safety instructions
Contents
1. Install hardware securing two sections together Install Cover Plate Tq Using a machinist level level machine by adjusting Leveling Setscrews in Support Feet Lu lt a Lu A amp N 2 tr lt 11 uu E NO IE E 31 NOTES 32 APPENDIX DECLARATION OF CONFORNITY CE _ SUNNEN 0000 1001 EC Declaration of Conformity According to the EU Machinery Directive 2006 42 EG Annex Il 1 A Manufacturer Sunnen Products Co 7910 Manchester 63143 St Louis Missouri USA Person residing within the Community authorized to compile the relevant technical documentation Julian Hooper Sunnen Products Ltd Centro 1 Maxted Rd HP2BL Hemel Hempstead Hertfordshire Description and identification of the machinery Make 0 meter Horizontal Hone Serial No 1001 Project Number XXXXX Project Name HTA Itis expressly declared that the machinery the machine2. 1310 1501 839 1310 734 987 FLOOR PLAN Sunnen Tube Hones viii 4790 4790 1310 I 1501 SECTION 1 INSTALLATION PURPOSE This Section is designed to aid user in unpacking inspecting and installing Sunnen Tube models HTA 2100 amp 4100 Hereafter referred to as the Machine see Figure 1 1 TOOLS amp MATERIALS The following tools and materials are required for unpacking and installing machine Wire Cutters Strippers Knife Screw Driver Std nose Hammer Slip Joint Pliers Crow Bar Cleaning Solvent Tin Snips Open End Wrench 17 19 amp 24 mm 3 4in INSTALLATION Read the following instructions carefully and thoroughly before unpacking inspecting and installing the Machine All references to right and left in these instructions are unless otherwise noted as seen by operator as one looks at Machine or assembly
3. UT EE dO diced ue pa qu de edens 9 Honing TOO uoo A a ERU EE C XX NN PN TR Ce 9 Workholding Fixture 4 xe RR E Tod eo t seed I es s 11 SETUP AND OPERATION aa ed aria esas ted 13 General saab RR RAG ae Rede eae ihn ba oe See aa ee laa ee 13 Safety Precautions ses eee e ge epo au dd aw eG ne tae aa 14 Operating Hints ea a 14 Setup amp Operation iiss caw a da eisen dd 14 ROUTINE MAINTENANCE consume a le AAs RR reet Ux e dete STRA 17 General ar as ER e aqq ee 17 ne Kaa Haas feed Shoe 17 Lubrieation es ee ek ee aa 17 Coolant Line Check dee Ene RR 18 Coolant Unam NU RES a 18 Auto Feed Clutch Adjustment ode ee kA a een 18 Handwheel amp Armature Removal 19 Feed Clutch aussen en ee EO DEREN HA ERR 20 Light Curtain Cleanmg 22 225555 exe RE RP RN NERIS ea nee aed Sects be PN 20 TROUBLESHOOTING ed Nox alo ee 21 AI YA NM 21 Operational Troubleshooting aaa 21 APPENDIKES A Check List Setup amp Operation 23 B Crosshatch Angle 25r RR 25 Coolant Flow Diagram 4 4 27 D Surface Roughness Table sse cbc 6
4. 9 H H H us WORKPIECE FIXTURE WORKPIECE FIXTURE WORKPIECE FIXTURE ES EE ES ES 0 D HEIGHT 0 D HEIGHT 0 D HEIGHT 55 ss 54 mm in mm in mm in mm in mm in mm in Or 6 38 15 224 88 175 7 0 143 5 6 225 9 0 140 5 4 50 2 0 216 85 200 8 0 128 5 0 250 10 0 126 45 75 3 0 201 79 225 90 115 44 275 110 112 4 3 NOMINAL OD 100 4 0 186 73 250 10 0 101 3 9 300 12 0 98 3 8 125 5 0 172 6 7 275 110 87 3 3 325 13 0 85 5 2 150 6 0 157 8 1 300 12 0 73 2 8 350 14 0 7i 27 175 70 123 5 6 325 13 0 80 22 375 15 0 58 22 200 8 0 129 5 0 350 14 0 46 17 400 16 0 48 1 6 225 9 0 115 44 375 15 0 33 12 125 170 21 11 250 10 0 101 39 400 16 0 19 0 6 450 18 0 18 0 6 275 11 0 7 3 3 y B yA El o ES FIXTURE CLAMPS POSITIONED ON TOP OF MACHINE BASE WORKPIECE OD WORKPIECE OD WORKPIECE OD WORKPIECE OD 38 280 mm 1 5 11 0 in 175 410 mm 6 9 16 0 in 225 460 8 9 18 0 in 475 610 mm 18 7 24 0 in FIGURE 2 5 Fixture CLEVIS WEDGE CLAMP N CLAMPS HANDLE CHAIN CHAIN SCREW ASSEMBLY LOCKING NUT CLAMP COLLAR SCREW
5. FIGURE 2 6 Fixture 12 SECTION 3 SETUP amp OPERATION GENERAL This section describes a step by step operating procedure for the Machine Prior to starting the Machine Operator shall ensure All prerequisites described in sections 1 and 2 are complete All personnel are clear of machine FIRST AND ALWAYS SAFETY PRECAUTIONS The following precautions should be followed to ensure maximum safety of personnel while working on or around Machine WARNING Most accidents occur through failure to N observe basic safety rules and or operating procedures Accident can be avoided by being alert and recognizing potentially hazardous situations before an accident occurs Individuals performing operation maintenance and or repair should have the necessary training skills and tools required to perform the functions properly and safely The safety information provided in this manual serves as a basic guide in an attempt to prevent injury or death Sunnen cannot anticipate every possible circumstance that might involve a potential safety hazards Therefore the safety warnings and precautions presented in this manual and other instructions packaged with this equipment can not be all inclusive If a tool procedure work method or operating technique that is not specifically mentioned by Sunnen is used you must satisfy yourself that it is safe for you and for others Make sure the product or machine wi
6. XA V m min 7272 To calculate the Crosshatch Angle consult following Formulas Stroke Speed V m min x 3 14 x RPM x tg 30 m min 1000 EXAMPLE 100 x 3 14 x 175 x 0 5774 31 73 m min 1000 Spindle Speed RPM 1000 x V m min RPM x 3 14 x tg 30 EXAMPLE 1000 30 165 5 RPM 100 3 14 x tg 0 5774 25 NOTES 26 APPENDIX C COOLANT SYSTEM FLOW DIAGRAM COOLANT SYSTEM with PAPER FILTER WORKPIECE FLOW CONTROL ON OFF VALVE enu M y y n CU RESERVOIR DRAIN PAPER SUMP PUMP FILTER 4 Y UN FILTERED INTAKE FLUID COOLANT SYSTEM COOLANT RESERVOIR with PAPER FILTER 27 NOTES 28 APPENDIX D SURFACE ROUGHNESS TABLE Rt Rz N1 N10 Ra CLA RMS GUS um um um pin pin Knocc 0 1 0 3 0 17 N 1 0 02 0 8 0 9 1 0 14 0 2 0 5 0 30 N2 0 04 1 6 1 8 1 9 13 0 3 0 7 0 43 0 06 2 4 2 6 2 9 12 0 4 0 8 0 52 N 3 0 08 3 2 3 5 3 8 11 0 5 1 0 0 65 0 10 4 0 4 4 4 8 0 6 1 2 0 77 N 4 0 12 4 8 5 3 5 8 0 65 1 4 0 86 0 14
7. CE compliance Warning Warns that a hazard from objects falling off work table exists and that proper Label precautions should be taken KA Warning Warns not to hold workpiece in hand without a torque C Label resisting fixture Warning Label Warns that an arc flash hazard exists 10 DRIVE SHAFT EXTENSION MPS 2220A MPS E Output Adapter Adapters Convert NR Style 0 fon 7 Together Configuration ANR Style Option ES O BE od One of each part number required per MPS MPS 2211A MPS 2212A MPS 2222A MPS 2221A driveshaft Input Drive Input Feed Output Feed Output Drive Adapter Adapter Adapter Adapter DRIVE SHAFT EXTENSION ANR 741 9 25 235 mm ANR 160 MPS 175 ANR 742 19 483 mm HONE HEAD nn MPS 2235A DRIVE SHAFT EXTENSION MPS 2220A ANR 744 42 75 1086 mm MPS E2015 5 9 150 mm Output Adapter ANR 746 72 25 1835 mm ra ANR Style Bolt Together Style Requires MPS E2015 and MPS 2220A to connect to HTA U Joint DRIVE SHAFT EXTENSION MPS E2015 5 9 150 mm MPS 2230A j MPS E2040 15 7 400 mm UJOINT Ps Epa 522594 MPS E2100 39 3 1000 mm MPS 2220A HONE HEAD MPS E2160 63 1800 mm Output Adapter 00 MPS Style Screw Together Connects directly to HTA U Joint FIGURE 2 3 HTA Drive Shaft Comparison for use with ANR Style Hone 4 Rotate input Yoke Adapter clockwise to engage and Lock into the Drive
8. Remove packing materials 2 Route Safety Arch Switch Cable behind and under machine e Attach Safety Arch Switch Cable and E Stop Cable HTA 4100 only along lower front section of carriage base with provided cable ties e Then connect to Main Electrical Enclosure NOTE The operational position of the switch with lts bracket is preset at the factory but should be checked after installation The switch should activate any time the arch is opened e If switch activation point needs to be reset LIGHT CURTAIN FUNCTION TEST reposition switch up or down using vertical slots in CE Machines Only Check Light Curtain operation switch bracket Take care that switch is not set too as follows see Figure 1 16 high causing roller plunger on switch to not have any travel left when safety arch is opened WARNING The test outlined below must be performed at 3 With machine at rest Verify that machine will installation according to employer s regular not start when safety arch is opened inspection program and after any maintenance tooling change setup adjustment or modification to Light Curtain System or the guarded machine Where a guarded machine is used by multiple operators or shifts it is suggested that the test be performed at each shift or operation change Testing 4 Verify that braking system is working properly Machine must come to a quick controlled stop when safety arch is opened Drive faults spindle coasting
9. 1 HTA HTA 4100 WORKPIECE BASE 4100 CARRIAGE BASE n c 1 FORKS POSITION FORKS POSITION FIGURE 1 1 Tube Hone FIGURE 1 2 Lifting Machines FORKS POSITION ALIGN BASES USING STRING or WIRE FORKS POSITION NS canbiace Base 1 NY workpiece FIGURE 1 3 Connecting Tables HTA4100 f Align holes in Workpiece Base with Carriage Base and install bolts securing two sections together NOTE Use sealant on washer inner faces to prevent oil leakage g Using a machinist level level Workpiece Base by adjusting Leveling Setscrews in Support feet using a 1 1 8 Open End Wrench refer to Figure 1 4 Install Cover Plate as shown refer to Figure 1 5 NOTE If needed Refer to I HTA 555 Special Instructions for cover installation 7 Inspect Machine and Components for dents scratches or damage resulting from improper handling by carrier If damage is evident immediately file a claim with carrier 8 For permanent installation secure Machines Support Feet to Floor with appropriate fasteners not supplied 9 HTA 4100 ONLY The Workpiece Ba
10. 1 3 of Stone length out of Workpiece to allow for overstroke 14 Press Teach Start Of Stroke button 15 Set Left Adjustable Stroke Stop 3 mm 1 8 in to left of Limit Switch Arm TABLE 3 1 Feed Rate 16 Rotate Handwheel until all the stones contact the bore wall Shaking the Honing Tool keeps the hone from binding in the bore while the stones are being fed out 17 Press RUN button on HMI 18 Position Coolant Nozzle to direct oil into the bore Ensure there is enough clearance for overstroking by the Honing Tool Use ONLY one Coolant Nozzle so metal chips may be properly The optimum cutting Speed is about 55m min Calculate Optimum Spindle Speed 17500 RPM Bore Diameter in millimeters SPINDLE FEED SETTING DIAMETER SPEED FOR FASTER STOCK REMOVAL flushed from the part during honing mm in RPM ROUGH FINISH INCREASE FEED 19 p COOLANT OFF b tt d th 501 2 350 10 30 IF STONES WEAR RAPIDLY 70958 75 3 230 10 40 Reduce Feed Rate Flow Control Valve on the Coolant Nozzle to check 100 4 175 20 so Use Harder Stones coolant flow Then press COOLANT ON 125 5 140 20 60 Always use this setting d
11. 4 Soft or exotic materials Use bronze bronze shoes Scratches in Bore 1 Improper feed A Decrease cutting pressure 2 Random 2 Improper stone A Use finer stone B Use softer stone 3 Improper or diluted coolant A Check coolant 4 NOTE Many honing problems such as poor stone life and rough finish are caused by wrong coolant insufficient coolant dirty coolant or contaminated coolant Use ONLY clean Sunnen Industrial Honing Oils or Water Based Coolant Make sure that coolant is neither diluted nor cut with other coolants Keep solvents and cleaning fluids away from Machine 22 APPENDIX A CHECK LIST SETUP OPERATION SEQUENCE ua 10 11 14 2 30 31 ETUP amp OPERATION Section 3 SHUT OFF all electrical power to the Machine 1 2 Install Workpiece 3 Turn ON Main Power 4 Release Emergency STOP Button 5 6 7 8 9 Press Power ON Button When instructed to Home Machine press HOME MACHINE button and wait to complete Press SETUP enter part specifications and then press Calculate Defaults button Press SETUP again and verify Spindle Speed Stroke Speed amp Spindle Load Enter desired Honing Time Assemble and install Honing Tool Use JOYSTICK to move carriage so Honing Tool can be connected 12 13 Use JOYSTICK to set end of Workpiece overst
12. Gearbox Shaft Thread Feed Control into Coupler Install and tighten three Screws M10 that clamp Coupler to Gearbox Shaft and torque to 65 N m 48 in lbs Adjust Feed Clutch see Auto Feed Clutch Adjustment Reinstall Coupling Cover and Brake Shield B Second Method see Figure 4 6 1 The Feed Control may be unthreaded from the Coupler and removed The Feed Control will have been threaded tightly into Coupler during use of the machine Use the following procedure to break the thread connection loose Turn OFF power to Machine at Master ON OFF Switch on Electrical Enclosure and install Lock Out Tag Remove any tooling connected to Spindle Drive Motor Loosen Setscrews and remove U Joint Assembly Loosen Setscrew to remove U Joint FEED SHAFT ASSEMBLY U JOINT ASSEMBLY ATAA N E W Screws securing Yoke YOKE CLUTCH FIGURE 4 6 Handwheel Method 2 Next the Feed Shaft Assembly must be removed from the Feed Control To do this Remove four Screws holding Yoke in place and remove Yoke Remove Feed Shaft Assembly from inside of Yoke Then reinstall Yoke with four Screws Remove Brake Shield and Coupling Cover Slip a inch 12 7mm diameter bar through holes in Yoke and use this bar to apply a torq
13. and stroker coasting are unacceptable OPTIONAL LIGHT CURTAIN ensures that Light Curtain and machine control CE Machines Only CE machines come with system work properly to stop the machine Failure to optional Light Curtain and guarding installed Light test properly could result in injury to personnel Curtain alignment must be tested for proper function after machine installation To check zx proceed as follows see Figure 1 13 R ET 1 Set Light Curtain to a height of 855mm as shown see Figure 1 14 _ e Check for signs of external damage to the light curtain transmitter receiver or cables and wiring E 2 Connect Light Curtain Cables to Light Curtain Receiver and Transmitter as shown see Figure 1 15 gt e Inspect electrical connections between guarded machine s control system and light curtain Verify 1 ELEC they are properly connected 855mm 3 Turn on power to machine 4 Verify that curtain is in alignment The individual beam indicators located on receiver will illuminate when alignment of a beam is not met refer to Figure 1 13 FIGURE 1 14 Light Curtain Height ROUTE CABLE TO LIGHT CURTAIN RECEIVER SAFETY ARCH SWITCH CABLE COOLANT CART CABLE LIGHT CURTAIN CABLE ROUTE CABLE TO LIGHT CURTAIN TRANSMITTER FIGURE 1 15 Light Curtain Cable Connecti
14. being described 1 Remove heavy duty plastic wrap from around shipping crate WARNING Use safety glasses or goggles when cutting bands 2 Cut remove and discard shipping bands 3 Remove Components from crate 4 Remove items shipped inside Coolant Reservoir 5 Remove nuts and bolts securing Base s to bottom of crate s use 3 4 Open End Wrench 6 Using a fork lift Remove Base s from skid and set it in place as follows RIGHT FRONT HTA 2100 ONLY a Machine Base should be lifted in center of Base from either front or back side see Figure 1 2 b Using a machinist level level machine by adjusting Leveling Setscrews in Support feet using a 1 1 8 Open End Wrench see Figure 1 4 HTA 4100 ONLY a Carriage Base should be lifted in center of Base from either front or back side see Figure 1 2 Then Workpiece Base should be lifted in center of Base and set it in line with Carriage Base see Figure 1 3 b Remove Cover Plate see Figure 1 5 NOTE If needed Refer to I HTA 555 Special Instructions for cover removal c Slide two sections together d Utilizing a string or wire align operator side of both Workpiece amp Carriage Bases refer to Figure 1 3 e Using a machinist level level Carriage Base by adjusting Leveling Setscrews in Support feet using 1 1 8 Open End Wrench see Figure 1 4 HTA 2100 FORKS POSITION
15. go of the Joystick 3 The Dwell Button provides the ability to dwell at any location in the bore by holding the button while in a tight spot in the bore SETUP 8 OPERATION Start up instructions for all HTA Series Machines 1 Install Workpiece refer to Section 2 2 Turn ON power at Main Power Disconnect Switch on Electrical Enclosure 3 Release all Emergency STOP Buttons 4 When instructed to Home Machine press HOME MACHINE button and wait to complete NOTE During homing the tool and driveshaft must be disconnected from the carriage 5 Press SETUP enter part specifications and then press Calculate Defaults button The software automatically calculates values as shown in tables on the next page 6 Press SETUP again and verify Spindle Speed Stroke Speed Spindle Stroker Load Selected on DISPLAY SETTINGS Screen 7 Enter desired Honing Time 8 Assemble and install Honing Tool refer to Section 2 9 If not connected Use JOYSTICK to move carriage so Honing Tool can be connected 10 Make sure the stones are loose and then use JOYSTICK to move Honing Tool to end of Workpiece then run Tool approximately 1 3 of Stone length out of Workpiece to allow for overstroke 11 Press Teach End Of Stroke button 12 Set Right Adjustable Stroke Stop at 3 mm 1 8 in to right of Limit Switch Arm see Figure 3 1 13 Use JOYSTICK to move Honing Tool to start of Workpiece then run Tool approximately
16. 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 equipment may be dangerous if used improperly Please read all warnings and instructions before attempting to use this machine Always disconnect power at main enclosure before servicing machine Always wear eye protection when operating this machine NEVER open or remove any machine cover or protective guard with power ON Always disconnect power at main enclosure before servicing this equipment DO NOT attempt any repair or maintenance procedure beyond those described in this book Contact your Sunnen Field Service Engineer or Technical Services Representative for repairs not covered in these instructions Due to the wide variety of machine configurations all possibilities cannot be described in these instructions Instructions for safe use and maintenance of optional equipment ordered through Sunnen will be provided through separate documentation and or training provided by your Sunnen Field Service Engineer or Technical Services Representative DO NOT attempt to defeat any safety device on this machine or on any of the optional equipment If specially built automation components
17. service not requiring power Turn OFF electrical power at Main Power Source when preforming maintenance on or cleaning of Electrical Control Enclosure An Arc Flash Hazard Exists Follow safe work AM practices and wear appropriate Personal Protective Equipment Follow proper lockout tagout procedures Failure to comply can result in death or injury When light curtain key switch is deactivated a cycle cannot begin however if machine is in middle of a cycle and switch is flipped machine will finish its stroke in that cycle and then come to a complete stop Clear area of excessive lubricant or lubricant spills DO NOT adjust stroke length while Spindle Retractor Carriage is not in locked position KEEP hands clear of all moving parts Stay clear of all moving parts To avoid personal injury allow spindle and stroking arm to come to a complete stop before removing part OPERATING HINTS There are several features on the HTA Machines for correcting problems in the bore These features are as follows 1 During honing cycle the Joystick can be used at any time to reduce Tight Spots Moving the Joystick in the opposite direction of the stroke will cause the stroke to instantly change direction 2 Additionally the Joystick can be used to stop or oscillate the stroke at either end of the bore for correcting barrel or bellmouth conditions By holding the Joystick at the end of the stroke it will short stroke until you let
18. sunnen com or e mail sunnen sunnen 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 your wrist strap or foot grounding devices B 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 static bubble wrap has b
19. 340 51 1000 175 NOTE Pressing Red E STOP Button will Shut OFF power to all machine functions After E STOP Button has been pressed E STOP Button must be released Cycle START Button must be pressed FIGURE 3 1 Stroker Stops before machine will operate When honing cycle is LIMIT SWITCH interrupted Timer will be reset when cycle is ARM restarted 25 Periodically check the coolant level on top of I Bes the filter paper in the coolant reservoir If the filter L paper is dirty and coolant is overflowing the paper then pull fresh paper across the drain screen and or Lie reduce coolant flow the workpiece o CAUTION Failure to advance the paper when it becomes dirty can cause the coolant to backup and overflow reservoir LEFT ADJUSTABLE RIGHT ADJUSTABLE STROKER STOP STROKER STOP 26 Retract stones slightly by turning Handwheel 27 Slide Honing Tool out of Bore NOTES WARNING An Arc Flash Hazard Exists Follow safe work practices and wear appropriate Personal Protective Equipment Follow proper lockout tagout procedures Failure to comply can result in death or injury SPINDLE DRIVE GEARBOX OPTIONAL GREASE FITTINGS SPINDLE CARRIAGE GREASE FITTING STROKER DRIVE BELT wh Al FIGURE 4 Lubrication Points 16 SECTION 4 ROUTINE MAINTENANCE
20. 5 6 6 2 6 8 0 7 1 6 1 00 0 16 6 4 7 0 7 7 0 8 1 7 1 07 0 18 7 2 7 9 8 6 10 0 9 1 9 1 20 0 20 8 0 8 8 9 6 1 1 2 3 1 45 N5 0 25 10 0 11 0 12 0 1 3 2 7 1 70 0 30 12 0 13 2 14 4 1 5 3 0 1 95 0 35 14 0 15 4 16 8 1 7 3 4 2 20 0 40 16 0 17 6 19 2 9 1 9 3 8 2 45 N6 0 45 18 0 19 8 21 6 2 3 4 2 2 70 0 50 20 0 22 0 24 0 2 7 5 2 3 45 0 65 26 0 28 6 31 2 8 3 7 7 0 4 60 N7 0 90 36 0 39 6 43 2 4 5 8 2 5 45 1 10 44 0 48 4 52 8 5 2 9 5 6 35 1 30 52 0 57 0 62 0 7 6 0 10 0 7 10 1 50 60 0 66 0 72 0 7 1 12 5 8 45 N8 1 80 72 0 79 0 86 0 9 6 16 5 11 20 2 50 100 0 110 120 6 13 0 22 0 15 10 N9 3 50 140 0 154 168 17 0 28 0 19 40 4 50 180 0 198 216 18 0 30 0 20 60 5 00 200 0 220 240 5 22 0 35 0 24 50 6 00 240 0 264 288 25 0 40 0 27 90 N10 7 00 280 0 308 336 28 0 45 0 31 40 8 00 320 0 352 384 29 NOTES 30 APPENDIX ALIGNMENT OF 4M MACHINES Aligning amp Connecting Tables Align front side of both halves of machine Utilizing a string or wire align operator side of both Workpiece Base amp Carriage Base Slide two sections together
21. 646 9 64 nen 5 9 9 ka 29 E Alignment of 4M Machines 31 F Declaration of Conformity 33 INTRODUCTION This Instruction Manual is provided to give the information required to install operate and maintain the Sunnen HTA Series Tube Hones models 2100 amp 4100 As there are numerous Workpieces that can be honed on this machine all possible combinations cannot be discussed here The determining factor as to whether a particular part or material can be honed in the machine will come with experience from working with the machine in your shop When ordering parts for or requesting information about your machine include the serial number of your machine READ THE FOLLOWING INSTRUCTION THOROUGHLY BEFORE UNPACKING INSPECTING OR INSTALLING THE SUNNEN TUBE HONE vi GENERAL INFORMATION amp SPECIFICATIONS Sunnen Tube Hone HTA Series Model HTA 2100 HTA 4100 Workpiece Range ID 64 533 mm 2 5 21 in Workpiece 9 Range OD 38 610 mm 1 5 24 in Workpiece Weight 3630 kg 8000 165 Stroke Length Range Stroke Rate Stroke Motor Up to 2 1 m 6 9 ft 82 7 in Up to 4 1 m 13 5 ft 161 4 in 1 52 27 4 mpm 5 90 fpm 1 48 kW 2 hp Spindle Speeds 20 to 300 rom Spindle Motor 2 24 kW 3 hp AC gear motor Set Up Time 10 15 min
22. 9 890625 22 6219 157480 4 0000 531250 13 4938 905512 23 0000 171875 4 3656 546875 13 8906 906250 23 0188 187500 4 7625 951181 14 0000 921875 23 4156 196850 5 0000 562500 14 2875 937500 23 8125 203125 5 1594 578125 14 6844 944862 24 0000 218750 5 5563 590551 15 0000 953125 24 2094 234375 5 9531 593750 15 0813 968750 24 6063 236220 6 0000 609375 15 4781 984252 25 0000 250000 6 3500 625000 15 8750 984375 25 0031 265625 6 7469 629921 16 0000 1 000000 25 4000 275591 FORMULAS MULTIPLY INCHES in x FEET 9 x 7 0000 640625 BY TO GET 25 4 MILLIMETERS mm 0 3048 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 EN UNNEN do not entitle the buyer to corresponding SUNNEN PRODUCTS COMPANY changes improvements additions or 7910 Manchester Road St Louis MO 63143 U S A replacements for equipment supplies or Phone 314 781 2100 5 accessories previously sold Information U S A Toll Free Sales and Service 1 800 325 3670 contained herein is considered to be Internati
23. 99 A1 Low voltage switchgear and control gear assemblies Part 1 Type tested and partially type tested assemblies EN 953 1997 10 Safety of machinery Guards General requirements for the design and construction of fixed and movable guards Reference to the technical standards and specifications used EN ISO 13849 1 2006 11 Safety of machinery Safety related parts of control Part 1 General principles for design N Signature St Louis Missouri USA 2010 04 08 Ya Mike Haughey Chief Operating Officer 33 NOTES 34 Like any machinery this equipment may be dangerous if used improperly Be sure to read and follow instructions for operation of equipment MANUFACTURED UNDER ONE OR MORE OF THE FOLLOWING UNITED STATES PATENTS 5 433 656 5 707 278 6 780 084 7 727 051 5 443 417 6 074 282 7 371 149 8 277 280 5 663 886 6 527 620 7 575 502 OTHER U S AND FOREIGN PATENTS PENDING SUNNEN SUNNEN PRODUCTS COMPANY ST LOUIS MO U S A LTA1015V ILO437V WARNING An Arc Flash Hazard Exists Follow safe work practices and wear appropriate Personal Protective Equipment Follow proper lockout tagout procedures Failure to comply can result in death or injury DO NOT WEAR COTTON OR HEAVY GLOVES WHILE OPERATING THIS EQUIPMENT IL1198 520 35 FRACTION DECIMAL MILLIME
24. BO COUPLER BRAKE RIGHT ANGLE BRACKE ARMATURE MAGNETIC BRAKE GAP 0 50mm E 0 02in LY SAFETY FEED CLUTCH HANDWHEEL SCREW TO SET RUNOUT FIGURE 4 4 Auto Feed Clutch Adjustment BRAKE BRACKET ASSEMBLY FIGURE 4 5 Handwheel Method 1 Parallelism Setting The right angle bracket that the magnetic brake is attached to must have a 90 angle for the brake to be perpendicular to the armature To set this first remove the Gear Box Coupling Cover The bracket angle can be set by bending the bracket toward or away from the Handwheel and visually checking that the brake is parallel to the armature Runout Setting The brake must be concentric with the armature The brake is made concentric with the armature by loosening the four screws on the flat plate attached to the back of the brake and moving the brake up and down and forward and backward There is extra clearance in plate screw holes for the brake O D to be moved concentric with the armature O D Retighten the four plate screws when concentricity 15 set Gap Setting Set the gap between the brake and the armature to be approximately 0 5mm 0 02in The gap is set by moving the brake toward or away from the armature The brake can be moved by loosening the two screws on the brake right angle bracket attaching it to the carriage base Retighten these screws when gap is set and then recheck par
25. CLOSURE CARRIAGE BASE FIGURE 2 1 Major Components 9 SUNNEN 00080 6 _ SUNNEN A WA 4 FIGURE 2 2 Operator Control Panel TABLE 2 1 Operator Control Panel 1 LCD Display and Operation of the machine can generally be done via the touch screen which means Touch Screen that a function may be started by touching the corresponding key on the screen Operator Panel 2 SAFETY Stop the machine in a emergency situation EMERGENCY STOP 3 Hardware Cycle Start the honing cycle if the machine is in AUTO START Button 4 Hardware Cycle Stop the honing cycle oO STOP Button 5 Joystick for manual Manual movement of the carriage for setup and to over ride the AUTO mode lt gt Stroke movement operating direction left right 6 Light Curtain CE Models ONLY Key Activated Light Curtain Machine will automatically Stop Key Switch when light beam is interrupted TABLE 2 3 Safety Symbols SYMBOL DESCRIPTION FUNCTION Warning Label Warns that an electrical hazard exists Warning Label Warns that safety glasses should be worn at all times when operating this machine 2 Warning Strip Warns that a physical hazard exists and that proper precautions should z be taken Label Designates this machine is
26. COPYRIGHT SUNNEN PRODUCTS COMPANY 2013 ALL RIGHTS RESERVED
27. 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 WARNING Turn OFF electrical power when performing service on your machine which does not require power Disconnect Machine from main power supply before any work is performed inside of Electrical Enclosure An Arc Flash Hazard Exists Follow safe work practices and wear appropriate Personal Protective Equipment Follow proper lockout tagout procedures Failure to comply can result in death or injury CLEANING Daily Wipe exterior of Machine with a clean dry cloth to remove any coolant dust and grim Empty Filter Paper Tray as required Monthly Wipe exterior of Machine with a clean dry cloth Then clean the exterior of Machine with warm water and a mild detergent or mild industrial solvent Rinse thoroughly with clean hot water and wipe dry Lightly lubricate following lubrication instructions GREASE FITTINGS LUBRICATION NOTE The intervals between lubrication will vary with amount of use your Machine receives Lubricate all components at least once every three 3 months CAUTION Be careful not to get oil grease on drive belts or feed clutch brake 1 SPINDLE CARRIAGE WAYS Spindle Carriage Ways Linear B
28. I HTA 4101 SUNNEN ORIGINAL INSTRUCTIONS Installation Setup and Operation INSTRUCTIONS for SUNNEN TUBE HONE Model HTA 2100 amp HTA 4100 READ THE FOLLOWING INSTRUCTIONS THOROUGHLY AND CAREFULLY BEFORE UNPACKING INSPECTING OR INSTALLING THE SUNNEN TUBE HONE SUNNEN AND THE SUNNEN LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY SUNNEN PRODUCTS COMPANY 7910 MANCHESTER ROAD ST LOUIS MO 63143 U S A 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 operation and maintenanc
29. OFIT 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 O 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 exclusive right without right t
30. Ring on the Spindle Nose 5 Slide Rubber Boot over Input Yoke Adapter refer to Figure 2 4 WORKHOLDING FIXTURE Position the Workholding Fixture as follows see Figure 2 5 1 Turn OFF all electrical power 2 Loosen four Socket Head Capscrews in base of Workholding Fixtures see Figure 2 6 3 Position Fixture so Workpiece will be clamped close to its Ends approx 300 500mm Configure Fixture height so centerline of Workpiece aligns with centerline of Spindle refer to Figure 2 5 STROKE STOP UNIVERSAL COVER 4 Lift Workpiece into Machine using a hoist as HONING gt required TOOL 3 CENTERLINE 5 Place tool inside Workpiece bore and snug tool with Handwheel 6 Place a level on driveshaft and raise or lower Screw Assembly on Workholding Fixture until driveshaft is level The centerline of the Workpiece should be in line with the centerline of the spindle 7 Wrap Chains around Workpiece and through Wedge Clamps Secure by inserting Locking Pins and Clevis Pins refer to Figure 2 6 8 Adjust tension on Chains using Clamp Handle Hand tighten to approximately 40 50 N m 2 8 3 5 bs ft FIGURE 2 4 Input Yoke Adapter 11 CAUTION 9 Tighten four Capscrews in base of each A kholding Fixt efer to Figure 2 6 Use care when tightening chains Over tightening IERI MINUM may distort workpiece 10 Tighten Clamp Collar Screw on Fixture Base
31. Stock Removal Rate Coolant Pump Pump Motor Coolant Capacity Pump Rate Coolant Requirements 130 cm hr 8 Centrifugal pump 0 248 kW 1 3 hp 182 L 48 gal 225 LPM 60 GPM Sunnen Industrial Honing Fluids Controls Siemens PLC with Touch Screen Floor Space Length 4790 mm 189 in 9580 mm 385 in Depth 987 mm 39 in 987 mm 39 in Height 1501 59 in 1501 mm 59 in Floor Weight Dry 1088 kg 2400 Ibs 1815 kg 4100 Ibs Floor Load 739 80 54 meter 151 Ibs sq ft Electrical Requirements Color Noise Emission 400 460V 50 60Hz 3Ph 15A Designed in accordance with NEC NFPA 79 Black Less than 76 dB A continuous Less than 78 dB A peak Load max noise condition in a typical factory environment Diameter range length range and workpiece weight are contingent on workpiece and application 2 For diameter sizes below 64mm 2 5in contact your local Sunnen Field Service Engineer For steel material with conventional abrasives Actual stock removal rates will vary depending on workpiece and application 4790 9580 4790 m Zr
32. TER EQUIVALENTS CHART FRACTION NCH DECIMAL 003937 007874 MILLIMETER FRACTION 0 2000 INCH DECIMAL 281250 296875 7 1438 7 5406 MILLIMETER FRACTION DECIMAL NCH MILLIMETER 656250 16 6688 669291 17 0000 011811 0 3000 312500 7 9375 671875 17 0656 015625 0 3969 314961 8 0000 687500 17 4625 015748 019685 0 4000 0 5000 328125 343750 8 3344 8 7313 703125 17 8594 708661 18 0000 023622 0 6000 354331 9 0000 718750 18 2563 027559 0 7000 359375 9 1281 734375 16 6531 031250 031496 0 7938 0 6000 375000 390625 9 5250 9 9219 748031 19 0000 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 13 096
33. Valves 3 Power up the Machine 4 Go to Run Screen 5 Press Coolant Off Button and pump waste coolant into waste container 6 As coolant flow drops off press Coolant ON Button 7 Press E Stop and turn OFF all power to the Machine 8 Close Coolant Control Valves 9 Return Coolant Nozzle s to Work Tray 10 Slide Reservoir out from under the Machine 11 Dip or siphon out any remaining coolant from the Reservoir 12 Clean Sludge from Reservoir and wipe clean 13 Fill Reservoir by pumping or pouring only approved Sunnen Industrial Honing Oil into the Coolant Reservoir 14 Slide Reservoir under the Machine AUTO FEED CLUTCH ADJUSTMENT Inspection and alignment should be made to the Auto Feed Clutch if unusual performance excessive heat or noise occurs during use see Figure 4 4 The Auto Feed Clutch consists of a low voltage electromagnet and an armature steel plate on the back of the manual handwheel Automatic feed up of the handwheel is accomplished by energizing the electromagnetic brake and creating frictional drag between the magnet and the armature Some intermittent noise is to be expected during use Alignment of the magnetic brake to the armature consists of three settings parallelism runout amp gap Refer to Fig 2 A in Repair Parts Manual amme RESERVOIR FIGURE 4 3 Coolant Reservoir GEARBOX COUPLER WRENCH FLAT MAGNETIC BRAKE GEARBOX COUPLER COVER GEAR
34. allelism HANDWHEEL amp ARMATURE REMOVAL Periodically inspect the Handwheel for signs of slippage wear or damage the gears inside the handwheel can strip when system is overfed While operating the machine with the grip Handwheel feel for slippage and ease of turning If slippage is felt or any damage is observed proceed as follows refer to Fig 2 A in Repair Parts Manual NOTE There are two methods of removing the Feed Control Remote Stone Feed Control Hone from the Machine A First Method see Figure 4 5 1 The Feed Control may be removed from Gear Box Shaft by removing Coupler as follows Turn OFF power to Machine at Master ON OFF Switch on Electrical Enclosure and install Lock Out Tag Remove any tooling connected 10 Spindle Drive Motor Remove Brake Shield and Coupling Cover Remove three Screws M10 that clamp Coupler to Gear Box Shaft Remove the two screws fastening Brake Bracket Assembly to Carriage Base The Feed Control can now be removed from Gearbox Shaft along with the Coupler The slot in the Coupler may need to be separated with a flat blade screw driver in order to release Coupler from Gearbox Shaft Separate Coupler from Feed Control using wrench flats as shown 2 Rebuild or replace Handwheel as required 3 Inspect Armature Resurface or replace Armature as required 4 Reassemble Feed Control as follows Slide Coupler all the way against shoulder of
35. are added to this system be sure that safety is not compromised If necessary obtain special enlarged work area safety system from Sunnen Products Co 1 DO NOT touch electrical components until main input power has been turned off and CHARGE lamps are extinguished WARNING The capacitors are still charged and can be quite dangerous TABLE OF CONTENTS Page TABLE OF CONTENTS rn er LIST OF APPENDINES INTRODUCTION oros vi GENERAL INFORMATION amp SPECIFICATIONS vii FLOOR LAYOUT Configuration Vili INSTALLATION a cia Sun da ei sea Ro 1 CT 1 Tooling amp Materials 8 a 1 Installation i o kenn a dan De le 1 Electrical Requirements R 3 Electrical Connection iu ea bee ted ded 3 Safety Afch Switch issu sea ODE GAL RE RE CERA en 4 Optional Light Curtain Lec _______ e au e e o 5 Light Curtain Function Check 6 PREPARING FOR OPERATION 202 6 bab aii 9 e uL MM Pp 9 Major Components gs austr E X 9 Operator Controls Has a an een e adea d eoa VUE 9 Safety Symbols
36. cal state and federal codes and regulations along with any special information provided on machine nameplate or electrical specification plate WARNING All wiring and electrical equipment service should be performed by authorized personnel ONLY CAUTION Note model electrical supply requirement printed on machine nameplate or electrical specification plate Do not attempt to connect machine if supply voltage is not following acceptable limits as noted on nameplate or electrical specification plate If supply voltage is not within these limits MACHINE WILL BE DAMAGED Verify supply voltage is same as voltage on Machine Nameplate or Electrical Specifications Plate PAPER ELECTRICAL FILTER PLUG FIGURE 1 8 Coolant Reservoir FIGURE 1 9 Coolant Nozzles ELECTRICAL CONNECTION Connect incoming Electrical Supply Cord not supplied to the Machine as follows see Figures 1 10 amp 1 11 NOTE 380V machines require a 12 4 SJO or SO electrical supply cord 460V machines require a 4FJ2 4SJO or SO electrical supply cord CAUTION Doors should be closed and latched during operation to prevent accidental interruption of operation from doors being opened 1 If applicable Loosen Safety Latches on door s to enclosure using a screwdriver and open Door WARNING Residual Voltage exists for 2 3 minutes after Master ON OFF Switch is turned OFF Before working inside Enclosur
37. cessive stone feed up A Decrease cutting pressure 2 2 Inadequate spindle speed A Increase spindle speed 2 3 Improper stone A Use harder stone B Use coarser stone 4 Improper or dilute coolant A Check coolant Bellmouth 1 Too much overstroke A Decrease overstroke 2 Improper stone A Use softer stone Barrel 1 Overstroke to short A Increase overstroke 2 Improper stone A Use finer stone Taper in Open Hole 1 Improper stroke A Lengthen overstroke on tight end 2 Stroker Arm and Spindle not aligned A Align Stroker Arm and Spindle Taper in Blind Hole 1 Improper stone length A Shorten stone and shoes to 3 4 Machine NOTE Many honing problems such as poor stone life and rough finish are caused by wrong coolant insufficient coolant dirty coolant or contaminated coolant Use ONLY clean Sunnen Industrial Honing Oils or Water Based Coolant Make sure that coolant is neither diluted nor cut with other coolants Keep solvents and cleaning fluids away from 21 PROBLEM PROBABLE CAUSE SOLUTIONS SEC Out Of Round 1 Undersize honing tool A Change honing tool 2 2 Fixture too tight A Loosen workpiece holding fixture 3 Mandrel not true A True stone amp shoes 4 Workpiece flexing thinwall A Decrease cutting pressure 2 5 Improper stone A Use softer stone Rough Finish 1 Improper feed A Decrease cutting pressure 2 2 Improper stone A Use finer stone 3 Improper or diluted coolant A Check coolant 4
38. e 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 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 Installation Wiring separation of power amp control wire wire type class used distance between drive and motor grounding 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 available at hitp www
39. e wait for all fans to stop running to allow drives to discharge 2 The machine has been shipped without the master ON OFF switch install Locate master ON OFF switch in base of electrical enclosure Then install Master ON OFF Switch in Door and secure with two screws WARNING You must use hole provided Drilling any new holes in electrical enclosure may void machine warranty 3 Route Electrical Supply Cord to Electrical Enclosure refer to Figure 1 10 4 Remove hole plug from entrance hole in enclosure and install an approved oil tight fitting not supplied 5 Insert Electrical Supply Cord through Oil Tight Fitting and route to Electrical Disconnect Block Allow for approximately 305 mm of cable from where it enters Enclosure then cut off excess refer to Figure 1 11 6 Strip 153 mm 6 in off cable s outer jacket MASTER ON OFF SWITCH NAMEPLATE ELECTRICAL DISCONNECT BLOCK ELECTRICAL DISCONNECT BLOCK PRE DRILLED HOLE FIGURE 1 11 Electrical Enclosure COMMON PLUG E STOP CABLE 4100 E STOP HTA4100 SENDER UNIT LIGHTS Floating Blanking Light indicates that one or more of the beams Receiver has been deactivated This light should not be illuminated If it is contact a Sunnen representative for repair Light indicates the protected machine is allowed to op
40. een 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 sensi tive 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 and tear belts fu
41. electrical supply cord where they connect to Disconnect Block 2 Set up and test all machine functions refer to Section 3 Setup amp Operation 3 After unpacking and installing Machine clean and lubricate refer to Section 4 Routine Maintenance NOTES SECTION 2 PREPARING FOR OPERATION GENERAL HONING TOOL Consult this section when preparing Machine for Assembly and install Honing Tool per instructions operation packaged with Tooling MAJOR COMPONENTS 1 Assemble Honing Tool see Figure 2 3 pss m of major components on machine see NOTE The HTA is designed to use both ANR and igure 2 I MPS driveshaft extensions ANR shafts are designed OPERATOR CONTROLS to bolt together and MPS shafts are designed to screw For location and function of Operator Controls see together Thus when using ANR Tooling on a MPS Figure 2 2 amp Table 2 1 Driveshafts a MPS2220A Output Adapter must be used refer to Figure 2 3 SAFETY SYMBOLS For a description of safety symbols that may be 2 Guide Honing Tool into the bore used on this machine refer to Table 2 2 3 Align Input Yoke Adapter on Honing Tool with Drive Ring and guide adapter onto Hex Shaft see Figure 2 4 SPLASH GUARDS OPERATOR CONTROL CONSOLE FEED CLUTCH HANDWHEEL WORKPIECE COOLANT BASE RESERVOIR ELECTRICAL EN
42. erate Machine Run Receiver Machine Stop Receiver Light indicates the protected machine is not allowed to operate Interlock Light indicates the protected machine is not Receiver allowed to operate until the protected zone is cleared and the start button is pressed and released Status Indicator Transmitter Indicates the light curtain is functional FIGURE 1 13 Light Curtain 7 Strip 6 mm 1 4 in of insulation off each wire 8 Connect Green Wire GRN to Ground Terminal beside Electrical Disconnect Block Earth Ground 9 Connect other three wires to Disconnect Block as noted on Block 1 1 L2 1 3 10 Route and secure Cord inside of Enclosure 11 Tighten Oil Tight Fitting 12 Close and secure lock Door to Enclosure Doors WILL NOT open unless Master ON OFF Switch is in OFF position 13 Route and connect Electrical Supply Cord to power source PLUG Machine s Electrical Supply Cord into a properly polarized grounding type wall receptacle 14 Turn ON Master ON OFF Switch Doors WILL NOT open unless Master ON OFF Switch is in OFF position SAFETY ARCH Machine comes with a Safety Arch Assembly attached to the Workpiece Base The Safety Arch Assembly has a Switch that detects when the arch is opened This Switch is prewired to be connected to the Main Electrical Enclosure and is assembled on Safety Arch Install Arch as follows see Figure 1 12 1
43. his equipment Installation amp Maintenance death always disconnect the main A A Contact with electrical components Work Area WARNING O DOE injuries occur a result of using air pressure at the nozzle must be below 205 kPa 30 pressurized air Maximum psi for cleaning purposes Wear protective clothing protective glasses and a protective face shield when using pressure air Clean up all leaked or spilled oil c immediately Oil leaked or spilled onto any hot surfaces or electrical components can cause a fire resulting in personal injury or death DO NOT operate machine while lifting devices are installed Ensure workpiece is securely fixtured and located before operating Ensure all guards are in place before operating Ensure area is clear of other personnel before operating machine When lifting part or tooling use proper lifting procedures DO NOT overreach keep proper footing and balance at all times Remove keys and wrenches from machine before honing Personal injury can result from slips or falls DO NOT leave tools or components laying around the work area and clean up all spilled fluids immediately Operation WARNING DO NOT wear loose clothing SS jewelry watches gloves or anything else that might catch on any part of the machine Push E STOP Button and turn OFF electrical power at Disconnect Switch on Electrical Enclosure when preforming
44. ll not be damaged or be made unsafe by any operation lubrication maintenance or repair procedures that you choose If any doubt arises about the correct safe method of performing any steps of these procedures DO NOT proceed Seek out expert assistance from a qualified person General WARNING To avoid personal injury or death carefully read and understand all instructions before attempting to operate any equipment DO NOT operate or work on a machine unless you read and understand the instructions and warnings in this and all other applicable manuals Go online to www sunnen com or contact Sunnen for replacement manuals Proper care is your responsibility Always follow all State and Federal health and safety laws and or local regulations Keep all visitors a safe distance from work area DO NOT use in dangerous environment DO NOT use machines in damp or wet locations or expose them to rain Keep work area well lighted Keep fingers away from any moving parts or pinch points to prevent pinching and crushing Wear proper safety items such as safety glasses gloves non slip safety shoes and other personal safety equipment as necessary or required WARNING To prevent personal injury or electrical power source before opening the electrical control box may cause injury or death Completely disconnect the main power remove all jewelry and use properly insulated tools when working on t
45. o 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 subsequent 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 true the above limitations
46. onal Division Fax 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 http www sunnen com PRINTED IN U S A 1301 Fax 314 781 2268 314 781 6128 e mail sunnen sunnen com 16 2719 1 062500 26 9880 MULTIPLY BY TO GET MILLIMETERS mm x 0 03937 INCHES in METERS m x 8281 FEET ft SWITZERLAND SUNNEN AG 41 71 649 33 33 Fax 41 71 649 34 34 sunnen ch e mail info sunnen ch SUNNEN ITALIA S R L Phone E oe 383 au 1 Fax 39 02 383 417 50 v sunnenitalia e mail sunnen sunnenitalia com RACES San SAS one 01 69 30 0000 33 01 69 30 1111 yv f e mail info 9 sunnen fr BELGA pum BeneLux BVBA Phone 32 38 80 28 00 Fax 32 38 44 39 01 www sunnen be e mail info sunnen be UK SUNNEN Products LTD Phone 44 1442 39 3939 Fax 44 1442 39 12 12 v sunnen co uk e mail hemel sunnen co uk Porann SUNNEN POLSKA Sp 2 0 0 Phone 48 814 3429 Fax 48 22 814 34 28 e mail sunnen Rus 8 5 7 295 258 43 43 Fax 7 495 258 91 75 u e mail sunnen sunnen russia ru UBLIC SUNNEN S R O 220 383 376 317 Fax 420 383 376 316 e mail sunnen sunnen cz IANGHAI SUNNEN MECHANICAL CO LTD 21 5813 3322 Fax 86 21 5813 2299 nsh com e mail shsunnen sunnensh com
47. ons CE Machines ONLY 6 rar FIGURE 1 16 Light Curtain WARNING When light curtain key switch is deactivated a cycle cannot begin however if machine is in middle ofa cycle and switch is flipped machine will finish its stroke in that cycle and then come to a complete stop 1 Interrupt light curtain system with proper size test object Test object size 30 mm diameter When using the test object guide it through the detection zone as shown below At least one individual beam indicator must be lit while test object is anywhere in detection zone 2 Start machine While machine is in motion interrupt detection zone with test object Machine should stop immediately Never insert test object into dangerous parts of machine 3 With machine at rest interrupt detection zone with test object Verify that machine will not start with test object in detection zone 4 Verify that braking system is working properly Machine must come to a quick controlled stop when light curtain is interrupted Drive faults spindle coasting and stroker coasting are unacceptable OPERATIONAL CHECK Read IOM Instructions Sections 1 and 2 thoroughly and carefully before performing Operational Check 1 Operate Machine and check rotation of Coolant Pump Rotation is indicated on pump fan cover If rotation is incorrect reverse any two wires red white or black of
48. ree cloth Painted light curtain surfaces may be cleaned with a mild de greasing cleaner or detergent GENERAL This section contains Troubleshooting information in table form which should be used when problems SECTION 5 TROUBLESHOOTING OPERATIONAL TROUBLESHOOTING occur with machine The table lists problems encountered possible causes and solutions for problems along with reference to section of manual where detailed instructions may be found to correct problems TABLE 5 1 Operational Troubleshooting Index For suggestions on correcting problems with bore conditions or with honing operation consult Table 5 1 Inadequate oil flow Inadequate relief in blind end length of bore True stone amp shoes frequently Adjust Oil Nozzle Provide sufficient relief Short stroke tight end Use hard tip stone PROBLEM PROBABLE CAUSE SOLUTIONS SEC Stone not cutting 1 Stone Glazing A Dress stone B Increase cutting pressure C Increase stroking speed D Use softer stone E Check coolant 4 2 Stone Loading A Dress stone B Increase stroking speed C Use softer stone D Use coarser stone E Check coolant 4 Slow stock removal 1 Improper spindle speed A Increase spindle speed 2 Inadequate stone feed up A Increase cutting pressure 3 Improper stone A Use softer stone B Use coarser stone 4 Improper or diluted coolant A Check coolant Poor stone life 1 Ex
49. roke 15 16 17 18 19 20 Press COOLANT OFF button 22 23 24 25 26 27 28 29 Rotate Handwheel until all the stones contact the bore wall Retract the stones slightly Press Teach End Of Stroke button Set end SAFETY SWITCH ACTIVATOR Use JOYSTICK to set start of Workpiece overstroke Press Teach End Of Stroke button Set end SAFETY SWITCH ACTIVATOR Position Coolant Nozzle Open the Flow Control Valve Press COOLANT ON Button Install and position Splash Guards Set the COOLANT and FEED to AUTO Set Feed Clutch value Set STROKER to AUTO mode Press Cycle START Button Install and position Splash Guards When feed is in AUTO mode honing Tool will continue to feed until Honing Cycle Time reaches zero 0 at which time the Honing Cycle ends Retract stones slightly Slide Honing Tool out of Bore 23 NOTES 24 APPENDIX B CROSSHATCH ANGLE 30 tg 15 0 2679 CROSSHATCH ANGLE 45 tg 22 5 0 4142 60 tg 30 0 5774 90 tg 45 CALCULATING 1 0 ANGLE 60 2 30 EXAMPLE TO CALCULATE OK ARE Bore Diameter 100 RPM 175 Crosshatch 60 PR RAS RRL KERR RER M RK RES NM ODO SARK KS ON X YS rr ere
50. ry fulfils all relevant provisions of the following EU Directives 2006 42 EG 2006 05 17 EU Machinery Directive 2006 42 EG 2006 95 EC 2006 12 12 Voltage limits Directive of the European Parliament and of the council of 12 December 2006 on the harmonization of the laws of Member States relating to electrical equipment designed for use within certain voltage limits codified version 2004 108 EC 2004 12 15 Directive 2004 108 EC of the European Parliament and of the Council of 15 December 2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility and repealing Directive 89 336 EEC Reference to the harmonized standards used as referred to in Article 7 2 EN 349 1993 04 Safety of machinery minimum gaps to avoid crushing of parts of the human body EN ISO 12100 1 2003 11 Safety of machinery Basic concepts general principles for design Part 1 Basic terminology methodology EN ISO 12100 2 2003 11 Safety of machinery Basic concepts general principles for design Part 2 Technical principles EN ISO 13850 2006 11 Safety of machinery Emergency stop Principles for design EN 18013857 2008 03 Safety of machinery Safety distances to prevent hazard zones being reached by upper and lower limbs EN ISO 14121 1 2007 Safety of machinery Risk assessment Part 1 Principles 1EC60204 1 2005 A1 Safety of machinery Equipment electrics of the machines Part 1 General rules EN 60439 1 19
51. se has one E Stop that must be connected to Carriage Base E Stop cable will be routed and connected later under Safety Arch Installation 10 Remove all packing materials 11 Remove bolt securing Operator Control Console and move Arm to operator position Then install grub screw to limit arm movement see Figure 1 6 Route and connect electrical plug to Main Electrical Enclosure 12 Remove packing material from two 2 Splash Guards on Machine see Figure 1 7 LEVELING BOLT 1 1 8 amp LOCKNUT FIGURE 1 4 Leveling Screws REFER TO SPECIAL INSTRUCTIONS FOR INSTALLING COVER PLATE SAFETY ARCH E STOP FIGURE 1 5 Cover Plate HTA 4100 ONLY OPERATOR CONTROL CONSOLE FIGURE 1 6 Operator Control Console SPLASH GUARD EN JF FIGURE 1 7 Splash Guard 13 Install coolant reservoir under machine and connect coolant hoses see Figure 1 8 Connect coolant intake and outlets supply lines to machines Route and connect Pump Electrical Plug to Main Electrical Enclosure 14 Check Coolant Nozzles see Figure 1 9 15 Clean Spindle Carriage Ways with solvent to remove antirust and any foreign materials 16 After cleaning Spindle Carriage Ways Lightly lubricate with Mobil Way Oil 300 or equivalent ELECTRICAL REQUIREMENTS wiring is to be performed by a competent Licensed Electrician in accordance with all lo
52. ses 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 RFI 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 Use of non SPC machines tooling abrasive fixturing coolant repair parts or filtration Incorrect software installation and or misuse gt Non authorized customer installed electronics and or software gt 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 LOSS OF USE REVENUE OR PR
53. ue to unthread Yoke from Coupler 5 8 inch right hand threaded connection 2 Rebuild or replace Handwheel as required 3 Inspect Armature Resurface or replace Armature as required 4 Reassemble Feed Control in reverse disassembly order FEED CLUTCH Periodically inspect the Feed Clutch for signs of slippage wear or damage the gears can strip when system is overfed If wear slippage or other damage is observed proceed as follows see Figure 4 7 1 Turn OFF power to Machine at Master ON OFF Switch on Electrical Enclosure and install Lock Out Tag 2 Remove any tooling connected to Spindle Drive Motor 3 Remove four 4 Socket Head Capscrews securing Feed Clutch to Handwheel 4 Rebuild or replace Feed Clutch 5 Attach Feed Clutch to Handwheel using four 4 Capscrews removed in step 3 20 que FEED CLUTCH HANDWHEEL CAPSCREW WA FEED LT CLUTCH y FIGURE 4 7 Feed Clutch FEED CLUTCH 6 Installation is now complete Power to machine may be turned ON OPTIONAL LIGHT CURTAIN CLEANING CE Machines Only Accumulation of oil dirt and grease on the front filter of the light curtain transmitter and receiver can affect the system operation Clean filters with a mild detergent or glass cleaner Use a clean soft lint f
54. uring the first few roughing strokes 20 Install and position Splash Guards 200 8 88 20 TOi For finishing use Feed Setting of 305 12 55 20 75 15 to 20 21 Setthe COOLANT and FEED to AUTO if Ad aee desired otherwise manual operation can be used TABLE FASE ana 22 Set Feed Clutch value as desired The setting oinmm RPM oinmm RPM oinmm RPM should be high enough that the clutch cycles on and under 40 430 155 118 360 48 off and is not constantly on see Tables 3 1 amp 3 2 45 388 160 110 380 46 50 350 165 106 400 44 IMPORTANT 55 318 170 103 425 41 5 60 292 175 100 450 36 If the clutch is constantly feeding it will become hot 65 270 180 97 475 37 and reduce the life of the clutch 70 250 185 95 500 35 E 233 130 92 525 53 23 Set STROKER to AUTO mode 80 219 195 90 550 31 206 200 Sie 3n 24 Press Cycle START Button to initiate a Honing 90 195 210 84 600 29 Cycl 100 175 220 80 625 28 ycie 105 167 230 76 650 27 When feed is in AUTO mode honing Tool will 110 160 240 73 675 26 250 38 a 55 continue to feed stones out to maintain spindle 120 146 260 67 725 24 load until Honing Cycle Time reaches zero 0 at 125 140 270 65 750 23 which time the Honing Cycle ends 130 135 280 63 800 22 138 156 SU S50 21 Pressing Cycle Stop Button will stop the cycle when 140 125 300 58 900 20 the stroker reaches the left end of the stroke 145 121 320 55 950 18 5 150 117
55. ushings are equipped with a grease fitting block Daily apply 1 pump of Mobilith AW 1 to each fitting see Figures 4 4 amp 4 1 Set up machine to stroke the full length of the machine stroke at 5 fpm for 10 minutes 2 SPINDLE DRIVE GEARBOX Optional Change ISO 220 EP mineral oil every 10000 hrs or 3 years whichever comes first NOTE Every 20000 hrs or 6 years if a synthetic lubricant is used Oil should be changed more frequently if used in hostile environment Siphon out old oil then fill with fresh ISO 220 EP mineral oil or its equivalent see Figures 4 4 amp 4 2 Capacity of the Spindle Drive Gearbox is 0 5 Liters 1 1 pint 3 STROKER DRIVE BELT Daily apply 1 pump of Mobilith AW 1 to fitting see Figures 4 4 4 STROKER GEARBOX Gearbox is a sealed and maintenance free a DRAIN FILLER PLUG Y 7 Hi IN PA mu DRAIN FIGURE 4 2 Gearbox Optional COOLANT LINES CHECK MONTHLY Trace out grease and oil Lines and inspect for leaks severe dents or kinks Proceed as follows Trace out the location of each grease and oil line Fitting and check for leaks Tighten any leaking Fittings and replace damaged parts COOLANT RESERVOIR Clean Coolant Reservoir and replace Coolant as follows using only Sunnen Industrial Honing Oil see Figure 4 3 1 Direct one or more Coolant Nozzles into an approved waste container 2 Open Coolant Control
Download Pdf Manuals
Related Search