installation instructions
Contents
1. 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 exclusive right without2. rear of the Feed Control Console see Figure 5 e PL6 Motor Cable 4 Pin Connector is for the Remote Feed Unit e PL7 Control Cable Pin Connector is for control signal output Machine s Main Electrical Control Panel e PL8 Used with MIPS 11 ONLY Transducer Cable 4 Pin Connector is for the Hydraulic Pressure Transducer FEED pu CONTROL CONSOLE F 9 PIN CONNECTOR CONTROL CABLE MACHINE S CONTROLS 4 PIN CONNECTOR MOTOR CABLE REMOTE FEED UNIT MPS 11 ONLY 4 PIN CONNECTOR HYDRAULIC PRESSURE TRASDUCER FIGURE 1 5 Feed Control Console REMOTE FEED UNIT CONNECTION Route Motor Cable between Feed Control Console and Remote Feed Unit Attach to 4 Pin Connector on Remote Feed Unit refer to Figure l 4 NOTE Ensure cable is free to move with the stroking action of the machine INSTALLING TRANSFORMER OR TRANSDUCER l Install Current Transformer see Appendix A on machines equipped with electric spindle drive motors or a Hydraulic Pressure Transducer see Appendix B on machines equipped with hydraulic spindle drive motors Appendix A Current Transformer Electric Spindle Drive Motor Appendix B Hydraulic Pressure Transducer Hydraulic Spindle Drive Motor 2 Route the Control Cable to the Machine s Main Electrical Control Panel NOTE Use Cord Connector where cable enters the panel to provide an oil tight connection WIRING OPTION
3. 85 10 80 10 90 FOR FAST STOCK REMOVAL INCREASE SPEED IF STONES WAEAR RAPIDLY 1 REDUCE FEED 2 USE HARDER STONES IF FEED IN PROGRESS LIGHT IS ON CONTINUALLY AND SPINDLE LOAD DECREASES 1 INCREASE FEED 2 DRESS STONES 3 USE SOFTER STONES SPINDLE LOAD METER FEED IN PROGRESS BUTTON LIGHT E STOP BUTTON RAPID FEED SWITCH HONING CYCLE MPS 11 ONLY SPINDLE SPEED SELECTOR SWITCH POWER ON OFF SWITCH FIGURE 2 1 Feed Control Console A CURRENT TRANSFORMER INSTALLATION INSTRUCTIONS FOR MACHINES EQUIPPED WITH ELECTRIC SPINDLE DRIVE MOTORS Install Current Transformer in Machine s Main Electrical Control Panel as follows using Ring Connectors see Figure A WARNING Turn electrical power off at main buss box or main power source when performing any maintenance on machine electrical system 1 Wrap Primary Winding on Current Transformer per Table A 1 NOTE The Zero Adjustment should be checked whenever there is a change in thenumber of turns on the Current Transformer 2 Connect two 2 Black Wires of Primary Winding in series with one phase of the Electrical Supply Voltage to the Spindle Drive Motor 3 Place Current Transformer in bottom of control panel 4 Place Currrent Transducer in bottom of control panel 5 Connect the White Wire MPS Control Cable to Terminal 1 on the Current Transducer 6 Connect t
4. Light should now be lit on Feed Control Console 13 Turn and hold the RAPID FEED Switch to EXPAND until all the stones contact the bore wall Shaking the honing tool shaft keeps the hone from binding in the bore while the stones are being fed out 14 Retract the stones slightly by turning RAPID FEED Switch to RETRACT Starting the hone with the stones pressed tightly against the bore wall would produce unnecessary stone wear CAUTION The STOP Button on Feed Control Console STOPS BOTH machine and feed functions refer to Figure 3 3 After STOP Button has been pressed it must be rotated counterclockwise before the machine and feed functions can be restarted 15 Press START Button If wired as Master Control Depress Start Button on Feed Control Console If wired as Slave Control Depress Start Button on Machine s Controls 12 TABLE 2 2 Spindle Speed Selector Switch TO COMPENSATE FOR PRESSURE CHANGES AT VARIOUS SPINDLE SPEEDS A SPINDLE SPEED SELCTOR SWITCH HASE BEEN INCOR PORATED INTO THE MPS 11 POSITION SWITCH AS FOLLOWS SPINDLE SPEED SWITCH POSITION BELOW 150 RPM 1 LOW 150 TO 275 RPM 2 MED ABOVE 275 RPM 3 HIGH REMOTE FEED wee UNIT INPUT YOKE gt ADAPTER FIGURE 3 2 Tool Installation TABLE 2 2 Spindle Speed Selector Switch DIAMETER SPINDLE ROUGH NORMAL BORE inches rpm BORE Clean Up 2 400 10 50 3 270 10 60 4 200 10 70 5 160 10 75 6 130 10 80 8 100 10
5. STOP Button or the Machine s STOP Switch will stop all machine and feed functions MACHINE CONTROL CIRCUIT TYPICAL 3 WIRE CONTROL MPS CONTROL START IPB o CYCLE E STOP START i z J TIMER CONTROLS T o RELAY 1CR2 MAX SIZE 6 0 AMPS CONTROL CIRCUIT FUSE HONE START ob RELAY ih oO 1CR2 OR TEN K eK oto PL7 7 amp 0 LOAD METER CIRCUIT SPINDEL MTR By starter FOR ELECTRICAL SPINDLE MOTOR CONTROL FUSE MAX SIZE 6 0 AMPS ir PL8 3 eli G eg MAX CONTACT RATING PRESSURE TRANSDUCER N PL8 1 1CR1 6 0 AMPS SPINDLE 1CR2 6 0 AMPS E STOP 6 0 AMPS FOR HYDRAULIC SPINDLE MOTOR FIGURE 1 8 Wiring Option 2 6 SECTION 2 PREPARING FOR OPERATION MAJOR CONTROLS For location of controls see Figure 2 1 for the function of the controls refer to Table 2 1 GENERAL This section is designed to aid the user in making adjustments to the Modular Power Feed System before the System and the Machine can be operated TABLE 2 1 Control Functions HONING CYCLE FEED SPINDLE SPEED Indicating Light Selector Knob Selector Switch Three Position NOMENCLATURE DESCRIPTION FUNCTION SPINDLE LOAD Meter Indicates the percentage of spindle load produced HONING TIME Timer Sets the length of the honing cycle Automatically stops all machine and fee
6. Set Machine s Stroke Stops to shortest distance 7 Turn OFF oil supply to Oil Nozzle 8 Rotate STOP Button to ensure it is not in the lock position 9 Depress START Button e Master Control Depress Start Button on Feed Control Console Honing Timer must be set for unit to operate e Slave Control Depress Start Button on Machine s Controls 10 Depress STOP Button on Feed Control Console BOTH the Machine and the Modular Power Feed System should STOP operating 11 Loosen two 2 Screws securing Feed Control Console Door 12 Turn RAPID FEED Switch to EXPAND see Figure 2 2 Shaft on Remote Feed Unit should rotate counterclockwise when looking into Remote Feed Unit If rotation is incorrect proceed as follows e Open Door on Feed Control Console e Reverse blue wires at terminals 8 and 5 on Terminal Block TB2 inside of the Feed Control Console e Close Door and recheck rotation 13 Move JUMPER to Position 1 refer to Figure 2 2 Use Position 2 ONLY if latching contact is not used in Option 1B NOTE Position 1 is for External Hold and Position 2 is for Self Hold refer to Figure 2 2 Zero L E D Adjustment Adjust Zero LED as follows see Figure 2 3 1 Remove any tooling from Remote Feed Unit 2 Set the Spindle Motor rpm at approximately mid range under a no load condition 3 Set Stroke Speed to slowest rate co TERMINAL BLOCK TB2 RAPID FEED SWITCH JU
7. and inspect for signs of damage resulting from the improper handling by carrier If damage is evident immediately file a claim with the carrier WARNING Turn electrical power off at main buss box or main power source when performing any maintenance on machine s electrical system INSTALLING SPINDLE NOSE ADAPTER The following procedure is for installing Spindle Nose Adapters see Figure 1 2 on machines equipped with 32mm or 40mm drive shafts see step 1 or on machines equipped with 4 or 5 Morse Tapered Drive see step 2 Consult your local Sunnen Field FIGURE 1 1 Modular Power Feed System Engineer if your machine drive assembly differs from the following SPIND HUB SCREW ae CAP FLATHEAD SHOULDER BOLT ai Pa G Ms Me INPUT a REMOTE FEED UNIT SIN DISASSEMBLY RING Y DLE i TORQUE A No AS DA Pres SE BRACKET FIGURE 1 2 Remote Feed Unit 4 7 SPINDLE MOTOR SHAFT SPINDLE SHOULDER RING FIGURE 1 3 Remote Feed Unit STEP 1 Spindle Nose Adapter 32 40mm e Align Keyway in Input Hub with the key on the Spindle Motor Shaft and slide hub onto shaft e Place Hub Screw Cap chamfer side out on end of Input Hub and secure with Flathead Bolt to Spindle Motor Shaft Tighten bolt 30 to 40 ft lbs 40 50 newton meters until hub is firmly seated against Spindle Shoulder STEP 2 Spindle Nose A
8. 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 and tear belts
9. 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 true the above l
10. while working on or around power stroked honing machines e Ensure all guards are in place before operating e Keep machine clear of tools or other foreign objects e Wear proper safety items such as safety glasses gloves non slip safety shoes and other personal safety equipment as necessary or required DO NOT wear loose clothing or jewelry while working on or around machine e Keep area around machine free of paper oil water and all other debris at all times e When lifting workpiece or tooling use proper Turn OFF electrical power at Electrical Control Enclosure Disconnect Switch when performing service not requiring power e Turn OFF electrical power at Main Power Source when performing maintenance on or cleaning of Electrical Control Enclosure DO NOT adjust stroke length while honing e Stay clear of all moving parts SETUP 8 OPERATION TYPICAL 1 Position workpiece so centerline of bore is in approximate alignment with center line of spindle motor shaft see Machine s Operating Instructions 2 Assemble the Sunnen Wide Range Power Honing Tool according to Installation Instructions packaged with tool see Figure 3 1 3 Slide Input Yoke Adapter onto the Hex Shaft of the Remote Feed Unit Turn Adapter to ensure it locks onto Pins in the Drive Ring see Figure 3 2 4 Slide Universal Cover over Input Yoke Adapter 5 Adjust Stroke Stops see Machine s Operating lifting procedure Instruct
11. www 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 on 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
12. 23 0188 23 4156 196850 5 0000 9 16 562500 14 2875 937500 23 8125 203125 5 1594 37 64 578125 14 6844 944882 24 0000 218750 15 64 234375 5 5563 5 9531 590551 19 32 593750 15 0000 15 0813 953125 968750 24 2094 24 6063 236220 6 0000 39 64 609375 15 4781 984252 25 0000 1 4 250000 6 3500 5 8 625000 15 8750 984375 25 0031 17 64 265625 6 7469 629921 16 0000 1 000000 25 4000 re 275591 FORMULAS MULTIPLY INCHES in FEET ft 7 0000 41 64 640625 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 0907 z SUNNEN SUNNEN PRODUCTS COMPANY 7910 Manchester Road St Louis MO 63143 Phone 314 781 2100 Fax 314 781 2268 U S A Toll Free Sales and Servic
13. 2500 7 9375 671875 17 0656 015625 0 3969 314961 8 0000 687500 17 4625 015748 0 4000 21 64 328125 8 3344 703125 17 8594 019685 0 5000 11 32 343750 8 7313 708661 18 0000 023622 0 6000 354331 9 0000 718750 18 2563 027559 0 7000 23 64 359375 9 1281 734375 18 6531 031250 0 7938 3 8 375000 9 5250 748031 19 0000 031496 0 8000 25 64 390625 9 9219 750000 19 0500 035433 0 9000 393701 10 0000 765625 19 4469 039370 046875 1 0000 1 1906 13 32 27 64 406250 421875 10 3188 10 7156 781250 787402 19 8438 20 0000 062500 1 5875 433071 11 0000 7196875 20 2406 078125 1 9844 7 16 437500 11 1125 812500 20 6375 078740 093750 2 0000 2 3813 29 64 15 32 453125 468750 11 5094 11 9063 826772 828125 21 0000 21 0344 109375 2 7781 472441 12 0000 843750 21 4313 118110 3 0000 31 64 484375 12 3031 859375 21 8281 125000 140625 3 1750 3 5719 1 2 500000 511811 12 7000 13 0000 866142 875000 22 0000 22 2250 156250 3 9688 33 64 515625 13 0969 890625 22 6219 157480 4 0000 17 32 531250 13 4938 905512 23 0000 171875 187500 4 3656 4 7625 35 64 546875 551181 13 8906 14 0000 906250 921875
14. I MPS 110D A SUNNEN Installation Setup and Operation INSTRUCTIONS for SUNNEN MODULAR POWER FEED SYSTEMS Model MPS 10 amp MPS 11 READ THE FOLLOWING INSTRUCTIONS THOROUGHLY AND CAREFULLY BEFORE UNPACKING INSPECTING OR INSTALLING THE SUNNEN MODULAR POWER FEED SYSTEMS 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 operation and mainten
15. MPER POSITION 2 POSITION 1 FIGURE 2 2 Feed Control Console Internal View 8 4 Set Machine s Stroke Stops to shortest distance 5 Turn OFF oil supply to Oil Nozzle t Turn STOP Button to ensure it is not in the lock position 6 Depress START Button e Master Control Depress Start Button on Feed e Control Console Honing Timer must be set for unit to operate e Slave Control Depress Start Button on Machine s Controls ADJUSTMENT POTENTIOMETER ZERO LED FIGURE 2 3 Zero LED Adjustment WARNING TAKE NECESSARY PRECAUTIONS TO PREVENT ELECTRICAL SHOCK WHILE COMPLETING ZERO ADJUSTMENT CONTROL IS WIRED AT 115 VOLTS 7 Open Door to Feed Control Console 8 Turn Zero Adjustment Potentiometer until Zero L E D begins to blink flicker e Adjust clockwise if Zero L E D is not on e Adjust counterclockwise if Zero L E D is on continuously NOTE When setting the Zero Adjustment the Hydraulic Sensitivity Adjustment SHOULD be adjusted to approximately its mid range setting refer to step 8 and Figure 2 4 9 Depress STOP Button on Feed Control Console 10 SHUT OFF power to the Modular Power Feed System and the Machine Calibration MPS 11 Only Spindle Load Meter Calibration for machines with hydraulic spindle drive motors 1 Install a Hydraulic Pressure Gage in the Hydraulic Supply Line to the Spindle Motor 2 Operate the machine under a no loa
16. NERAL INFORMATION amp SPECIFICATIONS Sunnen Modular Power Feed System MODEL MPS 10 MPS 11 Electrical Requirements 115 V 60 Hz 1 Ph 115 V 50 60 Hz 1 Ph Color Pearl Gray Pearl Gray INTRODUCTION This Instruction Manual is provided to give the information required to install and operate the Sunnen Modular Power Feed System Model MPS 10 is designed for power stroked machines equipped with electrl c spindle drive motors Use Appendix A with the following instructions Model MPS 11 is designed for power stroked machines equipped with hydraulic spindle drive motors Use Appendix B with the following instructions When ordering parts for or requesting information about your Unit include the model and serial numbers of your Machine READ THE FOLLOWING INSTRUCTIONS THOROUGHLY AND CAREFULLY BEFORE UNPACKING INSPECTING OR INSTALLING SUNNEN MODULAR POWER FEED SYSTEM vi SECTION 1 INSTALLATION GENERAL SUGGESTED TOOLS amp MATERIALS This section is designed to aid the user in unpacking The following tools and materials are suggested for inspecting and installing of Sunnen MPS Modular installing the Sunnen Modular Power Feed System Power Feed Systems Models MIPS 10 and MPS 11 Wire Cutters Strippers see Figure l l Screw Driver Std amp Jewelers Hex Key 1 8 amp 1 4 Slip Joint Pliers Small Nose Open End Wrench 7 1 Electrical Tape UNPACKING amp INSPECTING Unpack Modular Power Feed System
17. S When connecting cables to the Machine s Main Electrical Control Panel refer to the Wiring Diagram included in this instruction package The Feed Control Console can be wired for one of two modes of operation In either mode the STOP Button on the Feed Control Console is fully functional and will stop all machine and feed functions when depressed The modes are as follows MASTER CONTROL MODE Wiring Options 1A and 1B allow the Feed Control Console to control BOTH machine and feed functions Honing Cycle Start Button is used to start both machine and feed functions Honing cycle stops when Honing Timer times out when STOP Button is depressed or when Machine s Stop Button is depressed See step 1 Wiring Option 1A when control circuit exists on the machine or step 2 Wiring Option 1B when NO control circuit exists on the machine SLAVE CONTROL MODE Wiring Option 2 see step 3 allows the Machine s Controls to control BOTH machine and feed functions The feed cycle is started and stopped in conjunction with the machine s spindle from an auxiliary contact signal from the machine The Honing Cycle START Button and Honing Timer on the Feed Control Console are not functional in this mode NOTE The System requires 115V 1 Ph input Two optional Transformers are available from Sunnen PEM 516A Domestic PEM 517A Export 208 230 460V Primary 220 380 440V Primary 115V Secondary 115V Secondary 250 Volt Amps 250 Volt Amp
18. S SPINDLE SPEEDS A SPINDLE SPEED SELCTOR SWITCH HASE BEEN INCOR PORATED INTO THE MPS 11 POSITION SWITCH AS FOLLOWS SPINDLE SPEED SWITCH POSITION BELOW 150 RPM 1 LOW 150 TO 275 RPM 2 MED ABOVE 275 RPM 3 HIGH NOTE The Hydraulic Sensitivity Adjustment SHOULD be adjusted to approximately its mid range setting It SHOULD NOT be in its fullv counter clockwise setting refer to Figure 2 5 9 Turn the Sensitivity Adjustment Screw inside the Feed Control Console until Spindle Load Meter reads 100 at the calculated OPERATING PRESSURE refer to Figure 2 5 10 Check and readjust Zero L E D Adjustment as necessary 11 SHUT OFF power to the Machine and the Modular Power Feed System 12 Set RED Cycle Switch on rear of Honing Timer to 50 Hz or 60 Hz as required NOTE Switch is located on the lower right rear of Timer below point where wires are connected 13 Close Door to Feed Control Console and secure by tightening two 2 Screws f j j s4 q ED FIGURE 2 5 Feed Control Console Internal View SECTION 3 SETUP amp OPERATION GENERAL This section describes setup and operating procedures for the MPS 10 and MIPS 11 Prior to operating the Modular Power Feed System the Operator should ensure that all adjustments described in Section II are complete SAFETY PRECAUTIONS The following precautions should be followed to ensure maximum safety of personnel
19. ance 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 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 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 available at htip
20. d condition with no tooling installed refer to Section IIT Setup and Operation SIN TZ Y 3110 Q SPINDLE SPEED SELECTOR e SWITCH J INCREASE SENSITIVITY ADJUSTMENT SCREW FIGURE 2 4 Feed Control Console Internal View 3 Adjust the spindle speed to approximately 150 rpm 4 Measure the hydraulic pressure in the supply line to the Spindle Motor 5 Calculate the OPERATING PRESSURE adjusted for 3 H P at 150 rpm using the following formula CID motor Cubic Inch Displacement revolution FLOW RATE GPM co X RPM 5152 PRESSURE PSI 192 _ SSURE PSI SEM OPERATING PRESSURE Idle Speed Pressure PSI Sample Calculation SPINDLE SPEED RPM 150 SPINDLE SPEED SELETOR SWITCH 2 MED see Table 2 2 IDLE SPEED PRESSURE 150 RPM 75 Reading of hydraulic pressure gage CID 6 5IN REV obtain from hydraulic motor specifications GPM 8 5X150 _ 4 99 231 5152 PSI 1218 4 22 OPERATING PRESSURE 75 1218 1293 6 Operate the machine with tooling and a prehoned scrap workpiece installed refer to Section III Setup and Operation 7 Increase machine load by increasing feed until hydraulic pressure equals the calculated OPERATING PRESSURE 8 Adjust the Spindle Speed Selector Switch see Figure 2 5 and Table 2 2 TABLE 2 2 Spindle Speed Selector Switch TO COMPENSATE FOR PRESSURE CHANGES AT VARIOU
21. d functions at the end of a cycle START Pushbutton Switch Starts all machine and feed functions STOP Pushbutton Switch Stops all machine and feed functions Locking POWER White Lens Indicates when power to Modular Power Feed System is ON Indicating Light ON OFF Selector Switch Controls power to Feed Control Console RAPID FEED EXPAND RETRACT Jog Switch Manually feeds stones in or out during setup FEED IN PROGRESS Green Lens Indicates when stones are being expanded during honing cycle Controls spindle load Setting is based on bore diameter condition of bore material and stones used Compensates for changes in hydraulic pressure at various spindle speeds to maintain a 3 H P load NOTE Operative only when the MPS Feed Control Console is installed as Master Control to control BOTH feed and machine functions NOTE Installed on MPS 11 Units ONLY SPINDLE LOAD METER FEED IN PROGRESS LIGHT POWER ON OFF SWITCH START BUTTON HONING CYCLE E STOP RAPID FEED BUTTON SWITCH i MPS 11 ONLY SPINDLE SPEED SELECTOR SWITCH FIGURE 2 1 Feed Control Console 7 ADJUSTMENTS 1 Turn ON Electrical Power at Main Buss Box or Main Power Source 2 Remove any tooling from Remote Feed Unit 3 Turn ON power to Modular Power Feed System and the Machine 4 Set the Spindle Motor rpm at approximately mid range under a no load condition 5 Set Stroke Speed to slowest rate 6
22. dapter 4 5 Morse Taper e Loosen Locking Nut on Drive Assembly e Slide Morse Tapered Drive out of the machine s spindle taper e Remove Locking Nut e Remove Key e Install Locking Nut on Input Hub e Align Slots in Locking Nut and Input Hub and install Key e Install Input Hub in the machine s spindle taper Tighten Locking Nut INSTALLING REMOTE FEED UNIT a CAP pipas T E DISASSEMBLY oe RING 6 0 0 fecal DISASSEMBLY HUB SCREW REMOTE FEED UNIT at TORQUE o BRACKET CAUTION DO NOT install Remote Feed Unit unless Disassembly Ring is in place on Input Hub 1 Install Disassembly Ring on Input Hub see Figure 1 3 2 Install Remote Feed Unit by turning onto threaded Input Hub Hand tighten CABLE a 4 PIN a CONNECTOR lt CABLE lt TORQUE a BRACKET RIN wes FEED UNIT REMOTE SLIP e RING 4 PIN TORQUE CONNECTOR BRACKET CABLE FIGURE 1 4 Torque Bracket 3 Install Torque Bracket on Remote Feed Unit see Figure l 4 NOTE A Torque Bracket must be installed to prevent the Slip Ring on the Remote Feed Unit from turning while in operation If Torque Bracket supplied with the system does not work on your machine you will need to make a bracket for your machine FEED CONTROL CONSOLE 1 Position the Feed Control Console in a convenient location 2 Attach the Motor and Control Cables to bottom
23. duction sasra aari eed A beak E AE ER E e Reda E see eae del 2 Wedd e vi INSTALLATION General arg siae e aed da E R ie A 1 Suggested Tools amp Materials 2 0 0 eee eee ene teens 1 Unpacking amp Inspecting miami did 1 Installing Spindle Nose Adapter o 1 Installing Remote Feed Ult orina a de da as rads 2 Feed Control Console 2000 a a toii ba a dd di dd BUNA ad asd 3 Remote Feed Unit Connection o 3 Installing Transformer or Transducer o 3 Wiring Optlons amp 2 00h64 400 A Wiad ae Oe EW A Ee Ge Seated kha woke Saas 3 PREPARING FOR OPERATION General seecae eaa de ii da di tes 7 Major Controls iia es dea SOR Ree dd ee E Oe ee A be end bere wR LE 7 Adjustments 42eX6 eve A note au Meet cede eel heed ee bad she eek ee bow di 8 Zero LED Adjustment lt 4 oc veka dd ian ee Reda Gas nae ena a ddd chee hhh eed a aii alii 8 Calibration MPS 11 Only ccoo ria o dd bee ee eee bb big bed dee ees 9 SETUP amp OPERATION Gen ral parir a a a Stade GN UA Radel Bop eas A eee bene tones 11 Safety Precautions 2 0 2 0 icon e whew nds 11 Setup amp Operation Typical 20 ee eee ene e eee e eens 11 LIST OF APPENDIXES A Current Transformet ccc sc gece hata ad dkion 2a4 844 Ga SE Mae Se ea AAAG gue WE Raa Me ete ene o 13 B Hydraulic Pressure Transducer 0 eee tenet eens 15 SUNNEN AND THE SUNNEN LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY Copyright 2005 by Sunnen Products Company Printed in U S A Vv GE
24. e 16 2719 MULTIPLY MILLIMETERS mm METERS m U S A Automotive 1 800 772 2878 Industrial 1 800 325 3670 International Division Fax 314 781 6128 htto www sunnen com mail sunnen sunnen com 1 062500 26 9880 BY 0 03937 3 281 TO GET INCHES in FEET ft x x UK Sunnen ProDUCTS LTD Phone 44 1442393939 Fax 44 1442 39 12 12 www sunnen co uk e mail hemel sunnen co uk SWITZERLAND SUNNEN AG Phone 41 71 6493333 Fax 41 71 649 34 34 www sunnen ct e mail info sunnen ch CHINA SHANGHAI SUNNEN MECHANICAL Co LTD Fax 86 21 5 813 2299 e mail sales sunnensh com Fax 39 02 383 417 50 e mail sunnen sunnenitalia com SAS 33 01 69 30 0000 Fax 33 01 69 30 1111 www sunnen fr e mail info sunnen fr Russia SUNNEN RUS Phone 7 495 258 43 43 Fax 7 495 258 91 75 www sunnen ru e mail sunnen sunnen russia ru CZECH REPUBLIC SUNNEN S R O Phone 420 383 376 317 www sunnen c e mail sunnen sunnen cz Fax 420 383 376 316 POLAND SUNNEN POLSKA SP Z 0 0 Phone 48 22 814 34 29 Fax 48 22 814 34 28 www sunnen pl Email sunnen sunnen pl COPYRIGHT SUNNEN PRODUCTS COMPANY 2009 ALL RIGHTS RESERVED
25. elay or Spindle Contactor These are general wiring instructions Consult with your local sunnen field engineer or sunnen C Connect Blue Wire MPS Control Cable to products company for specific instructions for another Terminal on the same Normally Open wiring your machine Improper wiring could Auxiliary Contact in the Machine s Cycle Start result in personal injury or damage to the Circuitry equipment A Connect Yellow Wire MPS Control Cable and Violet Wire MPS Control Cable in series with the Control Circuit Fuse or in series with the Machine s STOP Switch as follows e Disconnect Wire from Machine s Control Circuit Fuse and connect to Violet Wire MPS Control Cable e Connect Yellow Wire MPS Control Cable to Machine s Control Circuit Fuse D Individually tape off ends of remaining wires THEORY OF OPERATION When the Machine s Controls are used to control BOTH the machine and feed functions MPS control is started and stopped through an Auxiliary Contact closure supplied by the Machine s Controls Master Controls The Auxiliary Contact can be either a normally open contact on the Cycle Relay or on the Spindle Motor Starter When the Auxiliary Contact closes it overrides the MPS Timer Contacts and energizes MPS relay 1 CR to place the MPS control in cycle When the Machine cycle stops the Auxiliary Contact opens and allows the 1 MPS control to drop out of cycle honing cycle will stop Depressing either the MPS
26. fuses filters etc Damages resulting from but not limited to gt 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 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 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
27. he Red Wire MPS Control Cable to Terminal 2 on the Current Transducer 7 Connect the Black Wire on the Current Transformer to Terminal 3 on the Current Transducer 8 Connect the White Wire on the Current Transformer to Terminal 4 on the Current Transducer TO ELECTRICAL SUPPLY VOLTAGE 7 N TEAN CURRENT Poron TRANSFORMER l STARTER LL CONTROL CABLE RED O RING CONNECTOR RING PRIMARY SCREW CONNECTOR WINDINGS A See Table A 1 E on next page WIRE SPINDLE DRIVE RING MOTOR CONNECTOR T NUT FIGURE A 1 Current Transformer 13 APPENDIX A TABLE A 1 Current Transformer THIS TABLE GIVES THE NUMBER OF REQUIRED TURNS OF WIRE THROUGH THE CENTER OF THE CURRENT TRANSFORMER FOR VARIOUS SPINDLE MOTORS BY HORSEPOWER amp LINE VOLTAGE THE NUMBER OF TURNS HAVE BEEN CALCULATED TO GIVE THE EQUIVALENT OF 5 0 HORSEPOWER LOAD WHEN SPINDLE LOAD METER READS 100 SPINDLE LINE NUMBER HORSEPOWER VOLTAGE OF TURNS 2 0 230 5 2 0 380 6 2 0 460 6 3 0 230 8 3 0 380 9 3 0 460 11 5 0 230 6 5 0 380 6 5 0 460 8 7 5 230 8 7 5 380 9 7 5 460 11 10 0 230 8 10 0 380 9 10 0 460 11 15 0 230 11 15 0 380 l2 15 0 460 14 20 0 230 9 20 0 380 12 20 0 460 14 Adding number of turns increase load meter sensitivity Reducing number of turns decreases load meter sensitivity NOTE The zero adjustment should be checked whenever there is a hange in the number of turns on the cur
28. imitations 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 Unit Always disconnect power at main enclosure before servicing Unit Always wear eye protection when operating this Unit 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 DO NOT attempt to defeat any safety device on this machine or on any of the optional equipment Unit MUST be operated at least 18 in 457 mm above floor WARNING Unit operates at EXTREMELY high temperatures Indicates CE version ONLY TABLE OF CONTENTS Page General Information a ike a ka pee ESS EP Ea pela A eS AE Veni ede aes ado 11 ESD Prevention Review cia a a ORES We CES Oba cea a be ews 11 Sunnen Limited Product Warranty o 111 Sunnen Software License Agreement iii Safety Instructions oi i pe neediness A EE ewe ee eee oe E A da iv General Information amp Specifications o o oooooooo eeaeee neee vi Intro
29. ions OUTUPUT FLANGE ADAPTER NIVERSAL INPUT YOKE ADAPTER DISASSEMBLY RING DRIVE amp FEED EXTENSION DISASSEMBLY RING RING FIGURE 3 1 Honing Tool 11 6 Adjust the Spindle Speed see Machine s Operating Instructions 7 MPS 11 ONLY For machines equipped with hydraulic spindle drive motors adjust the Spindle Speed Selector Switch This must be done to maintain a 3 H P load see Table 3 1 refer to Section 11 C 8 8 Adjust the Stroke Speed see Machine s Operating Instructions 9 Adjust the Oil Nozzle to ensure an ample amount of honing oil is supplied to the bore CAUTION Use ONLY full strength Sunnen Industrial Honing Oil 10 If Feed Control Console is wired to control BOTH machine and feed functions set Honing Time for one honing cycle by rotating Bezel on the Honing Timer to the desired honing time see Figure 3 3 Timer automatically resets each time Honing Cycle START Button is pushed until you readjust the honing cycle time 11 Adjust the Feed Knob to the lowest setting that gives good cutting action u amp h respect to bore diameter condition of the bore mated and stones wed see Table 3 2 NOTE The Feed Settings shown in the table are offered as a suggested starting point Experience with your particular machine and part will dictate the most eco nomical feed setting for your shop 12 Turn ON power to the Machine and the Modular Power Feed System Power
30. ngineer or sunnen products company for specific instructions for wiring your machine Improper wiring could result in personal injury or damage to the equipment A Connect Yellow Wire MPS Control Cable and Violet Wire MPS Control Cable in series with Machine s Control Circuit Fuse or Machine s EMERGENCY STOP Switch as follows e Disconnect Wire from Machine s Control Circuit Fuse and connect to Violet Wire MPS Control Cable e Connect Yellow Wire MPS Control Cable to Machine s Control Circuit Fuse B The Honing Machine may be started and stopped directly through the normally open auxiliary contacts of the MPS s Cycle Relay by wiring as follows NOTE Green and Orange Wires MPS Control Cable are connected beween the Machine s STOP Switch and Motor Starter Coil Black and Brown Wires MPS Control Cable are connected to an Auxiliary Contact to provide an external hold in from the Machine e Connect Orange Wire MPS Control Cable to the Machine s Wire leading to the Motor Starter Coil e Connect Green Wire MPS Control Cable to the Machine s Wire leading to the STOP Switch e Connect Black Wire MPS Control Cable to a Terminal on the Auxiliary Contact in the Machine s Cycle Start Circuitry e Connect Brown Wire MPS Control Cable to second Terminal on the same Auxiliary Contact in the Machine s Cycle Start Circuitry C Individually tape off ends of remaining wires THEORY OF OPERATION When
31. ning time This will close Timer Contacts ZI and 22 Contact 22 closes onlymomentarilywhile START Button 1 PB is being depressed Contact ZI remains closed during the entire honing cycle The closing of Contact 22 energizes Relay 1 CR Contact 1 CR1 which is wired in parallel with the Machine s START Switch energizes Machine s Cycle Relay CR Machine s Contact CRI which is wired in series with Timer Contact ZI closes providing a holding circuit for MPS Cycle Relay 1 CR Machine s Contact CR2 also closes energizing Machine s Contactor 1 M which turns the spindle ON When Honing TI times out or the MPS STOP Button or the Machine s STOP depressed cycle will STOP MACHINE CONTROL CIRCUIT MPS CONTROL START MAX SIZE 6 0 AMPS CONTROL zoyy_ TIMER CONTROLS la FUSE HONE START op a aL T BREAK CIRCUIT O Lo CONNECTION AT X A eS a ae pa A CR2 Jll SPINDEL MTR IM STARTER FOR ELECTRICAL SPINDLE MOTOR CONTROL FUSE MAX SIZE 6 0 AMPS lt MAX CONTACT RATING gt gt 1CR1 6 0 AMPS 1CR2 6 0 AMPS E STOP 6 0 AMPS SPINDLE MOTOR FOR HYDRAULIC SPINDLE MOTOR FIGURE 1 6 Wiring Option 1A 4 2 WIRING OPTION IB Master Control Mode for machine on which NO Control Circuit Exists see Figure l 7 WARNING These are general wiring instructions Consult with your local sunnen field e
32. rent transformer 14 15 B HYDRAULIC PRESSURE TRANSDUCER INSTALLATION INSTRUCTIONS FOR MACHINES EQUIPPED WITH HYDRAULIC SPINDLE DRIVE MOTORS Install the Hydraulic Pressure Transducer in the hydraulic supply line to the spindle motor as follows see Figure B 1 WARNING Turn electrical power off at main buss box or main power source when performing any maintenance on machine electrical system 1 Connect the Transducer Cable to the Transducer as labeled NOTE The motor must discharge into the Hydraulic Reservoir a meter out circuit is not acceptable 2 Route and connect the Transducer Cable to the bottom rear of the Feed FEED CONTROL CONSOLE PL6 PL8 PS FEED CONTROL CONSOLE 4 PIN CONNECTOR SUPPLY LINE HYDRAULIC PRESSURE TRANSDUCER NOTES Like any machinery this equipment may be dangerous if used improperly Be sure to read and follow instructions for operation of equipment FRACTION DECIMAL MILLIMETER EQUIVALENTS CHART NCH DECIMAL 003937 l FRACTION MILLIMETER 0 1000 NCH DECIMAL 281250 l FRACTION 9 32 7 1438 MILLIMETER H DECIMAL MILLIMETER 656250 INC FRACTION 16 6688 007874 0 2000 19 64 296875 7 5406 669291 17 0000 011811 0 3000 5 16 31
33. s 1 WIRING OPTION IA Master Control Mode B Replace the Machine s Hold In Contact with the for machine on which a Control Circuit Exists see MPS Auxiliary Contact as follows Figure 1 6 e Disconnect Wire s from one Terminal of the WARNING Machine s Cycle Hold In Contact and connect to These are general wiring instructions Consult Orange Wire MPS Control Cable with your local sunnen field engineer or sunnen Connect Black Wire MPS Control Cable to the products company for specific instructions for open Terminal on the Machine s Cycle Hold In wiring your machine Improper wiring could Contact result in personal injury or damage to the e Disconnect Wire s from second Terminal of the equipment Machine s Cycle Hold In Contact and connect to A Connect Yellow Wire MPS Control Cable and Cree We ee Conner Cale Violet Wire MPS Control Cable in series with Connect Brown Wire MPS Control Cable to the Machine s Control Circuit Fuse or Machine s open Terminal on the Machine s Cycle Hold In EMERGENCY STOP Switch as follows Contact e Disconnect Wire from Machine s Control Circuit C Individually tape off ends of remaining wires Fuse and connect to Violet Wire MPS Control Cable Connect Yellow Wire MPS Control Cable to Machine s Control Circuit Fuse THEORY OF OPERATION When the MPS Honing Cycle START Button 1 PB is depressed the Honing Timer TI will be automatially set to the desired preset ho
34. the MPS Honing Cycle START Button 1 PB is depressed the Honing Timer TI will be automatically set to the desired preset honing time This will close Timer Contacts 21 and 22 Contact 22 closes only momentarily while START Button 1 PB is being depressed Contact 21 remains closed during the entire honing cycle The closing of Contact 22 energizes Relay 1 CR Auxiliary Cycle Relay Contact 1 CR1 is wired in series with the spindle motor starter or hydraulic pump starter energizing Machine s Contactor 1 M which turns the spindle ON MPS Cycle Relay 1 CR remains energized until the Honing Timer TI times out or either the MPS STOP Button or the Machine s STOP Switch is depressed The honing cycle will STOP When Honing TI times out or the MPS STOP Button or the Machine s STOP depressed cycle will STOP MACHINE CONTROL CIRCUIT MPS CONTROL MAX SIZE 6 0 AMPS CONTROL FUSE IM OVERLOAD 1CR1 MH CONTROL FUSE MAX SIZE 6 0 AMPS T T CONTROL CABLE PRESSURE TRANSDUCER a FOR HYDRAULIC SPINDLE MOTOR MAX CONTACT RATING 1CR1 6 0 AMPS 1CR2 6 0 AMPS E STOP 6 0 AMPS SPINDLE MOTOR FIGURE 1 7 Wiring Option 1B 5 3 WIRING OPTION 2 Slave Control Mode see B Connect Black Wire MPS Control Cable to a Figure 1 8 Terminal on the Normally Open Auxiliary Contact in the Machine s Cycle Start Circuitry either the WARNING Cycle Start R
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