 8 7 Display will light up with CK 21 Logo and prompt you to clear above error conditions It will ask you to hit GREEN cycle start button to initialize stroker machine will then cycle stroking motor to find its Top Dead Center position When it has completed this exercise setup screen will be displayed CAUTION To prevent damage to pump a second person is needed at rear of machine to observe pump rotation at fan end of motor see Figure 1 9 8 Push Down arrow on numeric keypad until word COOLANT is highlighted To right of word COOLANT it will say AUTO Push right arrow key to change word AUTO to ON At this point coolant pump will
31. I CK 210G H SUNNEN Installation Setup and Operation INSTRUCTIONS for SUNNEN COMPUTERIZED VERTICAL HONING MACHINE Model CK 21 READ THE FOLLOWING INSTRUCTIONS THOROUGHLY AND CAREFULLY BEFORE UNPACKING INSPECTING OR INSTALLING THE SUNNEN COMPUTERIZED VERTICAL HONING SYSTEM SUNNEN AND THE SUNNEN LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY SUNNEN PRODUCTS COMPANY 7910 MANCHESTER AVENUE ST LOUIS MO 63143 U S A e PHONE 314 781 2100 GENERAL INFORMATION The Sunnen equipment has been designed and engineered for a wide variety of parts within the capacity and limitation of the equipment With proper care and maintenance this equipment will give years of service READ THE FOLLOWING INSTRUCTIONS CAREFULLY AND THOROUGHLY BEFORE UNPACKING INSPECTING OR INSTALLING THIS EQUIPMENT IMPORTANT Read any supplemental instructions BEFORE installing this equipment These supplemental instructions give you important information to assist you with the planning and installation of your Sunnen equipment Sunnen Technical Service Department is available to provide telephone assistance for installation programming amp troubleshooting of your Sunnen equipment All support is available during normal business hours 8 00 AM to 4 30 PM Central Time Review all literature provided with your Sunnen equipment This literature provides valuable information for proper installation oper
32. OSS OF USE REVENUE OR PROFIT SPC ASSUMES NO LIABILITY FOR PURCHASED ITEMS PRODUCED BY OTHER MANUFACTURERS WHO EXTEND SEPARATE WARRANTIES REGARDLESS OF ANY RIGHTS AFFORDED BY LAW TO BUYER SPC s LIABILITY IF ANY FOR ANY AND ALL CLAIMS FOR LOSS OR DAMAGES WITH RESPECT TO THE PRODUCTS AND BUYER S SOLE AND EXCLUSIVE REMEDY THEREFORE SHALL IN ALL EVENTS BE LIMITED IN AMOUNT TO THE PURCHASE PRICE OF THAT PORTION OF THE PRODUCTS WITH RESPECT TO WHICH A VALID CLAIM IS MADE Shipping Damages Except in the case of F 0 B Buyer s destination shipments SPC will not be liable for any settlement claims for obvious and or concealed shipping damages The customer bears the responsibility to unpack all shipments immediately and inspect for damage When obvious and or concealed damage is found the customer must immediately notify the carrier s agent to make an inspection and file a claim The customer should retain the shipping container and packing material SUNNEN SOFTWARE LICENSE AGREEMENT This document is a Legal Agreement between you as user and licensee Licensee and Sunnen Products Company SPC with respect to preprogrammed software Software provided by SPC for use on SPC Equipment By using the Software you as Licensee agree to become bound by the terms of this Agreement In consideration of payment of the license fee License Fee which is part of the price evidenced by your receipt Receipt SPC grants to you as Licensee a non exclusi
33. STAGE 1 0 DISPLAY BORE PROFILE BORE PROFILE GAIN NORMAL SETUP A CLEAR CYCLE COUNT NO SERIAL PORT TRANSFERS LANGUAGE ENGLISH RUN SCREEN and a description of each item on screen later in this manual FIGURE 2 3 Setup Screen TABLE 2 2 Machine Safety Symbols SYMBOL Gz O gt gt gt gt gt 2 j i 1 DESCRIPTION CAUTION ELECTRICAL CAUTION MOVING PARTS CAUTION DO NOT HIT HEAD WARNING LIGHT WARNING SAFETY GLASSES CAUTION DO NOT TOUCH DIRECTION OF ROTATION TO RAISE PART DIRECTION OF ROTATION DIRECTION OF ROTATION INCREASE DECREASE DIRECTION OF ROTATION LOCK UNLOCK DIRECTION TO INCREASE COOLANT FLOW LABEL FUNCTION Warns that an electrical hazard exists Warns that a finger hazard exists Warns of possible head injury from move arm Warns that power must be OFF when belt guard is opened to prevent injury Warns that safety glasses should be worn at all times when operating this machine Warns that a finger hazard exists Do not touch while stroker is operating Indicates direction to turn elevating crank to raise cradle Indicate the direction that motor or part is rotating Direction of rotation to increase and decrease the Stroke Length Adjustment Direction of rotation to lock and unlock the Stroke Length Adjustment Indicates to turn counter cloc
34. and tear belts fuses filters etc Damages resulting from but not limited to Shipment to the customer for items delivered to customer or customer s agent F O B Shipping Point gt Incorrect installation including improper lifting dropping and or placement gt Incorrect electric power beyond 10 of rated voltage including intermittent or random voltage spikes or drops gt Incorrect air supply volume and or pressure and or contaminated air supply gt Electromagnetic or radio frequency interference from surrounding equipment EMI gt Storm lightning flood or fire damage gt Failure to perform regular maintenance as outlined in SPC manuals gt Improper machine setup or operation causing a crash to occur gt Misapplication of the equipment gt Use of non SPC machines tooling abrasive fixturing coolant repair parts or filtration gt Incorrect software installation and or misuse gt Non authorized customer installed electronics and or software Customer modifications to SPC software THE LIMITED WARRANTY DESCRIBED HEREIN IS EXPRESSLY IN LIEU OF ALL ANY OTHER WARRANTIES SPC MAKES NO REPRESENTATION OR WARRANTY OF ANY OTHER KIND EXPRESS OR IMPLIED WHETHER AS TO MERCHANTABILITY FITNESS FOR A PARTICULAR PURPOSE OR ANY OTHER MATTER SPC IS NOT RESPONSIBLE FOR THE IMPROPER USE OF ANY OF ITS PRODUCTS SPC SHALL NOT BE LIABLE FOR DIRECT INDIRECT INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO L
35. ash screens Use ONLY Genuine Sunnen coolants in CK 21 Many poor honing performance indicators can be traced to incorrect honing fluids Incorrect honing fluids may also damage pump or related components minimum operating depth in reservoir is 89 mm 3 1 4 in Maximum capacity 1s 240 L 63 5 gal Minimum capacity is 144 L 38 gal FILTER REPLACEMENT Replace Filter Element in Filter Canisters as follows see Figure 4 2 1 While operating coolant pump observe reading of gage on top of filter canisters on back of machine If reading exceeds 38 PSI filter element is nearing or 1s at capacity 2 Turn OFF all electrical power to machine 3 Open air vents on top of canisters turn counterclockwise 4 Place a bucket or other suitable container under draincocks that are located on bottom of filter canister Open draincocks and drain about 2 liters 2 quarts from each canister to prevent spillage when removing elements 5 Close draincocks and air vents 6 Note Orientation of clamps and remove clamps and canister covers 7 Slowly pull out dirty filter element and place in a bucket to drain Dispose of filter elements in accordance with local requirements Fig Description Lubricant Amount Frequency A U Joint Assembly 2 Grease Fill Boot Monthly B Upright Fitting on back of tube SML 100 2 pumps Monthly Carriage Bushing SML 100 4 pumps Monthly D Connecting Rod 2 places SML 100
36. ation and maintenance of your equipment Troubleshooting information can also be found within the Instructions If you cannot find what you need call for technical support Where Applicable programming information for your Sunnen equipment is also included Most answers can be found in the literature packaged with your equipment Help us help you When ordering parts requesting information or technical assistance about your equipment please have the following information available e Have ALL MANUALS on hand The Customer Services Representative or Technician will refer to it e Have Model Number and Serial Number printed on your equipment Specification Nameplate e Where Applicable Have Drive model and all nameplate data Motor type brand and all nameplate data For Troubleshooting additional information may be required e Power distribution information type delta wye power factor correction other major switching devices used voltage fluctuations e Installation Wiring separation of power amp control wire wire type class used distance between drive and motor grounding e Use of any optional devices equipment between the Drive amp motor output chokes etc For fast service on your orders call Sunnen Automotive Customer Service toll free at 1 800 772 2878 Sunnen Industrial Customer Service toll free at 1 800 325 3670 Customers outside the USA contact your local authorized Sunnen Distributor Additional information avai
37. cation Valid options for COM x are COMI COM2 COM3 or COM4 Baudrate is an optional parameter which can be used to select baud rate at which transfer will be done If a baud rate is not specified baud rate will default to 9600 This will send all of setups to PC and store them in specified file To restore setups that have previously been saved by backup routine can be restored in a similar fashion as setups were backed up To restore setups select RESTORE SETUPS option using up and down arrow keys Once RESTORE SETUPS is highlighted press either left or right arrow keys Then go to PC and from DOS prompt type following command BACKUP filename COM x baudrate Where filename is name of file where setups are stored COM x is COM port that PC will use for communication Valid options for COM x are COMI COM2 COM3 or COM4 Baudrate is an optional parameter which can be used to select baud rate at which transfer will be done If a baud rate is not specified baud rate will default to 9600 This will send all of setups from file on PC to saved setups in machine In order to load new firmware into machine boot loader must already be installed in system If LOAD FIRMWARE INTO MEMORY selection is not displayed on screen you will need to load boot loader first To download boot loader into machine select LOAD BOOT LOADER INTO MEMORY option Pressing either left or right arrow will display message LOADING BOOT LOA
38. ccompanies poor stone life increase spindle speed or use a harder grade stone If stock removal rates are too low Increase stroking rate Use a higher feed rate Use a coarser stone Use a harder stone If bore is tapered remove taper as follows If bore is tight at bottom raise workpiece with elevating crank see Figure 3 1 If bore is tight at top lower workpiece There is also dwell feature activated by pushing BLUE dwell button You can push this button while machine is honing On RUN screen there are five marks in middle of screen that represent five locations in bore see Figure 3 2 Using up T and down ARROW keys you can move this marker to a place in bore that you would like to dwell When you press dwell button stroker will dwell for two seconds in location that you selected with arrow keys This button can be held in to make machine dwell longer Mandrel Adapter If workpiece gets bellmouthed during honing shorten stone only do not shorten shoe If workpiece gets barrel shaped during honing shorten shoe only do not shorten stone If mandrel runout is excessive replace concentric sleeve on mandrel adapter with an eccentric sleeve see Figure 3 3 If runout is still excessive turn sleeve around CV CK or GH Series Hone Heads If hole is bellmouthed shorten stroke If hole is barrel shaped lengthen stroke If stone becomes tapered check alignment guides for proper setting CV CK head only Also check Mai
39. cle Operator must then measure how much stock has been removed from bore Next operator highlights SWC CALC option and presses ENT Operator is prompted for an amount of stock that was removed The program will use that number and calculate SWC number and store that number on run screen 9 2 STAGE OPTIONS This option is only available when using GHTS tool In order to select this option move cursor to 2 STAGE OPTION and then press ENTER This will bring up a few lines of text that will allow operator to select which stone set to use and if both sets of stones have been run amount of stock to remove with second set of stones when running a two stage cycle The operation of GHTS tool will be explained in operation section of instructions 10 TOOL WEAR This option is only available with Sizeloc ON This option allows operator to add a specific amount of stone wear in addition to amount of stone wear that is calculated using SWC The following two items are displayed on screen for informational purposes 1 TIME This is amount of time that has elapsed since cycle has started Timer starts when start button is pressed 2 COUNT This is number of cycles that have been run on machine since either power has been removed or cycle counter has been cleared from run screen SIZELOC Sizeloc is a feature of machine that allows operator to run parts to same dimension without determining starting diameter To use Sizeloc operator needs
40. ct that all water based coolants have on painted surfaces wipe down all surfaces that come into contact with coolant Do this at end of each shift Q I cannot get my spindle speed selector to change from High to Lo speed What is causing this A One of two things First check to see that belt was changed to appropriate sheave If this has been done prox switch may be out of adjustment There should be a clearance of 1 mm 040 in between solid surface on bottom of idler and face of switch This is true only on Lo speed setting red LED will light when prox sees target Like any machinery this equipment may be dangerous if used improperly Be sure to read and follow instructions for opera tion of equipment NOTES APPENDIX A COOLANT FLOW DIAGRAM u SHUTOFF VALVE LOW PRESSURE RELIEF VALVE FILTER 10 PSI MAX CANISTERS HIGH PRESSURE RELIEF VALVE CLEAN OIL CLEAN OIL 4 DUMP PIPE INTAKE STRAINER ASSEMBLY DIRTY OIL FIGURE A 1 Coolant Flow Diagram 33 FRACTION DECIMAL MILLIMETER EQUIVALENTS CHART NCH DECIMAL 003937 1 FRACTION INCH MILLIMETER FRACTION 0 1000 DECIMAL 281250 7 1438 INCH MILLIMETER FRACTION DECIMAL MILLIMETER 656250 16 6688 007874 0 200
41. ere dene ce dik poe tetea hd rare re dd soba poet APBENDIXES 22 2 2 2022 222 were GENERAL INFORMATION SPECIFICATIONS ooccococcccco eens vi INTRODUCTION nio sa dais a ae BAG hed bad wie ne RR vi INSTALLATION P rpose ut A ree mek ua a 1 Tools amp Materi ls ui A A la Be AA ISA 1 Installation ur arras a a sues 1 Transtormer Installation ituaso eers solia t oe ow haa had Gale ls unsern ol Dar es 8 1 Electrical dara nr LA Almansa se ein hah Maal aoa 2 AAA es conan Cok te u EE OS 3 Operation Check earth am ann oe Raa be ae oe 3 Overatm Safety Guard s ii eck ee Ri owes ee Gok Raabe 4 PREPARING FOR OPERATION General ses a ha teat ach th ded Mine a nao td od aa sei poe 7 MajoriComponents an ran seat ee awa Bao ih odo ea ee a Ma eae ae eh bi aves 7 Operator Controls mesran cached pad va are RES oa pea ee Ee 8 Safety Symbols ci yee rer oe SEE ee pe ee age DS ae 9 A E CA ete oa Aa E tale elo engere ner rer Bee AAD menu Aly 9 Setup Screen Options nerne steed td ae Peace Gad als en 9 Speed DIMENSIONS Screen nee es Sake eR SRO he ee 10 Save Setup Screen ii reset a e Tee 12 Stroke Length Calculator Sereen cesar ra an Ba 12 serial Port Transfer Screen edad ae sean Rina onen ae Baas 12 A
42. ermine how much stock to remove and then add in extra feed out due to stone wear RUN SCREEN COUNT 0 TIME 30 PRESS F1 TO EDIT FEEDUP AMOUNT FEEDUP AMOUNT 0 0039 IN SPINDLE LOAD 0 20 40 60 80 100 STATUS STOPPED FEED POSN IN 0 0 0019 0 0039 DWELLS 0 JOG TOOL SIZELOC OFF SETUP A FEEDUP FOR FEED RATE 1 50 SWC 0 000000 IN SWC SCREEN FIGURE 3 2 Run Screen DWELL TYPE COUNTER SETUP SCREEN FIGURE 3 3 Mandrel Adapter Extra Fine Stones Finishing stones 280 grit and finer are available for applications where a finer finish is required When these fine grit stones use a conventional or vitrified bond there is a delicate balance between glazing which is caused by insufficient stone pressure and stone crumbling which is caused by excessive feed rates CK 21 has several features to aid in finding this balance and maintaining consistent honing performance first of these is Spindle Torque Preload feature which is found in setup screen This is percentage of spindle s full load that machine waits to see before machine stops Rapid advancing and starts to use programmed feed rate This is equivalent of how hard or soft a operator of CV 616 advances wheel at start of cycle Another feature is Load Meter and its display characteristics There are three displays that are available to operator First is BORE PROFILE This display shows a picture of load vs stro
43. ers for second set of stones column will be titled STAGE 2 1 SPINDLE SPEED 1 This is speed that spindle will rotate during honing cycle This speed will be used during complete cycle if you run a SIZED or TIMED cycle It will be used during first stage during a 2 STAGE cycle Overall speed range of machine is 90 to 550 RPM Speeds are broken down into two ranges 90 to 240 and 170 to 550 RPM To change from one speed range to another speed select belt must be changed on top of machine NOTE This speed must be in same range as Spindle Speed 42 CAUTION Belt change should only be done in setup screen 2 SPINDLE SPEED 2 This spindle speed will only be used during second stage of a 2 STAGE cycle Overall speed range of machine is 90 to 550 RPM Speeds are broken down into two ranges 90 to 240 and 250 to 550 RPM To change from one speed range to another speed select belt must be changed on top of machine NOTE This speed must be in same speed range as Spindle Speed 1 This option is only visible when 2 STAGE cycle is selected 3 STROKER SPEED 1 This is speed that stroker will move during a honing cycle Range of stroke speeds is 40 to 100 strokes per minute in increments of 10 strokes per minute NOTE FOR CV 616 OPERATORS Stroker speed is equivalent to setting strokes per minute using bottom three pulleys 4 STROKER SPEED 2 This stroke speed will only be used during second stage of a 2 STAGE
44. es more than 10 of machine s nameplate voltage All wiring is to be preformed by a competent licensed electrician Note Step down or voltage regulating transformers are external peripheral to machine tool and are considered primary input line source for machine Local electrical code or practice may require a circuit breaker or other switching device for isolation of electrical power when this type of transformer is used In such cases machine tool end user is required to supply necessary circuit breaker or switching device FAILURE TO COMPLY CAN RESULT IN PERSONAL INJURY AND OR DAMAGE TO MACHINE ELECTRICAL CONNECTIONS All wiring is to be performed by a competent Licensed Electrician in accordance with all local state and federal codes and regulations along with any special information provided on machine nameplate or electrical specification plate 1 Verify supply voltage is same as voltage listed on ELECTRICAL SPECIFICATION PLATE located on side of Electrical Enclosure CAUTION Doors are equipped with lockable Safety Door Latches Doors should be closed and latched during operation to prevent accidental interruption of operation from doors being opened Doors Latches should be Locked Out and Tagged during servicing to prevent machine from being powered up 2 If applicable Loosen Safety Latches on door s to enclosure using a screwdriver Or on CE models unlock doors to Electrical Control Enclosure using
45. fter that pressure may be increased slowly to recommended values CAUTION To ensure parts meet machine s specifications and do not cause damage use ONLY replacement parts supplied by Sunnen Indicates CE version ONLY 1 DO NOT touch electrical components until main input power has been turned off and CHARGE lamps extinguished WARNING The capacitors are still charged and can be quite dangerous IMPORTANT NOTE The temperature requirements of the Sunnen CK 21 Vertical Honing Machine have been established as 35 degrees C 95 degrees F Above this temperature an optional cooler will be available to handle temperatures from 35 to 46 C 95 to 115 F IT IS NOT recommended that the CK 21 Machine be operated at temperatures above 46 C 115 F Sunnen Products Company warrants the CK 21 Machine for operating environments up to 35 C 95 F For operating environments of 35 to 46 C 95 to 115 F the warranty only applies if the optional cooler is installed on the Machine No warranty coverage is offered for operating environments above 46 C 115 F TABLE OF CONTENTS Page GENERAL INFORMATION a e aa re por SDR Ne ii ESD PREVENTION REVIEW ii LIMITED PRODUCT WARRANTY ion ee le Me Bes he dad 111 SUNNEN SOFTWARE LICENSE AGREEMENT 0 0 0 cece eee nee 111 GENERAL SAFETY INSTRUCTIONS 0 eee ee eens iv TABLE OF CONTENTS ic
46. gine is of in line type it is now ready to be honed If it is of V type release cradle index latch at right end of cradle and rotate engine block into position for honing notches are at 15 30 45 and 90 degrees There is a notch at 135 degrees to help drain honing oil from engine block 10 For setup of CK type hone head refer to Installing Hone Head Machine Setup Set Stroke Length 1 Measure length of bore to be honed 2 Measure length of honing stones 3 Determine how much overstroke is desired for cycle 4 Using Stroke Length Calculator see Figure 3 14 operator just needs to enter three values found in steps 1 3 into stroke length calculator and machine will tell operator recommended stroke length and a stroke speed The formula to determine stroke length is stroke length 2 over stroke bore length stone length By adding bore diameter into calculator operator is given a suggestion as to where operator can set spindle speed NOTE Application specific parameters may require this value to be altered It is only a recommendation 5 Unlock stroke length lock knob see Figure 3 15 6 Turn large handwheel on drive arm until indicator points to required stroke length 7 Lock Stroke Length Lock Knob Set Stroke Position Overstroke 1 Toggle JOG indicator on Setup Screen to STROKER using UP DOWN arrow keys Hold jog button in UP position until stroker stops machine knows that this is TDC
47. ic bubble wrap has been included for use at the machine when an ESD safe workstation is not available You are now properly grounded and ready to begin work Following these few simple rules and using a little common sense will go a long way toward helping you and your company in the battle against the hazards of static electricity When you are working with ESD sen sitive devices make sure you GROUND ISOLATE NEUTRALIZE SUNNEN LIMITED PRODUCT WARRANTY Sunnen Products Company and its subsidiaries SPC warrant that all new SPC honing machines gaging equipment tooling and related equipment will be free of defects in material and or workmanship for a period of one year from the date of original shipment from SPC Upon prompt notification of a defect during the one year period SPC will repair replace or refund the purchase price with respect to parts that prove to be defective as defined above Any equipment or tooling which is found to be defective from improper use will be returned at the customer s cost or repaired if possible at customer s request Customer shall be charged current rates for all such repair Prior to returning any SPC product an authorization RMA and shipping instructions must be obtained from the Customer Service Department or items sent to SPC will be returned to the customer Warranty Limitations and Exclusions This Warranty does not apply to the following Normal maintenance items subject to wear
48. is run operator will enter amount of stock that was removed during that cycle The system will calculate SWC number From that point on operator will only need to enter amount of stock that will need to be removed The SWC number may need to adjusted slightly during operation Second Method The second method of using this machine employs the SIZELOC feature This is a very efficient method of removing varying amounts of stock The procedure is as follows 1 Gage bore to be honed and determine amount of stock that needs to be removed If you are rough honing plan to leave 0 08 mm 0 003 in for finish honing NOTE In this example assume that 0 18 mm 0 007 in of stock needs to be removed 2 Adjust all of parameters on setup screen that are required 3 Toggle to RUN screen see Figure 3 17 4 Toggle JOG option to TOOL 5 Retract stones enough so that tool can enter bore Then lower tool into bore NOTE Generally 0 8 mm 0 030 in is enough for tool to enter bore If more is used there is a greater chance that head will bounce around in cylinder and damage stones and increase cycle time 6 Set amount of stock to be removed by using Fl command indicated on Operator Interface In our example that would be 0 18 mm 0 007 in 7 To begin honing press GREEN cycle start button 8 When machine starts check to see that there is a good supply of honing fluid in contact with bore Adjust flow rate by u
49. ke position through bore In most cases it will display condition of bore i e taper barrel or bellmouth during cycle Second type of display is BAR GRAPH This display shows a bar graph of machine load as cycle progresses Last display is LOAD GRAPH This display will show machine load vs time Last display will help in optimizing Spindle Torque Preload STP value If you use load graph to determine STP ideal condition is to have trend of graph be horizontal If trend is upward STP is too low If trend is downward STP is too high 52 yen CONCENTRIC SLEEVE CHUCK WRENCH ECCENTRIC SLEEVE FIGURE 3 4 CV Mandrel Adapter TABLE 3 1 P28 Mandrels MAX BORE MAX BORE P28 STONE STONE MINIMUM LENGTH LENGTH FOR MANDREL USED LENGTH OVERSTROKE POSSIBLE EASY LIFT OUT mm in mm in mm in mm in 2 Stone 1 8 3 3 25 1 0 201 7 9 201 7 9 2 Stone 2 167 6 6 25 1 0 201 7 9 201 7 9 3 Stone 1 83 3 3 25 1 0 284 11 2 284 11 2 3 Stone 2 167 6 6 25 1 0 284 11 2 310 12 2 3 Stone 3 250 98 25 1 0 284 112 206 8 1 4 Stone 2 167 6 6 25 1 0 368 14 5 368 14 5 4 Stone 3 250 9 8 25 1 0 368 145 292 11 5 4 Stone 4 1330 13 1 25 1 0 368 14 5 NA NA 5 Stone 2 167 6 6 25 1 0 422 16 6 450 17 7 5 Stone 3 250 98 25 1 0 452 17 8 366 14 4 5 Stone 4 1330 13 1 25 1 0
50. kwise to increase the coolant flow Indicates that machine is in CE compliance 1 SAVED SETUPS This option allows operator to go to save setups screen This screen will be explained 2 STROKE LENGTH CALCULATOR This option allows operator to calculate recommended stroke length 3 JOG This option allows operator to select either stroker or tool to jog Once correct item is selected jog switch on operator station will jog selected item When jogging stroker turning switch in up position will jog stroker to top of stroke and turning switch in down position will jog stroker to bottom of stroke When jogging tool turning switch in up position will expand tool and turning switch in down position will retract tool NOTE TO CV 616 OPERATORS Jogging tool is same as rotating hand wheel to expand or retract hone head Jogging stroke is same as slowly engaging clutch level and letting hone stroke through cylinder without fully engaging clutch lever 4 UNITS This option allows operator to enter values in either inches or millimeters 5 CYCLE This option allows operator to select one of three types of cycles The First cycle type is SIZED This allows operator to enter amount of material that needs to be removed This value is entered on run screen The second cycle type is TIMED This allows operator to run a cycle for a set time e g plateau honing The third cycle type is 2 STAGE This cycle type allows
51. l type Operator MUST then press ENT key in order for dwell type to take effect In between time that operator presses F3 key and time that operator presses ENT machine will not dwell 3 JOG This option allows operator to jog either stroker or tool It operates the same way that jog feature worked in setup screen This option is disabled while machine is running 4 SETUP This option allows operator to toggle between one of three setups Left and right arrow keys change setup from AtoBtoC 5 SIZELOC This option allows operator to turn on size lock for current setup Sizeloc will be explained later in this manual left and right arrow keys will toggle between turning on Sizeloc and turning off Sizeloc 6 STONE WEAR SWC This option allows Operator to enter amount of stone wear Stone wear 1s measured in amount of stone wear per 0 001 in 0 01 mm of stock removal Machine will take stone wear number into account when it determines when to stop feeding out stones 7 BORE ADJ This option is only available when size lock is on This option allows operator to increase amount of stock that is being removed This is useful 1f operator is not using stone wear and starts to lose size because of stones wearing away Operator can enter a small amount of bore adjustment and be back within tolerance on next part 8 SWC CALC This option allows operator to calculate stone wear value To use this function operator must first run a cy
52. lable at http www sunnen com or e mail sunnen Osunnen com NOTE Sunnen reserves the right to change or revise specifications and product design in connection with any feature of our products contained herein Such changes do not entitle the buyer to corresponding changes improvements additions or replacements for equipment supplies or accessories previously sold Information contained herein is considered to be accurate based on available information at the time of printing Should any discrepancy of Information arise Sunnen recommends that user verify the discrepancy with Sunnen before proceeding ESD PREVENTION REVIEW Let s review the basics of a sound static control system and its effective implementation First in the three step plan 1 Always ground yourself when handling sensitive components or assemblies 2 Always use a conductive or shielded container during storage or transportation These materials create a Faraday cage which will isolate the contents from static charges Open ESD safe containers only at a static safe work station At the static safe work station follow these procedures before beginning any work A Put on your wrist strap or foot grounding devices Check all grounding cords to make sure they are properly connected to ground ensuring the effective dissipation of sta tic charges Make sure that your work surface is clean and clear of unnecessary materials particularly common plastics Anti stat
53. lant System 12 Release E Stop button by turning red knob as arrow indicates CAUTION Machine will not operate unless both of following conditions are met 13 Raise doors and lower lift handle 14 Direct oil spout into reservoir and turn on oil shut off valve 15 Push WHITE power ON OFF button BELT FIGURE 4 6 Rocker Arm 29 16 Display will light up with CK 21 Logo and prompt you to clear above error conditions It will ask you to hit GREEN cycle start button to initialize stroker machine will then cycle stroking motor to find its Top Dead Center position When it has completed this exercise setup screen will be displayed 17 Push Down arrow on numeric keypad until word COOLANT is highlighted To right of word COOLANT it will say AUTO Push right arrow key to change word AUTO to ON At this point coolant pump will begin to run 18 Listen for air being blown through honing fluid a Gurgling sound in reservoir If none is heard open manual control valve to wide open position and allow pump to purge air from honing fluid filtering system 19 As oil fills filter canisters air will escape through air vents When oil appears in air vents close vents NOTE Coolant should flow from oil spout Control amount of oil by regulating oil shut off valve 20 Turn OFF power 21
54. modify parameters that will describe manner in which auto dwell feature will operate screen shown in Figure 2 8 shows all possible options Screen will only show those options which are required for selected auto dwell type If operator is using either a SIZED honing cycle or a TIMED honing cycle only dwell type that will be available is FEED RATE 1 THRESHOLD If a 2 STAGE cycle is being used there are 3 auto dwell types available 2 STAGE THRESHOLD THRESHOLD FOR FEED RATE 1 ONLY and THRESHOLD FOR FEED RATE 2 ONLY 2 STAGE THRESHOLD will allow operator to set a threshold for each feed rate during honing cycle This option will enable auto dwell throughout entire honing cycle THRESHOLD FOR FEED RATE I ONLY will allow operator to set a threshold for first feed rate only Option will only turn on auto dwell during feed rate 1 THRESHOLD FOR FEED RATE 2 ONLY will allow operator to set a threshold for feed rate 2 only This option will only turn on auto dwell during second feed rate Regardless of which option is selected operator can always use manual dwell button Auto dwell feature does not work during Spark Out Auto dwell feature works by checking load every few strokes Number of strokes is selectable by operator If Auto Dwell Index is larger than threshold for active Feed Rate then machine will automatically dwell at tight spot during that stroke see Figure 2 9 We will use numbers in Figures 2 8 and 2 9 in an example If honing
55. n NORMAL mode it will show a full scale from 0 to 100 percent of full load In HIGH mode it will show a full scale of 0 to 30 percent of full load 13 SETUP This option allows operator to select between three different setups that are stored in machine These setups can be switched either here or in run screen Left and right arrows will toggle between three setups 14 CLEAR CYCLE COUNTER This option will allow operator to clear cycle counter When option 1s set to a YES cycle counter will be set to 0 15 SERIAL PORT TRANSFERS This option allows operator to go to serial port transfer screen This screen will be explained later in this manual 16 LANGUAGE This option allows operator to change language that all options are displayed in SPEEDS amp DIMENSIONS SCREEN This screen will allow operator to enter all of variables having to do with speeds and dimensions for a cycle see Figure 2 4 Below is a list of items and a description of each item on screen SPEED AND DIMENSIONS SPINDLE SPEED 1 RPM E 170 SPINDLE SPEED 2 RPM 170 STROKE SPEED 1 SPM 60 STROKE SPEED 2 SPM 60 FEED RATE 1 IN MIN 0 0050 FEED RATE 2 IN MIN 0 0025 SPINDLE TORQUE PRELOAD 1 20 RETRACT AMOUNT IN 0 025 FEEDUP FOR FEED RATE 1 50 RAPID SPINDLE SPEED 200 RAPID FEED RATE SETUP SCREEN FIGURE 2 4 Speeds amp Dimensions Screen NOTE If GHTS tool is selected there will be another column of numb
56. n acceptable limits then proceed WARNING Do not attempt to convert machine to a voltage outside 10 of machine s nameplate voltage 11 Set Overload LOL to 2 4 A for 208V supply 1 3 A for 380V supply 500 voltage for other voltages 12 For Model CK 21G and CK 21CG wires on primary side of transformer may need to be moved Check transformer connections and move as required Voltage Range Req Transformer Connections 380V 420V Terminals 1 and 2 420V 440V Terminals 1 and 3 440V 480V Terminals 1 and 4 13 Close and lock doors to electrical enclosure 14 Route and connect Electrical Supply cord to power source FLUIDS This machine is shipped without filter elements installed in Filter Canisters Install filter elements as follows see Figure 1 5 WARNING Check all guards and ensure they are in place and locked before operating machine 1 Remove Canister Cover Clamps and Covers Note orientation of clamp handles 2 Remove filter elements from protective bag and insert elements into Filter Canisters rotating elements slightly while inserting to make them slide down center post more easily 3 Replace Covers centering carefully on rubber gaskets to assure no leakage 4 Replace Clamps and tighten Tighten Hex Bolt in Clamp Halves until halves meet then tighten T Handle 5 Check to be sure that two latches on front of machine are securely latched see Figure 1 6 6 Check Quick
57. n guide 3 for taper If guide is tapered shorten guide on thick end and place 1 stone in 2 position and vice versa Stone Wear Stone wear can be dealt with in two ways 1 First way is for operator to calculate stone wear per stock removed and through operator interface tell machine how far to advance feed rod This is same method that was used on CV 616 or other manual honing machines method is as follows To calculate stone wear ratio divide amount of stone wear by stock removed You get amount of stock removed by gaging last cylinder honed To get stone wear subtract stock removed from base number from last cylinder Example 10 1 2 Base number from last cylinder 6 Stock removed from last cylinder 4 1 2 Difference stone wear 10 1 2 6 4 1 2 STONE WEAR _ _ 4 1 2 _ 75 OR 3 4 STOCK REMOVED 6 STONE WEAR RATIO 2 Second way of dealing with stone wear is through use of SWC option on run screen along with SWC calculator The stone wear calculator allows operator to enter amount of stock that has been removed and machine will determine how much stone wear has occurred This number is then stored on run screen By using SWC number operator will only need to enter amount of stock that needs to be removed The machine will take into account SWC number when it determines where it needs to stop in order to remove correct amount of stock The SWC feature works with size lock With size lock on machine will det
58. ndicated on slide Looseness less than thickness of one shim is acceptable Special instructions for using CK 4155 Setting Gage for large hone head in 102 203 mm 4 8 in range Move graduated slide so that pin contacts assembly If graduated slide reads 15 or less no additional shims should be added if slide reads over 15 remove assembly from Gage and add one shim 21 NOTE A properly shimmed assembly will slip into gage easily Both Guide Stone Assemblies must have same thickness of shims and each must fit in Setting Gage when assembled with shims 10 Rotate Drive Tube until numeral 1 appears on Hone Body Insert one stone assembly with shims in left hand set of holes beneath numeral 11 Insert other shimmed Stone Assembly beneath numeral 2 using procedure above 12 Insert shimmed Main Guide beneath numeral 3 on Hone Body 13 Place shimmed Centering Guide beneath numeral 4 on Hone Body Alignment Guide NOTE DO NOT use alignment guides when honing ported or keyway bores 14 Place Alignment Guide in setting gage with graduated slide set at 0 Loosen Clamp Screw on alignment guide with hex key wrench and slide to Shoulder Tighten Clamp and repeat procedure with second alignment guide 15 Place one of alignment guides in left hand set of holes above numeral 1 in hone body so guide and stone are in line 16 Place other alignment guide in left hand
59. ny packing material 2 Move machine to desired location 3 Remove four 4 Leveling Feet from accessory pack FIGURE 1 2 Belt System 4 Remove Jam Nuts from threaded shafts of leveling feet 5 While machine is on forklift thread leveling feet in holes provided in bottom corners of machine base 6 Position machine and lower into place 7 Stabilize machine using leveling feet 8 Screw Jam Nuts over top of threaded shaft and tighten to lock feet in place 9 Unlatch rear left belt cover using 4 mm hex wrench see Figure 1 2 Open cover and check to see that all belts are properly seated in their respective grooves after shipment It is advised that HI LO Range be on LO setting for initial setup Refer to Decal location inside cover 10 Remove Shipping Bracket form rear of machine TRANSFORMER INSTALLATION Most machine models are shipped wired for 230 volt To install optional transformer for other voltages refer to wiring instructions on front of transformer see Figure 1 3 2 RIGHT FIGURE 1 1 Computerized Vertical Honing Machine FIGURE 1 3 Transformer CAUTION A step down transformer is optional on some machine models Be certain to verify transformer Kva rating where applicable as well as local electrical code requirements before sizing and installing the incoming power wiring End user must use a step down transformer where factory electrical power vari
60. o run 17 Open manual control valve to wide open position and allow pump to purge air from honing fluid filtering system 18 As oil fills filter canisters air will escape through air vents When oil appears in air vents close vents NOTE Coolant should flow from oil spout Control amount of oil by regulating oil shut off valve 19 Turn OFF power 20 Wipe oil from around air vents COOLANT RESERVOIR CLEANING Periodically clean reservoir as follow see Figure 4 3 1 Turn OFF all electrical power to machine 2 Lower access doors on front of machine 3 At rear of machine unhook quick disconnect found on lower left side of back of machine It is check valved on both sides but there will be a minimal amount of oil that has been trapped in fitting 4 Unlatch two latches found below door on front of machine Gently pull Roll Out Reservoir forward until contact is made with stops on front of machine 28 QUICK DISCONNECT FIGURE 4 3 Coolant Reservoir Cleaning 5 Remove old coolant from reservoir 6 Scrape sludge from reservoir with a shovel or some other similar tool 7 Flush any remaining sludge from reservoir with a mild industrial solvent if required 8 Wipe reservoir dry to prevent contamination of new honing fluid 9 Push reservoir back in and re latch 10 Connect quick disconnect on rear of machine 11 Pour honing fluid into reservoir through splash screen Bleed Coo
61. position 2 Using Elevating Crank position workpiece so that stone protrudes from top of workpiece by amount of top overstroke desired 3 If Elevating crank will not raise or lower workpiece sufficiently to produce required top overstroke loosen Set Screw in drive tube and adjust length of drive tube as required Remember to tighten Set Screw 22 STROKE LENGTH SCREEN ENTER THE CYLINDER LENGTH 4 000 IN PRESS F1 TO EDIT CYLINDER LENGTH RECOMMENDED TOOL GHSS 3410 HOLDER GHG14C233 349 ALTERNATE TOOL GHSS 3410 ENTER THE BORE DIAMETER 4 000 IN HOLDER GHG14C233 348 SUGGESTED SETTINGS STROKE LENGTH 2 0 IN SPINDLE SPEED 190 RPM STROKER SPEED 80 SPM ENTER THE STONE LENGTH 3 0000 IN OVER STROKE AMOUNT 0 5000 IN CROSSHATCH ANGLE 30 0 DEG SETUP SCREEN FIGURE 3 14 Stroke Length Calculator Screen LOCK KNOB FIGURE 3 16 Spindle Speed 4 Check setup by again holding JOG button until tool stops at bottom of stroke Rotate tube manually to check for interference Set Spindle Speed and Stroking Rate CAUTION Belt changes should only be done while display is showing SETUP SCREEN If changed while any other screen is showing machine will display a FAULT message and a setup could be lost 1 Measure bore diameter to nearest 1 mm 040 in 2 If bore measures 85 mm 3 5 in or more put belt
62. r should be run Operator can turn coolant always on or off for dry honing The third option is AUTO which turns coolant on only when machine is running a cycle and shuts off at end of cycle 10 SPARK OUT TIME Spark out time is an amount of time that machine will run with a 0 feed rate Spark out time will start after stones have fed up total amount that they need to reach size Value entered will be numbers of seconds that spindle and stroker motors will run after stones have fed up to ending position Range of time is O to 255 seconds Using GHTS tool this option allows operator set spark out time for each set of stones differently 11 DISPLAY There are three types of displays that are available on machine The first is BORE PROFILE This display shows a picture of spindle load vs stroke through bore In most cases it will display condition of bore e g taper barrel or bellmouth during cycle The second type of display is a BAR GRAPH This display shows a bar graph of machine load as cycle progresses last display is LOAD GRAPH This display will show machine load versus time This last display will help in optimizing Spindle Torque Preload STP value NOTE TO CV 616 OPERATORS BAR GRAPH is similar to bar graph on current model CV 616 machines 12 BORE PROFILE GAIN This option allows operator to adjust sensitivity of bore profile display In LOW mode it will show a full scale from 0 to 200 percent of full load I
63. rtridges 21 Cover Clamp 22 Pressure gage 23 Drain valves 24 Pump and Motor assembly Electrical Enclosure 25 Quick Disconnect to Reservoir FIGURE 2 1 Computerized Vertical Honing Machine 2 of 2 7 SCREEN DWELL POWER JOG ON OFF ONE KEY Waele PAD J E STOP OEE CYCLE CYCLE START STOP FIGURE 2 2 Operator Controls OPERATOR CONTROLS For function and location of operator controls refer to Table 2 1 and Figure 2 2 TABLE 2 1 Operator Controls SYMBOL JOG t l POWER ON OFF CYCLE START lt gt CYCLE STOP E STOP O DWELL DESCRIPTION Displays machine setting Keypad Used in conjunction with display screen Selector Switch White Pushbutton Switch Green Pushbutton Switch Red Pushbutton Switch Red Locking Pushbutton Switch Blue Pushbutton Switch FUNCTION Switch moves up and down Switch performs following operations depending on which item is selected STROKER moves stroker up moves stroker down TOOL expands tool retract tool Switch is used to toggle electrical power to machine ON and OFF When ON button will laminated and run screen will have a light on in background which will allow you to read display Starts honing operation It is also used to initialize stroker Stops honing operation by bringing machine
64. s option will allow you to select which set of stones you want to run If you have run both sets you are given option of using both sets of stones When both sets of stones are selected you are given DISTANCE FROM FINAL FOR STAGE 2 value 2 When running a cycle with Sizeloc turned off and both sets of stones selected value that you enter in Feedup Amount is total amount of stock that will be removed using both sets of stones If for example Feedup amount is 0 0050 and distance from final for stage 2 is set to 0 0030 machine will run a cycle that will remove 0 0020 with first set of stones and then run a cycle that will remove 0 0030 with second set of stones same holds true when running a Sizeloc cycle except that amount of stock removed with second set of stones will be around 0 0030 It will depend on exactly how much stock was removed with first set of stones and location where second set of stones picks up load 3 One thing that is different about GHTS cycle is that there is now a 2 STAGE CHANGEOVER portion of cycle During this time spindle and stroker will stop while tool retracts first set of stones and expands second set of stones out to start position During this time the alarm on the stack light will sound just to let operator that cycle is still running button in handle to lift tool out of hole will not operate NOTES
65. sing manual oil shut off valve on front left hand side of machine 9 Ifthere is a tight spot in bore you may elect to have tool stay dwell in one area of bore longer than in other areas To set dwell to a specific spot move dwell indicator lt on side of bore profile display on screen using UP DOWN arrows then press BLUE dwell button NOTE If tight spot is consistently at top or bottom lower or raise workpiece using elevating crank 10 When machine has expanded tool to value that you have entered in step 7 it will turn off feed motor and stop spindle and stroker motors at TDC top dead center It will also automatically retract stones If there is not enough clearance in bore to prevent scratching or if status area of run screen takes a while to change from RAPID ADVANCE to STOPPED retract amount can be changed on setup screen 11 Lift tool from bore and gage part 12 Depending on type of stones that is used machine may remove amount of stock required or not The material that is left in bore is amount of stone wear that has occurred This can be compensated for in next cycle through use of Stone Wear Calculator 13 Sizeloc is a feature of machine which allows operator to run parts to same dimension without determining starting diameter Once bore has been honed to correct size Sizeloc should then be turned ON NOTE On Run Screen Feed up Amount message disappears from screen to remind operator that
66. ster stoneholder 2 Brush chips and grit from Master Stoneholder slots slide Moveable Stop to IN position move lever to open position Fixture is now ready for inserting new stone 3 Move Lever to open position and slide Movable Stop to IN position see Figure 3 8 4 Place Master Stoneholder in fixture Brush all loose chips from Stoneholder grooves and slots 5 Place Stone in Master Stoneholder see Figure 3 9 Lugs on stone sides should fit into cross slots of Master Stoneholder 6 Seat Stone in Master Stoneholder by pressing down with fingers Pull lever forward until Stoneholder hits stop Stone is now in place Install Guide Stone Shims 7 Place Setting Gage in bore to be honed then snug making sure to center see Figure 3 10 NOTE On CK 3155 Setting Gage make sure proper side of Turret faces Opening 8 Place Guide Stone Assembly in Setting Gage with graduated slide set at 0 see Figure 3 11 20 DRIVE TUBE OF MACHINE DRIVE TUBE OF HONE HEAD FIGURE 3 7 Install Hone Head INSERTER LEVER RA FIGURE 3 8 Open Position NOTE STONE AGAINST STOP FIGURE 3 10 Setting Gage GRADUATED SLIDE FIGURE 3 11 Stone Assembly FIGURE 3 13 Position Riser Blocks 9 Move graduated slide so that pin contacts guide If pin does not contact guide add aNo 19 shim and try again Now add necessary shims as i
67. t Operator can edit value in between cycles In order to edit value you need to hit F I button It will position cursor on current value Value can be entered using numeric keypad Feedup amount can be adjusted while machine is running see figure 2 11 The following options are available on run screen regardless of cycle type selected 1 DWELLS This option allows operator to enter a number of dwells that is needed for current bore This number will be decremented by 1 after every dwell This option is only active when dwell type is set to COUNTED Number is adjusted by using left and right arrow keys right arrow key will increase count by 1 and left arrow key will decrease count by 1 2 DWELL TYPE This option allows operator to change type of dwell two options are COUNTED and CONTINUOUS COUNTED dwell type is used to dwell for a number of consecutive cycles until dwell counter reaches 0 CONTINUOUS dwell type is used to dwell every cycle During a cycle dwell AUTO DWELL INDEX 40 RUN SCREEN COUNT 0 SPINDLE LOAD TIME 30 0 20 40 60 80 100 STATUS STOPPED FEED POSN IN 0 0 0019 o 4 SETUP A JOG TOOL DWELLS 0 DWELL TYPE COUNTER SIZELOC OFF SWC 0 000000 IN SWC SCREEN BORE ADJ SETUP SCREEN FIGURE 2 12 Run Screen with Sizeloc ON type can be modified If operator presses F3 key dwell type is highlighted Operator then can press either left or right arrow key to change dwel
68. t on setup screen and then hit F2 This saves all value in memory of machine operator is asked to enter a setup name Name can be from 1 to 10 characters long Any information pertaining to size lock is not saved with setup If stroke length calculator has been used stroke length will be saved along with setup To delete a setup operator should highlight setup that needs to be deleted and then hit F3 This deleted setup from machine s memory In order to get to other setups just hit down arrow while cursor is on bottom setup to go to next higher block of 10 setups If up arrow is pressed while first setup is selected machine will display previous block of 10 setups STROKE LENGTH CALCULATOR SCREEN This screen allows operator to calculate suggested stroke length spindle speed and stroke speed for a particular application see Figure 2 6 Operator will need to enter four items in this screen using arrow keys to select each item To edit any of values press Fl and then edit value that is in highlighted area Once bore length has been entered a suggested stroke length and stroke speed will be displayed on right hand side of screen Once bore diameter has been entered a suggested spindle speed will be displayed Once bore diameter has been entered and GHC tooling has been entered a recommended tool will be displayed based on bore diameter If two different tools could be used both tools will be displayed stroke length takes into
69. te safe for any operator exercising a normal degree of caution associated with machine tool use The CE version provides an extra level of protection by minimizing the risks of operator carelessness READ THE FOLLOWING INSTRUCTIONS CAREFULLY AND THOROUGHLY BEFORE UNPACKING INSPECTING OR INSTALLING THE SUNNEN COMPUTERIZED VERTICAL HONING MACHINE vi SECTION 1 INSTALLATION PURPOSE Consult this section when unpacking inspecting and installing Sunnen CK 21 Computerized Vertical Honing Machine see Figure 1 1 hereafter referred to as the Machine SUGGESTED TOOLS amp MATERIALS The following tools and materials are required for unpacking and installing your Machine Knife Crow Bar Slip Joint Pliers Screwdriver Std Open End Wrenches INSTALLATION Read the following instructions carefully and thoroughly before unpacking inspecting installing or operating your machine Hammer Tin Snips Cleaning Solvent Hex Wrenches All references to right and left in these instructions unless otherwise noted are as seen by operator as one looks at machine or assembly being described refer to Figure 1 1 NOTE When ordering parts for or requesting information about your Machine include Model and Serial Numbers printed on Nameplate of your Machine The Nameplate is located on Electrical Control Enclosure 1 Unpack machine and packaged components carefully Check contents against packing list before discarding a
70. time that is allowed is 1 99 seconds 3 2 STAGE cycle type FEEDUP AMOUNT This option allows operator to enter amount of material that needs to be removed Range of values is 0 0001 to 0 2500 in for English measuring system and 0 0025 6 350 mm for metric measuring system AUTO DWELL INDEX 40 RUN SCREEN COUNT 0 SPINDLE LOAD TIME 30 0 20 40 60 80 100 PRESS F1 TO EDIT FEEDUP AMOUNT FEEDUP AMOUNT 0 0039 IN STATUS STOPPED Mil FEED POSN IN 0 0 0019 0 0039 o 4 SETUP SIZELOC OFF JOG TOOL DWELLS 0 DWELL TYPE COUNTER TOOL WEAR 0 000000 IN SWC 0 000000 IN SWC SCREEN SETUP SCREEN FIGURE 2 9 Run Screen with Auto Dwell ON RUN SCREEN COUNT 0 SPINDLE LOAD TIME 30 0 20 40 60 80 100 FEEDUP AMOUNT 0 0050 IN STATUS STOPPED FEED POSN IN 0 0 0019 0 0039 A 4 SETUP SIZELOC OFF JOG TOOL DWELLS 0 DWELL TYPE COUNTER SWC 0 000000 IN SWC SCREEN SETUP SCREEN FIGURE 2 10 Run Screen with Sizeloc OFF RUN SCREEN COUNT 0 SPINDLE LOAD TIME 30 0 2040 60 80 100 STONE SET STAGE 1 2 DISTANCE FROM FINAL 0 0 0019 0 0039 FOR STAGE 2 0 0030 FINISHED 4 SETUP A _ JOG TOOL DWELLS 0 DWELL TYPE COUNTER FEEDUP AMOUNT 0 0050 IN STATUS STOPPED FEED POSN IN SIZELOC OFF SWC 0 000000 IN 2 STAGE OPTIONS SWC SCREEN SETUP SCREEN FIGURE 2 11 Run Screen with 2 Stage Op
71. total feedup amount that will be run with first set of speeds Once this percentage of cycle has been run feed rate spindle speed and stroke speed will change to second set of speeds If operator enters a feedup amount that is less than 0 001 in machine will not use a 2 stage feed process Machine will compare two feed rates and use smaller of two feed rates Machine will run entire cycle with smaller feed rate 10 RAPID SPINDLE SPEED Spindle speed used during rapid advance 11 RAPID FEED RATE Rate at which stones expand during rapid advance 12 STONE TYPE This option is only available for GHTS tool This option allows operator to enter type of material that is being used for second set of stones The available selections are ABRASIVE or PTH BRUSHES This value is used during calculation of feedup amount for two different sets of stones in GHTS hone head SAVE SETUPS SCREEN This screen allows operator to save current setups to memory of machine see figure 2 5 Operator can save up to 20 setups in machine If setup is saved using this screen setup will be able to be retrieved after power has been removed from machine Operator can load a program into current setups save current setups or delete a setup To load a setup operator should highlight setup that needs to be loaded and then hit F I This will load all values into current setup of machine To save a setup use should highlight an empty slo
72. true the above limitations may not apply Any alteration or reverse engineering of the software is expressly forbidden and is in violation of this agreement SPC reserves the right to update the software covered by this agreement at any time without prior notice and any such updates are covered by this agreement SAFETY INSTRUCTIONS READ FIRST This machine like any machine tool may be dangerous if used improperly Please read all warnings and instructions before attempting to use this machine DO NOT remove or defeat any safety device Always disconnect power at main enclosure before servicing machine Always wear eye protection when operating this machine DO NOT attempt any repair or maintenance procedure beyond those described in this book Contact your Sunnen Service Representative for repairs not covered in this book Much of the safety of honing operation is dependent upon how workpiece is fixtured Several standard fixturing components are available but each is limited to certain types of applications Homemade fixtures are also not uncommon and can be quite effective if designed and used properly Sometimes it is necessary to clamp workpieces lightly when honing with special fixtures in order to minimize bore distortion Likewise tooling for small diameter honing is inherently fragile Therefore Always start a new setup with a pressure that is much lower than recommended to test stability of tooling and fixturing A
73. uto Dwell Setup Screen iros Banden kn beschneiden wee 13 Run Sereen Options 3 5 bse ae hh gee ane a Sole Dre Baw we Banas 14 SIZE sarria as aa lalate nets Sia ta 15 SETUP amp OPERATION General Vas a De neun Rey il Se heed aoe ee 17 Safety Precautions A ur un SS SRH 17 Operation Lips aussen ernennen a ae ner aan ua 17 ee ee ea ds la rate ee 19 Setup ei ar me A A A 19 A A A ee a AE NE 23 ROUTINE MAINTENANCE Generali A ee it 27 Cleanin2 A REA rege ee ee AE 27 K brieationn ses un E A A eae 27 Coolant Lines Check ocu era a ba A nee 27 Coolant Level Check mirra erro ar dr dd bae 27 Filter R pla ement oori i A ee EE E 27 Coolant Reservoir team ar BD SA 28 Poly V Belt Tension A da Ded axle Sn er nee 29 Stroker Belt Tension ricas nd SE ge Sie ee 29 Rocker Arm Adjustment a eb 29 NO E 30 TROUBLESHOOTING General itches a ea re ee ee 31 Frequently Asked Questions 0 ne een 31 APPENDIX A Coolant Flow Diagram eda A we RI ea lach 33 GENERAL INFORMATION amp SPECIFICATIONS Sunnen CK 21 Computerized Vertical Honing Machine Diameter ID Range 19 0 to 203 0 mm 75 to 8 00 in For diameters below 19 0 mm 75 in or above 203 0 mm 8 00 in call Sunnen in St Louis Work Area 1450 x 8
74. ve right without right to sub license to use the particular copy of the SPC Software licensed hereunder only on the particular equipment sold with the Software SPC reserves all rights including rights not otherwise expressly granted and retain title and ownership to the Software including all subse quent copies or updates in any media The Software and all accompanying written materials are covered by copyrights owned by SPC If supplied on removable media floppy disk you as Licensee may copy the Software only for back up purposes or you may request that SPC copy the Software for you for the same purposes All other copying of the Software or of the accompanying written materials is expressly forbidden and is in violation of the Agreement The Software and accompanying written materials including the user s manual if any are provided in an as is condition without warranty of any kind including the implied warranties of merchantability and fitness for a particular purpose even if SPC has been advised of this purpose SPC specifically does not warrant that it will be liable as a result of the operation of the Software for any direct indirect consequential or accidental damages arising out of the use of or inability to use such product even if SPC has been advised of the possibility of such use It is recognized that some states do not allow the exclu sion or limitation of liability for consequential or accidental damages and to the extent this is
75. work area Visitors especially children should not be permitted near work area 14 DO NOT use Machine for other than its intended use Using machine for other purposes could result in loss of warranty or damage to Machine 15 Use ONLY factory authorized or recommended parts or replacement accessories Using parts or accessories other than those approved by manufacturer could result in damage to Machine and loss of warranty 16 Ensure Machine is properly grounded use ONLY recommended voltage and observe all local state and federal electrical safety codes and regulations WARNING Ensure all guards shields and safety switches are in place and in proper working order before operating this machine Further ensure that all other personnel are clear of machine and that your hands are clear of any moving part before turning on and operating machine Wear proper safety equipment when operating machine OPERATING TIPS If load meter is indicating loads of over 95 consis tently reduce spindle speed If lowest speed is being used increase feed rate to break down stone or use a softer stone Also verify that STP is set cor rectly by reviewing Load graph and observing trend Remember if starting load is higher than steady state operating load result is stone wear without corresponding stock removal If honing technique above does not result in greater stone life use a lower feed rate setting If a low operating load a

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